# US 12,119,497 B2 · Water loss reducing pasting mats for lead-acid batteries

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- Number: US 12,119,497 B2
- Document ID: US12119497B2
- Status: Granted
- Kind: B2
- Application number: 17/530,708
- Filed: 2021-11-19
- Published: 2022-03-10
- Granted: 2024-10-15
- Earliest claimed: 2014-06-17
- Assignees: Owens Corning Intellectual Capital, LLC
- Applicants: Owens Corning Intellectual Capital, LLC
- Inventors: Robert Huusken
- Web page: https://patentgrep.com/patent/US12119497B2

## CPC

- H01M 4/628: {Inhibitors, e.g. gassing inhibitors, corrosion inhibitors}
- H01M 4/38: of elements or alloys
- H01M 4/56: of lead
- H01M 10/06: Lead-acid accumulators (semi-lead accumulators H01M10/20)
- H01M 10/10: Immobilising of electrolyte
- Y02E 60/10: Energy storage using batteries
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

A non-woven fiber mat for lead-acid batteries is provided. The non-woven fiber pasting mat includes glass fibers coated with a sizing composition; a binder composition; and one or more additives. The additives reduce water loss in lead-acid batteries.

## Claims

### Claim 1

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 fiber pasting mat at least partially covering at least one of said first and second faces of at least one of said positive and said negative electrode, said fiber pasting mat comprising:
a plurality of fibers coated with a sizing composition;
a binder composition; and
one or more additives, said one or more additives comprising one or more of rubber additives, rubber derivatives, aldehyde, aldehyde derivatives, metal salts, fatty alcohol ethyoxylates, ethylene-propylene oxide block copolymers, sulphate esters, sulphonate esters, phosphate esters, sulphosuccinates, polyaspartic acid, perfluoroalkylsulfonic acid, polyvinylalcohol, lignin, lignin derivatives, phenol formaldehyde resin, cellulose, and wood flour,
wherein said one or more additives are operable to reduce water loss in the lead-acid battery.

### Claim 2 (depends on 1)

The lead-acid battery of claim 1, wherein said fibers comprise one or more of glass fibers, polyester fibers, polyolefin fibers, nylon fibers, aramid fibers, poly(phenylene sulfide) fibers, carbon fibers, silicon carbide (SiC) fibers, and boron nitride fibers.

### Claim 3 (depends on 2)

The lead-acid battery of claim 2, wherein said glass fibers have an average diameter of about 0.2 microns to about 30 microns.

### Claim 4 (depends on 2)

The lead-acid battery of claim 2, wherein said glass fibers have an average diameter of about 1 micron to about 25 microns.

### Claim 5 (depends on 2)

The lead-acid battery of claim 2, wherein said glass fibers are chopped fibers having an average length of between about 3 mm and about 60 mm.

### Claim 6 (depends on 1)

The lead-acid battery of claim 1, wherein said additive is included in at least one of the sizing composition and the binder composition.

### Claim 7 (depends on 1)

The lead-acid battery of claim 1, wherein said additive comprises about 0.1 weight percent to about 30 weight percent of said fiber pasting mat.

### Claim 8 (depends on 1)

The lead-acid battery of claim 1, wherein said additive is capable of shifting the hydrogen gassing potential of the negative electrode by at least −30 mV.

### Claim 9 (depends on 1)

The lead-acid battery of claim 1, wherein said fiber pasting mat has an electrical resistance of less than about 15/0.1 mm.

### Claim 10 (depends on 1)

The lead-acid battery of claim 1, wherein said fiber pasting mat is at least partially covering each of said first and second faces of said positive electrode.

### Claim 11 (depends on 1)

The lead-acid battery of claim 1, wherein said fiber pasting mat is at least partially covering each of said first and second faces of said negative electrode.

### Claim 12

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;
depositing said slurry onto a moving screen;
applying a binder onto the deposited slurry; and
heating said binder-coated slurry, to remove excess water and cure said binder, thereby forming a non-woven fiber mat, wherein said non-woven fiber mat includes one or more additives included in at least one of said sizing composition and said binder, said additives including one or more of rubber additives, rubber derivatives, aldehyde, aldehyde derivatives, metal salts, fatty alcohol ethyoxylates, ethylene-propylene oxide block copolymers, sulphate esters, sulphonate esters, phosphate esters, sulphosuccinates, polyacrylic acid, perfluoroalkylsulfonic acid, polyvinylalcohol, lignin, lignin derivatives, phenol formaldehyde resin, cellulose, and wood flour.