Electrode for electrochemical device and method for manufacturing electrode

• US 10,644,346 B2
• Filed: 04/27/2016
• Issued: 05/05/2020
• Est. Priority Date: 04/29/2015
• Status: Active Grant

• Current Assignee: LG Energy Solution Limited (LG Corporation)
• Original Assignee: LG Chem Limited (LG Corporation)
• Inventors: Jung, Hye-Ran, Lee, Hyeok-Moo, Kim, Hyo-Sik, Oh, Song-Taek
• Primary Examiner(s): Martin, Matthew T
• Application Number:
  US15/548,951
• Publication Number:
  US 20180097255A1
• Time in Patent Office: 1,469 Days
• CPC Class Codes: H01M 10/0525 Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
• CPC Class Codes: H01M 10/0585 of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators
• CPC Class Codes: H01M 2004/021 Physical characteristics, e.g. porosity, surface area
• CPC Class Codes: H01M 4/04 Processes of manufacture in general
• CPC Class Codes: H01M 4/0404 by coating on electrode collectors
• CPC Class Codes: H01M 4/043 involving compressing or compaction
• CPC Class Codes: H01M 4/13 Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
• CPC Class Codes: H01M 4/131 Electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
• CPC Class Codes: H01M 4/133 Electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
• CPC Class Codes: H01M 4/1391 of electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
• CPC Class Codes: H01M 4/1393 of electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
• CPC Class Codes: H01M 4/366 as layered products
• CPC Class Codes: H01M 4/525 of mixed oxides or hydroxides containing iron, cobalt or nickel for inserting or intercalating light metals, e.g. LiNiO2, LiCoO2 or LiCoOxFy
• CPC Class Codes: H01M 4/587 for inserting or intercalating light metals
• CPC Class Codes: H01M 4/622 being polymers
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product

Abstract

The present invention relates to an electrode for an electrochemical device and a method for manufacturing the same. More specifically, the present invention relates to an electrode for an electrochemical device having excellent electrolyte impregnation and improved battery output and lifecycle properties, and a method for manufacturing the electrode. The electrode according to the present invention enables an electrolyte to easily permeate into the electrode, thereby remarkably improving a lifecycle property or an output property due to high electrolyte impregnation. In addition, the method for manufacturing an electrode, according to the present invention, does not cause the deterioration of porosity of a lower electrode active material monolayer, the deterioration being caused by a step performed during the formation of an upper electrode active material monolayer.

Claims

1. An electrode for an electrochemical device, comprising:

an electrode current collector and an electrode active material layer formed on at least one surface of the electrode current collector,

wherein the electrode active material layer includes an electrode active material and has porosity of from 20% to 55%, and

the electrode active material layer has a layered structure in which a plurality of active material sublayers is stacked on one another, with a barrier layer including polymer resin between each active material sublayer,

wherein the electrode active material layer increases in porosity at least one of stepwise or gradually from a surface of the electrode current collector along a thickness direction of the electrode active material layer.

2. The electrode for an electrochemical device according to claim 1, wherein the electrode active material layer comprises:

a lowermost active material sublayer disposed on a surface of the electrode current collector; and

an nth active material sublayer or an uppermost active material sublayer, where n is an integer greater than 1, so that n active material sublayer are stacked in the electrode active material layer in a sequential order, and porosity increases at least one of stepwise or gradually from the lowermost active material sublayer toward the uppermost active material sublayer along a thickness direction of the electrode active material layer.

3. The electrode for an electrochemical device according to claim 2, wherein the lowermost active material sublayer has porosity of between 20% and 40%.

4. The electrode for an electrochemical device according to claim 2, wherein the uppermost active material sublayer has porosity of between 30% and 50%.

5. The electrode for an electrochemical device according to claim 2, wherein 90% or more of pores in the uppermost active material sublayer have a pore diameter of between 10 μ

m and 20 μ

m on the basis of longest pore diameter.

6. The electrode for an electrochemical device according to claim 2, wherein the electrode active material layer has a press strength of particles increasing at least one of stepwise or gradually from the lowermost electrode sublayer toward the uppermost active material sublayer along a thickness direction of the electrode active material layer.

7. The electrode for an electrochemical device according to claim 2, wherein the electrode active material layer has a diameter of particles increasing stepwise and/or gradually from the lowermost electrode sublayer toward the uppermost electrode sublayer along a thickness direction of the electrode active material layer.

8. The electrode for an electrochemical device according to claim 1, wherein the barrier layer includes at least one polymer resin selected from the group consisting of styrenebutadiene rubber, acrylonitrile-butadiene rubber, acrylonitrile-butadiene-styrene rubber, carboxymethylcellulose (CMC), hydroxyropylmethylcellulose, polyvinylalcohol, hydroxypropylcellulose, and diacetylcellulose.

9. The electrode for an electrochemical device according to claim 1, wherein the barrier layer has a thickness of between 0.5 μ

m and 5 μ

m.

10. The electrode for an electrochemical device according to claim 8, wherein the polymer resin has a glass transition temperature of between −

60°

C. and 55°

C.

11. The electrode for an electrochemical device according to claim 8, wherein the polymer resin has a boiling point of between 160°

C. and 250°

C.

12. An electrode assembly for an electrochemical device, comprising a negative electrode, a positive electrode, and a separator interposed between the negative electrode and the positive electrode, wherein the negative electrode and/or the positive electrode is defined in one of claim 1.

13. An electrochemical device comprising the electrode assembly defined in claim 12.

14. A method for manufacturing the electrode of claim 1, comprising:

forming a first active material sublayer on a surface of the electrode current collector by applying a slurry to the surface of the electrode current collector and drying the slurry to form the first electrode active material sublayer;

forming a barrier layer on a surface of the active material sublayer;

forming a second active material sublayer on the surface of the barrier layer by applying a slurry on a surface of the barrier layer, drying the slurry, and pressing the dried slurry to form the second electrode active material sublayer.

15. The method for manufacturing an electrode for an electrochemical device according to claim 14, wherein the pressing of the dried slurry is performed by a hot pressing method under condition of between 80°

C. and 120°

C.

16. The method for manufacturing an electrode for an electrochemical device according to claim 14, wherein porosity of the first electrode active material sublayer is lower than porosity of the second electrode active material sublayer.