JPS5826147B2 - Manufacturing method of battery separator sheet - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing patterned sheets of material suitable for conversion into battery separators.

Further details: The present invention relates to a method for manufacturing such sheets from plastic materials by calendering.

The invention further relates to a battery separator having gas escape passages across its surface.

Battery separators have been made in the past from the preferred plastic materials of the present invention, namely the materials described in US Pat. No. 3,351,495.

This patent specifies a molecular weight of at least 300,000, a standard low melt index of substantially zero and a
It is disclosed to make smooth surface battery separators from microporous polyolefins with reduced clays that are not smaller.

This patent specification also describes specific examples of the material.

Moreover, such plastic materials have in the past been extruded from ribbed caps to produce sheets suitable for converting into ribbed battery separators.

It is expected that the separator of the present invention will have the greatest direct utility for batteries classified as "free maintenance" batteries.

Because these batteries are charged at varying potentials (here very low currents), only relatively small amounts of gas are generated.

All this gas problems are troublesome and harmful.

If gas is trapped between the plates and the separator, it will block the plate area and result in a corresponding loss of battery capacity.

One aspect of the invention, according to which a sheet of material is passed through the nip of a pair of calendering holes to produce a sheet having an embossed pattern on at least one side;
The sheet having an embossed pattern of and is passed through the nip of a pair of sizing rolls to compress the protrusions of the embossed pattern into the inside of the sheet, thereby adjusting the thickness of the sheet. A method of manufacturing a patterned sheet of material suitable for use as a battery separator is provided.

According to another aspect of the invention, the sheet of material comprises a sheet of material having an embossed pattern on its surface, the embossed pattern comprising a plurality of structures constituting between 15 and 60% of the surface area of the sheet; The plurality of grooves are comprised of first and second groups, the grooves in each group are parallel to each other, and the grooves in each group are parallel to each other.
There is provided a battery separator produced by the above method, characterized in that the grooves of the group are arranged to intersect the grooves of the second group.

Embodiments of the invention will now be illustrated with reference to the accompanying drawings, in which: FIG.

Referring first to FIG. 1 and to describe the invention in detail as it is believed to be the easiest to carry out, the sheet extrusion die 10 of the apparatus 11 will be recognized.

The calendering device 11 also includes two calendering rolls 12 and 13.

A sheet of plastic material 14 is extruded by an extruder and fed into the nip of calendering rolls 12 and 13.

In the nip of rolls 12 and 13, the material is kept in ridges 15.

Below the calendering rolls 12 and 13 are two sizing rolls 16 and 17.

This sizing roll 17 also serves as a transport roll for receiving the sheet 14 passing under the sizing roll 16.

Furthermore, the cooling rolls 18 and 19 and the take-up roll 20 can be seen in FIG.

Applying the method of the invention, sheets suitable for conversion into battery separators can be produced continuously.

Some forms of linear sheet 14 can be seen in FIGS. 2 and 3.

Sheet 14 has two opposing major surfaces 25 and 26, one of which is flat 25 and the other 26.
is a continuous series of ribs 29 rising at regular intervals
have.

The ribs 29 extend upwardly from the base 30 of the surface 26.

When this sheet leaves the calendaring roll 13,
There is usually some lack of uniformity in overall thickness.

This is shown in section 27 of FIG.

The sheet is then sized to a uniform thickness.

This is shown in section 28 of FIG.

The device 11 and its operation (for further details), are made of plastic material, preferably U.S. Pat.
An oil-filled plastic material such as that shown in Example 2 of No. 51,495 is extruded substantially as shown in that patent.

The material has an average molecular weight of 350,000. Standard load melt index is 0, high melt index is 1.8
, polyethylene (Grex FF60-018) with a density of 0.95 and a reduced specific viscosity of 4.0 was used as a hese, and as a filler, an average particle size of about 0.02 microns and a surface area of 165
rr? /fl fine powder silica (Hi 5i1233 ) is blended.

10 volumes of the polyethylene, 15 volumes of the silica,
75 volumes of petroleum (Shellflex) and 2,6-di-tert-butyl-4-methylphenol (Ionol ) is milled in a two-roll mill for approximately 5 minutes, removed as a sheet, crushed in a Willey mill, and extruded as a sheet through a standard 2.5 cm extruder.

The sheet is self-supporting, extruded, easily deformable, and relatively planar as shown in FIG.

This relatively flat surface means that the sheet is surging (S) at the base.
This does not mean that it does not include corrugations and other irregularities of substantial size, such as erging and irregular cap lip structures.

Indeed, using the present method, a significant amount of such irregularities can be tolerated due to the inclusion of certain suitable calendering steps.

The self-supporting sheet is stretched through the air between the die 10 and the calendering rolls 12 and 13 and into the nip of the calendering rolls.

This calendering roll stretches the sheet from the base 10.

Both calendering rolls are driven and pressed,
Surface velocity is tuned.

In other words, the surfaces of the calendering rolls have the same speed of movement, even if the rotational speed of the smaller calendering roll 12 is clearly faster than that of the smaller roll 13.

Calendering sails 12 and 13 are preferably operated with a constant gap to produce sheets of near uniform thickness.

The calendering roll 13 is connected to the land 3
6+ has a plurality of lateral grooves 35 separated from each other and made at uniform intervals on its circumference.

As the material of sheet 14 passes between calendering rolls, it is rotomolded.

The flat side of this sheet, that is, the surface 25 is smooth on the roll 1
2, and the ribbed side or surface 26 is formed by a grooved roll 13.

The calendering roll 13 is normally warm, i.e. about 9.
91-93°C (240-225°F) is considered a suitable warm temperature.

The other calendering roll 12 has a general (smooth) calendering surface and a temperature of about 114 to 106°C (2
40-225°F) and further heated to 134°G (275°F).

The calendering roll 12 can be heated internally by passing steam or hot water through it.

The calendering roll 13 receives heat from the sheet 14, but can maintain an optimum operating temperature by cooling it by passing water inside it.

The sheet to be calendered preferably travels around at least 20% of the circumference of the roll 13, but is shown traveling a length of about 50% of the circumference of the fluted roll 13. There is.

Roll 13 serves as a transport roll and partially cures the sheet containing ribs during movement due to the residence time of the sheet and roll in contact.

This is necessary to impart some elasticity to the sheet and perfect the shape of the ribs prior to stretching from the forming surface.

However, this sheet is somewhat malleable for the next process as described below.
), it is not completely cured, ie, set.

Fixation in this case means establishing a relatively static state in the sheet.

The term "fixed" as used herein refers to heat set plastic used in special cases.
s) This is not related to G.

Instead, in the present specification (fixation here refers to U.S. Pat.
, 351,495, 2005, and the curing of thermoplastics such as the preferred high density polyethylene materials described herein.

Heating the roll 12 has been found to be useful in preventing leather-like properties and other forming defects that occur on the flat side of the sheet.

Now consider what adjustments are made to the irregularities created in the die area during extrusion as described above.

In the nip of the calendering rolls 12 and 13, the extruded sheet of plastic material is kept in the form of very small embankments 15.

To keep the calendering rolls at the desired spacing t
The most efficient operation of the method does not require extremely high pressures, for which it is desirable to keep the embankment at a very low level.

Thus, it is important to maintain a careful balance in the thickness of the extruded sheet and the gap between the calendering rolls 12 and 13.

In the case of special operations, the extruded sheet passes through the air gap 1
The bank + sheet at the highest point G in the nip of the calendering rolls has an average thickness of 1.25 mm (50 mils) and passes through the calendering rolls. The thickness of the base surface then averages 0.3 mm (12 mils) and the average height of the ribs on the base surface is 1 mm (40 mils).

Sheet 1 while keeping the uniformity of the sheet thickness to the minimum distortion.
4 from the calendering roll 13, it is necessary to pull the partially cured ribs out of the groove one at a time.

That is, it is necessary to remove the ribs directly from the grooves at a speed that is similar to the gears moving away from each other and at which the calendered sheet is not moved by the grooved rolls 13, or at a slightly higher speed.

If this removal is not slightly faster than the speed of movement of the calendering rolls 13, the sheet will tend to relax from being completely cured and unbuttoned and slightly stretched.

It has been discovered that this above-described cooling and unloading method substantially prevents deformation and loss of the rib structure and then provides a completely fixed sheet.

The sheet is transferred from roll 13 to roll 1 which is in contact with its flat side.
Passed on 7.

This roll 17 is preferably cooled and begins final fixing of the sheet as soon as it comes into contact with the sheet.

The sheet passes under a sizing roll 16 which has the same surface speed as roll 17.

The sheet is preferably cooled on a sizing roll 1
6 and the cooling Ising ring 17 with a predetermined dimensional gap.

It should be understood that in this case the sheet is fed to two sizing rolls prior to complete setting or curing, and no heat is applied during the preferred sizing process.

In fact, at least one of the sizing holes is kept cold.

However, in a special case, outside IJ −j,
That is, heating the roll 16 to heat the tip is expensive.

The sizing rule 16 strikes one rib at a time, compressing the apex of the rib and determining the final thickness of the sheet at 1 from the apex of the rib to the outer planar surface of the sheet.

Of course, if rolls 16 and 17 are used, they both serve to strip the sheet from roll 13 and transfer it onto roll 17 below roll 13.

The sheet passes from roll 17 to take-up roll 201, which in turn stretches the sheet from roll 17.

If it is desired to complete the fixing of the sheet, it can be passed over additional cooling rolls 18 and 19 as shown in FIG.

Of course, other cooling means may be used.

For example, the sheet may be moved over a long distance to room temperature to provide additional cooling.

In some instances, this additional cooling is unnecessary.

In any case, the sheet is further cooled if necessary to complete the fixing.

The oil-added composition appears to be particularly successful when about 30, more preferably 65 or more parts by volume of oil is added prior to extrusion, and the oil is retained in the sheet during the process.

That is, the oil-added composition is formed into a thin sheet, then pressed through calender rings 12 and 13G and protruded on at least one side of the sheet before fixing and soaking the sheet to remove at least a portion of the oil. It transforms the parts.

Then, the sheet is adjusted to a predetermined thickness by pressing the protrusions into the interior of the sheet in the opposite direction.

The thickness dimension of the sheet is then fixed, after which the sheet is soaked to remove at least a portion of the oil.

Details of this soaking process are described in the above-mentioned U.S. patent. 3. Specification Q of No. 351,495 describes this.

Many variations on this method are possible.

For example, the calendering roll 13 may have a series of concavities shaped like relatively round pits rather than ribs.

Under these conditions, the sheets of Figures 4 and 5 are produced.

Here, the concave shape in the roll 13 corresponds to the protrusion 45 on the sheet 46.
You will understand that it is the opposite.

As in the case of the linear sheet above, there is usually some irregularity present in the initially calendered sheet, as shown in section 47 of FIG.
This can be corrected by sizing rolls 16 and 17 as shown at 48 in FIG.

Although less critical since the protrusions are further rounded, the sheet is shaped and calendered in a manner similar to that of the sheet described above, so that the protrusions are taken out substantially directly from the recesses of the roll. It is desirable to peel it off.

In addition to changing the types of these protrusions, various rib spaces can also be used.

Generally, the rib pattern is repeated one after another along a linear sheet.

In some cases, it may be desirable to also provide a pattern on the rollers 12 and provide a structured pattern on both sides of the sheet 14.

Additionally, in some cases it is desirable to provide a matching pattern on the sizing roll that receives the calendered sheet and to more carefully size the sheet.

In some cases, it is also possible to vary the thickness of the final sheet there by adjusting the gap of the sizing rolls.

That is, calendering rolls 12 and 13 without modification.
It is also possible to produce sheets with a thickness that differs by only 0.0 degrees from the final thickness.

In other cases, it may be desirable to include an additional calendering step in the process.

By extruding a sheet of material containing an average amount of plastic above the approximate amount of material required for the final sheet, extremely high quality and uniform sheets can be produced using relatively basic and inexpensive equipment. .

Secondary sizing roll operations increase this possibility.

This, when combined with the system for removing the sheet from the calendering rolls and the use of highly oiled plastics, brings this possibility to an extreme.

Among other things, the nodules 15 in the nip of the calendering rolls help minimize quality variations caused by chain alignment of high molecular weight polymers.

It is surprising that the method can also be successfully applied to plastic materials containing high amounts of inorganic solid fillers.

Preferred plastic materials contain 5 to 60 parts by volume of inert filler material, with preferred embodiments containing 15 parts by volume of filler.

A suitable filler is dry, finely divided silica.

The method is therefore also applicable to plastic compositions containing very substantial amounts of inert inorganic solids.

In other special circumstances, the method of the present invention may be used to produce battery separator sheet materials most rapidly (but not oil-filled) using the preferred plastic materials as previously described. G can also be applied.

In particular, the process of the invention can be applied to polymeric systems that are highly plasticized, in some cases using materials other than oil.

Herein, in special circumstances, various combinations of the entire method or parts thereof may be used with the omission of certain steps.
This will be obvious to colleagues.

Patterned sheets produced according to the method of the invention may also have other special uses, for example other than battery separators, where other patterned porous membranes with similar properties are desired.

A special battery separator 110 will now be described with reference to FIG.

The battery separator 110 has two parallel ends, an upper end 111 and a lower end 112.

This further includes first and second side ends 113 and 114 respectively.
has.

This side edge extends at right angles to the distal end.

The edges define the outer boundaries of the rectangular sheet, which is shown to scale in FIG.

This sheet has a width of 14375 rran (5, i inches) and a height of 131.25 am (5, i inches).

Separator 110 has first and second opposing outer surfaces 115 and 116 (Figure 7).

Surface 115 has an essentially planar main surface 117 in which two groups of grooves 120 and 121 are formed.

One of the groups of grooves 120 preferably contains at least three parallel grooves spaced apart.

Each groove extends from 30 to 600 degrees to at least one end and at least one other side end of the separate rake and is open through these ends.

It is observed that the groove indicated by line 120 extends at a substantially 45° angle and is open at distal end 112 and side end 1131.

The other group of grooves 121 preferably also include at least three parallel grooves spaced apart.

Each groove extends from 30 to 60' from and is open through at least one end and at least one other side end of the separator.

It can be seen that the groove indicated by the line 121 extends at a substantially 45° angle and is open at the distal end 112 and side end 1141.

Of course, if the medium to length ratio is large enough, then some of the grooves will open from the top to the bottom.

However, this is not the preferred form.

The grooves preferably constitute a surface 115 with an area less than or equal to the area between the grooves under normal circumstances.

The grooves are also optimally maintained at a surface area of 30-50% to balance the ability to release gas and the ability to retain the paste (i.e., active material).

In this case, 50 to 70 mm of the surface area of the separator surface is left as paste contact surface area.

In some cases, the area of the groove is 15-60% of the surface area of the face, in other words, the area of the protrusion is 40-85% of the surface area of the face.
You can very well.

Grooves 120 and 121 intersect each other at an angle of 900 degrees, but this angle of intersection should preferably be kept within the angular limits of 75-105 degrees.

Although grooves 120 and 121 are nominally vertical or horizontal in FIG.
can be the upper end, extending at an angle of 45° to the vertical of the intended upright use position of the seat.

The angle of this groove with respect to the vertical (vertical axis) is most preferably 45[deg.] and preferably should be maintained within 30-60[deg.].

Grooves 120 and 121 are preferably 4 to 2 inches apart in each row.

The grooves are preferably 1.56 to 4.68 mm (1.56 to 4.68 mm) (1.56 to 1.6 inches) wide and 0.13 to 0.25 mm deep.
(5-10 mils).

These dimensions provide suitable overall operating characteristics in a type of battery sold as a "maintenance free" battery.

The most preferred embodiment has a groove area of 44 and a protrusion area of 56 on surface 115.

These grooves have a spacing of 9-36 rrrrn (
s inches) and 0.18 mm (7 mils) deep.

For separators with the most favorable pore characteristics, separator assembly is particularly important.

These pores extend into the separator.

Also, 90% of the holes have a diameter of less than 1μ, and 99 holes have a diameter of 5μ
It has the following diameter:

This sheet is preferably one of U.S. Pat. No. 3,351,49
5 plastic material in the form of 125 cm (50 inch) wide rolls.

The special separator rolls of this invention are preferably manufactured by the continuous process herein, but may sometimes be manufactured by other methods.

separator surface 115 substantially contacts the battery plates;
This provides good support for the paste on the battery plates and for holding the electrode in a stable location within the battery.

and the contact between the separator and the cathode (which provides a minimum amount of gas escape path for the necessary escape of gases generated at the cathode in the cell, without unduly compromising the required continuity). .

The fact that surface 115 has substantially the same amount of gas passage and flow potential when the machine direction of the sheet is oriented vertically as when the cross machine direction is oriented vertically indicates that the preferred form of the separator of the present invention This is an important aspect of

Expressed in another way, the edges 111, 112, 1
This means that it does not matter whether the upper end position is 13 or 114.

Referring to FIG. 8, surface 116 has an essentially planar major surface 125 with spaced apart protrusions 126.

The protrusions (126) constitute an area of the second surface 116 that is less than 50φ and usually more preferably less than 25φ and most preferably less than 20% smaller than the area between the protrusions.

The surface 116 preferably has substantially the same amount of opening between the protrusions extending between the ends and between the protrusions extending between the side edges, so that the separator faces the gas generating battery plates and has substantially the same amount of opening between the protrusions extending between the ends and between the protrusions extending between the side edges, so that the separator faces the gas generating battery plates and has substantially the same amount of openings between the protrusions extending between the ends and between the protrusions extending between the side ends. When erected either way, gas can flow between the protrusions across the major surface of face 116.

The term "openings across the surface of surface 116" means that an unobstructed straight line can be drawn across the surface (see FIG. You can understand it by looking at it.

That is, when the separator is placed in a vertical position Q with its surface 116 in contact with the gas generating plate, gas must pass around the protrusions as it passes across the suitably shaped surface 116.

The protrusions 126 are preferably formed on the main surface 125 by 0.38~
The distance between the button, the bottom of the groove and the major surface 125 is preferably between 0.13 and 62 mils.
．． 5rrrIrL (5-20 mils).

The total thickness of the web including grooves is 0.25-0.75m
m (10-30 mils), and the total thickness of the separator is preferably 0.63-2.3 rr including protrusions 126.
maintained at rrrL (25-92 mils).

The equality of gas passage across faces 15 and 16 is preferably equal when either end of the separator is in the top position.

That is, the battery separator shown in FIG. 6 can be used with either its horizontal or vertical axis in the vertical position.

The surface 116 of the battery separator is shown in detail (in order to describe this, please refer to B. Holenbek).
ck), J. Tate, A. Stokerato (5
tockett ) and D. Simmons (
) et al., and which claims priority for the invention in U.S. Patent Application No. 258,887.

The separator of the present invention substantially contacts the battery plates, provides good support for the paste on the battery plates, and provides good support for isolating the plates in a stable and uniform position within the battery. It provides a surface that serves as a suitable support.

Furthermore, it provides a minimal amount of gas escape path for gases generated during charging of the battery.

This is particularly important when using battery separators with very small pores.

The reason for this is that such pores do not seem to allow all of the heat to escape through the separator itself, as can be seen in the case of battery separators with large pores.

In a typical preferred separator of the present invention, the opposite side of the separator, which is to be placed opposite the anode (which normally generates a relatively large amount of gas), has a larger gas passage area and a smaller battery plate. has a contact area with

Furthermore, it has been found that providing non-directional features to the structural features relating to support and gas dispersion is highly advantageous in making the separator economical to use and manufacture.

That is, the preferred separators of the present invention can be cut or used with equally good and uniform properties in machine direction or cross-machine direction offsets placed in a vertical position.

For the sake of clarity (although the separator of the present invention has been described in terms of a particular cut sheet, generally consistent with the use of a single side of a battery plate, the separator may be wrapped around a series of battery plates). It also has great utility in applications in the form of longer rectangular sheets.

Here, 1' winding means, when used in a single battery, to wrap a specific length of separator material in an S-shape, preferably around the circumference of a nearby battery plate. are doing.

This single long piece of separator material is used for sheet 11
0 at one end of the first outer anode (opposed surface 116)
6 and 7).

This sheet is then folded around the edge of the anode so that surface 11
6 in contact with the opposite side of the anode.

As a result, the surface 115 of the sheet 110 faces the adjacent cathode.

The sheet 110 is then folded around the edge of the cathode so that side 1
15 is in contact with the back side of the cathode, ie the opposite side.

As a result, the surface 116 faces the adjacent anode.

The separator sheet is then folded around the edge of the anode and the operation is repeated at 1 so that the sheet encases the plate assembly to the cell.

This effectively gives each battery plate surface the same separator properties as a separate, discontinuous separator sheet.

The separator material herein can also be formed into a bag into which individual positive electrode plates can be slid.

From the inner surface 116 and the outer surface 11 of this bag-like object.
It may consist of 5.

For example, in certain applications where it is desired to use the structure of the structured separator surface 115 on both sides of the separator (there may be various variations available).

Obviously, many minor improvements can be made, such as rounding the corners where the grooves meet and changing the crossing angle of the grooves, without changing the basic overall orientation angle on the face of the separator.

In some situations, only an electrically insulating separator is required that includes an end, a first base surface, and a surface having a plurality of passages folded below the base surface and having an opening through the end. However, the present invention may be practiced less completely.

Of course, this passage constitutes no more than 60% of the surface area of the surface (and if the insulating separator is intended for use with a surface in a vertical position, it may be oblique to the vertical). Probably.

Again, the passageways are preferably arranged in an intersecting pattern with each intersecting passageway being oblique to the vertical, and the spacing between passageways is not greater than 3 inches at maximum separation and other dimensions as previously described. That's probably what you did.

The main embodiments of the invention are as follows: 1. Two surfaces suitable for converting into battery separators and having one surface flat and the other surface having a series of transverse ribs spaced apart by a certain distance. In the continuous production of sheets with opposing major surfaces, a self-supporting, easily deformable, relatively planar sheet of plastic material is extruded, the sheet is stretched in a gap, and two sheets having synchronous surface velocities are extruded. Calendaring the sheet through calendering rolls, one of the calendering rolls having spaced transverse grooves around its periphery and being heated, and the other of the calendering rolls having having a smooth calendered surface and being heated, thereby forming the planar surface against the grooved roll;
Forming a very small bank of material from the extruded sheet in the nip of the calendering roll and keeping the bank low, the calendered sheet is placed in a small portion of the circumference of the fluted calendering roll. partially cure the calendered sheet containing the ribs, moving the partially cured ribs substantially directly from the ridges and the calendered sheet from the grooves. Remove the sheet once at a speed very slightly higher than that at which it is moved by the attached rolls, thereby preventing substantial deformation and loss of the rib structure, and before the sheet is completely fixed. contacting the sheet with its flat side against a cold transfer roll and passing the sheet under a cold sizing roll having the same surface speed as the cold roll;
and passing the sheet through a preset sizing gap between the sizing roll and the cold roll, pressing the sizing rolls against the apexes of the ribs one at a time, and compressing the apexes of the ribs to form the ribs. determining the final thickness of the sheet at 1 from the apex to the outer planar surface of the sheet, and then further cooling the sheet to complete its fixation. Manufacturing method.

2. Prior to extrusion, add 30 volumes or more of oil to the plastic material and retain the oil in the core sheet of the process, and add 5 volumes of inert finely ground silica filler to the plastic material. The above-mentioned method is characterized in that the method is characterized in that the above filling is performed.

3. Suitable for conversion into battery separators and in the continuous production of sheets having two opposite major surfaces with at least one surface having a series of protrusions spaced apart by a distance (this is easily deformable). A body of plastic material capable of being made of plastic material is fed into the nip of two calendering rolls, with the proviso that at least one of the calendering rolls has concavities spaced at intervals on its circumference, Formed between two calendering rolls, where the concave shape produces a sheet with a protrusion thereon, and the formed sheet is placed between two sizing jigs with a preset sizing gap. A process for continuous production of a sheet, characterized in that the projections are compressed into the inside of the sheet by at least one of the sizing rolls to determine the final thickness of the sheet.

4. The other surface is planar and the body of material is a relatively planar extruded sheet stretched in the nip of the calendering rolls before being fed into the nip, one of the calendering rolls being The other of the two calendering rolls has a smooth calendering surface and is heated so that the planar surface is shaped by the smooth roll and the nip of the calendering roll has a smooth calendering surface. Form a very small bank of material from the extruded sheet and keep it low, between the two sizing rolls (
The method as described above, characterized in that at least one of the sizing rolls is kept cool and that no heat is supplied to the sheet during the sizing process.

5. Suitable for conversion into a battery separator and having two opposing major surfaces with at least one surface having a series of protrusions spaced apart, the sheet is Stretched in the air gap, the sheet is calendered between two calendering rolls, with the proviso that at least one of the calendering rolls has concavities spaced at intervals on its circumference; The two calendering rolls are heated, thereby causing the concave rolls to form the sheet into a sheet with protrusions and to reduce the size of the material from the sheet.

forming a bank and keeping it low, moving the calendered sheet around at least a portion of the circumference of the concave calendering roll and partially curing the sheet with the projections; , wherein the partially cured protrusions are removed substantially linearly from the concave shape of the roll to substantially prevent substantial deformation and lack of the protrusions. Law.

6. Suitable for conversion into battery separators and easy to manufacture ( The deformable plastic material body is fed to a roll forming means, the material body is roll formed to produce a formed sheet having a plurality of protrusions spaced apart at a certain distance, and the formed sheet having the protrusions is said partially cured sheet, and then adjusting the dimensions of said partially cured sheet to a predetermined sheet thickness by compressing said partially cured sheet. Continuous manufacturing method.

7. Forming the oiled thermoplastic composition into a thin sheet having two opposing substantially planar surfaces and applying pressure to the sheet before solidifying the sheet and before dipping the sheet. The dimensions of the sheet are adjusted to a predetermined thickness by forming protrusions on the 10,000 side and then pressing the protrusions against the ferrous side, still prior to solidification and soaking of the sheet. a method for producing a battery separator, the method comprising: fixing the thickness of the sheet; and soaking the sheet to remove at least a portion of the oil additive.

8. The protrusion is a protruding rib that extends across the linear sheet in a continuous direction, the other side is smoothed at the same time as the rib is formed, and sizing is performed by pressing the apex of the rib against the smooth side. The above method characterized by:

9. Feeding a body of polymeric material filled with oil and inert solids to a roll-forming means, rolling the body, curing the pattern, and dipping the sheet to remove the filling. 1. A continuous method for producing a patterned porous membrane, characterized in that at least a portion of the membrane is removed to produce a porous membrane.

10. A battery separator consisting of two parallel ends and first and second side ends extending at right angles to the ends, and first and second sides, where the ends meet the outer boundaries of the rectangular sheet. The first surface has a basically planar main surface and two groups of grooves pressed into it, and one group of political conditions exists in parallel at a certain interval. and 30 to 6 for at least one end and at least one side end.
The first surface includes at least three grooves extending at an angle of 00 degrees, the other group of political conditions extends at an angle of 30 to 60 degrees with respect to the group of grooves, and the surface area is smaller than the area between the grooves. constitutes an area of
the second surface has an essentially planar major surface with spaced apart protrusions, the protrusions constituting an area of the second surface that is less than the area between the protrusions, and the separator A battery separator having pores in the separator, wherein over 90 of the pores have a diameter of 1μ or less and 99% have a diameter of 5μ or less.

11. the second surface has a substantially equal opening between the protrusions between the distal end and the side end, thereby placing the separator in a vertical position facing the gas generating battery plate; The battery separator 12 is characterized by a scale in which gas flows across the main surface between the protrusions when the battery separator 12 is erected with one of the ends facing up, a surface consisting of a first base surface and a plurality of grooves. The electrically insulating separator comprising the iron surface covers 15-60% of the surface area, and the plurality of grooves are the first and second grooves.
It consists of a group of grooves, each of the grooves of the group consists of at least two parallel grooves spaced apart at a certain distance, and the grooves of the first group form grooves of other families at an angle of 75 to 105°. 1. An electrically insulating separator, characterized in that it is arranged over and over and at an angle of 30 to 60° to the vertical of a seat intended for upright stool.

13. The above separator, wherein the grooves constitute 30 to 50% of the surface area of the face.

14. The first group and the second group of grooves are substantially 90° to each other.
and intersects at an angle of substantially 45° to the vertical of the sheet intended for upright use.

15. a separator comprising a second separator surface opposite the first surface, the second surface having an essentially planar major surface with protrusions spaced apart at certain intervals, the protrusions being between the portions; A separator characterized in that the area of the first surface is smaller than the surface of the separator.

16. A separator comprising a second separator surface opposite the first surface, wherein the second surface has an essentially planar major surface with spaced apart protrusions; comprising not more than 20% of the area of said second surface and having substantially the same amount of opening between said portions at a substantially 45° angle to the groove when used upright; A separator characterized in that when the separator is used vertically with the protrusions on the two sides in contact with the gas generating surface, gas flows across the second side of the separator between the protrusions.

17. The grooves in each group are 625-12.5 mm (%-% inches) apart, and the width is 1.56-4.68 rIvn (%
~"7f; 3 inches) and has a depth of 5 to 10 mils.

18. An electrically insulating separator comprising an end, a first base surface, and a surface having a plurality of passages stamped into the base surface and opening through the end of the separator, wherein the passages have a surface area of the iron surface. When the insulating separator is in an upright state, it is perpendicular (as opposed to diagonal Q).
An insulating separator that is characterized by its unique features.

19. The passageways are arranged in an intersecting pattern, provided that each intersecting passageway crosses the insulating separator in an upright position (oblique to vertical when crossed, and the passageway is 12.5 mm for maximum separation). (3 inches) or more apart evenly and the width is 1.56 to 4.68 rrarL (mine ~ % inches)
and a depth of 0.13-0.25M (5-10 mils), and a thickness of the continuous portion of the separator of 0.13-0.25M (5-10 mils).
A separator characterized in that it is 5rML (5-20 mil).

[Brief explanation of drawings]

FIG. 1 is a schematic representation of a system for manufacturing a product according to the subject matter of the invention, and FIG. 2 is an enlarged partial top view of a battery separator sheet material manufactured according to the invention. This is a diagrammatic representation, and FIG. 3 shows the line 3-
3, and FIG. 4 is an enlarged partial schematic representation of a different battery separator made in accordance with the present invention, and FIG.
6 is a top view of one side of the preferred separator of the present invention, and FIG. 7 is an enlarged cross-section of the section 7 of the separator in FIG. 6, viewed in the direction of the arrow. FIG. 8 is a top view of opposing sides of a preferred separator of the present invention.

Claims (1)

Claims: 1. Passing a sheet of material through the nip of a pair of calendering rolls to produce a sheet having an embossed pattern on at least one side; The protrusions of the embossed pattern are compressed into the inside of the sheet through the nip of a sizing roll, thereby imparting a pattern suitable for use as a battery separator characterized by adjusting the thickness of the sheet. 2. Passing a sheet of material through the nip of a pair of calendering holes to produce a sheet having an embossed pattern on at least one side; through the nip of a pair of sizing hangers to compress the protrusions of the embossed pattern into the inside of the sheet, thereby adjusting the thickness of the sheet. Consisting of a sheet of material having an embossed pattern, the embossed pattern is buttoned in the form of a plurality of protrusions constituting 40 to 85φ of the sheet surface area, and the plurality of protrusions are located between them. [The first group of grooves and the second group of grooves are fixed, and the grooves in each group Q are parallel to each other and arranged so as to intersect with either the first group of grooves or the second group of grooves. , a method for producing a patterned sheet of material suitable for use as a battery separator.