Flat-pack battery separator

DETAILED DESCRIPTION A sheet of open-windowed hot-melt adhesive plastic defines a plurality of battery separators wherein the open windows have a web of nonwoven fibers disposed thereon which continues from one window portion to the next, however, that portion of the web crossing over the plastic areas between openings advantageously has an extremely low fiber density and those fibers are oriented substantially normal to the axis of a particular side of the opening.
Because of this advantageous structure, individual battery separator can be bonded to similarly made electrodes using a plastic material therein and other separators in a rather easy and efficient manner and yet produce a more complete seal to the battery pack itself.
An object of this invention is to provide a nonwoven battery separator that is disposed in registration with a plastic frame there around that can be thermally sealed to other separators disposed on similar plastic frames and electrodes alternatingly disposed therein.
Another object of this invention is to provide a method of producing the nonwoven web in registration with the plastic frame in one operation.
Still another object of the instant invention is to provide a battery separator, wherein the nonwoven web constitutes the body of the separator, with a periphery of low fiber density areas disposed on the plastic frame that are oriented normal to the axis of the frame so as to facilitate a more complete bond of plastic to plastic.
Finally, it is also an object of the present invention to produce a battery assembly utilizing the nonwoven battery separator of this invention, that significantly reduces costs heretofore required in flat-pack batteries.