Granted Patent B2

US 12,562,434 · App. 17/596,748 · Granted Feb 24, 2026

Inventors: Kevin E. Siters (Cheektowaga, NY); Kenneth B. Miller (Lockport, NY); Daniel Brandel (Lancaster, NY); Mark D. Stahlman (Niagara Falls, NY); Mauricio Munhoz de Souza (Amherst, NY); Bruce K. Zoitos (Williamsville, NY); Adam Kelsall (Williamsville, NY); Chad D. Cannan (Spring, TX)

Assignee: UNIFRAX I LLC

H01M50/44H01M10/052H01M50/403H01M50/42H01M50/4295H01M50/437

Abstract

Claims (43)

1 . A nonwoven fiber mat, consisting of:

B-glass fibers having an average fiber diameter of less than 0.5 micron and a specific surface area of 5.0 to 7.0 m 2 /g;

a binder consisting of nanofibrillated cellulose, starch, or polyvinyl acetate; and

optionally one or more additives selected from:

a conditioning agent consisting of an alkoxylated alcohol or a polyamidoamine resin, and

an additional glass fiber type,

wherein the fiber mat has a thickness of about 10 to about 700 microns and a basis weight of about 1 to about 70 g/m 2 .

2 . The nonwoven fiber mat of claim 1 , wherein the B-glass fibers are present in an amount of about 50 to about 100 weight percent of the fiber mat.

3 . The nonwoven fiber mat of claim 1 , wherein the binder is present in an amount of up to 20 weight percent of the fiber mat.

4 . The nonwoven fiber mat of claim 1 , wherein the conditioning agent is present.

5 . The nonwoven fiber mat of claim 4 , wherein the conditioning agent is present in an amount of about 1 to about 20 weight percent of the fiber mat.

6 . The nonwoven fiber mat of claim 1 , wherein the additional glass fiber type is present.

7 . The nonwoven fiber mat of claim 6 , wherein the additional glass fiber type comprises a C-glass fiber.

8 . The nonwoven fiber mat of claim 1 , having a heat stability of up to 650° C.

9 . The nonwoven fiber mat of claim 1 , wherein the fiber mat has a thickness of about 10 to about 100 microns and a basis weight of about 1 to about 25 g/m 2 .

10 . The nonwoven fiber mat of claim 1 , wherein the fiber mat has a thickness of about 200 to about 700 microns and a basis weight of about 30 to about 70 g/m 2 .

11 . The nonwoven fiber mat of claim 1 , consisting of about 80 to about 99 weight percent of the B-glass fibers and about 1 to about 20 weight percent of nanofibrillated cellulose.

12 . A battery comprising the nonwoven fiber mat of claim 1 .

13 . A lithium-ion battery comprising:

an anode;

a cathode;

an electrolyte solution; and

a separator placed between the anode and the cathode, wherein the separator has a thickness of about 10 to about 700 microns and a basis weight of about 1 to about 70 g/m 2 and consists of:

B-glass fibers having an average fiber diameter of less than 0.5 micron and a specific surface area of 5.0 to 7.0 m 2 /g, and

a binder consisting of nanofibrillated cellulose, starch, or polyvinyl acetate.

14 . The battery of claim 13 , wherein the separator has a thickness of about 10 to about 100 microns and a basis weight of about 1 to about 25 g/m 2 .

15 . The battery of claim 13 , wherein the separator has a thickness of about 200 to about 700 microns and a basis weight of about 30 to 70 g/m 2 .

16 . The battery of claim 13 , wherein the separator has a heat stability of up to 650° C.

17 . A method of making a nonwoven fiber mat, comprising:

forming a suspension consisting of:

B-glass fibers having an average fiber diameter of less than about 0.5 micron and a specific surface area of 5.0 to 7.0 m 2 /g,

a binder consisting of nanofibrillated cellulose, starch, or polyvinyl acetate; and

optionally one or more additives selected from:

a conditioning agent consisting of an alkoxylated alcohol or a polyamidoamine resin, and

an additional glass fiber type;

acidifying the suspension to a pH of about 2.8-3.5 to form a slurry;

distributing the slurry onto a screen; and

removing liquid from the slurry to provide a nonwoven fiber mat having a thickness of about 10 to about 700 microns and a basis weight of about 1 to about 70 g/m 2 .

18 . The method of claim 17 , wherein the conditioning agent is present in the suspension.

19 . The method of claim 17 , wherein removing liquid from the slurry comprising applying a vacuum to the slurry.

20 . The nonwoven fiber mat of claim 1 , wherein the binder consists of nanofibrillated cellulose or starch.

21 . The battery of claim 13 , wherein the binder consists of nanofibrillated cellulose or starch.

22 . The method of claim 17 , wherein the binder consists of nanofibrillated cellulose or starch.

Assignments (8)

Continuity (2)

References Cited (137)