JP5451652B2 - 微多孔膜を製造するための冷却ロールアセンブリおよび微多孔膜の製造方法 - Google Patents
微多孔膜を製造するための冷却ロールアセンブリおよび微多孔膜の製造方法 Download PDFInfo
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Description
微多孔膜の性質
A. 約25%〜約80%の空孔率
B. (20μmの厚さでの値に換算した)JIS P8117に従って測定される約20秒/100cm 3 〜約700秒/100cm 3 の透気度
C. 約3,000mN/20μm以上の突刺強度
D. (ASTM D882に従って測定される)少なくとも約60,000kPaの引張強度
E. 少なくとも約100%の引張伸び(ASTM D882)
F. 10%以下の熱収縮率
G. 0.5以下の厚変動
H. 少なくとも約145℃のメルトダウン温度
I. 140℃以下のシャットダウン温度
[実施例]
実施例1
測定装置:ウォーターズコーポレーションから市販されているGPC-150C、
カラム:昭和電工株式会社から市販されているShodex UT806M、
カラム温度:135℃、
溶媒(移動相):o−ジクロロベンゼン、
溶媒の流速:1.0ml/分、
試料濃度:0.1重量%(135℃で1時間溶解させたもの)、
注入量:500、
検出器:ウォーターズコーポレーションから市販されているDifferential Refractometer、および
検量線:所定の換算定数を用いて、単分散標準ポリスチレン試料の検量線から作成する。
比較実施例1
Claims (17)
- 押出物から熱を逃がすためのアセンブリであって、
a)前記押出物を受け取る位置に配置された少なくとも1つの上流ロールであって外表面粗さ≦1.0sを有する少なくとも1つの上流ロール;および、
b) 少なくとも1つの下流ロールであって外表面粗さ≧5.0sを有する少なくとも1つの下流ロール、を含み、前記下流ロールが前記上流ロールから前記押出物を受け取るよう、前記上流ロールおよび前記下流ロールが整列され、少なくとも1つの支持枠をさらに含み、前記上流ロールおよび前記下流ロールが、前記少なくとも1つの支持枠上に搭載され、前記支持枠により、前記押出物が前記上流ロールの一部および前記下流ロールの一部の周囲の円弧状経路、ならびに前記上流ロールと前記下流ロールとの間の直線状経路を移動するための、前記ロールの配置が提供されているアセンブリ。 - 前記ロールアセンブリの中を通して前記上流ロールおよび前記下流ロールと円弧状に接触して前記押出物を移動させるために、前記下流ロールを回転させるための前記支持枠上に搭載された駆動手段をさらに含む請求項1に記載のアセンブリ。
- 前記上流ロールまたは前記下流ロールのうちのなくとも1つが、前記押出物から熱を逃がすための冷却手段をさらに含む、請求項1又は2に記載のアセンブリ。
- 前記上流ロールが、前記駆動手段、または前記第一駆動手段と同期する第二駆動手段のいずれかによって回転する、請求項2又は3に記載のアセンブリ。
- 第三ロールをさらに含み、前記第三ロールが、前記上流ロールの下流かつ前記下流ロールの上流にあり、また、前記上流ロールから前記押出物を受け取って前記第三ロールの少なくとも一部の周囲の円弧状経路を移動させ、次いで前記下流ロールに向かう直線状経路を移動させるための位置に配置され、前記第三ロールが外表面粗さ≦1.0sを有する、請求項1〜4のいずれかに記載のアセンブリ。
- 第四ロールおよび第五ロールをさらに含み、前記第四ロールが、前記下流ロールから前記押出物を受け取る位置に配置され、かつ、前記第五ロールが、前記第四ロールから前記押出物を受け取る位置に配置され、前記第四ロールおよび第五ロールが、それぞれ、外表面粗さ≧5.0sを有する、請求項5に記載のアセンブリ。
- (a) 前記ロールアセンブリの中を通して前記上流ロール、前記第三ロール、前記下流ロール、前記第四ロール、および前記第五ロールと円弧状に接触して前記押出物を移動させるために、前記下流ロールおよび所望により前記第四ロールおよび/または前記第五ロールを回転させるための駆動手段、ならびに、所望により、
(b) 前記上流ロールおよび所望により前記第三ロールを回転させるための前記駆動手段と同期する第二駆動手段、をさらに含む、請求項6に記載のアセンブリ。 - 少なくとも前記上流および第三ロールが、前記押出物から熱を逃がすための冷却手段をさらに含む、請求項7に記載のアセンブリ。
- 微多孔膜を製造するための方法であって、
a) ポリオレフィンおよび少なくとも1種類の希釈剤を混合する工程;
b) 前記混合したポリオレフィンおよび希釈剤を、押出ダイを通して押し出して押出物を形成する工程;
c) 複数のロールに通して前記押出物から熱を逃がして冷却押出物を形成する工程であって、前記複数のロールが、i )前記押出物を受け取る位置に配置された上流ロールであって外表面粗さ≦1.0sを有する上流ロール;および、i i) 前記上流ロールから前記押出物を受け取る位置に配置された下流ロールであって外表面粗さ≧5.0sを有する下流ロール、を含む工程;
d) 前記冷却押出物を、少なくとも1方向に約1〜約10倍に延伸する工程;ならびに
e) 前記希釈剤の少なくとも一部を前記冷却押出物から除去して前記膜を形成する工程、
を含む方法。 - f) 前記膜を、少なくとも1方向に、約1.1〜約2.5倍の倍率に延伸する工程;および
g) 前記膜をヒートセットする工程、
をさらに含む、請求項9に記載の方法。 - 前記ポリオレフィンが、(i)ポリエチレン(PE))、(ii)超高分子量ポリエチレン(UHMWPE)、(iii)PEおよびPP、または(iv)PE、UHMWPE、およびPP、のうちのいずれか1つを含み、(ii)および(iv)を含む場合にUHMWPEは1×106〜15×106であり、PEとUHMWPEの総量を基準に約0重量%〜約40重量%を含み、(iii)および(iv)を含む場合にPPは約6×105〜約4×106の重量平均分子量、約3〜約30の分子量分布(Mw/Mn)、90J / g以上の融解熱を有するポリプロピレンであり、微多孔膜の総量を基準に約50%重量%以下を含む請求項9又は10に記載の方法。
- 前記方法を介して前記押出物を前進させるために、前記複数のロールが、前記下流ロール、または前記下流ロールおよび前記上流ロールと連動する1つ以上の駆動手段を含む、請求項9〜11のいずれか一項に記載の方法。
- 前記複数のロールが、前記上流ロール、前記下流ロール、または両方と連動する冷却手段を含む、請求項9〜12のいずれか一項に記載の方法。
- (a) 前記複数のロールが、(i)前記上流ロールの下流かつ前記下流ロールの上流に位置し、また、前記上流ロールから前記押出物を受け取るための位置に配置された第三ロールであって、外表面粗さ≦1.0sを有する第三ロール、(ii)第四ロール、および(iii)第五ロール、を含み、;前記第四ロールが、前記下流ロールから前記押出物を受け取る位置に配置され、前記第五ロールが、前記第四ロールから前記押出物を受け取る位置に配置され、前記第四ロールおよび前記第五ロールが、それぞれ、外表面粗さ≧5.0sを有し、;ならびに
(b) 前記押出物が、前記上流ロール、前記下流ロール、前記第三ロール、前記第四ロール、および前記第五ロールの少なくとも一部の周囲の円弧状経路、ならびにこれらのロールの間の直線状経路を移動する、請求項9〜13のいずれか一項に記載の方法。 - 前記方法を介して前記押出物を前進させるために、前記擾数のロールが、前記上流ロールまたは前記第三ロールのうちの少なくとも1つを回転させるための第一駆動手段、および前記下流ロール、前記第四ロール、または前記第五ロールのうちの少なくとも1つを回転させるための前記第一駆動手段と同期する第二駆動手段を含む、請求項14に記載の方法。
- 前記複数のロールが、前記押出物から熱を逃がすための、(i)前記上流ロール、(ii)前記第三ロール、または(iii)前記下流ロールのうちの少なくとも2つと連動する冷却手段を含む、請求項14又は15に記載の方法。
- 前記複数のロールが、前記第四ロールおよび/または前記第五ロールと連動する冷却手段を含む、請求項14〜16のいずれか一項に記載の方法。
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