"Stack And Folding Typed Electrode Assembly And Method For Preparation Of The Same"
Abstract:
Disclosed herein is a method of locating a plurality of pull cells constructed in a cathode/separator/anode structure, as basic units, on a separator sheet having a continuous length, further locating a unit electrode or a bi-cell on the separator sheet, and winding the pull cells and unit electrode or the bi-cell to continuously manufacture a stacking/folding type electrode assembly constructed in a structure in which anodes are located at the outermost electrodes forming the outside of the electrode assembly, respectively, wherein the method including a step of continuously supplying a cathode sheet, an anode sheet, a first separator sheet, and a second separator sheet, to manufacture the unit cells, successively arranging the unit cells on the second separator sheet from a first stage to an n stage, and winding the unit cells, a step of arranging cathode tabs and anode tabs at the respective stages, while the cathode tabs and the anode tabs are opposite to each other, and arranging electrode tabs having the same polarity between the neighboring stages, while the electrode tabs are opposite to each other, such that the electrode tabs having the same polarity are located all together at predetermined positions of the wound electrode assembly, and a step of supplying electrodes the number of which is odd from two electrode sheets and electrodes the number of which is even from one electrode sheet.
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Notices, Deadlines & Correspondence
20, YOIDO-DONG, YOUNGDUNGPO-GU, SEOUL 150-721, REPUBLIC OF KOREA
Inventors
1. KYONG WON KANG
103-1006, KUMHO HANSARANG APT., 111-12, MOK-DONG, JUNG-GU DAEJEON 301-782, REPUBLIC OF KOREA
2. HYANG MOK LEE
720-4, SUYU 2-DONG, GANGBUK-GU, SEOUL 142-888, REPUBLIC OF KOREA
3. BYUNGJIN CHOI
101-504, EXPO APT., JEONMIN-DONG, YUSEONG-GU, DAEJEON 305-761, REPUBLIC OF KOREA
4. EUNYOUNG GOH
405-404, YANGJIMAEUL KUNYOUNG VILLA, JANGHANG-DONG, ILSAN-GU GOYANG-SI, GYEONGGI-DO 411-380, REPUBLIC OF KOREA
5. SUNG-MIN HWANG
203, 594-17, NAEDEOK 1-DONG, SANGDANG-GU, CHEONGJU-SI, CHUNGCHEONGBUK-DO 360-806, REPUBLIC OF KOREA
6. OH YOUNG HYUN
128-304, HANVIT APT., EOEUN-DONG, YUSEONG-GU, DAEJEON 305-755, REPUBLIC OF KOREA
7. CHANG BUM AHN
7-306,, LG CHEM SAWON APT., 381-42, DORYONG-DONG, YUSEONG-GU DAEJEON 305-340, REPUBLIC OF KOREA
8. HYUN-CHUL JUNG
406-2202, DAEDEOK TECHO VALLEY, GWANPYEONG-DONG, YUSEONG-GU DAEJEON 305-509, REPUBLIC OF KOREA
9. WOOYONG LEE
202, SINYEOLLIP, LG CHEM SAWON APT., 388-11, DORYONG-DONG YUSEONG-GU, DAEJEON 305-340, REPUBLIC OF KOREA
Specification
STACK AND FOLDING-TYPED ELECTRODE ASSEMBLY AND METHOD FOR PREPARATION OF THE SAME
FIELD OF THE INVENTION
The present invention relates to a method of manufacturing a stacking/folding type electrode assembly, and, more particularly, to a method of manufacturing an electrode assembly including a step of continuously supplying a cathode sheet, an anode sheet, a first separator sheet, and a second separator sheet, to manufacture the unit cells, successively arranging the unit cells on the second separator sheet from a first stage to an nth stage, and winding the unit cells, a step of arranging cathode tabs and anode tabs at the respective stages, while the cathode tabs and the anode tabs are opposite to each other, and arranging electrode tabs having the same polarity between the neighboring stages, while the electrode tabs are opposite to each other, such that the electrode tabs having the same polarity are located all together at predetermined positions of the wound electrode assembly, and a step of supplying electrodes the number of which is odd ('odd-numbered electrodes') from two electrode sheets and electrodes the number of which is even ('even-numbered electrodes') from one electrode sheet.
BACKGROUND OF THE INVENTION
As mobile devices have been increasingly developed, and the demand for such mobile devices has increased, the demand for batteries has also sharply increased as an
energy source for the mobile devices. Accordingly, much research on batteries satisfying various needs has been carried out.
In terms of the shape of batteries, the demand for prismatic secondary batteries or pouch-shaped secondary batteries, which are thin enough to be applied to products, such as mobile phones, is very high. In terms of the material for batteries, the demand for lithium secondary batteries, such as lithium ion batteries and lithium ion polymer batteries, having high energy density, high discharge voltage, and high output stability, is very high.
Furthermore, secondary batteries may be classified based on the construction of an electrode assembly having a cathode/separator/anode structure. For example, the electrode assembly may be constructed in a jelly-roll (winding) type structure in which long-sheet type cathodes and long-sheet type anodes are wound while separators are disposed respectively between the cathodes and the anodes or in a stacking type structure in which pluralities of cathodes and anodes having a predetermined size are successively stacked while separators are disposed respectively between the cathodes and the anodes.
However, the conventional electrode assemblies have several problems.
First, the jelly-roll type electrode assembly is manufactured by densely winding the long-sheet type cathodes and the long-sheet type anodes with the result that the jelly-roll type electrode assembly is circular or elliptical in section. Consequently, stress, generated by the expansion and contraction of the electrodes during the charge and discharge of a battery, accumulates in the electrode assembly, and, when the stress accumulation exceeds a specific limit, the electrode assembly may be deformed. The deformation of the electrode assembly results in the
nonuniform gap between the electrodes. As a result, the performance of the battery is abruptly deteriorated, and the safety of the battery is not secured due to an internal short circuit of the battery. Furthermore, it is difficult to rapidly wind the long-sheet type cathodes and the long-sheet type anodes while maintaining uniformly the gap between the cathodes and anodes, with the result that the productivity is lowered.
Secondly, the stacking type electrode assembly is manufactured by sequentially stacking the plurality of unit cathodes and the plurality of unit anodes. As a result, it is additionally necessary to provide a process for transferring electrode plates, which are used to manufacture the unit cathodes and the unit anodes. Furthermore, a great deal of time and effort are required to perform the sequential stacking process, with the result that the productivity is lowered.
In order to solve the problems, there has been developed a stacking/folding type electrode assembly, which is a combination of the jelly-roll type electrode assembly and the stacking type electrode assembly. The stacking/folding type electrode assembly is constructed in a structure in which pluralities of cathodes and anodes having a predetermined size are successively stacked, while separators are disposed respectively between the cathodes and the anodes, to constitute a bi-cell or a full-cell, and then a plurality of bi-cells or a plurality of full-cells are wound while the bi-cells or the full cells are located on a long separator sheet. The details of the stacking/folding type electrode assembly are disclosed in Korean Patent Application Publication No. 2001-0082058, No. 2001-0082059, and No. 2001-0082060, which have been filed in the name of the applicant of the present patent application.
FIGS. 1 and 2 typically illustrate an exemplary structure of a conventional stacking/folding type electrode assembly including such pull cells as basic units and a process for manufacturing the stacking/folding type electrode assembly, respectively.
Referring to these drawings, a plurality of pull cells 10, 11, 12, 13, 14 ..., as unit cells, constructed in a structure in which a cathode, a separator, and an anode are sequentially arranged are stacked such that a separator sheet 20 is disposed between the respective pull cells. The separator sheet 20 has unit lengths sufficient to surround the respective pull cells. The separator sheet 20 is bent inward every unit length to successively surround the respective pull cells from the central pull cell 10 to the outermost pull cell 14. Then end of the separator sheet 20 is finished by thermal welding or an adhesive tape 25.
The stacking/folding type electrode assembly is manufactured, for example, by arranging the pull cells 10, 11, 12, 13, 14 ... on the long separator sheet 20 and sequentially winding the pull cells 10, 11, 12, 13, 14 . . . from one end 21 of the separator sheet 20.
When carefully observing the array combination of the pull cells as the unit cells, the first pull cell 10 and the second pull cell 11 are spaced from each other by a distance equivalent to the width corresponding to at least one pull cell. Consequently, during the winding process, the outside of the first pull cell 10 is surrounded by the separator sheet 20, and then, a lower electrode of the first pull cell 10 comes into contact with an upper electrode of the second pull cell 11.
During the sequential stacking of the second pull cell and the following pull cells 11, 12, 13, 14 . . . through the winding, the surrounding length of the separator
sheet 20 increases, and therefore, the pull cells are arranged such that the distance between the pull cells gradually increases in the winding direction.
Also, during the winding of the pull cells, it is required for cathodes of the pull cells to face anodes of the corresponding pull cells. Consequently, the first pull cell 10 and the second pull cell 11 are pull cells of which the upper electrode is a cathode, the third pull cell 12 is a pull cell of which the upper electrode is an anode, the fourth pull cell 13 is a pull cell of which the upper electrode is a cathode, and the fifth pull cell 14 is a pull cell of which the upper electrode is an anode. That is, except the first pull cell 10, the pull cells of which the upper electrode is a cathode and the pull cells of which the upper electrode is an anode are alternately arranged.
Consequently, the stacking/folding type electrode assembly considerably makes up for the defects of the jelly-roll type electrode assembly and the stacking type electrode assembly. However, it is preferred that the number of the anodes included in the electrode assembly be greater than the number of the cathodes included in the electrode assembly to prevent the dendritic growth at the anodes. When the electrode assembly is manufactured in a structure in which the anodes are located at the outermost electrodes of the electrode assembly while cathode tabs and anode tabs are opposite to each other, the total number of the unit electrodes is odd for any one electrode of the single electrode assembly. Consequently, when electrode assemblies are manufactured through a series of successive processes, such an odd-numbered electrode is left by one during the manufacture of each electrode assembly. As a result, the unit electrodes are inevitably wasted, and therefore, the manufacturing costs of the electrode assembly increase.
In conclusion, the stacking/folding type electrode assembly is preferred in the aspect of operational performance and safety of the battery. However, the stacking/folding type electrode assembly is disadvantageous in the aspect of manufacturing costs and productivity of the battery. Consequently, there is a high necessity for a method of manufacturing an electrode assembly that is capable of providing higher productivity and operational performance of the battery while making up for the above-mentioned defects.
Furthermore, the latest Bluetooth-based mobile devices require a very small-sized secondary battery. Consequently, there is a high necessity for a technology to manufacture a very small-sized electrode assembly using pull cells as basic units at low costs and high productivity.
SUMMARY OF THE INVENTION
Therefore, the present invention has been made to solve the above problems, and other technical problems that have yet to be resolved.
As a result of a variety of extensive and intensive studies and experiments to solve the problems as described above, the inventors of the present invention have found that, when continuously supplying electrode sheets and separator sheets to manufacture unit cells, successively arranging the unit cells on the separator sheet, winding the unit cells, constructing the electrode assembly such that the electrode tabs having the same polarity are located all together at predetermined positions of the wound electrode assembly, and supplying electrodes the number of which is odd from two electrode sheets and electrodes the number of which is even from one electrode sheet, to manufacture an electrode assembly constructed in a structure in which anodes
are located at the outermost electrodes of the electrode assembly, it is possible to fundamentally prevent the loss of electrodes, thereby greatly reducing the manufacturing costs of the electrode assembly, and, furthermore, when supplying and arranging unit cells used to manufacture the electrode assembly through a series of successive processes, it is possible to maximize production efficiency. The present invention has been completed based on these findings.
In accordance with one aspect of the present invention, the above and other objects can be accomplished by the provision of a method of locating a plurality of pull cells constructed in a cathode/separator/anode structure, as basic units, on a separator sheet having a continuous length, further locating a unit electrode or a bi-cell on the separator sheet, and winding the pull cells and unit electrode or the bi-cell to continuously manufacture a stacking/folding type electrode assembly constructed in a structure in which anodes are located at the uppermost and lowermost electrodes (the outermost electrodes) forming the outside of the electrode assembly, respectively, wherein the method comprising: continuously supplying an electrode sheet (a cathode sheet) to which a cathode active material is applied, an electrode sheet (an anode sheet) to which an anode active material is applied, a separator sheet (a first separator sheet) disposed between a cathode and an anode of a pull cell or a bi-cell, and another separator sheet (a second separator sheet) used to wind unit cells (the pull cells, the unit electrode, and the bi-cell), to manufacture the unit cells, successively arranging the unit cells on the second separator sheet from a first stage to an nth stage, and winding the unit cells; arranging cathode tabs and anode tabs at the respective stages, while the cathode tabs and the anode tabs are opposite to each other, and arranging electrode tabs having the same polarity between the neighboring stages, while the electrode tabs are opposite to each other, such that the electrode tabs having the same polarity are located all
together at predetermined positions of the wound electrode assembly; and supplying electrodes the number of which is odd ('odd-numbered electrodes') from two electrode sheets and electrodes the number of which is even ('even-numbered electrodes') from one electrode sheet.
When an electrode assembly is manufactured by the above-described method, although the electrode assembly is constructed in a structure in which pull cells are used as basic units, and electrode tabs are opposite to each other, electrodes of which the number is odd are supplied from two electrode sheets, and therefore, it is possible to manufacture the electrode assembly in a series of successive processes while preventing the loss of electrodes, thereby greatly improving production efficiency and greatly reducing the manufacturing costs of the electrode assembly.
In this specification, the term 'unit electrode' means an electrode of a cathode or anode structure. Consequently, when the unit electrode itself constitutes a unit cell, the unit cell means the one including only one electrode, not of a pull cell or bi-cell structure. When a unit cell at a specific stage is a unit cell, the unit cell itself may be a lower electrode (an electrode contacting a separator sheet) and, at the same time, an upper electrode.
Therefore, except in a case which will be particularly described hereinafter with discrimination, the term 'lower electrode' or 'upper electrode' is used as a concept including a unit electrode itself as well as a lower electrode or an upper electrode of a pull cell or a bi-cell.
Also, in this specification, the term 'single electrode' means an electrode to be cut from an electrode sheet into a predetermined size to manufacture a unit cell or an electrode cut from the electrode sheet. In this case, the single electrode may be used as
a cathode or an anode cut into a predetermined size to manufacture a pull cell or a bi-cell as a unit cell. Alternatively, the signal electrode itself may be used as a unit electrode of a unit cell.
The pull cell, as the basic unit, is not particularly restricted so long as the pull cell is constructed in a structure in which the upper electrode and the lower electrode of the unit cell have different polarities. For example, the pull cell may be constructed in i) a cathode/separator/anode stacking structure or ii) a cathode/separator/anode/separator/cathode/separator/anode stacking structure. Preferably, the pull cell is constructed in a cathode/separator/anode stacking structure. The number of pull cells wound while the pull cells are located on the second separator sheet may be decided based on various factors, such as the structures of the respective pull cells, required capacity of a finally manufactured battery, etc. Preferably, the number of the pull cells is 6 to 30.
The bi-cell means a unit cell constructed in a structure in which the same electrodes are located at opposite sides thereof, e.g., a cathode/separator/anode/separator/cathode stacking structure or an anode/separator/cathode/separator/anode stacking structure. The number of the cathodes, the anodes, and the separators constituting the bi-cell is not particularly restricted so long as the electrodes located at the opposite sides of the cell have the same polarity. The bi-cell may be classified as a unit cell (C-type bi-cell) constructed in an anode/separator/cathode/separator/anode stacking structure, i.e., a structure in which the anodes are located at the opposite sides of the cell, or a unit cell (A-type bi-cell) constructed in a cathode/separator/anode/separator/cathode stacking structure, i.e., a structure in which the cathodes are located at the opposite sides of the cell. A representative example of the C-type bi-cell is illustrated in FIG. 3.
As will be described hereinafter, the number of cathodes or anodes must be odd in consideration of the structural characteristics in that the anodes are located at the outermost electrodes of the unit cell. Consequently, the unit electrode or the bi-cell must constitute at least one unit cell. At this time, the unit electrode or the bi-cell is preferably located at the first stage, which is a winding start point, the n-1th stage, which is a winding end point, or the nth stage, in order to improve efficiency in manufacturing the unit electrode or the bi-cell. In consideration of a practical effect applicable to an actual manufacturing process, the unit electrode is more preferably located at the selected stage.
The electrode assembly according to the present invention is constructed in a structure in which the anodes are located at the outermost electrodes constituting the outside of the electrode assembly such that the anodes occupy relatively large area if possible. Consequently, for example, for a lithium secondary battery, it is possible to maximally retrain the dendritic growth of lithium metal at the anodes during the charge and discharge of the battery.
To this end, a unit electrode which is an anode or a pull cell or a bi-cell the
lower electrode of which is an anode is preferably arranged at the n-1 stage, which is a winding end point, and the nth stage on the second separator sheet having a continuous length.
Specifically, when a winding process is carried out in a fashion in which the second separator sheet is bent inward for each unit cell such that the unit cells are surrounded by the second separator sheet from the unit cell at the first stage to the unit cell at the nth stage, the lower electrode of the unit cell located at the n-1th stage constitutes the uppermost electrode of the electrode assembly, and the lower electrode
of the unit cell located at the nth stage constitutes the lowermost electrode of the electrode assembly. Consequently, the anodes are located at the outermost electrodes of the electrode assembly.
Also, when the unit cells are wound while being located on the second separator sheet according to the present invention, the separator sheet is disposed between the respective unit cells. Consequently, it is required that the respective unit cells be stacked such that the cathodes and the corresponding anodes face each other while the second separator sheet is disposed between the respective unit cells.
To this end, it is required that the first unit cell lie on the top of the second unit cell while the first unit cell is surrounded by the second separator sheet, and opposite electrodes of the first and second unit cells have opposite electrode structures at a region defined between the first unit cell and the second unit cell.
In order to satisfy the first condition, a spacing region corresponding to the size of a unit cell must be formed between the first stage on the second separator sheet where the first unit cell is located and the second stage where the second unit cell is located, or a spacing region corresponding to the size of a unit cell must be formed in front of the first stage on the second separator sheet where the first unit cell is located. Consequently, during the winding process, the first unit cell lies on the top of the second unit cell while the first unit cell is surrounded by the second separator sheet.
In order to satisfy the second condition, it is required to decide the arrangement of the lower electrodes and the upper electrodes of the unit cells in consideration of the position of the spacing region. For example, when the winding process is carried out while the spacing region is formed between the first stage and the second stage, it is required that the electrode assembly be constructed in a structure in which the lower
electrode of the first unit cell and the upper electrode of the second unit cell have opposite polarities, the lower electrode of the second unit cell and the upper electrode of the fourth unit cell have opposite polarities, and the lower electrode of the third unit cell and the upper electrode of the fifth unit cell have opposite polarities. On the other hand, when the winding process is carried out while the spacing region is formed in front of the first stage, it is required that the electrode assembly be constructed in the same structure as in the above-described structure except that the upper electrode of the first unit cell and the upper electrode of the second unit cell have opposite polarities.
In consideration of the above-mentioned facts, when the pull cell is arranged at the first stage of the second separator sheet (i.e., the first unit cell is a pull cell), it is preferred that the pull cells be alternately arranged at the second and subsequent stages such that upper and lower electrodes of the neighboring unit cells between the neighboring unit cells have opposite polarities. On the other hand, when the unit electrode is arranged at the first stage, it is preferred that the pull cells be arranged at the second and subsequent stages in the same electrode orientation fashion such that upper and lower electrodes of the neighboring unit cells between the neighboring unit cells have the same polarity.
When the pull cell is arranged at the first stage, for example, a unit electrode which is an anode or a C-type bi-cell may be arranged at the nth stage such that the anodes are located at the lower electrodes at the n-1th stage and the nth stage. At this time, in a structure in which the spacing region is formed in front of the first stage, a unit electrode which is an anode may be arranged at the nth stage, when the lower electrode of the pull cell at the first stage is an anode and the number of the pull cell arranged is odd and when the lower electrode of the pull cell at the first stage is a cathode and the number of the pull cell arranged is even. On the other hand, a C-type
bi-cell may be arranged at the n stage, when the lower electrode of the pull cell at the first stage is an anode and the number of the pull cell arranged is even and when the lower electrode of the pull cell at the first stage is a cathode and the number of the pull cell arranged is odd.
In the above description, the winding process is performed while the spacing region is formed in front of the first stage, On the other hand, when the winding process is performed while the spacing region is formed between the first stage and the second stage, the same structure may be applied while the pull cell at the first stage is turned over such that the upper and lower electrodes of the pull cell at the first stage are reversed.
Meanwhile, when the unit electrode is arranged at the first stage on the second separator sheet, the same structure is applied irrespective of the position of the spacing region. Specifically, in order that anodes are located at the lower electrodes of the nth stage and the n-1th stage when the unit electrode is arranged at the first stage, the pull cells of which the lower electrodes are cathodes are arranged at the second and subsequent stages in the same electrode orientation fashion when a cathode, as the unit electrode, is arranged at the first stage. On the other hand, when an anode, as the unit electrode, is arranged at the first stage, the pull cells of which the lower electrodes are anodes are arranged at the second and subsequent stages in the same electrode orientation fashion.
In the above-described definition, the structure in which the electrode tabs having the same polarities are located all together at the predetermined positions of the electrode assembly wound means, for example, the structure in which the cathode tabs are located all together at the right-side upper end of the electrode assembly and the
anode tabs are located all together at the left-side upper end of the electrode assembly, whereby the electrode tabs are coupled to a cathode lead and an anode lead, respectively. To this end, as previously defined, the cathode tabs and the anode tabs are arranged such that the cathode tabs and the anode tabs are opposite to each other at each stage of the second separator sheet, e.g., the cathode tabs and the anode tabs are arranged at the right-side upper ends and the left-side upper ends, and the electrode tabs having the same polarity are arranged between the neighboring stages such that the electrode tabs are opposite to each other. Consequently, when the cathode tab is located at the right-side upper end and the anode tab is located at the left-side upper end at an arbitrary stage, the cathode tab is located at the left-side upper end and the anode tab is located at the right-side upper end at its neighboring stage.
In the present invention, the odd-numbered electrodes (e.g. the cathodes) are supplied from two electrode sheets. Supply units for supplying the electrode sheets are not particularly restricted. For example, the supply units for the odd-numbered electrodes may be disposed above and below, or on the left and right side of, a supply unit for the even-numbered electrodes (e.g. the anodes) supplied from one electrode sheet. Also, separator sheet supply units may be disposed between the odd-numbered electrode sheets and the even-numbered electrode sheet.
In a preferred embodiment, the manufacturing method according to the present invention further comprises: (1) applying electrode active materials to electrode current-collector sheets having a continuous length, excluding regions where tabs will be formed, to manufacture electrode sheets, the electrode sheets including one electrode sheet of which the number of electrodes is even ('even-numbered electrode sheet') and two electrode sheets of which the number of electrodes is odd ('odd-numbered electrode sheets'); (2) punching the regions where the tabs will be formed of the electrode sheets
manufactured at Step (1) to form electrode tabs; (3) supplying the odd-numbered electrode sheets, among the electrode sheets of which the electrode tabs are formed at Step (2), through two supply units, respectively, and supplying the even-numbered electrode sheet and the first separator sheet through respective supply units, to manufacture single electrodes of a predetermined size and separators of a predetermined size; (4) forming unit cells, which constitutes the electrode assembly, using the single electrodes and the separators manufactured at Step (3) and arranging the unit cells on the second separator sheets having a continuous length in a predetermined orientation fashion; and (5) winding the unit cell located at the first stage with the second separator sheet once, and folding the second separator sheet from the second unit cells toward the outside where the neighboring unit cell is located such that the remaining unit cells are piled one above another.
According to circumstances, Step (3) and Step (4) may be simultaneously carried out.
At Step (1), the regions where tabs will be formed of each electrode sheet are not particularly restricted. Preferably, the tabs are formed at the left and right sides of the top of a single electrode cut into a predetermined size.
Also, the electrode tabs having the same polarities are opposite to each other between the neighboring stages such that the electrode tabs having the same polarities are located all together at predetermined positions of the electrode assembly wound. Preferably, the even-numbered electrode sheet is constructed in a structure in which two single electrodes formed at the position where the electrode tabs are symmetrically arranged at the neighboring stages are repeatedly formed in pairs. Consequently, single electrodes of which the tab directions are symmetrical are sequentially supplied
to unit cells, whereby the electrode tabs having the same polarities are opposite to each other between the neighboring stages.
In a preferred embodiment, the two odd-numbered electrode sheets include a first electrode sheet constructed in a structure in which single electrodes of which all electrode tabs are arranged in the same direction are successively formed and a second electrode sheet constructed in a structure in which single electrodes of which all electrode tabs are arranged in opposite directions are successively formed, the first electrode sheet and the second electrode sheet being supplied through a first supply unit and a second supply unit, respectively.
At this time, in order to arrange the cathode tab and the anode tab such that the cathode tab and the anode tab are opposite to each other at each stage, it is required that the electrode tab direction of the single electrode located at the first stage of each odd-numbered electrode sheet be opposite to the electrode tab direction of the single electrode located at the first stage of the even-numbered electrode sheet. To this end, it is preferred that the first electrode sheet and the second electrode sheet be alternately supplied beginning with the electrode sheet of which the electrode tabs are formed at the positions opposite to the electrode tab direction of the single electrode located at the first stage of the even-numbered electrode sheet.
In another preferred embodiment, the two odd-numbered electrode sheets include an electrode sheet ('a main electrode sheet') constructed in a structure in which two single electrodes of which electrode tabs are arranged in opposite directions are successively formed in pairs and another electrode sheet ('a subsidiary electrode sheet') constructed in a structure in which single electrodes of which electrode tabs are arranged in the same direction as the electrode tab of the electrode
formed at the start point of the main electrode sheet are successively formed, the main electrode sheet and the subsidiary electrode sheet being supplied through a first supply unit and a second supply unit, respectively.
At this time, the second supply unit may supply the single electrode to the unit cell located at the first stage or the nth stage, and the first supply unit may sequentially supply the single electrodes of which the tab directions are symmetrical to the remaining unit cells.
At Step (1), the electrode active material is applied to each electrode current-collector sheet having a continuous length, excluding regions where tabs will be formed, to manufacture an electrode sheet on which single electrodes are successively formed. The single electrodes are classified into cathodes and anodes.
Each cathode is manufactured, for example, by applying, drying, and pressing a mixture of a cathode active material, a conducting agent, and a binder to a cathode current collector, excluding regions where tabs will be formed. According to circumstances, a filler may be added to the mixture.
Generally, the cathode current collector has a thickness of 3 to 500 µm The cathode current collector is not particularly restricted so long as the cathode current collector has high conductivity while the cathode current collector does not induce any chemical change in the battery. For example, the cathode current collector may be made of stainless steel, aluminum, nickel, titanium, or plastic carbon. Alternatively, the cathode current collector may be made of aluminum or stainless steel the surface of which is treated with carbon, nickel, titanium, or silver. The cathode current collector may have micro concavo-convex parts formed at the surface thereof so as to increase the attaching force of the cathode active material. The cathode current collector may
be constructed in various forms, such as a film, a sheet, a foil, a net, a porous body, a foam body, and a non-woven fabric body.
For a lithium secondary battery, the cathode active material may be, but is not limited to, a layered compound, such as lithium cobalt oxide (LiCoC>2) or lithium nickel oxide (LiNiO2) or a compound replaced by one or more transition metals; lithium manganese oxide represented by a chemical formula Li1+xMn2-xO4 (where, x = 0 to 0.33) or lithium manganese oxide, such as LiMn03, LiMn2O3, or LiMnO2; lithium copper oxide (Li2CuO2); vanadium oxide, such as LiV3O8, LiFe3O4, V2O5, or Cu2V2O7; Ni-sited lithium nickel oxide represented by a chemical formula LiNi1-.xMxO2 (where, M= Co, Mn, Al, Cu, Fe, Mg, B, or Ga, and x = 0.01 to 0.3); lithium manganese composite oxide represented by a chemical formula LiMn2-xMxO2 (where, M= Co, Ni, Fe, Cr, Zn, or Ta, and x = 0.01 to 0.1) or a chemical formula Li2Mn3MO8 (where, M= Fe, Co, Ni, Cu, or Zn); LiMn2O4 having Li of a chemical formula partially replaced by alkaline earth metal ions; a disulfide compound; or Fe2(MoO4)3.
The conducting agent is generally added such that the conducting agent has 1 to 50 weight percent based on the total weight of the compound including the cathode active material. The conducting agent is not particularly restricted so long as the conducting agent has high conductivity while the conducting agent does not induce any chemical change in the battery. For example, graphite, such as natural graphite or artificial graphite; carbon blacks, such as carbon black, acetylene black, Ketjen black, channel black, furnace black, lamp black and thermal black; conductive fibers, such as carbon fibers and metallic fibers; metallic powders, such as carbon fluoride powder, aluminum powder and nickel powder; conductive whiskers, such as zinc oxide and potassium titanate; conductive metal oxides, such as titanium oxide; and polyphenylene derivatives may be used as the conducting agent.
The binder for the cathode active material is a component assisting in binding between the active material and conductive agent, and in binding with the current collector. The binder according to the present invention is typically added in an amount of 1 to 50 weight % based on the total weight of the compound including the cathode active material. As examples of the binder, there may be used polyvinylidene fluoride, polyvinyl alcohols, carboxymethylcellulose (CMC), starch, hydroxypropylcellulose, regenerated cellulose, polyvinyl pyrollidone, tetrafluoroethylene, polyethylene, polypropylene, ethylene-propylene-diene terpolymer (EPDM), sulfonated EPDM, styrene butadiene rubber, fluoro rubber, and various copolymers.
The filler is an optional component used to inhibit expansion of the cathode. There is no particular limit to the filler so long as it does not cause chemical changes in the battery and is a fibrous material. As examples of the filler, there may be used olefin polymers, such as polyethylene and polypropylene; and fibrous materials, such as glass fiber and carbon fiber.
On the other hand, the anode is manufactured by applying, drying, and pressing an anode active material to an anode current collector, excluding regions where tabs will be formed. According to circumstances, the conducting agent, the binder, and the filler, which were previously described, may be selectively added to the anode active material.
Generally, the anode current collector has a thickness of 3 to 500 µm. The anode current collector is not particularly restricted so long as the anode current collector has high conductivity while the anode current collector does not induce any chemical change in the battery. For example, the anode current collector may be made
of copper, stainless steel, aluminum, nickel, titanium, or plastic carbon. Alternatively, the anode current collector may be made of copper or stainless steel the surface of which is treated with carbon, nickel, titanium, or silver, or an aluminum-cadmium alloy. Like the cathode current collector, the anode current collector may have micro concavo-convex parts formed at the surface thereof so as to increase the attaching force of the anode active material. The anode current collector may be constructed in various forms, such as a film, a sheet, a foil, a net, a porous body, a foam body, and a non-woven fabric body.
As the anode active material, for example, there may be used carbon, such as non-graphitizing carbon or a graphite-based carbon; a metal composite oxide, such as LixFe2O3 (0≤x≤l), LixWO2 (O≤x≤1), SnxMe1-xMe'yOz (Me: Mn, Fe, Pb, Ge; Me': Al, B, P, Si, Group 1, 2, and 3 elements of the periodic table, halogen; 0
Documents
Application Documents
#
Name
Date
1
abstract.jpg
2011-08-21
2
236-delnp-2010-gpa.pdf
2011-08-21
3
236-delnp-2010-form-5.pdf
2011-08-21
4
236-delnp-2010-form-3.pdf
2011-08-21
5
236-delnp-2010-form-2.pdf
2011-08-21
6
236-delnp-2010-form-18.pdf
2011-08-21
7
236-delnp-2010-form-1.pdf
2011-08-21
8
236-delnp-2010-drawings.pdf
2011-08-21
9
236-delnp-2010-description (complete).pdf
2011-08-21
10
236-delnp-2010-correspondence-others.pdf
2011-08-21
11
236-delnp-2010-claims.pdf
2011-08-21
12
236-delnp-2010-abstract.pdf
2011-08-21
13
236-DELNP-2010-PCT-ISA-237.pdf
2016-02-19
14
236-DELNP-2010-PCT-ISA-210.pdf
2016-02-19
15
236-DELNP-2010-PCT-IB-308.pdf
2016-02-19
16
236-DELNP-2010-PCT-IB-304.pdf
2016-02-19
17
236-DELNP-2010-PCT-IB-301.pdf
2016-02-19
18
236-DELNP-2010-PCT Form.pdf
2016-02-19
19
236-DELNP-2010-FER.pdf
2016-07-14
20
Petition Under Rule 137 [13-01-2017(online)].pdf_41.pdf
2017-01-13
21
Petition Under Rule 137 [13-01-2017(online)].pdf_183.pdf