TECHNICAL FIELD
The present disclosure relates to the field of lead acid batteries. Particularly, but not
exclusively, the present disclosure relates to battery plates and battery plate rods of lead
acid batteries. Further, embodiments of the present disclosure disclose battery rods having
rectangular cross-section to provide the battery plate with substantially increased surface
area and consequently enhance the performance of the lead acid battery.
BACKGROUND
[002] Conventionally, lead acid batteries are employed as a rechargeable power source in
various environments such as, but not limited to, lighting and ignition of vehicle in
domestic/industrial applications, automobiles such as electric vehicles, micro hybrid
vehicles, heavy duty trucks, excavators and the like.
[003] Typically, a battery cell consists of two lead plates, a positive plate covered with a
paste of lead oxide and a negative made of sponge lead, with an insulating material
(separator) in between. The size of the battery plates and amount of electrolyte determines
the amount of charge lead acid batteries can store. It is well known in the art of
manufacturing lead acid batteries to use slotted or otherwise perforated plastic or hard
rubber tubes as active material retainers in tubular type plates. Plates employing perforated
or slotted plastic or hard rubber tubes to contain active material have been successfully
used in lead acid batteries, particularly those of the tubular plate type. However, there are
several disadvantages inherent in using plastic or hard rubber retainers. One such
disadvantage is that the plastic or rubber retainers occupy space within the lead acid battery.
However, the plastic or rubber retainers do not contribute towards increasing the electrical
capacity of the battery. In fact, the plastic or rubber retainers actually increase internal
battery electrical resistance. Furthermore, the operation of slotting or perforating the
retainers consumes time, labour and oftentimes requires expensive equipments.
[004] The existing battery plates comprising plurality of rods having tubular or cylindrical
shape. The plurality of rods are manufactured in high pressure die casting machines. The
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tubular rod structure of battery plates has some disadvantages such as the battery plates are
thick in construction thus limiting number of battery plates per battery, due to tubular
structure of battery plates charge acceptance is low, more active material is required to
cover the outer surface of tubular battery plates and many others. Further, the tubular
battery plates are manufactured through multi shot high pressure die casting machine which
is equipped with high precision requirements of lead filling in multi cavity tubes (moulds).
The casting process of multi-tube battery plates is carried through moulds have high cost.
Further, to manufacture multi-tube battery plates skilled manpower is required and the cost
of manufacturing battery plates using high pressure die casting machine is also high.
[005] The battery plates are manufactured using lead as a casting material. The existing
battery plates are manufactured in high pressure die casting machines as shown in Fig. 5.
The manufacturing of multi-tube batteries in high pressure die casting machine results in
generation of lead waste due to malfunctioning of machines and handling requirements.
The lead waste gets deposited in soil or mixed in air leading towards a severe impact on
environment.
[006] The present disclosure is directed to overcome one or more limitations stated above
or any other limitations associated with the prior art.
SUMMARY OF THE DISCLOSURE
[007] One or more shortcomings of conventional systems have been overcome, and
additional advantages are provided through the assembly of lead acid battery as claimed in
the present disclosure. Additional features and advantages are realized through the
techniques of the present disclosure. Other embodiments and aspects of the disclosure are
described in detail herein and are considered a part of the claimed disclosure.
[008] The limitations of the prior arts are addressed to a great extent by improving the
assembly of lead acid batteries. The lead acid battery assembly comprising plurality of
battery rods having flat type structure. The battery rods disclosed in the present disclosure
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is having a rectangular cross section. The flat type structure of battery rods is having many
advantages over existing battery rods such as the flat-type battery rods have maximum
thickness of 3.5 mm which results in assembling of a greater number of battery rods per
battery to give more power output, rectangular cross-section of battery rods causes
effective contact of active material which results in high charge acceptance and
manufacturing of the rods is cost effective. The active material from which the battery rods
are manufactured is lead, which is used as an active material to store charge effectively.
The battery rods as disclosed herein have lesser chance of sulfation during discharge of
electric current. The rectangular cross-section of rods results in increase in surface area and
consequently enhance the performance of the lead acid battery.
[009] A lead acid battery assembly to supply electric current comprising a plurality of rods
having rectangular cross-section. A first top bar having an inner surface and an outer
surface, wherein the inner surface is provided with plurality of protrusions. The protrusions
are adapted to receive the rods in gap between the adjacent protrusions. A second top bar
comprising plurality of holes, wherein the holes are adapted to receive the protrusions of
the first top bar.
[010] Additional features and advantages are realized through the techniques of the present
disclosure. Other embodiments and aspects of the disclosure are described in detail herein
and are considered as a part of the claimed disclosure.
[011] In one non-limiting embodiment of the present disclosure, the plurality of rods
comprises a head portion and a tail portion.
[012] In an embodiment of the present disclosure, cross-section of the head portion is
greater than cross-section of the tail portion.
[013] In an embodiment of the present disclosure, the tail portion is having uniform
rectangular cross-section.
[014] In an embodiment of the present disclosure, the plurality of rods are fixed with the
first top bar by welding.
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[015] In an embodiment of the present disclosure, each rod is manufactured separately
through pressure die casting process.
[016] In an embodiment of the present disclosure, the first top bar and the second top bar
are manufactured separately through pressure die casting process.
[017] In an embodiment of the present disclosure, the plurality of rods is having maximum
thickness of 3.5 mm.
[018] In an embodiment of the present disclosure, the plurality of protrusions extend
laterally from the inner surface of the first top bar.
[019] In an embodiment of the present disclosure, the rectangular cross-section of the rods
provides increase in surface area to improve conductivity of active material.
[020] It is to be understood that the aspects and embodiments of the disclosure described
above may be used in any combination with each other. Several of the aspects and
embodiments may be combined together to form a further embodiment of the disclosure.
[021] The foregoing summary is illustrative only and is not intended to be in any way
limiting. In addition to the illustrative aspects and features described above, further aspects
and features will become apparent by reference to the drawings and the following detailed
description.
BRIEF DESCRIPTION OF DRAWINGS
[022] The novel features and characteristic of the disclosure are set forth in the appended
claims. The disclosure itself, however, as well as a mode of use, further objectives and
advantages thereof, will best be understood by reference to the following detailed
description of an embodiment when read in conjunction with reference to the
accompanying drawings wherein like reference numerals represent like elements and in
which:
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[023] Fig. 1 illustrates a perspective view of an assembled battery plate in accordance with
the present disclosure;
[024] Fig. 2 illustrates a perspective view of flat type battery rod from Fig. 1, according to
an embodiment of the present disclosure;
[025] Fig. 3 illustrates a perspective view of first top bar and second top bar from Fig. 1,
according to an embodiment of the present disclosure;
[026] Fig. 4 illustrates an exploded view from Fig. 1, in accordance with the present
disclosure.
[027] Fig. 5 illustrates a perspective view a battery plate employed in existing batteries as
disclosed in the prior art.
[028] The figures depict embodiments of the disclosure for purposes of illustration only.
One skilled in the art will readily recognize from the following description that alternative
embodiments of the structures and methods illustrated herein may be employed without
departing from the objective of the disclosure described herein
DETAILED DESCRIPTION
[029] While the embodiments in the disclosure are subject to various modifications and
alternative forms, specific embodiment thereof has been shown by way of example in the
figures and will be described below. It should be understood, however, that it is not
intended to limit the disclosure to the particular forms disclosed, but on the contrary, the
disclosure is to cover all modifications, equivalents, and alternative falling within the scope
of the disclosure
[030] It is to be noted that a person skilled in the art would be motivated from the present
disclosure and modify construction and method of manufacturing the battery plate.
However, such modifications should be construed within the scope of the disclosure.
Accordingly, the drawings show only those specific details that are pertinent to understand
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the embodiments of the present disclosure, so as not to obscure the disclosure with details
that will be readily apparent to those of ordinary skill in the art having benefit of the
description herein.
[031] The terms “comprises”, “comprising”, or any other variations thereof used in the
disclosure, are intended to cover a non-exclusive inclusion, such that a system and method
that comprises a list of components does not include only those components but may
include other components not expressly listed or inherent to such system, method, or
assembly, or device. In other words, one or more elements in a system or device proceeded
by “comprises… a” does not, without more constraints, preclude the existence of other
elements or additional elements in the system or device.
[032] Accordingly, the present disclosure relates to a lead acid battery assembly to supply
electric current and construction of battery plates. The lead acid battery assembly
comprising plurality of rods and method of manufacturing the battery plates. The battery
plates are used as electrodes that contain lead to store charge. The battery plates are
immersed in an electrolyte solution within each battery cell and after giving a forming
charge to each battery plate electrochemical reactions take place in which lead in positive
battery plate gets oxidized and lead in negative electric plate gets reduced. The number of
battery plates in each cell of a battery determine the battery electrical performance.
[033] The battery plate disclosed in the present disclosure comprises plurality of rods, a
first top bar and a second top bar. The plurality of rods comprises a head portion and a tail
portion, wherein the tail portion has a uniform rectangular cross-section. The cross-section
of the head portion is greater than that of the tail portion. The head portion of the rod is
fixed with the first top bar by welding or any other connecting means. The first top bar
comprises an inner surface and an outer surface, wherein the inner surface is provided with
plurality of protrusions. The protrusions are spaced apart in such a manner that they provide
a gap between them, wherein the gap is adapted to receive the rod. The second top bar has
plurality of holes which are adapted to receive the protrusions of the first top bar.
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[034] The plurality of rods are manufactured through pressure die casting using lead as an
active material. The active material referred hereinafter in the present disclosure relates to
lead material which is used as an electrode coating material which takes part in
electrochemical reaction. The first top bar and the second top bar are manufactured
separately in pressure die casting machine. The separate manufacturing of top bars results
in lesser wastage of material and increases modularity of the top bars. Similarly, each rod
is manufactured separately in pressure die casting machine which results in formation of
highly dense grain structure of lead material. The increased density of grain structure
provides high corrosion resistance and ultimately improving service life of battery plate/
battery.
[035] The following paragraphs describe the present disclosure with reference to FIGs.1
to 4. In the figures, the same element or elements which have similar functions are indicated
by the same reference signs.
[036] Fig. 1 shows the assembled view of the battery plate (10). The battery plate (10)
comprises plurality of rods (1), a first top bar (2) and a second top bar (3). The plurality of
rods (1) having rectangular cross-section increases surface area of active material to get in
contact with electrolyte. The active material is defined as the material from which the
plurality of rods (1) are manufactured. The plurality of rods (1) as disclosed in the present
disclosure are manufactured from lead which is an active material. The number of rods (1)
present in each battery plate (10) determine performance of battery. The plurality of rods
(1) are fixed with the first top bar (2), the second top bar (3) is then secured with the first
top bar (1) to form the assembled structure of the battery plate (10) as shown in Fig. 1.
[037] In an embodiment of the present disclosure, the rod (1) comprises of a head portion
(11) and a tail portion (12). Referring to Fig. 2, the head portion (11) is having cross-section
greater than cross-section of the tail portion (12). The head portion (11) is fixed with the
first top bar (2) by welding or any other connecting means. The tail portion (12) have a
uniform rectangular cross-section. The rectangular cross-section of the rod (1) increases
the surface area of contact of rod (1) with active material resulting in higher efficiency of
current discharge. The efficiency of current discharge is based on the amount of active
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material coming in contact with the tail portion (12) of the rod (1). The plurality of rods (1)
have thickness of at most 3.5 mm.
[038] In an embodiment of the present disclosure, the first top bar (2) comprises an inner
surface (21) and an outer surface (22). Referring to Fig. 3 and 4 the inner surface (21) is
provided with plurality of protrusions (20), wherein the protrusions (20) are equally spaced
from each other to form gaps (23) which are adapted to receive the rods (1). The plurality
of protrusions (20) extend laterally from the inner surface (21) of the first top bar (2). The
gaps (23) are formed between the adjacent protrusions (20) of the first top bar (2). The
second top bar (3) comprises plurality of holes (30), wherein the holes are adapted to
receive the protrusions (20) present on the inner surface (21) of the first top bar (2).
[039] In another embodiment of present disclosure, a method of assembling the plurality
of rods (1) with the first top bar (2) and the second top bar (3) is disclosed. The plurality
of rods (1) are placed in the gaps (23) between the plurality of protrusions (20) of the first
top bar (2), in such a way that the head portion (11) of the rods (1) is aligned with upper
surface of the plurality of protrusions (20). The plurality of protrusions (20) are then
received in the plurality of holes (30) present in the second top bar (3) to assemble the first
top bar (2) with the second top bar (3). The plurality of rods (1) are then permanently fixed
with the first top bar (2) and the second top bar (3) by welding.
[040] In an embodiment of the present disclosure, the manufacturing of the components is
disclosed. The first top bar and the second top bar are manufactured separately in a pressure
die casting machine. The plurality of rods having rectangular cross-section are
manufactured through pressure die casting process in which one rod is manufactured at a
time. The manufacturing of one rod at a time gives a high density of grain structure of lead,
wherein lead is used as an active material for manufacturing the plurality of rods. The high
density of grain structure provides very high corrosion resistance and ultimately improving
service life of battery plate/battery (not shown in figures). The wastage of material during
filling of mould of single rod having rectangular cross-section is also reduced. Further, the
manufacturing of one rod at a time increases the efficiency of the rod to conduct electric
current due to formation of uniform layer of active material. The method of manufacturing
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each component separately in pressure die casting machine do not require skilled
manpower and is also highly economical.
[041] The plurality of battery rods have a flat configuration and are spaced by a predefined
distance with respect to each other. The flat type configuration of the rods is defined as the
rods having rectangular cross-section which provides an increased in surface area thereby
providing an improved active material conductivity. Consequently, this provides the
improved lead acid battery with enhanced power and energy densities. In one embodiment,
there may be formed one or more fins on each of the plurality of flat rods.
[042] Some of the advantages of the present disclosure are it provides improved lead-acid
batteries having enhanced battery plate corrosion resistance and reduction in the vertical
plate growth in the positive plates. The battery plates comprising plurality of rods having
rectangular cross-section. The battery plates are having maximum thickness of 3.5 mm
which results in assembling of greater number of battery rods per battery to give more
power output. The rectangular cross-section of rods causes increase in surface area
resulting in effective contact of active material with the electrolyte. The increased area of
contact of active material results in high charge acceptance and ultimately the battery
performance is improved to a greater extent.
[043] The battery rods having rectangular cross-section are manufactured in pressure die
casting machine wherein the pressure required to produce single battery rod is 10 times
lesser than the pressure required to produce existing battery rods in high pressure die
casting machine. The battery rods are manufactured individually i.e. one at a time in
pressure die casting machine. Further, during manufacturing of the battery rods using
pressure die casting machine do not require any skilled manpower or special maintenance.
Thus, the method of manufacturing the battery rods is also economical as it reduces the
production cost by at least 60% as compared to the conventional method of manufacturing
the same. The wastage of lead used in manufacturing of the rods is also reduced to a greater
extend by manufacturing one rod at a time. Due to reduction in wastage of lead makes the
method for manufacturing the rods environment friendly.
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[044] Lower ratio (i.e., positive active material/grid wire surface area) in comparison to
conventional lead acid batteries allows substantially improved electrical performance to be
obtained.
[045] The present disclosure provides a battery plate wherein the active material is retained
on the plates during plate fabrication and battery assembly. The optimized battery plate
design of the present disclosure provides the ability to tailor the plate design and thereby
obtain a cost-benefit relationship achieving substantial, significant costs savings due to
reduced plate material costs. The improved lead acid battery of the present disclosure
provides the ability to achieve higher power and energy densities per unit positive and
negative plate weight that are significant.
Equivalents:
[046] With respect to the use of substantially any plural and/or singular terms herein, those
having skill in the art can translate from the plural to the singular and/or from the singular
to the plural as is appropriate to the context and/or application. The various singular/plural
permutations may be expressly set forth herein for sake of clarity.
[047] It will be understood by those within the art that, in general, terms used herein, and
especially in the appended claims (e.g., bodies of the appended claims) are generally
intended as “open” terms (e.g., the term “including” should be interpreted as “including
but not limited to,” the term “having” should be interpreted as “having at least,” the term
“includes” should be interpreted as “includes but is not limited to,” etc.). It will be further
understood by those within the art that if a specific number of an introduced claim recitation
is intended, such an intent will be explicitly recited in the claim, and in the absence of such
recitation no such intent is present. For example, as an aid to understanding, the following
appended claims may contain usage of the introductory phrases “at least one” and “one or
more” to introduce claim recitations. However, the use of such phrases should not be
construed to imply that the introduction of a claim recitation by the indefinite articles “a”
or “an” limits any particular claim containing such introduced claim recitation to inventions
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containing only one such recitation, even when the same claim includes the introductory
phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a”
and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the
same holds true for the use of definite articles used to introduce claim recitations. In
addition, even if a specific number of an introduced claim recitation is explicitly recited,
those skilled in the art will recognize that such recitation should typically be interpreted to
mean at least the recited number (e.g., the bare recitation of “two recitations,” without
other modifiers, typically means at least two recitations, or two or more
recitations). Furthermore, in those instances where a convention analogous to “at least one
of A, B, and C, etc.” is used, in general such a construction is intended in the sense one
having skill in the art would understand the convention (e.g., “a system having at least one
of A, B, and C” would include but not be limited to systems that have A alone, B alone, C
alone, A and B together, A and C together, B and C together, and/or A, B, and C together,
etc.). In those instances, where a convention analogous to “at least one of A, B, or C, etc.”
is used, in general such a construction is intended in the sense one having skill in the art
would understand the convention (e.g., “a system having at least one of A, B, or C” would
include but not be limited to systems that have A alone, B alone, C alone, A and B together,
A and C together, B and C together, and/or A, B, and C together, etc.). It will be further
understood by those within the art that virtually any disjunctive word and/or phrase
presenting two or more alternative terms, whether in the description, claims, or drawings,
should be understood to contemplate the possibilities of including one of the terms, either
of the terms, or both terms. For example, the phrase “A or B” will be understood to include
the possibilities of “A” or “B” or “A and B.” While various aspects and embodiments have
been disclosed herein, other aspects and embodiments will be apparent to those skilled in
the art. The various aspects and embodiments disclosed herein are for purposes of
illustration and are not intended to be limiting, with the true scope and spirit being indicated
by the following claims.
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List of Reference Numerals:
Battery plate 10
Rods 1
First top bar 2
Second top bar 3
Head portion of rod 11
Tail portion of the rod 12
Inner surface of first top bar 21
Outer surface of first top bar 22
Protrusions 20
Gap 23
Holes 30

We Claim:
1. A lead acid battery assembly to supply electric current comprising:
a plurality of rods (1) having rectangular cross-section;
a first top bar (2) comprising an inner surface (21) and an outer surface (22);
the inner surface (21) is provided with plurality of protrusions (20), which are
adapted to receive the rods (1) in gaps (23) between the adjacent protrusions (20);
a second top bar (3) comprising plurality of holes (30), wherein the holes (30) are
adapted to receive the protrusions (20) of the first top bar (2).
2. The lead acid battery assembly as claimed in claim 1, wherein the plurality of rods (1)
comprising a head portion (11) and a tail portion (12).
3. The lead acid battery assembly as claimed in claim 1, wherein cross-section of the head
portion (11) is greater than cross-section of the tail portion (12).
4. The lead acid battery assembly as claimed in claim 1, wherein the tail portion (12) is
having uniform rectangular cross-section.
5. The lead acid battery assembly as claimed in claim 1, wherein the plurality of rods (1)
are fixed with the first top bar (2) by welding.
6. The lead acid battery assembly as claimed in claim 1, wherein each rod (1) is
manufactured separately through pressure die casting process.
7. The lead acid battery assembly as claimed in claim 1, wherein the first top bar (2) and
the second top bar (3) are manufactured separately through pressure die casting process.
8. The lead acid battery assembly as claimed in claim 1, the plurality of rods (1) is having
maximum thickness of 3.5 mm.
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9. The lead acid battery assembly as claimed in claim 1, wherein the plurality of
protrusions (20) extend laterally from the inner surface (21) of the first top bar (2).
10. The lead acid battery assembly as claimed in claim 1, wherein the rectangular crosssection of the rods (1) provides increase in surface area to improve conductivity of
active material.