Battery electrode sheet and manufacturing method therefor

• US 8,637,189 B2
• Filed: 08/05/2011
• Issued: 01/28/2014
• Est. Priority Date: 08/18/2010
• Status: Active Grant

• Current Assignee: GS Yuasa International Ltd. (GS Yuasa Corporation)
• Original Assignee: GS Yuasa International Ltd. (GS Yuasa Corporation)
• Inventors: Okabe, Kazuya, Ohtani, Yoshikatsu, Takaura, Yoshihiro
• Primary Examiner(s): Kalafut, Stephen J.
• Application Number:
  US13/204,549
• Publication Number:
  US 20120045689A1
• Time in Patent Office: 907 Days
• Field of Search: 429/233, 429/235, 429/236, 429/237, 429/245, 29/2
• US Class Current: 429/233
• CPC Class Codes: H01M 4/0435 Rolling or calendering
• CPC Class Codes: H01M 4/661 Metal or alloys, e.g. alloy coatings H01M4/669 take precedence
• CPC Class Codes: H01M 4/667 in the form of layers, e.g. coatings
• CPC Class Codes: H01M 4/668 Composites of electroconductive material and synthetic resins
• CPC Class Codes: H01M 4/70 characterised by shape or form
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y10T 29/10 Battery-grid making

Abstract

An electrode sheet includes a sheet of metal foil, at least one region coated with at least one active material layer subjected to working by rolling, the at least one coated region being provided in at least one central portion of the sheet of metal foil, at least one region uncoated with the at least one active material layer, the at least one uncoated region being provided in at least one edge portion of the sheet of metal foil, and at least one region subjected to working by drawing, the at least one drawn region being provided in at least a portion of the at least one uncoated region.

Claims

1. An electrode sheet comprising:

a sheet of metal foil;

at least one region coated with at least one active material layer subjected to working by rolling, the at least one coated region being provided in at least one central portion of the sheet of metal foil;

at least one region uncoated with the at least one active material layer, the at least one uncoated region being provided in at least one edge portion of the sheet of metal foil; and

at least one region subjected to working by drawing, the at least one drawn region being provided in at least a portion of the at least one uncoated region,

wherein there are a plurality of the drawn regions, the plurality of the drawn regions being provided in intermittent fashion in a long direction of the electrode sheet.

2. An electrode sheet according to claim 1, wherein the at least one drawn region is rectangular in shape.

3. An electrode sheet according to claim 2, wherein the at least one rectangular drawn region has at least one rounded corner.

4. An electrode sheet according to claim 1, wherein the electrode sheet is nonporous.

5. An electrode sheet according to claim 4, wherein a substrate material of the electrode sheet comprises is at least one member selected from among the group consisting of aluminum, copper, and metal-coated resin film.

6. An electrode sheet comprising:

a sheet of metal foil;

at least one region coated with at least one active material layer subjected to working by rolling, the at least one coated region being provided in at least one central portion of the sheet of metal foil;

at least one region uncoated with the at least one active material layer, the at least one uncoated region being provided in at least one edge portion of the sheet of metal foil;

at least one region subjected to working by drawing, the at least one drawn region being provided in at least a portion of the at least one uncoated region; and

at least one uncompressed region at which the at least one drawn region is not created,

wherein the at least one uncompressed region is provided between the at least one drawn region and the at least one coated region.

7. An electrode sheet comprising:

a sheet of metal foil;

at least one region coated with at least one active material layer subjected to working by rolling, the at least one coated region being provided in at least one central portion of the sheet of metal foil;

at least one region uncoated with the at least one active material layer, the at least one uncoated region being provided in at least one edge portion of the sheet of metal foil; and

at least one region subjected to working by drawing, the at least one drawn region being provided in at least a portion of the at least one uncoated region,

wherein the at least one drawn region is provided at only one side of the electrode sheet.

8. An electrode sheet comprising:

a metal thin film;

a coated region which is coated with an active material layer subjected to working by rolling, the coated region being provided in a central portion of the metal thin film;

an uncoated region which is not coated with the active material layer, the uncoated region being provided in an edge portion of the metal thin film; and

a drawn region which is subjected to working by drawing, the drawn region being provided in at least a portion of the uncoated region,

wherein the drawn region comprises a plurality of drawn regions, the plurality of the drawn regions being provided in intermittent fashion in a lengthwise direction of the metal thin film.

9. An electrode sheet according to claim 8, wherein the drawn region comprises a rectangular shape.

10. An electrode sheet according to claim 9, wherein the drawn region comprises a rounded corner.

11. An electrode sheet comprising:

a metal thin film;

a coated region which is coated with an active material layer subjected to working by rolling, the coated region being provided in a central portion of the metal thin film;

an uncoated region which is not coated with the active material layer, the uncoated region being provided in an edge portion of the metal thin film;

a drawn region which is subjected to working by drawing, the drawn region being provided in at least a portion of the uncoated region; and

an uncompressed region at which the drawn region is not created,

wherein the uncompressed region is provided between the drawn region and the coated region.

12. An electrode sheet comprising:

a metal thin film;

a coated region which is coated with an active material layer subjected to working by rolling, the coated region being provided in a central portion of the metal thin film;

an uncoated region which is not coated with the active material layer, the uncoated region being provided in an edge portion of the metal thin film; and

a drawn region which is subjected to working by drawing, the drawn region being provided in at least a portion of the uncoated region,

wherein the drawn region is provided at only one side of the metal thin film.

13. An electrode sheet manufacturing method, the method comprising:

preparing an electrode sheet having

at least one region coated with at least one active material layer, the at least one coated region being created in at least one central portion of the electrode sheet, and

at least one region uncoated with the at least one active material, the uncoated region being created in at least one edge portion of the electrode sheet;

subjecting a portion of the at least one uncoated region to working by a press so as to create at least one drawn region; and

subjecting the at least one coated region to working by rolling.

14. An electrode sheet manufacturing method according to claim 13, wherein the creation and the working by rolling of the at least one coated region is carried out before the creation of the at least one drawn region.

15. An electrode sheet manufacturing method according to claim 14, further comprising:

takeup of the electrode sheet;

wherein the takeup of the electrode sheet is carried out after the creation and the working by rolling of the at least one coated region but before the creation of the at least one drawn region.

16. An electrode sheet manufacturing method according to claim 13, wherein a linear load during the creation of the at least one drawn region is not less than 30% of a linear load during the creation and the working by rolling of the at least one coated region.

17. An electrode sheet manufacturing method according to claim 16, wherein a tension applied during the creation of the at least one drawn region is not less than 10 N and not more than 60 N.