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CN101687402B - 聚四氟乙烯多孔片卷及带卷 - Google Patents

聚四氟乙烯多孔片卷及带卷 Download PDF

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CN101687402B
CN101687402B CN2008800212826A CN200880021282A CN101687402B CN 101687402 B CN101687402 B CN 101687402B CN 2008800212826 A CN2008800212826 A CN 2008800212826A CN 200880021282 A CN200880021282 A CN 200880021282A CN 101687402 B CN101687402 B CN 101687402B
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perforated membrane
ptfe
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CN101687402A (zh
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永山知义
内田阳二
中园淳一
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Nitto Denko Corp
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Abstract

本发明提供制造时容易卷绕、并且容易切割的聚四氟乙烯多孔膜的片卷和不易发生走形的聚四氟乙烯多孔膜的带卷。本发明涉及聚四氟乙烯多孔膜与支撑体的层压体卷绕而成的片卷和聚四氟乙烯多孔膜与支撑体的层压体卷绕而成的带卷。后一带卷可以通过将前一片卷切割而得到。

Description

聚四氟乙烯多孔片卷及带卷
技术领域
本发明涉及将聚四氟乙烯(PTFE)卷绕而得到的片卷(sheet roll)及带卷(tape roll)。
背景技术
PTFE多孔膜的耐热性、耐化学品性、润滑性、低摩擦性、电绝缘性、柔软性、透气性等各种特性优良，应用于例如过滤膜、透气材料、电池用隔膜、电绝缘材料、人造血管、电缆捆扎材料等广泛的领域。
PTFE多孔膜的制造方法，一般为拉伸法(例如，参考日本特公昭42-13560号公报及日本特公昭51-18991号公报)。拉伸法是将PTFE粉末与液状润滑剂的混合物成形为薄膜状，然后将该薄膜拉伸而使其多孔化的方法，拉伸后，根据需要有时在PTFE熔点以上的温度下焙烧来提高多孔膜的强度。
通过拉伸法制造的PTFE多孔膜，最后卷绕到芯材上，成为片卷的形态，根据使用方式，多数切割为预定宽度后出货。
PTFE多孔膜是富有柔软性的材料，因此在向芯材上卷绕时片张力不恒定，有时难以卷绕。另外，将片卷切割为预定宽度得到带卷时，有时卷绕的PTFE多孔膜象软垫一样活动从而使切割不能顺畅地进行。另外，有时卷绕的PTFE多孔膜的带开卷而使成品发生走形。
发明内容
因此，本发明的目的在于提供制造时容易卷绕、并且也容易切割的PTFE多孔膜的片卷。本发明的另一目的在于提供不易发生走形的PTFE多孔膜的带卷。
本发明的片卷通过聚四氟乙烯多孔膜与支撑体的层压体卷绕而得到，
所述多孔膜为未焙烧的聚四氟乙烯多孔膜，
所述多孔膜的孔隙率为50％以上、80％以下，
所述多孔膜的长度方向的伸长率为200％以下、并且长度方向的强度为20N/mm2以上、80N/mm2以下，
所述多孔膜的宽度方向的伸长率为1000％以上、并且宽度方向的强度为1N/mm2以下。
本发明的带卷通过聚四氟乙烯多孔膜与支撑体的层压体卷绕而得到，
所述多孔膜为未焙烧的聚四氟乙烯多孔膜，
所述多孔膜的孔隙率为50％以上、80％以下，
所述多孔膜的长度方向的伸长率为200％以下、并且长度方向的强度为20N/mm2以上、80N/mm2以下，
所述多孔膜的宽度方向的伸长率为1000％以上、并且宽度方向的强度为1N/mm2以下。
本发明的片卷在制造时容易卷绕，并且也容易切割。另外，本发明的带卷不易发生走形。
附图说明
图1是本发明的片卷的一般方式的侧视图。
具体实施方式
本发明中使用的PTFE多孔膜，通常是通过拉伸法制造的PTFE多孔膜。也可以使用通过拉伸法以外的方法得到的长条PTFE多孔膜。
列举拉伸法的一个具体例，首先，将在PTFE微粉中添加液状润滑剂而得到的糊状混合物进行预成形。PTFE微粉从容易进行糊膏挤出的观点考虑，适合作为PTFE的材料。液状润滑剂只要能够将PTFE微粉的表面润湿、并且能够通过萃取或加热而除去则没有特别限制，可以例如使用：液体石蜡、石脑油、白油等烃。液状润滑剂的添加量相对于PTFE微粉100重量份为约5重量份～约50重量份是适当的。上述预成形在不使液状润滑剂挤出程度的压力下进行。
然后，将该预成形体优选进行糊膏挤出，得到成形体。成形体的形状只要是能够拉伸的形状则没有特别限制，例如可以是带、片、管等。成形体的尺寸设定为通过后述的拉伸使PTFE多孔膜达到所需厚度的尺寸即可。另外，在成形体制作阶段，可以通过常规方法适当除去液状润滑剂。
将该成形体沿至少单轴方向拉伸，得到PTFE多孔膜。拉伸倍数没有特别规定，如果考虑拉伸不均匀和拉伸时的断裂等，优选面积拉伸倍数(单轴方向的拉伸倍数与该方向的垂直方向的拉伸倍数的积)为50～900倍。拉伸温度也没有特别规定，一般比PTFE的熔点(327℃)低(通常为150～300℃)。
要提高强度、提高尺寸稳定性等时，将PTFE多孔膜在PTFE熔点以上的温度(通常为330～500℃)下加热通常60秒以下来进行焙烧。可以将拉伸温度设定为PTFE熔点以上的温度，在拉伸的同时进行焙烧。
本发明中，PTFE多孔膜的厚度可以根据用途和使用方式适当选择，例如，可以为10μm以上、80μm以下。
本发明中，PTFE多孔膜的孔隙率可以根据用途和使用方式适当确定，通常优选为50％以上、80％以下，更优选60％以上、80％以下，特别优选65％以上、75％以下。
本发明中，PTFE多孔膜可以是焙烧品也可以是未焙烧品。
作为PTFE多孔膜的一个优选例，可以列举：作为未焙烧的PTFE多孔膜，孔隙率为50％以上、80％以下，长度方向的伸长率为200％以下并且长度方向的强度为20N/mm2以上、80N/mm2以下，宽度方向的伸长率为1000％以上并且宽度方向的强度为1N/mm2以下的PTFE多孔膜。该PTFE多孔膜，在将两片PTFE多孔膜重叠时具有相互胶粘的自粘性。使用该具有自粘性的PTFE多孔膜的带，作为用于捆扎电缆、特别是手机、笔记本电脑、数码相机、数码摄像机、医疗用具等的绞链部等的布线材料中使用的极细同轴电缆的捆扎带有用，该捆扎带的重卷操作容易，因此也可以用于暂时固定的目的。该具有自粘性的PTFE多孔膜的优选特性是：其为未焙烧的PTFE多孔膜，孔隙率为65％以上、75％以下，长度方向的伸长率为100％以上、200％以下并且长度方向的强度为40N/mm2以上、80N/mm2以下，宽度方向的伸长率为1000％以上、6500％以下并且宽度方向的强度为0.1N/mm2以上、1.0N/mm2以下。另外，强度和伸长率通过后述的实施例中详细记载的拉伸试验求出。
使用具有自粘性的PTFE多孔膜的带卷和片卷中，有时会产生无意的PTFE多孔膜间的胶粘。但是，将该具有自粘性的PTFE多孔膜用于本发明的带卷和片卷时，由于PTFE多孔膜由支撑体支撑并且分离为各层，因此不易产生无意的PTFE多孔膜间的胶粘，得到操作性优良的带卷和片卷。
具有自粘性的PTFE多孔膜，可以通过在通常240～300℃、优选270～290℃的温度下以通常5～15倍、优选6～10倍的倍数以单轴拉伸(纵向拉伸)进行上述拉伸而得到。
本发明中，使用PTFE多孔膜与支撑体的层压体。该支撑体用于支撑PTFE多孔膜，具体而言，具有支撑PTFE多孔膜以防止PTFE多孔膜过度变形的作用。因此，作为支撑体，可以不受限制地使用具有柔软性，可形成卷；硬度，片卷切割时能够赋予片卷适度的硬度；强度，使卷易于卷绕并能够抑制片卷走形；和弹性的材料。
支撑体的材质优选树脂和/或纸。因此，作为支撑体，可以优选使用树脂薄膜、纸和在纸的至少单面上涂布有树脂的复合薄膜。作为树脂薄膜的例子，可以列举聚酯薄膜、聚丙烯薄膜、聚乙烯薄膜等。作为纸的例子，可以列举美术纸、铜版纸等。作为复合薄膜的例子，可以列举在纸上涂布有上述树脂薄膜的树脂成分的复合薄膜。作为支撑体，从具有适度的强度、厚度精度高、PTFE多孔膜的剥离性高的观点考虑，特别优选聚酯薄膜。
构成聚酯薄膜的聚酯，可以列举具有将选自乙二醇、1，3-丙二醇、1，4-丁二醇、1，6-环己烷二甲醇等的至少一种多元醇(特别是二醇)与选自对苯二甲酸、2，6-萘二甲酸等的至少一种多元羧酸(特别是二元羧酸)缩合(共缩合)而得到的结构的聚酯，作为具体例，可以列举聚对苯二甲酸乙二醇酯(PET)、聚对苯二甲酸丁二醇酯(PBT)、聚萘二甲酸乙二醇酯(PEN)等。其中，PET在成本、强度、厚度精度任一方面均优良，因此优选。
支撑体的厚度优选为25μm以上、50μm以下，更优选25μm以上、38μm以下。
PTFE多孔膜与支撑体的层压体，可以是PTFE多孔膜与支撑体不胶粘而仅重叠而成的层压体。即，可以是PTFE多孔膜与支撑体直接重叠而成的层压体。层压方法优选压接，此时的压力优选为0.1～0.3MPa。
层压体的厚度优选为35μm以上、130μm以下，更优选35μm以上、118μm以下。
片卷和带卷均通过将层压体卷绕而得到，一般而言，将片卷切割来制造带卷，但是，本发明中，通过其宽度来区别它们。即，宽度超过50mm的为片卷，宽度为50mm以下的为带卷。带卷的宽度在实用上优选为1～50mm。
卷绕为片卷和带卷的层压体中，PTFE多孔膜和支撑体的任何一者均可以位于上面(卷的最外周为上面)，从保护PTFE多孔膜的观点考虑，优选支撑体位于上面。
片卷和带卷的大小，可以根据用途和使用方式适当确定。从卷绕作业的容易度及形态稳定性的观点考虑，片卷和带卷通常具有芯材，但也可以是不具有芯材的形态。芯材可以使用公知的材料。
图1中示意地显示本发明的一般方式的片卷的侧视图。芯材2上卷绕有PTFE多孔膜4与支撑体(例如，聚酯薄膜)5的层压体3，构成片卷1。为了保护PTFE多孔膜4，支撑体5在片卷1中位于上面(卷的外周侧)。使用时，如图1所示，由开卷的层压体3的末端部，能够容易地将PTFE多孔膜4从支撑体5上剥离。另外，带卷的侧视图也与图1相同。
PTFE多孔片卷的制造典型地包括：PTFE微粉与液状润滑剂的混合物的预成形工序、所得预成形体的成形工序、所得成形体的拉伸工序、PTFE多孔膜的焙烧工序(任意)、PTFE多孔膜的卷绕工序，本发明的片卷可以通过在卷绕工序前补充进行例如使用压接辊等将PTFE多孔膜与支撑体层压的工序来制造。并且，本发明的带卷可以通过利用刀具、切纸机等将该片卷切割为预定宽度而得到。
在此，通过将PTFE多孔膜与支撑体层压，在卷绕时能够得到稳定的片张力，从而容易实施卷绕工序。另外，得到的片卷容易切割，切割时不良品的发生率低。切割得到的带卷不易发生由于带的开卷而引起的成品的走形，因此操作性良好。
由于本发明的层压体可以是PTFE多孔膜与支撑体仅直接重叠而形成的层压体，因此使用时能够容易地除去支撑体，本发明的片卷和带卷通过从卷中开卷出预定的长度后切割并进行适当加工，能够作为PTFE多孔膜用于过滤膜、透气材料、电池用隔膜、电绝缘材料、人造血管、电缆捆扎材料等各种用途。
以下，列举实施例和比较例详细说明本发明，但是，本发明不限于以下实施例。
实施例1
使用PTFE微粉，通过糊膏挤出制作厚度0.15mm的片。将该片在280℃下纵向拉伸10倍而制成PTFE多孔膜。使用压接辊，在0.2MPa的压力下将该多孔膜与作为支撑体的厚度25μm的聚酯薄膜压接而得到层压体，将该层压体卷绕到外径85mm的芯材上，得到PTFE多孔膜厚度为0.035mm的片卷。卷绕时层压体的张力恒定，容易卷绕。另外，将该片切割为宽度25mm，得到带卷。此时，容易切割，未观察到带卷的走形。
实施例2
使用PTFE微粉，通过糊膏挤出制作厚度0.15mm的片。将该片在280℃下纵向拉伸10倍而制成PTFE多孔膜。使用压接辊，在0.3MPa的压力下将该多孔膜与作为支撑体的厚度25μm的聚酯薄膜压接而得到层压体，将该层压体卷绕到外径85mm的芯材上，得到PTFE多孔膜厚度为0.026mm的片卷。卷绕时层压体的张力恒定，容易卷绕。另外，将该片切割为宽度25mm，得到带卷。此时，容易切割，未观察到带卷的走形。
比较例1
使用PTFE微粉，通过糊膏挤出制作厚度0.15mm的片。将该片在280℃下纵向拉伸10倍而制成PTFE多孔膜，将该PTFE多孔膜卷绕到外径85mm的芯材上，得到片厚度为0.08mm的片卷。卷绕时层压体的张力不恒定，需要进行适当调节。另外，将该片切割为宽度25mm，得到带卷。出现切割不整齐、走形等约40％的不良品。
从实施例1和2得到的带卷上开卷出的PTFE多孔膜的特性按照以下所述进行评价。结果如表1所示。从实施例1和2得到的带卷上开卷出的PTFE多孔膜显示自粘性。
(1)孔隙率
PTFE多孔膜的孔隙率如下求出：由PTFE多孔膜的体积和重量求出松密度，设定PTFE树脂的真密度为2.28g/cm3，由式
{1-(重量[g]/(厚度[cm]×面积[cm2]×真密度[2.28g/cm3]))}×100(％)求出。
(2)自粘力
将两片切割为宽度25mm×长度100mm的短条状的PTFE多孔膜试样仅以宽度25mm×长度25mm重叠，并使用重2kg的辊进行压接。将一个端部固定，在另一个端部上悬挂重物，通过推拉力计测定拉伸保持力。
(3)强度和伸长率
将切割为宽度25mm×长度100mm的短条状的PTFE多孔膜试样以夹盘间距10mm固定在拉伸测定器上，以200mm/分钟的速度将试样拉伸至断裂。由下式求出强度和伸长率。
强度(N/mm2)＝断裂时的应力(N)÷截面积(试样的厚度×宽度)(mm2)
伸长率(％)＝断裂时的夹盘间距÷初始夹盘间距×100
表1
Figure GSB00000994250300091
产业实用性
本发明的片卷和带卷通过从卷中开卷出预定长度后切割并进行适当加工，能够作为PTFE多孔膜用于过滤膜、透气材料、电池用隔膜、电绝缘材料、人造血管、电缆捆扎材料等各种用途。

Claims (5)

1.一种片卷，通过聚四氟乙烯多孔膜与支撑体的层压体卷绕而得到，
所述多孔膜为未焙烧的聚四氟乙烯多孔膜，
所述多孔膜的孔隙率为50％以上、80％以下，
所述多孔膜的长度方向的伸长率为200％以下、并且长度方向的强度为20N/mm2以上、80N/mm2以下，
所述多孔膜的宽度方向的伸长率为1000％以上、并且宽度方向的强度为1N/mm2以下。
2.一种带卷，通过聚四氟乙烯多孔膜与支撑体的层压体卷绕而得到，
所述多孔膜为未焙烧的聚四氟乙烯多孔膜，
所述多孔膜的孔隙率为50％以上、80％以下，
所述多孔膜的长度方向的伸长率为200％以下、并且长度方向的强度为20N/mm2以上、80N/mm2以下，
所述多孔膜的宽度方向的伸长率为1000％以上、并且宽度方向的强度为1N/mm2以下。
3.如权利要求2所述的带卷，其中，所述支撑体的材质为树脂和/或纸。
4.如权利要求2所述的带卷，其中，所述支撑体为聚酯薄膜。
5.如权利要求2所述的带卷，其中，所述多孔膜的厚度为10μm以上、80μm以下。
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EP2161127A1 (en) 2010-03-10
WO2008156173A1 (ja) 2008-12-24
JP2009023345A (ja) 2009-02-05
JP5220489B2 (ja) 2013-06-26
EP2161127A4 (en) 2012-03-07

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