Lead-Calcium Alloy Fiber Electrode for Battery Charge Acceptance
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Solution Overview
Problem
Lead-acid batteries face challenges in providing consistent, reliable performance, especially in start-stop vehicles with increasing electrical loads, requiring improved rechargeability and cycling performance.
Innovation Solution
A lead-acid battery design featuring a container with compartments containing positive and negative electrodes with cured carbon or carbonized fiber mat current collectors impregnated with electrochemically active materials, where at least one electrode comprises a lead-calcium alloy frame member, and an electrolyte within the container, enhancing charge acceptance and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional lead-acid battery electrodes are used, then the battery structure is simple and manufacturing is easy, but the charge acceptance is poor and cycling performance is inconsistent
Solution Approach 1:
The patent employs composite electrode structures combining carbon fiber mats with lead-calcium alloy current collectors. The carbon fiber mat provides enhanced charge acceptance and conductivity, while the lead-calcium alloy substrate provides structural support and electrochemical activity. This composite approach resolves the contradiction by improving reliability through superior material properties while maintaining a manufacturable structure.
Solution Approach 2:
The patent modifies electrode parameters by using cured or carbonized fiber mats instead of traditional materials, and by specifying lead-calcium alloy composition for the current collector. These parameter changes improve charge acceptance and cycling consistency without significantly complicating the manufacturing process, as the fiber mats can be impregnated with electrochemically active material using conventional techniques.
2Reliability
If lead-acid battery electrodes are designed for high power output, then the electrical load capacity is sufficient, but the rechargeability and charge acceptance are limited
Solution Approach 1:
The patent changes the material parameters of the electrode by using carbonized fiber mats which possess superior electrical conductivity and charge acceptance characteristics compared to traditional lead-acid electrode materials. The lead-calcium alloy current collector also provides optimized electrochemical parameters. These parameter changes enable the electrode to accept charge more efficiently while maintaining adequate power output capability.
Solution Approach 2:
The composite structure of carbon fiber mat combined with lead-calcium alloy current collector creates synergistic effects where the carbon fiber enhances charge acceptance and conductivity, while the alloy substrate maintains structural integrity and provides electrochemical activity. This composite material approach resolves the contradiction between rechargeability and power capacity.
3Strength
If conventional current collectors are used, then the manufacturing process is simple, but the strength and conductivity are insufficient for improved performance
Solution Approach 1:
The patent uses composite current collectors made from cured or carbonized fiber mats combined with lead-calcium alloy substrates. This composite structure provides enhanced strength and conductivity compared to conventional current collectors. The manufacturing process involves impregnating the fiber mat with electrochemically active material and curing or carbonizing it, which are standard industrial processes that maintain ease of manufacture while achieving superior mechanical and electrical properties.
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 exhibits improved charge acceptance, reduced self-discharge, and consistent performance, with the lead-calcium alloy contributing to increased strength, conductivity, and reduced water consumption, addressing the need for enhanced reliability and efficiency.
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
Implementation Method 2
The cured carbon or carbonized fiber mat current collector comprises a frame member composed of a lead-calcium alloy
Implementation Method 3
The cured carbon or carbonized fiber mat current collector comprises a frame member composed of a lead-calcium alloy
Implementation Method 4
The lead, lead dioxide and electrolyte provide a chemical means of storing electrical energy
Data Source
AI summary
A lead-acid battery is disclosed. The battery comprises a container with a cover having one or more compartments. One or more cell elements are provided in the one or more compartments. The cell elements comprise a positive electrode and a negative electrode. The positive electrode has a positive current collector and a positive electrochemically active material in contact therewith. The negative electrode has a negative current collector and a negative electrochemically active material in contact therewith. At least one of the positive electrode or the negative electrode comprises a cured carbon or carbonized fiber mat current collector impregnated with the respective electrochemically active material. The cured carbon or carbonized fiber mat current collector comprises a frame member composed of a lead-calcium alloy. Electrolyte is provided within the container. One or more terminal posts extend from the container or the cover and are electrically coupled to the cell elements.