Fiber mat for battery plate reinforcement

Patent metadata

Field	Value
Publication number	US-9843048-B2
Application number	US-201615213957-A
Country	US
Kind code	B2
Filing date	Jul 19, 2016
Priority date	Jul 31, 2012
Publication date	Dec 12, 2017
Grant date	Dec 12, 2017

Abstract

Embodiments of the invention provide batteries, electrodes, and methods of making the same. According to one embodiment, a battery may include a positive plate having a grid pasted with a lead oxide material, a negative plate having a grid pasted with a lead based material, a separator separating the positive plate and the negative plate, and an electrolyte. A nonwoven glass mat may be in contact with a surface of either or both the positive plate or the negative plate to reinforce the plate. The nonwoven glass mat may include a plurality of first coarse fibers having fiber diameters between about 6 μm and 11 μm and a plurality of second coarse fibers having fiber diameters between about 10 μm and 20 μm.

First claim

What is claimed is:

1. A lead-acid battery comprising:
a grid of lead alloy material;
a paste of an active material applied to the grid of lead alloy material; and
a nonwoven fiber mat disposed on a surface of the paste of the active material, wherein the nonwoven fiber mat comprises a tensile strength greater than 40 lbs/3 inch, wherein the nonwoven fiber mat comprises a mat thickness of about 0.009 inches or less, wherein the nonwoven fiber mat has a weight of about 0.40 lb/sq mat and wherein the fibers of the nonwoven fiber mat are composed entirely of an acrylic binder and a blend of coarse glass fibers having average fiber diameters of between 6 μm and 20 μm including:
a plurality of first coarse glass fibers having an average fiber diameter of 8 μm; and
a plurality of second coarse glass fibers having an average fiber diameter of 13 μm;
wherein the nonwoven fiber mat comprises 50% of the first coarse glass fibers and 50% of the second coarse glass fibers and wherein the acrylic binder is applied so that the nonwoven fiber mat has a loss on ignition content of the acrylic binder of between 20% and 28% to bond the plurality of first coarse glass fibers and the plurality of second coarse glass fibers together.

2. The lead-acid battery of claim 1 , wherein the nonwoven fiber mat comprises a tensile strength in the machine direction of at least 22 lbs/3 inch.

3. The lead-acid battery of claim 1 , wherein the nonwoven fiber mat comprises a tensile strength in the cross-machine direction of at least 13 lbs/3 inch.

4. The lead-acid battery of claim 1 , wherein the nonwoven fiber mat comprise a mat thickness of between about 0.006 inches and 0.008 inches.

5. A lead-acid battery comprising:
an anode;
a cathode;
a separator for separating the anode and the cathode;
an electrolyte; and
a nonwoven glass mat in contact with a surface of either or both the anode or the cathode, the nonwoven glass mat having a mat thickness of about 0.009 inches or less and a weight of about 0.40 lb/sq mat, the nonwoven glass mat being composed entirely of an acrylic binder and a blend of coarse glass fibers having average fiber diameters of between 6 μm and 20 μm including:
a plurality of first coarse fibers having an average fiber diameter of 8 μm; and
a plurality of second coarse fibers having an average fiber diameter of 13 μm;

wherein the nonwoven glass mat comprises 50% of the first coarse glass fibers and 50% of the second coarse glass fibers, wherein the acrylic binder is applied so that the nonwoven glass mat has a loss on ignition content of between 20% and 28% to bond the plurality of first coarse glass fibers and the plurality of second coarse glass fibers together, and wherein the nonwoven glass mat has a tensile strength in a machine direction of at least 22 lbs/3 inch and a tensile strength of at least 13 lbs/3 inch in a cross-machine direction.

6. The lead-acid battery of claim 5 , wherein the nonwoven glass mat has a thickness of 0.009 inches or less and a tensile strength of at least 35 lbs/3 inch.

7. The lead-acid battery of claim 6 , wherein the nonwoven glass mat has a thickness of 0.008 inches or less and a tensile strength of at least 40 lbs/3 inch.

Assignees

• Johns Manville

Inventors

• Guo Zhihua
• Nandi Souvik
• Asrar Jawed
• Dietz Iii Albert G

Classifications

• H01M50/494

  Tensile strength · CPC title

• H01M50/454

  comprising a non-fibrous layer and a fibrous layer superimposed on one another · CPC title

• H01M50/42

  Acrylic resins · CPC title

• H01M50/417

  Polyolefins · CPC title

• H01M50/489

  Separators, membranes, diaphragms or spacing elements inside the cells, characterised by their physical properties, e.g. swelling degree, hydrophilicity or shut down properties · CPC title