JP6525944B2 - リチウムイオン電池電極フィルムの多孔率の変化を生み出す方法 - Google Patents
リチウムイオン電池電極フィルムの多孔率の変化を生み出す方法 Download PDFInfo
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Images
Classifications
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- H01M4/525—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of nickel, cobalt or iron of mixed oxides or hydroxides containing iron, cobalt or nickel for inserting or intercalating light metals, e.g. LiNiO2, LiCoO2 or LiCoOxFy
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- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/10—Energy storage using batteries
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Description
本発明は、DOEによって授与されたDE−AR0000063の下、米国政府の支援によってなされたものである。米国政府は本発明に関して一定の権利を有する。
図2は、電極構造体を形成する、本明細書に記載された実施形態に基づく方法200の一実施形態の概要を示すプロセス流れ図である。この電極構造体は、横方向の多孔率勾配を有するカソード構造体350を含む。カソード構造体350は、図1に示したカソード構造体103a、103bと同様の構造体とすることができる。図3A〜3Dは、さまざまな形成段階におけるこの電極の略断面図である。
以下の予言的で非限定的な例は、本明細書に記載された実施形態をさらに示すために提供される。しかしながら、この例が全てを包括するものであることは意図されておらず、この例が、本明細書に記載された実施形態の範囲を限定することも意図されていない。
本明細書で使用されるとき、用語カレンダ加工は、堆積させた材料をローラに通し、ローラの下でその材料を、高温、高圧条件で圧縮するプロセスを指す。
以下の予言的で非限定的な例は、本明細書に記載された実施形態をさらに示すために提供される。しかしながら、この例が全てを包括するものであることは意図されておらず、この例が、本明細書に記載された実施形態の範囲を限定することも意図されていない。
Liイオン電池用の現在の電極は、カソード活性材料を堆積させるスリットコーティングプロセス、それに続く低速乾燥プロセス、およびフィルムの多孔率を決める最終的なカレンダステップを使用して製造されている。より高ローディングの電池を製造するためにはより厚い活性材料層が必要だが、この層が厚くなるにつれ、リチウムイオンがフィルムを貫いて移動することが困難になり、そのため活性材料の全体的な効率が低下する。活性材料の多孔率を段階的に変化させることによって、活性材料の全体的な効率を向上させることができると考えられている。さらに一歩進めると、フィルムの下部へのリチウムイオンの迅速な移動を可能にする高多孔率のチャネルが横方向次元において利用可能である場合には、より厚い(したがってより高ローディングの)電極を製造することができ、このような電極は非常に効率的に動作することができる。
以下の予言的で非限定的な例は、本明細書に記載された実施形態をさらに示すために提供される。しかしながら、この例が全てを包括するものであることは意図されておらず、この例が、本明細書に記載された実施形態の範囲を限定することも意図されていない。
図13は、電極の表面にセパレータを堆積させる、本明細書に記載された実施形態に基づくプロセスを示す。半乾燥吹付けによって堆積させたセパレータが機能することを証明するため、(74μmのベースラインカソードの表面に)半乾燥吹付けによって堆積させた30μmのポリビニルアルコール(「PVA」)(10重量%溶液)セパレータを使用してコインセルを製作した。最初の観察によれば、電解液は、セパレータおよびその下の電極層を完全に濡らすことができていた。しかしながら、カソードの上にPVAを吹き付けたときに電極の縁が露出したため、最初のサイクル中にセルは短絡した。
Claims (7)
- リチウムイオン電池のカソード構造体を形成する方法にして、段階的に変化するカソード構造体を形成する方法であって、
導電基板の上方に配置されたパターン形成されたマスクの開口を通してカソード活性材料を吹き付けることによって、前記カソード活性材料のパターン形成された層を前記導電基板に形成することと、前記パターン形成された層が複数のカソード活性フィーチャを含み、前記複数のカソード活性フィーチャが、前記複数のカソード活性フィーチャ間に配置された1つまたは複数のチャネルを有し、
カソード活性材料の前記パターン形成された層の上に、前記カソード活性材料のブランケット層を形成することと、
堆積したままの前記パターン形成された層およびブランケット層を圧縮して、ブランケット材料がその上に堆積した前記複数のカソード活性フィーチャを含む複数の第1の領域と、前記カソード活性フィーチャ間に配置された前記1つまたは複数のチャネル内に堆積した前記ブランケット材料を含む1つまたは複数の第2の領域とを形成することと
を含み、前記複数の第1の領域が第1の平均多孔率を有し、前記1つまたは複数の第2の領域が、前記第1の平均多孔率よりも大きい第2の平均多孔率を有する
方法。 - ブランケット層を形成することが、前記パターン形成された層の上に前記カソード活性材料を吹き付けることを含む、請求項1に記載の方法。
- 前記パターン形成されたマスクが、直径が約50マイクロメートルから100マイクロメートルの間のワイヤを有するワイヤメッシュ構造体を含み、前記ワイヤメッシュ構造体が、約5マイクロメートルから約200マイクロメートルの間の開口を有する、請求項2に記載の方法。
- 堆積したままの前記パターン形成された層を圧縮することが、堆積したままの前記パターン形成された層およびブランケット層をカレンダ加工することを含む、請求項1に記載の方法。
- 前記第1の平均多孔率が、同じ材料から形成された中実のフィルムと比較して約20%から約35%の間であり、前記第2の平均多孔率が、同じ材料から形成された中実のフィルムと比較して約40%から約70%の間である、請求項1に記載の方法。
- 前記導電基板がアルミニウムを含み、第1のカソード活性材料および第2のカソード活性材料がリチウムニッケルコバルトマンガン酸化物である、請求項1に記載の方法。
- 前記1つまたは複数のチャネルが前記導電基板の表面を露出させる、請求項1に記載の方法。
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