TWI312787B - Process for producing a porous polymeric memberane - Google Patents

Process for producing a porous polymeric memberane Download PDF

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TWI312787B
TWI312787B TW092117807A TW92117807A TWI312787B TW I312787 B TWI312787 B TW I312787B TW 092117807 A TW092117807 A TW 092117807A TW 92117807 A TW92117807 A TW 92117807A TW I312787 B TWI312787 B TW I312787B
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solvent
solution
polymer
film
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John Mattingley Neville
Kronfli Esam
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Fife Batteries Limite
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Description

1312787 , ϊ 玖、發明說明: (—)發明所屬之技術領域 本發明係關於多孔性聚合物膜。本發明特別地關於一 種製造多孔性聚合物膜之方法及此膜在鋰電池中或在燃料 電池中之用途。 (二)先前技術 多年來已知製造具鋰金屬陽極、及其中可添加或插入 鋰離子之材料之陰極之電池。此電池可使用鋰鹽於有機液 體(如碳酸伸丙酯)中之溶液作爲電解質,及如濾紙或聚 丙烯之分隔件。更近來,亦已建議使用固態離子傳導聚合 物作爲電解質。對於二次或可充電鋰電池,使用鋰金屬陽 極並不令人滿意,因爲枝狀物生長引發問題。現在可藉由 使用可在非常低電壓可逆地添加鋰離子之材料(如石墨) ,造成所謂之「鋰離子」、「搖椅」、或「搖擺」鋰充電 電池組,而排除此問題。這些鋰電池係基於在循環之充電 及放電部份時,其不僅含鋰金屬,亦含鋰離子在兩種添加 材料間來回搖擺之原理操作。
Gozdz等人(美國專利5,296,318)已提議一種聚合物 電解質,其包括75至92%氟亞乙烯與8至25%六氟丙烯之 共聚物,摻合鋰鹽與相容性溶劑,如碳酸伸乙酯/碳酸伸丙 酯混合物,而且由在如四氫呋喃之低沸點溶劑中之溶液流 延。GB 2 309 701 B專利(AE A Technology)敘述聚合電解 質組成物之黏附性可藉由將適當單不飽合基接枝至聚合物 鏈上而增強,而且在此情形,聚合物鏈可爲均一聚合物PVdF 1312787 ,或主要包括氟亞乙烯之共聚物或三聚物。亦可藉由首先 製造聚合物材料之多孔性膜,然後將此膜浸於鋰鹽於有機 溶劑之溶液中使電解質溶液組合聚合物膜,而製造固態聚 合物電解質,如EP 0 7 30 3 1 6 A專利(Elf Atochem)所述 。然而,製造多孔性膜之已知方法難以得到實質上大小均 勻之微孔及控制所得膜之多孔性。 燃料電池使用多孔性膜分隔陽極與陰極。此膜一般爲 多層組合件且可包括,例如,多孔性膜及一或更多層擴散 層。需要改良之膜以改良氣體至燃料電池板之均勻輸送。 (三)發明內容 本發明提供一種製造多孔性聚合物膜之方法,此方法 包括: a)製備在溶劑/非溶劑混合物中含戴亞乙烯之含聚合物之 溶液,其係藉由在加入溶劑前將聚合物分散於非溶劑中 t b )使此溶液保持在高溫直到聚合物完全溶劑合化; c )流延此溶液形成薄層;及 d )將此薄層乾燥形成膜。 此聚合物一般主要包括氟亞乙烯。因此,此聚合物可 爲均一聚合物,如聚氟亞乙烯(PVdF),或例如,氟亞乙烯 與六氟丙烯之共聚物,或三聚物。一般而言,較佳等級之 聚合物爲PVdF均一聚合物Solvay Solef 1015或6020,共 聚物 Solvay Solef 20615 或 20815 或 Atochem 2801,及含 氟亞乙烯、六氟丙烯與氯三氟乙烯之三聚物,如W0 02/11230 -6- 1312787 專利所述。 此聚合物亦可爲其中聚合物鏈主要包括氟亞乙烯之聚 合物,其上接枝單不飽合羧酸、磺酸或磷酸、酯、或醯胺 。接枝於聚合物鏈上之單體應在碳鏈R -中僅具有一個雙鍵 ,及一或更多個羧酸基-COOH、磺酸基-S020H、膦酸基-P〇(〇H)2、酯基-COOR’、或醯胺基-CONH2。通常單體越小, 碳鏈R -上具有少於5個碳原子,則越佳。例如,丙烯酸; 巴豆酸、乙烯基乙酸、甲基丙烯酸(其爲丁烯酸之異構物 );戊烯酸之異構物,如烯丙基乙酸等。亦可使用對應之 醯胺(及經取代醯胺)。在酯中,R’基可爲甲基、乙基或 丁基;例如,可使用如丙烯酸甲酯或丙烯酸丁酯之酯。一 些較佳之接枝單體爲丙烯酸或二甲基丙烯醯胺,但是一定 範圍之其他加入最終基之單體亦爲適當的。 接枝可藉照射法完成。例如,聚合物鏈基質及接枝單 體材料可一起接受連續或斷續照射;或更佳爲基質在接觸 單體材料前預先照射。此照射可使用電子束、加馬射線或X _ 射線。此照射因產生自由基而明顯地活化基質(聚合物鏈 )。接枝程度係由許多因素決定,最重要爲聚合物基質藉 照射預先活化之程度、活化聚合物接觸接枝單體材料之時 間長度、單體可穿透聚合物之程度、及聚合物與單體接觸 時之溫度。所得材料之接枝程度希望爲最終重量之2至20% ’更佳爲3至12%,例如,5%或10%。 其他之成分亦可存在於溶液中,例如,黏度改良劑, 如羧甲基纖維素,及表面張力改良劑,如草酸或順丁烯二 -7 - 1312787 酸。 將聚合物混合非溶劑形成漿液,然後加入溶劑形成均 質溶液。一般而言’形成聚合物與非溶劑之漿液且攪拌加 熱至約6 0 °C,較佳爲在非金屬容器中(例如,玻璃,或塑 膠’如聚丙烯),然後快速地加入溶劑(例如,5秒鐘內約 1公升)。 如果聚合物先混合溶劑,然後將非溶劑加入溶液,則 如此產生微凝膠,使得溶液不安定且不產生可再製膜。 非溶劑爲單獨使用時不溶解聚合物之液體。非溶劑應 不僅溶於溶劑中’亦應以實質上所有之比例與溶劑互溶。 —般而言’非溶劑之沸點比溶劑高,較佳爲高2 0 °C,更佳 爲高40 °C或更多。非溶劑之實例包括含6至20個碳原子之 醇類,如辛醇、癸醇與十二碳醇,及其混合物,較佳爲癸 醇、十二碳醇、及其混合物。特佳非溶劑爲十二碳醇與癸 醇之50:50混合物或僅十二碳醇。 溶劑爲可使聚合物溶解或膨脹之液體。此溶劑可選自 ,例如,酮類、醚類、N,N-二甲基甲醯胺(DMF)、N,N -二甲 基乙醯胺(DMA )、N,N-二乙基乙醯胺、N -甲基-2-吡咯啶酮 (NMP)、六甲基磷醯胺、四甲脲、與二甲基亞楓(DM SO)、或 其混合物。DMF與NMP爲較佳溶劑。更佳爲,NMP爲此溶劑 〇 溶液中非溶劑對溶劑之比例可不同。一般而言,溶劑/ 非溶劑混合物中之非溶劑比例爲2至3 0重量%,較佳爲5 至15重量%,更佳爲7至10重量%。 一 8 _ 1312787 溶液中之聚合物量通常爲3至30重量%,較佳爲5至20 重量%,更佳爲8至1 5重量%。 聚合物之溶解係在高溫發生。高溫爲高於室溫(取爲 2〇°C )之溫度。選擇之溫度係與使用之聚合物及溶劑/非溶 劑組合,及發生溶劑合化之時間量有關。一般而言,高溫 爲至少40°C,更常爲至少50°C,例如,55T:。如果溶劑合 化爲發生長期時間’則可使用較低之溫度。 —般而言,溶劑合化發生數日。此溶劑合化過程持續 直到聚合物完全溶劑合化。所需之確實溶劑合化時間視溶 劑/非溶劑混合物、聚合物之選擇、及使用之溫度而不同。 —般而言,溶劑合化發生4至14日,較佳爲5至10曰, 而且最佳爲5至7日。例如,視溶液中之非溶劑對溶劑比 例而定,PVdF (Solvay Solef 6020 / 1 00 1 )於 N-甲基-2-吡 咯啶酮及癸醇與十二碳醇之50:50混合物一般在5至14曰 中完全溶劑合化,一般爲10日。溶劑合化過程時之凝膠形 成緩慢而可忽略。溶劑合化亦爲不形成微凝膠而發生。 一旦聚合物完全溶劑合化,則此溶液在室溫安定數週 。因此,溶液之黏度不隨時間改變,及溶液之顏色維持固 定,而且溶劑或非溶劑不自溶液分離。此外,在流延時, 此溶液形成具一致性質之可再製膜。因此’立即將溶液流 延成膜爲不必要的。 此溶液一般流延於非多孔性基板上,如鋁箔或My 1 a r 膜。鋁箔一般爲約20微米厚,而Mylar膜一般爲約loo微 米厚。如果陽極或陰極係由不太多孔性之材料製成,則此 -9- 1312787 溶液亦可流延於陽極或陰極上。 在流延溶液時,一般在基板上將溶液流延成小於0 . 5 毫米厚,較佳爲小於0.3毫米厚之薄層。
膜係藉由在乾燥機中一般在至少兩個連續乾燥區中乾 燥而形成;此膜不接觸任何液體。較佳爲,乾燥機具有三 或四個乾燥區,最佳爲四個乾燥區。在各區中維持不同之 溫度,而且溫度按膜轉移方向在各區增加。在使用於移動 網上製造膜之刀輥連續法之乾燥區中之典型溫度値如下: 第一區 50°C 至 120°C 第二區 80°C 至 150°C。 典型之溫度配對可爲,例如,第一區爲65 °C及第二區爲 100°C,或第一區爲95°C及第二區爲120t。如果此機器具 有三或四個乾燥區,則各區之溫度變化可更緩和。例如, 在此機器具有四個乾燥區之處,各區可依序設爲65t、75 °C、95°C、及 110°C。 移動網之速度一般範圍爲0.2至5.0米/分鐘。網速視 乾燥區長度及區數量而不同。機器具有越多區,則網可較 快地行進而對膜性質無負面影響。 此溶液係在氣體存在下乾燥形成膜。在一個具體實施 例中,此氣體爲乾燥氣體,例如,乾燥空氣。例如,可使 用具低於-20 °C之露點之空氣’例如,-35 °C至-37 °C。然而 ,此氣體不需爲無水。此氣體亦可爲潮濕空氣,例如,在 1 6 °C於3 4%相對濕度之周圍條件供應之空氣。然而,如果空 氣濕度改變,則膜之滲透力亦改變。 -10- 1312787 所得多孔性聚合物膜可藉由改變非溶劑對溶劑之比例 、聚合物對溶劑/非溶劑之比例、第一與第二乾燥區之溫度 、及移動網之速度而控制其多孔性。 製造之膜之多孔性可在G u r 1 e y機上測量。如此產生使 用此機器測量不同膜之相對多孔性之指標。此機器測量1 00 立方米之空氣在小標準壓力差(i.215 kP a)通過一平方英 吋(6 . 45平方公分)膜之時間秒數。如此造成已知爲Gur ley 數或Gurley値之讀數。其亦可表示成具有單位Gurley秒 數。產生400至600之Gurley數(Gurley秒數)之商業膜 爲可得的。具<60之Gur 1 ey數之膜在用於電池組時趨於縮 短。然而,其適合用於燃料電池。具50至200,更佳爲60 至100之Gurley數之膜在本發明之內容中較佳。隨Gurley 數增加,膜之多孔性降低,表示空氣難以通過膜。視孔之 分布而定,其係由於具較小孔或較少較大孔之膜所造成。 依照本發明可製造薄至5微米之膜。因此,此膜具有 至少5微米,較佳爲1〇至30微米,更佳爲15至25微米 ,最佳爲17至22微米之厚度。 本發明之一個優點爲可製造具適合用於電池組之強度 之薄膜。此薄膜亦不縮短。 在第二態樣中,本發明提供一種包括含氟亞乙烯之聚 合物之膜’其具有5至30微米之厚度及5至300之Gurley 數(Gur 1 ey秒數)。此膜較佳爲具有50至200,更佳爲60 至100’最佳爲70至90之Gurley數。此膜迄今尙不可得 -11- 1312787 本發明亦提供本發明之膜或依照本發明製造之膜在電 池組中作爲分隔件之用途。此膜適合用於一定範圍之不同 型式電池組,例如,鎳-鎘、鎳金屬氫化物、鋰離子、與鋰 聚合物電池組。膜之可控制多孔性與厚度及這些膜之高強 度使其對此用途特別有利。 本發明亦提供本發明之膜或依照本發明製造之膜在燃 料電池中之用途。本發明亦提供含本發明膜之層壓物及此 層壓物在燃料電池中之用途。 (四)實施方式 本發明現在藉實例更詳細地敘述。 實例 這些實例中所述之膜所示之Gu r 1 ey數係在美國紐約州 Troy , 514 Fulton Street 之 Gurley Instruments 之 Automatic Densometer 4340 型上得到。 實例1 將100克具有0.210公升/克之固有黏度(DMF,25t )之PVdF (Solef 6020 )分散於70克辛醇中。將漿液攪拌 且加入900克之DMF。將混合物在55°C攪拌1日且在55°C 維持又6日,直到達成完全溶劑合化。 使用刀輥塗覆系統,將此溶液流延於以0 · 5米/分鐘移 動之聚酯網上。將刀葉間隙設爲0.32毫米,而且第1區之 乾燥區溫度爲651及第2區爲1〇〇 °C。如此造成具17微米 厚度及3 2 Gu r 1 e y秒數之空氣滲透力之最終微多孔性膜。 將第1區之乾燥溫度增至80°C及第2區爲l〇5°C,而製 -12- 1312787 造具17微米厚度及85 Gurley秒數之空氣滲透力之膜。 進一步將第1區之乾燥溫度增至95°C及第2區爲1 10°C ,而製造具17微米厚度及93 Gurley秒數之空氣滲透力之 膜。 實例2 將100克具有0.210公升/克之固有黏度(DMF,25 °C )之PVdF (Solef 6020 )分散於80克癸醇中。將漿液攪拌 且加入900克之NMP。如實例1所述,將混合物攪拌及加熱 直到達成完全溶劑合化。 使用刀輥流延系統,將此溶液流延於以0 . 5米/分鐘移 動之聚酯網上。將刀葉間隙設爲0.32毫米。乾燥區溫度及 膜性質敘述於以下表1。 表1 實例2.1 實例2.2 乾燥區溫度,第1區(°c) 95 110 乾燥區溫度,第2區(°C) 110 130 膜厚(微米) 14 16 空氣滲透力(Gurley秒數) 12 40 實例3 將100克具有0.210公升/克之固有黏度(DMF,25°C )之PVdF (Solef 6020 )分散於70克之癸醇與十二碳醇之 1 : 1 (重量比)混合物中。將漿液攪拌且加入900克之NMP 。將混合物在5 5 °C攪拌1日且在5 5 °C維持又1 0日,直到達 成完全溶劑合化。 -13- 1312787 ......." 使用刀輥塗覆系統,將此溶液流延於以0 . 5米/分鐘移 動之聚酯網上。將刀葉間隙設爲0 · 3 2毫米。乾燥區溫度及 膜性質敘述於以下表2。 ^_2. 實例3.1 實例3.2 乾燥區溫度,第1區(°c) 75 110 乾燥區溫度,第2區(°C) 110 130 膜厚(微米) 13 18 空氣滲透力(Gurley秒數) 70 180 眚例4 將100克具有0.210公升/克之固有黏度(DMF,25°C )之PVdF (Solef 6020 )分散於100克之癸醇與十二碳醇之 1 : 1 (重量比)混合物中。將槳液攪拌且加入900克之NMP 。如實例3所述,將混合物攪拌及加熱直到達成完全溶劑 合化。 使用刀輥塗覆系統,將此溶液流延於以0.5米/分鐘移 動之聚酯網上。將刀葉間隙設爲〇 . 3 2毫米。乾燥區溫度及 膜性質敘述於以下表3。 1312787 實例4.1 實例4.2 乾燥區溫度,第1區(°c) 75 110 乾燥區溫度,第2區(°C) 110 130 膜厚(微米) 22 24 空氣滲透力(Gurley秒數) 9 55 由以上之實例可了解,如果乾燥器爲較高之溫度’及 如果非溶劑之比例變小,則多孔性變小(即,Gu r 1 ey數增 加)。如果非溶劑與溶劑間之沸點差大於25°C,則膜品質 通常改良。 實例5 將1〇〇克具有0.210公升/克之固有黏度(DMF,25°C )之PVdF (Solef 6020 )分散於100克十二碳醇中。將漿液 攪拌且加入900克之NMP。如實例1所述,將混合物攪拌及 加熱直到達成完全溶劑合化。 使用刀輥塗覆系統,將此溶液流延於以〇 . 5米/分鐘移 動之聚酯網上。將刀葉間隙設爲0.30毫米。乾燥區溫度及 膜性質敘述於以下表4。 表 4 實例5 乾燥區溫度,第1區(°c) 75 乾燥區溫度,第2區(°C) 110 膜厚(微米) 24 空氣滲透力(Gurley秒數) 76 實例6 1312787 將100克具有0.210公升/克之固有黏度(DMF,25°C )之PVdF (Solef 6020 )分散於80克十二碳醇中。將漿液 攪拌且加入9 00克之NMP。如實例1所述,將混合物攪拌及 加熱直到達成完全溶劑合化。 使用刀輥塗覆系統,將此溶液流延於以0 . 5米/分鐘移 動之聚酯網上。將刀葉間隙設爲0 . 3 2毫米。乾燥區溫度及 膜性質敘述於以下表5。 表5 實例6 乾燥區溫度,第1區(°c) 85 乾燥區溫度,第2區rc) 110 膜厚(微米) 22 空氣滲透力(Gurley秒數) 146 實例7
將100克具有0.210公升/克之固有黏度(DMF,25°C )之PVdF (Solef 6020 )分散於60克十二碳醇中。將漿液 攪拌且加入900克之NMP。如實例1所述,將混合物攪拌及 加熱直到達成完全溶劑合化。 使用刀輥塗覆系統,將此溶液流延於以〇 . 5米/分鐘移 動之聚酯網上。將刀葉間隙設爲〇.3〇毫米。乾燥區溫度及 膜性質敘述於以下表6。
-16- 1312787 實例7 乾燥區溫度,第1區rc) 85 乾燥區溫度,第2區(°C) 110 膜厚(微米) 19 空氣滲透力(Gurley秒數) 88
% -17

Claims (1)

  1. rBnm i公苦积 ί 第 92 1 1 78 07 號 年4 月 3〇Γ ./ί.Χ 多孔性聚合物膜之製法」專利案 (2 009年4月修正) 拾、申請專利範圍: 1· 一種製造多孔性聚合物膜之方法,此方法包括·· a) 在溶劑/非溶劑混合物中製備含有含氟亞乙烯之聚合物 之溶液’該非溶劑之比例爲2至3 0重量%,其係藉由 在加入溶劑前將聚合物分散於非溶劑中,其中非溶劑 之沸點比溶劑高; b) 使此溶液保持在至少40 °C之高溫直到聚合物完全溶劑 鲁 合化(solvated); c) 流延此溶液形成薄層;及 d) 將此薄層乾燥形成膜。 2 .如申請專利範圍第1項乞方法,其中此溶液包括聚氟亞 乙烯(PVdF)。 3 .如申請專利範圍第1項之方法,其中溶劑爲N,N-二甲基 甲醯胺(DMF)、N,N-二甲基乙醯胺(DMA)、或N-甲基-2-吡咯啶酮(NMP)。 · 4.如申請專利範圍第1項之方法,其中非溶劑爲辛醇、癸 醇、十二碳醇、或其混合物。 5 .如申請專利範圍第1項之方法’其中此溶液溶劑合化至 多14日。 6 .如申請專利範圍第1項之方法,其中在氟亞乙烯上接枝 單不飽合羧酸、磺酸或磷酸、酯、或醯胺基。
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