WO2022254898A1 - 非水二次電池セパレータ用バインダー分散液、スラリー組成物、非水二次電池セパレータ、および非水二次電池 - Google Patents
非水二次電池セパレータ用バインダー分散液、スラリー組成物、非水二次電池セパレータ、および非水二次電池 Download PDFInfo
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- secondary battery
- polymer
- aqueous secondary
- battery separator
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- 125000000913 palmityl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- 125000002958 pentadecyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- WXZMFSXDPGVJKK-UHFFFAOYSA-N pentaerythritol Chemical compound OCC(CO)(CO)CO WXZMFSXDPGVJKK-UHFFFAOYSA-N 0.000 description 1
- GYDSPAVLTMAXHT-UHFFFAOYSA-N pentyl 2-methylprop-2-enoate Chemical compound CCCCCOC(=O)C(C)=C GYDSPAVLTMAXHT-UHFFFAOYSA-N 0.000 description 1
- ULDDEWDFUNBUCM-UHFFFAOYSA-N pentyl prop-2-enoate Chemical compound CCCCCOC(=O)C=C ULDDEWDFUNBUCM-UHFFFAOYSA-N 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 229920006287 phenoxy resin Polymers 0.000 description 1
- 239000013034 phenoxy resin Substances 0.000 description 1
- FURYAADUZGZUGQ-UHFFFAOYSA-N phenoxybenzene;sulfuric acid Chemical class OS(O)(=O)=O.C=1C=CC=CC=1OC1=CC=CC=C1 FURYAADUZGZUGQ-UHFFFAOYSA-N 0.000 description 1
- QIWKUEJZZCOPFV-UHFFFAOYSA-N phenyl 2-methylprop-2-enoate Chemical compound CC(=C)C(=O)OC1=CC=CC=C1 QIWKUEJZZCOPFV-UHFFFAOYSA-N 0.000 description 1
- WRAQQYDMVSCOTE-UHFFFAOYSA-N phenyl prop-2-enoate Chemical compound C=CC(=O)OC1=CC=CC=C1 WRAQQYDMVSCOTE-UHFFFAOYSA-N 0.000 description 1
- 235000021317 phosphate Nutrition 0.000 description 1
- 150000003012 phosphoric acid amides Chemical class 0.000 description 1
- 150000003013 phosphoric acid derivatives Chemical class 0.000 description 1
- 150000003014 phosphoric acid esters Chemical class 0.000 description 1
- 229920002627 poly(phosphazenes) Polymers 0.000 description 1
- 229920000767 polyaniline Polymers 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 229920002959 polymer blend Polymers 0.000 description 1
- 239000005518 polymer electrolyte Substances 0.000 description 1
- 229920000259 polyoxyethylene lauryl ether Polymers 0.000 description 1
- 239000000256 polyoxyethylene sorbitan monolaurate Substances 0.000 description 1
- 235000010486 polyoxyethylene sorbitan monolaurate Nutrition 0.000 description 1
- 239000001818 polyoxyethylene sorbitan monostearate Substances 0.000 description 1
- 235000010989 polyoxyethylene sorbitan monostearate Nutrition 0.000 description 1
- 229920001451 polypropylene glycol Polymers 0.000 description 1
- 229920001282 polysaccharide Polymers 0.000 description 1
- 239000005017 polysaccharide Substances 0.000 description 1
- 229920005749 polyurethane resin Polymers 0.000 description 1
- 229920002451 polyvinyl alcohol Polymers 0.000 description 1
- 229920002620 polyvinyl fluoride Polymers 0.000 description 1
- 229920000036 polyvinylpyrrolidone Polymers 0.000 description 1
- 239000001267 polyvinylpyrrolidone Substances 0.000 description 1
- 235000013855 polyvinylpyrrolidone Nutrition 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- UIIIBRHUICCMAI-UHFFFAOYSA-N prop-2-ene-1-sulfonic acid Chemical compound OS(=O)(=O)CC=C UIIIBRHUICCMAI-UHFFFAOYSA-N 0.000 description 1
- FBCQUCJYYPMKRO-UHFFFAOYSA-N prop-2-enyl 2-methylprop-2-enoate Chemical compound CC(=C)C(=O)OCC=C FBCQUCJYYPMKRO-UHFFFAOYSA-N 0.000 description 1
- QTECDUFMBMSHKR-UHFFFAOYSA-N prop-2-enyl prop-2-enoate Chemical compound C=CCOC(=O)C=C QTECDUFMBMSHKR-UHFFFAOYSA-N 0.000 description 1
- NHARPDSAXCBDDR-UHFFFAOYSA-N propyl 2-methylprop-2-enoate Chemical compound CCCOC(=O)C(C)=C NHARPDSAXCBDDR-UHFFFAOYSA-N 0.000 description 1
- PNXMTCDJUBJHQJ-UHFFFAOYSA-N propyl prop-2-enoate Chemical compound CCCOC(=O)C=C PNXMTCDJUBJHQJ-UHFFFAOYSA-N 0.000 description 1
- RUOJZAUFBMNUDX-UHFFFAOYSA-N propylene carbonate Chemical compound CC1COC(=O)O1 RUOJZAUFBMNUDX-UHFFFAOYSA-N 0.000 description 1
- XWGJFPHUCFXLBL-UHFFFAOYSA-M rongalite Chemical compound [Na+].OCS([O-])=O XWGJFPHUCFXLBL-UHFFFAOYSA-M 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- RSVDRWTUCMTKBV-UHFFFAOYSA-N sbb057044 Chemical compound C12CC=CC2C2CC(OCCOC(=O)C=C)C1C2 RSVDRWTUCMTKBV-UHFFFAOYSA-N 0.000 description 1
- 238000007650 screen-printing Methods 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 229910052814 silicon oxide Inorganic materials 0.000 description 1
- 229920002050 silicone resin Polymers 0.000 description 1
- 238000004088 simulation Methods 0.000 description 1
- 239000001632 sodium acetate Substances 0.000 description 1
- 235000017281 sodium acetate Nutrition 0.000 description 1
- 235000017557 sodium bicarbonate Nutrition 0.000 description 1
- 229910000030 sodium bicarbonate Inorganic materials 0.000 description 1
- 239000001509 sodium citrate Substances 0.000 description 1
- NLJMYIDDQXHKNR-UHFFFAOYSA-K sodium citrate Chemical compound O.O.[Na+].[Na+].[Na+].[O-]C(=O)CC(O)(CC([O-])=O)C([O-])=O NLJMYIDDQXHKNR-UHFFFAOYSA-K 0.000 description 1
- 235000011083 sodium citrates Nutrition 0.000 description 1
- HRZFUMHJMZEROT-UHFFFAOYSA-L sodium disulfite Chemical compound [Na+].[Na+].[O-]S(=O)S([O-])(=O)=O HRZFUMHJMZEROT-UHFFFAOYSA-L 0.000 description 1
- APSBXTVYXVQYAB-UHFFFAOYSA-M sodium docusate Chemical group [Na+].CCCCC(CC)COC(=O)CC(S([O-])(=O)=O)C(=O)OCC(CC)CCCC APSBXTVYXVQYAB-UHFFFAOYSA-M 0.000 description 1
- 229910001415 sodium ion Inorganic materials 0.000 description 1
- 235000019333 sodium laurylsulphate Nutrition 0.000 description 1
- 229940001584 sodium metabisulfite Drugs 0.000 description 1
- 235000010262 sodium metabisulphite Nutrition 0.000 description 1
- 235000010265 sodium sulphite Nutrition 0.000 description 1
- AKHNMLFCWUSKQB-UHFFFAOYSA-L sodium thiosulfate Chemical compound [Na+].[Na+].[O-]S([O-])(=O)=S AKHNMLFCWUSKQB-UHFFFAOYSA-L 0.000 description 1
- 235000019345 sodium thiosulphate Nutrition 0.000 description 1
- 229910021384 soft carbon Inorganic materials 0.000 description 1
- 229940035044 sorbitan monolaurate Drugs 0.000 description 1
- 239000001587 sorbitan monostearate Substances 0.000 description 1
- 235000011076 sorbitan monostearate Nutrition 0.000 description 1
- 229940035048 sorbitan monostearate Drugs 0.000 description 1
- 235000019337 sorbitan trioleate Nutrition 0.000 description 1
- 229960000391 sorbitan trioleate Drugs 0.000 description 1
- 239000011029 spinel Substances 0.000 description 1
- 229910052596 spinel Inorganic materials 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 125000004079 stearyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 229920005792 styrene-acrylic resin Polymers 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- KDYFGRWQOYBRFD-UHFFFAOYSA-L succinate(2-) Chemical compound [O-]C(=O)CCC([O-])=O KDYFGRWQOYBRFD-UHFFFAOYSA-L 0.000 description 1
- 239000001384 succinic acid Substances 0.000 description 1
- HXJUTPCZVOIRIF-UHFFFAOYSA-N sulfolane Chemical compound O=S1(=O)CCCC1 HXJUTPCZVOIRIF-UHFFFAOYSA-N 0.000 description 1
- 125000000472 sulfonyl group Chemical group *S(*)(=O)=O 0.000 description 1
- 238000010557 suspension polymerization reaction Methods 0.000 description 1
- 229920003051 synthetic elastomer Polymers 0.000 description 1
- 239000005061 synthetic rubber Substances 0.000 description 1
- 238000010345 tape casting Methods 0.000 description 1
- 239000011975 tartaric acid Substances 0.000 description 1
- 235000002906 tartaric acid Nutrition 0.000 description 1
- GEKDEMKPCKTKEC-UHFFFAOYSA-N tetradecane-1-thiol Chemical compound CCCCCCCCCCCCCCS GEKDEMKPCKTKEC-UHFFFAOYSA-N 0.000 description 1
- UWHCKJMYHZGTIT-UHFFFAOYSA-N tetraethylene glycol Chemical compound OCCOCCOCCOCCO UWHCKJMYHZGTIT-UHFFFAOYSA-N 0.000 description 1
- BFKJFAAPBSQJPD-UHFFFAOYSA-N tetrafluoroethene Chemical group FC(F)=C(F)F BFKJFAAPBSQJPD-UHFFFAOYSA-N 0.000 description 1
- YLQBMQCUIZJEEH-UHFFFAOYSA-N tetrahydrofuran Natural products C=1C=COC=1 YLQBMQCUIZJEEH-UHFFFAOYSA-N 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
- LDHQCZJRKDOVOX-UHFFFAOYSA-N trans-crotonic acid Natural products CC=CC(O)=O LDHQCZJRKDOVOX-UHFFFAOYSA-N 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- 150000003624 transition metals Chemical class 0.000 description 1
- SGCFZHOZKKQIBU-UHFFFAOYSA-N tributoxy(ethenyl)silane Chemical compound CCCCO[Si](OCCCC)(OCCCC)C=C SGCFZHOZKKQIBU-UHFFFAOYSA-N 0.000 description 1
- IPBROXKVGHZHJV-UHFFFAOYSA-N tridecane-1-thiol Chemical compound CCCCCCCCCCCCCS IPBROXKVGHZHJV-UHFFFAOYSA-N 0.000 description 1
- 125000002889 tridecyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- ZIBGPFATKBEMQZ-UHFFFAOYSA-N triethylene glycol Chemical compound OCCOCCOCCO ZIBGPFATKBEMQZ-UHFFFAOYSA-N 0.000 description 1
- 229960004418 trolamine Drugs 0.000 description 1
- 125000002948 undecyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- LSGOVYNHVSXFFJ-UHFFFAOYSA-N vanadate(3-) Chemical compound [O-][V]([O-])([O-])=O LSGOVYNHVSXFFJ-UHFFFAOYSA-N 0.000 description 1
- 238000009834 vaporization Methods 0.000 description 1
- 230000008016 vaporization Effects 0.000 description 1
- 239000006200 vaporizer Substances 0.000 description 1
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 1
- NLVXSWCKKBEXTG-UHFFFAOYSA-N vinylsulfonic acid Chemical compound OS(=O)(=O)C=C NLVXSWCKKBEXTG-UHFFFAOYSA-N 0.000 description 1
- 229910001928 zirconium oxide Inorganic materials 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M10/00—Secondary cells; Manufacture thereof
- H01M10/05—Accumulators with non-aqueous electrolyte
- H01M10/052—Li-accumulators
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
- H01M50/403—Manufacturing processes of separators, membranes or diaphragms
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
- H01M50/409—Separators, membranes or diaphragms characterised by the material
- H01M50/411—Organic material
- H01M50/414—Synthetic resins, e.g. thermoplastics or thermosetting resins
- H01M50/42—Acrylic resins
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
- H01M50/409—Separators, membranes or diaphragms characterised by the material
- H01M50/431—Inorganic material
- H01M50/434—Ceramics
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
- H01M50/409—Separators, membranes or diaphragms characterised by the material
- H01M50/443—Particulate material
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
- H01M50/409—Separators, membranes or diaphragms characterised by the material
- H01M50/446—Composite material consisting of a mixture of organic and inorganic materials
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
- H01M50/409—Separators, membranes or diaphragms characterised by the material
- H01M50/449—Separators, membranes or diaphragms characterised by the material having a layered structure
- H01M50/451—Separators, membranes or diaphragms characterised by the material having a layered structure comprising layers of only organic material and layers containing inorganic material
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
- H01M50/489—Separators, membranes, diaphragms or spacing elements inside the cells, characterised by their physical properties, e.g. swelling degree, hydrophilicity or shut down properties
-
- 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
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/10—Energy storage using batteries
-
- 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
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
Definitions
- the present disclosure relates to a binder for non-aqueous secondary battery separators that can be used to form a protective layer for separators in non-aqueous secondary batteries such as lithium ion secondary batteries. Further, the present disclosure provides a coating agent containing such a binder for a non-aqueous secondary battery separator, a non-aqueous secondary battery separator provided with a protective layer formed from a coating agent containing a binder for a non-aqueous secondary battery separator, and It relates to a non-aqueous secondary battery including this non-aqueous secondary battery separator.
- Non-aqueous secondary batteries are used in a wide range of applications because they are small, lightweight, have high energy density, and can be repeatedly charged and discharged.
- Lithium-ion secondary batteries in particular, are capable of obtaining high output, so they are used in a wide range of applications such as smartphones, tablets, notebook computers, and electric vehicles, and their demand is growing rapidly.
- the lithium-ion secondary battery has an electrically insulating separator layer between the electrodes to ensure safety in the event of an abnormality.
- This separator has a porous structure that allows the flow of lithium ions under normal conditions. play a role in preventing short circuits.
- Such separators further include a polyolefin sheet such as polyethylene or polypropylene having a porous structure, or a slurry composition based on these substrates containing non-conductive fine particles and a binder for the purpose of imparting heat resistance.
- a coated sheet provided with a protective layer formed by coating is used.
- Patent Document 1 discloses a protective layer using, as a separator binder, a water-soluble polymer obtained by polymerizing a (meth)acrylamide group-containing compound and a hydroxyl group-containing (meth)acrylic ester.
- Patent Document 2 discloses a protective layer using a water-soluble polymer containing 40% by mass or more of (meth)acrylamide and a particulate polymer as binders for a separator.
- Patent Document 3 a polymer of an amide group-containing ethylenically unsaturated monomer, a carboxyl group-containing ethylenically unsaturated monomer, and a carboxylic acid ester-containing ethylenically unsaturated monomer is used as a separator binder.
- a protective layer is disclosed.
- Such binders for separators that use water-soluble resins are excellent in heat resistance and electrolytic solution resistance, but there is a risk of poor coatability due to high viscosity, and non-aqueous binders when mixed with inorganic fine particles.
- binders for separators that use water-soluble resins are excellent in heat resistance and electrolytic solution resistance, but there is a risk of poor coatability due to high viscosity, and non-aqueous binders when mixed with inorganic fine particles.
- the internal resistance will increase due to filling the gaps between the inorganic fine particles.
- the moisture content of the separator is high, and the reaction between the battery members and moisture may deteriorate the cycle characteristics.
- the object of the present disclosure is a binder dispersion for a non-aqueous secondary battery separator having excellent electrolyte resistance, and a non-aqueous secondary solution containing such a binder for a non-aqueous secondary battery separator having excellent stability and coatability.
- the present disclosure includes a polymer (A1) and an aqueous medium,
- the polymer (A1) has an acid value of 15 mgKOH/g or less, and (meth)acrylamide of 40 to 80% by mass based on the total mass of the ethylenically unsaturated monomer mixture, and an octanol/water partition coefficient at 25°C.
- a polymer (A1a ) and The present invention relates to a binder dispersion for a non-aqueous secondary battery separator, which has a light transmittance of less than 70% at a wavelength of 400 nm at a solid content concentration of 5% by mass.
- the present disclosure includes a polymer (A1), a surfactant and an aqueous medium
- the polymer (A1) has an acid value of 15 mgKOH/g or less, and (meth)acrylamide of 50 to 85% by mass based on the total mass of the ethylenically unsaturated monomer mixture, and an octanol/water partition coefficient at 25°C.
- the present disclosure also relates to the binder dispersion for a non-aqueous secondary battery separator, wherein the polymer (A1) has a storage elastic modulus at 150° C. of 1.0 ⁇ 10 6 Pa or more.
- the polymer (A1) has an electrolytic solution swelling degree of less than 2 times when immersed in a mixed solvent having a volume ratio of ethylene carbonate and diethyl carbonate of 2:3 at 60 ° C. for 72 hours. It relates to the binder dispersion for the non-aqueous secondary battery separator.
- the present disclosure also relates to the binder dispersion for a nonaqueous secondary battery separator, which has a viscosity of 2,500 mPa ⁇ s or more and less than 25,000 mPa ⁇ s at a solid content concentration of 15% by mass.
- the present disclosure also relates to the binder dispersion for a non-aqueous secondary battery separator, which has a viscosity of 100 mPa ⁇ s or more and less than 15,000 mPa ⁇ s at a solid content concentration of 15% by mass.
- the present disclosure also relates to a slurry composition for a non-aqueous secondary battery separator containing inorganic fine particles and the binder dispersion for a non-aqueous secondary battery separator.
- the present disclosure further includes polymer (A2) (excluding polymer (A1)),
- the polymer (A2) relates to the slurry composition for the non-aqueous secondary battery separator, which is a particulate polymer having a glass transition temperature of -40 to 40°C.
- the present disclosure also relates to a non-aqueous secondary battery separator in which a protective layer formed from the slurry composition for a non-aqueous secondary battery separator is provided on at least one surface of a separator base material.
- the present disclosure also relates to a non-aqueous secondary battery including the non-aqueous secondary battery separator.
- a binder dispersion for a non-aqueous secondary battery separator having excellent electrolyte resistance and a slurry for a non-aqueous secondary battery separator containing such a binder for a non-aqueous secondary battery separator and having excellent solution stability and coatability
- a non-aqueous secondary battery separator having excellent heat resistance and adhesion to a separator substrate, provided with a protective layer formed from the composition, a slurry composition for a non-aqueous secondary battery separator, and the non-aqueous secondary It is possible to provide a non-aqueous secondary battery that has a battery separator and has low internal resistance and good cycle characteristics.
- a binder dispersion for a non-aqueous secondary battery separator a slurry composition for a non-aqueous secondary battery separator, a non-aqueous secondary battery separator, and a non-aqueous secondary battery according to the present disclosure will be described based on preferred embodiments.
- the present disclosure is not so limited.
- Each configuration can be replaced with any one that can exhibit a similar function, or any configuration can be added.
- the numerical range specified using "-” includes the numerical values described before and after "-” as the range of lower and upper values.
- film and “sheet” shall not be distinguished by thickness.
- the terms "(meth)acrylamide” and “(meth)acrylate” refer to “acrylamide or methacrylamide” and “acrylate or methacrylate”, respectively, unless otherwise specified.
- the ethylenically unsaturated monomer means a monomer having an ethylenically unsaturated double bond, and the ethylenically unsaturated monomer includes (meth)acrylamide and octanol/water partition at 25°C.
- a nonionic ethylenically unsaturated monomer (a-1b) having an octanol/water partition coefficient logarithm (Log Kow) at 25°C of 0.25 to 1.5, the Log Kow is 1.9 to 4.2
- a nonionic ethylenically unsaturated monomer (a-1b), a binder dispersion for a non-aqueous secondary battery separator, and a slurry composition for a non-aqueous secondary battery separator respectively.
- monomer (a-1a), monomer (a-1b), binder dispersion, and slurry composition are sometimes abbreviated as monomer (a-1a), monomer (a-1b), binder dispersion, and slurry composition.
- the monomer (a-1a) and the monomer (a-1b) are sometimes collectively referred to as the monomer (a-1).
- the polymer (A1a) and the polymer (A1b) may be collectively referred to as the polymer (A1).
- the various components appearing in the present specification may be used singly or in combination of two or more.
- a nonaqueous secondary battery is a secondary battery that does not use water as an electrolyte, and examples thereof include a lithium ion secondary battery (LIB), a sodium ion secondary battery, a magnesium secondary battery, and the like.
- LIB lithium ion secondary battery
- a sodium ion secondary battery sodium ion secondary battery
- a magnesium secondary battery magnesium secondary battery
- LIB is described as an example of a non-aqueous secondary battery.
- a slurry composition for a non-aqueous secondary battery can be applied.
- the binder dispersion for a non-aqueous secondary battery separator of the first embodiment contains a polymer (A1) and an aqueous medium,
- the polymer (A1) has an acid value of 15 mgKOH/g or less, and (meth)acrylamide of 40 to 80% by mass based on the total mass of the ethylenically unsaturated monomer mixture, and an octanol/water partition coefficient at 25°C.
- a polymer (A1a ) and Light transmittance at a wavelength of 400 nm is less than 70% at a solid content concentration of 5% by mass.
- the binder dispersion for a non-aqueous secondary battery separator of the second embodiment contains a polymer (A1), a surfactant and an aqueous medium, and the polymer (A1) has an acid value of 15 mgKOH/g or less, and 50 to 85% by weight (meth)acrylamide, based on the total weight of the ethylenically unsaturated monomer mixture, and an octanol/water partition coefficient Log Kow at 25°C of 1.9 to 4.2
- Light transmittance at 400 nm is less than 70%.
- a binder dispersion for a non-aqueous secondary battery separator having excellent electrolyte resistance can be obtained. Excellent stability and coatability.
- the aqueous medium refers to an aqueous dispersion medium or an aqueous solvent.
- aqueous medium it is preferable to use water, but if necessary, a water-soluble solvent can also be used.
- water-soluble solvents include alcohols, glycols, cellosolves, aminoalcohols, amines, ketones, carboxylic acid amides, phosphoric acid amides, sulfoxides, carboxylic acid esters, and phosphoric acid esters. , ethers, nitriles and the like.
- Surfactants include anionic surfactants, cationic surfactants and nonionic surfactants, and anionic surfactants and nonionic surfactants are preferred.
- the surfactant is preferably 0.05 to 2.0 parts by mass, more preferably 0.05 to 0.5 parts by mass with respect to 100 parts by mass of the polymer (A1), so that the polymer (A1 ) is further improved in polymerization stability in an aqueous medium.
- anionic surfactants include higher fatty acid salts such as sodium oleate, alkylarylsulfonates such as dodecylbenzenesulfonic acid, alkylsulfuric acid ester salts such as sodium lauryl sulfate, and sodium polyoxyethylene lauryl ether sulfate.
- Alkyl sulfosuccinate salts such as polyoxyethylene alkyl ether sulfate, sodium monooctyl sulfosuccinate, sodium dioctyl sulfosuccinate, sodium polyoxyethylene lauryl sulfosuccinate and derivatives thereof, polyoxyethylene distyrenated phenyl ether sulfate, etc.
- the surfactant is an alkyl sulfate salt or an alkyl sulfosuccinate ester salt because it is less likely to adversely affect the food resistance (seasoning resistance, microwave resistance) of the food packaging sheet. More preferably, the alkyl sulfate is lauryl sulfate, and the alkyl sulfosuccinate is dioctylsulfosuccinate.
- nonionic surfactants include polyoxyethylene alkyl ethers such as polyoxyethylene lauryl ether and polyoxyethylene stearyl ether, and polyoxyethylene alkylphenyl ethers such as polyoxyethylene octylphenyl ether and polyoxyethylene nonylphenyl ether.
- sorbitan higher fatty acid esters such as sorbitan monolaurate, sorbitan monostearate, sorbitan trioleate, polyoxyethylene sorbitan higher fatty acid esters such as polyoxyethylene sorbitan monolaurate, polyoxyethylene sorbitan monostearate, polyoxyethylene monostearate Polyoxyethylene higher fatty acid esters such as laurate and polyoxyethylene monostearate, glycerin higher fatty acid esters such as oleic acid monoglyceride and stearic acid monoglyceride, polyoxyethylene/polyoxypropylene block copolymers, polyvinyl alcohol, polyvinylpyrrolidone, poly and oxyethylene distyrenated phenyl ether.
- a polymerizable surfactant having one or more radically polymerizable unsaturated double bonds (vinyl group, (meth)acryloyl group) in the molecule can also be used as the surfactant.
- Polymerizable anionic surfactants include, for example, sulfosuccinic acid esters, alkyl ethers, alkylphenyl ethers, alkylphenyl esters, (meth)acrylate sulfates, and phosphates having a main skeleton.
- polymerizable nonionic surfactants include alkyl ethers, alkylphenyl ethers, alkylphenyl esters, and the like as the main skeleton.
- the polymer (A1) of the first embodiment has an acid value of 15 mg KOH / g or less, and based on the total weight of the ethylenically unsaturated monomer mixture, (meth)acrylamide 40 to 80% by mass, and at 25 ° C.
- An ethylenically unsaturated monomer mixture containing 20 to 60% by mass of a nonionic ethylenically unsaturated monomer (a-1a) having an octanol/water partition coefficient Log Kow of 0.25 to 1.5 is a polymer (A1a) of
- the polymer (A1) of the second embodiment has an acid value of 15 mgKOH/g or less, and based on the total mass of the ethylenically unsaturated monomer mixture, (meth)acrylamide 50 to 85 mass%, and 25
- Polymer (A1b) of the polymer mixture may contain other e
- a polymer has a glass transition temperature (Tg) of -40 to 40°C, it is defined as a polymer (A1) as long as it satisfies the above requirements.
- the acid value of the polymer (A1) is 15 mgKOH/g or less, more preferably 10 mgKOH/g or less.
- the slurry composition has better solution stability.
- Polymer (A1a)) [(Meth)acrylamide] (Meth)acrylamide in the polymer (A1a) is based on the total weight (100% by weight) of the ethylenically unsaturated monomer mixture, and contains 40 to 80% by weight, more preferably 45 to 75% by weight. . By containing in said range, electrolyte-resistant property and heat resistance can be improved significantly. Moreover, when it is blended with inorganic fine particles to form a slurry composition for a non-aqueous secondary battery separator, the compatibility with the inorganic fine particles is improved, and the solution stability of the slurry composition is also improved.
- the nonionic ethylenically unsaturated monomer (a-1a) has an octanol/water partition coefficient logarithm (Log Kow) of 0.25 to 1.5, more preferably 0.3 to 1.3. It is an ethylenically unsaturated monomer.
- Log Kow logarithm
- the polymer (A1a) becomes a dispersion system in the aqueous medium, and when it is made into a slurry composition, the gaps between the inorganic fine particles are not filled, and the ion permeability of the separator is improved. Good. This improves battery performance such as internal resistance and cycle characteristics.
- the binder has a high molecular weight for the good heat resistance and adhesiveness of the separator, the increase in viscosity is suppressed, and the coating properties of the slurry composition are also excellent.
- the Log Kow is 1.5 or less, the polymerization stability between (meth)acrylamide and an aqueous medium is good, and the stability of the slurry composition is also excellent.
- the nonionic ethylenically unsaturated monomer (a-1a) is based on the total weight (100% by weight) of the ethylenically unsaturated monomer mixture, and contains 20 to 60% by weight, more preferably 23 to It contains 55% by mass. Within the above range, the polymerizability in (meth)acrylamide and an aqueous medium is good, the polymer (A1a) can be stably dispersed in the aqueous medium, and the internal resistance of the battery is reduced. Also, when the polymer (A1a) has a large molecular weight, the increase in viscosity is suppressed, and both heat resistance and coatability can be achieved.
- the nonionic ethylenically unsaturated monomer is an ethylenically unsaturated monomer that does not have a charged functionality when in an aqueous medium. and an ethylenically unsaturated monomer having no sulfonyl group or the like.
- the octanol/water partition coefficient (Log Kow) is represented by the following (Formula 1), and is used as an index that indicates whether a certain compound X is likely to be partitioned into an aqueous phase or an oil phase (octanol).
- the other ethylenically unsaturated monomer (a-2) is an ethylenically unsaturated monomer other than (meth)acrylamide and the nonionic ethylenically unsaturated monomer (a-1), and (meth) It is an ethylenically unsaturated monomer polymerizable with acrylamide and a nonionic ethylenically unsaturated monomer (a-1).
- ethylenically unsaturated monomers (a-2) include aromatic ethylenically unsaturated substances such as vinyl naphthalene and phenoxyhexaethylene glycol methacrylate; Ethyl (meth)acrylate, propyl acrylate, 2-ethylhexyl methacrylate, octyl methacrylate, nonyl (meth)acrylate, decyl (meth)acrylate, undecyl (meth)acrylate, lauryl (meth)acrylate, tridecyl (meth)acrylate, tetradecyl (meth)acrylate ) acrylate, pentadecyl (meth) acrylate, hexadecyl (meth) acrylate, heptadecyl (meth) acrylate, stearyl (meth) acrylate, isostearyl (meth) acrylate, behenyl (meth) acrylate,
- Linear or branched alkyl group-containing ethylenic unsaturated monomers Fluorinated alkyl group-containing ethylenically unsaturated monomers such as trifluoroethyl (meth)acrylate and heptadecafluorodecyl (meth)acrylate; (anhydrous) maleic acid, fumaric acid, itaconic acid, citraconic acid, or their alkyl or alkenyl monoesters, ⁇ -(meth)acryloxyethyl succinate monoester, (meth)acrylic acid, crotonic acid, cinnamic acid Carboxy group-containing ethylenically unsaturated monomers such as; sulfo group-containing ethylenically unsaturated monomers such as 2-acrylamide 2-methylpropanesulfonic acid, methallylsulfonic acid, allylsulfonic acid, and vinylsulfonic acid, and salts thereof; N-methoxy
- other ethylenically unsaturated monomers (a-2) include (meth)acrylamide and nonionic ethylenically unsaturated monomer (a-1) in an aqueous medium.
- Butyl acrylate, styrene, or acrylic acid is preferable from the viewpoint of polymerization stability and good affinity with inorganic fine particles when used as a slurry composition.
- the other ethylenically unsaturated monomers (a-2) are ethylenically unsaturated monomers as long as the effects of the present invention are not impaired. It is preferably 5% by mass or less based on the total mass (100% by mass) of the mixture.
- (meth)acrylamide is contained in an amount of 50 to 85% by mass, more preferably 60 to 80% by mass, based on the total mass (100% by mass) of ethylenically unsaturated monomers. By containing in said range, electrolyte-resistant property and heat resistance can be improved significantly. Moreover, when it is blended with inorganic fine particles to form a slurry composition for a non-aqueous secondary battery separator, the compatibility with the inorganic fine particles is improved, and the solution stability of the slurry composition is also improved.
- the nonionic ethylenically unsaturated monomer (a-1b) has an octanol/water partition coefficient Log Kow of 1.9 to 4.2, preferably 2.0 to 4.2, more Ethylenically unsaturated monomers having a ratio of 2.2 to 3.5 are preferred.
- Log Kow is 1.9 or more
- the polymer (A1b) becomes a dispersion system in the aqueous medium, and when it is made into a slurry composition, the gaps between the inorganic fine particles are not filled and the ion permeability of the separator is good. is. This improves battery performance such as internal resistance and cycle characteristics.
- the binder has a high molecular weight for the good heat resistance and adhesiveness of the separator, the increase in viscosity is suppressed, and the coating properties of the slurry composition are also excellent. Moreover, the water content of the separator is reduced, and the cycle characteristics are excellent. Furthermore, when the Log Kow is 4.2 or less, the nonionic ethylenically unsaturated monomer (a-1b) is incorporated more uniformly, resulting in excellent adhesion and heat resistance.
- the nonionic ethylenically unsaturated monomer is an ethylenically unsaturated monomer that does not have a charged functionality when in an aqueous medium. and an ethylenically unsaturated monomer having no sulfo group or the like.
- the nonionic ethylenically unsaturated monomer (a-1b) preferably does not have a crosslinkable functional group, that is, it is preferably not a monomer having a crosslinkable functional group.
- the crosslinkable functional group is a functional group that gives a crosslinked structure to the side chains of the polymer, and examples thereof include a glycidyl group, an alkoxysilyl group, an ethylenically unsaturated group, and the like.
- a monomer having a crosslinkable functional group includes a monomer having a glycidyl group, a monomer having an alkoxysilyl group, and a monomer having two or more ethylenically unsaturated bond groups.
- the content of the nonionic ethylenically unsaturated monomer (a-1b) is 15 to 50% by mass, more preferably 20, based on the total mass of ethylenically unsaturated monomers (100% by mass). ⁇ 40% by mass.
- the ethylenically unsaturated monomer is 15% by mass or more, the water content in the separator can be reduced, resulting in excellent cycle characteristics. In addition, an increase in viscosity is suppressed, and the coating properties of the slurry composition are excellent. Further, when the ethylenically unsaturated monomer is 50% by mass or less, both adhesion and heat resistance of the separator can be achieved.
- alkoxysilyl group-containing ethylenically unsaturated monomers linear or branched alkyl group-containing ethylenically unsaturated monomers, or aromatic Ethylenically unsaturated monomers are preferred, especially butyl (meth)acrylate, or styrene.
- ethylenically unsaturated monomers (a-2) include those similar to the polymer (A1a).
- Other ethylenically unsaturated monomers (a-2) in the polymer (A1b) include (meth)acrylamide and a nonionic ethylenically unsaturated monomer (a-1) in an aqueous medium.
- Methyl (meth)acrylate, hydroxyethyl (meth)acrylate, or (meth)acrylic acid is preferable from the viewpoint of polymerization stability and good affinity with inorganic fine particles when used as a slurry composition.
- the content of the other ethylenically unsaturated monomers (a-2) is within the range that does not impair the effects of the present disclosure. It is preferably 5% by mass or less based on the total mass of the monomers (100% by mass).
- Method for producing polymer (A1) Any method such as solution polymerization, suspension polymerization, bulk polymerization and emulsion polymerization may be used as the method of polymerizing the ethylenically unsaturated monomer for producing the polymer (A1).
- the surfactant is preferably used together with the ethylenically unsaturated monomer mixture when polymerizing the polymer (A1).
- the stability of polymerization of (meth)acrylamide and the nonionic ethylenically unsaturated monomer (a-1) in an aqueous medium is excellent.
- the solid content concentration of the polymer (A1) in the binder dispersion is not particularly limited, it is preferably 7% by mass to 50% by mass.
- radical polymerization initiator used in the polymerization reaction a known oil-soluble polymerization initiator or water-soluble polymerization initiator can be used.
- the radical polymerization initiator is preferably used in an amount of 0.1 to 1.0 parts by mass, more preferably 0.1 to 0.5 parts by mass, with respect to 100 parts by mass of the ethylenically unsaturated monomer mixture. preferable.
- the viscosity of the binder dispersion can be adjusted within an appropriate range, and excellent heat resistance, adhesion and coatability can be achieved.
- the oil-soluble polymerization initiator is not particularly limited.
- Organic peroxides such as oxy-3,5,5-trimethylhexanoate and di-tert-butyl peroxide; 2,2'-azobisisobutyronitrile, 2,2'-azobis-2,4- azobis compounds such as dimethylvaleronitrile, 2,2′-azobis(4-methoxy-2,4-dimethylvaleronitrile), 1,1′-azobis-cyclohexane-1-carbonitrile;
- water-soluble polymerization initiators include ammonium persulfate (APS), potassium persulfate (KPS), hydrogen peroxide, 2,2′-azobis(2 -methylpropionamidine) dihydrochloride can be suitably used.
- APS ammonium persulfate
- KPS potassium persulfate
- hydrogen peroxide 2,2′-azobis(2 -methylpropionamidine) dihydrochloride
- a reducing agent may be used together with the polymerization initiator.
- the combined use of a reducing agent facilitates acceleration of the emulsion polymerization rate and polymerization at low temperatures.
- Reducing agents include, for example, ascorbic acid, ersorbic acid, tartaric acid, citric acid, glucose, reducing organic compounds such as metal salts such as formaldehyde sulfoxylate; sodium thiosulfate, sodium sulfite, sodium bisulfite, sodium metabisulfite reducing inorganic compounds such as; ferrous chloride, Rongalite, and thiourea dioxide. It is preferable to use 0.05 to 4 parts by mass of these reducing agents with respect to 100 parts by mass of the ethylenically unsaturated monomer.
- a buffer, a chain transfer agent, a basic compound, and the like can be used as necessary when polymerizing the ethylenically unsaturated monomer.
- buffering agents include sodium acetate, sodium citrate, sodium bicarbonate and the like.
- chain transfer agents include n-octylmercaptan, t-octylmercaptan, n-nonylmercaptan, t-nonylmercaptan, n-decylmercaptan, t-decylmercaptan, n-undecylmercaptan, t-undecylmercaptan, n-dodecylmercaptan, t-dodecylmercaptan, n-tridecylmercaptan, t-tridecylmercaptan, n-tetradecylmercaptan, t-tetradecylmercaptan, n-
- a basic compound is a compound used for neutralization.
- the basic compound include alkylamines such as trimethylamine, triethylamine and butylamine; alcohol amines such as 2-dimethylaminoethanol, 2-diethylaminoethanol, diethanolamine, triethanolamine and aminomethylpropanol; morpholine; and ammonia. be done.
- the binder dispersion of the present disclosure contains various additives such as antifoaming agents, leveling agents, preservatives, solvents, cross-linking agents, dispersants, binders, etc. as other optional components within the range that does not interfere with the effect. may contain.
- the storage modulus of the polymer (A1) at 150° C. is preferably 1.0 ⁇ 10 6 Pa or more and less than 1.0 ⁇ 10 10 Pa, more preferably 1.0 ⁇ 10 7 Pa or more. . Since the storage elastic modulus at 150° C. is within the above range, the separator using the polymer (A1) has excellent heat resistance, and the shrinkage of the separator in the high temperature range is suppressed, thereby preventing the non-aqueous secondary battery from shorting. It is preferable because it can be prevented.
- the polymer (A1) preferably has a degree of swelling of the electrolytic solution of less than 2 times when immersed in a mixed solvent having a volume ratio of ethylene carbonate and diethyl carbonate of 2:3 at 60° C. for 72 hours, more preferably less than 1.5 times.
- the degree of swelling of the electrolytic solution is less than 2 times, the swelling of the binder does not hinder the conductivity of lithium ions, which is preferable because it is possible to prevent an increase in internal resistance.
- the binder dispersion for a non-aqueous secondary battery separator of the present disclosure has a light transmittance of less than 70%, more preferably less than 50%, at a wavelength of 400 nm at a solid content concentration of 5% by mass.
- the dispersibility of the binder in the aqueous medium is sufficiently ensured, and when a slurry composition is prepared, the gaps between the inorganic fine particles are not filled and the ion permeability of the separator is improved. This improves battery performance such as internal resistance and cycle characteristics.
- the binder has a high molecular weight, the increase in viscosity is suppressed, and the slurry composition is excellent in coatability.
- the light transmittance can be obtained by dividing the light source into measurement wavelengths using a diffraction grating and calculating the ratio of the light (l) transmitted through the sample to the light (l 0 ) incident on the sample. ).
- Transmittance (%) (l/l 0 ) x 100
- the polymer (A1) is particulate and has an average particle diameter of 10 to 4,000 nm at a solid content concentration of 1% by mass. It is preferably 100 to 3,000 nm, more preferably 100 to 3,000 nm.
- the coatability is good, and when used as a slurry composition for a non-aqueous secondary battery separator by blending with inorganic fine particles, the gaps between the inorganic fine particles are not filled, and the non-aqueous An increase in the internal resistance of the secondary battery can be prevented. Further, even if the molecular weight is large, the increase in viscosity is suppressed, and both heat resistance and coatability can be achieved, which is preferable.
- the average particle size is obtained by diluting the binder dispersion with water to a solid content concentration of 1% by mass, and measuring about 5 ml of the diluted solution by, for example, a dynamic light scattering measurement method (measurement equipment is manufactured by Nanotrac UPA Co., Ltd., Microtrac Bell Co., etc.). ) can be measured and obtained. The peak of the volume particle size distribution data (histogram) obtained at this time is taken as the average particle size.
- the binder dispersion for a non-aqueous secondary battery separator of the first embodiment preferably has a mPa s of 2,500 or more and less than 25,000 mPa s at a solid content concentration of 15% by mass, more preferably 3 ,000 mPa ⁇ s or more and less than 20,000 mPa ⁇ s.
- the molecular weight is sufficient to exhibit heat resistance and adhesion, and the solution stability and coatability of the slurry composition are also excellent.
- the binder dispersion for a non-aqueous secondary battery separator of the second embodiment preferably has a viscosity of 100 mPa s or more and less than 15,000 mPa s, more preferably 500 mPa s, at a solid content concentration of 15% by mass. It is not less than 7000 mPa ⁇ s. By being within the above range, the molecular weight is sufficient to exhibit heat resistance and adhesion, and the solution stability and coatability of the slurry composition are also excellent.
- the binder dispersion of the present disclosure is a particulate polymer, the interaction between resins can be suppressed, and the binder dispersion can be excellent in handling such as coatability while maintaining a high molecular weight.
- the viscosity can be obtained by measuring with a Brookfield viscometer at 25° C., 20 rpm for 60 seconds.
- the slurry composition for a non-aqueous secondary battery separator is used to form a protective layer used in a non-aqueous secondary battery separator, and contains at least the binder dispersion for a non-aqueous secondary battery separator of the present disclosure and inorganic fine particles.
- the slurry composition for a non-aqueous secondary battery separator of the present disclosure has a good affinity between the binder dispersion and the inorganic fine particles, so it has excellent solution stability, and exhibits heat resistance and adhesion.
- the slurry composition preferably contains a polymer (A2) as necessary, and the polymer (A2) functions as an adhesive component, and is preferred because it improves adhesion to the separator substrate.
- the inorganic fine particles are preferably composed of an inorganic compound that does not deteriorate in the electrolyte of the non-aqueous secondary battery.
- Specific inorganic compounds include, for example, aluminum oxide, hydrated aluminum oxide, silicon oxide, magnesium oxide, calcium oxide, zirconium oxide, titanium oxide, silica, and ion conductive glass.
- One type of inorganic compound may be used, or two or more types may be used in combination.
- the average particle size of the inorganic fine particles is preferably 0.01 to 10 ⁇ m, more preferably 0.1 to 5 ⁇ m.
- the protective layer can achieve both film strength and lithium ion conductivity at a higher level.
- the average particle diameter of the inorganic fine particles is the particle diameter when the integrated value from the small particle diameter side is 50% in the volume-based (volume distribution) particle size distribution by the laser diffraction/scattering method or the homogeneous light scattering method. show.
- the polymer (A1) is preferably used in an amount of 0.1 to 10 parts by mass, more preferably 0.2 to 5 parts by mass, based on 100 parts by mass of the inorganic fine particles. Within the above range, it is possible to further improve the lithium ion conductivity of the protective layer and suppress the internal resistance while maintaining the adhesion between the inorganic fine particles and the excellent adhesion of the protective layer to the separator. can.
- the slurry composition for a non-aqueous secondary battery separator of the present disclosure preferably further contains a polymer (A2), and the polymer (A2) is a particulate polymer having a glass transition temperature (Tg) of ⁇ 40 to 40° C. is.
- the polymer (A2) is excluded when it corresponds to the polymer (A1).
- the polymer (A2) functions as an adhesive component to the substrate when it is made into a slurry composition.
- the polymer (A2) is not limited to any polymer as long as it has a glass transition temperature of ⁇ 40 to 40° C. and is particulate. Arbitrary components such as resins, polyester resins, natural polymers such as polysaccharides, etc.
- the content of the polymer (A2) in the slurry composition is preferably 200 parts by mass or less with respect to 100 parts by mass of the polymer (A1), and 10 to 100 parts by mass. Part is more preferred.
- the polymer (A2) is a polymer of ethylenically unsaturated monomers
- the same method as described for the polymer (A1) can be used for producing the polymer (A2).
- the polymer (A2) is a particulate polymer dispersed in an aqueous medium, which facilitates adhesion to the substrate.
- the polymer (A2) preferably has an average particle size of 50 to 500 nm, more preferably 60 to 400 nm, at a solid content concentration of 1% by mass. Within the above range, when a slurry composition is prepared, the gaps between the inorganic fine particles are not filled, and the ion permeability of the separator is improved.
- the average particle size can be obtained by measuring, for example, by a dynamic light scattering measurement method (measurement equipment manufactured by Nanotrac UPA Co., Ltd., Microtrac Bell, etc.). The peak of the volume particle size distribution data (histogram) obtained at this time is taken as the average particle size.
- the slurry composition for a non-aqueous secondary battery of the present disclosure contains, as other optional components, a polymer other than the polymer (A1) and the polymer (A2), a leveling agent, a dispersant, a thickener, a digestive It is preferable to add a foaming agent or the like.
- a polymer other than the polymer (A1) and the polymer (A2) a leveling agent
- a dispersant e.g., sodium sulfate, sodium bicarbonate, sodium bicarbonate, sodium bicarbonate, sodium bicarbonate, sodium bicarbonate, sodium bicarbonate, sodium bicarbonate, sodium bicarbonate, sodium bicarbonate, sodium bicarbonate, sodium bicarbonate, sodium bicarbonate, sodium bicarbonate, sodium bicarbonate, sodium bicarbonate, sodium bicarbonate, sodium bicarbonate, sodium bicarbonate, sodium bicarbonate, sodium bicarbonate, sodium bicarbonate, sodium bicarbonate, sodium bicarbonate, sodium bicarbonate, sodium bicarbonate, sodium
- the slurry composition for non-aqueous secondary batteries of the present disclosure is obtained by mixing the binder dispersion for non-aqueous secondary battery separators of the present disclosure, inorganic fine particles, and optional additives such as the polymer (A2). be done.
- the slurry composition can be obtained, for example, by dispersing the inorganic fine particles with a dispersing agent and then mixing the binder dispersion with optional additives.
- the slurry composition for non-aqueous secondary batteries of the present disclosure can be produced using a known disperser and mixer.
- Specific mixing devices include, for example, mixers such as disper, homomixer and planetary mixer; homogenizers; media type dispersers such as paint conditioner, ball mill, sand mill, attritor, pearl mill and coball mill; medialess dispersing machine; other examples include a roll mill and the like.
- the dispersing machine it is preferable to use a dispersing machine subjected to a treatment to prevent metal contamination from the dispersing machine. Ceramic beads such as glass beads, zirconia beads, and alumina beads are preferably used as media. Only one type of dispersing device may be used, or a plurality of types of devices may be used in combination.
- a protective layer made of a slurry composition is provided on at least one surface of the separator substrate. This protective layer improves the heat resistance of the separator, and reduces the risk of explosion of the non-aqueous secondary battery due to short-circuiting between the electrodes when the non-aqueous secondary battery is overheated.
- the separator base material is a porous layer sheet or non-woven fabric that has fine pores through which ions can pass.
- it can be constructed using known materials such as polyolefins such as polyethylene and polypropylene, cellulose, and aromatic polyamides.
- the method of forming the protective layer is preferably a method of applying a slurry composition.
- coating methods include die coating, dip coating, roll coating, doctor coating, knife coating, spray coating, gravure coating, screen printing, and electrostatic coating.
- rolling treatment may be performed using a lithographic press, calendar rolls, or the like.
- the thickness of the protective layer is preferably 0.5-10 ⁇ m, more preferably 1-5 ⁇ m. Within the above range, the protective layer can ensure sufficient strength as a film and exhibit excellent battery performance.
- Non-aqueous secondary battery of the present disclosure will be described using LIB as an example.
- the LIB has at least a battery body including a positive electrode, a negative electrode, and a separator provided between the positive electrode and the negative electrode, and an electrolytic solution impregnated in the battery body.
- the positive electrode and the negative electrode (hereinafter sometimes referred to as “electrodes”) have a current collector and a composite layer formed from a composite ink containing an electrode active material as an essential component.
- General inks for composite materials for electricity storage devices essentially contain an active material and a solvent, and optionally contain a conductive agent and a binder. It is preferable that the active material is contained as much as possible.
- a conductive additive is included, the ratio of the conductive additive to the solid content of the composite ink is preferably 0.1 to 15% by mass.
- a binder is included, the ratio of the binder to the solid content of the composite ink is preferably 0.1 to 15% by mass.
- a current collector applicable to various secondary batteries can be appropriately selected.
- the material of the current collector include metals such as aluminum, copper, nickel, titanium, and stainless steel, and alloys thereof.
- LIB it is preferable to use a current collector made of aluminum for the positive electrode and a current collector made of copper for the negative electrode.
- a flat foil is generally used, but a roughened surface, a perforated foil, and a mesh current collector can also be used.
- the thickness of the current collector is preferably 5 to 50 ⁇ m.
- the positive electrode active material is not particularly limited, but metal oxides capable of doping or intercalating lithium ions, metal compounds such as metal sulfides, conductive polymers, and the like can be used.
- metal oxides or metal compounds include transition metal oxides such as Fe, Co, Ni and Mn, composite oxides with lithium, and inorganic compounds such as transition metal sulfides.
- Specific examples of metal oxides or metal compounds include powders of transition metal oxides such as MnO, V 2 O 5 , V 6 O 13 , and TiO 2 , layered lithium nickel oxide, lithium cobalt oxide, lithium manganate, and spinel.
- Composite oxide powders of lithium and transition metals such as lithium manganate having a structure, lithium iron phosphate-based materials which are lithium acid compounds having an olivine structure, transition metal sulfide powders such as TiS 2 and FeS, and the like.
- the negative electrode active material is not particularly limited as long as it can dope or intercalate lithium ions.
- negative electrode active materials include metal Li, tin alloys thereof, silicon alloys, alloys such as lead alloys, metal oxides such as lithium titanate, lithium vanadate, and lithium silicate, polyacetylene, poly- Conductive polymers such as p-phenylene, amorphous carbonaceous materials such as soft carbon and hard carbon, artificial graphite such as highly graphitized carbon materials, carbonaceous powders such as natural graphite, carbon black, mesophase carbon black, resins Examples include carbon-based materials such as calcined carbon materials, vapor-grown carbon fibers, and carbon fibers.
- the conductive agent in the composite ink is not particularly limited as long as it is a conductive carbon material.
- conductive carbon materials include graphite, carbon black, conductive carbon fibers (carbon nanotubes, carbon nanofibers, carbon fibers), fullerenes, and the like.
- the binder in the composite ink is used to bind particles such as active materials and conductive carbon materials, or to bind conductive carbon materials and current collectors.
- binders used in composite inks include acrylic resins, polyurethane resins, polyester resins, phenol resins, epoxy resins, phenoxy resins, urea resins, melamine resins, alkyd resins, formaldehyde resins, silicone resins, fluororesins, carboxyl resins,
- cellulose resins such as methyl cellulose
- synthetic rubbers such as styrene-butadiene rubber and fluororubber
- conductive resins such as polyaniline and polyacetylene
- polymer compounds containing fluorine atoms such as polyvinylidene fluoride, polyvinyl fluoride, and tetrafluoroethylene.
- Modified products, mixtures, or polymers of these resins may also be used.
- the composite ink can be blended with film-forming aids, antifoaming agents, leveling agents, preservatives, pH adjusters, viscosity adjusters, etc., as needed.
- the electrolytic solution is a liquid obtained by dissolving an electrolyte containing lithium in a non-aqueous solvent.
- the electrolyte include LiBF 4 , LiClO 4 , LiPF 6 , LiAsF 6 , LiSbF 6 , LiCF 3 SO 3 , Li(CF 3 SO 2 ) 2 N, LiC 4 F 9 SO 3 , Li(CF 3 SO 2 ) 3 C, LiI, LiBr, LiCl, LiAlCl, LiHF 2 , LiSCN, LiBPh 4 and the like.
- non-aqueous solvents examples include carbonates such as ethylene carbonate, propylene carbonate, butylene carbonate, dimethyl carbonate, ethylmethyl carbonate, and diethyl carbonate; lactones such as ⁇ -butyl lactone, ⁇ -valerolactone, and ⁇ -octanoic lactone; , tetrahydrofuran, 2-methyltetrahydrofuran, 1,3-dioxolane, 4-methyl-1,3-dioxolane, 1,2-methoxyethane, 1,2-ethoxyethane, 1,2-dibutoxyethane and other glyme, methyl esters such as formate, methyl acetate and methyl propionate; sulfoxides such as dimethyl sulfoxide and sulfolane; and nitriles such as acetonitrile.
- carbonates such as ethylene carbonate, propylene carbonate, butylene carbonate, dimethyl carbonate, e
- the electrolytic solution as a polymer electrolyte that is gelled by being held in a polymer matrix.
- the polymer matrix include acrylic resins having polyalkylene oxide segments, polyphosphazene resins having polyalkylene oxide segments, and polysiloxane resins having polyalkylene oxide segments.
- Non-aqueous secondary batteries using the above materials are excellent in safety and battery characteristics.
- the nonaqueous secondary battery of the present disclosure can be used for industrial use, vehicle use, and mobile use.
- part means “mass part”
- % means “mass %”.
- Numerical values in the table are the mass of the solid content, and blanks indicate that they are not used.
- the methods for measuring the average particle size of the inorganic fine particles and the glass transition temperature (Tg) of the polymer are as follows.
- ⁇ Average particle size of inorganic fine particles The average particle size of the inorganic fine particles was obtained from the particle size when the integrated value from the small particle size side was 50% in the volume-based (volume distribution) particle size distribution according to the laser diffraction/scattering method.
- the glass transition temperature of the polymer was measured using a DSC (Differential Scanning Calorimeter, manufactured by TA Instruments). Specifically, an aluminum pan in which about 3 mg of dried resin was precisely weighed and an empty aluminum pan as a reference were set in a DSC measurement holder, and the temperature was increased at 10 ° C./min. The temperature at the intersection of the baseline on the low temperature side of the endothermic phenomenon in the obtained DSC curve and the tangent line at the point of inflection was defined as the glass transition temperature (Tg).
- DSC Different Scanning Calorimeter
- Example a1 ⁇ Production of binder dispersion for non-aqueous secondary battery separator> 48 parts of acrylamide, 47 parts of 2-hydroxyethyl acrylate, 3 parts of diacetone acrylamide, 2 parts of butyl acrylate and 90 parts of deionized water were mixed to obtain a mixture.
- the mixture was added dropwise over 60 minutes while the internal temperature was maintained at 80°C. After the dropping was completed, the mixture was further reacted at 80°C for 3 hours, and after confirming that the conversion rate exceeded 98% by measuring the solid content, the temperature was cooled to 30°C. The solid content was adjusted to 15% with ion-exchanged water to obtain a binder dispersion for a non-aqueous secondary battery separator containing the polymer (A1-1a). The solid content was obtained from the residue after baking at 150°C for 20 minutes.
- Examples 2a to 18a, Comparative Examples 1a to 6a Except for the formulation composition shown in Table 1A and the formulation amount (parts by mass), in the same manner as in Example 1a, the polymer (A1-2a to 18a) or polymer (A3a-1 to 6a) A binder dispersion for a water secondary battery separator was obtained.
- Example 6a, 8a, 10a and Comparative Example 5a after completion of the reaction, 25% aqueous ammonia was added to equimolar the carboxyl groups in the resin for neutralization.
- Comparative Examples 2a and 3a could not be synthesized due to poor polymerization stability.
- the acid value of a polymer is the number of mg of potassium hydroxide required to neutralize the acidic component contained in 1 g of the dried resin. According to the method described in JIS K2501, it was calculated by performing potentiometric titration using an automatic titrator ("COM-A19" manufactured by HIRANUMA) with a potassium hydroxide/ethanol solution.
- ⁇ Light transmittance> The resulting binder dispersion was adjusted to a solid content concentration of 5% with ion-exchanged water, placed in a quartz cell with an optical path length of 1 cm, and measured using a spectrophotometer ("V-770" manufactured by JASCO Corporation) at a wavelength of 400 nm. A transmission spectrum was measured. Ion-exchanged water was used for comparison.
- B Light transmittance of 50% or more and less than 70%.
- C Light transmittance of 70% or more.
- ⁇ Storage modulus> The obtained binder dispersion was dried at 40° C. for 72 hours to prepare a film having a thickness of about 0.5 mm.
- the obtained film was cut into strips of 5 mm in width and 20 mm in length as samples, and a dynamic viscoelasticity measuring device ("DVA-200" manufactured by IT Keisoku Co., Ltd.) was used to measure the storage elastic modulus at 150°C. It was measured.
- the measurement conditions are as follows. Measurement mode: Tensile frequency: 10Hz Strain: 0.01% Temperature rising condition: 10°C/min
- B: The storage elastic modulus is 1.0 ⁇ 10 6 or more and less than 1.0 ⁇ 10 7 Pa.
- C The storage modulus is less than 1.0 ⁇ 10 6 Pa.
- Viscosity> The viscosity of the resulting binder dispersion with a solid content concentration of 15% was measured with a B-type viscometer ("TVB-10" manufactured by Toki Sangyo) (temperature: 25 ° C., spindle rotation time: 60 seconds, spindle rotation number: 20 rpm).
- B Viscosity of 2,500 mPa ⁇ s or more and less than 3,000 mPa ⁇ s.
- B' Viscosity of 20,000 mPa ⁇ s or more and less than 25,000 mPa ⁇ s.
- C Viscosity of less than 2,500 mPa ⁇ s
- C' Viscosity of 25,000 mPa ⁇ s or more.
- ⁇ Average particle size The average particle size is measured by diluting a polymer solution to a solid content concentration of 1% by mass, and measuring about 5 ml of the diluted solution by a dynamic light scattering measurement method (measurement device manufactured by Nanotrac UPA Co., Ltd. Microtrac Bell). did. The peak of the volume particle size distribution data (histogram) obtained at this time was taken as the average particle size.
- B The particle size is 3,000 nm or more and less than 4,000 nm or 10 nm or more and less than 100 nm.
- C Particle size less than 10 nm or 4,000 nm or more.
- Electrolyte resistance is the easiness of dissolution and swelling of the polymer in the electrolyte, and was evaluated by the degree of swelling of the electrolyte. It can be said that the smaller the degree of swelling of the electrolytic solution, the better the resistance to the electrolytic solution.
- the obtained binder dispersion was dried at 40° C. for 72 hours to prepare a film having a thickness of about 1 mm. Subsequently, the film was cut into a size of 10 mm long ⁇ 10 mm wide to obtain a sample, which was immersed in a mixed solvent of ethylene carbonate and diethyl carbonate at a volume ratio of 2:3 at 60° C.
- Example 19a ⁇ Preparation of slurry composition for non-aqueous secondary battery separator> 42.4 parts of inorganic fine particles (alumina, average particle diameter 0.5 ⁇ m), 0.5 parts of polycarboxylic acid ammonium salt (BYK-154) as a dispersing agent and 42.7 parts of water are put into a bead mill to disperse alumina. A liquid was prepared.
- inorganic fine particles alumina, average particle diameter 0.5 ⁇ m
- BYK-154 polycarboxylic acid ammonium salt
- alumina dispersion 1.1 parts of a binder dispersion containing the polymer (A-1a) in terms of solid content, 0.6 parts of a 4% aqueous solution of carboxymethyl cellulose (CMC, Daicel 1220) as a thickener, After adding 0.3 parts of a silicon-based activator (BYK-349) and 0.2 parts of a silicon-based antifoaming agent (BYK-018) as a wetting agent, and adding water so that the solid content concentration becomes 43%. , and these were mixed to prepare a slurry composition for a non-aqueous secondary battery separator.
- a silicon-based activator BYK-349
- BYK-018 silicon-based antifoaming agent
- ⁇ Preparation of non-aqueous secondary battery separator> The above slurry composition was applied to one side of a separator substrate (9 ⁇ m porous polyethylene film) using a doctor blade so as to have a thickness of 3 ⁇ m. After that, it was dried in an oven at 80° C. to obtain a separator with a protective layer.
- a positive electrode and a negative electrode were punched out to 45 mm ⁇ 40 mm and 50 mm ⁇ 45 mm, respectively.
- the positive electrode and the negative electrode are placed facing each other through a separator with a protective layer and inserted into an aluminum laminate bag.
- a non-aqueous electrolytic solution in which LiPF6 was dissolved at a concentration of 1 M) was injected into the battery, and the aluminum laminate was sealed to fabricate a laminated non-aqueous secondary battery.
- Examples 20a-36a, 41a-42a, Comparative Examples 7a-11a A slurry composition for a non-aqueous secondary battery separator, a non-aqueous secondary battery separator, a non-aqueous secondary A battery was produced.
- Example 37a 42.4 parts of inorganic fine particles (alumina, average particle diameter 0.5 ⁇ m), 0.5 parts of polycarboxylic acid ammonium salt (BYK-154) as a dispersant, and 42.7 parts of water are put into a bead mill to disperse alumina. A liquid was prepared.
- alumina dispersion 1.0 part of the binder dispersion containing the polymer (A1-8a) in terms of solid content, and 0.1 part of the polymer (A2-1a) dispersion in terms of solid content, Carboxymethyl cellulose (CMC, Daicel 1220) 0.6 parts of 4% aqueous solution as a thickening agent, 0.3 parts of a silicone activator (BYK-349) as a wetting agent, and 0 silicone antifoaming agent (BYK-018) After adding 2 parts and adding water so that the solid content concentration became 43%, these were mixed to prepare a slurry composition for a non-aqueous secondary battery separator.
- CMC Carboxymethyl cellulose
- BYK-349 silicone activator
- BYK-018 silicone antifoaming agent
- Examples 38a-40a A slurry composition for a non-aqueous secondary battery separator, a non-aqueous secondary battery separator, a non-aqueous secondary A battery was produced.
- evaluation criteria ⁇ : No abnormalities were observed for 2 weeks or more from the start of storage. Very good. ⁇ : Some abnormality was observed during the period of 1 week or more and less than 2 weeks from the start of storage. Good. ⁇ : Some abnormality was observed for 4 days or more and less than 1 week after the start of storage. Usable. x: Some abnormality was observed within 3 days from the start of storage. There is a problem in practical use.
- ⁇ Coatability> Using the obtained separator, the coatability of the slurry composition was visually observed. [Evaluation criteria] ⁇ : The film thickness is uniform and there is no repelling. Very good. ⁇ : Less than 5% of the coated portion has unevenness and repellency. Good. ⁇ : Unevenness and cissing are present in 5% or more and less than 10% of the coated portion. Usable. x: 10% or more of the coated portion has unevenness or repellency. There is a problem in practical use.
- a binder dispersion for a non-aqueous secondary battery separator containing A1a and an aqueous medium, wherein the light transmittance at 400 nm at a solid content concentration of 5% by mass is less than 70%.
- the solution stability and coatability when used as a slurry composition, and the heat resistance and adhesion when used as a separator are good, and when used as a secondary battery. Low internal resistance and excellent cycle characteristics.
- Comparative Example 2 using an ethylenically unsaturated monomer with a Log Kow greater than 1.5
- Comparative Example 3 using more than 60% by mass of the nonionic ethylenically unsaturated monomer (a-1a)
- the polymerization stability was remarkably inferior.
- Comparative Examples 1a, 4a to 6a, or the slurry composition for the non-aqueous secondary battery separator that does not contain the polymer (A1a), the non-aqueous secondary battery separator, and the non-aqueous secondary battery also have any physical properties was extremely inferior, and it was hard to say that the level of practical use was satisfied.
- Example of Second Embodiment ⁇ Production of binder dispersion for non-aqueous secondary battery separator> 66 parts of acrylamide, 32 parts of t-butyl methacrylate, 2 parts of 1,9-nonanediol diacrylate, 1.0 part of 20% aqueous solution of Emal 2FG, and 90 parts of ion-exchanged water were mixed to obtain a mixture.
- a reactor equipped with a stirrer, a thermometer, a dropping funnel and a reflux device was charged with 450 parts of water and 30 parts of the mixed liquid. Next, after raising the internal temperature of the reaction vessel to 80° C.
- Examples 2b to 24b, Comparative Examples 1b to 7b Polymers (A1-2b to 24b) or polymers (A3-1b to 7b) were prepared in the same manner as in Example 1b, except that the formulations and amounts (parts by mass) shown in Tables 1B to 3B were used.
- examples 21b and 24b aggregates were confirmed during polymerization. Further, Comparative Example 7b could not be synthesized due to poor polymerization stability.
- the acid value of a polymer is the number of mg of potassium hydroxide required to neutralize the acidic component contained in 1 g of the dried resin. According to the method described in JIS K2501, it was calculated by performing potentiometric titration using an automatic titrator ("COM-A19" manufactured by HIRANUMA) with a potassium hydroxide/ethanol solution.
- ⁇ Light transmittance> The resulting binder dispersion was adjusted to a solid content concentration of 5% with ion-exchanged water, placed in a quartz cell with an optical path length of 1 cm, and measured using a spectrophotometer ("V-770" manufactured by JASCO Corporation) at a wavelength of 400 nm. A transmission spectrum was measured. Ion-exchanged water was used for comparison.
- B Light transmittance of 50% or more and less than 70%.
- C Light transmittance of 70% or more.
- ⁇ Storage modulus> The obtained binder dispersion was dried at 40° C. for 72 hours to prepare a film having a thickness of about 0.5 mm.
- the obtained film was cut into strips of 5 mm in width and 20 mm in length as samples, and a dynamic viscoelasticity measuring device ("DVA-200" manufactured by IT Keisoku Co., Ltd.) was used to measure the storage elastic modulus at 150°C. It was measured.
- the measurement conditions are as follows. Measurement mode: Tensile frequency: 10Hz Strain: 0.01% Temperature rising condition: 10°C/min
- B: The storage elastic modulus is 1.0 ⁇ 10 6 or more and less than 1.0 ⁇ 10 7 Pa.
- C The storage modulus is less than 1.0 ⁇ 10 6 Pa.
- Viscosity> The viscosity of the resulting binder dispersion with a solid content concentration of 15% was measured with a B-type viscometer ("TVB-10" manufactured by Toki Sangyo) (temperature: 25 ° C., spindle rotation time: 60 seconds, spindle rotation number: 20 rpm).
- B' Viscosity of 7000 or more and less than 15,000 mPa ⁇ s.
- C Viscosity less than 100 mPa ⁇ s
- C' Viscosity 15,000 mPa ⁇ s or more.
- ⁇ Average particle size The average particle size is measured by diluting a polymer solution to a solid content concentration of 1% by mass, and measuring about 5 ml of the diluted solution by a dynamic light scattering measurement method (measurement device manufactured by Nanotrac UPA Co., Ltd. Microtrac Bell). did. The peak of the volume particle size distribution data (histogram) obtained at this time was taken as the average particle size.
- B The average particle size is 3,000 nm or more and less than 4,000 nm or 10 nm or more and less than 100 nm.
- C The average particle size is less than 10 nm or 4,000 nm or more.
- Electrolyte resistance is the easiness of dissolution and swelling of the polymer in the electrolyte, and was evaluated by the degree of swelling of the electrolyte. It can be said that the smaller the degree of swelling of the electrolytic solution, the better the resistance to the electrolytic solution.
- the obtained binder dispersion was dried at 40° C. for 72 hours to prepare a film having a thickness of about 1 mm. Subsequently, the film was cut into a size of 10 mm long ⁇ 10 mm wide to obtain a sample, which was immersed in a mixed solvent of ethylene carbonate and diethyl carbonate at a volume ratio of 2:3 at 60° C.
- the Log Kow value of the ethylenically unsaturated monomer is obtained by using the YMB method (physical property estimation function) of the Hansen solubility parameter software HSPiP (ver.5.2.05) to convert the structural formula of the ethylenically unsaturated monomer into Smiles Calculated by converting to notation and inputting.
- Example 25 ⁇ Preparation of slurry composition for non-aqueous secondary battery separator> 42.4 parts of inorganic fine particles (alumina, average particle diameter 0.5 ⁇ m), 0.5 parts of polycarboxylic acid ammonium salt (BYK-154) as a dispersing agent and 42.7 parts of water are put into a bead mill to disperse alumina. A liquid was prepared.
- inorganic fine particles alumina, average particle diameter 0.5 ⁇ m
- BYK-154 polycarboxylic acid ammonium salt
- alumina dispersion 1.1 parts of a binder dispersion containing the polymer (A1-1b) in terms of solid content, 0.6 parts of a 4% aqueous solution of carboxymethyl cellulose (CMC, Daicel 1220) as a thickener, After adding 0.3 parts of a silicon-based activator (BYK-349) and 0.2 parts of a silicon-based antifoaming agent (BYK-018) as a wetting agent, and adding water so that the solid content concentration becomes 43%. , and these were mixed to prepare a slurry composition for a non-aqueous secondary battery separator.
- a silicon-based activator BYK-349
- BYK-018 silicon-based antifoaming agent
- ⁇ Preparation of non-aqueous secondary battery separator> The above slurry composition was applied to one side of a separator substrate (9 ⁇ m porous polyethylene film) using a doctor blade so as to have a thickness of 3 ⁇ m. After that, it was dried in an oven at 80° C. to obtain a separator with a protective layer.
- a positive electrode and a negative electrode were punched out to 45 mm ⁇ 40 mm and 50 mm ⁇ 45 mm, respectively.
- the positive electrode and the negative electrode are placed in an aluminum laminate bag with the positive electrode and the negative electrode facing each other with a separator with a protective layer interposed therebetween.
- a non-aqueous electrolytic solution in which LiPF 6 was dissolved at a concentration of 1 M) was injected, and the aluminum laminate was sealed to produce a laminated non-aqueous secondary battery.
- Example 49b 42.4 parts of inorganic fine particles (alumina, average particle diameter 0.5 ⁇ m), 0.5 parts of polycarboxylic acid ammonium salt (BYK-154) as a dispersant, and 42.7 parts of water are put into a bead mill to disperse alumina. A liquid was prepared.
- alumina dispersion 1.0 part of the binder dispersion containing the polymer (A1-11b) in terms of solid content, and 0.1 part of the polymer (A2-1b) dispersion in terms of solid content, Carboxymethyl cellulose (CMC, Daicel 1220) 0.6 parts of 4% aqueous solution as a thickening agent, 0.3 parts of a silicone activator (BYK-349) as a wetting agent, and 0 silicone antifoaming agent (BYK-018) After adding 2 parts and adding water so that the solid content concentration became 43%, these were mixed to prepare a slurry composition for a non-aqueous secondary battery separator.
- CMC Carboxymethyl cellulose
- BYK-349 silicone activator
- BYK-018 silicone antifoaming agent
- Example 50b to 51b A slurry composition for a non-aqueous secondary battery separator, a non-aqueous secondary battery separator, a non-aqueous secondary A battery was produced.
- evaluation criteria A: No abnormalities were observed for 4 weeks or more from the start of storage. Very good. ⁇ : Some abnormality was observed during the period of 1 week or more and less than 4 weeks from the start of storage. Good. ⁇ : Some abnormality was observed for 4 days or more and less than 1 week after the start of storage. Usable. x: Some abnormality was observed within 3 days from the start of storage. There is a problem in practical use.
- ⁇ Coatability> Using the obtained separator, the coatability of the slurry composition was visually observed. [Evaluation criteria] ⁇ : The film thickness is uniform and there is no repelling. Very good. ⁇ : Less than 5% of the coated portion has unevenness and repellency. Good. ⁇ : Unevenness and cissing are present in 5% or more and less than 10% of the coated portion. Usable. x: 10% or more of the coated portion has unevenness or repellency. There is a problem in practical use.
- a polymer (A1b) obtained by polymerizing 15 to 50% by mass of the nonionic ethylenically unsaturated monomer (a-1b) of .2 and having an acid value of 15 mgKOH/g or less, a surfactant, and an aqueous A binder dispersion for a non-aqueous secondary battery separator containing a medium, wherein the light transmittance at 400 nm is less than 70% at a solid content concentration of 5% by mass.
- Comparative Example 7 containing no surfactant was significantly inferior in polymerization stability.
- the non-aqueous secondary battery separator slurry composition, non-aqueous secondary battery separator, and non-aqueous secondary battery using Comparative Examples 1b to 6b or not containing the polymer (A1b) any physical properties are extreme. The result was inferior to the standard, and it is difficult to say that it satisfies the level of practical use.
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Abstract
Description
重合体(A1)は、酸価が15mgKOH/g以下、かつエチレン性不飽和単量体混合物の全質量を基準として、(メタ)アクリルアミド40~80質量%、および25℃におけるオクタノール/水分配係数の対数(LogKow)が0.25~1.5である非イオン性エチレン性不飽和単量体(a-1a)20~60質量%を含むエチレン性不飽和単量体混合物の重合体(A1a)であり、
固形分濃度5質量%の条件での波長400nmにおける光線透過率が70%未満である、非水二次電池セパレータ用バインダー分散液に関する。
重合体(A1)は、酸価が15mgKOH/g以下、かつエチレン性不飽和単量体混合物の全質量を基準として、(メタ)アクリルアミド50~85質量%、および25℃におけるオクタノール/水分配係数の対数(Log Kow)が1.9~4.2である非イオン性エチレン性不飽和単量体(a-1b)15~50質量%を含むエチレン性不飽和単量体混合物の重合体(A1b)であり、固形分濃度5質量%の条件での波長400nmにおける光線透過率が70%未満である、非水二次電池セパレータ用バインダー分散液に関する。
重合体(A2)は、ガラス転移温度-40~40℃の粒子状重合体である、前記非水二次電池セパレータ用スラリー組成物に関する。
しかしながら、本開示は、これに限定されるものではない。各構成は、同様の機能を発揮し得る任意のものと置換することができ、あるいは、任意の構成のものを付加することができる。
また、本明細書において「~」を用いて特定される数値範囲は、「~」の前後に記載される数値を下限値及び上限値の範囲として含むものとする。また、本明細書において「フィルム」や「シート」は、厚みによって区別されないものとする。
また、本明細書では、「(メタ)アクリルアミド」、「(メタ)アクリレート」と表記した場合には、特に説明がない限り、それぞれ、「アクリルアミドまたはメタクリルアミド」、「アクリレートまたはメタクリレート」を表すものとする。
また、エチレン性不飽和単量体とは、エチレン性不飽和二重結合を有する単量体を意味し、エチレン性不飽和単量体は、(メタ)アクリルアミドと、25℃におけるオクタノール/水分配係数の対数(Log Kow)が0.25~1.5である非イオン性エチレン性不飽和単量体(a-1a)と、前記Log Kowが1.9~4.2である非イオン性エチレン性不飽和単量体(a-1b)と、前記単量体(a-1a)又は単量体(a-1b)と重合可能なその他エチレン性不飽和単量体(a-2)とに分類される。
また、本明細書では、25℃におけるオクタノール/水分配係数の対数(Log Kow)が0.25~1.5である非イオン性エチレン性不飽和単量体(a-1a)、前記Log Kowが1.9~4.2である非イオン性エチレン性不飽和単量体(a-1b)、非水二次電池セパレータ用バインダー分散液、非水二次電池セパレータ用スラリー組成物を、それぞれ単量体(a-1a)、単量体(a-1b)、バインダー分散液、スラリー組成物と略記することがある。また、単量体(a-1a)及び単量体(a-1b)を総称して単量体(a-1)ということがある。
また、重合体(A1a)及び重合体(A1b)を総称して重合体(A1)ということがある。
なお、本明細書中に出てくる各種成分は特に注釈しない限り、それぞれ独立に一種単独でも二種以上を併用してもよい。
第1実施形態の非水二次電池セパレータ用バインダー分散液は、重合体(A1)と水性媒体を含み、
重合体(A1)は、酸価が15mgKOH/g以下、かつエチレン性不飽和単量体混合物の全質量を基準として、(メタ)アクリルアミド40~80質量%、および25℃におけるオクタノール/水分配係数の対数(LogKow)が0.25~1.5である非イオン性エチレン性不飽和単量体(a-1a)20~60質量%を含むエチレン性不飽和単量体混合物の重合体(A1a)であり、
固形分濃度5質量%の条件での波長400nmにおける光線透過率が70%未満である。
ここで水性媒体とは、水性の分散媒または水性の溶媒を指す。
水性媒体としては、水を使用することが好ましいが、必要に応じて、水溶性の溶剤を使用することもできる。水溶性の溶剤としては、例えば、アルコール類、グリコール類、セロゾルブ類、アミノアルコール類、アミン類、ケトン類、カルボン酸アミド類、リン酸アミド類、スルホキシド類、カルボン酸エステル類、リン酸エステル類、エーテル類、ニトリル類等が挙げられる。
界面活性剤としては、アニオン性界面活性剤、カチオン性界面活性剤、ノニオン性界面活性剤が挙げられるが、アニオン性界面活性剤またはノニオン性界面活性剤であることが好ましい。
界面活性剤を含むことで、重合体(A1)が水性媒体中に安定に分散でき、これを用いたスラリー組成物は、溶液安定性に優れるものとできる。
界面活性剤は、重合体(A1)100質量部に対して、好ましくは0.05~2.0質量部、より好ましくは0.05~0.5質量部含有することにより、重合体(A1)の水性媒体中での重合安定性がより向上する。
重合性ノニオン性界面活性剤としては、例えば、主骨格がアルキルエーテル、アルキルフェニルエーテル、アルキルフェニルエステル等が挙げられる。
第1実施形態の重合体(A1)は、酸価が15mgKOH/g以下、かつエチレン性不飽和単量体混合物の全質量を基準として、(メタ)アクリルアミド40~80質量%、および25℃におけるオクタノール/水分配係数の対数(LogKow)が0.25~1.5である非イオン性エチレン性不飽和単量体(a-1a)20~60質量%を含むエチレン性不飽和単量体混合物の重合体(A1a)である。
また、第2実施形態の重合体(A1)は、酸価が15mgKOH/g以下、かつエチレン性不飽和単量体混合物の全質量を基準として、(メタ)アクリルアミド50~85質量%、および25℃におけるオクタノール/水分配係数の対数(Log Kow)が1.9~4.2である非イオン性エチレン性不飽和単量体(a-1b)15~50質量%を含むエチレン性不飽和単量体混合物の重合体(A1b)である。
共通して上記エチレン性不飽和単量体混合物(a-1)は、必要に応じ、その他エチレン性不飽和単量体(a-2)を含んでいてもよい。
以下、第1実施形態の重合体(A1a)、第2実施形態の重合体(A1b)の各々について順に説明する。
[(メタ)アクリルアミド]
重合体(A1a)において(メタ)アクリルアミドは、エチレン性不飽和単量体混合物の全質量(100質量%)を基準として、40~80質量%含有し、より好ましくは45~75質量%含有する。上記の範囲で含有することにより、耐電解液性と耐熱性を大幅に向上することができる。また、無機微粒子と配合して非水二次電池セパレータ用スラリー組成物とした場合、無機微粒子との親和性が向上することで、スラリー組成物の溶液安定性も向上する。
非イオン性エチレン性不飽和単量体(a-1a)は、オクタノール/水分配係数の対数(LogKow)が0.25~1.5であり、より好ましくは0.3~1.3であるエチレン性不飽和単量体である。
Log Kowが0.25以上であることで、重合体(A1a)が水性媒体中で分散系となり、スラリー組成物とした場合に無機微粒子同士の隙間を埋めることがなく、セパレータのイオン透過性が良好である。これにより、内部抵抗やサイクル特性といった電池性能が向上する。また、セパレータの良好な耐熱性や密着性のためにバインダーを高分子量化した場合においても高粘度化が抑制され、スラリー組成物の塗工性にも優れる。Log Kowが1.5以下であることで、(メタ)アクリルアミドと水性媒体中での重合安定性が良好であり、スラリー組成物の安定性にも優れる。
また、重合体(A1a)の分子量が大きい場合にも高粘度化が抑制され、耐熱性と塗工性を両立できる。
なお、非イオン性エチレン性不飽和単量体とは、水性媒体中にあるときに、荷電された官能性を有さないエチレン性不飽和単量体であり、例えば、アミノ基、カルボキシル基、およびスルホニル基等を有さないエチレン性不飽和単量体である。
(式1)
Log Kow=Log(オクタノール相における化合物Xの濃度/水相における化合物Xの濃度)
その他エチレン性不飽和単量体(a-2)は、(メタ)アクリルアミドおよび非イオン性エチレン性不飽和単量体(a-1)以外のエチレン性不飽和単量体であり、(メタ)アクリルアミドおよび非イオン性エチレン性不飽和単量体(a-1)と重合可能なエチレン性不飽和単量体である。
エチレン性不飽和単量体(a-2)としては、例えば、ビニルナフタレン、フェノキシヘキサエチレングリコールメタクリレート等の芳香族系エチレン性不飽和体;
エチル(メタ)アクリレート、プロピルアクリレート、2-エチルヘキシルメタクリレート、オクチルメタクリレート、ノニル(メタ)アクリレート、デシル(メタ)アクリレート、ウンデシル(メタ)アクリレート、ラウリル(メタ)アクリレート、トリデシル(メタ)アクリレート、テトラデシル(メタ)アクリレート、ペンタデシル(メタ)アクリレート、ヘキサデシル(メタ)アクリレート、ヘプタデシル(メタ)アクリレート、ステアリル(メタ)アクリレート、イソステアリル(メタ)アクリレート、ベヘニル(メタ)アクリレート等の直鎖または分岐アルキル基含有エチレン性不飽和単量体;
トリフルオロエチル(メタ)アクリレート、ヘプタデカフルオロデシル(メタ)アクリレート等のフッ素化アルキル基含有エチレン性不飽和単量体;
(無水)マレイン酸、フマル酸、イタコン酸、シトラコン酸、または、これらのアルキルもしくはアルケニルモノエステル、コハク酸β-(メタ)アクリロキシエチルモノエステル、(メタ)アクリル酸、クロトン酸、けい皮酸等のカルボキシ基含有エチレン性不飽和単量体;
2-アクリルアミド2-メチルプロパンスルホン酸、メタリルスルホン酸、アリルスルホン酸、ビニルスルホン酸等のスルホ基含有エチレン性不飽和単量体およびその塩;
N-メトキシメチル-(メタ)アクリルアミド、N-エトキシメチル-(メタ)アクリルアミド、N-プロポキシメチル-(メタ)アクリルアミド、N-ブトキシメチル-(メタ)アクリルアミド、N,N-ジ(メトキシメチル)(メタ)アクリルアミド、N-エトキシメチル-N-メトキシメチル(メタ)アクリルアミド、N,N-ジ(エトキシメチル)(メタ)アクリルアミド、N,N-ジメチル(メタ)アクリルアミド、N,N-ジエチル(メタ)アクリルアミド、ジアセトン(メタ)アクリルアミド、等のアミド基含有エチレン性不飽和単量体;2-ヒドロキシエチル(メタ)アクリレート、2-ヒドロキシプロピル(メタ)アクリレート、4-ヒドロキシブチル(メタ)アクリレート、グリセロールモノ(メタ)アクリレート、アリルアルコール等の水酸基含有エチレン性不飽和単量体;
メトキシポリエチレングリコール(メタ)アクリレート、ポリエチレングリコール(メタ)アクリレート等のポリオキシエチレン基含有エチレン性不飽和単量体;
ジメチルアミノエチル(メタ)アクリレート、ジエチルアミノエチル(メタ)アクリレート、メチルエチルアミノエチル(メタ)アクリレート、ジメチルアミノスチレン、ジエチルアミノスチレン等が挙げられ、ジメチルアミノエチル(メタ)アクリレート、ジエチルアミノエチル(メタ)アクリレート、メチルエチルアミノエチル(メタ)アクリレート、テトラメチルピペリジル(メタ)アクリレート、ペンタメチルピペリジルメタクリレート、N,N-ジメチルアミノプロピル(メタ)アクリルアミド、N,N-ジエチルアミノプロピル(メタ)アクリルアミド等のアミノ基含有エチレン性不飽和単量体;
グリシジル(メタ)アクリレート、3,4-エポキシシクロヘキシルメチル(メタ)アクリレート等のエポキシ基含有エチレン性不飽和単量体;
アセトアセトキシ(メタ)アクリレート等のケトン基含有エチレン性不飽和単量体;
アリルアクリレート、1-メチルアリルアクリレート、ジアリルフタレート、3-ブテニルアクリレート、エチレングリコールジアクリレート、トリエチレングリコールジ(メタ)アクリレート、テトラエチレングリコールジ(メタ)アクリレート、トリメチロールプロパントリ(メタ)アクリレート、ペンタエリスリトールトリ(メタ)アクリレート、マレイン酸ジアリル等の2個以上のエチレン性不飽和基を有するエチレン性不飽和単量体;γ-メタクリロキシプロピルトリブトキシシラン、γ-アクリロキシメチルトリメトキシシラン、ビニルトリメトキシシラン、ビニルトリブトキシシラン、ビニルメチルジメトキシシラン等のアルコキシシリル基含有エチレン性不飽和単量体;
N-メチロール(メタ)アクリルアミド、N,N-ジメチロール(メタ)アクリルアミド、アルキルエーテル化N-メチロール(メタ)アクリルアミド等のメチロール基含有エチレン性不飽和単量体が挙げられる。
その他エチレン性不飽和単量体(a-2)を併用する場合、本発明の効果を妨げない範囲として、その他エチレン性不飽和単量体(a-2)は、エチレン性不飽和単量体混合物の全質量(100質量%)を基準として、5質量%以下であることが好ましい。
[(メタ)アクリルアミド]
重合体(A1b)において(メタ)アクリルアミドは、エチレン性不飽和単量体の全質量(100質量%)を基準として、50~85質量%含有し、より好ましくは60~80質量%含有する。上記の範囲で含有することにより、耐電解液性と耐熱性を大幅に向上することができる。また、無機微粒子と配合して非水二次電池セパレータ用スラリー組成物とした場合、無機微粒子との親和性が向上することで、スラリー組成物の溶液安定性も向上する。
非イオン性エチレン性不飽和単量体(a-1b)は、オクタノール/水分配係数の対数(Log Kow)が1.9~4.2であり、好ましくは2.0~4.2、より好ましくは2.2~3.5であるエチレン性不飽和単量体である。
Log Kowが1.9以上であることで、重合体(A1b)が水性媒体中で分散系となり、スラリー組成物とした場合に無機微粒子同士の隙間を埋めることがなくセパレータのイオン透過性が良好である。これにより、内部抵抗やサイクル特性といった電池性能が向上する。また、セパレータの良好な耐熱性や密着性のためにバインダーを高分子量化した場合においても高粘度化が抑制され、スラリー組成物の塗工性にも優れる。また、セパレータの水分量が低減し、サイクル特性に優れる。さらに、Log Kowが4.2以下であることで、非イオン性エチレン性不飽和単量体(a-1b)がより均一に組み込まれ密着性と耐熱性に優れる。
架橋性官能基とは、重合体の側鎖に、架橋構造を与える官能基であって、グリシジル基、アルコキシシリル基、またはエチレン性不飽和基等が挙げられる。
架橋性官能基を有する単量体とは、グリシジル基を有する単量体、アルコキシシリル基を有する単量体および二つ以上のエチレン性不飽和結合基を有する単量体等が挙げられる。
t-ブチルアクリレート(Log Kow=2.06)、イソブチルアクリレート(Log Kow=2.09)、ブチルアクリレート(Log Kow=2.23)、プロピルメタクリレート(Log Kow=2.28)、t-ブチルメタクリレート(Log Kow=2.67)、ペンチルアクリレート(Log Kow=2.70)、ブチルメタクリレート(Log Kow=2.84)、ペンチルメタクリレート(Log Kow=3.03)、ヘキシルアクリレート(Log Kow=3.11)、ヘキシルメタクリレート(Log Kow=3.50)、ヘプチルアクリレート(Log Kow=3.62)、2-エチルヘキシルアクリレート(Log Kow=4.01)、ヘプチルメタクリレート(Log Kow=4.01)、オクチルアクリレート(Log Kow=4.20)等の直鎖または分岐アルキル基含有エチレン性不飽和単量体;
フェニルアクリレート(Log Kow=1.97)、ベンジルアクリレート(Log Kow=2.32)、フェノキシエチルアクリレート(Log Kow=2.44)、フェノキシジエチレングリコールアクリレート(Log Kow=2.44)、フェニルメタクリレート(Log Kow=2.57)、スチレン(Log Kow=2.71)、ベンジルメタクリレート(Log Kow=2.91)、フェノキシエチルメタクリレート(Log Kow=3.02)、フェノキシジエチレングリコールメタクリレート(Log Kow=3.02)、フェノキシテトラエチレングリコールアクリレート(Log Kow=3.38)、o-メチルスチレン(Log Kow=3.40)、α-メチルスチレン(Log Kow=3.46)、m-メチルスチレン(Log Kow=3.46)、p-メチルスチレン(Log Kow=3.61)、フェノキシテトラエチレングリコールメタクリレート(Log Kow=3.96)、フェノキシヘキサエチレングリコールアクリレート(Log Kow=4.15)等の芳香族系エチレン性不飽和単量体;
ジシクロペンテニルオキシエチルアクリレート(Log Kow=2.57)、シクロヘキシルアクリレート(Log Kow=2.62)、ジシクロペンテニルアクリレート(Log Kow=2.98)、シクロヘキシルメタクリレート(Log Kow=3.06)、ジシクロペンタニルアクリレート(Log Kow=3.29)、ジシクロペンテニルメタクリレート(Log Kow=3.41)、ジシクロペンタニルメタクリレート(Log Kow=3.73)、イソボニルアクリレート(Log Kow=3.78)、イソボルニルメタクリレート(Log Kow=4.20)等のシクロアルキル基含有エチレン性不飽和単量体;
4-ヒドロキシビニルベンゼン(Log Kow=2.28)等の水酸基含有エチレン性不飽和単量体;
N-ペントキシメチル-アクリルアミド(Log Kow=1.90)、N,N-ジ(プロポキシメチル)アクリルアミド(Log Kow=1.90)、N-ペントキシメチル-メタアクリルアミド(Log Kow=2.29)、N,N-ジ(プロポキシメチル)メタアクリルアミド(Log Kow=2.29)、N,N-ジ(ブトキシメチル)アクリルアミド)(Log Kow=3.12)、N,N-ジ(ブトキシメチル)メタクリルアミド(Log Kow=3.51)等のアミド基含有エチレン性不飽和単量体;
2-ブテニルアクリレート(Log Kow=1.91)、1-ブテニルアクリレート(Log Kow=1.94)、エチレングリコールジメタクリレート(Log Kow=2.07)、アリルメタクリレート(Log Kow=2.10)、2-メチルアリルアクリレート(Log Kow=2.10)、アジピン酸ジビニル(Log Kow=2.12)、1,4-ブタンジオールジアクリレート(Log Kow=2.12)、イタコン酸ジアリル(Log Kow=2.19)、1-メチルアリルメタクリレート(Log Kow=2.50)、イソフタル酸ジアリル(Log Kow=2.51)、3-ブテニルメタクリレート(Log Kow=2.53)、2-ブテニルメタクリレート(Log Kow=2.60)、1,3-メチル-3-ブテニルアクリレート(Log Kow=2.62)、1-ブテニルメタクリレート(Log Kow=2.63)、2-メチルアリルメタクリレート(Log Kow=2.71)、1,4-ブタンジオールジメタクリレート(Log Kow=2.98)、フタル酸ジアリル(Log Kow=3.00)、1,3-メチル-3-ブテニルメタクリレート(Log Kow=3.01)、ジビニルベンゼン(Log Kow=3.93)等の2個以上のエチレン性不飽和基を有するエチレン性不飽和単量体;
γ-メタクリロキシメチルトリメトキシシラン(Log Kow=1.90)、γ-メタクリロキシプロピルトリメトキシシラン(Log Kow=2.42)、γ-アクリロキシプロピルメチルジメトキシシラン(Log Kow=2.47)、γ-メタクリロキシプロピルメチルジメトキシシラン(Log Kow=2.82)、ビニルトリエトキシシラン(Log Kow=3.12)、γ-アクリロキシプロピルトリメトキシシラン(Log Kow=3.50)、γ-アクリロキシプロピルトリエトキシシラン(Log Kow=3.50)、γ-メタクリロキシプロピルメチルジエトキシシラン(Log Kow=3.76)、γ-メタクリロキシプロピルトリエトキシシラン(Log Kow=3.86)等のアルコキシシリル基含有エチレン性不飽和単量体;が挙げられる。中でも、(メタ)アクリルアミドとの水性媒体中での重合安定性と重合体(A)の分散性が良好である点から、直鎖または分岐アルキル基含有エチレン性不飽和単量体、または芳香族系エチレン性不飽和単量体が好ましく、特にブチル(メタ)アクリレート、またはスチレンが好ましい。
その他エチレン性不飽和単量体(a-2)は前記重合体(A1a)と同様のものが挙げられる。
重合体(A1b)においての他エチレン性不飽和単量体(a-2)としては、(メタ)アクリルアミドと非イオン性エチレン性不飽和単量体(a-1)との水性媒体中での重合安定性と、スラリー組成物とした場合の無機微粒子との親和性が良好な点から、メチル(メタ)アクリレート、ヒドロキシエチル(メタ)アクリレート、または(メタ)アクリル酸が好ましい。
その他エチレン性不飽和単量体(a-2)を併用する場合、本開示の効果を妨げない範囲として、その他エチレン性不飽和単量体(a-2)の含有率は、エチレン性不飽和単量体全質量(100質量%)を基準として、5質量%以下であることが好ましい。
重合体(A1)を製造するためのエチレン性不飽和単量体の重合の方法は、溶液重合、懸濁重合、塊状重合、乳化重合などのいずれの方法を用いてもよい。
界面活性剤は、重合体(A1)を重合する際にエチレン性不飽和単量体混合物とともに用いることが好ましい。重合時に用いることにより、水性媒体中での(メタ)アクリルアミドと非イオン性エチレン性不飽和単量体(a-1)との重合安定性に優れる。
バインダー分散液中の重合体(A1)の固形分濃度は特に制限されないが、7質量%~50質量%であることが好ましい。
ラジカル重合開始剤は、エチレン性不飽和単量体混合物100質量部に対して、0.1~1.0質量部を用いることが好ましく、0.1~0.5質量部であることが更に好ましい。上記の範囲であることにより、バインダー分散液の粘度を適切な範囲内に調整でき、耐熱性、密着性と塗工性に優れる。
これら還元剤は、エチレン性不飽和単量体100質量部に対し、0.05~4質量部を用いることが好ましい。
緩衝剤としては、例えば、酢酸ナトリウム、クエン酸ナトリウム、重炭酸ナトリウム等が挙げられる。
連鎖移動剤としては、例えば、n-オクチルメルカプタン、t-オクチルメルカプタン、n-ノニルメルカプタン、t-ノニルメルカプタン、n-デシルメルカプタン、t-デシルメルカプタン、n-ウンデシルメルカプタン、t-ウンデシルメルカプタン、n-ドデシルメルカプタン、t-ドデシルメルカプタン、n-トリデシルメルカプタン、t-トリデシルメルカプタン、n-テトラデシルメルカプタン、t-テトラデシルメルカプタン、n-へプタデシルメルカプタン、t-ヘプタデシルメルカプタン、t-ヘキサデシルメルカプタン、n-ヘキサデシルメルカプタン等が挙げられる。
塩基性化合物は中和に使用される化合物である。この塩基性化合物としては、例えば、トリメチルアミン、トリエチルアミン、ブチルアミンなどのアルキルアミン、2-ジメチルアミノエタノール、2-ジエチルアミノエタノール、ジエタノールアミン、トリエタノールアミン、アミノメチルプロパノールなどのアルコールアミン、モルホリン、アンモニア等が挙げられる。
本開示のバインダー分散液には、効果を妨げない範囲で他の任意の成分として、消泡剤、レベリング剤、防腐剤、溶剤、架橋剤、分散剤、結着剤等、各種添加剤等を含んでもよい。
(式2)
透過率(%)=(l/l0)×100
粘度は、B型粘度計を用いて25℃、回転数20rpm、回転時間60秒で測定して求めることができる。
非水二次電池セパレータ用スラリー組成物は、非水二次電池セパレータに用いられる保護層を形成するために用いられ、少なくとも本開示の非水二次電池セパレータ用バインダー分散液と無機微粒子とを含む。本開示の非水二次電池セパレータ用スラリー組成物は、バインダー分散液と無機微粒子との親和性が良好であるため溶液安定性に優れ、耐熱性や密着性を発現セパレータの良好な耐熱性や密着性のためにバインダーを高分子量化した場合においても高粘度化が抑制され、スラリー組成物の塗工性にも優れる。
スラリー組成物は、必要に応じ、重合体(A2)を含むことが好ましく、重合体(A2)は接着成分としての機能を有し、セパレータ基材への密着性が向上するために好ましい。
無機微粒子は、非水二次電池の電解液中で変質しない無機化合物で構成されていることが好ましい。具体的な無機物化合物としては、例えば、酸化アルミニウム、水和アルミニウム酸化物、酸化ケイ素、酸化マグネシウム、酸化カルシウム、酸化ジルコニウム、酸化チタン、シリカ、イオン電導性ガラス等が挙げられる。無機化合物は1種類で使用してもよいし、2種類以上を組み合わせて使用してもよい。
無機微粒子の平均粒子径は、レーザー回析・散乱法または同的光散乱法による体積基準(体積分布)の粒度分布において、小粒子径側からの積算値が50%になるときの粒子径を示す。
本開示の非水二次電池セパレータ用スラリー組成物は、さらに重合体(A2)を含むことが好ましく、重合体(A2)は、ガラス転移温度(Tg)-40~40℃の粒子状重合体である。
なお、重合体(A2)は、重合体(A1)に該当する場合は除く。
重合体(A2)は、スラリー組成物とした場合に、基材への接着成分としての機能を有する。
重合体(A2)は、ガラス転移温度-40~40℃かつ粒子状であれば、どのような重合体であっても制限されず、アクリル樹脂、スチレンアクリル樹脂、ブタジエン系樹脂、オレフィン樹脂、ウレタン樹脂、ポリエステル樹脂、多糖類等の天然高分子等、任意の成分を使用することができるが、重合体(A1)との混合安定性や非導電性微粒子やオレフィン基材への密着性が良好な観点から、アクリル樹脂又はスチレンアクリル樹脂を用いることが好ましい。
重合体(A2)は、水性媒体に分散されてなる、粒子状重合体であり、これにより基材への接着性が発揮しやすい。また、重合体(A2)は、固形分濃度1質量%の条件での平均粒子径が50~500nmであることが好ましく、より好ましくは60~400nmである。上記の範囲であることにより、スラリー組成物とした場合に無機微粒子同士の隙間を埋めることがなくセパレータのイオン透過性が良好となる。
本開示の非水二次電池用スラリー組成物は、本開示の非水二次電池セパレータ用バインダー分散液と、無機微粒子と、重合体(A2)等の任意の添加剤とを混合して得られる。スラリー組成物は、例えば、無機微粒子を分散剤で分散した後、バインダー分散液と任意の添加剤とを混合して得ることができる。
本開示の非水二次電池セパレータは、セパレータ基材の少なくとも一方の面にスラリー組成物からなる保護層が設けられている。この保護層によりセパレータの耐熱性が向上し、非水二次電池が過熱した際に、両電極間でのショートが生じて、非水二次電池が爆発する危険性を低減することができる。
本開示の非水二次電池について、LIBを例に挙げて説明する。LIBは、少なくとも、正極と、負極と、正極と負極との間に設けられたセパレータとを備える電池本体と、電池本体に含浸された電解液とを有する。
なお、無機微粒子の平均粒子径および重合体のガラス転移温度(Tg)の測定方法は以下の通りである。
無機微粒子の平均粒子径は、レーザー回析・散乱法による体積基準(体積分布)の粒度分布において、小粒子径側からの積算値が50%になるときの粒子径から求めた。
重合体のガラス転移温度は、DSC(示差走査熱量計 TAインスツルメント社製)を使用して測定した。具体的には乾燥させた樹脂約3mgを精秤して入れたアルミニウムパンと、リファレンスである空のアルミニウムパンとをDSC測定ホルダーにセットし、10℃/分の昇温条件にて測定して得られたDSC曲線における吸熱現象の低温側のベースラインと変曲点での接線の交点の温度をガラス転移温度(Tg)とした。
<重合体(A2-1a)分散液の調製>
攪拌器、温度計、滴下ロート、還流器を備えた反応容器に、イオン交換水40部と界面活性剤としてアクアロンKH-10(第一工業製薬株式会社製)0.2部とを仕込み、別途、2-エチルヘキシルアクリレート61部、メチルメタクリレート30部、スチレン7部、メタクリルアミド0.5部、アクリル酸1.5部、イオン交換水53部および界面活性剤としてアクアロンKH-10(第一工業製薬株式会社製)1.8部をあらかじめ混合しておいたプレエマルジョンのうちの1%をさらに加えた。内温を60℃に昇温し充分に窒素置換した後、過硫酸カリウムの5%水溶液10部、および無水重亜硫酸ナトリウムの1%水溶液20部の10%を添加し重合を開始した。反応系内を60℃で5分間保持した後、内温を60℃に保ちながらプレエマルジョンの残りと過硫酸カリウムの5%水溶液、および無水重亜硫酸ナトリウムの1%水溶液の残りを1.5時間かけて滴下し、さらに2時間攪拌を継続した。固形分測定にて転化率が98%超えたことを確認後、温度を30℃まで冷却した。25%アンモニア水を添加して、pHを8.5とし、さらにイオン交換水で固形分を40%に調整してTgは-12℃の重合体(A2-1a)分散液を得た。なお、固形分は、150℃20分焼き付け残分により求めた。
<非水二次電池セパレータ用バインダー分散液の製造>
アクリルアミド48部、2-ヒドロキシエチルアクリレート47部、ジアセトンアクリルアミド3部、ブチルアクリレート2部、イオン交換水90部を混合して、混合液を得た。攪拌機、温度計、滴下ロート、還流器を備えた反応容器に、水450部、上記混合液30部を仕込んだ。次いで、反応容器の内温を80℃に昇温して窒素置換を充分行った後、開始剤として10%過硫酸アンモニウム水溶液25部(固形分2.5部)を添加して反応を開始した。内温を80℃に保ちながら、混合液を60分かけて滴下した。滴下完了後、更に3時間80℃で反応させて、固形分測定にて転化率が98%超えたことを確認後、温度を30℃まで冷却した。イオン交換水で固形分を15%に調整して、重合体(A1-1a)を含む非水二次電池セパレータ用バインダー分散液を得た。なお、固形分は、150℃20分焼き付け残分により求めた。
表1Aに示す配合組成、および配合量(質量部)とした以外は、実施例1aと同様の方法により、重合体(A1-2a~18a)または重合体(A3a-1~6a)を含む非水二次電池セパレータ用バインダー分散液を得た。なお、実施例6a、8a、10aおよび比較例5aについては、反応完了後、25%アンモニア水を樹脂中のカルボキシル基に対して当モルになるように添加して中和した。
また、比較例2a、3aは重合安定性不良のため、合成できなかった。
重合体の酸価は、乾燥させた樹脂1g中に含まれる酸性成分を中和するのに要する水酸化カリウムのmg数。JIS K2501に記載の方法に従い、自動滴定装置(HIRANUMA社製「COM-A19」)水酸化カリウム・エタノール溶液を用いて電位差滴定をおこない算出した。
得られたバインダー分散液を、イオン交換水で固形分濃度5%に調整し、光路長1cm石英セルに入れ、分光光度計(日本分光社製「V-770」)を用いて、波長400nmにおける透過スペクトルを測定した。比較対象はイオン交換水とした。
A:光線透過率50%未満。
B:光線透過率50%以上、70%未満。
C:光線透過率70%以上。
得られたバインダー分散液を40℃72時間乾燥し、厚さ約0.5mmのフィルムを作製した。得られたフィルムを幅5mm×長さ20mmの短冊状に切り出して試料とし、動的粘弾性測定装置(アイティー計測制御社製「DVA-200」)を用いて、150℃における貯蔵弾性率を測定した。測定条件は以下のとおりである。
測定モード:引張
周波数:10Hz
歪:0.01%
昇温条件:10℃/分
A:貯蔵弾性率が1.0×107Pa以上。
B:貯蔵弾性率が1.0×106以上1.0×107Pa未満。
C:貯蔵弾性率が1.0×106Pa未満。
得られた固形分濃度15%のバインダー分散液を、B型粘度計(東機産業製「TVB-10」)にて粘度を測定した(温度:25℃、スピンドル回転時間:60秒間、スピンドル回転数:20rpm)。
A:粘度が3,000mPa・s以上、20,000mPa・s未満。
B:粘度が2,500mPa・s以上、3,000mPa・s未満。
B’:粘度が20,000mPa・s以上、25,000mPa・s未満。
C:粘度が2,500mPa・s未満
C’:粘度が25,000mPa・s以上。
平均粒子径は、重合体の溶液を固形分濃度1質量%まで希釈し、該希釈液約5mlを動的光散乱測定法(測定装置はナノトラックUPA(株)マイクロトラックベル社製)により測定した。このとき得られた体積粒子径分布データ(ヒストグラム)のピークを平均粒子径とした。
A:粒子径が100nm以上、3,000nm未満。
B:粒子径が3,000nm以上、4,000nm未満または10nm以上、100nm未満。
C:粒子径が10nm未満または4,000nm以上。
<耐電解液性>
耐電解液性は、重合体の電解液への溶解・膨潤のしやすさであり、電解液膨潤度により評価した。電解液膨潤度が小さいほど、耐電解液性が良好であるといえる。
得られたバインダー分散液を40℃72時間乾燥し、厚さ約1mmのフィルムを作製した。続いて、フィルムを縦10mm×横10mmに切り出して試料とし、エチレンカーボネートとジエチルカーボネートとを体積比2:3の割合で混合した混合溶媒に60℃72時間浸漬した。浸漬前後での膜の膨潤度を下記の通り算出した。
膨潤度(倍)=(浸漬後質量)/(浸漬前質量)
A:膨潤度が1.5倍未満。
B:膨潤度が1.5倍以上、2倍未満。
C:膨潤度が2倍以上。
<非イオン性エチレン性不飽和単量体(a-1a)>
MA:メチルアクリレ-ト(log Kow 0.59)
MMA:メチルメタクリレート(log Kow 1.13)
EA:エチルアクリレ-ト(log Kow 1.08)
2HEMA:2-ヒドロキシエチルメタクリレート(log Kow 0.33)
DAAM:ジアセトンアクリルアミド(log Kow 0.82)
<その他エチレン性不飽和単量体(a-2)>
AA:アクリル酸(log Kow 0.67:イオン性エチレン性不飽和単量体)
2HEA:ヒドロキシエチルアクリレート(log Kow -0.22)
St:スチレン(log Kow 2.71)
BA:ブチルアクリレ-ト(log Kow 2.23)
EGDMA:エチレングリコールジメタクリレート(log Kow 2.07)
<非水二次電池セパレータ用スラリー組成物の調製>
無機微粒子(アルミナ、平均粒子径0.5μm)42.4部、分散剤としてのポリカルボン酸アンモニウム塩(BYK-154)0.5部および水42.7部をビーズミルに投入してアルミナの分散液を作製した。得られたアルミナ分散液に、重合体(A-1a)を含むバインダー分散液を固形分相当で1.1部、増粘剤としてカルボキシメチルセルロース(CMC、ダイセル1220)4%水溶液0.6部、濡れ剤としてシリコン系活性剤(BYK-349)を0.3部、シリコン系消泡剤(BYK-018)を0.2部添加し、水を固形分濃度43%になるように加えた後、これらを混合して非水二次電池セパレータ用スラリー組成物を作製した。
セパレータ基材(9μm多孔質ポリエチレンフィルム)の片面に、上記スラリー組成物をドクターブレードを用いて厚みが3μmになるように塗布した。その後80℃のオーブンで乾燥し、保護層付きセパレータを得た。
正極活物質としてLiNi0.5Mn0.3Co0.2O2 93部、導電剤としてアセチレンブラック4部、バインダーとしてポリフッ化ビニリデン3部、N-メチルピロリドン45部を入れて混合し、正極用合材インキを作製した。得られた正極用合材インキを、集電体となる厚さ20μmのアルミ箔上にドクターブレードを用いて塗布した後、80℃で加熱乾燥して電極の単位面積当たりの目付け量が20mg/cm2となるように調整した。さらにロールプレスによる圧延処理を行い、合材層の密度が3.1g/cm3となる正極を作製した。
負極活物質として人造黒鉛98部、カルボキシメチルセルロース1.5%水溶液66.7部(固形分として1部)をプラネタリーミキサーに入れて混練し、水33部、スチレンブタジエンエマルション48%水系分散液2.08部(固形分として1部)を混合して、負極用合剤インキを作製した。得られた負極用合材インキを、集電体となる厚さ20μmの銅箔上にドクターブレードを用いて塗布した後、80℃で加熱乾燥して電極の単位面積当たりの目付け量が12mg/cm2となるように調整した。さらにロールプレスによる圧延処理を行い、合材層の密度が1.5g/cm3となる負極を作製した。
正極と負極を各々45mm×40mm、50mm×45mmに打ち抜いた。保護層付きセパレータを介して正極と負極を対向させてアルミ製ラミネート袋に挿入し、真空乾燥の後、電解液(エチレンカーボネートとヂエチルカーボネートとを体積比2:3の割合で混合した混合溶媒にLiPF6を1Mの濃度で溶解させた非水系電解液)を注入し、アルミ製ラミネートを封口してラミネート型非水二次電池を作製した。
表4Aに示す組成、及び配合量(質量部)に変更した以外は、実施例19aと同様の方法により、非水二次電池セパレータ用スラリー組成物、非水二次電池セパレータ、非水二次電池を作製した。
無機微粒子(アルミナ、平均粒子径0.5μm)42.4部、分散剤としてのポリカルボン酸アンモニア塩(BYK-154)0.5部および水42.7部をビーズミルに投入してアルミナの分散液を作製した。得られたアルミナ分散液に、重合体(A1-8a)を含むバインダー分散液を固形分相当で1.0部と、重合体(A2-1a)分散液を固形分相当で0.1部、増粘剤としてカルボキシメチルセルロース(CMC、ダイセル1220)4%水溶液0.6部、濡れ剤としてシリコン系活性剤(BYK-349)を0.3部、シリコン系消泡剤(BYK-018)を0.2部添加し、水を固形分濃度43%になるように加えた後、これらを混合して非水二次電池セパレータ用スラリー組成物を作製した。
表4Aに示す組成、及び配合量(質量部)に変更した以外は、実施例37aと同様の方法により、非水二次電池セパレータ用スラリー組成物、非水二次電池セパレータ、非水二次電池を作製した。
<溶液安定性>
スラリー組成物を50℃で保管し、凝集、沈殿及び分離の有無を目視で観察した。
[評価基準]
◎:保管開始から2週間以上、異常が観察されなかった。極めて良好。
○:保管開始から1週間以上2週間未満の間に、何らかの異常が観察された。良好。
△:保管開始から4日間以上1週間未満の間に、何らかの異常が観察された。使用可。
×:保管開始から3日間以内に、何らかの異常が観察された。実用上問題あり。
得られたセパレータを用い、スラリー組成物の塗工性を目視で観察した。
[評価基準]
◎:膜厚が均等であり、はじきもない。極めて良好。
○:塗工部分の5%未満にむらやはじきがある。良好。
△:塗工部分の5%以上、10%未満にむらやはじきがある。使用可。
×:塗工部分の10%以上にむらやはじきがある。実用上問題あり。
<セパレータの耐熱性>
セパレータをMD(流れ方向)100mm×TD(垂直方向)100mmに切り出して試料とした。試料を3枚の紙に挟み、150℃のオーブン中に2時間静置した。オーブンから試料を取り出して冷却した後に、収縮率を以下の通り算出した。
試料面積(mm2)=(試料のMD長)×(試料のTD長)
収縮率(%)=[(加熱後の試料面積)/(加熱前の試料面積)]×100
[評価基準]
◎:収縮率が7%未満。極めて良好。
〇:収縮率が7%以上15%未満。良好。
△:収縮率が15%以上30%未満。実用上使用可。
×:収縮率が30%以上。実用上問題あり。
得られた保護層付きセパレータを幅25mm×長さ100mmに切り出し、セパレータの基材側とステンレス板とを両面テープで貼り合わせた。保護層側に幅18mmのセロハンテープを貼りつけて1kgの荷重でロール圧着した。温度50℃湿度50%の条件下に24時間静置後、セロハンテープの一端を180°方向に引っ張り、引張試験機(島津製作所社製「AGS-X」)にて剥離強度を測定した(剥離速度:10mm/min、単位:N/18mm幅)。
[評価基準]
◎:剥離強度が3N/18mm以上。極めて良好。
〇:剥離強度が2N/18mm以上3N/18mm未満。良好。
△:剥離強度が1.5N/18mm以上2N/18mm未満。実用上使用可。
×:剥離強度が1.5N/18mm未満。実用上問題あり。
<内部抵抗>
内部抵抗は、100mlの空気が試料を通過するのにかかる時間であり、透気度により評価した。かかる時間が短いほど、内部抵抗が小さい傾向があり、内部抵抗が良好であるといえる。JIS P8117に記載の方法に従い、ガーレー形通気性試験機(東洋精機製作所製「G-B3C」)を用いて透気度を測定した。
[評価基準]
◎:260sec/100ml未満。極めて良好。
○:260sec/100ml以上、270sec/100ml未満。良好。
△:270sec/100ml以上、280sec/100ml未満。実用上使用可。
×:280sec/100ml以上。実用上問題あり。
50℃恒温槽にて充電電流を60mAにて充電終止電圧を4.2Vで定電流定電圧充電(カットオフ電流0.6mA)を行った後、放電電流60mAで充電終止電圧3.0Vに達するまで定電流放電を行って、初回放電容量を求めた。この充放電サイクルを200回行い、放電容量維持率(初回放電容量に対する10回目の放電容量の百分率)を算出した。
放電容量維持率が高いほどサイクル特性が良好であるといえる。
[評価基準]
◎:放電容量維持率が90%以上。極めて良好。
〇:放電容量維持率が85%以上90%未満。良好。
△:放電容量維持率が80%以上85%未満。実用上使用可。
×:放電容量維持率が80%未満。実用上問題あり。
[実施例1b]
<非水二次電池セパレータ用バインダー分散液の製造>
アクリルアミド66部、t-ブチルメタクリレート32部、1,9-ノナンジオールジアクリレート2部、20%エマール2FG水溶液1.0部、イオン交換水90部を混合して、混合液を得た。攪拌機、温度計、滴下ロート、還流器を備えた反応容器に、水450部、上記混合液30部を仕込んだ。次いで、反応容器の内温を80℃に昇温して窒素置換を充分行った後、開始剤として10%過硫酸アンモニウム水溶液2.0部(固形分0.2部)を添加して反応を開始した。内温を80℃に保ちながら、混合液を60分かけて滴下した。滴下完了後、更に3時間80℃で反応させて、固形分測定にて転化率が98%超えたことを確認後、温度を30℃まで冷却した。イオン交換水で固形分を15%に調整して、重合体(A1-1b)を含む非水二次電池セパレータ用バインダー分散液を得た。なお、固形分は、150℃20分焼き付け残分により求めた。
表1B~3Bに示す配合組成、および配合量(質量部)とした以外は、実施例1bと同様の方法により、重合体(A1-2b~24b)または重合体(A3-1b~7b)を含む非水二次電池セパレータ用バインダー分散液を得た。なお、実施例4b、6b、12bおよび比較例5bについては、反応完了後、25%アンモニア水を樹脂中のカルボキシ基に対して当モルになるように添加して中和した。
実施例21b、24bは、重合中に凝集物が確認された。また、比較例7bは重合安定性不良のため、合成できなかった。
重合体の酸価は、乾燥させた樹脂1g中に含まれる酸性成分を中和するのに要する水酸化カリウムのmg数。JIS K2501に記載の方法に従い、自動滴定装置(HIRANUMA社製「COM-A19」)水酸化カリウム・エタノール溶液を用いて電位差滴定をおこない算出した。
得られたバインダー分散液を、イオン交換水で固形分濃度5%に調整し、光路長1cm石英セルに入れ、分光光度計(日本分光社製「V-770」)を用いて、波長400nmにおける透過スペクトルを測定した。比較対象はイオン交換水とした。
A:光線透過率50%未満。
B:光線透過率50%以上、70%未満。
C:光線透過率70%以上。
得られたバインダー分散液を40℃72時間乾燥し、厚さ約0.5mmのフィルムを作製した。得られたフィルムを幅5mm×長さ20mmの短冊状に切り出して試料とし、動的粘弾性測定装置(アイティー計測制御社製「DVA-200」)を用いて、150℃における貯蔵弾性率を測定した。測定条件は以下のとおりである。
測定モード:引張
周波数:10Hz
歪:0.01%
昇温条件:10℃/分
A:貯蔵弾性率が1.0×107Pa以上。
B:貯蔵弾性率が1.0×106以上1.0×107Pa未満。
C:貯蔵弾性率が1.0×106Pa未満。
得られた固形分濃度15%のバインダー分散液を、B型粘度計(東機産業製「TVB-10」)にて粘度を測定した(温度:25℃、スピンドル回転時間:60秒間、スピンドル回転数:20rpm)。
A:粘度が500以上、7000mPa・s未満。
B :粘度が100以上、500mPa・s未満。
B’:粘度が7000以上、15,000mPa・s未満。
C :粘度が100mPa・s未満
C’:粘度が15,000mPa・s以上。
平均粒子径は、重合体の溶液を固形分濃度1質量%まで希釈し、該希釈液約5mlを動的光散乱測定法(測定装置はナノトラックUPA(株)マイクロトラックベル社製)により測定した。このとき得られた体積粒子径分布データ(ヒストグラム)のピークを平均粒子径とした。
A:平均粒子径が100nm以上、3,000nm未満。
B:平均粒子径が3,000nm以上、4,000nm未満または10nm以上、100nm未満。
C:平均粒子径が10nm未満または4,000nm以上。
<耐電解液性>
耐電解液性は、重合体の電解液への溶解・膨潤のしやすさであり、電解液膨潤度により評価した。電解液膨潤度が小さいほど、耐電解液性が良好であるといえる。
得られたバインダー分散液を40℃72時間乾燥し、厚さ約1mmのフィルムを作製した。続いて、フィルムを縦10mm×横10mmに切り出して試料とし、エチレンカーボネートとジエチルカーボネートとを体積比2:3の割合で混合した混合溶媒に60℃72時間浸漬した。浸漬前後での膜の膨潤度を下記の通り算出した。
膨潤度(倍)=(浸漬後質量)/(浸漬前質量)
A:膨潤度が1.5倍未満。
B:膨潤度が1.5倍以上、2倍未満。
C:膨潤度が2倍以上。
エチレン性不飽和単量体のLog Kowの値は、ハンセン溶解度パラメータソフトHSPiP(ver.5.2.05)のYMB法(物性推算機能)により、エチレン性不飽和単量体の構造式をSmiles記法に変換して入力して算出した。
<非イオン性エチレン性不飽和単量体(a-1b)>
t-BA:t-ブチルアクリレ-ト(Log Kow 2.06)
BA:ブチルアクリレート(Log Kow 2.23)
t-BMA:t-ブチルメタクリレ-ト(log Kow 4.01)
St:スチレン(Log Kow 3.06)
2EHA:2-エチルヘキシルアクリレート(Log Kow 0.82)
1,4-BDDMA:1,4-ブタンジオールジメタクリレート(Log Kow 2.98)
<その他エチレン性不飽和単量体(a-2)>
AA:アクリル酸(Log Kow 0.2)
2HEA:ヒドロキシエチルアクリレート(Log Kow 0.01)
2HEMA:ヒドロキシエチルメタクリレート(Log Kow 0.7)
MMA:メチルメタクリレート(Log Kow 1.13)
iNA:イソノニルアクリレート(Log Kow 4.44)
1,9-NDDA:1,9-ノナンジオールジアクリレート(Log Kow 5.44)
<非水二次電池セパレータ用スラリー組成物の調製>
無機微粒子(アルミナ、平均粒子径0.5μm)42.4部、分散剤としてのポリカルボン酸アンモニウム塩(BYK-154)0.5部および水42.7部をビーズミルに投入してアルミナの分散液を作製した。得られたアルミナ分散液に、重合体(A1-1b)を含むバインダー分散液を固形分相当で1.1部、増粘剤としてカルボキシメチルセルロース(CMC、ダイセル1220)4%水溶液0.6部、濡れ剤としてシリコン系活性剤(BYK-349)を0.3部、シリコン系消泡剤(BYK-018)を0.2部添加し、水を固形分濃度43%になるように加えた後、これらを混合して非水二次電池セパレータ用スラリー組成物を作製した。
セパレータ基材(9μm多孔質ポリエチレンフィルム)の片面に、上記スラリー組成物をドクターブレードを用いて厚みが3μmになるように塗布した。その後80℃のオーブンで乾燥し、保護層付きセパレータを得た。
正極活物質としてLiNi0.5Mn0.3Co0.2O2 93部、導電剤としてアセチレンブラック4部、バインダーとしてポリフッ化ビニリデン3部、N-メチルピロリドン45部を入れて混合し、正極用合材インキを作製した。得られた正極用合材インキを、集電体となる厚さ20μmのアルミ箔上にドクターブレードを用いて塗布した後、80℃で加熱乾燥して電極の単位面積当たりの目付け量が20mg/cm2となるように調整した。さらにロールプレスによる圧延処理を行い、合材層の密度が3.1g/cm3となる正極を作製した。
正極と負極を各々45mm×40mm、50mm×45mmに打ち抜いた。保護層付きセパレータを介して正極と負極を対向させてアルミ製ラミネート袋に挿入し、真空乾燥の後、電解液(エチレンカーボネートとジエチルカーボネートとを体積比2:3の割合で混合した混合溶媒にLiPF6を1Mの濃度で溶解させた非水系電解液)を注入し、アルミ製ラミネートを封口してラミネート型非水二次電池を作製した。
表4Bに示す組成、及び配合量(質量部)に変更した以外は、実施例25bと同様の方法により、非水二次電池セパレータ用スラリー組成物、非水二次電池セパレータ、非水二次電池を作製した。
無機微粒子(アルミナ、平均粒子径0.5μm)42.4部、分散剤としてのポリカルボン酸アンモニア塩(BYK-154)0.5部および水42.7部をビーズミルに投入してアルミナの分散液を作製した。得られたアルミナ分散液に、重合体(A1-11b)を含むバインダー分散液を固形分相当で1.0部と、重合体(A2-1b)分散液を固形分相当で0.1部、増粘剤としてカルボキシメチルセルロース(CMC、ダイセル1220)4%水溶液0.6部、濡れ剤としてシリコン系活性剤(BYK-349)を0.3部、シリコン系消泡剤(BYK-018)を0.2部添加し、水を固形分濃度43%になるように加えた後、これらを混合して非水二次電池セパレータ用スラリー組成物を作製した。
表4Bに示す組成、及び配合量(質量部)に変更した以外は、実施例49bと同様の方法により、非水二次電池セパレータ用スラリー組成物、非水二次電池セパレータ、非水二次電池を作製した。
<溶液安定性>
スラリー組成物を50℃で保管し、凝集、沈殿及び分離の有無を目視で観察した。
[評価基準]
◎:保管開始から4週間以上、異常が観察されなかった。極めて良好。
○:保管開始から1週間以上4週間未満の間に、何らかの異常が観察された。良好。
△:保管開始から4日間以上1週間未満の間に、何らかの異常が観察された。使用可。
×:保管開始から3日間以内に、何らかの異常が観察された。実用上問題あり。
得られたセパレータを用い、スラリー組成物の塗工性を目視で観察した。
[評価基準]
◎:膜厚が均等であり、はじきもない。極めて良好。
○:塗工部分の5%未満にむらやはじきがある。良好。
△:塗工部分の5%以上、10%未満にむらやはじきがある。使用可。
×:塗工部分の10%以上にむらやはじきがある。実用上問題あり。
<セパレータの耐熱性>
セパレータをMD(流れ方向)100mm×TD(垂直方向)100mmに切り出して試料とした。試料を3枚の紙に挟み、150℃のオーブン中に2時間静置した。オーブンから試料を取り出して冷却した後に、収縮率を以下の通り算出した。
試料面積(mm2)=(試料のMD長)×(試料のTD長)
収縮率(%):=[1-(加熱後の試料面積)/(加熱前の試料面積)]×100
[評価基準]
◎:収縮率が7%未満。極めて良好。
〇:収縮率が7%以上15%未満。良好。
△:収縮率が15%以上30%未満。実用上使用可。
×:収縮率が30%以上。実用上問題あり。
セパレータを温度23℃湿度50%の条件下に3日間静置し、気化装置(VA-100 三菱化学社製)を用いて120℃の気化温度で抽出した水分量を、カールフィッシャー水分測定装置(CA-100 三菱化学社製)を用いて測定した。
[評価基準]
◎:水分量が1,500ppm未満。極めて良好。
〇:水分量が1,500ppm以上、2,000ppm未満。良好。
△:水分量が2,000ppm以上、3,000ppm未満。実用上使用可。
×:水分量が3,000ppm以上。実用上問題あり。
得られた保護層付きセパレータを幅25mm×長さ100mmに切り出し、セパレータの基材側とステンレス板とを両面テープで貼り合わせた。保護層側に幅18mmのセロハンテープを貼りつけて1kgの荷重でロール圧着した。温度25℃湿度50%の条件下に24時間静置後、セロハンテープの一端を180°方向に引っ張り、引張試験機(島津製作所社製「AGS-X」)にて剥離強度を測定した(剥離速度:10mm/分、単位:N/18mm幅)。
[評価基準]
◎:剥離強度が3N/18mm以上。極めて良好。
〇:剥離強度が2N/18mm以上、3N/18mm未満。良好。
△:剥離強度が1.5N/18mm、以上2N/18mm未満。実用上使用可。
×:剥離強度が1.5N/18mm未満。実用上問題あり。
<内部抵抗>
内部抵抗は、100mlの空気が試料を通過するのにかかる時間であり、透気度により評価した。かかる時間が短いほど、内部抵抗が小さい傾向があり、内部抵抗が良好であるといえる。JIS P8117に記載の方法に従い、ガーレー形通気性試験機(東洋精機製作所製「G-B3C」)を用いて透気度を測定した。
[評価基準]
◎:250秒/100ml未満。極めて良好。
○:250秒/100ml以上、270秒/100ml未満。良好。
△:270秒/100ml以上、280秒/100ml未満。実用上使用可。
×:280秒/100ml以上。実用上問題あり。
50℃恒温槽にて充電電流を60mAにて充電終止電圧を4.2Vで定電流定電圧充電(カットオフ電流0.6mA)を行った後、放電電流60mAで充電終止電圧3.0Vに達するまで定電流放電を行って、初回放電容量を求めた。この充放電サイクルを200回行い、放電容量維持率(初回放電容量に対する10回目の放電容量の百分率)を算出した。
放電容量維持率が高いほどサイクル特性が良好であるといえる。
[評価基準]
◎:放電容量維持率が90%以上。極めて良好。
〇:放電容量維持率が85%以上、90%未満。良好。
△:放電容量維持率が80%以上、85%未満。実用上使用可。
×:放電容量維持率が80%未満。実用上問題あり。
Claims (10)
- 重合体(A1)と水性媒体を含み、
重合体(A1)は、酸価が15mgKOH/g以下、かつエチレン性不飽和単量体混合物の全質量を基準として、(メタ)アクリルアミド40~80質量%、および25℃におけるオクタノール/水分配係数の対数(LogKow)が0.25~1.5である非イオン性エチレン性不飽和単量体(a-1a)20~60質量%を含むエチレン性不飽和単量体混合物の重合体(A1a)であり、
固形分濃度5質量%の条件での波長400nmにおける光線透過率が70%未満である、非水二次電池セパレータ用バインダー分散液。 - 重合体(A1)と界面活性剤と水性媒体を含み、
重合体(A1)は、酸価が15mgKOH/g以下、かつエチレン性不飽和単量体混合物の全質量を基準として、(メタ)アクリルアミド50~85質量%、および25℃におけるオクタノール/水分配係数の対数(Log Kow)が1.9~4.2である非イオン性エチレン性不飽和単量体(a-1b)15~50質量%を含むエチレン性不飽和単量体混合物の重合体(A1b)であり、
固形分濃度5質量%の条件での波長400nmにおける光線透過率が70%未満である、非水二次電池セパレータ用バインダー分散液。 - 重合体(A1)は、150℃における貯蔵弾性率が1.0×106Pa以上である、請求項1または2に記載の非水二次電池セパレータ用バインダー分散液。
- 重合体(A1)は、エチレンカーボネートとジエチルカーボネートとの体積比が2:3である混合溶媒に60℃72時間浸漬した際の電解液膨潤度が2倍未満である、請求項1~3のいずれか1項に記載の非水二次電池セパレータ用バインダー分散液。
- 固形分濃度15質量%における粘度が2,500mPa・s以上25,000mPa・s未満である、請求項1~4のいずれか1項に記載の非水二次電池セパレータ用バインダー分散液。
- 固形分濃度15質量%における粘度が100mPa・s以上15,000mPa・s未満である、請求項1~4のいずれか1項に記載の非水二次電池セパレータ用バインダー分散液。
- 無機微粒子と、請求項1~6のいずれか1項に記載の非水二次電池セパレータ用バインダー分散液を含む、非水二次電池セパレータ用スラリー組成物。
- さらに重合体(A2)(ただし、重合体(A1)は除く)を含み、
重合体(A2)は、ガラス転移温度-40~40℃の粒子状重合体である、請求項7に記載の非水二次電池セパレータ用スラリー組成物。 - セパレータ基材の少なくとも一方の面に、請求項7または8に記載の非水二次電池セパレータ用スラリー組成物から形成されてなる保護層が設けられてなる、非水二次電池セパレータ。
- 請求項9に記載の非水二次電池セパレータを備える非水二次電池。
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JP2018026266A (ja) * | 2016-08-10 | 2018-02-15 | 荒川化学工業株式会社 | リチウムイオン二次電池用セパレータ、リチウムイオン二次電池用セパレータの製造方法、及びリチウムイオン二次電池 |
JP2020087591A (ja) * | 2018-11-20 | 2020-06-04 | 三井化学株式会社 | 二次電池セパレータ用コート材原料、二次電池セパレータ用コート材原料の製造方法、二次電池セパレータ用コート材、二次電池セパレータ、二次電池セパレータの製造方法、および、二次電池 |
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JP2018026266A (ja) * | 2016-08-10 | 2018-02-15 | 荒川化学工業株式会社 | リチウムイオン二次電池用セパレータ、リチウムイオン二次電池用セパレータの製造方法、及びリチウムイオン二次電池 |
JP2020087591A (ja) * | 2018-11-20 | 2020-06-04 | 三井化学株式会社 | 二次電池セパレータ用コート材原料、二次電池セパレータ用コート材原料の製造方法、二次電池セパレータ用コート材、二次電池セパレータ、二次電池セパレータの製造方法、および、二次電池 |
WO2020203396A1 (ja) * | 2019-03-29 | 2020-10-08 | 三井化学株式会社 | 二次電池セパレータ用コート材 |
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