Polymer Fiber Coated Lead Acid Battery Electrodes

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Solution Overview

Problem

Lead acid batteries face challenges with electrode plates that lack durability and inertness in harsh environments, leading to reduced mechanical and physical properties, such as increased sulfation and antimony migration, which affect battery performance and lifespan.

Innovation Solution

The development of lead or lead alloy electrode plates coated with a porous, non-woven mat of polymer fibers, produced through electrospinning, which enhances mechanical and physical properties by providing a durable, inert, and porous coating that allows for improved electrolyte access and reduces sulfation and antimony migration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If electrode plates are made with lead or lead alloy grids coated with active material, then battery functionality is achieved, but mechanical durability and inertness deteriorate in harsh battery environments

Engineering Contradiction:

Improvedurability and inertnessVSAvoidmechanical and physical properties

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent applies composite materials by combining lead or lead alloy grids with active material coatings and polymer fiber coatings. This multi-layer composite structure provides both the electrochemical functionality of lead-based materials and the enhanced durability and inertness of polymer coatings, resolving the contradiction between achieving battery functionality and maintaining stability in harsh environments.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent uses thin polymer fiber coatings applied to the electrode plate surfaces. These thin film coatings provide protective functionality while maintaining the electrical and electrochemical properties of the underlying lead-based electrode structure, thereby improving reliability without compromising the essential battery functions.

Inventive Principle:

Principle #30Flexible shells and thin films

2Ease of manufacture

If electrode plates use traditional coatings, then manufacturing simplicity is maintained, but sulfation and antimony migration increase, reducing battery performance

Engineering Contradiction:

Improvecoating application simplicityVSAvoidsulfation and antimony migration

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The patent employs porous polymer fiber coatings that allow electrolyte penetration while providing a physical barrier against harmful processes. The porous structure enables ionic transport necessary for battery operation while preventing sulfation and antimony migration, thus reducing harmful factors without complicating the manufacturing process excessively.

Inventive Principle:

Principle #31Porous materials

3Reliability

If a porous polymer fiber coating is applied to electrode plates, then durability and inertness improve, but manufacturing complexity increases

Engineering Contradiction:

Improvedurability and inertnessVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces traditional mechanical coating methods with electrospinning technology. This substitution enables the formation of porous polymer fiber coatings with controlled morphology and properties through electrical fields rather than mechanical means, improving durability while managing manufacturing complexity through a specialized deposition process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent utilizes parameter changes in the electrospinning process (voltage, flow rate, distance, polymer concentration) to control the morphology, porosity, and thickness of the fiber coatings. By adjusting these parameters, the manufacturing process can be optimized to produce durable coatings with controlled properties, balancing reliability improvement with manufacturing feasibility.

Inventive Principle:

Principle #35Parameter changes

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 polymer fiber coating improves the mechanical and physical properties of electrode plates, enhancing durability, reducing sulfation, and inhibiting antimony migration, thereby extending battery life and performance.

Implementation Method 1

Electrospinning is a technique for producing polymeric fibers. Electrospinning utilizes the electrostatic attraction between a charged polymer and a grounded or oppositely charged collection plate to produce the fibers.

Methodology Applied

Scientific EffectElectrospinning: Electrostatic Deposition

Data Source

PatentUS11575119B2Coated lead acid battery electrode plates; method for making coated electrode plates and lead acid batteries containing coated electrode plates

Publication Date: 2023.02.07 TROJAN BATTERY COMPANY

AI summary

Disclosed are electrode plates for a lead acid battery. The electrode plates are formed of an electrode plate having a face, the electrode plate comprising a lead or lead alloy grid coated with an active material and the electrode plates having a porous, non-woven mat comprised of polymer fibers coating on the face of the electrode plate, as well as a method for making the coated electrode plates and lead acid batteries containing the coated electrode plates.