Stamped Grid Lead-Acid Battery Plate Assembly
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Solution Overview
Problem
Existing lead-acid batteries with absorbed glass mat (AGM) technology are expensive and inefficient due to the use of expanded metal grids, which result in low lead utilization and increased manufacturing costs, and require additional tooling for production.
Innovation Solution
A battery plate assembly using stamped electrically conductive grids with a grid pattern and highly absorbent separators, where the electrolyte is absorbed by the separators or active material, reducing the need for expanded metal grids and optimizing lead usage, and allowing for shared tooling for both positive and negative plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If expanded metal grids are used in AGM batteries, then the battery structure is stable and electrolyte retention is good, but lead utilization efficiency is low and manufacturing cost is high
Solution Approach 1:
The patent changes the grid manufacturing method from expansion process to stamping process, altering the physical parameters of grid formation. This enables better lead utilization while maintaining structural integrity and electrolyte retention capabilities through optimized stamping patterns and grid design
2Stability of the object's composition
If expanded metal grids are used in AGM batteries, then the battery structure is stable, but manufacturing cost increases due to additional tooling requirements
Solution Approach 1:
The patent adopts stamped grids that can be manufactured using simpler, more cost-effective stamping tools rather than expensive expansion tooling. The stamped grids achieve sufficient structural stability for their intended lifecycle without requiring the complex and costly expansion process equipment
Solution Approach 2:
The manufacturing process parameter changes from expansion to stamping, which fundamentally alters the tooling requirements and cost structure while maintaining the necessary grid stability for battery operation
3Strength
If expanded metal grids are used, then the grid provides sufficient structural support, but the lead usage efficiency is reduced
Solution Approach 1:
The patent transforms the grid manufacturing approach from expansion to stamping, changing the physical parameters of how the grid structure is formed. This enables more efficient use of lead material while maintaining adequate structural support through optimized stamping patterns and grid geometry
Solution Approach 2:
The stamped grid design allows for optimized segmentation of the grid structure, placing conductive elements only where needed for electrical function and structural support, thereby reducing unnecessary lead usage while maintaining strength
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 solution enhances lead utilization efficiency, reduces manufacturing costs, and improves the performance and durability of lead-acid batteries by using stamped grids and absorbent mats, enabling rapid charge and discharge with reduced internal resistance and electrolyte retention.
Implementation Method 1
employ an absorptive separator mat preferably of micro-fine glass fibers having a large surface area per unit of volume and a large porosity, enabling retention of the bulk of the acid electrolyte (capacity determining) of the cell in the separator(s)
Implementation Method 2
sealed lead-acid batteries of one or more cells operating on the oxygen cycle with internal recombination of oxygen during charge
Data Source
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AI summary
A battery plate assembly for a lead-acid battery is disclosed. The assembly includes a plates of op:post:ttg polarity each fbrrned by an electmeaily ednduetive grid body having opposed, top mid bottom frame and opposed first and second side frame elements, the top frame element having a lug and an opposing enlarged conductive section extending toward; the bottom frame element; a plurality of interconnecting electrically conductive grid elements defining a grid pattern defining a plurality of open areas, the grid elements including a plurality of radially extending vertical grid, wire elements connected to the top frame element, and a plurality of horizontal extending grid wire elements, the grid body having an active material provided thereon. A highly absorbent: separator is wrapped around at least a portion of the plate of a first polarity and extends to opposing plate face. An electrolye is provided, wherein substantially all of the electrolyie is absorbed by the separator or active material. A method for assembling a battery is also disclosed.