# G.H. Johnson & Associates, Inc. — Hazardous Materials Safety Interpretation - **operation:** document - **citation:** 98-0602 - **title:** G.H. Johnson & Associates, Inc. — Hazardous Materials Safety Interpretation - **source type:** guidance - **agency:** Pipeline and Hazardous Materials Safety Administration - **status:** guidance - **official:** true - **published on:** 1998-04-17 - **effective on:** Not available - **summary:** 98-0602 response to G.H. Johnson & Associates, Inc. concerning 173.159. - **machine formats:** - **json:** https://regulus.evalyn.ai/document/phmsa-interpretation-98-0602.json - **markdown:** https://regulus.evalyn.ai/document/phmsa-interpretation-98-0602.md - **app url:** https://regulus.evalyn.ai/document/phmsa-interpretation-98-0602 - **source url:** https://www.phmsa.dot.gov/sites/phmsa.dot.gov/files/legacy/interpretations/Interpretation%20Files/1998/980602.pdf **body:** <<>> • U.S. Department of Transportation Washington, D.C. 400 Seventh Street, S.W. 20590 Special Programs Research and Administration APR 1 7 1998 Mr. James A. Noone G.H. Johnson & Associates, Inc. 1211 Connecticut Avenue, N.W., Suite 302 Washington, D.C. 20036-2603 Dear Mr. Noone: This is in response to your letter of March 25, 1997, requesting clarification on the shipping requirements for batteries manüfactured by your company under the provisions of the Hazardous Materials Regulations (HMR; 49 CFR Parts 171-180). Specifically, you ask if your batteries are subject to the HMR. The information you provided demonstrates that your batteries are constructed in such a manner that the sulfuric acid electrolyte is completely sealed and cannot leak even if the battery is cracked open or punctured. In addition, the sulfuric acid electrolyte is absorbed in a fibrous glass separator. Thus, your batteries appear to meet the criteria for non-spillable batteries in § 173.159(d). When securely of the Hazardous Materials Regulations. packaged and protected against short circuits, non-spillable batteries are not subject to the provisions In addition, under the International Civil Aviation Organization's (ICAO) Technical Instructions for the Safe Transport of Dangerous Goods by Air, special provision A67, a non-spillable battery is considered to be non-regulated if, at a temperature of 55°C, the electrolyte will not flow from a cracked or ruptured case. I hope that this information is helpful. If you need further assistance, please contact us. Sincerely, i Chich Re Baliness Chief, Regulations Development Office of Hazardous Materials Standards <<>> G. H. Johnson & Associates, Inc. Government and Military Marketing Representatives for: OPTIMA S BATTERIES 113. THE ULTIMATE POWER SOURCE 127. March 25, 1998 J. Suzanne Hedgepeth Director Office of Hazardous Materials Exemptions and Approvals Office of the Associate Administrator For Hazardous Materials Safety Research and Special Programs Administration Department of Transportation 400 Seventh Street, SW Washington, DC 20590 Re: Request for Determination Dear Ms. Hedgepeth: I am writing to seek an updated determination from the U.S. Department of Transportation ("DOT") that batteries manufactured by OPTIMA Batteries, Inc. ("Optima"), of Aurora, Colorado, are not subject to the Hazardous Materials Regulations and, therefore, can be shipped commercially by air and surface means without restriction. Optima utilizes a spiral design for battery cells that was originally developed by The Gates Rubber Company ("Gates") of Denver, Colorado. The technology was invented by Gates in the 1970s, and commercial production began in 1987 under the Optima name. In 1990, Optima was incorporated as a division of Gates. In 1992, Optima was purchased from Gates by The Gylling Group of Scandinavia, the current parent company. This history of Optima is outlined in "The Optima Manual," Attachment A. In 1981, in response to a request by Gates, the Research and Special Programs Administration ("RSPA") of DOT informed Gates that because of the sealed design of the batteries eventually to be sold under the Optima name, such batteries were not subject to the Hazardous Materials Regulations. See Attachment B, letter of February 18, 1981, from Joseph T. Horning, Chief, Regulations Development Branch, Office of Hazardous Materials Regulations, Materials Transportation Bureau, RSPA. Colorado Office 270 Tahosa Road South, POB 457 Washington Office Alienspark, CO 80510-0457 1211 Connecticut Avenue, N.W., Suite 302 Tel: (303) 747-2065 Fax: (303) 747-2915 Washington, D.C. 20036-2603 E-mail: ghjassoc@mci2000.com Tel: (202) 466-7336 Fax: (202) 955-5879 E-mail: kn1211conn@aol.com <<>> Optima would like to obtain a current determination by the appropriate DOT office that its battery is not subject to the Hazardous Materials Regulations and is authorized for shipping by commercial means. So that a proper evaluation may be done pursuant to this request, I am enclosing the following additional materials: One-page promotional sheet showing technical specifications (Attachment C) A current Material Safety Data Sheet (MSDS), most recently revised on December 5, 1997 (Attachment D) Letter of June 2, 1995, from the International Air Transport Association ("IATA") confirming that Optima batteries are not regulated by the IATA Dangerous Goods Regulations (Attachment E) As explained in substantial detail in these attachments and in Attachment A, the Optima battery is completely sealed. In addition, the sulturic acid electrolyte is absorbed in a fibrous glass separator material. Because of the design and construction, acid cannot leak even if the battery were to be punctured.: For your information, we have been in communication with the U.S. Postal Service ("USPS) in recent weeks with respect to a determination that the Optima battery can be shipped by the USPS as a non-hazardous product. We have been advised that USPS is in the process of revising its regulations to reflect such a determination. We will forward documentation reflecting this change as we receive it from USPS. We would very much appreciate your expeditious consideration of this request. Please use the undersigned as the point of contact in the Washington Office of Johnson Associates/Optima: (202) 466-7330 (P); (202) 955-5879 (F). As indicated on this letterhead, the mailing address is: G.H. Johnson & Associates, Inc./OPTIMA Batteries, Washington Office, 1211 Connecticut Avenue, NW, Suite 302, Washington, DC 20036. information. Please do not hesitate to contact me should you require additional technical or other Sincerely, Tues Too Macer Washington Representative JAN: dkt 2 <<>> S - ОРІШМА SPIRALCELL" TECHNOLOGY BATTERIES THE ULTIMATE STARTER 7 дат: 800S ONLY OPTIMA's 800U 850/6 SPIRALCELL TECHNOLOGY™ OFFERS ALL THESE BENEFITS: available. Our patented SPIRALCELL Technology OPTIMA is the most advanced engine-starting battery provides many features and benefits not found in LONGER SHELF LIFE. conventional automotive batteries: With its low rate of self discharge, the OPTIMA can go is ideal for boats, farm equipment, collector cars, and unused for up to a year without recharging. The OPTIMA FASTER, CRISPER STARTS. power for faster, crisper starts. The 800U and 800S 12- The OPTIMA's SPIRALCELL Technology provides more other seasonal equipment. volt models deliver 800 Cold Cranking Amps at 0°F. FASTER RECHARGE. allow the OPTIMA to be recharged in less time than Greater plate surface area and lower internal resistance In performance tests, the OPTIMA lasted three to five LONGER BATTERY LIFE, GREATER SAVINGS. conventional automotive batteries. times longer than conventional, flat-plate batteries. FAST ENERGY RESPONSE. Electrolyte in the OPTIMA is completely absorbed. It COMPLETELY SEALED. faster when demanded by accessories such as stereos, The OPTIMA's low internal resistance provides power can't leak even if the battery is cracked open. This means winches, etc. the OPTIMA is safer for people, equipment, and the environment. BETTER RECOVERY FROM DISCHARGE. UNEQUALED VIBRATION RESISTANCE. Vibration is a primary killer of conventional batteries. vibration, and eliminates plate shedding. OPTIMA's tightly wound SPIRALCELL resists jarring and UNIVERSAL SIZE & FIT. The OPTIMA fits a wide variety of cars, trucks, and other equipment. The OPTIMA can be mounted in any position Tests prove the OPTIMA performs better in extreme cold MORE POWER IN ANY CLIMATE. - even upside-down. and hot temperatures than conventional lead-acid batteries of similar size. OUTSTANDING WARRANTY. Thanks to recombinant technology, absorbed electrolyte, ZERO MAINTENANCE / NO CORROSION Because the OPTIMA is built for some of the roughest warranties. See an OPTIMA dealer for complete warranty conditions, it's backed by one of the best automotive and sealed construction, the OPTIMA won't corrode details. battery terminals, cables, or the vehicle. And the OPTIMA never needs to have water added. OPTIMA Batteries, Inc. / 17500 E. 22nd Avenue / Aurora, CO 80011 / Phone (303) 340-7440 / Fax (303) 340-7474 Gylling Group of Scandinavia -- Established 1912 PN 06-1001 3/96 <<>> OPTUMA BATTERIES TECHNICAL THE ULTIMATE STARTER 800U 800S 850/6 INFORMATION Voltage PERFORMANCE RESEALABLE PRESSURE ERO-MAINTENANCE RELIEF VALVES TERMINALS Reserve Capacity Cold Cranking Amps 800 12 800 12 6 Capacity (C/20 rate) 120 min. 56 Amp Hours 120 min. 120 min 850 DIMENSIONS 56 Amp Hours 56 Amp Hours Length Height Width 915/16 Dual SAE & GM 39.5 Ibs. 7 13/16" 6 7/8" 915/16 7 13/16" 6 3/4" 9 29/32" 3 3/8" Type Post/Terminal Weight SAE Post 39.0 Ibs. 7 13/16 20.0 Ibs. BCI Group 34 34 SAE Post N/A Cranking Amperes vs. Temperature HEAVY-DUTY 1200 Amperage CAST-ON STRAPS 1000 CONSTRUCTION & RUGGED SPIRALCELL 800 CLOSE PLATE SPACING .. RESISTANCE & HIGHER SUPERIOR VIBRATION 600 POWER 400 200 GLASS SEPARATOR MICROPOROUS LEAD GRIDS HIGH-PURITY - 150F 0°F 20°F 32°F 40°F 60°F 80°F Temperature (OF) Charging Data Self Discharge Vehicle Charge: Voltage regulation - 13.8 to 14.4 Volts Voltage @ 74º Degrees F Normal Charging: : Voltage - 13.8 to 14.8 Volts Maximum Time - 6-8 hours Maximum Current - 10 Amps 13.0 12.8 Float Applications: Voltage - 13.2 to 13.8 Volts Maximum Time - Indefinite Maximum Current - 1 Amp 12.6 12.4 (at lower charge voltages) Boost Recharge: Voltage - 15.6 Volts (Regulated) 12.2 Maximum Current - 60 Amps Maximum Time - 1 hour 12.0 50 Duration (days) 100 150 200 NOTE: Charging systems should be voltage regulated. Warranty Information YOUR DEALER / DISTRIBUTOR (72 month) Consumer car/truck maining 48 months pro-rati No year replaceme (36 month) Commercial emaining 24 months pro-rate ne year replacemen 4 mont ar stereo/racir mainina 12 months pro-rat le year replaceme Abusive service Determined on individual basis OPTIMA Batteries, Inc. / 17500 E. 22nd Avenue / Aurora, CO 80011 / Fax (303) 340-7474 Phone (303) 340-7440 Gylling Group of Scandinavia -- Established 1912 <<>> Material Safety Data Sheet BATTERIES Number: OBI-0001 B Issue Date: 02/20/90 THE ULTIMATE POWER SOURCE™ Revision Date: 12/05/97 Section 1 - Material Identification Product Name: Sealed Lead Acid Battery Common Synonym: Automotive Battery UN Number: UN2800 (See Section 16 for additional information) Engine Starting Batteries Battery Model No. National Stock Number (NSN) 800U 6140-01-374-2243 800S 6140-01-378-8232 1000M 6140-01-441-4280 850/6 Not Available Deep Cycle Batteries Battery Model No. D750U National Stock Number (NSN) 6140-01-441-4272 D750S Not Available D900M Not Available Company Information Emergency Phone Number Optima Batteries, Incorporated Chemtrec 17500 E 22^d Avenue United States: 800-424-9300 Aurora, Colorado 80011 (303) 340-7400 International: 703-527-3887 Cage Code OUJ55 (collect) The OPTIMA sealed lead acid battery is considered an article as defined by 29 CFR 1910.1200( c) OSHA Hazard Communication. The information on this sheet is supplied at the customer's request for information only. Emergency Overview: Exposure not expected for product under normal conditions of use. In its manufactured and supplied state, the product is considered non-hazardous. Keep away from flames during and immediately after charge. No significant health effects are associated with the product. Section 2 - Composition Hazardous Components Material % by weight or volume CAS Number Lead Compounds 63 - 81 7439-92-1 Sulfuric Acid Electrolyte 17 - 25 7664-93-9 Case Matl Polypropylene 2-6 9003-07-0 Separator/Paster Paper Fibrous Glass 1-4 65997-17-3 Section 3 - Hazards Rating The Hazards rating for the Sealed Lead Acid Battery are: Hazards Rating (HMIS System) Health Flammability 0 Reactivity <<>> Section 4 - Hazards Identification Potential Health Effects None expected for finished product under normal conditions of use. Fire and Explosion The sealed lead acid battery is not considered flammable, but it will burn if involved in a fire. Short circuit can also result in fire. Evacuate area. Self-contained breathing apparatus must be worn to prevent possible inhalation of acid mists, smoke and decomposition products in a fire. Remove all ignition sources. Cool battery(s) to prevent rupture. Section 5 - First-Aid Inhalation - Not expected for product under normal conditions of use. However, if acid vapor is released due to overcharging or abuse of the battery, remove exposed person to fresh air. If breathing is difficult, oxygen may be administered. If breathing has stopped, artificial respiration should be started immediately. Seek medical attention. Eyes - Exposure not expected for product under normal conditions of use. However, if acid from broken battery case enters eyes, flush with water for at least 15 minutes. If irritation develops, seek prompt medical attention. Skin - Exposure not expected for product under normal conditions of use. However, if acid contacts skin, flush with water and mild soap. If irritation develops, seek medical attention. Ingestion - Not expected due to physical form of finished product. However, if any materials are ingested, seek prompt medical attention. Section 6 - Fire-fighting Measures Extinguishing media - Multipurpose dry chemical or multipurpose CO2. Fire fighting procedures - Evacuate area. Self-contained breathing apparatus must be worn to prevent possible inhalation of acid mists, smoke and decomposition products in a fire. Remove all ignition sources. Cool battery(s) to prevent rupture. Unusual fire and explosion hazards - Hydrogen gas may be produced and may explode if ignited. Remove all ignition sources. Ventilate area. Section 7 - Accidental Release Measures Spill or leak cleanup procedures: Avoid contact with acid materials. Use soda ash, baking soda or lime to neutralize acid if released Waste disposal: Dispose of in accordance with all local, state, and federal regulations. Handling - Do not carry battery by terminals. Do not drop battery, puncture or attempt to open battery case. Keep away from flames during and immediately after charge. Avoid prolonged Storage - Store at ambient room temperature. Do not subject product to open flame or fire. Avoid conditions which could cause arcing between battery terminals. Hygiene - Wash hands thoroughly before eating or smoking after handling batteries. Section 9 - Exposure Control Material Lead compounds Exposure Limits Sulfuric Acid Electrolyte 0.05 mg/m.3 1.00 mg/m3 OSHA 2 • <<>> - Section 10 -Personal Protection: Eye: Not necessary under normal conditions of use for finished product. Skin: Not necessary under normal conditions of use for finished product. Respiratory: Not necessary under normal conditions of use for finished product. Ventilation: Not necessary under normal conditions of use for finished product. Work Practices: Not necessary under normal conditions of use for finished product. Section 11 - Physical and Chemical Properties Boiling Point: N/A Appearance/Odor: Vapor Pressure: N/A N/A Specific Gravity (H2O=1): Vapor Density (air=1) N/A Melting Point: N/A Solubility in water: N/A Evaporation Rate: N/A N/A (Butyl Acetate = 1) Section 12 - Stability and Reactivity Stability: Stable Conditions to avoid: Avoid shorting, use only approved charging methods. Do not Hazardous reactions: puncture battery case N/A Decomposition Products: N/A Hazardous Polymerization: Will not occur Section 13 - Toxicological Information Threshold limit value: Not applicable for finished product. Route of entry: Not applicable for finished product under normal conditions of use. Signs of symptoms of acute exposure: None expected for finished product under normal conditions of use. Chromic Exposure: None expected for finished product under normal conditions of use. Medical Conditions aggravated by exposure: None expected for finished product under normal conditions of use. Effects of overexposure, conditions to avoid: No exposure expected for finished product. However, do not puncture or open battery case. Acid electrolyte may be released. Use only standard charging methods. If overcharged, battery may release gases (Hydrogen and oxygen). Carcinogen listing: NTS: no IARC: no OSHA regulated: NA for finished product under normal conditions of use. Section 14 - Disposal Considerations Send to a lead recycling facility which follows applicable Federal, State and Local regulations for routine disposition of spent or damaged batteries. The distributor / user is responsible to know that "spent" and/or "damaged" batteries (scrap batteries) are disposed of in an environmentally sound way in accordance with all applicable Federal, State, and Local Environmental Regulations. OPTIMA batteries are 100% recyclable by any licensed reclamation operation. Section 15 - Regulatory Information According to the OSHA Hazard Communication Standard, Sealed Lead Acid Battery in its manufactured and supplied state is considered non-hazardous. Transportation: Sealed Lead Acid Battery is not a DOT Hazardous Material. 3 <<>> Section 16 - Supplemental Information Under the Dangerous Goods Regulations, 34" Edition, Effective 1 January 1993, produced by International Air Transport Association (IATA): OPTIMA batteries are classified as non- regulated by special provisions A-48 and A-67 for UN Number of UN2800: Batteries, wet, non- spillable, electric storage: A-48: Packaging tests are not considered necessary. A-67: Non-spillable batteries are considered to be non-dangerous if, at a temperature of 55°C (130°F), the electrolyte will not flow from a ruptured or cracked case and there is no free liquid to flow and if, when packaged for transport, the terminals are protected from short circuit. The manufacturer of this finished article cannot foresee every possible use or misuse of the product. However, the following information is supplied: In its manufactured and supplied state, the product is considered non-hazardous. Excessive overcharging or abuse to the terminals can result in the release of gases (hydrogen and oxygen). As a general practice, batteries should not be used in enclosed, non-ventilated spaces. Avoid immersion in water as it may lead to hydrogen generation. If the battery is crushed in a collision or similar accident, the absorbent separator may be squeezed causing the release of a small amount of acid electrolyte. Neutralize the acid electrolyte with baking soda and flush with plenty of water. Under the Code of Federal Regulations #49, October 1, 1994 Edition, OPTIMA batteries are classified as an exception from all other requirements or conditions as stated in the following areas: Batteries, wet, 173.159 (d)(3)(i) and (d)(3)(i)(i). (d)(3)(i): vibration test (d) (3)(1)(i): pressure differential test These conditions have been tested and certified by the following: Energy Research Laboratory Information is on file at main company location. (ERL A/S), Batteritest Laboratory, Munkebjergvaenget 13, DK-5230, Odense M. Denmark. The information and recommendations contained herein have been compiled from sources believed to be reliable and to represent current knowledge on the subject. No warranty, guarantee, or representation contained herein and OPTIMA Batteries, Inc., its subsidiaries or affiliates assume no responsibility in connection therewith, nor can it be assumed that all acceptable safety measures are contained herein, or that other or additional measures may not be required under particular or exceptional conditions or circumstances. 4 <<>> _LULODUL the OPTIMA MANUAL <<>> the OPTIMA MANUAL OPTIMA BATTERIES THE ULTIMATE STARTER <<>> TABLE OF CONTENTS SECTION TOPIC PAGE Table of Contents........ ..i Introduction.. ... 1 2 The OPTIMA Manual....... 3 ...2 History of the OPTIMA Battery.. ....3 4 OPTIMA Concept and Design.. 5 4 Summary of Features and Benefits. 5 6 Understanding the OPTIMA Technology... .. 6 7 OPTIMA Versus Conventional Batteries.. 8 ....9 The OPTIMA: Features, Functions, Benefits 9 .. 13 The OPTIMA Battery: Applications and Advantages. ..23 Quick Reference Customer Benefit Chart ..28 10 Inappropriate Uses of OPTIMA S.L.I. Batteries. .... 11 ..29 Quality Control in Action - The Bitrode/Finishing Line ..30 12 Rating of S.L.I. Batteries (Starting, Lighting, Ignition)...... 13 .31 Basic Battery Technology and Terminology.. ..32 A. What is a Battery?.... ..32 B. Various Types of Batteries.. ..33 C. What Happens Inside a Lead-Acid Battery?... ..34 D. Types of Lead-Acid Batteries.. 36 14 Charging Procedures........ 37 A. Charging with an Alternator/Generator. 38 B. Charging with an External Charger.. ...38 C. Recommended Charging Limits for OPTIMA Batteries ......39 D. Problems Caused by Incorrect Charging Procedures. ...39 Appendix A: Glossary........... 41 <<>> THIS PAGE INTENTIONALLY LEFT BLANK August 14, 1996 <<>> 1. INTRODUCTION The OPTIMA battery represents a new standard for the automotive S.L.I (Starting, Lighting, Ignition) market. Its superior starting ability, high reserve capacity, long life, safety, and versatility make it outstanding for a wealth of uses. One customer recently praised it as "the most dependable, lowest maintenance battery on the market today." What makes the OPTIMA unique? Its SPIRALCELL, sealed design provides more power for faster, crisper starts at any temperature. It outperforms flat plate batteries by three to one. The OPTIMA delivers an amazing 800 cold cranking amps for the 12 volt 800S and 800U models. Completely sealed, the OPTIMA is maintenance-free; it is much safer than conventional batteries since it cannot spill or leak. Its tightly-wound spiral elements resist jarring and vibration, making the OPTIMA an ideal choice for almost any application or equipment. Introduced in 1984, the OPTIMA is the result of nearly 20 years of research and development. Originally developed by the Gates Rubber Company of Denver, Colorado, OPTIMA Batteries, Inc. is now owned by Gylling OPTIMA Batteries, A.B. of Stockholm, Sweden. All OPTIMA batteries are manufactured at the company's Colorado facility in Aurora. OPTIMA batteries are sold wholesale to distributors throughout the U.S. and abroad. in a wide range of applications including: While originally designed for the automotive S.L.I market, OPTIMA batteries are finding acceptance Commercial fleets - passenger cars, light trucks, vans, utility vehicles • Private automobiles, light trucks and vans • Diesel-powered vehicles - light and medium sized trucks • Agricultural, forestry and construction equipment - tractors, harvesters, dump trucks, water trucks, generators, fork lifts, skid loaders Marine starting applications - fishing boats, house boats, sail boats, ski boats • Collector and specialty vehicles - antique cars, show cars, custom cars, street rods, lowriders Motor sports and racing cars Car audio systems • Military Aerospace Ground Support Equipment (AGE), generators, and military vehicles This manual is a complete reference source regarding the OPTIMA's design, technical specifications, features, benefits, applications, warranty and more. Please contact us at 303-340-7440 (phone) or 303-340-7474 (fax) with any questions you many have about the OPTIMA battery. 1 August 14, 1996 <<>> 2. THE OPTIMA MANUAL in representing OPTIMA batteries. This manual is your source for reference, background information, and tools to enhance your success REFERENCE: Use this manual as a reference tool. You'll find the answers to most questions in "The OPTIMA Manual. " We've included summaries of features, functions, and benefits; specifications; applications; basic battery technology; warranty procedures; a glossary; and more. BACKGROUND INFORMATION: Learn about the OPTIMA battery, its advantages, and how it compares to conventional battery for so many applications. We've included a time line describing the battery's development. This technology. We start by explaining the new OPTIMA technology, describing why it is superior manual also covers basic battery technology, terminology, and testing procedures. TOOLS: Understand the OPTIMA technology and how to apply it to applications. Testimonial letters that describe how the OPTIMA battery is saving customers time and money are available. 2 J August 14, 1996 <<>> 3. HISTORY OF THE OPTIMA BATTERY 1973 Gates Rubber Company, one of the world's largest producers of rubber products for the automotive industry, develops the initial battery technology incorporating a SPIRALCELL with recombinant technology. The company produces millions of battery cells for tools, appliances, and emergency lighting. i 1983 Gates recognizes the need for an advanced automotive battery. The company begins research and development to further explore the battery technology. 1984 The S.L.I. (Starting, Lighting, Ignition) battery project team is established at Denver, Colorado. 1987 Limited S.L.I. production begins; the first automotive batteries go to market. 1990 Gates incorporates the division as OPTIMA Batteries, Inc. Gylling Teledata A/S of Norway begins limited importation and distribution of OPTIMA batteries. Soon after, Gylling obtains distribution rights for all of Scandinavia. 1991 Gates divests itself of OPTIMA Batteries, Inc. 1992 The Gylling Group of Scandinavia purchases OPTIMA Batteries, Inc. from Gates. 1993 Public demand for the OPTIMA battery begins to rapidly increase. 1994 OPTIMA Batteries, Inc. breaks ground for a new, larger, modern manufacturing facility in Aurora, Colorado. 1995 OPTIMA Batteries Inc. moves into its new headquarters in Aurora, Colorado. Sub-contract with General Motors is signed to develop a monoblock battery for their hybrid vehicles. 1996 Full production begins at new facility and sales efforts expand throughout the North and South America as well as world-wide. August 14, 1996 <<>> OPTIMA CONCEPT AND DESIGN Lighting, & Ignition) battery. Several parameters were of critical importance during the design of the OPTIMA S.L.I. (Starting, What requirements were crucial for the design of the OPTIMA battery? Capability High power for quick, sure engine starts. (Performance) • Ample electrical reserve capacity. V Safe to operate. v Compact in size and weight compared to traditional Construction S.L.I. batteries with similar output. r Compatible with most vehicles. v Operates in any position or orientation, even upside down. No spillage even if the case is cracked. r Recyclable. v Truly zero maintenance. Maintenance V Low self discharge rate for a long shelf life. r Long operational life. v Rapid charge (recharge) rate. Resilience Dependable even in extreme hot and cold temperatures. • Resistant to vibration, impact, and jarring. The OPTIMA battery, with significantly fewer parts, appears to be simple in design when compared to traditional battery construction. Still, it is a very complicated battery to mass produce. Not only is the design unique, but most of the manufacturing equipment had to be specially designed and built to produce the OPTIMA. 4 August 14, 1996 <<>> 5. SUMMARY OF FEATURES AND BENEFITS • SUPERIOR STARTING CAPACITY. The OPTIMA delivers 800 Cold Cranking Amps (C.C.A.) for the 800S and 800U models and 850 C.C.A. for the 6 volt battery (CCA is measured @ 0ºF or -18°C). The 1000M marine starting battery is rated at 1000 Cranking Amps (CA is measured @ 32°F OI 0°C). CANNOT CRACK DUE TO FREEZING. OPTIMA's unique separator material allows for expansion in the event of freezing. ZERO MAINTENANCE. Completely sealed. There is no venting to corrode the terminals, connectors, battery tray, or surrounding equipment. Customers never need to add water. EASY TO TRANSPORT. Because the OPTIMA battery is considered non-hazardous/now-dangerous, it can be shipped by air. FASTER RECHARGE. Recharge in less time due to low internal resistance and tight plate spacing. FITS MOST VEHICLES AND EQUIPMENT. HANDLES ABUSIVE TEMPERATURES. Operates effectively in extreme hot or cold temperatures. HIGH RESERVE CAPACITY. OPTIMA has a reserve capacity of 120 minutes. LONGER SHELF LIFE. After one year it will start most engines. Total shelf life is 2 years or more. MUCH SAFER. location and is less likely to explode. Absorbed electrolyte, no free acid to spill or leak. The OPTIMA can be installed in any OUTLASTS CONVENTIONAL BATTERIES. OPTIMA. The high purity lead grids minimize plate corrosion and plate deformation in the RESISTANT TO VIBRATION. Tightly-wound SPIRALCELL ™ resists jarring, vibration, and shedding of the active paste material. •. VERSATILITY OF INSTALLATION. OPTIMA can be installed in any orientation, even upside down. 5 August 14, 1996 <<>> 6. UNDERSTANDING THE OPTIMA TECHNOLOGY, conventional battery. To better understand the OPTIMA battery, let's compare it to the design and construction of a i in approximately 100 years. Traditional batteries are constructed with about 120 different parts and have undergone little change TERMINAL TAPERED POSTS VENT PLUGS THROUGH THE CONNECTORS PARTITION COVER -POST STRAP -PLATE LUGS POSITIVE PLATE ENVELOPE SEPARATORS : CONTAINER ELEMENT RESTS SEDIMENT SPACE Figure 1 CONVENTIONAL FLAT PLATE BATTERY 6 J August 14, 1996 <<>> The OPTIMA battery requires only 30 components; this means there is less opportunity for failure. Four letion origin. The scle pete are separated b injection-molded case. The cells are electrically connected with thick cast lead intercell straps. The design greatly reduces the potential for mechanical failure. electrolyte is injected and totally absorbed within the separator material between the plates. This unique pressure valve Resealable Corrosion-free/Zero maintenance terminals Minimal free space Heavy cast-on straps Individual cell chambers Sealed plastic case Starved electrolyte design Microporous glass separator Thin, high-purity grids Figure 2 OPTIMA SPIRALCELL BATTERY DESIGN 7 August 14, 1996 <<>> THIS PAGE INTENTIONALLY LEFT BLANK : August 14, 1996 : <<>> OPTIMA VERSUS CONVENTIONAL BATTERIES 21Z PLATE/ GRID CONSTRUCTION S OPTIMA Conventional battery design High purity lead plates are used to make the grid for cells of the OPTIMA battery. Two long In conventional batteries, each cell contains a series continuous bands of grid are wound into a tight of short flat grids. Materials such as antimony and spiral configuration then pressure inserted into calcium are added to the grids to improve strength individual cylinders within the case. This design and stiffness needed for manufacturing. These alloys provides the cell's mechanical strength, eliminating can increase plate corrosion, self discharge, internal the need for alloys in the lead. resistance, and promote shedding of the active material (lead paste applied to grid). Using unalloyed lead extends the life of the OPTIMA grid will resist corrosion and last longer OPTIMA battery by reducing grid corrosion. The As a result, the battery loses capacity and power. With age, the grids shed their active paste material. in high temperature environments. engines are harder to start and in cold temperatures. This power loss becomes especially noticeable when While conventional batteries are adversely affected by heat, the effects of heat on a high purity lead Using alloys in the grid sacrifices performance for OPTIMA battery are minimal. and paste adherence but lowers electrical strength. For example, antimony improves castability internal resistance. This low resistance allows the The use of high purity lead contributes to the low conductivity and increases the rate of self discharge and gassing. to meet the demands of vehicle electrical systems OPTIMA to deliver high amounts of power quickly When a conventional battery is stored for long and on-board electronic components. periods without recharging, the alloys in the grid corrode. This shortens the battery's life considerably. Another advantage of using the high purity lead is a low self-discharge rate. The alloys in conventional material and the grid, causing a loss of electrical batteries accelerate the reaction between the active charge. (See Figure 2) (See Figure 1) August 14, 1996 <<>> CELL DESIGN OPTIMA Conventional battery design Individual cells of the OPTIMA contain only two purity lead plates are wound into a tight spiral, and plates, one positive and one negative. These thin high The cell of a conventional battery contains several plates connected together and suspended in a pool of separator is very thin, allowing for closer plate are separated by an absorbent glass material. The electrolyte. Alloys are added to the lead grid to increase its strength and stiffness. Stiffness and the flow of current and lowers the internal resistance. spacing. The close proximity of the plates enhances strength are required for the plates to retain the active material during operation and to make the plates The porous separator material retains the electrolyte easier to work with during manufacturing. like a sponge, preventing the active material on the plates from drying out. intribute to corrosion, higher internal resistance at hile the alloys add strength to the grid, they al The tightly wound spiral allows the use of a very thin shedding of active grid material. more winds in the spiral. This increases the amount of Using thinner plates allows surface area in the cell, thus boosting the amount of Sufficient space between the plates in the cell is power generated from the battery. The plate surface electrical shorts. This material falls from the plates required for shedding of the active material to prevent similar size conventional battery and utilizes almost area of an OPTIMA cell is much larger than that of a and accumulates at the bottom of the case. the full height of the container. The extra space results in a larger battery with higher After the cell is wound, it is pressure-inserted into an internal resistance and lower energy density (energy individual cylinder chamber with a tight interference per pound) than the OPTIMA. fit. This design increases the strength of the cell and prevents the active paste from falling off or shedding. material throughout the life of the battery. When a The flat, suspended grids cannot retain the active lead The tightly wound cell resists vibration. There is no conventional battery is used in harsh conditions such free space between the plates. This prevents as high temperatures or high vibration, shedding of movement of the plates which causes plate to plate the active material increases. This causes a loss in shorting and shedding of the active material. battery power and capacity which leads to battery failure. Typically, the battery fails due to loss of active material or plate to plate shorting. 10 August 14, 1996 i <<>> ELECTROLYTE: OPTIMA • Conventional battery design The OPTIMA battery is an absorbed electrolyte, gas recombinant battery. All the electrolyte is A conventional battery is a flooded system. Flooded material between the plates in the SPIRALCELL. absorbed (like a sponge) within the separator the level of the plates. This excess electrolyte is required means that there is excess electrolyte in the battery above to prevent the plates from drying out, which causes The electrolyte consumes approximately 95% of sulfation of the active material. This leads to a failure of the voids in the separator material. The remaining the sulfated part of the plate, which reduces the capacity 5% is left as open space for gas passages. of the battery. positive plate combines with the hydrogen at the During the charging procedure, oxygen from the Gases in a conventional battery collect in the free space above the plates; which are then vented from the battery. negative plate to form water which recombines When a battery is overcharged, gassing increases. The can be totally sealed. Since the electrolyte is with the electrolyte. Thus, the OPTIMA battery gases being vented (hydrogen and oxygen) are very combustible. If ignited, they could cause a battery if the case is ruptured or broken. contained within the separator, it cannot leak, even explosion A portion of the vented gas corrodes the battery cables Since the electrolyte cannot escape via leakage, and connectors. This corrosion is often noticeable by the evaporation or venting, the plates will not dry out appearance of a white powder or blue/green fuzz on the and cause loss of capacity. terminals. Because the OPTIMA never needs water and does The conventional battery case must contain vents for vehicle. not vent, it can be mounted anywhere in the gases to escape. If the battery is tipped over or tilted, acid will leak from the vents. If the case is cracked or ruptured, the acid will spill. Loss of the acid will cause should not be installed in an air-tight space. Some Good engineering practices dictate that any battery the conventional battery to fail. The escaped acid can also cause harm to people, equipment, and the charging system fails, causing an abusive ventilation is necessary in case the vehicle's environment. overcharge. Overcharge could cause the OPTIMA's internal safety valves to release some of the pressure within the battery case. If this happens, some of the internal gases would escape. The sealed, no-venting design eliminates corrosion of battery cables, connectors, and vehicle components. August 14, 1996 <<>> i Figure 3 THE OPTIMA SPIRALCELL 12 August 14, 1996 <<>> 8. THE OPTIMA: FEATURES, FUNCTIONS, AND BENEFITS OPTIMA BATTERIES FEATURE FUNCTION BENEFIT 132* Greater plate surface area • Increases starting power. * 800 C.C.A. (cold cranking amps). • Recharges more quickly. SPIRAL Strigger mechanical V Withstands vibration thereby increasing life. • Eliminates shedding of active material. : + Reduces internal shorting. CELL High purity lead grid • Reduces corrosion for longer life. / Lower self discharge. • Lower internal resistance increases DESIGN conductivity for more starting power and. quicker recharging. Thinner plates / grid V Higher C.C.A. means more starting power. V Faster recharging. Closer, consistent plate spacing r More effective chemical reaction increases starting power. / Faster recharging. Reduced battery size V Higher power-to-weight ratio • Produces power equivalent to conventional batteries several times its size. V Fits more vehicles. August 14, 1996 <<>> Charger: Alternátor Power Current Supply HO Absorbed Separator PbO Electrolyte • Pb H2O 02 H2o Figure 4 ABSORBED ELECTROLYTE Figure 4 shows the absorbent separator material wound between the positive and negative plates of the OPTIMA SPIRALCELL. 14 August 14, 1996 - <<>> • • OPTIMA BATTERIES FEATURE FUNCTION BENEFIT Precise quantity of • Fills approximately 95% of the voids in : electrolyte in each cell (computer controlled filling process) sealed battery v Proper distribution of acid for efficient operation and longer life. ABSORBED Absorbent separator ELECTROLYTE material V Allows hydrogen and oxygen gases to recombine into water, making the battery completely maintenance free. & Tightly wound separator material prevents internal shorting between the battery failure. plates, eliminating a common cause of • Voids in the separator material provide expansion capacity in case the battery from cracking. freezes. This helps to prevent the case • No spilling/leaking. Absorbent separator ruptured. retains electrolyte even if case is V Allows use of taller plates to better utilize case height. This results in more plate surface areas and higher power. August 14, 1996 <<>> Figure 5 : The completely sealed OPTIMA recombinant battery prevents electrolyte from escaping. It can be mounted in any orientation, even upside down. 16 August 14, 1996 <<>> OPTIMA BATTERIES FEATURE FUNCT - **truncated:** true - **body characters:** 83409