Lead-Acid Negative Electrode Expander Blend for Start-Stop Cycling

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Solution Overview

Problem

Existing lead-acid batteries, particularly AGM batteries, face challenges in providing consistent reliable performance, supporting additional prolonged/intermittent loads, and maintaining optimal duration and frequency of stop events in start-stop vehicles.

Innovation Solution

The addition of specific additives, known as expanders, to the negative active material of lead-acid batteries, including fine particle barium sulfate, organic compounds (oxylignins), and a carbonaceous material, improves the battery's performance by enhancing cycling performance, reducing water loss, and extending service life.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional lead-acid battery negative active material is used, then manufacturing cost is low and manufacturing process is simple, but cycling performance is insufficient and water loss is high

Engineering Contradiction:

Improvecycling performanceVSAvoidnegative active material composition

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies composite materials by combining lead oxide with multiple expander additives including barium sulfate, organic compounds (oxylignins), and carbonaceous materials. This composite negative active material composition improves cycling performance and reduces water loss while maintaining manufacturing feasibility through established mixing and pasting processes.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the chemical composition parameters of the negative active material by incorporating specific expanders at controlled dosages. Barium sulfate provides structural stability, organic compounds enhance porosity and electrolyte absorption, and carbonaceous materials improve conductivity. These parameter changes collectively enhance cycling performance and reduce water loss.

Inventive Principle:

Principle #35Parameter changes

2Duration of action of moving object

If battery is designed for start-stop vehicle operation, then fuel saving is achieved, but battery endures prolonged/intermittent loads requiring improved endurance

Engineering Contradiction:

Improvebattery enduranceVSAvoidperformance consistency

Core Design Contradiction:

Duration of action of moving objectVSReliability

Solution Approach 1:

The composite negative active material with multiple expanders provides both improved endurance and consistent performance. Barium sulfate maintains structural integrity during prolonged loading, organic compounds enhance electrolyte retention for intermittent loads, and carbonaceous materials ensure stable conductivity. This composite structure enables the battery to reliably support start-stop operation cycles.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The expander additives act as beforehand cushioning by pre-establishing a robust porous structure and enhanced electrolyte absorption capacity in the negative active material. This prepares the battery to withstand the stress of prolonged and intermittent loads before they occur, maintaining performance consistency during actual start-stop operation.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If expanders are added to negative active material, then cycling performance and reduced water loss are achieved, but manufacturing process complexity increases

Engineering Contradiction:

Improveservice lifeVSAvoidpaste preparation process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by pre-mixing the expander additives with lead oxide to create a homogeneous composite powder before paste preparation. This pre-mixing step ensures uniform distribution of barium sulfate, organic compounds, and carbonaceous materials, simplifying subsequent paste making and plate formation processes while achieving the desired service life improvements.

Inventive Principle:

Principle #10Preliminary action

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 use of these expanders in lead-acid batteries results in improved endurance, cycling performance, and reduced water loss, enabling the batteries to function effectively in extended applications such as stop-start micro hybrid operation for fuel saving during vehicle operation.

Implementation Method 1

The lead, lead dioxide and electrolyte provide a chemical means of storing electrical energy which can perform useful work when the terminals of a battery are connected to an external circuit

Methodology Applied

Scientific EffectElectrochemical reactions:

Implementation Method 2

an absorbent glass mat (also referred to as 'AGM') lead-acid battery in which the electrolyte is absorbed and retained in a mat

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 3

AGM lead-acid batteries are recombinant batteries, that is, H2 and O2 generated during charging are recombined to water in the battery

Methodology Applied

Scientific EffectRecombination:

Data Source

PatentUS12266783B2Negative mass for lead-acid battery electrodes and lead-acid battery including same

Publication Date: 2025.04.01 CPS TECHNOLOGY HOLDINGS LLC

AI summary

A blended expander formula for use in the preparation of lead acid battery electrodes is disclosed. The mixture comprises fine particle barium sulfate, a first oxylignin, a second oxylignin, and a carbonaceous material. A method, a negative paste, and a negative electrode including the blended expander mixture are also disclosed. A lead-acid absorbent glass mat battery is further disclosed.