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Transcript of Rmyeo_Optima-New Technical Slides
8/12/2019 Rmyeo_Optima-New Technical Slides
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Lead Acid
Batteries
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Acquired in November 2000 by JCI
•Plant located in Aurora, Co
•Optima Batteries utilizes six sigma
methodology
•TS 16949 Certification
•Worldwide distribution
Optima Batteries
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Lead Acid Battery Basics
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• 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
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• 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
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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
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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
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Wet/Gel/AGM
Battery Basics-Manufacturing
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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
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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
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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
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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
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• 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
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• 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
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• 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
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Separator Distinctions
Separator
Battery Type
Polyethyleneor Polyvinyl
Chloride
Sheets
Polyethylene
Envelopes
100% Glass
Microfiber or Glass-
Polyolefin
Composite
Sheets
Gel AGM
Wet
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• 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
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Separators
OptimaWet
From BCI Website
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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
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Wet/Gel Battery Construction
From BCI Website
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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
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• 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
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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
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OPTIMAPerformance
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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
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Orientation FlexibilityNon-Spill
•Can be installed in almost any orientation/position
• Air shippable like gel and flat plate AGM
Vib ti P f
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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
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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
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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
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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
High Rate Cold Performance
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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 Performance
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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
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P f Ch
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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
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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