Glass Microfiber Pasting Carrier for Stable Lead-Acid Electrodes
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Solution Overview
Problem
Lead-acid batteries face issues with electrode expansion and contraction leading to breakage and increased weight due to the formation of lead sulfate, and highly conductive grids without porosity struggle to support pasting materials effectively.
Innovation Solution
A nonwoven fiber mat made of entangled glass microfibers with a binder is used as a pasting carrier, providing structural strength and wettability to support conductive materials while preventing them from passing through, and manufacturing involves dispersing glass microfibers in an aqueous solution and applying a binder to form a mat with specific thickness and porosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If highly conductive grids without porosity are used, then electrical conductivity is improved, but the ability to support pasting materials deteriorates
Solution Approach 1:
The patent applies composite materials by combining a highly conductive grid with a nonwoven pasting carrier made of glass microfibers and binder. The grid provides electrical conductivity while the nonwoven carrier provides mechanical support and porosity, creating a composite structure that resolves the contradiction between conductivity and support ability.
Solution Approach 2:
The nonwoven pasting carrier acts as an intermediary between the highly conductive grid and the pasting materials. It provides the necessary porosity and mechanical support while allowing the grid to maintain its electrical conductivity function, mediating between the conflicting requirements.
2Power
If lead sulfate forms on electrodes during discharge, then electrical energy is produced, but electrode weight increases and structure deteriorates
Solution Approach 1:
The nonwoven pasting carrier provides a porous structure that accommodates the formation of lead sulfate during discharge. The porosity allows the electrode to expand and contract without structural deterioration, managing the weight increase through proper material distribution and structure.
3Duration of action of moving object
If electrodes expand and contract during charge-discharge cycles, then electrochemical reactions occur, but electrode pieces break off
Solution Approach 1:
The patent changes the physical parameters of the electrode structure by using a nonwoven pasting carrier with specific porosity and mechanical properties. This allows the electrode to accommodate expansion and contraction through controlled deformation of the nonwoven structure rather than brittle failure, maintaining structural integrity during electrochemical reactions.
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 pasting carrier enhances electrode stability, reduces the weight and size of lead-acid batteries, and extends battery life by efficiently supporting pasting materials and managing electrochemical reactions, allowing for increased charge density and reduced lead usage.
Implementation Method 1
The wettability of the first pasting carrier enables the first pasting carrier to support the first conductive material by absorbing a portion of the first conductive material while preventing the first conductive material from passing through the first pasting carrier
Implementation Method 2
between 15 and 60 weight percentage of a binder that binds the smaller sized glass microfibers and the larger sized glass microfibers together
Data Source
AI summary
A pasting carrier for a lead-acid battery. The pasting carrier includes a nonwoven fiber mat having a thickness between 5 and 50 mils, the nonwoven fiber mat being composed of a plurality of entangled glass microfibers.