Laminated microporous film, battery separator, and non-aqueous electrolyte battery
View Patent ↗A laminated microporous film including a base which is formed from a non-woven fabric, and a surface layer which is formed on at least one of the surfaces of the base and includes a resin material and inorganic particles, wherein variation in thickness which is expressed using a standard deviation is equal to or less than 2.5%.
1. A laminated microporous film comprising:
a base which is formed from a non-woven fabric; and
a surface layer which is formed on at least one of the surfaces of the base and includes a resin material and inorganic particles,
wherein variation in thickness using a standard deviation is equal to or less than 1.7% of the laminated microporous film, air permeability is equal to or greater than 960 sec/100 ml and is equal to or less than 1100 sec/100 ml, and a portion of the surface layer is provided into holes of the non-woven fabric, after a film thickness uniforming process is performed on the laminated microporous film, and wherein pressure during the film thickness uniforming process is a linear load equal to or greater than 20 kgf/cm and equal to or less than 200 kgf/cm.
2. The laminated microporous film according to claim 1 , wherein the resin material includes polyvinylidene fluoride.
3. The laminated microporous film according to claim 2 , wherein the resin material has a three-dimensional mesh structure.
4. The laminated microporous film according to claim 1 , wherein the mass ratio of the inorganic particles to the resin material in the surface layer is within the range of 5:1 to 12:1.
5. The laminated microporous film according to claim 4 , wherein the inorganic particles are formed from at least one type of alumina (Al 2 O 3 ), titania (TiO 2 ) which has a rutile structure, or silica (SiO 2 ).
6. A laminated microporous film comprising:
a base which is formed from a non-woven fabric; and
a surface layer which is formed on at least one of the surfaces of the base and includes a resin material and inorganic particles,
wherein the laminated microporous film is formed by a pressurizing process being carried out on at least one of the surfaces of the surface layer, variation in thickness using a standard deviation is equal to or less than 1.7% of the laminated microporous film, air permeability is equal to or greater than 960 sec/100 ml and is equal to or less than 1100 sec/100 ml, and a portion of the surface layer is provided into holes of the non-woven fabric, after the pressurizing process, and wherein pressure during the pressurizing process is a linear load equal to or greater than 20 kgf/cm and equal to or less than 200 kgf/cm.
7. The laminated microporous film according to claim 6 , wherein the pressurizing process is a calendar process.
8. The laminated microporous film according to claim 6 , wherein variation in thickness which is expressed using a standard deviation is equal to or less than 2.5% of the laminated microporous film.
9. A separator comprising:
a base which is formed from a non-woven fabric; and
a surface layer which is formed on at least one of the surfaces of the base and includes a resin material and inorganic particles,
wherein variation in thickness using a standard deviation is equal to or less than 1.7% of the separator, air permeability is equal to or greater than 960 sec/100 ml and is equal to or less than 1100 sec/100 ml, and a portion of the surface layer is provided into holes of the non-woven fabric, after a film thickness uniforming process is performed on the separator, and wherein pressure during the film thickness uniforming process is a linear load equal to or greater than 20 kgf/cm and equal to or less than 200 kgf/cm.
10. A separator comprising:
a base which is formed from a non-woven fabric; and
a surface layer which is formed on at least one of the surfaces of the base and includes a resin material and inorganic particles,
wherein the separator is formed by a pressurizing process being carried out on at least one of the surfaces of the surface layer, variation in thickness using a standard deviation is equal to or less than 1.7% of the separator, air permeability is equal to or greater than 960 sec/100 ml and is equal to or less than 1100 sec/100 ml, and a portion of the surface layer is provided into holes of the non-woven fabric, after the pressurizing process, and wherein pressure during the pressurizing process is a linear load equal to or greater than 20 kgf/cm and equal to or less than 200 kgf/cm.
11. A non-aqueous electrolyte battery comprising:
a positive electrode;
a negative electrode;
a separator; and
a non-aqueous electrolyte,
wherein the separator is provided with a base which is formed from a non-woven fabric, and a surface layer which is formed on at least one of the surfaces of the base and includes a resin material and inorganic particles, variation in thickness using a standard deviation is equal to or less than 1.7% of the separator, air permeability is equal to or greater than 960 sec/100 ml and is equal to or less than 1100 sec/100 ml, and a portion of the surface layer is provided into holes of the non-woven fabric, after a film thickness uniforming process is performed on the separator, and wherein pressure during the film thickness uniforming process is a linear load equal to or greater than 20 kgf/cm and equal to or less than 200 kgf/cm.
12. A non-aqueous electrolyte battery comprising:
a positive electrode;
a negative electrode;
a separator; and
a non-aqueous electrolyte,
wherein the separator is provided with a base which is formed from a non-woven fabric, and a surface layer which is formed on at least one of the surfaces of the base and includes a resin material and inorganic particles, the separator is formed by a pressurizing process being carried out on at least one of the surfaces of the surface layer, variation in thickness using a standard deviation is equal to or less than 1.7% of the separator, air permeability is equal to or greater than 960 sec/100 ml and is equal to or less than 1100 sec/100 ml, and a portion of the surface layer is provided into holes of the non-woven fabric, after the pressurizing process, and wherein pressure during the pressurizing process is a linear load equal to or greater than 20 kgf/cm and equal to or less than 200 kgf/cm.
13. The non-aqueous electrolyte battery according to claim 12 , wherein the pressurizing process is a calendar process.
14. The non-aqueous electrolyte battery according to claim 12 , wherein variation in thickness which is expressed using a standard deviation is equal to or less than 2.5% of the separator.
15. The laminated microporous film according to claim 1 , wherein the inorganic particles are formed from alumina (Al 2 O 3 ).
16. The laminated microporous film according to claim 1 , wherein the non-woven fabric includes polyethylene terephthalate, wherein the resin material includes polyvinylidene fluoride, and wherein the inorganic particles are formed from alumina (Al 2 O 3 ).
17. The laminated microporous film according to claim 6 , wherein the inorganic particles are formed from alumina (Al 2 O 3 ).
18. The laminated microporous film according to claim 6 , wherein the non-woven fabric includes polyethylene terephthalate, wherein the resin material includes polyvinylidene fluoride, and wherein the inorganic particles are formed from alumina (Al 2 O 3 ).