Laminate-type battery and process for its manufacture

• US 6,335,114 B1
• Filed: 11/15/1999
• Issued: 01/01/2002
• Est. Priority Date: 11/16/1998
• Status: Expired due to Term

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Shinkai, Ryuichirou, Amano, Tadayoshi, Yamada, Manabu, Ueshima, Hiroshi, Hosokawa, Norikazu, Kami, Kenichiro
• Primary Examiner(s): Maples, John S.
• Application Number:
  US09/440,512
• Time in Patent Office: 778 Days
• Field of Search: 429/94, 429/211, 429/161, 429/162, 429/217, 429/245, 429/233
• US Class Current: 429/94
• CPC Class Codes: H01M 10/0431 Cells with wound or folded electrodes H01M10/045 takes precedence
• CPC Class Codes: H01M 10/0486 Frames for plates or membranes
• 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 10/4235 Safety or regulating additives or arrangements in electrodes, separators or electrolyte H01M10/4242 takes precedence
• CPC Class Codes: H01M 4/04 Processes of manufacture in general
• CPC Class Codes: H01M 4/0402 Methods of deposition of the material
• CPC Class Codes: H01M 4/0404 by coating on electrode collectors
• CPC Class Codes: H01M 4/0409 by a doctor blade method, slip-casting or roller coating
• CPC Class Codes: H01M 4/0416 involving impregnation with a solution, dispersion, paste or dry powder H01M4/0438 takes precedence
• CPC Class Codes: H01M 4/0433 Molding
• CPC Class Codes: H01M 4/0435 Rolling or calendering
• CPC Class Codes: H01M 4/0483 by methods including the handling of a melt H01M4/0438, take precedence
• CPC Class Codes: H01M 50/119 Metals
• CPC Class Codes: H01M 50/417 Polyolefins
• CPC Class Codes: H01M 50/423 Polyamide resins
• 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: H01M 50/469 tubular or cylindrical
• 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

There are provided coiled electrode batteries with high yields, while short-circuiting in the batteries is prevented. A coiled electrode battery according to the invention has coiled electrodes consisting of positive and negative poles 21, 22 and two separators 23 lying between them. In the coiled electrodes, insulating layers 216, 226 made of insulating resin are formed on both sides of the proximal sections of the protrusions 213, 223 of the positive and negative poles 21, 22. Thus, even if the non-protruding sections of the positive and negative electrodes 21, 22 become exposed due to winding misalignment of the separators 23 in the lengthwise direction, the presence of the insulating layers 216, 226 prevents short-circuits between the proximal sections of the protrusions 213, 223 of the positive and negative electrodes 21, 22. As a result, yields are increased as short-circuits are avoided inside the battery.

Claims

1. A laminate-type battery, comprising:

a laminated electrode prepared by laminating a positive plate formed by providing a positive pole active material layer on a surface of a positive pole sheet collector having one edge and another edge,

a negative plate formed by providing a negative pole active material layer on a surface of a negative pole sheet collector having one edge and another edge,

said one edge of the negative pole sheet collector being located on a side of said one edge of the positive pole sheet collector, and

a separator having one edge and another edge and lying between said positive plate and said negative plate,

said one edge of the separator being located on said side of said one edge of the positive pole sheet collector,

wherein the one edge of the collector of at least one of said positive plate and said negative plate, as a first electrode plate, has a protrusion that protrudes out beyond the one edge of the collector of the other electrode plate, as a second electrode plate, of opposite polarity, and

wherein a short-circuit preventing layer for preventing an electrical short-circuit between the first electrode plate and the second electrode plate is provided on or over the protrusion of the first electrode plate.

2. A laminate-type battery according to claim 1, which has a coiled electrode construction wherein said positive plate, said negative plate and said separator are coiled while laminated together, and said protrusion protrudes out in the coiled axial length direction.

3. A laminate-type battery according to claim 1, wherein said short-circuit preventing layer is made of an insulator.

4. A laminate-type battery according to claim 1, wherein said short-circuit preventing layer includes which extends from said one edge of the separator to said protrusion.

5. A laminate-type battery according to claim 4, wherein said another edge of the collector of the second electrode plate adjacent to the first electrode plate has a protrusion that protrudes out beyond a non-protruding other edge of the first electrode plate, said separator has a shape which covers both sides of the first electrode plate and said non-protruding edge of the first electrode plate, and a section of said separator which covers said non-protruding edge isolates said non-protruding edge from said protrusion of the second electrode plate adjacent to said non-protruding edge.

6. A laminate-type battery according to claim 1, wherein said separator is a porous film formed integrally on the surface of either of or both of said protrusion-provided electrode plate of said positive plate and said negative plate.

7. A laminate-type battery according to claim 6, wherein said porous film contains at least one type from among polypropylene, polybenzimidazole, polyimide, polyether imide, polyamidoimide, polyphenylene ether, polyallylate, polyacetal, polyamide, polyphenylene sulfide, polyethersulfone, polysulfone, polyether ketone, polyester resins, polyethylene naphthalate, ethylene-cycloolefin copolymers, polyvinylidene fluoride and vinylidene fluoride-hexafluoropropylene-tetrafluoroethylene copolymer.

8. A laminate-type battery according to claim 7, wherein said polyester resin is either or both polybutylene terephthalate and polyethylene terephthalate.

9. A laminate-type battery according to claim 6, wherein said porous film is provided with, in the direction of its thickness, a sponge-like interior and a surface having densely formed pores of a smaller size than in said interior.

10. A laminate-type battery according to claim 1, wherein either or both of said positive plate and said negative plate consist of at least an active material and a binder, and said binder comprises a hydrophilic polymer material with hydrophilic groups which is crosslinked together via a crosslinking agent which undergoes a binding reaction with said hydrophilic groups.

11. A laminate-type battery according to claim 1, wherein the active material layer is provided in an area on the surface of the collector of the first electrode plate, the collector also including a border area of the one edge wherein there is no active material and the short-circuit-preventing layer is provided on the border area.

12. A laminate-type battery according to claim 11, wherein the short-circuit-preventing layer is provided in a section of the border area proximate the active material-provided area of the collector.

13. A laminate-type battery according to claim 1, wherein the one edge of the collector of the positive plate protrudes out beyond the one edge of the collector of the negative plate, said another edge of the collector of the negative plate protrudes out beyond the other edge of the collector of the positive plate, and the short-circuit preventing layer is provided on or over both of the protrusions of the positive and negative plates.

14. A laminate-type battery, comprising:

a laminated electrode prepared by laminating a positive plate formed by providing a positive pole active material layer on a surface of a disk-shaped positive pole sheet collector,

a negative plate formed by providing a negative pole active material layer on a surface of a disk-shaped negative pole sheet collector, and

a disk-shaped separator lying between said positive plate and said negative plate,

wherein an edge of the collector of at least one of said positive plate and said negative plate, as a first electrode plate, has a protrusion that protrudes out beyond an edge of the collector of the other electrode plate, as a second electrode plate, of opposite polarity, and

wherein a short-circuit preventing layer for preventing an electrical short-circuit between the first electrode plate and the second electrode plate is provided on or over the protrusion of the first electrode plate.