Lead-acid battery containing fibrous mat
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- DARAMIC LLC
- Filing Date
- 2026-03-12
- Publication Date
- 2026-06-09
AI Technical Summary
【0060】 新規又は改良された電池、特に、本明細書に記載されている及び/又は示されている鉛酸電池;新規又は改良された、システム、車両、電池、強化型液式鉛酸電池、ディープサイクル電池、セパレータ、電池セパレータ、強化型液式鉛酸電池セパレータ、ディープサイクル電池セパレータ、セパレータ、繊維状マット、セル、電極、並びに/又は、かかるシステム、車両、電池、強化型液式鉛酸電池、ディープサイクル電池、セパレータ、電池セパレータ、強化型液式鉛酸電池セパレータ、ディープサイクル電池セパレータ、セパレータ、繊維状マット、セル、及び/若しくは電極の製造及び/若しくは使用方法;改良された鉛酸電池用セパレータを有する改良された電池、及び/又は、かかる改良されたセパレータを有するかかる電池の改良された使用方法;鉛酸電池において、電池寿命を改善する、電池故障を低減する、水分損失を低減する、フロート電流を低下させる、内部抵抗の増加を軽減する、湿潤性を増加させる、酸層化を低減する、酸拡散を改良する、活物質を 保存する、活物質の脱落を軽減する、及び/又は均一性を改良するための方法、システム、処理、及び電池セパレータ;改良された鉛酸電池用セパレータであって、改良された機能性コーティングを含む当該セパレータ、酸層化を低減する改良された電池セパレータ、酸拡散を改良する改良された電池セパレータ、活物質を保存する改良された鉛酸電池、活物質の脱落を軽減する改良された鉛酸電池セパレータ、かかる改良されたセパレータを含む改良された鉛酸電池、自動車用長寿命鉛酸電池、改良された液式鉛酸電池など、並びに/又は、低減した酸層化、改良された酸拡散、改良された活物質保存能力、及び/若しくは改良された活物質脱落低減能力を有する電池;ポリエチレンセパレータ及びこの間に繊維状マットが配置されている負極を有する電池、並びに/又は、かかる電池の製造及び/若しくは使用方法;多孔質膜及びこれに積層された繊維状マットを有する電池であって、繊維状マットがかかる電池において負極に隣接している、かかる電池、並びに/又は、かかる電池の製造及び/若しくは使用方法。
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Figure 2026094428000001_ABST
Abstract
Claims
1. An electrode array including one or more negative electrodes and one or more positive electrodes arranged alternately between the one or more negative electrodes; A fibrous mat envelope in which one of the one or more negative electrodes is disposed; and A porous membrane envelope in which the aforementioned fibrous mat envelope is disposed Lead-acid batteries, including those mentioned above.
2. The lead-acid battery according to claim 1, wherein the fibrous mat envelope is one of the list consisting of nonwoven fabrics, mesh, fleece, and combinations thereof.
3. The lead-acid battery according to claim 1, wherein the fibrous mat envelope comprises at least one material selected from the group consisting of glass fibers, pulp, polymers, and combinations thereof.
4. The fibrous mat envelope is formed from a polymer, and additionally from one or more of the group consisting of glass fibers, pulp, and combinations thereof; The lead-acid battery according to claim 1, wherein the polymer comprises one or more materials selected from the group consisting of polyolefins, polyesters, polyamides, polyimides, and combinations thereof.
5. The lead-acid battery according to claim 1, wherein the fibrous mat envelope comprises an inorganic material.
6. The lead-acid battery according to claim 5, wherein the inorganic material includes silica.
7. The lead-acid battery according to claim 1, wherein the fibrous mat envelope comprises a spun-bonded melt-nonwoven composite material.
8. The lead-acid battery according to claim 1, wherein the fibrous mat envelope includes a carbon fiber nonwoven fabric material.
9. The lead-acid battery according to claim 8, wherein the carbon fiber nonwoven material comprises conductive carbon, graphite, artificial graphite, activated carbon, acetylene black, carbon black, high surface area carbon black, graphene, high surface area graphene, Ketjenblack, carbon fiber, carbon filament, carbon nanotube, open-cell carbon foam, carbon mat, carbon felt, carbon buckminsterfullerene (Bucky Balls), scaly graphite, carbon oxide, and combinations thereof.
10. The lead-acid battery according to claim 1, wherein the fibrous mat envelope comprises conductive carbon, graphite, artificial graphite, activated carbon, carbon paper, acetylene black, carbon black, high surface area carbon black, graphene, high surface area graphene, Ketjenblack, carbon fiber, carbon filament, carbon nanotube, open-cell carbon foam, carbon mat, carbon felt, carbon buckminsterfullerene (Bucky Balls), aqueous carbon suspension, scaly graphite, carbon oxide, and combinations thereof.
11. The lead-acid battery according to claim 1, wherein the fibrous mat envelope contains a nucleating additive.
12. The nucleation additive is in the form of carbon, barium sulfate (BaSO4). ４ ), and one of the combinations thereof, the lead-acid battery according to claim 11.
13. The lead-acid battery according to claim 12, wherein the form of carbon includes conductive carbon, graphite, artificial graphite, activated carbon, carbon paper, acetylene black, carbon black, high surface area carbon black, graphene, high surface area graphene, Ketjenblack, carbon fiber, carbon filament, carbon nanotube, open-cell carbon foam, carbon mat, carbon felt, carbon buckminsterfullerene (Bucky Balls), aqueous carbon suspension, scaly graphite, carbon oxide, and combinations thereof.
14. The lead-acid battery according to claim 1, wherein the fibrous mat envelope includes a conductive layer disposed adjacent to the negative electrode.
15. The lead-acid battery according to claim 14, wherein the conductive layer comprises conductive carbon, graphite, artificial graphite, activated carbon, carbon paper, acetylene black, carbon black, high surface area carbon black, graphene, high surface area graphene, Ketjenblack, carbon fiber, carbon filament, carbon nanotube, open-cell carbon foam, carbon mat, carbon felt, carbon buckminsterfullerene (Bucky Balls), aqueous carbon suspension, scaly graphite, carbon oxide, and combinations thereof.
16. The lead-acid battery according to claim 1, wherein the porous membrane includes one or more arrays of ribs on at least one of its surfaces, and the one or more arrays of ribs are located on two of its surfaces.
17. The lead-acid battery according to claim 16, wherein the ribs of one or more arrays of the ribs have a height of about 10 μm to about 2.0 mm.
18. The lead-acid battery according to claim 1, wherein the porous membrane comprises at least one material selected from the group consisting of natural materials, synthetic materials, polyolefins, phenolic resins, polyvinyl chloride (PVC), natural rubber, synthetic rubber, synthetic wood pulp, glass fibers, lignin, cellulose fibers, and combinations thereof.
19. The lead-acid battery according to claim 1, wherein the porous membrane comprises polyethylene, silica, and processing oil.
20. The lead-acid battery according to claim 1, wherein the porous membrane is sealed on one of the following: one side of the positive electrode, two sides of the positive electrode, and three sides of the positive electrode.
21. The lead-acid battery according to claim 1, wherein the fibrous mat envelope is sealed on one of the following: one side of the negative electrode, two sides of the negative electrode, and three sides of the negative electrode.
22. The lead-acid battery according to claim 1, wherein the porous membrane has a porosity of more than approximately 55%.
23. The lead-acid battery according to claim 22, wherein the porous membrane has a porosity of more than approximately 60%.
24. The lead-acid battery according to claim 23, wherein the porous membrane has a porosity of more than approximately 65%.
25. The lead-acid battery according to claim 1, wherein the porous membrane is a microporous battery separator.
26. An electrode array including one or more negative electrodes and one or more positive electrodes arranged alternately between the one or more negative electrodes; One or more electrodes, and at least one of the one or more negative electrodes, at least partially A fibrous mat assembly including an embodying fibrous mat; and A porous membrane that envelops one of the one or more electrodes and a fibrous mat assembly, or at least one of the one or more positive electrodes adjacent to the one or more electrodes and the fibrous mat assembly; Lead-acid batteries, including those mentioned above.
27. The lead-acid battery according to claim 26, further comprising an active material associated with one or more negative electrodes; wherein the fibrous mat is integrated with the active material to a thickness of about 2% to about 50% of the mat thickness of the fibrous mat.
28. The lead-acid battery according to claim 27, wherein the fibrous mat is integrated with the active material to a thickness of approximately 5% to approximately 25% of the mat's thickness.
29. The lead-acid battery according to claim 28, wherein the fibrous mat is integrated with the active material to a thickness of about 5% to about 20% of the mat's thickness.
30. The lead-acid battery according to claim 29, wherein the fibrous mat is integrated with the active material to a thickness of approximately 10% to approximately 15% of the mat thickness.
31. The lead-acid battery according to claim 26, wherein the fibrous mat is one of the list consisting of nonwoven fabric, mesh, fleece, and combinations thereof.
32. The lead-acid battery according to claim 26, wherein the fibrous mat is formed from at least one material selected from the group consisting of glass fibers, pulp, polymers, and combinations thereof.
33. The fibrous mat is formed from a polymer, and additionally from one or more materials selected from the group consisting of glass fibers, pulp, and combinations thereof; The lead-acid battery according to claim 26, wherein the polymer comprises at least one selected from the group consisting of polyolefins, polyesters, polyamides, polyimides, and combinations thereof.
34. The lead-acid battery according to claim 26, wherein the fibrous mat includes an inorganic material.
35. The lead-acid battery according to claim 34, wherein the inorganic material includes silica.
36. The lead-acid battery according to claim 26, wherein the fibrous mat is a spun-bonded melt-nonwoven fabric composite material.
37. The lead-acid battery according to claim 26, wherein the fibrous mat is a carbon fiber nonwoven fabric material.
38. The lead-acid battery according to claim 37, wherein the carbon fiber nonwoven material comprises conductive carbon, graphite, artificial graphite, activated carbon, acetylene black, carbon black, high surface area carbon black, graphene, high surface area graphene, Ketjenblack, carbon fiber, carbon filament, carbon nanotube, open-cell carbon foam, carbon mat, carbon felt, carbon buckminsterfullerene (Bucky Balls), scaly graphite, carbon oxide, and combinations thereof.
39. The fibrous mat is made of conductive carbon, graphite, artificial graphite, activated carbon, carbon paper, acetyl The lead-acid battery according to claim 26, comprising Lenblack, carbon black, high surface area carbon black, graphene, high surface area graphene, Ketjenblack, carbon fiber, carbon filament, carbon nanotube, open-cell carbon foam, carbon mat, carbon felt, carbon buckminsterfullerene (Bucky Balls), aqueous carbon suspension, scaly graphite, carbon oxide, and combinations thereof.
40. The lead-acid battery according to claim 26, wherein the fibrous mat contains a nucleating additive.
41. The nucleation additive is in the form of carbon, barium sulfate (BaSO4). ４ The lead-acid battery according to claim 40, which is one of the combinations thereof.
42. The lead-acid battery according to claim 41, wherein the form of carbon includes conductive carbon, graphite, artificial graphite, activated carbon, carbon paper, acetylene black, carbon black, high surface area carbon black, graphene, high surface area graphene, Ketjenblack, carbon fiber, carbon filament, carbon nanotube, open-cell carbon foam, carbon mat, carbon felt, carbon buckminsterfullerene (Bucky Balls), aqueous carbon suspension, scaly graphite, carbon oxide, and combinations thereof.
43. The lead-acid battery according to claim 26, wherein the fibrous mat includes a conductive layer disposed adjacent to the negative electrode.
44. The lead-acid battery according to claim 43, wherein the conductive layer comprises conductive carbon, graphite, artificial graphite, activated carbon, carbon paper, acetylene black, carbon black, high surface area carbon black, graphene, high surface area graphene, Ketjenblack, carbon fiber, carbon filament, carbon nanotube, open-cell carbon foam, carbon mat, carbon felt, carbon buckminsterfullerene (Bucky Balls), aqueous carbon suspension, scaly graphite, carbon oxide, and combinations thereof.
45. The lead-acid battery according to claim 26, wherein the porous membrane includes one or more arrays of ribs on at least one of its surfaces.
46. The lead-acid battery according to claim 38, wherein one or more arrays of the ribs are located on each of the two surfaces thereof.
47. The lead-acid battery according to claim 46, wherein the ribs of the rib array have a height of about 10 μm to about 2.0 mm.
48. The lead-acid battery according to claim 26, wherein the porous membrane comprises at least one material selected from the group consisting of natural materials, synthetic materials, polyolefins, phenolic resins, polyvinyl chloride (PVC), natural rubber, synthetic rubber, synthetic wood pulp, glass fibers, lignin, cellulose fibers, and combinations thereof.
49. The lead-acid battery according to claim 26, wherein the porous membrane comprises polyethylene, silica, and processing oil.
50. The lead-acid battery according to claim 26, wherein the porous membrane is sealed on one of the following: one side of the positive electrode, two sides of the positive electrode, and three sides of the positive electrode.
51. The porous membrane is: one side of the one or more electrodes and fibrous mat assembly, two sides of the one or more electrodes and fibrous mat assembly, and the one or more electrodes and fibrous mat assembly. The lead-acid battery according to claim 26, which is sealed in one of three sides of a fibrous mat assembly.
52. The lead-acid battery according to claim 26, wherein the porous membrane is a microporous battery separator.
53. An electrode array including one or more negative electrodes and one or more positive electrodes arranged alternately with respect to each other; and A porous membrane that envelops at least one of the one or more negative electrodes located inside; A liquid lead-acid battery including, The porous membrane includes ribs on one or more of its surfaces; A liquid lead-acid battery in which a fibrous mat is placed inside the envelope.
54. The liquid lead-acid battery according to claim 53, wherein the ribs are at least partially on the surface of a porous membrane adjacent to the fibrous mat.
55. The liquid lead-acid battery according to claim 53, wherein the ribs have a height of about 10 μm to about 2.0 mm.
56. The liquid lead-acid battery according to claim 53, wherein the ribs have a height of about 5 μm to about 300 μm.
57. The liquid lead-acid battery according to claim 53, wherein the ribs have a height of about 25 μm to about 200 μm.
58. The liquid lead-acid battery according to claim 53, wherein the fibrous mat envelops one of the one or more negative electrodes.
59. The liquid lead-acid battery according to claim 53, wherein the fibrous mat is at least partially integrated with the negative electrode.
60. The liquid lead-acid battery according to claim 53, wherein the fibrous mat includes separate pieces disposed between the ribs.
61. The liquid lead-acid battery according to claim 53, wherein the fibrous mat has a thickness of about 50% to about 150% of the height of the ribs.
62. The liquid lead-acid battery according to claim 53, wherein the fibrous mat is disposed between the negative electrode and the porous membrane, and is optionally laminated on the porous membrane.
63. The liquid lead-acid battery according to claim 53, wherein the fibrous mat comprises at least one material selected from the group consisting of glass fibers, pulp, polymers, and combinations thereof.
64. The fibrous mat is formed from a polymer in combination with at least one material selected from the group consisting of glass fibers, pulp, and combinations thereof; The liquid lead-acid battery according to claim 53, wherein the polymer comprises at least one selected from the group consisting of polyolefins, polyesters, polyamides, polyimides, and combinations thereof.
65. The liquid lead-acid battery according to claim 53, wherein the fibrous mat includes an inorganic material.
66. The liquid lead-acid battery according to claim 65, wherein the inorganic material includes silica.
67. The liquid lead-acid battery according to claim 53, wherein the fibrous mat is a spun-bonded melt-nonwoven fabric composite material.
68. The liquid lead-acid battery according to claim 53, wherein the fibrous mat includes a carbon fiber nonwoven fabric material.
69. The liquid lead-acid battery according to claim 68, wherein the carbon fiber nonwoven material comprises conductive carbon, graphite, artificial graphite, activated carbon, acetylene black, carbon black, high surface area carbon black, graphene, high surface area graphene, Ketjenblack, carbon fiber, carbon filament, carbon nanotube, open-cell carbon foam, carbon mat, carbon felt, carbon buckminsterfullerene (Bucky Balls), scaly graphite, carbon oxide, and combinations thereof.
70. The liquid lead-acid battery according to claim 53, wherein the fibrous mat comprises conductive carbon, graphite, artificial graphite, activated carbon, carbon paper, acetylene black, carbon black, high surface area carbon black, graphene, high surface area graphene, Ketjenblack, carbon fiber, carbon filament, carbon nanotube, open-cell carbon foam, carbon mat, carbon felt, carbon buckminsterfullerene (Bucky Balls), aqueous carbon suspension, scaly graphite, carbon oxide, and combinations thereof.
71. The liquid lead-acid battery according to claim 53, wherein the fibrous mat contains a nucleating additive.
72. The nucleation additive is in the form of carbon, barium sulfate (BaSO4). ４ A liquid lead-acid battery according to claim 71, which is one of the combinations thereof.
73. The liquid lead-acid battery according to claim 72, wherein the form of carbon includes conductive carbon, graphite, artificial graphite, activated carbon, carbon paper, acetylene black, carbon black, high surface area carbon black, graphene, high surface area graphene, Ketjenblack, carbon fiber, carbon filament, carbon nanotube, open-cell carbon foam, carbon mat, carbon felt, carbon buckminsterfullerene (Bucky Balls), aqueous carbon suspension, scaly graphite, carbon oxide, and combinations thereof.
74. The liquid lead-acid battery according to claim 53, wherein the fibrous mat includes a conductive layer disposed adjacent to the negative electrode.
75. The lead-acid battery according to claim 74, wherein the conductive layer comprises conductive carbon, graphite, artificial graphite, activated carbon, carbon paper, acetylene black, carbon black, high surface area carbon black, graphene, high surface area graphene, Ketjenblack, carbon fiber, carbon filament, carbon nanotube, open-cell carbon foam, carbon mat, carbon felt, carbon buckminsterfullerene (Bucky Balls), aqueous carbon suspension, scaly graphite, carbon oxide, and combinations thereof.
76. The liquid lead-acid battery according to claim 53, wherein the porous membrane has ribs on its two surfaces.
77. The porous membrane comprises at least one material selected from the group consisting of natural materials, synthetic materials, polyolefins, phenolic resins, polyvinyl chloride (PVC), natural rubber, synthetic rubber, synthetic wood pulp, glass fibers, lignin, cellulose fibers, and combinations thereof. The liquid lead-acid battery according to claim 53.
78. The liquid lead-acid battery according to claim 53, wherein the porous membrane comprises polyethylene, silica, and processing oil.
79. The liquid lead-acid battery according to claim 78, wherein the processing oil is present in an amount of approximately 5% by weight to approximately 15% by weight of the porous membrane.
80. The liquid lead-acid battery according to claim 53, wherein the porous membrane is sealed on one of the following: one side of the negative electrode, two sides of the negative electrode, and three sides of the negative electrode.
81. The liquid lead-acid battery according to claim 53, wherein the fibrous mat is sealed on one of the following: one side of the negative electrode, two sides of the negative electrode, and three sides of the negative electrode.
82. The liquid lead-acid battery according to claim 53, wherein the porous membrane is a microporous battery separator.
83. A vehicle and a system comprising a lead-acid battery or liquid lead-acid battery according to any one of claims 1, 26, or 53.
84. The vehicle according to claim 83, wherein the vehicle is one selected from the group consisting of automobiles, trucks, motorcycles, all-terrain vehicles, motorcycles, forklifts, golf carts, hybrid vehicles, hybrid electric vehicles, electric vehicles, idle-start-stop ("ISS") vehicles, batteries for electric rickshaws, electric tricycles, electric bicycles, wheelchairs, and ships.
85. A lead-acid battery or liquid lead-acid battery according to any one of claims 1, 26, or 53, selected from the group consisting of plate batteries, liquid lead-acid batteries, reinforced liquid lead-acid batteries ("EFB"), valve-regulated lead-acid ("VRLA") batteries, gel batteries, absorbent glass mat ("AGM") batteries, deep cycle batteries, tubular batteries, power batteries, inverter batteries, PSoC batteries, vehicle batteries, start-light-ignition ("SLI") vehicle batteries, idle-start-stop ("ISS") vehicle batteries, automobile batteries, truck batteries, motorcycle batteries, all-terrain vehicle batteries, forklift batteries, golf cart batteries, hybrid electric vehicle batteries, electric vehicle batteries, wheelchair batteries, electric rickshaw batteries, electric tricycle batteries, electric bicycle batteries, and marine batteries.
86. A method for preventing acid displacement in a lead-acid battery, a liquid lead-acid battery, an enhanced liquid lead-acid battery, or a liquid lead-acid battery that operates in or is intended to operate in a partially charged state, the method comprising manufacturing the battery to have the same structure as the battery described in any of claims 1, 26, or 53.