Battery grid and method of making

• US 6,245,462 B1
• Filed: 05/20/1999
• Issued: 06/12/2001
• Est. Priority Date: 05/20/1999
• Status: Expired due to Fees

• Current Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Original Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Inventors: Mrotek, Edward N., Kao, Wen-Hong
• Primary Examiner(s): Dunn, Tom
• Assistant Examiner(s): PITTMAN, ZIDIA T
• Application Number:
  US09/315,445
• Time in Patent Office: 754 Days
• Field of Search: 429/233, 429/241, 429/242, 429/225, 29/2
• US Class Current: 429/241
• CPC Class Codes: H01M 4/70 characterised by shape or form
• CPC Class Codes: H01M 4/73 for lead-acid accumulators, e.g. frame plates
• CPC Class Codes: H01M 4/74 Meshes or woven material; Expanded metal
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y10T 29/10 Battery-grid making

Abstract

A battery grid, suitable for use in a lead-acid battery, with a grid upper portion having a grid wires defining a first grid pattern, and a grid lower portion electrically connected to the grid upper portion. The grid lower portion having grid wires defining a second grid pattern, wherein the first grid pattern is different from said second grid pattern to improve the conductivity of the grid.

Claims

1. A battery grid, suitable for use in a lead-acid battery, comprising:

a grid upper portion having grid wires defining a first grid pattern of open grid cells; and

a grid lower portion electrically connected to said grid upper portion, said grid lower portion having grid wires defining a second grid pattern of open grid cells, wherein said first grid pattern is different from said second grid pattern.

2. The battery grid as in claim 1, wherein one of said grid portions is expanded metal.

3. The battery grid as in claim 1, wherein one of said grid patterns is a diamond pattern.

4. The battery grid as in claim 1, wherein one of said grid patterns is a radial pattern.

5. The battery grid as in claim 1, wherein one of said grid patterns is a rectilinear pattern.

6. The battery grid as in claim 1, wherein a central grid portion having a grid wires defining a third grid pattern is electrically connected to at least one of the other grid portions.

7. A battery grid, suitable for use in a lead-acid battery, comprising:

a top frame member;

non-expanded metal wires extending from said top frame member and defining open grid cells; and

expanded metal wires electrically connected to said non-expanded metal wires.

8. The battery grid, as in claim 7, wherein said non-expanded metal wires are formed by stamping.

9. The battery grid, as in claim 7, wherein said non-expanded metal wires define a radial pattern.

10. The battery grid, as in claim 7, wherein said non-expanded metal wires define a rectilinear pattern.

11. A method for making a battery grid suitable for use in a lead-acid battery, comprising the steps of:

forming a diamond pattern of open grid cells in a first metal strip;

forming a non-diamond pattern of open grid cells in a second metal strip; and

joining said first metal strip to said second metal strip.

12. The method as in claim 11, wherein said first metal strip is joined to said second metal strip by laminating.

13. The method as in claim 11, wherein said first metal strip is joined to said second metal strip by spot welding.

14. A method of forming a battery grid suitable for use in a lead-acid battery, the steps comprising:

expanding an outer portion of a metal strip to form a first wire pattern of open grid cells; and

forming a different wire pattern of open grid cells in an unexpanded inner portion of said metal strip.

15. The method as in claim 14, wherein said different wire pattern is formed by stamping.

16. The method as in claim 14, wherein said different wire pattern is formed by perforation.

17. The method as in claim 14, wherein said different wire pattern is radial.

18. The method as in claim 14, wherein said different wire pattern is rectilinear.

19. A method for making a battery grid suitable for use in a lead-acid battery, comprising the steps of:

forming an expanded metal battery grid having an upper and lower portion; and

overlaying a metal strip having a pattern formed therein onto said upper portion of said expanded metal battery grid, wherein said metal strip overlays only said upper portion of said expanded metal grid and defines a grid pattern on said upper portion which is different from a pattern on said lower portion.

20. The method as in claim 19, wherein said metal strip is spot-welded to said expanded metal battery grid.