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BATTERY SEPARATOR REQUIREMENTS AND PERFORMANCE PARAMETERS PAPER, PRESENTED AT THE MAY 2006 BATTERY COUNCIL INTERNATIONAL CONFERENCE HELD IN TUCSON, ARZONIA
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Innovation from a Milled Powder Silica to Micropearl form in Rubber Separator Specialty Silica Summit May 2006, held in Atlanta Georgia
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CELLFORCEŽ: OPERATIONAL
EXPERIENCE AND PERFORMANCE OF A NEW HYBRID RUBBER-POLYETHYLENE
BATTERY SEPARATOR PRESENTED AT 9ELBC
The need for maximized service life and cycling capacity retention
for lead-acid battery applications that involve deep-discharge
duty requires the careful selection and use of component materials.
Use of antimonial grid alloys, specially formulated active materials
and separator characteristics can all play an important role in
achieving the designed battery performance. Reports in the literature
indicate that separator attributes can play a significant role in the
extension of a cycle-life by helping to control battery overcharge and
delaying the onset of gassing.
A new separator is now available to address these needs and is being
manufactured under the trade name, CellForceŽ. This separator was
introduced during 2001, has been well received by the industry, and is
now being used extensively by numerous battery manufacturers
world-wide. Data that examine chemical and physical material evaluations
and battery performance associated with the CellForceŽ rubber-polyethylene
separator will be presented.
Testing of motive power and other deep-cycle, flooded batteries from
several battery producers show improved top-of-charge voltage
characteristics that can both increase cycle-life and reduce maintenance
requirements.
Material characterization analyses and SEM photomicrographs of the CellForceŽ
separator indicate the potential for unique properties that are not
available to other separator matrixes. The test results also confirm
the possibility of reducing residual oil content while maintaining
acceptable chemical oxidation resistance and decreasing electrical resistance.
These improvements can benefit flooded as well as gel batteries.
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Comparison of Mercury
Porosimetry and Flow Porometry for the Testing of Battery Separator
Materials
Control of porosity is very important for proper functioning of
battery separators. Specifications of mean pore size and percent
porosity are commonly an integral part of separator acceptance
criteria. To date most testing of these parameters has relied
on mercury intrusion porosimetry. Recently, a new technique, flow
porometry, has been introduced which has the potential of more
accurately predicting product performance. This technique categorizes
pore structure based on flow rates through the membrane and is
specially useful in locating pore structure defects, which can
be a chief cause for product failure, and malfunctioning. Data
from both mercury intrusion and flow porometry analyses on different
types of separator materials are critically examined and discussed.
It is proposed that the battery industry could benefit by using
information created by flow porometry to augment its reliance
on mercury porosimetry data.
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Evaluation of Hybrid Rubber-Polyethylene
Industrial Battery Separators
Antimonial lead alloys continue to play a key role in the overall
success of the lead-acid battery in deep cycle applications. In
markets such as motive power and golf car, these alloys have long
been known to assist the performance of the positive plate by
promoting a healthy, grid-active material interface. Antimony,
on the other hand, is a well-established poison to the negative
plate and ultimately leads to gassing, water-loss and cell failure.
Reports in the literature indicate that specific battery separator
materials may be used to delay the onset of gassing by suppressing
the effects of antimony. Literature findings also suggest that
the suppression effect may be due to a combination of the chemical
make-up of the separator and its physical attributes. It is the
intention of this paper to introduce a novel method for evaluating
battery separator materials in terms of their ability to suppress
the deleterious effects of antimony. Results presented here indicate
that the chemical composition of the separator is a controlling
factor in suppressing the influence of antimony in the lead-acid
battery. Initial information on the characteristics of a new hybrid
rubber-polyethylene battery separator is also presented.
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article ]
Advances in Microporous
Rubber Separator Design
Battery performance criteria, separator design factors, and electrochemical
properties of rubber separators are presented. Physical features
of current three types of rubber separator products- sulfur cured
hard rubber separators, electron beam cross-linked flexible rubber
separators, and coated silica rubber separators- are modified
to improve performance in lead-acid batteries. Various aspects
of the new design features, their influences on battery performances,
and applications of the separators for different types of batteries
are discussed.
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article ]
The Influence of Rubber
Separators On Electrochemical Behavior of Lead-Acid Batteries
This paper represents manufacturing processes; physical, chemical
and electrochemical properties; performance in batteries; and
their application of currently available three types of battery
separators. Many aspects of lead-acid battery performance characteristics
which are unique electrochemical properties of rubber are given.
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article ]
Rubber Separators For Tomorrow:
Performance Characteristics And Selection Guide
A brief description is given of the basic differences in manufacturing
processes and composition of the three types of rubber separator,
namely: (I) sulfur-cured, hard rubber, Ace-SilŽ separator (II)
electron-beam crosslinked, Flex-SilŽ rubber separator; (III) coated
glass-mat Micropor-SilŽ separator containing rubber. The physical,
chemical, electrical and electrochemical properties of the three
types of rubber separator are considered and the primary differences
are explained. The beneficial performance characteristics found
with rubber separators are presented, such as on-charge voltage
characteristics, electrochemical compatibility for float-charging
systems, retardation of antimony transfer, prevention of dendrite
growth, and good wettability. Based on analysis of separator properties
and battery requirements, a selection guide for rubber separators
applicable to various types of lead/acid battery is compiled.
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article ]
Re-Inventing Hard-Rubber
Separators
Amerace MPI's electron-beam cured rubber separator known as Flex-SilŽ
has captured 90% of the US market for golf-car batteries. It is
now being promoted for other deep discharge applications. However,
the more traditional steam-cured Ace-SilŽ separator has been given
a new lease of life by designing it with a fluted reverse side
and 'interrupted' ribs. It is proving ideal for tubular positive
traction cells. MPI and their European agents, Termar, have therefore
decided to promote Ace-Sil as the company's top-of-the-range industrial
separator.
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article ]
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