JP2010086788A - Method of manufacturing electrode for electrochemical element - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing an electrode for electrochemical element, in which an electrode active material layer can be formed simply, uniformly, and with good adhesion on a current collector, in particular, on a porous current collector having a through-hole front and rear such as a punching metal and an expanded metal. <P>SOLUTION: The method of manufacturing the electrode for electrochemical element has a step in which an electrode active material layer is formed from an electrode composition containing an electrode active material, a conductive material, and a binder on the surface of a substrate, a step in which the electrode active material layer thus formed and the current collector are pasted through a conductive adhesive layer, and a step in which the substrate is separated from the electrode active material layer. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method for producing an electrode used for an electrochemical element such as a lithium ion secondary battery or an electric double layer capacitor (hereinafter, sometimes collectively referred to as “electrode for electrochemical element”), and Specifically, the present invention relates to a method for easily forming an electrode active material layer on a current collector, particularly a perforated current collector.

  Utilizing the small size, light weight, high energy density, and the ability to repeatedly charge and discharge, electrochemical devices such as lithium ion secondary batteries, electric double layer capacitors, and lithium ion capacitors are rapidly expanding their demand. ing. Lithium ion secondary batteries have a relatively high energy density and are therefore used in fields such as mobile phones and notebook personal computers. In addition, since the electric double layer capacitor can be rapidly charged and discharged, it is used as a memory backup compact power source for personal computers and the like. Furthermore, the electric double layer capacitor is expected to be applied as a large power source for electric vehicles. In addition, hybrid capacitors that make use of the advantages of lithium ion secondary batteries and electric double layer capacitors are attracting attention because of their high energy density and output density. With the expansion and development of applications, these electrochemical devices are required to be further improved such as lowering resistance, increasing capacity, and improving mechanical properties.

  The hybrid capacitor includes a polarizable electrode as a positive electrode and a nonpolarizable electrode as a negative electrode, and can increase an operating voltage and an energy density by using an organic electrolyte. In a hybrid capacitor, it has been proposed to use a material in which lithium ions are occluded in advance by a chemical method or an electrochemical method as a material that can occlude and desorb lithium ions (for example, Patent Documents 1 and 2). ).

  Also, a method of coating a current collector surface with a conductive adhesive layer has been proposed (for example, see Patent Document 3) for the purpose of reducing the internal resistance of the electrochemical element.

  In cases where large cells such as automobile power supplies are targeted, as a method of supporting lithium on the negative electrode in advance, the positive electrode current collector and the negative electrode current collector each have a hole penetrating the front and back, and the negative electrode active material reversibly recharges lithium. There has been proposed an organic electrolyte battery that can be supported in an electrochemical manner, and in which lithium derived from the negative electrode is supported by electrochemical contact with lithium arranged to face the negative electrode or the positive electrode (see, for example, Patent Document 4). In Patent Document 4, a hole that penetrates the front and back surfaces is provided in the current collector, and an electrode active material layer is formed on the front and back surfaces of the perforated current collector (hereinafter, the current collector having through holes is referred to as “hole”). May be referred to as an "open current collector"). With such a configuration, the capacitance is improved, and lithium ions can move between the front and back of the electrode without being blocked by the current collector. Through this, lithium can be electrochemically supported not only on the negative electrode arranged in the vicinity of lithium but also on the negative electrode arranged away from lithium. In addition, since lithium ions can freely move between the electrodes through the through holes, charging and discharging proceed smoothly.

  The electrode active material layer is formed by applying and drying a slurry of an electrode composition containing an electrode active material, a conductive material, and a binder on a current collector. In particular, for the purpose of simultaneously forming electrode active material layers on the front and back surfaces of the current collector, a pair of dies are arranged on both sides of the current collector transport path running in the vertical direction, and a pair of dies are disposed above the pair of dies. A twin blade method has been proposed in which the blade is provided and the slurry discharged from the die is scraped off by the blade to control the coating thickness. However, when the current collector is a perforated current collector having through-holes, it is difficult to apply the slurry to a uniform thickness, and the thickness and the amount of active material of the electrode active material layer in the obtained electrode are It is not constant, and the electrode performance varies. This method also requires two dies to apply the slurry from both sides of the current collector, and also requires two sets of paint tanks, supply pumps, filters, piping, etc. Resulting in an increase in cost. Further, in order to control the coating thickness and the surface state of the electrode, it is necessary to strictly adjust the clearance between the two dies, the discharge amount of the slurry, the clearance of the die lip portion, and the like. Furthermore, when a perforated current collector such as punching metal or expanded metal is conveyed to a general horizontal coating machine such as a comma coater, the slurry is transferred to a rotating roller, and the slurry is collected uniformly. It was difficult to apply on an electric body.

  As a method for forming an electrode active material layer with a uniform thickness on a perforated current collector, for example, in Patent Document 5, an electrode material is supplied to a pair of press rolls using a quantitative feeder, and between the press rolls. A method of simultaneously forming a sheet of electrode material and bonding to the current collector by supplying the current collector is disclosed.

In Patent Document 6, the slurry applied to the base material is brought into contact with the perforated current collector and integrated, and then the slurry is dried, the base material is peeled off, and an electrode active material layer is formed on the current collector. A method has been proposed. In this method, since the slurry layer is dried in a state where the base material is laminated, the solvent of the slurry is difficult to uniformly evaporate. For this reason, in patent document 5, the porous base material is used as a base material, the solvent is evaporated uniformly, and the thickness of the electrode active material after drying is made uniform.
JP-A-3-233860 JP-A-5-325965 JP 2002-75805 A International Publication No. 98/33227 JP 2007-5747 A JP 2008-41971 A

  However, in the method described in Patent Document 5, when the electrode material is transferred from the press roll to the current collector, the electrode material may remain on the press roll. As a result, the amount of the electrode material transferred to the current collector is not constant, the thickness of the electrode active material layer becomes uneven, and the electrode characteristics may vary.

  Also in the method of Patent Document 6, when the porous substrate is peeled from the electrode active material layer after the slurry is dried, the electrode material remains on the porous substrate, which causes the same problem. In addition, there is a problem that the slurry viscosity and the pore diameter of the porous substrate are limited due to the application and drying of the slurry.

  Accordingly, an object of the present invention is to form an electrode active material layer easily, uniformly and with good adhesion on a current collector, particularly a perforated current collector having front and back through holes such as punching metal and expanded metal. An object of the present invention is to provide a method for manufacturing an electrode for an electrochemical device.

  As a result of intensive studies to solve the above problems, the present inventor formed an electrode active material layer on the surface of the base material, and affixed it to a current collector through a conductive adhesive layer. It has been found that an electrode for an electrochemical element with good productivity and good quality can be produced with good adhesion to a perforated current collector that is difficult to apply, such as expanded metal.

That is, this invention which solves the said subject contains the following matters as a summary.
(1) A step of forming an electrode active material layer from an electrode composition containing an electrode active material, a conductive material and a binder on the substrate surface;
Bonding the formed electrode active material layer and the current collector through a conductive adhesive layer; and
The manufacturing method of the electrode for electrochemical elements which has the process of isolate | separating a base material from an electrode active material layer.

(2) The production method according to (1), wherein the substrate surface is subjected to a peeling treatment.

(3) The manufacturing method according to (1), wherein the base material is a base material made of a thermoplastic resin film, and one surface or both surfaces of the base material are subjected to release treatment with a thermosetting resin.

(4) The contact angle with water on the peel-treated surface of the substrate is 80 to 110 °,
The manufacturing method as described in (1) including the process of apply | coating the aqueous slurry containing the said electrode composition and water to the base-material surface by which the peeling process was carried out, and forming an electrode active material layer.

(5) After applying a slurry of an electrode composition containing an electrode active material, a conductive material and a binder, and drying to form an electrode active material layer, the electrode active material layer and the current collector are conductively bonded. The manufacturing method in any one of (1)-(4) bonded together through an agent layer.

(6) The manufacturing method according to (1), wherein the conductive adhesive layer includes a resin and conductive particles.

(7) The production method according to (6), wherein the resin is an acrylate polymer or a diene polymer.

(8) The production method according to (6) or (7), wherein the conductive particles are carbon particles.

(9) The production method according to (8), wherein the volume average particle size distribution of the carbon particles is multimodal.

(10) The production method according to (8), wherein the volume average particle size distribution of the carbon particles is bimodal.

(11) The carbon particles include carbon particles (A) having a volume average particle diameter of 0.01 μm or more and less than 1 μm and carbon particles (B) having a volume average particle diameter of 1 μm or more and 10 μm or less. The manufacturing method as described.

(12) The production method according to (11), wherein a ratio of the carbon particles (A) to the carbon particles (B) is in a range of 0.05 to 1 in terms of a weight ratio of (A) / (B).

(13) The manufacturing method according to any one of (1) to (12), wherein the current collector is a perforated current collector.

  ADVANTAGE OF THE INVENTION According to this invention, the electrode active material layer of uniform thickness can be easily formed with sufficient adhesiveness on current collectors, especially perforated current collectors such as punching metal and expanded metal. Furthermore, general equipment can be used, and an electrode for an electrochemical element can be produced with high productivity. In addition, since the electrode active material layer is formed on the base material, the electrode active material layer can be bonded to both surfaces of the current collector at the same time, so that productivity of electrode production can be increased.

  Hereinafter, the method for producing an electrode for an electrochemical element according to the present invention will be described more specifically with reference to the drawings. 1 and 2 show a schematic flow of the production method of the present invention.

The method for producing an electrode for an electrochemical element according to the present invention comprises a step of forming an electrode active material layer on the surface of a substrate 1 from an electrode composition containing an electrode active material, a conductive material and a binder (see FIG. 1),
Bonding the formed electrode active material layer and the current collector 2 through a conductive adhesive layer; and
It has the process of isolate | separating the base material 1 from an electrode active material layer (refer FIG. 2).

Hereinafter, the base material, electrode active material, conductive material, binder, current collector, conductive adhesive layer and the like used in the present invention will be described.
<Base material>
The base material used in the present invention can be used without any limitation on inorganic materials and organic materials as long as the electrode composition layer can be coated on the base material. For example, aluminum foil, copper foil, ionomer film (IO film), polyethylene film (PE film), polyethylene terephthalate film (PET film), polyethylene naphthalate film (PEN film), polyvinyl chloride film (PVC film), polychlorinated Vinylidene film (PVDC film), polyvinyl alcohol film (PVA film), polypropylene film (PP film), polyester film, polycarbonate film (PC film), polystyrene film (PS film), polyacrylonitrile film (PAN film), ethylene-acetic acid Vinyl copolymer film (EVA film), ethylene-vinyl alcohol copolymer film (EVOH film), ethylene - methacrylic acid copolymer film (EMAA film), nylon film (NY film, a polyamide (PA) film), cellophane, imide films, paper and the like. Moreover, you may use the film of the multilayered structure which accumulated the said film. Among these, a thermoplastic resin film is preferable from the viewpoint of versatility and handleability, and a PET film, a PE film, a PP film, a PVC film, and the like are particularly preferable.

  Although the thickness of a base material is not specifically limited, 5 micrometers-200 micrometers are suitable, and 30 micrometers-150 micrometers are more suitable. The width is not particularly limited, but is preferably about 100 mm to 1000 mm, and more preferably about 200 mm to 500 mm.

  The substrate surface on which the electrode active material layer is formed is preferably subjected to a peeling treatment. The peeling treatment may be performed only on one side of the base material or on both sides. The method of the peeling treatment is not particularly limited, but, for example, a method of applying a thermosetting resin such as an alkyd resin on a substrate and curing it, a method of applying a silicone resin on a substrate and curing it It is preferable to use a method of coating a fluororesin on a substrate. In particular, a release treatment using a thermosetting resin capable of easily forming a homogeneous release treatment layer is preferable, and alkyd from the viewpoint of the balance of the aqueous slurry coating property described later and the release property of the obtained electrode active material layer. Peeling treatment by resin coating and curing is preferred.

  When the electrode composition layer is formed by applying an aqueous slurry, the contact angle with water on the release-treated surface of the substrate is preferably in the range of 80 to 110 °, more preferably 90 to 100 °. When the contact angle with water on the release treatment surface is too small, the slurry coatability is good, but it may be difficult to release the electrode active material layer formed after drying the slurry from the substrate. is there. On the other hand, when the contact angle is too large, it is easy to peel the electrode active material layer from the substrate, but the slurry is repelled on the surface of the substrate, making uniform coating difficult. As described above, coating properties and releasability are generally incompatible characteristics. However, by setting the contact angle with water on the surface of the base material to be peeled within the above range, the coating properties of the aqueous slurry and the electrode activity are improved. The peelability of the material layer is balanced, an electrode composition layer having a uniform thickness can be formed, and the electrode active material layer can be easily peeled off.

  The base material can be used repeatedly. By repeatedly using the base material, the production cost of the electrode can be further reduced.

<Electrode composition>
The electrode active material layer is formed from an electrode composition including an electrode active material, a conductive material, and a binder.
(Electrode active material)
The electrode active material used in the present invention is a substance that transfers electrons in an electrode for an electrochemical element. The electrode active material mainly includes an active material for a lithium ion secondary battery, an active material for an electric double layer capacitor, and an active material for a lithium ion capacitor.

Examples of the active material for a lithium ion secondary battery include a positive electrode and a negative electrode. As the electrode active material used for the positive electrode of a lithium ion secondary battery electrode, _{specifically, LiCoO 2, LiNiO 2, LiMnO} 2, LiMn 2 O 4, LiFePO 4, lithium-containing composite metal oxides such as LiFeVO _4; Transition metal sulfides such as TiS ₂ , TiS ₃ , and amorphous MoS ₃ ; Cu ₂ V ₂ O ₃ , amorphous V ₂ O · P ₂ O ₅ , MoO ₃ , V ₂ O ₅ , V ₆ O _13, etc. These transition metal oxides are exemplified. Furthermore, conductive polymers such as polyacetylene and poly-p-phenylene are listed. Preferred is a lithium-containing composite metal oxide.

  Specific examples of the electrode active material used for the negative electrode of the lithium ion secondary battery electrode include carbonaceous materials such as amorphous carbon, graphite, natural graphite, mesocarbon microbeads (MCMB), and pitch-based carbon fibers; polyacene And the like, and the like. Crystalline carbonaceous materials such as graphite, natural graphite, and mesocarbon microbeads (MCMB) are preferable.

  The shape of the electrode active material used for the electrode for a lithium ion secondary battery is preferably a granulated particle. When the shape of the particles is spherical, a higher density electrode can be formed during electrode molding.

  The volume average particle diameter of the electrode active material used for the electrode for a lithium ion secondary battery is usually 0.1 to 100 μm, preferably 1 to 50 μm, more preferably 5 to 20 μm for both the positive electrode and the negative electrode.

The tap density of the electrode active material used for the electrode for the lithium ion secondary battery is not particularly limited, but preferably 2 g / cm ³ or more for the positive electrode and 0.6 g / cm ³ or more for the negative electrode.

  As the electrode active material used for the electric double layer capacitor electrode, a carbon allotrope is usually used. Specific examples of the allotrope of carbon include activated carbon, polyacene, carbon whisker, and graphite, and these powders or fibers can be used. A preferred electrode active material is activated carbon, and specific examples include activated carbon made from phenol resin, rayon, acrylonitrile resin, pitch, coconut shell, and the like.

  The volume average particle diameter of the electrode active material used for the electric double layer capacitor electrode is usually 0.1 to 100 μm, preferably 1 to 50 μm, and more preferably 5 to 20 μm.

The specific surface area of the electrode active material used in the electrode for an electric double layer capacitor, ^{30 m} 2 / g or more, preferably 500~5,000m ² / g, and more preferably are from 1,000~3,000m ² / g preferable. Since the density of the obtained electrode active material layer tends to decrease as the specific surface area of the electrode active material increases, an electrode active material layer having a desired density can be obtained by appropriately selecting the electrode active material.

  Electrode active materials used for electrodes for lithium ion capacitors include positive electrodes and negative electrodes. The electrode active material used for the positive electrode of the lithium ion capacitor electrode may be any material that can reversibly carry lithium ions and anions such as tetrafluoroborate. Specifically, an allotrope of carbon is usually used, and electrode active materials used in electric double layer capacitors can be widely used. When carbon allotropes are used in combination, two or more types of carbon allotropes having different average particle diameters or particle size distributions may be used in combination. Further, a polyacene organic semiconductor (PAS) which is a heat-treated product of an aromatic condensation polymer and has a polyacene skeleton structure having a hydrogen atom / carbon atom atomic ratio of 0.50 to 0.05 can also be used suitably. . Preferably, it is an electrode active material used for the electrode for electric double layer capacitors.

  The electrode active material used for the negative electrode of the electrode for lithium ion capacitors is a substance that can reversibly carry lithium ions. Specifically, electrode active materials used in the negative electrode of lithium ion secondary batteries can be widely used. Preferred examples include crystalline carbon materials such as graphite and non-graphitizable carbon, and polyacene-based materials (PAS) described as the positive electrode active material. These carbon materials and PAS are obtained by carbonizing a phenol resin or the like, activated as necessary, and then pulverized.

  The shape of the electrode active material used for the electrode for a lithium ion capacitor is preferably a granulated particle. When the shape of the particles is spherical, a higher density electrode can be formed during electrode molding.

  The volume average particle diameter of the electrode active material used for the lithium ion capacitor electrode is usually 0.1 to 100 μm, preferably 1 to 50 μm, more preferably 5 to 20 μm for both the positive electrode and the negative electrode. These electrode active materials can be used alone or in combination of two or more.

(Conductive material)
The conductive material used in the present invention is composed of an allotrope of particulate carbon that has conductivity and does not have pores that can form an electric double layer. Specifically, furnace black, acetylene black, and ketjen Examples thereof include conductive carbon black such as black (registered trademark of Akzo Nobel Chemicals Bethloten Fennaut Shap). Among these, acetylene black and furnace black are preferable.

  The volume average particle diameter of the conductive material used in the present invention is preferably smaller than the volume average particle diameter of the electrode active material, and the range thereof is usually 0.001 to 10 μm, preferably 0.05 to 5 μm, more preferably 0. 0.01 to 1 μm. When the volume average particle diameter of the conductive material is within this range, high conductivity can be obtained with a smaller amount of use. These conductive materials can be used alone or in combination of two or more. The amount of the conductive material is usually 0.1 to 50 parts by weight, preferably 0.5 to 15 parts by weight, and more preferably 1 to 10 parts by weight with respect to 100 parts by weight of the electrode active material. When the amount of the conductive material is within this range, the capacity of the battery using the obtained electrode can be increased and the internal resistance can be decreased.

(Binder)
The binder used in the present invention is not particularly limited as long as it is a compound capable of binding the electrode active material and the conductive material to each other. A suitable binder is a dispersion type binder having a property of being dispersed in a solvent. Examples of the dispersion-type binder include polymer compounds such as fluoropolymers, diene polymers, acrylate polymers, polyimides, polyamides, polyurethane polymers, and the like. Fluorine polymers, diene polymers Alternatively, an acrylate polymer is preferable, and a diene polymer or an acrylate polymer is more preferable in that the withstand voltage can be increased and the energy density of the electrochemical element can be increased.

  The diene polymer is a homopolymer of a conjugated diene or a copolymer obtained by polymerizing a monomer mixture containing a conjugated diene, or a hydrogenated product thereof. The proportion of the conjugated diene in the monomer mixture is usually 40% by weight or more, preferably 50% by weight or more, more preferably 60% by weight or more. Specific examples of the diene polymer include conjugated diene homopolymers such as polybutadiene and polyisoprene; aromatic vinyl / conjugated diene copolymers such as carboxy-modified styrene / butadiene copolymer (SBR); Examples thereof include vinyl cyanide / conjugated diene copolymers such as acrylonitrile / butadiene copolymer (NBR); hydrogenated SBR, hydrogenated NBR, and the like.

Acrylate polymer of the general formula ^{_{(1): CH 2 = CR}} 1 -COOR 2 ( wherein, ^{R 1} represents a hydrogen atom or a methyl group, ^{R 2} represents an alkyl group or a cycloalkyl group.) Is represented by It is a polymer containing the monomer unit derived from a compound. Specific examples of the compound represented by the general formula (1) include ethyl acrylate, propyl acrylate, isopropyl acrylate, n-butyl acrylate, isobutyl acrylate, t-butyl acrylate, n-amyl acrylate, Acrylates such as isoamyl acrylate, n-hexyl acrylate, 2-ethylhexyl acrylate, lauryl acrylate, stearyl acrylate; ethyl methacrylate, propyl methacrylate, isopropyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, methacryl Examples thereof include methacrylates such as t-butyl acid, n-amyl methacrylate, isoamyl methacrylate, n-hexyl methacrylate, 2-ethylhexyl methacrylate, lauryl methacrylate and stearyl methacrylate. Among these, acrylate is preferable, and n-butyl acrylate and 2-ethylhexyl acrylate are particularly preferable in that the strength of the obtained electrode can be improved. The ratio of the monomer unit derived from the compound represented by the general formula (1) in the acrylate polymer is usually 50% by weight or more, preferably 70% by weight or more. When an acrylate polymer in which the proportion of the monomer unit derived from the compound represented by the general formula (1) is within the above range is used, the heat resistance is high and the internal resistance of the obtained electrode for an electrochemical device is reduced. it can.

  As the acrylate polymer, a copolymerizable carboxylic acid group-containing monomer can be used in addition to the compound represented by the general formula (1). Specific examples include acrylic acid and methacrylic acid. Monobasic acid-containing monomers; dibasic acid-containing monomers such as maleic acid, fumaric acid, and itaconic acid. Among these, a dibasic acid-containing monomer is preferable, and itaconic acid is particularly preferable in terms of enhancing the binding property with the current collector and improving the electrode strength. These monobasic acid-containing monomers and dibasic acid-containing monomers can be used alone or in combination of two or more. The amount of the carboxylic acid group-containing monomer in the copolymerization is usually 0.1 to 50 parts by weight, preferably 0.5 to 20 parts per 100 parts by weight of the compound represented by the general formula (1). Part by weight, more preferably in the range of 1 to 10 parts by weight. When the amount of the carboxylic acid group-containing monomer is within this range, the binding property with the current collector is excellent, and the strength of the obtained electrode is improved.

  In addition to the compound represented by the general formula (1), a copolymerizable nitrile group-containing monomer can be used for the acrylate polymer. Specific examples of the nitrile group-containing monomer include acrylonitrile, methacrylonitrile, and the like. Among them, acrylonitrile is preferable in that the binding strength with the conductive adhesive layer is increased and the electrode strength can be improved. The amount of acrylonitrile is usually 0.1 to 40 parts by weight, preferably 0.5 to 30 parts by weight, more preferably 1 to 20 parts by weight with respect to 100 parts by weight of the compound represented by the general formula (1). Range. When the amount of acrylonitrile is within this range, the binding property with the conductive adhesive layer is excellent, and the strength of the obtained electrode is improved.

  The shape of the binder is not particularly limited, but it has good binding properties with the conductive adhesive layer, and since it can suppress deterioration of the capacity of the prepared electrode and repeated charge / discharge, the particles It is preferable that it is a shape. Examples of the particulate binder include those in which binder particles such as latex are dispersed in water, and powders obtained by drying such a dispersion.

  The glass transition temperature (Tg) of the binder is preferably 50 ° C. or lower, more preferably −40 to 0 ° C. When the glass transition temperature (Tg) of the binder is within this range, it is excellent in binding property with a small amount of use, strong in electrode strength, flexible, and easy to increase the electrode density by the pressing process at the time of electrode formation. Can be increased.

  The number average particle size of the binder is not particularly limited, but is usually 0.0001 to 100 μm, preferably 0.001 to 10 μm, and more preferably 0.01 to 1 μm. When the number average particle diameter of the binder is within this range, an excellent binding force can be imparted to the electrode active material layer even with a small amount of use. Here, the number average particle diameter is a number average particle diameter calculated as an arithmetic average value obtained by measuring the diameter of 100 binder particles randomly selected in a transmission electron micrograph. The shape of the particles can be either spherical or irregular. These binders can be used alone or in combination of two or more. The amount of the binder is usually 0.1 to 50 parts by weight, preferably 0.5 to 20 parts by weight, more preferably 1 to 10 parts by weight with respect to 100 parts by weight of the electrode active material. When the amount of the binder is within this range, sufficient adhesion between the obtained electrode active material layer and the conductive adhesive layer can be secured, the capacity of the electrochemical device can be increased, and the internal resistance can be decreased. .

(Surfactant)
Further, the electrode composition may contain a surfactant. The surfactant well disperses the electrode active material, the conductive material, and the binder, reduces the surface tension of the slurry, and improves the coatability. Specific examples of the surfactant include anionic surfactants such as alkyl sulfate ester salts, alkylbenzene sulfonates, fatty acid salts, and naphthalene sulfonic acid formalin condensates, polyoxyethylene alkyl ethers, glycerin fatty acid esters, and the like. Nonionic surfactants, cationic surfactants such as alkylamine salts and quaternary ammonium salts, amphoteric surfactants such as alkylamine oxides and alkylbetaines, anionic surfactants and nonionic surfactants Surfactants are preferred, and anionic surfactants are particularly preferred from the viewpoint of excellent durability of the electrochemical device.

  When using a surfactant, the blending amount is in the range of 0.5 to 20 parts by weight, preferably 1.0 to 10 parts by weight, and 2.0 to 5 parts per 100 parts by weight of the electrode active material. Part by weight is particularly preferred. When the compounding amount of the surfactant is within this range, the durability of the electrochemical element is excellent.

(Organic solvent)
The electrode composition may contain an organic solvent. By using an organic solvent, the coating property of the slurry is improved. In addition, when an organic solvent having a boiling point (normal pressure) of 50 to 150 ° C. is used, when the electrode composition layer formed by applying the aqueous slurry is dried, the organic solvent volatilizes simultaneously with the volatilization of water. The process can be simplified. Further, the organic solvent does not remain in the dried electrode active material layer, and the durability of the electrode is improved. Specific examples of the organic solvent include alcohols such as methanol, ethanol and isopropanol, alkyl esters such as methyl acetate and ethyl acetate, and ketones such as acetone and methyl ethyl ketone, preferably alcohols and alkyl esters. Alcohols are particularly preferable in view of excellent durability of the electrochemical element.

  When using an organic solvent, the compounding quantity is the range of 0.5-20 weight part with respect to 100 weight part of electrode active materials, 1.0-10 weight part is preferable, 2.0-5 weight Part is particularly preferred. When the blending amount of the organic solvent is within this range, the resulting electrochemical element is excellent in durability.

  Further, it is particularly preferable to use the above surfactant and an organic solvent in combination. By using the surfactant and the organic solvent in combination, the surface tension of the electrode composition slurry is further reduced, and the productivity is improved. In this case, the total amount of the surfactant and the organic solvent is in the range of 0.5 to 20 parts by weight, preferably 1.0 to 10 parts by weight, with respect to 100 parts by weight of the electrode active material. ˜5 parts by weight is particularly preferred.

(Dispersant)
The electrode composition may contain a dispersing agent in order to uniformly disperse these components in addition to the electrode active material, conductive material, and binder.

  Specific examples of the dispersant include cellulose derivatives such as carboxymethyl cellulose; poly (meth) acrylates such as sodium poly (meth) acrylate; polyvinyl alcohol, modified polyvinyl alcohol, polyethylene oxide; polyvinylpyrrolidone, polycarboxylic acid, oxidation Examples include starch, phosphate starch, casein, various modified starches, chitin, and chitosan derivatives. Among these, cellulose derivatives are particularly preferable.

  The cellulose derivative is a compound obtained by etherifying or esterifying at least a part of the hydroxyl group of cellulose, and is preferably water-soluble. Cellulose derivatives usually do not have a glass transition point. Specific examples include carboxymethyl cellulose, carboxymethyl ethyl cellulose, methyl cellulose, ethyl cellulose, ethyl hydroxyethyl cellulose, hydroxyethyl cellulose, and hydroxypropyl cellulose. Moreover, these ammonium salt and alkali metal salt are mentioned. Among these, a salt of carboxymethyl cellulose is preferable, and an ammonium salt of carboxymethyl cellulose is particularly preferable. The degree of etherification of the cellulose derivative is preferably 0.5 to 2, more preferably 0.5 to 1.5. Here, the degree of etherification is a value representing how many hydroxyl groups contained per 3 glucose units of cellulose are etherified on average. When the degree of etherification is within this range, the stability of the slurry containing the electrode composition is high, and solid matter sedimentation and aggregation are unlikely to occur. Furthermore, the coating property and fluidity | liquidity of a coating material improve by using a cellulose derivative.

<Current collector>
As the type of material constituting the current collector 2, for example, metal, carbon, conductive polymer, or the like can be used, and metal is preferably used. For example, various materials proposed for applications such as batteries and capacitors can be used. The positive electrode current collector is preferably aluminum, stainless steel, and the negative electrode current collector is preferably stainless steel, copper, nickel, etc. Can be used. Further, the current collector may have a structure having no through-hole, but the method of the present invention is particularly suitable for forming an electrode active material layer on a current collector having a through-hole (perforated current collector). Is suitable. Therefore, the current collector is, for example, an expanded metal, a punching metal, a metal net, a foam, an etching foil provided with through holes by etching, or a current collector with protrusions provided with protrusions and through holes using an embossing roll. Etc. are preferably used.

  The shape of the aperture portion of the apertured current collector is not particularly limited, and the aperture ratio is preferably 10% to 90%, more preferably 20% to 60%, and particularly preferably 40% to 60%. It is in. The aperture ratio is determined by planar observation of the perforated current collector. Specifically, the aperture ratio is determined by observing the perforated current collector in a plane and calculating the area of the through holes per unit area.

  By setting the aperture ratio of the current collector within the above range, it is possible to suppress capacity variation between lots when an electrochemical device is manufactured. In an electrochemical element using a current collector that does not have a normal aperture, if a non-facing surface is formed where the electrodes do not face each other when a stacked electrochemical element is produced, the non-facing surface is static. The electric capacity cannot be taken out. Furthermore, if the amount of active material per unit area of the electrode varies, the actual capacitance that can be taken out may be smaller than the capacitance calculated from the weight of the active material. It also leads to deterioration factors. For this reason, capacity variation occurs between lots of electrochemical elements, and the lifetime of the electrochemical elements may be further shortened. This is because the diffusion of electrolyte ions occurs only on the opposing surface of the positive and negative electrodes. However, by using a perforated current collector, electrolyte ions pass through the current collector and diffuse, so that the capacitance can be taken out from the non-facing surface where the electrodes do not face each other. Furthermore, even when using electrodes with different amounts of active material per unit area of the electrode, as long as the total weight of the electrode active material is matched, capacity balance can be easily achieved in the capacitor cell. Capacity variation between lots can be suppressed. In addition, since there is no charge bias in the cell, the lifetime of the electrochemical element can be extended.

  In addition, when the aperture ratio of the current collector is too high to support lithium on the negative electrode active material, the time required to support it is short, and unevenness of lithium support is unlikely to occur, but the strength of the current collector is It tends to drop and become wrinkled and cut. In addition, it becomes difficult to hold the active material or the like in the through-hole, and problems such as a decrease in yield during electrode manufacturing occur due to falling off of the active material or the like, or breakage of the electrode.

  On the other hand, when the aperture ratio is too low, the time required to support lithium on the negative electrode active material becomes long and problems such as a decrease in production efficiency and an increase in variation in cell characteristics occur, but the strength of the current collector is The electrode yield is increased because the active material is less likely to fall off. It is desirable that the aperture ratio and the hole diameter of the current collector are appropriately selected within the above range in consideration of the battery structure (stacked type, wound type, etc.) and productivity.

  The current collector is strip-shaped, and the thickness is not particularly limited, but is preferably 5 to 50 μm, and more preferably 10 to 40 μm. The width is not particularly limited, but is preferably about 100 to 1000 mm, more preferably about 200 to 500 mm.

<Conductive adhesive layer>
In the present invention, the electrode active material layer and the current collector are bonded together via a conductive adhesive layer. The conductive adhesive layer contains a conductive substance, preferably carbon particles, and if necessary, a resin component for molding. By including a resin in the conductive adhesive layer, the adhesion between the current collector and the electrode composition layer can be increased, the internal resistance of the electrochemical element can be reduced, and the output density can be increased.

  The resin suitably used for the conductive adhesive layer is the same as the binder exemplified in the above electrode composition layer, and is preferably a dispersive binder having a property of being dispersed in a solvent. Examples of the dispersion-type binder include polymer compounds such as fluorine-based polymers, diene-based polymers, acrylate-based polymers, polyimides, polyamides, polyurethane-based polymers, and fluorine-based polymers, diene-based polymers, or acrylates. Polymers are preferable, and diene polymers or acrylate polymers are more preferable in that the withstand voltage can be increased and the energy density of the electrochemical device can be increased.

  In the present invention, the content of the resin in the conductive adhesive layer is preferably 0.5 to 20 parts by weight, more preferably 1 to 15 parts by weight, particularly preferably 2 to 100 parts by weight of the carbon particles. 10 parts by weight.

  The conductive adhesive layer contains carbon particles and a suitably used resin, and may contain a dispersant for uniformly dispersing them. Specific examples of the dispersant are the same as those exemplified in the electrode composition. Among them, a cellulose-based polymer is preferable, and carboxymethyl cellulose, an ammonium salt or an alkali metal salt thereof is particularly preferable.

  The amount of these dispersants can be used within a range that does not impair the effects of the present invention, and is not particularly limited, but is usually 0.1 to 15 parts by weight, preferably 100 parts by weight of carbon particles. Is in the range of 0.5 to 10 parts by weight, more preferably 0.8 to 5 parts by weight.

  In the present invention, the conductive adhesive layer may be formed by applying a conductive adhesive slurry composition containing the above components to a current collector and drying, or the conductive adhesive slurry composition as an electrode. You may form by apply | coating and drying to an active material layer. The coating method of the conductive adhesive slurry composition is not particularly limited. For example, it is applied onto the current collector or the electrode active material layer by a doctor blade method, a dip method, a reverse roll method, a direct roll method, a gravure method, an extrusion method, a brush coating, or the like. However, it is preferable to form a conductive adhesive layer on the current collector with less complexity of the process. In addition, the conductive adhesive layer may be formed into a sheet by a dry method by supplying granulated particles made of a conductive adhesive onto the current collector or the electrode active material layer. Further, the conductive adhesive layer may be formed on the release film by a coating method or a dry method, and this may be transferred onto the current collector or the electrode active material layer.

  The thickness of the conductive adhesive layer is usually 0.01 to 20 μm, preferably 0.1 to 10 μm, and particularly preferably 1 to 5 μm. When the thickness of the conductive adhesive layer is within the above range, good adhesiveness can be obtained and the electron transfer resistance can be reduced.

(Carbon particles)
Carbon particles that are preferably used as the conductive material of the conductive adhesive layer include graphite having high conductivity due to the presence of delocalized π electrons (specifically, natural graphite, artificial graphite, etc.); Carbon black (specifically, acetylene black, ketjen black, other furnace blacks, channel blacks, thermal lamp blacks, etc.), which is a spherical aggregate in which several layers of carbon microcrystals are gathered to form a turbulent layer structure; Carbon whiskers and the like are mentioned. Among these, graphite or carbon black is used in that the carbon particles of the conductive adhesive layer are filled with high density, the electron transfer resistance can be reduced, and the internal resistance of the lithium ion capacitor can be reduced. Is particularly preferred.

  As the carbon particles, those listed above may be used alone, but it is particularly preferable to use two types in combination. Specific examples include graphite and carbon black, graphite and carbon fiber, graphite and carbon whisker, carbon black and carbon fiber, carbon black and carbon whisker, and preferably graphite and carbon black, graphite and carbon fiber, and carbon black. And carbon fiber, particularly preferably graphite and carbon black, a combination of graphite and carbon fiber, and the like. When carbon particles are used in this combination, the carbon particles of the conductive adhesive layer are filled with high density, so that the electron transfer resistance is reduced and the internal resistance of the electrochemical device is reduced.

The electrical resistivity of the carbon particles is preferably 0.0001 to 1 Ω · cm, more preferably 0.0005 to 0.5 Ω · cm, and particularly preferably 0.001 to 0.1 Ω · cm. When the electrical resistivity of the carbon particles is within this range, the electron transfer resistance of the conductive adhesive layer can be reduced and the internal resistance can be reduced. Here, the electrical resistivity is measured by using a powder resistance measurement system (MCP-PD51 type; manufactured by Dia Instruments Co., Ltd.) while measuring the resistance value while applying pressure to the carbon particles, and the resistance value converged with respect to the pressure. The electrical resistivity ρ (Ω · cm) = R × (S / d) is calculated from R (Ω), the area S (cm ² ) and the thickness d (cm) of the compressed carbon particle layer.

  The volume average particle diameter of the carbon particles is preferably 0.01 to 20 μm, more preferably 0.05 to 15 μm, and particularly preferably 0.1 to 10 μm. When the volume average particle diameter of the carbon particles is within this range, the carbon particles of the conductive adhesive layer are filled with high density, so that the electron transfer resistance is reduced and the internal resistance of the electrochemical device is reduced. Here, the volume average particle diameter is a volume average particle diameter calculated by measuring with a laser diffraction particle size distribution analyzer (SALD-3100; manufactured by Shimadzu Corporation).

  In the method for producing an electrode for an electrochemical element of the present invention, the volume average particle size distribution of the carbon particles used for the conductive adhesive layer is preferably multimodal. Here, multimodal is a state in which a plurality of peaks appear when the existence frequency of particles having the particle size is plotted against the particle size. The volume average particle size distribution of the carbon particles is preferably bimodal having two peaks. Specifically, the carbon particles include carbon particles (A) having a volume average particle diameter of 0.01 μm or more and less than 1 μm and carbon particles (B) having a volume average particle diameter of 1 μm or more and 10 μm or less. preferable. When the volume average particle size distribution of the carbon particles is bimodal, the carbon particles of the conductive adhesive layer are filled with high density, so that the electron transfer resistance is reduced and the internal resistance is reduced. Here, the volume average particle size distribution is a volume average particle size distribution calculated by measuring with a laser diffraction particle size distribution analyzer (SALD-3100; manufactured by Shimadzu Corporation).

  The ratio of the two types of carbon particles (A) and carbon particles (B) preferably used in the present invention is 0.05 to 1 in terms of (A) / (B) weight ratio, and 0.1 to 0.8. Is preferable, and 0.2 to 0.5 is particularly preferable. When the weight ratio of the two types of carbon particles is within this range, the carbon particles of the conductive adhesive layer are filled with high density, so that the electron transfer resistance is reduced and the internal resistance of the electrochemical device is reduced.

<Method for forming electrode active material layer>
In the manufacturing method of this invention, the electrode composition layer which consists of said each component is formed on the base material 1, and drying etc. are performed as needed and an electrode active material layer is obtained. As a preferable method for forming the electrode active material layer, for example, a method of supplying granulated particles made of an electrode composition onto a substrate and molding it into a sheet by a dry method (sheet molding method), using the electrode composition as a solvent. Although the method (coating method) etc. which apply | coat the dispersed slurry on a base material and volatilize a solvent are mentioned, the coating method is preferable at the point which can form uniformly on a base material.

  The electrode composition slurry is composed of an electrode active material, a conductive material, a binder, a dispersant, a surfactant and an organic solvent which are added as necessary, and water or an organic solvent such as N-methyl-2-pyrrolidone or tetrahydrofuran. It can manufacture by kneading in. The electrode composition slurry is preferably an aqueous slurry using water as a dispersion medium from the viewpoint of easy drying of the electrode active material layer and excellent environmental load.

  As a method for producing an aqueous slurry, water and the above-mentioned components can be mixed and produced using a mixer. As the mixer, a ball mill, a sand mill, a pigment disperser, a pulverizer, an ultrasonic disperser, a homogenizer, a planetary mixer, a Hobart mixer, and the like can be used. Also preferred is a method in which the electrode active material and the conductive material are first mixed using a mixer such as a crusher, a planetary mixer, a Henschel mixer, and an omni mixer, and then a binder is added and mixed uniformly. By adopting this method, a uniform slurry can be easily obtained.

  The viscosity of the slurry used in the present invention varies depending on the type of coating machine and the shape of the coating line, but is usually 100 to 100,000 mPa · s, preferably 1,000 to 50,000 mPa · s. Preferably, it is 5,000 to 20,000 mPa · s.

  The method for applying the slurry to the substrate is not particularly limited. Examples thereof include a doctor blade method, a dip method, a reverse roll method, a direct roll method, a gravure method, an extrusion method, and a brush coating method. The coating thickness of the slurry is appropriately set according to the thickness of the target electrode active material layer.

  Next, an electrode active material layer made of the electrode composition formed by applying the slurry is attached to the current collector 2 via a conductive adhesive layer. The application to the current collector may be performed immediately after the application of the slurry, but it is particularly preferable to perform the application to the current collector after drying the electrode composition layer. By drying the electrode composition layer, the layer thickness becomes constant and the strength is improved, so that it is easy to attach to the current collector. Moreover, since it sticks to a collector after drying, an electrode active material layer can be formed only in the required location on a collector. Furthermore, when the substrate is peeled off after being attached to the current collector, part of the electrode active material layer can be prevented from remaining on the substrate.

  Examples of the drying method include drying by warm air, hot air, low-humidity air, vacuum drying, and drying by irradiation with (far) infrared rays or electron beams. Among these, a drying method by irradiation with far infrared rays is preferable. The drying temperature and drying time in the present invention are preferably a temperature and a time at which the solvent in the slurry applied to the current collector can be completely removed, and the drying temperature is 100 to 300 ° C, preferably 120 to 250 ° C. The drying time is usually 1 minute to 60 minutes, preferably 5 minutes to 30 minutes.

  A more specific example of the electrode active material layer forming step by the coating method is shown in FIG. In FIG. 1, the winding body of the base material 1 is attached to the unwinder 10, the base material 1 is sent out from the unwinder 10, and the slurry of the electrode composition is discharged from the coating machine 3 onto the surface of the base material 1. An electrode composition layer is formed on the surface. In the figure, the formed electrode composition layer is not shown. Subsequently, the base material with the electrode composition layer formed on the surface is introduced into the dryer 4, and the electrode composition layer is dried to form an electrode active material layer. Then, the base material 1 which has an electrode active material layer is wound up with the winder 11, and the wound body of the base material 1 with an electrode active material layer is obtained.

<Attaching the electrode active material layer to the current collector>
The electrode active material layer is attached to the current collector through a conductive adhesive layer. The conductive adhesive layer may be performed before the drying or after the drying. Preferably, as described above, the electrode active material layer after the slurry is dried is interposed through the conductive adhesive layer. Affix to the current collector. At this time, by performing the pressing, the binder contained in the electrode active material layer is easily plastically deformed, and the adhesion between the current collector and the electrode composition is improved. Furthermore, an electrode having a smooth surface can be obtained by pressing. Moreover, if it presses after drying, an electrode density can be raised easily. Alternatively, the electrode active material layer and the current collector may be integrated via the conductive adhesive layer by hot pressing in which heat is applied simultaneously with pressing.

  Specific examples of the hot press method include a batch hot press and a continuous hot roll press, and a continuous hot roll press capable of improving productivity is preferable. Although it will not restrict | limit especially if the temperature of a hot press is a grade which does not impair a base material, Usually, it is 50-200 degreeC, Preferably it is 70-150 degreeC. When the temperature of the hot press is within this range, the electrode active material layer can be uniformly bonded to the current collector, and the electrode strength is excellent.

  The linear pressure of the hot press is not particularly limited as long as it does not damage the substrate, but is usually 50 to 2,000 KN / m, preferably 100 to 1,000 KN / m, particularly preferably 200 to 500 KN / m. is there. When the linear pressure of the hot press is within this range, the electrode active material layer can be uniformly bonded to the current collector, and the electrode strength is excellent.

(Separation of substrate from electrode active material layer)
The method for separating the base material from the electrode active material layer is not particularly limited. For example, after the electrode active material layer is pasted, the current collector on which the electrode active material layer is pasted and the base material are placed on separate rolls. By turning it, it can be easily separated. Thus, a current collector having an electrode active material layer is obtained.

  FIG. 2 shows a more specific aspect of a series of steps for attaching the electrode active material layer to the current collector and separating the base material as described above. In the figure, the electrode active material layer and the conductive adhesive layer are not shown. The electrode active material layer is formed on the surface of the substrate 1, and the conductive adhesive layer is formed on the surface of the electrode active material layer or the current collector. In FIG. 2, the wound body of the base material 1 with an electrode active material layer is attached to an unwinder 12, and the base material 1 with an electrode active material layer is sent out. Separately, a roll of the current collector 2 with a conductive adhesive layer is attached to the unwinder 14, and the current collector is sent out. Next, the substrate 1 with the electrode active material layer 1 and the current collector 2 are introduced into a laminator 16 equipped with a heating mechanism, subjected to hot pressing, and the electrode active material layer is placed on the current collector 2 through the conductive adhesive layer. The base material 1 is pasted. Next, the substrate 1 is peeled off from the electrode active material layer and wound up by a winder 13, and the current collector 2 on which the electrode active material layer is transferred is wound up by a winder 15 to wind the current collector with the electrode active material layer. The harvester is obtained. The formation of the conductive adhesive layer on the current collector and the attachment of the substrate 1 with the electrode active material layer can also be performed in-line. In this case, the current collector 2 on which the conductive adhesive layer is formed may be transferred as it is to the next step without being wound, and the substrate 1 with the electrode active material layer may be attached.

  In addition, the base material on which the electrode active material layer is formed is bonded to the other surface of the current collector on which the electrode active material layer is formed by hot pressing, and the electrode active material layer is formed on both sides of the current collector. An electrode for a chemical element can also be produced. Furthermore, as shown in FIG. 2, an electrode active material layer may be simultaneously formed on both sides of the current collector by the above method.

  EXAMPLES Hereinafter, although an Example and a comparative example demonstrate this invention further more concretely, this invention is not limited to these Examples. In the examples and comparative examples, “part” and “%” are based on weight unless otherwise specified. Each characteristic in an Example and a comparative example is measured in accordance with the following method.

(Peel strength of the electrode active material layer formed on the current collector)
The electrode is cut into a rectangle having a length of 100 mm and a width of 10 mm so that the coating direction of the electrode composition is the long side to obtain a test piece, and the cell composition tape (to JIS Z1522) is applied to the surface of the electrode composition layer with the electrode composition layer side down. The stress is measured when one end of the current collector is pulled in the vertical direction and pulled at a pulling speed of 50 mm / min. The measurement is performed three times, the average value is obtained, and this is taken as the peel strength. It shows that the adhesive strength of the electrode composition layer to the current collector increases as the peel strength increases.

(Contact angle of substrate surface with water)
2 μl of pure water is dropped on the substrate surface, the static contact angle is measured, and the contact angle with water on the substrate surface is calculated by the θ / 2 method.

(Measurement of aperture ratio)
The current collector is observed on a plane, and the area of the through hole per unit area is calculated to calculate the aperture ratio.

(Measurement of electrode active material layer thickness)
The thickness of the electrode active material layer is determined by forming an electrode active material layer on both sides of the current collector, and then using an eddy current displacement sensor (sensor head part EX-110V, amplifier unit part EX-V02: manufactured by Keyence Corporation). taking measurement. The thickness of each electrode active material layer is measured at intervals of 2 cm, and the average value thereof is taken as the thickness of the electrode active material layer.

(Electric characteristics of hybrid capacitor)
Charging is started at a constant current of 110 mA. When the charging voltage reaches 3.8 V, the voltage is maintained and constant voltage charging is performed, and charging is completed when constant voltage charging is performed for 20 minutes. Next, immediately after the end of charging, discharging is performed at a constant current of 110 mA until 2.1V is reached. This charge / discharge operation is performed for 3 cycles, and the capacity per volume and volume resistivity are obtained from the discharge curve of the third cycle.

<Example 1>
(Method for producing conductive adhesive slurry)
As carbon particles, 90 parts of graphite (KS-6; manufactured by Timcal) having a volume average particle diameter of 3.7 μm and an electric resistivity of 0.004 Ω · cm, a volume average particle diameter of 0.3 μm, and an electric resistivity of 0.06 Ω -10 parts of carbon black (Super-P; manufactured by Timcal Corporation), 4 parts of a 4.0% aqueous solution of carboxymethylcellulose (DN-10L; manufactured by Daicel Chemical Industries) as a dispersant, 4 parts as a solid content, as a binder A slurry composition for forming a conductive adhesive layer is prepared by mixing 8 parts of a 40% aqueous dispersion of a diene polymer with a solid content equivalent and 8 parts of ion-exchanged water so that the total solid content concentration is 30%. .

  The diene polymer is obtained by emulsion polymerization of 46.5 parts of styrene, 50 parts of butadiene, 3 parts of methacrylic acid, and 0.5 part of acrylic acid, Tg is −20 ° C., and the number average particle diameter is 0. A 25 μm copolymer is used.

  In addition, in FIG. 3, the volume average particle diameter distribution of the carbon particle used for the conductive adhesive slurry is shown.

(Method for producing current collector with conductive adhesive)
The conductive adhesive slurry obtained above was applied to both sides of an aluminum punching metal (made by Fukuda Metal Foil Powder Industry Co., Ltd.) with a thickness of 30 μm (opening ratio 50%) at a speed of 4 m / min using a die coater. Then, it is dried in a drying furnace to obtain an aluminum current collector for a positive electrode having a conductive adhesive layer having a thickness of 4 μm, which is wound up.

  Further, instead of aluminum punching metal, a copper punching metal (made by Fukuda Metal Foil Powder Co., Ltd.) having a thickness of 20 μm (opening ratio 50%) was used, and a conductive adhesive layer having a thickness of 4 μm was used in the same manner as above. A negative electrode copper current collector is obtained and wound up.

(Method for producing positive electrode slurry)
Carboxymethylcellulose ammonium salt having a degree of etherification of 0.6 and a 1% aqueous solution having a viscosity of 30 mPa · s is dissolved in 213.2 parts of ion-exchanged water, and a volume average particle diameter of 0. 50 parts of 035 μm acetylene black (Denka black powder: manufactured by Denki Kagaku Kogyo Co., Ltd.) is added and mixed and dispersed using a planetary mixer to obtain a conductive agent dispersion having a solid content concentration of 20%.

26 parts of the resulting conductive agent dispersion, 100 parts of activated carbon powder having an average particle size of 5 μm and a specific surface area of 2,000 m ² / g as the electrode active material, and an aqueous dispersion 7.5 having an acrylate polymer solid concentration of 40% 7.5 A suitable amount of water is added to 1 part of carboxymethylcellulose ammonium salt having a etherification degree of 0.6 and a 1% aqueous solution having a viscosity of 900 mPa · s, and the mixture is dispersed by using a planetary mixer. A positive electrode slurry falling between ˜20,000 mPa · s is obtained. The acrylate polymer is obtained by emulsion polymerization of 76 parts of 2-ethylhexyl acrylate, 20 parts of acrylonitrile and 4 parts of itaconic acid, and has a glass transition temperature (Tg) of −20 ° C. and a number average particle size of 0. A 15 μm copolymer is used.

(Production method of positive electrode)
Using a 38 μm thick polyethylene film (produced by Lintec Co., Ltd., contact angle with water on the substrate surface: 97 °) having a release treatment applied to the substrate using an alkyd resin, the slurry for positive electrode described above was used using a die coater. Coating at a speed of 10 m / min, and then drying in a drying furnace to obtain a substrate having an electrode active material layer having a thickness of 16 μm, which is wound up. Using the laminator (temperature: 100 ° C., linear pressure 300 kN / m), the wound base material with electrode active material layer is formed on both surfaces of the positive electrode aluminum collector with the conductive adhesive layer at a speed of 10 m / min. Finally, the base material is peeled off from the electrode active material layer to produce a double-sided electrode having an electrode active material layer of 44 μm on one side. The peel strength of the electrode active material layer from the current collector is 10 N / m.

(Production method of slurry for negative electrode)
100 parts of graphite (KS-4, manufactured by Timcal) having a volume average particle diameter of 2.7 μm, 4 parts of an aqueous dispersion having a solid content concentration of 40% of a diene polymer, and a 1% aqueous solution with a degree of etherification of 0.6 An appropriate amount of water is added to 1 part of carboxymethylcellulose ammonium salt having a viscosity of 900 mPa · s, and mixed and dispersed using a planetary mixer, and the slurry for negative electrode enters a viscosity between 5,000 and 20,000 mPa · s. Get. The diene polymer is obtained by emulsion polymerization of 46.5 parts of styrene, 50 parts of butadiene, 3 parts of methacrylic acid, and 0.5 part of acrylic acid, Tg is −20 ° C., and the number average particle diameter is 0. A 25 μm copolymer is used.

(Method for producing negative electrode)
Using a 38 μm-thick polyethylene film (produced by Lintec Corporation, contact angle with water on the surface of the substrate: 97 °) having a release treatment applied to the substrate with an alkyd resin, the above slurry for negative electrode using a die coater The substrate is coated at a speed of 12 m / min, and then dried in a drying furnace to obtain a substrate having an electrode active material layer having a thickness of 16 μm, which is wound up. The wound base material with electrode active material layer is bonded to both sides of the negative electrode copper current collector with conductive adhesive layer at a speed of 12 m / min using a laminator (temperature: 100 ° C., linear pressure 300 kN / m). Finally, the base material is peeled from the electrode active material layer to produce a double-sided electrode having an electrode active material layer of 25 μm on one side. The peel strength of the electrode active material layer from the current collector is 12 N / m.

(Preparation of measurement cell)
The double-sided electrode (positive electrode, negative electrode) produced above has an uncoated part where the electrode active material layer is not formed left 2 cm × 2 cm wide, and the part where the electrode active material layer is formed is 5 cm long Cut out to be 5 cm wide (the uncoated part is formed so as to extend one side of a 5 cm × 5 cm square on which the electrode active material layer is formed). 10 sets of positive electrodes and 11 sets of negative electrodes cut out in this way are prepared, and the uncoated portions are ultrasonically welded respectively. Further, a measurement electrode is produced by ultrasonically welding a tab material having a length of 7 cm, a width of 1 cm, and a thickness of 0.01 cm made of aluminum for the positive electrode and nickel for the negative electrode to the uncoated portions where the layers are welded to each other. The measurement electrode was vacuum-dried at 200 ° C. for 24 hours. Using a cellulose / rayon mixed non-woven fabric with a thickness of 35 μm as a separator, the terminal welds of the positive electrode current collector and the negative electrode current collector are arranged on opposite sides, and the positive electrode and the negative electrode are alternated and laminated. All the laminated electrodes are laminated so that the outermost electrode becomes a negative electrode. A separator is arranged on the uppermost part and the lowermost part, and four sides are taped.

  As a lithium electrode, a lithium metal foil (thickness 51 μm, length 5 cm × width 5 cm) bonded to an 80 μm-thick stainless steel mesh was used, and the lithium electrode was laminated so as to completely face the outermost negative electrode One sheet is placed at the top and one at the bottom. The terminal welding part (two sheets) of the lithium electrode current collector is resistance-welded to the negative electrode terminal welding part.

Laminate with the lithium foil placed at the top and bottom is placed inside the deep-drawn lower exterior film, covered with the exterior laminate film and fused on the three sides, and then ethylene carbonate, diethyl carbonate and propylene carbonate are used as the electrolyte. A solution obtained by dissolving LiPF ₆ at a concentration of 1 mol / liter is vacuum impregnated in a mixed solvent having a weight ratio of 3: 4: 1, and then the remaining one side is fused to produce a film type capacitor.

(Characteristic evaluation of cells)
When the cell was disassembled after being allowed to stand at room temperature for 16 days, lithium metal was completely lost. Therefore, it was determined that lithium was precharged to all the negative electrodes by moving between the front and back surfaces of the positive electrode and the negative electrode. As a result of the electrical characteristics, the cell capacity is 16 mAh / cc.

<Comparative Example 1>
In Example 1, the same operation is performed except that a perforated current collector not having a conductive adhesive layer is used to obtain a current collector having an electrode active material layer. The peel strength of the electrode active material layer from the current collector is 8 N / m. The cell capacity is 15.5 mAh / cc.

It is a schematic chart figure which shows 1 process of the manufacturing method which concerns on this invention. It is a schematic chart figure which shows 1 process of the manufacturing method which concerns on this invention. The volume average particle diameter distribution of the carbon particle used for the conductive adhesive slurry is shown.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Base material 2 ... Current collector 3 ... Coating machine 4 ... Dryer 10, 12, 14 ... Unwinder 11, 13, 15 ... Winder 16 ... Laminator

Claims (13)

Forming an electrode active material layer from an electrode composition comprising an electrode active material, a conductive material and a binder on the surface of the substrate;
Bonding the formed electrode active material layer and the current collector through a conductive adhesive layer; and
The manufacturing method of the electrode for electrochemical elements which has the process of isolate | separating a base material from an electrode active material layer.   The manufacturing method according to claim 1, wherein the substrate surface is subjected to a peeling treatment.   The manufacturing method according to claim 1, wherein the base material is a base material made of a thermoplastic resin film, and one or both surfaces thereof are subjected to a peeling treatment with a thermosetting resin. The contact angle with water on the release-treated surface of the substrate is 80 to 110 °,
The manufacturing method of Claim 1 including the process of apply | coating the aqueous slurry containing the said electrode composition and water to the base-material surface by which the peeling process was carried out, and forming an electrode active material layer.   After applying a slurry of an electrode composition containing an electrode active material, a conductive material and a binder, and drying to form an electrode active material layer, the electrode active material layer and the current collector are bonded to a conductive adhesive layer. The manufacturing method in any one of Claims 1-4 bonded together.   The manufacturing method according to claim 1, wherein the conductive adhesive layer contains a resin and conductive particles.   The production method according to claim 6, wherein the resin is an acrylate polymer or a diene polymer.   The manufacturing method according to claim 6 or 7, wherein the conductive particles are carbon particles.   The production method according to claim 8, wherein the volume average particle size distribution of the carbon particles is multimodal.   The production method according to claim 8, wherein the volume average particle size distribution of the carbon particles is bimodal.   The said carbon particle contains the carbon particle (A) whose volume average particle diameter is 0.01 micrometer or more and less than 1 micrometer, and the carbon particle (B) whose volume average particle diameter is 1 micrometer or more and 10 micrometers or less. Manufacturing method.   The method according to claim 11, wherein a ratio of the carbon particles (A) to the carbon particles (B) is in a range of 0.05 to 1 in terms of a weight ratio of (A) / (B).   The manufacturing method according to claim 1, wherein the current collector is a perforated current collector.

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