lead acid batteries. acquired in november 2000 by jci plant located in aurora, co optima 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
• 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 lead acid) which includes gel and AGM (absorbed glass mat).
Battery Basics-Definitions
• 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 be approximated by V = 0.84 + acid specific gravity.
Battery Basics-Cell Chemistry
D
C
D
C
D
C
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 more pronounced 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
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Battery Basics-Cell Chemistry
Battery Basics-Cell Schematic
Load
An
ode
Cat
hod
e
Electron Flow
Oxi
dat
ion
Red
uct
ion
Pos Ions
Neg Ions
─ +
e- e-
Electron Loss
Electron Gain
Discharge
Power
An
ode
Cat
hod
e
Electron Flow
Oxi
dat
ion
Red
uct
ion
Pos Ions
Neg Ions
─ +
e-e-
Electron Loss
Electron Gain
Charge
Oxide-Barton orBall Mill
Paste Mixing Plate Curing
Lead AlloyGrid
Production
ElementPreparation-Enveloping& Stacking
COS-CastOn Strap
ContainerHole Punch
Containerand CoverInjectionMolding
ElementInsertion
IntercellWelding
Containerand CoverHeat Seal
Post BurnPressure
Test
Formation
PlatePasting
OCVHRD-High
RateDischarge
Decorationand
Shipping
Acid FillingAcid Mixing
SulfuricAcid
Water
Gel
Silica
PhosphoricAcid
SodiumSulfate
Manufacturing-Wet/Gel
Yes
No
Manufacturing-AGM Flat PlateOxide-
Barton orBall Mill
Paste Mixing Plate Curing
Lead AlloyGrid
Production
ElementPreparation-
Stacking
COS-CastOn Strap
ContainerHole Punch
Containerand CoverInjectionMolding
ElementInsertion
IntercellWelding
Containerand CoverHeat Seal
Post BurnPressure
Test
Formation
PlatePasting
OCVHRD-High
RateDischarge
Decorationand
Shipping
Acid Filling
SulfuricAcid
Water Acid MixingSodiumSulfate
Manufacturing-AGM Spiral Wound
Oxide-Barton orBall Mill
Paste Mixing
Plate DryingLead AlloyGrid
Production
ElementPreparation-
Winding
COS-CastOn Strap
Containerand CoverInjectionMolding
ElementInsertion
Containerand CoverHeat Seal
Post Burn
PressureTest
Formation
PlatePasting
OCVHRD-High
RateDischarge
Decorationand
Shipping
Acid Filling
SulfuricAcid
Water
Acid Mixing
SodiumSulfate
ElementPartial
Insertion
Grid Production Processes
Lead Alloys
Battery Type
Book MoldPositive and
Negative
ExpandedMetal
Positive andNegative
ConcastNegative
PerforatedSheet
Positive andNegative
Gel
Wet & Flat Plate AGM
Spiral AGM
• Grid– Primary function is structural to support the active
material 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
• 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
• 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
Separator Distinctions
Separator
Battery Type
Polyethyleneor Polyvinyl
ChlorideSheets
PolyethyleneEnvelopes
100% GlassMicrofiber or
Glass-PolyolefinComposite
Sheets
Gel AGM
Wet
• 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
Positive Plate Negative Plate
OxygenGas
HydrogenGas
Separator
IT’S THE SEPARATOR AGM = Absorptive Glass Mat
Flooded is “Vented”Gas exchange with surroundings
AGM is “Sealed”Valve regulates
pressure and vacuum
Positive Plate AGM Separator Negative Plate
Oxygen Gas
Oxygen reacts at the negative plate resulting in negligible water loss
Wet or flooded vs AGM
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
• 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
Container/Cover Design
• Cylindrical cells provide superior mechanical structure to battery– Eliminates cell bulge– Permits higher valve
pressures, 7-8 psi, compared to flat plate, 1-5 psi
• Flat plate batteries can experience end wall bulge when pressure builds up on charge resulting in loss of performance
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
Orientation FlexibilityNon-Spill
•Can be installed in almost any orientation/position
•Air shippable like gel and flat plate AGM
The Optima AdvantageVibration Resistance
• The Optima Group 31 runs in excess of 9,000 hours at 5G’s
Why?
• High degree of separator compression, and tight interference fit between the element and cell wall
• Less parts, two plates per cell vs. multiple plates in flat 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 AFlooded
Comp BFlooded
Comp CFlooded
Vibration @ 5G's in Hours
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
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
OC
V
Optima DC Optima SLI Flooded Gr 34 SLI Flooded Gr 27 DC Marine
OCV STAND LOSS
OCV Stand Loss
High Rate Cold Performance
• More Power
− Optima has more high rate power (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
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
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5000
0 20 40 60 80 100 120 140
Run Time (sec)
Po
we
r (
Wa
tts
)
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
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)
Po
wer
(W
atts
)
Optima 900 CCA Flooded 950 CCA
High Rate Cold Performance
ORM CCA Power at 0 Degrees F
0
1000
2000
3000
4000
5000
6000
7000
8000
Optima-900 A FL1-700 A FL2-700 A AGM1-720 A FL3-700 A FL4-700 A
Pow
er (W
atts
)
Power @ 30 S Power @ 60 S
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
Tes
t C
on
dit
ion
s
Percent Return Based On Previous RC
Optima FL1 FL2
Optima construction with high density active materials and tight spiral woundcompression on the plates gives excellent cycle life. No cycle down and more capacity throughput.
0
20
40
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0 100 200 300 400Cycle Number
Rese
rve C
ap
acit
y (
Min
)
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