Abstract: In at least select embodiments, the instant disclosure is directed to new or improved battery separators, components, materials, additives, surfactants, lead acid batteries, systems, vehicles, and/or related methods of production and/or use. In at least certain embodiments, the instant disclosure is directed to surfactants or other additives for use with a battery separator for use in a lead acid battery, to battery separators with a surfactant or other additive, and/or to batteries including such separators. In at least certain select embodiments, the instant disclosure relates to new or improved lead acid battery separators and/or systems including improved water loss technology and/or methods of manufacture and/or use thereof.

Abstract: A separator includes a substrate and a coating layer on at least one surface of the substrate, wherein the coating layer includes first organic particles and second organic particles, and an average particle diameter of the first organic particles is larger than an average particle diameter of the second organic particles. The first organic particles protrude or extend to a height of about 0.1 ?m to about 0.5 ?m from a dented portion of a surface of the coating layer, and are distributed on the surface of the coating layer in an area ratio of about 5% or greater to less than 30% with respect to a total surface area of the coating layer. The separator may have improved adhesion to electrodes, insulation characteristics, and air permeability, and a battery including the separator may have improved lifespan characteristics.

Abstract: A binder composition for a secondary battery, and an anode and a lithium battery that include the binder composition are disclosed. The binder composition may include: first nanoparticles having a glass transition temperature of about 60° C. or greater and an average particle diameter of about 100 nm or less; and a first polymer binder having a glass transition temperature of about 20° C. or less.

Abstract: A microporous polyethylene battery separator material (212), for use in a flooded-cell type lead-acid battery, benefits from increased porosity, enhanced wettability, and exceptionally low electrical resistance when an electrolyte-soluble pore former is employed in the manufacturing process. The pore former (210) is soluble in electrolytic fluid and therefore dissolves in-situ in sulfuric acid during battery assembly. The dissolution of the pore former leaves behind additional, larger voids (220) in the separator material and thereby enhances ionic diffusion and improves battery performance.

Abstract: The present invention relates to a physicochemically-active porous membrane for electrochemical cells that purports dual functions: an electronic insulator (separator) and a unidirectional ion-transporter (electrolyte). The electrochemical cell membrane is activated for the transport of ions by contiguous ion coordination sites on the interior two-dimensional surfaces of the trans-membrane unidirectional pores. One dimension of the pore surface has a macroscopic length (1 nm-1000 ?m) and is directed parallel to the direction of an electric field, which is produced between the cathode and the anode electrodes of an electrochemical cell. The membrane material is designed to have physicochemical interaction with ions. Control of the extent of the interactions between the ions and the interior pore walls of the membrane and other materials, chemicals, or structures contained within the pores provides adjustability of the ionic conductivity of the membrane.

Abstract: Polyolefin woven and nonwoven fibers, filaments and fabrics made therefrom which comprise a melt blend which comprises (a) a polyolefin; and (b) at least one compound of the formula (I) R1-(hydrophilic oligomer) ??(I) wherein R1 is a straight or branched chain alkyl of 22 to 40 carbon atoms and the hydrophilic oligomer is a homo- or co-oligomer consisting of monomer units derived from monomers selected from the group consisting of ethylene oxide, propylene oxide, ethylene glycol, propylene glycol, epichlorhydrin, acrylic acid, methacrylic acid, ethylene imine, caprolactone, vinyl alcohol and vinyl acetate; and wherein the hydrophilic oligomer consists of between 2 and 10 monomer units, exhibit excellent durable wettability. The fabrics are useful in disposable diapers, training pants, feminine napkins, tampons, incontinence care products, wet and dry wipes, wound dressings, surgical capes, filter medial, battery separators and the like.

Abstract: An electrochemical energy store comprising a separator (40, 40a, 40b) is described, wherein said electrochemical energy store has a positively charged electrode (20), a negatively charged electrode (30), an electrolyte, and a porous separator (40, 40a, 40b) which separates the positively charged electrode (20) and the negatively charged electrode (30) from each other. The separator (40, 4a, 40b) includes at least one microporous foil which is produced using ion irradiation, among other things. The separator (40, 40a, 40b) farther includes ion ducts (43) extending at different angles from one another.

Abstract: A porous sheet which has good balance between electrolytic solution permeability and dry-up resistance, is superior in high-rate property, and is suitable for a separator for an electrochemical element, and a manufacturing method thereof are provided. The present invention relates to a porous sheet comprising a porous substrate containing non-fibrillar fibers having an average fiber diameter of 0.01-10 ?m and a net-like structural body composed of a polymer, the net-like structural body having penetrating pores with a pore diameter of 0.01-10 ?m, wherein the net-like structural body is present at the surface and at the internal of the porous substrate and the non-fibrillar fibers having an average fiber diameter of 0.01-10 ?m and the net-like structural body are entangled; to a separator for an electrochemical element comprising the porous sheet; and to a method for manufacturing the porous sheet.

Abstract: An alkaline dry battery of this invention includes: a positive electrode including at least one of a manganese dioxide powder and a nickel oxyhydroxide powder; a negative electrode including a zinc alloy powder; a separator interposed between the positive electrode and the negative electrode; an alkaline electrolyte; and a battery case for housing the positive electrode, negative electrode, the separator, and the alkaline electrolyte. The negative electrode further includes a surfactant that adsorbs to a surface of the zinc alloy powder during a non-discharge period and promptly desorbs from the surface of the zinc alloy powder upon start of discharge without impeding ion transfer in the alkaline electrolyte.

Abstract: A fuse module includes a wiring lug. The wiring lug includes a fuse clip member comprising a first pressure plate and a fuse clip, a lug box comprising a second pressure plate, and a securing member operably coupled to the lug box. The securing member operates between a first position and a second position to move the second pressure plate of the lug box with respect to the first pressure plate of the fuse clip member. The first pressure plate and the second pressure plate have a clamping relationship when the securing member is in the first position and have a non-clamping relationship when the securing member is in the second position.

Abstract: The instant invention is a separator for a battery having a zinc electrode. The battery separator according to the instant invention includes a microporous membrane, and a coating on at least one surface of the microporous membrane. The coating includes a mixture of 25-40 weight % polymer and 60-75 weight % surfactant combination. The polymer is cellulose acetate, and the surfactant combination includes a first surfactant and a second surfactant. The first surfactant, preferably, has an active ingredient selected from the group consisting of organic ethers, and the second surfactant is, preferably, an oxirane polymer with 2-ethylhexyl dihydrogen phosphate.

Abstract: A separator for a lead-acid battery enabling the lead acid battery to infallibly have a predetermined capacity after the initial charging and a prolonged service life by limiting the maximum quantity of reducing substance liberated or produced from the separator at or below a given level. The separator for a lead-acid battery comprising a porous membrane made mainly from a polyolefin resin, an inorganic powder and a mineral oil and containing a surface active agent as an auxiliary material, characterized in that the amount of any reducing substance liberated or eluted after 24 hours of electrolysis carried out at about 25° C. with a direct current of 1.2 A by using an electrolytic cell composed of the porous membrane, a positive electrode, a negative electrode and diluted sulfuric acid is 1.0 ml or less per 100 cm2 when calculated from the consumption of a (1/100)N potassium permanganate solution per 100 cm2 of the porous membrane.

Abstract: The present invention relates to a high capacity electrochemical cell having a cathode containing an oxide of copper as an active material, as well as an anode, an electrolyte, and separators for use with the cathodes of the invention in an alkaline electrochemical cell.

Abstract: A microporous polyethylene battery separator material (212), for use in a flooded-cell type lead-acid battery, benefits from increased porosity, enhanced wettability, and exceptionally low electrical resistance when an electrolyte-soluble pore former is employed in the manufacturing process. The pore former (210) is soluble in electrolytic fluid and therefore dissolves in-situ in sulfuric acid during battery assembly. The dissolution of the pore former leaves behind additional, larger voids (220) in the separator material and thereby enhances ionic diffusion and improves battery performance.

Abstract: Electrode assemblies easily impregnated with an electrolyte are provided. A sealing tape attached to the outer circumference of the electrode assembly comprises a material having an affinity for the electrolyte. Alternatively, the entire sealing tape or a portion of the tape is coated with the material. In another alternative, the surface of the sealing tape is rough, thereby improving wetting of the tape by the electrolyte and diffusion of the electrolyte into the tape. In another embodiment, first and second insulating plates comprise a material having an affinity for the electrolyte. In another alternative, the insulating plates comprise a mixture of a material having an affinity for the electrolyte and polypropylene or polyethylene. Alternatively, the surfaces of the insulating plates are coated with the material or with a surfactant that reduces the surface tension of the electrolyte.

Abstract: The present invention relates to a high capacity electrochemical cell having a cathode containing an oxide of copper as an active material, as well as an anode, an electrolyte, and separators for use with the cathodes of the invention in an alkaline electrochemical cell.

Abstract: A non-aqueous electrolyte primary battery including: a positive electrode including a fluorinated carbon; a negative electrode including a lithium metal; a non-aqueous electrolyte; and a separator, wherein the non-aqueous electrolyte includes a non-aqueous solvent and a solute dissolved therein, the non-aqueous solvent including ?-butyrolactone, and the separator includes a microporous membrane onto which a phosphoric acid ester is provided, the phosphoric acid ester being represented by the formula (1): where R1 is an alkyl group, R2 and R3 are each independently an alkylene group, and n is an integer.

Abstract: An article of manufacture comprises an ultrahigh molecular weight polyethylene (UHMWPE) mixed with a processing oil and a lubricant selected from the group consisting of fatty acid esters, ethoxylated fatty acid esters, glycol esters, PEG esters, glycerol esters, ethoxylated esters, sorbitol esters, ethoxylated sorbitol esters, aromatic ethoxylates, alcohol ethoxylates, mercaptan ethoxylates, modified ethoxylates, amide surfactants, phosphate esters, phosphonate esters, phosphite esters, alkyl sulfates, fatty acid ethers, alkyl ether sulfates, alkylaryl ether sulfates, sulfonates, naphthalene sulfonates, sulfosuccinates, sulfonated esters, sulfonated amides, alkyl ether carboxylates, alkylaryl ether carboxylates, quaternary amines, amino quaternary amines, ethoxylated amines, imidazoline derivatives, betaines, sultaines, aminopropionate, catechol derivatives, saturated fatty acids, unsaturated fatty acids, and combinations thereof. The method for making those articles is also disclosed.

Abstract: A microporous polyolefin battery separator membrane is extremely high in porosity, high in puncture strength, very low in shrinkage and with shutdown temperature of 130-140 degrees C. and melt integrity greater than 165 degrees C. It is made of UHMWPE having a weight-average molecular weight of 1×106 or more and an inert filler. A second microporous polyolefin battery separator has a shutdown temperature of between 95 and 110 degrees C. and a melt integrity of more than 165 degrees C. It is made from an UHMWPE having a weight-average molecular weight of 1×106 or more, a shutdown (LMWPE) having a weight-average molecular weight of 4500 or less and an inert filler. Both membranes have a thickness of 5-75 microns, a porosity of 30-95%, an air permeability of 1-200 sec/10 cc, an average pore diameter of 0.001 to 1 micron and puncture strength of more than 300 grams/25 ?m.

Abstract: A battery separator having a thermal shutdown mechanism and exhibiting excellent mechanical properties and low electrical resistance includes a water-scavenging and/or acid-scavenging material having reactive functional groups that chemically react with water or acid in the battery to remove the water or acid and thereby improve battery performance. The battery separator preferably includes a first polyolefin providing mechanical integrity and a second polyolefin including the water-scavenging or acid-scavenging reactive functional groups. The battery separator is preferably a microporous film including a polymer matrix throughout which the water-scavenging or acid-scavenging material is dispersed.

Abstract: Battery separators made of a wettable, uniform mat of melt blown fibers. The melt blown fibers are thermally bonded to one another. These fibers are made of a thermoplastic material. The fibers have a diameter in the range of 0.1 to 13 microns (?) and lengths greater than 12 millimeters (mm). The mat has a basis weight ranging from 6 to 160 grams per square meter (g/m2), a thickness of less than 75 microns (?), and an average pore size of 0.3 to 50 microns (?).

Abstract: The present invention is directed to a nonwoven composite fabric for use on batteries or fuel cells comprising one or more layers of fine denier spunbond filaments and at least one layer of barrier material, wherein said nonwoven composite fabric has an improved barrier performance as measured by an increase in the hydrostatic head to barrier layer basis weight ratio. In the present invention, a first fine denier layer is formed, comprising continuous spunbond thermoplastic filaments, with the size of the continuous filaments between about 0.7 and 1.2 denier, preferably less than or equal to 1 denier. A barrier layer is deposited onto the first fine denier layer. The barrier layer preferentially comprises microfibers of finite length, wherein the average fiber diameter is in the range of about 1 micron to about 10 microns, and preferably between about 1 micron and 5 microns, said layers being consolidated into a composite fabric.

Abstract: A nonwoven material having a laminated construction and including a first layer of nonwoven fibers defining a first surface of the material; a second layer of nonwoven fibers defining the opposite surface of the material; and a third layer of nonwoven fibers located between the first and second layers. The layers are bonded together to form a laminate. At least one of the nonwoven layers comprises a nonwoven web of meltblown fibers. Additionally, one or more of the layers has been rendered permanently hydrophilic by forming the nonwoven web from meltspun fibers of a normally hydrophobic polymer having a hydrophilic melt additive incorporated therein.

Abstract: An alkaline storage battery comprises: a positive electrode plate; a negative electrode plate; a separator; and an alkaline electrolyte retained by the positive electrode plate, the negative electrode plate, and the separator, wherein the separator has a large number of pores, such that a total volume A of the pores (per unit mass; cm3/g) is in the range of 1?A?5, and the ratio of the volume B of pores having a diameter of 100 ?m or more (per unit mass; cm3/g) to the total pore volume A is in the range of 7%?B/A?20% (i.e., B/A is between 0.07 and 0.2).

Abstract: The present invention relates to the separator for batteries wherein the non-woven cloth comprising fibers mainly composed of polyolefin type resin is provided with hydrophilic property on the fiber surface at least by sulfuric compound and characterized as follows: (a) the ratio of atomic mass of sulfur to atomic mass of carbon (S/C) is 5×10?3 to 30×10?3 (b) the tensile strength is not less than 3 kg/cm2 and the preparation method of this separator. The present invention also relates to the secondary batteries using this separator.

Abstract: A non-woven sheet of polyolefin fibers having opposed major surfaces is disclosed. Some areas of one or both of the major surfaces are hydrophilic as a consequence of an acrylic graft polymerized with the surfaces of the fibers in those areas while the fibers in other areas of that major surface are free of the graft and, as a consequence, remain hydrophobic. A battery separator composed of at least two such non-woven sheets is also disclosed, as well as batteries having a separator composed of at least one such non-woven sheet. Also disclosed is a non-woven sheet of polyolefin fibers where opposed major surfaces of the sheet are hydrophilic as a consequence of such an acrylic acid graft, but the ion exchange coefficients of the two major surfaces are different.

Abstract: A microporous polyolefin battery separator membrane is extremely high in porosity, high in puncture strength, very low in shrinkage and with shutdown temperature of 130–140 degrees C. and melt integrity greater than 165 degrees C. It is made of UHMWPE having a weight-average molecular weight of 1×106 or more and an inert filler. A second microporous polyolefin battery separator has a shutdown temperature of between 95 and 110 degrees C. and a melt integrity of more than 165 degrees C. It is made from an UHMWPE having a weight-average molecular weight of 1×106 or more, a shutdown (LMWPE) having a weight-average molecular weight of 4500 or less and an inert filler. Both membranes have a thickness of 5–75 microns, a porosity of 30–95%, an air permeability of 1–200 sec/10 cc, an average pore diameter of 0.001 to 1 micron and puncture strength of more than 300 grams/25 {circumflex over (l)}¼ m.

Abstract: An object of the present invention is to provide a thin battery separator having an excellent nitrate group trapping performance and a high piercing strength. The inventive separator for a secondary battery, which can accomplish such an object, is made of a resin composition mainly containing a polyolefin having a hydrophilic functional group, wherein the resin composition has a content (ratio to a total resin amount) of a low-density polyethylene of 20 mass % or less, a piercing strength of 5 to 100 N, a Metsuke of 20 to 75 g/m2, a thickness of 15 to 150 ?m, and an unneutralized hydrophilic functional group amount of 1×10?3 to 5×10?2 mol/m2.

Abstract: A battery separator having a thermal shutdown mechanism and exhibiting excellent mechanical properties and low electrical resistance includes a water-scavenging and/or acid-scavenging material having reactive functional groups that chemically react with water or acid in the battery to remove the water or acid and thereby improve battery performance. The battery separator preferably includes a first polyolefin providing mechanical integrity and a second polyolefin including the water-scavenging or acid-scavenging reactive functional groups. The battery separator is preferably a microporous film including a polymer matrix throughout which the water-scavenging or acid-scavenging material is dispersed.

Abstract: The invention includes novel anion exchange membranes formed by in situ polymerization of at least one monomer, polymer or copolymer on a woven support membrane and their methods of formation. The woven support membrane is preferably a woven PVC membrane. The invention also includes novel cation exchange membranes with or without woven support membranes and their methods of formation. The invention encompasses a process for using the membranes in electrodialysis of ionic solutions and in particular industrial effluents or brackish water or seawater. The electrodialysis process need not include a step to remove excess ions prior to electrodialysis and produces less waste by-product and/or by-products which can be recycled.

Abstract: A battery highly inhibited from suffering self-discharge. The battery is characterized by containing a built-in polymer which has in the molecule a carbodiimide unit represented the following formula (I): —[—R—N═C═N—)]n—  (I) wherein R means an organic group and n means an integer of 1 to 10,000).

Abstract: In an alkaline secondary battery provided with a positive electrode, a negative electrode, a separator to be interposed between the positive electrode and the negative electrode, and an alkaline electrolyte solution, the above-mentioned separator has carbon-carbon double bonds. Further, an average amount of carbon-carbon double bonds in the separator is in the range of 10 &mgr;mol/g to 200 &mgr;mol/g, and an average amount of increased nitrogen in the separator after the separator is immersed in an alkaline aqueous solution having ammonium salt dissolved therein is not less than 140 &mgr;g/g.

Abstract: An alkaline storage battery having excellent self-discharge characteristics even after a number of charge-discharge cycles is provided. The alkaline storage battery is provided with a case and an electrode group enclosed in the case, and a separator that is included in the electrode group retains at least 15 mg/cm2 of an electrolyte at least in a period after assembling the battery, from the time the separator is impregnated with the electrolyte to the time the battery is activated.

Abstract: Battery separators made of a wettable, uniform mat of melt blown fibers. The melt blown fibers are thermally bonded to one another. These fibers are made of a thermoplastic material. The fibers have a diameter in the range of 0.1 to 13 microns (&mgr;) and lengths greater than 12 millimeters (mm). The mat has a basis weight ranging from 6 to 160 grams per square meter (g/m2), a thickness of less than 75 microns (&mgr;), and an average pore size of 0.

Abstract: The separator 10a for use in the alkaline storage battery of the invention comprises densely and uniformly formed over the entire separator and entrained from the surface to the back plane of the separator, first fine paths (pores) 15 rendered hydrophilic and second fine paths (pores) 16 rendered non-hydrophilic. In this manner, the gas generated in the vicinity of the first fine paths (pores) 15 can immediately reach the second fine paths (pores) 16 formed in the vicinity of the first fine paths (pores) 15 and transferred. On the other hand, the ions that attempt passing through the second fine paths (pores) 16 can readily reach the first fine paths (pores) 15 formed in the vicinity of the second fine paths (pores) 16, and hence, the ions can be transferred through the first fine paths (pores) 15.

Abstract: The high rate discharge performance and cyclability are improved. A battery having a hich capacity density and excellent cyclability and safety performance can be produced. A composite active material provided with a polymer on the surface of a carbon-based active material in an amount of from 0.01% to 5% by weight is used. Further, a composite active material provided with a polymer on the surface of a carbon-based active material in an amount of from 0.04 to 4% by weight is used. In particular, the former composite active material is used as a positive active material while the latter composite active material is used as a negative active material to obtain a non-aqueous electrolyte battery.

Abstract: A separator for a wound electrochemical device comprising an expanded polytetrafluoroethylene membrane having pores defining an internal surface area, the internal surface area being substantially coated with a pore coating agent, the separator having a longitudinal modulus of greater than 20,000 lbs/in2.

Abstract: A lithium secondary battery including a positive electrode which is capable of occluding and releasing lithium, a negative electrode which is capable of occluding and releasing lithium, a separator between the positive electrode and the negative electrode, and a nonaqueous electrolyte comprising a nonaqueous solvent and a wettability improving agent. The nonaqueous solvent does not substantially wet the separator, and the wettability improving agent is dissolved in the nonaqueous solvent, improves the wettability of the nonaqueous solvent to the separator, and has an oxidative decomposition potential in a range of 4.5 V to 6.2 V.

Abstract: Battery separators made of a wettable, uniform mat of melt blown fibers. The melt blown fibers are thermally bonded to one another. These fibers are made of a thermoplastic material. The fibers have a diameter in the range of 0.1 to 13 microns (&mgr;) and lengths greater than 12 millimeters (mm). The mat has a basis weight ranging from 6 to 160 grams per square meter (g/m2), a thickness of less than 75 microns (&mgr;), and an average pore size of 0.3 to 50 microns (&mgr;).

Abstract: The preferred embodiment is to a battery separator for a nickel metal hydride (NiMH) battery. The separator includes a wettable, resilient nonwoven web having two spunbond layers sandwiching a melt blown layer. The web has a puncture strength of greater than 6 newtons, a tensile strength of greater than 200 newtons/meter, and an average pore size of less than 20 microns.

Abstract: A method for producing a battery separator is disclosed. The method comprises applying a coating of an ethylenically unsaturated monomer to the fibers of a non-woven sheet and polymerizing the monomer in situ on the fiber surfaces. The non-woven sheet is from 50 to 3000 microns thick, and is composed of polyolefin fibers having an average fiber diameter from 0.5 to 5 microns and a surface area from 0.2 to 30 square meters per gram.

Abstract: An aqueous alkaline electrolyte Ni-MH sealed secondary storage cell includes a bundle of electrodes placed in a container and made up of a plurality of negative and positive electrodes. The space separating the negative electrode from the positive electrode contains a separator. The separator is permeable to gases and a recombination device is placed between two adjacent negative electrodes and has a wetting angle of at least 45°, an average pore section of at least 103 &mgr;m2, and a thickness from 0.2 mm to 5 mm.

Abstract: A separator for an electrochemical cell and a method of assembling an electrochemical cell are provided. The separator includes a porous paper substrate impregnated and/or coated with a polymer solution that coagulates to prevent electrical shorting while allowing ion permeation. The method include the steps of providing a container having a bottom end and a top end and upstanding walls disposed therebetween, disposing positive electrode and negative electrodes in the container, providing a sheet of porous paper substrate, forming the sheet of porous substrate into a separator, applying alkaline solution to the separator, applying a liquid polymer material to the porous substrate in the presence of the alkaline solution so that the polymer solution coagulates to form a semi-solid material, and disposing the separator between the positive electrode and the negative electrode.

Abstract: A lithium secondary battery comprises a negative electrode capable of intercalating/deintercalating lithium ion, a positive electrode made of a lithium-containing metal oxide as an active positive material, and a nonaqueous electrolyte, and a polyvinylidene fluoride resin is disposed between said negative electrode and positive electrode so that the battery voltage doesn't rise beyond a predetermined value even when said battery is overcharged.

Abstract: A hydrophilized separator material includes a plurality of synthetic fibers impregnated with 0.01 to 10 g/m2 of at least one of an alkali hydroxide and an alkali carbonate. In addition, a method for manufacturing such a separator material as well as an alkaline cell or battery containing such a separator material.

Abstract: The present invention provides a nonaqueous secondary battery and a separator to be used therein. The separator comprises a polyolefin membrane containing one or more conjugated polyene compounds provided on the surface thereof. The nonaqueous secondary battery having this arrangement performs improved cycle life characteristics and shelf characteristics at high temperatures.

Abstract: There is provided a battery separator comprising synthetic resin fibers, wherein hydrophilization treatment, preferably plasma treatment is applied, and a contact angle to pure water indicates a value of 0 to 100 degrees; an alkali secondary battery in which a electrode group having the separator between a positive electrode and a negative electrode is sealed in a battery case together with an alkali electrolyte, in particular, a nickel-metal hydride secondary battery whose positive electrode is a nickel electrode and whose negative electrode is a hydrogen absorbing alloy electrode, wherein active substances of said nickel electrode comprising powders consisting essentially of nickel hydroxides and higher-order cobalt hydroxides formed a surface of a part or whole thereof are employed, thereby providing its superiority in both of self-discharge properties and charge and discharge cycle life performance.

Abstract: An alkaline storage battery comprises: a positive electrode plate; a negative electrode plate; a separator; and an alkaline electrolyte retained by the positive electrode plate, the negative electrode plate, and the separator, wherein the separator has a large number of pores, such that a total volume A of the pores (per unit mass; cm3/g) is in the range of 1≦A≦5, and the ratio of the volume B of pores having a diameter of 100 &mgr;m or more (per unit mass; cm3/g) to the total pore volume A is in the range of 7%≦B/A≦20% (i.e., B/A is between 0.07 and 0.2).

Abstract: A freestanding battery separator includes a microporous polymer web with passageways that provide overall fluid permeability. The polymer web preferably contains UHMWPE and a gel-forming polymer material. The structure of or the pattern formed by the gel-forming polymer material and wettability of the UHMWPE polymer web result in a reduction of the time required to achieve uniform electrolyte distribution throughout the lithium-ion battery. In a first embodiment, the gel-forming polymer material is a coating on the UHMWPE web surface. In a second embodiment, the gel-forming polymer material is incorporated into the UHMWPE web while retaining overall fluid permeability. Both embodiments produce hybrid gel electrolyte systems in which gel and liquid electrolyte co-exist.

Abstract: Battery separators made of a wettable, uniform mat of melt blown fibers. The melt blown fibers are thermally bonded to one another. These fibers are made of a thermoplastic material. The fibers have a diameter in the range of 0.1 to 13 microns (&mgr;) and lengths greater than 12 millimeters (mm). The mat has a basis weight ranging from 6 to 160 grams per square meter (g/m2), a thickness of less than 75 microns (&mgr;), and an average pore size of 0.3 to 50 microns (&mgr;).