Abstract: In at least one embodiment, a separator is provided with a fibrous mat for retaining the active material on an electrode of a lead-acid battery. New or improved mats, separators, batteries, methods, and/or systems are also disclosed, shown, claimed, and/or provided. For example, in at least one possibly preferred embodiment, a composite separator is provided with a fibrous mat for retaining the active material on an electrode of a lead-acid battery. In at least one possibly particularly preferred embodiment, a PE membrane separator is provided with at least one fibrous mat for retaining the active material on an electrode of a lead-acid battery. In accordance with at least certain embodiments, aspects and/or objects, the present invention, application, or disclosure may provide solutions, new products, improved products, new methods, and/or improved methods, and/or may address issues, needs, and/or problems of PAM shedding.

Abstract: A multilayer deep cycle battery separator comprising at least two layers of an automotive-sized separator bonded or welded together. The automotive-sized separator layers include a backweb having a backweb thickness between 6 to 10 mils, an overall thickness of between 25 to 65 mils, and a rib base width of between 20 to 35 mils. The automotive-sized separator layers also have an extraction time of between 45 to 75 seconds, thereby providing an overall extraction time of less than a standard deep cycle battery separator.

Abstract: A battery separator for a lead acid (storage) battery is made from a thermoplastic sheet material. The sheet material has a central region flanked by peripheral regions. The central region includes a plurality of longitudinally extending ribs that are integrally formed from the sheet material. The peripheral regions are free of ribs and may include a densified structure. Also disclosed are a method of producing the foregoing separator, an envelope separator made from the sheet material, and a method of making the envelope separator.

Abstract: In accordance with at least selected embodiments, the present disclosure or invention is directed to improved battery separators, high conductance separators, improved lead-acid batteries, such as flooded lead-acid batteries, high conductance batteries, improved systems, and/or, improved vehicles including such batteries, and/or methods of manufacture or use of such separators or batteries, and/or combinations thereof. In accordance with at least certain embodiments, the present disclosure or invention is directed to improved lead acid batteries incorporating the improved separators and which exhibit increased conductance. Particular, non-limiting examples may include lead acid battery separators having structure or features designed to improve conductance, lower ER, lower water loss, and the like.

Abstract: Improved battery separators, batteries, and systems, as well as methods relating thereto are disclosed herein for use in various lead acid batteries such as valve-regulated lead acid (VRLA) batteries that include one or more AGM layers. The improved battery separators described herein may provide a battery system with an advantage of a significantly decreased acid filling time and a significantly increased acid filling speed. Various improved batteries, methods and systems are described herein using such improved battery separators that increase acid filling speed and decrease acid filling time for a VRLA battery.

Abstract: A multilayer deep cycle battery separator comprising at least two layers of an automotive-sized separator bonded or welded together. The automotive-sized separator layers include a backweb having a backweb thickness between 6 to 10 mils, an overall thickness of between 25 to 65 mils, and a rib base width of between 20 to 35 mils. The automotive-sized separator layers also have an extraction time of between 45 to 75 seconds, thereby providing an overall extraction time of less than a standard deep cycle battery separator.

Abstract: A method for producing a microporous material comprising the steps of: providing an ultrahigh molecular weight polyethylene (UHMWPE); providing a filler, providing a processing plasticizer, adding the filler to the UHMWPE in a mixture being in the range of from about 1:9 to about 15:1 filler to UHMWPE by weight; adding the processing plasticizer to the mixture; extruding the mixture to form a sheet from the mixture; calendering the sheet; extracting the processing plasticizer from the sheet to produce a matrix comprising UHMWPE and the filler distributed throughout the matrix; stretching the microporous material in at least one direction to a stretch ratio of at least about 1.5 to produce a stretched microporous matrix; and subsequently calendering the stretched microporous matrix to produce a microporous material which exhibits improved physical and dimensional stability properties over the stretched microporous matrix.

Abstract: A battery separator for a lead acid (storage) battery is made from a thermoplastic sheet material. The sheet material has a central region flanked by peripheral regions. The central region includes a plurality of longitudinally extending ribs that are integrally formed from the sheet material. The peripheral regions are free of ribs and may include a densified structure. Also disclosed are a method of producing the foregoing separator, an envelope separator made from the sheet material, and a method of making the envelope separator.

Abstract: Disclosed herein are improved separators for lead acid batteries. The separators may include a porous membrane, a rubber, and at least one performance enhancing additive, positive and/or negative ribs, and/or lowered acid leachable total organic carbon.

Abstract: Improved battery separators, batteries, and systems, as well as methods relating thereto are disclosed herein for use in various lead acid batteries such as valve-regulated lead acid (VRLA) batteries that include one or more AGM layers. The improved battery separators described herein may provide a battery system with an advantage of a significantly decreased acid filling time and a significantly increased acid filling speed. Various improved batteries, methods and systems are described herein using such improved battery separators that increase acid filling speed and decrease acid filling time for a VRLA battery.

Abstract: A battery separator for a lead/acid battery is resistant to oxidation arising from the use of water or acid containing contaminants, for example chromium (Cr), manganese (Mn), titanium (Ti), copper (Cu), and the like. The separator is a microporous membrane including a rubber. The rubber is no more than about 12% by weight of the separator. The rubber may be rubber latex, tire crumb, and combinations thereof. The rubber may be impregnated into the microporous membrane. The microporous membrane may be a microporous sheet of polyolefin, polyvinyl chloride, phenol-formaldehyde resins, cross-linked rubber, or nonwoven fibers. A method for preventing the oxidation and/or extending battery life of the separator is also included.

Abstract: A separator for a lead acid battery is a porous membrane having a positive electrode face and a negative electrode face. A plurality of longitudinally extending ribs, a plurality of protrusions or a nonwoven material may be disposed upon the positive electrode face. A plurality of transversely extending ribs are disposed upon the negative electrode face. The transverse ribs disposed upon the negative electrode face are preferably juxtaposed to a negative electrode of the lead acid battery, when the separator is placed within that battery.

Abstract: A battery separator for a lead/acid battery is resistant to oxidation arising from the use of water or acid containing contaminants, for example chromium (Cr), manganese (Mn), titanium (Ti), copper (Cu), and the like. The separator is a microporous membrane including a rubber. The rubber is no more than about 12% by weight of the separator. The rubber may be rubber latex, tire crumb, and combinations thereof. The rubber may be impregnated into the microporous membrane. The microporous membrane may be a microporous sheet of polyolefin, polyvinyl chloride, phenol-formaldehyde resins, cross-linked rubber, or nonwoven fibers. A method for preventing the oxidation and/or extending battery life of the separator is also included.

Abstract: A separator for a lead acid battery is a porous membrane having a positive electrode face and a negative electrode face. A plurality of longitudinally extending ribs, a plurality of protrusions or a nonwoven material may be disposed upon the positive electrode face. A plurality of transversely extending ribs are disposed upon the negative electrode face. The transverse ribs disposed upon the negative electrode face are preferably juxtaposed to a negative electrode of the lead acid battery, when the separator is placed within that battery.

Abstract: A method for producing a microporous material comprising the steps of: providing an ultrahigh molecular weight polyethylene (UHMWPE); providing a filler; providing a processing plasticizer; adding the filler to the UHMWPE in a mixture being in the range of from about 1:9 to about 15:1 filler to UHMWPE by weight; adding the processing plasticizer to the mixture; extruding the mixture to form a sheet from the mixture; calendering the sheet; extracting the processing plasticizer from the sheet to produce a matrix comprising UHMWPE and the filler distributed throughout the matrix; stretching the microporous material in at least one direction to a stretch ratio of at least about 1.5 to produce a stretched microporous matrix; and subsequently calendering the stretched microporous matrix to produce a microporous material which exhibits improved physical and dimensional stability properties over the stretched microporous matrix.

Abstract: A battery separator has performance enhancing additives or coatings, fillers with increased friability, increased ionic diffusion, decreased tortuosity, increased wettability, reduced oil content, reduced thickness, decreased electrical resistance, and/or increased porosity. The separator in a battery reduces the water loss, lowers acid stratification, lowers the voltage drop, and/or increases the CCA.

Abstract: In accordance with at least selected embodiments or aspects, the present invention is directed to improved, unique, and/or complex performance lead acid battery separators, such as improved flooded lead acid battery separators, batteries including such separators, methods of production, and/or methods of use. The preferred battery separator of the present invention addresses and optimizes multiple separator properties simultaneously. It is believed that the present invention is the first to recognize the need to address multiple separator properties simultaneously, the first to choose particular multiple separator property combinations, and the first to produce commercially viable multiple property battery separators, especially such a separator having negative cross ribs.

Abstract: A method for producing a microporous material comprising the steps of: providing an ultrahigh molecular weight polyethylene (UHMWPE); providing a filler, providing a processing plasticizer, adding the filler to the UHMWPE in a mixture being in the range of from about 1:9 to about 15:1 filler to UHMWPE by weight; adding the processing plasticizer to the mixture; extruding the mixture to form a sheet from the mixture; calendering the sheet; extracting the processing plasticizer from the sheet to produce a matrix comprising UHMWPE and the filler distributed throughout the matrix; stretching the microporous material in at least one direction to a stretch ratio of at least about 1.5 to produce a stretched microporous matrix; and subsequently calendering the stretched microporous matrix to produce a microporous material which exhibits improved physical and dimensional stability properties over the stretched microporous matrix.

Abstract: A method for producing a microporous material comprising the steps of: providing an ultrahigh molecular weight polyethylene (UHMWPE); providing a filler, providing a processing plasticizer, adding the filler to the UHMWPE in a mixture being in the range of from about 1:9 to about 15:1 filler to UHMWPE by weight; adding the processing plasticizer to the mixture; extruding the mixture to form a sheet from the mixture; calendering the sheet; extracting the processing plasticizer from the sheet to produce a matrix comprising UHMWPE and the filler distributed throughout the matrix; stretching the microporous material in at least one direction to a stretch ratio of at least about 1.5 to produce a stretched microporous matrix; and subsequently calendering the stretched microporous matrix to produce a microporous material which exhibits improved physical and dimensional stability properties over the stretched microporous matrix.