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PE Separator for Lead Acid Battery

A complete turnkey solution for the production of PE separator for lead-acid batteries. From equipment to process formula, USEON has rich experience.

  • Equipment
  • Process formula
Get a quote →
PE separator production line: twin screw extruder under the feeding platform, calender in the foreground

What’s a UHMWPE separator

The ultra high molecular weight polyethylene separator (PE separator) is a microporous membrane that uses polyethylene as base material and silica as filler material. It is mainly used for lead-acid batteries, separating the positive and negative plates.

Compared with other types of separators, the PE separator has a smaller pore size and is easy to assemble mechanically. It reduces battery short circuits, improves capacity and cycle life, improves the assembly efficiency of the battery and reduces the rejection rate.

Mainly composed of

  • Silica
  • Ultra high molecular weight polyethylene
  • Special oil
  • Other additives
Schematic drawing of a lead-acid battery
Schematic drawing of a lead-acid battery
PE separator for lead-acid battery
PE separator for lead-acid battery
Micro structure of the PE separator
Micro structure of the PE separator

PE separator manufacturing process

The sheet is extruded with oil, then the oil is extracted to form the pores. Oil and solvent run in a loop beside the main line.

Mix and feed

  1. Raw materials
  2. Mixer
  3. Buffer mixer
  4. Loss-in-weight feeders, powder and oil

Extrude and calender

  1. Extruder, filter, gear pump and T-die
  2. Calender
  3. On-line thickness gauge
  4. Pull roll

Extract, treat and wind

  1. Oil extractor
  2. Oven
  3. Wetting agent coating
  4. Oven
  5. Pinhole detector & marker
  6. Winder

Recovery loop

  1. Mixed liquid tank
  2. Evaporator
  3. Oil tank
  4. Solvent tank
  1. Solvent vapour
  2. Carbon bed
  3. Steam regeneration
  4. Solvent tank
Block flow diagram of the PE separator manufacturing process, with the oil and solvent recovery loop
PE separator manufacturing process

Equipment composition

The equipment of the PE separator production line can be divided into the following sections.

01

Raw material storage, mixing

  • Silo structure, heating system, conveying method and control logic are designed to the characteristics of the raw materials.
  • Mixing aims at uniform dispersion of the raw materials and avoids the leakage of dust.

02

Extrusion and calendering

  • Special screw elements and screw combination of the extruder, designed to the material for good plasticizing and dispersion.
  • The channel of the die and the structure of the calender are designed to the material as well.

03

Extraction (pore forming)

  • Designed to the process requirements; the market does not have this machine. It is directly related to the porosity and oil content of the separator.
  • Know-how: stable control of the oil content, no breaks and folds of the separator, tension control, sealing, anti-corrosion and drying process control.

04

Functional treatment (wetting agent coating)

  • Hydrophilic treatment of the separator: wetting agent dilution, coating and drying.
  • The uniformity of the wetting agent and the amount of coating are controlled by a special mechanical structure.

05

Defect detection and winder

  • The pinhole detector finds pinholes and other defects on line, marks and records them.
  • The winder has special tension control and web guiding, with a special algorithm in the software.

06

Liquid raw material recycling

  • Directly related to the cost of the product and to environmental issues. Some companies ignore this section.
  • Without it a line can make a qualified product and still lose competitiveness on cost.
Elevation drawing of the PE separator line: main line above, tanks and recovery below
Equipment composition

Reference project

Lab line for UHMWPE lead-acid battery separator sheet

Raw material
UHMWPE powder 20–30%, paraffin oil 70–80%, other additives
Extruder
SAT40 twin screw extruder
Output
30 kg/h, about 500,000 m² per year
  1. Premixing
  2. Loss-in-weight feeders, powder and liquid
  3. Twin screw extruder
  4. Filter
  5. Gear pump
  6. Calender
  7. Cooling stack and edge cutting
  8. Thickness tester
  9. Haul-off
  10. Winder

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Production line and workshop layout

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PE separator production line, extruder and calender
PE separator production line, view 2
PE separator production line, view 3
PE separator production line, view 4
Proposed workshop layout for a PE separator plant
The proposed workshop layout

Get a quote

Tell us the separator you plan to make and the yearly output. We quote the complete line with the recovery section and the workshop layout, or a lab line to develop the formula first.

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  1. 01Separator width, thickness and yearly output
  2. 02Production line or lab line; process formula needed or not
  3. 03Line layout, recovery section and quotation
Souder Chen

Souder Chen

Head of Compounding Division

With USEON since 2008. Twin screw compounding, devolatilization and recycling lines.

souder.chen@useon.com+86 139 5186 5928

PE Separator for Lead Acid Battery

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