Heat-resistant separator

• US 20020045091A1
• Filed: 07/31/2001
• Published: 04/18/2002
• Est. Priority Date: 08/01/2000
• Status: Active Grant

• Current Assignee: Tonen Tapyrus Co., Ltd. (Nichiei Kogyo Co., Ltd.)
• Original Assignee: Tonen Tapyrus Co., Ltd. (Nichiei Kogyo Co., Ltd.)
• Inventors: Yamazaki, Masaki, Kamei, Toshikazu
• Granted Patent: US 6,730,439 B2
• Time in Patent Office: Days
• US Class Current: 429/62
• CPC Class Codes: B32B 5/00 Layered products characterised by the non- homogeneity or physical structure , i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
• CPC Class Codes: H01G 9/02 Diaphragms; Separators
• CPC Class Codes: H01M 10/052 Li-accumulators
• CPC Class Codes: H01M 10/4235 Safety or regulating additives or arrangements in electrodes, separators or electrolyte H01M10/4242 takes precedence
• CPC Class Codes: H01M 50/403 Manufacturing processes of separators, membranes or diaphragms
• CPC Class Codes: H01M 50/406 Moulding; Embossing; Cutting
• CPC Class Codes: H01M 50/414 Synthetic resins, e.g. thermoplastics or thermosetting resins
• CPC Class Codes: H01M 50/417 Polyolefins
• CPC Class Codes: H01M 50/423 Polyamide resins
• CPC Class Codes: H01M 50/44 Fibrous material
• CPC Class Codes: H01M 50/489 Separators, membranes, diaphragms or spacing elements inside the cells, characterised by their physical properties, e.g. swelling degree, hydrophilicity or shut down properties
• CPC Class Codes: H01M 50/494 Tensile strength
• CPC Class Codes: H01M 6/16 with organic electrolyte H01M6/18 takes precedence
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02E 60/13 Energy storage using capacitors
• CPC Class Codes: Y10T 428/27 Web or sheet containing structurally defined element or component, the element or component having a specified weight per unit area [e.g., gms/sq cm, lbs/sq ft, etc.]

Abstract

A heat-resistant separator composed of a non-woven fabric of high-melting resin, 1 to 20 μm in average fiber diameter, 5 to 300 g/m² in basis weight, 1 to 200 cc/cm²/sec in air permeability, and 0.01 to 1.0 mm in thickness, or a laminated heat-resistant separator composed of a laminate having a melt-blown, non-woven fabric layer of high-melting resin, 1 to 20 μm in average fiber diameter, 5 to 300 g/m² in basis weight, 1 to 200 cc/cm²/sec in air permeability, and 0.01 to 1.0 mm in thickness is more resistant to heat, and hence safer, and is suitable for batteries and electrical double-layer capacitors serviceable at high temperature.

Claims

1. A heat-resistant separator comprising:

a non-woven fabric of high-melting resin, said fabric being of

1 to 20 μ

m in average fiber diameter,

5 to 300 g/m² in basis weight,

1 to 200 cc/cm²/sec in air permeability, and

0.01 to 1.0 mm in thickness.

2. The heat-resistant separator according to claim 1, having a real part impedance of 20 Ω

.cm² or less at a frequency of 10 KHz and normal temperature.

3. The heat-resistant separator according to claim 1 or 2, having a maximum real part impedance at a frequency of 10 KHz and 100 to 180°

C. is 100 times or less of the real part impedance at normal temperature and 200 Ω

.cm² or less in the absolute value.

4. The heat-resistant separator according to one of claims 1 to 3, wherein said high-melting resin is selected from the group consisting of polyester, polyphenylene sulfide, polymethyl pentene and polyamide.

5. The heat-resistant separator according to claim 4, wherein said polyester is polybutylene terephthalate.

6. The heat-resistant separator according to one of claims 1 to 5, wherein said non-woven fabric is melt-blown.

12. The heat-resistant separator of one of claims 1 to 11 which is used for a battery or capacitor.

7. A laminated heat-resistant separator comprising:

a laminate having a melt-blown, non-woven fabric layer of high-melting resin, wherein said fabric layer being of

1 to 20 μ

m in average fiber diameter,

5 to 300 g/m² in basis weight,

1 to 200 cc/cm²/sec in air permeability, and

0.01 to 1.0 mm in thickness.

8. The laminated heat-resistant separator according to claim 7 composed of a melt-blown, non-woven fabric layer of high-melting resin and non-woven fabric layer having a shut-down function.

9. The laminated heat-resistant separator according to claim 8, wherein said non-woven fabric layer having a shut-down function is of polyolefin.

10. A laminated heat-resistant separator of polyphenylene sulfide, comprising:

two or more laminated layers of melt-blown, non-woven fabric of polyphenylene sulfide, said fabric having

a fiber diameter of 2.0 to 8.0 μ

m,

basis weight of 20 to 60 g/m²,

air permeability of 10 to 200 cc/cm²/sec,

thickness of 100 to 300 μ

m, and

strength of 10 N/50 mm or more in the MD direction.

11. The laminated heat-resistant separator of polyphenylene sulfide according to claim 10, wherein said melt-blown, non-woven fabric of polyphenylene sulfide for the laminated layers has an average fiber diameter of 2.0 to 8.0 μ

m, basis weight of 40 to 80 g/m², air permeability of 5 to 20 cc/cm²/sec, thickness of 100 to 180 μ

m, and strength of 40 N/50 mm or more in the MD direction.