Three-dimensional structure electrode and electrochemical element including same

Patent metadata

Field	Value
Publication number	US-11978911-B2
Application number	US-202217954856-A
Country	US
Kind code	B2
Filing date	Sep 28, 2022
Priority date	Oct 18, 2018
Publication date	May 7, 2024
Grant date	May 7, 2024

Abstract

The present invention relates to a three-dimensional structure electrode, a method for manufacturing same, and an electrochemical element including the electrode. The present invention is characterized by comprising: (a) an upper conductive layer and a lower conductive layer which have a structure constituting an assembly within which a conductive material and a porous nonwoven fabric including a plurality of polymeric fibers are three-dimensionally connected in an irregular and continuous manner, thereby forming a mutually connected porous structure; and (b) an active material layer forming the same assembly structure as the conductive layers and forming a three-dimensionally filled structure in which electrode active material particles are uniformly filled inside the mutually connected porous structure formed in the assembly structure, wherein the active material layer is formed between the upper conductive layer and the lower conductive layer.

First claim

The invention claimed is:

1. A method for manufacturing an electrode having a three-dimensional structure, the method comprising:
(a) preparing a polymer solution including a polymer and a solvent;
(b) preparing a first colloidal solution including a conductive material, a dispersant, and a dispersion medium;
(c) preparing a second colloidal solution including the conductive material, the dispersant, the dispersion medium, and active material particles;
(d) preparing three-dimensional structure fibers using the polymer solution, the first colloidal solution, and the second colloidal solution; and
(e) compressing the three-dimensional structure fibers,
wherein step (d) comprises:
simultaneously spinning the polymer solution and a first portion of the first colloidal solution to prepare a lower conductive layer;
simultaneously spinning the polymer solution and the second colloidal solution on top of the lower conductive layer to prepare an active material layer; and
simultaneously spinning the polymer solution and a second portion of the first colloidal solution on top of the active material layer to prepare an upper conductive layer,
wherein the upper conductive layer and the lower conductive layer each have a porosity that is smaller than a porosity of the active material layer.

2. The method of claim 1 , wherein step (d) is performed by using one method selected from the group consisting of: double electrospinning, double electrospray, double spray, and combinations thereof.

3. The method of claim 1 , wherein during step (d), a spinning rate of the polymer solution is 2 to 15 μl/min, and
wherein a spinning rate of the first and second portions of the first colloidal solution and the second colloidal solution is 30 to 300 μl/min.

4. The method of claim 1 , wherein the first colloidal solution includes 0.1 to 50% by weight of the conductive material based on a total weight of the first colloidal solution.

5. The method of claim 1 , wherein the polymer solution includes 5 to 30% by weight of the polymer based on a total weight of the polymer solution.

6. The method of claim 1 , wherein step (c) comprises:
injecting the conductive material into the active material particles to prepare a mixed powder;
grinding the mixed powder to obtain a composite of the active material particles and the conductive material; and
dispersing the composite within the dispersion medium to prepare the second colloidal solution.

7. The method of claim 1 , wherein step (b) includes dispersing the conductive material within the dispersion medium to prepare the first colloidal solution.

Assignees

• Ulsan Nat Inst Science & Tech Unist
• Lg Energy Solution Ltd

Inventors

• Uhm In Sung
• Lee Sang Young
• Kwon Yo Han
• Kim Ju Myung
• Lim Joon Won
• Lee Jae Hyun
• Kim Je Young
• Kim Seong Hyeok

Classifications

• H01M4/668 Primary

  Composites of electroconductive material and synthetic resins · CPC title

• H01M4/0435

  Rolling or calendering · CPC title

• H01M4/139

  Processes of manufacture · CPC title

• H01M4/74

  Meshes or woven material; Expanded metal · CPC title

• H01M10/0587

  of accumulators having only wound construction elements, i.e. wound positive electrodes, wound negative electrodes and wound separators · CPC title