Classifications

• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
  • H01M10/00—Secondary cells; Manufacture thereof
  • H01M10/04—Construction or 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
  • H01M10/00—Secondary cells; Manufacture thereof
  • H01M10/05—Accumulators with non-aqueous electrolyte
  • H01M10/058—Construction or 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
• • 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
  • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
• • 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
• • 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 a method for manufacturing electrodes, batteries, and positive electrodes.
• Patent Document 1 Technology relating to electrodes in which an active material layer is bonded to a current collecting layer has been known for some time (see, for example, Patent Document 1).
• the electrode of the present invention has a current collecting layer, an active material layer, and an intermediate layer.
• the active material layer is laminated and bonded to the current collecting layer, and contains an active material.
• the intermediate layer is provided midway along the lamination direction between the end side of the current collecting layer and the end of the active material layer, and is bonded to the current collecting layer and the active material layer.
• the battery of the present invention has a positive electrode, a negative electrode, and an insulator provided between the positive electrode and the negative electrode. At least one of the positive electrode and the negative electrode is the electrode.
• the method for manufacturing a positive electrode of the present invention is a method for manufacturing a positive electrode having a positive electrode current collecting layer, a positive electrode active material layer that is laminated and bonded to the positive electrode current collecting layer and contains a positive electrode active material, and an intermediate layer that is provided along the lamination direction between the end side of the positive electrode current collecting layer and the end of the positive electrode active material layer and is bonded to the positive electrode current collecting layer and the positive electrode active material layer.
• the positive electrode current collecting layer containing aluminum is used.
• an intermediate layer slurry that contains particles and a solvent having vaporizability and constitutes the intermediate layer after being applied to the positive electrode current collecting layer is used.
• a positive electrode active material layer slurry that contains the positive electrode active material and the solvent having vaporizability and constitutes the positive electrode active material layer after being applied to the positive electrode current collecting layer and the intermediate layer slurry is used.
• the method for manufacturing a positive electrode includes a coating process for coating the intermediate layer slurry and the positive electrode active material layer slurry. In the coating process, the intermediate layer slurry is coated onto the positive electrode current collecting layer with a contact angle set to 1° or more and 35° or less, and the positive electrode active material layer slurry is coated onto the positive electrode current collecting layer and the intermediate layer slurry.
• FIG. 1 is a perspective view showing a battery 1 according to a first embodiment.
• FIG. 2 is a perspective view showing a charging/discharging unit 10 of the battery 1.
• 3 is a cross-sectional view showing the charge/discharge body 10 taken along line 3A-3B in FIG. 2.
• 4 is a cross-sectional view showing the charge/discharge body 10 in region 4 in FIG. 3 .
• FIG. 3 is a side view that illustrates a manufacturing method of the positive electrode 100.
• FIG. 6 is a top view showing a schematic diagram of a state in which a slurry is applied to the positive electrode current collecting layer 110 in FIG. 5 .
• FIG. 2 is a side view showing a schematic diagram of a coating state of a positive electrode active material layer slurry 1100 and an intermediate layer slurry 1200 applied to a positive electrode current collecting layer 110.
• 13 is a graph showing the results of measuring the outer shape of a positive electrode active material layer 120 of the positive electrode 100 according to the first embodiment and a positive electrode active material layer in comparison.
• FIG. 6 is a cross-sectional view showing a charging/discharging body 20 of a battery according to a second embodiment.
• FIG. 11 is a cross-sectional view showing a charging/discharging body 30 of a battery according to a third embodiment.
• the electrodes in the embodiments of the present invention are described as positive electrodes.
• the electrodes in the embodiments of the present invention also include negative electrodes.
• the battery 1 in the embodiments of the present invention is described as a rectangular prism-shaped battery.
• the battery 1 in the embodiments of the present invention also includes a cylindrical battery.
• FIG. 1 is a perspective view showing a battery 1 of the first embodiment.
• FIG. 2 is a perspective view showing a charging/discharging body 10 of the battery 1.
• FIG. 3 is a cross-sectional view showing the charging/discharging body 10 at 3A-3B in FIG. 2.
• FIG. 4 is a cross-sectional view showing the charging/discharging body 10 in region 4 in FIG. 3.
• Battery 1 is, for example, a lithium ion secondary battery. As shown in Figs. 1 to 4, battery 1 includes a charge/discharge unit 10, an exterior body 50, and an external terminal 60. The main components included in battery 1 are described below.
• the charge/discharge body 10 is charged and discharged.
• the charge/discharge body 10 shown in Figs. 2 and 3 includes a positive electrode 100, a negative electrode 200, a separator 300, and an electrolyte (so-called electrolytic solution).
• the charge/discharge body 10 is formed, for example, by stacking the positive electrode 100, the negative electrode 200, and two separators 300 in the order of the positive electrode 100, the separator 300, the negative electrode 200, and the separator 300, and winding them into a rectangular shape.
• the charge/discharge body 10 is permeated with the electrolyte, particularly the separator 300.
• the charge/discharge body 10 is covered with an insulating sheet with the positive electrode current collector and the negative electrode current collector joined together.
• the positive electrode 100 (electrode) includes a positive electrode current collecting layer 110, a positive electrode active material layer 120, and an intermediate layer 130.
• the positive electrode current collecting layer 110 (current collecting layer) is, for example, configured in an elongated shape. That is, the positive electrode current collecting layer 110 is formed in a foil shape. At one end of the positive electrode current collecting layer 110 in the short direction X, a positive electrode current collecting portion 110a is provided along the longitudinal direction Y.
• the positive electrode current collecting layer 110 is, for example, formed of aluminum or an aluminum alloy.
• JIS standard A3003 is used.
• A3003 is a non-heat-treated type, and is an Al-Mn-based alloy.
• the thickness of the positive electrode current collecting layer 110 along the stacking direction Z is, for example, 10 ⁇ m.
• the thickness of the positive electrode current collecting layer 110 is selected, for example, within the range of 5 ⁇ m to 30 ⁇ m.
• the positive electrode active material layer 120 (active material layer) is provided on the positive electrode current collecting layer 110.
• the positive electrode active material layers 120 are laminated and bonded to both sides of the positive electrode current collecting layer 110, facing each other along the lamination direction Z.
• the thickness of the positive electrode active material layer 120 along the lamination direction Z is, for example, 30 ⁇ m or 40 ⁇ m.
• the thickness of the positive electrode active material layer 120 is selected, for example, within the range of 10 ⁇ m to 200 ⁇ m.
• the positive electrode active material layer 120 contains a positive electrode active material 121, a positive electrode binder 122, and a positive electrode conductive additive 123.
• a lithium-containing complex oxide is used for the positive electrode active material 121 (active material).
• the lithium-containing complex oxide is, for example, a metal element such as nickel (Ni), cobalt (Co), or manganese (Mn), and lithium (Li).
• the positive electrode active material 121 is formed in a particulate form.
• the average particle diameter (D50) of the positive electrode active material 121 is, for example, 25 ⁇ m.
• the average particle diameter (D50) of the positive electrode active material 121 is selected, for example, within the range of 1 ⁇ m to 50 ⁇ m.
• the positive electrode binder 122 bonds the positive electrode active material 121 together.
• PVdF polyvinylidene fluoride
• PTFE polytetrafluoroethylene
• PE polyethylene
• SBR styrene butadiene rubber
• nitrocellulose cyanoethyl cellulose
• various latexes acrylic resins, or mixtures thereof are used for the positive electrode binder 122.
• the positive electrode conductive assistant 123 improves the characteristics of the positive electrode 100.
• the positive electrode conductive assistant 123 is mixed with the positive electrode active material 121 and arranged to increase the electrical conductivity between the positive electrode current collecting layer 110 and the positive electrode active material 121. In other words, the positive electrode conductive assistant 123 ensures a conductive path between the positive electrode current collecting layer 110 and the positive electrode active material 121 in the positive electrode 100.
• a carbon-based material is used for the positive electrode conductive assistant 123.
• the carbon-based material is, for example, crystalline carbon, amorphous carbon, or a mixture thereof.
• the crystalline carbon is, for example, artificial graphite, natural graphite, or a mixture thereof.
• the natural graphite is, for example, flake graphite, lump graphite, or earthy graphite.
• the amorphous carbon is, for example, carbon black.
• Carbon black is, for example, acetylene black, ketjen black, channel black, furnace black, lamp black, thermal black, or a mixture thereof.
• the intermediate layer 130 (intermediate layer) is provided midway along the stacking direction Z between the end 110b of the positive electrode current collecting layer 110 and the end 120b of the positive electrode active material layer 120.
• the intermediate layer 130 is bonded to the positive electrode current collecting layer 110 and the positive electrode active material layer 120.
• the intermediate layer 130 is joined to the positive electrode current collecting layer 110 across the end 120b of the positive electrode active material layer 120 along the short-side direction X (crossing direction) that crosses the stacking direction Z.
• the intermediate layer 130 crossing the end 120b of the positive electrode active material layer 120 means that the intermediate layer 130 crosses the side 120a of the positive electrode active material layer 120.
• the first length L1 of the intermediate layer 130 along the short-side direction X of the part separated from the positive electrode active material layer 120 is longer than the second length L2 along the short-side direction X of the part joined to the positive electrode active material layer 120.
• the part separated from the positive electrode active material layer 120 is a part joined only to the positive electrode current collecting layer 110.
• the part joined to the positive electrode active material layer 120 is a part joined to both the positive electrode current collecting layer 110 and the positive electrode active material layer 120.
• the intermediate layer 130 faces the negative electrode active material layer 220 of the negative electrode 200 via the separator 300.
• the thickness t1 of the intermediate layer 130 along the stacking direction Z in the region joined to the positive electrode active material layer 120 is 1/10 or more and 1/2 or less of the thickness t2 of the positive electrode active material layer 120 along the stacking direction Z.
• the intermediate layer 130 contains particles 131, a binder 132, and an additive 133.
• the particles 131 are inorganic or organic.
• the particles 131 are, for example, alumina or boehmite. Compared to inorganic particles, organic particles are easier to disperse in a solvent. In particular, acrylic particles are relatively easier to disperse in a solvent.
• the particles 131 have an average particle diameter (D50) of 0.5 ⁇ m or more and 5.0 ⁇ m or more.
• the particles 131 are insulating. It is preferable that the particles 131 are heat resistant.
• the binder 132 bonds the particles 131 together.
• the binder 132 has insulating properties.
• the additive 133 for example, evenly disperses the particles 131 and the binder 132.
• the additive 133 is not essential for the intermediate layer 130.
• the positive electrode 100 may include an insulating layer that covers the positive electrode active material layer 120.
• the insulating layer has heat resistance.
• the insulating layer contains, for example, an inorganic material or an organic material and a binder.
• the inorganic material is, for example, alumina particles.
• the negative electrode 200 includes a negative electrode current collecting layer 210 and a negative electrode active material layer 220.
• the negative electrode current collecting layer 210 is configured, for example, in an elongated shape. That is, the negative electrode current collecting layer 210 is formed in a foil shape. At one end of the negative electrode current collecting layer 210 in the short side direction X, a negative electrode current collecting portion 210a is provided along the longitudinal direction Y. The negative electrode current collecting portion 210a of the negative electrode current collecting layer 210 faces the positive electrode current collecting portion 110a of the positive electrode current collecting layer 110 in the short side direction X.
• the negative electrode current collecting layer 210 is formed, for example, from copper or a copper alloy.
• the thickness of the negative electrode current collecting layer 210 along the stacking direction Z is, for example, 10 ⁇ m. The thickness of the negative electrode current collecting layer 210 is selected, for example, within the range of 5 ⁇ m to 30 ⁇ m.
• the negative electrode active material layer 220 is provided on the negative electrode current collecting layer 210.
• the negative electrode active material layers 220 are bonded to both sides of the negative electrode current collecting layer 210 and face each other along the stacking direction Z.
• the negative electrode active material layer 220 has a larger width along the short side direction X than the positive electrode active material layer 120.
• both ends of the negative electrode active material layer 220 in the short side direction X are located outside the both ends of the positive electrode active material layer 120 in the short side direction X.
• the thickness of the negative electrode active material layer 220 along the stacking direction Z is, for example, 30 ⁇ m or 40 ⁇ m.
• the thickness of the negative electrode active material layer 220 is selected within the range of, for example, 10 ⁇ m to 200 ⁇ m.
• the negative electrode active material layer 220 contains a negative electrode active material 221 and a negative electrode binder 222.
• the negative electrode active material layer 220 may also contain a negative electrode conductive additive 223.
• the negative electrode active material 221 is, for example, carbon.
• the carbon is, for example, graphite, non-graphitizable carbon (hard carbon), or easily graphitizable carbon (soft carbon).
• the graphite is, for example, natural graphite or artificial graphite.
• the natural graphite is, for example, flake graphite, lump graphite, or earthy graphite.
• the negative electrode active material 221 is formed in a particulate form.
• the average particle size (D50) of the negative electrode active material 221 is, for example, 25 ⁇ m.
• the average particle size (D50) of the negative electrode active material 221 is selected, for example, within the range of 1 ⁇ m to 50 ⁇ m.
• the negative electrode binder 222 bonds the negative electrode active materials 221 together.
• the negative electrode binder 222 is made of the same material as the positive electrode binder 122.
• the negative electrode conductive additive 223 improves the characteristics of the negative electrode 200.
• the negative electrode conductive additive 223 is mixed with the negative electrode active material 221 and arranged to increase the electrical conductivity between the negative electrode current collecting layer 210 and the negative electrode active material 221. In other words, the negative electrode conductive additive 223 ensures a conductive path between the negative electrode current collecting layer 210 and the negative electrode active material 221 in the negative electrode 200.
• the negative electrode 200 may include an insulating layer that covers the negative electrode active material layer 220.
• the insulating layer has heat resistance.
• the insulating layer contains, for example, an inorganic material or an organic material and a binder.
• the inorganic material is, for example, alumina particles.
• the separator 300 insulates the positive electrode 100 and the negative electrode 200.
• the separator 300 holds an electrolyte (so-called electrolytic solution).
• the separator 300 is formed in an elongated shape.
• the separator 300 has a larger width in the short-side direction X than the negative electrode active material layer 220.
• both ends of the positive electrode active material layer 120 in the short-side direction X and both ends of the negative electrode active material layer 220 in the short-side direction X are located within the range of the separator 300 along the short-side direction X.
• the thickness of the separator 300 along the stacking direction Z is, for example, 20 ⁇ m.
• the thickness of the separator 300 is selected within the range of, for example, 5 ⁇ m to 60 ⁇ m.
• the separator 300 is made of a porous material.
• the porous material include polyethylene, polypropylene, polyester, cellulose, and polyamide.
• the separator 300 may be made of a laminate of multiple different porous materials.
• the separator 300 may include an insulating layer.
• the insulating layer has heat resistance.
• the insulating layer contains, for example, an inorganic material or an organic material and a binder.
• the inorganic material is, for example, alumina particles.
• the electrolyte allows lithium ions to flow between the positive electrode 100 and the negative electrode 200.
• the electrolyte is also called an electrolytic solution.
• the electrolyte contains an organic solvent and a lithium salt.
• the electrolyte may also contain additives.
• the organic solvent may be, for example, a carbonate ester such as ethylene carbonate.
• the lithium salt may be, for example, lithium hexafluorophosphate (LiPF 6 ).
• the additive may be, for example, lithium hexafluorophosphate (LiPF 6 ) .
• the exterior body 50 houses the charging/discharging unit 10. As shown in FIG. 1, the exterior body 50 includes a container 51, a lid 52, a liquid injection plug 53, and a split valve 54.
• the container 51 is formed in a rectangular parallelepiped shape.
• the container 51 houses the charging/discharging unit 10.
• the lid 52 is welded to the container 51.
• the lid 52 is provided with a liquid injection hole.
• the liquid injection hole is a hole for injecting an electrolyte (so-called electrolytic solution) into the inside of the battery 1.
• the liquid injection plug 53 is attached to the liquid injection hole of the lid 52.
• the liquid injection plug 53 is inserted into the liquid injection hole and welded after the electrolyte is injected into the inside of the battery 1 through the liquid injection hole.
• the split valve 54 is provided on the lid 52.
• the split valve 54 is formed integrally with the lid 52.
• the split valve 54 splits toward the outside of the battery 1 when the internal pressure of the battery 1 exceeds a
• the external terminal 60 relays the input and output of power between the collector provided inside the battery 1 and an electrical device provided outside the battery 1.
• the electrical device is, for example, a relay or inverter provided in the vehicle.
• the external terminal 60 provided on one battery 1 is electrically connected to the external terminal 60 provided on the other battery 1 via a bus bar or the like, and relays the input and output of power between the one battery 1 and the other battery 1.
• the external terminal 60 includes a positive terminal 61 and a negative terminal 62.
• the positive terminal 61 is electrically connected to the positive electrode collector 110a of the positive electrode collector layer 110 via a positive electrode collector plate.
• the positive terminal 61 is attached to the lid 52 via a positive electrode insulating member.
• the negative terminal 62 is electrically connected to the negative electrode collector 210a of the negative electrode collector layer 210 via a negative electrode collector plate.
• the negative terminal 62 is attached to the lid 52 via a negative insulating member.
• Fig. 5 is a side view diagrammatically illustrating the manufacturing method of the positive electrode 100.
• Fig. 6 is a top view diagrammatically illustrating the state of application of the slurry to the positive electrode current collecting layer 110 in Fig. 5.
• Fig. 7 is a side view diagrammatically illustrating the state of application of the positive electrode active material layer slurry 1100 and the intermediate layer slurry 1200 applied to the positive electrode current collecting layer 110.
• the positive electrode active material layer slurry 1100 and the intermediate layer slurry 1200 are applied.
• the intermediate layer slurry 1200 is applied to the positive electrode current collecting layer 110.
• the positive electrode active material layer slurry 1100 is applied to the positive electrode current collecting layer 110 and the intermediate layer slurry 1200.
• the thickness of the intermediate layer slurry 1200 applied to the positive electrode current collecting layer 110 is set to be 1/10 or more and 1/2 or less of the thickness of the positive electrode active material layer slurry 1100 applied to the positive electrode current collecting layer 110. In the coating process, as shown in FIG.
• the contact angle ⁇ 1 of the intermediate layer slurry 1200 with respect to the positive electrode current collecting layer 110 is set to be 1° or more and 35° or less.
• the contact angle is based on the ⁇ /2 method (A half-angle method).
• the contact angle ⁇ 2 of the positive electrode active material layer slurry 1100 with respect to the positive electrode current collecting layer 110 is less than ⁇ 1.
• the positive electrode active material layer slurry 1100 used in the coating process contains a solvent in addition to the components that make up the positive electrode active material layer 120.
• the components that make up the positive electrode active material layer 120 include a positive electrode active material 121, a positive electrode binder 122, and a positive electrode conductive assistant 123.
• the solvent disperses the components contained in the positive electrode active material layer 120.
• a solvent that is vaporizable at temperatures equal to or higher than room temperature is used.
• the solvent is N-methyl-2-pyrrolidone (NMP).
• the intermediate layer slurry 1200 used in the coating process contains a solvent in addition to the components that make up the intermediate layer 130.
• the solvent disperses the particles 131 and binder 132 contained in the intermediate layer 130.
• a solvent that is vaporizable at temperatures above room temperature is used.
• the solvent is N-methyl-2-pyrrolidone (NMP).
• the manufacturing apparatus 1000 for the positive electrode 100 includes a conveying section 1010, a coating section 1020, a drying section 1030, and a rolling section 1040.
• the conveying unit 1010 conveys the members that constitute the positive electrode 100.
• the conveying unit 1010 includes conveying rollers 1011.
• the conveying section 1010 conveys the positive electrode current collecting layer 110 wound around a first roller (not shown) to the coating section 1020, the drying section 1030, and the rolling section 1040 via conveying rollers 1011 and the like.
• the conveying section 1010 winds the positive electrode current collecting layer 110, to which the positive electrode active material layer 120 and the intermediate layer 130 are bonded, around a second roller (not shown).
• the conveying roller 1011 and the first roller in contact with the positive electrode current collecting layer 110 also rotate, conveying the positive electrode current collecting layer 110.
• the conveying direction H of the positive electrode current collecting layer 110 corresponds to the longitudinal direction Y of the positive electrode current collecting layer 110.
• the coating unit 1020 applies slurry to the positive electrode current collecting layer 110 and the like.
• the coating unit 1020 includes a first coating head 1021, a first liquid supply pipe 1022, a second coating head 1023, and a second liquid supply pipe 1024.
• two first coating heads 1021 are provided along the conveying direction H of the positive electrode collecting layer 110, i.e., the short side direction X perpendicular to the longitudinal direction Y of the positive electrode collecting layer 110.
• the two first coating heads 1021 face each other along the short side direction X of the positive electrode collecting layer 110.
• An opening is formed in the first coating head 1021.
• the opening is connected to a first liquid supply pipe 1022.
• the intermediate layer slurry 1200 is supplied to each first coating head 1021 from a tank (not shown) via a pump (not shown) and the first liquid supply pipe 1022.
• Each first coating head 1021 faces the conveying roller 1011 via the positive electrode collecting layer 110.
• Each first coating head 1021 coats the positive electrode current collecting layer 110 with the intermediate layer slurry 1200 while the positive electrode current collecting layer 110 is being transported.
• the intermediate layer slurry 1200 is coated on the positive electrode current collecting layer 110 so as to face the positive electrode current collecting layer 110 in the short direction and along the long direction of the positive electrode current collecting layer 110.
• the second coating head 1023 is provided along the short direction X of the positive electrode current collecting layer 110, as shown in Figures 5 and 6.
• the second coating head 1023 is arranged with the two first coating heads 1021 along the conveying direction H of the positive electrode current collecting layer 110.
• the second coating head 1023 is located downstream of each of the first coating heads 1021 in the conveying direction H of the positive electrode current collecting layer 110.
• the second coating head 1023 has a long opening formed therein. The long opening is connected to the second liquid supply pipe 1024.
• the second coating head 1023 is supplied with the positive electrode active material layer slurry 1100 from a tank (not shown) via a pump (not shown) and the second liquid supply pipe 1024.
• the second coating head 1023 faces the conveying roller 1011 through the positive electrode current collecting layer 110. While the positive electrode current collecting layer 110 is being transported, the second coating head 1023 applies the positive electrode active material layer slurry 1100 to the positive electrode current collecting layer 110 and the intermediate layer slurry 1200.
• the drying section 1030 dries the slurry.
• the drying section 1030 is provided downstream of the coating section 1020 in the conveying direction H of the positive electrode current collecting layer 110.
• the drying section 1030 includes a dryer 1031.
• the dryer 1031 is provided along the transport direction H of the positive electrode current collecting layer 110, i.e., the longitudinal direction Y of the positive electrode current collecting layer 110.
• the dryer 1031 dries the positive electrode active material layer slurry 1100 and the intermediate layer slurry 1200 while the positive electrode current collecting layer 110 is being transported.
• the dryer 1031 is equipped with multiple heat sources along the transport direction H of the positive electrode current collecting layer 110.
• the dryer 1031 uses the multiple heat sources to dry the positive electrode active material layer slurry 1100 and the intermediate layer slurry 1200 under multiple conditions.
• the positive electrode active material layer slurry 1100 forms the positive electrode active material layer 120 by evaporating the solvent.
• the positive electrode active material layer slurry 1100 dries by evaporating the NMP contained in the positive electrode active material layer slurry 1100.
• the positive electrode active material layer slurry 1100 decreases in thickness along the stacking direction Z as it dries.
• the positive electrode active material layer 120 is bonded to the positive electrode current collecting layer 110.
• the intermediate layer slurry 1200 forms the intermediate layer 130 by evaporating the solvent.
• the intermediate layer slurry 1200 dries by evaporating the NMP contained in the intermediate layer slurry 1200.
• the intermediate layer slurry 1200 decreases in thickness along the stacking direction Z as it dries.
• the intermediate layer 130 is bonded to the positive electrode current collecting layer 110 and the positive electrode active material layer 120.
• the rolling section 1040 rolls the positive electrode current collecting layer 110, the positive electrode active material layer 120, and the intermediate layer 130, which are bonded together.
• the rolling section 1040 is provided downstream of the drying section 1030 in the conveying direction H of the positive electrode current collecting layer 110.
• the rolling section 1040 includes a rolling roller 1041 and a driven roller 1042.
• the rolling roller 1041 is provided along the short-side direction X of the positive electrode current collecting layer 110, as shown in FIG. 5.
• the rolling roller 1041 faces the positive electrode active material layer 120 and the intermediate layer 130 of the positive electrode 100.
• the driven roller 1042 is provided along the short-side direction X of the positive electrode current collecting layer 110, as shown in FIG. 5.
• the driven roller 1042 faces the rolling roller 1041 across the positive electrode 100.
• the driven roller 1042 faces the positive electrode current collecting layer 110 of the positive electrode 100.
• the rolling section 1040 determines the thickness of the positive electrode active material layer 120 by the distance between the rolling roller 1041 and the driven roller 1042.
• the configuration described with reference to FIG. 5 and FIG. 6 is a configuration in which the positive electrode active material layer 120 and the intermediate layer 130 are bonded to one side of the positive electrode current collecting layer 110. That is, the method for manufacturing the positive electrode 100 shown in FIG. 5 and FIG. 6 is a so-called single-sided coating method for manufacturing the positive electrode 100.
• the positive electrode 100 has the positive electrode active material layer 120 and the intermediate layer 130 bonded to both sides of the positive electrode current collecting layer 110. That is, the positive electrode 100 shown in FIG. 3 is configured by so-called double-sided coating. Therefore, in the method for manufacturing the positive electrode 100, after the configuration described with reference to FIG. 5 and FIG. 6, the positive electrode active material layer 120 and the intermediate layer 130 are bonded to the other side of the positive electrode active material layer 120.
• Fig. 8 is a graph showing the measurement results of the outer shape of the positive electrode active material layer 120 of the positive electrode 100 of the first embodiment and a comparative positive electrode active material layer.
• the solid line graph in FIG. 8 shows the measurement results of the external shape of the positive electrode active material layer 120 of the positive electrode 100 of the first embodiment.
• the dashed line graph in FIG. 8 shows the measurement results of the external shape of the positive electrode active material layer of the comparative positive electrode.
• the manufacturing conditions of the positive electrode 100 of the first embodiment and the comparative positive electrode differ only in whether or not an intermediate layer 130 is provided.
• the positive electrode 100 of the first embodiment is provided with an intermediate layer 130.
• the positive electrode of the comparative positive electrode is not provided with an intermediate layer 130.
• the vertical axis in FIG. 8 shows the layer thickness in the stacking direction Z of the positive electrode active material layer.
• the horizontal axis in FIG. 8 shows the distance in the short side direction X of the positive electrode active material layer.
• the ends of the positive electrode active material layer 120 of the positive electrode 100 of the first embodiment do not bulge in the stacking direction Z. That is, the positive electrode active material layer 120 of the positive electrode 100 of the first embodiment is prevented from becoming relatively thicker than other parts.
• the ends of the positive electrode active material layer of the comparative positive electrode bulge in the stacking direction Z. That is, the positive electrode active material layer of the comparative positive electrode is relatively thicker than other parts.
• the bulge at the ends of the positive electrode active material layer of the comparative positive electrode is 2% or more of the average layer thickness of the positive electrode active material layer.
• the positive electrode 100 has an intermediate layer 130 (intermediate layer).
• the intermediate layer 130 is provided midway along the stacking direction Z between the end 110b side of the positive electrode current collecting layer 110 (current collecting layer) and the end 120b of the positive electrode active material layer 120 (active material layer).
• the intermediate layer 130 is bonded to the positive electrode current collecting layer 110 and the positive electrode active material layer 120.
• the end 120b of the positive electrode active material layer 120 joined to the positive electrode current collecting layer 110 can be prevented from being repelled from the positive electrode current collecting layer 110 by using the intermediate layer 130 (the intermediate layer slurry 1200 during the manufacture of the positive electrode 100) during the manufacture.
• the fact that the positive electrode active material layer slurry 1100 is repelled from the positive electrode current collecting layer 110 means that the affinity between the positive electrode active material layer slurry 1100 and the positive electrode current collecting layer 110 is relatively low.
• the fact that the positive electrode active material layer slurry 1100 can be prevented from being repelled from the intermediate layer 130 means that the affinity between the positive electrode active material layer slurry 1100 and the intermediate layer slurry 1200 is relatively high.
• a positive electrode 100 can be obtained in which the end 120b of the positive electrode active material layer 120 is prevented from becoming relatively thicker than other parts.
• a battery 1 equipped with a positive electrode 100 in which the end portion 120b of the positive electrode active material layer 120 is prevented from becoming thick.
• the thickness of the positive electrode active material layer 120 can be made uniform.
• the intermediate layer 130 is joined to the positive electrode current collecting layer 110 across the end 120b of the positive electrode active material layer 120 along the short side direction X intersecting with the stacking direction Z.
• the end 120b of the positive electrode active material layer 120 (positive electrode active material layer slurry 1100 when manufacturing the positive electrode 100) joined to the positive electrode current collecting layer 110 can be sufficiently prevented from being repelled from the positive electrode current collecting layer 110 during manufacturing.
• the end 120b of the positive electrode active material layer 120 is most likely to be repelled from the positive electrode current collecting layer 110 during manufacturing.
• the end 120b of the positive electrode active material layer 120 joined to the positive electrode current collecting layer 110 can be sufficiently prevented from being repelled from the positive electrode current collecting layer 110 by being sufficiently interposed between the intermediate layer 130 during manufacturing.
• the intermediate layer 130 has a first length L1 along the short side direction X of the portion separated from the positive electrode active material layer 120 that is longer than a second length L2 along the short side direction X of the portion bonded to the positive electrode active material layer 120.
• the portion separated from the positive electrode active material layer 120 is bonded only to the positive electrode current collecting layer 110.
• the portion bonded to the positive electrode active material layer 120 is bonded to both the positive electrode current collecting layer 110 and the positive electrode active material layer 120.
• the thickness of the positive electrode active material layer 120 is 10 ⁇ m or more and 60 ⁇ m or less. The thinner the positive electrode active material layer 120 (positive electrode active material layer slurry 1100 during the manufacture of the positive electrode 100), the more likely it is to be repelled from the positive electrode current collecting layer 110 during manufacture. When the thickness of the positive electrode active material layer 120 is 10 ⁇ m or more and 60 ⁇ m or less, it is relatively thin. However, since the intermediate layer 130 is present in the positive electrode 100, the end 120b of the positive electrode active material layer 120 joined to the positive electrode current collecting layer 110 can be prevented from being repelled from the positive electrode current collecting layer 110 during manufacture.
• the thickness t1 of the intermediate layer 130 along the stacking direction Z in the region joined to the positive electrode active material layer 120 is 1/10 or more and 1/2 or less of the thickness t2 of the positive electrode active material layer 120 along the stacking direction Z.
• the intermediate layer 130 (intermediate layer slurry 1200 when manufacturing the positive electrode 100) prevents the end 120b of the positive electrode active material layer 120 (positive electrode active material layer slurry 1100 when manufacturing the positive electrode 100) from being repelled by the positive electrode current collecting layer 110 during manufacturing, while the thickness of the intermediate layer 130 that does not contribute to the battery reaction can be suppressed.
• the intermediate layer 130 contains insulating particles 131. With this configuration, the intermediate layer 130 can be formed from highly versatile particles 131.
• the intermediate layer 130 faces the negative electrode active material layer 220 of the negative electrode 200 via the separator 300 (insulator). With this configuration, the insulation between the positive electrode 100 and the negative electrode 200 can be supplemented by the separator 300.
• the intermediate layer slurry 1200 is applied to the aluminum positive electrode current collecting layer 110 with a contact angle set to 1° or more and 35° or less. With this configuration, it is possible to prevent the intermediate layer slurry 1200 from being repelled by the positive electrode current collecting layer 110.
• the intermediate layer slurry 1200 is applied to the aluminum positive electrode current collecting layer 110 with a contact angle set to 25° or less. This configuration sufficiently prevents the intermediate layer slurry 1200 from being repelled by the positive electrode current collecting layer 110.
• the thickness of the intermediate layer slurry 1200 applied to the positive electrode current collecting layer 110 is set to be 1/10 or more and 1/2 or less of the thickness of the positive electrode active material layer slurry 1100 applied to the positive electrode current collecting layer 110.
• the intermediate layer slurry 1200 prevents the ends of the positive electrode active material layer slurry 1100 from being repelled by the positive electrode current collecting layer 110, while the thickness of the intermediate layer 130 that does not contribute to the battery reaction can be suppressed.
• Fig. 9 is a cross-sectional view showing the charge/discharge body 20 of the battery of the second embodiment.
• the positive electrode 400 differs in the arrangement of the intermediate layer 430 relative to the positive electrode current collecting layer 110 and the positive electrode active material layer 120.
• the same components as those in the first embodiment are denoted by the same reference numerals and the description thereof is omitted.
• the intermediate layer 430 has a third length L3 along the short-side direction X of the portion separated from the positive electrode active material layer 120, which is shorter than a fourth length L4 along the short-side direction X of the portion joined to the positive electrode active material layer 120.
• the portion separated from the positive electrode active material layer 120 is a portion where the intermediate layer 430 is joined only to the positive electrode current collector layer 110.
• the portion joined to the positive electrode active material layer 120 is a portion where the intermediate layer 430 is joined to both the positive electrode current collector layer 110 and the positive electrode active material layer 120. As shown in FIG.
• the intermediate layer 430 is arranged in a relatively larger amount in the region where the positive electrode active material layer 120 and the positive electrode current collector layer 110 are present along the short-side direction X than in the region where the positive electrode active material layer 120 is not present and only the positive electrode current collector layer 110 is present.
• the third length L3 of the intermediate layer 430 at the portion separated from the positive electrode active material layer 120 is shorter than the fourth length L4 of the portion bonded to the positive electrode active material layer 120.
• Fig. 10 is a cross-sectional view showing the charge/discharge body 30 of the battery of the third embodiment.
• the positive electrode 500 differs in the arrangement of the intermediate layer 530 relative to the positive electrode current collecting layer 110 and the positive electrode active material layer 120.
• the same components as those in the first embodiment are denoted by the same reference numerals and the description thereof is omitted.
• the intermediate layer 530 is provided only between the positive electrode collector layer 110 and the positive electrode active material layer 120 along the stacking direction Z.
• the intermediate layer 530 is sandwiched between the positive electrode collector layer 110 and the positive electrode active material layer 120.
• the intermediate layer 530 is not provided in the region where the positive electrode active material layer 120 does not exist and only the positive electrode collector layer 110 exists along the short side direction X.
• the intermediate layer 530 is provided in the region where the positive electrode active material layer 120 and the positive electrode collector layer 110 exist along the short side direction X.
• the third embodiment is configured such that the intermediate layer 130 is not intentionally provided in the region where the positive electrode active material layer 120 does not exist and only the positive electrode collector layer 110 exists. That is, the third embodiment includes a configuration in which the intermediate layer 130 exists within the range of manufacturing error due to manufacturing error in the region where the positive electrode active material layer 120 does not exist and only the positive electrode collector layer 110 exists.
• the intermediate layer 530 is provided only between the positive electrode current collecting layer 110 and the positive electrode active material layer 120 along the stacking direction Z. With this configuration, it is possible to sufficiently prevent the end 120b of the positive electrode active material layer 120 (positive electrode active material layer slurry 1100 when manufacturing the positive electrode 100) that is joined to the positive electrode current collecting layer 110 from being repelled from the positive electrode current collecting layer 110 during manufacturing, while minimizing the intermediate layer 130 that does not contribute to the battery reaction.
• the battery of the present invention is not limited to the configuration of the battery described in the embodiment, and can be appropriately configured based on the contents described in the claims.
• the positive electrode active material is not limited to nickel (Ni), cobalt (Co) and manganese (Mn) based materials.
• the positive electrode active material of the present invention may be, for example, Fe (olivine iron) based.
• the negative electrode active material is not limited to carbon-based.
• the negative electrode active material of the present invention may be, for example, silicon-based.
• the battery of the present invention is not limited to a configuration in which the charging/discharging body is sealed by a container and a lid.
• the battery of the present invention can be applied to a configuration in which the charging/discharging body is sealed by a laminate film.
• the battery of the present invention is not limited to a lithium-ion battery.
• the battery of the present invention can be applied to, for example, a nickel-metal hydride battery.
• the battery of the present invention is not limited to a secondary battery.
• the battery of the present invention can be applied to a primary battery.
• the charging/discharging body is not limited to a wound type in which a positive electrode, separator, and negative electrode each formed in a long shape are bundled and wound.
• the charging/discharging body of the battery of the present invention can be a stacked type in which multiple positive electrodes, separators, and negative electrodes each formed in a rectangular shape are stacked alternately.
• the charge/discharge body can be a stacked type in which a single separator formed in a long shape is used, and multiple positive electrodes and multiple negative electrodes formed in a relatively short shape are arranged alternately while facing each other through the separator.
• the separator is folded and stacked, so that the positive electrodes and negative electrodes face each other through the separator.
• the charging/discharging body is not limited to a rectangular prism type.
• the charging/discharging body of the battery of the present invention can be a cylindrical or columnar type.
• the charge/discharge body is not limited to a configuration in which an insulating separator is provided between the positive electrode and the negative electrode.
• the battery of the present invention can be applied to a configuration in which an insulating layer is provided on at least one of the positive electrode and the negative electrode without providing a separator. Such a configuration corresponds to a so-called separatorless configuration.
• the charge/discharge body can be configured to have an insulating separator 300 between the positive electrode 100 and the negative electrode 200, or to have an insulating layer on the positive electrode 100 or an insulating layer on the negative electrode 200.
• the battery of the present invention is not limited to a configuration in which only one charging/discharging element is provided.
• the battery of the present invention can be applied to a configuration in which two or more charging/discharging elements are provided.
• the electrodes (positive and negative electrodes) of the present invention are not limited to a configuration in which the ends of the current collecting layer are joined to the current collecting plate.
• the electrodes of the battery of the present invention can be applied to a type in which an electrode tab protruding outward from the edge of the current collecting layer is joined to the current collecting plate.
• the electrodes (positive and negative electrodes) of the present invention are not limited to a configuration in which an active material layer is bonded to both sides of a current collecting layer.
• the electrodes can be applied to a configuration in which an active material layer is bonded to only one side of a current collecting layer.
• the method for manufacturing electrodes (positive and negative electrodes) of the present invention is not limited to a configuration in which an active material layer and an intermediate layer are formed by simultaneously applying and drying an active material layer slurry and an intermediate layer slurry.
• the method for manufacturing electrodes (positive and negative electrodes) of the present invention can be applied to a configuration in which the intermediate layer is first formed by applying and drying the intermediate layer slurry to the current collecting layer. In such a configuration, the active material layer is then formed by applying and drying the active material layer slurry to the current collecting layer and the intermediate layer.
• the manufacturing method of the electrodes (positive and negative electrodes) of the present invention is not limited to a configuration in which the first and second coating heads are provided independently.
• the manufacturing method of the electrodes (positive and negative electrodes) of the present invention can be applied to a configuration in which the first and second coating heads are integrated.

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• 2024
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