Specification
TECHNICAL FIELD
[0001] The invention relates to a positive electrode for a secondary
battery having a positive electrode active material layer containing a positive electrode active material and a positive electrode conductive agent, and to a secondary battery using the same.
BACKGROUND ART
[0002] Recently, portable electronic devices such as video cameras,
digital still cameras, cellular phones, and lap-top computers have spread
widely, resulting in a strong demand for these electronic devices with a small
size, a lightweight, and a long-life. A development of a battery as a power
supply, especially a small and lightweight secondary battery capable of
achieving a high energy density is in progress accordingly.
[0003] In particular, expectations are very high for secondary batteries
such as a lithium ion secondary battery that utilizes storage and release of
lithium ions for a charge-discharge reaction, and a lithium metal secondary
battery that utilizes deposition and dissolution of a lithium metal. One
reason is that these make it possible to achieve a higher energy density than
that achieved by a lead acid battery and a nickel-cadmium battery.
[0004] In recent years, advantages as being lightweight and high in
energy density are suitable for applications in vehicles such as electric
vehicles and hybrid electric vehicles, and thus research activities aiming for
larger size and higher power of the secondary batteries are actively performed
as well.
[0005] A secondary battery includes a positive electrode and a negative
electrode together with an electrolyte. The positive electrode has a positive
electrode active material layer on a positive electrode current collector. The
positive electrode active material layer contains a positive electrode active
material that contributes to a charge-discharge reaction.
[0006] Lithium-cobalt-based composite oxides such as a lithium cobalt
oxide (LiCoO2) are widely used as the positive electrode active material.
However, it has disadvantages in terms of such as price and supply. Thus,
lithium-manganese-based composite oxides which are low in price and low in
supply instability are used as well.
[0007] In particular, a lithium manganate (LiMn2O4), which has a spinel
structure and in which an operating voltage is about 4 V on a lithium metal
basis, is low in cost and excellent in safety, which is thus put into practical
use gradually in applications such as an electric tool application. Further,
expectations are also high for applications in vehicles.
[0008] On the other hand, a lithium-manganese-based composite oxide of
a high-voltage operation type, which has a spinel structure and in which an
operating voltage is 4.5 V or more on the lithium metal basis, is under review
in order to realize even more higher energy density. The
lithium-manganese-based composite oxide can be that which has, in addition
to manganese, other transition metal element, and a general expression thereof
is expressed by LiMxMn2-xO4 (where M is at least one kind of the transition
metal elements other than manganese, and x is 0 < x < 1). The
lithium-manganese-based composite oxide makes it possible to perform the
charge-discharge reaction at a higher voltage as compared to normal, resulting
in the higher energy density. Further, having the spinel structure allows
oxygen to be less likely to be released even at a high temperature. Thereby,
it is possible to achieve both the high energy density and the high safety at the
same time.
[0009] Incidentally, when an oxide having a lower conductivity than that
of a metal is used as the positive electrode active material, that oxide is mixed
with a positive electrode conductive agent such as a carbon material which is
high in conductivity. Generally, in this case, the positive electrode active
material and the positive electrode conductive agent are dispersed such as in a
solvent, in addition to a binder such as a polymer material, to provide slurry,
following which the resultant is coated on the positive electrode current
collector to form the positive electrode active material layer.
[0010] Materials such as amorphous carbon materials and crystalline
carbon materials are used as the positive electrode conductive agent, which are mixed on an as-needed basis. In a case of the amorphous carbon materials, the conductivity tends to become high since the contact area between particles increases when the specific surface area is increased. On the other hand, in a case of the crystalline carbon materials, the conductivity tends to become high when the crystallinity becomes high. [0011] Various proposals have been made for specific examples where a carbon material is used as the positive electrode conductive agent. For example, carbon black and black lead are used in combination as the positive electrode conductive agent, in order to improve properties such as a preservation property (for example, see Patent Document 1). To improve charge-discharge cycle characteristics under a high temperature environment, a 5 V-class lithium-manganese composite oxide is used as the positive electrode active material, and acetylene black and black lead are used as the positive electrode conductive agent (for example, see Patent Document 2). To improve high temperature cycle characteristics, a lithium-manganese composite oxide having a noble potential higher than 4.4 V to a potential of a lithium metal is used as the positive electrode active material, and a carbon material in which an interplanar spacing for lattice plane (002) is between 0.344 nm and 0.352 nm both inclusive is used as the positive electrode conductive agent (for example, see Patent Document 3). Incidentally, other than the carbon material, a metal nitride or a metal oxide is also used as the positive electrode conductive agent (for example, see Patent Document 4).
PRIOR ART DOCUMENT
PATENT DOCUMENT [0012]
Patent Document 1: Japanese Unexamined Patent Application Publication No. H11-283628
Patent Document 2: Japanese Unexamined Patent Application Publication No. 2003-257482
Patent Document 3: Japanese Unexamined Patent Application Publication No. 2006-066341
Patent Document 4: Japanese Unexamined Patent Application Publication No. 2003-142101
SUMMARY OF THE INVENTION
[0013] In the past, an operating voltage of a positive electrode active
material is 4.3 V or less on a lithium metal basis, and thus a carbon material
used as a positive electrode conductive agent is electrochemically inactive
during charging.
[0014] However, when the operating voltage is 4.5 V or over, an
unintended phenomenon occurs in which an anion is inserted between layers
of a crystalline carbon material during the charging and the anion is detached
from the layers during discharging. This anion is a hexafluorophosphate ion
(PF6-) when an electrolyte salt contained in an electrolyte is lithium
hexafluorophosphate (LiPF6). In this case, the crystalline carbon material
repeats expansion and contraction during charging and discharging, by which
the positive electrode active material layer is likely to be detached from a
positive electrode current collector. This consequently lowers
charge-discharge characteristics such as an initial efficiency and cycle
characteristics.
[0015] Incidentally, a measure may be contemplated in which only an
amorphous carbon material having no definite layer structure is used for the
positive electrode conductive agent, in order to solve the issue discussed
above. In this case, the unintended insertion and detachment of the anions
do not occur, which means that the expansion and the contraction caused
thereby do not occur. However, since the specific surface area of the
amorphous carbon material has to be increased in order to obtain high
conductivity about the same level as that obtained by using the crystalline
carbon material, it is necessary to increase an amount of the amorphous
carbon material. In this case, when the amount of the amorphous carbon
material is excessive, a decomposing reaction of the electrolyte is likely to
occur easily at the operating voltage of around 5 V, which, after all, results in
the degradation of the charge-discharge characteristics.
[0016] The invention has been made in view of such problems, and an
object thereof is to provide a positive electrode for a secondary battery
capable of improving charge-discharge characteristics, and a secondary
battery.
[0017] A positive electrode for a secondary battery according to one
embodiment of the invention includes a positive electrode active material
layer having a positive electrode active material and a positive electrode
conductive agent. An operating voltage of the positive electrode active
material is equal to or more than 4.5 V on a lithium metal basis. The positive
electrode conductive agent contains an amorphous carbon material and a
crystalline carbon material. In particular, as for the amorphous carbon
material, a specific surface area lies between 50 m2/g and 100 m2/g both
inclusive and a content in the positive electrode active material layer lies
between 0.5 mass% and 5 mass% both inclusive. As for the crystalline
carbon material, an interplanar spacing for lattice plane (002) is equal to or
more than 0.340 nm when measured by an X-ray diffraction method, a specific
surface area lies between 1 m2/g to 5 m2/g both inclusive, and a content in the
positive electrode active material layer lies between 0.5 mass% to 5 mass%
both inclusive. Also, a secondary battery according to one embodiment of the invention includes: a positive electrode including a positive electrode active material layer having a positive electrode active material and a positive electrode conductive agent; a negative electrode; and an electrolyte containing an electrolyte salt and a solvent. The positive electrode has a configuration similar to that of the positive electrode for the secondary battery described above.
[0018] In the positive electrode for the secondary battery or the secondary
battery according to one embodiment of the invention, the interplanar spacing, the specific surface area, and the content of the amorphous carbon material as well as the specific surface area and the content of the crystalline carbon material, each serving as the positive electrode conductive agent, are so normalized as to be in predetermined ranges, respectively. Thus, even when the positive electrode material of a high-voltage operation type is used to repeat an electrode reaction (charge/discharge), detachment of the positive electrode active material layer caused by expansion and contraction is less likely to occur. Further, a conductivity of the positive electrode active material layer increases, and a decomposing reaction of the electrolyte is suppressed.
[0019] According to the positive electrode for the secondary battery of one embodiment of the invention, the positive electrode active material of the high-voltage operation type is used, and the interplanar spacing, the specific surface area, and the content of the positive electrode conductive agent (the amorphous carbon material and the crystalline carbon material) are so normalized as to be in predetermined ranges. Therefore, according to the secondary battery that uses the positive electrode for the secondary battery of one embodiment of the invention, it is possible to improve the charge-discharge characteristics.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020]
[FIG. 1] A cross-sectional view illustrating a configuration of a first secondary
battery (a cylinder type) according to one embodiment of the invention.
[FIG. 2] A cross-sectional view illustrating a part of a coiled electrode body
shown in FIG. 1 in an enlarged fashion.
[FIG. 3] A plain view illustrating configurations of a positive electrode and a
negative electrode shown in FIG. 2.
[FIG. 4] An exploded perspective view illustrating a configuration of a second
secondary battery (a laminate film type) according to one embodiment of the
invention.
[FIG. 5] A cross-sectional view illustrating a configuration of the coiled
electrode body shown in FIG. 4 taken along a line V-V.
[FIG. 6] A cross-sectional view illustrating a configuration of a secondary
battery (a coin type) fabricated in Examples.
MODE FOR CARRYING OUT THE INVENTION
[0021] An embodiment of the invention will be described in detail below
with reference to drawings. The order of description is as follows.
1. First secondary battery (lithium ion secondary battery: cylinder type)
2. Second secondary battery (lithium ion secondary battery: laminate film type)
3. Third secondary battery (lithium-metal secondary battery)
[1. First Secondary Battery (Lithium Ion Secondary Battery: Cylinder Type)]
[0022] First, a first secondary battery according to an embodiment of the
invention will be described. FIGs. 1, 2, and 3 illustrate a cross-sectional
configuration of the secondary battery, a part of a coiled electrode body 20
shown in FIG. 1, and planer configurations of a positive electrode 21 and a
negative electrode 22 shown in FIG. 2, respectively. It is to be noted that a
positive electrode for a secondary battery according to the invention is used as
the positive electrode 21 of the secondary battery described herein.
[Overall Configuration of Secondary Battery]
[0023] This secondary battery is a lithium ion secondary battery in which
a capacity of the negative electrode 22 is expressed by storage and release of
lithium ions which are electrode reacting substances. As shown in FIG. 1,
the coiled electrode body 20 and a pair of insulating plates 12 and 13 are
accommodated in a battery can 11 having substantially a hollow cylindrical
shape.
[0024] The battery can 11 may have, for example, a hollow structure in
which one end is closed and the other end is opened, and may be configured
by a metallic material such as iron (Fe), aluminum (Al), and an alloy thereof.
A surface of the battery can 11 may be plated such as with nickel (Ni). The
pair of insulating plates 12 and 13 are so disposed as to sandwich the coiled
electrode body 20 from above and below, and as to extend vertically relative
to a coiled peripheral surface thereof.
[0025] A battery cover 14 may be configured by a material similar to that
of the battery can 11, for example. The battery cover 14, a safety valve
mechanism 15, and a thermosensitive resistor device (Positive Temperature
Coefficient: PTC device) 16 are swaged via a gasket 17 to the opened end of
the battery can 11. The inside of the battery can 11 is sealed. The safety
valve mechanism 15 and the thermosensitive resistor device 16 are provided at
an inner side of the battery cover 14. The safety valve mechanism 15 is
electrically connected to the battery cover 14 through the thermosensitive
resistor device 16. In the safety valve mechanism 15, a disk plate 15A
reverses to disconnect the electrical connection between the battery cover 14
and the coiled electrode body 20, when an internal pressure is equal to or
exceeds a certain level due to such as an internal short-circuit or heating from
the outside. The thermosensitive resistor device 16, since the resistance
increases (limits a current) according to an increase in temperature, is
configured to prevent abnormal heat generation caused by a large current.
The gasket 17 may be configured by an insulating material, and a surface
thereof may be coated with asphalt, for example.
[0026] As shown in FIG. 2, the coiled electrode body 20 is that in which
the positive electrode 21 and the negative electrode 22 are laminated with a
separator 23 in between and are coiled, and the center thereof may be inserted
with a center pin 24. The positive electrode 21 is connected with a positive
electrode lead 25 configured by a metallic material such as aluminum, and the
negative electrode 22 is connected with a negative electrode lead 26
configured by a metallic material such as nickel. The positive electrode lead
25 is electrically connected to the battery cover 14 by such as being welded to
the safety valve mechanism 15, and the negative electrode lead 26 is
electrically connected to the battery can 11 by such as being welded thereto.
[Positive Electrode]
[0027] The positive electrode 21 may be that in which a positive electrode
active material layer 21B is provided on both sides of a positive electrode
current collector 21 A, for example. However, the positive electrode active
material layer 21B may be provided only on one side of the positive electrode
current collector 21 A.
[0028] The positive electrode current collector 21A may be configured by
a metallic material such as aluminum, for example. The positive electrode
active material layer 21B includes a positive electrode active material and a
positive electrode conductive agent. The positive electrode active material
is any one or two or more kinds of positive electrode materials capable of
storing and releasing the lithium ions. However, the positive electrode
active material layer 21B may include other materials such as a positive
electrode binder on an as-needed basis.
[0029] An operating voltage of the positive electrode material is equal to
or more than 4.5 V on a lithium metal basis. One reason is that the lithium
ions are stored and released at a high voltage and thus an energy density
becomes high. Such positive electrode material (hereinafter referred to as a
"high-voltage operating positive electrode material") is not particularly
limited. However, in particular, a material such as a
lithium-manganese-based composite oxide having a spinel structure and a
lithium-cobalt-phosphate compound (LiCoP04) having an olivine structure is
preferable, in which a chemical formula of the lithium-manganese-based
composite oxide is expressed by the following formula (1). One reason
thereof is that it is readily available, and a sufficient energy density can be
obtained.
[0030]
LiMxMn2-xO4 (1)
(where M is at least one kind of nickel, cobalt (Co), iron, chromium (Cr), and
copper (Cu), and x is 0 < x < 1).
[0031] Specific examples of the lithium-manganese-based composite
oxide can be such as a lithium-nickel-manganese composite oxide
(LiNixMn2-xO4) and a lithium-chromium-manganese composite oxide
(LiCrxMn2-xO4), and, more specifically, can be such as LiNi0.5Mn1.5O4,
LiNi0.4Mn1.6O4, LiNi0.3Mn1.7O4, and LiCr0.5Mn1.5O4, for example.
[0032] It is to be noted that the positive electrode active material layer
2IB, as long as the high-voltage operating positive electrode material is
included therein as the positive electrode active material, may include other
positive electrode material in addition thereto. As other positive electrode
material, a lithium-containing compound (except for that which corresponds
to the high-voltage operating positive electrode material) is preferable, since a
high energy density can be obtained. The lithium-containing compound can
be such as a composite oxide having lithium (Li) and a transition metal
element as constituent elements, and a phosphate compound having lithium
and a transition metal element as constituent elements, for example. In
particular, the one having at least one kind of cobalt, nickel, manganese, and
iron as the transition metal element is preferable, since a higher energy
density can be obtained. A chemical formula thereof may be expressed by
LixM1O2 or LiyM2PO4, for example, where Ml and M2 are one or more kinds
of transition metal elements. Values of x and y vary according to a
charging-discharging state, which are normally 0.05 < x < 1.10 and 0.05 < y <
1.10, respectively.
[0033] The composite oxide having lithium and the transition metal
element can be such as lithium cobaltate (LixCoO2), lithium nickel oxide
(LixNiO2), and a lithium-nickel-based composite oxide expressed by the
following formula (2), for example. Also, the phosphate compound having
lithium and the transition metal element can be such as a lithium-iron
phosphate compound (LiFePO4) and a lithium-iron-manganese phosphate
compound (LiFe1-uMnuPO4 (u 30) such as ethylene
carbonate and propylene carbonate; and a low viscosity solvent (for example,
a viscosity of < 1 mPas) such as dimethyl carbonate, ethylmethyl carbonate,
and diethyl carbonate, is more preferable. One reason is that a dissociating
property of the electrolyte salt and a mobility of ions are improved.
[0074] Incidentally, the solvent may include one or two or more kinds of
chain halogenated carbonate esters and cyclic halogenated carbonate esters.
One reason is that, since a stable protective film is formed on the surface of
the negative electrode 22 during charging and discharging, the decomposing
reaction of the electrolyte is suppressed. Note that the term "halogenated"
means that at least a part of hydrogen is substituted by halogen. The chain
halogenated carbonate ester can be such as fluoromethylmethyl carbonate,
bis(fluoromethyl) carbonate, and difluoromethylmethyl carbonate, for
example. The cyclic halogenated carbonate ester can be such as
4-fluoro-l,3-dioxolane-2-one and 4,5-difluoro-l,3-dioxolane-2-one, for
example. Note that the cyclic halogenated carbonate ester includes a
geometric isomer as well. The contents of the chain halogenated carbonate
ester and the cyclic halogenated carbonate ester in the solvent are equal to or
more than 0.01 weight% and equal to or less than 50 weight%, for example.
[0075] Also, the solvent may include a cyclic carbonate ester having an
unsaturated carbon bond. One reason is that, since a stable protective film is
formed on the surface of the negative electrode 22 during charging and
discharging, the decomposing reaction of the electrolyte is suppressed. The
cyclic carbonate ester having the unsaturated carbon bond can be such as
vinylene carbonate and vinylethylene carbonate, for example, and the content
thereof in the solvent is equal to or more than 0.01 weight% and equal to or
less than 10 weight%, for example.
[0076] Further, the solvent may include a sultone (cyclic sulfonate ester)
or an acid anhydride. One reason is that a chemical stability of the
electrolyte is improved. The sultone can be such as propane sultone and
propene sultone, for example, and the content thereof in the solvent is equal to
or more than 0.5 weight% and equal to or less than 5 weight%, for example.
The acid anhydride can be such as a carboxylic acid anhydride, a disulfonic
acid anhydride, and a carboxylic acid sulfonic acid anhydride, for example.
The carboxylic acid anhydride can be such as a succinic anhydride, a glutaric
anhydride, and a maleic acid anhydride, for example. The disulfonic acid
anhydride can be such as an ethane disulfonic acid anhydride and a propane
disulfonic acid anhydride, for example. The carboxylic acid sulfonic acid
anhydride can be such as a sulfobenzoic acid anhydride, a sulfopropionic acid
anhydride, and a sulfobutyric acid anhydride, for example. The content of
the acid anhydride in the solvent is equal to or more than 0.5 weight% and
equal to or less than 5 weight%.
[0077] The electrolyte salt may include any one or two or more kinds of
light metal salts such as a lithium salt, for example. A series of electrolyte
salts described below may be used solely, or two or more kinds thereof may be
used in a mixed fashion.
[0078] For example, the lithium salt can be such as those as follows.
Lithium hexafluorophosphate (LiPF6), lithium tetrafluoroborate (LiBF4),
lithium perchloride (LiClO4), or lithium tetrafluoroarsenate (LiAsF6).
Lithium tetraphenylborate (LiB(C6H5)4), lithium methansulfonic acid
(LiCH3SO3), lithium trifluoromethane-sulfonic acid (LiCF3SO3), or lithium
tetrachloroaluminate (LiAlCl4). Di-lithium tetrafluorosilicate (Li2SiF6),
lithium chloride (LiCl), or lithium borate (LiBr). One reason is that the
excellent battery capacity, the cycle characteristics, and the preservation
characteristics are obtained.
[0079] In particular, one or two or more kinds of lithium
hexafluorophosphate, lithium tetrafluoroborate, lithium perchloride, and
lithium tetrafluoroarsenate are preferable. Further, in this case, at least one
of lithium hexafluorophosphate and lithium tetrafluoroborate is more
preferable, and lithium hexafluorophosphate is even more preferable. One
reason is that an internal resistance is reduced, by which a higher effect is
obtained.
[0080] It is preferable that the content of the electrolyte salt be equal to or
more than 0.3 mol/kg and equal to or less than 3.0 mol/kg for the solvent.
One reason is that a high ionic conductivity is achieved.
[Operation of Secondary Battery]
[0081] In this secondary battery, the lithium ions are released from the
positive electrode 21 and are stored in the negative electrode 22 through the
electrolyte impregnated in the separator 23 at the time of charging, for
example. On the other hand, the lithium ions are released from the negative
electrode 22 and are stored in the positive electrode 21 through the electrolyte
impregnated in the separator 23 at the time of discharging, for example.
[Manufacturing Method of Secondary Battery]
[0082] This secondary battery may be manufactured by a procedure
described below, for example.
[0083] First, the electrode 21 is fabricated. At the beginning, the
positive electrode active material and the positive electrode conductive agent
are mixed with such as the positive electrode binder on an as-needed basis to
provide a positive electrode mixture, following which the same is dispersed in
an organic solvent to provide paste-like positive electrode mixture slurry.
Then, the positive electrode mixture slurry is coated on the positive electrode
current collector 21A to form the positive electrode active material layer 21B.
Lastly, the positive electrode active material layer 21B is subjected to
compression molding by using such as a roll pressing machine, while heating
the same as necessary. In this case, the compression molding may be
repeated more than once.
[0084] Next, the negative electrode active material layer 22B is formed
on the negative electrode current collector 22A to fabricate the negative
electrode 22. In this case, a formation procedure similar to that of the
positive electrode 21 described above may be used. More specifically, a
negative electrode mixture, in which the negative electrode active material is
mixed with such as, on an as-needed basis, the negative electrode binder and
the negative electrode conductive agent, is dispersed in an organic solvent to
provide paste-like negative electrode mixture slurry, following which the
same is coated on both sides of the negative electrode current collector 22A,
and, as necessary, the compression molding is performed. Alternatively, a
formation procedure may be used which is different from that of the positive
electrode 21. More specifically, a vapor phase method such as an
evaporation method is used to deposit a negative electrode material on both
sides of the negative electrode current collector 22A.
[0085] Lastly, the positive electrode 21 and the negative electrode 22 as
well as the electrolyte are used to assemble the secondary battery. First, the
positive electrode lead 25 is connected to the positive electrode current
collector 21 A, and the negative electrode lead 26 is connected to the negative
electrode current collector 22A. Then, the positive electrode 21 and the
negative electrode 22 are laminated with the separator 23 in between and are
winded to fabricate the coiled electrode body 20, following which the center
pin 24 is inserted into the center of the winding. Then, the coiled electrode
body 20 is accommodated in the battery can 11 while sandwiching the same
with the pair of insulating plates 12 and 13. In this case, a tip of the positive
electrode lead 25 is connected to the safety valve mechanism 15, and a tip of
the negative electrode lead 26 is connected to the battery can 11. Then, the
electrolyte is injected in the battery can 11 to impregnate the same in the
separator 23. Lastly, the battery cover 14, the safety valve mechanism 15,
and the thermosensitive resistor device 16 are swaged via the gasket 17 to the
opened end of the battery can 11. Thereby, the secondary battery shown in
FIG. 1 to FIG. 3 is completed.
[0086] According to this first secondary battery, the interplanar spacing,
the specific surface area, and the content of the positive electrode conductive
agent (the amorphous carbon material and the crystalline carbon material) are
so normalized as to be in predetermined ranges, respectively, in a case where
the high-voltage operating positive electrode material is used as the positive
electrode active material. In this case, the positive electrode active material
layer 21B becomes less likely to expand and contract and is thus less likely to
be detached from the positive electrode current collector 21 A, as compared
with a case where the interplanar spacing and so forth are not normalized even
when a positive electrode active material and a positive electrode conductive
agent which are similar to those of the present embodiment are used. Further,
a conductivity of the positive electrode active material layer 21B increases,
and the decomposing reaction of the electrolyte is suppressed. Therefore, it
is possible to improve charge-discharge characteristics.
[2. Second Secondary Battery (Lithium Ion Secondary Battery: Laminate Film
Type)]
[0087] It is to be noted that the secondary battery according to the present
embodiment may be applied to that of a type other than the cylinder type.
FIG. 4 and FIG. 5 illustrate an exploded perspective configuration of the
second secondary battery and a cross-sectional configuration of a coiled
electrode body 30 shown in FIG. 4 taken along a line V-V, respectively. In
the following, description will be given on component elements of the
laminate film type, with reference to the component elements of the cylinder
type already described above as needed.
[0088] This secondary battery is a lithium ion secondary battery as in the
first secondary battery. As shown in FIG. 4, the coiled electrode body 30 is
accommodated inside of a film-like exterior member 40. The coiled
electrode body 30 is attached with a positive electrode lead 31 and a negative
electrode lead 32.
[0089] The positive electrode lead 31 and the negative electrode lead 32
may be led from the inside of the exterior member 40 to the outside in the
same direction, for example. The positive electrode lead 31 may be
configured of a metallic material such as aluminum, and the negative
electrode lead 32 may be configured of a metallic material such as copper,
nickel, and stainless steel, for example. These materials may have a shape of
a thin plate or a mesh, for example.
[0090] The exterior member 40 may be a laminate film in which a fusion
layer, a metal layer, and a surface protection layer are stacked in this order,
for example. In the laminate films, external edges in the fusion layers of the
two sheets of film are so attached to each other, such as by a fusion bonding
and an adhesive, that the fusion layers oppose the coiled electrode body 30.
The fusion layer may be a polymer film such as polyethylene and
polypropylene, for example. The metal layer may be a metal foil such as an
aluminum foil, for example. The surface protection layer may be a polymer
film such as nylon and polyethylene terephthalate, for example.
[0091] In particular, an aluminum laminate film in which a polyethylene
film, an aluminum foil, and a nylon film are stacked in this order is preferable
for the exterior member 40. However, a laminate film having other
laminated structure, a polymer film such as polypropylene, or a metal film
may be used in place of the aluminum laminate film.
[0092] A contact film 41 for preventing intrusion of the air is inserted
between the exterior member 40 and the positive electrode lead 31 and
between the exterior member 40 and the negative electrode lead 32. This
contact film 41 is configured of a material having a property of
close-attachment to the positive electrode lead 31 and to the negative
electrode lead 32. Such material can be a polyolefin resin such as
polyethylene, polypropylene, modified polyethylene, and modified
polypropylene, for example.
[0093] In the coiled electrode body 30, a positive electrode 33 and a
negative electrode 34 are laminated with a separator 35 and an electrolyte
layer 36 in between and are winded, and an outermost circumference thereof
is protected by a protective tape 37, as illustrated in FIGs. 3 and 5. In the
positive electrode 33, a positive electrode active material layer 33B is
provided on both sides of a positive electrode current collector 33A, which
have configurations similar to those of the positive electrode current collector
21A and the positive electrode active material layer 21B, for example. In the
negative electrode 34, a negative electrode active material layer 34B is
provided on both sides of a negative electrode current collector 34A, which
have configurations similar to those of the negative electrode current collector
22A and the negative electrode active material layer 22B, for example. The
separator 35 has a configuration similar to that of the separator 23.
[0094] The electrolyte layer 36 is that in which an electrolyte is retained
by a polymeric compound, and may include other material such as various
additives on an as-needed basis. The electrolyte layer 36 is in a so-called
gel-like state, which is preferable in that a high ionic conductivity (for
example, 1 mS/cm or more at the room temperature) can be obtained and that
a liquid leakage of the electrolyte is prevented.
[0095] For example, the polymer compound can be one or two or more
kinds of the following polymeric materials. Polyacrylonitrile, vinylidene
polyfluoride, polytetrafluoroethylene, polyhexafluoropropylene, polyethylene
oxide, polypropylene oxide, polyphosphazene, polysiloxane, and vinyl
polyfluoride. Vinyl polyacetate, polyvinyl alcohol, methyl polymethacrylate,
polyacrylic acid, polymethacrylic acid, styrene-butadiene rubber,
nitrile-butadiene rubber, polystyrene, and polycarbonate. A copolymer of
vinylidene fluoride and hexafluoropyrene. In particular, vinylidene
polyfluoride or the copolymer of vinylixlene fluoride and hexafluoropyrene is
preferable, since they are electrochemically stable.
[0096] The electrolyte has a composition similar to that of the electrolyte
in the first secondary battery. However, a solvent in the gel-like electrolyte
layer 36 is a broad concept that encompasses not only a solvent in a liquid
form but also a solvent having an ionic conductivity capable of dissociating an
electrolyte salt. Thus, in a case where a polymer compound having the ionic
conductivity is used, that polymer compound is encompassed as the solvent.
[0097] It is to be noted that the electrolyte may be used as it is in place of
the gel-like electrolyte layer 36 in which the electrolyte is retained by the
polymeric compound. In this case, the electrolyte is impregnated in the
separator 35.
[0098] In this secondary battery, the lithium ions are released from the
positive electrode 33 and are stored in the negative electrode 34 through the
electrolyte layer 36 at the time of charging, for example. On the other hand,
the lithium ions are released from the negative electrode 34 and are stored in
the positive electrode 33 through the electrolyte layer 36 at the time of
discharging, for example.
[0099] The secondary battery provided with the gel-like electrolyte layer
36 may be manufactured by three types of procedures described below, for
example.
[0100] In a first manufacturing method, the positive electrode 33 and the
negative electrode 34 are fabricated first by a procedure similar to that of the
positive electrode 21 and the negative electrode 22. More specifically, the
positive electrode active material layer 33B is formed on the positive
electrode current collector 33A to fabricate the positive electrode 33, and the
negative electrode active material layer 34B is formed on the negative
electrode current collector 34A to fabricate the negative electrode 34. Then,
a precursor solution containing the electrolyte, the polymer compound, and
the solvent is prepared and is coated on the positive electrode 33 and the
negative electrode 34, following which the solvent is evaporated to form the
gel-like electrolyte layer 36. Then, the positive electrode lead 31 is
connected to the positive electrode current collector 33A, and the negative
electrode lead 32 is connected to the negative electrode current collector 34A.
Then, the positive electrode 33 and the negative electrode 34 formed with the
electrolyte layer 36 are laminated with the separator 35 in between and are
winded, following which the protective tape 37 is adhered to the outermost
circumference thereof to thereby fabricate the coiled electrode body 30.
Lastly, the coiled electrode body 30 is sandwiched between the two sheets of
film-like exterior member 40, following which external edges of the exterior
members 40 are adhered to each other such as by a thermal fusion bonding to
seal the coiled electrode body 30. At this time, the contact film 41 is
inserted between the positive electrode lead 31 and the exterior member 40
and between the negative electrode lead 32 and the exterior member 40.
Thereby, the secondary battery shown in FIG. 4 and FIG. 5 is completed.
[0101] In a second manufacturing method, first, the positive electrode
lead 31 is connected to the positive electrode 33 and the negative electrode
lead 32 is connected to the negative electrode 34. Then, the positive
electrode 33 and the negative electrode 34 are laminated with the separator 35
in between and are winded, following which the protective tape 37 is adhered
to the outermost circumference thereof to thereby fabricate a coiled body as a
precursor of the coiled electrode body 30. Then, the coiled body is
sandwiched between the two sheets of film-like exterior member 40,
following which, excluding an outer circumferential edge on one side thereof,
remaining outer circumferential edges thereof are adhered such as by a
thermal fusion bonding to accommodate the coiled body inside the bag-like
exterior member 40. Then, an electrolyte composition containing: the
electrolyte; a monomer as a raw material of the polymer compound; a
polymerization initiator; and other material such as a polymerization inhibitor
where necessary, is prepared to inject the same into inside of the bag-like
exterior member 40, following which an opening of the exterior member 40 is
sealed such as by a thermal fusion bonding. Lastly, the monomer is
subjected to thermal polymerization to provide the polymer compound to
thereby form the gel-like electrolyte layer 36. Thus, the secondary battery is
completed.
[0102] In a third manufacturing method, the coiled body is formed first to
accommodate the same into inside of the bag-like exterior member 40 as in the
second manufacturing method, except for the use of the separator 35 in which
the polymer compound is coated on both sides thereof. The polymer
compound to be coated on the separator 35 can be, for example, a polymer
(such as homopolymer, copolymer, and multi-copolymer) having vinylidene
fluoride as the component, and, more specifically, can be such as: vinylidene
polyfluoride; a binary copolymer having vinylidene fluoride and
hexafluoropropylene as the components; and a ternary copolymer having
vinylidene fluoride, hexafluoropropylene, and chrorotrifluoroethylene as the
components. Note that the polymer compound may include, in addition to
the polymer having vinylidene fluoride as the component described above,
other one or two or more kinds of polymer compounds. Then, the electrolyte
is prepared to inject the same into inside of the exterior member 40, following
which an opening of the exterior member 40 is sealed such as by a thermal
fusion bonding. Lastly, the exterior member 40 is heated while a weight is
imposed thereon to closely attach the separator 35 to the positive electrode 33
and to the negative electrode 34 via the polymer compound. Thereby, the
electrolyte is impregnated in the polymer compound, and that polymer
compound is gelled to form the electrolyte layer 36. Thus, the secondary
battery is completed.
[0103] In the third manufacturing method, an battery expansion is
suppressed more than in the first manufacturing method. Also, the monomer
as a raw material of the polymer compound, the solvent, or the like hardly
remains in the electrolyte layer 36 as compared with the second manufacturing
method. Thus, a formation step of the polymer compound is well controlled.
Hence, a sufficient property of close-attachment is obtained between the
positive electrode 33 and the electrolytic layer 36, between the negative
electrode 34 and the electrolytic layer 36, and between the separator 35 and
the electrolytic layer 36.
[0104] According to the second secondary battery, the positive electrode
active material layer 33B has the configuration similar to that of the positive
electrode active material layer 21B. Therefore, it is possible to improve
charge-discharge characteristics for a reason similar to that of the first
secondary battery.
[3. Third Secondary Battery (Lithium Metal Secondary Battery)]
[0105] It is to be noted that the secondary battery according to the present
embodiment may be applied to a lithium metal secondary battery in which a
capacity of the negative electrode 22 is expressed by deposition and
dissolution of a lithium metal. A third secondary battery has a configuration
similar to that of the first secondary battery and is manufactured by a
procedure similar thereto, except that the negative electrode active material
layer 22B is configured by a lithium metal.
[0106] This secondary battery uses a lithium metal as a negative electrode
active material, to thereby make it possible to achieve a high energy density.
The negative electrode active material layer 22B may be present already from
the time of assembly. However, the negative electrode active material layer
may not be present at the time of the assembly, and may be formed by a
lithium metal deposited at the time of charging. Also, the negative electrode
active material layer 22B may be used also as a current collector to eliminate
the negative electrode current collector 22A.
[0107] In this secondary battery, the lithium ions are released from the
positive electrode 21, and are deposited as the lithium metal on a surface of
the negative electrode current collector 22A through the electrolyte
impregnated in the separator 23 at the time of charging, for example. On the
other hand, the lithium metal is eluted as the lithium ions from the negative
electrode active material layer 22B, which are stored in the positive electrode
21 through the electrolyte impregnated in the separator 23 at the time of
discharging, for example.
[0108] According to the third secondary battery, the positive electrode
active material layer 33B has the configuration similar to that of the positive
electrode active material layer 21B as well. Therefore, it is possible to
improve charge-discharge characteristics for a reason similar to that of the
first secondary battery. As a matter of course, the third secondary battery is
not limited to the cylinder type described for the first secondary battery, and
may be applied to the laminate film type described for the second secondary
battery.
EXAMPLES
[0109] Next, Examples of the invention will be described in detail.
(Experiment Examples 1-1 to 1-20)
[0110] A coin-type lithium metal secondary battery shown in FIG. 6 was
fabricated by a procedure described below. This secondary battery is that in
which an exterior can 54 accommodating therein a positive electrode 51 and
an exterior cup 55 accommodating therein a negative electrode 52 are swaged
through a separator 53 and a gasket 56.
[0111] First, the positive electrode 51 was fabricated. At the beginning,
lithium carbonate (Li2CO3), manganese oxide (MnO2), and nickel oxide (NiO)
were weighed such that they have a predetermined mole ratio, following
which they were mixed using a ball mill. Then, the mixture was baked under
the atmosphere for 10 hours at a temperature of 800 degrees centigrade, and
cooling was performed thereafter. Then, the mixture was mixed again using
a ball mill, following which the same was baked under the atmosphere for 10
hours at a temperature of 700 degrees centigrade to obtain a
lithium-nickel-manganese composite oxide (LiNi0.5Mn1.5O4) as the
high-voltage operating positive electrode material. Then, the LiNi0.5Mn1.5O4
as the positive electrode active material; acetylene black (the amorphous
carbon material) and black lead (the crystalline carbon material) as the
positive electrode conductive agent; and vinylidene polyfluoride as the
positive electrode binder, were mixed to provide the positive electrode
mixture. In this case, the interplanar spacing, the specific surface area, and
the content of the amorphous carbon material and of the crystalline carbon
material were set as shown in Table 1 to Table 5. The black lead as the
crystalline carbon material was obtained by baking petroleum pitch as a raw
material at a temperature from 1000 degrees centigrade to 2800 degrees
centigrade, and the baking temperature thereof was changed to control the
interplanar spacing. As for a mixing ratio (a mass ratio) of the positive
electrode active material, the positive electrode conductive agent, and the
positive electrode binder, a ratio of the positive electrode binder was 2.5 pts.
mass and was constant, and the remaining ratio was shared by the positive
electrode active material and the positive electrode conductive agent.
Namely, the ratio of the positive electrode active material is the remaining
ratio excluding the ratio of the positive electrode conductive agent and the
positive electrode binder from the total. Then, the positive electrode mixture
was dispersed in N-methyl-2-pyloridon to provide the paste-like positive
electrode mixture slurry. Then, the positive electrode mixture slurry was
coated on a positive electrode current collector 51A configured of an
aluminum foil (15 µm thick), following which a compression molding was
performed using a roll pressing machine to form a positive electrode active
material layer 51B. Lastly, the positive electrode current collector 51A
formed with the positive electrode active material layer 51B was punched into
a pellet having a diameter of 15 mm.
[0112] Then, as the solvent, ethylene carbonate (EC) and dimethyl
carbonate (DMC) were mixed, following which, as the electrolyte salt, lithium
phosphate hexafluoride (LiPF6) was dissolved to prepare the electrolyte. In
this case, a mixing ratio (a mass ratio) of the solvent was EC : DMC = 1:1,
and the content of the electrolyte salt for the solvent was 1 mol/kg.
[0113] Lastly, the positive electrode 51 and the negative electrode 52 (a
pellet-like lithium metal plate) were laminated with the separator 53
configured of a micro-porous polypropylene film (20 µm thick) in between,
following which the resultant was accommodated in an exterior can 54.
Then, the electrolyte was impregnated in the separator 53, following which,
through the gasket 56, the exterior cup 55 was overlaid and swaged. Thereby,
the coin-type secondary battery was completed.
[0114] Examination of charge-discharge characteristics (a capacity
retention rate) was performed on the secondary batteries according to the
Experiment Examples 1-1 to 1-20. The results shown in Table 1 to Table 5
were obtained accordingly.
[0115] In determining the capacity retention rate, two cycles of charging
and discharging were performed under an atmosphere of 45 degrees centigrade to measure a discharge capacity, following which the charging and discharging were repeated under the same atmosphere until a total of the number of cycles reached 50 cycles to measure a discharge capacity. From this result, the capacity retention rate (%) = (discharge capacity in the 50th cycle / discharge capacity in the second cycle) x 100 was calculated. In this case, charging was performed with a current of 0.3 mA until a voltage reached 4.95 V, and further charging was performed at the same voltage until the current reached 0.03 mA (constant-current constant-voltage charging), following which constant-current discharging was performed with the current of 0.3 mA until the voltage reached 3 V. [0116]
[Table 1]
Positive electrode active material: LiNi0.5Mn1.5O4
(Table Removed)
[0117]
[Table 2]
Positive electrode active material: LiNi0.5Mn1.5O4
(Table Removed)
[0118]
[Table 3]
Positive electrode active material: LiNi0.5Mn1.5O4
(Table Removed)
[0119]
[Table 4]
Positive electrode active material: LiNi0.5Mn1.5O4
(Table Removed)
[0120]
[Table 5]
Positive electrode active material: LiNi0.5Mn1.5O4
(Table Removed)
[0121] In the cases where LiNi0.5Mm.5O4 was used as the positive
electrode active material, the specific surface area and the content of the
amorphous carbon material as well as the interplanar spacing, the specific
surface area, and the content of the crystalline carbon material were optimized,
by which the capacity retention rate was increased. The ranges of
optimization were as follows: the specific surface area = 50 m2/g to 100 m2/g
and the content = 0.5 mass% to 5 mass% for the amorphous carbon material.
Also, for the crystalline carbon material, the interplanar spacing = 0.340 nm
to 0.343 nm, the specific surface area = 1 m2/g to 5 m2/g, and the content = 0.5
mass% to 5 mass%.
(Experiment Examples 2-1 to 2-4)
[0122] Procedures similar to those of the Experiment Examples 1-1 to
1-20 were carried out, except that lithium-chromium-manganese composite
oxide (LiCr0.5Mn1.5O4) or lithium-cobalt-phosphate compound (LiCoPCM) was
used for the positive electrode active material. In these cases, the interplanar
spacing, the specific surface area, and the content of the amorphous carbon
material and of the crystalline carbon material were set as shown in Table 6
and Table 7. In obtaining LiCr0.5Mn1.5O4, lithium hydroxide (LiOH), MnO2,
and chromium oxide (Cr2O3) were mixed. On the other hand, Li2CO3, cobalt
oxide (CoO), and ammonium phosphate ((NH4)2HPO4) were mixed in
obtaining LiCoP04. A procedure other than this was similar to that of the
case in which LiNi0.5Mn1.5O4 was obtained.
[0123] Examination of charge-discharge characteristics (an initial
efficiency) was performed on the secondary batteries according to the
Experiment Examples 2-1 to 2-4. The results shown in Table 6 and Table 7
were obtained accordingly.
[0124] In determining the initial efficiency, charging was performed
under an atmosphere of 25 degrees centigrade to measure a charge capacity,
following which discharging was performed under the same atmosphere to
measure a discharge capacity. From this result, the initial efficiency (%) =
(discharge capacity / charge capacity) x 100 was calculated. In this case,
charging was performed with a current of 0.3 mA until a voltage reached 5.1 V,
and further charging was performed at the same voltage until the current
reached 0.03 mA (constant-current constant-voltage charging), following
which constant-current discharging was performed with the current of 0.3 mA
until the voltage reached 3 V.
[0125]
[Table 6]
Positive electrode active material: LiCr0.5Mn1.5O4
(Table Removed)
[0126]
[Table 7]
Positive electrode active material: LiCoPO4
(Table Removed)
[0127] A result similar to that of the case where LiNi0.5Mn1.5O4 was used
was obtained also in the case where LiCr0.5Mn1.5O4 or LiCoPO4 was used as
the positive electrode active material.
[0128] It was confirmed from the results in the Table 1 to Table 7
described above that the charge-discharge characteristics improve when the
interplanar spacing, the specific surface area, and the content of the
amorphous carbon material and the crystalline carbon material as the positive
electrode conductive agent are in the normalized ranges, in a case where the
high-voltage operating positive electrode material is used as the positive
electrode active material.
[0129] It is to be noted that the cases where the lithium metal is used for
the negative electrode (the lithium metal secondary battery) have been
described in the Examples described above, for the purpose of simplifying
contents of the Experiments. However, a similar result should be obtained as
well in a case where a material such as a carbon material and a metallic
material is used for the negative electrode active material (a lithium-ion
secondary battery). This is because, in the invention, a feature reside in
conditions of the configuration of the positive electrode (the kind of the
positive electrode active material, and the kind and the property of the
positive electrode conductive agent), and operation and effect of the invention
are achieved based on that feature. Hence, in the case where the carbon
material or the metallic material is used, an absolute value such as of the
capacity retention rate may vary as compared with the case where the lithium
metal is used, but an effect of the invention by which the charge-discharge
characteristics improve should certainly be achieved.
[0130] Although the invention has been described in the foregoing with
reference to the embodiment and the Examples, the invention is not limited to
the modes described in the embodiment and the Examples but may be
modified in a wide variety of ways. For example, the capacity of the
negative electrode may include a capacity derived from the storage and the
release of the lithium ions and a capacity derived from the deposition and the
dissolution of the lithium metal, and may be expressed by a sum of those
capacities. In this case, a negative electrode material capable of storing and releasing the lithium ions is used for the negative electrode active material, and a chargeable capacity of the negative electrode material is set to be smaller than a discharge capacity of the positive electrode. [0131] Also, a structure of the battery may be such as of an angular type and a button type, and a structure of a battery device may be such as a laminated structure.
[0132] Also, an element of the electrode reacting substance may be
another group 1 element such as sodium (Na) and potassium (K), may be a group 2 element such as magnesium and calcium, or may be other light metal such as aluminum. An effect of the invention should be achieved without depending upon kinds of elements of the electrode reacting substance. Thus, a similar effect can be achieved even when the kinds thereof are altered. [0133] Also, although the description has been made for the interplanar spacing of the amorphous carbon material as to the normalized range drawn from the results according to the Examples, the description thereon does not completely deny a possibility that the interplanar spacing may become outside the range described above. That is, the normalized range described above is basically a range which is particularly preferable in achieving an effect of the invention. Thus, the interplanar spacing may be, to a certain degree, deviated from the range described above as long as an effect of the invention is achieved. The same is true for the specific surface area and the content of the amorphous carbon material and of the crystalline carbon material.
CLAIMS
1. A secondary battery, comprising:
a positive electrode including a positive electrode active material layer having a positive electrode active material and a positive electrode conductive agent;
a negative electrode; and
an electrolyte containing an electrolyte salt and a solvent,
wherein an operating voltage of the positive electrode active material is equal to or more than 4.5 V on a lithium metal (Li) basis, and
the positive electrode conductive agent contains an amorphous carbon material and a crystalline carbon material, a specific surface area of the amorphous carbon material lying between 50 m2/g and 100 m2/g both inclusive, a content of the amorphous carbon material in the positive electrode active material layer lying between 0.5 mass% and 5 mass% both inclusive, an interplanar spacing for lattice plane (002) of the crystalline carbon material being equal to or more than 0.340 nm when measured by an X-ray diffraction method, a specific surface area of the crystalline carbon material lying between 1 m2/g to 5 m2/g both inclusive, and a content of the crystalline carbon material in the positive electrode active material layer lying between 0.5 mass% to 5 mass% both inclusive.
2. The secondary battery according to claim 1, wherein the interplanar spacing of the crystalline carbon material is equal to or less than 0.343 nm.
3. The secondary battery according to claim 1, wherein the amorphous carbon material is an acetylene black, and the crystalline carbon material is a black-lead.
4. The secondary battery according to claim 1, wherein the positive
electrode active material is a lithium-manganese-based composite oxide
expressed by a following formula (1) or a lithium cobalt phosphate compound
(LiCoPO4):
LiMxMn2-xO4 (1), where M represents at least one of nickel (Ni), cobalt (Co), iron (Fe), chromium (Cr), and copper (Cu), a value of x satisfying 0 < x ≤ 1.
5. The secondary battery according to claim 4, wherein the positive electrode active material is a lithium-nickel-manganese composite oxide (LiNi0.5Mn1.5O4), a lithium-chromium-manganese composite oxide (LiCr0.5Mn1.5O4), or a lithium-cobalt phosphate compound.
6. The secondary battery according to claim 1, wherein the positive electrode active material layer contains a positive electrode binder.
7. A positive electrode for a secondary battery, comprising:
a positive electrode active material layer having a positive electrode active material and a positive electrode conductive agent,
wherein an operating voltage of the positive electrode active material is equal to or more than 4.5 V on a lithium metal basis, and
the positive electrode conductive agent contains an amorphous carbon
material and a crystalline carbon material, a specific surface area of the
amorphous carbon material lying between 50 m2/g and 100 m2/g both
inclusive, a content of the amorphous carbon material in the positive electrode
active material layer lying between 0.5 mass% and 5 mass% both inclusive, an
interplanar spacing for lattice plane (002) of the crystalline carbon material
being equal to or more than 0.340 nm when measured by an X-ray diffraction
method, a specific surface area of the crystalline carbon material lying
between 1 m2/g to 5 m2/g both inclusive, and a content of the crystalline carbon material in the positive electrode active material layer lying between 0.5 mass% to 5 mass% both inclusive.