JP4030306B2

JP4030306B2 - Battery manufacturing method

Info

Publication number: JP4030306B2
Application number: JP2001398052A
Authority: JP
Inventors: 明宏深田; 隆一岡崎; 富雄佐藤
Original assignee: NGK Spark Plug Co Ltd
Current assignee: Niterra Co Ltd
Priority date: 2001-12-27
Filing date: 2001-12-27
Publication date: 2008-01-09
Anticipated expiration: 2021-12-27
Also published as: JP2003197208A

Description

【０００１】
【発明の属する技術分野】
この発明は電池の製造方法、特に積層（スタック）タイプのリチウム一次電池等に適した製造方法に関する。
【０００２】
【従来の技術】
近年、ＩＣカードやカード型電卓などの電源用として薄型電池の需要が急速に増大している。代表的なものとしてはリチウムをアノード（電池負極）として用いたリチウム一次電池が知られている。このような薄型電池は、２枚の金属電極板の間に、セパレータにより分離された負極活物質層と正極活物質層とを挟み込む形で積層し、その積層体をケースに封入した構造が知られている。
【０００３】
特開平８−４５４８５には、以下のような技術が開示されている。すなわち、打抜により多数の正極ケースを形成した第一の帯状金属板と、同じく多数の負極ケースを形成した第二の帯状金属板とを対向させ、それら帯状金属板の間に、セパレータ、負極活物質層、正極活物質層及び電解液を挿入し、両帯状金属板を密封する。第一の帯状金属板と第二の帯状金属板とには、それぞれ厚肉の位置規制用金属板が一体化され、その穴にピンを挿通することにより対向配置の位置決めを行う。そして、上記の密封工程が終了後、正極ケース及び負極ケースを位置規制用金属板から切り離すことにより、電池を連続的に製造する方法が開示されている。該公報によると、２つの帯状金属板を密封するために、正極ケースと負極ケースとの周縁にシール材を接着し、そのシール材同士をさらに接着する方法が開示されている。
【０００４】
【発明が解決しようとする課題】
しかし、上記公報に開示された方法には以下のような改良すべき点がある。
▲１▼正極ケース及び負極ケースを金属で構成するため、両者を密封するためのシール材が別途必要であり、製造能率の低下と製造コスト増大とを招く。また、ケースが金属で構成されているため加工が面倒であり、可撓性がそれほど高くないために、ハンドリング時に高荷重が付加されると折れ曲がりや亀裂などを生じやすい。
▲２▼製造された電池は、性能検査や、初期電流安定化のための放電処理を行う必要がある。上記公報の方法では、位置規制用金属板から分離する前の状態においては、全ての電池の正極ケース同士及び負極ケース同士が帯状金属板に一体化され、電気的に導通している。従って、上記の検査や放電処理は、個々の電池を分離した状態でないと行うことができない。この場合、分離後の電池を処理装置へ個別にセットしなければならず、非常に能率が悪い。
【０００５】
本発明の第一の課題は、複数の薄型電池を高能率で製造でき、具体的にはその密封工程をより安価にかつ簡便に行うことができる電池の製造方法を提供することにある。また、第二の課題は、複数の薄型電池を高能率で製造できると共に、その検査や放電処理など、個別の電池の電気的処理を極めて能率的に行うことができる電池の製造方法を提供することにある。
【０００６】
【課題を解決するための手段及び作用・効果】
前記第一の課題を解決するために、本発明の電池の製造方法の第一は、
少なくとも第一シート面に開口する活物質充填室を形成した２枚の高分子材料からなるシート部材を用意し、それらの一方を第一電極活物質を充填するための第一シート部材とし、他方を第一電極活物質と異なる第二電極活物質を充填するための第二シート部材として、それらシート部材を、各活物質充填室が互いに重なり合い、かつ第一シート面同士が対向するように積層し、各活物質充填室に第一電極活物質及び第二電極活物質をそれぞれ充填し、第一シート面と反対側にて該第一電極活物質及び第二電極活物質とにそれぞれ接する第一及び第二の金属電極板を配置し、両シート部材の第一シート面の間に、第一電極活物質及び第二電極活物質とを互いに分離するシート状のセパレータを配置することにより、第一シート部材と第二シート部材とを第一電極活物質ケース及び第二電極活物質ケースとして、第一の金属電極板、第一電極活物質、セパレータ、第二電極活物質及び第二の金属電極板がこの順序で積層された電池単位が形成された積層シートアセンブリを製造する積層シートアセンブリ製造工程と、
電池単位を、第一シート部材及び第二シート部材の切断により分離する分離工程と、
その分離工程の前もしくは後において、個々の電池単位の互いに重なり合う活物質充填室の周囲に沿って、第一シート部材と第二シート部材とを直接結合した封着部を形成する封着工程と、
を含むことを特徴とする。
【０００７】
なお、本発明において第一電極活物質は正極活物質及び負極活物質の一方であり、第二電極活物質は他方である。また、「正極」及び「負極」は、電池起電力取り出しの観点から見た極性を意味し、電気化学的な意味での陽極（アノード）は負極に、陰極（カソード）は正極にそれぞれ相当する。
【０００８】
上記本発明の電池の製造方法の第一によると、正負の電極活物質を収容するための活物質ケースを高分子材料シートにより形成する。具体的には、第一シート部材と第二シート部材とを第一電極活物質ケース及び第二電極活物質ケースとして、第一の金属電極板、第一電極活物質、セパレータ、第二電極活物質及び第二の金属電極板がこの順序で積層された電池単位を形成した積層シートアセンブリを製造する。そして、電池単位の互いに重なり合う活物質充填室の周囲に沿って、第一シート部材と第二シート部材とを直接結合した封着部を形成することにより、電池単位の密封を行う。
【０００９】
上記の方法によると、第一電極活物質ケース及び第二電極活物質ケース、すなわち正極ケースと負極ケースがいずれも高分子材料で構成され、個々の電池単位の互いに重なり合う活物質充填室の周囲に沿って、第一電極活物質ケース及び第二電極活物質ケース、すなわち第一シート部材と第二シート部材とを、直接結合する形で封着部を形成する。従って、両ケースを密封するための別部材が不要となり、製造能率の向上と製造コスト削減を図ることができる。また、ケースが金属ではなく、それよりも弾性や可撓性に優れた高分子材料で構成されいるので、加工がはるかに容易であり、ハンドリング時に多少の荷重や局所変形が生じても、折れ曲がりや亀裂などを生じにくく、不良発生率を低減させることができる。そして、得られる電池自体は、薄膜化が容易な高分子材料でケースが構成されているため、より薄型の電池を得る上で有利であり、電池の可撓性が高いためハンドリングも容易である。
【００１０】
第一シート部材及び第二シート部材は、活物質充填室がシート面内方向にそれぞれ複数配列形成されたものであり、積層シートアセンブリは電池単位がシート面内方向に複数配列形成されたものとすることができる。この場合、電池単位を、第一シート部材及び第二シート部材の切断により分離する。そして、その分離工程の前もしくは後において、個々の個々の電池単位の互いに重なり合う活物質充填室の周囲に沿って、第一シート部材と第二シート部材とを直接結合した封着部を形成することができる。この方法によると、１つの積層シートアセンブリを製造することにより、複数の電池単位を一括製造でき、能率的である。そして、個々の電池単位の分離は、柔軟な高分子材料からなる第一シート部材及び第二シート部材の切断により行われるので、分離の加工が容易であり、バリ等も発生しにくい。なお、封着工程は、この切断の前に行っても切断の後で行ってもいずれでもよいが、切断前に行えばより能率的であり、さらに積層されたシートや活物質等の位置ずれも起こりにくいので、より有利である。
【００１１】
封着部の形成は、第一シート部材と第二シート部材とをなす高分子材料の溶着により行うことができる。この場合、第一シート部材と第二シート部材との基材を熱可塑性樹脂で構成しておき、その基材同士の熱融着にて封着部を形成することができる。他方、第一シート部材と第二シート部材との溶着面に、ホットメルト型接着剤層を形成しておき、この接着剤層同士の溶着を用いるようにすると、より低温で封着部を形成できる。特に、電池単位を、第一電極活物質としてリチウム金属シートを使用し、第二電極活物質としてＭｎＯ_２を使用したリチウム一次電池として構成する場合、封着部の形成を高温の熱融着で行うと、低融点のリチウム金属シートに熱影響が及びやすくなるので、この方法は特に有効である。ホットメルト型接着剤層は、例えば主剤がポリ酢酸ビニル、ポリビニルブチラール、アクリル樹脂、ポリイソブチレンポリアミド、エチレンと酢酸ビニル又はアクリル酸エステルとの共重合物等の熱可塑性樹脂からなるもの、あるいはテルペン樹脂、ロジン誘導体又はゴムなどの天然樹脂からなるものを使用できる。なお、溶着は通常の熱融着を用いてもよいが、超音波溶着を用いると熱発生が小さく、かつ封着部を確実に形成できるので好都合である。
【００１２】
次に、前記第二の課題を解決するために、本発明の電池の製造方法の第二は、高分子材料からなるシート部材に複数の活物質充填室を形成し、それら活物質充填室に電極活物質を充填するとともに、各活物質充填室に対応する位置に、電極活物質と接する電池正極及び負極となる第一及び第二の金属電極板を、異なる活物質充填室に対応するもの同士が互いに絶縁された形でシート面に沿って配置することにより、シート部材を電極活物質ケースとして、第一及び第二の金属電極板と電極活物質とが積層された電池単位が、シート面内方向に複数配列形成された積層シートアセンブリを製造する積層シートアセンブリ製造工程と
電池単位を、シート部材の切断により分離する分離工程とを含み、
シート部材の活物質充填室に隣接する位置に電極リード取出貫通部を形成し、第一及び第二の金属電極板の外縁から延出する第一及び第二の電極リード部を該電極リード取出貫通部内に露出させることを特徴とする。
【００１３】
この発明によると、高分子材料からなるシート部材に複数の活物質充填室を形成し、それら活物質充填室に充填された電極活物質に、電池正極及び負極となる第一及び第二の金属電極板を、異なる活物質充填室に対応するもの同士が互いに絶縁された形でシート面に沿って配置する。すなわち、異なる電池単位をなす金属電極板同士が高分子材料からなるシート部材上に互いに絶縁された状態で配置されるので、個別の電池単位の電気的処理を非分離状態で行うことができる。このような電気的処理は、電池電極に処理用端子を接続して行うことができる。そして、上記本発明によると、シート部材の活物質充填室に隣接する位置に電極リード取出貫通部を形成し、第一及び第二の金属電極板の外縁から延出する第一及び第二の電極リード部を該電極リード取出貫通部内に露出させるようにしたから、その露出する電極リード部に処理用端子を簡単に着脱できる。しかも、電池単位が分離されていないので、処理用端子を、電極リード取出貫通部内に露出する皇族の電極リード部に順次つなぎ換えながら処理を行えばよく、処理能率が飛躍的に高められる。
【００１４】
上記電気的処理としては、電池単位の検査測定処理を例示することができる。この場合、電極リード取出貫通部内に露出させた第一及び第二の電極リード部に測定用端子を接触させることにより、各電池単位の検査測定を分離工程に先立って行うことができる。検査測定項目は、例えば初期電流密度、初期起電力、内部抵抗などであるが、これに限定されるものではない。
【００１５】
また、上記電気的処理は、電池単位の初期電流安定化のための一時的な放電処理とすることができる。この場合、負荷抵抗を介して第一及び第二の電極リード部を短絡させることにより、各電池単位の放電処理を分離工程に先立って行うことができる。
【００１６】
第一及び第二の金属電極板の外縁から延出する第一及び第二の電極リード部は、シート面内方向に互いにずれた位置関係にて、電極リード取出貫通部内に露出させることができる。これによると、第一及び第二の電極リード部が平面的にずれた位置関係で配置されることから、積層シートアセンブリの積層方向における片面側、例えば水平に載置した積層シートアセンブリの上面側にて、正極用と負極用の２つの処理用端子を第一及び第二の電極リード部に接続でき、処理を一層容易にかつ能率的に行うことができる。
【００１７】
なお、上記本発明の第二の概念は、前記本発明の第一と結合することもできる。この場合、シート部材を２枚用いるので、以下のような態様が可能である。
（１）第一シート部材及び第二シート部材の少なくともいずれかの活物質充填室に隣接する位置に電極リード取出貫通部が形成され、第一及び第二の金属電極板の外縁から延出する第一及び第二の電極リード部を、シート面内方向に互いにずれた位置関係にて、電極リード取出貫通部内に露出させる。電極リード取出貫通部は、第一シート部材及び第二シート部材の両方に形成してもよいし、片側にだけを形成するようにしてもよい。後者の場合、その電極リード取出貫通部の形成されたシート部材の第二主表面側から、平面的にずれた位置関係で配置された第一及び第二の電極リード部に、処理用端子を接触させることができる。
【００１８】
（２）第一シート部材及び第二シート部材の活物質充填室に隣接する位置にそれぞれ電極リード取出貫通部を、第一シート部材及び第二シート部材を積層したとき互いに重なり合う位置関係にて形成し、第一及び第二の金属電極板の外縁から延出する第一及び第二の電極リード部を、電極リード取出貫通部内に露出させる。この場合、第一シート部材及び第二シート部材の両方に電極リード取出貫通部が形成されるので、仮に第一及び第二の電極リード部が平面的に重なり合って配置されていても、２つの処理用端子を、第一シート部材及び第二シート部材の各第二主表面側に振り分けて配置し、それぞれ第一及び第二の電極リード部に接触させるようにすればよい。ただし、（１）のように平面的にずれた位置関係で第一及び第二の電極リード部を配置することも可能であり、この場合は、２つの処理用端子を、第一シート部材及び第二シート部材のいずれか一方の第二主表面側に配置することが可能となる。また、このように電極リード取出貫通部を、第一シート部材及び第二シート部材の双方に形成すると、分離後の電池単位において、第一及び第二の電極リード部が、シート部材に基づく２つの活物質ケースの双方に対し、その縁から延出する形態となる。その結果、第一及び第二の電極リード部に最終的な電極端子を取り付けて電池アセンブリを製造する際に、第一及び第二の電極リード部の背後に回りこむシート部材部分が生じなくなるので、組立て工程が容易となる。
【００１９】
【発明の実施の形態】
以下、本発明の実施の形態を、図面を用いて説明する。
図１は、本発明に基づく薄型電池の製造工程の一例を、断面レイアウトにて示すものである。また、図２〜図８は、その主要な工程を平面レイアウトにて示すものである。工程の概略は以下の通りである。すなわち、高分子材料シートに対し、少なくとも第一シート面１ａ，３ａに開口する活物質充填室２，４をシート面内方向にそれぞれ複数配列形成した２枚のシート部材１，３を用意する（図１：工程▲２▼及び工程▲７▼、図３、図７）。それらシート部材１，３は、一方を、第一電極活物質５を充填するための第一シート部材１とし、他方を第一電極活物質と異なる第二電極活物質６を充填するための第二シート部材３として用いる。
【００２０】
図１の工程▲７▼に示すように、第一及び第二のシート部材１，３は、各活物質充填室２，４が互いに重なり合い、かつ第一シート面１ａ，３ａ同士が対向するように積層される。そして、各活物質充填室２，４に第一電極活物質５及び第二電極活物質６がそれぞれ充填される。また、第一シート面１ａ，３ａと反対側においては、第一電極活物質５及び第二電極活物質６とにそれぞれ接する第一及び第二の金属電極板７，８が配置される。そして、両シート部材１，３の第一シート面１ａ，３ａの間に、第一電極活物質５及び第二電極活物質６とを互いに分離するシート状のセパレータ９が配置される。図１においては、便宜のため電池単位１０を１つのみ示しているが、図７に示すように、電池単位１０は、シート部材１，３の面内方向に複数個形成される。
【００２１】
図１の工程▲７▼に戻り、各電池単位１０は、第一シート部材１と第二シート部材３とを第一電極活物質ケース１ｃ及び第二電極活物質ケース３ｃ（ただし、分離後：図１１及び図１２参照）とする形で、第一の金属電極板７、第一電極活物質５、セパレータ９、第二電極活物質６及び第二の金属電極板８がこの順序で積層されたものである。そして、第一及び第二のシート部材１，３に対し、各活物質充填室２，４に上記積層構造をそれぞれ形成することにより、シート面内方向に上記電池単位１０が複数配列形成された積層シートアセンブリ１１が得られる。
【００２２】
そして、図８に示すように、各電池単位１０を、第一シート部材１及び第二シート部材３の切断により積層シートアセンブリ１１から分離することにより、複数の電池単位１０を、該積層シートアセンブリ１１にもとづいて一括製造することができる。なお、図１３の工程▲１▼及び▲２▼に示すように、個々の電池単位１０の互いに重なり合う活物質充填室２，４の周囲に沿って、第一シート部材１と第二シート部材３とを直接結合した封着部１２を形成し、個々の電池単位１０を密封する。図１３の工程▲３▼（あるいは図８）に示すように、本実施形態では、封着部１２の形成を先に行い、その後電池単位１０を、カッター４２を用いて切断するようにしているが、先に電池単位１０の切断・分離を行ってから、個々の電池単位１０毎に封着部１２を形成してもよい。
【００２３】
図１３に示すように、封着部１２の形成は、第一シート部材１と第二シート部材３とをなす高分子材料の溶着により行うことができる。図９に示すように、第一シート部材１及び第二シート部材３は、いずれも厚さが８０〜１００μｍ程度であり、ポリエチレンあるいはポリエステル等の熱可塑性樹脂で構成された基材の両面にホットメルト型接着剤層１３，１３が形成されている。本実施形態では、ホットメルト型接着剤層１３，１３を、厚さ３０〜４０μｍ程度のエチレンと酢酸ビニルとの共重合体（エチレンビニルアセテート（ＥＶＡ）層として形成しているが、これに限定されるものではない。
【００２４】
図１３の工程▲２▼に示すように、封着部１２は、第一シート部材１と第二シート部材３との第一シート面１ａ，３ａ側の接着剤層同士の溶着により形成される。本実施形態では、図１３の工程▲１▼のように、第一シート部材１と第二シート部材３との隙間から、活物質充填室２，４内を減圧排気しつつ、図１３の工程▲２▼に示すように、超音波ホーン４０と封着支持ベース４１との間に第一シート部材１と第二シート部材３とを加圧し、その状態で超音波ホーン４０により超音波印加して、その加圧部近傍のホットメルト型接着剤層１３を溶融させて局所的に溶着を生じさせることにより、封着部１２を形成している。
【００２５】
活物質充填室２，４は、長尺のシート部材に所定間隔で１列のみ形成するようにしてもよい。この場合は、シート部材をロール状に巻き取って使用することで、電池単位の連続生産を行うための便宜をはかることができる。ただし、後述のように、積層シートアセンブリの製造工程の中には、シート部材の裏表を適宜反転させたほうが好都合な場合があり、この場合は、例えば方形のシート部材を単位としたバッチ処理がより実施しやすい。このように、シート部材をバッチ処理で扱う場合等においては、図３〜図７に示すように、第一シート部材１及び第二シート部材３には、活物質充填室２，４を縦横複数個ずつのマトリックス状に形成することが、１組のシート部材１，３から製造できる電池単位１０の製造個数を増加させる観点において望ましい。
【００２６】
図１、図２及び図７に示すように、第一シート部材１と第二シート部材３とは、シート部材１，３に一体的に取り付けられた位置決め部材２０にシート位置決め貫通部２１が形成されている。そして、図１に示すように、シート位置決め貫通部２１に位置決めピン２３を挿通することにより、それら第一シート部材１と第二シート部材３とを活物質充填室２，４が互いに重なり合うように位置決め積層される。シート位置決め貫通部２１の形成位置を、第一シート部材１と第二シート部材３（及び後述するマスク１５，１７，１９）の位置合わせの基準として用い、対応する位置関係にある貫通部に位置決めピン２３を挿通することにより、第一シート部材１と第二シート部材３の位置決め積層を迅速かつ正確に行うことができる。なお、シート位置決め貫通部２１は、シート部材１，３自身に形成してもよいが、シート自体が薄くかつ柔軟であることを考慮すれば、それよりも剛性の高い材質（例えば金属や硬質プラスチック）からなる位置決め部材２０をシート部材１，３に取り付け、その位置決め部材２０に貫通部２１を形成したほうが、位置決めピン２３の挿通時にシート部材１，３を変形させたりする心配がなくハンドリングも容易であり、さらに、貫通部２１への位置決めピン２３の挿通をよりスムーズに行うことができる。なお、位置決め部材２０（及びシート位置決め貫通部２１）を設けるのは、第一シート部材１と第二シート部材３との一方のみとしてもよいが、双方に設けることにより、位置決めの能率と精度とをより向上させることができる。
【００２７】
位置決め部材２０は、第一シート部材１と第二シート部材３とを外周縁部に沿って支持する枠部材２０とすることができる。これにより、比較的柔軟なシート部材１，３を安定的に支持できる。この場合、シート位置決め貫通部は、この枠部材２０に形成された貫通孔２１とすることができる。なお、図２及び図７に示すように、シート位置決め貫通部は位置決め部材２０の一縁に開放する切欠２１ａとしてもよい。例えば、本実施形態のように、第一シート部材１と第二シート部材３とが四辺形状に形成される場合は、枠部材２０は、それらシート部材１，３の少なくとも互いに対向する２辺に設けることが、位置決めピン２３を用いてシート部材１，３を展張状態で積層する上で好都合である。この場合、本実施形態のように、枠部材２０を、第一シート部材１及び第二シート部材３の４辺全てに設け、それらシート部材１，３を展張状態にて支持するものとすれば一層望ましい。
【００２８】
本発明が適用可能な電池の種類は特に限定されるものではないが、本実施形態では一例として、負極活物質５としてリチウム金属（ここではリチウム金属シート）を使用し、正極活物質６としてＭｎＯ_２を使用したリチウム一次電池を対象としている。カソードペーストは、例えば６０〜７０質量％の二酸化マンガン粉末と、５〜１０質量％のカーボンと、エチレンカーボネート、プロピレンカーボネート及びリチウムトリフレート塩（ＬｉＣＦ_３ＳＯ_３）とを主成分とする電解液２５〜３５質量％からなるものが、電池性能の確保の上で好適に使用できる。電解液のより好適な組成として、以下のものを例示できる：
１０〜４０質量％（望ましくは１５〜２５質量％）のエチレンカーボネート；
６０〜９０質量％（望ましくは７５〜８５質量％）のプロピレンカーボネート；０．５〜１．５ｍｏｌの（望ましくは０．８〜１．２質量％）リチウムトリフレート塩。
【００２９】
また、二酸化マンガン粉末は、電解二酸化マンガンのようになるべく表面積の大きい、不定形状のものを用いることが望ましい。好適には平均粒径が１０〜３０μｍ（望ましくは２０〜２５μｍ）であり、ＢＥＴ値（比表面積値）が３０〜５０ｍ^２／ｇ（望ましくは４０〜４５ｍ^２／ｇ）、及び総気孔率が０．０２〜０．０８ｃｍ^３／ｇ（望ましくは０．０４〜０．０６ｃｍ^３／ｇ）であるものを用いることが、電池性能の確保の上で好適である。
【００３０】
以下、図１の説明図の流れに従って、さらに詳細に説明する。
図１の工程▲１▼に示すように、第一シート部材１を、位置決めピン２３を枠部材２０の貫通孔２１に挿通しつつ、台５０の上にセットする。図２に示すように、枠部材２０には、その４つの角部にそれぞれ貫通孔２１が形成されている。また、４つの辺の各中央位置にも貫通孔２１が形成されているが、配置形態はこれに限られるものではない。
【００３１】
第一シート部材１（第二シート部材３も同様：工程▲７▼）は、活物質充填室２（４）がそれぞれシート厚さ方向に貫通する形で形成される。このような貫通形態の活物質充填室２（４）は、例えば図１の工程に▲２▼のように、打抜刃４９（あるいは打抜パンチでもよい）を用いて、通常の打抜法により簡単に形成できる利点がある。なお、図２０に示すように、第一シート部材１及び第二シート部材３に、第一シート面１ａ，３ａにのみ開口し、第二シート面１ｂ，３ｂには開口しない有底の活物質充填室２，４を形成することもできる。この場合、金属電極板７，８は、それら活物質充填室２，４の底面に配置することができる。
【００３２】
図１に戻り、シート部材１は、工程▲３▼（第二シート部材３も同様：工程▲７▼、以下、カッコ内は第二シート部材３の対応符号である）に示すように、第一シート面１ａ（３ａ）と反対側のシート面である第二シート面１ｂ（３ｂ）において、活物質充填室２（４）の開口が、第一金属電極板７（第二金属電極板８）により塞がれる。図４は、これを平面視状態にて表したものである。貫通形態の活物質充填室２（４）は、そのままでは底を有さないので、電極活物質５（６）を収容できない。そこで、第二シート面１ｂ（３ｂ）側の開口を金属電極板７（８）で塞ぐことにより底を形成でき、電極活物質５（６）の収容を問題なく行うことができる。本実施形態において金属電極板７，８は、いずれも厚さ３０〜５０μｍ程度のＣｕ箔を採用している。
【００３３】
金属電極板７（８）は、第二シート面１ｂ（３ｂ）において活物質充填室２（４）の開口周縁部に貼り付けることができる。打抜後のシート部材１（３）の第二シート面１ｂ（３ｂ）に金属電極板７（８）を貼り付けるのみで、活物質充填室２（４）の開口を簡単に塞ぐことができる。具体的には、図１０に示すように、金属電極板７（８）は、シート部材１（３）の第二シート面１ｂ（３ｂ）側に形成されたホットメルト型接着剤層１３を介して、熱接着する方法が簡便であり、かつ貼り付けを確実に行うことができる。本実施形態では、図示しないヒータを有したパンチ３０により、金属電極板７（８）をシート部材１（３）に押し付けながら加熱することにより、圧着形態にて貼り付けを行っている。
【００３４】
なお、第一シート部材１及び／又は第二シート部材３において、第二シート面１ｂ，３ｂ上に、活物質充填室２，４の開口を塞ぐ金属電極板７，８を配置する際は、以下のような工程を採用することができる。すなわち、図１の工程▲３▼及び図１４に示すように、複数の位置決め窓１６が形成された位置決めマスク部材１７を、シート部材１（３）の第二シート面１ｂ（３ｂ）上に、各位置決め窓１６が各活物質充填室２（４）に対応して位置するように重ね合わせ、その状態で各位置決め窓１６内に金属電極板７（８）を配置する。このようにすると、金属電極板７（８）を、シート部材１（３）に対する貼り付け位置に、正確かつ迅速に配置することができる。この場合、シート部材１（３）は、シート位置決め貫通部２１に位置決めピン２３を挿通して位置決めされていることから、位置決めマスク部材１７にマスク位置決め貫通部１７ａを形成しておき、該マスク位置決め貫通部１７ａとシート位置決め貫通部２１とに位置決めピン２３を挿入することにより、位置決めマスク部材１７をシート部材１（３）に正確かつ簡単に位置決め積層することができる。
【００３５】
圧着による金属電極板７の貼り付けは、図１の工程▲３▼に示すように、第一シート部材１を、第二シート面１ｂが上となるように配置して行うと容易である。この場合、活物質充填室２に第一電極活物質５を充填する工程は、工程▲４▼に示すように、金属電極板７を貼り付けた後、第一シート部材１の上下を反転させ、第一の金属電極板７を活物質充填室２の底として用いつつ、第一シート面１ａ側の開口から活物質充填室２に第一電極活物質５（本実施形態では厚さ４〜６μｍ程度のリチウム金属板）を充填するようにして行うことができる。シート反転を行うことで、金属電極板７の貼り付けと第一電極活物質５の充填とを、いずれも簡単活確実に行うことができる。図５は、第一電極活物質５を充填した状態の第一シート部材１の第一シート面１ａ側を平面視した状態を示している。
【００３６】
上記のように第一電極活物質５を第一シート部材１の活物質充填室２に充填した後、工程▲５▼に示すように、該活物質充填室２の第一シート面１ａ側の開口周縁部にセパレータ９を貼り付ける。セパレータ９は、電池反応のイオン通過を許容する厚さに形成された、例えばポリエチレンあるいはポリプロピレン等の樹脂にて構成され、厚さは２０〜３０μｍ程度である。このセパレータ９も、第一シート面１ａ（３ａ）において活物質充填室２（４）の開口周縁部に貼り付けることができる。その具体的な貼り付け方法は、図１０と同様に、第一及び第二のシート部材１，３の少なくともいずれかに対し、第一シート面１ａ（３ａ）側に形成されたホットメルト型接着剤層１３を介してセパレータ９を熱接着する工程を例示できる。セパレータ９を熱接着するのは、シート部材１，３の一方のみとしても、双方としてもいずれでもよいが、本実施形態では、第一シート部材１に熱接着している。このセパレータ９の接着も、図１の工程▲５▼に示すように、セパレータ位置決めマスク１９を用いて行うと便利である。セパレータ位置決めマスク１９には、マスク位置決め貫通部１９ａが形成され、ここに位置決めピン２３を挿入することにより、シート部材１にセパレータ位置決めマスク１９を正確かつ簡単に位置決め積層することができる。そして、セパレータ９は位置決め窓１８内に配置される。
【００３７】
なお、図１５に示すように、シート部材１の活物質充填室２の第一シート面１ａ側の開口をセパレータ９で塞いでおき、これを底として用いて電極活物質５を充填した後、第二シート面１ｂ側の開口を金属電極板７で塞ぐ工程を採用することも可能である。しかし、セパレータ９と比較すれば金属電極板７のほうが剛性が高いので、図１の工程▲４▼のほうが、電極活物質５を充填した後のハンドリングが容易である利点がある。
【００３８】
次に、図１に戻り、工程▲６▼に示すように、第一シート部材１の活物質充填室２に対応する位置において、セパレータ９上に第二電極活物質６を配置する。その後、工程▲７▼に示すように、該配置された第二電極活物質６が第二シート部材３の活物質充填室４内に収容されるように、該第二シート部材３をセパレータ９上に重ね合わせる。第二電極活物質６がハンドリング可能な剛性を有しているものであれば、第二シート部材３を第一シート部材１上に重ね合わせてから、第二電極活物質６を活物質充填室４内に収容することも可能である。しかし、第二電極活物質６がそのような剛性を有していない場合、例えばペースト状のものである場合は、先に積層した第二シート部材３の活物質充填室４内に第二電極活物質６を擦り切り充填しようとすると、第二電極活物質６が第二シート部材３の第二シート面３ｂに残留し、例えば活物質充填室４の開口周縁に貼り付けられる金属電極板８の密封状態が損なわれて活物質の漏れ出し等の問題を生ずる可能性がある。そこで、上記のように、セパレータ９上に第二電極活物質６を先に配置しておき、その後、第二電極活物質６が活物質充填室４内に収容されるように、第二シート部材３をセパレータ９上に重ね合わせるようにすれば、こうした不具合を生じにくくなる。
【００３９】
本実施形態では、前述のように第二電極活物質６がペースト状に形成されている。そこで、図１の工程▲６▼では、以下のような方法を採用している。すなわち、複数のペースト充填窓１４が形成された印刷マスク部材１５を、各ペースト充填窓１４が第一シート部材１の活物質充填室２に対応して位置するように、セパレータ９上に重ね合わせる。そして、その状態でペースト状の第二電極活物質６をペースト充填窓１４内にスキージ４８を用いて擦り切り充填した後、印刷マスク部材１５を取り外すことにより、該第二電極活物質６の塗布パターンを各セパレータ９上に形成する。この方法を用いると、複数の電池単位１０における第二電極活物質６の塗布パターンを、一種の印刷工程により一括して行うことができるので、非常に能率的である。図６は、第二電極活物質６の塗布パターンを形成後の第一シート部材１を平面視状態にて示すものである。
【００４０】
なお、印刷マスク部材１５にはマスク位置決め貫通部１５ａが形成されており、マスク位置決め貫通部１５ａとシート位置決め貫通部２１とに位置決めピン２３を挿入することにより、印刷マスク部材１５を第一シート部材１に正確かつ簡単に位置決め積層することができる。また、第二シート部材３は、第二シート面３ｂに対し活物質充填室４の開口を塞ぐ形で第二の金属電極板８を予め貼り付けたものを、セパレータ９上に重ね合わせるようにすれば、より能率的である。また、第二の金属電極板８をホットメルト型接着剤層により熱圧着する工程が、第二電極活物質６の塗布された第二シート部材３上で実施されないため、その熱影響が第二電極活物質６に及ばない利点もある。
【００４１】
図７は、第二シート部材３の積層により得られる積層シートアセンブリ１１を平面視した様子を示すものである。前述の通り、本実施形態では、図８に示すように、各活物質充填室２，４の周囲に沿って、図１３に示す工程により線状の封着部１２を形成する。この後、各電池単位１０はカッター等により切断・分離されるが、その切断に先立って、本実施形態では電池単位１０にいくつかの電気的処理が実施される。
【００４２】
そして、電気的処理を、電池単位１０を非分離状態で行うために、第一シート部材１及び第二シート部材３には、次のような工夫が施されている。すなわち、図４及び図７に示すように、第一シート部材１及び第二シート部材３の活物質充填室２，４に隣接する位置には、電極リード取出貫通部２４，２４が形成されている。第一シート部材１及び第二シート部材３の各電極リード取出貫通部２４，２４は、第一シート部材１及び第二シート部材３を積層したとき互いに重なり合う位置関係にて形成されている。一方、図１６に示すように、第一及び第二の金属電極板７，８の外縁からは、第一及び第二の電極リード部７ａ，８ａが延出して形成されている。そして、図７に示すように、これら第一及び第二の電極リード部７ａ，８ａが、シート面内方向に互いにずれた位置関係にて、電極リード取出貫通部２４内に露出している。
【００４３】
図１８に示すように、電極リード取出貫通部２４内に露出した第一及び第二の電極リード部７ａ，８ａには、それぞれ各電池単位１０の種々の電気的処理を行うための処理用端子（測定用端子）５１，５２を接触させることができる。これら電極リード部７ａ，８ａは、シート面内方向に互いにずれた位置関係にて配置されているから、２つの処理用端子５１，５２を、積層シートアセンブリ１１の同じ側、具体的には上面側にて電極リード部７ａ，８ａに当接させることができ、端子のセッティングが非常に容易である。そして、積層シートアセンブリ１１の上面側にて、処理用端子５１，５２を順次移動させながら、各電池単位１０の電気的処理を次々と能率的に行うことができる。また、複数組の処理用端子５１，５２を、複数の電池単位１０の電極リード部７ａ，８ａに同時に当接させ、それら電池単位１０に対する電気的処理を一括して行うこともできる。
【００４４】
図１９に示すように、処理用端子５１，５２を用いて行う電気的処理は、例えば各電池単位１０の検査測定である。検査測定項目は、例えば初期電流密度、初期起電力、内部抵抗などである。すなわち、処理用端子５１，５２を検査対象となる電池単位１０の電極リード部７ａ，８ａに接続し、切り替えスイッチ５３を検査用測定装置５３側に倒す。検査用測定装置５３は、例えば測定用電源と信号発生回路、起電力測定のための標準電池を組み込んだポテンシオスタットや、内部抵抗測定のための標準抵抗を組み込んだブリッジ回路などの種々の測定用回路、測定結果解析用のコンピュータ、表示モニタ及びプリンタなどの出力部を備えたものであり、上記の測定を系統的に行うとともに、その結果を順次出力することができる。
【００４５】
また、上記電気的処理は放電処理とすることもできる。この場合、切り替えスイッチ５３を負荷抵抗３０側に倒す。すると、電池単位１０の正極と負極は、この負荷抵抗３０を介して短絡され、放電する。放電を所定時間継続させたら、スイッチ５３の操作により負荷抵抗３０を切り離す。これにより、電池単位１０は内部電池反応の進行が安定化し、初期電流を安定化させることができる。
【００４６】
なお、本実施形態では、第一シート部材１及び第二シート部材３の両方に、電極リード取出貫通部２４，２４が互いに重なり合うように形成されている。従って、図１７に示すように、第一及び第二の電極リード部７ａ’，８ａ’が平面的に重なり合って配置されていても、２つの処理用端子を、第一シート部材１及び第二シート部材３の各第二主表面１ｂ，３ｂ側に振り分けて配置すれば、それぞれ第一及び第二の電極リード部７ａ’，８ａ’に接触させることができる。ただし、図１６のように平面的にずれた位置関係で第一及び第二の電極リード部７ａ，８ａを配置することで、処理用端子の接続がより容易となることはいうまでもない。この場合は、２つの処理用端子を、第一シート部材及び第二シート部材のいずれか一方の第二主表面側に配置することが可能となる。また、第一シート部材１及び第二シート部材３の両方に電極リード取出貫通部２４，２４を形成すると、図１１に示すように、分離後の電池単位１０において、第一及び第二の電極リード部７ａ，８ａが、シート部材に基づく２つの活物質ケース１ｃ，３ｃの双方に対し、その縁から延出する形態となる。その結果、第一及び第二の電極リード部７ａ，８ａに最終的な電極端子を取り付けて電池アセンブリを製造する際に、第一及び第二の電極リード部７ａ，８ａの背後に回りこむシート部材部分が生じなくなるので、組立て工程が容易となる。
【００４７】
上記のような電気的処理工程が終了すれば、図１３の工程▲３▼に示すように積層シートアセンブリ１１を切断・分離して、図１１に示す電池単位１０とし、図１２に示すように、その電池単位１０の外側を、モールドシート３３，３４で覆い、それらの外縁部を封着部３５により封着して、電池１００が得られる。なお、モールドシート３３，３４を有さない、図１１の状態の電池単位１０を電池製品とすることもある。
【図面の簡単な説明】
【図１】本発明の電池の製造方法の一実施形態を、断面表示にて示す工程説明図。
【図２】図１の主要工程を、平面視にて示す第一の工程説明図。
【図３】同じく第二の工程説明図。
【図４】同じく第三の工程説明図。
【図５】同じく第四の工程説明図。
【図６】同じく第五の工程説明図。
【図７】同じく第六の工程説明図。
【図８】同じく第七の工程説明図。
【図９】シート部材の断面構造の一例を示す図。
【図１０】ホットメルト型接着剤により金属電極板の接着工程を示す断面図。
【図１１】図１に続く工程説明図。
【図１２】図１１に続く工程説明図。
【図１３】封着工程の一例を示す説明図。
【図１４】位置決めマスク部材の使用方法を示す斜視図。
【図１５】電極活物質充填工程の変形例を示す断面図。
【図１６】電極リード部の第一の配置形態を示す斜視図。
【図１７】同じく第二の配置形態を示す斜視図。
【図１８】処理用端子の接続形態を説明する斜視図。
【図１９】処理用端子を用いた電気的処理の実施回路を説明する図。
【図２０】活物質充填室の形成態様の変形例を示す断面図。
【符号の説明】
１，３シート部材
１ａ，３ａ第一シート面
１ｃ，３ｃ電極活物質ケース
２，４活物質充填室
５第一電極活物質
６第二電極活物質
７，８金属電極板
７ａ，８ａ，７ａ’，８ａ’ 電極リード部
９セパレータ
１０電池単位
１１積層シートアセンブリ
１２封着部
２４電極リード取出貫通部
５１，５２処理用端子（測定用端子）[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a battery manufacturing method, and more particularly to a manufacturing method suitable for a stacked type lithium primary battery or the like.
[0002]
[Prior art]
In recent years, demand for thin batteries for power supplies such as IC cards and card-type calculators has increased rapidly. As a typical example, a lithium primary battery using lithium as an anode (battery negative electrode) is known. Such a thin battery is known to have a structure in which a negative electrode active material layer and a positive electrode active material layer separated by a separator are sandwiched between two metal electrode plates, and the laminate is enclosed in a case. Yes.
[0003]
JP-A-8-45485 discloses the following technique. That is, a first strip metal plate in which a large number of positive electrode cases are formed by punching and a second strip metal plate in which a large number of negative electrode cases are formed are opposed to each other, and a separator, a negative electrode active material is interposed between the strip metal plates. The layer, the positive electrode active material layer, and the electrolytic solution are inserted, and both the band-shaped metal plates are sealed. The first band-shaped metal plate and the second band-shaped metal plate are each integrated with a thick-wall position regulating metal plate, and the opposing arrangement is positioned by inserting a pin into the hole. And after said sealing process is complete | finished, the method of manufacturing a battery continuously by separating a positive electrode case and a negative electrode case from the metal plate for position control is disclosed. According to the publication, in order to seal two strip-shaped metal plates, a method is disclosed in which a sealing material is bonded to the periphery of the positive electrode case and the negative electrode case, and the sealing materials are further bonded to each other.
[0004]
[Problems to be solved by the invention]
However, the method disclosed in the above publication has the following points to be improved.
{Circle around (1)} Since the positive electrode case and the negative electrode case are made of metal, a sealing material for sealing both of them is necessary, resulting in a decrease in manufacturing efficiency and an increase in manufacturing cost. Further, since the case is made of metal, the processing is troublesome and the flexibility is not so high. Therefore, when a high load is applied during handling, bending or cracking is likely to occur.
(2) The manufactured battery needs to be subjected to performance inspection and discharge treatment for stabilizing the initial current. In the method of the above publication, in a state before separation from the position-regulating metal plate, the positive electrode cases and the negative electrode cases of all the batteries are integrated with the strip metal plate and are electrically connected. Therefore, the above inspection and discharge treatment can be performed only when individual batteries are separated. In this case, the separated batteries must be individually set in the processing apparatus, which is very inefficient.
[0005]
The first object of the present invention is to provide a battery manufacturing method that can manufacture a plurality of thin batteries with high efficiency, and more specifically, can perform the sealing process more inexpensively and easily. The second problem is to provide a battery manufacturing method capable of manufacturing a plurality of thin batteries with high efficiency and capable of extremely efficiently performing electrical processing of individual batteries such as inspection and discharge treatment. There is.
[0006]
[Means for solving the problems and actions / effects]
In order to solve the first problem, the first of the battery manufacturing methods of the present invention is:
Prepare at least a sheet member made of a polymer material having an active material filling chamber that opens to the first sheet surface, and one of them is a first sheet member for filling the first electrode active material, and the other As a second sheet member for filling a second electrode active material different from the first electrode active material, the sheet members are laminated so that the active material filling chambers overlap each other and the first sheet surfaces face each other. And filling each active material filling chamber with the first electrode active material and the second electrode active material, respectively, and contacting the first electrode active material and the second electrode active material on the opposite side of the first sheet surface, respectively. By disposing the first and second metal electrode plates and disposing a sheet-like separator separating the first electrode active material and the second electrode active material from each other between the first sheet surfaces of both sheet members, 1st sheet member and 2nd sheet The member is used as the first electrode active material case and the second electrode active material case, and the first metal electrode plate, the first electrode active material, the separator, the second electrode active material, and the second metal electrode plate are laminated in this order. A laminated sheet assembly manufacturing process for manufacturing a laminated sheet assembly in which the formed battery unit is formed;
A separation step of separating the battery unit by cutting the first sheet member and the second sheet member;
Before or after the separation step, a sealing step for forming a sealing portion that directly connects the first sheet member and the second sheet member along the periphery of the active material filling chambers of the individual battery units that overlap each other; ,
It is characterized by including.
[0007]
In the present invention, the first electrode active material is one of a positive electrode active material and a negative electrode active material, and the second electrode active material is the other. “Positive electrode” and “negative electrode” mean polarities from the viewpoint of battery electromotive force extraction, and in the electrochemical sense, the anode (anode) corresponds to the negative electrode, and the cathode (cathode) corresponds to the positive electrode. .
[0008]
According to the first method of manufacturing a battery of the present invention, an active material case for accommodating positive and negative electrode active materials is formed of a polymer material sheet. Specifically, the first sheet member and the second sheet member are used as the first electrode active material case and the second electrode active material case, and the first metal electrode plate, the first electrode active material, the separator, and the second electrode active material case. A laminated sheet assembly is manufactured in which a battery unit is formed by laminating a material and a second metal electrode plate in this order. Then, the battery unit is sealed by forming a sealing portion in which the first sheet member and the second sheet member are directly coupled along the periphery of the active material filling chambers that overlap each other in the battery unit.
[0009]
According to the above method, the first electrode active material case and the second electrode active material case, i.e., the positive electrode case and the negative electrode case are both made of polymer material, and are surrounded by the active material filling chambers of the individual battery units that overlap each other. The first electrode active material case and the second electrode active material case, that is, the first sheet member and the second sheet member are directly connected to form a sealing portion. This eliminates the need for a separate member for sealing both cases, thereby improving the production efficiency and reducing the production cost. In addition, the case is not made of metal, but is made of a polymer material that is more elastic and flexible than that, so it is much easier to process, and it can be bent even if some load or local deformation occurs during handling. And cracks are less likely to occur, and the incidence of defects can be reduced. The obtained battery itself is advantageous in obtaining a thinner battery because the case is made of a polymer material that can be easily thinned, and the battery is highly flexible and easy to handle. .
[0010]
The first sheet member and the second sheet member each have a plurality of active material filling chambers arranged in the sheet plane direction, and the laminated sheet assembly includes a plurality of battery units arranged in the sheet plane direction. can do. In this case, the battery unit is separated by cutting the first sheet member and the second sheet member. Then, before or after the separation step, a sealing portion is formed by directly connecting the first sheet member and the second sheet member along the periphery of the active material filling chambers of the individual battery units that overlap each other. be able to. According to this method, a plurality of battery units can be manufactured collectively by manufacturing one laminated sheet assembly, which is efficient. The separation of individual battery units is performed by cutting the first sheet member and the second sheet member made of a flexible polymer material, so that the separation process is easy and burrs and the like are not easily generated. The sealing step may be performed either before or after the cutting, but is more efficient if performed before the cutting, and further misalignment of laminated sheets and active materials. Is also more advantageous because it is less likely to occur.
[0011]
The sealing portion can be formed by welding a polymer material forming the first sheet member and the second sheet member. In this case, the base material of the first sheet member and the second sheet member is made of a thermoplastic resin, and the sealing portion can be formed by heat fusion between the base materials. On the other hand, if a hot melt type adhesive layer is formed on the welding surface of the first sheet member and the second sheet member, and the adhesive layer is used for welding, a sealing portion is formed at a lower temperature. it can. In particular, the battery unit uses a lithium metal sheet as the first electrode active material and MnO as the second electrode active material. ₂ This method is particularly effective when the sealing part is formed by high-temperature heat-sealing because the thermal influence is likely to be exerted on the low-melting-point lithium metal sheet. The hot-melt type adhesive layer is composed of, for example, a thermoplastic resin such as polyvinyl acetate, polyvinyl butyral, acrylic resin, polyisobutylene polyamide, a copolymer of ethylene and vinyl acetate or acrylate, or a terpene resin. , A rosin derivative or a natural resin such as rubber can be used. In addition, although normal heat fusion may be used for welding, it is advantageous to use ultrasonic welding because heat generation is small and a sealing portion can be formed reliably.
[0012]
Next, in order to solve the second problem, a second method of manufacturing a battery of the present invention is to form a plurality of active material filling chambers in a sheet member made of a polymer material, The electrode active material is filled, and the battery positive electrode and the first metal electrode plate serving as the negative electrode are in contact with the active material filling chambers at positions corresponding to the active material filling chambers, corresponding to different active material filling chambers. A battery unit in which the first and second metal electrode plates and the electrode active material are stacked is formed by arranging the sheet member as an electrode active material case by arranging the sheet members along the sheet surface in a mutually insulated form. A laminated sheet assembly manufacturing process for manufacturing a laminated sheet assembly in which a plurality of arrays are formed in an in-plane direction;
Separating the battery unit by cutting the sheet member,
An electrode lead extraction penetrating portion is formed at a position adjacent to the active material filling chamber of the sheet member, and the first and second electrode lead portions extending from the outer edges of the first and second metal electrode plates are extracted from the electrode lead. It is characterized by being exposed in the penetrating part.
[0013]
According to this invention, a plurality of active material filling chambers are formed in a sheet member made of a polymer material, and the first and second metals that become the battery positive electrode and the negative electrode are formed in the electrode active material filled in the active material filling chambers. The electrode plates corresponding to different active material filling chambers are arranged along the sheet surface in such a manner that the electrode plates are insulated from each other. That is, since the metal electrode plates forming different battery units are arranged in a state of being insulated from each other on the sheet member made of the polymer material, it is possible to perform electrical processing of individual battery units in a non-separated state. Such electrical processing can be performed by connecting a processing terminal to the battery electrode. And according to the said invention, the electrode lead extraction penetration part is formed in the position adjacent to the active material filling chamber of a sheet | seat member, and the 1st and 2nd extended from the outer edge of a 1st and 2nd metal electrode plate Since the electrode lead portion is exposed in the electrode lead extraction penetration portion, the processing terminal can be easily attached to and detached from the exposed electrode lead portion. In addition, since the battery units are not separated, the processing terminals may be connected while being sequentially connected to the imperial electrode lead portions exposed in the electrode lead extraction / penetration portions, so that the processing efficiency is dramatically improved.
[0014]
An example of the electrical process is an inspection measurement process for each battery. In this case, the measurement and measurement of each battery unit can be performed prior to the separation step by bringing the measurement terminals into contact with the first and second electrode lead portions exposed in the electrode lead extraction and penetration portion. The inspection measurement items include, for example, initial current density, initial electromotive force, internal resistance, and the like, but are not limited thereto.
[0015]
The electrical treatment can be a temporary discharge treatment for stabilizing the initial current of each battery. In this case, the discharge treatment of each battery unit can be performed prior to the separation step by short-circuiting the first and second electrode lead portions via the load resistance.
[0016]
The first and second electrode lead portions extending from the outer edges of the first and second metal electrode plates can be exposed in the electrode lead extraction penetrating portion in a positional relationship shifted from each other in the sheet plane direction. . According to this, since the first and second electrode lead portions are arranged in a positional relationship shifted in a plane, one side in the laminating direction of the laminated sheet assembly, for example, the upper side of the laminated sheet assembly placed horizontally Thus, the two processing terminals for the positive electrode and the negative electrode can be connected to the first and second electrode lead portions, and the processing can be performed more easily and efficiently.
[0017]
The second concept of the present invention can be combined with the first concept of the present invention. In this case, since two sheet members are used, the following modes are possible.
(1) An electrode lead extraction penetration portion is formed at a position adjacent to the active material filling chamber of at least one of the first sheet member and the second sheet member, and extends from the outer edges of the first and second metal electrode plates. The first and second electrode lead portions are exposed in the electrode lead extracting and penetrating portion in a positional relationship shifted from each other in the sheet plane direction. The electrode lead lead-out part may be formed on both the first sheet member and the second sheet member, or may be formed only on one side. In the latter case, the processing terminals are placed on the first and second electrode lead portions arranged in a positional relationship shifted in a planar manner from the second main surface side of the sheet member on which the electrode lead extraction penetration portion is formed. Can be contacted.
[0018]
(2) The electrode lead extraction penetration part is formed at a position adjacent to the active material filling chamber of the first sheet member and the second sheet member, respectively, in a positional relationship that overlaps each other when the first sheet member and the second sheet member are laminated. And the 1st and 2nd electrode lead part extended from the outer edge of a 1st and 2nd metal electrode plate is exposed in an electrode lead extraction penetration part. In this case, since the electrode lead extraction penetration portion is formed in both the first sheet member and the second sheet member, even if the first and second electrode lead portions are arranged so as to overlap in a plane, The processing terminals may be distributed and arranged on the second main surface sides of the first sheet member and the second sheet member so as to contact the first and second electrode lead portions, respectively. However, it is also possible to arrange the first and second electrode lead portions in a positional relationship shifted in a plane as in (1). In this case, the two processing terminals are connected to the first sheet member and It becomes possible to arrange | position to the any one 2nd main surface side of a 2nd sheet | seat member. In addition, when the electrode lead extraction penetration portion is formed in both the first sheet member and the second sheet member in this manner, the first and second electrode lead portions are based on the sheet member in the battery unit after separation. It becomes a form extended from the edge with respect to both of two active material cases. As a result, when manufacturing the battery assembly by attaching the final electrode terminals to the first and second electrode lead portions, there is no sheet member portion that wraps around behind the first and second electrode lead portions. The assembly process becomes easy.
[0019]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 shows an example of a manufacturing process of a thin battery according to the present invention in a cross-sectional layout. 2 to 8 show the main steps in a planar layout. The outline of the process is as follows. That is, two sheet members 1 and 3 are prepared in which a plurality of active material filling chambers 2 and 4 that open at least on the first sheet surfaces 1a and 3a are arranged in the in-plane direction of the polymer material sheet, respectively ( FIG. 1: Step (2) and Step (7), FIGS. 3 and 7). One of the sheet members 1 and 3 is a first sheet member 1 for filling the first electrode active material 5 and the other is a second electrode active material 6 for filling a second electrode active material 6 different from the first electrode active material. Used as a two-sheet member 3.
[0020]
As shown in step (7) in FIG. 1, the first and second sheet members 1 and 3 are such that the active material filling chambers 2 and 4 overlap each other and the first sheet surfaces 1a and 3a face each other. Is laminated. Then, the active material filling chambers 2 and 4 are filled with the first electrode active material 5 and the second electrode active material 6, respectively. In addition, on the side opposite to the first sheet surfaces 1 a and 3 a, first and second metal electrode plates 7 and 8 that are in contact with the first electrode active material 5 and the second electrode active material 6, respectively, are disposed. And between the 1st sheet surfaces 1a and 3a of both the sheet members 1 and 3, the sheet-like separator 9 which isolate | separates the 1st electrode active material 5 and the 2nd electrode active material 6 from each other is arrange | positioned. Although only one battery unit 10 is shown in FIG. 1 for convenience, a plurality of battery units 10 are formed in the in-plane direction of the sheet members 1 and 3 as shown in FIG.
[0021]
Returning to step (7) in FIG. 1, each battery unit 10 includes the first sheet member 1 and the second sheet member 3 in the first electrode active material case 1c and the second electrode active material case 3c (but after separation: 11 and 12), the first metal electrode plate 7, the first electrode active material 5, the separator 9, the second electrode active material 6 and the second metal electrode plate 8 are laminated in this order. It is a thing. And the said battery unit 10 was arranged in multiple numbers by the sheet | seat surface direction by forming the said laminated structure in each active material filling chamber 2 and 4 with respect to the 1st and 2nd sheet | seat members 1 and 3, respectively. A laminated sheet assembly 11 is obtained.
[0022]
Then, as shown in FIG. 8, each battery unit 10 is separated from the laminated sheet assembly 11 by cutting the first sheet member 1 and the second sheet member 3, so that a plurality of battery units 10 are separated from the laminated sheet assembly. 11 can be collectively manufactured. As shown in steps (1) and (2) in FIG. 13, the first sheet member 1 and the second sheet member 3 are arranged along the periphery of the active material filling chambers 2 and 4 of the individual battery units 10 that overlap each other. Are directly coupled to each other, and the individual battery units 10 are sealed. As shown in step (3) of FIG. 13 (or FIG. 8), in this embodiment, the sealing portion 12 is formed first, and then the battery unit 10 is cut using the cutter 42. However, the sealing unit 12 may be formed for each battery unit 10 after the battery unit 10 is cut and separated first.
[0023]
As shown in FIG. 13, the sealing portion 12 can be formed by welding a polymer material forming the first sheet member 1 and the second sheet member 3. As shown in FIG. 9, each of the first sheet member 1 and the second sheet member 3 has a thickness of about 80 to 100 μm and is hot on both surfaces of a base material made of a thermoplastic resin such as polyethylene or polyester. Melt type adhesive layers 13 and 13 are formed. In this embodiment, the hot-melt adhesive layers 13 and 13 are formed as a copolymer of ethylene and vinyl acetate (ethylene vinyl acetate (EVA) layer) having a thickness of about 30 to 40 μm, but the present invention is not limited thereto. Is not to be done.
[0024]
As shown in step (2) in FIG. 13, the sealing portion 12 is formed by welding the adhesive layers on the first sheet surfaces 1 a and 3 a side of the first sheet member 1 and the second sheet member 3. . In the present embodiment, as shown in step (1) in FIG. 13, the inside of the active material filling chambers 2 and 4 is evacuated from the gap between the first sheet member 1 and the second sheet member 3, while the step in FIG. As shown in (2), the first sheet member 1 and the second sheet member 3 are pressurized between the ultrasonic horn 40 and the sealing support base 41, and ultrasonic waves are applied by the ultrasonic horn 40 in this state. Then, the hot melt adhesive layer 13 in the vicinity of the pressurizing portion is melted to cause local welding, thereby forming the sealing portion 12.
[0025]
The active material filling chambers 2 and 4 may be formed in only one row at a predetermined interval on a long sheet member. In this case, the sheet member can be wound into a roll and used for convenience for continuous production in battery units. However, as will be described later, in the manufacturing process of the laminated sheet assembly, it may be convenient to appropriately reverse the front and back of the sheet member. In this case, for example, batch processing in units of square sheet members is performed. Easy to implement. As described above, when the sheet member is handled by batch processing, as shown in FIGS. 3 to 7, the first sheet member 1 and the second sheet member 3 include a plurality of active material filling chambers 2, 4. It is desirable to form the cells in a matrix form from the viewpoint of increasing the number of battery units 10 that can be manufactured from one set of sheet members 1 and 3.
[0026]
As shown in FIGS. 1, 2, and 7, the first sheet member 1 and the second sheet member 3 are formed with a sheet positioning through portion 21 in a positioning member 20 that is integrally attached to the sheet members 1 and 3. Has been. Then, as shown in FIG. 1, by inserting a positioning pin 23 into the sheet positioning through portion 21, the first sheet member 1 and the second sheet member 3 are overlapped with each other in the active material filling chambers 2, 4. Positioned and laminated. The position where the sheet positioning penetrating portion 21 is formed is used as a reference for alignment of the first sheet member 1 and the second sheet member 3 (and masks 15, 17, and 19 described later), and is positioned in the penetrating portions having the corresponding positional relationship. By inserting the pin 23, the first sheet member 1 and the second sheet member 3 can be positioned and laminated quickly and accurately. The sheet positioning through portion 21 may be formed in the sheet members 1 and 3 themselves. However, considering that the sheet itself is thin and flexible, a material having higher rigidity (for example, metal or hard plastic) is used. If the positioning member 20 is attached to the sheet members 1 and 3 and the through-hole 21 is formed in the positioning member 20, there is no fear that the sheet members 1 and 3 are deformed when the positioning pin 23 is inserted, and handling is easy. Further, the positioning pin 23 can be inserted into the penetrating portion 21 more smoothly. The positioning member 20 (and the sheet positioning through portion 21) may be provided only on one of the first sheet member 1 and the second sheet member 3, but by providing both, the positioning efficiency and accuracy are improved. Can be further improved.
[0027]
The positioning member 20 can be a frame member 20 that supports the first sheet member 1 and the second sheet member 3 along the outer peripheral edge. Thereby, the comparatively flexible sheet | seat members 1 and 3 can be supported stably. In this case, the sheet positioning through portion can be a through hole 21 formed in the frame member 20. 2 and 7, the sheet positioning through portion may be a notch 21 a that opens to one edge of the positioning member 20. For example, as in the present embodiment, when the first sheet member 1 and the second sheet member 3 are formed in a quadrilateral shape, the frame member 20 is on at least two sides of the sheet members 1 and 3 facing each other. It is convenient to provide the sheet members 1 and 3 in a stretched state using the positioning pins 23. In this case, as in the present embodiment, the frame member 20 is provided on all four sides of the first sheet member 1 and the second sheet member 3, and the sheet members 1 and 3 are supported in a stretched state. More desirable.
[0028]
The type of battery to which the present invention is applicable is not particularly limited, but in the present embodiment, as an example, lithium metal (here, a lithium metal sheet) is used as the negative electrode active material 5 and MnO is used as the positive electrode active material 6. ₂ It is intended for lithium primary batteries using. The cathode paste is, for example, 60 to 70 mass% manganese dioxide powder, 5 to 10 mass% carbon, ethylene carbonate, propylene carbonate, and lithium triflate salt (LiCF). ₃ SO ₃ ) And an electrolyte solution of 25 to 35% by mass can be suitably used for securing battery performance. The following can be illustrated as a more suitable composition of electrolyte solution:
10-40% by weight (preferably 15-25% by weight) ethylene carbonate;
60-90 wt% (desirably 75-85 wt%) propylene carbonate; 0.5-1.5 mol (desirably 0.8-1.2 wt%) lithium triflate salt.
[0029]
Further, it is desirable that the manganese dioxide powder has an indefinite shape having a surface area as large as that of electrolytic manganese dioxide. The average particle size is preferably 10 to 30 μm (desirably 20 to 25 μm), and the BET value (specific surface area value) is 30 to 50 m. ² / G (desirably 40-45m ² / G), and the total porosity is 0.02 to 0.08 cm ³ / G (preferably 0.04-0.06 cm ³ / G) is preferable in terms of ensuring battery performance.
[0030]
Hereinafter, it will be described in more detail according to the flow of the explanatory diagram of FIG.
As shown in step (1) of FIG. 1, the first sheet member 1 is set on the table 50 while the positioning pins 23 are inserted through the through holes 21 of the frame member 20. As shown in FIG. 2, the frame member 20 is formed with through holes 21 at four corners thereof. Moreover, although the through-hole 21 is formed also in each center position of four sides, an arrangement | positioning form is not restricted to this.
[0031]
The first sheet member 1 (the same applies to the second sheet member 3: step (7)) is formed in such a way that the active material filling chambers 2 (4) penetrate each in the sheet thickness direction. Such a penetrating active material filling chamber 2 (4) is formed by using a punching blade 49 (or a punching punch) as shown in (2) in the process of FIG. There is an advantage that it can be formed more easily. In addition, as shown in FIG. 20, the bottomed active material which opens only in the 1st sheet surface 1a, 3a in the 1st sheet member 1 and the 2nd sheet member 3, and does not open in the 2nd sheet surface 1b, 3b. Filling chambers 2 and 4 can also be formed. In this case, the metal electrode plates 7 and 8 can be disposed on the bottom surfaces of the active material filling chambers 2 and 4.
[0032]
Returning to FIG. 1, the sheet member 1 has a first step as shown in step (3) (the second sheet member 3 is also the same: step (7), hereinafter, the parentheses are the corresponding symbols of the second sheet member 3). In the second sheet surface 1b (3b) which is the sheet surface opposite to the one sheet surface 1a (3a), the opening of the active material filling chamber 2 (4) is the first metal electrode plate 7 (second metal electrode plate 8). ). FIG. 4 shows this in a plan view. The through-active material filling chamber 2 (4) does not have a bottom as it is, and therefore cannot accommodate the electrode active material 5 (6). Therefore, the bottom can be formed by closing the opening on the second sheet surface 1b (3b) side with the metal electrode plate 7 (8), and the electrode active material 5 (6) can be accommodated without any problem. In the present embodiment, the metal electrode plates 7 and 8 each employ a Cu foil having a thickness of about 30 to 50 μm.
[0033]
The metal electrode plate 7 (8) can be attached to the opening peripheral edge of the active material filling chamber 2 (4) on the second sheet surface 1b (3b). The opening of the active material filling chamber 2 (4) can be easily closed by simply attaching the metal electrode plate 7 (8) to the second sheet surface 1b (3b) of the punched sheet member 1 (3). . Specifically, as shown in FIG. 10, the metal electrode plate 7 (8) passes through the hot melt adhesive layer 13 formed on the second sheet surface 1 b (3 b) side of the sheet member 1 (3). Thus, the method of heat bonding is simple and can be reliably applied. In the present embodiment, the metal electrode plate 7 (8) is heated while being pressed against the sheet member 1 (3) by a punch 30 having a heater (not shown), thereby being bonded in a pressure-bonded form.
[0034]
In the first sheet member 1 and / or the second sheet member 3, when the metal electrode plates 7 and 8 that close the openings of the active material filling chambers 2 and 4 are disposed on the second sheet surfaces 1b and 3b, The following steps can be employed. That is, as shown in step (3) in FIG. 1 and FIG. 14, the positioning mask member 17 in which a plurality of positioning windows 16 are formed is placed on the second sheet surface 1b (3b) of the sheet member 1 (3). The positioning windows 16 are overlapped so as to correspond to the active material filling chambers 2 (4), and the metal electrode plates 7 (8) are arranged in the positioning windows 16 in this state. If it does in this way, the metal electrode plate 7 (8) can be arrange | positioned correctly and rapidly in the sticking position with respect to the sheet | seat member 1 (3). In this case, since the sheet member 1 (3) is positioned by inserting the positioning pin 23 into the sheet positioning through portion 21, the mask positioning through portion 17a is formed in the positioning mask member 17, and the mask positioning is performed. The positioning mask member 17 can be accurately and easily positioned and laminated on the sheet member 1 (3) by inserting the positioning pins 23 into the through portion 17a and the sheet positioning through portion 21.
[0035]
Bonding of the metal electrode plate 7 by pressure bonding is easy when the first sheet member 1 is arranged with the second sheet surface 1b facing upward, as shown in step (3) in FIG. In this case, in the step of filling the active material filling chamber 2 with the first electrode active material 5, as shown in step (4), after attaching the metal electrode plate 7, the first sheet member 1 is turned upside down. While using the first metal electrode plate 7 as the bottom of the active material filling chamber 2, the first electrode active material 5 (thickness 4 to 4 in this embodiment) is passed from the opening on the first sheet surface 1 a side to the active material filling chamber 2. It can be performed by filling a lithium metal plate of about 6 μm. By performing sheet inversion, both the attachment of the metal electrode plate 7 and the filling of the first electrode active material 5 can be performed simply and reliably. FIG. 5 shows a state in which the first sheet surface 1 a side of the first sheet member 1 in a state filled with the first electrode active material 5 is viewed in plan.
[0036]
After filling the active material filling chamber 2 of the first sheet member 1 with the first electrode active material 5 as described above, as shown in the step (5), the active material filling chamber 2 on the first sheet surface 1a side is provided. The separator 9 is affixed to the peripheral edge of the opening. The separator 9 is made of, for example, a resin such as polyethylene or polypropylene, and has a thickness of about 20 to 30 μm. This separator 9 can also be affixed to the opening peripheral part of the active material filling chamber 2 (4) on the first sheet surface 1a (3a). The specific affixing method is the same as in FIG. 10. The hot melt type adhesive formed on the first sheet surface 1 a (3 a) side with respect to at least one of the first and second sheet members 1, 3. The process of thermally bonding the separator 9 through the agent layer 13 can be exemplified. The separator 9 may be thermally bonded to either the sheet member 1 or 3 or both, but in the present embodiment, the separator 9 is thermally bonded to the first sheet member 1. It is convenient to bond the separator 9 using a separator positioning mask 19 as shown in step (5) in FIG. The separator positioning mask 19 is formed with a mask positioning through portion 19a, and the positioning pin 23 is inserted therein, whereby the separator positioning mask 19 can be positioned and laminated on the sheet member 1 accurately and easily. The separator 9 is disposed in the positioning window 18.
[0037]
As shown in FIG. 15, the opening on the first sheet surface 1 a side of the active material filling chamber 2 of the sheet member 1 is closed with the separator 9, and this is used as the bottom to fill the electrode active material 5, It is also possible to employ a step of closing the opening on the second sheet surface 1b side with the metal electrode plate 7. However, since the metal electrode plate 7 has higher rigidity than the separator 9, the process (4) in FIG. 1 has an advantage that handling after filling the electrode active material 5 is easy.
[0038]
Next, returning to FIG. 1, as shown in step (6), the second electrode active material 6 is disposed on the separator 9 at a position corresponding to the active material filling chamber 2 of the first sheet member 1. Thereafter, as shown in step (7), the second sheet member 3 is separated from the separator 9 so that the second electrode active material 6 arranged is accommodated in the active material filling chamber 4 of the second sheet member 3. Overlay on top. If the 2nd electrode active material 6 has the rigidity which can be handled, after the 2nd sheet | seat member 3 is piled up on the 1st sheet | seat member 1, the 2nd electrode active material 6 is filled with an active material filling chamber. 4 can also be accommodated. However, if the second electrode active material 6 does not have such rigidity, for example, if it is a paste, the second electrode is placed in the active material filling chamber 4 of the second sheet member 3 previously laminated. When the active material 6 is to be worn and filled, the second electrode active material 6 remains on the second sheet surface 3 b of the second sheet member 3, for example, the metal electrode plate 8 attached to the periphery of the opening of the active material filling chamber 4. There is a possibility that the sealed state may be impaired and problems such as leakage of the active material may occur. Therefore, as described above, the second electrode active material 6 is first disposed on the separator 9, and then the second sheet is placed so that the second electrode active material 6 is accommodated in the active material filling chamber 4. If the member 3 is superposed on the separator 9, such a problem is less likely to occur.
[0039]
In the present embodiment, as described above, the second electrode active material 6 is formed in a paste form. Therefore, in the process (6) in FIG. 1, the following method is adopted. That is, the printing mask member 15 formed with the plurality of paste filling windows 14 is overlaid on the separator 9 so that each paste filling window 14 is positioned corresponding to the active material filling chamber 2 of the first sheet member 1. . In this state, the paste-like second electrode active material 6 is scraped and filled into the paste filling window 14 using a squeegee 48, and then the printing mask member 15 is removed, whereby the application pattern of the second electrode active material 6 is obtained. Is formed on each separator 9. When this method is used, the application pattern of the second electrode active material 6 in the plurality of battery units 10 can be performed collectively by a kind of printing process, which is very efficient. FIG. 6 shows the first sheet member 1 after the application pattern of the second electrode active material 6 is formed in a plan view.
[0040]
The printing mask member 15 is provided with a mask positioning through portion 15a. By inserting a positioning pin 23 into the mask positioning through portion 15a and the sheet positioning through portion 21, the printing mask member 15 is attached to the first sheet member. 1 can be positioned and laminated accurately and easily. In addition, the second sheet member 3 is configured such that a second metal electrode plate 8 that has been attached in advance so as to close the opening of the active material filling chamber 4 with respect to the second sheet surface 3 b is superimposed on the separator 9. If so, it is more efficient. Further, since the step of thermocompression bonding the second metal electrode plate 8 with the hot-melt adhesive layer is not performed on the second sheet member 3 to which the second electrode active material 6 is applied, the thermal effect is second. There is also an advantage that does not reach the electrode active material 6.
[0041]
FIG. 7 shows a plan view of a laminated sheet assembly 11 obtained by laminating the second sheet member 3. As described above, in the present embodiment, as shown in FIG. 8, the linear sealing portion 12 is formed along the periphery of each active material filling chamber 2, 4 by the process shown in FIG. 13. Thereafter, each battery unit 10 is cut and separated by a cutter or the like, but prior to the cutting, some electrical processing is performed on the battery unit 10 in this embodiment.
[0042]
And in order to perform an electrical process in the non-separation state of the battery unit 10, the following devices are given to the first sheet member 1 and the second sheet member 3. That is, as shown in FIGS. 4 and 7, electrode lead extraction through portions 24 and 24 are formed at positions adjacent to the active material filling chambers 2 and 4 of the first sheet member 1 and the second sheet member 3. Yes. The electrode lead lead-out portions 24 and 24 of the first sheet member 1 and the second sheet member 3 are formed in a positional relationship where they overlap each other when the first sheet member 1 and the second sheet member 3 are stacked. On the other hand, as shown in FIG. 16, first and second electrode lead portions 7 a and 8 a are formed extending from the outer edges of the first and second metal electrode plates 7 and 8. As shown in FIG. 7, the first and second electrode lead portions 7 a and 8 a are exposed in the electrode lead extraction / penetration portion 24 in a positional relationship shifted from each other in the sheet plane direction.
[0043]
As shown in FIG. 18, the first and second electrode lead portions 7a and 8a exposed in the electrode lead extraction / penetrating portion 24 have processing terminals for performing various electrical processes for each battery unit 10, respectively. (Measurement terminals) 51 and 52 can be brought into contact with each other. Since these electrode lead portions 7a and 8a are disposed in a positional relationship shifted from each other in the sheet surface direction, the two processing terminals 51 and 52 are arranged on the same side of the laminated sheet assembly 11, specifically, the upper surface. The terminal can be brought into contact with the electrode lead portions 7a and 8a on the side, and the setting of the terminals is very easy. Then, the electrical processing of each battery unit 10 can be performed efficiently one after another while sequentially moving the processing terminals 51 and 52 on the upper surface side of the laminated sheet assembly 11. In addition, a plurality of sets of processing terminals 51 and 52 can be simultaneously brought into contact with the electrode lead portions 7a and 8a of the plurality of battery units 10 to perform electrical processing on the battery units 10 collectively.
[0044]
As shown in FIG. 19, the electrical processing performed using the processing terminals 51 and 52 is, for example, inspection measurement of each battery unit 10. The inspection measurement items are, for example, initial current density, initial electromotive force, internal resistance, and the like. That is, the processing terminals 51 and 52 are connected to the electrode lead portions 7a and 8a of the battery unit 10 to be inspected, and the changeover switch 53 is tilted to the inspection measuring device 53 side. The measurement device 53 for inspection includes various measurements such as a measurement power source, a signal generation circuit, a potentiostat incorporating a standard battery for measuring electromotive force, and a bridge circuit incorporating a standard resistor for measuring internal resistance. Circuit, a computer for measurement result analysis, a display monitor, a printer, and other output units. The above-described measurement can be performed systematically and the results can be sequentially output.
[0045]
The electrical treatment can be a discharge treatment. In this case, the changeover switch 53 is tilted to the load resistor 30 side. Then, the positive electrode and the negative electrode of the battery unit 10 are short-circuited via the load resistor 30 and discharged. When the discharge is continued for a predetermined time, the load resistor 30 is disconnected by operating the switch 53. Thereby, the battery unit 10 can stabilize the progress of the internal battery reaction, and can stabilize the initial current.
[0046]
In the present embodiment, the electrode lead extraction penetrating portions 24 and 24 are formed on both the first sheet member 1 and the second sheet member 3 so as to overlap each other. Therefore, as shown in FIG. 17, even if the first and second electrode lead portions 7a ′ and 8a ′ are arranged so as to overlap each other in plan view, the two processing terminals are connected to the first sheet member 1 and the second sheet member 1. If the sheet member 3 is distributed and arranged on the second main surfaces 1b and 3b side, it can be brought into contact with the first and second electrode lead portions 7a ′ and 8a ′, respectively. However, it goes without saying that the processing terminals can be more easily connected by arranging the first and second electrode lead portions 7a, 8a in a positional relationship shifted in a plane as shown in FIG. In this case, the two processing terminals can be arranged on the second main surface side of either the first sheet member or the second sheet member. Moreover, when the electrode lead extraction penetration parts 24 and 24 are formed in both the first sheet member 1 and the second sheet member 3, as shown in FIG. 11, in the battery unit 10 after separation, the first and second electrodes Lead part 7a, 8a becomes a form extended from the edge with respect to both of two active material cases 1c and 3c based on a sheet | seat member. As a result, when manufacturing the battery assembly by attaching the final electrode terminals to the first and second electrode lead portions 7a and 8a, the sheet wraps around the first and second electrode lead portions 7a and 8a. Since no member part is generated, the assembly process is facilitated.
[0047]
When the electrical processing steps as described above are completed, the laminated sheet assembly 11 is cut and separated as shown in step (3) of FIG. 13 to form the battery unit 10 shown in FIG. 11, and as shown in FIG. The outer side of the battery unit 10 is covered with the mold sheets 33 and 34, and the outer edge portions thereof are sealed with the sealing portion 35, whereby the battery 100 is obtained. The battery unit 10 in the state shown in FIG. 11 that does not have the mold sheets 33 and 34 may be used as a battery product.
[Brief description of the drawings]
BRIEF DESCRIPTION OF DRAWINGS FIG. 1 is a process explanatory view showing an embodiment of a battery manufacturing method of the present invention in a cross-sectional view.
FIG. 2 is a first process explanatory view showing the main process of FIG. 1 in a plan view;
FIG. 3 is also a second process explanatory view.
FIG. 4 is also a third process explanatory view.
FIG. 5 is also a fourth process explanatory diagram.
FIG. 6 is also a fifth process explanatory diagram.
FIG. 7 is also a sixth process explanatory view.
FIG. 8 is also a seventh process explanatory diagram.
FIG. 9 is a diagram illustrating an example of a cross-sectional structure of a sheet member.
FIG. 10 is a cross-sectional view showing a bonding process of a metal electrode plate with a hot melt adhesive.
FIG. 11 is a process explanatory diagram following FIG. 1;
12 is a process explanatory diagram following FIG. 11. FIG.
FIG. 13 is an explanatory diagram showing an example of a sealing process.
FIG. 14 is a perspective view showing how to use the positioning mask member.
FIG. 15 is a sectional view showing a modification of the electrode active material filling step.
FIG. 16 is a perspective view showing a first arrangement form of electrode lead portions.
FIG. 17 is a perspective view showing a second arrangement form.
FIG. 18 is a perspective view illustrating a connection form of processing terminals.
FIG. 19 illustrates an implementation circuit of electrical processing using a processing terminal.
FIG. 20 is a cross-sectional view showing a modified example of the formation mode of the active material filling chamber.
[Explanation of symbols]
1,3 Sheet material
1a, 3a First sheet surface
1c, 3c electrode active material case
2,4 Active material filling chamber
5 First electrode active material
6 Second electrode active material
7,8 Metal electrode plate
7a, 8a, 7a ', 8a' Electrode lead part
9 Separator
10 battery units
11 Laminated sheet assembly
12 Sealing part
24 Electrode lead extraction penetration
51,52 Processing terminal (Measurement terminal)

Claims

At least one sheet member (1, 3) made of a polymer material having an active material filling chamber (2, 4) opened on the first sheet surface (1a, 3a) is prepared, and one of them is a first member. The second sheet member (3) for filling the second electrode active material (6) different from the first electrode active material is the first sheet member (1) for filling the electrode active material (5). The sheet members (1, 3) are laminated such that the active material filling chambers (2, 4) overlap each other and the first sheet surfaces (1a, 3a) face each other, and each active material filling The chamber (2, 4) is filled with the first electrode active material (5) and the second electrode active material (6), respectively, and the first electrode active material is opposite to the first sheet surface (1a, 3a). (5) and the second electrode active material (6), the first and second metal electrode plates (7, 8) in contact with each other The first electrode active material (5) and the second electrode active material (6) are separated from each other between the first sheet surfaces (1a, 3a) of both sheet members (1, 3). By disposing a sheet-like separator (9), the first sheet member (1) and the second sheet member (3) are connected to the first electrode active material case (1c) and the second electrode active material case (3c). ), The first metal electrode plate (7), the first electrode active material (5), the separator (9), the second electrode active material (6) and the second metal electrode plate (8). A laminated sheet assembly production process for producing a laminated sheet assembly (11) formed with battery units (10) laminated in this order;
A sealing part (1) in which the first sheet member (1) and the second sheet member (3) are directly coupled along the periphery of the active material filling chambers (2, 4) of the battery unit (10) that overlap each other ( 12) forming a sealing step;
A method for producing a battery comprising:

The battery manufacturing method according to claim 1, wherein the sealing portion (12) is formed by welding a polymer material portion forming the first sheet member (1) and the second sheet member (3).

The battery manufacturing method according to claim 2, wherein the welding is performed by ultrasonic welding.

In the first sheet member (1) and the second sheet member (3), a plurality of the active material filling chambers (2, 4) are respectively formed in the sheet in-plane direction, and the laminated sheet assembly ( 11) is a plurality of battery units (10) arranged in the in-plane direction of the sheet,
The battery unit (10) is separated by cutting the first sheet member (1) and the second sheet member (3),
Before or after the separation step, a sealing portion in which the first sheet member and the second sheet member are directly coupled is formed along the periphery of the active material filling chambers of the individual battery units that overlap each other. 4. The method for producing a battery according to any one of 3 above.

The battery manufacturing method according to claim 4, wherein the active material filling chambers (2, 4) are formed in a matrix of a plurality of vertical and horizontal portions in the first sheet member (1) and the second sheet member (3). .

The first sheet member (1) and the second sheet member (3) are formed so that the active material filling chambers (2, 4) penetrate in the sheet thickness direction, respectively, and the first sheet surface ( In the second sheet surface (1b, 3b) which is the sheet surface opposite to 1a, 3a), the opening of the active material filling chamber (2, 4) of each sheet member (1, 3) is the first and second. The method for manufacturing a battery according to claim 1, wherein the battery electrode is closed by the metal electrode plate (7, 8).

The battery manufacturing method according to claim 6, wherein the metal electrode plate (7, 8) is attached to an opening peripheral edge of the active material filling chamber (2, 4) on the second sheet surface (1b, 3b). Method.

The battery manufacture according to claim 7, wherein the metal electrode plates (7, 8) are thermally bonded via a hot-melt adhesive layer (13) formed on the second sheet surface (1b, 3b) side. Method.

The said separator (9) is affixed on the opening peripheral part of the said active material filling chamber (2, 4) in said 1st sheet | seat surface (1a, 3a). Battery manufacturing method.

The separator (9) is a hot-melt adhesive layer formed on the first sheet surface (1a, 3a) side with respect to at least one of the first and second sheet members (1, 3). The method for producing a battery according to claim 9, wherein the battery is thermally bonded via 13).

The first sheet member (1) is disposed such that the second sheet surface (1b) is on top, and the second sheet surface is closed so as to close the opening of the active material filling chamber (2) in that state. After attaching the first metal electrode plate (7) to (1b), the first sheet member (1) is turned upside down, and the first metal electrode plate (7) is placed in the active material filling chamber. The first electrode active material (5) is filled in the active material filling chamber (2) from the opening on the first sheet surface (1a) side while being used as the bottom of (2). 2. A method for producing a battery according to item 1.

After filling the first electrode active material (5) into the active material filling chamber (2) of the first sheet member (1), the active material filling chamber (2) on the first sheet surface (1a) side The method for manufacturing a battery according to claim 11, wherein the separator (9) is attached to the periphery of the opening.

The second electrode active material (6) is disposed on the separator (9) at a position corresponding to the active material filling chamber (2) of the first sheet member (1). The second sheet member (3) is stacked on the separator (9) so that the two-electrode active material (6) is accommodated in the active material filling chamber (4) of the second sheet member (3). The method for producing a battery according to claim 12, which is combined.

The second electrode active material (6) is formed in a paste form, and a plurality of paste filling windows (14) are formed on the printing mask member (15), and each paste filling window (14) is formed on the first sheet member ( 1) superposed on the separator (9) so as to correspond to the active material filling chamber (2) of 1), and in this state, the paste-like second electrode active material (6) is placed in the paste filling window. 14. The coating pattern of the second electrode active material (6) is formed on each of the separators (9) by removing the printing mask member (15) after scraping and filling in (14). Battery manufacturing method.

The second sheet member (3) has the second metal electrode plate (8) attached in advance so as to block the opening of the active material filling chamber (4) with respect to the second sheet surface (3b). The method of manufacturing a battery according to claim 13 or 14, wherein the battery is superimposed on the separator (9).

In at least one of the first sheet member (1) and the second sheet member (3), the opening of the active material filling chamber (2, 4) is blocked on the second sheet surface (1b, 3b). When arranging the metal electrode plates (7, 8), the positioning mask member (17) in which a plurality of positioning windows (16) are formed is attached to the second sheet surface (1b, 3b), each positioning window (16) is overlaid so as to correspond to each of the active material filling chambers (2, 4), and in that state, the metal electrode plate (16) is placed in each positioning window (16). The method for manufacturing a battery according to claim 6, wherein 7, 8) is arranged.

The first sheet member (1) and / or the second sheet member (3) is a sheet positioning penetration (21) in a positioning member (20) integrally attached to the sheet member (1, 3). Are formed, and the first sheet member (1) and the second sheet member (3) are connected to the active material filling chamber (3) by inserting the positioning pins (23) into the sheet positioning through portions (21). The battery manufacturing method according to any one of claims 1 to 16, wherein positioning and stacking are performed such that 2, 4) overlap each other.

The positioning member (20) is a frame member (20) that supports the first sheet member (1) and the second sheet member (3) along an outer peripheral edge portion, and the sheet positioning through portion (21 18. The method for manufacturing a battery according to claim 17, wherein a through hole or a notch formed in the frame member (20).

The first sheet member (1) and the second sheet member (3) are formed in a quadrilateral shape, and the frame member (20) is provided on at least two sides of the sheet members (1, 3) facing each other. The method for producing a battery according to claim 18.

The frame member (20) is provided on all four sides of the first sheet member (1) and the second sheet member (3), and supports the sheet members (1, 3) in a stretched state. The method for producing a battery according to claim 19.

The first sheet member (1) and / or the second sheet member (3) are formed by forming sheet positioning through portions in the sheet members (1, 3), and positioning pins ( 23), the first sheet member (1) and the second sheet member (3) are positioned and laminated so that the active material filling chambers (2, 4) overlap each other. The manufacturing method of the battery of any one.

The mask positioning penetration (15a) is formed in the printing mask member (15), and the positioning pin (23) is inserted into the mask positioning penetration (15a) and the sheet positioning penetration (21). The battery manufacturing according to any one of claims 17 to 21, wherein the printing mask member (15) is positioned and laminated on the first sheet member (1) or the second sheet member (3) by being inserted. Method.

The mask positioning penetration (17a) is formed in the positioning mask member (17), and the positioning pin (23) is inserted into the mask positioning penetration (17a) and the sheet positioning penetration (21). 23. The battery manufacturing according to claim 17, wherein the positioning mask member (17) is positioned and laminated on the first sheet member (1) or the second sheet member (3) by being inserted. Method.

An electrode lead extraction penetration part (24) is formed at a position adjacent to the active material filling chamber (2, 4) of at least one of the first sheet member (1) and the second sheet member (3), The first and second electrode lead portions (7a, 7a ′, 8a, 8a ′) extending from the outer edges of the first and second metal electrode plates (7, 8) are displaced from each other in the sheet in-plane direction. The battery manufacturing method according to any one of claims 1 to 23, wherein the battery is exposed in the electrode lead lead-out portion (24) in a positional relationship.

In the first sheet member (1) and the second sheet member (3), electrode lead take-out penetrating portions (24, 24) are respectively positioned adjacent to the active material filling chambers (2, 4). When the member (1) and the second sheet member (3) are stacked, the first and second metal electrode plates (7, 8) are formed so as to overlap each other and extend from the outer edges of the first and second metal electrode plates (7, 8). The battery manufacturing method according to any one of claims 1 to 24, wherein the second electrode lead portion (7a, 8a) is exposed in the electrode lead extraction penetration portion (24).

A plurality of active material filling chambers (2, 4) are formed in the sheet member (1, 3) made of a polymer material, and the active material filling chambers (2, 4) are filled with the electrode active material (5, 6). In addition, first and second metal electrode plates (7, 8) serving as a battery positive electrode and a negative electrode in contact with the electrode active material (5, 6) are provided at positions corresponding to the respective active material filling chambers (2, 4). By disposing the ones corresponding to the different active material filling chambers (2, 4) along the sheet surface so as to be insulated from each other, the sheet member (1, 3) is used as an electrode active material case, A laminated sheet assembly in which a plurality of battery units (10) in which the first and second metal electrode plates (7, 8) and the electrode active material (5, 6) are laminated are formed in the in-plane direction of the sheet. 11) the laminated sheet assembly manufacturing process for manufacturing and the battery unit (10) And a separation step of separating by cutting the sheet member (1,3),
An electrode lead extraction penetration part (24) is formed at a position adjacent to the active material filling chamber (2, 4) of the sheet member (1, 3), and the first and second metal electrode plates (7, 8). The first and second electrode lead portions (7a, 7a ′, 8a, 8a ′) extending from the outer edge of the electrode lead are exposed in the electrode lead lead-out portion (24). .

The first and second electrode lead portions (7a, 8a) extending from the outer edges of the first and second metal electrode plates (7, 8) are displaced from each other in the sheet plane direction. 27. The method of manufacturing a battery according to claim 26, wherein the battery is exposed in the electrode lead lead-out portion (24).

By bringing the measurement terminals (51, 52) into contact with the first and second electrode lead portions (7a, 8a) exposed in the electrode lead extraction / penetrating portion (24), each battery unit (10 The method for manufacturing a battery according to any one of claims 24 to 27, wherein the inspection measurement of (2) is performed prior to the separation step.

By temporarily short-circuiting the first and second electrode lead portions (7a, 8a) via the load resistor (30), a temporary discharge process for stabilizing the initial current of each battery unit (10) is performed. The battery manufacturing method according to any one of claims 24 to 28, which is performed prior to the separation step.

30. The battery unit (10) is configured as a lithium primary battery by using lithium metal as the negative electrode active material (5) and using MnO ₂ as the positive electrode active material (6). The manufacturing method of the battery as described in claim | item.