JP6374969B2 - 金属箔と樹脂フィルムのラミネート用接着剤、該組成物を用いた積層体、電池外装用包装材および電池ケース - Google Patents
金属箔と樹脂フィルムのラミネート用接着剤、該組成物を用いた積層体、電池外装用包装材および電池ケース Download PDFInfo
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- JP6374969B2 JP6374969B2 JP2016539880A JP2016539880A JP6374969B2 JP 6374969 B2 JP6374969 B2 JP 6374969B2 JP 2016539880 A JP2016539880 A JP 2016539880A JP 2016539880 A JP2016539880 A JP 2016539880A JP 6374969 B2 JP6374969 B2 JP 6374969B2
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- Prior art keywords
- adhesive
- resin film
- metal foil
- laminating
- polyol
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- 239000011888 foil Substances 0.000 title claims description 105
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- 229910052751 metal Inorganic materials 0.000 title claims description 75
- 239000002184 metal Substances 0.000 title claims description 75
- 230000001070 adhesive effect Effects 0.000 title claims description 73
- 238000010030 laminating Methods 0.000 title claims description 48
- 239000005022 packaging material Substances 0.000 title claims description 32
- 239000000203 mixture Substances 0.000 title description 10
- 150000003077 polyols Chemical class 0.000 claims description 68
- 229920005862 polyol Polymers 0.000 claims description 65
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- 239000000539 dimer Substances 0.000 claims description 37
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- IISBACLAFKSPIT-UHFFFAOYSA-N bisphenol A Chemical compound C=1C=C(O)C=CC=1C(C)(C)C1=CC=C(O)C=C1 IISBACLAFKSPIT-UHFFFAOYSA-N 0.000 description 11
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- 125000001261 isocyanato group Chemical group *N=C=O 0.000 description 7
- NIMLQBUJDJZYEJ-UHFFFAOYSA-N isophorone diisocyanate Chemical compound CC1(C)CC(N=C=O)CC(C)(CN=C=O)C1 NIMLQBUJDJZYEJ-UHFFFAOYSA-N 0.000 description 7
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- UAEPNZWRGJTJPN-UHFFFAOYSA-N methylcyclohexane Chemical compound CC1CCCCC1 UAEPNZWRGJTJPN-UHFFFAOYSA-N 0.000 description 4
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- 238000003756 stirring Methods 0.000 description 4
- XSCLFFBWRKTMTE-UHFFFAOYSA-N 1,3-bis(isocyanatomethyl)cyclohexane Chemical compound O=C=NCC1CCCC(CN=C=O)C1 XSCLFFBWRKTMTE-UHFFFAOYSA-N 0.000 description 3
- CDMDQYCEEKCBGR-UHFFFAOYSA-N 1,4-diisocyanatocyclohexane Chemical compound O=C=NC1CCC(N=C=O)CC1 CDMDQYCEEKCBGR-UHFFFAOYSA-N 0.000 description 3
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- UKLDJPRMSDWDSL-UHFFFAOYSA-L [dibutyl(dodecanoyloxy)stannyl] dodecanoate Chemical compound CCCCCCCCCCCC(=O)O[Sn](CCCC)(CCCC)OC(=O)CCCCCCCCCCC UKLDJPRMSDWDSL-UHFFFAOYSA-L 0.000 description 3
- 239000012975 dibutyltin dilaurate Substances 0.000 description 3
- 125000005442 diisocyanate group Chemical group 0.000 description 3
- ZQPPMHVWECSIRJ-MDZDMXLPSA-N elaidic acid Chemical compound CCCCCCCC\C=C\CCCCCCCC(O)=O ZQPPMHVWECSIRJ-MDZDMXLPSA-N 0.000 description 3
- 150000002148 esters Chemical group 0.000 description 3
- 229920000578 graft copolymer Polymers 0.000 description 3
- RRAMGCGOFNQTLD-UHFFFAOYSA-N hexamethylene diisocyanate Chemical compound O=C=NCCCCCCN=C=O RRAMGCGOFNQTLD-UHFFFAOYSA-N 0.000 description 3
- QXJSBBXBKPUZAA-UHFFFAOYSA-N isooleic acid Natural products CCCCCCCC=CCCCCCCCCC(O)=O QXJSBBXBKPUZAA-UHFFFAOYSA-N 0.000 description 3
- OTLDLKLSNZMTTA-UHFFFAOYSA-N octahydro-1h-4,7-methanoindene-1,5-diyldimethanol Chemical compound C1C2C3C(CO)CCC3C1C(CO)C2 OTLDLKLSNZMTTA-UHFFFAOYSA-N 0.000 description 3
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- QGLRLXLDMZCFBP-UHFFFAOYSA-N 1,6-diisocyanato-2,4,4-trimethylhexane Chemical compound O=C=NCC(C)CC(C)(C)CCN=C=O QGLRLXLDMZCFBP-UHFFFAOYSA-N 0.000 description 2
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Description
〔1〕 ポリウレタン系接着剤に用いるポリオールであって、
鎖状ポリオレフィンポリオール(a1)及び/又は水添ダイマー酸由来の構成単位と水添ダイマージオール由来の構成単位とを有するポリエステルポリオール(a2)、飽和又は不飽和の環式炭化水素構造と2つ以上の水酸基とを併せ持つ水酸基含有炭化水素化合物(b)、及びポリイソシアネート(c)を含有する成分を重付加して得られ、前記水酸基含有炭化水素化合物(b)が架橋構造を有する飽和又は不飽和脂環構造を含むポリオールである、ポリウレタンポリオール。
〔2〕 鎖状ポリオレフィンポリオール(a1)及び/又は水添ダイマー酸由来の構成単位と水添ダイマージオール由来の構成単位とを有するポリエステルポリオール(a2)、飽和又は不飽和の環式炭化水素構造と2つ以上の水酸基とを併せ持つ水酸基含有炭化水素化合物(b)、及びポリイソシアネート(c)を含有する成分を重付加して得られるポリウレタンポリオール(A)と、飽和脂肪族及び/又は飽和脂環式ポリイソシアネート(B)と、を有する、金属箔と樹脂フィルムのラミネート用接着剤。
〔3〕 前記水酸基含有炭化水素化合物(b)が、架橋構造を有する飽和脂環構造を含むポリオールである、〔2〕に記載の金属箔と樹脂フィルムのラミネート用接着剤。
〔4〕 前記水酸基含有炭化水素化合物(b)が、ビスフェノール化合物である、〔2〕又は〔3〕に記載の金属箔と樹脂フィルムのラミネート用接着剤。
〔5〕 前記ポリイソシアネート(c)が、飽和脂環式ジイソシアネートである、〔2〕〜〔4〕のいずれかに記載の金属箔と樹脂フィルムのラミネート用接着剤。
〔6〕 前記鎖状ポリオレフィンポリオール(a1)が、実質的に不飽和炭化水素構造を含まないポリオレフィンポリオールである、〔2〕〜〔5〕のいずれかに記載の金属箔と樹脂フィルムのラミネート用接着剤。
〔7〕 (b)成分が、(a1)及び(a2)成分の総量100質量部に対して5〜100質量部であり、(c)成分に含まれるイソシアナト基数の比率が、(a1)、(a2)及び(b)成分に含まれる水酸基数に対して、0.5〜1.3である、〔2〕〜〔6〕のいずれかに記載の金属箔と樹脂フィルムのラミネート用接着剤。
〔8〕 前記ポリウレタンポリオール(A)に含まれる水酸基数に対する、ポリイソシアネート(B)に含まれるイソシアナト基数の比率が、1〜15である、〔2〕〜〔7〕のいずれかに記載の金属箔と樹脂フィルムのラミネート用接着剤。
〔9〕 溶剤(C)をさらに含む、〔2〕〜〔8〕のいずれかに記載の金属箔と樹脂フィルムのラミネート用接着剤。
〔10〕 金属箔と樹脂フィルムが、〔2〕〜〔9〕のいずれかに記載の金属箔と樹脂フィルムのラミネート用接着剤から得られる接着剤層を介して積層された、積層体。
〔11〕 前記金属箔がアルミニウム箔であり、前記樹脂フィルムが熱融着性樹脂フィルムを含有する、〔10〕に記載の積層体。
〔12〕 前記金属箔の厚さが10〜100μmであり、前記樹脂フィルムの厚さが9〜100μmである、〔10〕又は〔11〕に記載の積層体。
〔13〕 〔10〕〜〔12〕のいずれかに記載の積層体を用いて得られる、電池外装用包装材。
〔14〕 〔13〕に記載の電池外装用包装材を用いて得られる、電池ケース。
〔15〕 〔13〕に記載の電池外装用包装材を深絞り成形又は張り出し成形する、電池ケースの製造方法。
本発明の金属箔と樹脂フィルムのラミネート用接着剤において、前記ポリウレタンポリオール(A)は主剤に当たり、前記飽和脂肪族及び/又は飽和脂環式ポリイソシアネート(B)は硬化剤に当たる。
ここで、本明細書における「〜」は、「〜」という記載の前の値以上、「〜」という記載の後の値以下を意味する。
本発明に用いられるポリウレタンポリオール(A)は、上述したように(a1)及び/又は(a2)成分と、(b)成分と、(c)成分とを含有する成分を重付加して得られる。
本発明の「鎖状ポリオレフィンポリオール(a1)」は、脂環構造を含まないポリオレフィンポリオール(a1)を意味する。
本発明に用いられる鎖状ポリオレフィンポリオール(a1)(以下、「ポリオレフィンポリオール(a1)」ともいう)は、1種又は2種以上のオレフィンを重合又は共重合させてなるポリオレフィン骨格と、2つ以上の水酸基とを含有し、かつ脂環構造を有さないものであれば特に制限されない。具体例としては、ポリブタジエンポリオール、ポリイソプレンポリオールなどのポリジエンポリオール、ポリジエンポリオールとポリオレフィンのグラフト重合物およびこれらのポリジエンポリオールやグラフト重合物の水素添加物等が挙げられる。これらは、単独又は2種以上混合して使用することができる。本発明の金属箔と樹脂フィルムのラミネート用接着剤から得られる接着剤層の耐電解液性の観点からは、構造中に実質的に不飽和炭化水素構造を含まない、鎖状ポリオレフィンポリオールが好ましく、例えば、上記に挙げた各種ポリジエンポリオールやグラフト重合物の水素添加物が挙げられる。これらの市販品としては、例えば、GI−1000、GI−2000、GI−3000(いずれも日本曹達株式会社製)、エポール(出光興産株式会社製)等が挙げられる。
カラム:昭和電工株式会社製、KF−806L
カラム温度:40℃
試料:試料ポリマーの0.2質量%テトラヒドロフラン溶液
流量:2ml/分
溶離液:テトラヒドロフラン
検出器:示差屈折率計(RI)
本発明に用いられる、水添ダイマー酸由来の構成単位と、水添ダイマージオール由来の構成単位とを有するポリエステルポリオール(a2)(以下、「ポリエステルポリオール(a2)」ともいう)は、本発明の金属箔と樹脂フィルムのラミネート用接着剤から得られる接着剤層の耐電解液性の観点から、水添ダイマー酸由来の構成単位と、水添ダイマージオール由来の構成単位とを有する。
本発明に用いられる飽和又は不飽和の環式炭化水素構造と2つ以上の水酸基とを併せ持つ水酸基含有炭化水素化合物(b)(以下、「水酸基含有環式炭化水素(b)」ともいう)は、本発明の金属箔と樹脂フィルムのラミネート用接着剤から得られる接着剤層の耐電解液性の観点から、不飽和又は飽和脂環式炭化水素構造と2つ以上の水酸基を有し、その他の部分の構造が炭化水素から成る化合物であれば特に制限はない。
飽和環式炭化水素構造としては、シクロペンタン骨格、シクロヘキサン骨格、シクロヘプタン骨格等のシクロアルカン骨格、ノルボルナン骨格、アダマンタン骨格、トリシクロデカン骨格等の架橋構造を有する飽和脂環構造等が挙げられ、そのような構造を持つ水酸基含有環式炭化水素(b)としては、シクロペンタンジオール、シクロヘキサンジオール、シクロヘキサンジメタノール、ノルボルナンジオール、アダマンタンジオール、トリシクロデカンジメタノール等が挙げられる。これらは、単独又は2種以上混合して使用することができる。好ましくは架橋構造を有する飽和脂環構造を含むものであり、ノルボルナンジオール、アダマンタンジオール、トリシクロデカンジメタノール等が好ましい例として挙げられる。それらの市販品としては、アダマンタントリオール(出光興産株式会社製、三菱ガス化学株式会社製)、TCDアルコールDM(オクセア社製)等が挙げられる。
本発明に用いるポリイソシアネート(c)としては、イソシアナト基を2つ以上含有する化合物、もしくはその多量体であれば特に制限は無い。例えば、1,4−シクロヘキサンジイソシアネート、イソホロンジイソシアネート、メチレンビス(4−シクロヘキシルイソシアネート)、1,3−ビス(イソシアナトメチル)シクロヘキサン、1,4−ビス(イソシアナトメチル)シクロヘキサン、ノルボルナンジイソシアネート等の飽和脂環式ジイソシアネート、2,4−トリレンジイソシアネート、2,6−トリレンジイソシアネート、ジフェニルメタン−4,4′−ジイソシアネート、1,3−キシリレンジイソシアネート、1,4−キシリレンジイソシアネート等の芳香族ジイソシアネート、ヘキサメチレンジイソシアネート、2,4,4−トリメチルヘキサメチレンジイソシアネート、2,2,4−トリメチルヘキサンメチレンジイソシアネート等の脂肪族ジイソシアネート、またこれらのアロファネート化多量体、イソシアヌレート化物、ビウレット変性物等が挙げられる。これらは、単独又は2種以上混合して使用することができる。好ましくは飽和脂環式ジイソシアネートであり、1,4−シクロヘキサンジイソシアネート、イソホロンジイソシアネート、メチレンビス(4−シクロヘキシルイソシアネート)、1,3−ビス(イソシアナトメチル)シクロヘキサン、1,4−ビス(イソシアナトメチル)シクロヘキサン、ノルボルナンジイソシアネート等が挙げられ、特に好ましくはイソホロンジイソシアネート(3-イソシアナートメチル-3,5,5-トリメチルシクロへキシルイソシアネート)、メチレンビス(4−シクロヘキシルイソシアネート)(別名:ジシクロへキシルメタンー4,4’−ジイソシアネート)である。これらの市販品としては、デスモジュールI、デスモジュールW(それぞれバイエル社製)、IPDI、H12MDI(それぞれデグッサ社製)等が挙げられる。
本発明に用いるポリウレタンポリオール(A)の製造方法としては、ジブチルスズジラウレート、ジオクチルスズジラウレート、ビスマストリス2−エチルヘキサノエート、ジルコニウムテトラアセチルアセトネートのような公知のウレタン化触媒の存在下又は非存在下で、ポリオレフィンポリオール(a1)及び/又はポリエステルポリオール(a2)と、水酸基含有環式炭化水素化合物(b)と、ポリイソシアネート(c)とを重付加反応させることにより行える。触媒の存在下で反応させた方が、反応時間を短縮する意味では好ましい。またこの触媒は、ポリウレタンポリオール(A)と飽和脂肪族及び/又は飽和脂環式ポリイソシアネート(B)が反応して硬化する際の、硬化促進剤としても作用する為、存在することが好ましい。ただし、多く使用しすぎると、最終的に金属箔と樹脂フィルムのラミネート用接着剤としての物性に悪影響を及ぼす可能性があるので、使用量は、(a1)、(a2)、(b)および(c)成分の総量100質量部に対して0.001〜1質量部であることが好ましく、0.005〜0.5質量部がより好ましく、0.01〜0.3質量部が更に好ましい。また重付加の反応は、ポリオレフィンポリオール(a1)及び/又はポリエステルポリオール(a2)と、水酸基含有環式炭化水素化合物(b)と、ポリイソシアネート(c)とを全て一度に反応させても良いし、ポリオレフィンポリオール(a1)及び/又はポリエステルポリオール(a2)と、水酸基含有環式炭化水素化合物(b)とをそれぞれ別々に、もしくは適当に組み合わせてポリイソシアネート(c)と反応させた後、全ての成分を混合してさらに反応させても良い。後者の方法は例えば、水酸基含有環式炭化水素化合物(b)とポリイソシアネート(c)を反応させてポリウレタンポリイソシアネートを得た後、ポリオレフィンポリオール(a1)及び/又はポリエステルポリオール(a2)を反応させてポリウレタンポリオール(A)を得る、といった方法が挙げられる。
本発明における飽和脂肪族及び/又は飽和脂環式ポリイソシアネート(B)(以下、「ポリイソシアネート(B)」ともいう)は本発明の金属箔と樹脂フィルムのラミネート用接着剤に硬化剤として配合するものであり、前述のポリウレタンポリオール(A)製造の際の原料として記載したポリイソシアネート(c)とは区別して記載する。
本発明の金属箔と樹脂フィルムのラミネート用接着剤は、溶剤(C)を含んでも良い。溶剤(C)は、ポリウレタンポリオール(A)およびポリイソシアネート(B)を溶解又は分散可能なものであれば特に制限されない。例えば、トルエン、キシレン等の芳香族系有機溶剤、シクロヘキサン、メチルシクロヘキサン、エチルシクロヘキサン等の脂環式系有機溶剤、n−ヘキサン、n−ヘプタン等の脂肪族系有機溶剤、酢酸エチル、酢酸プロピル、酢酸ブチル等のエステル系有機溶剤、アセトン、メチルエチルケトン、メチルブチルケトン等のケトン系有機溶剤などが挙げられる。これらは、単独又は2種以上混合して使用することができる。
これらの中では、特にポリウレタンポリオール(A)の溶解性の見地から、酢酸エチル、酢酸プロピル、酢酸ブチル、トルエン、メチルシクロヘキサン、メチルエチルケトンが好ましく、トルエン、メチルエチルケトンがより好ましい。
溶剤(C)の含有量は、(A)、(B)及び(C)成分からなる金属箔と樹脂フィルムのラミネート用接着剤100質量部に対し、40〜95質量部が好ましく、50〜95質量部であることがより好ましく、80〜90質量部であることが更に好ましい。40質量部以上であれば、本発明の金属箔と樹脂フィルムのラミネート用接着剤の塗布時の操作性が良好となり、95質量部以下であれば、本発明の金属箔と樹脂フィルムのラミネート用接着剤を塗布・硬化して得られる積層体の厚み制御性が良好となる。
本発明の金属箔と樹脂フィルムのラミネート用接着剤は、必要に応じて、反応促進剤、粘着付与剤、可塑剤等の添加剤を含有していてもよい。反応促進剤は、ポリウレタンポリオール(A)およびポリイソシアネート(B)の反応を促進するためのものであり、たとえば、有機スズ化合物であるジオクチルスズジラウレート、ジオクチルスズジアセテートや、第3級アミンである2、4、6−トリス(ジメチルアミノメチル)フェノール、ジメチルアニリン、ジメチルパラトルイジン、N、N−ジ(β−ヒドロキシエチル)−p−トルイジン等が挙げられる。これらの反応促進剤は、単独又は2種以上を併用することができる。
本発明の積層体は、金属箔と樹脂フィルムを本発明の金属箔と樹脂フィルムのラミネート用接着剤(以下、単に「本発明のラミネート用接着剤」ということがある。)から得られる接着剤層を介して接合したものである。また本発明の積層体中に、金属箔と樹脂フィルムを本発明のラミネート用接着剤から得られる接着剤層を介して接合した層が含まれれば、他に金属箔同士及び/又は樹脂フィルム同士が本発明のラミネート用接着剤から得られる接着剤層を介して接合した層を含んでも良い。この接合方法は、ヒートラミネーション方式やドライラミネーション方式等の公知の方法を用いることができる。ヒートラミネーション方式とは、溶剤(C)を含まない本発明のラミネート用接着剤を、接着剤層に接する層表面にて加熱溶融、又は接着剤層に接する層と共に加熱押し出しすることにより、積層体の層間に介在させ、接着剤層を形成する方式である。また、ドライラミネーション方式とは、溶剤(C)を含む本発明のラミネート用接着剤を接着剤層に接する層表面に塗布、乾燥せしめた後に他方の層と重ね合せて圧着することにより、積層体の層間に介在させ、接着剤層を形成する方式である。
本発明の電池外装用包装材は、本発明の積層体の、金属箔の外側に耐熱性樹脂フィルムからなる外層を設けたものである。また、必要に応じて、機械的強度や耐電解液性などの特性を高めるために、第1中間樹脂層又は/及び第2中間樹脂層等を付加した構成にすることができる。好ましい形態としては、具体的に次のような構成にすることができる。なお、接着剤層は「本発明のラミネート用接着剤から得られる接着剤層」を意味し、金属箔層をアルミニウム箔層として例示している。
(1)外層/アルミニウム箔層/接着剤層/樹脂フィルム層
(2)外層/第1中間樹脂層/アルミニウム箔層/接着剤層/樹脂フィルム層
(3)外層/アルミニウム箔層/第2中間樹脂層/接着剤層/樹脂フィルム層
(4)外層/第1中間樹脂層/アルミニウム箔層/第2中間樹脂層/接着剤層/樹脂フィルム層
(5)コート層/外層/アルミニウム箔層/接着剤層/樹脂フィルム層
(6)コート層/外層/第1中間樹脂層/アルミニウム箔層/接着剤層/樹脂フィルム層
(7)コート層/外層/アルミニウム箔層/第2中間樹脂層/接着剤層/樹脂フィルム層
(8)コート層/外層/第1中間樹脂層/アルミニウム箔層/第2中間樹脂層/接着剤層/樹脂フィルム層
外層に使用する樹脂フィルムは、耐熱性、成形性、絶縁性等に優れたものであり、ポリアミド(ナイロン)樹脂又はポリエステル樹脂の延伸フィルムが一般的に使用される。この外層フィルムの厚さは、9〜50μm程度であり、9μm未満では包装材の成形を行うときに延伸フィルムの伸びが不足し、アルミニウム箔にネッキングが生じ、成形不良が起こり易い。一方、50μmを超える厚さの場合は、特段、成形性の効果が向上する訳でもなく、逆に体積エネルギー密度を低下させるとともにコストアップにつながるだけである。外層フィルムの厚さは10〜40μm程度であることがより好ましく、20〜30μmであることがさらに好ましい。
金属箔は、水蒸気等に対するバリア性の役割を担うもので、材質としては純アルミニウム系又はアルミニウム−鉄系合金のO材(軟質材)が一般的に使用され、かつ好ましい。アルミニウム箔の厚さとしては、加工性の確保及び酸素や水分の包装内への浸入を防止するバリア性確保のために、10〜100μm程度が好ましい。アルミニウム箔の厚さが10μm未満の場合は、成形時においてアルミニウム箔の破断が生じたり、ピンホールが発生したりして酸素や水分の浸入のおそれがある。一方、アルミニウム箔の厚さが100μmを超えた場合は、成形時の破断の改善効果やピンホール発生防止効果が特段向上するわけでなく、単に包装材の総厚さが厚く、質量が増加し、体積エネルギー密度が低下する。アルミニウム箔は、一般的に30〜50μm程度の厚さのものが使用され、40〜50μmの厚さのものを使用することが好ましい。なお、アルミニウム箔には、樹脂フィルムとの接着性向上や耐食性向上のため、シランカップリング剤やチタンカップリング剤等のアンダーコート処理、クロメート処理等の化成処理をしておくことが好ましい。
樹脂フィルムとしては、ポリプロピレン、ポリエチレン、マレイン酸変性ポリプロピレン、エチレン−アクリレート共重合体又はアイオノマー樹脂などの熱融着性樹脂フィルムが好ましい。これらの樹脂は、ヒートシール性を有し、腐食性の強いリチウム二次電池の電解液等に対する耐薬品性を向上させる役割を担うものである。これらのフィルム厚さは、9〜100μmが好ましく、より好ましくは20〜80μmであり、40〜80μmであるのが最も好ましい。樹脂フィルムの厚さが9μm以上であれば、十分なヒートシール強度が得られ、電解液等に対する耐食性が良好となる。樹脂フィルムの厚さが100μm以下であれば、電池外装用包装材の強度が十分でありかつ、成形性が良好となる。
本発明の電池外装用包装材は、外層の上にコート層を設けてもよい。コート層の形成法としては、ガスバリア性のポリマーをコートする方法、アルミニウム金属や酸化ケイ素・酸化アルミニウム等の無機酸化物を蒸着し、金属及び無機物の薄膜をコートする方法などがある。コート層を設けることにより、水蒸気及びその他のガスバリア性がより優れた積層体が得られる。
本発明の電池ケースは本発明の電池外装用包装材を成形することによって得られる。本発明の電池外装用包装材は耐電解液性や耐熱性、水蒸気及びその他のガスバリア性に優れており、二次電池、特にリチウムイオン電池用の電池ケースとして好適に用いられる。また、本発明の電池外装用包装材は成形性が非常に良好である為、公知の方法に従って成形することにより、本発明の電池ケースを簡便に得ることができる。成形の方法は特に限定されないが、深絞り成形又は張り出し成形によって成形すると、複雑な形状や寸法精度が高い電池ケースを作製することができる。
攪拌機、水分離器付き反応容器中に、水添ダイマージオールとして「Sovermol908」(BASF社製)を220.00g、水添ダイマー酸として「EMPOL1008」(BASF社製)を230.00g、触媒のブチルスズジラウレートとして「KS−1260」(堺化学工業製)を0.10g仕込み、約240℃、常圧下から始めて縮合水を流出させながら減圧しつつ脱水エステル化反応を行い、ポリエステルポリオール(以下、ポリエステルポリオール(1)と記す。)を得た。
攪拌装置、温度計およびコンデンサーを備えた反応容器中に、ビスフェノールA(新日鐵化学製、化合物名2,2−ビス(4−ヒドロキシフェニル)プロパン)を23.29g、「KS−1260」(堺化学工業製、ジブチルスズジラウレート)を0.01gおよび、「デスモジュールI」(バイエル社製イソホロンジイソシアネート)を34.02g、メチルエチルケトンを113.13g投入し、撹拌しながら、オイルバスを用いて85〜90℃に昇温した。その後、2.5時間撹拌しながら反応を継続して、ポリウレタンポリイソシアネート(以下、ポリウレタンポリイソシアネート(2)と記す。)のメチルエチルケトン溶液を得た。
ビスフェノールAの代わりにビスフェノールF(本州化学工業製)20gを用いた以外は、合成例2と同様にして、ポリウレタンポリイソシアネート(以下、ポリウレタンポリイソシアネート(3)と記す。)のメチルエチルケトン溶液を得た。
攪拌装置、温度計およびコンデンサーを備えた反応容器中に、ポリエステルポリオール(1)を112.50g、「TCDアルコールDM」(オクセア社製、トリシクロデカンジメタノール)12.50g、ヒドロキノンモノメチルエーテル(和光純薬工業製)を0.04g、「KS−1260」(堺化学工業製、ジブチルスズジラウレート)を0.03gおよび、「デスモジュールW」(バイエル社製、メチレンビス(4−シクロヘキシルイソシアネート))を28.97g、トルエンを70g投入し、撹拌しながら、オイルバスを用いて85〜90℃に昇温した。その後、2.5時間撹拌しながら反応を継続した。その後、赤外吸収スペクトルを測定し、イソシアナト基の吸収が消失していることを確認して反応を終了し、さらにトルエンを636.5g投入して撹拌溶解し、ポリウレタンポリオール(以下、ポリウレタンポリオール(4)と記す。)のトルエン溶液(固形分濃度18質量%)を得た。
合成例3と同様の方法で、表2に示すとおりの成分、量で合成を行い、ポリウレタンポリオール(4)〜(13)のトルエン溶液もしくはトルエンとメチルエチルケトンの混合溶媒溶液(固形分濃度18質量%)を得た。
表2中、GI−1000、GI−2000は日本曹達製水添ポリブタジエンポリオール、G−1000は日本曹達製ポリブタジエンポリオール、14BGは三菱化学製1,4−ブタンジオールである。
合成例1〜10および比較合成例11〜13について、表1、2に示す。
合成例4で得たポリウレタンポリオール(4)のトルエン溶液33.33g(固形分6.00g、トルエン27.33g)に「デュラネートTKA−100」(旭化成ケミカルズ株式会社製、ヘキサメチレンジイソシアネートイソシアヌレート化物)0.34g、トルエン15.08gを加えて金属箔と樹脂フィルムのラミネート用接着剤1を調製した。 次いで、このラミネート用接着剤1を用いて、以下のようにして外層/外層用接着剤/アルミニウム箔層/ラミネート用接着剤1/樹脂フィルムの構造を有する電池外装用包装材をドライラミネーション方式で製造した。
外層:延伸ポリアミドフィルム(厚さ25μm)
外層用接着剤:ウレタン系ドライラミネート用接着剤(東洋モートン株式会社製:AD502/CAT10、塗布量3g/m2(塗布時))
アルミニウム箔層:アルミニウム−鉄系合金のアルミニウム箔(AA規格8079−O材、厚さ40μm)
ラミネート用接着剤1:上記金属箔と樹脂フィルムのラミネート用接着剤1(塗布量:乾燥後の厚さが2μm)
樹脂フィルム:未延伸ポリプロピレンフィルム(厚さ30μm)
実施例1と同様の方法で、表3に示すとおりの成分、量で金属箔と樹脂フィルムのラミネート用接着剤2〜12の調製を行い、それぞれの金属箔と樹脂フィルムのラミネート用接着剤を用いて電池外装用包装材を製造した。
表3中、酸変性ポリプロピレンは、無水マレイン酸およびアクリル酸オクチルで変性した酸変性ポリプロピレン(酸価20mg/KOH)であり、ミリオネートMR−200は、日本ポリウレタン製ポリメリックジフェニルメタンジイソシアネートである。
得られた電池ケース用包装材料について、常態T字剥離強度、電解液溶媒浸漬後のT字剥離強度および85℃雰囲気下でのT字剥離強度を測定した。測定の条件、方法は下記の(1)〜(3)の通りである。各試験は、n=2で行い、その平均値をとった。また、結果を表4に示す(単位は全てN/15mm)。
(1)常態T字剥離強度
長さ150mm×幅15mmの試験片およびオートグラフAG−X(株式会社島津製作所製)を用いて、23℃×50%RH雰囲気下に剥離速度100mm/minで剥離させ、アルミニウム箔層と未延伸ポリプロピレンフィルム層間の180°剥離強度を測定した。
(2)電解液溶媒浸漬後のT字剥離強度
長さ150mm×幅15mmの試験片を電解液溶媒(エチレンカーボネート/ジエチルカーボネート、質量比50/50)に浸漬し、85℃雰囲気下に1日放置した後に取り出し、その試験片を用いて上記(1)と同様にしてアルミニウム箔層と未延伸ポリプロピレンフィルム層間の180°剥離強度を測定する。
(3)85℃雰囲気下でのT字剥離強度
長さ150mm×幅15mmの試験片およびオートグラフAG−X(株式会社島津製作所製)を用いて、85℃雰囲気下に放置し、試験片の温度が85℃になった後に剥離速度100mm/minで剥離させ、アルミニウム箔層と未延伸ポリプロピレンフィルム層間の180°剥離強度を測定する。
Claims (15)
- ポリウレタン系接着剤に用いるポリオールであって、
鎖状ポリオレフィンポリオール(a1)及び/又は水添ダイマー酸由来の構成単位と水添ダイマージオール由来の構成単位とを有するポリエステルポリオール(a2)、飽和又は不飽和の環式炭化水素構造と2つ以上の水酸基とを併せ持つ水酸基含有炭化水素化合物(b)、及びポリイソシアネート(c)を含有する成分を重付加して得られ、前記水酸基含有炭化水素化合物(b)が架橋構造を有する飽和又は不飽和脂環構造を含むポリオールである、ポリウレタンポリオール。 - 鎖状ポリオレフィンポリオール(a1)及び/又は水添ダイマー酸由来の構成単位と水添ダイマージオール由来の構成単位とを有するポリエステルポリオール(a2)、飽和又は不飽和の環式炭化水素構造と2つ以上の水酸基とを併せ持つ水酸基含有炭化水素化合物(b)、及びポリイソシアネート(c)を含有する成分を重付加して得られるポリウレタンポリオール(A)と、
飽和脂肪族及び/又は飽和脂環式ポリイソシアネート(B)と
を有する、金属箔と樹脂フィルムのラミネート用接着剤。 - 前記水酸基含有炭化水素化合物(b)が、架橋構造を有する飽和脂環構造を含むポリオールである、請求項2に記載の金属箔と樹脂フィルムのラミネート用接着剤。
- 前記水酸基含有炭化水素化合物(b)が、ビスフェノール化合物である、請求項2又は3に記載の金属箔と樹脂フィルムのラミネート用接着剤。
- 前記ポリイソシアネート(c)が、飽和脂環式ジイソシアネートである、請求項2〜4のいずれか1項に記載の金属箔と樹脂フィルムのラミネート用接着剤。
- 前記鎖状ポリオレフィンポリオール(a1)が、実質的に不飽和炭化水素構造を含まないポリオレフィンポリオールである、請求項2〜5のいずれか1項に記載の金属箔と樹脂フィルムのラミネート用接着剤。
- (b)成分が、(a1)及び(a2)成分の総量100質量部に対して5〜100質量部であり、(c)成分に含まれるイソシアナト基数の比率が、(a1)、(a2)及び(b)成分に含まれる水酸基数に対して、0.5〜1.3である、請求項2〜6のいずれか1項に記載の金属箔と樹脂フィルムのラミネート用接着剤。
- 前記ポリウレタンポリオール(A)に含まれる水酸基数に対する、ポリイソシアネート(B)に含まれるイソシアナト基数の比率が、1〜15である、請求項2〜7のいずれか1項に記載の金属箔と樹脂フィルムのラミネート用接着剤。
- 溶剤(C)をさらに含む、請求項2〜8のいずれか1項に記載の金属箔と樹脂フィルムのラミネート用接着剤。
- 金属箔と樹脂フィルムが、請求項2〜9のいずれか1項に記載の金属箔と樹脂フィルムのラミネート用接着剤から得られる接着剤層を介して積層された、積層体。
- 前記金属箔がアルミニウム箔であり、前記樹脂フィルムが熱融着性樹脂フィルムを含有する、請求項10に記載の積層体。
- 前記金属箔の厚さが10〜100μmであり、前記樹脂フィルムの厚さが9〜100μmである、請求項10又は11に記載の積層体。
- 請求項10〜12のいずれか1項に記載の積層体を用いて得られる、電池外装用包装材。
- 請求項13に記載の電池外装用包装材を用いて得られる、電池ケース。
- 請求項13に記載の電池外装用包装材を深絞り成形又は張り出し成形する、電池ケースの製造方法。
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