Separators for starter batteries

Separators for Starter Batteries 11.2.2.1 Polyethylene Pocket Separators... 

In the second half of the 1960s, at the same time but independently, three basically different plastic separators were developed. One was the polyethylene separator [16] already referred to in starter batteries, used only rarely in stationary batteries, but successful in traction batteries. The others were the microporous phenolic resin separator (DARAK) [18] and a microporous PVC separator [19], both of which became accepted as the standard separation for stationary batteries. They distinguish themselves by high porosity (about 70 percent) and thus very low electrical resistance and very low acid displacement, both important criteria for stationary batteries. 

It can be stated generally that requirements for traction battery separators in respect to mechanical properties and chemical stability are considerably higher than for starter battery separators. This is due to the fact that a forklift battery is typically... 

It can be stated generally that requirements for traction battery separators in respect to mechanical properties and chemical stability are considerably higher than those for starter battery separators. This is due to the fact that a forklift battery is typically operated for about 40 000-50 000 h in charge-discharge service, whereas a starter battery for only about 2000 h. The requirements for electrical resistance are lower because of the typically lower current densities for traction batteries. These differences are of course reflected in the design of modem traction battery separator material. 

The term leaf separator characterizes the customary stiff version of a starter battery separator that can be inserted individually between the electrodes on automatic stackers, in contrast to pocket separators. This processing requires considerably higher bending stiffness than for pocket separators, calling for thicker backwebs, typically 0.4-0.6 mm (Fig. 18 and 19). 

The production process is comparatively simple, even though — of course — the respective know-how is also decisive. The equipment for the production of sintered PVC separators is suitable in size and production capacity to be operated on its own by individual, medium-sized, starter battery plants, in contrast to the far larger units required for the production of polyethylene pocket material. 

Typical pore size distributions result in mean pore diameters of around 15 //m. Even long and intensive efforts did not succeed in decreasing this value decisively in order to enable production of micropo-rous pocketing material resistant to penetration [65, 66], In practice PVC separators prove themselves in starter batteries in climatically warmer areas, where the battery life is however noticeably reduced because of increased corrosion rates at elevated temperature and vibration due to the road condition. The failure modes are similar for all leaf separator versions shedding of positive active mass fills the mud room at the bottom of the container and leads to bottom shorts there, unless — which is the normal case — the grids of the positive electrodes are totally corroded beforehand. 

Even though this separation system has not yet entered the starter battery field, it should be discussed here as a possible option for the future. 

The individual starter battery separator systems have been described here they are evaluated comparatively. There are no standards for evaluating separators Therefore the comparison will be concentrated primarily on the effects on the performance of the starter battery, with other decisive criteria such as cost structure and effects on productivity indicated. 

The above comparative evaluation of starter battery separators refers to moderate ambient temperatures the standard battery tests arc performed at 40 or 50 °C. What happens, however, on going to significantly higher temperatures, such as 60 or 75 °C This question cannot be answered without considering the alloys used batteries with antimonial alloys show a water consumption that rises steeply with increasing temperature [40], leaving as the only possibilities for such applications either the hybrid construction, i.c., positive electrode with low-antimony alloy, negative electrode lead-calcium, or even both... 

Sintered PVC separators for open stationary batteries are produced in the same way as the corresponding starter battery version (Sec. 9.2.2.2). Their brittleness and thus difficult processability are disadvantages, as is their relatively low porosity the concerns about release of chloride ions and subsequent increased corrosion are to be considered here as well. On the other hand,... 

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