Abstract: Configurations of cross-linked or vulcanized amphophilic or quaternized block copolymer of haloalkyl epoxides and hydroxyl terminated alkadiene polymers are useful as battery separators in both primary and secondary batteries, particularly nickel-zinc batteries. The quaternized block copolymers are prepared by polymerizing a haloalkyl epoxide in the presence of a hydroxyl terminated 1,3-alkadiene to form a block copolymer that is then reacted with an amine to form the quaternized or amphophilic block copolymer that is then cured or cross-linked with sulfur, polyamines, metal oxides, organic peroxides and the like.

Abstract: Novel, improved battery separators carrying a plurality of polymeric ribs on at least one separator surface. The battery separators are produced by extruding a plurality of ribs in the form of molten polymeric rib providing material onto the surface of a battery separator to bond the material to the separator surface and cooling the extruded rib material to a solidified state. The molten polymeric rib providing material of this invention includes a mixture or blend of polypropylenes and an ethylene propylene diene terpolymer.

Abstract: A separator comprising a sheet of polymer material containing a filler and having an periphery area whose pores are filled with a dielectric elastomer.

Abstract: A method for forming a hydrophilic coating upon a porous substrate such as a reticulate electrode or a filter from a dispersed, perfluorocarbon copolymer. Perfluorocarbon copolymer is dispersed in a solvating medium, a substantial portion, but not necessarily all of the perfluorocarbon being solvated. The dispersion is applied to the substrate and the dispersion medium is removed.

Abstract: This disclosure is directed to improved redox type electrochemical cells, preferably those of the iron (+3)/iron (+2) or chromium (+3)/iron (+2) electrolyte variety, incorporating polymeric, ion-exchange separator membranes produced by radiation grafting techniques.

Abstract: An improved battery separator for lead-acid battery cells has low resistance to electrolyte ion transfer and can assist in holding paste in contact with a grid of an electrode plate during chemical reactions of the cell. The separator is formed by depositing an improved wetting composition to a polyolefin substrate comprised of entangled microfibers. The wetting composition which is deposited over and adhered to external surfaces of the microfibers is comprised of a substantially homogeneous admixture of an epoxy emulsion and a polyfunctional amine curing agent. When the separator is immersed in electrolyte, the amine groups in the cured resin of the wetting composition react with the acid electrolyte and are substantially completely neutralized forming a polymeric salt; in the process the fibers are rapidly wetted, providing a substantially permanent wetting characteristic in the electrolyte.

Abstract: In the electrolyte space between the positive and negative electrode plates of a storage battery, there are inserted separators made of a porous plate which has pyramid-shaped protrusions and depressions formed on both sides. The protrusions, distributed in a grid-like pattern, abut with their tips against the electrode plates and provide accurate plate spacing. Between the protrusions, the separator provides pass-like passages which form channels extending along the separator surface, for the removal of gases from the electrolyte space.

Abstract: A round battery is provided with a formed separator set to replace the conventional separators, the center insulator of the positive plates, the edge insulators of the positive plates and the edge insulators of the negative plates. A formed separator set including first and second separators is provided, the separators having wall-shaped lip portions extending between first and second separators when the separators are disposed in an assembled electrode assembly and appropriately positioned to extend over and insulate the inner periphery of the positive plates or electrodes, the non-joined portions of the outer periphery of the positive electrodes, and the outer periphery of the negative plate, to separate and insulate unlike plates from each other and to prevent the formation of conductive bridges at the edges of the plates.

Abstract: This disclosure is directed to improved redox type electrochemical cells, preferably those of the iron (+3)/iron (+2) electrolyte variety, incorporating polymeric, ion-exchange separator membranes produced by radiation grafting techniques.

Abstract: A battery separator having a low electrical resistance after extended use is made by thermal consolidation and thermal embossing of a paper web formed from a furnish containing a synthetic pulp the fibrils of which are filled with an inorganic filler, the web incorporating a wetting agent which is preferably an organic sulphonate, and organic succinate, or a phenol ethoxylate.

Abstract: A method for forming a membrane upon an electrode from a dispersed, perfluorocarbon copolymer. Perfluorocarbon is dispersed in a solvating medium, a substantial portion, but not necessarily all of the perfluorocarbon being solvated. The dispersion is applied to an electrode and the dispersion medium is removed.

Abstract: Inorganic-organic composites suitable for use as separators in alkaline storage batteries requiring gas permeability, thermal stability, chemical stability and good structural strength and a process for making them are disclosed. The composites are more thermally stable than prior art separator materials, retain aqueous alkaline electrolytes well and are chemically resistant to 31% KOH solutions at 110.degree. C.

Abstract: A flexible, porous battery separator comprising a coating applied to a porous, flexible substrate. The coating comprises:(a) a thermoplastic rubber-based resin which is insoluble and unreactive in the alkaline electrolyte,(b) a polar organic plasticizer which is reactive with the alkaline electrolyte to produce a reaction product which contains a hydroxyl group and/or a carboxylic acid group, and(c) a mixture of polar particulate filler materials which are unreactive with the electrolyte, the mixture comprising at least one first filler material having a surface area of greater than 25 meters.sup.2 /gram, at least one second filler material having a surface area of 10 to 25 meters.sup.2 /gram, wherein the volume of the mixture of filler materials is less than 45% of the total volume of the fillers and the binder, the filler surface area per gram of binder is about 20 to 60 meters.sup.2 /gram, and the amount of plasticizer is sufficient to coat each filler particle.A method of forming the battery separator.

Abstract: The instant invention is directed to a sheet product capable of forming an improved battery separator. The present sheet product is formed from a thin, acid-stable, porous material and has a first and a second major face with a plurality of separate, continuous, open channels on each major face such that each channel on each major face defines a separation between two channels on the other major face. Further, each channel defines an imaginary median line with at least some portions of at least some channels extending laterally with respect to the imaginary median line and each channel has at least one continuous contour line in the form of straight line segments such that every portion of each channel is capable of being at an acute angle of not greater than 70 degrees from an imaginary vertical line orientated from bottom to top of a battery containing the sheet product.

Abstract: The instant invention is directed to a sheet product capable of forming an improved battery separator. The present sheet product is formed from a thin, acid-stable, porous material and has a first and a second major face with a plurality of separate, continuous, open channels on each face such that each channel on each major face defines a separation between two channels on the other major face. Further, each channel defines an imaginary medium line with at least some portions of at least some channels extending laterally with respect to the imaginary medium line, and every portion of each channel is capable of being at an acute angle of not greater than 70 degrees from an imaginary vertical line oriented from bottom to top of a battery containing the sheet product.

Abstract: A dual function, composite absorber/barrier battery separator for alkaline cells is comprised of a moderately cross-linked polyvinyl alcohol film and a flexible, fibrous and wettable absorber web, the film being semipermeable to electrolyte flow. The film is mechanically bonded to a top surface of the web in a manner so as to minimize the delays of transitions from hydrodynamic flow to diffusional flow through the separator during cell operation.The invention also includes the method of making the composite separator.

Abstract: A battery separator material which is folded to form an envelope is heat sealed along at least two opposing edges thereof to form a battery separator. The separator material is comprised of discrete polyolefin pulp fibers in a sufficient amount to heat seal the separator along its edges. The fibers are bound by an organic polymeric binder. A process of forming the battery separator is also disclosed.

Abstract: Fabricated tubular bodies for use in a positive plate of a lead-acid battery are formed in a number of desirable ways from a mixture of fabrication components. In the invention methods the fabrication components are separated into differing sets of fabrication means, at least one of which sets consists of reinforced tapes. The mixture of fabrication components may, by braiding, cartridge-belt weaving or other processes, be arranged in predetermined relation to provide for highly effective retention and support of active material around current carrying grid portions of a positive plate when the said plate is immersed in an electrolyte of a lead-acid battery, to further provide preservation of dimensional stability and of said retention of active material over extended periods of operation of the said battery, and to still further provide for adequate communication between the active material and the electrolyte via tubular wall portions formed with a desirably controlled and predetermined porosity.

Abstract: This invention relates to an irradiation grafting process for preparing separator membranes for use in electrochemical cells, comprising contacting a polymeric base film with an aqueous solution of a hypophilic monomer and a polymerization retardant; and irradiating, said contacted film to form a graft membrane having low electrical resistivity and having monomer molecules uniformly grafted thereon.

Abstract: This invention is directed to a microporous film comprising a 40 to 90 volume percent polyolefin having a number average molecular weight of 15,000 or more and a weight average molecular weight of less than 300,000 and a 10 to 60 volume percent inorganic filler and having a void space rate or porosity of 30 to 75 volume percent based on the volume of the film. The microporous film of such specific composition and structure has a desired wettability and a much reduced electrical resistance. Said resistance being as low as 0.0006 .OMEGA.dm.sup.2 /sheet. Said film has sufficient flexibility and mechanical strength to make it useful in wide variety of applications, especially as separators in batteries or electrolytical apparatuses etc.

Abstract: A microporous film which comprises a matrix comprising 40 to 90 volume percent of a polyolefin having a number average molecular weight of 15,000 or more and 10 to 60 volume percent of an inorganic filler, said matrix having therein void spaces at a rate of 30 to 75 volume percent based on the volume of the film; and 2 to 20 weight percent, based on the total weight of the polyolefin and the inorganic filler, of an organic substance which is substantially insoluble in and inert to sulfuric acid and has a solubility parameter ranging from 7.3 inclusive to 8.4 exclusive; said organic substance, in its majority, adhering to the overall surface of the film including the outer surfaces of the film and the surfaces of the polyolefin walls defining said void spaces in cooperation with said inorganic filler.

Abstract: A flexible, porous battery separator comprising a coating applied to a porous, flexible substrate. The coating comprises:(a) a thermoplastic rubber-based resin which is insoluble and unreactive in the alkaline electrolyte,(b) a polar organic plasticizer which is reactive with the alkaline electrolyte to produce a reaction product which contains a hydroxyl group and/or a carboxylic acid group, and(c) a mixture of polar particulate filler materials which are unreactive with the electrolyte, the mixture comprising at least one first filler material having a surface area of greater than 25 meters.sup.2 /gram, at least one second filler material having a surface area of 10 to 25 meters.sup.2 /gram, wherein the volume of the mixture of filler materials is less than 45% of the total volume of the fillers and the binder, the filler surface area per gram of binder is about 20 to 60 meters.sup.2 /gram, and the amount of plasticizer is sufficient to coat each filler particle.A method of forming the battery separator.

Abstract: An alkaline nickel-zinc cell which has(1) a nickel-nickel hydroxide cathode;(2) a zinc-zinc oxide anode containing(a) a corrosion inhibitor such as PbO, SnO.sub.2, Tl.sub.2 O.sub.3, In(OHub.3, or mixtures thereof;(b) a slight corrosion accelerator such as CdO, Bi.sub.2 O.sub.3, Ga.sub.2 O.sub.3, or mixtures thereof; and(c) a zinc active material;(3) a mass-transport separator;(4) an alkaline electrolyte; and(5) means for charging the cell with an interrupted current having a frequency of from more than zero to 16 Hertz with a rest period of not less than 60 milliseconds.Another desirable feature is the use of a pressure-cutoff switch to terminate charging when the internal pressure of the cell reaches a selected value in the range of from 5 to 8 psig.

Abstract: A battery separator, and a method of forming the same, which exhibits good electrical conductivity and a high degree of inhibition to dendrite formation, is in the form of a thin sheet formed from a substantially uniform mixture of a thermoplastic rubber, a filler, a rubber modifier, and a processing aid.

Abstract: A non-gassing storage battery wherein oxygen is reduced at the negative electrodes submerged in the electrolyte. The storage battery consists of positive and negative electrodes separated from one another by separators, and of a liquid acidic or alkaline electrolyte. The separators are gas-permeable and have at least the upper peripheral region consisting of a micro-porous and gas-impermeable material in order to prevent escape of the oxygen into the gas chamber. The storage battery can be used primarily as a high performance storage battery, for example, as a starter battery in motor vehicles.

Abstract: There is disclosed a battery with a separator of ethylene-vinyl alcohol copolymer. Inert filler and plasticizer can be used. The separator can be used in acid or alkaline electrolyte.

Abstract: Inorganic-organic composites suitable for use as separators in alkaline storage batteries requiring gas permeability, thermal stability, chemical stability and good structural strength and a process for making them are disclosed. The composites are more thermally stable prior art separator materials, retain aqueous alkaline electrolytes well and are chemically resistant to 31% KOH solutions at 110.degree. C.

Abstract: The instant invention is directed to battery separator membranes useful in alkaline battery systems formed from a homogeneous admixture of a polyolefin, a plasticizer, and a filler selected from particulate material having a surface area of from 100 to 385 m.sup.2 /cc and a pore volume of at least 0.075 cc/gm.

Abstract: A cast film, sheet or coating of a cross-linked graft copolymer of an organic polymeric substrate and an ethylenically unsaturated organic monomer, which is useful as a ion-exchange membrane, particularly a separator for an alkaline battery. The graft copolymer is formed by initiating and effecting the graft copolymerization while the polymeric substrate and monomer are in solution.

Abstract: There is disclosed a novel cell separator made of a grafted membrane comprising a polyethylene film which is graft-copolymerized with a monomer having an ion exchange group, characterized in that said membrane has an area which is not grafted at all or an area of low degree grafting. By making use of this membrane, a small size and thin cell having excellent performance as well as satisfactory mechanical strength can be produced at low cost with great advantages.

Abstract: A battery separator, and a method of forming the same, which exhibits good electrical conductivity and a high degree of inhibition to dendrite formation, is in the form of a thin sheet formed from a substantially uniform mixture of a thermoplastic rubber and a filler in a volume ratio of from about 1:0.15 to 1:0.6. The thermoplastic rubber is preferably a styrene/elastomer/styrene block copolymer.

Abstract: Battery separators, filters and other porous semi-rigid products are provided by a thermoset resin impregnated fibrous web containing cellulosic fiber, synthetic wood pulp, paper making staple long fiber and thermoset resin. The temperature for thermosetting can exceed the Vicat softening and even the melting temperature of the synthetic pulp without the loss of the flexibilizing effect of the synthetic pulp. By extension the teaching reaches to non-fibrous and non-porous materials. A process is also revealed.

Abstract: A substrate for an alkaline battery separator is made of a light weight, porous, heat bonded, synthetic organic sheet material having a basis weight of less than about 35 gsm and a thickness of less than about 200 microns. The major fibrous component is synthetic pulp comprising thermoplastic polyolefin fibers having a prefused microfibrillar structure similar to wood pulp. The minor fibrous component is a high tenacity polyamide fiber having a fiber length greater than about 6 mm. The heat bonding by partial fusion of the microfibrillar polyolefin is sufficient to impart to the sheet material a wet tensile strength of at least 400 g/in. width while permitting retention of air permeability of about 100 liters per minute and more. The substrate exhibits excellent receptivity to impregnation by pore-forming battery separator coatings and is particularly well suited for use in nickel-zinc batteries.

Abstract: Substrates prepared from chemically inert organic fibers that are non-wettable are rendered wettable by mechanically attached coatings of hydrophilic inorganic particles. The resulting inorganic-organic composites are suitable for use as separators in alkaline storage cells.

Abstract: A battery separator composed of a composite sheet of film to which a monomer having a hydrophilic or electrolytic group is grafted is disclosed. Said film consists of a first polymeric layer containing a substance capable of catching a metal ion dissolved from a positive or negative active material and a second polymeric layer integrally bonded to either one or both sides of the first polymeric layer and which contains no such substance or contains it in a smaller amount that that contained in said first polymeric layer. Also disclosed is a method of producing a battery separator by irradiating such composite sheet of film with ionizing radiation and immersing the irradiated film in a solution of a monomer containing a hydrophilic or electrolytic group or bringing it into contact with the monomer solution to thereby graft the monomer to the film.

Abstract: A pair of boiler electrodes defines a volume therebetween to be filled with electrolyte to be heated by electrical current passage between the electrodes through the electrolyte. A microporous insulating barrier permeable to the electrolyte is disposed between the electrodes to limit current flow in the electrical current path between the electrodes to a level within the maximum allowable range of the electrode material, the barrier being spaced from the surface of the electrodes at least sufficiently to prevent concentration of current on the electrode surfaces. The barrier includes channels in the vertical direction to accommodate steam removal from the electrolyte.

Abstract: A high pressure, low porosity wet seal for a substrate in a fuel cell in which the seal is made up of a granular material having a particle size varying from 10 to 0.1 microns in size bonded together with polytetrafluoroethylene to prevent leakage of the gaseous fuel or oxidant from the cell.

Abstract: Dry mixed and sintered PVC battery separators having predetermined thicknesses less than 0.012 inch, porosities greater than about 50%, and pores sufficiently small to substantially prevent interplate "treeing" (i.e., less than about 10 microns average) are produced by: mixing about 3% to about 15% by volume of leachable, pore-forming particles with the PVC particles; scraping the particle mix into a layer less than about 0.012 inch thick; sintering the PVC into a continuous strip; compressing the strip in the temperature range of about 250.degree. F.-450.degree. F. to a thickness no greater than about 50% of its as-sintered thickness; thereafter immediately allowing the strip to recover much, but not all, of its as-sintered thickness; and cooling the strip to substantially fix the separator thickness at the recovered thickness. The leachable, pore-forming particles are preferably formed in situ by the thermal degradation of a gasifiable filler such as sodium bicarbonate.

Abstract: A tubular support sleeve for tubular storage battery plates comprises a seamless helical tubular lattice structure of fusible flat reinforced thermoplastic tapes, the tapes being fused to one another at their points of intersection. The tapes may be in the form of a laminate consisting of a central strength member having a fusible material on either side thereof. The support sleeve may be used alone or it may be used to contain a braided or felted retaining sleeve. Fusible flat reinforced thermoplastic tapes and staple fiber strands may be braided or woven together to produce a sleeve having combined support and retaining capabilities.

Abstract: As an article of manufacture, a microporous flexible shape or sheet of a sulfur-free, cured polymeric material of a curable rubber, an ethylene-propylene copolymer or mixtures of the curable rubber and ethylene-propylene copolymer; the article possesses an average pore size of less than 2 microns, a predetermined flexibility, and improved toughness, when compared to prior art sulfur cured articles.

Abstract: A battery separator, and a method of forming the same, which exhibits good electrical conductivity and a high degree of inhibition to dendrite formation, is in the form of a thin sheet formed from a substantially uniform mixture of a thermoplastic rubber and a filler in a volume ratio of from about 1:0.15 to 1:0.6. The thermoplastic rubber is preferably a styrene/elastomer/styrene block copolymer.

Abstract: An analytical system for determining whether separator materials should function satisfactorily in the alkaline environment of a secondary alkaline system comprises determining the rate at which zinc diffusion is occurring as well as whether or not the separator material is serving as a complete barrier. The overall analytical sequence also includes determining the following characteristics of the separator material: (1) freedom from either defects in the film or pores with larger than acceptable sizes, (2) suitability of the porosity, (3) satisfactory electrolyte transport, and (4) satisfactory resistance to chemical attack in the operating environment of the cell or battery system.

Abstract: Separator materials suitable for use in electrolytic cells, for example, for the electrolysis of alkali metal chloride brines, are sealed by a method which comprises coating the sections to be sealed with a synthetic thermoplastic sealing agent and ultrasonically sealing the coated portions.The method permits the sealing-in-place of separator materials and allows them to be unsealed and resealed without damage to the separators.

Abstract: A battery plate separator is characterized by polypropylene filter media material which is readily formed into pouches for receiving and encapsulating battery plates. The separator enables a free flow of electrolyte ions between adjacent plates while simultaneously preventing electrode dendrite penetration therebetween, is highly resistant to deterioration in the presence of electrolytes normally encountered in batteries, significantly extends the life of batteries constructed therewith, and provides a very thin yet highly efficient wrapping around the plates so that a greater number of plates may be packaged into a battery of given size for increased battery capacity.

Abstract: A continuous process for preparing a microporous flexible shape or sheet of a sulfur-free, cured polymeric material of a curable rubber, an ethylene-propylene copolymer or mixtures of the curable rubber and ethylene-propylene copolymer of a predetermined flexibility ranging from a drapable, conformable shape to a stiff material; electron beam curing of the curable polymeric material at low irradiation levels is one advantage of the continuous process as well as the capability of producing also backed materials using considerably thinner polymeric material layers thereon; the products obtained thereby are suitable as battery separators.

Abstract: A microporous film which comprises a matrix comprising 40 to 90 volume percent of a polyolefin having a number average molecular weight of 15,000 or more and 10 to 60 volume percent of an inorganic filler, said matrix having therein void spaces at a rate of 30 to 75 volume percent based on the volume of the film; and 2 to 20 weight percent, based on the total weight of the polyolefin and the inorganic filler, of an organic substance which is substantially insoluble in and inert to sulfuric acid and has a solubility parameter ranging from 7.3 inclusive to 8.4 exclusive; said organic substance, in its majority, adhering to the overall surface of the film including the outer surfaces of the film and the surfaces of the polyolefin walls defining said void spaces in cooperation with said inorganic filler.

Abstract: A material useful as a separator in batteries and a process for making the material is provided. This material is a polyolefin having grafted to it side chains derived from an ethylenically unsaturated ionogenic monomer and cross-linked with sulfur.

Abstract: A battery separator of reduced electric resistance comprising a self-supporting non-woven mat consisting essentially of a mixture of(A) olefinic resin fibers having a coarseness of from 4 to 13 decigrex,(B) olefinic resin fibers having a coarseness of less than 4 decigrex in an amount of not less than 3 parts by weight per 100 parts by weight of fibers (A) and(C) inert filter materials in an amount of 0 to about 600 parts by weight per 100 parts by weight in total fibers (A) and (B). The battery separator is produced by subjecting an aqueous dispersion of said mixture to a sheet-forming operation; drying the resulting wet non-woven mat; and heat-treating the dried mat at a temperature ranging from a point 20.degree. C. lower than the melting point of the fibers (A) and (B) to a point about 50.degree. C. higher than the melting point.

Abstract: A laminated microporous article consisting of at least two layers or plies, the first comprising either a thermoset or thermoplastic microporous material and the second comprising a polyester non-woven, heat bonded (in distinction of adhesive bonded) web. The resulting laminated microporous article is especially useful as a battery separator and exhibits superior propertries including improved electrical resistance, toughness and tear strength, and flexibility.

Abstract: A process is, herein, disclosed for preparing a membrane used for prevention of short-circuiting between the anode and the cathode of a battery comprising contacting a polyethylene film with an aqueous solution of acrylic acid, water, ethylene dichloride and ferrous salt or cupric salt and irradiating with ionizing radiation to obtain a polyethylene film with acrylic acid molecules grafted uniformly thereon.