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 Alkaline battery separator and process for producing the same

Details
Inventors: Tanaka, Masanao; Kimura, Koji; Tokutake, Nobutoshi;
Assignee: Japan Vilene Company, Ltd. (Tokyo, JP)
Primary Examiner: Kalafut; Stephen
Assistant Examiner: Crepeau; Jonathan
Attorney, Agent or Firm: Burgess, Ryan & Wayne, Wayne; Milton J., Moran; William R.

An alkaline battery separator comprising a hydrophilic nonwoven fabric obtainable by heat-fusing and hydro-entangling (1) polyolefin dividable composite fibers having an average fiber length of 20 to 60 mm, (2) high-strength fibers having an average fiber length of 30 to 60 mm and a fiber strength of 5 g/denier or more, and (3) polyolefin heat-sensitive-adhesive fibers having an average fiber length of 30 to 60 mm, to obtain a heat-fused and hydro-entangled nonwoven fabric by a dry-laid method, and imparting a hydrophilic property to the resulting heat-fused and hydro-entangled nonwoven fabric; these high-strength fibers accounting for 20 to 45 mass % with respect to a total mass of the polyolefin dividable composite fibers, the high-strength fibers and the polyolefin heat-sensitive-adhesive fibers. The alkaline battery separator exhibits an excellent breaking strength, and has practical and sufficient tensile strength and electrolyte-holding capacity properties.

DETAILED DESCRIPTION What is claimed is: 1.
An alkaline battery separator comprising a hydrophilic nonwoven fabric obtainable by substantially uniformly admixing (1) polyolefin dividable composite fibers having an average fiber length of 20 to 60 mm, said polyolefin dividable composite fibers being a combination of high-density polyethylene and polypropylene, (2) high-strength fibers having an average fiber length of 30 to 60 mm and a fiber strength of at least 7 g/denier, said high-strength fibers being polypropylene and/or ultra-high-strength polyethylene, and (3) polyolefin heat-sensitive-adhesive fibers having an average fiber length of 30 to 60 mm, said polyolefin heat-sensitive-adhesive fibers being composed of a core component of polypropylene and a sheath component of low-density polyethylene, to form a fiber web by a dry-laid method, subjecting the resulting fiber web to a heat-fusing treatment and a hydro-entangling treatment to obtain a heat-fused and hydro-entangled nonwoven fabric, and imparting a hydrophilic property to the resulting heat-fused and hydro-entangled nonwoven fabric; said high-strength fibers accounting for 25 to 40 mass % with respect to a total mass of said polyolefin dividable composite fibers, said high-strength fibers and said polyolefin heat-sensitive-adhesive fibers.
2.
The alkaline battery separator according to claim 1, wherein an average fiber diameter of fine fibers divided from said polyolefin dividable composite fiber is 1 to 10 .
mu.
m.
3.
The alkaline battery separator according to claim 1, wherein said polyolefin dividable composite fibers account for 30 to 60 mass % with respect to a total mass of said polyolefin dividable composite fibers, said high-strength fibers and said polyolefin heat-sensitive-adhesive fibers.
4.
The alkaline battery separator according to claim 1, wherein said high-strength fiber is polypropylene or ultra high-strength polyethylene fiber.
5.
The alkaline battery separator according to claim 1, wherein said ultra-high-strength polyethylene fiber has a fiber strength of 25 g/denier or more



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