EcoSmart Electrolyte Mixing

Our EcoSmart™ lead acid starter batteries obtain their extended life through an innovative, patented internal construction that, without the use of any electro-mechanical devices, causes a constant state of mixing of the liquid electrolyte in the battery while the vehicle is in motion. This increased flow throughout the starter battery eliminates the separation of the electrolyte (water and sulfuric acid), substantially reducing internal corrosion of the lead plates – the primary cause of battery failure – and greatly increasing battery life.  In addition, the constant flow of electrolyte (rather than a separation of the electrolyte causing a decreased reactive productive area) provides greater surface contact between the acid and the lead oxide.  Due to this greater surface area contact, the Company is able to produce cold cranking amps (CCA) equal to or greater than competitor’s starter batteries.

Reducing or eliminating negative influences (such as acid stratification and extreme temperatures) leads to a simultaneous improvement in the lead/acid battery’s overall performance (charging/recharging capability, cold-cranking capacity, cycle stability, service life and so forth). An electronically controlled, active temperature-management system guarantees the battery a superb recharging capacity.

The Effect:

  • Positive balance of charge even in unfavorable conditions (cold, short-trip driving)
  • Battery always maintains a very high SOC
  • Operation that’s easy on the battery

The average starter battery life in the United States is approximately 37 months.  Most automotive batteries fail due to the build-up of corrosion as well as a separation of the electrolyte from its water base thereby reducing the available interactive surface area to maintain an efficient charge.  Within a year of purchase, a typical starter lead/acid battery shows separation of its electrolyte into the following stratification: the bottom 10% to 20% of the area being deposits of corroded active lead oxide material, the middle 40% to 50% of the area being active electrolyte to generate electricity and the top 40% consisting of water.  The corroded material and separated water are non-reactive and are therefore non-power generating. EcoSmart™ products overcome this problem through the use of plastic bridge and pier inserts (shown below) inside the battery causing a meaningful increase in recirculation of the electrolyte as the vehicle is in motion.

The following set of pictures shows the effect of momentum on the battery, causing the electrolyte to circulate up the side of the battery cell wall
(1 & 2) Flow onto the bridge
(3)The bridge’s two holes allow the electrolyte to drop back down over the grids
(4) Completing the circulation cycle.

EcoVolt Advance Mixing Technology

A short multi-media video of our enhanced mixing technology can be seen here:  View Video

Acid stratification puts the stoichiometric, or electrochemical, relationship within a lead/acid battery out of balance. Stratification results in the upper third of the battery containing mostly water, while the bottom third has a greater density of sulfuric acid. This situation has a negative impact on the battery’s performance. On the other hand, permanently eliminating this phenomenon would reestablish an optimal stoichiometric balance, ensure the same level of lead activity throughout the battery and put an end premature corrosion.

EcoVolt’s EcoSmart™ technology is the answer: Simple flow chambers in the battery cells that act as bypasses use the kinetic energy of the vehicle’s motion to actively diffuse, or circulate, the electrolyte, putting a permanent end to stratification. What’s more, it also ensures that warmth is distributed equally throughout the electrolyte. The principle is not dependent on the mounting direction (lateral or tranverse) of the battery in the vehicle.

Major Benefits:

  • No electrical energy needed for mixing the electrolyte 
  • No moving parts
  • Stable electrochemical (stoichiometric) conditions
  • No stratification
  • No sharp drops in temperature
  • Heating causes no hot spots
  • Heat is distributed rapidly in the battery chambers
  • Works independently of the mounting direction in the vehicle