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  Battery paste additive and method for producing battery platesRelated Patent Categories: Chemistry: Electrical Current Producing Apparatus, Product, And Process, Current Producing Cell, Elements, Subcombinations And Compositions For Use Therewith And Adjuncts, Electrode, Chemically Specified Inorganic Electrochemically Active Material Containing, Lead Component Is Active Material, Lead OxideThe Patent Description & Claims data below is from USPTO Patent Application 20060240325. Brief Patent Description - Full Patent Description - Patent Application Claims
[0001] The present invention relates generally to battery pastes and the curing process for battery plates. In particular, an improvement to battery paste and the curing process for battery plates for lead acid batteries is disclosed. More specifically, the present invention comprises a battery paste additive of micronized tetra basic lead sulfate crystals used to promote formation of additional tetra basic lead sulfate in the paste and plates. As a result, the curing process is accelerated and the resultant positive and negative battery plates have improved performance characteristics. BACKGROUND OF THE INVENTION [0002] Traditional methods for producing battery plates for lead-acid batteries generally involve a mixing, curing and drying operation in which the active materials in the battery paste undergo chemical and physical changes that are used to establish the chemical and physical structure and subsequent mechanical strength necessary to form the battery plate. To produce typical battery plates, materials are added to commercial paste mixing machines common in the industry in the order of lead oxide, flock, water and sulfuric acid, which are then mixed to a paste consistency. During mixing, chemical reactions take place in the paste producing basic lead sulfates, the most common of which is tribasic lead sulfate. The final paste composition is a mixture of basic lead sulfates, unreacted lead monoxide and residual free lead particles. Pasting is the process of making a battery plate from the paste mix. This paste is dispersed into a commercial automatic pasting machine of a type common in the industry which applies the paste to a grid structure composed of a lead alloy. The paste is dispensed into a hopper on the pasting machine and from there the paste is applied to the grids at high speed. The paste plates are generally surface dried in a tunnel dryer of a type common in the industry and then either stacked in columns or placed on racks. The stacked or racked plates are then placed in curing chambers. In these chambers the plates are subjected to temperatures of 70.degree. C.-80.degree. C. in a high humidity atmosphere to convert the tribasic lead sulfate in the plates to tetra basic lead sulfate and to allow oxidation of the residual free lead. The finished plates are now ready for assembly into batteries. [0003] Two key factors important in the curing process are the formation of a proper crystal structure by converting tribasic lead sulfate (TRBLS) formed during paste mixing into tetra basic lead sulfate (TTBLS), and the formation of tetragonal lead oxide by oxidizing residual free lead metal. Generally, a crystal structure high in tetra basic lead sulfate will increase battery life. The general formula for converting tribasic lead sulfate to tetra basic lead sulfate is set forth below: 3PbO.PbSO.sub.4.H.sub.2O+PbO--->4PbO.PbSO.sub.4+H.sub.2O [0004] A common problem with traditional battery paste compositions and methods for curing is that the chemical characteristics of the resultant plates are not uniform, varying in quality. Other common problems include difficulty in the repeatability of production, uncertain and/or lengthy curing time, the large number of curing chambers needed to process plates, and high capital and energy costs. [0005] Consequently, a need exists for improvements in battery pastes which may be used with conventional paste mixing and curing processes, procedures and equipment to produce positive and/or negative battery plates having greater uniformity, more consistent quality, more consistent reproducibility, requiring shorter and more consistent curing times, requiring less curing chambers to process the plates and less capital and energy costs than traditional positive and/or negative battery plate pastes and methods of paste mixing and curing. [0006] The present invention overcomes the disadvantages and/or shortcomings of known prior art battery pastes and curing methods for battery plates and provides a significant improvement thereover. SUMMARY OF THE INVENTION [0007] A battery paste additive comprising micronized crystals of tetra basic lead sulfate and a method of producing the battery paste additive and battery plates is disclosed herein. The battery paste additive is added to a battery paste to promote and increase formation of tetra basic lead sulfate (TTBLS) crystals during paste mixing and curing. The battery paste additive may be used with conventional paste mixes and paste mixing and curing procedures and equipment to improve battery plate production and the resulting battery plates. [0008] Accordingly, an object of the invention is to provide a battery paste additive comprising micronized tetra basic lead sulfate crystals. [0009] Another object of the invention is to provide a battery paste additive that will reduce the time to cure the paste into the battery plate. [0010] Yet another object of the invention is to provide a battery paste additive that may be used with conventional paste mixes and conventional mixing and curing procedures and equipment. [0011] Yet another object of the invention is to provide a battery paste additive that improves the mechanical and physical strength of the resulting battery plate. [0012] Yet another object of the invention is to create battery plates which are uniform in physical structure and quality. [0013] Yet another object of the invention is to provide a battery paste additive allowing battery pastes and plates to be consistently reproducible. [0014] Yet another object of the invention is to provide a battery paste additive which is used in battery pastes to produce plates that are cured in a reasonably consistent duration of time. [0015] Yet another object of the invention is to provide a battery paste additive that may be used to produce positive battery plates. [0016] Yet another object of the invention is to provide a battery paste additive which may be used to produce negative battery plates. [0017] Yet another object of the invention is to provide a battery paste additive that reduces curing costs and capital costs associated with conventional curing procedures and curing chambers. [0018] Numerous other objects, features and advantages of the present invention will become readily apparent from the detailed description and from the claims which follow. BRIEF DESCRIPTION OF THE DRAWINGS [0019] FIG. 1 is a chart of the components for the automotive and industry paste mixes for positive and negative plates to which the battery additive has been added. [0020] FIG. 2 is a chart of the results of the effect of 1% (by weight of lead oxide) of the battery paste additive on industrial paste and plate curing for a first sample; [0021] FIG. 3 is a chart of the results of the effect of 1% (by weight of lead oxide) of the battery paste additive on industrial paste and plate curing for a second sample; Continue reading... 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