JP7324517B2 - 粘着フィルム、複合膜、全固体電池及び複合膜の製造方法 - Google Patents
粘着フィルム、複合膜、全固体電池及び複合膜の製造方法 Download PDFInfo
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- JP7324517B2 JP7324517B2 JP2020549416A JP2020549416A JP7324517B2 JP 7324517 B2 JP7324517 B2 JP 7324517B2 JP 2020549416 A JP2020549416 A JP 2020549416A JP 2020549416 A JP2020549416 A JP 2020549416A JP 7324517 B2 JP7324517 B2 JP 7324517B2
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Description
-複合膜の構成-
図1は、本発明の実施形態に係る複合膜の構成を模式的に示す断面図である。同図に示すように、本実施形態の複合膜10は、光硬化型の粘着剤組成物の硬化物により形成された樹脂膜1と、樹脂膜1の第1の面及び第2の面から端部が露出した状態で樹脂膜1に単層で固定された固体粒子3とを備えている。樹脂膜1は、後に説明するように、粘着剤組成物により形成された半硬化状態である第1の状態の粘着剤層に光を照射させることにより形成されている。本明細書において、「半硬化状態」とは、任意の基材上に塗工された場合に膜形状を維持できる程度の粘度を有しているとともに、後工程によってさらに硬化させて、硬化状態である第2の状態とすることが可能な状態のことを指すものとする。
図2は、本発明の実施形態に係る複合膜を用いて作製された全固体電池の一例を示す断面図である。本実施形態に係る全固体電池はリチウムイオン二次電池であるが、リチウムイオン一次電池など、他の種類の全固体電池であってもよい。
本実施形態の正極層15の構成は特に限定されず、全固体電池に一般的に用いられている材料及び構成を適用することができる。正極層15は、例えば、正極活物質を含む正極活物質層をアルミ箔等の集電体の表面に形成することにより得ることができる。
負極層17には、全固体電池に一般的に用いられている材料及び構成を適用することができる。例えば、負極活物質を含む負極活物質層を銅等の集電体の表面に形成することにより得ることができる。負極活物質層の厚みや密度は、電池の使用用途等に応じて適宜決定される。
<両面粘着フィルム>
本実施形態の複合膜10を作製するには、まず基材を有さない光硬化型の粘着フィルム20を準備する。図3は、本発明の実施形態に係る製造方法において用いられる粘着フィルム20の一例を示す断面図である。図3は模式図であるので、各部材の厚みや粒子の形状は同図に示す例に限定されない。
図4(a)~(d)は、本発明の実施形態に係る複合膜の製造方法を示す断面図である。本実施形態の製造方法には、ロール状の粘着フィルム20を用いてもよいし、シート状に裁断された粘着フィルム20を用いてもよい。
<粘着剤組成物1~6の調製>
まず、市販のUV硬化型の粘着剤A(主剤)に硬化剤としてトルエンジイソシアネート(TDI)-トリメチルプロパン(TMP)付加物を主剤100質量部に対して2.0質量部、4.0質量部、6.0質量部、8.0質量部をそれぞれ添加し、光重合開始剤としてα-ヒドロキシアルキルフェノン(iGM社製「Omnirad184」)をそれぞれ1.2質量部、1.2質量部、1.7質量部、1.7質量部添加することで、粘着剤組成物1~4を調製した。粘着剤Aは、アクリル系ポリマー及びビニルエステルを固形分として含有し、トルエン等の溶媒を含んでいた。表1に、粘着剤組成物の組成を示す。
粘着剤組成物1、4をそれぞれ用いて乾燥後の粘着剤層の膜厚が10μmである粘着フィルムを作製した。次に、図4(a)~(c)に示す手順により、これらの粘着フィルムと平均粒径が50μmの固体粒子Aとを用いて複合膜を作製した。熱プレス工程は、熱プレス機を用いて120℃、圧力2MPa/cm2、5分間の条件で行った。熱プレス後の粘着剤層には、400mJ/cm2の紫外線(UV)を照射して、これを硬化させた。ここで、固体粒子Aは、球状樹脂の表面にニッケルメッキ及び金メッキをこの順で形成することにより設けられた、導電性粒子である。
粘着剤組成物1、2、4をそれぞれ用いて乾燥後の粘着剤層の膜厚が15μmである粘着フィルムを作製した。次に、実施例1、2と同様の手順により、これらの粘着フィルムと平均粒径が50μmの固体粒子Aとを用いて複合膜を作製した。
粘着剤組成物1、2、4をそれぞれ用いて乾燥後の粘着剤層の膜厚が20μmである粘着フィルムを作製した。次に、実施例1、2と同様の手順により、これらの粘着フィルムと平均粒径が50μmの固体粒子Aとを用いて複合膜を作製した。
粘着剤組成物5を用いて乾燥後の粘着剤層の膜厚が20μmである粘着フィルムを作製した。次に、実施例1、2と同様の手順により、これらの粘着フィルムと平均粒径が50μmの固体粒子Aとを用いて複合膜を作製した。ただし、熱プレス後の粘着剤層には、1000mJ/cm2の紫外線(UV)を照射して、これを硬化させた。
粘着剤組成物1、4をそれぞれ用いて乾燥後の粘着剤層の膜厚が10μmである粘着フィルムを作製した。次に、実施例1、2と同様の手順により、これらの粘着フィルムと平均粒径が30μmの固体粒子Bとを用いて複合膜を作製した。固体粒子Bは、直径約30μmの球状樹脂の表面がニッケルメッキで覆われることにより導電性粒子となった粒子である。
粘着剤組成物6を用いて乾燥後の粘着剤層の膜厚が10μmである粘着フィルムを作製した。次に、粘着剤層上に平均粒径が50μmの固体粒子Aを分散させた状態で載置した後、実施例1、2と同じ条件で熱プレスを行って複合膜を作製した。粘着剤層は熱プレスの前に既に硬化されているため、UV照射は行わなかった。
膜厚が20μmの二軸延伸ポリプロピレンフィルム(OPPフィルム)上に固体粒子Aを分散させて載置した後、実施例1、2と同じ条件で熱プレスを行った。比較例2における充填率は、17.3~39.3%であった。しかし、固体粒子AはOPPフィルムの表面に存在しているだけであり、フィルム内に埋め込まれていなかった。
粘着剤組成物1を用いて乾燥後の粘着剤層の膜厚が25μmである粘着フィルムを作製した。次に、実施例1、2と同様の手順により、この粘着フィルムと平均粒径が50μmの固体粒子Aとを用いて複合膜を作製した。
粘着剤組成物1を用いて乾燥後の粘着剤層の膜厚が30μmである粘着フィルムを作製した。次に、実施例1、2と同様の手順により、この粘着フィルムと平均粒径が50μmの固体粒子Aとを用いて複合膜を作製した。
粘着剤組成物1、4をそれぞれ用いて乾燥後の粘着剤層の膜厚が15μmである粘着フィルムを作製した。次に、実施例1、2と同様の手順により、これらの粘着フィルムと固体粒子Bとを用いて複合膜を作製した。
粘着剤組成物1、4をそれぞれ用いて乾燥後の粘着剤層の膜厚が20μmである粘着フィルムを作製した。次に、実施例1、2と同様の手順により、これらの粘着フィルムと固体粒子Bとを用いて複合膜を作製した。
粘着剤組成物1を用いて乾燥後の粘着剤層の膜厚がそれぞれ25μm及び30μmである粘着フィルムを作製した。次に、実施例1、2と同様の手順により、これらの粘着フィルムと固体粒子Bとを用いて複合膜を作製した。
<固体粒子の露出状態の評価方法>
上述の実施例及び比較例にて作製された複合膜から第3の剥離ライナー及び第1の剥離ライナーを剥離し、目視により両面の光沢の有無を確認した。光沢が失われている面では固体粒子が露出していると判断した。また、複合膜を膜厚方向に切断し、切断面を光学顕微鏡で観察することにより、固体粒子の露出の有無を判断した。
表1に示す粘着剤組成物1~6について、UV照射前の23℃、100℃、120℃での貯蔵弾性率と、UV照射後の23℃、100℃、120℃での貯蔵弾性率とを測定した。具体的には、ポリエステルからなるフィルムに粘着剤組成物1~6を塗布し、溶剤を揮発させて粘着剤層を形成し、直径8mmの円形に切り出し、試験片とした。得られた試験片を直径8mmのパラレルプレートにエポキシ樹脂で固定し、そこに直径25mm以下のプレートを密着させて粘着剤層の貯蔵弾性率を測定した。粘着剤層の厚みは約1mmとした。測定にはレオメーター(TAインスツルメント社製「AR2000ex」)を用いた。測定温度-40℃~160℃、昇温速度3℃/min、ひずみ0.05%、周波数1Hzの条件で測定を行った。
表1に示す粘着剤組成物1~4を用いて乾燥後の膜厚が10μm、15μm、20μm、25μmの粘着剤層を有する粘着フィルムを作製し、当該粘着フィルムから幅20mm、長さ20mmの試験片を切り出した。また、膜厚が20μmのOPPフィルムからも他と同サイズの試験片を切り出した。次いで、23℃-50%RH雰囲気下にて、試験片から剥離シートを剥離し、露出した粘着剤層の表面のプローブタックを測定した。OPPフィルムの試験片については、そのままの状態でプローブタックを測定した。粘着剤層の表面に対して直径5mmφのステンレス製プローブを接触荷重1.5N/cm2で1秒間接触させた後、プローブを5cm/secの速度で粘着層の表面から離した。このときのプローブの剥がれる力を測定した。測定を10回行い、最大値と最小値を除いた8回の測定結果の平均値を求めた。
上記の実施例及び比較例で作製された複合膜から軽剥離側の第3の剥離ライナーを剥がした状態で目視により膜の収縮度合いを確認した。膜の収縮が全く見られない場合には、「優」と判断し、一部収縮が見られるものの、使用のしやすさに影響を与えない場合には「良」と判断し、収縮が大きい場合には「不良」と判断した。
上記の実施例及び比較例で作製された複合膜を光学顕微鏡にて500倍に拡大し、一定面積の複合膜内に含まれる固体粒子の個数を数えた。固体粒子A、Bとも粒径のばらつきが非常に小さいことから、直径Dの固体粒子が占める面積をπD2/4として、複合膜における固体粒子の充填率を算出した。
粘着剤組成物1~6のUV照射前後の貯蔵弾性率の測定結果を表2にまとめた。また、粘着剤組成物1~4を用いて作製された粘着剤層のUV照射前とUV照射後の測定結果を表3にまとめた。なお、表2及び表3で斜線を引いてある欄については、測定を行っていないことを示す。
1a 粘着剤層
3 固体粒子
5 第1の剥離ライナー
7 第2の剥離ライナー
9 第3の剥離ライナー
10 複合膜
11 圧力
15 正極層
17 負極層
20 粘着フィルム
Claims (13)
- 光硬化型の粘着剤組成物を含む粘着剤層を備えた粘着フィルムの前記粘着剤層の第1の面の上に単層の固体粒子を分散させて載置する工程と、
前記粘着剤層の前記第1の面を第1の剥離ライナーで覆い、反対側の第2の面を第2の剥離ライナーにより覆った状態で圧力及び熱をかけることにより、前記粘着剤層内に前記固体粒子を押し込む工程と、
前記粘着剤層に光を照射することにより、前記粘着剤層を硬化させ、前記第1の面及び前記第2の面から端部が露出した状態で前記固体粒子が固定された樹脂膜を形成する工程とを備え、
前記固体粒子を分散させる際における前記粘着剤層の膜厚tは、前記固体粒子の平均粒径をDとするとき、0.45D以下である、複合膜の製造方法。 - 請求項1に記載の複合膜の製造方法において、
前記粘着剤層の120℃での周波数1Hzにおける貯蔵弾性率は、1×102Pa以上、1×106Pa以下であり、
前記樹脂膜の23℃での周波数1Hzにおける貯蔵弾性率は、硬化前の前記粘着剤層の23℃での周波数1Hzにおける貯蔵弾性率よりも大きく、且つ1×105Pa以上である、複合膜の製造方法。 - 請求項1又は2に記載の複合膜の製造方法において、
平面視における(前記固体粒子の外形面積の合計値)/(前記固体粒子が固定された領域の前記樹脂膜の面積)の値は、30%以上80%以下である、複合膜の製造方法。 - 光硬化型の粘着剤組成物の硬化物により形成された樹脂膜と、
前記樹脂膜に単層で固定された固体粒子とを備え、
前記固体粒子は、すべてが前記樹脂膜の第1の面及び第2の面の両面から端部が露出し、
前記樹脂膜は、温度23℃で相対湿度50%におけるプローブタック試験による測定値が0N/cm 2 である、複合膜。 - 請求項4に記載の複合膜において、
平面視における(前記固体粒子の外形面積の合計値)/(前記固体粒子が固定された領域の前記樹脂膜の面積)の値は、30%以上80%以下である、複合膜。 - 請求項4又は5に記載の複合膜において、
平面視における(前記固体粒子の外形面積の合計値)/(前記固体粒子が固定された領域の前記樹脂膜の面積)の値は、55%以上80%以下である、複合膜。 - 請求項4~6のいずれか1項に記載の複合膜において、
前記樹脂膜は、23℃での周波数1Hzにおける貯蔵弾性率が、1×105Pa以上である、複合膜。 - 請求項4~7のいずれか1項に記載の複合膜において、
前記樹脂膜は、23℃での周波数1Hzにおける貯蔵弾性率が、1×106Pa以上である複合膜。 - 請求項4~8のいずれか1項に記載の複合膜において、
前記固体粒子は、イオン伝導性を有する固体電解質粒子である、複合膜。 - 請求項4~8のいずれか1項に記載の複合膜において、
前記固体粒子は、導電性粒子である、複合膜。 - 請求項9に記載の複合膜と、
前記複合膜の前記第1の面上に、前記固体粒子と接するように設けられた固体の正極層と、
前記複合膜の前記第2の面上に、前記固体粒子と接するように設けられた固体の負極層と、を備えている全固体電池。 - 請求項1~3のいずれか1項に記載の製造方法に用いる粘着フィルムであって、
光硬化型の粘着剤組成物を含み且つ基材を有さない、固体粒子を固定するための粘着剤層を備え、
前記粘着剤層は、光の照射を受けると第1の状態から貯蔵弾性率が上昇して第2の状態へ移行し、
前記粘着剤層の膜厚tは、前記固体粒子の平均粒径をDとするとき、0.45D以下である、粘着フィルム。 - 請求項12に記載の粘着フィルムにおいて、
前記粘着剤層は、前記第1の状態における120℃での周波数1Hzにおける貯蔵弾性率が1×102Pa以上1×106Pa以下であり、前記第2の状態における23℃での周波数1Hzにおける貯蔵弾性率が前記第1の状態における23℃での周波数1Hzにおける貯蔵弾性率よりも大きく、且つ1×105Pa以上である、粘着フィルム。
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