Lead Strip Caster Nozzle Design for Impurity-Free Casting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional lead-acid battery grid manufacturing processes, such as gravity casting and continuous casting, are prone to incorporating lead impurities and dross, leading to deformations and defects in the grids, which can result in battery performance degradation and reduced lifespan.
Innovation Solution
A lead strip caster system comprising a ladle, a nozzle, and rotating rollers with controlled molten lead flow and temperature management, designed to produce a continuous lead strip with reduced impurities and defects, featuring a horizontal orientation to prevent dross migration and improved fluid flow control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional continuous casting machines draw molten lead from an open pool, then the casting process can be continuous and efficient, but lead impurities and dross are drawn into the cast strip causing deformations and defects
Solution Approach 1:
The patent extracts and removes the harmful open pool configuration from the casting system. By eliminating the open pool and its associated impurity layer, the system prevents dross and impurities from being drawn into the cast strip while maintaining continuous casting operation.
Solution Approach 2:
The patent introduces an intermediary closed-channel system between the molten lead source and the casting rollers. This closed channel acts as a mediator that allows molten lead to reach the rollers without exposure to atmospheric oxygen, thereby preventing dross formation and impurity incorporation.
2Reliability
If gravity casting is used to produce positive plate grids, then corrosion-resistant grain structure can be achieved, but the process is slow and laborious
Solution Approach 1:
The patent changes the critical parameter of molten lead flow control by using a closed-channel delivery system with controlled discharge. This allows the molten lead to be delivered in a controlled manner to the rollers, enabling continuous casting at higher speeds while maintaining the corrosion-resistant grain structure through proper cooling and solidification control.
Solution Approach 2:
The patent implements continuous casting by delivering molten lead continuously through the closed channel to the rotating rollers. This eliminates the batch-by-batch nature of gravity casting, maintaining the corrosion-resistant grain structure through continuous controlled solidification while dramatically increasing production speed and eliminating manual labor.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system produces high-quality lead strips with reduced impurities and defects, enhancing battery performance and lifespan by preventing dross incorporation and optimizing molten lead flow and temperature control.
Implementation Method 1
The molten lead may progressively harden as it moves downstream of the passage
Implementation Method 2
The molten lead may progressively harden as it moves downstream of the passage
Data Source
AI summary
In one embodiment, a lead strip caster for battery grids includes a ladle, a nozzle, and a pair of rollers. The lead strip caster produces a continuous lead strip for use as battery positive plate grids. The ladle has an inlet to receive molten lead and has an outlet. The nozzle has at least one passage that communicates with the outlet of the ladle in order to receive molten lead from the ladle. The first roller is situated at a first exterior side of the nozzle. The first roller rotates via a first driver. The second roller is situated at a second exterior side of the nozzle. The second roller rotates via a second driver.