Pasting paper made of glass fiber nonwoven comprising carbon graphite

Patent metadata

Field	Value
Publication number	US-10084170-B2
Application number	US-201414489140-A
Country	US
Kind code	B2
Filing date	Sep 17, 2014
Priority date	Oct 3, 2013
Publication date	Sep 25, 2018
Grant date	Sep 25, 2018

Abstract

Embodiments of the invention provide an absorptive glass mat (AGM) battery having a positive electrode, a negative electrode, and a nonwoven fiber separator positioned between the electrodes. The separator includes a mixture of glass fibers having diameters between about 8 μm to 13 μm and glass fibers having diameters of at least 6 μm and a silane sizing. An acid resistant binder bonds the glass fibers to form the separator. A wetting component is applied to the separator to increase the wettability such that the separator has or exhibits an average water wick height of at least 1.0 cm after exposure to water for 10 minutes. A conductive material is disposed on at least one surface of the separator such that when the separator is positioned adjacent an electrode, the conductive material contacts the electrode. An electrical resistance of less than 100,000 ohms per square enables electron flow about mat.

First claim

What is claimed is:

1. An absorptive glass mat (AGM) battery comprising:
a positive electrode;
a negative electrode;
a nonwoven fiber mat separator positioned between the positive electrode and the negative electrode, the nonwoven fiber mat separator comprising:
a mixture of glass fibers comprising:
a plurality of first glass fibers having diameters between about 8 μm to 13 μm; and
a plurality of second glass fibers having diameters of at least 6 μm, the plurality of second glass fibers comprising a silane material sizing;
an acid resistant binder that bonds the plurality of first and second glass fibers to form the nonwoven fiber separator, wherein:
the acid resistant binder comprises between about 5% and 45% by weight of the nonwoven fiber mat separator;
the acid resistant binder comprises a carbon-based conductive material;
the acid resistant binder comprises between about 5% and 30% by mass of the carbon-based conductive material;
the carbon-based conductive material is disposed throughout the nonwoven fiber separator so as to contact the positive or the negative electrode;
the nonwoven fiber separator comprises between about 1% and 25% by mass of the carbon-based conductive material, the nonwoven fiber separator having an electrical resistance of less than about 100,000 ohms per square to enable electron flow about the nonwoven fiber separator; and

a wetting component applied to the nonwoven fiber separator to increase the wettability of the nonwoven fiber separator such that the nonwoven fiber separator has or exhibits an average water wick height of at least 1.0 cm after exposure to water for 10 minutes conducted according to method ISO8787.

2. The lead-acid battery according to claim 1 , wherein the mixture of glass fibers comprises between about 10% to 20% of the first glass fibers and between about 60% to 80% of the second glass fibers.

3. The lead-acid battery according to claim 1 , wherein the nonwoven fiber separator has an area weight of between about 100 g/m 2 and about 400 g/m 2 .

4. The lead-acid battery according to claim 1 , wherein the wetting component comprises one or more of cotton fibers, cellulose fibers, or polyester fibers that are bonded with the nonwoven fiber separator.

5. The lead-acid battery according to claim 4 , wherein the one or more of cotton fibers, cellulose fibers, or polyester fibers form a mat that is bonded to at least one side of the nonwoven fiber separator.

6. The lead-acid battery according to claim 4 , wherein the one or more of cotton fibers, cellulose fibers, or polyester fibers are entangled with the mixture of coarse glass fibers to form the nonwoven fiber separator.

7. The lead-acid battery according to claim 1 , wherein the binder comprises a plurality of conductive fibers or conductive particles.

8. The lead-acid battery according to claim 1 , wherein the carbon-based conductive material comprises a plurality of carbon fibers that are entangled with the mixture of coarse glass fibers of the nonwoven fiber separator.

9. A nonwoven fiber separator for an AGM battery, the nonwoven fiber separator comprising:
a mixture of glass fibers comprising:
a plurality of first glass fibers having diameters between about 8 μm to 13 μm; and
a plurality of second glass fibers having diameters of at least 6 μm, the plurality of second glass fibers comprising a silane material sizing;
an acid resistant binder that bonds the plurality of first and second glass fibers to form the nonwoven fiber separator, wherein:
the acid resistant binder comprises between about 5% and 45% by weight of the nonwoven fiber mat separator;
the acid resistant binder comprises a carbon-based conductive material;
the acid resistant binder comprises between about 5% and 30% by mass of the carbon-based conductive material;
the carbon-based conductive material is disposed throughout the nonwoven fiber mat separator so as to contact a positive or a negative electrode;
the nonwoven fiber separator comprises between about 1% and 25% by mass of the carbon-based conductive material, the nonwoven fiber separator having an electrical resistance of less than about 100,000 ohms per square to enable electron flow about the nonwoven fiber separator; and

a wetting component applied to the nonwoven fiber separator to increase the wettability of the nonwoven fiber separator such that the nonwoven fiber separator has or exhibits an average water wick height of at least 1.0 cm after exposure to water for 10 minutes conducted according to method ISO8787.

10. The nonwoven fiber separator according to claim 9 , wherein the nonwoven fiber separator has an area weight of between about 150 g/m 2 and about 300 g/m 2 .

11. The nonwoven fiber separator according to claim 9 , wherein the wetting component comprises cotton fibers having diameters between about 0.5 μm to 3 μm.

12. The nonwoven fiber separator according to claim 9 , wherein the nonwoven fiber separator comprises between about 70% to 95% of the mixture of coarse glass fibers and between about 5% to 30% of the binder.

13. The nonwoven fiber separator according to claim 9 , wherein the mixture of glass fibers comprises between about 10% to 20% of the first glass fibers and between about 60% to 80% of the second glass fibers.

14. The nonwoven fiber separator according to claim 9 , wherein the carbon-based conductive material further comprises carbon fibers that are between about 8 mm to 12 mm in length and having diameters between about 6 μm to 10 μm.

15. The nonwoven fiber separator according to claim 9 , wherein the binder comprises one or more of acrylic, melamine, phenolic, or urea formaldehyde (UF) binders.

16. A method of manufacturing a nonwoven fiber separator for use in a lead-acid battery, the method comprising:
providing a mixture of glass fibers comprising:
a plurality of first glass fibers having diameters between about 8 μm to 13 μm; and
a plurality of second glass fibers having diameters of at least 6 μm, the plurality of second glass fibers comprising a silane material sizing;
applying an acid resistant binder to the mixture of glass fibers to couple the mixture of glass fibers together to form the nonwoven fiber separator; wherein:
the acid resistant binder comprises between about 5% and 45% by weight of the nonwoven fiber separator;
the acid resistant binder comprises a carbon-based conductive material;
the acid resistant binder comprises between about 5% and 30% by mass of the carbon-based conductive material;
the carbon-based conductive material is disposed throughout the nonwoven fiber separator as to contact a positive or a negative electrode;
the nonwoven fiber separator comprises between about 1% and 25% by mass of the carbon-based conductive material, the nonwoven fiber separator having an electrical resistance of less than a about 100,000 ohms per square to enable electron flow about the nonwoven fiber separator; and
applying a wetting component to the nonwoven fiber separator to increase the wettability of the nonwoven fiber separator such that the nonwoven fiber separator has or exhibits an average water wick height of at least 1.0 cm after exposure to water for 10 min conducted according to method ISO8787.

17. The method of claim 16 , wherein the nonwoven fiber separator has an area weight of between about 150 g/m 2 and about 300 g/m 2 .

18. The method of claim 16 , wherein the nonwoven fiber separator comprises between about 10% to 40% of the wetting component.

19. The method of claim 16 , wherein applying the wetting

Assignees

• Johns Manville

Inventors

• Ketzer Michael
• Albert Gerold
• Guo Zhihua
• Nandi Souvik
• Asrar Jawed
• Dietz Iii Albert G

Classifications

• H01M50/403 Primary

  Manufacturing processes of separators, membranes or diaphragms · CPC title

• H01M50/489

  Separators, membranes, diaphragms or spacing elements inside the cells, characterised by their physical properties, e.g. swelling degree, hydrophilicity or shut down properties · CPC title

• H01M50/437

  Glass · CPC title

• H01M2/1613

  Electricity · mapped topic

• H01M2/1686 Primary

  Electricity · mapped topic