Lead-Acid Battery Pasting Paper for Stratification and Charge Balance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional pasting papers for lead acid batteries fail to effectively prevent electrolyte stratification, maintain high-rate dischargeability, and ensure charge acceptability, particularly in idling stop-and-start systems, due to large fiber diameters and insulating properties that increase electrical resistance.
Innovation Solution
A nonwoven fabric with an average fiber diameter of 2.0 μm or less, composed of insulating fibers and electrically conductive carbon fibers, where the carbon fibers have a diameter of 10 μm or less and are distributed in a non-uniform manner to enhance sheet resistivity and prevent electrolyte stratification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional pasting paper with large fiber diameter (100 μm or more maximum pore size) is used, then the durability and protection of pole plate active material is improved, but the electrolyte cannot be held and electrolyte stratification cannot be effectively prevented
Solution Approach 1:
The patent applies local quality by creating a dual-structure nonwoven fabric where different regions serve different functions: the glass fiber network provides structural support and durability, while the fine polyester fibers create small pores for electrolyte retention. This local differentiation of fiber functions resolves the contradiction between durability and electrolyte holding capability.
Solution Approach 2:
The patent uses composite materials by combining glass fibers (for durability and electrolyte resistance) with fine polyester fibers (for electrolyte retention through small pores). This composite structure integrates the advantages of both materials, achieving both pole plate protection and effective prevention of electrolyte stratification simultaneously.
2Reliability
If a nonwoven fabric with very thick fiber (average fiber diameter of 8 μm or more) is used, then the fall-off inhibition of pole plate active material is improved, but the maximum pore size becomes very large (exceeds 100 μm) and cannot prevent electrolyte stratification
Solution Approach 1:
The patent segments the fiber structure into two distinct size categories: glass fibers with diameter of 3-12 μm for structural support and fall-off prevention, and fine polyester fibers with diameter of 1-5 μm for creating small pores. This segmentation allows each fiber type to optimize its function, resolving the contradiction between fall-off inhibition and electrolyte retention.
Solution Approach 2:
The patent changes the fiber diameter parameter by introducing fine fibers (1-5 μm) alongside thicker glass fibers (3-12 μm). This parameter variation creates a bimodal fiber size distribution that simultaneously provides structural integrity and small pore formation, preventing electrolyte stratification while maintaining fall-off inhibition.
3Stability of the object's composition
If a fine fiber with average fiber diameter of 2 μm or less is used to inhibit electrolyte stratification, then the electrolyte retention is improved, but the electrical resistance between pole plates increases and charge acceptability decreases
Solution Approach 1:
The patent uses glass fibers as an intermediary conductive network between the fine polyester fibers and the electrolyte. The glass fibers provide a conductive pathway that bridges the insulating fine fibers, maintaining electrical conductivity while allowing the fine fibers to perform their electrolyte retention function. This intermediary structure resolves the contradiction between electrolyte retention and electrical conductivity.
Solution Approach 2:
The glass fibers serve multiple functions simultaneously: they provide structural support for fall-off prevention, maintain electrolyte resistance, and crucially, provide electrical conductivity pathways. This multi-functionality allows the fine fiber structure to retain electrolyte effectively while the glass fiber network maintains charge acceptability through conductivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution achieves inhibition of electrolyte stratification, high-rate dischargeability, and improved charge acceptability by ensuring better electrolyte retention and reaction kinetics, while maintaining high sheet strength and preventing excessive pore size.
Implementation Method 1
a nonwoven fabric composed of a fine fiber having a fiber diameter per fiber (average fiber diameter) of 2 μm or less... electrolyte retention
Implementation Method 2
a nonwoven fabric composed of an insulating fiber and an electrically conductive material... electrically conductive carbon fibers... sheet resistivity
Data Source
AI summary
[Problem] To provide a pasting paper for lead acid batteries compatibly achieving inhibition of electrolyte stratification, a high-rate dischargeability, and charge acceptability in a lead acid battery to be used in an ISS system.[Means for Resolution] A pasting paper for lead acid batteries, which is a nonwoven fabric composed of an insulating fiber and an electrically conductive material, wherein the average fiber diameter in the nonwoven fabric is 2.0 μm or less, and the coefficient of variation of sheet resistivity of the nonwoven fabric indicating that the electrically conductive material is distributed in a non-uniform manner in the nonwoven fabric is 0.03 or more.