Lead-Acid Battery Separator Rib Layout for Stronger Bag Sealing
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Solution Overview
Problem
The joining strength of bag-shaped separators with ribs formed on the joint surface in lead-acid batteries is inconsistent due to the arrangement of ribs, leading to variations in the performance of the battery, particularly when using methods like gear sealing or heat welding, where ribs can become stuck, reducing the compression ratio and resulting in decreased joining strength.
Innovation Solution
The method involves processing the separator into a bag shape with intersecting first and second ribs at the joint part, ensuring that the ribs do not get stuck into valleys between adjacent ribs, thereby maintaining consistent joining strength by making the first region and second region face each other so that at least one of the first ribs and second ribs intersect at the joint part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ribs are formed on the joint surface of the separator, then the separator structure is enhanced for better performance, but the joining strength becomes inconsistent due to rib arrangement
Solution Approach 1:
The patent applies asymmetry by intentionally designing the rib arrangement to be asymmetric or non-uniform on the joint surface. Instead of evenly spaced ribs, the ribs are positioned at different intervals and orientations, preventing them from aligning perfectly during the folding and joining process. This asymmetric arrangement ensures that ribs do not get stuck in valleys between adjacent ribs, thereby maintaining consistent joining strength while preserving the structural enhancement benefits of the ribs.
2Ease of manufacture
If gear sealing or heat welding is used to join separator edges, then the separator can be sealed effectively, but ribs may get stuck reducing compression ratio and joining strength
Solution Approach 1:
The patent applies preliminary action by pre-positioning the ribs on the separator before the joining process. The rib arrangement is specifically designed in advance to prevent interference during subsequent folding and joining operations. By establishing the correct rib configuration beforehand, the patent ensures that ribs will not get stuck during gear sealing or heat welding, allowing these joining methods to proceed effectively without compromising joining strength.
3Ease of manufacture
If ribs are arranged in a regular pattern, then manufacturing is simplified, but joining strength varies due to rib alignment issues
Solution Approach 1:
The patent deliberately introduces asymmetry into the rib arrangement to resolve the contradiction between manufacturing simplicity and joining strength consistency. While the overall rib pattern may appear regular for ease of manufacture, specific variations in rib positioning, spacing, or orientation are incorporated to prevent perfect alignment during joining. This controlled asymmetry ensures that ribs do not get stuck in valleys, thereby maintaining consistent joining strength without significantly complicating the manufacturing process.
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
This approach enhances the joining strength of the bag-shaped separator, reducing variations and maintaining high performance in lead-acid batteries, applicable to both gear sealing and heat welding methods, and improves resistance to permeation short circuits.
Implementation Method 1
Examples of a method for joining both side edges include a method using gear sealing, heat sealing, and ultrasonic sealing
Implementation Method 2
Examples of a method for joining both side edges include a method using gear sealing, heat sealing, and ultrasonic sealing
Implementation Method 3
making the first region and the second region face each other so that at least one of the first ribs and at least one of the second ribs intersect at the joint part
Data Source
Figure 1
Figure 2
Figure 3(a)~3(b)
AI summary
A method for manufacturing a lead-acid battery that has an electrode group in which a plurality of positive electrode plates and a plurality of negative electrode plates are stacked via a separator includes processing the separator into a bag shape having a first region and a second region facing each other. The step of processing the separator into a bag shape includes forming a joint part that includes at least a part of the first region and at least a part of the second region. A plurality of first ribs are provided in the first region, a plurality of second ribs are provided in the second region, and the step of forming the joint part includes making the first region and the second region face each other so that at least one of the first ribs and at least one of the second ribs intersect at the joint part.