Embossed separators, batteries and methods

Patent metadata

Field	Value
Publication number	US-9698401-B2
Application number	US-201615254350-A
Country	US
Kind code	B2
Filing date	Sep 1, 2016
Priority date	Nov 21, 2011
Publication date	Jul 4, 2017
Grant date	Jul 4, 2017

Abstract

An improved, new, modified, or more robust embossed battery separator for a storage battery, a method for its production, an envelope embossed separator, batteries including the embossed separators and/or envelopes, and/or related methods for the production and/or use of the embossed separators, embossed envelopes, and/or batteries including such embossed separators and/or envelopes.

First claim

We claim:

1. A battery separator for a storage battery comprising:
a microporous membrane having at least one embossed rib and a densified rigid internal skeletal frame;
wherein said at least one embossed rib runs in a longitudinal direction; and
wherein said densified rigid internal skeletal frame comprises compressed transverse ribs of lesser height than said at least one embossed rib.

2. The battery separator of claim 1 wherein said at least one embossed rib is sinusoidal.

3. The battery separator of claim 1 wherein said microporous membrane comprising a mixture of a thermoplastic polymer and a filler, and having a plurality of micropores therethrough.

4. The battery separator of claim 1 wherein said microporous membrane comprises a mixture of a thermoplastic polymer, a filler, and a pore former.

5. The battery separator of claim 1 wherein said microporous membrane exhibits a 5% or less change over time in a parameter selected from the group consisting of thickness, resiliency, and/or compression.

6. The battery separator of claim 1 further comprising a pasting paper adhered to at least one face of the microporous membrane.

7. The battery separator of claim 6 wherein said pasting paper comprises a nonwoven material.

8. The battery separator of claim 6 wherein said pasting paper comprises at least one rib co-embossed with said microporous membrane.

9. A battery comprising the separator of claim 8 .

10. The battery separator of claim 6 further comprising a gelling agent adhered to said pasting paper.

11. A battery comprising the separator of claim 6 .

12. The battery separator of claim 1 further comprising a nonwoven adhered to a face of the microporous membrane.

13. The battery separator of claim 12 wherein said nonwoven comprises at least one of a gelling agent, sodium sulfate, chemically active minerals, or carbonaceous materials.

14. The battery separator of claim 12 wherein said nonwoven comprises at least one rib co-embossed with said microporous membrane.

15. A battery comprising the separator of claim 14 .

16. A battery comprising the separator of claim 12 .

17. The battery separator of claim 1 further comprising co-embossed material adhered to a face of said microporous membrane.

18. The battery separator of claim 1 wherein said microporous membrane being in a form selected from the group consisting of an envelope, a leaf, or a wrapping.

19. A battery comprising the separator of claim 1 .

20. The battery separator of claim 1 wherein said densified rigid internal skeletal frame comprises compressed membrane longitudinal calendered ribs of lesser height than said at least one embossed rib.

21. A battery comprising the separator of claim 20 .

22. A battery separator for a storage battery comprising:
a microporous membrane having an embossed rib and a densified rigid internal skeletal frame;
wherein said embossed rib runs in a longitudinal direction;
wherein said densified rigid internal skeletal frame comprises compressed, calendered membrane longitudinal ribs and transverse ribs;
wherein said membrane longitudinal ribs are of lesser height than said embossed rib; and
wherein said membrane transverse ribs are of lesser height than said longitudinal ribs.

23. A battery comprising the separator of claim 22 .

24. The battery separator of claim 22 further comprising a pasting paper adhered to a face of the microporous membrane.

25. A storage battery comprising the separator of claim 24 .

26. The battery separator of claim 22 further comprising a nonwoven adhered to a face of the microporous membrane.

27. The battery separator of claim 26 wherein said nonwoven comprises least one of a gelling agent, sodium sulfate, chemically active minerals, or carbonaceous materials.

28. A storage battery comprising the separator of claim 27 .

29. A storage battery comprising the separator of claim 26 .

Assignees

• Daramic Llc

Inventors

• Miller Eric H
• Chambers Jeffrey K
• Timmons John R

Classifications

• H01M10/06

  Lead-acid accumulators (semi-lead accumulators H01M10/20) · CPC title

• H01M10/0585

  of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators · CPC title

• H01M4/14

  Electrodes for lead-acid accumulators · CPC title

• H01M10/12 Primary

  Construction or manufacture · CPC title

• H01M50/454

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