JP6222296B2 - Porous membrane - Google Patents

Description

  The present invention relates to a porous membrane.

Nonaqueous electrolyte batteries such as lithium ion secondary batteries are widely used as batteries for personal computers, cellular phones, portable information terminals, and the like.
In a nonaqueous electrolyte battery, a separator is usually used as a member for separating a positive electrode and a negative electrode. Conventionally, a porous film made of polyolefin has been used as a separator, but it has a problem that heat resistance is not sufficient.
As a separator excellent in heat resistance, for example, Patent Document 1 proposes a separator in which a porous film made of polyolefin and a porous film made of polyvinyl alcohol are laminated.

JP 2008-186721 A

  However, a separator in which a porous film made of polyolefin and a porous film containing an inorganic powder are laminated is easy to curl, and there is a problem that workability at the time of battery assembly is lowered.

The present invention includes the following inventions.
[1] A porous membrane comprising a compound having a hydrophobic group and a nonionic hydrophilic group, an inorganic powder, and a binder resin.
[2] The porous membrane according to [1], wherein the compound having a hydrophobic group and a nonionic hydrophilic group is a nonionic surfactant.
[3] The porous membrane according to [1] or [2], wherein the inorganic powder is a metal oxide, a metal hydroxide, or a metal carbonate.
[4] The porous membrane according to any one of [1] to [3], wherein the nonionic hydrophilic group has a polyoxyethylene structure.
[5] The porous membrane according to any one of [1] to [4], wherein the binder resin is a water-soluble resin.
[6] The porous film according to any one of [1] to [5] and another porous film different from the porous film according to any one of [1] to [5] are laminated. Laminated porous film.
[7] A coating liquid comprising a compound having a hydrophobic group and a nonionic hydrophilic group, an inorganic powder, a binder resin, and a solvent.
[8] A separator for a non-aqueous electrolyte battery including the porous film according to any one of [1] to [5].
[9] A nonaqueous electrolyte battery using the nonaqueous electrolyte battery separator according to [8].

  ADVANTAGE OF THE INVENTION According to this invention, the lamination | stacking porous film which is hard to curl which laminated | stacked the porous film which consists of polyolefin, and the porous film containing inorganic powder can be obtained.

<Porous membrane of the present invention>
The porous membrane of the present invention (hereinafter sometimes referred to as the present porous membrane) has a structure having pores connected to the inside thereof, and is porous, so that a gas or liquid is transferred from one surface to the other. In addition, since it contains inorganic powder, it has high heat resistance, and shape stability at high temperatures can be imparted to the laminated porous film including this porous membrane. Therefore, this porous membrane is suitably included in the separator for nonaqueous electrolyte batteries.

Furthermore, the present porous membrane can suppress curling by including a compound having a hydrophobic group and a nonionic hydrophilic group (hereinafter sometimes referred to as the present compound).
A porous membrane made of polyolefin and a porous membrane containing an inorganic powder have different polarities, and therefore have a different affinity for water and may have different water absorption when placed in the same environment. Therefore, a difference occurs in the dimensional change amount of each film when water is absorbed, and curling occurs in the laminated porous film.
Inorganic powders generally have a high polarity and thus have a strong interaction with water. Such an inorganic powder interacts with the nonionic hydrophilic group of the present compound, whereby the present compound adheres to the surface of the inorganic powder, and the hydrophobic group of the present compound causes the inorganic powder to It is considered that the interaction between the inorganic powder and water can be reduced by covering the surface. Therefore, the moisture content of the present porous membrane can be lowered, and curling is suppressed because it becomes close to the moisture content of the porous membrane made of polyolefin.

  The water content of the present porous membrane is preferably less than 0.15%. When the water content of the porous membrane is less than 0.15%, the amount of curling is reduced, and the charge / discharge cycle characteristics of the nonaqueous electrolyte battery using the porous membrane tend to be high.

<Compound having hydrophobic group and nonionic hydrophilic group>
Examples of the nonionic hydrophilic group include a group having a polyoxyethylene structure and a hydroxy group. Moreover, this compound preferably does not have an ionic group such as an anionic group and a cationic group. An anionic group in this specification is an acid group having a pKa of less than 10 such as a salt such as a sulfonate and a carboxylate, and a sulfonic acid and a carboxylic acid.
That is, a general hydroxy group having a pKa of 10 or more corresponds to a nonionic group, not an anionic group.

  Examples of the hydrophobic group include a hydrocarbon group, a group containing a fluorocarbon group, and a group containing silicon, and a hydrocarbon group is preferable.

  The hydrocarbon group is preferably a hydrocarbon group having 3 to 30 carbon atoms. The hydrocarbon group having 3 to 30 carbon atoms is propyl group, isopropyl group, butyl group, isobutyl group, sec-butyl group, t-butyl group, pentyl group, isopentyl group, hexyl group, isohexyl group, heptyl group, isoheptyl group. , Octyl group, isooctyl group, nonyl group, isononyl group, decyl group, undecyl group, dodecyl group, tridecyl group, tetradecyl group, pentadecyl group, hexadecyl group, heptadecyl group, octadecyl group, nonadecyl group, icosyl group (= eicosyl group) , Heicosyl group (= heneicosyl group), docosyl group, tricosyl group, tetracosyl group, pentacosyl group, hexacosyl group, heptacosyl group, octacosyl group, nonacosyl group, triacontyl group, propenyl group, allyl group, isopropenyl group, butenyl group, isobute Group, pentenyl group, hexenyl group, heptenyl group, octenyl group, nonenyl group, decenyl group, undecenyl group, dodecenyl group, tridecenyl group, tetradecenyl group, pentadecenyl group, hexadecenyl group, heptadecenyl group, octadecenyl group, nonacenyl group, icocenyl group (= Eicosenyl group), heicosenyl group (= heneicosenyl group), dococenyl group, tricocenyl group, tetracocenyl group, pentacocenyl group, hexacocenyl group, heptacocenyl group, octacocenyl group, nonacosenyl group, triaconenyl group, propynyl group, 2-propynyl group , Isopropynyl, butynyl, isobutynyl, pentynyl, hexynyl, heptynyl, octynyl, nonynyl, decynyl, undecynyl, dodecynyl, tridecyl Nyl group, tetradecynyl group, pentadecynyl group, hexadecynyl group, heptadecinyl group, octadecynyl group, nonadecynyl group, icosinyl group (= eicosinyl group), heicosinyl group (= heneicosinyl group), docosinyl group, tricosinyl group, tetracosinyl group, hexacosinyl group Group, heptacosinyl group, octacosinyl group, nonacosynyl group, triacontinyl group and the like.

The group containing a fluorocarbon group is preferably a fluorocarbon group having 3 to 30 carbon atoms. Examples of the group containing a fluorocarbon group having 3 to 30 carbon atoms include groups in which some or all of the hydrogen atoms of the hydrocarbon group have been replaced with fluorine atoms. For example, perfluoropropyl, isoperfluoropropyl, perfluorobutyl, isoperfluorobutyl, sec-perfluorobutyl, t-perfluorobutyl, perfluoropentyl, isoperfluoropentyl, Fluorohexyl group, isoperfluorohexyl group, perfluoroheptyl group, isoperfluoroheptyl group, perfluorooctyl group, isoperfluorooctyl group, perfluorononyl group, isoperfluorononyl group, perfluorodecyl group, perfluoro Undecyl group, perfluorododecyl group, perfluorotridecyl group, perfluorotetradecyl group, perfluoropentadecyl group, perfluorohexadecyl group, perfluoroheptadecyl group, perfluorooctadecyl group, perful Rononadecyl group, perfluoroicosyl group (= perfluoroeicosyl group), perfluorohenecosyl group (= perfluoroheneicosyl group), perfluorodocosyl group, perfluorotricosyl group, perfluorotetracosyl group Group, perfluoropentacosyl group, perfluorohexacosyl group, perfluoroheptacosyl group, perfluorooctacosyl group, perfluorononacosyl group, perfluorotriacontyl group, perfluoropropenyl group, perfluoro Allyl group, isoperfluoropropenyl group, perfluorobutenyl group, isoperfluorobutenyl group, perfluoropentenyl group, perfluorohexenyl group, perfluoroheptenyl group, perfluorooctenyl group, perfluorononenyl group, Perfluorodecenyl group, per Fluorodecenyl, perfluorododecenyl, perfluorotridecenyl, perfluorotetradecenyl, perfluoropentadecenyl, perfluorohexadecenyl, perfluoroheptade Senyl group, perfluorooctadecenyl group, perfluorononadecenyl group, perfluoroicosenyl group (= perfluoroeicosenyl group), perfluoroheneicosenyl group (= perfluoroheneicosyl group) Nyl group), perfluorodocosenyl group, perfluorotricocenyl group, perfluorotetracocenyl group, perfluoropentacocenyl group, perfluorohexacocenyl group, perfluoroheptacosenyl group, perfluorooctacose. Nyl group, perfluorononacosenyl group, perfluorotriacontenyl group, perfluoropropynyl group 2-perfluoropropynyl group, isoperfluoropropynyl group, perfluorobutynyl group, isoperfluorobutynyl group, perfluoropentynyl group, perfluorohexynyl group, perfluoroheptynyl group, perfluorooctynyl Group, perfluorononynyl group, perfluorodecynyl group, perfluoroundecynyl group, perfluorododecynyl group, tridecynyl group, tetradecynyl group, pentadecynyl group, hexadecynyl group, heptadecynyl group, perfluorooctadecynyl group, perfluoro Fluorononadecynyl group, perfluoroicosinyl group (= perfluoroeicosinyl group), perfluorohenicosinyl group (= perfluoroheneicosinyl group), perfluorodocosinyl group, perfluorotricosinyl group, perfluoro Tetrakoshi Group, perfluorohexyl stiffness group, perfluoro hexa stiffness group, perfluoro hepta stiffness group, perfluorooctanoate stiffness group, perfluoro nona stiffness group, and perfluoro thoria Continentale sulfonyl group.
The hydrocarbon group and the fluorocarbon group may be linked by an ether bond, a thioether bond, an ester bond, an amide bond, or the like.

  Examples of the group containing silicon include an alkylsilyl group, a dialkylsilyl group, a trialkylsilyl group, an alkylsiloxane, a dialkylsiloxane, and a trialkylsiloxane.

  This compound is preferably a nonionic surfactant.

  As this compound, polyethylene glycol-polypropylene glycol diblock copolymer, polyethylene glycol-polypropylene glycol block copolymer such as polypropylene glycol-polyethylene glycol-polypropylene glycol triblock copolymer; polyoxyethylene alkyl ether, polyoxyethylene Compounds having a polyoxyethylene structure such as alkyl phenyl ether, polyethylene glycol fatty acid ester, polyethylene oxide polypropylene oxide block copolymer, polyoxyethylene fatty acid amide, ethylene oxide-propylene oxide copolymer; and polyoxyethylene sorbitan fatty acid ester, etc. Sorbitan derivatives of Polyoxyethylene alkyl ether is preferred.

  As polyoxyethylene alkyl ether, polyoxyethylene methyl ether, polyoxyethylene ethyl ether, polyoxyethylene propyl ether, polyoxyethylene isopropyl ether, polyoxyethylene butyl ether, polyoxyethylene isobutyl ether, polyoxyethylene sec-butyl ether, Polyoxyethylene-t-butyl ether, polyoxyethylene pentyl ether, polyoxyethylene isopentyl ether, polyoxyethylene hexyl ether, polyoxyethylene isohexyl ether, polyoxyethylene heptyl ether, polyoxyethylene isoheptyl ether, polyoxyethylene Octyl ether, polyoxyethylene isooctyl ether, polyoxyethylene Ether, polyoxyethylene isononyl ether, polyoxyethylene decyl ether, polyoxyethylene undecyl ether, polyoxyethylene dodecyl ether, polyoxyethylene tridecyl ether, polyoxyethylene tetradecyl ether, polyoxyethylene pentadecyl ether, poly Oxyethylene hexadecyl ether, polyoxyethylene heptadecyl ether, polyoxyethylene octadecyl ether, polyoxyethylene nonadecyl ether, polyoxyethylene icosyl ether (= polyoxyethylene eicosyl ether), polyoxyethylene heicosyl ether ( = Polyoxyethylene henecosyl ether), polyoxyethylene docosyl ether, polyoxyethylene tricosyl ether Tellurium, polyoxyethylene tetracosyl ether, polyoxyethylene pentacosyl ether, polyoxyethylene hexacosyl ether, polyoxyethylene heptacosyl ether, polyoxyethylene octacosyl ether, polyoxyethylene nonacosyl ether, and polyoxyethylene triacon And ruether.

  This compound can be easily obtained from the market. Commercially available products include “Emulgen (registered trademark, manufactured by Kao Corporation)”, “New Coal (manufactured by Nippon Emulsifier Co., Ltd.)”, “Leox (registered trademark, manufactured by Lion Corporation)”, “Leocor (registered trademark, Lion Corporation) "Lionol (registered trademark, manufactured by Lion Corporation)", "Reosolve (registered trademark, manufactured by Lion Corporation)", "Raol (registered trademark, manufactured by Lion Corporation)", "Emalmin (registered trademark)" Sanyo Chemical Co., Ltd.), Sannonic (registered trademark, Sanyo Chemical Industry Co., Ltd.), New Pole (registered trademark, Sanyo Chemical Industry Co., Ltd.), and Sanmorin (registered trademark, Sanyo Chemical Industries, Ltd.) Kogyo Co., Ltd.).

The content of the present compound with respect to 100 parts by mass of the inorganic powder is preferably 0.05 to 10 parts by mass. Preferably it is 0.1 mass part or more, More preferably, it is 0.2 mass part or more, More preferably, it is 0.3 mass part or more. Moreover, it is preferably 5 parts by mass or less, more preferably 3 parts by mass or less, and further preferably 1.5 parts by mass or less.
If the content of the present compound exceeds 10 parts by mass with respect to 100 parts by mass of the inorganic powder, the heat resistance of the porous membrane tends to be impaired.

<Inorganic powder>
Examples of the inorganic powder include metal oxides, metal hydroxides, metal carbonates, metal nitrides, metal carbides, metal hydroxides, and metal sulfates, preferably metal oxides, metal hydroxides. And metal carbonates, more preferably metal oxides.

  The metal oxide may contain other metal components such as metal hydroxide and metal carbonate. The ratio of the other metal components contained in the metal oxide is usually 30% or less, preferably 20% or less, more preferably 10% or less, further preferably 5%, based on the total amount of the metal oxide. % Or less, particularly preferably 1% or less. Among metal oxides, alumina is preferable in terms of further improving chemical stability and shape stability at high temperature, and α-alumina is more preferable.

  Specific inorganic powders include calcium oxide, magnesium oxide, titanium oxide, alumina, aluminum hydroxide, magnesium hydroxide, calcium carbonate, magnesium carbonate, barium carbonate, calcium sulfate, magnesium sulfate, barium sulfate, talc, clay, kaolin. , Silica, hydrotalcite, diatomaceous earth, mica, zeolite, glass and the like. These can be used alone or in combination of two or more.

  The proportion of the inorganic powder in the present porous membrane usually exceeds 50% by mass of the present porous membrane, preferably 70% by mass or more, more preferably 90% by mass or more, and further preferably 95% by mass or more. is there. Further, it is preferably 99.5% or less, more preferably 99%, and even more preferably 98% or less.

<Binder resin>
The binder resin binds inorganic powders, and binds the present porous membrane to another porous membrane different from the present porous membrane (hereinafter also referred to as other porous membrane). It also has a function to wear. The binder resin is preferably a resin that is insoluble in the electrolyte solution of the non-aqueous electrolyte battery and is electrochemically stable within the use range of the non-aqueous electrolyte battery. Examples of the binder resin include polyolefins such as polyethylene and polypropylene; fluorine-containing resins such as polyvinylidene fluoride and polytetrafluoroethylene; vinylidene fluoride-hexafluoropropylene-tetrafluoroethylene copolymer, and ethylene-tetrafluoro. Fluorine-containing rubbers such as ethylene copolymers; styrene-butadiene copolymers and their hydrides; methacrylates, acrylonitrile-acrylate copolymers, and styrene-acrylate copolymers (meta ) Acrylate ester copolymer; Rubber such as ethylene propylene rubber; Polyvinyl acetate; Polyphenylene ether, Polysulfone, Polyethersulfone, Polyphenylene sulfide, Polyetherimide, Polyamide, Polyethylene Resins having a melting point or glass transition temperature of 180 ° C. or higher, such as imide, polyamideimide, polyetheramide, polyester, aromatic polyester, and polyetheretherketone; polycarbonate; polyacetal; and carboxyalkyl cellulose, alkyl cellulose, hydroxyalkyl cellulose And polymers such as water-soluble resins such as starch, polyvinyl alcohol, sodium alginate, polyethylene glycol, cellulose ether, polyacrylic acid, polyacrylamide, and polymethacrylic acid.
Among these, a fluorine-containing resin, a fluorine-containing rubber, a resin having a melting point or glass transition temperature of 180 ° C. or higher, and a water-soluble resin are preferable. A fluorine-containing resin, a fluorine-containing rubber, and a resin having a melting point and a glass transition temperature of 180 ° C. or higher are preferable because of higher stability in the use range of the nonaqueous electrolyte battery.
A water-soluble resin is preferable in terms of process and environmental load. Among water-soluble resins, carboxyalkyl cellulose, alkyl cellulose, hydroxyalkyl cellulose, starch, polyvinyl alcohol, and sodium alginate are preferable, and cellulose ether is more preferable. These binder resins may be used alone or in combination of two or more.

  Examples of the cellulose ether include carboxymethyl cellulose (CMC), hydroxyethyl cellulose (HEC), carboxyethyl cellulose, methyl cellulose, ethyl cellulose, cyanethyl cellulose, and oxyethyl cellulose. Among them, CMC and HEC excellent in chemical and thermal stability are preferable, and CMC is more preferable.

  The polyamide is preferably an aromatic polyamide, and particularly preferably a para-oriented aromatic polyamide (hereinafter sometimes referred to as “para-aramid”).

  Para-aramid is usually obtained by condensation polymerization of a para-oriented aromatic diamine and a para-oriented aromatic dicarboxylic acid halide, and the amide bond is in the para position of the aromatic ring or an oriented position equivalent thereto (for example, 4,4′-biphenylene, It consists essentially of repeating units that are bound together in an opposite orientation, such as 1,5-naphthalene, 2,6-naphthalene, etc. Examples of para-aramid include poly (paraphenylene terephthalamide), poly (parabenzamide), poly (4,4′-benzanilide terephthalamide), poly (paraphenylene-4,4′-biphenylenedicarboxylic amide), poly (Paraphenylene-2,6-naphthalenedicarboxylic acid amide), poly (2-chloro-paraphenylene terephthalamide), para-phenylene type such as paraphenylene terephthalamide / 2,6-dichloroparaphenylene terephthalamide copolymer or para Para-aramid having a structure conforming to the orientation type may be mentioned.

  The polyimide is preferably an aromatic polyimide, more preferably a wholly aromatic polyimide. The aromatic polyimide is usually produced by condensation polymerization of an aromatic dianhydride and a diamine. Examples of the dianhydride include pyromellitic dianhydride, 3,3 ′, 4,4′-diphenylsulfonetetracarboxylic dianhydride, 3,3 ′, 4,4′-benzophenonetetracarboxylic dianhydride. Examples include anhydrides, 2,2′-bis (3,4-dicarboxyphenyl) hexafluoropropane, and 3,3 ′, 4,4′-biphenyltetracarboxylic dianhydride. Examples of the diamine include oxydianiline, paraphenylenediamine, benzophenonediamine, 3,3′-methylenedianiline, 3,3′-diaminobenzophenone, 3,3′-diaminodiphenylsulfone, and 1,5 ′. -Naphthalenediamine.

  The polyamideimide is preferably an aromatic polyamideimide. Aromatic polyamideimides are usually obtained from these condensation polymerizations using aromatic dicarboxylic acids and aromatic diisocyanates, and can also be obtained from these condensation polymerizations using aromatic dianhydrides and aromatic diisocyanates. Can do. Examples of the aromatic dicarboxylic acid include isophthalic acid and terephthalic acid. Examples of the aromatic dianhydride include trimellitic anhydride. Examples of the aromatic diisocyanate include 4,4'-diphenylmethane diisocyanate, 2,4-tolylene diisocyanate, 2,6-tolylene diisocyanate, orthotolylane diisocyanate, and m-xylene diisocyanate.

  The ratio of the inorganic powder to the total amount of the binder resin and the inorganic powder in the present porous membrane is usually more than 50% by mass, preferably 70% by mass or more, more preferably 90% by mass or more, and further preferably. Is 95% by mass or more. Further, it is preferably 99.5% or less, more preferably 99%, and even more preferably 98% or less. When the proportion of the inorganic powder is within the specific range, the present porous membrane having an excellent balance between ion permeability and difficulty in powder removal can be obtained. Powder falling is a phenomenon in which inorganic powder is peeled off from the porous membrane.

The present porous may contain other components as long as the function of the present porous is not impaired.
Examples of other components include a dispersant, a plasticizer, and a pH adjuster.

The thickness of the present porous membrane is usually 0.1 to 20 μm, preferably 1 to 10 μm.
When the thickness is less than 0.1 μm, the heat resistance of the separator for a nonaqueous electrolyte battery including the porous membrane tends to be insufficient. For example, when a laminated porous film obtained by laminating the present porous film and a porous film made of polyolefin is used for a separator for a non-aqueous electrolyte battery, the thickness of the present porous film is 0.1 μm. If the temperature is less than 20 μm, the separator may shrink without being able to resist the heat shrinkage of the porous membrane made of polyolefin when heat is generated due to an accident or the like in the nonaqueous electrolyte battery. The thickness may increase and the battery capacity may decrease.

The porosity of the present porous membrane is usually 20 to 80% by volume, preferably 30 to 70% by volume.
If the porosity is less than 20% by volume, the amount of electrolyte retained may be reduced, and if it exceeds 80% by volume, the heat resistance of the porous membrane may be impaired. There is a risk that it will not be possible.

  The pore diameter of the porous membrane of the present porous membrane is preferably 3 μm or less, more preferably 1 μm or less from the viewpoint of having excellent ion permeability and preventing particles from entering the positive electrode and the negative electrode.

  The permeability of the present porous membrane is usually expressed by air permeability. The air permeability of the present porous membrane is usually 30 to 1000 sec / 100 cc, preferably 50 to 800 sec / 100 cc.

The basis weight of the present porous membrane is usually 4 to 20 g / m ² , preferably 5 to 12 g / m ² . If the basis weight is less than 4 g / m ² , the strength may be insufficient, and if it exceeds 20 g / m ² , the thickness of the porous membrane may increase and the battery capacity may decrease.

<Laminated porous film>
This porous membrane is used for a separator for a non-aqueous electrolyte battery as a laminated porous film laminated with other porous membranes (hereinafter sometimes referred to as this laminated porous film). Examples of the other porous membrane include papermaking of viscose rayon and natural cellulose; mixed paper obtained by making fibers of cellulose and polyester; electrolytic paper; kraft paper; manila paper; polyethylene nonwoven fabric and polypropylene nonwoven fabric Polyester nonwoven fabric, glass fiber, porous polyolefin (for example, porous polyethylene, porous polypropylene), porous polyester, aramid fiber, polybutylene terephthalate nonwoven fabric, para-type wholly aromatic polyamide, polyvinylidene fluoride, tetrafluoroethylene, fluorine Non-woven fabrics or porous membranes such as copolymers of vinylidene fluoride and propylene hexafluoride, fluorine-containing resins such as fluororubber; membranes such as proton conducting polymers; A porous film made of polyolefin (hereinafter sometimes referred to as a polyolefin film) is preferred.

  The present laminated porous film may have a plurality of other porous films and a plurality of the present porous films. For example, the present porous film may be laminated on both surfaces of the other porous film. Moreover, when this porous film is laminated | stacked on both surfaces of another porous film, this porous film may contain the different this compound, inorganic powder, and binder resin, respectively.

  The polyolefin membrane melts and becomes non-porous when the battery generates heat violently, thereby giving a shutdown function to the laminated porous film. In addition, since the present porous membrane has heat resistance at a high temperature at which shutdown occurs, the present laminated porous film has shape stability even at a high temperature.

The moisture content of the present laminated porous membrane is preferably less than 0.15%.
If the water content of the porous membrane is 0.15% or more, the charge / discharge cycle characteristics of the battery may be impaired.

  The 50% breakdown voltage of a non-aqueous electrolyte battery including the laminated porous film as a separator for a non-aqueous electrolyte battery is preferably 4.40 V or more. The non-aqueous electrolyte secondary battery has a large battery voltage of 4.40 V or more, and even when the battery capacity is large, abnormal heat generation when an internal short circuit occurs is suppressed, that is, excellent safety against an internal short circuit. It will be a thing.

The membrane resistance of the present laminated porous film is preferably 0.25 to 5.00 Ω · cm ² from the viewpoint of battery characteristics (ion permeability, load characteristics). If the membrane resistance is less than 0.25 Ω · cm ² , the ion permeability is excellent, but the risk of occurrence of a short-circuit may increase, and if it exceeds 5.00 Ω · cm ² , good ion permeability May not be obtained, and battery characteristics may be deteriorated. In order to increase the membrane resistance, for example, the thickness of the other porous membrane and / or the present porous membrane may be increased or the porosity may be decreased. The thickness of the porous membrane and / or the porous membrane may be reduced or the porosity may be increased.

  The thickness of the laminated porous film is usually 5 to 75 μm, preferably 10 to 50 μm. If the thickness of the laminated porous film is less than 5 μm, the laminated porous film may be easily broken, and if it exceeds 75 μm, the thickness of the laminated porous film is increased and the battery capacity is increased. There is a risk of becoming smaller.

The volume basis weight of the porous membrane contained in the laminated porous film is usually 0.5 to 20 cc / m ² , preferably 1 to 10 cc / m ² from the viewpoint of stability during heating and battery characteristics. is there. If the volume basis weight is less than 0.5 cc / m ² , the laminated porous film may be easily broken when heated. If it exceeds 20 cc / m ² , the thickness of the laminated porous film May become thicker and the battery capacity may be reduced. However, when this porous membrane is laminated on both surfaces of other porous membranes, the volume per unit area is the total value of both surfaces.

  The air permeability of the laminated porous film is usually 50 to 2000 sec / 100 cc, preferably 70 to 1000 sec / 100 cc. If the air permeability exceeds 2000 sec / 100 cc, battery characteristics (ion permeability, load characteristics) may be impaired.

  The present laminated porous film may contain other porous films and porous layers such as an adhesive layer and a protective layer other than the porous film and the present porous film as long as the object of the present invention is not impaired.

<Polyolefin film>
Examples of the polyolefin contained in the polyolefin film include a high molecular weight homopolymer or copolymer obtained by polymerizing ethylene, propylene, 1-butene, 4-methyl-1-pentene, 1-hexene, or the like. Can be mentioned. High molecular weight polyethylene is preferable. These polyolefins may be used alone or in combination of two or more.

The molecular weight of the polyolefin is such that when this laminated porous film is used as a separator for a non-aqueous electrolyte battery in a non-aqueous electrolyte battery, the weight average molecular weight is 1 from the viewpoint of preventing dissolution of the polyolefin membrane in the electrolyte. It is preferable in it being * 10 < ⁵ > -15 * 10 < ⁶ >.

  The proportion of the polyolefin contained in the polyolefin film is usually more than 50% by volume of the total solid content contained in the polyolefin film, preferably 70% by volume or more, more preferably 90% by volume or more, and still more preferably 95%. Volume% or more.

  The polyolefin film may contain components other than polyolefin as long as the function of the polyolefin film is not impaired.

  The thickness of the polyolefin film is usually 4 to 50 μm, preferably 5 to 30 μm. If the thickness is less than 4 μm, the strength of the laminated porous film may be insufficient. If the thickness exceeds 50 μm, the thickness of the laminated porous film may be increased, and the battery capacity may be reduced. is there.

The porosity of the polyolefin film is usually 20 to 80% by volume, preferably 30 to 70% by volume.
If the porosity is less than 20% by volume, the amount of electrolyte retained may be reduced, and if it exceeds 80% by volume, there may be insufficient pore formation at a high temperature at which shutdown occurs. There is a risk that the current cannot be interrupted.

  The pore diameter of the polyolefin membrane has excellent ion permeability when the laminated porous film is used as a separator for a non-aqueous electrolyte battery, and prevents particles from entering the positive electrode and the negative electrode. Therefore, it is preferably 3 μm or less, more preferably 1 μm or less.

  The polyolefin film has a structure having pores connected to the inside thereof, and gas, liquid, ions, and the like can be transmitted from one surface to the other surface. The transmittance is usually expressed by air permeability. The air permeability of the polyolefin membrane is usually 30 to 1000 sec / 100 cc, preferably 50 to 800 sec / 100 cc.

The basis weight of the polyolefin film is usually 4 to 15 g / m ² , preferably 5 to 12 g / m ² . If the basis weight is less than 4 g / m ² , the strength of the laminated porous film may be insufficient, and if it exceeds 15 g / m ² , the thickness of the laminated porous film increases, resulting in a battery capacity. May become smaller.

<Manufacturing method of the present porous membrane>
As a method for producing the present porous membrane, a coating liquid containing the present compound, an inorganic powder, and a binder resin (hereinafter sometimes referred to as the present coating liquid) is applied to a substrate, and then the porous film is prepared. After forming the film and then removing the base material, and after applying the coating liquid to the base material, it is immersed in a solvent that can be mixed with the coating liquid and does not dissolve the binder resin. And a method of forming a porous film by drying and then removing the substrate.

  The coating liquid usually contains a solvent that dissolves the binder resin. In addition, the coating liquid may contain a pH adjuster, a dispersant, a plasticizer, alcohol, and the like as long as the object of the present invention is not impaired, and preferably contains alcohol.

  Examples of the alcohol include methanol, ethanol, 1-propanol, isopropyl alcohol, 2-butanol, tert-butyl alcohol, 1-butanol, isobutyl alcohol, sec-butyl alcohol, t-butyl alcohol, pentyl alcohol, isopentyl alcohol, hexyl. Examples include alcohol, isohexyl alcohol, heptyl alcohol, isoheptyl alcohol, octyl alcohol, isooctyl alcohol, octyl alcohol, isooctyl alcohol, nonyl alcohol, isononyl alcohol, decyl alcohol, ethylene glycol, propylene glycol, and butanediol. .

  The content of alcohol in the present coating solution is not particularly limited, and may be an amount that can provide a property that allows easy application to other porous membranes. The content of alcohol in the present coating liquid is preferably 1 to 1000 parts by mass, more preferably 2 to 500 parts by mass, and further preferably 3 to 300 parts by mass with respect to 1 part by mass of the binder resin. Yes, even more preferably 5 to 200 parts by mass.

<Other porous membrane production methods>
Other porous membranes may be produced by known methods, or commercially available products may be used.

<Method for producing polyolefin film>
As the polyolefin film, there can be used a film or sheet formed using polyolefin, which is uniaxially or biaxially stretched to form fine pores. As a method for producing a polyolefin film, for example, as described in JP-A-7-29563, there is a method in which a plasticizer is added to a thermoplastic resin to form a film, and then the plasticizer is removed with an appropriate solvent. Can be mentioned. For example, when the polyolefin film is formed from a polyolefin resin containing a high molecular weight polyethylene having a weight average molecular weight exceeding 1,000,000 and a low molecular weight polyolefin having a weight average molecular weight of 10,000 or less, from the viewpoint of production cost, It is preferable to manufacture by the method including each process.
(A) 100 parts by mass of high molecular weight polyethylene, 5 to 200 parts by mass of a low molecular weight polyolefin, and 100 to 400 parts by mass of an inorganic filler such as calcium carbonate are kneaded to obtain a polyolefin resin composition.
(B) A sheet is formed using the polyolefin resin composition.
(C) The inorganic filler is removed from the sheet obtained in the step (b).
(D) The sheet obtained in step (c) is stretched to obtain a polyolefin film.
It is a method including.

<Method for producing the present laminated porous film>
As a method of laminating the present porous membrane and other porous membranes, the method of separately producing the other porous membrane and the present porous membrane and laminating each, and the other porous membrane, Examples of the method include forming the porous film by applying the coating solution, and the latter method is preferable because it is simpler.

Examples of a method for forming the porous film by applying the coating liquid to another porous film include a method including the following steps.
(A) A coating liquid in which an inorganic powder is dispersed in a solution in which the present compound and binder resin are dissolved in a solvent is prepared.
(B) The coating liquid is applied to another porous film to form a coating film.
(C) The binder resin is precipitated from the coating film by means such as solvent removal or immersion in a solvent that does not dissolve the binder resin, and dried as necessary.

  When the binder resin is an aromatic polyamide, examples of the solvent that dissolves the binder resin include polar amide solvents and polar urea solvents. Specific examples include N, N-dimethylformamide, N, N-dimethylacetamide, N-methyl-2-pyrrolidone (NMP), and tetramethylurea.

  When the binder resin is para-aramid, it is preferable to add an alkali metal or alkaline earth metal chloride for the purpose of improving the solubility of para-aramid in a solvent. Specific examples include lithium chloride and calcium chloride. The amount of the chloride added is preferably in the range of 0.5 to 6.0 mol, more preferably in the range of 1.0 to 4.0 mol, per 1.0 mol of the amide group of the paraamide. If the chloride is less than 0.5 mol, the solubility of para-aramid may be insufficient, and if it exceeds 6.0 mol, the solubility of the chloride in the solvent may be substantially exceeded, which may be undesirable. Generally, when the alkali metal or alkaline earth metal chloride is less than 2% by mass, the solubility of para-aramid may be insufficient, and when it exceeds 10% by mass, the solubility of the chloride will be insufficient. There is.

  In the case where the binder resin is an aromatic polyimide, as the solvent for dissolving the binder resin, dimethyl sulfoxide, cresol, and o-chlorophenol are preferably used in addition to those exemplified as the solvent for dissolving the aromatic polyamide. it can.

  When the binder resin is a water-soluble resin, the solvent for dissolving the binder resin includes water, alcohols such as methanol, ethanol, isopropanol, acetone, toluene, xylene, hexane, N-methylpyrrolidone, N, N- Examples thereof include dimethylacetamide, N, N-dimethylformamide, etc., either alone or in combination within a compatible range. Among these, from the viewpoint of process and environmental load, 80% by mass or more of the medium is preferably water, and only water is more preferable.

In the case where the solvent contains water, it is preferable to perform a hydrophilic treatment on the other porous membrane in advance before coating on the other porous membrane. By subjecting other porous membranes to a hydrophilic treatment, applicability is further improved, and a more homogeneous main porous membrane can be obtained. This hydrophilization treatment is particularly effective when the concentration of water in the solvent is high.
Other methods for hydrophilizing the porous membrane may be any method, and specific examples include chemical treatment with acid or alkali, corona treatment, plasma treatment and the like.
Here, in addition to the ability to hydrophilize other porous membranes in a relatively short time, the corona treatment is limited to modification by corona discharge only in the vicinity of the surface of other porous membranes. There is an advantage that high coatability can be secured without changing the properties of the coating.

  The removal of the solvent from the coating liquid applied on the other porous membrane is generally a method by heat drying. The coating film before heat-drying can be immersed in a solvent that does not dissolve the binder resin to precipitate the binder resin, and then the solvent can be removed by heat-drying. In addition, when a coating liquid is apply | coated on another porous membrane, the temperature which does not change the air permeability of the other porous membrane after drying is preferable.

  The method for applying the present coating liquid to other porous membranes is not particularly limited as long as it can uniformly wet coat, and a conventionally known method can be adopted. For example, a capillary coating method, a spin coating method, a slit die coating method, a spray coating method, a roll coating method, a screen printing method, a flexographic printing method, a bar coater method, a gravure coater method, a die coater method, and the like can be employed. The thickness of the porous film to be formed can be controlled by adjusting the coating amount of the coating solution, the concentration of the coating solution, and the content ratio of the inorganic powder and the binder resin. In addition, a resin film, a metal belt, a drum, or the like can be used as a support during coating.

  Examples of the method for preparing the coating liquid include a method of stirring by a method such as a mechanical stirring method, an ultrasonic dispersion method, a high-pressure dispersion method, or a media dispersion method. Since the inorganic powder can be dispersed more uniformly, the high pressure dispersion method is more preferable.

<Nonaqueous electrolyte battery>
The non-aqueous electrolyte battery includes a positive electrode, a negative electrode, a separator for a non-aqueous electrolyte battery sandwiched between opposing surfaces of the positive electrode and the negative electrode, and a non-aqueous electrolyte.

As the non-aqueous electrolyte, for example, a non-aqueous electrolyte in which a lithium salt is dissolved in an organic solvent can be used. Lithium salts include LiClO ₄ , LiPF ₆ , LiAsF ₆ , LiSbF ₆ , LiBF ₄ , LiCF ₃ SO ₃ , LiN (SO ₂ CF ₃ ) ₂ , LiC (SO ₂ CF ₃ ) ₃ , Li ₂ B ₁₀ Cl ₁₀ , One or a mixture of two or more of lower aliphatic carboxylic acid lithium salts, LiAlCl _{4 and the} like can be mentioned. The lithium salt is selected from the group consisting of LiPF ₆ containing fluorine, LiAsF ₆ , LiSbF ₆ , LiBF ₄ , LiCF ₃ SO ₃ , LiN (CF ₃ SO ₂ ) ₂ , and LiC (CF ₃ SO ₂ ) ₃ among these. It is preferable to use those containing at least one selected from the above.

  Examples of the non-aqueous electrolyte include propylene carbonate, ethylene carbonate, dimethyl carbonate, diethyl carbonate, ethyl methyl carbonate, 4-trifluoromethyl-1,3-dioxolan-2-one, 1,2-di (methoxycarbonyloxy) ) Carbonates such as ethane; 1,2-dimethoxyethane, 1,3-dimethoxypropane, pentafluoropropyl methyl ether, 2,2,3,3-tetrafluoropropyl difluoromethyl ether, tetrahydrofuran, 2-methyltetrahydrofuran, etc. Ethers; esters such as methyl formate, methyl acetate and Y-butyrolactone; nitriles such as acetonitrile and butyronitrile; amides such as N, N-dimethylformamide and N, N-dimethylacetamide Carbamates such as 3-methyl-2-oxazolidone; sulfur-containing compounds such as sulfolane, dimethyl sulfoxide and 1,3-propane sultone, or those obtained by introducing a fluorine group into the above-mentioned substances can be used. Two or more of these are used in combination.

  Among these, those containing carbonates are preferred, and cyclic carbonates and acyclic carbonates, or mixtures of cyclic carbonates and ethers are more preferred. As a mixture of cyclic carbonate and acyclic carbonate, ethylene carbonate and dimethyl have a wide operating temperature range and are hardly decomposable even when a graphite material such as natural graphite or artificial graphite is used as the negative electrode active material. A mixture comprising carbonate and ethyl methyl carbonate is preferred.

As the positive electrode, a material in which a mixture containing a positive electrode active material, a conductive agent and a binder is supported on a current collector is usually used. Specifically, as the positive electrode active material, a material containing a material capable of doping and dedoping lithium ions, a carbonaceous material as a conductive agent, and a thermoplastic resin as a binder can be used. Examples of the material that can be doped / undoped with lithium ions include lithium composite oxides containing at least one transition metal such as V, Mn, Fe, Co, and Ni. Among these, lithium composite oxides having an α-NaFeO ₂ type structure such as lithium nickelate and lithium cobaltate, and lithium composite oxides having a spinel type structure such as lithium manganese spinel are preferable in that the average discharge potential is high. Can be mentioned.

  The lithium composite oxide may contain various metal elements, particularly at least one selected from the group consisting of Ti, V, Cr, Mn, Fe, Co, Cu, Ag, Mg, Al, Ga, In, and Sn. A composite containing the metal element such that the at least one metal element is 0.1 to 20 mol% with respect to the sum of the number of moles of the metal element and the number of moles of Ni in the lithium nickelate. Use of lithium nickelate is preferable because cycle characteristics in use at a high capacity are improved.

  Examples of the binder include polyvinylidene fluoride, vinylidene fluoride copolymer, polytetrafluoroethylene, tetrafluoroethylene-hexafluoropropylene copolymer, tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer, ethylene -Tetrafluoroethylene copolymers, vinylidene fluoride-hexafluoropropylene-tetrafluoroethylene copolymers, thermoplastic resins such as thermoplastic polyimide, polyethylene, and polypropylene.

  Examples of the conductive agent include carbonaceous materials such as natural graphite, artificial graphite, cokes, and carbon black. As the conductive material, each may be used alone, for example, artificial graphite and carbon black may be mixed and used.

  As the negative electrode, for example, a material capable of doping and dedoping lithium ions, lithium metal, or a lithium alloy can be used. Materials that can be doped / undoped with lithium ions include carbonaceous materials such as natural graphite, artificial graphite, cokes, carbon black, pyrolytic carbons, carbon fibers, and fired organic polymer compounds, and lower potential than the positive electrode. And chalcogen compounds such as oxides and sulfides for doping and dedoping lithium ions. As a carbonaceous material, a carbonaceous material mainly composed of graphite materials such as natural graphite and artificial graphite, because it has a high potential flatness and a low average discharge potential, so that a large energy density can be obtained when combined with a positive electrode. Is preferred.

  As the negative electrode current collector, Cu, Ni, stainless steel, or the like can be used. In particular, in a lithium secondary battery, Cu is preferable because it is difficult to form an alloy with lithium and it can be easily processed into a thin film. As a method of supporting the mixture containing the negative electrode active material on the negative electrode current collector, a method of pressure molding, or a method of pasting into a paste using a solvent or the like and applying pressure to the current collector by pressing after drying Is mentioned.

  The shape of the battery of the present invention is not particularly limited, and may be any of a paper type, a coin type, a cylindrical type, a square type, a laminate type, and the like.

In each of the following examples, comparative examples, and reference examples, each physical property of the laminated porous film was measured by the following method.
(1) Curl measurement: The laminated porous film was cut into an 8 cm × 8 cm square, held at room temperature for 1 day at a dew point of −30 ° C., and then the height at which the end was lifted was measured.
The appearance was judged according to the following criteria. C shows a completely curled state, A and B are preferable, and A is more preferable.
A: No lifting at the end.
B: Only the end portion is lifted, but most of the portions other than the end portion are not lifted and are flat.
C: Both ends approach and are wound into a cylindrical shape.
(2) Dimension retention: Cut a laminated porous film into a square of 5 cm x 5 cm square, draw a square ruled line at a center of 4 cm square, sandwich between two sheets of paper, and hold in a 150 ° C oven for 1 hour After that, it was taken out and the dimensions of the square were measured, and the dimensional retention was calculated. The calculation method of the dimensional retention rate is as follows.
Length of crease line before heating in the vertical direction (TD): W1
Length of ruled line after heating in the vertical direction (TD): W2
Dimensional retention (%) in the vertical direction (TD) = W2 / W1 × 100
(3) Air permeability: Measured according to JIS P8117.

Example 1
100 parts by mass of alumina fine particles (manufactured by Sumitomo Chemical; trade name “AKP3000”), 3 parts by mass of carboxymethyl cellulose (manufactured by Daicel Finechem, product number 1110), polyoxyethylene alkyl ether (manufactured by Sanyo Chemical Industries, Ltd.); 11) Water was added to 0.5 parts by weight of the mixture so that the solid content was 29% by weight, and the resulting mixture was rotated and revolving mixer “Awatori Netaro” (manufactured by Shinky Corporation; registered trademark) The mixture was stirred and mixed twice at room temperature at 2000 rpm for 30 seconds. 14 parts by mass of isopropyl alcohol was added to the obtained mixture to obtain a coating solution as a uniform slurry having a solid content of 28% by weight. The obtained coating liquid was applied by a doctor blade method onto a porous film (thickness 12 μm, porosity 41%) made of polyethylene subjected to corona treatment 20 W / (m ² / min). The laminate as the coated product was dried at 65 ° C. for 5 minutes to obtain a laminated porous film (1) in which the present porous membrane and a porous membrane made of polyethylene were laminated. The basis weight of the porous membrane in the laminated porous film (1) was 6.2 g / m ² . Table 1 shows the physical properties of the laminated porous film (1).

(Example 2)
A laminated porous film (2) was obtained in the same manner as in Example 1 except that 0.5 part by mass of the polyoxyethylene alkyl ether in Example 1 was changed to 1 part by mass. The basis weight of the porous film in the laminated porous film (2) was 6.6 g / m ² . Table 1 shows the physical properties of the laminated porous film (2).

(Comparative Example 1)
A laminated porous film (3) was obtained in the same manner as in Example 1 except that 0.5 part by mass of the polyoxyethylene alkyl ether in Example 1 was not added. The basis weight of this porous membrane in the laminated porous film (3) was 6.9 g / m ² . Table 1 shows the physical properties of the laminated porous film (3).

  The laminated porous films (1) and (2) obtained in Examples 1 and 2 were able to reduce the curl amount while maintaining a high dimensional change rate and air permeability.

  According to the present invention, a laminated porous film obtained by laminating a porous film made of polyolefin that is difficult to curl and a porous film containing an inorganic powder can be obtained.

Claims (9)

A compound having a hydrophobic group and a nonionic hydrophilic group, an inorganic powder, and a binder resin,
The nonionic hydrophilic group has a polyoxyethylene structure;
The ratio of the inorganic powder to the total amount of the inorganic powder and the binder resin is 70% by mass or more,
A porous membrane for a non-aqueous electrolyte secondary battery having a water content of less than 0.15%.   The porous membrane for a non-aqueous electrolyte secondary battery according to claim 1, wherein the compound having a hydrophobic group and a nonionic hydrophilic group is a nonionic surfactant.   The porous membrane for a nonaqueous electrolyte secondary battery according to claim 1 or 2, wherein the inorganic powder is a metal oxide or a metal carbonate.   The porous membrane for a nonaqueous electrolyte secondary battery according to any one of claims 1 to 3, wherein the inorganic powder is alumina. The porous membrane for a nonaqueous electrolyte secondary battery according to any one of claims 1 to 4, wherein the compound having a hydrophobic group and a nonionic hydrophilic group is polyoxyethylene alkyl ether.   The porous membrane for a non-aqueous electrolyte secondary battery according to any one of claims 1 to 5, wherein the binder resin is a water-soluble resin.   A separator for a non-aqueous electrolyte secondary battery in which the porous film according to claim 1 and another porous film different from the porous film are laminated.   The separator for nonaqueous electrolyte secondary batteries containing the porous film in any one of Claims 1-6.   A non-aqueous electrolyte secondary battery using the separator for a non-aqueous electrolyte secondary battery according to claim 7 or 8.