Batteries, separators, components and compositions with heavy metal removal capability and related methods
View Patent ↗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.
1. A lead acid battery separator having a front face and a reverse face, the separator comprising
a porous, silica filled, polymer membrane having a backweb with integral ribs, wherein the ribs comprise of positive ribs on the front face, and a plurality of negative cross ribs on the reverse face, and
wherein the polymer membrane further comprises apatite particles and/or hydroxyapatite particles, said particles binding at least a portion of heavy metal, said heavy metal including lead.
2. The battery separator of claim 1 , wherein the positive ribs are longitudinal ribs.
3. The battery separator of claim 2 , wherein the negative cross ribs are shorter and more tightly spaced than the longitudinal ribs.
4. The battery separator of claim 1 , wherein the negative cross ribs have a spacing of from 0.254 mm to 1.27 mm.
5. The battery separator of claim 1 , wherein the negative cross ribs have a radius of from 0.0508 mm to 0.152 mm.
6. The battery separator of claim 3 , wherein the negative cross ribs are transversely extending.
7. The battery separator of claim 1 , wherein the negative cross ribs comprise fissures or recesses to form channels in the separator.
8. The battery separator of claim 1 , wherein the separator has an overall thickness of from 0.2 to 4 mm.
9. The battery separator of claim 1 , wherein the particles have a D 50 particle size from 10 microns to 80 microns.
10. The battery separator of claim 1 , wherein the separator is a porous polyethylene and silica filled battery separator having the particles substituted for at least a portion of the silica filler.
11. In a battery, the improvement comprising the battery separator of claim 1 .
12. The battery according to claim 11 , wherein the battery is a flooded lead acid battery.
13. The battery according to claim 11 , wherein the battery is an enhanced flooded lead acid battery (EFB).
14. In a battery, the improvement comprising the battery separator of claim 3 .
15. The battery according to claim 14 , wherein the battery is a flooded lead acid battery.
16. In a battery, the improvement comprising the battery separator of claim 6 .
17. The battery according to claim 16 , wherein the battery is a flooded lead acid battery.
18. The lead acid battery separator of claim 1 ,
wherein the positive ribs are longitudinal ribs, the negative cross ribs are shorter and more tightly spaced than the longitudinal ribs, and the negative cross ribs are transversely extending.