EP2668328A1 - Thin macroporous polymer films - Google Patents

Thin macroporous polymer films

Info

Publication number
EP2668328A1
EP2668328A1 EP11805844.5A EP11805844A EP2668328A1 EP 2668328 A1 EP2668328 A1 EP 2668328A1 EP 11805844 A EP11805844 A EP 11805844A EP 2668328 A1 EP2668328 A1 EP 2668328A1
Authority
EP
European Patent Office
Prior art keywords
welded
fibers
polymer
film according
equal
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP11805844.5A
Other languages
German (de)
French (fr)
Inventor
Ekkehard Beer
Michael Kube
Matthias Pascaly
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Evonik Operations GmbH
Original Assignee
Evonik Degussa GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Evonik Degussa GmbH filed Critical Evonik Degussa GmbH
Publication of EP2668328A1 publication Critical patent/EP2668328A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06CFINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
    • D06C7/00Heating or cooling textile fabrics
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • DTEXTILES; PAPER
    • D03WEAVING
    • D03DWOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D25/00Woven fabrics not otherwise provided for
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5412Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sheath-core
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/555Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving by ultrasonic heating
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • D04H3/04Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments in rectilinear paths, e.g. crossing at right angles
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00Secondary cells; Manufacture thereof
    • H01M10/05Accumulators with non-aqueous electrolyte
    • H01M10/052Li-accumulators
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/409Separators, membranes or diaphragms characterised by the material
    • H01M50/411Organic material
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/409Separators, membranes or diaphragms characterised by the material
    • H01M50/411Organic material
    • H01M50/414Synthetic resins, e.g. thermoplastics or thermosetting resins
    • H01M50/417Polyolefins
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/409Separators, membranes or diaphragms characterised by the material
    • H01M50/411Organic material
    • H01M50/414Synthetic resins, e.g. thermoplastics or thermosetting resins
    • H01M50/42Acrylic resins
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/409Separators, membranes or diaphragms characterised by the material
    • H01M50/411Organic material
    • H01M50/414Synthetic resins, e.g. thermoplastics or thermosetting resins
    • H01M50/423Polyamide resins
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/409Separators, membranes or diaphragms characterised by the material
    • H01M50/44Fibrous material
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/489Separators, membranes, diaphragms or spacing elements inside the cells, characterised by their physical properties, e.g. swelling degree, hydrophilicity or shut down properties
    • H01M50/494Tensile strength
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00Secondary cells; Manufacture thereof
    • H01M10/05Accumulators with non-aqueous electrolyte
    • H01M10/052Li-accumulators
    • H01M10/0525Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10Energy storage using batteries
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture

Definitions

  • the invention relates to a film comprising polymer fibers, at least to the
  • a fiber is understood to be a thin structure in relation to the length, which is flexible and can absorb no tensile forces but only tensile forces. Fibers buckle under pressure. In nature and technology fibers usually occur in a larger composite, they form a specific structure. Fibers of very large, virtually unlimited length are filaments, fibers of limited length are staple fibers.
  • Staple fibers in turn divide into actually spinnable staple fibers and below a limit length of about 15 mm flock fibers.
  • a yarn according to DIN 60900 is a collective term for all linear textile structures. Thereafter, a yarn is analogous to a long, thin structure of one or more fibers. It is a textile intermediate that can be made into fabrics, crocheted, knitted and embroidered or used for sewing.
  • Porous films are usually obtained by subjecting films, e.g. Polymer films, perforated or damage their original structure mechanically or chemically. Such materials can be supplied to a wide variety of uses, for example as
  • Packaging materials, separation and filtration membranes or as separators are packaged, separation and filtration membranes or as separators.
  • German patent application DE 10 2009 047 440 discloses production and properties of thin, perforated films which are stable for coating or impregnation processes.
  • the films contain or are made of metal or polymer and are perforated by means of a laser emitting at a suitable wavelength.
  • open area An important variable that characterizes openwork material is the open area. It is given through the pores and is determined by considering the material as a two-dimensional structure and the area occupied by the pores in relation to the total set of the material occupied area. If the pores are arranged regularly, elementary cells can be found that can be used to determine the open area. The edge length of the patches can be selected, for example, equal to 100 times the pore diameter.
  • F max tensile strength
  • a porous film is obtained by densifying a woven or knitted fabric comprising or consisting of polymer fibers such that the fibers are welded together at least at their points of intersection and / or at least partly fused together or non-positively or positively connected to each other. After such treatment, the fibers have lost their original shape in cross-section, but are still recognizable as such, for example under light microscopic observation. By contrast, the macroscopic structure no longer has the properties of a conventional fabric or knitted fabric - individual threads or fibers can no longer be separated off.
  • the invention thus relates to a porous film, which is characterized in that the film comprises polymer fibers which are welded together at least at the points of intersection between the pores, in particular thermally welded, swell welded, cold-welded, ultrasonically welded and / or at least partially together
  • the porous film according to the invention has the advantage of a homogeneous structure and a good tensile strength in the longitudinal and in the transverse direction. Another advantage is that the claimed film can easily be wound up without the connections of the fibers at the crossover points impeding the winding up. When winding up this film neither break the individual fibers, nor the compounds at the crossover points.
  • the invention likewise relates to a process for the production of the porous film, which is characterized in that a woven or knitted fabric comprising or consisting of thermoplastic polymer fibers is compacted under a surface or line pressure at least once, the polymer fibers at least on the
  • Crossover points welded together in particular thermowelded, swell welded, cold-welded, ultrasonically welded, and / or at least partially fused together or non-positively or positively connected to each other. This is done at a surface or line pressure less than or equal to 500 N / mm, and a temperature less than or equal to 50% below the melting temperature of the lowest melting polymer.
  • the inventive method has the advantage that the macroscopic thickness of the resulting film can be adjusted, by continuously adjustable
  • the invention therefore also relates to the film obtained according to the method and the use of the film according to the invention or the invention obtained as a separator in batteries, as well as packaging material, membrane, filter, and as a carrier material for ceramic composite membranes.
  • One possible use of the film according to the invention is, for example, as a carrier of a ceramic coating in the production of ceramic separators, for example the SEPARION® separator, which is particularly suitable for use in high-performance lithium-ion batteries because of its temperature and chemical resistance.
  • the invention is therefore also a lithium-ion battery, the
  • the film according to the invention may have a thickness of less than or equal to 100 ⁇ m and / or an open area of greater than or equal to 20%. This makes them suitable for use as a separator in a battery. Particularly preferably, the film may have a thickness of less than or equal to 20 ⁇ m. This makes them suitable for use as a separator in a high-performance battery, particularly preferably in a lithium-ion battery.
  • the fibers of the film according to the invention may advantageously contain or consist of a plastic with a low melting point. An example of a partial
  • Melting polymer is polyethylene terephthalate (PET), which melts at 210 - 235 ° C.
  • PET polyethylene terephthalate
  • a preferred plastic may be Vestamelt®.
  • mixtures of fibers which can bring about fusion or fusion are advantageous, particularly preferably in the longitudinal direction of the polyester and in the transverse direction
  • polymer fibers of the film according to the invention may comprise or consist of at least one thermoplastic polymer. More preferably, the polymer of these fibers may be selected from polyacrylonitrile, polyester, polyamide, polyimide, polyaramid, polyolefins, PTFE, PVDF, PES, PUR, or a combination of these polymers.
  • polymer fibers of the film according to the invention may comprise or consist of at least one thermoplastic and at least one non-thermoplastic polymer, core-shell fibers, and / or co-extrudates.
  • polymer fibers of the film according to the invention comprise at least one thermoplastic and at least one non-thermoplastic polymer, these may be selected from core-shell fibers, wherein the core material comprises or is at least one non-thermoplastic polymer,
  • thermoplastic polymer fibers in warp direction and non-thermoplastic
  • thermoplastic polymer fibers in the warp direction and thermoplastic
  • Polymer fibers comprising or consisting of a finer thermoplastic and non-thermoplastic polymer fibers, or
  • the film according to the invention which comprises polymer fibers made of or with thermoplastic and non-thermoplastic polymer, has the advantage that the film according to the invention or obtained according to the invention has a greater tensile strength than a film which consists of an extruded polymer composition.
  • a particular advantage is that such a film calendering or further processing in roll-to-roll processes, for example
  • the film of the invention or obtained according to the invention with ceramic material can coat and subsequently heat treated, for example in the preparation of SEPARION ® separator.
  • the film has the advantage that its tensile strength can be adapted to the requirements of calendering, for example by selecting the non-thermoplastic polymer for the fibers in the warp direction.
  • the film has the advantage that very thin Films can be obtained by selecting particularly thin thermoplastic and / or non-thermoplastic polymer fibers.
  • thermosetting polymer fiber core also gives the film according to the invention more strength. Also, this selection affects the thickness of the porous film because the material does not deform so easily. Although the film according to the invention has a higher stability and thus a low deformability and a higher shear modulus, a less elastic behavior in the calendering gap is to be considered.
  • the polymer fibers may particularly preferably be coated fibers which are obtained by methods known to the person skilled in the art, for example the so-called
  • Bicomponent spins or coextrusion are particularly preferred.
  • Further preferred fibers may also be staple fibers as "spunbond” or very short and fine meltblown fibers available from Fare SpA, Via Pastrengo 31, Fagnono, Olona (VA), 21054, Italy.
  • the films according to the invention or those obtained according to the invention can be converted into ceramic composite membranes by coating with ceramic dispersions.
  • An example of the prior art is SEPARION ® in which a polymeric web is used instead of a perforated polymer film.
  • the further subject of the invention is a process for the preparation of
  • porous film according to the invention characterized in that a woven or knitted fabric comprising or consisting of thermoplastic polymer fibers, under a surface or line pressure of less than or equal to 500 N / mm, and a temperature less than or equal to 50% below the melting temperature of the lowest melting polymer is compressed at least once, wherein the polymer fibers at least to the
  • Crossover points welded together in particular thermowelded, source welded, cold-welded, ultrasound l-welded, and / or at least partially fused together or positively or non-positively connected to each other.
  • the woven or knitted fabric is continuously compressed in calenders or belt presses.
  • a line pressure of less than or equal to 500 N / mm is used.
  • plate presses are favored for a discontinuous procedure.
  • a temperature less than or equal to 10% below the melting temperature of the lowest melting polymer may be selected.
  • At least one additional calendering is the additional functionality, preferably by applying a further fabric or nonwoven.
  • a further fabric or nonwoven Preferably, an extremely thin aramid nonwoven can be calendered.
  • PET Polyethylene terephthalate
  • the tensile strengths were determined according to DIN EN ISO 527-1 in each case in the so-called “material direction” (MD) known to the person skilled in the art and in “cross direction” (CD). The results are shown in Table 1. At a line pressure of 300 N / mm, a transport speed of 10 m / min and a temperature of 220 ° C, a porous film according to the invention was obtained with a thickness of 14 ⁇ . The measured tensile strengths are shown in Table 1 in row 1. The tensile strengths of calendering the fabric in a line pressure of
  • Line 3 shows the tensile strengths of those obtained from the same fabric
  • Line 4 shows the tensile strengths of those obtained from the same fabric
  • PET films with thicknesses of 18 ⁇ or 1 1 ⁇ were perforated two-dimensionally with a laser. This area perforation can be performed with C02 lasers. The method is based on the one-dimensional perforation as it is performed, for example, at the companies Maag or Micro Laser Tech and u.a. in JP63023936 or JP1 1077872.
  • the resulting perforated films had an open area of 22% and 15%, respectively, summarized in lines 5 and 6 of Table 1, respectively.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Textile Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Cell Separators (AREA)
  • Nonwoven Fabrics (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)

Abstract

The invention relates to a foil which includes polymeric fibres, the polymeric fibres of which are interwelded, more particularly heat welded, solvent welded, cold welded, ultrasonically welded and/or at least partly interfused or positively or nonpositively interconnected at the crossing points between the pores at least, a process for production thereof, and also use thereof.

Description

Dünne, makroporöse Polymerfolien  Thin, macroporous polymer films
Die Erfindung betrifft eine Folie, die Polymerfasern aufweist, die zumindest an den The invention relates to a film comprising polymer fibers, at least to the
Überkreuzungspunkten zwischen den Poren miteinander verschweißt, insbesondere thermoverschweißt, quellverschweißt, kaltverschweißt, ultraschall-verschweißt und/oder zumindest teilweise miteinander verschmolzen oder kraft- oder formschlüssig miteinander verbunden sind. Crossover points between the pores welded together, in particular thermowelded, swell-welded, cold-welded, ultrasonically welded and / or at least partially fused together or non-positively or positively connected to each other.
Unter einer Faser wird im Rahmen der vorliegenden Erfindung ein im Verhältnis zur Länge dünnes Gebilde verstanden, welches flexibel ist und keine Druck-, sondern nur Zugkräfte aufnehmen kann. Fasern knicken bei Druckbelastung. In Natur und Technik kommen Fasern meist in einem größeren Verbund vor, sie bilden eine bestimmte Struktur. Fasern sehr großer, praktisch unbegrenzter Länge heißen Filamente, Fasern begrenzter Länge Spinnfasern. In the context of the present invention, a fiber is understood to be a thin structure in relation to the length, which is flexible and can absorb no tensile forces but only tensile forces. Fibers buckle under pressure. In nature and technology fibers usually occur in a larger composite, they form a specific structure. Fibers of very large, virtually unlimited length are filaments, fibers of limited length are staple fibers.
Spinnfasern teilen sich wiederum in tatsächlich verspinnbare Stapelfasern und unter einer Grenzlänge von etwa 15 mm Flockfasern. Im Unterschied dazu ist ein Garn nach DIN 60900 ein Sammelbegriff für alle linienförmigen textilen Gebilde. Danach ist ein Garn sinngemäß ein langes, dünnes Gebilde aus einer oder mehreren Fasern. Es ist ein textiles Zwischenprodukt, welches zu Geweben, Gestricken, Gewirken und Stickereien verarbeitet werden kann oder auch zum Nähen verwendet wird. Staple fibers in turn divide into actually spinnable staple fibers and below a limit length of about 15 mm flock fibers. In contrast, a yarn according to DIN 60900 is a collective term for all linear textile structures. Thereafter, a yarn is analogous to a long, thin structure of one or more fibers. It is a textile intermediate that can be made into fabrics, crocheted, knitted and embroidered or used for sewing.
Poröse Folien werden üblicherweise erhalten, indem man Folien, z.B. Polymerfilme, perforiert oder deren ursprüngliche Struktur mechanisch oder chemisch schädigt. Derartige Materialien können unterschiedlichsten Verwendungen zugeführt werden, beispielsweise als Porous films are usually obtained by subjecting films, e.g. Polymer films, perforated or damage their original structure mechanically or chemically. Such materials can be supplied to a wide variety of uses, for example as
Verpackungsmaterialien, Trenn- und Filtrationsmembranen oder als Separatoren. Packaging materials, separation and filtration membranes or as separators.
Die deutsche Patentanmeldung DE 10 2009 047 440 offenbart Herstellung und Eigenschaften von dünnen, perforierten Folien, die für Beschichtungs- oder Imprägnierungsprozesse stabil sind. Die Folien enthalten oder sind aus Metall oder Polymer und werden mittels eines bei einer geeigneten Wellenlänge emittierenden Lasers perforiert. German patent application DE 10 2009 047 440 discloses production and properties of thin, perforated films which are stable for coating or impregnation processes. The films contain or are made of metal or polymer and are perforated by means of a laser emitting at a suitable wavelength.
Eine wichtige Größe, das durchbrochenes Material charakterisiert, ist die offene Fläche. Sie ist durch die Poren gegeben und wird bestimmt, indem man das Material als zweidimensionales Gebilde betrachtet und die von den Poren eingenommene Fläche ins Verhältnis zur gesamten von dem Material eingenommenen Fläche setzt. Sind die Poren regelmäßig angeordnet, lassen sich Elementarzellen finden, von denen man bei der Bestimmung der offenen Fläche ausgehen kann. Die Kantenlänge der Flächenstücke kann zum Beispiel gleich dem 100- fachen Porendurchmesser gewählt werden. An important variable that characterizes openwork material is the open area. It is given through the pores and is determined by considering the material as a two-dimensional structure and the area occupied by the pores in relation to the total set of the material occupied area. If the pores are arranged regularly, elementary cells can be found that can be used to determine the open area. The edge length of the patches can be selected, for example, equal to 100 times the pore diameter.
Eine weitere wichtige Größe, die für das Verarbeiten des durchbrochenen Materials von Bedeutung ist, ist die Zugfestigkeit, abgekürzt Fmax. Sie wird im Rahmen der Erfindung gemäß DIN EN ISO 527-1 bestimmt. Die Aufgabe der vorliegenden Erfindung besteht darin, ein alternatives durchbrochenes Material bereit zu stellen, dessen offene Fläche bei minimaler Dicke und guter Zugfestigkeit auf einfache Weise kontrolliert werden kann. Another important quantity of importance for processing the openwork material is the tensile strength, abbreviated F max . It is determined in the context of the invention according to DIN EN ISO 527-1. The object of the present invention is to provide an alternative perforated material whose open area can be easily controlled with minimum thickness and good tensile strength.
Es wurde gefunden, dass eine poröse Folie erhalten wird, indem ein Gewebe oder Gewirke, das Polymerfasern aufweist oder aus diesen besteht, derart verdichtet wird, dass die Fasern zumindest an ihren Überkreuzungspunkten miteinander verschweißt und/oder zumindest teilweise miteinander verschmolzen oder kraft- oder formschlüssig miteinander verbunden sind. Nach einer solchen Behandlung haben die Fasern im Querschnitt ihre ursprüngliche Form verloren, sind aber, zum Beispiel unter lichtmikroskopischer Betrachtung, noch als solche erkennbar. Das makroskopische Gebilde dagegen hat nicht mehr die Eigenschaften eines herkömmlichen Gewebes oder Gewirkes - einzelne Fäden oder Fasern lassen sich nicht mehr abtrennen. It has been found that a porous film is obtained by densifying a woven or knitted fabric comprising or consisting of polymer fibers such that the fibers are welded together at least at their points of intersection and / or at least partly fused together or non-positively or positively connected to each other. After such treatment, the fibers have lost their original shape in cross-section, but are still recognizable as such, for example under light microscopic observation. By contrast, the macroscopic structure no longer has the properties of a conventional fabric or knitted fabric - individual threads or fibers can no longer be separated off.
Gegenstand der Erfindung ist also eine poröse Folie, welche dadurch gekennzeichnet ist, dass die Folie Polymerfasern aufweist, die zumindest an den Überkreuzungspunkten zwischen den Poren miteinander verschweißt, insbesondere thermoverschweißt, quellverschweißt, kaltverschweißt, ultraschall-verschweißt und/oder zumindest teilweise miteinander The invention thus relates to a porous film, which is characterized in that the film comprises polymer fibers which are welded together at least at the points of intersection between the pores, in particular thermally welded, swell welded, cold-welded, ultrasonically welded and / or at least partially together
verschmolzen oder kraft- oder formschlüssig miteinander verbunden sind. Die erfindungsgemäße poröse Folie hat den Vorteil einer homogenen Struktur sowie einer guten Zugfestigkeit in Längs- und in Querrichtung. Ein weiterer Vorteil besteht darin, dass sich die beanspruchte Folie leicht aufwickeln lässt, ohne dass die Verbindungen der Fasern an den Überkreuzungspunkten das Aufwickeln behindern. Beim Aufwickeln dieser Folie brechen außerdem weder die einzelnen Fasern, noch die Verbindungen an den Überkreuzungspunkten. fused or non-positively or positively connected with each other. The porous film according to the invention has the advantage of a homogeneous structure and a good tensile strength in the longitudinal and in the transverse direction. Another advantage is that the claimed film can easily be wound up without the connections of the fibers at the crossover points impeding the winding up. When winding up this film neither break the individual fibers, nor the compounds at the crossover points.
Ebenfalls Gegenstand der Erfindung ist ein Verfahren zur Herstellung der porösen Folie, welches dadurch gekennzeichnet ist, dass ein Gewebe oder Gewirke, das thermoplastische Polymerfasern aufweist oder aus diesen besteht, unter einem Flächen- oder Liniendruck zumindest einmal verdichtet wird, wobei die Polymerfasern zumindest an den The invention likewise relates to a process for the production of the porous film, which is characterized in that a woven or knitted fabric comprising or consisting of thermoplastic polymer fibers is compacted under a surface or line pressure at least once, the polymer fibers at least on the
Überkreuzungspunkten miteinander verschweißt, insbesondere thermoverschweißt, quellverschweißt, kaltverschweißt, ultraschall-verschweißt, und/oder zumindest teilweise miteinander verschmolzen oder kraft- oder formschlüssig miteinander verbunden werden. Dies erfolgt bei einem Flächen- oder Liniendruck kleiner gleich 500 N/mm, und einer Temperatur kleiner gleich 50% unterhalb der Schmelztemperatur des am niedrigsten schmelzenden Polymers. Crossover points welded together, in particular thermowelded, swell welded, cold-welded, ultrasonically welded, and / or at least partially fused together or non-positively or positively connected to each other. This is done at a surface or line pressure less than or equal to 500 N / mm, and a temperature less than or equal to 50% below the melting temperature of the lowest melting polymer.
Das erfindungsgemäße Verfahren hat den Vorteil, dass die makroskopische Dicke der erhaltenen Folie eingestellt werden kann, und zwar durch kontinuierlich einstellbaren The inventive method has the advantage that the macroscopic thickness of the resulting film can be adjusted, by continuously adjustable
Liniendruck im Walzenspalt eines Kalanders oder einer Bandpresse beim Verdichten, sowie durch das Einstellen der Temperatur der Walzen. Weiterhin ist an dem erfindungsgemäßen Verfahren vorteilhaft, dass dünne Folien mit Dicken kleiner gleich 200 μηι, bevorzugt kleiner gleich 50 μηι, besonders bevorzugt extrem dünne Folien mit Dicken kleiner gleich 20 μηι erhalten werden. Mit Auswahl der Maschenweite und Fadenstärke, sowie der Bedingungen beim Verdichten, nämlich Liniendruck, Spaltweite und Temperatur werden auch die offene Fläche und die Lochgröße kontrolliert. Außerdem ist eine diskontinuierliche Folienfertigung unter den gleichen Einflussgrößen in Plattenpressen möglich. Diese Verfahren ermöglichen insbesondere die Verwendung derart hergestellter porösen Folie als eine Komponente des Separators in Hochleistungsbatterien, zum Beispiel als Träger einer keramischen Line pressure in the nip of a calender or a belt press during compression, and by adjusting the temperature of the rollers. Furthermore, it is advantageous in the process according to the invention that thin films having thicknesses of less than or equal to 200 μm, preferably less than or equal to 50 μm, particularly preferably extremely thin films having thicknesses of less than or equal to 20 μm, can be obtained. By selecting the mesh size and thread thickness, as well as the conditions of compression, namely line pressure, gap width and temperature, the open area and the hole size are controlled. In addition, a discontinuous film production under the same parameters in plate presses is possible. In particular, these methods make it possible to use such a porous film as a component of the separator in high-performance batteries, for example as a carrier for a ceramic
Beschichtung des Separators. Beispiele keramische Beschichtungen aufweisender Coating of the separator. Examples having ceramic coatings
Separatoren sind in den Patentanmeldungen DE 19741498, DE 1981 1708, DE 19812035, DE 19820580, DE 19824666, DE 10142622, DE 10208280, DE 10208277, DE 10238941 , DE 10238944, DE 10238945, DE 10240032, DE 10255121 , DE 10255122, DE 10347570, DE 10347569, DE 10347566, DE 10347568, DE 10347567, DE 10 2004 018929, DE 10 2004 018930, DE 10 2005 029124, DE 10 2005 042215, DE 10 2007 005156 Separators are described in the patent applications DE 19741498, DE 1981 1708, DE 19812035, DE 19820580, DE 19824666, DE 10142622, DE 10208280, DE 10208277, DE 10238941, DE 10238944, DE 10238945, DE 10240032, DE 10255121, DE 10255122, DE 10347570 DE 10347569, DE 10347566, DE 10347568, DE 10347567, DE 10 2004 018929, DE 10 2004 018930, DE 10 2005 029124, DE 10 2005 042215, DE 10 2007 005156
DE 10 2009 002680 beschrieben. DE 10 2009 002680.
Gegenstand der Erfindung ist deshalb auch die verfahrensgemäß erhaltene Folie und die Verwendung der erfindungsgemäßen oder erfindungsgemäß erhaltenen Folie als Separator in Batterien, außerdem als Verpackungsmaterial, Membran, Filter, und als Trägermaterial für keramische Kompositmembranen. The invention therefore also relates to the film obtained according to the method and the use of the film according to the invention or the invention obtained as a separator in batteries, as well as packaging material, membrane, filter, and as a carrier material for ceramic composite membranes.
Eine mögliche Verwendung der erfindungsgemäßen Folie ist beispielsweise als Träger einer keramischen Beschichtung bei der Herstellung keramischer Separatoren, zum Beispiel des SEPARION® Separators, der wegen seiner Temperatur- und Chemikalienbeständigkeit besonders für die Verwendung in hochleistungsfähigen Lithiumionen- Batterien geeignet ist. One possible use of the film according to the invention is, for example, as a carrier of a ceramic coating in the production of ceramic separators, for example the SEPARION® separator, which is particularly suitable for use in high-performance lithium-ion batteries because of its temperature and chemical resistance.
Gegenstand der Erfindung ist deshalb auch eine Lithiumionen- Batterie, die die The invention is therefore also a lithium-ion battery, the
erfindungsgemäße Folie als Separator aufweist. Has inventive film as a separator.
Die Erfindung wird im Folgenden näher erläutert. The invention will be explained in more detail below.
Die erfindungsgemäße Folie kann eine Dicke von kleiner oder gleich 100 μηι und/oder eine Offene Fläche von größer oder gleich 20 % aufweisen. Dies macht sie für den Einsatz als Separator in einer Batterie geeignet. Besonders bevorzugt kann die Folie eine Dicke von kleiner oder gleich 20 μηι aufweisen. Dies macht sie für den Einsatz als Separator in einer Hochleistungsbatterie, besonders bevorzugt in einer Lithiumionen-Batterie, geeignet. Die Fasern der erfindungsgemäßen Folie können vorteilhaft einen Kunststoff mit niedrigem Schmelzpunkt enthalten oder aus diesem bestehen. Ein Beispiel für ein teilweise The film according to the invention may have a thickness of less than or equal to 100 μm and / or an open area of greater than or equal to 20%. This makes them suitable for use as a separator in a battery. Particularly preferably, the film may have a thickness of less than or equal to 20 μm. This makes them suitable for use as a separator in a high-performance battery, particularly preferably in a lithium-ion battery. The fibers of the film according to the invention may advantageously contain or consist of a plastic with a low melting point. An example of a partial
schmelzendes Polymer ist Polyethylenterephthalat (PET), das bei 210 - 235 °C schmilzt. Ein bevorzugter Kunststoff kann Vestamelt® sein. In einer weiteren Ausführung der Erfindung sind Mischungen von Fasern vorteilhaft, die das Verschweißen bzw. Verschmelzen bewirken können, besonders bevorzugt in Längsrichtung Polyester- und in Querrichtung Melting polymer is polyethylene terephthalate (PET), which melts at 210 - 235 ° C. A preferred plastic may be Vestamelt®. In a further embodiment of the invention, mixtures of fibers which can bring about fusion or fusion are advantageous, particularly preferably in the longitudinal direction of the polyester and in the transverse direction
Polyolefinfasern. Die Polymerfasern der erfindungsgemäßen Folie können zumindest ein thermoplastisches Polymer aufweisen oder daraus bestehen. Besonders bevorzugt kann das Polymer dieser Fasern ausgewählt sein aus Polyacrylnitril, Polyester, Polyamid, Polyimid, Polyaramid, Polyolefinen, PTFE, PVDF, PES, PUR, oder eine Kombination dieser Polymere. Polyolefin fibers. The polymer fibers of the film according to the invention may comprise or consist of at least one thermoplastic polymer. More preferably, the polymer of these fibers may be selected from polyacrylonitrile, polyester, polyamide, polyimide, polyaramid, polyolefins, PTFE, PVDF, PES, PUR, or a combination of these polymers.
Weiterhin besonders bevorzugt können die Polymerfasern der erfindungsgemäßen Folie zumindest ein thermoplastisches und zumindest ein nicht-thermoplastisches Polymer, Core- Shell Fasern, und/oder Coextrudate aufweisen oder daraus bestehen. With particular preference the polymer fibers of the film according to the invention may comprise or consist of at least one thermoplastic and at least one non-thermoplastic polymer, core-shell fibers, and / or co-extrudates.
Falls die Polymerfasern der erfindungsgemäßen Folie zumindest ein thermoplastisches und zumindest ein nicht-thermoplastisches Polymer aufweisen, können diese ausgewählt sein aus Core-Shell-Fasern, wobei das Kernmaterial zumindest ein nicht-thermoplastisches Polymer aufweist oder ist, If the polymer fibers of the film according to the invention comprise at least one thermoplastic and at least one non-thermoplastic polymer, these may be selected from core-shell fibers, wherein the core material comprises or is at least one non-thermoplastic polymer,
coextrudierte Fasern,  coextruded fibers,
thermoplastische Polymerfasern in Kett-Richtung und nicht-thermoplastische  thermoplastic polymer fibers in warp direction and non-thermoplastic
Polymerfasern in Schussrichtung,  Polymer fibers in weft direction,
nicht-thermoplastische Polymerfasern in Kett-Richtung und thermoplastische  non-thermoplastic polymer fibers in the warp direction and thermoplastic
Polymerfasern in Schussrichtung,  Polymer fibers in weft direction,
Polymerfasern, die feinere thermoplastische und nicht-thermoplastische Polymerfasern aufweisen oder aus einem solchen Fasergemisch bestehen, oder  Polymer fibers comprising or consisting of a finer thermoplastic and non-thermoplastic polymer fibers, or
eine Kombination aus diesen Fasern sein. a combination of these fibers.
Die erfindungsgemäße Folie, die Polymerfasern aus oder mit thermoplastischem und nichtthermoplastischem Polymer aufweist, hat den Vorteil, dass die erfindungsgemäße oder erfindungsgemäß erhaltene Folie eine größere Zugfestigkeit aufweist, als eine Folie, die aus einer extrudierten Polymermasse besteht. Besonderer Vorteil ist, dass sich eine solche Folie kalandrieren oder in Rolle-zu-Rolle Prozessen weiter bearbeiten, zum Beispiel The film according to the invention, which comprises polymer fibers made of or with thermoplastic and non-thermoplastic polymer, has the advantage that the film according to the invention or obtained according to the invention has a greater tensile strength than a film which consists of an extruded polymer composition. A particular advantage is that such a film calendering or further processing in roll-to-roll processes, for example
wärmebehandeln lässt. Ganz besonderer Vorteil ist, dass sich die erfindungsgemäße oder erfindungsgemäß erhaltene Folie mit keramischem Material beschichten und anschließend wärmebehandeln lässt, zum Beispiel bei der Herstellung des SEPARION® Separators. Des Weiteren hat die Folie den Vorteil, dass sich ihre Zugfestigkeit an die Erfordernisse des Kalandrierens anpassen lässt, indem man z.B. das nicht-thermoplastische Polymer für die Fasern in Kett-Richtung auswählt. Außerdem hat die Folie den Vorteil, dass besonders dünne Folien erhalten werden können, indem man besonders dünne thermoplastische und/oder nicht-thermoplastische Polymerfasern auswählt. heat treatable. Is quite special advantage that the film of the invention or obtained according to the invention with ceramic material can coat and subsequently heat treated, for example in the preparation of SEPARION ® separator. Furthermore, the film has the advantage that its tensile strength can be adapted to the requirements of calendering, for example by selecting the non-thermoplastic polymer for the fibers in the warp direction. In addition, the film has the advantage that very thin Films can be obtained by selecting particularly thin thermoplastic and / or non-thermoplastic polymer fibers.
Ein duroplastischer Polymerfaserkern verleiht der erfindungsgemäßen Folie überdies mehr Festigkeit. Auch beeinflusst diese Auswahl die Dicke der porösen Folie, da sich das Material nicht so leicht verformt. Die erfindungsgemäße Folie weist zwar eine höhere Stabilität und somit eine geringe Verformbarkeit und ein höheres Schubmodul auf, doch ist ein weniger elastisches Verhalten im Kalanderspalt zu beachten. Besonders bevorzugt können die Polymerfasern ummantelte Fasern sein, die mittels dem Fachmann bekannter Verfahren erhalten werden, zum Beispiel dem sogenannten A thermosetting polymer fiber core also gives the film according to the invention more strength. Also, this selection affects the thickness of the porous film because the material does not deform so easily. Although the film according to the invention has a higher stability and thus a low deformability and a higher shear modulus, a less elastic behavior in the calendering gap is to be considered. The polymer fibers may particularly preferably be coated fibers which are obtained by methods known to the person skilled in the art, for example the so-called
Bicomponentenspinnen oder der Coextrusion. Unter der Vielzahl ummantelter Fasern können zum Beispiel solche mit einem PET-Kern, ummantelt mit PA, besonders bevorzugt sein. Weiterhin bevorzugte Fasern können auch Stapelfasern als„Spunbond" oder sehr kurze und feine Meltblown-Fasern sein, die bei der Firma Fare SpA, Via Pastrengo 31, Fagnono, Olona (VA), 21054, Italy, erhältlich sind. Bicomponent spins or coextrusion. Among the plurality of coated fibers, for example, those having a PET core coated with PA may be particularly preferred. Further preferred fibers may also be staple fibers as "spunbond" or very short and fine meltblown fibers available from Fare SpA, Via Pastrengo 31, Fagnono, Olona (VA), 21054, Italy.
Es ist außer dem zuvor Gesagten jede weitere dem Fachmann für Textilien bekannte It is beyond the foregoing any further known to the skilled textiles expert
Kombination an Fasern und Polymeren möglich. Combination on fibers and polymers possible.
Des Weiteren können die erfindungsgemäßen bzw. erfindungemäß erhaltenen Folien durch Beschichtung mit keramischen Dispersionen in keramische Kompositmembranen überführt werden. Ein Beispiel des Standes der Technik ist SEPARION®, worin ein Polymervlies an Stelle eines perforierten Polymerfilmes verwendet wird. Furthermore, the films according to the invention or those obtained according to the invention can be converted into ceramic composite membranes by coating with ceramic dispersions. An example of the prior art is SEPARION ® in which a polymeric web is used instead of a perforated polymer film.
Der weitere Gegenstand der Erfindung ist ein Verfahren zur Herstellung der The further subject of the invention is a process for the preparation of
erfindungsgemäßen porösen Folie, welches dadurch gekennzeichnet ist, dass ein Gewebe oder Gewirke, das thermoplastische Polymerfasern aufweist oder aus diesen besteht, unter einem Flächen- oder Liniendruck kleiner gleich 500 N/mm, und einer Temperatur kleiner gleich 50% unterhalb der Schmelztemperatur des am niedrigsten schmelzenden Polymers zumindest einmal verdichtet wird, wobei die Polymerfasern zumindest an den porous film according to the invention, characterized in that a woven or knitted fabric comprising or consisting of thermoplastic polymer fibers, under a surface or line pressure of less than or equal to 500 N / mm, and a temperature less than or equal to 50% below the melting temperature of the lowest melting polymer is compressed at least once, wherein the polymer fibers at least to the
Überkreuzungspunkten miteinander verschweißt, insbesondere thermoverschweißt, quellverschweißt, kaltverschweißt, ultraschal l-verschweißt, und/oder zumindest teilweise miteinander verschmolzen oder kraft- oder formschlüssig miteinander verbunden werden. Crossover points welded together, in particular thermowelded, source welded, cold-welded, ultrasound l-welded, and / or at least partially fused together or positively or non-positively connected to each other.
Bevorzugt wird das Gewebe oder Gewirke kontinuierlich in Kalandern oder Bandpressen verdichtet. Vorzugsweise wird ein Liniendruck kleiner gleich 500 N/mm eingesetzt. Weiterhin favorisiert werden für eine diskontinuierliche Verfahrensweise Plattenpressen. Ebenso bevorzugt kann eine Temperatur kleiner oder gleich 10 % unterhalb der Schmelztemperatur des am niedrigsten schmelzenden Polymers gewählt werden. In dem erfindungsgemäßen Verfahren kann es vorteilhaft sein, das Gewebe oder Gewirke zumindest zweimal zu verdichten, wobei sich jedes weitere Verdichten von dem Preferably, the woven or knitted fabric is continuously compressed in calenders or belt presses. Preferably, a line pressure of less than or equal to 500 N / mm is used. Furthermore, plate presses are favored for a discontinuous procedure. Also preferably, a temperature less than or equal to 10% below the melting temperature of the lowest melting polymer may be selected. In the method according to the invention, it may be advantageous to compress the fabric or knit at least twice, with each further densification of the
vorhergehenden Verdichten in dem Liniendruck, der Spaltbreite, und/oder der Temperatur unterscheidet. Die Herstellung der Gewebe und Gewirke erfolgt gemäß dem Stand der Technik, zum Beispiel bei den Firmen Andritz in Krefeld, Webatex in Bayreuth oder Sefar Schweiz, sowie die erfindungsgemäße Weiterverarbeitung mittels eines Kalanders. previous densities in line pressure, gap width, and / or temperature. The production of the woven and knitted fabric is carried out according to the state of the art, for example at the companies Andritz in Krefeld, Webatex in Bayreuth or Sefar Switzerland, as well as the further processing according to the invention by means of a calender.
Vorteil zumindest eines weiteren Kalandrierens ist die zusätzliche Funktionalität, vorzugsweise durch Aufbringung eines weiteren Gewebes oder Vlieses. Bevorzugt kann ein extrem dünnes Aramidvlies aufkalandriert werden. Advantage of at least one additional calendering is the additional functionality, preferably by applying a further fabric or nonwoven. Preferably, an extremely thin aramid nonwoven can be calendered.
Beispiele 1 bis 4. Examples 1 to 4.
Polyethylenterephthalat (PET) Gewebe mit 10 dtex, entsprechend monofil 27 μηι,  Polyethylene terephthalate (PET) fabric with 10 dtex, corresponding to monofilament 27 μηι,
Maschenweite 135 μηι und einer Dicke von 44 μηι, gezeigt in Abbildung 1 , wurde unter verschiedenen Liniendrücken, Temperaturen und Transportgeschwindigkeiten kalandriert. Mesh size 135 μηι and a thickness of 44 μηι, shown in Figure 1, was calendered under different line pressures, temperatures and transport speeds.
Die Zugfestigkeiten wurden gemäß DIN EN ISO 527-1 jeweils in der dem Fachmann bekannten sogenannten„material direction" (MD) und in„cross direction" (CD) bestimmt. Die Ergebnisse zeigt die Tabelle 1. Bei einem Liniendruck von 300 N/mm, einer Transportgeschwindigkeit von 10 m/min und einer Temperatur von 220 °C wurde eine erfindungsgemäße poröse Folie mit einer Dicke von 14 μηι erhalten. Die gemessenen Zugfestigkeiten zeigt Tabelle 1 in Zeile 1. Die Zugfestigkeiten der beim Kalandrieren des Gewebes bei einem Liniendruck von The tensile strengths were determined according to DIN EN ISO 527-1 in each case in the so-called "material direction" (MD) known to the person skilled in the art and in "cross direction" (CD). The results are shown in Table 1. At a line pressure of 300 N / mm, a transport speed of 10 m / min and a temperature of 220 ° C, a porous film according to the invention was obtained with a thickness of 14 μηι. The measured tensile strengths are shown in Table 1 in row 1. The tensile strengths of calendering the fabric in a line pressure of
150 N/mm, einer Transportgeschwindigkeit von 3 m/min, und einer Temperatur von 210 °C erhaltenen erfindungsgemäßen Folie sind in Zeile 2 festgehalten.  150 N / mm, a transport speed of 3 m / min, and a temperature of 210 ° C obtained film according to the invention are recorded in line 2.
Zeile 3 zeigt die Zugfestigkeiten der aus dem gleichen Gewebe erhaltenen Line 3 shows the tensile strengths of those obtained from the same fabric
erfindungsgemäßen Folie beim Liniendruck von 250 N/mm, einer Transportgeschwindigkeit von 3 m/min, und einer Temperatur von 210 °C. Diese Folie ist gezeigt in Abbildung 2. film according to the invention at a line pressure of 250 N / mm, a transport speed of 3 m / min, and a temperature of 210 ° C. This slide is shown in Figure 2.
Zeile 4 zeigt die Zugfestigkeiten der aus dem gleichen Gewebe erhaltenen Line 4 shows the tensile strengths of those obtained from the same fabric
erfindungsgemäßen Folie beim Liniendruck von 300 N/mm, einer Transportgeschwindigkeit von 3 m/min, und einer Temperatur von 210 °C. film according to the invention at a line pressure of 300 N / mm, a transport speed of 3 m / min, and a temperature of 210 ° C.
Vergleichsbeispiele 5 und 6. Comparative Examples 5 and 6.
Handelsübliche PET Folien mit Dicken von 18 μηι bzw. 1 1 μηι wurden mit einem Laser zweidimensional perforiert. Diese flächige Perforation kann mit C02 Lasern durchgeführt werden. Das Verfahren ist angelehnt an die eindimensionale Perforation wie sie bspw. bei den Firmen Maag oder Micro Laser Tech durchgeführt wird und u.a. in den Schriften JP63023936 oder JP1 1077872 offenbart ist.  Commercially available PET films with thicknesses of 18 μηι or 1 1 μηι were perforated two-dimensionally with a laser. This area perforation can be performed with C02 lasers. The method is based on the one-dimensional perforation as it is performed, for example, at the companies Maag or Micro Laser Tech and u.a. in JP63023936 or JP1 1077872.
Die resultierenden perforierten Folien wiesen eine Offene Fläche von 22 % bzw. 15 % auf, zusammengefasst in den Zeilen 5 bzw. 6 der Tabelle 1. The resulting perforated films had an open area of 22% and 15%, respectively, summarized in lines 5 and 6 of Table 1, respectively.
Die Messung der CD Zugfestigkeit der 1 1 μηι dicken perforierten Folie, Pos. 6, scheiterte, da die Messbereichsuntergrenze unterschritten wurde. Muster Dicke Offene Zugfestigkeit The measurement of CD tensile strength of 1 1 μηι thick perforated film, pos. 6, failed because the lower limit of the measurement range was exceeded. Pattern Thickness Open Tensile Strength
(Mm) Fläche Fmax  (Mm) Area Fmax
(%)  (%)
MD CD  MD CD
(N/cm) (N/cm) (N / cm) (N / cm)
Beispiel example
Erfindungsgemäße  invention
1. 14 34 14 14 poröse Folie  1. 14 34 14 14 porous film
Erfindungsgemäße  invention
2. 18 28 8 8 poröse Folie  2. 18 28 8 8 porous film
Erfindungsgemäße  invention
3. 12 21 5 5 poröse Folie  3. 12 21 5 5 porous film
Erfindungsgemäße  invention
4. 10 23 5 5 poröse Folie  4. 10 23 5 5 porous film
5. Perforierte PET-Folie 18 22 4 35. Perforated PET film 18 22 4 3
6. Perforierte PET-Folie 1 1 15 4 6. Perforated PET film 1 1 15 4
Tabelle 1. Table 1.

Claims

Patentansprüche: claims:
1. Poröse Folie, 1. porous film,
dadurch gekennzeichnet,  characterized,
dass die Folie Polymerfasern aufweist, die zumindest an den Überkreuzungspunkten zwischen den Poren miteinander verschweißt, insbesondere thermoverschweißt, quellverschweißt, kaltverschweißt, ultraschall-verschweißt und/oder zumindest teilweise miteinander verschmolzen oder kraft- oder formschlüssig miteinander verbunden sind.  the film comprises polymer fibers which are welded together, at least at the points of intersection between the pores, in particular thermally welded, swell-welded, cold-welded, ultrasonically welded and / or at least partially fused together or non-positively or positively connected with each other.
2. Folie gemäß Anspruch 1 , 2. A film according to claim 1,
die eine Dicke von kleiner oder gleich 100 μηι, bevorzugt 50 μηι, besonders bevorzugt kleiner gleich 20 μηι und/oder eine Offene Fläche von größer oder gleich 20 % aufweist.  having a thickness of less than or equal to 100 μηι, preferably 50 μηι, more preferably less than or equal to 20 μηι and / or has an open area of greater than or equal to 20%.
3. Folie nach Anspruch 1 oder 2, 3. A film according to claim 1 or 2,
dadurch gekennzeichnet,  characterized,
dass die Polymerfasern zumindest ein thermoplastisches Polymer aufweisen oder daraus bestehen.  the polymer fibers comprise or consist of at least one thermoplastic polymer.
4. Folie nach Anspruch 3, 4. A film according to claim 3,
dadurch gekennzeichnet,  characterized,
dass das Polymer der Fasern ausgewählt ist aus Polyacrylnitril, Polyester, Polyamid, Polyimid, Polyaramid, Polyolefin, PTFE, PVDF, PES, PUR, oder eine Kombination dieser Polymere.  the polymer of the fibers is selected from polyacrylonitrile, polyester, polyamide, polyimide, polyaramid, polyolefin, PTFE, PVDF, PES, PUR, or a combination of these polymers.
5. Folie nach zumindest einem der Ansprüche 1 bis 3, 5. A film according to at least one of claims 1 to 3,
dadurch gekennzeichnet,  characterized,
dass die Polymerfasern zumindest ein thermoplastisches und zumindest ein nichtthermoplastisches Polymer, Core-Shell Fasern, und/oder Coextrudate aufweisen oder daraus bestehen.  the polymer fibers comprise or consist of at least one thermoplastic and at least one non-thermoplastic polymer, core-shell fibers, and / or co-extrudates.
6. Verfahren zur Herstellung einer porösen Folie gemäß zumindest einem der 6. A process for producing a porous film according to at least one of
vorhergehenden Ansprüche, dadurch gekennzeichnet,  preceding claims, characterized
dass ein Gewebe oder Gewirke, das thermoplastische Polymerfasern aufweist oder aus diesen besteht, unter einem Flächen- oder Liniendruck kleiner gleich 500 N/mm, und einer Temperatur kleiner gleich 50% unterhalb der Schmelztemperatur des am niedrigsten schmelzenden Polymers that a woven or knitted fabric comprising or comprising thermoplastic polymer fibers this is, under a surface or line pressure less than or equal to 500 N / mm, and a temperature equal to or less than 50% below the melting temperature of the lowest-melting polymer
zumindest einmal verdichtet wird, wobei die Polymerfasern zumindest an den  is compressed at least once, wherein the polymer fibers at least to the
Überkreuzungspunkten miteinander verschweißt, insbesondere thermoverschweißt, quellverschweißt, kaltverschweißt, ultraschall-verschweißt, und/oder zumindest teilweise miteinander verschmolzen oder kraft- oder formschlüssig miteinander verbunden werden.  Crossover points welded together, in particular thermowelded, swell welded, cold-welded, ultrasonically welded, and / or at least partially fused together or non-positively or positively connected to each other.
7. Verfahren nach Anspruch 6, 7. The method according to claim 6,
dadurch gekennzeichnet,  characterized,
dass das Gewebe oder Gewirke zumindest zweimal verdichtet wird, wobei  that the woven or knitted fabric is compacted at least twice, wherein
sich jedes weitere Verdichten von dem vorhergehenden Verdichten  each further compacting from the previous compacting
in dem Liniendruck, der Spaltbreite, und/oder der Temperatur unterscheidet.  in the line pressure, the gap width, and / or the temperature is different.
8. Poröse Folie, erhalten nach zumindest einem der Ansprüche 6 oder 7. 8. Porous film obtained according to at least one of claims 6 or 7.
9. Verwendung der porösen Folie gemäß zumindest einem der Ansprüche 1 bis 8 als Separator in Batterien, Verpackungsmaterial, Membran, Trägermaterial für keramische Kompositmembranen, Filter. 9. Use of the porous film according to at least one of claims 1 to 8 as a separator in batteries, packaging material, membrane, carrier material for ceramic composite membranes, filters.
10. Lithiumionen-Batterie, einen Separator gemäß zumindest einem der Ansprüche 1 bis 8 aufweisend. 10. A lithium ion battery comprising a separator according to at least one of claims 1 to 8.
EP11805844.5A 2011-01-26 2011-12-22 Thin macroporous polymer films Withdrawn EP2668328A1 (en)

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JP2014505147A (en) 2014-02-27

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