CARBON - LEAD BLENDS FOR USE IN HYBRID ENERGY STORAGE DEVICES

• US 20130004841A1
• Filed: 06/01/2012
• Published: 01/03/2013
• Est. Priority Date: 06/03/2011
• Status: Active Grant

• Current Assignee: BASF SE
• Original Assignee: EnerG2 Technologies, Incorporated (BASF SE)
• Inventors: Feaver, Aaron M., Costantino, Henry R., Chang, Alan Tzu-Yang, Geramita, Katharine, Thompkins, Leah A., Sakshaug, Avery
• Granted Patent: US 10,522,836 B2
• Time in Patent Office: Days
• US Class Current: 429/204
• CPC Class Codes: C08K 3/04 Carbon
• CPC Class Codes: C08K 3/08 Metals
• CPC Class Codes: C08K 7/22 Expanded, porous or hollow particles
• CPC Class Codes: H01B 1/02 mainly consisting of metals or alloys
• CPC Class Codes: H01B 1/04 mainly consisting of carbon-silicon compounds, carbon or silicon
• CPC Class Codes: H01B 1/18 the conductive material comprising carbon-silicon compounds, carbon or silicon
• CPC Class Codes: H01G 11/50 specially adapted for lithium-ion capacitors, e.g. for lithium-doping or for intercalation
• CPC Class Codes: H01M 10/06 Lead-acid accumulators semi-lead accumulators H01M10/20
• CPC Class Codes: H01M 2004/021 Physical characteristics, e.g. porosity, surface area
• CPC Class Codes: H01M 4/14 Electrodes for lead-acid accumulators
• CPC Class Codes: H01M 4/56 of lead
• CPC Class Codes: H01M 4/583 Carbonaceous material, e.g. graphite-intercalation compounds or CFx
• CPC Class Codes: H01M 4/625 Carbon or graphite
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02E 60/13 Energy storage using capacitors
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries

Abstract

The present application is directed to blends comprising a plurality of carbon particles and a plurality of lead particles. The blends find utility in any number of electrical devices, for example, in lead acid batteries. Methods for making and using the blends are also disclosed.

Claims

1. A blend comprising carbon and lead, wherein the blend comprises a total impurity content of less than 500 ppm of all elements having atomic numbers ranging from 11 to 92, excluding lead, as measured by proton induced x-ray emission.

2. The blend of claim 1, wherein the blend comprises a plurality of carbon particles and a plurality of lead particles, wherein the carbon particles comprise lead within a pore structure or on a surface of the carbon particles.

3. The blend of claim 1, wherein the blend comprises a plurality of carbon particles and a plurality of lead particles.

4. The blend of claim 1, wherein the carbon comprises a total of less than 500 PPM of elements having atomic numbers ranging from 11 to 92, excluding lead, as measured by proton induced x-ray emission.

5. The blend of claim 4, wherein the carbon comprises a total of less than 100 PPM of elements having atomic numbers ranging from 11 to 92, excluding lead, as measured by proton induced x-ray emission.

6. The blend of claim 1, wherein the blend comprises a total of less than 100 PPM of elements having atomic numbers ranging from 11 to 92, excluding lead, as measured by proton induced x-ray emission.

9. The blend of claim 1, wherein the blend comprises a total of less than 10 PPM of elements having atomic numbers ranging from 11 to 92, excluding lead, as measured by proton induced x-ray emission.

12. The blend of claim 1, wherein the lead is in the form of lead (II) oxide, lead (IV) oxide, lead acetate, lead carbonate, lead sulfate, lead orthoarsenate, lead pyroarsenate, lead bromide, lead caprate, lead carproate, lead caprylate, lead chlorate, lead chloride, lead fluoride, lead nitrate, lead oxychloride, lead orthophosphate sulfate, lead chromate, lead chromate, basic, lead ferrite, lead sulfide, lead tungstate or combinations thereof.

13. The blend of claim 1, wherein the mass percent of carbon as a percentage of the total mass of carbon and lead ranges from 0.5% to 3.0%.

14. The blend of claim 1, wherein the mass percent of carbon as a percentage of the total mass of carbon and lead ranges from 1.0% to 2.0%.

15. The blend of claim 1, wherein the volume percent of carbon as a percentage of the total volume of carbon and lead ranges from 1% to 20%.

18. The blend of claim 1, wherein the surface area percent of carbon as a percentage of the total surface area of carbon and lead ranges from 80% to 99%.

19. The blend of claim 1, wherein the carbon surface area residing in pores less than 20 angstroms as a percentage of the total surface area residing in pores less than 20 angstroms of carbon and lead ranges from 20% to 60%.

23. The blend of claim 3, wherein the volume average particle size of carbon particles relative to the volume average particle size of lead particles ranges from 0.1:

1 to 2;

1.

25. The blend of claim 1, wherein the capacitance of the carbon measured at a rate of 1 mA is greater than 250 F/g.

27. The blend of claim 1, wherein the ash content of the blend, excluding the ash associated with lead, is less than 0.01% as calculated from proton induced x-ray emission data.

28. The blend of claim 1, wherein the carbon comprises less than 10 ppm iron as measured by proton induced x-ray emission.

29. The blend of claim 1, wherein the carbon comprises less than 5 ppm nickel as measured by proton induced x-ray emission.

32. The blend of claim 1, wherein the carbon comprises less than 5 ppm of each of manganese, nickel, mercury and platinum as measured by proton induced x-ray emission.

33. The blend of claim 1, wherein the carbon comprises an undetectable amount of manganese, nickel, mercury and platinum as measured by proton induced x-ray emission.

34. The blend of claim 1, wherein the carbon comprises less than 5 ppm chromium, less than 10 ppm iron, less than 5 ppm nickel, less than 20 ppm silicon, less than 5 ppm zinc, and bismuth, silver, copper, mercury, manganese, platinum, antimony and tin are not detected as measured by proton induced x-ray emission.

41. The blend of claim 1, wherein the carbon comprises a BET specific surface area of at least 20 m²/g.

42. The blend of claim 1, wherein the carbon comprises a BET specific surface area of at least 700 m²/g.

44. The blend of claim 1, wherein the carbon comprises a BET specific surface area of at least 1500 m²/g.

46. The blend of claim 1, wherein the carbon comprises a total pore volume of at least 1.0 cc/g.

47. The blend of claim 1, wherein the carbon comprises a total pore volume of at least 0.7 cc/g.

48. The blend of claim 1, wherein the carbon comprises a total pore volume of at least 0.5 cc/g.

49. The blend of any claim 1, wherein the carbon comprise a DFT pore volume of at least 0.25 cc/g for pores less than 20 angstroms.

50. The blend of claim 1, wherein the carbon comprise a DFT pore volume of at least 0.75 cc/g for pores greater than 20 angstroms.

56. The blend of claim 1, wherein the carbon comprises a pore volume ranging from 0.4 cc/g to 1.4 cc/g and an R factor of 0.2 or less at relative humidities ranging from about 10% to 100%.

57. The blend of claim 56, wherein the carbon comprises an R factor of 0.6 or less.

62. The blend of claim 1, wherein the carbon comprises an R factor greater than 1.6.

63. The blend of claim 1, wherein the carbon comprises an R factor ranging from 1.2 to 1.6.

64. The blend of claim 1, wherein the carbon comprises an R factor below 1.2.

65. The blend of claim 1, wherein the carbon comprises a pH of less than 6.

66. The blend of claim 1, wherein the carbon comprises a pH range of 5.0-6.5.

67. The blend of claim 1, wherein the carbon comprises a pH of greater than 7.

68. An electrical energy storage device comprising the blend claim 1.

69. The device of claim 68, wherein the device is a battery comprising:

a) at least one positive electrode comprising a first active material in electrical contact with a first current collector;

b) at least one negative electrode comprising a second active material in electrical contact with a second current collector; and

c) an electrolyte comprising water and sulfuric acid;

wherein the positive electrode and the negative electrode are separated by an inert porous separator, and wherein at least one of the first or second active materials comprises a blend according to claim 1, and the first or second current collector comprises lead.

74. An electrode comprising a binder and the blend claim 1.

83. A composition comprising the blend of claim 1 and an electrolyte.

87. A method for preparing the composition of claim 83, the method comprising admixing the blend and the electrolyte.

90. The device of claim 68, wherein the electrical energy storage device is for use in a microhybrid, start-stop hybrid, mild-hybrid vehicle, vehicle with electric turbocharging, vehicle with regenerative braking, hybrid vehicle, an electric vehicle, industrial motive power such as forklifts, electric bikes, golf carts, aerospace applications, a power storage and distribution grid, a solar or wind power system, a power backup system or a cellular tower power system.

94. The blend of claim 1, wherein the carbon comprises a pH of greater than 8.

7-8. -8. (canceled)

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