Lead-Based Alloy Composition for Longer-Life Lead-Acid Electrodes
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Solution Overview
Problem
The performance of lead-acid batteries is dependent on the chemical composition of their constituent materials, and existing materials do not adequately address issues such as anodic corrosion, positive active material degradation, and irreversible sulfation, leading to reduced capacity and cycle-life.
Innovation Solution
The use of a lead-based alloy comprising bismuth, antimony, arsenic, and tin as alloying additions to produce doped leady oxide powders, which are then used to formulate pastes for lead-acid battery electrodes, enhancing the electrodes' performance through improved oxidation rates and energy storage capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional lead-based materials are used in battery electrodes, then manufacturing cost is reduced, but anodic corrosion and positive active material degradation occur leading to reduced cycle-life
Solution Approach 1:
The patent applies composite materials by combining lead with multiple alloying elements (bismuth, antimony, arsenic, and tin) in specific proportions to create a composite lead-based alloy. This composite structure provides both corrosion resistance and improved electrochemical performance, resolving the contradiction between reliability and material simplicity.
Solution Approach 2:
The patent applies parameter changes by precisely controlling the concentration ranges of alloying elements (e.g., bismuth at 0.003-0.09 wt%, antimony at 0.001-0.03 wt%) to optimize both corrosion resistance and electrochemical activity. These parameter adjustments enable improved cycle-life without excessive complexity.
2Quantity of substance
If existing electrode materials are used, then manufacturing process is simplified, but irreversible sulfation occurs reducing energy storage capacity
Solution Approach 1:
The patent applies parameter changes by optimizing the chemical composition parameters of the lead-based alloy, specifically controlling the content of alloying elements to prevent irreversible sulfation while maintaining manufacturing feasibility. The specified concentration ranges balance performance improvement with process simplicity.
Solution Approach 2:
The patent uses small, controlled amounts of alloying elements that can be easily incorporated into the lead-based material during standard manufacturing processes. These minor compositional adjustments provide significant performance benefits without requiring complex manufacturing changes.
3Productivity
If standard lead-based alloys are used, then production cost is minimized, but oxidation rates and electrochemical performance are insufficient
Solution Approach 1:
The patent applies parameter changes by adjusting the oxidation state and composition of the lead-based alloy through controlled addition of alloying elements. These parameter modifications enhance oxidation rates and electrochemical performance while keeping alloying element content within economically viable ranges.
Solution Approach 2:
The patent applies local quality by creating specific compositional zones within the electrode material where alloying elements are concentrated to enhance oxidation activity at critical interfaces, while maintaining overall cost-effectiveness through controlled distribution of these elements.
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 doped leady oxide powders improve the cycle-life and energy storage capacity of lead-acid batteries by stabilizing the electrodes and reducing degradation processes.
Implementation Method 1
oxidizing the lead-based alloy during the milling to form doped leady oxide
Implementation Method 2
Lead-acid batteries produce electricity through the reversible oxidation and reduction of metallic lead and lead dioxide electrodes
Data Source
AI summary
A lead-based alloy containing alloying additions of bismuth, antimony, arsenic, and tin is used for the production of doped leady oxides, lead-acid battery active materials, lead-acid battery electrodes, and lead-acid batteries.