FIELD OF THE INVENTION

The present invention in general relates to lead acid batteries for inverter applications.
More particularly, the present invention relates to a method of manufacturing lead acid
5 batteries in jumbo tubular containers with lesser number of plates, thereby optimising the
quantity of lead used, reducing the assembling operation and time, and a lead acid battery
thereof.
BACKGROUND OF THE INVENTION
10
Lead acid batteries for inverter applications are manufactured in standard sized containers,
which are generally classified as jumbo tubular containers, long tubular containers or tall
tubular containers depending upon the height of the container. The dimensions of these
containers are as follows (with a variation of ± few mm as per different manufacturers):
15
Tall tubular container : 508 * 190 * 412 (Length*Width*Height)
Long tubular container : 508* 190 * 357 (Length*Width*Height)
Jumbo tubular container : 520 * 279 * 283 (Length*Width*Height).
20 Other dimensions of the containers are also available for smaller capacity batteries, but
they are less common. It can be seen that the tall tubular containers have a smaller width
than jumbo tubular containers but have a higher height. Tall tubular and long tubular
containers differ only in the height, whereas jumbo tubular container has all the three
dimensions different. The jumbo tubular containers used for batteries are shorter in height
25 but have greater width. The battery plates (positive and negative electrodes) used in jumbo
tubular containers are also shorter in height. To accommodate required quantity of active
material for desired capacity of the battery, more number of plates is to be used in such
containers.
3
Each battery container has to be divided into six compartments for inserting six cells (each
cell is a combination of positive and negative plates in different combinations as per the
required capacity).
5 The height of the plates used in these containers is kept in consistence with the height of
the container. The plates are placed in vertical position in the containers with lug side on
the top. It is a general trade practice that same capacity batteries are made in different
types of containers. To accommodate required active material for a particular capacity of a
battery, the number of plates has to be changed according to the size of the plates.
10
Hence, if a 150 Ah capacity battery is made in a tall tubular container, the plate size would
be larger and number of plates would be less. On the other hand, if same capacity battery
is to be made in jumbo tubular container, the plate height would be smaller but the number
of plates would be more. In jumbo tubular containers, as per usual practice, six
15 compartments are made by dividing the container widthwise into six compartments. Figure
1 illustrates a photographic image showing the widthwise division of jumbo tubular
container and lug position at top. Owing to the lesser height of the jumbo tubular container,
generally the plates having height up to 150 mm are used. But, if the plate height is less, to
achieve the desired capacity of the battery, number of plates is to be increased. However,
20 it is important to note that the greater the number of plates, the greater is the time required
for assembling them as a cell of a battery and consequently productivity of the battery
making process is affected.
Therefore, it will be beneficial if a lead acid battery can be manufactured in jumbo tubular
25 containers with lesser number of plates, thereby optimising the quantity of lead used,
reducing the assembling operation and time without reducing the capacity of the battery.
The present invention discloses such a method of manufacturing lead acid batteries in
jumbo tubular containers and a lead acid battery thereof.
30 OBJECT OF THE INVENTION
4
It is therefore an object of the present invention to provide an advantageous and
economical method for assembling the battery plates into cells and placing the cells in the
battery container.
5 Yet another object of the present invention is to provide a lead acid battery, with minimum
number of plates without affecting the capacity of the battery.
SUMMARY OF THE INVENTION
10 In one aspect, the present invention provides a method of manufacturing lead acid
batteries in jumbo tubular containers with lesser number of plates, thereby optimising the
quantity of lead used, reducing the assembling operation and time without reducing the
capacity of the battery. The jumbo tubular battery container is divided lengthwise into six
compartments. Plates having length greater than that of the height of the jumbo tubular
15 container are placed in the compartments of the jumbo tubular container. To place longer
plates in these compartments, the plates are placed in a lateral (transverse) position
instead of vertical position with lug pointing sideways. An added advantage of this method
is that the height of plates can be equal to the plates, which can be accommodated in tall
tubular containers.
20
In yet another aspect, the present invention discloses a lead acid battery manufactured in
jumbo tubular containers with lesser number of plates, thereby optimising the quantity of
lead used, reducing the assembling operation and time without reducing the capacity of the
battery. The jumbo tubular container of the lead acid battery comprises six compartments
25 divided lengthwise. Plates having length greater than that of the height of the jumbo tubular
container are placed in these compartments in a lateral (transverse) position instead of
vertical position with lug pointing sideways.
The foregoing is a summary and thus contains, by necessity, simplifications,
30 generalizations and omissions of detail; consequently, those skilled in the art will
appreciate that the summary is illustrative only and is not intended to be in any way limiting
5
of the invention. As will also be apparent to one skilled in the art, the arrangements
disclosed herein may be implemented in a number of ways, and such changes and
modifications may be made without departing from this invention and its broader aspects.
5 Other aspects, inventive features, and advantages of the present invention, as defined
solely by the claims, will become apparent in the non-limiting detailed description set forth
below.
BRIEF DESCRIPTION OF THE DRAWINGS
10
The above and other objects and features of the invention will become apparent from the
following description of preferred embodiments taken in conjunction with the
accompanying drawings.
15 Figure 1 illustrates a photographic image showing the conventional widthwise division of
jumbo tubular containers and lug position at top.
Figure 2 illustrates a photographic image showing the lengthwise division of jumbo tubular
container into six cells and lateral placement of plates with lug sideways according to the
20 present invention.
Figure 3 illustrates the top view, front view and side view of the jumbo tubular container
according to the present invention.
25 Figure 4 illustrates the top view, sectional front view and side sectional view of the lateral
placement of plates in the jumbo tubular container according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
30 The embodiments of the present invention will now be described more fully with reference
to the accompanying drawings, in which some of the embodiments are shown. The
6
following description is intended to be illustrative of embodiments of the invention and
should not be taken to be limiting.
In one embodiment of the present invention, a method of manufacturing lead acid batteries
5 in jumbo tubular containers with lesser number of plates, thereby optimising the quantity of
lead used, reducing the assembling operation and time without reducing the capacity of the
battery is provided. In the method, the jumbo tubular battery container is divided
lengthwise into six compartments. Plates having length greater than that of the height of
the jumbo tubular container are placed in the compartments of the jumbo tubular container.
10 To place longer plates in these compartments, the plates are placed in a lateral
(transverse) position with lug pointing sideways.
In another embodiment, a lead acid battery manufactured in jumbo tubular containers with
lesser number of plates, thereby optimising the quantity of lead used, reducing the
15 assembling operation and time without reducing the capacity of the battery is provided.
The jumbo tubular container of the lead acid battery comprises six compartments divided
lengthwise. Plates having length greater than that of the height of the jumbo tubular
container are placed in these compartments in a lateral (transverse) position instead of
vertical position with lug pointing sideways.
20
Figure 2 illustrates a photographic image showing the lengthwise division of jumbo tubular
container into six cells and lateral placement of plates with lug sideways according to the
present invention.
25 In the present invention, six compartments are made in a jumbo tubular container by
dividing lengthwise. In this case, longer plates can be placed but these plates are placed
laterally, instead of vertically, with lug position at the side instead of at the top.
Figure 3 illustrates the top view, front view and side view of the jumbo tubular container
30 according to the present invention and figure 4 illustrates the top view, sectional front view
7
and side sectional view of the lateral placement of plates in the jumbo tubular container
according to the present invention.
The present invention shall now be explained with the help of a non-limiting example. In
5 the example, plate sizes and plate numbers are only indicative.
EXAMPLE: If a plate of 150 mm height is used in a lead acid battery, active material
pasted on it can be only 234 gms, whereas a plate of 256 mm height can hold 470 gms of
active material.
10
If for a 150 Ah lead acid battery, 930 gms of active material is required, then 4 plates
having 150 mm height have to be assembled. In case, plates having 256 mm height are
used, only 2 plates will be sufficient.
15 From the above example, it is clear that by making the lead acid battery according to the
present invention, the number of plates can be reduced by 2 as compared with the
conventional lead acid battery of the same capacity.
During the battery manufacturing process, plate casting and pasting of different size
20 consumes same amount of time. Moulds for casting different sized plates are different but
casting time is roughly the same. Pasting is a continuous process and is done through a
conveyor. Since lesser number of plates (half as illustrated in the above example) is to be
used as per present invention, plate casting and plate pasting operations are also reduced.
25 Moreover, during assembly of the plates into a group/cell, the operator has to assemble
positive and negative plates in a comb set and the lugs and straps are fused together.
Hence, the more the number of plates to be assembled, the more is the time required. The
grouping of lesser number of plates consumes lesser time and increases productivity.
30 Since plates having higher height cannot be accommodated in jumbo tubular containers by
placing them vertically, the jumbo tubular container in the present invention is divided
8
lengthwise and plates having higher height are placed laterally. An added advantage of the
present invention is that height of plates can be equal to the plates, which can be
accommodated in tall tubular containers.
5 While the foregoing written description of the invention enables one of ordinary skills to
make and use what is considered presently to be the best mode thereof, those of ordinary
skill will understand and appreciate the existence of variations, combinations and
equivalents of the specific embodiments method and details herein.
10 While the preferred embodiments of the invention have been described and illustrated, it
will be appreciated that various changes can be made therein without departing from the
scope of the invention.

We claim:

1. A method of manufacturing lead acid batteries in jumbo tubular containers
comprising the steps of:
5 dividing the jumbo tubular container into six compartments;
placing plates of the lead acid battery in the said compartments; and
fusing lugs and straps of the plates together,
wherein,
the jumbo tubular container is divided lengthwise;
10 the plates of the lead acid battery are having length greater than that of
the height of the jumbo tubular container; and
the plates of the lead acid battery are placed transversely with lug pointing
sideways to the jumbo tubular container.
15 2. The method as claimed in claim 1, wherein the length of the plates of the lead acid
battery is equal to the length of plates of a lead acid battery manufactured in tall
tubular container.
3. A lead acid battery comprising:
20 a jumbo tubular container divided into six compartments; and
a plurality of plates placed in said compartments,
wherein,
the jumbo tubular container is divided lengthwise;
the plates are having length greater than that of the height of the jumbo
25 tubular container; and
the plates are placed transversely in said compartments with lug of the
plates pointing sideways to the jumbo tubular container.
4. The lead acid battery as claimed in claim 3, wherein the length of the plates is
30 equal to the length of plates of a lead acid battery manufactured in tall tubular
container.