Multi-Material Battery Grid for Uniform Current Transport
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Solution Overview
Problem
Lead acid batteries face challenges with high weight, low energy density, poor high-rate discharge performance, and reduced service life due to inefficient grid designs, which hinder their capacity and sustainability.
Innovation Solution
A multi-material battery grid with a planar spatial configuration and Koch fractal curve active material utilization enhancer, incorporating primary and secondary current collectors, corrosion-resistant coatings, and an air core, optimized for uniform current transport and maximum active material utilization, reduces weight and enhances discharge performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional grid design is used, then structural strength is maintained, but weight is high and energy density is low
Solution Approach 1:
The patent employs multi-material construction for the grid, combining different materials with complementary properties. The grid includes a base material providing structural strength and additional materials optimized for electrical conductivity and corrosion resistance, achieving a balance between weight reduction and structural integrity
Solution Approach 2:
Different regions of the grid are constructed with different material compositions tailored to their specific functional requirements. High-stress areas use materials optimized for mechanical strength, while current collection areas use materials with superior electrical conductivity, eliminating the need for uniform heavy construction throughout
2Power
If grid size is increased to improve current transport, then electrical performance improves, but weight increases
Solution Approach 1:
The grid utilizes composite material structures where high-conductivity materials are strategically placed in current transport pathways. This allows for thinner, lighter grid sections in areas requiring high electrical performance without compromising current transport capability
Solution Approach 2:
The patent incorporates three-dimensional current collectors and multi-layered grid structures that provide enhanced current transport pathways in multiple dimensions. This volumetric approach to current collection allows for reduced two-dimensional grid footprint and weight while maintaining or improving electrical performance
3Productivity
If uniform grid structure is used, then manufacturing is simple, but active material utilization is inefficient and current density is non-uniform
Solution Approach 1:
The grid features spatially varying material compositions, wire diameters, and spacing configurations tailored to local current density requirements. Areas with higher current density demands have enhanced grid structures, while lower-demand areas use simplified constructions, maximizing active material utilization throughout the electrode
Solution Approach 2:
The grid is divided into multiple segments or zones with different structural characteristics optimized for their specific functions. This segmentation allows each region to be independently optimized for active material utilization while maintaining overall grid integrity through standardized connection points
4Reliability
If grid corrosion resistance is improved through material selection, then service life increases, but cost and manufacturing complexity increase
Solution Approach 1:
The grid employs composite material structures combining corrosion-resistant materials with cost-effective base materials. Corrosion-resistant coatings or alloying elements are applied only where needed to protect against electrochemical degradation, extending service life without requiring expensive materials throughout the entire grid structure
Solution Approach 2:
The patent incorporates intermediate protective layers or coatings between the base grid material and the corrosive battery environment. These intermediary layers provide corrosion protection while allowing the use of more cost-effective and manufacturable base materials
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 solution improves battery capacity, energy density, high-rate discharge performance, and service life by optimizing current collection and transport, reducing corrosion, and minimizing weight, thereby enhancing overall battery efficiency and sustainability.
Implementation Method 1
An active material utilization enhancer is configured in a lateral cross-section of the grid wires with maximum surface perimeter
Implementation Method 2
a corrosion resistant coating
Implementation Method 3
an air core
Implementation Method 4
a primary current collector and transporter, a secondary current collection enhancer and transporter
Data Source
AI summary
The present disclosure provides a multi-physics engineered multi-material electrode grid plate for improved performance of a battery having uniform current collection and transport. The grid comprises a plurality of vertical grid wires (102, 406), a plurality of horizontal grid wires (104, 404), a plurality of frame grid wires, wherein the vertical grid wires (102, 406) and the horizontal grid wires (104, 404) provided between the frame grid wires for current transport. An active material current collector (108, 408) is provided for current collection and an active material utilization enhancer (601) is configured in a lateral cross-section of the grid wires ((102, 406) (104, 404)) with maximum surface perimeter.