To provide a convenient and effective method for suppressing the penetration of dendrite over the microporous film mainly containing the base portion, which occupies the most part of the entire separator (total area), rather than the peculiar concept (resulting in a difficult measure), in which only the pore structure of the rib portion is densified or contracted for suppressing dendrite from penetrating through the rib portion. A separator for a lead-acid battery, containing a microporous film obtained in such a manner that a raw material composition mainly containing a polyolefin resin, silica powder, and a plasticizer is melt-kneaded and formed into a film, from which the plasticizer is entirely or partially removed, the raw material composition containing glass flakes having an average particle diameter of from 20 to 800 m and an average thickness of 0.2 to 8 m and having no self-film formability in an amount of from 2 to 15% by weight based on a total amount of the silica powder and the glass flakes, the glass flakes in the microporous film being disposed in such a manner that a plane direction thereof is substantially oriented in a plane direction of the microporous film, a value of (the content of the glass flakes in the microporous film)/(the average thickness of the glass flakes in the microporous film) being 1 or more.

To provide a convenient and effective method for suppressing the penetration of dendrite over the microporous film mainly containing the base portion, which occupies the most part of the entire separator (total area), rather than the peculiar concept (resulting in a difficult measure), in which only the pore structure of the rib portion is densified or contracted for suppressing dendrite from penetrating through the rib portion. A separator for a lead-acid battery, containing a microporous film obtained in such a manner that a raw material composition mainly containing a polyolefin resin, silica powder, and a plasticizer is melt-kneaded and formed into a film, from which the plasticizer is entirely or partially removed, the raw material composition containing glass flakes having an average particle diameter of from 20 to 800 m and an average thickness of 0.2 to 8 m and having no self-film formability in an amount of from 2 to 15% by weight based on a total amount of the silica powder and the glass flakes, the glass flakes in the microporous film being disposed in such a manner that a plane direction thereof is substantially oriented in a plane direction of the microporous film, a value of (the content of the glass flakes in the microporous film)/(the average thickness of the glass flakes in the microporous film) being 1 or more.

An electrode assembly for a high cycling battery is disclosed. The electrode assembly includes a separator envelope comprising a backweb of material. The backweb has opposing sides, a contact area including a plurality of vertical, continuous major ribs of substantially the same height spaced across the contact area and projecting from one of the opposing sides forming acid conduits therebetween. A rim area is provided on each respective end of the contact area and has a plurality of vertical shoulder ribs. The backweb of material is folded and each rim area, aligned by the folding of the backweb, at least partially secured to itself to form the separator envelope. A negative electrode is received in the separator envelope and a positive electrode is positioned adjacent to the negative electrode, separated from the negative electrode by the separator envelope. A separator and plate assembly and a lead-acid battery are also disclosed.

A process of forming a cross-linked electronically active hydrophilic co-polymer is provided and includes the steps of: a. mixing an intrinsically electronically active material with water to form an intermediate mixture; b. adding at least one hydrophilic monomer, at least one hydrophobic monomer, and at least one cross-linker to the intermediate mixture to form a co-monomer mixture; and c. polymerising the co-monomer mixture.

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).

In accordance with at least selected embodiments or aspects, the present invention is directed to improved, unique, and/or high performance ISS lead acid battery separators, such as improved ISS flooded lead acid battery separators, ISS batteries including such separators, methods of production, and/or methods of use. The preferred ISS separator may include negative cross ribs and/or PIMS minerals. In accordance with more particular embodiments or examples, a 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 selected embodiments or aspects, the present invention is directed to improved, unique, and/or high performance ISS lead acid battery separators, such as improved ISS flooded lead acid battery separators, ISS batteries including such separators, methods of production, and/or methods of use. The preferred ISS separator may include negative cross ribs and/or PIMS minerals. In accordance with more particular embodiments or examples, a 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 battery has anodes, cathodes, separators, and electrolyte. Particles of loose hydrated alkali aluminum silicate contact the anodes and cathodes and are immersed in the electrolyte, to enhance operability of the battery. The maximum dimensions of at least a majority of the particles are between about 5-10 mm, and they range in shape from spherical to irregular.

Electrical energy storage device for powering portable devices such as vehicles or consumer electronics includes barriers to minimize migration of thermal energy and propagation of combustion in the rare event that electrical energy storage cells fail, burst and ignite. A burst structure is provided to vent gas from the device in a desired direction in the event pressure within the device exceeds a maximum value. Biased vents permit gases emanating from a portable electrical energy storage cell within an electrical energy storage module to escape and isolate other electrical energy storage cells from the gases.