JP6888937B2 - Battery manufacturing method - Google Patents

Description

The present invention relates to a method for manufacturing a battery.

Conventionally, in the process of manufacturing a bipolar type battery, a first electrode current collector sheet is supplied from a roll wound with a sheet-shaped current collector, and insulators are provided on the current collector at predetermined intervals. A plurality of layers are arranged, and a negative electrode layer, an electrolyte layer, and a positive electrode layer are laminated between a pair of insulators to form a battery structure, and a second pole current collector supplied from another roll is insulated from these battery structures. A method has been adopted in which the battery is placed on the body and then cut at the position of the insulator (for example, Patent Document 1).

Japanese Unexamined Patent Publication No. 2008-053103

However, in the method of the above-mentioned conventional example, it is easy to make the outer shape of the battery into a rectangular plate shape, but it is not easy to obtain a battery having a free shape.

The present invention has been made in view of the above circumstances, and one of its objects is to provide a method for manufacturing a battery capable of easily obtaining a battery having a desired shape.

The present invention that solves the problems of the above conventional example includes a cell cell in which a first pole current collector, a positive electrode active material layer, a separator, a negative electrode active material layer, and a second pole current collector are laminated in this order. A method for manufacturing a lithium-ion battery having a battery exterior including a cell, and forming a three-dimensional shape by repeating ejection and solidification of a powdery, liquid, or paste-like material in a predetermined molding region. The step of forming the battery exterior includes the step of forming the battery exterior using the material laminating device, and the step of forming the first exterior portion having a predetermined shape is a step of forming the first exterior portion having a predetermined shape using the material laminating device. A step of arranging a first electrode current collector having a main portion having a shape included in the first exterior portion formed in a predetermined shape on the first exterior portion, and the first exterior portion. A step of forming a first frame portion for fixing the peripheral edge portion of the main portion of the first pole current collector arranged above on the first exterior portion by using the material laminating device, and at least the first step. A separator having a shape that covers the area surrounded by the inner edge of the frame portion 1 and is included in the area surrounded by the outer edge of the first frame portion so that the peripheral edge portion thereof overlaps the first frame portion. The process of positioning and arranging the separator and the second frame portion for fixing the peripheral edge portion of the separator arranged on the first frame portion on the first frame portion are formed by using the material laminating device. A second pole current collector having a main portion having a shape that covers at least the region surrounded by the inner edge of the second frame portion and is included in the region surrounded by the outer edge of the second frame portion. A step of positioning and arranging the peripheral portion of the main portion so as to overlap the second frame portion, and a second exterior portion having a shape covering at least the main portion of the second pole current collector. It is determined to have a step of forming on the second frame portion and the second pole current collector by using a material laminating device.

Further, here, the step of filling the region surrounded by the first frame portion with the first electrode active material composition containing the first electrode active material and the electrolytic solution, and the second step. The region surrounded by the frame portion may include a step of filling the second electrode active material composition containing the second electrode active material and the electrolytic solution. The step of forming the first frame portion and the step of filling the region surrounded by the first frame portion with the first electrode active material composition may be performed in parallel at the same time. The step of forming the second frame portion and the step of filling the region surrounded by the second frame portion with the first electrode active material composition may be performed in parallel at the same time.

Further, the separator may be formed by using a material laminating device.

According to the present invention, since a battery is manufactured using a material laminating device that repeatedly discharges and solidifies a powdery, liquid, or paste-like material to form a three-dimensional shape, the battery is configured according to a desired shape. By solidifying the material to be used, a battery having a desired shape can be easily manufactured.

It is explanatory drawing which shows typically the manufacturing method of the battery which concerns on embodiment of this invention. It is explanatory drawing which schematically represents another manufacturing method of the battery which concerns on embodiment of this invention. It is explanatory drawing which shows the example of the outer shape and the partial cross section of the battery obtained by the manufacturing method of the battery which concerns on an example of Embodiment of this invention. It is explanatory drawing which shows the shape example of the current collector and the separator used in the manufacturing method of the battery which concerns on an example of Embodiment of this invention. It is explanatory drawing which schematically represents yet another manufacturing method of the battery which concerns on embodiment of this invention. It is explanatory drawing which shows the example of the battery obtained by still another manufacturing method of the battery which concerns on embodiment of this invention. It is explanatory drawing which shows the example of the battery manufactured by the example of another manufacturing method of the battery which concerns on embodiment of this invention.

Embodiments of the present invention will be described with reference to the drawings. In the method for manufacturing a battery according to the embodiment of the present invention, as illustrated in FIG. 1, the powdery, liquid or paste-like material is repeatedly discharged and solidified in a predetermined molding region (processing range). A material laminating device (so-called 3D printer) for forming a three-dimensional shape is used.

This material laminating device uses a binder injection method that injects a liquid binder onto a powder bed to achieve selective solidification, and controls the heat generation position with a beam or the like while supplying the material to selectively select the material. A directional energy deposition method that melts and solidifies (bonds), a material extrusion method that extrudes a fluid material from a nozzle and solidifies it while depositing it, and a method that ejects material droplets and selectively deposits and solidifies them ( There are a material injection method using an inkjet method, etc., a powder bed melt bonding method that selectively melt-bonds (solidifies) the area where the powder is laid by heat energy, a sheet lamination method, a photopolymerization method, etc. (" 2013 Patent Application Technology Trend Survey Report 3D Printer ”, published by the Patent Office), whichever method is used here.

The present invention includes a step of forming a battery exterior using a material laminating device, and the material constituting the battery exterior is particularly limited as long as it is a material having high durability against an electrolytic solution (electrolyte and solvent). However, it is used by selecting from polyphenylsulfone (PPSF) resin, acrylate-based photocurable resin with high degree of cross-linking, polyethylene (PE) resin, polypropylene (PP) resin, ABS resin and PJP (plant-derived plastic) resin. Is preferable. As the material constituting the exterior of the battery, a material laminating device 10 of a different type can be used depending on the selected material. For example, if the above-mentioned acrylate-based photocurable resin is adopted, a material laminating apparatus 10 using a photopolymerization method is used. When ABS resin and PJP (plant-derived plastic) resin are used, the material laminating device 10 using the powder bed melt-bonding method is used, and when a highly heat-resistant resin such as polyphenylsulfone resin is used, it is in powder form. A binder injection method can be used in which a liquid binder is sprayed onto the resin of the above to realize selective solidification.

In the battery manufacturing method of the present embodiment, the first pole current collector 11, the positive electrode active material 12, the separator 13, the negative electrode active material 14, and the second pole current collector 15 are prepared in advance. The first-pole current collector and the second-pole current collector (hereinafter collectively referred to as current collectors when it is not necessary to distinguish them) have a shape contained in the first exterior portion and the second exterior portion, which will be described later, respectively. Each main part has a current take-out part (also referred to as a tab part) which is electrically connected to a current collector and takes out a current to the outside. The current extraction unit may be integrally formed with the current collector, or may be an electric connection of different members.

A metal current collector or a resin current collector can be used as the first pole current collector 11 and the second pole current collector 15, respectively, and known metal current collectors and Japanese Patent Publication No. 2012-150905 are available. And known resin current collectors and the like described in International Publication No. WO 2015/005116 and the like can be used.

As the metal current collector, a metal current collector generally used for lithium ion batteries can be used, and copper, aluminum, titanium, nickel, tantalum, niobium, hafnium, zirconium, zinc, tungsten, bismuth, antimony, and these. An alloy containing one or more of the above, and a current collector made of one or more metals selected from the group consisting of stainless alloys can be used.

The shape of the metal collector may be any of a thin plate, a metal foil, and a mesh, and another metal layer is further formed on the surface of the metal collector by a method such as sputtering, electrodeposition, or coating. It may be a metal leaf.

As the resin current collector, a conductive polymer material or a current collector based on a polymer obtained by imparting conductivity to a non-conductive polymer material can be used.

Examples of the conductive polymer material include polyaniline, polypyrrole, polythiophene, polyacetylene, polyparaphenylene, polyphenylene vinylene, polyacrylonitrile, polyoxadiazole and the like. For the purpose of improving the conductivity of the resin current collector containing the conductive polymer material, it is preferable to further contain a conductive filler described later.

Non-conductive polymer materials include polyethylene (PE), polypropylene (PP), polymethylpentene (PMP), polycycloolefin (PCO), polyethylene terephthalate (PET), polyether nitrile (PEN), and polytetrafluoroethylene. (PTFE), styrene butadiene rubber (SBR), polyacrylonitrile (PAN), polymethylacrylate (PMA), polymethylmethacrylate (PMMA), polyvinylidene fluoride (PVdF), epoxy resin, silicone resin and mixtures thereof. Be done.

As the non-conductive polymer material, polyethylene (PE), polypropylene (PP), polymethylpentene (PMP) and polycycloolefin (PCO) are preferable, and polyethylene (PE) is more preferable from the viewpoint of electrical stability. , Polypropylene (PP) and Polymethylpentene (PMP).

The polymer obtained by imparting conductivity to the non-conductive polymer material can be obtained by mixing the non-conductive polymer material and the conductive filler, and the conductive filler is obtained from the material having conductivity. Selected from fillers. Preferably, from the viewpoint of suppressing ion permeation in the current collector, it is preferable to use a filler obtained from a material having no conductivity with respect to ions used as a charge transfer medium. Specific examples thereof include fillers obtained from carbon materials, alloy materials such as aluminum, gold, silver, copper, iron, platinum, chromium, tin, indium, antimony, titanium, nickel and stainless steel (SUS). It is not limited to these. Among them, from the viewpoint of corrosion resistance, a filler obtained from aluminum, stainless steel, a carbon material or nickel is preferable, and a filler obtained from a carbon material is more preferable. These conductive fillers may be used alone or in combination of two or more. As the conductive filler, a particle-based ceramic material or a resin material coated with the metal shown above by plating or the like can also be used.

The shape of the conductive filler may be a particle shape, a fibrous shape, or an aggregate thereof.

The resin current collector can be obtained by a known method described in Japanese Patent Publication No. 2012-150905 and International Publication No. WO 2015/005116, and as a specific example, acetylene black as a conductive filler in polypropylene can be obtained. After dispersing 5 to 20 parts of the above, rolled with a hot press machine and the like can be mentioned. Further, the thickness thereof is not particularly limited, and the same as known ones or appropriately modified ones can be applied.

As the positive electrode current collector 7 and the negative electrode current collector 8, a metal current collector or a resin current collector may be used as they are, or a metal current collector or a resin current collector having a conductive layer formed on the surface thereof may be used, from the viewpoint of battery characteristics and the like. Therefore, it is preferable that it is a metal current collector or a resin current collector on which a conductive layer is formed.

The positive electrode active material composition 12 is obtained by mixing positive electrode active material particles and an electrolytic solution. Here, as the positive electrode active material particles, a composite oxide of lithium and a transition metal (for example, LiCoO ₂ , LiNiO ₂ , LiMnO ₂ and LiMn ₂ O ₄ ), a transition metal oxide (for example, MnO ₂ and V ₂ O ₅ ), Transition metal sulfides (eg MoS ₂ and TiS ₂ ) and conductive polymers (eg polyaniline, polyvinylidene fluoride, polypyrrole, polythiophene, polyacetylene, poly-p-phenylene and polycarbazole) and the like can be used.

Further, the negative electrode active material composition 14 is obtained by mixing the negative electrode active material particles with an electrolytic solution. Here, as the negative electrode active material particles, graphite, non-graphitizable carbon, amorphous carbon, a fired polymer compound (for example, one obtained by calcining a phenol resin, a furan resin, etc. and carbonizing), cokes (for example, pitch coke, etc. Needle coke and petroleum coke, etc.), carbon fibers, conductive polymers (eg, polyacetylene and polypyrrole, etc.), tin, silicon, and metal alloys (eg, lithium-tin alloys, lithium-silicon alloys, lithium-aluminum alloys, and lithium-aluminum). - manganese alloy), there composite oxide of lithium and transition metals (e.g., Li ₄ Ti ₅ O1 _2, etc.) and the like.

In the present embodiment, at least a part of the surface of the positive electrode active material particles and the negative electrode active material particles contained in the positive electrode active material composition 12 and the negative electrode active material composition 14, respectively, is a coating resin and a conductive auxiliary agent. It is preferable that the coating active material particles are coated with a coating agent containing.

When the periphery of the active material particles is coated with a coating agent, the volume change of the electrode that occurs during charging / discharging is alleviated, and deterioration of the electrode due to repeated charging / discharging can be suppressed. Further, since the electrode can be formed without binding using a binder such as PVdF, the first electrode active material and the electrolytic solution are contained in the region surrounded by the first frame portion. The second electrode active material composition comprising the step of filling the first electrode active material composition and the second electrode active material and the electrolytic solution in the region surrounded by the second frame portion. It is preferable because it facilitates the step of filling the material.

It should be noted that by not adding the binder, since the active material is not immobilized in the electrode, it also has an effect of further improving the mitigation ability against the volume change of the electrode active material, which is preferable.

Examples of the coating resin include vinyl resin, urethane resin, polyester resin, polyamide resin, epoxy resin, polyimide resin, silicone resin, phenol resin, melamine resin, urea resin, aniline resin, ionomer resin, and polycarbonate. Among these, vinyl resin, urethane resin, polyester resin or polyamide resin are preferable.

As the conductive auxiliary agent contained in the coating agent, it can be selected and used from materials having conductivity.

Materials with conductivity include metals [aluminum, stainless steel (SUS), silver, gold, copper, titanium, etc.], conductive carbon [carbon nanofibers, graphite, carbon black, acetylene black, vulcan (registered trademark), and ket. Chain black (registered trademark), black pearl (registered trademark), furnace black, channel black, thermal lamp black, carbon nanotubes (single-walled carbon nanotubes and multi-walled carbon nanotubes, etc.), carbon nanohorns, carbon nanoballoons, hard carbon, fullerenes, etc. ] And mixtures thereof, etc., but not limited to these.

These conductive auxiliaries may be used alone or in combination of two or more. Moreover, these alloys or metal oxides may be used. From the viewpoint of electrical stability, it is preferably aluminum, stainless steel, carbon, silver, gold, copper, titanium and a mixture thereof, more preferably silver, gold, aluminum, stainless steel and conductive carbon, and even more preferably. It is conductive carbon.

The conductive auxiliary agent includes a non-conductive material such as a particle-based ceramic material and a resin material coated with a conductive material (a metal material among the above-mentioned conductive auxiliary agent materials) by plating or the like, and a non-conductive material. A mixture of a conductive material and a conductive material (a metal material among the above-mentioned conductive aid materials) can also be used.

Further, as a conductive auxiliary agent, a conductive fiber in which a metal having good conductivity or graphite is uniformly dispersed in a synthetic fiber, a conductive fiber in which the surface of an organic fiber such as a synthetic fiber is coated with a metal, or the like can be used. it can.

The weight ratio of the coating resin contained in the coating agent to the conductive auxiliary agent is preferably coating resin: conductive auxiliary agent = 100: 1 to 100: 200, and more preferably 100: 5 to 100: 100. Within this range, the conductivity of the positive electrode active material layer 5 and the negative electrode active material layer 6 becomes good.

For the coating active material particles, for example, in a state where the active material particles are placed in a universal mixer and stirred at 30 to 500 rpm, a resin solution containing a coating resin is added dropwise over 1 to 90 minutes, and a conductive additive is further added. It can be obtained by mixing, raising the temperature to 50 to 200 ° C. with stirring, reducing the pressure to 0.007 to 0.04 MPa, and then holding the mixture for 10 to 150 minutes.

It can be confirmed that the coating active material particles are obtained by observing the magnified observation image of the coating active material particles obtained by using a scanning electron microscope or the like.

When the positive electrode active material particles or the negative electrode active material particles are mixed with the electrolytic solution to obtain the positive electrode active material composition 12 or the negative electrode active material composition 14, the electrolytic solution is used for manufacturing a lithium ion battery. An electrolytic solution containing an electrolyte and a non-aqueous solvent can be used.

As the electrolyte, those used in ordinary electrolytes for lithium-ion batteries can be used, and lithium salts of inorganic acids such as _{LiPF 6} , LiBF ₄ , LiSbF ₆ , _{LiAsF 6} and LiClO _{4 and LiN (CF 3} SO) can be used. ₂ ) There are lithium salts of organic acids such as ₂ , LiN (C ₂ F ₅ SO ₂ ) ₂ and LiC (CF ₃ SO ₂ ) _{3. Of these, LiPF 6} is preferable from the viewpoint of battery output and charge / discharge cycle characteristics.

As the non-aqueous solvent, those used in ordinary electrolytic solutions for lithium ion batteries can be used, for example, lactone compounds, cyclic or chain carbonates, chain carboxylic acid esters, cyclic or chain ethers, and the like. Phosylate esters, nitrile compounds, amide compounds, sulfones, sulfolanes and the like and mixtures thereof can be used. One type of this non-aqueous solvent may be used alone, or two or more types of non-aqueous solvents may be used in combination.

Among the above examples of non-aqueous solvents, lactone compounds, cyclic carbonates, chain carbonates and phosphate esters are preferable from the viewpoint of battery output and charge / discharge cycle characteristics, and lactone compounds and cyclics are more preferable. Carbonate ester and chain carbonate ester are more preferable, and a mixed solution of cyclic carbonate ester and chain carbonate ester is more preferable. Particularly preferred is propylene carbonate (PC) or a mixture of propylene carbonate and ethylene carbonate (EC).

The concentration of the electrolyte contained in the electrolytic solution is preferably 0.1 to 3 mol / L, more preferably 0.5 to 2 mol / L, based on the volume of the electrolytic solution.

In the present invention, the positive electrode active material layer 12 and the negative electrode active material layer 14 preferably contain a fibrous conductive filler together with the above-mentioned coating active material particles from the viewpoint of reducing ionic resistance and the like. Examples of the fibrous conductive filler include carbon fibers such as PAN-based carbon fibers and pitch-based carbon fibers, conductive fibers obtained by uniformly dispersing a metal or graphite having good conductivity in synthetic fibers, and stainless steel. Examples thereof include metal fibers obtained by fiberizing metal, conductive fibers in which the surface of organic fibers is coated with metal, and conductive fibers in which the surface of organic fibers is coated with conductive resin. Among these conductive fibers, carbon fiber is preferable.

When the positive electrode active material layer 12 and the negative electrode active material layer 14 contain the fibrous conductive filler, the proportion of the fibrous conductive filler may be 0.5 to 5% by weight based on the weight of the coating active material particles. preferable.

The thickness of the positive electrode active material layer 12 and the negative electrode active material layer 14 is preferably 200 μm or more. It is more preferably 500 μm or more, still more preferably 1000 μm or more. If it is thicker than this thickness, the amount of active material per unit volume increases, and a battery having a large storage capacity can be obtained.

In the positive electrode active material composition 12 and the negative electrode active material composition 14, it is preferable that the active material particles and the conductive auxiliary agent are contained in a concentration of 10 to 60% by weight based on the weight of the electrolytic solution.

It is also preferable that the positive electrode active material composition 12 and the negative electrode active material composition 14 further contain a heat or photocurable compound. When the positive electrode active material composition 12 and the negative electrode active material composition 14 further contain a heat or photocurable compound, the positive electrode active material composition 12 and the negative electrode active material composition 14 are filled in predetermined regions, respectively, and then further. The positive electrode active material composition 12 and the negative electrode active material composition 14 can be gelled by heating or irradiating with ultraviolet rays. It is preferable to gel the positive electrode active material composition 12 and the negative electrode active material composition 14 because the arrangement of the separator and the arrangement of the current collector are facilitated.

Further, in the present embodiment, a separator 13 cut into a desired shape is prepared. The separator 13 includes a hydrocarbon resin such as polyvinylidene fluoride-hexafluoropropylene (PVdF-HFP), a porous film made of polyolefin (polyethylene, polypropylene, etc.), and a multilayer film of a porous film (for example, PP / PE). / PP three-layer structure laminate, etc.), non-woven fabric made of synthetic fibers (polyester fiber, aramid fiber, etc.), glass fiber, etc., and those with ceramic fine particles such as silica, alumina, and titania attached to their surfaces, etc. A known separator for a lithium ion battery or the like can be used. The shape of the separator 13 will be described later.

With the above preparations, in the present embodiment, the battery is manufactured by the following steps.

In the present embodiment, as illustrated in FIG. 1, first, the lower portion 21 of the battery exterior in which the first electrode current collector 11 is arranged is formed (FIG. 1, steps a to c), and the first electrode composition (FIG. 1, steps a to c) is formed. (For example, the positive electrode active material 12 is included) is filled (step d), and the separator 13 is arranged (step e). Then, the upper portion 22 of the battery exterior on which the second electrode current collector 15 is arranged is formed while including the second electrode composition (for example, the negative electrode active material 14) (steps f to j). As a result, the battery exterior 20 seals the laminated body in which the first pole current collector 11, the layer of the positive electrode active material 12, the separator 13, the layer of the negative electrode active material 14, and the second pole current collector 15 are laminated. ..

More specifically, in the example of FIG. 1, first, the material laminating device 10 is used to form the battery exterior 20 in a predetermined modeling region, and the bottom portion 21a of the battery exterior lower portion 21 (corresponding to the first exterior member). (Fig. 1: Step a). Here, the shape of the bottom portion 21a is adjusted to a desired shape as the battery shape. For example, when the battery shape is a heart-shaped columnar body, the bottom portion 21a is a heart-shaped flat plate.

Next, the first pole current collector 11 is arranged on the bottom portion 21a (FIG. 1: step b). As illustrated in FIG. 4, the first pole current collector 11 is arranged with a main portion 11a arranged at a position included in the shape (predetermined shape) of the bottom portion 21a (superposed so that there is no protruding portion). It has a tab portion 11b that extends outward from at least a part of the peripheral edge portion of the main portion 11a (convex shape in the example of FIG. 4) and is arranged so as to project outward from the bottom portion 21a. In FIG. 4, since the first pole current collector 11, the separator 13, and the second pole current collector 15 are shown in an overlapping manner, the outer shape of the first pole current collector 11 (and the separator 13) is partially drawn. Although it is hidden, the hidden part is indicated by a broken line.

Next, the material laminating device 10 is used on the peripheral edge portion of the main portion of the first pole current collector 11 (the range of a predetermined length from the outer peripheral edge of the main portion 11a, which does not cover the entire main portion 11a). The peripheral portion of the main portion of the first pole current collector arranged on the first pole current collector is sandwiched between the first exterior portion and the first exterior portion to be fixed on the first exterior portion. The frame portion [frame portion (corresponding to the lower portion of the frame body) of the lower portion 21 of the battery exterior] 21b of 1 is formed (FIG. 1: step c). FIG. 1 shows a cross section fractured on a surface passing through the central portion of the first pole current collector 11, so that a space is generated between the frame portions 21b, but the frame portion 21b is the first pole. The peripheral edge of the current collector 11 is sealed (sandwiched between the bottom 21a and the frame 21b) over the entire circumference, and a columnar space is substantially formed here.

Then, the first electrode active material (for example, the positive electrode active material 12) and the electrolytic solution are placed in a region (the columnar space) surrounded by the frame portion 21b arranged on the peripheral edge of the first electrode current collector 11. The first electrode composition comprising is filled (FIG. 1: Step d).

Next, the separator 13 is positioned and arranged on the outer lower portion 21 (on the frame portion 21b) so that the peripheral edge portion thereof overlaps the first frame portion (FIG. 1: step e). Here, the separator 13 has a shape that covers at least the region surrounded by the inner edge of the first frame portion and is included in the region surrounded by the outer edge of the first frame portion, for example, the first pole collection. The shape is similar to that of the main portion 11a of the electric body 11, or has a shape that does not generate a gap between the main portion 11a and the frame portion 21b. The separator 13 seals the first electrode composition.

Next, a material laminating device 10 is used on the peripheral edge portion of the separator 13 (a range of a predetermined length from the outer peripheral edge of the separator 13 and the entire separator 13 is not covered), and the peripheral edge portion of the separator is attached to the first peripheral portion. A second frame portion [frame portion (corresponding to the frame body) of the upper portion 22 of the battery exterior] 22a to be fixed on the first frame portion is formed by sandwiching the frame portion between the two frames (FIG. 1: Step f). ). In this step, the frame portion 22a may be formed so as to have the same shape as the frame portion 21b in a plan view (that is, on the first exterior member).

FIG. 1 shows a cross section broken at a surface passing through the central portion of the first pole current collector 11 and the separator 13, so that a space is generated between the frame portions 22a. The peripheral edge of the separator 13 is sealed over the entire circumference (so as to be sandwiched between the frame portion 22a and the frame portion 21b), and a columnar space is substantially formed here.

A second electrode active material (for example, the negative electrode active material 14) and an electrolytic solution are contained in a region (the columnar space) surrounded by the frame portion 22a arranged on the peripheral edge of the separator 13. The electrode composition of (Fig. 1: Step g) is filled.

Next, the second pole current collector 15 is positioned so that the peripheral edge portion of the main portion overlaps the second frame portion 22a, and is arranged on the frame portion 22a (FIG. 1: step h). The second pole current collector 15 is arranged so that its peripheral edge is supported by the frame portion 22a. The second pole current collector 15 has a shape that covers at least the region surrounded by the inner edge of the second frame portion and is included in the region surrounded by the outer edge of the second frame portion. It has a portion 15a and a tab portion 15b that extends outward from at least a part of the peripheral edge portion of the main portion 15a (in one example, has a convex shape) and is arranged so as to project outward from the frame portion 22a. As an example, the second pole current collector 15 has the same shape as the first pole current collector 11 and has a shape that does not form a gap between the second pole current collector 15 and the frame portion 22a. The second electrode composition is sealed by the second electrode current collector 15.

Next, as a second exterior portion having a shape that covers at least the main portion of the second pole current collector, the material laminating device 10 is used on the second pole current collector 15 to cover the upper portion 22 of the battery exterior. The flat surface portion 22b (corresponding to the second exterior member, and the frame portions 21b, 22a correspond to the frame body arranged between the first exterior member and the second exterior member) is formed (FIG. 1: FIG. Step i). In this way, the battery exterior 20 is formed by the battery exterior lower portion 21 and the battery exterior upper portion 22, and the first pole current collector 11, the positive electrode active material 12 layer, the separator 13, the negative electrode active material 14 layer, and the second pole collection. A laminated body formed by laminating the electric bodies 15 is sealed, and a lithium ion battery having a battery exterior including a cell is obtained. Further, at this time, the tab portion 11b of the first pole current collector 11 and the tab portion 15b of the second pole current collector 15 are in a state of protruding from the battery exterior 20 to the outside (FIG. 1: Step j, FIG. 3). These tab portions 11b and 15b function as current extraction portions (electrodes) of the lithium ion battery manufactured here. Note that FIG. 3 shows a partially fractured surface of the battery for the sake of explanation.

As described above, according to the example of the present embodiment, since the battery exterior 20 can be formed in a free shape by the material laminating device 10, a lithium ion battery having a desired shape can be manufactured.

In the above description of the present embodiment, with respect to the steps a, c, f, and i of FIG. 1, a plurality of battery components are processed in parallel using a plurality of material laminating devices 10, and other steps are performed. Regarding (steps b, d, e, g, h in FIG. 1), a plurality of processed products processed by the plurality of material laminating devices 10 may be sequentially processed (FIG. 1). 2). In this way, the efficiency of manufacturing is improved.

The material laminating apparatus 10 (s) used in each of the steps a, c, f, and i in FIG. 1 may be separate or shared in each of the steps a, c, f, and i. It doesn't matter.

Further, in the description so far, the bottom surface shape of the battery exterior 20 has been made flat, but the present embodiment is not limited to this. For example, when the battery exterior 20 has an array shape (peanut-like shape), as illustrated in FIG. 5, the bottom portion 21a of the battery exterior lower portion 21 having a cup-shaped portion arranged in a row (on the first exterior member). (Equivalent) may be formed (FIG. 5: step a).

Further, the first pole current collector 11, the second pole current collector 15, and the separator 13 may also be formed by using the material laminating device 10', 10 ″ for laminating the respective materials.

That is, the first pole current collector 11 is formed on the bottom portion 21a by the material laminating device 10'for laminating the materials of the current collector (FIG. 5: step b). At this time, the first pole current collector 11 extends outward from at least a part of the main portion 11a contained in the bottom portion 21a and the peripheral edge portion of the main portion 11a (in one example, has a convex shape), and is outside the bottom portion 21a. It is processed into a shape including the tab portion 11b protruding to.

Next, while sealing (sandwiching) at least a part of the first pole current collector 11 on the main portion 11a side of the tab portion 11b, the frame portion (lower part of the frame body) of the battery exterior lower portion 21 is used by using the material laminating device 10. 21b is formed (FIG. 5: step c).

Then, on the first electrode current collector 11, the first electrode active material (for example, the positive electrode active material 12) and the electrolytic solution are contained in the region surrounded by the lower portion 21 of the battery exterior (the two connected cup-shaped spaces). The first electrode composition comprising and is filled (FIG. 5: step d).

Next, the separator 13 is formed on the outer lower portion 21 (on the frame portion 21b) by using the material laminating device 10 ″ for laminating the materials of the separator 13 (FIG. 5: step e). Here, the separator 13 is the frame. The shape is such that no gap is formed between the portion 21b and the separator 13, whereby the separator 13 seals the first electrode composition.

Next, the material laminating device 10 is used on the peripheral edge portion of the separator 13 (a range of a predetermined length from the outer peripheral edge of the separator 13 to not cover the entire separator 13), and the frame portion (frame) of the upper portion 22 of the battery exterior (Corresponding to the body) 22a is formed (FIG. 5: step f).

A second electrode active material (for example, the negative electrode active material 14) and an electrolytic solution are contained in the region (the columnar space) surrounded by the frame portion 22a on the separator 13. (Fig. 5: Step g).

Next, the second pole current collector 15 is formed on the second electrode active material by using the material laminating device 10'for laminating the materials of the current collector (FIG. 5: step h). At this time, the second pole current collector 15 is also extended outward from at least a part of the main portion 15a included in the range surrounded by the frame portion 22a and the peripheral portion of the main portion 15a in a plan view (example). Then, it is processed into a shape including a tab portion 15b protruding outward from the frame portion 22a).

Next, using the material laminating device 10, at least a part of the tab portion 15b of the second pole current collector 15 on the main portion 15a side is sealed (sandwiched), and the upper body portion 22b'(while sandwiching) the upper body portion 22 of the battery exterior 22 ( It corresponds to the second exterior member, and again, the frame portions 21b and 22a correspond to the frame body arranged between the first exterior member and the second exterior member) (FIG. 5: step i). ). The upper body portion 22b'is also processed into a desired shape, such as a shape in which two cup-shaped bodies are arranged in a row.

From this, the battery exterior 20 is formed by the battery exterior lower portion 21 and the battery exterior upper portion 22, and the first pole current collector 11, the positive electrode active material 12 layer, the separator 13, the negative electrode active material 14 layer, and the second pole collection. The laminated body formed by laminating the electric bodies 15 is in a sealed state. Further, at this time, the tab portion 11b of the first pole current collector 11 and the tab portion 15b of the second pole current collector 15 are in a state of protruding outward from the battery exterior 20 (FIG. 5: step j, FIG. 6). These tab portions 11b and 15b function as current extraction portions (electrodes) of the lithium ion battery manufactured here. Note that FIG. 6 shows a state in which the battery is partially broken for the sake of explanation.

Further, also in the example of FIG. 5, the first pole current collector 11, the separator 13, and the second pole current collector 15 are processed into a desired shape in advance instead of being formed by using the material laminating device 10. You may prepare the prepared ones and arrange the pre-processed ones in the steps b, e, and h of FIG. 5, respectively.

Further, in the above description, the battery exterior 20 (including the bottom portion 21a, the frame portions 21b, 22a, and the flat surface portion 22b and the upper body portion 22b') and the current collectors 11 and 15 are in direct contact with each other (including the bottom portion 21a, the frame portions 21b, 22a, and the flat surface portion 22b and the upper body portion 22b'). In some cases, the electrolytic solution enters during this period), but the present embodiment is not limited to this example.

That is, the seal member 30 may be arranged between the battery exterior 20 (including the bottom portion 21a, the frame portions 21b, 22a, and the flat surface portion 22b and the upper body portion 22b') and the current collectors 11 and 15 (including the bottom portion 21a, the frame portions 21b, 22a, and the flat surface portion 22b and the upper body portion 22b'). FIG. 7). As the sealing member, for example, an epoxy resin, a urethane resin, or the like can be used.

In this example, the seal member 30 is also formed using the material laminating device 10. Specifically, in the example of FIG. 7, between the bottom portions 21a, the frame portions 21b, 22a, and the flat surface portions 22b and the upper body portions 22b', which constitute the battery exterior 20, the current collectors 11, 15, and the separator 13. An example in which a layer of the sealing member 30 is formed by using the material laminating device 10 is shown. In this case, as the material laminating device 10 for forming the seal member 30, for example, when a two-component epoxy resin is used, a method of simultaneously injecting and solidifying from two nozzles is adopted.

If the seal member 30 is provided in this way, the battery exterior 20 is not necessarily required to have resistance to the electrolytic solution, so that a wider variety of materials can be used for the battery exterior 20.

The battery manufactured by the method of the present embodiment may be further enclosed in a moisture-proof container such as an aluminum laminate film and a metal container. Durability can be further improved by enclosing it in a moisture-proof container.

Further, in an example of the present embodiment, before forming the bottom portion 21a of the battery exterior 20, a support portion 40 having a flat bottom surface and a recessed portion along the outer shape of the bottom portion 21a is formed in advance. A battery may be formed on the support unit 40 by each step illustrated in FIG. 5 and the like. In this case, the support portion 40 may be formed by using the material laminating device 10 as, for example, a water-soluble powder fixed with a water-soluble adhesive. In this example, after forming a battery on the support portion 40, the support portion 40 is dissolved (if it is water-soluble, with water or the like) to obtain a battery. Further, the support unit 40 does not necessarily have to be soluble, and may be any as long as it can be separated from the battery. Further, the material of the support portion 40 may be the same as the material of the battery exterior 20 as long as the densities are different. As an example, the support portion 40 can be separated from the battery exterior 20 by forming the support portion 40 which is coarser than the battery exterior 20 and contains more air by using the same material as the battery exterior 20.

10, 10', 10 "material laminating device, 11 1st pole current collector, 12 positive electrode active material, 13 separator, 14 negative electrode active material, 15 2nd pole current collector, 20 battery exterior, 21 battery exterior lower part, 22 Upper part of battery exterior, 30 seal members, 40 support part.

Claims (3)

A positive electrode active material layer in which at least a part of the surface of the first electrode current collector is coated with a coating resin and a coating agent containing a conductive auxiliary agent , a separator, and at least a part of the surface is a coating resin and a conductive auxiliary agent. It is a method for manufacturing a lithium ion battery having a cell cell in which a negative electrode active material layer coated with a coating agent containing the mixture and a second electrode current collector are laminated in this order, and a battery exterior containing the cell. hand,
A step of forming the battery exterior by using a material laminating device that repeatedly discharges and solidifies a powdery, liquid, or paste-like material in a predetermined molding region to form a three-dimensional shape is included.
The process of forming the battery exterior is
A step of forming a first exterior portion having a predetermined shape by using the material laminating device, and
A step of arranging a first pole current collector having a main portion having a shape contained in the first exterior portion formed in a predetermined shape on the first exterior portion via a layer of a sealing member. ,
The material laminating device is used to form a first frame portion for fixing the peripheral edge portion of the main portion of the first pole current collector arranged on the first exterior portion on the first exterior portion. Process and
A separator having a shape that covers at least the region surrounded by the inner edge of the first frame portion and is included in the region surrounded by the outer edge of the first frame portion, and the peripheral portion thereof is the first frame portion. The process of positioning so that they overlap with each other and arranging them through the layers of the sealing member,
A second frame portion for fixing the peripheral edge portion of the separator arranged on the first frame portion on the first frame portion is formed via a layer of a sealing member by using the material laminating device. Process and
A second pole current collector having a main portion having a shape that covers at least the region surrounded by the inner edge of the second frame portion and is included in the region surrounded by the outer edge of the second frame portion is the main body. A step of positioning and arranging the peripheral portion of the portion so as to overlap the second frame portion.
A second exterior portion having a shape that covers at least the main portion of the second pole current collector is placed on the second frame portion and the second pole current collector by using a material laminating device . The process of forming through layers and
A method for manufacturing a lithium ion battery. The method for manufacturing a lithium ion battery according to claim 1.
The first electrode active material composition containing the first electrode active material and the electrolytic solution is contained in the region surrounded by the first frame portion, and the sealing member is referred to the first frame portion. And the process of filling through
A second electrode active material composition containing a second electrode active material and an electrolytic solution is provided in a region surrounded by the second frame portion, and the sealing member is provided with the second frame portion. And the process of filling through
A method for manufacturing a lithium ion battery including. The method for manufacturing a lithium ion battery according to claim 1 or 2.
A method for manufacturing a lithium ion battery, which comprises forming the separator using a material laminating device.

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