JP5519642B2 - 微多孔性高分子膜、かかる膜の作製方法、およびそれを用いたバッテリーセパレータフィルム - Google Patents
微多孔性高分子膜、かかる膜の作製方法、およびそれを用いたバッテリーセパレータフィルム Download PDFInfo
- Publication number
- JP5519642B2 JP5519642B2 JP2011508758A JP2011508758A JP5519642B2 JP 5519642 B2 JP5519642 B2 JP 5519642B2 JP 2011508758 A JP2011508758 A JP 2011508758A JP 2011508758 A JP2011508758 A JP 2011508758A JP 5519642 B2 JP5519642 B2 JP 5519642B2
- Authority
- JP
- Japan
- Prior art keywords
- polyethylene
- diluent
- microporous membrane
- layer
- less
- 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.)
- Expired - Fee Related
Links
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- 239000004698 Polyethylene Substances 0.000 claims description 147
- 229920000573 polyethylene Polymers 0.000 claims description 147
- -1 polyethylene Polymers 0.000 claims description 94
- 239000003085 diluting agent Substances 0.000 claims description 76
- 239000012982 microporous membrane Substances 0.000 claims description 68
- 125000004432 carbon atom Chemical group C* 0.000 claims description 40
- 230000035699 permeability Effects 0.000 claims description 15
- 239000003792 electrolyte Substances 0.000 claims description 8
- HBBGRARXTFLTSG-UHFFFAOYSA-N Lithium ion Chemical compound [Li+] HBBGRARXTFLTSG-UHFFFAOYSA-N 0.000 claims description 4
- 229910001416 lithium ion Inorganic materials 0.000 claims description 4
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Classifications
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C48/18—Articles comprising two or more components, e.g. co-extruded layers the components being layers
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- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
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Landscapes
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Electrochemistry (AREA)
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Dispersion Chemistry (AREA)
- Power Engineering (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Cell Separators (AREA)
- Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
- Laminated Bodies (AREA)
Description
(1)(a)少なくとも、Mw1.0×106未満であり不飽和末端基量が炭素原子10,000個あたり0.20未満である第1のポリエチレンと第1の希釈剤とを合わせること、および(b)少なくとも、Mw1.0×106未満であり不飽和末端基量が炭素原子10,000個あたり0.20未満である第2のポリエチレンと第2の希釈剤とを合わせること;
(2)少なくとも、Mw1.0×106未満であり不飽和末端基量が炭素原子10,000個あたり0.20以上である第3のポリエチレンと第3の希釈剤とを合わせること;
(3)合わせたポリエチレンと希釈剤から、第1のポリエチレンを含む第1の層、第2のポリエチレンを含む第2の層、および第1および第2の層の間に位置し第3のポリエチレンを含む第3の層を有する多層押出物であって、不飽和末端基量が炭素原子10,000個あたり0.20以上であるポリエチレンを、押出物中のポリエチレンの総重量に対して4.0重量%〜35.0重量%の範囲の量で含む押出物、を形成して製造すること、および
(4)第1、第2、および第3の希釈剤の少なくとも一部を多層押出物から除去して膜を作製すること
を含む方法に関する。
Mw1.0×106未満であり不飽和末端基量が炭素原子10,000個あたり0.20未満である第1のポリエチレンを含む第1の層;
Mw1.0×106未満であり不飽和末端基量が炭素原子10,000個あたり0.20未満である第2のポリエチレンを含む第2の層;
第1および第2の層の間に位置し、Mwが1.0×106以下であり不飽和末端基量が炭素原子10,000個あたり0.20以上である第3のポリエチレンを含む第3の層;を含み、かつ
不飽和末端基量が炭素原子10,000個あたり0.20以上でありMw<1.0×106である多層微多孔性膜中のポリエチレンの総量が、多層微多孔性膜の総重量に対して4.0重量%〜35.0重量%の範囲である、多層微多孔性膜に関する。
[1]微多孔性膜の組成および構造
重量平均分子量(「Mw」)が1.0×106未満、例えば1.0×105〜0.95×106の範囲であり、かつ不飽和末端基量が炭素原子10,000個あたり0.20未満であるPE1を含む第1の層;Mwが1.0×106未満、例えば1.0×105〜0.95×106の範囲であり、かつ不飽和末端基量が炭素原子10,000個あたり0.20未満であるPE2を含む第2の層;およびMwが1.0×106未満、例えば1.0×105〜1.0×106の範囲であり、かつ不飽和末端基(例えば、末端炭素−炭素不飽和結合)の量が炭素原子10,000個あたり0.20以上であるPE3を含む第3の層、を含む。第3の層は、第1の層と第2の層の間に位置する。膜中のPE3の総量は、通常約4.0重量%〜35.0重量%、または約5.0重量%〜25.0重量%の範囲である(重量パーセントは、膜の重量、例えば、膜に含まれるのがポリマーと孔のみである場合の膜中のポリマーの総重量、が基準)。第3の層の厚さは、通常、第1、第2、および第3の層を合わせた厚さの約4.0%〜約21.0%、約10.0%〜約20.0%、または10.0%〜約15.0%の範囲である。ある実施形態においては、第1および第2の層は、5.0重量%未満または1.0重量%未満のPE3を含み、第3の層は、5.0重量%未満または1.0重量%未満のPE1、PE2、またはPE1とPE2の両方を含む。ある実施形態においては、第1、第2、および第3の層は、ポリマーから本質的になる。別の実施形態においては、第1、第2、および第3の層は、ポリエチレン、またはポリエチレンと酸化防止剤、不活性充填剤等の1つまたは複数から本質的になる。
[2]多層微多孔性膜の作製に用いる材料
多層微多孔性膜の作製に用いるポリマー
多層微多孔性膜の作製に用いる希釈剤
[3]多層微多孔性ポリオレフィン膜の作製方法
(1)および(2)ポリマーと希釈剤を合わせる
(3)押出し
随意の冷却
随意の延伸
(4)希釈剤除去
(5)随意の膜の延伸(乾燥延伸)
(6)膜の幅の縮小
(7)熱硬化
[4]膜特性
A.シャットダウン温度が133.0℃未満であること
B.自己放電容量が110.0mAh以下であること
C.透気度が15秒/100cm3(1.0μmの膜厚さに標準化)以下であること
D.突刺強度が235mN/μm以上であること
E.約25%〜約80%の範囲の空孔率
F.メルトダウン温度が145℃以上であること
G.105℃におけるMD熱収縮率≦5.5%;105℃におけるTD熱収縮率≦4.0%
[5]電池
[6]実施例
実施例1
(1)スキン層ポリエチレン溶液の調製
(2)コア層ポリエチレン溶液の調製
(3)膜の作製
実施例2〜6
比較例1〜3
Claims (15)
- Mw1.0×106未満であり不飽和末端基量が炭素原子10,000個あたり0.20未満である第1のポリエチレンを含む第1の層、
Mw1.0×106未満であり不飽和末端基量が炭素原子10,000個あたり0.20未満である第2のポリエチレンを含む第2の層、および
第1および第2の層の間に位置する、Mw1.0×106未満であり不飽和末端基量が炭素原子10,000個あたり0.20以上である第3のポリエチレンを含む第3の層を含む多層膜であり、不飽和末端基量が炭素原子10,000個あたり0.20以上でありMw1.0×106未満である多層微多孔性膜中のポリエチレンの総量が、多層微多孔性膜の総重量に対して4.0重量%〜35.0重量%の範囲であり、且つ、133.0℃以下のシャットダウン温度および110.0mAh以下の自己放電容量を有する微多孔性膜。 - 105℃における4.0%以下のTD熱収縮を有する、請求項1に記載の微多孔性膜。
- 18.0μm以上の厚さ、1ミクロンあたり235mN以上の標準化突刺強度、および15秒/100cm3/ミクロン以下の標準化透気度を有する、請求項1又は2に記載の微多孔性膜。
- 105℃における5.5%以下のMD熱収縮、40%〜50%の範囲の空孔率、1400Kg/cm3以上のMD引張り強さ、1350Kg/cm3以上のTD引張り強さ、および145℃以上のメルトダウン温度を有する、請求項1〜3のいずれかに記載の微多孔性膜。
- 多層微多孔性膜が三層膜であり、第1および第2のポリエチレンが同じ重量平均分子量および同じ不飽和末端基量を有し、かつ少なくとも1つの層が、Mw1.0×106以上である第4のポリエチレンをさらに含む、請求項1〜4のいずれかに記載の微多孔性膜。
- 第3の層が、多層微多孔性膜の全厚さの4.0%〜25.0%の範囲の厚さを有する、請求項1〜5のいずれかに記載の微多孔性膜。
- 第3のポリエチレンの総量が、多層微多孔性膜の総重量に対して5.0重量%〜25重量%の範囲である、請求項1〜6のいずれかに記載の微多孔性膜。
- 請求項1〜7のいずれかに記載の、微多孔性膜を含むバッテリーセパレータフィルム。
- 微多孔性膜の作製方法であって、
(1)(a)少なくとも、Mw1.0×106以下であり不飽和末端基量が炭素原子10,000個あたり0.20未満である第1のポリエチレンと第1の希釈剤とを合わせること、および(b)少なくとも、Mw1.0×106以下であり不飽和末端基量が炭素原子10,000個あたり0.20未満である第2のポリエチレンと第2の希釈剤とを合わせること;
(2)少なくとも、Mw1.0×106以下であり不飽和末端基量が炭素原子10,000個あたり0.20以上である第3のポリエチレンと第3の希釈剤とを合わせること;
(3)ポリエチレンと希釈剤を合わせたものから、第1のポリエチレンを含む第1の層、第2のポリエチレンを含む第2の層、および第1および第2の層の間に位置し第3のポリエチレンを含む第3の層を有する多層押出物であって、不飽和末端基量が炭素原子10,000個あたり0.20以上であるポリエチレンを、押出物中のポリエチレンの総重量に対して4.0重量%〜35.0重量%の範囲の量で含む押出物、を形成して製造すること;および
(4)第1、第2、および第3の希釈剤の少なくとも一部を多層押出物から除去して膜を作製することを含む微多孔膜の製造方法。 - (a)第1の希釈剤と合わせた第1のポリエチレンの量が25.0〜30.0重量%の範囲であり、第1の希釈剤の量が70.0〜75.0重量%の範囲であり(重量パーセントは両方とも、第1のポリエチレンと第1の希釈剤を合わせたものが基準);
かつ
(b)第3の希釈剤と合わせた第3のポリエチレンの量が20.0〜30.0重量%の範囲であり、第3の希釈剤の量が70.0〜80.0重量%の範囲である(重量パーセントは両方とも、第3のポリエチレンと第3の希釈剤を合わせたものが基準)、
請求項9に記載の微多孔膜の製造方法。 - 分子量が1.0×106以上である第4のポリエチレンを、第1、第2、または第3のポリエチレンの少なくとも1つと合わせることをさらに含む、請求項9又は10に記載の微多孔膜の製造方法。
- 第2のポリエチレンが第1のポリエチレンと同じポリエチレンであり、第1の希釈剤が第2の希釈剤と同じであり、
第1および第2の層が、17.25〜22.5重量%の第1のポリエチレン、70.0〜75.0重量%の第1の希釈剤、および6.25〜9.3重量%の第4のポリエチレンを含み;かつ
第3の層が、13.8〜24.9重量%の第3のポリエチレン、70〜80重量%の第3の希釈剤、および3.4〜9.3重量%の第4のポリエチレンを含み、第3の希釈剤が第1および第2の希釈剤と同じである、
請求項11に記載の微多孔膜の製造方法。 - 請求項8に記載のバッテリーセパレータフィルム、アノード、およびカソードを含む電池であって;バッテリーセパレータフィルムが、アノードとカソードの間に位置する電池。
- 請求項13に記載の電池が、電動工具、電気自動車またはハイブリッド電気自動車のための電力原である電池。
- 電解質がリチウムイオンを含む、請求項13又は14に記載の電池。
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PCT/JP2009/065551 WO2010027065A2 (en) | 2008-09-02 | 2009-09-01 | Microporous polymeric membranes, methods for making such membranes, and the use of such membranes as battery separator film |
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