Microporous polyolefin film

Abstract

A microporous polyolefin film which comprises 5 to 95 wt. % polyethylene (A) having a viscosity-average molecular weight (Mv) of 2,000,000 or higher, a first-melting-peak signal height as determined by DSC (differential scanning calorimetry) of 3.0 mW/mg or higher, a specific surface area of 0.7 m 2 /g or larger, and an average particle diameter of 1 to 150 μm and 95 to 5 wt. % polyethylene (B) having an Mw of 10,000 to 200,000, excluding 10,000 and 200,000, wherein the ratio of the Mv of the compound (A) to that of the compound (B), (A)/(B), is 10 or higher, the film as a whole has a molecular weight of 300,000 to 1,500,000, and the film has a fuse temperature of 120 to 140° C., a breaking temperature of 150° C. or higher, and a ratio of the piercing strength at 25° C. to the piercing strength at 140° C. of from 0.01 to 0.25.

1 . A microporous polyolefin film which comprises 5 to 95 wt % of polyethylene (A) having a viscosity average molecular weight (Mv) of 2,000,000 or more, a first melting-peak signal height as determined by DSC (differential scanning calorimetry) of 3.0 mW/mg or more, a specific surface area of 0.7 m 2 /g or more, and an average particle size of 1 to 150 μm and 95 to 5 wt % of polyethylene (B) having an Mw of more than 10,000 and less than 200,000, wherein the Mv ratio of the component (A) to the component (B), (A)/(B), is 10 or more, the film as a whole has a molecular weight of 300,000 to 1,500,000, and the film has a fuse temperature of 120 to 140° C., a film breakage temperature of 150° C. or more, and a ratio of the piercing strength at 140° C. to the piercing strength at 25° C. of 0.01 to 0.25.  
   
   
       2 . The microporous polyolefin film according to  claim 1 , wherein the fuse temperature is 120 to 135° C.  
   
   
       3 . The microporous polyolefin film according to  claim 1 , wherein the fuse temperature is 120 to 133° C.  
   
   
       4 . The microporous polyolefin film according to any of  claims 1  to  3  having a short-circuit temperature of 152° C. or more.  
   
   
       5 . The microporous polyolefin film according to  claim 1  having a thermal shrinkage starting temperature in a TD direction of 90° C. or more.  
   
   
       6 . The microporous polyolefin film according to  claim 5  having a thermal shrinkage starting temperature in the TD direction of 100° C. or more.  
   
   
       7 . The microporous polyolefin film according to  claim 6  having a thermal shrinkage starting temperature in the TD direction of 110° C. or more.  
   
   
       8 . The microporous polyolefin film according to  claim 1  having a film thickness of 5 to 24 μm.  
   
   
       9 . The microporous polyolefin film according to  claim 1  having a porosity of 30 to 60%.  
   
   
       10 . The microporous polyolefin film according to  claim 1  having a 25° C. piercing strength of 3 to 10 N/20 μm.  
   
   
       11 . A process for producing a microporous polyolefin film which has a molecular weight of 300,000 to 1,500,000 as a whole of the film, a fuse temperature of 120 to 140° C., a film breakage temperature of 150° C. or more, and a ratio of the piercing strength at 140° C. to the piercing strength at 25° C. of 0.01 to 0.25, the process comprising kneading a mixture comprising a polyolefin composition comprising 5 to 95 wt % of polyethylene (A) having a viscosity average molecular weight (Mv) of 2,000,000 or more, a first melting-peak signal height as determined by DSC (differential scanning calorimetry) of 3.0 mW/mg or more, a specific surface area of 0.7 m 2 /g or more and an average particle size of 1 to 150 μm and 95 to 5 wt % of polyethylene (B) having an Mw of more than 10,000 and less than 200,000, wherein the Mv ratio of the component (A) to the component (B), (A)/(B), is 10 or more, with a plasticizer; extruding the kneaded product and then molding the product into a gel-like sheet to cool and solidify the sheet; drawing the resulting gel-like sheet; extracting the plasticizer to dry the sheet; and thermally fixing the film, wherein the thermal fixation step comprises a step of drawing the film in a TD direction after extracting the plasticizer and a subsequent step of thermally shrinking the film in the TD direction with reference to film width after the drawing step.  
   
   
       12 . The process according to  claim 11 , wherein the drawing step is a step of drawing the film after extracting the plasticizer by at least 20% in the TD direction and the thermal shrinkage step is a step of thermally shrinking the film after extracting the plasticizer by at least 10% in the TD direction with reference to the film width after the drawing step.  
   
   
       13 . The microporous polyolefin film according to  claim 1 , wherein said film has a fuse temperature of 120 to 133° C., a short-circuit temperature of 152° C. or more, a thermal shrinkage starting temperature in the TD direction of 110° C. or more and a film thickness of 5 to 24 μm.  
   
   
       14 . The microporous polyolefin film according to  claim 1 , wherein said film has a fuse temperature of 120 to 133° C., a short-circuit temperature of 152° C. or more, a thermal shrinkage starting temperature in the TD direction of 110° C. or more and a porosity of 30 to 60%.  
   
   
       15 . The microporous polyolefin film according to  claim 1 , wherein said film has a fuse temperature of 120 to 133° C., a short-circuit temperature of 152° C. or more, a thermal shrinkage starting temperature in the TD direction of 110° C. or more and a 25° C. piercing strength of 3 to 10 N/20 μm.