MULTI-LAYER, MICROPOROUS POLYOLEFIN MEMBRANE, ITS PRODUCTION METHOD, BATTERY SEPARATOR, AND BATTERY

Abstract

A multi-layer, microporous polyolefin membrane comprising first microporous layers constituting at least both surface layers and at least one second microporous layer disposed between both surface layers; said first microporous layer being made of a first polyolefin comprising (i) polypropylene, or (ii) a mixture of 50% or more by mass of polypropylene and a polyethylene resin; said second microporous layer being made of a second polyolefin comprising (i) a mixture of 7% or less by mass of ultra-high-molecular-weight polyethylene having weight-average molecular weight of 1×106 or more and the other polyethylene than said ultra-high-molecular-weight polyethylene, (ii) the other polyethylene than said ultra-high-molecular-weight polyethylene, or (iii) a mixture of 50% or less by mass of polypropylene and said mixture (i) or said polyethylene (ii); said second microporous layer having a larger average pore diameter than that of said first microporous layer; and the total thickness of said first microporous layers being 15-60% per 100% of the total thickness of said first and second microporous layers.

Description

FIELD OF THE INVENTION

The present invention relates to a multi-layer, microporous polyolefin membrane having suitably well-balanced permeability, mechanical strength, meltdown properties, electrolytic solution absorption, and electrolytic solution retention, a method for producing such a multi-layer, microporous polyolefin membrane, a battery separator formed by such a multi-layer, microporous polyolefin membrane, and a battery comprising such a separator.

BACKGROUND OF THE INVENTION

Microporous polyolefin membranes are used for battery separators for primary batteries and secondary batteries such as lithium ion secondary batteries, lithium-polymer secondary batteries, nickel-hydrogen secondary batteries, nickel-cadmium secondary batteries, nickel-zinc secondary batteries, silver-zinc secondary batteries, etc. When the microporous polyolefin membrane is used for battery separators, particularly lithium ion battery separators, its performance largely affects the properties, productivity and safety of batteries. Accordingly, the microporous polyolefin membrane is required to have suitable permeability, mechanical properties, dimensional stability, shutdown properties, meltdown properties, etc. As is known, it is desirable for the batteries to have a relatively low shutdown temperature and a relatively high meltdown temperature for improved battery safety properties, particularly for batteries exposed to high temperatures during under operating conditions. High separator permeability is desirable for high battery capacity. A separator with high mechanical strength is desirable for improved battery assembly and fabrication properties.

In general, microporous membranes consisting essentially of polyethylene (i.e., they contain polyethylene only with no significant presence of other species) have low meltdown temperatures, while those composed only of polypropylene have high shutdown temperatures. Accordingly, microporous membranes comprising polyethylene and polypropylene as main components are preferable for battery separators. Proposals have thus been made to provide microporous membranes formed from mixed resins of polyethylene and polypropylene, and multi-layer, microporous membranes comprising polyethylene layers and polypropylene layers.

Japanese Patent 3589778, discloses a multi-layer, porous membrane having a three-layer structure of a porous polypropylene membrane and porous membranes made of a mixture of polyethylene and polypropylene on both surfaces of porous polypropylene membrane. The porous membrane's internal electrical resistance increases to such an extent as to shut down electric current immediately after the melting of the polyethylene in the membrane occurs. The maximum temperature of the membrane is the melting point of polyethylene+20° C. or lower, AC voltage is applied through electrodes attached to both surfaces of the multi-layer, porous membrane impregnated with an electrolytic solution, to generate heat by resistance at a speed of 10-50° C./second.

WO 2004/089627 discloses a microporous polyolefin membrane made of polyethylene and polypropylene as indispensable components, which is constituted by two or more layers, the polypropylene content being more than 50% and 95% or less by mass in at least one surface layer, and the polyethylene content being 50-95% by mass in the entire membrane. The membrane has improved permeability, high-temperature strength and safety, as well as low shutdown temperature and high short-circuiting temperature.

JP7-216118A discloses a battery separator formed by a porous film comprising polyethylene and polypropylene as indispensable components and having two microporous layers with different polyethylene contents, the polyethylene content being 0-20% by weight in one microporous layer, 21-60% by weight in the other microporous layer, and 2-40% by weight in the overall film. The battery separator has improved shutdown-starting temperature and mechanical strength.

JP10-279718A discloses a battery separator formed by a multi-layer, porous film made of polyethylene and polypropylene as indispensable components, the film having a polyethylene-poor layer whose polyethylene content is 0-20% by weight, and a polyethylene-rich layer which contains 0.5% by weight or more of polyethylene having a melt index of 3 or more and has a polyethylene content of 61-100% by weight per 100% by weight of the total of polyethylene and polypropylene. The battery separator is capable of preventing the temperature of a lithium battery from excessively rising by the reaction of a lithium metal deposited on an anode with an electrolyte when the battery is overcharged.

For instance, JP2002-321323A discloses, as a microporous polyolefin membrane having excellent safety and strength, a microporous polyolefin membrane having a microporous membrane A comprising polyethylene and polypropylene as indispensable components, and a microporous polyethylene membrane B, which are integrally laminated to have a three-layer structure of membrane A/membrane B/membrane A, or membrane B/membrane A/membrane B.

With respect to the properties of separators, not only permeability, mechanical strength, dimensional stability, shutdown properties and meltdown properties, but also battery productivity such as electrolytic solution absorption, and battery cyclability such as electrolytic solution retention have recently been given importance. Particularly electrodes for lithium ion batteries expand and shrink according to the intrusion and departure of lithium, and recent increase in battery capacity leads to larger expansion ratios. Because separators are compressed when the electrodes expand, the separators are required to suffer as little decrease in electrolytic solution retention by compression as possible. However, when the separators are provided with larger pore diameters to have improved electrolytic solution absorption, the electrolytic solution retention of the separators decrease. Battery separators disclosed in Japanese Patent 3589778A, WO 04/089627, JP7-216118A, JP10-279718A and JP2002-321323A are insufficient in electrolytic solution absorption and/or retention. Thus, microporous membranes for battery separators are desired which have improved and well-balanced permeability, mechanical strength, meltdown properties, and electrolytic solution absorption and retention characteristics.

OBJECTS OF THE INVENTION

Accordingly, an object of the present invention is to provide a multi-layer, microporous polyolefin membrane having well-balanced permeability, mechanical strength, meltdown properties, electrolytic solution absorption, and electrolytic solution retention.

Another object of the present invention is to provide a battery separator formed by such a multi-layer, microporous polyolefin membrane. A further object of the present invention is to provide a battery comprising such a separator.

DISCLOSURE OF THE INVENTION

As a result of intense research in view of the above objects, the inventors have found that when (a) a multi-layer, microporous polyolefin membrane is composed of at least one first microporous layer and at least one second microporous layer, when (b) the first microporous layer is made of a first polyolefin comprising (i) polypropylene, or (ii) a mixture of 50% or more by mass of polypropylene and a polyethylene resin, when (c) the second microporous layer is made of a second polyolefin comprising (i) a mixture of 7% or less by mass of ultra-high-molecular-weight polyethylene having Mw of 1×10⁶ or more and the other polyethylene than the ultra-high-molecular-weight polyethylene, (ii) the other polyethylene than the ultra-high-molecular-weight polyethylene, or (iii) a mixture of 50% or less by mass of polypropylene and said polyethylene mixture (i) or said polyethylene (ii), when (d) said second microporous layer has a larger average pore diameter than that of said first microporous layer, and when (e) the total thickness of said first microporous layers (the thickness of the first microporous layer in the case of a two layer structure) is 15-60% per 100% of the total thickness of said first and second layers, the multi-layer, microporous polyolefin membrane has well-balanced permeability, mechanical strength, meltdown properties, electrolytic solution absorption, and electrolytic solution retention. The present invention has been completed based on such finding.

Thus, the multi-layer, microporous polyolefin membrane of the present invention comprises first microporous layers constituting at least both surface layers and at least one second microporous layer disposed between both surface layers; said first microporous layer being made of a first polyolefin comprising (i) polypropylene, or (ii) a mixture of 50% or more by mass of polypropylene and a polyethylene resin; said second microporous layer being made of a second polyolefin comprising (i) a mixture of 7% or less by mass of ultra-high-molecular-weight polyethylene having weight-average molecular weight of 1×10⁶ or more and the other polyethylene than said ultra-high-molecular-weight polyethylene, (ii) the other polyethylene than said ultra-high-molecular-weight polyethylene, or (iii) a mixture of 50% or less by mass of polypropylene and said mixture (i) or said polyethylene (ii); said second microporous layer having a larger average pore diameter than that of said first microporous layer; and the total thickness of said first microporous layers being 15-60% per 100% of the total thickness of said first and second microporous layers.

It is preferable that said first microporous layer has an average pore diameter of 0.005-0.1 μm, and that said second microporous layer has an average pore diameter of 0.02-0.5 μm. The average pore diameter ratio of said second microporous layer to said first microporous layer is preferably more than 1/1 and 10/1 or less.

The pore diameter distribution curve of said second microporous layer obtained by mercury intrusion porosimetry preferably has at least two peaks. Said second microporous layer preferably comprises dense domains having a main peak in a range of 0.01-0.08 μm and coarse domains having at least one sub-peak in a range of more than 0.08 μm and 1.5 μm or less in said pore diameter distribution curve. The pore volume ratio of said dense domains to said coarse domains is preferably 0.5-49.

The multi-layer, microporous polyolefin membrane preferably has a three-layer structure having said first microporous layers on both surfaces of said second microporous layer. Said first polyolefin preferably comprises polypropylene or a mixture of 50% or more by mass of polypropylene and high-density polyethylene having a weight-average molecular weight of 1×10⁴ to 5×10⁵. The other polyethylene than said ultra-high-molecular-weight polyethylene is preferably high-density polyethylene having a weight-average molecular weight of 1×10⁴ to 5×10⁵.

The first method for producing a multi-layer, microporous polyolefin membrane according to the present invention comprises the steps of (1) melt-blending a first polyolefin comprising (i) polypropylene, or (ii) a mixture of 50% or more by mass of polypropylene and a polyethylene resin, and a membrane-forming solvent to prepare a first polyolefin solution; (2) melt-blending a second polyolefin comprising (i) a mixture of 7% or less by mass of ultra-high-molecular-weight polyethylene having weight-average molecular weight of 1×10⁶ or more and the other polyethylene than said ultra-high-molecular-weight polyethylene, (ii) the other polyethylene than said ultra-high-molecular-weight polyethylene, or (iii) a mixture of 50% or less by mass of polypropylene and said mixture (i) or said polyethylene (ii), and a membrane-forming solvent to prepare a second polyolefin solution; (3) simultaneously extruding said first and second polyolefin solutions through a die, such that said first polyolefin solution forms at least both surface layers, while said second polyolefin solution forms at least one layer between both surface layers; (4) cooling the resultant extrudate to form a multi-layer, gel-like sheet; (5) stretching said multi-layer, gel-like sheet; (6) removing said membrane-forming solvent from the stretched multi-layer, gel-like sheet; and (7) stretching the resultant multi-layer, microporous membrane to 1.1-1.8 folds in at least one direction.

The second method for producing a multi-layer, microporous polyolefin membrane according to the present invention comprises the steps of (1) melt-blending a first polyolefin comprising (i) polypropylene, or (ii) a mixture of 50% or more by mass of polypropylene and a polyethylene resin, and a membrane-forming solvent to prepare a first polyolefin solution; (2) melt-blending a second polyolefin comprising (i) a mixture of 7% or less by mass of ultra-high-molecular-weight polyethylene having weight-average molecular weight of 1×10⁶ or more and the other polyethylene than said ultra-high-molecular-weight polyethylene, (ii) the other polyethylene than said ultra-high-molecular-weight polyethylene, or (iii) a mixture of 50% or less by mass of polypropylene and said mixture (i) or said polyethylene (ii), and a membrane-forming solvent to prepare a second polyolefin solution; (3) extruding said first and second polyolefin solutions through separate dies and immediately laminating them, such that said first polyolefin solution forms at least both surface layers, while said second polyolefin solution forms at least one layer between both surface layers; (4) cooling the resultant laminate to form a multi-layer, gel-like sheet; (5) stretching said multi-layer, gel-like sheet; (6) removing said membrane-forming solvent from the stretched multi-layer, gel-like sheet; and (7) stretching the resultant multi-layer, microporous membrane to 1.1-1.8 folds in at least one direction.

The third method for producing a multi-layer, microporous polyolefin membrane according to the present invention comprises the steps of (1) melt-blending a first polyolefin comprising (i) polypropylene, or (ii) a mixture of 50% or more by mass of polypropylene and a polyethylene resin, and a membrane-forming solvent to prepare a first polyolefin solution; (2) melt-blending a second polyolefin comprising (i) a mixture of 7% or less by mass of ultra-high-molecular-weight polyethylene having weight-average molecular weight of 1×10⁶ or more and the other polyethylene than said ultra-high-molecular-weight polyethylene, (ii) the other polyethylene than said ultra-high-molecular-weight polyethylene, or (iii) a mixture of 50% or less by mass of polypropylene and said mixture (i) or said polyethylene (ii), and a membrane-forming solvent to prepare a second polyolefin solution; (3) extruding said first and second polyolefin solutions through separate dies; (4) cooling the resultant extrudates to form first and second gel-like sheets; (5) stretching each gel-like sheet; (6) laminating the stretched first and second gel-like sheets, such that said stretched first gel-like sheet forms at least both surface layers, while said stretched second gel-like sheet forms at least one layer between both surface layers; (7) removing said membrane-forming solvent from the resultant multi-layer, gel-like sheet; and (8) stretching the resultant multi-layer, microporous membrane to 1.1-1.8 folds in at least one direction.

The fourth method for producing a multi-layer, microporous polyolefin membrane according to the present invention comprises the steps of (1) melt-blending a first polyolefin comprising (i) polypropylene, or (ii) a mixture of 50% or more by mass of polypropylene and a polyethylene resin, and a membrane-forming solvent to prepare a first polyolefin solution; (2) melt-blending a second polyolefin comprising (i) a mixture of 7% or less by mass of ultra-high-molecular-weight polyethylene having weight-average molecular weight of 1×10⁶ or more and the other polyethylene than said ultra-high-molecular-weight polyethylene, (ii) the other polyethylene than said ultra-high-molecular-weight polyethylene, or (iii) a mixture of 50% or less by mass of polypropylene and said mixture (i) or said polyethylene (ii), and a membrane-forming solvent to prepare a second polyolefin solution; (3) extruding said first and second polyolefin solutions through separate dies; (4) cooling the resultant extrudates to form first and second gel-like sheets; (5) stretching each gel-like sheet; (6) removing said membrane-forming solvent from each stretched gel-like sheet to form first and second microporous polyolefin membranes; (7) stretching at least said second microporous polyolefin membrane to 1.1-1.8 folds in at least one direction; and (8) laminating said first and second microporous polyolefin membranes, such that said first microporous polyolefin membrane forms at least both surface layers, while said second microporous polyolefin membrane forms at least one layer between both surface layers.

The battery separator of the present invention is formed by the above multi-layer, microporous polyolefin membrane.

The battery of the present invention comprises the above separator formed by the multi-layer, microporous polyolefin membrane.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a graph showing a typical pore diameter distribution curve.

FIG. 2 is a schematic view showing a method for measuring a meltdown temperature.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The multi-layer, microporous polyolefin membrane of the present invention comprises at least one first microporous layer made of a first polyolefin (polypropylene, or polypropylene+polyethylene resin), and at least one second microporous layer made of a second polyolefin [(i) 7% or less by mass of ultra-high-molecular-weight polyethylene having Mw of 1×10⁶ or more+the other polyethylene than said ultra-high-molecular-weight polyethylene, (ii) the other polyethylene than said ultra-high-molecular-weight polyethylene, (iii) 50% or less by mass of polypropylene+said mixture (i), or (iv) 50% or less by mass of polypropylene+said polyethylene (ii)]. In the case of the three or more layer structure, the multi-layer, microporous polyolefin membrane comprises the first microporous layers constituting both surface layers, and at least one second microporous layer disposed between both surface layers. Both surface layers may have the same or different compositions, though the same composition is preferable.

[1] Composition of a Multi-Layer, Microporous Polyolefin Membrane

(A) First Polyolefin

The first polyolefin comprises (1) polypropylene or (2) a mixture of 50% or more by mass of polypropylene and a polyethylene resin.

(1) Polypropylene

Polypropylene may be a propylene homopolymer or a copolymer of propylene and the other olefin, though the homopolymer is preferable. The copolymer may be a random or block copolymer. The other olefins than propylene include α-olefins such as ethylene, butene-1, pentene-1, hexene-1,4-methylpentene-1, octene-1, vinyl acetate, methyl methacrylate, styrene, etc., and diolefins such as butadiene, 1,5-hexadiene, 1,7-octadiene, 1,9-decadiene, etc. The percentage of the other olefin in the propylene copolymer is preferably in a range not deteriorating the properties of polypropylene such as heat resistance, compression resistance, heat shrinkage resistance, etc., specifically less than 10% by mol.

The weight-average molecular weight (Mw) of polypropylene is preferably 1×10⁴ to 4×10⁶, more preferably 3×10⁵ to 3×10⁶. The molecular weight distribution (Mw/Mn) of polypropylene is preferably 1.01-100, more preferably 1.1-50.

(2) Mixture of Polypropylene and Polyethylene Resin

The percentage of polypropylene is 50% or more by mass based on 100% by mass of the mixture. When it is less than 50% by mass, the multi-layer, microporous polyolefin membrane has low meltdown properties and electrolytic solution retention. This percentage is preferably 70% or more by mass, more preferably 80% or more by mass.

The polyethylene resin is (a) ultra-high-molecular-weight polyethylene, (b) the other polyethylene than the ultra-high-molecular-weight polyethylene, or (c) a polyethylene composition, a mixture of the ultra-high-molecular-weight polyethylene and the other polyethylene.

(a) Ultra-High-Molecular-Weight Polyethylene

The ultra-high-molecular-weight polyethylene has Mw of 1×10⁶ or more. The ultra-high-molecular-weight polyethylene may be an ethylene homopolymer, or an ethylene.α-olefin copolymer containing a small amount of the other α-olefin. The α-olefin other than ethylene is preferably propylene, butene-1, pentene-1, hexene-1,4-methylpentene-1, octene-1, vinyl acetate, methyl methacrylate, or styrene. The Mw of the ultra-high-molecular-weight polyethylene is preferably 1×10⁶ to 15×10⁶, more preferably 1×10⁶ to 5×10⁶, most preferably 1×10⁶ to 3×10⁶.

(b) Other Polyethylene than Ultra-High-Molecular-Weight Polyethylene

The other polyethylene than the ultra-high-molecular-weight polyethylene is preferably at least one selected from the group consisting of high-density polyethylene, medium-density polyethylene, branched low-density polyethylene, and linear low-density polyethylene, and its Mw is preferably 1×10⁴ to 5×10⁵. The more preferred polyethylene is high-density polyethylene, and its Mw is preferably 1×10⁵ to 5×10⁵, more preferably 2×10⁵ to 4×10⁵. The other polyethylene than the ultra-high-molecular-weight polyethylene may be an ethylene homopolymer, or a copolymer containing a small amount of the other α-olefin such as propylene, butene-1, hexene-1, etc. Such copolymer is preferably produced using a single-site catalyst.

(c) Polyethylene Composition

The polyethylene composition is a mixture comprising the above ultra-high-molecular-weight polyethylene and the other polyethylene. The molecular weight distribution (weight-average molecular weight Mw/number-average molecular weight Mn) of this polyethylene composition is preferably controlled depending on applications.

(d) Molecular Weight Distribution Mw/Mn

Mw/Mn is a measure of a molecular weight distribution; the larger this value, the wider the molecular weight distribution. Though not restricted, the Mw/Mn of the polyethylene resin is preferably 5-300, more preferably 5-100, most preferably 5-30. When the Mw/Mn is less than 5, the percentage of a high-molecular-weight component is too high to conduct melt extrusion easily. On the other hand, when the Mw/Mn is more than 300, the percentage of a low-molecular-weight component is too high, resulting in decrease in the strength of the microporous membrane. The Mw/Mn of polyethylene (homopolymer or an ethylene.α-olefin copolymer) can be properly controlled by a multi-stage polymerization. The multi-stage polymerization method is preferably a two-stage polymerization method comprising forming a high-molecular-weight polymer component in the first stage, and forming a low-molecular-weight polymer component in the second stage. In the case of the polyethylene composition, the larger the Mw/Mn, the larger difference in Mw exists between the ultra-high-molecular-weight polyethylene and the other polyethylene, and vice versa. The Mw/Mn of the polyethylene composition can be properly controlled by the molecular weights and mixing ratios of components.

(B) Second Polyolefin

A second polyolefin comprises (i) a mixture of 7% or less by mass of ultra-high-molecular-weight polyethylene having weight-average molecular weight of 1×10⁶ or more and the other polyethylene than said ultra-high-molecular-weight polyethylene (polyethylene composition), (ii) the other polyethylene than said ultra-high-molecular-weight polyethylene, or (iii) a mixture of 50% or less by mass of polypropylene and said mixture (i) or said polyethylene (ii).

(1) Other Polyethylene than Ultra-High-Molecular-Weight Polyethylene

The other polyethylene than the ultra-high-molecular-weight polyethylene may be the same as described above. It is preferably high-density polyethylene.

(2) Polyethylene Composition

The polyethylene composition may be the same as the mixture (polyethylene composition) for the first polyolefin, except that the percentage of the ultra-high-molecular-weight polyethylene is 7% or less by mass. When the percentage of the ultra-high-molecular-weight polyethylene is more than 7% by mass, the later-described hybrid structure is not formed.

The Mw/Mn of the above polyethylene (1) and the above polyethylene composition (2) may be the same as described above.

(3) Polypropylene

The percentage of polypropylene is 50% or less by mass based on 100% by mass of the second polyolefin. When it is more than 50% by mass, the multi-layer, microporous polyolefin membrane has low electrolytic solution absorbability. The percentage of polypropylene is preferably 30% or less by mass, more preferably 20% or less by mass, most preferably 15% or less by mass.

(C) Other Components

In addition to the above components, the polyolefin may contain the other polyolefins than the above polyethylene resin and polypropylene, or heat-resistant resins having melting points or glass transition temperatures (Tg) of 170° C. or higher, in amounts not deteriorating the properties of the microporous membrane.

(a) Other Polyolefins

The other polyolefins than the above polyethylene resin and polypropylene may be at least one selected from the group consisting of (a) polybutene-1, polypentene-1, poly-4-methylpentene-1, polyhexene-1, polyoctene-1, polyvinyl acetate, polymethyl methacrylate, polystyrene and an ethylene.α-olefin copolymer, each of which may have Mw of 1×10⁴ to 4×10⁶, and (b) a polyethylene wax having Mw of 1×10³ to 1×10⁴. Polybutene-1, polypentene-1, poly-4-methylpentene-1, polyhexene-1, polyoctene-1, polyvinyl acetate, polymethyl methacrylate and polystyrene are not restricted to homopolymers, but may be copolymers containing other α-olefins.

(b) Heat-Resistant Resins

The heat-resistant resins are preferably crystalline resins having melting points of 170° C. or higher, which may be partially crystalline, and amorphous resins having Tg of 170° C. or higher. The melting point and Tg are determined by differential scanning calorimetry (DSC) according to JIS K7121. Specific examples of the heat-resistant resins include polyesters such as polybutylene terephthalate (melting point: about 160-230° C.), polyethylene terephthalate (melting point: about 250-270° C.), etc., fluororesins, polyamides (melting point: 215-265° C.), polyarylene sulfide, polyimides (Tg: 280° C. or higher), polyamideimides (Tg: 280° C.), polyether sulfone (Tg: 223° C.), polyetheretherketone (melting point: 334° C.), polycarbonates (melting point: 220-240° C.), cellulose acetate (melting point: 220° C.), cellulose triacetate (melting point: 300° C.), polysulfone (Tg: 190° C.), polyetherimide (melting point: 216° C.), etc.

[2] Production Method of Multi-Layer, Microporous Polyolefin Membrane

(A) First Production Method

The first method for producing a multi-layer, microporous polyolefin membrane comprises the steps of (1) melt-blending a first polyolefin with a membrane-forming solvent to prepare a first polyolefin solution, (2) melt-blending a second polyolefin with a membrane-forming solvent to prepare a second polyolefin solution, (3) simultaneously extruding the first and second polyolefin solutions through a die, (4) cooling the resultant extrudate to form a multi-layer, gel-like sheet, (5) stretching the multi-layer, gel-like sheet, (6) removing the membrane-forming solvent from the multi-layer, gel-like sheet, (7) drying the resultant multi-layer, microporous membrane, and (8) stretching the multi-layer, microporous membrane. After the step (8), if necessary, a heat treatment step (9), a step (10) of cross-linking with ionizing radiations, a hydrophilizing treatment step (11), etc. may be conducted.

(1) Preparation of First Polyolefin Solution

The first polyolefin is melt-blended with a membrane-forming solvent to prepare the first polyolefin solution. The first polyolefin solution may contain various additives such as an antioxidant, ultraviolet absorbers, antiblocking agents, pigments, dyes, inorganic fillers, pore-forming agents such as fine silicate powder, etc. in a range not deteriorating the effects of the present invention, if necessary.

The membrane-forming solvent is preferably liquid at room temperature. The use of a liquid solvent makes it possible to conduct stretching at a relatively high magnification. The liquid solvents may be aliphatic, alicyclic or aromatic hydrocarbons such as nonane, decane, decalin, p-xylene, undecane, dodecane, liquid paraffin, etc., mineral oil distillates having boiling points comparable to those of the above hydrocarbons, and phthalates liquid at room temperature such as dibutyl phthalate, dioctyl phthalate, etc. To obtain a multi-layer, gel-like sheet having a stable liquid solvent content, it is preferable to use non-volatile liquid solvents such as liquid paraffin. A solvent which is miscible with polyethylene in a melt-blended state but solid at room temperature may be used instead of or with the liquid solvent. Such solid solvent includes stearyl alcohol, ceryl alcohol, paraffin waxes, etc. However, when only a solid solvent is used, uneven stretching, etc. are likely to occur.

The viscosity of the liquid solvent is preferably 30-500 cSt, more preferably 30-200 cSt, at 25° C. When the viscosity at 25° C. is less than 30 cSt, the polyolefin solution is easily foamed, resulting in difficulty in blending. On the other hand, when the viscosity is more than 500 cSt, the removal of the liquid solvent is difficult.

Though not particularly restricted, the uniform melt-blending of the first polyolefin solution is preferably conducted in a double-screw extruder to achieve a high concentration. The membrane-forming solvent may be added before starting melt-blending, or supplied to the double-screw extruder in an intermediate portion during blending, though the latter is preferable.

The melt-blending temperature of the first polyolefin solution is preferably in a range from the melting point Tm₁ of the polypropylene to Tm₁+80° C. Because the polypropylene has a melting point of about 155-175° C., the melt-blending temperature is preferably 160-250° C., more preferably 170-240° C.

A ratio L/D of the screw length L to the screw diameter D in the double-screw extruder is preferably in a range of 20-100, more preferably in a range of 35-70. When L/D is less than 20, melt-blending is insufficient. When L/D is more than 100, the residing time of the polyolefin solution in the double-screw extruder is too long. The cylinder of the double-screw extruder preferably has an inner diameter of 40-100 mm.

The concentration of the first polyolefin solution is preferably 10-75% by mass, more preferably 20-70% by mass. When the concentration is less than 10% by mass, productivity is low, and large swelling or neck-in occurs at the die exit during extrusion, resulting in decrease in the formability and self-supportability of the multi-layer, gel-like sheet. On the other hand, when the concentration is more than 75% by mass, the formability of the multi-layer, gel-like sheet is deteriorated.

(2) Preparation of Second Polyolefin Solution

The second polyolefin is melt-blended with a membrane-forming solvent to prepare a second polyolefin solution. Because conditions other than described below may be the same as in the preparation of the first polyolefin solution, their explanation will be omitted. The solvent used in the second polyolefin solution may be the same as or different from the solvent used in the first polyolefin solution. Preferably, the same solvent is used.

The melt-blending temperature of the second polyolefin solution is preferably in a range of the melting point Tm₂ of the polyethylene resin contained in the second polyolefin (the other polyethylene than the ultra-high-molecular-weight polyethylene or the polyethylene composition)+10° C. to Tm₂+120° C. Specifically, the melt-blending temperature is preferably 140-250° C., more preferably 170-240° C., because the other polyethylene than the ultra-high-molecular-weight polyethylene and the polyethylene composition have melting points of about 130-140° C.

To obtain a good hybrid structure, the concentration of the second polyolefin solution is preferably 25-50% by mass, more preferably 25-45% by mass.

(3) Extrusion

The first and second polyolefin solutions are supplied from their extruders to a die, combined in a laminar form therein, and simultaneously extruded therefrom in a sheet form. In the case of producing the three or more layer, microporous membrane, the first and second polyolefin solutions are combined in a laminar form, such that the first polyolefin solution forms at least both surface layers, while the second polyolefin solution forms at least one layer between the surface layers, and simultaneously extruded in a sheet form.

Any of a flat die method and an inflation method may be used for the extrusion. Usable in any method is a multi-manifold method, in which the solutions are supplied to separate manifolds and laminated at a lip inlet of a multi-layer extrusion die, or a block method, in which solutions are combined to a laminar flow in advance and supplied to a die. Because the multi-manifold method and the block method per se are known, their detailed explanations will be omitted. The multi-layer-sheet-forming flat die preferably has a gap of 0.1-5 mm. The extrusion temperature is preferably 140-250° C., and the extruding speed is preferably 0.2-15 m/minute. The thickness ratio of the first microporous layer to the second microporous layer can be controlled by adjusting the amounts of the first and second polyolefin solutions extruded.

(4) Formation of Multi-Layer, Gel-Like Sheet

The resultant laminar extrudate is cooled to form a multi-layer, gel-like sheet. Cooling is preferably conducted at least to a gelation temperature at a speed of 50° C./minute or more. Cooling is preferably conducted to 25° C. or lower. Such cooling sets the micro-phases of the first and second polyolefins separated by the membrane-forming solvent. Generally, the slower cooling speed provides the multi-layer, gel-like sheet with larger pseudo-cell units, resulting in a coarser higher-order structure. On the other hand, the higher cooling speed results in denser cell units. The cooling speed less than 50° C./minute leads to increased crystallinity, making it unlikely to provide the multi-layer, gel-like sheet with suitable stretchability. Usable as the cooling method are a method of bringing the extrudate into contact with a cooling medium such as cooling air, cooling water, etc., a method of bringing the extrudate into contact with cooling rolls, etc.

(5) Stretching of Multi-Layer, Gel-Like Sheet

The multi-layer, gel-like sheet is stretched in at least one direction. The multi-layer, gel-like sheet can be uniformly stretched because it contains the membrane-forming solvent. The multi-layer, gel-like sheet is preferably stretched to a predetermined magnification after heated, by a tenter method, a roll method, an inflation method or a combination thereof. The stretching may be conducted monoaxially or biaxially, though the biaxial stretching is preferable. In the case of biaxial stretching, any of simultaneous biaxial stretching, sequential stretching or multi-stage stretching (for instance, a combination of the simultaneous biaxial stretching and the sequential stretching) may be used, though the simultaneous biaxial stretching is preferable.

The stretching magnification is preferably 2 folds or more, more preferably 3-30 folds in the case of monoaxial stretching. In the case of biaxial stretching, the stretching magnification is preferably 3 folds or more in any direction, namely 9 folds or more, more preferably 16 folds or more, most preferably 25 folds or more, in area magnification. With the area magnification of 9 folds or more, the pin puncture strength of the multi-layer, microporous membrane is improved. When the area magnification is more than 400 folds, stretching apparatuses, stretching operations, etc. are restricted.

To obtain a good hybrid structure, the stretching temperature is preferably in a range of the crystal dispersion temperature Tcd₂ of the other polyethylene than ultra-high-molecular-weight polyethylene or the polyethylene composition in the second polyolefin to Tcd₂+25° C., more preferably in a range of Tcd₂+10° C. to Tcd₂+25° C., most preferably in a range of Tcd₂+15° C. to Tcd₂+25° C. When the stretching temperature is lower than Tcd₂, the polyethylene resin is so insufficiently softened that the multi-layer, gel-like sheet is easily broken by stretching, failing to achieve high-magnification stretching.

The “crystal dispersion temperature” is determined by measuring the temperature characteristics of the dynamic viscoelasticity of the polyethylene resin according to ASTM D 4065. Because the ultra-high-molecular-weight polyethylene, the other polyethylene than the ultra-high-molecular-weight polyethylene, and the first and second polyethylene compositions have crystal dispersion temperatures of about 90-100° C., the stretching temperature is usually 90-125° C., preferably 100-125° C., more preferably 105-125° C.

The above stretching causes cleavage between polyethylene lamellas and polypropylene lamellas, making the polyethylene phases and polypropylene phases finer and forming large numbers of fibrils. The fibrils form a three-dimensional network structure. The stretching improves the mechanical strength of the microporous membrane and expands its pores, making the multi-layer, microporous membrane particularly suitable for battery separators.

Depending on the desired properties, stretching may be conducted with a temperature distribution in a thickness direction, to provide the multi-layer, microporous membrane with further improved mechanical strength. The detailed description of this method is given by Japanese Patent 3347854.

(6) Removal of Membrane-Forming Solvent

For the purpose of removing (washing away) the membrane-forming solvent, a washing solvent is used. Because the first and second polyolefin phases are separated from a membrane-forming solvent phase, the removal of the membrane-forming solvent provides a porous membrane constituted by fibrils forming a fine three-dimensional network structure and having pores communicating three-dimensionally and irregularly. Suitable washing solvents include, for instance, volatile solvents such as saturated hydrocarbons such as pentane, hexane, heptane, etc., chlorinated hydrocarbons such as methylene chloride, carbon tetrachloride, etc., ethers such as diethyl ether, dioxane, etc., ketones such as methyl ethyl ketone, etc., linear fluorocarbons such as trifluoroethane, C₆F₁₄, C₇F₁₆, etc., cyclic hydrofluorocarbons such as C₅H₃F₇, etc., hydrofluoroethers such as C₄F₉OCH₃, C₄F₉OC₂H₅, etc., perfluoroethers such as C₄F₉OCF₃, C₄F₉OC₂F₅, etc.

The washing of the multi-layer, gel-like sheet can be conducted by immersion in the washing solvent and/or the showering of the washing solvent. The washing solvent used is preferably 300-30,000 parts by mass per 100 parts by mass of the membrane. The washing temperature is usually 15-30° C., and if necessary, heating may be conducted during washing. The heating temperature during washing is preferably 80° C. or lower. Washing is preferably conducted until the amount of the remaining liquid solvent becomes less than 1% by mass of that added.

(7) Drying

The multi-layer, microporous membrane deprived of the membrane-forming solvent is dried by a heat-drying method, a wind-drying method, etc. The drying temperature is preferably equal to or lower than Tcd₂, particularly 5° C. or more lower than Tcd₂. Drying is conducted until the remaining washing solvent becomes preferably 5% or less by mass, more preferably 3% or less by mass, per 100% by mass (on a dry basis) of the multi-layer, microporous membrane. Insufficient drying undesirably leads to decrease in the porosity of the multi-layer, microporous membrane by the subsequent stretching and heat treatment, resulting in poor permeability.

(8) Stretching of Multi-Layer, Microporous Membrane

The dried multi-layer, microporous membrane is stretched (re-stretched) at least monoaxially. The stretching of the multi-layer, microporous membrane can be conducted while heating, by a tenter method, etc. like above. The stretching may be monoaxial or biaxial. In the case of biaxial stretching, any one of simultaneous biaxial stretching or sequential stretching may be used, though the simultaneous biaxial stretching is preferable. Incidentally, because the re-stretching is usually conducted on the multi-layer, microporous membrane in a long sheet form, which is obtained from the stretched multi-layer, gel-like sheet, the directions of MD and TD in the re-stretching is the same as those in the stretching of the multi-layer, gel-like sheet. This is true in other production methods.

The stretching temperature of the multi-layer, microporous membrane is preferably the melting point Tm₂ or lower, more preferably in a range of Tcd₂ to Tm₂. When the stretching temperature is higher than Tm₂, a melt viscosity is too low to conduct good stretching, resulting in low permeability. When the stretching temperature is lower than Tcd₂, the first and second polyolefins are insufficiently softened, so that the membrane is likely to be broken by stretching, failing to achieve uniform stretching. Specifically, the stretching temperature is usually 90-135° C., preferably 95-130° C.

The monoaxial stretching magnification of the multi-layer, microporous membrane is preferably 1.1-1.8 folds. In the case of monoaxial stretching, it is 1.1-1.8 folds in a longitudinal or transverse direction. In the case of biaxial stretching, the multi-layer, microporous membrane may be stretched at the same or different magnifications, though preferably the same, as long as the stretching magnifications in both directions are within 1.1-1.8 folds.

With the multi-layer, microporous membrane stretched to 1.1-1.8 folds, the second polyolefin layer has a hybrid structure having a large average pore diameter. Because the percentage of polypropylene is 50% or more by mass in the first polyolefin layer, the first polyolefin layer is not provided with a large average pore diameter unlike the second polyolefin layer, even if it is stretched to 1.1-1.8 folds.

When the stretching magnification of the multi-layer, microporous membrane is less than 1.1 folds, the second microporous layer does not have a hybrid structure, resulting in poor permeability, electrolytic solution absorption and electrolytic solution retention. When this magnification is more than 1.8 folds, too fine fibrils are formed, and the heat shrinkage resistance and the electrolytic solution retention are reduced. This stretching magnification is more preferably 1.2-1.6 folds.

(9) Heat Treatment

The dried multi-layer, microporous membrane is preferably heat-treated. The heat treatment stabilizes crystals, resulting in uniform lamella layers. The heat treatment may comprise heat-setting and/or annealing. The heat-setting is preferably conducted by a tenter method or a roll method. The heat-setting temperature is preferably in a range from Tcd₂ to Tm₂, more preferably in a range of the stretching (re-stretching) temperature of the multi-layer, microporous membrane ±5° C., most preferably in a range of the stretching temperature of the multi-layer, microporous membrane ±3° C.

The annealing is a heat treatment with no load applied to the multi-layer, microporous membrane, and may be conducted by using a heating chamber with a belt conveyer or an air-floating-type heating chamber. The annealing may be conducted continuously after the heat-setting with the tenter slackened. The annealing temperature is preferably Tm₂ or lower, more preferably in a range from 60° C. to Tm₂−5° C. Such annealing provides the multi-layer, microporous membrane with high permeability and strength.

(10) Cross-Linking

The multi-layer, microporous membrane may be cross-linked by ionizing radiation rays such as α-rays, β-rays, γ-rays, electron beams, etc. In the case of irradiating electron beams, the amount of electron beams is preferably 0.1-100 Mrad, and the accelerating voltage is preferably 100-300 kV. The cross-linking treatment elevates the meltdown temperature of the multi-layer, microporous membrane.

(11) Hydrophilizing Treatment

The multi-layer, microporous membrane may be subjected to a hydrophilizing treatment (treatment of imparting hydrophilic property). The hydrophilizing treatment may be a monomer-grafting treatment, a surfactant treatment, a corona-discharging treatment, etc. The monomer-grafting treatment is preferably conducted after the cross-linking treatment.

In the case of the surfactant treatment, any of nonionic surfactants, cationic surfactants, anionic surfactants and amphoteric surfactants may be used, and the nonionic surfactants are preferred. The multi-layer, microporous membrane is dipped in a solution of the surfactant in water or a lower alcohol such as methanol, ethanol, isopropyl alcohol, etc., or coated with the solution by a doctor blade method.

(B) Second Production Method

The second method for producing a multi-layer, microporous polyolefin membrane comprises the steps of (1) melt-blending a first polyolefin and a membrane-forming solvent to prepare a first polyolefin solution, (2) melt-blending a second polyolefin and a membrane-forming solvent to prepare a second polyolefin solution, (3) extruding said first and second polyolefin solutions through separate dies and immediately laminating them, (4) cooling the resultant laminate to form a multi-layer, gel-like sheet, (5) stretching the multi-layer, gel-like sheet, (6) removing the membrane-forming solvent from the multi-layer, gel-like sheet, (7) drying the resultant multi-layer, microporous membrane, and (8) stretching the multi-layer, microporous membrane. After the step (8), if necessary, a heat treatment step (9), a step (10) of cross-linking with ionizing radiations, a hydrophilizing treatment step (11), etc. may be conducted.

Because the second method is the same as the first method except for the step (3), only the step (3) will be explained. The first and second polyolefin solutions are extruded in a sheet form through adjacent dies each connected to each of plural extruders, and immediately laminated while each solution is hot (for example, 100° C. or more). The other conditions may be the same as in the first method.

(C) Third Production Method

The third method for producing a multi-layer, microporous polyolefin membrane comprises the steps of (1) melt-blending a first polyolefin and a membrane-forming solvent to prepare a first polyolefin solution, (2) melt-blending a second polyolefin and a membrane-forming solvent to prepare a second polyolefin solution, (3) extruding the first polyolefin solution through one die to form a first extrudate, (4) extruding the second polyolefin solution through another die to form a second extrudate, (5) cooling both of the resultant first and second extrudates to form first and second gel-like sheets, (6) stretching each of the first and second gel-like sheets, (7) laminating the stretched first and second gel-like sheets, (8) removing the membrane-forming solvent from the resultant multi-layer, gel-like sheet, (9) drying the resultant multi-layer, microporous membrane, and (10) stretching the multi-layer, microporous membrane. Between the steps (7) and (8), a step (11) of stretching the multi-layer, gel-like sheet, etc. may be conducted. After the step (10), a heat treatment step (12), a step (13) of cross-linking with ionizing radiations, a hydrophilizing treatment step (14), etc. may be conducted.

The steps (1) and (2) may be the same as in the first method, the steps (3) and (4) may be the same as in the first method except for extruding each of the first and second polyolefin solutions from a separate die, the step (5) may be the same as in the first method except for cooling the first and second gel-like sheets separately, the step (6) may be the same as in the first method except for stretching the first and second gel-like sheets separately, and the step (8)-(10) may be the same as in the first method. The steps (11)-(14) may be the same as described above. In the stretching step (6), the stretching temperature of the first gel-like sheet is preferably Tm₁ or lower, more preferably the crystal dispersion temperature Tcd₁ of the first polyolefin resin or higher and lower than Tm₁.

The polypropylene has a crystal dispersion temperature of about 100-110° C.

The step (7) of laminating the stretched first and second gel-like sheets will be explained below. In the case of producing the three or more layer, microporous membrane, the stretched first and second gel-like sheets are laminated, such that at least both surface layers are constituted by the stretched first gel-like sheet, while at least one layer between both surface layers is constituted by the stretched second gel-like sheet. The lamination method is not particularly restricted, but it is preferably a hot lamination method. The hot lamination method includes a heat-sealing method, an impulse sealing method, an ultrasonic lamination method, etc., and the heat-sealing method is preferable. Preferable as the heat-sealing method is a heat roll method, which heat-seals the overlapped first and second gel-like sheets through a pair of heat rolls. To fully bond the gel-like sheets, the heat-sealing temperature is preferably 90-135° C., more preferably 90-115° C., and the heat-sealing pressure is preferably 0.01-50 MPa. The thickness ratio of the first microporous layer to the second microporous layer can be controlled by adjusting the thickness of the first and second gel-like sheets. Stretching may be conducted while laminating, for instance, by passing the gel-like sheets through multi-stages of heat rolls.

(D) Fourth Production Method

The fourth method for producing a multi-layer, microporous polyolefin membrane comprises the steps of (1) melt-blending a first polyolefin and a membrane-forming solvent to prepare a first polyolefin solution, (2) melt-blending a second polyolefin and a membrane-forming solvent to prepare a second polyolefin solution, (3) extruding the first polyolefin solution through one die, (4) extruding the second polyolefin solution through another die, (5) cooling both of the resultant extrudates to form first and second gel-like sheets, (6) stretching each of the first and second gel-like sheets, (7) removing the membrane-forming solvent from each of the stretched first and second gel-like sheets, (8) drying each of the resultant first and second microporous polyolefin membranes, (9) stretching at least the second microporous polyolefin membrane, and (10) laminating the first and second microporous polyolefin membranes. If necessary, a heat treatment step (11) may be conducted between the steps (8) and (9). After the step (10), a step (12) of stretching the multi-layer, microporous membrane, a heat treatment step (13), a step (14) of cross-linking with ionizing radiations, a hydrophilizing treatment step (15), etc. may be conducted.

The steps (1) and (2) may be the same as in the first method, the steps (3) and (4) may be the same as in the first method except for extruding each of the first and second polyolefin solutions from a separate die, the step (5) may be the same as in the first method except for forming the first and second gel-like sheets separately, the step (6) may be the same as in the third method, the step (7) may be the same as in the first method except for removing the membrane-forming solvent from each gel-like sheet, and the step (8) may be the same as in the first method except for drying the microporous membranes separately. The steps (12)-(15) may be the same as described above.

In the step (9), at least the second microporous polyolefin membrane is stretched. Its stretching temperature is preferably Tm₂ or lower, more preferably Tcd₂ to Tm₂. If necessary, the first microporous polyolefin membrane may be stretched. Its stretching temperature is preferably Tm₁ or lower, more preferably Tcd₁ to Tm₁. In any case of stretching the first and second microporous polyolefin membranes, the stretching magnification may be the same as in the first method.

In the step (10), in the case of producing the three or more layer, microporous membrane, the first and second microporous membranes are laminated, such that at least both surface layers are constituted by the first microporous polyolefin membrane, and that at least one layer between both surface layers is constituted by the stretched second microporous polyolefin membrane. The lamination method is preferably a hot lamination method, more preferably a heat-sealing method. The heat-sealing temperature is preferably 90-135° C., more preferably 90-115° C. The heat-sealing pressure is preferably 0.01-50 MPa. Stretching may be conducted while laminating, for instance, by passing the gel-like sheets through multi-stages of heat rolls.

In the heat treatment step (11), the heat-setting temperature of the first microporous membrane is preferably Tm₁ or lower, more preferably Tcd₁ to (Tm₁−10° C.). The annealing temperature of the first microporous membrane is preferably Tm₁ or lower, more preferably 60° C. to (Tm₁−5° C.). The heat-setting temperature of the second microporous membrane is preferably Tcd₂ to Tm₂, more preferably the stretching temperature ±5° C., most preferably the stretching temperature ±3° C. The annealing temperature of the second microporous membrane is preferably Tm₂ or lower, more preferably 60° C. to (Tm₂−5° C.).

[3] Structure and Properties of Multi-Layer, Microporous Polyolefin Membrane

(A) First Microporous Layer

(1) Average Pore Diameter

The average pore diameter of the first microporous layer is 0.005-0.1 μm, preferably 0.01-0.05 μm.

(2) Number of Layers

In the case of the three or more layer structure, the first microporous layers need only constitute at least both surface layers. In the case of the four or more layer structure, the multi-layer, microporous polyolefin membrane may have three or more first microporous layers, if necessary. For instance, a first microporous layer having a different composition than that of both surface layers may be provided between both surface layers.

(3) Function of First Microporous Layer

With both surface layers constituted by the first microporous layer, the multi-layer, microporous polyolefin membrane is provided with high mechanical strength, meltdown properties and electrolytic solution retention.

(B) Second Microporous Layer

(1) Average Pore Diameter

The average pore diameter of the second microporous layer is 0.02-0.5 μm, preferably 0.02-0.1 μm.

(2) Structure

As shown in FIG. 1, the second microporous layer has a hybrid structure that its pore diameter distribution curve obtained by mercury intrusion porosimetry has at least two peaks, a main peak in a pore diameter range of 0.01-0.08 μm, and at least one sub-peak in a pore diameter range of more than 0.08 μm and 1.5 μm or less. The main peak represents dense domains, and the sub-peaks represent coarse domains. The second microporous layer has a larger average pore diameter than the first microporous layer because of the existence of the coarse structure. The hybrid structure is derived from the above other polyethylene than ultra-high-molecular-weight polyethylene or the polyethylene composition (mixture of 7% or less by mass of the ultra-high-molecular-weight polyethylene and the other polyethylene). When the percentage of the ultra-high-molecular-weight polyethylene is more than 7% by mass, the hybrid structure is not formed, resulting in poor electrolytic solution absorption.

In a preferred example of the second microporous layer, the dense domains have a main peak (first peak) at a pore diameter of about 0.04-0.07 μm, and the coarse domains have at least a second peak at pore diameter of about 0.1-0.11 μm, a third peak at a pore diameter of about 0.7 μm, and a fourth peak at a pore diameter of about 1-1.1 μm. The sub-peaks need not have the third and fourth peaks. FIG. 1 shows an example of the measured pore diameter distribution curve. In this example, the first to fourth peaks are located at about 0.06 μm, about 0.1 μm, about 0.7 μm, and about 1.1 μm, respectively.

The pore volume ratio of the dense domains to the coarse domains is determined by S₁ and S₂ shown in FIG. 1. A hatched area S₁ on the smaller diameter side than a vertical line L₁ passing the first peak corresponds to the pore volume of the dense domains, and a hatched area S₂ on the larger diameter side than a vertical line L₂ passing the second peak corresponds to the pore volume of the coarse domains. The pore volume ratio S₁/S₂ of the dense domains to the coarse domains is preferably 0.5-49, more preferably 0.6-10, most preferably 0.7-2.

Though not restricted, dense domains and coarse domains are irregularly entangled to form a hybrid structure in any cross sections of the second microporous layer viewed in longitudinal and transverse directions. The hybrid structure can be observed by a transmission electron microscope (TEM), etc.

(3) Number of Layers

In the case of the three or more layer structure, the multi-layer, microporous polyolefin membrane may have at least one second microporous layer. In the case of the four or more layer structure, the multi-layer, microporous polyolefin membrane may have pluralities of second microporous layers, if necessary. Pluralities of second microporous layers may have different compositions.

(4) Function of Second Microporous Layer

The second microporous layer has a larger average pore diameter than that of the first microporous layer. Accordingly, when there is at least one second microporous layer between both surface layers, the multi-layer, microporous polyolefin membrane has high permeability and electrolytic solution absorption.

(C) Average Pore Diameter Ratio

The average pore diameter ratio of the first microporous layer to the second microporous layer is preferably more than 1/1 to 10/1 or less, more preferably 1.5/1-5/1.

(D) Arrangement and Ratio of First and Second Microporous Layers

The arrangement of the first and second microporous layers in the multi-layer, microporous polyolefin membrane is divided roughly into (i) a two-layer structure of the first microporous layer and the second microporous layer, and (ii) a three or more layer structure of first microporous layers constituting both surface layers, and at least one second microporous layer disposed between both surface layers. As described above, in the case of the three or more layer structure, as long as at least one second microporous layer is disposed between both surface layers, in addition, one or both of the first and second microporous layers may be disposed between both surface layers. In the case of disposing plural microporous layers between both surface layers, the arrangement of the plural microporous layers is not particularly restricted. Though not restrictive, the multi-layer, microporous polyolefin membrane preferably has a three-layer structure of first microporous layer/second microporous layer/first microporous layer.

The total thickness of the first microporous layers (the thickness of the first microporous layer in the case of the two layer structure) is preferably 15-60% per 100% of the total thickness of the first and second microporous layers. When this ratio is less than 15%, the multi-layer, microporous polyolefin membrane has low meltdown properties. When it is more than 60%, the multi-layer, microporous polyolefin membrane has low permeability, electrolytic solution absorption and electrolytic solution retention. This ratio is more preferably 15-50%. In the case of the three-layer structure, the thickness ratio of first microporous layer/second microporous layer/first microporous layer is preferably 0.08/0.84/0.08 to 0.3/0.4/0.3, more preferably 0.1/0.8/0.1 to 0.25/0.5/0.25.

(E) Properties

The above multi-layer, microporous polyolefin membrane has the following properties.

(1) Air Permeability of 20-400 Seconds/100 cm³ (Converted to the Value at 20-μm Thickness)

When the air permeability measured according to JIS P8117 is 20-400 seconds/100 cm³, batteries with separators formed by the multi-layer, microporous membrane have large capacity and good cyclability. When the air permeability is less than 20 seconds/100 cm³, shutdown does not sufficiently occur when the temperatures inside the batteries are elevated. Air permeability P₁ measured on a multi-layer, microporous membrane having a thickness T₁ according to JIS P8117 is converted to air permeability P₂ at a thickness of 20 μm by the equation of P₂=(P₁×20)/T₁.

(2) Porosity of 25-80%

When the porosity is less than 25%, the multi-layer, microporous membrane does not have good air permeability. When the porosity exceeds 80%, battery separators formed by the multi-layer, microporous membrane have insufficient strength, resulting in large likelihood of the short-circuiting of electrodes.

(3) Pin Puncture Strength of 2,000 Mn or More (Converted to the Value at 20-μm Thickness)

The pin puncture strength (converted to the value at 20-μm thickness) of the multi-layer, microporous membrane is represented by the maximum load measured when the multi-layer, microporous membrane is pricked with a needle of 1 mm in diameter with a spherical end surface (radius R of curvature: 0.5 mm) at a speed of 2 mm/second. When the pin puncture strength is less than 2,000 mN/20 μm, short-circuiting is likely to occur in batteries with separators formed by the multi-layer, microporous membrane.

(4) Tensile Rupture Strength of 49,000 kPa or More

With tensile rupture strength of 49,000 kPa or more in both longitudinal and transverse directions according to ASTM D882, the multi-layer, microporous polyolefin membrane is unlikely to be broken when used as a battery separator. The tensile rupture strength is preferably 80,000 kPa or more.

(5) Heat Shrinkage Ratio of 12% or Less

When the heat shrinkage ratio after exposed to 105° C. for 8 hours exceeds 12% in both longitudinal and transverse directions, heat generated in batteries with separators formed by the multi-layer, microporous membrane causes the shrinkage of the separators, making it highly likely that short-circuiting occurs on the edges of the separators.

(6) Meltdown Temperature of 150° C. or Higher

The meltdown temperature of the multi-layer, microporous polyolefin membrane is 150° C. or higher, preferably 150-190° C. The meltdown temperature is determined as follows: As shown in FIG. 2, a test piece TP having a size of 3 mm and 10 mm in the stretching directions MD and TD, respectively, is cut out of a multi-layer, microporous polyolefin membrane 1, and the test piece TP is heated from room temperature at a speed of 5° C./minute, with its upper end 1a gripped by a holder 2 and a weight 3 of 2 g attached to its lower end 1b. A temperature at which the test piece TP elongates by 50% of its length (100%) at room temperature is defined as the meltdown temperature.

[4] Battery Separator

The battery separator formed by the above multi-layer, microporous polyolefin membrane preferably has a thickness of 3-200 μm, more preferably 5-50 μm, most preferably 10-35 μm, though properly selectable depending on the types of batteries.

[5] Battery

The multi-layer, microporous polyolefin membranes of the present invention may be used as separators for secondary batteries such as lithium ion secondary batteries, lithium-polymer secondary batteries, nickel-hydrogen secondary batteries, nickel-cadmium secondary batteries, nickel-zinc secondary batteries, silver-zinc secondary batteries, particularly for lithium ion secondary batteries. Explanations will be made below on the lithium ion secondary batteries. However, the invention is not limited to lithium-ion secondary batteries.

The lithium secondary battery comprises a cathode and an anode laminated via a separator, and the separator contains an electrolytic solution (electrolyte). The electrode may have a known structure, not particularly restricted. The electrode structure may be, for instance, a coin type in which disc-shaped cathode and anode are opposing, a laminate type in which planar cathode and anode are alternately laminated, a toroidal type in which ribbon-shaped cathode and anode are wound, etc.

The cathode usually comprises a current collector, and a cathodic active material layer capable of absorbing and discharging lithium ions, which is formed on the current collector. The cathodic active materials may be inorganic compounds such as transition metal oxides, composite oxides of lithium and transition metals (lithium composite oxides), transition metal sulfides, etc. The transition metals may be V, Mn, Fe, Co, Ni, etc. Preferred examples of the lithium composite oxides are lithium nickelate, lithium cobaltate, lithium manganate, laminar lithium composite oxides based on α-NaFeO₂, etc. The anode comprises a current collector, and a negative-electrode active material layer formed on the current collector. The negative-electrode active materials may be carbonaceous materials such as natural graphite, artificial graphite, cokes, carbon black, etc.

The electrolytic solutions are obtained by dissolving lithium salts in organic solvents. The lithium salts may be LiClO₄, LiPF₆, LiAsF₆, LiSbF₆, LiBF₄, LiCF₃SO₃, LiN(CF₃SO₂)₂, LiC(CF₃SO₂)₃, Li₂B₁₀Cl₁₀, LiN(C₂F₅SO₂)₂, LiPF₄(CF₃)₂, LiPF₃(C₂F₅)₃, lower aliphatic carboxylates of lithium, LiAlCl₄, etc. The lithium salts may be used alone or in combination. The organic solvents may be organic solvents having high boiling points and high dielectric constants such as ethylene carbonate, propylene carbonate, ethylmethyl carbonate, γ-butyrolactone, etc.; organic solvents having low boiling points and low viscosity such as tetrahydrofuran, 2-methyltetrahydrofuran, dimethoxyethane, dioxolane, dimethyl carbonate, diethyl carbonate, etc. These organic solvents may be used alone or in combination. Because the organic solvents having high dielectric constants have high viscosity, while those having low viscosity have low dielectric constants, their mixtures are preferably used.

When the battery is assembled, the separator is impregnated with the electrolytic solution, so that the separator (multi-layer, microporous membrane) is provided with ion permeability. The impregnation treatment is usually conducted by immersing the multi-layer, microporous membrane in the electrolytic solution at room temperature. When a cylindrical battery is assembled, for instance, a cathode sheet, a separator formed by the multi-layer, microporous membrane and an anode sheet are laminated in this order, and the resultant laminate is wound to a toroidal-type electrode assembly. The resultant electrode assembly is charged into a battery can and then impregnated with the above electrolytic solution, and a battery lid acting as a cathode terminal provided with a safety valve is caulked to the battery can via a gasket to produce a battery.

The present invention will be explained in more detail referring to Examples below without intention of restricting the scope of the present invention.

Example 1

(1) Preparation of First Polyolefin Solution

Dry-blended were 100 parts by mass of a first polyolefin comprising 15% by mass of high-density polyethylene (HDPE) having a weight-average molecular weight (Mw) of 3.0×10⁵ and a molecular weight distribution (Mw/Mn) of 8.6, and 85% by mass of a propylene homopolymer (PP) having Mw of 5.3×10⁵, and 0.2 parts by mass of tetrakis [methylene-3-(3,5-ditertiary-butyl-4-hydroxyphenyl)-propionate] methane as an antioxidant. HDPE had a melting point of 135° C. and a crystal dispersion temperature of 100° C. 60 parts by mass of the resultant mixture was charged into a strong-blending double-screw extruder having an inner diameter of 58 mm and L/D of 52.5, and 40 parts by mass of liquid paraffin [50 cst (40° C.)] was supplied to the double-screw extruder via a side feeder. Melt-blending was conducted at 230° C. and 250 rpm to prepare a first polyolefin solution.

(2) Preparation of Second Polyolefin Solution

Dry-blended were 100 parts by mass of HDPE having Mw of 3.5×10⁵ and Mw/Mn of 9.5, and 0.2 parts by mass of the above antioxidant. HDPE had a melting point of 135° C. and a crystal dispersion temperature of 100° C. 35 parts by mass of the resultant mixture was charged into the double-screw extruder, and 65 parts by mass of the liquid paraffin was supplied to the double-screw extruder via a side feeder. Melt-blending was conducted at 230° C. and 250 rpm to prepare a second polyolefin solution.

The Mw and Mw/Mn of HDPE and PP were measured by a gel permeation chromatography (GPC) method under the following conditions.

Measurement apparatus: GPC-150C available from Waters Corporation,

Column: Shodex UT806M available from Showa Denko K.K.,

Column temperature: 135° C.,

Solvent (mobile phase): o-dichlorobenzene,

Solvent flow rate: 1.0 ml/minute,

Sample concentration: 0.1% by mass (dissolved at 135° C. for 1 hour),

Injected amount: 500 μl,

Detector: Differential Refractometer available from Waters Corp., and Calibration curve: Produced from a calibration curve of a single-dispersion, standard polystyrene sample using a predetermined conversion constant.

(3) Production of Microporous Membrane

The first and second polyolefin solutions were supplied to a three-layer-extruding T-die from each double-screw extruder, and extruded therefrom to form a laminate of a first solution layer, a second solution layer and a first solution layer at thickness ratio of 0.06/0.88/0.06. The resultant extrudate was cooled while passing through cooling rolls controlled at 15° C. The resultant three-layer, gel-like sheet was simultaneously biaxially stretched to 5 folds in both longitudinal and transverse directions by a tenter-stretching machine at 117° C. The stretched three-layer, gel-like sheet was fixed to an aluminum frame plate of 20 cm×20 cm, immersed in a methylene chloride bath controlled at 25° C. to remove the liquid paraffin while vibrating at 100 rpm for 3 minutes, and dried at room temperature by air. The dried membrane was re-stretched to 1.4 folds in a transverse direction by a batch-stretching machine at 128.5° C. With the re-stretched membrane kept fixed to the batch-stretching machine, it was heat-set at 128.5° C. for 10 minutes to produce a three-layer, microporous polyolefin membrane of a first microporous layer, a second microporous layer and a first microporous layer at a thickness ratio 0.1/0.8/0.1. The average thickness of each layer was determined by measuring the thickness of each layer obtained by peeling the three-layer, microporous membrane over a 30-cm width at a 10-mm longitudinal interval by a contact thickness meter, and averaging the measured thickness.

Example 2

(1) Preparation of First Polyolefin Solution

A first polyolefin solution was prepared in the same manner as in Example 1, except that the first polyolefin comprised 5% by mass of HDPE and 95% by mass of PP.

(2) Preparation of Second Polyolefin Solution

Dry-blended were 100 parts by mass of a polyethylene composition comprising 2% by mass of ultra-high-molecular-weight polyethylene (UHMWPE) having Mw of 2.0×10⁶ and Mw/Mn of 8, and 98% by mass of HDPE having Mw of 3.5×10⁵ and Mw/Mn of 8.6, and 0.2 parts by mass of the above antioxidant. 40 parts by mass of the resultant mixture was charged into the double-screw extruder, and 60 parts by mass of the liquid paraffin was supplied to the double-screw extruder via a side feeder. Melt-blending was conducted at 230° C. and 250 rpm to prepare a second polyolefin solution.

(3) Production of Microporous Membrane

A three-layer, microporous polyolefin membrane having a first microporous layer, a second microporous layer and a first microporous layer at a thickness ratio of 0.1/0.8/0.1 was produced in the same manner as in Example 1, except that a thickness ratio of first solution layer/second solution layer/first solution layer was 0.07/0.86/0.07, and that the re-stretching temperature and the heat-setting temperature were both 127.5° C.

Example 3

(1) Preparation of First Polyolefin Solution

A first polyolefin solution was prepared in the same manner as in Example 1 except for using only PP as a first polyolefin, and setting its concentration at 65% by mass.

(2) Preparation of Second Polyolefin Solution

Dry-blended were 100 parts by mass of a polyethylene composition comprising 5% by mass of UHMWPE having Mw of 2.0×10⁶ and Mw/Mn of 8, and 95% by mass of HDPE having Mw of 3.0×10⁵ and Mw/Mn of 8.6, and 0.2 parts by mass of the above antioxidant. 40 parts by mass of the resultant mixture was charged into a double-screw extruder, and 60 parts by mass of liquid paraffin was supplied to the double-screw extruder via a side feeder. Melt-blending was conducted at 230° C. and 250 rpm to prepare a second polyolefin solution.

(3) Production of Microporous Membrane

A three-layer, microporous polyolefin membrane having a first microporous layer, a second microporous layer and a first microporous layer at a thickness ratio of 0.1/0.8/0.1 was produced in the same manner as in Example 1, except that both the stretching temperature and the heat-setting temperature of the multi-layer, microporous membrane were 127° C.

Example 4

(1) Preparation of First Polyolefin Solution

A first polyolefin solution was prepared in the same manner as in Example 1.

(2) Preparation of Second Polyolefin Solution

Dry-blended were 100 parts by mass of a second polyolefin comprising 90% by mass of HDPE having Mw of 3.0×10⁵ and Mw/Mn of 8.6, and 10% by mass of PP having Mw of 5.3×10⁵, and 0.2 parts by mass of the above antioxidant. 35 parts by mass of the resultant mixture was charged into a double-screw extruder, and 65 parts by mass of liquid paraffin was supplied to the double-screw extruder via a side feeder. Melt-blending was conducted at 230° C. and 250 rpm to prepare a second polyolefin solution.

(3) Production of Microporous Membrane

A three-layer, microporous polyolefin membrane having a first microporous layer, a second microporous layer and a first microporous layer at a thickness ratio of 0.1/0.8/0.1 was produced in the same manner as in Example 1, except that both the stretching temperature and the heat-setting temperature of the multi-layer, microporous membrane were 127° C.

Example 5

A three-layer, microporous polyolefin membrane having a first microporous layer, a second microporous layer and a first microporous layer at a thickness ratio of 0.2/0.6/0.2 was produced in the same manner as in Example 1, except that a thickness ratio of first polyolefin solution/second polyolefin solution/first polyolefin solution was 0.15/0.70/0.15, and that both the re-stretching temperature and the heat-setting temperature were 128° C.

Example 6

(1) Preparation of First Polyolefin Solution

A first polyolefin solution was prepared in the same manner as in Example 1, except for using a first polyolefin comprising 50% by mass of HDPE and 50% by mass of PP having Mw of 2.0×10⁶, and setting its concentration at 35% by mass.

(2) Preparation of Second Polyolefin Solution

A second polyolefin solution was prepared in the same manner as in Example 1 except for using HDPE having Mw of 3.0×10⁵ and Mw/Mn of 8.6.

(3) Production of Microporous Membrane

A three-layer, microporous polyolefin membrane having a first microporous layer, a second microporous layer and a first microporous layer at a thickness ratio of 0.1/0.8/0.1 was produced in the same manner as in Example 1, except that a thickness ratio of first polyolefin solution/second polyolefin solution/first polyolefin solution was 0.1/0.8/0.1, and that both the re-stretching temperature and the heat-setting temperature were 127° C.

Comparative Example 1

Dry-blended were 100 parts by mass of a polyolefin comprising 30% by mass of UHMWPE having Mw of 2.0×10⁶ and Mw/Mn of 8, and 70% by mass of HDPE having Mw of 3.0×10⁵ and Mw/Mn of 8.6, and 0.2 parts by mass of the above antioxidant. 30 parts by mass the resultant mixture was charged into a double-screw extruder, and 70 parts by mass of liquid paraffin was supplied to the double-screw extruder via a side feeder. Melt-blending was conducted at 230° C. and 250 rpm to prepare a polyolefin solution. A microporous polyolefin membrane was produced in the same manner as in Example 1, except that only this polyolefin solution was used, that the stretching temperature of the gel-like sheet was 115° C., that the microporous membrane was not stretched, and that the heat-setting temperature was 128° C.

Comparative Example 2

A three-layer, microporous polyolefin membrane was produced in the same manner as in Example 2, except that the thickness ratio of a surface layer, an inner layer and a surface layer was 0.33/0.34/0.33, that the stretching temperature of the gel-like laminate sheet was 117.5° C., and that both the re-stretching temperature and the heat-setting temperature were 129° C.

Comparative Example 3

A microporous polyolefin membrane was produced in the same manner as in Example 1, except that only the same second polyolefin solution as in Example 2 except that its concentration was 40% by mass was used, that the stretching temperature of the gel-like sheet was 118.5° C., and that the stretching and heat-setting temperatures of the microporous membrane was 129° C.

Comparative Example 4

(1) Preparation of Second Polyolefin Solution A

Dry-blended were 100 parts by mass of a second polyolefin A comprising 5% by mass of UHMWPE having Mw of 2.0×10⁶ and Mw/Mn of 8, 75% by mass of HDPE having Mw of 3.0×10⁵ and Mw/Mn of 8.6, and 20% by mass of PP having Mw of 5.3×10⁵, and 0.2 parts by mass of the above antioxidant. 35 parts by mass of the resultant mixture was charged into a double-screw extruder, and 65 parts by mass of liquid paraffin was supplied to the double-screw extruder via a side feeder. Melt-blending was conducted at 230° C. and 250 rpm to prepare a second polyolefin solution A.

(2) Preparation of Second Polyolefin Solution B

A second polyolefin solution B was prepared in the same manner as in Example 1 except for using a second polyolefin B having the same composition as in Example 2.

(3) Production of Microporous Membrane

A three-layer, microporous polyolefin membrane having a surface layer, an inner layer and a surface layer at a thickness ratio of 0.1/0.8/0.1 was produced in the same manner as in Example 1, except that the second polyolefin solutions A and B were used to form the surface and inner layers, that the stretching temperature of the gel-like laminate sheet was 117.5° C., and that the stretching and heat-setting temperatures of the multi-layer, microporous membrane were 127° C.

The properties of the microporous membranes in Examples 1-6 and Comparative Examples 1-4 were measured by the following methods. The results are shown in Tables 1.

(1) Average Thickness (μm)

The thickness of each microporous membrane was measured by a contact thickness meter at 5-mm longitudinal intervals over the width of 30 cm, and averaged.

(2) Air Permeability (sec/100 cm³/20 μm)

Air permeability P₁ measured on each microporous membrane having a thickness T₁ according to JIS P8117 was converted to air permeability P₂ at a thickness of 20 μm by the equation of P₂=(P₁×20)/T₁.

(3) Porosity (%)

Measured by a weight method.

(4) Pin Puncture Strength (mN/20 μm)

The maximum load was measured, when each microporous membrane having a thickness T₁ was pricked with a needle of 1 mm in diameter with a spherical end surface (radius R of curvature: 0.5 mm) at a speed of 2 mm/second. The measured maximum load L₁ was converted to the maximum load L₂ at a thickness of 20 μm by the equation of L₂=(L₁×20)/T₁, and used as pin puncture strength.

(5) Tensile Rupture Strength and Tensile Rupture Elongation

Measured on a rectangular test piece having a width of 10 mm according to ASTM D882.

(6) Heat Shrinkage Ratio (%)

The shrinkage ratio of each microporous membrane was measured three times in both longitudinal and transverse directions when exposed to 105° C. for 8 hours, and averaged.

(7) Meltdown Temperature (° C.)

Using a thermomechanical analyzer (TMA/SS6000 available from Seiko Instruments Inc.), a test piece TP of 10 mm (TD) and 3 mm (MD) was heated from room temperature at a speed of 5° C./minute under a load of 2 g according to the method shown in FIG. 2. The temperature at which the test piece TP elongated by 50% of its length (100%) at room temperature was used as “meltdown temperature.”

(8) Average Pore Diameter of Surface and Inner Layers

Each of three membranes obtained by peeling the three-layer, microporous membrane was measured with respect to average pore diameter by a mercury intrusion porosimetry (measuring device: Poresizer Type 9320, manufactured by Micromeritics Ltd.). The average pore diameter of the surface layer is an average of pore diameters measured on two surface layers.

(9) Pore Diameter Distribution

The pore diameter distribution of the microporous membrane was measured by mercury intrusion porosimetry. In the case of the triple-layer, microporous membrane, the pore diameter distribution was measured on a microporous membrane constituting an inner layer.

(10) Pore Volume Ratio in Inner Layer

Calculated from S₁/S₂ shown in FIG. 1.

(11) Electrolytic Solution Absorption Speed

Using a dynamic-surface-tension-measuring apparatus (DCAT21 with high-precision electronic balance, available from Eko Instruments Co., ltd.), a microporous membrane sample was immersed in an electrolytic solution (electrolyte: 1 mol/L of LiPF₆, solvent: ethylene carbonate/dimethyl carbonate at a volume ratio of 3/7) kept at 18° C., to determine an electrolytic solution absorption speed by the formula of [weight increment (g) of microporous membrane/weight (g) of microporous membrane before absorption]. The absorption speed is expressed by a relative ratio, assuming that the absorption speed of the microporous membrane of Comparative Example 1 is 1.

(12) Liquid-Retaining Ratio Under Pressure

The microporous membrane sample of 60 mm in width and 100 mm in length was impregnated with γ-butyrolactone to saturation, to measure the amount A (g/g) of the liquid retained per a unit weight of the sample before pressing. A filter paper and an aluminum foil were laminated in this order on each surface of the liquid-absorbed sample. The resultant laminate was sandwiched by a pair of plate jigs, and pressed at 1.96 MPa (20 kgf/cm²) and 60° C. for 5 minutes. The amount B (g/g) of the liquid retained per a unit weight of the sample after pressing was measured in the same manner as above. A liquid-retaining ratio (B/A) per a unit sample weight was calculated as an index of liquid-retaining ability. The liquid-retaining ratio is expressed by a relative ratio, assuming that the liquid-retaining ratio of the microporous membrane of Comparative Example 1 is 1.

TABLE 1
No.	Example 1	Example 2	Example 3
First Polyolefin
UHMWPE Mw(1)/MWD(2)/% by mass	—/—/—	—/—/—	—/—/—
HDPE Mw/MWD/% by mass	3.0 × 105/8.6/15	3.0 × 105/8.6/5	—/—/—
PP Mw/% by mass	5.3 × 105/85	5.3 × 105/95	5.3 × 105/100
Second Polyolefin
UHMWPE Mw/MWD/% by mass	—/—/—	2.0 × 106/8/2	2.0 × 106/8/5
HDPE Mw/MWD/% by mass	3.5 × 106/9.5/100	3.0 × 105/8.6/98	3.0 × 105/8.6/95
PP Mw/% by mass	—/—	—/—	—/—
Production Conditions
Concentration(3) (% by mass)	60/35	60/40	65/40
Simultaneous Extrusion
Layer Structure(4)	(I)/(II)/(I)(6)	(I)/(II)/(I)	(I)/(II)/(I)
Thickness Ratio(5)	0.06/0.88/0.06	0.07/0.86/0.07	0.06/0.88/0.06
Stretching of Multilayer, Gel-Like Sheet
Temperature (° C.)/Magnification (MD × TD)	117/5 × 5	117/5 × 5	117/5 × 5
Stretching of Multi-Layer, Microporous Membrane
Temperature (° C.)/Direction/Magnification (folds)	128.5/TD/1.4	127.5/TD/1.4	127/TD/1.4
Heat-setting
Temperature (° C.)/Time (minute)	128.5/10	127.5/10	127/10
Properties of Multi-Layer, Microporous Membrane
Average Thickness (μm)	21.5	20.4	21
Thickness Ratio(5)	0.1/0.8/0.1	0.1/0.8/0.1	0.1/0.8/0.1
Air Permeability (sec/100 cm3/20 μm)	278	307	314
Porosity (%)	41.0	40.6	41.3
Pin Puncture Strength (mN/20 μm)	4,792	5,292	5,439
Tensile Rupture Strength (kPa)
MD	107,604	123,480	124,950
TD	141,022	162,680	162,680
Tensile Rupture Elongation (%)
MD	145	130	120
TD	120	110	110
Heat Shrinkage Ratio (%)
MD	3.0	3.9	4.3
TD	3.8	4.3	4.6
Meltdown Temperature (° C.)	159	159	162
Higher-Order Structure
Average Pore Diameter (μm) in Surface/Inner(7)	0.02/0.05	0.02/0.05	0.02/0.04
Average Pore Diameter Ratio(8)	2.5	2.5	2.0
Peaks (μm) of Pore Diameter Distribution(9)	0.07/0.11/0.7/—	0.04/0.1/0.7/—	0.05/0.1/0.7/—
Pore Volume Ratio(10)	0.86	0.88	0.91
Electrolytic Solution Absorption Speed	2.8	2.9	2.9
Liquid-Retaining Ratio Under Pressure	1.1	1.2	1.2
No.	Example 4	Example 5	Example 6
First Polyolefin
UHMWPE Mw(1)/MWD(2)/% by mass	—/—/—	—/—/—	—/—/—
HDPE Mw/MWD/% by mass	3.0 × 105/8.6/15	3.0 × 105/8.6/15	3.0 × 105/8.6/50
PP Mw/% by mass	5.3 × 105/85	5.3 × 105/85	2.0 × 106/50
Second Polyolefin
UHMWPE Mw/MWD/% by mass	—/—/—	—/—/—	—/—/—
HDPE Mw/MWD/% by mass	3.0 × 106/8.6/90	3.5 × 105/9.5/100	3.0 × 105/8.6/100
PP Mw/% by mass	5.3 × 105/10	—/—	—/—
Production Conditions
Concentration(3) (% by mass)	60/35	60/35	35/35
Simultaneous Extrusion
Layer Structure(4)	(I)/(II)/(I)(6)	(I)/(II)/(I)	(I)/(II)/(I)
Thickness Ratio(5)	0.06/0.88/0.06	0.15/0.70/0.15	0.1/0.8/0.1
Stretching of Multilayer, Gel-Like Sheet
Temperature (° C.)/Magnification (MD × TD)	117/5 × 5	117/5 × 5	117/5 × 5
Stretching of Multi-Layer, Microporous Membrane
Temperature (° C.)/Direction/Magnification (folds)	127/TD/1.2	128/TD/1.4	127/TD/1.4
Heat-setting
Temperature (° C.)/Time (minute)	127/10	128/10	127/10
Properties of Multi-Layer, Microporous Membrane
Average Thickness (μm)	20.2	21.0	20.0
Thickness Ratio(5)	0.1/0.8/0.1	0.2/0.6/0.2	0.1/0.8/0.1
Air Permeability (sec/100 cm3/20 μm)	223	395	355
Porosity (%)	42	41	43
Pin Puncture Strength (mN/20 μm)	4,684	4,018	4,753
Tensile Rupture Strength (kPa)
MD	124,460	100,450	107,800
TD	138,180	135,240	140,140
Tensile Rupture Elongation (%)
MD	120	140	120
TD	125	105	110
Heat Shrinkage Ratio (%)
MD	4.0	5.5	5.0
TD	4.3	6.0	5.5
Meltdown Temperature (° C.)	160	160	170
Higher-Order Structure
Average Pore Diameter (μm) in Surface/Inner(7)	0.02/0.06	0.02/0.06	0.02/0.06
Average Pore Diameter Ratio(8)	3	3	3
Peaks (μm) of Pore Diameter Distribution(9)	0.07/0.1/—/—	0.06/0.1/0.7/—	0.07/0.1/0.7/—
Pore Volume Ratio(10)	0.71	0.71	1.28
Electrolytic Solution Absorption Speed	2.6	1.7	2.0
Liquid-Retaining Ratio Under Pressure	1	1.4	1.3
No.	Com. Ex. 1(1)	Com. Ex. 2	Com. Ex. 3
First Polyolefin
UHMWPE Mw(1)/MWD(2)/% by mass	—/—/—	—/—/—	—/—/—
HDPE Mw/MWD/% by mass	—/—/—	3.0 × 105/8.6/5	—/—/—
PP Mw/% by mass	—/—	5.3 × 105/95	—/—
Second Polyolefin
UHMWPE Mw/MWD/% by mass	2.0 × 106/8/30	2.0 × 106/8/2	2.0 × 106/8/2
HDPE Mw/MWD/% by mass	3.0 × 105/8.6/70	3.0 × 105/8.6/98	3.0 × 105/8.6/98
PP Mw/% by mass	—/—	—/—	—/—
Production Conditions
Concentration(3) (% by mass)	—/30	40/40	—/40
Simultaneous Extrusion
Layer Structure(4)	—	(I)/(II)/(I)(6)	—
Thickness Ratio(5)	—	—	—
Stretching of Multilayer, Gel-Like Sheet
Temperature (° C.)/Magnification (MD × TD)	115/5 × 5	117.5/5 × 5	118.5/5 × 5
Stretching of Multi-Layer, Microporous Membrane
Temperature (° C.)/Direction/Magnification (folds)	—/—/—	129/TD/1.4	129/TD/1.4
Heat-setting
Temperature (° C.)/Time (minute)	128/10	129/10	129/10
Properties of Multi-Layer, Microporous Membrane
Average Thickness (μm)	21	20.1	19.5
Layer Thickness Ratio(5)	—	0.33/0.34/0.33	—
Air Permeability (sec/100 cm3/20 μm)	307	726	230
Porosity (%)	40.2	35.0	39.5
Pin Puncture Strength (mN/20 μm)	4,557	3,479	4,704
Tensile Rupture Strength (kPa)
MD	132,300	102,900	116,620
TD	102,900	122,500	155,820
Tensile Rupture Elongation (%)
MD	180	135	150
TD	270	110	115
Heat Shrinkage Ratio (%)
MD	3.7	3.4	1.8
TD	3.6	3.9	2.6
Meltdown Temperature (° C.)	150	160	144
Higher-Order Structure
Average Pore Diameter (μm) in Surface/Inner(7)	—/0.025(12)	0.02/0.05	—/0.05(12)
Average Pore Diameter Ratio(8)	—	2.5	—
Peaks (μm) of Pore Diameter Distribution(9)	0.025/—/—/—	0.04/0.1/—/—	0.04/0.1/0.7/1
Pore Volume Ratio(10)	—	0.88	0.91
Electrolytic Solution Absorption Speed	1	1	3.5
Liquid-Retaining Ratio Under Pressure	1	1	0.5
No.	Com. Ex. 4(13)
First Polyolefin
UHMWPE Mw(1)/MWD(2)/% by mass	2.0 × 106/8/5
HDPE Mw/MWD/% by mass	3.0 × 105/8.6/75
PP Mw/% by mass	5.3 × 105/20
Second Polyolefin
UHMWPE Mw/MWD/% by mass	2.0 × 106/8/2
HDPE Mw/MWD/% by mass	3.0 × 105/8.6/98
PP Mw/% by mass	—/—
Production Conditions
Concentration(3) (% by mass)	35/40
Simultaneous Extrusion
Layer Structure(4)	A/B/A(14)
Thickness Ratio(5)	—
Stretching of Multilayer, Gel-Like Sheet
Temperature (° C.)/Magnification (MD × TD)	117.5/5 × 5
Stretching of Multi-Layer, Microporous Membrane
Temperature (° C.)/Direction/Magnification (folds)	127/TD/1.4
Heat-setting
Temperature (° C.)/Time (minute)	127/10
Properties of Multi-Layer, Microporous Membrane
Average Thickness (μm)	19.5
Layer Thickness Ratio(5)	0.1/0.8/0.1
Air Permeability (sec/100 cm3/20 μm)	230
Porosity (%)	39.5
Pin Puncture Strength (mN/20 μm)	4,704
Tensile Rupture Strength (kPa)
MD	116,620
TD	155,820
Tensile Rupture Elongation (%)
MD	150
TD	115
Heat Shrinkage Ratio (%)
MD	1.8
TD	2.6
Meltdown Temperature (° C.)	156
Higher-Order Structure
Average Pore Diameter (μm) in Surface/Inner(7)	0.04/0.05
Average Pore Diameter Ratio(8)	1.25
Peaks (μm) of Pore Diameter Distribution(9)	0.04/0.1/0.7/—
Pore Volume Ratio(10)	0.91
Electrolytic Solution Absorption Speed	3.5
Liquid-Retaining Ratio Under Pressure	0.5
Note:
(1)Mw represents a weight-average molecular weight.
(2)MWD represents a molecular weight distribution (Mw/Mn).
(3)The concentration of the first polyolefin solution/the concentration of the second polyolefin solution.
(4)The layer structure of a surface layer, an inner layer and a surface layer.
(5)The thickness ratio of a surface layer, an inner layer and a surface layer.
(6)(I) represents the first polyolefin solution, and (II) represents the second polyolefin solution.
(7)The average pore diameter of the surface layer and the inner layer, respectively.
(8)(Average pore diameter of second microporous layer)/(average pore diameter of first microporous layer).
(9)The first to fourth peaks of the pore diameter distribution of the inner layer.
(10)The pore volume ratio of the inner layer.
(11)Although the single-layer, microporous membrane of Comparative Example 1 was composed of a polyethylene mixture different from any of the first and second polyolefins, it is listed in the column of “Second Polyolefin.”
(12)The average pore diameter of the single-layer, microporous membrane.
(13)The composition of the first polyolefin A is listed in the column of “First Polyolefin,” and the composition of the second polyolefin B is listed in the column of “Second Polyolefin.”
(14)“A” represents the first polyolefin solution A, and “B” represents the second polyolefin solution B.

As shown in Table 1, each three-layer, microporous polyolefin membrane of Examples 1-6 had a structure in which the second microporous layer had a larger average pore diameter than that of the first microporous layer, thereby exhibiting excellent electrolytic solution absorption, and electrolytic solution retention. They further had excellent permeability, pin puncture strength, tensile rupture strength, tensile rupture elongation, heat shrinkage resistance and meltdown properties.

The single-layer, microporous membrane of Comparative Example 1 was poorer than those of Examples 1-6 in meltdown properties, electrolytic solution absorption, and electrolytic solution retention, because it did not have the first microporous layer in which the percentage of polypropylene was 50% or more by mass and the second microporous layer having a hybrid structure.

The three-layer, microporous membrane of Comparative Example 2 was poorer than those of Examples 1-6 in permeability, electrolytic solution absorption, and electrolytic solution retention, because the total thickness of the first microporous layers was more than 60% per 100% of the total thickness of the first and second microporous layers.

The single-layer, microporous membrane of Comparative Example 3 was poorer than those of Examples 1-6 in meltdown properties and electrolytic solution retention, because it did not have the first microporous layer in which the percentage of polypropylene was 50% or more by mass.

The three-layer, microporous membrane of Comparative Example 4 was poorer than those of Examples 1-6 in meltdown properties and electrolytic solution retention, because it had three second microporous layers.

EFFECT OF THE INVENTION

The multi-layer, microporous polyolefin membrane of the present invention has suitably well-balanced permeability, mechanical strength, meltdown properties, electrolytic solution absorption, and electrolytic solution retention. Separators formed by the multi-layer, microporous polyolefin membrane of the present invention provide batteries with excellent safety, heat resistance, storage properties and productivity.

Claims

1. A multi-layer, microporous polyolefin membrane comprising first microporous layers constituting at least both surface layers and at least one second microporous layer disposed between both surface layers; said first microporous layer being made of a first polyolefin comprising (i) polypropylene, or (ii) a mixture of 50% or more by mass of polypropylene and a polyethylene resin; said second microporous layer being made of a second polyolefin comprising (i) a mixture of 7% or less by mass of ultra-high-molecular-weight polyethylene having weight-average molecular weight of 1×106 or more and the other polyethylene than said ultra-high-molecular-weight polyethylene, (ii) the other polyethylene than said ultra-high-molecular-weight polyethylene, or (iii) a mixture of 50% or less by mass of polypropylene and said mixture (i) or said polyethylene (ii); said second microporous layer having a larger average pore diameter than that of said first microporous layer; and the total thickness of said first microporous layers being 15-60% per 100% of the total thickness of said first and second microporous layers.

2. The multi-layer, microporous polyolefin membrane according to claim 1, wherein said first microporous layer has an average pore diameter of 0.005-0.1 μm, and said second microporous layer has an average pore diameter of 0.02-0.5 μm.

3. The multi-layer, microporous polyolefin membrane according to claim 1, wherein the average pore diameter ratio of said second microporous layer to said first microporous layer is more than 1/1 and 10/1 or less.

4. The multi-layer, microporous polyolefin membrane according to claim 1, wherein the pore diameter distribution curve of said second microporous layer obtained by mercury intrusion porosimetry has at least two peaks.

5. The multi-layer, microporous polyolefin membrane according to claim 1, wherein said second microporous layer comprises dense domains having a main peak in a range of 0.01-0.08 μm and coarse domains having at least one sub-peak in a range of more than 0.08 μm and 1.5 μm or less, in said pore diameter distribution curve.

6. The multi-layer, microporous polyolefin membrane according to claim 5, wherein the pore volume ratio of said dense domains to said coarse domains is 0.5-49.

7. The multi-layer, microporous polyolefin membrane according to claim 1, wherein it has a three-layer structure having said first microporous layers on both surfaces of said second microporous layer.

8. The multi-layer, microporous polyolefin membrane according to claim 1, wherein said first polyolefin comprises polypropylene or a mixture of 50% or more by mass of polypropylene and high-density polyethylene having a weight-average molecular weight of 1×104 to 5×105.

9. The multi-layer, microporous polyolefin membrane according to claim 1, wherein said other polyethylene than ultra-high-molecular-weight polyethylene is high-density polyethylene having a weight-average molecular weight of 1×104 to 5×105.

10. A method for producing the multi-layer, microporous polyolefin membrane recited in claim 1, comprising the steps of (1) melt-blending a first polyolefin comprising (i) polypropylene, or (ii) a mixture of 50% or more by mass of polypropylene and a polyethylene resin, and a membrane-forming solvent to prepare a first polyolefin solution; (2) melt-blending a second polyolefin comprising (i) a mixture of 7% or less by mass of ultra-high-molecular-weight polyethylene having weight-average molecular weight of 1×106 or more and the other polyethylene than said ultra-high-molecular-weight polyethylene, (ii) the other polyethylene than said ultra-high-molecular-weight polyethylene, or (iii) a mixture of 50% or less by mass of polypropylene and said mixture (i) or said polyethylene (ii), and a membrane-forming solvent to prepare a second polyolefin solution; (3) simultaneously extruding said first and second polyolefin solutions through a die, such that said first polyolefin solution forms at least both surface layers, while said second polyolefin solution forms at least one layer between both surface layers; (4) cooling the resultant extrudate to form a multi-layer, gel-like sheet; (5) stretching said multi-layer, gel-like sheet; (6) removing said membrane-forming solvent from the stretched multi-layer, gel-like sheet; and (7) stretching the resultant multi-layer, microporous membrane to 1.1-1.8 folds in at least one direction.

11. A method for producing the multi-layer, microporous polyolefin membrane recited in claim 1, comprising the steps of (1) melt-blending a first polyolefin comprising (i) polypropylene, or (ii) a mixture of 50% or more by mass of polypropylene and a polyethylene resin, and a membrane-forming solvent to prepare a first polyolefin solution; (2) melt-blending a second polyolefin comprising (i) a mixture of 7% or less by mass of ultra-high-molecular-weight polyethylene having weight-average molecular weight of 1×106 or more and the other polyethylene than said ultra-high-molecular-weight polyethylene, (ii) the other polyethylene than said ultra-high-molecular-weight polyethylene, or (iii) a mixture of 50% or less by mass of polypropylene and said mixture (i) or said polyethylene (ii), and a membrane-forming solvent to prepare a second polyolefin solution; (3) extruding said first and second polyolefin solutions through separate dies and immediately laminating them, such that said first polyolefin solution forms at least both surface layers, while said second polyolefin solution forms at least one layer between both surface layers; (4) cooling the resultant laminate to form a multi-layer, gel-like sheet; (5) stretching said multi-layer, gel-like sheet; (6) removing said membrane-forming solvent from the stretched multi-layer, gel-like sheet; and (7) stretching the resultant multi-layer, microporous membrane to 1.1-1.8 folds in at least one direction.

12. A method for producing the multi-layer, microporous polyolefin membrane recited in claim 1, comprising the steps of (1) melt-blending a first polyolefin comprising (i) polypropylene, or (ii) a mixture of 50% or more by mass of polypropylene and a polyethylene resin, and a membrane-forming solvent to prepare a first polyolefin solution; (2) melt-blending a second polyolefin comprising (i) a mixture of 7% or less by mass of ultra-high-molecular-weight polyethylene having weight-average molecular weight of 1×106 or more and the other polyethylene than said ultra-high-molecular-weight polyethylene, (ii) the other polyethylene than said ultra-high-molecular-weight polyethylene, or (iii) a mixture of 50% or less by mass of polypropylene and said mixture (i) or said polyethylene (ii), and a membrane-forming solvent to prepare a second polyolefin solution; (3) extruding said first and second polyolefin solutions through separate dies; (4) cooling the resultant extrudates to form first and second gel-like sheets; (5) stretching each gel-like sheet; (6) laminating the stretched first and second gel-like sheets, such that said stretched first gel-like sheet forms at least both surface layers, while said stretched second gel-like sheet forms at least one layer between both surface layers; (7) removing said membrane-forming solvent from the resultant multi-layer, gel-like sheet; and (8) stretching the resultant multi-layer, microporous membrane to 1.1-1.8 folds in at least one direction.

13. A method for producing the multi-layer, microporous polyolefin membrane recited in claim 1, comprising the steps of (1) melt-blending a first polyolefin comprising (i) polypropylene, or (ii) a mixture of 50% or more by mass of polypropylene and a polyethylene resin, and a membrane-forming solvent to prepare a first polyolefin solution; (2) melt-blending a second polyolefin comprising (i) a mixture of 7% or less by mass of ultra-high-molecular-weight polyethylene having weight-average molecular weight of 1×106 or more and the other polyethylene than said ultra-high-molecular-weight polyethylene, (ii) the other polyethylene than said ultra-high-molecular-weight polyethylene, or (iii) a mixture of 50% or less by mass of polypropylene and said mixture (i) or said polyethylene (ii), and a membrane-forming solvent to prepare a second polyolefin solution; (3) extruding said first and second polyolefin solutions through separate dies; (4) cooling the resultant extrudates to form first and second gel-like sheets; (5) stretching each gel-like sheet; (6) removing said membrane-forming solvent from each stretched gel-like sheet to form first and second microporous polyolefin membranes; (7) stretching at least said second microporous polyolefin membrane to 1.1-1.8 folds in at least one direction; and (8) laminating said first and second microporous polyolefin membranes, such that said first microporous polyolefin membrane forms at least both surface layers, while said second microporous polyolefin membrane forms at least one layer between both surface layers.

14. A battery separator formed by the multi-layer, microporous polyolefin membrane recited in claim 1.

15. A battery comprising a separator formed by the multi-layer, microporous polyolefin membrane recited in claim 1.