US2011076562A1PendingUtilityA1

Mixture of basic lead sulfates

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Individually held — no corporate assignee on recordPriority: Sep 29, 2009Filed: Sep 29, 2010Published: Mar 31, 2011
Est. expirySep 29, 2029(~3.2 yrs left)· nominal 20-yr term from priority
Inventors:George E. Mayer
C01P 2006/14C01P 2006/10H01M 4/5825C01P 2006/40H01M 4/20H01M 4/362C01G 21/20Y02E60/10
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Claims

Abstract

A microporous lead-containing solid material is produced, which can serve as a carrier for desired materials into a reaction for various desired purposes. For example, if the microporous solid is impregnated with borax it tends to inhibit the growth of unduly large crystals of tetrabasic lead, which is useful in producing batteries having improved functional qualities.

Claims

exact text as granted — not AI-modified
1 . A composition of matter comprising lead sulfates which has high internal porosity and density <3.5 g/cc. 
     
     
         2 . The composition of matter of  claim 1  further comprising predominantly tetrabasic lead sulfate and tribasic lead sulfate. 
     
     
         3 . The combination of matter of  claim 1 , wherein the pores of the material comprising basic lead sulfates are impregnated with a material capable of altering the pattern of crystal growth of other substances. 
     
     
         4 . The combination of matter of  claim 3 , wherein the material capable of altering the pattern of crystal growth of other substances is selected from the group consisting of borax or another combination of an alkaline anion with a suitable cation, selected from the group consisting of borates, phosphates, acid phosphates, silicates, and fluoborates. 
     
     
         5 . A method of manufacture of a composition of matter comprising basic lead sulfates which has high internal porosity and density <3.5 g/cc, said method comprising the steps of mixing leady lead oxide, water and sulfuric acid into a doughy mass, said mixing step being performed very rapidly and at elevated temperature, followed by grinding, such that the doughy mass is reduced to a fine powder of lead salts. 
     
     
         6 . The method of  claim 5 , where the ratio of oxide to water to sulfuric acid is 100 parts by weight of oxide, to from 10 to 30 parts water, to from 10 to 30 parts of 50 wt % sulfuric acid (1.400 sp.gr.), preferably 100 parts by weight of oxide to 10 parts by weight of water to 15 parts by weight of acid. 
     
     
         7 . The method of  claim 5 , where the water is heated to >70° C. (preferably >90° C.) and mixed with the oxide, this mixture then being mixed with the acid, which is added rapidly (<5 minutes), preferably as a fine spray in <2 minutes. 
     
     
         8 . The method of  claim 5 , wherein the powder is ground until it achieves a degree of fineness such that >99% of the particles thus produced will pass through a 325 mesh sieve. 
     
     
         9 . The method of  claim 8 , comprising the further step of collecting the smaller or lighter particles (<325 mesh) in a wet scrubber. 
     
     
         10 . The method of  claim 8 , comprising the further step of collecting the smaller or lighter particles (<325 mesh) in a baghouse. 
     
     
         11 . The method of  claim 8 , comprising the further step of collecting the smaller or lighter particles (<325 mesh) in a dropout system. 
     
     
         12 . The method of  claim 8 , comprising the further step of separating the heavier, coarser grinder throughput from the finer particles by an air classifier, and collecting any additional finer particles. 
     
     
         13 . The method of  claim 5 , comprising the further step of mixing the fine powder with a modifying additive that will modify the growth of tetrabasic lead sulfate and/or promote the growth of other small lead salt crystals, where the low-density porous lead salt particles act as a carrier for the modifying additive. 
     
     
         14 . The method of  claim 13 , wherein the modifying additive is provided in an aqueous solution, and comprising the further step of suspending the fine microporous powder of lead salts in the aqueous solution, boiling the solution to expel air from the pores of the fine powder, and wherein heating is continued until the water is driven off and the modifying additive is dispersed substantially within each microporous grain. 
     
     
         15 . The method of  claim 13 , wherein the modifying additive is selected from the group comprising borax and other combinations of an alkaline anion with a suitable cation such as borates, phosphates, acid phosphates, silicates or fluoborates. 
     
     
         16 . A method of making a battery paste, comprising the steps of mixing a conventional battery paste comprising leady oxides, water and sulfuric acid with a nucleant material for tetrabasic lead sulfate and with the fine porous powder and modifying additive of  claim 13 . 
     
     
         17 . The method of  claim 16 , wherein the nucleant material is mixed intimately with the oxide at the start of paste mixing and the fine porous powder and modifying additive is added near the end of paste mixing, after acid addition is complete. 
     
     
         18 . The method of  claim 16 , wherein the nucleant is added after mixing leady oxide with water, before acid addition and mixture, and the fine porous powder which contains the modifying additive is added at the end of acid addition and before final mixing. 
     
     
         19 . A method of making a battery plate, comprising the steps of making the battery paste of  claim 16 , applying the paste to battery plate grids and curing the paste at >70° C., such that tetrabasic lead sulfate crystals are grown that are more numerous and/or smaller than would be grown without the fine porous powder and modifying additive. 
     
     
         20 . A method of making a battery paste, comprising the steps of making the battery paste of  claim 16 , applying the paste to battery plate grids and curing the plates at <70° C. such that no or limited secondary nucleation of tetrabasic lead sulfate occurs. 
     
     
         21 . A lead-acid battery, which contains positive and/or negative plates made according to the method of  claim 19 . 
     
     
         22 . A lead-acid battery, which contains positive and/or negative plates made according to the method of  claim 20 . 
     
     
         23 . A composition of matter comprising a microporous inorganic solid mixed with a modifying additive that, in a process for forming lead-containing compounds, will modify the growth of tetrabasic lead sulfate and/or promote the growth of other small lead salt crystals, where the microporous solid acts as a carrier for the modifying additive.

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