Lead Storage Battery Ear Portion Thinning Prevention
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Solution Overview
Problem
Lead storage batteries used in idling stop system vehicles experience premature degradation due to frequent partial state of charge, leading to 'phenomenon of thinning of an ear portion' which results in increased resistance and potential rupture of the negative electrode current collector, reducing battery performance and lifespan.
Innovation Solution
A lead storage battery design with a mass ratio of positive to negative electrode material of 1.35 or more, incorporating a bisphenol-based resin with sulfone or sulfonate groups, aluminum ions in the electrolyte, and a non-woven fabric between the negative electrode plate and separator, along with specific surface areas and active material content, to enhance cycle characteristics and prevent ear portion thinning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a lead storage battery is used in a partial state of charge (PSOC) state, then the battery can meet the power demands of idling stop system vehicles, but the negative electrode ear portion thins and ruptures, reducing battery lifespan
Solution Approach 1:
The patent applies local quality by creating a surface layer on the negative electrode grid with specific composition (Pb-Sn-Ca alloy containing 0.5-2.0 mass% Sn and 0.1-1.0 mass% Ca) that differs from the base grid material. This surface layer is specifically designed to suppress thinning of the ear portion during PSOC operation, while the rest of the electrode maintains its original properties for optimal power delivery.
Solution Approach 2:
The patent uses composite materials by combining Pb-Sn-Ca alloy with specific proportions of tin (0.5-2.0 mass%) and calcium (0.1-1.0 mass%) in the negative electrode grid. This composite alloy structure provides both the electrical conductivity needed for PSOC operation and the structural stability to prevent ear portion rupture, resolving the contradiction between adaptability and lifespan.
2Reliability
If the negative electrode grid contains higher Sn content to suppress thinning, then ear portion stability improves, but manufacturing cost increases
Solution Approach 1:
The patent applies parameter changes by optimizing the Sn content to a specific range (0.5-2.0 mass%) rather than using high amounts. This controlled parameter adjustment achieves sufficient ear portion stability and thinning suppression while controlling material costs. The Ca content is also optimized (0.1-1.0 mass%) to work synergistically with Sn, allowing lower individual concentrations while maintaining reliability.
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 battery maintains performance and extends lifespan by reducing ear portion thinning and rupture, improving ISS cycle characteristics, charge acceptance, and low-temperature discharge performance, while also suppressing electrolyte solution decrease and penetration short circuits.
Implementation Method 1
lead sulfate generated in the negative electrode ear portion is easily reduced to metallic lead
Implementation Method 2
an electrolytic solution accommodated in the cell chamber
Data Source
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AI summary
The present disclosure relates to a lead storage battery including a battery case having a cell chamber; an electrode plate group being provided in the cell chamber and including a separator, and a positive electrode plate and a negative electrode plate that are alternately stacked with the separator disposed therebetween; and an electrolytic solution accommodated in the cell chamber. The positive electrode plate and the negative electrode plate respectively include an electrode material filled portion comprised of an electrode material, a current collector that supports the electrode material filled portion, and an ear portion provided on the upper peripheral portion of the current collector. S1/V1 is 8.9 cm-1 or more, wherein S1 represents a total surface area of the positive electrode material filled portion and the negative electrode material filled portion and V1 represents an apparent total volume of the positive electrode material filled portion and the negative electrode material filled portion. p1/n1 is 1.35 or more, wherein p1 represents a mass of the positive electrode material and nl represents a mass of the negative electrode material.