# US 10,770,704 B2 · Separators for VRLA batteries and methods relating thereto

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- Number: US 10,770,704 B2
- Document ID: US10770704B2
- Status: Granted
- Kind: B2
- Application number: 16/199,654
- Filed: 2018-11-26
- Published: 2019-06-20
- Granted: 2020-09-08
- Earliest claimed: 2015-05-05
- Assignees: Daramic, LLC
- Applicants: Daramic, LLC
- Inventors: Eric H. Miller; Robert W. Saffel
- Web page: https://patentgrep.com/patent/US10770704B2

## CPC

- H01M 50/44: Fibrous material
- H01M 10/121: {Valve regulated lead acid batteries [VRLA]}
- H01M 50/434: Ceramics
- H01M 50/437: Glass
- H01M 50/446: Composite material consisting of a mixture of organic and inorganic materials
- H01M 50/454: comprising a non-fibrous layer and a fibrous layer superimposed on one another
- H01M 50/417: Polyolefins
- H01M 50/463: Separators, membranes or diaphragms characterised by their shape
- H01M 50/489: Separators, membranes, diaphragms or spacing elements inside the cells, characterised by their physical properties, e.g. swelling degree, hydrophilicity or shut down properties
- H01M 50/491: Porosity
- Y02E 60/10: Energy storage using batteries
- Y02P 70/50: Manufacturing or production processes characterised by the final manufactured product
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## 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.

## Claims

### Claim 1

A battery separator comprising:
at least one microporous polyolefin separator layer, said microporous polyolefin separator layer having a first surface and a second surface;
at least said first surface comprising at least one of the list consisting of ribs, embossments, acid filling channels, and a combination thereof;
at least said second surface comprising at least one of the list consisting of ribs, embossments, acid filling channels, mini cross ribs, and a combination thereof;
said microporous polyolefin separator layer comprises first areas comprising a first set of pores and a compressed pore structure; and further comprises second areas comprising a second set of pores and a pore structure less compressed than the pore structure of the first areas;
optionally at least one first Absorptive Glass Mat (“AGM”) layer adjacent to one of said first surface or said second surface.

### Claim 2 (depends on 1)

The battery separator of claim 1, wherein said first set of pores are smaller than said second set of pores.

### Claim 3 (depends on 1)

The battery separator of claim 1, wherein said microporous polyolefin separator layer comprises polyethylene and silica.

### Claim 4 (depends on 1)

The battery separator of claim 1, wherein said ribs are about 8.0 μm to about 1.0 mm tall.

### Claim 5 (depends on 1)

The battery separator of claim 1, wherein said ribs are spaced about 1.0 μm to about 10 mm apart.

### Claim 6 (depends on 1)

The battery separator of claim 1, wherein said embossments are textured embossments, straight pattern embossments, wavy pattern embossments, embossments in a picture pattern, zigzag pattern embossments, or a combination thereof.

### Claim 7 (depends on 1)

The battery separator of claim 1, wherein said at least one first AGM layer comprises glass fibers, polymeric fibers, or a combination thereof.

### Claim 8 (depends on 1)

The battery separator of claim 1, wherein said at least one first AGM is nonwoven.

### Claim 9 (depends on 1)

The battery separator of claim 1, comprising at least one second AGM layer adjacent to one of said first surface or said second surface.

### Claim 10 (depends on 9)

The battery separator of claim 9, wherein said at least one second AGM layer is adjacent to a surface that is opposite of said at least one first AGM layer.

### Claim 11 (depends on 1)

The battery separator of claim 1, wherein said separator is about 10% to about 40% compressible at a pressure at least about 10 kPa.

### Claim 12 (depends on 1)

The battery separator of claim 1, wherein said first surface comprises ribs, embossments, and acid filling channels.

### Claim 13 (depends on 1)

The battery separator of claim 1, wherein said second surface at least comprises mini cross ribs.

### Claim 14 (depends on 1)

The battery separator of claim 1, further comprising a coating of a surfactant on at least one of said first surface or said second surface of said microporous polyolefin separator layer.

### Claim 15

A Valve Regulated Lead Acid (“VRLA”) battery comprising:
a positive electrode, a negative electrode, an electrolyte; and a composite battery separator;
and the composite battery separator comprises at least one microporous polyolefin separator layer, said microporous polyolefin separator layer having a first surface and a second surface; at least said first surface comprising at least one of the list consisting of ribs, embossments, acid filling channels, and a combination thereof; at least said second surface comprising at least one of the list consisting of ribs, embossments, acid filling channels, mini cross ribs, and a combination thereof; said microporous polyolefin separator layer comprises first areas comprising a first set of pores and a compressed pore structure; and further comprises second areas comprising a second set of pores and a pore structure less compressed than the pore structure of the first areas; and at least one first Absorptive Glass Mat (“AGM”) layer adjacent to one of said first surface or said second surface.

### Claim 16 (depends on 15)

The VRLA battery of claim 15, wherein an AGM layer of the composite separator is placed against the positive electrode.

### Claim 17 (depends on 15)

The VRLA battery of claim 15, wherein ribs, embossments, or acid filling channels on the microporous polyolefin separator layer are placed against the negative electrode.

### Claim 18 (depends on 15)

The VRLA battery of claim 15, comprising at least one second AGM layer adjacent to one of said first surface or said second surface.

### Claim 19

A battery separator comprising:
at least one microporous polyolefin separator layer, said microporous polyolefin separator layer having a first surface and a second surface;
at least said first surface comprising at least one of the list consisting of ribs, embossments, acid filling channels, and a combination thereof;
at least said second surface comprising at least one of the list consisting of ribs, embossments, acid filling channels, mini cross ribs, and a combination thereof;
said microporous polyolefin separator layer comprises first areas comprising a first set of pores and a compressed pore structure; and further comprises second areas comprising a second set of pores and a pore structure less compressed than the pore structure of the first areas;
at least one first Absorptive Glass Mat (“AGM”) layer adjacent to one of said first surface or said second surface.

### Claim 20 (depends on 19)

The battery separator of claim 19, comprising at least one second AGM layer adjacent to one of said first surface or said second surface.