WO2014021891A1 - Batterie - Google Patents

Batterie Download PDF

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Publication number
WO2014021891A1
WO2014021891A1 PCT/US2012/049260 US2012049260W WO2014021891A1 WO 2014021891 A1 WO2014021891 A1 WO 2014021891A1 US 2012049260 W US2012049260 W US 2012049260W WO 2014021891 A1 WO2014021891 A1 WO 2014021891A1
Authority
WO
WIPO (PCT)
Prior art keywords
container
battery according
battery
plate elements
cell
Prior art date
Application number
PCT/US2012/049260
Other languages
English (en)
Inventor
Darwin D. DELANS
Original Assignee
Onepoint Solutions, Llc
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Onepoint Solutions, Llc filed Critical Onepoint Solutions, Llc
Priority to PCT/US2012/049260 priority Critical patent/WO2014021891A1/fr
Publication of WO2014021891A1 publication Critical patent/WO2014021891A1/fr

Links

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
    • H01M10/16—Suspending or supporting electrodes or groups of electrodes in the case
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/218—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material
    • H01M50/22—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material of the casings or racks
    • H01M50/227—Organic material
    • 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
    • H01M10/121—Valve regulated lead acid batteries [VRLA]
    • 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
    • H01M10/126—Small-sized flat cells or batteries for portable equipment
    • 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
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/528—Fixed electrical connections, i.e. not intended for disconnection
    • H01M50/529—Intercell connections through partitions, e.g. in a battery casing
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/204—Racks, modules or packs for multiple batteries or multiple cells
    • H01M50/207—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape
    • H01M50/209—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape adapted for prismatic or rectangular cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/271—Lids or covers for the racks or secondary casings
    • H01M50/273—Lids or covers for the racks or secondary casings characterised by the material
    • H01M50/278—Organic material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/502—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing
    • H01M50/505—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing comprising a single busbar
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/543—Terminals
    • H01M50/547—Terminals characterised by the disposition of the terminals on the cells
    • H01M50/548—Terminals characterised by the disposition of the terminals on the cells on opposite sides of the cell
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/543—Terminals
    • H01M50/552—Terminals characterised by their shape
    • H01M50/553—Terminals adapted for prismatic, pouch or rectangular cells
    • 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

Definitions

  • U.S. Patent No. 4,983,475 was issued on January 8, 1991, to Delans and is an earlier development by the present inventor in the field of batteries .
  • U.S. Patent No. 5,512,388 was issued on April 30, 1996, to Pulley et al . and provides a teaching of cell assembly having an open side for inserting active elements. See the language in the abstract and the description of this feature at col. 2, starting at line 49. See also the description at col. 3, starting at line 38.
  • U.S. Patent No. 1,664,126 was issued on March 27, 1928, to Meisekothen and teaches an integral side cover for a battery container at E of Fig. 4 and on page 1, starting at line 95.
  • U.S. Patent No. 6,551,741 was issued on April 22, 2003, to Hamada et al . and shows a small chemical battery best seen in the top view of Fig. IB.
  • the present invention relates to a battery with a container which has its cover on the side instead of the top. This arrangement allows plate elements to be inserted face first through the side instead of edge first through the top. This configuration also has its terminal posts mounted onto the container before the plate elements are inserted .
  • tabs are arranged on opposite sides of alternating plates instead of on the top edge.
  • the head space within the container will be filled with a liquid-absorbing material which will act as an electrolyte reservoir for sealed valve-regulated lead acid (VRLA) batteries with an Absorbed Glass Mat (AGM) or other chemical couples.
  • VRLA valve-regulated lead acid
  • AGM Absorbed Glass Mat
  • the electrolyte is acid.
  • An additional feature of the present invention is that a separate cover, when sealed to the container, acts as a compressor to ensure the plate elements are touching each other, thus providing maximum performance and life. This is particularly true for sealed VRLA AGM batteries.
  • the present invention relates to a battery with a specially configured container wherein either single or multiple plate elements are housed and compressed.
  • the container is arranged such that insertion of each plate element is made face first through an open front side which is subsequently sealed by a separate cover affixed thereto .
  • a container with only a single plate element may have its two external terminal posts heat sealed at opposite ends of the container. Each plate element is attached to the positive and negative posts by spot welding or other conventional means . After assembly, the separate cover is sealed to the open side of the container, thus simultaneously compressing the single plate element to a predetermined compressive pressure.
  • the container depth has been sized so that the desired amount of compression is applied to the plate elements when the separate cover is attached to the open side, thus increasing their effectiveness.
  • the separate cover may include suitably located vent and filler holes.
  • a plurality of cells may be combined into a multi-cell embodiment. Standard manufacturing techniques are used to connect individual cells together or to connect end cells with external terminal posts and a transitional strap. The cells of a multi-celled version are arranged vertically, i.e. plate elements are edge to edge instead of face to face, so that the battery footprint is minimized. Thus, the resulting battery is tall and thin.
  • Fig. 1 is a broken-away, top perspective view of a prior art battery container.
  • Fig. 1A is a perspective view of plural prior art plate elements, each with a positive tab on a top edge of a positive plate and a negative tab on a top edge of a negative plate.
  • FIG. 2 is an exploded, side perspective view of a first embodiment of a single-cell battery container of the present invention.
  • FIG. 2A is a perspective view of plural plate elements of the present invention with a positive tab on a left vertical side of a positive plate and a negative tab on a right vertical side of a negative plate.
  • FIG. 3 is an exploded, side perspective view of a first embodiment of a multi-cell battery container of the present invention.
  • Fig. 4 is a cross-sectional side view of a pre-cast post for the first embodiment of the present invention.
  • Fig. 5 is a cut-away, top, perspective, cross-sectional view of a conventional post, top cover and container used in a prior art battery.
  • Fig. 6 is a broken-away, cross-sectional side view of the pre-cast post attached to the first embodiment of the multi-cell container of Fig. 3 of the present invention.
  • Fig. 7A is a top plan view of a plastic transitional strap with an encapsulated metallic electrical conductor in the first embodiment of the battery container of the present invention.
  • the metallic electrical conductor inside the transitional strap is shown in dashed lines.
  • Fig. 7B is a broken-away, cross-sectional side view of the transitional strap attached to the first embodiment of the multi-cell container of Fig. 3 of the present invention.
  • Fig. 7C is a broken-away, cross-sectional end view of the transitional strap at the left side and the pre-cast post at the right side of the first embodiment of the multi-cell container of Fig. 3 of the present invention.
  • FIG. 8 is an exploded, side perspective view of the first embodiment of the single-cell container of Fig. 2 with the plural plate elements of Fig. 2A and the posts of Fig. 4 installed.
  • FIG. 9A is an exploded, side perspective view of the first embodiment of the multi-cell container of Fig. 3 with the transitional strap of Fig. 7A installed on the right side and the pre-cast posts of Fig. 4 installed on the left side of the container.
  • the transitional strap hidden on the right outer side of the container is shown in dashed lines .
  • FIG. 9B is an exploded, side perspective view of a wider multi-cell container of the present invention with the posts and the transitional strap installed .
  • Fig. 10A is a cross-sectional, top plan view of a second embodiment of a single-cell container of the present invention.
  • Fig. 10B is a cross-sectional, side view of the second embodiment of the single-cell container of Fig. 10A of the present invention.
  • Fig. IOC is a cross-sectional, top plan view of four single cells connected together with a transitional bus bar at the far right side.
  • Fig. 10D is a top plan view of a negative plate, with a full-width tab at its left side, for insertion into the second embodiment of the container of the present invention.
  • FIG. 10E is a top plan view of a positive plate, with a full-width tab at its right side, for insertion into the second embodiment of the container of the present invention.
  • FIG. 10F is a cross-sectional side view of a second embodiment of the multi-cell container of the present invention.
  • Fig. 11A is a closed, side perspective view of the second embodiment of either the single-cell container of Fig. 10A or the multi-cell container of Fig. 10F of the present invention.
  • FIG. 11B is a broken-away, top perspective view of plural plate elements with two posts in a prior art battery.
  • Fig. 12 is an open side view of the first embodiment of the multi-cell container of Figs. 3 and 9A with a plurality of plate elements installed, the transitional strap of Fig. 7A at the right side and two pre-cast posts of Fig. 4 at the left side.
  • Fig. 13A is a closed, side perspective view of the first embodiment of the multi-cell container of Fig. 9A with the transitional strap of Fig. 7A on the right outer side.
  • Fig. 13B is a broken-away, closed, left end perspective view of the first embodiment of the multi-cell container of Fig. 13A with the pre-cast posts of Fig. 4 installed.
  • FIG. 1 As shown in Fig. 1, most prior art single and multi-cellular, sealed, valve-regulated, lead acid (VRLA) batteries use a container 20 that has four vertical sides 22, only two of which are shown, a top cover (not shown) , and a bottom (also not shown) .
  • the typical multi-cellular container 20 has a plurality of plate elements 21 shown in Fig. 1A.
  • the plural plate elements 21 have multiple positive plates 24, each with a tab 34, and multiple negative plates 24, each also with a tab 36.
  • a thin glass mat (not shown) is placed between adjacent plate elements 21.
  • the plural plate elements 21 are then compressed and installed in Fig. 1.
  • the top of the container 20 is open to allow vertical insertion of the plural plate elements 21 of Fig.
  • Each plate element 21 is assembled and put under compression outside the container 20. Plural plate elements 21 are then inserted bottom edge first through the open top of the container 20 into a cell 32. Inter-cell connections 28 bridge adjacent pluralities of plate elements 21 by overhanging a top edge 30 of a cell- dividing wall 23. Each individual plate 24 has either one positive tab 34 or one negative tab 36, as seen in Fig. 1A. Each inter-cell connection 28 connects one plurality of plate elements 21 in one cell 32 with a plurality of plate elements 21 in the adjacent cell 32. An external positive post 38 is connected to its adjacent plurality of plate elements 21 (not shown) and an external negative post 40 is connected to its adjacent plurality of plate elements 21 (also not shown) .
  • each cell 32 is filled with electrolyte through filler holes (not shown) in the top cover (also not shown) .
  • FIG. 2 shows a first embodiment of a container 200 for a single-cell battery of the present invention.
  • the container 200 has end walls 210 in which holes 220 are punched for terminal ends of posts (not shown) to protrude through.
  • a separate cover 230 has a filler vent hole 240 punched through its center.
  • the holes 220 and 240 may be formed by other methods, e.g. drilling.
  • the cover 230 is aligned parallel to a back wall 260.
  • Fig. 2A shows plural plate elements 221 having multiple positive plates 324, each with a tab 334 at the left side. Multiple negative plates 324, each with a tab 336 at the right side, are inter- leafed with the multiple positive plates 324.
  • the plural plate elements 221 are inserted in the direction of an arrow 226 into the container 200 of Fig. 2 and compressively sealed inside by the cover 230.
  • FIG. 3 shows a first embodiment of a multi- cell container 300 for the present invention.
  • the container 300 has end walls 310 in which holes 320 are punched or formed in other ways for terminal ends of posts (not shown) to protrude through one end wall 310 and also for transitional straps (not shown) to be attached to the opposite end wall 310.
  • Internal middle cells 322 have holes 325 for plate elements (not shown) to be connected with other plate elements (not shown) in adjacent end cells 328.
  • a wall 319 separates adjacent end cells 328 and adjacent middle cells 322 horizontally while walls 326 separate vertically adjacent opposite end cells 328 from the middle cells 322.
  • a separate cover 330 is used to seal the open side of the container 300 and has plural filler vent holes 340 punched through or formed in other conventional ways for access to each of the middle cells 322 and the end cells 328.
  • each single cell and multi-cell container of the present invention has holes 220 and 320, respectively, for at least two external pre-cast posts 400, as shown in Fig. 4.
  • Each post 400 is either heat sealed or glued to the end walls 210 of the container 200 or one end wall 310 of the container 300, shown respectively in Figs. 2 and 3.
  • the pre-cast post 400 of Fig. 4 is composed of a lead terminal 410, a copper insert 420 through the center of the lead terminal 410, and a plastic collar 430 which partially surrounds the lead terminal 410.
  • Fig. 5 shows a prior art lead post 500 protruding through a plastic cover 530 which has been heat sealed to a top edge of the container 20 of Fig. 1.
  • a gas-fired torch is used either to melt a lead stick (not shown) or to melt part of the lead post 500 to a lead insert 510 of the cover 530 in order to fuse the post 500 to the insert 510.
  • FIG. 6 shows internal details of the multi- cell container 300 of Fig. 3.
  • the container 300 there are two plate elements 221 in two separate cells 328 and 322 divided by the wall 326 having the hole 325 punched through or formed in other ways for inter-connection of the plate elements 221.
  • Multiple positive plates (not shown) each with a tab 334 at one side, and multiple interleaved negative plates (also not shown) , each with a tab 336 at an opposite side, constitute plural plate elements 221.
  • the pre-cast post of Fig. 4 is heat sealed or glued in an area 440 of the end wall 310 of the container 300 in Fig. 6 over the hole 320.
  • the copper insert 420 of the pre-cast post 400 is then spot welded in a mating area, indicated by an arrow 321, of a riser 329 which is affixed to a strap 327.
  • the fusion by spot welding provides an electrical circuit between the inside and the outside of the container 300.
  • Minimal heat is required to fuse the copper insert 420 to the riser 329.
  • a key benefit is that a spot welder uses considerably less sustained heat then presently used gas-fired torches which require sustained heat to fuse the components together. Less heat minimizes the chance of distorting the plastic collar 430 partially surrounding the lead terminal 410 of the post 400. This benefit reduces the possibility of a fluid leak around the mating area 440 between the collar 430 and the end wall 310.
  • Head space 323 in the cells 328 and 322 is filled with an electrolyte- absorbing material and serves as a reservoir which will add life to sealed batteries using VRLA and AGM technology.
  • This reservoir feeds acid to a glass mat (not shown) packed between adjacent plate elements 221 inside the container 300.
  • Fig. 7A shows a top view of a transitional strap 700 which includes a metallic electric conductor 710, shown in phantom lines, and a plastic casing 720.
  • Plastic plugs 730 provide access for spot welding the metallic electric conductor 710 inside the plastic casing 720 to the plate element (not shown) underneath.
  • Fig. 7B shows a side view of the transitional strap 700 heat sealed or glued in the area 440 at the right side of the multi-cell container 300 of Fig. 3.
  • the container 300 of Fig. 7B there are two plate elements 221 in two separate but adjacent end cells 328 divided by the wall 319.
  • Multiple positive plates (not shown) each with the tab 334 at one end, and multiple negative plates (also not shown) , each with the tab 336 protruding from the opposite end, constitute plural plate elements 221.
  • Each cell 328 has its own hole 320 through the end wall 310.
  • the hole 320 allows a bottom end 316 of a protuberance 318 of the conductor 710 to be spot-welded to the riser 329.
  • the plate strap 327 connects the riser 329 to the plate element 221 in each cell 328.
  • Heat sealing the mating area 440 and generating minimal heat by the spot welder preserves the integrity of the bond between the metallic conductor 710 and its plastic casing 720 and also minimizes the chance of electrolyte leaking through the holes 320.
  • the head space 323 in the two adjacent cells 328 is filled with electrolyte-absorbing material to serve as a reservoir to feed acid to the glass mats (not shown) packed between adjacent plate elements 221 inside the container 300.
  • Fig. 7C is a cross-sectional end view of the transitional strap 700 of Fig. 7A at the left side and the pre-cast post 400 of Fig. 4 at the right side with the plate elements 221 inside the multi- cell container 300.
  • the pre-cast post 400 at the right side is heat sealed or glued in the mating area 440 to the end wall 310 of the container 300.
  • Fig. 8 is similar to Fig. 2 in that Fig. 8 shows the single-cell container 200 with the end walls 210 having the holes 220 filled by the pre- cast posts 400 of Fig. 4.
  • One post 400 is positive and the other is negative.
  • Plural plate elements 221 have multiple positive plates 324, each with the tab 334 on the left side and multiple negative plates 324, each with the tab 336 on the right side.
  • the plural plate elements 221 are inserted in the direction of the arrow 226 into the container 200 until they rest against the back wall 260.
  • the separate cover 230 compresses the plural plate elements 221 when the cover 230 is sealed over the open side of the container 200.
  • the separate cover 230 has the filler vent hole 240 used to fill the container 200 with acid. After the filling is completed, a vent plug 250 is installed.
  • Fig. 9A is similar to Fig. 3 in that Fig. 9A shows the multi-cell container 300 with the left end wall 310 having the holes 320 filled by the pre-cast posts 400 of Fig. 4. Again, one post is positive and the other is negative. At the right end wall 310 in Fig. 9A, the holes 320 are filled by the protuberances 318 of the transitional strap 700 shown in phantom lines.
  • the separate cover 330 has its vent plugs 350 installed in the holes 340.
  • Fig. 9B shows a multi-cell container 600 wider than the container 300 of Fig. 9A. If the wider container 600 is employed, then the pre-cast posts 400, the transitional strap 700 and the holes 320 are shifted so that they are aligned along a dashed center line 302. The separate cover 330 provides compression to this wider battery when installed into the open side of the container 600.
  • Fig. 10A is a top plan view of a second embodiment of a single-cell container 800 with a negative plate 825 and a positive plate (not shown) behind the negative plate 825.
  • Fig. 10A also shows top views of an external positive connector 834, an external negative connector 836, clamping bars 842, center bars 844, bolts 852 and pins 854 to be discussed in regard to Fig. 10B.
  • Fig. 10B is a side view of the container 800 cut away to show interleaved negative plates 825 and positive plates 824 which are secured at both ends by the clamping bars 842 that are tied by the pins 854 through the tabs 834E and 836D to the center bars 844 which in turn are tied to internal posts 846 of T bars 848.
  • the external connector 836 of the left T bar 848 serves as the external negative connection to the external positive connection of an adjacent cell (not shown) .
  • the external connector 834 of the right T bar 848 serves as the external positive connection to the external negative connection of another adjacent cell (also not shown) .
  • the T bar 848 is one metallic piece and is molded into end walls 810 when the container 800 is formed.
  • Fig. IOC shows four single-cell batteries, each in their individual containers 800.
  • a transitional strap or bus bar 870 connects the external positive connector 834 of the top cell with the external negative connector 836 of the bottom cell.
  • the external positive connector 834 of the top left cell overlaps on top of the negative connector 836 (not shown) of the top right cell and are secured together by the bolts 852.
  • the external positive connector 834 of the bottom right cell overlaps on top of the external negative connector 836 (not shown) of the bottom left cell .
  • Fig. 10D shows a top plan view of the negative plate 825, seen in the side view of Fig. 10B, with its negative tab 836D at its left side.
  • Fig. 10E shows a top plan view of the positive plate 824, seen in the side view of Fig. 10B, with its positive tab 834E at its right side.
  • Fig. 10F shows a side view of two cells, of the type shown in Fig. 10B, in a single elongated housing 900 having a common wall 910 into which a T bar 948 is molded. Otherwise, each cell is the same as the single cell seen in Fig. 10B. Note that an external positive connector 934 on the right side is slightly higher in height than an external negative connector 936 on the left side so that a plurality of double-cell containers 900 may be coupled directly together.
  • Fig. 11A is a closed, side perspective view of either the single-cell container 800 of Fig. 10A or the multi-cell container 900 of Fig. 10F.
  • the external positive connectors 834 or 934 protrude from the right side while the external negative connectors 836 or 936 protrude from the left side.
  • the separate cover 330 seals the plate elements (not shown) inside the container 800 or 900.
  • FIG. 11B shows the prior art container 20 of a lithium ion battery with the plates 24 installed therein. Because the positive post 38 and the negative post 40 are on the same side, the entire width of the plates 24 cannot be connected to their posts, thus creating a higher resistance path for electrical current.
  • the second embodiment of this invention uses the entire width of each plate as an exit path for the current, thus reducing internal resistance and improving operating efficiency. These advantages result in a reduction of the size and cost of the battery .
  • Fig. 12 is an open side view of the multi- cell container 300 of Figs. 3 and 9A in which each cell in Fig. 12 contains a plurality of plate elements 221. However, in Fig. 12, only one plate is seen in each cell because the remaining plates are hidden from view behind the top plate.
  • each plate element 221 has the positive plate (not shown) with its tab 334 and the negative plate (also not shown) with its tab 336 on its opposite side.
  • two pre-cast posts 400 of Fig. 4 protrude from the end walls 310.
  • one post 400 is positive and the other post 400 is negative.
  • the transitional strap 700 of Fig. 7A connects two adjacent cells together.
  • Fig. 13A shows the container 300 closed by the separate cover 330 of Figs. 3 and 9A.
  • the vent plugs 350 are installed in the filler vent holes 340.
  • the transitional strap 700 is shown at the right end of the container 300.
  • FIG. 13B shows a perspective view of the left end of Figs. 12 and 13A.
  • the container 300 with the separate cover 330 sealed over the front side, has at its left end two pre-cast posts 400 of Fig. 4.
  • one post 400 is positive and the other post 400 is negative.
  • the plural plate elements 221 in Fig. 8 are identical to the plural plate elements 221 in Fig. 6 and are accessible to connect the positive tab 334 in the one cell 328 to the negative tab 336 in the adjacent cell 322, as seen at the bottom of Fig. 6, or to the external pre-cast post 400, as seen at the top of Fig. 6, by using an electric spot welder.
  • a sealed VRLA battery having fiber glass mats inside requires compression to hold the acid-filled mats against the plate elements 221 inside the containers 200, 300 and 600. With higher compression, there is less chance of the mats and the plate elements 221 being out of contact with each other. Compression is applied by the separate covers 230 and 330 only after each plate element 221 is installed in its cell 322 or 328.
  • the head space 323 at both ends of Figs. 6 and 7B can be filled with glass fibers and partially saturated with electrolyte to act as a reservoir. Over time and after much use, a VRLA battery dries out between the prior art plate elements 21 of Fig. 1. However, the electrolyte reservoir provided in the head space 323 of Figs. 6 and 7B will replace the dried-out electrolyte, thus improving the life and the reliability of the battery.
  • a negative strap (not shown), which connects all negative plate tabs 34 together for the plural plate elements 21, can corrode. This phenomenon is called negative plate strap corrosion. It occurs when the negative tabs 34 are not sufficiently wetted by the electrolyte.
  • the separate cover 330 for the open side instead of the top cover (not shown) on the prior art container 20 of Fig. 1, allows adjacent plate elements 221 to be positioned edge to edge rather than face to face.
  • This edge-to-edge arrangement makes it possible to connect together multiple plate elements 221 that are assembled with the plates 324 having their positive tabs 334 and their negative tabs 336 pointing in opposite directions.
  • Fig. 8 shows plural plate elements 221 having multiple positive plates 324, each with the tab 334 and multiple negative plates 324, each with the tab 336 on opposite sides inside the single-cell container 200 while Fig.
  • FIG. 12 shows plural plate elements 221 having the multiple plates (not shown) with their positive tabs 334 and their negative tabs 336 on opposite sides thereof inside the multi-cell container 300 .
  • the plate elements 21 are shown having plural plates 24 with their positive tabs 34 and their negative tabs 36 positioned so that the tabs 34 and 36 are not opposing each other.
  • the plate elements 221 with the opposing tabs 334 and 336 of the plates can be connected internally in the multi-cell containers 300 and 600 .
  • Opposing tabs 334 and 336 dis- tribute the current load evenly over the surface area of each plate 324 , thus reducing effective grid resistance and promoting better usage of the active material inside the battery.
  • This benefit results in more power output and longer battery life.
  • Another advantage is that the battery develops more power per pound of lead used and has an improved cycle life.
  • the battery of the present invention weighs less than the standard prior art battery of Fig. 1 with the same chemistry and capacity.
  • the plate elements 221 of the present invention are not inserted into the containers 200 , 300 and 600 under compression, as is the case with the plate elements 21 in the container 20 of the prior art battery shown in Fig. 1 .
  • greater compression can be applied on the plate elements 221 inside the present invention when the separate cover 230 or 330 is sealed over the open side of the container 200, 300 or 600, respectively.
  • the containers 200, 300 and 600 have their plate elements 221 arranged with the faces experiencing air temperature through radiation, thus reducing heat buildup within each cell 322 and 328. This feature adds to improved battery life.
  • the container 300 may have any number of cells, even though only six are shown, three positioned end to end in a top line and the same number of cells in a bottom line. This container 300 allows access to the two tabs 334 and 336 on opposite sides of each pair of the plates 324 (not shown) so that connections may be spot welded between adjacent cells.
  • the standard open top of the prior art battery of Fig. 1 has only the top edge exposed for spot welding. Therefore, the tabs 34 and 36 must be on the top edge of their respective plates 24 so that the tabs 34 and 36 are accessible for spot welding to the tabs 34 and 36 of adjacent plates 24.
  • the thin configuration of the battery container of the present invention can be used advantageously in a motor vehicle, such as an automobile, because it requires less space under the hood, thus providing more room for other equipment.
  • the present invention uses vertical space.
  • the thinness of the containers 200, 300 and 600 opens up the possibility that the battery may be mounted in a location other than the engine compartment under the hood. Other possible locations are in the trunk, inside a door panel or even under a seat.
  • the configuration of the present invention is less obtrusive than the prior art battery of Fig. 1.
  • multiple battery containers of the present invention may be stacked one on top of another in order to minimize space for use in trucks, marine vessels, military vehicles, telecommunication systems and any other system which requires an uninterruptible power supply.
  • a spot welder may easily make all electrical connections, for example, as seen in Fig. 6, including the post 400 to the plate element 221 inside the cell 328 and, as seen in Fig. 7B, including the transitional strap 700 to the plate elements 221 inside the cells 328.
  • Spot welding provides a fast and high quality weld in comparison to the slower weld of more variable quality around the prior art post 500 of Fig. 5. This advantage occurs because a spot welder takes much less time by using concentrated heat to effect a proper connection in Fig. 6 between the post 400 and the plate strap 327 via the riser 329.
  • the burning process used in making the prior art battery of Fig. 1 takes more time and more heat, thus resulting in welds of inconsistent quality and the possibility of distorting the plastic cover 530 of Fig. 5.
  • Another benefit of the present invention is that the plural plate elements 221 can be easily placed in the container 200, 300 or 600 before compression is applied by the separate cover 230 or 330, respectively.
  • the separate cover 230 or 330 When sealed over the open side of the container 200, 300 or 600, the separate cover 230 or 330, respectively, compresses evenly across the surface of any fiber glass mats layered between the faces of the plate elements 221. In effect, the separate cover 230 or 330 acts as a compression device as it is sealed over the open sides of the container 200, 300 or 600, respectively.
  • the back wall 260 of the container 200 seen in Fig. 8 is parallel to the separate cover 230, thus aiding in providing even compression across the surface of the plural plate elements 221.
  • both sides of the end wall 210 or 310 of Figs. 6 and 8, respectively, are accessible to the spot welder for connecting the external precast post 400 and the transitional strap 700 to the internal plate element 221.
  • the spot welder uses minimal heat to effect the seal therebetween, thus reducing the possibility of distorting the plastic collar 430, best seen in Fig. 6, around the post 400 and the plastic casing 720, best seen in Fig. 7B, of the transitional strap 700.
  • the posts 38 and 40 are initially cast onto the adjacent plate elements 21 and then each plate element 21, with the post 38 or 40 attached thereto, is inserted bottom edge (not shown) first into the container 20.
  • the top cover (not shown) is then placed over the posts 38 and 40 and heat sealed to the container 20.
  • the cover 530 has the lead insert 510 molded into the cover 530.
  • a gas-fed torch is used to fuse the post 500 to the lead insert 510 or a lead stick (not shown) is melted around the post 500 and the lead insert 510 to create a seal.
  • significantly more heat is required to make this seal around the prior art post of Fig. 5.
  • this extra heat increases the likelihood of separating the plastic cover 530 from the lead insert 510.
  • the battery of the present invention has a longer life than the prior art battery of Fig. 1 because of several factors: uniform usage of the active material of the plate elements 221 inside the container 200, 300 or 600, thus resulting in less stress on the plate elements 221; less stratification of the electrolyte; less sulfation; better heat dissipation; uniform compression of the plate elements 221; and an improved seal around the post 400 due to the use of the spot welder.
  • the thin configuration of the containers 200, 300 and 600 allows more horizontal space for other components under the hood of an automobile.
  • this configuration also allows the battery to be mounted in locations other than the engine compartment under the hood.
  • Such other locations include but are not limited to the trunk, the door panel and under the floor.
  • this configuration of the present invention enables stacking one battery container 300 or 600 on top of the other in a small and compact manner.
  • this configuration minimizes the space required for multiple battery applications, such as for trucks, marine vessels, military vehicles, telecommunication systems and any other system requiring an uninterruptible power supply backup system.
  • locating the positive tabs 334 and the negative tabs 336 of the multiple alternating plates 24 of the plate elements 221 180 degrees apart improves performance of the battery of the present invention over the prior art battery of Fig. 1. Also, higher cranking amps per pound of lead results for car batteries. More power is also provided over time for other applications, such as backup units for telecommunication and computer systems.
  • the smaller and lightweight battery of the present invention is also less costly to manufacture. Moreover, it saves purchasers valuable floor space. Furthermore, valuable extra space under the hood of an automobile is provided for car manufacturers. As a result of the usage of the lightweight battery of the present invention, a slight improvement in gas mileage occurs for automobiles .
  • opposing tabs 334 and 336 distribute the current load evenly over the surface area of the plates 324 of the plate elements 221, thus reducing effective grid resistance and promoting better use of the active material inside the containers 200, 300 and 600. This arrangement results in more output power and longer battery life.
  • each cell 322 and 328 has at least two side walls experiencing the ambient air temperature, thus enhancing cooling which extends battery life.
  • the back wall 260 is parallel to the separate cover 230 when the latter is sealed to the open side of the container 200, thus providing for uniform compression which yields better battery performance. This uniform compression also occurs for the containers 300 and 600 shown in Figs. 9A and 9B, respectively.
  • Electrolyte may also be added quickly to the single cell of the container 200 in Fig. 2 through the filler vent hole 240, which is then closed by the plug 250 of Fig. 8.
  • the multi-cell container 300 is only one cell thick. Even compression is applied simultaneously to each plate element 221 when the separate cover 330 is attached to the open side of the multi-cell container 300. The same even compression is applied to the plural plate elements 221 in Fig. 8 when the separate cover 230 is attached to the open side of the single-cell container 200.
  • the plural plate elements 221 are placed face first, as best seen in Figs. 8 and 12, instead of edge first, as is the case with the plate elements 21 of the prior art container 20 of Fig. 1. This face first placement of the plate elements 221 occurs in both the single-cell container 200 of Fig. 8, the multi-cell container 300 of Fig. 12, and the wide container 600 of Fig. 9B.
  • the spot welder connects the external pre-cast post 400, which has been heat sealed or glued in the mating area 440 to the end wall 310 of the container 300, to the strap 327 to the plate element 221 via the riser 329 prior to installing the separate cover 330 of Fig. 3 over the open side of the container 300.
  • the end result of the present invention is that more power in terms of watts over time is obtained out of both the single-cell battery of Figs. 2 and 8, the multi-cell battery of Figs. 6, 7B, 9A, and 12, and the wide battery of Fig. 9B.
  • the electrolyte is suspended in the absorbing glass mat (AGM) .
  • AGM absorbing glass mat
  • a fiber glass mat is placed between adjacent plate elements 21.
  • the mat is filled with acid to a saturation point of 92% to 98%, thus leaving only 2% to 8% open space in the mat.
  • This open space allows oxygen gas, generated by electrolysis of water in the electrolyte solution at the positive plate during recharge, to migrate towards and to recombine with hydrogen ions on the negative plate, thus reforming the water in the electrolyte.
  • the electrolytic solution is held between the plate elements 21 by capillary attraction to the glass mat.
  • Capillary attraction is a known physical phenomenon defined as the "force that results from greater adhesion of a liquid to a solid surface than internal cohesion of the liquid itself and that causes the liquid to be raised against a vertical surface", according to the American Heritage Dictionary at page 199 (Houghton Mifflin Co. 1970) .
  • the battery container 300 has head space 323 that is free and open in front and back of the cells 322 and 328.
  • the head space 323 is filled with an electrolyte- absorbing material such as, but not necessarily limited to, fiber glass filaments. Enough electrolyte is already incorporated into the absorbent glass mats between the plate elements 221, plus any other material in the head space 323, to the saturation point of 92% to 98%.
  • Drying out is a very common cause of failure in sealed VRLA AGM batteries. This drying out process can be caused by several careless and abusive actions, such as overcharging the battery, using nontemperature-compensated chargers, exposing the battery to very high ambient temperatures, and mounting the battery in nonair-conditioned cabinets . All of these actions increase the electrolysis of the water in the electrolytic solution. The gases generated, if expelled from the battery before they recombine into water, result in the permanent loss of the water and eventually a drying out which results in a failure of the battery.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Connection Of Batteries Or Terminals (AREA)

Abstract

La présente invention a trait à une batterie qui est équipée d'un récipient, de la largeur d'une cellule, qui est doté d'une partie supérieure, d'une partie inférieure, de deux parois d'extrémité, d'une paroi latérale fermée et d'un côté ouvert. De multiples éléments de plaque sont formés en connectant ensemble une pluralité de plaques positives, chacune d'entre elles étant dotée d'une languette sur un côté, et une pluralité de plaques négatives, chacune d'entre elles étant dotée d'une languette sur un côté opposé. Les multiples éléments de plaque sont insérés par la face et sont positionnés au moyen du côté ouvert dans le récipient. Un couvercle séparé assure l'étanchéité du côté ouvert du récipient et comprimer les multiples éléments de plaque dans le récipient. La batterie peut être une batterie de type au lithium-ion, de type au plomb-acide, à régulation par soupape ou sans entretien.
PCT/US2012/049260 2012-08-02 2012-08-02 Batterie WO2014021891A1 (fr)

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Application Number Priority Date Filing Date Title
PCT/US2012/049260 WO2014021891A1 (fr) 2012-08-02 2012-08-02 Batterie

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PCT/US2012/049260 WO2014021891A1 (fr) 2012-08-02 2012-08-02 Batterie

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WO2014021891A1 true WO2014021891A1 (fr) 2014-02-06

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2016186707A1 (fr) * 2015-05-18 2016-11-24 Johnson Controls Technology Company Module de batterie au lithium-ion comprenant des éléments de réception de dilatation et procédé de fabrication comprenant un thermoscellage de couvercle à base de boîtier

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2678960A (en) * 1953-03-03 1954-05-18 C & D Batteries Inc Battery terminal post mounting
US4603093A (en) * 1983-02-03 1986-07-29 California Institute Of Technology Lead-acid battery
US7208247B2 (en) * 2003-06-27 2007-04-24 Motorola Inc. Interconnect for rechargeable computer batteries
US20100143795A1 (en) * 2006-10-02 2010-06-10 Kenneth Michael Partington Battery and a Process for Making a Battery
US20110212354A1 (en) * 2007-06-29 2011-09-01 Toyota Jidosha Kabushiki Kaisha Power storage apparatus
US20120070714A1 (en) * 2010-09-22 2012-03-22 Chambers Jeffrey K Batteries, separators, components, and compositions with heavy metal removal capability and related methods
US20120070727A1 (en) * 2010-09-21 2012-03-22 Hollingsworth & Vose Company Glass compositions with leachable metal oxides and ions

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2678960A (en) * 1953-03-03 1954-05-18 C & D Batteries Inc Battery terminal post mounting
US4603093A (en) * 1983-02-03 1986-07-29 California Institute Of Technology Lead-acid battery
US7208247B2 (en) * 2003-06-27 2007-04-24 Motorola Inc. Interconnect for rechargeable computer batteries
US20100143795A1 (en) * 2006-10-02 2010-06-10 Kenneth Michael Partington Battery and a Process for Making a Battery
US20110212354A1 (en) * 2007-06-29 2011-09-01 Toyota Jidosha Kabushiki Kaisha Power storage apparatus
US20120070727A1 (en) * 2010-09-21 2012-03-22 Hollingsworth & Vose Company Glass compositions with leachable metal oxides and ions
US20120070714A1 (en) * 2010-09-22 2012-03-22 Chambers Jeffrey K Batteries, separators, components, and compositions with heavy metal removal capability and related methods

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2016186707A1 (fr) * 2015-05-18 2016-11-24 Johnson Controls Technology Company Module de batterie au lithium-ion comprenant des éléments de réception de dilatation et procédé de fabrication comprenant un thermoscellage de couvercle à base de boîtier

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