WO2016093242A1 - アルミナスラリー - Google Patents
アルミナスラリー Download PDFInfo
- Publication number
- WO2016093242A1 WO2016093242A1 PCT/JP2015/084426 JP2015084426W WO2016093242A1 WO 2016093242 A1 WO2016093242 A1 WO 2016093242A1 JP 2015084426 W JP2015084426 W JP 2015084426W WO 2016093242 A1 WO2016093242 A1 WO 2016093242A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- alumina
- porous film
- mass
- slurry
- coating layer
- Prior art date
Links
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 title claims abstract description 197
- 239000002002 slurry Substances 0.000 title claims abstract description 107
- 238000000034 method Methods 0.000 claims abstract description 95
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- 239000002612 dispersion medium Substances 0.000 claims abstract description 35
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims abstract description 26
- 239000002245 particle Substances 0.000 claims abstract description 20
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 18
- 229910052757 nitrogen Inorganic materials 0.000 claims abstract description 13
- 238000003795 desorption Methods 0.000 claims abstract description 6
- 239000011247 coating layer Substances 0.000 claims description 79
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- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 12
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Images
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- C09D127/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Coating compositions based on derivatives of such polymers
- C09D127/02—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Coating compositions based on derivatives of such polymers not modified by chemical after-treatment
- C09D127/12—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Coating compositions based on derivatives of such polymers not modified by chemical after-treatment containing fluorine atoms
- C09D127/16—Homopolymers or copolymers of vinylidene fluoride
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
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- C09D129/00—Coating compositions based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an alcohol, ether, aldehydo, ketonic, acetal, or ketal radical; Coating compositions based on hydrolysed polymers of esters of unsaturated alcohols with saturated carboxylic acids; Coating compositions based on derivatives of such polymers
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- C—CHEMISTRY; METALLURGY
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Definitions
- the present invention relates to an alumina slurry. More specifically, an alumina slurry suitable for forming a coating layer excellent in air permeability, heat resistance, etc., constituting a laminated porous film that can be used as a battery separator, etc., a laminated porous film obtained by using this, and the The present invention relates to a separator for a non-aqueous electrolyte secondary battery using a laminated porous film and a non-aqueous electrolyte secondary battery.
- the polymer porous body with many fine communication holes is made of ultra-pure water, purification of chemicals, separation membranes used for water treatment, waterproof and moisture-permeable films used for clothing, sanitary materials, etc., or secondary batteries, etc. It is used in various fields such as battery separators.
- Secondary batteries are widely used as power sources for portable devices such as OA, FA, household appliances or communication devices.
- portable devices using lithium ion secondary batteries are increasing because they have a high volumetric efficiency and are reduced in size and weight when installed in devices.
- large-scale secondary batteries are being researched and developed in many fields related to energy / environmental issues, including road leveling, uninterruptible power supply (UPS), and electric vehicles. Since it is excellent in voltage and long-term storage properties, the use of lithium ion secondary batteries, which are one type of non-aqueous electrolyte secondary batteries, is expanding.
- the working voltage of a lithium ion secondary battery is usually designed with an upper limit of 4.1V to 4.2V.
- the aqueous solution causes electrolysis and cannot be used as an electrolyte. Therefore, so-called non-aqueous electrolytes using organic solvents are used as electrolytes that can withstand high voltages.
- the solvent for the non-aqueous electrolyte a high dielectric constant organic solvent capable of allowing more lithium ions to be present is used, and organic carbonate compounds such as propylene carbonate and ethylene carbonate are mainly used as the high dielectric constant organic solvent. in use.
- a highly reactive electrolyte such as lithium hexafluorophosphate is dissolved in the solvent and used.
- a separator is interposed between the positive electrode and the negative electrode from the viewpoint of preventing an internal short circuit.
- the separator is required to have insulating properties due to its role.
- a porous film is used as a separator.
- SD characteristic A characteristic that contributes to the safety of the battery separator is a shutdown characteristic (hereinafter referred to as “SD characteristic”).
- This SD characteristic is a function that can prevent the subsequent increase in temperature inside the battery because the pores of the porous film are blocked when the temperature is about 100 to 150 ° C., and as a result, ion conduction inside the battery is blocked. It is.
- the lowest temperature among the temperatures at which the micropores of the porous film are blocked is referred to as a shutdown temperature (hereinafter referred to as “SD temperature”).
- SD temperature shutdown temperature
- porous film used as the separator as described above for example, a multilayer porous film having a porous coating layer containing a metal oxide such as alumina and a resin binder on at least one surface of a polyolefin resin porous film. Proposed (Patent Documents 1 to 5).
- the coating layer is formed, for example, by coating and drying a slurry prepared by blending alumina, a resin binder, and other components.
- Patent Document 6 includes an inorganic oxide powder such as ⁇ -alumina that satisfies specific conditions, a binder, and a solvent, and has an insulating property on at least one surface of a positive electrode, a negative electrode, or a separator constituting a lithium ion secondary battery.
- a slurry for forming a porous membrane is disclosed.
- Patent Document 7 describes a method for wet pulverizing powders such as alumina in order to obtain a stable slurry with little change in viscosity even when a small amount of a dispersant is used.
- preliminary pulverization is performed separately from the multistage pulverization, and the pulverized media is switched to a smaller one at a predetermined timing in the multistage pulverization.
- a grinding method is disclosed.
- Patent Document 8 as a method for producing an alumina organic solvent dispersion having excellent dispersion stability in various organic solvents, metal aluminum or a hydrolyzable aluminum compound is hydrolyzed in an organic solvent and peptized in the presence of an acid. A method for obtaining an alumina organic solvent dispersion is disclosed.
- the slurry is hydrolyzed with 4 to 10 moles of water of metal aluminum or hydrolyzable aluminum compound to form an alumina slurry, and 0.01 to 0.2 mol of metal aluminum or hydrolyzable aluminum compound. It is characterized by peptization in the presence of double organic sulfonic acids.
- a slurry in which alumina or the like is dispersed in a dispersion medium is used, but the surface state of inorganic particles such as alumina changes due to slight differences in firing conditions or storage conditions. Cheap. For this reason, when the slurry is stored for a long period of time, the viscosity is not stable, and as a result, the productivity of the laminated porous film is not stable.
- a laminated porous film is produced using a coating liquid containing a slurry whose viscosity is not stable, a phenomenon occurs such that the surface smoothness of the laminated porous film is significantly impaired due to uneven viscosity of the coating liquid.
- Patent Document 6 has an object to provide an inorganic oxide powder suitable for forming an inorganic oxide porous film excellent in ion permeability, heat resistance, and insulation, but viscosity stability when slurryed. There is no disclosure or suggestion regarding improvement.
- the powder pulverization step is required a plurality of times, and the operation is complicated.
- Patent Document 8 is a document relating to a method for producing an alumina organic solvent dispersion.
- the slurry is further dissolved to obtain an alumina concentration of 10 to 15% by weight and an average particle size of less than 0.1 ⁇ m.
- An alumina dispersion is obtained.
- the dispersion medium is preferably aqueous, and the concentration of alumina in the slurry and the average particle diameter of alumina are preferably higher than this.
- such alumina is more easily aggregated and settled in the dispersion medium, and when used as a slurry, it is expected to be inferior in long-term storage.
- An object of the present invention is to obtain an alumina slurry that is excellent in viscosity stability during long-term storage when alumina is dispersed in an aqueous solvent to form a slurry.
- an alumina slurry obtained by dispersing alumina satisfying specific conditions in a dispersion medium can solve the above problems, and have completed the present invention. That is, the present invention relates to the following.
- the alumina slurry is characterized in that the content of the alumina in the slurry is 30% by mass or more and 70% by mass or less, and the content of water in the dispersion medium is 50% by mass or more.
- a laminated porous film having a coating layer on at least one side of a polyolefin-based resin porous film, wherein the coating layer contains the alumina slurry and the resin binder according to any one of the above [1] to [3] A laminated porous film which is formed using a liquid.
- the resin binder is at least one selected from polyvinyl alcohol, polyvinylidene fluoride, carboxymethylcellulose, polyacrylic acid, and polyacrylic acid derivatives.
- a laminated porous film having a coating layer on at least one surface of a polyolefin-based resin porous film when a dispersion containing the slurry and a resin binder is used In the production of the film, since a uniform coating layer can be stably formed by a coating method, the productivity of the film can be stabilized.
- the laminated porous film is suitably used for a separator for non-aqueous electrolyte secondary batteries.
- the expression “main component” includes the intention to allow other components to be contained within a range that does not interfere with the function of the main component, unless otherwise specified.
- the content includes 50% by mass or more, preferably 70% by mass or more, and particularly preferably 90% by mass or more (including 100% by mass).
- X to Y (X and Y are arbitrary numbers) is described, it means “preferably larger than X” and “preferably smaller than Y” with the meaning of “X or more and Y or less” unless otherwise specified. Is included.
- the alumina slurry of the present invention is an alumina slurry obtained by dispersing alumina in a dispersion medium, and the alumina has a primary average particle size of 0.1 ⁇ m or more and 1.0 ⁇ m or less, and the alumina satisfies the following conditions ( 1), the content of the alumina in the slurry is 30% by mass or more and 70% by mass or less, and the content of water in the dispersion medium is 50% by mass or more. .
- alumina used in the alumina slurry of the present invention examples include ⁇ alumina, ⁇ alumina, ⁇ alumina, ⁇ alumina, and pseudo boehmite.
- alpha alumina is preferable from a viewpoint that it is chemically inactive when incorporating in a battery.
- the alumina used in the present invention has a primary average particle size of 0.1 ⁇ m or more and 1.0 ⁇ m or less.
- the primary average particle diameter of the alumina is preferably 0.2 ⁇ m or more, more preferably 0.3 ⁇ m or more.
- the primary average particle diameter of the alumina is preferably 0.8 ⁇ m or less, more preferably 0.7 ⁇ m or less.
- the alumina slurry of the present invention is excellent in viscosity stability during long-term storage.
- Dv1 (M) When the value of Dv1 (M) is less than or equal to the value of Dv1 (80), the viscosity of the alumina slurry increases during long-term storage, and the slurry, the dispersion containing the slurry, and the dispersion are used. The productivity of the laminated porous film obtained in this way decreases.
- Dv1 (80) is preferably 0.001 to 0.01 mL / g, more preferably 0.002 to 0.01 mL / g, and still more preferably 0.003 to 0.01 mL / g. It is a range.
- Dv1 (M) is preferably in the range of 0.003 to 0.05 mL / g, more preferably 0.004 to 0.05 mL / g, and still more preferably 0.005 to 0.05 mL / g.
- the pore diameter r1 and pore volume Dv1 (M), Dv1 (80) of alumina are values measured by a nitrogen desorption method based on JIS Z8831-2 (2010).
- the value of Dv1 (80) / Dv1 (M), which is the ratio of Dv1 (M) to Dv1 (80), is less than 1.00, preferably 0.90 or less, more preferably 0.85 or less, More preferably, it is 0.80 or less.
- the lower limit value of the ratio is not particularly limited, but is preferably 0.20 or more, more preferably 0.25 or more, and further preferably 0.30 or more.
- the alumina preferably further satisfies the following condition (2) from the viewpoint of viscosity stability during long-term storage of the resulting alumina slurry.
- Dv2 (80) is preferably 0.001 to 0.01 mL / g, more preferably 0.002 to 0.01 mL / g, and still more preferably 0.003 to 0.01 mL / g. It is a range.
- Dv2 (M) is preferably in the range of 0.005 to 0.03 mL / g, more preferably 0.006 to 0.03 mL / g, and still more preferably 0.007 to 0.03 mL / g.
- the pore diameter r2 and pore volume Dv2 (M), Dv2 (80) of alumina are values measured by a nitrogen adsorption method based on JIS Z8831-2 (2010).
- the value of Dv2 (80) / Dv2 (M), which is the ratio of Dv2 (M) to Dv2 (80), is preferably less than 1.00, more preferably 0.95 or less, and even more preferably 0.8. 90 or less.
- the lower limit value of the ratio is not particularly limited, but is preferably 0.20 or more, more preferably 0.40 or more, and further preferably 0.60 or more.
- alumina satisfying the above condition (1), preferably further satisfying the condition (2) can be appropriately selected and used. Further, by treating alumina not satisfying the above conditions under high temperature and high humidity conditions, an alumina satisfying the condition (1), preferably further satisfying the condition (2) is prepared, and this may be used for the alumina slurry of the present invention. it can.
- the treatment conditions at this time are preferably a temperature of 60 to 100 ° C. and a relative humidity of 50 to 100%, more preferably a temperature of 70 to 100 ° C. and a relative humidity of 60 to 90%.
- the treatment time can be appropriately selected within the range in which alumina that satisfies the condition (1), preferably the condition (2) is obtained.
- alumina satisfying the condition (1), preferably the condition (2), and having excellent viscosity stability when slurried is presumed as follows.
- transition alumina other than ⁇ -alumina partially contained in the alumina undergoes a volume change and the pores are expanded.
- the viscosity stability in the slurry is improved.
- the specific surface area of the alumina used in the present invention is preferably 5.0 m 2 / g or more and 15.0 m 2 / g or less. If a specific surface area is 5.0 m ⁇ 2 > / g or more, the viscosity stability at the time of long-term storage of the alumina slurry obtained will improve. Further, when the laminated porous film obtained using the alumina slurry of the present invention is incorporated as a separator in a non-aqueous electrolyte secondary battery, the penetration of the electrolyte solution becomes faster, and the productivity of the non-aqueous electrolyte secondary battery is good. Become.
- the specific surface area of alumina is more preferably 5.5 m 2 / g or more, further preferably 6.0 m 2 / g or more, more preferably 13.0 m 2 / g or less, and further preferably 11.0 m. 2 / g or less.
- the “specific surface area of alumina” is a value measured by a constant volume gas adsorption method, and can be specifically measured by the method described in Examples.
- the alumina slurry of the present invention is obtained by dispersing the alumina in a dispersion medium.
- the dispersion medium is not particularly limited as long as it can disperse alumina in a moderately uniform and stable manner.
- the cost and environmental load, the viscosity stability during long-term storage of the alumina slurry, and the alumina slurry When used for forming a coating layer in a laminated porous film described later, from the viewpoint of coating properties when the coating layer is formed by a coating method, the content of water in the dispersion medium is 50% by mass or more, and 70 % By mass or more is preferable, 80% by mass or more is more preferable, and 85% by mass or more is more preferable.
- the content of water in the dispersion medium is 100% by mass or less, preferably 99% by mass or less, more preferably 95% by mass or less.
- the dispersion medium that can be used other than water include N-methylpyrrolidone, N, N-dimethylformamide, N, N-dimethylacetamide, water, dioxane, acetonitrile, lower alcohol, glycols, glycerin, lactic acid ester, and the like. Is mentioned.
- the dispersion medium preferably contains a lower alcohol having 1 to 4 carbon atoms.
- the lower alcohol is preferably a monohydric alcohol having 1 to 4 carbon atoms, more preferably at least one selected from methanol, ethanol and isopropyl alcohol. These can be used alone or in combination of two or more.
- the dispersion medium is preferably a mixed dispersion medium of water and a lower alcohol having 1 to 4 carbon atoms, more preferably a mixed dispersion medium of water and a monovalent alcohol having 1 to 4 carbon atoms, and water and isopropyl alcohol.
- a mixed dispersion medium is more preferable.
- the content of the lower alcohol having 1 to 4 carbon atoms in the dispersion medium is preferably 1% by mass or more, more preferably 5% by mass or more, preferably 20% by mass or less, more preferably 15% by mass or less. It is.
- the content of the alumina in the alumina slurry of the present invention is 30% by mass or more, preferably 40% by mass or more, more preferably from the viewpoints of coating properties and quick drying properties of the dispersion using the alumina slurry. It is 45 mass% or more.
- the content of alumina in the alumina slurry is 70% by mass or less, preferably 65% by mass or less, more preferably 60% by mass. It is as follows.
- ⁇ Method for producing alumina slurry> There is no restriction
- the dispersion treatment method is not particularly limited.
- a dispersion treatment using a bead mill from the viewpoint of preventing mixing of the ground product.
- types of beads used in the bead mill include glass beads and ceramic beads. From the viewpoint of the hardness of the beads, ceramic beads are preferable, and one or more ceramic beads selected from titania, alumina, zirconia, and zircon are more preferable.
- the bead diameter is preferably 0.1 mm or more and 3 mm or less, more preferably 1.5 mm or less, and still more preferably 0.8 mm or less from the viewpoint of the dispersibility of alumina.
- the filling rate of beads in the bead mill is preferably 30% or more, more preferably 50% or more, still more preferably 70% or more, and preferably 90% or less.
- the temperature and average residence time during the dispersion treatment are no particular restrictions. For example, when continuous dispersion is performed using a bead mill, the dispersion is usually performed at a temperature of 10 to 50 ° C. and an average residence time of 0.1 to 60 minutes. Processing can be performed.
- the alumina slurry of the present invention is excellent in viscosity stability during long-term storage. Specifically, the alumina slurry obtained by mixing and dispersing the alumina and the dispersion medium was used at a temperature of 25 ° C. using a B-type viscometer (“TVB10H” manufactured by Toki Sangyo Co., Ltd.).
- the ratio ⁇ 72 / ⁇ 1 of the slurry viscosity ⁇ 72 is preferably less than 10, more preferably less than 5, and still more preferably less than 3.
- the values of ⁇ 24 / ⁇ 1 and ⁇ 72 / ⁇ 1 are both preferably 0.1 or more, more preferably 0.2 or more, and still more preferably 0.3 or more.
- the values of ⁇ 24 and ⁇ 72 are both preferably in the range of 10 to 4000 mPa ⁇ s, more preferably in the range of 15 to 3800 mPa ⁇ s, and in the range of 20 to 3600 mPa ⁇ s. More preferably. If the values of ⁇ 24 / ⁇ 1 and ⁇ 72 / ⁇ 1 and the values of ⁇ 24 and ⁇ 72 are within such a range, the viscosity stability during long-term storage of the alumina slurry is sufficient, and the slurry is laminated. Productivity is stabilized when used for forming a coating layer of a porous film. Moreover, the coating property at the time of forming the coating layer is also improved.
- the alumina slurry of the present invention can be used for abrasives, molding of ceramic molded bodies, formation of non-aqueous electrolyte secondary battery electrodes or separator coating layers, reflection layers of light reflecting materials, and the like. In particular, it is suitably used for forming a coating layer of a laminated porous film described later.
- the laminated porous film of the present invention is a laminated porous film having a coating layer on at least one surface of a polyolefin resin porous film, and the coating layer uses a dispersion containing the alumina slurry of the present invention and a resin binder described later. Is formed. Below, each component which comprises the laminated porous film of this invention is demonstrated.
- the laminated porous film of the present invention has a polyolefin resin porous film from the viewpoint of chemical stability inside the battery.
- the polyolefin resin used for the polyolefin resin porous film include homopolymers or copolymers obtained by polymerizing ⁇ -olefins such as ethylene, propylene, 1-butene, 4-methyl-1-pentene, and 1-hexene. . Two or more of these homopolymers or copolymers can also be mixed.
- a polypropylene-based resin or a polyethylene-based resin it is preferable to use a polypropylene-based resin or a polyethylene-based resin, and it is particularly preferable to use a polypropylene-based resin from the viewpoint of maintaining the mechanical strength, heat resistance, and the like of the laminated porous film of the present invention.
- Polypropylene resins that can be used for polyolefin resin porous films include homopolypropylene (propylene homopolymer), or propylene and ethylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-heptene, Examples thereof include random copolymers or block copolymers with ⁇ -olefins such as octene, 1-nonene and 1-decene.
- homopolypropylene is more preferably used from the viewpoint of maintaining the mechanical strength and heat resistance of the laminated porous film of the present invention.
- the polypropylene resin preferably has an isotactic pentad fraction (mmmm fraction) exhibiting stereoregularity of 80 to 99%. More preferably, it is 83 to 98%, and still more preferably 85 to 97%. If the isotactic pentad fraction is 80% or more, the mechanical strength of the film is good. On the other hand, the upper limit of the isotactic pentad fraction is defined by the upper limit obtained industrially at the present time, but this is not the case when a more regular resin is developed in the industrial level in the future. is not.
- the isotactic pentad fraction (mmmm fraction) is the same direction for all five methyl groups that are side chains with respect to the main chain of carbon-carbon bonds composed of any five consecutive propylene units. Means the three-dimensional structure located at or its proportion. Signal assignment of the methyl group region is as follows. It conforms to Zambelli et al ("Macromolecules", 8, 687 (1975)).
- M w / M n which is a parameter indicating the molecular weight distribution of the polypropylene resin is preferably 2.0 to 10.0. More preferred is 2.0 to 8.0, and still more preferred is 2.0 to 6.0. The smaller the M w / M n is, the narrower the molecular weight distribution is. However, when M w / M n is less than 2.0, there are problems such as deterioration of extrusion moldability, and industrial production. It is also difficult. On the other hand, when M w / M n exceeds 10.0, the low molecular weight component increases, and the mechanical strength of the laminated porous film tends to decrease. M w / M n of the polypropylene resin is measured by a GPC (gel permeation chromatography) method.
- GPC gel permeation chromatography
- the density of the polypropylene resin is preferably 0.890 to 0.970 g / cm 3 , more preferably 0.895 to 0.970 g / cm 3 , and 0.900 to 0.970 g / cm 3. More preferably.
- a density of 0.890 g / cm 3 or more is preferable because an appropriate SD characteristic can be exhibited when the laminated porous film is used for a separator for a non-aqueous electrolyte secondary battery.
- 0.970 g / cm 3 or less is preferable in that appropriate SD characteristics can be expressed and stretchability is maintained.
- the density of the polypropylene resin is measured according to JIS K7112 (1999) using a density gradient tube method.
- the melt flow rate (MFR) of the polypropylene resin is not particularly limited, but usually the MFR is preferably 0.5 to 15 g / 10 minutes, and 1.0 to 10 g / 10 minutes. It is more preferable. When the MFR is 0.5 g / 10 min or more, the resin has a high melt viscosity at the time of molding, and sufficient productivity can be ensured. On the other hand, the mechanical strength of the obtained laminated porous film can be sufficiently maintained by setting it to 15 g / 10 min or less.
- the MFR of the polypropylene resin is measured under conditions of a temperature of 230 ° C. and a load of 2.16 kg according to JIS K7210 (1999).
- the method for producing the polypropylene resin is not particularly limited, and a known polymerization method using a known olefin polymerization catalyst, for example, a multisite catalyst or a metallocene catalyst represented by a Ziegler-Natta type catalyst. And suspension polymerization method, melt polymerization method, bulk polymerization method, gas phase polymerization method, and bulk polymerization method using a radical initiator.
- a known polymerization method using a known olefin polymerization catalyst for example, a multisite catalyst or a metallocene catalyst represented by a Ziegler-Natta type catalyst.
- suspension polymerization method melt polymerization method, bulk polymerization method, gas phase polymerization method, and bulk polymerization method using a radical initiator.
- polypropylene resin examples include trade names “Novatech PP”, “WINTEC” (manufactured by Nippon Polypro Co., Ltd.), “Notio”, “Toughmer XR” (manufactured by Mitsui Chemicals, Inc.), “Zeras”.
- Polyethylene resins that can be used for polyolefin resin porous films include low-density polyethylene, linear low-density polyethylene, linear ultra-low-density polyethylene, medium-density polyethylene, high-density polyethylene, and copolymers based on ethylene.
- ⁇ -olefins having 3 to 10 carbon atoms such as ethylene and propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene; vinyl esters such as vinyl acetate and vinyl propionate; acrylic Copolymerization with one or more comonomers selected from unsaturated carboxylic acid esters such as methyl acrylate, ethyl acrylate, methyl methacrylate, ethyl methacrylate, and unsaturated compounds such as conjugated dienes and non-conjugated dienes. Polymer or multi-component copolymer or a mixed composition thereof. .
- the ethylene unit content of the ethylene polymer is usually more than 50% by mass.
- polyethylene resins at least one polyethylene resin selected from low density polyethylene, linear low density polyethylene, and high density polyethylene is preferable, and high density polyethylene is more preferable.
- the density of the polyethylene resin is preferably 0.910 to 0.970 g / cm 3 , more preferably 0.930 to 0.970 g / cm 3 , and 0.940 to 0.970 g / cm 3. 3 is more preferable.
- a density of 0.910 g / cm 3 or more is preferable because an appropriate SD characteristic can be exhibited when the laminated porous film is used for a separator for a non-aqueous electrolyte secondary battery.
- 0.970 g / cm 3 or less is preferable in that appropriate SD characteristics can be expressed and stretchability is maintained.
- the density of the polyethylene resin is measured according to JIS K7112 (1999) using a density gradient tube method.
- the melt flow rate (MFR) of the polyethylene resin is not particularly limited, but usually the MFR is preferably 0.03 to 30 g / 10 minutes, and preferably 0.3 to 10 g / 10 minutes. It is more preferable. When the MFR is 0.03 g / 10 min or more, the melt viscosity of the resin during the molding process is sufficiently low, so that productivity is excellent. On the other hand, if it is 30 g / 10 minutes or less, sufficient mechanical strength can be obtained.
- the MFR of the polyethylene resin is measured under conditions of a temperature of 190 ° C. and a load of 2.16 kg according to JIS K7210 (1999).
- the production method of the polyethylene resin is not particularly limited, and is a known polymerization method using a known olefin polymerization catalyst, for example, a multisite catalyst represented by a Ziegler-Natta type catalyst or a metallocene catalyst.
- a polymerization method using a single site catalyst may be mentioned.
- As a polymerization method of the polyethylene resin there are a one-stage polymerization, a two-stage polymerization, or a multistage polymerization more than that, and any method of the polyethylene resin can be used.
- additives that are generally blended with the resin can be appropriately added to the polyolefin-based resin porous film as long as the effects of the present invention are not significantly impaired.
- recycled resin generated from trimming loss such as ears, silica, talc, kaolin, Inorganic particles such as calcium carbonate, pigments such as carbon black, flame retardants, weathering stabilizers, heat stabilizers, antistatic agents, melt viscosity modifiers, crosslinking agents, lubricants, nucleating agents, plasticizers, anti-aging agents, oxidation
- additives such as an inhibitor, a light stabilizer, an ultraviolet absorber, a neutralizer, an antifogging agent, an antiblocking agent, a slip agent, and a colorant.
- various resins and low molecular weight compounds such as waxes may be
- the polyolefin resin porous film may be a single layer or a laminate. Among them, a single layer of the polyolefin resin-containing layer (hereinafter sometimes referred to as “A layer”), within a range that does not interfere with the function of the A layer, the A layer and other layers (hereinafter referred to as “B layer”) Is sometimes preferred).
- the B layer may be a layer containing a polyolefin resin different from the A layer.
- a two-layer structure in which A layer / B layer is laminated a three-layer structure in which A layer / B layer / A layer, or B layer / A layer / B layer are laminated can be exemplified.
- the order of stacking with layers having other functions is not particularly limited. As the number of layers, four layers, five layers, six layers, and seven layers may be increased as necessary.
- the method for producing a polyolefin-based resin porous film can be suitably used a conventionally known method for producing a porous film, and is not particularly limited, but is usually a precursor for forming a polyolefin-based resin porous film.
- a method of forming a polyolefin-based resin porous film by producing a non-porous film-like material and making the same porous is preferable.
- a method for producing a non-porous membrane that is a precursor for forming a polyolefin-based resin porous film there is no particular limitation on the method for producing a non-porous membrane that is a precursor for forming a polyolefin-based resin porous film, and a known method can be used.
- a method may be used in which an extruder is used to melt a polyolefin resin or a mixture of a polyolefin resin as a raw material for a porous film and various additives, extrude from a T-die, and cool and solidify with a cast roll.
- a method of cutting a film-like material manufactured by a tubular method into a flat shape can be applied.
- the method for making the nonporous membrane-like material is not particularly limited, and a known method such as wet uniaxial or more stretched porous or dry uniaxial or more stretched porous can be used.
- a known method such as wet uniaxial or more stretched porous or dry uniaxial or more stretched porous can be used.
- the stretching method in stretching and stretching there are methods such as a roll stretching method, a rolling method, a tenter stretching method, and a simultaneous biaxial stretching method, and these methods are used alone or in combination of two or more to perform uniaxial stretching or biaxial stretching. Do. Among these, sequential biaxial stretching is preferable from the viewpoint of controlling the porous structure.
- stretching with a solvent as needed is also applied. Furthermore, for the purpose of improving dimensional stability, heat treatment or relaxation treatment can be performed after stretching.
- ⁇ crystal in the nonporous film-like material when a polypropylene resin is used for the polyolefin resin porous film, it is preferable to generate a so-called ⁇ crystal in the nonporous film-like material. If ⁇ -crystals are generated in the non-porous film-like material, even if no filler or other additive is used, fine pores can be easily formed by stretching, so it has excellent air permeability. A polyolefin resin porous film can be obtained.
- a method of generating ⁇ crystals in a non-porous film of a polypropylene resin a method in which a substance that promotes the formation of ⁇ crystals of the polypropylene resin is not added, or as described in Japanese Patent No. 3739481
- ⁇ crystal nucleating agent examples include the following, but are not particularly limited as long as they increase the generation and growth of ⁇ crystals of the polypropylene resin. Further, ⁇ crystal nucleating agents may be used in combination of two or more. Examples of the ⁇ crystal nucleating agent include amide compounds; tetraoxaspiro compounds; quinacridones; iron oxides having a nanoscale size; potassium 1,2-hydroxystearate, magnesium benzoate or magnesium succinate, magnesium phthalate, etc.
- Alkali or alkaline earth metal salts of carboxylic acids represented by: aromatic sulfonic acid compounds represented by sodium benzenesulfonate or sodium naphthalenesulfonate; di- or triesters of dibasic or tribasic carboxylic acids; phthalocyanine blue Phthalocyanine pigments typified by, for example; a two-component compound comprising component A which is an organic dibasic acid and a component B which is an oxide, hydroxide or salt of a Group 2 metal in the periodic table; a cyclic phosphorus compound; Composition composed of magnesium compounds And the like.
- Other specific types of nucleating agents are described in JP-A No. 2003-306585, JP-A No. 08-144122, and JP-A No. 09-194650.
- ⁇ crystal nucleating agents examples include ⁇ crystal nucleating agent “NJESTER NU-100” manufactured by Shin Nippon Rika Co., Ltd.
- polypropylene resins to which a ⁇ crystal nucleating agent is added include polypropylene resins “Bepol® B-022SP” manufactured by Aristech, and polypropylene resins “Beta ( ⁇ ) -PP®BE60-7032” manufactured by Borealis. ", A polypropylene resin” BNX BETAPP-LN "manufactured by Mayzo.
- the blending ratio of the ⁇ crystal nucleating agent to be added to the polypropylene resin constituting the polyolefin resin porous film needs to be appropriately adjusted depending on the type of the ⁇ crystal nucleating agent or the composition of the polypropylene resin.
- the amount is preferably 0.0001 to 5 parts by mass with respect to 100 parts by mass of the resin. Further, 0.001 to 3 parts by mass is more preferable, and 0.01 to 1 part by mass is further preferable. If the blending ratio of the ⁇ crystal nucleating agent is 0.0001 parts by mass or more with respect to 100 parts by mass of the polypropylene resin, the ⁇ crystal of the polypropylene resin can be generated and grown sufficiently at the time of production.
- the laminated porous film is used as a separator for a non-aqueous electrolyte secondary battery, sufficient ⁇ crystal activity is expressed, and a desired air permeability is obtained.
- the blending ratio of the ⁇ crystal nucleating agent is 5 parts by mass or less with respect to 100 parts by mass of the polypropylene resin, the cost is advantageous, and the ⁇ crystal nucleating agent bleeds onto the polyolefin resin porous film surface. There is no such thing and it is preferable.
- the polyolefin resin porous film has a laminated structure
- its production method is roughly divided into the following three types depending on the order of the porous formation and lamination.
- (I) A method in which each layer is made porous, and then the layers made porous are laminated or bonded with an adhesive or the like.
- (Ii) A method of laminating each layer to produce a laminated nonporous film-like material, and then making the nonporous film-like material porous.
- Iii A method in which one of the layers is made porous and then laminated with another layer of non-porous film to make it porous.
- the method (ii) from the viewpoint of simplification of the process and productivity, and in particular, in order to ensure the interlayer adhesion between the two layers, a laminated nonporous film-like material is obtained by coextrusion.
- a method of forming a porous layer after preparing is particularly preferable.
- the thickness of the polyolefin resin porous film is preferably 5 to 100 ⁇ m, more preferably 8 to 50 ⁇ m, and still more preferably 10 to 30 ⁇ m. If the thickness of the polyolefin resin porous film is 5 ⁇ m or more, when the laminated porous film of the present invention is used as a separator for a non-aqueous electrolyte secondary battery, substantially necessary electrical insulation can be obtained. Even when a large force is applied to the protruding portion of the electrode, it is difficult to break through the separator and is excellent in safety.
- the electrical resistance can be reduced when the laminated porous film of the present invention is used as a separator for a non-aqueous electrolyte secondary battery. It can be secured sufficiently.
- the laminated porous film of the present invention has a coating layer on at least one surface of the polyolefin resin porous film.
- the coating layer is formed by using the alumina slurry of the present invention and a dispersion containing a resin binder (hereinafter also referred to as “dispersion for forming a coating layer”), and includes at least alumina and a resin binder.
- the alumina slurry used for the dispersion is as described above.
- the resin binder acts as a binder for alumina in the coating layer, and is used to improve the adhesion between the coating layer containing a large amount of alumina and the polyolefin resin porous film.
- the resin binder used for the coating layer the coating layer containing a large amount of alumina and the polyolefin resin porous film can be bonded well, and is electrochemically stable, and the laminated porous film can be used for non-aqueous electrolyte secondary batteries. As long as it is stable with respect to an organic electrolyte when used as a separator, it can be used without particular limitation.
- Ethylene-acrylic acid copolymers such as polymers, polyvinylidene fluoride, polyvinylidene fluoride-hexafluoropropylene, polyvinylidene fluoride-trichloroethylene, polytetrafluoroethylene, fluorine-based rubber, styrene-butadiene rubber, nitrile butadiene rubber, polybutadiene rubber , Polyacrylonitrile, polyacrylic acid and its derivatives, polymethacrylic acid and its derivatives, carboxymethyl cellulose, hydroxyethyl cellulose, cyanoethyl cellulose, polyvinyl alcohol, Roh ethyl polyvinyl alcohol, polyviny
- resin binders may be used alone or in combination of two or more.
- polyoxyethylene, polyvinyl alcohol, polyvinylidene fluoride are used because they are relatively stable in a dispersion medium mainly composed of water used in the dispersion for forming a coating layer and in an electrolytic solution inside the battery.
- Polyvinyl pyrrolidone, polyacrylonitrile resin, styrene-butadiene rubber, carboxymethyl cellulose, polyacrylic acid and its derivatives, and maleic acid-modified polyolefins are preferred, from polyvinyl alcohol, polyvinylidene fluoride, carboxymethyl cellulose, polyacrylic acid, and polyacrylic acid derivatives. At least one selected is more preferable.
- the content of alumina with respect to the total amount of alumina and resin binder is preferably in the range of 80% by mass or more and 99.9% by mass or less.
- the content of the alumina is more preferably 92% by mass or more, further preferably 95% by mass or more, and particularly preferably 98% by mass or more.
- the coating layer exhibits excellent air permeability, and the binding property of alumina can also be maintained. Therefore, it is preferable to mix the alumina slurry and the resin binder in the coating layer forming dispersion so that the content ratio of the alumina and the resin binder falls within the above range.
- the acid component It is preferable to add an acid component to the coating layer forming dispersion. By blending the acid component, aggregation of alumina in the dispersion for forming the coating layer is suppressed, and the viscosity stability during long-term storage of the dispersion is improved, so that a uniform coating layer can be formed. .
- the acid component may remain in the coating layer as an acid itself, or may remain in the coating layer as a salt formed by reaction with an alkaline impurity in the coating layer.
- the acid component preferably has a first acid dissociation constant (pK a1 ) of 5 or less in a dilute aqueous solution at 25 ° C. and no second acid dissociation constant (pK a2 ) or 7 or more.
- acid components having such characteristics include lower primary carboxylic acids such as formic acid, acetic acid, propionic acid, and acrylic acid; nitro acids such as nitric acid and nitrous acid; and halogens such as perchloric acid and hypochlorous acid.
- Oxo acids such as hydrochloric acid, hydrofluoric acid, hydrobromic acid; phosphoric acid, salicylic acid, glycolic acid, lactic acid, ascorbic acid, erythorbic acid, and the like. These may be used alone or in combination of two or more. Among these, at least one selected from formic acid, acetic acid, nitric acid, hydrochloric acid, and phosphoric acid is preferable from the viewpoint that pH can be lowered by addition in a small amount, availability, and acid stability are high. When the acid component satisfies the above-described conditions, the aggregation of alumina is suppressed, and the viscosity stability during long-term storage of the coating layer-forming dispersion is improved.
- the acid component is blended in the coating layer forming dispersion in the range of 10 mass ppm or more and 10000 mass ppm or less.
- the blending amount of the acid component is more preferably 100 mass ppm or more and 9000 mass ppm or less, and further preferably 1000 mass ppm or more and 8000 mass ppm or less. If the compounding amount of the acid component in the dispersion for forming a coating layer is 10 mass ppm or more, a dispersion having excellent viscosity stability during long-term storage can be obtained, and a uniform coating layer can be formed.
- the non-aqueous electrolyte secondary battery Does not adversely affect performance.
- the dispersion for forming a coating layer may contain a dispersion aid, a stabilizer, a thickener, etc. in order to improve the dispersion stability and optimize the viscosity suitable for forming the coating layer.
- a dispersion medium may be further added. It is preferable to use a dispersion medium in which alumina, a resin binder, and other components can be dissolved or dispersed in a reasonably uniform and stable manner, and the same dispersion medium as exemplified in the alumina slurry can be used.
- the dispersion for forming the coating layer can be prepared, for example, by mixing the alumina slurry of the present invention, the resin binder, and other components used as necessary, and further dispersing the treatment as necessary.
- a method for mixing and dispersing each component contained in the coating layer forming dispersion the same method as exemplified in the method for producing the alumina slurry can be used.
- the coating layer is formed using the above-described dispersion for forming a coating layer.
- the method for forming the coating layer include a co-extrusion method, a laminating method, and a coating method.
- the coating layer is preferably formed by a coating method. That is, it is preferable to form a coating layer by applying a coating layer-forming dispersion on at least one side of the polyolefin resin porous film.
- the dispersion for forming a coating layer may be applied only to one side of the polyolefin resin porous film or may be applied to both sides depending on the application. That is, in the laminated porous film of the present invention, the coating layer may be formed only on one side of the polyolefin-based resin porous film, or may be formed on both sides.
- the coating method of the coating layer forming dispersion is not particularly limited as long as it can realize a required layer thickness and coating area.
- gravure coater method small diameter gravure coater method, reverse roll coater method, transfer roll coater method, kiss coater method, dip coater method, knife coater method, air doctor coater method, blade coater method, rod coater method, squeeze coater method, cast Examples include a coater method, a die coater method, a screen printing method, and a spray coating method.
- the coating layer containing an alumina and a resin binder can be formed on the polyolefin resin porous film.
- the method for removing the dispersion medium is not particularly limited as long as it does not adversely affect the polyolefin resin porous film.
- a method of drying at a temperature below the melting point while fixing a polyolefin resin porous film, a method of drying under reduced pressure at a low temperature, and dipping in a poor solvent for the resin binder to solidify the resin binder and simultaneously extract the solvent The method etc. are mentioned.
- a coating layer is formed on the polyolefin resin porous film, and the laminated porous film of the present invention can be produced.
- the total thickness of the laminated porous film of the present invention can be appropriately selected depending on the application.
- the total thickness of the laminated porous film is preferably 5 to 100 ⁇ m, more preferably 8 to 50 ⁇ m, and still more preferably 10 to 30 ⁇ m.
- the total thickness is 5 ⁇ m or more, it is possible to obtain substantially the necessary electrical insulation as a separator for a non-aqueous electrolyte secondary battery.
- the thickness of the coating layer in the laminated porous film is preferably 0.5 ⁇ m or more, more preferably 1 ⁇ m or more, further preferably 2 ⁇ m or more, and particularly preferably 3 ⁇ m or more from the viewpoint of heat resistance.
- the thickness of the coating layer is preferably 90 ⁇ m or less, more preferably 50 ⁇ m or less, still more preferably 30 ⁇ m or less, and particularly preferably 10 ⁇ m or less from the viewpoint of ensuring communication and providing excellent air permeability.
- the thickness of the said coating layer means the thickness per layer.
- the porosity is preferably 30% or more, more preferably 35% or more, and further preferably 40% or more. If the porosity is 30% or more, it is possible to obtain a laminated porous film that ensures communication and has excellent air permeability.
- the porosity of the laminated porous film is preferably 70% or less, more preferably 65% or less, and further preferably 60% or less. If the porosity is 70% or less, the strength of the laminated porous film can be sufficiently maintained, which is preferable from the viewpoint of handling.
- the air permeability of the laminated porous film of the present invention is preferably 1000 sec / 100 mL or less, more preferably 10 to 800 sec / 100 mL, and further preferably 50 to 500 sec / 100 mL. If the air permeability is 1000 seconds / 100 mL or less, it is preferable that the laminated porous film has a communication property and can exhibit excellent air permeability characteristics.
- the air permeability represents the difficulty of air passage in the film thickness direction, and is specifically expressed as the time required for 100 mL of air to pass through the film. Therefore, it means that the smaller the numerical value is, the easier it is to pass through, and the higher numerical value is, the more difficult it is to pass.
- the air permeability of the laminated porous film of the present invention is low, it can be used for various applications. For example, when used as a separator for a non-aqueous electrolyte secondary battery, a low air permeability means that lithium ions can be easily transferred, which is preferable because battery performance is excellent.
- the air permeability (Gurley value) of the laminated porous film is measured by a method based on JIS P8117 (2009).
- the laminated porous film of the present invention preferably has SD characteristics when used as a battery separator.
- the air permeability after heating at 135 ° C. for 5 seconds is preferably 10,000 seconds / 100 mL or more, more preferably 25000 seconds / 100 mL or more, and further preferably 50000 seconds / 100 mL or more.
- the shrinkage rate at 150 ° C. is preferably less than 10% in both the longitudinal direction and the transverse direction, more preferably less than 9%, and less than 8%. Further preferred. If the shrinkage rate at 150 ° C. is less than 10%, even when abnormal heat is generated exceeding the SD temperature, it is suggested that the dimensional stability is good and the heat resistance is maintained, which prevents film breakage and prevents internal short circuit. The temperature can be improved. The lower limit of the shrinkage is 0%.
- the shrinkage rate of the laminated porous film can be measured, for example, by the following method.
- the coating layer is formed using the dispersion containing the alumina slurry of the present invention, a uniform coating layer can be obtained, and the surface smoothness of the coating layer is also improved.
- surface smoothness for example, using a fine shape measuring instrument ("ET4000A" manufactured by Kosaka Laboratory Co., Ltd.), a viewing angle of 300 ⁇ m ⁇ 400 ⁇ m was observed on the surface of the coating layer side of the laminated porous film, and more than the surroundings. It can be evaluated by counting the number of protrusions protruding from 5 ⁇ m or more (amount of roughness), and the smaller the amount of roughness, the better the surface smoothness.
- the amount of roughness is preferably less than 100 pieces / mm 2 , and more preferably less than 80 pieces / mm 2 , since film conveyance troubles and appearance defects can be reduced.
- the lower limit is not particularly limited and is ideally 0 piece / mm 2 , but in reality, it is preferably 10 ⁇ 10 piece / mm 2 or more.
- Nonaqueous electrolyte secondary battery a nonaqueous electrolyte secondary battery containing the laminated porous film of the present invention as a battery separator will be described with reference to FIG.
- Both electrodes of the positive electrode plate 21 and the negative electrode plate 22 are wound in a spiral shape so as to overlap each other via the battery separator 10, and the outside is stopped with a winding tape to form a wound body.
- the winding process will be described in detail.
- One end of the battery separator is passed between the slit portions of the pin, and the pin is slightly rotated to wind one end of the battery separator around the pin. At this time, the surface of the pin is in contact with the coating layer of the battery separator.
- the positive electrode and the negative electrode are arranged so as to sandwich the battery separator, and the pins are rotated by a winding machine to wind the positive and negative electrodes and the battery separator. After winding, the pin is pulled out of the wound object.
- the wound body integrally wound with the positive electrode plate 21, the battery separator 10 and the negative electrode plate 22 is accommodated in a bottomed cylindrical battery case and welded to the positive and negative electrode lead bodies 24 and 25.
- the electrolyte is injected into the battery can, and after the electrolyte has sufficiently penetrated into the battery separator 10 or the like, the positive electrode lid 27 is sealed around the opening periphery of the battery can via the gasket 26, and precharging and aging are performed.
- a cylindrical non-aqueous electrolyte secondary battery is produced.
- an electrolytic solution in which a lithium salt is used as an electrolytic solution and is dissolved in an organic solvent is used.
- the organic solvent is not particularly limited.
- esters such as propylene carbonate, ethylene carbonate, butylene carbonate, ⁇ -butyrolactone, ⁇ -valerolactone, dimethyl carbonate, methyl propionate or butyl acetate, nitriles such as acetonitrile, Examples include 2-dimethoxyethane, 1,2-dimethoxymethane, dimethoxypropane, 1,3-dioxolane, ethers such as tetrahydrofuran, 2-methyltetrahydrofuran or 4-methyl-1,3-dioxolane, or sulfolane.
- LiPF 6 lithium hexafluorophosphate
- a solvent obtained by mixing 2 parts by mass of methyl ethyl carbonate relative to ethylene carbonate 1 part by weight is preferred.
- an alkali metal or a compound containing an alkali metal integrated with a current collecting material such as a stainless steel net is used.
- the alkali metal include lithium, sodium, and potassium.
- the compound containing an alkali metal include an alloy of an alkali metal and aluminum, lead, indium, potassium, cadmium, tin or magnesium, a compound of an alkali metal and a carbon material, a low potential alkali metal and a metal oxide, and the like. Or a compound with a sulfide or the like.
- the carbon material may be any material that can be doped and dedoped with lithium ions, such as graphite, pyrolytic carbons, cokes, glassy carbons, a fired body of an organic polymer compound, Mesocarbon microbeads, carbon fibers, activated carbon and the like can be used.
- lithium cobalt oxide, lithium nickel oxide, lithium manganese oxide, manganese dioxide, metal oxide such as vanadium pentoxide or chromium oxide, metal sulfide such as molybdenum disulfide, etc. are used as active materials.
- These positive electrode active materials are combined with conductive additives and binders such as polytetrafluoroethylene as appropriate, and finished with a current collector material such as a stainless steel mesh as a core material. It is done.
- ⁇ Evaluation method> (1) Primary average particle diameter of alumina The primary average particle diameter of alumina was measured using a laser diffraction particle size distribution analyzer ("HORIBA LA-920" manufactured by Horiba, Ltd.) using sodium hexametaphosphate as a dispersant. .
- Pore diameter and pore volume of alumina The pore diameter and pore volume of alumina are determined based on JIS Z8831-2 (2010) by using “NOVA-1200” manufactured by Cantachrome Corporation. Then, the nitrogen partial pressure was gradually increased from 0.02 atm to 0.98 atm, and the amount of nitrogen adsorbed and desorbed on alumina was measured.
- Viscosity of Alumina Slurry was produced by the method described in Examples and Comparative Examples described below, and the viscosity of the alumina slurry after 1 hour, 24 hours, and 72 hours after production was measured using a B-type viscometer ( Using “TVB10H” manufactured by Toki Sangyo Co., Ltd.), it was measured at a peripheral speed of 100 rpm at a temperature of 25 ° C., and it was set as ⁇ 1 , ⁇ 24 , and ⁇ 72 (mPa ⁇ s), respectively. However, when the following applies, it is assumed that measurement cannot be performed normally, and in Table 1, “measurement impossible” is indicated. ⁇ When the viscosity fluctuates by 10% or more even after 3 minutes from the start of measurement ⁇ When cracks occur in the slurry during measurement
- Viscosity stability of alumina slurry (long-term storage) The viscosity stability of the alumina slurry was evaluated according to the following criteria.
- the total thickness of the laminated porous film was calculated as an average value obtained by measuring five in-plane areas of the laminated porous film with a 1/1000 mm dial gauge.
- Coating Layer Thickness was calculated as the difference between the total thickness of the laminated porous film after the coating layer was formed and the polyolefin resin porous film thickness.
- Roughness and surface smoothness Roughness is measured using a fine shape measuring instrument ("ET4000A" manufactured by Kosaka Laboratory Ltd.) on the coating layer side surface of the laminated porous film at a viewing angle of 300 ⁇ m ⁇ 400 ⁇ m. The number of convex portions protruding 5 ⁇ m or more from the surroundings was counted. The surface smoothness was evaluated according to the following criteria based on the roughness value. A: The amount of roughness is less than 100 pieces / mm 2 C: The amount of roughness is 100 pieces / mm 2 or more
- the raw material pellets were again put into an extruder, melted, extruded from a T die (die), and cooled and solidified with a casting roll at 124 ° C. to produce a film-like material.
- the film-like material was stretched 4.6 times in the longitudinal direction at 100 ° C. using a longitudinal stretching machine, then stretched 2.1 times in the transverse direction at 150 ° C. with a transverse stretching machine, and then heat-set at 153 ° C. Went.
- Example 1 Alumina (“LS-410” manufactured by Nippon Light Metal Co., Ltd., primary average particle size 0.48 ⁇ m, Dv1 (M) 0.0077 mL / g, Dv1 (80) 0.0077 mL / g, Dv2 (M) 0.0080 mL / g, Dv2 (80) 0.0080 mL / g, specific surface area 6.90 m 2 / g) was allowed to stand for 3 days in a constant temperature and humidity chamber set at a temperature of 80 ° C. and a relative humidity of 80%, and then allowed to cool and then taken out. . Table 1 shows the properties of the obtained treated alumina.
- the obtained alumina slurry was allowed to stand for 1 week, and then 61.8 parts by mass of the alumina slurry, 9.9 parts by mass of an aqueous solution of 5% by mass polyvinyl alcohol (“PVA-124” manufactured by Kuraray Co., Ltd.), ion exchange 28.3 parts by mass of water was mixed, and hydrochloric acid was added to a total amount of 70 ppm to obtain a dispersion for forming a coating layer having a solid content concentration of 33% by mass.
- PVA-124 polyvinyl alcohol
- the obtained dispersion for forming a coating layer was applied to the polyolefin resin porous film using a gravure roll (lattice type, number of lines: 25 L / inch, depth 290 ⁇ m, cell capacity 145 mL / m 2 ), and then 45 ° C. Were dried in a drying oven to form a coating layer, and a laminated porous film having a total thickness of 24 ⁇ m was obtained. Said evaluation was performed about the obtained laminated porous film. The results are shown in Table 1.
- Example 2 The alumina before the treatment was “LS-410” manufactured by Nippon Light Metal Co., Ltd. (primary average particle size 0.60 ⁇ m, Dv1 (M) 0.0074 mL / g, Dv1 (80) 0.0074 mL / g, Dv2 (M) 0 .0077 mL / g, Dv2 (80) 0.0077 mL / g, specific surface area 6.23 m 2 / g) except that the slurry was changed to an alumina slurry and a laminated porous film having a total thickness of 24 ⁇ m in the same manner as in Example 1. It produced and the said evaluation was performed. The results are shown in Table 1.
- Example 3 The untreated alumina was “LS-410” manufactured by Nippon Light Metal Co., Ltd. (primary average particle size 0.53 ⁇ m, Dv1 (M) 0.0062 mL / g, Dv1 (80) 0.0062 mL / g, Dv2 (M) 0 .0061 mL / g, Dv2 (80) 0.0061 mL / g, specific surface area 6.27 m 2 / g) except that the slurry was changed to an alumina slurry and a laminated porous film having a total thickness of 24 ⁇ m in the same manner as in Example 1. It produced and the said evaluation was performed. The results are shown in Table 1.
- Example 4 The alumina before the treatment was made by Nippon Light Metal Co., Ltd. “LS-410” (primary average particle size 0.66 ⁇ m, Dv1 (M) 0.0049 mL / g, Dv1 (80) 0.0049 mL / g, Dv2 (M) 0
- a laminate slurry having an alumina slurry and a total thickness of 24 ⁇ m was obtained in the same manner as in Example 1 except that the particle size was changed to 0073 mL / g, Dv2 (80) 0.0073 mL / g, and specific surface area 6.04 m 2 / g. It produced and the said evaluation was performed. The results are shown in Table 1.
- Example 1 Alumina slurry and a laminated porous film having a total thickness of 25 ⁇ m were prepared in the same manner as in Example 1 except that the same lot of alumina as used in Example 1 was used without being put in a thermostatic chamber. The evaluation was performed. The results are shown in Table 1.
- Example 2 Alumina slurry and a laminated porous film having a total thickness of 26 ⁇ m were prepared in the same manner as in Example 2 except that the same lot of alumina as used in Example 2 was used without being placed in a constant temperature and humidity chamber. The evaluation was performed. The results are shown in Table 1.
- Example 3 Alumina slurry and a laminated porous film having a total thickness of 25 ⁇ m were prepared in the same manner as in Example 3 except that the same lot of alumina as that used in Example 3 was used without being placed in a constant temperature and humidity chamber. The evaluation was performed. The results are shown in Table 1.
- Example 4 Alumina slurry and a laminated porous film having a total thickness of 25 ⁇ m were prepared in the same manner as in Example 4 except that the same lot of alumina as that used in Example 4 was used without being placed in a constant temperature and humidity chamber. The evaluation was performed. The results are shown in Table 1.
- the alumina slurries of Examples 1 to 4 have excellent viscosity stability during long-term storage, and the laminated porous film formed by using this to form a coating layer has excellent surface smoothness.
- the alumina slurries of Comparative Examples 1 to 4 have poor viscosity stability during long-term storage, and the laminated porous film having a coating layer obtained using this has low surface smoothness and poor productivity. there were.
- a laminated porous film having a coating layer on at least one surface of a polyolefin-based resin porous film when a dispersion containing the slurry and a resin binder is used.
- the laminated porous film is suitably used as a separator for non-aqueous electrolyte secondary batteries. In addition to this, it can be applied to various uses that require air permeability.
- sanitary materials such as disposable paper diapers and sanitary items such as pads or bed sheets for absorbing body fluids; medical materials such as surgical clothing or base materials for warm compresses; for clothing such as jumpers, sportswear or rainwear Materials: Building materials such as wallpaper, roof waterproofing materials, heat insulating materials, sound absorbing materials, etc .; desiccants; moisture-proofing agents; oxygen scavengers; disposable warmers; .
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Abstract
Description
またアルミナを含むスラリーの調製方法として、特許文献7には、少量の分散剤を用いた場合でも粘度の変化が少なく安定なスラリーを得るために、アルミナをはじめとする粉体を湿式粉砕する際に、順次メディア径の小さい粉砕メディアを使用して多段粉砕する湿式粉砕方法において、あらかじめ多段粉砕とは別に予備粉砕を実施し、多段粉砕において所定のタイミングで粉砕メディアの直径を小さいものに切り替える湿式粉砕方法が開示されている。
特許文献8には、各種有機溶媒における分散安定性に優れるアルミナ有機溶媒分散液の製造方法として、有機溶媒中で金属アルミニウム又は加水分解性アルミニウム化合物を加水分解し、酸の存在下に解膠してアルミナ有機溶媒分散液を得る方法が開示されている。該方法では、金属アルミニウム又は加水分解性アルミニウム化合物に対して4~10モル倍の水により加水分解してアルミナスラリーとし、金属アルミニウム又は加水分解性アルミニウム化合物に対して0.01~0.2モル倍の有機スルホン酸の存在下に解膠することを特徴としている。
特許文献6はイオン透過性、耐熱性、絶縁性に優れる無機酸化物多孔膜の形成に好適な無機酸化物粉末の提供を課題とするものであるが、これをスラリー化した場合の粘度安定性等の向上に関する開示及び示唆はない。
特許文献7に開示された方法では、粉体の粉砕工程が複数回必要であり、操作が煩雑である。
また特許文献8はアルミナ有機溶媒分散液の製造方法に関する文献であり、一旦アルミナスラリーを得た後、さらにこれを解謬して、アルミナ濃度10~15重量%、平均粒径0.1μm未満のアルミナ分散液を得るものである。前述の積層多孔フィルムにおける被覆層の形成に用いるアルミナスラリーにおいては、分散媒は水系であることが好ましく、アルミナのスラリー中の濃度、及びアルミナの平均粒径もこれより高いことが好ましい。しかしながらこのようなアルミナは分散媒中でより凝集、沈降しやすく、スラリーとした場合には長期保存性に劣ることも予想される。
すなわち本発明は、下記に関する。
[1]アルミナを分散媒に分散させてなるアルミナスラリーであって、該アルミナは一次平均粒径が0.1μm以上、1.0μm以下であり、かつ該アルミナが下記の条件(1)を満たし、該スラリー中の該アルミナの含有量が30質量%以上、70質量%以下であり、かつ、該分散媒中の水の含有量が50質量%以上であることを特徴とするアルミナスラリー。
条件(1):JIS Z8831-2(2010年)に基づき窒素脱離法により測定したアルミナの細孔径r1(Å)と細孔容量Dv1(mL/g)の関係において、r1=80における細孔容量Dv1(80)と、20≦r1≦80におけるDv1の最大値Dv1(M)が、Dv1(M)>Dv1(80)である。
[2]前記アルミナが、さらに下記の条件(2)を満たすことを特徴とする、上記[1]に記載のアルミナスラリー。
条件(2):JIS Z8831-2(2010年)に基づき窒素吸着法により測定したアルミナの細孔径r2(Å)と細孔容量Dv2(mL/g)の関係において、r2=80における細孔容量Dv2(80)と、20≦r2≦80におけるDv2の最大値Dv2(M)が、Dv2(M)>Dv2(80)である。
[3]前記分散媒が、炭素数1~4の低級アルコールを1質量%以上、20質量%以下の範囲で含有する、上記[1]又は[2]に記載のアルミナスラリー。
[4]ポリオレフィン系樹脂多孔フィルムの少なくとも片面に被覆層を有する積層多孔フィルムであって、該被覆層が上記[1]~[3]のいずれかに記載のアルミナスラリー及び樹脂バインダーを含有する分散液を用いて形成されたものである、積層多孔フィルム。
[5]前記樹脂バインダーが、ポリビニルアルコール、ポリフッ化ビニリデン、カルボキシメチルセルロース、ポリアクリル酸、及びポリアクリル酸誘導体から選ばれる少なくとも1種である、上記[4]に記載の積層多孔フィルム。
[6]上記[4]又は[5]に記載の積層多孔フィルムを用いた非水電解液二次電池用セパレータ。
[7]上記[6]に記載の非水電解液二次電池用セパレータを用いた非水電解液二次電池。
なお、本発明において、「主成分」と表現した場合には、特に記載しない限り、当該主成分の機能を妨げない範囲で他の成分を含有することを許容する意を包含し、主成分の含有量は50質量%以上、好ましくは70質量%以上、特に好ましくは90質量%以上(100質量%を含む)を占める意を包含するものである。
また、「X~Y」(X,Yは任意の数字)と記載した場合、特に断りのない限り「X以上Y以下」の意と共に、「好ましくはXより大きい」及び「好ましくはYより小さい」の意を包含するものである。
本発明のアルミナスラリーは、アルミナを分散媒に分散させてなるアルミナスラリーであって、該アルミナは一次平均粒径が0.1μm以上、1.0μm以下であり、かつ該アルミナが下記の条件(1)を満たし、該スラリー中の該アルミナの含有量が30質量%以上、70質量%以下であり、かつ、該分散媒中の水の含有量が50質量%以上であることを特徴とする。
条件(1):JIS Z8831-2(2010年)に基づき窒素脱離法により測定したアルミナの細孔径r1(Å)と細孔容量Dv1(mL/g)の関係において、r1=80における細孔容量Dv1(80)と、20≦r1≦80におけるDv1の最大値Dv1(M)が、Dv1(M)>Dv1(80)である。
本発明のアルミナスラリーは上記構成を有するものであり、特に上記特定の条件(1)を満たすアルミナを用いることにより、長期保存しても粘度の変動が極めて小さいものとなる。
以下に、本発明のアルミナスラリーを構成する各成分について説明する。
本発明のアルミナスラリーに用いるアルミナは、αアルミナ、γアルミナ、θアルミナ、κアルミナ、擬ベーマイトなどが挙げられる。中でも、本発明のアルミナスラリーを非水電解液二次電池用セパレータ用の積層多孔フィルムに用いる場合には、電池に組み込んだ際に化学的に不活性であるという観点で、αアルミナが好ましい。
なお、本発明において「アルミナの一次平均粒径」は、実施例に記載の方法によって測定及び算出される。
上記効果を得る観点から、Dv1(80)は好ましくは0.001~0.01mL/g、より好ましくは0.002~0.01mL/g、さらに好ましくは0.003~0.01mL/gの範囲である。また、Dv1(M)は、好ましくは0.003~0.05mL/g、より好ましくは0.004~0.05mL/g、さらに好ましくは0.005~0.05mL/gの範囲である。
アルミナの上記細孔径r1及び細孔容量Dv1(M)、Dv1(80)は、JIS Z8831-2(2010年)に基づき窒素脱離法により測定される値である。
Dv1(80)/Dv1(M)の値が上記の範囲であれば、本発明のアルミナスラリーは長期保存時の粘度安定性に優れるものとなる。
条件(2):JIS Z8831-2(2010年)に基づき窒素吸着法により測定したアルミナの細孔径r2(Å)と細孔容量Dv2(mL/g)の関係において、r2=80における細孔容量Dv2(80)と、20≦r2≦80におけるDv2の最大値Dv2(M)が、Dv2(M)>Dv2(80)である。
該アルミナが上記条件(2)を満たす場合、本発明のアルミナスラリーはより長期保存時の粘度安定性に優れるものとなる。上記効果を得る観点から、Dv2(80)は好ましくは0.001~0.01mL/g、より好ましくは0.002~0.01mL/g、さらに好ましくは0.003~0.01mL/gの範囲である。また、Dv2(M)は、好ましくは0.005~0.03mL/g、より好ましくは0.006~0.03mL/g、さらに好ましくは0.007~0.03mL/gの範囲である。
アルミナの上記細孔径r2及び細孔容量Dv2(M)、Dv2(80)は、JIS Z8831-2(2010年)に基づき窒素吸着法により測定される値である。
Dv2(80)/Dv2(M)の値が上記の範囲であれば、本発明のアルミナスラリーは長期保存時の粘度安定性に優れるものとなる。
上記処理方法により、条件(1)、好ましくはさらに条件(2)を満たし、スラリー化した際に粘度安定性に優れるアルミナを調製できる理由については定かではないが、以下のように推察される。
アルミナを高温条件下で加湿すると、該アルミナに一部含まれるαアルミナ以外の遷移アルミナが体積変化を起こして細孔が広がる。これとともに、加湿によりアルミナの表面の水酸基の一部に水分子が水素結合して、該水酸基の活性が下がり、その結果スラリーとした際の粘度安定性が向上していると考えられる。
上記観点から、アルミナの比表面積はより好ましくは5.5m2/g以上、さらに好ましくは6.0m2/g以上であり、より好ましくは13.0m2/g以下、さらに好ましくは11.0m2/g以下である。
なお、本発明において「アルミナの比表面積」は定容量式ガス吸着法により測定される値であり、具体的には実施例に記載の方法で測定できる。
本発明のアルミナスラリーは、上記アルミナを分散媒に分散させたものである。分散媒としてはアルミナを適度に均一かつ安定に分散させることができるものであれば特に制限はないが、コスト及び環境負荷の点、アルミナスラリーの長期保存時の粘度安定性、並びに、アルミナスラリーを後述する積層多孔フィルムにおける被覆層の形成に用いる際に、該被覆層を塗布法で形成する際の塗工性の観点から、分散媒中の水の含有量は50質量%以上であり、70質量%以上が好ましく、80質量%以上がより好ましく、85質量%以上がさらに好ましい。また、該分散媒中の水の含有量は100質量%以下であり、好ましくは99質量%以下、より好ましくは95質量%以下である。
水以外に用いることのできる分散媒としては、例えば、N-メチルピロリドン、N,N-ジメチルホルムアミド、N,N-ジメチルアセトアミド、水、ジオキサン、アセトニトリル、低級アルコール、グリコール類、グリセリン、乳酸エステルなどが挙げられる。中でも、分散媒は炭素数1~4の低級アルコールを含有することが好ましい。該低級アルコールとしては、炭素数1~4の1価のアルコールが好ましく、メタノール、エタノール及びイソプロピルアルコールから選ばれる少なくとも1種がより好ましい。これらは1種又は2種以上を組み合わせて用いることができる。
上記の中でも、分散媒は水と炭素数1~4の低級アルコールとの混合分散媒が好ましく、水と炭素数1~4の1価のアルコールとの混合分散媒がより好ましく、水とイソプロピルアルコールとの混合分散媒がさらに好ましい。
分散媒中の炭素数1~4の低級アルコールの含有量は、好ましくは1質量%以上、より好ましくは5質量%以上であり、好ましくは20質量%以下、より好ましくは15質量%以下の範囲である。
本発明のアルミナスラリーを製造する方法には特に制限はなく、例えば、所定量のアルミナと分散媒とを混合し、分散処理する方法が挙げられる。該分散処理方法としては特に制限はないが、例えば、ボールミル、ビーズミル、遊星ボールミル、振動ボールミル、サンドミル、コロイドミル、アトライター、ロールミル、高速インペラー分散、ディスパーザー、ホモジナイザー、高速衝撃ミル、超音波分散、撹拌羽根等による機械撹拌法等が挙げられる。これらの中でも、磨砕物の混入防止の観点から、ビーズミルを用いて分散処理することが好ましい。
ビーズミルに用いられるビーズの種類としては、ガラスビーズ、セラミックビーズなどが挙げられる。ビーズの硬度の観点からは、セラミックビーズが好ましく、チタニア、アルミナ、ジルコニア、及びジルコンから選ばれる1種以上のセラミックビーズがより好ましい。ビーズ径は、好ましくは0.1mm以上、3mm以下であり、アルミナの分散性の観点から、より好ましくは1.5mm以下、さらに好ましくは0.8mm以下である。
また、ビーズミル中のビーズの充填率は、分散効率の観点から、好ましくは30%以上、より好ましくは50%以上、さらに好ましくは70%以上であり、好ましくは90%以下である。
分散処理時の温度及び平均滞留時間についても特に制限はなく、例えばビーズミルを用いて連続的に分散を行う場合、通常、温度10~50℃、平均滞留時間0.1~60分の範囲で分散処理を行うことができる。
前記η24/η1及びη72/η1の値や、前記η24及びη72の値がかかる範囲であれば、アルミナスラリーの長期保存時の粘度安定性が十分であり、該スラリーを積層多孔フィルムの被覆層形成に用いた際に生産性が安定する。また該被覆層形成時の塗工性も良好になる。
本発明の積層多孔フィルムは、ポリオレフィン系樹脂多孔フィルムの少なくとも片面に被覆層を有する積層多孔フィルムであって、該被覆層が前記本発明のアルミナスラリー及び後述する樹脂バインダーを含有する分散液を用いて形成されたものである。
以下に、本発明の積層多孔フィルムを構成する各成分について説明する。
本発明の積層多孔フィルムは、電池内部での化学的安定性などの観点から、ポリオレフィン系樹脂多孔フィルムを有する。
ポリオレフィン系樹脂多孔フィルムに用いるポリオレフィン系樹脂としては、エチレン、プロピレン、1-ブテン、4-メチル-1-ペンテン、1-ヘキセンなどのα-オレフィンを重合した単独重合体又は共重合体が挙げられる。また、これらの単独重合体又は共重合体を2種以上混合することもできる。この中でもポリプロピレン系樹脂、又は、ポリエチレン系樹脂を用いることが好ましく、特に、本発明の積層多孔フィルムの機械的強度、耐熱性などを維持する観点から、ポリプロピレン系樹脂を用いることが好ましい。
ポリオレフィン系樹脂多孔フィルムに用いることのできるポリプロピレン系樹脂としては、ホモポリプロピレン(プロピレン単独重合体)、又はプロピレンとエチレン、1-ブテン、1-ペンテン、1-へキセン、1-へプテン、1-オクテン、1-ノネンもしくは1-デセンなどα-オレフィンとのランダム共重合体又はブロック共重合体などが挙げられる。この中でも、本発明の積層多孔フィルムの機械的強度、耐熱性などを維持する観点から、ホモポリプロピレンがより好適に使用される。
アイソタクチックペンタッド分率(mmmm分率)とは、任意の連続する5つのプロピレン単位で構成される炭素-炭素結合による主鎖に対して側鎖である5つのメチル基がいずれも同方向に位置する立体構造あるいはその割合を意味する。メチル基領域のシグナルの帰属は、A.Zambelli et al(“Macromolecules”,8,687(1975))に準拠する。
ポリプロピレン系樹脂のMw/MnはGPC(ゲルパーミエーションクロマトグラフィー)法によって測定される。
ポリプロピレン系樹脂の密度は、密度勾配管法を用いてJIS K7112(1999年)に準じて測定される。
ポリプロピレン系樹脂のMFRはJIS K7210(1999年)に従い、温度230℃、荷重2.16kgの条件で測定される。
ポリオレフィン系樹脂多孔フィルムに用いることのできるポリエチレン系樹脂としては、低密度ポリエチレン、線状低密度ポリエチレン、線状超低密度ポリエチレン、中密度ポリエチレン、高密度ポリエチレン及びエチレンを主成分とする共重合体、すなわち、エチレンとプロピレン、1-ブテン、1-ペンテン、1-ヘキセン、1-ヘプテン、1-オクテンなどの炭素数3~10のα-オレフィン;酢酸ビニル、プロピオン酸ビニルなどのビニルエステル;アクリル酸メチル、アクリル酸エチル、メタクリル酸メチル、メタクリル酸エチルなどの不飽和カルボン酸エステル、共役ジエンや非共役ジエンのような不飽和化合物の中から選ばれる1種又は2種以上のコモノマーとの共重合体又は多元共重合体あるいはその混合組成物が挙げられる。エチレン系重合体のエチレン単位の含有量は通常50質量%を超えるものである。
ポリエチレン系樹脂の密度は、密度勾配管法を用いてJIS K7112(1999年)に準じて測定される。
ポリエチレン系樹脂のMFRはJIS K7210(1999年)に従い、温度190℃、荷重2.16kgの条件で測定される。
ポリオレフィン系樹脂多孔フィルムには、前述した樹脂のほか、本発明の効果を著しく阻害しない範囲内で、一般に樹脂に配合される添加剤を適宜添加できる。
上記添加剤としては、成形加工性、生産性及びポリオレフィン系樹脂多孔フィルムの諸物性を改良、調整する目的で添加される、耳などのトリミングロス等から発生するリサイクル樹脂やシリカ、タルク、カオリン、炭酸カルシウム等の無機粒子、カーボンブラック等の顔料、難燃剤、耐候性安定剤、耐熱安定剤、帯電防止剤、溶融粘度改良剤、架橋剤、滑剤、核剤、可塑剤、老化防止剤、酸化防止剤、光安定剤、紫外線吸収剤、中和剤、防曇剤、アンチブロッキング剤、スリップ剤又は着色剤などの添加剤が挙げられる。
またポリオレフィン系樹脂多孔フィルムの開孔を促進するため、及び成形加工性を付与するために、本発明の効果を著しく阻害しない範囲で、各種樹脂や、ワックス等の低分子量化合物を添加してもよい。
ポリオレフィン系樹脂多孔フィルムは、単層でもよく、積層でもよい。中でも、前記ポリオレフィン系樹脂を含む層(以下「A層」と称する場合がある)の単層、当該A層の機能を妨げない範囲で、当該A層と他の層(以降「B層」と称する場合がある)との積層が好ましい。なお、B層がA層とは異なるポリオレフィン系樹脂を含む層であってもよい。
具体的にはA層/B層を積層した2層構造、A層/B層/A層、もしくは、B層/A層/B層として積層した3層構造などが例示できる。また、他の機能を持つ層と組み合わせて3種3層の様な形態も可能である。この場合、他の機能を持つ層との積層順序は特に問わない。層数としては、4層、5層、6層、7層と必要に応じて増やしてもよい。
ポリオレフィン系樹脂多孔フィルムの製造方法は、従来公知の多孔性フィルムの製造方法を好適に用いることができ、特に限定されるものではないが、通常、ポリオレフィン系樹脂多孔フィルムを形成するための前駆体である無孔膜状物を作製し、これを多孔化することによってポリオレフィン系樹脂多孔フィルムを形成する方法が好ましい。
ポリプロピレン系樹脂の無孔膜状物中にβ晶を生成させる方法としては、前記ポリプロピレン系樹脂のα晶の生成を促進させる物質を添加しない方法や、特許第3739481号公報に記載されているように過酸化ラジカルを発生させる処理を施したポリプロピレンを添加する方法、及び組成物にβ晶核剤を添加する方法などが挙げられる。
本発明で用いることのできるβ晶核剤としては以下に示すものが挙げられるが、ポリプロピレン系樹脂のβ晶の生成及び成長を増加させるものであれば特に限定されない。またβ晶核剤は2種以上を組み合わせて用いてもよい。
β晶核剤としては、例えば、アミド化合物;テトラオキサスピロ化合物;キナクリドン類;ナノスケールのサイズを有する酸化鉄;1,2-ヒドロキシステアリン酸カリウム、安息香酸マグネシウムもしくはコハク酸マグネシウム、フタル酸マグネシウムなどに代表されるカルボン酸のアルカリもしくはアルカリ土類金属塩;ベンゼンスルホン酸ナトリウムもしくはナフタレンスルホン酸ナトリウムなどに代表される芳香族スルホン酸化合物;二もしくは三塩基カルボン酸のジもしくはトリエステル類;フタロシアニンブルーなどに代表されるフタロシアニン系顔料;有機二塩基酸である成分Aと周期律表第2族金属の酸化物、水酸化物もしくは塩である成分Bとからなる二成分系化合物;環状リン化合物とマグネシウム化合物からなる組成物などが挙げられる。そのほか核剤の具体的な種類については、特開2003-306585号公報、特開平08-144122号公報、特開平09-194650号公報に記載されている。
β晶核剤の配合割合がポリプロピレン系樹脂100質量部に対して0.0001質量部以上であれば、製造時において十分にポリプロピレン系樹脂のβ晶を生成及び成長させることができるので、得られる積層多孔フィルムを非水電解液二次電池用セパレータとして用いる際にも十分なβ晶活性を発現し、所望の透気性能が得られる。また、β晶核剤の配合割合がポリプロピレン系樹脂100質量部に対して5質量部以下であれば、コスト的にも有利になるほか、ポリオレフィン系樹脂多孔フィルム表面へのβ晶核剤のブリードなどがなく好ましい。
(i)各層を多孔化したのち、多孔化された各層をラミネートしたり接着剤等で接着したりして積層する方法。
(ii)各層を積層して積層無孔膜状物を作製し、ついで当該無孔膜状物を多孔化する方法。
(iii)各層のうちいずれか1層を多孔化したのち、もう1層の無孔膜状物と積層し、多孔化する方法。
本発明においては、その工程の簡略さ、生産性の観点から(ii)の方法を用いることが好ましく、なかでも2層の層間接着性を確保するために、共押出で積層無孔膜状物を作製した後、多孔化する方法が特に好ましい。
本発明の積層多孔フィルムは、前記ポリオレフィン系樹脂多孔フィルムの少なくとも片面に被覆層を有する。該被覆層は、本発明のアルミナスラリー、及び樹脂バインダーを含有する分散液(以下「被覆層形成用分散液」ともいう)を用いて形成されるものであり、アルミナ及び樹脂バインダーを少なくとも含む。該分散液に用いられるアルミナスラリーは前述のとおりである。
樹脂バインダーは、被覆層中のアルミナの結合剤として作用し、該アルミナを多く含む被覆層と、ポリオレフィン系樹脂多孔フィルムとの接着性を向上させるために用いられる。
被覆層に用いられる樹脂バインダーとしては、アルミナを多く含む被覆層と、ポリオレフィン系樹脂多孔フィルムとを良好に接着でき、電気化学的に安定で、かつ積層多孔フィルムを非水電解液二次電池用セパレータとして使用する際に有機電解液に対して安定なものであれば、特に制限なく用いることができる。
具体的には、ポリエーテル、ポリアミド、ポリイミド、ポリアミドイミド、ポリアラミド、ポリオキシエチレン、エチレン-酢酸ビニル共重合体(酢酸ビニル由来の構造単位が0~20モル%のもの)、エチレン-エチルアクリレート共重合体などのエチレン-アクリル酸共重合体、ポリフッ化ビニリデン、ポリフッ化ビニリデン-ヘキサフルオロプロピレン、ポリフッ化ビニリデン-トリクロロエチレン、ポリテトラフルオロエチレン、フッ素系ゴム、スチレン-ブタジエンゴム、ニトリルブタジエンゴム、ポリブタジエンゴム、ポリアクリロニトリル、ポリアクリル酸及びその誘導体、ポリメタクリル酸及びその誘導体、カルボキシメチルセルロース、ヒドロキシエチルセルロース、シアノエチルセルロース、ポリビニルアルコール、シアノエチルポリビニルアルコール、ポリビニルブチラール、ポリビニルピロリドン、ポリN-ビニルアセトアミド、架橋アクリル樹脂、ポリウレタン、エポキシ樹脂、マレイン酸変性ポリオレフィンなどが挙げられる。これらの樹脂バインダーは1種単独で使用してもよく、2種以上を組み合わせて用いてもよい。
これらの中でも、被覆層形成用分散液に用いられる、水を主成分とする分散媒中及び電池の内部における電解液中で比較的安定であることから、ポリオキシエチレン、ポリビニルアルコール、ポリフッ化ビニリデン、ポリビニルピロリドン、ポリアクリロニトリル樹脂、スチレン-ブタジエンゴム、カルボキシメチルセルロース、ポリアクリル酸及びその誘導体、マレイン酸変性ポリオレフィンが好ましく、ポリビニルアルコール、ポリフッ化ビニリデン、カルボキシメチルセルロース、ポリアクリル酸、及びポリアクリル酸誘導体から選ばれる少なくとも1種がより好ましい。
したがって被覆層形成用分散液には、アルミナと樹脂バインダーとの含有量比が上記範囲となるように、アルミナスラリーと樹脂バインダーとを配合することが好ましい。
被覆層形成用分散液には、さらに酸成分を配合することが好ましい。該酸成分を配合することで、被覆層形成用分散液中のアルミナの凝集を抑制し、該分散液の長期保存時の粘度安定性が向上するため、均一な被覆層を形成することができる。
当該酸成分は、酸そのものとして被覆層中に残存していてもよいし、被覆層中のアルカリ性不純物と反応して形成された塩として被覆層中に残存していてもよい。
被覆層形成用分散液への酸成分の配合量が10質量ppm以上であれば、長期保存時の粘度安定性に優れる分散液が得られ、均一な被覆層を形成できる。また、該酸成分の配合量が10000質量ppm以下であれば、該被覆層を有する積層多孔フィルムを非水電解液二次電池用セパレータに用いた際にも、非水電解液二次電池の性能に悪影響を与えない。
被覆層は、上述した被覆層形成用分散液を用いて形成される。該被覆層の形成方法としては、共押出法、ラミネート法、塗布法などが挙げられるが、連続生産性の観点から、塗布法により形成することが好ましい。すなわち、前記ポリオレフィン系樹脂多孔フィルムの少なくとも片面に、被覆層形成用分散液を塗布して被覆層を形成することが好ましい。
被覆層形成用分散液は、その用途に応じて、ポリオレフィン系樹脂多孔フィルムの片面だけに塗布されてもよいし、両面に塗布されてもよい。すなわち本発明の積層多孔フィルムにおいて、被覆層は、ポリオレフィン系樹脂多孔フィルムの片面にのみ形成されていてもよく、両面に形成されていてもよい。
好ましくは上記方法を用いることにより、ポリオレフィン系樹脂多孔フィルムに被覆層を形成し、本発明の積層多孔フィルムを製造できる。
本発明の積層多孔フィルムの総厚みは、用途に応じて適宜選択することができる。該積層多孔フィルムを非水電解液二次電池用セパレータとして使用する場合には、積層多孔フィルムの総厚みは好ましくは5~100μm、より好ましくは8~50μm、さらに好ましくは10~30μmである。該総厚みが5μm以上であれば、非水電解液二次電池用セパレータとして実質的に必要な電気絶縁性を得ることができ、例えば電極の突起部分に大きな力がかかった場合でも非水電解液二次電池用セパレータを突き破って短絡しにくく、安全性に優れる。また、積層多孔フィルムの総厚みが100μm以下であれば、積層多孔フィルムの電気抵抗を小さくすることができるので、電池の性能を十分に確保することができる。
一方、積層多孔フィルムの空孔率は70%以下が好ましく、65%以下がより好ましく、60%以下がさらに好ましい。空孔率が70%以下であれば、積層多孔フィルムの強度を十分に保持することができ、ハンドリングの観点からも好ましい。
透気度はフィルム厚み方向の空気の通り抜け難さを表し、具体的には100mLの空気が当該フィルムを通過するのに必要な時間で表現されている。そのため、数値が小さい方が通り抜け易く、数値が大きい方が通り抜け難いことを意味する。すなわち、その数値が小さい方がフィルムの厚み方向の連通性がよいことを意味し、その数値が大きい方がフィルム厚み方向の連通性が悪いことを意味する。連通性とはフィルム厚み方向の孔のつながり度合いである。本発明の積層多孔フィルムの透気度が低ければ様々な用途に使用することができる。例えば非水電解液二次電池用セパレータとして使用する場合、透気度が低いということはリチウムイオンの移動が容易であることを意味し、電池性能に優れるため好ましい。
積層多孔フィルムの透気度(ガーレー値)は、JIS P8117(2009年)に準拠した方法で測定される。
積層多孔フィルムの収縮率は、例えば下記の方法で測定することができる。
積層多孔フィルムを長さ150mm×幅10mmのサイズに切り出し、長さ方向に100mmの間隔で2点印を入れてサンプルを作製し、150℃に設定したオーブンに当該サンプルを入れ、1時間静置する。当該サンプルをオーブンから取り出して冷却した後、印を入れた2点間の長さを測定し、以下の式にて収縮率を算出する。
収縮率(%)=100-加熱後の長さ
以上の測定を、積層多孔フィルムの縦方向、横方向についてそれぞれ行う。
フィルムの搬送トラブルや外観不良を軽減できることから、ザラつき量は100個/mm2未満であることが好ましく、80個/mm2未満であることがさらに好ましい。下限については、特に制限はなく、0個/mm2が理想であるが、現実的には10-10個/mm2以上であることが好ましい。
続いて、本発明の積層多孔フィルムを電池用セパレータとして収容している非水電解液二次電池について、図1を参照して説明する。
正極板21、負極板22の両極は電池用セパレータ10を介して互いに重なるようにして渦巻き状に捲回し、巻き止めテープで外側を止めて捲回体とする。
前記捲回工程について詳しく説明する。電池用セパレータの片端をピンのスリット部の間に通し、ピンを少しだけ回転させて電池用セパレータの一端をピンに巻きつけておく。この時、ピンの表面と電池用セパレータの被覆層とが接触している。その後、電池用セパレータを間に挟むようにして正極と負極を配置し、捲回機によってピンを回転させて、正負極と電池用セパレータを捲回する。捲回後、ピンは捲回物から引き抜かれる。
有機溶媒としては特に限定されないが、例えばプロピレンカーボネート、エチレンカーボネート、ブチレンカーボネート、γ-ブチロラクトン、γ-バレロラクトン、ジメチルカーボネート、プロピオン酸メチルもしくは酢酸ブチルなどのエステル類、アセトニトリル等のニトリル類、1,2-ジメトキシエタン、1,2-ジメトキシメタン、ジメトキシプロパン、1,3-ジオキソラン、テトラヒドロフラン、2-メチルテトラヒドロフランもしくは4-メチル-1,3-ジオキソランなどのエーテル類、又はスルホランなどが挙げられ、これらを単独で又は2種以上を混合して用いることができる。
なかでも、エチレンカーボネート1質量部に対してメチルエチルカーボネートを2質量部混合した溶媒中に六フッ化リン酸リチウム(LiPF6)を1.0mol/Lの割合で溶解した電解質が好ましい。
(1)アルミナの一次平均粒径
アルミナの一次平均粒径は、ヘキサメタリン酸Naを分散剤として用いて、レーザー回折式粒度分布測定装置(堀場製作所製「HORIBA LA-920」)を用いて測定した。
アルミナの細孔径及び細孔容積は、JIS Z8831-2(2010年)に基づき、カンタクローム社製「NOVA-1200」を用いて、アルミナを液体窒素温度まで冷却した後、窒素分圧を0.02気圧から0.98気圧まで段階的に上昇させながら、アルミナへの窒素吸着量及び脱離量を測定することで算出した。
アルミナの比表面積は、(2)の細孔径及び細孔容積の測定において、低圧力側におけるアルミナへの窒素吸着量の数値を用いて、BET5点法にて算出した。
後述の実施例及び比較例に記載の方法でアルミナスラリーを製造し、製造後1時間後と24時間後、72時間後のアルミナスラリーの粘度を、B型粘度計(東機産業(株)製「TVB10H」)を用いて、温度25℃で100rpmの周速にて測定し、それぞれη1、η24、η72(mPa・s)とした。
但し、以下に該当する場合、正常に測定できないものとし、表1において「測定不能」と表記した。
・測定開始から3分以上経過しても粘度が10%以上変動する場合
・測定時のスラリーに亀裂が入る場合
アルミナスラリーの粘度安定性は、下記の基準で評価した。
A:η72/η1、η24/η1の値がいずれも10未満
C:η72/η1、η24/η1の値のいずれかが10以上、又は測定不能
積層多孔フィルムの総厚みは、1/1000mmのダイアルゲージにて、積層多孔フィルムの面内を不特定に5箇所測定し、その平均値として算出した。
被覆層の厚みは、被覆層形成後の積層多孔フィルムの総厚みと、ポリオレフィン系樹脂多孔フィルムの厚みとの差として算出した。
ザラつき量は、微細形状測定機((株)小阪研究所製「ET4000A」)を用いて、積層多孔フィルムの被覆層側表面について300μm×400μmの視野角を観察し、周囲よりも5μm以上突き出た凸部の個数を集計した。表面平滑性は、このザラつき量の値をもって以下の基準で評価した。
A:ザラつき量が100個/mm2未満
C:ザラつき量が100個/mm2以上
ポリプロピレン系樹脂(日本ポリプロ(株)製「ノバテックPP FY6HA」、密度:0.90g/cm3、MFR:2.4g/10min)と、β晶核剤として、3,9-ビス[4-(N-シクロヘキシルカルバモイル)フェニル]-2,4,8,10-テトラオキサスピロ[5.5]ウンデカンを準備した。このポリプロピレン系樹脂100質量部に対して、β晶核剤を0.2質量部の割合で各原材料をブレンドし、東芝機械株式会社製の同方向二軸押出機(口径:40mmφ、L/D:32)に投入し、設定温度300℃で溶融混合後、水槽にてストランドを冷却固化し、ペレタイザーにてストランドをカットし、原料ペレットを作製した。
前記膜状物を、縦延伸機を用いて100℃で縦方向に4.6倍延伸し、その後、横延伸機にて150℃で横方向に2.1倍延伸後、153℃で熱固定を行った。続いて弛緩処理を行い、さらにVETAPHONE社製ジェネレータCP1を使用し、出力0.4kW、速度10m/minでコロナ表面処理を施すことで、ポリオレフィン系樹脂多孔フィルム(厚み20μm)を得た。
アルミナ(日本軽金属(株)製「LS-410」、一次平均粒径0.48μm、Dv1(M)0.0077mL/g、Dv1(80)0.0077mL/g、Dv2(M)0.0080mL/g、Dv2(80)0.0080mL/g、比表面積6.90m2/g)を、温度80℃、相対湿度80%に設定した恒温恒湿槽に3日間静置し、放冷後取り出した。得られた処理後のアルミナの性状は表1に示すとおりである。
得られたアルミナ52.6質量部、イソプロピルアルコール5.3質量部、イオン交換水42.1質量部を混合し、温度25℃、平均滞留時間0.6分の条件にてビーズミル処理を行い、アルミナスラリーを得た。使用したビーズミルの詳細条件は下記のとおりである。
装置 :アイメックス社製「NVM-1.5」
ビーズ:φ0.5mmジルコニア製ビーズ(充填率85%)
周速 :10m/秒
吐出量:350mL/分
得られたアルミナスラリーについて前記評価を行った。結果を表1に示す。
得られた被覆層形成用の分散液を前記ポリオレフィン系樹脂多孔フィルムにグラビアロール(格子型、線数:25L/インチ、深度290μm、セル容量145mL/m2)を用いて塗布した後、45℃の乾燥炉にて乾燥させて被覆層を形成し、総厚み24μmの積層多孔フィルムを得た。
得られた積層多孔フィルムについて前記評価を行った。結果を表1に示す。
処理前のアルミナを日本軽金属(株)製「LS-410」(一次平均粒径0.60μm、Dv1(M)0.0074mL/g、Dv1(80)0.0074mL/g、Dv2(M)0.0077mL/g、Dv2(80)0.0077mL/g、比表面積6.23m2/g)に変更したこと以外は、実施例1と同様の方法でアルミナスラリー及び総厚み24μmの積層多孔フィルムを作製し、前記評価を行った。結果を表1に示す。
処理前のアルミナを日本軽金属(株)製「LS-410」(一次平均粒径0.53μm、Dv1(M)0.0062mL/g、Dv1(80)0.0062mL/g、Dv2(M)0.0061mL/g、Dv2(80)0.0061mL/g、比表面積6.27m2/g)に変更したこと以外は、実施例1と同様の方法でアルミナスラリー及び総厚み24μmの積層多孔フィルムを作製し、前記評価を行った。結果を表1に示す。
処理前のアルミナを日本軽金属(株)製「LS-410」(一次平均粒径0.66μm、Dv1(M)0.0049mL/g、Dv1(80)0.0049mL/g、Dv2(M)0.0073mL/g、Dv2(80)0.0073mL/g、比表面積6.04m2/g)に変更したこと以外は、実施例1と同様の方法でアルミナスラリー及び総厚み24μmの積層多孔フィルムを作製し、前記評価を行った。結果を表1に示す。
実施例1で使用したアルミナと同一ロットのアルミナを、恒温恒湿槽に入れずに用いたこと以外は、実施例1と同様の方法でアルミナスラリー及び総厚み25μmの積層多孔フィルムを作製し、前記評価を行った。結果を表1に示す。
実施例2で使用したアルミナと同一ロットのアルミナを、恒温恒湿槽に入れずに用いたこと以外は、実施例2と同様の方法でアルミナスラリー及び総厚み26μmの積層多孔フィルムを作製し、前記評価を行った。結果を表1に示す。
実施例3で使用したアルミナと同一ロットのアルミナを、恒温恒湿槽に入れずに用いたこと以外は、実施例3と同様の方法でアルミナスラリー及び総厚み25μmの積層多孔フィルムを作製し、前記評価を行った。結果を表1に示す。
実施例4で使用したアルミナと同一ロットのアルミナを、恒温恒湿槽に入れずに用いたこと以外は、実施例4と同様の方法でアルミナスラリー及び総厚み25μmの積層多孔フィルムを作製し、前記評価を行った。結果を表1に示す。
一方、比較例1~4のアルミナスラリーは長期保存時の粘度安定性に劣り、これを用いて得られた被覆層を有する積層多孔フィルムは、表面平滑性が低く、生産性にも劣るものであった。
該積層多孔フィルムは、非水電解液二次電池用セパレータ等として好適に用いられる。またこれ以外にも、透気特性が要求される種々の用途にも応用することができる。具体的には、使い捨て紙オムツ、生理用品等の体液吸収用パットもしくはベッドシーツ等の衛生材料;手術衣もしくは温湿布用基材等の医療用材料;ジャンパー、スポーツウエアもしくは雨着等の衣料用材料;壁紙、屋根防水材、断熱材、吸音材等の建築用材料;乾燥剤;防湿剤;脱酸素剤;使い捨てカイロ;鮮度保持包装もしくは食品包装等の包装材料等の資材として好適に利用できる。
20 二次電池
21 正極板
22 負極板
24 正極リード体
25 負極リード体
26 ガスケット
27 正極蓋
Claims (7)
- アルミナを分散媒に分散させてなるアルミナスラリーであって、該アルミナは一次平均粒径が0.1μm以上、1.0μm以下であり、かつ該アルミナが下記の条件(1)を満たし、該スラリー中の該アルミナの含有量が30質量%以上、70質量%以下であり、かつ、該分散媒中の水の含有量が50質量%以上であることを特徴とするアルミナスラリー。
条件(1):JIS Z8831-2(2010年)に基づき窒素脱離法により測定したアルミナの細孔径r1(Å)と細孔容量Dv1(mL/g)の関係において、r1=80における細孔容量Dv1(80)と、20≦r1≦80におけるDv1の最大値Dv1(M)が、Dv1(M)>Dv1(80)である。 - 前記アルミナが、さらに下記の条件(2)を満たすことを特徴とする、請求項1に記載のアルミナスラリー。
条件(2):JIS Z8831-2(2010年)に基づき窒素吸着法により測定したアルミナの細孔径r2(Å)と細孔容量Dv2(mL/g)の関係において、r2=80における細孔容量Dv2(80)と、20≦r2≦80におけるDv2の最大値Dv2(M)が、Dv2(M)>Dv2(80)である。 - 前記分散媒が、炭素数1~4の低級アルコールを1質量%以上、20質量%以下の範囲で含有する、請求項1又は2に記載のアルミナスラリー。
- ポリオレフィン系樹脂多孔フィルムの少なくとも片面に被覆層を有する積層多孔フィルムであって、該被覆層が請求項1~3のいずれか1項に記載のアルミナスラリー及び樹脂バインダーを含有する分散液を用いて形成されたものである、積層多孔フィルム。
- 前記樹脂バインダーが、ポリビニルアルコール、ポリフッ化ビニリデン、カルボキシメチルセルロース、ポリアクリル酸、及びポリアクリル酸誘導体から選ばれる少なくとも1種である、請求項4に記載の積層多孔フィルム。
- 請求項4又は5に記載の積層多孔フィルムを用いた非水電解液二次電池用セパレータ。
- 請求項6に記載の非水電解液二次電池用セパレータを用いた非水電解液二次電池。
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US20160351880A1 (en) | 2016-12-01 |
US9935303B2 (en) | 2018-04-03 |
JP6002353B1 (ja) | 2016-10-05 |
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