ELECTRICAL STORAGE DEVICE AND METHOD FOR MANUFACTURING THE SAME

• US 20140106191A1
• Filed: 12/17/2013
• Published: 04/17/2014
• Est. Priority Date: 06/28/2011
• Status: Active Grant

• Current Assignee: Murata Manufacturing Co Limited
• Original Assignee: Murata Manufacturing Co Limited
• Inventors: Itaya, Masaharu, Horikawa, Keiji, Sawada, Manabu, Harada, Hiroyuki, Ueba, Yuusuke, Ehara, Yukio, Ueda, Yasuhiko, Fukuda, Yasutake
• Granted Patent: US 9,514,893 B2
• Time in Patent Office: Days
• US Class Current: 429/82
• CPC Class Codes: H01G 11/12 Stacked hybrid or EDL capacitors
• CPC Class Codes: H01G 11/20 Reformation or processes for removal of impurities, e.g. scavenging
• 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 11/72 specially adapted for integration in multiple or stacked hybrid or EDL capacitors
• CPC Class Codes: H01G 11/80 Gaskets; Sealings
• CPC Class Codes: H01G 11/82 Fixing or assembling a capacitive element in a housing, e.g. mounting electrodes, current collectors or terminals in containers or encapsulations
• 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 50/30 Arrangements for facilitating escape of gases
• CPC Class Codes: H01M 50/394 Gas-pervious parts or elements
• CPC Class Codes: H01M 50/417 Polyolefins
• CPC Class Codes: H01M 50/426 Fluorocarbon polymers
• CPC Class Codes: H01M 50/429 Natural polymers
• CPC Class Codes: H01M 50/46 Separators, membranes or diaphragms characterised by their combination with electrodes
• CPC Class Codes: H01M 50/627 Filling ports
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02E 60/13 Energy storage using capacitors
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10T 29/49114 including adhesively bonding

Abstract

An electrical storage unit that includes a positive electrode, which includes a positive-electrode collector electrode and a positive-electrode active material layer on the positive-electrode collector electrode, a negative electrode, which includes a negative-electrode collector electrode and a negative-electrode active material layer on the negative-electrode collector electrode, the negative-electrode active material layer facing the positive-electrode active material layer, and a first insulating layer bonded to the positive electrode and the negative electrode and separating the positive electrode from the negative electrode. The first insulating layer is bonded to part of a surface of the positive electrode and part of a surface of the negative electrode and includes a communication path for connecting the outside of the electrical storage unit to the inside of the electrical storage unit.

Claims

1. An electrical storage device, comprising:

a positive electrode including a positive-electrode collector electrode and a positive-electrode active material layer disposed on the positive-electrode collector electrode;

a negative electrode including a negative-electrode collector electrode and a negative-electrode active material layer disposed on the negative-electrode collector electrode such that the negative-electrode active material layer faces the positive-electrode active material layer;

a first insulating layer bonded to the positive electrode and to the negative electrode to insulate the positive electrode from the negative electrode; and

at least one channel defined by the first insulating layer, the at least one channel extending between a surface of the positive electrode and a surface of the negative electrode.

2. The electrical storage device according to claim 1, wherein the at least one channel provides a communication path between the surfaces of the positive and negative electrodes and the outside of the electrical storage device.

3. The electrical storage device according to claim 1, wherein the at least one channel has a width of at least 50 μ

m and at most 100 mm.

4. The electrical storage device according to claim 1, wherein the first insulating layer comprises a particulate insulator.

5. The electrical storage device according to claim 1, further comprising a porous second insulating layer surrounded by the positive electrode, the negative electrode, and the first insulating layer.

6. The electrical storage device according to claim 5, wherein the second insulating layer has a lower air permeability than the first insulating layer.

7. The electrical storage device according to claim 1, wherein the electrical storage device includes a plurality of the first insulating layers, and the at least one channel is disposed between the plurality of the first insulating layers.

8. The electrical storage device according to claim 1, further comprising an electrolyte disposed in the at least one channel.

9. The electrical storage device according to claim 1, wherein the first insulating layer has a grid-like pattern that defines a plurality of channels.

10. The electrical storage device according to claim 1,

wherein the first insulating layer is bonded to three sides of the positive-electrode active material layer and the negative-electrode active material layer, and

wherein the at least one channel is disposed at a fourth side of the positive-electrode active material layer and the negative-electrode active material layer.

11. The electrical storage device according to claim 1, wherein the first insulating layer comprises a plurality of columnar insulating layers bonded to the positive electrode and to the negative electrode.

12. The electrical storage device according to claim 1, wherein the first insulating layer comprises a pair of insulating layers disposed on respective sides of the positive-electrode active material layer and the negative-electrode active material layer.

13. The electrical storage device according to claim 1, wherein the first insulating layer comprises a plurality of columnar insulating layers bonded to side surfaces of the positive-electrode active material layer and the negative-electrode active material layer.

14. The electrical storage device according to claim 13, wherein a plurality of gaps between the plurality of columnar insulating layers define a plurality of channels.

15. A method for manufacturing an electrical storage device, the method comprising:

forming an electrical storage unit that includes;

a positive electrode including a positive-electrode collector electrode and a positive-electrode active material layer disposed on the positive-electrode collector electrode,

a negative electrode including a negative-electrode collector electrode and a negative-electrode active material layer on the negative-electrode collector electrode, such that the negative-electrode active material layer faces the positive-electrode active material layer, and

a first insulating layer bonded to the positive electrode and to the negative electrode to insulate the positive electrode from the negative electrode;

forming an electrode composite sheet that includes a plurality of the positive-electrode collector electrodes or a plurality of the negative-electrode collector electrodes integrated via the first insulating layer;

bonding the first insulating layer to a surface of the positive electrode and a surface of the negative electrode; and

forming a channel between the positive electrode and the negative electrode.

16. The method for manufacturing an electrical storage device according to claim 15, wherein the channel provides a communication path between the surfaces of the positive and negative electrodes and the outside of the electrical storage device.

17. The method for manufacturing an electrical storage device according to claim 16, further comprising supplying an electrolyte to the electrical storage unit through the communication path after the step of forming the electrical storage unit.

18. A method for manufacturing an electrical storage device, the method comprising:

forming an electrical storage unit that includes;

a positive electrode including a positive-electrode collector electrode and a positive-electrode active material layer disposed on the positive-electrode collector electrode,

a negative electrode including a negative-electrode collector electrode and a negative-electrode active material layer disposed on the negative-electrode collector electrode, such that the negative-electrode active material layer faces the positive-electrode active material layer, and

a first insulating layer bonded to the positive electrode and to the negative electrode to insulate the positive electrode from the negative electrode;

bonding the first insulating layer to a surface of the positive electrode and a surface of the negative electrode;

forming a communication path between the surfaces of the positive and negative electrodes and the outside of the electrical storage unit.

19. The method for manufacturing an electrical storage device according to claim 18, further comprising:

forming a positive-electrode negative-electrode integrated sheet that includes a plurality of the electrical storage units aligned in at least one direction; and

dividing adjacent electrical storage units aligned in the at least one direction.

20. The method for manufacturing an electrical storage device according to claim 18, further comprising supplying an electrolyte to each of the plurality of electrical storage units through respective communication paths after the step of forming the electrical storage units.