Selection and incorporation of the appropriate separator profile
gives the Battery Design Engineer a method to achieve
optimal performance. Profiles can be selected to lower the electrical
resistance and subsequently deliver maximum power from
the battery for automotive applications. Automated enveloper
processing can be improved, and puncture shorts in the sealing
area can be minimized. Applications such as motive power
that require frequent, deep discharging will benefit by selecting
profiles with increased rib pitch to prevent shedding of active
material. For battery designs with limited acid volume, novel
approaches like the serrated rib can be selected to eliminate
the rib mass. For tubular batteries, the separator profile should
be chosen to ensure proper support of the active material. A
sinusoidal, diagonal or tightly spaced separator profile will provide
this design function. Selection of an optimal separator
profile also helps to meet the performance demands of stationary
battery applications by decreasing electrical resistance
and subsequently increasing power, minimizing problems associated
with gel filling, and allowing sufficient space for gelled
electrolyte to contact the negative electrode. Coupled with various
profile options, additives for the separator can be employed
to lowerwater loss and special separator processes can be used to
improve separator puncture resistance and minimize the potential
for shorting to achieve maximum battery performance.
The objective of the separator manufacturer is to be able
to recommend and describe optimal profile options to the Battery
Design Engineer, and to continually propose novel profiles
through extensive R&D work. The ultimate goal is to anticipate
the as-yet, unarticulated needs of the battery design, and then to
develop new ways to further improve the profile design and performance
characteristics. The separator is therefore much more
than “just a spacer”!