JP2019212638A - Skeleton-forming agent, electrode arranged by use thereof, and manufacturing method of electrode - Google Patents

Abstract

To provide an electrode superior in cycle life characteristic.SOLUTION: An electrode of a nonaqueous electrolyte secondary battery comprises an active material layer of which the skeleton is formed by a skeleton-forming agent, provided that the skeleton-forming agent is present on a surface of the active material layer and in the active material layer. The skeleton-forming agent comprises a silicate having a siloxane bond or a phosphate as a component.SELECTED DRAWING: Figure 1

Description

    The present invention relates to a skeleton-forming agent used for forming a skeleton of an active material layer in an electrode of a nonaqueous electrolyte secondary battery, an electrode using the same, and a method for producing the electrode.

    Secondary batteries are used in fields ranging from electronic devices to automobiles, large power storage systems, etc. The market size is expected to grow to an industry of 10 trillion yen or more. In particular, information and communication devices such as smartphones and tablet terminals have been remarkably popularized, and the worldwide penetration rate has exceeded 30%.

    In addition, the application range of secondary batteries to power sources for next-generation vehicles such as electric vehicles (EV) and plug-in hybrid vehicles (PHEV) is also expanding. In addition, secondary batteries have been used for household backup power, storage of natural energy, load leveling, etc., triggered by the 2011 Great East Japan Earthquake, and the applications of secondary batteries are expanding. Thus, the secondary battery is indispensable for the introduction of energy saving technology and new energy technology.

    Conventionally, secondary batteries have been mainly alkaline secondary batteries such as nickel-cadmium batteries and nickel-hydrogen batteries. However, due to their small size, light weight, high voltage, and no memory effect, non-aqueous electrolyte secondary batteries, In particular, the use of lithium secondary batteries (lithium ion batteries) is increasing. The nonaqueous electrolyte secondary battery is composed of a positive electrode, a negative electrode, a separator, an electrolytic solution or an electrolyte, and a battery case (storage case).

    Electrodes such as a positive electrode and a negative electrode are composed of an active material, a conductive additive, an organic polymer binder, and a current collector. In general, an electrode is manufactured by mixing an active material, a conductive additive, and an organic binder in a solvent to form a slurry, coating it on a current collector, drying, and rolling with a roll press or the like. The

    Rolling after drying the electrode increases the contact area with the conductive aid and current collector by shrinking the volume of the active material layer of the electrode, that is, the coating layer comprising the active material, conductive aid, and binder. This is to make it happen. Thereby, the electron conduction network of an active material layer is built firmly, and electronic conductivity is improved.

    The binder is used to bind an active material and an active material, an active material and a conductive aid, an active material and a current collector, a conductive aid and a current collector, and the like. The binder is a “solution type” that uses a liquid form dissolved in a solvent, a “dispersion type (emulsion / latex type)” in which the solid content is dispersed in the solvent, and the binder precursor is reacted with heat or light. It can be roughly classified into “reaction type” used.

    The binder can be classified into an aqueous system and an organic solvent system depending on the solvent type. For example, polyvinylidene fluoride (PVdF) is a dissolution type binder, and an organic solvent such as N-methyl-2-pyrrolidone (NMP) is used when preparing an electrode slurry. Styrene butadiene rubber (SBR) is a dispersion type binder and is used by dispersing SBR fine particles in water. Polyimide (PI) is a reactive binder, and a PI precursor is dissolved or dispersed in a solvent such as NMP, and heat treatment is performed to advance imidization and crosslinking reaction to obtain tough PI.

    Although it varies depending on the molecular weight of the binder, substituents, and the like, examples of the soluble binder include polyvinylidene fluoride (PVdF) and ethylene-vinyl acetate (EVA). Examples of the dispersion type binder include styrene butadiene rubber (SBR), polytetrafluoroethylene (PTFE), urethane rubber, polypropylene (PP), polyethylene (PE), polyvinyl acetate (PVAc), and nitrocellulose. Examples of the reactive binder include polyimide (PI), polyamide (PA), polyamideimide (PAI), polybenzimidazole (PBI), polybenzoxazole (PBO), and the like.

    In addition, organic solvent binders such as N-methyl-2-pyrrolidone (NMP) are considered to have an adverse effect on the environment, and are therefore required to be recovered when the electrodes are dried. This is a cause of increasing manufacturing costs. In addition, the organic solvent-based binder swells in a high-temperature electrolyte and increases electrode resistance, so that it is difficult to use in a high-temperature environment.

    Water-based soluble binders are inferior in oxidation resistance or reduction resistance, and are often gradually decomposed by repeated charge and discharge, and sufficient life characteristics cannot be obtained. Moreover, since the ionic conductivity is low, the output characteristics are lacking. Dispersion-type binders have the advantage that water can be used as a solvent, but dispersion stability is easily impaired by the degree of acid and alkali (pH), water concentration, or environmental temperature, and segregation, aggregation, and precipitation occur during electrode slurry mixing. It is easy to cause. Further, the binder fine particles dispersed in water have a particle diameter of 1 to 800 nm. When moisture is vaporized by drying, the particles are fused to form a film. Since this film does not have electrical conductivity and ionic conductivity, a slight difference in the amount used greatly affects the output characteristics and life characteristics of the battery.

    In the case of the above-mentioned dissolution type or dispersion type binder, it is combined with an active material that causes a rapid volume change with charge / discharge such as sulfur (S), silicon (Si), tin (Sn), and aluminum (Al). In this case, a stable life characteristic cannot be obtained, and the charge / discharge capacity becomes half or less in several cycles.

    On the other hand, the reactive binder is excellent in all of heat resistance, binding property and chemical resistance. In particular, PI exhibits high heat resistance and binding properties, and even with an active material having a large volume change, stable life characteristics can be obtained, and the binder is less likely to swell even in a high-temperature electrolyte.

    According to Non-Patent Document 1, it is disclosed that by combining PI and a high-strength current collector, deterioration of the current collector can be prevented and further life characteristics can be improved.

    According to Patent Document 1, it is disclosed that a LiFePO 4 / SiO-based lithium ion secondary battery using PI for a positive electrode and a negative electrode can be stably charged and discharged even at a high temperature of 120 ° C. On the other hand, when PI is used, since it has excellent binding properties with the current collector, when combined with an active material having a large volume change, the current collector may be wrinkled or cracked during initial charge and discharge. Therefore, it is necessary to use an iron foil or a stainless steel foil having high mechanical strength for the current collector.

    In addition to the organic binder, there are few reports in the field of non-aqueous electrolyte secondary batteries. However, Patent Documents 2 to 4 disclose techniques using an inorganic binder for secondary battery electrodes. Patent Document 2 includes an amorphous carbon material containing an inorganic binder, a conductive agent, a binder, and a solvent, and has a viscosity in the range of 2000 mPa · s to 10,000 mPa · s. Electrodes and non-aqueous electrolyte secondary batteries have been proposed. Moreover, it is shown that the decomposition reaction of a binder may be suppressed by including an inorganic binder.

    Patent Document 3 and Patent Document 4 provide a physically and chemically stable lithium ion battery using an inorganic binder. On the other hand, as described above, an electrode is generally composed of an active material layer (a layer made of an active material, a conductive additive, and a binder) and a current collector, but is different from the active material layer on the active material layer. Sometimes a layer is provided.

    For example, Patent Document 5 proposes a non-aqueous secondary battery using an electrode sheet having a layer mainly composed of metal or metalloid oxide and an auxiliary layer including at least one water-insoluble particle. The auxiliary layer provided on the electrode sheet is composed of water-insoluble conductive particles and a binder, and may be further mixed with particles having substantially no conductivity. The particles having substantially no conductivity are oxides, and an oxide containing a compound that dissolves both acidic and alkaline is preferred. In addition, it is shown that the binder used when forming an electrode mixture can be used for the binder used for an auxiliary | assistant layer.

    As such secondary batteries, batteries having various shapes such as a cylindrical type, a square type, and a laminate type are widely used. In addition, a cylindrical type is adopted for a relatively small capacity battery from the viewpoint of pressure resistance and ease of sealing, and a square type is adopted for a relatively large capacity battery for ease of handling.

    If attention is paid to the electrode structure of the secondary battery, there are roughly classified two types, a stacked type and a wound type. That is, in a stacked type battery, an electrode group in which positive electrodes and negative electrodes are alternately stacked via separators is housed in a battery case. Many of the stacked type batteries have a rectangular battery case. On the other hand, a wound type battery is housed in a battery case in a state in which a positive electrode and a negative electrode are wound in a spiral shape with a separator interposed therebetween. Winding type battery cases include cylindrical and square types.

Patent 5728721 Patent 5293020 JP-A-11-144736 JP 10-523411 A International Publication No. 1996/027910

Takashi Mukai et al., Development of Lithium Ion Battery Active Materials and Electrode Material Technology, Science & Technology Co., Ltd. 269-311 (2014), ISBN: 978-4-86428-089-1. Masahiro Yanagida et al., 83rd Annual Meeting of the Electrochemical Society, 1T28, (2016)

    As described above, Non-Patent Document 1 and Patent Document 1 do not hold as electrodes because wrinkles, cracks, etc. occur when a thin copper foil or the like is used for the current collector (see FIG. 19). On the other hand, if a high-strength iron foil or stainless steel foil is used for the current collector, wrinkles, cracks and the like can hardly be caused even if the current collector is thin. However, since the current collector has very high strength and excellent toughness, the electrode punching process is difficult, and the active material layer may fall off during cutting or burrs may occur on the cut surface.

    In addition, PI is so excellent in chemical resistance that it is insoluble in almost all organic solvents. Therefore, for preparing the electrode slurry, polyamic acid (polyamic acid), which is a PI precursor, is used by dissolving it in NMP, heat-treated at 200 ° C. or higher, and proceeding with imidization reaction (dehydration cyclization reaction) to perform PI treatment. Get. And after imidation reaction, it heat-processes at a still higher temperature, raise | generates a crosslinking reaction, and PI with high mechanical strength is obtained. From the viewpoint of electrode life, it is preferable that the heat treatment is performed at a high temperature so that PI is not carbonized. However, heat treatment at 200 ° C. or higher not only makes the electrode less flexible and difficult to handle, but also oxidizes the active material and the current collector surface, and causes irreversible capacity. In addition, heat treatment at a high temperature also causes an increase in power consumption during electrode manufacturing.

    There are also some PI binders that are imidized into PI and dispersed in the solvent, but using an electrode that has been imidized at the time of addition to the slurry results in an electrode with poor adhesion strength and improved life characteristics. Inferior. Many reactive binders such as PI occlude alkali metal ions during initial charging, but cannot be extracted during discharging, causing irreversible capacity. For example, depending on the molecular structure, PI has an irreversible capacity of 500-1000 mAh / g. Therefore, an electrode using a reactive binder has a low initial charge / discharge efficiency, and the battery capacity is greatly reduced.

    By the way, in order to confirm the safety of the battery, a nail penetration test is performed. If a nail is inserted into a fully charged battery, heat generation exceeding 600 ° C. may be observed even for a battery with a nominal capacity of 1 Ah class. Non-Patent Document 1 shows that a battery using a Si-based active material is greatly improved in battery nail penetration safety. Further, it has been shown that the safety of a battery using a Si-based negative electrode and a heat-resistant nonwoven fabric separator is further improved.

    Non-Patent Document 2 examines this phenomenon. When the electronic conductivity of the electrode active material layer is high, the heat generation temperature of the battery and the nail during nail penetration is high, and the electron conductivity of the electrode active material layer is low. The results show that the battery and nail heat generation temperature during nail penetration is also lowered. That is, the electronic conductivity of the electrode active material layer greatly contributes to the safety of battery nail penetration. If the electronic conductivity of the active material layer is high, the current value flowing through the nail increases, the amount of heat generated by the nail and the battery also increases, and if the electronic conductivity is low, the current value flowing through the nail decreases, The calorific value per unit time is reduced.

An alloy-based active material improves electron conductivity when alloyed with an alkali metal. For example, discharged Si is a semiconductor and has a low electronic conductivity, but a charged Li _x Si alloy (0 <x ≦ 4.4) is a conductor and has a high electronic conductivity. . That is, in the Si-based negative electrode, the short-circuited Si-based active material is delithiated due to an internal short circuit, and the electron conductivity of the electrode is drastically decreased, and the current is interrupted, thereby suppressing an increase in battery temperature. It is done.

    However, in an electrode with a large amount of conductive aid in the active material layer or an electrode using a material in which a highly conductive material is coated or combined with the active material, the electron conductivity of the active material layer is increased, Even if a Si-based material is used, the current interruption mechanism as described above is difficult to function, and the temperature rise of the battery cannot be sufficiently suppressed. Therefore, in order to design a battery with an emphasis on safety, an electrode with a low conductivity of the active material layer has to be used. Conversely, an electrode composition that places importance on safety has a low possibility of a battery having a low output because of its low electronic conductivity.

    Even in a battery using an electrode with low electronic conductivity of the active material layer, the instantaneous heat generation at the time of an internal short circuit cannot be eliminated, so when the binder is carbonized by this heat generation, the electron conductivity of the electrode increases, Safety will be compromised. Even if it is an organic reaction type binder that is excellent in heat resistance, the heat resistant temperature is limited to about 400 ° C, and carbonization occurs when the temperature rise due to internal short circuit exceeds the heat resistant temperature of the binder, so a binder that does not carbonize is required. ing.

Moreover, as for the active material, it is generally known that a material having a small volume change exhibits good life characteristics. For example, a volume change of about 4 times occurs in the Si charge reaction (Si + 4.4Li ++ 4.4e− → Li4.4Si), and the initial charge in the SiO charge reaction (SiO + 8.4Li ++ 8.4e− → Li4.4Si + Li ₄ SiO ₄ ). Except for the volume change for Li ₄ SiO ₄ production, the volume change is about 2.7 times, so that SiO exhibits excellent life characteristics as compared with Si.

    As another example, in a negative electrode using a mixture of Si and alumina, as compared with a pure Si negative electrode, the capacity decreases as the Si ratio decreases, but the life characteristics tend to be improved. Alumina is inactive with Li and does not contribute to the charge / discharge reaction, but it becomes a buffer material for the volume change of Si, and the volume change of the entire electrode can be reduced.

For example, in the charging reaction of the Si negative electrode, a volume change of about 4 times occurs before the charging due to the reaction of the following formula 1, and the stress applied to the electrode binder is also about 4 times.
Si + 4.4Li ++ 4.4e− → Li4.4Si (formula 1)

In the case of a negative electrode to which Si and an equimolar amount of Al ₂ O ₃ are added, since Al ₂ O ₃ is inactive with Li, the charging reaction is as shown in Formula (2) from a macro viewpoint. With such an electrode, the volume change of the electrode is halved compared to a pure Si electrode, so the stress applied to the electrode binder is also halved. Therefore, an electrode mixed with a material whose volume change is smaller than that of Si is expected to have a tendency to improve the life characteristics, although the capacity decreases as the Si ratio decreases.
0.5Si + 0.5Al ₂ O ₃ + 2.2Li ++ 2.2e−
→ 0.5Li4.4Si + 0.5Al ₂ O ₃ (Formula 2)

    However, in the actual life characteristics, although there is a slight life improvement effect, the Si deterioration rate in each cycle does not change so much. This is because, from a microscopic viewpoint, the volume change of the Si particles itself is about four times, so that the stress applied to the electrode binder is not different from Equation 1, and eventually stress is concentrated on the binding portion. In particular, in the case of electrodes in which electrode materials or electrode materials and current collectors are point-bonded with a binder, the bonded portion receives stress due to volume change intensively, the binding property is lost, and the conductive network of the electrodes Easily destroyed.

    On the other hand, when the binder is surface-bonded, the binder uniformly disperses the stress, so that the conductive network is not easily destroyed. However, the binder inhibits the movement of ions, so that the output characteristics are deteriorated. Although depending on the type of binder, point adhesion is likely to occur when the amount of the binder is small, and surface adhesion is likely to occur when the amount of the binder is large.

    Among the various binders, the binder that can stably charge and discharge the alloy-based active material is currently limited to a reaction type such as PI. However, the reactive binder uses an organic solvent during the production of the slurry, and the heat treatment process requires 200 ° C. or higher. The obtained electrode has a large irreversible capacity derived from the binder, and there is a limit on safety.

    In addition, it is difficult to exhibit sufficient life characteristics with only the reactive binder, and it is necessary to combine it with SiO or a high-strength current collector foil. Organic substances have a low melting point, are easily soluble in organic solvents, and are flammable. Inorganic substances are known to have a high melting point, are hardly soluble in organic solvents, are incombustible, and have high thermal conductivity. . Therefore, if a binder composed of an inorganic material can be used, there is a high possibility that an electrode having high heat resistance and excellent electrolytic solution resistance and heat dissipation can be obtained.

    However, many inorganic binders have not been adapted for use in non-aqueous electrolyte secondary battery electrodes. Inorganic binders can be broadly classified into four types: silicate-based, phosphate-based, sol-based, and cement-based. Among these, the present inventors have developed a silicate system and a phosphate system, particularly alkali metal silica having strong binding properties to all metals, oxides, and carbon, and heat resistance of 1000 ° C. or more. We focused on the acid salt system.

    The silicate system may be an alkali metal silicate, a silicate of a guanidine compound, or a silicate of an ammonium compound. A silicate salt-based inorganic binder is a compound mainly composed of silicon (Si) having a siloxane bond (-Si-O-Si-) and oxygen (O), and an organic material having a carbon-based skeleton. Different from the binder (see FIG. 21a).

    In addition, a part of the Si site in the siloxane bond is replaced with a transition metal element such as Al, Zr, Ti, Mg, Mo, Sr, Ca, Zn, Ba, B, W, Ta, Ce, Hf, and Y. It may be.

Silicates include orthosilicate (A ₄ SiO ₄ ), metasilicate (A ₂ SiO ₃ ), pyrosilicate (A ₆ Si ₂ O ₇ ), and disilicate (A ₂ Si ₂ O ₅ ). There are many types such as polysilicates such as tetrasilicate (A ₂ Si ₄ O ₉ ), A ₂ Si ₂ O ₅ , A ₂ Si ₃ O ₇ , A ₂ Si ₄ O ₉ , These may be hydrates. In addition, their structures can be broadly classified into crystalline silicates and amorphous silicates (A = alkali metal element, guanidine compound, ammonium compound). Such a silicate tends to lower the melting point as the proportion of A in the silicate increases, and at the same time exhibits solubility in water.

Industrially, silicates can be continuously varied in the proportion of A in the silicate, any salt can be adjusted, and the general molecular formula of silicate is A ₂ O · NSiO represented by ₂ of the form.

    Due to this difference in molecular skeleton, it exhibits higher heat resistance and oxidation resistance than organic binders, and is used in various fields such as fireproofing agents, waterproofing agents, bleaching agents, detergents, soaps, coating agents, sealing agents, and civil engineering ground reinforcement agents. However, there are almost no reports in the field of non-aqueous electrolyte secondary batteries.

    The phosphate system may be a magnesium phosphate salt or a calcium phosphate salt in addition to an aluminum phosphate salt.

    In the phosphoric acid inorganic binder, water is removed from the hydroxyl group by heating, a covalent bond is formed between phosphorus and oxygen, and a dehydration condensation reaction occurs. In this dehydration condensation reaction, a maximum of six sites can be reacted per molecule centering on the transition metal (M), and a three-dimensional polymerized transition metal phosphate can be obtained. That is, it is a compound having phosphorus (P) having an aluminophosphate bond, oxygen (O), and transition metal (M) as main molecular skeletons, and is different from an organic binder having a carbon-based skeleton (see FIG. 21b). .

    Also, some of the transition metal sites are Al, Mg, Ca, Cu, Fe, Ba, Ti, Mn, Mo, Mg, Si, Sr, Ca, Zn, Ba, B, W, Ta, Ce, Hf, It may be substituted with a transition metal element such as Y.

Specifically, the aluminum phosphate salt includes primary aluminum phosphate salt (Al (H ₂ PO ₄ ) ₃ ), aluminum hydrogen phosphate salt (Al ₂ (H ₂ PO ₄ ) ₃ ), aluminum metaphosphate ( Al (PO ₃ ) ₃ ). Magnesium phosphate salts include primary magnesium phosphate (Mg (H ₂ PO ₄ ) ₃ ), magnesium hydrogen phosphate (MgHPO ₄ ), and magnesium metaphosphate (Mg (PO ₃ ) ₂ ). The calcium phosphate salt includes primary calcium phosphate (Ca (H ₂ PO ₄ ) ₃ ), calcium hydrogen phosphate (CaHPO ₄ ), tricalcium phosphate (Ca ₃ (H ₂ PO ₄ ) ₂ ), calcium metaphosphate ( Ca (PO ₃ ) ₂ ), which may be hydrates. Their structures can be broadly classified into crystalline phosphates and amorphous phosphates.

Industrially, phosphate can be continuously changed in the proportion of M and P in the phosphate, any salt can be adjusted, and the general molecular formula of phosphate is M -It is expressed in the form of nH _x PO ₄ (M = Al or Mg, Ca).

The sol system is a colloidal solution in which fine oxide particles are dispersed in water. The particle size of the oxide is 10 nm or more and 200 nm or less, and hydroxyl groups exist on the surface thereof. For example, when the oxide is SiO ₂ , a siloxane bond is formed by dehydration condensation. This siloxane bond is formed inside the oxide particle, and therefore has a lower binding force than a silicate salt. Moreover, pH management is important and there is a problem that it is difficult to stably maintain the sol state. In the present invention, since the sol system hardly penetrates into the active material layer, use as a skeleton-forming agent is not preferable.

    Patent Document 2 indicates that the binder decomposition reaction may be suppressed by including an inorganic binder in the binder. This is because carbon materials (graphite, soft carbon, hard carbon, etc.) have a charge / discharge plateau potential in the vicinity of 0.1 V (vs. Li + / Li), and the electrode has a strong reducing power, so it has excellent reduction resistance. It seems that the decomposition reaction is suppressed by the inorganic binder.

    However, since the alloy material is higher than the charge / discharge plateau potential of the carbon material and has a reducing power weaker than that of the carbon electrode, the decomposition reaction of the binder does not occur so much. Therefore, even if the binder decomposition reaction is suppressed, the life characteristics of the alloy-based electrode are not greatly improved.

    In Patent Document 2, the inorganic binder includes inorganic particles, and the particle size of the inorganic particles is preferably 1 nm to 100 nm, more preferably 1 nm to 50 nm, and still more preferably 1 nm to 10 nm. , Is shown. It is described that a binder having better dispersibility and adhesive strength of the electrode mixture can be obtained by using such a particle size.

    Since the inorganic particles have a higher specific gravity than the carbon material, as the particle size of the inorganic particles increases, the sedimentation rate of the particles increases and the dispersibility and the adhesive force decrease. Therefore, it is effective to use particles of 100 nm or less. However, during drying after electrode coating, particles of 100 nm or less prevent escape of vaporized water, the coating film foams, the binding property with the current collector decreases, and a uniform electrode is difficult to obtain. There is a problem. Moreover, since such an electrode does not contain an organic binder excellent in flexibility, it is fragile and breaks when the electrode is bent. Therefore, it is not suitable for a wound type battery.

    On the other hand, it is known that an alloy-based active material has a higher capacity than a conventional carbon-based active material. For example, Si has a high electric capacity of 2800 to 4000 mAh / g, SiO of 1300 to 2000 mAh / g, Sn of 700 to 1000 mAh / g, and S of 800 to 1500 mAh / g. For this reason, even a slight error may cause a large variation in electrode capacity, which may deteriorate the life characteristics and output characteristics. In addition, the adjustment of the viscosity of the electrode slurry is difficult to control because it changes dramatically depending on the amount of solvent used.

Patent Document 3 and Patent Document 4 provide physically and chemically stable lithium ion batteries using an inorganic binder. Examples of electrodes include a graphite negative electrode (graphite anode) and a LiCoO ₂ positive electrode (LiCoO ₂ cathode). The graphite negative electrode is composed of 1.0 g of lithium hydroxide, 23.4 g of an inorganic binder (lithium polysilicate) and 45.0 g of graphite powder.

    Therefore, when the total solid content of the active material, the conductive additive and the binder is 100% by mass, the active material is 64.8% by mass and the inorganic binder is 33.7% by mass.

The LiCoO ₂ positive electrode is composed of 1.0 g of lithium hydroxide, 1.9 g of graphite powder, 2.9 g of C-100 carbon black, 24 g of inorganic binder (lithium polysilicate) and 85.6 g of graphite powder. ing.

    Therefore, when the total solid content of the active material, conductive additive and binder is 100% by mass, the active material is 74.2% by mass and the inorganic binder is 20.8% by mass. %. In addition, in patent document 3 and patent document 4, the inorganic binder has no description regarding the inorganic particles, and no inorganic particles are included in the examples.

    Patent Documents 2 to 4 described above are intended to improve the decomposition reaction of the binder and the swelling caused by the electrolytic solution, which are difficult to realize with conventional organic binders. By using an Si-based or Sn-based alloy material as an active material and a binder that does not easily swell with an electrolytic solution, it is likely that the operating temperature of the electrode can be expanded and the capacity can be increased.

    However, since the silicate binder is strongly alkaline and the phosphate binder is strongly acidic, the alloy active material at the time of electrode slurry preparation is dissolved, and hydrogen gas is generated to foam the slurry. . In particular, since the temperature is high when the electrode is dried, the amount of hydrogen gas generated increases, and even uniform electrode production does not remain. Further, when a current collector that is not resistant to alkali or acid is used, the current collector is deteriorated.

For example, when a Si active material and an alkali metal silicate system come into contact, a reaction of Si + 2OH− + H ₂ O → SiO ₃ − + 2H ₂ ↑ occurs. For this reason, there are currently only options for alkali- or acid-resistant active materials, that is, carbon-based materials. In addition, the binder, which is one of the constituent elements of the electrode, is used to bind the active material and the active material, the active material and the conductive aid, the active material and the current collector, and the conductive aid and the current collector. However, since current batteries employ organic binders such as PVdF or SBR, their thermal conductivity is small compared to inorganic materials such as active materials, conductive assistants, and current collectors, making it difficult to transfer heat. . In addition, since silicate-based and phosphate-based inorganic binders have a higher specific gravity than conventional organic binders, the amount of binder used during electrode fabrication is limited by the solid content of the active material, conductive assistant and binder. When the total is 100% by mass, sufficient binding force is not exhibited unless it is 20% by mass or more. In particular, when a material having a large volume change is used, 30 to 70% by mass is necessary. Therefore, the ratio of the active material of an electrode reduces and an electrode energy density falls.

    As described above, the inventors of the present application initially studied the application of a silicate-based or phosphate-based binder, but when applying a silicate-based or phosphate-based binder as a binder, It has been found that it does not hold as a practical electrode, including many problems. Therefore, the inventors have made researches so that the silicate system and the phosphate system can be applied to the electrode instead of the binder, and the present invention has been made. The present invention can solve the above-mentioned conventional problems and problems newly discovered by the inventors.

    The skeleton-forming agent according to the present invention is a skeleton-forming agent used for an electrode of a nonaqueous electrolyte secondary battery, and includes a silicate having a siloxane bond as a component or a phosphate having an aluminophosphate bond as a component. It is characterized by including. According to this configuration, by using a skeleton-forming agent containing silicate or phosphate for the electrode, an electrode having excellent heat resistance, high strength, and improved cycle life characteristics can be obtained.

The skeleton-forming agent and the silicate have a crystal or amorphous structure represented by the general formula A ₂ O.nSiO ₂ , and A is Li, Na, K, triethanolammonium group, tetramethanol. It is at least any one of an ammonium group, a tetraethanolammonium group, and a granidine group, and n is 0.5 or more and 5.0 or less.

Preferably, in the skeleton-forming agent, A in the general formula is Li or Na, and n is 1.6 or more and 3.9 or less, and more preferably 2.0 or more and 3.5 or less. A is preferably Na from the viewpoint of excellent mechanical strength, binding property, and wear resistance for skeleton formation. Li is excellent in the input / output characteristics of the battery because a skeleton-forming body having high ion conductivity is obtained. However, even if it is Na, if the number n of SiO ₂ exceeds 5.0, the binding property to the active material layer or the separator is inferior, and the volume change of the electrode during charging / discharging, the nail penetration test, etc. For this reason, peeling and cracking are likely to occur. Further, the viscosity becomes too low, and the dispersibility stability with ceramics described later is lowered.

  On the contrary, when n is less than 0.5, the viscosity is high, so that the skeleton-forming agent does not easily penetrate or be applied to the electrode active material layer or the separator. Further, when kneading with ceramics, the amount of heat generated increases.

    The silicate is preferably amorphous. Amorphous silicates do not break in a specific direction like crystals, so the life characteristics of the electrode are improved. In addition, since resistance to hydrofluoric acid is improved, electrode collapse derived from hydrofluoric acid can be made difficult to occur.

    Amorphous solids usually consist of disordered molecular arrangements and do not possess a distinguishable crystal lattice. In addition, the solubility of amorphous solids is higher than the crystalline form and does not have a constant melting point. Therefore, there is no clear peak in the powder X-ray diffraction (XRD) pattern, and there is no melting endothermic peak in the differential thermal analysis (DTA) curve or differential scanning calorimetry (DSC) curve. Is shown.

    That is, amorphous silicate does not have a sharp peak characteristic of crystalline form in XRD, and is typical for a diffraction angle (2θ) in the range of 15 ° to 40 ° by Cu-Kα rays. It shows a broad broad peak, the so-called halo pattern. More particularly, essentially the same XRD pattern as in FIG. 17 is shown.

However, even if halo patterns are obtained by XRD, not all of them are amorphous. However, it is only a limited condition that the crystal grain is less than 5 nm from the Scherrer formula shown in Formula 3. That is, when the crystal grain is 5 nm or more, the diffraction line is wide and the pattern does not resemble amorphous.
D (Å) = 0.9λ / (β × cos θ) (Equation 3)
(Where D is the size of the crystal grain, λ is the wavelength of the X-ray tube, β is the spread of the diffraction line depending on the size of the crystal grain, and θ is the diffraction angle)

    Further, when the amorphous state changes to the crystalline state, a large amount of heat is generated. Therefore, it is possible to determine the crystalline state of the silicate by measuring this. The amorphous silicate can be obtained by heat-treating the electrode at a temperature rising rate of 10 ° C./h or higher and a temperature of 80 ° C. or higher and 600 ° C. or lower.

    Preferably, in the skeleton forming agent, the solid content concentration of the silicate is 0.1% by mass or more and 30% by mass or less. More preferably, they are 0.1 mass% or more and 15 mass% or less.

    The skeleton-forming agent further contains a surfactant, and the surfactant is 0.001% by mass or more and 5.0% by mass or less. According to this configuration, the lyophilicity of the skeleton-forming agent to the active material layer is improved, and the skeleton-forming agent penetrates uniformly into the active material layer. Therefore, a uniform skeleton is formed in the active material layer, and the cycle life characteristics are further improved. If it is less than 0.001% by mass, the skeleton-forming agent is difficult to penetrate into an active material layer containing a large amount of carbon-based materials such as graphite, hard carbon, and conductive assistants. If there is no defoaming agent, the surface of the active material layer foams and it is difficult to form a strong skeleton.

    The skeleton-forming agent further contains alkali-resistant inorganic particles. According to this configuration, when the skeleton-forming agent is applied to the electrode, the inorganic particles are laminated on the surface of the active material layer of the electrode, the active material layer is covered with the layer of inorganic particles, and the active material layer Also contains inorganic particles.

    As a result, it is possible to form a strong skeleton in the active material layer, and to suppress the occurrence of peeling and cracks during drying. Lipophilicity with the liquid is obtained. In addition, the inorganic particle layer provides a high strength electrode with excellent heat resistance and excellent wear resistance. In addition, the layer of inorganic particles replaces the separator, and the battery can be configured without using a separate separator.

Preferably, in the skeleton forming agent, when the total solid content including the silicate and the alkali-resistant inorganic particles is 100% by mass, the silicate is 5% by mass to 80% by mass. The alkali-resistant inorganic particles are 20% by mass or more and 95% by mass or less, and the median diameter (D ₅₀ ) of the alkali-resistant inorganic particles is 0.2 μm or more and 20 μm or less.

Here, the median diameter (D ₅₀ ) means a volume-based particle diameter in the laser diffraction / scattering particle diameter distribution measuring method. The laser diffraction / scattering particle size distribution measuring method is a method of measuring the particle size by utilizing a phenomenon in which the light intensity distribution of diffracted and scattered light varies depending on the particle size when a laser beam is applied to the particle.

    When the skeleton-forming agent contains the above alkali-resistant inorganic particles, the skeleton-forming agent is less likely to foam when dried at a high temperature. When the skeleton forming agent is foamed, the binding property with the active material layer and the separator is lowered, and it becomes difficult to obtain sufficient strength.

The reason for setting the median diameter (D ₅₀ ) of the alkali-resistant inorganic particles to 0.2 μm or more and 20 μm or less is that voids are formed by the gaps between the inorganic particles, and a good lyophilic property with the electrolyte is obtained. From the viewpoint of the output characteristics of the battery, it is more preferably 0.25 μm or more and 10 μm or less, and further preferably 0.3 μm or more and 2 μm or less.

    If the particle size of the inorganic particles is larger than this range, the thixotropic property tends to be low and dilatancy tends to be exhibited, and the dispersion stability when the inorganic particles are added to the skeleton-forming agent is lowered. Conversely, if the particle size is smaller than this range, when a skeleton with a thickness exceeding 2 μm is formed, there is no escape route for moisture vaporized during drying, the coating film foams, and the binding property with the current collector is reduced. In addition, it is difficult to obtain a uniform electrode.

    The reason why the inorganic particles require alkali resistance is that silicate exhibits strong alkalinity (pH 12 or more). In addition to the alkali resistance, the skeleton-forming agent is desirably inorganic particles having excellent resistance to dissolution in an electrolytic solution.

The inorganic particles satisfying such conditions were selected from the group consisting of Al, Zr, Ti, Si, Mg, Mo, Sr, Ca, Zn, Ba, B, W, Ta, Ce, Hf and Y, for example. Examples thereof include oxides, hydroxides, nitrides, carbides, carbonate compounds, and sulfate compounds of at least one element. Among these, Al ₂ O ₃ , ZrO ₂ , TiO ₂ , SiO ₂ , CaO, MgO, CeO, from the viewpoint of being a material that is less susceptible to oxidative decomposition and reductive decomposition during charging and discharging of the battery and that has less irreversible capacity. Y ₂ O ₃ , AlN, WC, SiC, B ₄ C, BN, TaC, TiC, TiB ₂ , HfB ₂ , Si ₃ N ₄ , TiN, CaCO ₃ , MgSO ₄ , Al ₂ (SO ₄ ) ₃ , CaSO ₄ , ZrSiO ₄ is preferably contained.

In addition, Al ₂ O ₃ , ZrO ₂ , TiO ₂ , SiO ₂ , MgO, CeO, Y ₂ O ₃ , WC, SiC, B ₄ C, TaC, TiC from the viewpoint of being a material with a small irreversible capacity of the battery. Si ₃ N ₄ , TiN, CaCO ₃ , MgSO ₄ , CaSO ₄ , and ZrSiO ₄ are preferably contained. With these materials, it is possible to suppress the large volume shrinkage of the silicate that occurs during drying and to have sufficient strength even when dried at low temperatures.

On the other hand, the phosphate has a crystal or amorphous structure represented by the general formula M · nH _x PO ₄ , M is at least one of Al, Ca, and Mg, and x is 0 or more 2 or less, and n is 0.5 or more and 5 or less.

    M is preferably Al from the viewpoint of excellent mechanical strength, binding property, and wear resistance for skeleton formation. x is preferably 1 to 2 and more preferably 2 from the viewpoint of excellent binding properties for skeleton formation. n is preferably from 0.5 to 5.0, more preferably from 2.5 to 3.5, from the viewpoint of excellent mechanical strength for forming the skeleton, binding properties, and wear resistance. As in the case of silicate, the phosphate is preferably amorphous.

    Preferably, in the skeleton forming agent, the solid content concentration of the phosphate is 0.1% by mass or more and 30% by mass or less. More preferably, they are 0.1 mass% or more and 15 mass% or less.

    The skeleton-forming agent contains a surfactant, and the surfactant is preferably 0.001% by mass or more and 5.0% by mass or less.

    The skeleton-forming agent preferably further contains acid-resistant inorganic particles. According to this configuration, when the skeleton-forming agent is applied to the electrode, the inorganic particles are laminated on the surface of the active material layer of the electrode, the active material layer is covered with the layer of inorganic particles, and the active material layer Also contains inorganic particles.

    As a result, it is possible to form a strong skeleton in the active material layer, and to suppress the occurrence of peeling and cracks during drying. Lipophilicity with the liquid is obtained. In addition, the inorganic particle layer provides a high strength electrode with excellent heat resistance and excellent wear resistance. In addition, the layer of inorganic particles replaces the separator, and the battery can be configured without using a separate separator.

Preferably, in the skeleton forming agent, when the total solid content including the phosphate and the acid-resistant inorganic particles is 100% by mass, the phosphate is 5% by mass to 80% by mass. The acid-resistant inorganic particles are 20% by mass or more and 95% by mass or less, and the median diameter (D ₅₀ ) of the acid-resistant inorganic particles is 0.2 μm or more and 20 μm or less.

By containing the acid-resistant inorganic particles in the skeleton-forming agent, the skeleton-forming agent is less likely to foam when dried at a high temperature. When the skeleton forming agent is foamed, the binding property with the active material layer and the separator is lowered, and it becomes difficult to obtain sufficient strength. The median diameter (D ₅₀ ) of the acid-resistant inorganic particles is preferably 0.2 μm or more and 20 μm or less.

    The reason why the inorganic particles require acid resistance is that phosphate exhibits strong acidity (pH 1-2). In addition to the acid resistance, the skeleton-forming agent is desirably inorganic particles that have excellent resistance to dissolution in an electrolytic solution.

The inorganic particles satisfying such a condition are, for example, at least one element selected from the group consisting of Al, Zr, Ti, Si, Mo, Sr, Ba, B, W, Ta, Ce, Hf and Y. Examples thereof include oxides, hydroxides, nitrides, carbides, carbonate compounds, and sulfate compounds. Among these, Al ₂ O ₃ , ZrO ₂ , TiO ₂ , SiO ₂ , CeO, Y ₂ O ₃ , WC are used from the viewpoint that they are less susceptible to oxidative decomposition and reductive decomposition during charging and discharging of the battery and have a low irreversible capacity. SiC, B ₄ C, BN, TaC, TiC, TiB ₂ , HfB ₂ , Si ₃ N ₄ , TiN, and ZrSiO ₄ are preferably contained.

In addition, Al ₂ O ₃ , ZrO ₂ , TiO ₂ , SiO ₂ , CeO, Y ₂ O ₃ , WC, SiC, B ₄ C, BN, TaC, TiC from the viewpoint of being a material with low irreversible capacity of the battery. , Si ₃ N ₄ , TiN, ZrSiO ₄ are preferably contained. With these materials, it is possible to suppress the large volume shrinkage of the phosphate generated during drying and to have sufficient strength even when dried at a low temperature.

    In the silicate system and the phosphate system, the silicate system is preferable from the viewpoints of battery life and input / output characteristics, irreversible capacity, moisture absorption resistance, heat resistance, and the like.

    The electrode according to the present invention is an electrode for a non-aqueous electrolyte secondary battery, and the skeleton-forming agent according to any one of claims 1 to 7 is present at least on the surface of the active material layer. It is characterized by being. According to this configuration, the skeleton-forming agent containing silicate or phosphate forms the skeleton of the electrode, and the electrode has excellent heat resistance, high strength, and improved cycle life characteristics. In addition, when a binder containing silicate or phosphate is used, it does not hold as an electrode. However, by attaching a skeleton-forming agent to the surface of the active material layer, an electrode having excellent cycle life characteristics can be obtained.

    Here, the nonaqueous electrolyte secondary battery is a secondary battery using an electrolyte that does not contain water as a main component. For example, a lithium secondary battery (lithium ion battery), a sodium battery (sodium ion battery), a potassium battery ( Potassium ion battery). In addition, the electrode is not particularly limited as long as it is an electrode used for a nonaqueous electrolyte secondary battery, and the material and shape of the electrode are not particularly limited.

    The electrode includes a negative electrode and a positive electrode. First, regarding the negative electrode, the negative electrode active material used for the negative electrode is not particularly limited as long as it is a material capable of reversibly occluding and releasing alkali metal ions (lithium ions, sodium ions, potassium ions, etc.). For example, Li, Na, K, C, Mg, Al, Si, P, Ca, Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Ga, Ge, Y, Zr, Nb, At least one element selected from the group consisting of Mo, Pd, Ag, Cd, In, Sn, Sb, W, Pb and Bi, alloys, composites, oxides, chalcogenides or halogens using these elements Any chemical compound may be used.

    From the viewpoint that the discharge plateau region can be observed within the range of 0 to 1 V (vs. Li + / Li), Li, Na, K, C, Mg, Al, Si, Ti, Zn, Ge, Fe, Mn, Ag, Preference is given to at least one element selected from the group consisting of Cu, In, Sn and Pb, and allotropes, alloys or oxides using these elements.

Further, from the viewpoint of energy density, the element is preferably Al, Si, Zn, Ge, Ag, Sn, or the like, and the alloy is Si—Al, Al—Zn, Si—Mg, Si—La, Al—Ge, Si-Ge, Si-Ag, Si-Sn, Si-Ti, Si-Y, Si-Cr, Si-Ni, Si-Zr, Si-V, Si-Nb, Si-Mo, Zn-Sn, Ge- Each combination of Ag, Ge—Sn, Ge—Sb, Ag—Sn, Ag—Ge, Sn—Sb, and the like is preferable, and examples of the oxide include Fe ₂ O ₃ , CuO, MnO ₂ , NiO, and Li ₄ Ti _5. O ₁₂ , H ₂ Ti ₁₂ O ₂₅ , Na ₂ Ti ₃ O _{7 and the} like are preferable. The alloy may be a solid solution alloy, a eutectic alloy, a hypoeutectic alloy, a hypereutectic alloy, or a peritectic alloy. Further, the surface of the active material particles may be coated with a material excellent in electron conductivity or ceramics. Two or more materials capable of reversibly occluding and releasing lithium may be used.

    The shape of the active material particles is not particularly limited, and may be spherical, elliptical, faceted, belt-like, fiber-like, flake-like, donut-like, or hollow. Materials capable of reversibly occluding and releasing alkali metal ions (lithium ions, sodium ions, potassium ions) can be used as materials and solid electrolytes that can absorb and release alkali metal ions during the initial charging process. Compounds that decompose are more preferred.

    The solid electrolyte is not particularly limited as long as it is a substance having ion conductivity, but is preferably a solid electrolyte represented by LiαXβYγ. In the formula, 0 <α ≦ 4, 0 ≦ β ≦ 2, and 0 ≦ γ ≦ 5. The solid electrolyte also serves as a buffer material that can reversibly occlude and release alkali metal ions.

X is, for example, one or more of Si, Ti, Mg, Ca, Al, V, Ge, Zr, Mo, and Ni, and Y is O, S, F, Cl, Br, I, P, B ₂ O ₃ , C ₂ O ₄ , CO ₃ , PO ₄ , S, CF ₃ SO ₃ , or SO ₃ . More specifically, for example, LiF, LiCl, LiBr, LiI , Li 3 N, LiPON, Li 2 C2O 4, Li 2 CO 3, LiAlCl 4, Li 2 O, Li 2 S, LiSO 4, Li 2 SO 4 , Li ₃ PO ₄ , Li ₃ VO ₄ , Li ₄ GeO ₄ , Li ₂ Si ₂ O ₅ , Li ₂ SiO ₃ , Li ₄ SiO ₄ , Li ₄ ZrO ₄ , LiMoO ₄ , LiAlF ₄ , Li ₃ Ni ₂ , LiBF ₄ , LiCF ₃ SO ₃ , NaF, NaCl, NaBr, NaI, Na ₃ N, NaPON, Na ₂ C ₂ O ₄ , Na ₂ CO ₃ , NaAlCl ₄ , Na ₂ O, Na ₂ S, NaSO ₄ , Na ₂ SO ₄ , Na ₃ PO ₄ , Na ₃ VO ₄ , Na ₄ GeO ₄ , Na ₂ Si ₂ O ₅ , Na ₂ SiO ₃ , Na ₄ SiO ₄ , Na ₄ ZrO ₄ , NaMoO ₄ , NaAlF ₄ , Na ₃ Ni ₂ , NaBF ₄ , NaCF ₃ SO ₃ , KF, KCl, KBr, KI, K ₃ N, KPON, K ₂ C ₂ O ₄ , K ₂ CO ₃ , KAlCl ₄ , K ₂ O, K ₂ S, KSO ₄ , K ₂ SO ₄ , K ₃ PO ₄ , K ₃ VO ₄ , K ₄ GeO ₄ , K ₂ Si ₂ O ₅ , K ₂ SiO ₃ , K ₄ SiO ₄ , K ₄ ZrO ₄ , KMoO ₄ , KAlF ₄ , K ₃ Ni ₂ , Examples thereof include KBF ₄ and KCF ₃ SO ₃ , and one or more of these can be used.

Examples of compounds capable of occluding and releasing alkali metal ions and compounds that decompose into solid electrolytes include, for example, SiO, GeO, GeS, GeS ₂ , SnO, SnO ₂ , SnC ₂ O ₄ , SnO—P ₂ O ₅ , SnO-B ₂ O ₃ , SnS, SnS ₂ , Sb ₂ S ₃ , SnF ₂ , SnCl ₂ , SnI ₂ , SnI _{4 and the} like may be used, and two or more of these may be used. However, a substance capable of occluding and releasing alkali metal ions and a compound capable of decomposing into a solid electrolyte are preferably pre-doped because the battery capacity is extremely reduced before pre-doping before the battery is assembled. .

    Regarding the pre-doping method, patent literature (Japanese Patent Application Laid-Open No. 2015-088437) and non-patent literature ("Measurement and Analysis Data Collection of Lithium Secondary Battery Members", Chapter 3, Section 30, pp. 200-205, Technical Information Association) ), Known methods such as an electrochemical method, an alkali metal attaching method, and a mechanical method can be used. Although the reason is not clear, in the present invention, the electrode to which the skeleton is formed is Si, Si alloy, Si composite, Si oxide, or a mixture containing one or more of these, and particularly remarkable cycle life improvement. The effect is demonstrated.

    When an active material powder having a small particle size is used as the particle size of the active material, particle collapse tends to be reduced and the life characteristics of the electrode tend to be improved. In addition, the specific surface area increases and the output characteristics tend to be improved. For example, according to non-patent literature (the latest technological trend of rare metal-free secondary batteries, Chapter 3, Section 1, Section 4, PP. 125-135, CM Publishing, 2013), the particle size of the active material is small. Then, it is described that the initial discharge capacity is increased and the cycle life is improved, and it can be seen that the active material particle size is correlated with the initial charge / discharge efficiency and the cycle life.

    However, since the nano-order active material is difficult to handle, it is preferable to granulate and use it. For example, in Patent No. 552503, a nano-granular body using a granulating binder of at least one of polyimide, polybenzimidazole, styrene butadiene rubber, polyvinylidene fluoride, carboxymethyl cellulose, and polyacrylic acid. The negative electrode used is shown. By granulating the nano-order active material, stress applied to the copper foil due to expansion and contraction of the negative electrode active material is relieved, and deformation of the copper foil can be prevented.

On the other hand, it is also conceivable to use the skeleton former of the present invention as a binder for granulation of the negative electrode active material described above. In that case, the primary particles of the active material are preferably in the median diameter (D ₅₀ ) range of 0.01 μm to 10 μm, and the active material particles (secondary particles) after granulation have a median diameter (D ₅₀ ). It is preferably in the range of 1 μm to 100 μm.

    Moreover, as the granulation method of the active material, known granulation methods can be applied, for example, fluidized bed granulation method, stirring granulation method, rolling granulation method, spray drying method, extrusion granulation method. , Rolling granulation method, and coating granulation method. Of these, spray drying and fluidized bed granulation are particularly preferred.

    In the spray drying method, for example, a suspension in which an active material is dispersed in a skeleton-forming agent is sprayed from above to a greenhouse heated to 50 to 300 ° C. at 1 to 30 mL / min and an air pressure of 0.01 to 5 MPa. Thus, agglomerated grains are produced and a granulated product is obtained by drying the aggregated grains.

    In the fluidized bed granulation method, for example, the powder raw material is put into a fluidized bed granulator and warm air heated to 50 to 300 ° C. is sent from below to flow the powder raw material (granulated material precursor). Then, water in which the skeleton-forming agent is dissolved in the mixed powder raw material is sprayed from above with a nozzle, and the skeleton-forming agent is uniformly sprayed on the powder surface at 1 to 30 mL / min and an air pressure of 0.01 to 5 MPa. Thus, agglomerated grains are produced and a granulated product is obtained by drying the aggregated grains.

    However, when an active material with poor alkali resistance such as Si or Sn is used, there is a high possibility that it does not work as a negative electrode by reacting with the skeleton-forming agent to generate hydrogen gas. Therefore, when the skeleton-forming agent of the present invention is used, hydrogen gas is generated by spraying the skeleton-forming agent on secondary particles granulated in advance with an organic binder for granulation to form a skeleton on the granulated product. It seems to be possible to reduce as much as possible.

    Moreover, a well-known thing can be used as an organic binder for granulation. For example, it may be a binder used for a positive electrode or a negative electrode, but from the viewpoint of the chemical stability, heat resistance, reduction resistance, etc. of the granule, polybenzimidazole, styrene butadiene rubber, polyvinylidene fluoride, carboxymethyl cellulose, Polyvinyl alcohol, polyacrylic acid, cellulose nanofiber, polyimide, polyamide, and polyamideimide are preferable.

    The amount of the granulating binder is not particularly limited as long as it is an amount capable of binding the active material particles, but is preferably in the range of 0.1 to 30% by mass with respect to the granulated body. In addition to the active material particles and the granulating binder, the granulated body may contain a conductive additive for imparting electron conductivity as necessary. It is preferable that the skeleton-forming agent is contained within a range of 0.2 to 30% by mass with respect to the granulated body. The granule thus obtained not only improves the cycle life characteristics, but also improves the slurry coatability.

    The conductive aid for the negative electrode is not particularly limited as long as it has electronic conductivity, and the above-described metals, carbon materials, conductive polymers, conductive glass, and the like can be used. Specifically, acetylene black (AB), ketjen black (KB), furnace black (FB), thermal black, lamp black, channel black, roller black, disk black, carbon black (CB), carbon fiber (for example, registration) Vapor growth carbon fiber named VGCF, which is a trademark), carbon nanotube (CNT), carbon nanohorn, graphite, graphene, glassy carbon, amorphous carbon, and the like, and one or more of these may be used.

    When the total of the active material, binder, and conductive additive contained in the negative electrode is 100% by mass, it is preferable that 0 to 20% by mass of the conductive additive is contained. That is, the conductive auxiliary agent is contained as necessary. When it exceeds 20 mass%, since the ratio of the active material as a battery is small, an electrode capacity density tends to become low.

    The negative electrode binder is a commonly used binder such as polyvinylidene fluoride (PVdF), polytetrafluoroethylene (PTFE), polyimide (PI), polyamide, polyamideimide, aramid, polyacryl, styrene butadiene rubber (SBR). , Ethylene-vinyl acetate copolymer (EVA), styrene-ethylene-butylene-styrene copolymer (SEBS), carboxymethyl cellulose (CMC), chitansan gum, polyvinyl alcohol (PVA), ethylene vinyl alcohol, polyvinyl butyral (PVB), Ethylene vinyl alcohol, polyethylene (PE), polypropylene (PP), polyacrylic acid, lithium polyacrylate, sodium polyacrylate, potassium polyacrylate, ammonium polyacrylate, Methyl acrylate, ethyl polyacrylate, amine polyacrylate, polyacrylate ester, epoxy resin, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), nylon, vinyl chloride, silicone rubber, nitrile rubber, cyanoacrylate, urea Resin, melamine resin, phenol resin, latex, polyurethane, silylated urethane, nitrocellulose, dextrin, polyvinylpyrrolidone, vinyl acetate, polystyrene, chloropropylene, resorcinol resin, polyaromatic, modified silicone, methacrylic resin, polybutene, butyl rubber, 2 -Propenoic acid, cyanoacrylic acid, methyl methacrylate, glycidyl methacrylate, acrylic oligomer, 2-hydroxyethyl acrylate , Alginic acid, starch, to sell, sucrose, glue, casein, may also be an organic material such as cellulose nanofibers alone or in combination of two or more thereof.

    Moreover, what mixed these organic binders and inorganic binders may be used. The inorganic binder may be silicate, phosphate, sol, cement, or the like. For example, lithium silicate, sodium silicate, potassium silicate, cesium silicate, guanidine silicate, ammonium silicate, fluorosilicate, borate, lithium aluminate, sodium aluminate, potassium Aluminate, aluminosilicate, lithium aluminate, sodium aluminate, potassium aluminate, polyaluminum chloride, polyaluminum sulfate, polyaluminum sulfate silicate, aluminum sulfate, aluminum nitrate, ammonium alum, lithium alum, sodium alum, potassium Alum, chrome alum, iron alum, manganese alum, nickel ammonium sulfate, diatomaceous earth, polyzirconoxane, polytantaloxane, mullite, white carbon, silica sol, colloidal Rica, fumed silica, alumina sol, colloidal alumina, fumed alumina, zirconia sol, colloidal zirconia, fumed zirconia, magnesia sol, colloidal magnesia, fumed magnesia, calcia sol, colloidal calcia, fumed calcia, titania sol, colloidal titania, fume Dotitania, zeolite, silicoaluminophosphate zeolite, sepiolite, montmorillonite, kaolin, saponite, aluminum phosphate, magnesium phosphate, calcium phosphate, iron phosphate, copper phosphate, zinc phosphate, titanium phosphate Salt, manganese phosphate salt, barium phosphate salt, tin phosphate salt, low melting point glass, plaster, gypsum, magnesium cement, resurge cement, Portland Instruments, blast furnace cement, fly ash cement, silica cement, phosphate cement, concrete, inorganic material of the solid electrolyte and the like may be used singly, and may be used in combination of two or more thereof.

    Among these, lithium silicate, sodium silicate, potassium silicate, guanidine silicate, ammonium silicate, from the viewpoints of binding properties, electrolytic solution elution resistance, redox resistance, energy density, etc. Inorganic materials such as silicofluoride, aluminosilicate, aluminum phosphate, magnesium phosphate, and calcium phosphate are preferred.

    However, when a negative electrode is produced with an inorganic binder, the specific gravity of the inorganic binder is large, and therefore the electrode energy density per weight tends to be low. In addition, in an inorganic binder with strong acid or alkali, if an active material with poor chemical resistance such as Si or Sn is contained, hydrogen gas is generated during mixing of the slurry, which makes electrode coating difficult and heat drying. In this process, it is foamed and a uniform electrode cannot be manufactured. Further, when a current collector having poor chemical resistance is used, the current collector is deteriorated.

    Conventionally, when an alloy-based negative electrode active material is used as the negative electrode binder, for example, PI is preferred from the viewpoint of suppressing the volume change of the active material accompanying charge / discharge and improving the cycle life characteristics of the battery. However, in the present invention, since the volume change can be suppressed by the skeleton-forming agent, all of the above-described commonly used ones can be used.

    When the total of the active material, binder and conductive additive contained in the negative electrode is 100% by mass, the binder is preferably contained in an amount of 0.1 to 60% by mass, more preferably 0.5 to 30% by mass. .

    When the binder is less than 0.1% by mass, the mechanical strength of the electrode is low, so that when the skeleton is formed, the active material tends to fall off, and the cycle life characteristics of the battery may be deteriorated. On the other hand, when it exceeds 60% by mass, the ionic conductivity is low, the electric resistance is high, and the ratio of the active material as a battery is small, so the electrode capacity density tends to be low.

    The current collector used for the negative electrode is not particularly limited as long as it is a material that has electronic conductivity and can conduct electricity to the held negative electrode active material. For example, conductive materials such as C, Ti, Cr, Ni, Cu, Mo, Ru, Rh, Ta, W, Os, Ir, Pt, Al, Au, and alloys containing two or more of these conductive materials ( For example, stainless steel) can be used. When a material other than the above-described conductive material is used, for example, it may be a multi-layered structure of dissimilar metals such as iron coated with Cu or Ni.

    From the viewpoint of high electrical conductivity and good stability in the electrolytic solution, the current collector is preferably C, Ti, Cr, Au, Fe, Cu, Ni, stainless steel, etc., and further has reduction resistance and material cost. From the viewpoint, C, Cu, Ni, stainless steel and the like are preferable. In addition, when using iron for a current collection base material, in order to prevent oxidation of the current collection base material surface, it is preferable that it is what was coat | covered with Ni or Cu. Moreover, since the volume change of the negative electrode material accompanying charging / discharging is large in the conventional alloy-based negative electrode, the current collecting base material is preferably stainless steel or iron, but in the present invention, the current collector is a skeleton forming agent. Since it is possible to relieve the stress applied to the above, all of the above-mentioned commonly used ones can be used.

    The shape of the current collector includes a linear shape, a rod shape, a plate shape, a foil shape, and a porous shape. Among these, a porous shape is obtained because the packing density can be increased and the skeleton-forming agent easily penetrates into the active material layer. It may be. Examples of the porous shape include a mesh, a woven fabric, a non-woven fabric, an embossed body, a punched body, an expanded body, a foamed body, and the like. The body is preferred.

    Next, the active material used for the positive electrode for the positive electrode is not particularly limited as long as it is a positive electrode active material used in a non-aqueous electrolyte secondary battery. Known electrodes including alkali metal transition metal oxides, vanadium, sulfur, solid solution systems (lithium-excess system, sodium-excess system, potassium-excess system), carbon systems, organic systems, and the like are used.

Examples of the alkali metal transition metal oxide system include LiCoO ₂ , Li _0.9 Na _0.1 CoO ₂ , LiNiO ₂ , LiNi _0.5 Co _0.5 O ₂ , LiNi _0.33 Mn _0.33 Co _0.33 O ₂ , LiNi _0.5 Mn _0.2 Co _0.3 O 2, LiNi _0.6 Mn _0.2 Co _0.2 O ₂ , LiNi _0.8 Mn _0.1 Co _0.1 O ₂ , Li (Ni, Co, Al) O ₂ , LiMnO ₂ , LiMn ₂ O ₄ , LiFePO ₄ , LiFe _0.5 Mn _0.5 PO ₄ , LiMnPO ₄ , Li ₂ MnSiO ₄ , Li ₂ FeSiO ₄ , Li ₂ (Mn, Fe) SiO ₄ , Li ₂ CoSiO ₄ , Li ₂ MgSiO ₄ , Li ₂ CaSiO ₄ , Li ₂ ZnSiO ₄ , LiNb ₂ O ₅ , LiNbO ₂ , LiFeO ₂ , _{LiMgO 2, LiCaO 2, LiTiO 2} , LiTiS 2, LiCrO 2, LiRuO 2, LiCuO 2, LiZ _{O 2, LiMoO 2, LiMoS 2} , LiTaO 2, LiWO 2, NaCoO 2, NaNiO 2, NaNi 0.33 Mn 0.33 Co 0.33 O 2, NaMnO 2, NaMn 2 O 4, NaFePO 4, NaFe 0.5 Mn 0.5 PO 4, NaMnPO 4 Na ₂ MnSiO ₄ , Na ₂ FeSiO ₄ , Na ₂ (Mn, Fe) SiO ₄ , Na ₂ CoSiO ₄ , Na ₂ MgSiO ₄ , Na ₂ CaSiO ₄ , Na ₂ ZnSiO ₄ , NaNb ₂ O ₅ , NaNbO ₂ , NaFeO _{2, NaMgO 2, NaCaO 2,} NaTiO 2, NaTiS 2, NaCrO 2, NaRuO 2, NaCuO 2, NaZnO 2, NaMoO 2, NaMoS 2, NaTaO 2, NaWO 2, KCoO 2, KNiO 2, kNi 0.33 Mn 0.33 Co 0.33 _{O 2, KMnO 2, KMn 2} O 4, KFePO 4 _{KFe 0.5 Mn 0.5 PO 4, KMnPO} 4, K 2 MnSiO 4, K 2 FeSiO 4, K 2 (Mn, Fe) SiO 4, K 2 CoSiO 4, K 2 MgSiO 4, K 2 CaSiO 4, K 2 ZnSiO 4, KNb ₂ O ₅ , KNbO ₂ , KFeO ₂ , KMgO ₂ , KCaO ₂ , KTiO ₂ , KTiS ₂ , KCrO ₂ , KRuO ₂ , KCuO ₂ , KZnO ₂ , KMoO ₂ , KMoS ₂ , KTaO ₂ , KWO ₂ etc. .

Examples of the vanadium type include LiV ₂ O ₅ , LiVO ₂ , Li ₃ VO ₄ , Li ₃ V ₂ (PO ₄ ) ₃ , NaV ₂ O ₅ , NaVO ₂ , Na ₃ VO ₄ , Na ₃ V ₂ (PO _{4 3} ), KV ₂ O ₅ , KVO ₂ , K ₃ VO ₄ , K ₃ V ₂ (PO ₄ ) _{3 and the} like. Examples of the sulfur type include sulfur, carbon sulfide, polysulfide, polysulfide carbon, sulfur-modified polyacrylonitrile, disulfide compound, sulfur-modified rubber, sulfur-modified pitch, sulfur-modified anthracene, and metal sulfide. The solid solution system, for _{example, Li 2 MnO 3 -LiNiO 2,} Li 2 MnO 3 -LiMnO 2, Li 2 MnO 3 -LiCoO 2, Li 2 MnO 3 -Li (Ni, Mn) O 2, Li 2 MnO 3 - Li (Ni, Co) O ₂ , Li ₂ MnO ₃ —Li (Mn, Co) O ₂ , Li ₂ MnO ₃ —Li (Ni, Mn, Co) O ₂ , Na ₂ MnO ₃ —NaNiO ₂ , Na ₂ MnO _{3 -NaMnO 2, Na 2 MnO 3} -NaCoO 2, Na 2 MnO 3 -Na (Ni, Mn) O 2, Na 2 MnO 3 -Na (Ni, Co) O 2, Na 2 MnO 3 -Na (Mn, _{Co) O 2, Na 2 MnO} 3 -Na (Ni, Mn, Co) O 2, K 2 MnO 3 -KNiO 2, K 2 MnO 3 -KMnO 2, K 2 MnO 3 -KCoO 2, K 2 MnO 3 - _{K (Ni, Mn) O 2} , K 2 MnO 3 -K ( _{i, Co) O 2, K} 2 MnO 3 -K (Mn, Co) O 2, K 2 MnO 3 -K (Ni, Mn, Co) O 2, include like.

    Examples of the carbon system include graphite, soft carbon, hard carbon, and glassy carbon. Organic systems include rubeanic acid, tetracyanoquinodimethane, triquinoxalinylene, phenazine dioxide, trioxotriangulene, indigo carmine, nitronyl nitroxide radical compounds, radialene compounds, aliphatic cyclic nitroxyl radicals, Examples include benzoquinones.

The positive electrode active material described above may be used alone or in combination of two or more. From the viewpoint of energy density, for example, LiCoO ₂ , LiMn ₂ O ₄ , LiFePO ₄ , LiFe _0.5 Mn _0.5 PO ₄ , LiMnPO ₄ , LiNi _0.33 Mn _0.33 Co _0.33 O ₂ , LiNi _0.5 Mn _0.2 Co _0.3 O ₂ , LiNi _0.6 Mn _0.2 Co _0.2 O ₂ , LiNi _0.8 Mn _0.1 Co _0.1 O ₂ , Li (Ni, Co, Al) O ₂ , solid solution system, vanadium system, and sulfur system are preferable. The shape of the active material particles is not particularly limited, and may be spherical, elliptical, faceted, belt-like, fiber-like, flake-like, donut-like, or hollow.

On the other hand, as in the case of the negative electrode, it is also conceivable to use the skeleton-forming agent of the present invention as the above-mentioned binder for granulation of the positive electrode active material. In that case, the primary particles of the active material are preferably in the range of median diameter (D ₅₀ ) of 0.01 μm to 10 μm, and the active material particles (secondary particles) after granulation have a median diameter (D ₅₀ ) of 1 μm. It is preferable to be within a range of ˜100 μm. The granulation method of the active material is substantially the same as the granulation method of the negative electrode active material, and a known granulation method can be applied.

    Further, the conductive auxiliary agent is not particularly limited as long as it has electronic conductivity, and examples thereof include metals, carbon materials, conductive polymers, conductive glasses, and the like, but high electronic conductivity and oxidation resistance. From this point of view, a carbon material is preferable. Specifically, acetylene black (AB), ketjen black (KB), furnace black (FB), thermal black, lamp black, channel black, roller black, disk black, carbon black (CB), carbon fiber (for example, registration) Vapor growth carbon fiber named VGCF, which is a trademark), carbon nanotube (CNT), carbon nanohorn, graphite, graphene, glassy carbon, amorphous carbon and the like, and one or more of these may be used.

    When the total of the active material, binder, and conductive additive contained in the positive electrode is 100% by mass, it is preferable that 0 to 20% by mass of the conductive aid is contained. That is, the conductive auxiliary agent is contained as necessary. When it exceeds 20 mass%, since the ratio of the active material as a battery is small, an electrode capacity density tends to become low.

    The positive electrode binder is a commonly used binder such as polyvinylidene fluoride (PVdF), polytetrafluoroethylene (PTFE), polyimide (PI), polyamide, polyamideimide, polyacryl, styrene butadiene rubber (SBR), ethylene. -Vinyl acetate copolymer (EVA), styrene-ethylene-butylene-styrene copolymer (SEBS), carboxymethylcellulose (CMC), chitansan gum, polyvinyl alcohol (PVA), polyvinyl butyral (PVB), ethylene vinyl alcohol, polyethylene ( PE), polypropylene (PP), polyacrylic acid, lithium polyacrylate, sodium polyacrylate, potassium polyacrylate, ammonium polyacrylate, methyl polyacrylate, polyacrylic acid Chill, polyacrylate amine, polyacrylate ester, epoxy resin, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), nylon, vinyl chloride, silicone rubber, nitrile rubber, cyanoacrylate, urea resin, melamine resin, phenol resin , Latex, polyurethane, silylated urethane, nitrocellulose, dextrin, polyvinylpyrrolidone, vinyl acetate, polystyrene, chloropropylene, resorcinol resin, polyaromatic, modified silicone, methacrylic resin, polybutene, butyl rubber, 2-propenoic acid, cyanoacrylic acid , Methyl methacrylate, glycidyl methacrylate, acrylic oligomer, 2-hydroxyethyl acrylate, polyacetal, alginic acid, den Emissions, sucrose, to sell, glue, casein, may also be an organic material such as cellulose nanofibers alone or in combination of two or more thereof. Moreover, what mixed these organic binders and inorganic binders may be used.

    The inorganic binder may be, for example, a silicate type, a phosphate type, a sol type, or a cement type. However, when a positive electrode is manufactured using only an inorganic binder, the specific gravity of the inorganic binder is large, and thus the electrode energy density per weight tends to be low.

    Conventionally, when using a positive electrode active material of sulfur type, vanadium type, or solid solution type, the positive electrode binder is highly bonded from the viewpoint of suppressing the volume change of the active material accompanying charge / discharge and improving the cycle life characteristics of the battery. However, in the present invention, since the volume change can be suppressed by the skeleton-forming agent, all of the above-mentioned commonly used ones can be used.

    When the total of the active material, binder, and conductive additive contained in the positive electrode is 100% by mass, the binder is preferably contained in an amount of 0.1-60% by mass. When the binder is less than 0.1% by mass, the mechanical strength of the electrode is low, so that when the skeleton is formed, the active material tends to fall off, and the cycle life characteristics of the battery may be deteriorated. On the other hand, when it exceeds 60% by mass, the ionic conductivity is low, the electric resistance is high, and the ratio of the active material as a battery is small, so that the electrode capacity density tends to be low.

    The current collector used for the positive electrode is not particularly limited as long as it is a material that has electronic conductivity and can conduct electricity to the held positive electrode active material. For example, conductive materials such as C, Ti, Cr, Ni, Cu, Mo, Ru, Rh, Ta, W, Os, Ir, Pt, Au, and Al, and alloys containing two or more of these conductive materials ( For example, stainless steel) can be used. When a material other than the above-described conductive material is used, for example, a multi-layered structure of dissimilar metals such as iron coated with Al may be used. From the viewpoint of high electrical conductivity and good stability in the electrolytic solution, the current collector is preferably C, Ti, Cr, Au, Al, stainless steel or the like, and C from the viewpoint of oxidation resistance and material cost. Al, stainless steel and the like are preferable. More preferably, carbon-coated Al and carbon-coated stainless steel are preferable.

    The shape of the current collector includes a linear shape, a rod shape, a plate shape, a foil shape, and a porous shape. Among these, a porous shape is obtained because the packing density can be increased and the skeleton-forming agent easily penetrates into the active material layer. It may be. Examples of the porous shape include a mesh, a woven fabric, a non-woven fabric, an embossed body, a punched body, an expanded body, and a foamed body. Among these, the shape of the current collecting base material is an embossed body because of excellent output characteristics, or A foam is preferred.

    Moreover, this electrode is an electrode for nonaqueous electrolyte secondary batteries, Comprising: The frame | skeleton formation agent of any one of Claim 1 thru | or 7 exists in an active material layer at least. According to this configuration, by applying a skeleton-forming agent to the electrode, the skeleton-forming agent penetrates into the active material layer, thereby forming a strong skeleton in the active material layer. Thereby, the volume change of an electrode is relieve | moderated and the insulation of the electrode surface improves.

    In this electrode, the skeleton-forming agent according to any one of claims 1 to 7 is present in the active material layer, and a gap exists between the active materials in the active material layer. To do. According to this configuration, by applying a skeleton-forming agent to the electrode, the skeleton-forming agent penetrates into the active material layer, so that the gap between the active materials in the active material layer is not completely filled with the skeleton-forming agent, A gap between the active materials remains. Thereby, the expansion and contraction of the active material during charge / discharge is allowed, and the occurrence of wrinkles, cracks and the like of the current collector of the electrode is suppressed.

    In addition, this electrode has a layer containing the alkali-resistant inorganic particles on the surface of the layer of the silicate skeleton-forming agent. According to this configuration, by providing the layer of inorganic particles, it is possible to form a strong skeleton and to suppress the occurrence of peeling and cracks during drying. In addition, the layer of inorganic particles can replace the separator, and a battery can be configured without using a separate separator. In addition, when the skeleton forming agent is phosphate-based, a layer containing acid-resistant inorganic particles is used.

Preferably, in this electrode, the skeleton forming agent per unit area of the electrode coated on one side is 0.01 mg / cm ² or more and 3 mg / cm ² or less, or the unit area of the electrode coated on both sides the skeleton-forming agent per are, at 0.02 mg / cm ² or more 6 mg / cm ² or less. More preferably, the skeleton forming agent per unit area of the electrode coated on one side is 0.05 mg / cm ² or more and 3 mg / cm ² or less, or the unit per unit area of the electrode coated on both sides The skeleton-forming agent is 0.1 mg / cm ² or more and 6 mg / cm ² or less.

    In addition, the electrode includes an active material that can be alloyed with an alkali metal or an active material that can occlude alkali metal ions, an organic binder, and the skeleton-forming agent.

    Preferably, in this electrode, when the total solid content of the active material, the conductive additive, the binder, and the skeleton-forming agent is 100% by mass, the skeleton-forming agent is preferably 0.1% by mass or more and 30% by mass or less. Preferably, they are 0.2 mass% or more and 20 mass% or less, More preferably, they are 0.5 mass% or more and 10 mass% or less.

    The separator according to the present invention is a separator for a nonaqueous electrolyte secondary battery, wherein the skeleton-forming agent according to any one of claims 1 to 7 is present at least on the surface. And

    According to this configuration, the separator has high strength, excellent heat resistance, and improved cycle life characteristics. Here, what is generally used for a nonaqueous electrolyte secondary battery can be used for a separator. Moreover, it does not specifically limit as a material of a separator. The separator may be coated or filled with a ceramic layer so as not to melt down due to local heat generation during a short circuit. Examples of the shape of the separator include a microporous film, a woven fabric, a nonwoven fabric, and a green compact, and the shape is not particularly limited.

    By applying the skeleton-forming agent to the separator, the separator base material melts down due to local heat generation at the time of the short circuit, and the short circuit of the battery can be suppressed. Moreover, since the oxidation of the separator on the positive electrode side can be suppressed when the battery is charged, the self-discharge of the battery is suppressed. In addition, since the heat resistance of the separator is improved, the safety of nail penetration and overcharge is improved.

    Further, the silicate skeleton-forming agent may contain inorganic particles such as ceramics having alkali resistance. In that case, the particle diameter of the ceramic is preferably in the range of 0.2 to 20 μm, and more preferably in the range of 0.25 to 10 μm. However, in the phosphate system, inorganic particles such as ceramics having acid resistance may be included. In that case, it is the same as the silicate system.

    In addition, the separator which apply | coated and filled the frame | skeleton formation agent with respect to the ceramic layer of the existing ceramic coat separator, and may improve the heat resistance may be sufficient.

    The porosity of the separator is preferably 30% or more, and more preferably 40% or more and 90% or less from the viewpoint of alkali metal ion conductivity and dendrite resistance. Moreover, it is preferable that the air permeability obtained by the Gurley test method is 3000 seconds / 100 cc or less. Here, the porosity was calculated from the apparent density of the separator and the true density of the solid content of the constituent material by the formula of porosity (%) = 100− (apparent density of the separator / true density of the material solid content) × 100. Value. The Gurley air permeability is an air resistance according to a Gurley tester method defined in JIS P 8117.

Preferably, in the separator, the skeleton forming agent per unit area of the separator coated on one side is 0.01 mg / cm ² or more and 3 mg / cm ² or less, or the unit area of the separator coated on both sides is the skeleton-forming agent per are, at 0.02 mg / cm ² or more 6 mg / cm ² or less.

    A method for producing an electrode according to the present invention is a method for producing an electrode of a nonaqueous electrolyte secondary battery, wherein a skeleton-forming agent containing a silicate having a siloxane bond as a component or a skeleton-forming agent containing a phosphate is used. Step A applied to the surface of the active material layer of the electrode and Step B for drying the electrode. According to this configuration, an electrode having excellent heat resistance, high strength, and improved cycle life characteristics can be produced by using the skeleton-forming agent for producing the electrode.

    Further, in this electrode manufacturing method, in the step A, the skeleton-forming agent penetrates from the surface of the active material layer to the inside.

    In the electrode manufacturing method, the step A is a step of impregnating the electrode in a tank containing the skeleton-forming agent.

    Preferably, in this electrode manufacturing method, the solid content concentration of the silicate or phosphate in the skeleton forming agent is 0.1 to 30 parts by mass, and the step B is performed at a temperature of 60 ° C. or higher. This is a heat treatment step. If it is dried at a temperature lower than 60 ° C., the binding strength with the electrode and the separator is low, and these moisture cannot be sufficiently removed, so that it is difficult to obtain stable life characteristics when the battery is assembled.

    Here, the method for producing the electrode is, for example, by applying a slurry obtained by mixing an active material, a binder, and a conductive additive added as necessary, into a current collector, and temporarily drying, The electrode is obtained by filling the active material layer with water in which the skeleton-forming agent is dissolved and performing heat treatment at 60 ° C. or higher. That is, the electrode obtained by the slurry coating method is obtained by filling the active material layer with the skeleton-forming agent and heat-treating the electrode. The temporary drying is not particularly limited as long as the solvent in the slurry can be volatilized and removed, and examples thereof include a method of performing a heat treatment in the atmosphere at a temperature of 50 to 200 ° C.

    In addition, since the heat treatment can shorten the heat treatment time and the strength of the skeleton-forming agent is improved when the temperature becomes high, the heat treatment is preferably 80 ° C. or higher, more preferably 100 ° C. or higher, desirably 110 ° C. It is above ℃. The upper limit temperature of the heat treatment is not particularly limited as long as the current collector does not melt, and may be raised to, for example, about 1000 ° C. which is the melting point of copper. In the case of a conventional electrode, the upper limit temperature was estimated to be much lower than 1000 ° C. because the electrode binder may be carbonized or the current collector may be softened. The upper limit of the temperature is 1000 ° C. because the agent exhibits excellent heat resistance and is stronger than the strength of the current collector.

    Moreover, the time of heat processing can be performed by hold | maintaining for 0.5 to 100 hours. The atmosphere for the heat treatment may be in the air, but it is preferable to perform the treatment in a non-oxidizing atmosphere in order to prevent the current collector from being oxidized. Under a non-oxidizing atmosphere means an environment where the amount of oxygen gas is less than in air. For example, a reduced pressure environment, a vacuum environment, a hydrogen gas atmosphere, a nitrogen gas atmosphere, a rare gas atmosphere, or the like may be used.

    In the case of an electrode using a material having an irreversible capacity, it is preferable that the irreversible capacity is canceled by lithium doping. The lithium doping method is not particularly limited. For example, (i) a local cell is formed by attaching metal lithium to a portion where there is no active material layer on the electrode current collector and injecting it, thereby forming an electrode active material. A method of doping lithium into the active material layer, and (ii) a method of doping metal lithium on the active material layer on the electrode current collector and forcibly short-circuiting by pouring, and doping lithium into the electrode active material, (iii) ) A method in which metallic lithium is deposited on the active material layer by vapor deposition or sputtering, and lithium is doped into the electrode active material by solid-phase reaction. (Iv) The electrode before battery construction is electrochemically applied in an electrolyte solution. Examples thereof include a method of doping lithium, and (v) a method of doping lithium into the active material by adding metallic lithium to the active material powder and mixing it.

    In addition, as an electrode manufacturing method, for example, an active material or an active material precursor is formed on the current collector using a chemical plating method, a sputtering method, a vapor deposition method, a gas deposition method, or the like. Although it is good also as the method of integrating, the slurry coating method is preferable from a viewpoint of the lyophilic property of a frame | skeleton formation agent, and electrode manufacturing cost.

    A battery according to the present invention includes the electrode according to any one of claims 8 to 13 or the separator according to claim 14. According to this configuration, a battery having excellent cycle life characteristics and good safety can be obtained.

    For example, in the case of a battery using the above-described electrode (positive electrode or negative electrode), a battery structure in which the positive electrode and the negative electrode are joined via a separator and sealed in an electrolytic solution can be considered. The structure of the battery is not limited to this, and can be applied to existing battery forms and structures such as a stacked battery and a wound battery.

  The electrolyte used in this battery may be any liquid or solid that can move alkali metal ions from the positive electrode to the negative electrode, or from the negative electrode to the positive electrode, and is the same as the electrolyte used in a known nonaqueous electrolyte secondary battery. Can be used. For example, an electrolytic solution, a gel electrolyte, a solid electrolyte, an ionic liquid, and a molten salt are exemplified. Here, the electrolytic solution refers to a solution in which an electrolyte is dissolved in a solvent.

Since the electrolyte needs to contain an alkali metal ion, the electrolyte salt is not particularly limited as long as it is used in a non-aqueous electrolyte secondary battery, but lithium salt, sodium salt, potassium salt, etc. Alkali metal salts are preferred. Examples of the alkali metal salt include lithium hexafluorophosphate (LiPF ₆ ), lithium perchlorate (LiClO ₄ ), lithium tetrafluoroborate (LiBF ₄ ), lithium trifluoromethanesulfonate (LiCF ₃ SO ₄ ), lithium bistrifluoromethane. Sulfonimide (LiN (SO ₂ CF ₃ ) ₂ ), lithium bispentafluoroethanesulfonyl imide (LiN (SO ₂ C ₂ F ₅ ) ₂ ), lithium bisoxalate borate (LiBC ₄ O ₈ ), sodium hexafluorophosphate , Sodium perchlorate, sodium tetrafluoroborate, sodium trifluoromethanesulfonate and sodium trifluoromethanesulfonate, potassium hexafluorophosphate, potassium perchlorate, potassium tetrafluoroborate, It is possible to use at least one or more selected from the group consisting of such as trifluoromethane sulfonic acid potassium and trifluoromethanesulfonic acid imide potassium.

    Examples of the solvent for the electrolyte include propylene carbonate (PC), ethylene carbonate (EC), dimethyl carbonate (DMC), diethyl carbonate (DEC), ethyl methyl carbonate (EMC), γ-butyrolactone (GBL), and methyl-γ- Butyrolactone, methyl lactone, 2-methyltetrahydrofuran, 1,3-dioxolane (DOL), 4-methyl-1,3-dioxolane, 1,2-dimethoxyethane, 1,2-diethoxyethane, diethyl ether, furan, dimethyl Furan, tetrahydrofuran (THF), methyltetrahydrofuran (MeTHF), tetrahydroplan (THP), dioxane (DIOX), crown ether, dimethoxymethane (DMM), dimethoxyethane (DME), diglyme, Triglyme, tetraglyme, methyl acetate (MA), ethyl acetate (EA), propyl acetate, isopropyl acetate, butyl acetate, methyl fluoroacetate, ethyl trifluoroacetate, methyl propionate, ethyl propionate, propyl propionate, methyl formate, Ethyl formate, propyl formate, ethyl butyrate, propyl butyrate, propyl methylbutyrate, vinyl acetate, methyl cyanoacetate, γ-valerolactone, σ-valerolactone, ε-caprolactone, γ-hexalactone, γ-undecalactone, phosphoric acid Trimethyl (TMP), triethyl phosphate (TEP), tri-n-propyl phosphate, trioctyl phosphate, triphenyl phosphate, N, N-dimethylformamide (DMF), ethylenediamine, pyridine, N-methylimidazo Dimethyl sulfate, dimethyl sulfite, dipropyl sulfite, ethylene sulfite, dimethyl sulfone, ethyl methyl sulfone, diphenyl sulfone, sulfolane, methyl sulfolane, methyl methanesulfonate, methyl benzenesulfonate, methyl trifluoromethanesulfonate, Propanesulfone, butanesulfone, dimethylsulfoxide, diphenyldisulfide, dimethylsulfide, diethylsulfide, acetonitrile, propanenitrile, adiponitrile, valeronitrile, glutanitrile, malononitrile, succinonitrile, pimelonitrile, suberonitrile, isobutyronitrile, biphenyl, anhydrous succinate Acid, t-butylbenzene, naphthalene, cyclohexylbenzene, benzotriazole, thio , Toluene, methyl ethyl ketone, benzene, fluorobenzene, hexafluorobenzene, nitromethane, N, N-dimethylformamide, dimethyl sulfoxide, vinylene carbonate (VC), vinyl ethylene carbonate (EVC), fluoroethylene carbonate (FEC), ethylene sal At least one selected from the group consisting of fight (ES) can be used.

    Ionic liquids and molten salts are classified into pyridine type, alicyclic amine type, aliphatic amine type, etc., depending on the type of cation (cation). Various ionic liquids or molten salts can be synthesized by selecting the type of anion (anion) to be combined therewith. As cations, ammonium, phosphonium ions, inorganic ions such as imidazolium salts and pyridinium salts, and examples of anions used include halogens such as bromide ions and triflate, borons such as tetraphenylborate, hexafluoro Phosphorus such as phosphate.

The ionic liquid and the molten salt include, for example, a cation such as imidazolinium, Br—, Cl—, BF ₄ —, PF ₆ —, (CF ₃ SO ₂ ) ₂ N—, CF ₃ SO ₃ —, FeCl _4. It can be obtained by a known synthesis method comprising a combination with an anion such as-. If it is an ionic liquid or molten salt, it can function as an electrolyte without adding an electrolyte.

    An electrical apparatus according to the present invention includes the battery according to claim 19.

    Examples of electrical equipment include irons, foamers, integrated computers, clothes dryers, medical equipment, intercoms, wearable terminals, video equipment, air conditioners, air circulators, horticulture machines, motorcycles, ovens, music players, music recorders , Hot air heaters, toys, car components, flashlights, loudspeakers, car navigation systems, cassette cookers, household storage batteries, nursing care machines, humidifiers, dryers, oil dispensers, water dispensers, suction machines, safes, glue guns, mobile phones, Portable information devices, air purifiers, air-conditioning clothes, game machines, fluorescent lamps, hair removal machines, cordless phones, coffee makers, coffee warmers, ice shavers, kotatsu, copy machines, haircuts, shavers, lawn mowers, automobiles, Lighting equipment, dehumidifier, sealer, shredder, automatic external defibrillator, rice cooker, stereo, strike Speaker, trouser press, smartphone, rice mill, washing machine, toilet seat with washing function, sensor, fan, submarine, blower, vacuum cleaner, tablet, body fat scale, fishing gear, digital camera, TV, TV receiver, TV Games, displays, disk changers, desktop computers, railways, TVs, electric carpets, desk lamps, electric heaters, electric pots, electric blankets, calculators, electric carts, electric wheelchairs, electric tools, electric cars, electric brushes, electric toothbrushes, Telephone, electric bicycle, electric shock insecticide, electromagnetic cooker, electronic notebook, electronic musical instrument, electronic lock, electronic card, microwave oven, electronic mosquito trap, electronic cigarette, telephone, toaster, dryer, transceiver, clock, drone, garbage disposal machine , Notebook computers, incandescent bulbs, soldering irons, panel heaters , Halogen heater, fermenter, baking machine, hybrid vehicle, personal computer, personal computer peripherals, clippers, panel heater, video camera, video deck, airplane, emergency light, emergency storage battery, ship, beauty equipment, printer, copier , Crusher, sprayer, facsimile, forklift, plug-in hybrid car, projector, hair dryer, hair iron, headphones, disaster prevention equipment, crime prevention equipment, home theater, hot sand maker, hot plate, pump, aromatic machine, massage machine, mixer, mill , Movie player, monitor, mochi machine, water heater, floor heating panel, radio, radio cassette, lantern, radio control, laminator, remote control, range, water heater, refrigerator, cool air fan, cool air fan, air conditioner, robot, work Pro, GPS, etc.

    Unlike the case where it uses as a binder, the frame | skeleton formation agent which concerns on this invention can suppress generation | occurrence | production of a wrinkle, a crack, etc. unlike the case where it uses as a binder. In addition, life characteristics better than the conventional one can be obtained. In addition, even when the active material layer has high electronic conductivity, heat generation due to an internal short circuit can be reduced.

It is a figure which shows the cross section of the electrode which applied the frame | skeleton formation agent concerning one Embodiment of this invention. It is a figure which shows an example of application | coating of the frame | skeleton formation agent concerning one Embodiment of this invention. It is a figure which shows an example of the manufacturing process of the electrode concerning one Embodiment of this invention. It is a figure which shows the cycle life characteristic of the electrode concerning one Embodiment of this invention. It is a figure which shows the relationship between the skeleton density of the electrode concerning one Embodiment of this invention, and discharge capacity. It is a figure which shows the cycle life characteristic of the electrode concerning one Embodiment of this invention. It is a figure which shows the relationship between the skeleton density of the electrode concerning one Embodiment of this invention, and discharge capacity. It is a figure which shows the cycle life characteristic of the electrode concerning one Embodiment of this invention. It is a figure which shows the cycle life characteristic of the electrode to which the frame | skeleton formation agent containing surfactant concerning one Embodiment of this invention is applied. It is the figure which compared the cycle life characteristic of the electrode which applied the frame | skeleton formation agent concerning one Embodiment of this invention, and the electrode which is not applied. It is the figure which compared the cycle life characteristic of the electrode which applied the frame | skeleton formation agent concerning one Embodiment of this invention, and the electrode which is not applied. It is a figure which shows the cross section of the electrode which applied the frame | skeleton forming agent containing the inorganic particle concerning one Embodiment of this invention. It is a figure which shows the initial stage charge / discharge curve of the battery which does not use the separator concerning one Embodiment of this invention. It is a figure which shows the SEM image of Si granule to which the frame | skeleton formation agent concerning one Embodiment of this invention is applied. It is a figure which shows the charging / discharging curve in each rate concerning one Embodiment of this invention. It is a figure which shows the result of the peeling test which compared the electrode which applied the frame formation agent concerning one Embodiment of this invention, and the electrode which is not applied. Silicate (Na ₂ O · nSiO ₂₎ shows an X-ray diffraction (XRD) patterns of the powder. It is a diagram showing the cycle life characteristics and after 200 cycles of the electrodes of the electrode of reference example containing an alkali metal silicate _{(Li 0.05 Na 1.95 O · 2.8SiO} 2) as a binder. It is a copy of the photograph which shows the electrical power collector in the conventional Si negative electrode. It is a figure which shows the glow discharge emission-spectral-analysis result which compared the electrode which coat-impregnated the frame | skeleton formation agent, and the electrode which is not coat-impregnated. It is a figure which shows the silicate system molecular formula and the phosphate system molecular formula.

Hereinafter, although one embodiment concerning the present invention is described based on a drawing, the present invention is not limited to this embodiment. In particular, in this embodiment, an electrode of a lithium secondary battery (lithium ion battery) will be described as an example, but the present invention is not limited to this. Further, as an example of the skeleton-forming agent, an alkali metal silicate aqueous solution mainly containing Na ₂ O.3SiO ₂ will be described, but the skeleton-forming agent is not limited thereto.

-First embodiment-
[1. Electrode manufacturing method]
First, as an example of this embodiment, a method for manufacturing an electrode of a lithium secondary battery will be described. In addition, although an electrode has a negative electrode and a positive electrode, a negative electrode and a positive electrode mainly differ in a collector and an active material, and the manufacturing method is the same. Therefore, the manufacturing method of a negative electrode is demonstrated and the manufacturing method of a positive electrode is abbreviate | omitted suitably.

    The negative electrode is manufactured by applying an electrode material to a copper foil. First, for example, a rolled copper foil having a thickness of 10 μm is manufactured, and a copper foil wound in advance in a roll shape is prepared. The negative electrode material is made into a paste by mixing artificial graphite obtained by baking and graphitizing a carbon precursor with a binder, a conductive aid or the like. In this embodiment, as an example, PVdF is used as a binder, and acetylene black (AB) is used as a conductive additive. Then, an electrode material is applied to the surface of the copper foil, dried, and pressure-treated to complete the negative electrode body.

    The positive electrode is manufactured by applying an electrode material to an aluminum foil. The electrode material for the positive electrode is made into a paste by mixing lithium-transition metal oxide with a binder, a conductive additive or the like. In this embodiment, as an example, PVdF is used as the binder and AB is used as the conductive additive. Hereinafter, the positive electrode body and the negative electrode body may be collectively referred to as an electrode body, the copper foil and the aluminum foil may be collectively referred to as a current collector, and the electrode material applied to the current collector may be referred to as an active material layer.

On the other hand, in this embodiment, the skeleton formation agent used for an electrode main body is prepared beforehand. The skeleton-forming agent is produced by purifying Na ₂ O.3SiO ₂ , which is an alkali metal silicate having a siloxane bond, by dry or wet process, and adjusting the water. For example, according to the following formula 4 in the dry type and according to the following formula 5 in the wet type. At this time, a surfactant is mixed. As an example of the skeleton-forming agent of this embodiment, the solid content concentration of Na ₂ O.3SiO _{2 in} the skeleton-forming agent is 5% by mass, and the surfactant is 0.04% by mass.
Na ₂ CO ₃ + 3SiO ₂ → Na ₂ O.3SiO ₂ + CO ₂ ↑ (Formula 4)
2NaOH + 3SiO ₂ → Na ₂ O.3SiO ₂ + H ₂ O (Formula 5)

    Then, a skeleton-forming agent is applied to the surface of each electrode body to coat the active material layer. The coating method of the skeleton-forming agent is a method of impregnating the electrode body into a tank storing the skeleton-forming agent, a method of dripping or coating the skeleton-forming agent on the surface of the electrode body, spray coating, screen printing, curtain method, spin Perform by coating, gravure coating, die coating, etc. The skeleton-forming agent applied to the surface of the electrode body penetrates into the active material layer and enters the gaps between the active material and the conductive aid. Then, the electrode body is dried by warm air, heating, or the like at 110 ° C. to 160 ° C. to cure the skeleton-forming agent. Thereby, the skeleton forming agent forms the skeleton of the active material layer.

    Finally, each electrode main body, that is, the negative electrode main body and the positive electrode main body is cut to a desired size to complete an electrode having a skeleton formed.

    Moreover, the manufacturing method of an electrode mentioned above is realizable with a manufacturing apparatus. A current collector wound up in a roll shape is sent out, and the electrode material is applied to the current collector in the active material layer coating apparatus, and the electrode material is dried with warm air in the first drying apparatus, and the skeleton forming agent In the coating device, the skeleton-forming agent is applied to the surface of the electrode body, and in the second drying device, the skeleton-forming agent is dried and cured with warm air, and is wound up into a roll again. Finally, the electrode wound in a roll shape is cut into a desired size.

    According to the electrode manufacturing method described above, an electrode having high strength, excellent heat resistance, and improved cycle life characteristics can be continuously manufactured. In addition, by using a silicate having a siloxane bond as a binder and as a skeleton-forming agent, the copper foil does not wrinkle or crack, and the active material layer cracks or warps, and expansion due to the generated gas also occurs. It can be used as an electrode.

    Further, the positive electrode and the negative electrode obtained as described above are joined together via a separator, and sealed in a state of being immersed in an electrolytic solution, whereby a lithium secondary battery can be obtained. According to the lithium secondary battery of this structure, it can function as a lithium secondary battery with good safety. The structure of the lithium secondary battery is not particularly limited, and can be applied to existing battery forms and structures such as a stacked battery and a wound battery.

[2. Electrode configuration]
The negative electrode for a non-aqueous electrolyte secondary battery manufactured by the above manufacturing process includes a copper foil current collector and an active material layer containing an active material, a conductive additive, and a binder on the surface thereof. Further, the surface of the active material layer is coated with a cured skeleton-forming agent, and the cured skeleton-forming agent is also present inside the active material layer. Further, the skeleton-forming agent inside the active material layer is present in these gaps so as to cover the active material, the conductive additive and the binder. The density of the skeleton-forming agent of the active material layer is 0.7 mg / cm ² as an example, it is preferable in the range of 0.1mg~3mg / cm ^2.

The positive electrode includes an aluminum foil current collector and an active material layer containing an active material, a conductive additive, and a binder on the surface thereof. Further, the surface of the active material layer is coated with a cured skeleton-forming agent, and the cured skeleton-forming agent is also present inside the active material layer. Further, the skeleton forming agent inside the active material layer is present in these gaps so as to cover the active material, the conductive additive and the binder. The density of the skeleton-forming agent of the active material layer is 0.5 mg / cm ² as an example, it is preferable that the 0.1mg~3mg / cm ^2.

    The electrode of this embodiment has high strength and excellent heat resistance, and the cycle life characteristics are improved. In addition, as shown in the results of a nail penetration test described later, the nail penetration safety is also improved. In addition, since the skeleton-forming agent is applied from the surface of the electrode by coating or impregnation, the skeleton-forming agent exists in the gap so as to cover the active material, the conductive additive, and the binder inside the active material layer. . That is, when the skeleton-forming agent is kneaded and used in the binder, the skeleton-forming agent is present in the active material layer with almost no gap. In the electrode of this embodiment, there is a certain gap in the active material layer. It will be. Thereby, expansion | swelling and shrinkage | contraction of an electrode are permitted, and generation | occurrence | production of a wrinkle, a crack, etc. of a collector can be suppressed.

[3. Structure of skeleton-forming agent]
As described above, the skeleton forming agent of this embodiment has a solid content concentration of Na ₂ O.3SiO ₂ , which is an alkali metal silicate having a siloxane bond, of 7.5 mass%, and a surfactant of 0.09. % By weight, the rest being water. Note that a surfactant is not essential, but the lyophilicity to the active material layer is improved, and the skeleton-forming agent penetrates uniformly into the active material layer.

In addition, the skeleton-forming agent of this embodiment uses alkali metal sodium silicate Na ₂ O.3SiO ₂ as a silicate, but is not limited to this, and instead of Na, Li, K, triethanolammonium Group, tetramethanol ammonium group, tetraethanol ammonium group, or granidine group.

    The reason why Na is used is that Na has high strength and excellent cycle life characteristics. Moreover, it is also possible to use Na and Li together, and ion conductivity improves by using Li. In this case, Li <Na is preferable, and by doing so, a skeleton-forming agent that maintains a certain strength and has good ion conductivity is obtained. More specifically, when the total of Na and Li is 100 mol%, Na is preferably in the range of 51 to 99%, Li is in the range of 1 to 49%, Na is 70 to 98%, and Li is More preferably, it is in the range of 2 to 30%.

Further, the skeleton-forming agent of this embodiment has a SiO ₂ coefficient of 3, but is not limited thereto, and may be 0.5 or more and 5.0 or less, preferably 2.0 or more and 4.5 or less. More preferably, it is 2.2 or more and 3.8 or less.

    Further, the skeleton-forming agent of the present embodiment can also be used for coating existing electrodes. In this way, the electrode has high strength, excellent heat resistance, and improved cycle life characteristics.

    In addition, the skeleton-forming agent of the present embodiment can be used by coating the surface of the separator. In this way, a separator having high strength, excellent heat resistance, and improved cycle life characteristics is obtained.

[4. Example]
Hereinafter, in this embodiment, examples in which various changes such as the solid content concentration and the skeleton density of the skeleton-forming agent, their tests, results, and effects will be described.

<Examination of n number and skeleton density in Na ₂ O · nSiO ₂ >
(Examples 1 to 18 and Comparative Example 1)
A Si-C granule is used as the electrode active material, and the framework forming agent Na is used under the conditions of 0.2 C-rate, cutoff potential 0.01 V to 1.2 V (vs. Li + / Li), 30 ° C. _This is a test for cycle life characteristics when the solid content concentration of ₂ O.nSiO ₂ is changed from 0 mass% to 20 mass% and the value of n is changed to 2.0, 2.5, and 3.0. Si-C granules (D ₅₀ = 9.8 μm) consist of Si (D ₅₀ = 1.1 μm), artificial graphite (D ₅₀ = 1 μm) (Si: artificial graphite = 29: 71% by mass), and granulation It was produced by spray-drying a suspension composed of an auxiliary agent under conditions of a liquid feeding speed of 6 g / min, a spraying pressure of 0.1 MPa, and a drying temperature of 80 to 180 ° C.

Polyvinyl alcohol (PVA, Poval 1400) was used as the granulation aid. 1 mass% of PVA is contained with respect to 100 mass% of solid content which consists of Si, artificial graphite, and PVA. Note that the value of D ₅₀ indicates the median diameter by a laser diffraction-scattering particle size distribution measurement method.

The test electrode (1.4 mAh / cm ² ) is a slurry (solid content ratio: 85: 3: 1: 1: made of Si—C granulated body, AB, vapor grown carbon fiber (VGCF), copper flakes, PVdF. 10 mass%) was applied to a copper foil, and after being immersed in an aqueous solution in which a predetermined skeleton-forming agent was dissolved, it was produced by heat treatment at 160 ° C. As the counter electrode, metal lithium foil was used. As the separator, a glass nonwoven fabric (manufactured by Toyo Russia Co., Ltd., GA-100) and a polyethylene (PE) microporous membrane (20 μm) were used. As the electrolytic solution, 1.0 M LiPF ₆ / (EC: DEC = 50: 50 vol%, + vinylene carbonate 1% by mass) was used.

Table 1 shows the solid content concentrations of the skeleton-forming agents of Examples 1 to 18 and Comparative Example 1, and the values of n of Na ₂ O · nSiO ₂ . The inorganic skeleton-forming agent is prepared by mixing a mixture of Na ₂ CO ₃ and SiO ₂ so as to have the composition shown in Table 1 below, heating and melting at 1000 ° C. or higher, cooling, and dissolving in water. Produced.

FIG. 4 is a graph showing the cycle life characteristics of Examples 1 to 18 and Comparative Example 1. As is clear from FIG. 4, the negative electrode (Examples 1 to 18) coated with the skeleton-forming agent has greatly improved life characteristics compared to the negative electrode (Comparative Example 1) not coated. Among these, the solid content concentration of Na ₂ O.nSiO ₂ showed particularly excellent cycle life characteristics within the range of 2 to 10% by mass. As for the value of n in Na ₂ O · nSiO ₂ , 3.0 showed particularly excellent cycle life characteristics.

FIG. 5 is a graph showing the relationship between the density (skeleton density) of the skeleton-forming bodies of Examples 1 to 18 and Comparative Example 1 and the discharge capacity at each cycle. As is clear from FIG. 5, in the electrode using Si—C granule (Si: artificial graphite = 29: 71% by mass) as the active material, the skeleton density is 0.04 to 3.15 mg / cm ^2. It can be seen that a sufficient discharge capacity can be obtained in this case. More preferably, the skeleton density is 0.1 to 2.5 mg / cm ² .

(Examples 19 to 36 and Comparative Example 2)
In Examples 19 to 36 and Comparative Example 2, as the active material, the composition of the Si—C granulated body was changed from Si: artificial graphite = 29: 71 mass% to 46:54 mass%, and the capacity density of the test electrode Is 1.2 mAh / cm ^2, and is the same as the previous tests (Examples 1 to 18 and Comparative Example 1). Table 2 shows the solid content concentrations of the skeleton-forming agents of Examples 19 to 36 and Comparative Example 2, and the values of n of Na ₂ O · nSiO ₂ .

FIG. 6 is a graph showing the cycle life characteristics of Examples 19 to 36 and Comparative Example 2. As is apparent from FIG. 6, the life characteristics of the negative electrode (Examples 19 to 36) coated with the skeleton-forming agent are greatly improved compared to the negative electrode (Comparative Example 2) not coated. Among these, the solid content concentration of Na ₂ O.nSiO ₂ showed particularly excellent cycle life characteristics within the range of 2 to 10% by mass. As for the value of n in Na ₂ O · nSiO ₂ , 3.0 showed particularly excellent cycle life characteristics.

FIG. 7 is a graph showing the relationship between the density (skeleton density) of the skeleton-forming bodies of Examples 19 to 36 and Comparative Example 2 and the discharge capacity at each cycle. As is clear from FIG. 7, in the electrode using Si—C granule (Si: artificial graphite = 46: 54 mass%) as the active material, the skeleton density is 0.03 to 3.45 mg / cm ^2. It can be seen that a sufficient discharge capacity can be obtained in this case. More preferably, the skeleton density is 0.1 to 2.5 mg / cm ² .

(Examples 37 to 40 and Comparative Example 3)
In Examples 37 to 40, the active material is Si (D ₅₀ = 1.1 μm), the skeleton-forming agent is Li _0.05 Na _1.95 O.3SiO ₂ , the capacity density of the test electrode is 3.0 mAh / cm ² , and the charge / discharge test Is the same as the previous tests (Examples 1 to 18 and Comparative Example 1), except that the conditions were 0.1 C-rate and cutoff potential of 0.01 V to 1.4 V (vs. Li + / Li). Table 3 shows the solid content concentrations of the skeleton-forming agents of Examples 37 to 40 and Comparative Example 3, and the skeleton density of the electrodes. The inorganic skeleton-forming agent is prepared by mixing a mixture of Li ₂ CO ₃ , Na ₂ CO ₃ and SiO ₂ so as to have the composition shown in Table 3, heating and melting to 1000 ° C. or higher, cooling, It was prepared by dissolving in.

FIG. 8 is a graph showing cycle life characteristics of Examples 37 to 40 and Comparative Example 3. As is clear from FIG. 8, the negative electrode (Examples 37 to 40) coated with the skeleton-forming agent had an initial discharge capacity exceeding 1800 mAh / g, but the negative electrode (Comparative Example 3) that was not coated The discharge capacity was 56.7 mAh / g. As can be seen by comparing the negative electrode coated with the skeleton-forming agent (Examples 37 to 40) and the non-coated negative electrode (Comparative Example 3), a dramatic improvement in cycle life characteristics was shown. Among these, the solid content concentration of Li _0.05 Na _1.95 O.3SiO ₂ showed particularly excellent cycle life characteristics within the range of 0.5 to 2.5% by mass. In an electrode using Si as the active material, it was found that a discharge capacity exceeding 2000 mAh / g can be obtained when the skeleton density is 0.12 to 0.90 mg / cm ² .

    Next, the batteries after charging and discharging (after 20 cycles) of Examples 37 to 40 and Comparative Example 3 were disassembled and the test electrodes were observed. In Comparative Example 3, the active material layer was peeled from the current collector. On the other hand, Examples 37 to 40 were not peeled off from the current collector, and neither wrinkles nor cracks were observed in the current collector. From this result, it was revealed that the electrode coated and filled with the skeleton forming agent improved the adhesion between the active material layer and the current collector and improved the electrode performance.

<Examination of surfactant>
(Example 41 and Example 42)
In Example 41, Si—C granule (Si: artificial graphite = 29: 71% by mass) was used as the electrode active material, and the solid content concentration of Na 2 O · nSiO 2 was 6% by mass and n as the skeleton-forming agent. Other conditions with the value adjusted to 2.5 and the skeleton density adjusted to 0.84 mg / cm ² are the same as in Example 10.

    Example 42 was the same as Example 41 except that 0.05% by mass of a nonionic surfactant (registered trademark: Triton X-100) was added as a skeleton-forming agent.

    FIG. 9 is a graph showing a comparison of cycle life characteristics of an electrode to which a surfactant is not added to a skeleton-forming agent (Example 41) and an electrode to which a surfactant is added to a skeleton-forming agent (Example 42). It is. As apparent from FIG. 9, it can be seen that the cycle life characteristics are improved by adding a surfactant. This is because the lyophilic property of the skeleton-forming agent to the active material layer is improved by the surfactant, and a uniform skeleton is formed in the active material layer. The surfactant of the present embodiment uses a nonionic surfactant, but is not limited thereto, and may be an anionic surfactant, a cationic surfactant, an amphoteric surfactant, or a nonionic surfactant. .

<Nail penetration safety>
(Example 43 and Comparative Example 4)
A test was conducted on the safety of a battery to which a negative electrode using a skeleton-forming agent was applied. The test method is based on a nail penetration test in which a battery model is pierced with a nail and the state of smoke or ignition of the battery model is examined. In the test, a 1.1 Ah battery model in which a plurality of negative electrodes, separators, and positive electrodes were stacked in an aluminum laminate casing and an electrolyte solution was enclosed was used. The positive electrode (4.2 mAh / cm ² ) was produced by applying a slurry of LiNi _0.33 Co _0.33 Mn _0.33 O ₂ , AB, and PVdF to aluminum foil (20 μm) and heat-treating it at 160 ° C. The negative electrode (4.6 mAh / cm ² ) is produced by applying a slurry of artificial graphite (D ₅₀ = 20 μm), AB, and an acrylic binder to a copper foil (10 μm) and then heat-treating it at 160 ° C. It was.

In Example 43, as shown in FIG. 2, the negative electrode was immersed in an aqueous solution in which a skeleton-forming agent was dissolved, and then heat-treated at 150 ° C. Scaffolding agent, Na ₂ O · 3SiO _2, nonionic surfactant (trademark: Triton X-100) in form of an aqueous solution, Na ₂ O · 3SiO solid concentration of ₂ 6 wt%, surfactant The solid content concentration of 0.05% by mass was used. The skeleton density of the electrode is 0.9 mg / cm ² per side. In this test, since the positive electrode and the negative electrode are produced by coating on both sides, the skeleton density on both sides is 1.8 mg / cm ² . A battery using a negative electrode to which no skeleton-forming agent was applied was used as Comparative Example 4.

As the electrolytic solution, 1M LiPF ₆ / ethylene carbonate (EC): diethyl carbonate (DEC) = 50: 50 vol%, and 1% by mass of vinylene carbonate were used. As the separator, a polypropylene (PP) microporous film (23 μm) was used. In the nail penetration test, this battery model was charged to 4.2 V at 0.1 C-rate, and then a steel nail (φ3 mm, round shape) was penetrated into the center of the battery at a speed of 1 mm / sec in a 25 ° C. environment. The battery voltage, nail temperature, and casing temperature were measured.

    In a conventional battery model (Comparative Example 4) using a negative electrode without a skeleton-forming agent, when nail penetration was performed, the battery voltage dropped to 0 V and a large amount of smoke was generated. This is because the separator melts down due to heat generated when a short circuit occurs inside the battery model.

  On the other hand, the battery model using the artificial graphite negative electrode using the skeleton-forming agent (Example 43) maintains a voltage of 3 V or more even when nail penetration is performed, no smoke is generated, and the temperature of the casing and the nail Also, at 50 ° C. or less, almost no heat was generated due to short circuit. This seems to be because the skeleton present in the active material layer of the negative electrode coats the active material to block the movement of electrons and suppress short circuit.

<Electrode peeling test>
(Example 43 and Comparative Example 4)
A peel test of the negative electrode used in the batteries of Example 43 and Comparative Example 4 was performed. The peel test is based on JIS K685, and a pressure-sensitive adhesive tape (Scotch, No. 845, Book Tape) is pressure-bonded to the negative electrode active material layer with a 1 kg roller, and the tensile speed is 300 mm / min and the angle is 180 ° in a 25 ° C. environment. The condition was evaluated. FIG. 16 shows photographs of the negative electrode and the adhesive tape of Example 43 and Comparative Example 4 after the peel test. As is clear from FIG. 16, the negative electrode of Comparative Example 4 that did not use the skeleton-forming agent had the peeled active material layer attached to the adhesive tape, but the negative electrode of Example 43 that used the skeleton-forming agent was The active material layer is hardly attached to the adhesive tape. It was shown that the peel strength is improved.

<Examination of negative electrode active material>
(Examples 44 to 59 and Comparative Examples 5 to 20)
Using various negative electrode active materials shown in Table 4, the effects of the presence or absence of a skeleton-forming agent were compared. In Examples 44 to 59, a slurry composed of the negative electrode active material, AB, and PVdF shown in Table 4 was applied to a copper foil (10 μm), and the active material layer was impregnated with a skeleton-forming agent using a spray gun. It was fabricated by heat treatment at 160 ° C. The solid content ratio of the electrode slurry was 88% by mass for the electrode active material, 4% by mass for AB, and 8% by mass for PVdF.

The skeleton forming agent is an aqueous solution composed of Li _0.05 Na _1.95 O · 3SiO ₂ and a nonionic surfactant (registered trademark: Triton X-100), and the solid content concentration of Li _0.05 Na _1.95 O · 3SiO ₂ is 7.5. A material having a mass% and a surfactant solid content concentration of 0.03 mass% was used. In this test, the test electrode is manufactured by single-sided coating.

    The test battery used lithium metal as a counter electrode and 1M LiPF6 / ethylene carbonate (EC): diethyl carbonate (DEC) = 50: 50 vol%, and 1% by mass of vinylene carbonate as an electrolyte. As the separator, a polypropylene (PP / PE / PP) three-layer microporous film (25 μm) was used. In the charge / discharge test, the current density is 0.1 mA / cm 2 and the test environment temperature is 30 ° C. The cut-off potential, the electrode active material density (one side), the electrode thickness, and the skeleton density (one side) are as shown in Table 4. .

Table 5 is a table | surface which shows the cycle life characteristic test result of each electrode (Examples 44-59) which has frame | skeleton formation. Table 6 is a table showing a cycle life characteristic test result of each electrode (Comparative Examples 5 to 20) that did not form a skeleton as a comparison. As is clear from comparison between Table 5 and Table 6, an electrode using Si, SiO, Ge, In, and Fe ₂ O ₃ as an active material exhibits excellent cycle life characteristics by using a skeleton-forming agent. It was. Among these, the electrode (Example 56 and Comparative Example 17) using Si as the active material showed a particularly remarkable difference. This is probably because the strong skeleton-forming agent was built in the active material layer, thereby suppressing the destruction of the electronic conductive network accompanying the volume change.

On the other hand, in Ag, Ag ₂ O, Sb, Sb ₂ S ₃ , SnO ₂ , CuO, NiO, artificial graphite, and hard carbon, there was no significant difference in cycle life characteristics depending on the presence or absence of a skeleton-forming agent. Since these active materials have a small volume change compared with Si, SiO, Ge, In, and Fe ₂ O ₃ , it is considered that no clear difference was shown in this test condition.

    However, in Sn, the cycle life characteristics deteriorated when a skeleton-forming agent was used. This is probably because Sn had a high dissolution rate in addition to the skeleton-forming agent and the shape of the active material could not be maintained, so that the capacity was deteriorated.

<Examination of mixing ratio of Si and graphite>
(Examples 60 to 63 and Comparative Examples 21 to 24)
In an electrode using a mixture of Si (1 μm) and artificial graphite (19 μm) as a negative electrode active material, the presence or absence of the effect of skeleton formation was compared. In Examples 60 to 63, a slurry composed of the negative electrode active material, AB, and PVdF shown in Table 7 was applied to copper foil (10 μm), and the active material layer was impregnated with a skeleton-forming agent using a spray gun. It was fabricated by heat treatment at 160 ° C.

For comparison, electrodes that were not impregnated with the skeleton-forming agent were prepared (Comparative Examples 21 to 24). The solid content ratio of the electrode slurry was 88% by mass for the electrode active material, 4% by mass for AB, and 8% by mass for PVdF. The skeleton forming agent is an aqueous solution composed of Li _0.05 Na _1.95 O · 3SiO ₂ and a nonionic surfactant (registered trademark: Triton X-100), and the solid content concentration of Li _0.05 Na _1.95 O · 3SiO ₂ is 7.5. A material having a mass% and a surfactant solid content concentration of 0.03 mass% was used. In this test, the test electrode is manufactured by single-sided coating.

The test battery used lithium metal as a counter electrode and 1M LiPF6 / ethylene carbonate (EC): diethyl carbonate (DEC) = 50: 50 vol%, and 1% by mass of vinylene carbonate as an electrolyte. As the separator, a polypropylene (PP / PE / PP) three-layer microporous film (25 μm) was used. In the charge / discharge test, the current density was 0.1 C-rate, the test environment temperature was 30 ° C., and the cutoff potential was 0.0 to 1.4 V (vs. Li + / Li). The skeleton density (one side) is as shown in Table 8. The capacity density of the test electrode was 3.0 mAh / cm ² .

    FIG. 10 is a graph showing a comparison of the cycle life characteristics of Examples 60 to 63 to which the skeleton-forming agent was applied and Comparative Examples 21 to 24 that were not applied to the skeleton-forming agent. As is apparent from FIG. 10, when the total amount of the active material contained in the negative electrode is 100% by mass, an electrode having Si of 10% by mass or less (Example 60, Example 61, Comparative Example 21, and Comparative Example 22). However, although no significant change was observed, the life characteristics of the electrodes (Example 62, Example 63, Comparative Example 23, and Comparative Example 24) having an Si amount of 20% by mass or more were clearly improved. I understand. In particular, in the electrode having 50% by mass of Si (Example 63 and Comparative Example 24), the effect of improving the overwhelming life characteristics was shown by forming a skeleton.

<Examination of various positive electrode materials>
Using each positive electrode active material, the effect on the coating amount of the skeleton-forming agent was compared. The test electrode was prepared by applying a slurry composed of the positive electrode active material, AB, and PVdF shown in Table 9 onto an aluminum foil (20 μm), impregnating the active material layer with a skeleton forming agent using a spray gun, It was produced by heat treatment with. The solid content ratio of the electrode slurry was 90% by mass for the electrode active material, 5% by mass for AB, and 5% by mass for PVdF.

Skeleton-forming agent used in Examples 64 to 72 has a Na ₂ O · 2.8SiO ₂ nonionic surfactant (trademark: Triton X-100) in aqueous solution comprising, solid Na ₂ O · 3SiO ₂ A component having a partial concentration of 5.5% by mass and a surfactant solid content of 0.03% by mass was used. The skeleton-forming agent used in Examples 73 to 81 is an aqueous solution composed of Na ₂ O · 2.8SiO ₂ and a nonionic surfactant (registered trademark: Triton X-100), and is a solid solution of Na ₂ O · 3SiO ₂ . A component having a partial concentration of 1.1% by mass and a surfactant solid content of 0.03% by mass was used.

    Table 9 shows the skeleton density and cut-off potential per one electrode surface of Examples 64-81. However, about Example 72 and Example 81, only the first charge was charged to 4.6V.

In this test, the test electrode is manufactured by applying one side so that the electrode capacity is 2.0 mAh / cm ² . The test battery used lithium metal as a counter electrode and 1M LiPF ₆ / ethylene carbonate (EC): diethyl carbonate (DEC) = 50: 50 vol% as an electrolyte. As the separator, a polypropylene (PP / PE / PP) three-layer microporous film (25 μm) was used. The charge / discharge test was performed at a test environment temperature of 30 ° C. and a charge / discharge rate of 0.1 C-rate up to 1 to 10 cycles.

Table 10 is a table | surface which shows the cycle life characteristic test result of Examples 64-81. As apparent from Table 10, the positive electrode (Examples 64 to 72) having a skeletal density of greater than 0.5 mg / cm ^2, the positive electrode having a skeleton density of 0.5 mg / cm ² or less (Examples 73 to 81) It can be seen that the discharge capacity is small compared to. In the positive electrode, it was found that the skeleton density (one side) is preferably 0.5 mg / cm ² or less.

<High temperature durability of positive electrode>
(Examples 82 to 84 and Comparative Examples 21 to 23)
Example 82 is the same as Example 74 except that the electrode capacity was changed to 1.0 mAh / cm ² and the skeleton density was changed to 0.06 mg / cm ² . Example 83 is the same as Example 76 except that the electrode capacity was changed to 1.0 mAh / cm ² and the skeleton density was changed to 0.07 mg / cm ² . Example 84 is the same as Example 81 except that the electrode capacity was changed to 1.0 mAh / cm ² and the skeleton density was changed to 0.11 mg / cm ² . Comparative Example 21 is the same as Example 74 except that the electrode capacity was 1.0 mAh / cm ² and no skeleton-forming body was provided. Comparative Example 22 is the same as Example 76 except that the electrode capacity was 1.0 mAh / cm ² and no skeleton-forming body was provided. Comparative Example 23 is the same as Example 81 except that the electrode capacity was 1.0 mAh / cm ² and no skeleton-forming body was provided.

All the batteries were produced using the positive electrodes of Examples 82 to 84 and Comparative Examples 21 to 23. The negative electrode ( ² mAh / cm ² ) was prepared by applying a slurry of SiO, AB, and polyimide (PI) to copper foil (40 μm) and then heat-treating at 300 ° C. The solid content ratio of the negative electrode slurry was 79% by mass for the electrode active material, 3% by mass for AB, and 18% by mass for PI. Note that the negative electrode is electrochemically supplemented with Li for an irreversible capacity before being assembled into a battery.

The test battery used 1M LiPF ₆ / ethylene carbonate (EC): diethyl carbonate (DEC) = 50: 50 vol%, and 1% by mass of vinylene carbonate as an electrolytic solution. As the separator, a glass nonwoven fabric (manufactured by Toyo Russia Co., Ltd., GA-100) was used. In the charge / discharge test, the test environmental temperature was set to 80 ° C., and charge / discharge was repeated 10 cycles at a current density of 0.1 C-rate, followed by 30 cycles of charge / discharge at 1 C-rate. The cut-off potentials were 4.15 V to 2.0 V in Example 82 and Comparative Example 21, 4.15 to 2.0 V in Example 83 and Comparative Example 22, and 4.25 V to 2 in Example 84 and Comparative Example 23. 0.0V.

    FIG. 11 is a graph comparing the cycle life characteristics of Examples 82 to 84 with the skeleton-forming agent applied and Comparative Examples 21 to 23 without the skeleton-forming agent. As is clear from FIG. 11, it can be seen that Examples 82 to 84 to which the skeleton forming agent was applied have improved cycle life characteristics as compared with Comparative Examples 21 to 23. When a PVdF binder is exposed to a high-temperature electrolyte, it absorbs the electrolyte and swells to increase the electrode resistance. However, the electrodes (Examples 82 to 84) coated with a skeleton-forming agent having excellent swelling resistance are used. Thus, it seems that the swelling of the binder is suppressed even in an electrolyte solution as high as 80 ° C. Moreover, it is thought that the application | coating of frame | skeleton formation agent to the positive electrode active material layer also suppressed decomposition | disassembly of electrolyte solution, and contributed to the improvement effect of cycle life characteristics.

[5. Effects of this embodiment]
According to the above embodiment, the following effects are obtained. By using a skeleton-forming agent containing A ₂ O.3SiO ₂ (A = Na, Li) for the electrode, the electrode has excellent heat resistance, high strength, and improved cycle life characteristics. In addition, a tough current collector is not essential, and the occurrence of wrinkles and cracks in the current collector can be suppressed. Further, it is not necessary to use a binder with a large irreversible capacity. Moreover, even if the electronic conductivity of the active material layer is high, heat generation due to an internal short circuit can be reduced. Moreover, it has heat resistance exceeding 1000 degreeC and a frame | skeleton formation agent does not carbonize. Even in an electrode using an alloy material having a large volume change and a binder having a low adhesive strength, good life characteristics can be obtained. Further, the active material layer does not swell even when it comes into contact with a high-temperature electrolyte.

-Second embodiment-
[1. Structure of skeleton-forming agent and electrode]
Next, a second embodiment of the present invention will be described. The difference between the second embodiment and the first embodiment is that the skeleton-forming agent mainly contains ceramics. FIG. 12 shows an electrode cross-sectional image of the second embodiment. The skeleton-forming agent of the second embodiment includes a ceramic powder or a solid electrolyte powder excellent in alkali resistance.

    FIG. 3 shows an example of the manufacturing process. By coating the skeleton-forming agent of the second embodiment on the surface of the electrode body, the alumina in the skeleton-forming agent is laminated on the surface of the active material layer to electrically An insulating ceramic layer or a solid electrolyte layer is formed on the surface of the active material layer, and a skeleton-forming agent penetrates into the active material layer.

    As a result, it is possible to form a strong skeleton, to suppress the occurrence of peeling and cracks during drying, and to form a void due to the gap between the inorganic particles and to maintain a good electrolyte solution. Liquidity is obtained. In addition, the ceramic layer can be used instead of the separator, and the battery can be configured without using a separate separator.

[2. Example]
Next, examples in which various changes are made in the second embodiment, such as the composition of the skeleton-forming agent, will be described.

<Examination of the ratio of Na ₂ O.3SiO ₂ and α-Al ₂ O ₃ >
(Examples 85-87 and Comparative Example 23)
Table 11 shows the solid composition of the skeleton-forming agent used in Examples 85-87. In addition, an electrode using polyimide (PI) as a skeleton forming agent was produced (Comparative Example 23). As α-Al ₂ O ₃ , a powder having a median diameter (D ₅₀ ) of 0.95 μm by a laser diffraction / scattering particle size distribution measurement method was used. The solid content concentration of the skeleton-forming agent was 10% by mass when the solid content of Na ₂ O.3SiO ₂ and α-Al ₂ O ₃ was 100% by mass.

The negative electrode (4.0 mAh / cm ² ) is a skeleton forming agent shown in Table 11 using a spray gun after coating and regulating a slurry of SiO, carbon black (CB), and acrylic binder on copper foil (10 μm). Was coated and impregnated into the active material layer and heat-treated at 160 ° C. The skeleton density of the electrode is 3.0 mg / cm ² per side. The solid content ratio of the negative electrode slurry was 90 mass% for SiO, 5 mass% for CB, and 5 mass% for an acrylic binder. Note that the negative electrode is electrochemically supplemented with Li for an irreversible capacity before being assembled into a battery.

The positive electrode (2.0 mAh / cm ² ) was produced by applying a slurry of LiFePO ₄ , CB, and an acrylic binder to an aluminum foil (20 μm) and heat-treating it at 160 ° C. The solid content ratio of the positive electrode slurry was 91% by mass for LiFePO ₄ , 5% by mass for CB, and 4% by mass for the acrylic binder. The test battery used 1M LiPF6 / ethylene carbonate (EC): diethyl carbonate (DEC) = 50: 50 vol%, and 1% by mass of vinylene carbonate as an electrolytic solution.

    In this test, no separator is used. The charge / discharge test was performed at a test environment temperature of 60 ° C. and a current density of 0.1 C-rate. The cutoff potential was 4.0V to 2.5V.

    In FIG. 13, the initial stage charge / discharge curve of the test battery of Examples 85-87 is shown. It turns out that it functions as a battery without using a separator. In Comparative Example 23, no battery test was performed. This is because the electrode resistance is increased by coating PI on the active material layer, and Li ions cannot be doped electrochemically.

<Examination of alkali-resistant ceramic particle size>
As shown in Table 12, the α-Al ₂ O ₃ particle size was changed, and the skeleton-forming agent was applied and dried on the surface of the electrode body, and the coating property, new liquid property, binding property, foamed state, and aggregation were obtained. The state and the sedimentation state were observed. The skeleton-forming agent is an aqueous solution composed of Li _0.05 Na _1.95 O.3SiO ₂ and α-Al ₂ O ₃ . The solid content concentration of the skeleton-forming agent is 25% by mass when the solid content of Li _0.05 Na _1.95 O.3SiO ₂ and α-Al ₂ O ₃ is 100% by mass. In addition, the particle size of the inorganic particle shown in Table 12 means the median diameter (D ₅₀ ) by the laser diffraction / scattering particle size distribution measurement method. As shown in Table 12, in the second embodiment, it can be seen that the particle diameter of the ceramic is preferably in the range of 0.2 to 20 μm.

[3. Effects of this embodiment]
According to the above embodiment, the following effects are obtained. A strong skeleton can be formed on the active material layer by applying the skeleton-forming agent used in the first embodiment and a powder excellent in alkali resistance (D ₅₀ = 0.2 to 20 μm) to the electrode surface. Further, it is possible to suppress the occurrence of peeling and cracks during drying, and pores are formed by the gaps between the inorganic particles, so that good lyophilicity with the electrolyte is obtained. In addition, the ceramic layer can replace the separator, and the battery can be configured without using a separate separator.

-Other embodiments-
<Frame formation of active material granulation>
(Examples 88 to 93)
It is a test about the manufacturing method of Si granule to which a frame formation agent is applied.
The Si granule is sprayed with a suspension composed of Si (D ₅₀ = 1 μm), AB, VGCF and PI under conditions of a liquid feed rate of 5 g / min, a spray pressure of 0.1 MPa, and a drying temperature of 80 to 180 ° C. It dried and produced so that it might become D50 = 5-8 micrometers. The solid content ratio of the suspension is as shown in Table 13.

Next, the Si granule to which the skeleton-forming agent was applied was transferred to the fluidized bed by the granulation obtained by spray drying, and the skeleton-forming agent (Li _0.2 adjusted to a solid content concentration of 0.5% by mass). The particles were coated using Na _1.8 O · nSiO ₂ ). The skeleton-forming agent was adjusted to 1% by mass when the granulated body obtained by spray drying and the skeleton-forming agent were 100% by mass.

    In FIG. 14, the SEM image of Si granule (Examples 88-93) to which the obtained frame | skeleton formation agent was applied is shown. In Example 88, the amount of PI contained in the suspension was small, and it was difficult to obtain a spherical shaped granule, but it was found that a spherical granule was easily obtained as the PI amount increased. It was also found that when fiber-like particles such as VGCF were added, a sea urchin granule was easily formed.

<Aluminum phosphate-based skeleton-forming agent (Example 94)>
The test electrode (4.0 mAh / cm ² ) was prepared by applying a slurry composed of Si (1 μm), CB, and PVdF binder onto copper foil (40 μm) and adjusting the skeleton-forming agent to the active material layer using a spray gun. It was produced by impregnating with a coating and heat-treating at 300 ° C. As the skeleton-forming agent, aluminum phosphate (Al ₂ O ₃ .3P ₂ O ₅ ) was dissolved in water and adjusted to have a solid content of 5% by mass. The skeleton density of the electrode is 2.0 mg / cm ² per side. The solid content ratio of the negative electrode slurry was 90 mass% for Si, 4 mass% for CB, and 8 mass% for the PVdF binder.

The test battery used metal Li as a counter electrode, and used 1 M LiPF ₆ / ethylene carbonate (EC): diethyl carbonate (DEC) = 50: 50 vol%, and 1% by mass of vinylene carbonate as an electrolyte. As the separator, a glass nonwoven fabric (manufactured by Toyo Roshi Co., Ltd., GA-100) was used. The charge / discharge test was performed at a test environment temperature of 30 ° C. and was charged / discharged at a current density of 0.1 C-rate, 0.5 C-rate, and 1.0 C-rate. The cut-off potential was 1.0V to 0.01V. In FIG. 15, the charge / discharge curve in each rate of Example 94 is shown. It was found that even when aluminum phosphate (Al ₂ O ₃ .3P ₂ O ₅ ) was used as the skeleton-forming agent, stable reversible capacity was exhibited.

<Evaluation as binder>
(Comparative Example 24)
This is a test using a skeleton-forming agent as a binder. The binder was adjusted by adding water so that the solid content concentration of the alkali metal silicate (Li _0.05 Na _1.95 O · 2.8SiO ₂ ) was 40% by mass. For the test negative electrode ( ² mAh / cm ² ), a slurry made of Si (D ₅₀ = 1 μm), carbon black, and an inorganic binder was applied to a copper foil (10 μm) and heat-treated at 150 ° C. The solid content ratio of the electrode slurry was 19 mass% for Si, 4 mass% for CB, and 76 mass% for the binder.

(Comparative Example 25)
Comparative Example 25 is the same as Comparative Example 24 except that the alkali metal silicate was changed to the primary aluminum phosphate (Al ₂ O ₃ .3P ₂ O ₅ ) as the binder. In addition, the commercially available reagent (made by Aesar) was used for the aluminum phosphate salt.

(Reference Example 1)
As a binder, alkali metal silicate (Li _0.05 Na _1.95 O · 2.8SiO ₂ ) and α-Al ₂ O ₃ (D ₅₀ = 3 μm) were mixed so as to be ₅₀ : ₅₀ % by mass. It adjusted by adding water so that solid content concentration might be 40 mass%. Other conditions are the same as in Comparative Example 24.

(Reference Example 2)
As a binder, aluminum phosphate (Al ₂ O ₃ .3P ₂ O ₅ ) and α-Al ₂ O ₃ (D ₅₀ = 3 μm) were mixed so as to be ₅₀ : ₅₀ % by mass, and the solid content of the mixture It adjusted by adding water so that a density | concentration might be 40 mass%. Other conditions are the same as in Comparative Example 25.

    In Comparative Example 25, Si and alkali metal silicate reacted during the mixing of the slurry to generate hydrogen gas and the slurry was foamed. In Comparative Example 25 and Comparative Example 26, when temporary drying was performed at 80 ° C., the active material layer expanded and a uniform electrode could not be obtained. Furthermore, when the electrodes of Comparative Example 25 and Comparative Example 26 were heat-treated at 150 ° C., the active material layer contracted greatly in volume, the active material layer cracked, and dropped from the current collector.

    On the other hand, in Reference Example 1, Si and alkali metal silicate reacted during mixing of the slurry to generate hydrogen gas, and the slurry was foamed. However, the active material layer was not expanded by temporary drying at 80 ° C. It was. Furthermore, when this electrode was heat-treated at 150 ° C., volume shrinkage was suppressed as compared with Comparative Example 25, and cracking of the active material layer and falling off from the current collector were eliminated.

    In Reference Example 2, since no hydrogen gas was generated during the mixing of the slurry, the slurry did not foam, and the active material layer did not expand even when temporarily dried at 80 ° C. Further, when this electrode was heat-treated at 150 ° C., the active material layer was not cracked or dropped off from the current collector as compared with Comparative Example 25.

    In Comparative Example 25 and Comparative Example 26, the reason why the active material layer expanded at 80 ° C. was that when the slurry was dried, vaporized gas (water vapor) was trapped in the active material layer, and the active material layer expanded. Seem. Furthermore, at 150 ° C., the active material layer seems to have cracked due to the large volume shrinkage derived from the alkali metal silicate or the aluminum phosphate salt, and the active material layer was detached from the current collector.

On the other hand, Reference Example 1 and Reference Example 2 contain Al ₂ O ₃ having no binding property as a binder, and gas is discharged from between Al ₂ O ₃ and Al ₂ O ₃ particles when the electrode is dried. It seems that the active material layer did not swell. Furthermore, at 150 ° C., Al ₂ O ₃ seems to suppress the volume shrinkage of the alkali metal silicate and the aluminum phosphate salt and prevent the active material layer from cracking and falling off the current collector.

    These phenomena, for example, when the rice cake is heated, the water vapor inside is trapped in the rice cake and expands, but in the case of cookies whose main ingredient is wheat flour, water vapor can be released from the gaps in the wheat flour. This is the same as swelling is less likely to occur.

Using the electrodes of Reference Example 1 and Reference Example 2, a charge / discharge test was performed. The battery is 1M LiPF ₆ / EC: DEC = 50: 50 vol. %, + VC1% by mass), a semi-cell using a polyolefin microporous membrane (20 μm) and a glass nonwoven fabric (GA-100) as a separator and metal Li as a counter electrode was produced. The charge / discharge test was performed at an environmental temperature of 30 ° C., a current density of 0.25 C-rate, and a cut-off potential of 1.5 V to 0.01 V.

    Comparing the initial charge and discharge efficiency, the alkali metal silicate system (Reference Example 1) is 71%, the aluminum phosphate salt system (Reference Example 2) is 67%, and the alkali metal silicate system is more initial. The charge / discharge efficiency was good. This means that the alkali metal silicate has a smaller irreversible capacity than aluminum phosphate.

    FIG. 18 shows the cycle life characteristics of Reference Example 1 and an electrode photograph (current collector side) after 200 cycles. The capacity retention rate after 100 cycles was 78% with respect to the initial discharge capacity of 2609 mAh / g. The formation of a strong inorganic binder (alkali metal silicate) skeleton in the active material layer makes it difficult to destroy the conductive network due to the expansion and contraction of Si, and is considered to have an excellent capacity retention rate. . The reason why a thin copper foil can be used without causing distortion seems to be because the strength of the inorganic binder (alkali metal silicate) is higher than that of copper.

<Confirmation analysis of inorganic skeleton-forming agent>
(Reference Example 3)
This is a test for confirming whether or not the skeleton-forming agent penetrates into the electrode. For the simulated electrode, a slurry made of Al ₂ O ₃ (D ₅₀ = 9 μm), AB, PVdF binder is applied to copper foil (10 μm), and the active material layer is impregnated with a skeleton-forming agent using a spray gun. It was fabricated by heat treatment at 150 ° C. As the skeleton-forming agent, alkali metal silicate (Na ₂ O.3SiO) was dissolved in water and adjusted to have a solid content of 8% by mass. In addition, surfactant is not added. The solid content ratio of the simulated electrode slurry was 85% by mass for α-Al ₂ O ₃ , 5% by mass for CB, and 10% by mass for the PVdF binder.

(Reference Example 4)
Reference Example 4 is the same as Reference Example 3 except that it is an electrode not coated and impregnated with a skeleton-forming agent for comparison. FIG. 20 shows glow discharge emission spectroscopic analysis (GDS) results of Reference Example 3 and Reference Example 4. The GDS measurement conditions were a measurement diameter of 4 mmφ and a Ne gas pressure of 2000 Pa. The measurement wavelength was 121 nm for H, 685 nm for F, 130 nm for O, 156 nm for C, 396 nm for Al, and 251 nm for Si. The time on the horizontal axis is the time for the sputtering treatment and is an index corresponding to the depth direction of the active material layer (direction from the electrode surface to the current collector). The intensity on the vertical axis is the emission intensity and is an index corresponding to the element content. As is clear from FIG. 20, the presence of Si cannot be confirmed in Reference Example 4, whereas in Reference Example 3, Si exists in the deep layer although the presence of Si is not constant from the surface to the inside. Was confirmed. From this result, it was proved that the skeleton-forming agent can penetrate into the active material layer by applying the skeleton-forming agent to the electrode surface.

As described above, the preferred embodiments of the present invention have been described with reference to the drawings, but various additions, modifications, or deletions can be made without departing from the spirit of the present invention. For example, various concentrations and ratios such as the solid content concentration of the alkali metal silicate as the skeleton-forming agent are not limited to the numerical values of the above-described embodiments. In the above-described embodiment, the alkali metal silicate is not limited to A ₂ O.3SiO ₂ (A = Li, Na) Li or Na, and the coefficient of SiO ₂ is not limited to 2-3. Further, the skeleton-forming agent is not limited to primary aluminum phosphate (Al ₂ O ₃ .3P ₂ O ₅ ) as a phosphate, and the coefficient of P ₂ O ₅ is not limited to 3. Therefore, such a thing is also included in the scope of the present invention.

Claims (8)

A skeleton forming agent used for forming a skeleton of an active material layer in an electrode of a nonaqueous electrolyte secondary battery containing an active material capable of being alloyed with an alkali metal or an active material capable of occluding alkali metal ions,
Including a silicate having a siloxane bond as a component or a phosphate,
The silicate has a crystalline or amorphous structure represented by the general formula A ₂ O · nSiO ₂ , and A is at least one of Na and K.
The phosphate has a crystal or amorphous structure represented by the general formula M · nH _x PO ₄ , and M 1 is at least one of Al, Ca, and Mg.
Skeleton-forming agent. N in the general formula of the silicate is 1.6 or more and 3.9 or less,
X in the general formula of the phosphate is 2 or less, and n is 0.5 or more and 5 or less,
The skeleton forming agent according to claim 1. In addition, including a surfactant,
The skeleton forming agent according to claim 1 or 2. In addition, including alkali-resistant or acid-resistant inorganic particles,
The skeleton forming agent according to any one of claims 1 to 3.   An electrode comprising: the skeleton-forming material according to claim 1; and an active material capable of being alloyed with an alkali metal or an active material capable of occluding an alkali metal ion. The skeleton-forming material is
Present at least on the surface of the active material layer,
The electrode according to claim 5. The skeleton-forming material is
Present at least on the surface of the active material layer,
The electrode according to claim 5 or 6. A method for producing an electrode of a nonaqueous electrolyte secondary battery, comprising:
At least an active material that can be alloyed with an alkali metal or an active material that can occlude alkali metal ions, and a conductive additive are kneaded to produce an electrode material that becomes an active material layer. Including a step of manufacturing an electrode by coating an electrode material on the surface of a plate-like, foil-like, or porous collector,
A silicate having a siloxane bond as a component, which has a crystal or amorphous structure represented by the general formula A ₂ O · nSiO ₂ , and A is at least one of Na and K, or a general formula M A skeleton-forming agent containing a phosphate having a crystalline or amorphous structure represented by nH _x PO ₄ and M being at least one of Al, Ca, and Mg, The manufacturing method of an electrode provided with the process A which coats on the surface of this, and the process B which dries the said electrode.