WO2000023267A1 - Separateur de batterie - Google Patents

Separateur de batterie Download PDF

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Publication number
WO2000023267A1
WO2000023267A1 PCT/US1998/022586 US9822586W WO0023267A1 WO 2000023267 A1 WO2000023267 A1 WO 2000023267A1 US 9822586 W US9822586 W US 9822586W WO 0023267 A1 WO0023267 A1 WO 0023267A1
Authority
WO
WIPO (PCT)
Prior art keywords
ribs
backweb
major
battery separator
submini
Prior art date
Application number
PCT/US1998/022586
Other languages
English (en)
Inventor
James Young
Francis E. Alexander
Daniel E. Weerts
Original Assignee
Amtek Research International Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Amtek Research International Llc filed Critical Amtek Research International Llc
Priority to AU11993/99A priority Critical patent/AU1199399A/en
Priority to PCT/US1998/022586 priority patent/WO2000023267A1/fr
Priority to CA002269091A priority patent/CA2269091A1/fr
Priority to DE29904614U priority patent/DE29904614U1/de
Publication of WO2000023267A1 publication Critical patent/WO2000023267A1/fr

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/489—Separators, membranes, diaphragms or spacing elements inside the cells, characterised by their physical properties, e.g. swelling degree, hydrophilicity or shut down properties
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/403—Manufacturing processes of separators, membranes or diaphragms
    • H01M50/406—Moulding; Embossing; Cutting
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/409—Separators, membranes or diaphragms characterised by the material
    • H01M50/411—Organic material
    • H01M50/414—Synthetic resins, e.g. thermoplastics or thermosetting resins
    • H01M50/417—Polyolefins
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/463—Separators, membranes or diaphragms characterised by their shape
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/06—Lead-acid accumulators
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries

Definitions

  • This invention relates to a battery separator for use in flooded cell type lead acid batteries.
  • the positive and negative electrodes or “plates” are separated by a battery separator.
  • the battery separator typically has "ribs" or protrusions extending from at least one planar face of the separator.
  • Such ribs are formed in one of several ways : the ribs can be formed integrally with the backweb of the separator; the ribs can be subsequently applied to the backweb as a bead of the same or different material as the backweb; or the ribs can be formed by embossing the backweb.
  • the ribs function to provide proper spacing between the plates and to provide a space wherein free electrolyte resides.
  • the battery separator currently used by most flooded cell type lead acid battery manufacturers is of the microporous polyethylene type.
  • This type of separator has a composition consisting essentially of an ultra high molecular weight polyethylene, a filler (typically amorphous silica) , a plasticizer (typically a processing oil) , and certain minor ingredients such as an antioxidant, lubricant and carbon black.
  • Microporous polyethylene separator material is commercially manufactured by passing the ingredients through a heated extruder, passing the extrudate generated by the extruder through a die and into the nip formed by two heated calender rolls to form a continuous web, extracting a substantial amount of the processing oil from the web by use of a solvent, drying the extracted web, slitting the web into lanes of predetermined width, and winding the lanes into rolls.
  • Such separators and a method of manufacturing them are described in U.S. Patent No. 3,351,495.
  • Microporous polyethylene separators typically have a configuration comprising a backweb having a predetermined thickness, and a plurality of parallel ribs spaced apart a predetermined distance and extending outwardly from one planar surface of the backweb.
  • the ribs extend continuously in a longitudinal direction parallel to the edges of the separator material.
  • the thickness of the backweb and height and spacing of the ribs is specified to the separator manufacturer by the battery manufacturer; the specifications are designed to maximize certain battery characteristics desired by the battery manufacturer.
  • SLI Starting-lighting-ignition
  • mini-ribs between such "major” ribs to add stiffness to separator webs having thinner backwebs .
  • Such mini-ribs have a lower height than he major ribs and are spaced closer together.
  • the height of such mini-ribs typically varies between about 0.006 inch and bout 0.009 inch.
  • the spacing of such mini-ribs varies between about 0.060 inch and about 0.250 inch.
  • Such ribs are formed during manufacture of the microporous polyethylene separator by providing that one of the two heated calender rolls forming he nip through which the extrudate from the extruder is fed is engraved with grooves so that the ribs are formed as an integral part of the separator web.
  • integrally formed ribs in the polyethylene type separator undergoes extraction along with the backweb and, because it has relatively more volume than a portion of the backweb occupying the same planar surface area, generally the ribs retain more processing oil than the backweb, thereby raising the overall electrical resistance of the separator.
  • a battery separator having a longitudinal dimension, a width dimension perpendicular to said longitudinal dimension, upper and lower planar faces, and a plurality of ribs (at least three) projecting from at least one planar face, said ribs extending in a direction substantially parallel to the longitudinal dimension (axis) of the separator, each of the ribs being formed of a plurality of individual projecting embossments forming a corrugated structure comprised of alternating ridges and furrows.
  • the ribs may extend from one or both planar faces of the separator.
  • the ribs extend from both planar faces, adjacent projecting embossments (ridges) on one planar face are separated by an indentation (furrow) which forms a projecting embossment (ridge) on the other planar face of the separator.
  • the ribs projecting from one planar surface may have a height equal to or different from the height of the ribs extending from the other planar surface.
  • the improved battery separator of the 08/837,286 patent application employs an embossable base web comprised of a backweb having a plurality of submini-ribs extending from at least one planar face thereof, the base web being embossed with a plurality of major ribs, each major rib being substantially parallel to the longitudinal axis of the backweb and extending into at least one, and preferably two, adjacent submini-ribs to form a separator having improved compression resistance.
  • the base embossable base web having submini-ribs thereon is separately disclosed and claimed in U.S. Patent Application No. 08/837,287 filed April 11, 1997.
  • 08/837,286 have embossed (major) ribs that are disposed substantially parallel to the longitudinal dimension (axis) of the separator, and were designed for use in batteries having flat plates. It has been found that when attempting to use such separators to envelope (wrap) tubular plates the separator tended to nest down around the plate. In addition, acid (electrolyte) stratification and gas release were not satisfactory.
  • This invention relates to a battery separator having a longitudinal dimension, a width dimension perpendicular to said longitudinal dimension, upper and lower planar faces, a plurality of submini-ribs extending from at least one of said planar faces, and a plurality of major ribs extending diagonally across the width of the separator, the major ribs being comprised of individual projecting embossments forming a corrugated structure having alternating ridges and furrows extending through at least some of the submini-ribs.
  • FIG. 1 is a partial top view of the upper planar surface of the separator of this invention showing the relative location of the major ribs and with the submini-ribs omitted.
  • FIG. 2 is an enlarged partial edge view in cross-section of a major rib of the separator of this invention taken along line 2-2 of FIG. 1.
  • FIG. 3 is a partial perspective top view of the upper planar surface of the separator of this invention showing the relative location of both the major ribs and the submini-ribs.
  • FIG. 4 is an enlarged partial edge view in cross-section of the separator of this invention taken along line 4-4 of FIG. 3.
  • FIG. 5 is a partial top view of a major rib embossed into submini-ribs.
  • FIGS. 6 through 8 are partial top views of individual major ribs illustrating several variations on the angle of the ridges and valleys of the major rib to the longitudinal axis of the separator.
  • FIG. 1 is a partial top view of a piece of the separator 10 of this invention. Projecting from the upper planar surface 12 of separator 10 are a plurality of major ribs 14a through 14w. For the sake of clarity, only major ribs 14a, 14b, 14u, 14v and 14w have been identified on FIG. 1, the major ribs located between 14b and 14u being 14c- 14t, respectively. Again, for sake of clarity, only major ribs 14 are illustrated, the submini- ribs being omitted.
  • the major ribs 14 are disposed across the width of the separator diagonally to the longitudinal axis of the separator 10.
  • the longitudinal axis of separator 10 extends in the direction of the arrow and is parallel to longitudinal edges 17 and 18 thereof.
  • the separator material is manufactured in roll form with the longitudinal dimension being several thousand feet .
  • the angle of the major ribs 14 to the longitudinal axis of separator 10 may vary between about 6 degrees and about 45 degrees.
  • major ribs 14 do not extend all the way to the edge of separator 10, as seen by reference to major ribs 14a, 14v and 14w in
  • FIG. 1 A margin free of major ribs is thereby left to permit overlapping and sealing of the edges of the separator where it is formed into an envelope around a plate. In some applications, however, it may be desirable to extend the major ribs to the edges of the separator.
  • submini-ribs 15 are disposed substantially parallel to the longitudinal axis of separator 10.
  • submini-ribs 16 extend from the lower planar surface 13 of separator 10.
  • Submini-ribs 16 are of the same size and spacing as submini-ribs 15; however, submini-ribs 16 are preferably spaced so that they do not fall in the same plane as submini-ribs 15.
  • Major ribs 14 are formed by embossing separator
  • FIG. 2 is a partial edge view in cross-section of separator 10 taken along Line 2-2 of FIG. 1.
  • Major rib 14a projects above upper planar surface 12 of backweb 20 and below lower planar surface 13 thereof. Adjacent submini-ribs 15 and 16 are shown extending from the upper planar face 12 and lower planar face 13, respectively, of backweb 20.
  • major rib 14a is a corrugated structure comprised of alternating ridges and furrows 22a and 23a, 22b and 23b, 22c and 23c, etc., respectively extending from upper planar surface 12.
  • that part of major rib 14a extending from lower planar surface 13 is a corrugated structure comprised of alternating ridges and furrows 24a and 25a, 24b and 25b, 24c and 25c, etc., respectively.
  • a ridge on one planar surface forms the furrow on the other planar surface, and vice versa.
  • the underside of ridge 22a extending from upper planar surface 12 forms the furrow 25a of that portion of major rib 14 extending from lower planar surface 13.
  • major ribs 14 are being embossed into the separator base sheet comprised of the backweb 20 and submini-ribs 15 and 16, they are pressed into submini- ribs 15 and 16 at the intersections of the submini-ribs and the lanes forming major ribs 14. Those portions of submini-ribs 15 and 16 thus incorporated into major ribs 14 provide increased compression resistance thereto.
  • the spacing and size of major ribs 14 and submini-ribs 15 and 16 is such that each "section" of a major rib 14 diagonally intersects at least one and preferably at least two or three submini-ribs.
  • a "section" of a major rib 14 is meant that portion of a major rib encompassed between a ridge and an adjacent furrow and between the edges of the major rib lane extending between said ridge and said adjacent furrow.
  • FIG. 4 A side view illustrating the relationship between major ribs 14 and submini-ribs 15 and 16 is illustrated in FIG. 4 and a top view of this relationship is illustrated in FIG. 5.
  • FIG. 5 the various "sections" of major rib 14 are designated by the reference numerals 30a through 30e.
  • major ribs 14 and submini- ribs 15 and 16 can be seen in cross-section by reference to FIG. 4.
  • the length dimension of the ridges 22 and 24, i.e., the length of the ridges 22 and 24 from one side wall 26 to the other side wall 28 of major rib 14, is selected in accordance with the desired width of the rib. This dimension will generally be between about 0.020 and about 0.100 inch.
  • the frequency of the ridges, i.e., the number of ridges per unit of rib length, will preferably be between about 5 and about 25 ridges per inch.
  • the height of the ridges 22 and 24 above the respective planar surfaces 12 and 13 of the backweb 20 is selected in accordance with the height of the major ribs
  • the submini-ribs 15 are particularly useful in providing improved compression resistance when the desired height of major ribs 14 is greater than about 0.030 inch.
  • the distance between adjacent major ribs 14 will generally be between about 0.25 to about 1.0 inch.
  • the height of the submini-ribs above the upper planar surface of the separator will_ generally be between about 0.003 inch and about 0.009 inch. Selection of an appropriate height for the submini-ribs 15 will depend upon the height of the major ribs 14 and the desired compression resistance.
  • the width of the submini-ribs will generally be between about 0.010 inch and about 0.020 inch.
  • the submini-ribs 15 will generally be evenly spaced, between about 0.025 inch and about 0.050 inch, across the width of the separator.
  • the width of the separator of this invention can be any width used by battery manufacturers; generally this width will range between about 2 to about 12 inches with side edges 16 and 18 being parallel to each other.
  • the thickness of backweb 20 of the separator 10 will typically range between about 0.002 to about 0.025 inch.
  • the corrugated structure forming the rib of this invention illustrated in FIG. 3 is shown as being triangular, with each individual embossed projection thus being wedge shaped. It is preferred, however, to round the wedge shaped embossments, as seen in FIG. 2.
  • One of the advantages obtained in using the separator of the present invention is that, since the ribs are a corrugated structure formed of adjacent ridges and furrows, and the major ribs are disposed at a diagonal to the longitudinal axis of the separator, when wrapped around a tubular plate the separator provides a substantially barrier free environment for flow of electrolyte and any gases released during charging and discharging since the ribs contact the plates only in the ridge area.
  • the use of submini-ribs to provide higher major rib height without loss of compression resistance also allows separators to be made with thinner backwebs which means a savings in the amount of material required to make a specified square footage of separator product.
  • submini-ribbed separator product Another advantage to the submini-ribbed separator product is that longer production runs between tooling changes can be made compared to manufacturing separator product with major ribs being formed on the production line. Also, solvent extraction and drying of submini-ribbed product is easier and faster than a product having major ribs formed integrally thereon during manufacture.
  • separator of the invention is illustrated as having major ribs 14 extending from both planar surfaces 12 and 13 of the backweb 20, the invention is intended to include a separator where the major ribs extend from only one planar face.
  • the height of the ribs 14 above planar surfaces 12 and 13, respectively, of backweb 20 may be the same or the height of the ribs on one side may be greater or lesser than the height of the ribs on the other side.
  • the submini-ribs 15 and 16 have been described as extending from both planar surfaces of the separator. In such a configuration the submini-ribs on the two planar surfaces may have the same or different heights. However, the separator may be configured so that submini-ribs extend from only one planar face.
  • adjacent ridges of a major rib 14 may vary in height.
  • the formation of the ribs of the present invention involves plastic deformation of the backweb material at the location where the embossing takes place. Plastic deformation indicates that the material was loaded beyond its yield point which, by definition, means that it has experienced plastic flow. It has been shown that oxidation resistance is improved in the area of plastic deformation due to oil being driven to the surface upon collapse of micropores ._
  • thermoplastic polymers include polymers and copolymers of ethylene, propylene, butylene, vinyl chloride and styrene.
  • Suitable thermoset compositions include phenolics, ethylene/propylene/diene, isoprene, butadiene, styrene and similar thermosetting polymers.
  • the ribs have been illustrated in the preferred embodiment disclosed herein as having ridges and furrows that are perpendicularly aligned with the longitudinal edges of the lanes forming major ribs 14.
  • the alignment of the ridges and furrows may be such as to form an angle to the longitudinal edges of said lanes.
  • the alignment may be perpendicular to the longitudinal axis of the separator, or perpendicular to a diagonal line lying along the mirror image of the angle between the diagonal line forming the axis of the major ribs 14 and the longitudinal axis of the separator. Examples of such alternative configurations are illustrated in FIGS. 6-8.
  • ridges and furrows may have the patterns disclosed in copending patent application Serial No. 08/646,764. The disclosure of this patent application is hereby incorporated by reference.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Cell Separators (AREA)
  • Electrophonic Musical Instruments (AREA)
  • Primary Cells (AREA)
  • Fluid-Pressure Circuits (AREA)

Abstract

L'invention concerne un séparateur (10) de batterie destiné à être utilisé dans les batteries au plomb à accumulateurs immergés, lequel séparateur comprend un élément (20) de support constitué d'un matériau poreux, résistant à l'électrolyte et gaufrable, pourvu d'une pluralité de nervures (14a) principales et de nervures (15, 16) secondaires s'étendant à partir d'une surface plane (12, 13) au moins de l'élément (20) de support, dans toute la largeur de l'élément (20) de support. Ces nervures (15, 16) secondaires s'étendent dans une direction sensiblement parallèle à la dimension longitudinale de l'élément (20) de support. Les nervures (14a) principales s'étendent en diagonale par rapport à la dimension longitudinale de l'élément (20) de support. Chaque nervure principale (14a) se présente sous la forme d'une structure ondulée gaufrée comprenant une alternance de crêtes et de sillons (22a, b et c, 23a, b et c, 24a, b et c et 25a, b et c). Le séparateur (10) est particulièrement utile dans une batterie au plomb à accumulateurs immergés à plaques tubulaires.
PCT/US1998/022586 1998-10-21 1998-10-21 Separateur de batterie WO2000023267A1 (fr)

Priority Applications (4)

Application Number Priority Date Filing Date Title
AU11993/99A AU1199399A (en) 1998-10-21 1998-10-21 Battery separator
PCT/US1998/022586 WO2000023267A1 (fr) 1998-10-21 1998-10-21 Separateur de batterie
CA002269091A CA2269091A1 (fr) 1998-10-21 1998-10-21 Separateur de batterie
DE29904614U DE29904614U1 (de) 1998-10-21 1999-03-12 Batteriescheider

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US1998/022586 WO2000023267A1 (fr) 1998-10-21 1998-10-21 Separateur de batterie

Publications (1)

Publication Number Publication Date
WO2000023267A1 true WO2000023267A1 (fr) 2000-04-27

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ID=22268157

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1998/022586 WO2000023267A1 (fr) 1998-10-21 1998-10-21 Separateur de batterie

Country Status (4)

Country Link
AU (1) AU1199399A (fr)
CA (1) CA2269091A1 (fr)
DE (1) DE29904614U1 (fr)
WO (1) WO2000023267A1 (fr)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9461291B2 (en) 2011-11-21 2016-10-04 Daramic, Llc Embossed separators, batteries and methods
CN112970143A (zh) * 2018-09-04 2021-06-15 达拉米克有限责任公司 电池隔板、电极组件、系统及相关方法
CN114221094A (zh) * 2021-11-26 2022-03-22 南京雷文斯顿企业管理咨询有限公司 一种电池隔膜及其制备方法
CN114678661A (zh) * 2015-10-07 2022-06-28 达拉米克有限责任公司 铅酸电池隔板、铅酸电池、车辆及其相关方法
CN115395177A (zh) * 2015-10-07 2022-11-25 达拉米克有限责任公司 电池隔板、富液式铅酸电池和相关方法

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4369236A (en) * 1981-03-04 1983-01-18 W. R. Grace & Co. Battery separator
US4403024A (en) * 1982-01-11 1983-09-06 W. R. Grace & Co. Battery separator
US5679479A (en) * 1996-05-08 1997-10-21 Amtek Research International Llc Battery separator
US5789103A (en) * 1997-04-11 1998-08-04 Amtek Research International Llc Battery separator and method of making

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4369236A (en) * 1981-03-04 1983-01-18 W. R. Grace & Co. Battery separator
US4403024A (en) * 1982-01-11 1983-09-06 W. R. Grace & Co. Battery separator
US5679479A (en) * 1996-05-08 1997-10-21 Amtek Research International Llc Battery separator
US5789103A (en) * 1997-04-11 1998-08-04 Amtek Research International Llc Battery separator and method of making

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9461291B2 (en) 2011-11-21 2016-10-04 Daramic, Llc Embossed separators, batteries and methods
CN114678661A (zh) * 2015-10-07 2022-06-28 达拉米克有限责任公司 铅酸电池隔板、铅酸电池、车辆及其相关方法
CN115395177A (zh) * 2015-10-07 2022-11-25 达拉米克有限责任公司 电池隔板、富液式铅酸电池和相关方法
CN114678661B (zh) * 2015-10-07 2024-05-07 达拉米克有限责任公司 铅酸电池隔板、铅酸电池、车辆及其相关方法
CN112970143A (zh) * 2018-09-04 2021-06-15 达拉米克有限责任公司 电池隔板、电极组件、系统及相关方法
CN114221094A (zh) * 2021-11-26 2022-03-22 南京雷文斯顿企业管理咨询有限公司 一种电池隔膜及其制备方法

Also Published As

Publication number Publication date
CA2269091A1 (fr) 2000-04-21
DE29904614U1 (de) 1999-07-15
AU1199399A (en) 2000-05-08

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