Multilayer separator and methods of manufacture and use

Abstract

A multilayer deep cycle battery separator comprising at least two layers of an automotive-sized separator bonded or welded together. The automotive-sized separator layers include a backweb having a backweb thickness between 6 to 10 mils, an overall thickness of between 25 to 65 mils, and a rib base width of between 20 to 35 mils. The automotive-sized separator layers also have an extraction time of between 45 to 75 seconds, thereby providing an overall extraction time of less than a standard deep cycle battery separator.

1 . A multilayer deep cycle battery separator. 
     
     
         2 . The multilayer deep cycle battery separator of  claim 1  comprising at least two layers of an automotive-sized battery separator connected or bonded or welded together. 
     
     
         3 . The multilayer deep cycle battery separator of  claim 2  comprising two layers of automotive-sized separator. 
     
     
         4 . The multilayer deep cycle battery separator of  claim 2  wherein said automotive-sized battery separator layers comprise:
 a backweb having a backweb thickness of between 5 and 10 mils, an overall thickness of between 25 and 65 mils, and 
 a rib having a rib base width of between 20 and 35 mils. 
 
     
     
         5 . The multilayer deep cycle battery separator of  claim 2  wherein said automotive-sized battery separator layers have an extraction time of between 45 to 75 seconds. 
     
     
         6 . The multilayer deep cycle battery separator of  claim 2  wherein said automotive-sized battery separator layers are selected from the group consisting of: a PE separator; a PVC separator; a rubber separator; a phenolic resin separator; a PP separator; a cellulosic materials separator; and combinations thereof. 
     
     
         7 . The multilayer deep cycle battery separator of  claim 2  wherein said automotive-sized battery separator layers comprise at least one layer of PE separator. 
     
     
         8 . The multilayer deep cycle battery separator of  claim 7  wherein said automotive-sized battery separator layers comprise two layers of PE separators. 
     
     
         9 . The multilayer deep cycle battery separator of  claim 2  wherein said layers of automotive-sized separator are welded together. 
     
     
         10 . The multilayer deep cycle battery separator of  claim 9  wherein said layers of automotive-sized separator are welded together by welding techniques selected from the group consisting of: heat; pressure; heat and pressure; sonic welding; vibration; crimping; laser; and combinations thereof. 
     
     
         11 . The multilayer deep cycle battery separator of  claim 2  wherein said layers of automotive-sized separator are connected together by a layer of adhesive. 
     
     
         12 . The multilayer deep cycle battery separator of  claim 11  wherein said adhesive is selected from the group consisting of: a standard adhesive; latex rubber; a coating with a basic solution of sodium silicate that is ultimately neutralized with acid; and combinations thereof. 
     
     
         13 . The multilayer deep cycle battery separator of  claim 2  further including an additive. 
     
     
         14 . The multilayer deep cycle battery separator of  claim 13  wherein said additive is selected from the group consisting of: ground rubber; latex rubber; one or more lignins; sodium sulfate; and combinations thereof. 
     
     
         15 . The multilayer deep cycle battery separator of  claim 2  wherein said layers of automotive-sized separator are without any welding or other means of attachment. 
     
     
         16 . The multilayer deep cycle battery separator of  claim 2  wherein said layers of automotive-sized separator are positioned together by being enveloped, wrapped, sleeved or stacked. 
     
     
         17 . The multilayer deep cycle battery separator of  claim 2  wherein said layers of automotive-sized separator are embossed together. 
     
     
         18 . The multilayer deep cycle battery separator of  claim 17  wherein said layers are embossed together by two or more layers being fed through a pair of mated rollers with a three-dimensional pattern, whereby when the two or more layers are embossed, the original shape of ribs being modified in the pattern of the embossed roll. 
     
     
         19 . The multi-layer deep cycle battery separator of  claim 18  wherein points of connectivity of said embossed layers are across an entire face of the separator. 
     
     
         20 . The multilayer deep cycle battery separator of  claim 2  comprising two layers of automotive-sized separator connected in a back to back configuration by which backwebs of each layer are positioned adjacent to one another. 
     
     
         21 . The multilayer deep cycle battery separator of  claim 2  comprising two separators stacked on top of one another. 
     
     
         22 . The multi-layer deep cycle battery separator of  claim 20  comprising two layers of automotive-sized separator connected in a back to back configuration and wherein at least one of the layers further includes negative ribs, which negative ribs are thereby positioned between the two backwebs of the two layers. 
     
     
         23 . The multilayer deep cycle battery separator of  claim 2  comprising two layers of automotive-sized separator together in a rib to rib configuration with ribs stacked on top of each other or with ribs offset from one another, a ribbed separator and a flat sheet, wherein at least one of the layers comprises ribs. 
     
     
         24 . The multilayer deep cycle battery separator of  claim 23  wherein said ribs are selected from the group consisting of: straight vertical ribs; sinusoidal; diagonal; discontinuous; embattlement; cross rib patterns; and combinations thereof, or wherein said ribs are straight vertical ribs. 
     
     
         25 . The multilayer deep cycle battery separator of  claim 2  having an extraction time of less than a standard deep cycle battery separator, having an extraction time of at least ⅔ less than a standard deep cycle battery separator, having an extraction time of between ⅖ and ⅔ less than a standard deep cycle battery separator, having a stiffness greater than a standard deep cycle battery separator, having a compression greater than a standard deep cycle battery separator, having a rib mass less than a standard deep cycle battery separator, and/or having fewer pinholes than a standard deep cycle battery separator. 
     
     
         26 . The multilayer deep cycle battery separator of  claim 13  wherein said additive or additives are between the layers, and/or wherein said additive or additives are pocketed into a welded region. 
     
     
         27 . The multilayer deep cycle battery separator of  claim 2  comprising a composite structure. 
     
     
         28 . The multilayer deep cycle battery separator of  claim 27  wherein said composite structure includes a stiffening material between the layers. 
     
     
         29 . The multilayer deep cycle battery separator of  claim 28  wherein said stiffening material is selected from the group consisting of: a glass mat; glass fibers; a synthetic mat; synthetic fibers; and combinations thereof. 
     
     
         30 . A battery comprising a multilayer deep cycle battery separator, and/or deep cycle battery comprising a multilayer separator according to  claim 2 . 
     
     
         31 . In the manufacturing of a battery, the improvement comprising a multi-layer deep cycle battery separator according to  claim 2 . 
     
     
         32 . A method of separating a battery's positive and negative electrodes including using at least one of the multi-layer deep cycle battery separators according to  claim 2 . 
     
     
         33 . A method of manufacturing a deep cycle battery separator comprising the step of assembling a multi-layer deep cycle battery separator according to  claim 2 . 
     
     
         34 . A method of producing a lead acid battery where two layers of automotive-sized separator are used in such a manner to replace a thicker deep cycle battery separator. 
     
     
         35 . The method of producing a lead acid battery of  claim 34 , where a positive electrode is enveloped, wrapped or sleeved with one separator while a negative electrode is enveloped, wrapped or sleeved with another separator. 
     
     
         36 . The multilayer deep cycle battery separator of  claim 4 , wherein the separator comprises two layers of automotive-sized separators which are connected in a back to back manner such that the backweb of each of the two layers are adjacent. 
     
     
         37 . The multilayer deep cycle battery separator of  claim 36 , wherein the backwebs of the two layers are connected by a plurality of welds. 
     
     
         38 . The multilayer deep cycle battery separator of  claim 4 , wherein the separator comprises two layers of automotive-sized separators which are connected in a stacked manner such that the ribs of one of the layers faces the backweb of the other of the layers and wherein the layers are connected with welds at one or more edge of the layers. 
     
     
         39 . The multilayer deep cycle battery separator of  claim 36 , wherein one of the two layers comprises negative ribs which are thereby positioned between the two layers. 
     
     
         40 . The multilayer deep cycle battery separator of  claim 4 , wherein the separator comprises two layers of automotive-sized separators which are connected rib to rib with the ribs of one of the two layer aligned with the ribs on the other of the two layers. 
     
     
         41 . The multilayer deep cycle battery separator of  claim 2 , wherein the separator comprises two layers, a first of the two layers comprising a backweb having a backweb thickness of between 5 and 10 mils, an overall thickness of between 25 and 65 mils, and a rib having a rib base width of between 20 and 35 mils, a second of the two layers comprising a backweb and wherein the two layers are connected in a manner such that the ribs of the first of the two layers faces the backweb of the second layer of the two layers. 
     
     
         42 . The multilayer deep cycle battery separator of  claim 4 , wherein the separator comprises two layers of automotive-sized separators which are connected rib to rib with the ribs of one of the two layer are offset from the ribs on the other of the two layers.