JP2015225855A - 固体電解質が濃度勾配を有する全固体電極の製造方法 - Google Patents
固体電解質が濃度勾配を有する全固体電極の製造方法 Download PDFInfo
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Abstract
【解決手段】 正極集電体−正極活物質層−固体電解質層−負極活物質層−負極集電体で積層され、正極活物質層は正極活物質、固体電解質、及び導電材を含み、負極活物質層は負極活物質及び固体電解質を含み、正極活物質層は正極集電体に近い正極活物質の濃度が固体電解質層に近い正極活物質の濃度よりも高く、負極活物質層は負極集電体に近い負極活物質の濃度が固体電解質層に近い負極活物質の濃度よりも高く、濃度の高低は連続的な勾配を有する全固体電極の製造方法であって、活物質は、相異なる濃度を有する1つ以上のエアロゾルタンクから流量を調節して噴射、導入されることを特徴とする。
【選択図】図3
Description
また本発明は、活物質体積比率(VRa、active material volume ratio=活物質体積/[活物質体積+固体電解質体積])を、固体電解質界面で0.1〜0.5の範囲に、集電体界面で0.5〜0.9の範囲に維持することが好ましい。
図1に示すように、特許文献2は、実施例として正極活物質層を2層に分け、第2正極活物質層の固体電解質の比率を第1正極活物質層よりも高くして製作した電極を開示している。
図2は、本発明の濃度勾配を有する全固体電極製造のための複数のエアロゾルを模式化した図面である。
図2に示すように、本技術の濃度勾配電極の製作のために、濃度の異なる2つ以上の物質組成を有する原料タンクを準備した。各エアロゾル発生器で生成される各エアロゾルのフローを調節して相異なる組成の原料が混合蒸着されるようにする。また、フローの調節によって濃度変化の傾きを自由に変更することができる。
図3に示すような具体例では、正極活物質層の活物質/固体電解質の比率が濃度勾配を有するようにして、出力性能及び高容量化を達成することができる。固体電解質界面では、集電体界面よりも固体電解質の比率を高く配置してイオンの拡散がうまくできるようにして出力性能を上げ、集電体界面に近いほど活物質の比率を高くして電池の高容量化が可能なように配置する。
図4に示すように、活物質の体積比率(VRa、active material volume ratio=活物質体積/[活物質体積+固体電解質体積])は、固体電解質界面0.1〜0.5、集電体界面0.5〜0.9を維持し、濃度の変化は直線、曲線形態に変化してもよい。
例えば、発生器1を負極活物質/固体電解質層用とし、発生器2を固体電解質層用とし、発生器3を正極活物質/固体電解質層用とする方法を取ることができる。
エアロゾルデポジション法(Aerosol Deposition Method、ADM)は、サブマイクロメーターの大きさを有する原料粉末を、ノズルを介して基板に高速衝突させ、高密度の厚膜を室温で形成できる工程であって、1990年後半、日本のAkedo博士が提案してから多くの発展を挙げてきた。特に、室温でも結晶質の特性を有する高密度厚膜を形成することができるという点、金属、セラミック、ポリマーなどの原料粉末を用いて様々な基板上にコーティングできるという点、及び原料粉末の化学量論比が厚膜でもそのまま維持される点など、既存の溶射工程と比較して多くの長所を有する新たなコーティング技術として大きな関心を集めている。
図6は、本発明の実施例1の電極の濃度勾配を示すグラフである。
正極活物質(LiCoO2)、負極活物質(黒鉛)、及び固体電解質(硫化物系Li2S−P2S5)を準備した。濃度勾配を有する正極活物質層をコーティングするために、エアロゾル発生器1に、組成が活物質/固体電解質=30/70(v/v)の原料粉末を充填し、エアロゾル発生器2に、組成が活物質/固体電解質=70/30(v/v)の原料粉末を充填した。固体電解質電極の表面にエアロゾルコーティングを行う時、初期は発生器1のフローだけ噴射させ、順次その量を減らして発生器2の噴射量を増加させ、最終的に発生器1のフローは停止させて発生器2のフローだけを噴射したところ、固体電解質の表面に、活物質の比率が、初期の30%から集電体に近い面の70%に変化した電極を得た。電極全体の活物質体積比率は50%であった。
図7は、本発明の実施例2の電極の濃度勾配を示すグラフである。
正極活物質(LiCoO2)、負極活物質(黒鉛)、及び固体電解質(硫化物系Li2S−P2S5)を準備した。濃度勾配を有する正極活物質層をコーティングするために、エアロゾル発生器1に、組成が活物質/固体電解質=50/50(v/v)の原料粉末を充填し、エアロゾル発生器2に、組成が活物質/固体電解質=70/30(v/v)の原料粉末を充填した。固体電解質電極の表面にエアロゾルコーティングを行う時、初期は発生器1のフローだけ噴射させ、順次その量を減らして発生器2のフローを増加させ、最終的に発生器1のフローは停止させ、発生器2のフローだけを噴射したところ、固体電解質の表面に、活物質の比率が、初期の50%から、集電体に近い面の70%に変化した電極を得た。電極全体の活物質体積比率は60%であった。
図8は、本発明の実施例3の電極の濃度勾配を示すグラフである。
正極活物質(LiCoO2)、負極活物質(黒鉛)、及び固体電解質(硫化物系Li2S−P2S5)を準備した。固体電解質層及び濃度勾配を有する正極活物質層をコーティングするために、エアロゾル発生器1に、組成が活物質/固体電解質=0/100(v/v)の原料粉末を充填し、エアロゾル発生器2に、組成が活物質/固体電解質=70/30(v/v)の原料粉末を充填した。エアロゾル発生器1のフローを発生させて固体電解質層を製造した(固体電解質層の製作)。次に、発生器2のフローを増加させ、発生器2のフローを減少させてコーティングし、最終的に発生器1のフローを停止させ、発生器2のフローだけ維持した(濃度勾配正極活物質層の製作)。電極全体の活物質体積比率は55%であった。
図9は、本発明の比較例1、2の電極の濃度勾配を示すグラフである。
濃度勾配のない正極活物質層をコーティングするために、エアロゾル発生器1に、組成が活物質/固体電解質=70/30(v/v)の原料粉末を充填して固体電解質電極の表面にエアロゾルコーティングを行った。
濃度勾配のない正極活物質層をコーティングするために、エアロゾル発生器1に、組成が活物質/固体電解質=50/50(v/v)の原料粉末を充填して固体電解質電極の表面にエアロゾルコーティングを行った。
比較例の準備材料は正極活物質(LiCoO2)、負極活物質(黒鉛)、固体電解質(硫化物系Li2S−P2S5)であった。
実施例2は、比較例2に比して20%高い電極比率(高容量)でもほぼ同様の出力性能を示す。
実施例3は、比較例よりもその性能が向上した。
Claims (7)
- 正極集電体−正極活物質層−固体電解質層−負極活物質層−負極集電体で積層された全固体電池の電極製造方法であって、前記正極活物質層は正極活物質、固体電解質、及び導電材を含み、前記負極活物質層は負極活物質及び固体電解質を含み、前記正極活物質層では正極集電体に近い正極活物質の濃度が前記固体電解質層に近い正極活物質の濃度よりも高く、前記負極活物質層では負極集電体に近い負極活物質の濃度が前記固体電解質層に近い負極活物質の濃度よりも高く、濃度の高低は連続的な勾配を有することを特徴とする固体電解質が濃度勾配を有する全固体電極の製造方法。
- 活物質は、相異なる濃度を有する1つ以上のエアロゾルタンクから流量を調節して噴射、導入されることを特徴とする請求項1に記載の固体電解質が濃度勾配を有する全固体電極の製造方法。
- 活物質体積比率(VRa、active material volume ratio=活物質体積/[活物質体積+固体電解質体積])は、固体電解質界面で0.1〜0.5、集電体界面で0.5〜0.9を維持することを特徴とする請求項1に記載の固体電解質が濃度勾配を有する全固体電極の製造方法。
- 第1発生器を有するエアロゾルタンクには活物質と固体電解質とが1:1〜3:7の体積比で含まれ、第2発生器を有するエアロゾルタンクには前記活物質と前記固体電解質とが7:3の体積比で含まれることを特徴とする請求項2に記載の固体電解質が濃度勾配を有する全固体電極の製造方法。
- 固体電解質の表面をコーティングする前記第1発生器の流量を増加させる段階と、前記第1発生器の流量を維持する段階と、前記第1発生器の流量を0になるまで減少させ、前記第2発生器の流量を増加させる段階と、前記第2発生器の流量を維持する段階と、を含むことを特徴とする請求項4に記載の固体電解質が濃度勾配を有する全固体電極の製造方法。
- 第1発生器を有するエアロゾルタンクには固体電解質だけ含まれ、第2発生器を有するエアロゾルタンクには活物質と前記固体電解質が7:3の体積比で含まれることを特徴とする請求項2に記載の固体電解質が濃度勾配を有する全固体電極の製造方法。
- 前記第1発生器の流量を増加させて固体電解質層を製造する段階と、前記第1発生器の流量を0になるまで減少させ、前記第2発生器の流量を増加させる段階と、前記第2発生器の流量を維持する段階と、を含むことを特徴とする請求項6に記載の固体電解質が濃度勾配を有する全固体電極の製造方法。
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