Electrode and method of manufacturing an electrode

Abstract

The present invention relates to an electrode and a method of manufacturing an electrode, and more particularly, to an electrode capable of preventing a bending phenomenon of an electrode active material coating or a peeling or breaking phenomenon of the electrode active material, and a method of manufacturing the electrode. The electrode according to the present invention includes a base current collector made of a metal material, and a unit electrode attached to the base current collector, wherein the unit electrode includes a unit current collector made of a metal material and having a size smaller than that of the base current collector, and an electrode active material applied on one surface of the unit current collector.

Description

[0001] Cross Reference to Related Applications

[0002] This application claims the benefit of priority to Korean Patent Application No. 10-2021-0049475, filed on April 15, 2021, and Korean Patent Application No. 10-2022-0014452, filed on February 3, 2022, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present invention relates to an electrode and a method for manufacturing an electrode, and more specifically, to an electrode and a method for manufacturing an electrode capable of preventing bending of the electrode active material coating or peeling or cracking of the electrode active material. Background Technology

[0004] Unlike primary batteries, secondary batteries are rechargeable and offer greater potential for compact size and high capacity. Therefore, much research has been conducted on secondary batteries recently. These batteries are manufactured in packages containing a single battery cell or packages in which dozens of battery cells are interconnected. As a result, secondary batteries are widely used as power sources for vehicle drive motors.

[0005] Typically, through a metal substrate (metal current collector) 11 (see...) Figure 1 The electrode 10 of a secondary battery is manufactured by applying (coating) electrode active material 12 to the electrode.

[0006] Figure 1 It is a perspective view illustrating the state in which electrodes, manufactured according to relevant technologies, are then wound into a roll. Figure 2 It is a diagram of the electrode from Figure 1 The roll manufactured in the process is unrolled and cut using a cutter to obtain a cross-sectional view of the state of the electrode used by realizing the electrode into a specific shape.

[0007] Reference Figure 1 Because the electrode 10 must be transferred or stored before use, the electrode 10 coated with the electrode active material 12 is wound into the shape shown below. Figure 1 The (electrode) roll 30 is shown. When using electrodes of a specific shape while winding and storing electrodes in this manner, such as... Figure 2 The electrodes shown are unrolled from the electrode roll and cut using a cutter 50 to produce electrodes of the desired size.

[0008] There are two problems with the relevant technology in this process.

[0009] First, in the existing electrode, the electrode 10 coated with the electrode active material 12 is wound into a roll 30, and a bending phenomenon of the electrode active material coating or a peeling or breaking phenomenon of the electrode active material occurs at a wound portion of the roll 30. That is, when the electrode 10 is bent, a tension is applied to the electrode active material 12, thereby causing the peeling or breaking phenomenon.

[0010] Second, in the process according to the related art, since the process of cutting the electrode is performed after the electrode active material is applied, a peeling phenomenon of the electrode active material occurs in the cutting process. That is, since the cutting blade 51 of the cutter 50 has a thickness as shown in FIG. 2, when it is deeply inserted into the electrode active material 12 to cut the electrode 10, a tension is applied to the electrode active material 12, and thus the electrode active material 12 is peeled. Figure 2

[0011] As described above, in the method of manufacturing an electrode according to the related art, there is a problem in that a peeling phenomenon of the electrode active material inevitably occurs during the manufacturing process. SUMMARY

[0012] TECHNICAL PROBLEM

[0013] The present application is intended to solve the above problems, and an object of the present application is to provide an electrode and a method of manufacturing an electrode capable of preventing a bending phenomenon of an electrode active material coating or a peeling or breaking phenomenon of an electrode active material from occurring.

[0014] TECHNICAL SOLUTION

[0015] The electrode according to the present application includes a base current collector made of a metal material, and a unit electrode attached to the base current collector, wherein the unit electrode includes a unit current collector made of a metal material and having a size smaller than that of the base current collector, and an electrode active material applied on one surface of the unit current collector.

[0016] The unit electrode can be provided in a plurality, and each of the unit electrodes can have a block shape.

[0017] The base current collector can have a plate shape.

[0018] The unit current collector can have a plate shape, and the electrode active material can be applied to the entire top surface of the unit current collector.

[0019] The plurality of unit electrodes can be arranged to form columns and rows on one surface of the base current collector.

[0020] The arrangement configuration of the plurality of unit electrodes can correspond to the configuration of the base current collector. ​

[0021] The electrode can further include an electrode tab portion extending from one end of the substrate current collector.

[0022] A method of manufacturing an electrode according to the present application includes a unit current collector manufacturing process of cutting a current collector substrate made of a metal material to have a predetermined area and shape based on a plan view, thereby manufacturing a unit current collector; a unit electrode manufacturing process of applying an electrode active material on one surface of the unit current collector to manufacture a unit electrode; and a unit electrode attachment process of attaching the unit electrode on a substrate current collector made of a metal material and having a size greater than that of the unit current collector.

[0023] In the unit electrode attachment process, a plurality of the unit electrodes having a block shape can be attached on the substrate current collector.

[0024] In the unit electrode attachment process, the plurality of unit electrodes can be arranged to form columns and rows on one surface of the substrate current collector.

[0025] In the unit electrode attachment process, the plurality of unit electrodes can be arranged such that a configuration formed by arranging the plurality of unit electrodes corresponds to a configuration of the substrate current collector.

[0026] The method can further include, between the unit electrode manufacturing process and the unit electrode attachment process, a unit electrode storage process of stacking and storing the unit electrode.

[0027] The method can further include, between the unit electrode manufacturing process and the unit electrode storage process, a unit electrode inspection process of inspecting whether the unit electrode is defective to discard a defective unit electrode.

[0028] An electrode assembly including an electrode according to the present application, the electrode assembly being an electrode assembly formed by alternately stacking electrodes and separators, wherein each of the electrodes includes: a substrate current collector made of a metal material; and a unit electrode attached to the substrate current collector, wherein the unit electrode includes: a unit current collector made of a metal material and having a size smaller than that of the substrate current collector; and an electrode active material applied on one surface of the unit current collector.

[0029] Advantageous effects

[0030] In the electrode and the method of manufacturing an electrode according to the present application, it is possible to prevent a bending phenomenon of an electrode active material coating or a peeling or breaking phenomenon of the electrode active material from occurring at the electrode. BRIEF DESCRIPTION OF DRAWINGS

[0031] Figure 1is a perspective view illustrating a state in which an electrode according to the related art is manufactured and then wound into a roll.

[0032] Figure 2 is a sectional view illustrating a state in which a roll manufactured from Figure 1 the electrode according to the related art is unwound and cut using a cutter to use the electrode by implementing the electrode into a specific shape.

[0033] Figure 3 is a view illustrating an electrode according to Embodiment 1 of the present application.

[0034] Figure 4 is a plan view illustrating a state in which unit electrodes according to Embodiment 1 of the present application are attached to a substrate current collector having various sizes and shapes.

[0035] Figure 5 is a view illustrating main processes in a method of manufacturing an electrode according to Embodiment 2 of the present application.

[0036] Figure 6 is a conceptual view illustrating some processes in a method of manufacturing an electrode according to Embodiment 2 of the present application.

[0037] Figure 7 is a view illustrating a unit electrode inspection process in a method of manufacturing an electrode according to Embodiment 2 of the present application. DETAILED DESCRIPTION

[0038] Hereinafter, preferred embodiments of the present application will be described in detail with reference to the accompanying drawings so as to be easily practiced by one of ordinary skill in the art. However, the present application can be embodied in various different forms and should not be limited to the following examples.

[0039] In order to clearly explain the present application, detailed descriptions of parts irrelevant to the description or related known technologies that can unnecessarily obscure the gist of the present application are omitted, and in the present application, reference numerals are added to components in each drawing. In this case, throughout the application, the same or similar elements are assigned the same or similar reference numerals.

[0040] Further, the terms or words used in the present application and claims should not be interpreted as common meanings or dictionary-based meanings, but should be interpreted as meanings and concepts conforming to the principle that the inventor can properly define the terms in order to describe and explain his or her application in the best way based on the technical concept of the present application.

[0041] Embodiment 1

[0042] Figure 3 is a view illustrating an electrode according to Embodiment 1 of the present application.Figure 4 is a plan view illustrating a state in which a unit electrode of an electrode according to Embodiment 1 of the present application is attached to a substrate current collector having various sizes and shapes.

[0043] Referring to Figure 3 , the electrode 100 according to Embodiment 1 of the present application includes a substrate current collector 110 and a unit electrode 120. The substrate current collector 110 is a current collector made of a metal material and forms a lowermost substrate surface of the electrode 100. The unit electrode 120 can be attached to the substrate current collector 110. The unit electrode 120 is made of a metal material and includes a unit current collector 121 having a size smaller than that of the substrate current collector 110 and an electrode active material 122 applied to one surface of the unit current collector 121. Here, the unit current collector 121 can also have a plate shape. The substrate current collector 110 can also have a plate shape. A plurality of unit electrodes 120 can be provided. Further, each unit electrode 120 can have a block shape.

[0044] Figure 3 (b) of FIG. 1 illustrates a state in which one unit electrode 120 is attached to one substrate current collector 110. Of course, in the electrode 100 according to Embodiment 1 of the present application, a plurality of unit electrodes 120 are attached to the substrate current collector 110 to form the electrode 100. However, in order to facilitate description, Figure 3 (b) of FIG. 1 illustrates a state in which only one unit electrode 120 is attached to the substrate current collector 110. Further, Figure 3 (a) of FIG. 1 illustrates a side view when a side portion of the electrode 100 is observed at a position where the unit electrode 120 shown in Figure 3 (b) is attached. Referring to Figure 3 (a) of FIG. 1, the substrate current collector 110 is disposed at a lowermost position, and the unit electrode 120 is attached on the substrate current collector (in Figure 3 (a) of FIG. 1, the unit electrode 120 is represented by a dotted line frame).

[0045] Further, the unit electrode 120 can also include the unit current collector 121 disposed at a lower side and the electrode active material 122 applied to a top surface of the unit current collector. Here, the electrode active material 122 can be applied on the entire top surface of the unit current collector 121. The electrode active material 122 can be applied to the top surface of the unit current collector 121, and a bottom surface of the unit current collector 121 can be attached to the substrate current collector.

[0046] When the electrode 100 is manufactured in this manner, a bending phenomenon of a coating of the electrode active material 122 or a peeling or breaking phenomenon of the electrode active material 122 can be prevented from occurring at the electrode.

[0047] Specifically, in the existing electrode, when the electrode coated with the electrode active material is wound into a roll, a bending phenomenon of the electrode active material coating or a peeling or breaking phenomenon of the electrode active material occurs at the wound portion of the roll. However, in the case of the present application, since the block-shaped unit electrode 120 only needs to be attached to the plate-shaped base current collector 110, tension due to bending does not act on the electrode active material 122, thereby preventing the peeling or breaking phenomenon of the electrode active material 122.

[0048] Referring to Figure 4 , the electrode 100 according to Embodiment 1 of the present application can have a configuration in which a plurality of unit electrodes 120 are arranged to form columns and rows on one surface of the base current collector 110. In addition, the configuration in which the plurality of unit electrodes 120 are arranged can correspond to the configuration of the base current collector 110. When formed in this way, the electrode 100 having various shapes and sizes can be easily manufactured. Figure 4 Examples of manufacturing three types of electrodes 100 are illustrated. As shown in Figure 4 , even though the shapes of the electrodes 100 are different from each other, since all of the electrodes can be manufactured by attaching the same unit electrode 120, the electrodes 100 can be more efficiently manufactured.

[0049] In addition, in the process according to the related art, since the process of cutting the electrode 100 is performed after the electrode active material 122 is applied, a peeling phenomenon of the electrode active material 122 occurs in the cutting process. However, in the case of the present application, since the cutting is performed in the state of the current collector on which the electrode active material is not applied, and the process of cutting the electrode is not performed after the electrode active material 122 is applied, the peeling phenomenon of the electrode active material 122 can be prevented from occurring in the cutting process.

[0050] Referring to Figure 3 and Figure 4 , in order to facilitate the manufacturing, the electrode 100 according to Embodiment 1 of the present application can further include an electrode tab portion 111 extending from one end of the base current collector 110. As described above, when the electrode tab portion 111 is continuously formed on the current collector, the process of attaching the electrode tab can be omitted, and thus the production efficiency can be further improved.

[0051] Embodiment 2

[0052] Figure 5 is a view illustrating main processes in a method of manufacturing an electrode according to Embodiment 2 of the present application. Figure 6 is a conceptual view illustrating some processes in a method of manufacturing an electrode according to Embodiment 2 of the present application. Figure 7is a view illustrating a unit electrode inspection process in a method of manufacturing an electrode according to Embodiment 2 of the present application.

[0053] Embodiment 2 of the present application is different from Embodiment 1 in that Embodiment 2 relates to a method of manufacturing an electrode according to Embodiment 1.

[0054] Repetitive description on Embodiment 1 will be omitted as much as possible, and Embodiment 2 will be described focusing on the differences. That is, contents not described in Embodiment 2 can be obviously considered as those of Embodiment 1 as needed.

[0055] Referring to Figure 5 , the method of manufacturing an electrode 100 according to Embodiment 2 of the present application can include a unit current collector manufacturing process (S10), a unit electrode manufacturing process (S20), and a unit electrode attachment process (S30).

[0056] The unit current collector manufacturing process (S10) can be a process of manufacturing a unit current collector 121 by cutting a current collector base material made of a metal material to have a predetermined area and shape based on a plan view. The size and shape of the unit current collector 121 can be determined according to the purpose and situation of design. Batch production of the unit current collector 121 can be performed according to the size and shape of the unit current collector 121 determined at one time. The plurality of unit current collectors 121 manufactured in this way can have the same shape and size as each other. In addition, the unit current collector 121 can be formed in a rectangular (or square) shape for convenience of attachment, or can be formed in a thin plate shape.

[0057] The unit electrode manufacturing process (S20) can be a process of applying an electrode active material on one surface of the unit current collector 121 to manufacture a unit electrode 120. As Figure 6 indicated in (b) of FIG. 2, the process of applying the electrode active material 122 can be performed while a plurality of unit current collectors 121 having the same shape are conveyed on the conveyor belt B.

[0058] In addition, the unit electrode attachment process (S30) can be a process of attaching the unit electrode 120 manufactured in advance on a base current collector 110 made of a metal material and having a size greater than that of the unit current collector 121 (see Figure 4 ). In the unit electrode attachment process (S30), a plurality of unit electrodes 120 each having a block shape can be attached to the base current collector 110.

[0059] In this case, the attachment (or bonding) between the substrate current collector 110 and the unit electrode 120 can be performed using a vaporized foil actuator welding (VFAW) method. When the unit electrode 120 is bonded to the substrate current collector 110 via vaporized foil actuator welding, adhesion between conductive metals with low resistance can be achieved.

[0060] Multiple unit electrodes 120 can be arranged to form columns and rows on one surface of the substrate current collector 110. Furthermore, the configuration of the multiple unit electrodes 120 can correspond to the configuration of the substrate current collector 110. When formed in this way, electrodes 100 with various shapes and sizes can be easily manufactured.

[0061] Reference Figure 6 A unit electrode storage process (S25) for stacking and storing unit electrodes 120 can be further performed between the unit electrode manufacturing process (S20) and the unit electrode attaching process (S30). Figure 6 Figure (d) illustrates a method for stacking and storing unit electrodes 120 in the unit electrode storage process (S25).

[0062] According to relevant technologies, such as Figure 6 As shown in (c), when an electrode coated with an active electrode material is wound into a roll 30, bending or peeling of the active electrode material occurs at the wound portion of the roll 30, and in addition to bending or peeling, cracking also occurs. However, as Figure 6 As shown in (a), (b), and (d), in the case of the present invention, since only the conveying, stacking, and storage steps of the block-shaped unit electrodes are performed, and the step of winding the unit electrodes into rolls is not performed, peeling or cracking of the electrode active material 122 can be prevented. Even after the storage step, since only the step of attaching the unit electrodes to the substrate current collector is performed, peeling of the electrode active material does not occur throughout the entire process.

[0063] In addition, refer to Figure 7The method of manufacturing an electrode according to Embodiment 2 of the present application can further include a cell electrode inspection process (S23) of inspecting whether the cell electrode 120 is defective to discard the defective cell electrode 120 between the cell electrode manufacturing process (S20) and the cell electrode storage process (S25). The cell electrode inspection process (S23) can be performed on the cell electrode 120 manufactured in the cell electrode manufacturing process (S20). The inspection of whether the electrode 100 is defective can be performed immediately after the completion of the cell electrode manufacturing process (S20). Also, for the cell electrode 120 determined to be defective, only one cell electrode 120 determined to be defective can be discarded.

[0064] In the related art, since the electrode 100 is wound in a roll shape, when a certain portion of the electrode 100 is defective, the entire roll 30 must be discarded. However, in the method of manufacturing an electrode according to Embodiment 2 of the present application, only one cell electrode 120 determined to be defective can be discarded to prevent an increase in manufacturing cost due to the discarding of the entire roll. As a result, an improvement in productivity can also be obtained.

[0065] Embodiment 3

[0066] Embodiment 3 of the present application differs from Embodiment 1 in that Embodiment 3 relates to an electrode assembly manufactured using the electrode according to Embodiment 1.

[0067] Repetitive content with Embodiment 1 will be omitted as much as possible, and Embodiment 3 will be described focusing on the differences. That is, content not described in Embodiment 3 can be obviously considered as content of Embodiment 1 as needed.

[0068] The electrode assembly (not shown) according to Embodiment 3 of the present application can be an electrode assembly formed by alternately stacking separators on the electrode 100 manufactured in Embodiment 1.

[0069] That is, in the electrode assembly according to Embodiment 3 of the present application, the electrode 100 can include a base current collector 110 made of a metal material and a cell electrode 120 attached to the base current collector 110.

[0070] Here, the cell electrode 120 can be made of a metal material and include a cell current collector 121 having a size smaller than that of the base current collector 110 and an electrode active material 122 applied to one surface of the cell current collector 121.

[0071] Figure 4 The electrode 100 formed by attaching a plurality of cell electrodes 120 to the base current collector 110 is illustrated. Thus, when the electrode 100 and the separator are alternately stacked, the electrode assembly according to Embodiment 3 of the present application can be manufactured.

[0072] While embodiments of the present application have been described with reference to particular embodiments, it will be apparent to those skilled in the art that various changes and modifications can be made without departing from the spirit and scope of the application as defined in the following claims.

[0073] [Reference Signs]

[0074] 100: electrode

[0075] 110: substrate current collector

[0076] 111: electrode tab portion

[0077] 120: unit electrode

[0078] 121: unit current collector

[0079] 122: electrode active material

[0080] B: conveyor belt.

Claims

1. An electrode comprising: a base current collector made of a metal material; and a unit electrode attached to the base current collector, wherein the unit electrode comprises: a unit current collector made of a metal material and having a size smaller than that of the base current collector; and an electrode active material applied on one surface of the unit current collector, wherein the unit electrode is provided in a plurality, and each of the unit electrodes has a block shape.

2. The electrode according to claim 1, wherein the base current collector has a plate shape.

3. The electrode according to claim 1, wherein the unit current collector has a plate shape, and the electrode active material is applied to the entire top surface of the unit current collector.

4. The electrode according to claim 1, wherein the plurality of unit electrodes are arranged to form columns and rows on one surface of the base current collector.

5. The electrode according to claim 1, wherein the arrangement of the plurality of unit electrodes corresponds to the arrangement of the base current collector.

6. The electrode according to claim 1, further comprising an electrode tab portion extending from one end of the base current collector.

7. A method of manufacturing an electrode, the method comprising: a unit current collector manufacturing step (S10) of cutting a current collector base material made of a metal material into a predetermined area and shape based on a plan view, thereby manufacturing a unit current collector; a unit electrode manufacturing step (S20) of applying an electrode active material on one surface of the unit current collector to manufacture a unit electrode; and a unit electrode attachment step (S30) of attaching the unit electrode on a base current collector made of a metal material and having a size larger than that of the unit current collector, wherein, in the unit electrode attachment step, a plurality of the unit electrodes having a block shape are attached on the base current collector. In the unit electrode attachment step, the plurality of unit electrodes are arranged to form columns and rows on one surface of the base current collector. In the unit electrode attachment step, the plurality of unit electrodes are arranged such that an arrangement formed by arranging the plurality of unit electrodes corresponds to an arrangement of the base current collector. a unit electrode storage step (S25) of stacking and storing the unit electrodes.

8. The method of claim 7, wherein, a unit electrode inspection step (S23) of inspecting the unit electrodes for defects to discard defective unit electrodes.

9. The method of claim 7, wherein, 12. An electrode assembly formed by alternately stacking electrodes and separators, 10. The method according to claim 7, further comprising between the unit electrode manufacturing step (S20) and the unit electrode attaching step (S30): wherein each of the electrodes comprises:

11. The method according to claim 10, further comprising between the unit electrode manufacturing process (S20) and the unit electrode storing process (S25): a base current collector made of a metal material; and a unit electrode attached to the base current collector, wherein the unit electrode comprises: a unit current collector made of a metal material and having a size smaller than that of the base current collector; and an electrode active material applied on one surface of the unit current collector, wherein the unit electrode is provided in a plurality, and each of the unit electrodes has a block shape. ​ ​ ​ ​ ​

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