Secondary battery with improved destratification

Patent metadata

Field	Value
Publication number	US-10050254-B2
Application number	US-201013393972-A
Country	US
Kind code	B2
Filing date	Sep 3, 2010
Priority date	Sep 4, 2009
Publication date	Aug 14, 2018
Grant date	Aug 14, 2018

Abstract

The present disclosure relates to lead-acid batteries and the manufacture of lead-acid batteries containing acid pump devices to promote the circulation of electrolyte within the battery and/or battery cells to reduce acid stratification and improve battery performance. In various embodiments, battery cell components are assembled within an acid pump assembly that encloses the battery cell components on at least the bottom and ends. In various embodiments, at least a portion of the acid pumps may be integrally molded with or secured to various parts of the battery housing including the cover, side walls, and cell walls. In various embodiments; space for the acid pumps is created by varying the shape of the battery housing (e.g., the side walls or cell walls) and/or by modifying the shape, size, and or position of one or more of the battery electrodes or separators.

First claim

What is claimed is:

1. A lead-acid battery comprising:
a battery housing comprising:
a base;
a battery housing side wall;
a cell wall; and
a cover;

a battery element provided inside of the battery housing, comprising:
a positive plate,
a negative plate, and
a separator positioned between the positive plate and the negative plate;

a vacant space in the battery housing not occupied by the battery element;
and
an acid pump, the acid pump comprising a throat having a top edge and a head tank in fluid communication with the throat, wherein the throat extends in a direction perpendicular to a bottom surface of the head tank;
wherein the head tank comprises a solid structure having:
a first side wall having a side wall front edge, a side wall back edge, a side wall top edge and a side wall bottom edge; and
a back wall extending parallel to the throat having a back wall first side edge, a back wall second side edge, a back wall top edge, and a back wall bottom edge,
a bottom wall having a bottom wall front edge, a bottom wall back edge, and a bottom wall side edge;
the first side wall being coupled to the bottom wall along an intersection between the bottom wall side edge and the side wall bottom edge;
the back wall being coupled to the bottom wall along an intersection between the bottom wall back edge and the back wall bottom edge;
the first side wall being coupled to the back wall along an intersection between the back wall side edge and the side wall back edge;
the first side wall having a height measured from the side wall bottom edge to the side wall top edge which decreases from a tallest point at the intersection between the side wall back edge and the back wall side edge towards the side wall front edge;
wherein the first side wall, the back wall, the bottom wall, and a second side wall comprise the head tank such that the head tank has an open side defined on two sides by the bottom wall front edge and side wall front edge, the throat top edge being coupled to the bottom wall front edge and extending perpendicularly from the bottom wall;
and
wherein the acid pump is an insert comprising a separate structure from the battery housing including at least the head tank;
wherein at least a portion of the vacant space is occupied by the acid pump; and
wherein at least a portion of the acid pump is an integral part of, attached to, or in communication with the battery housing.

2. The lead-acid battery of claim 1 wherein at least a portion of the vacant space is formed by placing the battery element offset from center in the battery housing.

3. The lead-acid battery of claim 1 wherein:
the separator has a width greater than the width of the positive plate and the negative plate; and
at least a portion of the vacant space is formed by configuring the separator and the positive plate and the negative plate such that the vacant space is created between an end of a positive plate or a negative plate and a portion of the battery housing.

4. The lead-acid battery of claim 1 wherein at least a portion of the vacant space is formed by the cell wall being shaped to form vacant space between the cell wall and the battery element.

5. The lead-acid battery of claim 1 wherein at least a portion of the acid pump is part of or connected to the cover.

6. The lead-acid battery of claim 1 wherein at least a portion of the acid pump is part of or connected to the battery housing side wall and/or the cell wall.

7. The lead-acid battery of claim 1 , wherein the first side wall and the second side wall extend perpendicularly from the bottom surface.

8. The lead-acid battery of claim 7 , wherein the head tank has a mouth in a top region and is seated above the throat.

9. The lead-acid battery of claim 1 , wherein the head tank has a mouth in a top region and is seated above the throat.

10. The lead-acid battery of claim 1 , wherein the head tank first side wall is joined perpendicularly to the bottom surface.

11. The lead-acid battery of claim 1 , wherein the second side wall is coupled to the back wall along the back wall second side edge, the second side wall decreasing in height as it extends away from the back wall towards the open side.

12. The lead-acid battery of claim 1 , wherein the throat includes two or more parallel ridges.

13. The lead-acid battery of claim 12 , wherein the ridges extend in a perpendicular direction away from the bottom surface.

14. The lead-acid battery of claim 1 , wherein at least a portion of the acid pump is divided into a plurality of sections.

15. A lead-acid battery comprising:
a battery housing;
an acid pump, at least a portion of which is an integral part of, attached to, or in communication with the battery housing, the acid pump comprising:
a throat and a head tank in fluid communication with the throat, wherein the head tank is defined by a solid structure having:
a back wall;
a first side wall having a first side wall front edge, first side wall back edge, a first side wall bottom edge, and a first side wall top edge;
a second side wall having a second side wall front edge and a second side wall back edge; and
a base having a base front edge and base back edge;
wherein the back wall is perpendicularly coupled to the first side wall along the first side wall back edge, second side wall along the second side wall back edge, and base along the base back edge;
wherein the first side wall and second side wall are perpendicularly coupled to the base;
wherein the first side wall has a height measured from the first side wall bottom edge to the first side wall top edge, the height decreasing from the first side wall back edge towards the first side wall front edge,
wherein the first side wall front edge, second side wall front edge, and base front edge define an open side;
and
wherein the throat has a top edge coupled to the bottom wall front edge and the throat extends in a perpendicular direction away from the base.

16. The lead-acid battery of claim 15 , wherein the throat includes two or more parallel ridges.

17. The lead-acid battery of claim 16 , wherein the ridges extend in a perpendicular direction away from the base.

18. The lead-acid battery of claim 15 , wherein at least a portion of the acid pump is divided into a plurality of sections.

19. The lead-acid battery of claim 15 , wherein at least one of the first and second side walls have a first and second height, the first height being taller than the second height, wherein the first height is closer to the back wall than the second height.

20. The lead-acid battery of claim 15 , wherein the first and second sidewalls extend perpendicularly away from the back wall, and wherein the first and second sidewalls decrease in height as they extend away from the back wall.

21. The lead-acid battery of claim 15 , wherein the first and second sidewalls have a first height which is greater closer to the back wall than a second height farther away from the back wall.

22. An acid pump for a lead-acid battery, the acid pump comprising:
a throat and a head tank in fluid communication with the throat;
wherein the head tank is defined by a solid structure having a back wall, first side wall, a second side wall, and a base;
the first side wall having a first side wall front edge, a first side wall back edge, a first side wall top edge, and a first side wall bottom edge, the first side wall having a height as measured from the first side wall bottom edge to the f

Assignees

• Jin Zoe H
• Baxa Michael S
• Wruck William J
• Adams Kenneth A
• Franklin Lisa M
• Andersen Glenn W
• Mrotek Edward N
• Johnson Controls Tech Co

Inventors

• Jin Zoe H
• Baxa Michael S
• Wruck William J
• Adams Kenneth A
• Franklin Lisa M
• Andersen Glenn W
• Mrotek Edward N

Classifications

• H01M10/4214 Primary

  Arrangements for moving electrodes or electrolyte · CPC title

• B60L2200/26

  Rail vehicles · CPC title

• B60L2200/12

  Bikes · CPC title

• B60L50/16

  with provision for separate direct mechanical propulsion · CPC title

• B60L2200/18

  Buses · CPC title