A non-woven fiber mat for lead-acid batteries is provided. The non-woven fiber pasting mat includes glass fibers coated with a sizing composition; a binder composition; and one or more additives. The additives reduce water loss in lead-acid batteries.

In accordance with at least certain embodiments of the present invention, a novel concept of utilizing PIMS minerals as a filler component within a microporous lead-acid battery separator is provided. In accordance with more particular embodiments or examples, the PIMS mineral (preferably fish meal, a bio-mineral) is provided as at least a partial substitution for the silica filler component in a silica filled lead acid battery separator (preferably a polyethylene/silica separator formulation). In accordance with at least selected embodiments, the present invention is directed to new or improved batteries, separators, components, and/or compositions having heavy metal removal capabilities and/or methods of manufacture and/or methods of use thereof.

In accordance with at least certain embodiments of the present invention, a novel concept of utilizing PIMS minerals as a filler component within a microporous lead-acid battery separator is provided. In accordance with more particular embodiments or examples, the PIMS mineral (preferably fish meal, a bio-mineral) is provided as at least a partial substitution for the silica filler component in a silica filled lead acid battery separator (preferably a polyethylene/silica separator formulation). In accordance with at least selected embodiments, the present invention is directed to new or improved batteries, separators, components, and/or compositions having heavy metal removal capabilities and/or methods of manufacture and/or methods of use thereof.

A lead-acid battery has a plurality of individual cells and a plurality of measurement circuits which are mounted on the respective individual cells in a manner integrated in the lead-acid battery. Each measurement circuit is designed to measure a respective individual cell voltage. A method is provided for measuring individual cell voltages of the lead-acid battery having the plurality of measurement circuits integrated in the battery and arranged on the individual cells. In the method, the respective individual cell voltages are measured using the measurement circuits.

A lead-acid battery has a plurality of individual cells and a plurality of measurement circuits which are mounted on the respective individual cells in a manner integrated in the lead-acid battery. Each measurement circuit is designed to measure a respective individual cell voltage. A method is provided for measuring individual cell voltages of the lead-acid battery having the plurality of measurement circuits integrated in the battery and arranged on the individual cells. In the method, the respective individual cell voltages are measured using the measurement circuits.

Proton-conducting gel electrolytes with acid immobilized within a covalently cross-linked polymer network and composites containing the gel electrolytes provide low ionic resistance, minimize acid stratification, and prevent dendrite growth. The gel electrolytes can be formed from monomers dissolved in concentrated sulfuric acid and subsequently covalently cross-linked between the battery electrodes, or the covalently cross-linked gel electrolytes can be formed in water and subsequently exchanged into sulfuric acid. The mechanical properties of these gels can often be enhanced with the addition of silica powder, silica fiber, or other additives. In some cases, the covalently cross-linked gel electrolytes are formed in the presence of a conventional silica-filled polyethylene separator or within a low density fiber mat to provide mechanical reinforcement and controlled spacing between the battery electrodes. The covalently cross-linked gel electrolytes provide low ionic resistance, and increased power capacity of the battery, because the polymer networks can be formed at low concentrations (<20% solids).

Proton-conducting gel electrolytes with acid immobilized within a covalently cross-linked polymer network and composites containing the gel electrolytes provide low ionic resistance, minimize acid stratification, and prevent dendrite growth. The gel electrolytes can be formed from monomers dissolved in concentrated sulfuric acid and subsequently covalently cross-linked between the battery electrodes, or the covalently cross-linked gel electrolytes can be formed in water and subsequently exchanged into sulfuric acid. The mechanical properties of these gels can often be enhanced with the addition of silica powder, silica fiber, or other additives. In some cases, the covalently cross-linked gel electrolytes are formed in the presence of a conventional silica-filled polyethylene separator or within a low density fiber mat to provide mechanical reinforcement and controlled spacing between the battery electrodes. The covalently cross-linked gel electrolytes provide low ionic resistance, and increased power capacity of the battery, because the polymer networks can be formed at low concentrations (<20% solids).

A method of manufacturing an electrochemical cell having a gel electrolyte. An electrochemical cell is provided having a cell casing, and a first electrode, a second electrode, an electrolyte solution and a temperature activated gelling agent disposed within the cell casing. A gel electrolyte comprising the electrolyte solution and the gelling agent is formed by passing a current through the electrochemical cell such that the temperature of the gelling agent exceeds the activation temperature of the gelling agent.

The present invention provides a porous body which contains sheath-core type binder fibers and a resin binder, and which is characterized in that: the resin binder (the solid content) is contained in an amount of more than 5.0 parts by mass but less than 50 parts by mass relative to 100 parts by mass of the porous body; and if P (N) is the penetration strength of the porous body and B (g/m.sup.2) is the weight per square meter of the porous body, P and B satisfy P/B>0.070.

A battery separator has performance enhancing additives or coatings, fillers with increased friability, increased ionic diffusion, decreased tortuosity, increased wettability, reduced oil content, reduced thickness, decreased electrical resistance, and/or increased porosity. The separator in a battery reduces the water loss, lowers acid stratification, lowers the voltage drop, and/or increases the CCA. The separators include or exhibit performance enhancing additives or coatings, increased porosity, increased void volume, amorphous silica, higher oil absorption silica, higher silanol group silica, reduced electrical resistance, a shish-kebab structure or morphology, a polyolefin microporous membrane containing particle-like filler in an amount of 40% or more by weight of the membrane and ultrahigh molecular weight polyethylene having shish-kebab formations and the average repetition periodicity of the kebab formation from 1 nm to 150 nm, decreased sheet thickness, decreased tortuosity, separators especially well-suited for enhanced flooded batteries.