Michael Maul

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Bio

Michael Maul was named VP of Technology for Polypore International in 2023. He is responsible for leading research and development efforts for Daramic® and Celgard® membrane battery separators and for the specialty membrane solution business. In 2022, Mr. Maul joined the Company as VP of Technology for Daramic to drive the future of innovation in membrane technologies and the advancement of performance in lead-acid batteries through the novel design of battery separators.


He brings 26 years of extensive experience and innovative processes to multiple industries including laser printing and additive manufacturing, and has led integrated supply chains to deliver cutting-edge products to the market.


Mr. Maul holds a Bachelor of Science degree in mechanical engineering from the University of Kentucky in Lexington, Kentucky, and a master’s degree in business from Midway University in Midway, Kentucky.


Stratosphere: Empowering the next-generation flooded and AGMe-VRLA batteries to transcend stratification
Michael Maul, VP of Technology, Polypore International, LLC, United States

Empowering the Next-Generation Flooded and AGMe-VRLA Batteries to Transcend Stratification Stratification of battery electrolyte has challenged the flooded lead-acid battery (FLB) since its inception, especially in cycling applications where the electrolyte density gradient stratification exacerbates battery sulfation. Standard FLB separators do not regulate the distribution of the acid and stratification causes instability for monitoring systems measuring an OCV that represents the charge state of the battery. Absorbent Glass Mat (AGM) separator technology provides a solution to these stratification issues, improving the efficiency of battery management systems. However, this comes with increased complexity and cost of more than 2X. Daramic’s innovative StratosphereTM technology, featuring a proprietary gelation composite affixed to a microporous substrate, adeptly controls the electrolyte stratification by volumetrically swelling into the void space between electrodes by 50%, meanwhile, absorbing and immobilizing the electrolyte. This technology retards stratification ensuring more uniform electrolyte concentration, good ion transport and reliable charge-state communication with battery management systems. This results in ≥2X longer cycle life in Partial State of Charge (PSoC) applications, while maintaining affordability of FLB compared to AGM batteries. Furthermore, for AGM batteries, Daramic® StratosphereTM separator technology can replace AGM separator, decreasing filling and formation times, negating the need for vacuum systems, high battery compression (>5%), or expensive VRLA manufacturing processes. Daramic® StratosphereTM technology consolidates the best aspects of AGM Valve-Regulated Lead-Acid Batteries (VRLA), Gel VRLA and FLB separator technologies like no other separator, providing a stable voltage consistent with typical AGM VRLA, a cycle life consistent with typical Gel VRLA, and the low cost, ease of manufacturing associated with FLB. The introduction of Daramic® StratosphereTM technology represents a significant advancement and evolution in the field of lead-acid batteries, reinforcing its position as one of the most cost-effective battery technologies available today.