Batteries, separators, components and compositions with heavy metal removal capability and related methods

• US 10,329,425 B2
• Filed: 06/06/2017
• Issued: 06/25/2019
• Est. Priority Date: 09/22/2010
• Status: Active Grant

• Current Assignee: Daramic LLC (Asahi Kasei Corporation)
• Original Assignee: Daramic LLC (Asahi Kasei Corporation)
• Inventors: Chambers, Jeffrey K., Shah, Tejas R.
• Primary Examiner(s): Gatewood, Daniel S
• Application Number:
  US15/614,740
• Publication Number:
  US 20170267863A1
• Time in Patent Office: 749 Days
• Field of Search: None
• CPC Class Codes: C08L 89/00 Compositions of proteins; Compositions of derivatives thereof foodstuff preparations A23J3/00
• CPC Class Codes: H01M 10/10 Immobilising of electrolyte
• CPC Class Codes: H01M 50/446 Composite material consisting of a mixture of organic and inorganic materials
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

In accordance with at least certain embodiments of the present invention, a novel concept of utilizing PIMS minerals as a filler component within a microporous lead-acid battery separator is provided. In accordance with more particular embodiments or examples, the PIMS mineral (preferably fish meal, a bio-mineral) is provided as at least a partial substitution for the silica filler component in a silica filled lead acid battery separator (preferably a polyethylene/silica separator formulation). In accordance with at least selected embodiments, the present invention is directed to new or improved batteries, separators, components, and/or compositions having heavy metal removal capabilities and/or methods of manufacture and/or methods of use thereof.

Claims

1. A lead acid battery separator having a front face and a reverse face, the separator comprising

a porous, silica filled, polymer membrane having a backweb with integral ribs, wherein the ribs comprise of positive ribs on the front face, and a plurality of negative cross ribs on the reverse face, and

wherein the polymer membrane further comprises apatite particles and/or hydroxyapatite particles, said particles binding at least a portion of heavy metal, said heavy metal including lead.

2. The battery separator of claim 1, wherein the positive ribs are longitudinal ribs.

3. The battery separator of claim 2, wherein the negative cross ribs are shorter and more tightly spaced than the longitudinal ribs.

4. The battery separator of claim 1, wherein the negative cross ribs have a spacing of from 0.254 mm to 1.27 mm.

5. The battery separator of claim 1, wherein the negative cross ribs have a radius of from 0.0508 mm to 0.152 mm.

6. The battery separator of claim 3, wherein the negative cross ribs are transversely extending.

7. The battery separator of claim 1, wherein the negative cross ribs comprise fissures or recesses to form channels in the separator.

8. The battery separator of claim 1, wherein the separator has an overall thickness of from 0.2 to 4 mm.

9. The battery separator of claim 1, wherein the particles have a D₅₀ particle size from 10 microns to 80 microns.

10. The battery separator of claim 1, wherein the separator is a porous polyethylene and silica filled battery separator having the particles substituted for at least a portion of the silica filler.

11. In a battery, the improvement comprising the battery separator of claim 1.

12. The battery according to claim 11, wherein the battery is a flooded lead acid battery.

13. The battery according to claim 11, wherein the battery is an enhanced flooded lead acid battery (EFB).

14. In a battery, the improvement comprising the battery separator of claim 3.

15. The battery according to claim 14, wherein the battery is a flooded lead acid battery.

16. In a battery, the improvement comprising the battery separator of claim 6.

17. The battery according to claim 16, wherein the battery is a flooded lead acid battery.

18. The lead acid battery separator of claim 1,

wherein the positive ribs are longitudinal ribs, the negative cross ribs are shorter and more tightly spaced than the longitudinal ribs, and the negative cross ribs are transversely extending.