CA1319233C - Gas recombinant separator - Google Patents

Abstract

ABSTRACT OF THE DISCLOSURE
Described is a porous flexible sheet of about 96.5 to 99.5 weight percent amorphous precipitated silica and from about 0.5 to about 3.5 weight percent fibrillated, unsintered polymer, e.g., polytetrafluoroethylene. The sheet is useful as a separator in absorbed electrolyte gas recombinant batteries, e.g., lead-acid batteries. The sheet is prepared by subjecting a dry mixture of the silica and polymeric material, e.g., polytetrafluoroethylene, in the above proportions to mechanical shear blending forces to fibrillate the polymer and thereafter dry forming the resulting admixture into sheet form.

Description

131~233 GAS RECOMBINANT SEPARATOR

DESCRIPTION OF THE INVENTION
The present invention is directed to silica-containing battery separators. In commonly used electric storage batteries, such as the well known 12-volt battery employed in automobiles, separators are placed between battery plates of opposite polarity to prevent the two plates from touching and causing an electrical short. The sepa-rator is typically a microporous article fabricated from a polymeric material, e.g., natural or synthetic rubber, or a polyolefin. The separator may have a backing material of, for example, a non-woven web. The pores of the separator should be as small as possible since this reduces the danger of active materials being forced through or growing through the separator, thereby causing an electrical short.
Siliceous fillers have been used to prepare microporous battery separators. See, for example, U.S. Patent 2,302,832, which describes the use of a silica hydrogel in a rubber binder; U.S. Patent 3,351,495, which describes synthetic and natural zeolites, precipi-tated metal silicates, such as calcium silicate, and silica gels as the inorganlc fi]ler and extender for separators of high molecular weight polyolefins; and U.S. Patents 3,696,061, 4,226,926, and 4,237,083, which describe the use of finely divided, precipitated amorphous silica, such as Hi-Sil~ 233 silica, in microporous battery separators. Precipitated amorphous silica is prepared by uninter-rupted acidification with inorganic acid, e.g., hydrochloric, sulfuric or carbonic acid, of an aqueous solution Gf sodium silicate to produce a finely-divided siliceous powder. Hi-Sil~ 233 silica is reported to have a BET surface area of between 140 and 160 square meters per gram. See, for example, U.S. Patent 2,940,830.

- 2 - 13~ ~23.3 Amorphous precipitated silica is used as the vehicle for introducing porosity into and for reinforcing polymeric material utilized to fabricate the battery separator. Such precipitated silica is highly absorbent and can absorb a substantial quantity of an 5 aqueous or organic liquid while remaining free flowing. In practice, the amorphous precipitated silica is loaded with a liquid of choice, e.g., water or oil, and then blended with the polymeric material. The liquid absorbed by the silica filler is subsequently removed to impart porosity to the polymeric material. Battery separators containing 10 between about 5 and about 70, e.g., between 15 and 50, weight percent of siliceous filler have been reported in the above-described patents.
Recently, completely sealed electric storage batteries have been commercialized. These sealed batteries, e.g., lead-acid batteries, are sealed so that they can operate above atmospheric 15 pressure. Such batteries are reported to use a highly porous and partially saturated glass microfiber separator. Such batteries are referred to as electrolyte gas recombinant batteries since gas evolved at the battery plates is recombined within the battery. The battery separator used in the recombinant absorbed electrolyte battery is a 20 key ~tructural element of the battery because it absorbs sufficient electrolyte to provide normal battery electrical capacity whi]e leaving enough pores, which do not contain electrolyte, so that gas, i.e., oxygen, can freely pass through it. The separator is reported to require the following physical properties:
1. High absorptivity in order to hold a sufficient quantity of electrolyte, i.e., battery acid;
2. Relatively small through-pores with high tortuosi~y in order to prevent shorts and dendrite growth;

3. High total porosity so that electrical resistance of the 30 separator is low;

4. Readily wet by sulfuric acid; and 5. Resistant to attack by sulfuric acid and to oxidation.
It has now been discovered that non-woven, porous flexible sheets comprised principally of amorphous precipitated silica and a 35 minor amount of fibrillated, unsintered fibers of a polymeric resin, e.g., a perfluorinated polymer such as polytetrafluoroethylene, may be used as a separator for elec~rolyte gas recombinant batteries.

- 3 - ~ 3 ~ , 3 3 DETAILED DESCRIPTION OF THE INVENTION
The separator of the present invention is a non-woven, porous flexible sheet or mat of from about 96.5 to about 99.5 weight percent synethic amorphous silica, e.g., amorphous precipitated 5 silica, and from about 0.5 to about 3.5 weight percent of fibrillated, unsintered fibers of a polymeric material, particularly a perfluori-nated polymer such as polytetrafluoroethylene. More particularly, the sheet consists essentially of from 97.5 to 99, e.g., about 98, weight percent synthetic amorphous silica and from about 1 to 2.5, e.g., 2, 10 weight percent of the polymeric material.
Polymeric materials that may be used to prepare the battery separators described herein are those that are solid and that form flbrils or fibers, e.g., microfibers, when subjected to intensive mixing, i.e., fibrillation. The process of fibrillation involves 15 subjecting solid particles, e.g., spherical particles, to sufficient shear stress along the orientation axis of the particle so that the molecules of the particle slip relative to each other with the consequent formation of an elongated thin fibril.
Fibrillatable polymeric materials that may be used herein 20 may be selected from high molecular weight polyolefins such as polyethylene, polypropylene, polybutene, polyisobutylene, copolymers of ethylene and propylene, copolymers of ethylene and butene, co-polymers of propylene and butene and terpolymers of ethylene, propylene and butene. Other polymers contemplated include the 25 polyacrylates such as polymethyl acrylate, polymethyl methacrylate and, more generally, polymers prepared from the C1-C4 alkyl esters of acrylic and methacrylic acid. Also contemplated are products obtained from natural materials such as cellulose.
Halogen, e.g., fluorine and/or chlorine, containing poly-30 meric resins contemplated herein include polyvinyl chloride,polyvinylidene chloride, copolymers of vinyl chloride and vinyl acetate, polyvinyl fluoride, polyvinylidene fluoride and per-fluorinated polymeric materials. Perfluorinated polymers are preferred because of their high reslstance to chemical at~ack.
35 Examples of such perfluorinated polymeric materials include polytetra-fluoroe~hylene (PTFE), polychlorotrifluoroethylene, polyhexafluoro-- 4 _ 1319233 propylene, copoly~ers of chlorotrifluoroethylene and ethylene, copolymers of ethylene and tetrafluoroethylene, copolymers of hexa-fluoropropylene and tetrafluoroethylene, copolymers of vinylidene fluoride with tetrafluoroethylene, hexafluoropropylene~ chlorotri-5 fluoroethylene or pentafluoropropylene, and terpolymers of vinylidenefluoride, hexafluoropropylene and tetrafluoroethylene. Also contemplated are fluoroalkyl acrylates such as poly (1,1-dihydro-perfluorobutyl acrylate), poly (3-perfluoro methoxy-1,1-dihydroper-fluoropropyl acrylate, poly (trifluoroisopropyl methacrylate) and the 10 condensation product of adipic acid and 2,2,3,3,4,4-hexafluoro-pentanediol.
Other perfluorinated polymers contemplated include fluori-nated polymers containing functional groups, such as sulfonic acid or carboxylic acid groups, or alkali metal, e.g., sodium, or ammonium 15 salts thereof. Typical examples of such perfluorinated polymers are those described in U.S. Patent Nos. 3,282,875, 3,624,053, 3,849,243, 3,506,635 and British Patent No. 1,145,445. The aforesaid per-fluorinated polymers are those typically having a fluorinated hydrocarbon backbone chain to which are attached the functional groups 20 or pendant side chains which in turn carry the functional groups.
These polymers are prepared by copolymerizing a first fluorinated vinyl monomer(s) such as vinyl fluoride, hexafluoropropylene, vinylidene fluoride, trifluoroethylene, chlorotrifluoroethylene, perfluoro (alkyl vinyl ether), tetrafluoroethylene or mixtures 25 thereof, with a second fluorinated vinyl monomer(s) having the functional acid group attached thereto or attached to a pendant side chain, e.g., -C(Rf)F-CF2-SO2F~ -O-C(Rf)F-CF2-SO2F~
~C(Z)F~tW, or -O~C(Z)F~tW, wherein Rf is F, Cl, or a C1-C10 perfluoroalkyl group, Z is F or CF3, t is a number from 1 30 to 12 and W is -COOR or -CN, wherein R is lower alkyl, e.g., C1-C4 alkyl. Such materials are offered under the trademarks NAFION~ by E. I. Du Pont de Nemours and Company, and FLEMION~ by the Asahi Glass Company, Ltd.
The aforesaid polymeric materials may be used in various 35 forms. Of particular utility are fine powders and colloidal aqueous dispersions of the polymers. Finely divided granular forms may also _ 5 _ ~3~9233 be used. Aqueous colloidal dispersions are preferred. Aqueous dispersions containing from about 30 to abou~ 70 weight percent solids are contemplated. Polytetrafluoroethylene (PTFE) is preferred.
A variety of commercially available forms of PTFE may be 5 used to prepare the porous flexible sheet of the present invention.
Among such forms are TEFLON~ K-10 and K-20 fluorocarbon polymer.
TEFLON K-10 is a free-flowing white powder having an average particle size of about 500 microns. TEFLON~ K-20 fluorocarbon poly~er is an aqueous suspensoid of the fluorocarbon particles which range in size 10 from about 0.05 to about 0.5 microns. Both the K-10 and K-20 forms are offered by the E. I. du Pont de Nemours & Company. TEFLON~ K-20 typically contains about 33 percent by weight solids and the dis-persion is stabilized with approximately 1 percent by weight of a nonionic surfactant. Other aqueous suspensoids of fluorocarbon 15 polymer, e.g., those containing from about 30 to about 70 weight percent solids may also be used. The higher solids content suspensoids will contain higher amounts of surfactant for stabili-zation. An aqueous dispersion of the fluorocarbon polymer, e.g, PTFE, is preferred because of the smaller particle size of the fluorocarbon 20 polymer present in the dispersion.
The preparation of polytetrafluoroethylene is well known and is illustrated by U.S. Patent Nos. 2,510,112, 2,587,357, and 2,685,707. The particle size of the PTFE may vary from 0.05 to about 500 microns depending on the supplier and the product form, i.e., a 25 free-flowing white powder or aqueous dispersion. Powdered PTFE may, of course, be dispersed by the use of typical nonionic surfactants, such as used in the preparation of TEFLON~ K-20 fluorocarbon polymer.
The preparation of the other described polymeric materials, e.g., by bulk, solvent or emulsion polymerization, is known from the polymer 30 literature.
It has been recognized that, when subjected to shear stresses, small particles of polymeric materials, e.g., perfluorinated polymers such as PTFE, will form fibrils or fibers of a microscopic slze. Such forces involve a combination of compression and 35 attenuation forces which have the effect of lengthening and separating the polymer particles. The aspect ratio of the fibrils, i.e., the - 6 - 13~9~3~

length to diameter ratio will be in the range of about 100:1 to about 1000: 1.
In accordance with an embodiment of the present invention, a mixture of silica and fibrillatable polymeric material is subjected to 5 mechanical working, i.e., mechanical shear blending (fibrillating), to form a mixture of silica and polymer fibrils. The shear blending i5 preferably conducted at temperatures of between about 50C. and about 110C. for between about 0.5 and 10 minutes. More particularly, the blending is performed at temperatures of between about 70C. and 90C.
10 for between about 1 and 3, e.g., 2, minutes. Care should be observed during the shear blending or fibrillating of the polymeric material alone or of the polymer-silica mixture that temperatures sufficient to melt or sinter the resin are not reached. Further, it is preferred that the shear blending be conducted for a time sufficient to form 15 initial fibrils or fibers of the polymer but that such shear blending i9 not continued beyond a time when the initial fibrils are themselves broken down into smaller fibers.
Fibrillation or intensive mixing of the polymer or polymeric material-silica blend may be performed in commercially available 20 intensive mixing devices which are sometimes referred to as internal mixers, kneading mixers, double-blade batch mixers as well as intensive mixers. The most popular mixer of this type is the sigma blade or sigma-arm mixer. Some commercially available mixers of this type are those sold under the common designations Banbury mixer, ~ogul 25 mixer, C. W. Brabender Prep mixer and C. W. Brabender sigma-blade mixer.
In accordance with an embodiment of the present invention, precipitated amorphous silica and fibrillatable polymeric material are combined and blended to form a homogeneous mixture in the relative 30 amounts previously described. The homogeneous mixture may be prepared by low energy mixing of the silica and polymer before subjecting the mixture to shear blending forces or the homogeneous mixture can be prepared in the intensive mixer previously described. Further, it is contemplated that a master batch of silica and polymeric material 35 comprising about 90 to 95 weight percent silica and about 5 to 10 weight percent polymeric material may be prepared and this master ~ 7 ~ ~3~ ~33 batch diluted with additional silica to produce the compositions described for the porous flexible sheet. Still further, i~ is con-templated that the polymeric material may be first fibrillated and the fibrils then combined with the silica with gentle mixing or 5 blending.
In a further embodiment of the present invention, it is contemplated that a mixture of silica and fibrillatable polymeric material is added to a heel of silica-fibrillated polymer (usually of the same relative composition). It has been found that the time 10 required for intensive mixing of the resulting mixture is signi-ficantly reduced from that required for the silica-fibrillatable polymeric material blend alone. The heel can represent from about 1 to about 10 weight percent of the total solids subjected to intensive mixing.
The blending of an aqueous dispersion of polymeric material such as PTFE, e.g., TEFL0~ K-20, with silica to prepare an admixture of between about 96.5 and 99.5 weight percent silica and 0.5 and 3.5 weight percent fibrillatable polymeric material does not result in the formation of a tacky or putty-like mixture since the silica is capable 20 of absorbing all of the water used to disperse the polymer particles and still remain dry to the touch and free-flowing. Such admixtures will be referred to herein as being substantially dry.
In accordance with an embodiment of the present invention, a substantially dry admixture of fibrillatable polymeric material, e.g., 25 PTFE, and silica, e.g., amorphous precipitated silica, is subjected to mechanical shear blending forces9 i.e., the mixture is shear blended dry, to form a substantially dry, substantially homogeneous mixture of silica and fibrillated, unsintered polymeric material, e.g., per-fluorinated polymer. Such blending is performed in the absence of 30 added liquid. The resulting shear blended mixture of silica and fibrillated polymeric material has a consistency of a putty~like or dough-like material.
The silica-fibrillated polymeric material mixture is then formed into a porous flexible sheet by dry rolling or passing it 35 ehrOugh sets of rollers, e.g., the mixture is calendered. Forming of the silica-fibrillated polymer mixture into sheets is performed at - 8 - ~3~233 temperatures of between about 50C. and about 110C., preferably between 70C. and 90C. Conditions employed in the dry rolling are such as to avoid sintering of the fibrillated polymeric material, e.g., perfluorinated polymer particles and/or fibrils, and to avoid 5 further frac~uring of the polymeric material fibrils. Forming of the sheet can be accomplished by passing the admixture through one or more sets of rollers, e.g., heated rollers, having roll gaps ranging from about 5 to about 100 mils.
Amorphous precipitated silica used to prepare the silica 10 fibrillated polymer blend is a free-flowing, white, fluffy, pulverulent powder that is dry to touch. Despite appearing dry, the silica normally contains between about 2 and 8 percent "free water" by weight. Free water i8 that water which is removed from the silica by heating it at 105C. for 24 hours. Precipitated silica also contains 15 "bound water", which refers to that water removed by heating the silica at ignition temperature, i.e., 1000C. to 1200C. for an extended period, e.g., 24 hours. Bound water can constitute between about 2 and 6 weight percent of the silica. Amorphous precipitated silica has a high capacity for absorbing liquids, such as water, and 20 can absorb significant quantities of liquid and still remain dry to the touch and free-flowing. For example, amorphous precipitated silica may absorb between about 1 and about 180 milliliters of water per 100 grams of silica and still remain free-flowing. Chemically, finely-divided, amorphous precipitated silica contains at least 85, 25 typically at least 90 and more typically 93-97 weight percent SiO2 on an anhydrous basis, i.e., not including free water.
Amorphous precipitated silica that may be used in the present inventi~n to form the porous flexible sheet will commonly have a BET surface area from about 30 to about 300 square meters per gram, 30 usually between about 100 and about 200 square meters per gram; an oil absorption of from about 100 to about 300 milliliters of oil, e.g., dibutyl phthalate, per 100 grams of silica, usually between about 150 and 250 milliliters of oil per 100 grams of silica; and a water absorption value of from about 100 to about 200 milliliters per 100 35 grams of silica. The median agglomerate particle size of the silica product will be between about 2 and about 20 micrometers, as measured by a Coulter counter.

_ 9 _ ~3~923~

Amorphous precipitated silica may be prepared by a reaction of an aqueous solution of a soluble silicate, e.g., sodium, lithium or potasslum silicate, most usually sodium silicate, with inorganic mineral acid, most notably carbonic acid, sulfuric acid or 5 hydrochloric acid. Typically sodium silicate having an SiO2:Na20 ratio of about 3.3:1 is used to prepare the aqueous solution of soluble silicate. Particularly suited as the mineral acid is carbonic acid, which is formed in situ by the introduction of carbon dioxide ineo the silicate solution. This method for preparing amorphous 10 precipitated silica is described in U.S. Patent No. 2,940,830. The resulting precipitated silica is usually washed in suitable vessels to remove a substantial portion of the soluble alkaline metal inorganic salt incorporated therein during the precipitation process and thereafter, the pH of the silica adjusted with an inorganic mineral 15 acid, usually hydrochloric acid (although sulfuric acid may be used), to a final essentially neutral pH of between about 6.5 and about 7.3.
The resulting silica is dried, e.g., in a rotary or drum drier, or spray dried, and the dried product screened to produce the commercial product.
Also contemplated is amorphous precipitated silica prepared in accordance with the method described in U.S. Patent 3,129,134.
There, the silica is prepared by precipitating water-insoluble siliceous product from an aqueous alkali metal silicate solution in the presence of finely-divided particles of a water-insoluble 25 inorganic metal salt, e.g., inorganic metal salts of carbonic acid such as the alkaline earth metal salts of carbonic acid, e.g., calcium carbonate. The water-insoluble inorganic metal salt is then substantially r-emoved from the resulting insoluble siliceous precipitate by treatment with acid, e.g., hydrochloric acid. This 30 treatment converts the cation of the insoluble inorganic salt into a water-soluble salt of the treatment acid and liberates the anion of the salt as a gas. The resulting amorphous precipitated silica is composed of agglomerates of substantially hollow spherical particles having a predominant hollow particle size (diameter) of between 5 x 35 10 mm (0.005 microns) and 5 x 10 3 mm (5 microns). The silica has a BET surface area of between about 50 and 250 square meters per ~3~9~33 gram, preferably between 75 and 200 square meters per gram, and an oil absorption of from about 150 to 300, preferably from about 200 to 300, more preferably from about 230 to 270, milliliters of oil per 100 grams of silica. The silica desirably contains less than 2 weight 5 percent of the oxide of the metal of the water-insoluble inorganic metal salt, e.g., calcium oxide, and preferably contains less than 1, more preferably less than 0.5, and most preferably less than 0.1, weight percent of such metal oxide.
Amorphous precipitated silica also useful in the preparation 10 of the porous flexible sheet of the present invention are those materials described in British Patent Publication 2,169,129. T~le preparative method described in said publication involves preparing an aqueous alkaline metal silicate solution having a particular alkaline metal oxide concentration at preselected temperatures. Thereafter, 15 additional alkaline metal silicate and acidifying agent are added slowly and simultaneously to the aqueous alkaline metal silicate solution with agitation and at a rate sufficient to maintain the initial alkaline metal oxide concentration at substantially the same level until various multiples of the initial amount of alkaline metal 20 silicate have been added. Thereafter, additional acidifying agent is added to the resulting slurry until the pH is from about 8 to about 9 and the resulting slightly alkaline slurry aged. Subsequent to the aging step, additional acidifying agent is added to the aged slurry until the pH thereof is acidic, e.g., from about 3.8 to about 4.7, and 25 the precipitated silica recovered from the acidified slurry washed and dried.
In one embodiment described in the aforesaid British Patent Publication, the initial aqueous alkaline metal silicate contains between about 2.1 and 2.6 grams per liter of alkaline metal oxide at a 30 temperature of between about 82C. and 85C. Further alkaline metal silicate in amounts equal to from about 14.5 to about 19 times the amount of alkaline metal silicate present in the first aqueous alkaline metal silicate solution is added during the simultaneous addition of further alkaline metal silicate and acid. In a second 35 embodiment, the alkaline metal oxide concentration of the ~irst 2 3 ~

aqueous alkaline metal silicate solution is from about 5.6 to about 7.2 grams per liter and the temperature thereof is between about 88C.
and about 92C. Between 2 and about 5 times the amount of alkaline metal silicate present in the first aqueous alkaline metal silicate 5 solution is added during the simultaneous addition of said further alkaline metal silicate and acidifying agent.
Aging of the aforedescribed alkaline precipitated silica slurry can be from about 15 to 90 minutes, although longer aging times may be utilized. Aging temperatures are usually at the temperature of 10 the liquid reaction medium, but such temperatures are not critical.
In a preferred embodiment of the present invention, the synthetic amorphous silica is precipitated silica. However, it is contemplated that the synthetic amorphous silica may comprise a mixture of precipitated silica and small amounts, e.g., up to 10 15 weight percent of pyrogenic silica andtor silica gel. More particularly, the synthetic amorphous silica may comprise amorphous precipitated silica and from 0 to about 10 weight percent, e.g., from about 5 to 10 weight percent, of pyrogenic silica, silica gel or mixtures of pyrogenic silica and silica gel.
Pyrogenic or fumed silicas are prepared commonly by reacting silicon tetrachloride vapor with oxygen and hydrogen gas at high temperatures. Pyrogenic silicas have high external surface areas.
Silica gels are of two types ~ hydrogels and aerogels. Hydrogels may be prepared by reacting a soluble silicate such as sodium silicate 25 with strong sulfurlc acid. The gel is washed salt-free, dried, micronized and classified. Aerogels may be prepared from hydrogels by displacing the water content with an alcohol which is recovered by heating the gel- in an autoclave. Gels generally have a BET surface area in the range of from 300 to 1000 square meters per gram. Both 30 pyrogenic silicas and silica gels and their preparation are well known in the art.

Amorphous precipitated silica was dry blended with sufficient TEFLON~ K-20 aqueous suspensoid of fluorocarbon ~PTFE) 35 particles to provide 1, 2 and 3 weight percent of the fluorocarbon particles in the resulting blend. Blending was performed for 2 - 12 - 1 3 ~3 ~

minutes in a Brabender Plastograph Model PLV3 mixer at 90C. and 50 rpm. The silica had a BET surface area of about 163 m /gram, an oil absorption of about 197 milliliters, and average agglomerate particle size of about 13.5 microns. The silica had a pH of 6.6 and contained 5 6.3 weight percent "free" w~ter. The blended samples were hand rolled dry immediately after being removed from the Brabender into thin sheets of from about 75 to 100 mils (0.19 to 0.25 centimeters). Two inch (5.1 centimeters) diameter discs prepared from the silica-2%
fluorocarbon blend were tested for electrical resistance in a 10 laboratory cell at 25C. The electrolyte used was an aqueous solution of 37.5 weight percent sulfuric acid. Resistance values varied from 1.5 to 2.4 milliohm - in 2 (square inches) per 10 mils (0.01 inches).

120 grams of the amorphous precipitated silica used in Example 1 was dry blended with TEFLON~ K-20 aqueous suspensoid of fluorocarbon particles in an amount sufficient to obtain 2 weight percent fluorocarbon particles in a Brabender mixer for two minutes at 90C. and 50 rpm. The resulting blend was rolled out dry on sluminum 20 foil using a roller filled with water having a temperature of about 72C. Two inch (5.1 centimeter) diameter discs cut from these sheets were tested for electrical resistance in a laboratory cell at 25C.
using an aqueous solution of 37.5 weight percent sulfuric acid as the electrolyte. Resistance values obtained were about 2.5-2.6 milliohm -25 in /0.01 inch.

The procedure of Example 2 was repeated with 40 grams of theamorphous precipitated silica and sufficient of the TEFL0~ K-20 suspensoid to obtain a blend of silica - 1.5 weight percent 30 fluorocarbon. Blending was at 70C. in the Brabender for 2~ minutes at 50 rpm. Resistance values of discs cut from sheets dry formed from the blend varied from 5 to 9 milliohm - in /0.01 inch.
While the invention has been described in detail with respect to certain embodiments thereof, it is understood that the 35 invention is not intended to be limited to such details except as and insofar as they appear in the appended claims.

Claims (24)

1. A method for preparing a non-woven, porous flexible sheet of silica and fibrillated polymeric material, comprising subjecting a free-flowing, substantially dry mixture of from about 96.5 to about 99.5 weight percent particulate synthetic amorphous silica and about 0.5 to about 3.5 weight percent of fibrillatable polymeric material to mechanical shear blending forces at temperatures insufficient to sinter the polymeric material, thereby to form a substantially dry, substantially homogeneous mixture of silica and unsintered, fibrillated polymeric material, and thereafter dry-forming the blending mixture into a flexible sheet, said synthetic amorphous silica comprising precipitated silica and from 0 to about 10 weight percent of pyrogenic silica, silica gel or mixtures of pyrogenic silica and silica gel.

2. The method of claim 1 wherein the polymeric material is a perfluorinated polymer.

3. The method of claim 2 wherein the perfluorinated material is polytetrafluoroethylene.

4. The method of claim 3 wherein an aqueous dispersion of polytetrafluoroethylene is mixed with the silica.

5. The method of claim 4 wherein the mixture contains from about 97.5 to about 99 weight percent silica and from about 1 to about 2.5 weight percent polytetrafluoroethylene.

6. The method of claim 5 wherein temperatures of between about 50°C. and about 110°C. are used to shear blend the silica -polytetrafluoroethylene mixture, and to form the resulting shear blended mixture into sheet form.

7. The method of claim 6 wherein the sheet has a thickness of from about 5 to about 100 mils.

8. The method of claim 6 wherein the blended mixture is formed into a sheet by dry rolling the mixture with a heated roller.

9. The method of claim 1 wherein the mixture of synthetic amorphous silica and fibrillatable polymeric material is subjected to mechanical shear blending in the presence of a heel of from about 96.5 to about 99.5 weight percent synthetic amorphous silica and from about 0.5 to about 3.5 weight percent of fibrillated polymeric material.

10. The method of claim 9 wherein the heel is from about 1 to about 10 weight percent of the silica-fibrillatable polymeric material blend to be subjected to mechanical shear blending.

11. The method of claim 10 wherein the polymeric material is a perfluorinated polymer.

12. The method of claim 11 wherein the perfluorinated polymer is polytetrafluoroethylene.

13. The method of claim 12 wherein temperatures of between about 50°C. and about 110°C. are used to shear blend the silica-polytetrafluoroethylene mixture, and to form the resulting shear blended mixture into sheet form.

14. A non-woven, porous flexible sheet consisting essentially of from about 96.5 to about 99.5 weight percent synthetic amorphous silica and from about 0.5 to about 3.5 weight percent of fibrillated, unsintered polymeric material, said synthetic amorphous silica comprising precipitated silica and from 0 to about 10 weight percent of pyrogenic silica, silica gel or mixtures of pyrogenic silica and silica gel.

15. The porous flexible sheet of claim 14 wherein the polymeric material is a perfluorinated polymer.

16. The porous flexible sheet of claim 15 wherein the perfluorinated polymer is polytetrafluoroethylene.

17. The porous flexible sheet of claim 16 wherein the sheet contains from about 97.5 to about 99 weight percent silica and from about 2.5 to 1 percent polytetrafluoroethylene.

18. The porous flexible sheet of claim 17 wherein the sheet has a thickness of from about 5 to about 100 mils.

19. A separator for an electrolyte gas recombinant battery comprising a non-woven, porous flexible sheet consisting essentially of from about 96.5 to about 99.5 weight percent synthetic amorphous silica and from about 0.5 to about 3.5 weight percent of fibrillated, unsintered polymeric material, said synthetic amorphous silica comprising precipitated silica and from 0 to about 10 weight percent of pyrogenic silica, silica gel or mixtures of pyrogenic silica and silica gel.

20. The separator of claim 19 wherein the polymeric material is a perfluorinated polymer.

21. The separator of claim 20 wherein the perfluorinated polymer is polytetrafluoroethylene.

22. The separator of claim 21 wherein the separator consists essentially of from about 97.5 to about 99 weight percent silica and from about 1 to about 2.5 weight percent polytetra-fluoroethylene.

23. The separator of claim 22 wherein the sheet has a thickness of from about 5 to about 100 mils.

24. The separator of claim 22 wherein the battery is a lead-acid battery.