Temperature Controlled, Auto Timed, Variable Amperage Cascading-Water Furmation Method for Use With High Antimony and Maintenance Free Lead-Acid Batteries

FIG. 1 is a schematic of the preferred embodiment process of our invention, alternate cooling fluid pathways being shown with broken lines and arrows;

FIG. 2 is a graph showing the simulated electrolyte temperature of a sixty-five amp hour capacity during a conventional formation process, after introducing electrolyte into the battery.

FIG. 3 is a graph showing the electrolyte temperature of a sixty-five amp hour capacity battery during the cascade cooling process of our invention after filling the battery with electrolyte, using a modified constant voltage technique, where a low initial current charge is provided by connecting additional resistance across the load in the first 5 hours, followed by a constant voltage throughout the remaining formation process;

FIG. 4 is a graph of the temperature of the electrolyte of a sixty-five amp hour battery during the preferred embodiment cascade formation of our invention showing the levels of current provided to the batteries by a rectifying circuit superimposed on the graph, the lower constant final formation temperature resulting from this process being illustrated to the right on this graph;

FIG. 5 is a graph showing the temperature of electrolyte in a battery during a conventional formation process in which thermal runaway has occurred.

Although specific forms of the invention have been selected for illustration in the drawings, and the following description is drawn in specific terms for the purpose of describing forms of the invention, this description is not intended to limit the scope of the invention as defined in the appended claims.

Referring to FIG. 1, the first step in the preferred process of applicants' invention is to separate a plurality of batteries into a plurality of sets, such as sets designated generally 10, 12, and 14 in FIG. 1. The set 10 comprises batteries 16, 18, and 20; the set 12 comprises batteries 22, 24, and 26; and the set 14 comprises batteries 28, 30, and 32. In the preferred process, this step is not done radomly but batteries are sorted into sets depending on the capacity, type and/or stage of formation of these batteries.

After separating the plurality of batteries into a plurality of sets such as 10, 12, and 14, the next step in applicants' preferred process is to provide a plurality of container means 34, 36, and 38 for holding a plurality of battery sets such as sets 10, 12, and 14 respectively. These sets are placed into their respective container means and electrically connected together for connection with a separate external rectifying circuit. For example, in container No. 34, the battery set 10 has the positive terminals connected together to a single power line 42 while the negative terminals are all connected to the power line 44. The power lines 42 and 44 are readily adaptable to be connected to a rectifier for forming and charging the batteries in the set 10. The remaining sets of batteries shown in FIG. 1 are each individually connected to a separate rectifying source in a similar manner. This allows individual circuit controls for each individual set of batteries in the stack of battery sets. Each of the container means with its accompanying set of batteries is then stacked at a plurality of positions at different heights above a forming room floor. In FIG. 1, container means 34 is shown above container means 36 and container means 36 is shown above container means 38. In the preferred embodiment the container means with the respective set of batteries are stacked vertically above one another.

In the preferred process of applicants' invention, the next step is to continuously provide a cooling fluid, such as water, to fill the first container means 34 with battery set 10 to a predetermined level 50, container means 34 being positioned at the greatest height above the forming room floor 40. The flow of cooling fluid or water from a source of water such as cooling tower 46 is represented by the curved line and arrow 48. When the water has reached this level 50, it is allowed to overflow container 34 and enter a second lower adjacent container means such as container 36 as schematically represented by the line and arrow 52. After container means 36 fills to predetermined level 56, the water overflows to enter container means 38 (see curved line and arrow 54) whereupon container means 38 fills to predetermined level 58 after which the cooling fluid or water overflows to enter the adjacent lower container means or to flow onto the forming room floor, or, as in FIG. 1, to be conveyed to cooling tower 46 (see line and arrow 60). Cooling tower 46 or other cooling means acts to remove the heat from the water whereupon the cooling water is returned to the highest container means 34.

It will be appreciated that as the water passes through the cooling tower 46, a considerable amount of heat is removed and it is desirable that the batteries sorted into the highest container means such as container means 34 be those batteries most in need of cooling. In general, these are batteries of higher capacities or batteries which for various reasons are prone to generating more heat during the formation or charging processes. Hence, battery set 10 in container means 34 is preferably a set of unformed high-capacity batteries.

FIG. 2 is a simulated graph of the temperature of electrolyte of a sixty-five amp hour capacity batteries as it undergoes a conventional "one shot" modified constant voltage formation process without using the cascading water process of applicants' invention. The ambient room temperature and temperature of the filling acid is 90.degree. F. The abscissa is Temperature in degrees Fahrenheit and the ordinate is Hours after fill, that is, hours after filling the battery with electrolyte. In the initial five hours or so after filling the battery with electrolyte, the temperature of the electrolyte exceeds 150.degree. F. peaking near 190.degree. F. which is potentially harmful to the battery. After the heat of neutralization is past, the temperature gradually decreases to below 150.degree. F. at 14 hours past filling. Near the end of formation, between 22 and 23 hours after filling, when the back voltage of the batteries is high and the concentration of the acid is approaching 1.265 specific gravity, the temperature of the electrolyte begins to rise again into the danger zone above 150.degree. F.

In constrast to FIG. 2, our cooling process in combination with a modified constant voltage process results in a temperature curve shown in FIG. 3; (the abscissa and ordinate being the same). During this process, 100.degree.-125.degree. F. cooling fluid is circulated into contact with 5 sides of the batteries. It will be noted that at no time does the temperature of the electrolyte exceed 150.degree. F., otherwise known as the danger zone. The heat of neutralization is still present and the temperature peaks near 150.degree. F. after four hours after filling. However, it gradually decreases to between 110.degree. F. and 130.degree. F. for several hours before rising slightly near the end of formation when the back voltage is high and when, in a "one shot" process, the specific gravity approaches 1.265. The end of the formation process is critical from a temperature standpoint since separator damage is likely to result at this time even with slightly elevated i.e., 150+.degree. F., "one shot" end-of-formation temperatures.

FIG. 4 shows the preferred way of controlling the current while continuing the flow of water during the charging process. It is a graph of temperature of electrolyte versus hours after filling as in FIGS. 2 and 3. The curve is similar to that of FIG. 3 with the current set at a first predetermined level during a first predetermined initial period, for example, 5 Amps for the first five hours. Then, after the heat of neutralization has peaked, the current is raised to a second predetermined level for a second predetermined period, for example, 15 Amps for fifteen hours. Finally, the current is lowered to a third predetermined level for a third predetermined period, for example, 5 Amps for four hours. This third adjustment in current to a lower current level helps to reduce the temperature rise in the electrolyte near the end of formation. This temperature is shown in FIGS. 2 and 3, but not in FIG. 4.

FIG. 5 demonstrates thermal runaway in a battery undergoing formation which, sometimes happens when applicants' process is not followed. A charging level current of 15 Amps is set at the beginning of the formation process and the temperature of the electrolyte increases beyond the danger level of 150.degree. due to the heat of neutralization. Because of the accumulation of the heat of neutralization and the heat generated by the high charging level of 15 Amps, the temperature of the electrolyte does not taper off as in FIGS. 2 through 4 to come back below the danger level but continues to rise with probable destruction to the battery.

As was previously indicated, batteries at various stages of formation can be sorted into different sets. Examples of the types of sets that may be desired are unformed and unfilled batteries of maintenance free, high antimony types of various uniform capacities, batteries which are partially formed but not fully charged and batteries which require a boost charge. The amount of heat which the batteries in these different sets give off will differ. The batteries in the set of highest capacity unformed and unfilled batteries, when the electrolyte is initially added, will generate the greatest amount of heat and therefore, should be placed in a position in the vertical stack of container means which will receive the coolest water or cooling fluid. In FIG. 1 this is container means 34 and battery set 10. As the cooling fluid enters the container means 34, the warmer fluid moves gradually to the top with the cooler fluid remaining at the bottom of the container means 34 to enter the adjacent lower container means 36. Of the sets above described of batteries, batteries which are partially formed and not fully charged will generate more heat than those batteries which require only a boost charge. Hence, it is desirable to place this set of batteries as set 12 in container means 36. Again the warmest water will gradually move to the top of the tank to overflow and enter the lower adjacent tank 38. Hence, the warmest water will enter the third tank and batteries requiring the least amount of cooling should be placed in this tank. Of the battery sets described above, those requiring boost charge will generate the least amount of heat and they should be placed in the container means 38 as set 14. As described previously, the warmest water will again rise to the top, overflow tank means 38 onto the floor of the forming room or, alternatively, through a purification or neutralization system and then to a cooling tower for return to the vertical array of containing means where it will repeat the cascading process through several container means. The types of sets which might be formed from a plurality of batteries are not limited to the description of the sets given above.

The present invention also provides a novel method of utilizing a "one shot" formation technique in combination with these cooling techniques to form batteries while achieving improved formation efficiencies. According to the method of the present invention, dry, unformed batteries of similar cranking capacities may be simultaneously formed using the same rectification facilities regardless of whether those batteries are high antimony lead acid batteries or are maintenance free, i.e., low antimony or calcium lead acid batteries. According to the preferred method of the present invention, dry, unformed high antimony stock of a preselected cranking capacity and/or dry, unformed maintenance free stock of a preselected capacity are filled with a conventional relatively higher gravity "one shot" formation electrolyte and then immediately divided into preselected matrix groups. The matrix groups of high antimony lead acid batteries, preferably comprise a four by five matrix of approximately twenty batteries per group, while the maintenance free batteries are divided into preselected numbers of matrix groups of approximately sixteen-eighteen batteries, preferably in a four by four plus matrix. Each matrix should then preferably be immediately transferred into cooling tubs, one for each matrix group, each of the batteries within each matrix being spaced apart from its adjacent batteries by a distance sufficient to allow fluid to freely circulate therebetween. Once disposed in these tubs, each group is then promptly wired in series to interconnect each battery of the group, and each of the tubs should be arranged in sets of vertical arrays and the connections from each group connected to individual rectification units of a central timing/charging system. Thereafter a three phase charging process should immediately be begun. In the first phase, circulation of a cooling fluid, preferably water, which is maintained at a temperture of about 100.degree.-125.degree. F. should be circulated through each of the tubs. A fixed amperage "anti-pickling" charge is applied at this point, at a rate of 4 to 6, preferably 5, amps for 1-5 hours, preferably 2-3 hours, during which time the heat of neutralization is dissipated into the cooling fluid and the exothermic chemical reactions between the electroylte and the battery plate materials will have passed a point where thermal runaway is likely to occur. The preferred electrolyte for use in this method is a conventionally, relatively higher gravity "one shot" formation electrolyte as for example, a sulphuric acid electrolyte containing 30-40 grams per liter of sodium sulphate and, having a specific gravity of between 1150 and 1220, the particular gravity to be used having been determined according to the relative capacities of the batteries to be formed.

At the completion of phase one of the charging cycle, the circulation of 100.degree.-125.degree. F. cooling fluid is continued, while the rate of charge is automatically shifted into a variable length charge cycle at a rate of 15-18 amps for a preselected time "y" where "y" is greater than 3.8.times.-86 and is less than 4.6.times.-24, and preferably, between 4.0.times.-57 and 4.5.times.-40, suitable complete formations having been obtained when "y" was equal to 4.times. minus 40, the higher values (i.e., up to 4.5.times.) being necessary only to compensate for capacity variations within a matrix set which results from slightly different oxide amounts etc. from battery to battery.

At the completion of phase 2 of the charging cycle, circulation of cooling fluid having temperatures between 100.degree.-125.degree. F. is continued while the charging system is automatically shifted to a "clearing charge" of a 4 to 8 preferably 5-7 amp rate for 5 to 7, preferably 6 hours.

As mentioned above, the preferred temperature of cooling fluid circulated around the batteries to be formed is between 100.degree.-125.degree. F. It would, of course, be possible particularly during the colder winter months, to chill water or other cooling fluids substantially below the preferred minimum 100.degree. F. Applicants have found, however, that such chilling of the cooling fluid to such temperatures is not desirable, and if complete formation is to be obtained using the "one shot" formation process, it is extremely desirable to maintain the batteries to be formed in a bath which is controlled within this temperature range throughout all phases of the formation and charging process. As shown in particular in FIGS. 3 and 4, the maintenance of cooling fluid temperatures in this range insures that from at least one hour after filling through to the end of the entire formation process, the electrolyte temperatures are maintained between 110.degree. F. and 150.degree. F. and preferably during the later phases of the formation process stablized between 120.degree. and 130.degree. F., and preferably about 125.degree. F. It is theorized that rigorous control of the electrolyte temperatures of batteries undergoing a formation process enables that formation to proceed at an optimum rate, that is, by maintaining the formation electrolyte within this desired temperature range the thermodynamics of the primary and secondary reactions occurring during formation are shifted so that reaction kinetics more strongly favor complete formation of the active paste materials while shifting the reaction kinetics away from secondary reactions which may compete with the primary reaction for starting materials while producing end product complexes acting as inhibitors of the primary reaction to thereby reduce the overall yield of the primary reaction, i.e., the completeness of formation. Accordingly, as seen in particular in FIG. 1, alternate circulation pathways are provided for ensuring that the temperature of the cooling fluid is maintained within this optimum range. It may, for example, be desirable to introduce cooling fluid as for example by pathway 100 directly into a tub from which that cooling fluid is removed for return to the cooling tower 46. Alternatively, as shown via pathway 102, it may be desired to return cooling fluid to the cooling tower after it has passed through a plurality of tubs, but less than all the tubs in a vertical array. Finally, as illustrated by pathway 104, it may be desired, particularly in colder weather, to shunt some or all of the cooling fluid by the cooling tower 46 so that the cooling fluid is rapidly raised by recirculation to the desired temperature range.

Using the method of the present invention, complete formation may be obtained using relatively less current that that heretofore necessary to complete formation. Thus, considerable success has been achieved in completing the formation of, for example, a 300 amp hour battery by applying a total of approximately 1200 amp hours of formation current to that battery, instead of the heretofore industry wide acceptable standard of 4.5 times the number of amp hours of battery capacity, or 1350 amp hours for a 300 amp hour battery. This savings of approximately 8% in the total current required to charge a battery is coupled with a substantial decrease in the formation time required for the battery. While under production conditions, it is advisable to use closer to 4.5 times the amp hour of battery capacity to compensate for individual battery variations, corresponding increases in efficiency are believed to nonetheless be maintained under these conditions.

Accordingly, instead of continuously charging a battery at a constant low amperage rate for longer periods of time, shorter charging cycles charging cycle may now be established, thereby enabling a given battery production facility to run on a five day work week instad of the heretofore required seven day work week. Due to the nature of this charging technique, considerable overtime expenses have accordingly been eliminated through the use of this method.

It will be understood that various changes in the details, materials and arrangement of parts which have been herein described and illustrated in order to explain the nature of this invention may be made by those skilled in the art within the principle and scope of the invention as expressed in the following claims.

It will further be understood that the "Abstract of the Disclosure" set forth above is intended to provide a non-legal technical statement of the contents of the disclosure in compliance with the Rules of Practice of the United States Patent and Trademark Office, and is not intended to limit the scope of the invention described and claimed herein.