JP2011181531A - Energy device and method of manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To solve problems that, in an energy device of thin type obtained by laminating a plurality of sheet type unit devices and joining in series or parallel when an adhesive is spread between joint surfaces and solidified, a gap is formed between the joint surfaces, characteristics of the device are varied, and thickness of the device increases. <P>SOLUTION: A recess is formed in an outer surface of the joined unit device. By giving the adhesive to the recess, the adhesive is prevented to flow out between both joint surfaces, and generation of the gap is prevented between both joint surfaces. Then, stability of the characteristics is achieved. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to an energy device typified by a battery or a power storage device and a manufacturing method thereof.

  In recent years, with the development of portable devices such as personal computers and mobile phones, an energy device having a high energy density and excellent storability as a power source has been demanded. In response to the above demand, secondary batteries using lithium or lithium ions have been developed. On the other hand, apart from the above-mentioned small fields, in the energy field with much larger capacity such as electric vehicles and energy storage, the features of the high capacity and high energy density of the energy device have attracted attention, leading to new fields of use of secondary batteries. Development of is being considered.

  In general, the energy device using lithium ions reversibly occludes / releases lithium ions, and reversibly occludes / releases lithium ions, and a negative electrode using a simple substance or a compound having a potential close to lithium as an active material. A basic component includes a positive electrode using, as an active material, a simple substance or a compound exhibiting a higher potential than lithium, and an electrolyte layer interposed between the negative electrode and the positive electrode and using lithium ions as a charge transfer medium.

As the negative electrode active material, various types of graphite, tin, silicon or many simple substances or compounds containing these are known in addition to lithium metal, and as the positive electrode active material, sulfur, LiCoO ₂ , LiNiO ₂ , or Many simple substances and compounds such as LiMn ₂ O ₄ are known.

As for the electrolyte layer, a solution type using a fluid electrolyte solution, a polymer gel type in which the electrolyte is gelled with a polymer and non-fluidized, and a solid electrolyte layer having lithium ion conductivity have been put into practical use. Is in the process of conversion. Among them, an energy device using a solid electrolyte is expected to be a highly safe energy device because there is no risk of leakage as compared with a solution type, and is stable such as Li _x PO _y N _z called LiPO ₄ or LIPON. Many highly solid electrolytes have also been found.

  Furthermore, in an energy device using a solid electrolyte, it is not necessary to use a separator between both electrodes, and a thin film forming method such as screen printing, vapor deposition, or sputtering can be applied to form an active material layer or a solid electrolyte layer as a basic constituent element. Therefore, it can be expected to be much thinner than the polymer gel type, and a higher energy density can be expected as the thickness becomes thinner.

  However, since the solid electrolyte does not penetrate into the active material layer like the solution electrolyte, there is a limit to the increase in capacity even if the active material layer is increased in order to increase the capacity. It is difficult to improve the capacity density even if the active material layer is sterically operated such as mixing a solid electrolyte material in the active material layer.

  Therefore, as a means for solving the problem of energy capacity, a thin sheet-like unit device having a positive electrode active material layer, a solid electrolyte layer, and a negative electrode active material layer as a sheet-like device is prepared, and a plurality of these unit devices are joined to form a voltage. Alternatively, it was considered preferable to increase the capacity and manufacture a device having a large energy capacity.

In addition, some conventional techniques for manufacturing a thin and high-capacity device by joining thin components are disclosed. That is, in an electrochemical device using an organic electrolyte solution containing lithium ions, a technique for joining an active material layer and a separator made of a polymer porous film is disclosed (for example, see Patent Document 1 or 2).

  Patent Document 1 discloses a technique in which an adhesive made of polymer resin powder is disposed between an active material layer and a separator layer and bonded to each other, and a layer having no electronic conductivity is formed on the bonding surface. At the same time, it is shown that an electrolyte solution penetrates into this layer to form an ion conductive layer. Patent Document 2 discloses that a positive and negative electrode active material layer is temporarily bonded to a separator made of a polymer porous film containing an electrolytic solution with an adhesive in advance, and then both electrodes are pressure-bonded with the polymer porous film interposed therebetween. Techniques to do this are disclosed.

JP 2001-6744 A JP 2002-184468 A

  When stacking and bonding sheet-like unit devices between bonding surfaces to form energy devices, it is important that the electron conductivity be maintained as uniformly as possible between the bonding surfaces as wide as possible. It is. Furthermore, even when the surface of each sheet-like unit device has electronic conductivity, a gap is formed between the bonding surfaces by an adhesive made of a resin that develops and cures between the bonding surfaces. Cheap. In this case, not only the thickness of the composite device is increased and the storage property is deteriorated, but also the internal resistance of the device varies depending on the contact state between the bonding surfaces in the gap portion, resulting in variation in characteristics. Such variations in characteristics and storage problems occur even if the adhesive has electrical conductivity. That is, for joining sheet-like unit devices using a solid electrolyte, it is important to suppress the generation of non-uniform voids by the adhesive applied to the joining, and to make close contact between the surfaces where the electronic conductivity is maintained as much as possible.

  However, none of the configurations described in Patent Documents 1 and 2 suggests bonding that maintains electronic conductivity between solid bonding surfaces or suppression of voids by an adhesive applied between the surfaces.

  The present invention realizes bonding between surfaces in which uniform electronic conductivity is maintained by suppressing the generation of voids between bonding surfaces when stacking and bonding sheet-like unit devices to produce a high energy device. The purpose is to stabilize the characteristics of the energy device.

  In order to solve the above-described problems, an energy device of the present invention includes a second active material having a polarity opposite to the first active material layer having the first polarity, the electrolyte layer, and the first active material layer. An energy device in which a plurality of sheet-like unit devices laminated with a material layer are joined, and adjacent unit devices are joined with an adhesive applied to a recess provided on the outer surface of at least one unit device. It is characterized by having a configuration. With this configuration, strong bonding is possible with the concave portions provided at predetermined positions while maintaining sufficient electronic conductivity between the bonding surfaces.

  Adhesive is applied to the concave portion provided at a predetermined position on the bonding surface of the sheet-like unit device, so that even if the unit devices are pressed against each other, a large amount of adhesive is spread between the bonding planes. There is no. Therefore, strong bonding is possible with the concave portion provided at a predetermined position while the electron conductivity between the bonding surfaces is sufficiently maintained. In addition to avoiding the generation of uneven bonding force due to the adhesive at the bonding surface, electrical bonding between the bonding surfaces is caused by voids formed when a large amount of adhesive is spread and cured between the bonding planes. Inhibition of bonding and expansion of the energy device thickness caused by the formation of the space are suppressed. In addition, as long as the effect of the present invention can be maintained, the adhesive does not need to remain in the concave portion after joining, and may be developed to the vicinity of the concave portion.

  Here, the adhesive preferably has electronic conductivity. This is because it is possible to further ensure the electronic conductivity between the joint surfaces. In order to connect each unit device or to make a terminal to be connected to the outside, it is preferable to arrange at least a conductor portion disposed between the surfaces or bonding surfaces of adjacent unit devices. The conductor portion is preferably made of any one of a tab, a conductive thin film, and a current collector. The electrolyte layer may be in the form of a gel or a solid. However, in the case of a solid, the entire unit device is formed hard, so that the above bonding effect becomes remarkable.

  In order to realize the above-described configuration, the energy device manufacturing method according to the present invention forms a recess on the surface of a sheet-like unit device including a first active material layer, an electrolyte layer, and a second active material layer. A unit device forming step, an adhesive applying step of applying an adhesive to the concave portion, a stacking step of stacking the unit devices to which the adhesive is applied, and a bonding step of bonding the stacked unit devices.

  Furthermore, the current collector may be a continuous body, and a plurality of unit devices may be formed with a predetermined interval, and if necessary, the step of cutting the exposed portion of the current collector other than the unit device may be included. good.

  According to the present invention, when a high energy device is manufactured by laminating and bonding sheet-like unit devices, the generation of voids between bonded surfaces is suppressed, and bonding between surfaces in which uniform electron conductivity is maintained is achieved. Realization and stabilization of the characteristics of the combined energy device can be achieved.

Schematic cross-sectional view of the energy device according to Embodiment 1 of the present invention Schematic sectional view of the energy device according to the second embodiment of the present invention Schematic sectional view of an energy device according to Embodiment 3 of the present invention Schematic sectional view of an energy device according to Embodiment 4 of the present invention Schematic cross-sectional view of an energy device according to Embodiment 5 of the present invention Schematic sectional view of the energy device according to the sixth embodiment of the present invention Schematic sectional view of the energy device according to the seventh embodiment of the present invention Schematic explaining the method to form a recessed part in the unit device in Embodiment 1 of this invention

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. In addition, the same code | symbol is attached | subjected and demonstrated to what has the same structure. The present invention is not limited to the following contents as long as it is based on the basic features described in this specification.

(Embodiment 1)
FIG. 1 is a schematic cross-sectional view for explaining the configuration of an energy device according to Embodiment 1 of the present invention. In FIG. 1, a first active material layer 1 that is a positive electrode layer and a second active material layer 3 that is a negative electrode layer and has a polarity opposite to that of the first active material layer are opposed to each other with an electrolyte layer 5 interposed therebetween. Yes. In the unit device 21 in which the first active material layer 1, the second active material layer 3, and the electrolyte layer 5 are laminated, the sheet-like current collector 2 is joined to the first active material layer 1, and the sheet-like conductive thin film 6 is joined to the second active material layer 3. In the unit device 22 in which the first active material layer 1, the second active material layer 3, and the electrolyte layer 5 are laminated, the sheet-like current collector 4 is joined to the second active material layer 3, and the sheet-like electrical conduction is performed. The conductive thin film 6 is bonded to the first active material layer 1. The adhesive 8 is accommodated in a recess 7 provided in a surface layer where the unit device 21 and the unit device 22 face each other. The amount of the adhesive 8 may be an amount that is sufficient for exhibiting the bonding force when the unit device 21 and the unit device 22 are bonded, and is an amount that does not overflow from the concave portion 7 at the same time. The tabs 9A and 9B are joined to the current collectors 2 and 4, respectively, and are electrically connected to the outside. The current collector plate 10 is provided between layers showing different polarities. The current collectors 2 and 4 are provided on the outermost part of the energy device. The first active material layer 1 may be a negative electrode layer, and the second active material layer may be a positive electrode layer.

  FIG. 1 shows a state immediately before an energy device is formed by joining two unit devices, which are a unit device 21 and a unit device 22, in series. In this configuration, it is only necessary that at least one of the conductive thin film 6 and the current collector plate 10 is disposed on the bonding surface between the unit devices 21 and 22. These are conductor portions between unit devices.

  A concave portion 7 is formed on at least one joint surface of the unit devices 21 and 22, and an adhesive 8 is applied to the inside of the concave portion 7, and the unit devices 21 and 22 are bonded to each other with the adhesive 8. . Since the adhesive 8 is applied to the concave portion 7 provided on the bonding surface of the unit devices 21 and 22, even if the unit devices 21 and 22 are pressed together, the adhesive 8 is developed in a large amount between the bonding planes. Never happen. Therefore, strong bonding is possible because of the recesses 7 while maintaining sufficient electronic conductivity between the bonding surfaces. Furthermore, not only can the generation of uneven bonding force due to the adhesive 8 be avoided at the bonding surface, but also the electrical space between the bonding surfaces due to voids formed when the adhesive 8 is spread and cured between the surfaces. It is possible to suppress the increase in the thickness of the energy device due to the inhibition of the mechanical joining and the formation of the space.

  When the conductive thin film 6 formed on the bonding surface of the unit device is thin, the recess 7 is formed so as to extend to the internal active material layer 1 or 3 as shown in FIG. 1 or FIGS. It is preferable. (Explanation of the amount of adhesive has been added elsewhere) Further, as shown in FIG. 1, the positions of the recesses 7 provided in the unit device 21 and the recesses 7 provided in the unit device 22 correspond to each other. More preferably. That is, when providing the recessed part 7 in both the surfaces to join, it is preferable that the recessed parts 7 exist in the position which respond | corresponds. When the recesses 7 are in corresponding positions, when the unit device 21 and the unit device 22 are joined, the adhesive 8 in the recess 7 of the unit device 21 and the adhesive 8 in the recess 7 of the unit device 22 Since the volume of the recess can be doubled by facing the recess compared to the case where it is not so, the elastic effect of the adhesive is more greatly manifested when the displacement due to the external force occurs. Deviation is unlikely to occur.

  The unit devices 21 and 22 can be joined by simply laminating the unit devices 21 and 22 to which the adhesive 8 is applied to the recess 7 according to the configuration shown in FIG. In the configuration in which the recesses 7 are provided in the unit devices 21 and 22, the adhesive 8 is held inside the recesses 7, and the phenomenon in which the adhesive 8 is spread unevenly between the joint surfaces and is cured is suppressed, and between the joint surfaces. The formation of voids is suppressed. In order to enhance the bonding force and improve the adhesion between the surfaces allowing the electron conductivity, it is preferable to add a bonding step of pressing the unit device laminate with a flat plate mold or a roller.

  The installation location and shape of the recess 7 are arbitrary, but are preferably selected in consideration of the variation state of energy devices caused by the bonding strength and the electronic conductivity state between the bonding surfaces. The cross-sectional shape of the recess 7 can be selected from an independent circular, elliptical, triangular, polygonal, straight, curved, wavy, zigzag groove or any combination of these at a predetermined position on the joint surface. it can. From the viewpoint of bonding force, the cross-sectional shape inside the recess 7 is preferably U-shaped, and it is preferable to provide the hemispherical recesses 7 at the corresponding positions on both sides where they are bonded facing each other. In this configuration, since the surfaces are joined with the spherically cured adhesive, a large joining force can be formed with a small amount of adhesive applied.

  As described above, in the present embodiment, a highly adhesive bond in which electronic conductivity is ensured is formed. Therefore, the adhesive 8 applied to the recess 7 is not methacrylic unless it affects the function of the energy device. A solvent-based adhesive in which a resin such as a resin is dissolved, or an adhesive such as a thermosetting resin such as an epoxy resin can be applied. Since the evaporation path of the solvent is limited after the unit devices 21 and 22 are joined, a thermosetting resin is particularly preferable. For the adhesive 8, it is more preferable to use an adhesive having electron conductivity such as silver paste or carbon paste from the viewpoint of electron conductivity.

Next, the conductor structure near the joint surface of each unit device will be described. A conductive thin film 6 is provided on the surface of the unit devices 21 and 22, and a current collecting plate 10 is provided between the bonding surfaces. When the active material layer on the bonding surface side of the unit device is poor in conductivity, it is preferable to provide the conductive thin film 6 and the current collector plate 10, but it is not essential. Further, only one of them may be provided. Current collector 2,
4, the tabs 9A and 9B are provided, but the current collectors 2 and 4 may not be provided, and the tabs 9A and 9B may be provided directly on the active material layers 1 and 3.

  That is, it is preferable to provide a conductor portion composed of any of the tabs 9A, 9B, the conductive thin film 6, and the current collectors 2, 4 between the surface layers or bonding surfaces of at least the adjacent unit devices 21, 22. In addition, when the energy device finally formed is accommodated in a conductive container, a configuration in which the container serves as the current collectors 2 and 4 at both ends is preferable.

  Although FIG. 1 shows the configuration of an energy device including two unit devices, even in the case of an energy device including three or more unit devices, two adjacent unit devices have the configuration shown in FIG. Thus, the above effect can be obtained. In that case, the first active material layer 1 may be a negative electrode layer, and the second active material layer may be a positive electrode layer.

  Next, a method for manufacturing an energy device having the configuration according to the first embodiment will be described. First, the first active material layer 1, the electrolyte layer 5, the second active material layer 3, and the conductive thin film 6 are sequentially formed on one surface of the current collector 2 (unit device forming step). At that time, the recesses 7 are formed in the conductive thin film 6 and the second active material layer 3 that become the bonding surfaces. In this way, the unit device 21 is formed. On the other hand, on the one surface of the current collector 4, each layer is formed in the order of the second active material layer 3, the electrolyte layer 5, the first active material layer 1, and the conductive thin film 6 in the reverse order. Form. Although not shown, each device is formed by forming each layer in the order of the second active material layer 3, the electrolyte layer 5, the first active material layer 1, and the current collector 2 on the current collector 10 provided with the recess 7. May be produced.

When the first active material layer 1 is a positive electrode, the active material is generally reversible higher than lithium by inserting and extracting lithium ions such as sulfur (S), TiS ₂ , LiCO ₂ , LiNiO ₂ and LiMn ₂ O _4. A simple substance or a complex oxide known to exhibit a potential can be used. Further, when the second active material layer 3 is a negative electrode, the active material layer material occludes lithium ions such as various types of graphite, simple substances such as silicon (Si) and tin (Sn), and alloys containing these in addition to lithium metal. Many simple substances and compounds that are known to release and exhibit a reversible potential close to that of lithium metal are applicable.

  For the electrolyte layer 5, many solid electrolytes known to exhibit ionic conductivity such as LiPO 4 and LixPOyNz in which a part of oxygen is replaced with nitrogen can be applied. Moreover, even if it is a gel-like electrolyte in which a porous membrane resin such as polyolefin is impregnated with an electrolyte solution of a lithium salt containing a monomer or polymer and immobilized, the electrolyte solution is gelled and thinned. Good. Polyacrylonitrile-based, polyvinylidene fluoride-based, polymethyl methacrylate-based, and other polymer gel electrolytes can also be used. Use a copolymer matrix that combines vinylidene fluoride, hexafluoropropylene, chlorotrifluoroethylene, tetrafluoroethylene, hexafluoropropylene, perfluoroalkyl vinyl ether, fluoroolefin, vinylene carbonate, hexafluoroacetone and other polymerized units. You can also. Further, it may be an intrinsic polymer electrolyte comprising a polyether compound obtained by adding ethylene oxide or propylene oxide to a polyamine compound, an ion-exchangeable layered compound and an ionic substance, or other constitution. The effects of the present invention are not limited to the above materials, and therefore the gel polymer and intrinsic polymer that can be used in the present invention are not limited to the above. In addition, when using a solid electrolyte for the electrolyte layer 5, since the unit devices 21 and 23 whole are hard, the effect by joining of this structure becomes remarkable.

As a method of forming the active material layers 1 and 3 on the current collectors 2 and 4, the active material alone or a compound, a conductive agent such as carbon black added as necessary, vinylidene fluoride, PTEF, or the like Using a slurry prepared using a binder, a mixed material containing a solid electrolyte, and a solvent such as n-methylpyrrolidone, a thin film can be formed using a coating technique such as screen printing or offset printing. The active material layers 1 and 3 may be formed on the current collectors 2 and 4 by a dry thin film forming technique such as vapor deposition and sputtering using the above active material as a target.

  In the case of forming the electrolyte layer 5 containing the solid electrolyte, the slurry prepared using the binder and the solvent is applied to the thin film by using a coating technique such as screen printing or offset printing, as in the case of forming the active material layer. Can be formed. The electrolyte layer 5 can also be formed by applying a dry thin film forming method such as vapor deposition or sputtering using a solid electrolyte raw material as a target. Among these, the dry film forming method is capable of forming a dense and thin layer and is preferable for forming the unit device in the present embodiment. The method of forming each layer is arbitrarily selected and combined depending on the material and the required layer thickness.

  An aluminum foil, plate, or sheet can be applied to the current collector 2 that contacts the first active material layer 1 that is the positive electrode. Moreover, copper foil, a board | plate, and a sheet | seat are suitable for the electrical power collector 4 which contacts the 2nd active material layer 3 which is a negative electrode.

  Next, a method for forming the recess 7 will be described. In order to form the concave portion 7, a method of applying pressure with a flat plate-shaped or roller-shaped mold having a convex portion at a predetermined position of the laminate formed as described above can be applied. Or the method of forming the recessed part 7 by laser irradiation is applicable.

  Further, as a method for forming the concave portion 7, there is a method in which masking is partially performed at the time of forming the surface layer (conductive thin film 6 and active material layers 1 and 3) of the unit device to be a bonding surface. An example of this forming method will be described with reference to FIG. FIG. 8A is a plan view showing the mask, and FIGS. 8B and 8C are perspective views for explaining the formation of the recess 7. First, the first active material layer 1, the electrolyte layer 5, and the second active material layer 3 are sequentially stacked on the current collector 2 to form a stacked body. A part of the conductive thin film 6 is formed by vapor deposition while masking the laminated body with a mask 31 (FIG. 8B). Next, a part of the conductive thin film 6 is formed by vapor deposition while masking with the mask 32 (FIG. 8C). By doing in this way, the recessed part 7 is formed in the location masked by the convex part 33 of the masks 31 and 32. FIG.

  When the concave portion 7 is formed by the pressurization method, the operation is simple. However, depending on the conditions, there is a possibility that the thin unit device is physically destroyed. Moreover, when forming the recessed part 7 by the laser method, it is suitable for forming the recessed part 7 of desired depth, but depending on conditions, there exists a possibility that the vicinity of the part irradiated with the laser may change with heat. Therefore, the method of forming the concave portion 7 by masking is more preferable among these.

  The method for forming the unit device 22 is different from the unit device 21 only in the formation order of each layer, and thus detailed description thereof is omitted.

  Next, the adhesive 8 is applied to the recesses 7 of the unit devices 21 and 22 formed as described above (adhesive application step). At this time, it is necessary to apply a predetermined amount of adhesive 8 to the recess 7 formed in a predetermined place. For example, a jig having projections patterned in the same manner as the positions of the recesses 7 is brought into contact with a layer of the adhesive 8 adjusted to a predetermined thickness, and the adhesive 8 is applied to each recess 7 via the jig. It may be affixed.

  Next, the unit device 21 to which the adhesive 8 is applied and the unit device 22 are laminated (lamination process). When the concave portions 7 are provided at the corresponding positions on both the joining surfaces, it is necessary to align the positions so that the respective concave portions 7 do not shift. Therefore, it is preferable to apply a known positioning mechanism.

  Finally, the unit device 21 and the unit device 22 are bonded (joining process). Basically, the joining is completed by laminating the unit devices 21 and 22 to which the adhesive 8 is applied. However, if the laminate is pressed with a flat plate or a smooth roller, the bonding force is further increased and the reliability of bonding having electronic conductivity between the bonding surfaces is increased.

  In the step of forming the unit devices 21 and 22, a plurality of unit devices 21 and 22 are formed at a predetermined interval using the current collectors 2 and 4 as a base as a continuum, and thereafter, the unit devices 21 and 22 You may cut | disconnect the electrical power collectors 2 and 4 in which 22 is not formed. By using such a continuous current collector, productivity is improved. For the step of forming the recess 7, the step of applying the adhesive, and the laminating step, a method of performing a method on a unit plate surface separated for each unit device and a method of performing a plurality of continuous unit devices can be applied. is there. Since these have advantages and disadvantages, they are preferably selected in consideration of the complexity and continuity of the apparatus.

(Embodiment 2)
FIG. 2 is a schematic cross-sectional view for explaining the configuration of the energy device according to the second embodiment of the present invention. FIG. 2 shows a state immediately before the energy device is configured by joining the unit device 22 and the unit device 22 in parallel.

  The configuration shown in FIG. 2 is different from the configuration described with reference to FIG. 1 in that the first active material layers 1 are bonded to each other at the bonding surface using the unit device 22 instead of the unit device 21. A tab 9A is joined to the current collector 11 arranged between the joining surfaces. By connecting the tabs 9B, the two unit devices 22 are connected in parallel. Other than this, the configuration is the same as that of FIG.

  A concave portion 7 is formed on at least one joint surface between the unit devices 22, and an adhesive 8 is applied to the inside of the concave portion 7, and the unit devices 22 are bonded with the adhesive 8. Therefore, even with this configuration, the same effect as in the first embodiment can be obtained. In FIG. 2, the positions of the recesses 7 do not correspond to each other on the opposing joint surfaces, but it is preferable to form the recesses 7 at the corresponding positions as in FIG. 1.

  In this configuration, the unit devices 22 are connected in parallel. When unit devices are connected in series as shown in FIG. 1, it is not necessary to provide a tab on the joint surface. On the other hand, when the unit devices 22 are connected in parallel as shown in FIG. 2, at least one of the conductive thin film 6 and the current collector 11 is disposed between the bonding surfaces, and the bonding surface has electron conductivity. It is preferable to join the tab 9A to form a predetermined circuit. That is, in the case where the unit devices 22 having the same configuration are joined to form a parallel connection configuration, the tab 9A needs to be provided at least between the joining surfaces. Although the current collector 2 is provided with the tab 9B, the current collector 2 may not be provided, and the active material layer 3 may be directly provided with the tab 9B. With these configurations, a large-capacity energy device in which the first active material layers 1 and the second active material layers 3 are connected and the unit devices are connected in parallel is obtained.

  That is, it is preferable to provide a conductor portion composed of any of the tabs 9A, 9B, the conductive thin film 6 and the current collector 2 between at least the surface layers or the bonding surfaces of the adjacent unit devices 22. In addition, when the energy device finally formed is accommodated in a conductive container, a configuration in which the container serves as the current collectors 2 at both ends is preferable.

  In the step of forming the unit device 22, the current collector 4 as a base is formed as a continuous body, a plurality of unit devices 22 are formed at a predetermined interval, and then the current collector in which the unit devices 22 are not formed. The body 4 may be cut. By using such a continuous current collector, productivity is improved.

  Since the manufacturing method of the energy device in the second embodiment is the same as the method described in the first embodiment, the description thereof is omitted.

(Embodiment 3)
FIG. 3 is a schematic cross-sectional view for explaining the configuration of the energy device according to the third embodiment of the present invention. FIG. 3 shows a state immediately before the unit device 23 and the unit device 23 are joined in series to form an energy device.

  The configuration shown in FIG. 3 is different from the configuration described with reference to FIG. 1 in that unit devices 23 are used instead of the unit devices 21 and 22. In the unit device 23, the second active material layer 3, the electrolyte layer 5, the second active material layer 3, and the conductive thin film 6 are provided in this order on the first surface of the current collector 13. On the surface, a first active material layer 1, an electrolyte layer 5, a second active material layer 3, and a conductive thin film 6 are provided in this order. That is, the unit device 23 itself has a structure in which two battery unit cells are connected in series. And the recessed part 7 is provided in the surface where unit devices 23 join. The terminal board (current collector) 12 is provided on the outermost part of the energy device. In FIG. 3, the positions of the recesses 7 do not correspond to each other on the opposing joint surfaces, but it is preferable to form the recesses 7 at the corresponding positions as in FIG. 1.

  Each surface of the current collector 13 is provided in contact with the first active material layer 1 and the second active material layer 3. Therefore, it is preferable to perform surface treatment with copper, aluminum, gold, carbon, or the like in advance in accordance with the type of active material layer in contact with the surface of the current collector 13. This prevents the surface of the current collector 13 from being corroded or inactivated.

  A recess 7 is formed on at least one joint surface between the unit devices 23, and an adhesive 8 is applied to the inside of the recess 7, and the unit devices 23 are bonded to each other with the adhesive 8. Therefore, even with this configuration, the same effect as in the first embodiment can be obtained.

  Also in this configuration, at least one of the conductive thin film 6 and the current collector plate 10 is disposed on the joint surface between the unit devices 23. These are conductor portions between unit devices. A predetermined electrical connection is formed by using an end surface layer of the unit device 23 or a conductor portion between the unit devices 23.

  Moreover, it is preferable that at least one of the conductive thin film 6 and the current collector 12 is applied to both ends (surface layer which is the outermost surface) of the plurality of unit devices to be stacked. The tabs 9A and 9B may be arranged directly on the conductive thin film 6 and the active material layer that are both ends of the plurality of unit devices. That is, it is preferable to provide a conductor portion composed of any of the tabs 9A and 9B, the conductive thin film 6, and the current collectors 10 and 12 between the surface layers or bonding surfaces of the plurality of adjacent unit devices 23. In addition, when the energy device finally formed is accommodated in a conductive container, a configuration in which the container serves as the current collectors 12 at both ends is preferable.

  Hereinafter, a manufacturing method of the configuration according to the third embodiment will be described. First, the first active material layer 1, the electrolyte layer 5, the second active material layer 3, and the conductive thin film 6 are sequentially formed on one surface (first surface) of the sheet-like current collector 13. Then, the second active material layer 3, the electrolyte layer 5, the first active material layer 1, and the conductive thin film 6 are sequentially formed on the second surface facing the first surface (unit device forming step). And the recessed part 7 is formed in the electroconductive thin film 6 and the active material layers 1 and 3 used as a joint surface. In this way, the unit device 23 is formed. Hereinafter, the energy device is manufactured by the same process as described in the first embodiment by combining the unit device 23 in which the recess 7 is formed on the active material layer 1 side and the unit device 23 in which the recess 7 is formed on the active material layer 3 side. Form.

  In the step of forming the unit device 23, the base current collector 13 is a continuous body, a plurality of unit devices 23 are formed at a predetermined interval, and thereafter, the current collector on which the unit devices 23 are not formed. The body 13 may be cut. By using such a continuous current collector, productivity is improved.

(Embodiment 4)
FIG. 4 is a schematic cross-sectional view for explaining the configuration of the energy device according to the fourth embodiment of the present invention. FIG. 4 shows a state immediately before a device is formed by joining unit devices 24 and unit devices 24 in parallel.

  The configuration shown in FIG. 4 is different from the configuration described with reference to FIG. 2 in that a unit device 24 is used instead of the unit device 22. The unit device 24 has a configuration in which the second active material layer 2, the electrolyte layer 5, the first active material layer 1, and the conductive thin film 6 are provided on any surface of the current collector 14 in this order. The current collector 14 is provided such that both surfaces thereof are in contact with the active material layer 3 having the same polarity. The tab 9A is joined to the current collectors 11 and 12, and the tab 9B is joined to the current collector 14, and is electrically connected to the outside. Further, the tab unit 9A and the tabs 9B are connected to each other so that the four unit battery cells are connected in parallel.

  A recess 7 is formed on at least one joint surface between the unit devices 24, and an adhesive 8 is applied to the inside of the recess 7, and the unit devices 24 are bonded together with the adhesive 8. Therefore, even with this configuration, the same effect as in the first embodiment can be obtained. In FIG. 4, the positions of the recesses 7 do not correspond to each other on the joint surfaces facing each other, but it is preferable to form the recesses 7 at the corresponding positions as in FIG. 1.

  A conductive thin film 6 is provided on the surface of the unit device 24, and a current collecting plate 11 is provided between the bonding surfaces. That is, at least one of the conductive thin film 6, the current collector plate 11, or the tab 9 </ b> A is disposed on the joint surface between the unit devices 24. These are conductor portions between the unit devices 24. A predetermined electrical connection is formed by using an end surface layer of the unit device 24 or a conductor portion between the unit devices 24.

  As in the second embodiment, when the unit devices 24 are connected in parallel as shown in FIG. 4, at least one of the conductive thin film 6 or the current collector 11 is disposed between the bonding surfaces, and the electrons on the bonding surfaces are arranged. It is preferable that the tab 9A is joined to a portion having conductivity to form a predetermined circuit. That is, when joining the unit devices 24 of the same configuration to form a parallel connection configuration, it is necessary to provide the tab 9A at least between the joining surfaces. And it is necessary to arrange | position the tab 9A also to the electrical power collector 14 which both surfaces are contacting the active material layer 3 of the same polarity. In addition, it is preferable that at least one of the conductive thin film 6 and the current collector 12 is applied to both ends (surface layer serving as the outermost surface) of the plurality of unit devices 24 to be stacked. The tabs 9A and 9B may be arranged directly on both ends of the plurality of unit devices 24, between the bonding surfaces, the current collector 14 serving as the basis of the unit devices, or the conductive portion between the bonding surfaces. With these configurations, a large-capacity energy device in which the first active material layers 1 and the second active material layers 3 are connected and the unit devices are connected in parallel is obtained.

  That is, it is preferable to provide a conductor portion including any of the tab 9A, the conductive thin film 6, and the current collectors 11 and 14 between at least the surface layers or bonding surfaces of the plurality of adjacent unit devices 24. In addition, when the energy device finally formed is accommodated in a conductive container, a configuration in which the container serves as the current collectors 12 at both ends is preferable.

The manufacturing method having the configuration in the fourth embodiment is that the second active material layer 3, the electrolyte layer 5, the first active material layer 1, and the conductive thin film 6 are sequentially formed on both surfaces of the current collector 14 in the same order. Since this is the same as that of the third embodiment, the description thereof is omitted.

  In the step of forming the unit device 24, a plurality of unit devices 24 are formed at a predetermined interval with the current collector 14 serving as a base being a continuous body, and then the current collector on which the unit devices 24 are not formed. The body 14 may be cut. By using such a continuous current collector, productivity is improved.

(Embodiment 5)
FIG. 5 is a schematic cross-sectional view for explaining the configuration of the energy device according to the fifth embodiment of the present invention. FIG. 5 shows a state immediately before the unit device 24 is joined in parallel with three sheets to form an energy device. Other configurations are the same as those of the fourth embodiment.

  A recess 7 is formed on at least one joint surface between the unit devices 24, and an adhesive 8 is applied to the inside of the recess 7, and the unit devices 24 are bonded together with the adhesive 8. Therefore, even with this configuration, the same effect as in the first embodiment can be obtained. In FIG. 5, the positions of the recesses 7 do not correspond to each other on the opposing joint surfaces, but it is preferable to form the recesses 7 in the corresponding positions as in FIG. 1.

  In the step of forming the unit device 24, a plurality of unit devices 24 are formed at a predetermined interval with the current collector 14 serving as a base being a continuous body, and then the current collector on which the unit devices 24 are not formed. The body 14 may be cut. By using such a continuous current collector, productivity is improved.

(Embodiment 6)
FIG. 6 is a schematic cross-sectional view for explaining the configuration of the energy device according to the sixth embodiment of the present invention. FIG. 6 shows an energy device in which a plurality of unit devices 24 formed on a continuous current collector 14 are zigzag folded without being separated into individual unit devices 24, and adjacent unit devices 24 are joined together. It shows a state immediately before is constructed. The tab 9A is joined to the current collectors 11 and 12, and the tab 9B is joined to the current collector 14, and is electrically connected to the outside. Further, the unit battery cells are connected in parallel by connecting the tabs 9A. That is, the electrical connection form of the three unit devices 24 is the same as that of the fifth embodiment.

  A recess 7 is formed on at least one joint surface between the unit devices 24, and an adhesive 8 is applied to the inside of the recess 7, and the unit devices 24 are bonded together with the adhesive 8. Therefore, even with this configuration, the same effect as in the first embodiment can be obtained. In FIG. 6, the positions of the recesses 7 do not correspond to each other on the opposing joint surfaces, but it is preferable to form the recesses 7 at the corresponding positions as in FIG. 1.

  Hereinafter, a manufacturing method of the configuration in the fifth embodiment will be described. First, the second active material layer 3, the electrolyte layer 5, the first active material layer 1, and the conductive thin film 6 are sequentially formed on both surfaces of the continuous sheet-like current collector 14 with a predetermined interval (unit device). Forming step). At that time, the recesses 7 are formed in the conductive thin film 6 and the first active material layer 1 to be the bonding surfaces. In this way, the unit devices 24 are formed with a predetermined interval between the continuous current collectors 14, and the exposed portions of the current collectors 14 are formed. That is, the exposed portion is a portion other than the unit device 24 formed. In the sixth embodiment, the current collector 14 is cut so as to include a necessary number of unit devices 24. The current collector 14 is cut before a laminating process described later.

Next, as in Embodiment 1, an adhesive application step is performed. Then, the unit devices 24 to which the adhesive 8 is applied are laminated (lamination process). As described above, since the exposed portion is provided between the plurality of unit devices 24, the current collector 14 can be bent without being separated. Further, the unit devices 24 can be folded in a zigzag manner using the continuous current collector 14 in this manner, so that the number of steps for connecting the unit devices 24 can be reduced.

  Finally, the joining process is performed as in the first embodiment. Note that the bonding step can be performed collectively for a plurality of unit devices. In addition, a joined body obtained by combining a plurality of unit devices and a single unit device can be combined and joined together.

(Embodiment 7)
FIG. 7 is a schematic cross-sectional view for explaining the configuration of the energy device according to the seventh embodiment of the present invention. FIG. 7 shows a state immediately before the unit devices 24 are joined in parallel in three sheets and stacked in a flat wound shape, and adjacent unit devices 24 are joined together to form an energy device. The tab 9A is joined to the current collectors 11 and 12, and the tab 9B is joined to the current collector 14, and is electrically connected to the outside. Moreover, four unit battery cells are connected in parallel by connecting tabs 9A. That is, the electrical connection form of the three unit devices 24 is the same as that of the fifth and sixth embodiments.

  A recess 7 is formed on at least one joint surface between the unit devices 24, and an adhesive 8 is applied to the inside of the recess 7, and the unit devices 24 are bonded together with the adhesive 8. Therefore, even with this configuration, the same effect as in the first embodiment can be obtained.

  Hereinafter, a manufacturing method of the configuration in the present embodiment will be described. First, in the same manner as in the sixth embodiment, a plurality of unit devices 24 are formed on a current collector 14 which is a continuous body, with a predetermined interval (exposed portion of the current collector 14), and an adhesive 8 is formed in the recess 7. Give.

  Then, the unit devices 24 to which the adhesive 8 is applied are laminated (lamination process). As described above, since the exposed portion is provided between the plurality of unit devices 24, the current collector 14 can be bent without being separated. Further, the number of steps for connecting the unit devices 24 can be reduced by making the unit devices 24 into a flat winding shape by using the continuous current collector 14 in this way.

  Finally, the joining process is performed as in the first embodiment. Note that the bonding step can be performed collectively for a plurality of unit devices. In addition, a joined body obtained by combining a plurality of unit devices and a single unit device can be combined and joined together.

  As described above, in the energy device of the present invention, a plurality of sheet-like unit devices each including the first active material layer, the electrolyte layer, and the second active material layer having the opposite polarity to the first active material layer are stacked. In addition, a concave portion to which an adhesive is applied is provided on at least one surface of the adjacent surfaces of the unit devices, and the plurality of unit devices are joined by the adhesive. With this configuration, the reliability at the time of joining is significantly increased, and a highly reliable energy device is realized.

  The present invention relates to an energy device of a type in which a sheet-like unit device is configured and a plurality of the unit devices are stacked to form a stacked body, and the voltage and capacity are increased, and the reliability of bonding of the stacked body is improved. The

DESCRIPTION OF SYMBOLS 1 1st active material layer 2, 4, 10, 11, 13, 14 Current collector 3 2nd active material layer 5 Electrolyte layer 6 Conductive thin film 7 Recessed part 8 Adhesive 9A, 9B Tab 12 Terminal board (current collector)
21, 22, 23, 24 Unit device 31, 32 Mask 33 Projection

Claims (6)

An energy device in which a plurality of sheet-like unit devices in which a first active material layer, an electrolyte layer, and a second active material layer having a polarity opposite to that of the first active material layer are stacked are joined,
The energy device includes an adhesive that joins adjacent unit devices, and the adhesive is applied to a recess provided on an outer surface of at least one of the adjacent unit devices. The energy device according to claim 1, wherein the adhesive is an adhesive having electronic conductivity. The energy device according to claim 1, further comprising a conductor portion disposed on at least one of a surface of the adjacent unit device and a bonding surface. The energy device according to claim 1, wherein the electrolyte layer is solid. A unit device forming step of forming a recess on the surface of a sheet-like unit device comprising a first active material layer, an electrolyte layer, and a second active material layer having a polarity opposite to that of the first active material layer; Manufacture of an energy device comprising an adhesive application step for applying an adhesive to the recess, a lamination step for laminating the unit devices to which the adhesive is applied, and a joining step for joining the laminated unit devices. Law. The unit device forming step includes a step of forming a plurality of the unit devices having the concave portions on the surface thereof on a sheet-like current collector,
The method for producing an energy device according to claim 5, further comprising a step of cutting a portion of the sheet-like current collector other than the unit device prior to the stacking step.

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