METHOD FOR MANUFACTURING ELECTRODE HAVING POROUS COATING LAYER, ELECTRODE MANUFACTURED THEREFROM, AND ELECTROCHEMICAL DEVICE COMPRISING THE SAME

• US 20120003545A1
• Filed: 09/09/2011
• Published: 01/05/2012
• Est. Priority Date: 06/30/2009
• Status: Abandoned Application

• Current Assignee: LG Chem Limited (LG Corporation)
• Original Assignee: LG Chem Limited (LG Corporation)
• Inventors: Lee, Joo Sung, Kim, Jong-Hun, Park, Pil-Kyu, Hong, Jang-Hyuk, Shin, Byoung-Jin, Kim, In-Chul, Cho, Byeong-Gyu, Jin, Sun-Mi, Yoon, Su-Jin
• Application Number:
  US13/229,009
• Publication Number:
  US 20120003545A1
• Time in Patent Office: Days
• US Class Current: 429/246
• CPC Class Codes: C23C 18/1212 Zeolites, glasses
• CPC Class Codes: C23C 18/1216 Metal oxides C23C18/1212 takes precedence
• CPC Class Codes: C23C 18/122 Inorganic polymers, e.g. silanes, polysilazanes, polysiloxanes
• CPC Class Codes: C23C 18/1254 Sol or sol-gel processing
• CPC Class Codes: C23C 18/1295 with after-treatment of the deposited inorganic material
• CPC Class Codes: H01G 11/24 characterised by structural features of the materials making up or comprised in the electrodes, e.g. form, surface area or porosity; characterised by the structural features of powders or particles used therefor
• CPC Class Codes: H01G 11/28 arranged or disposed on a current collector; Layers or phases between electrodes and current collectors, e.g. adhesives
• CPC Class Codes: H01G 11/46 Metal oxides
• CPC Class Codes: H01G 11/50 specially adapted for lithium-ion capacitors, e.g. for lithium-doping or for intercalation
• 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 4/0404 by coating on electrode collectors
• CPC Class Codes: H01M 4/0471 involving thermal treatment, e.g. firing, sintering, backing particulate active material, thermal decomposition, pyrolysis
• 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 4/139 Processes of manufacture
• CPC Class Codes: H01M 50/434 Ceramics
• CPC Class Codes: H01M 50/44 Fibrous material
• CPC Class Codes: H01M 50/46 Separators, membranes or diaphragms characterised by their combination with electrodes
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02E 60/13 Energy storage using capacitors

Abstract

A method for manufacturing an electrode may include (S1) preparing a sol solution containing a metal alkoxide compound, and (S2) forming a porous non-woven coating layer of an inorganic fiber by electroemitting the sol solution onto an outer surface of an electrode active material layer formed on at least one surface of a current collector. The porous non-woven coating layer formed on the outer surface of the electrode active material layer may be made from an inorganic fiber having excellent thermal stability. When an electrochemical device is overheated, the porous non-woven coating layer may contribute to suppression of a short circuit between a cathode and an anode and performance improvement of an electrochemical device due to uniform distribution of pores.

Claims

1. A method for manufacturing an electrode, the method comprising:

(S1) preparing a sol solution containing a metal alkoxide compound; and

(S2) forming a porous non-woven coating layer of an inorganic fiber by electroemitting the sol solution onto an outer surface of an electrode active material layer formed on at least one surface of a current collector.

2. The method for manufacturing an electrode according to claim 1,

wherein a metal of the metal alkoxide compound includes at least one selected from the group consisting of an alkali metal, an alkaline earth metal, and a transition metal.

3. The method for manufacturing an electrode according to claim 2,

wherein the alkaline metal is lithium.

4. The method for manufacturing an electrode according to claim 1,

wherein the metal alkoxide compound includes at least one selected from the group consisting of silicone-containing alkoxide, aluminum-containing alkoxide, and titanium-containing alkoxide.

5. The method for manufacturing an electrode according to claim 4,

wherein the silicone-containing alkoxide is tetra-alkyl (having 1 to 4 carbon atoms)-ortho-silicate, the aluminum-containing alkoxide is at least one selected from the group consisting of aluminum-sec-butoxide, aluminum isoprotoxide, and aluminum ethoxide, and the titanium-containing alkoxide is titanium isopropoxide or titanium alkyl (having 1 to 4 carbon atoms) alkoxide.

6. The method for manufacturing an electrode according to claim 1,

wherein the sol solution further contains a binder.

7. The method for manufacturing an electrode according to claim 6,

wherein the binder is at least one selected from the group consisting of polyvinylidene fluoride-co-hexafluoropropylene, polyvinylidene fluoride-co-trichloroethylene, polymethylmethacrylate, polyacrylonitrile, polyvinylpyrrolidone, polyvinylacetate, polyvinylalcohol, polyethylene-co-vinyl acetate, polyethylene oxide, cellulose acetate, cellulose acetate butyrate, cellulose acetate propionate, cyanoethylpullulan, cyanoethylpolyvinylalcohol, cyanoethylcellulose, cyanoethylsucrose, pullulan, carboxyl methyl cellulose, and a low-molecular-weight compound having a molecular weight of 10,000 g/mol or less.

8. The method for manufacturing an electrode according to claim 6, further comprising:

after the (S2) step,

performing a thermal treatment to decompose an organic component in the porous non-woven coating layer.

9. The method for manufacturing an electrode according to claim 1,

wherein the electroemitting is electrospraying or electrospinning.

10. An electrode, comprising:

(a) a current collector and an electrode active material layer formed on at least one surface of the current collector; and

(b) a porous non-woven coating layer of an inorganic fiber formed on an outer surface of the electrode active material layer.

11. The electrode according to claim 10,

wherein the inorganic fiber includes an inorganic oxide of which a metal is at least one selected from the group consisting of an alkali metal, an alkaline earth metal, and a transition metal.

12. The electrode according to claim 11,

wherein the alkaline metal is lithium.

13. The electrode according to claim 10,

wherein the inorganic fiber includes at least one selected from the group consisting of SiO₂, Al₂O₃, BaTiO₃, and TiO₂.

14. The electrode according to claim 10,

wherein the inorganic fiber is formed by electroemitting.

15. The electrode according to claim 14,

wherein the electroemitting is electrospraying or electrospinning.

16. The electrode according to claim 10,

wherein the inorganic fiber has an average diameter between 0.001 and 1000 nm.

17. The electrode according to claim 10,

wherein the porous non-woven coating layer has a thickness between 0.1 and 100 μ

m.

18. The electrode according to claim 10,

wherein the porous non-woven coating layer has an average pore size between 0.01 and 10 μ

m.

19. The electrode according to claim 10,

wherein the non-woven fabric has a porosity between 1 and 80%.

20. An electrochemical device, comprising:

a cathode; and

an anode,

wherein either or both of the cathode and the anode is an electrode defined in claim 10.

21. The electrochemical device according to claim 20,

wherein the electrochemical device is a lithium secondary battery.