WO2010122873A1 - 鉛蓄電池用負極板の製造法及び鉛蓄電池 - Google Patents

鉛蓄電池用負極板の製造法及び鉛蓄電池 Download PDF

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WO2010122873A1
WO2010122873A1 PCT/JP2010/055479 JP2010055479W WO2010122873A1 WO 2010122873 A1 WO2010122873 A1 WO 2010122873A1 JP 2010055479 W JP2010055479 W JP 2010055479W WO 2010122873 A1 WO2010122873 A1 WO 2010122873A1
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Prior art keywords
carbon
negative electrode
coating layer
lead
plate
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PCT/JP2010/055479
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English (en)
French (fr)
Inventor
古川淳
門馬大輔
高田利通
トリュー ラン ラム
ロザリー ルーエイ
ピーター ニゲル ハイフ
Original Assignee
古河電池株式会社
コモンウエルス サイエンティフィック アンド インダストリアル リサーチ オーガニゼーション
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Priority to CA2759689A priority Critical patent/CA2759689A1/en
Priority to US13/265,944 priority patent/US9450232B2/en
Priority to EP10766932.7A priority patent/EP2424011A4/en
Priority to JP2011510269A priority patent/JP5680528B2/ja
Priority to CN201080029032.4A priority patent/CN102484245B/zh
Priority to MX2011011106A priority patent/MX340874B/es
Publication of WO2010122873A1 publication Critical patent/WO2010122873A1/ja

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/14—Electrodes for lead-acid accumulators
    • H01M4/16—Processes of manufacture
    • H01M4/20—Processes of manufacture of pasted electrodes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/04—Processes of manufacture in general
    • H01M4/0402—Methods of deposition of the material
    • H01M4/0416—Methods of deposition of the material involving impregnation with a solution, dispersion, paste or dry powder
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/04—Processes of manufacture in general
    • H01M4/0438—Processes of manufacture in general by electrochemical processing
    • H01M4/044—Activating, forming or electrochemical attack of the supporting material
    • H01M4/0445—Forming after manufacture of the electrode, e.g. first charge, cycling
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/04—Processes of manufacture in general
    • H01M4/0438—Processes of manufacture in general by electrochemical processing
    • H01M4/045—Electrochemical coating; Electrochemical impregnation
    • H01M4/0452—Electrochemical coating; Electrochemical impregnation from solutions
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/14—Electrodes for lead-acid accumulators
    • H01M4/16—Processes of manufacture
    • H01M4/22—Forming of electrodes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/36—Selection of substances as active materials, active masses, active liquids
    • H01M4/362—Composites
    • H01M4/366—Composites as layered products
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/62—Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
    • H01M4/624—Electric conductive fillers
    • H01M4/625—Carbon or graphite
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/06—Lead-acid accumulators
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M2004/026—Electrodes composed of, or comprising, active material characterised by the polarity
    • H01M2004/027—Negative electrodes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/62—Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
    • H01M4/621—Binders
    • H01M4/622—Binders being polymers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/62—Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
    • H01M4/621—Binders
    • H01M4/622—Binders being polymers
    • H01M4/623—Binders being polymers fluorinated polymers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

  • the present invention relates to a method for manufacturing a negative electrode plate for a lead storage battery and a lead storage battery that are applied to industrial applications such as hybrid car applications and windmills that repeatedly perform rapid charging and discharging with PSOC.
  • a first carbon material such as carbon black having a negative electrode active material filled plate as a main body and conductive carbon on the surface thereof
  • a second carbon material such as activated carbon having a capacitor capacity and / or a pseudo capacitor capacity.
  • the negative electrode plate proposed in the above-mentioned Patent Document 1 is a porous carbon mixture coating layer having a negative electrode and a capacitor function.
  • the bond between the carbon coating layer and the negative electrode plate body on the lower surface is the carbon coating. Since this is a bond due to the mechanical anchor effect contained in the layer, the carbon mixture coating layer is easily peeled off from the surface of the negative electrode in the lead-acid battery manufacturing process such as the chemical conversion process and the initial charging process, Further, as a result of this, the carbon mixture coating layer does not function sufficiently, resulting in inferior rapid discharge performance at low temperatures and the like, and the expected performance cannot be obtained.
  • the present invention eliminates the above-mentioned problems, improves the method for producing a negative electrode plate for lead-acid batteries that does not cause interfacial separation between the carbon mixture coating layer and the negative electrode plate body, and has improved conductivity, and rapid discharge performance at low temperatures. Is to provide a lead acid battery.
  • a first carbon material having conductivity and a second carbon material having a capacitor capacity and / or a pseudo capacitor capacity on at least a part of the surface of the negative electrode active material-filled plate After forming a coating layer of a carbon mixture formed by mixing two kinds of carbon materials and a binder, lead ions sufficient to move from the negative electrode active material-filled plate into the carbon mixture coating layer are generated.
  • a negative electrode for a lead storage battery wherein after the process, chemical conversion or initial charging is performed to deposit lead, and the carbon mixture coating layer and the negative electrode plate are connected and integrated with at least a part of the interface with the deposited lead. It exists in the manufacturing method of a board. Furthermore, as described in claim 2, the present invention resides in a lead storage battery comprising a negative electrode plate manufactured by the manufacturing method described in claim 1.
  • the interface between the manufactured negative electrode plate body and the carbon mixture coating layer is peel-resistant and has a peel resistance in which the interfacial bonds are partially or entirely bonded together with lead.
  • a negative electrode plate for a lead storage battery is produced, which improves conductivity and further improves battery characteristics.
  • the lead storage battery since the lead storage battery uses the negative electrode plate having the above-described peel resistance and improved conductivity as the negative electrode, the low-temperature rapid discharge performance in PSOC is improved.
  • a carbon mixture is applied to at least a part of the surface to form a coating layer.
  • the carbon mixture is applied to the entire surfaces, to the entire surface of the surface, or to both surfaces or a part of the surface, thereby forming the coating layer.
  • the carbon mixture is composed of a mixture of a first carbon material that secures conductivity, a second carbon material that secures capacitor capacity and / or pseudo capacitor capacity, and at least a binder.
  • the present invention provides a carbon mixture coating layer formed by forming a carbon mixture coating layer on the upper surface of the negative electrode active material-filled plate before performing these chemical conversion treatments and initial charge treatments.
  • a carbon mixture coating layer formed by forming a carbon mixture coating layer on the upper surface of the negative electrode active material-filled plate before performing these chemical conversion treatments and initial charge treatments.
  • the lead ion generation means and the subsequent lead precipitation means which are the characteristics of the present invention, are formed in the air after forming a carbon mixture coating layer on the negative electrode surface. Then, the carbon mixture coating layer is made into a porous coating layer, and the negative electrode active material is oxidized. As a result, lead ions are easily generated when the electrolytic solution is injected thereafter. Furthermore, a long soaking time after the electrolyte injection is provided, so that a larger amount of lead ions can be easily diffused into the porous carbon mixture coating layer. Thus, lead is deposited by the subsequent charging process to bring about the integration.
  • lead ions trapped in the second carbon material such as activated carbon mixed in the carbon mixture coating layer are inhibited from reacting with sulfate ions.
  • Lead crystals are less likely to grow, and the mutual interface between the negative electrode plate body and the carbon mixture coating layer provides an environment in which sulfation is less likely to occur.
  • a similar environment is created for the inner and outer surfaces of the carbon mixture coating layer.
  • the composition of the carbon mixture is 5 to 70 parts by weight of the first carbon material, 20 to 80 parts by weight of the second carbon material and 1 to 20 parts by weight of the binder, 0 to 10 parts by weight of the thickener, and short fiber. It is prepared by blending as desired from 0 to 16 parts by weight of the reinforcing material.
  • the first carbon material is necessary for ensuring conductivity, and carbon black such as acetylene black and furnace black, ketjen black, graphite, and the like are suitable, and at least one of these is selected and used. If the blending amount of the first carbon material is less than 5 parts by weight, the conductivity cannot be ensured, resulting in a decrease in the capacitor capacity, and if it exceeds 70 parts by weight, the conductive effect is saturated.
  • a more preferred amount is 10 to 60 parts by weight.
  • the second carbon material is necessary for securing the capacity as a capacitor and / or a pseudo capacitor, and activated carbon, carbon black, graphite and the like are suitable, and at least one of them is selectively used. If the blending amount is less than 20 parts by weight, the capacity of the capacitor is insufficient, and if it exceeds 80 parts by weight, the proportion of the first carbon material is relatively reduced, and the capacity is rather lowered. A more preferred amount is 30 to 70 parts by weight.
  • the binder is necessary for bonding the first and second carbon materials and the negative electrode surface constituting the lead battery to ensure electrical connection and maintaining the porous state of the coating layer. .
  • polychloroprene As the binder, polychloroprene, SBR, PTFE, PVDF, etc. are suitable. If the amount is less than 1 part by weight, the bond is insufficient, and if it exceeds 20 parts by weight, the bonding effect is saturated and the conductivity decreases as an insulator. Let A more preferred amount is 5 to 15 parts by weight.
  • a thickener is useful for preparing a carbon mixture in a paste form.
  • cellulose derivatives such as CMC and MC, polyacrylates, polyvinyl alcohol, and the like are suitable.
  • NMP and the like are suitable. Is appropriate. In the case of using a thickener, when the dry residue exceeds 10 parts by weight, the conductivity of the mixture is impaired.
  • the short fiber reinforcing material is useful for suppressing the occurrence of cracks due to drying when a carbon mixture is prepared in a paste form and applied to a negative electrode active material-filled plate to form a coating layer.
  • the material may be stable in sulfuric acid acid such as carbon, glass, PET, and tetron, and the thickness is preferably 20 ⁇ m or less and the length is preferably 0.1 mm to 4 mm. If the blending amount exceeds 16 parts by weight, the relative blending ratio of the carbon material and the binder is lowered to deteriorate the performance, and the conductivity is also lowered.
  • the amount of the carbon mixture with respect to 100 parts by weight of the negative electrode active material constituting the lead storage battery is preferably 1 to 15 parts by weight.
  • the porosity of the porous carbon mixture coating layer is preferably 40% to 90%. If it is less than 40%, the movement of the electrolytic solution is hindered and the discharge performance is reduced. If it exceeds 90%, the capacitor function effect will be saturated and the thickness will be increased, which will be supported by the design. A more preferable porosity is 50 to 80%. More detailed examples of the present invention are given below.
  • the negative electrode plate manufactured in this manner is laminated with a positive electrode plate manufactured by a known method via an AGM separator, an electrode plate group is assembled, and this is stored in a battery case, and the rate of 5 hours is regulated by the positive electrode capacity regulation.
  • a 2 V lead acid battery with a capacity of 10 Ah was assembled.
  • the electrode plate group was prepared with a spacer so that the degree of compression was 50 kPa.
  • a sulfuric acid aqueous solution having a specific gravity of 1.30 in which 30 g / l of aluminum sulfate ⁇ 18 hydrate was dissolved was injected as an electrolytic solution, and immediately charged with 1A for 20 hours until the battery voltage reached 1.75V. Discharged at 2A. Thereafter, the battery was charged again at 1 A for 15 hours and discharged at 2 A to a battery voltage of 1.75 V, and when the 5-hour rate capacity was measured, the capacity of the battery was 10 Ah.
  • Example 2 After the electrolyte injection in Example 1, soaking was performed for 1 hour prior to charging with 1A for 20 hours. Other than that was carried out similarly to the Example, and manufactured lead acid battery.
  • the lead paste carbon mixture coating layer applied on both surfaces of the negative electrode conversion plate in Example 1 is dried in a non-oxidizing atmosphere, for example, in a nitrogen atmosphere at 60 ° C. for 1 hour to prevent oxidation of the negative electrode active material.
  • Example 1 except that a lead-acid battery was assembled in the same manner as in Example 1 and the electrolyte was injected therein, followed by discharging for 1 hour in 1A of Example 1 and discharging for 30 hours in 1A.
  • a lead storage battery was manufactured in the same manner as described above.
  • a positive electrode aging plate and a negative electrode aging plate used for a control valve type lead storage battery were manufactured by a known method. Further, for the negative electrode aged plate, 5 wt. %, And after forming the coating layer of the carbon mixture, after injecting the electrolyte solution, soaking was performed for 1 hour prior to charging with 1A for 20 hours. A lead-acid battery was manufactured. Comparative Example 1 A lead-acid battery was produced by treating in the same manner as in Example 1 except that the paste-like carbon mixture applied on the negative electrode conversion plate was dried at 60 ° C. for 1 hour in a non-oxidizing nitrogen atmosphere.
  • a PSOC low temperature rapid discharge test was performed as follows. That is, the fully charged lead acid battery was discharged at 2A for 2.5 hours to make SOC 50%, then left at ⁇ 30 ° C. for 16 hours, then discharged at 150A for 10 seconds, and the voltage at 10 seconds was measured. Moreover, each lead storage battery was disassembled after the test, and the presence or absence of interface peeling between the carbon mixture coating layer and the negative electrode plate body was examined. The results are shown in Table 2 below.
  • the lead storage batteries of Examples 1 to 4 of the present invention were able to suppress a decrease in voltage even when sudden discharge was performed at a low PSOC and extremely low temperature. This is because, as described in Examples 1 to 4, before the chemical conversion or the initial charging, the lead ion in the vicinity of the negative electrode is excessively processed, and as a result, the negative electrode active material-filled plate and the carbon mixture coating layer are formed in the subsequent charging. Are bonded and integrated with lead deposited at the mutual interface, so that the interface peeling is prevented, and as a result, the conductivity is improved, the voltage drop is suppressed, and the function of the coating layer is improved. .
  • Comparative Example 1 in which this operation was not performed, the voltage was remarkably reduced, and the interface was separated.
  • the above carbon mixture was applied to and dried on one side of the negative electrode active material-filled plate, or both sides or part of one side to form a carbon mixture coating layer.
  • the lead ion generation treatment is performed before the first charge, a negative electrode without interfacial peeling can be produced and the low temperature rapid discharge characteristics of the lead storage battery are improved.

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  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
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Abstract

　負極活物質充填板の表面にカーボン合剤被覆層を有する構成の負極板の課題である該負極活物質充填板と該カーボン合剤被覆層との界面剥離を防止し、低下急放電特性を向上した鉛蓄電池用負極板の製造法を提供する。　負極活物質充填板の表面の少なくとも一部に、導電性を有する第1カーボン材料とキャパシタ容量及び/又は擬似キャパシタ容量を有する第2カーボン材料から成る2種類のカーボン材料と少なくとも結着剤を混合して成るカーボン合剤の被覆層を形成した後、該負極活物質充填板から該カーボン合剤被覆層内へ移動するに充分な鉛イオンを生成させる工程を経た後、化成又は初充電を行い該カーボン合剤被覆層と負極板との相互界面の少なくとも一部を析出鉛で連結し一体化したこと。

Description

鉛蓄電池用負極板の製造法及び鉛蓄電池
　本発明は、ＰＳＯＣで急速充放電を繰り返すハイブリッド自動車用途や風車などの産業用に適用される鉛蓄電池用負極板の製造法及び鉛蓄電池に関する。
　従来、負極活物質充填板を本体とし、その表面に導電性を有するカーボンブラックなどの第１カーボン材料とキャパシタ容量及び／又は擬似キャパシタ容量を有する活性炭などの第２カーボン材料から選ばれた少なくとも２種類のカーボン材料と結着剤を混合して成るカーボン合剤の被覆層を形成することにより、ＰＳＯＣで急速充放電を繰り返してもキャパシタの機能により寿命を大幅に延長することができるようにした鉛蓄電池用負極板が特表２００７−５０６２３０号公報で提案されている。
特表２００７−５０６２３０号公報
　しかし乍ら、上記特許文献１に提案の負極板は、負極とキャパシタ機能を有するポーラスなカーボン合剤被覆層とは、そのカーボン被覆層とその下面の負極板本体との結合は、該カーボン被覆層に含有する機械的なアンカー効果による結合であるため、この負極板をその後化成工程や初充電工程などの鉛蓄電池の製造工程において、該カーボン合剤被覆層が負極の表面から剥離し易く、また、これに伴い、該カーボン合剤被覆層が充分に機能しない結果、低温における急放電性能などが劣り、期待した性能が得られない問題があった。
　本発明は、上記の課題を解消し、該カーボン合剤被覆層と負極板本体との界面剥離を生じない且つ導電性の向上した鉛蓄電池用負極板の製造法と低温における急放電性能を向上した鉛蓄電池を提供することに在る。
　本発明は、請求項１に記載の通り、負極活物質充填板の表面の少なくとも一部に、導電性を有する第１カーボン材料とキャパシタ容量及び／又は擬似キャパシタ容量を有する第２カーボン材料とから成る２種類のカーボン材料と結着剤を混合して成るカーボン合剤の被覆層を形成した後、該負極活物質充填板から該カーボン合剤被覆層内へ移動するに足る鉛イオンを生成させる工程を経た後、化成又は初充電を行い鉛を析出させ該カーボン合剤被覆層と負極板とを、その界面の少なくとも一部を析出鉛で連結一体化したことを特徴とする鉛蓄電池用負極板の製造法に存する。
　更に本発明は、請求項２に記載の通り、請求項１に記載の製造法により製造した負極板を具備したことを特徴とする鉛蓄電池に存する。
　請求項１に係る発明によれば、製造された該負極板本体と該カーボン合剤被覆層との界面相互が部分的に或いは全面的に析出した鉛で一体に結合した耐剥離性を有する堅牢で且つ導電性が向上し、更には、電池特性の向上をもたらす鉛蓄電池用負極板が製造される。
　請求項２に係る発明によれば、鉛蓄電池は、上記の耐剥離性を有し、且つ導電性の向上した負極板を負極として用いるので、ＰＳＯＣでの低温急放電性能の向上をもたらす。
　本発明の実施形態例を以下に詳述する。
　本発明の鉛蓄電池用負極板の製造には、従来と同様に、出発原料として、鉛又は鉛合金の多孔集電板にリサージと硫酸などの練液から成る負極活物質原料を充填した後、常法により、熟成処理して成る負極熟成板から成る負極活物質充填板や前記の負極活物質原料充填板や負極熟成板を化成処理して成る負極化成板から成る負極活物質充填板を製造素材として使用する。
　本発明によれば、先ず第一に、かかる負極活物質充填板を加熱乾燥後、その少なくとも表面の一部にカーボン合剤を塗布し、その被覆層を形成する。詳細には、その両表面全体に、或いはその片面全体に或いはその両面又は片面の一部にカーボン合剤を塗布し、その被覆層を形成する。
　そのカーボン合剤は、導電性を確保する第１カーボン材料とキャパシタ容量及び／又は擬似キャパシタ容量を確保する第２カーボン材料と少なくとも結着剤との混合物から成る。
　ところで、該負極活物質充填板の表面を該カーボン合剤被覆層を形成したものを、直ちに、その充填板が負極熟成板である場合は、化成処理を行い、次いで初充電処理を行い、負極化成板の場合は、初充電処理を行い、夫々表面がポーラスなカーボン合剤被覆層で被覆された鉛蓄電池用負極板を製造するときは、いずれの場合も、負極活物質充填板とカーボン合剤被覆層との相互の界面の結着は、結着剤による機械的なアンカーによる結合に過ぎないので、化成処理や初充電処理において、その界面に剥離を生じ良好な化成処理や初充電処理ができず、導電性やキャパシタ容量の低下した負極板をもたらし、これを負極とした鉛蓄電池とした場合は、急放電特性の劣化や使用寿命の短命化をもたらすことが判明した。
　かかる課題を解決するため、本発明は、負極活物質充填板の上面にカーボン合剤被覆層を形成して成るものを、これら化成処理や初充電処理を行う前に、該カーボン合剤被覆層と該負極活物質充填板との結合一体化する手段として、電解液浸漬下で負極活物質充填板から該カーボン合剤被覆層内に足る鉛イオンを移動拡散を起こす処理を施した後、化成処理や初充電処理を行うことにより、該カーボン合剤被覆層と該負極活物質充填板との界面に析出した鉛により一体的に結合した剥離のない且つ導電性の向上した鉛蓄電池用負極板を製造することができるようにしたものである。
　本発明の特徴とする鉛イオンの生成手段とその後の鉛析出手段としては、該負極活物質充填板として負極化成板を用いる場合は、負極の表面にカーボン合剤被覆層を形成した後に空気中で乾燥してカーボン合剤被覆層をポーラスな被覆層とすると共に、負極活物質を酸化させること、これにより、その後、電解液を注入したときに鉛イオンが生成し易くなる。更に、電解液注入後のソーキング時間を長く取ること、これにより、ポーラスなカーボン合剤被覆層内へのより大量の鉛イオンの流入拡散がより容易に行われる。而して、その後の充電処理により鉛の析出を行い上記の一体化がもたらされる。更に、また、負極活物質の活性化工程を放電から始めること、これにより、鉛イオンを生成させ、次いで充電により鉛を析出させることも有効である。
　因みに、従来のカーボン合剤被覆層を欠く負極熟成板に、まず、例えば上記の放電処理を行うと、次の充電過程で、溶解した鉛イオンが負極表面にデンドライト状に析出し、短絡を起こし易くなる。これに対し、本発明の負極はカーボン合剤被覆層を有するため、これが鉛イオンをトラップするため、短絡は起こらない。
　而も、本発明による負極板の製造過程で、そのカーボン合剤被覆層に混入している活性炭などの第２カーボン材料に捕捉された鉛イオンは硫酸イオンとの反応が抑制されるため、硫酸鉛の結晶が成長し難くなり、負極板本体と該カーボン合剤被覆層との相互界面はサルフェーションを起こし難くなる環境をもたらす。カーボン合剤被覆層内部及び外表面についても同様の環境を生ずる。結局、負極板本体とカーボン合剤被覆層とが鉛により結合された、後記に明らかにするように、界面剥離のない堅牢で且つ鉛蓄電池の低温における急放電特性の向上をもたらす負極板が製造されることとなる。
　該カーボン合剤の配合組成は、第１カーボン材料５~７０重量部、第２カーボン材料２０~８０重量部及び結着剤１~２０重量部、増粘剤０~１０重量部、短繊維状補強材０~１６重量部から所望に配合して調製する。
　第１カーボン材料は、導電性を確保するのに必要で、アセチレンブラックやファーネスブラックなどのカーボンブラック、ケッチェンブラック、黒鉛などが適当であり、これらから少なくとも１種を選択使用する。
　該第１カーボン材料の配合量は５重量部未満では導電性を確保できず、キャパシタ容量の低下を招き、７０重量部を超えると導電効果が飽和する。より好ましい量は１０~６０重量部である。
　第２カーボン材料はキャパシタ及び／又は擬似キャパシタとしての容量を確保するのに必要で、活性炭、カーボンブラック、黒鉛などが適当であり、これらから少なくとも１種を選択使用する。配合量は２０重量部未満ではキャパシタ容量が不足し、８０重量部を超えると相対的に第１カーボン材料の割合が減少して、むしろ容量が低下する。より好ましい量は３０~７０重量部である。
　結着剤は第１及び第２カーボン材料同士、並びにこれらと鉛電池を構成する負極表面を結合して電気的な接続を確保すると共に、被覆層がポーラスな状態を維持するのに必要である。結着剤としては、ポリクロロプレン、ＳＢＲ、ＰＴＦＥ、ＰＶＤＦなどが適当で、１重量部未満では結合が不充分となり、２０重量部を超えると結合効果が飽和すると共に、絶縁体として導電性を低下させる。より好ましい量は５~１５重量部である。
　増粘剤はカーボン合剤をペースト状に調製するのに有用で、水性のペーストにはＣＭＣやＭＣなどのセルロース誘導体、ポリアクリル酸塩、ポリビニルアルコールなどが適当であり、有機系にはＮＭＰなどが適当である。増粘剤を用いる場合は、乾燥残分が１０重量部を超えると合剤の導電性を損なうのでこれ以下が好ましい。
　短繊維状補強材は、カーボン合剤をペースト状に調製し負極活物質充填板に塗布しその被覆層を形成する場合、乾燥による亀裂の発生を抑制するのに有用である。その材質はカーボン、ガラス、ＰＥＴ、テトロンなど硫酸酸性中で安定であれば良く、太さは直径２０μｍ以下、長さは０．１ｍｍ~４ｍｍが好ましい。配合量は１６重量部を超えるとカーボン材料や結着剤の相対的な配合比率を下げて性能を損なうと共に、導電性も低下させるのでこれ以下が好ましい。
　鉛蓄電池を構成する負極活物質重量１００重量部に対するカーボン合剤の量は１~１５重量部が好ましい。１重量部未満では被覆した効果が充分に得られず、１５重量部を超えると被覆層の厚みが厚くなって効果が飽和する。より好ましいカーボン合剤の量は３~１０重量部である。ポーラスなカーボン合剤被覆層の気孔率は４０％~９０％が好ましい。４０％未満では電解液の移動が阻害され、放電性能の低下を招く。９０％を超えるとキャパシタ機能効果が飽和すると共に、厚みが厚くなり、設計に支承をきたす。より好ましい気孔率は５０~８０％である。
　本発明の更に詳細な実施例を以下に示す。
　制御弁式鉛蓄電池に用いる従来の正極化成板と負極化成板を公知の方法で製造した。そして、その負極化成板の耳部を除く両面全体に下記表１に示す配合組成から成るペースト状のカーボン合剤を乾燥重量換算で鉛の充填活物質重量の５ｗｔ．％を塗布し、その被覆層を形成した後、空気中６０℃で１時間乾燥し、ポーラスなカーボン合剤被覆層を形成すると同時に鉛負極活物質を酸化させた。このときのカーボン合剤被覆層の気孔率は７５％であった。このようにして製造した負極板を公知の方法で製造した正極板とをＡＧＭセパレータを介し積層し、極板群を組み立て、これを電槽内に収納して、正極容量規制で、５時間率容量が１０Ａｈで２Ｖの鉛蓄電池を組み立てた。尚、極板群の圧迫度は５０ｋＰａになるようにスペーサーを入れて調製した。
　次に、硫酸アルミニウム・１８水塩を３０ｇ／ｌ溶解した比重１．３０の硫酸水溶液を電解液として注入した後、直ちに、１Ａで２０時間充電を行い、その後電池電圧が１．７５Ｖに達するまで２Ａで放電した。その後、再び１Ａで１５時間の充電と２Ａで電池電圧１．７５Ｖまで放電し、５時間率容量を測定したところ、該電池の容量は１０Ａｈであった。
Figure JPOXMLDOC01-appb-T000001
　実施例１における電解液注入後、１Ａで２０時間充電を行うに先立ち、１時間ソーキングを行った。それ以外は実施例と同様にして鉛蓄電池を製造した。
　実施例１における負極化成板の両面全体に塗布した鉛ペースト状カーボン合剤被覆層の乾燥を非酸化性の雰囲気中、例えば、窒素雰囲気中６０℃で１時間行って負極活物質の酸化を防止したこと、実施例１と同様に鉛蓄電池を組み立て、これに電解液を注入後、実施例１の１Ａで２０時間の充電に先立ち、１Ａで３０時間放電を行ったこと以外は、実施例１と同様にして鉛蓄電池を製造した。
　公知の方法で制御弁式鉛蓄電池に用いる正極熟成板と負極熟成板を製造した。更に、該負極熟成板につき、その両面全体に該カーボン合剤を乾燥重量換算で負極活物質重量の５ｗｔ．％を塗布し、該カーボン合剤の被覆層を形成した後、電解液を注入後、１Ａで２０時間充電に先立ち、１時間ソーキングを行ったこと、それ以外は実施例１と同様に処理して鉛蓄電池を製造した。
　比較例１
　負極化成板に塗布し形成したペースト状カーボン合剤の乾燥を非酸化性の窒素雰囲気中６０℃で１時間乾燥した以外は、実施例１と同様に処理して鉛蓄電池を製造した。
　低温急放電試験
　上記の実施例１~４の夫々の鉛蓄電池及び比較例１の鉛蓄電池につき、ＰＳＯＣ低温急放電試験を次のように行った。即ち、完全充電した鉛蓄電池を２Ａで２．５時間放電してＳＯＣ５０％とした後、−３０℃で１６時間放置し、その後１５０Ａで１０秒間放電し、１０秒目電圧を測定した。また、試験終了後に各鉛蓄電池を解体して、カーボン合剤被覆層と負極板本体の界面剥離の有無を調べた。その結果を下記表２に示す。
Figure JPOXMLDOC01-appb-T000002
 　表２に明らかな通り、本発明の実施例１~４の鉛蓄電池は低ＰＳＯＣ且つ極低温化で急放電を行っても電圧の低下は抑えられた。これは化成又は初充電前に夫々実施例１~４に記載のように、負極近傍の鉛イオンが過剰になる処理を行った結果、その後の充電で負極活物質充填板とカーボン合剤被覆層は、その相互界面に析出した鉛で結合し一体化されるので、界面剥離が防止され、その結果、導電性が向上し、電圧低下が抑制され、該被覆層はキャパシタとしての機能が良くなる。一方、この操作を行わなかった比較例１は電圧の低下が著しく、且つ該界面間が剥離した。
　尚、上記のカーボン合剤を、負極活物質充填板の片面全面或いは両面又は片面の一部に塗布乾燥してカーボン合剤被覆層を形成したものを、実施例１~４と同様に、化成又は初充電前に、鉛イオン生成処理を行うときも、界面剥離のない負極が製造できると共に、鉛蓄電池の低温急放電特性の向上をもたらした。

Claims (2)

  1. 　負極活物質充填板の表面の少なくとも一部に、導電性を有する第１カーボン材料とキャパシタ容量及び／又は擬似キャパシタ容量を有する第２カーボン材料とから成る２種類のカーボン材料と結着剤を混合して成るカーボン合剤の被覆層を形成した後、該負極活物質充填板から該カーボン合剤被覆層内へ移動するに足る鉛イオンを生成させる工程を経た後、化成又は初充電を行い鉛を析出させ該カーボン合剤被覆層と負極板とを、その界面の少なくとも一部を析出鉛で連結一体化したことを特徴とする鉛蓄電池用負極板の製造法。
  2. 　請求項１に記載の製造法により製造した負極板を具備したことを特徴とする鉛蓄電池。
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US9450232B2 (en) 2016-09-20
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