Binder composition, method of producing binder composition, and method of producing all-solid-state battery

Patent metadata

Field	Value
Publication number	US-11912853-B2
Application number	US-202117339026-A
Country	US
Kind code	B2
Filing date	Jun 4, 2021
Priority date	Jun 9, 2020
Publication date	Feb 27, 2024
Grant date	Feb 27, 2024

Abstract

A binder composition includes a dispersion medium and a group of binder particles. The group of binder particles is dispersed in the dispersion medium. The group of binder particles include a polymer material. The polymer material includes a constitutional unit originated from vinylidene difluoride. The group of binder particles has a number-based particle size distribution. The particle size distribution satisfies the following conditions: “0.19≤X≤0.26”, “0.69≤Y≤0.76”, and “0≤Z≤0.05”. Here, “X” represents a frequency of particles each having a particle size of less than or equal to 40 μm. “Y” indicates a frequency of particles each having a particle size of more than 40 μm and less than or equal to 110 μm. “Z” indicates a frequency of particles each having a particle size of more than 110 μm and less than or equal to 250 μm.

First claim

What is claimed is:

1. A method of producing an all-solid-state battery, the method comprising:
preparing a slurry composition by mixing a binder composition with a sulfide-based solid electrolyte;
pulverizing an aggregate included in the slurry composition;
forming a separator by applying the slurry composition to a surface of a substrate and drying the slurry composition after pulverizing the aggregate; and
producing an all-solid-state battery including the separator, wherein
said binder composition consists essentially of 1 mass % to 15 mass % of a group of binder particles and the remainder of a dispersion medium,
the group of binder particles is dispersed in the dispersion medium,
the group of binder particles includes a polymer material,
the polymer material includes a constitutional unit originated from vinylidene difluoride,
the group of binder particles has a number-based particle size distribution, and
the number-based particle size distribution satisfies conditions of the following formulae (1) to (3):
0.19≤X≤0.26  (1),

0.69≤Y≤0.76  (2), and

0≤Z≤0.05  (3)

where
in the formula (1), X represents a frequency of particles each having a particle size of less than or equal to 40 μm,
in the formula (2), Y represents a frequency of particles each having a particle size of more than 40 μm and less than or equal to 110 μm, and
in the formula (3), Z represents a frequency of particles each having a particle size of more than 110 μm and less than or equal to 250 μm.

2. The method of producing the all-solid-state battery according to claim 1 , wherein the sulfide-based solid electrolyte has a specific surface area of less than or equal to 5.3 m 2 /g.

3. The method of producing the all-solid-state battery according to claim 1 , wherein the aggregate is pulverized to maintain the slurry composition at a temperature of less than or equal to 50° C.

4. The method of producing the all-solid-state battery according to claim 1 , wherein the aggregate is pulverized by ultrasonic wave.

5. The method of claim 1 , wherein the dispersion medium includes butyl butyrate.

Assignees

• Toyota Motor Co Ltd
• Kureha Corp

Inventors

• Osada Naoki
• Kawashima Shohei
• Furuya Ryosuke
• Nagasawa Yoshiyuki
• Sakuma Mitsuyasu

Classifications

• C08L27/16 Primary

  Homopolymers or copolymers or vinylidene fluoride · CPC title

• C08J3/28

  Treatment by wave energy or particle radiation · CPC title

• H01M4/623 Primary

  fluorinated polymers · CPC title

• H01M10/0525

  Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries · CPC title

• H01M10/0562

  Solid materials · CPC title