阅读说明：本技术 电池中的格栅板 (Grid plate in battery ) 是由 S·库奇博特拉 N·P·饶 S·J·迪纳加尔 于 2021-04-23 设计创作，主要内容包括：公开了一种电池中的格栅板(200、300、400、500、600、700),该格栅板(200、300、400、500、600、700)包括：具有边缘(204)的矩形衬垫构件(201)以及散布在矩形衬垫构件(201)的整个表面(201a)上的多个二维形状腔室(202、203、301、302、303、401、402、501、502、503、601、602、701、702、703)的组合。膏体设置在多个二维形状腔室(202、203、301、302、303、401、402、501、502、503、601、602、701、702、703)的组合中的每个二维形状腔室中,并且连接凸耳(205)从矩形衬垫构件(201)的边缘(204)中的一个延伸以形成电池的电端子。这种具有改进的机械强度的格栅板(200、300、400、500、600、700)具有增加的参与电池中的反应的活性材料的表面面积。(Disclosed is a grid plate (200, 300, 400, 500, 600, 700) in a battery, the grid plate (200, 300, 400, 500, 600, 700) comprising: a combination of a rectangular cushion member (201) having an edge (204) and a plurality of two-dimensionally shaped chambers (202, 203, 301, 302, 303, 401, 402, 501, 502, 503, 601, 602, 701, 702, 703) dispersed over the entire surface (201a) of the rectangular cushion member (201). A paste is disposed in each two-dimensional shaped chamber of a combination of a plurality of two-dimensional shaped chambers (202, 203, 301, 302, 303, 401, 402, 501, 502, 503, 601, 602, 701, 702, 703), and a connecting lug (205) extends from one of the edges (204) of the rectangular gasket member (201) to form an electrical terminal for the battery. Such grid plates (200, 300, 400, 500, 600, 700) with improved mechanical strength have an increased surface area of active material participating in the reactions in the cell.)

1. A grid plate (200, 300, 400, 500, 600, 700) in a battery, the grid plate (200, 300, 400, 500, 600, 700) comprising:

a rectangular cushion member (201) having an edge (204);

a combination of a plurality of two-dimensional shaped chambers (202, 203, 301, 302, 303, 401, 402, 501, 502, 503, 601, 602, 701, 702, 703) dispersed over the entire surface (201a) of the rectangular cushion member (201);

a paste disposed in each two-dimensional shape chamber of the combination of the plurality of two-dimensional shape chambers (202, 203, 301, 302, 303, 401, 402, 501, 502, 503, 601, 602, 701, 702, 703); and

a connecting lug (205), the connecting lug (205) extending from one of the edges (204) of the rectangular gasket member (201) to form an electrical terminal for the battery.

2. A grid plate (200, 300, 400, 500, 600, 700) according to claim 1, wherein each two-dimensionally shaped chamber of the combination of the plurality of two-dimensionally shaped chambers (202, 203, 301, 302, 303, 401, 402, 501, 502, 503, 601, 602, 701, 702, 703) comprises a support member to hold the paste.

3. The grid plate (200, 300, 400, 500, 600, 700) of claim 1, wherein a shape of each two-dimensionally shaped chamber in the combination of the plurality of two-dimensionally shaped chambers (202, 203, 301, 302, 303, 401, 402, 501, 502, 503, 601, 602, 701, 702, 703) is one of rectangular, square, diamond, parallelogram, trapezoid, inverted trapezoid, triangle, circle, square, oval, hexagon, octagon, and irregular polygon.

4. A grid plate (200, 300, 400, 500, 600, 700) according to claim 1, wherein the plurality of two-dimensionally shaped chambers (202, 203, 301, 302, 303, 401, 402, 501, 502, 503, 601, 602, 701, 702, 703) on the surface (201a) of the rectangular cushion member (201) are equally spaced and symmetrically arranged with respect to a central axis (X-X') of the rectangular cushion member (201).

5. The grid plate (200) of claim 1, wherein the combination of the plurality of two-dimensionally shaped chambers is a combination of a plurality of square chambers (203) and a plurality of irregular polygonal chambers (202).

6. The grid plate (300) of claim 1, wherein the combination of the plurality of two-dimensionally shaped chambers is a combination of a plurality of hexagonal chambers (301), a plurality of diamond-shaped chambers (302), and a plurality of triangular chambers (303).

7. The grid plate (400) of claim 1, wherein the combination of a plurality of two-dimensionally shaped chambers is a combination of a plurality of circular chambers (401) and a plurality of elliptical chambers (402).

8. The grid plate (500) of claim 1, wherein the combination of a plurality of two-dimensionally shaped chambers is a combination of a plurality of parallelogram chambers (501), a plurality of rectangular chambers (503), and a plurality of triangular chambers (502).

9. The grid plate (600) of claim 1, wherein the combination of the plurality of two-dimensionally shaped chambers is a combination of a plurality of trapezoidal chambers (601) and a plurality of inverted trapezoidal chambers (602).

10. The grid plate (700) of claim 1, wherein the combination of a plurality of two-dimensionally shaped chambers is a combination of a plurality of parallelogram chambers (701), a plurality of triangular chambers (702), and a plurality of irregular polygon chambers (703).

11. A grid plate (200, 300, 400, 500, 600, 700) according to claim 1, wherein the material of the rectangular pad member (201) is a lead alloy.

12. The grid plate (200, 300, 400, 500, 600, 700) of claim 1, wherein the paste comprises a binder for binding particles of active material produced when the paste is formed in the grid plate (200, 300, 400, 500, 600, 700).

13. The grid plate (200, 300, 400, 500, 600, 700) of claim 1, wherein a surface area of active material produced when forming the paste in the grid plate (200, 300, 400, 500, 600, 700) is about 8000mm²To about 12000mm²Within the range of (1).

14. The grid plate (200, 300, 400, 500, 600, 700) of claim 1, wherein a capacity of a panel formed by the grid plate (200, 300, 400, 500, 600, 700) is in a range of about 3.5 ampere-hours (Ah) to about 5 Ah.

15. The grid plate (200, 300, 400, 500, 600, 700) of claim 1, wherein a percentage increase in capacity of the cells having the grid plate (200, 300, 400, 500, 600, 700) is in a range of 3% to about 35%.

16. A grid plate (200, 300, 400, 500, 600, 700) according to claim 1, wherein the rectangular gasket member (201) with the combination of the plurality of two-dimensionally shaped cavities (202, 203, 301, 302, 303, 401, 402, 501, 502, 503, 601, 602, 701, 702, 703) is cast in a mold and trimmed to coat the paste in said each two-dimensionally shaped cavity.

17. The grid plate (200, 300, 400, 500, 600, 700) of claim 1, wherein the active material in a negative battery plate formed by the grid plate (200, 300, 400, 500, 600, 700) is spongy lead, and the active material in a positive battery plate formed by the grid plate (200, 300, 400, 500, 600, 700) is lead dioxide.

Technical Field

The present subject matter relates to batteries. More specifically, the construction of grid plates in batteries is disclosed.

Background

In recent years, rechargeable energy storage devices have been widely used as energy sources for several electronic and power units. Common rechargeable energy storage devices include, for example, lead-acid batteries, nickel-cadmium batteries, nickel-metal hydride batteries, nickel-zinc batteries, and lithium rechargeable batteries. Lead-acid batteries are a mature, reliable and established technology, relatively inexpensive and simple to manufacture.

A lead-acid battery includes an acid for a battery, a plurality of negative battery plates, a plurality of positive battery plates, and a battery separator between each positive battery plate and each negative battery plate. The battery acid is a high purity solution of sulfuric acid and water. The positive electrode plates and the negative electrode plates of the battery, which have the battery separators in the middle, are alternately stacked and immersed in an acid for the battery. The battery separator separates the positive battery plate from the negative battery plate. The positive and negative battery plates are connected at the top using cast bus bars welded to the plates.

The positive battery plate and the negative battery plate form the electrodes of a single cell in a lead acid battery. The most commonly used positive and negative battery plates in lead acid batteries are pasted plates. The paste-coated polar plate comprises a grid plate, and paste is coated in air holes/holes of the grid plate. Both the positive and negative plates are constructed using a lead grid alloy on which an active material coated with lead sulfate is applied. The active material of both plates, i.e. lead sulfate, is then formed using a rectifier. The rectifier charges the positive and negative plates disposed in a tank containing sulfuric acid. During this charging process, the redox reaction converts the lead sulfate of the positive plate into lead dioxide by oxidation and converts the lead sulfate of the negative plate into spongy lead by reduction. Thus, the positive battery plates are metal grids with lead dioxide as the active material, and the negative battery plates are metal grids with spongy lead as the active material.

The composition of the grid and the surface area of the active material available to participate in the electrochemical reactions within the cell are typical factors for the mechanical strength, performance, and life of the cell.

Drawings

The detailed description is made with reference to the accompanying drawings. Like reference numerals refer to like features and components throughout the drawings.

Fig. 1A and 1B (prior art) schematically show a perspective view and a partially enlarged front view of a prior art grid plate.

Fig. 2A and 2B exemplarily show a perspective view and a partially enlarged front view of a grid plate according to a first embodiment of the present invention.

Fig. 3A and 3B exemplarily show a perspective view and a partially enlarged front view of a grid plate according to a second embodiment of the present invention.

Fig. 4A and 4B exemplarily show a perspective view and a partially enlarged front view of a grid plate according to a third embodiment of the present invention.

Fig. 5A and 5B exemplarily show a perspective view and a partially enlarged front view of a grid plate according to a fourth embodiment of the present invention.

Fig. 6A and 6B exemplarily show a perspective view and a partially enlarged front view of a grid plate according to a fifth embodiment of the present invention.

Fig. 7A and 7B exemplarily show a perspective view and a partially enlarged front view of a grid plate according to a sixth embodiment of the present invention.

Fig. 8A-8C exemplarily show graphical representations describing the performance of different embodiments of grid plates and of batteries employing different embodiments of grid plates exemplarily shown in fig. 1A and 1B-7A and 7B.

Detailed Description

Conventional grid plates (such as 100) in lead acid batteries are developed with lead bars (such as 101) connected at right angles as exemplarily shown in fig. 1A and 1B. Fig. 1A and 1B (prior art) schematically illustrate a perspective view and a partially enlarged front view of a prior art grid plate 100. The paste is applied in rectangular slots 102 between the lead bars 101. In such a grid plate 100, more electrode active materials are available for electrochemical reactions. However, the mechanical strength of the grid plate 100 is compromised. Such stacked grid plates 100 use an external compressive force and are positioned in a housing to form a battery. Grid plates with low mechanical strength (such as 100) can fail when subjected to such compressive forces and lead to battery failure.

In other designs of grid plates, a skeletal structure having air holes therein is used to contain the paste. In order to improve the performance of batteries using such grid plates, higher utilization of the active material of the grid plates is required. For higher active material utilization, higher active material availability is required. For higher availability of active material, it is desirable to increase the surface area of active material on the grid plate. In order to increase the surface area of the active material, in conventional designs, the density of pores, the size of pores, and the porosity of the active material are increased. The utilization of the active material is increased, but the strength of the skeletal structure is reduced.

There is a need for an improved grid plate design for a lead acid battery that produces a greater surface area of available active material without compromising the mechanical strength of the grid plate, thereby enabling improved and efficient performance of the lead acid battery, overcoming all of the problems disclosed above and other problems of the known art.

In the present invention, an improved grid design is presented that has a larger surface area of active material than conventional designs. In one embodiment, a grid plate in a battery is disclosed. The grid plate includes: a rectangular cushion member (backing member); a combination of a plurality of two-dimensionally shaped chambers dispersed throughout the surface of a rectangular cushion member; a paste disposed in each two-dimensional shape chamber in a combination of at least two-dimensional shape chambers; and a connecting lug extending from one of the edges of the rectangular gasket member to form an electrical terminal of the battery.

In an embodiment, each two-dimensional shape chamber in the combination of the plurality of two-dimensional shape chambers comprises a support member to hold the paste. Each two-dimensionally shaped chamber is rectangular, square, diamond, parallelogram, trapezoid, inverted trapezoid, triangle, circle, square, oval, hexagon, octagon, or irregular polygon in shape. In an embodiment, the plurality of two-dimensionally shaped chambers on the surface of the rectangular cushion member are equally spaced and symmetrically disposed about a central axis of the rectangular cushion member.

In one embodiment, the combination of the plurality of two-dimensional shaped chambers is a combination of a plurality of square shaped chambers and a plurality of irregular polygonal shaped chambers.

In one embodiment, the combination of the plurality of two-dimensional shaped chambers is a combination of a plurality of hexagonal shaped chambers, a plurality of diamond shaped chambers, and a plurality of triangular shaped chambers.

In an embodiment, the combination of the plurality of two-dimensionally shaped chambers is a combination of a plurality of circular chambers and a plurality of elliptical chambers.

In one embodiment, the combination of the plurality of two-dimensionally shaped chambers is a combination of a plurality of parallelogram chambers, a plurality of rectangular chambers, and a plurality of triangular chambers.

In one embodiment, the combination of the plurality of two-dimensional shaped chambers is a combination of a plurality of trapezoidal chambers and a plurality of inverted trapezoidal chambers.

In one embodiment, the combination of the plurality of two-dimensionally shaped chambers is a combination of a plurality of parallelogram chambers, a plurality of triangle chambers, and a plurality of irregular polygon chambers.

In one embodiment, the surface area of the active material produced when forming the paste in the grid plate is about 800mm²To about 12000mm²Within the range of (1). In another embodiment, the capacity of the panel formed from the grid plates is in a range of about 3.5 ampere-hours (Ah) to about 5 Ah. In one embodiment, the percentage increase in capacity of the cells having grid plates is in the range of 3% to about 35%.

The material of the rectangular pad member is a lead alloy. In one embodiment, the paste includes a binder for binding the particles of active material produced when the paste is formed in the grid plates. In one embodiment, the active material in the negative battery plates formed from the grid plates is spongy lead and the active material in the positive battery plates formed from the grid plates is lead dioxide. In an embodiment, a combined rectangular cushion member having a plurality of two-dimensionally shaped cavities is cast in a mold and trimmed to coat a paste in each two-dimensionally shaped cavity.

Fig. 2A and 2B exemplarily show a perspective view and a partially enlarged front view of a grid plate 200 according to a first embodiment of the present invention. As exemplarily shown, the grid plate 200 includes a rectangular cushion member 201, a combination of a plurality of chambers 202 and 203, and a connecting lug 205. The rectangular pad member 201 is made of lead alloy. In one embodiment, rectangular pad member 201 is made of a lead-antimony alloy. The connecting lug 205 extends from the edge 204 of the cushion member 201. The connecting lugs 205 extend to form the terminals of the battery employing the grid plate 200. Connecting lugs 205 extend from the upper corners of the gasket member 201 and carry the current strap to the cast buss bars (not shown) of the cells. The cast buss bar is provided with posts attached to the inter-cell and terminal connectors of the battery.

The rectangular cushion member 201 has a flat surface 201a with two-dimensionally shaped chambers 202 and 203 dispersed throughout the surface 201 a. As exemplarily shown in fig. 2A and 2B, the two-dimensional shaped chambers 202 and 203 are an irregular polygonal chamber 202 and a square chamber 203. The combination of irregular polygonal (i.e., I-shaped) chambers 202 and square chambers 203 is created on the flat surface 201a of the rectangular cushion member 201. The combination of chambers 202 and 203 are equally spaced and symmetrically disposed about the central axis X-X' of the cushion member 201. The I-shaped chambers 202 are created uniformly over the entire surface 201a of the rectangular cushion member 201, and the square chambers 203 are scattered in the gaps between the I-shaped chambers 202. The chambers 202 and 203 are through holes having a depth equal to the thickness of the cushion member 201. In an embodiment, the chambers 202 and 203 may include support members to keep the paste from falling out. The space between the I-shaped chamber 202 and the square chamber 203 is also uniformly maintained over the entire surface 201a of the cushion member 201. The paste is disposed in the I-shaped cavity 202 and the square cavity 203. The size of the I-shaped chamber 202 and the size of the square chamber 203 are also uniformly maintained over the entire surface 201a of the cushion member 201. Within the dimensions of the rectangular backing member 201, the evenly distributed I-shaped cavities 202 and square cavities 203 that hold the paste ensure the mechanical strength of the backing member 201 and also increase the amount of active material available to participate in the reaction of the cell.

Fig. 3A and 3B exemplarily show a perspective view and a partially enlarged front view of a grid plate 300 according to a second embodiment of the present invention. As exemplarily shown, the grid plate 300 further includes a rectangular cushion member 201, a combination of a plurality of chambers 301, 302, and 303, and a connecting lug 205. The configuration of the rectangular cushion member 201 and the connecting lugs is as disclosed in the detailed description of fig. 2A and 2B. The two-dimensional shaped chambers 301, 302, and 303 are hexagonal chambers 301, diamond shaped chambers 302, and triangular shaped chambers 303. The combination of hexagonal chamber 301, diamond-shaped chamber 302, and triangular chamber 303 is created on the flat surface 201a of the cushion member 201. Triangular shaped chambers 303 are created at areas near the edges (such as 204) of the cushion member 201. The combination of chambers 301, 302 and 303 are equally spaced and symmetrically disposed about the central axis X-X' of the cushion member 201. The hexagonal cavities 301 are uniformly created over the entire surface 201a of the cushion member 201, and the rhombic cavities 302 are scattered in the gaps between the hexagonal cavities 301. The gap between the hexagonal chamber 301 and the rhombic chamber 302 is also uniformly maintained over the entire surface 201a of the cushion member 201. The gaps between the hexagonal chambers 301 and the triangular chambers 303 and the gaps between the diamond-shaped chambers 302 and the triangular chambers 303 (which are disposed near the edges, such as 204, of the cushion member 201) are uniformly and equally maintained over the entire surface 201a of the cushion member 201. The dimensions of the hexagonal chamber 202, the diamond-shaped chamber 302, and the triangular chamber 303 are also uniformly maintained over the entire surface 201a of the cushion member 201. The paste is disposed in chambers 301, 302 and 303. The chambers 301, 302, and 303 are through holes having a depth equal to the thickness of the backing member 201 for holding the paste. In an embodiment, the chambers 301, 302 and 303 may comprise support members to keep the paste from falling out. Within the dimensions of the rectangular backing member 201, the uniformly distributed hexagonal cavities 202, diamond-shaped cavities 302, and triangular cavities 303 that hold the paste ensure the mechanical strength of the backing member 201 and also increase the amount of active material available to participate in the reaction of the battery.

Fig. 4A and 4B exemplarily show a perspective view and a partially enlarged front view of a grid plate 400 according to a third embodiment of the present invention. As exemplarily shown, the grid plate 400 further includes a rectangular cushion member 201, a combination of a plurality of chambers 401 and 402, and a connecting lug 205. The configuration of the rectangular cushion member 201 and the connecting lugs 205 is as disclosed in the detailed description of fig. 2A and 2B. The two-dimensional shaped chambers 401 and 402 are a circular chamber 401 and an elliptical chamber 402. The combination of circular chamber 401 and elliptical chamber 402 is created on the flat surface 201a of the cushion member 201. The combination of chambers 401 and 402 are equally spaced and symmetrically disposed about the central axis X-X' of cushion member 201. Elliptical chambers 402 are interspersed in the gaps between circular chambers 401. The gap between the elliptical chamber 402 and the circular chamber 401 is also uniformly maintained over the entire surface 201a of the cushion member 201. The dimensions of the circular chamber 401 and the elliptical chamber 402 (such as the radius and perimeter of the chambers) are uniformly maintained over the entire surface 201a of the cushion member 201. The paste is disposed in chambers 401 and 402. Chambers 401 and 402 are through holes having a depth equal to the thickness of backing member 201 for holding the paste. In an embodiment, chambers 401 and 402 may include support members to keep the paste from falling out. Within the dimensions of the rectangular backing member 201, the circular chambers 401 and elliptical chambers 402, which maintain the uniform distribution of the paste, ensure the mechanical strength of the backing member 201 and also increase the amount of active material available to participate in the reaction of the cell.

Fig. 5A and 5B exemplarily show a perspective view and a partially enlarged front view of a grid plate 500 according to a fourth embodiment of the present invention. As exemplarily shown, the grid plate 500 further includes a rectangular cushion member 201, a combination of a plurality of chambers 501, 502, and 503, and a connecting lug 205. The configuration of the rectangular cushion member 201 and the connecting lugs 205 is as disclosed in the detailed description of fig. 2A and 2B. The two-dimensional shape chambers 501, 502, and 503 are a parallelogram chamber 501, a triangle chamber 502, and a rectangular chamber 503. The combination of these chambers 501, 502 and 503 are equally spaced and symmetrically disposed about the central axis X-X' of the cushion member 201. Triangular chambers 502 are formed proximate to the edges, such as 204, of the cushion member 201. The rectangular chamber 503 is centrally located along the length of the cushion member 201 parallel to the axis X-X'. The gaps between the rectangular chambers 503 are equal, the gaps between the parallelogram chambers 501 are equal, and the gaps between the triangular chambers 502 and the parallelogram chambers 501 are equal. The dimensions of the chambers 501, 502, and 503 (such as the lengths of the sides of the chambers) are uniformly maintained over the entire surface 201a of the cushion member 201. The chambers 501, 502, and 503 are through holes having a depth equal to the thickness of the backing member 201 for holding the paste. In an embodiment, the chambers 501, 502 and 503 may comprise support members to keep the paste from falling out. The orientation and position of the parallelogram 501 is symmetrical about the axis X-X'. In one embodiment, the orientation and position of the parallelogram 501 is also symmetric about axis A-A'. Axis X-X 'and axis a-a' divide grid plate 500 into four sections. The combination of chambers 501, 502 and 503 and their positions relative to the edge, such as 204, of the grid plate 500 are duplicated in the other three sections. Within the dimensions of the rectangular backing member 201, the rectangular chambers 503, the parallelogram chambers 501 and the triangular chambers 502, which maintain the uniform distribution of the paste, ensure the mechanical strength of the backing member 201 and also increase the amount of active material available to participate in the reaction of the battery.

Fig. 6A and 6B exemplarily show a perspective view and a partially enlarged front view of a grid plate 600 according to a fifth embodiment of the present invention. As exemplarily shown, the grid plate 600 further includes a rectangular cushion member 201, a combination of a plurality of chambers 601 and 602, and a connecting lug 205. The configuration of the rectangular cushion member 201 and the connecting lugs 205 is as disclosed in the detailed description of fig. 2A and 2B. The two-dimensional shaped chambers 601 and 602 are a trapezoidal chamber 601 and an inverted trapezoidal chamber 602. The combination of these chambers 601 and 602 are equally spaced and symmetrically disposed about the central axis X-X' of the cushion member 201. Vertically alternating trapezoidal chambers 601 and inverted trapezoidal chambers 602 are formed on the entire surface 201a of the cushion member 201. The gap between chambers 601 and 602 is maintained uniformly and equally. The dimensions of the chambers 601 and 602 (such as the length of the sides of the chambers 601 and 602) are uniformly maintained over the entire surface 201a of the cushion member 201. The chambers 601 and 602 are through holes having a depth equal to the thickness of the backing member 201 for holding the paste. In an embodiment, chambers 601 and 602 may include support members to keep the paste from falling out. Within the dimensions of the rectangular backing member 201, the uniformly distributed trapezoidal chambers 601 and inverted trapezoidal chambers 602 that hold the paste ensure the mechanical strength of the backing member 201 and also increase the amount of active material available to participate in the reaction of the cell.

Fig. 7A and 7B exemplarily show a perspective view and a partially enlarged front view of a grid plate 700 according to a sixth embodiment of the present invention. As exemplarily shown, the grid plate 700 further includes a rectangular cushion member 201, a combination of a plurality of chambers 701, 702, and 703, and a connecting lug 205. The configuration of the rectangular cushion member 201 and the connecting lugs 205 is as disclosed in the detailed description of fig. 2A and 2B. The two-dimensional shaped chambers 701, 702, 703 are a parallelogram chamber 701, a triangle chamber 702, and an irregular polygon chamber 703. The combination of the parallelogram chambers 701, the triangular chambers 702, and the irregular polygon chambers 703 is created on the flat surface 201a of the cushion member 201. Triangular chambers 702 and irregular polygonal chambers 703 are created at regions near the edges, such as 204, of cushion member 201. The combination of chambers 701, 702, and 703 are equally spaced and symmetrically disposed about a central axis X-X' of the cushion member 201. The gaps between the chambers 701, 702, and 703 are uniformly maintained over the entire surface 201a of the cushion member 201. The gap between the parallelogram chambers 701 is equal over the entire surface 201a of the cushion member 201. The dimensions of the parallelogram chambers 701, the triangular chambers 702 and the irregular polygonal chambers 703 are also uniformly maintained over the entire surface 201a of the cushion member 201. The chambers 701, 702, and 703 are through holes having a depth equal to the thickness of the backing member 201 for holding the paste. In an embodiment, chambers 701, 702, and 703 may include support members to keep the paste from falling out. The uniformly distributed parallelogram cavities 701, triangular cavities 702, and irregular polygonal cavities 703 that hold the paste within the dimensions of the rectangular backing member 201 ensure the mechanical strength of the backing member 201 and also increase the amount of active material available to participate in the reaction of the cell.

In each of the grating plates 200, 300, 400, 500, 600 and 700 exemplarily shown in fig. 2A to 7A, the uniform gap between the chambers is provided with the material of the cushion member 201. The material of the pad member 201 is a lead alloy. The even distribution of the lead alloy between the chambers and around the edges ensures the mechanical strength of the grid plates 200, 300, …, 700. Casting the material of the cushion member 201 in a mold results in a grid plate 200, 300, …, 700 with a combined chamber. Molds for cavities of different shapes and cavities of different combined shapes were obtained and lead alloy was poured therein. Upon cooling, the cast, rectangular cushion member 201 having a combination of two-dimensionally shaped cavities is trimmed and a paste is applied in each cavity of the grid plates 200, 300, …, 700. The paste includes lead sulfate. Paste-coated grid plates 200, 300, …, 700 are formed to obtain battery plates with active material in each chamber. In one embodiment, the paste includes a binder for binding the particles of the active material. In an embodiment, the same design of grid plates 200, 300, …, 700 are used to form the positive and negative battery plates. The active material used in the negative plate of the battery is spongy lead, and the active material used in the positive plate of the battery is lead dioxide.

The positive and negative active materials in the chamber participate in the electrochemical reaction in the cell and are discharged during the reaction process. The depth of the cavity in the backing member 201 allows the active material to expand, and the uniform distribution of the backing member 201 about the cavity limits the stresses to which the cavity walls are subjected due to the expansion of the active material. Due to the expansion of the active material in the cavities of grid plate 201, sulfate ions from the battery acid are difficult to enter the cavities, thereby reducing the discharge rate of grid plates 200, 300, …, 700, and in turn, the discharge rate of the battery. Furthermore, the depth of the chambers and the distribution density of the chambers over the entire surface 201a of the cushion member 201 ensure that more active material is available to participate in the reaction, thereby increasing the utilization of the active material in the grid plates 200, 300, …, 700. In an embodiment, the support members in each chamber of each grid plate 200, 300, …, 700 keep the paste from falling out. In an embodiment, the support member may be a raised edge of the chamber, a protrusion within the space of the chamber, or the like.

In one embodiment, according toThe shape of the chamber, maintaining a minimum distance of 5 millimeters (mm) to 2mm between chambers 202, 203, 301, 302, 303, 401, 402, 501, 502, 503, 601, 602, 701, 702, 703 in a grid plate 200, 300, …, 700 to maintain the mechanical strength of the grid plate 200, 300, …, 700 to achieve an increased surface area of active material in chambers 202, 203, 301, 302, 303, 401, 402, 501, 502, 503, 601, 602, 701, 702, 703. The dimensions of the rectangular pad member 201 in each grid plate 200, 300, 400, 500, 600, and 700 are the same as the dimensions (i.e., length and width) of the conventional grid plate 100. The surface area of the active material produced when forming the paste in grid plates 200, 300, …, 700 is about 8000mm²To 12000mm²Within the range of (1). Suppose the surface area of the active material in the rectangular slots 102 of a conventional grid plate 100 is A mm². Relative to the surface area of active material in grid plate 100: the surface area of the active material in chambers 202 and 203 in grid plate 200 is 1.3A (1.3 times A) mm²(ii) a The surface area of the active material in chambers 301, 302, and 303 in grid plate 300 is 1.2A mm²(ii) a The surface area of the active material in chambers 401 and 402 in grid plate 400 is 1.08A mm²(ii) a The surface area of the active material in the chambers 501, 502 and 503 in the grid plate 500 is 1.04A mm²(ii) a The surface area of the active material in chambers 601 and 602 in grid plate 600 is 1.04A mm²(ii) a And the surface area of the active material in chambers 701, 702, and 703 in grid plate 700 is 1.03A mm². In one embodiment, the capacity of the panel formed by grid plates 200, 300, …, 700 is in the range of about 3.5 ampere-hours (Ah) to about 5 Ah. In an embodiment, the percentage increase in capacity of the battery having grid plates 200, 300, …, 700 is in a range of 3% to about 35%. Increase the surface area (mm)²) The volume (mm) of the active material of the battery plate is increased³) This in turn increases the mass (grams) of the active material, thereby increasing the capacity (Ah) of the cell plate. This will enhance the utilization (i.e., efficiency) of the panels in the battery.

Fig. 8A-8C exemplarily show graphical representations describing the performance of different embodiments of grid plates 100, 200, 300, 400, 500, 600, and 700 and the performance of batteries employing different embodiments of grid plates 100, 200, 300, 400, 500, 600, and 700 exemplarily shown in fig. 1A and 1B (prior art) through 7A and 7B. As exemplarily shown in fig. 8A, grid plate 200 having a combination of I-shaped cavities 202 and square cavities 203 has the largest surface area of active material, and grid plate 700 having a combination of parallelogram cavities 701, irregular polygon cavities 703, and triangular cavities 702 has the smallest surface area of active material. The grid plate 700 is densely packed with porous active material, however, the amount of active material packed in the I-shaped and square cells 202 and 203 of the grid plate 200 is higher due to the size of the cells 202 and 203 in the grid plate 200. The surface area of the active material of grid plates 300, 400, 500, 600 is in a range between the surface areas of grid plates 200 and 700. Further, the surface area of the active material in the grid plates 200, 300, …, 700 is greater than the surface area of the active material of the conventional grid plate 100.

As exemplarily shown in fig. 8B, the panel formed by the grid plate 200 having the combination of the I-shaped chamber 202 and the square chamber 203 has the largest capacity due to the largest surface area of the active material. Due to the surface area of the active material in grid plate 700, the panel formed by grid plate 700 with the combination of parallelogram chambers 701, irregular polygon chambers 703 and triangular chambers 702 has the smallest capacity. The panel formed by grid plates 300, 400, 500, 600 has a capacity in the range between the capacities of the panels formed by grid plates 200 and 700. Further, the capacity of the panel formed by grid plates 200, 300, …, 700 is greater than the capacity of the panel formed by conventional grid plate 100.

Fig. 8C exemplarily illustrates the percentage increase in the capacity of a battery employing the grid plates 200, 300, …, 700 relative to the capacity of a battery employing the conventional grid plate 100. As exemplarily shown, batteries employing grid plates 200 having a combination of I-shaped and square shaped chambers exhibit a higher percentage of capacity increase relative to batteries employing conventional grid plates 100. Further, batteries employing grid plates 200, 300, …, 700 exhibit a significant increase in battery capacity relative to batteries employing conventional grid plates 100.

Improvements and modifications may be included herein without departing from the scope of the invention.

List of reference numerals

100 conventional grating plate

101 lead rod

102 rectangular slot

200 Grating plate of the first embodiment of the invention

201 rectangular cushion member

201a surface of a rectangular cushion member

202 square chamber

203I-shaped cavity

204 rectangular cushion member edge

205 connecting lug

300 grid plate of a second embodiment of the invention

301 hexagonal chamber

302 diamond chamber

303 triangular chamber

400 grid plate of a third embodiment of the invention

401 circular chamber

402 oval chamber

500 grid plate of a fourth embodiment of the present invention

501 parallelogram chamber

502 triangular chamber

503 rectangular chamber

600 grid plate according to a fifth embodiment of the invention

601 trapezoidal chamber

602 inverted trapezoidal chamber

700 grid plate of a sixth embodiment of the present invention

701 parallelogram chamber

702 triangular chamber

703 irregular polygonal chamber