Performance study of High strength binder and regularization

Objective:
To assess the material characteristics and to impart the advantages to batteries.
Assessment Stages:
Hs binder assessment carried out in three stages

3. Battery
level studies

2. Plate level
studies 1. Material level
studies

1. Material Level Study

o Fiber Dia
o Physical Appearance/Structure
o Acid & Thermal Resistance test
2. Plate Level Study
o Fibers Distribution
o Vibration Loss
o Plate Drop test
o Puncture resistance test (Ambient & Oven soaked)
3. Battery Level Study
o 3 Variants
 Only +ve Plate with HS Binder
 Only –ve Plate with HS Binder
 Both Plates with HS Binder
o Performance Assessment as per JIS D5301
 Both Short Term & LLE
* Cost Impact Calculation
 Performance study of High strength binder and regularization

1. Material level study:

Regular High Strength

Thread like Flat Structure 


Structure
 Low dense 
High dense
material material
Fiber Diameter in µ

Regular Polyester Fiber Binder 17-20

High Strength Binder 4-7

Acid & Thermal Resistance:

Add 2 grams of fiber to

300 ml of 1.3 Sp.gr
Sulfuric Acid

0
Reflux at 80 C for 36
hours

Cool the liquid

Filter

Characterize fiber
 Performance study of High strength binder and regularization

Regular High Strength

Binder Binder
Fiber shrinkage observed in the regular polyester after the test.

Fiber Diameter in µ

Fiber Before After

Polyester 17-20 12-14

High Strength 4-7 4-7

2. Plate level studies:

Fiber
Distribution * More

Vibration 3 times lesser

loss #

Drop
test # 4 times lesser

Puncture
strength * High grid to paste
bonding
* - Higher the Better
# - Lower the Better
 Performance study of High strength binder and regularization

Fiber Distribution: G16 Plates

More fiber distribution observed in the Plates with High strength binder

Good
Binder
distribution

Regular Binder High Strength Binder

Vibration loss:

Positive Plate (G16)

0.6
% of Vibration loss

0.45
0.34
0.3

0.15
0.08

0
Regular Binder HS Binder
 Performance study of High strength binder and regularization

Negative Plate (GN3)

0.59
0.6
% of Vibration loss

0.45

0.3
0.19
0.15

0
Regular Binder HS Binder

 High Strength binder exhibits 3 times lesser vibration loss

Drop test:

G16 - Positive Plate

2.5
2
% of Vibration loss

2
1.5
1
0.5
0.5
0
Regular Binder HS Binder
 Performance study of High strength binder and regularization

Puncture strength as per ASTM D5748:

Regular Plate

Puncture Oven Soaked @650C

Positive Plates Ambient
Strength For one hour

4544 6805

M 15 grams 4845 6304

4876 6500

2262 3166

Z 12 grams 2317 3395

2042 3250

1755 3786

L 12 grams 1683 3962

1854 3793

2272 3166

M 12 grams 1979 3395

1875 3250

1977 2577

C 13 grams 1787 2441

1652 2892

3298 4169

C 17 grams 3340 4332

2858 4526

1756 2549
G16
grams 1851 2381
Regular
1812 2255

1830 2776
G16
grams 1969 2441
HS BINDER
1992 2669
 Performance study of High strength binder and regularization

Tested pellet with HS Binder

• The puncture strength values are comparable (Regular and Trial)

• Active material to grid bonding is more in HS binder added plates as
the pallet shape doesn’t deformed.

3. Battery level studies: 38B20R

38B20R batteries assembled with 3 different variants.

Both Positive &

Only Negative Plate Negative
Only Positive Plate
 Performance study of High strength binder and regularization

Electrical testing carried out as per JIS D5301:2006

Battery ( 3 Variants)
Test
1 2 3

C20 √ √ √

C5 √ √ √

CAT √ √ √

HRD √ √ √

CCA √ √ √

RCT √ √ √

LLE √ √ √
 Performance study of High strength binder and regularization

Only +ve Plate Only -ve Plate Both Plates

Regular Batteries with HS Binder with HS Binder with HS Binder

Battery- Battery- Battery- Battery- Battery- Battery- Battery- Battery- Battery- Battery- Battery- Battery-
Test Requirement 1 2 3 1 2 3 1 2 3 1 2 3

C20 ≥ 35 Ah 36.8 38.2 31.0 38.2 38.5 38.2 38.1 38.1 38 37.9 38 37.8

C5 ≥ 28 Ah - - - 33.2 33.4 33.3 34.1 34 34 31.4 32.5 30.8

RCT ≥ 55 minutes 58.24 56.56 57.74 56.8 57 56.5 58.5 58.1 58.2 57.6 56.8 55.2

5th Sec
Voltage ≥ 9.5 V 9.87 9.88 9.84 9.93 9.92 9.9 10.1 10.1 10.11 10.1 10.09 10.11
HRD

Time to
reach 6V ≥ 3.5 minutes 3.53 3.48 3.32 3.41 3.22 3.35 3.73 3.68 3.65 3.71 3.63 3.7

30th Sec
Voltage ≥ 7.2 V 7.31 7.24 7.52 8.45 8.46 8.45 8.64 8.64 8.65 8.62 8.62 8.6
CCA

Time to
reach 7.2 V ≥ 30 Seconds 24 20 22 58 56 56 76 73 75 73 69 70

10th Minute
Current ≥ 3.5 4.89 5.24 5.19 6.27 6.98 6.84 6.19 6.29 6.17 5.85 6.02 5.73
CAT A

LLE ≥ 1300 Cycles 1440 1440 1440 1440 1920 1920 1920 1920 1920 1920 1920 1920

Only -ve and both Plates variants exhibits better performance in terms of Charge acceptance and HRD.
 Performance study of High strength binder and regularization

Cost Impact Calculation:

38B20R
• Regular binder cost/Kg : 2.47 $ = Rs. 171
• HS binder cost/kg : 3.47 $ = Rs. 240.33

Positive paste weight 63.2 grams

Negative paste weight 51.8 grams

Plate count 5+5

UOM Regular Trial

Positive Paste weight/ Battery Grams 1896 1896

Negative Paste Weight/Battery Grams 1554 1554

Binder in Paste weight/ Battery Grams 3.792 3.792

Binder in Negative Weight/Battery Grams 3.108 3.108

Binder cost in positive plate

Rs 0.648 0.911
/Battery

Binder cost in Negative

Rs 0.531 0.747
plate/Battery

Total Binder cost Rs 1.179 1.658

Cost impact per battery Rs 0.263 0.216 0.479

Cost impact per Ah Rs 0.007 0.006 0.0136

Only Positive

Only Negative

Both Positive & Negative