Fibrous Mat Battery Separator for Acid Stratification Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Enhanced flooded lead acid batteries face challenges such as acid stratification, increased internal resistance, and reduced cycle life due to antimony poisoning and active material shedding, which affect their performance and longevity, especially in start/stop applications.
Innovation Solution
A novel battery separator with a fibrous mat and a porous membrane having ribs and enhanced porosity, incorporating additives like amorphous silica and silanol group silica to improve retention of active material and reduce electrical resistance, thereby preventing acid stratification and shedding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional separators are used in enhanced flooded lead acid batteries, then manufacturing cost is reduced, but acid stratification occurs and cycle life decreases
Solution Approach 1:
The separator is divided into multiple functional layers: a base separator layer and an overlaid fibrous mat layer. This segmentation allows each layer to perform specific functions - the base layer provides structural support and basic separation, while the fibrous mat layer specifically addresses acid stratification and active material retention, thereby extending cycle life without requiring complete redesign of the entire separator system.
Solution Approach 2:
The separator combines different materials with complementary properties: the base separator material (providing structural integrity and electrical insulation) and the fibrous mat material (providing acid mixing channels and active material retention). This composite structure synergistically improves reliability and cycle life while maintaining manufacturing feasibility through established composite material processing techniques.
2Power
If separator porosity is increased to improve acid diffusion, then cold cranking amps increase, but mechanical strength decreases
Solution Approach 1:
The separator structure separates the functions of mechanical support and acid diffusion by using distinct layers: the base separator layer maintains mechanical strength and structural integrity, while the overlaid fibrous mat layer provides high porosity channels for acid diffusion. This segmentation allows optimization of each layer for its specific function without compromising the other, enabling increased cold cranking amps while maintaining sufficient separator strength.
Solution Approach 2:
Different regions of the separator have different porosity characteristics tailored to local requirements. The fibrous mat layer exhibits higher porosity in regions where acid diffusion is critical, while the base separator layer maintains lower porosity for structural support. This local quality differentiation allows the separator to simultaneously achieve high cold cranking amps through improved acid diffusion and adequate mechanical strength through structured support regions.
3Reliability
If fibrous mat is added to the separator to prevent active material shedding, then retention improves, but manufacturing complexity increases
Solution Approach 1:
The fibrous mat layer is pre-formed and then overlaid onto the base separator layer in a straightforward manufacturing process. This preliminary preparation of the fibrous mat allows it to be integrated into the separator structure before battery assembly, ensuring active material retention functionality is built-in from the start rather than requiring additional processing steps later, thus maintaining ease of manufacture while achieving improved retention.
Solution Approach 2:
The manufacturing process merges the base separator layer and fibrous mat layer into a single integrated separator component through overlay and bonding. This combining approach ensures that both layers work together as a unified structure for active material retention, while the process itself remains relatively simple - essentially layering one material onto another - thereby maintaining ease of manufacture despite the enhanced retention functionality.
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 effectively reduces acid stratification, increases cold cranking amps, and enhances battery life by improving acid diffusion and retention of active material, leading to better performance and longer cycle life in enhanced flooded lead acid batteries.
Implementation Method 1
improving acid diffusion
Implementation Method 2
enhanced flooded lead acid batteries
Implementation Method 3
increasing wettability
Data Source
AI summary
In at least one embodiment, a separator is provided with a fibrous mat for retaining the active material on an electrode of a lead-acid battery. New or improved mats, separators, batteries, methods, and/or systems are also disclosed, shown, claimed, and/or provided. For example, in at least one possibly preferred embodiment, a composite separator is provided with a fibrous mat for retaining the active material on an electrode of a lead-acid battery. In at least one possibly particularly preferred embodiment, a PE membrane separator is provided with at least one fibrous mat for retaining the active material on an electrode of a lead-acid battery. In accordance with at least certain embodiments, aspects and/or objects, the present invention, application, or disclosure may provide solutions, new products, improved products, new methods, and/or improved methods, and/or may address issues, needs, and/or problems of PAM shedding, NAM shedding, electrode distortion, active material shedding, active material loss, and/or physical separation, electrode effectiveness, battery performance, battery life, and/or cycle life, and/or may provide new battery separators, new battery technology, and/or new battery methods and/or systems that address the challenges arising from current lead acid batteries or battery systems, especially new battery separators, new battery technology, and/or new battery methods and/or systems adapted to prevent or impede the shedding of active material from the electrodes, preferably or particularly in enhanced flooded lead acid batteries, PSoC batteries, ISS batteries, ESS batteries, and/or the like.