# US 2021/0242449 A1 · Improved flooded lead acid batteries utilizing an improved separator with a fibrous mat, and methods and systems using the same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2021/0242449 A1 - Document ID: US20210242449A1 - Status: Published application - Kind: A1 - Application number: 17/049,163 - Filed: 2019-04-18 - Published: 2021-08-05 - Earliest claimed: 2019-04-18 - Assignees: Daramic, LLC - Applicants: Daramic, LLC - Inventors: Jorg Deiters; Matthew Stainer; Anna L. Verderame; J. Kevin Whear - Web page: https://patentgrep.com/patent/US20210242449A1 ## CPC - H01M 4/14: Electrodes for lead-acid accumulators - H01M 10/06: Lead-acid accumulators (semi-lead accumulators H01M10/20) - H01M 10/12: Construction or manufacture - H01M 50/409: Separators, membranes or diaphragms characterised by the material - H01M 50/46: Separators, membranes or diaphragms characterised by their combination with electrodes - H01M 50/466: U-shaped, bag-shaped or folded - H01M 50/474: characterised by their position inside the cells - H01M 50/477: characterised by their shape - H01M 50/48: characterised by the material - H01M 50/491: Porosity - H01M 50/443: Particulate material - H01M 50/494: Tensile strength - H01M 2220/20: Batteries in motive systems, e.g. vehicle, ship, plane - Y02E 60/10: Energy storage using batteries - Y02P 70/50: Manufacturing or production processes characterised by the final manufactured product - 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 - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract A flooded lead acid battery and a vehicle comprising the same are described herein. The flooded lead acid battery comprises an electrode array, comprising one or more negative plates and one or more positive plates alternately arranged and interleafed with one another. In some embodiments, a negative plate is wrapped or enveloped with a fibrous mat, and a porous membrane is wrapped or enveloped about an adjacent positive electrode. In some embodiments, a fibrous mat is at least partially integrated into a negative plate, and a porous membrane is enveloped about either the negative plate with the fibrous mat partially integrated therein or around an adjacent positive plate. In other embodiments, a negative plate is enveloped with a porous membrane having ribs, and a fibrous mat is present between the wrapped negative plate and the porous membrane enveloping the negative plate. Methods, systems, and vehicles utilizing the disclosed batteries are also provided. ## Claims ### Claim 1 A lead acid battery comprising: an electrode array comprising one or more negative electrodes, and one or more positive electrodes interleaved between said one or more negative electrodes; a fibrous mat envelope with one of said one or more negative electrodes disposed therein; and a porous membrane envelope with said fibrous mat envelope disposed therein, wherein said battery may be selected from the group consisting of: a flat Plate battery, a flooded lead acid battery, an enhanced flooded lead acid battery (“EFB”), a valve regulated lead acid (“VRLA”) battery, a gel battery, an absorptive glass mat (“AGM”) battery, a deep cycle battery, a tubular battery, a motive battery, an inverter battery, a PSoC battery, a vehicle battery, a starting-lighting-ignition (“SLI”) vehicle battery, an idling-start-stop (“ISS”) vehicle battery, an automobile battery, a truck battery, a motorcycle battery, an all-terrain vehicle battery, a forklift battery, a golf cart battery, a hybrid-electric vehicle battery, an electric vehicle battery, a wheel chair battery, an e-rickshaw battery, an e-trike battery, an e-bike battery, and a marine vessel battery. ### Claim 2 (depends on 0) The lead acid battery of claim 0, wherein said fibrous mat envelope: is one of the list consisting of a nonwoven, mesh, fleece, and combinations thereof; is formed from a polymer and additionally with one or more of the group consisting of glass fibers, pulp, and combinations thereof; is formed from a polymer and additionally with one or more of the group consisting of glass fibers, pulp, and combinations thereof, said polymer comprising one or more material selected from the group consisting of a polyolefin, a polyester, a polyamide, a polyimide, and combinations thereof; comprises an inorganic material; comprises an inorganic material, wherein said inorganic material comprises silica; comprises a spun-bond melt-nonwoven composite material; comprises a carbon fiber nonwoven material; comprises a carbon fiber nonwoven material, wherein said carbon fiber nonwoven material comprises conductive carbon, graphite, artificial graphite, activated carbon, acetylene black, carbon black, high surface area carbon black, graphene, high surface area graphene, keitjen black, carbon fibers, carbon filaments, carbon nanotubes, open-cell carbon foam, a carbon mat, carbon felt, carbon Buckminsterfullerene (Bucky Balls), flake graphite, oxidized carbon, and combinations thereof; comprises conductive carbon, graphite, artificial graphite, activated carbon, carbon paper, acetylene black, carbon black, high surface area carbon black, graphene, high surface area graphene, keitjen black, carbon fibers, carbon filaments, carbon nanotubes, open-cell carbon foam, a carbon mat, carbon felt, carbon Buckminsterfullerene (Bucky Balls), an aqueous carbon suspension, flake graphite, oxidized carbon, and combinations thereof; comprises a nucleation additive; comprises a nucleation additive, wherein said nucleation additive is one of a form of carbon, Barium Sulfate (BaSO4), or combinations thereof; comprises a nucleation additive, wherein said nucleation additive is a form of carbon, said form of carbon comprises conductive carbon, graphite, artificial graphite, activated carbon, carbon paper, acetylene black, carbon black, high surface area carbon black, graphene, high surface area graphene, keitjen black, carbon fibers, carbon filaments, carbon nanotubes, open-cell carbon foam, a carbon mat, carbon felt, carbon Buckminsterfullerene (Bucky Balls), an aqueous carbon suspension, flake graphite, oxidized carbon, and combinations thereof; or is sealed on one of the following consisting of one side of said negative electrode, two sides of said negative electrode, and three sides of said negative electrode. ### Claim 3 (canceled) ### Claim 4 (canceled) ### Claim 5 (canceled) ### Claim 6 (canceled) ### Claim 7 (canceled) ### Claim 8 (canceled) ### Claim 9 (canceled) ### Claim 10 (canceled) ### Claim 11 (canceled) ### Claim 12 (canceled) ### Claim 13 (canceled) ### Claim 14 (depends on 0) The lead acid battery of claim 0, wherein said fibrous mat envelope comprises a conductive layer disposed adjacent to said negative electrode, wherein said conductive layer may comprise conductive carbon, graphite, artificial graphite, activated carbon, carbon paper, acetylene black, carbon black, high surface area carbon black, graphene, high surface area graphene, keitjen black, carbon fibers, carbon filaments, carbon nanotubes, open-cell carbon foam, a carbon mat, carbon felt, carbon Buckminsterfullerene (Bucky Balls), an aqueous carbon suspension, flake graphite, oxidized carbon, and combinations thereof. ### Claim 15 (canceled) ### Claim 16 (depends on 0) The lead acid battery of claim 0, wherein said porous membrane comprises one or more arrays of ribs on at least one surface thereof or on two surfaces thereof, and wherein said one or more arrays of ribs may have a height of about 10 □m to about 2.0 mm. ### Claim 17 (canceled) ### Claim 18 (depends on 0) The lead acid battery of claim 0, wherein said porous membrane: comprises at least one material selected from the group consisting of natural materials, synthetic materials, polyolefins, phenolic resins, poly vinyl chloride (PVC), natural rubber, synthetic rubber, synthetic wood pulp, glass fibers, lignins, cellulosic fibers, and combinations thereof; comprises polyethylene, silica, and processing oil; is sealed on one of the following consisting of one side of said positive electrode, two sides of said positive electrode, and three sides of said positive electrode; has a Porosity of greater than about 55%, greater than about 60%, or greater than about 65%; or is a microporous battery separator. ### Claim 19 (canceled) ### Claim 20 (canceled) ### Claim 21 (canceled) ### Claim 22 (canceled) ### Claim 23 (canceled) ### Claim 24 (canceled) ### Claim 25 (canceled) ### Claim 26 A lead acid battery comprising: an electrode array comprising one or more negative electrodes, and one or more positive electrodes interleaved between said one or more negative electrodes; one or more electrode and fibrous mat assemblies comprising a fibrous mat at least partially integrated into at least one of said one or more negative electrodes; and a porous membrane enveloping one of said one or more electrode and fibrous mat assemblies or at least one of said one or more positive electrodes adjacent to said one or more electrode and fibrous mat assemblies, wherein said battery may be selected from the group consisting of: a flat Plate battery, a flooded lead acid battery, an enhanced flooded lead acid battery (“EFB”), a valve regulated lead acid (“VRLA”) battery, a gel battery, an absorptive glass mat (“AGM”) battery, a deep cycle battery, a tubular battery, a motive battery, an inverter battery, a PSoC battery, a vehicle battery, a starting-lighting-ignition (“SLI”) vehicle battery, an idling-start-stop (“ISS”) vehicle battery, an automobile battery, a truck battery, a motorcycle battery, an all-terrain vehicle battery, a forklift battery, a golf cart battery, a hybrid-electric vehicle battery, an electric vehicle battery, a wheel chair battery, an e-rickshaw battery, an e-trike battery, an e-bike battery, and a marine vessel battery. ### Claim 27 (depends on 26) The lead acid battery of claim 26 further comprising an active material associated with said one or more negative electrodes; wherein said fibrous mat is integrated into said active material from about 2% to about 50%, from about 5% to about 25%, from about 5% to about 20%, or from about 5% to about 15% of a mat thickness of said fibrous mat. ### Claim 28 (canceled) ### Claim 29 (canceled) ### Claim 30 (canceled) ### Claim 31 (depends on 26) The lead acid battery of claim 26, wherein said fibrous mat: is one of the list consisting of a nonwoven, mesh, fleece, and combinations thereof; is formed of a polymer and additionally with one or more chosen from one of the group consisting of glass fibers, pulp, and combinations thereof; is formed of a polymer and additionally with one or more chosen from one of the group consisting of glass fibers, pulp, and combinations thereof, wherein said polymer comprises at least one selected from the group consisting of a polyolefin, a polyester, a polyamide, a polyimide, and combinations thereof; comprises an inorganic material; comprises an inorganic material, which comprises silica; is a spun-bond melt-nonwoven composite material; or comprises conductive carbon, graphite, artificial graphite, activated carbon, carbon paper, acetylene black, carbon black, high surface area carbon black, graphene, high surface area graphene, keitjen black, carbon fibers, carbon filaments, carbon nanotubes, open-cell carbon foam, a carbon mat, carbon felt, carbon Buckminsterfullerene (Bucky Balls), an aqueous carbon suspension, flake graphite, oxidized carbon, and combinations thereof. ### Claim 32 (canceled) ### Claim 33 (canceled) ### Claim 34 (canceled) ### Claim 35 (canceled) ### Claim 36 (canceled) ### Claim 37 (depends on 26) The lead acid battery of claim 26, wherein said fibrous mat is a carbon fiber nonwoven material, and said carbon fiber nonwoven material may comprise conductive carbon, graphite, artificial graphite, activated carbon, acetylene black, carbon black, high surface area carbon black, graphene, high surface area graphene, keitjen black, carbon fibers, carbon filaments, carbon nanotubes, open-cell carbon foam, a carbon mat, carbon felt, carbon Buckminsterfullerene (Bucky Balls), flake graphite, oxidized carbon, and combinations thereof. ### Claim 38 (canceled) ### Claim 39 (canceled) ### Claim 40 (depends on 26) The lead acid battery of claim 26, wherein said fibrous mat comprises a nucleation additive, wherein said nucleation additive may be one of a form of carbon, barium sulfate (BaSO4), and combinations thereof, and wherein said form of carbon may comprise conductive carbon, graphite, artificial graphite, activated carbon, carbon paper, acetylene black, carbon black, high surface area carbon black, graphene, high surface area graphene, keitjen black, carbon fibers, carbon filaments, carbon nanotubes, open-cell carbon foam, a carbon mat, carbon felt, carbon Buckminsterfullerene (Bucky Balls), an aqueous carbon suspension, flake graphite, oxidized carbon, and combinations thereof. ### Claim 41 (canceled) ### Claim 42 (canceled) ### Claim 43 (depends on 26) The lead acid battery of claim 26, wherein said fibrous mat comprises a conductive layer disposed adjacent to said negative electrode, and wherein said conductive layer may comprise conductive carbon, graphite, artificial graphite, activated carbon, carbon paper, acetylene black, carbon black, high surface area carbon black, graphene, high surface area graphene, keitjen black, carbon fibers, carbon filaments, carbon nanotubes, open-cell carbon foam, a carbon mat, carbon felt, carbon Buckminsterfullerene (Bucky Balls), an aqueous carbon suspension, flake graphite, oxidized carbon, and combinations thereof. ### Claim 44 (canceled) ### Claim 45 (depends on 26) The lead acid battery of claim 26, wherein said porous membrane comprises one or more arrays of ribs on at least one surface thereof or on each of two surfaces thereof, wherein said arrays of ribs may have a height of about 10 μm to about 2.0 mm. ### Claim 46 (canceled) ### Claim 47 (canceled) ### Claim 48 (depends on 26) The lead acid battery of claim 26, wherein said porous membrane: comprises at least one material selected from the group consisting of natural materials, synthetic materials, polyolefins, phenolic resins, poly vinyl chloride (PVC), natural rubber, synthetic rubber, synthetic wood pulp, glass fibers, lignins, cellulosic fibers, and combinations thereof; or comprises polyethylene, silica, and processing oil; or is a microporous battery separator. ### Claim 49 (canceled) ### Claim 50 (depends on 26) The lead acid battery of claim 26, wherein said porous membrane is: sealed on one of the following consisting of one side of said positive electrode, two sides of said positive electrode, and three sides of said positive electrode; or said porous membrane is sealed on one of the following consisting of one side of said one or more electrode and fibrous mat assemblies, two sides of said one or more electrode and fibrous mat assemblies, and three sides of said one or more electrode and fibrous mat assemblies. ### Claim 51 (canceled) ### Claim 52 (canceled) ### Claim 53 A flooded lead acid battery comprising: an electrode array comprising one or more negative electrodes and one or more positive electrodes alternately arranged with respect to one another; a porous membrane enveloping at least one of said one or more negative electrodes, wherein said porous membrane comprises ribs on one or more surfaces thereof, a fibrous mat is disposed within said envelope. ### Claim 54 (depends on 53) The flooded lead acid battery of claim 53, wherein said ribs are at least partially on a surface of the porous membrane adjacent to said fibrous mat, and optionally wherein said ribs have a height from 10 μm to about 2.0 mm, from about 5 μm to about 300 μm, or from 25 μm to 200 μm. ### Claim 55 (canceled) ### Claim 56 (canceled) ### Claim 57 (canceled) ### Claim 58 (depends on 53) The flooded lead acid battery of claim 53, wherein said fibrous mat: envelopes one of said one or more negative electrodes; is at least partially integrated into said negative electrode; comprises discrete pieces disposed between said ribs; has a thickness from about 50% of the height of said ribs to about 150% of the height of said ribs; is disposed between said negative electrode and said porous membrane and optionally laminated to the porous membrane; comprises at least one material selected from the group consisting of glass fibers, pulp, a polymer, and combinations thereof; is formed from a polymer in combination with at least one material selected from the group consisting of glass fibers, pulp, and combinations thereof; is formed from a polymer in combination with at least one material selected from the group consisting of glass fibers, pulp, and combinations thereof, wherein said polymer comprises at least one selected from the group consisting of a polyolefin, a polyester, a polyamide, a polyimide, and combinations thereof; comprises an inorganic material; comprises an inorganic material, wherein said inorganic material comprises silica; is a spun-bond melt-nonwoven composite material; comprises a carbon fiber nonwoven material; comprises carbon fiber nonwoven material, wherein said carbon fiber nonwoven material comprises conductive carbon, graphite, artificial graphite, activated carbon, acetylene black, carbon black, high surface area carbon black, graphene, high surface area graphene, keitjen black, carbon fibers, carbon filaments, carbon nanotubes, open-cell carbon foam, a carbon mat, carbon felt, carbon Buckminsterfullerene (Bucky Balls), flake graphite, oxidized carbon, and combinations thereof; comprises conductive carbon, graphite, artificial graphite, activated carbon, carbon paper, acetylene black, carbon black, high surface area carbon black, graphene, high surface area graphene, keitjen black, carbon fibers, carbon filaments, carbon nanotubes, open-cell carbon foam, a carbon mat, carbon felt, carbon Buckminsterfullerene (Bucky Balls), an aqueous carbon suspension, flake graphite, oxidized carbon, and combinations thereof; comprises a nucleation additive; comprises a nucleation additive, wherein said nucleation additive is one of a form of carbon, Barium Sulfate (BaSO4), and combinations thereof; comprises a nucleation additive, wherein said nucleation additive is a form of carbon wherein said form of carbon comprises conductive carbon, graphite, artificial graphite, activated carbon, carbon paper, acetylene black, carbon black, high surface area carbon black, graphene, high surface area graphene, keitjen black, carbon fibers, carbon filaments, carbon nanotubes, open-cell carbon foam, a carbon mat, carbon felt, carbon Buckminsterfullerene (Bucky Balls), an aqueous carbon suspension, flake graphite, oxidized carbon, and combinations thereof; comprises a conductive laver disposed adjacent to said negative electrode; comprises a conductive laver disposed adjacent to said negative electrode, wherein said conductive laver comprises conductive carbon, graphite, artificial graphite, activated carbon, carbon paper, acetylene black, carbon black, high surface area carbon black, graphene, high surface area graphene, keitjen black, carbon fibers, carbon filaments, carbon nanotubes, open-cell carbon foam, a carbon mat, carbon felt, carbon Buckminsterfullerene (Bucky Balls), an aqueous carbon suspension, flake graphite, oxidized carbon, and combinations thereof; or is sealed on one of the following consisting of one side of said negative electrode, two sides of said negative electrode, and three sides of said negative electrode. ### Claim 59 (canceled) ### Claim 60 (canceled) ### Claim 61 (canceled) ### Claim 62 (canceled) ### Claim 63 (canceled) ### Claim 64 (canceled) ### Claim 65 (canceled) ### Claim 66 (canceled) ### Claim 67 (canceled) ### Claim 68 (canceled) ### Claim 69 (canceled) ### Claim 70 (canceled) ### Claim 71 (canceled) ### Claim 72 (canceled) ### Claim 73 (canceled) ### Claim 74 (canceled) ### Claim 75 (canceled) ### Claim 76 (depends on 53) The flooded lead acid battery of claim 53, wherein said porous membrane: has ribs on two surfaces thereof; comprises at least one material selected from the group consisting of natural materials, synthetic materials, polyolefins, phenolic resins, poly vinyl chloride (PVC), natural rubber, synthetic rubber, synthetic wood pulp, glass fibers, lignins, cellulosic fibers, and combinations thereof; comprises polyethylene, silica, and processing oil; comprises polyethylene, silica, and processing oil, wherein said processing oil is in an amount of approximately 5% by weight of said porous membrane to approximately 15% by weight of said porous membrane; is sealed on one of the following consisting of one side of said negative electrode, two sides of said negative electrode, and three sides of said negative electrode; or is a microporous battery separator. ### Claim 77 (canceled) ### Claim 78 (canceled) ### Claim 79 (canceled) ### Claim 80 (canceled) ### Claim 81 (canceled) ### Claim 82 (canceled) ### Claim 83 (depends on 1) A system comprising: a vehicle, and said lead acid battery or flooded lead acid battery of claim 1, wherein said vehicle may be one chosen from the group consisting of an automobile, a truck, a motorcycle, an all-terrain vehicle, a motorcycle, a forklift, a golf cart, a hybrid vehicle, a hybrid-electric vehicle, an electric vehicle, an idling-start-stop (“ISS”) vehicle, an e-rickshaw battery, an e-trike an e-bike a wheel chair, and a marine vessel. ### Claim 84 (canceled) ### Claim 85 (canceled) ### Claim 86 (depends on 1) A method for preventing acid displacement in a lead acid battery, a flooded lead acid battery, an enhanced flooded lead acid battery, or a flooded lead acid battery operating or intended to be operated in a partial state of charge, which comprises manufacturing the battery so that it has a structure identical to the battery of claim 1. ### Claim at position 87 87-89. (canceled)