Water loss separators used with lead acid batteries, systems for improved water loss performance, and methods of manufacture and use thereof

Patent metadata

Field	Value
Publication number	US-2016254573-A1
Application number	US-201615054504-A
Country	US
Kind code	A1
Filing date	Feb 26, 2016
Priority date	Feb 26, 2015
Publication date	Sep 1, 2016
Grant date	—

Abstract

In at least select embodiments, the instant disclosure is directed to new or improved battery separators, components, materials, additives, surfactants, lead acid batteries, systems, vehicles, and/or related methods of production and/or use. In at least certain embodiments, the instant disclosure is directed to surfactants or other additives for use with a battery separator for use in a lead acid battery, to battery separators with a surfactant or other additive, and/or to batteries including such separators. In at least certain select embodiments, the instant disclosure relates to new or improved lead acid battery separators and/or systems including improved water loss technology and/or methods of manufacture and/or use thereof. In at least select embodiments, the instant disclosure is directed toward a new or improved lead acid battery separator or system with one or more surfactants and/or additives, and/or methods for constructing lead acid battery separators and batteries with such surfactants and/or additives for improving and/or reducing water loss from the battery.

First claim

1 . New or improved battery separators for lead acid batteries having one or more layers, coatings, components, or materials containing at least one water loss reducing additive or surfactant that provides a reduction in water loss of more than 10%, in some embodiments, more than 25%, in some embodiments, more than 40%, and in some select embodiments more than 50% compared with known lead acid battery systems.

2 . The battery separator of claim 1 optimized or designed such that there is little or no impact on the electrical resistance of the system.

3 . The battery separator of claim 1 optimized or designed to at least one of extend the life cycle of a battery, to reserve capacity, and to optimize CCA.

4 . In a battery, the improvement comprising the separator of claim 1 .

5 . In a vehicle, the improvement comprising the battery of claim 4 .

6 . Surfactants or other additives for use with a battery separator, battery component, or other layer or material in a lead acid battery, and that provides a reduction in water loss of more than 10%, in some embodiments, more than 25%, in some embodiments, more than 40%, and in some select embodiments more than 50% compared with known lead acid battery systems.

7 . The surfactants or additives of claim 6 selected, optimized or designed such that there is little or no impact on the electrical resistance of the system.

8 . The surfactants or additives of claim 6 selected, optimized or designed to at least one of extend the life cycle of a battery, to reserve capacity, and to optimize CCA.

9 . In a battery separator or component, the improvement comprising the surfactants or additives of claim 6 .

10 . In a battery, the improvement comprising the separator or component of claim 9 .

11 . In a vehicle, the improvement comprising the battery of claim 10 .

12 . A novel or improved surfactant or additive for a separator of a lead acid battery that provides a reduction in water loss of more than 10%, in some embodiments, more than 25%, in some embodiments, more than 40%, and in some select embodiments more than 50% compared with known lead acid battery systems.

13 . The surfactant or additive of claim 12 wherein at least one of: the separator of a lead acid battery reduces water and/or water vapor loss and/or vapor loss from the lead acid battery, the surfactant reduces the float current, reduces the level of gas evolution on charge, reduces the level of gas evolution on charge which results in loss of water from H 2 gas escape from the electrolyte, is designed to tailor the functionality of the wetting agent to provide the desired balance of wetting, electrical resistance, ion transfer, over voltage protection, the like, and/or combinations thereof, improving separator life within the environment of the lead acid battery, is stable under the conditions required to manufacture a UHMWPE battery separator, exhibits some solubility characteristics in the process oil, is soluble in water and/or electrolyte and can be coated or spray applied to the separator surface, has the ability to be added anytime within the separator manufacturing process, has the ability to be applied within the battery or other components as a supplement to the separator or in place thereof, is provided with the electrolyte as a pre-mix or added as a stand-alone to the cell, is coated on the separator with a water based application after removal of processing oil to achieve the desired concentration, is mixed with oil/solvent and infused into the separator during normal manufacturing steps, is mixed with processing oil and remain in the separator at the desired level through end process, is used as replacements for the normal residual oil left within a separator, is between 0.5 to 60% of the processing oil and PE, silica, is combined with an additive in or on the separator, the additive being an alkoxylated alcohol additive, the surfactant and additive are optimized to improve and/or reduce water loss, an additive includes zinc, zinc sulfate, bismuth, silver, selenium, cadmium, the like, and/or combinations thereof, the surfactant is a low or very low HLB surfactant, the low or very low HLB surfactant is created from a hydrocarbon with functional groups, said surfactant is a low foam surfactant, said surfactant has linear hydrophobic groups and ethylene oxide and propylene oxide monomers, said surfactant is a nonionic surfactant, said nonionic surfactant is a methallyl-capped nonionic surfactant, and/or combinations thereof.

14 . In a lead acid battery, the improvement comprising the separator of claim 13 .

15 . In a vehicle, the improvement comprising the battery of claim 14 .

16 . A method of reducing water loss of a lead acid battery comprising the step of providing a surfactant or additive to the battery, separator, or component of a lead acid battery to provide a reduction in water loss of more than 10%, in some embodiments, more than 25%, in some embodiments, more than 40%, and in some select embodiments more than 50% compared with known lead acid battery systems.

17 . The method of claim 16 including at least one of: providing the surfactant in or on the battery separator, providing the surfactant in or with an additive, wherein the additive is an alkoxylated alcohol additive, optimizing the surfactant and/or additive to improve and/or reduce water loss, wherein an additive includes zinc, zinc sulfate, bismuth, silver, selenium, cadmium, the like, and/or combinations thereof, and/or combinations thereof.

Assignees

• Daramic Llc

Inventors

• Chambers Jeffrey K

Classifications

• H01M50/431

  Inorganic material · CPC title

• H01M50/411

  Organic material · CPC title

• H01M50/449

  having a layered structure · CPC title

• H01M50/40 Primary

  Separators; Membranes; Diaphragms; Spacing elements inside cells · CPC title

• H01M50/454

  comprising a non-fibrous layer and a fibrous layer superimposed on one another · CPC title