ENERGY STORAGE DEVICES COMPRISING CARBON-BASED ADDITIVES AND METHODS OF MAKING THEREOF
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.
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 m 2 /g to 2000 m 2 /g; and
a second carbon additive having a surface area from 3 m 2 /g to 50 m 2 /g.
2 . The energy storage device of claim 1 , wherein the first carbon additive has a surface area of from 150 m 2 /g to 350 m 2 /g.
3 . The energy storage device of claim 1 , wherein the first carbon additive has a surface area from 1300 m 2 /g to 1600 m 2 /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 m 2 /g to 350 m 2 /g.
6 . The energy storage device of claim 4 , wherein the first carbon additive has a surface area from 1300 m 2 /g to 1600 m 2 /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 m 2 /g to 10 m 2 /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 m 2 /g to 50 m 2 /g.
16 . The energy storage device of claim 15 , wherein the first carbon additive has a surface area of from 500 m 2 /g to 750 m 2 /g.
17 . The energy storage device of claim 15 , wherein the first carbon-based additive has a surface area from 1500 m 2 /g to 2000 m 2 /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 m 2 /g to 10 m 2 /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 m 2 /g to 50 m 2 /g.
27 . The energy storage device of claim 26 , wherein the first carbon additive has a surface area of from 500 m 2 /g to 750 m 2 /g.
28 . The energy storage device of claim 26 , wherein the first carbon-based additive has a surface area from 1500 m 2 /g to 2000 m 2 /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 m 2 /g to 10 m 2 /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 m 2 /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 m 2 /g to 50 m 2 /g.
38 . The energy storage device of claim 37 , wherein the first carbon additive has a surface area of from 1500 m 2 /g to 2000 m 2 /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 m 2 /g to 10 m 2 /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 —SO 3 or —COOH; and
a second carbon-based additive having a surface area from 3 m 2 /g to 50 m 2 /g.
48 . The energy storage device according to claim 47 , wherein the first carbon-based additive has a surface area from 800 m 2 /g to 1300 m 2 /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 m 2 /g to 10 m 2 /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.