Prime Planet Energy & Solutions, Inc.

Toyota Jidosha Kabushiki Kaisha

Katsushi Enokihara

Naohiro Mashimo

Haruka Shionoya

Masanori Kitayoshi

Tetsuya Mimura

Takenori Ikeda

Tomoyuki Uezono

Takahiko Nakano

Aiko Nagano

Kouji Yamashiro

Shou Ishiyama

Shuhei Takeshita

A method for manufacturing an electrode is provided, the method including coating and drying of an electrode paste and being able to highly suppress variations in the weight per unit area of the active material layer. The method for manufacturing an electrode disclosed herein includes the steps of: coating an electrode paste onto a current collecting foil from a die; and drying the coated electrode paste. Here, the current collecting foil is conveyed by a backup roll. A variation in at least one of thickness and width of the coated electrode paste is measured. The peripheral speed of the backup roll is changed according to a measurement result of the variation so that the variation becomes small.

Method for manufacturing electrode and electrode paste coating device

According to the present disclosure, an electrode having an electrode mixture layer with a desired film thickness can be stably produced. An electrode production apparatus disclosed herein includes: a first roll; a second roll; third roll; a rolling gap for rolling an electrode material to form a mixture coated film, formed between the first roll and the second roll; and a compression bonding gap for compressedly bonding the mixture coated film and an electrode current collector, formed between the second roll and the third roll. The electrode production apparatus further includes a spring-like mechanism configured to bias the third roll toward the second roll. The compression bonding gap fluctuates in response to the fluctuation of the reaction force from the mixture coated film. As a result, the film thickness variation of the electrode mixture layer after the production can be reduced.

Electrode production apparatus

The method for producing a secondary battery electrode disclosed here includes steps of: preparing a moisture powder formed by aggregated particles that contain electrode active material particles, a binder resin, and solvent, wherein a solid phase, liquid phase, and gas phase in at least 50 number % or more of the aggregated particles in the moisture powder form a pendular or funicular state; forming a coating film composed of the moisture powder, on an electrode current collector, while the gas phase remains present; carrying out depression/elevation transfer into a surface part of the coating film; forming an electrode active material layer by drying the coating film; and pressing the electrode active material layer. The electrode active material particles are aspherical particles in which a ratio of a short side to a long side in a cross sectional view is less than 0.95.

Secondary battery electrode and method for producing the electrode

A method for producing secondary battery electrodes includes a step of preparing a moisture powder formed of aggregated particles that contain electrode active material particles, a binder resin, and solvent, wherein the solid phase, liquid phase, and gas phase in at least 50 number % of the aggregated particles form a pendular state or a funicular state; a step of forming, using the moisture powder, a coating film while the gas phase remains present; a step of forming a first groove that extends in a first direction, by transferring depressions and elevations, using a first roll die, into the coating film; and a step of forming a second groove that extends in a different direction, by transferring depressions and elevations, using a second roll die, into the coating film. Depression/elevation transfer is carried out in such a manner that the second groove is made deeper than the first groove.

Method for producing secondary battery electrodes

The electrodes disclosed herein, a low-density region having a relatively low electrode density and a high-density region having a relatively high electrode density are repeated on a surface of the electrode active material layer in a predetermined pattern at a constant pitch. The electrode active material layer is evenly divided into three layers of an upper layer, an intermediate layer, and a lower layer in a thickness direction from the surface of the active material layer to the electrode current collector, and when the electrode densities (g/cm) of the upper layer, the intermediate layer, and the lower layer of the low-density region are respectively d, d, and dand the electrode densities (g/cm) of the upper layer, the intermediate layer, and the lower layer of the high-density region are respectively d, d, and d, a relation of d/d<d/dis satisfied.

An electrode having both high energy density and ion diffusivity includes an electrode active material layer on either a positive-or negative-electrode current collector, in which the electrode active material layer has a concave/convex shape on its surface in a predetermined pattern at a constant pitch. In a cross-sectional SEM image of the electrode active material layer, linear cracks are unevenly distributed in a concave portion compared to in a convex portion.

According to the present disclosure, an electrode having an electrode mixture layer with a desired film thickness can be stably produced. A producing method disclosed herein includes detecting the surface position of a mixture coated film by a first sensor; detecting the surface position of a second roll by a second sensor; detecting the film thickness of the mixture coated film based on detection results of the first sensor and the second sensor; and adjusting a relatively rotation speed of a third roll based on the film thickness. And, the detected positions of the first sensor and the second sensor in a circumferential direction of the second roll are substantially identical. Due to this method, the change in the film thickness of the electrode mixed layer of produced electrode can be suppressed.

Method for producing electrode

A method of producing an electrode disclosed here includes a step in which a moisture powder formed of agglomerated particles; a step in which by using the moisture powder, a coating film composed of the moisture powder is formed on an electrode current collector, with a gas phase of the coating film being remained so that the average film thickness of the coating film is 50 μm or more; a step in which the coating film on the current collector is transported, concavo-convex transfer is performed using a roll mold, and thus at least one groove extending in the transport direction is formed in a center of a surface part of the coating film, with the groove being formed to have a depth satisfying ( 9/10×t)>t; and a step in which the coating film formed on the current collector is dried to form an electrode active material layer.

Method of producing electrode for secondary battery

An electrode disclosed here includes a surface part of an electrode active material layer has a plurality of first grooves extending in a width direction of the electrode current collector and at least one second groove extending in a longitudinal direction of an electrode current collector. The first groove is formed to be continuous from one end to another end. Here, a region in which the first groove and the second groove are formed is uniformly divided into three layers, which are an upper layer, an intermediate layer and a lower layer, in a thickness direction from the surface of the electrode active material layer to the electrode current collector, and when electrode densities (g/cm) of the upper layer, the intermediate layer and the lower layer of the groove are d, d, and d, respectively, a relationship of 0.8<(d/d)<1.1 is satisfied.

Electrode for non-aqueous electrolyte solution secondary battery, method of producing electrode and non-aqueous electrolyte solution secondary battery including electrode

A method for manufacturing an electrode disclosed herein includes: steps of forming a coating film composed of an electrode material by passing the electrode material through a gap between a rotating first roll and a rotating second roll; adhering the coating film to the second roll and conveying the coating film; and transferring the conveyed coating film onto an electrode current collector conveyed by a conveying device to form an electrode mixture layer composed of the coating film. The speed ratio between a peripheral speed of the second roll and a conveying speed of the electrode current collector is changed by changing the peripheral speed of the second roll on the basis of the thickness of the coating film or the width of the gap. The timing of the change in the speed ratio is allowed to be based on the Equation (1) described in the description.

Method for manufacturing electrode and apparatus for manufacturing electrode

A method for producing secondary battery electrodes includes a step of preparing a moisture powder formed of aggregated particles that contain a plurality of electrode active material particles, a binder resin, and solvent, wherein the solid phase, liquid phase, and gas phase in at least 50 number % or more of the aggregated particles in the moisture powder form a pendular state or a funicular state; a step of forming a coating film composed of the moisture powder on an electrode current collector, while the gas phase remains present; a step of forming a depression in the coating film by carrying out, using a die having an elevation of prescribed height, depression/elevation transfer into the coating film; and a step of carrying out depression/elevation transfer, using a die having an elevation higher than the elevation of prescribed height, by pressing the higher elevation into the depression that has been formed.

At the time of forming a paste layer on a substrate sheet by use of three rolls placed at right angles, in order to offset a variation amount of a first gap due to thermal expansion of the rolls, a variation amount in a given detection period is calculated by use of outputs of a first sensor configured to detect a coating film surface of a second-roll coating film of a second roll and a second sensor configured to detect a second-roll surface, and the first roll is moved by use of a first-roll moving mechanism.

Coating applicator for providing a belt-shaped paste layer

In manufacturing an electrode that is obtained by forming an active material layer on a current collector foil, a film formation process unit that forms the active material layer by layering granules obtained by granulating a powder of an active material and supplying the layered granules onto a first surface of the current collector foil, and a flattening process unit that chips off a convex portion on a surface of the active material layer that has exited the film formation process unit by a tip of a blade are used.

Method of manufacturing electrode plate and device for manufacturing electrode plate

Manufacturing method of paste-layer-attached sheet and coating applicator

A manufacturing method manufactures an electrode by use of a manufacturing apparatus including a B-roll configured to convey granules, a C-roll configured to convey a metal foil, and a cooling portion configured to cool down the metal foil on an upstream side relative to the C-roll in terms of a conveying direction of the metal foil. Further, the manufacturing apparatus cools down the metal foil by use of the cooling portion, supplies the metal foil thus cooled down by the cooling portion to the C-roll, and transfers the granules to the metal foil in a deposition gap between the B-roll and the C-roll.

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Toyota, Japan

Katsushi Enokihara