POROUS LAYER, SEPARATOR FORMED BY LAMINATING POROUS LAYER, AND NON-AQUEOUS ELECTROLYTE SECONDARY BATTERY INCLUDING POROUS LAYER OR SEPARATOR

• US 20170162849A1
• Filed: 07/31/2015
• Published: 06/08/2017
• Est. Priority Date: 08/29/2014
• Status: Active Grant

• Current Assignee: Sumitomo Chemical Company Limited
• Original Assignee: Sumitomo Chemical Company Limited
• Inventors: MURAKAMI, Chikara, KURAKANE, Kosuke, HARA, Syusaku
• Granted Patent: US 9,865,856 B2
• Time in Patent Office: Days
• CPC Class Codes: B32B 2457/10 Batteries
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 5/28 impregnated with or embedded in a plastic substance not used
• CPC Class Codes: B32B 5/30 one layer being formed of particles, e.g. chips, granules, powder
• CPC Class Codes: B32B 5/32 at least two layers being foamed and next to each other
• CPC Class Codes: H01M 50/403 Manufacturing processes of separators, membranes or diaphragms
• CPC Class Codes: H01M 50/417 Polyolefins
• CPC Class Codes: H01M 50/42 Acrylic resins
• CPC Class Codes: H01M 50/423 Polyamide resins
• CPC Class Codes: H01M 50/426 Fluorocarbon polymers
• CPC Class Codes: H01M 50/429 Natural 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 50/491 Porosity
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

In a porous layer of the present invention, in a case where the porous layer is divided into 32 sections, a degree of variability in voidage that is measured in the 32 sections is 16.0% or lower. Each of the 32 sections is a rectangular parallelepiped whose longitudinal length is 2.3 μm, transverse length is 2.3 μm, and thickness is identical with that of the porous layer. The porous layer of the present invention and a separator formed by laminating the porous layer are suitable as a member for a non-aqueous electrolyte secondary battery that has an excellent cycle characteristic.

Claims

1-9. -9. (canceled)

10. A porous layer for a non-aqueous electrolyte secondary battery separator, wherein:

in a case where said porous layer is divided into 32 sections, a degree of variability in voidage that is measured in the 32 sections is 16.0% or lower, each of the 32 sections being a rectangular parallelepiped whose longitudinal length is 2.3 μ

m, transverse length is 2.3 μ

m, and thickness is identical with that of said porous layer;

said porous layer contains (i) a resin which is one or more resins selected from the group consisting of polyolefins, fluorine-containing resins, fluorine-containing rubbers, aromatic polyamides, wholly aromatic polyamides (aramid resins), rubbers, resins whose melting point or glass transition temperature is 180°

C. or higher, and water-soluble polymers and (ii) a filler;

a content of the filler is 60 mass % or higher and 99 mass % or lower relative to said porous layer containing the resin and the filler; and

the filler is a filler in which, in terms of average particle diameter obtained based on a volume, (i) D10 is 0.005 μ

m to 0.4 μ

m, D50 is 0.01 μ

m to 1.0 μ

m, and D90 is 0.5 μ

m to 5.0 μ

m and (ii) a difference between D10 and D90 is 2 μ

m or less.

12. The porous layer as set forth in claim 10, wherein:

in a case where said porous layer is divided into 32 sections, a degree of variability in voidage that is measured in the 32 sections is 7.0% or lower, each of the 32 sections being a rectangular parallelepiped whose longitudinal length is 2.3 μ

m, transverse length is 2.3 μ

m, and thickness is identical with that of said porous layer.

15. A non-aqueous electrolyte secondary battery laminated separator which is formed by laminating a porous layer for a non-aqueous electrolyte secondary battery separator recited in claim 10 on one surface or each of both surfaces of a porous film which contains polyolefin as a main component.

17. A member for a non-aqueous electrolyte secondary battery, said member comprising:

a positive electrode;

a non-aqueous electrolyte secondary battery laminated separator recited in claims 15; and

a negative electrode,

the positive electrode, the non-aqueous electrolyte secondary battery laminated separator, and the negative electrode being arranged in this order.

19. A non-aqueous electrolyte secondary battery comprising:

a porous layer for a non-aqueous electrolyte secondary battery separator recited in claim 10.

21. A non-aqueous electrolyte secondary battery comprising:

a non-aqueous electrolyte secondary battery laminated separator recited in claim 15.

11. A porous layer for a non-aqueous electrolyte secondary battery separator, wherein:

in a case where said porous layer is divided into 32 sections, a degree of variability in voidage that is measured in the 32 sections is 16.0% or lower, each of the 32 sections being a rectangular parallelepiped whose longitudinal length is 2.3 μ

m, transverse length is 2.3 μ

m, and thickness is identical with that of said porous layer;

said porous layer contains a resin which is one or more resins selected from the group consisting of polyolefins and fluorine-containing resins; and

said porous layer does not contain a filler.

13. The porous layer as set forth in claim 11, wherein:

in a case where said porous layer is divided into 32 sections, a degree of variability in voidage that is measured in the 32 sections is 7.0% or lower, each of the 32 sections being a rectangular parallelepiped whose longitudinal length is 2.3 μ

m, transverse length is 2.3 μ

m, and thickness is identical with that of said porous layer.

14. The porous layer as set forth in claim 11, wherein:

said porous layer is a resin layer containing a fibrillar resin or a granular resin.

16. A non-aqueous electrolyte secondary battery laminated separator which is formed by laminating a porous layer for a non-aqueous electrolyte secondary battery separator recited in claim 11 on one surface or each of both surfaces of a porous film which contains polyolefin as a main component.

18. A member for a non-aqueous electrolyte secondary battery, said member comprising:

a positive electrode;

a non-aqueous electrolyte secondary battery laminated separator recited in claim 16; and

a negative electrode,

the positive electrode, the non-aqueous electrolyte secondary battery laminated separator, and the negative electrode being arranged in this order.

20. A non-aqueous electrolyte secondary battery comprising:

a porous layer for a non-aqueous electrolyte secondary battery separator recited in claim 11.

22. A non-aqueous electrolyte secondary battery comprising:

a non-aqueous electrolyte secondary battery laminated separator recited in claim 16.