SEPARATOR-INTEGRATED ELECTRODE PLATE, ELECTRODE PLATE PAIR, STACKED ELECTRIC POWER STORAGE ELEMENT, AND METHOD OF MANUFACTURING SEPARATOR-INTEGRATED ELECTRODE PLATE

• US 20180138482A1
• Filed: 11/10/2017
• Published: 05/17/2018
• Est. Priority Date: 11/17/2016
• Status: Active Grant

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: SAKURAI, Takahiro
• Granted Patent: US 10,644,288 B2
• Time in Patent Office: Days
• CPC Class Codes: H01M 10/00 Secondary cells; Manufacture thereof
• CPC Class Codes: H01M 10/0413 Large-sized flat cells or batteries for motive or stationary systems with plate-like electrodes
• 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 4/36 Selection of substances as active materials, active masses, active liquids
• CPC Class Codes: H01M 4/64 Carriers or collectors
• CPC Class Codes: H01M 50/406 Moulding; Embossing; Cutting
• CPC Class Codes: H01M 50/417 Polyolefins
• CPC Class Codes: H01M 50/426 Fluorocarbon polymers
• 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: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product

Abstract

A separator-integrated electrode plate includes a current collector plate; an active material layer formed on the current collector plate; and a resin separator layer formed on the active material layer. A belt-like laser-cut end portion along a laser-cut edge that is laser-cut in a thickness direction of the separator-integrated electrode plate and forms part of a peripheral edge of the separator-integrated electrode plate has a resin-permeated portion in which a resin forming the resin separator layer permeates the active material layer over a width that is more than twice a thickness of the resin separator layer.

Claims

1. A separator-integrated electrode plate comprising:

a current collector plate;

an active material layer formed on the current collector plate; and

a resin separator layer formed on the active material layer,

wherein a belt-like laser-cut end portion along a laser-cut edge that is laser-cut in a thickness direction of the separator-integrated electrode plate and forms part of a peripheral edge of the separator-integrated electrode plate has a resin-permeated portion in which a resin forming the resin separator layer permeates the active material layer over a width that is more than twice a thickness of the resin separator layer.

2. The separator-integrated electrode plate according to claim 1, wherein

the resin separator layer includes a stretched porous resin film and is bonded to the active material layer.

3. The separator-integrated electrode plate according to claim 1, wherein

the active material layer and the resin separator layer are provided on each of both surfaces of the current collector plate.

4. An electrode plate pair comprising:

the separator-integrated electrode plate according to claim 3;

a second current collector plate; and

a pair of second active material layers respectively formed on both surfaces of the second current collector plate,

wherein a second electrode plate is stacked such that one of the second active material layers is placed on one of the resin separator layers of the separator-integrated electrode plate.

5. A stacked electric power storage element comprising

a stacked electrode assembly configured such that a plurality of electrode plate pairs each according to claim 4 are stacked together.

6. A method of manufacturing a separator-integrated electrode plate, the separator-integrated electrode plate including:

a current collector plate;

an active material layer formed on the current collector plate; and

a resin separator layer formed on the active material layer, wherein a belt-like laser-cut end portion along a laser-cut edge that is laser-cut in a thickness direction of the separator-integrated electrode plate and forms part of a peripheral edge of the separator-integrated electrode plate has a resin-permeated portion in which a resin forming the resin separator layer permeates the active material layer over a width that is more than twice a thickness of the resin separator layer, the method comprising;

a resin permeation step in which thermal energy is applied to a belt-like uncut permeation region, including a cutting planned portion in the uncut permeation region, of an uncut integrated electrode plate including an uncut current collector plate, an uncut active material layer formed on the uncut current collector plate, and an uncut resin separator layer formed on the uncut active material layer to melt an in-region portion, located in the uncut permeation region, of the uncut resin separator layer, the resin is caused to permeate an in-region active material portion, located in the uncut permeation region, of the uncut active material layer; and

a post-permeation cutting step in which the cutting planned portion of the uncut integrated electrode plate is laser-cut such that the resin-permeated portion having the width is formed after laser cutting.

7. The method according to claim 6, wherein

when causing the resin to permeate the in-region active material portion located in the uncut permeation region in the resin permeation step, a heating body heated to equal to or higher than a melting point of the resin is pressed against the uncut permeation region of the uncut integrated electrode plate, the resin forming the in-region portion of the uncut resin separator layer is melted to cause the resin to permeate the in-region active material portion.

8. The method according to claim 6, wherein

when causing the resin to permeate the in-region active material portion located in the uncut permeation region in the resin permeation step, a melting laser beam is irradiated to the uncut permeation region of the uncut integrated electrode plate, the resin forming the in-region portion of the uncut resin separator layer is melted to cause the resin to permeate the in-region active material portion.

9. A method of manufacturing a separator-integrated electrode plate, the separator-integrated electrode plate including:

a current collector plate;

an active material layer formed on the current collector plate; and

a resin separator layer formed on the active material layer, wherein a belt-like laser-cut end portion along a laser-cut edge that is laser-cut in a thickness direction of the separator-integrated electrode plate and forms part of a peripheral edge of the separator-integrated electrode plate has a resin-permeated portion in which a resin forming the resin separator layer permeates the active material layer over a width that is more than twice a thickness of the resin separator layer, the method comprising;

a permeation cutting step in which thermal energy is applied to a belt-like uncut permeation region, including a cutting planned portion in the uncut permeation region, of an uncut integrated electrode plate including an uncut current collector plate, an uncut active material layer formed on the uncut current collector plate, and an uncut resin separator layer formed on the uncut active material layer to melt an in-region portion, located in the uncut permeation region, of the uncut resin separator layer, the resin is caused to permeate an in-region active material portion, located in the uncut permeation region, of the uncut active material layer; and

simultaneously, the cutting planned portion of the uncut integrated electrode plate is laser-cut such that the resin-permeated portion having the width is formed after laser cutting.

10. A method of manufacturing a separator-integrated electrode plate, the separator-integrated electrode plate including:

a current collector plate;

an active material layer formed on the current collector plate; and

a resin separator layer formed on the active material layer, wherein a belt-like laser-cut end portion along a laser-cut edge that is laser-cut in a thickness direction of the separator-integrated electrode plate and forms part of a peripheral edge of the separator-integrated electrode plate has a resin-permeated portion in which a resin forming the resin separator layer permeates the active material layer over a width that is more than twice a thickness of the resin separator layer, the method comprising;

a before-permeation cutting step in which an uncut integrated electrode plate including an uncut current collector plate, an uncut active material layer formed on the uncut current collector plate, and an uncut resin separator layer formed on the uncut active material layer is laser-cut; and

a post-cutting permeation step in which thermal energy is applied to the laser-cut end portion to melt the resin forming the resin separator layer, the resin is caused to permeate the active material layer, such that the resin-permeated portion having the width is formed along the laser-cut edge generated by the laser cutting.