# US 12,113,237 B2 · Separators with fibrous mat, lead acid batteries using the same, and methods and systems associated therewith

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- Number: US 12,113,237 B2
- Document ID: US12113237B2
- Status: Granted
- Kind: B2
- Application number: 18/203,140
- Filed: 2023-05-30
- Published: 2023-09-28
- Granted: 2024-10-08
- Earliest claimed: 2021-06-26
- Assignees: Daramic, LLC
- Applicants: Daramic, LLC
- Inventors: Eric H. Miller; Ahila Krishnamoorthy; James P. Perry; J. Kevin Whear
- Web page: https://patentgrep.com/patent/US12113237B2

## CPC

- H01M 10/06: Lead-acid accumulators (semi-lead accumulators H01M10/20)
- H01M 50/44: Fibrous material
- B01D 69/1071: {Woven, non-woven or net mesh}
- H01M 10/12: Construction or manufacture
- H01M 50/414: Synthetic resins, e.g. thermoplastics or thermosetting resins
- H01M 50/417: Polyolefins
- H01M 50/42: Acrylic resins
- H01M 50/437: Glass
- H01M 50/451: comprising layers of only organic material and layers containing inorganic material
- H01M 50/454: comprising a non-fibrous layer and a fibrous layer superimposed on one another
- B01D 2325/028: Microfluidic pore structures
- B01D 2325/0281: Fibril, or microfibril structures
- B01D 2325/20: Specific permeability or cut-off range
- B01D 2325/26: Electrical properties
- 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
- B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28)
- 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

In at least one embodiment, a separator is provided with a fibrous mat for retaining the active material on an electrode of a lead-acid battery. New or improved mats, separators, batteries, methods, and/or systems are also disclosed, shown, claimed, and/or provided. For example, in at least one possibly preferred embodiment, a composite separator is provided with a fibrous mat for retaining the active material on an electrode of a lead-acid battery. In at least one possibly particularly preferred embodiment, a PE membrane separator is provided with at least one fibrous mat for retaining the active material on an electrode of a lead-acid battery. In accordance with at least certain embodiments, aspects and/or objects, the present invention, application, or disclosure may provide solutions, new products, improved products, new methods, and/or improved methods, and/or may address issues, needs, and/or problems of PAM shedding, NAM shedding, electrode distortion, active material shedding, active material loss, and/or physical separation, electrode effectiveness, battery performance, battery life, and/or cycle life, and/or may provide new battery separators, new battery technology, and/or new battery methods and/or systems that address the challenges arising from current lead acid batteries or battery systems, especially new battery separators, new battery technology, and/or new battery methods and/or systems adapted to prevent or impede the shedding of active material from the electrodes, preferably or particularly in enhanced flooded lead acid batteries, PSoC batteries, ISS batteries, ESS batteries, and/or the like.

## Claims

### Claim 1

A flooded lead-acid battery separator assembly comprising:
a microporous membrane which comprises a thermoplastic polymer and a mixing profile;
a nonwoven fibrous mat;
said fibrous mat being disposed adjacent to said microporous membrane, wherein said fibrous mat comprises fibers selected from the group consisting of: glass fibers, synthetic fibers, and combinations thereof;
wherein said fibrous mat may be a single layer, double layer, or other multi-layer mat; and
wherein said fibrous mat may include an additive impregnated into or coated on one or more surfaces of said fibrous mat; and
wherein an average diameter of the fibers included in the fibrous mat is 7.2 μm (±0.5 μm);
wherein said fibrous mat has: an average pore size of less than about 5 μm, and an air permeability in the range of approximately 1500 l/m2·s to approximately 2500 l/m2·s; and
wherein said microporous membrane and fibrous mat are laminated together.

### Claim 2 (depends on 1)

The flooded lead-acid battery separator assembly of claim 1, wherein said fibrous mat has a thickness, in the range of 100 μm to 900 μm, and preferably in the range of 200 μm to 450 μm.

### Claim 3 (depends on 1)

The flooded lead-acid battery separator assembly of claim 1, wherein said fibrous mat has an electrical resistance less than an electrical resistance in the range of approximately 6 mΩ·cm2 to approximately 14 mΩ·cm2.

### Claim 4 (depends on 1)

The flooded lead-acid battery separator assembly of claim 1, wherein said fibrous mat has an area weight in the range of approximately 50 g/m2 to approximately 65 g/m2.

### Claim 5 (depends on 1)

The flooded lead-acid battery separator assembly of claim 1, wherein said fibrous mat has a preferred binder content in the range of approximately 15% by weight to approximately 21% by weight.

### Claim 6 (depends on 1)

The flooded lead-acid battery separator assembly of claim 1, wherein said fibrous mat has a tensile strength in a machine direction of approximately 200 N/50 mm.

### Claim 7 (depends on 1)

The flooded lead-acid battery separator assembly of claim 1, wherein said fibrous mat has a tensile strength in a cross-machine direction of approximately 150 N/50 mm.

### Claim 8 (depends on 1)

The flooded lead-acid battery separator assembly of claim 1, wherein said fibrous mat comprises a synthetic fibers.

### Claim 9 (depends on 1)

The flooded lead-acid battery separator assembly of claim 1, wherein said synthetic fibers are selected from the group consisting of: polypropylene, polyethylene terephthalate, acrylic, other plastics, polymer, homopolymer, copolymer, and any combination thereof.

### Claim 10 (depends on 1)

The flooded lead-acid battery separator assembly of claim 1, wherein said fibrous mat comprises an additive selected from the group consisting of: rubber, silica, soluble fibers, a gelling agent, a surfactant, and combinations thereof.

### Claim 11 (depends on 1)

The flooded lead-acid battery separator assembly of claim 1, wherein said microporous membrane comprises said mixing profile comprising one from the group consisting of: broken ribs, angled serrated ribs, serrated ribs, embossed ribs, negative cross ribs, and any combination thereof.

### Claim 12 (depends on 1)

The flooded lead-acid battery separator assembly of claim 1, wherein said microporous membrane comprises a plurality of broken ribs, wherein said plurality of broken ribs are defined by an angular orientation.

### Claim 13 (depends on 12)

The flooded lead-acid battery separator assembly of claim 12, wherein said angular orientation is relative to a machine direction of said microporous membrane, and said angular orientation is an angle chosen from the group consisting of: between greater than zero degrees (0°) and less than 180 degrees) (180°, and between greater than 180 degrees (180°) and less than 360 degrees (360°).

### Claim 14 (depends on 1)

The flooded lead-acid battery separator assembly of claim 1, wherein said microporous membrane comprises a rubber.

### Claim 15 (depends on 14)

The flooded lead-acid battery separator assembly of claim 14, wherein said rubber is selected from the group consisting of: latex, methyl rubber, polybutadiene, chloroprene rubbers, butyl rubber, bromobutyl rubber, polyurethane rubber, epichlorhydrin rubber, polysulphide rubber, chlorosulphonyl polyethylene, polynorbornene rubber, acrylate rubber, fluorine rubber, silicone rubber, copolymer rubbers, and combinations thereof.

### Claim 16 (depends on 15)

The flooded lead-acid battery separator assembly of claim 15 wherein said copolymer rubbers is selected from the group consisting of: styrene/butadiene rubbers, acrylonitrile/butadiene rubbers, ethylene/polypropylene rubbers (EPM and EPDM), ethylene/vinyl acetate rubbers, and combinations thereof.

### Claim 17 (depends on 14)

The flooded lead-acid battery separator assembly of claim 14, wherein said rubber is cross-linked or uncross-linked.

### Claim 18 (depends on 12)

A flooded lead-acid battery comprising the separator assembly of claim 12.

### Claim 19 (depends on 14)

A flooded lead-acid battery comprising the separator assembly of claim 14.