Polyamide imide fiber, non-woven fabric composed of the fiber, process for manufacture of the non-woven fabric, and separator for electronic component

• US 9,023,534 B2
• Filed: 07/27/2006
• Issued: 05/05/2015
• Est. Priority Date: 07/29/2005
• Status: Active Grant

• Current Assignee: Toyobo MC Corp.
• Original Assignee: Toyoda Gosei Company Limited (Toyota Motor Corporation)
• Inventors: Nakamori, Masahiko, Ohta, Yasuo, Kobayashi, Hisato, Oda, Syoji, Taniguchi, Nobuyuki, Sakura, Daisuke, Shimeno, Katsuya
• Primary Examiner(s): Ryan, Patrick
• Assistant Examiner(s): Anthony, Julian
• Application Number:
  US11/997,049
• Publication Number:
  US 20100151333A1
• Time in Patent Office: 3,204 Days
• Field of Search: 429/247, 429/249, 429/221, 428/221, 442/327
• US Class Current: 429/247
• CPC Class Codes: B01D 2323/39 Electrospinning
• CPC Class Codes: B01D 71/64 Polyimides; Polyamide-imides; Polyester-imides; Polyamide acids or similar polyimide precursors
• CPC Class Codes: B01D 71/641 Polyamide-imides
• CPC Class Codes: D01D 5/0038 the fibre formed by solvent evaporation, i.e. dry electro-spinning
• CPC Class Codes: D01F 6/78 from copolycondensation products
• CPC Class Codes: D04H 1/42 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
• CPC Class Codes: D04H 1/4342 Aromatic polyamides
• CPC Class Codes: D04H 1/43838 Ultrafine fibres, e.g. microfibres
• CPC Class Codes: D04H 3/02 characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
• CPC Class Codes: H01G 11/52 Separators
• CPC Class Codes: H01G 9/02 Diaphragms; Separators
• CPC Class Codes: H01M 50/414 Synthetic resins, e.g. thermoplastics or thermosetting 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 8/0687 Reactant purification by the use of membranes or filters
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02E 60/13 Energy storage using capacitors
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10T 428/298 Physical dimension
• CPC Class Codes: Y10T 442/60 : Nonwoven fabric [i.e., nonwoven strand or fiber material]
• CPC Class Codes: Y10T 442/608 : Including strand or fiber material which is of specific structural definition
• CPC Class Codes: Y10T 442/697 : Containing at least two chemically different strand or fiber materials

Abstract

The present invention provides a fiber having a nano-order fiber diameter, which is produced by without a process of dehydration and cyclization by a heat treatment after fiber spinning and has excellent heat resistance and mechanical strength, and a non-woven fabric composed of the fiber, and discloses the polyamide-imide fiber and the non-woven fabric having an average fiber diameter of from 0.001 μm to 1 μm and also discloses the process for producing threrof. The present invention also provides a separator for an electronic component which has a high conductivity and a small separator thickness and is improved in safety during reflow soldering or short-circuiting, and discloses the separator composed of a non-woven fabric obtained by an electro-spinning method.

Claims

1. A non-woven fabric, comprising a polyamide-imide fiber having an average fiber diameter in the range of from 0.001 μ

m to 1 μ

m,

wherein the-polyamide-imide fiber comprises a polyamide-imide containing a

2. The non-woven fabric of claim 1, wherein the polyamide-imide is of formula (I):

3. The non-woven fabric of claim 2, wherein Ar₁ is

4. The non-woven fabric of claim 1, wherein the polyamide-imide fiber comprises a polyamide-imide containing a

5. The non-woven fabric of claim 1, wherein the polyamide-imide has a glass transition temperature of at least 235°

C.

6. A process for producing the non-woven fabric of claim 1, comprising:

preparing a solution containing the polyamide-imide and an organic solvent, spinning a fiber from the obtained solution by an electro-spinning method, and collecting the fiber containing the polyamide-imide on a collecting substrate.

7. A separator for use in an electronic component, the separator comprising a non-woven fabric produced by the method of claim 6.

8. The separator of claim 7, wherein the electronic component is a battery or a capacitor.

9. A separator for use in an electronic component, the separator comprising the non-woven fabric of claim 1.

10. The separator for use in an electronic component according to claim 9, wherein air permeability of the separator is in the range of from 1 sec/100 cc Air to 2000 sec/100 cc Air.

11. The separator for use in an electronic component according to claim 9, wherein the fiber contains the polyamide-imide as a main component.

12. The separator for use in an electronic component according to claim 11, wherein the polyamide-imide has inherent viscosity of 0.2 dL/g or more.

13. The separator according to claim 12, wherein the electronic component is a battery or a capacitor.

14. The separator according to claim 11, wherein the electronic component is a battery or a capacitor.

15. The separator of claim 9, wherein the electronic component is a battery or a capacitor.

16. The separator of claim 10, wherein the electronic component is a battery or a capacitor.

17. A non-woven fabric, comprising a polyamide-imide fiber having an average fiber diameter in the range of from 0.001 μ

m to 1 μ

m,

wherein the polyamide-imide fiber comprises a polyamide-imide containing a

18. A process for producing the non-woven fabric of claim 17, comprising:

preparing a solution containing the polyamide-imide and an organic solvent, spinning a fiber from the obtained solution by an electro-spinning method, and collecting the fiber containing the polyamide-imide on a collecting substrate.

19. A separator for use in an electronic component, the separator comprising the non-woven fabric of claim 17.

20. The separator of claim 19, wherein the electronic component is a battery or a capacitor.

21. The non-woven fabric of claim 17, wherein the polyamide-imide is of formula (I):

22. The non-woven fabric of claim 21,

wherein Ar₁ is

23. The non-woven fabric Of Claim 17, wherein the polyamide-imide fiber comprises a polyamide-imide containing a

24. The non-woven fabric of claim 17, wherein the polyamide-imide has a glass transition temperature of at least 235°

C.

25. A polyamide-imide fiber having an average fiber diameter in the range of from 0.001 μ

m to 1 μ

m,

wherein the polyamide-imide fiber comprises a polyamide-imide containing a

26. The polyamide-imide fiber of claim 25, wherein the polyamide-imide is of formula (I):

27. The polyamide-imide fiber of claim 26, wherein Ar₁ is

28. The polyamide-imide fiber of claim 25, wherein the polyamide-imide has a glass transition temperature of at least 235°

C.

29. The polyamide-imide fiber of claim 25, wherein the polyamide-imide is obtained from reacting an acid component with an amine component or a diisocyanate component, the amine component comprises o-tolidine, and the diisocyanate component comprises o-tolidinediisocyanate.

30. The polyamide-imide fiber of claim 29, wherein the polyamide-imide is of formula (I):

31. The polyamide-imide fiber of claim 30, wherein Ar₁ is

32. The polyamide-imide fiber of claim 29, wherein the polyamide-imide has a glass transition temperature of at least 235°

C.