Rajah tubular battery electrode and method of making same

Abstract

An improved tubular battery plate six in number arranged in the shape of duo triad
Each cylindrical tubular plate is concentric with other four in number cylindrical tubular
plates. So each of six cylindrical tubular plate will have four concentric cylindrical plates
in total 24 number of concentric cylindrical plates connected alternately to give polarity
as positive and negative are joined together as the positive terminal or the negative
terminal thus forming the tubular battery.

Inventors: Dr.A.B.Rajib Hazarika,PhD,FRAS,AES

Address :Anjena Manzil, Kadomtola,
Modhupur,Nagaon,Assam-782001

Current U.S. Class: 429/140 ; 29/623.5; 429/238

Current International Class: H01M 4/76 (20060101); H01M 4/70 (20060101);
H01M 002/18 ()
Field of Search: 429/140,141,136,139,238 29/623.1-623.5 428/36,398
138/107,170,178,DIG.2
References Cited [Referenced By]
U.S. Patent Documents

2305121 December 1942 Wheat

2806076 September 1957 Yamaura et al.
2896006 July 1959 Sundberg
2904611 September 1959 Duddy
3207632 September 1965 Dickover et al.
3267190 August 1966 Malloy
4048398 September 1977 Sundberg
4144115 March 1979 Sundberg
4328292 May 1980 Remer
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 Other References

Encyclopedia of Polymer Science and Technology Suppl. vol. 1 "Photocuring"

pp. 367-378, 1976, John Wiley and Sons Inc. .
Dixon et al., "The Curing of Unsaturated Polyester Resins With Visible Light";
32nd Annual Conf., 1977, Reinforced Plastics/Composites Instit.-The Society of
the Plastics Industry; Sect. 5-D, pp. 1-6..

Claims

The embodiments of the invention in which an exclusive property or privilege is claimed

are defined as follows:

1. An improved tubular battery plate six in number arranged in the shape of duo
triad of the type having a first electrically conductive cross member, a plurality of
spaced electrically conductive spines extending from the first cross member, a glass braid
sheath enveloping each spine and forming a tube therewith, active material disposed
within the tube, a second nonconductive cross member affixed to and sealing the tube, the
improvement which comprises the sheath being fabricated by:

(a) saturating the braid with a photo curable resin,

(b) curing the braid by exposing the braid to at least one light source so that the braid
becomes rigid,

(c) shaping the braid into a sheath, and

(d) sizing the sheath to pre-selected lengths.

2. Each cylindrical tubular plate is concentric with other eight in number cylindrical
tubular plates. So each of six cylindrical tubular plate will have four concentric
cylindrical plates.

3. The total number of cylindrical battery plate in concentric form goes to the product of
number of tubular with the number of concentric cylindrical battery plates according to
claim 2 is equal to 6 X 4 = 24(twenty four) concentric cylindrical plates.

4. The need for concentric cylindrical plates is for polarity i.e, positive and negative
charged plates which comes alternately.

5. A method for fabricating six tubular battery plates arranged in the shape of duo
triad, the plates having a plurality of spaced electrically conductive spines extending
from an upper cross member, each spine substantially enveloped by a glass braid sheath
forming a tube therewith, the method comprising:

(a) saturating the braid with a photo curable resin,

(b) curing the braid by exposing the braid to at least one light source so that the braid
becomes rigid,

(c) shaping the braid into a sheath,

(d) sizing the sheaths to pre-selected lengths,

(e) placing the sheaths over the spines to form the tubes,

(f) filling the interior of the tubes with active material, and

(g) sealing the tubes with a lower cross member.

6. The method according to claim 5 wherein the active material is lead dioxide.

7. As usual the acid is sulphuric acid(H2 SO4).

Description

TECHNICAL FIELD

This invention relates to storage batteries in general and more particularly to six
tubular battery plates arranged in the shape of duo triad and a process for making
them.

BACKGROUND ART

Secondary batteries employing tubular plate construction generally exhibit superior

electrical capacity to weight ratios when compared to similarly sized secondary batteries
employing conventional flat pasted grids. This desirable phenomenon primarily occurs
because the tube-type electrode design exposes a substantially greater surface area of
active material to the electrolyte contained within the battery. Accordingly, since the
electrolyte is able to freely circulate about the tubes and through the porous tube sheaths
that contain more material, the tubular plate battery is capable of delivering higher
capacities. In addition, by securely enveloping the active material in the porous but rigid
sheath, the tubular plate battery is better protected from the deleterious effects caused by
shocks and vibration.

In brief, tubular plate batteries generally include positive plates characterized by a lead
alloy grid having a series of spaced, electrically conductive spines appended to a first
electrically conductive cross member. A porous, rigid sheath is enveloping each spine to
form a plurality of hollow tubes. Each tube, packed with active material, is bottom sealed
and connected to adjoining tubes by a second nonconductive cross member. Generally,
the negative plates are conventional pasted plates.

As with most secondary battery designs, the positive (tubular) plates and the negative
plates are disposed in an alternating spaced relationship within the battery case. A
separator is positioned between the plates. Moreover, a number of positive plates and
negative plates are electrically ganged together (positive to positive, negative to negative)
to form a cell. A plurality of interconnected cells constitutes a battery.

Initially, the sheaths were made from slotted hard rubber but over the years, battery
designers have turned to woven plastic and braided glass sheaths to provide superior
service. Indeed, some present day glass sheaths are made by saturating a glass braid with
an alcohol/phenolic solution and then passing the saturated sheath over a shaping mandrel
in the presence of radiant heaters to drive off the alcohol in vapor form. After the sheath
is rough cut to a desired length (anywhere from about 4 inches [10.6 cm] to about 28
inches [71.12 cm]), the sheath is dipped into a dilute alcohol/phenolic solution to increase
resin pick-up whereupon, it is then baked in an oven. The sheath is then dipped for a
second time and baked again for approximately a half hour.

It should be readily apparent from the foregoing discussion that this method is both
energy intensive and a source of industrial pollution. Moreover, large quantities of
expensive solvent are necessary to affect a stiff tube with specified resin content.

Indeed, the aforementioned process of making tubular sheaths is running into the
combined problems posed by: (1) increasingly stringent regulations restricting the
amount of air pollution caused by solvent effluents; (2) the constantly escalating cost of
energy; (3) the rising cost of expensive organic solvents; and (4) the flammable nature of
the alcohol solution.

Clearly a more economic and practical method for manufacturing tube sheaths is
desirable.

SUMMARY OF THE INVENTION

Accordingly there is provided an improved tubular electrode and a method for making
same.

Briefly, the glass braid, comprising the sheath, is saturated with a photo curable resin. In
one embodiment of the invention, the braid is cured in the presence of visible light
whereupon it is shaped into a hollow sheath. In an alternative embodiment of the
invention, the braid is first partially cured in the presence of visible light whereupon it is
shaped into a hollow sheath. The sheath is then fully cured, again in the presence of light.
After the ultimately cured sheath has been cut to a pre-selected length, each individual
sheath is top sealable disposed about the spaced spines comprising a tubular plate
electrode to form a plurality of tubes extending there from. Active material is then
introduced into these tubes whereupon the tubes are bottom sealed and interconnected by
an electrically non-conducting cross member.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial top sectional view of a tubular concentric plate electrode in duo triad
shape of Rajah battery.
FIG. 2 is a side view of a tubular cylindrical electrode in duo triad shape of Rajah battery.

PREFERRED MODE FOR CARRYING OUT THE INVENTION

Referring to FIG. 1, there is shown a Rajah tubular battery with duo triad shaped
cylindrical concentric plate 24 in number. The odd concentric plates in each of six
cylindrical tubular plates are joined to form a negative terminal. The even numbered
concentric cylindrical tubular plates are joined to form a positive terminal. Each of
concentric plates are at equal distance of 5mm-8mm apart radially.

FIG. 2 is a detailed side view of the Rajah tubular battery in duo triad shape with
cylindrical concentric tubulars. Only the other six tubes can be seen whereas the rest of
tubes are hidden.

In normal commercial practice, a battery employing tubular plate construction contains a

series of alternating positive tubular plates 10 and standard negative, flat, pasted plates
(not shown). The top cross member 12, the lug 26 and the spines 14 are generally made
from lead alloy whereas the bottom cross member 22 and the associated standoffs 24 are
made from polyethylene. The active material 20 is lead dioxide (PbO2).

As was alluded to earlier, the present practice of processing glass sheaths 28 for tubes 18
suffers from a number of serious shortcomings. The disclosed processes, on the other
hand, substantially reduce the problems posed by pollution, high energy consumption and
expensive solvent waste.

While in accordance with the provisions of the statutes, there is illustrated and described
herein specific embodiments of the invention, those skilled in the art will understand that
changes may be made in the form of the invention covered by the claims and that certain
features of the invention may sometimes be used to advantage without a corresponding
use of the other features.