METHOD FOR PRODUCING BATTERY SEPARATORS CONTAINING FUSIBLE BINDERS

Abstract: A method for producing a battery separator from a slurry of fibers which are resistant to the chemicals which are found in a battery, and a thermoplastic binder for the fibers. The method comprises the steps of casting the slurry onto a screen, draining the liquid of the slurry from fibers and binder which collect on the screen, and drying the fibers and binder without softening the binder. Subsequently, usually after it has been rolled, packaged and shipped, the separator is cut to size and heated to soften the binder. In a preferred embodiment, the fibers are glass fibers having an average diameter less than 3 mu m. In another preferred embodiment, the fibers are organic.

Description: TITLE METHOD FOR PRODUCING BATTERY SEPARATORS CONTAINING FUSIBLE BINDERS s BACKGROUND OF THE INVENTION FIELD OF THE INVENTION The piesent invention telates geneially to the field ot battenes. especially to the field ot lecombinant 01 \ al\ e tegulated lead acid ( VRLA") battenes and. moie speciticalK to a method foi pioducing batteiy sepai atois containing fusible bindei s and l () tibei s pietei ably. glass iibei s Such sepaiatoi s ha\ e been manufactuied by a method which ιn\ a wet papei making piocess. sheets of glass fibeis and fusible tibei s. and heating the fusible fibeis to cause them to bond the sheet into a moie 01 less stable condition The sheets aie sometimes loimed into desued shapes, e g . pockets into which batteiv plates can be inseited and the edges aie heated so that fusible I s fibeis theiein weld the sheets in the toimed shapes In use, the sepaiatois aie positioned between the positive and negative plates of battenes. wheie they pievent metal conduction, but do not pievent the migiation ot ions, between the plates Sepaiatois foi VRLA battenes. in seiv ice, have unfilled voids thiough which oxygen can migi te between the positive and negative plates 20 DESCRIPTION OF THE PRIOR ART I S patent 4.265.985. Gianted Ma 5. 1981 to O'Rell et al . discloses the pi oduction ot batteι\ sepaiatoi tiom a slunv composed ot 30 to 70 weight peicent of polyolel tibei s, 15 to 30 weight peicent of a paniculate siliceous fillei and 1 to 35 2s w eight peicent of long tibeis which aie polyestei papei making staple fibei s. aciyhc papei making staple tibeis, glass tibeis, oi mixtuies of polyestei , aciyhc and glass fibei s The sluuy is cast on the scieen of papeimaking appaiatus and is piessed between opposed haid toll befoie being tiansfened to an open mesh metal belt and passed thiough an unheated oven and then ovei a plui ahty ot cans with suifaces 30 heated to about 270° F The patent suggests that some bonding lesults fiom melting of the poh oletin fibeis at tibei junctions A Japanese patent application published June 19. 1 82, undei Numbei JP 57098975. discloses a sepaiatoi pioduced fiom a slimy of glass fibeis having an average diametci ot 05 μm and polvethvlene iibeis ing an aveiage diametei ot 20 mil The sluii) is cast on a sciecn as a nanow belt, dehvdiated and dned The dned sepaiatoi is cut to si/e. and tolded to toim a bag high tiequencv welding is then used to tuse the edges ol the bag The polvethvlene tibeis can constitute horn 25 to 50 peicent bv weight ol the total iibeis A papei entitled " Sealed Cai Batten " which was published bv Mitsushita in Octobei, 1 86. in an internal newslettei. discloses that a ne lv developed sepaiatoi piovides impioved leliabihty and pioductivitv because it is in pouch toim. and that an impiovement the addition ol highlv lesihent PET les tibei to the constituent matenal '" The authois weie awaie. the papei also savs. that ultiasonic welding could be used lo make a pouch toim horn a thick mat sepaiatoi. but "a need to latchet up the welding technology level was lecognized " US patent No 5.436.094. gianted Julv 25 1995 assigned to Mitsui Petiochemical Industnes. Ltd ("Mitsui "" ) discloses the pioduction ol a sepaiatoi matenal "with melt adhesion bonds '" tioin a slu containing 5 to 95 peicent by weight ot a svnthetic pulp, and 5 to 50 peicent bv weight ot a polymei bindei The patent also discloses that 40 peicent bv weight oi less of othei svnthetic oi inoiganic tibeis can be used, naming, as "othei svnthetic oi inoiganic tibeis " . polypiopylene. polvethylene. nylon, polvestei. acivlic. Modacivl. glass, silica and lock wool tibeis The sepaiatoi matenal is pioduced bv dispeising m watei and dehbenzing. foi example m a pulpei. the synthetic pulp, bindei and the auxihaiv fibeis. it used, letining the slu , and teeding the lelined sluπy onto the wue ot a Fouidnniei oi othei papei making machine The web which toi s on the wne is then spiaved with a suitactant and dehvdiated bv suction, bv piessmg. oi both, and dned and heat tiealed to toim melt-adhesion bonds ' ot the bindei among the fibeis " The use ol what is called "the method ot the hot an thiough type "" is disclosed as being opeiable foi the heat tieatment This method is descnbed as involving heating the dned web fiom above while withdi awing an horn below as the web is being advanced on a "mesh-hke " suppoit. and heat ti eating by passing the heated web ovei a hot loll, thiough a hot oven, oi thiough an infia-ied heatei. oi by sub|ectιng it to ultiasonic eneigv EPO 587682 B 1 gi nted Apnl 12.1995. discloses anolhei method toi pioducing a si ilai pioduct horn a mixtuie of glass tibeis and at least one tvpe ol synthetic iibeis The svnthetic tibeis can be (a) a mixtuie ot at least two types ot fibeis with different melting points, a first tv pe which softens when the sheet is manufactured ( i.e.. during a heat treatment step) and a second type which melts w hen the sheet is lormed, or (b) compound fibeis. which can be of the sheath core or side by side type, consisting of a first synthetic material w hich sottens w hen the sheet is manufactured ( i.e.. s during a heat treatment step ) and a second synthetic material which melts when the sheet is w elded. In both cases, a sepai ator matenal is produced bv suspending the fibers in acidif ied ater, casting the suspension on the screen of a paper making machine, and drying and heat treating the fibers: fibei to fiber bonds are formed as a consequence of the melting which occurs during the f inal heat treating step and subsequent re- 10 solidification of the lower melting fibers or of the lower melting synthetic material ot the composite libers. The separator sheet can be cut to size and stacked between alternate positive and negative batten, plates to produce assemblies which are used in the pioduetion ol batteries. 01 it can. as the reference states, be welded bv high frequency oi ultrasonic welding to form pockets w hich receiv e the plates of battenes from which such i s assemblies are produced. The reference also states that high frequency or ultrasonic welding is desirable because it prov ides resistant welding whereas hot seam welding is much more fragile. BRIEF DESCRIPTION OF THE PRESENT INVENTION 20 When separator produced by the methods o\ ~ US patent No. 5.436.094 and ol EPO 587 682 B 1 is cut to size, for example in preparation for the production ol a stack of negative and positive battery plates w ith the separator positioned between adjacent plates, oi for the production ot a welded, envelope-type separator that is closed on all but one side, and in which a batterv plate is encased, some of the sepai ator neeessaπlv 25 becomes scrap. Furthermore, it is sometimes necessary to scrap separator, as produced, because its physical properties are not within specifications. Because ot the bonds formed during production of the separator by the prior art methods, it is difficult, if not impossible, to produce a slurry containing that scrap and additional fibers which can be cast on the screen of a paper making machine to produce non-woven sheets from which 30 additional separator can be made. The instant inv ention is based upon the discovery that separator material can be produced from a slum formed by dispersing in water and defiberizing. for example in a pulper. glass fibers and heat bonding fibers, e.g.. sheath- core fibers with a polyethylene sheath and a polypropylene core, refining, and feeding the resulting slurry onto the w ire of a Fourdπnier or other paper making machine: the web w hich toi ms on the w ne can then be spiaved it desued w ith a sui tactant dehvdiated bv suction bv piessmg 01 both and dned al a tempeiatuie sufficiently low that melt-adhesion bonds do not toi m among the t ibei s The unbonded, non-wov en sheet which lesults can be tested to make sine that it meets specil ications and. it so can be s lolled, packaged, and shipped to anothei location foi example, tiom a sepaiatoi manutactuiei to a batteiv manutactuiei If the sheet does not meet specif ications it can be slui ned. eithei alone 01 w ith additional tibei s. and the slui iv can be ted onto the w ne ot a Fouidi iniei 01 othei papei making machine and piocessed as descnbed above to pioduce unbonded, non-w o en sheet so that the matenal hich did not meet 10 specifications is lecycled The sepaiatoi w hich met specifications and was shipped can be lemov ed fiom the package and cut to size in piepaiation foi the pioduction ot a stack ot negativ e and positiv e battei v plates with the sepaiatoi positioned between adjacent plates oi toi the pioduction ol welded sepaiatoi that is closed on all but one side and in which a batteiv plate can be encased Sciaps which aie toi med when the sepaiatoi is cut I to size can be sluined w ith additional fibeis watei and the like, to pioduce a new sluiiv which can be ted onto the w ue ot a Fouidiiniei oi othei papei making machine and piocessed as descnbed abov e to pioduce non-w ov en sepai atoi The sized, unbonded sepaiatoi is then heated to a tempei atuie suff i iently high to soften the bindei . attei which it is cooled to a ten iei atuie suff iciently low that the bindei lesohdifies and 20 toi ms a bonded sepaiatoi bv binding the tibei s to one anothei at points of contact, the bonded sepai atoi is then used to pioduce the stacks of negativ e and positive plates w ith sepai atoi betw een adjacent plates w hich aie lequued toi batteiy pioduction Sepaiatoi which is pioduced accoi ding to the method ot the instant inv ention has a given wet stiength as pioduced w hich is usually measuied in the machine duection. which is 2s the duection the matenal moves on the papei making machine, and in the ti ansveise duection, which is acioss the web at a light angle to the machine duection The wet stiength lemains the same until attei the matenal is bonded, which, the instant invention contemplates vv ill be done at a batteiy-making facility Aftei bonding, the wet stiength is substantially highei than the giv en wet stiength in both the machine duection and in 30 the tiansv ei se duection DESCRIPTION OF THE PREFERRED EMBODIMENTS In the following examples, and elsewheie heiein. the tetms "peicent" and paits" lefei to peicent and paits bv weight, unless otheiwise indicated, m means metei oi meters, mm means millimeter or millimeters, g means gram or grams, μm means micrometer or micrometers, and all temperatures are in degrees C. These examples constitute the best modes presently contemplated by the inv entor, but are presented solely to lllustiate and disclose, and are not to be construed as limiting, the invention. 5 EXAMPLE 1 Glass fiber separator hand sheets were produced in a laboratory apparatus by depositing a furnish on a wire or screen, and draining the furnish. The apparatus comprised a tank with a screen in the bottom, a drain below the screen, a valve which l () opened and closed the dram, and paddles which w ere moved back and forth to simulate the mov ement of a turnish in commercial papermaking apparatus and establish a "machine direction" parallel to the direction of paddle movement. The furnish comprised acidified water. pH 2.7. and solids composed of 25 parts synthetic sheath core fibers having a polyester core and a polyester sheath. 13 parts Johns Manville 206 15 glass fibers, average fiber diameter of 0.76 μm. 52 parts Johns Mansville 210X glass fibers, average fiber diameter of 3.0 μm and 10 parts textile glass fibers ranging from about 6 to 8 mm in length. The furnish was poured into the apparatus and drained through the screen to produce a layer on the screen with a grammage of about 167 g/m\ The separator hand sheets were heated in a drying oven to about 100° C. for 30 20 minutes, and were then found to have a thickness (under a load of 10.34 KPa) of 1 mm. The furnish described above is also used to produce non-woven, un-bonded separator material on a Fourdrinier paper making machine where the final drying steps are controlled so that the separator is not heated to a temperature sufficiently high to soften the polyester sheath of the sheath core fibers, usually not higher than about 125° 25 C. The dried separator is then rolled, packaged, and shipped to the plant of a batten, manufacturer, where sheets are cut from the separator, heated to about 130° C. cooled and used to produce stacks of negative and positive plates with separator between adjacent plates. These stacks are then used to produce batteries. The sheath core fibers used in Example 1 are commercially available under the 30 designation So it N 720 from Kuraray. The Johns Mansville 206 and 210 glass fibers used in Example 1 and in subsequent Examples have the same nominal compositions, but vary slightly from time to time. Mean v alues, in percent by weight, calculated from data furnished by Johns Manville for the period when the examples were carried out. are given below: SiO : 65.40 A1;0 ; 2.99 CaO 5.88 MgO 2.79 Na ; 0 16. 1 1 K 2 O 0.69 B;O-, 5.3 1 F; 1.02 Johns Manville also indicates that the glass contains Fe^O-,. TiOi. ZrO ; . C O,. SrO. BaO. MnO. ZnO. Li 0. SO, and Pb in amounts less than 0. 1 c /< Various other slurries can be used as described in Example ! to produce separator by the method of the instant invention. Examples of the solids, in parts by weight, in some such slurries are identified in the following table: The separator produced by the method oϊ any of Examples 1 -3 can be cut to size and assembled between positive and negative plates to produce plate stacks which can then be used to produce complete batteries in a known manner. The steps of cutting the separator to size and producing assemblies of alternate positive and negative plates with separator between the plates are usually carried out by a battery manufacturer to whom the separator is shipped by the separator manufacturer. The separator of Examples 1 -3 contains sheath core fibers with a thermoplastic polyester core and a thermoplastic polvester sheath which has a lower softening temperature than the core. It is desirable to heat the separator, before a battery is produced therefrom, so that the sheath is softened, and serves as a binder for the separator. Heretofore, this heating has been done by the separator manufacturer, who then rolled and packed the bonded separator, and shipped it to a battery manufacturer. The present invention is based upon the discovery that it is highly advantageous to postpone the heating step which produces the bonded separator until attei the sepaiatoi has been tolled and shipped to the batteiv manutactuiei The heating can be cained out attei the sepaiatoi has been cut to si/e. and eithei just befoie 01 |iιst aftei it has been assembled between positive and negative batteiy plates All sciap that is pioduced when the unbonded sepaiatoi is cut to size can be lecycled by adding it to a slu of the same composition, and toiming a sepaiatoi as descnbed abo e tiom that slum It will be appieciated that the sheath coie fibeis ultimately seived as bindei s toi the glass tibeis in the sepaiatois pioduced as descnbed above Othei combination fibeis can also be used in a similai mannei. foi example sheath coie oi side by side fibeis ol polyethylene and polypiopylene. the toimei pieteiably being the sheath when the tibeis aie ot the sheath coie type Similaily. two difteient kinds ol oiganic fibeis can be substituted toi the sheath coie fibeis Foi example a mixtuie ot high density polyethylene svnthetic pulp and theimallv adhenng jolyestei type composite tibeis can leplace the sheath coie fibeis Suitable pol olefin synthetic pulps aie disclosed in the Mitsui patent identified above. US No 5.436.094. as aie suitable theimallv adhenng polyestei type and polyestei teiephthalate composite tibeis which aie commeicially available fiom Unitika Co undei the designations MELTY 4080 and Estei EP 303 The synthetic pulps identified in tables 1.2 and 3, below, aie disclosed by the Mitsui patent Table 1 Theimallv adhenng pohestei t pe composite tibeis Lmtik Co Table Polveth lene teiephthalate tibei s Unitika Co Table 3 The f ollowing compositions in pai ts by weight aie disclosed by the Mitsui patent as suitable toi use in pi oducing sepai atoi accoi dmg to the method ot Examples 1 -4 of that patent The following compositions in pai ts by weight, aie disclosed by the Mitsui patent as suitable loi use in pioducing sepaiatoi accoidmg to the method of Examples 5 and 7- 10 of that patent (Example 6 is patently gaibled. stating that 1Q C A by weight of each of two constituents was used) The pioceduies of Examples 1 thiough 5 and 7 thiough 10 of the Mitsui patent aie l epeated except that the final heating ot the sepai atoi is to a tempeiatuie sutticientlv low that melting ot the constituents of the sepaiatoi does not occui Accoidingly these pioceduies constitute piactice ot the method ot the instant inv ention The sepaiatoi that is pioduced when these pioceduies aie lepeated is composed of a majoi poition of fibeis which aie compaiativ ely high melting and a minoi poi tion of a substantially lowei melting bindei matenal It is desiiable to heat the sepaiatoi betoie the pioduction of a batteiy theiefiom is complete, so that at least the low ei melting bindei matenal is softened and sen es as a bindei toi the sepaiatoi This heating can be cau ied out attei the sepai atoi has been cut to size oi even attei it has been assembled between positive and negative batteiy plates All sciap that is pioduced when the sepai atoi is cut to size can be lecycled bv adding it to a slum of the same composition and foiming a sepaiatoi as descnbed above fiom that slum The pioceduies of Examples 1 thiough 5 and 7 thiough 10 ot the Mitsui patent aie also l epeated except that a sluuy is made fiom glass tibei s and the constituents of one ot the Mitsui examples and that slum is cast on a scieen dunned and dned at a tempeiatuie sufliciently low that melting of the constituents of the sepaiatoi does not occui It is usually pietened that the glass fibei s constitute fiom about 70 to 97 peicent of the solids in the sluny that the glass fibeis have an aveiage fibei diametei not gieatet than about 3 μm and be composed of a glass which is lesistant to sulfunc acid and othei constituents that aie piesent in stoiage battenes In these instances the sepaiatoi that is pi oduced is composed of glass fibeis, a compaiatively low melting bindei matenal and a highei melting bindei matenal The pioceduies aie also lepeated except that the piopoiiions ol the lowei melting bindei matenal and ot the highei melting bindei matenal aie changed so that in ditteient pioceduies each constitutes horn 30 peicent to 70 peicent The pioceduies ot Examples 1 3 heieol aie also lepeated except that othei sheath coie and side by side tibeis aie substituted toi the tibeis designated Sofit N 720 which weie used in the Example 1 3 pioceduies and the piopoiiions of glass tibeis \M\ fiom about 50 to 97 peicent while the piopoitions of sheath coie and side bv side iibeis van fiom about 3 to 50 peicent Pieteiablv the piopoitions of glass Iibeis van tiom about 70 to 95 peicent while the piopoitions of sheath coie and side by side tibeis van horn about 5 to 30 peicent It will be appieciated that vaiious changes and modifications can be made horn the specific details ot the invention as descnbed heiein without depaiting tiom the spun and scope of the attached claims and that in its essential details the invention is a method loi pioducing a batten sepaiatoi tiom a slimy ot tibeis which aie lesistant to the chemicals hich aie lound in a batteiv and a theimoplastic bindei toi the tibeis The method compiises casting the slimy onto a scieen diaining the liquid ol the shiny fiom fibeis and bindei which collect on the scieen and diving the fibeis and bindei without softening the bindei In a pieteued case when the sepaiatoi is to be used with a lead acid batteiv the fibeis aie glass and have an aveiage diametei not gieatei than about 3 μm oi a mixtuie ot such glass fibeis and oiganic tibeis most desuablv polvoletin tibeis polvethvlene teiephthalate tibeis oi mixtuies of the two It is also pieteued that at least some pieteiablv at least 50 peicent of the glass tibeis be miciotibeis I e have diametei s less than 1 μm It is also desiiable toi at least some of the oiganic tibeis to be sheath coie fibeis having a theimoplastic coie and a theimoplastic sheath which has a lowei soltening tempeiatuie Sheath coie fibeis having a polypiopylene coie and a polyethylene sheath aie highlv desiiable In anothei pieteued instance when the sepaiatoi is to be used with an alkaline batteiv the fibeis aie oiganic most desπably polvoletin fibeis oi polyethylene teiephthalate and have an aveiage diametei not gieatei than about 3μm In eithei case attei piocessmg ol the sepaiatoi is complete e g altei it has been cut to size foi stacking with batten plates it is heated to a tempeiatuie sufficiently high to activate the theimoplastic bindei When a sepaiatoi pioduced by the method ot the invention is welded eg to toim it into a pocket in which a batten plate is leceived, the theimoplastic bindei is activated, as is any highei melting theimoplastic material theiein I I

Claims: I claim 1 A method loi pioducing an assembly ot positive and negative batteiy plates with a sepaiatoi between adjacent ones ot the plates ot the assembly said method compiis g the steps of foimmg a sluiiv of iibeis which aie lesistant to the chemicals which aie found in a batteiv and a theimoplastic bindei toi the tibeis casting the slum onto a scieen dunning the liquid ot the sluny fiom tibeis and bindei which collect on the scieen. foiming an unbonded sepaiatoi by diying the fibeis and bindei without softening the bindei, heating the unbonded sepaiatoi to a tempeiatuie sufficiently high to soften the bindei cooling the sepaiatoi to a tenψeiatuie sufficiently low that the bindei lesohdifies and toims a bonded sepaiatoi bv binding the tibeis to one anothei at points ot contact and stacking alternating positive and negative batten plates with sheets ol the bonded sepaiatoi between adjacent ones ot the plates without packaging ot the bonded sepaiatoi subsequent to the afoiesaid cooling step 2 A method loi pioducing a batteiy sepaiatoi as claimed in claim 1 wheiein. attei the tibeis aie dned without sotten g the bindei. the sepaiatoi is tabiicated. and is then heated to a tempeiatuie sufficiently high to make the theimoplastic bindei effective as a bindei toi the tibeis 3 A method foi pioducing a batteiy sepaiatoi as claimed in claim 1 wheiein the tibeis aie glass fibeis and the theimoplastic bindei is oiganic 4 A method foi pioducing a batteiy sepaiatoi as claimed in claim 1 wheiein the fibeis aie polvoletin fibeis and the theimoplastic bindei is an oiganic liav ing a softening tempeiatuie lowei than that ot the polvoletin fibeis 5 A method as claimed in claim 1 foi pioducing an assembly of positive and negative batteiy plates with a sepaiatoi between adjacent ones of the plates of the assembly, wheiein the sepaiatoi is fabncated to toim a pluiality of pockets one of the plates is placed in each of the sepaiatoi pockets, and the assembly ot batteiy plates is pioduced fiom a pluiality of the plates in sepaiatoi pockets and batteiy plates between adjacent ones ot the plates in sepaiatoi pockets 6 A method loi pioducing a batteiy sepaiatoi tiom a sluny of fibeis which aie lesistant to the chemicals which aie found in a batten, and a theimoplastic bindei foi the fibei s said method compiising the steps of casting the slun y onto a scieen. di aining the liquid of the sluny tiom tibei s and bindei hich collect on the scieen. diying the fibei s and bindei without softening the bindei . and sepai ating the dned fibeis and bindei tiom the scieen A method toi pioducing a batten sepaiatoi as claimed in claim 5 wheiein the tibei s aie glass fibei s and the thei moplastic bindei is oiganic A method toi pioducing a batten sepaiatoi as claimed in claim 5 wheiein the tibeis aie polvoletin fibei s and the thei moplastic bindei is an oiganic having a softening tempeiatuie lowei than that of the polvoletin fibeis A method as claimed in claim 3 toi pi oducing an assembly of positive and negative battei y plates with a sepaiatoi between adjacent ones of the plates ot the assembly w heiein not moie than 10 peicent of the glass fibei s hav e chametei s gieatei than 3 μm and at least 50 peicent of the glass fibeis hav e diametei s less than 1 μm A method as claimed in claim 3 foi pioducing an assembly of positive and negative batteiy plates with a sepaiatoi between adjacent ones of the plates of the assembly wheiein at least 30 peicent of the fibeis of the sluny are glass fibeis A method as claimed in claim 3 foi pi oducing an assembly ot positive and negative battei y plates with a sepai atoi between adjacent ones of the plates ot the assembly wheiein fiom 50 to 97 peicent ot the fibei s ot the slurry aie glass tibei s

Inventors: ZGURIS GEORGE C, ZGURIS, GEORGE, C.
Applicants: KVG TECHNOLOGIES INC, KVG TECHNOLOGIES, INC.
Application year: 2001
Main classification: H01M2
IPC codes: H01M2