METHOD FOR PRODUCING POROUS LAMINATE AND POROUS LAMINATE

• US 20110305940A1
• Filed: 08/19/2011
• Published: 12/15/2011
• Est. Priority Date: 09/22/2005
• Status: Abandoned Application

• Current Assignee: Mitsubishi Plastics Incorporated (Mitsubishi Chemical Holdings Corporation)
• Original Assignee: Mitsubishi Plastics Incorporated (Mitsubishi Chemical Holdings Corporation)
• Inventors: USAMI, Yasushi, Nemoto, Tomoyuki, Takagi, Jun, Teshima, Satoshi
• Application Number:
  US13/213,122
• Publication Number:
  US 20110305940A1
• Time in Patent Office: Days
• US Class Current: 429/144
• CPC Class Codes: B29C 44/04 consisting of at least two parts of chemically or physically different materials, e.g. having different densities
• CPC Class Codes: B29C 44/3453 Feeding the blowing agent to solid plastic material
• CPC Class Codes: B29C 44/5627 by mechanical deformation, e.g. crushing, embossing, stretching
• CPC Class Codes: B29C 55/005 characterised by the choice of materials
• CPC Class Codes: B29C 55/023 using multilayered plates or sheets
• CPC Class Codes: B29C 67/20 for porous or cellular articles, e.g. of foam plastics, coarse-pored chemical aspects of working up macro-molecular substances to porous or cellular articles C08J9/00
• CPC Class Codes: B29K 2105/04 cellular or porous
• CPC Class Codes: B32B 2038/0028 Stretching, elongating
• CPC Class Codes: B32B 2305/30 Fillers, e.g. particles, powders, beads, flakes, spheres, chips
• CPC Class Codes: B32B 2323/10 Polypropylene
• CPC Class Codes: B32B 2457/10 Batteries
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/20 using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 38/0032 increasing porosity B32B38/04 takes precedence
• CPC Class Codes: B32B 5/20 foamed in situ
• CPC Class Codes: B32B 5/32 at least two layers being foamed and next to each other
• CPC Class Codes: C08J 2203/08 Supercritical fluid
• CPC Class Codes: C08J 2323/10 Homopolymers or copolymers of propene
• CPC Class Codes: C08J 2323/12 Polypropene
• CPC Class Codes: C08J 2423/00 : Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
• CPC Class Codes: C08J 9/0061 : characterized by the use of several polymeric components
• CPC Class Codes: C08J 9/122 : Hydrogen, oxygen, CO2, nitrogen or noble gases
• CPC Class Codes: H01M 10/052 : Li-accumulators
• 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 50/426 : Fluorocarbon polymers
• CPC Class Codes: H01M 50/446 : Composite material consisting of a mixture of organic and inorganic materials
• CPC Class Codes: H01M 50/451 : comprising layers of only organic material and layers containing inorganic material
• CPC Class Codes: H01M 50/457 : comprising three or more layers
• CPC Class Codes: H01M 50/491 : Porosity
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02P 20/54 : using solvents, e.g. supercritical solvents or ionic liquids
• CPC Class Codes: Y10T 428/24355 : Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
• CPC Class Codes: Y10T 428/24998 : Composite has more than two layers

Abstract

A process for producing a porous laminate having many micropores interconnected in the thickness direction, which comprises: a step in which a laminate is produced which comprises at least three layers comprising an interlayer made of a thermoplastic resin having a hard segment and a soft segment and two nonporous outer layers made of a filler-containing resin and located as outer layers respectively on both sides of the interlayer; a step in which the laminate obtained is impregnated with a supercritical or subcritical fluid and this state is relieved to vaporize the fluid and thereby make the interlayer porous; and a step in which the two nonporous outer layers located respectively on both sides are made porous by stretching.

Claims

1-5. -5. (canceled)

6. A porous laminate, comprising:

a pair of outer layers, which are a first outer layer and a second outer layer, comprising a resin composition comprising a filler and a thermoplastic resin, which is disposed on outermost surfaces of the porous laminate; and

an interlayer, comprising a polypropylene resin composition not comprising a filler, which is disposed between the first and second outer layers,

wherein a large number of micro-pores interconnectable in a thickness direction thereof are present through the first and second outer layers and the interlayer; and

wherein a gas permeability of the porous laminate is set to 1 to 10,000 seconds/100 ml.

7. The laminate of claim 6, wherein the polypropylene resin composition of the interlayer comprises ethylene-propylene rubber.

11. The laminate of claim 7, wherein a content ratio of ethylene of the ethylene-propylene rubber contained in the polypropylene resin composition of the interlayer is 7 to 80 mass %.

16. The laminate of claim 6, wherein the filler is an inorganic filler.

17. The laminate of claim 16, wherein the inorganic filler comprises at least one substance selected from the group consisting of barium sulfate, calcium carbonate, and titanium oxide;

wherein the filler has an average particle diameter of 0.01 to 25 μ

m; and

wherein the laminate has a content of the filler is 5 to 40 parts by mass, based on an entire part by mass of the laminate of 100.

18. The laminate of claim 6, wherein the resin composition comprised in the first and second outer layers comprises a plasticizer.

19. The laminate of claim 6, wherein the first and second outer layers comprise at least one rough surface, having micro-irregularities.

20. The laminate of claim 6, having a heat shrinkage percentage of not more than 20%;

wherein a maximum height (Rmax) of a surface of the laminate is not less than 2 μ

m; and

wherein a mass per unit area of the laminate is 10 to 30 g/m², when the mass per unit area is based on a thickness of 25 μ

m.

21. A separator, comprising the laminate of claim 6, wherein the separator is suitable for a battery.

22. A battery, comprising the separator of claim 21.

23. The laminate of claim 6, wherein the interlayer comprises a hard segment and a soft segment.

24. The laminate of claim 23, wherein the hard segment of the interlayer is present in a ratio of 5 to 95 mass % and the soft segment of the interlayer is present in a ratio of 95 to 5 mass %.

25. The laminate of claim 23, wherein the hard segment of the interlayer comprises at least one material selected from the group consisting of polystyrene, polyethylene, polypropylene, polyurethane, polyester, polyamide, polybutylene terephthalate, and fluororesin.

26. The laminate of claim 23, wherein the hard segment comprises at least one propylene resin.

27. The laminate of claim 23, wherein the propylene resin comprises at least one copolymer comprising, in polymerized form, propylene and one, two, or three monomers selected from the group consisting of ethylene, 1-butene, 1-pentene, 1-hexene, 4-methyl-1-pentene, 1-heptene, 1-octene, and 1-decene.

28. The laminate of claim 7, wherein the ethylene-propylene rubber comprises ethylene and propylene and a non-conjugate diene monomer selected from the group consisting of dicyclopentadiene, ethylidene norbornene, and hexadiene.

29. The laminate of claim 7, wherein the ethylene-propylene rubber comprises ethylene as 10 to 80 mass % of an entire mass of the rubber.

30. The laminate of claim 7, wherein the ethylene-propylene rubber comprises ethylene as 10 to 60 mass % of an entire mass of the rubber.

31. The laminate of claim 6, wherein an average particle diameter of the filler is 0.05 to 7 μ

m.

32. The laminate of claim 6, wherein an average particle diameter of the filler is 0.1 to 5 μ

m.

8-10. -10. (canceled)

12-15. -15. (canceled)