DE202016009027U1 - Lead-acid battery with improved performance and improved battery separators - Google Patents

Abstract

A battery separator comprising multiple zones of varying patterns of serrations, depressions and/or discontinuous ridges on at least one side thereof.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority over and the benefit of U.S. Provisional Patent Application Serial No 62/238,373 , filed October 7, 2015; the PCT patent application, serial number PCT/ US2016/012805 , filed January 11, 2016 (which takes priority over the U.S. provisional patent application, serial number 62/238,373 , filed October 7, 2015); and 62/385,347 , filed September 9, 2016. The entirety of each of them is incorporated herein by reference in its entirety.

AREA

In accordance with at least selected embodiments, the present disclosure is directed to improved lead-acid batteries, such as flooded lead-acid batteries, improved systems including a lead-acid battery and a battery separator, improved battery separators, improved Vehicles incorporating such systems and/or methods of manufacture and/or use or combinations thereof. In accordance with at least certain embodiments, the present disclosure or invention is directed to improved flooded lead-acid batteries and/or improved battery separators for such batteries and/or methods of making, testing and/or using such improved flooded lead-acid batteries -Acid batteries or combinations thereof.

Additionally, disclosed herein is a method, system, battery, and/or battery separator for reducing acid stratification, thereby increasing battery life and battery performance in a flooded lead-acid battery and in those batteries operating in partial charge states are revealed.

BACKGROUND

To reduce fuel consumption and tailpipe emissions, automobile manufacturers have established different levels of electric hybridization. One form of hybrid electric vehicle (HEV) is sometimes referred to as the “micro-HEV” or “microhybrid”. In such micro-HEVs or similar vehicles, an automobile may have an idle start/stop function (ISS) that allows the engine to start at various times during the idle start/stop phase and/or a regenerating period Braking process can be switched off. Although this improves the vehicle's fuel economy, it also increases the burden on the battery, which must power ancillary equipment (such as air conditioning, media players, and the like) while the vehicle is not in motion.

Conventional vehicles (such as automobiles without start/stop capability) may use conventional flooded lead-acid batteries, such as start-light ignition (SLI) lead-acid batteries. Because the engine never switches off during operation, energy is only drawn from the battery when the engine is started. Therefore, the battery is typically in an overcharged state, not a partially charged state. For example, such a conventional flooded lead-acid battery may be in a charge state that is more than 95% charged, more than 96%, more than 97%, more than 98%, more than 99% or even is more than 100% charged, as is often the case in a state of overcharge. When overcharged, gas bubbles (e.g. hydrogen gas bubbles) are created inside the traditional lead-acid battery and these circulating gas bubbles cause the liquid electrolyte (acid) to mix within the battery.

Start/Stop vehicles, on the other hand, continuously draw energy from the battery, which is therefore constantly in a state of partial charge. With a partial charge, no gas bubbles are generated and the internal mixing of the electrolyte is significantly reduced, which leads to the formation of acid layers within the battery. Therefore, acid stratification is a problem within flooded lead-acid batteries for start/stop operation and various improved flooded batteries, while acid stratification occurs in more conventional or traditional flooded lead-acid batteries that are in a state of Overcharge or full charge (or close to full charge) was no problem at all.

Acid stratification is the term for the process by which denser sulfuric acid concentrates at the bottom of the battery, resulting in a corresponding higher concentration of water at the top of the battery. Acid stratification is not desirable within a flooded lead-acid battery, such as an improved flooded lead-acid battery or a flooded lead-acid battery for start/stop operation. The reduced levels of acid in the top of the battery can inhibit uniformity and charge acceptance within the battery system and can increase the variation in internal resistance from top to bottom along the height of the battery. Elevated levels of acid at the bottom of the battery artificially raise the voltage of the battery, which may interfere with battery control systems and may pass unintended/erroneous health signals to a battery control system. Overall, acid stratification results in higher resistance along parts of the battery, which can lead to electrode problems and/or shorter battery life. Given that start/stop batteries and/or other improved flooded lead-acid batteries are expected to become more and more prevalent in hybrid and fully electric vehicles to increase vehicle fuel efficiency and CO ₂ emissions, solutions to reduce acid stratification and/or to improve acid mixing are urgently needed.

In some cases, acid stratification can be avoided by using VRLA (valve-controlled lead-acid) technology, where the acid is immobilized either by a gelled electrolyte and/or by a battery separator system with an absorbent glass mat (AGM). becomes. Unlike the free-flowing electrolyte in flooded lead-acid batteries, the electrolyte in VRLA-AGM batteries is absorbed on a fibrous or fibrous material, such as a fiberglass mat, a polymer fiber mat, a gelled electrolyte, and so on. However, VRLA AGM battery systems are significantly more expensive to manufacture than flooded battery systems. VRLA-AGM technology may in some cases be more susceptible to overcharging, may dry out in high heat, may be subject to gradual loss of capacity, and may have lower specific energy. Similarly, in some cases, gel VRLA technologies may have higher internal resistance and may have reduced charge absorption.

Thus, there is a need to further improve flooded lead-acid batteries, such as improved flooded batteries for start/stop operation, which are not subject to acid stratification during operation and/or have reduced or significantly reduced levels of acid stratification during operation to develop. There is a need for improved enhanced flooded lead-acid batteries with improved uniformity and performance compared to those already available and with performance comparable to that found in certain VRLA AGM batteries. competes or even surpasses it.

SHORT VERSION

In accordance with at least selected embodiments, the present disclosure or invention may address the above and other needs. For example, at least in certain embodiments, the present disclosure or invention is directed to new, improved, or optimized flooded lead-acid batteries, systems and separators for enhanced flooded lead-acid batteries, and methods of manufacturing, testing, and/or Use of the same and/or vehicles comprising the same is directed or can provide this.

New, improved or optimized enhanced flooded lead-acid batteries with special types of separators are disclosed herein. Surprisingly, it has been found that through an appropriate selection of characteristic features of the surfaces of separators (and optionally with a specific battery plate orientation and separator orientation in the vehicle) acid stratification can be reduced and/or prevented and a corresponding increase in battery performance can be determined, and although a performance that is close to, equal to or even greater than the performance of certain VRLA AGM or VRLA-AGM batteries. Furthermore, it has surprisingly been found that when one or more of the separators described herein are used together with one or more of the batteries described herein, and used in motion, such motion of the batteries and separators according to the invention improves mixing or circulation the acid and/or reduced or completely prevented acid stratification, without the need for certain mechanical aids or certain internals for the acid mixing (approximately like a pump for mixing the acid) is required. Various embodiments are described in more detail below.

In accordance with at least selected embodiments, aspects or objectives, the present disclosure is directed to improved lead-acid batteries, such as flooded lead-acid batteries, improved systems including a lead-acid battery and a battery separator, improved battery -Separators, improved vehicles incorporating such systems, and/or methods of manufacture and/or use.

In accordance with at least selected embodiments, aspects or objectives, the present disclosure may include enhanced flooded lead-acid batteries, such as enhanced flooded batteries for start/stop operation, which are not subject to acid stratification during operation and/or reduced or having significantly reduced acid stratification during operation, improved enhanced flooded lead-acid batteries with improved uniformity such as acid mixing uniformity and the like, improved batteries operating in a partial charge state and/or performance compared to what was previously available , and/or provide improved enhanced flooded lead-acid batteries with performance that at least competes with or exceeds certain VRLA AGM batteries.

BRIEF DESCRIPTION OF THE DRAWINGS

• 1A - 1H includes a series of photographs comparing cells exposed to 90 start/stop events or cycles. The top row, 1A - 1D , illustrates cells with a serrated ridge separator according to an exemplary embodiment. The bottom row, 1E - 1H , illustrates cells with a conventional fixed rib separator in which such solid ribs extend vertically along the separator.
• 2A - 2H includes a series of photographs comparing cells exposed to 60 start/stop events or cycles followed by a night's sleep. The test cells are provided with separators similar to those used in 1A - 1H wherein the top row shows a serrated rib separator according to an exemplary embodiment and the bottom row shows cells with conventional solid rib separator.
• 3A - 3H includes a series of photographs comparing cells exposed to 90 start/stop events or cycles. The test cells in the top row are equipped with separators with serrated ribs with closer spacing compared to those in 1A - 1H and 2A - 2H are shown can be compared. The bottom row is provided with cells with a conventional fixed rib separator, the fixed ribs being vertical along the separator.
• 4A - 4H includes a series of photographs comparing cells exposed to 90 start/stop events or cycles. The top row represents cells with a well separator according to exemplary embodiments. The bottom row represents cells with a conventional separator that includes fixed large and fixed small ribs, such large and small solid ribs extending vertically along the separator.
• 5A - 5H includes a series of photographs comparing cells exposed to 90 start/stop events or cycles. The top row represents cells with a well separator according to exemplary embodiments. The bottom row represents cells with a separator with solid ridges running vertically along the separator combined with wells.
• 6A - 6H includes a set of photographs comparing cells exposed to 90 start/stop events or cycles. The top row represents cells with a well separator according to exemplary embodiments and the bottom row represents cells with a separator that includes solid ribs that run diagonally along the separator (at a small angle relative to the vertical direction of the separator).
• 7A and 7B contain photographs comparing a conventional solid rib separator (7A) and no separator at all (7B) in a vessel filled with 1.28 specific gravity acid being mixed.
• 8th includes a photograph of cells constructed using a serrated rib separator according to the present disclosure before being tested for acid stratification.
• 9 includes a photograph of the cells of the 8th , which are assembled in a housing for acid stratification testing. Lead tapes are placed over the group of electrodes and separators.
• 10 includes a photograph of a cross-sectional view of a serration or serrated ridge on a separator used in accordance with various embodiments described herein.
• 11 includes two views of the profile of a serrated separator used in accordance with various embodiments described herein.
• 12 shows a graph of the conductivity of sulfuric acid solutions at 25°C (77°F). This diagram helps understand that acid stratification can result in uneven current due to differences in conductivity in the high and low acid regions of the cell and/or battery. Chart shows data from http://myweb.wit.edu/sandinic/Research/conductivity%20v %20concentration.pdf accessed July 26, 2016; where conductivity is measured in Siemens/centimeter and is presented as a function of the concentration of the sulfuric acid solution as a percentage of weight.
• 13A - 13F includes photographs of cells similar to those in the 6A - 6H cells shown are constructed. However, for those in the 13A until 13F In the cells shown, the separator is inserted into the system perpendicular to the direction of movement of the vehicle, whereas for the cells in the 6A - 6H In the cells shown, the separator was inserted into the system parallel to the direction of movement.
• 14 includes a photograph of a battery separator having serrated ridges in accordance with various embodiments described herein, which separator was used to encase electrodes for making a start/stop flooded automotive lead-acid battery for testing, the results being of this test are described below.
• 15A-15D include diagrams of multiple serrated profiles for a separator according to various embodiments herein. Various optimized profiles for separators to improve and enhance acid mixing are disclosed herein and those in the 15A-15D The diagrams shown are merely examples of such optimized profiles; many other optimized profiles fall within the scope of the improved separators, batteries, systems and methods described and claimed herein.
• 16 includes a diagram showing a cycle test for an example of an enhanced flooded battery or a flooded battery operating in an enhanced mode.
• 17A shows a horizontal acceleration profile with lateral or side-to-side motion, modeled as a sinusoidal acceleration, to which the battery separator was subjected for analysis using Computational Fluid Dynamics (CFD). 17B - 17E shows a visual comparison of a solid fin separator and a serrated fin separator, each after approximately 6 seconds (as shown) and the in 17A exposed to defined movement and analyzed using CFD. Both analyzed separators encased a positive electrode plate (“positive wrap” or “positive wrap”).
• 18A and 18B shows a separator with fixed ribs, which is the in 17A defined motion with horizontal acceleration for 60 seconds and analyzed using CFD to show the mixing of a layered electrolyte of a flooded lead-acid battery. 18C shows the volumetric uniformity of the acid fraction of the analysis of 18A and 18B .
• 19A and 19B shows a separator with serrated ribs, which is the in 17A subjected to defined motion for 60 seconds and analyzed using CFD to show the mixing of a layered electrolyte of a flooded lead-acid battery. 19C shows the volume uniformity of the analysis of 19A and 19B .
• 20A-20B show a comparison of the CFD analyzes of 18A-18C and 19A-19C .
• 21 defines a rocking motion used in a CFD analysis of a serrated fin separator.
• 22 shows a pictorial representation of the CFD analysis of a separator with serrated ribs, which is the in 21 is exposed to the movement described.
• 23 is a schematic representation of a separator that forms a negative electrode plate (“negative wrap” or “negative wrap”) of a flooded lead-acid battery, such as an enhanced flooded lead-acid battery and/or an ISS flooded battery. Lead-acid battery, covered.
• 24A is a graphical representation of a CFD analysis of a negative wrapping serrated separator subjected to lateral movement and further compares this to a graphical representation of a CFD analysis of a positive wrapping serrated separator subjected to the same lateral movement. 24B is a graphical representation of the volume uniformity of the negative envelope separator with serrated ribs of 24A . 24C is a graphical comparison of the volume uniformity of negative-enveloping and positive-enveloping serrated separators.
• 25A-25F show variables of interrupted rib structures according to exemplary embodiments of the present disclosure.
• 26A - 26G illustrate broken rib battery separators according to exemplary embodiments of the present disclosure and as defined in the structures shown therein.
• 27A and 27B is a graphical comparison of a CFD analysis of a negative wrap separator with serrated ribs and a negative wrap separator with interrupted ribs subjected to lateral movement. 27C and 27D shows a comparison of the volumetric uniformity of several CFD analyzes of previously described separators subjected to lateral movement.
• 28A and 28B is a graphical comparison of a CFD analysis of a negative wrap separator with fixed ribs and a negative wrap separator with interrupted ribs subjected to lateral movement. 28C shows a comparison of the volumetric uniformity of multiple CFD analyzes of a solid-fin separator, a serrated-fin separator, and an interrupted-fin separator - all enveloping negative ones.
• 29A describes a separator with three zones with different interrupted rib structures. 29B shows broken rib variable for a three zone separator with broken ribs. 29C shows broken rib variable for a single zone broken rib separator.
• 30A-30H show variations of separators with interrupted rib structures with multiple zones.
• 31A - 31D shows graphical representations of CFD analyzes of four different three-zone, negative wrap separators with interrupted rib structures.
• 32A and 32B is a graphical comparison of CFD analyzes of a negative-enveloping three-zone interrupted-fin separator and a negative-enveloping one-zone interrupted-fin separator (as in 26D shown) that are exposed to lateral movement. 32C shows a comparison of the volumetric uniformity of several CFD analyzes of previously described separators subjected to lateral movement.
• 33A-33C illustrate the headspace of batteries with baffles according to exemplary embodiments of the present disclosure.
• 34A-34H illustrate variations of exemplary embodiments of the present disclosure.
• 35 shows a separator for a high cell battery with a rib structure as essentially shown in 26D is shown.
• 36 shows a changing volume uniformity over time of the CFD analysis of the in 35 Separator shown in comparison to other separator designs.
• 37 shows comparisons of the velocity contour time course of the inventive concept 1 of the high acid mixing profile with the conventional high profile of the solid guide elements.
• 38 shows an exemplary spacer according to the invention with a structure of interrupted ribs, which can be arranged, for example, between a flat separator and an electrode.
• 39A-39C show exemplary embodiments of dimensional values representing inventive motif power separator profiles, spacing and headspace in, for example, tall batteries or battery cases.
• 40 and 41 show profile prototypes of exemplary inventive acid mixture profiles.
• 42A and 42B includes images showing the mixing advantage of a profile according to the invention over a conventional solid rib profile.

DETAILED DESCRIPTION

In various embodiments described herein, a separator is employed that increases electrolyte mixing and/or circulation in a flooded lead-acid battery. In certain embodiments, a separator is used that reduces acid stratification. In various embodiments, a lead-acid battery is disclosed in which acid stratification is greatly reduced compared to a known battery due to an improved or enhanced separator or separator system for acid mixing and for preventing or at least reducing acid stratification and the negative effects of acid stratification. Such batteries can be used, for example, in vehicles with batteries that are in motion. And in various embodiments, movement of the vehicle (e.g., an electric vehicle or partially electric vehicle having a start/stop lead-acid battery) results in the actual mixing of the acid or electrolyte associated with the enhanced battery separator described herein , unexpectedly to the significant reduction in acid stratification shown herein as well as the significant improvement in acid mixing shown herein in a start/stop flooded lead-acid battery and/or an enhanced flooded lead-acid battery or one Battery operating in an enhanced mode. For example, stopping and starting the start/stop electric vehicle provides the energy in the various embodiments herein to mix the acid/electrolyte within the enhanced flooded lead-acid batteries and to improve acid mixing and reduce acid stratification or to prevent it altogether.

Exemplary embodiments of separators (preferably improved acid mixing separators, sheets, wrappers, casings, bags or envelopes) described herein preferably consist of a porous membrane (such as a microporous membrane with pores of less than about 1 µm, a mesoporous or macroporous membrane with pores larger than about 1 µm, a porous polymer membrane or a porous-filled polymer membrane) made of suitable natural or synthetic materials such as polyolefin, polyethylene, polypropylene, phenolic resin, polyvinyl chloride (PVC), rubber, synthetic wood pulp (SWP), glass fibers, cellulose fibers or combinations thereof, more preferably a microporous membrane made of thermoplastic polymers. The preferred microporous membranes can have pore diameters of about 0.1 µm (100 nm) and porosities of about 60%. The thermoplastic polymers can in principle include any acid-resistant thermoplastic materials suitable for use in lead-acid batteries. The preferred thermoplastic polymers include polyvinyls and polyolefins. Polyvinyls include PVC, for example. The polyolefins include, for example, polyethylene, ultra-high molecular weight polyethylene (UHMWPE) and polypropylene. A preferred embodiment may include a mixture of filler (e.g., silicon dioxide) and UHMWPE. In general, the preferred separator can be made by mixing about 30 wt% silica with about 10 wt% UHMWPE and about 60 wt% processing oil in an extruder. The mixture may also contain small amounts of other additives or agents common in separator technology (such as wetting agents, dyes, antistatic additives, similar materials, or combinations thereof) and is extruded into the form of a flat sheet. The potentially preferred polyolefin separator may include a silica-filled microporous layer of polyolefin (with or without residual oil and one or more additives or surfactants) having serrated ridges, projections, enclosures, depressions, embossments, and combinations thereof on one or more of their surfaces (and may preferentially provide acid mixing action in conjunction with electrolyte sloshing from vehicle motion).

The separator is preferably made of a polyolefin, such as polypropylene, ethylene-butene copolymer and preferably polyethylene, even more preferably high molecular weight polyethylene, ie polyethylene with a molecular weight of at least 600,000, or high density polyethylene, e.g. polyethylene with a molecular weight of at least 500,000. manufactured. In some embodiments, one or more ultra-high molecular weight polyethylenes are used, that is, polyethylenes with a molecular weight of at least 1,000,000, particularly greater than 4,000,000, and in some cases 5,000,000 to 8,000,000 (measured by viscometry and calculated by the Margolie equation), a standard load melt index of substantially 0 (measured as in ASTM D 1238 (Condition E) using a standard load of 2,160 g) and a viscosity number of not less than 600 ml /g, preferably not less than 1,000 ml/g, more preferably not less than 2,000 ml/g and most preferably not less than 3,000 ml/g (determined in a solution of 0.02 g of polyolefin in 100 g of decalin at 130 °C).

In accordance with at least one embodiment, the separator consists of an ultra-high molecular weight polyethylene (UHMWPE) mixed with a processing oil and silica, for example precipitated silica and/or silica powder. In accordance with at least another embodiment, the separator consists of an ultra-high molecular weight polyethylene (UHMWPE) mixed with a processing oil, additive and silica, for example precipitated precipitated silica. The separator preferably comprises a homogeneous mixture of 8-100% by volume of polyolefin, 0-40% by volume of a plasticizer and 0-92% by volume of inert filler material. In some cases the preferred filler is dry, finely divided silica. However, the filler can be selected from the group consisting of: silica, mica, montmorillonite, kaolinite, asbestos, talc, diatomaceous earth, vermiculite, natural and synthetic zeolites, cement, calcium silicate, clay, aluminum silicate, sodium aluminum silicate, aluminum polysilicate, aluminum oxide-silica gels, glass particles , carbon black, activated carbon, carbon fiber, charcoal, graphite, titanium oxide, iron oxide, copper oxide, zinc oxide, lead oxide, tungsten, antimony oxide, zirconium oxide, magnesia, aluminum oxide, molybdenum disulfide, zinc sulfide, barium sulfate, strontium sulfate, calcium carbonate, magnesium carbonate and the like and various combinations thereof .

The preferred plasticizer is petroleum oil and/or a wax. Since the plasticizer is the component most easily removed from the polymer-filler-plasticizer composition, it is useful for imparting porosity to the battery separator. Pores can also be formed by other processes or materials such as the removal of particles.

The separator has an average pore size of less than 5 µm, preferably less than 1 µm in diameter. Preferably more than 50% of the pores have a diameter of 0.5 µm or less. It is preferred that at least 90% of the pores have a diameter of less than 0.9 µm. The microporous separator preferably has an average pore size in the range of 0.05-0.9 µm, in some cases 0.1-0.3 µm.

Pore size can in some cases be measured using the mercury intrusion method described in Ritter, H.L. and Drake, L.C., Ind. Eng. Chem. Anal. Ed., 17, 787 (1945). In this process, mercury is pressed into pores of different sizes by changing the pressure exerted on the mercury using a porosimeter (porosimeter model 2000, Carlo Erba). The pore distribution can be determined by evaluating the raw data with the MILESTONE 200 software.

The thickness of the separator is preferably greater than 0.1 mm and less than or equal to 5.0 mm. The thickness of the separator can be in the range of 0.15-2.5mm, 0.25-2.25mm, 0.5-2.0mm, 0.5-1.5mm or 0.75-1, 5 mm (these thicknesses take into account the thickness of the entire separator including all serrated ribs, projections, depressions, etc.). In some cases the separator may be approximately 0.8mm or 1.1mm thick. The separator may or may not include a laminate or other layer (e.g., a nonwoven layer and/or an AGM layer) adhered to one or more of its surfaces. One or both electrodes may also be wrapped with one or more glass mats or fiberglass layers and/or with a porous plate wrapping.

In various, possibly preferred embodiments, the microporous polyolefin separator layer has ribs, such as serrated, projecting, angled, or interrupted ribs, or combinations thereof. The preferred ribs may be 8 µm to 1 mm high and may be spaced from 1 µm to 20 mm, while the preferred backing thickness of the microporous polyolefin separator layer (excluding the ridges or embossments) is about 0.05 mm to about 0.50 mm can be (for example, in certain embodiments approximately 0.25 mm). For example, the ribs can be 0.05mm, 0.1mm, 0.2mm, 0.3mm, 0.4mm, 0.5mm, 0.6mm, 0.7mm, 0.8mm, 0.9mm, 1.0mm, 1.2mm, 1.4mm, 1.6mm, 1.8mm, 2.0mm, 2.25mm, 2.5mm, 2.75mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm or 10 mm apart. In some embodiments, the ribs may be in a structure such as on one side of the separator layer or on both sides of the polyolefin separator, from 0°-90° in relation to each other. In some embodiments, the acid mixing fins may be front, positive or negative side fins. Various structures including ribs on both sides of the Separator or the separator layer, may include positive ribs and negative longitudinal or transverse ribs on the second side or back of the separator, such as. B. smaller, closely spaced negative longitudinal or transverse ribs or mini-ribs. Such negative longitudinal or transverse ribs may in some cases have a height of about 0.025 mm to about 0.1 mm, and preferably a height of about 0.075 mm, but can be up to 0.25 mm in size. Other structures may include ribs on both sides of the separator with negative mini-ribs on the second side or back of the separator (mini-ribs that extend in the same direction versus a transverse direction compared to the main ribs on the other side of the separator). Such negative mini-ribs may in some cases have a height of about 0.025 mm to about 0.25 mm, and preferably a height of about 0.050 mm to about 0.125 mm.

The ribs may be serrated in certain preferred embodiments. The serrations can have an average tip length of about 0.05 mm to about 1 mm. For example, the average tip length may be greater than or equal to 0.05mm, 0.1mm, 0.2mm, 0.3mm, 0.4mm, 0.5mm, 0.6mm, 0.7mm, be 0.8 mm or 0.9 mm; and/or less than or equal to 1.0 mm, 0.9 mm, 0.8 mm, 0.7 mm, 0.6 mm, 0.5 mm, 0.4 mm, 0.3 mm, 0.2 mm or 0.1 mm.

The serrations can have an average base length of about 0.05 mm to about 1 mm. For example, the average base length may be greater than or equal to approximately 0.05 mm, 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm , 0.8mm or 0.9mm; and/or less than or equal to 1.0 mm, 0.9 mm, 0.8 mm, 0.7 mm, 0.6 mm, 0.5 mm, 0.4 mm, 0.3 mm, 0.2 mm or 0.1 mm.

When serrations are present, they can have an average height of about 0.05 mm to about 4 mm. For example, the average height may be greater than or equal to approximately 0.05mm, 0.1mm, 0.2mm, 0.3mm, 0.4mm, 0.5mm, 0.6mm, 0.7mm , 0.8 mm or 0.9 mm; and/or less than or equal to approximately 1.0 mm, 0.9 mm, 0.8 mm, 0.7 mm, 0.6 mm, 0.5 mm, 0.4 mm, 0.3 mm, 0, Be 2mm or 0.1mm. In embodiments in which the serrated height is equal to the rib height, the serrated ribs can also be referred to as projections. Such ranges may apply both to separators for traction-type industrial start/stop batteries, where the total thickness of the separator is typically about 1 mm to about 4 mm, and to automotive start/stop batteries, where the total thickness of the separator may be approximately less (e.g. typically about 0.3 mm to about 1 mm).

The tines can have an average center distance of about 0.1 mm to about 50 mm. For example, the average center-to-center distance may be greater than or equal to approximately 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9mm, 1.0mm, 1.25mm or 1.5mm; and/or less than or equal to approximately 1.5 mm, 1.25 mm, 1.0 mm, 0.9 mm, 0.8 mm, 0.7 mm, 0.6 mm, 0.5 mm, 0, Be 4mm, 0.3mm or 0.2mm.

The points can have an average height to base width ratio of 0.1:1 to 500:1. For example, the average height to base width ratio may be greater than or equal to approximately 0.1:1, 25:1, 50:1, 100:1, 150:1, 200:1, 250:1, 300:1, 350 :1 or 450:1; and/or less than or equal to approximately 500:1, 450:1, 400:1, 350:1, 300:1, 250:1, 200:1, 150:1, 100:1, 50:1 or 25: be 1.

The serrations may have an average base width to tip spacing ratio of about 1000:1 to about 0.1:1. For example, the average base width to tip width ratio may be greater than or equal to approximately 0.1:1, 1:1, 2:1, 3:1, 4:1, 5:1, 6:1, 7:1, 8 :1, 9:1, 10:1, 15:1, 20:1, 25:1, 50:1, 100:1, 150:1, 200:1, 250:1, 300:1, 350:1 , 450:1, 500:1, 550:1, 600:1, 650:1, 700:1, 750:1, 800:1, 850:1, 900:1, 950:1 and/or less than or equal to approximately 1000:1, 950:1, 900:1, 850:1, 800:1, 750:1, 700:1, 650:1, 600:1, 550:1, 500:1, 450:1, 400:1, 350:1, 300:1, 250:1, 200:1, 150:1, 100:1, 50:1, 25:1, 20:1, 15:1, 10:1, 9: 1, 8:1, 7:1, 6:1, 5:1, 4:1, 3:1, 2:1 or 1:1.

In some embodiments, the separator may be provided with depressions. Depressions are typically protrusion-like features or depressions on one or more surfaces of the separator. The thickness of the depressions can be from 1-99% of the thickness of the separator. For example, the average thickness of the depressions may be less than about 95%, 90%, 85%, 80%, 75%, 70%, 65%, 60%, 55%, 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10% or 5% of that of the separator. The depressions can be arranged in rows along the separator. The rows or lines can be arranged at a distance of approximately 1 µm to 10 mm. For example, the rows may be approximately 0.05mm, 0.1mm, 0.2mm, 0.3mm, 0.4mm, 0.5mm, 0.6mm, 0.7mm, 0.8mm , 0.9mm, 1.0mm, 1.2mm, 1.4mm, 1.6mm, 1.8mm, 2.0mm, 2.25mm, 2.5mm, 2.75mm, 3mm, 4mm, 5mm, 6mm, 7mm, 8 mm, 9 mm or 10 mm apart. Conversely, the depressions may be arranged in a random arrangement or in a random manner.

The depressions may have an average depression length of about 0.05 mm to about 1 mm. For example, the average length of the depression may be greater than or equal to approximately 0.05 mm, 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0. 7mm, 0.8mm or 0.9mm; and/or less than or equal to approximately 1.0 mm, 0.9 mm, 0.8 mm, 0.7 mm, 0.6 mm, 0.5 mm, 0.4 mm, 0.3 mm, 0, Be 2mm or 0.1mm.

The depressions may have an average depression width of about 0.01 mm to about 1 mm. For example, the average width of the depression may be greater than or equal to approximately 0.05 mm, 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0. 7mm, 0.8mm or 0.9mm; and/or less than or equal to approximately 1.0 mm, 0.9 mm, 0.8 mm, 0.7 mm, 0.6 mm, 0.5 mm, 0.4 mm, 0.3 mm, 0, Be 2mm or 0.1mm.

The wells may have an average center distance of about 0.1 mm to about 50 mm. For example, the average center-to-center distance may be greater than or equal to approximately 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9mm, 1.0mm, 1.25mm or 1.5mm; and/or less than or equal to approximately 1.5 mm, 1.25 mm, 1.0 mm, 0.9 mm, 0.8 mm, 0.7 mm, 0.6 mm, 0.5 mm, 0, Be 4mm, 0.3mm or 0.2mm.

The depressions can have a quadrangular shape, for example square and rectangular. The depressions may have an average depression length to depression width ratio of about 0.1:1 to about 100:1, for example, the average length to base width ratio may be greater than or equal to about 0.1:1, 1:1, 2 :1, 3:1, 4:1, 5:1, 6:1, 7:1, 8:1, 9:1, 10:1, 15:1, 20:1, 25:1, 50:1 , 100:1, 150:1, 200:1, 250:1, 300:1, 350:1, 450:1, 500:1, 550:1, 600:1, 650:1, 700:1, 750 :1, 800:1, 850:1, 900:1, 950:1 and/or less than or equal to approximately 1000:1, 950:1, 900:1, 850:1, 800:1, 750:1, 700:1, 650:1, 600:1, 550:1, 500:1, 450:1, 400:1, 350:1, 300:1, 250:1, 200:1, 150:1, 100: 1, 50:1, 25:1, 20:1, 15:1, 10:1, 9:1, 8:1, 7:1, 6:1, 5:1, 4:1, 3:1, be 2:1 or 1:1.

In some embodiments, the depressions may be substantially circular. Circular depressions can have a diameter of about 0.05 to about 1.0 mm. For example, the average recess diameter may be greater than or equal to approximately 0.05 mm, 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm , 0.8mm or 0.9mm; and/or less than or equal to approximately 1.0 mm, 0.9 mm, 0.8 mm, 0.7 mm, 0.6 mm, 0.5 mm, 0.4 mm, 0.3 mm, 0, Be 2mm or 0.1mm.

Various other shapes for the depressions may also be included. By way of example only, such depressions may be triangular, pentagonal, hexagonal, heptagonal, octagonal, oval, elliptical, and combinations thereof.

In some embodiments, the separator may include a combination of ribs, corrugations, depressions, or combinations thereof. For example, a separator may include a series of serrated ribs running from top to bottom along the separator and a second series of serrated ribs running horizontally along the separator. In other embodiments, the separator may include an alternating series of serrated ribs, depressions, continuous, discontinuous or interrupted solid ribs, or combinations thereof.

Table 1 immediately below contains several specific embodiments of separators, presented as mere examples and not to be considered limiting, with serrations and/or depressions and with various parameters that may be used in forming such separators, so to speak Prevent acid stratification and improve acid mixing with a flooded lead-acid battery (sometimes called an enhanced flooded battery). Table 1 Separator samples Back fabric thickness (mm) Separate r thickness with rib (mm) Distance between ribs (mm) Negative side rib profile (mm) Serrated ridge and/or depression features Serrated separator profile 0.25 0.85 7 N/A 0.75 tall; 2.5mm spacing between tines in a single row Serrated separator profile 2 0.25 1.0 11 0.075 1mm spacing between tines in a single row. Separator profile with large recess 0.25 1.0 N/A N/A 12.3 mm distance in one or more directions n; 18 mm distance in one or more directions n. Separator profile with small recess 0.25 0.7 N/A N/A 9 mm distance in one or more directions n; 5 mm distance in one or more directions n.

The separators disclosed herein preferably provide improved electrolyte mixing and/or acid circulation compared to conventional separators. In certain embodiments, the separators provide less acid stratification, as measured by the electrolyte density at the top and bottom of the cell. The density difference can be less than 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, 5%, 2.5% or 1% after the cell 30, Has experienced 60, 90 or more start/stop events or cycles. In certain selected embodiments, the density difference may be less than 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, 5%, 2.5% or 1%, after the cell has been idle for 24, 48, 72 or more hours.

In some embodiments, the improved separator may include a coating on one or both sides. Such a coating may contain a surfactant or other material. In some embodiments, the coating may include one or more materials described, for example, in U.S. Patent Publication No. 2012/0094183 which are hereby expressly incorporated by reference. For example, such a coating can reduce the overcharge voltage of the battery system, thereby extending battery life with less grid corrosion and preventing drying out and/or water loss.

The separator used herein in various embodiments may be provided with one or more additives. This is because additives can improve separators for certain start/stop flooded lead-acid batteries for certain vehicles. One such additive that may be present in the polyolefin is a surfactant, while another such additive may include one or more latex additives. Suitable surfactants include surfactants such as salts of alkyl sulfates; alkylaryl sulfonate salts; alkylphenol-alkylene oxide addition products; Soap; alkyl naphthalene sulfonate salts; dialkyl esters of sulfosuccinate salts; quaternary amines; block copolymers of ethylene oxide and propylene oxide; and salts of mono- and dialkyl phosphate esters. The additive may be a nonionic surfactant such as polyol fatty acid esters, polyethoxylated esters, polyethoxylated fatty alcohols, alkyl polysaccharides such as alkyl polyglycosides and mixtures thereof, amine ethoxylates, sorbitan fatty acid ester ethoxylates, organosilicone-based surfactants, ethylene vinyl acetate terpolymers, ethoxylated alkyl aryl phosphate esters and sucrose esters of fatty acids.

• • R ein nichtaromatischer Kohlenwasserstoffrest mit 10 bis 4200 Kohlenstoffatomen, bevorzugter Weise 13 bis 4200, ist, der durch Sauerstoffatome unterbrochen sein kann;
• • R1 ist H, -(CH2)kCOOMx+1/x oder -(CH2)k-SO3MX+1/X, bevorzugter Weise H, wobei k = 1 oder 2;
• • M ein Alkalimetall- oder Erdalkalimetallion, H+ oder NH4+ ist, wobei nicht alle Variablen M gleichzeitig die Bedeutung H+ haben;
• • n = 0 oder 1;
• • m = 0 oder eine ganze Zahl von 10 bis 1400; und
• • x = 1 oder 2, wobei das Verhältnis von Sauerstoffatomen zu Kohlenstoffatomen in der Verbindung nach Formel (I) im Bereich von 1:1,5 bis 1:30 liegt und m und n nicht gleichzeitig 0 sein können, jedoch in bevorzugter Weise nur eine der Variablen n und m von 0 verschieden ist.

In certain embodiments, the additive may be represented by a compound Formula (I) = R(OR ¹ ) _n (COOM ^x+ _1/x ) _m (I)
in the

• • R is a non-aromatic hydrocarbon radical having 10 to 4200 carbon atoms, preferably 13 to 4200, which may be interrupted by oxygen atoms;
• • R1 is H, -(CH2)kCOOMx+1/x or -(CH2)k-SO3MX+1/X, preferably H, where k = 1 or 2;
• • M is an alkali metal or alkaline earth metal ion, H+ or NH4+, whereby not all variables M have the meaning H+ at the same time;
• • n = 0 or 1;
• • m = 0 or an integer from 10 to 1400; and
• • x = 1 or 2, where the ratio of oxygen atoms to carbon atoms in the compound according to formula (I) is in the range from 1:1.5 to 1:30 and m and n cannot be 0 at the same time, but preferably only one of the variables n and m is different from 0.

Non-aromatic hydrocarbon residues are residues that do not contain any aromatic groups or that do not themselves represent any. The hydrocarbon residues can be interrupted by oxygen atoms, i.e. contain one or more ether groups.

R is preferably a straight-chain or branched aliphatic hydrocarbon radical which can be interrupted by oxygen atoms. Saturated, non-crosslinked hydrocarbon radicals are particularly preferred.

• • R ein Kohlenwasserstoffrest mit 10 bis 180, in bevorzugter Weise 12 bis 75 und besonders bevorzugt 14 bis 40 Kohlenstoffatomen ist, die durch 1 bis 60, bevorzugter Weise 1 bis 20 und ganz besonders bevorzugt 1 bis 8 Sauerstoffatomen unterbrochen werden können, besonders bevorzugt ein Kohlenwasserstoffrest der Formel R²-[(OC₂H₄)_p (OC₃H₆)_q]-, in dem
  • ◯ R² ein Alkylrest mit 10 bis 30 Kohlenstoffatomen, bevorzugter Weise 12 bis 25, besonders bevorzugt 14 bis 20 Kohlenstoffatomen ist;
  • ◯ P eine ganze Zahl von 0 bis 30, bevorzugter Weise 0 bis 10, besonders bevorzugt 0 bis 4 ist; und
  • ◯ q eine ganze Zahl von 0 bis 30, bevorzugter Weise 0 bis 10, besonders bevorzugt 0 bis 4 ist; und
  • ◯ Verbindungen besonders bevorzugt sind, bei denen die Summe von p und q = 0 bis 10, insbesondere 0 bis 4;
• • n=1; und
• • m=0.

The use of the compounds of formula (I) to prepare an additive for various battery separators described herein can also provide these separators with effective protection against oxidative destruction. In some embodiments, battery separators containing an additive containing a compound of formula (I) are preferred, in which

• • R is a hydrocarbon radical with 10 to 180, preferably 12 to 75 and particularly preferably 14 to 40 carbon atoms, which can be interrupted by 1 to 60, preferably 1 to 20 and very particularly preferably 1 to 8 oxygen atoms, particularly preferably one Hydrocarbon radical of the formula R ² -[(OC ₂ H ₄ ) _p (OC ₃ H ₆ ) _q ]-, in which
  • ◯ R ² is an alkyl radical with 10 to 30 carbon atoms, preferably 12 to 25, particularly preferably 14 to 20 carbon atoms;
  • ◯ P is an integer from 0 to 30, preferably 0 to 10, particularly preferably 0 to 4; and
  • ◯ q is an integer from 0 to 30, preferably 0 to 10, particularly preferably 0 to 4; and
  • ◯ Compounds are particularly preferred in which the sum of p and q = 0 to 10, in particular 0 to 4;
• • n=1; and
• • m=0.

The formula R ² -[(OC ₂ H ₄ ) _p (OC ₃ H ₆ ) _q ]- also includes those compounds in which the order of the groups in square brackets differs from that shown. For example, suitable according to the disclosure are compounds in which the parenthesized residue is formed by alternating (OC ₂ H ₄ ) and (OC ₃ H ₆ ) groups.

Additives in which R ² is a straight-chain or branched alkyl radical with 10 to 20, preferably 14 to 18, carbon atoms have proven to be particularly advantageous. OC ₂ H ₄ preferably represents OCH ₂ CH ₂ , OC ₃ H ₆ represents OCH(CH ₃ )CH ₂ and/or OCH ₂ CH(CH ₃ ).

Alcohols (p = q = 0; m = 0) are particularly preferred additives, with primary alcohols being particularly preferred, fatty alcohol ethoxylates (p = 1 to 4, q = 0), fatty alcohol propoxylates (p = 0; q = 1 to 4) and fatty alcohol alkoxylates (p = 1 to 2; q = 1 to 4) ethoxylates of primary alcohols are preferred. The fatty alcohol alkoxylates are accessible, for example, by reacting the corresponding alcohols with ethylene oxide or propylene oxide.

• • R ein Alkanrest mit 20 bis 4200, bevorzugter Weise 50 bis 750 und besonders bevorzugt 80 bis 225 Kohlenstoffatomen ist;
• • M ein Alkalimetall- oder Erdalkalimetallion, H+ oder NH₄+, insbesondere ein Alkalimetallion wie Li+, Na+ und K+ oder H+ ist, wobei nicht alle Variablen M gleichzeitig die Bedeutung H+ haben;
• • N = 0;
• • m eine ganze Zahl von 10 bis 1400 ist; und
• • x = 1 oder 2.

Additives of type m = 0, which are not or only partially soluble in water and sulfuric acid, have proven to be particularly advantageous. Also preferred are additives which contain a compound according to formula (I), where

• • R is an alkane radical with 20 to 4200, preferably 50 to 750 and particularly preferably 80 to 225 carbon atoms;
• • M is an alkali metal or alkaline earth metal ion, H+ or NH ₄ +, in particular an alkali metal ion such as Li+, Na+ and K+ or H+, whereby not all variables M have the meaning H+ at the same time;
• • N = 0;
• • m is an integer from 10 to 1400; and
• • x = 1 or 2.

Suitable additives to be mentioned here are in particular polyacrylic acids, polymethacrylic acids and acrylic acid-methacrylic acid copolymers, the acid groups of which are at least partially, e.g. B. preferably 40%, particularly preferably 80%, are neutralized. The percentage refers to the number of acid groups. Poly(meth)acrylic acids that are completely present in the salt form are particularly preferred. Poly(meth)acrylic acids mean polyacrylic acids, polymethacrylic acids and acrylic acid-methacrylic acid copolymers. Poly(meth)acrylic acids are preferred and in particular polyacrylic acids with an average molar mass M _w of 1,000 to 100,000 g/mol, particularly preferably 1,000 to 15,000 g/mol and very particularly preferably 1,000 to 4,000 g/mol. The molecular weight of the poly(meth)acrylic acid polymers and copolymers is determined by measuring the viscosity of a 1% aqueous solution of the polymer neutralized with sodium hydroxide solution (Fikentscher constant).

Also suitable are copolymers of (meth)acrylic acid, in particular copolymers which, in addition to (meth)acrylic acid, contain ethylene, maleic acid, methyl acrylate, ethyl acrylate, butyl acrylate and/or ethylhexyl acrylate as comonomer. Copolymers which contain at least 40% by weight, preferably at least 80% by weight, of (meth)acrylic acid monomer are preferred, the percentages being based on the acid form of the monomers or polymers.

Alkaline metal and alkaline earth metal hydroxides such as potassium hydroxide and in particular sodium hydroxide are particularly suitable for neutralizing the polyacrylic acid polymers and copolymers.

The microporous polyolefin can be provided with the additive or additives in various ways. The additives can, for example, be applied to the finished polyolefin (e.g. after extraction) or added to the mixture to produce the polyolefin. According to a preferred embodiment, the additive or a solution of the additive is applied to the surface of the polyolefin. This variant is particularly suitable for the application of non-thermostable additives and additives that are soluble in the solvent used for the subsequent extraction. Particularly suitable solvents for the additives according to the present disclosure are alcohols with low molecular weight, such as methanol and ethanol, as well as mixtures of these alcohols with water. The application can take place on the side facing the negative electrode, on the side facing the positive electrode or on both sides of the separator.

The additive can have a density of at least 0.5 g/m ² , 1.0 g/m ² , 1.5 g/m ² , 2.0 g/m ² , 2.5 g/m ² , 3, 0g/ ^m2 , 3, 5g/m2, 4.0g/ ^m2 , 4.5g/ ^m2 , 5.0g/ ^m2 , 5.5g/ ^{m2 ,} 6.0g / m ² , 6.5 g/m ² , 7.0 g/ m ² , 7.5 g/m ² , 8.0 g/m ² , 8.5 g/m ² , 9.0 g/m 2 ² , 9.5 g/m ² or 10.0 g/m ² are present. The additive can be applied on the separator in a density between 0.5 - 10 g/m ² , 1.0 - 10.0 g/m ² , 1.5 - 10.0 g/m ² , 2.0 - 10, 0 g/m ² , 2.5 - 10.0 g/m ² , 3.0 - 10.0 g/m ² , 3.5 - 10.0 g/m ² , 4.0 - 10.0 g /m ² , 4, 5 - 10.0 g/m ² , 5.0 - 10.0 g/m ² , 5.5 - 10.0 g/m ² , 6.0 - 10.0 g/m 2 ² , 6.5 - 10.0 g/m ² , 7.0 - 10.0 g/m ² , 7.5 - 10.0 g/m ² , 5.0 - 10.5 g/m ² , 5.0 - 11.0 g/m ² , 5.0 - 12.0 g/m ² or 5.0 - 15.0 g/m ² are present.

The application can also be carried out by roller application or by immersing the polyolefin in the additive or a solution of the additive and then optionally removing the solvent (e.g. by drying). The order can also be carried out in any other known way. In this way, the application of the additive can be combined, for example, with the extraction often used in polyolefin production.

The following photographic examples in 1A-7B include an acid-based electrolyte with red dye contained in the acid to make the electrolyte with the higher acid density and the lower to visually represent the higher pH value and distinguish it with the lower acid density and the higher pH value.

Now referring to 1A - 1H Shown is a series of photographs comparing cells with a separator with serrated or projecting ribs according to an exemplary embodiment (top row) with cells with a separator with conventional solid ribs (bottom row), such solid ribs vertically along the separator get lost. The distance between the projecting ribs (rib tip to rib tip) for the separators shown in the top row was approximately 11 mm. 1A - 1H Figure 1 shows the side of the battery separator that typically faces the positive electrode in the flooded lead-acid battery, such as a flooded lead-acid battery in a partially charged state. However, such ribs may alternatively face the negative electrode or may be present on both sides of the separator (e.g. may also be present on the side of the separator designed to face the negative electrode in the flooded lead). acid battery). 1A - 1H shows samples in same vessel on opposite sides. 1A and 1E show cells before the mixing event, 1B and 1F show cells after 30 start/stop cycles, 1C and 1G show cells after 60 start/stop cycles and 1D and 1H show cells after 90 start/stop cycles. A first field 1 symbolizes a state clear = 0.99 to 1,030, a second field 2 symbolizes a state pink = 1,030 to 1,160, a third field 3 symbolizes a state red = 1,160 to 1,280. In the 1D and 1H Cells shown were subjected to 90 start/stop events or cycles with the separators and covered electrodes parallel to the direction of movement. As in 1A - 1H shown, cells with separators with serrated ribs exhibited significantly less acid stratification than cells with conventional separators after 30 ( 1B , 1F) , 60 ( 1C , 1G) and 90 ( 1D , 1H) Start/stop cycles or events.

Now referring to 2A - 2H A series of photographs is shown showing the same cell type as those in 1A - 1H compare shown. 2A - 2H shows samples in same vessel on opposite sides. 2A and 2E show cells before the mixing event, 2 B and 2F show cells after 30 start/stop cycles, 2C and 2G show cells after 60 start/stop cycles and 2D and 2H show cells after a night's rest. A first field 1 symbolizes a state clear = 0.99 to 1,030, a second field 2 symbolizes a state pink = 1,030 to 1,160, a third field 3 symbolizes a state red = 1,160 to 1,280. The cells were subjected to 60 start/stop events or cycles while in a vehicle traveling 25 miles per hour, followed by an overnight rest. The top row ( 2A - 2D ) shows cells with a serrated ribbed separator according to exemplary embodiments, while the bottom row ( 2E - 2H) Cells with a conventional solid finned conventional separator shows, in the 2F - 2H Acid stratification zones 20 are shown. As in 2A - 2H presented, cells with serrated, ribbed separators show significantly less acid stratification than cells with conventional separators. Such tests confirmed the laboratory results shown in the photographs of 1A - 1H are shown.

Now turning to 3A - 3H were cells with a serrated, ridged separator with closer spacing according to exemplary embodiments (top row, 3A - 3D ) with cells with a conventional solid ribbed separator (bottom row, 3E - 3H) compared, in which the fixed ribs run vertically along the separator. 3A - 3H shows samples in same vessel on opposite sides. 3A and 3E show cells before the mixing event, 3B and 3F show cells after 30 start/stop cycles, 3C and 3G show cells after 60 start/stop cycles and 3D and 3H show cells after 90 start/stop cycles. A first field 1 symbolizes a state clear = 0.99 to 1,030, a second field 2 symbolizes a state pink = 1,030 to 1,160, a third field 3 symbolizes a state red = 1,160 to 1,280. The distance between the projecting ribs for the separators shown in the top row was approximately 7 mm. Cells were exposed to 90 start/stop events or cycles. As in 3A - 3H presented, show cells with serrated ribbed separators after 30 ( 3B , 3F) , 60 ( 3C , 3G) and 90 ( 3D , 3H) Start/stop cycles or events have significantly less acid stratification than cells with conventional separators.

Now referring to 4A - 4H shows a series of photographs comparing cells with a recessed separator according to exemplary embodiments (top row, 4A - 4D ) with cells with a conventional separator that has fixed large and fixed small ribs (bottom row, 4E - 4H) includes, such large and small solid ribs running vertically along the separator. 4A - 4H show samples in the same vessel on opposite sides. 4A and 4E show cells before the mixing event, 4B and 4F show cells after 30 start/stop cycles, 4C and 4G show cells after 60 start/stop cycles and 4D and 4H show cells after 90 start/stop cycles. A first field 1 symbolizes a state clear = 0.99 to 1,030, a second field 2 symbolizes a state pink = 1,030 to 1,160, a third field 3 symbolizes a state red = 1,160 to 1,280. Cells were exposed to 90 start/stop events or cycles. As in 4A - 4H presented, show cells with recessed separators after 30 ( 4B , 4F) , 60 ( 4C , 4G) and 90 ( 4D , 4H) Start/stop cycles or events have significantly less acid stratification than cells with conventional separators. Consequently, the solid ribs that appear, for example, in the bottom row of photographs in 4 shown is actually the acid mixing for the separator within an idle start/stop lead-acid battery.

Regarding 5A - 5H a series of photographs show a comparison of cells with a recessed separator according to exemplary embodiments (top row, 5A - 5D ) with cells with a separator, which has solid ribs running vertically along the separator, combined with depressions (bottom row, 5E - 5H) having. 5A - 5H show samples in the same vessel on opposite sides. 5A and 5E show cells before the mixing event, 5B and 5F show cells after 30 start/stop cycles, 5C and 5G show cells after 60 start/stop cycles and 5D and 5H show cells after 90 start/stop cycles. A first field 1 symbolizes a state clear = 0.99 to 1,030, a second field 2 symbolizes a state pink = 1,030 to 1,160, a third field 3 symbolizes a state red = 1,160 to 1,280. Cells were exposed to 90 start/stop events or cycles. As in 5A - 5H presented, show cells with recessed separators (top row, 5A - 5D ) a lower acid stratification than the start/stop lead-acid battery cells in the bottom row ( 5E - 5H) with separators which have the combination of the solid ribs with the depressions. However, some acid mixture is shown in the bottom row, for example when compared to the bottom rows of the photographs in the 1A-4H . For example, in some images, a specific area or pocket of low acid density can be seen in the bottom row; however, acid mixing is also seen. In particular, pockets 50 with low density acid are shown. The bottom row of photographs shows that a combination of serrations and solid ridges or a combination of recesses and solid ridges may prove effective in various batteries, systems and methods in accordance with the present disclosure.

Now referring to 6A - 6H Shown is a set of photographs illustrating cells with a recessed separator according to exemplary embodiments (top row, 6A - 6D ) compare to cells with a separator that has solid ribs running diagonally along the separator at a small angle relative to the vertical direction of the separator. 6A and 6E show cells before the mixing event, 6B and 6F show cells after 30 start/stop cycles, 6C and 6G show cells after 60 start/stop cycles and 6D and 6H show cells after 90 start/stop cycles. A first field 1 symbolizes a state clear = 0.99 to 1,030, a second field 2 symbolizes a state pink = 1,030 to 1,160, a third field 3 symbolizes a state red = 1,160 to 1,280. Cells were exposed to 90 start/stop events or cycles. As in 6A - 6H presented, show the cells with recessed separators (top row, 6A - 6D ) less acid stratification than the start/stop lead-acid battery cells in photos, as shown in the bottom rows of the 1A-4H are shown. Regarding the bottom row of photographs in 6E - 6H , at 60 cycles or 60 start/stop events you can see that there is still some acid stratification; however, acid stratification improves after 90 cycles.

7A and 7B include photographs showing a conventional fixed rib separator ( 7A) and no separator at all ( 7B) compare in a vessel filled with acid with a specific gravity of 1.28 mixed. 7A includes a photograph of a conventional rib separator; Acid stratification is indicated by the concentration of red acid at the bottom of the vessel and the clear liquid at the top of the vessel. 7B includes a photograph of a lead grid electrode only without a separator therein; much less acid stratification has occurred, indicated by the red color throughout the vessel. 7A and 7B help illustrate that a traditional solid fin separator can impede acid mixing and promote acid stratification within a start/stop flooded lead-acid battery. Likewise poses 7B provides a form of benchmark in that there is no separator with which the different separators can be compared and contrasted.

8th includes a photograph of cells constructed using a serrated rib separator according to the present disclosure before testing for acid stratification.

9 includes a photograph of the cells of 8th , which are assembled in a housing for acid stratification testing. Lead tapes are placed over the group of electrodes and separators. Once acid has been added to the casing, the acid level may be several mm above these lead bands (in some cases approximately 3 mm above the lead bands, just by way of example). Since this housing containing electrodes and separator is tested for acid stratification within the cell, in certain embodiments it may be preferred that the direction of movement of the test mimic the movement of the start/stop electric vehicle. The movement is therefore substantially parallel to the plates and separators of the photograph, so that acid is moved over the surface of the electrodes as the vehicle is started, accelerated, decelerated and/or stopped. 9 can also be viewed as if the top of the photo is towards the front bumper of an electric vehicle with start/stop capability, while the bottom of the photo is of 9 approaches the rear bumper of the same electric vehicle and the viewer looks down at the group of electrodes, separators and lead strips that will soon be filled with acid for acid stratification tests. In other words, the electrodes and separators are parallel to the movement created in the test.

10 includes a photograph of a cross-sectional view of a serration or serrated ridge on a separator used in accordance with various embodiments described herein.

11 includes two views of the profile of a serrated separator used in accordance with various embodiments described herein.

12 shows a graph of the conductivity of sulfuric acid solutions at 25°C (77°F). The graph shows the conductivity (S/cm) versus the sulfuric acid concentration (% by weight). A first arrow 121 symbolizes SG = 1.26 and a second arrow symbolizes SG = 1.28. This diagram helps understand that acid stratification can cause unevenness in current due to differences in conductivity in the high and low acid areas of the cell and/or battery.

13A - 13F include photographs of cells similar to those in 6A - 6H cells shown are constructed. 13A and 13D show cells before the mixing event, 13B and 13E show cells after 30 start/stop cycles, 13C and 13F show cells after 60 start/stop cycles. A first field 1 symbolizes a state clear = 0.99 to 1,030, a second field 2 symbolizes a state pink = 1,030 to 1,160, a third field 3 symbolizes a state red = 1,160 to 1,280. For those in 13A - 13F However, in the cells shown, the separator was inserted into the system perpendicular to the direction of movement of the vehicle. 13A - 13F shows no mixing at 90° “perpendicular” to the direction of movement. While for the cells in 6A - 6H the separator was inserted into the system parallel to the direction of movement, similar to the direction descriptions of 9 above. In various embodiments, it may be preferred that the separator is positioned parallel to the direction of movement for the vehicle and the battery system. This is because the in 13A - 13F Photographs shown show that after 60 start/stop cycles or events ( 13C , 13F) Acid stratification still occurs without good acid mixing. Using the top row of 13A - 13C As an example, although a recessed separator is used therein according to various embodiments of the present disclosure, acid stratification still occurred and acid mixing was not optimal.

14 includes a photograph of a battery separator having serrated ridges in accordance with various embodiments described herein, the separator being used to form electrodes for making a start/stop flooded lead-acid automotive battery for testing, the results of which are described below become, to envelop.

15A-15D include diagrams of multiple serrated profiles for a separator according to various embodiments herein. Disclosed herein are various optimized profiles for separators to improve and improve acid mixing and the diagrams presented in the 15A-15D are merely examples of such optimized profiles. Many other optimized profiles fall within the scope of the improved separators, batteries, systems and processes described herein. 15D shows an offset 150 of 0.052 [1.31mm] between rows of projections.

16 includes a diagram showing a cycle test for an example of an enhanced flooded battery or a flooded battery operating in an enhanced mode. The diagram shows SoC in % over a life cycle. Improved flooded systems are working in newer battery applications. Batteries today operate in lower states of charge than previously known flooded lead-acid batteries, which often operate in an overcharge state or more than 100% charged. Therefore, such an improved flooded battery can operate in a state of charge (SoC) that is in some cases less than 95%, in some cases less than 90%, in some cases less than 85%, in some cases less than 80%, in in some cases less than 70%, in some cases less than 60%, in some cases less than 50%, in some cases less than 25%, in some cases even less than 10%. In this particular diagram, the cycle test was performed for a battery with a depth of discharge (DoD) of 17.5% and the separator used was a conventional finned separator like the one shown in the bottom row of photographs in 1 will be shown. This particular battery demonstrated the ability to deliver energy and operate well in a lead sulfate-rich environment under highly cycling conditions in a partially discharged state of charge. Batteries like the one for 16 tested and used in start/stop applications have dramatically increased energy throughput compared to standard SLI batteries (such as those specified in standards such as EN50342). Since such enhanced flooded batteries and/or flooded batteries for start/stop applications operate in a partial state of charge, they must have higher charging efficiency and/or be able to accept charge more easily. In certain cases, improved flooded batteries use various additives in conjunction with one or more of the electrodes to increase charging efficiency and/or to produce a battery that accepts charging more easily. However, the improved separator(s) described herein can achieve the same goal.

The separators, processes, batteries and battery systems described herein can provide improved electrolyte circulation and mixing with less acid stratification over time. This is particularly important for deep cycling and/or enhanced flooded lead-acid batteries, where acid stratification can significantly reduce battery performance. Various flooded lead-acid batteries, improved flooded lead-acid batteries and their applications can benefit from the improved separators, processes, batteries and systems described herein. Various start/stop vehicles, including, but not limited to, various electric vehicles, automobiles, hybrid vehicles, forklifts, golf carts, Neighborhood Electric Vehicles (NEV), etc. may benefit from the improved separators, batteries, battery systems and methods described herein , particularly vehicles and/or batteries that are not adequately charged and are in a partially charged state.

The exemplary embodiments of enhanced flooded separators described herein, which may be known as acid mixing separators, may be used in enhanced flooded batteries, particularly in moving batteries, and surprisingly and unexpectedly provide significant performance in enhanced flooded batteries Improved acid mixing and/or circulation, which significantly reduces or completely eliminates acid stratification in the enhanced flooded battery. This can be crucial as the flow and circulation of the acid along the entire separator means that the entire battery is being used, rather than just a smaller portion of the battery being in use. Namely, in the improved separators, batteries, systems, and methods of the present disclosure, the electrolyte (e.g., sulfuric acid) flows freely to and along all or nearly all portions of the separator, and thus flows freely to and along all or nearly all portions of the positive active material and the negative active material on the electrodes. Conversely, with acid stratification (see the acid stratification in the lower rows of photos in the 1A - 4H , in which a red indicator has been added to the acid so that the acid is clearly visible and present in approximately the lower halves of these test cells while a clear liquid, namely water, is clearly visible and present in approximately the upper halves of these test cells), whole parts of the Separators and therefore entire portions of the positive active material and the negative active material on either side of such separator are completely devoid of acid and are therefore not used to their full potential to power the associated device/vehicle using the battery . Thus, the improved separators, batteries, systems and methods described herein significantly reduce acid stratification in a flooded lead-acid battery, for example an enhanced flooded battery.

The reason for concern about acid stratification is the resulting non-uniformity of current density on the surfaces of the positive and negative plates or electrodes. The Indian 12 Graph shown illustrates the conductivity of H ₂ SO ₄ vs. the concentration of sulfuric acid weight percentage.

In some preferred embodiments of the present disclosure, the serrations, depressions, and/or discontinuous ribs present on one or more surfaces of the separator are unevenly distributed. Additionally, in some preferred embodiments, the serrations are the depressions gene and/or the interrupted ribs on one or more surfaces of the separator differ in certain zones or areas on at least one side of the separator. For example, the spikes and depressions themselves may be non-uniform in size (eg, randomly distributed in size) and the spacing between the spikes and/or depressions may be random and/or non-uniform. For example, various serrations and/or depressions used herein may be present on one or both surfaces of a separator in an ordered or disordered arrangement. In addition, various ribs used here, such as serrated ribs, may be nonlinear. For example, some serrated ridges may have a wavy or non-linear pattern.

In various embodiments, the effects of the enhanced flooded separators described herein for the enhanced flooded batteries are enhanced when the separator is positioned within the enhanced flooded battery such that the improvements to the separator are parallel to the direction of movement in which a battery is in motion. Such effects can be seen by comparing the desirable results of 6 with the less desirable results of 13 be recognized. In the recordings in the 13 Acid stratification is still observed even though separators with improved acid mixture profiles are used. This is because the cells in 13 positioned so that the improvements on the separator and electrodes are perpendicular to the direction in which the battery moves in the vehicle. Placing the battery in the vehicle with the electrodes and separators parallel to the start and stop inertia can in some cases allow better mixing of the acid than vertical positioning.

The various improved separators described herein, for example those with serrations to improve acid mixing and acid circulation, may have different spacing and/or different patterns. Just show them as an example 15A - 15D Examples of serrated ridges that may be effective in the present exemplary embodiments. Such patterns and other patterns (both uniform and non-uniform, as well as ordered and disordered) can enable improved CCA (cold cranking amperage) within the flooded lead-acid battery, as well as other important improvements in the battery's electrical performance. In zigzag patterns like those in the 15A - 15D shown (as an example only), there is an approximately 53% reduction in surface area over a separator with a fixed rib (a control), which allows for less rib contact on the PAM (the positive active material), resulting in improved CCA performance leads. In such patterns as those in the 15A - 15D shown, there can be 33% less rib mass compared to a solid rib profile (a control), allowing for higher acid availability and improved performance. Additionally, it may be important to maintain PAM (positive active material) compression with a balance of fin mass and openings for mixing and acid availability.

Further, the placement of the protrusion(s) (such as depressions, serrations, or the like) and design must preferably be optimized for compression so as not to facilitate PAM degradation, and preferably supported over the grid frame so as not to dislodge the pellet Press contact with the positive grid frame or current collector.

The batteries of the present disclosure can result in cost savings with less lead required for superior performance due to increased PAM utilization. This in turn could reduce the cost of the battery, which is a need for automakers, and could reduce the weight of the battery, which is also a need for automakers.

In some cases, the improved separators used in the present disclosure may have optimized profiles that, when compared to the rib surface of a conventional rib profile such as a solid vertical rib profile, have a rib surface area that is 10 - 90% of that conventional rib surface area, preferably 30 - 70% of this conventional rib surface and more preferably in some cases 40-60% of this conventional rib surface. All of this depends on the fin geometry, fin spacing and the end goal of improving acid mixing and preventing acid stratification, all of which are optimized.

Examples

8th and 9 show battery experiments carried out in a cell container. The battery test cell shown in these photographs, with a white case and a group of lead electrodes, had the following general characteristics: Table 2 Length (mm) width (mm) Height (mm) The ke (mm) annotation Cell container 158 48 202 N/A Acid level 173 mm Positive plate 10 pcs. N/A 142 129 2 N/A Negative plate 11 pcs. N/A 142 129 1.5 N/A Group of plates 142 with separate r-overlap 48 146 mm including strap N/A Group is all panels welded together with a band across the top

In additional examples shown below, a commercial Group 31 19 Plate/Group Ca/Ca extended the battery test data. In this table, the separators marked “new” have the in the shell of the 14 Serrated profile shown, while results marked “Control” have solid ridges vertically along the separator. These results proved to be unexpected and/or surprising results in improving battery performance for start/stop enhanced flooded lead-acid batteries using improved separators according to the present disclosure. Significantly, the results in the table below showed improvements even when the batteries had not been placed in significant motion in a vehicle, but were only in general motion while moving from place to place within a facility for testing. Thus, when combined with the movement of a vehicle and/or the energy of various start/stop events, battery performance results can improve even more significantly. Table 3 High Rate Discharge (HRD) CCA on Midtronic Tension New-1 1347 930 12.98 New-2 1369 935 12.98 New-3 1352 910 12.96 New-4 1371 925 12.96 New-5 1348 913 12, 98 New-6 1377 931 12, 98 New-7 1374 930 12.98 New-8 1368 933 12, 98 New-9 1380 934 12, 98 New-10 1368 927 12.95 Average 1365.4 926.8 12,973 Std. deviation 12.02 8.64 0.01 Control-1 1295 874 12.86 Control-2 1321 902 12.86 Control-3 1303 884 12.86 Control-4 1323 890 12.89 Control-5 1316 894 12.87 Control-6 1312 883 12.88 Control-7 1314 895 12.86 Control-8 1328 897 12.86 Control-9 1319 886 12.89 Control-10 1343 928 12.89 Average 1317.4 893.3 12,872 Hours - Deviation 13.19 14.63 0.01 New to Control Average Improvement 48 33.5 0.101 % improvement 3.5% 3.6% 0.8% Std. Deviation Improvement (1.17) (5.99) (0.00) Remarks Higher discharge power with improved quality Improved cold start with standard deviation

The CFD examples related to 18A - 32B will be discussed show a cell in a short battery such as used in ISS, SLI or golf car batteries. The ones in the 35-37 and 39 The CFD examples discussed show a cell in a high battery, such as those used in the powertrain industry, such as forklift batteries.

The short cell examples show a separator that is approximately 142 mm wide and approximately 129 mm high, with a backsheet thickness of approximately 250 μm and a rib height of approximately 600 μm. The short cell examples also show approximately 3 mm between each side edge of the separator and the sidewall boundary of the battery case and a headspace above the separator of approximately 44 mm.

The tall cell examples show a separator that is approximately 158 mm wide and approximately 406 mm high, a back wall thickness of approximately 500 μm, and a fin height of approximately 1.8 mm. The tall cell examples also show approximately 3mm between each side edge of the separator and the sidewall boundary of the battery case and a headspace above the separator of approximately 51mm.

The importance of Midtronic's CCA test is that it is not a global standard test, but a handheld device that uses an algorithm to quickly and easily calculate the performance of the battery. Increasing the surface area of the positive grid exposed to acid using the acid mixing separator allows for improved conductivity and improved electrode performance. Although not an industry standard, it is now used in purchasing decisions around the world for simplicity and ease of use. Improving the performance of this algorithm tester is the key to customer satisfaction, and the acid mixing separator improvements facilitate this result, as shown in Table 3.

The following examples describe detailed analyzes of example separators and batteries using computational fluid dynamics (CFD) to quantify the effectiveness of the example embodiments disclosed herein to acid stratification within a lead-acid battery or a flooded lead-acid battery or an enhanced flooded battery or a flooded start/stop battery when idle. The models were generally started in a state of complete stratification, with the highest concentration of acid in the lower part of the battery and water in the upper part of the battery with an interface in between.

A sinusoidal graphical representation of lateral movement is in 17A where the position of the profile is shown as position (ft) over time (s). This movement can be described as moving the separators and/or batteries from a starting position to a positive displacement of 1 foot (ft), reversing the direction to move the modeled separators and/or batteries back to and beyond the starting position and to a negative 1 -Foot displacement, and reversing direction to bring the model back to the starting position are described. This movement described above occurs in 1 second. This motion pattern was used in all CFD models that simulated horizontal lateral or horizontal sideways motion and was repeated as many times as necessary to perform the analyzes for the desired length of time. The CFD analyzes described herein utilized lateral or lateral movement that occurred in a direction parallel to the cross-machine direction of the exemplary separator. In other words, the movement was horizontal and in a direction parallel to the main plane of the exemplary separators. 17A shows a liquid level 170, a movement 171, a first arrow 172 symbolizing SG = 1.0, and a second arrow 173 symbolizing SG = 1.26.

wobei
φ der Volumendurchschnitt von φ ist;
φ_c der Wert des ausgewählten Skalars in einer Zelle ist; und
V_c das Zellvolumen ist.Furthermore, from the analysis of the CFD models, a volume uniformity index (φ) of the acid volume fraction throughout the liquid electrolyte was derived, where perfectly mixed electrolyte would have a uniformity index of 1.0. This value was calculated using the following Equation 1: $$\phi =1-\frac{{\displaystyle {\sum }_c\left|{\phi }_c-\overline{\phi }\right|{\mathrm{<figure-callout\; id="2"\; label="v\; c"\; filenames="DE202016009027U1\_0029.png,DE202016009027U1\_0054.png"\; state="\{\{state\}\}">v</figure-callout>}}_c}}{2\left|\overline{\phi }\right|{\displaystyle {\sum }_c{v}_c}}|$$

where
φ is the volume average of φ;
φ _c is the value of the selected scalar in a cell; and
V _c is the cell volume.

17B - 17E show a comparison of a separator with fixed ribs ( 17B and 17D show fixed deflection elements with a solution time of 6.84 and 6.8416 seconds respectively) and a separator with serrated ribs ( 17C and 17E show jagged deflection elements with a solution time of 5.92465 or 6 seconds), each of which is the in 17A exposed to a defined movement and analyzed using CFD. Both separators analyzed were positive-enveloping separators, meaning that the separators enveloped a positive electrode plate with the solid or serrated (and also broken, as described below) ridges facing the positive electrode plate.

• - Überwachte Volumengleichförmigkeit der Volumsfraktion der Säure durch die ganze Flüssigkeit
• - Perfekte Durchmischung = 1,0
• - Ausgangswert = 0,32
• - durchschnittlicher Wert zwischen 56 und 58 Sekunden = 0,34
• - Veränderung = 7% 19A und 19B zeigen Leitelemente mit Zacken bzw. einen positiv umhüllenden Separator mit gezackten Rippen, der 60 Sekunden lang einer seitlichen Bewegung ausgesetzt und unter Verwendung von CFD analysiert wurde, um das Mischen eines geschichteten Elektrolyten einer Flooded-Blei-Säure-Batterie zu zeigen (Massenfraktion von H2SO4 der Flüssigkeit 191, 19A Sub-Modell-Ergebnisse bei 60 Sekunden bzw. 60 (s) Lösungszeit, 19B Sub-Modell-Ergebnisse bei 6 Sekunden bzw. 6,0 (s) Lösungszeit). Es ist zu sehen, dass es ein gewisses Ausmaß von Mischen am Außenumfang des Separators mit verstärktem Mischen zwischen den inneren gezackten Rippen gibt. 19A und 19B zeigen:
• - Über die größere Zeitdauer zeigt sich, wie erwartet, ein Mehr an Mischen
• - Hauptsächlich an den Taschenenden, aber ebenfalls erkennbar in der Mitte - nicht zu erkennen bei 6s.

18A and 18B show a solid fin positive envelope separator subjected to lateral motion for 60 seconds and analyzed using CFD to show mixing of a layered electrolyte of a flooded lead-acid battery (mass fraction of liquid H2SO4 181, 18A Sub-model results at 60 seconds or 57.4 (s) solution time, 18B Sub-model results at 6.8 seconds and 6.8 (s) solution time, respectively). It can be seen that there is a small amount of mixture at the outer perimeter of the separator, but very little, if any, mixture between the solid ribs. 18A and 18B show that there is more mixing (as expected) over the longer period of time. 18C shows the volume uniformity of the analysis and shows that lateral motion mixing resulted in a 7% increase in volume uniformity. 18C shows a graph that shows the mixing quality over time. The volume uniformity of the acid fraction () is shown over physical time (sec). An arrow 182 symbolizes better mixing.

• - Monitored volumetric uniformity of the volume fraction of acid throughout the liquid
• - Perfect mixing = 1.0
• - Initial value = 0.32
• - average value between 56 and 58 seconds = 0.34
• - Change = 7% 19A and 19B show serrated vanes and a serrated ridge positive envelope separator, respectively, subjected to lateral motion for 60 seconds and analyzed using CFD to demonstrate mixing of a layered electrolyte of a flooded lead-acid battery (mass fraction of H2SO4 the liquid 191, 19A Sub- Model results at 60 seconds or 60 (s) solution time, 19B Sub-model results at 6 seconds and 6.0 (s) solution time, respectively). It can be seen that there is some degree of mixing at the outer perimeter of the separator with increased mixing between the inner serrated ribs. 19A and 19B show:
• - As expected, there is more mixing over the longer period of time
• - Mainly at the ends of the pockets, but also noticeable in the middle - not noticeable on 6s.

• - Überwachte Volumengleichförmigkeit der Volumsfraktion der Säure durch die ganze Flüssigkeit
• - Perfekte Durchmischung = 1,0
• - Ausgangswert = 0,32
• - Durchschnittlicher Wert zwischen 58 und 60 Sekunden = 0,36
• - Veränderung = 12%

19C shows the volume uniformity of the analysis and shows that lateral motion mixing resulted in a 12% increase in volume uniformity. 19C shows a graph that shows the mixing quality over time. The volume uniformity of the acid fraction () is shown over physical time (sec). An arrow 192 symbolizes better mixing. The and is:

• - Monitored volumetric uniformity of the volume fraction of acid throughout the liquid
• - Perfect mixing = 1.0
• - Initial value = 0.32
• - Average value between 58 and 60 seconds = 0.36
• - Change = 12%

• - Gezacktes Design mischt gründlicher als festes Design
• - Mengenmäßig wie auch qualitativ
• - 5% besseres Mischen
• - Unterschied im Mischen zeigt sich bereits früh im Zeitverlauf
• - Bestätigt das Durchführen der optimierungs-CFD-Analyse < 60 Sekunden

20A is a side by side comparison of the CFD mixing results in the 18A , 18B and 19A , 19B Separators shown (mass fraction of H2SO4 of liquid 201, 20A fixed sub-model (left) and jagged sub-model (right), results at 60 seconds, solution time 42 seconds). 20A shows fixed baffles and that a serrated design mixes more thoroughly than a solid design. 20B shows a graph that describes the mixing quality over time. The volume uniformity of the acid fraction () is shown over physical time (sec). An arrow 202 symbolizes better mixing. It is shown that the serrated fin positive wrap separator provides a 5% increase in mixing uniformity compared to the solid fin positive wrap separator. Reference number 200 symbolizes that an initial improvement in mixing only increases over time.

• - Serrated design blends more thoroughly than solid design
• - Quantitatively as well as qualitatively
• - 5% better mixing
• - Difference in mixing becomes apparent early on over time
• - Confirms performing optimization CFD analysis < 60 seconds

• - Verwenden eines aktualisierten Beschleunigungsprofils;
• - Profil:
  • - Sinusbewegung von 0° auf 15° auf 0° für 0,5 Sekunden
  • - Pause für 0,5 Sekunden
  • - Sinusbewegung von 0° auf 15° auf 0° für 0,5 Sekunden
• - Gesamtzykluszeit beträgt 2 Sekunden
  • - Ereignisdauer 60 Sekunden (30 Zyklen) 22 zeigt eine bildliche Darstellung der CFD-Analyse eines Separators mit gezackten Rippen, welcher der in 21 beschriebenen Schaukelbewegung ausgesetzt ist (Massenfraktion von H2SO4 der Flüssigkeit 221, Lösungszeit 7,8 (s)).

21 shows a graph representing rotation over time. A cell rotation (degrees) is shown over physical time (sec). 21 defines a rocking motion used in a CFD analysis of a positive envelope separator with serrated ribs.

• - Using an updated acceleration profile;
• - Profile:
  • - Sinusoidal movement from 0° to 15° to 0° for 0.5 seconds
  • - Pause for 0.5 seconds
  • - Sinusoidal movement from 0° to 15° to 0° for 0.5 seconds
• - Total cycle time is 2 seconds
  • - Event duration 60 seconds (30 cycles) 22 shows a pictorial representation of the CFD analysis of a separator with serrated ribs, which is the in 21 is exposed to the described rocking motion (mass fraction of H2SO4 of the liquid 221, solution time 7.8 (s)).

23 is a schematic representation of a separator containing or encasing a negative electrode plate (negative envelope) of a flooded lead-acid battery, with the solid or serrated (and, as described hereinafter, broken) ridges facing the positive electrode plate. 23 shows a modified geometry of the submodel so that the separator has the negative plate (instead of the positive plate) and the jagged geometry underwent 60 seconds of horizontal acceleration. 23 shows a fluid region 230, a negative plate 231, a positive plate 232 and a serrated separator 233.

• - Überwachte Volumengleichförmigkeit der Volumsfraktion der Säure für die gesamte Flüssigkeit
• - Perfekte Durchmischung =1,0
• - Ausgangswert = 0,32
• - Durchschnittlicher Wert zwischen 58 und 60 Sekunden = 0,39
• - Veränderung = 22%

24A is a graphical representation of a CFD analysis of a negative envelope separator (negative envelope 241) with serrated ribs (or serrated baffles) subjected to lateral movement and further compares this to a graphical representation of a CFD analysis of a positive envelope separator (positive envelope 242) with serrated ribs subjected to the same lateral movement (mass fraction of H2SO4 of liquid 243, dissolution time 60 (s)). 24B shows a graphical representation of mixing quality over time. The volume uniformity of the acid fraction () is shown over physical time (sec). An arrow 244 symbolizes better mixing. 24B is a graphical representation of the volume uniformity of the negative envelope separator with serrated ribs of 24A , showing a 22% change in volume uniformity from the start of stratification to 60 seconds of mixing.

• - Monitored volumetric uniformity of the volume fraction of acid for the entire liquid
• - Perfect mixing =1.0
• - Initial value = 0.32
• - Average value between 58 and 60 seconds = 0.39
• - Change = 22%

• - Durch negative Umhüllung gesteigertes Mischen
  • - Positive Umhüllung = 12% Verbesserung beim Durchmischen
  • - Negative Umhüllung = 22% Verbesserung beim Durchmischen

24C shows a graphical representation of mixing quality over time. The volume uniformity of the acid fraction () is shown over physical time (sec). An arrow 245 symbolizes better mixing. 24C is a graphical comparison of the volume uniformity of a negative envelope serrated separator and a positive envelope serrated separator, showing that the negative envelope separator has a 10% increase in mixing over the positive envelope separator.

• - Mixing increased by negative wrapping
  • - Positive envelope = 12% improvement in mixing
  • - Negative envelope = 22% improvement in mixing

Now turning to 25A - 25F show several exemplary embodiments discontinuous rib arrangements with variables defining various discontinuous rib patterns used in CFD analyses.

• - gezeigte Wiederholungseinheit
• - drei stetige Variable
  • • 1 mm < Höhe < 15 mm
  • • 15° < Winkel < 165°
  • • 0,5 mm < Säulenabstand < 15 mm
• - drei binäre Variable
  • - Säule 1 Richtungänderung
  • - Säule 2 Richtungänderung
  • - Säule 1 auf 2 Richtungänderung
• - Abhängige Variable stellen sicher:
  • - Volle Abdeckung der Separatorfläche
  • - Überlappung zwischen den Säulen
  • - Zentrierte Säulen im Separator

25A shows:

• - repeated unit shown
• - three continuous variables
  • • 1 mm < height < 15 mm
  • • 15° < angle < 165°
  • • 0.5 mm < column spacing < 15 mm
• - three binary variables
  • - Pillar 1 change of direction
  • - Pillar 2 change of direction
  • - Pillar 1 to 2 direction change
• - Dependent variables ensure:
  • - Full coverage of the separator surface
  • - Overlap between columns
  • - Centered columns in the separator

• - gezeigte Wiederholungseinheit
• - drei stetige Variable
  • - Höhe = 9,6 mm
  • - Winkel = 72°
  • - Säulenabstand = 3 mm
  • - Stärke = 1mm
• - drei binäre Variable
  • - Säule 1 kein Abwechseln
  • - Säule 2 Abwechseln
  • - Säule 1 and 2 kein Umspringen
• - Abhängige Variable stellen sicher:
  • - Volle Abdeckung der Separatorfläche
    • - 13 Säulen von Säulen 1 und 2
  • - Überlappung zwischen den Säulen
  • - Zentrierte Säulen im Separator

25B shows:

• - repeated unit shown
• - three continuous variables
  • - Height = 9.6mm
  • - Angle = 72°
  • - Column spacing = 3 mm
  • - Thickness = 1mm
• - three binary variables
  • - Pillar 1 no alternation
  • - Column 2 Alternate
  • - Columns 1 and 2 no jumping around
• - Dependent variables ensure:
  • - Full coverage of the separator surface
    • - 13 columns from columns 1 and 2
  • - Overlap between columns
  • - Centered columns in the separator

• - gezeigte Wiederholungseinheit
• - drei stetige Variable
  • - Höhe = 9,8 mm
  • - Winkel = 77,2°
  • - Säulenabstand = 3,09 mm
  • - Stärke = 1mm
• - drei binäre Variable
  • - Säule 1 kein Abwechseln
  • - Säule 2 Abwechseln
  • - Säule 1 and 2 kein Umspringen
• - Abhängige Variable stellen sicher:
  • - Volle Abdeckung der Separatorfläche
    • - 13 Säulen von Säulen 1 und 2
  • - Überlappung zwischen den Säulen
  • - Zentrierte Säulen im Separator

25C shows:

• - repeated unit shown
• - three continuous variables
  • - Height = 9.8mm
  • - Angle = 77.2°
  • - Column spacing = 3.09 mm
  • - Thickness = 1mm
• - three binary variables
  • - Pillar 1 no alternation
  • - Column 2 Alternate
  • - Columns 1 and 2 no jumping around
• - Dependent variables ensure:
  • - Full coverage of the separator surface
    • - 13 columns from columns 1 and 2
  • - Overlap between columns
  • - Centered columns in the separator

• - gezeigte Wiederholungseinheit
• - drei stetige Variable
  • - Höhe = 9,6 mm
  • - Winkel = 74,7°
  • - Säulenabstand = 3 m
  • - Stärke = 1mm
• - drei binäre Variable
  • - Säule 1 kein Abwechseln
  • - Säule 2 Abwechseln
  • - Säule 1 auf 2 kein Umspringen
• - Abhängige Variable stellen sicher:
  • - Volle Abdeckung der Separatorfläche
    • - 13 Säulen von Säulen 1 und 2
  • - Überlappung zwischen den Säulen
  • - Zentrierte Säulen im Separator

25D shows:

• - repeated unit shown
• - three continuous variables
  • - Height = 9.6mm
  • - Angle = 74.7°
  • - Column spacing = 3 m
  • - Thickness = 1mm
• - three binary variables
  • - Pillar 1 no alternation
  • - Column 2 Alternate
  • - No switching from column 1 to 2
• - Dependent variables ensure:
  • - Full coverage of the separator surface
    • - 13 columns from columns 1 and 2
  • - Overlap between columns
  • - Centered columns in the separator

• - gezeigte Wiederholungseinheit
• - drei stetige Variable
  • - Höhe = 9,5 mm
  • - Winkel =78,3°
  • - Säulenabstand = 3,09 mm
  • - Stärke = 1mm
• - drei binäre Variable
  • - Säule 1 kein Abwechseln
  • - Säule 2 Abwechseln
  • - Säule 1 auf 2 kein Umspringen
• - Abhängige Variable stellen sicher:
  • - Volle Abdeckung der Separatorfläche
    • - 13 Säulen von Säulen 1 und 2
  • - Überlappung zwischen den Säulen
  • - Zentrierte Säulen im Separator

25E shows:

• - repeated unit shown
• - three continuous variables
  • - Height = 9.5mm
  • - Angle =78.3°
  • - Column spacing = 3.09 mm
  • - Thickness = 1mm
• - three binary variables
  • - Pillar 1 no alternation
  • - Column 2 Alternate
  • - No switching from column 1 to 2
• - Dependent variables ensure:
  • - Full coverage of the separator surface
    • - 13 columns from columns 1 and 2
  • - Overlap between columns
  • - Centered columns in the separator

• - gezeigte Wiederholungseinheit
• - drei stetige Variable
  • - Höhe = 9,6 mm
  • - Winkel = 73,8°
  • - Säulenabstand = 3 mm
  • - Stärke = 1mm
• - drei binäre Variable
  • - Säule 1 kein Abwechseln
  • - Säule 2 Abwechseln
  • - Säule 1 auf 2 kein Umspringen
• - Abhängige Variable stellen sicher:
  • - Volle Abdeckung der Separatorfläche
    • - 13 Säulen von Säulen 1 und 2
  • - Überlappung zwischen den Säulen
  • - Zentrierte Säulen im Separator

25F shows:

• - repeated unit shown
• - three continuous variables
  • - Height = 9.6mm
  • - Angle = 73.8°
  • - Column spacing = 3 mm
  • - Thickness = 1mm
• - three binary variables
  • - Pillar 1 no alternation
  • - Column 2 Alternate
  • - No switching from column 1 to 2
• - Dependent variables ensure:
  • - Full coverage of the separator surface
    • - 13 columns from columns 1 and 2
  • - Overlap between columns
  • - Centered columns in the separator

26A - 26G illustrate broken rib battery separators according to exemplary embodiments of the present disclosure and as shown in the patterns of 25A-25F Are defined. Example battery separators are in the 26A-26G shown; Additionally, exemplary battery separators disclosed herein may include any number of columns 2606 ¹ - 2006 ⁿ .

• - Begonnen mit schlechtest möglichem Fall
  • - 100% Säureschichtung
  • - Beschränkte Bewegung (z. B. 60 Sekunden)
• - Gleichmäßig gemischte Säure
  • - Ermöglicht bessere Ausnützung der Elektroden beim Aufnehmen von Energie und beim Bereitstellen von Energie
  • - Verhindert tote Zonen oder sulfatierte Bereiche auf der Elektrode, die anfällig für Ablösen sind und verbessert daher PSoC

27A and 27B is a graphical comparison of a CFD analysis of a negative wrap separator with serrated ribs and a negative wrap separator with broken ribs (as in 26D shown) that have been subjected to substantially lateral or horizontal movement ( 27A , serrated baffles, serrated, negative envelope, mass fraction of liquid H2SO4 271, solution time 60 (s), 27B , Concept 1 design, negative envelope, mass fraction of H2SO4 of liquid 271, solution time 60 (s)). 27C and 27D shows a comparison of the volumetric uniformity of several CFD analyzes of previously described separators subjected to lateral movement. 27C shows a graph showing a design comparison over 60 seconds. A volume uniformity () over time [sec] is shown. An arrow 272 symbolizes better mixing. A 6% increase is shown with a double arrow 273.

• - Started with worst possible case
  • - 100% acid layering
  • - Limited movement (e.g. 60 seconds)
• - Evenly mixed acid
  • - Enables better utilization of the electrodes when absorbing energy and providing energy
  • - Prevents dead zones or sulfated areas on the electrode that are prone to peeling and therefore improves PSoC

The negative envelope separator with broken ribs results in a 26% increase in mixing after 60 seconds compared to the negative envelope separator with serrated ribs. In 27D 1, an illustration with a fixed rib 274, an illustration with a serrated rib 275, an illustration with a serrated rib and a negative envelope 276, and an illustration with an optimized rib and a negative envelope 277 are shown.

• - Kurven angepasst, um bei gleichem Startwert von Volumengleichmäßigkeit zu beginnen
  • - Variationen in der Geometrie beeinflussen absolute Werte
• - Gezeigte prozentuelle Zuwächse sind relativ zu dem Startpunkt der Gleichmäßigkeit des jeweiligen Designs

Now turning to 28A and 28B These show a graphical comparison of a CFD analysis of a negative wrap separator with fixed ribs and a negative wrap separator with interrupted ribs (as in 26D shown) that have been subjected to substantially lateral or horizontal movement as shown ( 28A , solid baffles, solid, negative envelope, mass fraction of H2SO4 of liquid 281, solution time 60 (s), 28B , Concept 1 design, negative envelope, mass fraction of H2SO4 of liquid 281, solution time 60 (s)). 28C shows a comparison of the volumetric uniformity of several CFD analyzes of previously described separators subjected to substantially lateral or horizontal movement. 28C shows a graph showing a design comparison over 60 seconds. A volume uniformity () is shown over physical time [sec]. A 13% increase 282, a 22% increase 283 and a 28% increase 284 are shown. The negative wrap separator with interrupted ribs gives a 28% increase in mixing after 60 seconds.

• - Adjusted curves to start at the same starting value of volume uniformity
  • - Variations in geometry affect absolute values
• - Percentage increases shown are relative to the starting point of uniformity of each design

• - Separator ist in 3 Zonen geteilt
  • - Jede Zone ist 47,33 mm breit
• - Rippengeometrie von Zone 1 und 2 und 3 kann unabhängig voneinander verändert sein
• - Zackengeometrie von Zone 3 kann identisch zu jener von Zone 1 sein
• - 12 unabhängige Variable

29A describes a separator having three zones with different interrupted rib patterns, the zones changing in a lateral direction along the cross-machine direction of the separator. It is noted that the zones may also be distributed in the machine direction of the separator or in both the machine and cross-machine directions of the separator. It will further be appreciated that there may be any number of zones in one or both directions. Additionally For example, the edges of the separator themselves can be their own zones, so that the edges are optimized with a particular design and/or a ribbed pattern and/or a broken ribbed pattern or the like for even better results. In certain preferred embodiments herein, the zones of the separator (for a multi-zone separator) are formed such that the mass of patterning in each zone is relatively uniform and/or that the patterned separator runs well on battery manufacturing equipment and/or that battery manufacturing due to the efficiency of acid filling occurs more quickly. 29A shows:

• - Separator is divided into 3 zones
  • - Each zone is 47.33mm wide
• - Rib geometry of zones 1 and 2 and 3 can be changed independently of each other
• - Serration geometry of Zone 3 can be identical to that of Zone 1
• - 12 independent variables

• - Aufgabe
  • - Maximieren des Volumengleichmäßigkeitszuwachses
• - Zwölf Variable
  • • 2 mm < Höhe_1,2 < 12 mm
  • • 45° < Winkel_1,2 < 135°
  • • 0,5 mm < Säulenabstand_1,2 < 12 mm
  • • Säule 1 Richtungänderung_1,2
  • • Säule 2 Richtungänderung_1,2
  • • Säule 1 auf 2 Richtungänderung_1,2

29B shows broken rib pattern variables for the zoned separator. The subscript numbers “1” and “2” refer to two different broken rib patterns. In certain embodiments, zone 1 and zone 3 (index "1") contain identical patterns, such as broken rib patterns, with zone 2 (index "2") having a pattern, such as a broken rib pattern, similar to that in zones 1 and 1 3 differs. 29B shows:

• - Task
  • - Maximize volume uniformity growth
• - Twelve variables
  • • 2 mm < height _1.2 < 12 mm
  • • 45° < angle _1.2 < 135°
  • • 0.5 mm < column spacing _1.2 < 12 mm
  • • Pillar 1 change of direction _1,2
  • • Pillar 2 change of direction _1,2
  • • Pillar 1 to 2 change of direction _1,2

• - gezeigte Wiederholungseinheit
  • - drei stetige Variable
    • • 2 mm<Höhe < 12 mm
    • • 45° < Winkel < 135°
    • • 0,5 mm < Säulenabstand < 12 mm

• - drei binäre Variable
  • - Säule 1 Richtungänderung
  • - Säule 2 Richtungänderung
  • - Säule 1 auf 2 Richtungänderung
• - Abhängige Variable stellen sicher
  • - Volle Abdeckung der Separatorfläche
  • - Überlappung zwischen den Säulen
  • - Zentrierte Säulen im Separator

29C shows broken rib variables for a single zone separator with broken ribs. 29C shows:

• - repeated unit shown
  • - three continuous variables
    • • 2 mm<height < 12 mm
    • • 45° < angle < 135°
    • • 0.5 mm < column spacing < 12 mm

• - three binary variables
  • - Pillar 1 change of direction
  • - Pillar 2 change of direction
  • - Pillar 1 to 2 direction change
• - Dependent variable ensure
  • - Full coverage of the separator surface
  • - Overlap between columns
  • - Centered columns in the separator

30A - 30H show variations of separators with three zones and interrupted rib patterns.

31A - 31D show graphical representations of CFD analyzes of four different negative-enveloping three-zone separators with interrupted rib patterns. 31A shows 15% increase over negative envelope with serrated rib, 31B shows 13% increase over negative envelope with serrated rib, 31C shows 8% increase over negative envelope with serrated rib, and 31D shows 8% increase over negative envelope with serrated rib ( 31A - 31D , mass fraction of H2SO4 of liquid 311, dissolution time 5 (s)).

• - Zuwachs an Volumengleichmäßigkeit, gezeigt relative zum Startpunkt für jedes Design
• - Designs mit negativer Umhüllung

32A and 32B is a graphical comparison of CFD analyzes of a negative-enveloping three-zone interrupted-rib separator and a negative-enveloping one-zone interrupted-rib separator (as in 26D shown) that was subjected to lateral movement. 32A and 32B shows concepts 1 and 2, separators with negative wrapping. 32A shows concept 2, design, 32B shows concept 1, design ( 32A and 32B , mass fraction of H2SO4 of liquid 321, dissolution time 60 (s)). 32C shows a comparison of the volumetric uniformity of the acid fraction of several CFD analyzes of previously described separators subjected to lateral movement; In this graph it is shown that the three zone separator gives a 1% increase in mixing compared to the single zone separator. 32C shows a graph showing a design comparison over 60 seconds. A volume uniformity () is shown over a real time (sec). A 13% increase 322, a 22% increase 323, a 28% increase 324 and a 29% increase 325 are shown. 32C shows:

• - Gain in volume uniformity shown relative to the starting point for each design
• - Negative wrap designs

33A - 33C illustrate the headspace of batteries with baffles according to exemplary embodiments of the present disclosure. 33a shows design 1 - middle triangle. The first deflector design features an upside down triangle in the center of the headspace. Deflector width = 0.06 m, deflector height = 0.05 m, rounding radius = 0.02 m. 33B shows design 2 - opposite arches. The second deflector design has two arc-shaped deflectors from each side wall, height from ceiling = 0.03 m, deflector width = 0.05 m, deflector height = 0.05 m, arc radius = 0.05 m. 33C shows design 3 - middle divider. The third deflector includes a rectangular divider located in the center of the volume. Deflector width = 0.005 m, deflector height = coincides with the upper edge of the deflector element. These baffles can be used with any of the exemplary separators described herein. In these embodiments, the headspace of each battery is optimized to better utilize the power or energy (both horizontal and vertical energy) of the moving or sloshing electrolyte and/or the acid wave or wave motion to improve acid mixing and the volumetric uniformity of the acid fraction in the throughout the lead-acid battery and along all parts of the electrode plates within the battery to approach or even achieve volume uniformity of 1.0 (fully mixed). The deflection elements may be formed or attached to the lid or interior walls of the battery casing, or may take the form of a device that is attached to the electrode straps. The baffles may also have flat surfaces, curved convex or concave shapes, concavo-convex shapes, sharp or filleted edges, or any other shape. Additionally, the electrode bands can be designed or moved to better cooperate with the baffles or other splashing and/or agitation that the electrolyte may experience during movement of the battery. The baffles may also float on the electrode or have one or more pivots to optimize the effects of splashes and/or movements that the electrolyte may experience during movement of the battery.

Additionally, the battery design can change to facilitate acid destratification. One such example may include mounting the battery on resilient mounts such as. B. springs or rubber or another viscoelastic material to allow the battery to continue moving or wobbling after a change in speed. The battery case can be made larger by adding more electrolyte to increase the head pressure of the total electrolyte supply within the battery. The battery can also be designed as a horizontal cylinder or an oval or even a sphere. In addition, the housing cover can be designed as a dome.

34A - 34H illustrate various details of exemplary embodiments of the present disclosure.

34A shows a computational fluid dynamics (CFD) in the left illustration, where fixed deflection elements and an upper edge of the plates 341 are shown and a solution time of 5.0038 (s) is provided. 1) Vehicle movement promotes mixing in the battery headspace, 2) No mixing occurs between the plates. In the right representation of the 34A 341a shows: the battery headspace, always just water, 341b shows some mixing taking place at the interface & a little more at edges, 341c shows a little more mixing outside of positive enveloped plate, 341d shows minimal mixing after lateral movement the lower half of the battery, concentrated acid, and 341e shows separator ribs act as solid baffles that contain the lateral movement of the acid. A double arrow 341f is also shown, which symbolizes movement. In addition, there are 34A The following simulation conditions are provided in the illustration on the right: - Time 60 seconds; Reach 2 feet forward, 2 feet back; Number of Cycles: 30, - Positive Wrapped & Standard Rib Profile. In addition, pure water, 0% acid 341g and concentrated acid (35% by weight) 341h are provided.

wobei φ das durchschnittliche Säurevolumen, φ_C das Volumen der Säure in ausgewählter Zelle (z.B. Pixel), V_C das Volumen in der ausgewählten Zelle und C die Anzahl der Zellen (+10 Millionen) angibt. 342b zeigt die Annäherung an die asymptotische Grenze nach 60 Sekunden an. Der Gleichmäßigkeitsindex beschreibt die Verteilung einer bestimmten Menge (z.B. Säure) in einem gegebenen Gesamtvolumen (z.B. Batteriegehäuse). Wenn die Säure gleichmäßig verteilt ist, ist die sich ergebende Indexzahl 1,0. Außerdem ist ein CFD-Modell von schwappender Säure vorgesehen, Advektionskräfte, Diffusion (z.B. Ficksches Gesetz) und Turbulentes Mischen. Außerdem ist in 34B ein Pfeil 342c vorgesehen, der ein besseres Mischen symbolisiert. 34B shows a diagram of the time course of the mixing quality, showing the volume uniformity of the acid fraction () over physical time (sec). 342a shows the starting point with no movement and a uniformity index at 0.32. The uniformity index is determined by the following formula: $$\mathrm{\phi }=1-\frac{{\displaystyle {\sum }_C\left|{\mathrm{\phi }}_C-\overline{\phi }\right|{\mathrm{<figure-callout\; id="2"\; label="v\; C"\; filenames="DE202016009027U1\_0029.png,DE202016009027U1\_0054.png"\; state="\{\{state\}\}">v</figure-callout>}}_C}}{2\left|\overline{\phi }\right|{\displaystyle {\sum }_C{v}_C}}$$

where φ is the average volume of acid, φ _C is the volume of acid in selected cell (e.g. pixel), V _C is the volume in the selected cell and C is the number of cells (+10 million). 342b shows the approach to the asymptotic limit after 60 seconds. The uniformity index describes the distribution of a certain amount (e.g. acid) in a given total volume (e.g. battery housing). If the acid is evenly distributed, the resulting index number is 1.0. Also provided is a CFD model of sloshing acid, advection forces, diffusion (e.g. Fick's law) and turbulent mixing. Furthermore, in 34B an arrow 342c is provided, which symbolizes better mixing.

34C shows a jagged rib profile 343a, a mixing uniformity report list 343b, localized mixing 343c, and an extensive mixing interface 343d. In addition, the mass fraction of H2SO4 of the liquid is 343e, a solid rib profile (volume uniformity index @ 0.34) 343f, a serrated rib profile (volume uniformity index @ 0.36) 343g, a movement in the lateral direction +5% 343h, a serrated rib +5% 343i, and total +10% 343j shown.

34D shows a fluid space 344a, a negative plate 344b, a positive plate 344c, a serrated separator 344d. Furthermore shows 34D a mixing uniformity report list 344e and a significant movement of the concentrated acid into the dilution range 344f. 344g shows, 1) Negative wrapping provides better mixing of acid with bulk or acid in the spatial area and 2) Serrated rib allows acid to move across the surface of the plate. Also, a serrated rib (volume uniformity @ 0.36) is 344h, a serrated rib & negative wrap (volume uniformity @ 0.39) is 344i, a lateral movement is +5% 344j, a serrated rib is +5% 344k, change to negative Coverage +8% 344l, and total +18% 344m shown.

34E shows two solutions 345a (solution 1 - serrated rib), 345b (solution 2 - concept design) which aim to convert sideways movement into vertical acid mixing. Solution 1 (345a) shows serrated ribs and solution 2 (345b) shows a concept design. Solution 1 (345a): Break the rib to allow acid mixing, Solution 2 (345b): Optimize the tine design (angle, column spacing & height) to optimize mixing.

34F a mixing uniformity report list 346a shows that the highly concentrated acid column extends higher into the vertical space 346b, and that a significant improvement in acid mixing can be achieved due to: 1) optimized profile and 2) negative envelope 346c. Also shown is water (acid wt. 0%) 346d, and concentrated acid (acid wt. 35%) 346e. Also shown is an example with serrated rib & negative wrap (volume uniformity @ 0.39) 346f and an example with optimized rib profile & negative wrap (volume uniformity @ 0.42) 346g. A lateral movement +5% 346h, a serrated rib +5% 346i, a change to negative envelope +8% 346j, an optimized serrated profile 5% 346k and a total +23% 346l shown.

34G shows: Step 1 (347a): Loading the PSoC; H ₂ SO ₄ , with only a portion of the electrode remaining functional; Effect: Reduction proportional to functional area (50%). 34G also shows: Step 2 (347b): Discharging the PSoC; When discharged, PbSO ₄ is generated on the electrode surface in the functional area; Impact: Reduction proportional to functional area (50%) & time to reduce large sulfate crystals. 34G also shows: Step 3 (347c): continuous discharge in PSoC; Crystalline layer of PbSO ₄ is created deep in the electrode, ultimately causing it to lose its functionality; Impact: Reduction proportional to functional area (50%) & time to reduce large sulfate crystals. 34G also shows a functional area 347d and sulfate crystals 347e. 34H shows technical/economic needs 348a, Power output (starting engine) 348b, Cyclization in PSoC 348c, Dynamic charge absorption 348d, Short circuit protection during deep discharge 348e, Endurance at high temperature 348f, Lower system costs 348g, Solutions 348h, Low ER separator 348i, Passive acid mixing 348j , Passive Acid Mixing Lower Water Loss 348k, Microporous Polymer Structure 348l, Excess Electrolyte 348m, Faster Assembly & Fewer Components 348n, EFB without Solutions 348o, EFB with Solutions 348p, VRLA-AGM 348q, Poor 348r and Excellent 348s.

• Gleichmäßigkeitsindex von $$\mathrm{\phi }=1-\frac{{\displaystyle {\sum }_C\left|{\mathrm{\phi }}_C-\overline{\phi }\right|{\mathrm{<figure-callout\; id="2"\; label="V\; C"\; filenames="DE202016009027U1\_0029.png,DE202016009027U1\_0054.png"\; state="\{\{state\}\}">V</figure-callout>}}_C}}{2\left|\overline{\phi }\right|{\displaystyle {\sum }_C{V}_C}}$$
  
  wobei φ der Volumendurchschnitt von φ ist, φ_C der Wert des ausgewählten Skalars in einer Zelle ist und V_C das Zellenvolumen ist. Dieser Gleichmäßigkeitsindex beschreibt die Verteilung einer bestimmten Menge in einem Volumen. Wenn die Menge gleich verteilt ist, ist der sich ergebende Wert 1. Der Bericht ist in Anwendungen nützlich, wo eine gleichmäßige Flussrate über das gesamte Volumen hinweg wünschenswert ist. Wärmetauscher, Katalysatoren und Filter sind Beispiel solcher Anwendungen.

The uniformity of a scalar set in a volume is calculated as:

• Uniformity index of $$\mathrm{\phi }=1-\frac{{\displaystyle {\sum }_C\left|{\mathrm{\phi }}_C-\overline{\phi }\right|v_C}}{2\left|\overline{\phi }\right|{\displaystyle {\sum }_C{v}_C}}$$
  
  where φ is the volume average of φ, φ _C is the value of the selected scalar in a cell, and V _C is the cell volume. This uniformity index describes the distribution of a certain amount in a volume. If the quantity is equally distributed, the resulting value is 1. The report is useful in applications where a consistent flow rate across the entire volume is desirable. Heat exchangers, catalytic converters and filters are examples of such applications.

35 shows a separator for a high cell battery with a rib pattern essentially as shown in 26D is shown. A mass fraction of H2SO4 of the liquid is 349 and a solution time of 60(s) is provided.

36 shows changing volume uniformity over time derived from CFD analysis of the in 35 Separator shown in comparison to other separator designs. A design comparison over 60 seconds is shown (volume uniformity () over physical time [sec]). The test cells were simulated to undergo lateral movement as in 17A shown, with the separators lying parallel to the direction of movement, were exposed for 60 seconds. The thin bottom line represents a short separator with a solid rib pattern and the thick bottom line represents a tall separator with a solid rib pattern. The upper thin line represents a short separator with a preferred broken rib pattern and the upper thick line represents a tall separator with a preferred broken rib pattern. As can be seen, the short separator with a solid rib pattern showed a 13% increase in its volume uniformity compared to the tall separator with a solid rib pattern, which only showed a 7% increase. The short separator with a preferred interrupted rib pattern showed a 28% increase in volume uniformity. The tall separator with a preferred interrupted rib pattern showed a 62% increase in volume uniformity with 60 seconds of lateral movement - the best increase of the tested selection.

37 shows comparisons of the velocity contour time course of the inventive concept 1 of the high acid mixing profile with the conventional high profile of the solid baffles. A speed contour time recording 350, concept 1, to the power of 351, and fixed deflection elements to the power of 352 are shown.

38 shows an exemplary spacer according to the invention with a pattern of interrupted ribs which can be arranged between a separator and an electrode. As can be seen, the interrupted ribs are held in place by a network of thin stringers. The stringers are shown in vertical and horizontal arrangements, but it goes without saying that other angles can be made.

39A - 39C show exemplary embodiments of dimensional values applicable to inventive Motive Power, Spacing and Headspace type separator profiles in, for example, tall batteries or battery cases. In 39B A separator 390, a negative plate 391, a positive plate 392 and a gap 393 are shown.

40 and 41 show profile prototypes of exemplary inventive acid mixture profiles.

42A and 42B include images showing the mixing advantage of a profile according to the invention over a conventional solid rib profile. 42A shows concept 1 - 30 movements water/acid well mixed. 42B shows control profile with fixed ribs - 30 movements water/acid remain layered. Also shown is well mixed 421, unmixed - water 422 and unmixed - acid 423.

Additionally, the battery design can change to facilitate acid destratification. One such example may include mounting the battery on resilient mounts, such as springs or rubber or other viscoelastic material, to allow the battery to continue moving or being shaken after a change in speed. The battery case can be made larger by adding more electrolyte to increase the head pressure of the total electrolyte supply within the battery. The battery can also be designed as a horizontal cylinder or an oval or even a sphere. In addition, the housing cover can be designed as a dome.

The separators described herein may further be used in combination with other devices used to prevent/reverse acid stratification, such as baffles, dip tubes, acid pumps or bubblers, positive displacement devices, or any combination thereof. Many such devices are disclosed below: U.S. Patent Application Publications Nos. 2012/0214032 to Franklin et al., no. 2004/0067410 to Jones and No. 2003/0148170 to Jones and U.S. Patent Nos. 6,274,263 to Jones, No. 4,629,622 to Yonezu et al. and no. 4,565,748 to Dahl; all of which are hereby incorporated by reference. The separator can be in sheet form, as a sheath or as a full tube/sheath. The separator may further be provided with a full-side crimp/seal or with intermittent crimps/seals and may even be provided with openings at the bottom fold of the folded separator.

It should be understood that any of the rib patterns described herein may have spacing between columns to allow gas to rise during overload events. Furthermore, the broken rib pattern does not require machine direction spacing between rows of broken ribs to provide strength when the separator is folded to form a shell. In addition, the separators can be further embossed with interrupted ribs. It is further understood that each of the rib patterns or other projections may be disposed on any interior surface of the battery case or on any surface on one or both of the positive and negative electrodes. For batteries installed in vehicles, a preferred embodiment may place the separators in an orientation that is generally parallel to the movement of the vehicle to take advantage of the starting and stopping motion of that vehicle.

It is believed that the improved separators described herein, such as the interrupted fin separators described herein, may further help prevent the formation of sulfate crystals and may also help provide more uniform heat distribution and/or heat mixing and/or thermal or To provide heat dissipation (heat dissipation in less time compared to known separators such as solid fin separators for flooded lead-acid batteries) via the separator. It is also believed that the exemplary broken rib separators described herein may also provide improved or faster or efficient filling of flooded lead-acid batteries, gel batteries, and/or enhanced flooded batteries.

In various embodiments of the present disclosure, the disclosed separator provides reduced acid stratification or even complete elimination of acid stratification altogether, such that the degree of mixing or volumetric uniformity of the acid or electrolyte within the flooded lead-acid battery is or is 1.0 close to 1.0. In various embodiments, the separator disclosed herein is also a low electrical resistance (ER) separator. In such embodiments, the separator may include improvements such as improved fillers that improve porosity, pore size, internal pore surface area, wettability, and/or surface area of the separator. In some embodiments, the improved fillers have a high structural morphology and/or a reduced particle size and/or a different amount of silanol groups than previously known fillers and/or are more hydroxylated than previously known fillers. The improved fillers can absorb more oil and/or allow for the incorporation of a greater amount of processing oil during separator formation without concomitant shrinkage or compression when the oil is removed after extrusion. For example, the improved separator is made using a silica having an intrinsic oil absorption value of about 175 to 350 ml/100 gm, in some embodiments 200 to 350 ml/100 gm, in some embodiments 250 to 350 ml/100 gm, and in some other embodiments 260 to 320 ml/100 g, although other oil absorption values are also possible.

The fillers can reduce the so-called hydration sphere of electrolyte ions, improving their transport across the membrane and thereby reducing the battery's total electrical resistance or ER, such as: B. an improved flooded battery or an improved system.

The filler or fillers may contain various species (such as polar species such as metals) that facilitate the flow of electrolyte and ions through the separator. This also results in reduced overall electrical resistance since such a separator is used in a flooded battery such as an improved flooded battery.

The low ER microporous separators herein may further include a new and improved pore morphology and/or a new and improved fibril morphology such that the separator helps to significantly reduce electrical resistance in a flooded lead-acid battery, if such Separator is used in such a flooded lead-acid battery. Such improved pore morphology and/or fibril morphology can result in a separator whose pores and/or fibrils approximate a shish-kebab (or shish-kabob) type morphology. Another way to describe the novel and improved pore shape and structure is that it is a structured fibril morphology in which silica knots or nodules of silica are attached to the kebab formations on the polymer fibrils (the fibrils are sometimes called shale) within of the battery separator are present. Additionally, in certain embodiments, the silica structure and the pore structure of a separator according to the present invention may be described as a skeletal structure or a vertebral structure or a spine structure, with silica nodes on the "kebabs" of the polymer along the fibrils of the polymer such as vertebrae or disks (the "kebabs") ") appear, sometimes oriented substantially perpendicular to an elongated central spine or fibril (long-chain polymer crystal) that approximates a spinal columnar shape (the "shish").

In some cases, the improved battery comprising the improved separator with the improved pore morphology and/or fibril morphology may have 20% less, in some cases 25% less, in some cases 30% less electrical resistance, and in some cases even a decrease in electrical resistance Resistance (“ER”) by more than 30% (which can reduce the internal resistance of the battery), while such a separator maintains and maintains a balance of other important, desirable mechanical properties of lead-acid battery separators. Furthermore, in certain embodiments, the separators described herein have a new and/or improved pore shape such that more electrolyte flows through or fills the pores and/or cavities compared to known separators. The ultra-high molecular weight polyethylene in the separator may comprise a polymer in a shish kebab formation comprising multiple long chain crystals (the skewer formations) and multiple folded chain crystals (the kebab formations), wherein the average repetition or periodicity of the kebab -Formations from 1 nm to 150 nm, preferably from 10 nm to 120 nm and more preferably from 20 nm to 100 nm (at least on parts of the rib side of the separator). In certain of these low ER embodiments of the present separator, the separator for a lead-acid battery described herein comprises a filler selected from the group consisting of silicon dioxide, precipitated silicon dioxide, fumed silicon dioxide and precipitated amorphous silicon dioxide; wherein the molecular ratio of OH to Si groups within the filler, as measured by ²⁹ Si NMR, is in a range from 21:100 to 35:100, in some embodiments from 23:100 to 31:100, in some embodiments from 25 :100 to 29:100 and in certain preferred embodiments is 27:100 or higher.

In certain selected embodiments, the disclosed separators have a reduced electrical resistance, for example an electrical resistance of no more than approximately approximately 200 mΩ.cm ² , 180 mΩ.cm ² , 160 mΩ.cm ² , 140 mΩ.cm ² , 120 mΩ.cm ² , 100 mΩ.cm ² , 80 mΩ.cm ² , 60 mΩ.cm ² , 50 mΩ.cm ² , 40 mΩ.cm ² , 30 mΩ.cm ² or 20 mΩ.cm ² . In various embodiments, the separators described herein demonstrate a reduction in ER of approximately 20% or more compared to a known separator of equal strength. For example, a known separator may have an ER value of 60 mΩ.cm ² ; thus, a separator according to the present invention would have an ER value of less than about 48 mΩ.cm ² for the same thickness. The low ER separators described herein may have some or all of the features described in the preliminary US Patent Application No. 62/319,959 , which is owned by Daramic, LLC and filed on April 8, 2016, which provisional application is incorporated herein by reference in its entirety.

According to at least selected embodiments, the present disclosure is directed to improved lead-acid batteries, such as flooded lead-acid batteries, improved systems comprising a lead-acid battery and/or a battery separator, improved battery separators Vehicles, including such systems, methods of manufacture or use, or combinations thereof. According to at least certain embodiments, the present disclosure is directed to improved flooded lead-acid batteries, improved battery separators for such batteries, and/or methods of making, testing, or using such improved flooded lead-acid batteries, or combinations thereof. Additionally, disclosed herein is a method, system, battery, and/or battery separator for reducing acid stratification, improving battery life, and improving performance in a flooded lead-acid battery.

Exemplary separators as disclosed herein may preferably be characterized as having or providing improved conductivity over time. Conductivity can be determined as a cold start amplifier (CCA), which is measured, for example, in a Midtronics tester. For example, a lead-acid battery equipped with the separator according to the invention can have a decrease of less than 10%, less than 9%, less than 8%, less than 7%, less than 6%, less than 5%, less than 4% , less than 3%, less than 2%, less than 1%, or less than 0.5% CCA over a 30 day period as measured by a Midtronics CCA tester.

The separator according to the invention preferably comprises a porous membrane (such as a microporous membrane with pores of less than about 1 micron, a mesoporous or a macroporous membrane with pores of more than about 1 micron) made of natural or synthetic materials such as polyolefin, polyethylene, polypropylene, phenolic resin , PVC, rubber, synthetic wood pulp (SWP), glass fibers, cellulose fibers or combinations thereof; more preferably a microporous membrane made of thermoplastic polymers. The preferred microporous membranes can have pore diameters of about 0.1 microns (100 nanometers) and porosities of about 60%. The thermoplastic polymers can in principle comprise any acid-resistant thermoplastic materials suitable for use in lead-acid batteries. The preferred thermoplastic polymers include polyvinyls and polyolefins. Polyvinyls include, for example, polyvinyl chloride (PVC). The polyolefins include, for example, polyethylene such as ultra-high molecular weight polyethylene (UHMWPE) and polypropylene. A preferred embodiment may include a mixture of filler (e.g., silicon dioxide) and UHMWPE.

The porous membrane layer may be a polyolefin such as polypropylene, ethylene-butene copolymer and preferably polyethylene, more preferably high molecular weight polyethylene (e.g. polyethylene with a molecular weight of at least 600,000), more preferably ultra-high molecular weight polyethylene (e.g. polyethylene with a molecular weight of at least 1,000,000, especially more than 4,000,000, and most preferably 5,000,000 to 8,000,000 (measured by viscometry and calculated according to the Margolie equation)) with a standard load melt index of essentially 0 (measured according to ASTM D 1238 (Condition E) using a standard load of 2,160 g) and having a viscosity number of not less than 600 ml/g, preferably not less than 1,000 ml/g, more preferably not less than 2,000 ml/g, and most preferably of not less than 3,000 ml/g (determined in a solution of 0.02 g of polyolefin in 100 g of decalin at 130 ° C).

According to at least one embodiment, the porous membrane may contain an ultra-high molecular weight polyethylene (UHMWPE) blended with a processing oil and precipitated silica. According to at least one embodiment, the microporous membrane may contain a blended ultra-high molecular weight polyethylene (UHMWPE) mixed with a processing oil, with an additive, and with precipitated silica. The mixture may also contain small amounts of other additives or agents, as is common in separator technology (such as wetting agents, dyes, antistats chemical additives and/or the like). In certain cases, the microporous polymer layer may be a homogeneous mixture of 8 to 100% by volume of polyolefin, 0 to 40% by volume of a plasticizer and 0 to 92% by volume of inert filler material. The filler can be dry, finely divided silicon dioxide. The preferred plasticizer is petroleum. Since the plasticizer is the easiest component to remove from the polymer filler plasticizer composition, it is useful for imparting porosity to the battery separator.

In some embodiments, the porous membrane may be prepared by blending in an extruder approximately 30% by weight silicon dioxide with approximately 10% by weight UHMWPE and approximately 60% by weight processing oil. The microporous membrane can be made by passing the ingredients through a heated extruder, passing the extrudate produced by the extruder through a die into a nip formed by two heated calender rolls to form a continuous web from the Web a substantial amount of the processing oil is extracted using a solvent by drying the extracted web by cutting the web into sub-webs of a predetermined width and winding the sub-webs into rolls. The calender rolls may be engraved with various groove patterns to provide ribs, serrations, embossing, and the like to the membrane. Alternatively or additionally, ribs and the like may be imparted to the porous membrane by passing the extruded membrane through additional, suitably grooved calender rolls or presses.

The porous membrane can be provided in various ways with the additive, surfactant, agents, fillers or additives. For example, the additive or additives may be applied to the porous membrane when it is finished (e.g., after extraction) and/or added to the mixture used to prepare the membrane. According to a preferred embodiment, the additive or a solution of the additive is applied to the surface of the porous membrane. This variant is particularly suitable for the use of non-thermo-stable additives and additives that are soluble in the solvent used for the subsequent extraction. Low molecular weight alcohols such as methanol and ethanol as well as mixtures of these alcohols with water are also particularly suitable as solvents for the additives according to the invention. The application can take place on the side facing the negative electrode, the side facing the positive electrode or on both sides of the microporous membrane.

The application can also be carried out by immersing the microporous membrane in the additive or in a solution of the additive and then optionally removing the solvent, e.g. B. by drying. In this way, the application of the additive can be combined, for example, with the extraction that is often used during separator production.

Another preferred option is to mix the additive or additives into the mixture of thermoplastic polymer and optional fillers and other additives used to create the porous membrane. The additive-containing homogeneous mixture is then formed into a web-shaped material.

The separator according to the invention may be a low-ER separator, a low-water-loss separator and/or may have at least one section which has projections, interrupted ribs, serrated ribs, discontinuous ribs and/or the like (instead of solid ribs). to improve acid mixing or the conductivity of the separator. Projections include features such as short rib segments, nubs, embossments and the like. The projections can be located either on one side or on both sides of the separator. Typically, the protrusions are located at least on the side facing the positive plate (the positive active material or PAM). The projections may be arranged in rows, with the projections in each row spaced apart from one another and from the projections in adjacent rows. In some cases, the protrusions may be located on the side of the separator facing the positive active material, on the side of the separator facing the negative active material (or NAM), or on both sides of the separator.

In some embodiments of the present invention, the projections are ribs having a rib height of at least about 0.005 mm, 0.01 mm, 0.025 mm, 0.05 mm, 0.075 mm, 0.1 mm, 0.2 mm, 0.3 mm, 0.4mm, 0.5mm, 0.6mm, 0.7mm, 0.8mm, 0.9mm, 1.0mm, 1.1mm, 1.2mm, 1.3mm, 1.4mm or 1.5mm.

In some embodiments of the present invention, the projections are short length ribs having a rib width of at least about 0.005mm, 0.01mm, 0.025mm, 0.05mm, 0.075mm, 0.1mm, 0.2mm, 0.3mm mm, 0.4mm, 0.5mm, 0.6mm, 0.7mm, 0.8mm, 0.9mm, 1.0mm, 1.1mm, 1.2mm, 1.3 mm, 1.4mm or 1.5mm. The ribs can have a width between approximately 0.005-1.5 mm, 0.01-1.0 mm, 0.025-1.0 mm, 0.05-1.0 mm, 0.075-1.0 mm, 0.1- 1.0mm, 0.2-1.0mm, 0.3-1.0mm, 0.4-1.0mm, 0.5-1.0mm, 0.4-0.8mm or 0.4-0.6 mm.

The separator may have negative longitudinal or transverse fins or mini-fins, such as negative fins having a height of about 25 to 250 microns, perhaps preferably about 50 to 125 microns, and more preferably about 75 microns.

In certain embodiments, the projections may include ribs, each rib having a longitudinal axis disposed at an angle of 0° to less than 180° relative to the top edge of the separator. In some cases, all ribs in the separator may be arranged at the same angle, whereas in other embodiments there may be ribs arranged at different angles. For example, in some embodiments, the separator may include rows of ribs, with at least some of the rows having ribs at an angle θ relative to the top edge of the separator. All ribs in a single row may have the same approximate angle, although in other cases a single row of ribs may have different angles.

In certain cases, an entire surface of the separator includes rows of protrusions, while in other embodiments, certain fragments of the separator surface do not include protrusions. These fragments may occur along any edge of the separator, including the top, bottom, or sides, or may occur toward the center of the separator, with the fragment surrounded on one or more sides with portions of protrusions.

In certain, possibly preferred, embodiments with interrupted ribs (see 1 ) the section contains at least two sets of rows, with ribs in the first row arranged at an angle of 0° to less than 180° and ribs in the second row arranged at an angle of 0° to less than 180°, the may be the same or different to the angle for the ribs in the first row of rows. 40 includes a representation of a separator (100) including a top edge (101) with sets of first (102) and second (103) rows.

In certain other, possibly preferred embodiments (see 41 ), the second section has at least two sets of rows, with ribs in the first row arranged at an angle of 0° to less than 180° and ribs in the second row arranged at an angle of 0° to less than 180° , which may be the same or different to the angle for the ribs in the first row of rows. 41 comprises a representation of a separator (400) including an upper edge (401) with a central first section (402) and an outer second section (403).

In some cases, the second section includes a fifth set of rows of ribs, referred to herein as R ⁵ (404), at an angle θ ⁵ (405) relative to the top edge of the back panel, where θ ⁵ is from 0° to 90°, from 30° to 85°, from 45° to 85°, from 60° to 85°, from 60° to 80° or from 60° to 75°. A preferred value for θ ⁵ is 90°. The section may include a sixth set of rows, referred to herein as R ⁶ (406), having an angle θ ⁶ (407), with ribs having an angle θ ⁶ relative to the top edge of the back panel, with θ ⁶ of between 90° and is less than 180°, from 95° to 150°, from 95° to 120°, from 100° to 120° or from 105° to 120°. A preferred value for θ ⁶ is 90°. The ribs in different rows may have the same (as shown in 400) or different dimensions. The distance between adjacent rows can be from -5 to 5 mm, with negative numbers indicating the degree of overlap of the rows. The distance can be measured from midrib to midrib.

When different rows are present, the rows may occur in a repeating pattern. The simplest repeating pattern -R ⁵ -R ⁶ - can be seen in (400). Other patterns include -R ⁵ -R ⁵ -R ⁶ -; -R ⁵ -R ⁵ -R ⁵ -R ⁶ - ; ^{-R5 -R5 -R6 -R6} -; ^{-R5 -R5} -R5 ^{-R5 -R6 -} ; ^{-R6 -R5} -R5 ^{-R5 -R6 -} ; ^{-R5 -R5 -R5 -R6 -R6} -; and the same.

In some selected embodiments, the porous separator may have negative longitudinal or transverse ribs on the opposite side of the membrane as projections. The negative or back ribs may be arranged parallel to the top edge of the separator or at an angle thereto. Example For example, the transverse ribs can be oriented approximately 90°, 80°, 75°, 60°, 50°, 45°, 35°, 25°, 15° or 5° relative to the top edge. The transverse ribs can be oriented approximately 90-60°, 60-30°, 60-45°, 45-30° or 30-0° relative to the top edge. Typically, the transverse ribs are located on the side of the membrane facing the negative electrode. In some embodiments of the present invention, the ribbed membrane may have a transverse transverse rib height of at least about 0.005 mm, 0.01 mm, 0.025 mm, 0.05 mm, 0.075 mm, 0.1 mm, 0.2 mm, 0.3 mm, 0 .4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm or 1.0 mm. In some embodiments of the present invention, the ribbed membrane may have a cross-rib height of no more than about 1.0 mm, 0.5 mm, 0.25 mm, 0.20 mm, 0.15 mm, 0.10 mm, or 0.05 mm.

In some embodiments of the present invention, the ribbed membrane may have a transverse rib width of at least about 0.005 mm, 0.01 mm, 0.025 mm, 0.05 mm, 0.075 mm, 0.1 mm, 0.2 mm, 0.3 mm, 0 .4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm or 1.0 mm. In some embodiments of the present invention, the ribbed membrane may have a transverse transverse rib width of no more than about 1.0 mm, 0.5 mm, 0.25 mm, 0.20 mm, 0.15 mm, 0.10 mm, or 0.05 mm have.

In certain selected embodiments, the porous membrane may have a transverse rib height of approximately 0.10-0.15 mm and a longitudinal rib height of approximately 0.1-0.15 mm. In some embodiments, the porous membrane may have a transverse rib height of approximately 0.10-0.125 mm and a longitudinal rib height of approximately 0.1-0.125 mm.

The microporous membrane may have a backsheet thickness that is at least 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm or 1.0 mm. The ribbed separator may have a backsheet thickness no more than approximately 1.0 mm, 0.9 mm, 0.8 mm, 0.7 mm, 0.6 mm, 0.5 mm, 0.4 mm, 0. 3 mm, 0.2 mm or 0.1 mm. In some embodiments, the microporous membrane may have a backsheet thickness between approximately 0.1-1.0 mm, 0.1-0.8 mm, 0.1-0.5 mm, 0.1-0.5 mm, 0.1 -0.4 mm, 0.1-0.3 mm. In some embodiments, the microporous membrane may have a backsheet thickness of approximately 0.2 mm.

The separators of the present invention may be provided in either sheet form or in the form of a wrap, sleeve, bag or envelope. In some embodiments, a microporous membrane, which may be covered on at least one side with at least one layer of fibers, is provided as a bag or envelope. When the fibrous layer is present, it is preferred that the microporous membrane has a larger surface area than the fibrous layers. Thus, when the microporous membrane and the fiber layers are combined, the fiber layers do not completely cover the microporous layer. It is preferred that at least two opposing edge portions of the membrane layer remain uncovered to provide edges for heat sealing, facilitating the formation of pockets or sleeves. The separators can be processed into hybrid envelopes. The hybrid envelope may be formed by forming one or more slits or openings before, during, or after folding the separator sheet in half and joining the edges of the separator sheet to form a sleeve. The sides are joined together using welds or mechanical seals to form seams that bring one side of the separator sheet into contact with another side of the separator sheet. Weld seams can, for example, be produced using heat or ultrasound processes. This process results in an envelope shape with a bottom folded edge and two side edges.

Separators disclosed herein in the form of an envelope may include one or more slots or openings along the folded or sealed folds of the envelope. The length of the openings can be at least 1/50th, 1/25th, 1/20th, 1/15th, 1/10th, 1/8th, 1/5th, 1/4th. or 1/3. the length of the entire edge. The length of the openings can be 1/50. to 1/3rd, 1/25th to 1/3rd, 1/20th to 1/3rd, 1/20th to 1/4th, 1/15th to 1/4th, 1/15th to 1/5. or 1/10. to 1/5. the length of the entire edge. The hybrid envelope may have 1-5, 1-4, 2-4, 2-3, or 2 openings, which may or may not be evenly spaced along the length of the bottom edge. It is preferred that there is no opening in the corner of the envelope. The slits may be cut after the separator is folded and sealed to form an envelope, or the slits may be formed before the porous membrane is formed into the envelope.

Separators such as those disclosed herein can be characterized by improved conductivity over time. Conductivity can be determined as a cold start amplifier (CCA), which is measured, for example, in a Midtronics tester. For example, one with the invention Separator equipped lead-acid battery have a decrease of less than 10%, less than 9%, less than 8%, less than 7%, less than 6%, less than 5%, less than 4%, less than 3% , less than 2%, less than 1%, or less than 0.5% CCA over a 30 day period as measured with a Midtronics CCA tester. In contrast, the CCA decrease observed in conventional batteries under similar conditions is often much larger.

The separators provided herein enable the production of batteries with reduced water loss and lower float currents in batteries compared to batteries made from conventional separators. In some embodiments, water loss can be reduced by more than 10%, 20%, 30%, 40%, 50%, 60%, 70% or 80%. In some embodiments, the trickle current may be reduced by more than 10%, 20%, 30%, 40%, 50%, 60%, 70%, or 80%. Batteries made using the disclosed separators show reduced increases in internal resistance over time and, in some cases, no increased internal resistance.

In addition to reducing water loss and extending battery life, possible preferred separators also offer other benefits. In terms of assembly, the separators feature the negative cross-rib design to maximize bending rigidity and ensure highest manufacturing productivity. To avoid short circuits during high-speed assembly and later in life, the separators have superior puncture and oxidation resistance compared to standard PE separators.

According to at least selected embodiments, the present disclosure or invention is directed to improved battery separators, low ER or high conductivity separators, improved lead-acid batteries, such as flooded lead-acid batteries, high conductivity batteries, and/or improved vehicles the same batteries and/or methods for producing or using such separators or batteries and/or combinations thereof. According to at least certain embodiments, the present disclosure or invention is directed to improved lead-acid batteries that include the improved separators and that have increased conductivity.

It is believed that the improved separators described herein, such as the interrupted fin separators described herein, may further help prevent the formation of sulfate crystals and may also help provide more uniform heat distribution and/or thermal mixing and/or heat - or to provide heat dissipation (heat dissipation in less time compared to known separators, such as solid fin separators for flooded lead-acid batteries) via the separator. It is also believed that the exemplary broken rib separators described herein may also provide improved or faster or more efficient filling of flooded lead-acid batteries, gel batteries, and/or enhanced flooded batteries.

In various embodiments of the present disclosure, the disclosed separator provides reduced acid stratification or even complete elimination of acid stratification altogether, such that the degree of mixing or volumetric uniformity of the acid or electrolyte within the flooded lead-acid battery is 1.0 or approaches almost 1.0. In various embodiments, the separator disclosed herein is also a low electrical resistance (ER) separator. In such embodiments, the separator may include improvements such as improved fillers that increase the porosity, pore size, internal pore surface area, wettability, and/or surface area of the separator. In some embodiments, the improved fillers have a high structural morphology and/or a reduced particle size and/or a different amount of silanol groups than previously known fillers and/or are more highly hydroxylated than previously known fillers. The improved fillers can absorb more oil and/or allow for the incorporation of a greater amount of processing oil during the separator formation process without concomitant shrinkage or compression when the oil is removed after extrusion. For example, the improved separator is made using a silica having an intrinsic oil absorption value of about 175 to 350 ml/100g, in some embodiments 200 to 350 ml/100g, in some embodiments 250 to 350 ml/100gm, and in some further embodiments 260-320 ml /100g, although other oil absorption values are also possible.

The fillers can further reduce the so-called hydration sphere of electrolyte ions, improving their transport through the membrane and thereby again reducing the total electrical resistance or ER of the battery, such as an enhanced flooded battery or system.

The filler or fillers may contain various species (such as polar species such as metals) that facilitate the flow of electrolyte and ions through the separator. This also results in reduced overall electrical resistance since such a separator is used in a flooded battery such as an enhanced flooded battery.

The low ER microporous separators herein may further include a novel and improved pore morphology and/or novel and improved fibril morphology such that the separator helps to significantly reduce electrical resistance in a flooded lead-acid battery when such a separator used in such a flooded lead-acid battery. Such improved pore morphology and/or fibril morphology can result in a separator whose pores and/or fibrils approximate a shish-kebab (or shish-kabob)-type morphology. Another way to describe the novel and improved pore shape and structure is a structured fibril morphology, in which silica knots or knots of silica at the kebab formations on the polymer fibrils (the fibrils sometimes called shishes (skewers)) within of the battery separator are present. Additionally, in certain embodiments, the silica structure and the pore structure of a separator according to the present invention may be described as a skeletal structure or a vortex structure or a spine structure, where silica nodes appear on the kebabs of polymer along the fibrils of the polymer like whorls or disks (the "kebabs") and sometimes oriented substantially perpendicular to an elongated central spine or fibril (long chain polymer crystal) that approximates a spine-like shape (the “shish”).

In some cases, the improved battery comprising the improved separator with the improved pore morphology and/or fibril morphology may be 20% lower, in some cases 25% lower, in some cases 30% lower electrical resistance, and in some cases even more than 30% demonstrate lower electrical resistance (“ER”) drop (which can reduce the internal resistance of the battery), while such a separator maintains and maintains a balance of other, desirable key mechanical properties of lead-acid battery separators. Furthermore, in certain embodiments, the separators described herein have a new and/or improved pore shape such that more electrolyte flows through or fills the pores and/or cavities compared to known separators. The ultra-high molecular weight polyethylene in the separator may comprise polymer in a shish-kebab formation comprising a plurality of extended long chain crystals (the shish/skewer formations) and a plurality of folded chain crystals (the kebab formations), wherein the average repetition or periodicity of the kebab formations is 1 nm to 150 nm, preferably 10 nm to 120 nm and more preferably 20 nm to 100 nm (at least on portions of the rib side of the separator). In certain of these low ER embodiments of the present separator, the separator for a lead-acid battery described herein comprises a filler selected from the group consisting of silicon dioxide, precipitated silicon dioxide, fumed silicon dioxide and precipitated amorphous silicon dioxide; wherein the molecular ratio of OH to Si groups within the filler, as measured by ²⁹ Si NMR, in some embodiments in a range from 21:100 to 35:100, in some embodiments from 23:100 to 31:100, in some Embodiments from 25:100 to 29:100 and in certain preferred embodiments at 27:100 or higher. lies

In certain selected embodiments, the disclosed separators have a reduced electrical resistance, for example an electrical resistance of no more than about 200 mΩ.cm ² , 180 mΩ. cm ² , 160 mΩ.cm ² , 140 mΩ.cm ² , 120 mΩ.cm ² , 100 mΩ.cm ² , 80 mΩ.cm ² , 60 mΩ.cm ² , 50 mΩ.cm ² , 40 mΩ.cm ² , 30 mΩ.cm ² or 20 mΩ.cm ² . In various embodiments, the separators described herein demonstrate a reduction in ER of about 20% or more compared to a known separator of the same strength. For example, a known separator may have an ER value of 60 mΩ.cm ² ; thus, a separator according to the present invention would have an ER value of less than about 48 mΩ.cm ² at the same thickness. The low ER separators described herein may have some or all of the features set forth in the preliminary US Patent Application No. 62/319,959 , owned by Daramic, LLC and filed on April 8, 2016, which provisional application is hereby incorporated by reference in its entirety.

According to at least selected embodiments, the present disclosure is directed to improved lead-acid batteries, such as flooded lead-acid batteries, to improved systems that include a lead-acid battery and/or a battery separator, to improved battery separators , directed to improved vehicles with such systems, methods of manufacture or use, or combinations thereof. According to at least certain embodiments, the present disclosure is directed to improved flooded lead-acid batteries, improved battery separators for such batteries, and/or Ver are directed to the manufacture, testing or use of such improved flooded lead-acid batteries or combinations thereof. Additionally, disclosed herein is a method, system, battery, and/or battery separator for reducing acid stratification, improving battery life, and improving performance in a flooded lead-acid battery.

In various embodiments of the present disclosure, the disclosed separator provides reduced acid stratification or even complete elimination of acid stratification altogether, such that the degree of mixing or volumetric uniformity of the acid or electrolyte within the flooded lead-acid battery is 1.0 or approaches almost 1.0. In various embodiments, the separator disclosed herein is also a low electrical resistance (ER) separator. In such embodiments, the separator may include improvements such as improved fillers that increase the porosity, pore size, internal pore surface area, wettability, and/or surface area of the separator. In some embodiments, the improved fillers have a high structural morphology and/or a reduced particle size and/or a different amount of silanol groups than previously known fillers and/or are more highly hydroxylated than previously known fillers. The improved fillers can absorb more oil and/or allow for the incorporation of a greater amount of processing oil during the separator formation process without concomitant shrinkage or compression when the oil is removed after extrusion. For example, the improved separator is made using a silica having an intrinsic oil absorption value of approximately 175 to 350 ml/100g, in some embodiments 200 to 350 ml/100g, in some embodiments 250 to 350 ml/100gm, and in some further embodiments 260-320 ml /100g, although other oil absorption values are also possible.

The fillers can further reduce the so-called hydration sphere of electrolyte ions, improving their transport across the membrane and thereby further reducing the overall electrical resistance or ER of the battery, such as an enhanced flooded battery or system.

The filler or fillers may contain various species (such as polar species such as metals) that facilitate the flow of electrolyte and ions through the separator. This also results in reduced overall electrical resistance since such a separator is used in a flooded battery, such as an enhanced flooded battery.

The low ER microporous separators herein may further include a novel and improved pore morphology and/or novel and improved fibril morphology such that the separator helps to significantly reduce electrical resistance in a flooded lead-acid battery when such a separator used in such a flooded lead-acid battery. Such improved pore morphology and/or fibril morphology can result in a separator whose pores and/or fibrils approximate a shish-kebab (or shish-kabob)-type morphology. Another way to describe the novel and improved pore shape and structure is a structured fibril morphology, in which silica knots or knots of silica at the kebab formations on the polymer fibrils (the fibrils sometimes called shishes/skewers) within the Battery separator is present. Additionally, in certain embodiments, the silica structure and the pore structure of a separator according to the present invention may be described as a skeletal structure or a vortex structure or a spine structure, where silica nodes appear on the kebabs of the polymer along the polymer fibrils like whorls or disks (the "kebabs") and sometimes substantially aligned perpendicular to an elongated central spine or fibril (long chain polymer crystal) that approximates a spine-like shape (the “shish”).

In some cases, the improved battery comprising the improved separator with the improved pore morphology and/or fibril morphology may have a 20% lower, in some cases 25% lower, in some cases 30% lower electrical resistance, and in some cases even lower show more than 30% drop in electrical resistance (“ER”) (which can reduce the internal resistance of the battery), while such a separator maintains and maintains a balance of other important, desirable mechanical properties of lead-acid battery separators. Furthermore, in certain embodiments, the separators described herein have a new and/or improved pore shape such that more electrolyte flows through or fills the pores and/or cavities compared to known separators. The ultra-high molecular weight polyethylene in the separator may comprise polymer in a shish-kebab formation having a plurality of long chain crystals (the shish/skewer formations) and a plurality of folded chain crystals (the kebab formations), the average repeat being or Periodicity of kebab formations at 1 nm to 150 nm, preferably at 10 nm to 120 nm and more preferably at 20 nm to 100 nm (at least on sections of the rib side of the separator). In certain of these low ER embodiments of the present separator, the separator for a lead-acid battery described herein comprises a filler selected from the group consisting of silicon dioxide, precipitated silicon dioxide, fumed silicon dioxide and precipitated amorphous silicon dioxide; wherein the molecular ratio of OH to Si groups within the filler as measured by ²⁹ Si-NMR is in a range from 21:100 to 35:100, in some embodiments from 23:100 to 31:100, in some embodiments from 25:100 to 29:100 and in certain preferred embodiments from 27:100 or higher.

In certain selected embodiments, the disclosed separators have a reduced electrical resistance, for example an electrical resistance of no more than about 200 mΩ.cm ² , 180 mΩ.cm ² , 160 mΩ.cm ² , 140 mΩ.cm ² , 120 mΩ. cm ² , 100 mΩ.cm ² , 80 mΩ.cm ² , 60 mΩ.cm ² , 50 mΩ.cm ² , 40 mΩ.cm ² , 30 mΩ.cm ² or 20 mΩ.cm ² . In various embodiments, the separators described herein demonstrate a reduction in ER of about 20% or more compared to a known separator of the same strength. For example, a known separator may have an ER value of 60 mΩ.cm ² ; thus, a separator according to the present invention would have an ER value of less than about 48 mΩ.cm ² at the same thickness. The low ER separators described herein may include some or all of the features described in U.S. Provisional Patent Application No. 62/319,959 , owned by Daramic, LLC and filed on April 8, 2016, which provisional application is hereby incorporated by reference in its entirety.

According to at least selected embodiments, the present disclosure is directed to improved lead-acid batteries, such as flooded lead-acid batteries, improved systems comprising a lead-acid battery and/or a battery separator, improved battery separators , improved vehicles including such systems, methods of manufacture or use, or combinations thereof. According to at least certain embodiments, the present disclosure is directed to improved flooded lead-acid batteries, improved battery separators for such batteries, and/or methods of making, testing, or using such improved flooded lead-acid batteries, or combinations thereof. Additionally disclosed herein is a method, system, battery and/or battery separator for reducing acid stratification, improving battery life and performance in a flooded lead-acid battery.

In some embodiments, the improved high conductivity separator may be a low ER separator, a low water loss separator, a broken or serrated fin separator, and/or may optionally have a coating on one or both sides. Such a coating may contain a surfactant or other material. In some embodiments, the coating may include one or more materials described, for example, in U.S. Patent Publication No. 2012/0094183 which are hereby expressly incorporated by reference. For example, such a coating can reduce the overcharge voltage of the battery system, thereby extending battery life with less corrosion of the grid and prevention of drying out and/or water loss.

The separator used in various embodiments herein may be provided with one or more additives. This is because additives can improve the separators for certain stop/start flooded lead-acid batteries for certain vehicles. One such additive that may be present in the polyolefin is a surfactant, while another such additive may include one or more latex additives. Suitable surfactants include surfactants such as salts of alkyl sulfates; alkylaryl sulfonate salts; alkylphenol-alkylene oxide addition products; Soap; alkyl naphthalene sulfonate salts; dialkyl esters of sulfosuccinate salts; quaternary amines; block copolymers of ethylene oxide and propylene oxide; and salts of mono- and dialkyl phosphate esters. The additive may be a nonionic surfactant such as polyol fatty acid esters, polyethoxylated esters, polyethoxylated fatty alcohols, alkyl polysaccharides such as alkyl polyglycosides and mixtures thereof, amine ethoxylates, sorbitan fatty acid ester ethoxylates, organosilicone-based surfactants, ethylene vinyl acetate terpolymers, ethoxylated alkyl aryl phosphate esters and sucrose esters of fatty acids.

The above written description of structures and procedures has been presented for illustrative purposes. Examples are used to disclose exemplary embodiments, including the best mode, and to enable anyone skilled in the art to practice the invention, including making and using devices or systems and performing incorporated processes. These examples are not intended to be exhaustive or that The invention should be limited to the precise steps and/or forms disclosed, and many modifications and variations are possible in light of the above teachings. The features described here can be combined in any combination. Steps of a method described herein may be performed in any physically possible order. The patentable scope of the invention is defined by the appended claims and may include other examples that may occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal expressions of the claims or if they have equivalent structural elements with insubstantial differences from the literal expressions of the claims.

The compositions and methods of the appended claims are not limited in scope by the specific compositions and methods described herein, which are intended to illustrate some aspects of the claims. Any compositions and methods that are functionally equivalent are intended to fall within the scope of the claims. Various modifications of the compositions and methods in addition to those shown and described herein are intended to fall within the scope of the appended claims. While only certain representative compositions and process steps disclosed herein are specifically described, other combinations of the compositions and process steps are also intended to be included within the scope of the appended claims, even if not expressly stated. Thus, a combination of steps, elements, components or components may be explicitly or less clearly mentioned herein, but other combinations of steps, elements, components and components are included although not explicitly stated.

As used in the description and the appended claims, the singular forms "a" and "the" include multiple references unless the context clearly dictates otherwise. Ranges may be expressed herein as "approximately" a particular value and/or "approximately" another particular value. When such a range is expressed, another embodiment is encompassed by one particular value and/or the other particular value. Similarly, when values are expressed as approximations, using the prefix "approximately", it is understood that the particular value constitutes another embodiment. It is further understood that the endpoints of each of the ranges are significant both with respect to the other endpoint and independently of the other endpoint.

“Optional” means that the event or circumstance described below may or may not occur and that the description includes cases in which the event or circumstance occurs and cases in which it does not.

In the description and claims of this specification, the word "comprise" and variations of the word, such as "comprise" and "comprises", means "including, but not limited to" and does not imply any other additions, components, integers or to exclude steps. The terms “consisting essentially of” and “consisting of” may be used instead of “comprising” and “including” to describe more specific embodiments of the invention and also to disclose them. “Exemplary” means “an example of” and is not intended to suggest a preferred or ideal embodiment. “How” is not used in a limiting sense, but rather for explanatory or exemplary purposes.

Unless otherwise specified, all numbers expressing geometries, dimensions, etc. used in the description and claims are to be understood as a minimum and not as an attempt to limit the application of the doctrine of equivalence to the scope of the claims, and should be interpreted in light of the number of significant figures and common rounding approaches.

Unless otherwise defined, all technical and scientific terms used herein have the same meanings as generally understood by those skilled in the art to which the disclosed invention pertains. The publications cited herein and the materials for which they are cited are expressly incorporated by reference.

1. 1. Batterie-Separator zur Verbesserung des Säuremischens in einer Flooded-Blei-Säure-Batterie, umfassend:
   • eine poröse Rückenbahn und eine Vielzahl von unterbrochenen Rippen, die sich von mindestens einer Seite der Rückenbahn aus erstrecken; und wobei
   • mindestens ein Abschnitt der Vielzahl von unterbrochenen Rippen durch eine Winkelausrichtung definiert ist, um das Säuremischen insbesondere während der Batteriebewegung zu verbessern, wobei der Separator parallel zur Start/Stopp-Bewegung der Batterie positioniert ist.
2. 2. Batterie-Separator nach Ausführungsform 1, wobei die Winkelausrichtung relativ zu einer Maschinenrichtung des Separators ist und die Winkelausrichtung ein Winkel ist, der aus der Gruppe ausgewählt ist, die aus zwischen größer als null Grad (0°) und kleiner als 180 Grad (180°) und größer als 180 Grad (180°) und kleiner als 360 Grad (360°) besteht.
3. 3. Batterie-Separator nach Ausführungsform 1, ferner umfassend:
   • einen oder mehrere Sätze von Rippen innerhalb der Vielzahl von unterbrochenen Rippen; und
   • einen ersten Satz von Rippen innerhalb des einen oder der mehreren Sätze von Rippen mit einer ersten Winkelausrichtung;
   • mindestens einen zweiten Satz von Rippen innerhalb des einen oder der mehreren Sätze von Rippen mit einer zweiten Winkelausrichtung.
4. 4. Batterie-Separator nach Ausführungsform 1, wobei die Vielzahl der unterbrochenen Rippen in einer Anordnung von Säulen und Reihen angeordnet sind.
5. 5. Batterie-Separator nach Ausführungsform 4, wobei die Säulen durch variablen Säulenabstand getrennt sind.
6. 6. Batterie-Separator nach Ausführungsform 4, wobei die Reihen durch variablen Reihenabstand getrennt sind.
7. 7. Batterie-Separator nach Ausführungsform 1, wobei die Vielzahl von unterbrochenen Rippen in einer Anordnung von Säulen angeordnet ist; die Anordnung von Säulen in einer Vielzahl von Säulenabschnitten angeordnet ist; und mindestens einer der Vielzahl von Säulenabschnitten eine andere Anordnung der Vielzahl der unterbrochenen Rippen im Vergleich zu mindestens einer anderen der Vielzahl von Säulenabschnitten aufweist.
8. 8. Batterie-Separator nach Ausführungsform 1, wobei die Vielzahl der unterbrochenen Rippen in einer Anordnung von Reihen angeordnet ist; die Anordnung von Reihen in einer Vielzahl von Reihenabschnitten angeordnet ist; und mindestens einer der Vielzahl von Reihenabschnitten eine andere Anordnung der Vielzahl der unterbrochenen Rippen im Vergleich zu mindestens einer anderen der Vielzahl von Reihenabschnitten aufweist.
9. 9. Batterie-Separator nach Ausführungsform 1, wobei der Separator aus der Gruppe ausgewählt ist, die aus Polyolefin, Kautschuk, Polyvinylchlorid, Phenolharzen, Cellulose oder Kombinationen davon besteht.
10. 10. Batterie-Separator nach Ausführungsform 1, wobei der Separator einen umfasst, der aus der Gruppe ausgewählt ist, die aus einem Füllstoff, einem Tensid oder Kombinationen davon besteht.
11. 11. Batterie-Separator nach Ausführungsform 1, ferner umfassend: eine absorbierende Glasmatte.
12. 12. Separator, umfassend:
    • eine oder mehrere Rippen, die auf dem Separator angeordnet sind;
    • wobei der Separator in einer Batterie angeordnet ist und in einem sauren Elektrolyt eingetaucht ist, das in der Batterie angeordnet ist;
    • wobei die eine oder die mehreren Rippen das Mischen des sauren Elektrolyten während einer Geschwindigkeitsänderung der Batterie fördern.
13. 13. Blei-Säure-Batterie, umfassend den Separator nach einer der Ausführungsformen 1-12.
14. 14. Blei-Säure-Batterie nach Ausführungsform 13, umfassend einen oder mehrere Separatoren oder Abstandshalter, wobei der eine oder die mehreren Separatoren oder Abstandshalter jeweils eine Vielzahl von diskreten Rippen umfassen, die sich von einer Bahn oder einem Gerüst aus Material aus erstrecken; wobei die Vielzahl der diskreten Rippen jeweils durch eine Winkelausrichtung relativ zu einer Maschinenrichtung des einen oder der mehreren Separatoren oder Abstandshalter definiert ist; den einen oder die mehreren Sätze von Rippen innerhalb der Vielzahl von diskreten Rippen; und einen ersten Satz des einen oder der mehreren Sätze von Rippen mit einer identischen Winkelausrichtung der Rippen.
15. 15. Blei-Säure-Batterie nach einer der Ausführungsformen 13 bis 14, wobei die Blei-Säure-Batterie eine Flooded-Blei-Säure-Batterie ist, eine Batterie, die im Teilladungszustand arbeitet oder in einer Anwendung verwendet wird, die aus der Gruppe ausgewählt ist, die aus einer Leerlauf-Stopp/Start-Anwendung, einer Fahrkraftanwendung und eine Deep-Cycle-Anwendung oder Kombinationen davon besteht.
16. 16. Blei-Säure-Batterie nach Ausführungsform 13, wobei die Blei-Säure-Batterie in einer Batterie in einem Teilladungszustand verwendet wird.
17. 17. Blei-Säure-Batterie nach Ausführungsform 13, wobei die Blei-Säure-Batterie einer Bewegungs- und Stoppbewegung ausgesetzt ist.
18. 18. Blei-Säure-Batterie nach Ausführungsform 17, wobei jeder der einen oder mehreren Separatoren allgemein parallel zu einer Richtung der Bewegungs- und der Stoppbewegung angeordnet ist.
19. 19. Blei-Säure-Batterie nach Ausführungsform 13, ferner umfassend:
    • eine Batterie mit einer abwechselnden Folge von positiven und negativen Elektroden; wobei
    • der Separator um die negativen Elektroden angeordnet ist.
20. 20. Blei-Säure-Batterie nach Ausführungsform 19, wobei die Vielzahl der unterbrochenen Rippen benachbart zu den positiven Elektroden liegen.
21. 21. Verfahren zur Verringerung der Säureschichtung in einer Batterie, umfassend:
    • Bereitstellen einer Batterie, wobei die Batterie eine oder mehrere positive Elektroden und eine oder mehrere negative Elektroden aufweist;
    • Bereitstellen eines oder mehrerer Separatoren, wobei ein Separator zwischen jeder der einen oder mehreren positiven Elektroden und der einen oder mehreren negativen Elektroden angeordnet ist und wobei jeder der einen oder mehreren Separatoren mit einer Vielzahl von Rippen, die durch eine Winkelausrichtung definiert sind, vorgesehen ist;
    • Bereitstellen eines Elektrolyten; und
    • Bereitstellen von Bewegung für die Batterie.
22. 22. Verfahren zur Verringerung der Säureschichtung in einer Batterie nach Ausführungsform 21, ferner umfassend:
    • Anordnen der mehreren alternierenden positiven und negativen Elektroden parallel zu einer Bewegungsrichtung.
23. 23. Verfahren zur Verringerung der Säureschichtung in einer Batterie nach Ausführungsform 21, ferner umfassend:
    • umhüllendes Anordnen jedes des/der einen oder mehreren Separatoren um die negativen Elektroden.
24. 24. Verfahren zur Verringerung der Säureschichtung in einer Batterie nach Ausführungsform 23, wobei die Vielzahl der Rippen benachbart zu den positiven Elektroden liegen.
25. 25. Verfahren zur Verringerung der Säureschichtung in einer Batterie nach Ausführungsform 21, ferner umfassend:
    • Bereitstellen eines Fahrzeugs, das in der Lage ist, sich zu bewegen und anzuhalten; und
    • Anordnen der Batterie in dem Fahrzeug, so dass die Vielzahl der Separatoren parallel zu der Bewegungs- und Stoppbewegung ist.
26. 26. Verfahren zur Verringerung der Säureschichtung in einer Batterie nach Ausführungsform 21, wobei das Gehäuse und der Deckel einen Innenraum in einem oberen Abschnitt der Batterie definieren; und Bereitstellen eines oder mehrerer Ablenkelemente in dem Innenraum, um mindestens einen Teil des Elektrolyten, der während der Bewegung in Bewegung versetzt werden kann, zu der Batterie umzuleiten.
27. 27. Blei-Säure-Batterie, umfassend:
    • ein Gehäuse und einen Deckel;
    • eine Vielzahl von positiven und negativen Elektroden, wobei Bänder an den positiven bzw. negativen Elektroden angebracht sind;
    • ein Elektrolyt auf Säurebasis; wobei
      • das Gehäuse und der Deckel miteinander verbunden sind, um ein darin angeordnetes Innenvolumen zu bilden;
      • wobei die Vielzahl von positiven und negativen Elektroden und der Elektrolyt auf Säurebasis in mindestens einem unteren Teil des Innenvolumens untergebracht sind; und
    • ein oder mehrere Ablenkelemente, die in einem oberen Teil des Innenvolumens angeordnet sind.
28. 28. Blei-Säure-Batterie nach Ausführungsform 27, wobei die Ablenkelemente auf mindestens einem Abschnitt des Deckels angeordnet sind.
29. 29. Blei-Säure-Batterie nach Ausführungsform 27, wobei die Ablenkelemente auf mindestens einem Abschnitt des Gehäuses angeordnet sind.
30. 30. Blei-Säure-Batterie nach Ausführungsform 27, wobei sich die Ablenkelemente von den Bändern aus erstrecken.
31. 31. Blei-Säure-Batterie nach Ausführungsform 27, wobei die Ablenkelemente aus einem Gegenstand gebildet sind, der von dem Gehäuse und dem Deckel verschieden und getrennt ist.
32. 32. Blei-Säure-Batterie nach Ausführungsform 31, wobei die Ablenkelemente an den Bändern angebracht sind.
33. 33. Blei-Säure-Batterie nach Ausführungsform 27, wobei die Ablenkelemente eine gekrümmte Oberfläche aufweisen.
34. 34. Blei-Säure-Batterie nach Ausführungsform 27, wobei die Ablenkelemente eine allgemein ebene Oberfläche aufweisen.
35. 35. Blei-Säure-Batterie nach Ausführungsform 27, wobei die Ablenkelemente eine Oberfläche aufweisen, die allgemein senkrecht zu einer längslaufenden Länge der Elektroden ist.
36. 36. Batterie-Separator nach Ausführungsform 1, wobei der Separator das Säuremischen fördert oder das Säuremischen gegenüber herkömmlichen Separatoren mit festem Rippenprofil verbessert.
37. 37. In einer Flooded-Blei-Säure-Batterie umfasst die Verbesserung den Separator nach Ausführungsform 36.
38. 38. In einem Start/Stopp-Fahrzeug umfasst die Verbesserung die Batterie nach Ausführungsform 37.
39. 39. Fahrzeug nach Ausführungsform 38, wobei die Batterie Platten aufweist und die Platten im Wesentlichen parallel zur Richtung der Fahrzeugbewegung positioniert sind.
40. 40. Säuremischender-Rippen-Separator mit einem positiven Flächenrippenprofil, welches das Säuremischen derart verbessert, dass es in 60 Sekunden des Mischens mindestens eine Erhöhung der Säuredurchmischung um mindestens 15% und eine Volumengleichmäßigkeit von mindestens 0,37 liefert.
41. 41. Säuremischender-Rippen-Separator mit einem positiven Oberflächenrippenprofil, welches das Säuremischen derart verbessert, dass es in 60 Sekunden des Mischens mindestens eine Erhöhung der Säuredurchmischung um mindestens 20% und eine Volumengleichmäßigkeit von mindestens 0,38 liefert.
42. 42. Säuremischender-Rippen-Separator mit einem positiven Oberflächenrippenprofil, welches das Säuremischen derart verbessert, dass es in 60 Sekunden des Mischens mindestens eine Erhöhung der Säuredurchmischung um mindestens 25% und eine Volumengleichmäßigkeit von mindestens 0,40 liefert.
43. 43. Säuremischender-Rippen-Separator mit einem positiven Oberflächenrippenprofil, welches das Säuremischen derart verbessert, dass es in 60 Sekunden des Mischens mindestens eine Erhöhung der Säuredurchmischung um mindestens 30% und eine Volumengleichmäßigkeit von mindestens 0,42 liefert.
44. 44. Säuremischender-Rippen-Separator nach einer der Ausführungsformen 40 - 43, wobei der Separator ein negativer Plattenumschlag ist.
45. 45. Säuremischender-Rippen-Separator mit einem positiven Oberflächenrippenprofil, welches das Säuremischen derart verbessert, dass in 60 Sekunden des Mischens mindestens eines von einer Zunahme der Säuredurchmischung um mindestens 5% und einer Zunahme der Volumengleichmäßigkeit um mindestens 0,01 gegenüber einem Standard-Separator mit festen Rippen auftritt.
46. 46. Säuremischender-Rippen-Separator mit einem positiven Oberflächenrippenprofil, welches das Säuremischen derart verbessert, dass in 60 Sekunden des Mischens mindestens eines von einer Zunahme der Säuredurchmischung von 10% und einer Zunahme der Volumengleichmäßigkeit um mindestens 0,02 auftritt.
47. 47. Säuremischender-Rippen-Separator mit einem positiven Oberflächenrippenprofil, welches das Säuremischen derart verbessert, dass in 60 Sekunden des Mischens mindestens eines von einer Zunahme der Säuredurchmischung von 15% und einer Zunahme der Volumengleichmäßigkeit um mindestens 0,03 auftritt.
48. 48. Säuremischender-Rippen-Separator mit einem positiven Oberflächenrippenprofil, welches das Säuremischen derart verbessert, dass in 60 Sekunden des Mischens mindestens eines von einer Zunahme der Säuredurchmischung von 20% und einer Zunahme der Volumengleichmäßigkeit um mindestens 0,035 auftritt.
49. 49. Säuremischender-Rippen-Separator mit einem positiven Oberflächenrippenprofil, welches das Säuremischen derart verbessert, dass in 60 Sekunden des Mischens mindestens eines von einer Zunahme der Säuredurchmischung von 25% und einer Zunahme der Volumengleichmäßigkeit um mindestens 0,04 auftritt.
50. 50. Säuremischender-Rippen-Separator nach einer der Ausführungsformen 45 - 49, wobei der Separator ein negativer Plattenumschlag ist.
51. 51. Säuremischender-Rippen-Separator für einen negativen Plattenumschlag mit einem positiven Oberflächenrippenprofil, welches das Säuremischen derart verbessert, dass in 60 Sekunden des Mischens mindestens eines von einer Zunahme der Säuredurchmischung von 25% und einer Zunahme der Volumengleichmäßigkeit um mindestens 0,40 auftritt.
52. 52. Säuremischender-Rippen-Separator für einen negativen Plattenumschlag für eine Flooded-Blei-Säure-Batterie mit einem positiven Oberflächenrippenprofil, welches das Säuremischen derart verbessert, dass in 60 Sekunden des Mischens mindestens eines von einer Zunahme der Säuredurchmischung von 28% und einer Zunahme der Volumengleichmäßigkeit um mindestens 0,41 auftritt.
53. 53. In einer Batterie umfasst die Verbesserung den Separator nach mindestens einer der Ausführungsformen 40 - 52.
54. 54. In einem Fahrzeug umfasst die Verbesserung die Batterie nach Ausführungsform 53.
55. 55. Fahrzeug nach Ausführungsform 54, wobei die Batterie mit den Platten parallel zur Länge des Fahrzeugs positioniert ist.
56. 56. Verbesserte Blei-Säure-Batterien, wie Flooded-Blei-Säure-Batterien, verbesserte Systeme, die eine Blei-Säure-Batterie und/oder einen Batterie-Separator aufweisen, verbesserte Batterie-Separatoren, verbesserte Fahrzeuge, die solche Systeme umfassen, Herstellungs- oder Verwendungsverfahren oder Kombinationen davon; verbesserte Flooded-Blei-Säure-Batterien, verbesserte Batterie-Separatoren für solche Batterien und/oder Verfahren zur Herstellung, Prüfung oder Verwendung solcher verbesserten Flooded-Blei-Säure-Batterien oder Kombinationen davon; ein Verfahren, ein System, eine Batterie und/oder einen Batterie-Separator zur Verringerung der Säureschichtung, zur Verbesserung der Batterielebensdauer und -leistung in einer Flooded-Blei-Säure-Batterie; und Kombinationen davon, wie hierin gezeigt oder beschrieben.
57. 57. Separatoren, die im Vergleich zu herkömmlichen Separatoren eine verbesserte Elektrolytmischung und/oder Säurezirkulation bieten; Separatoren, die für eine geringere Säureschichtung sorgen, gemessen anhand der Elektrolytdichte oben und unten in der Zelle; wobei der Dichteunterschied weniger als 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, 5%, 2,5% oder 1% betragen kann, nachdem die Zelle 30, 60, 90 oder mehr Start/Stopp-Ereignisse oder -Zyklen durchlaufen hat; wobei der Dichteunterschied weniger als 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, 5%, 2,5% oder 1% betragen kann, nachdem die Zelle 24, 48, 72 oder mehr Stunden in Ruhe verbracht hat; und Kombinationen davon, wie hierin gezeigt oder beschrieben.

The following embodiments are also the subject of the present invention:

1. 1. Battery separator for improving acid mixing in a flooded lead-acid battery, comprising:
   • a porous back panel and a plurality of interrupted ribs extending from at least one side of the back panel; and where
   • at least a portion of the plurality of interrupted ribs is defined by an angular orientation to improve acid mixing, particularly during battery movement, with the separator positioned parallel to the start/stop movement of the battery.
2. 2. The battery separator according to embodiment 1, wherein the angular orientation is relative to a machine direction of the separator and the angular orientation is an angle selected from the group consisting of greater than zero degrees (0°) and less than 180 degrees ( 180°) and greater than 180 degrees (180°) and less than 360 degrees (360°).
3. 3. Battery separator according to embodiment 1, further comprising:
   • one or more sets of ribs within the plurality of interrupted ribs; and
   • a first set of ribs within the one or more sets of ribs having a first angular orientation;
   • at least a second set of ribs within the one or more sets of ribs with a second angular orientation.
4. 4. The battery separator according to Embodiment 1, wherein the plurality of interrupted ribs are arranged in an array of columns and rows.
5. 5. Battery separator according to embodiment 4, wherein the columns are separated by variable column spacing.
6. 6. Battery separator according to embodiment 4, wherein the rows are separated by variable row spacing.
7. 7. The battery separator according to Embodiment 1, wherein the plurality of interrupted ribs are arranged in an array of columns; the array of columns is arranged in a plurality of column sections; and at least one of the plurality of column sections has a different arrangement of the plurality of interrupted ribs compared to at least another one of the plurality of column sections.
8. 8. The battery separator according to Embodiment 1, wherein the plurality of interrupted ribs are arranged in an array of rows; the arrangement of rows is arranged in a plurality of row sections; and at least one of the plurality of row sections has a different arrangement of the plurality of interrupted ribs compared to at least another one of the plurality of row sections.
9. 9. The battery separator according to embodiment 1, wherein the separator is selected from the group consisting of polyolefin, rubber, polyvinyl chloride, phenolic resins, cellulose or combinations thereof.
10. 10. The battery separator according to embodiment 1, wherein the separator comprises one selected from the group consisting of a filler, a surfactant, or combinations thereof.
11. 11. The battery separator according to embodiment 1, further comprising: an absorbent glass mat.
12. 12. Separator comprising:
    • one or more ribs arranged on the separator;
    • wherein the separator is disposed in a battery and is immersed in an acidic electrolyte disposed in the battery;
    • wherein the one or more ribs promote mixing of the acidic electrolyte during a change in speed of the battery.
13. 13. Lead-acid battery comprising the separator according to one of embodiments 1-12.
14. 14. The lead-acid battery of embodiment 13, comprising one or more separators or spacers, the one or more separators or spacers each comprising a plurality of discrete ribs extending from a sheet or framework of material; wherein the plurality of discrete ribs are each defined by an angular orientation relative to a machine direction of the one or more separators or spacers; the one or more sets of ribs within the plurality of discrete ribs; and a first set of the one or more sets of ribs with an identical angular orientation of the ribs.
15. 15. The lead-acid battery according to any one of embodiments 13 to 14, wherein the lead-acid battery is a flooded lead-acid battery, a battery that operates in a partial charge state or is used in an application selected from the group is selected, which consists of an idle stop/start application, a traction application and a deep cycle application or combinations thereof.
16. 16. The lead-acid battery according to Embodiment 13, wherein the lead-acid battery is used in a battery in a partial charge state.
17. 17. Lead-acid battery according to embodiment 13, wherein the lead-acid battery is subjected to moving and stopping movement.
18. 18. The lead-acid battery according to embodiment 17, wherein each of the one or more separators is arranged generally parallel to a direction of moving and stopping movement.
19. 19. Lead-acid battery according to embodiment 13, further comprising:
    • a battery with an alternating series of positive and negative electrodes; where
    • the separator is arranged around the negative electrodes.
20. 20. The lead-acid battery according to embodiment 19, wherein the plurality of interrupted ribs are adjacent to the positive electrodes.
21. 21. A method for reducing acid stratification in a battery, comprising:
    • Providing a battery, the battery having one or more positive electrodes and one or more negative electrodes;
    • providing one or more separators, a separator disposed between each of the one or more positive electrodes and the one or more negative electrodes, and wherein each of the one or more separators is provided with a plurality of ribs defined by an angular orientation;
    • providing an electrolyte; and
    • Providing exercise for the battery.
22. 22. A method for reducing acid stratification in a battery according to Embodiment 21, further comprising:
    • Arranging the plurality of alternating positive and negative electrodes parallel to a direction of movement.
23. 23. A method for reducing acid stratification in a battery according to Embodiment 21, further comprising:
    • enveloping each of the one or more separators around the negative electrodes.
24. 24. A method of reducing acid stratification in a battery according to embodiment 23, wherein the plurality of fins are adjacent to the positive electrodes.
25. 25. A method for reducing acid stratification in a battery according to Embodiment 21, further comprising:
    • Providing a vehicle capable of moving and stopping; and
    • Arranging the battery in the vehicle so that the plurality of separators are parallel to the moving and stopping movement.
26. 26. A method of reducing acid stratification in a battery according to embodiment 21, wherein the case and the lid define an interior space in an upper portion of the battery; and providing one or more baffles in the interior to redirect at least a portion of the electrolyte capable of being agitated during movement to the battery.
27. 27. Lead-acid battery comprising:
    • a housing and a lid;
    • a plurality of positive and negative electrodes, with bands attached to the positive and negative electrodes, respectively;
    • an acid-based electrolyte; where
      • the housing and the lid are connected together to form an internal volume disposed therein;
      • wherein the plurality of positive and negative electrodes and the acid-based electrolyte are housed in at least a lower portion of the internal volume; and
    • one or more baffles disposed in an upper portion of the interior volume.
28. 28. Lead-acid battery according to embodiment 27, wherein the deflection elements are arranged on at least a portion of the lid.
29. 29. Lead-acid battery according to embodiment 27, wherein the deflection elements are arranged on at least a portion of the housing.
30. 30. Lead-acid battery according to embodiment 27, wherein the deflection elements extend from the bands.
31. 31. The lead-acid battery according to Embodiment 27, wherein the baffles are formed of an object different and separate from the case and the lid.
32. 32. Lead-acid battery according to embodiment 31, wherein the deflection elements are attached to the bands.
33. 33. Lead-acid battery according to embodiment 27, wherein the deflection elements have a curved surface.
34. 34. Lead-acid battery according to embodiment 27, wherein the deflection elements have a generally flat surface.
35. 35. The lead-acid battery of embodiment 27, wherein the deflection elements have a surface that is generally perpendicular to a longitudinal length of the electrodes.
36. 36. The battery separator of embodiment 1, wherein the separator promotes acid mixing or improves acid mixing over conventional fixed rib profile separators.
37. 37. In a flooded lead-acid battery, the improvement includes the separator according to embodiment 36.
38. 38. In a start/stop vehicle, the improvement includes the battery according to embodiment 37.
39. 39. The vehicle of embodiment 38, wherein the battery has plates and the plates are positioned substantially parallel to the direction of vehicle movement.
40. 40. Acid mixing rib separator having a positive surface rib profile that improves acid mixing such that it provides at least a 15% increase in acid mixing and a volume uniformity of at least 0.37 in 60 seconds of mixing.
41. 41. Acid mixing fin separator having a positive surface fin profile that improves acid mixing such that it provides at least a 20% increase in acid mixing and a volume uniformity of at least 0.38 in 60 seconds of mixing.
42. 42. Acid mixing fin separator having a positive surface fin profile that improves acid mixing such that it provides at least a 25% increase in acid mixing and a volume uniformity of at least 0.40 in 60 seconds of mixing.
43. 43. Acid mixing fin separator having a positive surface fin profile that improves acid mixing such that it provides at least a 30% increase in acid mixing and a volume uniformity of at least 0.42 in 60 seconds of mixing.
44. 44. The acid mixing fin separator of any of embodiments 40-43, wherein the separator is a negative plate envelope.
45. 45. Acid mixing rib separator having a positive surface rib profile which improves acid mixing such that in 60 seconds of mixing at least one of at least a 5% increase in acid mixing and at least a 0.01 increase in volume uniformity over a standard separator occurs with solid ribs.
46. 46. Acid mixing fin separator having a positive surface fin profile which improves acid mixing such that in 60 seconds of mixing at least one of a 10% increase in acid mixing and at least a 0.02 increase in volume uniformity occurs.
47. 47. Acid mixing fin separator having a positive surface fin profile which improves acid mixing such that in 60 seconds of mixing at least one of a 15% increase in acid mixing and at least a 0.03 increase in volume uniformity occurs.
48. 48. Acid mixing fin separator having a positive surface fin profile which improves acid mixing such that in 60 seconds of mixing at least one of a 20% increase in acid mixing and at least a 0.035 increase in volume uniformity occurs.
49. 49. Acid mixing fin separator having a positive surface fin profile which improves acid mixing such that in 60 seconds of mixing at least one of a 25% increase in acid mixing and at least a 0.04 increase in volume uniformity occurs.
50. 50. The acid mixing fin separator of any one of embodiments 45-49, wherein the separator is a negative plate envelope.
51. 51. Acid mixing rib separator for a negative plate envelope having a positive surface rib profile which improves acid mixing such that in 60 seconds of mixing at least one of a 25% increase in acid mixing and at least a 0.40 increase in volume uniformity occurs.
52. 52. Acid mixing fin separator for a negative plate envelope for a flooded lead-acid battery having a positive surface fin profile which improves acid mixing such that in 60 seconds of mixing at least one of a 28% increase in acid mixing and an increase the volume uniformity by at least 0.41 occurs.
53. 53. In a battery, the improvement includes the separator according to at least one of embodiments 40-52.
54. 54. In a vehicle, the improvement includes the battery according to embodiment 53.
55. 55. Vehicle according to embodiment 54, wherein the battery is positioned with the plates parallel to the length of the vehicle.
56. 56. Improved lead-acid batteries, such as flooded lead-acid batteries, improved systems comprising a lead-acid battery and/or a battery separator, improved battery separators, improved vehicles incorporating such systems, Methods of manufacture or use or combinations thereof; improved flooded lead-acid batteries, improved battery separators for such batteries and/or methods for making, testing or using such improved flooded lead-acid batteries or combinations thereof; a method, a system, a battery and/or a battery separator for reducing acid stratification, improving battery life and performance in a flooded lead-acid battery; and combinations thereof as shown or described herein.
57. 57. Separators that provide improved electrolyte mixing and/or acid circulation compared to conventional separators; Separators that provide less acid stratification, as measured by electrolyte density at the top and bottom of the cell; where the density difference can be less than 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, 5%, 2.5% or 1% after the cell 30, has experienced 60, 90 or more start/stop events or cycles; where the density difference can be less than 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, 5%, 2.5% or 1% after the cell 24, spent 48, 72 or more hours at rest; and combinations thereof as shown or described herein.

QUOTES INCLUDED IN THE DESCRIPTION

This list of documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• US 62/238373 [0001]
• US 2016012805 A [0001]
• US 62/385347 [0001]
• US 2012/0094183 [0039, 0187]
• US 20120214032 A [0134]
• US 20040067410 A [0134]
• US 20030148170 A [0134]
• US 6274263 B [0134]
• US 4629622 A [0134]
• US 4565748 A [0134]
• US 62319959 B [0142, 0178, 0185]

Claims (15)

A battery separator comprising multiple zones of varying patterns of serrations, depressions and/or discontinuous ridges on at least one side thereof. Battery separator after Claim 1 , comprising three zones of varying patterns of serrations, depressions and/or interrupted ribs. Battery separator after Claim 1 , comprising more than three zones of varying patterns of serrations, depressions and/or interrupted ribs. Battery separator after one or more of the Claims 1 until 3 , wherein each zone comprises two or more rows of serrations, depressions and/or interrupted ribs, the rows being rows in the machine direction or rows in the cross-machine direction. Battery separator after one or more of the Claims 1 until 4 , wherein the zones change in a lateral direction along a cross-machine direction of the separator or change in a machine direction of the separator. Battery separator after Claim 5 , wherein the zones change in the lateral direction along a cross-machine direction of the separator. Battery separator after Claim 5 , with the zones changing in a machine direction of the separator. Battery separator after one or more of the Claims 1 until 7 , comprising zones of varying interrupted ribs. Battery separator after Claim 8 , wherein one or more of the ribs are arranged at an angle of greater than 0° to less than 180° with respect to the top edge of the separator. Battery separator after Claim 9 , wherein all of the ribs are arranged at an angle of greater than 0° to less than 180° with respect to the top edge of the separator. Battery separator after Claim 9 or 10 , wherein the angled ribs are arranged at an angle of 45° to 135° with respect to the top edge of the separator. Battery separator after one or more of the Claims 9 until 11 , where the height of the ribs, which are arranged at an angle, is from 2 to 12 mm. An improved stop/start flooded lead-acid battery comprising the battery separator after one or more of the Claims 1 until 12 . Battery after Claim 13 , where the difference between the electrolyte concentration at the top and bottom is less than 50% after the stop/start flooded lead-acid battery undergoes 30 - 90 start/stop cycles. Battery separator after one or more of the Claims 9 until 12 , comprising transverse miniribs on at least one side thereof.

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