Battery having an electrode structure comprising long metal fibers and a production method therefor

• US 9,680,147 B2
• Filed: 10/19/2011
• Issued: 06/13/2017
• Est. Priority Date: 10/16/2010
• Status: Active Grant

• Current Assignee: Jenax Inc.
• Original Assignee: Jenax Inc.
• Inventors: Kim, Kwonseok
• Primary Examiner(s): Lee, James
• Application Number:
  US13/879,120
• Publication Number:
  US 20130202960A1
• Time in Patent Office: 2,064 Days
• Field of Search: 429121-347
• CPC Class Codes: D04H 1/4234 Metal fibres
• CPC Class Codes: H01M 4/02 Electrodes composed of, or comprising, active material
• 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 4/64 Carriers or collectors
• CPC Class Codes: H01M 4/661 Metal or alloys, e.g. alloy coatings H01M4/669 take precedence
• CPC Class Codes: H01M 4/74 Meshes or woven material; Expanded metal
• CPC Class Codes: H01M 4/806 Nonwoven fibrous fabric containing only fibres
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y10T 29/49108 Electric battery cell making
• CPC Class Codes: Y10T 29/49115 including coating or impregnating

Abstract

The present invention relates to a battery having an electrode structure using long metal fibers, and to a production method therefor. According to one embodiment of the present invention, the battery has an electrode structure comprising: an electrically-conductive network which is formed by physical connection or chemical bonding between one or more long metal fibers; and a first electrically active material which is bound to the electrically-conductive network.

Claims

1. A battery including an electrode structure, the electrode structure comprising:

a conductive network formed by long metal fibers physically contacting or chemically bonded to one another;

a first electrically active material that is impregnated into pores of the conductive network; and

a pre-coated layer on surfaces of some or all of the long metal fibers;

wherein the pre-coated layer has a second electrically active material different from the first electrically active material and having chemical affinity with the first electrically active material,

wherein the metal fibers are randomly arranged to be tangled to each other to form the pores in the conductive network, and the first electrically active material is bound to the some or all of the long metal fibers by forming a sintered body through thermal treatment between the first electrically active material and second electrically active material having the chemical affinity with the first electrically active material.

2. The battery of claim 1, wherein the long metal fibers form a nonwoven structure in which the long metal fibers are randomly arranged to be coupled to one another.

3. The battery of claim 1, wherein the long metal fibers are formed of two or more different types of metals.

4. The battery of claim 1, wherein the electrode structure has a planar shape by being compressed, or a deformed shape by bending, winding, and/or stacking the planar shape.

5. The battery of claim 1, wherein each of the long metal fibers has a thickness ranging from 1 μ

m to 200 μ

m.

6. The battery of claim 1, wherein each of the long metal fibers has a length ranging from 5 mm to 1000 mm.

7. The battery of claim 1, wherein each of the long metal fibers comprises stainless steel, aluminum, nickel, titanium, copper, an alloy thereof, or a combination thereof.

8. The battery of claim 1, wherein the first electrically active material comprises an active material for a primary battery or a secondary battery.

9. The battery of claim 1, further comprising an electrolytic solution infiltrated into pores between the first electrically active material and the conductive network.

10. The battery of claim 1, wherein the first electrically active material and the second electrically active material each comprise an electrically active material for a cathode selected from the group consisting of oxide, phosphate, sulfide, and fluoride, each of which includes two or more components selected from lithium, nickel, cobalt, chromium, magnesium, strontium, vanadium, lanthanum, cerium, iron, cadmium, lead, and/or manganese.