Binder for secondary battery functional layer, slurry composition for secondary battery functional layer, functional layer for secondary battery, and secondary battery

Abstract

The purpose of the present invention is to provide a binder for a functional layer of a secondary battery, with which it is possible to form a functional layer having excellent thermal shrinkage resistance and electrolyte affinity. This binder for a functional layer of a secondary battery contains a particulate polymer and is characterized in that the particulate polymer contains a cyano group-containing monomer unit, a cyclic ether-containing monomer unit and a carboxyl group-containing monomer unit, and the content of the cyclic ether-containing monomer unit in the particulate polymer is 5 mass% or more.

Description

[Technical Field]

[0001] The present invention relates to a binder for a secondary battery functional layer, a slurry composition for a secondary battery functional layer, a functional layer for a secondary battery, and a secondary battery. [Background technology]

[0002] Secondary batteries such as lithium-ion secondary batteries are small, lightweight, have high energy density, and can be repeatedly charged and discharged, and are therefore used in a wide range of applications. Secondary batteries generally include battery components such as electrodes (positive and negative electrodes) and a separator that separates the positive and negative electrodes to prevent short circuits between them.

[0003] Here, as the battery component of the secondary battery, a component having a functional layer containing a binder and, optionally, particles (hereinafter referred to as "functional particles") that are blended to enable the battery component to exhibit a desired function is used. Specifically, a separator for a secondary battery is used that includes an adhesive layer containing a binder or a porous membrane layer containing a binder and non-conductive particles as functional particles on a separator substrate, and an electrode for a secondary battery is used that includes the above-mentioned adhesive layer or porous membrane layer on an electrode substrate formed by providing an electrode mixture layer on a current collector.

[0004] In order to further improve the performance of secondary batteries, attempts have been made to improve binders. For example, Patent Document 1 discloses a binder for non-aqueous secondary battery functional layers, which contains a particulate polymer containing (meth)acrylic acid alkyl ester monomer units, aromatic monovinyl monomer units, epoxy / N-methylol crosslinkable monomer units, and polyethylenically unsaturated crosslinkable monomer units in predetermined proportions, and which has a swelling degree in a non-aqueous electrolyte solution within a predetermined range. According to Patent Document 1, the use of this binder makes it possible to form a functional layer that exhibits excellent adhesion both before and after immersion in an electrolyte solution, and further makes it possible to improve the life characteristics of non-aqueous secondary batteries equipped with such a functional layer. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Patent No. 6515574 Summary of the Invention [Problem to be solved by the invention]

[0006] In order to increase the capacity of secondary batteries, it is necessary to reduce the thickness of battery components. However, when the functional layer formed using the binder of the above-mentioned conventional technology is reduced in thickness, there is still room for improvement in the heat shrinkage resistance of the functional layer.

[0007] Furthermore, in order to increase the capacity of secondary batteries, it is also desirable to increase the density of secondary batteries. However, increasing the density of secondary batteries may decrease the injection speed of electrolyte during the manufacture of the secondary battery, i.e., the electrolyte injection property of the secondary battery. Here, in order to ensure sufficiently high electrolyte injection property while increasing the density of secondary batteries, it is desirable to increase the affinity of the functional layer of the secondary battery for the electrolyte (hereinafter, sometimes referred to as "electrolyte affinity"). However, the functional layer formed using the binder of the above-mentioned conventional technology has room for improvement in electrolyte affinity.

[0008] Therefore, an object of the present invention is to provide a binder for a functional layer of a secondary battery that can form a functional layer that has excellent resistance to heat shrinkage and affinity for an electrolyte solution. Another object of the present invention is to provide a slurry composition for a secondary battery functional layer that can form a functional layer that has excellent resistance to heat shrinkage and affinity for an electrolyte solution. Another object of the present invention is to provide a functional layer for a secondary battery that has excellent resistance to heat shrinkage and affinity for an electrolyte. A further object of the present invention is to provide a secondary battery including the functional layer. [Means for solving the problem]

[0009] The present inventors have conducted extensive research to solve the above problems, and have newly discovered that the heat shrinkage resistance and electrolyte affinity of a functional layer can be improved by using a binder containing a specific particulate polymer, thereby completing the present invention.

[0010] The present invention aims to advantageously solve the above-mentioned problems, and provides a binder for a secondary battery functional layer, which comprises a particulate polymer, characterized in that the particulate polymer comprises a cyano group-containing monomer unit, a cyclic ether-containing monomer unit, and a carboxyl group-containing monomer unit, and the content of the cyclic ether-containing monomer unit in the particulate polymer is 5 mass% or more. By using a binder containing a particulate polymer having the above-mentioned predetermined composition, a functional layer excellent in heat shrinkage resistance and electrolyte affinity can be formed. In the present invention, "containing a monomer unit" means that "a polymer obtained using the monomer contains a repeating unit derived from the monomer." In addition, in the present invention, the "content ratio (mass%)" of each monomer unit (each repeating unit) contained in the polymer is 1 H-NMR and 13 It can be measured using nuclear magnetic resonance (NMR) techniques such as C-NMR.

[0011] In the binder for a secondary battery functional layer of the present invention, the content of the cyclic ether-containing monomer unit in the particulate polymer is preferably 40 mass% or less. If the content of the cyclic ether-containing monomer unit in the particulate polymer is equal to or less than the above-mentioned predetermined value, the heat shrinkage resistance and the affinity for the electrolyte solution of the functional layer can be further improved, and the adhesiveness of the functional layer can be increased.

[0012] In addition, in the binder for a secondary battery functional layer of the present invention, the particulate polymer preferably has one glass transition temperature. If the particulate polymer has one glass transition temperature, the adhesiveness of the functional layer can be improved.

[0013] Furthermore, in the binder for a secondary battery functional layer of the present invention, the particulate polymer preferably has a glass transition temperature of 20° C. or lower. If the glass transition temperature of the particulate polymer is equal to or lower than the above-mentioned predetermined value, the adhesiveness of the functional layer can be improved. In the present invention, the "glass transition temperature" of the particulate polymer can be measured by the method described in the examples of this specification.

[0014] In addition, in the binder for a secondary battery functional layer of the present invention, the content of the cyano group-containing monomer unit in the particulate polymer is preferably 2% by mass or more and 30% by mass or less. If the content of the cyano group-containing monomer unit in the particulate polymer is within the above-mentioned range, the affinity of the functional layer for the electrolyte solution can be further improved and the adhesiveness of the functional layer can be increased. Furthermore, if the content of the cyano group-containing monomer unit in the particulate polymer is within the above-mentioned range, the internal resistance of a secondary battery including a functional layer can be reduced.

[0015] Furthermore, in the binder for a secondary battery functional layer of the present invention, the content of the carboxyl group-containing monomer unit in the particulate polymer is preferably 0.1% by mass or more and 10% by mass or less. If the content of the carboxyl group-containing monomer unit in the particulate polymer is within the above-mentioned range, the affinity of the functional layer for the electrolyte solution can be further improved and the adhesiveness of the functional layer can be increased.

[0016] In addition, in the binder for a secondary battery functional layer of the present invention, the particulate polymer preferably further contains (meth)acrylic acid alkyl ester monomer units, and the content of the (meth)acrylic acid alkyl ester monomer units in the particulate polymer is preferably 40% by mass or more and 92% by mass or less. If the content of the (meth)acrylic acid alkyl ester monomer units in the particulate polymer is within the above-mentioned range, the heat shrinkage resistance and electrolyte affinity of the functional layer can be further improved, and the adhesiveness of the functional layer and the cycle characteristics of a secondary battery including the functional layer can be improved.

[0017] Furthermore, in the binder for a secondary battery functional layer of the present invention, the particulate polymer preferably has a gel content of 85 mass % or more. If the gel content of the particulate polymer is equal to or greater than the above-mentioned predetermined value, the cycle characteristics of a secondary battery including the functional layer can be improved. In the present invention, the "gel content of the particulate polymer" can be measured using the method described in the examples of this specification.

[0018] In the binder for a secondary battery functional layer of the present invention, the particulate polymer preferably has a volume average particle diameter of 0.05 μm or more and 0.25 μm or less. If the volume average particle diameter of the particulate polymer is within the above range, the adhesiveness and affinity for the electrolyte solution of the functional layer can be further improved. In the present invention, the "volume average particle size" refers to the particle size at which the cumulative volume calculated from the small diameter side in the particle size distribution (volume basis) measured by laser diffraction method is 50%.

[0019] The present invention also aims to advantageously solve the above-mentioned problems, and provides a slurry composition for a secondary battery functional layer, which is characterized by containing any one of the binders described above. By using a slurry composition containing any one of the binders described above, a functional layer having excellent heat shrinkage resistance and electrolyte affinity can be formed.

[0020] Here, the slurry composition for a secondary battery functional layer of the present invention may further contain functional particles.

[0021] For example, in the slurry composition for a secondary battery functional layer of the present invention, the functional particles may contain non-conductive particles. The slurry composition for a secondary battery functional layer of the present invention containing non-conductive particles as functional particles can be suitably used for forming a porous membrane layer.

[0022] Furthermore, in the slurry composition for a secondary battery functional layer of the present invention, the non-conductive particles preferably have a volume average particle diameter of 1.5 μm or less. If the volume average particle diameter of the non-conductive particles is equal to or less than the above-mentioned predetermined value, the adhesiveness of the porous membrane layer as the formed functional layer can be improved.

[0023] The present invention also aims to advantageously solve the above-mentioned problems, and provides a functional layer for a secondary battery of the present invention, which is formed using the above-mentioned slurry composition for a secondary battery functional layer. The functional layer formed from the above-mentioned slurry composition has excellent heat shrinkage resistance and electrolyte affinity.

[0024] The present invention also aims to advantageously solve the above-mentioned problems, and provides a secondary battery comprising the above-mentioned functional layer for a secondary battery. The secondary battery comprising the above-mentioned functional layer has excellent electrolyte injection properties.

[0025] In this specification, a functional layer containing a binder and non-conductive particles such as inorganic particles is referred to as a "porous membrane layer" or a "heat-resistant layer," and a functional layer containing a binder but not containing non-conductive particles such as inorganic particles is referred to as an "adhesive layer." The "binder" mentioned above preferably includes, for example, the binder for the secondary battery functional layer of the present invention. Generally, the porous membrane layer (heat-resistant layer) functions to improve heat resistance and strength, while the adhesive layer functions to improve adhesion. However, the porous membrane layer (heat-resistant layer) may also have the function of improving adhesion in addition to the function of improving heat resistance and strength, and such a porous membrane layer (heat-resistant layer) may be referred to as a "heat-resistant adhesive layer." [Effects of the Invention]

[0026] According to the present invention, it is possible to provide a binder for a secondary battery functional layer that can form a functional layer that has excellent heat shrinkage resistance and affinity for an electrolyte solution. Furthermore, according to the present invention, it is possible to provide a slurry composition for a secondary battery functional layer, which is capable of forming a functional layer having excellent resistance to heat shrinkage and affinity for an electrolyte solution. Furthermore, according to the present invention, it is possible to provide a functional layer for a secondary battery that has excellent resistance to heat shrinkage and affinity for an electrolyte solution. Furthermore, according to the present invention, a secondary battery including the functional layer can be provided. DETAILED DESCRIPTION OF THE INVENTION

[0027] Hereinafter, embodiments of the present invention will be described in detail. Here, the binder for a secondary battery functional layer of the present invention (hereinafter sometimes simply referred to as "binder") is used in the production of any functional layer (e.g., a porous membrane layer and an adhesive layer) that performs functions such as reinforcement or adhesion in a secondary battery. For example, the binder for a secondary battery functional layer of the present invention can be used to prepare a slurry composition for a secondary battery functional layer of the present invention (hereinafter sometimes simply referred to as "slurry composition"). The slurry composition for a secondary battery functional layer of the present invention can be used to form the above-mentioned functional layer. Furthermore, the functional layer for a secondary battery of the present invention is formed from the slurry composition for a secondary battery functional layer of the present invention. The secondary battery of the present invention comprises the functional layer for a secondary battery of the present invention. For example, the secondary battery of the present invention comprises a positive electrode, a negative electrode, and a separator as battery components, and at least one of the above-mentioned battery components comprises the functional layer for a secondary battery of the present invention. That is, the secondary battery of the present invention comprises a battery component having the functional layer of the present invention.

[0028] (Binder for secondary battery functional layer) The binder of the present invention contains a predetermined particulate polymer. The binder of the present invention is usually a composition in which the particulate polymer is dispersed in a solvent. The binder of the present invention may further contain components other than the particulate polymer and the solvent (hereinafter referred to as "other components").

[0029] <Particulate polymer> The particulate polymer is a component that functions as a binder, imparting adhesiveness to the functional layer formed using a slurry composition containing the binder, and also retaining components contained in the functional layer (e.g., functional particles such as non-conductive particles) from detaching from the functional layer.

[0030] Here, the particulate polymer contains a cyano group-containing monomer unit, a cyclic ether-containing monomer unit, and a carboxyl group-containing monomer unit. The content of the cyclic ether-containing monomer unit in the particulate polymer is a predetermined value or more. The particulate polymer may optionally further contain monomer units other than the cyano group-containing monomer unit, the cyclic ether-containing monomer unit, and the carboxyl group-containing monomer unit (hereinafter referred to as "other monomer units").

[0031] Since the binder of the present invention contains the particulate polymer having the above-described composition, the functional layer formed using the binder of the present invention can exhibit excellent heat shrinkage resistance and electrolyte affinity. In addition, the functional layer formed using the binder of the present invention also has excellent adhesiveness. The reason why the binder of the present invention can improve the heat shrinkage resistance, electrolyte affinity, and adhesiveness of the functional layer is not clear, but is presumed to be as follows. First, since the particulate polymer in the binder of the present invention contains a carboxyl group-containing monomer unit, it is presumed that the particle stability is excellent and the particle surface has high hydrophilicity, thereby improving the electrolyte affinity and adhesion of the functional layer. Furthermore, since the particulate polymer in the binder of the present invention contains a cyano group-containing monomer unit, the inside of the particle becomes hydrophobic, and the carboxyl groups of the above-mentioned carboxyl group-containing monomer unit are relatively unevenly distributed on the particle surface, increasing the amount of surface acid, which is thought to improve the electrolyte affinity and adhesion of the functional layer. Furthermore, the particulate polymer in the binder of the present invention contains a cyclic ether-containing monomer unit at a content ratio equal to or greater than a predetermined value, and thus has a cyclic ether structure on the particle surface. It is presumed that the cyclic ether structure of the particulate polymer interacts with the surface of the separator substrate (e.g., a surface hydrophilized by surface treatment) and other components, such as a water-soluble polymer, contained in the functional layer. This interaction stabilizes the layer structure of the functional layer, thereby improving the heat shrinkage resistance and electrolyte affinity of the functional layer. It is also presumed that this interaction improves the adhesion of the functional layer.

[0032] <Cyano group-containing monomer unit> Examples of cyano group-containing monomers that can form cyano group-containing monomer units include (meth)acrylonitriles such as acrylonitrile and methacrylonitrile; α-halogenoacrylonitriles such as α-chloroacrylonitrile and α-bromoacrylonitrile; 2-cyanoethyl (meth)acrylates such as 2-cyanoethyl acrylate and 2-cyanoethyl methacrylate; and 2-cyanoethyl acrylamide. From the viewpoint of further improving the adhesiveness of the functional layer, it is preferable to use (meth)acrylonitrile, and it is more preferable to use acrylonitrile. These may be used alone or in combination of two or more in any ratio. In the present invention, "(meth)acrylonitrile" means acrylonitrile and / or methacrylonitrile, and "(meth)acrylate" means acrylate and / or methacrylate.

[0033] When the total repeating units (total monomer units) contained in the particulate polymer is taken as 100% by mass, the content of the cyano group-containing monomer units is preferably 2% by mass or more, more preferably 5% by mass or more, even more preferably 10% by mass or more, and preferably 30% by mass or less, more preferably 25% by mass or less, and even more preferably 20% by mass or less. When the content of the cyano group-containing monomer units in the particulate polymer is equal to or greater than the lower limit, the electrolyte affinity and adhesiveness of the functional layer can be further improved. On the other hand, when the content of the cyano group-containing monomer units in the particulate polymer is equal to or less than the upper limit, the electrolyte affinity and adhesiveness of the functional layer can be further improved, and the internal resistance of a secondary battery including the functional layer can be reduced.

[0034] <Cyclic ether-containing monomer unit> The cyclic ether-containing monomer capable of forming the cyclic ether-containing monomer unit is not particularly limited as long as it is a monomer containing a cyclic ether structure, and examples thereof include a monomer containing an epoxy group (epoxy ring) (epoxy group-containing monomer unit), a monomer containing an oxetanyl group (oxetane ring) (oxetanyl group-containing monomer unit), etc. Among them, it is preferable to use an epoxy group-containing monomer from the viewpoint of further improving the heat shrinkage resistance, affinity for the electrolyte solution, and adhesiveness of the functional layer. Examples of epoxy group-containing monomers include allyl glycidyl ether, glycidyl (meth)acrylate, 3,4-epoxycyclohexylmethyl methacrylate, and 4-hydroxybutyl acrylate glycidyl ether.

[0035] When the total repeating units (total monomer units) contained in the particulate polymer is taken as 100% by mass, the content of the cyclic ether-containing monomer units must be 5% by mass or more, preferably 10% by mass or more, preferably 40% by mass or less, and more preferably 30% by mass or less. When the content of the cyclic ether-containing monomer units in the particulate polymer is equal to or greater than the above-mentioned lower limit, the functional layer formed using the binder can exhibit excellent heat shrinkage resistance, electrolyte affinity, and adhesiveness. Furthermore, when the content of the cyclic ether-containing monomer units in the particulate polymer is equal to or greater than the above-mentioned lower limit, the gel content of the particulate polymer increases, thereby improving the cycle characteristics of a secondary battery including the functional layer. On the other hand, when the content of the cyclic ether-containing monomer units in the particulate polymer is equal to or less than the above-mentioned upper limit, the heat shrinkage resistance, electrolyte affinity, and adhesiveness of the functional layer can be further improved.

[0036] <Carboxyl group-containing monomer unit> Examples of carboxyl-containing monomers capable of forming carboxyl-group-containing monomer units include monocarboxylic acids and derivatives thereof, dicarboxylic acids and acid anhydrides thereof, and derivatives thereof. Examples of the monocarboxylic acid include acrylic acid, methacrylic acid, and crotonic acid. Examples of the monocarboxylic acid derivatives include 2-ethylacrylic acid, isocrotonic acid, α-acetoxyacrylic acid, β-trans-aryloxyacrylic acid, and α-chloro-β-E-methoxyacrylic acid. Examples of dicarboxylic acids include maleic acid, fumaric acid, and itaconic acid. Examples of dicarboxylic acid derivatives include methylmaleic acid, dimethylmaleic acid, phenylmaleic acid, chloromaleic acid, dichloromaleic acid, fluoromaleic acid, and maleic acid monoesters such as nonyl maleate, decyl maleate, dodecyl maleate, octadecyl maleate, and fluoroalkyl maleate. Examples of the acid anhydrides of dicarboxylic acids include maleic anhydride, acrylic anhydride, methyl maleic anhydride, and dimethyl maleic anhydride. Furthermore, as the carboxyl group-containing monomer, an acid anhydride that generates a carboxyl group upon hydrolysis can also be used. These may be used alone or in combination of two or more. Among these, from the viewpoint of further improving the affinity and adhesiveness of the functional layer to the electrolyte solution, it is preferable to use acrylic acid, methacrylic acid, and itaconic acid, and it is more preferable to use acrylic acid and methacrylic acid.

[0037] When the total repeating units (total monomer units) contained in the particulate polymer is taken as 100% by mass, the content of the carboxyl group-containing monomer units is preferably 0.1% by mass or more, more preferably 1% by mass or more, even more preferably 2% by mass or more, and preferably 10% by mass or less, and more preferably 5% by mass or less. If the content of the carboxyl group-containing monomer units in the particulate polymer is equal to or greater than the lower limit, the affinity and adhesiveness of the functional layer for the electrolyte can be further improved. On the other hand, if the content of the carboxyl group-containing monomer units in the particulate polymer is equal to or less than the upper limit, the adhesiveness of the functional layer can be further improved.

[0038] <Other monomer units> The particulate polymer may contain other monomer units in addition to the above-mentioned cyano group-containing monomer units, cyclic ether-containing monomer units, and carboxyl group-containing monomer units. The monomer units are not particularly limited, but preferably include (meth)acrylic acid alkyl ester monomer units and crosslinkable monomer units. If the particulate polymer further contains (meth)acrylic acid alkyl ester monomer units, the adhesiveness of the functional layer can be further improved. Furthermore, if the particulate polymer further contains crosslinkable monomer units, the heat shrinkage resistance of the functional layer can be further improved. As described above, the (meth)acrylic acid alkyl ester monomer unit and the crosslinkable monomer unit are monomer units other than cyano group-containing monomer units, cyclic ether-containing monomer units, and carboxyl group-containing monomer units. Therefore, the (meth)acrylic acid alkyl ester monomers capable of forming the (meth)acrylic acid alkyl ester monomer units and the crosslinkable monomers capable of forming the crosslinkable monomer units do not include the above-mentioned cyano group-containing monomers, cyclic ether-containing monomers, and carboxyl group-containing monomers. In the present invention, (meth)acrylic means acrylic and / or methacrylic.

[0039] <<(Meth)acrylic acid alkyl ester monomer unit>> Examples of (meth)acrylic acid alkyl ester monomers that can form (meth)acrylic acid alkyl ester monomer units include alkyl acrylates such as methyl acrylate, ethyl acrylate, n-propyl acrylate, isopropyl acrylate, n-butyl acrylate, t-butyl acrylate, isobutyl acrylate, n-pentyl acrylate, isopentyl acrylate, hexyl acrylate, heptyl acrylate, octyl acrylate, 2-ethylhexyl acrylate, nonyl acrylate, decyl acrylate, lauryl acrylate, n-tetradecyl acrylate, and stearyl acrylate. methacrylic acid alkyl esters such as methyl methacrylate, ethyl methacrylate, n-propyl methacrylate, isopropyl methacrylate, n-butyl methacrylate, t-butyl methacrylate, isobutyl methacrylate, n-pentyl methacrylate, isopentyl methacrylate, hexyl methacrylate, heptyl methacrylate, octyl methacrylate, 2-ethylhexyl methacrylate, nonyl methacrylate, decyl methacrylate, lauryl methacrylate, n-tetradecyl methacrylate, stearyl methacrylate, and glycidyl methacrylate. These may be used alone or in combination of two or more. Among these, from the viewpoints of further improving the adhesiveness of the functional layer and further improving the heat shrinkage resistance, it is preferable to use 2-ethylhexyl acrylate and butyl acrylate, and it is more preferable to use butyl acrylate.

[0040] When all repeating units (total monomer units) contained in the particulate polymer are taken as 100% by mass, the content of (meth)acrylic acid alkyl ester monomer units is preferably 40% by mass or more, more preferably 50% by mass or more, and preferably 92% by mass or less, and more preferably 80% by mass or less. If the content of (meth)acrylic acid alkyl ester monomer units in the particulate polymer is equal to or greater than the above-mentioned lower limit, the adhesiveness of the functional layer can be further improved. On the other hand, if the content of (meth)acrylic acid alkyl ester monomer units in the particulate polymer is equal to or less than the above-mentioned upper limit, the heat shrinkage resistance of the functional layer can be further improved, and the cycle characteristics of a secondary battery including the functional layer can be improved.

[0041] <<Crosslinkable monomer unit>> The crosslinkable monomer capable of forming a crosslinkable monomer unit is a monomer capable of forming a crosslinked structure during or after polymerization by heating or irradiation with energy rays. Examples of crosslinkable monomers include polyfunctional monomers having two or more polymerization reactive groups. Examples of such polyfunctional monomers include divinyl monomers such as divinylbenzene, 1,3-butadiene, isoprene, and allyl methacrylate; di(meth)acrylic acid alkyl ester monomers such as ethylene dimethacrylate, diethylene glycol dimethacrylate, ethylene glycol dimethacrylate (EDMA), diethylene glycol diacrylate, and 1,3-butylene glycol diacrylate; tri(meth)acrylic acid alkyl ester monomers such as trimethylolpropane trimethacrylate and trimethylolpropane triacrylate; N-methylol group-containing monomers such as N-methylol(meth)acrylamide; and γ-methacryloxypropyltrimethoxysilane. These may be used alone or in combination of two or more. Among these, from the viewpoint of further improving the heat shrinkage resistance of the functional layer, it is preferable to use divinylbenzene, allyl methacrylate, ethylene glycol dimethacrylate, and N-methylol acrylamide, and it is more preferable to use allyl methacrylate and N-methylol acrylamide.

[0042] When the total repeating units (total monomer units) contained in the particulate polymer is taken as 100% by mass, the content of the crosslinkable monomer units is preferably 0.1% by mass or more, more preferably 0.2% by mass or more, and even more preferably 0.4% by mass or more, and is preferably 10% by mass or less, more preferably 5% by mass or less, and even more preferably 2% by mass or less. If the content of the crosslinkable monomer units in the particulate polymer is equal to or greater than the above lower limit, the heat shrinkage resistance of the functional layer can be further improved. On the other hand, if the content of the crosslinkable monomer units in the particulate polymer is equal to or less than the above upper limit, the adhesiveness of the functional layer can be further improved.

[0043] <Properties of particulate polymer> The structure of the particulate polymer contained in the binder of the present invention is not particularly limited, and may be any of a block copolymer, a graft copolymer, and a random copolymer, but is preferably a random copolymer. The particulate polymer may have a core-shell structure comprising a core and a shell covering at least a part of the outer surface of the core, but it is preferable that the particulate polymer does not have a core-shell structure. Therefore, it is particularly preferable that the particulate polymer is a random copolymer that does not have a core-shell structure.

[0044] <<Structure and Glass Transition Temperature of Particulate Polymers>> When the particulate polymer is a random copolymer without a core-shell structure, the particulate polymer can be homogenized, the durability of the particulate polymer against the electrolyte (electrolyte resistance) can be increased, and the dispersibility of the particulate polymer in the slurry composition can also be improved. Furthermore, since the viscosity of the slurry composition can be reduced, it becomes easier to remove moisture from the functional layer when the slurry composition is dried to form the functional layer. As a result, the adhesion of the functional layer can be further improved. In the present invention, whether or not the particulate polymer is a random copolymer having no core-shell structure is determined by measuring the glass transition temperature. Specifically, when a particulate polymer that is a copolymer has one glass transition temperature, the particulate polymer satisfies both of the following conditions: (1) it does not have a core-shell structure, and (2) it is a random copolymer (i.e., it corresponds to a random copolymer that does not have a core-shell structure). On the other hand, when a particulate polymer has two or more glass transition temperatures, the particulate polymer does not satisfy at least one of the above conditions (1) and (2) (i.e., it does not correspond to a "random copolymer that does not have a core-shell structure").

[0045] The glass transition temperature of the particulate polymer is preferably 20°C or lower, more preferably 10°C or lower, and even more preferably 0°C or lower. If the glass transition temperature of the particulate polymer is lower than the upper limit, the adhesiveness of the functional layer can be further improved. The lower limit of the glass transition temperature of the particulate polymer is not particularly limited, but is usually -100°C or higher.

[0046] <<Electrolyte swelling rate>> In the present invention, the "electrolyte swelling degree" of the particulate polymer can be determined as a value (times) obtained by dividing the weight of a film (binder film) formed from the particulate polymer after immersion in a specific non-aqueous electrolyte solution under predetermined conditions by the weight before immersion. Specifically, the binder film can be formed using the method described in the examples of this specification, and the degree of swelling can be measured using the measurement method described in the examples. The swelling degree of the particulate polymer in the electrolyte solution is preferably 2 times or more, more preferably 3 times or more, and preferably 8 times or less, and more preferably 6 times or less. If the swelling degree of the particulate polymer in the electrolyte solution is within the above-mentioned range, the internal resistance of the secondary battery can be reduced. The degree of swelling of the particulate polymer in an electrolyte solution can be adjusted by changing the type and amount of the monomer used and the polymerization reaction conditions (for example, polymerization temperature, polymerization reaction time, etc.).

[0047] <<Volume average particle size>> The volume average particle diameter of the particulate polymer is preferably 0.05 μm or more, more preferably 0.10 μm or more, even more preferably 0.14 μm or more, and preferably 0.25 μm or less, more preferably 0.20 μm or less. If the volume average particle diameter of the particulate polymer is above the lower limit, the air permeability of the functional layer is increased, thereby further improving the affinity of the functional layer for the electrolyte. On the other hand, if the volume average particle diameter of the particulate polymer is below the upper limit, the adhesion and affinity of the functional layer for the electrolyte can be further improved.

[0048] <<Gel content>> The gel content of the particulate polymer is preferably 85% by mass or more, more preferably 90% by mass or more. If the gel content of the particulate polymer is equal to or more than the lower limit, the amount of components eluted into the electrolyte can be reduced, and the cycle characteristics of a secondary battery having a functional layer can be improved. The upper limit of the gel content of the particulate polymer is not particularly limited, but is usually 99% by mass or less. The gel content can be adjusted by changing the polymerization temperature, the type and amount of additives such as molecular weight modifiers, the conversion rate (amount of monomer consumed) when the reaction is stopped, etc. For example, the gel content can be increased by reducing the amount of molecular weight modifier used during polymerization, and the gel content can be decreased by increasing the amount of molecular weight modifier used during polymerization.

[0049] <Preparation of particulate polymer> The particulate polymer is prepared by polymerizing a monomer composition containing the above-mentioned monomers. Here, the content ratio of each monomer in the monomer composition is usually set to the same as the content ratio of the monomer unit in the desired particulate polymer. The polymerization mode of the particulate polymer is not particularly limited, and any method such as solution polymerization, suspension polymerization, bulk polymerization, or emulsion polymerization may be used. The polymerization reaction may be addition polymerization such as ionic polymerization, radical polymerization, or living radical polymerization. The emulsifier, dispersant, polymerization initiator, and polymerization aid used in the polymerization may be any commonly used agent, and the amounts used are also the amounts commonly used. Here, when preparing a particulate polymer composed of a random copolymer not having a core-shell structure, the production of a block copolymer and a graft copolymer can be suppressed by initiating polymerization in the monomer state in the monomer composition, rather than in the oligomer state in which the monomers are polymerized to a certain extent.

[0050] <Solvent> As the solvent that can be contained in the binder of the present invention, known solvents that can disperse the above-mentioned particulate polymer can be used. Among them, it is preferable to use water as the solvent. Note that at least a part of the solvent that can be contained in the binder is not particularly limited and can be the polymerization solvent used in preparing the particulate polymer.

[0051] <Preparation of binder for non-aqueous secondary battery functional layer> The method for preparing the binder of the present invention is not particularly limited, but for example, when the particulate polymer is prepared in a solvent such as water and the particulate polymer is obtained as a dispersion, the dispersion of the particulate polymer may be used as the binder as it is, or other components may be added to the dispersion of the particulate polymer to form the binder. Examples of other components include other components described later in the section "Slurry composition for secondary battery functional layer."

[0052] (Slurry composition for secondary battery functional layer) The slurry composition of the present invention is a composition used to form a functional layer, and contains the binder described above, and optionally further contains functional particles and other components. That is, the slurry composition of the present invention typically contains a particulate polymer and a solvent, and optionally further contains functional particles and other components. Furthermore, since the slurry composition of the present invention contains the binder described above, a functional layer having excellent heat shrinkage resistance and electrolyte affinity can be obtained by drying the slurry composition of the present invention, for example, on a substrate. Furthermore, the functional layer also has excellent adhesive properties. Since the functional layer has excellent electrolyte affinity as described above, a secondary battery including the functional layer has excellent electrolyte injectability. In particular, even when a secondary battery including the functional layer is highly densified for the purpose of increasing the capacity of the secondary battery, the electrolyte injectability of the secondary battery can be ensured to be sufficiently high.

[0053] <Binder> As the binder, the above-mentioned binder of the present invention containing at least a particulate polymer is used. The amount of binder in the slurry composition is not particularly limited. For example, when the slurry composition contains functional particles such as non-conductive particles described below, the amount of binder in the slurry composition is, in terms of solid content, preferably 0.5 parts by mass or more, more preferably 1.0 parts by mass or more, and preferably 6.0 parts by mass or less, and more preferably 3.0 parts by mass or less, per 100 parts by mass of the functional particles. If the amount of binder in the slurry composition is above the lower limit, the adhesion of the functional layer can be further improved. On the other hand, if the amount of binder in the slurry composition is below the upper limit, the air permeability of the functional layer is increased, and the affinity of the functional layer to the electrolyte can be further improved.

[0054] <Functional particles> Here, as the functional particles for enabling the functional layer to exhibit the intended function, for example, when the functional layer is a porous membrane layer, non-conductive particles can be used. In particular, since the functional layer formed using the slurry composition of the present invention has excellent heat shrinkage resistance, the slurry composition of the present invention containing non-conductive particles as functional particles can be suitably used for forming a porous membrane layer that improves the heat resistance and strength of battery components.

[0055] <<Non-conductive particles>> Specifically, the non-conductive particles that can be used in the porous membrane layer of a secondary battery are not particularly limited, and both inorganic and organic particles can be used, although inorganic particles are typically used. Among these, materials that are stable and electrochemically stable in the environment in which the secondary battery is used are preferred. From this perspective, preferred examples of non-conductive particle materials include oxide particles such as aluminum oxide (alumina), hydrated aluminum oxide (boehmite), silicon oxide, magnesium oxide (magnesia), calcium oxide, titanium oxide (titania), BaTiO3, ZrO, and alumina-silica composite oxide; nitride particles such as aluminum nitride and boron nitride; covalently bonded crystalline particles such as silicon and diamond; sparingly soluble ionic crystalline particles such as barium sulfate, calcium fluoride, and barium fluoride; and clay particles such as talc and montmorillonite. Furthermore, these particles may be subjected to element substitution, surface treatment, solid solution formation, etc., as needed. As the material for the non-conductive particles, it is preferable to use alumina, boehmite, and barium sulfate from the viewpoint of suppressing aggregation and increasing the dispersibility of the functional layer slurry composition. The non-conductive particles may be used alone or in combination of two or more kinds.

[0056] The volume average particle diameter of the non-conductive particles is preferably 0.1 μm or more, more preferably 0.3 μm or more, even more preferably 0.6 μm or more, and preferably 1.5 μm or less, more preferably 1.0 μm or less. If the volume average particle diameter of the non-conductive particles is above the lower limit, the air permeability of the functional layer is increased, thereby further improving the affinity of the functional layer for the electrolyte. On the other hand, if the volume average particle diameter of the non-conductive particles is below the upper limit, the adhesiveness of the functional layer can be further improved.

[0057] <Other ingredients> The slurry composition may further contain other components in addition to the components described above. There are no particular limitations on the other components as long as they do not excessively adversely affect the battery reaction in the secondary battery having the functional layer. The type of other components may be one type or two or more types. Examples of other components include surfactants, wetting agents, leveling agents, dispersants, electrolyte decomposition inhibitors, and water-soluble polymers.

[0058] From the viewpoint of further improving the heat shrinkage resistance of the functional layer, it is preferable to use a water-soluble polymer as another component. In the present invention, the polymer being "water-soluble" means that when 0.5 g of the polymer is dissolved in 100 g of water at 25°C, the insoluble content is less than 1 mass %. The water-soluble polymer is not particularly limited, but from the viewpoint of further improving the heat shrinkage resistance of the functional layer, it is preferable to use carboxymethyl cellulose and polyacrylamide, and it is more preferable to use carboxymethyl cellulose.

[0059] The amount of water-soluble polymer in the slurry composition is not particularly limited. For example, when the slurry composition contains functional particles such as non-conductive particles described below, the amount of water-soluble polymer in the slurry composition, calculated as solid content, is preferably 0.2 parts by mass or more, more preferably 0.4 parts by mass or more, more preferably 3 parts by mass or less, more preferably 2 parts by mass or less, and even more preferably 1.5 parts by mass or less, per 100 parts by mass of the functional particles. If the amount of water-soluble polymer in the slurry composition is above the lower limit, the heat shrinkage resistance of the functional layer can be further improved. On the other hand, if the amount of water-soluble polymer in the slurry composition is below the upper limit, sufficiently high coating stability can be ensured when the slurry composition is applied to a substrate to form a functional layer.

[0060] In addition, from the viewpoint of improving the stability of the slurry composition, it is preferable to use a dispersant as another component. The dispersant is not particularly limited, and for example, sodium polyacrylate can be used. Note that the dispersant is a component different from the water-soluble polymer described above. The amount of dispersant in the slurry composition is not particularly limited. For example, when the slurry composition contains functional particles such as non-conductive particles described below, the amount of dispersant in the slurry composition, in terms of solid content, is preferably 0.1 parts by mass or more, more preferably 0.2 parts by mass or more, even more preferably 0.5 parts by mass or more, and preferably 2 parts by mass or less, and more preferably 1 part by mass or less, per 100 parts by mass of the functional particles. If the amount of dispersant in the slurry composition is above the above lower limit, the stability of the slurry composition can be further improved. On the other hand, if the amount of dispersant in the slurry composition is below the above upper limit, the moisture content of the functional layer formed by coating the slurry composition on a substrate can be kept low.

[0061] Furthermore, from the viewpoint of improving the coatability of the slurry composition, it is preferable to use a surfactant as another component. The surfactant is not particularly limited, and for example, a polyethylene glycol type surfactant can be used. Note that the surfactant is a component different from the water-soluble polymer and dispersant described above. The amount of surfactant in the slurry composition is not particularly limited. For example, when the slurry composition contains functional particles such as non-conductive particles described below, the amount of surfactant in the slurry composition, in terms of solid content, is preferably 0.05 parts by mass or more, more preferably 0.1 parts by mass or more, and preferably 0.5 parts by mass or less, and more preferably 0.3 parts by mass or less, per 100 parts by mass of the functional particles. If the amount of surfactant in the slurry composition is above the above lower limit, the coating properties of the slurry composition on the substrate can be sufficiently ensured. On the other hand, if the amount of surfactant in the slurry composition is below the above upper limit, the adhesion of the functional layer can be sufficiently high. Furthermore, the lower limit of the amount of surfactant in the slurry composition is not particularly limited, but is usually 0.1 parts by mass or more.

[0062] <Preparation of Slurry Composition> The method for preparing the slurry composition is not particularly limited. For example, when the slurry composition is a slurry composition for a porous membrane layer, the slurry composition can be prepared by mixing a binder, non-conductive particles, and other components used as needed in the presence of a solvent. Furthermore, when the slurry composition is a slurry composition for an adhesive layer, for example, the binder, which is a dispersion of a particulate polymer, can be used as is or diluted with a solvent to form the slurry composition, or the binder and other components used as needed can be mixed in the presence of a solvent to prepare the slurry composition. The solvent used in preparing the slurry composition may be the solvent (e.g., water) described in the section "Binder for Secondary Battery Functional Layer." The solvent used in preparing the slurry composition may also be the solvent contained in the binder. The mixing method is not particularly limited, but mixing can be performed using a commonly used stirrer or disperser.

[0063] (Functional layer for secondary batteries) The functional layer of the present invention is a layer that performs functions such as reinforcement or adhesion within a secondary battery. Examples of functional layers include a porous membrane layer that improves heat resistance and strength, and an adhesive layer that improves adhesion. The functional layer of the present invention is formed from the above-mentioned slurry composition of the present invention. For example, the functional layer can be formed by applying the above-mentioned slurry composition to the surface of a suitable substrate to form a coating film, and then drying the formed coating film. That is, the functional layer of the present invention is composed of a dried product of the above-mentioned slurry composition, and typically contains at least a particulate polymer, and optionally further contains functional particles and other components. Note that since each component contained in the functional layer is contained in the above-mentioned slurry composition, the preferred abundance ratio of each component is the same as the preferred abundance ratio of each component in the slurry composition.

[0064] The functional layer of the present invention is formed from the slurry composition of the present invention containing the binder of the present invention, and therefore has excellent heat shrinkage resistance and electrolyte affinity. In addition, the functional layer of the present invention also has excellent adhesiveness. As described above, the functional layer of the present invention has excellent electrolyte affinity, and therefore a secondary battery including the functional layer has excellent electrolyte injectability. In particular, even when a secondary battery including the functional layer is highly densified for the purpose of increasing the capacity of the secondary battery, the electrolyte injectability of the secondary battery can be ensured to be sufficiently high.

[0065] <Base material> Here, there is no limitation on the substrate to which the slurry composition is applied, and for example, a coating film of the slurry composition may be formed on the surface of a release substrate, the coating film may be dried to form a functional layer, and the release substrate may be peeled off from the functional layer. In this way, the functional layer peeled off from the release substrate may be used as a free-standing film to form a battery component of a secondary battery. However, from the viewpoint of omitting the step of peeling off the functional layer and improving the production efficiency of the battery component, it is preferable to use a separator substrate or an electrode substrate as the substrate. Specifically, when preparing the porous membrane layer or the adhesive layer, it is preferable to apply the slurry composition onto the separator substrate or the electrode substrate. Furthermore, in order to improve the adhesion between the formed functional layer and substrates such as separator substrates and electrode substrates, the surface of the substrate may be subjected to a surface treatment such as corona treatment or plasma treatment to make it hydrophilic.

[0066] <<Current collector>>

[0067] <<Separator substrate>> The separator substrate is not particularly limited, but examples thereof include known separator substrates such as organic separator substrates. The organic separator substrate is a porous member made of an organic material. Examples of the organic separator substrate include a microporous membrane or nonwoven fabric containing a polyolefin resin such as polyethylene or polypropylene, or an aromatic polyamide resin, and polyethylene microporous membranes and nonwoven fabrics are preferred because of their excellent strength.

[0068] <<Electrode base material>> The electrode substrates (positive electrode substrate and negative electrode substrate) are not particularly limited, but examples thereof include electrode substrates in which an electrode mixture layer containing electrode active material particles and a binder is formed on a current collector. As the current collector, a material that is electrically conductive and electrochemically durable is used. Specifically, as the current collector, for example, a current collector made of iron, copper, aluminum, nickel, stainless steel, titanium, tantalum, gold, platinum, etc. can be used. Among them, copper foil is particularly preferred as the current collector used for the negative electrode. Furthermore, aluminum foil is particularly preferred as the current collector used for the positive electrode. Note that the above materials may be used alone or in combination of two or more types in any ratio. The electrode active material particles contained in the electrode mixture layer in the electrode substrate are not particularly limited, and known electrode active material particles can be used. Furthermore, the binder contained in the electrode mixture layer of the electrode substrate can be any binder used for electrode mixture layers.

[0069] <Method for forming functional layer> Examples of methods for forming a functional layer on a substrate such as the separator substrate or electrode substrate include the following methods. 1) A method in which the slurry composition of the present invention is applied to the surface of a substrate (in the case of an electrode substrate, the surface on the electrode mixture layer side; the same applies hereinafter) and then dried; 2) a method of immersing a substrate in the slurry composition of the present invention and then drying the same; and 3) A method in which the slurry composition of the present invention is applied to a release substrate, dried to produce a functional layer, and the resulting functional layer is transferred to the surface of the substrate. Among these, the method 1) is particularly preferred because it allows for easy control of the thickness of the functional layer. Specifically, the method 1) includes a step of applying a slurry composition onto a substrate (application step) and a step of drying the slurry composition applied onto the substrate to form a functional layer (drying step).

[0070] <<Coating process>> In the coating step, the method for coating the slurry composition onto the substrate is not particularly limited, and examples thereof include a doctor blade method, a reverse roll method, a direct roll method, a gravure method, an extrusion method, and a brush coating method.

[0071] <<Drying process>> In the drying step, the method for drying the slurry composition on the substrate is not particularly limited and any known method can be used. Examples of drying methods include drying with warm air, hot air, or low-humidity air, vacuum drying, and drying by irradiation with infrared rays or electron beams. The drying conditions are not particularly limited, but the drying temperature is preferably 40°C to 150°C, and the drying time is preferably 2 to 30 minutes.

[0072] The thickness of the functional layer formed is preferably 0.5 μm or more, more preferably 1 μm or more, and preferably 4 μm or less, and more preferably 3 μm or less. If the thickness of the functional layer is equal to or greater than the lower limit, the thermal shrinkage resistance of the functional layer can be sufficiently high. On the other hand, if the thickness of the functional layer is equal to or less than the upper limit, the thinning of the functional layer can facilitate the increase in capacity of the secondary battery.

[0073] (Battery component with functional layer) The battery components (separator and electrode) having the functional layer of the present invention may have components other than the functional layer of the present invention and the substrate, as long as the effects of the present invention are not significantly impaired. Such components are not particularly limited, and include a porous membrane layer and an adhesive layer that do not fall under the functional layer of the present invention. The battery component may also have a plurality of types of functional layers of the present invention. For example, the separator may have a porous membrane layer formed on a separator substrate from the slurry composition for a porous membrane layer of the present invention, and an adhesive layer formed on the porous membrane layer from the slurry composition for an adhesive layer of the present invention. A battery component provided with the functional layer of the present invention has excellent heat shrinkage resistance and electrolyte affinity, and can also be well bonded to adjacent battery components.

[0074] (Secondary battery) The secondary battery of the present invention includes the functional layer of the present invention described above. More specifically, the secondary battery of the present invention includes a positive electrode, a negative electrode, a separator, and an electrolyte solution, and the functional layer for a secondary battery described above is included in at least one of the positive electrode, the negative electrode, and the separator, which are battery components. The secondary battery of the present invention has an excellent electrolyte injectability because it includes the functional layer of the present invention, which has high electrolyte affinity. In particular, the secondary battery of the present invention can ensure sufficiently high electrolyte injectability even when the battery is made denser for the purpose of increasing capacity, etc. Furthermore, the secondary battery of the present invention has excellent battery characteristics such as cycle characteristics because it includes the functional layer of the present invention, which has high adhesiveness, and the battery components are well bonded to each other.

[0075] <Positive electrode, negative electrode, and separator> At least one of the positive electrode, negative electrode, and separator used in the secondary battery of the present invention is a battery component having the functional layer of the present invention described above. Note that the positive electrode, negative electrode, and separator not having the functional layer of the present invention are not particularly limited, and known positive electrodes, negative electrodes, and separators can be used.

[0076] <Electrolyte> As the electrolyte, an organic electrolyte solution in which a supporting electrolyte is dissolved in an organic solvent is usually used. For example, in lithium-ion secondary batteries, a lithium salt is used as the supporting electrolyte. Examples of lithium salts include LiPF6, LiAsF6, LiBF4, LiSbF6, LiAlCl4, LiClO4, CF3SO3Li, CF4F9SO3Li, CF3COOLi, (CF3CO)2NLi, (CF3SO2)2NLi, and (C2F5SO2)NLi. Among these, LiPF6, LiClO4, and CF3SO3Li are preferred because they are easily soluble in solvents and exhibit a high degree of dissociation. One type of electrolyte may be used alone, or two or more types may be used in combination. Generally, the lithium ion conductivity tends to increase as the supporting electrolyte with a higher degree of dissociation is used, so the lithium ion conductivity can be adjusted by the type of supporting electrolyte.

[0077] The organic solvent used in the electrolyte is not particularly limited as long as it can dissolve the supporting electrolyte. For example, in lithium ion secondary batteries, carbonates such as dimethyl carbonate (DMC), ethylene carbonate (EC), diethyl carbonate (DEC), propylene carbonate (PC), butylene carbonate (BC), ethyl methyl carbonate (EMC), and vinylene carbonate (VC) are preferred; esters such as γ-butyrolactone and methyl formate; ethers such as 1,2-dimethoxyethane and tetrahydrofuran; and sulfur-containing compounds such as sulfolane and dimethyl sulfoxide. Mixtures of these solvents may also be used. Among these, carbonates are preferred due to their high dielectric constant and wide stable potential range. Generally, the lower the viscosity of the solvent used, the higher the lithium ion conductivity, so the lithium ion conductivity can be adjusted by the type of solvent. The concentration of the electrolyte in the electrolytic solution can be adjusted as appropriate. Known additives may also be added to the electrolytic solution.

[0078] <Secondary battery manufacturing method> The secondary battery of the present invention described above can be produced, for example, by stacking a positive electrode and a negative electrode with a separator interposed therebetween, rolling or folding the stack as necessary, placing the stack in a battery container, injecting an electrolyte into the battery container, and sealing the container. At least one of the positive electrode, negative electrode, and separator is a battery component having the functional layer of the present invention. If necessary, the battery container may contain an expanded metal, a fuse, an overcurrent prevention element such as a PTC element, or a lead plate to prevent pressure buildup within the battery and overcharging and discharging. The shape of the battery may be, for example, a coin type, a button type, a sheet type, a cylindrical type, a rectangular type, a flat type, or any other suitable shape. [Example]

[0079] The present invention will be specifically described below based on examples, but the present invention is not limited to these examples. In the following description, "%" and "parts" representing amounts are based on mass unless otherwise specified. Furthermore, in a polymer produced by copolymerizing multiple types of monomers, the proportion of a repeating unit (monomer unit) formed by polymerizing a certain monomer in the polymer usually coincides with the ratio (feed ratio) of that certain monomer to all the monomers used in the polymerization of the polymer, unless otherwise specified. In the examples and comparative examples, the volume average particle size, glass transition temperature, gel content, and swelling degree in electrolyte of the particulate polymer, the adhesion, affinity for electrolyte, and heat shrinkage resistance of the functional layer, and the cycle characteristics of the secondary battery were measured and evaluated by the following methods, respectively.

[0080] <Volume average particle size of particulate polymer> The volume-average particle size of the particulate polymer was measured by laser diffraction. Specifically, an aqueous dispersion containing the prepared particulate polymer (adjusted to a solids concentration of 0.1% by mass) was used as a sample. The particle size distribution (volume basis) was measured using a laser diffraction particle size distribution analyzer (manufactured by Beckman Coulter, Inc., product name "LS-13 320"), and the particle size D50 at which the cumulative volume calculated from the smallest diameter side reached 50% was taken as the volume-average particle size.

[0081] <Glass transition temperature of particulate polymer> The prepared aqueous dispersion containing the particulate polymer was pre-dried for 3 days in an environment of 50% relative humidity and 23 to 26°C temperature to form a pre-film with a thickness of 2 ± 0.5 mm. The pre-formed film was dried for 10 hours in a vacuum dryer at a temperature of 120°C. The dried film was then used as a sample and its glass transition temperature (°C) was measured using a differential scanning calorimeter (DSC7200, manufactured by SII Corporation) in accordance with JIS K7121 under conditions of a measurement temperature of -100°C to 180°C and a heating rate of 5°C / min.

[0082] <Gel content of particulate polymer> The prepared aqueous dispersion containing the particulate polymer was dried under an environment of 50% humidity and 23 to 25°C temperature to form a film with a thickness of 1 ± 0.3 mm. The formed film was dried in a vacuum dryer at 60°C for 10 hours. The dried film was then cut into 3 to 5 mm square pieces, and approximately 1 g was precisely weighed. The mass of the film piece obtained by cutting was designated as w0. This film piece was immersed in 50 g of tetrahydrofuran (THF) for 24 hours. The film piece was then removed from the THF and vacuum dried at 105°C for 3 hours, and the mass of the insoluble matter, w1, was measured. The gel content was then calculated using the following formula. Gel content (mass%) = (w1 / w0) × 100

[0083] <Electrolyte swelling degree of particulate polymer> The prepared aqueous dispersion containing the particulate polymer was dried under an environment of 50% relative humidity and 23 to 25°C temperature to form a film with a thickness of approximately 0.1 mm. The formed film was cut into approximately 2 cm squares and its weight (weight before immersion) was measured. Then, it was immersed in an electrolyte at a temperature of 60°C for 72 hours. The immersed film was pulled out, the electrolyte was wiped off, and its weight (weight after immersion) was immediately measured. The value of (weight after immersion) / (weight before immersion) [times] was defined as the electrolyte swelling degree. The electrolyte used was a solution prepared by dissolving LiPF6 at a concentration of 1 mol / L in a mixed solvent of ethylene carbonate and ethyl methyl carbonate in a 3:7 (mass ratio). The smaller the electrolyte swelling degree of the particulate polymer, the higher the electrolyte resistance of the particulate polymer.

[0084] <Adhesion of functional layer> The separators with functional layers produced in the examples and comparative examples were each cut into a width of 10 mm and a length of 50 mm to prepare test pieces. Next, a stainless steel plate with double-sided tape (Nitto Denko No. 5608) attached was prepared, and the functional layer of the test piece was attached to the double-sided tape. One end of the separator substrate was then pulled at a speed of 50 mm / min so that the peeling angle was 180°, and the peel strength was measured. The adhesiveness of the functional layer was evaluated according to the following criteria. A: Peel strength 10N / m or more B: Peel strength 5N / m or more and less than 10N / m C: Peel strength less than 5N / m

[0085] <Electrolyte affinity of functional layer> The prepared aqueous dispersion containing the particulate polymer was applied to a 20 μm-thick aluminum foil using a doctor blade film applicator and dried at 50°C for 15 minutes, forming a 20±2 μm-thick functional layer on the aluminum foil. The aluminum foil with the functional layer was dried in a vacuum dryer at 60°C for 10 hours. The aluminum foil with the functional layer was then cut into 100 mm square pieces, and the electrolyte contact angle was measured at 10 points using a portable contact angle meter (Kyowa Interface Science, PCA-11). The average value was calculated, and the electrolyte affinity of the functional layer was evaluated according to the following criteria. Note that a lower electrolyte contact angle indicates a higher wettability of the functional layer to the electrolyte and a higher electrolyte affinity. A: The average electrolyte contact angle is less than 40° B: Average electrolyte contact angle is 40° or more and less than 50° C: Average electrolyte contact angle is 50° or more

[0086] <Heat shrinkage resistance of functional layer> The separators with functional layers produced in the examples and comparative examples were cut into squares measuring 12 cm wide x 12 cm long, and a square with a side length of 10 cm was drawn inside each square to prepare a test piece. The test piece was then placed in a constant temperature bath at 150°C and left there for 1 hour to heat, after which the change in the area of ​​the square drawn inside (= {(area of ​​square before heating - area of ​​square after heating) / area of ​​square before heating} x 100%) was calculated as the thermal shrinkage rate, and the heat shrinkage resistance of the functional layer was evaluated according to the following criteria. The smaller this thermal shrinkage rate, the better the heat shrinkage resistance of the functional layer. A: Heat shrinkage rate is less than 10% B: Heat shrinkage rate is 10% or more and less than 20% C: Heat shrinkage rate is 20% or more but less than 30% D: Heat shrinkage rate is 30% or more

[0087] <Cycle characteristics of secondary batteries> The fabricated lithium ion secondary battery was left standing for 24 hours in an environment of 25° C. Thereafter, at 25° C., it was charged to 4.2 V (cutoff condition: 0.02 C) using a constant voltage-constant current (CC-CV) method at a charge rate of 1 C, and discharged to 3.0 V using a constant current (CC) method at a discharge rate of 1 C, and the initial capacity C0 was measured. Furthermore, the same charge / discharge cycle was repeated in a 25°C environment, and the capacity C1 after 300 cycles was measured. The capacity retention rate ΔC = (C1 / C0) × 100 (%) was calculated and evaluated according to the following criteria. A higher capacity retention rate indicates less decrease in discharge capacity and better cycle characteristics. A: Capacity retention rate ΔC is 85% or more B: Capacity retention rate ΔC is 75% or more and less than 85% C: Capacity retention rate ΔC is less than 75%

[0088] Example 1 <Preparation of aqueous dispersion containing particulate polymer> To a reactor equipped with a stirrer, 90 parts of ion-exchanged water, 0.05 parts of sodium dodecylbenzenesulfonate (manufactured by Kao Chemical Corporation, "Neopelex G-15") as an emulsifier, and 0.23 parts of ammonium persulfate were supplied, the gas phase was replaced with nitrogen gas, and the temperature was raised to 70°C. Separately, in a separate vessel, 50 parts of ion-exchanged water, 0.1 parts of sodium dodecylbenzenesulfonate (Kao Chemical Corporation, "Neopelex G-15") as an emulsifier, 76.6 parts of butyl acrylate (BA) as a (meth)acrylic acid alkyl ester monomer, 10 parts of acrylonitrile (AN) as a cyano group-containing monomer, 10 parts of allyl glycidyl ether (AGE) as a cyclic ether-containing monomer, 3 parts of acrylic acid (AA) as a carboxyl group-containing monomer, and 0.4 parts of allyl methacrylate (AMA) as a crosslinkable monomer were mixed to obtain a monomer composition. This monomer composition was continuously added to the reactor over 4 hours to carry out polymerization. The reaction was carried out at 70°C during the addition. After completion of the addition, the temperature was raised to 80°C and the mixture was stirred for 3 hours to terminate the reaction, producing an aqueous dispersion (binder) containing a particulate polymer. The obtained aqueous dispersion (binder) containing the particulate polymer was used to measure and evaluate the volume average particle size, glass transition temperature, gel content, and electrolyte swelling degree of the particulate polymer, as well as the electrolyte affinity of the functional layer. The results are shown in Table 1. Since the obtained particulate polymer had one glass transition temperature, it was confirmed that the particulate polymer was a random copolymer having no core-shell structure.

[0089] <Preparation of Slurry Composition for Functional Layer> Alumina particles (AKP-3000, manufactured by Sumitomo Chemical, volume average particle diameter D50 = 0.7 μm) were used as non-conductive particles, sodium polyacrylate (Aron T-50, manufactured by Toa Gosei) was used as a dispersant, and carboxymethyl cellulose (1220, manufactured by Daicel FineChem Co., Ltd.) with an etherification degree of 0.8 to 1.0 was used as a water-soluble polymer. The viscosity of a 1% aqueous solution of carboxymethyl cellulose was 10 to 20 mPa·s. A mixture of 100 parts of non-conductive particles, 0.5 parts of dispersant, and ion-exchanged water was processed for 1 hour in a bead mill (LMZ015, manufactured by Ashizawa Finetech) to obtain a dispersion. Furthermore, 3 parts (solids equivalent) of an aqueous dispersion containing a particulate polymer as a binder, 1.5 parts (solids equivalent) of a 1% aqueous solution of carboxymethylcellulose (CMC) as a water-soluble polymer, and 0.3 parts of a polyethylene glycol surfactant (Noptex ED-052, manufactured by San Nopco) were mixed to prepare a slurry composition for the functional layer with a solids concentration of 40% by mass.

[0090] <Fabrication of a separator with a functional layer on one side (separator with functional layer)> A polyethylene separator substrate (manufactured by Asahi Kasei Corporation, product name "ND412", thickness: 12 μm) was prepared. The functional layer slurry composition prepared above was applied to the surface of the prepared separator substrate and dried at a temperature of 50°C for 3 minutes to obtain a separator (separator with functional layer; functional layer thickness: 3 μm) with a functional layer (porous membrane) on one side. The resulting separator with functional layer was used to evaluate the adhesion of the functional layer. The results are shown in Table 1.

[0091] <Preparation of negative electrode> A 5 MPa pressure vessel equipped with a stirrer was charged with 33 parts of 1,3-butadiene as an aliphatic conjugated diene monomer, 3.5 parts of itaconic acid as a carboxylic acid group-containing monomer, 63.5 parts of styrene as an aromatic vinyl monomer, 0.4 parts of sodium dodecylbenzenesulfonate as an emulsifier, 150 parts of ion-exchanged water, and 0.5 parts of potassium persulfate as a polymerization initiator. After thorough stirring, the mixture was heated to 50°C to initiate polymerization. The polymerization reaction was stopped by cooling when the polymerization conversion rate reached 96%, yielding a mixture containing a particulate binder (styrene-butadiene copolymer) as a negative electrode binder. The mixture was then adjusted to pH 8 by adding a 5% aqueous sodium hydroxide solution, and unreacted monomer was removed by heated vacuum distillation. The mixture was then cooled to below 30°C to yield an aqueous dispersion containing the negative electrode binder. A planetary mixer was charged with 48.75 parts of artificial graphite (theoretical capacity: 360 mAh / g) as the negative electrode active material, 48.75 parts of natural graphite (theoretical capacity: 360 mAh / g), and 1 part of carboxymethyl cellulose as a thickener (solids equivalent). The mixture was then diluted with ion-exchanged water to a solids concentration of 60% and kneaded for 60 minutes at a rotation speed of 45 rpm. Next, 1.5 parts (solids equivalent) of the aqueous dispersion containing the negative electrode binder was added and kneaded for 40 minutes at a rotation speed of 40 rpm. Ion-exchanged water was then added to the mixture to a viscosity of 3000±500 mPa·s (measured with a Brookfield viscometer at 25°C and 60 rpm), thereby preparing a slurry composition for the negative electrode composite layer. The negative electrode composite layer slurry composition was applied to the surface of a 15 μm thick copper foil current collector using a comma coater in an amount of 11±0.5 mg / cm 2 Thereafter, the copper foil coated with the slurry composition for a negative electrode composite layer was transported at a speed of 400 mm / min through an oven at a temperature of 80°C for 2 minutes and then through an oven at a temperature of 110°C for 2 minutes to dry the slurry composition on the copper foil, thereby obtaining a negative electrode blank in which a negative electrode composite layer was formed on a current collector. Thereafter, the negative electrode composite layer side of the prepared negative electrode blank was roll-pressed under conditions of a temperature of 25±3°C and a linear pressure of 11 t (tons), so that the density of the negative electrode composite layer became 1.60 g / cm 3 Thereafter, the negative electrode was left for one week in an environment of a temperature of 25±3°C and a relative humidity of 50±5%.

[0092] <Preparation of positive electrode> The planetary mixer uses Co-Ni-Mn lithium composite oxide active material NMC111, LiNi 1 / 3 Co 1 / 3 Mn 1 / 3 A slurry composition for a positive electrode composite layer was prepared by adding 96 parts of ethanol (O2), 2 parts of acetylene black (manufactured by Denki Kagaku Kogyo Co., Ltd., product name "HS-100") as a conductive material, and 2 parts of polyvinylidene fluoride (manufactured by Kureha Chemical Industry Co., Ltd., product name "KF-1100") as a binder, and further adding and mixing N-methyl-2-pyrrolidone (NMP) as a dispersion medium so that the total solids concentration was 67%. Next, the obtained slurry composition for the positive electrode composite layer was applied to a 20 μm thick aluminum foil current collector using a comma coater in an amount of 20±0.5 mg / cm 2 The coating was applied so that the The aluminum foil was then transported at a speed of 200 mm / min through an oven at a temperature of 90°C for 2 minutes and then through an oven at a temperature of 120°C for 2 minutes to dry the slurry composition on the aluminum foil, thereby obtaining a positive electrode substrate having a positive electrode composite layer formed on the current collector. Thereafter, the positive electrode composite layer side of the prepared positive electrode blank was roll-pressed under conditions of a temperature of 25±3°C and a linear pressure of 14 tonnes, until the density of the positive electrode composite layer became 3.40 g / cm 3 Thereafter, the positive electrode was left for one week in an environment of a temperature of 25±3°C and a relative humidity of 50±5%.

[0093] <Preparation of secondary battery> The pressed positive electrode obtained above was cut into a 4 cm x 4 cm square, and the pressed negative electrode was cut into a 4.2 cm x 4.2 cm square. The separator with functional layer obtained above was cut into a 5 cm x 5 cm square. Next, the cut-out separator with functional layer was placed with the functional layer side facing the positive electrode composite layer of the pressed positive electrode. Furthermore, the cut-out negative electrode with the negative electrode composite layer side facing the side of the placed separator with functional layer that was not in contact with the positive electrode was placed to obtain a battery component laminate (positive electrode / functional layer / separator substrate / negative electrode). The resulting laminate was then wrapped in an aluminum packaging material that served as the battery's exterior, and an electrolyte solution (solvent: ethylene carbonate (EC) / diethyl carbonate (DEC) / vinylene carbonate (VC) (volume ratio = 68.5 / 30 / 1.5), electrolyte: 1 mol / L LiPF6) was poured into the battery so that no air remained. The opening of the aluminum packaging material was then heat-sealed at 150°C, and the aluminum packaging material was hermetically closed to produce a 40 mAh stacked lithium-ion secondary battery. The cycle characteristics of this lithium-ion secondary battery were evaluated. The results are shown in Table 1.

[0094] (Examples 2 to 10, 13 to 16, 20, Comparative Examples 1 to 5) In the preparation of the aqueous dispersion containing the particulate polymer of Example 1, the types and amounts of the monomers used were changed so that the content ratios of various monomer units in the resulting particulate polymer were as shown in Tables 1 and 2. In the same manner as in Example 1, an aqueous dispersion containing the particulate polymer, a slurry composition for a functional layer, a separator with a functional layer, a negative electrode, a positive electrode, and a secondary battery were produced, and various measurements and evaluations were carried out. The results are shown in Tables 1 and 2.

[0095] Example 11 In the preparation of the aqueous dispersion containing the particulate polymer of Example 1, the amount of butyl acrylate (BA) used as the (meth)acrylic acid alkyl ester monomer was changed from 76.6 parts to 77.6 parts, and 2 parts of methacrylic acid (MAA) were used as the carboxyl group-containing monomer instead of 3 parts of acrylic acid (AA), and the amount of emulsifier (sodium dodecylbenzenesulfonate) used in the reactor was changed from 0.05 parts to 0.02 parts. Except for this, the aqueous dispersion containing the particulate polymer, the slurry composition for the functional layer, the separator with the functional layer, the negative electrode, the positive electrode, and the secondary battery were prepared in the same manner as in Example 1, and various measurements and evaluations were carried out. The results are shown in Table 1.

[0096] Example 12 In the preparation of the aqueous dispersion containing the particulate polymer of Example 1, the amount of butyl acrylate (BA) used as the (meth)acrylic acid alkyl ester monomer was changed from 76.6 parts to 77.6 parts, and 2 parts of methacrylic acid (MAA) was used as the carboxyl group-containing monomer instead of 3 parts of acrylic acid (AA), and the amount of emulsifier (sodium dodecylbenzenesulfonate) used in the reactor was changed from 0.05 parts to 0.1 parts. Except for this, the aqueous dispersion containing the particulate polymer, the slurry composition for the functional layer, the separator with the functional layer, the negative electrode, the positive electrode, and the secondary battery were prepared in the same manner as in Example 1, and various measurements and evaluations were carried out. The results are shown in Table 1.

[0097] Example 17 In preparing the slurry composition for the functional layer of Example 1, except that boehmite particles (APYRAL AOH60, manufactured by Nabaltec, particle size 0.9 μm) were used instead of alumina particles (AKP-3000, manufactured by Sumitomo Chemical, volume average particle size D50 = 0.7 μm) as the inorganic particles, an aqueous dispersion containing a particulate polymer, a slurry composition for the functional layer, a separator with a functional layer, a negative electrode, a positive electrode, and a secondary battery were prepared in the same manner as in Example 1, and various measurements and evaluations were performed. The results are shown in Table 2.

[0098] Example 18 In preparing the slurry composition for the functional layer of Example 1, barium sulfate particles (TS-3, particle diameter 0.6 μm, manufactured by Takehara Chemical Co., Ltd.) were used instead of alumina particles (AKP-3000, volume average particle diameter D50 = 0.7 μm, manufactured by Sumitomo Chemical Co., Ltd.) as the inorganic particles. An aqueous dispersion containing a particulate polymer, a slurry composition for the functional layer, a separator with a functional layer, a negative electrode, a positive electrode, and a secondary battery were prepared in the same manner as in Example 1, and various measurements and evaluations were performed. The results are shown in Table 2.

[0099] Example 19 In preparing the slurry composition for the functional layer of Example 1, except that anionic polyacrylamide (Polystron 117, manufactured by Arakawa Chemical Industries, Ltd.) was used instead of carboxymethyl cellulose (CMC) as the water-soluble polymer, an aqueous dispersion containing a particulate polymer, a slurry composition for the functional layer, a separator with a functional layer, a negative electrode, a positive electrode, and a secondary battery were prepared in the same manner as in Example 1, and various measurements and evaluations were performed. The results are shown in Table 2.

[0100] In addition, in Tables 1 and 2 shown below, "BA" indicates a butyl acrylate unit; "2EHA" indicates a 2-ethylhexyl acrylate unit, "EA" indicates an ethyl acrylate unit; "AN" indicates an acrylonitrile unit; "MAN" represents a methacrylonitrile unit; "AGE" represents an allyl glycidyl ether unit, "GMA" indicates a glycidyl methacrylate unit; "AA" represents an acrylic acid unit; "MAA" indicates a methacrylic acid unit, "AMA" indicates an allyl methacrylate unit; "NMA" indicates an N-methylolacrylamide unit; "CMC" stands for carboxymethyl cellulose; "PEG type" indicates that the surfactant is a polyethylene glycol type.

[0101] [Table 1]

[0102] [Table 2]

[0103] From Tables 1 and 2, it can be seen that by using the binders of Examples 1 to 20, which contain particulate polymers containing cyano group-containing monomer units, cyclic ether-containing monomer units, and carboxyl group-containing monomer units, and in which the content ratio of cyclic ether-containing monomer units is a predetermined value or more, it is possible to form functional layers with excellent heat shrinkage resistance and electrolyte affinity. On the other hand, when the binder of Comparative Example 1 containing a particulate polymer in which the content ratio of cyclic ether-containing monomer units is less than the specified value is used, the functional layer formed is found to be inferior in both heat shrinkage resistance and electrolyte affinity. Furthermore, even when the binders of Comparative Examples 2 and 3, which do not contain a cyclic ether-containing monomer unit, are used, the functional layers formed are found to be inferior in both heat shrinkage resistance and electrolyte affinity. Furthermore, when the binder of Comparative Example 4 containing a particulate polymer not containing a cyano group-containing monomer unit was used, the functional layer formed had good heat shrinkage resistance but poor affinity for the electrolyte. Furthermore, when the binder of Comparative Example 5 containing a particulate polymer not containing a carboxyl group-containing monomer unit was used, the functional layer formed had good heat shrinkage resistance but poor affinity for the electrolyte. [Industrial Applicability]

[0104] According to the present invention, it is possible to provide a binder for a secondary battery functional layer that can form a functional layer that has excellent heat shrinkage resistance and affinity for an electrolyte solution. Furthermore, according to the present invention, it is possible to provide a slurry composition for a secondary battery functional layer, which is capable of forming a functional layer having excellent resistance to heat shrinkage and affinity for an electrolyte solution. Furthermore, according to the present invention, it is possible to provide a functional layer for a secondary battery that has excellent resistance to heat shrinkage and affinity for an electrolyte solution. Furthermore, according to the present invention, a secondary battery including the functional layer can be provided.

Claims

1. A binder for a secondary battery functional layer containing a particulate polymer, the particulate polymer contains a cyano group-containing monomer unit, a cyclic ether-containing monomer unit, and a carboxyl group-containing monomer unit, the content of the cyano group-containing monomer unit in the particulate polymer is 2% by mass or more and 30% by mass or less, the content of the cyclic ether-containing monomer unit in the particulate polymer is 5% by mass or more and 40% by mass or less, The binder for a secondary battery functional layer, wherein the content of the carboxyl group-containing monomer unit in the particulate polymer is 0.1% by mass or more and 10% by mass or less.

2. The binder for a secondary battery functional layer according to claim 1 , wherein the particulate polymer has one glass transition temperature.

3. 3. The binder for a secondary battery functional layer according to claim 1, wherein the particulate polymer has a glass transition temperature of 20°C or lower.

4. The particulate polymer further contains a (meth)acrylic acid alkyl ester monomer unit, The binder for a secondary battery functional layer according to any one of claims 1 to 3, wherein the content of the (meth)acrylic acid alkyl ester monomer unit in the particulate polymer is 40% by mass or more and 92% by mass or less.

5. 5. The binder for a secondary battery functional layer according to claim 1, wherein the particulate polymer has a gel content of 85% by mass or more.

6. 6. The binder for a secondary battery functional layer according to claim 1, wherein the particulate polymer has a volume average particle diameter of 0.05 μm or more and 0.25 μm or less.

7. A slurry composition for a secondary battery functional layer, comprising the binder for a secondary battery functional layer according to any one of claims 1 to 6.

8. The slurry composition for a secondary battery functional layer according to claim 7 , further comprising functional particles.

9. The slurry composition for a secondary battery functional layer according to claim 8 , wherein the functional particles include non-conductive particles.

10. The slurry composition for a secondary battery functional layer according to claim 9 , wherein the non-conductive particles have a volume average particle size of 1.5 μm or less.

11. A secondary battery functional layer formed using the slurry composition for a secondary battery functional layer according to any one of claims 7 to 10.

12. A secondary battery comprising the functional layer for a secondary battery according to claim 11.

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