Patent US3870567A successfully refreshed from Google Patents.
US3870567A
Expired / Lapsed
US
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Battery separator manufacturing process
Assignee: WR Grace and Co
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Filing: 1972-12-21
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Granted: 1975-03-11
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Expires: 1992-12-21
Abstract
Abstract Battery separators and the like are produced from non woven mats of thermoplastic fibers which fibers contain an internal wetting agent that is relatively insoluble in battery electrolite and tends to bloom under conditions of use. After preliminary formation the nonwoven mat is heated and then compressed to increase the effectiveness of the wetting agent. The fibers may be formed from polypropylene resin that is treated at unusually high temperatures prior to extrusion and the extrudate attenuated, collected on a drum and compressed to form a preferred separator with small pores and high porosity.
Inventors
- 👤 Nigel Innes Palmer
- 👤 Nathan Sugarman
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-28 17:28
CPC Classifications
D; D04; D04H; D04H3/00; D04H3/08; D04H3/16; H; H01; H01M; H01M50/00; H01M50/40; H01M50/409; H01M50/489; H01M50/491; Y; Y02; Y02E; Y02E60/00; Y02E60/10; Y10; Y10T; Y10T156/00; Y10T156/10; Y10T156/1002; Y10T156/1007; Y10T156/1016; Y10T428/00; Y10T428/24; Y10T428/24628; Y10T428/24669; Y10T428/24694; Y10T428/24942; Y10T428/24992
Claims Analysis
Total Claims: 10
Claim 1
Independent Claim
158 words
A method for producing a battery separator using nonwoven fibers formed from a polymeric resin having a degree of undesirable hydrophobia, solid below 180*F, extrudable as a hot melt and resistant to degradation by at least either acids or alkalies comprising forming a mixture of said polymeric resin and wetting agent, the wetting agent being included in an amount of 0.5 - 20 percent by weight based on the weight of the resin with said amount being (a) incompatable with the resin below the resin''s melting point such that the wetting agent will bloom over a period of time at ambient temperatures in a battery yet (b) compatable with the resin at the extrusion temperature; extruding said mixture as a hot plastic through a die opening and forming a fiber containing said wetting agent therein; forming said fiber into a web comprising Other like fibers; developing said wetting agent by heating said fiber and forming said battery separator.
Claim 2
Independent Claim
158 words
A method for producing a battery separator using nonwoven fibers formed from a polymeric resin having a degree of undesirable hydrophobia, solid below 180*F, extrudable as a hot melt and resistant to degradation by at least either acids or alkalies comprising forming a mixture of said polymeric resin and wetting agent, the wetting agent being included in an amount of 0.5 - 20 percent by weight based on the weight of the resin with said amount being (a) incompatable with the resin below the resin''s melting point such that the wetting agent will bloom over a period of time at ambient temperatures in a battery yet (b) compatable with the resin at the extrusion temperature; extruding said mixture as a hot plastic through a die opening and forming a fiber containing said wetting agent therein; forming said fiber into a web comprising Other like fibers; developing said wetting agent by heating said fiber and forming said battery separator.
Claim 3
Independent Claim
111 words
A METHOD FOR PRODUCING A BATTERY SEPARATOR USING NONWOVEN FIBERS FORMED A POLYMERIC RESIN HAVING A DEGREE OF UNDESIRABLE HYDROPHOBIA, SOLID BELOW 180*F, EXTRUDABLE AS A HOT MELT AND RESISTANT TO DEGRADATION BY AT LEAST EITHER ACIDS OR ALKALIES COMPRISING FORMING A MIXTURE OF SAID POLYMERIC RESIN AND WETTING AGENT, THE WETTING AGENT BEING INCLUDED IN AN AMOUNT OF 0.5 -20 PERCENT BY WEIGHT BASED ON THE WEIGHT OF THE RESIN WITH SAID AMOUNT BEING (A) INCOMPATABLE WITH THE RESIN BELOW THE RESIN''S MELTING POINT SUCH THAT THE WETTING AGENT WILL BLOOM OVER A PERIOD OF TIME AT AMBIENT TEMPERATURES IN A BATTERY YET (B) COMPATABLE WITH THE RESIN AT THE
Claim 4
Independent Claim
111 words
A METHOD FOR PRODUCING A BATTERY SEPARATOR USING NONWOVEN FIBERS FORMED A POLYMERIC RESIN HAVING A DEGREE OF UNDESIRABLE HYDROPHOBIA, SOLID BELOW 180*F, EXTRUDABLE AS A HOT MELT AND RESISTANT TO DEGRADATION BY AT LEAST EITHER ACIDS OR ALKALIES COMPRISING FORMING A MIXTURE OF SAID POLYMERIC RESIN AND WETTING AGENT, THE WETTING AGENT BEING INCLUDED IN AN AMOUNT OF 0.5 -20 PERCENT BY WEIGHT BASED ON THE WEIGHT OF THE RESIN WITH SAID AMOUNT BEING (A) INCOMPATABLE WITH THE RESIN BELOW THE RESIN''S MELTING POINT SUCH THAT THE WETTING AGENT WILL BLOOM OVER A PERIOD OF TIME AT AMBIENT TEMPERATURES IN A BATTERY YET (B) COMPATABLE WITH THE RESIN AT THE
Claim 5
Dependent Claim
16 words
The method of claim 1 wherein the wetting agent development includes applying pressure to said web.
Claim 6
Dependent Claim
34 words
The method of claim 2 wherein said wetting agent is comprised of two surfactants, one of which is relatively soluble in battery electrolyte and the other of which is relatively insoluble in battery electrolyte.
Claim 7
Dependent Claim
41 words
The method of claim 3 wherein the surfactant that is relatively soluble in battery electrolyte is relatively water soluble and relatively oil insoluble and the surfactant that is relatively insoluble in battery electrolyte is relatively water insoluble and relatively oil soluble.
Claim 8
Dependent Claim
80 words
The method of claim 1 wherein said mixture is formed by melt blending, forming a solution of said wetting agent and said resin and said mixture is subjected to a thermal treatment at a temperature in excess of 550*F and sufficiently high to at least partially degrade the resin prior to extrusion and said fiber formation includes attenuation immediately beyond said die opening in a hot gas stream with a wetting agent retention of 65 + or - 5 percent.
Claim 9
Dependent Claim
130 words
The method of claim 1 wherein said wetting agent is mixed with said resin in an amount of 1 - 10 percent by weight based on the weight of the resin, said fiber is formed with said other fibers from said mixture through a common die through independent die openings, said fibers being formed with diameters between 0.05 and 50 microns, said web being formed by collecting said fibers on a continuously moving take-up device from 1-30 inches from said die openings in an amount having a basis weight between 10 and 500 grams per square meter and said web is compressed to a permanent thickness of between 5 and 50 mils, to a web porosity retention greater than 40 percent and a maximum pore size less than 40 microns.
Claim 10
Dependent Claim
88 words
The method of claim 6 wherein said resin and said wetting agent are in solution at the time of extrusion and are brought to a heterogeneous state after extrusion but before development, and said development includes compression of said web and said heating includes the heating of said web to a temperature between the softening point and the melting point of the resin and said development proceeds until said web acquires resistance to delamination in the sulfuric acid environment of a lead-acid storage battery and resistance to tearing.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1978-03-10 | 1978-09-09 | 1979-03-11 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1982-03-10 | 1982-09-09 | 1983-03-11 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1986-03-10 | 1986-09-09 | 1987-03-11 | $7700.00 | Window Closed / Lapsed |