Shell strength consideration: improved impact safety performance of lead-acid batteries

Time：2025-03-21 09:39:01

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Therefore, improving the impact safety performance of lead-acid batteries has become an important issue to ensure their reliable operation and reduce potential risks, and the shell strength is the core consideration.

As a widely used energy storage device, lead-acid batteries play a key role in many fields such as transportation, communication base stations, and uninterruptible power supplies. Its working environment is complex and diverse, and it often faces external shocks such as vibration and collision. Therefore, improving the impact safety performance of lead-acid batteries has become an important issue to ensure their reliable operation and reduce potential risks, and the shell strength is the core consideration.

1. Impact risk and consequence analysis of lead-acid batteries

In the transportation scene, the bumpy vibration of cars and electric vehicles when driving, or the collision accident, the lead-acid battery will be affected by different degrees of impact. If the communication base station encounters natural disasters such as earthquakes and strong winds, the battery placed in it may also be affected by the displacement or fall of the equipment. Once the lead-acid battery is hit, the shell as the first line of defense, if the strength is insufficient, it is easy to crack, deformation and other conditions. If the shell is broken, the electrolyte will leak. Sulfuric acid electrolyte is highly corrosive, which will not only corrode the surrounding equipment and facilities, but also cause burns to personnel. Electrolyte leakage will also cause the imbalance of the electrochemical reaction inside the battery, resulting in battery performance degradation or even failure, seriously affecting the normal operation of the device. If the impact causes an internal short circuit of the battery, it may also cause a fire or even an explosion, resulting in serious safety hazards and property losses.

2. Existing lead-acid battery shell material and strength defects

Traditional lead-acid battery shells are mostly made of polypropylene (PP) or polyvinyl chloride (PVC) materials. PP material has a certain degree of chemical corrosion resistance and processing formability, but the strength is relatively low, and it is easy to crack when subjected to a large impact. PVC material cost is low, but its impact resistance is not good, in low temperature environment, the material becomes brittle, more easily damaged by impact. Moreover, some lead-acid battery shell design pays too much attention to cost control, thin wall thickness, simple structure, lack of effective anti-impact reinforcement structure. This shell may barely cope with minor collisions in the face of daily transportation and installation, but once it encounters a more violent impact, it is difficult to withstand and cannot provide reliable protection for the internal structure of the battery.

3. Enhance the housing strength to enhance the impact safety performance strategy

i.Optimize shell material selection

High strength engineering plastics can be selected, such as polycarbonate (PC) and acrylonitrile-butadiene-styrene copolymer (ABS) alloy material (PC/ABS). PC has good mechanical properties, high impact strength and dimensional stability, while ABS has excellent formability, chemical resistance and surface gloss. After alloying the two, the advantages of both are combined, and the impact strength of the shell is significantly improved while maintaining good machining performance. For example, some high-end power tools use lead-acid batteries, using PC/ABS alloy shell, after several simulated drops, impact tests, the shell is still intact, effectively protecting the internal structure of the battery.

ii. Innovative shell structure design

Honeycomb or multi-layer composite structure is used to design the shell. The honeycomb structure has the characteristics of light weight and high strength, and its unique hexagonal unit can effectively disperse the external force and evenly distribute the impact energy to the entire shell, thus improving the anti-impact ability of the shell. The multi-layer composite structure can combine materials with different properties, the outer layer uses high-strength and wear-resistant materials to withstand the impact force, the middle layer uses buffer materials to absorb the impact energy, and the inner layer uses corrosion-resistant materials to protect the inside of the battery. For example, in some large energy storage lead-acid batteries, the use of steel plate and rubber, plastic multi-layer composite shell structure, not only greatly enhances the strength of the shell, but also has a good shock absorption buffer effect, effectively reducing the impact on the battery internal impact.

iii. Strengthen the shell manufacturing process control

During the shell manufacturing process, the injection molding process parameters are strictly controlled to ensure the uniform distribution of materials and avoid defects such as bubbles and shrinkage marks to ensure the overall strength of the shell. For example, the injection temperature, pressure and injection speed are precisely controlled so that the plastic is fully filled in the mold to form a dense, uniform shell structure. At the same time, strict quality testing is carried out on the manufactured shell, using ultrasonic flaw detection, pressure testing and other means to detect whether there are internal defects in the shell and whether the actual strength meets the design requirements. Only through the strict inspection of the shell, can we enter the subsequent battery assembly process, and ensure the quality and strength of the lead-acid battery shell from the source.

iv. Carry out simulation analysis and test verification

Finite element analysis (FEA) software was used to simulate the stress distribution and deformation of lead-acid battery shell under different impact conditions. By establishing an accurate model, the possible weak links of the shell can be predicted in advance, so as to carry out targeted optimization design. In the product development stage, a large number of actual impact tests are carried out, including drop tests, pendulum impact tests, etc., to simulate the impact situation in various real scenarios. According to the test results, the material selection, structural design and manufacturing process are repeatedly adjusted and optimized until the impact resistance of the lead-acid battery shell reaches the ideal level.

To improve the anti-impact safety performance of lead-acid batteries, the reliability and safety of lead-acid batteries in complex external environments can be significantly improved by optimizing material selection, innovative structural design, strengthening manufacturing process control and using simulation analysis and testing verification methods from the consideration of shell strength. This not only helps to extend the battery life, reduce maintenance costs, but also provides a strong guarantee for the safety of related equipment and personnel, and promotes the safe and stable application of lead-acid batteries in various fields. In actual production and application, we should continue to pay attention to the development of new materials and new processes, and continue to explore more effective shell strength enhancement programs to adapt to the increasingly diverse and harsh use environment.

Statement: The articles on this site are written by the GSGT team or reprinted from other media or compiled by AI.No reproduction without permission.For copyright or other issues, please contact:gsgtpower@163.com.

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