CN102560901A - 电池活性物质支架用纺粘无纺布及其制造方法 - Google Patents

电池活性物质支架用纺粘无纺布及其制造方法 Download PDF

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CN102560901A
CN102560901A CN2011103485602A CN201110348560A CN102560901A CN 102560901 A CN102560901 A CN 102560901A CN 2011103485602 A CN2011103485602 A CN 2011103485602A CN 201110348560 A CN201110348560 A CN 201110348560A CN 102560901 A CN102560901 A CN 102560901A
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朴瑞镇
金东旭
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Abstract

本发明涉及一种电池活性物质支架用纺粘无纺布及其制造方法,所述纺粘无纺布由具有相互不同纤度的多层纤维结构构成,其第一纤维层使用喷嘴直径在200μm内且具有喷丝头直径为0.4μm的喷丝头数为200~300个孔的喷嘴,制造纤度为1~3旦的长丝,其第二纤维层使用与第一纤维层相同大小的喷嘴及孔直径的喷丝头数为30~180个孔的喷嘴,纤度为5~15旦的聚酯长丝纤维,在连续移动的旋转带上以多层网进行层叠并通过热封或者针扎方式而制造。由粗纤度纤维构成的第二纤维层上活性物质的附着力增强,由低纤度纤维构成的第一纤维层防止已附着活性物质的渗漏,进而保持坚固的附着性,防止活性物质的渗漏和极板的相互附着,使得分离性变得优秀。

Description

电池活性物质支架用纺粘无纺布及其制造方法
技术领域
本发明涉及一种电池活性物质支架用纺粘无纺布及其制造方法,更具体地涉及一种附着于车载蓄电池的铅和氧化铅的表面,提高制造工序的简便性并且安装于蓄电池内部时能够防止通过与稀硫酸的反应下生成的活性物质铅糊的流出,使得以优秀的耐久性极大地增加电池寿命的多层结构的电池活性物质支架用纺粘无纺布及其制造方法。
背景技术
通常广泛使用于汽车、船舶、农机或其他产业的各种电池(battery)由于在内部排列有大量稀硫酸与板(plate)形态的铅及氧化铅极板,稀硫酸与铅的相互反应下生成电荷。极板由附着有铅的网孔(mesh)形态的网与铅糊及对其进行支持和保护的外部盖组成。具体来说,如图1所示,起到外部盖作用的支架3一直以来主要采用一般纸浆材质的木浆纸(pulp tissue)或玻璃纤维的玻璃纤维毡等。但是,上述木浆纸材质的分离膜具有耐高温性能弱、耐氧化性弱、易溶解于电解质的缺点,无法保护极板,直至电池寿命结束为止,并且,在利用玻璃纤维毡支持活性物质的方法中,活性物质与正极板之间的结合力弱,导致蓄电池性能降低,并且由于其主要成分玻璃纤维的特性,导致作业效率和生产效率下降等诸多问题。
因此,为了解决上述问题,韩国专利申请第1997-0080771号的“针对蓄电池用极板支持活性物质的方法及其蓄电池”公示内容为“根据一般蓄电池用极板支持活性物质的方法,其通过交叉玻璃纤维而制造的玻璃纤维毡以适当的压力附着于隔离板而支持正极板的活性物质,一种蓄电池用极板支持活性物质的方法,其特征在于,将活性物质铅糊附着于网孔形基板并将无纺布附着于极板的上下面而支持极板的活性物质”。
但是,上述专利发明中公示的方法与目前现有的技术,即韩国专利申请第1993-0030048号“碱性锌蓄电池”中公示的结构相似。即,“一种碱性锌蓄电池,其形成一种能够分离Ni正极与Zn负极之间的聚丙烯无纺布,上述Ni正极、Zn负极及聚丙烯无纺布的外部配置多层分离膜,该多层分离膜具有多层微孔膜,其特征在于,上述多层分离膜的Zn负极与聚丙烯无纺布之间形成棉无纺布”。两种技术方法均认可根据无纺布的特性能够将其作为优秀的电池分离膜,引用这种技术思想而提出相应方法,根据这种现状在电池领域将无纺布作为分离膜而使用的方法大量公示。
但是,如上所述,利用无纺布的电池主要是针对锂离子电池等的方案,关于铅蓄电池用分离膜相关问题,目前尚未提出解决问题的合理方案。
尤其是,上述前者的发明,其主要目的在于,增强基板与活性物质之间的结合力,避免组装工序过程中出现脱落或耷拉等现象,通过提高作业效率及生产效率,解决一直以来因采用现有的玻璃纤维毡而出现的问题。但是,普通无纺布也存在一定问题,例如:由于其表面气孔被堵塞,作为活性物质的铅膏(lead paste)不易附着,并且纤度大且纤维结构数少的外部盖使铅糊渗出,在各个工序中施加一定压力,经熟成过程之后存在相互间不分离的问题,但目前对此问题尚未提出任何解决方法。
发明内容
考虑到上述现有技术中存在的技术问题,本发明的主要目的在于,提供一种车载电池活性物质支架用纺粘无纺布,其特征在于,通过将无纺布作为构成各种电池极板的活性物质支架而用作外部盖,以解决上述现有的问题,提高活性物质的附着性能,防止渗漏,增强分离性。
本发明的另一个目的在于,提供一种更加容易制造作为上述具有优秀特性的电池活性物质支架,而具有相互不同纤度的多层纺粘无纺布的制造方法。
本发明的再一个目的在于,除了上述明确提出的目的之外实现另一目的,即根据本说明书提出的整体技术,使该技术领域的普通技术人员能够简单导出。
上述本发明的目的通过提供一种纺粘无纺布而实现,其具有纺粘无纺布的相互不同的纤度的多层纤维层结构,一面由细纤度纤维构成而另一面由粗纤度纤维组成。
为了实现上述目的,本发明的电池活性物质支架用纺粘无纺布,其特征在于,由具有相互不同纤度的多层构成聚酯无纺布,其第一纤维层使用喷嘴直径在200μm内且具有喷丝头直径为0.4μm的喷丝头数为200~300个的孔(hole)的喷嘴,优选地使用具有220~280个孔的喷嘴,更优选地使用具有240个孔的喷嘴,制造纤度为1~3旦的长丝,其第二纤维层使用上述相同大小的喷嘴及孔直径的喷丝头数量为30~180个,优选地使用具有50~80个孔的喷嘴,对纤度为5~15旦的聚酯长丝纤维进行纺丝,在连续移动的旋转带(spinbelt)上以多层网进行层叠并通过热封或者针扎方式而制造。
根据本发明的其他结构,其特征在于,上述第一纤维层与第二纤维层的组成比例为50∶50。
根据本发明的另一个其他结构,其特征在于,上述无纺布的基本重量为10~40g/m2
根据本发明的再一个其他结构,其特征在于,上述具有相互不同纤度的多层长纤维聚酯无纺布使用固有粘度(IV)为0.60~0.70dl/g的聚酯。
为了实现上述其他目的,本发明的电池活性物质支架用纺粘无纺布的制造方法,其特征在于,包括如下步骤:第一纤维层通过具有200~300个孔的喷嘴进行纺丝或伸展而形成纤度为1~3旦的低纤度长丝,第二纤维层通过具有30~180个孔的喷嘴进行纺丝或伸展而制造纤度为5~15旦的粗纤度长丝纤维的步骤;将上述制造的聚酯长丝纤维在连续移动的传送带上层叠成网的步骤;以及针对上述层叠的网进行热封或针扎的步骤。
如上构成的本发明的电池活性物质支架用纺粘无纺布,第一纤维层由细纤度纤维构成,第二纤维层由粗纤度纤维构成,由此由粗纤度纤维构成的第二纤维层提高活性物质的附着能力,由细纤度纤维构成的第一纤维层防止已附着的活性物质的渗漏,保持坚固的附着性,进而防止活性物质的泄露,极板之间避免相互附着而使得分离性变得优秀,解决了将无纺布使用为上述现有的电池活性物质支架时存在的问题。
附图说明
图1作为普通铅蓄电池的概略图,即为表示极板及支持该极板的分离膜结构的放大图;
图2是本发明的电池分离膜活性物质支架用多层结构的纺粘无纺布的剖视图;
图3是表示电池极板制造工序的制造工序流程图。
具体实施方式
下面,将参照附图并根据优选实施例对本发明进行详细说明。
图1作为普通的铅蓄电池的概略图,即为表示极板及其构成材料的放大图;图2是本发明的电池分离膜活性物质支架用多层结构的纺粘无纺布的剖视图。
如图2所示,本发明的电池分离膜活性物质支架用纺粘无纺布由第一纤维层31与第二纤维层32组成。
图3是表示车载电池极板制造过程的流程图,作为通常电池用极板准备将铅板以网孔形态加工的板,氧化铅及铅粉与水和硫酸及其他添加剂混合而制造成铅糊(paste)涂于移动的网孔形铅板。然后,在上述如上准备的铅板的上部及下部,作为活性物质支架3赋予本发明的无纺布。该极板根据上/下部滚轴轻轻挤压,并按照所需形状进行切割。接着,为了干燥极板的表面,在70~120℃范围内执行预干燥。将预干燥的极板叠加为多层后,为了进行熟成而在规定温度和压力下,在室内熟成3~7日。之后,通过上述工序熟成的极板各自分离后,置于蓄电池盒,并填充稀硫酸。
上述过程中,当无纺布作为活性物质支架而无法与活性物质适当附着时,就会出现与活性物质分离的现象,并且,当活性物质从支架渗漏时,熟成过程之后,极板无法进行个别分离,导致产生不良。因此,无纺布的一侧面需要优秀的结合性,确保与活性物质的结合度,另一侧面应稠密并需要支架,以免活性物质渗漏。
因此,如图2所示,根据本发明优先实施形态的车载电池极板的活性物质支架用多层结构纺粘无纺布呈特定结构的多层形态,其使用聚酯树脂而制造。具体地说,在挤压机中熔融聚酯切片,使用喷嘴直径在200μm内且具有喷丝头直径为0.4μm的喷丝头数为200~300个孔的喷嘴,优选地使用具有220~280个孔的喷嘴,更优选地使用具有240个孔的喷嘴进行熔融纺丝,通过喷射器在空气压力下进行伸展,制造纤度为1~3旦的长丝,由此形成本发明的无纺布的第一纤维层。此时,当长丝纤度小于1旦时,每个喷丝头的聚合物喷出量则会变小,死结现象频繁发生,因此不能低于1旦。相反,当长丝纤度大于3旦时,出现活性物质渗漏现象,进而导致在预干燥或熟成工序中层叠的极板无法分离的问题。
其次,本发明的无纺布的第二纤维层由聚酯树脂制造,与第一纤维层的形成相同,在挤压机中熔融聚酯切片,使用喷嘴直径在200μm内且具有喷丝头直径为0.4μm的喷丝头数为30~180个孔的喷嘴,通过喷射器在空气压力下进行伸展,制造纤度为5~15旦的长丝。此时,当第二纤维层的纤度超过15旦时,纤维间的空间(气孔)过度变大,导致活性物质无法稳固地附着。
上述纺丝而伸展的纤维,在连续移动的传送带上,层叠成第一纤维层和第二纤维层的多层网,并以规定厚度层叠的长丝网通过热封或针扎过程形成为无纺布。
根据本发明的优选实施形态,无纺布的基本重量小于10g/m2时,活性物质的支持力弱,相反,无纺布的基本重量大于40g/m2时,厚度过大,导致不利于发挥分离膜的特性。
如图1所示,电池极板在作为铅板的网孔2表面涂敷活性物质1,按照上述工序制造的本发明的多层纤维结构的纺粘无纺布作为支架3附于活性物质的表面,与活性物质接触的一面作为第二纤维层32,即通过附着由粗纤度长丝构成的纤维层,确保活性物质与纤维层结合良好,使其背面成为由低纤度长丝构成的第一纤维层31,纤维的密集度高,确保上述活性物质1不易渗漏。
因此,根据本发明的纺粘无纺布,如上所述地构成车载电池极板时能够控制与活性物质的结合性及根据活性物质的稀硫酸的溶出性,以便确保极大地增加寿命的车载电池性能。
并且,根据本发明的另一优选实施形态,本发明的活性物质支架用无纺布,在干燥器中对固有粘度(IV)为0.60~0.70dl/g的聚酯切片进行结晶化及干燥,使得水分率达到100pm以下。如果使用固有粘度(IV)不足0.60dl/g的聚酯切片,则会导致无纺布的强度降低,相反,如果使用固有粘度(IV)超过0.70dl/g的聚酯切片,则会无法顺利进行纺丝,由此具有无法实现高速生产的缺点。
上述进行结晶化而干燥的切片,在温度为220~300℃的挤压机中进行熔融,使得第一纤维层的长丝在喷丝头数为200~300个孔的喷嘴中纺丝。当喷丝头数超过300个时,喷丝头间的距离过小,纺丝时无法做到充分的冷却,并在相互干扰下很容易发生死结。并且,当喷丝头数不足200个时,纤度变大,进而无法满足所需特性。构成上述第二纤维层的喷嘴由30~180个喷丝头构成。当喷嘴不足30个喷丝头时,纤度过大,导致纤维间的气孔大小变大,由此无法保持充分的活性物质,当喷嘴超过180个喷丝头时,由于纤度过小,因而纤维间的气孔变小,导致活性物质的渗透性弱化。
如上进行纺丝的聚合物在通过蜂窝形状的室而喷射的10~25℃的冷却空气下进行冷却、固化,此时,冷却空气风速优选为10m/min~45m/min。冷却的聚合物通过气压为2~10kg/cm2的喷射器而伸展长丝。
关于各个长丝纤维的纤度,对长丝进行纺丝,以便确保第二纤维层的纤度为5~15旦、第一纤维层的纤度为1~3旦。将这种长丝按照规定角度和速度与冲击板冲击而分散长丝,在移动的传送带上均匀地利用下部的吸入装置进行层叠而形成网。上述网的基本重量由聚合物的喷出量与旋转带的速度而决定。本发明的优选实施形态中,使上述网的基本重量达到10~40g/m2
上述网的基本重量根据喷丝头的孔数、喷出量及传送带的速度进行调节,如上形成的网为了具备规定的形态及物理特性等,通过热封或针扎方式制造成根据本发明的无纺布。
根据其他优选实施形态,构成根据本发明的无纺布的上述第二纤维层的粗纤度长丝纤维能够具有圆形以外的其他形态。
根据本发明的另一优选实施形态,上述纤维层可以具备中空形态,此时,中空型的粗纤度聚酯长丝纤维,其喷丝头内纺丝孔槽的数量为2~4个,其槽的宽度为0.05~0.3mm,其槽的间隔为0.05~0.3mm,其槽的内径为0.4~1.2mm,喷丝头毛细管长度(capillary length)为0.1~1.0mm。
如上所述,根据本发明制造的具有相互不同纤度的多层纤维结构的聚酯纺粘无纺布,不限于通常的方法,但是,如图3所示,在电池极板制造工序流程图中能够适用为电池活性物质支架。

Claims (4)

1.一种电池活性物质支架用纺粘无纺布,其特征在于,由具有相互不同的纤度的多层纤维构成聚酯无纺布,其第一纤维层使用喷嘴直径在200μm内且具有喷丝头直径为0.4μm的喷丝头数为200~300个孔的喷嘴,制造纤度为1~3旦r的长丝,其第二纤维层使用具有与第一纤维层相同大小的喷嘴及孔直径的喷丝头数为30~180个孔的喷嘴,对纤度为5~15旦的聚酯长丝纤维进行纺丝,在连续移动的旋转带上以多层网进行层叠并通过热封或者针扎方式而制造。
2.根据权利要求1所述的电池活性物质支架用纺粘无纺布,其特征在于,所述无纺布的基本重量为10~40g/m2
3.根据权利要求1所述的电池活性物质支架用纺粘无纺布,其特征在于,所述聚酯无纺布使用固有粘度(IV)为0.60~0.70d1/g的聚酯。
4.一种电池活性物质支架用纺粘无纺布的制造方法,其特征在于,包括如下步骤:
第一纤维层通过具有200~300个孔的喷嘴进行纺丝及伸展而形成纤度为1~3旦的低纤度长丝,第二纤维层通过具有30~180个孔的喷嘴进行纺丝及伸展而制造纤度为5~15旦的粗纤度长丝纤维的步骤;
将所述制造的聚酯长丝纤维在连续移动的传送带上层叠成网的步骤;以及
对所述层叠的长丝网进行热封或针扎的步骤。
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