Phenolic resin and battery separator impregnated therewith

Claim 2

A CELLULOSIC PERMEABLE BATTERY SEPARATOR WHICH COMPRISES A CELLULOSIC SUBSTRATE THRORUGHLY IMPREGNATED WITH A RESOLE OF NUMBER AVEGAGE MOLECULAR WEIGHT OF BETWEEN 130 AND 300 AND A COMBINED ALDEHYDE TO PHENOL MOLAR RATIO OF BETWEEN 1.6:1 AND 2.8:1 AND AN ANTI-MIGRATORY AGENT FOR REDUCING THE DEGREE OF MIGRATION AND IMPROVING OXIDATIVE RESISTANCE SELECTED FROM THE GROUP CONSISTING OF PHENOL, O-, M-, AND P-CRESOL, HYDROQUINONE AND CATECHOL, WHEREIN THE WEIGHT RATIO OF RESOLE TO ANTI-MIGRATORY AGENT IS BETWEEN 100:7 AND 100:32 AND WHEREIN THE RESOLE IS ADVANCED TO AN UNFUSIBLE STATE.

Claim 3

The battery separator of claim 1 wherein the weight ratio of resole to cellulose substrate is between 1:4 and 1:1.

Claim 4

The battery separator of claim 1 wherein the cellulosic substrate has a Gurley porosity of about 1 to 25 seconds measured with 5-ounce cylinder and a 1/4 square inch orifice.

Claim 5

The battery separator of claim 1 wherein the resole is the reaction product of formaldehyde and phenol.

Claim 6

The battery separator of claim 1 wherein the anti-migratory agent is phenol.

Claim 7

A cellulosic permeable battery separator which comprises a cellulosic substrate, thoroughly impregnated with a phenol-formaldehyde resole of number average molecular weight of between 130 and 300 and a combined aldehyde to phenol molar ratio of between 1.6:1 and 2.8:1 and an anti-migratory agent for reducing the degree of migration and improving oxidative resistance selected from the group consisting of phenol, o-, m-, and p-cresol, wherein the weight ratio of resole to anti-migratory agent is between 100:9 and 100:16, wherein the resole is advanced to an infusible state, wherein the weight ratio of resole to cellulose substrate is between 1:4 and 1:1 and wherein the cellulosic substrate has a Gurley porosity of about 1 to 25 seconds measured with a 5-ounce cylinder and a 1/4 square inch orifice.

Claim 8

A cellulosic permeable battery separator which comprises a cellulosic substrate, thoroughly impregnated with a phenol-formaldehyde resole of number average molecular weight of between 130 and 300 and a combined aldehyde to phenol molar ratio of between 1.6:1 and 2.8:1 and an anti-migratory agent for reducing the degree of migration and improving oxidative resistance selected from the group consisting of phenol, o-, m-, and p-cresol, wherein the weight ratio of resole to anti-migratory agent is between 100:9 and 100:16, wherein the resole is advanced to an infusible state, wherein the weight ratio of resole to cellulose substrate is between 1:4 and 1:1 and wherein the cellulosic substrate has a Gurley porosity of about 1 to 25 seconds measured with a 5-ounce cylinder and a 1/4 square inch orifice.

Claim 9

A resin composition comprising in admixture a resole and an anti-migratory agent for reducing the degree of migration and improving oxidative resistance selected from the group consisting of phenol, o-, m-, and p-cresol, hydroquinone, and catechol, wherein the resole has a number average molecular weight of between 130 and 300 and an aldehyde to phenol molar ratio of between 1.6:1 and 2.8:1 and the weight ratio of resole to anti-migratory agent is in the range of 100:7 to 100:32.

Claim 10

A resin composition comprising in admixture a resole and an anti-migratory agent for reducing the degree of migration and improving oxidative resistance selected from the group consisting of phenol, o-, m-, and p-cresol, hydroquinone, and catechol, wherein the resole has a number average molecular weight of between 130 and 300 and an aldehyde to phenol molar ratio of between 1.6:1 and 2.8:1 and the weight ratio of resole to anti-migratory agent is in the range of 100:7 to 100:32.

Claim 11

The resin composition of claim 7 wherein the resole is the reaction product of formaldehyde and phenol.

Claim 12

The resin composition of claim 7 wherein the anti-migratory agent is phenol.

Claim 13

A process for the manufacture of a cellulosic battery separator comprising: A. preparing a resin admixture of an anti-migratory agent for reducing the degree of migration and improving oxidative resistance selected from the group consisting of phenol, o-, m-, and p-cresol, hydroquinone, and catechol and a resole resin of number average molecular weight of between 130 and 300 and an aldehyde to phenol molar ratio of between 1.6:1 and 2.8:1, wherein the weight ratio of resole to anti-migratory agent is in the range of 100:7 to 100:32, B. impregnating a cellulose substrate with the resin admixture, and C. heating the impregnated substrate to advance the resole to the infusible stage.

Claim 14

A process for the manufacture of a cellulosic battery separator comprising: A. preparing a resin admixture of an anti-migratory agent for reducing the degree of migration and improving oxidative resistance selected from the group consisting of phenol, o-, m-, and p-cresol, hydroquinone, and catechol and a resole resin of number average molecular weight of between 130 and 300 and an aldehyde to phenol molar ratio of between 1.6:1 and 2.8:1, wherein the weight ratio of resole to anti-migratory agent is in the range of 100:7 to 100:32, B. impregnating a cellulose substrate with the resin admixture, and C. heating the impregnated substrate to advance the resole to the infusible stage.

Claim 15

A process for the manufacture of a cellulose battery separator comprising: A. swelling a cellulose substrate with a swelling agent selected from the group consisting of phenol, o-, m-, and p-cresol, hydroquinone, and catechol, B. impregnating the swollen cellulose substrate with a resole of number average molecular weight of between 130 and 300 and an aldehyde to phenol mol ratio of between 1.6:1 and 2.8:1, and C. heating the impregnated substrate to advance the resole to the infusible stage; Wherein the weight ratio of resole to anti-migratory agent is in the range of 100:7 to 100:32.

Claim 16

A process for the manufacture of a cellulose battery separator comprising: A. swelling a cellulose substrate with a swelling agent selected from the group consisting of phenol, o-, m-, and p-cresol, hydroquinone, and catechol, B. impregnating the swollen cellulose substrate with a resole of number average molecular weight of between 130 and 300 and an aldehyde to phenol mol ratio of between 1.6:1 and 2.8:1, and C. heating the impregnated substrate to advance the resole to the infusible stage; Wherein the weight ratio of resole to anti-migratory agent is in the range of 100:7 to 100:32.