Lead Acid Batteries. Acquired in November 2000 by JCI Plant located in Aurora, Co Optima Batteries utilizes six sigma methodology TS 16949 Certification.

Lead Acid Batteries

Acquired in November 2000 by JCI

•Plant located in Aurora, Co

•Optima Batteries utilizes six sigma methodology

•TS 16949 Certification

•Worldwide distribution

Optima Batteries

Lead Acid Battery Basics

• A battery is a device that converts chemical energy into electrical energy.

• A cell is the basic electrochemical unit.

• A battery consists of one or more cells connected in series, or in parallel, or both.

• Batteries, in general, are classified as primary, i.e., non-rechargeable, or secondary, i.e., rechargeable. Zinc-manganese dioxide, LeClanche’ or alkaline, cells are primary batteries. Lead-acid batteries are secondary batteries. Advanced secondary batteries include nickel metal hydride and lithium ion.

• Types of lead-acid batteries include round or cylindrical and prismatic or rectangular cells.

• Lead acid batteries can be classified further as wet, i.e., flooded, or VRLA (valve regulated lead acid) which includes gel and AGM (absorbed glass mat).

Battery Basics-Definitions

• At the positive plate: PbO2 + 4H+ + SO42- + 2e- PbSO4 + 2H2O

• At the negative plate: Pb + SO42- PbSO4 + 2e-

• Total Cell Reaction: PbO2 + Pb +2H2SO4 2PbSO4 +2H2O

Note: Active materials include lead dioxide, lead and sulfuric acid.

Note: Battery OCV depends only acid specific gravity and the cell voltage can be approximated by V = 0.84 + acid specific gravity.

Battery Basics-Cell Chemistry

D

C

D

C

D

C

Additional Reactions of Significance

• Oxygen Reaction Cycle:: ½O2 + Pb PbO

PbO + H2SO4 PbSO4 + H2O

Note: Oxygen reaction cycle is a benchmark characteristic of VRLA batteries. It is more pronounced with AGM than with gel constructions.

• Severe Overcharge Reaction: 2H2O O2 + 4H+ + 4e-

Note: This results in water loss due to venting of O2 and can be life limiting.

• Positive Grid Corrosion: Pb + 2H2O PbO2 + 4H+ + 2e-

Note: This results in water loss and can be life limiting.

C

C

C

C

Battery Basics-Cell Chemistry

Battery Basics-Cell Schematic

Load

An

ode

Cat

hod

e

Electron Flow

Oxi

dat

ion

Red

uct

ion

Pos Ions

Neg Ions

─ +

e- e-

Electron Loss

Electron Gain

Discharge

Power

An

ode

Cat

hod

e

Electron Flow

Oxi

dat

ion

Red

uct

ion

Pos Ions

Neg Ions

─ +

e-e-

Electron Loss

Electron Gain

Charge

Wet/Gel/AGM

Battery Basics-Manufacturing

Oxide-Barton orBall Mill

Paste Mixing Plate Curing

Lead AlloyGrid

Production

ElementPreparation-Enveloping& Stacking

COS-CastOn Strap

ContainerHole Punch

Containerand CoverInjectionMolding

ElementInsertion

IntercellWelding

Containerand CoverHeat Seal

Post BurnPressure

Test

Formation

PlatePasting

OCVHRD-High

RateDischarge

Decorationand

Shipping

Acid FillingAcid Mixing

SulfuricAcid

Water

Gel

Silica

PhosphoricAcid

SodiumSulfate

Manufacturing-Wet/Gel

Yes

No

Manufacturing-AGM Flat PlateOxide-

Barton orBall Mill

Paste Mixing Plate Curing

Lead AlloyGrid

Production

ElementPreparation-

Stacking

COS-CastOn Strap

ContainerHole Punch

Containerand CoverInjectionMolding

ElementInsertion

IntercellWelding

Containerand CoverHeat Seal

Post BurnPressure

Test

Formation

PlatePasting

OCVHRD-High

RateDischarge

Decorationand

Shipping

Acid Filling

SulfuricAcid

Water Acid MixingSodiumSulfate

Manufacturing-AGM Spiral Wound

Oxide-Barton orBall Mill

Paste Mixing

Plate DryingLead AlloyGrid

Production

ElementPreparation-

Winding

COS-CastOn Strap

Containerand CoverInjectionMolding

ElementInsertion

Containerand CoverHeat Seal

Post Burn

PressureTest

Formation

PlatePasting

OCVHRD-High

RateDischarge

Decorationand

Shipping

Acid Filling

SulfuricAcid

Water

Acid Mixing

SodiumSulfate

ElementPartial

Insertion

Grid Production Processes

Lead Alloys

Battery Type

Book MoldPositive and

Negative

ExpandedMetal

Positive andNegative

ConcastNegative

PerforatedSheet

Positive andNegative

Gel

Wet & Flat Plate AGM

Spiral AGM

• Grid– Primary function is structural to support the active

material and carry the current– Secondary function is electrochemical in nature as the

grids participate in redox reactions at the positive and negative active material interface, i.e., corrosion

– Desired features• Low resistivity• Strength• Corrosion resistance for positives• High purity

Grid

• Grid Alloys

– Lead/Lead Tin

• Soft, generally too weak to use in flat plate designs

• Low gassing

• Low self discharge

• Continuous grid making processes for spiral wound design

– Lead Calcium Silver

• Low gassing

• Low self discharge

• Slower processing compared to lead antimony

– Lead Antimony

• High gassing

• High self discharge

• Easily cast and fabricated

• Good cycle life

Grid Alloy

• Paste – High Paste Density

• Stronger material with less shedding in wet or gel designs– Shedding is not an issue with AGM designs because of

the compression of the separator against the plates and the tight interference fit with the cell container

• Better contact with the grid interface• Reduced initial capacity which cycles up to give longer

service life in cycling applications• Lower efficiency at high discharge rates

– Low Paste Density• Initial capacity is high• Higher efficiency at high discharge rates• Poorer service life in cycling applications

Paste

Separator Distinctions

Separator

Battery Type

Polyethyleneor Polyvinyl

ChlorideSheets

PolyethyleneEnvelopes

100% GlassMicrofiber or

Glass-PolyolefinComposite

Sheets

Gel AGM

Wet

• Separator– Wet

• Microporous polyethylene envelopes– Extrusion formed– Backweb thickness– Oil content– Silica content

– Gel• Microporous polyethylene sheets• Polyvinyl chloride sheets

– AGM• Glass microfiber sheets

– Compression is an important design feature– Glass-polyolefin composites under development– Made on conventional paper making equipment

Separator Sources

Separators

OptimaWet

From BCI Website

Positive Plate Negative Plate

OxygenGas

HydrogenGas

Separator

IT’S THE SEPARATOR AGM = Absorptive Glass Mat

Flooded is “Vented”Gas exchange with surroundings

AGM is “Sealed”Valve regulates

pressure and vacuum

Positive Plate AGM Separator Negative Plate

Oxygen Gas

Oxygen reacts at the negative plate resulting in negligible water loss

Wet or flooded vs AGM

Wet/Gel Battery Construction

From BCI Website

Optima AGM Battery Construction

Optima has lower internal resistance compared to flat plate batteries•Optima has less internal parts (~30) vs traditional batteries (120+)•Optima has over the partition, solid lead connectors vs through the partition inter-cell welds

• Factors affecting internal resistance of the battery– Size of lead conductors– Plate surface area– Plate spacing– Separator resistivity– Electrolyte type

• Gel has higher resistance than flooded or AGM designs which negatively impacts high rate and cold performance

– Electrolyte concentration– Temperature

Element Characteristics

Container/Cover Design

• Cylindrical cells provide superior mechanical structure to battery– Eliminates cell bulge– Permits higher valve

pressures, 7-8 psi, compared to flat plate, 1-5 psi

• Flat plate batteries can experience end wall bulge when pressure builds up on charge resulting in loss of performance

OPTIMAPerformance

What is Optima?

•Advanced lead acid battery technology

•Spiral wound cells

•Sealed AGM design

•Current OE applications –Daimler Chrysler

•Minivan Diesel (Graz, Austria)•PT Cruiser Diesel (Toluca, Mexico)•Jeep Liberty Diesel (Toledo, USA)

–FORD•GT

–GM•Silverado Military Truck

Orientation FlexibilityNon-Spill

•Can be installed in almost any orientation/position

•Air shippable like gel and flat plate AGM

The Optima AdvantageVibration Resistance

• The Optima Group 31 runs in excess of 9,000 hours at 5G’s

Why?

• High degree of separator compression, and tight interference fit between the element and cell wall

• Less parts, two plates per cell vs. multiple plates in flat plate designs

• No intercell welds to fail

Source: AGM Development Team

Vibration Performance

Vibration @ 5G's in Hours

0

2000

4000

6000

8000

10000

12000

Optima Comp AFlooded

Comp BFlooded

Comp CFlooded

Vibration @ 5G's in Hours

Gassing Characteristics

• Gassing– Less than flat plate/prismatic design

• Why?– Higher purity materials – 99.99% pure lead– Alloys – Optima uses a binary tin lead alloy

compared to a flooded battery that uses a multi component alloy (silver, tin, calcium, aluminum, etc… less impurities)

– Oxygen reaction cycle

Source: AGM Development Team

Optima batteries show a higher OCV on stand compared to flooded batteries. OCV does not tell the whole story. You also must look at the OCV vs SOC relationship.

10.00

10.50

11.00

11.50

12.00

12.50

13.00

13.50

0 200 400 600 800 1000 1200

Days @ 25 C

OC

V

Optima DC Optima SLI Flooded Gr 34 SLI Flooded Gr 27 DC Marine

OCV STAND LOSS

OCV Stand Loss

High Rate Cold Performance

• More Power

− Optima has more high rate power (CCA) than comparably sized flat plate batteries

• Why?

− Higher specific acid gravity than flooded

− Lower internal resistance than flooded due to thinner positive plates than flooded and no inter-cell welds

Lower internal impedance gives Optima (50 A-hrs) better power output than higer rated capacity flooded (72 A-hrs). This lets Optima compete with higher rated flooded.

1000

1500

2000

2500

3000

3500

4000

4500

5000

0 20 40 60 80 100 120 140

Run Time (sec)

Po

we

r (

Wa

tts

)

Optima Gr 34 SLI Flooded OE Gr 65

-20Degrees F/300 A Discharge

High power, more run time gives Optima more available energy

High Rate Cold Performance

High Rate Cold PerformanceHiger voltage/lower internal impedance give lower capacity Optima (900 CCA/155 min RC) better power output than higer capacity JCI flooded (950 CCA/195 min RC)

6000

6500

7000

7500

8000

8500

9000

9500

10000

0 5 10 15 20 25 30

Run Time (sec)

Po

wer

(W

atts

)

Optima 900 CCA Flooded 950 CCA

High Rate Cold Performance

ORM CCA Power at 0 Degrees F

0

1000

2000

3000

4000

5000

6000

7000

8000

Optima-900 A FL1-700 A FL2-700 A AGM1-720 A FL3-700 A FL4-700 A

Pow

er (W

atts

)

Power @ 30 S Power @ 60 S

Performance on Charge

Optima's reserve capacity recovery is up to 25% more than flooded product indicating a better charge acceptance.

Optima

Optima

Optima

Optima

FL1

FL1

FL1

FL1

FL2

FL2

FL2

FL2

0 20 40 60 80 100

80F 14.4V

80F 13.3V

32F 14.4V

32F 13.3V

Tes

t C

on

dit

ion

s

Percent Return Based On Previous RC

Optima FL1 FL2

Optima construction with high density active materials and tight spiral woundcompression on the plates gives excellent cycle life. No cycle down and more capacity throughput.

0

20

40

60

80

100

120

140

160

180

200

220

240

0 100 200 300 400Cycle Number

Rese

rve C

ap

acit

y (

Min

)

155 Min RC/75 A-hr C/20 Optima Group 31

185 Min RC/98 A-hr C/20 Flooded Group 31Repetitive Reserve Capacity Cycle Life

Repetitive RC Cycling @ 80 F

Median Automotive Battery Life

20

30

40

50

60

70

HotWeather

MildWeather

Lif

e (M

on

ths)

Hot Weather Mild Weather

AGM has longer life in warm temperatures

Battery life increases with cooler temperatures

Typical flooded expected life

Decreasing Temperature

Field Returns