JP5772397B2 - Battery electrode manufacturing method and battery electrode - Google Patents

Description

In the present invention, a conductive layer and an active material layer are sequentially stacked on a conductive foil-shaped electrode plate so that an uncoated portion that exposes the surface of the foil-shaped electrode plate is formed. The present invention relates to a battery electrode manufacturing method for producing a battery electrode, and a battery electrode.

Such a battery electrode constitutes a power generation element that is a main part of the battery. In the power generation element, an active material layer is laminated on a foil electrode plate for each of the positive electrode side and the negative electrode side to form an electrode. In many cases, the positive electrode and the negative electrode are alternately stacked with a separator interposed therebetween.
In this battery electrode, when the active material is laminated on the foil electrode plate, the adhesion between the foil electrode plate and the active material may not always be sufficiently ensured depending on the selection of the material.
In such a case, as described in Patent Document 1 below, between the foil electrode plate and the active material layer, a conductor layer (so-called, for improving the adhesion between them and reducing the contact resistance) It is considered that the undercoat layer is disposed.
By disposing the conductor layer between the foil electrode plate and the active material layer, the adhesive strength of the active material layer can be improved, and the battery capacity and life characteristics can be improved.

Japanese Patent Laid-Open No. 2008-60060

However, when a conductor layer for improving adhesion is disposed between the foil-like electrode plate and the active material layer, a negative effect may occur in the electrode manufacturing process.
In other words, the conductive layer is formed on the foil electrode plate in consideration of the purpose of forming the conductive layer so that the conductive layer is surely present in the upper active material layer formation region. In general, the region for forming the conductor layer is made wider than the region for forming the active material layer so that the region for forming the conductor layer completely includes the region for forming the active material layer.
Therefore, on the foil electrode plate, there is a region where the lower conductor portion is exposed at the boundary between the uncoated portion where the active material layer is not formed and the active material layer formation region. Will do.

In the manufacturing process of the electrode, there is a step of detecting the formation position of the active material layer and performing some processing based on the detected position information. The detection of the formation position of the active material layer includes the edge of the active material layer. In many cases, the position is detected by an optical position detection means.
When detecting the edge position of the active material layer with the optical position detection means, the state of the reflected light needs to change clearly on both sides of the edge position of the active material layer in order to accurately detect the position. There is.
In general, there is a clear difference in the state of reflected light from the foil-like electrode plate and the active material layer as the base material, but they are usually similar in color between the active material layer and the conductor layer. In many cases, the states of the reflected light from them are similar, making it difficult to distinguish clearly.
For this reason, as described above, on the foil electrode plate, the conductor portion on the lower layer side is exposed at the boundary between the uncoated portion where the active material layer is not formed and the active material layer forming region. If there is an active region, the boundary position between the formation region of the active material layer and the exposed region of the conductor portion is difficult to specify accurately depending on the optical position detection means as described above. Will contain errors.
This detection error of the edge position of the active material layer results in a decrease in processing accuracy and a decrease in battery performance in a process using the position information.
The present invention has been made in view of such circumstances, and the object thereof is to provide an active material layer even when a conductor layer is disposed between a foil electrode plate and an active material layer in a battery electrode. It is in the point that the edge position of can be detected with high accuracy.

  1st invention of this application is a conductor layer, an active material layer, and the area | region other than the formation position of the uncoated part which exposes the surface of the said foil-like electrode board on the foil-like electrode board which has electroconductivity. In the method for manufacturing a battery electrode in which a battery electrode is manufactured by sequentially stacking and laminating, an upper layer is formed on at least a part of an edge portion on the side where the uncoated part is present in the active material layer forming region. A step of forming an active material layer protruding portion in which an edge of the active material layer on the side is located on the uncoated portion side with respect to an edge of the conductor layer on the lower layer side, and in the protruding portion of the active material layer And a step of specifying the position of the active material layer by an optical position detecting means.

That is, as a laminated form of the conductor layer and the active material layer on the foil electrode plate, the edge of the upper active material layer is closer to the uncoated part side than the edge of the lower conductor layer The active material layer is laminated in a state where the active material layer protrudes to the uncoated part side of the conductor layer.
As a result, in the region where the active material layer or the like is arranged as described above, the lower conductive layer is not exposed, and therefore it is difficult to discriminate between the conductive layer and the active material layer by the optical position detection means. Even so, the edge position of the active material layer can be detected with high accuracy.
In the portion of the active material layer that protrudes from the region where the conductor layer is formed, the conductor layer does not exist between the foil-like electrode plate, but the portion does not exist because the conductor layer does not exist. It does not contribute to the operation at all, but only slightly reduces the battery capacity.
Moreover, the portion of the active material layer that protrudes from the region where the conductor layer is formed need not be a large area, and may be the minimum necessary area, so that the battery capacity seen from the entire active material layer is only slightly reduced. It is.

According to a second invention of the present application, in addition to the configuration of the first invention, a distance between an edge of the active material layer and an edge of the conductor layer is 2 mm at the protruding portion of the active material layer. It is set as follows.
That is, it was confirmed by experiments that the decrease in the adhesive strength between the active material layer and the foil electrode plate can be sufficiently suppressed by setting the protruding width of the active material layer from the conductor layer to 2 mm or less.

In addition to the structure of the first or second invention, the third invention of the present application is an edge of the active material layer at the protruding portion of the active material layer formed on the foil-like electrode plate on the positive electrode side. On the boundary portion between the active material layer and the uncoated portion on the foil-like electrode plate on the positive electrode side based on the detected position information, the position is detected by the optical position detection means, A short-circuit prevention layer having an electric resistance larger than that of the foil electrode plate is formed.
That is, when the power generation element is configured by arranging the positive electrode and the negative electrode to face each other, the negative electrode side active material layer formation region is usually larger than the positive electrode side active material layer formation region, It is designed so that an expensive positive electrode active material can effectively contribute to battery operation. In the case of a lithium ion battery, the active material layer on the negative electrode side is formed to have a larger area than the formation region of the active material layer on the positive electrode side, so that the active material layer on the negative electrode side is formed during charging. It is possible to prevent Li electrodeposition from occurring at a location where there is not.
This means that the portion of the positive electrode on which the positive electrode active material layer is not formed faces the negative electrode.
In such a state, when the portion where the positive electrode active material layer is not formed and the negative electrode side portion come into contact with each other due to the intrusion of foreign matter, a large short-circuit current flows due to the low electrical resistance of the contact portion. Will end up.
Therefore, in the foil-like electrode plate on the positive electrode side, a short-circuit accident in which a large current flows by forming a short-circuit prevention layer having a large electrical resistance in a portion of the portion where the positive electrode active material layer is not formed and facing the negative electrode-side electrode To prevent.
This short-circuit prevention layer needs to be accurately arranged along the edge of the positive electrode active material layer. As described above, the edge position of the positive electrode active material layer is accurately detected, and the detection information is used. It is particularly effective to form a short-circuit prevention layer.

According to a fourth invention of the present application, in addition to the configuration of any one of the first to third inventions, an edge position of the active material layer in the protruding portion of the active material layer is used as the optical position detection means. Based on the detected position information, a cutting position of the foil electrode plate in a state where the conductor layer and the active material layer are laminated is set.
That is, in an electrode manufacturing process, after laminating an active material layer or the like on a foil-like electrode plate, a plurality of electrodes are often manufactured together by cutting and separating into a plurality.
When adopting such a manufacturing process, it is necessary that the area of the active material layer at the time of cutting and separation be set with high accuracy. If the area of the active material layer varies due to this cutting, battery capacity variation may be caused. become.
In such a case, it is particularly effective to accurately detect the edge position of the active material layer and set the cutting position using the detection information.

  According to a fifth invention of the present application, in addition to the configuration of any one of the first to fourth inventions, the foil electrode plate is formed in a long band shape, and the conductor layer and the active material layer Is formed in a strip shape extending in the longitudinal direction of the foil electrode plate in a state where the uncoated part is located at the widthwise end of the foil electrode plate, and the active material layer and the uncoated part, A range extending substantially over the entire length of the boundary portion is set as the protruding portion of the active material layer.

That is, when a conductor layer and an active material layer are formed in a strip shape on a long strip-like foil electrode plate in a state extending in the longitudinal direction, the active material layer extending in the longitudinal direction of the foil electrode plate The edge of the active material layer can be detected with high accuracy over substantially the entire length of the boundary with the coating portion.
This makes it possible to accurately perform various types of processing on the long strip electrode.

  In addition, the sixth invention of the present application provides a conductive layer and an active material in a region other than a formation position of an uncoated portion that exposes the surface of the foil-shaped electrode plate on the conductive foil-shaped electrode plate. In the battery electrode in which the layers are sequentially stacked and stacked, at least a part of the edge portion on the existing side of the uncoated portion in the active material layer forming region, the end of the active material layer on the upper layer side An active material layer protruding portion whose edge is located closer to the uncoated portion than the edge of the conductor layer on the lower layer side is formed.

That is, as a laminated form of the conductor layer and the active material layer on the foil electrode plate, the edge of the upper active material layer is closer to the uncoated part side than the edge of the lower conductor layer The active material layer is laminated in a state where the active material layer protrudes to the uncoated part side of the conductor layer.
As a result, in the region where the active material layer or the like is arranged as described above, the lower conductor layer is not exposed, so that the edge position of the active material layer can be detected with high accuracy by the optical position detecting means.

According to a seventh aspect of the present application, in addition to the structure of the sixth aspect, a distance between an edge of the active material layer and an edge of the conductor layer is 2 mm at the protruding portion of the active material layer. It is set as follows.
That is, by setting the protruding width of the active material layer from the conductor layer to 2 mm or less, it is possible to sufficiently suppress the decrease in the adhesive strength between the positive electrode active material layer and the foil-like positive electrode plate.

In addition to the configuration of the sixth or seventh invention described above, the eighth invention of the present application is provided on the boundary portion between the active material layer and the uncoated portion of the foil-like electrode plate on the positive electrode side. Further, a short-circuit prevention layer having a larger electric resistance than that of the foil electrode plate is formed.
By providing a short-circuit prevention layer having a higher electrical resistance than the foil-like electrode plate on the positive electrode side on the boundary portion between the active material layer and the uncoated part in the foil-like electrode plate on the positive electrode side, When configured to prevent a large short circuit current from flowing when the positive electrode side electrode and the negative electrode side electrode are in contact, the edge position of the positive electrode active material layer is accurately detected, and the detection information is used. The short-circuit prevention layer can be formed with high accuracy.

According to the first invention, in the battery electrode, even when the conductor layer is disposed between the foil electrode plate and the active material layer, the edge of the upper active material layer is located on the lower layer side. Accurate positioning of the edge of the active material layer by placing the active material layer on the uncoated part side of the conductor layer and protruding from the conductor layer to the uncoated part side It can be detected well.
Further, according to the second aspect, even when the active material layer protrudes from the conductor layer, it is possible to sufficiently suppress a decrease in the adhesive strength between the active material layer and the foil electrode plate.
According to the third aspect, the edge position of the positive electrode active material layer can be detected with high accuracy, and the short-circuit prevention layer can be formed with high accuracy.
According to the fourth aspect of the invention, variation in battery capacity can be suppressed by accurately detecting the edge position of the active material layer and cutting the electrode using the detected information.
Further, according to the fifth aspect, since the edge of the active material layer can be detected with high accuracy over substantially the entire length in the longitudinal direction of the foil-like electrode plate, various treatments for the long band-like electrode are performed with high accuracy. It becomes possible.

Further, according to the sixth invention of the present application, the edge position of the active material layer can be accurately detected even when the conductor layer is disposed between the foil electrode plate and the active material layer. .
Further, according to the seventh invention of the present application, even when the active material layer is laminated in a state of protruding to the uncoated part side from the conductor layer, the adhesive strength between the active material layer and the foil electrode plate is reduced. Can be sufficiently suppressed.
According to the eighth invention of the present application, the edge position of the positive electrode active material layer can be detected with high accuracy, and the short-circuit prevention layer can be formed with high accuracy.

The principal part expanded sectional view concerning embodiment of this invention The figure which shows the manufacturing process of the electrode foil concerning embodiment of this invention The figure which shows the manufacturing process of the electrode foil concerning embodiment of this invention The figure which shows the manufacturing process of the electrode foil concerning embodiment of this invention The figure which shows the manufacturing process of the electrode foil concerning embodiment of this invention Schematic explanatory drawing of the press work process with respect to the electrode foil concerning embodiment of this invention The figure which shows the press work with respect to the electrode foil concerning embodiment of this invention The perspective view which shows the structure of the electric power generation element concerning embodiment of this invention. The graph which shows the experimental data concerning embodiment of this invention The graph which shows the experimental data concerning embodiment of this invention The perspective view which shows the internal structure of the battery concerning embodiment of this invention. 1 is an external perspective view of a battery according to an embodiment of the present invention. The figure which shows the manufacturing process of the electrode foil concerning another embodiment of this invention. A figure explaining the measurement method of peel strength

Hereinafter, an embodiment of a method for producing a positive electrode for a battery according to the present invention will be described with reference to the drawings.
In the present embodiment, a non-aqueous electrolyte secondary battery (more specifically, a lithium ion battery), which is an example of a secondary battery, is illustrated as a battery, and a manufacturing method thereof will be described.

[Configuration of Nonaqueous Electrolyte Secondary Battery RB]
As shown in the perspective view of FIG. 12, the non-aqueous electrolyte secondary battery RB of the present embodiment has a lid on the open surface of a bottomed tubular body (more specifically, a bottomed rectangular tubular body). It has a battery casing BC (hereinafter simply referred to as “casing BC”) formed by covering and welding the portion 2. The lid portion 2 is formed of a strip-shaped rectangular plate material, and a terminal bolt 5 that is a positive electrode terminal and a terminal bolt 7 that is a negative electrode terminal are attached to a surface on the outer side of the casing BC. It has been.
The can body 1 is a flat rectangular parallelepiped shape in accordance with the shape of the lid portion 2, and therefore, the casing BC as a whole has a flat, substantially rectangular parallelepiped shape.

On the inner side of the casing BC, the power generation element 3 and current collectors 4 and 6 indicated by a two-dot chain line in FIG. 11 are housed and disposed in a state of being immersed in the electrolytic solution. FIG. 11 shows the inner side of the casing BC as a perspective view looking up from the lower side with the can 1 removed.
The current collectors 4 and 6 are members for electrically connecting the power generation element 3 and the terminal bolts 5 and 7, and both are formed of a conductor.
The current collector 4 and the current collector 6 have a relationship in which substantially the same shape is arranged symmetrically, but the materials are different. The positive electrode side current collector 4 is made of aluminum, and the negative electrode side current collector 6 is made of copper.

The current collectors 4 and 6 are formed by bending and forming a narrow, substantially rectangular plate member made of the above metal material into a predetermined shape, and the lid portion 2 which is a surface on which the terminal bolts 5 and 7 are arranged. A portion extending along the surface of the cover 2 and bent in the vicinity of the end in the longitudinal direction of the cover 2 by 90 degrees downward (opposite to the side where the terminal bolts 5 and 7 are present). It has a substantially L-shaped bent shape that is continuous with a portion extending in the normal direction of the inner surface. In the vertical posture portions of the current collectors 4 and 6, connection portions 4 a and 6 a for being bent further toward the power generation element 3 and connected to the power generation element 3 are formed.
The substantially L-shaped current collectors 4, 6 are arranged in a posture along the lid portion 2 and the narrow side surface of the can body 1 that is connected to the end portion in the longitudinal direction of the lid portion 2 in an orthogonal posture. .

As will be described in detail later, the power generation element 3 is a positive electrode foil-shaped electrode plate (hereinafter referred to as a “foil-shaped positive electrode plate”) and a negative electrode, both of which are made of a conductive material and formed into a long strip shape. An active material is applied to each of the foil-like electrode plates on the side (hereinafter referred to as “foil-like negative electrode plate”) to produce a positive electrode side electrode and a negative electrode side electrode, which are also laminated with a long separator interposed therebetween. It is comprised as what is called a winding type electric power generation element wound in the state.
In the state where the power generating element 3 is wound as described above, the uncoated portion 3a of the positive electrode (the portion where the foil-like positive electrode plate is exposed without applying the positive electrode active material) is lateral (foil-like). It protrudes in the direction orthogonal to the longitudinal direction of the positive electrode plate, and the uncoated portion 3b of the negative electrode (the portion where the negative electrode active material is not applied and the foil-shaped negative electrode plate is exposed) is on the opposite side (foil) Projecting in a direction perpendicular to the longitudinal direction of the negative electrode plate.
The power generation element 3 of the present embodiment is adapted to a flat casing BC by winding a positive electrode and a negative electrode in a flat shape.
The power generating element 3 is disposed in the can 1 so that the winding axis of the positive electrode or the like is parallel to the longitudinal direction of the lid 2, and as schematically shown in FIG. The connecting portion 4a of the current collector 4 enters the position of the uncoated portion 3a of the electrode, and the connecting portion 6a of the current collector 6 enters the position of the uncoated portion 3b of the negative electrode.
The uncoated portion 3a of the positive electrode is welded to the connecting portion 4a of the current collector 4 in a bundled state, and the uncoated portion 3b of the negative electrode is connected to the connecting portion 6a of the current collector 6 in a bundled state. And the power generation element 3 is supported by the current collectors 4 and 6.

As described above, the terminal bolt 5 on the positive electrode side attached to the lid 2 made of metal (specifically, aluminum) is electrically connected to the current collector 4 on the positive electrode side, and the terminal bolt on the negative electrode side. 7 is electrically connected to the current collector 6 on the negative electrode side.
The current collector 4 on the positive electrode side is electrically connected to the terminal bolt 5 via a rivet 8 integrally formed on the head side of the terminal bolt 5, and the rivet 8 includes the current collector 4, the current collector 4, and the current collector 4. Lower gasket 12 for electrical insulation between rivet 8 and lid 2, upper gasket 11 for electrical insulation between lid 2 and terminal bolt 5 including lid 2 and rivet 8 and lid 2 In this state, the current collector 4 is caulked at the inner end portion of the casing BC, thereby fixing the current collector 4 to the lid portion 2.
The negative electrode side has the same configuration, and the negative electrode side current collector 6 is electrically connected to the terminal bolt 7 via a rivet 15 integrally formed on the head side of the terminal bolt 7. The electrical current between the terminal 6 including the electrical current 6, the current collector 6 and the lower gasket 18 for electrical insulation between the rivet 15 and the lid 2, the lid 2 and the rivet 15 and the lid 2 The current collector 6 is fixed to the lid portion 2 by being caulked at the inner end of the casing BC in a state of passing through the upper gasket 17 for insulation.
The upper gaskets 11 and 17 and the lower gaskets 12 and 18 also serve as a hermetic seal between the lid 2 and the rivets 8 and 15 penetrating the lid 2.

[Manufacturing process of non-aqueous electrolyte secondary battery RB]
Next, the manufacturing process of the secondary battery RB having the above configuration will be described mainly with respect to the manufacturing process of the electrode plate of the power generation element 3.
[Production process of positive electrode]
First, the manufacturing process of the positive electrode of the power generation element 3 will be described.
As described above, the positive electrode is prepared by applying a positive electrode active material to a foil-shaped positive plate. In this embodiment, an aluminum foil having excellent oxidation resistance is used as the foil-shaped positive plate. In the present embodiment, the aluminum foil is formed in a long band shape having a width of 160 mm, and the thickness of the aluminum foil may be 12 μm to 25 μm, but is preferably 15 μm. Other than aluminum foil, titanium, stainless steel, nickel, conductive polymer, etc. can be formed into a foil shape and used as a foil-like positive electrode plate.
In the present embodiment, lithium iron phosphate (LiFePO ₄ ) is used as the positive electrode active material applied to the foil-shaped positive electrode plate, and the relation between the foil-shaped positive electrode plate and the positive electrode active material layer is related thereto. A conductor layer (so-called “undercoat layer”) for improving the adhesion strength of the positive electrode active material layer to reduce contact resistance is applied between the conductor layer and the positive electrode active material layer. Are stacked one after another.
In the present embodiment, as a coating agent for forming this conductor layer, acetylene black 10% by weight, glycerated chitosan 4.5% by weight, pyrrolimetic acid 4.5% by weight and NMP (N-methyl-2- (Pyrrolidone) 81% by weight is used as a slurry, and this coating agent is applied to both the front and back surfaces of the foil-like positive electrode plate.

FIG. 2A shows a state in which the conductor layer 21 is formed on the surface of the aluminum foil 22 that is a foil-like positive electrode plate in a plan view.
In FIG. 2A, an arrow B indicates the width direction of the long strip-shaped aluminum foil 22, and the areas to be the uncoated portions 3a are set at both ends in the width direction. The conductor layer 21 is formed in a strip shape extending in the longitudinal direction of the aluminum foil 22 (the direction indicated by the arrow A in FIG. 2A) in the central region in the width direction other than the formation position of the uncoated portion 3a. Yes. In this embodiment, the widths of the portions where the conductor layers 21 at both ends in the width direction are not formed (the length in the width direction of the aluminum foil 22) are set to 10 mm, respectively.
Note that FIG. 2B shows an enlarged view of a portion showing a schematic position surrounded by a two-dot chain line D in FIG. 2A for comparison with a processing state in a subsequent process. .
The aluminum foil 22 is in the form of a long band, and the aluminum foil 22 wound in a roll shape is fed and conveyed in the longitudinal direction of the aluminum foil 22 (the direction indicated by the arrow A in FIG. 2A). On the aluminum foil 22 to be conveyed, the conductor layer 21 is applied by gravure coating. In the present embodiment, the coating thickness of the conductor layer 21 is set so that the thickness of the conductor layer 21 is 1 μm to 2 μm after drying.
In the present embodiment, two strips of the positive electrode are produced by simultaneous processing. That is, the length of the aluminum foil 22 in the width direction (the direction indicated by the arrow B in FIG. 2A) is twice the width of the positive electrode, and the final step of the manufacturing process of the positive electrode. 2 is cut at the center position in the width direction indicated by a one-dot chain line C in FIG.
The position where the conductor layer 21 is applied is detected by optically detecting the edge position of the aluminum foil 22 in the width direction (direction indicated by arrow B), and based on the position information, the center position in the width direction of the aluminum foil 22; It is controlled with high accuracy so that the central position of the coating width of the conductor layer 21 coincides.
The conductor layer 21 is dried after coating.
The above coating process of the conductor layer 21 is repeated on the opposite surface of the aluminum foil 22.

After the conductor layer 21 is applied and further dried, the active material layer and the short-circuit prevention layer are then applied in a state of being overlaid on the conductor layer 21.
In the present embodiment, as described above, lithium iron phosphate (LiFePO ₄ ) is used as the positive electrode active material.
When the short-circuit prevention layer is assembled as the power generation element 3, in the portion where the positive electrode active material is not applied in the positive electrode side electrode, it is applied and formed on the portion facing the negative electrode active material layer of the negative electrode side electrode, This is to prevent the uncoated portion 3a of the positive electrode and the negative electrode from facing each other. By providing a short-circuit prevention layer, even when the separator is broken due to intrusion of foreign matter, it is possible to prevent the occurrence of an event such as heat generation due to contact between the negative electrode active material layer and the foil-like positive electrode plate. .
This short-circuit prevention layer is applied after the application of the positive electrode active material layer, but the application of the positive electrode active material layer and the application of the short-circuit prevention layer are performed in series, and the short-circuit prevention layer is in a state where the positive electrode active material layer is not dried. Is applied. By doing in this way, the peeling strength of a short circuit prevention layer can be raised.

First, application of the positive electrode active material layer will be described.
The positive electrode active material layer is a mixture of 87% by weight of micro-sized particles of LiFePO ₄ powder, 5% by weight of acetylene black as a conductive aid, and 8% by weight of polyvinylidene fluoride (PVDF) as a binder. , NMP (N-methyl-2-pyrrolidone) was added to form a positive electrode mixture paste on both the front and back surfaces of the aluminum foil 22 coated with the conductor layer 21, and the conductor layer 21 and the aluminum foil 22 stacked structures are formed.
Note that the micro-sized particles of LiFePO ₄ having a D50 (median diameter) of 20 μm are used, and all the LiFePO ₄ particles are covered with a carbon coat layer having a layer thickness of about 1 nm. This carbon coat layer is included in the particle diameter of the LiFePO ₄ particles.
The coating process is the same as the coating process of the conductor layer 21, and the aluminum foil 22 on which the conductor layer 21 is formed is fed and conveyed in the longitudinal direction thereof, and the conductor layer 21 of the aluminum foil 22 that is conveyed. The above paste is applied by die coating to form a strip-like positive electrode active material layer 23 extending in the longitudinal direction of the aluminum foil 22, and the state shown in FIG.
As shown in FIG. 3A, the positive electrode active material layer 23 is applied in a strip shape extending in the longitudinal direction of the aluminum foil 22 (the direction indicated by the arrow A in FIG. 3A). The coating thickness of the positive electrode active material layer 23 may be 40 μm to 130 μm, and is 130 μm in this embodiment.
The positive electrode active material layer 23 is applied by optically detecting the edge position of the aluminum foil 22 in the width direction (the direction indicated by arrow B in FIG. 3A) or the edge position of the conductor layer 21 in the width direction. Based on the positional information, the center position in the width direction of the aluminum foil 22 or the conductor layer 21 and the center position of the coating width of the positive electrode active material layer 23 are controlled with high accuracy.

The coating width of the positive electrode active material layer 23 (the coating width in the direction indicated by the arrow B in FIG. 3A) is the exposed region of the aluminum foil 22 that becomes the uncoated portion 3a at both ends in the width direction of the aluminum foil 22. Is set to a coating width that completely covers the conductor layer 21.
FIG. 3B shows an enlarged view of the region surrounded by the two-dot chain line D in FIG. 3A, corresponding to FIG. 2B.
The edge of the conductor layer 21 in FIG. 2B is indicated by a broken line E in FIG. 3B, and the edge in the width direction (direction indicated by arrow B) of the positive electrode active material layer 23 on the upper layer side is The positive electrode active material layer 23 protrudes from the conductor layer 21 so as to be located on the region side where the aluminum foil 22 to be the uncoated portion 3a is exposed from the edge of the conductor layer 21 on the lower layer side indicated by the broken line E. ing.
For convenience of explanation, a portion where the positive electrode active material layer 23 protrudes from the position where the conductor layer 21 is formed to the exposed region side of the aluminum foil 22 may be referred to as an “active material layer protruding portion”.
In the present embodiment, in the longitudinal direction of the aluminum foil 22, the positive electrode active material layer 23 protrudes from the conductor layer 21 over the entire length of the coating range of the conductor layer 21 and the positive electrode active material layer 23. A range extending over substantially the entire length of the boundary portion between the material layer and the uncoated portion is set as the protruding portion of the active material layer.
A distance W between the edge position of the positive electrode active material layer 23 and the edge position (position indicated by a broken line E) of the conductor layer 21 in the width direction (direction indicated by arrow B) of the aluminum foil 22 (FIG. 3B). Reference) sets the coating width of the positive electrode active material layer 23 to be 2 mm or less.

After the application of the positive electrode active material layer 23, the short-circuit prevention layer is subsequently applied in the same transport path.
The short-circuit prevention layer is obtained by mixing the fine particles of the electrically insulating member with a binder and further mixing it with an appropriate liquid to form a paste on both front and back surfaces of the aluminum foil 22 coated with the positive electrode active material layer 23. Apply.
As the fine particles of the electrical insulating member, organic particles such as polyimide powder can be used in addition to inorganic particles such as Al ₂ O ₃ , SiO ₂ , ZrO ₂ , TiO ₂ and MgO. Of these, Al ₂ O ₃ is preferably used from the viewpoints of stability and ease of handling, and γ-type alumina particles are particularly preferable from the viewpoint of adhesion to the foil-like positive electrode plate and bonding strength.
The particle diameter of the fine particles can be 1 nm to 2000 nm as the median of the primary particle diameter, but it is preferable to use 1 nm to 200 nm from the viewpoint of adhesion to the foil-like positive electrode plate and bonding strength. More preferably, it is 1 nm-20 nm.
Polyvinylidene fluoride (PVDF), polyimide, polyamideimide, etc. can be used as the binder to be mixed with the fine particles of the electrically insulating member, but from the viewpoint of adhesion and foil strength with the foil-like positive electrode plate, It is preferable to use PVDF.
In this embodiment, 2.1 kg of NMP solution containing 2.1 kg of γ-type alumina particles having a particle size of 5 nm, a specific surface area of 96 m ² / g, and a tap density of 0.04 g / cm 3 and 12% of PVDF as a binder. (2.567 kg as the amount of PVDF) was mixed with a solution dissolved in 6.0 kg of NMP and uniformly dispersed to obtain a slurry-like short-circuit preventing paste.
The constituent material of the short-circuit prevention layer 24 is not necessarily the electrical insulating member as described above, but it is necessary that the electrical resistance is sufficiently high, and at least the electrical resistance is higher than that of the aluminum foil 22. meaningless.

The coating process is the same as the coating process of the positive electrode active material layer 23 and the like, and the short-circuit prevention layer 24 is formed by die coating on the aluminum foil 22 fed and conveyed in a state where the positive electrode active material layer 23 and the like are coated. Application is made as shown in FIG.
FIG. 4B is an enlarged view of the vicinity of the region indicated by a two-dot chain line D in FIG. 4A in correspondence with FIGS. 2B and 3B.
The application position of the short-circuit prevention layer 24 overlaps the edge of the positive electrode active material layer 23 at both end positions of the positive electrode active material layer 23 in the width direction of the aluminum foil 22 (the direction indicated by arrow B in FIG. 4A). At the same time, it extends in the longitudinal direction of the aluminum foil 22 (the direction indicated by the arrow A in FIG. 4A) from the edge of the positive electrode active material layer 23 to the exposed portion side of the aluminum foil 22 over a set width range. It is applied in a strip shape.

As shown in FIG. 1 showing the vicinity of the boundary between the positive electrode active material layer 23 and the short-circuit prevention layer 24 as an enlarged cross-sectional view in the longitudinal direction of the aluminum foil 22, the short-circuit prevention layer 24 is not coated with the positive electrode active material layer 23. It is formed on the boundary part with the processing part 3a, and is applied in a state of spreading from the position overlapping the inclined part near the edge of the positive electrode active material layer 23 to the exposed region of the aluminum foil 22. Further, the coating thickness of the short-circuit prevention layer 24 is set to 3 μm to 15 μm so that the short-circuit prevention layer 24 does not become higher than the coating portion of the positive electrode active material layer 23.
Thus, the reason why the short-circuit prevention layer 24 is applied from the inclined portion in the vicinity of the edge of the positive electrode active material layer 23 is to increase the bonding strength between the positive electrode active material layer 23 and the short-circuit prevention layer 24. In addition, the height of the short-circuit prevention layer 24 is set lower than the height of the positive electrode active material layer 23. In the short-circuit prevention layer 24, the binder is used to reliably bind the metal oxide fine particles. This is because the amount of used is increased, and when applied in a state of being placed on the positive electrode active material layer 23, it is difficult to separate from the press roll in the press processing described later. In FIG. 1, the positive electrode active material layer 23 and the short-circuit prevention layer 24 are shown in a state where they are applied to both the front and back surfaces of the aluminum foil 22, and the thickness of each layer is not necessarily drawn in an accurate ratio. Absent.

The coating width of the short-circuit prevention layer 24 in the width direction of the aluminum foil 22 (the direction indicated by the arrow B in FIG. 1 and the like) is such that when the positive electrode and the negative electrode are wound, The width is set so as to cover a region where the positive electrode active material layer 23 is not applied in a region facing the application portion of the negative electrode active material layer of the side electrode.
That is, the application width of the negative electrode active material layer of the negative electrode is set to be slightly wider than the positive electrode active material layer 23 described above, and the difference between the application width of the positive electrode active material layer 23 and the application width of the negative electrode active material layer. This portion is filled with the short-circuit prevention layer 24.
As for the application position of the short-circuit prevention layer 24, the edge position of the positive electrode active material layer 23 in the width direction of the aluminum foil 22 is detected by optical position detection means using an optical sensor such as an imaging device, and the detection information thereof. The position of the positive electrode active material layer 23 is specified based on the above, and the edge of the short-circuit prevention layer 24 is controlled with high accuracy so as to overlap the inclined portion of the edge of the positive electrode active material layer 23 (see FIG. 1). ing.

As this optical position detection means, for example, the vicinity of the edge position of the positive electrode active material layer 23 is imaged by an imaging device, and the positive electrode active material layer is obtained from the color change information in the width direction of the aluminum foil 22 in the captured image. What is necessary is just to specify the edge position of 23.
By controlling the application position of the short-circuit prevention layer 24 or the transport position of the aluminum foil 22 in the width direction of the aluminum foil 22 based on the detection information of the edge position of the positive electrode active material layer 23 thus detected. The short-circuit prevention layer 24 can be applied with high accuracy.
Thus, the optical position detection means continuously detects the edge position of the positive electrode active material layer 23 over the entire length of the application of the short-circuit prevention layer 24 in relation to control the formation position of the short-circuit prevention layer 24. As described above, the active material layer protrudes from a range that extends over substantially the entire length of the boundary between the positive electrode active material layer 23 and the uncoated portion 3a.
After the positive electrode active material layer 23 and the short-circuit prevention layer 24 are applied to the aluminum foil 22, the aluminum foil 22 is subjected to a drying process. Is applied and dried.

After the conductor layer 21, the positive electrode active material layer 23, and the short-circuit prevention layer 24 are formed on the front and back surfaces of the aluminum foil 22 through the above steps, press working is performed.
The press processing includes press processing for suppressing the bending of the positive electrode, and press processing for increasing the density of the positive electrode active material layer 23. The aluminum foil 22 (positive electrode active material) fed and conveyed The material having the layer 23 or the like applied thereto is sequentially processed.
The press processing is performed by a press processing apparatus PM schematically shown in FIG.
The press working apparatus PM pulls out the aluminum foil 22 from the roll 31 of the aluminum foil 22 coated with the positive electrode active material layer 23 and the like, and applies a predetermined tension to the conveyance system 32 and the positive electrode active material layer 23 and the like. Of the applied aluminum foil 22, an intermittent roll press device 33 for extending the exposed portions of the aluminum foil 22 at both ends in the width direction, and a main roll for extending the entire application region of the positive electrode active material layer 23. A press device 34 is provided.

As schematically shown in the perspective view of FIG. 7, the intermittent roll press device 33 includes a pair of pressure rollers 35 and 36 sandwiching the conveyance path of the aluminum foil 22, and a pair of pressure rollers by a motor (not shown). The rollers 35 and 36 are driven to rotate.
One pressure roller 35 of the pair of pressure rollers 35, 36 has a convex portion 35 a that protrudes in a plate shape with a low step at both end portions in the width direction of the circumferential surface thereof at a set interval. It is formed in a state aligned in the circumferential direction.
The shape of the convex portion 35a is formed in a substantially rectangular shape when viewed from the normal direction of the peripheral surface of the pressure roller 35. More specifically, the convex portion 35a has a rectangular shape with rounded corners on the inner side.
The positions where the convex portions 35a are formed on the pressure roller 35 are set at positions corresponding to both ends in the width direction of the aluminum foil 22 on which the positive electrode active material layer 23 and the like are applied and formed. Only the exposed part of the foil 22 is pressed.
The uncoated portion of the positive electrode active material layer 23 is pressed by the convex portion 35a of the pressure roller 35 and stretched in advance to suppress the bending of the positive electrode, which will be described in detail later.

As a specific size of each part in the intermittent roll press device 33, the pressure roller 35 is a cylindrical roller having a diameter of 118 mm, and a convex portion 35a having a height of 1 mm is formed.
If the interval (pitch) of the convex portions 35a in the circumferential direction in the pressure roller 35 is set to 15 mm to 50 mm, a desired stretching effect can be obtained, and a particularly good result can be obtained by setting it to about 30 mm. It was.
The pair of pressure rollers 35 and 36 press and process the sandwiched conveyed product with a predetermined pressure. In the present embodiment, the pair of pressure rollers 35 and 36 is set to apply a linear pressure of 100 kgf / cm ² or more. .

In the present embodiment, the main roll press device 34 uses a press roller having a diameter of 300 mm and presses the application forming portion of the positive electrode active material layer 23 with a linear pressure of 200 kgf / cm ² .
The relationship between the linear pressure by the intermittent roll press device 33 and the linear pressure by the main roll press device 34 is set so that the linear pressure by the intermittent roll press device 33 is at least 30% or more of the linear pressure by the main roll press device 34. It was confirmed that no bending occurred.
In the present embodiment, the transport system 32, the intermittent roll press device 33 and the main roll press device 34 drive and drive the aluminum foil 22 coated with the positive electrode active material layer 23 and the like at a speed of 20 m / min or more. Yes.
The tension applied to the aluminum foil 22 by the transport system 32 may be about 10N to 60N, but is preferably 20N to 30N.

The aluminum foil 22 coated and formed with the positive electrode active material layer 23 and the like is drawn out from the roll 31 and passed through the intermittent roll press device 33 and the main roll press device 34 to be subjected to a press working process. As shown in FIG. 6, a pressurization mark 25 corresponding to the convex portion 35a of the pressure roller 35 is formed. In the present embodiment, the positive electrode active material layer 23 having a thickness of 130 μm is compressed to a thickness of 80 μm on one side by the above-described press processing, and an intermittent roll press device is applied to an uncoated portion of the positive electrode active material layer 23. A press mark 25 rolled to 95% of the original thickness is formed in the portion pressed at 33.
If the application forming portion of the positive electrode active material layer 23 on the aluminum foil 22 is pressed by the main roll press device 34 without the press processing in the intermittent roll press device 33, the positive electrode active material layer 23 is formed by applying a strong pressure. Although the portion extends in the longitudinal direction, the exposed portion of the aluminum foil 22 does not act so strongly, and the elongation in the longitudinal direction is reduced.
As a specific example, when the elongation ratio in the longitudinal direction before and after the press working in the coating formation portion of the positive electrode active material layer 23 is 0.346%, the elongation in the longitudinal direction before and after the press working in the exposed portion of the aluminum foil 22 is performed. The rate is 0.031%, and the elongation rate is more than 10 times.
No measures are taken against the difference in elongation, and the aluminum foil 22 coated with the positive electrode active material layer 23 and the like is cut at the position indicated by a one-dot chain line C in FIG. The positive electrode active material layer 23 is curved like a bow in a posture where the application side is convex.
On the other hand, as described above, the exposed portion of the aluminum foil 22 is pressed by the intermittent roll press device 33 and stretched to extend in the longitudinal direction in the coating formation portion of the positive electrode active material layer 23, and to form aluminum. The extension in the longitudinal direction of the exposed portion of the foil 22 is balanced, and the curvature when cut at the position indicated by the alternate long and short dash line C in FIG. 5 is sufficiently suppressed.

When the press working process is completed as described above, the aluminum foil 22 coated with the positive electrode active material layer 23 is then cut in the longitudinal direction.
The cutting position is a position indicated by a one-dot chain line C in FIG. 5. By cutting at the position indicated by the one-dot chain line C, two strips of positive electrode on the same shape are obtained.
This cutting process is performed in the same manner as the apparatus shown in FIG. 6, for example, at a position indicated by an alternate long and short dash line C while feeding and transporting the aluminum foil 22 after the press processing (coated with the positive electrode active material layer 23 or the like). Cut with a cutter blade.
The position of the one-dot chain line C is the center of the coating range of the positive electrode active material layer 23 in the width direction, and the setting of the cutting position by a cutter or the like is the width direction of the positive electrode active material layer 23 in the width direction of the aluminum foil 22 The edge positions at both ends are detected by optical position detection means using an optical sensor such as an imaging device, and control is performed so as to cut the center of both edge positions.
As this optical position detection means, as in the case of the application of the short-circuit prevention layer 24, for example, the vicinity of the edge position of the positive electrode active material layer 23 is imaged with an imaging device, and the aluminum foil 22 in the captured image is captured. The edge position of the positive electrode active material layer 23 may be specified from the color change information in the width direction.
Based on the detection information of the edge position of the positive electrode active material layer 23 thus detected, the position of the cutter or the transport position of the aluminum foil 22 in the width direction of the aluminum foil 22 is controlled, so that the positive electrode active material layer 23 is controlled. The aluminum foil 22 coated with the material layer 23 can be cut with high accuracy. Of course, only one of the edge positions at both ends in the width direction of the positive electrode active material layer 23 is optically detected, and a position separated from the detection position by ½ of the coating width of the positive electrode active material layer 23 is defined as a cutting position. It may be specified.
As described above, the optical position detection means continuously detects the edge position of the positive electrode active material layer 23 over the entire length of the aluminum foil 22 in relation to controlling the cutting position of the aluminum foil 22. As described above, the active material layer protrudes from a range that extends over substantially the entire length of the boundary between the positive electrode active material layer 23 and the uncoated portion 3a.

[Negative electrode manufacturing process]
Next, the manufacturing process of the negative electrode of the power generation element 3 will be described.
Similarly to the case of the positive electrode, the negative electrode on the negative electrode was prepared by simultaneous processing, and as a final step in the manufacturing process of the negative electrode, the two continuous electrodes were formed in the width direction. It cut | disconnects in the width direction center position, and isolate | separates into two negative electrode side electrodes.
As described above, the negative electrode is prepared by applying a negative electrode active material to a foil-like negative electrode plate. In this embodiment, a copper foil that is stable in a reduction field and excellent in conductivity is made of a foil-like negative electrode plate. Used as This copper foil is formed in the shape of a long strip having a width of 170 mm, and the thickness may be 7 μm to 15 μm, but in this embodiment, the thickness is 10 μm. Other than copper foil, nickel, iron, stainless steel, titanium, aluminum, calcined carbon, conductive polymer, conductive glass, Al-Cd alloy, etc., and copper for improving adhesion, conductivity and oxidation resistance. Such a surface treated with carbon, nickel, titanium, silver or the like can be formed into a foil shape and used as a foil-like positive electrode plate. Among these, nickel foil, iron foil, and alloy foil including them in part are also stable in a reduction field and excellent in conductivity.
In the present embodiment, graphite is used as the negative electrode active material applied to the foil-like negative electrode plate, but various materials that occlude and release Li ions can be used in addition to graphite. For example, lithium titanate having a spinel crystal structure, lithium metal, lithium-containing alloy (for example, lithium-aluminum, lithium-lead, lithium-tin, lithium-aluminum-tin and lithium-gallium), wood alloy, amorphous Carbon, fibrous carbon, petroleum pitch carbon, coal coke carbon, and the like can be used.
Further, the carbon material can be modified by adding phosphorus or boron in addition to metal oxides such as tin oxide and silicon oxide. Alternatively, lithium may be inserted into the carbon material in advance by using graphite and lithium metal or a lithium-containing alloy together or by electrochemical reduction.

About said negative electrode active material, NMP is added to the mixture which consists of 94 weight% of graphite, and PVDF6 weight% which is a binder, it is set as a paste at the negative mix paste, and is apply | coated to both front and back surfaces of copper foil.
In the negative electrode of the present embodiment, the layers corresponding to the conductor layer 21 and the short-circuit prevention layer 24 in the positive electrode are not formed. However, the method of applying the paste of the negative electrode active material itself is the same as that of the positive electrode active material. This is the same as the coating step, and the negative electrode active material paste is applied by die coating on the copper foil fed and conveyed in the longitudinal direction.
The negative electrode active material layer has a layer thickness of 40 μm to 60 μm and is applied in a strip shape extending in the longitudinal direction of the copper foil. Moreover, the capacity | capacitance of a positive electrode and a negative electrode was adjusted so that the capacity | capacitance of a negative electrode might be 140 when the capacity | capacitance of a positive electrode was set to 100.
The application position of the negative electrode active material layer is obtained by optically detecting the width direction edge position of the copper foil, and based on the position information, the center position of the copper foil in the width direction and the center of the application width of the negative electrode active material layer It is controlled with high accuracy so that the position matches.
A region having a width (length in the width direction of the copper foil) of 10 mm located on both sides of the application region of the negative electrode active material layer is an uncoated portion 3b.
After the negative electrode active material layer is applied to the copper foil, it is subjected to a drying treatment. Further, the negative electrode active material layer is also applied to the opposite surface of the copper foil by the above-described process, followed by a drying treatment.

After the negative electrode active material layers are formed on both the front and back surfaces of the copper foil by the above steps, a pressing process is performed as in the case of the positive electrode.
The press processing for the negative electrode is also the same as the press processing for the positive electrode, the press for suppressing the bending of the negative electrode, the press for increasing the density of the negative active material layer, etc. There is processing.
The apparatus used for the press processing is the same as that of the positive electrode, and the press working apparatus PM schematically shown in FIG. Then, the press working for suppressing the bending of the negative electrode and the press working for increasing the density of the negative electrode active material layer are sequentially performed.

In the press processing of the negative electrode, the intermittent roll press device 33 is set to form a pressure trace of 0.03 μm, for example, for a 10 μm copper foil, and the main roll press device 34 is set to 40 μm to 60 μm. The negative electrode active material layer is set to be compressed to a thickness of 24 μm to 37 μm.
Also in the negative electrode side electrode, the exposed portion of the copper foil is pressed and stretched by the intermittent roll press device 33, thereby extending in the longitudinal direction in the coating formation portion of the negative electrode active material layer by pressing of the main roll press device 34. The extension in the longitudinal direction of the exposed portion of the copper foil balances and the bending of the negative electrode is sufficiently suppressed.

When the press processing is completed as described above, the copper foil coated with the negative electrode active material layer is then cut in the longitudinal direction.
This process is also the same as that of the positive electrode, and is cut at the center position in the width direction of the application range of the negative electrode active material layer while feeding and conveying the copper foil (the negative electrode active material layer applied).
This cutting may be performed by optically detecting the edge positions at both ends in the width direction of the negative electrode active material layer and cutting the centers of the both edge positions with a cutter or the like.

[Assembly of power generation element 3]
The power generation element 3 winds the positive electrode 41 and the negative electrode 42 manufactured as described above by a predetermined length around a flat plate-shaped winding shaft with the separator 43 interposed therebetween. A state schematically shown in FIG. FIG. 8 shows a state in which the winding shaft removed after winding is removed.
As the separator 43, a microporous film or a nonwoven fabric such as polyolefin, polyester, polyacrylonitrile, polyphenylene sulfide, polyimide, or fluororesin can be used. When the wettability of the separator 43 is poor, a treatment with a surfactant or the like may be performed.

[Assembly of secondary battery RB]
The power generation element 3 assembled as described above is assembled by welding to the assembly on the lid 2 side.
As for the assembly on the lid 2 side, on the positive electrode side, the rivet 8 on the head side of the terminal bolt 5 is assembled to the lid 2 through the upper gasket 11, the lid portion 2, the lower gasket 12 and the current collector 4. The end of the rivet 8 on the inner side of the casing BC is caulked and fixed.
Even on the negative electrode side, the rivet 15 on the head side of the terminal bolt 7 is assembled to the lid part 2 through the upper gasket 17, the lid part 2, the lower gasket 18 and the current collector 6. Secure the end of the side by caulking.
The power generating element 3 welds an uncoated portion 3a (a portion where the aluminum foil is exposed) of the positive electrode 41 to the connecting portion 4a of the current collector 4 by ultrasonic welding or the like, and uncoated the negative electrode 42 The work part 3b (the part where the copper foil is exposed) is welded to the connection part 6a of the current collector 6 by ultrasonic welding or the like.
When the power generation element 3 is assembled, the assembly on the lid portion 2 side is inserted into the can body 1, and the edge of the lid portion 2 and the open end of the can body 1 are welded by laser welding.
Then, secondary battery RB is completed through processes, such as electrolyte injection and initial charge. As an electrolytic solution, in this embodiment, LiPF ₆ (hexafluorophosphoric acid) is used in a mixed solvent of ethylene carbonate (EC), dimethyl carbonate (DMC), and methyl ethyl carbonate (MEC) in a volume ratio of 30:40:30. What melt | dissolved lithium in the ratio of 1 mol / L (liter) was used.
In addition, all the processes from preparation of the positive electrode side electrode and negative electrode side electrode described above to battery assembly are performed in a dry room having a dew point of −50 ° C. or less.

[Evaluation of secondary battery RB]
Next, evaluation of the secondary battery RB manufactured by changing the manufacturing conditions in the above process will be described.
As the evaluation of the secondary battery RB here, two items of the battery capacity variation between the secondary batteries RB and the peel strength of the positive electrode active material layer 23 in the positive electrode are evaluated.
First, the variation in battery capacity between the secondary batteries RB will be described.
In the above process, when the positive electrode active material layer 23 is applied on the conductor layer 21 on the aluminum foil 22 which is a foil-like positive electrode plate, the width of the positive electrode active material layer 23 is shown in FIG. The edge in the direction (direction indicated by arrow B) protrudes from the edge of the conductor layer 21 indicated by the broken line E to the region where the aluminum foil 22 is exposed by the distance “W”.
This is for preventing the conductor layer 21 from being exposed. If the conductor layer 21 is exposed, it causes variations in the battery capacity of the secondary battery RB.
In the manufacturing process of the secondary battery RB in which the positive electrodes on the two strips as described above are integrally manufactured, when the positive electrode on the two strips are connected to each strip, It is necessary to make the application width of the positive electrode active material layer 23 match as much as possible in each strip and to sufficiently suppress the capacity variation.
In the cutting operation of the positive electrode, the edge position in the width direction of aluminum foil 22 (the direction indicated by arrow B in FIG. 5 and the like) is detected, and the cutting position is set based on the detection information. An error in the application position of the positive electrode active material layer 23 on the aluminum foil 22 (the error in the width direction) causes a variation in battery capacity of the secondary battery RB.

For this reason, in the manufacturing process of the secondary battery RB, the reference for setting the cutting position is not the width direction edge position of the aluminum foil 22 but the width direction edge position of the positive electrode active material layer 23.
In addition, although the short circuit prevention layer 24 is apply | coated to the width direction edge position of the positive electrode active material layer 23, this short circuit prevention layer 24 can be considered substantially transparent, and the width | variety of the positive electrode active material layer 23 is sufficient as it. It hardly affects the detection of the direction edge position.
As described above, when the position of the edge in the width direction of the positive electrode active material layer 23 is used as a reference, the conductor layer 21 and the positive electrode active material layer 23 are almost the same color, and both are optically accurate. It is difficult to discriminate.
For this reason, if the conductor layer 21 is exposed, the edge position in the width direction of the conductor layer 21 is erroneously detected as the edge position of the cathode active material layer 23, and the like. The position of the edge in the width direction cannot be detected with high accuracy, and the variation in the area of the positive electrode active material layer 23 in each strip when the positive electrode is cut and separated into each strip becomes large, and the secondary battery RB Battery capacity will vary.
The influence of the positional relationship between the edge of the conductor layer 21 and the edge of the positive electrode active material layer 23 in the positive electrode on the positive electrode side electrode was evaluated by experiments.
The results of the evaluation experiment are shown in Table 1.
The secondary battery RB whose experimental results are shown in Table 1 was manufactured as a secondary battery RB having a capacity of 5 Ah with the coating width of the positive electrode active material layer 23 being 90 mm.

In Table 1, “extruding amount” is the value of the distance “W” in FIG. 3B, and “extruding amount” is a negative value, which is the width direction of the positive electrode active material layer 23. This indicates that the edge position is a value of the width at which the conductor layer 21 is exposed by being retreated from the edge position in the width direction of the conductor layer 21.
The value shown as “capacity variation” in Table 1 indicates the capacity variation of the secondary battery RB with respect to each “extension amount”, and is generated by cutting and separating at the position indicated by the one-dot chain line C in FIG. A secondary battery RB was produced with each of the positive electrodes on the strip, and the difference in battery capacity between them was taken. This battery capacity is constant current charge at 5A, followed by constant voltage charge at 4.2V for 1.5 hours, and then constant current discharge at 5A until 2.5V is reached. It was calculated from the value.
FIG. 9 is a graph showing the relationship between “amount of protrusion” and “capacity variation” in Table 1.
As is apparent from the graph of FIG. 9, when “the amount of protrusion” is a negative value, that is, in the state where the conductor layer 21 is exposed, “the amount of protrusion” is larger than the capacitance variation is large. In a region larger than “0”, that is, in a state where the conductor layer 21 is completely covered with the positive electrode active material layer 23, the capacitance variation is constant at a small value.

Next, the evaluation of the peel strength of the positive electrode active material layer 23 will be described.
As described above, the positive electrode active material layer 23 completely covers the conductor layer 21 to suppress the variation in the battery capacity of the secondary battery RB, but on the other hand, it protrudes from the coating region of the conductor layer 21. Further, since the conductor layer 21 does not exist between the positive electrode active material layer 23 and the aluminum foil 22, adhesion with the aluminum foil 22 becomes a problem.
Therefore, the adhesion of the positive electrode active material layer 23 to the aluminum foil 22 is evaluated as the peel strength of the positive electrode active material layer 23. What is the peel strength of the positive electrode active material layer 23 with respect to the above-mentioned “extension amount”? Was measured.

The above peel strength is such that the finished positive electrode is cut into a size of about 5.0 cm × 3.5 cm, and a tape having a width of 18 mm is formed so that the length of the bonded portion between the positive electrode and the tape is about 3 cm. Further, after pasting on the vicinity of the short-circuit prevention layer 24, the stuck tape was peeled off, and the force required for peeling was measured with a force gauge. As shown in FIG. 14, the tape 51 affixed to the positive electrode 41 is folded back at the tip 51a side, and the tip 51a is sandwiched between the tips of the force gauge, as shown in FIG. Pulled in the direction to obtain peel strength.
The measurement results of the peel strength are shown in the “Peel strength” column of Table 1 as values for each “extrusion amount”.

FIG. 10 shows a graph of the relationship between “extrusion amount” and “peel strength” in Table 1.
The data of “peeling strength” in the region where the corresponding “extrusion amount” is a value of “0” or less is used to prevent a short circuit at the edge of the positive electrode active material layer 23 on the conductor layer 21. Since the peel strength is measured by forming the layer 24 and peeling off the short-circuit prevention layer 24, the peel strength measured is constant at a sufficiently large value.
On the other hand, the data of “peel strength” in the region where the corresponding “protrusion amount” is a value larger than “0” indicates that the positive electrode active material layer 23 has a “protrusion amount” of 1.0 mm or less. A value equivalent to that on the conductor layer 21 is shown. When the “extrusion amount” exceeds 1.0 mm, the “peel strength” gradually decreases, and the “extruding amount” is 2.0 mm or less. To the extent, it shows that a certain “peel strength” is secured.
In the region where the “extrusion amount” exceeds 2.0 mm, the “peel strength” is a constant value, and the actual peel strength of the positive electrode active material layer 23 is caused by the measurement background (other than the positive electrode active material layer 23). It is lowered to the extent that it is buried in the force required for peeling.
From the above evaluation results of “peel strength”, in the above-described manufacturing process, the interval between the edge position of the positive electrode active material layer 23 and the edge position of the conductor layer 21 (indicated by “W” in FIG. 3B). The coating width of the positive electrode active material layer 23 is set so that the distance) is 2 mm or less, but the distance between the edge position of the positive electrode active material layer 23 and the edge position of the conductor layer 21 is 1 mm or less. It can be said that it is more preferable to set the coating width of the positive electrode active material layer 23 so that

[Another embodiment]
Hereinafter, other embodiments of the present invention will be listed.
(1) In the above embodiment, the case where the positive electrode is manufactured in batches for two strips is illustrated, but for example, as shown in FIG. In addition, the positive electrode active material layer 23 and the like may be formed, and may be configured to be cut and separated into four strips at the position of the one-dot chain line C in the final step, or may be manufactured with a larger number of strips. In FIG. 13, the same reference numerals as those in FIG. 5 are assigned to elements corresponding to those in FIG.
(2) In the above embodiment, in the longitudinal direction of the aluminum foil 22, a range extending over substantially the entire length of the boundary portion between the positive electrode active material layer 23 and the uncoated portion 3 a is set as the protruding portion of the active material layer. However, it is not always necessary to have the full length, and only a portion where the edge position of the positive electrode active material layer 23 needs to be detected may be used.
(3) In the above embodiment, as the optical position detection means, the boundary portion between the positive electrode active material layer 23 and the uncoated portion 3a is imaged by an imaging device, and the positive electrode active material layer 23 is detected from the imaging information. Although the case where the edge position is detected is illustrated, for example, the detection information of the optical sensor that detects the reflected light by scanning the beam light at the boundary portion between the positive electrode active material layer 23 and the uncoated portion 3a. Based on the above, the specific configuration of the optical position detection means such as detecting the edge position of the positive electrode active material layer 23 from the change in the amount of reflected light can be variously changed.

(4) In the above embodiment, as the press processing, press processing for suppressing the bending of the positive electrode side electrode and press processing for increasing the density of the positive electrode active material layer are sequentially performed. Although illustrated, a step of winding the electrode in a roll shape may be provided between the two types of press processing. In addition, after performing press processing for increasing the density of the positive electrode active material layer, press processing for suppressing the bending of the positive electrode side electrode may be performed.
(5) In the above embodiment, the case where the conductor layer 21 is formed on a foil-like positive electrode plate (positive electrode foil-like electrode plate) is described as an example. The present invention is applied to a case where a conductor layer is disposed between a foil-like negative electrode plate and a negative electrode active material layer due to the relationship between the negative electrode plate (foil-like electrode plate on the negative electrode side) and the negative electrode active material. be able to.

3a Uncoated part 21 Conductor layer 22 Foil-shaped electrode plate 23 Active material layer 24 Short-circuit prevention layer

Claims (13)

A conductive layer and an active material layer are sequentially stacked and stacked so that an uncoated portion that exposes the surface of the foil electrode plate is formed on the conductive foil electrode plate. A method for producing an electrode for a battery,
In at least a part of the edge portion on the existing side of the uncoated portion in the active material layer formation region, the edge of the active material layer on the upper layer side is more than the edge of the conductor layer on the lower layer side. Forming an active material layer protrusion located on the uncoated part side;
And a step of identifying an existing position of the active material layer by optical position detection means at the protruding portion of the active material layer.   The battery electrode manufacturing method according to claim 1, wherein a distance between an edge of the active material layer and an edge of the conductor layer is set to 2 mm or less at the protruding portion of the active material layer. The optical position detection means detects the edge position of the active material layer in the protruding portion of the active material layer formed on the foil electrode plate on the positive electrode side,
On the basis of the detected position information, on the boundary portion between the active material layer and the uncoated portion on the foil-like electrode plate on the positive electrode side, a short circuit prevention having a larger electric resistance than the foil-like electrode plate The manufacturing method of the battery electrode of Claim 1 or 2 which forms a layer. An edge position of the active material layer at the protruding portion of the active material layer is detected by the optical position detection means,
The battery electrode according to any one of claims 1 to 3, wherein a cutting position of the foil electrode plate in a state in which the conductor layer and the active material layer are laminated is set based on the detected position information. Manufacturing method. The foil-like electrode plate is formed in a long band shape, and the conductor layer and the active material layer are in the state in which the uncoated portion is located at the widthwise end of the foil-like electrode plate. Formed in a strip shape extending in the longitudinal direction of the plate,
The manufacturing of the battery electrode according to any one of claims 1 to 4, wherein a range over a substantially entire length of a boundary portion between the active material layer and the uncoated portion is set as the protruding portion of the active material layer. Method. A battery in which a conductor layer and an active material layer are sequentially stacked on a conductive foil-like electrode plate in a region other than the formation position of an uncoated portion that exposes the surface of the foil-like electrode plate. Electrode,
In at least a part of the edge portion on the existing side of the uncoated portion in the active material layer formation region, the edge of the active material layer on the upper layer side is more than the edge of the conductor layer on the lower layer side. The battery electrode in which the active material layer protrusion part located in the said uncoated part side is formed.   The battery electrode according to claim 6, wherein a distance between an edge of the active material layer and an edge of the conductor layer is set to 2 mm or less at the protruding portion of the active material layer. A foil-like electrode plate having conductivity;
A conductor layer laminated on the foil electrode plate;
An active material layer laminated on the conductor layer;
An uncoated portion where the foil electrode plate is exposed;
An active material layer protruding part from which the active material layer protrudes from the formation position of the conductor layer to the uncoated part side;
A battery electrode comprising: The short-circuit prevention layer whose electric resistance is larger than the said foil-like electrode plate is formed on the boundary part of the said active material layer and the said uncoated part in the said foil-like electrode plate on the positive electrode side. 9. The battery electrode according to any one of 8 above . The battery electrode according to claim 9, wherein the short-circuit prevention layer extends from a position overlapping an inclined portion of an edge of the active material layer to an exposed region of the foil electrode plate . The battery electrode according to claim 10, wherein a height of the short-circuit prevention layer in the stacking direction is lower than a height of the active material layer in the stacking direction. The battery electrode according to any one of claims 6 to 11, wherein the protruding portion of the active material layer is formed in a range extending over substantially the entire length of a boundary portion between the active material layer and the uncoated portion. A power generation element having the battery electrode according to any one of claims 6 to 12,
  A housing for storing the power generation element;
A battery comprising:

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