CN1481037A - 电池隔离器 - Google Patents

电池隔离器 Download PDF

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CN1481037A
CN1481037A CNA03132875XA CN03132875A CN1481037A CN 1481037 A CN1481037 A CN 1481037A CN A03132875X A CNA03132875X A CN A03132875XA CN 03132875 A CN03132875 A CN 03132875A CN 1481037 A CN1481037 A CN 1481037A
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battery isolator
isolator according
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gurley
battery
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CN1271729C (zh
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���ɵ¡�W�����˶�
罗纳德·W·考尔
J·R·迪斯
小仓静雄
K
唐纳德·K·西蒙斯
魏祥云
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SIKAD CO
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/403—Manufacturing processes of separators, membranes or diaphragms
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/403—Manufacturing processes of separators, membranes or diaphragms
    • H01M50/406—Moulding; Embossing; Cutting
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/409—Separators, membranes or diaphragms characterised by the material
    • H01M50/411—Organic material
    • H01M50/414—Synthetic resins, e.g. thermoplastics or thermosetting resins
    • H01M50/417—Polyolefins
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/409—Separators, membranes or diaphragms characterised by the material
    • H01M50/44—Fibrous material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/409—Separators, membranes or diaphragms characterised by the material
    • H01M50/449—Separators, membranes or diaphragms characterised by the material having a layered structure
    • H01M50/451—Separators, membranes or diaphragms characterised by the material having a layered structure comprising layers of only organic material and layers containing inorganic material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/463—Separators, membranes or diaphragms characterised by their shape
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/489—Separators, membranes, diaphragms or spacing elements inside the cells, characterised by their physical properties, e.g. swelling degree, hydrophilicity or shut down properties
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/489—Separators, membranes, diaphragms or spacing elements inside the cells, characterised by their physical properties, e.g. swelling degree, hydrophilicity or shut down properties
    • H01M50/491—Porosity
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49108—Electric battery cell making

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  • Chemical & Material Sciences (AREA)
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  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Inorganic Chemistry (AREA)
  • Cell Separators (AREA)

Abstract

本发明涉及一种电池隔离器。所述电池隔离器包括一种微孔薄膜，后者具有一个第一部分和一个第二部分。所述第一部分结合于所述第二部分。所述结合部位具有一个大于5g/in的强度。所述薄膜具有一个小于1.7mils的厚度，小于50sec/10cc的Gurley，和一个大于400g/mil的击穿强度。

Description

电池隔离器
相关申请
本申请是2000年7月11日提交的美国共同悬而未决的专利申请No.09/614,500的部分继续申请。
技术领域
本发明涉及一种电池隔离器(battery separator)及其制造方法，所述电池隔离器具有改进的强度性能。
背景技术
在2000年1月18日提交的美国专利申请No.09/484,184(在此引入作为参考)中，公开了一种由“塌陷泡沫(collapsed bubble)”技术制造的电池隔离器。所述“塌陷泡沫”技术涉及一种用于制造薄膜的已知的吹塑薄膜挤压技术的变形。在吹塑薄膜挤压技术中，聚合物通过一个环形模具被挤压出来而形成一个“泡沫”，所述泡沫被冷却和塌陷，但是塌陷的泡沫不会永久地粘结于其自身。见Berins，M.L.，Ed.，Plastics Engineering Handbook第5版(Chapman & Hall，NewYork，NY(1991)出版)pp.102-105，其在此引入作为参考。在所述“塌陷泡沫”技术中，当所述泡沫塌陷在其自身上时，其设计为永久性地粘结在其自身上。在前述申请中，挤压出来的聚合物是双物质挤压(co-extruded)的聚合物，即，形成两个不同层的两种不同的聚合物。
Celgard2402和2502平坦片膜是预先存在的产品，其通过“塌陷泡沫”技术制造。这些薄膜的相关特性在表2中列出。Celgard2400、2500和849平坦片膜是通过一种吹塑薄膜挤压技术制造的预先存在的产品。这些薄膜的相关特性在表1和2中列出。Celgard2400和2500与Celgard2402和2502的相关点在于，后两种产品是前两种产品的塌陷泡沫变形，并且是前两种产品厚度的2倍。
在美国专利No.5,565,281中，公开了一种双层电池隔离器，其中一层具有强度性能，而另一层具有断路性能。两种独立制造的层结合在一起。
在美国专利No.5,667,911中，公开了一种交叉叠置的电池隔离器。在这种隔离器中，单轴取向的板层结合在一起，从而使其成角度地偏置(即，在每个板层的单轴取向之间的20°和90°之间的一个角度)。
在美国专利No.5,922,492中，公开了一种复合电池隔离器。这种隔离器将两种不同的材料连接在一起，一个微孔薄膜和一个非织造织物通过层叠结构连接。
在美国专利No.5,952,120中，公开了一种三层电池隔离器，该电池隔离器具有两个夹着一个隔离层的强度层。
发明内容
本发明涉及一种电池隔离器。所述电池隔离器包括一个微孔薄膜，所述微孔薄膜具有一个第一部分和一个第二部分。所述第一部分与所述第二部分结合在一起。所述结合部位的强度大于5g/in。所述薄膜的厚度小于1.7密耳(mils)，小于50sec/10cc的Gurley，和大于400g/mil的击穿强度。
发明描述
本发明提供了一个具有结合在一起的两部分的微孔电池隔离器。每一部分由一个非双物质挤压层构成，并且由相同的材料制成。为了获得比现有技术的隔离器更大的击穿强度，所述现有技术的隔离器为具有给定厚度的单个多层隔离器，当两部分组合在一起时，本发明将作成一定尺寸的两部分结合在一起，从而具有与现有技术隔离器相同的厚度。本发明优选由一种塌陷泡沫技术制成，即，一种吹塑薄膜技术制成，其中一单种融熔聚合物(或者聚合物的混合物)被挤压通过一个环形模具，从所述模具发出的泡沫具有一个第一部分和一个第二部分(每一部分基本上占据所述泡沫的圆周的一半)，并且然后所述泡沫塌陷在其自身上，并且在形成微孔之前结合在一起(优选通过退火和拉伸)。当从所述模具发出泡沫时，其基本上沿着机器方向上取向。因此，当所述泡沫塌陷在其自身上并且结合时，第一部分和第二部分基本上在相同方向上取向(在取向部分之间的角度偏移小于15°)，即，在第一部分和第二部分之间没有显著的角度偏置(例如在美国专利No.5,667,911中公开的)。通过允许泡沫的融熔(或者接近融熔)的聚合物结接在一起而以相同的步骤进行塌陷和结合操作。通过使泡沫塌陷在其自身上并且对其进行结合，在与现有技术隔离器相同厚度的情况下获得了增加的击穿强度。
通过前述技术，第一部分和第二部分在结合时提供了用于微孔形成工艺(即，退火和拉伸操作)的母体，并且由相同材料制成。所述材料通常为聚烯烃、优选为聚乙烯或者聚丙烯、其共聚物和其混合物，并且最优选为聚乙烯和聚丙烯。
在退火和拉伸后生产的最终的隔离器是微孔薄膜。在此使用的微孔是指孔隙率小于60％和平均微孔尺寸在0.005-10微米之间的薄膜。优选地，所述薄膜的孔隙率为20-60％，并且其平均微孔尺寸为0.01-5微米，并且最优选是30-50％的孔隙率和0.5-2微米的平均微孔尺寸。
所述隔离器的厚度小于1.7密耳，并且优选厚度在0.5-1.5密耳的范围之内。
所述隔离器具有一个Gurley，后者利用小于50sec/10cc的水在12.2英寸处10cc的空气通过ASTM-D726测量。优选地，所述Gurley小于45sec/10cc，并且最优选地，小于35sec/10cc。
所述隔离器的击穿强度，通过横跨最终产品的宽度、在2mm/sec的速率处、以最大偏移量为6mm、大于400g/mil，利用一个MitechStevens LFRA组织分析器、一个1.65mm直径的针和0.5mm半径记录数据，10次测量取平均值。
如上所述，所述薄膜通过利用Celgard式工艺(挤压、退火、拉伸)由塌陷泡沫技术制造。进一步的细节在如下所述的例子中描述。
在表I中，利用商业上存在的Celgard产品849与本发明进行对比。所有产品利用相同的工艺制造，除了在本发明的示例中增加了线速度，从而其厚度可以相匹配。表I
示例标记#   849  pe1     pe2     pe3
树脂   HDPE  HDPE     HDPE     HDPE
产品薄膜   pe-单层  pe/pe     pe/pe     pe/pe
厚度(mil)   1.1  1.22     1.23     1.23
Gurley(sec/10cc空气)   36-51  21     23     33-34
击穿强度(g/mil)   380-400  450     440-460     460-480
附着力(克/英寸)  42     46     51
在表II中，商业上存在的Celgard产品2400、2402、2500和2502与本发明进行对比。所有的产品通过基本上相同的工艺制造，除了本发明中线速度被增加，从而使其厚度可以相互匹配。
表II
示例标记# 2400 2402  2500  2502  Pp1  Pp2  Pp3  Pp4
树脂 pp pp  pp  pp  pp  pp  pp  pp
产品薄膜 pp-单层 pp/pp  pp-单层  pp/pp  pp/pp  pp/pp  pp/pp  pp/pp
厚度(mil) 1 2  1  2  1  1  0.68  0.65
Gurley(sec/10cc空气) 23-29 40-90 7-10 14-26 19-23 21-25 8-10 9-12
击穿强度(g/mil) 400-450 350-390  300-350  250-300  490-540  540-590  470-520  530-580
附着力(克/英寸) n/a  n/a  5  ＞20  ＞20  ＞20  ＞20
本发明可以通过其它形式体现出来，而不脱离其精神和实质性特性，并且因此，应当参照所附权利要求，而不是参照前述说明，确定本发明的范围。

Claims (13)

1.一种电池隔离器，包括：
一种微孔薄膜，具有
一个第一非双物质挤压部分，和
一个第二非双物质挤压部分，所述第一部分结合于所述第二部分，所述结合部位具有一个大于5g/in的强度，并且所述第一部分和第二部分由相同的材料制成，并且基本上沿着相同的方向取向，并且
所述薄膜具有
一个小于1.5密耳的厚度
小于50sec/10cc的Gurley，和
一个大于400g/mil的击穿强度。
2.根据权利要求1所述的电池隔离器，其特征在于，所述微孔薄膜具有小于60％的孔隙率和0.005-10微米的平均微孔尺寸。
3.根据权利要求2所述的电池隔离器，其特征在于，所述微孔薄膜具有范围在20％-60％的孔隙率和0.01-5微米的平均微孔尺寸。
4.根据权利要求3所述的电池隔离器，其特征在于，所述薄膜具有范围在30％-50％的孔隙率和0.05-2微米的平均微孔尺寸。
5.根据权利要求1所述的电池隔离器，其特征在于，所述厚度范围在0.5-1.5密耳。
6.根据权利要求1所述的电池隔离器，其特征在于，所述Gurley小于50sec/10cc。
7.根据权利要求1所述的电池隔离器，其特征在于，所述Gurley小于45sec/10cc。
8.根据权利要求1所述的电池隔离器，其特征在于，所述Gurley小于35sec/10cc。
9.根据权利要求1所述的电池隔离器，其特征在于，所述击穿强度大于425克/密耳。
10.根据权利要求1所述的电池隔离器，其特征在于，所述材料是聚烯烃。
11.根据权利要求10所述的电池隔离器，其特征在于，所述聚烯烃选自由下述材料组成的一组：聚乙烯、聚丙烯、其共聚物和其混合物。
12.根据权利要求1所述的电池隔离器，其特征在于，所述强度大于15克/密耳。
13.根据权利要求1所述的电池隔离器，其特征在于，所述第一部分和第二部分由一种塌陷泡沫形成。
CNB03132875XA 2002-08-21 2003-07-24 电池隔离件 Expired - Lifetime CN1271729C (zh)

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US10/225,018 US6921608B2 (en) 2000-07-11 2002-08-21 Battery separator

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CN103943878B (zh) * 2013-01-21 2016-08-17 汽车能源供应公司 层叠型电池及其制造方法

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US6921608B2 (en) 2005-07-26
CA2434353A1 (en) 2004-02-21
US20030099877A1 (en) 2003-05-29
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