Ultrasonic Paste Coating for Uniform Lead-Acid Electrode Thickness

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Traditional methods for transferring and applying lead-acid battery active material paste result in inconsistent electrode thickness and inefficiencies due to challenges in maintaining paste viscosity, leading to suboptimal battery performance and reduced lifecycle.

Innovation Solution

A paste coating system utilizing ultrasonic transducers to regulate viscosity of thixotropic lead-acid paste, integrated with a controller for real-time monitoring and adjustment, ensures uniform application without compromising material properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If traditional mechanical stirring or heating is used to reduce paste viscosity, then the paste becomes easier to dispense, but the material's electrochemical and physical properties are altered or damaged

Engineering Contradiction:

Improvepaste dispensabilityVSAvoidmaterial properties integrity

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent replaces traditional mechanical stirring systems and thermal heating systems with an ultrasonic vibration system. The ultrasonic transducer generates high-frequency vibrations that reduce paste viscosity through acoustic energy, eliminating the need for mechanical shear forces and thermal input that would damage the paste's electrochemical properties.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical state parameters of the paste by applying ultrasonic vibration at specific frequencies and amplitudes. This acoustic energy input temporarily reduces the viscosity of the thixotropic paste, making it easier to dispense without altering its chemical composition or electrochemical characteristics.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If excessive pumping pressure is applied to move thixotropic paste, then the paste flows more readily, but de-watering occurs resulting in lowered porosity and compromised battery cell performance

Engineering Contradiction:

Improvepaste flow rateVSAvoidpaste porosity and structure

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent replaces high-pressure pumping systems with an ultrasonic-assisted dispensing system. The ultrasonic vibrations reduce the paste's resistance to flow, allowing it to be dispensed at low pressures through a die-cut coater, thereby preventing de-watering and maintaining the paste's porous structure essential for battery performance.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If chemical additives are used to adjust paste viscosity, then the paste becomes easier to handle, but the material's electrochemical properties are compromised

Engineering Contradiction:

Improvepaste handlingVSAvoidelectrochemical properties

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent replaces chemical viscosity modifiers with a physical ultrasonic vibration method. The ultrasonic transducer directly reduces paste viscosity through acoustic energy, eliminating the need for chemical additives that would alter or compromise the electrochemical properties of the lead-acid paste.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Device complexity

If traditional paste application methods are used, then the coating process is simple, but inconsistencies in electrode thickness and uniformity occur

Engineering Contradiction:

Improvecoating system simplicityVSAvoidelectrode thickness uniformity

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent introduces ultrasonic vibration to the paste application process. The ultrasonic transducer, positioned adjacent to the die-cut coater, vibrates the paste at high frequencies during dispensing, ensuring smooth, consistent flow and uniform coating thickness on the grid, thereby improving manufacturing precision without significantly complicating the overall system.

Inventive Principle:

Principle #18Mechanical vibration

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 system achieves uniform and consistent application of active material paste on lead grids, enhancing battery performance and extending lifecycle by maintaining material integrity.

Implementation Method 1

a ultrasonic transducer adjacent to the one or more dispensing heads configured to regulate viscosity of the paste

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Implementation Method 2

regulate viscosity of the paste such that the paste is coated onto the grid uniformly without risking material properties

Methodology Applied

Scientific EffectThixotropy: Thixotropy

Data Source

PatentUS20250379204A1Control of Lead Acid Paste Transference Through Use of Ultrasonics for Viscosity Regulation

Publication Date: 2025.12.11 TBS ENG LTD

AI summary

A paste coating system comprises a dispensing head assembly operatively connected to a coating frame, the dispensing head assembly including one or more dispensing heads configured to dispense paste (thixotropic and/or non-Newtonian) onto a grid with respect to the coating frame, and a ultrasonic transducer adjacent to the one or more dispensing heads configured to regulate viscosity of the paste such that the paste is coated onto the grid uniformly without risking material properties. The paste coating system also comprises a controller configured to automatically control operation of the dispensing head assembly and ultrasonic transducer during coating according to one or more coating profile.