MICROPOROUS POLYETHYLENE SEPARATORS - TODAY AND TOMORROW - SEPARATOR DEVELOPMENT TRENDS FOR MODERN AUTOMOTIVE BATTERIES

During the past decade, the design of modern automotive batteries has undergone a fundamental change. The introduction of microporous polyethylene pocket separators has resulted in an approximately 8% better volume utilization. Besides increasing the energy density, the polyethylene envelope has enabled an improvement in cold-cranking performance and has raised the production efficiency. A first failure-mode analysis of pocket-separated automotive batteries in Europe with respect to leaf separation is presented. For comparable service life, a shift in failure mode has been found. Although corrosion of the positive electrode still dominates, a significant increase in positive active-material shedding is noted. This is certainly a consequence of the general trend towards lower antimony contents. Shorting through the separator is only found in cases of severe battery mistreatment. This positive, intermediary result is supplemented by an outlook on emerging development trends. Future automotive batteries will experience elevated operating temperatures, higher cycling loads, and maintenance freedom. Battery tests at temperatures up to 75-degrees-C with various alloy combinations show that the hybrid design is best suited to meet the expected requirements. Microporous polyethylene pocket separation is not expected to be a limiting factor; the trend to lower antimony alloy content and increased cycling load will demonstrate the advantage of this separation even more clearly than in the past. Optimization of the already achieved, balanced separator characteristics profile with the reference parameters of electrical performance, water loss, durability and machinability will stimulate further development work.