PET-PBT Non-Woven Gauntlet for Battery Burst Strength
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Solution Overview
Problem
Current non-woven gauntlets for lead-acid batteries face challenges in achieving high burst strength while maintaining low electrical resistance, which limits their application in demanding battery types such as stationary gel and flooded batteries due to mechanical weaknesses and increased electrical resistance when attempting to enhance mechanical properties.
Innovation Solution
A non-woven, cartridge belt type gauntlet is developed using spunbond, needled, and flat thermobonded bicomponent PET-PBT fabric, assembled at regular intervals with a thermoplastic resin impregnation, offering improved mechanical strength and reduced electrical resistance through specific manufacturing processes and material properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If point-bonded polyester spunbond material is used to provide fabric strength through melting PET filament, then manufacturing process is simplified, but electrical resistance increases and burst strength is insufficient
Solution Approach 1:
The patent uses a composite non-woven fabric structure combining PET (polyethylene terephthalate) and PBT (polybutylene terephthalate) filaments. The PBT component provides lower melting point for bonding while PET contributes to mechanical strength and oxidation resistance. This composite approach resolves the contradiction by achieving both adequate burst strength and manufacturability.
Solution Approach 2:
The patent changes the material parameters by introducing PBT filaments with lower melting point (around 220°C) compared to PET (around 260°C). This parameter change allows the fabric to be bonded at lower temperatures, reducing electrical resistance while maintaining manufacturing simplicity. The bonding point density and filament composition are optimized to balance strength and conductivity.
2Strength
If more bonding points are created by hot calendar to increase fabric strength, then burst strength improves, but electrical resistance increases
Solution Approach 1:
The patent changes the bonding mechanism by using PBT's lower melting point to create bonds at reduced temperature and pressure. This results in fewer but more effective bonding points that maintain fabric integrity while preserving electrical conductivity. The bonding point size and distribution are optimized to minimize electrical resistance pathways.
Solution Approach 2:
The patent creates localized bonding zones rather than uniform bonding across the entire fabric. The hot calendar applies heat and pressure selectively to create discrete bonding points only where needed for structural integrity, leaving other areas with lower bonding density to maintain electrical conductivity. This local quality approach resolves the contradiction between strength and electrical resistance.
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 new gauntlet achieves a burst pressure of over 16 bars and electrical resistance of less than 180 mΩ.cm², enhancing both mechanical and electrical properties simultaneously, allowing for efficient constraining of active mass and maintaining battery capacity over its life, even in aggressive filling technologies and demanding applications.
Implementation Method 1
the latter having a lower melting point and being melted during calendaring in order to impart the fabric strength
Implementation Method 2
flat thermobonded bicomponent PET-PBT nonwoven fabric
Implementation Method 3
the non-woven fabric is impregnated with a thermoplastic resin
Data Source
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AI summary
The present invention concerns non-woven, cartridge belt type gauntlet for lead acid batteries comprising two sheets of spunbond, needled and flat calendared thermobonded bicomponent PET-PBT nonwoven fabric assembled together at regular intervals.