Lead-Carbon Interface Layer Formation for Battery Sulfurization

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Solution Overview

Problem

The existing hybrid lead-carbon batteries face issues with sulfurization of the negative electrode, leading to reduced energy storage efficiency and shortened battery life due to the lack of strong chemical bonding between carbon and lead materials, which limits the addition ratio of carbon and increases production costs.

Innovation Solution

A method is developed to form a lead-carbon compound interface layer by causing an acidic solution to contact with a carbon material and a lead-containing material, forming a carbon-containing plumbate precursor and then reducing the ionic lead to create a chemically bonded lead-carbon compound interface layer on the substrate, enhancing the structural strength and bonding between carbon and lead.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of stationary object

If carbon material is added to the lead electrode to increase contact area, then battery life time is improved, but structural strength of the lead electrode decreases

Engineering Contradiction:

Improvebattery life timeVSAvoidstructural strength of lead electrode

Core Design Contradiction:

Duration of action of stationary objectVSStrength

Solution Approach 1:

The patent creates a composite lead-carbon structure where carbon materials are integrated into the lead electrode matrix. This composite approach allows the carbon to provide conductivity and extend battery life while the lead matrix maintains structural integrity, resolving the contradiction between extending life through carbon addition and maintaining structural strength.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies carbon materials specifically at the negative electrode where sulfurization occurs, rather than uniformly throughout the entire battery structure. This localized application targets the specific problem area (negative electrode sulfurization) while minimizing the impact on overall structural strength of the lead electrode.

Inventive Principle:

Principle #3Local quality

2Strength

If high pressure and high temperature treatment is applied to form chemical bonds, then bonding strength between carbon and lead is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvebonding strength at carbon-lead interfaceVSAvoidmanufacturing process simplicity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent changes the chemical parameters of the interface by introducing plumbate precursors that form chemical bonds between carbon and lead at milder conditions. Instead of relying on physical contact alone or extreme pressure-temperature treatment, the chemical composition parameter is modified to enable bonding at more manufacturable conditions.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces plumbate precursors as an intermediary substance that facilitates bonding between carbon and lead. These precursors act as a chemical mediator that enables bond formation without requiring extreme pressure and temperature conditions, thus simplifying the manufacturing process while achieving strong interfaces.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If noble metals are used to bond carbon and lead materials, then interface bonding is improved, but production cost increases

Engineering Contradiction:

Improveinterface bonding reliabilityVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent replaces expensive noble metals with plumbate precursors that form lead-carbon compound interfaces. These plumbate-based interfaces provide reliable bonding without the high cost of noble metals, effectively substituting a cheap material (lead-based plumbate) for an expensive one (noble metals) while maintaining the required reliability.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent creates a lead-carbon compound interface that copies the beneficial bonding function of noble metals but uses abundant, inexpensive lead-based chemistry instead. The plumbate precursor system replicates the interface bonding capability without requiring scarce noble metal resources, thus reducing production cost while maintaining reliability.

Inventive Principle:

Principle #26Copying

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

This method improves the lifespan and utilization efficiency of hybrid lead-carbon batteries by inhibiting sulfurization and reducing the need for expensive noble metals, resulting in a cost-effective and durable energy storage solution.

Implementation Method 1

causing an acidic solution to contact with a carbon material and a lead-containing material to form a carbon-containing plumbate precursor

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Implementation Method 2

reducing the ionic lead in the carbon-containing plumbate precursor to form the lead-carbon compound interface layer

Methodology Applied

Scientific EffectReduction: Reduction

Data Source

PatentUS11349110B2Method for forming lead-carbon compound interface layer on lead-based substrate

Publication Date: 2022.05.31 NAT FORMOSA UNIV

AI summary

The present disclosure discloses a method for forming a lead-carbon compound interface layer on a lead-based substrate, wherein the lead-based substrate has a surface, and the method includes steps of: causing an acidic solution to contact with a carbon material and a lead-containing material to form a carbon-containing plumbate precursor having an ionic lead; and reducing the ionic lead in the carbon-containing plumbate precursor to form the lead-carbon compound interface layer on the surface.