Fiber-containing polymer film and method of manufacturing same, and electrochemical device and method of manufacturing same

Patent metadata

Field	Value
Publication number	US-9831480-B2
Application number	US-61927009-A
Country	US
Kind code	B2
Filing date	Nov 16, 2009
Priority date	Nov 19, 2008
Publication date	Nov 28, 2017
Grant date	Nov 28, 2017

Abstract

A fiber-containing polymer film contains a host polymer and fibrous substances. The fiber-containing polymer film has an orientation area where the fibrous substances are oriented in a direction substantially parallel to a main surface of the fiber-containing polymer film and in substantially the same direction.

First claim

What is claimed is:

1. A fiber-containing polymer film for an electrochemical device comprising:
a host polymer that contains at least one selected from the group consisting of polyvinylidene fluoride, fluorine rubbers, and polyethylene oxide; and
a fibrous substance consisting of polyacrylonitrile, the fibrous substance having an average fiber diameter of 100 to 500 nm and an average fiber length of 10 to 100 μm;
the fiber-containing polymer film having an orientation area where the fibrous substance is oriented in a direction substantially parallel to a main surface of the fiber-containing polymer film and in substantially the same direction.

2. The fiber-containing polymer film according to claim 1 , wherein the orientation area exists over the whole area of the fiber-containing polymer film.

3. The fiber-containing polymer film according to claim 1 , wherein the fiber-containing polymer film contains 10 to50% by volume of the fibrous substance based on the total volume of the fiber-containing polymer film.

4. An electrochemical device comprising a polymer solid electrolyte film constructed by impregnating the fiber-containing polymer film according to claim 1 with an electrolyte salt.

5. The fiber-containing polymer film according to claim 1 , which additionally comprises inorganic particles.

6. The fiber-containing polymer film according to claim 1 , which additionally comprises an electrolyte salt.

7. The fiber-containing polymer film according to claim 6 , wherein the electrolyte salt is a lithium salt.

8. A method of manufacturing a fiber-containing polymer film, the method comprising:
preparing a coating material comprising a host polymer that contains at least one selected from the group consisting of polyvinylidene fluoride, fluorine rubbers, and polyethylene oxide, a fibrous substance consisting of a polymer compound, and a solvent;
applying the coating material onto a support substrate by extrusion so as to form a coating film; and
eliminating the solvent from the coating film so as to form a fiber-containing polymer film,
the fiber-containing polymer film having an orientation area where the fibrous substance is oriented in a direction substantially parallel to a main surface of the fiber-containing polymer film and in substantially the same direction.

9. The method of manufacturing a fiber-containing polymer film according to claim 8 , wherein applying the coating comprises expelling the coating material at an extrusion pressure of 1 to 30 kg/cm 2 from an outlet having a slit width of at least 10 times an average fiber diameter of the fibrous substance but not more than an average fiber length thereof so that the coating material is applied onto the support substrate and forms the coating film.

10. The method of manufacturing a fiber-containing polymer film according to claim 8 , wherein the fibrous substance has an average fiber diameter of 100 to 500 nm and an average fiber length of 10 to 100 μm.

11. The method of manufacturing a fiber-containing polymer film according to claim 8 , wherein the polymer compound has a melting point of 180° C. or higher.

12. The method of manufacturing a fiber-containing polymer film according to claim 8 , wherein the polymer compound is selected from the group consisting of polyacrylonitrile, polyamide-imide, polyvinyl alcohol, and polyimide.

13. A method of manufacturing an electrochemical device, the method comprising the steps of:
forming a fiber-containing polymer film by the method of manufacturing a fiber-containing polymer according to claim 8 ; and
impregnating the fiber-containing polymer film with an electrolyte salt.

14. A method of manufacturing a fiber-containing polymer film, the method comprising:
preparing a first coating material containing a host polymer that contains at least one selected from the group consisting of polyvinylidene fluoride, fluorine rubbers, and polyethylene oxide, and a solvent;
preparing a second coating material containing a fibrous substance consisting of a polymer compound and a dispersant;
applying the first coating material onto a support substrate so as to form a first coating film;
applying the second coating material onto the first coating film by extrusion so as to form a second coating film; and
eliminating the solvent and dispersant from the first and second coating films so as to form a fiber-containing polymer film containing the host polymer and fibrous substance,
the fiber-containing polymer film having an orientation area where the fibrous substance is oriented in a direction substantially parallel to a main surface of the fiber-containing polymer film and in substantially the same direction.

15. The method of manufacturing a fiber-containing polymer film according to claim 14 , wherein applying the second coating comprises expelling the coating material at an extrusion pressure of 1 to 30 kg/cm 2 from an outlet having a slit width of at least 10 times an average fiber diameter of the fibrous substance but not more than an average fiber length thereof so that the second coating material is applied onto the first coating film and forms the second coating film.

16. The method of manufacturing a fiber-containing polymer film according to claim 14 , wherein the fibrous substance has an average fiber diameter of 100 to 500 nm and an average fiber length of 10 to 100 μm.

17. The method of manufacturing a fiber-containing polymer film according to claim 14 , wherein the polymer compound has a melting point of 180° C. or higher.

18. The method of manufacturing a fiber-containing polymer film according to claim 14 , wherein the polymer compound is selected from the group consisting of polyacrylonitrile, polyamide-imide, polyvinyl alcohol, and polyimide.

19. A method of manufacturing an electrochemical device, the method comprising the steps of:
forming a fiber-containing polymer film by the method of manufacturing a fiber-containing polymer according to claim 14 ; and
impregnating the fiber-containing polymer film with an electrolyte salt.

Assignees

• Naoi Katsuo
• Emoto Kazutoshi
• Hinoki Kiyonori
• Saegusa Masahiro
• Nishizawa Kenji
• Kougo Mitsuo
• Tdk Corp

Inventors

• Naoi Katsuo
• Emoto Kazutoshi
• Hinoki Kiyonori
• Saegusa Masahiro
• Nishizawa Kenji
• Kougo Mitsuo

Classifications

• C08J7/0427

  with only one layer of a composition containing a polymer binder (with more layers C08J7/042) · CPC title

• C08J2327/00

  Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers · CPC title

• C08J2309/02

  Copolymers with acrylonitrile · CPC title

• Y10T428/24132

  including grain, strips, or filamentary elements in different layers or components parallel · CPC title

• H01M50/414

  Synthetic resins, e.g. thermoplastics or thermosetting resins · CPC title