U-Shaped AGM Battery Stacking Aid for Low-Complexity Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing stacking aids for AGM batteries are material-intensive, complex to assemble, and costly due to their robust construction, which complicates handling and increases production costs, while also failing to effectively prevent bulging and maintain contact between electrode plates.
Innovation Solution
A stacking aid design featuring a U-shaped base body with a support element and orthogonal cheeks, equipped with strip-shaped plastic insulators and rectangular tubes, which provides lateral protection and simplifies assembly by reducing material usage and eliminating load-bearing elements, allowing for modular expansion and easy alignment of batteries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If robust construction with multiple load-bearing elements is used to prevent bulging, then reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent removes the complex load-bearing side panels and intermediate shelves from the stacking aid design. Instead, it uses only a simple base element and cover element that perform exclusively lateral protection functions, while the AGM batteries themselves provide the necessary compression force to prevent bulging through their own weight and internal pressure resistance.
Solution Approach 2:
The AGM batteries serve their dual function: they are both the stored energy source and the compression mechanism that prevents housing bulging. Their weight and structural integrity automatically apply the necessary compressive force on the plate packs, eliminating the need for separate active compression or support mechanisms in the stacking aid.
2Reliability
If robust construction with multiple load-bearing elements is used to prevent bulging, then reliability is improved, but ease of manufacture deteriorates
Solution Approach 1:
The patent removes the complex load-bearing side panels and intermediate shelves from the stacking aid design. Instead, it uses only a simple base element and cover element that perform exclusively lateral protection functions, while the AGM batteries themselves provide the necessary compression force to prevent bulging through their own weight and internal pressure resistance.
Solution Approach 2:
The stacking aid is divided into simple functional segments: the base element for lateral protection, the AGM batteries for compression and energy storage, and the cover element for top protection. This segmentation allows each component to be manufactured independently with simple geometry, facilitating easier production and assembly.
3Strength
If material-intensive construction is used to ensure force dissipation, then strength is improved, but manufacturing cost increases
Solution Approach 1:
The patent removes the material-intensive load-bearing side panels and intermediate shelves that were traditionally used to dissipate forces. The design relies on the inherent strength of the AGM batteries and their mounting configuration to provide necessary structural support, significantly reducing material consumption.
Solution Approach 2:
The base element and cover element are designed as simple, inexpensive components made from minimal material. Rather than using expensive, material-intensive robust construction, the patent employs simple protective elements that perform their lateral protection function effectively with minimal material input.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a system comprising a stacking aid (1) and a plurality of AGM batteries arranged in the stacking aid (1), wherein an AGM battery has a housing with first side walls and electrode plates arranged in the housing, wherein the first side walls and the electrode plates are aligned parallel, wherein the stacking aid (1) has a U-shaped base body (2) which has exclusively a support element (3) for receiving the AGM batteries and two cheeks (4, 5) aligned orthogonally to the support element (3), wherein the cheeks (4, 5) are arranged on one end and the other end of the support element (3), wherein the support element (3) receives a plurality of AGM batteries arranged in rows one above the other, wherein both the support element (3) and the first side walls of the AGM battery housings are aligned horizontally, wherein the cheeks (4, 5) are configured toexclusively as lateral protection for the AGM batteries received by the support element (3) and wherein the support element (3) is equipped on its underside (6) facing away from the cheeks with strip-shaped insulators (7) made of plastic which serve as feet.