CN104247126B - 制造果冻卷式电极组件的方法和制造果冻卷式聚合物二次电池的方法 - Google Patents
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Abstract
本发明涉及一种制造果冻卷式电极组件的方法,并提供了制造电极组件的方法,包括:切刻步骤,用于通过将单向伸长的阴极和阳极切刻成预定尺寸和形状来形成多个电极单元,将电极单元切刻成通过在电极单元的两端上的连接单元而彼此电连接;堆叠步骤,通过在其间布置有分隔物的情况下堆叠阴极和阳极来形成单元电池;和卷绕步骤,通过使连接单元弯曲来卷绕单元电池,使得阴极和阳极的电极单元彼此交迭。而且,本发明提供一种使用获得的电极组件制造二次电池的方法。在根据本发明制造能够易于简化其生产过程的果冻卷式电极组件和聚合物二次电池时,能够制造均展现极好的设计灵活性的果冻卷式电极组件和聚合物二次电池。而且,本发明的目的是提供一种加工在制造电极组件时使用的分隔物以对应于电极组件的形状的有效方法。
Description
技术领域
本公开涉及一种制造果冻卷式电极组件的方法和一种制造包括该电极组件的聚合物二次电池的方法,并且更具体地,涉及一种制造允许提高设计灵活性的果冻卷式电极组件的方法和一种制造包括该电极组件的聚合物二次电池的方法。
背景技术
通常而言,通过层压其间布置有分隔物的阴极和阳极并在单一方向上卷绕阴极和阳极层压件,来制造果冻卷式聚合物电池。在图1中图示了制造这种果冻卷式电极组件的示意性过程以及通过该过程获得的果冻卷式电极组件。
在图1中,可通过在单一方向上卷绕多个电极而获得果冻卷式电极组件1,该方法与通过层压多个电极如堆叠式电极组件或者堆叠/折叠式电极组件来制造电极组件的方法不同,该方法不需要层压多个电极和分隔物的过程。因此,该方法的优点在于,制造过程比其它方法相对更简单,由此易于生产。
然而,当电极组件1被制造成这种果冻卷式电极组件时,如图1中所示,使用:两个直线电极,也就是阳极31和阴极33,两者都大致具有在单一方向上伸长的矩形形状;以及分隔物50。因此,如上所述,通过层压其间布置有分隔物50的阳极31和阴极33并且仅仅卷绕阳极31和33而获得的果冻卷式电极组件1以及使用这种电极组件获得的电池通常具有图1中所示的矩形形状,这可能限制电池的形状。结果,与堆叠式或堆叠/折叠式聚合物电池相比,设计自由度明显降低。
韩国专利公开No.2002-0082729公开了一种制造钮扣式锂电池的方法,其中通过将圆形电极集电板联接至四边形连接单元来制造果冻卷式电池。然而,该专利文献中提供的二次电池受限于钮扣式锂电池。特别地,该专利文献公开了分隔物被设置在阴极集电板和阳极集电板之间,但是未特别描述分隔物的形状。同样地,该专利文献未描述关于与集电板的形状对应的分隔物形状的具体内容。
因此,当使用四边形分隔物时,设计自由度可能受限,并且当使用具有与集电板相同形状的分隔物时,必须对分隔物进行加工,以具有与集电板相同的形状。另外,当分隔物被加工成具有特定形状时,应提前以与电极板形状相对应的形状来实现分隔物。在该情况下,要求特定的尺寸精确度。特别地,分隔物通常为塑性材料形成的非常薄的膜,因而不易于被切割成具有预定形状,这导致难以实现期望形状。
发明内容
技术问题
本公开的一方面可提供制造均展现极好的设计灵活性的果冻卷式电极组件和聚合物二次电池的方法,在制造该果冻卷式电极组件和聚合物二次电池时,其生产过程能够易于简化。
本公开的一方面也可提供一种加工在制造电极组件时使用的分隔物以对应于电极组件的形状的有效方法。
技术解决方案
根据本公开的一方面,一种制造电极组件的方法可包括:切刻操作,即,对在一个方向上伸长的阴极和阳极进行切刻以具有恒定的尺寸和形状,从而形成多个电极单元,其中电极单元通过在每个电极单元的两端处形成的连接单元而彼此电连接;层压操作,即,在其间布置有分隔物50的情况下对阴极和阳极进行层压以形成单元电池;和卷绕操作,即,通过使连接单元弯曲来卷绕单元电池,使得阴极和阳极的电极单元彼此交迭。
根据本公开示例性实施例的制造电极组件的方法还可包括:分隔物结合操作,即,在卷绕操作之后,对形状不与电极单元的形状对应的额外分隔物进行结合以形成分隔物结合体;和切割操作,即,切割分隔物结合体。
在该情况下,可通过焊接分隔物来形成分隔物结合体,并且可在分隔物的玻璃化转变温度(Tg)±20℃的温度内执行焊接。
同样地,可通过使用刀具、模具、剪刀、激光束等切割分隔物,执行切割操作。
连接单元可由与电极单元的集电板相同的材料形成。在该情况下,连接单元可被涂覆有与电极单元相同的电极活性材料。
根据本公开的另一方面,一种制造二次电池的方法可包括将通过上述方法制造的电极组件封装在电池壳体内。
根据本公开示例性实施例的制造二次电池的方法还可包括将电池壳体加工成与电极组件的形状相对应的形状。
有利效果
根据本公开,可以以各种形状实现果冻卷式电极组件,由此提高了二次电池的设计灵活性。
此外,可易于切除额外分隔物,以对应于所制造的电极组件的形状。
附图说明
图1是示出制造果冻卷式电极组件的传统方法的示意图和通过该方法获得的电极组件的顶视图。
图2是示出制造根据本公开示例性实施例的具有改进形状灵活性的果冻卷式电极组件的方法的示意图和通过该方法获得的电极组件的顶视图。
具体实施方式
现在将参考附图详细地描述本公开的示例性实施例。
然而,本公开可以以许多不同形式来例示,并且不应被解释为限于在此提出的特定实施例。更确切地,提供这些实施例,以便本公开将彻底和完整,并且将本公开的范围完全传达给本领域技术人员。
在附图中,为了清晰,可能夸大了元件的形状和尺寸,并且将始终使用相同的附图标记来标识相同或类似的元件。
本公开涉及一种制造果冻卷式电极组件的方法。这里,本发明人已经发现,能够提高电池的设计灵活性,这是因为在果冻卷式电极组件的制造中,通过根据期望形状对在其上发生电池的充电/放电反应的电极平面的形状切刻,能够实现各种形状的电池。
本公开提供一种通过在单一方向上卷绕层压件来制造果冻卷式电极组件的方法。这里,通过层压其间布置有分隔物的单一阳极和单一阴极来形成层压件,其中阳极包括阳极活性材料层,并具有阳极突片,其中阳极集电板的一个表面或两个表面都被涂覆有阳极活性材料;并且阴极包括阴极活性材料层,并具有阴极突片,其中阴极集电板的一个表面或两个表面都被涂覆有阴极活性材料。根据本公开示例性实施例的这种制造果冻卷式电极组件的方法在图2中示意性地示出。
本发明的实施例
参考图2,在根据本公开的示例性实施例的电极组件1的制造中,阳极31和阴极33中的每个包括:多个电极单元10,该电极单元10被涂覆有电极活性材料,从而导致电池中的充电/放电反应;和连接单元20,连接单元20被配置成将电极单元10彼此电联接。可通过对电极31或33切刻来形成电极单元10和连接单元20。当通过对电极31或33切刻来形成电极单元10时,电极31或33可被切刻以形成将电极单元10彼此电联接的连接单元20,从而电极单元10起一个电极的作用,而无任何短路。
根据将实现的电池形状,可以以各种形状实现电极单元10。例如,电极单元10可形成如图2中所示的圆形形状,并且也可实现为各种形状,诸如四边形和椭圆形形状。
同时,连接单元20用于将相邻电极单元电联接,从而整体用作一个电极。在制造果冻卷式电极组件1时,连接单元20在电极单元10的横向表面处形成,以便能够在连接单元20处折叠电极单元10,但是不特别限制连接单元20的位置。在该情况下,不特别限制连接单元20的形状,但是连接单元20可以以各种形状形成。
此外,根据需要,可适当地调节连接单元20的宽度。然而,当连接单元20具有过大宽度时,就难以实现电极单元10的期望形状。在卷绕时,张力被施加,从而允许电极被紧密地附接至分隔物50。在该情况下,当连接单元20具有过小宽度时,连接单元20可能由于卷绕期间对其施加的张力而破裂。例如,连接单元20的宽度可处于关于在其上设置有连接单元20的电极单元10的长度的5%-30%的范围内。
同时,根据电极单元10之间的间隙来确定连接单元20的长度,但是本公开不限于此。然而,由于电极层压件具有在卷绕方向上从内部至外部逐渐增加的高度,考虑到该事实,期望将连接单元20设计成使得连接单元20的长度能够从内部至外部逐渐增大。
阳极31和阴极33可分别具有与电极单元10和连接单元20相同的形状。由于通过层压其间布置有分隔物50的阳极31和阴极33以及在一个方向上卷绕阳极31和阴极33的层压件来形成果冻卷式电极组件1,所以阴极33和阳极31的电极单元10及连接单元20的形状可分别在相应的电极处相同。
可通过对电极切刻来形成包括电极单元10和连接单元20的电极,同时留有连接单元20以防止电极单元10彼此分离,其中,在单一方向上伸长的集电板的一个表面或两个表面被涂覆有每种电极活性材料。
可不受限地执行切刻,只要电极能够成形为具有电极单元和连接单元即可。例如,可使用冲压模具形成电极。在该情况下,电极单元和连接单元的形状可分别与上述阴极和阳极相同。因此,可同时在阴极和阳极上执行切刻,并且也可使用相同模具执行切刻。
当卷绕电极层压件以制造果冻卷式电极组件时,可通过层压电极单元和连接单元以相对应并且然后在一个方向上卷绕电极单元的层压件,来制造电极组件。在该情况下,可在每个电极单元的两侧处形成的连接单元处弯曲和卷绕电极层压件。结果,可在垂直于平面的方向上层压电极单元,从而形成下列果冻卷式电极组件,其中依次交替地层压阴极、分隔物和阳极。
同时,可通过从一个集电板切刻来形成电极单元和连接单元,因而,电极单元和连接单元可具有相同材料。在该情况下,连接单元可以是未被涂覆有电极活性材料的未电镀部分。当连接单元作为上述未电镀部分形成时,可防止由于弯曲连接单元而使电极活性材料从集电板分离所导致的电池中的短路问题。同样地,可在每个连接单元的一个表面或两个表面上涂覆有电极活性材料。当如上所述连接单元被涂覆有电极活性材料时,可促进电池的充电/放电反应,这导致电池容量的增加。
可通过在阴极和阳极之间的界面上层压在单一方向上伸长的分隔物,并且卷绕电极层压件,来形成本公开中提供的上述果冻卷式电极组件。因此,在制造果冻卷式电极组件时使用的分隔物包括额外分隔物①,如图2所示,该额外分隔物的形状不对应于电极单元的形状。当存在这种额外分隔物①时,在将电极组件引入到电池壳体时,可能需要其中容纳该分隔物的单独空间。结果,由于难以实现期望的电池设计,应移除该额外分隔物。然而,不易于切除该额外分隔物而移除,这是因为额外分隔物由柔软材料形成,诸如聚酯,并且非常薄,这使得难以将额外分隔物切割成对应于电极单元的形状。
通过将从阴极和阳极的电极单元向外突出的额外分隔物结合以形成分隔物结合体并且切割该额外分隔物,能够在额外分隔物上容易地执行切割过程。一片分隔物不易于切除,但是当若干片分隔物结合以变得相对刚硬时,可更易于切除分隔物。
例如,可使用通过向分隔物施加温度和压力来焊接分隔物的方法等等产生分隔物结合体,但是本公开不限于此。在该情况下,考虑到分隔物的结合性,分隔物的结合温度可处于(Tg–20)℃至(Tg+20)℃(这里,“Tg”为分隔物的玻璃化转变温度)的范围内,但本公开不限于此。
所产生的分隔物结合体可被切割为与电极单元的形状相对应的形状。当分隔物由聚合物材料形成时,可在特定温度和压力下软化聚合物材料,因而可使分隔物结合。同样地,由于多个分隔物被结合在一个位置处并且被切割,因此可通过一次切割操作将所有的分隔物都切割成具有相同形状。
在该情况下,可通过使用刀具、模具、剪刀、激光束执行切割操作,但本公开不限于此。
在该情况下,术语“相同形状”不仅涉及与阳极和阴极的电极单元的形状完全对应的形状,并且可被用作下列含义,即可保留分隔物的仅稍微额外部分。
通过将由此获得的电极组件封装在电池壳体内,可获得聚合物二次电池。在该情况下,电池壳体可为袋式壳体,并且可以形成为与封装在电池壳体内的电极组件的形状相对应的形状。
此外,可获得包括两个或更多个二次电池的电池组,并且也可获得包括至少一个二次电池的装置。该装置可为移动电话、便携式计算机、智能电话、智能平板、上网本、轻型电动车辆(LEV)、电动车辆、混合动力电动车辆、插电式混合动力电动车辆或蓄电系统。
虽然上文已经示出和描述了示例性实施例,但是对本领域技术人员而言显而易见的是,在不偏离所附权利要求书限定的本公开的精神和范围的情况下,能够做出变型和变体。
1:电极组件
10:电极单元
20:连接单元
31:阳极
32:阴极
41:阴极突片
43:阳极突片
50:分隔物
①:额外分隔物
Claims (8)
1.一种制造电极组件的方法,包括:
切刻操作:以恒定的尺寸和形状对在一个方向上伸长的阴极和阳极进行切刻以形成多个电极单元,其中所述电极单元借助于在每个所述电极单元的两端处形成的连接单元而彼此电连接;
层压操作:在分隔物布置在所述阴极和所述阳极的情况下对所述阴极和所述阳极进行层压以形成单元电池;和
卷绕操作:通过使所述连接单元弯曲来卷绕所述单元电池,使得所述阴极和所述阳极的所述电极单元彼此交迭,
形成操作:在所述卷绕操作之后,通过将形状不与所述电极单元的形状相对应的额外分隔物结合,以形成分隔物结合体;和
切割操作:切割所述分隔物结合体。
2.根据权利要求1所述的方法,其中,通过焊接所述分隔物来形成所述分隔物结合体。
3.根据权利要求2所述的方法,其中,在所述分隔物的玻璃化转变温度(Tg)±20℃的温度内执行所述焊接。
4.根据权利要求1所述的方法,其中,通过使用刀具、模具、剪刀、激光束切割所述分隔物,来执行所述切割操作。
5.根据权利要求1所述的方法,其中,所述连接单元由与所述电极单元的集电板的材料相同的材料形成。
6.根据权利要求5所述的方法,其中,所述连接单元被涂覆有与所述电极单元所涂覆的电极活性材料相同的电极活性材料。
7.一种制造二次电池的方法,包括将通过权利要求1-6中任一项所述的方法制造的电极组件封装在电池壳体内。
8.根据权利要求7所述的方法,还包括将所述电池壳体加工成与所述电极组件的形状相对应的形状。
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