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MOLECULAR REBAR® Adoption of dCNT in lead acid batteries

Mohamed Sharif, Venkat B

Black Diamond Structures, Austin TX USA

Who We Are

Black Diamond Structures is a developer, manufacturer, and marketer of innovative nanomaterial products and solutions based on

revolutionary carbon nanotube (CNT) technology, MOLECULAR REBAR®

Our Partners

MOLECULAR REBAR®: Global Adoption

Global Adoption:

– Products Commercially Available and being sold to Lead Acid Battery Manufacturers– Working with >100 battery manufacturers worldwide, each at various stages of development

and/or commercial sales.– Recent approval for use in major Automotive OEM batteries. (SLI)– Have proven that Molecular Rebar can help battery manufacturers meet new OEM requirements

for “Advanced Automotive Battery” applications. – Large amount of data on full-scale production batteries, not just 2V hand-built cells– Approved to discuss three Mfr’s publicly at this time (Eastman – India, Pacific Battery – Fiji, Tianjin

Lantian Power Sources – China)

Why the rapid adoption?– Technology is innovative, cutting-edge, and scientifically sound– Cost effective performance improvements over a wide variety of applications– Low risk to use– No (or very low) capital expenditure by manufacturer; very easy to use and implement– Highly technical staff works hand in hand with your company during ramp up.– World-class technical support from Black Diamond Structures

Clumps of Dirty, Entangled CNT’s

Bulk Carbon

Nanotubes

Clean, Detangled MR Discrete, Individual Tubes

Key Competitive Advantage

Detangling/ Separation

Formulation -Dispersion

MasterBatch -

Concentrate

MOLECULAR REBAR® Technology

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MR in Lead Paste(or other substrates)

Customer Integration

w/ End-Product

Key Features:

• Used in Negative Electrode or Negative & Positive Electrodes

• Improved Consistency in Capacity & CCA Throughout Life

• Extended Cycle Life / Reduced Warranty Failures

• Increased Electrical Performance

• Enhanced Plate Strength / Durability

Batteries provided by Pacific Batteries Ltd (NS40)

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Flooded SLI BatteriesPb1100 Series Products

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Flooded SLI BatteriesPb1100 Series Products: Base Performance

C20 Measurement (EN-50432-6)

• Pb1100 Series has no negative effect on capacity

• Also true for RC measurements

CCA Performance (EN-50432-6)

• Pb1100 Series elongate discharge; Ah-out higher

• CCA remains consistent throughout life and cycling

Control Pb1100N Series Pb1100N SeriesControl Pb1100N Series Control Pb1100N Series

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Protocol Stress factor Improvements by Molecular Rebar

SAE-J240@70C

Ability of battery to perform lightload endurance @75C

50-60% cycle life increase

SAE-J2185@50C

Ability of battery to perform heavy dutycycling

12-35% cycle life increase

VDA-RC Endurance

Enhanced ability to retain the rated capacity through out life

20% cycle life increase

VDA-Repetitive over discharge

Ability of battery to recover after parasitic loads (Very deep discharge)

6-25% cycle life increase

SAE J240-LLE SAE J2185-HLE

^12%

^35%

VDA-RCE VDA-ROD

Summary

Flooded SLI BatteriesPb1100 Series Products: Life cycle tests

^50%

^60%

^20%

Enhanced Flooded Battery: Pb1200 Series

• Product = Pb1200Nx & Pb1200Px

• Key Features:– Use in Negative and/or Positive Electrode

• Pb1200 Series provides balancedperformance increases across the following tests: – CCA/Capacity– Charge Acceptance– Durability Life Cycle Tests– Micro-Hybrid Life Cycle Tests– Gassing Tests

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Nissan 90% SoC Charge Acceptance

• Current measured relative to C20 current

• Pb1200 negative recipe improves response; further

EN-50342-6 Dynamic Charge• Pb1200 Series improves DCA metric by

~15%

• Test mimics detailed, real-life, start-stop duty cycle

Flooded EFB BatteriesPb1200 Series Products

Increases SBA S0101 Cycle Life

Pb1200Nx and Pb1200Px increases cycle life up to 500%

Pb1200Nx increases cycle life up to 60%

The failure mode in MR batteries shifted to separators

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SBA S0101 Cycle Life

Flooded EFB BatteriesPb1200 Series Products: Life cycle tests

HRPSoC Cycle Life

Pb1200Nx increases HRPSoC cycling 60%

Pb1200Nx lowers charging voltages

Reserve Capacity measurements taken after each segment show MR batteries remain healthier, longer

Pb1200 Series: Actual Customer Production line Produced 12V testing example

Formulated for Balanced Performance Enhancements

80%

100%

120%

140%

160%

180%

17.5% DOD Endurance₁

50% DOD Endurance₁

J2185 - Heavy Duty Life Cycle₃

CPT CCA Duration₂

Water Consumption₂ ₃

J537 Static Charge

Acceptance₃

Dynamic Charge

Acceptance₁

Pb1200 Series Control Batteries

1 - EN 50342-6

2 - EN 50342-1

3 - SAE

Pb1200 vs Control Battery Performance

J537 Cold Charge Acceptance₃

Many innovations targetimproving one aspect ofperformance, often atthe detriment of others.

The Pb1200 Series aimsto bring a balancedsolution to your batterydesign, enhancingperformance to meetyour customers’requirements withoutcompromising existingqualities.

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Deep Cycle Batteries: The Challenges of Today

Inconsistent in performance throughout life

Capacity/backup loss in 1 year as seen in inverter batteries

Capacity/backup loss in 3 months as seen in E-rickshaw batteries

Poor charge acceptance / always on deficit charging

Due to poor charging efficiency of battery active materials

Due to power outages/ improper chargers

E-rickshaw batteries needs a day-charge after 3 months

Results in sulphation/ reduces life

Heavy water loss/ needs maintenance

Due to poor charging efficiency of battery active materials

Power supplied wasted in gassing

Sulphated negative plate

Key Features:

• Used in Negative plate

(Pb2100N-Flat; Pb2200N-Tubular)

• Improved Ah-in during charge

• Increases time between charges

• No daytime recharge needed

• Reduced water consumption

• More consistent capacity through life

Batteries provided by Eastman (80Ah Tubular)

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Deep Cycle Flooded: E-RickshawPb2100 and Pb2200 Series Products

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15 A/14.4 V

Av. CON = 10.2 hAv. MR = 7.9 h

15 A/15.2V

Av. CON = 15.6 hAv. MR = 12.0 h

10 A/15.2 V

Av. CON = 32.3 hAv. MR = 20.9 h

Note Axis Scale

ControlPb2100N

ControlPb2100N

Pb2100 and Pb2200 Series Products: Shorter recharge time with any chargerDeep Cycle Flooded: E-Rickshaw

• To fully charge, a flooded battery must absorb >110% of its last discharge

• Pb2100 and Pb2200N series product decreases the time to reach this 110% return at various current and voltage settings as available in the market charger

Recharge time taken by E-rickshaw battery to restore 110% of capacity with and without MR

• Pb2100 and 2200 Series Products:

– Delay onset of daytime charge, enables more productive workdays

– Convert more of Ah Input into useable capacity

– Improve charge Efficiency

• Control batteries experience capacity decay sooner across all recharge scenarios

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>300% Improved

Deep Cycle Flooded: E-RickshawPb2100 and Pb2200 Series Products: Lab Simulation Testing

>170% Improved

Protocol: “Workday” = 10 “trips” defined as 5x[30 min DCH + 10 min RST] resulting in 80% DOD over 10 h. At “Night”, battries are charge by one of 3 recharge scenarios: locked at 8 h, 10 h, or 110% Ah-return of previous DCH.

Observations by Drivers & Owners using Pb2100N:

Drivers using 4x80Ah Pb2100 batteries monitored for voltages, charging time and water loss

Pb2100N batteries DID NOT NEED A DAYTIME RECHARGE (~11hr run before charging)

Control batteries needed a 2-3 hour recharge (~5.25hr run before charging).

Water consumption dramatically reduced (less maintenance)

Drivers’ earnings increased ~100 Rs/day due to lack of day time charge (+80km more)

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Shaded Area Shows Charge Periods

Deep Cycle Flooded: E-RickshawPb2100 and Pb2200 Series Products: Field Trial Data

Key Features:

• Reduced Deficit Charging

• Extended Life

• Faster Recharge Times

• Lower Water Consumption

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Stationary: SolarPb3200 series product

Decentralized Rural Electrification (DRE) Test

Stationary: SolarPb3200 series product: DRE Life cycle test

• Pb3200 series product extends capacity retention more than 70% • Decentralized Rural Electrification simulation replicates real-world failures which

Pb3200 series product delays (H2O loss, deficit CHR, sulfation, AM loss)• Pb3200 series product is taking in more Ah per charge without increasing water loss

Stationary: SolarPb3200 series product: DRE Life cycle test (Tear Down)

Pb3200N Negative

• Non-uniform material utilization• Material soft and puffing/falling out• Heavily sulfated surface• Large insulative Sulphate crystals

• Shiny surface, plate still usable • No sulfate present on surface• Smaller and uniformly sized crystals

Control Negative

How to use

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• Material is shipped as a black pourable aqueous Solution which is added directly to the paste mixer

• MOLECULAR REBAR® products are formulated for ease of use and incorporation

• Sold in • 10L jugs for Samples• 55 gallon (208 L) Drums• 1,250L totes.

• A volume of pasting water is replaced with the MOLECULAR REBAR® liquid so total liquid volume remains the same

Paste Mixer

Summary

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Formulated Products Available for:• Automotive

• Flooded SLI: Pb1100 Series

• Enhanced Flooded: Pb1200 Series

• Adv. Auto VRLA: Pb1300 Series

• 2W Automotive VRLA: Pb1400 Series

• Deep Cycle / Motive

• Fld e-Rickshaw: Pb2100/2200 Series

• VRLA for Mobility: Pb2300 Series

• Stationary

• Inverter Flooded: Pb3100 Series

• Solar Flooded: Pb3200 Series

• Renewables VRLA: Pb3300 Series

MOLECULAR REBAR® Enhances:• Performance of cyclic battery

– More consistent capacity through life

– Improved Ah-in during charge

– Increases time between charges

– No daytime recharge needed

– Reduced water consumption

• Mechanical Durability

• CCA & Capacity Consistency Thru Life

• Charge Acceptance– EN 50342-6 DCA

– SAE J537 Charge Acceptance

– Nissan 90% SOC Recharge

• Cycle life as defined by:– VDA Repetitive Over Discharge

– VDA Reserve Capacity Durability

– SAE J2185

– eRickshaw Lab Simulations

– Decentralized Rural Electrification Model

– EN 50342-6 17.5% DoD

– EN 50342-6 50% DoD

– EN 50342-6 MHT

– SBA S0101

– Many OEM and Other Specifications

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THANK YOU FOR YOUR ATTENTION!Venkat B: venkatb@bd-structures.comRegional Sales Manager+91 85279 88890 (Office)

Mohamed Sharif: msharif@bd-structures.comApplication Development Engineer+91 75062 73409 (Office)

Special Thanks to Our Partners: ®