9elbc presentation

CellForce®: 

CellForce® Operational Experience & Performance of the New Hybrid Rubber-Polyethylene Battery Separator

OUTLINE: 

OUTLINE Background of CellForce Development Objectives Milestones Material Analysis & Characterization Battery Performance Testing Independent Battery Manufacturers MPLP Technical Center Summary & Future Work

MILESTONES for CellForceA Natural Extension of Over 70 Years Experience with Rubber Battery Separator Manufacturing : 

MILESTONES for CellForce A Natural Extension of Over 70 Years Experience with Rubber Battery Separator Manufacturing 1999- First Prototypes 9/2000- Introduced to the Industry at 7ELBC 1/2001- Manufacturing Line Commissioned 6/2001- Patent Coverage Issued

Development Objectives: 

Development Objectives Electrochemical Benefits of Rubber Stable TOC Voltage During Cycling Reduced Battery Maintenance Handling Characteristics of PE Envelope and Sleeve Designs Puncture and Tear Resistant Compatible with Established Separator Manufacturing Methods Basic PE Manufacturing Process Competitive Pricing

MATERIAL PROPERTIESKEY VARIABLES: 

MATERIAL PROPERTIES KEY VARIABLES RESIDUAL OIL CONTENT PORE STRUCTURE & VOLUME POROSITY ELECTRICAL RESISTANCE OXIDATION RESISTANCE PUNCTURE RESISTANCE TENSILE/ELONGATION

REDUCED ELECTRICAL RESISTANCE For CellForce: 

REDUCED ELECTRICAL RESISTANCE For CellForce Approximately 25% Lower Residual Oil – 18% Back Web Thickness – 0,5 mm Rib Pattern – Same Pore Volume PE at 65% CellForce at 62%

EXAMPLE OF LOWERED ELECTRICAL RESISTANCE: 

EXAMPLE OF LOWERED ELECTRICAL RESISTANCE C5 Capacity @ 570 Ah 1 Hour Rate CellForce 1:14:45 PE 1:10:25 Approximate 5% Improvement 30 Minute Rate CellForce 35:55 PE 33:10 Approximate 8% Improvement

Slide8: 

PE CellForce

MICROSTRUCTURENormal PE: 

MICROSTRUCTURE Normal PE

MICROSTRUCTURECellForce: 

MICROSTRUCTURE CellForce

MICROSTRUCTURECellForce: 

MICROSTRUCTURE CellForce

MICROSTRUCTURECellForce: 

MICROSTRUCTURE CellForce

LIQUID FLOW RATECellForce vs. PE: 

LIQUID FLOW RATE CellForce vs. PE

Capillary Flow PorometryShows Increased Electrolyte Transfer: 

Capillary Flow Porometry Shows Increased Electrolyte Transfer

MOTIVE POWERBATTERY TESTING: 

MOTIVE POWER BATTERY TESTING Accelerated Life Testing PE vs. CellForce

TEST METHODACCELERATED 3 CYCLES/DAY: 

TEST METHOD ACCELERATED 3 CYCLES/DAY Cells held at 50°C in water bath Discharge 70% DoD for C5 Rate set for 2 hour discharge; 1,70 vpc Charge Charge factor at 1,2 2 hours for 65% of charge factor 4 hours for 35% of charge factor Equalization Charge as required Failure at 80% nominal capacity

Slide17: 

Ave Cycles to Failure C/F- 950 to 1000+ PE- 725 Tubular Positive Cells 450 Ah C5 Accelerated-High Temperature Cycling

MOTIVE POWERBATTERY TESTING: 

MOTIVE POWER BATTERY TESTING Low Maintenance Life Testing PE vs. CellForce

TESTING DETAILS: 

TESTING DETAILS Controls (PE) versus CellForce Regular PE PE with Additive for Sb Suppression Cell Capacity C6 at 425 Ah 11 Plate, 6% Sb Pos & 3% Sb Neg 2 Cycles/24 hours 80% DoD IEI Re-Charge Regimen

Slide23: 

High Initial Voltage 1500 cycles 40 mV lower

Slide24: 

Divergence CellForce Water Usage 11% less

Slide25: 

Divergence CellForce 25% less

MOTIVE POWERBATTERY TESTING: 

MOTIVE POWER BATTERY TESTING Accelerated Life Testing PE vs. CellForce

TEST METHODACCELERATED 2 CYCLES/DAY: 

TEST METHOD ACCELERATED 2 CYCLES/DAY Cells held at 35°C in water bath Discharge 75% DoD for C5 Rate set for 3 hour discharge; 1,25 I5 Charge Charge factor at 1,2 3 hours for 84% of charge factor 1,05 I5 6 hours for 36% of charge factor 0,225 I5 Failure at 80% nominal capacity

TEST METHOD: 

TEST METHOD Low Maintenance Pulse Charging 5%C5 Overcharge per Cycle 80% DoD Capacity Check at 50 Cycle Intervals

Slide30: 

Increase Overcharge To 6% @ 350 Cycles CellForce TOC 21 mV Higher

TEST METHOD: 

TEST METHOD Fixed Overcharge Testing Continuous Cycling 3 Hr Discharge @ C5 (75% DoD) 9 Hr Charge at Charge Factor of 1,152 Measured Capacity @ 50 Cycle Intervals

Slide33: 

CellForce – 41 mV Higher

Slide34: 

CellForce – 0.39 V PE – 0.36 V

TESTING DETAILS: 

TESTING DETAILS Control PE vs. CellForce 12 V Batteries – C6 425 Ah Ambient Temp 8 Hr. Discharge to 80% DoD Two-step Recharge to 1,05 Charge Factor Step 1- 2,37 V @ 0,15 C6 for 5,25 hrs (98%) Step 2- 2,65 V @ 0,05 C6 for 2 hours (105%)

Slide37: 

CellForce 7% less

DEEP CYCLEBATTERY TESTING: 

DEEP CYCLE BATTERY TESTING BCI Life Cycle Testing PE vs. CellForce Life—EOCC—Water Loss

Slide39: 

GC-2 BATTERY TESTING Average Cycle Life PE – 388 cycles CellForce – 453 cycles FLEX-SIL Rubber Separator >700 cycles

Slide40: 

GC-2 BATTERY TESTING

Slide41: 

GC-2 BATTERY TESTING

SUMMARY: 

SUMMARY CellForce Being Used Successfully Americas, Europe and Asia-Pacific Both Flat Plate and Tubular Motive Power, Deep Cycle, Stationary Flooded and Gel No Field Related Problems Reported Normal Battery Failure Modes No Oil Release Incidents Improved Material and Battery Related Characteristics TOC Voltage & Battery Maintenance Lower ER Extension of Cycle Life

FUTURE WORK: 

FUTURE WORK Optimize the Beneficial Effect of the Natural Rubber Component Continue Investigation of Effects of Residual Oil Content on Key Material Properties Continue Development of the Next Generation CellForce