FIELD OF THE INVENTION

The present invention relates to a low cost Lead Acid Storage Battery with advancement in bottom bar. More particularly, the present invention is directed to bottom bar of the lead acid battery with self locking arrangement which would importantly allow reducing the length of very costly lead spine that is unnecessarily consumed without any required lead functionalities of the portion of the lead spine which get inserted into the bottom bar just to achieve a locking of the spine with respect to the bottom bar, thereby saving the cost of lead material that is saved without affecting the battery performance and output.

BACKGROUND OF THE INVENTION
The lead–acid battery is a rechargeable battery having a very low energy-to-weight ratio and a low energy-to-volume ratio, and ability to supply high surge currents, means that the cells have a relatively large power-to-weight ratio. These features, along with their low cost, make them attractive for use in motor vehicles to provide the high current required by automobile starter motorsor backup power for inverters.

A conventional Lead Acid Battery as shown in accompanying Figure 1(a), basically includes Plates, Separator, and Electrolyte, Hard Plastic with a hard rubber case. In the batteries, the plates are of two types, positive and negative. The positive one consists of Lead dioxide and negative one consists of Sponge Lead. These two plates are separated using a separator which is an insulating material. This total construction is kept in a hard plastic case with an electrolyte. The electrolyte is usually water and sulfuric acid. The hard plastic case is one cell.

The lead-acid battery is the most commonly used type of storage battery and is well-known for its application in automobiles. The battery is made up of several cells, each of which consists of lead plates immersed in an electrolyte of dilute sulfuric acid. A single cell store typically 2.1V. Due to this reason, A 12V lead acid battery consists of 6 cells and provide 6 x 2.1V/Cell = 12.6V typically. The charge storage capacity of a lead acid batter is expressed in Amp-Hour.

The chemical process involved in Lead Acid battery’s charging and discharging condition is well known to the person in the related art. The diluted sulfuric acid H2SO4 molecules break into two parts when the acid dissolves. It will create positive ions 2H+ and negative ions SO4-. As we told before, two electrodes are connected as plates, Anode and Cathode. Anode catches the negative ions and cathode attracts the positive ions. This bonding in Anode and SO4- and Cathode with 2H+ interchange electrons and which is further react with the H2O or with the water (Diluted sulfuric acid, Sulfuric Acid + Water).
The battery has two states of chemical reaction, Charging and Discharging.

Lead-Acid Battery Discharging:

When the battery is discharging (i.e., supplying a current), atoms from the spongy lead on the negative plates combine with sulfate molecules to form lead sulfate and hydrogen. As always, electrons are left behind on the negative plates so that they maintain a negative potential. The hydrogen released in the electrolyte combines with the lead peroxide on the positive plate, removing electrons from the plate to keep a positive potential. The combination of lead peroxide and hydrogen at the positive electrode produces water and lead sulfate. The water dilutes the electrolyte, making it a weaker solution, and the lead sulfate that is produced at both positive and negative plates tends to ?ll the pores of the active material. Both these effects (dilution of the electrolyte and formation of lead sulfate) render each cell less ef?cient and eventually cause the battery output voltage to fall.

Lead-Acid Battery Recharging:

When the battery is recharged, a current (conventional direction) is made to ?ow into the positive electrode of each cell. This current causes the lead sulfate at the negative electrode to recombine with hydrogen ions, thus re-forming sulfuric acid in the electrolyte and Spongy lead on the negative plates. Also, the lead sulfate on the positive electrodes recombines with water to regenerate lead peroxide on the positive plates and sulfuric acid in the electrolyte. The final result of charging the cell is that the electrodes are re-formed and the electrolyte is returned to its original strength. With proper care a lead—acid battery is capable of sustaining a great many cycles of charge and discharge, giving satisfactory service for several years.

As this battery container mainly contains sulfuric acid hence the materials used for making a lead acid battery container must be resistant to sulfuric acid. The material container should also be free from those impurities which are deleterious to the sulfuric acid. Especially iron and manganese are intolerable.

At inside bottom floor of lead acid battery container, there are usually ribs/bottom bars to hold the positive lead acid battery plates and another two ribs to hold the negative plates. The ribs or prisms serve as supports for the plates and at the same time protect them from short-circuits that would otherwise occur as a result of fall of the active material from the plates on to the bottom of the container. The container is the most basic part of construction of lead acid battery.

Regular type Bottom Bars usually involved to support the lead spine have a conventional locking arrangement wherein a portion of the lead spine facing the bottom bar is essentially required to be inserted into a corresponding slotted portion of the bottom bar to effect the secured male-female locking of the lead spine with respect to the bottom bar. Thus, in the existing types of bottom bars there is a continuing necessity of providing certain required added length of the expensive lead spine to get into the slot of the bottom bar to lock it securely without any lead based battery functionality. Hence is the same called for wastage of cost extensive Lead.

There has been thus a need to develop a new configuration of bottom bar with locking arrangement which would save consumption of costly and scarce lead material and thus favour achieving lower cost of storage battery.

OBJECTS OF THE INVENTION

The basic object of the present invention is directed to advancements in bottom bar configuration for Lead Acid Storage Batterywhich would on one hand favour the desired locking of the lead spine with respect to the bottom bar and yet on the other hand avoid the unwanted use of extra length of the costly lead spine simply to achieve the inter-locking with the bottom bar slot thereby saving of expensive lead without affecting battery performance and output.

A further object of the present invention is directed to provide a lead acid storage battery wherein the advancement in the bottom bar is adapted to be user friendly and cost effective to achieve a leak proof locking of the lead spine with respect to the bottom bar and the usual tubular insulating cover for the lead spine.

A still further object of the present invention is directed to provide a lead acid storage battery with advancement in bottom bar for mounting of lead spines favouring saving lead which is costly and presently in crisis for inadequate supply and thus reducing cost of the battery also.

A still further object of the present invention is directed to provide advancement in Bottom bar for Lead Acid Storage Battery to facilitate customers/battery manufacturers to enable them to reduce high cost lead in their raw materials usage and in turn provide for advancements in lead acid battery by way of a cost effective and user friendly locking arrangement of spine with the bottom bar with ease of production.

SUMMARY OF THE INVENTION

Thus according to the basic aspect of the present invention there is provided a bottom bar unit of a plate assembly of a lead acid storage battery comprising:

plurality of upwardly projecting locking members for cooperating with respective insulating tubular cover housing respective lead spine;

each said upwardly projecting locking member having an extended top for inserting into the bottom open end of respective tubular cover and enable resting the adjacent end face of a corresponding lead spine and having atleast a radially outwardly extending resilient member adapted to lock against the inner wall of respective insulating tubular cover surrounding the respective said lead spine to effect an external locking of the bottom bar with respect to the said tubular cover surrounding the respective lead spine free of any required male -female inter locking of the spine end with the bottom bar .

According to another aspect there is provided a bottom bar unit of a plate assembly of a lead acid storage battery as above wherein said external locking of the bottom bar with respect to the said tubular cover free of any required male -female inter locking of the lead spine end with the bottom bar favour reducing the length of the lead spine by upto about 10mm and avoiding any required internal disposition of the lead spine within the bottom bar locking member.

According to another aspect of the present invention there is provided bottom bar unit of a plate assembly of a lead acid storage battery as above wherein each said upwardly projecting locking member comprises of a cylindrical base and a coaxial projected top portion , said coaxial projected top portion having atleast a downwardly extending circumferential flanged adapted to cooperate with the inside dimensions of the tubular cover for secured external locking of the bottom bar with respect to the inside dimensions of the tubular member.

According to yet another aspect of the present invention there is provided bottom bar unit of a plate assembly of a lead acid storage battery as above wherein the closed extended top of the said respective upwardly projecting locking member is configured to have a substantially flat dimension matching the corresponding end face dimension of the lead spine.

According to yet another aspect of the present invention there is provided a bottom bar unit of a plate assembly of a lead acid storage battery as above wherein the outer dimension of the said coaxial projected top portion is having atleast a region of reduced dimension carrying said outwardly resilient member to favour external locking member of extended outer dimension beyond said outer dimensions of said locking member o together provide for both locking and leak proof securing of the bottom bar with respect to the tubular cover supporting the respective spine and active material content therein.

According to further aspect there is provided a bottom bar unit of a plate assembly of a lead acid storage battery as above wherein said coaxial projected top portion having atleast a region of reduced dimension is having an internal cut out portion inside of the outer diameter matching the diameter of the tubular cover internal dimension and the diameter of the resiliently outwardly disposed external locking member extending beyond the said outer diameter to effect said leak proof locking with respect to the internal dimensions of the tubular cover housing the lead spine.

According to yet another aspect of the present invention there is provided a bottom bar unit of a plate assembly of a lead acid storage battery as above wherein the height of the extended top of locking member adapted to enter into said tubular cover is of about 7 mm which enable secured fixing involving radially outwardly extending resilient member adapted to lock against the inner wall of respective insulating tubular cover.

According to another aspect of the present invention there is provided a bottom bar unit of a plate assembly of a lead acid storage battery as above wherein the bottom bar is provided with dimensions and number of said upwardly extending plurality of locking members depending upon the size of the battery and number of lead spine based battery unit involved.

According to yet another aspect of the invention there is provided bottom bar unit of a plate assembly of a lead acid storage battery as above wherein said plurality of upwardly projecting locking members are integrally formed with respect to said bottom bar and having selective number of said locking members which correspond to the number of lead spine based batter unit.

According to yet another aspect there is provided a bottom bar unit of a plate assembly of a lead acid storage battery as above which is a bottom bar unit for positive plate assembly of the lead acid storage battery involving plurality of spaced apart spines joined to a top bar said bottom bar unit having corresponding number of said upwardly projecting locking members.

According to yet further aspect of the present invention there is provided a Lead acid storage battery having bottom bar unit of a plate assembly as above comprising:

battery housing;
plate assembly including plurality of lead spine substantially vertically disposed through insulating tubular cover;
bottom bar having plurality of upwardly projecting locking members cooperating with respective insulating tubular cover housing respective lead spine;

each said upwardly projecting locking member having an extended top for inserting into the bottom open end of respective tubular cover and enable resting the adjacent end face of said corresponding lead spine and a radially outwardly extending resilient member adapted to lock against the inner wall of the respective insulating tubular cover surrounding the respective lead spine to effect an external locking of the bottom bar with respect to the said tubular cover surrounding the respective lead spine free of any required male -female inter locking of the spine end with the bottom bar.

According to another aspect of the present advancement there is provided a Lead acid storage battery as above wherein said external locking of the bottom bar with respect to the said tubular cover free of any required male -female inter locking of the spine end with the bottom bar favour reducing the length of the lead spine by about 10mm and avoiding any required internal disposition of the lead spine within the bottom bar locking member.

According to yet another aspect of the present advancement there is provided a Lead acid storage battery as above wherein each said upwardly projecting locking member comprises of a cylindrical base and a coaxial projected top portion of reduced dimension than said cylindrical base, said coaxial projected top portion having a downwardly extending circumferential flanged adapted to cooperate with the inside dimensions of the tubular cover for secured external locking of the bottom bar with respect to the inside dimensions of the tubular member.

According to yet further aspect of the present advancement there is provided aLead acid storage battery as above wherein the closed extended top of the said respective upwardly projecting locking member is configured to have a substantially flat dimension matching the corresponding end face dimension of the lead spine.

According to yet further aspect of the present advancement there is provided a Lead acid storage battery as above wherein the height of the extended top of locking member adapted to enter into said tubular cover which enable secured fixing with involving radially outwardly extending resilient member adapted to lock against the inner wall of respective insulating tubular cover.

According to another aspect of the present advancement there is provided aLead acid storage battery as above wherein the bottom bar is provided with dimensions and number of said upwardly extending plurality of locking members depending upon the size of the battery and number of lead spine based battery unit involved.

According to yet another aspect of the present advancement there is provided a Lead acid storage battery as above wherein said plurality of upwardly projecting locking members are integrally formed with respect to said bottom bar and having selectively said locking members which correspond to the number of lead spine based battery unit.

According to a further aspect of the present advancement there is provided a Lead acid storage battery as above wherein said bottom bar unit comprises bottom bar unit for positive plate assembly of the lead acid storage battery involving plurality of spaced apart spines joined to a top bar said bottom bar unit having corresponding number of said upwardly projecting locking members.

According to yet another aspect of the present invention there is provided a Lead acid storage battery as above wherein said bottom bar is adapted for locking involving said upwardly projected locking member enabling securing with respect to the lead spine free of any insertion in any slot in said locking member and also favouring locking of the tubular cover carrying active material by way of the outwardly resilient member of the projected locking member.

The above and other objects and advantages of the present invention are described hereunder in greater details with reference to the following accompanying non limiting illustrative examples.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Figure 1a: shows the structural details of a conventional assembled lead acid battery.
Figure 1b-d: shows the gauntlet, spine and bottom bar of existing configuration used in storage battery.
Figure 2: shows the schematic assembly of existing bottom bar configuration with spine and gauntlet for disposition in Lead Acid Storage Battery.
Figure 3: shows the sectional view of the existing bottom bar assembly showing the locking area wherein spine lock with the bottom bar and spine enter in the bottom bar of 3mm long for locking.
Figure 4: shows the enlarged view of the lock portion to show the detailed shape and size of lock on existing bottom bar.
Figure 5A, 5B and 5C: shows the enlarged view of lock portion to show the detailed shape and size of lock on modified bottom bar according to present invention allowing reduced length of spine that is inserted in the bottom bar.
Figure 6: shows the shape and dimensions of modified bottom bar with provision for Locking anchor according to present invention.
Figure 7: shows (a) the assembly view of the developed self locking bottom bar according to present invention wherein spine do not enter in the bottom bar, thus 3mm spine length shortened and cost will be reduced; (b) details of locking arrangement in modified bottom bar.

DETAILED DESCRIPTION OF THE INVENTION WITH REFERENCE TO ACCOMPNAYING FIGURES

The present invention as discussed hereinbefore is thus directed to advancement in Bottom Bar configuration of plate assembly for use in manufacture of Lead Acid Storage Battery. More specifically, the bottom bar has been developed to favour cost effective manufacture of lead acid storage battery by way of possible reduction in the length of the cost extensive lead spine usually forming the plate grid of the battery. Bottom Bar, itself can be locked with the Lead Spines fitted in active material /lead oxide filled Tubular bag (battery Plate) of the Lead Acid Storage Battery without affecting the performance and output of the Battery.

Accompanying Figure 1b-d shows the basic components in a storage battery like the lead spines and the gauntlet within which the spines are equally spaced and are insulated from each other and the bottom bar on which the spines are locked in a manner to protect from short circuit that would otherwise occur as a result of fall of the active material from the plates on to the bottom of the container. Accompanying Figure 2 shows existing assembly with spine(2), gauntlet(1) and bottom bar(3)(Old Design). In that case spine lock with thebottom bar(3), spine(2) enter in the bottom bar of 3mm length for locking.Figure 2 shows existing Bottom Bar where STAR LOCK exists inside the Bottom Bar bulb for 6.2mm x 22 tubes Bottom Bar with 2.3mm spines. Accompanying Figure 3 shows the section view of the assembly for more clarification. Accompanying Figure 4 shows the enlarged view of the lock portion to show the detailed shape and size of lock on existing bottom bar. In this type of lock arrangement of existing bottom bar,battery manufacturers use to insert at least 3mm length of the Lead spines inside the Bottom Bar. Said inserted portion of the Lead spines has no participation in Battery performance/Capacity/output. Hence there is a wastage of Lead.

Present invention thus provides for a new bottom bar configuration with self locking arrangement that enable reducing the inserted length of the spine within the lock and hence save lead material. Accompanying Figure 5 shows the new bottom bar configuration and enlarged view of lock portion to show the detailed shape and size of lock on modified bottom bar according to present invention allowing reduced length of spine, eliminating the portion that is usually inserted in the bottom bar, without affecting battery performance/capacity/output.
It may be noted in the figure that the bottom bar assembly comprises a plurality of upwardly projecting locking members for cooperating with respective insulating tubular cover housing respective lead spine wherein each said upwardly projecting locking member having an extended top for inserting into the bottom open end of respective tubular cover and enable resting the adjacent end face of a corresponding lead spine and a radially outwardly extending resilient member adapted to lock against the inner wall of respective insulating tubular cover surrounding the respective said lead spine to effect an external locking of the bottom bar with respect to the said tubular cover surrounding the respective lead spine free of any required male -female inter locking of the spine end with the bottom bar. Importantly also, external locking of the bottom bar with respect to the said tubular cover is free of any required male -female inter locking of the spine end with the bottom bar favour reducing the length of the lead spine by about 10mm and avoiding any required internal disposition of the lead spine within the bottom bar locking member.
In this bottom bar configuration following salient structural features are implemented:
(i) Locking anchor with certain Radius of the Self Locked Bottom bar placed in both the stitched side of the Tubular Bag.
(ii) Radius of the Bulb all around the spine is leak proof, to arrest the Lead oxides Powder inside the Tubular bag ( Gauntlet ).
(iii) Inside Base of individual Bulb or Tube of Self Locked Bottom Bar are it’s Height to arrest the shading of Lead Oxide Powder, from the Bottom of the Tubular Bag (Gauntlet ) i.e. Battery Plate.
(iv) Made of specially blended Polyolefinmaterials .
(v) Entire dimensions i.e. Height, Radius, OD, Locking Anchor and the Design of the Base of the products is selected to ensure Self Locked Bottom Bar.

Accompanying Figure 6 shows the shape and dimensions of the modified bottom bar according to present invention where the locking anchor is having segmented sloped portions with sharp edges so that the spines can be snap fitted with bottom bar in a leak proof manner with this locks, implemented in a 22 tubes Bottom Bar with 2.3mm spines, without having extended length of spine inserted in bottom bar and hence saving amount of lead material consumed in each battery.

Accompanying Figure 7 shows (a) the assembly view of the developed self locking bottom bar(4) according to present invention wherein spine do not enter in the bottom bar, thus 3mm spine length shortened and associated material cost will be reduced; (b) details of locking anchor arrangement to hold spine in leak proof manner in modified bottom bar.

WE CLAIM:

1. Bottom bar unit of a plate assembly of a lead acid storage battery comprising:

plurality of upwardly projecting locking members for cooperating with respective insulating tubular cover housing respective lead spine;

each said upwardly projecting locking member having an extended top for inserting into the bottom open end of respective tubular cover and enable resting the adjacent end face of a corresponding lead spine and having atleast a radially outwardly extending resilient member adapted to lock against the inner wall of respective insulating tubular cover surrounding the respective said lead spine to effect an external locking of the bottom bar with respect to the said tubular cover surrounding the respective lead spine free of any required male -female inter locking of the spine end with the bottom bar .

2. Bottom bar unit of a plate assembly of a lead acid storage battery as claimed in claim 1 wherein said external locking of the bottom bar with respect to the said tubular cover free of any required male -female inter locking of the lead spine end with the bottom bar favour reducing the length of the lead spine by upto about 10mm and avoiding any required internal disposition of the lead spine within the bottom bar locking member.

3. Bottom bar unit of a plate assembly of a lead acid storage battery as claimed in anyone of claims 1 or 2 wherein each said upwardly projecting locking member comprises of a cylindrical base and a coaxial projected top portion , said coaxial projected top portion having atleast a downwardly extending circumferential flanged adapted to cooperate with the inside dimensions of the tubular cover for secured external locking of the bottom bar with respect to the inside dimensions of the tubular member.

4. Bottom bar unit of a plate assembly of a lead acid storage battery as claimed in anyone of claims 1 to 3 wherein the closed extended top of the said respective upwardly projecting locking member is configured to have a substantially flat dimension matching the corresponding end face dimension of the lead spine.

5. Bottom bar unit of a plate assembly of a lead acid storage battery as claimed in anyone of claims 1 to 4 wherein the outer dimension of the said coaxial projected top portion is having atleast a region of reduced dimension carrying said outwardly resilient member to favour external locking member of extended outer dimension beyond said outer dimensions of said locking member o together provide for both locking and leak proof securing of the bottom bar with respect to the tubular cover supporting the respective spine and active material content therein.

6. Bottom bar unit of a plate assembly of a lead acid storage battery as claimed in anyone of claims 1 to 5 wherein said coaxial projected top portion having atleast a region of reduced dimension is having an internal cut out portion inside of the outer diameter matching the diameter of the tubular cover internal dimension and the diameter of the resiliently outwardly disposed external locking member extending beyond the said outer diameter to effect said leak proof locking with respect to the internal dimensions of the tubular cover housing the lead spine.

7. Bottom bar unit of a plate assembly of a lead acid storage battery as claimed in anyone of claims 1 to 6 wherein the height of the extended top of locking member adapted to enter into said tubular cover is of about 7 mm which enable secured fixing involving radially outwardly extending resilient member adapted to lock against the inner wall of respective insulating tubular cover.

8. Bottom bar unit of a plate assembly of a lead acid storage battery as claimed in anyone of claims 1 to 7 wherein the bottom bar is provided with dimensions and number of said upwardly extending plurality of locking members depending upon the size of the battery and number of lead spine based battery unit involved.

9. Bottom bar unit of a plate assembly of a lead acid storage battery as claimed in anyone of claims 1 to 8 wherein said plurality of upwardly projecting locking members are integrally formed with respect to said bottom bar and having selective number of said locking members which correspond to the number of lead spine based batter unit.

10. Bottom bar unit of a plate assembly of a lead acid storage battery as claimed in anyone of claims 1 to 9 which is a bottom bar unit for positive plate assembly of the lead acid storage battery involving plurality of spaced apart spines joined to a top bar said bottom bar unit having corresponding number of said upwardly projecting locking members.

11. Lead acid storage battery having bottom bar unit as claimed in anyone of claims 1 to 10 comprising:

battery housing;
plate assembly including plurality of lead spine substantially vertically disposed through insulating tubular cover;
plurality of upwardly projecting locking members for cooperating with respective insulating tubular cover housing respective lead spine;

each said upwardly projecting locking member having an extended top for inserting into the bottom open end of respective tubular cover and enable resting the adjacent end face of a corresponding lead spine and having a radially outwardly extending resilient member adapted to lock against the inner wall of respective insulating tubular cover surrounding the respective said lead spine to effect an external locking of the bottom bar with respect to the said tubular cover surrounding the respective lead spine free of any required male -female inter locking of the spine end with the bottom bar .

12. Lead acid storage battery as claimed in claim 11 wherein said external locking of the bottom bar with respect to the said tubular cover free of any required male -female inter locking of the spine end with the bottom bar favour reducing the length of the lead spine by about 10mm and avoiding any required internal disposition of the lead spine within the bottom bar locking member.

13. Lead acid storage battery as claimed in anyone of claims 11 or 12 wherein each said upward projecting locking member comprises of a cylindrical base and a coaxial projected top portion of reduced dimension than said cylindrical base ,said coaxial projected top portion having a downwardly extending circumferential flanged adapted to cooperate with the inside dimensions of the tubular cover for secured external locking of the bottom bar with respect to the inside dimensions of the tubular member.

14. Lead acid storage battery as claimed in anyone of claims 11 to 13 wherein the closed extended top of the said respective upwardly projecting locking member is configured to have a substantially flat dimension matching the corresponding end face dimension of the lead spine.

15. Lead acid storage battery as claimed in anyone of claims 11 to 14 wherein the height of the extended top of locking member adapted to enter into said tubular cover is of about 7 mm which enable secured fixing involving radially outwardly extending resilient member adapted to lock against the inner wall of respective insulating tubular cover.

16. Lead acid storage battery as claimed in anyone of claims 11 to 15 wherein the bottom bar is provided with dimensions and number of said upwardly extending plurality of locking members depending upon the size of the battery and number of lead spine based battery unit involved.

17. Lead acid storage battery as claimed in anyone of claims 11 to 16 wherein said plurality of upwardly projecting locking members are integrally formed with respect to said bottom bar and having selective number of said locking members which correspond to the number of lead spine based battery unit.

18. Lead acid storage battery as claimed in anyone of claims 11 to17 wherein said bottom bar unit comprises bottom bar unit for positive plate assembly of the lead acid storage battery involving plurality of spaced apart spines joined to a top bar said bottom bar unit having corresponding number of said upwardly projecting locking members.

19. Lead acid storage battery as claimed in anyone of claims 11 to 18 wherein said bottom bar is adapted for locking involving said upwardly projected locking member enabling securing with respect to the lead spine free of any insertion in any slot in said locking member and also favouring locking of the tubulat cover carrying active material by way of the outwardly resilient member of the projected locking member.