Battery separator fabric and related method of manufacture
 A battery separator fabric comprising a nonwoven fibrous web of thermoplastic fibers having top and bottom surface fibers and inner fibers. The surfaces of the top and bottom surface fibers of the fibrous web are seared and fused together to form film-like surfaces having pores, while the surface fibers and inner fibers of the web remain substantially unaffected. Searing and fusing of the surface fibers are accomplished by simultaneously applying heat to the top and bottom surfaces of the fibrous web so as to sear the surfaces of the thermoplastic fibers, and pressure to insure that the seared fibers make contact with each other to secure themselves together. As the seared fibers make contact with each other, film-like surfaces are formed with pores being created in the surfaces. The pores are created because a majority of spaces remain between the surface fibers. In addition, the heat and pressure are controlled by varying the temperature and pressure so that the surface fibers and the inner fibers of the fibrous web are substantially unaffected. The unaffected top and bottom and inner fibers along the porous film-like surfaces, permit the fibrous web to substantially retain its original porosity. This results in a film-like fabric having excellent porosity, which is well-suited as a battery separator. 
International Paper Company
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D04H Y10T Y10T B01D B01D Y10T Y10T Y10T
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Randy Ronald Roland Stanley
Rogers Greenberg Bernier Littman