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Method of forming a carbon based active layer for an anode of a lead carbon battery and the active layer formed therefrom

a technology of lead carbon batteries and active layers, which is applied in the field of forming carbon based active layers for lead carbon batteries and the active layers therefrom, can solve the problems of battery capacity loss, difficulty in achieving a high number of charge-discharge cycles, and deterioration of rate capability

Inactive Publication Date: 2019-11-07
TEEBS R&D LLC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The patent is about a method of making an active layer for a lead carbon battery and the active layer formed therefrom. The method involves combining a solvent mixture containing poly(vinylidene fluoride), an optional electrically conductive filler, and a solvent with a non-solvent to form a precipitate comprising activated carbon in a fibrillated poly(vinylidene fluoride) matrix. The precipitate is then separated from the solvent and non-solvent, and the resulting active layer is formed. The active layer comprises greater than or equal to 85 weight percent of the activated carbon, 1 to 15 weight percent of the fibrillated poly(vinylidene fluoride), and 0 to 10 weight percent of an electrically conductive filler. The lead carbon battery comprises an activated carbon anode, a cathode, acid, and a casing. The technical effects of this patent are a more efficient active layer for lead carbon batteries that can improve performance and a better understanding of the process behind its formation.

Problems solved by technology

The limitations of lead acid batteries include difficulties in achieving a high number of charge-discharge cycles and a deterioration of rate capability.
While both the anode and cathode contribute to these limitations, the lead metal anode is susceptible to incomplete charging as a certain amount is lost in the replating process, causing a loss in battery capacity.
In addition, the structure of the anode changes, which usually results in less integrity and connectedness that causes additional losses in rate capability.
Since both electrode coatings can utilize the same current collector, the incomplete charging of the lead metal anode affects the mechanical properties of the cathode electrode on the opposite side of the foil.
Also, the loss in connectedness with the resulting loss in rate capability limits the current that is available to the cathode, even without any cathode electrode degradation.
Unfortunately though, the prior activated carbon anodes have not been shown as being capable of achieving the desired high storage capabilities.

Method used

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  • Method of forming a carbon based active layer for an anode of a lead carbon battery and the active layer formed therefrom
  • Method of forming a carbon based active layer for an anode of a lead carbon battery and the active layer formed therefrom

Examples

Experimental program
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example 1

on of an Activated Carbon Anode Using a Phase Inversion Technique

[0044]A porous activated carbon (AC)-PVDF anode was prepared using a phase inversion technique using water as the non-solvent. Specifically, 1 gram of PVDF was dissolved in 42.5 grams of acetone to form a 20% solution by mass using a rotor-stator mixer at room temperature (about 23 degrees Celsius (° C.)). It is noted that other mixing devices are considered as well, for example, FlackTek planetary mixers. 19 grams of activated carbon was added to the PVDF mixture. Portions of the solvent mixture were injected into 25 milliliters of water by rapidly squirting the solvent mixture into the water via a pipette and filtering the precipitate until all of the solvent mixture was precipitated. The water was being actively mixed via a stir bar during the injecting. During the phase inversion process acetone quickly diffused out from the AC-PVDF mixture and formed a macroporous AC-PVDF material, where the PVDF fibrillated in th...

example 2

Porosity on the Discharge Capacity

[0047]Twelve activated carbon anodes were prepared using the phase inversion method with varying concentration of the PVDF and activated carbon. The porosities and discharge capacities of the activated carbon anodes were determined and the results are illustrated in FIG. 5. In FIG. 5, the samples represented with the diamonds contained 9 wt % of fibrillated poly(vinylidene fluoride) and 91 wt % of the activated carbon; the samples represented with the circles contained 7 wt % of fibrillated poly(vinylidene fluoride) and 93 wt % of the activated carbon; and the samples represented by the triangles contained 5 wt % of fibrillated poly(vinylidene fluoride) and 95 wt % of the activated carbon; and the sample represented by the square illustrates that a porosity of almost 70 volume percent was capable of being prepared. FIG. 5 illustrates that increasing the activated carbon anode porosity resulted in an increase in the discharge capacity.

[0048]The disch...

examples 3-6

rbon Electrodes Formed by Other Methods

[0049]The layer of Example 3 was formed by mixing PVDF in acetone using an ultrasonic mixer. Activated carbon was added to the solution and mixed to form a solvent mixture comprising having a weight ratio of the activated carbon to the PDVF of 90:10. The solvent mixture was cast onto a polyester film using a drawdown bar with a gap height of 3 to 4 millimeters. The mixture was dried in air at room temperature and a 25 mm circular die was used to cut the sample and form the layer of Example 3. The layer of Example 3 produced a fractured, brittle sample that could not be tested.

[0050]The layer of Examples 4-6 was formed by mixing PVDF in acetone using an ultrasonic mixer. Activated carbon was added to the solution and mixed to form a solvent mixture comprising having a weight ratio of the activated carbon to the PDVF of 80:20 for Example 4, 90:10 for Example 5, and 95:5 for Example 6. The solvent mixture was put in a mold having a diameter of 25 ...

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Abstract

A method of making an active layer for an activated carbon anode in a lead carbon battery includes forming a solvent mixture including poly(vinylidene fluoride) and a solvent; combining the solvent mixture with a non-solvent to form a precipitate comprising an activated carbon in a fibrillated poly(vinylidene fluoride) matrix; separating the precipitate from the solvent and the non-solvent; and forming the active layer from the precipitate. An active layer is formed by the method. A lead carbon battery includes an activated carbon anode comprising the active layer and a current collector, wherein the active layer is in electrical contact with the current collector; a lead oxide cathode that is in electrical contact with a cathode side current collector; an acid located in between the activated carbon anode and the cathode; and a casing encapsulating the activated carbon anode, the cathode, and the acid.

Description

CROSS-REFERENCE TO RELATED APPLICATION[0001]This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62 / 667,799 filed May 7, 2018. The related application is incorporated herein in its entirety by reference.BACKGROUND[0002]Conventional, commercial lead acid batteries rely on negative electrodes (anodes) that are composed of lead metal and positive electrodes (cathodes) that are composed of lead dioxide to generate an electric current. The limitations of lead acid batteries include difficulties in achieving a high number of charge-discharge cycles and a deterioration of rate capability. While both the anode and cathode contribute to these limitations, the lead metal anode is susceptible to incomplete charging as a certain amount is lost in the replating process, causing a loss in battery capacity. In addition, the structure of the anode changes, which usually results in less integrity and connectedness that causes additional losses in rate capability.[0003]...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): H01M4/22H01M10/12H01M4/04H01M4/583H01M4/62C01B32/312H01M50/406
CPCH01M10/12H01M4/625H01M4/0497H01M2004/027H01M2004/021C01B32/312C01P2004/03H01M4/22H01M4/583H01M4/0404H01M4/16H01M4/56H01M4/623Y02E60/10H01M4/14H01M4/663H01M4/96Y02E60/50Y02P70/50H01M50/406H01M10/20C08J3/09C08J3/215C08J9/28C08J3/095C08J3/096C08J3/097C08J3/14C08J5/18C08K3/013C08K3/04H01M4/622C08J2205/044C08J2327/16C08J2329/04C08J2379/08C08J2427/20C08K2201/005
Inventor TURI, ERANBEARD, TREVORKILHENNY, BRETTWANG, WEI
Owner TEEBS R&D LLC
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