JP2013116442A - Method for manufacturing laminated porous film - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a laminated porous film with wrinkle generation suppressed, the film made by laminating a cover layer on at least one side of a porous film of a polyolefin-based resin by coating.SOLUTION: The method for manufacturing a laminated porous film made by laminating a cover layer on at least one side of a porous film of a polyolefin-based resin by coating is characterized by conveying the porous film of a polyolefin-based resin superposed on a support film at least in a takeup step.

Description

  The present invention relates to a method for producing a laminated porous film using a polyolefin resin porous film, a battery separator and a battery using the laminated porous film. The laminated porous film produced by the present invention and a battery separator using the same can be used as packaging, sanitary, animal husbandry, agricultural, architectural, medical, separation membrane, light diffusion plate, battery separator. In particular, it can be suitably used as a separator for nonaqueous electrolyte batteries.

  The polymer porous body with many fine communication holes is used for separation membranes used for the production of ultrapure water, purification of chemicals, water treatment, waterproof and moisture-permeable films used for clothing and sanitary materials, and batteries. It is used in various fields such as battery separators.

  In particular, secondary batteries are widely used as power sources for portable devices such as OA, FA, household electric appliances, and communication devices. Among them, portable devices using lithium ion secondary batteries are increasing because they have a high volumetric efficiency when mounted on devices, leading to a reduction in size and weight of the devices. On the other hand, large-sized secondary batteries are being researched and developed in many fields related to energy / environmental issues, including road leveling, UPS, and electric vehicles, and are excellent in large capacity, high output, high voltage, and long-term storage. Therefore, the use of lithium ion secondary batteries, which are a kind of non-aqueous electrolyte secondary battery, is expanding.

  The working voltage of a lithium ion secondary battery is usually designed with an upper limit of 4.1V to 4.2V. At such a high voltage, the aqueous solution causes electrolysis and cannot be used as an electrolyte. Therefore, so-called non-aqueous electrolytes using organic solvents are used as electrolytes that can withstand high voltages. As the solvent for the non-aqueous electrolyte, a high dielectric constant organic solvent capable of allowing more lithium ions to be present is used, and organic carbonate compounds such as propylene carbonate and ethylene carbonate are mainly used as the high dielectric constant organic solvent. It is used. As a supporting electrolyte that becomes a lithium ion source in the solvent, a highly reactive electrolyte such as lithium hexafluorophosphate is dissolved in the solvent and used.

  In the lithium ion secondary battery, a separator is interposed between the positive electrode and the negative electrode from the viewpoint of preventing an internal short circuit. Of course, the separator is required to have insulating properties due to its role. Moreover, it is necessary to have a microporous structure in order to provide air permeability as a lithium ion passage and a function of diffusing and holding the electrolyte. In order to satisfy these requirements, a porous film is used as a separator.

  With the recent increase in battery capacity, the importance of battery safety has increased. As a characteristic that contributes to the safety of the battery separator, there is a shutdown characteristic (hereinafter referred to as “SD characteristic”). This SD characteristic is a function that can prevent a subsequent increase in temperature inside the battery because the micropores are blocked when the temperature is about 100 to 150 ° C., and as a result, ion conduction inside the battery is blocked. At this time, the lowest temperature among the temperatures at which the micropores of the laminated porous film are blocked is referred to as a shutdown temperature (hereinafter referred to as “SD temperature”). When used as a battery separator, it is necessary to have this SD characteristic.

  However, in recent years, with the increase in energy density and power of lithium ion secondary batteries, the normal shutdown function does not function sufficiently, and the temperature inside the battery exceeds about 150 ° C., the melting point of polyethylene, and further increases In addition, the separator may break. Therefore, in order to ensure safety, a separator having both current SD characteristics and heat resistance is required.

  In response to the demand, a separator (Patent Document 1) in which a porous film of a water-soluble polymer and a porous film of polyolefin are laminated, and a coating layer containing an inorganic filler and a resin binder on at least one surface of the polyolefin resin porous film is the surface. A porous film (Patent Document 2) formed on a polyolefin resin porous film (Patent Document 3) having a porous layer made of an inorganic filler and polyvinyl alcohol, and an inorganic filler and a resin binder on at least one surface of the polyolefin resin porous film. A laminated porous film (Patent Document 4) in which a heat-resistant layer is laminated has been proposed.

JP 2004-227972 A JP 2007-280911 A JP 2008-186721 A WO2011 / 062285

  When forming a coating layer on the porous film, in order to ensure adhesion between the coating layer and the polyolefin porous film, a surface treatment such as corona treatment is usually applied to the surface on which the coating layer is provided. . However, polyolefin resin porous films for battery separators are very thin and porous, so that the film tends to wrinkle during and / or after surface treatment such as corona treatment, and the surface treatment is performed. There is a problem that the porous film cannot be applied neatly. In addition, because of the characteristics of being very thin and porous, there is a problem that wrinkles are easily formed in the porous film even in a process of providing a coating layer on the polyolefin porous film. In particular, if wrinkles occur in the porous film before coating with the coating solution, uniform coating cannot be performed, and as a result, the main performances such as heat resistance and air permeability of the separator become non-uniform. In addition, if wrinkles occur in the winding process after uniform coating, a large pressure is applied to the wrinkled part in the wound product, and the performance as a separator is similarly uneven. It is not preferable because it adversely affects the workability of the battery when combined with the above.

  Then, an object of this invention is to provide the manufacturing method of the lamination | stacking porous film formed by laminating | coating a coating layer by a coating on the at least single side | surface of the polyolefin resin porous film in which generation | occurrence | production of wrinkles was suppressed.

  The present inventors have investigated from various aspects about the cause of wrinkles in the laminated porous film and the solution thereof in the process of forming a coating layer on the polyolefin resin porous film by coating or the like. At least the winding step, Or at least in the coating process, it discovered that generation | occurrence | production of a wrinkle could be suppressed by overlapping and conveying the said polyolefin resin porous film with a support film, and completed this invention.

That is, the present invention
(1) A method for producing a laminated porous film in which a coating layer is laminated on at least one surface of a polyolefin resin porous film by coating, and at least in the winding step, the polyolefin resin porous film is overlapped with a support film. The manufacturing method characterized by conveying,
(2) A method for producing a laminated porous film in which a coating layer is laminated on at least one surface of a polyolefin resin porous film by coating, and at least in the coating step, the polyolefin resin porous film is overlapped with a support film and conveyed. The production method characterized by:
(3) A method for producing a laminated porous film in which a coating layer is laminated on at least one surface of a polyolefin resin porous film by coating, and the polyolefin resin porous film is supported on the support film from at least a coating step to a winding step. And the manufacturing method, wherein
(4) The manufacturing method according to any one of (1) to (3), wherein the polyolefin-based resin porous film and the support film are temporarily adhered.
(5) The manufacturing method of any one of (1)-(4) whose thickness of the said support film is 6-100 micrometers.

(6) The manufacturing method according to any one of (1) to (5), wherein a tensile elastic modulus of the support film is 0.7 GPa or more.
(7) The manufacturing method according to any one of (1) to (6), wherein the support film is a polyester film.
(8) The manufacturing method according to any one of (1) to (7), wherein the coating layer includes a filler and a resin binder.
(9) A laminated porous film obtained by the production method according to any one of (1) to (8),
(10) A nonaqueous electrolyte battery separator using the laminated porous film according to (9), and a nonaqueous electrolyte battery separator using the nonaqueous electrolyte battery separator according to (11) (10), It is to provide.

  In the present invention, in the method for producing a laminated porous film in which a coating layer is laminated on at least one surface of a polyolefin resin porous film by coating, the polyolefin resin porous film in at least the winding process or at least the coating process. By overlapping and transporting the film with the support film, there is almost no generation of wrinkles, and continuous stable coating can be realized. Further, from the coating step to the winding step, the polyolefin-based resin porous film is transported while being overlapped with the support film, so that wrinkles are not generated and stable coating can be performed.

Schematic flow sheet of an example of a coating apparatus used in the production method of the present invention The partially broken perspective view of the battery which accommodates the lamination | stacking porous film of this invention

  Hereinafter, embodiments of the method for producing a laminated porous film of the present invention will be described in detail.

  In the present invention, the expression “main component” includes the intention to allow other components to be contained within a range that does not interfere with the function of the main component, unless otherwise specified. Although the content ratio is not specified, the main component is intended to include 50% by mass or more, preferably 70% by mass or more, particularly preferably 90% by mass or more (including 100%) in the composition. .

  In addition, when described as “X to Y” (X and Y are arbitrary numbers), “X is preferably greater than X” and “preferably smaller than Y”, together with the meaning of “X to Y” unless otherwise specified. Is included.

(Polyolefin resin porous film)
Examples of the polyolefin resin used in the polyolefin resin porous film include homopolymers or copolymers obtained by polymerizing ethylene, propylene, 1-butene, 4-methyl-1-pentene, 1-hexane, and the like. Among these, a polypropylene resin and a polyethylene resin are preferable.

(Polypropylene resin)
Examples of polypropylene resins include homopropylene (propylene homopolymer), or propylene and ethylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, etc. Examples thereof include random copolymers with α-olefins and block copolymers. Among these, homopolypropylene is more preferably used from the viewpoint of maintaining the mechanical strength and heat resistance of the laminated porous film.

  Moreover, as a polypropylene resin, it is preferable that the isotactic pentad fraction (mmmm fraction) which shows stereoregularity is 80 to 99%. More preferably 83-98%, still more preferably 85-97%. If the isotactic pentad fraction is too low, the mechanical strength of the film may be reduced. On the other hand, the upper limit of the isotactic pentad fraction is defined by the upper limit that can be obtained industrially at the present time, but this is not the case when a more regular resin is developed in the industrial level in the future. is not.

The isotactic pentad fraction (mmmm fraction) is the same direction for all five methyl groups that are side chains with respect to the main chain of carbon-carbon bonds composed of arbitrary five consecutive propylene units. Means the three-dimensional structure located at or its proportion. Signal assignment of the methyl group region is as follows. Zambelli
et al (Macromolecules 8,687, (1975)).

  Moreover, as a polypropylene resin, it is preferable that Mw / Mn which is a parameter which shows molecular weight distribution is 2.0-10.0. More preferably, 2.0 to 8.0, and still more preferably 2.0 to 6.0 is used. This means that the smaller the Mw / Mn, the narrower the molecular weight distribution. However, if the Mw / Mn is 2.0 or more, there is no problem such as deterioration of extrusion moldability, and industrial production is easy. It becomes. On the other hand, if Mw / Mn is 10.0 or less, the low molecular weight component is small and the mechanical strength of the laminated porous film is not lowered. Mw / Mn is obtained by GPC (gel permeation chromatography) method.

Further, the melt flow rate (MFR) of the polypropylene-based resin is not particularly limited, but usually the MFR is preferably 0.5 to 15 g / 10 minutes, and 1.0 to 10 g / 10 minutes. It is more preferable. When the MFR is 0.5 g / 10 min or more, the resin has a high melt viscosity at the time of molding, and sufficient productivity can be ensured. On the other hand, the mechanical strength of the obtained laminated porous film can be sufficiently maintained by setting it to 15 g / 10 min or less. MFR is JIS
According to K7210, measurement is performed under the conditions of a temperature of 230 ° C. and a load of 2.16 kg.

  The method for producing the polypropylene resin is not particularly limited, and a known polymerization method using a known polymerization catalyst, for example, a multisite catalyst represented by a Ziegler-Natta type catalyst or a metallocene catalyst. And a polymerization method using a single site catalyst.

Examples of the polypropylene resin include trade names “Novatech PP” “WINTEC” (manufactured by Nippon Polypro), “Versify” “Notio” “Tafmer XR” (manufactured by Mitsui Chemicals), “Zeras” “Thermolan” (Mitsubishi Chemical) ), “Sumitomo Noblen”, “Tough Selenium” (manufactured by Sumitomo Chemical Co., Ltd.), “Prime TPO” (manufactured by Prime Polymer), “Adflex”, “Adsyl”, “HMS-PP (PF814)” (manufactured by Sun Allomer) Commercially available products such as “Inspire” (Dow Chemical) can be used.

  The polyolefin resin porous film used in the present invention preferably has β activity.

  In the polyolefin resin porous film of the present invention, the presence or absence of “β activity” is determined by holding the laminated porous film with a differential scanning calorimeter from 25 ° C. to 240 ° C. at a heating rate of 10 ° C./min for 1 minute. When the temperature was lowered from 240 ° C. to 25 ° C. at a cooling rate of 10 ° C./min and held for 1 minute, and when the temperature was raised again from 25 ° C. to 240 ° C. at a heating rate of 10 ° C./min, When the derived crystal melting peak temperature (Tmβ) is detected, it is determined to have β activity.

  Further, the β activity of the porous film is calculated by the following formula using the crystal heat of fusion derived from α crystal (ΔHmα) and the crystal heat of fusion derived from β crystal (ΔHmβ) of the polypropylene resin to be detected.

β activity (%) = [ΔHmβ / (ΔHmβ + ΔHmα)] × 100
For example, when the polypropylene resin is homopolypropylene, the amount of heat of crystal melting derived from the β crystal (ΔHmβ) detected mainly in the range of 145 ° C. or higher and lower than 160 ° C., and mainly detected at 160 ° C. or higher and 170 ° C. or lower. It can be calculated from the heat of crystal melting (ΔHmα) derived from the α crystal. Further, for example, in the case of random polypropylene copolymerized with 1 to 4 mol% of ethylene, the crystal melting heat amount (ΔHmβ) derived from the β crystal detected mainly in the range of 120 ° C. or more and less than 140 ° C., and mainly 140 It can be calculated from the crystal melting calorie (ΔHmα) derived from the α crystal detected in the range of from 0 ° C. to 165 ° C.

  The β activity of the polyolefin resin porous film is preferably 20% or more, and more preferably 40% or more and 60% or more. If the laminated porous film has a β activity of 20% or more, a lot of fine and uniform pores are formed by stretching, and as a result, a separator for a lithium ion battery having high mechanical strength and excellent air permeability is obtained. Can do.

  The upper limit of β activity is not particularly limited, but the higher the β activity, the more effective the effect is obtained.

  The presence or absence of the β activity can also be determined by a diffraction profile obtained by wide-angle X-ray diffraction measurement of a laminated porous film subjected to a specific heat treatment.

  Specifically, a wide-angle X-ray diffraction measurement was performed on the laminated porous film which was subjected to heat treatment at 170 ° C. to 190 ° C., which is a temperature exceeding the melting point of the polypropylene resin, and was slowly cooled to form and grow β crystals. When the diffraction peak derived from the (300) plane of the β crystal of the resin is detected in the range of 2θ = 16.0 ° to 16.5 °, it is determined that there is β activity.

  Details on the β crystal structure and wide angle X-ray diffraction of polypropylene resins can be found in Macromol. Chem. 187, 643-652 (1986), Prog. Polym. Sci. Vol. 16, 361-404 (1991), Macromol. Symp. 89, 499-511 (1995), Macromol. Chem. 75, 134 (1964), and references cited therein. A detailed evaluation method of β activity using wide-angle X-ray diffraction will be described in the examples described later.

  The β activity can be measured regardless of whether the polypropylene resin porous film has a single layer structure or is laminated with another porous layer.

  Further, if a layer containing a polypropylene resin other than the layer made of polypropylene resin is laminated, it is preferable that both layers have β activity.

  As a method for obtaining the β activity described above, a method of adding polypropylene subjected to a treatment for generating a peroxide radical as described in Japanese Patent No. 3739481, and a method of adding a β crystal nucleating agent to the composition Etc.

(Β crystal nucleating agent)
Examples of the β-crystal nucleating agent used in the present invention include the following, but are not particularly limited as long as they increase the formation / growth of β-crystals of a polypropylene resin, and two or more types thereof. May be used in combination.

  Examples of the β crystal nucleating agent include amide compounds; tetraoxaspiro compounds; quinacridones; iron oxides having a nanoscale size; potassium 1,2-hydroxystearate, magnesium benzoate or magnesium succinate, magnesium phthalate, etc. Alkali or alkaline earth metal salts of carboxylic acids represented by: aromatic sulfonic acid compounds represented by sodium benzenesulfonate or sodium naphthalenesulfonate; di- or triesters of dibasic or tribasic carboxylic acids; phthalocyanine blue Phthalocyanine pigments typified by: a two-component compound comprising component A which is an organic dibasic acid and a component B which is an oxide, hydroxide or salt of a Group IIA metal of the periodic table; a cyclic phosphorus compound; Made of magnesium compound Such as the formation thereof. In addition, specific types of nucleating agents are described in JP-A No. 2003-306585, JP-A Nos. 06-228966, and JP-A Nos. 09-194650.

As a commercial product of β crystal nucleating agent, β crystal nucleating agent “NJESTER NU-100” manufactured by Shin Nippon Rika Co., Ltd., as a specific example of polypropylene resin added with β crystal nucleating agent, polypropylene manufactured by Aristech “Bepol”
B-022SP ”, polypropylene manufactured by Borealis“ Beta (β) -PP BE60-7032 ”, polypropylene manufactured by Mayzo“ BNX BETAPP-LN ”, and the like.

  The ratio of the β-crystal nucleating agent added to the polypropylene resin needs to be appropriately adjusted depending on the type of the β-crystal nucleating agent or the composition of the polypropylene-based resin. 0.0001 to 5.0 parts by mass of the agent is preferred. 0.001-3.0 mass parts is more preferable, and 0.01-1.0 mass part is still more preferable. If it is 0.0001 part by mass or more, β crystals of polypropylene resin can be sufficiently produced and grown at the time of production, and sufficient β activity can be secured even when used as a separator, and the desired air permeability performance can be obtained. can get. Addition of 5.0 parts by mass or less is preferable because it is economically advantageous and there is no bleeding of the β crystal nucleating agent on the surface of the laminated porous film.

  Further, when a layer containing a polypropylene resin other than the layer made of polypropylene resin is laminated, the amount of β crystal nucleating agent added to each layer may be the same or different. The porous structure of each layer can be appropriately adjusted by changing the addition amount of the β crystal nucleating agent.

(Other ingredients)
In addition to the components described above, additives generally blended in the resin composition can be appropriately added to the polypropylene resin within a range that does not significantly impair the effects of the present invention. Examples of the additive include recycling resin, silica, talc, kaolin, calcium carbonate, and the like, which are added for the purpose of improving and adjusting molding processability, productivity, and various physical properties of the laminated porous film. Inorganic particles such as, pigments such as titanium oxide and carbon black, flame retardants, weathering stabilizers, heat stabilizers, antistatic agents, surfactants, melt viscosity improvers, crosslinking agents, lubricants, nucleating agents, plasticizers, Additives such as anti-aging agents, antioxidants, light stabilizers, UV absorbers, neutralizing agents, anti-fogging agents, anti-blocking agents, slip agents or coloring agents can be mentioned.

(Polyethylene resin)
In the present embodiment, a polyethylene resin porous film is suitably used as the porous film laminated with the porous film made of the polypropylene resin.

  Specific examples of the polyethylene resin include ultra low density polyethylene, low density polyethylene, high density polyethylene, linear low density polyethylene, and homopolymer polyethylene such as ultra high molecular weight polyethylene having a characteristic molecular weight, as well as ethylene. A propylene copolymer or a copolymer polyethylene of a polyethylene resin and another polyolefin resin can be used. Among these, homopolymer polyethylene or copolymer polyethylene having an α-olefin comonomer content of 2 mol% or less is preferable, and homopolymer polyethylene is more preferable. There is no restriction | limiting in particular about the kind of alpha-olefin comonomer.

Density of the polyethylene resin is preferably 0.910~0.970g / cm ^3, more preferably 0.930~0.970g / cm ^3, 0.940~0.970g / cm ³ is more preferable. A density of 0.910 g / cm ³ or more is preferable because it can have appropriate SD characteristics. On the other hand, 0.970 g / cm ³ or less is preferable in that it can have an appropriate SD characteristic and can maintain stretchability. The density can be measured according to JIS K7112 using a density gradient tube method.

  Further, the melt flow rate (MFR) of the polyethylene resin is not particularly limited, but usually the MFR is preferably 0.03 to 30 g / 10 minutes, and preferably 0.3 to 10 g / 10 minutes. It is more preferable. If the MFR is 0.03 g / 10 min or more, the melt viscosity of the resin during the molding process is sufficiently low, which is excellent in productivity and preferable. On the other hand, if it is 30 g / 10 minutes or less, since sufficient mechanical strength can be obtained, it is preferable.

  MFR is measured in accordance with JIS K7210 under conditions of a temperature of 190 ° C. and a load of 2.16 kg.

  The polymerization catalyst for the polyethylene resin is not particularly limited, and may be any Ziegler type catalyst, Philips type catalyst, Kaminsky type catalyst or the like. As a polymerization method of the polyethylene resin, there are a one-stage polymerization, a two-stage polymerization, or a multistage polymerization more than that, and any method of the polyethylene resin can be used.

(Porosification promoting compound)
It is preferable to add the porosity promoting compound X that promotes porosity to the polyethylene resin. By adding the porosity promoting compound X, a porous structure can be obtained more efficiently, and the shape and diameter of the pores can be easily controlled.

  The porosity promoting compound X is not limited, but specific examples thereof include a porosity promoting compound X selected from a modified polyolefin resin, an alicyclic saturated hydrocarbon resin or a modified product thereof, an ethylene copolymer, or a wax. More preferably, at least one of them is included. Among these, an alicyclic saturated hydrocarbon resin or a modified product thereof, an ethylene copolymer, or a wax, which is more effective when made porous, is more preferable, and a wax is more preferable from the viewpoint of moldability.

  Examples of alicyclic saturated hydrocarbon resins and modified products thereof include petroleum resins, rosin resins, terpene resins, coumarone resins, indene resins, coumarone-indene resins, and modified products thereof.

  In the present invention, the petroleum resin is a C4 to C10 aliphatic olefin or diolefin obtained from a by-product such as by thermal decomposition of naphtha, or a C8 or more aromatic compound having an olefinically unsaturated bond. An aliphatic, aromatic and copolymer petroleum resin obtained by singly or copolymerizing one or more of the compounds contained therein.

  Examples of petroleum resins include aliphatic petroleum resins mainly containing C5 fraction, aromatic petroleum resins mainly containing C9 fraction, copolymer petroleum resins thereof, and alicyclic petroleum resins. . Examples of terpene resins include terpene resins and terpene-phenol resins derived from β-pinene, and examples of rosin resins include rosin resins such as gum rosin and utdrodine, and esterified rosin resins modified with glycerin and pentaerythritol. The alicyclic saturated hydrocarbon resin and the modified product thereof have relatively good compatibility when mixed with a polyethylene resin, but a petroleum resin is more preferable in terms of color tone and thermal stability, and a hydrogenated petroleum resin is used. More preferably.

  Hydrogenated petroleum resin is obtained by hydrogenating petroleum resin by a conventional method. Examples thereof include hydrogenated aliphatic petroleum resins, hydrogenated aromatic petroleum resins, hydrogenated copolymer petroleum resins and hydrogenated alicyclic petroleum resins, and hydrogenated terpene resins. Among hydrogenated petroleum resins, hydrogenated alicyclic petroleum resins obtained by copolymerizing and hydrogenating a cyclopentadiene compound and an aromatic vinyl compound are particularly preferable. Examples of commercially available hydrogenated petroleum resins include “ALCON” (manufactured by Arakawa Chemical Industries).

  The ethylene copolymer in the present invention is a compound obtained by copolymerizing ethylene and one or more of vinyl acetate, unsaturated carboxylic acid, unsaturated carboxylic acid anhydride, or carboxylic acid ester. It is.

  The ethylene copolymer preferably has an ethylene monomer unit content of 50% by mass or more, more preferably 60% by mass or more, and still more preferably 65% by mass or more. On the other hand, regarding the upper limit, the content of ethylene monomer units is preferably 95% by mass or less, more preferably 90% by mass or less, and further preferably 85% by mass or less. If the content of the ethylene monomer unit is within a predetermined range, a porous structure can be formed more efficiently.

  As the ethylene copolymer, those having an MFR (JIS K7210, temperature: 190 ° C., load: 2.16 kg) of 0.1 g / 10 min to 10 g / 10 min are preferably used. If the MFR is 0.1 g / 10 min or more, the extrudability can be maintained satisfactorily. On the other hand, if the MFR is 10 g / 10 min or less, the strength of the film is hardly lowered, which is preferable.

  The ethylene-based copolymer includes “EVAFLEX” (manufactured by Mitsui DuPont Polychemical Co.), “Novatech EVA” (manufactured by Nippon Polyethylene Co., Ltd.) as an ethylene-vinyl acetate copolymer, and “NUC as an ethylene-acrylic acid copolymer. Copolymer "(manufactured by Nihon Unicar)," Evaflex-EAA "(Mitsui / DuPont Polychemical)," REXPEARL EAA "(manufactured by Nippon Ethylene)," ELVALOY "as an ethylene- (meth) acrylic acid copolymer (Mitsui / DuPont Polychemical Co., Ltd.), “REXPEARL EMA” (manufactured by Nippon Ethylene Co., Ltd.), “REXPEARL EEA” (manufactured by Nippon Ethylene Co., Ltd.) as an ethylene-ethyl acrylate copolymer, ethylene-methyl (meth) acrylic acid co "Acrylift" as a polymer "Bondyne" (manufactured by Sumitomo Chemical Co., Ltd.), ethylene-glycidyl methacrylate copolymer, ethylene-vinyl acetate-glycidyl methacrylate terpolymer, ethylene-acrylic as an ethylene-vinyl acetate-maleic anhydride terpolymer “Bond First” (manufactured by Sumitomo Chemical Co., Ltd.) or the like is commercially available as an ethyl acrylate-glycidyl methacrylate terpolymer.

  The wax in the present invention is an organic compound that satisfies the following properties (a) and (b).

  (A) The melting point is 40 ° C to 200 ° C.

  (A) The melt viscosity at a temperature 10 ° C. higher than the melting point is 50 Pa · s or less.

  For waxes, polar or nonpolar waxes, polypropylene waxes, polyethylene waxes and wax modifiers are included. Specifically, polar wax, nonpolar wax, Fischer-Tropsch wax, oxidized Fischer-Tropsch wax, hydroxy stearamide wax, functionalized wax, polypropylene wax, polyethylene wax, wax modifier, amorphous wax, carnauba wax , Castor oil wax, microcrystalline wax, beeswax, carnauba wax, castor wax, plant wax, candelilla wax, Japanese wax, ouricury wax, rice bran wax, rice bran wax, jojoba wax, bay wax, montan wax, ozo Kelite wax, ceresin wax, petroleum wax, paraffin wax, chemically modified hydrocarbon wax, substituted amide wax, and combinations thereof Allowed and derivatives. Among these, paraffin wax, polyethylene wax, and microcrystalline wax are preferable from the viewpoint of efficiently forming a porous structure, and microcrystalline wax that can further reduce the pore diameter is more preferable from the viewpoint of SD characteristics. Examples of commercially available polyethylene wax include “FT-115” (manufactured by Nippon Seiwa), and examples of microcrystalline wax include “Hi-Mic” (manufactured by Nippon Seiwa).

  The blending amount of the porosity promoting compound X is set as a lower limit with respect to 100 parts by mass of the polyethylene resin contained in one layer when the microporous is formed by peeling the interface between the polyethylene resin and the porosity promoting compound X. 1 part by mass or more is preferable, 5 parts by mass or more is more preferable, and 10 parts by mass or more is still more preferable. On the other hand, the upper limit is preferably 50 parts by mass or less, more preferably 40 parts by mass or less, and still more preferably 30 parts by mass or less. By setting the blending amount of the porosity promoting compound X to 1 part by mass or more with respect to 100 parts by mass of the polyethylene-based resin, an effect of expressing a desired good porous structure is sufficiently obtained. Moreover, the more stable moldability is securable because the compounding quantity of the said porosity promotion compound X shall be 50 mass parts or less.

  If necessary, in addition to the polyethylene resin and the porosity promoting compound X, a thermoplastic resin may be used as long as the thermal characteristics of the porous film, specifically, the porosity is not impaired. Examples of other thermoplastic resins that can be mixed with the polyethylene resin include styrene resins such as styrene, AS resin, and ABS resin: polyvinyl chloride, fluorine resin, polyethylene terephthalate, polybutylene terephthalate, and polycarbonate. Or ester resins such as polyarylate; ether resins such as polyacetal, polyphenylene ether, polysulfone, polyethersulfone, polyetheretherketone or polyphenylene sulfide; polyamides such as 6 nylon, 6-6 nylon and 6-12 nylon Examples thereof include thermoplastic resins such as resins.

  Moreover, what is called rubber components, such as a thermoplastic elastomer, may be added as needed. Examples of the thermoplastic elastomer include styrene / butadiene, polyolefin, urethane, polyester, polyamide, 1,2-polybutadiene, polyvinyl chloride, and ionomer.

  In addition to the polyethylene-based resin and the porosity promoting compound X, additives or other components that are generally blended in the resin composition may be included. Examples of the additive include recycling resin, silica, talc, kaolin, carbonic acid, etc., which are added for the purpose of improving / adjusting the processability, productivity, and various physical properties of the laminated porous film. Inorganic particles such as calcium, pigments such as titanium oxide and carbon black, flame retardants, weathering stabilizers, heat stabilizers, antistatic agents, melt viscosity improvers, crosslinking agents, lubricants, nucleating agents, plasticizers, anti-aging agents And additives such as antioxidants, light stabilizers, ultraviolet absorbers, neutralizers, antifogging agents, antiblocking agents, slip agents, and coloring agents.

Among them, the nucleating agent is preferable because it has an effect of controlling the crystal structure of the polyethylene resin and reducing the porous structure at the time of stretching and opening. Examples of commercially available products include “Gelall D” (manufactured by Shin Nippon Chemical Co., Ltd.), “Adeka Stub” (manufactured by Asahi Denka Kogyo Co., Ltd.), “Hyperform” (manufactured by Milliken Chemical Co., Ltd.), or “IRGACLEAR”
D "(manufactured by Ciba Special Chemicals) and the like. Moreover, as a specific example of the polyethylene resin to which the nucleating agent is added, “Rike Master” (manufactured by Riken Vitamin Co., Ltd.) and the like are commercially available.

(Layer structure of polyolefin resin porous film)
In the present invention, the polyolefin resin porous film may be a single layer or a laminate. When laminating two or more layers, it is preferable to laminate a layer containing a polypropylene resin and a layer containing a polyethylene resin.

  The layer structure of the polyolefin resin porous film is not particularly limited as long as at least one layer containing a polypropylene resin (hereinafter referred to as “A layer”) is present. In addition, other layers (hereinafter referred to as “B layer”) can be laminated as long as they do not interfere with the function of the polyolefin resin porous film. The structure which laminated | stacked the intensity | strength maintenance layer, the heat-resistant layer (high melting temperature resin layer), the shutdown layer (low melting temperature resin layer), etc. are mentioned. For example, when using as a separator for a lithium ion battery, a low melting point resin layer that ensures the safety of the battery is laminated by closing the hole in a high temperature atmosphere as described in JP-A No. 04-181651. Is preferred.

  Specific examples include a two-layer structure in which A layers / B layers are stacked, a three-layer structure in which A layers / B layers / A layers, or B layers / A layers / B layers are stacked. In addition, it is possible to adopt a form of three types and three layers in combination with layers having other functions. In this case, the order of stacking with layers having other functions is not particularly limited. Further, the number of layers may be increased as necessary to 4 layers, 5 layers, 6 layers, and 7 layers.

  The physical properties of the polyolefin resin porous film of the present invention can be freely adjusted by the layer constitution, lamination ratio, composition of each layer, and production method.

(Manufacturing method of polyolefin resin porous film)
Next, although the manufacturing method of the polyolefin resin porous film of this invention is demonstrated, this invention is not limited only to the lamination | stacking porous film manufactured by this manufacturing method.

  The method for producing the non-porous film is not particularly limited, and a known method may be used. For example, a method of melting a thermoplastic resin composition using an extruder, extruding from a T die, and cooling and solidifying with a cast roll. Is mentioned. Moreover, the method of cutting open the film-like thing manufactured by the tubular method and making it planar is also applicable.

  There are no particular limitations on the method for making the nonporous membrane-like material, and known methods such as wet uniaxial or more stretched porous and dry uniaxial or more stretched porous may be used. As the stretching method, there are methods such as a roll stretching method, a rolling method, a tenter stretching method, and a simultaneous biaxial stretching method, and these methods are used alone or in combination of two or more to perform uniaxial stretching or biaxial stretching. Among these, sequential biaxial stretching is preferable from the viewpoint of controlling the porous structure.

  Moreover, in this invention, when making a polyolefin resin porous film into a lamination, a manufacturing method is divided roughly into the following four according to the order of porous formation and lamination.

(A) A method of laminating each porous layer after laminating each porous layer or bonding with an adhesive or the like.

(B) A method of laminating each layer to produce a laminated nonporous film-like material and then making the nonporous film-like material porous.

(C) A method in which one of the layers is made porous and then laminated with another layer of a nonporous film to make it porous.

(D) A method of forming a laminated porous film by preparing a porous layer and then applying a coating such as inorganic / organic particles or depositing metal particles.

  In the present invention, it is preferable to use the method (b) from the viewpoint of the simplicity of the process and productivity, and in particular, in order to ensure the interlayer adhesion between the two layers, a laminated nonporous film-like material is obtained by coextrusion. A method of forming a porous layer after preparing is particularly preferable.

  Below, the detail of the manufacturing method of a polyolefin resin porous film is demonstrated.

  First, a mixed resin composition of a polypropylene resin and, if necessary, a thermoplastic resin and additives is prepared. For example, raw materials such as polypropylene resin, β crystal nucleating agent, and other additives as required, preferably using Henschel mixer, super mixer, tumbler type mixer, etc., or by hand-blending all ingredients in a bag After mixing, the mixture is melt-kneaded with a single-screw or twin-screw extruder, a kneader or the like, preferably a twin-screw extruder, and then cut to obtain pellets.

  The pellets are put into an extruder and extruded from a T-die extrusion die to form a film. The type of T die is not particularly limited. For example, when the laminated porous film of the embodiment of the present invention has a laminated structure of two types and three layers, the T die may be a multi-manifold type for two types and three layers or a feed block type for two types and three layers. .

  The gap of the T die to be used is determined from the final required film thickness, stretching conditions, draft rate, various conditions, etc., but is generally about 0.1 to 3.0 mm, preferably 0.5. -1.0 mm. If it is 0.1 mm or more, it is preferable from a viewpoint of production speed, and if it is 3.0 mm or less, since a draft rate becomes small, it is preferable from a viewpoint of production stability.

  In extrusion molding, the extrusion temperature is appropriately adjusted depending on the flow characteristics and moldability of the resin composition, but is generally preferably 180 to 350 ° C, more preferably 200 to 330 ° C, and further preferably 220 to 300 ° C. A temperature of 180 ° C. or higher is preferable because the viscosity of the molten resin is sufficiently low and the moldability is excellent and the productivity is improved. On the other hand, by setting the temperature to 350 ° C. or lower, it is possible to suppress the deterioration of the resin composition, and hence the mechanical strength of the laminated porous film obtained.

  When the β crystal nucleating agent is added, the cooling and solidification temperature by the cast roll is very important, and the ratio of β crystal of the polypropylene resin in the film-like material can be adjusted. The cooling and solidification temperature of the cast roll is preferably 80 to 150 ° C, more preferably 90 to 140 ° C, and still more preferably 100 to 130 ° C. It is preferable to set the cooling and solidification temperature to 80 ° C. or higher because the ratio of β crystals in the film can be sufficiently increased. Further, it is preferable to set the temperature to 150 ° C. or lower because troubles such as the extruded molten resin sticking to and wrapping around the cast roll hardly occur and the film can be efficiently formed into a film.

  It is preferable to adjust the β crystal ratio of the polypropylene resin of the film-like material before stretching to 20 to 100% by setting the cast roll in the temperature range. 40-100% is more preferable, 50-100% is still more preferable, and 60-100% is the most preferable. By setting the β crystal ratio in the film-like material before stretching to 30% or more, a polyolefin-based resin porous film having good gas permeability can be obtained because it is easily made porous by the subsequent stretching operation.

  The β crystal ratio in the film before stretching is detected when the film is heated from 25 ° C. to 240 ° C. at a heating rate of 10 ° C./min using a differential scanning calorimeter. It is calculated by the following formula using the crystal melting calorie (ΔHmα) derived from the α crystal and the crystal melting calorie (ΔHmβ) derived from the β crystal of the polypropylene resin (A).

β crystal ratio (%) = [ΔHmβ / (ΔHmβ + ΔHmα)] × 100
In the stretching step, uniaxial stretching may be performed in the longitudinal direction or the transverse direction, or biaxial stretching may be performed. Moreover, when performing biaxial stretching, simultaneous biaxial stretching may be sufficient and sequential biaxial stretching may be sufficient. When producing the polyolefin resin porous film of the present invention, sequential biaxial stretching is more preferable because the stretching conditions can be selected in each stretching step and the porous structure can be easily controlled.

  The longitudinal direction of the film and the film is referred to as “longitudinal direction”, and the direction perpendicular to the longitudinal direction is referred to as “lateral direction”. In addition, stretching in the longitudinal direction is referred to as “longitudinal stretching”, and stretching in the direction perpendicular to the longitudinal direction is referred to as “lateral stretching”.

  When using sequential biaxial stretching, the stretching temperature needs to be changed from time to time depending on the composition of the resin composition to be used, the crystal melting peak temperature, the degree of crystallinity, etc., but the stretching temperature in the longitudinal stretching is preferably about 0 to 130 ° C. More preferably, it is controlled in the range of 10 to 120 ° C, and more preferably 20 to 110 ° C. The longitudinal draw ratio is preferably 2 to 10 times, more preferably 3 to 8 times, still more preferably 4 to 7 times. By performing longitudinal stretching within the above range, it is possible to develop an appropriate pore starting point while suppressing breakage during stretching.

  On the other hand, the stretching temperature in transverse stretching is generally 100 to 160 ° C, preferably 110 to 150 ° C, and more preferably 120 to 140 ° C. Moreover, a preferable lateral stretch ratio is 2 to 10 times, more preferably 3 to 8 times, and still more preferably 4 to 7 times. By transversely stretching within the above range, the pore starting point formed by longitudinal stretching can be appropriately expanded, and a fine porous structure can be expressed.

  The stretching speed in the stretching step is preferably 500 to 12000% / min, more preferably 1500 to 10,000% / min, and further preferably 2500 to 8000% / min.

  The porous film thus obtained is preferably subjected to heat treatment for the purpose of improving dimensional stability. In this case, the effect of dimensional stability can be expected by setting the temperature to preferably 100 ° C. or higher, more preferably 120 ° C. or higher, and still more preferably 140 ° C. or higher. On the other hand, the heat treatment temperature is preferably 170 ° C. or lower, more preferably 165 ° C. or lower, and further preferably 160 ° C. or lower. When the heat treatment temperature is 170 ° C. or lower, it is preferable because the heat treatment hardly melts polypropylene and maintains a porous structure. Moreover, you may perform a 1-20% relaxation process as needed during the heat processing process. In addition, the porous film of this invention is obtained by uniformly cooling and winding up after heat processing.

(surface treatment)
The surface treatment in the present invention means a physical and / or chemical surface modification treatment that can improve the surface adhesion of the polyolefin resin porous film. Examples thereof include, but are not limited to, corona treatment, plasma treatment, plasma treatment under atmospheric pressure, flame plasma treatment (flame treatment), and UV treatment. In the present invention, the surface treatment can be performed using known conditions and equipment that can be used in polyolefin resin porous films.

  In the present invention, the porous film can be subjected to a surface treatment over the entire width, or can be subjected to a surface treatment in a stripe (partial). In the production of the laminated porous film, the non-treated portion cannot be applied by coating or the like, or even if it can be applied, it can be peeled off because it is not in close contact with the porous film of the substrate. Therefore, even when a stripe coated product is required, it can be manufactured by full surface coating.

(Method for producing laminated porous film)
The present invention relates to a method for producing a laminated porous film by laminating a coating layer on at least one surface of a polyolefin resin porous film by coating. A schematic flow sheet of an example of a coating apparatus used in the production method of the present invention is shown in FIG.

  In one preferred embodiment of the present invention, at least in the winding step, the polyolefin resin porous film is conveyed while being overlapped with the support film. Specifically, a laminated porous film in which a coating layer is laminated by coating on at least one surface of a polyolefin-based resin porous film exits the drying process and enters, for example, another stage before the winding process. The support film is unwound by unwinding means such as an unwinding roll, the support film is overlapped with the opposite surface provided with the coating layer of the polyolefin resin porous film, and both films are conveyed. The support film may be peeled off from the laminated porous film before winding up the laminated porous film, or may be taken up together with the laminated porous film.

  In another preferred embodiment of the present invention, at least in the coating step, the polyolefin resin porous film is conveyed while being overlapped with the support film. Specifically, in an arbitrary stage before coating, for example, the support film is unwound by unwinding means such as another unwinding roll, and the support film is placed on the opposite surface on which the coating layer of the polyolefin resin porous film is provided. The two layers are transported so as to be attached, and a coating layer is formed on the polyolefin resin porous film. The support film may be peeled off at any stage that enters the drying process immediately after coating, or the polyolefin-based resin porous film and the support film may be stacked and transported also in the process after the drying process.

  In another preferred embodiment of the present invention, the polyolefin resin porous film is conveyed while being overlapped with the support film at least from the coating step to the winding step. That is, at any stage before coating, the support film is unwound by unwinding means such as another unwinding roll so that the support film is attached to the opposite surface on which the polyolefin resin porous film coating layer is provided. Then, both films are transported to form a coating layer on the polyolefin resin porous film, and then transported to the winding step while the polyolefin resin porous film and the support film are stacked. The support film may be peeled off from the laminated multilayer film before winding up the laminated porous film, or may be taken up together with the laminated porous film.

  In the present invention, stacking the polyolefin resin porous film and the support film includes simply stacking the two films without temporarily adhering them, and temporarily adhering both films. Temporary adhesion refers to reducing the slipperiness of both films due to pressure, electrostatic force, etc.Among them, the method of forming a slightly adhesive layer on a support film and press-bonding has a great effect of stabilizing transportability, and the coating process When a support film is used in the drying step, it is preferable to make temporary contact.

  The thickness of the support film is preferably 6 to 100 μm. Moreover, it is preferable that the tensile elasticity modulus of a support film is 0.7 GPa or more. The thickness and the tensile elastic modulus can be selected as appropriate. It is preferable that the thickness is thin in the case of a material having a large tensile elastic modulus, and the thickness is thick in the case of a material having a small tensile elastic modulus. A tensile modulus of 0.7 GPa or more is preferable because the effect of suppressing wrinkles can be exhibited effectively.

  Examples of the support film that can be used in the present invention include thermoplastic resin films such as polyethylene terephthalate film, acrylic film, fluororesin film, polyimide film, nylon film, non-porous polyolefin film, and polystyrene film. Polyethylene terephthalate film is preferable from the viewpoint of being easily adhered to a polyolefin resin film and being easily peeled off.

  In the present invention, the drying means in the drying step includes a drying furnace (hot air circulation, jet, etc.), an infrared heater, and the like. As a transport system in the drying furnace, there are a roll support system, a floating system, and the like. Since the transportability in the drying furnace is stabilized by stacking the support films, there is an advantage that the drying temperature can be raised.

(Coating layer)
In this invention, a coating layer can also be formed over the full width of a porous film, and can also form a coating layer partially, such as stripe form. As a method of partially forming the coating layer, it is only necessary to devise so that the coating head can be partially coated. For example, in the case of a gravure coating method, a gravure roll is partially formed (the portion where the coating layer is to be formed). And the like, and the diameter of the gravure roll at the portion where the non-coated portion is desired to be formed is slightly smaller than the coated portion. In the case of the die coating method, a shim may be inserted between die lips at positions where the non-coated portion is to be formed to suppress discharge of the coating liquid. The partial coating layer can also be formed by partially performing a surface treatment before coating. If the surface tension difference between the non-processed part and the coating solution is large, it can be formed only by the energy difference. After coating the entire surface including the non-processed part, the coating layer of the non-processed part with low adhesion is peeled off. It can also be formed.

  The non-coated part can be provided at both ends of the porous film of the base material and / or can be provided at several places in the width direction. Therefore, it is preferable to leave both ends of the film as coated portions. By setting the end portion as the coating surface, the winding becomes clean and it is possible to prevent the pressure from being concentrated on the end portion of the coated surface of the wound roll.

  Usually, a laminated porous film forms a coating layer on a wide porous film, and is then slit to a predetermined width. However, when the coating layer is hard, there is a problem that the slit blade is easily worn. When the coating layer is formed in a stripe shape as described above, the film can be slit at the non-processed portion, and wear of the slit blade can be prevented.

(Heat resistant layer)
In the present invention, various coating layers can be used as the coating layer. In the present invention, a heat-resistant layer containing a filler and a resin binder is particularly preferable. The heat-resistant layer is applied to the surface of the porous film by applying a filler-containing resin solution (dispersion) in which a filler and a resin binder are dissolved or dispersed in a solvent to the surface of the polyolefin resin porous film that has been surface-treated. Can be formed. The components constituting the heat-resistant layer and the production method thereof are described below.

(Filler)
Examples of the filler that can be used in the present invention include an inorganic filler and an organic filler, but are not particularly limited.

  Examples of inorganic fillers include carbonates such as calcium carbonate, magnesium carbonate and barium carbonate; sulfates such as calcium sulfate, magnesium sulfate and barium sulfate; chlorides such as sodium chloride, calcium chloride and magnesium chloride, aluminum oxide and oxidation In addition to oxides such as calcium, magnesium oxide, zinc oxide, titanium oxide, and silica, silicates such as talc, clay, and mica can be used. Among these, barium sulfate and aluminum oxide are preferable.

  Examples of organic fillers include ultra high molecular weight polyethylene, polystyrene, polymethyl methacrylate, polycarbonate, polyethylene terephthalate, polybutylene terephthalate, polyphenylene sulfide, polysulfone, polyethersulfone, polyetheretherketone, polytetrafluoroethylene, polyimide, polyether. Examples thereof include thermoplastic resins such as imide, melamine, and benzoguanamine, and thermosetting resins. Among these, cross-linked polystyrene and the like are particularly preferable.

  The average particle size of the filler is preferably 0.1 μm or more, more preferably 0.2 μm or more, still more preferably 0.3 μm or more, and the upper limit is preferably 3.0 μm or less, more preferably 1.5 μm or less. It is. By setting the average particle size to 0.1 μm or more, it is preferable from the viewpoint of reducing the shrinkage rate of the laminated porous film and making it difficult to break the film, and achieving heat resistance. On the other hand, when the average particle size is 3.0 μm or less, it is preferable from the viewpoint of reducing the shrinkage rate of the laminated porous film and making it difficult to break the membrane. Moreover, it is preferable that an average particle diameter shall be 1.5 micrometers or less from a viewpoint of forming a porous layer with small layer thickness favorably, and the viewpoint of the dispersibility in the porous layer of an inorganic filler.

  In the present embodiment, the “average particle diameter of the inorganic filler” is a value measured according to a method using SEM.

  In the heat-resistant layer, the ratio of the filler to the total amount of the filler and the resin binder (hereinafter referred to as “F%”) is preferably 92% by mass or more, more preferably 95% by mass or more, and 98% by mass. The above is more preferable. If the F% is 92% by mass or more, it is preferable because a laminated porous film having connectivity can be produced and excellent air permeation performance can be exhibited.

(Resin binder)
As an example of a resin binder that can be used in the present invention, the filler, the polyolefin-based resin porous film can be satisfactorily bonded, is electrochemically stable, and a laminated porous film is used as a battery separator. There is no particular limitation as long as it is stable with respect to the organic electrolyte. Specifically, ethylene-vinyl acetate copolymer (EVA, vinyl acetate-derived structural unit is 20 to 35 mol%), ethylene-acrylic acid copolymer such as ethylene-ethyl acrylate copolymer, fluororesin [Polyvinylidene fluoride (PVDF), polyvinylidene fluoride-hexafluoropropylene, polyvinylidene fluoride-trichloroethylene, etc.], fluorinated rubber, styrene-butadiene rubber (SBR), nitrile butadiene rubber (NBR), polybutadiene rubber (BR), poly Acrylonitrile (PAN), polyacrylic acid (PAA), carboxymethyl cellulose (CMC), hydroxyethyl cellulose (HEC), polyvinyl alcohol (PVA), cyanoethyl polyvinyl alcohol, polyvinyl butyral (PVB), polyvinyl chloride Rupiroridon (PVP), poly N- vinyl acetamide, polyether, polyamide, polyimide, polyamideimide, polyaramide, crosslinked acrylic resin, polyurethane, and epoxy resin. These organic binders may be used alone or in combination of two or more. Among these, polyvinyl alcohol, polyvinylidene fluoride, styrene-butadiene rubber, carboxymethyl cellulose, and polyacrylic acid are preferable.

(Method for forming heat-resistant layer)
In the present invention, a filler-containing resin solution (dispersion) in which the filler and the resin binder are dissolved or dispersed in a solvent is coated (applied) on the surface of the polyolefin resin porous film that has been surface-treated. By this, a heat-resistant layer can be formed on the surface of the porous film.

  As the solvent, it is preferable to use a solvent in which the filler and the resin binder can be dissolved or dispersed uniformly and stably. Examples of such a solvent include N-methylpyrrolidone, N, N-dimethylformamide, N, N-dimethylacetamide, water, ethanol, toluene, hot xylene, and hexane. In addition, in order to stabilize the inorganic filler-containing resin solution or to improve the coating property to the polyolefin resin porous membrane, the dispersion liquid contains a dispersant such as a surfactant, a thickener, a wetting agent, a disinfectant. Various additives such as foaming agents, pH adjusting agents including acids and alkalis, and the like may be added. These additives are preferably those that can be removed upon solvent removal or plasticizer extraction, but are electrochemically stable in the range of use of the lithium ion secondary battery, do not inhibit the battery reaction, and are up to about 200 ° C. If stable, it may remain in the battery (in the laminated porous film).

  Examples of a method for dissolving or dispersing the filler and the resin binder in a solvent include, for example, a ball mill, a bead mill, a planetary ball mill, a vibrating ball mill, a sand mill, a colloid mill, an attritor, a roll mill, a high-speed impeller dispersion, a disperser, a homogenizer, and a high-speed Examples thereof include an impact mill, ultrasonic dispersion, a mechanical stirring method using stirring blades, and the like.

  The method for applying the dispersion to the surface of the polyolefin resin porous film is not particularly limited as long as it can realize the required layer thickness and application area. Examples of such coating methods include gravure coater method, small diameter gravure coater method, reverse roll coater method, transfer roll coater method, kiss coater method, dip coater method, knife coater method, air doctor coater method, blade coater method, rod Examples include a coater method, a squeeze coater method, a cast coater method, a die coater method, a screen printing method, and a spray coating method. Moreover, the said dispersion liquid may be apply | coated only to the single side | surface of a polyolefin resin porous film in light of the use, and may be applied to both surfaces.

  The solvent is preferably a solvent that can be removed from the dispersion applied to the polyolefin resin porous film. As a method for removing the solvent, any method that does not adversely affect the polyolefin resin porous film can be adopted without any particular limitation. As a method for removing the solvent, for example, a method in which a polyolefin resin porous film is fixed and dried at a temperature below its melting point, a method in which drying is performed at a low temperature under reduced pressure, or a resin binder is solidified by being immersed in a poor solvent for the resin binder. And a method of extracting the solvent at the same time.

  In addition, the lamination | stacking porous film which laminated | stacked the heat resistant layer on the surface of the polyolefin resin porous film of this invention can also be manufactured using a method different from the manufacturing method mentioned above. For example, the raw material for polyolefin resin porous film is introduced into one extruder, the raw material for the heat-resistant layer is introduced into the other extruder, integrated with a single die, and a laminated film is formed. It is also possible to adopt a processing method.

  In the present invention, after the surface treatment of the present invention is performed on the surface of the polyolefin resin porous film, the heat-resistant layer can be formed in-line, but after the surface treatment, the porous film is wound up and offline in a separate process. A heat-resistant layer can also be formed.

(Shape and physical properties of laminated porous film)
As described above, the thickness of the laminated porous film obtained using the production method of the present invention is preferably 5 to 100 μm. More preferably, it is 8-50 micrometers, More preferably, it is 10-30 micrometers. When it is used as a battery separator, if it is 5 μm or more, substantially necessary electrical insulation can be obtained. For example, even when a large force is applied to the protruding portion of the electrode, the battery separator is broken and short-circuited. It is difficult and safe. Moreover, since the electrical resistance of a laminated porous film can be made small if a film thickness is 100 micrometers or less, the performance of a battery can fully be ensured.

  The heat resistant layer is preferably 0.5 μm or more, more preferably 2 μm or more, still more preferably 3 μm or more, and particularly preferably 4 μm or more from the viewpoint of improving heat resistance. The upper limit is preferably 90 μm or less, more preferably 50 μm or less, still more preferably 30 μm or less, and particularly preferably 10 μm or less from the viewpoint of permeability and high battery capacity.

  In the laminated porous film of the present invention, the porosity is preferably 30% to 70% as described above, and if it is 30% or more, it is possible to obtain a laminated porous film that ensures communication and has excellent air permeability. . Moreover, if it is 70% or less, the intensity | strength of a laminated porous film will not fall easily, and it is preferable also from a viewpoint of handling.

  As described above, the laminated porous film of the present invention has an air permeability measured in accordance with JIS P8117 of 2000 seconds / 100 ml or less.

  In addition, when used as a battery separator, in order to provide SD characteristics, the air permeability after heating at 135 ° C. for 5 seconds is set to 10,000 seconds / 100 ml or more, and the pores are quickly closed when abnormal heat is generated. It shuts off so that troubles such as battery rupture can be avoided.

(battery)
A nonaqueous electrolyte battery containing the laminated porous film of the present invention as a battery separator will be described with reference to FIG.

  Both electrodes of the positive electrode plate 21 and the negative electrode plate 22 are wound in a spiral shape so as to overlap each other via the battery separator 10, and the outside is stopped with a winding tape to form a wound body.

  A wound body in which the positive electrode plate 21, the battery separator 10 and the negative electrode plate 22 are integrally wound is housed in a bottomed cylindrical battery case and welded to the positive and negative electrode lead bodies 24 and 25. Next, the electrolyte is injected into the battery can, and after the electrolyte has sufficiently penetrated into the battery separator 10 or the like, the positive electrode lid 27 is sealed around the opening periphery of the battery can via the gasket 26, and precharging and aging are performed. A secondary battery 20 made of a cylindrical nonaqueous electrolyte battery is produced.

  As the electrolytic solution, an electrolytic solution in which a lithium salt is used as an electrolyte and this is dissolved in an organic solvent is used. The organic solvent is not particularly limited. For example, propylene carbonate, ethylene carbonate, butylene carbonate, γ-butyrolactone, γ-valerolactone, esters such as dimethyl carbonate, methyl propionate or butyl acetate, and nitriles such as acetonitrile. 1,2-dimethoxyethane, 1,2-dimethoxymethane, dimethoxypropane, 1,3-dioxolane, ethers such as tetrahydrofuran, 2-methyltetrahydrofuran or 4-methyl-1,3-dioxolane, or sulfolane These may be used alone or in combination of two or more.

  Especially, the electrolyte which melt | dissolved lithium hexafluorophosphate (LiPF6) in the ratio of 1.0 mol / L in the solvent which mixed 2 mass parts of methyl ethyl carbonate with respect to 1 mass part of ethylene carbonate is preferable.

  As the negative electrode, an alkali metal or a compound containing an alkali metal integrated with a current collecting material such as a stainless steel net is used. Examples of the alkali metal include lithium, sodium, and potassium. Examples of the compound containing an alkali metal include an alloy of an alkali metal and aluminum, lead, indium, potassium, cadmium, tin or magnesium, a compound of an alkali metal and a carbon material, a low potential alkali metal and a metal oxide, and the like. Or a compound with a sulfide or the like.

  When a carbon material is used for the negative electrode, the carbon material may be any material that can be doped and dedoped with lithium ions, such as graphite, pyrolytic carbons, cokes, glassy carbons, a fired body of an organic polymer compound, Mesocarbon microbeads, carbon fibers, activated carbon and the like can be used.

  In this embodiment, as a negative electrode, a carbon material having an average particle size of 10 μm is mixed with a solution in which vinylidene fluoride is dissolved in N-methylpyrrolidone to form a slurry, and this negative electrode mixture slurry is passed through a 70-mesh net. After removing the large particles, uniformly apply to both sides of the negative electrode current collector made of a strip-shaped copper foil having a thickness of 18 μm and dry, and then compression-molded with a roll press machine, cut, strip-shaped negative electrode plate and We use what we did.

  As the positive electrode, lithium cobalt oxide, lithium nickel oxide, lithium manganese oxide, manganese dioxide, metal oxide such as vanadium pentoxide or chromium oxide, metal sulfide such as molybdenum disulfide, etc. are used as active materials. , These positive electrode active materials are combined with conductive additives and binders such as polytetrafluoroethylene as appropriate, and finished with a current collector material such as a stainless steel mesh as a core material. It is done.

  In the present embodiment, a strip-like positive electrode plate produced as follows is used as the positive electrode. That is, lithium graphite oxide (LiCoO2) was added and mixed in a mass ratio of 90: 5 (lithium cobalt oxide: phosphorus graphite) as a conductive additive, and this mixture and polyvinylidene fluoride were mixed with N- A solution dissolved in methylpyrrolidone is mixed to form a slurry. This positive electrode mixture slurry is passed through a 70-mesh net to remove large particles, and then uniformly applied to both sides of a positive electrode current collector made of an aluminum foil having a thickness of 20 μm, dried, and then compressed by a roll press. After forming, it is cut into a strip-like positive electrode plate.

[Example]
Examples and Comparative Examples are shown below, and the production method of the present invention will be described in more detail. However, the present invention is not limited to these.

(Evaluation of wrinkles)
Evaluation of wrinkles entering the laminated porous film during winding was performed according to the following criteria.

◎: No wrinkle observed by visual observation ○: Little wrinkle observed by visual observation (within practical range)
Δ: Partially wrinkled by visual observation ×: Wrinkled all over the visual observation (polyolefin-based resin porous film)
As the A layer, polypropylene resin (Prime Polymer Co., Prime Polypro F300SV, density: 0.90 g / cm ³ , MFR: 3.0 g / 10 min) and β crystal nucleating agent, 3,9-bis [4 -(N-cyclohexylcarbamoyl) phenyl] -2,4,8,10-tetraoxaspiro [5.5] undecane was prepared. Each raw material is blended at a ratio of 0.2 part by mass of β-crystal nucleating agent with respect to 100 parts by mass of polypropylene resin, and the same direction twin screw extruder manufactured by Toshiba Machine Co., Ltd. 32), melted and mixed at a preset temperature of 300 ° C., cooled and solidified in a water bath, cut into strands with a pelletizer, and produced polypropylene resin composition pellets. The β activity of the polypropylene resin composition was 80%.

Next, as a mixed resin composition constituting the B layer, glycerin is added to 100 parts by mass of high-density polyethylene (manufactured by Nippon Polytechnic Co., Ltd., Novatec HD HF560, density: 0.963 g / cm ³ , MFR: 7.0 g / 10 min). Add 0.04 parts by mass of monoester and 10 parts by mass of microcrystalline wax (Hi-Mic 1080, manufactured by Nippon Seiwa Co., Ltd.), melt and knead at 220 ° C. using the same type twin screw extruder, and pellets A resin composition processed into a shape was obtained.

  Using the two kinds of raw materials, using a separate extruder so that the outer layer is A layer and the intermediate layer is B layer, it is extruded from a die for lamination molding through a feed block of two kinds and three layers, By cooling and solidifying with a casting roll, a two-layered / three-layered film-like product of A layer / B layer / A layer was produced.

  The laminated film-like product is stretched 4.6 times in the longitudinal direction using a longitudinal stretching machine, and then stretched 1.9 times in the transverse direction at 98 ° C. by a transverse stretching machine, and then subjected to heat setting / relaxation treatment. It was. As a result, a laminated porous film made of polyolefin resin having a film thickness of 20 μm and an air permeability of 450 seconds / 100 ml was obtained.

  The resulting porous film made of polyolefin resin was prepared using a corona treatment device (Kasuga Denki Co., Ltd., aluminum 5 type electrode, 2 ridges x 6, line speed: 50 m / min, treatment output: 1.5 kW), Corona surface treatment was performed under the conditions of the following examples.

(Coating fluid for heat-resistant layer)
39.2 parts by mass of alumina (manufactured by Sumitomo Chemical Co., Sumiko Random AA-03, average particle size: 0.3 μm), polyvinyl alcohol (manufactured by Kuraray Co., Ltd., PVA120, degree of saponification: 98.0-99.0, average degree of polymerization) : 2000) A dispersion in which 0.8 part by mass was dispersed in 60.0 parts by mass of water was obtained.

(Support film A)
A polyethylene terephthalate film (Mitsubishi Resin, thickness: 12 μm) having the same width as the polyolefin resin porous film was used as the support film A.

(Support film B)
A pressure-sensitive adhesive 1499M manufactured by Soken Chemical Co., Ltd. was applied to one side of the support film A so that the thickness after drying was 10 μm, a fine adhesion layer was formed, and the support film B was used.

[Example 1]
The dispersion was entirely coated on the corona-treated surface of the polyolefin resin porous film with a test coater (manufactured by Hirano Tech Seed) equipped with a gravure coating method to obtain a laminated porous film. Here, in the winding process, the support film A was unwound from an unwinding roll, and this was superposed on the polyolefin resin porous film and conveyed.

[Example 2]
With the same test coater as in Example 1, the dispersion was partially (striped) coated on the corona-treated surface of the polyolefin resin porous film to obtain a laminated porous film. Here, in the winding process, the support film A was unwound from an unwinding roll, and this was superposed on the polyolefin resin porous film and conveyed.

[Example 3]
Using the same test coater as in Example 1, the dispersion was entirely coated on the corona-treated surface of the polyolefin resin porous film to obtain a laminated porous film. here,
At the stage before coating, the support film B is unwound from an unwinding roll so that the pressure-sensitive adhesive side is in contact with the porous film, and after being superimposed on the polyolefin resin porous film, coating is performed, and then the coating process is started. In the winding process, the support film was transported while being superimposed on the polyolefin resin porous film.

[Example 4]
With the same test coater as in Example 1, the dispersion was partially (striped) coated on the corona-treated surface of the polyolefin resin porous film to obtain a laminated porous film. Here, in the stage before coating, the support film B is unwound from an unwinding roll so that the pressure-sensitive adhesive side is in contact with the porous film, and is applied to the polyolefin-based resin porous film. In the winding process from the construction process, the support film was stacked on the polyolefin resin porous film and conveyed.

[Comparative Example 1]
Using the same test coater as in Example 1, the dispersion was entirely coated on the corona-treated surface of the polyolefin resin porous film to obtain a laminated porous film.

[Comparative Example 2]
With the same test coater as in Example 1, the dispersion was partially (striped) coated on the corona-treated surface of the polyolefin resin porous film to obtain a laminated porous film.

The evaluation result about Examples 1-4 and Comparative Examples 1-2 is shown below.

As shown in Table 1, the production method of the present invention was able to suppress the generation of wrinkles by transporting the polyolefin resin porous film over the support film in the winding step. Further, from the coating step to the winding step, the polyolefin-based resin porous film was transported while being overlapped with the support film, so that wrinkles were not generated and the coating could be performed stably.

Claims (11)

  A method for producing a laminated porous film in which a coating layer is laminated on at least one surface of a polyolefin resin porous film by coating, and at least in the winding process, the polyolefin resin porous film is overlapped with a support film and conveyed. This manufacturing method characterized by these.   A method for producing a laminated porous film in which a coating layer is laminated on at least one surface of a polyolefin resin porous film by coating, and at least in the coating step, the polyolefin resin porous film is transported while being overlapped with a support film. This manufacturing method is characterized.   A method for producing a laminated porous film comprising a coating layer laminated on at least one surface of a polyolefin resin porous film, wherein the polyolefin resin porous film is overlapped with a support film from at least a coating step to a winding step. This manufacturing method characterized by conveying.   The manufacturing method of any one of Claims 1-3 with which the said polyolefin resin porous film and support film are temporarily closely_contact | adhered.   The manufacturing method of any one of Claims 1-4 whose thickness of the said support film is 6-100 micrometers.   The manufacturing method of any one of Claims 1-5 whose tensile elasticity modulus of the said support film is 0.7 GPa or more.   The manufacturing method according to claim 1, wherein the support film is a polyester film.   The said coating layer contains a filler and a resin binder, The manufacturing method of any one of Claims 1-7 characterized by the above-mentioned.   The laminated porous film obtained by the manufacturing method of any one of Claims 1-8.   A separator for a non-aqueous electrolyte battery using the laminated porous film according to claim 9.   A nonaqueous electrolyte battery using the separator for a nonaqueous electrolyte battery according to claim 10.

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