Rmyeo_Optima-New Technical Slides

8/12/2019 Rmyeo_Optima-New Technical Slides

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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 leadacid) 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 beapproximated 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 morepronounced 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

A n o d e

C a t h o d e

Electron Flow

O x i d a t i o n

R e d u c t i o n

Pos Ions

Neg Ions

─ +

e- e-

ElectronLoss ElectronGain

Discharge

Power

A n o d e

C a t h o d e

Electron Flow

O x i d a t i o n

R e d u c t i o n

Pos Ions

Neg Ions

─ +

e- e-

ElectronLossElectronGain

Charge



Wet/Gel/AGM

Battery Basics-Manufacturing



Oxide-

Barton or

Ball Mill

Paste Mixing Plate Curing

Lead Alloy Grid

Production

Element

Preparation-

Enveloping

& Stacking

COS-Cast

On Strap

Container

Hole Punch

Container

and Cover

Injection

Molding

Element

Insertion

Intercell

Welding

Container

and Cover

Heat Seal

Post Burn Pressure

Test

Formation

Plate

Pasting

OCV

HRD-High

Rate

Discharge

Decoration

and

Shipping

Acid FillingAcid Mixing

Sulfuric

Acid

Water

Gel

Silica

Phosphoric

Acid

Sodium

Sulfate

Manufacturing-Wet/Gel

Yes

No



Manufacturing-AGM Flat Plate

Oxide-

Barton or

Ball Mill

Paste Mixing Plate Curing

Lead Alloy Grid

Production

Element

Preparation-

Stacking

COS-Cast

On Strap

Container

Hole Punch

Container

and Cover

Injection

Molding

Element

Insertion

Intercell

Welding

Container

and Cover

Heat Seal

Post Burn Pressure

Test

Formation

Plate

Pasting

OCV

HRD-High

Rate

Discharge

Decoration

and

Shipping

Acid Filling

Sulfuric

Acid

Water Acid MixingSodium

Sulfate



Manufacturing-AGM Spiral Wound

Oxide-

Barton or

Ball Mill

Paste Mixing

Plate DryingLead Alloy Grid

Production

Element

Preparation-

Winding

COS-Cast

On Strap

Container

and Cover

Injection

Molding

Element

Insertion

Container

and Cover

Heat Seal

Post Burn

Pressure

Test

Formation

Plate

Pasting

OCV

HRD-High

Rate

Discharge

Decoration

and

Shipping

Acid Filling

Sulfuric

Acid

Water

Acid Mixing

Sodium

Sulfate

Element

Partial

Insertion



Grid Production Processes

Lead Alloys

Battery Type

Book Mold

Positive and

Negative

Expanded

Metal

Positive and

Negative

Concast

Negative

Perforated

Sheet

Positive and

Negative

Gel

Wet & Flat Plate AGM

Spiral AGM



• Grid

– Primary function is structural to support the activematerial 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

Chloride

Sheets

Polyethylene

Envelopes

100% Glass

Microfiber or Glass-

Polyolefin

Composite

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

Oxygen

Gas

Hydrogen

Gas

Separator

IT’S THE SEPARATOR

AGM = Absorptive Glass Mat

Flooded is “Vented”

Gas exchange with

surroundings

AGM is “Sealed”

Valve regulates

pressure andvacuum

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

C t i /C D i



Container/Cover Design

• Cylindrical cells provide superiormechanical structure to battery

– Eliminates cell bulge

– Permits higher valvepressures, 7-8 psi, compared

to flat plate, 1-5 psi

• Flat plate batteries canexperience end wall bulge whenpressure builds up on chargeresulting 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

Vib ti P f



The Optima Advantage

Vibration Resistance• The Optima Group 31 runs

in excess of 9,000 hours

at 5G’s

Why?

• High degree of separatorcompression, and tight

interference fit between

the element and cell wall

• Less parts, two plates per

cell vs. multiple plates inflat 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 A

Flooded

Comp B

Flooded

Comp C

Flooded

Vibration @ 5G's in Hours

G i Ch t i ti



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

OCV St d L



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

O C 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 ratepower (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)

P o w e r ( W a t t s )

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 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)

P o w e r ( W a t t s )

Optima 900 CCA Flooded 950 CCA



P f Ch



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

T e s t C

o n d i t i o n s

Percent Return Based On Previous RC

Optima FL1 FL2

R titi RC C li @ 80 F



Optima construction with high density active materials and tight spiral wound

compression 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

R e s e r v e C a

p a c i t y ( M i n )

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



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