WO2020073887A1 - 二次电池及其制造方法、电极构件及其制造方法、集流体的制造方法 - Google Patents

二次电池及其制造方法、电极构件及其制造方法、集流体的制造方法 Download PDF

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Publication number
WO2020073887A1
WO2020073887A1 PCT/CN2019/109961 CN2019109961W WO2020073887A1 WO 2020073887 A1 WO2020073887 A1 WO 2020073887A1 CN 2019109961 W CN2019109961 W CN 2019109961W WO 2020073887 A1 WO2020073887 A1 WO 2020073887A1
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WIPO (PCT)
Prior art keywords
conductive layer
electrode member
manufacturing
layer
active material
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
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PCT/CN2019/109961
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English (en)
French (fr)
Inventor
梁成都
张子格
薛庆瑞
李伟
李静
王鹏翔
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Contemporary Amperex Technology Co Ltd
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Contemporary Amperex Technology Co Ltd
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Priority to JP2021519770A priority Critical patent/JP7212773B2/ja
Priority to KR1020207034285A priority patent/KR102821629B1/ko
Publication of WO2020073887A1 publication Critical patent/WO2020073887A1/zh
Anticipated expiration legal-status Critical
Priority to JP2023003604A priority patent/JP7595688B2/ja
Ceased legal-status Critical Current

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/531—Electrode connections inside a battery casing
    • H01M50/533—Electrode connections inside a battery casing characterised by the shape of the leads or tabs
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/04—Processes of manufacture in general
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/04—Processes of manufacture in general
    • H01M4/0402—Methods of deposition of the material
    • H01M4/0404—Methods of deposition of the material by coating on electrode collectors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
    • H01M4/139—Processes of manufacture
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/64—Carriers or collectors
    • H01M4/66—Selection of materials
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/64—Carriers or collectors
    • H01M4/66—Selection of materials
    • H01M4/665—Composites
    • H01M4/667—Composites in the form of layers, e.g. coatings
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/64—Carriers or collectors
    • H01M4/70—Carriers or collectors characterised by shape or form
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/64—Carriers or collectors
    • H01M4/70—Carriers or collectors characterised by shape or form
    • H01M4/72—Grids
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/528—Fixed electrical connections, i.e. not intended for disconnection
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/531—Electrode connections inside a battery casing
    • H01M50/536—Electrode connections inside a battery casing characterised by the method of fixing the leads to the electrodes, e.g. by welding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/572—Means for preventing undesired use or discharge
    • H01M50/584—Means for preventing undesired use or discharge for preventing incorrect connections inside or outside the batteries
    • H01M50/586—Means for preventing undesired use or discharge for preventing incorrect connections inside or outside the batteries inside the batteries, e.g. incorrect connections of electrodes
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

  • the present invention relates to the field of batteries, and in particular, to a secondary battery and a method for manufacturing the same, an electrode member and a method for manufacturing the same, and a method for manufacturing a current collector.
  • the electrode member of a secondary battery generally includes a current collector and an active material layer coated on the surface of the current collector.
  • some electrode members select a multi-layer structure current collector.
  • the current collector includes an insulating base 11 and a conductive layer 12 connected to the surface of the insulating base 11, The active material layer 13 is coated on the surface of the conductive layer 12.
  • the insulating substrate 11 is a soft material (such as PET plastic), and the conductive layer 12 is usually made of metal.
  • the elastic modulus of the insulating substrate 11 is smaller than that of the conductive layer 12, so the ductility of the insulating substrate 11 is higher than The ductility of the conductive layer 12.
  • the insulating substrate 11 exerts a force on the conductive layer 12, and since the connection force between the insulating substrate 11 and the conductive layer 12 is small, when the conductive layer 12 extends to a certain extent, The conductive layer 12 may be detached from the surface of the insulating base 11, thereby affecting the performance of the electrode member.
  • the object of the present invention is to provide a secondary battery and its manufacturing method, electrode member and its manufacturing method, and current collector manufacturing method, which can reduce stress concentration and reduce the risk of the conductive layer falling , To ensure the performance of the electrode member.
  • the present invention provides an electrode member of a secondary battery.
  • the electrode member includes an insulating substrate, a first conductive layer, and an active material layer.
  • the first conductive layer is provided on the surface of the insulating base, and the active material layer is provided on a side of the first conductive layer away from the insulating base.
  • the first conductive layer is provided with a strip-shaped groove extending in the height direction.
  • the electrode member further includes a second conductive layer having a first portion located in the strip-shaped groove.
  • the second conductive layer further includes a second portion, the second portion is disposed on a surface of the first conductive layer away from the insulating substrate and connected to the first portion, and the active material layer is disposed on the first Two parts of the surface away from the first conductive layer.
  • the first conductive layer includes a body portion and a protrusion extending from the body portion, the body portion is coated with the active material layer, and the protrusion is not coated with the active material layer.
  • the strip-shaped groove includes a first groove formed in the protrusion, and the second portion is at least partially located on a surface of the protrusion away from the insulating base.
  • the bar-shaped groove further includes a second groove formed in the body portion, and the first groove communicates with the second groove.
  • the electrode member further includes a protective layer provided on a surface of the second portion away from the protrusion and connected to the active material layer, and the first groove does not exceed the protective layer.
  • the rigidity of the second conductive layer is less than the rigidity of the first conductive layer.
  • the strip-shaped groove penetrates the first conductive layer in the thickness direction, and the first portion of the second conductive layer is connected to the insulating base.
  • the present invention also provides a secondary battery.
  • the secondary battery includes an electrode assembly including the electrode member.
  • the present invention also provides a method for manufacturing a current collector.
  • the manufacturing method of the current collector includes: providing an insulating base; fixing a conductive material to the surface of the insulating base to form a first conductive layer, and the first conductive layer is provided with a strip-shaped groove extending in a height direction.
  • the conductive material is fixed to the surface of the insulating substrate by vapor deposition or chemical plating.
  • the manufacturing method of the current collector further includes: applying a conductive paste to a part of the surface of the first conductive layer, and filling the conductive paste into the strip-shaped groove. After the conductive paste is cured, a second conductive layer is formed.
  • the present invention also provides a method for manufacturing an electrode member.
  • the manufacturing method of the electrode member includes: providing a current collector manufactured according to the current collector manufacturing method; applying a slurry including an active material to a partial area of the surface of the first conductive layer, and allowing the The slurry including the active material is filled into the strip-shaped groove; the slurry including the active material is cured to form an active material layer, and then the active material layer is rolled; the metal foil is welded to the first A region of a conductive layer not coated with the active material layer; a part of the metal foil and a part of the current collector are cut off to form a plurality of spaced-apart conductive structures and a plurality of spaced-apart electrical guides.
  • the method for manufacturing the electrode member further includes: applying a slurry including an insulating material to a partial area of the surface of the first conductive layer, the slurry including the insulating material curing to form a protective layer; the protective layer It is formed before welding the metal foil.
  • the present invention also provides a method for manufacturing a secondary battery.
  • the manufacturing method of the secondary battery includes: providing a positive electrode member, a negative electrode member, and a separator, and winding the positive electrode member, the separator, and the negative electrode member together to form an electrode assembly, wherein the positive electrode member and At least one of the negative electrode members is manufactured according to the manufacturing method of the electrode member; providing an adapter sheet, laminating and welding a plurality of conductive structures of the electrode assembly to the adapter sheet; providing a top cover plate and fixing to Electrode terminal of the top cover plate, and welding the adapter piece to the electrode terminal; providing a housing, placing the electrode assembly into the housing, and then connecting the top cover plate to the housing .
  • the present invention also provides another method for manufacturing an electrode member.
  • the manufacturing method of the electrode member includes: providing a current collector manufactured by the current collector manufacturing method; applying a slurry including an active material to a partial area of the surface of the second conductive layer; curing the including Slurry of active material and form an active material layer, and then roll the active material layer; weld a metal foil to an area of the first conductive layer not coated with the second conductive layer; cut off the metal foil A part of the material and a part of the current collector form a plurality of spaced-apart conductive structures and a plurality of spaced-apart electrical guides.
  • the manufacturing method of the electrode member further includes: applying a slurry including an insulating material to a part of the surface of the second conductive layer, and then curing the slurry including the insulating material and forming a protective layer.
  • the protective layer is formed before welding the metal foil.
  • the present invention also provides another method for manufacturing a secondary battery.
  • the manufacturing method of the secondary battery includes: providing a positive electrode member, a negative electrode member, and a separator, and winding the positive electrode member, the separator, and the negative electrode member together to form an electrode assembly, wherein the positive electrode member and At least one of the negative electrode members is manufactured according to the another method of manufacturing the electrode member; providing a transition piece, laminating and welding a plurality of conductive structures of the electrode assembly to the transition piece; providing A top cover plate and an electrode terminal fixed to the top cover plate, and welding the adapter piece to the electrode terminal; providing a case, placing the electrode assembly into the case, and then placing the top cover plate Connected to the housing.
  • a strip-shaped groove is formed on the first conductive layer, and the strip-shaped groove can effectively release the force on the first conductive layer, reduce stress concentration, and effectively The risk of the first conductive layer falling off the surface of the insulating substrate ensures the performance of the electrode member.
  • FIG. 1 is a schematic diagram of an electrode member in the prior art.
  • FIG. 2 is a schematic diagram of the electrode member of FIG. 1 during the rolling process.
  • FIG. 3 is a schematic diagram of the insulating substrate and the conductive layer of the electrode member of FIG. 1 before being rolled.
  • FIG. 4 is a schematic diagram of the insulating substrate and the conductive layer of the electrode member of FIG. 1 after being rolled.
  • FIG. 5 is a schematic diagram of a secondary battery according to the present invention.
  • FIG. 6 is a cross-sectional view of an electrode assembly according to the present invention.
  • FIG. 7 is a schematic diagram of a first embodiment of an electrode member according to the present invention.
  • FIG. 8 is a cross-sectional view taken along line A-A of FIG. 7.
  • FIG. 9 is a schematic diagram of the electrode member of FIG. 7 during the molding process.
  • FIG. 10 is another schematic diagram of the electrode member of FIG. 7 during the molding process.
  • FIG. 11 is a schematic diagram of the first conductive layer of FIG. 10 after being rolled.
  • FIG. 12 is another schematic diagram of the electrode member of FIG. 7 during the molding process.
  • FIG. 13 is a schematic view of the electrode member of FIG. 7 after being wound.
  • FIG. 14 is a schematic diagram of a second embodiment of the electrode member according to the present invention.
  • 15 is a cross-sectional view taken along line B-B of FIG. 14.
  • FIG. 16 is a schematic diagram of the insulating substrate and the first conductive layer in FIG. 15.
  • FIG. 17 is a schematic diagram of a third embodiment of an electrode member according to the present invention.
  • FIG. 19 is a schematic diagram of a fourth embodiment of the electrode member according to the present invention.
  • FIG. 20 is a cross-sectional view taken along line D-D of FIG. 19.
  • 21 is a schematic diagram of the first conductive layer of the electrode member of FIG. 19.
  • FIG. 22 is a schematic diagram of a fifth embodiment of the electrode member according to the present invention.
  • Fig. 23 is a cross-sectional view taken along line E-E of Fig. 22.
  • FIG. 24 is a schematic diagram of the first conductive layer of the electrode member of FIG. 22.
  • the secondary battery of the present invention includes an electrode assembly.
  • the electrode assembly includes a positive electrode member 2, a negative electrode member 3 and a separator 4.
  • the separator 4 is provided between the positive electrode member 2 and the negative electrode member 3.
  • the positive electrode member 2, the separator 4, and the negative electrode member 3 are stacked and wound into a flat shape.
  • the electrode assembly is the core component of the secondary battery to realize the charge and discharge function.
  • the secondary battery of the present invention may be a soft-pack battery, and the electrode assembly formed by winding the positive electrode member 2, the separator 4, and the negative electrode member 3 is directly encapsulated in a packaging bag.
  • the packaging bag may be an aluminum plastic film.
  • the secondary battery of the present application may also be a hard-shell battery.
  • the secondary battery mainly includes an electrode assembly, a case 5, a top cover plate 6, an electrode terminal 7 and an adapter sheet 8.
  • the housing 5 may have a hexahedral shape or other shapes.
  • a cavity is formed inside the case 5 to accommodate the electrode assembly and the electrolyte.
  • the case 5 forms an opening at one end, and the electrode assembly can be placed into the receiving cavity of the case 5 through the opening.
  • the housing 5 may be made of conductive metal materials such as aluminum or aluminum alloy, or may be made of insulating materials such as plastic.
  • the top cover plate 6 is provided in the casing 5 and covers the opening of the casing 5, so that the electrode assembly is enclosed in the casing 5.
  • the electrode terminal 7 is provided on the top cover plate 6.
  • the upper end of the electrode terminal 7 protrudes to the upper side of the top cover plate 6, and the lower end can pass through the top cover plate 6 and extend into the housing 5.
  • the adapter piece 8 is provided in the housing 5 and fixed to the electrode terminal 7. Both the electrode terminal 7 and the adapter tab 8 are two, the positive electrode member 2 is electrically connected to one electrode terminal 7 via one adapter tab 8, and the negative electrode member 3 is electrically connected to the other electrode terminal 7 via another adapter tab 8.
  • the adapter piece 8 is welded to the electrode terminal 7.
  • At least one of the positive electrode member 2 and the negative electrode member 3 adopts the electrode member 1 described later.
  • the electrode member 1 of the first embodiment includes an insulating base 11, a first conductive layer 12 and an active material layer 13.
  • the first conductive layer 12 is provided on both surfaces of the insulating base 11, and the active material layer 13 is provided on the side of the first conductive layer 12 away from the insulating base 11.
  • the material of the insulating substrate 11 may be a PET (polyethylene terephthalate) film or a PP (polypropylene) film.
  • the material of the first conductive layer 12 is selected from at least one of a metal conductive material and a carbon-based conductive material; the metal conductive material is preferably at least one of aluminum, copper, nickel, titanium, silver, nickel-copper alloy, aluminum zirconium alloy, The carbon-based conductive material is preferably at least one of graphite, acetylene black, graphene, and carbon nanotubes.
  • the first conductive layer 12 may be formed on the surface of the insulating substrate 11 by at least one of vapor deposition method and electroless plating.
  • the vapor deposition method is preferably a physical vapor deposition method (Physical Vapor Deposition, PVD), such as a thermal evaporation method (Thermal Evaporation Deposition).
  • the active material layer 13 may also be provided on the surface of the first conductive layer 12 by coating.
  • the active material such as lithium manganate, lithium iron phosphate
  • binder, conductive agent and solvent can be made into a slurry, and then the slurry is coated on the outer surfaces of the two first conductive layers 12, after the slurry is cured The active material layer 13 is formed.
  • the first conductive layer 12 is provided with a strip-shaped groove G that extends substantially along the height direction Z and is used to relieve the stress of the first conductive layer 12.
  • the length of the strip groove G in the width direction X is 0.001 mm to 1 mm, and it is much smaller than the length of the strip groove G extending in the height direction Z.
  • the bar-shaped groove G may be linear or curved, and as a whole, the bar-shaped groove G only needs to extend approximately along the height direction Z; that is to say, between the extending direction of the bar-shaped groove G and the height direction Z There may be a small included angle (for example, the included angle may be less than 10 °).
  • the thickness of the insulating base 11 may be 1 ⁇ m-20 ⁇ m, and the thickness of the first conductive layer 12 may be 0.1 ⁇ m-10 ⁇ m. Since the first conductive layer 12 is relatively thin, the burrs generated by the first conductive layer 12 during the cutting of the electrode member 1 are small, and it is difficult to puncture the separator 4 of more than ten microns, thereby avoiding a short circuit and improving safety performance.
  • the first conductive layer 12 includes a body portion 121 and a protrusion 122 extending from the body portion 121, the body portion 121 is coated with an active material layer 13, and the protrusion 122 is not coated with the active material layer 13.
  • the active material layer 13 may be directly coated on the surface of the main body 121. Of course, alternatively, other materials may be provided between the main body 121 and the active material layer 13.
  • the portion of the insulating base 11 corresponding to the protrusion 122 and the protrusion 122 form an electric guide portion P.
  • the electric guide portions P may be plural and arranged at intervals in the width direction X. Referring to FIG. 13, after the electrode member 1 is wound and formed, the plurality of electrical guides P are stacked in the thickness direction Y.
  • the electrode member 1 further includes a protective layer 15 provided on the side of the protrusion 122 away from the insulating base 11 and connected to the active material layer 13.
  • the protective layer 15 includes an adhesive and an insulating material.
  • the insulating material includes at least one of aluminum oxide and aluminum oxyhydroxide.
  • the binder, the insulating material and the solvent are mixed together to prepare a slurry, which is coated on the surface of the protrusion 122 and forms the protective layer 15 after curing.
  • the hardness of the protective layer 15 is greater than the hardness of the protrusion 122.
  • the electrode member 1 further includes a conductive structure 16 that is welded to a region of the protrusion 122 that is not covered by the protective layer 15. 7 and 8, the conductive structures 16 are fixed on both sides of each electrical guide P in the thickness direction Y. Referring to FIG. 13, after the electrode member 1 is wound and formed, all the conductive structures 16 are stacked and welded to the adapter sheet 8 at the same time. Referring to FIG. 5, the current in the electrode member 1 can be output to the outside via the adapter 8 and the electrode terminal 7.
  • the electrode member 1 of the first embodiment can be formed in the following steps:
  • the first conductive layer 12 is formed on the surface of the insulating substrate 11 by vapor deposition or chemical plating, thereby preparing a composite tape; referring to FIG. 9, during the molding process, the first conductive layer 12 is reserved Strip groove G.
  • the active material layer 13 and the protective layer 15 are simultaneously coated on the surface of the first conductive layer 12.
  • a metal foil material for example, aluminum foil
  • a plurality of electrical guide portions P and a plurality of conductive materials are cut along the broken line in FIG.
  • the structure 16 further obtains the electrode member 1 shown in FIG. 7.
  • the first conductive layer 12 may be formed on the surface of the insulating substrate 11 by vapor deposition or chemical plating, so the connection force between the first conductive layer 12 and the insulating substrate 11 is small, under the action of external forces , It may cause the first conductive layer 12 to easily fall off the surface of the insulating base 11.
  • the insulating base 11 Since the elastic modulus of the insulating base 11 is smaller than that of the first conductive layer 12, the ductility of the insulating base 11 is higher than that of the first conductive layer 12. In the step (three), the insulating base 11 is stretched under pressure. Since the insulating base 11 has high ductility, the insulating base 11 exerts a force on the first conductive layer 12.
  • the force on the first conductive layer 12 cannot be released, so when the first conductive layer 12 extends to a certain extent, the force on the first conductive layer 12 will be greater than the insulating base 11 and the first conductive layer
  • the connecting force between 12 causes the insulating base 11 and the first conductive layer 12 to slide relative to each other, so that the first conductive layer 12 falls off from the surface of the insulating base 11 and affects the performance of the electrode member 1.
  • a strip-shaped groove G is formed on the first conductive layer 12, and the strip-shaped groove G can effectively release the force on the first conductive layer 12, reduce the stress concentration, and avoid the first conductive layer 12
  • the applied force is too large, which effectively reduces the risk of the first conductive layer 12 falling off from the surface of the insulating base 11 and guarantees the performance of the electrode member 1.
  • FIG. 11 shows the state of the first conductive layer 12 after rolling, in which the broken line shows the state of the bar-shaped groove G before rolling.
  • the force on the first conductive layer 12 is gradually concentrated in the strip groove G; when the force on the first conductive layer 12 is too large, the first conductive layer 12 will Cracking along the strip groove G under the action of force, so as to release the stress in time, avoid the acting force on the first conductive layer 12 is greater than the connecting force between the insulating base 11 and the first conductive layer 12, reduce the insulating base 11 The probability of slipping relative to the first conductive layer 12 ensures the performance of the electrode member 1.
  • the current generated by the active material layer 13 flows through the main body 121 to the protrusion 122, that is, on the first conductive layer 12, the current generally flows in the height direction Z, therefore, the first The overcurrent area of the conductive layer 12 depends on the area of the cross section of the first conductive layer 12 perpendicular to the height direction Z.
  • the strip groove G generally extends in the height direction Z, and its length in the width direction X is very small, that is, the size of the strip groove G in the height direction Z is larger than that of the strip groove G in the width direction X size of. Therefore, when the first conductive layer 12 is cracked along the strip-shaped groove G during the rolling process, the strip-shaped groove G has little effect on the overcurrent area of the first conductive layer 12, thereby ensuring the The overcurrent capability meets the requirements.
  • step (3) as the rolling progresses, the force on the first conductive layer 12 will gradually increase; referring to FIG. 11, when the electrode member 1 is rolled for a certain length in the width direction X, the first conductive layer 12 The applied force will drive the first conductive layer 12 to crack along the strip groove G, thereby releasing the stress in time. Since the first conductive layer 12 has a large length in the width direction X, preferably, there are a plurality of strip-shaped grooves G, and the plurality of strip-shaped grooves G are arranged at intervals in the width direction X.
  • the plurality of strip-shaped grooves G can release stress in a stepwise manner during the rolling process, avoiding that the acting force on the first conductive layer 12 is greater than the connecting force between the insulating base 11 and the first conductive layer 12, reducing the insulating base The probability of slipping relative to the first conductive layer 12 ensures the performance of the electrode member 1.
  • the strip groove G penetrates the first conductive layer 12 in the thickness direction Y, that is, in the thickness direction Y, the depth of the strip groove G is equal to the thickness of the first conductive layer 12. At this time, the first conductive layer 12 is more likely to crack along the strip groove G during the rolling process, thereby releasing the stress in time.
  • step (2) the active material layer 13 may be filled into the strip groove G, therefore, the current on the active material layer 13 may flow to the first conductive layer 12 through the peripheral wall of the strip groove G, thereby improving the The current collecting capability of a conductive layer 12.
  • step (3) even if the first conductive layer 12 is cracked along the strip-shaped groove G, the active material layer 13 will be filled to the cracked portion under the action of the roller pressure.
  • the protective layer 15 has a high strength, and can provide support for the protrusion 122 during the rolling of the electrode member 1, limit the deformation of the protrusion 122, and reduce the probability of the protrusion 122 cracking To improve the overcurrent capability of the electrode member 1.
  • the protrusion 122 may come off due to vibration and other factors; therefore, the protective layer 15 is preferably connected to the active material layer 13 so that the protective layer 15 can be fixed to the active material layer 13 to increase the protective layer
  • the bonding force of 15 on the electrode member 1 improves the seismic resistance and prevents the protective layer 15 from falling off together with the protrusion 122.
  • the protrusion 122 is most likely to bulge near the root of the active material layer 13 (that is, the boundary between the protrusion 122 and the main body 121), so when the protective layer 15 is connected to the active material layer 13, the protrusion can be reduced
  • the deformation of the portion 122 reduces the probability of cracks, thereby improving the overcurrent capability of the electrode member 1.
  • FIGS. 14 to 16 are schematic diagrams of the second embodiment of the electrode member of the present invention.
  • the depth of the strip groove G is smaller than the thickness of the first conductive layer 12.
  • the first conductive layer 12 of the second embodiment has a larger flow area.
  • the cross section of the strip groove G may be U-shaped or V-shaped.
  • the electrode member 1 of the third embodiment further includes a second conductive layer 14 having a first portion 141 located in the strip-shaped groove G.
  • the first part 141 is filled into the strip groove G, and the current around the strip groove G can be transmitted through the first part 141; in other words, the first part 141 can repair the conductive network of the first conductive layer 12 and increase the overcurrent area To ensure the overcurrent capability of the electrode assembly 1 as a whole.
  • the active material layer 13 is filled into the strip groove G, therefore, the distribution of the active material layer 13 is not uniform, that is, the thickness of the active material layer 13 at the strip groove G is Thickness greater than other locations.
  • the active material layer 13 may deposit lithium at a position corresponding to the strip groove G.
  • the first portion 141 is filled in the strip-shaped groove G, thereby ensuring the flatness of the first conductive layer 12, improving the uniformity of the distribution of the active material layer 13, and reducing the risk of lithium deposition.
  • the second conductive layer 14 further includes a second portion 142 disposed on the surface of the first conductive layer 12 away from the insulating base 11 and connected to the first portion 141, and the active material layer 13 disposed on the second portion 142 away from the first The surface of the conductive layer 12.
  • the second conductive layer 14 may be a metallic material or a non-metallic material.
  • the second conductive layer 14 is preferably a non-metallic material that does not easily generate burrs.
  • the conductive carbon, the binder, and the solvent can be first made into a slurry, and then the slurry is coated on the first conductive layer 12, and the second conductive layer 14 is formed after the slurry is cured. During the coating process, the slurry is filled into the strip groove G and the first portion 141 is formed.
  • step (2) the slurry of the second conductive layer 14 may be applied to the first conductive layer 12 first, and then the slurry of the active material layer 13 and the slurry of the protective layer 15 may be applied to the second The surface of the conductive layer 14.
  • step (three) even if the first conductive layer 12 is cracked along the strip groove G, the second portion 142 will be filled to the cracked portion under the action of the roller pressure, so that even if the first conductive layer 12 is repaired
  • the conductive network increases the overcurrent area to ensure the overall overcurrent capability of the electrode assembly 1.
  • the current of the second conductive layer 14 can only be conducted to the first conductive layer 12 through the surface of the first conductive layer 12.
  • the first portion 141 of the second conductive layer 14 is embedded in the strip-shaped groove G on the first conductive layer 12, therefore, not only can current be conducted to the first conductive layer 12 through the surface of the first conductive layer 12, but also Conduction can be conducted through the peripheral wall of the strip groove G, thereby increasing multiple conduction paths, forming a multi-point conductive network, improving the conductivity of the electrode member 1, reducing the polarization of the electrode member 1 and the secondary battery, and improving the secondary High rate charge and discharge performance of the battery.
  • the second portion 142 is at least partially located on the surface of the protrusion 122 away from the insulating base 11.
  • the protective layer 15 may be disposed on the surface of the second portion 142 away from the protrusion 122.
  • the conductive structure 16 is welded to the area of the protrusion 122 not covered by the second portion 142.
  • the main body portion 121 is extended by the insulating base 11, and the protrusion 122 is hardly extended.
  • the main body 121 and the insulating base 11 apply a force to the protrusion 122 when they are extended, and because the protrusion 122 is thin, the protrusion 122 will generate micro cracks under the force.
  • the second portion 142 is provided on the surface of the protrusion 122. Therefore, even if the protrusion 122 generates a crack during rolling, the current at the crack can be transmitted outward through the second portion 142, thereby achieving The repair of the conductive network ensures the overall overcurrent capability of the electrode member 1.
  • the rigidity of the second conductive layer 14 is less than the rigidity of the first conductive layer 12. That is to say, the second conductive layer 14 is more easily deformed when stressed.
  • the second portion 142 will also deform along with the protrusion 122; even if the protrusion 122 cracks due to excessive deformation, the second portion 142 is less likely to break, thereby ensuring the transmission of current.
  • the strip-shaped groove G penetrates the first conductive layer 12 in the thickness direction Y, and the first portion 141 of the second conductive layer 14 is connected to the insulating base 11.
  • the first portion 141 is embedded in the strip-shaped groove G and adhered to the insulating base 11, thereby increasing the connection strength of the first conductive layer 12, the second conductive layer 14, and the insulating base 11.
  • the bar-shaped groove G of the fourth embodiment includes a first groove G1 formed in the protrusion 122.
  • step (3) the portion of the insulating base 11 corresponding to the main body 121 is stretched, and the portion of the insulating base 11 corresponding to the main body 121 exerts a force on the portion of the insulating base 11 corresponding to the protrusion 122. As a result, the portion of the insulating base 11 corresponding to the protrusion 122 is extended.
  • the protrusion 122 is limited by the protective layer 15 and is therefore almost inextensible; the portion of the insulating base 11 corresponding to the protrusion 122 will exert a force on the protrusion 122 when it is expanded, if the force is greater than the insulation base 11 and the protrusion Due to the connection force of the portion 122, the protrusion 122 is easily detached from the insulating base 11.
  • the first groove G1 can effectively release the force on the protrusion 122, reduce the stress concentration, avoid excessive force on the protrusion 122, effectively reduce the probability of the protrusion 122 falling off, and ensure The performance of the electrode member 1.
  • the first groove G1 does not exceed the protective layer 15 in a direction away from the active material layer 13.
  • the area covered by the protection layer 15 of the protrusion 122 is subjected to the greatest stress. Therefore, the first groove G1 only needs to be provided in the area covered by the protection layer 15 of the protrusion 122.
  • the area of the protrusion 122 that is not covered by the protective layer 15 is less stressed, and there is no risk of falling off. If the first groove G1 extends to the area of the protrusion 122 that is not covered by the protective layer 15, it will decrease The overcurrent capability of the protrusion 122.
  • the bar-shaped groove G further includes a second groove G2 formed in the main body 121, and the first groove G1 communicates with the second groove G2.
  • step (3) the main body 121 extends under the force applied by the insulating base 11. Since the protrusion 122 is restricted by the protective layer 15, the protrusion 122 is almost inextensible. Therefore, the area of the main body 121 near the protrusion 122 is subjected to the reaction force of the protrusion 122. In other words, the area of the main body 121 close to the protrusion 122 receives the force of the insulating base 11 and the protrusion 122 at the same time. Therefore, the area of the main body 121 close to the protrusion 122 is easily detached from the insulating base 11.
  • the second groove G2 extends to the area of the main body 121 near the protrusion 122, thereby effectively releasing the force on the main body 121, reducing the stress concentration, and effectively reducing the insulating base 11 and the main body
  • the probability of 121 relative slippage ensures the performance of the electrode member 1.
  • the strip-shaped groove G further includes a plurality of third grooves G3 arranged at intervals in the width direction X, and the third grooves G3 are formed in the body portion 121.
  • each third groove G3 is located between two adjacent second grooves G2; in the height direction Z, the third groove G3 and the second groove G2 are offset from each other.
  • the bar-shaped groove G of the fifth embodiment includes a third groove G3 and a fourth groove G4 formed in the body portion 121.
  • the third grooves G3 are plural and arranged at intervals in the width direction X
  • the fourth grooves G4 are plural and arranged at intervals in the width direction X.
  • each third groove G3 is located between two adjacent fourth grooves G4.
  • the third groove G3 and the fourth groove G4 are offset from each other.
  • the third groove G3 and the fourth groove G4 are dispersedly arranged in the width direction X and the height direction Z, which can improve the stress relief effect and improve the uniformity.
  • the present application also provides a method for manufacturing a secondary battery, which can improve the safety performance of the secondary battery.
  • Secondary battery manufacturing methods include:
  • a positive electrode member 2 a negative electrode member 3, and a separator 4, and wind the positive electrode member 2, the separator 4, and the negative electrode member 3 to form an electrode assembly; wherein, the positive electrode member 2 and the negative electrode At least one of the members 3 adopts the aforementioned electrode member 1;
  • a transition piece 8 is provided, and a plurality of conductive structures 16 of the electrode assembly are stacked and welded to the transition piece 8;
  • a case 5 is provided, the electrode assembly is placed into the case 5, and then the top cover plate 6 is connected to the case 5.
  • the thickness of the first conductive layer 12 is small; when a foreign object pierces the electrode member 1 of the secondary battery, the first conductive layer 12 is generated at the location pierced by the foreign object The burr is small, it is difficult to puncture the diaphragm 4, thereby avoiding short circuit and improving safety performance.
  • a strip groove G is formed on the first conductive layer 12, and the strip groove G can effectively release the force on the first conductive layer 12, reduce the stress concentration, and effectively reduce the first conductive layer 12 from The risk of the surface of the insulating substrate 11 falling off ensures the performance of the electrode member 1 and the secondary battery.

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Abstract

本发明提供一种二次电池及其制造方法、电极构件及其制造方法、集流体的制造方法。电极构件包括绝缘基体、第一导电层以及活性物质层；第一导电层设置于绝缘基体的表面，活性物质层设置于第一导电层的远离绝缘基体的一侧；第一导电层设有沿高度方向延伸的条形凹槽，所述条形凹槽用于释放第一导电层的应力。二次电池包括电极组件，电极组件包括所述的电极构件。

Description

二次电池及其制造方法、电极构件及其制造方法、集流体的制造方法 技术领域
本发明涉及电池领域，尤其涉及一种二次电池及其制造方法、电极构件及其制造方法、集流体的制造方法。
背景技术
二次电池的电极构件通常包括集流体和涂覆在集流体表面的活性物质层。为了提高二次电池的安全性能，一些电极构件选择一种多层结构的集流体，参照图1至图3，所述集流体包括绝缘基体11和连接于绝缘基体11表面的导电层12，而活性物质层13涂覆于导电层12的表面。
在电极构件的生产过程中，需要辊压活性物质层13，以将活性物质层13压薄，提高能量密度。绝缘基体11为一种较软的材质(例如PET塑料)，而导电层12通常为金属材质，绝缘基体11的弹性模量小于导电层12的弹性模量，因此绝缘基体11的延展性高于导电层12的延展性。在绝缘基体11延展的过程中，绝缘基体11会对导电层12施加作用力，而由于绝缘基体11和导电层12之间的连接力较小，因此，当导电层12延展到一定程度时，可能会造成导电层12从绝缘基体11的表面脱落，从而影响电极构件的性能。
发明内容
鉴于背景技术中存在的问题，本发明的目的在于提供一种二次电池及其制造方法、电极构件及其制造方法、集流体的制造方法，其能降低应力集中，减小导电层脱落的风险，保证电极构件的性能。
为了实现上述目的，本发明提供了一种二次电池的电极构件。
所述电极构件包括绝缘基体、第一导电层以及活性物质层。所述第一导电层设置于所述绝缘基体的表面，所述活性物质层设置于所述第一导电层的远离所述绝缘基体的一侧。所述第一导电层设有沿高度方向延伸的条形凹槽。
所述电极构件还包括第二导电层，所述第二导电层具有位于所述条形凹槽内的第一部分。
所述第二导电层还包括第二部分，所述第二部分设置于所述第一导电层远离所述绝缘基体的表面且与所述第一部分连接，所述活性物质层设置于所述第二部分的远离所述第一导电层的表面。
所述第一导电层包括主体部和从所述主体部延伸的突部，所述主体部涂覆有所述活性物质层，所述突部未涂覆所述活性物质层。所述条形凹槽包括形成于所述突部的第一凹槽，且所述第二部分至少部分位于所述突部的远离所述绝缘基体的表面。
所述条形凹槽还包括形成于所述主体部的第二凹槽，所述第一凹槽与所述第二凹槽连通。
所述电极构件还包括保护层，所述保护层设置于所述第二部分的远离所述突部的表面且连接于所述活性物质层，所述第一凹槽不超出所述保护层。
所述第二导电层的刚度小于所述第一导电层的刚度。
所述条形凹槽沿厚度方向贯通所述第一导电层，且所述第二导电层的所述第一部分与所述绝缘基体连接。
所述条形凹槽为多个，且所述多个条形凹槽沿宽度方向间隔布置。
为了实现上述目的，本发明还提供了一种二次电池。所述二次电池包括电极组件，电极组件包括所述的电极构件。
为了实现上述目的，本发明还提供了一种集流体的制造方法。所述集流体的制造方法包括：提供绝缘基体；将导电材料固定到所述绝缘基体的表面以形成第一导电层，且所述第一导电层设有沿高度方向延伸的条形凹槽。
所述导电材料通过气相沉积法或化学镀固定于绝缘基体的表面。
所述集流体的制造方法还包括：将导电浆料涂布到所述第一导电层的表面的部分区域，并使所述导电浆料填充到条形凹槽内。所述导电浆料固化后形成第二导电层。
为了实现上述目的，本发明还提供了一种电极构件的制造方法。所述电 极构件的制造方法包括：提供根据所述的集流体的制造方法制造出的集流体；将包括活性物质的浆料涂覆到所述第一导电层的表面的部分区域，并使所述包括活性物质的浆料填充到所述条形凹槽内；所述包括活性物质的浆料固化后形成活性物质层，然后辊压所述活性物质层；将金属箔材焊接到所述第一导电层的未涂覆所述活性物质层的区域；切除所述金属箔材的一部分和所述集流体的的一部分，形成多个间隔设置的导电结构和多个间隔设置的电引导部。
所述电极构件的制造方法还包括：将包括绝缘材料的浆料涂覆到所述第一导电层的表面的部分区域，所述包括绝缘材料的浆料固化后形成保护层；所述保护层在焊接所述金属箔材之前形成。
为了实现上述目的，本发明还提供了一种二次电池的制造方法。所述二次电池的制造方法包括：提供正极构件、负极构件和隔膜，并将所述正极构件、所述隔膜和所述负极构件卷绕为一体以形成电极组件，其中，所述正极构件和所述负极构件中的至少一个是根据所述电极构件的制造方法制出；提供转接片，将所述电极组件的多个导电结构层叠并焊接于转接片；提供顶盖板和固定于顶盖板的电极端子，并将所述转接片焊接到所述电极端子；提供壳体，将所述电极组件放置到所述壳体内，然后将所述顶盖板连接到所述壳体。
为了实现上述目的，本发明还提供了另一种电极构件的制造方法。所述电极构件的制造方法包括：提供所述的集流体的制造方法制造出的集流体；将包括活性物质的浆料涂覆到所述第二导电层的表面的部分区域；固化所述包括活性物质的浆料并形成活性物质层，然后辊压所述活性物质层；将金属箔材焊接到所述第一导电层的未涂覆所述第二导电层的区域；切除所述金属箔材的一部分和所述集流体未的一部分，形成多个间隔设置的导电结构和多个间隔设置的电引导部。
所述的电极构件的制造方法还包括：将包括绝缘材料的浆料涂覆到所述第二导电层的表面的部分区域，然后固化所述包括绝缘材料的浆料并形成保护层。所述保护层在焊接所述金属箔材之前形成。
为了实现上述目的，本发明还提供了另一种二次电池的制造方法。所述二次电池的制造方法包括：提供正极构件、负极构件和隔膜，并将所述正极构件、所述隔膜和所述负极构件卷绕为一体以形成电极组件，其中，所述正极构件和所述负极构件中的至少一个是根据所述的另一种电极构件的制造方法制出；提供转接片，将所述电极组件的多个导电结构层叠并焊接于所述转接片；提供顶盖板和固定于顶盖板的电极端子，并将所述转接片焊接到所述电极端子；提供壳体，将所述电极组件放置到所述壳体内，然后将所述顶盖板连接到所述壳体。
本发明的有益效果如下：在本申请中，第一导电层上形成有条形凹槽，而条形凹槽能够有效地释放第一导电层上的作用力，降低应力集中，有效地减小第一导电层从绝缘基体表面脱落的风险，保证电极构件的性能。
附图说明
图1为现有技术的电极构件的示意图。
图2为图1的电极构件在辊压过程中的示意图。
图3为图1的电极构件的绝缘基体和导电层在辊压前的示意图。
图4为图1的电极构件的绝缘基体和导电层在辊压后的示意图。
图5为根据本发明的二次电池的示意图。
图6为根据本发明的电极组件的断面图。
图7为根据本发明的电极构件的第一实施例的示意图。
图8为图7沿线A-A作出的剖视图。
图9为图7的电极构件在成型过程中的一示意图。
图10为图7的电极构件在成型过程中的另一示意图。
图11为图10的第一导电层在辊压后的示意图。
图12为图7的电极构件在成型过程中的又一示意图。
图13为图7的电极构件在卷绕后的示意图。
图14为根据本发明的电极构件的第二实施例的示意图。
图15为图14沿线B-B作出的剖视图。
图16为图15中绝缘基体和第一导电层的示意图。
图17为根据本发明的电极构件的第三实施例的示意图。
图18为图17沿线C-C作出的剖视图。
图19为根据本发明的电极构件的第四实施例的示意图。
图20为图19沿线D-D作出的剖视图。
图21为图19的电极构件的第一导电层的示意图。
图22为根据本发明的电极构件的第五实施例的示意图。
图23为图22沿线E-E作出的剖视图。
图24为图22的电极构件的第一导电层的示意图。
其中，附图标记说明如下：
1电极构件                      5壳体
11绝缘基体                     6顶盖板
12第一导电层                   7电极端子
121主体部                      8转接片
122突部                        9辊轮
13活性物质层                   G条形凹槽
14第二导电层                   G1第一凹槽
141第一部分                    G2第二凹槽
142第二部分                    G3第三凹槽
15保护层                       G4第四凹槽
16导电结构                     P电引导部
2正极构件                      X宽度方向
3负极构件                      Y厚度方向
4隔膜                          Z高度方向
具体实施方式
下面将结合本申请实施例中的附图，对本申请实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本申请一部分实施例，而不是全部的实施例。以下对至少一个示例性实施例的描述实际上仅仅是说明性的，决不作为对本申请及其应用或使用的任何限制。基于本申请中的实施 例，本领域普通技术人员在没有开展创造性劳动前提下所获得的所有其他实施例，都属于本申请保护的范围。
在本申请的描述中，需要理解的是，使用“第一”、“第二”等词语来限定零部件，仅仅是为了便于对相应零部件进行区别，如没有另行声明，上述词语并没有特殊含义，因此不能理解为对本申请保护范围的限制。
本发明的二次电池包括电极组件，参照图6，电极组件包括正极构件2、负极构件3以及隔膜4，隔膜4设置于正极构件2和负极构件3之间。正极构件2、隔膜4及负极构件3堆叠并卷绕成扁平状。电极组件为二次电池实现充放电功能的核心部件。
本发明的二次电池可为软包电池，正极构件2、隔膜4和负极构件3卷绕形成的电极组件直接封装在包装袋内。所述包装袋可为铝塑膜。
当然，本申请的二次电池也可为硬壳电池。具体地，参照图5，二次电池主要包括电极组件、壳体5、顶盖板6、电极端子7及转接片8。
壳体5可具有六面体形状或其它形状。壳体5内部形成空腔，以容纳电极组件和电解液。壳体5在一端形成开口，而电极组件可经由所述开口放置到壳体5的收容腔。壳体5可由铝或铝合金等导电金属的材料制成，也可由塑胶等绝缘材料制成。
顶盖板6设置于壳体5并覆盖壳体5的开口，从而将电极组件封闭在壳体5内。电极端子7设置于顶盖板6，电极端子7的上端突出到顶盖板6上侧，下端可穿过顶盖板6并延伸到壳体5内。转接片8设置于壳体5内并固定于电极端子7。电极端子7和转接片8均为两个，正极构件2经由一个转接片8与一个电极端子7电连接，负极构件3经由另一个转接片8与另一个电极端子7电连接。转接片8焊接于电极端子7。
在二次电池中，正极构件2和负极构件3中的至少一个采用后述的电极构件1。
图7至图13为本发明的电极构件1的第一实施例的示意图。参照图7和图8，第一实施例的电极构件1包括绝缘基体11、第一导电层12以及活性物质层13。第一导电层12设置于绝缘基体11的两个表面，活性物质层13设置于第一导电层12的远离绝缘基体11的一侧。
绝缘基体11材质可为PET(聚对苯二甲酸乙二醇酯)膜或PP(聚丙烯) 膜。
第一导电层12的材料选自金属导电材料、碳基导电材料中的至少一种；金属导电材料优选铝、铜、镍、钛、银、镍铜合金、铝锆合金中的至少一种，所述碳基导电材料优选石墨、乙炔黑、石墨烯、碳纳米管中的至少一种。
第一导电层12可通过气相沉积法(vapor deposition)、化学镀(electroless plating)中的至少一种形成于绝缘基体11的表面。其中，气相沉积法优选物理气相沉积法(Physical Vapor Deposition，PVD)，例如热蒸发法(Thermal Evaporation Deposition)。
活性物质层13也可通过涂布的方式设置到第一导电层12的表面。可将活性材料(例如锰酸锂、磷酸铁锂)、粘结剂、导电剂及溶剂制成浆料，然后将浆料涂布在两个第一导电层12的外表面，浆料固化后形成活性物质层13。
参照图9，第一导电层12设有条形凹槽G，条形凹槽G大体沿高度方向Z延伸且用于释放第一导电层12的应力。条形凹槽G沿宽度方向X的长度为0.001mm～1mm，且远小于条形凹槽G沿高度方向Z延伸的长度。条形凹槽G可为直线状或曲线状，从整体上看，条形凹槽G只要近似沿高度方向Z延伸即可；也就是说，条形凹槽G的延伸方向与高度方向Z之间可存在较小的夹角(例如，所述夹角可小于10°)。
绝缘基体11的厚度可为1μm～20μm，第一导电层12的厚度可为0.1μm～10μm。由于第一导电层12较薄，所以在裁切电极构件1的过程中，第一导电层12产生的毛刺较小，很难刺破十几微米的隔膜4，从而避免短路，提高安全性能。另外，当异物刺穿二次电池的电极构件1时，由于第一导电层12厚度较小，因此第一导电层12在被异物刺穿的部位产生的毛刺较小，很难刺破隔膜4，从而避免短路，提高安全性能。
第一导电层12包括主体部121和从主体部121延伸的突部122，主体部121涂覆有活性物质层13覆盖，突部122未涂覆活性物质层13。其中，活性物质层13可直接涂覆于主体部121的表面，当然，可替代地，主体部121和活性物质层13之间也可设置其它物质。
绝缘基体11的与突部122对应的部分和突部122形成电引导部P。电引导部P可为多个并沿宽度方向X间隔布置。参照图13，当电极构件1卷绕 成型后，所述多个电引导部P沿厚度方向Y层叠布置。
电极构件1还包括保护层15，保护层15设置于突部122的远离绝缘基体11的一侧且连接于活性物质层13。
保护层15包括粘结剂和绝缘材料。所述绝缘材料包括三氧化二铝和羟基氧化铝中的至少一种。粘结剂、绝缘材料及溶剂混合在一起制备出浆料，所述浆料涂布在突部122的表面，并在固化后形成保护层15。保护层15的硬度大于突部122硬度。
电极构件1还包括导电结构16，导电结构16焊接于突部122的未被保护层15覆盖的区域。参照图7和图8，各电引导部P沿厚度方向Y的两侧均固定有导电结构16。参照图13，当电极构件1卷绕成型后，所有的导电结构16层叠设置并同时焊接到转接片8。参照图5，电极构件1中的电流可经由转接片8和电极端子7对外输出。
第一实施例的电极构件1可按照下述步骤成型：
(一)通过气相沉积法或化学镀在绝缘基体11的表面形成第一导电层12，从而制备出一种复合带材；参照图9，在成型过程中，第一导电层12上预留出条形凹槽G。
(二)参照图10，在第一导电层12的表面上同时涂布活性物质层13和保护层15。
(三)辊压活性物质层13，以将活性物质层13压实，提高密度。
(四)参照图12，辊压完成后，在第一导电层12上焊接金属箔材(例如铝箔)，然后，沿着图12中的虚线裁切出多个电引导部P和多个导电结构16，进而得到图7所示的电极构件1。
在步骤(一)中，第一导电层12可通过气相沉积法或化学镀形成于绝缘基体11的表面，所以第一导电层12与绝缘基体11之间的连接力较小，在外力作用下，可能会造成第一导电层12容易从绝缘基体11的表面脱落。
由于绝缘基体11的弹性模量小于第一导电层12的弹性模量，因此绝缘基体11的延展性高于第一导电层12的延展性。在步骤(三)中，绝缘基体11受压延展，由于绝缘基体11的延展性高，所以绝缘基体11会对第一导电层12施加作用力。在现有技术中，第一导电层12上的作用力无法释放，所以当第一导电层12延展到一定程度时，第一导电层12上的作用力会大于绝 缘基体11和第一导电层12之间的连接力，造成绝缘基体11和第一导电层12相对滑移，以使第一导电层12从绝缘基体11的表面脱落，影响电极构件1的性能。
而在本申请中，第一导电层12上形成有条形凹槽G，而条形凹槽G能够有效地释放第一导电层12上的作用力，降低应力集中，避免第一导电层12上的作用力过大，有效地减小第一导电层12从绝缘基体11表面脱落的风险，保证电极构件1的性能。
具体地，图11示出第一导电层12在辊压后的状态，其中虚线示出条形凹槽G在辊压前的状态。在步骤(三)的辊压过程中，第一导电层12上的作用力逐渐集中在条形凹槽G；当第一导电层12上的作用力偏大时，第一导电层12会在力的作用下沿着条形凹槽G裂开，从而及时释放应力，避免第一导电层12上的作用力大于绝缘基体11和第一导电层12之间的连接力，减小绝缘基体11和第一导电层12相对滑移的概率，保证电极构件1的性能。
在二次电池的使用过程中，活性物质层13产生的电流经由主体部121流动到突部122，也就是说，在第一导电层12上，电流大体沿高度方向Z流动，因此，第一导电层12的过流面积取决于第一导电层12的垂直于高度方向Z的横截面的面积。在本申请中，条形凹槽G大体沿高度方向Z延伸，其在宽度方向X上的长度很小，即条形凹槽G沿高度方向Z的尺寸大于条形凹槽G沿宽度方向X的尺寸。因此，当第一导电层12在辊压过程中沿条形凹槽G裂开时，条形凹槽G对第一导电层12的过流面积影响较小，进而保证第一导电层12的过流能力满足要求。
在步骤(三)中，随着辊压的进行，第一导电层12上的作用力会逐渐增大；参照图11，电极构件1沿宽度方向X辊压一定长度时，第一导电层12上的作用力会带动第一导电层12沿条形凹槽G裂开，从而及时释放应力。由于第一导电层12在宽度方向X上具有较大的长度，因此，优选地，条形凹槽G为多个，且所述多个条形凹槽G沿宽度方向X间隔布置。所述多个条形凹槽G可以在辊压过程中分级释放应力，避免第一导电层12上的作用力大于绝缘基体11和第一导电层12之间的连接力，减小绝缘基体11和第一导电层12相对滑移的概率，保证电极构件1的性能。
参照图8和图9，条形凹槽G沿厚度方向Y贯通第一导电层12，也就 是说，沿厚度方向Y，条形凹槽G的深度等于第一导电层12的厚度。此时，第一导电层12在辊压过程中更容易沿条形凹槽G裂开，从而及时释放应力。
在步骤(二)中，活性物质层13可以填充到条形凹槽G中，因此，活性物质层13上的电流可以经过条形凹槽G的周壁流动到第一导电层12，从而提高第一导电层12的集流能力。在步骤(三)中，即使第一导电层12沿着条形凹槽G裂开，活性物质层13也会在辊压力的作用下填充到裂开的部位。
由于绝缘基体11的弹性模量较小，因此，在步骤(三)中，与主体部121对应的绝缘基体11会向突部122的下侧延展，导致突部122内侧的绝缘基体11鼓起变形，而突部122容易在绝缘基体11的作用力下变形，从而产生裂纹。而在本申请中，保护层15具有较高的强度，可以在辊压电极构件1的过程中为突部122提供支撑力，限制突部122的变形，减小突部122产生裂纹的概率，改善电极构件1的过流能力。
在二次电池工作过程中，由于震动等因素可能会导致突部122脱落；因此，保护层15优选连接于活性物质层13，这样可以将保护层15固定到活性物质层13，增大保护层15在电极构件1上的结合力，提高抗震能力，避免保护层15连同突部122一起脱落。同时，突部122最容易在靠近活性物质层13的根部(也就是突部122与主体部121的交界处)鼓起，所以，当保护层15与活性物质层13相连时，可以减小突部122的变形，降低产生裂纹的概率，从而改善电极构件1的过流能力。
下面对其它的四个实施例进行说明。为了简化描述，以下仅主要介绍其它四个实施例与第一实施例的不同之处，未描述的部分可以参照第一实施例进行理解。
图14至图16为本发明电极构件的第二实施例的示意图。参照图14和图16，沿厚度方向Y，条形凹槽G的深度小于第一导电层12的厚度。与第一实施例相比，第二实施例的第一导电层12的过流面积较大。条形凹槽G的截面可为U形或V形。
图17和图18为本发明电极构件的第三实施例的示意图。参照图17和图18，与第一实施例相比，第三实施例的电极构件1还包括第二导电层14，第二导电层14具有位于条形凹槽G内的第一部分141。第一部分141填充到条形凹槽G内，条形凹槽G周围的电流可以经过第一部分141传输；换句话说，第一部分141可以修复第一导电层12的导电网络，增大过流面积，保证电极构件1整体的过流能力。
在第一实施例中，活性物质层13填充到条形凹槽G内，因此，活性物质层13的分布并不均匀，也就是说，活性物质层13在条形凹槽G处的厚度要大于其它位置的厚度。在二次电池的工作过程中，活性物质层13可能会在与条形凹槽G对应的位置析锂。而在第三实施例中，第一部分141填充在条形凹槽G内，从而保证第一导电层12的平整度，改善活性物质层13分布的均匀性，降低析锂风险。
第二导电层14还包括第二部分142，第二部分142设置于第一导电层12远离绝缘基体11的表面且与第一部分141连接，活性物质层13设置于第二部分142的远离第一导电层12的表面。
第二导电层14可以为金属材料，也可以为非金属材料。为了减小异物刺穿电极构件1时产生的毛刺，第二导电层14优选为不易产生毛刺的非金属材料。具体地，可先将导电碳、粘结剂及溶剂制成浆料，然后将浆料涂布到第一导电层12上，浆料固化后形成第二导电层14。在涂布过程中，浆料填充到条形凹槽G内并形成第一部分141。
在步骤(二)中，可先将第二导电层14的浆料涂布到第一导电层12上，然后再将活性物质层13的浆料和保护层15的浆料涂布到第二导电层14的表面。
在步骤(三)中，即使第一导电层12沿着条形凹槽G裂开，第二部分142也会在辊压力的作用下填充到裂开的部位，从而即使修复第一导电层12的导电网络，增大过流面积，保证电极构件1整体的过流能力。
如果第二导电层14仅设置在第一导电层12的表面，那么第二导电层14的电流只能通过第一导电层12的表面传导到第一导电层12。在本申请中，第二导电层14的第一部分141嵌入第一导电层12上的条形凹槽G，因此，电流不仅可以通过第一导电层12的表面传导到第一导电层12，还可以通过 条形凹槽G的周壁传导，从而增加多个传导路径，形成多点位的导电网络，改善电极构件1的导电性能，减小电极构件1和二次电池的极化，改善二次电池的高倍率充放电性能。
第二部分142至少部分位于突部122的远离绝缘基体11的表面。保护层15可设置于第二部分142的远离突部122的表面。导电结构16焊接于突部122的未被第二部分142覆盖的区域。
在步骤(三)中，主体部121在绝缘基体11的带动下延展，而突部122几乎无延展。主体部121和绝缘基体11在延展时向突部122施加作用力，而由于突部122较薄，所以在力的作用下，突部122会产生微裂纹。而在本申请中，第二部分142设置于突部122的表面，因此，即使突部122在辊压的过程中产生裂纹，裂纹处的电流也能够经由第二部分142向外传输，从而实现导电网络的修复，保证电极构件1整体的过流能力。
第二导电层14的刚度小于第一导电层12的刚度。也就是说，在受力时，第二导电层14更容易变形。当突部122变形时，第二部分142也会随着突部122变形；即使突部122因变形过大而裂开，第二部分142也不易出现断裂，从而保证电流的传输。
条形凹槽G沿厚度方向Y贯通第一导电层12，且第二导电层14的第一部分141与绝缘基体11连接。第一部分141嵌入到条形凹槽G内并粘接于绝缘基体11，从而增大第一导电层12、第二导电层14及绝缘基体11的连接强度。
图19至图21为本发明电极构件的第四实施例的示意图。参照图19至图21，与第三实施例相比，第四实施例的条形凹槽G包括形成于突部122的第一凹槽G1。
在步骤(三)中，绝缘基体11的与主体部121对应的部分受压延展，绝缘基体11的与主体部121对应的部分会对绝缘基体11的与突部122对应的部分施加作用力，从而带动绝缘基体11的与突部122对应的部分延展。而突部122受到保护层15的限制，因此几乎不可延展；绝缘基体11的与突部122对应的部分在延展时会向突部122施加作用力，如果所述作用力大于绝缘基体11与突部122的连接力，突部122容易从绝缘基体11脱落。而在 本申请中，第一凹槽G1可以有效地释放突部122上的作用力，降低应力集中，避免突部122上的作用力过大，有效地减小突部122脱落的概率，保证电极构件1的性能。
优选地，沿远离活性物质层13的方向，第一凹槽G1不超出保护层15。突部122的被保护层15覆盖的区域所受到的应力最大，因此，第一凹槽G1只需要设置在突部122的被保护层15覆盖的区域即可。而突部122的未被保护层15覆盖的区域所受的作用力较小，不存在脱落风险，如果第一凹槽G1延伸到突部122的未被保护层15覆盖的区域，反而会降低突部122的过流能力。
条形凹槽G还包括形成于主体部121的第二凹槽G2，第一凹槽G1与第二凹槽G2连通。
在步骤(三)中，主体部121在绝缘基体11施加的作用力下延展。由于突部122受到保护层15的限制，突部122几乎不可延展，因此，主体部121的靠近突部122的区域会受到突部122的反作用力。也就是说，主体部121的靠近突部122的区域同时承受绝缘基体11和突部122的作用力，因此，主体部121的靠近突部122的区域很容易从绝缘基体11脱落。而在本申请中，第二凹槽G2延伸到主体部121的靠近突部122的区域，从而有效地释放主体部121上的作用力，降低应力集中，有效地减小绝缘基体11和主体部121相对滑移的概率，保证电极构件1的性能。
条形凹槽G还包括多个沿宽度方向X间隔布置的第三凹槽G3，第三凹槽G3形成于主体部121。在宽度方向X上，各第三凹槽G3位于相邻的两个第二凹槽G2之间；在高度方向Z上，第三凹槽G3和第二凹槽G2彼此错开。
图22至图24为本发明电极构件的第五实施例的示意图。参照图22至图24，第五实施例的条形凹槽G包括形成于主体部121的第三凹槽G3和第四凹槽G4。第三凹槽G3为多个并沿宽度方向X间隔布置，第四凹槽G4为多个并沿宽度方向X间隔布置。
在宽度方向X上，各第三凹槽G3位于相邻的两个第四凹槽G4之间。在高度方向Z上，第三凹槽G3和第四凹槽G4彼此错开。第三凹槽G3和第四凹槽G4在宽度方向X和高度方向Z分散布置，可以改善应力释放效果，提高均匀性。
本申请还提供了一种二次电池的制造方法，该制造方法能够提高二次电池的安全性能。二次电池的制造方法包括：
提供正极构件2、负极构件3和隔膜4，并将所述正极构件2、所述隔膜4和所述负极构件3卷绕为一体以形成电极组件；其中，所述正极构件2和所述负极构件3中的至少一个采用前述的电极构件1；
提供转接片8，将所述电极组件的多个导电结构16层叠并焊接于所述转接片8；
提供顶盖板6和固定于顶盖板6的电极端子7，并将所述转接片8焊接到所述电极端子7；
提供壳体5，将所述电极组件放置到所述壳体5内，然后将所述顶盖板6连接到所述壳体5。
在制出的二次电池所采用的电极构件1中，第一导电层12厚度较小；当异物刺穿二次电池的电极构件1时，第一导电层12在被异物刺穿的部位产生的毛刺较小，很难刺破隔膜4，从而避免短路，提高安全性能。另外，第一导电层12上形成有条形凹槽G，而条形凹槽G能够有效地释放第一导电层12上的作用力，降低应力集中，有效地减小第一导电层12从绝缘基体11表面脱落的风险，保证电极构件1和二次电池的性能。

Claims (19)

  1. 一种二次电池的电极构件(1)，包括绝缘基体(11)、第一导电层(12)以及活性物质层(13)；
    所述第一导电层(12)设置于所述绝缘基体(11)的表面，所述活性物质层(13)设置于所述第一导电层(12)的远离所述绝缘基体(11)的一侧；
    所述第一导电层(12)设有沿高度方向(Z)延伸的条形凹槽(G)。
  2. 根据权利要求1所述的电极构件(1)，其特征在于，所述电极构件(1)还包括第二导电层(14)，所述第二导电层(14)具有位于所述条形凹槽(G)内的第一部分(141)。
  3. 根据权利要求2所述的电极构件(1)，其特征在于，所述第二导电层(14)还包括第二部分(142)，所述第二部分(142)设置于所述第一导电层(12)远离所述绝缘基体(11)的表面且与所述第一部分(141)连接，所述活性物质层(13)设置于所述第二部分(142)的远离所述第一导电层(12)的表面。
  4. 根据权利要求3所述的电极构件(1)，其特征在于，
    所述第一导电层(12)包括主体部(121)和从所述主体部(121)延伸的突部(122)，所述主体部(121)涂覆有所述活性物质层(13)，所述突部(122)未涂覆所述活性物质层(13)；
    所述条形凹槽(G)包括形成于所述突部(122)的第一凹槽(G1)，且所述第二部分(142)至少部分位于所述突部(122)的远离所述绝缘基体(11)的表面。
  5. 根据权利要求4所述的电极构件(1)，其特征在于，所述条形凹槽(G)还包括形成于所述主体部(121)的第二凹槽(G2)，所述第一凹槽(G1)与所述第二凹槽(G2)连通。
  6. 根据权利要求4所述的电极构件(1)，其特征在于，所述电极构件(1)还包括保护层(15)，所述保护层(15)设置于所述第二部分(142)的远离所述突部(122)的表面且连接于所述活性物质层(13)，所述第一凹槽(G1)不超出所述保护层(15)。
  7. 根据权利要求2所述的电极构件(1)，其特征在于，所述第二导电层(14)的刚度小于所述第一导电层(12)的刚度。
  8. 根据权利要求2所述的电极构件(1)，其特征在于，所述条形凹槽(G)沿厚度方向(Y)贯通所述第一导电层(12)，且所述第二导电层(14)的所述第一部分(141)与所述绝缘基体(11)连接。
  9. 根据权利要求1所述的电极构件(1)，其特征在于，所述条形凹槽(G)为多个，且所述多个条形凹槽(G)沿宽度方向(X)间隔布置。
  10. 一种二次电池，其特征在于，包括电极组件，电极组件包括权利要求1-9中任一项所述的电极构件(1)。
  11. 一种集流体的制造方法，其特征在于，包括：
    提供绝缘基体(11)；
    将导电材料固定到所述绝缘基体(11)的表面以形成第一导电层(12)，且所述第一导电层(12)设有沿高度方向(Z)延伸的条形凹槽(G)。
  12. 根据权利要求11所述的集流体的制造方法，其特征在于，所述导电材料通过气相沉积法或化学镀固定于绝缘基体(11)的表面。
  13. 根据权利要求11或12所述的集流体的制造方法，其特征在于，所述制造方法还包括：
    将导电浆料涂布到所述第一导电层(12)的表面的部分区域，并使所述导电浆料填充到条形凹槽(G)内；
    所述导电浆料固化后形成第二导电层(14)。
  14. 一种电极构件的制造方法，其特征在于，包括：
    提供根据权利要求11或12所述的制造方法制造出的集流体；
    将包括活性物质的浆料涂覆到所述第一导电层(12)的表面的部分区域，并使所述包括活性物质的浆料填充到所述条形凹槽(G)内；
    所述包括活性物质的浆料固化后形成活性物质层(13)，然后辊压所述活性物质层(13)；
    将金属箔材焊接到所述第一导电层(12)的未涂覆所述活性物质层(13)的区域；
    切除所述金属箔材的一部分和所述集流体的一部分，形成多个间隔设置的导电结构(16)和多个间隔设置的电引导部(P)。
  15. 根据权利要求14所述的电极构件的制造方法，其特征在于，
    所述制造方法还包括：将包括绝缘材料的浆料涂覆到所述第一导电层(12)的表面的部分区域，所述包括绝缘材料的浆料固化后形成保护层(15)；
    所述保护层(15)在焊接所述金属箔材之前形成。
  16. 一种二次电池的制造方法，其特征在于，包括：
    提供正极构件(2)、负极构件(3)和隔膜(4)，并将所述正极构件(2)、所述隔膜(4)和所述负极构件(3)卷绕为一体以形成电极组件，其中，所述正极构件(2)和所述负极构件(3)中的至少一个是根据权利要求14或15所述电极构件的制造方法制出；
    提供转接片(8)，将所述电极组件的多个导电结构(16)层叠并焊接于转接片(8)；
    提供顶盖板(6)和固定于顶盖板(6)的电极端子(7)，并将所述转接片(8)焊接到所述电极端子(7)；
    提供壳体(5)，将所述电极组件放置到所述壳体(5)内，然后将所述顶盖板(6)连接到所述壳体(5)。
  17. 一种电极构件的制造方法，其特征在于，包括：
    提供根据权利要求13所述的制造方法制造出的集流体；
    将包括活性物质的浆料涂覆到所述第二导电层(14)的表面的部分区域；
    固化所述包括活性物质的浆料并形成活性物质层(13)，然后辊压所述活性物质层(13)；
    将金属箔材焊接到所述第一导电层(12)的未涂覆所述第二导电层(14)的区域；
    切除所述金属箔材的一部分和所述集流体的一部分，形成多个间隔设置的导电结构(16)和多个间隔设置的电引导部(P)。
  18. 根据权利要求17所述的电极构件的制造方法，其特征在于，
    所述制造方法还包括：将包括绝缘材料的浆料涂覆到所述第二导电层(14)的表面的部分区域，然后固化所述包括绝缘材料的浆料并形成保护层(15)；
    所述保护层(15)在焊接所述金属箔材之前形成。
  19. 一种二次电池的制造方法，其特征在于，包括：
    提供正极构件(2)、负极构件(3)和隔膜(4)，并将所述正极构件(2)、所述隔膜(4)和所述负极构件(3)卷绕为一体以形成电极组件，其中，所述正极构件(2)和所述负极构件(3)中的至少一个是根据权利要求17或18所述电极构件的制造方法制出；
    提供转接片(8)，将所述电极组件的多个导电结构(16)层叠并焊接于所述转接片(8)；
    提供顶盖板(6)和固定于顶盖板(6)的电极端子(7)，并将所述转接片(8)焊接到所述电极端子(7)；
    提供壳体(5)，将所述电极组件放置到所述壳体(5)内，然后将所述顶盖板(6)连接到所述壳体(5)。
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