Embossed separators, batteries and methods
An improved, new, modified, or more robust embossed battery separator for a storage battery, a method for its production, an envelope embossed separator, batteries including the embossed separators and/or envelopes, and/or related methods for the production and/or use of the embossed separators, embossed envelopes, and/or batteries including such embossed separators and/or envelopes.
1. A battery separator for a storage battery comprising:
a microporous membrane having at least one embossed rib and a densified rigid internal skeletal frame;
wherein said at least one embossed rib runs in a longitudinal direction; and
wherein said densified rigid internal skeletal frame comprises compressed transverse ribs of lesser height than said at least one embossed rib.
2. The battery separator of claim 1 wherein said at least one embossed rib is sinusoidal.
3. The battery separator of claim 1 wherein said microporous membrane comprising a mixture of a thermoplastic polymer and a filler, and having a plurality of micropores therethrough.
4. The battery separator of claim 1 wherein said microporous membrane comprises a mixture of a thermoplastic polymer, a filler, and a pore former.
5. The battery separator of claim 1 wherein said microporous membrane exhibits a 5% or less change over time in a parameter selected from the group consisting of thickness, resiliency, and/or compression.
6. The battery separator of claim 1 further comprising a pasting paper adhered to at least one face of the microporous membrane.
7. The battery separator of claim 6 wherein said pasting paper comprises a nonwoven material.
8. The battery separator of claim 6 wherein said pasting paper comprises at least one rib co-embossed with said microporous membrane.
9. A battery comprising the separator of claim 8 .
10. The battery separator of claim 6 further comprising a gelling agent adhered to said pasting paper.
11. A battery comprising the separator of claim 6 .
12. The battery separator of claim 1 further comprising a nonwoven adhered to a face of the microporous membrane.
13. The battery separator of claim 12 wherein said nonwoven comprises at least one of a gelling agent, sodium sulfate, chemically active minerals, or carbonaceous materials.
14. The battery separator of claim 12 wherein said nonwoven comprises at least one rib co-embossed with said microporous membrane.
15. A battery comprising the separator of claim 14 .
16. A battery comprising the separator of claim 12 .
17. The battery separator of claim 1 further comprising co-embossed material adhered to a face of said microporous membrane.
18. The battery separator of claim 1 wherein said microporous membrane being in a form selected from the group consisting of an envelope, a leaf, or a wrapping.
19. A battery comprising the separator of claim 1 .
20. The battery separator of claim 1 wherein said densified rigid internal skeletal frame comprises compressed membrane longitudinal calendered ribs of lesser height than said at least one embossed rib.
21. A battery comprising the separator of claim 20 .
22. A battery separator for a storage battery comprising:
a microporous membrane having an embossed rib and a densified rigid internal skeletal frame;
wherein said embossed rib runs in a longitudinal direction;
wherein said densified rigid internal skeletal frame comprises compressed, calendered membrane longitudinal ribs and transverse ribs;
wherein said membrane longitudinal ribs are of lesser height than said embossed rib; and
wherein said membrane transverse ribs are of lesser height than said longitudinal ribs.
23. A battery comprising the separator of claim 22 .
24. The battery separator of claim 22 further comprising a pasting paper adhered to a face of the microporous membrane.
25. A storage battery comprising the separator of claim 24 .
26. The battery separator of claim 22 further comprising a nonwoven adhered to a face of the microporous membrane.
27. The battery separator of claim 26 wherein said nonwoven comprises least one of a gelling agent, sodium sulfate, chemically active minerals, or carbonaceous materials.
28. A storage battery comprising the separator of claim 27 .
29. A storage battery comprising the separator of claim 26 .