Battery components comprising fibers
Battery components are generally provided. In some embodiments, the battery components can be used as pasting paper and/or capacitance layers for batteries, such as lead acid batteries. The battery components described herein may comprise a plurality of fibers. The battery component may include, in some embodiments, a plurality of fibers and, optionally, one or more additives such as conductive carbon and/or activated carbon. In certain embodiments, the plurality of fibers include relatively coarse glass fibers (e.g., having an average diameter of greater than or equal to 2 microns), relatively fine glass fibers (e.g., having an average diameter of less than 2 microns), and/or fibrillated fibers. In some instances, such fibers may be present in amounts such that the battery component has a particular surface area, mean pore size, and/or dry tensile strength.
1. A battery component, comprising:
a plurality of fine glass fibers having an average fiber diameter of less than 2 microns, wherein the plurality of fine glass fibers are present in an amount greater than or equal to 30 wt % and less than or equal to 60 wt % versus the total weight of the battery component;
a plurality of coarse glass fibers having an average fiber diameter of greater than or equal to 2 microns, wherein the plurality of coarse glass fibers are present in an amount greater than or equal to 30 wt % and less than or equal to 60 wt % versus the total weight of the battery component;
a plurality of fibrillated fibers present in an amount greater than or equal to 1 wt % and less than or equal to 15 wt % versus the total weight of the battery component;
a resin present in an amount greater than or equal to 1 wt % and less than or equal to 10 wt % versus the total weight of the battery component; and
a plurality of bicomponent fibers present in an amount of greater than 0 wt % and less than or equal to 8 wt % versus the total weight of the battery component, wherein the battery component has a surface area of greater than or equal to 0.5 m 2 /g and less than or equal to 100 m 2 /g.
2. A battery plate, comprising:
a lead grid; and
a battery component as in claim 1 .
3. A battery component as in claim 1 , wherein the battery component comprises activated carbon and conductive carbon.
4. A battery component as in claim 1 , wherein the battery component comprises a hydrogen suppressant in an amount of less than or equal to 2 wt % versus the total weight of the battery component.
5. A battery component as in claim 1 , wherein the total weight of fine glass fibers and coarse glass fibers is less than or equal to 98 wt % versus the total weight of the battery component.
6. A battery component as in claim 1 , wherein the plurality of fine glass fibers have an average fiber diameter of less than or equal to 1 micron.
7. A battery component as in claim 1 , wherein the plurality of coarse glass fibers have an average fiber diameter of greater than 5 microns.
8. A battery component as in claim 1 , wherein the plurality of fibrillated fibers have an average length of less than or equal to 25 mm.
9. A battery component as in claim 1 , wherein the plurality of fibrillated fibers have a Canadian Standard Freeness (CSF) of greater than or equal to 20 CSF and less than or equal to 650 CSF.
10. A battery component as in claim 1 , wherein the plurality of fibrillated fibers comprise cellulose-based fibers, acrylics, liquid crystalline polymers, polyoxazoles, aramids, p-aramids, polyethylenes, polyesters, polyamides, cotton, polyolefins, and/or olefins.
11. A battery component as in claim 1 , wherein the resin is a hydrophobic resin.
12. A battery component as in claim 1 , wherein the battery component has a basis weight of greater than or equal to 10 g/m 2 and less than or equal to 200 g/m 2 .
13. A battery component as in claim 1 , wherein the battery component has a specific surface area of greater than or equal to 0.2 m 2 /g and less than or equal to 5 m 2 /g.
14. A battery component as in claim 1 , wherein the battery component has a maximum pore size greater than or equal to 5 microns and less than or equal to 100 microns.
15. A battery component as in claim 1 , wherein the battery component has a mean pore size of greater than or equal to 0.1 microns and less than or equal to 15 microns.
16. A battery component as in claim 1 , wherein the battery component has a dry tensile strength of greater than or equal to 0.1 pounds per inch and less than or equal to 15 pounds per inch.
17. A battery component, comprising:
a plurality of fine glass fibers having an average fiber diameter of less than 2 microns, wherein the plurality of fine glass fibers are present in an amount greater than or equal to 30 wt % and less than or equal to 60 wt % versus the total weight of the battery component;
a plurality of coarse glass fibers having an average fiber diameter of greater than or equal to 2 microns, wherein the plurality of coarse glass fibers are present in an amount greater than or equal to 30 wt % and less than or equal to 60 wt % versus the total weight of the battery component;
a plurality of fibrillated fibers present in an amount greater than or equal to 1 wt % and less than or equal to 15 wt % versus the total weight of the battery component; and
a resin present in an amount greater than or equal to 1 wt % and less than or equal to 10 wt % versus the total weight of the battery component,
wherein the battery component has an air permeability of greater than or equal to 1 CFM and less than or equal to 1000 CFM, and
wherein the battery component has a surface area of greater than or equal to 0.5 m 2 /g and less than or equal to 100 m 2 /g.
18. A battery component, comprising:
a plurality of fine glass fibers having an average fiber diameter of less than 2 microns, wherein the plurality of fine glass fibers are present in an amount greater than or equal to 30 wt % and less than or equal to 60 wt % versus the total weight of the battery component;
a plurality of coarse glass fibers having an average fiber diameter of greater than or equal to 2 microns, wherein the plurality of coarse glass fibers are present in an amount greater than or equal to 30 wt % and less than or equal to 60 wt % versus the total weight of the battery component;
a plurality of fibrillated fibers present in an amount greater than or equal to 1 wt % and less than or equal to 15 wt % versus the total weight of the battery component; and
a resin present in an amount greater than or equal to 1 wt % and less than or equal to 10 wt % versus the total weight of the battery component,
wherein the resin is hydrophobic, and
wherein the battery component has a surface area of greater than or equal to 0.5 m 2 /g and less than or equal to 100 m 2 /g.
19. A battery component, comprising:
a plurality of fine glass fibers having an average fiber diameter of less than 2 microns;
a plurality of coarse glass fibers having an average fiber diameter of greater than or equal to 2 microns; and
a plurality of fibrillated fibers,
wherein the battery component has a surface area of greater than or equal to 0.5 m 2 /g and less than or equal to 100 m 2 /g,
wherein the battery component has a mean pore size of greater than or equal to 0.1 microns and less than or equal to 15 microns, and
wherein the battery component has a dry tensile strength in the machine direction of greater than or equal to 0.1 lbs. per inch and less than or equal to 15 lbs. per inch.
20. A lead acid battery comprising,
a negative plate;
a positive plate; and
a battery component as in claim 1 disposed between the negative and positive plates.