Improved lead acid battery separators, batteries and related methods

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.

1 - 14 . (canceled) 
     
     
         15 . A separator for a lead acid battery having a front face facing a positive electrode and a reverse face facing a negative electrode, the separator comprising:
 a porous polyolefin membrane is silica-filled, contains processing oil, and includes one or more surfactants, the polyolefin membrane having a backweb with integral ribs, wherein said ribs consist of integral ribs on the front face, the front face ribs running parallel to buoyant forces and integral negative cross ribs on the reverse face, the reverse face ribs running across the reverse face and perpendicular to buoyant forces; and   said separator having at least one of: an acid leachable total organic carbon (TOC) of < 100 ppm; a backweb thickness in the range of 125-250 microns; a puncture resistance of > 10 N; an oxidation resistance (Perox @ 40 hours) of > 50% of the original CMD elongation; an electrical resistance of < 10 mohms-in 2 ; a water loss with an antimony alloy of < 1.5 g/Ah; and a water loss with a non-antimony alloy of <0.8 g/Ah,   wherein the lead acid battery is an idle start stop (ISS) battery.   
     
     
         16 . The separator of  claim 15  further having a stiffness (CMD) of > 20 mN. 
     
     
         17 . In a lead acid battery, the improvement comprising the separator of  claim 15 . 
     
     
         18 . In a vehicle, the improvement comprising the lead acid battery of  claim 17 . 
     
     
         19 . The separator of  claim 15  wherein the acid leachable TOC is < 50 ppm. 
     
     
         20 . The separator of  claim 15  wherein the acid leachable TOC is < 75 ppm. 
     
     
         21 . The separator of  claim 16  having a basis weight of 120 to 154 gsm. 
     
     
         22 . The separator of  claim 16  having a backweb thickness of 125-250 microns. 
     
     
         23 . A battery comprising the separator of  claim 15 . 
     
     
         24 . A battery comprising the separator of  claim 22 . 
     
     
         25 . The separator of  claim 15  wherein said separator having at least three of the following characteristics: a backweb thickness in the range of 125-250 microns; a puncture resistance of > 10 N; an oxidation resistance (Perox @ 40 hours) of > 50% of the original CMD elongation; an electrical resistance of < 1 O mohms-in 2  ; a water loss with an antimony alloy of < 1.5 g/Ah; and a water loss with a non-antimony alloy of <0.8 g/Ah. 
     
     
         26 . The separator of  claim 15  wherein the porous, silica-filled, polyolefin membrane is a microporous, silica-filled, polyethylene membrane. 
     
     
         27 . The separator of  claim 15  wherein the separator further includes a laminate, glass-mat or nonwoven. 
     
     
         28 . A separator for a lead acid battery having a front face facing a positive electrode and a reverse face facing a negative electrode, the separator comprising:
 a porous polyolefin membrane is silica-filled, contains processing oil, and includes one or more surfactants, the polyolefin membrane having a backweb with integral ribs, wherein said ribs consist of integral ribs on the front face, the front face ribs running parallel to buoyant forces and integral negative cross ribs on the reverse face, the reverse face ribs running across the reverse face and perpendicular to buoyant forces; and   said separator having at least one of: an acid leachable total organic carbon (TOC) of < 100 ppm; a backweb thickness in the range of 125-250 microns; a puncture resistance of > 10 N; an oxidation resistance (Perox @ 40 hours) of > 50% of the original CMD elongation; an electrical resistance of < 10 mohms-in 2 ; a water loss with an antimony alloy of < 1.5 g/Ah; and a water loss with a non-antimony alloy of <0.8 g/Ah.   
     
     
         29 . A separator for a lead acid battery having a front face facing a positive electrode and a reverse face facing a negative electrode, the separator comprising:
 a porous polyolefin membrane is silica-filled, contains processing oil, and includes one or more surfactants, the polyolefin membrane having a backweb with integral ribs, wherein said ribs consist of integral ribs on at least one of the front face and the reverse face thereof; and   said separator having at least one of: an acid leachable total organic carbon (TOC) of < 100 ppm; a backweb thickness in the range of 125-250 microns; a puncture resistance of > 10 N; an oxidation resistance (Perox @ 40 hours) of > 50% of the original CMD elongation; an electrical resistance of < 10 mohms-in 2 ; a water loss with an antimony alloy of < 1.5 g/Ah; and a water loss with a non-antimony alloy of <0.8 g/Ah,   wherein the lead acid battery is an idle start stop (ISS) battery.