Multifunctional Web for Lead-Acid Battery Separator
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional pasting papers made of natural fibers in lead-acid batteries disintegrate in sulfuric acid, leading to erosion of lead plates and reduced battery life cycles, especially under increased load conditions and environmental stressors.
Innovation Solution
A multifunctional web comprising natural fibers and heat-sealable synthetic fibers that forms a net structure, where natural fibers disintegrate in sulfuric acid, leaving a synthetic fiber net to maintain paste adhesion and reduce friction and erosion, while maintaining humidity absorption and compression between lead plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pasting paper made of natural fibers is used, then humidity absorption and paste retention during production are achieved, but the paper disintegrates in sulfuric acid leading to gap formation and lead plate erosion
Solution Approach 1:
The pasting paper is made from a composite of natural fibers (for humidity absorption and paste retention) and synthetic heat-resistant fibers (for durability in sulfuric acid). This composite structure allows the paper to maintain its functional properties while resisting disintegration in the electrolyte, thereby preventing gap formation and lead plate erosion throughout the battery's operational life.
2Ease of manufacture
If natural fibers are used for pasting paper, then paste adhesion and humidity absorption are maintained, but friction causes erosion of lead plates over time
Solution Approach 1:
The combination of natural fibers and synthetic heat-resistant fibers creates a pasting paper that retains paste effectively during manufacturing while the synthetic fiber network provides long-term structural support that reduces friction-induced erosion during battery operation.
Solution Approach 2:
Different regions of the pasting paper have different functions: the natural fiber components provide paste adhesion and humidity absorption properties, while the synthetic fiber components provide erosion resistance and structural integrity in the harsh electrolyte environment.
3Ease of manufacture
If conventional pasting paper is used, then initial paste support is provided, but gap formation occurs between lead plates during battery operation
Solution Approach 1:
The composite structure of natural and synthetic fibers ensures that the pasting paper maintains its structural integrity in sulfuric acid, preventing gap formation between lead plates while continuing to support the paste throughout the battery's operational life.
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 multifunctional web extends the life cycle of lead-acid batteries by preventing gap formation and erosion, improving performance and durability under high cycle and environmental stress conditions.
Implementation Method 1
A multifunctional web comprising natural fibres and heat-sealable fibres
Implementation Method 2
In order to absorb humidity from the lead paste and in order to ensure that the paste remains on the grid during the production process
Implementation Method 3
Conventional pasting paper is made of natural fibres that will be disintegrated over time by the sulphuric acid
Implementation Method 4
These AGM batteries have a better life cycle due to the pressure between separator and plate
Data Source
AI summary
The present invention relates to a multifunctional web for use in a lead-acid battery comprising natural fibers and heat-sealable fibers, the use of the multifunctional web in a lead-acid battery, a lead plate comprising a metal grid coated with a lead paste contacting the multifunctional web, a method of preparing the lead plate and a lead-acid battery assembly comprising the lead plate.