1. The Furukawa Battery Co., Ltd Japan
Advancement in Lead-Acid Battery Technology and the UltraBattery for Micro-HEV and Renewable Energy Storage Applications
7th International Battery Expo & Recycling Conference IBRX India Goa 4th March  2015, Marriott Goa, India
Dr. Jun Furukawa
Senior Fellow
General Manager
UltraBattery Commercialization Dept.
Corporate Planning & Strategy Div.
The Furukawa Battery Co., Ltd Japan

2. Presentation Outline
1. Advancement in lead-acid battery technology
2. Enhanced flooded lead acid battery (EFB) and the UltraBattery for micro-HEV applications
3. The UltraBattery for renewable energy storage applications
4. Conclusions

3. Presentation Outline
1. Advancement in lead-acid battery technology
2. Enhanced flooded lead acid battery (EFB) and the UltraBattery for micro-HEV applications
3. The UltraBattery for renewable energy storage applications
4. Conclusions

4. Performance improvement measures
1) PAM Softening ▪ Positive Plate
: Alloy, Grid Design
Additives, Density
PAM Structure
2) Pos. Grid Corrosion ▪ Negative Plate
: Additives, Grid Design
NAM Structure
▪ Electrolyte
3) NAM Sulfation : Additives, S.G.
▪ Separator (AGM)
: Elasticity, Pore Structure
▪ Assembly
4) Charge Acceptability : Compression

5. 1) PAM softening ⇒ Control the crystal structure
Additives suppress PbO2 crystal coarsening (softening) and shedding
SEM observation of PbO2 microstructure
Initial state
After cycle testing
PAM crystal particles coarsening　　　　　　　　　　　　　　　　⇒ Softening and shedding
PAM keeps finer crystal particles ⇒ Suppress softening
Without additive
With additive

6. 1) PAM softening : Effect of additive
Number of cycles
・Battery type:12V-50Ah
・Discharge:1CA,21min
・Charge:multi step charge,104%
10HR Capacity Ratio(%)
Additive A>No Additive

7. 1) PAM softening : Effect of PAM density
Number of cycles
20HR Capacity Ratio(%)
4.5g/cc> 4.4g/cc> 4.3g/cc
・Battery type:2V-2Ah
・Discharge:0.25CA,2hr
・Charge:2step CC,110%

8. 1) PAM softening : Effect of compression (AGM)
Number of cycles
10HR Capacity Ratio(%)
・Battery type:2V-17Ah
・Discharge:1CA,21min
・Charge:multi step charge,104%
60kPa>30kPa

9. A>B>C 1) PAM softening : Mechanical elasticity of AGM separator
Number of cycles
Initial thickness ratio(%)
A>B>C

10. 1) PAM softening : Pore structure of AGM separator

11. A>B>C 1) PAM softening : AGM separator 20HR Capacity Ratio(%)
・Battery type:2V-17Ah
・Discharge:1CA,21min
・Charge:multi step charge,104%
Number of cycles

12. C21 alloy (Ba-added Pb-Ca-Sn alloy)
2) Positive grid corrosion and growth
C21 alloy (Ba-added Pb-Ca-Sn alloy)

13. 2) Optimized positive grid design by computer aided engineering (CAE)
Conventional
Optimized

14. Accelerated sulfation test
3) NAM sulfation and 4) charge acceptability
: Additive for electrolyte
PbSO4 crystal modifier
➣ Disordered crystal shape
➣ Finer crystals
Accelerated sulfation test
Non additive
Before testing
After testing
With additive

15. 3) NAM sulfation and 4) Charge acceptability
Expander : Conductive carbon
C.B. 1.0%> C.B. 0.4%> No Additive
・Battery type:12V-50Ah
・Discharge:1CA,21min
・Charge:multi step charge,104%
Number of cycles
10HR Capacity Ratio(%)

16. 3) NAM sulfation and 4) Charge acceptability
Expander : BaSO4 and Lignosulfonate

17. Presentation Outline
1. Advancement in lead-acid battery technology
2. Enhanced flooded lead acid battery (EFB) and the UltraBattery for micro-HEV applications
3. The UltraBattery for renewable energy storage applications
4. Conclusions

18. Global Fuel Economy Regulations
Global Passenger Vehicle Powertrain Scenario
Source: IEA2011 & Continental 48V eco-Hybrid Systems

19. Honda and Suzuki adopted Furukawa Battery’s EFB in 2012.

20. Hierarchy of lead acid battery technologies
The UltraBattery technology can truly exert its ability only in a lead-acid battery with higher performance.
Conventional
lead-acid
Advanced lead-acid
UltraBattery

21. Actual configuration of the UltraBattery
・Capacitor layer coating
・Similar assembly process to conventional battery

22. The UltraBattery products
➣ The flooded type UltraBattery for the aftermarket
➣ M-42, N-55, Q-85 and S-95, released in April 2013
➣ Honda adopted the Q-85-size flooded type UltraBattery for Odyssey Absolute vehicle released in November 2013

23. DCA cycle life test under 80% SOC
The flooded type UltraBattery shows around two times longer life compared with EFB (Enhanced Flooded Battery )

24. Presentation Outline
1. Advancement in lead-acid battery technology
2. Enhanced flooded lead acid battery (EFB) and the UltraBattery for micro-HEV applications
3. The UltraBattery for renewable energy storage applications
4. Conclusions

25. The stationary UltraBattery for renewable energy storage applications
UB V, 2,000Wh
UB V, 1,000Wh
UB V, 600Wh

26. Advantages of the UltraBattery
✓✓ ✓ ✓
✓ ✓ ✓✓
✓✓✓ ✓
✓ ✓ ✓
✓✓ ✓
✓ ✓ ✓ ✓

27. Results of HR-PSOC Cycle Test
0.5C10A capacity test (when EOCV reaches V)

28. The UltraBattery energy storage system in Iwaki Plant
※1Battery Condition Watcher ※2Battery Management Unit

29. The UltraBattery energy storage system in Iwaki Plant

31. Presentation Outline
1. Advancement in lead-acid battery technology
2. Enhanced flooded lead acid battery (EFB) and the UltraBattery for micro-HEV applications
3. The UltraBattery for renewable energy storage applications
4. Conclusions

32. Conclusions
1. The Furukawa Battery developed advanced technology for automotive and stationary lead-acid batteries.
2. The flooded type UltraBattery exhibits excellent performance.
3. The flooded type UltraBattery suppresses fuel consumption of the stop/start vehicle.
4. The flooded type UltraBattery was adopted by Honda Odyssey Absolute vehicle released in November 2013 in Japan.
5. The Furukawa Battery released the stationary UltraBattery energy storage system in 2013.
6. The Battery Monitoring Unit (BMU) has been developed in 2014.

33. Thank you for your kind attention
Dr. Jun Furukawa
Senior Fellow
General Manager
UltraBattery Commercialization Dept.
Corporate Planning & Strategy Div.
The Furukawa Battery Co., Ltd Japan
Thank you for your kind attention