CN106003915A - 蓄电设备用外装构件 - Google Patents
蓄电设备用外装构件 Download PDFInfo
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- CN106003915A CN106003915A CN201610187407.9A CN201610187407A CN106003915A CN 106003915 A CN106003915 A CN 106003915A CN 201610187407 A CN201610187407 A CN 201610187407A CN 106003915 A CN106003915 A CN 106003915A
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- Prior art keywords
- exterior member
- coating
- layer
- corrosion
- storage device
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Abstract
本发明涉及一种蓄电设备用外装构件,其具有:金属箔层;在金属箔层的第一面上直接形成或隔着第一防腐蚀处理层而形成的被覆层;在金属箔层的第二面上形成的第二防腐蚀处理层;在第二防腐蚀处理层上形成的粘接层;和在粘接层上形成的密封层,其中,被覆层含有选自由氟系树脂、聚氨酯系树脂和聚酯系树脂组成的组中的至少一种,拉伸试验(根据JIS K 7127)中被覆层与粘接层和密封层的层叠体在10%拉伸时的强度差小于0.400N/mm。
Description
技术领域
本发明涉及蓄电设备用外装构件。
背景技术
作为蓄电设备,已知有例如锂离子二次电池、镍氢和铅蓄电池等二次电池、以及双电层电容器等电化学电容器。由于便携设备的小型化或设置空间的限制等,要求蓄电设备的进一步小型化,能量密度较高的锂离子二次电池受到了关注。作为锂离子二次电池中使用的外装构件,以往一直使用金属制的罐,但最近,大多使用重量轻、散热性高、低成本的多层膜。
锂离子二次电池的电解液由碳酸亚丙酯、碳酸亚乙酯、碳酸二甲酯、碳酸二乙酯和碳酸甲乙酯等非质子性的溶剂和电解质构成。作为电解质,使用LiPF6和LiBF4等锂盐。可是,这些锂盐会因水解反应而产生氢氟酸。氢氟酸有可能引起电池部件的金属面的腐蚀、或者引起作为外装构件的多层膜的各层间的层压强度的下降。
因此,对于上述外装构件,在多层膜内部设置铝箔等作为阻隔层,抑制了水分从多层膜的表面浸入。作为上述外装构件,例如已知有具有耐热性的基材层、第1粘接层、阻隔层、可防止由氢氟酸引起的腐蚀的防腐蚀处理层、第2粘接层和密封层按照该顺序依次层叠而成的多层膜。这样,使用了具有铝箔作为阻隔层的外装构件的锂离子二次电池也称作铝层压型的锂离子二次电池。
关于铝层压型的锂离子二次电池,例如有通过下述方法得到的锂离子二次电池:在外装构件的一部分上通过冷成型而形成凹部,在该凹部内收纳正极、隔膜、负极和电解液等电池要素,将外装构件的剩余部分折回并将相互的边缘部分通过热封而贴合在一起。这样的锂离子二次电池也称作轧花型锂离子二次电池。近年来,为了提高能量密度,还制造了在贴合的外装构件的两侧形成凹部,从而能够收纳更多的电池要素的轧花型锂离子二次电池。
通过冷成型而形成的凹部越深,则锂离子二次电池的能量密度变得越高。可是,形成的凹部越深,成型时的外装构件上越容易发生针孔或断裂。因此,外装构件的基材层使用了拉伸膜来保护金属箔(例如参照专利文献1、2)。
现有技术文献
专利文献
专利文献1:日本专利第3567230号公报
专利文献2:日本专利第4559547号公报
发明内容
专利文献1的技术中,为了提高成型性,基材层使用了拉伸强度和伸长量为规定值以上的拉伸聚酰胺膜或拉伸聚酯膜。可是,当使用拉伸聚酰胺膜作为基材层时,存在下述问题:在电解液注液工序等中在拉伸聚酰胺膜上附着电解液时,拉伸聚酰胺膜会溶解。因此,提出了一种使用了在拉伸聚酰胺膜的外侧进一步层叠了拉伸聚酯膜而得到的基材层的外装构件(专利文献2),但成型性有不一定充分的倾向。
于是,在上述的外装构件进行了形成凹部的深冲成型的情况下,成型加工后的外装构件有可能在基材层侧发生大幅翘曲。这种倾向特别是在制造单侧成型加工电池时是显著的。外装构件的翘曲据认为是因为在一边拉伸外装构件一边进行成型加工时,拉伸的基材层试图回到原来的状态而引起的,专利文献1和专利文献2中得到的外装构件难以解决上述翘曲的问题。
此外,成型加工后的翘曲会在将外装构件往下一工序等吸附搬送时成为引起吸附误差的原因、或者在下一工序的热封时成为引起热封不良的原因。
本发明是鉴于上述情况而完成的,其目的是提供一种即使外表面上附着电解液也不易变质、能够在保持优良的成型性的同时减少成型加工后的翘曲的蓄电设备用外装构件。
本发明者特别是对于上述翘曲的问题考虑如下。即,在专利文献1和专利文献2的外装构件中,夹着金属箔层,在其一侧配置有使用了聚酯膜或聚酰胺膜等的基材层,在另一侧配置有酸改性聚烯烃系树脂等热粘接性树脂层,与热粘接性树脂层相比,基材层在拉伸试验中的弹性区域(当去除载荷时恢复到原始长度的区域)的拉伸强度显著大,对于成型加工时的拉伸而要试图复原的力在基材层侧变得更大,所以会发生上述翘曲的问题。在上述认识的基础上,发明者们完成了本发明。
本发明提供一种蓄电设备用外装构件,其具有:金属箔层;在金属箔层的第一面上直接形成或隔着第一防腐蚀处理层而形成的被覆层;在金属箔层的第二面上形成的第二防腐蚀处理层;在第二防腐蚀处理层上形成的粘接层;和在粘接层上形成的密封层,其中,被覆层含有选自由氟系树脂、聚氨酯系树脂和聚酯系树脂组成的组中的至少一种,在拉伸试验(根据JIS K 7127)中被覆层与粘接层和密封层的层叠体在10%拉伸时的强度差小于0.400N/mm。
根据本发明,即使在外表面附着电解液也不易变质、能够在保持优良的成型性的同时还能够减少成型加工后的翘曲。
本发明中,被覆层的厚度优选为3~30μm。由此,在维持成型性的同时,能够进一步减小拉伸试验中的被覆层的单膜与密封层在10%拉伸时的强度差,能够进一步减少成型加工后的翘曲。
另外,本发明中,优选密封层由聚烯烃系树脂形成。此外,优选粘接层和密封层的合计厚度为被覆层的厚度的2~8倍。
本发明中,优选的是,氟系树脂是通过异氰酸酯系固化剂固化后的四氟化型的氟树脂,并且固化剂1个分子内的NCO官能团当量为1000~5000。或者本发明中,优选的是,聚氨酯系树脂是使用1个分子内的(甲基)丙烯酰基的官能团当量为1000~5000的氨酯(甲基)丙烯酸酯低聚物而得到的。由此,在维持成型性和耐电解液性的同时,能够进一步减少成型加工后的翘曲。
根据本发明,可以提供一种即使在外表面上附着电解液也不易变质、在保持优良的成型性的同时、能够减少成型加工后的翘曲的蓄电设备用外装构件。此外,在使用拉伸膜的以往的方法中,需要在拉伸膜与阻隔层之间设置粘接层,但在本发明中,并不一定需要上述的粘接层,所以能够实现成本降低和和薄型化。
附图说明
图1是本发明的一个实施方式的蓄电设备用外装构件的概略截面图。
图2是本发明的另一个实施方式的蓄电设备用外装构件的概略截面图。
符号说明
10,20外装构件(蓄电设备用外装构件)、11被覆层、12金属箔层、13防腐蚀处理层、14粘接层、15密封层、21被覆层、22第一防腐蚀处理层、23金属箔层、24第二防腐蚀处理层、25粘接层、26密封层。
具体实施方式
以下,对本发明的实施方式进行详细说明。此外,本发明不受以下的实施方式的限定。
[外装构件]
下面对本发明的一个实施方式的蓄电设备用外装构件进行说明。图1是表示本发明的一个实施方式的蓄电设备用外装构件(以下仅称作“外装构件10”)的概略截面图。如图1所示,外装构件10具有:发挥阻隔功能的金属箔层12;在金属箔层12的第一面上形成的被覆层11;在金属箔层12的与上述第一面相反侧的第二面上形成的防腐蚀处理层13;以及在防腐蚀处理层13上依次层叠的粘接层14和密封层15。使用外装构件10形成蓄电设备时,被覆层11成为最外层,密封层15成为最内层。对构成外装构件10的各层,以下进行详细说明。
(被覆层)
被覆层11起到下述作用:可赋予外装构件10对在制造蓄电设备时的热封的耐热性和即使附着电解液也不易变质的耐电解液性,并且可抑制加工或流通时可能发生的针孔。
被覆层11是按照在拉伸试验(根据JIS K 7127(旧标准JIS K 7113-2):测定环境为23℃、50%RH、试样宽为6mm、标线间距离为35mm、拉伸速度为50mm/分钟)中被覆层(的单膜)与粘接层和密封层的层叠体在10%拉伸时的强度差小于0.400N/mm的方式来形成。
这样,通过将被覆层的单膜与粘接层和密封层的层叠体在10%拉伸时的强度差抑制得小于0.400N/mm,则针对成型加工所产生的拉伸,试图复原的两层的力变得接近,所以能够抑制成型加工后的翘曲。此外,从更加容易抑制翘曲的观点出发,该强度差优选为小于0.350N/mm,更优选为小于0.300N/mm。此外,强度差的下限没有特别限制,但优选为0.200N/mm。
作为被覆层,可以列举出含有聚氨酯系树脂、氟系树脂、聚酯系树脂、聚烯烃系树脂、环氧系树脂、聚氯乙烯树脂等的被覆层,但在本实施方式中,特别是被覆层使用含有选自由氟系树脂、聚氨酯系树脂和聚酯系树脂组成的组中的至少一种的被覆层。此外,聚酯系树脂可以是非晶性聚酯系树脂,也可以是聚氨酯系树脂或聚氨酯系(甲基)丙烯酸系树脂。
在本实施方式中,氟系树脂是通过异氰酸酯系固化剂固化后的四氟化型的氟树脂,固化剂1个分子内的NCO官能团当量优选为1000~5000,更优选为1200~4000。另外,在本实施方式中,聚氨酯系树脂优选为使用1个分子内的(甲基)丙烯酰基的官能团当量为1000~5000、优选为1100~3500的氨酯(甲基)丙烯酸酯低聚物而得到的树脂。在本实施方式中,在使用聚氨酯系树脂的情况下,可以通过将分散在水中的聚氨酯树脂进行涂布、干燥来得到被覆层;另外,在使用聚酯系树脂的情况下,可以通过将分散在水中的聚酯系树脂进行涂布、干燥来得到被覆层。
当所述官能团当量低于1000时,通过异氰酸酯系固化剂固化后的氟系树脂或聚氨酯系树脂的刚性容易变高,柔软性受到损害,所以成型性有容易下降的倾向。
另一方面,当所述官能团当量超过5000时,通过异氰酸酯系固化剂固化后的氟系树脂或聚氨酯系树脂的柔软性容易提高,但交联密度下降,所以耐电解液性有容易下降的倾向。
作为氨酯(甲基)丙烯酸酯低聚物,可以列举出使多元醇、聚异氰酸酯和(甲基)丙烯酸羟基酯反应而得到的氨酯(甲基)丙烯酸酯低聚物。被覆层11是通过将至少含有氨酯(甲基)丙烯酸酯低聚物和光聚合引发剂的活性能量射线固化性树脂组合物涂布或涂装于金属箔层上、并照射活性能量射线来形成的,并且在金属箔层12的第一面上,不经由粘接剂等而直接形成。
作为多元醇,可以列举出聚酯多元醇、聚醚多元醇、聚碳酸酯多元醇、聚己内酯多元醇、开环四氢呋喃环氧丙烷共聚物、乙二醇、丙二醇、1,4-丁二醇、1,5-戊二醇、1,6-己二醇、新戊二醇、1,4-环己烷二甲醇、己二酸聚四亚甲基二醇、双酚A的二醇。此外,它们之中,更优选含有-CH2CH2O-或-CH2CH(CH3)O-的重复单元的多元醇。
聚异氰酸酯是具有2个以上的异氰酸酯基的化合物。作为聚异氰酸酯,例如可以列举出甲苯二异氰酸酯、二苯基甲烷二异氰酸酯、氢化二苯基甲烷二异氰酸酯、六亚甲基二异氰酸酯、异佛尔酮二异氰酸酯、苯二甲撑二异氰酸酯、氢化苯二甲撑二异氰酸酯、四甲基苯二甲撑二异氰酸酯、三甲基六亚甲基二异氰酸酯、1,5-萘二异氰酸酯、降冰片烯二异氰酸酯、联甲苯胺二异氰酸酯、对苯二异氰酸酯和赖氨酸二异氰酸酯。
(甲基)丙烯酸羟基酯含有1个以上的(甲基)丙烯酰基和羟基。作为(甲基)丙烯酸羟基酯,可以列举出(甲基)丙烯酸2-羟基乙酯、(甲基)丙烯酸2-羟基丙酯、(甲基)丙烯酸2-羟基丁酯、2-羟基-3-苯氧基丙基(甲基)丙烯酸酯、丙烯酸4-羟基丁酯、新戊二醇单(甲基)丙烯酸酯、三羟甲基丙烷三(甲基)丙烯酸酯、季戊四醇三(甲基)丙烯酸酯、二季戊四醇四(甲基)丙烯酸酯。
活性能量射线固化性树脂组合物可以进一步含有与上述氨酯(甲基)丙烯酸酯低聚物不同的树脂、(甲基)丙烯酸酯单体、光聚合引发剂、和硅烷偶联剂等。
上述光聚合引发剂具有通过被照射活性能量射线而具有引发氨酯(甲基)丙烯酸酯低聚物和(甲基)丙烯酸酯单体的聚合的作用。作为该光聚合引发剂,可以使用4-二甲基氨基苯甲酸、4-二甲基氨基苯甲酸酯、2,2-二甲氧基-2-苯基苯乙酮、苯乙酮二乙基缩酮、烷氧基苯乙酮、苄基二甲基缩酮、二苯甲酮和3,3-二甲基-4-甲氧基二苯甲酮、4,4-二甲氧基二苯甲酮、4,4-二氨基二苯甲酮等二苯甲酮衍生物;苯甲酰基苯甲酸烷基酯、双(4-二烷基氨基苯基)酮、苄基和苄基甲基缩酮等苄基衍生物;苯偶姻和苯偶姻异丁基醚等苯偶姻衍生物;以及苯偶姻异丙基醚、2-羟基-2-甲基苯丙酮、1-羟基环己基苯基酮、氧杂蒽酮、噻吨酮、噻吨酮衍生物、芴、2,4,6-三甲基苯甲酰基二苯基氧化膦、双(2,6-二甲氧基苯甲酰基)-2,4,4-三甲基戊基氧化膦、双(2,4,6-三甲基苯甲酰基)-苯基氧化膦和2-甲基-1-[4-(甲硫基)苯基]-2-吗啉基丙烷-1,2-苄基-2-二甲基氨基-1-(吗啉基苯基)-丁酮-1等。
硅烷偶联剂是具有有机官能团和水解性基团的硅烷化合物。通过使活性能量射线固化性树脂组合物含有硅烷偶联剂,可以进一步提高被覆层11与金属箔层12的表面粘接强度。硅烷偶联剂只要是能够有助于提高与金属箔层12的粘接性的硅烷偶联剂就行,没有特别限定。作为硅烷偶联剂,例如可以列举出含有乙烯基的硅烷偶联剂、含有环氧基的硅烷偶联剂、含有苯乙烯基的硅烷偶联剂、含有甲基丙烯酰基的硅烷偶联剂、含有丙烯酰基的硅烷偶联剂、含有氨基的硅烷偶联剂、含有脲基的硅烷偶联剂、含有巯基的硅烷偶联剂、含有硫醚基的硅烷偶联剂、含有异氰酸酯基的硅烷偶联剂和含有烯丙基的硅烷偶联剂等含有有机官能团的硅烷偶联剂。从粘接性提高的观点出发,硅烷偶联剂优选为含有甲基丙烯酰基的硅烷偶联剂或含有丙烯酰基的硅烷偶联剂。
作为硅烷偶联剂中的上述水解性基团,例如可以列举出甲氧基和乙氧基等碳数为1~6的烷氧基、乙酰氧基、以及2-甲氧基乙氧基等。
作为上述含有甲基丙烯酰基的硅烷偶联剂,例如可以列举出3-甲基丙烯酰氧基丙基甲基二甲氧基硅烷、3-甲基丙烯酰氧基丙基三甲氧基硅烷、3-甲基丙烯酰氧基丙基甲基二乙氧基硅烷和3-甲基丙烯酰氧基丙基三乙氧基硅烷等。作为含有丙烯酰基的硅烷偶联剂,例如可以列举出3-丙烯酰氧基丙基三甲氧基硅烷等。
活性能量射线固化性树脂组合物含有与上述氨酯(甲基)丙烯酸酯低聚物不同的树脂、(甲基)丙烯酸酯单体、光聚合引发剂或硅烷偶联剂时的优选的含量如下所述。与上述氨酯(甲基)丙烯酸酯低聚物不同的树脂的含量相对于活性能量射线固化性树脂组合物的总量优选为5~30质量%。(甲基)丙烯酸酯单体的含量相对于活性能量射线固化性树脂组合物的总量优选为50~95质量%。光聚合引发剂的含量相对于氨酯(甲基)丙烯酸酯的总量优选为1~10质量%。硅烷偶联剂的含量相对于活性能量射线固化性树脂组合物的总量优选为0.5~10质量%。
作为照射到被覆层11的活性能量射线,可以使用从氙灯、低压水银灯、高压水银灯、超高压水银灯、金属卤化物灯、碳弧灯和钨灯等光源发出的紫外线、以及从通常20~2000kV的粒子加速器取出的电子束、α射线、β射线和γ射线等。
活性能量射线的照射条件没有特别限定,可以根据需要来适当设定,但通常优选按照使积累光量达到100mJ/cm2以上、更优选使积累光量达到300mJ/cm2以上的方式来设定条件。
作为氟系树脂,可以列举出聚四氟乙烯、四氟乙烯-乙烯共聚物、四氟乙烯-乙烯基共聚物等四氟化型的氟树脂、聚氯三氟乙烯、氯化三氟乙烯-乙烯共聚物、氯化三氟乙烯-乙烯基共聚物等三氟化型的氟树脂、聚偏氟乙烯等二氟化型的氟树脂、或者四氟乙烯-全氟烷基乙烯基醚共聚物、四氟乙烯-六氟丙烯共聚物、聚氟乙烯等其它的氟树脂等。其中,优选由于具有稳定结构因而耐电解液性优良的四氟化型的氟树脂,更优选赋予了溶剂可溶性的四氟乙烯-乙烯基共聚物。此外,上述的氟系树脂可以单独使用或组合使用。
氟系树脂优选用异氰酸酯系固化剂进行了固化。通过使用异氰酸酯作为这些树脂的固化剂,可以提高涂膜(被覆层)的耐热性,而且由于交联结构变密,所以被覆层的膜强度增加,可以维持更良好的成型性。
作为异氰酸酯,可以列举出异氰酸甲酯、六亚甲基二异氰酸酯、异佛尔酮二异氰酸酯等脂肪族异氰酸酯;二苯基甲烷二异氰酸酯、甲苯二异氰酸酯等芳香族异氰酸酯等。上述的异氰酸酯可以单独使用或组合使用。其中,异氰酸酯优选含有容易提高涂膜(被覆层)的强度的芳香族异氰酸酯,特别是更优选含有甲苯二异氰酸酯。芳香族异氰酸酯比脂肪族异氰酸酯的反应性高。因此,在使用芳香族异氰酸酯时,在涂布被覆层并使溶剂干燥后的阶段,反应完成到了某个程度,即使干燥后立即卷绕也不易发生粘连。不过,芳香族异氰酸酯中使用二苯基甲烷二异氰酸酯时,由于反应性过高,所以适用期(potlife)容易下降,长时间的涂布倾向于变得困难。此外,当异氰酸酯含有甲苯二异氰酸酯时,从使上述作用效果更加容易显现的观点出发,异氰酸酯中的甲苯二异氰酸酯的异氰酸酯基的含量优选为50~100质量%,更优选为60~90质量%。
被覆层11的厚度优选为3~30μm、更优选为5~20μm。本实施方式中,被覆层11直接形成于金属箔层12上,被覆层11与金属箔层12之间不需要粘接层。因此,可以削减粘接层所花费的成本。另外,通过将被覆层11的厚度设定为20μm以下,就容易制成比以往更薄的外装构件的结构。
另外,优选粘接层14和密封层15的合计厚度为被覆层11的厚度的2~8倍(粘接层和密封层的合计厚度/被覆层的厚度)。由此,能够降低成型加工后的外装构件的翘曲量。
(金属箔层)
金属箔层12可以使用铝和不锈钢等各种金属箔,从防湿性和延展性等加工性以及成本的观点出发,金属箔优选为铝箔。作为铝箔,可以使用一般的软质铝箔。其中,从耐针孔性和成型时的延展性优良的观点出发,优选使用含有铁的铝箔。
含有铁的铝箔(100质量%)中的铁的含量优选为0.1~9.0质量%,更优选为0.5~2.0质量%。铁的含量如果为0.1质量%以上,则外装构件10倾向于具有优良的耐针孔性和延展性。另外,铁的含量如果为9.0质量%以下,则外装构件10倾向于具有优良的柔软性。
从阻隔性、耐针孔性和加工性的观点出发,金属箔层12的厚度优选为9~200μm、更优选为15~100μm。
(防腐蚀处理层)
防腐蚀处理层13起到抑制因电解液、或电解液与水分的反应所产生的氢氟酸而引起的金属箔层12的腐蚀的作用。
作为防腐蚀处理层13,优选利用涂布型或浸渍型的耐酸性的防腐蚀处理剂来形成。上述的防腐蚀处理层对金属箔层12的酸具有优良的防腐蚀效果。
作为防腐蚀处理剂,例如可以列举出由氧化铈、磷酸盐和各种热固性树脂构成的氧化铈溶胶处理用的防腐蚀处理剂、由铬酸盐、磷酸盐、氟化物和各种热固性树脂构成的铬酸盐处理用的防腐蚀处理剂等。
防腐蚀处理层13只要是能够使金属箔层12获得充分的耐蚀性就行,就不限于上述的防腐蚀处理层。防腐蚀处理层13例如也可以通过磷酸盐处理或勃姆石处理等来形成。
防腐蚀处理层13可以是单层,也可以是多层。另外,防腐蚀处理层13中还可以含有硅烷偶联剂等添加剂。
从防腐蚀功能和作为锚固层的功能的观点出发,防腐蚀处理层13的厚度优选为10nm~5μm、更优选为20~500nm。
(粘接层)
粘接层14是将形成有防腐蚀处理层13的金属箔层12和密封层15粘接起来的层。外装构件10根据形成粘接层14的粘接成分的不同而大致分为热层压结构和干式层压结构这两种结构。
热层压构成中的形成粘接层14的粘接成分(粘接树脂)优选为将聚烯烃系树脂用马来酸酐等酸进行接枝改性而得到的酸改性聚烯烃系树脂。酸改性聚烯烃系树脂由于在无极性的聚烯烃系树脂的一部分上导入了极性基团,所以例如当作为密封层15使用由聚烯烃系树脂膜等形成的无极性的层、而且作为防腐蚀处理层13使用具有极性的层时,能够使上述的两层牢固地密合。另外,通过使用酸改性聚烯烃系树脂,具有下述倾向:可以提高对电解液等内容物的耐性,电池内部即使产生氢氟酸,也容易防止因粘接层14的劣化而引起的密合力的下降。
粘接层14中使用的酸改性聚烯烃系树脂可以单独使用,也可以并用2种以上。
作为酸改性聚烯烃系树脂中使用的聚烯烃系树脂,可以列举出例如低密度、中密度或高密度的聚乙烯;乙烯-α烯烃共聚物;聚丙烯;含有丙烯作为共聚成分的嵌段或无规共聚物;和丙烯-α烯烃共聚物等。另外,也可以使用使丙烯酸或甲基丙烯酸等极性分子与上述的物质共聚而得到的共聚物、以及交联聚烯烃等聚合物等。
作为对上述聚烯烃系树脂进行改性的酸,可以列举出羧酸、环氧化合物和酸酐等,优选马来酸酐。
在为热层压结构的情况下,粘接层14可以通过将上述粘接成分用挤出装置挤出来形成。
作为干式层压结构中的粘接层14的粘接成分,例如可以列举出可以使作为固化剂的2官能以上的芳香族系或脂肪族系异氰酸酯化合物与聚酯多元醇、聚醚多元醇、丙烯酸酯多元醇等主剂作用的双组分固化型的聚氨酯系粘接剂。
不过,当使用上述的双组分固化型的聚氨酯系粘接剂时,粘接层14在多数情况下具有酯基或氨基甲酸酯基等水解性较高的结合部。因此,在要求更高的可靠性的用途中优选采用热层压结构的粘接层14。
干式层压结构的粘接层14可以通过在防腐蚀处理层13上涂布粘接成分后,进行干燥来形成。此外,如果使用聚氨酯系粘接剂,涂布后,例如通过在40℃下进行4天以上的老化,可使主剂的羟基与固化剂的异氰酸酯基进行反应而实现牢固的粘接。
从粘接性、追随性、加工性等观点出发,粘接层14的厚度优选为2~50μm、更优选为3~20μm。
(密封层)
密封层15是对外装构件10赋予由热封产生的密封性的层。作为密封层15,可以列举出由聚烯烃系树脂或对聚烯烃系树脂用马来酸酐等酸进行了接枝改性而成的酸改性聚烯烃系树脂构成的树脂膜,但是从热封部的耐热性和热封强度提高方面来看,优选聚烯烃系树脂。
作为聚烯烃系树脂,例如可以列举出低密度、中密度或高密度的聚乙烯;乙烯-α烯烃共聚物;聚丙烯;含有丙烯作为共聚成分的嵌段或无规共聚物;和丙烯-α烯烃共聚物等。上述聚烯烃系树脂可以单独使用,也可以2种以上并用。
作为对聚烯烃系树脂进行改性的酸,可以列举出例如与在粘接层14的说明中所列举酸同样的酸。
密封层15可以是单层膜和多层膜中的任一种,可以根据所需要的功能来选择。例如,从赋予防湿性的观点出发,可以使用夹入了乙烯-环状烯烃共聚物或聚甲基戊烯等树脂的多层膜。
另外,密封层15中还可以配合阻燃剂、润滑剂、防粘连剂、抗氧化剂、光稳定剂和粘着赋予剂等各种添加材料。
从确保绝缘性的观点出发,密封层15的厚度优选为10~100μm、更优选为20~60μm。
作为外装构件10,可以是通过干式层压而层叠了密封层15的外装构件,但从提高粘接性的观点出发,例如,也可以是通过使用了酸改性聚烯烃系树脂作为粘接层14的夹层层压法而层叠了密封层15的外装构件,也可以是粘接层14和密封层15被同时挤出(使用共挤出制法)而层叠得到的外装构件。其中,从使粘接性更加优良的观点出发,外装构件10优选为使用共挤出制法将粘接层14和密封层15层叠而得到的外装构件。
下面,对本发明的其它实施方式的蓄电设备用外装构件20(以下仅称作“外装构件20”)进行说明。图2是本发明的另一个实施方式的蓄电设备用外装构件的概略截面图。如图2所示,外装构件20具有:发挥阻隔功能的金属箔层23;在金属箔层23的第一面上隔着第一防腐蚀处理层22形成的被覆层21;在金属箔层23的第二面上形成的第二防腐蚀处理层24;以及在第二防腐蚀处理层24上依次层叠的粘接层25和密封层26。被覆层21可以在金属箔层23的第一面上仅仅隔着第一防腐蚀处理层22来形成,也可以隔着第一防腐蚀处理层22和粘接层来形成。当被覆层21的形成不使用粘接层时,可以削减由粘接剂所花费的成本,并且可以减薄外装构件。当使用粘接层时,作为构成该粘接层的粘接剂,可以使用在上述粘接层14的干式层压结构中所列举的双组分固化型的聚氨酯系粘接剂。使用外装构件20来形成蓄电设备时,被覆层21成为最外层,密封层26成为最内层。
被覆层21起到下述作用:可赋予外装构件对在制造蓄电设备时的热封的耐热性、和即使附着电解液也不易变质的耐电解液性,并且可抑制加工或流通时可能发生的针孔。第一防腐蚀处理层22起到下述作用:可抑制因电解液、或因电解液与水分的反应所产生的氢氟酸而引起的金属箔层23的腐蚀、而且可提高金属箔层23与被覆层21的密着力。第二防腐蚀处理层24起到下述作用:可抑制因电解液、或因电解液与水分的反应所产生的氢氟酸而引起的金属箔层23的腐蚀。粘接层25是将形成有第二防腐蚀处理层24的金属箔层23与密封层26进行粘接的层。密封层26是对外装构件20赋予热封的密封性的层。
外装构件20的被覆层21、金属箔层23、粘接层25和密封层26分别可以制成与上述外装构件10的被覆层11、金属箔层12、粘接层14和密封层15同样的构成。另外,外装构件20的第一防腐蚀处理层22和第二防腐蚀处理层24均可以设定成与上述外装构件10的防腐蚀处理层13同样的构成。
[单膜的制造方法]
被覆层11的单膜可以用下述方法得到:在拉伸聚酯膜等基材层上涂布含有氨酯(甲基)丙烯酸酯低聚物的活性能量射线固化性树脂组合物并进行干燥,照射活性能量射线而形成交联结构后,或者,涂布含有氟系树脂的树脂材料并进行干燥,再进行热处理而形成交联结构后,或者,将分散到水中的聚氨酯树脂或聚酯树脂进行涂布、干燥后,从基材层上剥离。
[外装构件的制造方法]
以下,以上述外装构件10为例对外装构件的制造方法进行说明。下述内容是制造方法的一例子,本实施方式的外装构件的制造方法不受下述内容的限定。
作为外装构件10的制造方法,可以列举出例如具有下述工序S1~S3的方法。
工序S1:在金属箔层12的一个面(第二面)上形成防腐蚀处理层13的工序。
工序S2-1:在金属箔层12的另一个面(与第二面相反侧的第一面)上涂布活性能量射线固化性树脂组合物,并进行干燥,照射活性能量射线,形成被覆层11的工序。涂布方法没有特别限定,可以采用凹版涂布、逆向涂布、辊涂法和棒涂法等各种方法。涂布后,将溶剂成分干燥,然后例如以累积光量为500mJ/cm2的条件照射320nm以下的波长的紫外线,形成被覆层11。此外,在外装构件20中,被覆层21可以与上述同样地形成于第一防腐蚀处理层22上。
工序S2-2:在金属箔层12的另一个面(与第二面相反侧的第一面)上涂布氟系树脂并进行干燥,形成被覆层11的工序。涂布方法没有特别限定,可以采用凹版涂布、逆向涂布、辊涂法、棒涂法等各种方法。涂布后,例如可以在60℃下进行7天的老化处理,以促进固化。此外,在外装构件20中,被覆层21可以与上述同样地形成于第一防腐蚀处理层22上。
工序S3:在金属箔层12的一个面上形成的防腐蚀处理层13上隔着粘接层14贴合密封层15的工序。此外,对于外装构件20,也可以以此为基准来实施工序。
(工序S1)
在工序S1中,在金属箔层12的一个面上涂布防腐蚀处理剂并进行干燥,从而形成防腐蚀处理层13。作为防腐蚀处理剂,例如可以列举出上述的氧化铈溶胶处理用的防腐蚀处理剂和铬酸盐处理用的防腐蚀处理剂等。防腐蚀处理剂的涂布方法没有特别限定,可以采用凹版涂布、逆向涂布、辊涂法和棒涂法等各种方法。此外,在外装构件20中,第一和第二防腐蚀处理层可以与上述同样地形成于金属箔层23的两面。第一和第二防腐蚀处理层的形成顺序没有特别限制。
(工序S2-1、S2-2)
在金属箔层的外侧层叠基材层的通用的外装构件的情况下,由于是隔着粘接层进行层叠,所以需要老化等工序。可是,被覆层11的形成不需要介入粘接层,工序S2中不需要老化等工序。其结果是,可以缩短单件工时(tacttime),显著地提高制造效率。进而,由于不使用粘接剂等,所以成本也能够大幅降低。
(工序S3)
在工序S3中,在依次层叠被覆层11、金属箔层12和防腐蚀处理层13而成的层叠体的防腐蚀处理层13上形成粘接层14,并贴合用于形成密封层15的树脂膜。密封层15的层叠优选通过夹层层压法来进行。此外,对于外装构件20,也可以以此为基准来实施工序。
经过以上说明的工序S1~S3,可以得到外装构件10或外装构件20。此外,外装构件10和外装构件20的制造方法的工序顺序不限于依次实施上述工序S1~S3的方法。例如,也可以在进行了工序S2-1或S2-2之后再进行工序S1。
实施例
以下,列举实施例来具体地说明本发明,但本发明不受以下记载的限定。[外装构件制作中使用的材料]
在实施例和比较例中,外装构件的金属箔层、防腐蚀处理层、粘接层和密封层所使用的材料如下所示。
(金属箔层)
金属箔:软质铝箔8079材(东洋铝公司制、厚度:30μm)。
(防腐蚀处理层)
防腐蚀处理剂:主要含有氧化铈、磷酸和丙烯酸系树脂的涂布型氧化铈溶胶处理用的防腐蚀处理剂。
(粘接层)
粘接树脂:用马来酸酐进行了接枝改性的聚丙烯系树脂(商品名“ADMER”、三井化学公司制(厚度为10μm~20μm))。
(密封层)
密封树脂:通过挤出成型来制膜的聚丙烯膜(厚度为10μm~60μm)。
(被覆层)
实施例和比较例的作为被覆层使用的材料和密封层如下所示。此外,得到的被覆层等的10%拉伸强度通过拉伸试验(根据JIS K 7127(旧标准JIS K7113-2):测定环境为23℃、50%RH、试样宽为6mm、标线间距离为35mm、拉伸速度为50mm/分钟)来测定。
表1
[外装构件的制作]
(实施例1~3、比较例1~2)
相对于四氟乙烯-乙烯基共聚树脂的主剂,将表1中所示的异氰酸酯系固化剂分别按照使OH/NCO=1的摩尔比进行配合。将上述树脂涂布于金属箔层的第一面上,在100℃下干燥5分钟。涂布后,为了得到交联结构,在60℃下进行7天的老化处理,形成了被覆层。
接着,在金属箔层的与形成有被覆层的面相反侧的面(第二面)上形成的防腐蚀处理层上涂布粘接树脂,在涂布面上贴合密封膜的进行了电晕处理的面,在防腐蚀处理层上隔着粘接层形成了密封层。将得到的层叠体在190℃下进行加热压粘而得到各外装构件。
(实施例4~5、比较例3~5)
相对于表1所示的氨酯(甲基)丙烯酸酯低聚物,按照使固体成分比为5质量%的量添加1-羟基-环己基-苯基-酮(BASF公司制、商品名:IRGACURE184),得到活性能量射线固化性树脂组合物。在金属箔层的一个面(第二面)上涂布氧化铈溶胶处理用的防腐蚀处理剂,形成了防腐蚀处理层。使用棒涂器将活性能量射线固化性树脂组合物涂布于金属箔的未形成有防腐蚀处理层的面(第一面)上,在100℃下加热干燥5分钟,形成了被覆层。
在金属箔的与形成了被覆层的面相反侧的面(第二面)上形成的防腐蚀处理层上涂布粘接树脂,在涂布面上贴合密封膜的进行了电晕处理的面,在防腐蚀处理层上隔着粘接层形成了密封层。将得到的层叠体在190℃下进行加热压粘,由此得到了各外装构件。
(实施例6~9、比较例6~7)
使用棒涂器将分散到水中的聚氨酯或聚酯涂布于金属箔的未形成有防腐蚀处理层的面(第一面)上,在150℃下加热干燥5分钟,形成了被覆层。
在金属箔的与形成了被覆层的面相反侧的面(第二面)上形成的防腐蚀处理层上涂布粘接树脂,在涂布面上贴合密封膜的进行了电晕处理的面,在防腐蚀处理层上隔着粘接层形成了密封层。将得到的层叠体在190℃下进行加热压粘,由此得到了各外装构件。
[外装构件的评价]
(成型性)
将实施例和比较例中得到的外装构件切成150mm×190mm的坯料形状,在室温为23℃、露点温度为-35℃的成型环境下,一边改变成型深度,一边进行冷成型。成型时,使用在与外装构件平行的面上具有100mm×150mm的形状、并具有1.5mm的冲头角半径(Rcp)、0.75mm的冲头凸缘半径(Rp)的冲切模具、和具有0.75mm的口模半径(Rd)的压铸模。根据下述基准评价成型性。评价结果示于表2中。
“A”:能够不发生断裂或裂纹地进行成型深度为4mm以上的深冲成型。
“B”:能够不发生断裂或裂纹地进行成型深度为3mm以上但小于4mm的深冲成型。
“C”:在成型深度小于3mm的深冲成型中发生断裂或裂纹。
(成型加工后的翘曲量)
将实施例和比较例中得到的外装构件切成120mm×260mm的形状,使密封层朝着上方配置于成型装置内。将成型装置的成型深度设定为3mm,在室温为23℃、露点温度为-35℃的环境下进行冷成型。冲切模具使用具有70mm×80mm的长方形的横截面、底面具有0.75mm的冲孔半径(RP)、侧面具有1.5mm的冲孔角半径(RCP)的模具。另外,压铸模使用开口部上表面上具有0.75mm的口模半径(RD)的压铸模。冲切模具与压铸模之间的间隙设定为0.20mm。成型区域设定为在切下的外装构件的长度方向的大致中央处分开的半面的大致中央。即,按照下述方式配置成型区域:使成型区域的两端在距离切下的外装构件的宽度方向的两端分别为25mm的位置。将成型加工后的外装构件按照使翘起层侧朝着上面的方式在室温为23℃、露点温度为-35℃的环境下静置60分钟,测定未成型的区域的边缘的翘曲量(离静置面的距离)。翘曲量的测定结果示于表2中。
(耐电解液性)
在实施例和比较例中得到的外装构件的被覆层(或基材层)侧表面上,滴下添加了微量的水(1500ppm)的电解液(溶剂:碳酸亚乙酯/碳酸二甲酯/碳酸二乙酯=1/1/1、电解质:LiPF6(浓度为1M))。放置24小时后,将滴下的电解液用异丙醇擦掉。然后,根据下述基准评价外装构件的滴下部位的外观。评价结果示于表2中。
“A”:无法辨认出滴下了电解液的部位。
“B”:在滴下了电解液的部位能够辨认出轮廓,但未受到溶解等损伤。
“C”:滴下了电解液的部位因电解液而受到了溶解等损伤。
表2
*拉伸强度差:被覆层与粘接层和密封层的层叠体在10%拉伸时的强度差
如表1和2所示,具备本发明的全部构成的实施例中,成型加工后的翘曲量为10mm以内,减少了翘曲量。另外,还具有优良的成型性和耐电解液性。
Claims (6)
1.一种蓄电设备用外装构件,其具有:
金属箔层;
在所述金属箔层的第一面上直接形成或隔着第一防腐蚀处理层而形成的被覆层;
在所述金属箔层的第二面上形成的第二防腐蚀处理层;
在所述第二防腐蚀处理层上形成的粘接层;和
在所述粘接层上形成的密封层,
其中,所述被覆层含有选自由氟系树脂、聚氨酯系树脂和聚酯系树脂组成的组中的至少一种,
在根据JIS K 7127进行的拉伸试验中所述被覆层与所述粘接层和所述密封层的层叠体在10%拉伸时的强度差小于0.400N/mm。
2.根据权利要求1所述的蓄电设备用外装构件,其中,所述被覆层的厚度为3~30μm。
3.根据权利要求1或2所述的蓄电设备用外装构件,其中,所述密封层由聚烯烃系树脂形成。
4.根据权利要求1~3任一项中所述的蓄电设备用外装构件,其中,所述粘接层和所述密封层的合计厚度为所述被覆层的厚度的2~8倍。
5.根据权利要求1~4任一项中所述的蓄电设备用外装构件,其中,所述氟系树脂是通过异氰酸酯系固化剂固化后的四氟化型氟树脂,所述固化剂1个分子内的NCO官能团当量为1000~5000。
6.根据权利要求1~5任一项中所述的蓄电设备用外装构件,其中,所述聚氨酯系树脂是使用1个分子内的(甲基)丙烯酰基的官能团当量为1000~5000的氨酯(甲基)丙烯酸酯低聚物而得到的。
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- 2016-03-29 JP JP2017510049A patent/JP6708979B2/ja not_active Expired - Fee Related
- 2016-03-29 CN CN201620250452.XU patent/CN205705574U/zh not_active Expired - Fee Related
- 2016-03-29 KR KR1020177030011A patent/KR20170131513A/ko unknown
- 2016-03-29 CN CN201610187407.9A patent/CN106003915A/zh active Pending
- 2016-03-29 WO PCT/JP2016/060227 patent/WO2016158997A1/ja active Application Filing
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2017
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CN110678998A (zh) * | 2017-06-02 | 2020-01-10 | 住友电工超效能高分子股份有限公司 | 蓄电装置用构件、其制造方法和蓄电装置 |
CN114678637A (zh) * | 2022-04-18 | 2022-06-28 | 江苏睿捷新材料科技有限公司 | 一种锂离子电池包装用铝塑复合膜及电池 |
Also Published As
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CN205705574U (zh) | 2016-11-23 |
JPWO2016158997A1 (ja) | 2018-02-08 |
WO2016158997A1 (ja) | 2016-10-06 |
US20180019449A1 (en) | 2018-01-18 |
JP6708979B2 (ja) | 2020-06-10 |
US10319958B2 (en) | 2019-06-11 |
KR20170131513A (ko) | 2017-11-29 |
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