Current collector, electrode structure, nonaqueous electrolyte battery and electrical storage device, and method for producing current collector

Patent metadata

Field	Value
Publication number	US-9508994-B2
Application number	US-201314397115-A
Country	US
Kind code	B2
Filing date	May 10, 2013
Priority date	May 15, 2012
Publication date	Nov 29, 2016
Grant date	Nov 29, 2016

Abstract

A current collector, an electrode structure, a non-aqueous electrolyte battery, and an electrical storage device capable of providing superior shut down function are provided. According to the present invention, a current collector having a resin layer on at least one side of a conductive substrate, wherein: the resin layer has a thermoplastic resin dispersed in a thermosetting resin base material, the thermoplastic resin encapsuling a conductive agent; a value given by (average thickness of the conductive agent)/(average thickness of the thermoplastic resin) is 0.5 to 3; the conductive agent is formulated so that a value of volume % given by (conductive agent)/(conductive agent+thermoplastic resin) is 10 to 50%; and formulation ratio of the thermoplastic resin is 10 to 65%, is provided.

First claim

The invention claimed is:

1. A current collector having a resin layer on at least one side of a conductive substrate, wherein:
the resin layer has a thermoplastic resin dispersed in a thermosetting resin base material, the thermoplastic resin encapsuling at least a part of a conductive agent;
the thermosetting resin base material is formed with a composition comprising a thermosetting resin and a hardening agent;
the conductive agent is substantially dispersed only in the thermoplastic resin;
a value given by (average thickness of the conductive agent)/(average thickness of the thermoplastic resin) is 0.5 to 3;
the conductive agent is formulated so that a value of volume % given by (the conductive agent)/(the conductive agent+the thermoplastic resin) is 10% to 50%; and
formulation ratio of the thermoplastic resin is 10% to 65 volume %, wherein the formulation ratio is given by the formula: (volume of the thermoplastic resin+volume of the conductive agent)/(volume of the thermoplastic resin+volume of the conductive agent+volume of the thermosetting resin+volume of the hardening agent).

2. The current collector of claim 1 , wherein the thermoplastic resin has a melting point of 50° C. or higher and 200° C. or lower.

3. The current collector of claim 1 , wherein a value given by (average thickness of the thermoplastic resin)/(average thickness of the thermosetting resin base material) is 0.9 to 3.5.

4. The current collector of claim 1 , wherein the thermoplastic resin is at least one selected from the group consisting of a polyethylene-based resin, a polypropylene-based resin, a polyvinylidene fluoride-based resin, a polyvinyl butyral-based resin, and modified resins thereof.

5. The current collector of claim 1 , wherein the conductive agent comprises carbon black.

6. The current collector of claim 1 , wherein:
the thermosetting resin is a mixture or a copolymer comprising at least one type selected from the group consisting of a polyacrylic acid-based resin, a nitrocellulose-based resin, and a chitosan-based resin.

7. An electrode structure comprising an active material layer or an electrode material layer on the resin layer of the current collector of claim 1 .

8. A non-aqueous electrolyte battery or an electrical storage device comprising the electrode structure of claim 7 .

9. A method for manufacturing a current collector according to claim 1 , the method comprising the steps of:
applying a resin layer material on at least one side of a conductive substrate; and
baking the resin layer material at 120° C. to 230° C.; wherein
the resin layer material is obtained by emulsifying a thermoplastic resin solution in a thermosetting resin solution, the thermoplastic resin solution having a thermoplastic resin and a conductive agent dispersed or dissolved in an organic solvent, and the thermosetting resin solution having a thermosetting resin and a hardening agent dispersed or dissolved in water.

Assignees

• Uacj Corp
• Uacj Foil Corp

Inventors

• Kato Osamu
• Saito Sohei
• HONKAWA Yukiou
• Wasamoto Mitsuyuki
• Kataoka Tsugio
• Yamabe Satoshi

Classifications

• H01M4/666

  in the form of mixed materials (H01M4/668 takes precedence) · CPC title

• H01M2200/103

  Fuse · CPC title

• H01M4/667 Primary

  in the form of layers, e.g. coatings · CPC title

• H01M10/052

  Li-accumulators · CPC title

• H01M4/663

  containing carbon or carbonaceous materials as conductive part, e.g. graphite, carbon fibres · CPC title