WO2016199551A1 - 金属箔と樹脂フィルムのラミネート用接着剤、積層体、電池外装用包装材並びに電池ケース及びその製造方法 - Google Patents
金属箔と樹脂フィルムのラミネート用接着剤、積層体、電池外装用包装材並びに電池ケース及びその製造方法 Download PDFInfo
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- WO2016199551A1 WO2016199551A1 PCT/JP2016/064655 JP2016064655W WO2016199551A1 WO 2016199551 A1 WO2016199551 A1 WO 2016199551A1 JP 2016064655 W JP2016064655 W JP 2016064655W WO 2016199551 A1 WO2016199551 A1 WO 2016199551A1
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- resin film
- adhesive
- metal foil
- laminating
- polyol
- Prior art date
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- C08G18/791—Nitrogen characterised by the polyisocyanates used, these having groups formed by oligomerisation of isocyanates or isothiocyanates containing isocyanurate groups
- C08G18/792—Nitrogen characterised by the polyisocyanates used, these having groups formed by oligomerisation of isocyanates or isothiocyanates containing isocyanurate groups formed by oligomerisation of aliphatic and/or cycloaliphatic isocyanates or isothiocyanates
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
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- Y02E60/10—Energy storage using batteries
Definitions
- the present invention is produced using an adhesive for laminating a metal foil and a resin film, and an adhesive for laminating the metal foil and a resin film, which is suitable for an adhesive for an exterior material of a secondary battery such as a lithium ion battery.
- the present invention relates to a laminated body, a battery packaging material using the laminated body, a battery case obtained by molding the battery packaging material, and a method for producing the battery case.
- a lithium-containing compound is used as a positive electrode material, and a carbon material such as graphite or coke is used as a negative electrode material.
- a lithium salt such as LiPF 6 or LiBF 4
- an electrolytic solution in which a lithium salt such as LiPF 6 or LiBF 4 is dissolved as an electrolyte in an aprotic solvent having penetrating power such as ethylene carbonate, propylene carbonate, or diethyl carbonate, or its
- An electrolyte layer made of a polymer gel impregnated with an electrolytic solution is provided.
- a packaging material for battery cases a laminate in which a heat-resistant resin stretched film layer as an outer layer, an aluminum foil layer, and an unstretched thermoplastic resin film layer as an inner layer are sequentially laminated is known. Yes.
- a solvent having a penetrating power such as an electrolyte solution passes through a film layer serving as a sealant in a laminate used for the exterior of the battery. Then, the laminate strength between the aluminum foil layer and the resin film layer is lowered, which may cause the electrolyte to leak out.
- an adhesive layer containing a resin containing a functional group reactive with an isocyanate such as an acid anhydride group, a carboxyl group or a hydroxyl group, and a polyfunctional isocyanate compound is provided between the aluminum foil layer and the inner layer.
- Patent Document 1 a modified polyolefin resin obtained by graft polymerization of an ethylenically unsaturated carboxylic acid or an anhydride thereof to a propylene homopolymer or a copolymer of propylene and ethylene and a polyfunctional isocyanate compound are used as an organic solvent. Describes a method of forming an adhesive layer by using a solvent-type adhesive dissolved or dispersed in the above.
- the modified polyolefin resin of Patent Document 1 has a change over time during long-term storage or after dissolution of the solvent, and often the operability during application may become unstable, and the adhesive strength of the formed adhesive layer There was a risk of variations. Moreover, there also existed a problem that it was inferior to the adhesive force in the high temperature which assumed the vehicle-mounted use etc.
- Patent Document 2 an adhesive composition containing a polyolefin polyol and a polyfunctional isocyanate curing agent as essential components and further added with a thermoplastic elastomer and / or a tackifier is disclosed in Patent Document 3,
- Adhesive compositions containing one or more polyisocyanate compounds selected from the group consisting of diisocyanates are described.
- JP 2010-92703 A Japanese Patent Laying-Open No. 2005-63685 JP2011-187385A
- Patent Document 2 and Patent Document 3 when the electrolyte solution that has permeated the film layer that becomes the sealant in the laminate in the long-term use comes into contact with the adhesive layer, the adhesive strength is reduced, and the quality of the battery may be reduced. there were. Among them, there is a problem in that the adhesive force is remarkably lowered at the time of contact with the electrolytic solution for a long time, and the risk of leakage of the electrolytic solution is further increased.
- the present invention has been completed under such background technology, and its purpose is to laminate a metal foil for lamination and a resin film, which has excellent adhesive strength and excellent balance between heat resistance and electrolyte resistance. It is to provide an adhesive. Another object of the present invention is to provide a laminate of a metal foil and a resin film that is excellent in heat resistance and electrolytic solution resistance in a well-balanced manner and is suitable for a battery exterior packaging material. Furthermore, another object of the present invention is to provide a battery case which is formed by using a battery exterior packaging material comprising the laminate and has a good balance between heat resistance and electrolyte resistance, and a method for producing the same. is there.
- the present invention relates to the following [1] to [15].
- Adhesion for laminating a metal foil and a resin film comprising a polyol (A), a polyisocyanate multimer (B), and a metal compound (C) which is a compound of at least one metal of Group 7 and Group 12.
- the polyester polyol (a12) comprises a polyester polyol having a structural unit derived from a hydrogenated dimer acid and a structural unit derived from a hydrogenated dimer diol.
- Adhesive [4] The laminate of the metal foil and the resin film as described in any one of [1] to [3], wherein the saturated aliphatic polyisocyanate multimer (b1) includes an isocyanurate of saturated aliphatic polyisocyanate. Adhesive.
- [10] A laminate in which a metal foil and a resin film are laminated via an adhesive layer obtained from the adhesive for laminating a metal foil and a resin film according to any one of [1] to [9].
- a battery exterior packaging material obtained using the laminate according to any one of [10] to [12].
- [14] A battery case obtained by using the battery exterior packaging material according to [13].
- the chain polyolefin polyol (a11) contains at least one of polybutadiene polyol and hydrogenated polybutadiene polyol, preferably at least one of polybutadiene polyol and hydrogenated polybutadiene polyol, more preferably hydrogenated polybutadiene polyol.
- the hydroxyl group-containing cyclic hydrocarbon (a2) has a saturated alicyclic structure having a crosslinked structure, preferably a norbornane skeleton, an adamantane skeleton, or a tricyclodecane skeleton, more preferably tricyclodecane.
- the adhesive for laminating a metal foil and a resin film according to any one of the above [2] to [9] and [16], which has a skeleton.
- the polyisocyanate (a3) is a saturated alicyclic diisocyanate, preferably 1,4-cyclohexane diisocyanate, isophorone diisocyanate, methylene bis (4-cyclohexyl isocyanate), 1,3-bis (isocyanatomethyl) cyclohexane. 1,4-bis (isocyanatomethyl) cyclohexane or norbornane diisocyanate, more preferably methylene bis (4-cyclohexyl isocyanate), any one of [2] to [9], [16] and [17] above
- the saturated alicyclic polyisocyanate multimer (b2) is at least one of isophorone diisocyanate allophanated multimer and isocyanurate, and preferably is an allophanated multimer of isophorone diisocyanate. [1]-[9], [16]-[18] The adhesive for laminating a metal foil and a resin film according to any one of the above.
- the adhesive for laminating a metal foil and a resin film of the present invention has excellent adhesive strength, and the laminate of the metal foil and the resin film formed using the adhesive for laminating the metal foil and the resin film is heat resistant.
- it is suitable as a material for a packaging material for battery exteriors used in the production of secondary batteries such as lithium ion batteries because of its excellent balance of electrolyte resistance.
- the battery case formed using the packaging material for battery exterior of the present invention is excellent in balance between heat resistance and electrolytic solution resistance, and by using it, a safe secondary battery having a long life is provided. be able to.
- the adhesive for laminating a metal foil and a resin film includes a polyol (A), a polyisocyanate multimer (B), and a metal compound that is a compound of at least one metal of Group 7 and Group 12.
- (C) is an adhesive for laminating a metal foil and a resin film, wherein the polyisocyanate polymer (B) is composed of a saturated aliphatic polyisocyanate polymer (b1) and a saturated alicyclic polyisocyanate. Multimer (b2) is included.
- the polyol (A) hits the main agent
- the polyisocyanate multimer (B) hits the curing agent
- the metal compound (C) hits the reaction accelerator.
- the adhesive for laminating the metal foil and the resin film according to the present embodiment can be suitably used for bonding the metal foil and the resin film, and is particularly useful as an adhesive for laminating the metal foil and the resin film.
- the laminate can be suitably used as a packaging material for battery exterior.
- “to” in this specification means a value not less than the value before the description of “to” and not more than the value after the description of “to”.
- the polyol (A) used in the present embodiment (hereinafter sometimes referred to as “(A) component” or “(A)”) is particularly limited as long as it contains two or more hydroxyl groups in the molecular structure.
- a chain polyolefin polyol (a11), a polyester polyol (a12), and a hydroxyl group-containing cyclic hydrocarbon compound having both a saturated cyclic hydrocarbon structure and two or more hydroxyl groups It is preferable to include a polyurethane polyol (A1) obtained by polyaddition of at least one selected from three types of a2) and a component containing polyisocyanate (a3).
- the polyol (A) is a polyurethane polyol obtained by polyaddition of a component containing at least one of a chain polyolefin polyol (a11) and a polyester polyol (a12) and a polyisocyanate (a3) ( More preferably, A2) is included.
- the polyol (A) is a hydroxyl group-containing cyclic carbonization having at least one of a chain polyolefin polyol (a11) and a polyester polyol (a12), a saturated cyclic hydrocarbon structure and two or more hydroxyl groups.
- polyurethane polyol (A3) obtained by polyaddition of the hydrogen compound (a2) and the component containing the polyisocyanate (a3).
- Said polyol (A), polyurethane polyol (A1), polyurethane polyol (A2) and polyurethane polyol (A3) contain at least one kind of chain polyolefin polyol (a11) and polyester polyol (a12) as a derived component.
- the chain polyolefin polyol (a11) is included from the viewpoint of resistance to electrolytic solution.
- the polyol (A) may contain a polyol other than the polyurethane polyols (A1), (A2) and (A3) as long as the effects of the present embodiment are not hindered. Is preferably not included.
- the content of the polyurethane polyol (A1) in the polyol (A) is preferably 80% by mass or more, more preferably 90% by mass or more, and still more preferably 95%. It is at least mass%, more preferably 100 mass%.
- the content of the polyurethane polyol (A2) in the polyol (A) is preferably 80% by mass or more, more preferably 90% by mass or more, and still more preferably 95%. It is at least mass%, more preferably 100 mass%.
- the content of the polyurethane polyol (A3) in the polyol (A) is preferably 80% by mass or more, more preferably 90% by mass or more, and still more preferably 95%. It is at least mass%, more preferably 100 mass%.
- the total content of the component (a11), component (a12), component (a2), and component (a3) in the polyol (A) is preferably 80% by mass or more, more preferably 90% by mass or more, and still more preferably Is 95% by mass or more, more preferably 100% by mass.
- the chain polyolefin polyol (a11) in the present embodiment means a polyolefin polyol that does not contain an alicyclic structure.
- the chain polyolefin polyol (a11) (hereinafter also referred to as “polyolefin polyol (a11)” or “(a11) component” or “(a11)”) used in the present embodiment is one or two in the molecule. There is no particular limitation as long as it contains a polyolefin skeleton obtained by polymerizing or copolymerizing the above olefins and two or more hydroxyl groups and does not have an alicyclic structure.
- the chain polyolefin polyol (a11) may be either hydrogenated (hydrogenated product) or non-hydrogenated (non-hydrogenated product), but from the viewpoint of resistance to electrolytic solution, A hydrogenated product (hydrogenated product) is preferred.
- Specific examples of the chain polyolefin polyol (a11) include polydiene polyols such as polybutadiene polyol and polyisoprene polyol, graft polymers of polydiene polyol and polyolefin, and hydrogenated products of these polydiene polyols and graft polymers. Can be mentioned. These can be used individually or in mixture of 2 or more types.
- Examples of these commercially available products include G-1000, G-3000, GI-1000, GI-3000 (all manufactured by Nippon Soda Co., Ltd.), Epaul (manufactured by Idemitsu Kosan Co., Ltd.), and the like.
- polyester polyol (a12) The polyester polyol (a12) of the present embodiment (hereinafter also referred to as “(a12) component” or “(a12)”)) is particularly suitable if it contains an ester bond and two or more hydroxyl groups in the molecule. Not limited.
- the polyester polyol (a12) is preferably at least one of a polyester polyol having a structural unit derived from a hydrogenated dimer acid and a structural unit derived from a hydrogenated dimer diol, and castor oil, from the viewpoint of the resistance to electrolytic solution.
- polyester polyol having a structural unit derived from a hydrogenated dimer acid and a structural unit derived from a hydrogenated dimer diol
- a polyester having a structural unit derived from a hydrogenated dimer acid and a structural unit derived from a hydrogenated dimer diol More preferably, it is a polyol.
- the “dimer acid” in the present embodiment is a dimer acid (dimer acid) obtained by reacting a fatty acid having an ethylenic double bond (hereinafter also referred to as “unsaturated fatty acid A”) at the double bond portion. ).
- the unsaturated fatty acid A preferably has 14 to 22 carbon atoms. By having a relatively long hydrocarbon chain in this way, it is considered that the resistance to electrolytic solution is improved.
- the dimer acid is preferably a dimer acid obtained by reacting an unsaturated fatty acid A having 2 to 4 ethylenic double bonds with an unsaturated fatty acid A having 1 to 4 ethylenic double bonds.
- the dimer acid obtained by reacting an unsaturated fatty acid A having two ethylenic double bonds and an unsaturated fatty acid A having one or two ethylenic double bonds.
- the two unsaturated fatty acids A that are components derived from these dimer acids may be of different types or the same type.
- the unsaturated fatty acid A include tetradecenoic acid (tuzuic acid, mascoic acid, myristoleic acid), hexadecenoic acid (such as palmitoleic acid), octadecenoic acid (such as oleic acid, elaidic acid, and vaccenic acid), eicosenoic acid (gadrene).
- the obtained dimer acid is usually a dimer acid mixture having a different structure depending on the bonding site or isomerization of a double bond, and may be used separately, but can be used as it is. Further, the obtained dimer acid contains a small amount of monomeric acid (for example, 6% by mass or less, particularly 4% by mass or less), trimer acid or higher polymer acid (for example, 6% by mass or less, particularly 4% by mass or less). May be.
- hydrogenated dimer acid refers to a saturated dicarboxylic acid obtained by hydrogenating the carbon-carbon double bond of the dimer acid.
- examples of commercially available hydrogenated dimer acids include EMPOL1008 and EMPOL1062 (both manufactured by BASF), PRIPOL1009 (produced by Croda), and the like.
- the “hydrogenated dimer diol” in the present embodiment refers to a reduction of at least one of the dimer acid, the hydrogenated dimer acid, and a lower alcohol ester thereof in the presence of a catalyst, and a carboxylic acid or carboxylate moiety of the dimer acid.
- the main component is a diol obtained by hydrogenating the double bond.
- Examples of commercially available hydrogenated dimer diols include Sovermol 908 (manufactured by BASF) and PRIPOL 2033 (manufactured by Croda).
- the polyester polyol (a12) used in the present embodiment comprises an acid component having the hydrogenated dimer acid as an essential component and an alcohol component having the hydrogenated dimer diol as an essential component, and an esterification catalyst such as butyltin dilaurate. It can manufacture by performing a condensation reaction (dehydration esterification reaction) in presence of this. Alternatively, by performing an ester exchange reaction between an ester component having the lower alkyl ester of the hydrogenated dimer acid as an essential component and an alcohol component having the hydrogenated dimer diol as an essential component in the presence of a transesterification catalyst. Can be manufactured.
- Hydroxyl group-containing cyclic hydrocarbon compound (a2) (hereinafter referred to as “hydroxyl group-containing cyclic hydrocarbon (a2)” or “(”) having both a saturated cyclic hydrocarbon structure and two or more hydroxyl groups used in the present embodiment.
- a2) component "or" (a2) ) is a saturated alicyclic carbonization from the viewpoint of the electrolytic solution resistance of the adhesive layer obtained from the adhesive for laminating the metal foil and resin film of this embodiment.
- saturated cyclic hydrocarbon structures include cycloalkane skeletons such as cyclopentane skeleton, cyclohexane skeleton and cycloheptane skeleton, saturated alicyclic structures having a crosslinked structure such as norbornane skeleton, adamantane skeleton, and tricyclodecane skeleton.
- Examples of the hydroxyl group-containing cyclic hydrocarbon (a2) having such a structure include cyclopentanediol, cyclohexanediol, cyclohexanedimethanol, norbornanediol, adamantanediol, tricyclodecane dimethanol, adamantanetriol and the like. These can be used individually or in mixture of 2 or more types. Preferably, it contains a saturated alicyclic structure having a crosslinked structure, and norbornanediol, adamantanediol, tricyclodecane dimethanol, adamantanetriol and the like are preferable examples. Examples of such commercially available products include adamantanetriol (manufactured by Idemitsu Kosan Co., Ltd., Mitsubishi Gas Chemical Co., Ltd.), TCD alcohol DM (manufactured by Oxair).
- polyisocyanate (a3) The polyisocyanate (a3) used in the present embodiment (hereinafter also referred to as “(a3) component” or “(a3)”) is particularly a compound containing two or more isocyanato groups, or a multimer thereof. There is no limit.
- saturated fats such as 1,4-cyclohexane diisocyanate, isophorone diisocyanate, methylene bis (4-cyclohexyl isocyanate), 1,3-bis (isocyanatomethyl) cyclohexane, 1,4-bis (isocyanatomethyl) cyclohexane, norbornane diisocyanate
- Aromatic diisocyanates such as cyclic diisocyanate, 2,4-tolylene diisocyanate, 2,6-tolylene diisocyanate, diphenylmethane-4,4'-diisocyanate, 1,3-xylylene diisocyanate, 1,4-xylylene diisocyanate, Aliphatic diisocyanates such as hexamethylene diisocyanate, 2,4,4-trimethylhexamethylene diisocyanate, 2,2,4-trimethylhexanemethylene diisocyanate,
- Saturated alicyclic diisocyanates are preferred, 1,4-cyclohexane diisocyanate, isophorone diisocyanate, methylene bis (4-cyclohexyl isocyanate), 1,3-bis (isocyanatomethyl) cyclohexane, 1,4-bis (isocyanatomethyl) And cyclohexane, norbornane diisocyanate, and the like, particularly preferably isophorone diisocyanate (3-isocyanatomethyl-3,5,5-trimethylcyclohexyl isocyanate), methylenebis (4-cyclohexyl isocyanate) (also known as dicyclohexylmethane-4, 4′-diisocyanate).
- Examples of these commercially available products include Death Module I, Death Module W (each manufactured by Bayer), IPDI, and H12MDI (each manufactured by Degussa).
- the reaction may be performed in the presence of a catalyst, and is preferable.
- the addition amount of the catalyst is preferably 0.001 to 1.00 parts by mass, and 0.005 to 0 with respect to 100 parts by mass of the total amount of the components (a11), (a12), (a2) and (a3). .50 parts by mass is more preferable, and 0.01 to 0.30 parts by mass is still more preferable. If it is 0.001 part by mass or more, the reaction is sufficiently quick, and if it is 1 part by mass or less, the adhesive force can be maintained.
- the polyolefin polyol (a11) and / or the polyester polyol (a12), the hydroxyl group-containing cyclic hydrocarbon compound (a2), and the polyisocyanate (a3) may be reacted all at once.
- the polyolefin polyol (a11) and / or the polyester polyol (a12) and the hydroxyl group-containing cyclic hydrocarbon compound (a2) are reacted with the polyisocyanate (a3) separately or in an appropriate combination, The components may be mixed and further reacted.
- a hydroxyl group-containing cyclic hydrocarbon compound (a2) and a polyisocyanate (a3) are reacted to obtain a polyurethane polyisocyanate, and then a polyolefin polyol (a11) and / or a polyester polyol (a12) are reacted. To obtain a polyurethane polyol.
- the polyaddition reaction may be performed in a solvent.
- a solvent there is no restriction
- the amount of the solvent added is preferably 50 to 500 parts by weight, more preferably 50 to 200 parts by weight, based on 100 parts by weight of the total amount of the components (a11), (a12), (a2) and (a3). More preferably, it is 80 to 120 parts by mass.
- an antioxidant such as hydroquinone monomethyl ether may be added.
- the addition amount of the antioxidant is preferably 0.001 to 1.00 parts by mass with respect to 100 parts by mass of the total amount of the components (a11), (a12), (a2) and (a3), 0.005 Is more preferably 0.50 parts by mass, and still more preferably 0.01-0.35 parts by mass.
- the ratio of the number of isocyanate groups contained in the polyisocyanate (a3) to the number of hydroxyl groups contained in the components (a11), (a12) and (a2) when the polyurethane polyol is produced (hereinafter also referred to as “NCO / OH ratio”) Is preferably 0.5 to 1.1, more preferably 0.7 to 1.05, and still more preferably 0.8 to 1.0. If it is 0.5 or more, the adhesive force of the adhesive layer obtained from the adhesive for laminating the metal foil and the resin film of the present embodiment is less likely to be lowered even when in contact with the electrolytic solution.
- the number of hydroxyl groups contained in each polyol component can be determined by Method A of JIS K1557-1: 2007 (titration method).
- the number of isocyanate groups contained in each isocyanate component can be determined according to JIS K 6806: 2003 (titration method).
- the component may not be included, but is preferably included.
- the ratio of the component (a2) to the total amount of 100 parts by mass of the components (a11) and (a12) when producing the polyurethane polyol is preferably 1 to 100 parts by mass, The amount is more preferably 5 to 50 parts by mass, and further preferably 5 to 20 parts by mass. If it is 1 part by mass or more, the adhesive force of the adhesive layer obtained from the adhesive for laminating the metal foil and the resin film is less likely to decrease even when in contact with the electrolytic solution. The solubility in the solvent and the operability during application of the adhesive for laminating the metal foil and the resin film are improved.
- the polyisocyanate multimer (B) in the present embodiment (hereinafter sometimes referred to as “(B) component” or “(B)”) is the adhesive for laminating the metal foil and the resin film of the present embodiment. Is added as a curing agent.
- the adhesive for laminating the metal foil and the resin film becomes excellent in heat resistance and electrolytic solution resistance. The reason is unknown, but it is presumed that the structures such as isocyanurates and allophanated multimers are excellent in heat resistance and electrolyte resistance.
- the polyisocyanate multimer (B) in the present embodiment includes both a saturated aliphatic polyisocyanate multimer (b1) and a saturated alicyclic polyisocyanate multimer (b2).
- the metal foil and the resin are compared with the saturated aliphatic polyisocyanate multimer (b1) alone.
- the adhesive strength obtained when the adhesive layer obtained from the adhesive for laminating the film is in contact with the electrolytic solution becomes high, and on the contrary, the adhesive at a higher temperature than the saturated alicyclic polyisocyanate multimer (b2) alone. Strength increases.
- the polyisocyanate multi-isocyanate (B) of the present embodiment is obtained by preparing the saturated aliphatic polyisocyanate multi-mer (b1) and the saturated alicyclic polyisocyanate during the preparation of the adhesive for laminating the metal foil and the resin film. Either a premixed multimer (b2) may be charged or may be charged separately.
- the saturated aliphatic polyisocyanate multimer (b1) (hereinafter, also referred to as “(b1) component” or “(b1)”) used in the present embodiment is a saturated aliphatic group having two or more isocyanato groups. If it is a multimer of a compound, it will not restrict
- the saturated alicyclic polyisocyanate multimer (b2) used in the present embodiment (hereinafter sometimes referred to as “(b2) component” or “(b2)”) has two or more isocyanate groups and a saturated alicyclic ring. If it is a multimer of the compound which has a structure, it will not restrict
- saturated fats such as 1,4-cyclohexane diisocyanate, isophorone diisocyanate, methylene bis (4-cyclohexyl isocyanate), 1,3-bis (isocyanatomethyl) cyclohexane, 1,4-bis (isocyanatomethyl) cyclohexane, norbornane diisocyanate
- a multimer such as a cyclic diisocyanate
- examples of the multimer include an allophanatized multimer, an isocyanurate, a biuret modified product, and the like. , Isocyanurate and biuret-modified products are preferred.
- the polyisocyanate polymer (B) may contain a polyisocyanate polymer other than the saturated aliphatic polyisocyanate polymer (b1) and the saturated alicyclic polyisocyanate polymer (b2). Preferably not.
- the total amount of the saturated aliphatic polyisocyanate multimer (b1) and the saturated alicyclic polyisocyanate multimer (b2) in the polyisocyanate multimer (B) is preferably 80% by mass or more, more preferably It is 90 mass% or more, More preferably, it is 95 mass% or more.
- Mass ratio of saturated aliphatic polyisocyanate multimer (b1) to total amount of saturated aliphatic polyisocyanate multimer (b1) and saturated alicyclic polyisocyanate multimer (b2) [(b1) / ((b1 ) + (B2))] is preferably 0.05 to 0.70, more preferably 0.10 to 0.60, still more preferably 0.20 to 0.50, and still more preferably 0.30 to 0. .40.
- the ratio of the number of isocyanate groups contained in the saturated aliphatic polyisocyanate multimer (b1) and the saturated alicyclic polyisocyanate multimer (b2) to the number of hydroxyl groups contained in the polyol (A) (NCO / OH ratio) is: 1 to 15 is preferable, and 2 to 13 is more preferable.
- the NCO / OH ratio is 1 or more, the adhesive strength of the adhesive layer obtained from the adhesive for laminating the metal foil and the resin film of the present embodiment, in particular, to the resin film is improved, and the NCO / OH ratio is If it is 15 or less, the adhesive force of the adhesive layer obtained from the adhesive for laminating the metal foil and the resin film of this embodiment will not easily decrease even when it comes into contact with the electrolytic solution.
- Metal compound (C) which is a compound of at least one metal of Group 7 and Group 12 Metal compound (C) which is a compound of at least one metal of group 7 and group 12 of the periodic table in the present embodiment (hereinafter referred to as “metal compound (C) of group 7 and / or 12” or “metal” Compound (C) ”or“ (C) component ”or“ (C) ”) is a large amount of polyurethane polyol (A) and polyisocyanate in the adhesive for laminating the metal foil and resin film of the present embodiment. It mix
- the metal compound (C), which is a compound of at least one metal of Group 7 and Group 12 used in the present embodiment, is Group 7 selected from manganese, tennetium, rhenium, Group 12 selected from zinc, cadmium, and mercury. These compounds containing each metal element can be used alone or in combination.
- a metal carboxylate more preferably at least one metal carboxylate selected from manganese and zinc, and zinc carboxylate. It is still more preferable that it contains.
- the metal compound (C) which is a compound of at least one metal of Group 7 and Group 12 is zinc neodecanoate (C 20 H 38 O 4 Zn), hexoate zinc (zinc octylate, 2-ethyl Zinc hexanoate, C 16 H 30 O 4 Zn), zinc stearate (C 36 H 70 O 4 Zn), zinc acetylacetonate (C 10 H 14 O 4 Zn), hexoate manganese (manganese octylate, 2 - ethylhexanoate manganese, C 16 H 30 O 4 Mn ) is preferably, zinc neodecanoate (C 20 H 38 O 4 Zn ), hexoate zinc (zinc octoate, zinc 2-ethylhexanoate, C 16 H 30 O 4 Zn) is more preferred.
- reaction accelerators other than component (C) dibutyltin dilaurate, dioctyltin dilaurate, dioctyltin diacetate, which are organotin compounds, and 2,4,6-tris (dimethylaminomethyl) phenol, dimethyl, which are tertiary amines.
- Aniline, dimethylparatoluidine, N, N-di ( ⁇ -hydroxyethyl) -p-toluidine and the like may be used in combination.
- the ratio of the metal compound (C), which is a compound of at least one metal of Group 7 and Group 12, with respect to 100 parts by mass of the polyol (A) is not particularly limited, but the metal compound with respect to 100 parts by mass of the polyol (A).
- the content of (C) is preferably 0.0001 to 5 parts by mass, more preferably 0.001 to 3 parts by mass, and more preferably 0.01 to 1.5 parts by mass in terms of the metal mass.
- the amount is preferably 0.03 to 1.5 parts by mass. If it is 0.0001 part by mass or more, the adhesive force of the adhesive layer obtained from the adhesive for laminating the metal foil and the resin film of the present invention becomes sufficiently high even after being immersed in the electrolyte for a long period of time, and 5 parts by mass. If it is below, normal adhesive strength will become high.
- the Group 7 and / or Group 12 metal compound (C) may be added during the synthesis of the polyol (A) or may be added during the adjustment of the adhesive. ⁇ Solvent
- the adhesive for laminating a metal foil and a resin film according to the present embodiment may include a solvent (D) (hereinafter sometimes referred to as “(D) component” or “(D)”).
- a solvent (D) hereinafter sometimes referred to as “(D) component” or “(D)”.
- the solvent (D) can dissolve or disperse the polyol (A), the polyisocyanate multimer (B), and the metal compound (C) that is a compound of at least one metal of Group 7 and Group 12, There is no particular limitation.
- aromatic organic solvents such as toluene and xylene
- alicyclic organic solvents such as cyclohexane, methylcyclohexane and ethylcyclohexane
- aliphatic organic solvents such as n-hexane and n-heptane
- ethyl acetate propyl acetate
- ester organic solvents such as butyl acetate
- ketone organic solvents such as acetone, methyl ethyl ketone, and methyl butyl ketone.
- the content of the solvent (D) is preferably 30 to 80% by mass, more preferably 40 to 80% by mass, and more preferably 50 to The amount is more preferably 80% by mass, and further preferably 60 to 80% by mass.
- the operability at the time of application of the adhesive for laminating the metal foil and the resin film of the present embodiment becomes good, and if it is 80% by mass or less, the metal foil and the resin of the present embodiment.
- the thickness controllability of the laminate obtained by applying and curing a film laminating adhesive is improved.
- the adhesive for laminating the metal foil and the resin film of the present embodiment may contain additives such as a tackifier and a plasticizer as necessary.
- the tackifier is not particularly limited.
- polyterpene resin, rosin resin and the like can be mentioned.
- petroleum system aliphatic (C5) resin, aromatic (C9) resin, copolymer (obtained from naphtha cracked oil fraction) C5 / C9) resin, alicyclic resin and the like.
- the hydrogenated resin which hydrogenated the double bond part of these resin is mentioned.
- This tackifier may be used alone or in combination of two or more.
- the plasticizer is not particularly limited, and examples thereof include liquid rubber such as polyisoprene and polybutene, and process oil.
- thermoplastic resin such as an acid-modified polyolefin resin or a thermoplastic elastomer may be included as long as the effect of the present embodiment is not impaired.
- thermoplastic resins and thermoplastic elastomers that can be blended include ethylene-vinyl acetate copolymer resins, ethylene-ethyl acrylate copolymer resins, SEBS (styrene-ethylene-butylene-styrene), and SEPS (styrene-ethylene-propylene-styrene). ) And the like.
- the total content of the components (A), (B), (C) and (D) in the adhesive for laminating the metal foil and the resin film according to the present embodiment is preferably 80% by mass or more, more preferably. Is 90% by mass or more, more preferably 95% by mass or more.
- the metal foil and the resin film may be simply referred to as an adhesive for laminating the metal foil and the resin film of the present embodiment (hereinafter simply referred to as “laminate adhesive of the present embodiment”).
- laminate adhesive of the present embodiment are laminated via an adhesive layer obtained from (1).
- the resin films may include a layer joined via an adhesive layer obtained from the laminating adhesive according to the present embodiment.
- this bonding method a known method such as a heat lamination method or a dry lamination method can be used.
- the heat lamination method means that the adhesive for laminating according to this embodiment, which does not contain the solvent (D), is heated and melted on the surface of the layer in contact with the adhesive layer, or together with the layer in contact with the adhesive layer.
- an adhesive layer is formed by interposing between the layers of the laminate by heating and extruding.
- the dry lamination method is a method in which the laminating adhesive of the present embodiment containing the solvent (D) is applied to the surface of the layer in contact with the adhesive layer, dried, and then overlapped with the other layer.
- the adhesive layer is formed by interposing between the layers of the laminated body.
- the use of the laminate of the present embodiment is not particularly limited, a useful application is packaging.
- the contents to be packaged in this laminate include liquid materials containing acids, alkalis, organic solvents, etc., such as putty (thickening putty, thinning putty etc.), paint (oil-based paint etc.), lacquer ( Clear lacquers, etc.) and solvent-based ones such as automotive compounds.
- this laminated body is suitable also for packaging the electrolyte solution of a lithium ion battery, it can be used as a packaging material for battery exteriors, and is preferable.
- the metal foil is an aluminum foil
- the resin film includes a heat-fusible resin film
- an outer layer made of a heat-resistant resin film is provided outside the aluminum foil. .
- the packaging material for battery exterior of the present embodiment is obtained using the laminate of the present embodiment.
- the packaging material for battery exterior of the present embodiment is preferably a laminate of the present embodiment in which an outer layer made of a resin film, particularly a heat resistant resin film, is provided on the outside of the metal foil.
- an outer layer made of a resin film, particularly a heat resistant resin film is provided on the outside of the metal foil.
- it can be set as the structure which added the 1st intermediate resin layer or / and the 2nd intermediate resin layer, etc. as needed.
- the adhesive layer means “an adhesive layer obtained from the laminating adhesive according to the present embodiment”, and the metal foil layer is exemplified as an aluminum foil layer.
- outer layer / aluminum foil layer / adhesive layer / resin film layer (2) outer layer / first intermediate resin layer / aluminum foil layer / adhesive layer / resin film layer (3) outer layer / aluminum foil layer / second intermediate Resin layer / adhesive layer / resin film layer (4) outer layer / first intermediate resin layer / aluminum foil layer / second intermediate resin layer / adhesive layer / resin film layer (5) coat layer / outer layer / aluminum foil layer / Adhesive layer / resin film layer (6) coat layer / outer layer / first intermediate resin layer / aluminum foil layer / adhesive layer / resin film layer (7) coat layer / outer layer / aluminum foil layer / second intermediate resin layer / Adhesive layer / resin film layer (8) coat layer / outer layer / first intermediate resin layer / aluminum foil layer / second intermediate resin layer / adhesive layer / resin film layer
- first intermediate resin layer polyamide resin, polyester resin, polyethylene resin or the like is used for the purpose of improving the mechanical strength of the battery exterior packaging material.
- second intermediate resin layer similarly to the first intermediate resin layer, a polyamide resin, a polyester resin, or a heat-adhesive extruded resin such as polyethylene resin or polypropylene is used mainly for the purpose of improving the resistance to electrolyte.
- resin film layer a single-layer resin film or a multilayer resin film (produced by two-layer coextrusion or three-layer coextrusion) can be used.
- the second intermediate resin layer can also be a single-layer resin film or a multilayer co-extruded resin film.
- the thicknesses of the first intermediate resin layer and the second intermediate resin layer are not particularly limited, but when they are provided, they are usually about 0.1 to 30 ⁇ m.
- the resin film used for the outer layer is excellent in heat resistance, moldability, insulation, etc., and a stretched film of polyamide (nylon) resin or polyester resin is generally used.
- the thickness of the outer layer film is about 9 to 50 ⁇ m. If the thickness is less than 9 ⁇ m, the stretched film is insufficiently stretched when the packaging material is formed, necking occurs in the aluminum foil, and molding defects tend to occur. On the other hand, in the case of a thickness exceeding 50 ⁇ m, the effect of formability is not particularly improved, but conversely, the volume energy density is lowered and only the cost is increased.
- the thickness of the outer layer film is more preferably about 10 to 40 ⁇ m, and further preferably 20 to 30 ⁇ m.
- the film is sized to a predetermined size so that each of the three directions of 0 °, 45 °, and 90 ° is the tensile direction when the stretching direction of the stretched film is 0 °.
- the tensile strength is 150 N / mm 2 or more, preferably 200 N / mm 2 or more, more preferably 250 N / mm 2 or more, and the elongation by three-direction tension is 80% or more.
- the tensile strength is 150 N / mm 2 or more, or the elongation by tension is 80% or more, the above effect is sufficiently exhibited.
- the tensile strength and the elongation value due to tension are values until breakage in a film tensile test (test piece length 150 mm ⁇ width 15 mm ⁇ thickness 9 to 50 ⁇ m, pulling speed 100 mm / min). Test specimens are cut out in three directions.
- the metal foil plays a role of barrier properties against water vapor and the like, and as a material, an O material (soft material) of a pure aluminum system or an aluminum-iron system alloy is generally used and preferable.
- the thickness of the aluminum foil is preferably about 10 to 100 ⁇ m in order to ensure processability and barrier properties to prevent oxygen and moisture from entering the package. If the thickness of the aluminum foil is less than 10 ⁇ m, the aluminum foil may break during molding or a pinhole may occur, which may lead to the ingress of oxygen or moisture.
- the aluminum foil generally has a thickness of about 30 to 50 ⁇ m, and preferably has a thickness of 40 to 50 ⁇ m.
- the aluminum foil is preferably subjected to a chemical conversion treatment such as an undercoat treatment such as a silane coupling agent or a titanium coupling agent, or a chromate treatment in order to improve the adhesion to the resin film and the corrosion resistance.
- the resin film is preferably a heat-fusible resin film such as polypropylene, polyethylene, maleic acid-modified polypropylene, ethylene-acrylate copolymer, or ionomer resin. These resins have a heat-sealing property and play a role of improving chemical resistance against an electrolytic solution or the like of a lithium secondary battery having strong corrosivity.
- the film thickness is preferably 9 to 100 ⁇ m, more preferably 20 to 80 ⁇ m, and most preferably 40 to 80 ⁇ m. When the thickness of the resin film is 9 ⁇ m or more, sufficient heat seal strength is obtained, and the corrosion resistance against the electrolytic solution and the like is good. If the thickness of the resin film is 100 ⁇ m or less, the strength of the packaging material for battery exterior is sufficient and the moldability is good.
- the battery exterior packaging material of the present embodiment may be provided with a coat layer on the outer layer.
- the method for forming the coating layer include a method of coating a gas barrier polymer, a method of depositing an inorganic oxide such as aluminum metal, silicon oxide, and aluminum oxide, and coating a thin film of metal and inorganic material.
- the battery case of the present embodiment is obtained using the battery exterior packaging material of the present embodiment.
- it can be obtained by molding a battery packaging material.
- the packaging material for battery exterior of the present embodiment is excellent in electrolytic solution resistance, heat resistance, water vapor and other gas barrier properties, and is suitably used as a battery case for a secondary battery, particularly a lithium ion battery.
- the packaging material for battery exteriors of this Embodiment has very favorable moldability, the battery case of this Embodiment can be obtained simply by shape
- the forming method is not particularly limited, but when it is formed by deep drawing or stretch forming, a battery case having a complicated shape and high dimensional accuracy can be produced.
- DM (manufactured by Oxea, tricyclodecane dimethanol), hydroquinone monomethyl ether (manufactured by Wako Pure Chemical Industries, Ltd.) as an antioxidant, 0.04 g, and catalyst“ KS-1260 ”(Sakai Chemical Industry) 0.03 g of dibutyltin dilaurate), 30.00 g of “Desmodur W” (manufactured by Bayer, methylenebis (4-cyclohexylisocyanate)) as component (a3), and 70.000 of toluene as solvent (D).
- 00g was added and the temperature was raised to 85-90 ° C using an oil bath while stirring. . Thereafter, the reaction was continued with stirring for 2.5 hours.
- polyurethane polyol (hereinafter referred to as polyurethane polyol)).
- a toluene solution (solid content concentration: 50% by mass) was obtained.
- Table 1 shows the formulation composition in Synthesis Example 2.
- Synthesis Examples 3 to 7 Synthesis was carried out in the same manner as in Synthesis Example 2 except that the formulation shown in Table 1 was used, to obtain a toluene solution (solid content concentration 50 mass%) of polyurethane polyols (2) to (6).
- G-1000 is a polybutadiene polyol manufactured by Nippon Soda Co., Ltd.
- HS 2B-5500 is a polyester polyol (castor oil) manufactured by Toyokuni Oil Co., Ltd.
- the number of hydroxyl groups contained in the components (a11), (a12) and (a2) was measured based on Method A of JIS K 1557-1: 2007 (titration method).
- the number of isocyanate groups contained in the isocyanate (a3) was measured based on JIS K 6806: 2003 (titration method). Based on these measured values, the ratio “NCO / OH ratio” of the number of isocyanate groups contained in the polyisocyanate (a3) to the number of hydroxyl groups contained in the components (a11), (a12) and (a2) was determined. The results are shown in Table 1.
- Example 1 As component (A), 60.00 g of a toluene solution of the polyurethane polyol (1) obtained in Synthesis Example 2 (solid content: 30.00 g, toluene: 30.00 g) was used, and as component (b1), “Duranate TKA-100” was used.
- the number of hydroxyl groups contained in the polyurethane polyol (1) as the component (A) was measured based on method A of JIS K1557-1: 2007 (titration method). Further, the number of isocyanate groups contained in Duranate TKA-100 as component (b1) and Desmodur XP 2565 as component (b2) were measured based on JIS K 6806: 2003 (titration method), respectively. Based on these measured values, the ratio of the number of isocyanate groups contained in the saturated aliphatic polyisocyanate multimer (b1) and the saturated alicyclic polyisocyanate multimer (b2) to the number of hydroxyl groups contained in the polyol (A). was calculated. The results are shown in Table 2. Next, using this laminating adhesive 1, a battery exterior packaging material having a structure of outer layer / outer layer adhesive / aluminum foil layer / laminating adhesive 1 / resin film was produced by a dry lamination method. Details of each layer are as follows.
- Outer layer stretched polyamide film (thickness 25 ⁇ m)
- Adhesive for outer layer Adhesive for urethane-based dry laminate (AD502 / CAT10, manufactured by Toyo Morton Co., Ltd., application amount 3 g / m 2 (at the time of application))
- Aluminum foil layer Aluminum-iron alloy aluminum foil (AA standard 8079-O material, thickness 40 ⁇ m)
- Laminating adhesive 1 Laminating adhesive 1 (application amount: thickness after drying is 2 ⁇ m)
- Resin film Unstretched polypropylene film (thickness 40 ⁇ m)
- Examples 2 to 14, Comparative Examples 1 to 9 Except for the formulations shown in Tables 2 to 4, adhesives 2 to 23 (compositions 2 to 23) for laminating a metal foil and a resin film were prepared in the same manner as in Example 1. Next, a battery outer packaging material was produced in the same manner as in Example 1 except that the laminating adhesives 2 to 23 were used in place of the laminating adhesive 1. Details of each component in Tables 2 to 4 are as follows.
- Acid modified polypropylene acid modified polypropylene modified with maleic anhydride and octyl acrylate (acid value 20 mg / KOH) ⁇ Duranate TKA-100: Isocyanurate of hexamethylene diisocyanate manufactured by Asahi Kasei Chemicals Co., Ltd. ⁇ Hexamethylene diisocyanate: Reagent manufactured by Tokyo Chemical Industry Co., Ltd.
- Desmodur Z 4470 Bayer, isophorone diisocyanate (70 parts by mass) and butyl acetate (30 parts by mass) Isophorone diisocyanate: Tokyo Reagents manufactured by Kasei Kogyo Co., Ltd.
- BiCAT Z manufactured by Shepherd Chemical, zinc neodecanoate • Hexoate zinc: manufactured by Toei Chemical Co., Ltd., zinc 2-ethylhexanoate (65 parts by mass) Mixture of mineral spirits (35 parts by mass)-Fco Chem ZNS-P: ADEKA Co., Ltd., zinc stearate-Zinc acetylacetonate: Reagents manufactured by Tokyo Chemical Industry Co., Ltd.-Hexate Manganese: Toei Chemical Co., Ltd.
- KS-1260 Sakai Chemical Industry Co., Ltd., dibutyltin dilaurate Titanium acetylacetonate: Reagent manufactured by Tokyo Chemical Industry Co., Ltd.
- BiCAT8210 Mixture of Tris (2-ethylhexanoic acid) bismuth (bismuth tris (2-ethylhexanoate)) (89 parts by mass) and 2-ethylhexanoic acid (11 parts by mass) manufactured by Shepherd Chemical
- the metal foil and resin film laminating adhesive of the present invention has excellent adhesive strength even after being immersed in a long-term electrolyte or at high temperatures, particularly aluminum foil and a heat-fusible resin film. It is suitable for joining with.
- the laminate of the present invention is excellent in heat resistance and electrolytic solution resistance, it is suitably used for a packaging material for battery exteriors used in the production of secondary batteries such as lithium ion batteries, and this laminate is molded. Thus, a battery case excellent in heat resistance and electrolytic solution resistance can be produced. By using the battery case, a safe secondary battery with a long life can be manufactured.
Abstract
Description
〔1〕ポリオール(A)、ポリイソシアネートの多量体(B)、並びに7族及び12族の少なくとも1種の金属の化合物である金属化合物(C)を有する、金属箔と樹脂フィルムのラミネート用接着剤であって、前記ポリイソシアネートの多量体(B)が、飽和脂肪族ポリイソシアネートの多量体(b1)及び飽和脂環式ポリイソシアネートの多量体(b2)を含む、金属箔と樹脂フィルムのラミネート用接着剤。
〔2〕前記ポリオール(A)が、鎖状ポリオレフィンポリオール(a11)及びポリエステルポリオール(a12)の少なくとも1種、飽和の環式炭化水素構造と2つ以上の水酸基とを併せ持つ水酸基含有環式炭化水素化合物(a2)、並びにポリイソシアネート(a3)を含有する成分を重付加して得られる、ポリウレタンポリオールを含む、上記〔1〕に記載の金属箔と樹脂フィルムのラミネート用接着剤。
〔3〕前記ポリエステルポリオール(a12)が、水添ダイマー酸由来の構成単位と水添ダイマージオール由来の構成単位とを有するポリエステルポリオールを含む、上記〔2〕に記載の金属箔と樹脂フィルムのラミネート用接着剤。
〔4〕前記飽和脂肪族ポリイソシアネートの多量体(b1)が、飽和脂肪族ポリイソシアネートのイソシアヌレート体を含む、上記〔1〕~〔3〕のいずれかに記載の金属箔と樹脂フィルムのラミネート用接着剤。
〔5〕前記飽和脂環式ポリイソシアネートの多量体(b2)が、イソホロンジイソシアネートの多量体を含む、上記〔1〕~〔4〕のいずれかに記載の金属箔と樹脂フィルムのラミネート用接着剤。
〔6〕前記ポリオール(A)に含まれる水酸基数に対する、飽和脂肪族ポリイソシアネートの多量体(b1)及び飽和脂環式ポリイソシアネートの多量体(b2)に含まれるイソシアナト基数の比率が、1~15である、上記〔1〕~〔5〕のいずれかに記載の金属箔と樹脂フィルムのラミネート用接着剤。
〔7〕前記金属化合物(C)が、7族及び12族の少なくとも一種のカルボン酸塩を少なくとも1種以上含む、上記〔1〕~〔6〕のいずれかに記載の金属箔と樹脂フィルムのラミネート用接着剤。
〔8〕前記金属化合物(C)が亜鉛又はマンガンのカルボン酸塩を含む、上記〔1〕~〔7〕のいずれかに記載の金属箔と樹脂フィルムのラミネート用接着剤。
〔9〕溶剤(D)をさらに含む、上記〔1〕~〔8〕のいずれかに記載の金属箔と樹脂フィルムのラミネート用接着剤。
〔10〕金属箔と樹脂フィルムが、上記〔1〕~〔9〕のいずれかに記載の金属箔と樹脂フィルムのラミネート用接着剤から得られる接着剤層を介して積層された、積層体。
〔11〕前記金属箔がアルミニウム箔であり、前記樹脂フィルムが熱融着性樹脂フィルムを含有する、上記〔10〕に記載の積層体。
〔12〕前記金属箔の厚さが10~100μmであり、前記樹脂フィルムの厚さが9~100μmである、上記〔10〕又は〔11〕に記載の積層体。
〔13〕上記〔10〕~〔12〕のいずれかに記載の積層体を用いて得られる、電池外装用包装材。
〔14〕上記〔13〕に記載の電池外装用包装材を用いて得られる、電池ケース。
〔15〕上記〔13〕に記載の電池外装用包装材を深絞り成形又は張り出し成形する、電池ケースの製造方法。
〔16〕前記鎖状ポリオレフィンポリオール(a11)は、ポリブタジエンポリオール及び水添ポリブタジエンポリオールの少なくとも1種を含み、好ましくはポリブタジエンポリオール及び水添ポリブタジエンポリオールの少なくとも1種であり、より好ましくは水添ポリブタジエンポリオールを含み、更に好ましくは水添ポリブタジエンポリオールである、上記〔2〕~〔9〕のいずれかに記載の金属箔と樹脂フィルムのラミネート用接着剤。
〔17〕前記水酸基含有環式炭化水素(a2)は、架橋構造を有する飽和脂環構造を有し、好ましくはノルボルナン骨格、アダマンタン骨格、又はトリシクロデカン骨格を有し、より好ましくはトリシクロデカン骨格を有する、上記〔2〕~〔9〕、及び〔16〕のいずれかに記載の金属箔と樹脂フィルムのラミネート用接着剤。
〔18〕前記ポリイソシアネート(a3)は、飽和脂環式ジイソシアネートであり、好ましくは1,4-シクロヘキサンジイソシアネート、イソホロンジイソシアネート、メチレンビス(4-シクロヘキシルイソシアネート)、1,3-ビス(イソシアナトメチル)シクロヘキサン、1,4-ビス(イソシアナトメチル)シクロヘキサン、又はノルボルナンジイソシアネートであり、より好ましくはメチレンビス(4-シクロヘキシルイソシアネート)である、上記〔2〕~〔9〕、〔16〕及び〔17〕のいずれかに記載の金属箔と樹脂フィルムのラミネート用接着剤。
〔19〕前記飽和脂環式ポリイソシアネートの多量体(b2)は、イソホロンジイソシアネートのアロファネート化多量体及びイソシアヌレート体の少なくとも1種であり、好ましくはイソホロンジイソシアネートのアロファネート化多量体である、上記〔1〕~〔9〕、〔16〕~〔18〕のいずれかに記載の金属箔と樹脂フィルムのラミネート用接着剤。
本実施の形態に係る金属箔と樹脂フィルムのラミネート用接着剤は、ポリオール(A)、ポリイソシアネートの多量体(B)、並びに7族及び12族の少なくとも1種の金属の化合物である金属化合物(C)を有する、金属箔と樹脂フィルムのラミネート用接着剤であって、前記ポリイソシアネートの多量体(B)が、飽和脂肪族ポリイソシアネートの多量体(b1)及び飽和脂環式ポリイソシアネートの多量体(b2)を含む。
本実施の形態に係る金属箔と樹脂フィルムのラミネート用接着剤において、前記ポリオール(A)は主剤に当たり、ポリイソシアネートの多量体(B)は硬化剤に当たり、金属化合物(C)は反応促進剤に当たる。
ここで、本明細書における「~」は、「~」という記載の前の値以上、「~」という記載の後の値以下を意味する。
本実施の形態に用いられるポリオール(A)(以下、「(A)成分」又は「(A)」ということがある)は、分子構造に2つ以上の水酸基を含有するものであれば特に制限されないが、耐電解液性の観点から、鎖状ポリオレフィンポリオール(a11)、ポリエステルポリオール(a12)、及び飽和の環式炭化水素構造と2つ以上の水酸基とを併せ持つ水酸基含有環式炭化水素化合物(a2)の3種から選ばれる少なくとも1種、並びにポリイソシアネート(a3)を含有する成分を重付加して得られる、ポリウレタンポリオール(A1)を含むことが好ましい。
同様の観点から、ポリオール(A)は、鎖状ポリオレフィンポリオール(a11)及びポリエステルポリオール(a12)の少なくとも1種、及びポリイソシアネート(a3)を含有する成分を重付加して得られる、ポリウレタンポリオール(A2)を含むことがより好ましい。
同様の観点から、ポリオール(A)は、鎖状ポリオレフィンポリオール(a11)及びポリエステルポリオール(a12)の少なくとも1種、飽和の環式炭化水素構造と2つ以上の水酸基とを併せ持つ水酸基含有環式炭化水素化合物(a2)、並びにポリイソシアネート(a3)を含有する成分を重付加して得られる、ポリウレタンポリオール(A3)を含むことが更に好ましい。
上記のポリオール(A)、ポリウレタンポリオール(A1)、ポリウレタンポリオール(A2)及びポリウレタンポリオール(A3)は、由来成分として、鎖状ポリオレフィンポリオール(a11)及びポリエステルポリオール(a12)の少なくとも1種を含むことが好ましいが、耐電解液性の観点から、鎖状ポリオレフィンポリオール(a11)を含むことがより好ましい。
ポリオール(A)がポリウレタンポリオール(A1)を含む場合、ポリオール(A)中における、ポリウレタンポリオール(A1)の含有量は、好ましくは80質量%以上、より好ましくは90質量%以上、更に好ましくは95質量%以上、より更に好ましくは100質量%である。
ポリオール(A)がポリウレタンポリオール(A2)を含む場合、ポリオール(A)中における、ポリウレタンポリオール(A2)の含有量は、好ましくは80質量%以上、より好ましくは90質量%以上、更に好ましくは95質量%以上、より更に好ましくは100質量%である。
ポリオール(A)がポリウレタンポリオール(A3)を含む場合、ポリオール(A)中における、ポリウレタンポリオール(A3)の含有量は、好ましくは80質量%以上、より好ましくは90質量%以上、更に好ましくは95質量%以上、より更に好ましくは100質量%である。
ポリオール(A)中における、(a11)成分、(a12)成分、(a2)成分、及び(a3)成分の総含有量は、好ましくは80質量%以上、より好ましくは90質量%以上、更に好ましくは95質量%以上、より更に好ましくは100質量%である。
本実施の形態の鎖状ポリオレフィンポリオール(a11)は、脂環構造を含まないポリオレフィンポリオールを意味する。
本実施の形態に用いられる鎖状ポリオレフィンポリオール(a11)(以下、「ポリオレフィンポリオール(a11)」又は「(a11)成分」又は「(a11)」ともいう)は、分子中に1種又は2種以上のオレフィンを重合又は共重合させてなるポリオレフィン骨格と、2つ以上の水酸基とを含有し、かつ脂環構造を有さないものであれば特に制限されない。
鎖状ポリオレフィンポリオール(a11)は、水素化されたもの(水素添加物)であっても水素化されていないもの(非水素添加物)であってもよいが、耐電解液性の観点から、水素添加物(水添体)の方が好ましい。
鎖状ポリオレフィンポリオール(a11)の具体例としては、ポリブタジエンポリオール、ポリイソプレンポリオールなどのポリジエンポリオール、ポリジエンポリオールとポリオレフィンのグラフト重合物及びこれらのポリジエンポリオールやグラフト重合物の水素添加物等が挙げられる。これらは、単独又は2種以上混合して使用することができる。
これらの市販品としては、例えば、G-1000、G-3000、GI-1000、GI-3000(いずれも日本曹達株式会社製)、エポール(出光興産株式会社製)等が挙げられる。
本実施の形態のポリエステルポリオール(a12)(以下、「(a12)成分」又は「(a12)」ともいう)は、分子中にエステル結合と、2つ以上の水酸基を含有するものであれば特に制限されない。
また、ポリエステルポリオール(a12)は、耐電解液性の観点から、水添ダイマー酸由来の構成単位と水添ダイマージオール由来の構成単位とを有するポリエステルポリオール、及びヒマシ油の少なくとも1種が好ましく、水添ダイマー酸由来の構成単位と水添ダイマージオール由来の構成単位とを有するポリエステルポリオールを含むことがより好ましく、水添ダイマー酸由来の構成単位と水添ダイマージオール由来の構成単位とを有するポリエステルポリオールであることが更に好ましい。
不飽和脂肪酸Aの炭素数は、14~22が好ましい。このように比較的長い炭化水素鎖を有することにより、耐電解液性が向上するものと考えられる。
上記ダイマー酸は、好ましくはエチレン性二重結合を2~4個有する不飽和脂肪酸Aとエチレン性二重結合を1~4個有する不飽和脂肪酸Aとを反応して得られる二量体酸であり、より好ましくはエチレン性二重結合を2個有する不飽和脂肪酸Aとエチレン性二重結合を1又は2個有する不飽和脂肪酸Aとを反応して得られる二量体酸である。これら二量体酸の由来成分である2つの不飽和脂肪酸Aは、異なる種類であっても同一の種類であってもよい。
上記不飽和脂肪酸Aとしては、テトラデセン酸(ツズ酸、マッコウ酸、ミリストオレイン酸)、ヘキサデセン酸(パルミトレイン酸等)、オクタデセン酸(オレイン酸、エライジン酸、バクセン酸等)、エイコセン酸(ガドレイン酸等)、ドコセン酸(エルカ酸、セトレイン酸、ブラシジン酸等)、テトラデカジエン酸、ヘキサデカジエン酸、オクタデカジエン酸(リノール酸等)、エイコサジエン酸、ドコサジエン酸、オクタデカトリエン酸(リノレン酸等)、エイコサテトラエン酸(アラキドン酸等)等が挙げられ、オレイン酸もしくはリノール酸がもっとも好ましい。得られるダイマー酸は、通常、二重結合の結合部位や異性化によって、構造が異なるダイマー酸混合物であり、分離して使用してもよいが、そのまま使用できる。さらに、得られるダイマー酸は、少量のモノマー酸(例えば6質量%以下、特に4質量%以下)やトリマー酸以上のポリマー酸等(例えば6質量%以下、特に4質量%以下)を含有していてもよい。
本実施の形態に用いられる飽和の環式炭化水素構造と2つ以上の水酸基とを併せ持つ水酸基含有環式炭化水素化合物(a2)(以下、「水酸基含有環式炭化水素(a2)」又は「(a2)成分」又は「(a2)」ともいう)は、本実施の形態の金属箔と樹脂フィルムのラミネート用接着剤から得られる接着剤層の耐電解液性の観点から、飽和脂環式炭化水素構造と2つ以上の水酸基を有し、その他の部分の構造が炭化水素からなる化合物であれば特に制限はない。
飽和環式炭化水素構造としては、シクロペンタン骨格、シクロヘキサン骨格、シクロヘプタン骨格等のシクロアルカン骨格、ノルボルナン骨格、アダマンタン骨格、トリシクロデカン骨格等の架橋構造を有する飽和脂環構造等が挙げられ、そのような構造を持つ水酸基含有環式炭化水素(a2)としては、シクロペンタンジオール、シクロヘキサンジオール、シクロヘキサンジメタノール、ノルボルナンジオール、アダマンタンジオール、トリシクロデカンジメタノール、アダマンタントリオール等が挙げられる。これらは、単独又は2種以上混合して使用することができる。好ましくは架橋構造を有する飽和脂環構造を含むものであり、ノルボルナンジオール、アダマンタンジオール、トリシクロデカンジメタノール、アダマンタントリオール等が好ましい例として挙げられる。それらの市販品としては、アダマンタントリオール(出光興産株式会社製、三菱ガス化学株式会社製)、TCDアルコールDM(オクセア社製)等が挙げられる。
本実施の形態に用いるポリイソシアネート(a3)(以下、「(a3)成分」又は「(a3)」ともいう)としては、イソシアナト基を2つ以上含有する化合物、もしくはその多量体であれば特に制限はない。例えば、1,4-シクロヘキサンジイソシアネート、イソホロンジイソシアネート、メチレンビス(4-シクロヘキシルイソシアネート)、1,3-ビス(イソシアナトメチル)シクロヘキサン、1,4-ビス(イソシアナトメチル)シクロヘキサン、ノルボルナンジイソシアネート等の飽和脂環式ジイソシアネート、2,4-トリレンジイソシアネート、2,6-トリレンジイソシアネート、ジフェニルメタン-4,4′-ジイソシアネート、1,3-キシリレンジイソシアネート、1,4-キシリレンジイソシアネート等の芳香族ジイソシアネート、ヘキサメチレンジイソシアネート、2,4,4-トリメチルヘキサメチレンジイソシアネート、2,2,4-トリメチルヘキサンメチレンジイソシアネート等の脂肪族ジイソシアネート、またこれらのアロファネート化多量体、イソシアヌレート体、ビウレット変性物等が挙げられる。これらは、単独又は2種以上混合して使用することができる。好ましくは飽和脂環式ジイソシアネートであり、1,4-シクロヘキサンジイソシアネート、イソホロンジイソシアネート、メチレンビス(4-シクロヘキシルイソシアネート)、1,3-ビス(イソシアナトメチル)シクロヘキサン、1,4-ビス(イソシアナトメチル)シクロヘキサン、ノルボルナンジイソシアネート等が挙げられ、特に好ましくはイソホロンジイソシアネート(3-イソシアナートメチル-3,5,5-トリメチルシクロへキシルイソシアネート)、メチレンビス(4-シクロヘキシルイソシアネート)(別名:ジシクロへキシルメタン-4,4’-ジイソシアネート)である。これらの市販品としては、デスモジュールI、デスモジュールW(それぞれバイエル社製)、IPDI、H12MDI(それぞれデグッサ社製)等が挙げられる。
本実施の形態に用いるポリウレタンポリオールの製造方法の一例としては、ジブチルスズジラウレート、ジオクチルスズジラウレート、ビスマストリス(2-エチルヘキサノエート)、ジルコニウムテトラアセチルアセトネートのような公知のウレタン化触媒の存在下又は非存在下で、ポリオレフィンポリオール(a11)及び/又はポリエステルポリオール(a12)と、ポリイソシアネート(a3)と、必要に応じて水酸基含有環式炭化水素化合物(a2)とを重付加反応させることにより行える。反応時間を短縮するために、触媒の存在下で反応させてもよく、かつ好ましい。触媒の添加量は、(a11)、(a12)、(a2)及び(a3)成分の総量100質量部に対して0.001~1.00質量部であることが好ましく、0.005~0.50質量部がより好ましく、0.01~0.30質量部が更に好ましい。0.001質量部以上であれば、十分に反応が早くなり、1質量部以下であれば接着力を保持できる。
溶媒の添加量は、(a11)、(a12)、(a2)及び(a3)成分の総量100質量部に対して50~500質量部であることが好ましく、50~200質量部がより好ましく、80~120質量部が更に好ましい。
なお各ポリオール成分に含まれる水酸基数は、JIS K 1557-1:2007(滴定法)のA法にて求めることができる。各イソシアネート成分に含まれるイソシアナト基数は、JIS K 6806:2003(滴定法)にて求めることができる。
本実施の形態におけるポリイソシアネートの多量体(B)(以下、「(B)成分」又は「(B)」ということがある)は、本実施の形態の金属箔と樹脂フィルムのラミネート用接着剤に硬化剤として配合するものである。
このように、ポリイソシアネートを多量体にすることにより、金属箔と樹脂フィルムのラミネート用接着剤が耐熱性及び耐電解液性に優れたものとなる。その理由は不明であるが、イソシアヌレート体及びアロファネート化多量体等の構造が耐熱性及び耐電解液性に優れているからであると推測される。
なお、本実施の形態のポリイソシアネートの多量体(B)は、金属箔と樹脂フィルムのラミネート用接着剤の調製時に、飽和脂肪族ポリイソシアネートの多量体(b1)及び飽和脂環式ポリイソシアネートの多量体(b2)を予め混合したものを投入しても、別々に投入しても構わない。
ポリイソシアネートの多量体(B)中における、飽和脂肪族ポリイソシアネートの多量体(b1)及び飽和脂環式ポリイソシアネートの多量体(b2)の合計量は、好ましくは80質量%以上、より好ましくは90質量%以上、更に好ましくは95質量%以上である。
本実施の形態における周期律表の7族及び12族の少なくとも1種の金属の化合物である金属化合物(C)(以下、「7族及び/又は12族の金属化合物(C)」又は「金属化合物(C)」又は「(C)成分」又は「(C)」ともいう)は、本実施の形態の金属箔と樹脂フィルムのラミネート用接着剤中のポリウレタンポリオール(A)及びポリイソシアネートの多量体(B)の反応を促進するための反応促進剤として配合するものである。
7族及び12族の少なくとも1種の金属の化合物である金属化合物(C)として、例えば、金属ヘキサン酸塩、金属オクチル酸塩(2-エチルヘキサン酸塩)、金属ネオデカン酸塩、金属ステアリン酸塩、金属オレイン酸塩等の金属カルボン酸塩、金属アセチルアセトナート等が挙げられる。中でも長期電解液浸漬後の接着強度の観点から、金属カルボン酸塩を含むことが好ましく、マンガン及び亜鉛から選ばれる金属のカルボン酸塩を少なくとも1種以上含むことがより好ましく、亜鉛のカルボン酸塩を含むことが更に好ましい。
具体的には、7族及び12族の少なくとも1種の金属の化合物である金属化合物(C)は、ネオデカン酸亜鉛(C20H38O4Zn)、ヘキソエート亜鉛(オクチル酸亜鉛、2-エチルヘキサン酸亜鉛、C16H30O4Zn)、ステアリン酸亜鉛(C36H70O4Zn)、亜鉛アセチルアセトナート(C10H14O4Zn)、ヘキソエートマンガン(オクチル酸マンガン、2-エチルヘキサン酸マンガン、C16H30O4Mn)が好ましく、ネオデカン酸亜鉛(C20H38O4Zn)、ヘキソエート亜鉛(オクチル酸亜鉛、2-エチルヘキサン酸亜鉛、C16H30O4Zn)がより好ましい。
ポリオール(A)100質量部に対する、7族及び12族の少なくとも1種の金属の化合物である金属化合物(C)の比率は特に制限されないが、ポリオール(A)100質量部に対して、金属化合物(C)の含有量は金属の質量で換算して0.0001質量部~5質量部が好ましく、0.001質量部~3質量部がより好ましく、0.01~1.5質量部がより好ましく、0.03~1.5質量部が更に好ましい。0.0001質量部以上であれば、本発明の金属箔と樹脂フィルムのラミネート用接着剤から得られる接着剤層の接着力が長期間電解液に浸漬後においても十分に高くなり、5質量部以下であれば常態の接着強度が高くなる。なお、7族及び/又は12族の金属化合物(C)は、ポリオール(A)の合成時に添加しても、接着剤の調整時に添加してもよい。
<溶剤(D)>
溶剤(D)は、ポリオール(A)、ポリイソシアネートの多量体(B)及び7族及び12族の少なくとも1種の金属の化合物である金属化合物(C)を溶解又は分散可能なものであれば特に制限されない。例えば、トルエン、キシレン等の芳香族系有機溶剤、シクロヘキサン、メチルシクロヘキサン、エチルシクロヘキサン等の脂環式系有機溶剤、n-ヘキサン、n-ヘプタン等の脂肪族系有機溶剤、酢酸エチル、酢酸プロピル、酢酸ブチル等のエステル系有機溶剤、アセトン、メチルエチルケトン、メチルブチルケトン等のケトン系有機溶剤などが挙げられる。これらは、単独又は2種以上混合して使用することができる。
これらの中では、特にポリオール(A)の溶解性の見地から、酢酸エチル、酢酸プロピル、酢酸ブチル、トルエン、メチルシクロヘキサン、メチルエチルケトンが好ましく、トルエンがより好ましい。
本実施の形態に係る金属箔と樹脂フィルムのラミネート用接着剤中における、溶剤(D)の含有量は、30~80質量%が好ましく、40~80質量%であることがより好ましく、50~80質量%であることが更に好ましく、60~80質量%であることが更に好ましい。30質量%以上であれば、本実施の形態の金属箔と樹脂フィルムのラミネート用接着剤の塗布時の操作性が良好となり、80質量%以下であれば、本実施の形態の金属箔と樹脂フィルムのラミネート用接着剤を塗布・硬化して得られる積層体の厚み制御性が良好となる。
本実施の形態の金属箔と樹脂フィルムのラミネート用接着剤は、必要に応じて、粘着付与剤、可塑剤等の添加剤を含有していてもよい。
本実施の形態の積層体は、金属箔と樹脂フィルムが本実施の形態の金属箔と樹脂フィルムのラミネート用接着剤(以下、単に「本実施の形態のラミネート用接着剤」ということがある。)から得られる接着剤層を介して積層されたものである。
また本実施の形態の積層体中に、金属箔と樹脂フィルムを本実施の形態のラミネート用接着剤から得られる接着剤層を介して接合した層が含まれれば、他に金属箔同士及び/又は樹脂フィルム同士が本実施の形態のラミネート用接着剤から得られる接着剤層を介して接合した層を含んでもよい。この接合方法は、ヒートラミネーション方式やドライラミネーション方式等の公知の方法を用いることができる。本実施の形態において、ヒートラミネーション方式とは、溶剤(D)を含まない本実施の形態のラミネート用接着剤を、接着剤層に接する層表面にて加熱溶融、又は接着剤層に接する層と共に加熱押し出しすることにより、積層体の層間に介在させ、接着剤層を形成する方式である。また、本実施の形態において、ドライラミネーション方式とは、溶剤(D)を含む本実施の形態のラミネート用接着剤を接着剤層に接する層表面に塗布、乾燥せしめた後に他方の層と重ね合せて圧着することにより、積層体の層間に介在させ、接着剤層を形成する方式である。
本実施の形態の電池外装用包装材は、本実施の形態の積層体を用いて得られる。
本実施の形態の電池外装用包装材は、本実施の形態の積層体の、金属箔の外側に樹脂フィルム特に耐熱性樹脂フィルムからなる外層を設けたものであることが好ましい。また、必要に応じて、機械的強度や耐電解液性などの特性を高めるために、第1中間樹脂層又は/及び第2中間樹脂層等を付加した構成にすることができる。好ましい形態としては、具体的に次のような構成にすることができる。なお、接着剤層は「本実施の形態のラミネート用接着剤から得られる接着剤層」を意味し、金属箔層をアルミニウム箔層として例示している。
(1)外層/アルミニウム箔層/接着剤層/樹脂フィルム層
(2)外層/第1中間樹脂層/アルミニウム箔層/接着剤層/樹脂フィルム層
(3)外層/アルミニウム箔層/第2中間樹脂層/接着剤層/樹脂フィルム層
(4)外層/第1中間樹脂層/アルミニウム箔層/第2中間樹脂層/接着剤層/樹脂フィルム層
(5)コート層/外層/アルミニウム箔層/接着剤層/樹脂フィルム層
(6)コート層/外層/第1中間樹脂層/アルミニウム箔層/接着剤層/樹脂フィルム層
(7)コート層/外層/アルミニウム箔層/第2中間樹脂層/接着剤層/樹脂フィルム層
(8)コート層/外層/第1中間樹脂層/アルミニウム箔層/第2中間樹脂層/接着剤層/樹脂フィルム層
上記において、第1中間樹脂層としては、ポリアミド樹脂、ポリエステル樹脂又はポリエチレン樹脂等が電池外装用包装材の機械的強度を向上させる目的で使用される。第2中間樹脂層としては、第1中間樹脂層と同様にポリアミド樹脂、ポリエステル樹脂又はポリエチレン樹脂やポリプロピレン等の熱接着性押出し樹脂が、主として耐電解液性を向上させる目的で使用される。樹脂フィルム層は、単層の樹脂フィルム、複層の樹脂フィルム(2層の共押出し又は3層の共押出し等により製造する)が使用できる。また、第2中間樹脂層も単層の樹脂フィルムや複層の共押出し樹脂フィルムが使用できる。第1中間樹脂層及び第2中間樹脂層の厚さは、特に限定されないが、これらを設ける場合は、通常0.1~30μm程度である。
外層に使用する樹脂フィルムは、耐熱性、成形性、絶縁性等に優れたものであり、ポリアミド(ナイロン)樹脂又はポリエステル樹脂の延伸フィルムが一般的に使用される。この外層フィルムの厚さは、9~50μm程度であり、9μm未満では包装材の成形を行うときに延伸フィルムの伸びが不足し、アルミニウム箔にネッキングが生じ、成形不良が起こり易い。一方、50μmを超える厚さの場合は、特段、成形性の効果が向上する訳でもなく、逆に体積エネルギー密度を低下させるとともにコストアップにつながるだけである。外層フィルムの厚さは10~40μm程度であることがより好ましく、20~30μmであることがさらに好ましい。
金属箔は、水蒸気等に対するバリア性の役割を担うもので、材質としては純アルミニウム系又はアルミニウム-鉄系合金のO材(軟質材)が一般的に使用され、かつ好ましい。アルミニウム箔の厚さとしては、加工性の確保及び酸素や水分の包装内への浸入を防止するバリア性確保のために、10~100μm程度が好ましい。アルミニウム箔の厚さが10μm未満の場合は、成形時においてアルミニウム箔の破断が生じたり、ピンホールが発生したりして酸素や水分の浸入のおそれがある。一方、アルミニウム箔の厚さが100μmを超えた場合は、成形時の破断の改善効果やピンホール発生防止効果が特段向上するわけでなく、単に包装材の総厚さが厚く、質量が増加し、体積エネルギー密度が低下する。アルミニウム箔は、一般的に30~50μm程度の厚さのものが使用され、40~50μmの厚さのものを使用することが好ましい。なお、アルミニウム箔には、樹脂フィルムとの接着性向上や耐食性向上のため、シランカップリング剤やチタンカップリング剤等のアンダーコート処理、クロメート処理等の化成処理をしておくことが好ましい。
樹脂フィルムとしては、ポリプロピレン、ポリエチレン、マレイン酸変性ポリプロピレン、エチレン-アクリレート共重合体又はアイオノマー樹脂などの熱融着性樹脂フィルムが好ましい。これらの樹脂は、ヒートシール性を有し、腐食性の強いリチウム二次電池の電解液等に対する耐薬品性を向上させる役割を担うものである。これらのフィルム厚さは、9~100μmが好ましく、より好ましくは20~80μmであり、40~80μmであるのが最も好ましい。樹脂フィルムの厚さが9μm以上であれば、十分なヒートシール強度が得られ、電解液等に対する耐食性が良好となる。樹脂フィルムの厚さが100μm以下であれば、電池外装用包装材の強度が十分でありかつ、成形性が良好となる。
本実施の形態の電池外装用包装材は、外層の上にコート層を設けてもよい。コート層の形成法としては、ガスバリア性のポリマーをコートする方法、アルミニウム金属や酸化ケイ素、酸化アルミニウム等の無機酸化物を蒸着し、金属及び無機物の薄膜をコートする方法などがある。コート層を設けることにより、水蒸気及びその他のガスバリア性がより優れた積層体が得られる。
本実施の形態の電池ケースは、本実施の形態の電池外装用包装材を用いて得られる。例えば、電池外装用包装材を成形することによって得られる。
本実施の形態の電池外装用包装材は、耐電解液性や耐熱性、水蒸気及びその他のガスバリア性に優れており、二次電池、特にリチウムイオン電池用の電池ケースとして好適に用いられる。また、本実施の形態の電池外装用包装材は成形性が非常に良好であるため、公知の方法に従って成形することにより、本実施の形態の電池ケースを簡便に得ることができる。成形の方法は特に限定されないが、深絞り成形又は張り出し成形によって成形すると、複雑な形状や寸法精度が高い電池ケースを作製することができる。
撹拌機、水分離器付き反応容器中に、水添ダイマージオールとして「Sovermol908」(BASF社製)を220.00g、水添ダイマー酸として「EMPOL1008」(BASF社製)を230.00g、触媒のブチルスズジラウレートとして「KS-1260」(堺化学工業株式会社製)を0.10g仕込み、約240℃において、常圧下から始めて縮合水を流出させながら減圧しつつ脱水エステル化反応を行い、ポリエステルポリオール(以下、ポリエステルポリオール(1)と記す。)を得た。
撹拌装置、温度計及びコンデンサーを備えた反応容器中に、(a11)成分として「GI-1000」(日本曹達株式会社製、水添ポリブタジエンポリオール)を108.00g、(a2)成分として「TCDアルコールDM」(オクセア社製、トリシクロデカンジメタノール)を12.00g、酸化防止剤としてヒドロキノンモノメチルエーテル(和光純薬工業株式会社製)を0.04g、触媒として「KS-1260」(堺化学工業株式会社製、ジブチルスズジラウレート)を0.03g、(a3)成分として「デスモジュールW」(バイエル社製、メチレンビス(4-シクロヘキシルイソシアネート))を30.00g、及び溶剤(D)としてトルエンを70.00g投入し、撹拌しながら、オイルバスを用いて85~90℃に昇温した。その後、2.5時間撹拌しながら反応を継続した。その後、赤外吸収スペクトルを測定し、イソシアナト基の吸収が消失していることを確認して反応を終了し、さらにトルエンを80.00g投入して撹拌溶解し、ポリウレタンポリオール(以下、ポリウレタンポリオール(1)と記す。)のトルエン溶液(固形分濃度50質量%)を得た。合成例2における配合組成を表1に示す。
表1に示す配合にしたこと以外は合成例2と同様の方法で合成を行い、ポリウレタンポリオール(2)~(6)のトルエン溶液(固形分濃度50質量%)を得た。なお、表1中のG-1000は日本曹達株式会社製のポリブタジエンポリオール、HS 2B-5500は豊国製油株式会社製のポリエステルポリオール(ヒマシ油)である。
なお、合成例2~7において、(a11)、(a12)及び(a2)成分に含まれる水酸基数をJIS K 1557-1:2007(滴定法)のA法に基づいて測定し、また、ポリイソシアネート(a3)に含まれるイソシアナト基数をJIS K 6806:2003(滴定法)に基づいて測定した。これらの測定値に基づいて、(a11)、(a12)及び(a2)成分に含まれる水酸基数に対する、ポリイソシアネート(a3)に含まれるイソシアナト基数の比率「NCO/OH比」を求めた。その結果を表1に示す。
(A)成分として合成例2で得たポリウレタンポリオール(1)のトルエン溶液60.00g(固形分30.00g、トルエン30.00g)を用い、これに(b1)成分として「デュラネートTKA-100」(旭化成ケミカルズ株式会社製、ヘキサメチレンジイソシアネートのイソシアヌレート体)を3.20g、(b2)成分として「デスモジュール XP 2565」(バイエル社製、イソホロンジイソシアネートのアロファネート化多量体(80質量部)及び酢酸ブチル(20質量部)の混合物)を7.30g、(C)成分として「BiCAT Z」(Shepherd Chemical社製、ネオデカン酸亜鉛)を0.06g、溶剤(D)としてトルエンを99.44g加えて、金属箔と樹脂フィルムのラミネート用接着剤1(組成物1)を調製した。
なお、(A)成分であるポリウレタンポリオール(1)に含まれる水酸基数を、JIS K 1557-1:2007(滴定法)のA法に基づいて測定した。また、(b1)成分であるデュラネートTKA-100及び(b2)成分であるデスモジュール XP 2565に含まれるイソシアナト基数を、それぞれ、JIS K 6806:2003(滴定法)に基づいて測定した。これらの測定値に基づいて、ポリオール(A)に含まれる水酸基数に対する、飽和脂肪族ポリイソシアネートの多量体(b1)及び飽和脂環式ポリイソシアネートの多量体(b2)に含まれるイソシアナト基数の比率を算出した。その結果を表2に示す。
次いで、このラミネート用接着剤1を用いて、外層/外層用接着剤/アルミニウム箔層/ラミネート用接着剤1/樹脂フィルム、という構造を有する電池外装用包装材を、ドライラミネーション方式で製造した。各層の詳細は、次のとおりである。
外層用接着剤:ウレタン系ドライラミネート用接着剤(AD502/CAT10、東洋モートン株式会社製、塗布量3g/m2(塗布時))
アルミニウム箔層:アルミニウム-鉄系合金のアルミニウム箔(AA規格8079-O材、厚さ40μm)
ラミネート用接着剤1:上記のラミネート用接着剤1(塗布量:乾燥後の厚さが2μm)
樹脂フィルム:未延伸ポリプロピレンフィルム(厚さ40μm)
表2~表4に示す配合としたこと以外は実施例1と同様にして、金属箔と樹脂フィルムのラミネート用接着剤2~23(組成物2~23)を調製した。
次いで、ラミネート用接着剤1に代えてラミネート用接着剤2~23を用いたこと以外は実施例1と同様にして、電池外装用包装材を製造した。
なお、表2~表4中における各成分の詳細は、次のとおりである。
・デュラネートTKA-100:旭化成ケミカルズ株式会社製、ヘキサメチレンジイソシアネートのイソシアヌレート体
・ヘキサメチレンジイソシアネート:東京化成工業株式会社製の試薬
・デスモジュール XP 2565:バイエル社製、イソホロンジイソシアネートのアロファネート化多量体(80質量部)及び酢酸ブチル(20質量部)の混合物
・デスモジュール Z 4470:バイエル社製、イソホロンジイソシアネートのイソシアヌレート体(70質量部)及び酢酸ブチル(30質量部)の混合物
・イソホロンジイソシアネート:東京化成工業株式会社製の試薬
・BiCAT Z:Shepherd Chemical社製、ネオデカン酸亜鉛
・ヘキソエート亜鉛:東栄化工株式会社製、2-エチルヘキサン酸亜鉛(65質量部)及びミネラルスピリット(35質量部)の混合物
・エフコ・ケム ZNS-P:株式会社ADEKA製、ステアリン酸亜鉛
・亜鉛アセチルアセトナート:東京化成工業株式会社製の試薬
・ヘキソエートマンガン:東栄化工株式会社製、オクチル酸マンガン(42質量部)及びミネラルスピリット(58質量部)の混合物
・KS-1260:堺化学工業株式会社製、ジブチルスズジラウレート
・チタニウムアセチルアセトナート:東京化成工業株式会社製の試薬
・BiCAT8210:Shepherd Chemical社製、トリス(2-エチルヘキサン酸)ビスマス(ビスマストリス(2-エチルヘキサノエート))(89質量部)及び2-エチルヘキサン酸(11質量部)の混合物
得られた電池外装用包装材から長さ150mm×幅15mmに切り出したものを試験片として用い、電解液溶媒浸漬後のT字剥離強度、長期電解液溶媒浸漬後のT字剥離強度及び85℃雰囲気下でのT字剥離強度を測定した。測定の条件、方法は下記の(1)~(3)のとおりである。各試験は、n=2で行い(2個の試験片について測定を行い)、その平均値をとった。また、結果を表2~表4に示す(単位は全てN/15mm)。
長さ150mm×幅15mmの試験片を、85℃の電解液溶媒(エチレンカーボネート/ジエチルカーボネート、質量比50/50)に1日浸漬した後、取り出した。次いで当該試験片について、オートグラフAG-X(島津製作所製)を用いて、23℃×50%RH雰囲気下、剥離速度100mm/minの条件で、アルミニウム箔層と未延伸ポリプロピレンフィルム層(樹脂フィルム)との間の180°剥離強度を測定した。その結果を表2~表4に示す。
85℃の電解液溶媒に浸漬する期間を1日から4週間に変更する以外は(1)と同じ方法で、アルミニウム箔層と未延伸ポリプロピレンフィルム層との間の180°剥離強度を測定した。その結果を表2~表4に示す。
長さ150mm×幅15mmの試験片及びオートグラフAG-X(株式会社島津製作所製)を用いて、85℃雰囲気下に放置し、試験片の温度が85℃になった後に剥離速度100mm/minで剥離させ、アルミニウム箔層と未延伸ポリプロピレンフィルム層との間の180°剥離強度を測定した。その結果を表2~表4に示す。
表2及び表3の結果から、本発明の金属箔と樹脂フィルムのラミネート用接着剤(実施例1~14)は、電解液溶媒浸漬後のT字剥離強度、長期電解液溶媒浸漬後のT字剥離強度及び85℃雰囲気下でのT字剥離強度のいずれにおいてもバランスよく優れていることがわかる。
Claims (15)
- ポリオール(A)、ポリイソシアネートの多量体(B)、並びに7族及び12族の少なくとも1種の金属の化合物である金属化合物(C)を有する、金属箔と樹脂フィルムのラミネート用接着剤であって、
前記ポリイソシアネートの多量体(B)が、飽和脂肪族ポリイソシアネートの多量体(b1)及び飽和脂環式ポリイソシアネートの多量体(b2)を含む、金属箔と樹脂フィルムのラミネート用接着剤。 - 前記ポリオール(A)が、鎖状ポリオレフィンポリオール(a11)及びポリエステルポリオール(a12)の少なくとも1種、飽和の環式炭化水素構造と2つ以上の水酸基とを併せ持つ水酸基含有環式炭化水素化合物(a2)、並びにポリイソシアネート(a3)を含有する成分を重付加して得られる、ポリウレタンポリオールを含む、請求項1に記載の金属箔と樹脂フィルムのラミネート用接着剤。
- 前記ポリエステルポリオール(a12)が、水添ダイマー酸由来の構成単位と水添ダイマージオール由来の構成単位とを有するポリエステルポリオールを含む、請求項2に記載の金属箔と樹脂フィルムのラミネート用接着剤。
- 前記飽和脂肪族ポリイソシアネートの多量体(b1)が、飽和脂肪族ポリイソシアネートのイソシアヌレート体を含む、請求項1~3のいずれかに記載の金属箔と樹脂フィルムのラミネート用接着剤。
- 前記飽和脂環式ポリイソシアネートの多量体(b2)が、イソホロンジイソシアネートの多量体を含む、請求項1~4のいずれかに記載の金属箔と樹脂フィルムのラミネート用接着剤。
- 前記ポリオール(A)に含まれる水酸基数に対する、飽和脂肪族ポリイソシアネートの多量体(b1)及び飽和脂環式ポリイソシアネートの多量体(b2)に含まれるイソシアナト基数の比率が、1~15である、請求項1~5のいずれかに記載の金属箔と樹脂フィルムのラミネート用接着剤。
- 前記金属化合物(C)が、7族及び12族の少なくとも一種の金属のカルボン酸塩を少なくとも1種以上含む、請求項1~6のいずれかに記載の金属箔と樹脂フィルムのラミネート用接着剤。
- 前記金属化合物(C)が亜鉛又はマンガンのカルボン酸塩を含む、請求項1~7のいずれかに記載の金属箔と樹脂フィルムのラミネート用接着剤。
- 溶剤(D)をさらに含む、請求項1~8のいずれかに記載の金属箔と樹脂フィルムのラミネート用接着剤。
- 金属箔と樹脂フィルムが、請求項1~9のいずれかに記載の金属箔と樹脂フィルムのラミネート用接着剤から得られる接着剤層を介して積層された、積層体。
- 前記金属箔がアルミニウム箔であり、前記樹脂フィルムが熱融着性樹脂フィルムを含有する、請求項10に記載の積層体。
- 前記金属箔の厚さが10~100μmであり、前記樹脂フィルムの厚さが9~100μmである、請求項10又は請求項11に記載の積層体。
- 請求項10~12のいずれかに記載の積層体を用いて得られる、電池外装用包装材。
- 請求項13に記載の電池外装用包装材を用いて得られる、電池ケース。
- 請求項13に記載の電池外装用包装材を深絞り成形又は張り出し成形する、電池ケースの製造方法。
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