Dr. Pedro Britto and Carlos Perez

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Presentation transcript:

MOLECULAR REBAR® For Use in Micro-Hybrid Automotive and 2-Wheel VRLA Automotive Dr. Pedro Britto and Carlos Perez Black Diamond Structures, Austin TX USA

Who We Are Black Diamond Structures is a developer, manufacturer, and marketer of innovative nanomaterial products and solutions based on revolutionary carbon nanotube (CNT) technology, MOLECULAR REBAR® “soul of a start up with the resources of a multinational corporation” Our Partners

MOLECULAR REBAR® Technology Key Technical Advantage Bulk Carbon Nanotubes Customer Integration w/ End-Product Detangling/ Separation Formulation - Dispersion Master Batch - Concentrate MR is, again, a novel derivative of CNT, produced by MRD. MRDs competitive advantage is our patented 3 step process… An artifacts of the scale up process Woolen balls No theoretical properties Donate those theoretical properties back ONLY when discrete, ONLY when packaged appropriately MENTION = high impurity rates, EH+S concerns, data generated is similar to carbon, similar size to carbon Mechanical or Structural improvements to Materials (melting points < 500C Tear, impact, toughness and crack improvements (dramatic) Reduced co-efficient of expansion and contraction (dramatic) Improved adhesion and other surface phenomena (dramatic) Strength and modulus combinations with above Transport properties Heat and electrical Ion and molecular transport Electromagnetic fields effects Absorptions and reflection that can be controlled Fields affect MR and MR affects field Fabrication of unique structures due to size and viscosity Thin MR oriented randomly, in transverse plane and planar Multi-layers to take advantage of surface properties Clumps of Dirty, Entangled CNT’s MR in Lead Paste (or other substrates) Clean, Detangled MR Discrete, Individual Tubes

Superior Incorporation in H2O/Acid, PbO Floating Carbon (70%) Carbon in Flux (Moving /) 20% Sunken Carbon (10%) Advanced Carbon MOLECULAR REBAR® uniformly mixes with water and acid in battery paste. Advanced Carbons do not MR is strongly attracted to the lead as automotive-grade lead oxide is added to mixtures of MR and water or acid Advanced Carbons are not MR has most efficient interaction with lead, water, and acid vs competitive carbon offerings MR is a competitive advantage for battery makers Floating Carbon (70%) + 10 g PbO Carbon in Flux (Moving /) (20%) Carbon (10%) Lead Homogenous Mixture 100% Molecular Rebar® + 10 g PbO Cleared Acid Lead/MR (100%)

Not Another Carbon

About us: Product & Packaging Material is shipped as a black pourable liquid which is added directly to the paste mixer for both NEGATIVE & POSITIVE plates MOLECULAR REBAR® products are formulated for ease of use and incorporation Sold in 1,250L Totes, 200L Drums or 10L Jugs. 9 Month Shelf life A volume of pasting water is replaced with the MOLECULAR REBAR® liquid so total liquid volume remains the same 10L Jug Pb2100N Paste Mixer

About us : Products (by Application) NAM Product PAM Product Automotive SLI & Heavy Truck – Conventional Flooded Pb1100N Pb1100P Start/Stop – Enhanced Flooded Pb1200N Pb1200P Advanced Auto - VRLA Pb1300Nx Pb1300Px Motorcycle – VRLA Pb1400N Pb1400P Motive Power eRickshaw - Flooded (Tubular) Pb2100N eRickshaw - Flooded (Flat Plate) Pb2200N eVehicles - VRLA Pb2300N Pb2300P Lift Trucks – Flooded Pb4100Nx Pb4100Px Stationary Inverter - Flooded Pb3100N Solar - Flooded Pb3200N Solar (PSOC)- VRLA Pb3300N Pb3300P Advanced Renewables & Utilities - VRLA Pb3400Nx Pb3400Px Telecom - VRLA Pb3500Nx Pb3500Px Commercial Product / Active Validation

Global Adoption - MOLECULAR REBAR® Technology Products Commercially Available and being sold to Lead Acid Battery Manufacturers across multiple end-use applications Working with >120 battery manufacturers worldwide, each at various stages of development and/or commercial sales. Recent approval for use in major Automotive OEM batteries. (SLI) Have proven that Molecular Rebar can help battery manufacturers meet new OEM requirements for “Advanced Automotive Battery” applications. Extremely large amount of data on full-scale production batteries. Invited to and participating in the CENELEC technical work group (Major Auto OEM’s, large battery MFR’s, limited supplier involvement). Approved to discuss three Mfr’s publicly at this time (Eastman – India, Pacific Battery – Fiji, Tianjin Lantian Power Sources – China) Why the rapid adoption? Technology is innovative, cutting-edge, and scientifically sound Cost effective performance improvements over a wide variety of applications Low risk to use No (or very low) capital expenditure by manufacturer; very easy to use and implement Highly technical staff works hand in hand with your company during ramp up. World-class technical support from Black Diamond Structures

Motorcycle VRLA Batteries: Pb1400 Series Products = Pb1410N & Pb1400P Key Features: Used in Negative or Negative + Positive Electrodes No change to existing paste process or recipe Improved Consistency in Capacity + CCA Throughout Life Extended Cycle Life / Reduced Warranty Failures Increased Electrical Performance Enhanced Plate Strength / Durability Customer approved anonymous release 7Ah VRLA data included

Motorcycle VRLA Batteries: Pb1400 Series Products: Improved & Maintained Cold Cranking Amps Molecular Rebar® provides higher CCA Molecular Rebar® maintains higher CCA throughout life Initial JIS D 5302: CCA Duration 50% DOD OEM Life Cycle Test @ 40⁰C Control 10L Pb1410N 20L Pb1410N Control 10L Pb1410N 20L Pb1410N Need the 20L a different color so doesn’t get confused with NP 1. Discharge for 2 hours @ 2.5X 10-hour rate (50% DOD) 2. Recharge @ 2.5X 10-hour rate with voltage limit of 14.4 V; 5 hours or minimum 108% charge return -Repeat steps (1-2) 15X, Rest 24 hours, perform high-rate discharge at 40°C -Repeat entire sequence for 6X, total of 90 cycles Pb1400 increases CCA Duration 50% increase with 10L of Pb1410N 100% increase with 20L of Pb1410N

Motorcycle VRLA Batteries: Pb1400 Series Products: Improves Capacity Retention & Recharge-ability C10 Capacity Cycling Under Various Charging Protocols MR maintains higher more consistent capacity under all charging protocols Controls cannot recharge under standard JIS charging protocol: MR enables the use of JIS charging in these batteries Combination of Pb1410N & Pb1400P provides a more significant shift in capacity retention than Pb1410N alone Control Pb1410N Pb1400P & Pb1410N

Motorcycle VRLA Batteries: Pb1400 Series Products: Improves Cycle Life (JIS C 8702) Molecular Rebar® extends cycle life by maintaining capacity JIS C8702 C10 Capacity Check JIS C8702 Total Cycles 90% Improvement 20% Improvement Discharge at 1.9 A for 2 hours (~55% DOD) Charge at 2.28 A and 14.1 V for 6 hours Repeat 50x C10 measured every 50 cycles or when voltage drops during cycling

Motorcycle VRLA Batteries: Pb1400 Series Products: Provides More Consistent Microstructure SEM Imagery Post OEM Cycle Life Test Control NAM Pb1410N NAM Control lacks uniformity and has significant crystal growth Molecular Rebar® restricts growth and promotes uniformity

Pb1400 Series Motorcycle VRLA: Customer Testimonial #1 Post ABNT 15941 (similar to JIS D5302 Light Load): CONTROL failed HRD check @ 5,600 cycles Pb1400 never failed and were stopped @ 10,600 cycles C10 post cycling was 4Ah for CONTROL and 5Ah for Pb1400 Customer produced 6Ah Motorcycle VRLA batteries using Pb1400 Series and found 2X Improvement in Cycle Life Pb1400 enabled >10,000 ABNT/JIS Light Load cycles Commercially launched in several high-warranty return product lines using 10L Pb1410N & 34L Pb1400P Added benefit: able to reduce formation time by 25% Optimizing Pb1400 Series loadings for implementation in all of their products to reduce warranty claims and formation time CONTROL – 5,600 cycles Pb1400 – 10,600 cycles MR Plate has higher integrity, even after ~2X cycling Failure mode of CON: Positive Grid Corrosion MR loadings are per 1,000kg oxide batch

Motorcycle VRLA Batteries: Pb1400 Series Products: Summary Products = Pb1410N & Pb1400P Key Features: CCA enhanced initially and maintained throughout cycling Pb1410N dose response: improvement with 20L > 10L Better Charge Acceptance & Capacity Retention Pb1400P with Pb1410N further enhances Life Cycle is Significantly Increased 50% DoD OEM Test JIS C8702 JIS D5302 Light Load Test MOLECULAR REBAR® can be optimized to meet your objectives

Enhanced Flooded Batteries for Start-Stop: Pb1200 Series Product Development Progression Pb1200 Series: New Formulations for PAM & NAM optimized based on Customer & OEM feedback for balanced performance and value. 2014 Performance Focus Micro-Hybrid Cycle Life (SBA & HRPSoC) No Negative Impact to CCA/RC (SAE J537) Charge Acceptance (SAE J537) 2016 Performance Focus Charge Acceptance (SAE J537, EN 50342-6, OEM) Improve CCA (SAE J537, EN 50342-6) Reduce Gassing (EN 50342-6) Durability Cycle Life (EN 50342-6 17.5% & 50% DOD) Pb1200 Series provides balanced performance increases across the following tests: CCA/Capacity Charge Acceptance Durability Life Cycle Tests Micro-Hybrid Life Cycle Tests Gassing Tests -Doubled customer base over the last 12 months -Now working with >70 battery manufacturers worldwide, each at various stages of development and commercialization -Recent approval for use in major automotive OEM batteries -5 dedicated sales and technical teams locally available around the world -10 kg to 50 T capacity through construction of new plant -More than doubled our staff

Enhanced Flooded Batteries for Start-Stop: Pb1200 Series: Formulated for Balanced Performance Pb1200 Series: Actual Customer Production line Produced 12V testing example Pb1200 vs Control Battery Performance Many innovations target improving one aspect of performance, often at the detriment of others. The Pb1200 Series aims to bring a balanced solution to your battery design, enhancing performance to meet your customers’ requirements without compromising existing qualities. J537 Cold Charge Acceptance₃ 1 - EN 50342-6 2 - EN 50342-1 3 - SAE

Enhanced Flooded Batteries for Start-Stop: Pb1200 Series: Enhanced Durability In aggressive, modern cycling tests Pb1200 Series products prevail over control batteries by up to 57% Represents a synergy of charge acceptance enhancements and material strengthening Teardown analyses reveal delayed active material shedding, reduced corrosion and decreased sulfation +57% +46% +44% +68% +56% 50% -/+,17.5 -, 2185 -/+ +23%

Enhanced Flooded Batteries for Start-Stop: Pb1200 Series: More Consistent Active Material Structure After >4 Months of intensive PSOC cycling: CON plates indicate heavy, hard sulfation of various sizes and arrangements across the plate surface Pb1210N decreases sulfate crystal size and frequency to allow the majority of the plate to remain as active sponge lead Plates are noticeably stronger to the touch upon teardown; MR strength benefits retained through life Micrographs at 1000x resolution illustrate Pb1210N’s ability to ensure uniform NAM crystal structure even after > 4 Months of Cycling CON Mid-Life Pb1210N Mid-Life Increased plate strength will likely: Improve battery performance in vibrational tests Delay battery failure when material shedding is a failure mode Interconnections of the molecular rebar

Pb1200 EFB: Summary Pb1200 Series For EFB Enhance: Charge Acceptance EN 50342-6 DCA SAE J537 Charge Acceptance Nissan 90% SOC Recharge Deep Discharge performance Mechanical Durability CCA & Capacity Consistency Cycle life as defined by: EN 50342-6 17.5% DoD EN 50342-6 50% DoD EN 50342-6 MHT SBA S0101 VDA Repetitive Over Discharge VDA Reserve Capacity Durability SAE J2185 Many OEM and Other Specifications Formulated products available for: Automotive Conventional Flooded: Pb1100 Series Enhanced Flooded: Pb1200 Series Advanced Automotive VRLA: Pb1300 Series 2-Wheeler Automotive VRLA: Pb1400 Series Deep Cycle / Motive Flooded for e-Rickshaw: Pb2100 & Pb2200 Series VRLA for Mobility Assistance: Pb2300 Series Stationary Inverter Flooded: Pb3100 Series Solar Flooded: Pb3200 Series Renewables VRLA: Pb3300 Series

Thank you for your attention! Visit us at Booth #xx Our new ISO 9001:2015 Testing Facility! Special Thanks to Our Partners: To support our customers: 16ct 300A channels 48ct 100A channels 64ct 25A channels 1ct 1500A HRD unit Thank you for your attention! Carlos Perez: cperez@bd-structures.com Regional Sales Manager