Pasting Textile Battery Electrode Acid Transport

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Solution Overview

Problem

Conventional pasting materials in lead-acid batteries face issues with acid transport, adhesion to active material, capillary action, plate strength, conductivity, and cyclability, leading to limitations in manufacturing efficiency, lead usage, and cycling capacity, particularly in high-speed and high-cycling applications.

Innovation Solution

A battery electrode with a pasting textile comprising fibers longer than 20 µm and a denier greater than 2, which improves adhesion, acid transport, and plate integrity, allowing for reduced lead usage and enhanced cycling capacity by integrating a fiber web that can replace both pasting paper and glass mat separators.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If conventional pasting materials are used, then manufacturing process is simple, but acid transport and capillary action are insufficient

Engineering Contradiction:

Improveacid transportVSAvoidpasting material structure

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The patent employs a porous pasting material with controlled pore structure that enhances acid transport and capillary action while maintaining manufacturing simplicity. The porous structure allows electrolyte penetration and active material distribution without requiring complex manufacturing processes.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The invention uses composite pasting materials combining organic and inorganic components to achieve improved acid transport properties. The composite structure provides both capillary action for acid movement and structural integrity for plate strength.

Inventive Principle:

Principle #40Composite materials

2Strength

If conventional pasting materials are used, then manufacturing cost is low, but plate strength and integrity are reduced

Engineering Contradiction:

Improveplate strengthVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent modifies key parameters of the pasting material including fiber length, denier, and composition ratios to enhance plate strength. These parameter changes are achieved through standard manufacturing processes, maintaining ease of manufacture while improving mechanical properties.

Inventive Principle:

Principle #35Parameter changes

3Strength

If conventional pasting materials are used, then manufacturing process is straightforward, but adhesion to active material is poor

Engineering Contradiction:

Improveadhesion strengthVSAvoidpasting material composition

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The invention employs composite pasting materials with specific fiber compositions that enhance adhesion to active material. The composite structure includes components that chemically and mechanically bond with the active material, improving adhesion without requiring complex application processes.

Inventive Principle:

Principle #40Composite materials

4Temperature

If conventional pasting materials are used, then drying temperature requirements are high, but manufacturing efficiency is reduced

Engineering Contradiction:

Improvedrying temperatureVSAvoidmanufacturing speed

Core Design Contradiction:

TemperatureVSProductivity

Solution Approach 1:

The patent uses pasting materials with modified composition and structure that reduce drying temperature requirements. The material formulation allows for lower temperature curing while maintaining performance, enabling higher manufacturing line speeds and improved productivity.

Inventive Principle:

Principle #35Parameter changes

5Quantity of substance

If conventional pasting materials are used, then lead content in electrodes is high, but material cost increases

Engineering Contradiction:

Improvelead contentVSAvoidgrid thickness

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

The invention applies pasting materials with enhanced properties in specific locations where lead reduction is needed. The improved pasting material allows for thinner grids in non-critical areas while maintaining structural integrity, thereby reducing overall lead content without compromising manufacturing feasibility.

Inventive Principle:

Principle #3Local quality

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 solution enhances acid transport, adhesion, and plate strength, enabling higher cycling capacity and reserve capacity, reducing lead usage, and improving manufacturing efficiency, while also mitigating acid stratification and extending battery life.

Implementation Method 1

A pasting textile that allows for enhanced capillary action compared to conventional pasting material

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Data Source

PatentEP2401782B1Battery electrode and method for manufacturing same

Publication Date: 2020.06.03 CPS TECHNOLOGY HOLDINGS LLC

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AI summary

A battery electrode with a pasting textile, fabric, or scrim made with an electrode grid (e.g., a stamped grid or expanded metal grid) coated in battery electrode and covered with pasting textile formed of a bonded, non- woven fiber web. The web is formed from one or more fibers with an average length greater than 20 µm. In various embodiments, the web is formed from one or more spun, continuous fibers. The battery electrode may be made in a continuous process where multiple grids are formed in a single sheet, coated with electrode active material, and the scrim before being cut into individual electrodes.