Separator Pocket With Interrupted Weld Seam for Battery Degassing
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Solution Overview
Problem
Existing separator pocket designs for lead-acid batteries face issues with particle accumulation leading to short circuits and gas contamination, which can cause electrode failure, as they either allow particles to accumulate on the electrode plate or require large degassing openings that allow electrolyte particles to enter and cause encrustations.
Innovation Solution
A separator pocket design with a weld seam interrupted to form a degassing opening, accompanied by a second weld seam positioned as a spacer to create a flow barrier, preventing particle accumulation on the electrode plate and ensuring degassing while maintaining a closed top design to prevent gas contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the separator pocket is closed at the upper edge to prevent particle accumulation, then short circuit risk is reduced, but gas released during operation causes the separator pocket to expand and interfere with proper battery operation
Solution Approach 1:
The upper edge of the separator pocket is segmented into two parts: a closed section to prevent particle accumulation and a recess that remains open to allow gas escape. This segmentation resolves the contradiction by providing both particle containment and gas venting functions simultaneously.
Solution Approach 2:
Different regions of the separator pocket upper edge have different properties: most of the upper edge is closed to prevent particle ingress, while a specific local region (the recess) remains open to facilitate gas release. This local quality differentiation allows the system to achieve both particle prevention and gas venting.
2Object-generated harmful factors
If the recess for current collector tab passage is enlarged to allow gas escape, then degassing is improved, but suspended particles from the electrolyte flow into the receiving space and deposit on the electrode plate
Solution Approach 1:
The upper edge is segmented into a closed portion and an open recess portion. The closed portion prevents particle ingress while the open recess allows gas escape, resolving the contradiction between particle prevention and gas venting.
Solution Approach 2:
The recess is designed as a localized open region with specific dimensions that balance gas escape capability with particle prevention. The closed upper edge surrounding the recess provides the protective function while the recess itself provides the venting function.
3Ease of manufacture
If the separator pocket is completely open at the top for electrode plate fitting, then electrode installation is facilitated, but particles accumulate on the upper edge of the electrode plate forming short-circuit bridges
Solution Approach 1:
The separator pocket is pre-formed with a closed upper edge and a recess during manufacturing. This preliminary structuring allows the electrode plate to be installed through the open recess without risking particle accumulation, as the closed structure is already in place to prevent particle ingress during operation.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a separator for an electrode plate (5) of a plate-shaped electrode (3) of a battery (1), in particular a lead-acid battery, with a separator pocket (12) providing a receiving space (13) for the electrode plate (5), the separator pocket having two overlapping separator sheets (14, 15) which are welded together along their respective longitudinal sides (16, 17) and their upper end faces (18), wherein the weld seam (19) connecting the upper end faces (18) has an interruption which forms a recess (20) for the passage of a current collector tab (8) arranged on the upper edge of the electrode plate (5), wherein the weld seam (19) is interrupted in an edge section adjacent to a longitudinal side (16, 17) to form a degassing opening (21), wherein a second weld seam (22) is provided spaced apart from the weld seam (19).which is positioned directly opposite the degassing opening (21) of the first weld (19).