ENERGY STORAGE DEVICES COMPRISING CARBON-BASED ADDITIVES AND METHODS OF MAKING THEREOF

• US 20120251876A1
• Filed: 03/07/2012
• Published: 10/04/2012
• Est. Priority Date: 03/07/2011
• Status: Abandoned Application

• Current Assignee: Exide Technologies
• Original Assignee: Exide Technologies
• Inventors: Jagannathan, Sudhakar
• Application Number:
  US13/413,923
• Publication Number:
  US 20120251876A1
• Time in Patent Office: Days
• US Class Current: 429/204
• CPC Class Codes: H01M 10/08 Selection of materials as electrolytes
• CPC Class Codes: H01M 10/12 Construction or manufacture
• CPC Class Codes: H01M 4/0416 involving impregnation with a solution, dispersion, paste or dry powder H01M4/0438 takes precedence
• CPC Class Codes: H01M 4/044 Activating, forming or electrochemical attack of the supporting material
• CPC Class Codes: H01M 4/0445 Forming after manufacture of the electrode, e.g. first charge, cycling
• CPC Class Codes: H01M 4/14 Electrodes for lead-acid accumulators
• CPC Class Codes: H01M 4/22 Forming of electrodes
• CPC Class Codes: H01M 4/628 Inhibitors, e.g. gassing inhibitors, corrosion inhibitors
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

The present invention is directed to energy storage devices, such as lead-acid batteries, and methods of improving the performance thereof, through the incorporation of one or more carbon-based additives.

Claims

1. An energy storage device, comprising:

an electrode comprising lead;

an electrode comprising lead dioxide;

a separator between the electrode comprising lead and the electrode comprising lead dioxide;

an aqueous electrolyte solution containing sulfuric acid;

a first carbon-based additive having an oil absorption number of 100 to 300 ml/100 g and surface area from 50 m²/g to 2000 m²/g; and

a second carbon additive having a surface area from 3 m²/g to 50 m²/g.

2. The energy storage device of claim 1, wherein the first carbon additive has a surface area of from 150 m²/g to 350 m²/g.

3. The energy storage device of claim 1, wherein the first carbon additive has a surface area from 1300 m²/g to 1600 m²/g.

4. The energy storage device of claim 1, wherein the first carbon-based additive has an oil absorption number from 300 ml/100 g to 400 ml/100 g.

5. The energy storage device of claim 4, wherein the first carbon additive has a surface area of from 150 m²/g to 350 m²/g.

6. The energy storage device of claim 4, wherein the first carbon additive has a surface area from 1300 m²/g to 1600 m²/g.

7. The energy storage device of claim 1, wherein the energy storage device is a lead-acid battery.

8. The energy storage device of claim 7, wherein the first and second carbon-based additives enhance the discharge capacity, static charge acceptance, charge power, and discharge power, life cycle of the lead-acid battery, and combinations thereof.

9. The energy storage device according to claim 7, wherein the lead-acid battery has a discharge capacity 2% to 20% greater than standard at a C/20 discharge rate for 20 hours.

10. The energy storage device according to claim 7, wherein the lead-acid battery has a static charge acceptance from 50% to 150% greater than standard when charged at 2.4V/Cell for 10 min at 0°

F.

11. The energy storage device of claim 7, wherein the lead-acid battery has a charge power from 75% to 100% greater than standard from 40% to 80% state of charge.

12. The energy storage device of claim 7, wherein the lead-acid battery has a discharge power from 20% to 400% greater than standard from 40% to 100% state of charge.

13. The energy storage device according to claim 7 wherein the lead-acid battery comprises a dry unformed negative plate surface area of 5 m²/g to 10 m²/g.

14. The energy storage device according to claim 7, wherein the lead-acid battery provides from 20% to 500% greater cycles than standard in a HRPSoC test.

15. An energy storage device, comprising:

an electrode comprising lead;

an electrode comprising lead dioxide;

a separator between the electrode comprising lead and the electrode comprising lead dioxide;

an aqueous electrolyte solution containing sulfuric acid;

a mesoporous first carbon-based additive a surface area from 500 m2/g to 2000 m2/g; and

a second carbon-based additive having a surface area from 3 m²/g to 50 m²/g.

16. The energy storage device of claim 15, wherein the first carbon additive has a surface area of from 500 m²/g to 750 m²/g.

17. The energy storage device of claim 15, wherein the first carbon-based additive has a surface area from 1500 m²/g to 2000 m²/g.

18. The energy storage device of claim 15, wherein the energy storage device is a lead-acid battery.

19. The energy storage device of claim 15, wherein the first and second carbon-based additives enhance the discharge capacity, static charge acceptance, charge power, discharge power, life cycle of the lead-acid battery and combinations thereof.

20. The energy storage device according to claim 19, wherein the lead-acid battery has a discharge capacity 2% to 20% greater than standard at a C/20 discharge rate for 20 hours.

21. The energy storage device according to claim 19, wherein the lead-acid battery has a static charge acceptance from 50% to 150% greater than standard when charged at 2.4 V/cell to 15 min at 0°

F.

22. The energy storage device according to claim 19, wherein the lead-acid battery has a charge power from 75% to 200% greater than standard from 40% to 80% state of charge.

23. The energy storage device according to claim 19, wherein the lead-acid battery has a discharge power from 10% to 500% greater than standard from 40% to 100% state of charge.

24. The energy storage device according to claim 19, wherein the lead-acid battery comprises a dry unformed plate surface area of 5 m²/g to 10 m²/g.

25. The energy storage device according to claim 19, wherein the lead-acid battery provides 20% to 500% greater cycles than standard in a HRPSoC test.

26. An energy storage device, comprising:

an electrode comprising lead;

an electrode comprising lead dioxide;

a separator between the electrode comprising lead and the electrode comprising lead dioxide;

an aqueous electrolyte solution containing sulfuric acid;

a microporous first carbon-based additive; and

a second carbon-based additive having a surface area from 3 m²/g to 50 m²/g.

27. The energy storage device of claim 26, wherein the first carbon additive has a surface area of from 500 m²/g to 750 m²/g.

28. The energy storage device of claim 26, wherein the first carbon-based additive has a surface area from 1500 m²/g to 2000 m²/g.

29. The energy storage device of claim 26, wherein the energy storage device is a lead-acid battery.

30. The energy storage device of claim 29, wherein the first and second carbon-based additives enhance the discharge capacity, static charge acceptance, charge power, discharge power, life cycle of the lead-acid battery and combinations thereof.

31. The energy storage device according to claim 29, wherein the lead-acid battery has a discharge capacity 2% to 20% greater than standard at a C/20 discharge rate for 20 hours.

32. The energy storage device according to claim 29, wherein the lead-acid battery has a static charge acceptance from 50% to 150% greater than standard when charged at 2.4 V/cell to 15 min at 0°

F.

33. The energy storage device according to claim 29, wherein the lead-acid battery has a charge power from 75% to 200% greater than standard from 40% to 80% state of charge.

34. The energy storage device according to claim 29, wherein the lead-acid battery has a discharge power from 10% to 500% greater than standard from 40% to 100% state of charge.

35. The energy storage device according to claim 29, wherein the lead-acid battery comprises a dry unformed plate surface area of 5 m²/g to 10 m²/g.

36. The energy storage device according to claim 29, wherein the lead-acid battery provides 20% to 500% greater cycles than standard in a HRPSoC test.

37. An energy storage device, comprising:

an electrode comprising lead;

an electrode comprising lead dioxide;

a separator between the electrode comprising lead and the electrode comprising lead dioxide;

an aqueous electrolyte solution containing sulfuric acid;

a first carbon-based additive having a surface area from 500 m²/g to 2000 m^2/5, further comprising pores having a width of less than 2 nm and pores having a width from 2 nm to 50 nm;

a second carbon-based additive having a surface area from 3 m²/g to 50 m²/g.

38. The energy storage device of claim 37, wherein the first carbon additive has a surface area of from 1500 m²/g to 2000 m²/g.

39. The energy storage device of claim 37, wherein the energy storage device is a lead-acid battery.

40. The energy storage device of claim 39, wherein the first and second carbon-based additives enhance the discharge capacity, static charge acceptance, charge power, discharge power, life cycle of the lead-acid battery and combinations thereof.

41. The energy storage device according to claim 39, wherein the lead-acid battery has a discharge capacity 2% to 20% greater than standard at a C/20 discharge rate for 20 hours.

42. The energy storage device according to claim 39, wherein the lead-acid battery has a static charge acceptance from 50% to 150% greater than standard when charged at 2.4 V/cell to 15 min at 0°

F.

43. The energy storage device according to claim 39, wherein the lead-acid battery has a charge power from 75% to 200% greater than standard from 40% to 80% state of charge.

44. The energy storage device according to claim 39, wherein the lead-acid battery has a discharge power from 10% to 500% greater than standard from 40% to 100% state of charge.

45. The energy storage device according to claim 39, wherein the lead-acid battery comprises a dry unformed plate surface area of 5 m²/g to 10 m²/g.

46. The energy storage device according to claim 39, wherein the lead-acid battery provides 20% to 500% greater cycles than standard in a HRPSoC test.

47. An energy storage device, comprising:

an electrode comprising lead;

an electrode comprising lead dioxide;

a separator between the electrode comprising lead and the electrode comprising lead dioxide;

an aqueous electrolyte solution containing sulfuric acid;

a first carbon-based additive having a surface area from 100 m2/g to 200 m2/5, wherein the first carbon-based additive is functionalized with —

SO₃ or —

COOH; and

a second carbon-based additive having a surface area from 3 m²/g to 50 m²/g.

48. The energy storage device according to claim 47, wherein the first carbon-based additive has a surface area from 800 m²/g to 1300 m²/g.

49. The energy storage device of claim 47, wherein the energy storage device is a lead-acid battery.

50. The energy storage device of claim 49, wherein the first and second carbon-based additives enhance the discharge capacity, static charge acceptance, charge power, discharge power, life cycle of the lead-acid battery and combinations thereof.

51. The energy storage device according to claim 49, wherein the lead-acid battery has a discharge capacity 2% to 20% greater than standard at a C/20 discharge rate for 20 hours.

52. The energy storage device according to claim 49, wherein the lead-acid battery has a static charge acceptance from 50% to 150% greater than standard when charged at 2.4 V/cell to 15 min at 0°

F.

53. The energy storage device according to claim 49, wherein the lead-acid battery has a charge power from 75% to 200% greater than standard from 40% to 80% state of charge.

54. The energy storage device according to claim 49, wherein the lead-acid battery has a discharge power from 10% to 500% greater than standard from 40% to 100% state of charge.

55. The energy storage device according to claim 49, wherein the lead-acid battery comprises a dry unformed plate surface area of 5 m²/g to 10 m²/g.

56. The energy storage device according to claim 49, wherein the lead-acid battery provides 20% to 500% greater cycles than standard in a HRPSoC test.

57. A method of reducing shedding of an active material in a lead-acid battery comprising the steps of:

a. Providing a negative active material suitable for use in a lead-acid battery;

b. Adding to the active material from 0.5% wt. to 3% wt. of a carbon-based additive having a surface area from 3 to 50 m2/g;

c. Applying the resulting paste to a cell;

d. Curing the paste;

e. Over forming the cell assembly using a constant current;

wherein the paste is retained, or shows no disfiguration for 100% to 500% longer than high surface area carbons.