Disclosed is a battery separator, comprising two fiber regions comprising glass fibers, and a middle fiber region disposed between them comprising larger average diameter fibers and specified amounts of silica, or fine fibers, or both; and processes for making the separator. Also disclosed is a batt
Disclosed is a battery separator, comprising two fiber regions comprising glass fibers, and a middle fiber region disposed between them comprising larger average diameter fibers and specified amounts of silica, or fine fibers, or both; and processes for making the separator. Also disclosed is a battery separator, comprising a fiber region and either one or two silica-containing region(s) adjacent thereto, each of the regions containing a specified amount of silica; and processes for making the separator. Such separators are useful, e.g., in lead-acid batteries.
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1. A battery separator, comprising: a fiber region; andeither (a) a silica-containing region adjacent to the fiber region, or(b) a first silica-containing region and a second silica-containing region, wherein the fiber region is disposed between the first silica-containing region and the second sili
1. A battery separator, comprising: a fiber region; andeither (a) a silica-containing region adjacent to the fiber region, or(b) a first silica-containing region and a second silica-containing region, wherein the fiber region is disposed between the first silica-containing region and the second silica-containing region;wherein the fiber region and each silica-containing region contains fibers having an average diameter from about 2 to about 25 μm;wherein the fiber region contains less than 2% by weight silica; andwherein each silica-containing region independently contains greater than or equal to 2% by weight silica. 2. The battery separator according to claim 1, wherein each silica-containing region independently contains 2 to about 30% by weight silica. 3. The battery separator according to claim 1, wherein the thickness of the fiber region constitutes greater than or equal to 25% of the total separator thickness, and the thickness of the silica-containing region(s) constitutes greater than or equal to 30% of the total separator thickness. 4. A lead-acid battery comprising a negative plate, a positive plate, and a battery separator according to claim 1, wherein the battery separator is disposed between the negative and positive plates. 5. The battery separator according to claim 1, wherein the fiber region comprises fibers having an average diameter from about 3 to about 15 μm. 6. The battery separator according to claim 1, wherein the fiber region comprises glass fibers having an average diameter from about 3 to about 15 μm. 7. The battery separator according to claim 1, wherein the fiber region comprises glass fibers having an average diameter from about 0.4 to about 1.8 μm. 8. The battery separator according to claim 1, wherein the thickness of the fiber region constitutes 10-40% of the total separator thickness. 9. The battery separator according to claim 1, wherein the fiber region comprises from about 5 to about 50% by weight glass fibers having an average diameter from about 0.1 to less than 2 μm. 10. The battery separator according to claim 1, wherein the fiber region comprises from about 5 to about 50% by weight glass fibers having an average diameter from about 0.8 to about 1.6 μm. 11. The battery separator according to claim 1 comprising a first silica-containing region and a second silica-containing region, each silica-containing region comprising glass fibers, wherein the average glass fiber diameter of the first silica-containing region differs from the average glass fiber diameter of the second silica-containing region by greater than or equal to 0.5 μm. 12. The battery separator according to claim 11, wherein each of the silica-containing regions comprises from about 2 to about 40% by weight silica, and wherein the specific surface area of each of the silica-containing regions is from about 1 to about 300 m2/g. 13. The battery separator according to claim 1, wherein the fiber region comprises from about 1 to about 40% by weight glass fibers having an average diameter from about 0.1 to less than 2 μm, and wherein the specific surface area of the fiber region is from about 1 to about 25 m2/g. 14. The battery separator according to claim 1, wherein the fiber region comprises from about 1 to 50% by weight glass fibers having an average diameter from about 0.1 to less than 2 μm, and wherein the tensile strength (machine direction) of the separator is about 2.00 to about 2.40 lbs/inch and/or the tensile strength (cross direction) of the separator is about 1.75 to about 2.20 lbs/inch. 15. The battery separator according to claim 1, wherein the separator exhibits an acid filling time of about 17 to about 155 seconds. 16. The battery separator according to claim 1, wherein the separator exhibits an acid stratification distance from about 2.5 to about 16 cm. 17. The battery separator according to claim 1, wherein the separator exhibits an acid filling time of about 17 to about 50 seconds. 18. The battery separator according to claim 1, wherein the thickness of the fiber region constitutes 1-49% of the total separator thickness.
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