Dr. Edward Shaffer Speaks at The Battery Show in Novi, Michigan
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Higher Energy Density
The theoretical energy density for lead acid electro-chemistry is 167Wh/kg. However, the active leady materials have to have a heavy structure to support them that is non-active...lead grids, a system for connecting individual cells together, (inter-cell connections), an internal distribution “buzz bar” to carry the high currents out to terminals, (top lead) and a robust sealed case to package all the componentry and prevent acid from leaking. With all this structure added today’s best lead acid batteries achieve <38Wh/kg which means they are only 23% efficient. Most VRLA batteries achieve less than 32Wh/kg.
Advanced Battery Concepts has achieved >67Wh/kg on batteries specifically designed for energy and >50 Wh/Kg on it initial product line. That's a 40%+ increase!
In addition to improving the specific energy density it is possible to improve the volumetric energy density (Wh/l) by eliminating the grids, inter-cell connectors, top lead and standing terminal posts. This means a battery can be smaller for the equivalent energy. Improvements from today’s 85Wh/l to >120Wh/l are possible with GreenSeal® designs.
In an SLI environment our batteries can be up to 30% smaller in size and provide the same energy density and greater power.
More effective management of the active materials through improved uniform current can be achieved by eliminating the lead grid, inter-cell connector and top lead arrangement and replacing them with a thin, uniform large active material surface area. Uniform working of the active material results in much greater charge acceptance allowing the battery to be recharged in a significantly shorter period of time.
Our batteries have reduced the recharge time by up to 50%!
Cycle life of today’s lead acid batteries can be improved through…
More uniform working of the electro-chemically active leady materials by eliminating grids and top lead.
Uniform compression of the separator material that retains acid used in the electro-chemical reaction.
Improved sealing of the battery case to prevent loss of water during “gassing”.
Consistent vent pressures to prevent loss of water during “gassing”.
Improvements to gas recombination chemistry.
Advanced Battery Concepts undertakes considerable back to back competitor product testing and has consistently and reliably demonstrated minimum cycle life improvements of between 2x and up to 6x. (Dependent on comparator batteries tested and type of cycle testing undertaken).
Power in traditional prismatic batteries is limited by the complex top lead and grid structure required to support the leady active materials resulting in non - uniform current flow through torturous resistive pathways. Advanced Battery Concepts GreenSealⓇ designs work the active materials in a uniform manner over a large surface area with significantly simplified current pathways resulting in significantly higher power.
Our group 24 battery is achieving >1000 CCA vs. 550 CCA in a typical group 24 with 25% less weight!
Extreme Vibration Resistance
By eliminating lead grids, inter-cell connects, top lead and traditional cases and lids Advanced Battery Concepts simplified design is far more robust with fewer components to fail. Using the SAE J930 Off Road Vibration test performed by a third party testing center our battery achieved 20X the life versus high quality AGM batteries designed specifically for harsh vibration environments.
Enabled Lower Systems Installation Cost
Traditionally, many batteries of lower voltage are connected together to make higher voltage packs. Building higher voltage monoblock batteries 24V, 36V, 48V, 60V etc. reduces cable size and complexity reducing the installation cost to the consumer. In addition, racking / battery box’s can be simplified or eliminated.
Pack Heat Generation
Using higher voltage monoblock batteries reduces pack heat generation significantly. I2R...this results in longer battery cycle life and reduced cost of ownership. Typically on a 500 kVA UPS pack we achieve 37% less heat generation which translates into significant life improvements and maintenance cost reductions.
Novel Shapes, Batteries Used as Structural Components and Captivated Aftermarket
Removing the requirement for lead grids and top lead allows interesting planer shaped batteries to be concieved.
A battery can now be shaped to follow the wheel profile of an E-Bike, triangle, circle or a battery that is thin and long. Novel shapes are possible using Advanced Battery’s Greenseal® Technology.
In addition, the battery can be designed to be a structural component allowing simplification of sub assemblies (assemble seat post directly to the battery for an eBike. ..). Batteries can fit in locations not possible before offering a lower center of gravity combined with weight and volume savings.
Novel shapes result in captivated aftermarket for OEM'S and battery producers.
Products Can be Designed for Energy or Power or Both
Traditionally lead acid batteries offer the consumer a choice of either high energy or high power. Advanced Battery Concepts also produces high energy or high power batteries but in a smaller lighter footprint.
In addition, Advanced Battery Concepts BiPolar+ technology allows batteries to have both power and energy. Our BCI Group 24 SLI battery delivers over 1,200 CCA (2X the CCA power of conventional group 24’s), with an additional 20%+ of energy. This battery is 13lbs (6kg) lighter than competitors group 24 batteries.
GreenSeal® batteries are THE safest batteries for large format energy storage. The battery design eliminates many of the components used in today’s lead acid battery designs including grids and top lead which are the cause of many of the traditional failure modes of existing lead acid batteries such as….
Cast on strap integrity, through partition weld failure, post to terminal fusion…all of which can lead to today’s batteries potentially exploding.
In addition, GreenSeal® batteries do not suffer from plate thickness control issues, grid growth / corrosion, envelope puncture, bent short wires or sealing / leakage issues…all of which lead to scrap and warranty claims which ultimately lead to more batteries than necessary in circulation.
With energy densities approaching that of Lithium at pack level bipolar lead acid batteries offer a much safer alternative for large format static and motive energy storage applications at a fraction of the cost.