Separator for lead acid battery

文档序号：246741 发布日期：2021-11-12 浏览：27次中文

阅读说明：本技术 用于铅酸电池的隔离件 (Separator for lead acid battery ) 是由巴威·库马尔·耶格亚-拉曼尼古拉斯·克莱门特霍华德·于于 2020-04-09 设计创作，主要内容包括：一般地提供了电池隔离件和包括电池隔离件的铅酸电池。电池隔离件可以具有提高其用于铅酸电池的适用性的一个或更多个特征。例如,本文所述的电池隔离件可以具有提高其对新兴的富液型电池应用(例如扩展式富液型电池应用)的适用性的一个或更多个特征。(Battery separators and lead acid batteries including battery separators are generally provided. The battery separator may have one or more features that improve its suitability for use in a lead-acid battery. For example, the battery separators described herein may have one or more features that improve their applicability to emerging flooded battery applications (e.g., extended flooded battery applications).)

1. A lead-acid battery comprising:

a battery separator; and

a battery plate, wherein:

the battery separator includes a nonwoven web containing synthetic fibers,

the synthetic fibers comprise greater than 80 weight percent of the nonwoven web,

the synthetic fibers comprise discontinuous fibers having an average length of greater than or equal to 0.1mm and less than or equal to 300mm,

the apparent density of the battery separator is greater than or equal to 40gsm/mm and less than or equal to 200gsm/mm,

the porosity of the battery separator is greater than or equal to 70%, and

the cell separator has a mean flow pore size of greater than or equal to 1 micron and less than or equal to 15 microns.

2. A lead-acid battery comprising:

a battery separator; and

a battery plate, wherein:

the battery separator includes a nonwoven web containing synthetic fibers,

the synthetic fibers comprise discontinuous fibers having an average length of greater than or equal to 0.1mm and less than or equal to 300mm,

the battery separator has a puncture strength greater than 20N,

the battery separator has a porosity greater than or equal to 70%,

the cell separator has a mean flow pore size of greater than or equal to 1 micron and less than or equal to 15 microns.

3. A lead-acid battery comprising:

a battery separator; and

a battery plate, wherein

The battery separator includes a nonwoven web containing synthetic fibers,

the synthetic fibers comprise discontinuous fibers having an average length of greater than or equal to 0.1mm and less than or equal to 300mm,

the nonwoven web comprises fibrillated fibers,

the porosity of the battery separator is greater than or equal to 70%, and

the cell separator has a mean flow pore size of greater than or equal to 1 micron and less than or equal to 15 microns.

4. A lead-acid battery comprising:

a battery separator; and

a battery plate, wherein

The battery separator includes a nonwoven web containing synthetic fibers,

the synthetic fibers comprise multi-component fibers,

the synthetic fibers comprise greater than 80 weight percent of the nonwoven web,

the synthetic fibers comprise discontinuous fibers having an average length of greater than or equal to 0.1mm and less than or equal to 300mm,

the porosity of the battery separator is greater than or equal to 70%, and

the cell separator has a mean flow pore size of greater than or equal to 1 micron and less than or equal to 15 microns.

5. A battery separator comprising:

a nonwoven web comprising synthetic fibers, wherein:

the synthetic fibers comprise discontinuous fibers having an average length of greater than or equal to 0.1mm and less than or equal to 300mm,

the battery separator has a porosity greater than or equal to 70%,

the cell separator has a mean flow pore size of greater than or equal to 1 micron and less than or equal to 15 microns, an

The battery separator is a bag separator.

6. The battery separator of claim 5, wherein the battery separator is placed in a lead acid battery.

7. The lead-acid battery of any of claims 1-4 or the battery separator of claim 6, wherein the lead-acid battery is a flooded battery.

8. The lead acid battery of claim 7, wherein the flooded battery is an extended flooded battery.

9. The lead-acid battery or battery separator according to any preceding claim, wherein the nonwoven web comprises multicomponent fibers; optionally, wherein the multicomponent fibers are present in an amount less than or equal to 45 weight percent of the web.

10. A lead-acid battery or battery separator according to any preceding claim, wherein the multicomponent fibres comprise bicomponent fibres.

11. The lead acid battery or battery separator according to any preceding claim, wherein the nonwoven fibrous web comprises non-fibrillated fibers.

12. The lead acid battery or battery separator according to any preceding claim, wherein the synthetic fibers comprise non-fibrillated fibers.

13. The lead-acid battery or battery separator according to any preceding claim, wherein non-fibrillated synthetic fibers comprise greater than or equal to 5 wt.% and less than or equal to 45 wt.% of the fiber web.

14. The lead acid battery or battery separator according to any preceding claim, wherein the synthetic fibers comprise fibrillated fibers.

15. The lead acid battery or battery separator according to any preceding claim, wherein fibrillated fibers comprise greater than or equal to 55 wt% and less than or equal to 95 wt% of the fiber web.

16. A lead-acid battery or battery separator according to any preceding claim, wherein the non-woven fibre web comprises particles.

17. The lead-acid battery or battery separator according to any preceding claim, wherein glass fibers comprise less than or equal to 20 wt% of the nonwoven web.

18. A lead-acid battery or battery separator according to any preceding claim, wherein the synthetic fibres comprise crimped fibres.

19. A lead-acid battery or battery separator according to any preceding claim, wherein the non-woven fibre web comprises natural fibres.

20. The lead acid battery or battery separator according to any preceding claim, wherein the fibrillated fibres comprise natural fibres.

21. A lead-acid battery or battery separator according to any preceding claim, wherein resin comprises less than or equal to 20 wt% of the non-woven web.

22. A lead-acid battery or battery separator according to any preceding claim, wherein the thickness of the battery separator is greater than or equal to 0.4mm and less than or equal to 2 mm.

23. The lead-acid battery or battery separator according to any preceding claim, wherein the basis weight of the battery separator is greater than or equal to 80gsm and less than or equal to 250 gsm.

24. The lead acid battery or battery separator according to any preceding claim, wherein the apparent density of the battery separator is greater than or equal to 60gsm/mm and less than or equal to 200 gsm/mm.

25. The lead acid battery or battery separator according to any preceding claim, wherein the maximum pore size of the battery separator is greater than or equal to 8 microns and less than or equal to 25 microns.

26. A lead-acid battery or battery separator according to any preceding claim, wherein the breakdown voltage of the battery separator is greater than or equal to 0.5 kV.

27. The lead-acid battery or battery separator according to any preceding claim, wherein the contact angle of the battery separator is greater than or equal to 0 ° and less than or equal to 120 °.

28. The lead acid battery or battery separator of any preceding claim, wherein the puncture strength of the battery separator is greater than or equal to 12N.

29. The lead-acid battery or battery separator according to any preceding claim, wherein the puncture strength of the battery separator is greater than or equal to 16N.

30. The lead-acid battery or battery separator according to any preceding claim, wherein the puncture strength of the battery separator is greater than or equal to 20N.

31. The lead acid battery or battery separator of any preceding claim, wherein the tensile strength of the battery separator is greater than or equal to 10 pounds per inch.

32. The lead-acid battery or battery separator according to any preceding claim, wherein the battery separator has an elongation at break of greater than or equal to 0% and less than or equal to 500%.

33. The lead-acid battery or battery separator according to any preceding claim, wherein the battery separator has an elongation at break of greater than or equal to 10% and less than or equal to 100%.

34. The lead-acid battery or battery separator according to any preceding claim, wherein the battery separator has a three-dimensional structure comprising surfaces that: the surface comprises protrusions extending in a mid-plane of the surface and/or recesses extending below the mid-plane of the surface.

35. The lead acid battery or battery separator of claim 34, wherein the average distance from the midplane of the surface to the protrusion is greater than or equal to 0.1mm, greater than or equal to 0.5mm, greater than or equal to 1mm, or greater than or equal to 1.5 mm.

36. The lead acid battery or battery separator according to any of claims 34 to 35, wherein the average distance from the mid-plane of the surface to the depression is greater than or equal to 0.1mm, greater than or equal to 0.5mm, greater than or equal to 1mm, or greater than or equal to 1.5 mm.

37. The lead acid battery or battery separator according to any of claims 34 to 36, wherein the average nearest neighbor distance between the protrusions is greater than or equal to 0.1mm, greater than or equal to 10mm, greater than or equal to 25mm, or greater than or equal to 100 mm.

38. The lead acid battery or battery separator according to any of claims 34 to 37, wherein the average nearest neighbor distance between the depressions is greater than or equal to 0.1mm, greater than or equal to 10mm, greater than or equal to 25mm, or greater than or equal to 100 mm.

39. The lead acid battery or battery separator according to any of claims 34 to 38, wherein at least a portion of the projections are discrete.

40. The lead acid battery or battery separator according to any of claims 34 to 39, wherein at least a portion of the projections are interconnected.

41. The lead acid battery or battery separator according to any of claims 34 to 40, wherein at least a portion of the depressions are discrete.

42. The lead acid battery or battery separator according to any of claims 34 to 41, wherein at least a portion of the depressions are interconnected.

43. The lead acid battery or battery separator according to any of claims 34 to 42, wherein the protrusions and/or depressions form a repeating pattern.

44. The lead acid battery or battery separator according to any of claims 34 to 43, wherein the protrusions and/or depressions are randomly distributed across the surface.

45. A lead-acid battery or battery separator according to any preceding claim, wherein the battery separator comprises two surfaces each comprising a protrusion extending above the mid-plane of the surface and/or a recess extending below the mid-plane of the surface.

46. The lead-acid battery or battery separator according to any preceding claim, wherein the battery separator is embossed, corrugated, rippled, micrex-machined and/or corrugated.

47. A lead-acid battery or battery separator as claimed in any preceding claim wherein the battery separator is pleated.

48. A lead-acid battery or battery separator according to any preceding claim, wherein the battery separator comprises ribs and/or dots.

49. A lead-acid battery or battery separator according to any preceding claim, wherein the battery separator is a single layer separator.

50. The lead acid battery or battery separator according to any of claims 1 to 48, wherein the battery separator is a multilayer separator.

51. A lead-acid battery or battery separator according to any preceding claim, wherein the battery separator is a bag separator.

52. The lead acid battery or battery separator according to any of claims 1 to 50, wherein the battery separator is a vane separator.

53. The lead-acid battery or battery separator according to any of claims 1 to 50, wherein the battery separator is a folded separator.

54. A lead-acid battery or battery separator according to any preceding claim, wherein the non-woven fibre web is wet laid.

55. A lead-acid battery or battery separator according to any preceding claim, wherein the non-woven web is carded.

56. A lead-acid battery or battery separator according to any preceding claim, wherein the non-woven web is calendered.

Technical Field

The present invention relates generally to separators for batteries, and more particularly to separators for lead acid batteries.

Background

Separators are commonly employed in batteries to separate the battery plates therein. However, many such separators are undesirable for emerging lead acid battery applications for a variety of reasons. For example, such separators may immerse contaminants in the electrolyte, may be less mechanically robust than desired, and/or may include pores that inhibit the flow of electrolyte therethrough in size and/or number. Accordingly, there is a need for improved spacer designs.

Disclosure of Invention

Battery separators, related assemblies, and related methods are generally described.

In some embodiments, a lead acid battery is provided that includes a battery separator and a battery plate. The battery separator includes a nonwoven web comprising synthetic fibers, the synthetic fibers comprising greater than 80% by weight of the nonwoven web. The synthetic fibers comprise discontinuous fibers having an average length of greater than or equal to 0.1mm and less than or equal to 300 mm. The battery separator has an apparent density of greater than or equal to 40gsm/mm and less than or equal to 200gsm/mm, a porosity of greater than or equal to 70%, and a mean flow pore size of greater than or equal to 1 micron and less than or equal to 15 microns.

In some embodiments, a lead acid battery is provided that includes a battery separator and a battery plate. The battery separator includes a nonwoven web containing synthetic fibers. The synthetic fibers comprise discontinuous fibers having an average length of greater than or equal to 0.1mm and less than or equal to 300 mm. The battery separator has a puncture strength greater than 20N, a porosity greater than or equal to 70%, and a mean flow pore size greater than or equal to 1 micron and less than or equal to 15 microns.

In some embodiments, a lead acid battery is provided that includes a battery separator and a battery plate. The battery separator includes a nonwoven web containing synthetic fibers. The synthetic fibers comprise discontinuous fibers having an average length of greater than or equal to 0.1mm and less than or equal to 300 mm. The battery separator comprises fibrillated fibers. The battery separator has a porosity of greater than or equal to 70% and a mean flow pore size of greater than or equal to 1 micron and less than or equal to 15 microns.

In some embodiments, a lead acid battery is provided that includes a battery separator and a battery plate. The battery separator includes a nonwoven web comprising synthetic fibers, the synthetic fibers comprising greater than 80% by weight of the nonwoven web. The synthetic fibers comprise discontinuous fibers having an average length of greater than or equal to 0.1mm and less than or equal to 300 mm. Synthetic fibers include multicomponent fibers. The battery separator has a porosity of greater than or equal to 70% and a mean flow pore size of greater than or equal to 1 micron and less than or equal to 15 microns.

In some embodiments, a battery separator is provided. The battery separator includes a nonwoven web containing synthetic fibers. The synthetic fibers comprise discontinuous fibers having an average length of greater than or equal to 0.1mm and less than or equal to 300 mm. The battery separator has a porosity of greater than or equal to 70% and a mean flow pore size of greater than or equal to 1 micron and less than or equal to 15 microns. The battery separator is a bag separator.

Other advantages and novel features of the invention will become apparent from the following detailed description of various non-limiting embodiments of the invention when considered in conjunction with the drawings. In the event that the present specification and a document incorporated by reference include conflicting and/or inconsistent disclosure, the present specification shall control. If two or more documents incorporated by reference include disclosures that are inconsistent and/or inconsistent with respect to each other, the document with a dated lead should be taken as the subject of the application.

Drawings

Non-limiting embodiments of the present invention will be described by way of example with reference to the accompanying drawings, which are schematic and are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated is typically represented by a single numeral. For purposes of clarity, not every component may be labeled in every drawing, nor every component of every embodiment of the invention may be shown, where illustration is not necessary to allow those of ordinary skill in the art to understand the invention. In the figure:

fig. 1 is a schematic illustration of a battery separator according to some embodiments;

fig. 2 is a schematic illustration of a battery separator comprising two layers according to some embodiments;

fig. 3 is a schematic view of a folding spacer according to some embodiments;

fig. 4 is a schematic illustration of a folded separator folded around a battery plate according to some embodiments;

fig. 5 is a schematic view of a bag-type separator according to some embodiments;

fig. 6A-6D are schematic diagrams of battery separators including protrusions and recesses, according to some embodiments; and

fig. 7 is a schematic diagram of a lead acid battery according to some embodiments.

Detailed Description

Battery separators and lead acid batteries including battery separators are generally provided. In some embodiments, the battery separators described herein have one or more features that improve their applicability to emerging liquid-rich battery applications, such as extended-enriched battery (extended-flooded battery) applications. Extended flooded cells typically operate under more severe conditions than other types of lead acid batteries, and therefore, battery separators that can withstand these more severe environments are advantageous for use therein.

As an example, battery separators comprising a combination of components that do not leach significant contaminants into the electrolyte during operation of the flooded cell (e.g., due to oxidation in the cell) may be desirable for use in these cells. Examples of such components may include non-continuous synthetic fibers (e.g., staple fibers), fibrillated fibers, crimped fibers, and multi-component fibers. Some battery separators suitable for use in a flooded cell may contain minimal or no components that leach significant contaminants into the electrolyte during operation of the extended flooded cell, for example, contain minimal or no extruded components and/or contain minimal or no components that undergo significant oxidation under conditions of operation of the flooded cell. Some battery separators may contain relatively small amounts of such contaminants, such as relatively small amounts of solvents and/or mineral oils (e.g., relatively small amounts of alkanes and/or fatty acids). For example, in some embodiments, the battery separator is substantially free of solvent and mineral oil (e.g., substantially free of alkanes and/or fatty acids).

As another example, the battery separator may exhibit one or more mechanical properties that indicate resistance to deformation and/or failure. This may be desirable in the case of flooded cells (e.g., extended flooded cells) that include one or more components that may have sharp protrusions (e.g., cell plates that include a metal grid with sharp protrusions). Resistance to deformation and puncture upon contact with such sharp protrusions may advantageously allow the battery separator to be present in a battery including such sharp protrusions without experiencing mechanical failure. This may desirably improve the life and/or robustness of the extended flooded battery in which the battery separators are placed. Some battery separators may have other mechanical properties that are advantageous for use in flooded battery applications, such as wear resistance, scratch resistance, and/or reduced brittleness.

As a third example, the battery separator may be particularly robust at elevated temperatures. Liquid-rich cells may operate at high temperatures (such as those found in hot climates and/or automotive engines), and therefore cell separators that do not melt and/or deform significantly at these operating temperatures are desirable. Battery separators configured to be robust at elevated temperatures may contain minimal or no components (e.g., resins) that melt at low temperatures. In some embodiments, the battery separator comprises multi-component fibers to bond the battery separator together (e.g., to replace all or a portion of the resin originally used). The melting point of a portion of the multicomponent fibers may be higher than the temperature at which the extended rich cell operates.

As a fourth example, the battery separator may have a morphology that is particularly suitable for use in flooded battery applications (e.g., extended flooded battery applications). The battery separator may have both a relatively large open volume (which may allow electrolyte to flow therethrough with reduced resistance) and may contain solid components sufficiently spaced apart to impede and/or slow dendrite growth therethrough. These features can be combined in a single battery separator by designing the battery separator to have a high porosity but a small pore size and/or to include relatively tortuous pores. It is believed that fibrillated fibers may be particularly suitable for forming such battery separators because fibrillated fibers form fibrils that reduce pore size while not significantly reducing pore volume. As another configuration, the battery separator may have a three-dimensional structure that gives it a desired small pore size and also has a relatively large open volume (including pores and/or spaces between different portions of the battery separator, such as recesses therein and/or spaces between protrusions therein). In some embodiments, the battery separator has a relatively low apparent density, which may be indicative of a relatively large open volume.

In some embodiments, the battery separators described herein and/or batteries including such separators may include one or more of the features and advantages described above. It should be understood that different battery separators will be suitable for different types of lead acid battery applications, and not all embodiments described herein will have each of the advantageous features described above. For other reasons, some of the battery separators described herein may have a subset of such features, or may be suitable for use in flooded lead acid batteries. It should also be understood that some of the battery separators described herein may have one or more of the above-described features, but may be configured for use or employed in other types of batteries besides flooded lead acid batteries.

As described above, some embodiments relate to battery separators. Fig. 1 shows one non-limiting embodiment of a battery separator 101. In some embodiments, the battery separator is a single layer battery separator (e.g., it may comprise a single layer that is a fibrous web). In other embodiments, the battery separator comprises two or more layers. For example, fig. 2 shows one non-limiting embodiment of a bi-layer battery separator 102 comprising a first layer 112 and a second layer 122. The first and second layers may be the same, may be of the same type but different in one or more respects (e.g., the battery separator may include two webs having different porosities and/or containing different types of fibers), or may be of different types.

The battery separators described herein may have a variety of suitable designs. In some embodiments, such as the embodiment shown in fig. 1 and 2, the battery separator is a leaf separator. Other suitable types of battery separators include, but are not limited to, folded separators, pouch separators, z-folded separators, sleeve separators, corrugated separators, C-wound separators, and U-wound separators. Fig. 3 illustrates one non-limiting embodiment of a folded separator 103, which folded separator 103 may be folded around a battery plate when placed in a lead acid battery. This configuration is shown in fig. 4, where the folded separator 104 is folded around the battery plate 204. Fig. 5 shows one non-limiting embodiment of a bag spacer 105, the bag spacer 105 being sealed on three sides and open on the last side. The battery plates may be positioned inside a pocket (not shown) formed by the separator when placed in a lead acid battery.

Without wishing to be bound by any particular theory, in some cases, it may be challenging to fabricate battery separators (e.g., folded separators, pouch separators) other than blade separators from relatively rigid materials. Accordingly, in embodiments where such battery separators are desired, it may be advantageous to include a relatively large amount of flexible components (e.g., synthetic fibers, natural fibers) and/or a relatively small amount of rigid components (e.g., glass fibers). Particularly with respect to bag-type spacers, it is often desirable to form the bag-type spacers by first forming a flat sheet, then folding the flat sheet, and finally bonding the edges of the folded panels together. This is often accomplished by applying heat to melt the components at the edges of the flat sheet so that a thermal bond is formed along the edges of the folded panels. Accordingly, it may be desirable for the bag-type barrier to contain one or more components, such as multi-component fibers, that may be melt-bonded.

As described elsewhere herein, the battery separator may include one or more webs of fibers. The web can be a nonwoven web, such as a wet laid (wetlaid) nonwoven web, a non-wetlaid (non-wetlaid) nonwoven web (e.g., a dry laid nonwoven web, such as a carded nonwoven web). The web may also be a calendered nonwoven web. In some embodiments, the fiber web has one or more features that impart physical properties to the separator, such that it is advantageous for use in a lead acid battery. For example, the web may have a structure of: the structure allows for the flow of a suitable electrolyte therethrough and/or is mechanically and/or chemically robust enough not to undergo significant degradation and/or leach significant components into the battery when used in advanced lead acid applications.

When present, the fiber web may comprise a variety of suitable types of fibers. In some embodiments, the fiber web comprises synthetic fibers. A variety of suitable synthetic fibers may be employed in the webs described herein. For example, the web may comprise one or more of the following types of synthetic fibers: poly (alkene) fibers (e.g., poly (propylene) fibers, poly (ethylene) fibers), acrylic fibers (e.g., dry-spun acrylic fibers, modified acrylic fibers, wet-spun acrylic fibers), fibers formed from halogenated polymers (e.g., fibers formed from fluorinated polymers, such as poly (vinyl chloride) fibers, poly (tetrafluoroethylene) fibers, poly (vinylidene fluoride) fibers), poly (styrene) fibers, poly (sulfone) fibers, poly (ether sulfone) fibers, poly (carbonate) fibersNylon fibers, poly (urethane) fibers, fibers comprising phenolic resins, poly (ester) fibers, poly (aramid) fibers (e.g., p-poly (aramid) fibers, m-poly (aramid) fibers, Kevlar (Kevlar) fibers, Nomex (Nomex) fibers), poly (imide) fibers, poly (phenylene ether) fibers, poly (phenylene sulfide) fibers, poly (methylpentene) fibers, poly (ether ketone) fibers, liquid crystal polymer fibers (e.g., poly (p-phenylene-2, 6-benzobismuthyl)Oxazole) fibers; poly (ester) -based liquid crystalline polymers, such as fibers produced by the polycondensation of 4-hydroxybenzoic acid and 6-hydroxynaphthalene-2-carboxylic acid), regenerated cellulose, celluloid, cellulose acetate, and carboxymethyl cellulose. The synthetic fibers may include non-continuous synthetic fibers, synthetic staple fibers, fibrillated synthetic fibers, non-fibrillated synthetic fibers, crimped synthetic fibers, uncrimped synthetic fibers, single component synthetic fibers, and/or multi-component synthetic fibers (e.g., bicomponent synthetic fibers). In embodiments where there is more than one web, each web may independently comprise synthetic fibers including one or more of the types of fibers described above.

When present in the web, the total amount of synthetic fibers can comprise a relatively large percentage of the web. For example, in some embodiments, the fiber web includes a total amount of synthetic fibers that is greater than 80 weight percent, greater than or equal to 85 weight percent, greater than or equal to 90 weight percent, or greater than or equal to 95 weight percent of the fiber web. In some embodiments, the web comprises a total amount of synthetic fibers that is less than or equal to 100 wt.%, less than or equal to 95 wt.%, less than or equal to 90 wt.%, or less than or equal to 85 wt.% of the web. Combinations of the above ranges are also possible (e.g., greater than 80% and less than or equal to 100% by weight of the web). In some embodiments, the synthetic fibers comprise 100% by weight of the web. Other ranges are also possible. In embodiments where there is more than one web, each web may independently comprise a total amount of synthetic fibers in one or more of the above amounts.

In some embodiments, the synthetic fibers (e.g., the synthetic fibers listed above) are discontinuous synthetic fibers (e.g., staple fibers). Non-continuous synthetic fibers may include fibers formed by processes that involve cutting continuous filaments into shorter lengths. In some embodiments, the web comprises groups of non-continuous synthetic fibers (e.g., staple fibers) cut to a specific length, with only slight variations in length between individual fibers. The non-continuous synthetic fibers may include fibrillated fibers, non-fibrillated fibers, crimped fibers, and/or uncrimped fibers.

The average fiber length of the synthetic fibers (e.g., non-fibrillated synthetic fibers, non-continuous synthetic fibers, synthetic staple fibers, crimped synthetic fibers, uncrimped synthetic fibers) in the web can be greater than or equal to 0.1mm, greater than or equal to 0.2mm, greater than or equal to 0.5mm, greater than or equal to 1mm, greater than or equal to 2mm, greater than or equal to 5mm, greater than or equal to 10mm, greater than or equal to 15mm, greater than or equal to 20mm, greater than or equal to 25mm, greater than or equal to 30mm, greater than or equal to 38mm, greater than or equal to 40mm, greater than or equal to 45mm, greater than or equal to 50mm, greater than or equal to 55mm, greater than or equal to 60mm, greater than or equal to 65mm, greater than or equal to 70mm, greater than or equal to 76mm, greater than or equal to 80mm, greater than or equal to 85mm, or equal to, Greater than or equal to 90mm, greater than or equal to 100mm, greater than or equal to 125mm, greater than or equal to 150mm, greater than or equal to 175mm, greater than or equal to 200mm, or greater than or equal to 250 mm. The average fiber length of the synthetic fibers (e.g., non-fibrillated synthetic fibers, non-continuous synthetic fibers, synthetic staple fibers, crimped synthetic fibers, uncrimped synthetic fibers) in the web can be less than or equal to 300mm, less than or equal to 250mm, less than or equal to 200mm, less than or equal to 175mm, less than or equal to 150mm, less than or equal to 125mm, less than or equal to 100mm, less than or equal to 90mm, less than or equal to 85mm, less than or equal to 80mm, less than or equal to 76mm, less than or equal to 70mm, less than or equal to 65mm, less than or equal to 60mm, less than or equal to 55mm, less than or equal to 50mm, less than or equal to 45mm, less than or equal to 40mm, less than or equal to 38mm, less than or equal to 30mm, less than or equal to 25mm, less than or equal to 20mm, less than or equal to 15mm, less than or equal to 10mm, less than or equal to 5mm, or equal to, Less than or equal to 2mm, less than or equal to 1mm, less than or equal to 0.5mm, or less than or equal to 0.2 mm. Combinations of the above ranges are also possible (e.g., greater than or equal to 0.1mm and less than or equal to 300mm, greater than or equal to 1mm and less than or equal to 100mm, or greater than or equal to 38mm and less than or equal to 76 mm). Other ranges are also possible.

In embodiments where there is more than one synthetic fiber-containing web, each synthetic fiber-containing web can independently contain synthetic fibers having an average length within one or more of the above ranges (e.g., non-fibrillated synthetic fibers, non-continuous synthetic fibers, synthetic staple fibers, crimped synthetic fibers, uncrimped synthetic fibers). In embodiments where the web comprises more than one type of synthetic fibers (e.g., crimped synthetic fibers and uncrimped synthetic fibers), each type of synthetic fibers may independently have an average length within one or more of the above ranges and/or all of the synthetic fibers may simultaneously have an average length within one or more of the above ranges.

The synthetic fibers (e.g., non-fibrillated synthetic fibers, non-continuous synthetic fibers, synthetic staple fibers, crimped synthetic fibers, uncrimped synthetic fibers) included in the webs described herein may have a suitable average diameter. In some embodiments, the fiber web comprises synthetic fibers (e.g., non-fibrillated synthetic fibers, non-continuous synthetic fibers, synthetic staple fibers, crimped synthetic fibers, uncrimped synthetic fibers) having an average diameter of: greater than or equal to 0.1 micrometers, greater than or equal to 0.2 micrometers, greater than or equal to 0.5 micrometers, greater than or equal to 1 micrometer, greater than or equal to 2 micrometers, greater than or equal to 3 micrometers, greater than or equal to 4 micrometers, greater than or equal to 5 micrometers, greater than or equal to 7.5 micrometers, greater than or equal to 10 micrometers, greater than or equal to 12.5 micrometers, greater than or equal to 15 micrometers, greater than or equal to 17.5 micrometers, greater than or equal to 20 micrometers, greater than or equal to 25 micrometers, greater than or equal to 30 micrometers, or greater than or equal to 40 micrometers. In some embodiments, the fiber web comprises synthetic fibers (e.g., non-fibrillated synthetic fibers, non-continuous synthetic fibers, synthetic staple fibers, crimped synthetic fibers, uncrimped synthetic fibers) having an average diameter of: less than or equal to 50 microns, less than or equal to 40 microns, less than or equal to 30 microns, less than or equal to 25 microns, less than or equal to 20 microns, less than or equal to 17.5 microns, less than or equal to 15 microns, less than or equal to 12.5 microns, less than or equal to 10 microns, less than or equal to 7.5 microns, less than or equal to 5 microns, less than or equal to 4 microns, less than or equal to 3 microns, less than or equal to 2 microns, less than or equal to 1 micron, less than or equal to 0.5 microns, or less than or equal to 0.2 microns. Combinations of the above ranges are also possible (e.g., greater than or equal to 0.1 micrometers and less than or equal to 50 micrometers, greater than or equal to 1 micrometer and less than or equal to 20 micrometers, or greater than or equal to 5 micrometers and less than or equal to 15 micrometers). Other ranges are also possible.

In embodiments where there is more than one synthetic fiber-containing web, each synthetic fiber-containing web can independently contain synthetic fibers (e.g., non-fibrillated synthetic fibers, non-continuous synthetic fibers, synthetic staple fibers, crimped synthetic fibers, uncrimped synthetic fibers) having an average diameter within one or more of the ranges set forth above. In embodiments where the web comprises more than one type of synthetic fibers (e.g., crimped synthetic fibers and uncrimped synthetic fibers), each type of synthetic fibers may independently have an average diameter within one or more of the above-described ranges and/or all of the synthetic fibers may simultaneously have an average diameter within one or more of the above-described ranges.

In embodiments where there is more than one synthetic fiber-containing web, each synthetic fiber-containing web can independently contain synthetic fibers (e.g., non-fibrillated synthetic fibers, non-continuous synthetic fibers, synthetic staple fibers, crimped synthetic fibers, uncrimped synthetic fibers) having an average aspect ratio within one or more of the aforementioned ranges. In embodiments where the web comprises more than one type of synthetic fibers (e.g., crimped synthetic fibers and uncrimped synthetic fibers), each type of synthetic fibers may independently have an average aspect ratio within one or more of the above-described ranges and/or all of the synthetic fibers may simultaneously have an average aspect ratio within one or more of the above-described ranges.

The non-fibrillated synthetic fibers (e.g., synthetic staple fibers, crimped synthetic fibers, uncrimped synthetic fibers) can comprise any suitable percentage of the web when and if present in the web. In some embodiments, the non-continuous synthetic fibers (e.g., non-fibrillated synthetic fibers, synthetic staple fibers, crimped synthetic fibers, uncrimped synthetic fibers) comprise greater than or equal to 0 wt.%, greater than or equal to 5 wt.%, greater than or equal to 10 wt.%, greater than or equal to 15 wt.%, greater than or equal to 20 wt.%, greater than or equal to 25 wt.%, greater than or equal to 30 wt.%, greater than or equal to 35 wt.%, greater than or equal to 40 wt.%, greater than or equal to 45 wt.%, greater than or equal to 50 wt.%, greater than or equal to 60 wt.%, greater than or equal to 70 wt.%, greater than or equal to 80 wt.%, or greater than or equal to 90 wt.% of the web. The non-fibrillated synthetic fibers (e.g., non-continuous synthetic fibers, synthetic staple fibers, crimped synthetic fibers, uncrimped synthetic fibers) can constitute less than or equal to 100 weight percent, less than or equal to 90 weight percent, less than or equal to 80 weight percent, less than or equal to 70 weight percent, less than or equal to 60 weight percent, less than or equal to 50 weight percent, less than or equal to 45 weight percent, less than or equal to 40 weight percent, less than or equal to 35 weight percent, less than or equal to 30 weight percent, less than or equal to 25 weight percent, less than or equal to 20 weight percent, less than or equal to 15 weight percent, less than or equal to 10 weight percent, or less than or equal to 5 weight percent of the web. Combinations of the above ranges are also possible (e.g., greater than or equal to 0 wt.% and less than or equal to 100 wt.% of the web, greater than or equal to 5 wt.% and less than or equal to 45 wt.% of the web, or greater than or equal to 15 wt.% and less than or equal to 35 wt.% of the web). Other ranges are also possible. In some embodiments, the non-fibrillated synthetic fibers (e.g., synthetic staple fibers, crimped synthetic fibers, uncrimped synthetic fibers) comprise 100 weight percent of the web.

In embodiments where there is more than one web, each web can independently comprise non-fibrillated synthetic fibers (e.g., synthetic staple fibers, crimped synthetic fibers, uncrimped synthetic fibers) in one or more of the amounts described above. In embodiments where the web comprises more than one type of non-fibrillated synthetic fibers (e.g., crimped synthetic fibers and uncrimped synthetic fibers), the web may comprise each type of non-fibrillated synthetic fibers independently in one or more of the amounts described above and/or may comprise all of the non-fibrillated synthetic fibers simultaneously in one or more of the amounts described above.

In some embodiments, the fiber web comprises fibrillated fibers. As known to those of ordinary skill in the art, fibrillated fibers include parent fibers that are branched into smaller diameter fibrils, which in some cases may be further branched into fibrils of even smaller diameters, where further branching is also possible. The branched nature of the fibrils may increase the surface area of a web employing the fibrillated fibers and may increase the number of contact points between the fibrillated fibers and other fibers in the web. Such an increase in the points of contact between the fibrillated fibers and other fibers in the fiber web may improve the mechanical properties (e.g., flexibility, strength) of the fiber web.

When present and if present, the fibrillated fibers may comprise synthetic fibrillated fibers, non-limiting examples of which include poly (ester) fibers, nylon fibers, poly (aramid) fibers (e.g., p-poly (aramid) fibers, m-poly (aramid) fibers), poly (imide) fibers, poly (olefin) fibers (e.g., poly (ethylene) fibers, poly (propylene) fibers), poly (ether ketone) fibers, poly (ethylene terephthalate) fibers, acrylic fibers, liquid crystal polymer fibers (e.g., poly (p-phenylene-2, 6-benzobisoxazole) (pbga)Oxazole) fibers; poly (ester) -based liquid crystalline polymers, such as fibers produced by the polycondensation of 4-hydroxybenzoic acid and 6-hydroxynaphthalene-2-carboxylic acid), regenerated cellulose (e.g., lyocell, viscose), celluloid, cellulose acetate, and carboxymethyl cellulose. Alternatively or additionally, the fibrillated fibers may also include natural fibers, such as natural cellulose fibers and/or wool. In embodiments where there is more than one fiber web, each fiber web may independently comprise fibrillated fibers including one or more of the types of fibers described above.

In some embodiments, the fiber web comprises discontinuous fibrillated fibers. The average fiber length of the fibrillated fibers in the fiber web may be greater than or equal to 0.1mm, greater than or equal to 0.2mm, greater than or equal to 0.3mm, greater than or equal to 0.4mm, greater than or equal to 0.5mm, greater than or equal to 0.75mm, greater than or equal to 1mm, greater than or equal to 2mm, greater than or equal to 3mm, greater than or equal to 4mm, greater than or equal to 5mm, greater than or equal to 7.5mm, greater than or equal to 10mm, greater than or equal to 15mm, greater than or equal to 20mm, greater than or equal to 25mm, or greater than or equal to 30 mm. The average fiber length of the fibrillated fibers in the fiber web may be less than or equal to 50mm, less than or equal to 30mm, less than or equal to 25mm, less than or equal to 20mm, less than or equal to 15mm, less than or equal to 10mm, less than or equal to 7.5mm, less than or equal to 5mm, less than or equal to 4mm, less than or equal to 3mm, less than or equal to 2mm, less than or equal to 1mm, less than or equal to 0.75mm, less than or equal to 0.5mm, less than or equal to 0.4mm, less than or equal to 0.3mm, or less than or equal to 0.2 mm. Combinations of the above ranges are also possible (e.g., greater than or equal to 0.1mm and less than or equal to 50mm, greater than or equal to 0.1mm and less than or equal to 25mm, or greater than or equal to 0.5mm and less than or equal to 10 mm). Other ranges are also possible. In embodiments where there is more than one fibrous web comprising fibrillated fibers, each fibrous web comprising fibrillated fibers may independently comprise fibrillated fibers having an average length within one or more of the ranges set forth above.

The fibrillated fibers employed in the fiber webs described herein can have a suitable average fiber diameter. In some embodiments, the fiber web comprises fibrillated fibers having an average diameter of: greater than or equal to 0.05 micrometers, greater than or equal to 0.075 micrometers, greater than or equal to 0.1 micrometers, greater than or equal to 0.2 micrometers, greater than or equal to 0.3 micrometers, greater than or equal to 0.4 micrometers, greater than or equal to 0.5 micrometers, greater than or equal to 0.75 micrometers, greater than or equal to 1 micrometer, greater than or equal to 2 micrometers, greater than or equal to 3 micrometers, greater than or equal to 4 micrometers, greater than or equal to 5 micrometers, greater than or equal to 7.5 micrometers, greater than or equal to 10 micrometers, greater than or equal to 12.5 micrometers, greater than or equal to 15 micrometers, greater than or equal to 17.5 micrometers, greater than or equal to 20 micrometers, greater than or equal to 25 micrometers, greater than or equal to 30 micrometers, greater than or equal to 40 micrometers, greater than or equal to 50 micrometers, or greater than or equal to 75 micrometers. In some embodiments, the fiber web comprises fibrillated fibers having an average diameter of: less than or equal to 100 micrometers, less than or equal to 75 micrometers, less than or equal to 50 micrometers, less than or equal to 40 micrometers, less than or equal to 30 micrometers, less than or equal to 25 micrometers, less than or equal to 20 micrometers, less than or equal to 17.5 micrometers, less than or equal to 15 micrometers, less than or equal to 12.5 micrometers, less than or equal to 10 micrometers, less than or equal to 7.5 micrometers, less than or equal to 5 micrometers, less than or equal to 4 micrometers, less than or equal to 3 micrometers, less than or equal to 2 micrometers, less than or equal to 1 micrometer, less than or equal to 0.75 micrometers, less than or equal to 0.5 micrometers, less than or equal to 0.4 micrometers, less than or equal to 0.3 micrometers, less than or equal to 0.2 micrometers, less than or equal to 0.1 micrometer, or less than or equal to 0.075 micrometers. Combinations of the above ranges are also possible (e.g., greater than or equal to 0.05 microns and less than or equal to 100 microns, greater than or equal to 0.1 microns and less than or equal to 20 microns, or greater than or equal to 0.1 microns and less than or equal to 10 microns). Other ranges are also possible.

Some webs may comprise fibrillated fibers in which the average diameter of the parent fibers is within one or more of the aforementioned ranges, some webs may comprise fibrillated fibers in which the average diameter of the fibrils is within one or more of the aforementioned ranges, and some webs may comprise fibrillated fibers in which the average diameter of both the parent fibers and the fibrillated fibers is within one or more of the aforementioned non-overlapping ranges. In embodiments where there is more than one web comprising fibrillated fibers, each web comprising fibrillated fibers may independently comprise fibrillated fibers having an average diameter of parent fibers and/or fibrils within one or more of the ranges described above.

The fibrillated fibers, when present and if present, can have any suitable Canadian Standard Freeness (Canadian Standard Freeness). The canadian standard freeness of the fibrillated fibers may be selected to provide a desired pore size and/or air permeability to the web and/or the separator. In general, lower values of canadian standard freeness are associated with smaller pore sizes and lower air permeabilities of webs and/or separators comprising fibrillated fibers, and higher values of canadian standard freeness are associated with larger pore sizes and higher air permeabilities of webs and/or separators comprising fibrillated fibers. The canadian standard freeness of the fibrillated fibers can be greater than or equal to 0 CSF, greater than or equal to 1 CSF, greater than or equal to 2 CSF, greater than or equal to 5 CSF, greater than or equal to 10 CSF, greater than or equal to 20 CSF, greater than or equal to 45 CSF, greater than or equal to 100 CSF, greater than or equal to 150 CSF, greater than or equal to 200 CSF, greater than or equal to 250 CSF, greater than or equal to 300 CSF, greater than or equal to 350 CSF, greater than or equal to 400 CSF, greater than or equal to 450 CSF, greater than or equal to 500 CSF, greater than or equal to 550 CSF, greater than or equal to 600 CSF, greater than or equal to 650 CSF, greater than or equal to 700 CSF, or greater than or equal to 750 CSF. The canadian standard freeness of the fibrillated fibers can be less than or equal to 800 CSF, less than or equal to 750 CSF, less than or equal to 700 CSF, less than or equal to 650 CSF, less than or equal to 600 CSF, less than or equal to 550 CSF, less than or equal to 500 CSF, less than or equal to 450 CSF, less than or equal to 400 CSF, less than or equal to 350 CSF, less than or equal to 300 CSF, less than or equal to 250 CSF, less than or equal to 200 CSF, less than or equal to 150 CSF, less than or equal to 100 CSF, less than or equal to 45 CSF, less than or equal to 20 CSF, less than or equal to 10 CSF, less than or equal to 5 CSF, less than or equal to 2 CSF, or less than or equal to 1 CSF. Combinations of the above ranges are also suitable (e.g., greater than or equal to 0 CSF and less than or equal to 800 CSF, greater than or equal to 45 CSF and less than or equal to 800 CSF, greater than or equal to 300 CSF and less than or equal to 700 CSF, or greater than or equal to 550 CSF and less than or equal to 650 CSF). Other ranges are also possible. Canadian standard freeness of fibrillated fibers can be measured according to the canadian standard freeness test, which is specified by TAPPI test method T-227-om-17 freeness of pulp. This test may provide an average CSF value.

The fibrillated fibers can comprise any suitable percentage of the fiber web when and if present in the fiber web. The fibrillated fibers may constitute greater than or equal to 0 wt.%, greater than or equal to 5 wt.%, greater than or equal to 10 wt.%, greater than or equal to 15 wt.%, greater than or equal to 20 wt.%, greater than or equal to 25 wt.%, greater than or equal to 30 wt.%, greater than or equal to 35 wt.%, greater than or equal to 40 wt.%, greater than or equal to 45 wt.%, greater than or equal to 50 wt.%, greater than or equal to 55 wt.%, greater than or equal to 60 wt.%, greater than or equal to 65 wt.%, greater than or equal to 70 wt.%, greater than or equal to 75 wt.%, greater than or equal to 80 wt.%, greater than or equal to 85 wt.%, greater than or equal to 90 wt.%, or greater than or equal to 95 wt.% of the fiber web. The fibrillated fibers may constitute less than or equal to 100 weight percent, less than or equal to 95 weight percent, less than or equal to 90 weight percent, less than or equal to 85 weight percent, less than or equal to 80 weight percent, less than or equal to 75 weight percent, less than or equal to 70 weight percent, less than or equal to 65 weight percent, less than or equal to 60 weight percent, less than or equal to 55 weight percent, less than or equal to 50 weight percent, less than or equal to 45 weight percent, less than or equal to 40 weight percent, less than or equal to 35 weight percent, less than or equal to 30 weight percent, less than or equal to 25 weight percent, less than or equal to 20 weight percent, less than or equal to 15 weight percent, less than or equal to 10 weight percent, or less than or equal to 5 weight percent of the fiber web. Combinations of the above ranges are also possible (e.g., greater than or equal to 0 wt.% and less than or equal to 100 wt.% of the web, greater than or equal to 55 wt.% and less than or equal to 95 wt.% of the web, or greater than or equal to 65 wt.% and less than or equal to 85 wt.% of the web). Other ranges are also possible. In some embodiments, the fibrillated fibers comprise 100 weight percent of the fiber web. In embodiments where there is more than one fiber web, each fiber web may independently comprise fibrillated fibers in one or more of the amounts described above.

In some embodiments, the fiber web comprises multicomponent fibers. Multicomponent fibers may contain more than one component per fiber. In some embodiments, the multicomponent fibers are synthetic multicomponent fibers. Non-limiting examples of suitable components that may be present in the multicomponent fiber include poly (olefins), such as poly (ethylene), poly (propylene), and poly (butylene); polyesters and/or copolyesters, such as poly (ethylene terephthalate) and poly (butylene terephthalate); polyamides, such as nylon and aramid; and halogenated polymers such as poly (tetrafluoroethylene). In embodiments where there is more than one web comprising multicomponent fibers, each web comprising multicomponent fibers may independently comprise multicomponent fibers including one or more of the types of fibers described above.

When present, the multicomponent fibers can have a variety of suitable structures. In some embodiments, the multicomponent fibers comprise bicomponent fibers (i.e., fibers comprising two components). The bicomponent fibers can have a variety of suitable configurations. For example, the web may comprise one or more of the following types of bicomponent fibers: core/sheath fibers (e.g., concentric core/sheath fibers, non-concentric core-sheath fibers), split fibers, side-by-side fibers, and "islands-in-the-sea" fibers. When a core-sheath bicomponent fiber is present, the sheath may have a lower melting temperature than the core. When heated, the sheath may melt before the core, binding other fibers within the web together, while the core remains solid. Non-limiting examples of suitable bicomponent fibers (where the component having the lower melting temperature is listed first and the component having the higher melting temperature is listed second) include the following: poly (ethylene)/poly (ethylene terephthalate), poly (propylene)/poly (ethylene terephthalate), co- (ethylene terephthalate)/poly (ethylene terephthalate), poly (butylene terephthalate)/poly (ethylene terephthalate), co- (polyamide)/polyamide, and poly (ethylene)/poly (propylene). In embodiments where there is more than one web comprising multicomponent fibers, each web comprising multicomponent fibers may independently comprise multicomponent fibers including one or more of the types of fibers described above.

In some embodiments, the web comprises discontinuous multicomponent fibers. The average fiber length of the multicomponent fibers in the web can be greater than or equal to 0.1mm, greater than or equal to 0.2mm, greater than or equal to 0.5mm, greater than or equal to 1mm, greater than or equal to 2mm, greater than or equal to 5mm, greater than or equal to 10mm, greater than or equal to 15mm, greater than or equal to 20mm, greater than or equal to 25mm, greater than or equal to 30mm, greater than or equal to 38mm, greater than or equal to 40mm, greater than or equal to 45mm, greater than or equal to 50mm, greater than or equal to 55mm, greater than or equal to 60mm, greater than or equal to 65mm, greater than or equal to 70mm, greater than or equal to 76mm, greater than or equal to 80mm, greater than or equal to 85mm, greater than or equal to 90mm, greater than or equal to 100mm, greater than or equal to 125mm, greater than or equal to 150mm, greater than or equal to 175mm, greater than or equal to 200mm, or equal to 250 mm. The average fiber length of the multicomponent fibers in the web can be less than or equal to 300mm, less than or equal to 250mm, less than or equal to 200mm, less than or equal to 175mm, less than or equal to 150mm, less than or equal to 125mm, less than or equal to 100mm, less than or equal to 90mm, less than or equal to 85mm, less than or equal to 80mm, less than or equal to 76mm, less than or equal to 70mm, less than or equal to 65mm, less than or equal to 60mm, less than or equal to 55mm, less than or equal to 50mm, less than or equal to 45mm, less than or equal to 40mm, less than or equal to 38mm, less than or equal to 30mm, less than or equal to 25mm, less than or equal to 20mm, less than or equal to 15mm, less than or equal to 10mm, less than or equal to 5mm, less than or equal to 2mm, less than or equal to 1mm, less than or equal to 0.5mm, or less than or equal to 0.2 mm. Combinations of the above ranges are also possible (e.g., greater than or equal to 0.1mm and less than or equal to 300mm, greater than or equal to 2mm and less than or equal to 100mm, or greater than or equal to 38mm and less than or equal to 76 mm). Other ranges are also possible. In embodiments where there is more than one web comprising multicomponent fibers, each web comprising multicomponent fibers may independently comprise multicomponent fibers having an average length within one or more of the ranges set forth above.

The multicomponent fibers employed in the webs described herein may have suitable average diameters. In some embodiments, the fiber web comprises multicomponent fibers having an average diameter of: greater than or equal to 0.1 micrometers, greater than or equal to 0.2 micrometers, greater than or equal to 0.5 micrometers, greater than or equal to 0.75 micrometers, greater than or equal to 1 micrometer, greater than or equal to 2 micrometers, greater than or equal to 3 micrometers, greater than or equal to 4 micrometers, greater than or equal to 5 micrometers, greater than or equal to 7.5 micrometers, greater than or equal to 10 micrometers, greater than or equal to 12.5 micrometers, greater than or equal to 15 micrometers, greater than or equal to 17.5 micrometers, greater than or equal to 20 micrometers, greater than or equal to 25 micrometers, greater than or equal to 30 micrometers, or greater than or equal to 40 micrometers. In some embodiments, the fiber web comprises multicomponent fibers having an average diameter of: less than or equal to 50 microns, less than or equal to 40 microns, less than or equal to 30 microns, less than or equal to 25 microns, less than or equal to 20 microns, less than or equal to 17.5 microns, less than or equal to 15 microns, less than or equal to 12.5 microns, less than or equal to 10 microns, less than or equal to 7.5 microns, less than or equal to 5 microns, less than or equal to 4 microns, less than or equal to 3 microns, less than or equal to 2 microns, less than or equal to 1 micron, less than or equal to 0.75 microns, less than or equal to 0.5 microns, or less than or equal to 0.2 microns. Combinations of the above ranges are also possible (e.g., greater than or equal to 0.1 micrometers and less than or equal to 20 micrometers, greater than or equal to 1 micrometer and less than or equal to 20 micrometers, or greater than or equal to 5 micrometers and less than or equal to 15 micrometers). Other ranges are also possible. In embodiments where there is more than one web comprising multicomponent fibers, each web comprising multicomponent fibers may independently comprise multicomponent fibers having an average diameter within one or more of the ranges set forth above.

When present in the web and if present in the web, the multicomponent fibers can comprise any suitable percentage of the web. The multicomponent fibers can comprise greater than or equal to 0 wt%, greater than or equal to 5 wt%, greater than or equal to 10 wt%, greater than or equal to 15 wt%, greater than or equal to 20 wt%, greater than or equal to 25 wt%, greater than or equal to 30 wt%, greater than or equal to 35 wt%, greater than or equal to 40 wt%, greater than or equal to 45 wt%, greater than or equal to 50 wt%, greater than or equal to 60 wt%, greater than or equal to 70 wt%, greater than or equal to 80 wt%, or greater than or equal to 90 wt% of the web. In some embodiments, the multicomponent fibers comprise less than or equal to 100 weight percent, less than or equal to 90 weight percent, less than or equal to 80 weight percent, less than or equal to 70 weight percent, less than or equal to 60 weight percent, less than or equal to 50 weight percent, less than or equal to 45 weight percent, less than or equal to 40 weight percent, less than or equal to 35 weight percent, less than or equal to 30 weight percent, less than or equal to 25 weight percent, less than or equal to 20 weight percent, less than or equal to 15 weight percent, less than or equal to 10 weight percent, or less than or equal to 5 weight percent of the web. Combinations of the above ranges are also possible (e.g., greater than or equal to 0 wt.% and less than or equal to 100 wt.% of the web, greater than or equal to 5 wt.% and less than or equal to 45 wt.% of the web, or greater than or equal to 15 wt.% and less than or equal to 35 wt.% of the web). In some embodiments, the multicomponent fibers comprise 100% by weight of the web. Other ranges are also possible. In embodiments where there is more than one web, each web can independently comprise multicomponent fibers in one or more of the amounts described above.

In some embodiments, the fiber web comprises crimped fibers. As known to those of ordinary skill in the art, crimped fibers include one or more undulations and/or one or more undulations that extend generally along at least a portion of the fiber (in other words, at least a portion of the fiber has a generally undulating and/or undulating structure). The undulations and/or waves can include naturally occurring undulations and/or waves (e.g., undulations and/or waves formed during fiber formation) and/or undulations and/or waves formed during chemical processing of the fibers. Crimped fibers generally have a more open structure than uncrimped fibers and can therefore increase the porosity of the web in which they are positioned. Crimped fibers may be and/or may include synthetic, staple, and/or non-continuous fibers and may thus have one or more of the characteristics described above with respect to these fiber types.

In some embodiments, the fiber web comprises glass fibers. The glass fibers may include microglass fibers and/or chopped strand glass fibers. As an example, the fiber web may comprise microglass fibers produced by drawing a glass melt from a tip of a bushing into continuous fibers and then subjecting the continuous fibers to a flame blowing process and/or a rotational spinning process. In some embodiments, the fiber web may comprise microglass fibers formed by a remelting process. As another example, the fiber web may contain chopped strand glass fibers produced by drawing a glass melt from the tip of the sleeve into continuous fibers and then cutting the continuous fibers into short fibers. The chopped strand glass fibers may include chopped strand glass fibers having a relatively small amount of alkali metal oxide (e.g., sodium oxide, magnesium oxide) in the fibers. In some embodiments, the chopped strand glass fibers may include a relatively large amount of calcium oxide and/or aluminum oxide. In embodiments where there is more than one web comprising glass fibers, each web comprising glass fibers may independently comprise glass fibers comprising one or more of the types of fibers described above.

The glass fibers may have a suitable average length if present in the web and when present in the web. In some embodiments, the glass fibers have an average length of greater than or equal to 0.01mm, greater than or equal to 0.02mm, greater than or equal to 0.03mm, greater than or equal to 0.04mm, greater than or equal to 0.05mm, greater than or equal to 0.075mm, greater than or equal to 0.1mm, greater than or equal to 0.2mm, greater than or equal to 0.3mm, greater than or equal to 0.4mm, greater than or equal to 0.5mm, greater than or equal to 0.75mm, greater than or equal to 1mm, greater than or equal to 2mm, greater than or equal to 3mm, greater than or equal to 4mm, greater than or equal to 5mm, greater than or equal to 7.5mm, greater than or equal to 10mm, greater than or equal to 20mm, greater than or equal to 50mm, greater than or equal to 100mm, or greater than or equal to 200 mm. In some embodiments, the glass fibers have an average length of less than or equal to 300mm, less than or equal to 200mm, less than or equal to 100mm, less than or equal to 50mm, less than or equal to 20mm, less than or equal to 10mm, less than or equal to 7.5mm, less than or equal to 5mm, less than or equal to 4mm, less than or equal to 3mm, less than or equal to 2mm, less than or equal to 1mm, less than or equal to 0.75mm, less than or equal to 0.5mm, less than or equal to 0.4mm, less than or equal to 0.3mm, less than or equal to 0.2mm, less than or equal to 0.1mm, less than or equal to 0.075mm, less than or equal to 0.05mm, less than or equal to 0.04mm, less than or equal to 0.03mm, or less than or equal to 0.02 mm. Combinations of the above ranges are also possible (e.g., greater than or equal to 0.01mm and less than or equal to 300mm, greater than or equal to 0.1mm and less than or equal to 2mm, or greater than or equal to 0.2mm and less than or equal to 1 mm). Other ranges are also possible. In embodiments where there is more than one web comprising glass fibers, each web comprising glass fibers may independently comprise glass fibers having an average length within one or more of the ranges set forth above.

The glass fibers can have a suitable average diameter if present in the web and when present in the web. In some embodiments, the glass fibers have an average diameter of greater than or equal to 0.1 micrometers, greater than or equal to 0.2 micrometers, greater than or equal to 0.3 micrometers, greater than or equal to 0.4 micrometers, greater than or equal to 0.5 micrometers, greater than or equal to 0.6 micrometers, greater than or equal to 0.7 micrometers, greater than or equal to 0.8 micrometers, greater than or equal to 0.9 micrometers, greater than or equal to 1 micrometer, greater than or equal to 1.25 micrometers, greater than or equal to 1.5 micrometers, greater than or equal to 1.75 micrometers, greater than or equal to 2 micrometers, greater than or equal to 2.25 micrometers, greater than or equal to 2.5 micrometers, greater than or equal to 3.5 micrometers, greater than or equal to 4 micrometers, greater than or equal to 5 micrometers, greater than or equal to 7.5 micrometers, greater than or equal to 10 micrometers, greater than or equal to 15 micrometers, greater than or equal to 20 micrometers, or greater than or equal to 30 micrometers. In some embodiments, the glass fibers have an average diameter of less than or equal to 40 microns, less than or equal to 30 microns, less than or equal to 20 microns, less than or equal to 15 microns, less than or equal to 10 microns, less than or equal to 7.5 microns, less than or equal to 5 microns, less than or equal to 4 microns, less than or equal to 3.5 microns, less than or equal to 3 microns, less than or equal to 2.5 microns, less than or equal to 2.25 microns, less than or equal to 2 microns, less than or equal to 1.75 microns, less than or equal to 1.5 microns, less than or equal to 1.25 microns, less than or equal to 1 micron, less than or equal to 0.9 microns, less than or equal to 0.8 microns, less than or equal to 0.7 microns, less than or equal to 0.6 microns, less than or equal to 0.5 microns, less than or equal to 0.4 microns, less than or equal to 0.3 microns, or less than or equal to 0.2 microns. Combinations of the above ranges are also possible (e.g., greater than or equal to 0.1 microns and less than or equal to 40 microns, greater than or equal to 0.4 microns and less than or equal to 20 microns, or greater than or equal to 0.8 microns and less than or equal to 2.5 microns). Other ranges are also possible. In embodiments where there is more than one web comprising glass fibers, each web comprising glass fibers may independently comprise glass fibers having an average diameter within one or more of the ranges described above.

In some embodiments, if glass fibers are present in the fiber web, the glass fibers may comprise a relatively small amount of the fiber web. For example, the glass fibers can comprise less than or equal to 20 weight percent, less than or equal to 17.5 weight percent, less than or equal to 15 weight percent, less than or equal to 12.5 weight percent, less than or equal to 10 weight percent, less than or equal to 7.5 weight percent, less than or equal to 5 weight percent, less than or equal to 4 weight percent, less than or equal to 3 weight percent, less than or equal to 2 weight percent, or less than or equal to 1 weight percent of the fiber web. In some embodiments, the glass fibers comprise greater than or equal to 0 wt%, greater than or equal to 1 wt%, greater than or equal to 2 wt%, greater than or equal to 3 wt%, greater than or equal to 4 wt%, greater than or equal to 5 wt%, greater than or equal to 7.5 wt%, greater than or equal to 10 wt%, greater than or equal to 12.5 wt%, greater than or equal to 15 wt%, or greater than or equal to 17.5 wt% of the fiber web. Combinations of the above ranges are also possible (e.g., greater than or equal to 0 wt.% and less than or equal to 20 wt.% of the web, greater than or equal to 0 wt.% and less than or equal to 10 wt.% of the web, or greater than or equal to 0 wt.% and less than or equal to 5 wt.% of the web). In some embodiments, the fiber web comprises 0 wt% glass fibers. Other ranges are also possible. In embodiments where there is more than one web, each web can independently comprise glass fibers in one or more of the amounts described above.

In some embodiments, the fiber web comprises one or more additional types of fibers other than those described above. For example, the fibrous web can comprise natural fibers (e.g., cellulosic fibers, such as non-fibrillated cellulosic fibers). When the fiber web includes natural cellulose fibers, the natural cellulose fibers may be wood (e.g., cedar) fibers, such as softwood fibers and/or hardwood fibers.

Exemplary softwood fibers include fibers obtained from: mercerized southern pine ("mercerized southern pine fibers or HPZ fibers"), northern bleached softwood kraft (e.g., fibers obtained from oak Flash (Robur Flash) (oak Flash fibers ")), southern bleached softwood kraft (e.g., fibers obtained from Brunswick pine (" unruly pine fibers ")), and/or chemically treated mechanical pulp (" CTMP fibers "). For example, HPZ fibers are available from Buckeye Technologies, inc. of montphy, tennessee; oak glitter fiber is available from Rottneros AB of stockholm, sweden; and the larelix fibers are available from Georgia-Pacific, atlanta, Georgia.

Exemplary hardwood fibers include fibers obtained from eucalyptus ("eucalyptus fibers"). Eucalyptus fibers are commercially available from: for example, (1) Suzano Group ("Suzano fiber") by Suzano brazil; (2) group Portuguecel Soporcel (a "fiber of Cacia") from Portuguese; (3) tembec, Inc. (Tarascon fibers), of Temification, Quebec, Canada; (4) kartonimex intercellel ("Acacia fiber") of dusseldov, germany; (5) Mead-Westvaco ("Westvaco fiber"), stanford, connecticut; and (6) Georgia-Pacific ("Leaf River fiber") by Atlanta, Georgia.

In some embodiments, the web comprises one or more types of particles. For example, the web may comprise rubber particles (i.e., particles comprising rubber), sulfate particles (i.e., particles comprising sulfate), and/or other types of inorganic particles (i.e., particles comprising inorganic compounds other than sulfate).

Without wishing to be bound by any particular theory, it is believed that the inclusion of rubber particles in the fibrous web may advantageously improve the performance of a battery in which the battery separator is placed, as the rubber may scavenge certain heavy metals (e.g., antimony) present in the battery that are believed to reduce the performance of the battery. It is believed that the rubber particles from the fibrous web may at least partially dissolve in the electrolyte upon exposure to the electrolyte and, once dissolved in the electrolyte, may bind to the heavy metals therein, thereby removing the heavy metals from the electrolyte. Since it is believed that heavy metals present in the electrolyte undesirably deposit on the battery plates (in some cases, are irreversible) and/or increase water consumption, it is believed that rubbers that prevent such phenomena by scavenging heavy metals from the electrolyte may improve battery operation.

A variety of suitable types of rubber particles may be employed in the webs described herein. In some embodiments, the fiber web includes rubber particles that include natural rubber. As an example, the web may comprise rubber particles comprising: smoked sheet rubber, light crepe rubber, felt crepe rubber, brown crepe rubber, flat bark crepe rubber (flat bark rubber), Hevea brasiliensis rubber and/or natural rubber latex. In some embodiments, the fiber web includes rubber particles comprising synthetic rubber. For example, the web may comprise rubber particles comprising: styrene-butadiene rubber, acrylonitrile butadiene rubber, poly (butadiene) rubber, poly (isoprene) rubber, nitrile rubber, butyl rubber, ethylene propylene diene rubber, silicone rubber, poly (sulfide) rubber and/or poly (acrylate) rubber. The rubber particles may comprise vulcanized rubber and/or unvulcanized rubber. In embodiments where there is more than one web comprising rubber particles, each web comprising rubber particles may independently comprise rubber particles comprising one or more of the types of rubbers described above.

The web may contain rubber particles having a suitable average diameter. In some embodiments, the fiber web comprises rubber particles having an average diameter of: greater than or equal to 1 micron, greater than or equal to 2 microns, greater than or equal to 3 microns, greater than or equal to 4 microns, greater than or equal to 5 microns, greater than or equal to 7.5 microns, greater than or equal to 10 microns, greater than or equal to 12.5 microns, greater than or equal to 15 microns, greater than or equal to 17.5 microns, greater than or equal to 20 microns, greater than or equal to 25 microns, greater than or equal to 30 microns, greater than or equal to 40 microns, greater than or equal to 50 microns, or greater than or equal to 75 microns. In some embodiments, the fiber web comprises rubber particles having an average diameter of: less than or equal to 100 microns, less than or equal to 75 microns, less than or equal to 50 microns, less than or equal to 40 microns, less than or equal to 30 microns, less than or equal to 25 microns, less than or equal to 20 microns, less than or equal to 17.5 microns, less than or equal to 15 microns, less than or equal to 12.5 microns, less than or equal to 10 microns, less than or equal to 7.5 microns, less than or equal to 5 microns, less than or equal to 4 microns, less than or equal to 3 microns, or less than or equal to 2 microns. Combinations of the above ranges are also possible (e.g., greater than or equal to 1 micron and less than or equal to 100 microns, greater than or equal to 2 microns and less than or equal to 40 microns, or greater than or equal to 3 microns and less than or equal to 20 microns). Other ranges are also possible. In embodiments where there is more than one web comprising rubber particles, each web comprising rubber particles may independently comprise rubber particles having an average diameter within one or more of the ranges described above.

When present in the web, the rubber particles may comprise a suitable portion of the web. In some embodiments, the rubber particles comprise greater than or equal to 0 wt%, greater than or equal to 1 wt%, greater than or equal to 2 wt%, greater than or equal to 3 wt%, greater than or equal to 4 wt%, greater than or equal to 5 wt%, greater than or equal to 7.5 wt%, greater than or equal to 10 wt%, greater than or equal to 12.5 wt%, greater than or equal to 15 wt%, or greater than or equal to 17.5 wt% of the fiber web. In some embodiments, the rubber particles comprise less than or equal to 20 wt.%, less than or equal to 17.5 wt.%, less than or equal to 15 wt.%, less than or equal to 12.5 wt.%, less than or equal to 10 wt.%, less than or equal to 7.5 wt.%, less than or equal to 5 wt.%, less than or equal to 4 wt.%, less than or equal to 3 wt.%, less than or equal to 2 wt.%, or less than or equal to 1 wt.% of the web. Combinations of the above ranges are also possible (e.g., greater than or equal to 0 wt.% and less than or equal to 20 wt.% of the web, greater than or equal to 0 wt.% and less than or equal to 10 wt.% of the web, or greater than or equal to 0 wt.% and less than or equal to 5 wt.% of the web). In some embodiments, the fiber web comprises 0 wt.% rubber particles. Other ranges are also possible. In embodiments where there is more than one web, each web may independently contain rubber particles in one or more of the amounts described above.

Without wishing to be bound by any particular theory, it is believed that the inclusion of the sulfate particles in the web may advantageously reduce the tendency of a battery having a battery separator disposed therein to form a short circuit. It is believed that a short circuit may form when dissolved lead ions precipitate from the electrolyte onto one or more portions of the battery, thereby creating lead deposits that together form a conductive short circuit path through the battery. It is also believed that the sulfate salt may inhibit the dissolution of lead sulfate into the electrolyte due to the homoionic effect, thereby reducing the total amount of lead ions in the electrolyte. It is believed that a reduction in the amount of lead ions present in the electrolyte reduces the tendency of lead ions therein to precipitate from the electrolyte, and thus, the lead sulfate particles thereby inhibit the occurrence of short circuits.

A variety of suitable types of sulfate particles may be employed in the webs described herein. Non-limiting examples of suitable types of sulfates that may be included in the sulfate particles include alkali metal sulfates (e.g., sodium sulfate, potassium sulfate), alkaline earth metal sulfates (e.g., magnesium sulfate, calcium sulfate), aluminum sulfate, and transition metal sulfates (e.g., cobalt sulfate, zinc sulfate). In embodiments where there is more than one web comprising sulfate particles, each web comprising sulfate particles may independently comprise sulfate particles comprising one or more of the above-described sulfates.

The web may comprise sulphate particles having a suitable average diameter. In some embodiments, the fiber web comprises sulfate particles having an average diameter of: greater than or equal to 0.01 micrometers, greater than or equal to 0.02 micrometers, greater than or equal to 0.05 micrometers, greater than or equal to 0.1 micrometers, greater than or equal to 0.2 micrometers, greater than or equal to 0.5 micrometers, greater than or equal to 0.75 micrometers, greater than or equal to 1 micrometer, greater than or equal to 2 micrometers, greater than or equal to 3 micrometers, greater than or equal to 4 micrometers, greater than or equal to 5 micrometers, greater than or equal to 7.5 micrometers, greater than or equal to 10 micrometers, greater than or equal to 12.5 micrometers, greater than or equal to 15 micrometers, greater than or equal to 17.5 micrometers, greater than or equal to 20 micrometers, greater than or equal to 22.5 micrometers, greater than or equal to 25 micrometers, greater than or equal to 30 micrometers, greater than or equal to 40 micrometers, greater than or equal to 50 micrometers, or greater than or equal to 75 micrometers. In some embodiments, the fiber web comprises sulfate particles having an average diameter of: less than or equal to 100 micrometers, less than or equal to 75 micrometers, less than or equal to 50 micrometers, less than or equal to 40 micrometers, less than or equal to 30 micrometers, less than or equal to 25 micrometers, less than or equal to 22.5 micrometers, less than or equal to 20 micrometers, less than or equal to 17.5 micrometers, less than or equal to 15 micrometers, less than or equal to 12.5 micrometers, less than or equal to 10 micrometers, less than or equal to 7.5 micrometers, less than or equal to 5 micrometers, less than or equal to 4 micrometers, less than or equal to 3 micrometers, less than or equal to 2 micrometers, less than or equal to 1 micrometer, less than or equal to 0.75 micrometers, less than or equal to 0.5 micrometers, less than or equal to 0.2 micrometers, less than or equal to 0.1 micrometer, less than or equal to 0.05 micrometers, or less than or equal to 0.02 micrometers. Combinations of the above ranges are also possible (e.g., greater than or equal to 0.01 micrometers and less than or equal to 100 micrometers, greater than or equal to 1 micrometer and less than or equal to 50 micrometers, or greater than or equal to 3 micrometers and less than or equal to 20 micrometers). Other ranges are also possible. In embodiments where there is more than one web comprising sulfate particles, each web comprising sulfate particles may independently comprise sulfate particles having an average diameter within one or more of the ranges set forth above.

The sulfate particles may comprise a suitable portion of the web if and when present in the web. In some embodiments, the sulfate particles comprise greater than or equal to 0 wt.%, greater than or equal to 1 wt.%, greater than or equal to 2 wt.%, greater than or equal to 3 wt.%, greater than or equal to 4 wt.%, greater than or equal to 5 wt.%, greater than or equal to 7.5 wt.%, greater than or equal to 10 wt.%, greater than or equal to 12.5 wt.%, greater than or equal to 15 wt.%, or greater than or equal to 17.5 wt.% of the web. In some embodiments, the sulfate particles comprise less than or equal to 20 wt.%, less than or equal to 17.5 wt.%, less than or equal to 15 wt.%, less than or equal to 12.5 wt.%, less than or equal to 10 wt.%, less than or equal to 7.5 wt.%, less than or equal to 5 wt.%, less than or equal to 4 wt.%, less than or equal to 3 wt.%, less than or equal to 2 wt.%, or less than or equal to 1 wt.% of the web. Combinations of the above ranges are also possible (e.g., greater than or equal to 0 wt.% and less than or equal to 20 wt.% of the web, greater than or equal to 0 wt.% and less than or equal to 10 wt.% of the web, or greater than or equal to 0 wt.% and less than or equal to 5 wt.% of the web). In some embodiments, the web comprises 0 wt% sulfate particles. Other ranges are also possible. In embodiments where there is more than one web, each web may independently comprise sulfate particles in one or more of the amounts described above.

The inclusion of inorganic particles other than sulfate in the fibrous web can provide a number of advantages to the battery separator. For example, such inorganic particles may reduce the pore size of the web without significantly altering the porosity of the web, increase wicking and/or wettability of the web, improve electrolyte adsorption through the web, and/or scavenge harmful contaminants such as heavy metal ions (which may provide some or all of the advantages described above with respect to the rubber particles). As an example, in some embodiments, the inorganic particles may contain very fine pores that produce increased capillary forces, which increases electrolyte adsorption and/or contaminant capture. In some embodiments, the fibrous web comprises inorganic particles that encapsulate the fibers therein and act to reduce the pore size and/or pore size variation of the fibrous web.

A variety of suitable inorganic particles can be included in the webs described herein. For example, the fiber web may comprise silica particles (e.g., fumed silica particles, natural and/or mined silica particles, fused silica particles, precipitated silica particles, agglomerated silica particles), clay particles, talc particles, particles comprising diatom algae (e.g., diatomaceous earth), zeolite particles, titanium dioxide particles, and/or ash particles (e.g., rice hull ash particles). In embodiments where there is more than one inorganic particle-containing web, each inorganic particle-containing web can independently contain inorganic particles that contain one or more of the above types of inorganic materials.

The web may comprise inorganic particles having a suitable average diameter. In some embodiments, the fiber web comprises inorganic particles having an average diameter of: greater than or equal to 1 micron, greater than or equal to 2 microns, greater than or equal to 3 microns, greater than or equal to 4 microns, greater than or equal to 5 microns, greater than or equal to 7.5 microns, greater than or equal to 10 microns, greater than or equal to 12.5 microns, greater than or equal to 15 microns, greater than or equal to 17.5 microns, greater than or equal to 20 microns, greater than or equal to 25 microns, greater than or equal to 30 microns, greater than or equal to 40 microns, greater than or equal to 50 microns, or greater than or equal to 75 microns. In some embodiments, the fiber web comprises inorganic particles having an average diameter of: less than or equal to 100 microns, less than or equal to 75 microns, less than or equal to 50 microns, less than or equal to 40 microns, less than or equal to 30 microns, less than or equal to 25 microns, less than or equal to 20 microns, less than or equal to 17.5 microns, less than or equal to 15 microns, less than or equal to 12.5 microns, less than or equal to 10 microns, less than or equal to 7.5 microns, less than or equal to 5 microns, less than or equal to 4 microns, less than or equal to 3 microns, or less than or equal to 2 microns. Combinations of the above ranges are also possible (e.g., greater than or equal to 1 micron and less than or equal to 100 microns, greater than or equal to 2 microns and less than or equal to 20 microns, or greater than or equal to 3 microns and less than or equal to 10 microns). Other ranges are also possible. In embodiments where there is more than one inorganic particle-containing web, each inorganic particle-containing web can independently contain inorganic particles having an average diameter within one or more of the ranges set forth above.

The fibrous web may comprise inorganic particles having a suitable average specific surface area. In some embodiments, the fibrous web comprises inorganic particles having an average specific surface area of: greater than or equal to 10m²A ratio of/g to 20m or more²A ratio of 30m or more in terms of/g²A ratio of 40m or more in terms of/g²A ratio of/g to 50m or more²A number of grams of greater than or equal to 75m²A ratio of/g to 100m or more²A ratio of/g to 150m or more²(ii) g, greater than or equal to 200m²A ratio of/g to 250m or more²A number of grams of more than or equal to 300m²A ratio of/g to 350m or more²A ratio of the total of the carbon atoms to the total of 400m²A number of grams of more than or equal to 450m²A ratio of/g to 500m or more²A ratio of/g to 600m or more²A ratio of/g to 800m or more²A ratio of/g to 1000m or more²(ii) a value of/g, or greater than or equal to 1500m²(ii) in terms of/g. In some embodiments, the fibrous web comprises inorganic particles having an average specific surface area of: less than or equal to 2000m²(ii) each of the molar ratios is less than or equal to 1500m²A ratio of/g to 1000m or less²Per g, less than or equal to 800m²G, less than or equal to 600m²A ratio of/g to 500m or less²A ratio of/g to 450m or less²(ii) g, less than or equal to 400m²Per g, less than or equal to 350m²(ii) g, less than or equal to 300m²(ii) 250m or less per gram²(ii) g, less than or equal to 200m²Per g, less than or equal to 150m²A ratio of/g to 100m or less²(ii) g, less than or equal to 75m²A ratio of/g to 50m or less²A ratio of 40m or less per gram²A ratio of 30m or less in terms of/g²(ii)/g, or less than or equal to 20m²(ii) in terms of/g. Combinations of the above ranges are also possible (e.g., greater than or equal to 10 m)²A number of grams of less than or equal to 2000m²A ratio of/g to 50m or more²A number of grams of less than or equal to 1000m²(ii)/g, or 400m or more²G is less than or equal to 600m²In terms of/g). Other ranges are also possible. In embodiments where there is more than one inorganic particle-containing web, each inorganic particle-containing web can independently contain inorganic particles having an average specific surface area within one or more of the ranges set forth above.

The specific Surface Area of the inorganic particles can be determined according to section 10 of Battery material specification Valve Regulated Recombinant Batteries (Recommended Battery Materials Specifications Valve Regulated Recombinant Batteries) Recommended by Battery Council International Standard BCIS-03A (2009), section 10 being Standard Test Method for Surface Area of Recombinant Battery Separator pad (Standard Test Method for Surface Area of Recombinant Battery Separator pad). According to this technique, the specific surface area is measured via adsorption analysis with nitrogen using a BET surface analyzer (e.g. Micromeritics Gemini III 2375 surface area analyzer); sample size in 3/4 "tube was 0.5 grams to 0.6 grams; and the sample was degassed at 100 ℃ for a minimum of 3 hours.

The inorganic particles may comprise a suitable portion of the fibrous web, if present in the fibrous web and when present in the fibrous web. In some embodiments, the inorganic particles comprise greater than or equal to 0 wt%, greater than or equal to 1 wt%, greater than or equal to 2 wt%, greater than or equal to 3 wt%, greater than or equal to 4 wt%, greater than or equal to 5 wt%, greater than or equal to 7.5 wt%, greater than or equal to 10 wt%, greater than or equal to 12.5 wt%, greater than or equal to 15 wt%, or greater than or equal to 17.5 wt% of the fiber web. In some embodiments, the inorganic particles comprise less than or equal to 20 wt%, less than or equal to 17.5 wt%, less than or equal to 15 wt%, less than or equal to 12.5 wt%, less than or equal to 10 wt%, less than or equal to 7.5 wt%, less than or equal to 5 wt%, less than or equal to 4 wt%, less than or equal to 3 wt%, less than or equal to 2 wt%, or less than or equal to 1 wt% of the fiber web. Combinations of the above ranges are also possible (e.g., greater than or equal to 0 wt.% and less than or equal to 20 wt.% of the web, greater than or equal to 0 wt.% and less than or equal to 10 wt.% of the web, or greater than or equal to 0 wt.% and less than or equal to 5 wt.% of the web). In some embodiments, the fiber web comprises 0 wt% inorganic particles. Other ranges are also possible. In embodiments where there is more than one web, each web can independently comprise inorganic particles in one or more of the amounts described above.

In some embodiments, the fiber web further comprises a resin (e.g., a non-fibrous resin). The resin may include polymers such as styrene acrylate, styrene butyl acrylate, styrene butadiene, poly (methyl methacrylate), copolymers of styrene and methyl methacrylate, phenolic resins, acrylonitrile rubber, poly (ethylene), and/or poly (urethane).

The resin may comprise a relatively small amount of the web if present in the web and when present in the web. For example, the resin (e.g., non-fibrous resin) can comprise less than or equal to 20 wt.%, less than or equal to 17.5 wt.%, less than or equal to 15 wt.%, less than or equal to 12.5 wt.%, less than or equal to 10 wt.%, less than or equal to 7.5 wt.%, less than or equal to 5 wt.%, less than or equal to 4 wt.%, less than or equal to 3 wt.%, less than or equal to 2 wt.%, or less than or equal to 1 wt.% of the fiber web. In some embodiments, the resin (e.g., non-fibrous resin) comprises greater than or equal to 0 wt%, greater than or equal to 1 wt%, greater than or equal to 2 wt%, greater than or equal to 3 wt%, greater than or equal to 4 wt%, greater than or equal to 5 wt%, greater than or equal to 7.5 wt%, greater than or equal to 10 wt%, greater than or equal to 12.5 wt%, greater than or equal to 15 wt%, or greater than or equal to 17.5 wt% of the fiber web. Combinations of the above ranges are also possible (e.g., greater than or equal to 0 wt.% and less than or equal to 20 wt.% of the web, greater than or equal to 0 wt.% and less than or equal to 10 wt.% of the web, or greater than or equal to 0 wt.% and less than or equal to 5 wt.% of the web). In some embodiments, the fiber web comprises 0 wt.% resin (e.g., non-fibrous resin). Other ranges are also possible. In embodiments where there is more than one web, each web may independently comprise resin in one or more of the amounts described above.

The webs described herein may have a relatively high porosity. In some embodiments, the porosity of the web is greater than or equal to 50%, greater than or equal to 55%, greater than or equal to 60%, greater than or equal to 65%, greater than or equal to 70%, greater than or equal to 75%, greater than or equal to 80%, greater than or equal to 85%, greater than or equal to 90%, or greater than or equal to 95%. In some embodiments, the porosity of the web is less than or equal to 99%, less than or equal to 95%, less than or equal to 90%, less than or equal to 85%, less than or equal to 80%, less than or equal to 75%, less than or equal to 70%, less than or equal to 65%, less than or equal to 60%, or less than or equal to 55%. Combinations of the above ranges are also possible (e.g., greater than or equal to 50% and less than or equal to 99%, greater than or equal to 60% and less than or equal to 90%, or greater than or equal to 70% and less than or equal to 80%). Other ranges are also possible. In embodiments where there is more than one web, the porosity of each web can be independently within one or more of the ranges described above.

The porosity of the web is equal to 100% - [ the solidity of the web ]. The solidity of the web is equal to the percentage of the interior of the web occupied by the solid material. One non-limiting way of determining the solidity of the web is described in this paragraph, but other methods are possible. The method described in this paragraph includes determining the basis weight and thickness of the web and then applying the following formula: solidity ═ 100% basis weight of the web/(density of web-forming components) ·. The density of the web-forming components is equal to the average density of the material or materials (e.g., fibers, particles, resins) of the web-forming components, which is typically specified by the manufacturer of each material. The average density of the materials forming the components of the web can be determined by: (1) determining the total volume of all components in the web; and (2) dividing the total mass of all components in the web by the total volume of all components in the web. If the mass and density of each component of the web are known, the volume of the total components in the web can be determined by: (1) for each type of component, dividing the total mass of the components in the web by the density of the component; and (2) adding the volumes of each component. If the mass and density of each component of the web are unknown, the volume of all components in the web can be determined according to Archimedes' principle.

The webs described herein may have suitable mean flow pore sizes. In some embodiments, the web has a mean flow pore size of greater than or equal to 0.01 microns, greater than or equal to 0.02 microns, greater than or equal to 0.05 microns, greater than or equal to 0.1 microns, greater than or equal to 0.2 microns, greater than or equal to 0.5 microns, greater than or equal to 0.75 microns, greater than or equal to 1 micron, greater than or equal to 2 microns, greater than or equal to 3 microns, greater than or equal to 4 microns, greater than or equal to 5 microns, greater than or equal to 6 microns, greater than or equal to 7 microns, greater than or equal to 8 microns, greater than or equal to 10 microns, greater than or equal to 12.5 microns, greater than or equal to 15 microns, greater than or equal to 17.5 microns, greater than or equal to 20 microns, greater than or equal to 25 microns, greater than or equal to 30 microns, or greater than or equal to 40 microns. In some embodiments, the web has a mean flow pore size of less than or equal to 50 microns, less than or equal to 40 microns, less than or equal to 30 microns, less than or equal to 25 microns, less than or equal to 20 microns, less than or equal to 17.5 microns, less than or equal to 15 microns, less than or equal to 12.5 microns, less than or equal to 10 microns, less than or equal to 8 microns, less than or equal to 7 microns, less than or equal to 6 microns, less than or equal to 5 microns, less than or equal to 4 microns, less than or equal to 3 microns, less than or equal to 2 microns, less than or equal to 1 micron, less than or equal to 0.75 microns, less than or equal to 0.5 microns, less than or equal to 0.2 microns, less than or equal to 0.1 microns, less than or equal to 0.05 microns, or less than or equal to 0.02 microns. Combinations of the above ranges are also possible (e.g., greater than or equal to 0.01 micrometers and less than or equal to 50 micrometers, greater than or equal to 1 micrometer and less than or equal to 15 micrometers, or greater than or equal to 3 micrometers and less than or equal to 7 micrometers). Other ranges are also possible. In embodiments where there is more than one web, the mean flow pore size of each web can be independently within one or more of the ranges described above. The mean flow pore size of the web may be determined according to ASTM F316 (2003).

The webs described herein may have a suitable maximum pore size. In some embodiments, the web has a maximum pore size of greater than or equal to 0.01 microns, greater than or equal to 0.02 microns, greater than or equal to 0.05 microns, greater than or equal to 0.1 microns, greater than or equal to 0.2 microns, greater than or equal to 0.5 microns, greater than or equal to 0.75 microns, greater than or equal to 1 micron, greater than or equal to 2 microns, greater than or equal to 3 microns, greater than or equal to 4 microns, greater than or equal to 5 microns, greater than or equal to 6 microns, greater than or equal to 7 microns, greater than or equal to 8 microns, greater than or equal to 10 microns, greater than or equal to 12.5 microns, greater than or equal to 15 microns, greater than or equal to 17.5 microns, greater than or equal to 20 microns, greater than or equal to 25 microns, greater than or equal to 30 microns, greater than or equal to 40 microns, or greater than equal to 50 microns. In some embodiments, the web has a maximum pore size of less than or equal to 70 microns, less than or equal to 50 microns, less than or equal to 40 microns, less than or equal to 30 microns, less than or equal to 25 microns, less than or equal to 20 microns, less than or equal to 17.5 microns, less than or equal to 15 microns, less than or equal to 12.5 microns, less than or equal to 10 microns, less than or equal to 8 microns, less than or equal to 7 microns, less than or equal to 6 microns, less than or equal to 5 microns, less than or equal to 4 microns, less than or equal to 3 microns, less than or equal to 2 microns, less than or equal to 1 micron, less than or equal to 0.75 microns, less than or equal to 0.5 microns, less than or equal to 0.2 microns, less than or equal to 0.1 micron, less than or equal to 0.05 microns, or less than or equal to 0.02 microns. Combinations of the above ranges are also possible (e.g., greater than or equal to 0.01 micrometers and less than or equal to 70 micrometers, greater than or equal to 8 micrometers and less than or equal to 25 micrometers, or greater than or equal to 10 micrometers and less than or equal to 15 micrometers). Other ranges are also possible. In embodiments where there is more than one web, the maximum pore size of each web can independently be within one or more of the ranges described above. The maximum pore size of the web may be determined according to ASTM F316 (2003).

The webs described herein may have a suitable basis weight. In some embodiments, the basis weight of the web is greater than or equal to 2g/m²Greater than or equal to 5g/m²Greater than or equal to 10g/m²Greater than or equal to 20g/m²Greater than or equal to 30g/m²Greater than or equal to 40g/m²Greater than or equal to 50g/m²Greater than or equal to 60g/m²80g/m or more²Greater than or equal to 100g/m²Greater than or equal to 120g/m²Greater than or equal to 150g/m²Greater than or equal to 200g/m²Greater than or equal to 250g/m²Greater than or equal to 300g/m²Or greater than or equal to 400g/m². In some embodiments, the basis weight of the web is less than or equal to 500g/m²Less than or equal to 400g/m²Less than or equal to 300g/m²Less than or equal to 250g/m²Less than or equal to 200g/m²Less than or equal to 150g/m²Less than or equal to 120g/m²Less than or equal to 100g/m²Less than or equal to 80g/m²Less than or equal to 60g/m²Less than or equal to 50g/m²Less than or equal to 40g/m²Less than or equal to 30g/m²Less than or equal to 20g/m²Less than or equal to 10g/m²Or less than or equal to 5g/m². Combinations of the above ranges are also possible (e.g., greater than or equal to 2 g/m)²And is less than or equal to 500g/m²Greater than or equal to 40g/m²And less than or equal to 150g/m²Greater than or equal to 60g/m²And is less than or equal to 120g/m²). Other ranges are also possible. In embodiments where there is more than one web, the basis weight of each web can be independently within one or more of the ranges described above. The basis weight of the web may be determined according to ISO 536: 2012.

The webs described herein may have a suitable thickness. In some embodiments, the web has a thickness of greater than or equal to 0.01mm, greater than or equal to 0.02mm, greater than or equal to 0.05mm, greater than or equal to 0.075mm, greater than or equal to 0.1mm, greater than or equal to 0.2mm, greater than or equal to 0.3mm, greater than or equal to 0.4mm, greater than or equal to 0.5mm, greater than or equal to 0.6mm, greater than or equal to 0.7mm, greater than or equal to 0.8mm, greater than or equal to 1mm, greater than or equal to 2mm, greater than or equal to 3mm, or greater than or equal to 4 mm. In some embodiments, the web has a thickness of less than or equal to 5mm, less than or equal to 4mm, less than or equal to 3mm, less than or equal to 2mm, less than or equal to 1mm, less than or equal to 0.8mm, less than or equal to 0.7mm, less than or equal to 0.6mm, less than or equal to 0.5mm, less than or equal to 0.4mm, less than or equal to 0.3mm, less than or equal to 0.2mm, less than or equal to 0.1mm, less than or equal to 0.075mm, less than or equal to 0.05mm, or less than or equal to 0.02 mm. Combinations of the above ranges are also possible (e.g., greater than or equal to 0.01mm and less than or equal to 5mm, greater than or equal to 0.1mm and less than or equal to 1mm, or greater than or equal to 0.2mm and less than or equal to 0.6 mm). Other ranges are also possible. In embodiments where there is more than one web, the thickness of each web can independently be within one or more of the ranges described above. The thickness of the web may be determined according to CIS-03A, 9 months 2009, method 10 at an applied pressure of 10 kPa.

The webs described herein may have suitable specific surface areas. In some embodiments, the specific surface area of the fiber web is greater than or equal to 0.01m²A ratio of 0.02m or more in terms of/g²A ratio of 0.03m or more in terms of/g²A ratio of 0.04m or more in terms of/g²A ratio of 0.05m or more in terms of/g²A ratio of 0.06m or more in terms of/g²A ratio of 0.08m or more in terms of/g²A ratio of 0.1m or more in terms of/g²A ratio of 0.2m or more in terms of/g²A ratio of 0.3m or more in terms of/g²A ratio of 0.4m or more in terms of/g²A ratio of 0.5m or more in terms of/g²A ratio of 0.75m or more in terms of/g²A ratio of 1m or more in terms of/g²A ratio of 2m or more in terms of/g²A ratio of 5m or more in terms of/g²A ratio of 10m or more in terms of/g²A ratio of/g to 20m or more²A ratio of/g to 50m or more²A ratio of/g to 100m or more²(ii)/g, or 200m or more²(ii) in terms of/g. In some embodiments, the specific surface area of the fiber web is less than or equal to 400m²(ii) g, less than or equal to 200m²A ratio of/g to 100m or less²A ratio of/g to 50m or less²A ratio of/g to 20m or less²A ratio of 10m or less in terms of/g²(ii) 5m or less per g²A ratio of 2m or less in terms of/g²(ii) 1m or less per g²A ratio of 0.75m or less in terms of/g²A ratio of 0.5m or less in terms of/g²A ratio of 0.4m or less in terms of/g²A ratio of 0.3m or less in terms of/g²A ratio of 0.2m or less in terms of/g²A ratio of 0.1m or less in terms of/g²A ratio of 0.08m or less to/g²A ratio of 0.06m or less in terms of/g²A ratio of 0.05m or less in terms of/g²A ratio of 0.04m or less in terms of/g²A ratio of 0.03m or less in terms of/g²(ii)/g, or 0.02m or less²(ii) in terms of/g. Combinations of the above ranges are also possible (e.g., greater than or equal to 0.01 m)²A number of grams of less than or equal to 400m²A ratio of 0.04m or more in terms of/g²A ratio of 0.5m or less to/g²(ii)/g, or 0.1m or more²A ratio of 0.3m or less to/g²In terms of/g). Other ranges are also possible. In embodiments where there is more than one web, the specific surface area of each web can independently be within one or more of the ranges described above.

The specific surface area of the web may be determined according to battery association international standard BCIS-03A (2009), section 10 of "recommended battery material specification valve regulated recombinant batteries", section 10 being "standard test method for surface area of recombinant battery separator mat". According to this technique, specific surface area is measured via adsorption analysis with nitrogen using a BET surface analyzer (e.g., Micromeritics Gemini III 2375 surface area analyzer); sample size in 3/4 "tube was 0.5 grams to 0.6 grams; and the sample was degassed at 100 ℃ for a minimum of 3 hours.

The webs described herein may have suitable air permeability. In some embodiments, the web has an air permeability of greater than or equal to 0 CFM, greater than or equal to 0.1 CFM, greater than or equal to 0.2 CFM, greater than or equal to 0.3 CFM, greater than or equal to 0.4 CFM, greater than or equal to 0.5 CFM, greater than or equal to 0.75 CFM, greater than or equal to 1 CFM, greater than or equal to 2 CFM, greater than or equal to 3 CFM, greater than or equal to 4 CFM, greater than or equal to 5 CFM, greater than or equal to 7.5 CFM, greater than or equal to 10 CFM, greater than or equal to 20 CFM, or greater than or equal to 30 CFM. In some embodiments, the web has an air permeability of less than or equal to 50 CFM, less than or equal to 30 CFM, less than or equal to 20 CFM, less than or equal to 10 CFM, less than or equal to 7.5 CFM, less than or equal to 5 CFM, less than or equal to 4 CFM, less than or equal to 3 CFM, less than or equal to 2 CFM, less than or equal to 1 CFM, less than or equal to 0.75 CFM, less than or equal to 0.5 CFM, less than or equal to 0.4 CFM, less than or equal to 0.3 CFM, less than or equal to 0.2 CFM, or less than or equal to 0.1 CFM. Combinations of the above ranges are also possible (e.g., greater than or equal to 0 CFM and less than or equal to 50 CFM, greater than or equal to 0.1 CFM and less than or equal to 5 CFM, or greater than or equal to 0.5 CFM and less than or equal to 3 CFM). Other ranges are also possible. In embodiments where there is more than one web, the air permeability of each web may independently be within one or more of the ranges described above. The air permeability of the web may be determined according to ASTM test standard D737-04(2016) at a pressure of 125 Pa.

The webs described herein may have suitable water contact angles. In some embodiments, the web has a water contact angle of greater than or equal to 0 °, greater than or equal to 1 °, greater than or equal to 2 °, greater than or equal to 5 °, greater than or equal to 10 °, greater than or equal to 20 °, greater than or equal to 40 °, greater than or equal to 60 °, greater than or equal to 80 °, greater than or equal to 90 °, greater than or equal to 100 °, or greater than or equal to 120 °. In some embodiments, the web has a water contact angle of less than or equal to 150 °, less than or equal to 120 °, less than or equal to 100 °, less than or equal to 90 °, less than or equal to 80 °, less than or equal to 60 °, less than or equal to 40 °, less than or equal to 20 °, less than or equal to 10 °, less than or equal to 5 °, less than or equal to 2 °, or less than or equal to 1 °. Combinations of the above ranges are also possible (e.g., greater than or equal to 0 ° and less than or equal to 150 °, greater than or equal to 0 ° and less than or equal to 120 °, greater than or equal to 0 ° and less than or equal to 90 °, or greater than or equal to 0 ° and less than or equal to 80 °). Other ranges are also possible. In embodiments where there is more than one web, the water contact angle of each web can independently be within one or more of the ranges described above. The water contact angle of the web may be determined according to ASTM D5946 (2009). In some embodiments, the web has a water contact angle within one or more of the above ranges and is not subjected to a surface treatment to increase its hydrophilicity or hydrophobicity. In other words, some webs may have contact angles within one or more of the above ranges, and the webs and fibers therein may have unmodified surfaces.

In some embodiments, the webs described herein have a relatively high machine direction tensile strength. For example, the web may have a machine direction tensile strength of greater than or equal to 2 lbs/inch, greater than or equal to 5 lbs/inch, greater than or equal to 7.5 lbs/inch, greater than or equal to 10 lbs/inch, greater than or equal to 12.5 lbs/inch, greater than or equal to 15 lbs/inch, greater than or equal to 17.5 lbs/inch, greater than or equal to 20 lbs/inch, greater than or equal to 30 lbs/inch, greater than or equal to 50 lbs/inch, or greater than or equal to 75 lbs/inch. The web may have a machine direction tensile strength of less than or equal to 100 lbs/inch, less than or equal to 75 lbs/inch, less than or equal to 50 lbs/inch, less than or equal to 30 lbs/inch, less than or equal to 20 lbs/inch, less than or equal to 17.5 lbs/inch, less than or equal to 15 lbs/inch, less than or equal to 12.5 lbs/inch, less than or equal to 10 lbs/inch, less than or equal to 7.5 lbs/inch, or less than or equal to 5 lbs/inch. Combinations of the above ranges are also possible (e.g., greater than or equal to 2 lbs/inch and less than or equal to 100 lbs/inch, greater than or equal to 10 lbs/inch and less than or equal to 100 lbs/inch, or greater than or equal to 15 lbs/inch and less than or equal to 100 lbs/inch). Other ranges are also possible. In embodiments where there is more than one web, the machine direction tensile strength of each web may independently be within one or more of the ranges described above. The machine direction tensile strength of the web may be determined according to BCIS 03B (2018).

In some embodiments, the webs described herein have a relatively high elongation at break. For example, the elongation at break of the web can be greater than or equal to 0%, greater than or equal to 1%, greater than or equal to 2%, greater than or equal to 5%, greater than or equal to 7.5%, greater than or equal to 10%, greater than or equal to 15%, greater than or equal to 20%, greater than or equal to 25%, greater than or equal to 30%, greater than or equal to 40%, greater than or equal to 50%, greater than or equal to 75%, greater than or equal to 100%, greater than or equal to 150%, greater than or equal to 200%, greater than or equal to 300%, or greater than or equal to 400%. The elongation at break of the web can be less than or equal to 500%, less than or equal to 400%, less than or equal to 300%, less than or equal to 200%, less than or equal to 150%, less than or equal to 100%, less than or equal to 75%, less than or equal to 50%, less than or equal to 40%, less than or equal to 30%, less than or equal to 25%, less than or equal to 20%, less than or equal to 15%, less than or equal to 10%, less than or equal to 7.5%, less than or equal to 5%, less than or equal to 2%, or less than or equal to 1%. Combinations of the above ranges are also possible (e.g., greater than or equal to 0% and less than or equal to 500%, or greater than or equal to 10% and less than or equal to 100%). Other ranges are also possible. In embodiments where there is more than one web, the elongation to break of each web can independently be within one or more of the ranges described above. The elongation at break of the web can be determined according to BCIS 03B (2018).

In some embodiments, the webs described herein have relatively high puncture strength. For example, the web can have a puncture strength of greater than or equal to 2N, greater than or equal to 4N, greater than or equal to 6N, greater than or equal to 8N, greater than or equal to 10N, greater than or equal to 12N, greater than or equal to 14N, greater than or equal to 16N, greater than or equal to 18N, greater than or equal to 20N, greater than or equal to 22.5N, greater than or equal to 25N, greater than or equal to 27.5N, greater than or equal to 30N, greater than or equal to 35N, greater than or equal to 42N, greater than or equal to 50N, or greater than or equal to 75N. The web can have a puncture strength of less than or equal to 100N, less than or equal to 75N, less than or equal to 50N, less than or equal to 42N, less than or equal to 35N, less than or equal to 30N, less than or equal to 27.5N, less than or equal to 25N, less than or equal to 22.5N, less than or equal to 20N, less than or equal to 18N, less than or equal to 16N, less than or equal to 14N, less than or equal to 12N, less than or equal to 10N, less than or equal to 8N, less than or equal to 6N, or less than or equal to 4N. Combinations of the above ranges are also possible (e.g., greater than or equal to 2N and less than or equal to 100N, greater than or equal to 12N and less than or equal to 42N, or greater than or equal to 16N and less than or equal to 25N). Other ranges are also possible. In embodiments where there is more than one web, the puncture strength of each web can be independently within one or more of the ranges described above. The puncture strength of the web may be determined according to BCIS 03B (2018).

The webs described herein may have a suitable electrical resistance. In some embodiments, the electrical resistance of the fiber web is greater than or equal to 0 ohms cm²Greater than or equal to 0.1 ohm cm²Greater than or equal to 0.2 ohm cm²Greater than or equal to 0.3 ohm cm²Greater than or equal to 0.4 ohm cm²Greater than or equal to 0.5 ohm cm²Greater than or equal to 0.6 ohm cm²Greater than or equal to 0.7 ohm cm²Greater than or equal to 0.8 ohm cm²Greater than or equal to 1 ohm cm²Or greater than or equal to 1.25 ohms cm². In some embodiments, the electrical resistance of the fiber web is less than or equal to 1.5 ohms cm²Less than or equal to 1.25 ohm cm²Less than or equal to 1 ohm cm²Less than or equal to 0.8 ohm cm²Less than or equal to 0.7 ohm cm²Less than or equal to 0.6 ohm cm²Less than or equal to 0.5 ohm cm²Less than or equal to 0.4 ohm cm²Less than or equal to 0.3 ohm cm²Less than or equal to 0.2 ohm cm²Or less than or equal to 0.1 ohm cm². Combinations of the above ranges are also possible (e.g., greater than or equal to 0 ohms cm)²And less than or equal to 1.5 ohm cm²Greater than or equal to 0 ohm cm²And less than or equal to 0.5 ohm cm²Or greater than or equal to 0 ohm cm²And less than or equal to 0.3 ohm cm²). Other ranges are also possible. In embodiments where there is more than one web, the resistance of each web can be independently within one or more of the ranges described above. The resistance of the web can be determined according to IS 6071-1986.

In some embodiments, the webs described herein have a relatively high breakdown voltage. As used herein, the breakdown voltage is the minimum voltage that, when applied across a web, causes a portion of the web to become conductive. Generally, the breakdown voltage represents the dielectric strength of the dry fibrous web. Typically, the breakdown voltage of the web without short circuits will be relatively high. However, a short circuit (e.g., due to dendrite formation) will produce a relatively low breakdown voltage.

The breakdown voltage of the fiber web may be greater than or equal to 0.1kV, greater than or equal to 0.2kV, greater than or equal to 0.3kV, greater than or equal to 0.4kV, greater than or equal to 0.5kV, greater than or equal to 0.6kV, greater than or equal to 0.7kV, greater than or equal to 0.8kV, greater than or equal to 0.9kV, greater than or equal to 1kV, greater than or equal to 2kV, greater than or equal to 3kV, greater than or equal to 4kV, greater than or equal to 5kV, greater than or equal to 6kV, or greater than or equal to 8 kV. The breakdown voltage of the fiber web may be less than or equal to 10kV, less than or equal to 8kV, less than or equal to 6kV, less than or equal to 5kV, less than or equal to 4kV, less than or equal to 3kV, less than or equal to 2kV, less than or equal to 1kV, less than or equal to 0.9kV, less than or equal to 0.8kV, less than or equal to 0.7kV, less than or equal to 0.6kV, less than or equal to 0.5kV, less than or equal to 0.4kV, less than or equal to 0.3kV, or less than or equal to 0.2 kV. Combinations of the above ranges are also possible (e.g., greater than or equal to 0.1kV and less than or equal to 10kV, greater than or equal to 0.5kV and less than or equal to 5kV, or greater than or equal to 0.8kV and less than or equal to 3 kV). Other ranges are also possible. In embodiments where there is more than one web, the breakdown voltage of each web can be independently within one or more of the ranges described above.

In short, the breakdown voltage of a web can be measured by: 100V was applied across the web using a 10cm by 10cm electrode, and then the voltage applied across the web was increased until a current of 18mA was generated. The applied voltage at which a current of 18mA or more is first measured is the breakdown voltage.

In some embodiments, the battery separator has a three-dimensional structure. The three-dimensional structure may comprise a surface: the surface comprises protrusions extending in the mid-plane of the surface and/or recesses extending below the mid-plane of the surface. Fig. 6A shows one non-limiting embodiment of a battery separator 106A having one such surface, and fig. 6B shows one non-limiting embodiment of a battery separator 106B having two such surfaces opposite each other. Referring to fig. 6A, the upper surface 10A includes a midplane 12A. Half of surface 10A is above midplane 12A and half of surface 10A is below midplane 12A. The portion of surface 10A extending above midplane 12A forms protrusion 14A and the portion of surface 10A extending below midplane 12A forms depression 16A.

It should be understood that fig. 6A and 6B are merely exemplary, and that other arrangements of the projections and recesses relative to the midplane are possible. For example, the surface may include protrusions that are discrete from one another (e.g., form discrete peaks) and/or may include interconnected protrusions (e.g., protrusions that form a network across at least a portion of the web, protrusions connected by a portion of the web that also extends above a midplane thereof). Similarly, the surface may comprise depressions that are discrete from one another (e.g., form discrete depressions) and/or may comprise interconnected depressions (e.g., depressions that form a network across at least a portion of the web, depressions that are connected by a portion of the web that also extends below its mid-plane). As an example, fig. 6C depicts protrusions 21C and 22C interconnected with each other and protrusions 23C and 24C discrete from each other. Fig. 6C also depicts recesses 25C and 26C interconnected with each other and recesses 27C and 28C discrete from each other. As another example, fig. 6D shows a top view of the battery separator, showing protrusions 21D and 22D interconnected with each other and protrusions 23D and 24D discrete from each other.

In some embodiments, the surface comprises protrusions and/or depressions forming a repeating pattern, and in some embodiments, the surface comprises protrusions and/or depressions randomly distributed across the surface. The surface may include protrusions and/or depressions that may be relatively uniform in shape and/or size, and/or may include protrusions and/or depressions that differ in shape and/or size.

When the battery separator includes two surfaces including protrusions and/or recesses, the protrusions and/or recesses on the two surfaces may be aligned (e.g., one surface may include protrusions in locations where the opposing surface includes recesses, the two opposing surfaces may include protrusions in the same locations and/or may include recesses in the same locations), or may be misaligned. The protrusions and depressions in both surfaces of the battery separator may be similar in shape and/or size, and/or may be different in shape and/or size.

The three-dimensional structures (e.g., including protrusions extending above the midplane of the surface and/or recesses extending below the midplane of the surface) may be formed in a variety of suitable ways. In some embodiments, molding techniques may be used that allow the geometry of the battery separator to be controlled without negatively impacting additional beneficial properties (e.g., porosity) of the battery separator. The three-dimensional structure of the layer may be changed during and/or after the manufacture of the layer. Non-limiting examples of suitable methods include, but are not limited to, corrugating, pleating, embossing, creping, and micrex processing.

In some embodiments, corrugation or pleating may be used to form a three-dimensional structure in the battery separator. The corrugating or pleating may be done in the machine direction or the cross direction. In some embodiments, the corrugation or pleating may create a fold, curve, undulation, or pleat within the battery separator.

In some embodiments, embossing may be used to form a three-dimensional structure in the battery separator. Several different techniques may be used to emboss the layers. For example, a roller system may be used to apply pressure to the layer to form surface features (e.g., indentations) having a particular pattern. In some cases, the battery separator may be formed on a wire mesh (e.g., a tilted table, a rotary former, a circular former) having a grid pattern. The grid pattern may create areas with more or less slurry and thus may create a non-uniform thickness profile (e.g., indentations) across the battery separator. In some such embodiments, the indentations may be in the form of a grid pattern, and may have a depth and/or area coverage percentage in the layer within one or more of the ranges described herein. In embodiments where the battery separator is a wet-laid battery separator (e.g., it is a wet-laid fibrous web), the battery separator may be embossed during the wet stage using a calender roll having a defined pattern. The embossed battery separator may include repeating units (e.g., square indentations) of one or more shapes. The repeating units may have a defined shape which may be, for example, substantially circular, square, rectangular, trapezoidal, polygonal, or elliptical in cross-section and/or in top view (i.e., as viewed from above). The shape may be regular or irregular. Any suitable shape may be embossed on the ply.

In some embodiments, the plurality of indentations in the embossed battery separator may be arranged to form a pattern. In some embodiments, the pattern of indentations may be simple (e.g., a checkered pattern) or more complex (e.g., a honeycomb pattern). In other cases, the pattern may be cubic, hexagonal, and/or polygonal, for example. The pattern of indentations may be regular or irregular.

In some embodiments, corrugation may be used to form a three-dimensional structure in the battery separator. In some embodiments, creping refers to the rapid change in speed and angle of the sheet path utilized by smooth rolls to create a three-dimensional structure of flat wet sheet. In some embodiments, corrugation may be used to form irregular shapes, such as irregular wave patterns, in the battery separator. In some embodiments, corrugation may be used to form regular shapes. In some embodiments, the corrugation may create a fold, curve, undulation, or pattern within the battery separator.

In some embodiments, micrex processing may be used to form three-dimensional structures in the battery separator. micrex processing is similar to creping but is performed on fully dried sheets. In some embodiments, micrex processing may be used to form irregular shapes, such as irregular wave patterns, in the battery separator. In some embodiments, a regular shape may be formed using micrex machining. In some embodiments, the micrex process can create a fold, bend, undulation, or pattern within the battery separator.

It is to be understood that while in some embodiments the layers may have a three-dimensional structure, for example, they may be corrugated, pleated, embossed, corrugated, and/or micrex processed, in some embodiments the battery separators described herein are not corrugated, unpleated, unembossed, uncreped, and/or micrex processed. Further, it is understood that in some embodiments, more than one technique may be used to form the three-dimensional structures (e.g., corrugation and embossing) in the separators described herein. The three-dimensional structure is typically formed prior to any large scale structure formation of the battery separator (e.g., prior to forming the flat sheet into a pocket separator, prior to folding the flat sheet to form a folded separator).

In some embodiments, the protrusions extending above the surface of the spacer may take the form of ribs. In general, the Ribs may have any suitable shape and be arranged in any suitable pattern, as described in PCT/IB/064420 entitled Battery Separator with Ribs and a Method of Casting the Ribs on the Separator, filed on 11.9.2014, which is incorporated herein by reference in its entirety. For example, the ribs may be in the form of lines (e.g., continuous, discontinuous) or dots arranged in rows on top of one or more layers of the battery separator. In some embodiments, there may be no ribs on the battery separator.

Non-limiting examples of suitable materials from which the ribs can be formed include thermoplastics such as plastisols (e.g., poly (vinyl chloride), poly (acrylate) blended with plasticizers), poly (olefins) (e.g., poly (ethylene), poly (propylene), poly (butylene), copoly (ethylene-octene), poly (ethylene vinyl acetate)), poly (esters), poly (styrene), acrylonitrile-butadiene-styrene (ABS), poly (vinyl chloride), poly (imide), poly (urethane); and thermosets such as poly (urethane), poly (acrylate), poly (epoxide), reactive plastisols, phenolic resins, poly (imide), rubbers (e.g., natural, synthetic); and combinations thereof.

When the spacer includes a protrusion therein that extends above the midplane of the surface and/or a recess therein that extends below the midplane of the surface, the average distance from the midplane of the surface to the protrusion and/or recess may be a plurality of suitable values. In some embodiments, the average distance from the midplane of the surface to the protrusion and/or depression is greater than or equal to 0.1mm, greater than or equal to 0.2mm, greater than or equal to 0.3mm, greater than or equal to 0.4mm, greater than or equal to 0.5mm, greater than or equal to 0.75mm, greater than or equal to 1mm, greater than or equal to 1.25mm, or greater than or equal to 1.5 mm. In some embodiments, the average distance from the midplane of the surface to the protrusion and/or depression is less than or equal to 2mm, less than or equal to 1.5mm, less than or equal to 1.25mm, less than or equal to 1mm, less than or equal to 0.75mm, less than or equal to 0.5mm, less than or equal to 0.4mm, less than or equal to 0.3mm, or less than or equal to 0.2 mm. Combinations of the above ranges are also possible (e.g., greater than or equal to 0.1mm and less than or equal to 1.5 mm). Other ranges are also possible. As used herein, the distance from the midplane of the surface to the protrusion is the distance between the midplane of the surface and the point of the protrusion that extends furthest from the midplane of the surface. Similarly, herein, the distance from the midplane of the surface to the recess is the distance between the midplane of the surface and the point of the recess that extends furthest from the midplane of the surface.

When the spacer comprises a protrusion therein extending above the mid-plane of the surface and/or a recess therein extending below the mid-plane of the surface, the average nearest neighbor distance between the protrusions and/or recesses may be a plurality of suitable values. In some embodiments, the average nearest neighbor distance between a protrusion and/or a depression is greater than or equal to 0.1mm, greater than or equal to 0.2mm, greater than or equal to 0.5mm, greater than or equal to 1mm, greater than or equal to 2mm, greater than or equal to 5mm, greater than or equal to 7.5mm, greater than or equal to 10mm, greater than or equal to 12.5mm, greater than or equal to 15mm, greater than or equal to 20mm, greater than or equal to 25mm, greater than or equal to 30mm, greater than or equal to 40mm, greater than or equal to 50mm, greater than or equal to 75mm, or greater than or equal to 100 mm. In some embodiments, the average nearest neighbor distance between projections and/or depressions is less than or equal to 200mm, less than or equal to 100mm, less than or equal to 75mm, less than or equal to 50mm, less than or equal to 40mm, less than or equal to 30mm, less than or equal to 25mm, less than or equal to 20mm, less than or equal to 15mm, less than or equal to 12.5mm, less than or equal to 10mm, less than or equal to 7.5mm, less than or equal to 5mm, less than or equal to 2mm, less than or equal to 1mm, less than or equal to 0.5mm, or less than or equal to 0.2 mm. Combinations of the above ranges are also possible (e.g., greater than or equal to 0.1mm and less than or equal to 200 mm). Other ranges are also possible.

In some embodiments, a battery separator (e.g., a battery separator comprising a fiber web) may have one or more advantageous properties as a whole. It is to be understood that the battery separator as a whole may have one or more properties (e.g., porosity, mean flow pore size, maximum pore size, basis weight, thickness, specific surface area, air permeability, contact angle, tensile strength, elongation at break, puncture strength, resistance, breakdown voltage) that fall within the ranges described elsewhere herein with respect to the fibrous web. This may occur, for example, if the battery separator comprises only a single fiber web. This may also occur if the battery separator comprises two webs and/or one or more webs and one or more other components than webs. Further values for particular values of some characteristics of the battery separator are described in additional detail below.

The battery separators described herein may have a relatively high porosity. In some embodiments, the porosity of the separator is greater than or equal to 50%, greater than or equal to 55%, greater than or equal to 60%, greater than or equal to 65%, greater than or equal to 70%, greater than or equal to 75%, greater than or equal to 80%, greater than or equal to 85%, greater than or equal to 90%, or greater than or equal to 95%. In some embodiments, the battery separator has a porosity of less than or equal to 99%, less than or equal to 95%, less than or equal to 90%, less than or equal to 85%, less than or equal to 80%, less than or equal to 75%, less than or equal to 70%, less than or equal to 65%, less than or equal to 60%, or less than or equal to 55%. Combinations of the above ranges are also possible (e.g., greater than or equal to 50% and less than or equal to 99%, greater than or equal to 70% and less than or equal to 95%, or greater than or equal to 80% and less than or equal to 90%). The porosity of the battery separator may be determined by following the method described above with respect to the fiber web for the battery separator.

The battery separator described herein may have a suitable basis weight. In some embodiments, the basis weight of the battery separator is greater than or equal to 2g/m²Greater than or equal to 5g/m²Greater than or equal to 10g/m²Greater than or equal to 20g/m²Greater than or equal to 30g/m²Greater than or equal to 40g/m²Greater than or equal to 50g/m²Greater than or equal to 60g/m²70g/m or more²80g/m or more²Greater than or equal to 90g/m²Greater than or equal to 100g/m²Greater than or equal to 120g/m²Greater than or equal to 150g/m²170g/m or more²Greater than or equal to 200g/m²Greater than or equal to 250g/m²Greater than or equal to 300g/m²Or greater than or equal to 400g/m². In some embodiments, the basis weight of the battery separator is less than or equal to 500g/m²Less than or equal to 400g/m²Less than or equal to 300g/m²Less than or equal to 250g/m²Less than or equal to 200g/m²170g/m or less²Less than or equal to 150g/m²Less than or equal to 120g/m²Less than or equal to 100g/m²Less than or equal to 90g/m²Less than or equal to 80g/m²Less than or equal to 70g/m²Less than or equal to 60g/m²Less than or equal to 50g/m²Less than or equal to 40g/m²Less than or equal to 30g/m²Less than or equal to 20g/m²Less than or equal to 10g/m²Or less than or equal to 5g/m². Combinations of the above ranges are also possible (e.g., greater than or equal to 2 g/m)²And less than or equal to 500g/m²80g/m or more²And is less than or equal to 250g/m²Greater than or equal to 90g/m²And is less than or equal to 170g/m²). Other ranges are also possible. The basis weight of the battery separator may be determined according to ISO 536: 2012.

The battery separator described herein may have a suitable thickness. In some embodiments, the battery separator has a thickness of greater than or equal to 0.01mm, greater than or equal to 0.02mm, greater than or equal to 0.05mm, greater than or equal to 0.075mm, greater than or equal to 0.1mm, greater than or equal to 0.2mm, greater than or equal to 0.3mm, greater than or equal to 0.4mm, greater than or equal to 0.5mm, greater than or equal to 0.6mm, greater than or equal to 0.7mm, greater than or equal to 0.8mm, greater than or equal to 1mm, greater than or equal to 1.3mm, greater than or equal to 2mm, greater than or equal to 3mm, greater than or equal to 4mm, greater than or equal to 5mm, or greater than or equal to 7.5 mm. In some embodiments, the battery separator has a thickness of less than or equal to 10mm, less than or equal to 7.5mm, less than or equal to 5mm, less than or equal to 4mm, less than or equal to 3mm, less than or equal to 2mm, less than or equal to 1.3mm, less than or equal to 1mm, less than or equal to 0.8mm, less than or equal to 0.7mm, less than or equal to 0.6mm, less than or equal to 0.5mm, less than or equal to 0.4mm, less than or equal to 0.3mm, less than or equal to 0.2mm, less than or equal to 0.1mm, less than or equal to 0.075mm, less than or equal to 0.05mm, or less than or equal to 0.02 mm. Combinations of the above ranges are also possible (e.g., greater than or equal to 0.01mm and less than or equal to 10mm, greater than or equal to 0.4mm and less than or equal to 2mm, or greater than or equal to 0.7mm and less than or equal to 1.3 mm). Other ranges are also possible. The thickness of the battery separator may be determined according to CIS-03A, 9 months 2009, method 10 under an applied pressure of 10 kPa.

The battery separators described herein may have a suitable apparent density. In some embodiments, the battery separator has an apparent density of greater than or equal to 40gsm/mm, greater than or equal to 50gsm/mm, greater than or equal to 60gsm/mm, greater than or equal to 70gsm/mm, greater than or equal to 80gsm/mm, greater than or equal to 90gsm/mm, greater than or equal to 100gsm/mm, greater than or equal to 110gsm/mm, greater than or equal to 120gsm/mm, greater than or equal to 130gsm/mm, greater than or equal to 150gsm/mm, greater than or equal to 175gsm/mm, greater than or equal to 200gsm/mm, greater than or equal to 250gsm/mm, greater than or equal to 300gsm/mm, greater than or equal to 400gsm/mm, or greater than or equal to 500 gsm/mm. In some embodiments, the battery separator has an apparent density of less than or equal to 600gsm/mm, less than or equal to 500gsm/mm, less than or equal to 400gsm/mm, less than or equal to 300gsm/mm, less than or equal to 250gsm/mm, less than or equal to 200gsm/mm, less than or equal to 175gsm/mm, less than or equal to 150gsm/mm, less than or equal to 130gsm/mm, less than or equal to 120gsm/mm, less than or equal to 110gsm/mm, less than or equal to 100gsm/mm, less than or equal to 90gsm/mm, less than or equal to 80gsm/mm, less than or equal to 70gsm/mm, less than or equal to 60gsm/mm, or less than or equal to 50 gsm/mm. Combinations of the above ranges are also possible (e.g., greater than or equal to 40gsm/mm and less than or equal to 600gsm/mm, greater than or equal to 40gsm/mm and less than or equal to 200gsm/mm, greater than or equal to 60gsm/mm and less than or equal to 200gsm/mm, or greater than or equal to 150gsm/mm and less than or equal to 150 gsm/mm). Other ranges are also possible. The apparent density of the battery separator may be determined by: the basis weight and thickness of the battery separator are derived as described elsewhere herein, and then the basis weight of the battery separator is divided by the thickness of the battery separator. When the battery separator has a three-dimensional structure and/or includes protrusions and/or ribs, the thickness of the battery separator is understood to be the thickness of the three-dimensional structure of the battery separator (i.e., its thickness after being molded to have a three-dimensional structure) and should include any protrusions (e.g., including any convolutions, bends, undulations, pleats, and/or ribs).

In some embodiments, the battery separator exhibits a relatively high lifetime when subjected to an electrochemical oxidation test according to IS 6071-1986. The test involves exposing the battery separator to an overcharge condition until the voltage drop across the battery separator is 0V. Overcharging the cell results in the release of oxygen at the positive electrode, which causes the electrolyte to become oxidized. As the electrolyte becomes oxidized, the battery separator degrades and its resistivity decreases. This results in a reduced voltage drop across the cell separator. When the measured voltage drop across the battery separator is 0V, it shows no resistance to current lumens. Lifetime is the time that elapses between the beginning of the exposure of the battery separator to an overcharge condition and the moment the voltage drop across the battery separator is 0V.

In some embodiments, the battery separator exhibits the following lifetimes when subjected to an electrochemical oxidation test according to IS 6071-1986: greater than or equal to 500 hours, greater than or equal to 600 hours, greater than or equal to 700 hours, greater than or equal to 800 hours, greater than or equal to 900 hours, greater than or equal to 1000 hours, greater than or equal to 2000 hours, greater than or equal to 3000 hours, greater than or equal to 4000 hours, greater than or equal to 5000 hours, greater than or equal to 6000 hours, greater than or equal to 7000 hours, greater than or equal to 8000 hours, or greater than or equal to 9000 hours. In some embodiments, the battery separator exhibits the following lifetimes when subjected to an electrochemical oxidation test according to IS 6071-1986: less than or equal to 10000 hours, less than or equal to 9000 hours, less than or equal to 8000 hours, less than or equal to 7000 hours, less than or equal to 6000 hours, less than or equal to 5000 hours, less than or equal to 4000 hours, less than or equal to 3000 hours, less than or equal to 2000 hours, less than or equal to 1000 hours, less than or equal to 900 hours, less than or equal to 800 hours, less than or equal to 700 hours, or less than or equal to 600 hours. Combinations of the above ranges are possible (e.g., greater than or equal to 500 hours and less than or equal to 10000 hours, greater than or equal to 700 hours and less than or equal to 10000 hours, or greater than or equal to 1000 hours and less than or equal to 10000 hours). Other ranges are also possible.

As described above, some embodiments relate to lead acid batteries, such as lead acid batteries including the battery separators described herein. However, battery separators may also be used for other battery types, and reference herein to a lead acid battery should not be construed as limiting. Lead-acid batteries generally include a first battery plate (e.g., a negative battery plate) comprising lead and a second battery plate (e.g., a positive battery plate) comprising lead dioxide. During discharge, electrons are transferred from the first battery plate to the second battery plate while the lead paste in the first battery plate is oxidized to form lead sulfate and the lead dioxide in the second battery plate is reduced to also form lead sulfate. During charging, electrons are transferred from the second battery plate to the first battery plate while the lead sulfate in the first battery plate is reduced to form lead and the lead sulfate in the second battery plate is oxidized to form lead dioxide. The lead-acid battery can also include an electrolyte (e.g., an electrolyte comprising sulfuric acid) configured to transport sulfate ions between the first and second battery plates upon charging during discharging. One or more battery separators may be placed between the first battery plate and the second battery plate.

Fig. 7 illustrates one non-limiting embodiment of a lead-acid battery including a battery separator. In fig. 7, a lead acid battery includes battery separator 107 and battery plates 207 and 307. It should be understood that some embodiments may relate to lead acid batteries including blade separators (e.g., as shown in fig. 7), and some embodiments may relate to lead acid batteries including other types of separators (e.g., folded separators, pouch separators). It should also be understood that some embodiments may be directed to batteries that include additional components (e.g., a second separator, electrolyte, housing, external wiring, etc.) in addition to those shown in fig. 7. Such components are described in further detail below.

Some embodiments relate to lead acid batteries that are flooded batteries, such as flooded batteries that include one or more of the battery separators described herein. The rich liquid type battery may be a conventional rich liquid type battery, or may be an extended rich liquid type battery. In some embodiments, the flooded cell is unsealed and gases generated therein (e.g., during discharge, during charge) are vented to the environment surrounding the cell through one or more vents therein. Additionally or alternatively, the vents may allow acids, vapors, condensates, and/or other substances to flow into and/or out of the flooded cell. Extended flooded batteries may have several advantages over other types of lead acid batteries. For example, the extended rich battery may exhibit a partial state of charge and deep cycle performance that is two times greater than conventional lead-acid batteries, may be capable of providing power during a large number of engine starts and/or extended engine off periods, may exhibit improved charge acceptance over conventional lead-acid batteries, may be designed to withstand a hot environment (e.g., engine room, hot climate), and/or may be particularly suitable for start-stop vehicle technology with limited energy regeneration.

The battery plates (e.g., first battery plate, negative battery plate, second battery plate, positive battery plate) described herein generally include a battery paste disposed on a grid. The battery paste included in the first battery plate (e.g., the negative battery plate) may include lead, and/or may include both lead and lead dioxide (e.g., prior to full charge, during manufacturing, battery assembly, and/or during one or more portions of the methods described herein). The battery paste included in the second battery plate (e.g., the positive battery plate) may include lead dioxide, and/or may include both lead and lead dioxide (e.g., prior to full charge, during manufacture, during battery assembly, and/or during one or more portions of the methods described herein). In some embodiments, the grid (e.g., the grid included in the first battery plate, the grid included in the negative battery plate, the grid included in the second battery plate, the grid included in the positive battery plate) comprises lead and/or a lead alloy.

In some embodiments, one or more battery plates (e.g., first battery plate, negative battery plate, second battery plate, positive battery plate) may also include one or more additional components. For example, the battery plate may include a reinforcing material, such as an extender. When present, the extender may comprise barium sulfate, carbon black and lignosulfonate as the main components. The components of the extender (e.g., carbon black and/or lignosulfonate, and/or any other components, if present) may or may not be pre-mixed. IN some embodiments, the battery plate may comprise a commercially available extender, such as an extender produced by Hammond Lead Products (Hammond, IN) (e.g.,extenders) or extenders manufactured by Atomized Products Group, Inc (Garland, TX). Additional examples of reinforcing materials include chopped organic fibers (e.g., average length of 0.125 inches or more), chopped glass fibers, metal sulfates (e.g., nickel sulfate, copper sulfate), red lead (e.g., containing Pb)₃O₄The material of (d), lead monoxide and paraffin oil.

It should be understood that while the additional components described above may be present in any combination of battery plates in a battery (e.g., in a first battery plate or negative battery plate and a second battery plate or positive battery plate, in a first battery plate or negative battery plate but not in a second battery plate or positive battery plate, in a second battery plate or positive battery plate but not in a first battery plate or negative battery plate, not in a battery plate), some additional components may be particularly advantageous for certain types of battery plates. For example, extenders, metal sulfates, and paraffins may be particularly advantageous for use in a second battery plate or a positive battery plate. One or more of these components may be present in the second or positive battery plate and not in the first or negative battery plate. Some of the additional components described above may have utility in many types of battery plates (e.g., first battery plate, negative battery plate, second battery plate, positive battery plate). Non-limiting examples of such components include fibers (e.g., chopped organic fibers, chopped glass fibers). In some embodiments, these components may be present in both the first and second battery plates, and/or may be present in both the negative and positive battery plates.

The webs (e.g., nonwoven webs) and battery separators described herein may be produced using a suitable process (e.g., a wet-laid process). Typically, a wet-laid process involves mixing one or more types of fibers together; for example, a plurality of non-fibrillated synthetic fibers (e.g., acetate fibers) may be mixed together with a plurality of fibrillated fibers and/or a plurality of multicomponent fibers to provide a fiber slurry. The slurry may be, for example, a water-based slurry. In some embodiments, the fibers are stored in various storage tanks, optionally alone or in combination, before being mixed together.

For example, each of a plurality of fibers or fiber types may be mixed together and pulped in a separate vessel. As an example, a plurality of non-fibrillated synthetic fibers may be mixed together and pulped in one vessel, and a plurality of fibrillated synthetic fibers may be mixed and pulped in a second vessel. A plurality of fibers may then be combined together into a single fiber blend. Suitable fibers can be processed through a pulper before and/or after being mixed together. In some embodiments, the combination of fibers is processed through a pulper and/or storage tank before being mixed together. It will be appreciated that other components may also be introduced into the mixture. Further, it is understood that other combinations of fiber types, such as those described herein, may be used in the fiber mixture.

In some embodiments, the fiber web may be formed by a wet-laid process. For example, in some embodiments, a single dispersion (e.g., pulp) or slurry in a solvent (e.g., an aqueous solvent such as water) may be applied to a wire belt of a papermaking machine (e.g., a fourdrinier papermaking machine or a rotary former) to form a single layer supported by the wire belt. The application of vacuum to the dispersion of fibers may be continued during the above process to remove the solvent from the fibers, thereby producing an article comprising a monolayer. In some embodiments, multiple layers may be formed simultaneously or sequentially in a wet-laid process. For example, the first layer may be formed as described above, and then one or more layers may be formed on the first layer by following the same steps. As an example, a slurry or dispersion in a solvent may be applied to a first layer on a mesh conveyor belt, and a vacuum is applied to the slurry or dispersion to form a second layer on the first layer. Additional layers may be formed on the first and second layers by following this same process.

Any suitable method for producing a fiber slurry may be used. In some embodiments, additional additives are added to the slurry to facilitate processing. The temperature may also be adjusted to a suitable range, such as 33 ° F to 140 ° F (e.g., 50 ° F to 85 ° F). In some cases, the temperature of the slurry is maintained. In some cases, the temperature is not actively adjusted.

In some embodiments, the wet-laid process uses similar equipment as in conventional papermaking processes, such as a hydropulper, a former or headbox, a dryer, and optionally a converter. In some cases, the fiber web and/or battery separator may also be manufactured with a laboratory handsheet mold. As described above, the pulp may be prepared in one or more pulpers. After the slurry is properly mixed in the pulper, the slurry may be pumped into a headbox where it may or may not be combined with other slurries. Other additives may or may not be added. The slurry may also be diluted with additional water such that the final concentration of fibers is within a suitable range, such as from about 0.1 wt% to 0.5 wt%.

In some cases, the pH of the fiber slurry may be adjusted as desired. For example, the fibers of the slurry may be dispersed under acidic or neutral conditions.

The slurry may optionally be passed through a centrifugal cleaner and/or a pressure screen to remove undesirable materials (e.g., non-fiberized materials) prior to being sent to the headbox. The slurry may or may not be passed through additional equipment (e.g., a refiner or fluffer) to further enhance the dispersion of the fibers. For example, fluffers may be used to smooth out or remove lumps or protrusions that may occur at any point during the formation of the fiber slurry. The fibers may then be collected onto a screen or wire at an appropriate rate using any suitable equipment (e.g., a fourdrinier, rotary former, or inclined wire fourdrinier).

In some embodiments, a non-wet-laid process (e.g., an air-laid process or a carding process) may be used to form a web (e.g., a nonwoven web) and/or a battery separator. For example, a web may be formed by blowing fibers onto a conveyor belt in an air-laying process. As another example, the web may be formed by a carding process, in which the fibers are manipulated by a roller and extensions (e.g., hooks, needles) associated with the roller.

In some embodiments, one or more additional processes may be performed after the web is formed (e.g., to form additional layers on the web to incorporate one or more additional components into the web). For example, the web may be exposed to a slurry comprising one or more components (e.g., one or more types of particles). The web may be immersed in the slurry and/or the slurry may be deposited onto the web. After the web is exposed to the slurry, excess slurry may be removed.

As another example of an additional process, a portion (or all) of the water remaining in the web may be removed. This can be accomplished by drying the web until it has the desired weight percent moisture. In some embodiments, the web is dried using an oven, a drying can, and/or a Yankee dryer (Yankee dryer).

As a third example, the web may be calendered. Calendering the web can include compressing the web using a calender roll while moving the web. In some embodiments, the pressure applied by the calender rolls is from 500psi to 800psi (e.g., 550psi to 750psi, 550psi to 700psi, 550psi to 650psi, 550psi to 600psi, 600psi to 750psi, 600psi to 700psi, 650psi to 750psi, 700psi to 750 psi); the calender roll has a temperature of 40 ℃ to 120 ℃ (e.g., 40 ℃ to 85 ℃, 50 ℃ to 85 ℃, 60 ℃ to 85 ℃, 65 ℃ to 75 ℃, 70 ℃ to 85 ℃, 35 ℃ to 80 ℃, 35 ℃ to 70 ℃, 35 ℃ to 60 ℃, 35 ℃ to 50 ℃); and/or the web is moved at a line speed of 5 feet per minute to 100 feet per minute (e.g., 5 feet per minute to 80 feet per minute, 10 feet per minute to 50 feet per minute, 15 feet per minute to 100 feet per minute, 15 feet per minute to 25 feet per minute, or 20 feet per minute to 90 feet per minute). Other ranges of pressure, temperature and linear velocity are also possible.

After the battery separator is formed, a battery including the battery separator may be assembled. The final assembled battery may also include other components, such as a first battery plate and a second battery plate. These components may be placed in a housing and optionally compressed. If compressed, the thickness of one or more battery components may decrease. An electrolyte, such as 1.28spg sulfuric acid, may then be added to the cell.

After assembly, the battery may undergo a forming step during which the battery becomes fully charged and ready for operation. Shaping may include passing current through an assembly of alternating negative and positive battery plates separated by separators. During forming, the battery paste in the negative and positive battery plates may be converted into negative and positive active materials, respectively. For example, lead dioxide in a battery paste disposed on a negative battery plate may be converted to lead, and/or lead in a battery paste disposed on a positive battery plate may be converted to lead dioxide.

Example 1

This example describes the manufacture and characterization of four battery separators that may be suitable for extended flooded battery applications. The separator has high porosity, high puncture and tensile strength, and is formed from components that do not exhibit significant leaching in a lead acid battery.

Battery separators a-C are made by wet-laying a mixture of synthetic fibrillated fibers and synthetic bicomponent fibers to form a nonwoven web. The battery separator D is manufactured by wet-laying a mixture of synthetic fibrillated fibers, synthetic bicomponent fibers, and poly (ester) fibers. The synthetic fibrillated fibers had an average length of 0.9mm and an average parent fiber diameter of 5 microns. The synthetic bicomponent fibers have an average length of 6mm and an average diameter of 10 to 13 microns. The poly (ester) fibers had an average length of 3mm and an average diameter of 2.5 microns. Table 1 below shows the relative amounts of each fiber type in the battery separator. Table 2 below shows selected physical properties of the battery separator.

The battery separator E is manufactured by carding a mixture of synthetic bicomponent fibers and poly (ester) fibers and then thermally bonding. The synthetic bicomponent fibers have an average length of 38mm and an average diameter of 12 to 13 microns. The polyester fibers had an average length of 3mm and an average diameter of 2.5 microns.

Table 1.

Table 2.

While several embodiments of the present invention have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and/or structures for performing the functions and/or obtaining the results and/or one or more of the advantages described herein, and each of such variations and/or modifications is deemed to be within the scope of the present invention. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the teachings of the present invention is/are used. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the invention described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, the invention may be practiced otherwise than as specifically described and claimed. The present invention is directed to each individual feature, system, article, material, kit, and/or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and/or methods, if such features, systems, articles, materials, kits, and/or methods are not mutually inconsistent, is included within the scope of the present invention.

All definitions, as defined and used herein, should be understood to take precedence over dictionary definitions, definitions in documents incorporated by reference, and/or ordinary meanings of the defined terms.

The indefinite articles "a" and "an" as used herein in the specification and in the claims are to be understood as meaning "at least one" unless expressly specified to the contrary.

The phrase "and/or" as used herein in the specification and in the claims should be understood to mean "either or both" of the elements so combined, i.e., the elements that are present together in some cases and separately in other cases. Multiple elements recited with "and/or" should be understood in the same way, i.e., "one or more" of such associated elements. In addition to the elements specifically identified by the "and/or" clause, other elements may optionally be present, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, when used in conjunction with open language such as "comprising," a reference to "a and/or B" may refer in one embodiment to a alone (optionally including elements other than B); may refer to B alone (optionally including elements other than a) in another embodiment; and in yet another embodiment may refer to both a and B (optionally including other elements); and so on.

As used herein in the specification and in the claims, "or" should be understood to have the same meaning as "and/or" as defined above. For example, when separating items in a list, "or" and/or "should be understood as being inclusive, i.e., including at least one of the plurality of elements or list of elements, but also including more than one of the plurality of elements, and optionally including additional unrecited items. Merely explicitly stating the opposite term, such as "only one" or "exactly one," or "consisting of … … when used in a claim, means including exactly one of a plurality or list of elements. In general, the term "or" as used herein should only be understood to mean an exclusive alternative (i.e., "one or the other, but not both") when there are exclusive terms such as "any," "one," "only one," or "exactly one" in the foregoing. "consisting essentially of … …" when used in a claim shall have its ordinary meaning as used in the patent law field.

As used herein in the specification and in the claims, the phrase "at least one," when referring to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but does not necessarily include at least one of each and every element specifically listed in the list of elements, and does not exclude any combination of elements in the list of elements. The definition also allows that elements other than those specifically identified in the list of elements referred to by the phrase "at least one" may optionally be present, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, "at least one of a and B" (or, equivalently, "at least one of a or B," or, equivalently, "at least one of a and/or B") can refer, in one embodiment, to at least one a, optionally including more than one a, with no B present (and optionally including elements other than B); in another embodiment, it may refer to at least one B, optionally including more than one B, with no a present (and optionally including elements other than a); in yet another embodiment, it may refer to at least one a, optionally including more than one a, and at least one B, optionally including more than one B (and optionally including other elements); and so on.

It will also be understood that, unless explicitly stated to the contrary, in any methods claimed herein that include more than one step or action, the order of the steps or actions of the method is not necessarily limited to the order in which the steps or actions of the method are recited.

In the claims, as well as in the specification above, all transitional phrases such as "comprising," including, "" carrying, "" having, "" containing, "" involving, "" holding, "" consisting of … … and the like are to be understood to be open-ended, i.e., to mean including but not limited to. As described in the united states patent office patent examination program manual, section 2111.03, the transitional phrases "consisting of … …" and "consisting essentially of … …" alone should be closed or semi-closed transitional phrases, respectively.

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Separator for lead acid battery

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