BATTERIES, SEPARATORS, COMPONENTS, AND COMPOSITIONS WITH HEAVY METAL REMOVAL CAPABILITY AND RELATED METHODS

• US 20190309166A1
• Filed: 06/24/2019
• Published: 10/10/2019
• 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.
• Granted Patent: US 11,208,558 B2
• Time in Patent Office: Days
• 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 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 negative cross ribs rib patterns include;

continuous linear ribs, cross-hatched, sinusoidal or wavy continuous, sinusoidal or wavy discontinuous, intermittent and registered linear, or other rib patterns which include combinations or variations of the foregoing.

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

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

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

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

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

7. The lead acid battery separator of claim 1, wherein the negative cross ribs have a height of between approximately 0.02 mm to approximately 0.30 mm.

8. The lead acid battery separator of claim 1, wherein the polymer membrane has a thickness of between approximately 0.065 mm to approximately 0.750 mm.

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

10. The lead acid battery separator of claim 1, wherein the particles have a D50 particle size from 10 μ

m to 80 μ

m.

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

12. The lead acid 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.

13. 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.

14. A battery comprising the lead acid battery separator of claim 1.

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

16. The battery according to claim 14, wherein the battery is an enhanced flooded lead acid battery (EFB).

17. A battery comprising the lead acid battery separator of claim 3.

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

19. A battery comprising the lead acid battery separator of claim 4.

20. The battery according to claim 19, wherein the battery is a flooded lead acid battery.

24. The lead acid battery separator of claim 1, wherein the membrane comprises one of the following consisting of:

a microporous or macroporous thermoplastic material, preferably polyethylene, polypropylene, polyvinyl chloride, and the mixtures thereof;

rubber;

polyolefin;

phenolic;

crosslinked phenolic resin;

cellulosic;

glass;

or combinations thereof.

25. The lead acid battery separator of claim 1, wherein the separator may be a cut piece separator or a wrap, envelope, pouch, sleeve, or pocket type separator.

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

a porous silica-filled membrane having a backweb with a plurality of negative cross ribs on the reverse face, and

wherein a nonwoven material is bonded or laminated to the front face.

22. The lead acid battery separator of claim 21, wherein the nonwoven material comprises one of the following consisting of:

synthetic, natural, organic or inorganic materials or blends, such as fiberglass, polyester (PET), recycled PET, heavy glass-mat, or combinations thereof.

23. The lead acid battery separator of claim 21, wherein the negative cross ribs rib pattern may be continuous linear ribs, cross-hatched, sinusoidal or wavy continuous, sinusoidal or wavy discontinuous, intermittent and registered linear, or other rib patterns which include combinations or variations of the foregoing.

27. The lead acid battery separator of claim 21, wherein the membrane comprises one of the following consisting of:

a microporous or macroporous thermoplastic material, preferably polyethylene, polypropylene, polyvinyl chloride, and the mixtures thereof;

rubber;

polyolefin;

phenolic;

crosslinked phenolic resin;

cellulosic;

glass;

or combinations thereof.

28. The lead acid battery separator of claim 21, wherein the separator may be a cut piece separator or a wrap, envelope, pouch, sleeve, or pocket type separator.

26. 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 a plurality of negative cross ribs on the reverse face, and the positive face may be smooth or flat, have projections, have ribs, or have a nonwoven bonded or laminated thereto.