Stamped grid having offset horizontal wires

• US 6,203,948 B1
• Filed: 07/09/1999
• Issued: 03/20/2001
• Est. Priority Date: 11/26/1997
• Status: Expired due to Term

• Current Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Original Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Inventors: Kao, Wen-Hong, Troxel, Jeffrey L., Mrotek, Edward N.
• Primary Examiner(s): Kalafut, Stephen
• Assistant Examiner(s): TSANG FOSTER, SUSY N
• Application Number:
  US09/350,854
• Time in Patent Office: 620 Days
• Field of Search: 29/2, 429/233, 429/241, 429/242, 429/243, 429/244
• US Class Current: 429/241
• CPC Class Codes: H01M 4/72 Grids
• CPC Class Codes: H01M 4/73 for lead-acid accumulators, e.g. frame plates
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

A stamped grid for a lead-acid battery having a grid pattern that is optimized for electrical performance. The stamped grid includes an electrically conductive grid body having opposed top and bottom frame elements, opposed first and second side frame elements and a plurality of interconnecting grid wire elements forming a grid pattern. The grid wire elements include a plurality of vertical wire elements connected to both top and bottom frame elements, a plurality of vertical wire elements connected to the top frame element and one of either the first or second side frame elements and a plurality of cross grid elements that interconnect the vertical wire elements. Each of the vertical grid elements that is connected to the top frame element and one of either the first or second side frame elements includes a plurality of the cross frame elements connected thereto at a substantially 90° angle. Optionally, the cross grid elements in the middle portion of the grid are arranged in an offset or staggered relationship. The vertical grid elements and the cross frame elements define open areas for supporting electrochemical paste where most of the open areas are within the two percent of being the same size.

Claims

1. A grid for a battery comprising:

an electrically conductive grid body having opposed top and bottom frame elements and opposed first and second side frame elements; and

a plurality of interconnecting electrically conductive grid elements defining a grid pattern defining a plurality of open areas, the interconnecting grid elements including

a plurality of radially extending vertical grid wire elements connected to the top frame element, a first portion of the radially extending vertical grid wire elements being connected to the top frame element and the first side frame element, the first portion of the radially extending vertical grid wire elements including a first innermost vertical grid wire element located furthest from the first side frame element, a second portion of the radially extending vertical grid wire elements being connected to the top frame element and the second side frame element, the second portion of the radially extending vertical grid wire elements including a second innermost vertical grid wire element located furthest from the second side frame element, and a third portion of the radially extending vertical grid wire elements located between the first portion of the radially extending vertical grid wire elements and the second portion of the radially extending vertical grid wire elements, the third portion of the radially extending grid wire elements being connected to the top frame element and the bottom frame element, and

a plurality of spaced-apart cross wire grid elements, a first set of the spaced-apart cross wire grid elements extending between the first side frame and the first innermost vertical grid wire element, a second set of the spaced-apart cross wire grid elements extending between the first innermost and the second innermost vertical grid wire elements, and a third set of the spaced-apart cross wire grid elements extending between the second side frame and the second innermost vertical grid wire element,

wherein a plurality of the second set of cross wire grid elements are connected to the third portion of the radially extending vertical grid wire elements in a staggered manner so that the plurality of the second set of cross wire grid elements that are connected to the third portion of the radially extended vertical grid elements in a staggered manner are not continuous.

2. The grid of claim 1 wherein:

a plurality of the first set of cross wire grid elements are connected to the first portion of the radially extending vertical grid wire elements in a staggered manner and a plurality of the third set of cross wire grid elements are connected to the second portion of the radially extending vertical grid wire elements in a staggered manner so that the plurality of the first set of the cross wire grid elements that are connected to the first portion of the radially extended vertical grid elements in a staggered manner and the plurality of the third set of the cross wire grid elements that are connected to the second portion of the radially extended vertical grid wire elements in a staggered manner are not continuous.

3. The grid of claim 2 wherein:

the first set of the cross wire grid elements are connected to the first portion of the radially extending vertical grid wire elements at substantially a 90°

angle to the first portion of the radially extending vertical grid wire elements, and

the third set of the cross wire grid elements are connected to the second portion of the radially extending vertical grid wire elements at substantially a 90°

angle to the second portion of the radially extending vertical grid wire elements.

4. The grid of claim 1 wherein:

the first side frame element and the second side frame element each include a lower corner having a rounded shape.

5. The grid of claim 1 wherein:

the first side frame element and the second side frame element each include a lower corner having a substantially square shape.

6. The grid of claim 1 wherein:

the radially extending vertical grid wire elements in the third portion of the radially extending vertical grid wire elements have a varying width which increases from a bottom of the grid wire element connected to the bottom frame element to a top of the grid wire element connected to the top frame element.

7. The grid of claim 1 wherein:

at least 95% of the open areas are within ten percent of the being the same size.

8. The grid of claim 1 wherein:

the second set of the cross wire grid elements are connected to the third portion of the radially extending vertical grid wire elements such that the second set of the cross wire grid elements are parallel.

9. A grid for a battery comprising:

an electrically conductive grid body having opposed top and bottom frame elements and opposed first and second side frame elements; and

a plurality of interconnecting electrically conductive grid elements defining a grid pattern defining a plurality of open areas, the interconnecting grid elements including

a plurality of radially extending vertical grid wire elements connected to the top frame element, a first portion of the radially extending vertical grid wire elements being connected to the top frame element and the bottom frame element, and

a plurality of spaced-apart cross wire grid elements extending between the first side frame and the second side frame

wherein a plurality of cross wire grid elements that are connected to the first portion of the radially extending vertical grid wire elements are connected in a staggered manner so that the cross wire grid elements that are connected to the first portion of the radially extending vertical grid wire elements in a staggered manner are not continuous.

10. The grid of claim 9 wherein:

the radially extending vertical grid wire elements in the first portion of the radially extending vertical grid wire elements have a varying width which increases from a bottom of the grid wire element connected to the bottom frame element to a top of the grid wire element connected to the top frame element.

11. The grid of claim 9 wherein:

at least 95% of the open areas are within ten percent of the being the same size.

12. The grid of claim 9 wherein:

the plurality of radially extending vertical grid wire elements connected to the top frame element includes a second portion of radially extending vertical grid wire elements connected to the top frame element and the first side frame element and a third portion of radially extending vertical grid wire elements connected to the top frame element and the second side frame element.