Battery separators

Claim 2

A battery separator comprising a laminate of at least one first layer affording a profiled exterior appropriate for juxtaposition to the positive plate of a lead acid battery and containing at least 75% by weight of synthetic pulp and at least one other layer adherent to the first layer, said second layer containing from 30 to 60% by weight of cellulose fibers and not more than 70% by weight synthetic pulp.

Claim 3

A separator as claimed in claim 1 in which the first layer also contains a minor portion of cellulose fibres.

Claim 4

A separator as claimed in claim 1 in which the first layer or the second layer or both also contain a minor portion by weight of fibres having a higher stiffness than the synthetic pulp fibres, or fibres effective to impart increased stiffness to the separator.

Claim 5

A separator as claimed in claim 3 in which the said fibres are selected from the group consisting of glass fibres, polyester fibres and polycarbonate fibres.

Claim 6

A separator as claimed in claim 1 in which the synthetic pulp fibres are subjected to chemical treatment prior to being formed into the furnish used to form the waterleaf, the chemical treatment being designed to increase the wettability of the fibres.

Claim 7

A separator as claimed in claim 5 in which the chemical treatment comprises an oxidative process consisting of or including treatment of the fibres with chromic acid, nitric acid, nitric acid-hydrochloric acid blends such as aqua regia, hypochlorite, permanganate, chlorosulphonic acid, hydrogen peroxide, corona discharge, ozone or ultra-violet radiation.

Claim 8

A separator as claimed in claim 1 incorporating as a wetting agent an effective amount of wetting agent selected from the group consisting of a quaternary ammonium wetting agent, a sulphonate wetting agent and a succinate wetting agent.

Claim 9

A separator as claimed in claim 1 in which the laminated material has the profiled exterior imparted to the first layer by a hot calendering process.

Claim 10

A separator as claimed in claim 8 in which the surface pore size of the separator is controlled by applying overall consolidation to the surface of the first layer to achieve fusion of the synthetic pulp fibres to each other immediately adjacent the surface without significant consolidation in the body of the separator.

Claim 11

A battery separator which comprises a laminate of a first layer affording a profiled exterior appropriate for juxtaposition to the positive plate of a lead acid battery and containing at least 75% by weight of polyethylene synthetic pulp fibres, 0 to 25% by weight of cellulose pulp fibre and 0 to 25% by weight of synthetic fibres having a stiffness greater than the polyethylene fibres, and a second layer adherent to the first layer and containing 30 to 60% by weight of cellulose pulp fibres, 40 to 70% by weight of polyethylene synthetic pulp fibres and 0 to 25% by weight of synthetic fibres having a stiffness greater than the polyethylene fibres, the separator having parallel spaced lines of consolidation, the consolidation being such that polyethylene fibres are fused to each other in each area of consolidation through the first layer and into the second layer whereby the adherence of the layers is increased.

Claim 12

A battery separator which comprises a laminate of a first layer affording a profiled exterior appropriate for juxtaposition to the positive plate of a lead acid battery and containing at least 75% by weight of polyethylene synthetic pulp fibres, 0 to 25% by weight of cellulose pulp fibre and 0 to 25% by weight of synthetic fibres having a stiffness greater than the polyethylene fibres, and a second layer adherent to the first layer and containing 30 to 60% by weight of cellulose pulp fibres, 40 to 70% by weight of polyethylene synthetic pulp fibres and 0 to 25% by weight of synthetic fibres having a stiffness greater than the polyethylene fibres, the separator having parallel spaced lines of consolidation, the consolidation being such that polyethylene fibres are fused to each other in each area of consolidation through the first layer and into the second layer whereby the adherence of the layers is increased.

Claim 13

A separator as claimed in claim 10 in which the lines of consolidation are 0.5 to 2 mm wide and are spaced by 1 to 4 mms, the spacing between lines being greater than the width of the lines.

Claim 14

A separator as claimed in claim 10 in which the thickness of the material of the separator is at least 40% of the thickness of the material before consolidation.

Claim 15

A battery separator comprising a laminate of at least one first layer affording a profiled exterior appropriate for juxtaposition to the positive plate of a lead acid battery and containing at least 75% by weight of a synthetic pulp, 0 to 25% by weight of cellulose fibres and 10 to 20% by weight of fibres having a higher stiffness than said synthetic pulp and at least one other layer adherent to the first layer, said second layer containing as solids 30 to 60% by weight cellulose pulp fiber and not more than 70% by weight synthetic pulp.

Claim 16

A battery separator comprising a laminate of at least one first layer affording a profiled exterior appropriate for juxtaposition to the positive plate of a lead acid battery and containing at least 75% by weight of a synthetic pulp, 0 to 25% by weight of cellulose fibres and 10 to 20% by weight of fibres having a higher stiffness than said synthetic pulp and at least one other layer adherent to the first layer, said second layer containing as solids 30 to 60% by weight cellulose pulp fiber and not more than 70% by weight synthetic pulp.