Pasting paper made of glass fiber nonwoven comprising carbon graphite

Patent metadata

Field	Value
Publication number	US-9685646-B2
Application number	US-201414489093-A
Country	US
Kind code	B2
Filing date	Sep 17, 2014
Priority date	Oct 3, 2013
Publication date	Jun 20, 2017
Grant date	Jun 20, 2017

Abstract

Embodiments of the invention provide a lead-acid battery having a positive electrode, a negative electrode, and a separator positioned between the electrodes to electrically insulate the electrodes. Battery includes a nonwoven fiber mat positioned adjacent an electrode. Mat includes a mixture of first glass fibers having diameters between 8 μm to 13 μm and second glass fibers having diameters of at least 6 μm and a silane sizing. An acid resistant binder bonds the glass fibers to form mat. A wetting component is applied to increase the wettability such that mat 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 a surface of mat such that when mat is 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. A lead-acid battery comprising:
a positive electrode;
a negative electrode;
a separator positioned between the positive electrode and the negative electrode so as to electrically insulate the positive and negative electrodes; and
a nonwoven fiber mat positioned adjacent the positive electrode or the negative electrode, the nonwoven fiber mat comprising: a relatively homogenous mixture of coarse 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 mat;
a wetting component applied to the nonwoven fiber mat to increase the wettability of the nonwoven fiber mat such that the nonwoven fiber mat 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, wherein the wetting component comprises fibers having a diameter of between about 0.5 μm and about 3 μm; and
a conductive material disposed on at least one surface of the nonwoven fiber mat or throughout the nonwoven fiber mat such that when the nonwoven fiber mat is positioned adjacent the positive or negative electrode, the conductive material contacts the positive or the negative electrode, the nonwoven fiber mat having an electrical resistance of less than about 100,000 ohms per square to enable electron flow about the nonwoven fiber mat, wherein the conductive material comprises conductive fibers having a diameter of between about 6 μm and about 10 μm, the fibers having a length of between about 8 mm and 12 mm.

2. The lead-acid battery according to claim 1 , wherein the mixture of coarse glass fibers comprise between about 10% to 95% of the first glass fibers and between about 5% to 80% of the second glass fibers.

3. The lead-acid battery according to claim 1 , wherein the nonwoven fiber mat has an area weight of between about 10 g/m 2 and about 100 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 mat.

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 mat.

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 mat.

7. 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 mat.

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

9. The lead-acid battery according to claim 1 , wherein the nonwoven fiber mat is affixed to a polyethylene separator, a phenol saturated paper separator, or an AGM separator.

10. A nonwoven fiber mat for a lead-acid battery, the nonwoven fiber mat comprising:
a relatively homogenous mixture of coarse 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 mat;
a wetting component applied to the nonwoven fiber mat to increase the wettability of the nonwoven fiber mat such that the nonwoven fiber mat 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, wherein the wetting component comprises fibers having a diameter of between about 0.5 μm and about 3 μm; and
a conductive material disposed on at least one surface of the nonwoven fiber mat or throughout the nonwoven fiber mat such that when the nonwoven fiber mat is positioned adjacent a positive or a negative electrode of a lead-acid battery, the conductive material contacts the positive or negative electrode, the nonwoven fiber mat having an electrical resistance of less than about 100,000 ohms per square to enable electron flow about the nonwoven fiber mat, wherein the conductive material comprises conductive fibers having a diameter of between about 6 μm and about 10 μm, the fibers having a length of between about 8 mm and 12 mm.

11. The nonwoven fiber mat according to claim 9 , wherein the nonwoven fiber mat has an area weight of between about 10 g/m 2 and about 100 g/m 2 .

12. The nonwoven fiber mat according to claim 9 , wherein the wetting component comprises cotton fibers having diameters between about 0.1 μm to 10 μm.

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

14. The nonwoven fiber mat according to claim 9 , wherein the mixture of coarse glass fibers comprise between about 10% to 95% of the first glass fibers and between about 5% to 80% of the second glass fibers.

15. The nonwoven fiber mat according to claim 9 , wherein the 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.

16. The nonwoven fiber mat according to claim 9 , wherein the binder comprises one or more of acrylic, melamine, phenolic, or urea formaldehyde binders.

17. A method of manufacturing a nonwoven fiber mat for use in a lead-acid battery, the method comprising: providing a mixture of coarse 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 coarse glass fibers to couple the mixture of coarse glass fibers together to form the nonwoven fiber mat;
applying a conductive material to at least one surface of the nonwoven fiber mat or throughout the nonwoven fiber mat such that when the nonwoven fiber mat is positioned adjacent a positive or a negative electrode of a battery, the conductive material contacts the positive or the negative electrode, the nonwoven fiber mat having an electrical resistance of less than about 100,000 ohms per square so as to enable electron flow about the nonwoven fiber mat wherein the conductive material comprises conductive fibers having a diameter of between about 6 μm and about 10 μm, the fibers having a length of between about 8 mm and 12 mm; and
applying a wetting component to the nonwoven fiber mat to increase the wettability of the nonwoven fiber mat such that the nonwoven fiber mat has or exhibits an average water wick height of at least 0.5 cm after exposure to water for 10 minutes conducted according to method ISO8787, wherein the wetting component comprises fibers having a diameter of between about 0.5 μm and about 3 μm.

18. The method of claim 16 , wherein the significant por

Assignees

• Johns Manville

Inventors

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

Classifications

• H01M4/806 Primary

  Nonwoven fibrous fabric containing only fibres · CPC title

• H01M50/457

  comprising three or more layers · CPC title

• H01M50/451

  comprising layers of only organic material and layers containing inorganic material · CPC title

• H01M50/454

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

• H01M50/417

  Polyolefins · CPC title