Specification
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[DESCRIPTION]
INTEGRATED ELECTRODE ASSEMBLY AND SECONDARY BATTERY
USING THE SAME
[TECHNICAL FIELD]
5 The present invention relates to an integrated electrode assembly and a
secondary battery using the same and more particularly to an integrated electrode
assembly including a cathode, an anode, and a separation layer integrated between the
cathode and the anode, the separation layer including 3 phases including a liquid-phase
component containing an ionic salt, which partially flows from the separation layer into
10 the electrodes (i.e., the cathode and the anode) during preparation of the integrated
electrode assembly to greatly improve wetting properties of the electrodes and to
increase ionic conductivity of the electrodes, a solid-phase component supporting the
separation layer between the cathode and the anode, and a polymer matrix having
affinity for the liquid-phase component and providing binding force with the cathode
15 and the anode.
[BACKGROUND ART]
Increasing price of energy sources due to depletion of fossil fuels and an
increased interest in environmental pollution have brought about increased demand for
environmentally friendly alternative energy sources as an indispensable element for
20 future life. Studies on various power generation technologies such as nuclear, solar,
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wind, and tidal power generation technologies have continued to be conducted and
power storage devices for more efficient use of such generated energy also continue to
be of great interest. Secondary batteries have been used as such power storage
devices. Among secondary batteries, lithium secondary batteries have begun to be
5 used for mobile devices and, along with increasing demand for reduced weight and high
voltage and capacity, recently, use of lithium secondary batteries has been significantly
extended to electric vehicles, hybrid electric vehicles, and auxiliary power sources
based upon smart grid.
However, numerous challenges, which have yet to be addressed, remain before
10 lithium secondary batteries can be used as large-capacity power sources. One i
important challenge is to improve energy density and increase safety. Another
important challenge is to reduce process time and to achieve uniform wetting for largearea
electrodes. Many researchers have conducted intensive studies on materials that
can satisfy low cost requirements while increasing energy density and have also put
15 effort into studies on materials for improving safety.
Ni-based or Mn-based materials having higher capacity than LiCoC>2, which
has been conventionally used, are typical examples of materials being studied for
energy density improvement. Materials that are based on Li alloying reactions with Si
or Sn rather than based on intercalation reactions are typical examples of materials for
20 anodes being studied as alternatives to conventional graphite-based materials.
A stable olivine-based cathode active material such as LiFePC>4, a cathode
active material such as LLtTisOn, or the like have been studied to improve safety.
However, such materials for safety improvement inherently have a low energy density
and do not fundamentally solve safety problems associated with the structure of lithium
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secondary batteries.
Secondary battery safety may be largely divided into internal safety and
external safety and may further be divided into electrical safety, impact safety, and
thermal safety. Occurrence of these safety problems commonly entails temperature
5 increase, which necessarily results in contraction of a stretched separator that is
generally used.
Although many researchers have suggested all-solid-state batteries to resolve
this safety issue, all-solid-state batteries have a lot of problems in replacing batteries
available on the market.
10 First, currently used electrode active materials are in a solid state. Thus, when
a solid electrolyte or a polymer electrolyte is used, the surface area of the electrolyte in
contact with the active material for lithium ion movement is significantly reduced.
Therefore, the ionic conductivity is very low even when the solid or polymer electrolyte
has a conductivity of 10"5 s/cm, similar to the current liquid electrolyte. Second, the
15 ionic conductivity at the solid-solid interface or the solid-polymer interface should be
much lower for the same reason. Third, even when a solid electrolyte with high
conductivity is used, the ionic conductivity is still very low due to a polymer binder that
should be employed to provide binding force that is essential to battery formation.
Fourth, to form a battery, not only the separation layer needs to have ionic conductivity
20 but the cathode and anode active materials also need to employ materials for ionic
conductivity improvement to increase ionic conductivity of the electrodes. However,
if a solid electrolyte or a polymer electrolyte is included as an electrode component, the
capacity is reduced.
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Thus, there is a great need to provide a battery structure that prevents shortcircuiting
due to separator contraction and provides excellent battery performance.
[DISCLOSURE]
[TECHNICAL PROBLEM]
5 Therefore, the present invention has been made to solve the above and other
technical problems that have yet to be resolved.
As a result of a variety of extensive and intensive studies and various
experiments, the present inventors have found that an integrated electrode assembly,
which includes a separation layer including three phases including a liquid-phase
10 component containing an ionic salt, a solid-phase component supporting the
separation layer between a cathode and an anode, and a polymer matrix incorporating
the liquid-phase component and the solid-phase component therein, prevents shortcircuiting
due to separator contraction, greatly improves wetting properties of the
electrodes, and increases ionic conductivity. The present invention has been
15 completed based on this finding.
[TECHNICAL SOLUTION]
Therefore, an integrated electrode assembly in accordance with the present
invention includes a cathode, an anode, and a separation layer integrated between the
cathode and the anode, the separation layer including 3 phases including a liquid-phase
20 component containing an ionic salt, the liquid-phase component partially flowing from
.4.
] the separation layer into the cathode and the anode during preparation of the integrated
electrode assembly to greatly improve wetting properties of the cathode and the anode
and to increase ionic conductivity of the cathode and the anode, a solid-phase
; component supporting the separation layer between the cathode and the anode, and a
5 polymer matrix having affinity for the liquid-phase component and providing binding
force with the cathode and the anode.
Experiments conducted by the present inventors showed that the internal risk
of the secondary battery is highest when the secondary battery is in a charged state
with increased energy and, when the secondary battery is in a charged state, short-
10 circuiting may be caused by separator contraction or the like in four situations: (1)
where a charged cathode and a charged anode contact each other, (2) where a charged
cathode and an anode current collector contact each other, (3.) where an anode current
collector and a cathode current collector contact each other, and (4) where a cathode
current collector and a charged anode contact each other.
15 Experiments conducted in all of the situations with charged electrodes in a
dry room showed that most serious thermal runaway occurred upon contact between a
charged anode and a cathode current collector, contrary to what was expected.
Through intensive study, we found that such thermal runaway was caused by, for
example, a rapid exothermic reaction of 4Al+302 ->2Al203 at an Al foil which serves
20 as a cathode current collector. The shapes of Al foils were hard to identify in all
occurrences of battery explosion.
Although the experiments showed that thermal runaway occurred only when
a charged anode and a cathode current collector contact each other, it cannot be
concluded that the other three situations are safe. In batteries, any contact between
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i portions of a cathode and an anode is risky.
On the other hand, the integrated electrode assembly according to the present
,. invention has excellent high-temperature safety since a polymer matrix and a solidphase
component do not contract at high temperature, preventing the occurrence of
5 mishaps such as explosion that occurred in the above experiments.
In addition, it is possible to increase ionic conductivity of the electrodes (i.e.,
the anode and cathode), thereby improving battery performance, since the liquid-phase
component flows into and impregnates the electrodes in an electrode assembly
preparation process, for example, in a lamination process. Further, since the
10 electrodes are uniformly wetted by electrolyte, it is possible to minimize electrode
degradation caused by non-uniform permeation of electrolyte, which is the most
serious problem associated with large-area electrodes. Accordingly, the electrolyte
state of the electrode assembly of the present invention may be defined such that a
partial liquid-phase component derived from the separation layer is included or
15 incorporated in the electrodes. Here, the amount of the liquid-phase component
derived from the separation layer which is included or incorporated in the electrodes is
not particularly limited. For example, the amount of the liquid-phase component
included or incorporated in the electrodes may be 10 to 90% based on the total amount
of the liquid-phase component included in the electrode assembly.
20 The weight ratio of the liquid-phase component to the polymer matrix is
preferably from 3:7 to 9:1. When the content of the liquid-phase component is
excessively low, an insufficient amount of liquid-phase component may flow into the
electrodes, failing to increase ionic conductivity of the electrodes. Conversely, when
the content of the liquid-phase component is excessively high, an excess of liquid-
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I phase component may negatively affect the process. Therefore, the weight ratio of
the liquid-phase component to the polymer matrix is more preferably from 5:5 to 8:2.
The polymer matrix may be in the form of a mixture of linear polymer and
cross-linked polymer. In this case, the weight ratio of the linear polymer to the
5 cross-linked polymer is preferably 1:9 to 8:2 although the weight ratio of the linear
polymer to the cross-linked polymer is not particularly limited so long as a
viscoelastic structure can be formed. An excessively low or high content of linear
polymer is undesirable since this reduces elasticity and degrades mechanical
properties, reducing impregnation performance of the liquid-phase component.
10 Although the types of the polymers that constitute the polymer matrix in the
present invention are not particularly limited, preferred examples of the polymers
include at least one selected from the group consisting of an oxide-based non-crosslinked
polymer, a polar non-cross-linked polymer, and a cross-linked polymer having
a three-dimensional network structure.
15 More preferably, the polymer matrix includes both an oxide-based non-crosslinked
polymer and a polar non-cross-linked polymer.
Non-limiting examples of the oxide-based non-cross-linked polymer include
at least one selected from the group consisting of poly(ethylene oxide),
polypropylene oxide), poly(oxymethylene), and poly(dimethylsiloxane).
20 Non-limiting examples of the polar non-cross-linked polymer include at least
one selected from the group consisting of polyacrylonitrile, poly(methyl
methacrylate), polyvinyl chloride), poly(vinylidene fluoride),
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poly(vinylidenefluoride-co-hexafluoropropylene), poly(ethylene imine), and poly(pphenylene
terephthalamide).
The cross-linked polymer included in the polymer matrix in the present
invention may include a polymer obtained from monomers having at least two
5 functional groups or a copolymer obtained from monomers having at least two
functional groups and polar monomers having one functional group.
Although the type of the monomers having at least two functional groups is
not particularly limited, the monomers preferably include at least one selected from
the group consisting of trimethylolpropane ethoxylate triacrylate, polyethylene glycol
10 dimethacrylate, polyethylene glycol diacrylate, divinylbenzene, polyester
dimethacrylate, divinyl ether, trimethylolpropane, trimethylolpropane trimethacrylate,
and ethoxylated bis phenol A dimethacrylate.
Although the type of the polar monomers having one functional group is not
particularly limited, the polar monomers preferably include at least one selected from
15 the group consisting of methyl methacrylate, ethyl methacrylate, butyl methacrylate,
methyl acrylate, butyl acrylate, ethylene glycol methyl ether acrylate, ethylene glycol
methyl ether methacrylate, acrylonitrile, vinyl acetate, vinyl chloride, and vinyl
fluoride.
The separation layer preferably includes 2 to 80% by weight of the solid-
20 phase component based on the weight of the polymer matrix. When the separation
layer includes less than 2% by weight of the solid-phase component based on the
weight of the polymer matrix, disadvantageous^, the effects of supporting the
separation layer, for example, mechanical strength of the separation layer, may be
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insufficient. When the separation layer includes more than 80% by weight of the
solid-phase component based on the weight of the polymer matrix, disadvantageous^,
ionic conductivity may be decreased, reducing battery performance, and brittleness
may occur during charge/discharge due to high rigidity. Therefore, the separation
5 layer more preferably includes 20 to 50% by weight of the solid-phase component
based on the weight of the polymer matrix.
Although the composition of the liquid-phase component is not particularly
limited so long as the liquid-phase component can partially flow into the electrodes,
increasing ionic conductivity of the electrodes, the liquid-phase component is
10 preferably an electrolyte containing an ionic salt.
For example, the ionic salt may include, but is not limited to, a lithium salt
and the lithium salt may include, but is not limited to, at least one selected from the
group consisting of LiCl, LiBr, Lil, LiClCU, LiBF4, LiBioClio, LiPF6, LiCF3S03,
LiCF3C02, LiAsF6, LiSbF6, LiAlCU, CH3S03Li, (CF3S02)2NLi, chloroborane lithium,
15 lower aliphatic carboxylic acid lithium, and lithium tetraphenylborate.
The electrolyte may include, but is not limited to, at least one selected from the
group consisting of ethylene carbonate, propylene carbonate, butylene carbonate,
vinylene carbonate, diethyl carbonate, dimethyl carbonate, ethyl methyl carbonate,
gamma-butyrolactone, sulfolane, methyl acetate, and methyl propionate.
20 The solid-phase component is a solid compound that is not reactive with
lithium ions and preferably includes solid-phase particles having a mean particle
diameter of 10 nm to 5 [xm. When the mean particle diameter of the solid-phase
component is too small, disadvantageously, the solid-phase component may be present
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i in the form of clusters, resulting in a failure to properly support the separation layer.
Conversely, when the mean particle diameter of the solid-phase component is too great,
• disadvantageously, the thickness of the separation layer may be greater than needed.
Therefore, the mean particle diameter of the solid-phase component is more preferably
5 50 nm to 200 nm.
In a preferred embodiment, the solid compound may include, but is not limited
to, at least one selected from the group consisting of an oxide, a nitride, and a carbide
that are not reactive with lithium ions.
Preferred examples of the oxide that is not reactive with lithium ions may
10 include, without being limited to, at least one selected from the group consisting of
MgO, Ti02 (rutile) and A1203.
In the electrode assembly of the present invention, the cathode may be
produced, for example, by adding a cathode mix including a cathode active material to a
solvent such as NMP to prepare a slurry and applying the slurry to a cathode current
15 collector, followed by drying. Optionally, the cathode mix may further include a
binder, a conductive material, a filler, a viscosity controller, and an adhesion promoter.
The cathode current collector is generally manufactured to a thickness of 3 to
500 urn. Any cathode current collector may be used without particular limitation so
long as high conductivity is provided without causing chemical changes in the battery.
20 Examples of the cathode current collector include stainless steel, aluminum, nickel,
titanium, sintered carbon, or aluminum or stainless steel surface-treated with carbon,
nickel, titanium or silver. Similar to the anode current collector, the cathode current
collector may include fine irregularities on the surface thereof so as to enhance adhesion
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to the cathode active material. In addition, the cathode current collector may be used
in various forms such as a film, a sheet, a foil, a net, a porous structure, a foam and a
nonwoven fabric.
The cathode active material is a lithium transition metal oxide including two or
5 more transition metals as a substance that causes electrochemical reaction, and
examples thereof include, but are not limited to, layered compounds such as lithium
cobalt oxide (IJC0O2) or lithium nickel oxide (LiNiC^) substituted by one or more
transition metals, lithium manganese oxide substituted by one or more transition metals,
lithium nickel-based oxides represented by the formula LiNii-yMy02 (in which M=Co,
10 Mn, Al, Cu, Fe, Mg. B, Cr, Zn or Ga, the lithium nickel-based oxide including at least
one of the elements, and 0.01 I
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15 A mixture of an organic electrolyte of 1M LiPF6 in EC:DEC (1:1), PEO,
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PEGDMA, and AI2O3 in a weight ratio of 76:15.4:6.6:2 was prepared and benzoin was I
added as a UV initiator in an amount of 3% by weight relative to PEGDMA to prepare a
precursor of a 3-phase separation layer. The precursor was coated on a glass plate,
which was then irradiated with ultraviolet light for 1 minute to produce a 3-phase
20 separation layer through photopolymerization.
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A mixture of an organic electrolyte of 1M LiPF6 in ECrDEC (1:1), PVdFHFPPVdF-
HFP, and AI2O3 in a weight ratio of 76:22:2 was prepared, acetone was
added as a solvent in an amount of 20% by weight relative to the total weight, and the
mixture was homogenized. The mixture was then casted onto a glass plate and acetone
5 was evaporated for 10 hours under an argon gas atmosphere in a glove box to produce a
solid electrolyte membrane.
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Experimental Example 1>
Ionic conductivity and tensile strength were measured for each of the 3-phase j
10 separation layer of Example 1 and the solid electrolyte membrane of Comparative Example 1.
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As a result, Example 1 and Comparative Example 1 exhibited similar levels of I
ionic conductivity of 1.2 mS/cm and 1.7 mS/cm. On the other hand, as can be seen
from FIG. 3, the measurement results of tensile strength showed that the tensile strength }
15 of the 3-phase separation layer of Example 1 having a viscoelastic structure was greatly
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improved over that of the solid electrolyte membrane of Comparative Example 1.
Graphite, PVdF and carbon black were added to N-methyl-pyrrolidinone to
20 prepare a slurry and the slurry was applied to a Cu foil. The slurry-applied Cu foil was ;
then dried for 2 hours at about 130°C to prepare an anode. In addition,
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Li(NiMnCo)02/LiMn02, PVdF and carbon black were added to N-methyl-pyrrolidinone
to prepare a slurry and the slurry was applied to a Cu foil. The slurry-applied Cu foil
was then dried for 2 hours at about 130°C to prepare a cathode.
The 3-phase separation layer precursor of Example 1 was coated on the anode,
5 which was then irradiated with ultraviolet light for 1 minute to produce a 3-phase
separation layer through photopolymerization.
The cathode was placed on the anode coated with the 3-phase separation layer,
followed by lamination to prepare an integrated electrode assembly. The integrated
electrode assembly was then inserted into a pouch without an impregnation process to
10 fabricate a secondary battery. *
A polyolefin-based separator was placed between the anode and cathode of
Example 2, which was then inserted into a pouch. An electrolyte of 1M LiPF6 in
15 EC:DEC (1:1) was then introduced into the pouch to fabricate a secondary battery.
Experimental Example 2>
The secondary batteries of Example 2 and Comparative Example 2 were
charged in a constant current (CC) mode at a current density of 0.1 C to 4.2 V and were '
20 then maintained in a constant voltage (CV) mode at 4.2 V and charging was completed
when current density reached 0.05 C. During discharge, the secondary batteries were
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discharged in a CC mode at a current density of 0.1 C to 2.5V. Then, charge/discharge
was repeated 50 times under the same conditions as above. Results are shown in FIG.
4.
It can be seen from FIG. 4 that the secondary battery of Example 2 including
5 the integrated electrode assembly employing the 3-phase separation layer exhibits
charge/discharge properties similar to the secondary battery of Comparative Example 2
employing the liquid electrolyte and the separator although the secondary battery of
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Example 2 has not been subjected to an impregnation process. Therefore, the
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secondary battery of Example 2 is free from the problem of poor impregnation of
10 electrolyte which has been pointed out as a problem of the solid electrolyte.
[INDUSTRIAL APPLICABILITY]
As is apparent from the above description, an integrated electrode assembly
according to the present invention has an advantage in that it is possible to prevent
short-circuiting due to separator contraction. In addition, electrolyte is impregnated
15 into the electrodes during preparation of the electrode assembly. Therefore, it is
possible to greatly alleviate the problem of increased process time and the problem of '
non-uniform electrodes associated with wetting., It is also possible to improve ionic
conductivity of the electrodes.
It will be apparent to those skilled in the art that various applications and
20 modifications can be made based on the above description without departing from the
scope of the invention.
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[CLAIMS]
[Claim 1 ] An integrated electrode assembly comprising a cathode, an anode, and
a separation layer integrated between the cathode and the anode, the separation layer
comprising 3 phases comprising: I
5 a liquid-phase component containing an ionic salt, the liquid-phase component
partially flowing from the separation layer into the cathode and the anode during
preparation of the integrated electrode assembly to increase ionic conductivity of the
cathode and the anode;
a solid-phase component supporting the separation layer between the cathode
10 and the anode; and
a polymer matrix having affinity for the liquid-phase component and providing
binding force with the cathode and the anode.
[Claim 2] The integrated electrode assembly according to claim 1, wherein a
weight ratio of the liquid-phase component to the polymer matrix is from 3:7 to 9:1.
15 [Claim 3] The integrated electrode assembly according to claim 1, wherein the
polymer matrix comprises at least one selected from the group consisting of an oxide- [
based non-cross-linked polymer, a polar non-cross-linked polymer, and a cross-linked
polymer having a three-dimensional network structure.
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[Claim 4] The integrated electrode assembly according to claim 3, wherein the
oxide-based non-cross-linked polymer comprises at least one selected from the group
consisting of poly(ethylene oxide), poly(propylene oxide), poly(oxymethylene), and
poly(dimethylsiloxane).
5 [Claim 5] The integrated electrode assembly according to claim 3, wherein the
polar non-cross-linked polymer comprises at least one selected from the group
consisting of polyacrylonitrile, poly(methyl methacrylate), poly(vinyl chloride),
poly(vinylidene fluoride), poly(vinylidenefluoride-co-hexafluoropropylene),
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poly(ethylene imine), and poly(p-phenylene terephthalamide). j
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10 [Claim 6] The integrated electrode assembly according to claim 3, wherein the '
cross-linked polymer comprises a polymer obtained from monomers having at least i
two functional groups or a copolymer obtained from monomers having at least two
functional groups and polar monomers having one functional group. [Claim 7] The integrated electrode assembly according to claim 6, wherein the
I
15 monomers having at least two functional groups comprise at least one selected from
the group consisting of trimethylolpropane ethoxylate triacrylate, polyethylene glycol
dimethacrylate, polyethylene glycol diacrylate, divinylbenzene, polyester
dimethacrylate, divinyl ether, trimethylolpropane, trimethylolpropane trimethacrylate,
and ethoxylated bis phenol A dimethacrylate. .
20 [Claim 8] The integrated electrode assembly according to claim 6, wherein the
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polar monomers having one functional ..group comprise at least one selected from the
group consisting of methyl methacrylate, ethyl methacrylate, butyl methacrylate,
methyl acrylate, butyl acrylate, ethylene glycol methyl ether acrylate, ethylene glycol
methyl ether methacrylate, acrylonitrile, vinyl acetate, vinyl chloride, and vinyl
5 fluoride.
[Claim 9] The integrated electrode assembly according to claim 1, wherein the
separation layer comprises 2 to 80% by weight of the solid-phase component based on
the weight of the polymer matrix.
[Claim 10] The integrated electrode assembly according to claim 1, wherein the
10 liquid-phase component is an electrolyte containing an ionic salt.
[Claim l l ] The integrated electrode assembly according to claim 10, wherein
the ionic salt is a lithium salt.
[Claim 12] The integrated electrode assembly according to claim 11, wherein
the lithium salt comprises at least one selected from the group consisting of LiCl,
15 LiBr, Lil, LiC104, LiBF4, LiBioClio, LiPF6, L1CF3SO3, LiCF3C02, LiAsF6, LiSbF6,
LiAlCU, CH3S03Li, (CF3S02)2NLi, chloroborane lithium, lower aliphatic carboxylic
acid lithium, and lithium tetraphenylborate.
[Claim 13] The integrated electrode assembly according to claim 10, wherein
the electrolyte comprises at least one selected from the group consisting of ethylene
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carbonate, propylene carbonate, butylene carbonate, vinylene carbonate, diethyl
carbonate, dimethyl carbonate, ethyl methyl carbonate, gamma-butyrolactone, sulfolane,
methyl acetate, and methyl propionate.
[Claim 14l The integrated electrode assembly according to claim 1, wherein the
5 solid-phase component is a solid compound that is not reactive with lithium ions and
comprises solid-phase particles having a mean particle diameter of 10 nm to 5 urn.
[Claim 15] The integrated electrode assembly according to claim 14, wherein
the solid compound comprises at least one selected from the group consisting of an
oxide, a nitride, and a carbide that are not reactive with lithium ions.
10 [Claim 16] The integrated electrode assembly according to claim 15, wherein
the oxide that is not reactive with lithium ions comprises at least one selected from the
group consisting of MgO, Ti02 (rutile) and AI2O3.
[Claim 17] A method for preparing the integrated electrode assembly according
to claim 1, the method comprising:
15 (1) homogenizing a linear polymer, monomers for a cross-linked polymer, a
liquid-phase component comprising an ionic salt, a solid-phase component, and a
polymerization initiator into a mixture;
(2) coating the mixture on one electrode;
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(3) inducing polymerization reaction through UV irradiation or heating to form
a separation layer; and
(4) placing a counter electrode on the separation layer, followed by pressing.
[Claim 18] A lithium secondary battery comprising the integrated electrode
5 assembly according to any one of claims 1 to 16.
[Claim 19] A battery module comprising the lithium secondary battery
according to claim 18 as a unit battery.
[Claim 20] A battery pack comprising the battery module according to claim 19.
[Claim 21] The battery pack according to claim 20, wherein the battery pack is
10 used as a power source of a middle or large-sized device.
[Claim 22] The battery pack according to claim 21, wherein the middle or largesized
device is an electric vehicle, a hybrid electric vehicle, a plug-in hybrid electric
vehicle, or a power storage system-