Post on 15-Dec-2015
transcript
Separator design, formula and construction to maintain electrical performance of the lead acid battery
Source: Nielsen Media Index & TGI Survey
Percentage of Cars per Driving Age Population
0 10 20 30 40 50 60 70 80 90 100
China
India
Thailand
South Korea
Germany
Great Britian
Saudia Arabia
USA
Penetration (%)
Major Cities Population
0 5 10 15 20 25 30
Milano
Essen
London
Paris
Philadelphia
Chicago
Los Angeles
New York
Calcutta
Shanghai
Mumbai
Tokyo
Population (millions)
European Cities
Asian Cities
USA Cities
Sources: US Census Bureau and Times Atlas of the World, tenth edition
Average Temperature by Major City
0.0 5.0 10.0 15.0 20.0 25.0 30.0
Essen
Paris
London
Milano
Chicago
New York
Philadelphia
Los Angeles
Tokyo
Shanghai
Mumbai
Calcutta
Mean Yearly Temp (degrees C)
Asian Cities
European Cities
USA Cities
Source: www.weatherbase.com
Rubber Separators
PE Separators
Water Loss Test21 Days Overcharge 2.4 V/Cell at 40 °C
Positive PbSb 1.6 % / Negative PbCa – 2 Shot Formation
1.5
0.8
0
1
2
Water Loss [g/Ah]
PE Separator
Daramic HP+
+ 40% Improvement
Water Loss21 Days Overcharge 2.4 V/Cell at 40 °C
Positive PbCa / Negative PbCa – 2 Shot Formation
0.8
0.6
0
1
Water Loss [g/Ah]
PE Separator
DARAMIC HP+
25% Improvement
Antimony Released from Positive Grid
Antimony Poisons Negative
Electrode
Negative Electrode
Depolarizes
Higher Recharge Currents
Increased Heat and Gassing
Results in Loss of Capacity and Battery Failure
80% DOD Cycling Test at 55°C
0.0
2.0
4.0
6.0
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10.0
12.0
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Cycles
En
d o
f C
har
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Cu
rren
t (A
)
Rubber
80% DOD Cycling Test at 55°C
0.0
2.0
4.0
6.0
8.0
10.0
12.0
0 50 100 150 200 250 300 350
Cycles
En
d o
f C
har
ge
Cu
rren
t (A
)
Rubber
PVC
80% DOD Cycling Test at 55°C
0.0
2.0
4.0
6.0
8.0
10.0
12.0
0 50 100 150 200 250 300 350
Cycles
En
d o
f C
har
ge
Cu
rren
t (A
)
Rubber
Standard PE
PVC
80% DOD Cycling Test at 55°C
0.0
2.0
4.0
6.0
8.0
10.0
12.0
0 50 100 150 200 250 300 350
Cycles
En
d o
f C
har
ge
Cu
rren
t (A
)
Rubber
Daramic HD
Standard PE
PVC
Oxidation Resistance
Increase Separator Back-web ThicknessIncrease Mass, Electrical Resistance and Acid
Displacement
Laminate Glassmat to SeparatorPrevents Shedding, Adds Component
Formulation Changes Polymer and Anti-Oxidant
Oxidation Resistance Test – Perox 80
1) Measure Separator Mechanical Propertiesa) Elongation, Puncture Resistance
2) Soak Separator in Oxidizing Solutiona) Hydrogen Peroxide / Sulfuric Acidb) Elevated Temperature 80 degree C
3) Measure Remaining Separator Propertiesa) After Soaking various times (e.g. 20, 40, … hours)
4) Determine Rate of Oxidation with Drop in Mechanical Properties
PEROX 80: Oxidation Resistance
0
50
100
150
200
250
300
350
400
450
0 10 20 30 40 50 60
Soak Time (hrs)
CM
D E
long
atio
n (%
)
Daramic HP
End of Life < 100%
PEROX 80: Oxidation Resistance
0
50
100
150
200
250
300
350
400
450
0 10 20 30 40 50 60
Soak Time (hrs)
CM
D E
long
atio
n (%
)
End of Life < 100%
Daramic HP
Daramic HP +
25% Longer
Weight Loss in Perox 80 Solution
0.00
1.00
2.00
3.00
4.00
5.00
6.00
0 50 100 150 200 250 300 350 400
Soak Time (minutes)
Wei
gh
t L
oss
(w
t%)
Standard PE Separator
Weight Loss in Perox 80 Solution
0.00
1.00
2.00
3.00
4.00
5.00
6.00
0 50 100 150 200 250 300 350 400
Soak Time (minutes)
Wei
gh
t L
oss
(w
t%)
Standard PE Separator
PE Separator with additive
Additive Level
Asian Market Summary
SLI, Stationary and Motive Power Batteries High Population DensitiesElevated Ambient TemperatureUse of Antimony Alloy
Elevated Temp & Antimony Alloy
SLI Application Water Loss => Battery Dry-Out Rubber Additive to PE Separator Daramic HP+
Motive Power and Deep Cycle Application Negative Electrode Poisoning Loss of Capacity Rubber Additive to PE Separator Daramic HD
Oxidation Resistance Rubber increases protection ~ 25%
Characteristic Units Daramic HP Daramic HP+ (1)
Profile UI UI
Rubber Additive No Yes
Back-web Thickness microns 200 200
Puncture Resistance N 13.3 13.0
Electrical Resistance mohms-cm2 48.1 50.0
Porosity % 59.9 58.5
Acid Wet-out seconds 9.4 15.6
Residual Oil wt %
Back-web 10.4 10.4
Total 16.2 16.5
CMD Elongation % 368 414
Oxidation Resistance PEROX
CMD Elongation 20 hours 274 360
CMD Elongation 40 hours 112 214
Acid Shrinkage % 0.44 0.31
SLI Application
(1) US Patent 5,221,587 W. Boehnstedt et.al
Characteristic Units Daramic CL Daramic HD (1)
Profile BC BC
Rubber Additive No Yes
Back-web Thickness microns 500 500
Electrical Resistance mohms-cm2 265 210
Porosity % 57.4 54.3
Ash Content wt % 69.3 72.8
Residual Oil wt %
Back-web 14.8 15.1
Total 20.4 20.5
CMD Elongation % 256 339
Oxidation Resistance PEROX
CMD Elongation 20 hours 132 226
Acid Shrinkage % 1.3 1.2
(1) US Patent 5,221,587 W. Boehnstedt et.al
Deep Cycle Application
Taipei 101
End