Bisphenol-Based Resin Electrode for Lead Storage Battery Sulfation

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Solution Overview

Problem

Lead storage batteries used in idling stop systems face challenges with sulfation and stratification due to incomplete charging, leading to reduced cycle characteristics and performance.

Innovation Solution

A bisphenol-based resin is developed through a reaction involving a bisphenol-based compound, aminobenzenesulfonic acids, and formaldehyde derivatives, with a benzoxazine ring content of 15 mass % or less, which improves storage stability and cycle characteristics by suppressing reactant coarsening and maintaining a high specific surface area.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If the lead storage battery is used in idling stop systems with frequent engine start-stop cycles, then the battery must handle heavy discharge loads, but sulfation occurs and cycle characteristics are lowered

Engineering Contradiction:

Improvedischarge load capabilityVSAvoidcycle characteristics

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

The patent modifies the chemical composition parameters of the negative electrode active material by incorporating specific compounds (aminobenzenesulfonic acid and formaldehyde condensates) to change the electrochemical properties and prevent sulfation, thereby maintaining reliability under heavy power demands

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite negative electrode material combining lead-based active material with condensates of phenols, aminobenzenesulfonic acid, and formaldehyde, where the composite structure provides both high power capability and resistance to sulfation

Inventive Principle:

Principle #40Composite materials

2Duration of action of moving object

If complete charging is not easily performed, then the battery operates in a partially charged state, but stratification phenomenon occurs and sulfation accumulates on the polar plate

Engineering Contradiction:

Improveoperational flexibilityVSAvoidbattery performance

Core Design Contradiction:

Duration of action of moving objectVSReliability

Solution Approach 1:

The patent applies preliminary protective action by pre-treating the negative electrode with specific chemical compounds that prevent sulfation formation before it can occur during partial charging cycles, thereby maintaining performance over extended operational periods

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent converts the harmful effect of partial charging (which causes sulfation) into a beneficial outcome by using the same partial charging conditions to promote formation of a protective layer that prevents sulfation and improves overall battery performance

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Quantity of substance

If the concentration of dilute sulfuric acid becomes high in the lower part of the polar plate, then sulfation occurs, but the reactivity is lowered and active material exfoliates from the current collector

Engineering Contradiction:

Improveelectrolyte concentrationVSAvoidconnection strength

Core Design Contradiction:

Quantity of substanceVSStrength

Solution Approach 1:

The patent applies local quality improvement by creating a negative electrode with non-uniform chemical composition and structure that provides enhanced protection specifically at regions prone to high sulfuric acid concentration and sulfation, thereby maintaining connection strength throughout the electrode

Inventive Principle:

Principle #3Local quality

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 bisphenol-based resin enhances storage stability and cycle characteristics, balancing charge acceptability, discharge characteristics, and cycle performance in lead storage batteries, making them suitable for severe environments like idling stop systems.

Implementation Method 1

obtained by a reaction of (a) a bisphenol-based compound, (b) at least one selected from the group consisting of aminobenzenesulfonic acids and aminobenzenesulfonic acid derivatives, and (c) at least one selected from the group consisting of formaldehyde and formaldehyde derivatives

Methodology Applied

Scientific EffectCondensation polymerization:

Implementation Method 2

a content of a structural unit that is obtained by the reaction of the component (a), the component (b) and the component (c) and also has a benzoxazine ring is 15 mass % or less

Methodology Applied

Scientific EffectBenzoxazine ring formation:

Data Source

PatentUS9997782B2Bisphenol-based resin, electrode, lead storage battery, production methods for these, and resin composition

Publication Date: 2018.06.12 RESONAC CORP

AI summary

An electrode includes an electrode layer including an electrode active material or a raw material of an electrode active material and a bisphenol-based resin, and a current collector supporting the electrode layer. The bisphenol-based resin is obtained by a reaction of (a) a bisphenol-based compound, (b) at least one selected from the group consisting of aminobenzenesulfonic acids and aminobenzenesulfonic acid derivatives, and (c) at least one selected from the group consisting of formaldehyde and formaldehyde derivatives, wherein a content of a structural unit that is obtained by the reaction of the component (a), the component (b) and the component (c) and also has a benzoxazine ring is 15 mass % or less. A production method for the electrode is also disclosed.