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

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

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