Separator design, formula and
construction to maintain electrical
performance of the lead acid battery
Percentage of Cars per Driving Age Population
USA
Saudia Arabia
Great Britian
Germany
South Korea
Thailand
India
China
0
10
20
30
40
50
60
Penetration (%)
Source: Nielsen Media Index & TGI Survey
70
80
90
100
Major Cities Population
Tokyo
Mumbai
Shanghai
Calcutta
New York
Los Angeles
Chicago
Philadelphia
Paris
European Cities
Asian Cities
USA Cities
London
Essen
Milano
0
5
10
15
20
25
Population (millions)
Sources: US Census Bureau and Times Atlas of the World, tenth edition
30
Average Temperature by Major City
Calcutta
Mumbai
Shanghai
Tokyo
Los Angeles
Philadelphia
New York
Asian Cities
European Cities
USA Cities
Chicago
Milano
London
Paris
Essen
0.0
5.0
10.0
15.0
20.0
Mean Yearly Temp (degrees C)
Source: www.weatherbase.com
25.0
30.0
Rubber Separators
PE Separators
Water Loss Test
21 Days Overcharge 2.4 V/Cell at 40 °C
Positive PbSb 1.6 % / Negative PbCa – 2 Shot Formation
Water Loss [g/Ah]
2
1.5
+ 40% Improvement
0.8
1
0
Water Loss
21 Days Overcharge 2.4 V/Cell at 40 °C
Positive PbCa / Negative PbCa – 2 Shot Formation
Water Loss [g/Ah]
0.8
1
0.6
0
25% Improvement
Increased Heat
and Gassing
Higher Recharge
Currents
Antimony Released
from Positive Grid
Results in Loss
of Capacity and
Battery Failure
Negative Electrode
Depolarizes
Antimony Poisons
Negative Electrode
80% DOD Cycling Test at 55°C
12.0
End of Charge Current (A)
10.0
8.0
6.0
Rubber
4.0
2.0
0.0
0
50
100
150
200
Cycles
250
300
350
80% DOD Cycling Test at 55°C
12.0
PVC
End of Charge Current (A)
10.0
8.0
6.0
Rubber
4.0
2.0
0.0
0
50
100
150
200
Cycles
250
300
350
80% DOD Cycling Test at 55°C
12.0
PVC
End of Charge Current (A)
10.0
Standard
PE
8.0
6.0
Rubber
4.0
2.0
0.0
0
50
100
150
200
Cycles
250
300
350
80% DOD Cycling Test at 55°C
12.0
PVC
End of Charge Current (A)
10.0
Standard
PE
8.0
6.0
Rubber
4.0
Daramic
HD
2.0
0.0
0
50
100
150
200
Cycles
250
300
350
Oxidation Resistance
Increase Separator Back-web Thickness
 Increase Mass, Electrical Resistance and Acid
Displacement
Laminate Glassmat to Separator
 Prevents Shedding, Adds Component
Formulation Changes
 Polymer and Anti-Oxidant
Oxidation Resistance Test – Perox 80
1) Measure Separator Mechanical Properties
a)
Elongation, Puncture Resistance
2) Soak Separator in Oxidizing Solution
a)
b)
Hydrogen Peroxide / Sulfuric Acid
Elevated Temperature 80 degree C
3) Measure Remaining Separator Properties
a)
After Soaking various times (e.g. 20, 40, … hours)
4) Determine Rate of Oxidation with Drop in Mechanical
Properties
PEROX 80: Oxidation Resistance
450
400
CMD Elongation (%)
350
300
250
Daramic HP
200
150
100
End of Life < 100%
50
0
0
10
20
30
Soak Time (hrs)
40
50
60
PEROX 80: Oxidation Resistance
450
400
350
CMD Elongation (%)
Daramic HP +
300
250
Daramic HP
200
25% Longer
150
100
End of Life < 100%
50
0
0
10
20
30
Soak Time (hrs)
40
50
60
Weight Loss in Perox 80 Solution
6.00
Weight Loss (wt%)
5.00
4.00
3.00
2.00
Standard PE
Separator
1.00
0.00
0
50
100
150
200
250
Soak Time (minutes)
300
350
400
Weight Loss in Perox 80 Solution
6.00
Additive Level
Weight Loss (wt%)
5.00
PE Separator
with additive
4.00
3.00
2.00
Standard PE
Separator
1.00
0.00
0
50
100
150
200
250
Soak Time (minutes)
300
350
400
Asian Market Summary
SLI, Stationary and Motive Power Batteries
High Population Densities
Elevated Ambient Temperature
Use of Antimony Alloy
Elevated Temp & Antimony Alloy
SLI Application
 Water Loss => Battery Dry-Out
 Rubber Additive to PE Separator
 Daramic HP+
Motive Power and Deep Cycle Application




Negative Electrode Poisoning
Loss of Capacity
Rubber Additive to PE Separator
Daramic HD
Oxidation Resistance
 Rubber increases protection ~ 25%
SLI Application
Characteristic
Units
Daramic HP
Daramic HP+ (1)
Profile
UI
UI
Rubber Additive
No
Yes
Back-web Thickness
microns
200
200
Puncture Resistance
N
13.3
13.0
Electrical Resistance
mohms-cm2
48.1
50.0
%
59.9
58.5
Acid Wet-out
seconds
9.4
15.6
Residual Oil
wt %
Back-web
10.4
10.4
Total
16.2
16.5
368
414
CMD Elongation 20 hours
274
360
CMD Elongation 40 hours
112
214
0.44
0.31
Porosity
CMD Elongation
%
Oxidation Resistance PEROX
Acid Shrinkage
%
(1) US Patent 5,221,587 W. Boehnstedt et.al
Deep Cycle Application
Daramic CL
Daramic HD (1)
Profile
BC
BC
Rubber Additive
No
Yes
Characteristic
Units
Back-web Thickness
microns
500
500
Electrical Resistance
mohms-cm2
265
210
%
57.4
54.3
Ash Content
wt %
69.3
72.8
Residual Oil
wt %
Back-web
14.8
15.1
Total
20.4
20.5
256
339
132
226
1.3
1.2
Porosity
CMD Elongation
%
Oxidation Resistance PEROX
CMD Elongation 20 hours
Acid Shrinkage
%
(1) US Patent 5,221,587 W. Boehnstedt et.al
Taipei 101
End