WO2000072393A1 - Battery grid and method of making - Google Patents
Battery grid and method of making Download PDFInfo
- Publication number
- WO2000072393A1 WO2000072393A1 PCT/US2000/012569 US0012569W WO0072393A1 WO 2000072393 A1 WO2000072393 A1 WO 2000072393A1 US 0012569 W US0012569 W US 0012569W WO 0072393 A1 WO0072393 A1 WO 0072393A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- grid
- pattern
- battery
- expanded metal
- metal strip
- Prior art date
Links
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
- H01M4/64—Carriers or collectors
- H01M4/70—Carriers or collectors characterised by shape or form
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
- H01M4/64—Carriers or collectors
- H01M4/70—Carriers or collectors characterised by shape or form
- H01M4/72—Grids
- H01M4/73—Grids for lead-acid accumulators, e.g. frame plates
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/02—Electrodes composed of, or comprising, active material
- H01M4/64—Carriers or collectors
- H01M4/70—Carriers or collectors characterised by shape or form
- H01M4/72—Grids
- H01M4/74—Meshes or woven material; Expanded metal
-
- 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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/10—Battery-grid making
Definitions
- the present invention relates to battery grids, and more particularly to lead-acid battery grids having a plurality of grid patterns.
- Grids for lead-acid batteries provide structural support for the active material therein, and also serve as a current collector during discharge and current distributor during recharge. Accordingly, grid designs seek to optimize the amount of active material supportable by the grid to increase the current collection and distribution characteristics of the grid while minimizing the grid weight .
- Known prior art grid designs such as shown in Figs. 1-3, include a top frame member 2 and a bottom frame member 3 joined by a plurality of metal wires 4 forming a pattern interposed between the frame members 2, 3.
- a lug 5 formed as an integral part of the top frame member 2 is interconnected with adjacent grids in a battery.
- Known grid patterns include a diamond pattern, characterized by wires defining diamond shaped grid cells, such as shown in Figs. 1 and 2, a rectangular pattern, characterized by rectangular grid cells, a radial pattern characterized by wires extending radially from a common point, such as shown in Fig. 3, and other grid patterns, such as disclosed in U.S. Patent No. 5,582,936. These particular patterns have certain advantages and disadvantages which are discussed in further detail below.
- Battery grids are commonly manufactured by processes, such as casting, expanded metal forming, and stamping. Cast battery grids are manufactured by pouring molten lead into a mold, allowing the lead to cool, and then separating the grid from the mold. The casting process is capable of producing a variety of efficient grid designs, which are limited only by the ability of mold makers to make the mold.
- the casting process is, however, an expensive process which discourages its use.
- the process requires the use of a mold coating to facilitate separation of the grid from the mold, and for an increased throughput, a plurality of expensive molds are required.
- the casting process is still a batch process which tends to have a lower productivity (i.e., produces less product over a given time period) than a grid manufacturing process which is "continuous," such as expanded metal forming.
- Grids formed from expanded metal are less expensive than molded grids because of the higher productivity of the expanded metal forming process over the casting process .
- battery grids are formed by expanding metal through a process in which a strip of cast or wrought lead material is pierced and then pulled or expanded.
- the grid mass is substantially evenly distributed across the grid, and the grid is limited in wire pattern, wire shape, and lead distribution.
- Two particularly common expanded metal forming processes, rotary expansion and reciprocated expansion have been developed.
- a lead strip is cut with a rotary cutter, the wires are extruded above and below the plane of the strip and then expanded in the horizontal directions to form a diamond grid pattern interposed between top and bottom frame members.
- wires defining a diamond grid pattern are cut and expanded in a direction perpendicular to a surface of the strip. After expansion, the strip is rotated 90°, and the grid is coined.
- the size of the diamond and the wire width are variables in either process.
- the wire angle and wire size of an expanded metal grid pattern are limited to ensure proper expansion without breaking the wires.
- the wire angle as shown in Fig. 1, is the angle A of the grid wires with respect to the top or bottom frame member 2, 3, and is typically less than 40° in an expanded metal grid.
- This wire angle limitation creates a zigzag path for current to flow through the grid.
- the zig-zag pattern increases the grid resistance because the current does not flow directly to the collecting lug, such as in a radial grid formed by casting.
- the wire size limitation also limits the taper rate to 15% or less for the rotary process, and 60% or less for the reciprocated process.
- the taper rate is the rate at which a wire width can be changed along its length. For example, with a 15% taper rate, the maximum wire width near the current collecting lug is 15% wider at the grid top than that at the grid bottom. More lead mass in the lug area would enhance the current carrying capability of the grid and reduce the grid resistance because the current generated in a plate flows toward the lug. These features are difficult to achieve using the expansion process. Thus, the conductivity of expanded metal grids tend to be lower than a similar size cast grid.
- the present invention provides a battery grid, suitable for use in a lead-acid battery, with a grid upper portion having a grid wires defining a first grid pattern, and a grid lower portion electrically connected to the grid upper portion.
- the grid lower portion has grid wires which define a second grid pattern.
- the first grid pattern is different from said second grid pattern to improve the conductivity of the grid.
- a battery grid in another aspect of the present invention, includes a top frame member. Non-expanded metal wires extending from the top frame member are electrically connected to expanded metal wires to form a multi pattern grid.
- the general objective of the present invention is to provide a battery grid with improved conductivity. This objective is accomplished by providing a grid having more than one grid pattern.
- Another objective of the present invention is to provide a battery grid which can be produced using a high productivity process. This objective is accomplished by providing a method of making a battery grid which includes a metal expanding process .
- Yet another objective of the present invention is to extend the service life of the grid. This objective is accomplished by incorporating a second grid pattern with an enlarged top frame portion and/or side frames, the service life of the grid can be extended because of reduced growth grid.
- Fig. 2 is a schematic of another prior art battery grid having a diamond pattern
- Fig. 3 is a schematic of a prior art battery grid having a radial pattern
- Fig. 4 is a schematic of a battery grid incorporating the present invention with an upper portion having a rectilinear grid pattern;
- Fig. 5 is a schematic of a battery grid incorporating the present invention with an upper portion having a radial grid pattern
- Fig. 6 is a schematic of another battery grid incorporating the present invention with an upper portion having a radial grid pattern
- Fig. 7 is a schematic of a battery grid incorporating the present invention with a rectilinear grid pattern joined to an upper portion of a battery grid having a diamond grid pattern.
- a lead- acid battery grid 10 has a top frame member 12 and an opposing bottom frame member 14.
- a lower portion 16 of the grid 10 includes a plurality of expanded metal wires 24 defining a diamond grid pattern, and extend from the bottom frame member 14 toward the top frame member 12.
- the expanded metal wires 24 are joined to an upper portion 18 of the grid 10 which include a plurality of wires 26 defining a rectilinear grid pattern extending from the top frame member 12 toward the bottom frame member 14.
- the wires 24, 26 are electrically connected to allow electrical current to flow therebetween.
- a current collection lug 28 is formed as an integral part of the top frame member 12, and, preferably, includes an enlarged conductive section, such as described in U.S. Patent No. 5,582,936, which is fully incorporated herein by reference.
- the mass of the wires 26 in the upper portion of the grid is greater than the mass of the expanded metal grid wires 24 to improve grid conductivity.
- Fig. 5 and 6 disclose additional, more preferred, embodiments of the present invention, and have like components referenced with the same reference numbers and differentiated with a "'" or » '"'.
- Desirable grid patterns provide a grid 10 with a low grid resistivity, which translates into a high efficiency, and a low grid weight.
- Resistivity of Grid, RG, and grid efficiency can be calculated by methods known in the art, such as by modeling a grid as a network of resistors.
- the grid efficiency is defined to be the geometric area of the grid divided by RG and grid weight.
- RG is defined to be the overall resistance times the geometric area of the grid.
- the grid weight is calculated by multiplying grid density with the total volume of the wire members.
- each wire is assumed to act as a resistor, and its resistance is determined by the conductivity of the grid material, length and the average cross-section of the wire.
- the potential and current distributions in a grid can be determined by application of Kirchhoff's first law to each grid node, namely, that the algebraic sum of all currents flowing into the node, i.e., the junction of wire members, must be zero. Assuming homogeneous distribution of current, the total current flow through a grid under a given voltage drop is calculated and the overall grid resistance is defined by Ohm's law. Details of this modeling technique are described in the literature (W. Tiedemann, J. Newman and F. DeSua in Power Sources 6, D.H. Collins Ed., Academic, New York, 1976) .
- Grid 1 schematically shown in Fig. 1
- Grid 2 schematically shown in Fig. 2
- Grid 3 schematically shown in Fig. 4
- Grid 4 schematically shown in Fig.
- Grid 5 is similar to Grid 3, but has 12 expanded diamond rows at the lower portion 16* and a radial pattern in the grid upper portion 18'.
- the maximum radial wire width in this grid is 0.120".
- Grid 5 is the same as Grid 4 except the maximum radial wire width being 0.150" which allows a higher taper rate (0.011" per row vs 0.009" in Grid 4) .
- Grid 6, schematically shown in Fig. 6, is the same as Grid 5 except that there are only 8 expanded diamond rows at the lower portion 16''.
- the cast grid, schematically shown on Fig. 3, is a cast grid having a radial pattern with the parameters disclosed in Table I.
- the data in Table I clearly suggests that the cast grid with a radial wire pattern has the best grid conductivity and efficiency.
- the grid efficiency of the expanded metal grids is only 50% to 60% of the cast grid.
- the conductivity and efficiency of an expanded metal grid will be higher if the diamond size is smaller (Grid 2 vs Grid 1) .
- the resistivity is lowered and the efficiency increases (Grid 3 vs Grid 1) .
- the radial wire pattern in the upper portion of the grid is better than the rectilinear pattern (Grid 4 vs Grid 3) .
- Wider radial wires near the lug improves grid conductivity and efficiency (Grid 5 vs Grid 4) . Bigger radial wire portion on the top (Grid 6 vs Grid 5) improves grid conductivity and efficiency.
- Grid 6 Comparing Grid 6 and the cast grid, even though Grid 6 is 6.7 g heavier, the efficiency of Grid 6 is 83% of the cast grid, an increase of 60% over the conventional expanded metal grid.
- the difference in grid resistivity is less than 4% which translates into a difference in cold crank voltage of about 16 mV per battery under a typical cold crank current density. This difference is within the variation among batteries and is negligible.
- a slightly heavier grid and a little difference in cold crank voltage are a small price to pay comparing to cost savings because the grids including a diamond pattern can be formed using a "continuous" process which can be produced significantly faster than the cast grids.
- One method of forming a grid incorporating the present invention includes the steps of expanding outer portions of a wide strip to form the lower portion of a grid; stamping an inner unexpanded portion of the strip with a radial wire pattern and the lug to form the upper part of the grid.
- Example II a grid incorporating the present invention is compared to prior art grids .
- the experimental results comparing the efficiencies of prior art grids to a grid incorporating the present invention are disclosed in Table II below.
- a grid 30 incorporating the present invention is formed by overlaying and then spot welding a lead strip 32 of 0.008" thickness onto a 0.030" thick expanded metal grid 34.
- the lead strip has a 2" wide pre-stamped rectilinear pattern with 0.2" frames 31 and rails 33 0.5" apart.
- the grid 30 Upon joining the lead strip 32 to the expanded metal grid 34, the grid 30 has a .038" thick upper portion 36, and .030" thick lower portion 38.
- the grid weight and RG of this grid are listed in Table II under “Test . " One can see from Table II that the conventional expanded metal grid is inferior to the cast grid equivalent in grid conductivity and efficiency.
- the difference in RG of the 0.037" strip and the cast grid would be responsible for 0.27 V difference in cold crank voltage under a typical cold crank current density.
- the test grid is 5 g lighter, the resistance is 20% lower, and efficiency is 40% higher than that of the 0.037" thick grid. With the test grid, the cold crank voltage is only 0.16 V lower and yet the grid is 8 g lighter than the cast equivalent .
- One can match the grid weight of the cast grid by attaching a second strip with a more efficient pattern, such as a radial wire pattern, and with more lead to further reduce the difference in grid resistivity and thus the cold crank voltage.
- the grid 10, shown in Fig 5 may be produced by forming a lead strip into a radial wire pattern having a lug 28, by methods known in the art, such as stamping, cutting, and the like, forming a grid upper frame member 12 and grid upper portion 18.
- the radial wire pattern strip is joined to a grid lower portion 16 formed from an expanded metal strip using methods known in the art, such as lamination, spot-welding, or the like.
- the joined strips provide a battery grid 10 having different upper and lower grid patterns to provide improved conductivity.
Abstract
Description
Claims
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU48294/00A AU4829400A (en) | 1999-05-20 | 2000-05-09 | Battery grid and method of making |
JP2000620688A JP2003529892A (en) | 1999-05-20 | 2000-05-09 | Storage battery grid and method of manufacturing the same |
BR0010786-7A BR0010786A (en) | 1999-05-20 | 2000-05-09 | Battery grid and manufacturing method |
MXPA01011816A MXPA01011816A (en) | 1999-05-20 | 2000-05-09 | Battery grid and method of making. |
EP00930482A EP1192679A1 (en) | 1999-05-20 | 2000-05-09 | Battery grid and method of making |
CA002371416A CA2371416A1 (en) | 1999-05-20 | 2000-05-09 | Battery grid and method of making |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/315,445 US6245462B1 (en) | 1999-05-20 | 1999-05-20 | Battery grid and method of making |
US09/315,445 | 1999-05-20 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2000072393A1 true WO2000072393A1 (en) | 2000-11-30 |
Family
ID=23224464
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2000/012569 WO2000072393A1 (en) | 1999-05-20 | 2000-05-09 | Battery grid and method of making |
Country Status (9)
Country | Link |
---|---|
US (1) | US6245462B1 (en) |
EP (1) | EP1192679A1 (en) |
JP (1) | JP2003529892A (en) |
CN (1) | CN1351768A (en) |
AU (1) | AU4829400A (en) |
BR (1) | BR0010786A (en) |
CA (1) | CA2371416A1 (en) |
MX (1) | MXPA01011816A (en) |
WO (1) | WO2000072393A1 (en) |
Families Citing this family (19)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6274274B1 (en) | 1999-07-09 | 2001-08-14 | Johnson Controls Technology Company | Modification of the shape/surface finish of battery grid wires to improve paste adhesion |
US6942944B2 (en) * | 2000-02-29 | 2005-09-13 | Illinois Institute Of Technology | Battery system thermal management |
US8273474B2 (en) * | 2000-02-29 | 2012-09-25 | Illinois Institute Of Technology | Battery system thermal management |
US7000297B2 (en) * | 2001-11-28 | 2006-02-21 | Wilson Greatbatch Technologies, Inc. | Electrochemical cell current collector having openings of progressively larger sizes converging at a tab |
US20060216595A1 (en) * | 2005-03-22 | 2006-09-28 | Holliday Rex W | Battery assembly having improved lug profile |
KR101317113B1 (en) | 2005-05-23 | 2013-10-11 | 존슨 컨트롤스 테크놀러지 컴퍼니 | Battery grid |
US20080131774A1 (en) * | 2005-11-08 | 2008-06-05 | Yuichi Tsuboi | Negative Electrode Current Collector for Lead Storage Battery and Lead Storage Battery Including the Same |
MX2009009385A (en) * | 2007-03-02 | 2009-10-12 | Johnson Controls Tech Co | Negative grid for battery. |
US8741487B1 (en) | 2008-08-28 | 2014-06-03 | Greatbatch Ltd. | Electrode current collector with stress-relieving mesh structure |
JP4818484B2 (en) * | 2009-10-26 | 2011-11-16 | パナソニック株式会社 | Assembled battery |
EP2543100B1 (en) | 2010-03-03 | 2014-05-07 | Johnson Controls Technology Company | Battery grids and methods for manufacturing same |
CN105428661B (en) | 2010-04-14 | 2018-06-12 | 约翰逊控制技术公司 | Accumulator and accumulator plate component |
US9748578B2 (en) | 2010-04-14 | 2017-08-29 | Johnson Controls Technology Company | Battery and battery plate assembly |
DE102010040538A1 (en) * | 2010-09-10 | 2012-03-15 | Robert Bosch Gmbh | Electrode for use in e.g. drive battery of motor car, has electrical conductive structural element provided in electrical conductive carrier film for controlling electric resistance between point at carrier film and terminal portion |
US9761883B2 (en) | 2011-11-03 | 2017-09-12 | Johnson Controls Technology Company | Battery grid with varied corrosion resistance |
IN2014CH02207A (en) | 2013-05-31 | 2015-07-03 | Gs Yuasa Int Ltd | |
DE102013111109A1 (en) | 2013-10-08 | 2015-04-09 | Johnson Controls Autobatterie Gmbh & Co. Kgaa | Grid arrangement for a plate-shaped battery electrode of an electrochemical accumulator and accumulator |
DE102013111667A1 (en) | 2013-10-23 | 2015-04-23 | Johnson Controls Autobatterie Gmbh & Co. Kgaa | Grid arrangement for a plate-shaped battery electrode and accumulator |
US10447040B2 (en) | 2014-10-15 | 2019-10-15 | Cummins Power Generation Ip, Inc. | Programmable inverter for controllable grid response |
Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
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GB1377039A (en) * | 1972-06-02 | 1974-12-11 | Rhein Westfael Elect Werk Ag | Accumulator plate |
JPS6351054A (en) * | 1986-08-20 | 1988-03-04 | Matsushita Electric Ind Co Ltd | Grid body lead storage battery |
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US1524610A (en) | 1922-07-01 | 1925-01-27 | A E Thompson | Rotary grid-molding machine |
US2079727A (en) | 1935-12-14 | 1937-05-11 | Wirtz John | Automatic battery grid casting machine |
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FR2388417A1 (en) | 1977-04-18 | 1978-11-17 | Baroclem Sa | PROCESS AND MACHINE FOR THE MANUFACTURE OF ELECTRODE SUPPORT GRIDS FOR ELECTRIC ACCUMULATORS |
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US4151331A (en) | 1978-02-23 | 1979-04-24 | The Gates Rubber Company | Offset perforated lead-acid battery grid |
US4196757A (en) | 1978-02-23 | 1980-04-08 | The Gates Rubber Company | Offset perforated lead-acid battery grid method |
US4221032A (en) * | 1979-04-04 | 1980-09-09 | Cousino Impact Corporation | Method of forming expanded metal grids particularly lead grids for storage battery plates |
US4345452A (en) | 1979-08-15 | 1982-08-24 | General Battery Corporation | Cam shaft operated punch press for expanding lead alloy battery grid material |
DE3015725C2 (en) | 1980-04-24 | 1982-07-22 | Accumulatorenwerk Hoppecke Carl Zoellner & Sohn, 5000 Köln | Machine for casting and punching grids for lead-acid batteries |
GB2090170B (en) * | 1980-07-18 | 1984-02-01 | Shin Kobe Electric Machinery | A process of producing plate grids for a lead acid storage battery and plate grids produced thereby |
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US5582936A (en) | 1994-11-16 | 1996-12-10 | Globe-Union, Inc. | Lead-acid batteries with optimum current collection at grid lugs |
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-
1999
- 1999-05-20 US US09/315,445 patent/US6245462B1/en not_active Expired - Fee Related
-
2000
- 2000-05-09 AU AU48294/00A patent/AU4829400A/en not_active Abandoned
- 2000-05-09 EP EP00930482A patent/EP1192679A1/en not_active Withdrawn
- 2000-05-09 CA CA002371416A patent/CA2371416A1/en not_active Abandoned
- 2000-05-09 JP JP2000620688A patent/JP2003529892A/en active Pending
- 2000-05-09 WO PCT/US2000/012569 patent/WO2000072393A1/en not_active Application Discontinuation
- 2000-05-09 CN CN00807816A patent/CN1351768A/en active Pending
- 2000-05-09 BR BR0010786-7A patent/BR0010786A/en not_active Application Discontinuation
- 2000-05-09 MX MXPA01011816A patent/MXPA01011816A/en not_active Application Discontinuation
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GB1377039A (en) * | 1972-06-02 | 1974-12-11 | Rhein Westfael Elect Werk Ag | Accumulator plate |
JPS6351054A (en) * | 1986-08-20 | 1988-03-04 | Matsushita Electric Ind Co Ltd | Grid body lead storage battery |
Non-Patent Citations (1)
Title |
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PATENT ABSTRACTS OF JAPAN vol. 012, no. 268 (E - 638) 27 July 1988 (1988-07-27) * |
Also Published As
Publication number | Publication date |
---|---|
CN1351768A (en) | 2002-05-29 |
CA2371416A1 (en) | 2000-11-30 |
US6245462B1 (en) | 2001-06-12 |
AU4829400A (en) | 2000-12-12 |
BR0010786A (en) | 2002-06-04 |
MXPA01011816A (en) | 2003-09-04 |
JP2003529892A (en) | 2003-10-07 |
EP1192679A1 (en) | 2002-04-03 |
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