ELECTRIC STORAGE BATTERIES

Abstract: A battery of recombinant type has two or more cells separated from one another by the material of plastics bags (18) which contain the plates and separators of each cell and constitute intercell partitions. The cells contain substantially no free unabsorbed electrolyte. The intercell connectors (22) pass over the intercell partitions (18) and are there provided with a ring (24) of plastics material or a layer of epoxy resin which constitutes an electrolyte creepage barrier.

Description: ELECTRIC STORAGE BATTERIES TECHNICAL FIELD The present invention relates to electric storage batteries and in particular, though not exclusively, to lead acid storage batteries, and is particularly 5. concerned with such batteries of so called "sealed" or "recombinant" type in which the amount of electrolyte present is restricted so that there is substantially no free unahsorbed electrolyte in the cells, and the gases evolved during operation or charging are induced to 10. recombine within the battery. ' BACKGROUND * ART Recombinant batteries are known, but it is an object of the invention to provide an economical battery structure which may be easily assembled. 15. DISCLOSURE OF THE ' INVENTION According to the present invention an electric storage battery has a compartment containing two cells separated from one another by an intercell partition, each cell comprising at least one positive electrode 20. and at least one negative electrode separated from each other by separators of absorbent fibrous material and containing substantially no free unabsorbed electrolyte, the positive plates of one cell being connected to the negative plates of the other cell 25. by an intercell connector which passes over or through the intercell partition and is not sealed thereto, in which the intercell connector is provided with an electrolyte creepage barrier. It has been found that, contrary to conventional •. 30 teaching, in recombinant batteries containing subsfantially no free unabsorbed electrolyte the intercell partitions do not need to be sealed to the battery lid in order to prevent the battery failing prematurely due to ionic intercell leakage. In the preferred embodiment of the invention the electrodes and separators of each cell are within a respective plastics bag, the material of the plastics 5. bags constituting the intercell partition. In this embodiment such an intercell partition is not sealed to the battery lid and the intercell con¬ nector merely passes over the . intercell partition and is not sealed to it. The baτtery's performance is not significantly impaired because intercell ionic leakage is not a serious problem in recombinant reduced electrolyte batteries. It is however believed that with the passage of time the surface of the plate straps and intercell 15 ' connectors of such batteries, which are typically of lead or lead alloy, will become somewhat corroded by the action of the electrolyte and that this surface will therefore become somewhat granular and porous This granular surface will provide a wic ing path 20 for electrolyte by virtue of capillary effects, that is to say that electrolyte will pass up -the plates and along the plate straps and intercell connectors and will then constitute an electrolyte path for intercell ionic leakage. 25 The provision in accordance with the invention of an electrolyte creepage barrier above the intercell partition ensures that although- wieking of electrolyte may occur along the plate straps, the electrolyte path is interrupted by the electrolyte creepage 5. barrier so that ionic leakage currents can not pass from one cell to the other. The electrolyte creepage barrier may take many forms and may even comprise a non-corroάible metallic sheath extending around and sealed to the intercell 10. connector. However, in a preferred form of the invention the creepage barrier comprises a ring of plastics material moulded around the intercell connector. Such a ring may be applied by means of a four-part mould, and it will be appreciated that it is important 15. that the ring of plastics material be substantially sealed to the intercell connector so as to prevent ■ ' electrolyte wieking through a gap between the intercell connector and the creepage barrier. In a further preferred form of the invention the creepage barrier 20. comprises a film of organic material extending around the intercell connector. Such a film may be apτ>lied by inverting the battery aftεr_ the plate . straps .have been ormed and dipping them and the intercell connector into a bath of organic liquid such 25. as epoxy resin or a laquer so as to leave them coated with the material which subsequently hardens. The creepage barriers may be applied by any convenient means, such as with a four-partmould when the plate strap is in position, or by moulding it around preformed plate straps 30. which are subsequently connected to the plate lugs. The creepage barriers form an electrolyte-tight seal with the intercell connectors, but it will be appreciated that their external shape may be varied at will. Preferably, however, the battery is inverted immediately after form- 35. ation of the plate straps and the latter are dipped whilst still hot into a fluidised bed of epoxy resin powder incorporating a curing agent. The epoxy dust sticks to the hot surface of the plate straps and cures to form an impervious layer but does not stick to the other 5. components of the battery which, are cold. As mentioned above the cells contain essentially no free unabsorbed electrolyte, and in the most preferred condition of the cells the amount of electrolyte is not sufficient to saturate the pores in the electrodes 10. and in the separators. The electrolyte absorption ratio of the separator material is preferably greater than 100% Electrolyte absorption ratio is the. ratio, as a percentage, of the volume of electrolyte absorbed by the wetted portion of the separator material to the dry 15. volume of that portion of the separator material which is wetted, wh.en a strip of the dry separator material is suspended vertically above a body of aqueous sulphuric acid electrolyte of 1.270 SG containing 0.01% weight sodium lauryl sulphonate with 1 cm of the lower end of 20. the strip immersed in the electrolyte, after a steady state wicking condition has been reached at 20 C at a relative humidity of less than 50%. The thickness measurement for the electrolyte absorption ratio measurement is carried out with a 25. micrometer at a loading of 10 kilopascals C1.- 5 psil and foot area of 200 square millimetres Cin accordance with t method of British. Standard Specification No. 32.89.1. We also prefer that the separator material should have a wicking heigh.t of at least 5 cms on the above test 30. namely that the electrolyte should have, risen to a height of at least 5 cms above the surface of the electrolyte into which the strip of separator material ' dips when the steady state condition has been reached. We find that these, two requirements are met by OMP fibrous blotting paper like materials made from fibres having diameters in the range 0.01 microns, or less, up to 10 microns, the average of the diameters of the fibres being less than 10 microns and nreferably less 5. than 5 microns, the weight to fibre density ratio, namely the ratio of the weight of the fibrous material in grams/square metre to the density in grams/cubic centimetre of the material from which the individual fibres are made preferably being at least 20 10. preferably 30 and especially 50. This combination of properties gives a material which is highly resistant to "treeing through", namely growth of lead dendrites from the positive electrode of a lead acid battery to the 15. negative electrode producing short circuits, whilst at the same time, even when containing large amounts of absorbed electrolyte, still providing a substantial degree of gas transmission capability. The amount of electrolyte added is "typically in- 20. the range 7 to 12 is of sulphuric acid of 1.270 SG per cell in the discharged state of the cell, per Amphere hour of capacity of the cell. Recombinant lead acid batteries operate under superat ospheric pressure e.g. from 1.1 bars upwards 25. and due to the restricted amount of electrolyte, the high electrolyte absorption ratio of the separator, and there being at least as much negative active material ' capacity as positive active material capacity and the higher electrochemical efficiency of the 30. negative electrode, the cell operates under the so- called "oxygen cycle" in which oxygen during charging or overcharging at the positive is transported, iτ is believed, through the gas phase in the separator to the surface of the negative which is damp with sulph- 5. uric acid and there recomhines with the lead to form lead oxide which is converted to lead sulphate by the sulphuric acid. Loss of water is thus avoided as is excess gas pressure inside the cell. If the charging conditions generate oxygen at a faster rate than it 10. can be transported to the negative and react thereat, then the excess oxygen is vented from the cell. The amount of electrolyte added is not highly critical since it is observed that if a slight excess of electrolyte is added above that required to saturate 15. the porosity of the cell components the recombination mechanism is suppressed and electrolyte is lost by electrolysis until the electrolyte volume has reached the correct amount for the cell in question, i.e. the cell porosity has reached the correct degre.e of 20. unsaturation, when the recombination mechanism comes into operation again and a steady state recombination condition related to the rate of charging which is used is established. The electrodes may be spirally wound or prismatic, 25. e.g. of cast, cast and rolled, rolled and punched or expanded rectilinear form. The prismatic electrodes may be folded and interleaved or arranged in a zig-zag interleaved relationship.. Conventional grid alloys may be used to make the 30. electrodes but for the folded or wound embodiments, softer materials such as pure lead or lead/calcium alloys e.g. with up to 0.1% calcium and optionally up to 1.0% tin are preferred. Gas venting means are preferably provided in the fo ■ - y O of a non-return valve so that air cannot obtain access to the interior of the battery although gas generated therein can escape to atmosphere. The intercell partition must resist degradation by 5. τhe electrolyte. Thus it may be polyethylene or poly¬ propylene or polyvinyl chloride film for a lead acid battery, and may have a thickness of less than 0,010 inches. The invention may be put into practice in various ways and two specific embodiments will be described by 10. way of example to illustrate the invenτion with reference τo τhe accompanying diagrammatic drawings. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a perspecτive view of a recombinant ulticell battery having flat plates in accordance with. 15. the present invention with one corner cut away; Figure 2 is a electron scanning photomicrograph of a preferred separator material at 1000 fold magnification ; and Figure 3 is a view similar to Figure 2 at 4000 20. fold magnification. BEST MODE OF CARRYING OUT THE INVENTION Referring first to Figure 1, the battery has a container 10 of plastics material such as polypropylene containing six cell packs 1*4. A cell pack is made up 25. by assembling a stack of positive and negative plates, each of which has a plate lug, interleaved with compres¬ sible absorbent microfine glass material which will be described in more detail below. The stack is then inserted into a plastics bag 18, of for instance poly-- 30. propylene which is seamed at 20. The plastics bag extends up above the plates and separators, but not as far as the tops of the plate lugs. Six such cell packs are slid into the container, and τhe relatively low coefficient of friction between the bags and the container enables τhe cell packs to be 35. a relatively tight fit in the container, thus ensuring ip^^n i^~^ contact between the plates and the separators. The container has no fixed intercell partions and the plastics bags 18 serve the function of the partitions. As mentioned above the' plastics bags extend above the 5. tops of the separators and plates and this is important since it ensures that the separator material in adjacent cells cannot come into contact. The negative and positive plates within each cell pack are connected together by respective plate straps 10. 22 which are fused to the plate lugs in any conventional manner. Every alternate plate strap ρass-es over an intercell partition constituted by the wall of two plastics bags to form an intercell connector in the usual manner. 15. As will be seen the plate straps 22 are of rect¬ angular section, and at the portion where they form intercell connectors, that is to say where they pass over the intercell partitions, they are each provided with an electrolyte creepage barrier 24 extending about 20. 1 cm along the plate straps/intercell connectors and about 5 mm thick, their external shape corresponding* to that of the plate straps. CM 1P A reduced amount of electrolyte is added to each - cell, either prior to sealing, e.g. hot plate welding a lid to the container or after such sealing, e.g. by injecting through holes in the lid. It is not critical 5. if the bags should extend slightly above the plate lugs, since the flexible plastics material will simply be depressed by the mould in which the plate straps are formed, or by the plate straps themselves. . The electrode supports are cast prismatic grids 10. made from a lead, 0.07% calcium, 0.7% tin alloy. The grids are 1.2 mms thick and are rigid and self support¬ ing ' and resist deformation even under load. They have good creep resistance. The separators are highly absorbent blotting paper- 15. like short staple fibre glass matting about 1 mm thick, there being fibres βl as thin as 0.2 microns and fibres 60 as thick as 2 microns in diameter, the average of the diameters of the fibres being about 0.5 microns. Figures 2 and 3 show this material at different 20. magnifications, Figure 2 at 1000 fold and Figure 3 at 4000 fold. It will be observed that the material whilst highly absorbent still has a very large amount of open space between the individual fibres. The material 25. when tested for its wicking and electrolyte absorption capabilities as. described above absorbs electrolyte so that the liquid has wicked .up to a . height of 20 cms after 2 hours and this is th.e steady state condition. This 20 cms of material absorbs 113% of its own dry 30. volume of electrolyte, and this is its electrolyte absorption ratio. The separator material weighs 200 grams/square metre and has a porosity of 9O-9.5% as measured by mercury intrusion penetrometry. The density of the glass from which the fibres of the separator are made 5. is 2.6.9 g/cc; the weight to fibre density is thus 74. The arrangement shown in Figure 1 may be assemble by forming plate packs of interleaved pasted plates and separators and partitions in a jig and then inserting the complete assembly into the container, 10. or the cell packs may be inserted sequentially into the container and electrolyte then added to the cells . The battery terminals are then connected to or formed on the plate straps and the lid sealed to the container In an alternative embodiment, which is not 15. illustrated, the plastics bags extend up above the intercell connectors which pass through, open topped slots formed in the material of the bag. In a further embodiment, which is also not illustrated, the electrolyte creepage barrier is 20. secured to the lid of the battery. This may be achieved by adhesive, but is preferably* achieved by hot welding at the same time as the lid is welded to the case, and. gives the cell packs additional sτability which may be required for certain application 25. due to the absence of fixed intercell partitions. In a still further embodiment, which is not illustr ated the battery is inverted immediately after formatio of the plate straps and the latter are. dipped whilst still hot into a fluidised bed of epoxy resin powder 30. incorporating a curing agent. The epoxy dust sticks to the hot surface of the plate straps and cures to form a • impervious layer but does not stick, to the other components of the battery which are cold. The imperyio layer of epoxy resin acts as the electrolyte creepage barrier . o;. >. . I

Claims: CLAIMS - 1. An electric storage battery having a compartment containing two cells eparatee from one another by an intercell partition, each cell comprising at least one positive electrode and at least one negative electrode separated from each other by separators of absorbent fibrous material and containing substantially no free unabsorbed electrolyte, the positive plates of one cell -being connected to the negative plates of the other cell by an intercell connector which passes over or through the intercell partition and is not sealed thereto, in which the intercell connector is provided with an electrolyte creepage barrier. 2. A battery as claimed in Claim 1 in which the creepage barrier comprises a ring of plastics material moulded around the-intercell connector. 3. A battery as claimed in Claim 1 in which the creepage barrier comprises a film of organic material extending around the intercell connector. 4. A battery as claimed in Claim 3 in which, the organic material comprises epojxy resin. 5. A battery as claimed in Claim 3 or Claim 4 in which the epoxy resin is applied to the intercell connector whilst the latter is hot by dipping it into a fluidised bed of particles of the organic material. 6. A battery as claimed in any one. of Claims 1 to 4 in which the electrodes and separators of each, cell are within a respective plastics bag, the material of the plastics bags constituting the intercell partition. 7. A battery as claimed. in any one of Claims.1 to 4 in which the amount of ele.ctrolyte. in each cell is not sufficient to saturate, the. pores in the electrodes, and in the separators. 8. A battery as claimed in any of Claims 1 to 4 in which, the electrolyte absorption ratio of the separator material is in excess of 100%. 9.. A battery as claimed in any one of Claims 1 to 4 in which, the separator material comprises microfine glass fibres. 10. A battery as claimed in Claim 2 in which, the electrolyte creepage barrier is. secured to the lid of the battery.

Inventors: PEARSON E
Applicants: CHLORIDE GROUP LTD, PEARSON E
Application year: 1980
Main classification: H01M2
IPC codes: H01M2, H01M10