Abstract: A battery separator includes a porous substrate and a thermal fuse material adhered to at least one surface of said porous substrate. The thermal fuse material is adhered to the substrate surface in a predetermined geometric array thereupon so as to establish open areas of the at least one substrate surface to thereby allow ionic migration therethrough. The thermal fuse material forming the geometric array on the substrate surface may itself define open pores to further facilitate such ionic migration. The thermal fuse material melts at or near a predetermined threshold temperature so that the substrate's permeability irreversibly becomes significantly decreased and thus interrupts the chemical reaction in an electrochemical battery. In such a manner, batteries of improved safety may be provided using the separators of this invention.

Abstract: The present invention is directed to microporous membranes having a surfactant impregnated therein which is coated on at least one surface thereof with a polymer coating, such as cellulose acetate. The polymer coating possesses functional groups in the presence of an aqueous alkaline environment which permits it to undergo hydrogen bonding with water and to transport battery electrolyte through the coating by diffusion. The presence of the coating on the normally hydrophobic substrate membrane, when used in conjunction with a suitable surfactant, increases the wettability of the substrate membrane and thereby lowers its electrical resistance. The coating also serves to immobilize various soluble electrode derived ions at the coating-electrolyte interface thereby hindering their penetration into the pores of the substrate microporous membrane.

Abstract: The present invention is directed to microporous membranes having a surfactant impregnated therein which is coated on at least one surface thereof with a polymer coating, such as cellulose acetate. The polymer coating possesses functional groups in the presence of an aqueous alkaline environment which permits it to undergo hydrogen bonding with water and to transport battery electrolyte through the coating by diffusion. The presence of the coating on the normally hydrophobic substrate membrane, when used in conjunction with a suitable surfactant, increases the wettability of the substrate membrane and thereby lowers its electrical resistance. The coating also serves to immobilize various soluble electrode derived ions at the coating-electrolyte interface thereby hindering their penetration into the pores of the substrate microporous membrane.

Abstract: The present invention provides a microporous membrane having deposited on at least one surface thereof a porous, uniform coating of a low hydrogen over-potential material. The coated microporous membrane is particularly suited for use as a battery separator in a rechargeable zinc electrode containing battery, which is resistant to penetration by zinc dendrites and is capable of increasing the uniformity of current density upon recharging of the battery.A battery employing said coated microporous membrane as a battery separator as well as a process for using said coated microporous membrane is also provided.