CA1104204A - Cascading-water, lead-acid storage battery neutralization, forming and charging method - Google Patents
Cascading-water, lead-acid storage battery neutralization, forming and charging methodInfo
- Publication number
- CA1104204A CA1104204A CA308,218A CA308218A CA1104204A CA 1104204 A CA1104204 A CA 1104204A CA 308218 A CA308218 A CA 308218A CA 1104204 A CA1104204 A CA 1104204A
- Authority
- CA
- Canada
- Prior art keywords
- container means
- batteries
- predetermined
- cooling fluid
- level
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
- 238000000034 method Methods 0.000 title claims abstract description 39
- 238000007600 charging Methods 0.000 title claims abstract description 21
- 238000006386 neutralization reaction Methods 0.000 title claims abstract description 17
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 title abstract description 27
- 239000002253 acid Substances 0.000 title abstract description 4
- 239000003792 electrolyte Substances 0.000 claims abstract description 28
- 238000004519 manufacturing process Methods 0.000 claims abstract description 7
- 230000015572 biosynthetic process Effects 0.000 claims description 25
- 239000012809 cooling fluid Substances 0.000 claims description 21
- 238000005755 formation reaction Methods 0.000 description 24
- 238000001816 cooling Methods 0.000 description 16
- 239000012530 fluid Substances 0.000 description 4
- 239000002826 coolant Substances 0.000 description 3
- 238000013021 overheating Methods 0.000 description 3
- 238000013459 approach Methods 0.000 description 2
- 239000000498 cooling water Substances 0.000 description 2
- 230000006378 damage Effects 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 230000005484 gravity Effects 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 239000007921 spray Substances 0.000 description 2
- 238000009825 accumulation Methods 0.000 description 1
- 238000010420 art technique Methods 0.000 description 1
- 235000019628 coolness Nutrition 0.000 description 1
- 230000003111 delayed effect Effects 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000001999 grid alloy Substances 0.000 description 1
- 230000020169 heat generation Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000000746 purification Methods 0.000 description 1
- 230000000630 rising effect Effects 0.000 description 1
- 239000005060 rubber Substances 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M10/00—Secondary cells; Manufacture thereof
- H01M10/06—Lead-acid accumulators
- H01M10/12—Construction or manufacture
- H01M10/128—Processes for forming or storing electrodes in the battery container
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M10/00—Secondary cells; Manufacture thereof
- H01M10/60—Heating or cooling; Temperature control
- H01M10/61—Types of temperature control
- H01M10/613—Cooling or keeping cold
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M10/00—Secondary cells; Manufacture thereof
- H01M10/60—Heating or cooling; Temperature control
- H01M10/62—Heating or cooling; Temperature control specially adapted for specific applications
- H01M10/627—Stationary installations, e.g. power plant buffering or backup power supplies
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M10/00—Secondary cells; Manufacture thereof
- H01M10/60—Heating or cooling; Temperature control
- H01M10/65—Means for temperature control structurally associated with the cells
- H01M10/656—Means for temperature control structurally associated with the cells characterised by the type of heat-exchange fluid
- H01M10/6567—Liquids
- H01M10/6568—Liquids characterised by flow circuits, e.g. loops, located externally to the cells or cell casings
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M10/00—Secondary cells; Manufacture thereof
- H01M10/60—Heating or cooling; Temperature control
- H01M10/65—Means for temperature control structurally associated with the cells
- H01M10/659—Means for temperature control structurally associated with the cells by heat storage or buffering, e.g. heat capacity or liquid-solid phase changes or transition
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/37—Measurements
- G05B2219/37462—Resistor, potentiometers
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/42—Servomotor, servo controller kind till VSS
- G05B2219/42212—Rotation over, selection of smallest, shortest angle, distance
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/10—Energy storage using batteries
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Electrochemistry (AREA)
- General Chemical & Material Sciences (AREA)
- Secondary Cells (AREA)
Abstract
CASCADING-WATER, LEAD-ACID STORAGE BATTERY
NEUTRALIZATION, FORMING AND CHARGING METHOD
Abstract of the Disclosure A method for producing batteries having plastic cases wherein a plurality of sets of batteries are placed in a plurality of portable tanks or tubs which are posi-tioned at different heights above the floor and filled with water, filling the highest tub first and allowing it to overflow to fill the adjacent lower tub and so on until all tubs are filled and overflowing. Before the water is added to the tanks, electrolyte is added to unfilled, unformed batteries and a separate rectifier circuit is connected to each set of batteries for passing current therethrough to form or charge the batteries.
NEUTRALIZATION, FORMING AND CHARGING METHOD
Abstract of the Disclosure A method for producing batteries having plastic cases wherein a plurality of sets of batteries are placed in a plurality of portable tanks or tubs which are posi-tioned at different heights above the floor and filled with water, filling the highest tub first and allowing it to overflow to fill the adjacent lower tub and so on until all tubs are filled and overflowing. Before the water is added to the tanks, electrolyte is added to unfilled, unformed batteries and a separate rectifier circuit is connected to each set of batteries for passing current therethrough to form or charge the batteries.
Description
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Background of the Invention This invention relates to the production of batteries having plastic cases during the neutralization, forming and charging stages.
Description of the Prior Art One of the classical problems in the battery industry is controlling temperature and time of battery formation. When electrolyte is first added to an unfilled, unformed battery and interacts with the paste on the plates of the element assembly within the battery, a great deal of heat is generated; this heat being referred to as the heat of neutralization. Heat con-tinues to be generated by the battery during the forma-tion and charging process while high current flow is present through the batteries. It is uneconomical to purchase and maintain sufficient equipment to form batteries at a current low enough to prevent the heating of the batteries.
Various means have been devised to cool batteries during the neutralization, formation, and charging process in order to avoid internal overheating of the batteries which, if not properly controlled, results in destruction of the battery. The problem of dissipating heat which is generated during the formation of a battery has been aggravated by the widespread use of plastic battery cases throughout the automotive battery industry. Unlike rubber, composition, or glass ;~
z~
cases previously used by the industry, plastic cases tend to have a low heat transfer coefficient which tends to insulate the interior of the battery making it particularly susceptible to overheating problems.
Several approaches, such as circulating water baths in which batteries stand in low rows of tanks per-manently erected on the floor of the forming room have been used in attempts to dissipate the heat produced when using high current during the battery neutralization, formation and charging process. While this has been successful, it is a highly restrictive technique and does ~ :
not allow individual rectifying circuit control for batteries at various stages of neutralization, formation, and charging. Another method which has been used is :
the water spray ~ ., .
- i .
Z~4 in which the batteries are sprayed with water or cooling fluid. However, this approach is not as good as the circulating bath method since the water spray does not have the heat conducting capacity of the fcrmer method.
Chilled electrolyte has been used as a method of reducing the heat of neutralization. However, this is an expensive method and while it reduces the high initial peak, the possibility of high heat developing during formation exists as well as the possibility of having a delayed 10 thermal runaway.
Due to the relatively higher volumes of batteries produced, and the plastic case designs, the various grid alloys and oxide mixtures now commonly used in the production of automotive batteries, the prior art techniques above have not proved satisfactory and relatively long formation times have therefore been necessitated to insure that overheating does not occur during formation.
Summary of the Invention In its broad scope the invention consists of a method for producing batteries having plastic cases comprising the steps of: (a) providing a plurality of container means for holding a plurality of batteries; (b) placing a plurality of batteries into each of said container means;
(c) stacking said plurality of container means at a plur-ality of positions at different heights above a forming room floor; (d) charging said batteries in said container means; (e) continuously providing cooling fluid to fill a first container means to a predetermined level, said first 30 container means being positioned at the greatest height, above said forming room floor; (f) causing said cooling 11~42~4 fluid to overflow said first container means and to enter a second adjacent container means located below said first container means; and (g) causing said overflow cooling fluid to enter each adjacent lower container means of said plurality.
In the preferred embodiment there is provided a battery production method wherein sets of batteries are placed in a plurality of portable tanks or tubs; the batteries within each tub being electrically inter-connected within that tub so that a minimum number ofleads are required for subsequent connection to a charging circuit. The tubs are then stacked at a plurality of heights above the forming room floor and in the preferred embodiment the tubs are disposed substantially vertically above one another. Each tub of batteries is readily interchangeable ~'S
X~
with the other tubs in the various vertical positions.
Cooling fluid such as water is introduced into the highest tub to a predetermined level above whicil the water over-flows and begins to fill the adjacent lower tub which in turn overflows to fill the remaining tubs until all the tubs have been filled with water and are overflowing. If desired, the overflow cooling fluid or water coming from the last tub at the lowest position can be conveyed to a cooling tower which removes the heat from the cooling fluid and the cooling fluid is than conveyed to the tub in the highest position.
Since each of the tubs of batteries are inter-changeable in the various heights above the floor and further since the cascading action of the water described -above tends to skim off and pass on only the warmest portions of the coolant from one tub to the next, it is desirable to establish a flow pattern of coolant so that immediately upon its reintroduction into the system from the cooling tower, the coolant is utilized to ser-vice batteries which are undergoing the-initial phases of the formation process, which phases are responsible for the greatest generation of heat. Accordingly, those ~ -batteries nearing the end of the formation process and/or which are being given a boost charge, may be suitably arranged in vertical position to receive the effluent or overflow from "primary" or higher tubs, whereby a given amount of cooling fluid and/or cooling tower capacity cools a maximum number of batteries in a minimum amount of forming room space.
11~4Z~3i4 Applicant's preferred form of the invention also includes a process whereby a lower rate of current is used to pass through the batteries immediately following the introduction of electrolyte into unfil'ed, unformed batteries. This will avoid unnecessary heat generation while the heat of neutralization is being reduced or accommodated. Following the initial stage after a predetermined amount of time, the amount of current is increased until a second predetermined period is 10 finished at which time the current is again lowered during the final charging stage.
These and other features of embodiments of the invention will become apparent from the following description with reference to the accompanying drawings.
Brief Description of the Drawings Fig. 1 is a schematic of the preferred embodiment process of our invention.
Fig. 2 is a graph showing the temperature of the 20 battery electrolyte during a conventional formation process after introducing electrolyte into the battery.
Fig. 3 is a graph showing the temperature of the electrolyte in a battery during the cascade formation process of our invention after filling the battery with electrolyte.
Fig. 4 is a graph of the temperature of the elec-trolyte in a battery during the preferred embodiment cascade formation of our invention showing the levels of current provided to the batteries by a rectifying 30 circuit superimposed on the graph.
Fig. 5 is a graph showing the temperature of A~
-11~4Z~4 electrolyte in a battery during a conventional formation process in which thermal runaway of the electrolyte has occurred.
Z~4 Description of the Preferred Embodiment Although specific forms of the invention have been selected for illustration in the drawings, and the following description is drawn in specific terms for the purpose of describing forms of the invention, this description is not intended to limit the scope of the invention which is defined in the appended claims.
Referring to Fig. 1, the first step in the preferred process of applicant's invention is to separate a plurality of batteries into a plurality of sets such as sets designated generally 10, 12, and 14 in Fig. 1.
The set 10 comprises batteries 16, 18, and 20; the set 12 comprises batteries 22, 24, and 26; and the set 14 comprises batteries 28, 30, and 32. In the preferred process, this step is not done randomly but batteries are sorted into sets depending on the stage of formation, that is, batteries at a similar stage of formation are sorted into a single set.
After separating the plurality of batteries into a plurality of sets such as 10, 12, and 14, the -next step in applicant's preferred process is to provide a plurality of container means 34, 36, and 38 for holding a plurality of battery sets such as sets 10, 12, and 14 respectively. These sets are placed into their respec-tive container means and electrically connected together for connection with a separate external rectifying circuit. For example, in container No. 34, the battery set 10 has the positive terminals connected together to a single power line 42 while the negative terminals are all connected to the power line 44. The power lines 42 ~r _7_ '' and 44 are readily adaptable to be connected to a recti-fier for forming and charging the batteries in the set 10.
The remaining sets of batteries shown in Fig. 1 are each individually connected to a separate rectifying source in a similar manner. This allows individual circuit controls for each individual set of batteries in the stack of battery sets. Each of the container means with its accompanying set of batteries is then stacked at a plurality of positions at different heights above a forming room floor. In Fig. 1, container means 34 is shown above container means 36 and container means 36 is shown above container means 38. In the preferred embodi-ment the container means with the respective sets of batteries are stacked vertically above one another.
In the preferred process of applicant's inven-tion, the next step is to continuously provide a cooling fluid, such as water, to fill the first container means 34 with battery set 10 to to a predetermined level 50, container means 34 being positioned at the greatest height above the forming room floor 40. The flow of cooling fluid or water from a source of water such as cooling tower 46 is represented by the curved line and arrow 48. When the water has reached this level 50, it is allowed to overflow container 34 and enter a second lower adjacent container means such as container 36 as schematically represented by the line and arrow 52.
After container means 36 fills to predetermined level 56, the water overflows to enter container means 38 (see curved line and arrow 54) whereupon container means 38 fills to predetermined level 58 after which the cooling ~ .
Z~
fluid or water overflows to enter the adjacent lower container means or to flow onto the forming room floor, or, as in Fig. 1, to be conveyed to cooling tower 46 (see line and arrow 60). Cooling tower 46 or other cooling means acts to remove the heat from the water whereupon the cool water is returned to the highest container means 34.
It will be appreciated that as the water passes through the cooling tower 46, a considerable amount of heat is removed and it is desirable that the batteries sorted into the highest container means such as container means 34 be those batteries most in need of cooling. In general, these are unformed, unfilled batteries where electrolyte is about to be added since a considerable amount of heat is generated when electrolyte first comes in contact with the pasted plates of the batteries. This heat is known as the heat of neutralization. It is desir-able, therefore, to position the container means having unformed and unfilled batteries in the highest position where the coldest water is introduced. Hence, battery set 10 in container means 34 in the preferred process is a set of unformed, unfilled batteries with electrolyte to be added before the set is connected to the rectifying means.
Fig. 2 is a graph of the temperature of the ~ -electrolyte in the batteries as it undergoes a conven-tional formation process without using the cascading water process of applicant's invention. The ambient room temperature and temperature of the filling acid is 90 degrees Fahrenheit. The abscissa is Temperature .. , _g_ . " ~
in degrees Fahrenheit and the ordinate is Hours after fill, that is, hours after filling the battery with electrolyte. In the initial five hours or so after filling the battery with electrolyte the temperature of the electrolyte exceeds 150 degrees Fahrenheit peaking near 190 degrees Fahrenheit which is potentially harmful to the battery. After the heat of neutralization is past the temperature gradually decreases to below 150 degrees Fahrenheit at 14 hours past filling. Near the end of formation, between 22 and 23 hours after filling, when the back voltage of the batteries is high and the con-centration of the acid is approaching 1.265 specific gravity, the temperature of the electrolyte begins to rise again into the danger zone above 150 degrees Fahrenheit.
In contrast to Fig 2, our process results in a temperature curve shown in Fig. 3. The abscissa and ordinate are the same but it will be noted that at no time does the temperature of the electrolyte exceed 150 degrees Fahrenheit, otherwise known as the danger zone.
The heat of néutralization is still present and the tem-perature peaks near 150 degrees Fahrenheit after four hours after filling. However, it gradually decreases to between 110 and 130 degrees Fahrenheit for several hours before rising slightly near the end of formation when the back voltage is high.
Fig. 4 shows the preferred way of controlling the current while continuing the flow of water during the charging process. It is a graph of temperature of electrolyte versus hours after filling as in Figs. 2 ; , -10-and 3. The curve is similar to that of Fig. 3 with the current set at a first predetermined level during a first predetermined initial period, for example, 5 Amps for the first five hours. Then, after the heat of neutralization has peaked, the current is raised to a second predeter-mined level for a second predetermined period, for example, 15 Amps for fifteen hours. Finally, the current is lowered to a third predetermined level for a third predetermined period for example, 5 Amps for four hours.
This third adjustment in current to a lower current level helps to reduce the temperature rise in the elec-trolyte near the end of formation due to the back voltage and increase in specific gravity of the electrolyte.
This temperature rise is shown in Figs. 2 and 3 but not in Fig. 4.
Fig. 5 demonstrates thermal runaway in a battery undergoing formation which, sometimes happens -when applicant's process is not followed. A charging level current of 15 Amps is set at the beginning of the formation process and the temperature of the electrolyte increases beyond the danger level of 150 degrees due to the heat of neutralization. Because of the accumulation of the heat of neutralization and the heat generated by the high charging level of 15 Amps, the temperature of the electrolyte does not taper off as in Figs. 2 through 4 to come back below the danger level but continues to rise with probable destruction to the battery.
As was previously indicated, batteries at various stages of formation can be sorted into different sets. Examples of the types of sets that may be . --11-- .
~1S~ 4 desired are unformed and unfilled batteries, batteries which are partially formed but not fully charged and batteries which require a boost charge. The amount of heat which the batteries in these different sets give off will differ. The batteries in the set of unformed and unfilled batteries, when the electrolyte is initially added, will generate the greatest amount of heat and therefore should be placed in a position in the vertical stack of container means which will receive the coolest water or cooling fluid. In Fig. 1 this is container means 34 and battery set 10. As the cooling fluid enters the container means 34, the warmer fluid moves gradually to the top with the cooler fluid remaining at the bottom of the container means. The warmest water then overflows the container means 34 to enter the adja-cent lower container means 36. Of the sets above described of batteries, batteries which are partially formed and not fully charged will generate more heat than those batteries which require only a boost charge.
Hence, it is desirable to place this set of batteries as set 12 in container means 36. Again the warmest water will gradually move to the top of the tank to overflow and enter the lower adjacent tank 38. Hence, the warm-est water will enter the third tank and batteries re-quiring the least amount of cooling should be placed in this tank. Of the battery sets described above, those requiring boost charge will generate the least amount of heat and they should be placed in the container means 38 as set 14. As described previously, the warmest water will again rise to the top, overflow tank means 38 onto ~4Z~
the floor of the forming room or, alternatively, through a purification or neutralization system and then to a cool-ing tower for return to the vertical array of containing means where it will repeat the cascading process through several container means. The types of sets which might be formed from a plurality of batteries are not limited to the description of the sets given above.
As discussed earlier, each set of batteries is connected to an individual rectifying means and as a par-ticular set of batteries, for example, batteries which have passed the stage of neutralization, requires less amount of cooling, it can be disconnected from the recti-fying means, removed from the stack or array of container means or positioned in a different position at a differ-ent height in the vertical array while a new set of unformed, unfilled batteries, for example, can be placed in the highest position to receive the maximum amount of cooling. Hence, the features of individual circuit control for each set and the interchangeability of each set with one another at varying heights above the battery forming room floor provide a process for cooling the maxi- -mum number of batteries with a minimum amount of forming room floor space.
It will be understood that various changes in the details, materials and arrangement of parts which have been herein described and illustrated in order to explain the nature of this invention may be made by those skilled in the art within the principle and scope of the inven-tion as expressed in the following claims.
Background of the Invention This invention relates to the production of batteries having plastic cases during the neutralization, forming and charging stages.
Description of the Prior Art One of the classical problems in the battery industry is controlling temperature and time of battery formation. When electrolyte is first added to an unfilled, unformed battery and interacts with the paste on the plates of the element assembly within the battery, a great deal of heat is generated; this heat being referred to as the heat of neutralization. Heat con-tinues to be generated by the battery during the forma-tion and charging process while high current flow is present through the batteries. It is uneconomical to purchase and maintain sufficient equipment to form batteries at a current low enough to prevent the heating of the batteries.
Various means have been devised to cool batteries during the neutralization, formation, and charging process in order to avoid internal overheating of the batteries which, if not properly controlled, results in destruction of the battery. The problem of dissipating heat which is generated during the formation of a battery has been aggravated by the widespread use of plastic battery cases throughout the automotive battery industry. Unlike rubber, composition, or glass ;~
z~
cases previously used by the industry, plastic cases tend to have a low heat transfer coefficient which tends to insulate the interior of the battery making it particularly susceptible to overheating problems.
Several approaches, such as circulating water baths in which batteries stand in low rows of tanks per-manently erected on the floor of the forming room have been used in attempts to dissipate the heat produced when using high current during the battery neutralization, formation and charging process. While this has been successful, it is a highly restrictive technique and does ~ :
not allow individual rectifying circuit control for batteries at various stages of neutralization, formation, and charging. Another method which has been used is :
the water spray ~ ., .
- i .
Z~4 in which the batteries are sprayed with water or cooling fluid. However, this approach is not as good as the circulating bath method since the water spray does not have the heat conducting capacity of the fcrmer method.
Chilled electrolyte has been used as a method of reducing the heat of neutralization. However, this is an expensive method and while it reduces the high initial peak, the possibility of high heat developing during formation exists as well as the possibility of having a delayed 10 thermal runaway.
Due to the relatively higher volumes of batteries produced, and the plastic case designs, the various grid alloys and oxide mixtures now commonly used in the production of automotive batteries, the prior art techniques above have not proved satisfactory and relatively long formation times have therefore been necessitated to insure that overheating does not occur during formation.
Summary of the Invention In its broad scope the invention consists of a method for producing batteries having plastic cases comprising the steps of: (a) providing a plurality of container means for holding a plurality of batteries; (b) placing a plurality of batteries into each of said container means;
(c) stacking said plurality of container means at a plur-ality of positions at different heights above a forming room floor; (d) charging said batteries in said container means; (e) continuously providing cooling fluid to fill a first container means to a predetermined level, said first 30 container means being positioned at the greatest height, above said forming room floor; (f) causing said cooling 11~42~4 fluid to overflow said first container means and to enter a second adjacent container means located below said first container means; and (g) causing said overflow cooling fluid to enter each adjacent lower container means of said plurality.
In the preferred embodiment there is provided a battery production method wherein sets of batteries are placed in a plurality of portable tanks or tubs; the batteries within each tub being electrically inter-connected within that tub so that a minimum number ofleads are required for subsequent connection to a charging circuit. The tubs are then stacked at a plurality of heights above the forming room floor and in the preferred embodiment the tubs are disposed substantially vertically above one another. Each tub of batteries is readily interchangeable ~'S
X~
with the other tubs in the various vertical positions.
Cooling fluid such as water is introduced into the highest tub to a predetermined level above whicil the water over-flows and begins to fill the adjacent lower tub which in turn overflows to fill the remaining tubs until all the tubs have been filled with water and are overflowing. If desired, the overflow cooling fluid or water coming from the last tub at the lowest position can be conveyed to a cooling tower which removes the heat from the cooling fluid and the cooling fluid is than conveyed to the tub in the highest position.
Since each of the tubs of batteries are inter-changeable in the various heights above the floor and further since the cascading action of the water described -above tends to skim off and pass on only the warmest portions of the coolant from one tub to the next, it is desirable to establish a flow pattern of coolant so that immediately upon its reintroduction into the system from the cooling tower, the coolant is utilized to ser-vice batteries which are undergoing the-initial phases of the formation process, which phases are responsible for the greatest generation of heat. Accordingly, those ~ -batteries nearing the end of the formation process and/or which are being given a boost charge, may be suitably arranged in vertical position to receive the effluent or overflow from "primary" or higher tubs, whereby a given amount of cooling fluid and/or cooling tower capacity cools a maximum number of batteries in a minimum amount of forming room space.
11~4Z~3i4 Applicant's preferred form of the invention also includes a process whereby a lower rate of current is used to pass through the batteries immediately following the introduction of electrolyte into unfil'ed, unformed batteries. This will avoid unnecessary heat generation while the heat of neutralization is being reduced or accommodated. Following the initial stage after a predetermined amount of time, the amount of current is increased until a second predetermined period is 10 finished at which time the current is again lowered during the final charging stage.
These and other features of embodiments of the invention will become apparent from the following description with reference to the accompanying drawings.
Brief Description of the Drawings Fig. 1 is a schematic of the preferred embodiment process of our invention.
Fig. 2 is a graph showing the temperature of the 20 battery electrolyte during a conventional formation process after introducing electrolyte into the battery.
Fig. 3 is a graph showing the temperature of the electrolyte in a battery during the cascade formation process of our invention after filling the battery with electrolyte.
Fig. 4 is a graph of the temperature of the elec-trolyte in a battery during the preferred embodiment cascade formation of our invention showing the levels of current provided to the batteries by a rectifying 30 circuit superimposed on the graph.
Fig. 5 is a graph showing the temperature of A~
-11~4Z~4 electrolyte in a battery during a conventional formation process in which thermal runaway of the electrolyte has occurred.
Z~4 Description of the Preferred Embodiment Although specific forms of the invention have been selected for illustration in the drawings, and the following description is drawn in specific terms for the purpose of describing forms of the invention, this description is not intended to limit the scope of the invention which is defined in the appended claims.
Referring to Fig. 1, the first step in the preferred process of applicant's invention is to separate a plurality of batteries into a plurality of sets such as sets designated generally 10, 12, and 14 in Fig. 1.
The set 10 comprises batteries 16, 18, and 20; the set 12 comprises batteries 22, 24, and 26; and the set 14 comprises batteries 28, 30, and 32. In the preferred process, this step is not done randomly but batteries are sorted into sets depending on the stage of formation, that is, batteries at a similar stage of formation are sorted into a single set.
After separating the plurality of batteries into a plurality of sets such as 10, 12, and 14, the -next step in applicant's preferred process is to provide a plurality of container means 34, 36, and 38 for holding a plurality of battery sets such as sets 10, 12, and 14 respectively. These sets are placed into their respec-tive container means and electrically connected together for connection with a separate external rectifying circuit. For example, in container No. 34, the battery set 10 has the positive terminals connected together to a single power line 42 while the negative terminals are all connected to the power line 44. The power lines 42 ~r _7_ '' and 44 are readily adaptable to be connected to a recti-fier for forming and charging the batteries in the set 10.
The remaining sets of batteries shown in Fig. 1 are each individually connected to a separate rectifying source in a similar manner. This allows individual circuit controls for each individual set of batteries in the stack of battery sets. Each of the container means with its accompanying set of batteries is then stacked at a plurality of positions at different heights above a forming room floor. In Fig. 1, container means 34 is shown above container means 36 and container means 36 is shown above container means 38. In the preferred embodi-ment the container means with the respective sets of batteries are stacked vertically above one another.
In the preferred process of applicant's inven-tion, the next step is to continuously provide a cooling fluid, such as water, to fill the first container means 34 with battery set 10 to to a predetermined level 50, container means 34 being positioned at the greatest height above the forming room floor 40. The flow of cooling fluid or water from a source of water such as cooling tower 46 is represented by the curved line and arrow 48. When the water has reached this level 50, it is allowed to overflow container 34 and enter a second lower adjacent container means such as container 36 as schematically represented by the line and arrow 52.
After container means 36 fills to predetermined level 56, the water overflows to enter container means 38 (see curved line and arrow 54) whereupon container means 38 fills to predetermined level 58 after which the cooling ~ .
Z~
fluid or water overflows to enter the adjacent lower container means or to flow onto the forming room floor, or, as in Fig. 1, to be conveyed to cooling tower 46 (see line and arrow 60). Cooling tower 46 or other cooling means acts to remove the heat from the water whereupon the cool water is returned to the highest container means 34.
It will be appreciated that as the water passes through the cooling tower 46, a considerable amount of heat is removed and it is desirable that the batteries sorted into the highest container means such as container means 34 be those batteries most in need of cooling. In general, these are unformed, unfilled batteries where electrolyte is about to be added since a considerable amount of heat is generated when electrolyte first comes in contact with the pasted plates of the batteries. This heat is known as the heat of neutralization. It is desir-able, therefore, to position the container means having unformed and unfilled batteries in the highest position where the coldest water is introduced. Hence, battery set 10 in container means 34 in the preferred process is a set of unformed, unfilled batteries with electrolyte to be added before the set is connected to the rectifying means.
Fig. 2 is a graph of the temperature of the ~ -electrolyte in the batteries as it undergoes a conven-tional formation process without using the cascading water process of applicant's invention. The ambient room temperature and temperature of the filling acid is 90 degrees Fahrenheit. The abscissa is Temperature .. , _g_ . " ~
in degrees Fahrenheit and the ordinate is Hours after fill, that is, hours after filling the battery with electrolyte. In the initial five hours or so after filling the battery with electrolyte the temperature of the electrolyte exceeds 150 degrees Fahrenheit peaking near 190 degrees Fahrenheit which is potentially harmful to the battery. After the heat of neutralization is past the temperature gradually decreases to below 150 degrees Fahrenheit at 14 hours past filling. Near the end of formation, between 22 and 23 hours after filling, when the back voltage of the batteries is high and the con-centration of the acid is approaching 1.265 specific gravity, the temperature of the electrolyte begins to rise again into the danger zone above 150 degrees Fahrenheit.
In contrast to Fig 2, our process results in a temperature curve shown in Fig. 3. The abscissa and ordinate are the same but it will be noted that at no time does the temperature of the electrolyte exceed 150 degrees Fahrenheit, otherwise known as the danger zone.
The heat of néutralization is still present and the tem-perature peaks near 150 degrees Fahrenheit after four hours after filling. However, it gradually decreases to between 110 and 130 degrees Fahrenheit for several hours before rising slightly near the end of formation when the back voltage is high.
Fig. 4 shows the preferred way of controlling the current while continuing the flow of water during the charging process. It is a graph of temperature of electrolyte versus hours after filling as in Figs. 2 ; , -10-and 3. The curve is similar to that of Fig. 3 with the current set at a first predetermined level during a first predetermined initial period, for example, 5 Amps for the first five hours. Then, after the heat of neutralization has peaked, the current is raised to a second predeter-mined level for a second predetermined period, for example, 15 Amps for fifteen hours. Finally, the current is lowered to a third predetermined level for a third predetermined period for example, 5 Amps for four hours.
This third adjustment in current to a lower current level helps to reduce the temperature rise in the elec-trolyte near the end of formation due to the back voltage and increase in specific gravity of the electrolyte.
This temperature rise is shown in Figs. 2 and 3 but not in Fig. 4.
Fig. 5 demonstrates thermal runaway in a battery undergoing formation which, sometimes happens -when applicant's process is not followed. A charging level current of 15 Amps is set at the beginning of the formation process and the temperature of the electrolyte increases beyond the danger level of 150 degrees due to the heat of neutralization. Because of the accumulation of the heat of neutralization and the heat generated by the high charging level of 15 Amps, the temperature of the electrolyte does not taper off as in Figs. 2 through 4 to come back below the danger level but continues to rise with probable destruction to the battery.
As was previously indicated, batteries at various stages of formation can be sorted into different sets. Examples of the types of sets that may be . --11-- .
~1S~ 4 desired are unformed and unfilled batteries, batteries which are partially formed but not fully charged and batteries which require a boost charge. The amount of heat which the batteries in these different sets give off will differ. The batteries in the set of unformed and unfilled batteries, when the electrolyte is initially added, will generate the greatest amount of heat and therefore should be placed in a position in the vertical stack of container means which will receive the coolest water or cooling fluid. In Fig. 1 this is container means 34 and battery set 10. As the cooling fluid enters the container means 34, the warmer fluid moves gradually to the top with the cooler fluid remaining at the bottom of the container means. The warmest water then overflows the container means 34 to enter the adja-cent lower container means 36. Of the sets above described of batteries, batteries which are partially formed and not fully charged will generate more heat than those batteries which require only a boost charge.
Hence, it is desirable to place this set of batteries as set 12 in container means 36. Again the warmest water will gradually move to the top of the tank to overflow and enter the lower adjacent tank 38. Hence, the warm-est water will enter the third tank and batteries re-quiring the least amount of cooling should be placed in this tank. Of the battery sets described above, those requiring boost charge will generate the least amount of heat and they should be placed in the container means 38 as set 14. As described previously, the warmest water will again rise to the top, overflow tank means 38 onto ~4Z~
the floor of the forming room or, alternatively, through a purification or neutralization system and then to a cool-ing tower for return to the vertical array of containing means where it will repeat the cascading process through several container means. The types of sets which might be formed from a plurality of batteries are not limited to the description of the sets given above.
As discussed earlier, each set of batteries is connected to an individual rectifying means and as a par-ticular set of batteries, for example, batteries which have passed the stage of neutralization, requires less amount of cooling, it can be disconnected from the recti-fying means, removed from the stack or array of container means or positioned in a different position at a differ-ent height in the vertical array while a new set of unformed, unfilled batteries, for example, can be placed in the highest position to receive the maximum amount of cooling. Hence, the features of individual circuit control for each set and the interchangeability of each set with one another at varying heights above the battery forming room floor provide a process for cooling the maxi- -mum number of batteries with a minimum amount of forming room floor space.
It will be understood that various changes in the details, materials and arrangement of parts which have been herein described and illustrated in order to explain the nature of this invention may be made by those skilled in the art within the principle and scope of the inven-tion as expressed in the following claims.
Claims (12)
1. A method for producing batteries having plastic cases comprising the steps of:
(a) separating a plurality of batteries into a plurality of sets;
(b) providing a plurality of container means for holding a plurality of battery sets;
(c) placing said sets of batteries into said container means, one set for each container means and electrically interconnecting said batteries in each set for connection to a separate rectifying means for each set;
(d) stacking said plurality of container means at a plurality of positions at different heights above a forming room floor;
(e) connecting each set of said batteries to said separate rectifying means for charging said plurality of batteries in each set;
(f) continuously providing cooling fluid to fill a first container means to a predetermined level, said first container means being posi-tioned at the greatest height above said forming room floor;
(g) causing said cooling fluid to overflow said first container means and to enter a second adjacent container means located below said first container means; and (h) causing said overflow cooling fluid to enter each adjacent lower container means of said plurality.
(a) separating a plurality of batteries into a plurality of sets;
(b) providing a plurality of container means for holding a plurality of battery sets;
(c) placing said sets of batteries into said container means, one set for each container means and electrically interconnecting said batteries in each set for connection to a separate rectifying means for each set;
(d) stacking said plurality of container means at a plurality of positions at different heights above a forming room floor;
(e) connecting each set of said batteries to said separate rectifying means for charging said plurality of batteries in each set;
(f) continuously providing cooling fluid to fill a first container means to a predetermined level, said first container means being posi-tioned at the greatest height above said forming room floor;
(g) causing said cooling fluid to overflow said first container means and to enter a second adjacent container means located below said first container means; and (h) causing said overflow cooling fluid to enter each adjacent lower container means of said plurality.
2. The invention of Claim 1 wherein said method further comprises the steps of:
(i) conveying said overflow cooling fluid from a last container means to a heat removing means for removing heat from said cooling fluid; and (j) returning said cooling fluid from said heat removing means to said container means in said highest position.
(i) conveying said overflow cooling fluid from a last container means to a heat removing means for removing heat from said cooling fluid; and (j) returning said cooling fluid from said heat removing means to said container means in said highest position.
3. The method of Claim 1 wherein step (a) further comprises sorting batteries which are at a similar stage of formation into a single set.
4. The method of Claim 3 wherein step (a) further comprises sorting a plurality of unformed, unfilled batteries into a first set; step (c) further comprises placing said first set in said first container means; and said method further comprises the step (k) of filling said unformed, unfilled batteries with electrolyte before step (e).
5. The method of Claim 4 wherein said method further comprises the steps of (1) setting said charging current at a predetermined first level during a predeter-mined initial charging period for said unformed, unfilled batteries whereby heat of neutralization is reduced said step (1) being initiated after step (e); and (m) setting said charging current at a predetermined second level after said initial period, said second level being maintained for a predetermined second period.
6. The invention of Claim 5 wherein said method further comprises the step of (n) setting said charging current at a predetermined third level for a predetermined third period after said second period.
7. The invention of Claim 6 wherein said first and third predetermined levels are less than said second predetermined level.
8. The invention of Claim 6 wherein said pre-determined first level is about five Amps and said pre-determined initial charging period is about five hours;
and said predetermined second level is about fifteen Amps and said predetermined second period is about fifteen hours; and said predetermined third level is about five Amps and said predetermined third period is about four hours.
and said predetermined second level is about fifteen Amps and said predetermined second period is about fifteen hours; and said predetermined third level is about five Amps and said predetermined third period is about four hours.
9. The invention of Claim 5 wherein the temperature of said electrolyte is maintained below a predetermined temperature.
10. The invention of Claim 9 wherein said predetermined temperature is 150 degrees Fahrenheit.
11. The invention of Claim 4 wherein said method further comprises sorting partially formed but uncharged batteries into a second set in step (a), placing said second set in a second container means in step (c) and stacking said second container means adjacent and below said first container means in step (d); and separating charged batteries requiring a boost charge in a third set in step (a), placing said third set in a third container means in step (c) and stacking said third container means in a position adjacent and below said second container means in step (d).
12. A method for producing batteries having plastic cases comprising the steps of:
(a) providing a plurality of container means for holding a plurality of batteries;
(b) placing a plurality of batteries into each of said container means;
(c) stacking said plurality of container means at a plurality of positions at different heights above a forming room floor;
(d) charging said batteries in said container means;
(e) continuously providing cooling fluid to fill a first container means to a predetermined level, said first container means being positioned at the greatest height above said forming room floor;
(f) causing said cooling fluid to overflow said first container means and to enter a second adjacent container means located below said first container means; and (g) causing said overflow cooling fluid to enter each adjacent lower container means of said plurality.
(a) providing a plurality of container means for holding a plurality of batteries;
(b) placing a plurality of batteries into each of said container means;
(c) stacking said plurality of container means at a plurality of positions at different heights above a forming room floor;
(d) charging said batteries in said container means;
(e) continuously providing cooling fluid to fill a first container means to a predetermined level, said first container means being positioned at the greatest height above said forming room floor;
(f) causing said cooling fluid to overflow said first container means and to enter a second adjacent container means located below said first container means; and (g) causing said overflow cooling fluid to enter each adjacent lower container means of said plurality.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US821,527 | 1977-08-03 | ||
| US05/821,527 US4117387A (en) | 1977-08-03 | 1977-08-03 | Cascading-water, lead-acid storage battery neutralization forming and charging method |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1104204A true CA1104204A (en) | 1981-06-30 |
Family
ID=25233614
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA308,218A Expired CA1104204A (en) | 1977-08-03 | 1978-07-26 | Cascading-water, lead-acid storage battery neutralization, forming and charging method |
Country Status (2)
| Country | Link |
|---|---|
| US (1) | US4117387A (en) |
| CA (1) | CA1104204A (en) |
Families Citing this family (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4215307A (en) * | 1978-05-30 | 1980-07-29 | General Battery Corporation | Temperature controlled, auto timed, variable amperage cascading-water furmation method for use with high antimony and maintenance free lead-acid batteries |
| US4604564A (en) * | 1977-08-03 | 1986-08-05 | General Battery Corporation | Temperature controlled, auto timed, variable amperage cascading-water formation method for use with high antimony and maintenance free lead-acid batteries |
| US4325429A (en) * | 1980-05-27 | 1982-04-20 | General Battery Corporation | Unitary battery formation tub |
| US4290444A (en) * | 1980-06-19 | 1981-09-22 | General Battery Corporation | Flow control device for use with a battery formation tub |
| US4415847A (en) * | 1981-08-07 | 1983-11-15 | Energy Development Associates, Inc. | Method and apparatus for supplying cooling liquid to a storage battery |
| US4425192A (en) | 1982-12-07 | 1984-01-10 | Allied Corporation | Method of forming battery electrodes |
| RU2250539C2 (en) * | 2002-07-09 | 2005-04-20 | Виктор Александрович Дзензерский | Device for assembling lead cells using forced control of electrolyte circulation into storage batteries |
| US9379419B2 (en) | 2013-05-13 | 2016-06-28 | The Boeing Company | Active thermal management and thermal runaway prevention for high energy density lithium ion battery packs |
| CN111969281B (en) * | 2020-08-27 | 2022-03-29 | 界首市南都华宇电源有限公司 | Vertical rotary cooling system for lead-acid battery |
| FR3150043A1 (en) * | 2023-06-19 | 2024-12-20 | Fives | PROCESS FOR FORMING AND AGING CELLS FOR ELECTRIC BATTERIES |
Family Cites Families (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US649491A (en) * | 1899-09-30 | 1900-05-15 | Elmer A Sperry | Electric storage battery. |
| US1157028A (en) * | 1911-11-23 | 1915-10-19 | Sangamo Electric Co | Mechanism for regulating the charging rate of storage batteries. |
| US2528266A (en) * | 1947-12-13 | 1950-10-31 | Gen Motors Corp | Battery charging and forming apparatus |
| DE2414758B2 (en) * | 1974-03-27 | 1976-04-15 | Varta Batterie Ag, 3000 Hannover | ELECTROLYTE COOLING DEVICE FOR ACCUMULATOR BATTERIES CONSISTING OF MULTIPLE CELLS |
-
1977
- 1977-08-03 US US05/821,527 patent/US4117387A/en not_active Expired - Lifetime
-
1978
- 1978-07-26 CA CA308,218A patent/CA1104204A/en not_active Expired
Also Published As
| Publication number | Publication date |
|---|---|
| US4117387A (en) | 1978-09-26 |
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