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

Patent metadata

Field	Value
Publication number	US-9786919-B2
Application number	US-201314399492-A
Country	US
Kind code	B2
Filing date	May 10, 2013
Priority date	May 15, 2012
Publication date	Oct 10, 2017
Grant date	Oct 10, 2017

Abstract

Current collector, an electrode structure, a non-aqueous electrolyte battery, and an electrical storage device having 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 is provided. Here, thermoplastic resin particles substantially free of a conductive agent are dispersed in a thermosetting resin base material containing the conductive agent to structure the resin layer; a value of mass ratio given by (thermoplastic resin particles)/(conductive agent) is 0.3 to 1.5; and a value given by (average thickness of conductive agent)/(average thickness of thermoplastic resin particles) is 0.3 to 4.0.

First claim

The invention claimed is:

1. A current collector having a resin layer on at least one side of a conductive substrate, wherein:
thermoplastic resin particles substantially free of a conductive agent are dispersed in a thermosetting resin base material containing particles of conductive agent to structure the resin layer, wherein the thermoplastic resin particles substantially free of a conducting agent do not provide a conductive pathway for electrons via the thermoplastic resin particles;
a value of mass ratio given by (thermoplastic resin particles)/(conductive agent) is 0.3 to 1.5;
a value given by (average thickness of conductive agent)/(average thickness of thermoplastic resin particles) is 0.3 to 4.0; and
a value given by (average thickness of thermoplastic resin particles)/(average thickness of thermosetting resin base material) is 1.0 to 3.0;
wherein the thermosetting resin base material containing the particles of conductive agent and the thermoplastic resin particles substantially free of a conductive agent have different thermal expansion coefficients, and the thermoplastic resin particles are configured to expand with an increase in temperature to sever a connection between the particles of conductive agent.

2. The current collector of claim 1 , wherein a value given by (average thickness of conductive agent)/(average thickness of thermosetting resin base material) is 1.0 to 3.0.

3. The current collector of claim 1 , wherein the thermoplastic resin particles are water-insoluble.

4. The current collector of claim 1 , wherein a value of mass ratio given by (conductive agent)/(thermosetting resin base material) is 0.1 to 0.5.

5. The current collector of claim 1 , wherein a value of mass ratio given by (thermoplastic resin particles)/(thermosetting resin base material) is 0.09 to 0.4.

6. The current collector of claim 1 , wherein the thermosetting resin base material is formed from a resin composition comprising a thermosetting resin, a hardening agent, and particles of conductive agent.

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

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

9. The current collector of claim 1 , wherein the thermoplastic resin particles are one or more types of resin selected from the group consisting of polyethylene-based resin, polypropylene-based resin, polyvinylidene fluoride-based resin, polyvinyl butyral-based resin, and modified resins thereof.

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

11. A non-aqueous electrolyte battery or an electrical storage device comprising the electrode structure of claim 10 .

12. A method for manufacturing a current collector according to claim 1 , 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 to 230° C.; wherein
the resin layer material comprises:
a thermosetting resin solution containing a thermosetting resin, a hardening agent and particles of conductive agent; and
thermoplastic resin particles dispersed in the thermosetting resin solution.

13. The method of claim 12 , wherein the resin layer material is prepared by a method comprising the steps of:
(1) preparing an aqueous emulsion of the thermosetting resin;
(2) mixing the emulsion with particles of conductive agent;
(3) further adding the emulsion to the mixture obtained by step (2);
(4) adding the thermoplastic resin particles to the mixture obtained by step (3); and
(5) adding the hardening agent to the mixture obtained by step (4); wherein
the particles of conductive agent are added so that a value of mass ratio given by (conductive agent)/(thermosetting resin+hardening agent+conductive agent) is 0.1 to 0.5.

14. The method of claim 13 , wherein the hardening agent is added so that a value of mass ratio of solid content given by (hardening agent)/(thermosetting resin) is 0.02 to 0.5.

Assignees

• Uacj Corp
• Uacj Foil Corp

Inventors

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

Classifications

• H01M4/661 Primary

  Metal or alloys, e.g. alloy coatings (H01M4/669 take precedence) · CPC title

• Y02E60/13

  Energy storage using capacitors · CPC title

• H01G11/70

  characterised by their structure · CPC title

• H01M4/625 Primary

  Carbon or graphite · CPC title

• H01G11/68

  characterised by their material · CPC title