Method for producing hybrid negative plate for lead-acid storage battery and lead-acid storage battery

• US 9,524,831 B2
• Filed: 08/26/2010
• Issued: 12/20/2016
• Est. Priority Date: 08/27/2009
• Status: Active Grant

• Current Assignee: Commonwealth Scientific & Industrial Research Organisation (Commonwealth Of Australia As Represented By Department Of Industry, Innovation, Climate Change, Science, Research And Tertiary Education), Furukawa Battery Company Limited (Furukawa Electric Company Limited)
• Original Assignee: Commonwealth Scientific & Industrial Research Organisation (Commonwealth Of Australia As Represented By Department Of Industry, Innovation, Climate Change, Science, Research And Tertiary Education), Furukawa Battery Company Limited (Furukawa Electric Company Limited)
• Inventors: Momma, Daisuke, Akasaka, Yuichi, Shibata, Satoshi, Furukawa, Jun, Takada, Toshimichi, Lam, Lan Trieu, Louey, Rosalie, Haigh, Nigel Peter
• Primary Examiner(s): HARRIS, GARY D
• Application Number:
  US13/392,651
• Publication Number:
  US 20120263977A1
• Time in Patent Office: 2,308 Days
• Field of Search: 429/7, 429/122
• US Class Current: 1/1
• CPC Class Codes: H01G 11/38 Carbon pastes or blends; Binders or additives therein
• CPC Class Codes: H01G 11/42 Powders or particles, e.g. composition thereof
• CPC Class Codes: H01G 11/86 specially adapted for electrodes carbonisation or activation of carbon for the manufacture of electrodes H01G11/34
• CPC Class Codes: H01M 4/0411 by extrusion
• CPC Class Codes: H01M 4/043 involving compressing or compaction
• CPC Class Codes: H01M 4/20 of pasted electrodes
• CPC Class Codes: H01M 4/366 as layered products
• CPC Class Codes: H01M 4/625 Carbon or graphite
• CPC Class Codes: H01M 4/627 Expanders for lead-acid accumulators
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02E 60/13 Energy storage using capacitors
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries

Abstract

There is provided a method for producing a hybrid negative plate for a lead-acid storage battery which is improved in the production working efficiency and the productivity and enhances the quick charge and discharge characteristics and the discharge characteristics at a low temperature under PSOC of a lead-acid storage battery.

A carbon mixture sheet produced by such a way that a carbon mixture prepared by mixing two types of carbon materials consisting of a first carbon material having electroconductivity and a second carbon material having capacitor capacitance and/or pseudocapacitor capacitance, and at least a binder, is adhered by pressure to the surface of a negative plate in a wet state, so that a hybrid negative plate is produced. The lead-acid storage battery provided with the hybrid negative plate is improved in the discharge characteristics.

Claims

1. A method for producing a hybrid negative plate for a lead-acid storage battery comprising the steps of:

(i) preparing a carbon mixture comprising a first carbon material having electroconductivity and a second carbon material having capacitor capacitance and/or pseudocapacitor capacitance, and a binder;

(ii) forming the carbon mixture into a sheet;

(iii) preparing a negative active material-filled plate comprising a current collector plate coated with negative active battery material;

(iv) applying said carbon mixture sheet prepared in step (ii) to the negative active material-filled plate of step (iii) when the plate is in a wet state to form a hybrid negative plate;

(v) roll pressing the hybrid negative plate formed in step (iv); and

(vi) after step (v), drying the hybrid negative plate.

2. The method for producing a hybrid negative plate for a lead-acid storage battery according to claim 1, wherein the method comprises drying the carbon mixture sheet before applying the carbon mixture sheet to the negative active material-filled plate.

3. The method for producing a hybrid negative plate for a lead-acid storage battery according to claim 1, wherein the applying of the carbon mixture sheet to the negative active material-filled plate in step (iv) is performed when the sheet is in a wet state.

4. The method for producing a hybrid negative plate for a lead-acid storage battery according to claim 1, wherein the carbon mixture is formed into a sheet by an extrusion forming method or a coating method.

5. The method for producing a hybrid negative plate for a lead-acid storage battery according to claim 4, wherein the coating method comprises applying the carbon mixture to a porous sheet.

6. The method for producing a hybrid negative plate for a lead-acid storage battery according to claim 1, wherein after the step of applying the carbon mixture sheet to the negative active material-filled plate, pressure is applied to the hybrid negative plate to facilitate adherence between the sheet and plate.

7. The method for producing a hybrid negative plate for a lead-acid storage battery according to claim 1, wherein the carbon mixture contains the first carbon material in an amount of 5 and 70 parts by weight of the total weight of the carbon mixture.

8. The method for producing a hybrid negative plate for a lead-acid storage battery according to claim 1, wherein the carbon mixture contains the first carbon material in an amount of 10 and 60 parts by weight of the total weight of the carbon mixture.

9. The method for producing a hybrid negative plate for a lead-acid storage battery according to claim 1, wherein the carbon mixture contains the second carbon material in an amount of 20 and 80 parts by weight of the total weight of the carbon mixture.

10. The method for producing a hybrid negative plate for a lead-acid storage battery according to claim 9, wherein the carbon mixture contains the second carbon material in an amount of 30 and 70 parts by weight of the total weight of the carbon mixture.

11. The method for producing a hybrid negative plate for a lead-acid storage battery according to claim 1, wherein the carbon mixture comprises a pore forming agent.

12. The method for producing a hybrid negative plate for a lead-acid storage battery according to claim 11, wherein the pore forming agent is at least one selected from the group of a zinc powder, a camphor powder, a naphthalene powder and aluminum powder.

13. The method for producing a hybrid capacitor negative plate for a lead-acid storage battery according to claim 11, wherein the pore forming agent is aluminum.

14. The method for producing a hybrid capacitor negative plate for a lead-acid storage battery according to claim 13, wherein the aluminum is provided in an amount of 3 to 20 parts by weight of the total weight of the carbon mixture.

15. The method for producing a hybrid capacitor negative plate for a lead-acid storage battery according to claim 14, wherein the aluminum is provided in an amount of 5 to 15 parts by weight of the total weight of the carbon mixture.

16. The method for producing a hybrid capacitor negative plate for a lead-acid storage battery according to claim 1, wherein the binder is provided in an amount of less than 10 parts by weight of the total weight of the carbon mixture.

17. The method for producing a hybrid negative plate for a lead-acid storage battery according to claim 1, wherein the carbon mixture comprises a short fiber reinforcing material.

18. The method for producing a hybrid negative plate for a lead-acid storage battery according to claim 17, wherein the short fiber reinforcing material comprises individual fibers having dimensions between 1 to 30 μ

m in thickness and 0.05 to 4.0 mm in length.

19. A lead-acid storage battery provided with the hybrid negative plate produced by the method according to claim 1.

20. The method for producing a hybrid negative plate for a lead-acid storage battery according to claim 1, wherein the carbon mixture comprises a mixed amount of from 5 to 70 parts by weight of the first carbon material, from 20 to 80 parts by weight of the second carbon material, from 1 to 20 parts by weight of the binder and a thickener in an amount of less than 10 parts by weight.