JPH11339783A - Manufacture of battery electrode utilizing infrared ray irradiation - Google Patents

Abstract

PROBLEM TO BE SOLVED: To promote the adhesion of a part of more between an electrode and an electrode separator without adding heat or pressure and prevent the deterioration of an electrode material without using a cover sheet in manufacture by irradiating infrared ray to at least one of an electrode containing an active material and a charge separator electrochemically inert thereto. SOLUTION: An electrode separator electrochemically inert to the component of a battery is affixed to the battery formed of a polymer material covered with a melt adhesive after heating and/or electrochemically neutralizing a specified area other than the active area of an electrode material by collective irradiation with infrared ray. Since the heat absorbed by the electrode dissolves and hardens at least a part of the electrode separator, the adhesion is promoted. The infrared ray may be irradiated after the adhering process of the electrode separator, and the adhesion is further facilitated preliminarily punching the electrode separator into the form of a specified heating area. In order to prevent the short-circuit of the battery, the electrode is preferably affixed to the charge separator so that the circumferential end parts are mutually matched.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing an electrode for a battery using infrared irradiation, and more particularly, the present invention relates to a charge separator using a step of promoting adhesion between a charge separator and an electrode by infrared irradiation. The present invention relates to a method for producing an electrode having: The present invention further relates to a method for producing a battery using the electrode.

[0002]

BACKGROUND OF THE INVENTION Charge separators (also known as electrode masks) have been used in the manufacture of battery electrodes for several years. Although methods of making electrodes with charge separators are utilized in the art, there are problems with the adhesion between the charge separator and the electrode in the prior art. That is,
Adhesion between conventional charge separators and electrodes is achieved by direct pressure from a hot wheel laminator. Such conventional methods require heat and pressure to thermally laminate the charge separator to the electrode, which can lead to undesirable changes in the physical properties of the electrode material.

[0003]

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a method of bonding between a charge separator and an electrode which does not require a mechanical method such as heat or pressure.

[0004]

Means for Solving the Problems The inventors of the present invention have made intensive studies to achieve the above object, and as a result, by irradiating the electrode region where the charge separator is moved upward with infrared rays, the adhesion between the charge separator and the electrode is reduced. The present inventors have found that the electrode material can be prevented from deteriorating without using a cover sheet at the time of production, and the present invention has been completed.

The present invention has been completed based on the above-mentioned findings, and a first gist of the present invention is to provide a process for manufacturing an electrode containing an active material, a method of producing an electrochemically inactive charge for the electrode. A step of manufacturing a separator, a step of bonding the charge separator to at least a part of the electrode, and
The present invention resides in a method for manufacturing a battery electrode, comprising a step of irradiating at least one of the electrode and the charge separator with infrared rays to promote adhesion between at least a part of the charge separator and at least a part of the electrode.

[0006] A second aspect of the present invention is a first aspect of the present invention, in which a first material containing an active material is contained.
A step of manufacturing an electrode, a step of manufacturing a second electrode containing an active material, a step of manufacturing a charge separator that is electrochemically inert to the first and second electrodes and the related electrolyte, Adhering to at least a part of at least one of first and second electrodes, the first electrode;
Irradiating at least one of the second electrode or the charge separator with infrared light to promote adhesion between at least a part of the charge separator and at least a part of one of the first and second electrodes; Separator, a step of applying the electrolyte to the first or second electrode that is bonded to the charge separator, and by attaching the first or second electrode that is not bonded to the charge separator to the electrolyte, At least a portion of the electrolyte is sandwiched between the first and second electrodes and disposed on the upper surface of the charge separator.

[0007]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below with reference to the drawings. The present invention is not limited to the embodiments and descriptions illustrated below, as the invention is capable of various embodiments.

FIG. 1 shows a process 10 for bonding a charge separator to a battery electrode. The process 10 is performed on a substantially continuous web feed system that includes a web 12 of a first electrode material 13, an infrared source (hereinafter referred to as an "IR source") 14, a charge separator applicator. 18, first optional curing station 20, electrolyte applicator 24, second curing station 28, web 30 of second electrode material 32, third optional curing station 34, and final product collection zone 4
Consists of zero. The first and second electrode materials 13, 32 combine with the active material 13 ', 32' thereon, respectively.

In operation, the first electrode material 13 is sent from the web 12 to the IR source 14. As shown in FIG.
The source 14 focuses and irradiates a specific portion of the electrode 13 on which the charge separator is affixed with infrared rays 15. The electrode 13 absorbs infrared radiation 15 so that the infrared radiation 15 heats a particular preselected region 17 of the electrode material. In particular, a carbon material such as carbon black or graphite contained in the electrode material is sensitive to infrared rays, and thus absorbs infrared rays 15 emitted from the IR source 14 well. Carbon is preferred as an infrared-sensitive material, but other materials capable of absorbing infrared light may be included in the electrode. Furthermore, to facilitate heating of the electrodes,
Other infrared sensitive materials may be used in conjunction with the electrodes.

In order to bond the charge separator, it is necessary to properly heat the electrodes, which can be prepared by heating the exposed surface at a suitable temperature to at least partially dissolve the charge separator. Irradiation of infrared rays sufficient for the electrodes is sufficient, and is not particularly limited because it can be easily understood by those skilled in the art. IR source 14 may use a conventional infrared source such as a laser or an infrared lamp. In addition, the IR source may include means for focusing infrared radiation, energy or heat on a particular preselected area 17.

By means of concentrating the infrared radiation 15 on the preselected area 17, the infrared radiation 15 is limitedly directed to the preselected area 17 of the electrode 13 to receive the charge separator. In this case, since only the specific region is heated, the active region 16 of the electrode 13 is hardly heated. Therefore, it is possible to avoid a change in the active material 13 ′ of the electrode 13 due to heat. The electrode 13 for IR irradiation
Exposure of the preselected region 17 also has the effect of reducing the electrochemical conductivity of the electrode / active material portion that adheres to the charge separator. This effect allows for uniform electrical conductivity between the electrode and the manufactured battery.

In FIG. 1, after a preselected region 17 of electrode 13 has been heated and / or electrochemically neutralized (reduced conductivity), a specific heating of the electrode is performed by a charge separator applicator 18. Charge separator 1 in part
9 is pasted. The charge separator 19 is a component of the battery,
That is, the first electrode material 13, the second electrode material 32, the active material 13'32 'that binds to both the first and second electrodes, and a material that is electrochemically inert to the electrolyte 26, preferably melt adhesion. Manufactured from a polymer material coated with an agent, but is chemically inert to the rest of the battery components and can be applied in the form of a curable medium, adversely affecting the mechanical and chemical integrity of the battery. There is no particular limitation unless given. Specifically, a polymerizable compound, polypropylene, wax,
Silicon sealants and the like can be mentioned. It should be noted that the term curable can be replaced by the term polymerizable, and the medium may be made of a heat conductive material.

After attaching the charge separator 19 to the specific heating portion (preselected region) 17 of the electrode 13, the heat absorbed by the electrode causes at least a part of the charge separator 19 to melt / harden. This dissolution / hardening effectively promotes the adhesion between the charge separator 19 and the electrode. To further facilitate this bonding and to allow for substantial alignment of the charge separator 19 with the electrodes and optimal bonding between the charge separator 19 and the electrodes, specific heating portions of the electrodes 13 (preselected areas) Preferably, the charge separator 19 is stamped into a preselected shape substantially corresponding to 17. Stamped charge separator 19
May be combined with a carrier substrate to facilitate its handling and transport. Note that the charge separator may take any desired shape, size, and thickness, for example,
It may be substantially rectangular, substantially triangular, or substantially circular.

Further, the charge separator applicator 18
May be specifically programmed by a conventional programming technique so that the charge separator 19 is attached to the electrode 13. This attachment is desirably performed such that the outer peripheral end 20 of the charge separator substantially matches the outer peripheral end 21 of the electrode (see FIG. 2). Such a relationship minimizes the possibility of a short circuit in the final manufactured battery. Further, pressure may be applied to one or both of the charge separator 19 and the electrode to promote adhesion therebetween.

Further, a means for imparting uniform electrochemical activity may be combined with the charge separator 19. Such means include, when coupled to the charge separator 19, a first
It is desirable to use a neutralizing material that can penetrate the active material 13 ′ of the electrode 13. The neutralizing material has a function of actually deactivating a part of the active material which is considered to be ionically and electronically conductive. In addition, IR irradiation and I
A neutralizing material that is activated by the heat resulting from the R irradiation may be used, in which case the neutralizing material is believed to be absorbed in the thermally generated voids in the IR treated area of the first electrode. Since neutralization by the neutralizing material occurs directly below the surface of the charge separator 19, the remaining active portion 16 of the electrode 13 can be provided with uniform electrochemical conductivity and greater energy density for the battery. Will be possible.

After bonding the charge separator 19 to the electrode 13,
The first curing station 22 is exposed. Depending on the composition of the material, the curing station may comprise a UV source, an oven, or any other conventional means used for curing or polymerizing the material. Although the use of the first curing station 22 has been specified, it is contemplated that the curing of the charge separator may be delayed until co-curing with the particular electrolyte is performed (described below). Alternatively, after partially curing the charge separator in the first curing station 22, and after applying the electrolyte, the charge separator may be completely cured in the same curing station as the electrolyte (eg, the second curing station 28). Is sometimes preferred.
Further, although not shown, if the process further utilizes a first electrode web of a material having the active material in a partially cured state, full curing may take place at the same curing station as the charge separator and / or electrode. Done.

Next, the electrolyte 26 is applied to the upper surface of the first electrode 13 and the upper surface of the adjacent charge separator 19 by a conventional electrolyte applicator 34. Thereafter, the relevant portions of the first electrode 13 are combined with the electrolyte 26, the charge separator 19, and / or the second curing station 28 for curing the partially cured active material 13 '(optional), as previously described. Exposure to Curing can be performed by conventional techniques. Further, it is preferable that the curing treatment of the electrolyte is not performed until after the second electrode material 32 is attached.

After at least partially curing the electrolyte 26, a second electrode material 32 from the second web 30 is applied to the electrolyte 26. The charge separator 19 is electrochemically inert with respect to the rest of the battery components and is not at least permeated by the electrolyte or active material of the electrode to which it is attached. Therefore, the electrolyte 26 may be at least partially sandwiched between the active material 13 ′ of the first electrode 13 and the active material 32 ′ of the second electrode 32, and may come into contact with the charge separator 19, but pass therethrough. (See also FIG. 5).

After attaching the second electrode material 32, the electrolyte 26
If only partially cured, the battery components are then exposed to a third curing station 34 to completely cure the electrolyte. Battery 3 fully assembled
6 proceeds from there to a die cutter 38, if necessary, where the battery is cut into a predetermined geometry (substantially corresponding to the outer shape of the previously applied charge separator). . Charge separator applicator 18
As in the case of, the die cutter 38 can be
The battery is programmed to cut into a predetermined shape.

A battery 36 (shown in FIGS. 5 and 6) composed of the first electrode 13, the first active material 13 ', the charge separator 19, the electrolyte 26, the second active material 32', and the second electrode 32
It is collected in the product collection zone 40 for subsequent storage and use. As can be seen, the outer peripheral end 20 of the charge separator 19 forms a plane with the outer peripheral end 21 of the first electrode 13,
As a result, the outer peripheral end 21 preferably forms a plane with the outer peripheral end 33 of the second electrode 32. This alignment substantially prevents overlap of the battery components and prevents shorting of the battery due to such overlap. In addition,
In the figure, a charge separator 1 is provided on only one of the electrodes.
Although the arrangement of 9 is illustrated, another charge separator may be attached to one or both of the electrodes.

FIG. 3 illustrates another process 50 for bonding a charge separator to an electrode used in the manufacture of a battery. Process 50 is also performed on a substantially continuous web feed system and comprises the same system components to produce battery 36 of FIGS. Therefore, the same reference numerals are used to indicate the same system components. Also in this case, the first and second electrode materials are respectively combined with the active material thereon.

Process 50 includes the charge separators 18 and I
Substantially similar to process 10 except for the location and function of R source 14. In process 50, instead of being exposed to IR source 14, web 12 of electrode material 13 is first exposed to charge separator applicator 18. Here, as shown in FIG. 4, the charge separator 19 is attached to the surface of the electrode 13. Further, instead of attaching the charge separator 19 to a preselected heating portion of the electrode, the charge separator 19
Is first bonded to the substrate 52. The substrate 52 is preferably affixed to the upper surface of the charge separator and serves as a medium for absorbing infrared rays and transmitting generated heat to the underlying charge separator, and is preferably made of a material sensitive to infrared rays. At the same time, the substrate 52 is preferably releasable from the charge separator 19 so that the substrate can be removed from the charge separator after bonding to the underlying electrode (described below). Specific examples of substrate 52 include, but are not limited to, melinex polyester, polypropylene, or any other polymer-based coating that does not adversely react with infrared sources.

Further, the charge separator 19 is preferably attached to the substrate 52 before the charge separator is attached to the electrode. The substrate is applied by printing, etching or silk screen.

Further, as shown in FIG.
May be coupled to the charge separator 19 and the substrate 52 (preferably sandwiched therebetween). The IR-sensitive layer 54 absorbs infrared radiation emitted by the IR source 14, as described below, and is particularly useful when the substrate does not absorb infrared radiation.

After the charge separator 19, substrate 52, and IR-sensitive layer 54 have been applied to the electrode 13, they are then
Exposure to source 14. The IR source comprises any conventional means, such as a laser for focusing infrared radiation, energy, and / or heat to a particular preselected area, but directs infrared radiation to a selected portion of the top surface of substrate 52. It is programmed to direct and emit.

The infrared-sensitive material, ie, the substrate 52 and the IR-sensitive
One or both of layers 54 absorbs at least a portion of the infrared radiation emitted from IR source 14. Due to the precise focusing nature of the IR beam, the infrared radiation emitted from the IR source 14 "images" only a preselected portion of the infrared sensitive material, and that portion absorbs infrared energy and is heated. This heat causes selected portions 56 of the charge separator, located adjacent to the IR-sensitive material, to adhere to the underlying electrode. Specifically, the molten adhesive layer of the charge separator melts when exposed to the transmitted heat, so that the "sticky"
And adhere to the electrode. Thus, only the imaged portion of the charge separator, ie, the preselected region 56, adheres to the electrode. This is essentially a thermally induced material transfer. Furthermore, since this heat is hardly applied to the active part of the electrode,
Areas of the electrode that do not accept the charge separator are not affected.

As an alternative to the charge separator 19 combined with the substrate 52 and / or the infrared sensitive layer 54, a charge separator at least partially made of infrared
3 may be attached. In this embodiment, the charge separator absorbs infrared radiation, so that the infrared radiation emitted from the IR source 14 forms an image such that the infrared-sensitive charge separator adheres to the electrode in the desired shape. As described above, the adhesion induced by the imaging between the charge separator and the electrode is performed without applying stray infrared radiation to the active portion of the underlying electrode. Also,
The IR irradiation also reduces or eliminates the electrochemical conductivity of the active material electrode located below the charge separator, which also has the effect of enabling more uniform electrochemical conductivity between the electrode and the manufactured battery. .

A preselected charge separator shape has an IR
After imaging the beam on the electrode 13, the remaining substrate 60,
The IR-sensitive material 64 (if present) and the unimaged charge separator region 62 are removed from the electrode, leaving the desired charge separator shape on the electrode. The subsequent steps are substantially the same as process 10, as can be seen in FIG. 3, with optional curing at first curing station 22, application of electrolyte 26 from electrolyte applicator 24,
It comprises the steps of curing at a second curing station 28, applying a second electrode from a second electrode web 30, optional curing at a third curing station 34, and collecting the product at a product collection zone 40. .

The above description and drawings are merely illustrative of the present invention, and various modifications and changes can be made in the present invention without departing from the gist thereof.

[0030]

The method of arranging the charge separator on the electrode according to the present invention is excellent in adhesive strength and durability, can enhance the performance of the battery system, and has high industrial value.

[Brief description of the drawings]

FIG. 1 is a schematic diagram of a process according to one embodiment of the present invention.

FIG. 2 is an exploded view of a part of the process according to FIG.

FIG. 3 is a schematic diagram of a process according to another embodiment of the present invention.

FIG. 4 is an exploded view of a part of the process according to FIG.

FIG. 5 is a front side sectional view of a battery manufactured according to the present invention.

FIG. 6 is a sectional view taken along line 6-6 in FIG. 5;

[Explanation of symbols]

 10: Process of bonding charge separator to battery electrode 12: First electrode material web 13: First electrode material 13 ': Active material 14: Infrared source 15: Infrared 16: Remaining active portion of electrode 13 17: Electrode Specific preselected regions of material 18: Charge separator applicator 19: Charge separator 20: Peripheral end of charge separator 21: Peripheral end of first electrode 22: First optional curing station 24: Electrolyte applicator 28: Second curing station 30: Second electrode material web 32: Second electrode material 32 ': Active material 33: Outer peripheral end of second electrode 34: Third optional curing station 36: Battery 38: Die cutter 40: Product recovery Zone 50: Other processes for bonding charge separators 52: Substrate 54: Infrared sensitive layer 56: Charge separator Selected portions 60: the remaining substrate 62: charge separator region 64 of the non-imaging: sensitive IR material (if present)

Claims (23)

[Claims] 1. A process for producing an electrode containing an active material,
Manufacturing a charge separator that is electrochemically inert to the electrode, bonding at least a portion of the electrode to the charge separator, and irradiating at least one of the electrode or the charge separator with infrared light. A step of promoting adhesion between at least a part of the charge separator and at least a part of the electrode. 2. The method according to claim 1, wherein the step of promoting the adhesion includes the step of irradiating at least a part of the electrode with the infrared ray before the charge separator is adhered to the electrode. 3. The method of manufacturing the charge separator, comprising:
3. The method according to claim 1, further comprising a step of manufacturing the charge separator into a desired shape prior to the step of bonding the charge separator. 4. The method according to claim 1, wherein the step of bonding the charge separator is performed before the step of irradiating the infrared rays. 5. The method according to claim 1, further comprising a step of releasably bonding at least a part of the charge separator to at least one of the substrate and the infrared absorbing layer. 6. The substrate according to claim 5, wherein said substrate is capable of absorbing infrared rays.
The production method described in 1. 7. The method according to claim 5, further comprising, after adhering at least a part of the charge separator to at least a part of the electrode, removing one or both of the charge separator and the related substrate from the electrode. 7. The production method according to 6. 8. The method according to claim 1, wherein said step of producing an electrode further comprises a step of producing an electrode capable of absorbing infrared rays. 9. The method of claim 1, wherein both the charge separator and the electrode have an outer edge, and the method further comprises substantially aligning the outer edge of the charge separator with the outer edge of the electrode. Item 9. The method according to any one of Items 1 to 8. 10. The method of claim 1, wherein the step of producing the charge separator further comprises the step of coating the charge separator with one or both of a molten adhesive and a thermoplastic polymer.
9. The method according to any one of items 9 to 9. 11. The method according to claim 1, wherein the step of producing the charge separator includes a step of producing the charge separator from a polymerizable compound. 12. The method according to claim 1, further comprising a step of curing the charge separator. 13. The method according to claim 1, further comprising the step of imparting uniform electrochemical activity in said manufactured battery.
The production method according to any one of the above. 14. The step of imparting uniform electrochemical activity includes applying a neutralizing material that penetrates the active material into the charge separator after adhering the charge separator to at least a portion of the electrode. 14. The method according to claim 13, wherein the charge separator has a step of deactivating a part of the applied active material of the electrode. 15. The step of imparting uniform electrochemical activity includes exposing at least a portion of the active material to the infrared rays to deactivate a portion of the active material of the electrode to which the charge separator is attached. 14. The method according to claim 13, further comprising:
Or the production method according to 14. 16. A process for manufacturing a first electrode including an active material, a process for manufacturing a second electrode including an active material, and a charge which is electrochemically inactive with respect to the first and second electrodes and a related electrolyte. Manufacturing a separator, bonding the charge separator to at least a part of at least one of the first and second electrodes, and irradiating at least one of the first electrode, the second electrode, or the charge separator with infrared light. Thereby promoting the adhesion between at least a part of the charge separator and at least a part of one of the first and second electrodes, wherein the charge separator and the first or second adhesively bonded to the charge separator Applying the electrolyte to an electrode, and attaching the first or second electrode that is not bonded to the charge separator to the electrolyte, thereby reducing the amount of the electrolyte. A method for manufacturing an electrode for a battery, comprising a step of at least partly being sandwiched between the first and second electrodes and disposed on an upper surface of the charge separator. 17. The method according to claim 16, further comprising a step of curing the charge separator and the electrolyte. 18. The method according to claim 17, wherein the step of curing the charge separator is performed prior to the step of curing the electrolyte. 19. The method according to claim 17, wherein the step of curing the charge separator and the step of curing the electrolyte are performed substantially simultaneously. 20. The method according to claim 16, further comprising a step of partially curing the charge separator prior to the step of applying the electrolyte. 21. The manufacturing method according to claim 16, further comprising a step of imparting uniform electrochemical activity in the manufactured battery. 22. The method of providing a uniform electrochemical activity, comprising applying a neutralizing material that penetrates the active material into the charge separator prior to curing the electrolyte. 22. The manufacturing method according to claim 21, further comprising a step of deactivating a part of the active material of the electrode. 23. The step of imparting uniform electrochemical activity includes deactivating a portion of the active material of the electrode to which the charge separator is attached by exposing at least a portion of the active material to the infrared light. 22. The method of claim 21, further comprising:
Or the production method according to 22.