Anti-sulphation pasting mats for lead-acid batteries

A lead-acid battery comprising:

• a positive electrode having a first face and a second face opposite said first face and a negative electrode having a first face and a second face opposite said first face, wherein each of said positive and negative electrode is immersed within an electrolyte;
• a non-woven fiber pasting mat at least partially covering a surface of at least one of said first and second faces of at least one of said positive and said negative electrode, said non-woven fiber pasting mat comprising:
• a plurality of fibers coated with a sizing composition, wherein the sizing composition comprises a film former selected from a group consisting of polyvinyl acetates, polyurethanes, modified polyolefins, polyesters epoxides, and mixtures thereof;
• and
• a binder composition comprising one or more organic active compounds, said organic active compounds comprising one or more of sulphosuccinate (di-octyl);
• polyvinylalcohol;
• colloidal silica;
• polyacrylamide;
• phosphonic acid;
• polyacrylic acid;
• phosphate ester;
• polycarboxylic acid;
• polymeric anionic compounds;
• hexamethylenediaminetetrakis;
• chitin;
• chitosan;
• inulin;
• polyaspartic acid;
• polysuccinimide;
• iminodisuccinate;
• maleic acid/acrylic acid copolymer;
• maleic acid/acrylamide copolymer;
• humic acid;
• calcium salt of polymers from naphtalenenesulphonic acid condensed with formaldehyde;
• sodium salt of condensed sulfonated naphtalene;
• perfluoroalkylsulfonic acid;
• and cellulose,
• wherein the binder composition holds the fibers together to form a non-woven mat, and
• wherein said organic active compounds are present in the binder composition in an amount from about 0.05 to about 25.0 wt. % of said binder composition, and wherein said organic active compounds reduce formation of lead sulphate on said negative electrode.

A method of forming a non-woven fiber mat for use in a lead-acid battery, said method comprising:

• dispersing a plurality of fibers into an aqueous slurry, said fibers being coated with a sizing composition, wherein the sizing composition comprises a film former selected from a group consisting of polyvinyl acetates, polyurethanes, modified polyolefins, polyesters epoxides, and mixtures thereof;
• depositing said slurry onto a screen;
• applying a binder onto the deposited slurry;
• and
• heating said binder-coated slurry, thereby curing said binder coated slurry and forming a non-woven fiber mat, wherein said fiber mat includes one or more organic active compounds included in said binder in an amount from about 0.05 to about 25.0 wt. % of said binder, said organic active compounds comprising one or more of sulphosuccinate (di-octyl);
• polyvinylalcohol;
• colloidal silica;
• polyacrylamide;
• phosphonic acid;
• polyacrylic acid;
• phosphate ester;
• polycarboxylic acid;
• polymeric anionic compounds;
• hexamethylenediaminetetrakis;
• chitin;
• chitosan;
• inulin;
• polyaspartic acid;
• polysuccinimide;
• iminodisuccinate;
• maleic acid/acrylic acid copolymer;
• maleic acid/acrylamide copolymer;
• humic acid;
• calcium salt of polymers from naphtalenenesulphonic acid condensed with formaldehyde;
• sodium salt of condensed sulfonated naphtalene;
• perfluoroalkylsulfonic acid;
• and cellulose.

A non-woven retainer mat for contacting a separator in a lead-acid battery comprising:

• a plurality of fibers coated with a sizing composition, wherein the sizing composition comprises a film former selected from a group consisting of polyvinyl acetates, polyurethanes, modified polyolefins, polyesters epoxides, and mixtures thereof;
• and
• a binder composition comprising one or more organic active compounds, said organic active compounds comprising one or more of sulphosuccinate (di-octyl);
• polyvinylalcohol;
• colloidal silica;
• polyacrylamide;
• phosphonic acid;
• polyacrylic acid;
• phosphate ester;
• polycarboxylic acid;
• polymeric anionic compounds;
• hexamethylenediaminetetrakis;
• chitin;
• chitosan;
• inulin;
• polyaspartic acid;
• polysuccinimide;
• iminodisuccinate;
• maleic acid/acrylic acid copolymer;
• maleic acid/acrylamide copolymer;
• humic acid;
• calcium salt of polymers from naphtalenenesulphonic acid condensed with formaldehyde;
• sodium salt of condensed sulfonated naphtalene;
• perfluoroalkylsulfonic acid;
• and cellulose,
• wherein the binder composition holds the fibers together to form a non-woven mat, and
• wherein said organic active compounds are present in the binder composition in an amount from about 0.05 to about 25.0 wt. % of said binder composition, and
• wherein said organic active compounds are operable to reduce sulphation in a lead-acid battery.