Method for manufacturing electrode of rechargeable battery

Abstract

A method of manufacturing an electrode of a rechargeable battery, the method comprising: a first step of injection-molding a plate-shaped electrode sheet in an injection mold using an electrode mixture input to an injection device to obtain a molded electrode sheet; step 2, moving the formed electrode plate to a metal substrate; and a third step of laminating the metal substrate and the molded electrode sheet.

Description

Technical Field

[0001] Embodiments relate to a method of manufacturing an electrode of a rechargeable battery. Background Art

[0002] Unlike primary batteries, rechargeable batteries are batteries that are repeatedly charged and discharged. Small-capacity rechargeable batteries are used in small portable electronic devices such as mobile phones, laptop computers, and video cameras, and large-capacity secondary batteries are used as power sources for driving motors in hybrid vehicles and electric vehicles.

[0003] For example, a rechargeable battery includes: an electrode assembly that performs charging and discharging, a bag that accommodates the electrode assembly, and an electrode terminal that electrically connects the electrode assembly and extends to the outside of the bag. The electrode assembly includes: a winding type electrode assembly in which a negative electrode plate and a positive electrode plate are wound on both sides with a separator between the negative electrode plate and the positive electrode plate; and a stacked type electrode assembly in which a negative electrode plate and a positive electrode plate are stacked on both sides with a separator between the negative electrode plate and the positive electrode plate.

[0004] The electrode plate process for manufacturing the electrode plate includes: a mixing step of mixing active material slurry; a coating step of coating the coated portion of the active material slurry on a metal substrate; a pressing step of compressing the coated portion of the active material slurry; a cutting step of cutting the metal substrate; and a shearing step.

[0005] In the coating step, loss occurs in the active material slurry and the metal substrate due to deviation of the conditions at the start of production, and in the cutting step, loss occurs in the active material slurry and the metal substrate due to the punching of the electrode plate. In the shearing step, wrinkles appear in the uncoated area, increasing the defect rate. In addition, if the type of rechargeable battery is changed, time loss occurs due to changing to a metal substrate of a different width and changing the coating mold. Summary of the invention

[0006] The embodiment includes a method for manufacturing an electrode of a rechargeable battery. The method includes: a first step of injecting a plate-shaped electrode sheet into an injection mold using an electrode mixture input into an injection device to obtain a molded electrode sheet; a second step of moving the molded electrode sheet onto a metal substrate; and a third step of laminating the metal substrate and the molded electrode sheet.

[0007] In the third step, the metal substrate may be cut, the molded electrode sheet may be laminated on one surface of the metal substrate in a pressing device, and the molded electrode sheet may be laminated on the other surface of the metal substrate.

[0008] In the third step, the metal substrate may be cut, and in a pressing device, the molded electrode sheets may be disposed on both surfaces of the metal substrate and laminated.

[0009] For the positive electrode, the electrode mixture may include a positive electrode active material, a binder, a conductive material, and a curing agent, and may have a positive electrode active material:binder:conductive material:curing agent ratio of 96.9:1.8:2:2.

[0010] For the positive electrode, based on 100 wt % of the electrode mixture, the electrode mixture may include: 85.0 wt % to 98.5 wt % of a positive electrode active material, 0.5 wt % to 5.0 wt % of a binder, 0.5 wt % to 5.0 wt % of a conductive material, and 0.5 wt % to 5.0 wt % of a curing agent.

[0011] The binder helps the positive electrode active material and the conductive material to be bonded to the metal substrate, and can be formed of one of polyvinylidene fluoride, polyvinyl alcohol, carboxymethyl cellulose (CMC), starch, hydroxypropyl cellulose, regenerated cellulose, polyvinyl pyrrolidone, tetrafluoroethylene, polyethylene, polypropylene, ethylene-propylene-diene terpolymer (EPDM), sulfonated EPDM, styrene-butadiene rubber and fluororubber.

[0012] The conductive material may include a non-linear first conductive material and a linear second conductive material.

[0013] The nonlinear first conductive material may include at least one of Denka black and a carbon-based material, wherein the Denka black and the carbon-based material include carbon black, acetylene black, Ketjen black, channel black, furnace black, lamp black, thermal black and conductive carbon black.

[0014] The nonlinear first conductive material may have an average particle size of 50 nm to 110 nm, the linear second conductive material may be a linear carbon nanotube (CNT) manufactured by a wet grinding process, and the average length of the linear carbon nanotube may be 1 μm to 5 μm.

[0015] The curing agent may include one of an epoxy resin and a phenolic resin.

[0016] The epoxy resin may include at least one of bisphenol A epoxy resin, bisphenol F epoxy resin, bisphenol S epoxy resin, bisphenol epoxy resin, novolac epoxy resin, cresol novolac epoxy resin, bisphenol A novolac epoxy resin, bisphenol F novolac epoxy resin, novolac salicylic acid novolac epoxy resin, alicyclic epoxy resin, aliphatic chain epoxy resin, glycidyl ester type epoxy resin and modified resins thereof.

[0017] The phenolic resin may include at least one of bisphenol F, bisphenol A, bisphenol S, polyvinylphenol, phenol, cresol, alkylphenol, catechol, novolac resin and halogenated substitutes thereof.

[0018] In the second step, the electrode sheet, which may be molded and separated from the injection mold and then freely dropped or may be moved using a jig, is moved onto the metal substrate.

[0019] For the negative electrode, based on 100 wt % of the electrode mixture, the electrode mixture may include: 85.0 wt % to 98.5 wt % of a negative electrode active material, 0.5 wt % to 5.0 wt % of a binder, 0.5 wt % to 5.0 wt % of a conductive material, and 0.5 wt % to 5.0 wt % of a curing agent.

[0020] In the first step, a rectangular space is formed using an upper mold and a lower mold of an injection mold, and the electrode sheet is formed into a plate-shaped rectangular parallelepiped.

[0021] In the first step, the overall thickness of the electrode sheet may be formed uniformly.

[0022] In the first step, the chamfer of the electrode sheet where the thickness gradually becomes thinner on the outer portion of one surface of the electrode sheet is formed by a convex circular area at the corner of the inner space of the lower mold in the upper mold and the lower mold of the injection mold.

[0023] In the third step, the metal substrate is unwound and continuously supplied to a pressing device, and the electrode sheets are laminated on both surfaces of the metal substrate in the pressing device, and the metal substrate laminated with the electrode sheets is rewound.

[0024] According to an embodiment of the present disclosure, a method for manufacturing an electrode of a rechargeable battery includes: a first step of injecting a plate-shaped electrode sheet into an injection mold using an electrode mixture input into an injection device; a second step of moving the electrode sheet formed in the first step onto a metal substrate; and a third step of laminating the metal substrate and the electrode sheet.

[0025] In the third step, the metal substrate is cut, the electrode sheet may be laminated on one surface of the metal substrate, and the electrode sheet may be laminated on the other surface of the metal substrate in a pressing device.

[0026] In the third step, the metal substrate is cut, and in a pressing device, electrode sheets may be disposed on both surfaces of the metal substrate and laminated.

[0027] In the case of a positive electrode, the electrode mixture may include a positive electrode active material, a binder, a conductive material, and a curing agent, and may have a positive electrode active material:binder:conductive material:curing agent ratio of 96.9:1.8:2:2.

[0028] In the case of a positive electrode, based on 100 wt % of the electrode mixture, the electrode mixture may include: 85.0 wt % to 98.5 wt % of a positive electrode active material, 0.5 wt % to 5.0 wt % of a binder, 0.5 wt % to 5.0 wt % of a conductive material, and 0.5 wt % to 5.0 wt % of a curing agent.

[0029] The binder helps the positive electrode active material and the conductive material to be bonded to the metal substrate, and can be formed of one of polyvinylidene fluoride, polyvinyl alcohol, carboxymethyl cellulose (CMC), starch, hydroxypropyl cellulose, regenerated cellulose, polyvinyl pyrrolidone, tetrafluoroethylene, polyethylene, polypropylene, ethylene-propylene-diene terpolymer (EPDM), sulfonated EPDM, styrene-butadiene rubber and fluororubber.

[0030] The conductive material may include a non-linear first conductive material and a linear second conductive material.

[0031] The nonlinear first conductive material may include at least one selected from the group consisting of Denka black and carbon-based materials such as carbon black, acetylene black, Ketjen black, channel black, furnace black, lamp black, thermal black, and conductive black (Super-P).

[0032] The nonlinear first conductive material may have an average particle size of 50 nm to 110 nm, the linear second conductive material may be a linear carbon nanotube (CNT) manufactured by a wet grinding process, and the average length of the carbon nanotube may be 1 μm to 5 μm.

[0033] The curing agent may be formed of one of an epoxy-based resin and a phenol-based resin.

[0034] The epoxy resin may include at least one selected from the group consisting of bisphenol A epoxy resin, bisphenol F epoxy resin, bisphenol S epoxy resin, bisphenol epoxy resin, novolac epoxy resin, cresol novolac epoxy resin, bisphenol A novolac epoxy resin, bisphenol F novolac epoxy resin, novolac salicylic acid novolac epoxy resin, alicyclic epoxy resin, aliphatic chain epoxy resin, glycidyl ester type epoxy resin and modified resins thereof.

[0035] The phenolic resin may include at least one selected from the group consisting of bisphenol F, bisphenol A, bisphenol S, polyvinylphenol, phenol, cresol, alkylphenol, catechol, novolac resin and halogenated substitutes thereof.

[0036] In the second step, the electrode sheet, which is molded and separated from the injection mold and then freely dropped or moved with a jig, may be moved onto a metal substrate.

[0037] In the case of a negative electrode, based on 100 wt % of the electrode mixture, the electrode mixture may include: 85.0 wt % to 98.5 wt % of a negative electrode active material, 0.5 wt % to 5.0 wt % of a binder, 0.5 wt % to 5.0 wt % of a conductive material, and 0.5 wt % to 5.0 wt % of a curing agent.

[0038] In the first step, a rectangular space may be formed using an upper mold and a lower mold of an injection mold, and the electrode sheet may be formed into a plate-shaped rectangular parallelepiped.

[0039] In the first step, the overall thickness of the electrode sheet may be formed uniformly.

[0040] In the first step, a chamfer of the electrode sheet where the thickness gradually becomes thinner on the outer portion of one surface of the electrode sheet is formed by a convex circular area at a corner of an inner space of a lower mold in an upper mold and a lower mold of an injection mold.

[0041] In the third step, the metal substrate may be unwound and continuously supplied to a pressing device, and the electrode sheets are laminated on both surfaces of the metal substrate in the pressing device, and the metal substrate laminated with the electrode sheets is rewound. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Features will become apparent to those skilled in the art by describing in detail exemplary embodiments with reference to the accompanying drawings, in which:

[0043] Figure 1 is a flow chart of a method for manufacturing an electrode of a rechargeable battery according to one or more embodiments of the present disclosure;

[0044] Figure 2 A cross-sectional view of using an electrode mixture to inject and mold an electrode sheet and moving the electrode sheet in a method for manufacturing an electrode of a rechargeable battery according to one or more embodiments of the present disclosure;

[0045] Figure 3 For injection molding according to one or more embodiments of the present disclosure Figure 2 An exploded perspective view of an injection mold for an electrode sheet;

[0046] Figure 4 For use according to one or more embodiments of the present disclosure Figure 3 A perspective view of an electrode sheet injection-molded by an injection mold;

[0047] Figure 5 is a cross-sectional view of laminating a moving electrode sheet on both sides of a metal substrate according to one or more embodiments of the present disclosure;

[0048] Figure 6is a cross-sectional view of an injection mold for injection-molding an electrode sheet using an electrode mixture in a method for manufacturing an electrode of a rechargeable battery according to one or more embodiments of the present disclosure;

[0049] Figure 7 According to one or more embodiments of the present disclosure Figure 6 A top view of the interior of the lower mold of the injection mold;

[0050] Figure 8 For use according to one or more embodiments of the present disclosure Figure 6 A side view of an electrode sheet injection-molded by an injection mold; and

[0051] Fig. 9 is a cross-sectional view of laminating electrode sheets on both sides of a metal substrate in a method of manufacturing an electrode of a rechargeable battery according to one or more embodiments of the present disclosure. DETAILED DESCRIPTION

[0052] Example embodiments will now be described more fully hereinafter with reference to the accompanying drawings; however, they may be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey exemplary implementations to those of ordinary skill in the art.

[0053] In the accompanying drawings, the dimensions of layers and regions may be exaggerated for clarity of illustration. It will also be understood that if a layer or element is referred to as being "on" another layer or element, it can be directly on the other layer or element, or intervening layers or elements may also exist. Further, it will be understood that if a layer is referred to as being "below" another layer, it can be directly below the other layer, or one or more intervening layers may also exist. In addition, it will be understood that if a layer is referred to as being "between" two layers, it can be the only layer between the two layers, or one or more intervening layers may also exist. The same reference numerals refer to the same elements throughout.

[0054] Hereinafter, the present disclosure will be more fully described with reference to the attached drawings showing exemplary embodiments of the present disclosure. As will be appreciated by those skilled in the art, the described embodiments may be modified in various ways without departing from the spirit or scope of the present disclosure. The drawings and descriptions are to be considered illustrative rather than restrictive in nature.

[0055] Figure 1 1 is a flow chart of a method for manufacturing an electrode of a rechargeable battery according to one or more embodiments of the present disclosure. Figure 1 , the method for manufacturing an electrode of a rechargeable battery according to the first embodiment includes a first step ST1 , a second step ST2 , and a third step ST3 .

[0056] Figure 2 is a cross-sectional view of injecting and molding an electrode sheet using an electrode mixture and moving the electrode sheet in a method of manufacturing an electrode of a rechargeable battery according to one or more embodiments, and Figure 3 For injection molding according to one or more embodiments Figure 2 An exploded perspective view of the injection mold of the electrode sheet.

[0057] See also Figure 1 to Figure 3 In the first step ST1, the electrode mixture M input to the injection device 10 is used to inject and mold a flat plate-shaped electrode sheet S1 in the injection mold 20. In the second step ST2, the electrode sheet S1 molded in the first step ST1 is moved to the metal substrate S2 (see Figure 5 In the third step ST3, the electrode 40 (see Figure 5 ) by laminating the metal substrate S2 and the electrode sheet S1 (see Figure 5 That is, in the third step ST3, the metal substrate S2 and the electrode sheet S1 are attached to each other by pressing the metal substrate S2 and the electrode sheet S1 at a high temperature.

[0058] If a positive electrode is manufactured, the electrode mixture M input to the injection device 10 may be configured to form a positive electrode. The positive electrode mixture M may contain a positive electrode active material, a binder, a conductive material, and a curing agent, and these have a set ratio. For example, the positive electrode active material, the binder, the conductive material, and the curing agent may have a ratio of 96.9:1.8:2:2.

[0059] In addition, based on 100wt% of the positive electrode mixture, the positive electrode mixture M may include: 85.0wt% to 98.5wt% of the positive electrode active material, 0.5wt% to 5.0wt% of the binder, 0.5wt% to 5.0wt% of the conductive material, and 0.5wt% to 5.0wt% of the curing agent. The positive electrode active material is the part that acts as the positive electrode in the electrode. If the positive electrode active material is less than 85.0wt%, the performance of the positive electrode active material may be reduced. By setting the maximum value of the positive electrode active material to 98.5wt%, the binder, the conductive material, and the curing agent may be included.

[0060] The binder helps the positive electrode active material and the conductive material to be bonded to the metal substrate S2. If the binder is less than 0.5 wt%, injection molding of the electrode sheet S1 may be difficult due to weak bonding force, and if the binder exceeds 5.0 wt%, the effects of other components may be reduced.

[0061] For example, the binder may include or be formed from: one of polyvinylidene fluoride, polyvinyl alcohol, carboxymethyl cellulose (CMC), starch, hydroxypropyl cellulose, regenerated cellulose, polyvinyl pyrrolidone, tetrafluoroethylene, polyethylene, polypropylene, ethylene-propylene-diene terpolymer (EPDM), sulfonated EPDM, styrene-butadiene rubber and fluororubber.

[0062] The conductive material may include a nonlinear first conductive material and a linear second conductive material. The conductive material contributes to the conductivity of the positive electrode active material and the metal substrate S2. If the conductive material is less than 0.5wt%, the conductivity of the positive electrode active material and the metal substrate S2 may be reduced because the conductive assistance is weak, and if the conductive material exceeds 5.0wt%, the effects of other components may be reduced.

[0063] For example, the nonlinear first conductive material may include at least one of Denka black and a carbon-based material (such as carbon black, acetylene black, Ketjen black, channel black, furnace black, lamp black, thermal black, and Super-P). The nonlinear first conductive material may have an average particle size of 50 nm to 110 nm, and the linear second conductive material may be a linear carbon nanotube (CNT) manufactured by a wet grinding process. The average length of the linear carbon nanotube may be 1 μm to 5 μm.

[0064] The curing agent hardens the electrode mixture M injected into the mold 20 , allowing the electrode mixture M to be separated from the injection mold 20 and move to the metal substrate S2 .

[0065] The curing agent helps to shape the electrode mixture M into the electrode sheet S1. If the curing agent is less than 0.5 wt%, the moldability of the electrode sheet S1 may be reduced because the molding aid is weak, and if the curing agent exceeds 5.0 wt%, the effects of other components may be reduced.

[0066] For example, the curing agent may include one of epoxy resin and phenolic resin. In addition, the epoxy resin may include at least one of bisphenol A epoxy resin, bisphenol F epoxy resin, bisphenol S epoxy resin, bisphenol epoxy resin, novolac epoxy resin, cresol novolac epoxy resin, bisphenol A novolac epoxy resin, bisphenol F novolac epoxy resin, phenolic salicylic acid novolac epoxy resin, alicyclic epoxy resin, aliphatic chain epoxy resin, glycidyl ester type epoxy resin and modified resin thereof.

[0067] In addition, the phenolic resin may include at least one of bisphenol F, bisphenol A, bisphenol S, polyvinylphenol, phenol, cresol, alkylphenol, catechol, novolac resin and halogenated substitutes thereof.

[0068] If a negative electrode is manufactured, the electrode mixture M input to the injection device 10 can be configured to form a negative electrode. The negative electrode mixture M may include a negative electrode active material, a binder, a conductive material, and a curing agent. In addition, based on 100wt% of the negative electrode mixture M, the negative electrode mixture M may include 85.0wt% to 98.5wt% of the negative electrode active material, 0.5wt% to 5.0wt% of the binder, 0.5wt% to 5.0wt% of the conductive material, and 0.5wt% to 5.0wt% of the curing agent. Because the effects of the binder, the conductive material, and the curing agent on the negative electrode active material are the same as the effects of the binder, the conductive material, and the curing agent on the positive electrode active material of the positive electrode, a detailed description is omitted.

[0069] In the first step ST1, a rectangular space may be formed using the upper mold 21 and the lower mold 22 of the injection mold 20, and the electrode sheet S1 may be formed into a plate-shaped rectangular parallelepiped. In the first step ST1, the overall thickness of the electrode sheet S1 may be uniformly formed. In some embodiments, the temperature of the injection mold 20 may be in the range of 100°C to 230°C.

[0070] Figure 3 For injection molding according to one or more embodiments Figure 2 An exploded perspective view of the injection mold of the electrode sheet, Figure 4 For use according to one or more embodiments Figure 3 A perspective view of an electrode sheet being injection molded in an injection mold. Figure 2 to Figure 4 In order to manufacture the electrode sheet S1, an injection device 10 and an injection mold 20 may be prepared.

[0071] The injection device 10 may be configured to inject the electrode mixture M input to the hopper 11 into the inside of the injection mold 20 connected to the discharge port 13 by rotating the screw 12. A heater 14 may be provided outside the screw 12 and the discharge port 13 to facilitate the injection of the electrode mixture M.

[0072] The injection mold 20 may include an upper mold 21 and a lower mold 22 for molding the electrode sheet S1. The upper mold 21 may include a plate forming area 211 formed into a shape corresponding to a plate by rectangular parallelepiped carving, and an injection hole 212 for injecting the electrode mixture M into the interior of the injection mold 20. The injection hole 212 may be provided in a variety of line types so that the electrode mixture M can be uniformly and quickly injected into the interior of the injection mold 20. The lower mold 22 may be formed with a plate forming area 221 formed into a shape corresponding to a plate by rectangular parallelepiped carving. The inner surface of the lower mold 22 may have a rectangular shape.

[0073] Figure 5 FIG. 1 is a cross-sectional view of laminating a moving electrode sheet on both sides of a metal substrate according to one or more embodiments. Figure 1 to Figure 5 In the second step ST2 , the electrode sheet S1 , which is molded and separated from the injection mold 20 and then freely dropped or moved using a jig (not shown), may be moved onto the metal substrate S2 .

[0074] In the third step ST3, the metal substrate S2 is cut. In the third step ST3, in the pressing device 30, the electrode sheet S1 can be laminated on one surface of the metal substrate S2 by heat pressure P, and the electrode sheet S1 can be laminated on the other surface of the metal substrate S2 by heat pressure P. The electrode sheet S1 can be laminated on both surfaces of the metal substrate S2 by two heat pressure lamination processes. Therefore, the electrode 40 of the rechargeable battery can be completed.

[0075] See also Figure 5 In the third step ST3, in the pressing device 30, the electrode sheet S1 may be disposed on both surfaces of the metal substrate S2 and may be laminated. Through a single lamination process, the electrode sheet S1 is laminated on both sides of the metal substrate S2, respectively. Thus, the electrode 40 of the rechargeable battery may be completed.

[0076] In this way, by producing the electrode sheet S1 using the injection mold 20, no loss of the electrode mixture (including active materials) occurs, wrinkles are prevented from being generated in the uncoated area of ​​the metal substrate S2, and loss of the metal substrate S2 due to edge shearing can be minimized.

[0077] Different electrode sheets S1 can be injection molded by replacing the injection mold 20, thereby reducing material loss and time loss when converting electrode specifications.

[0078] The injection mold 20 molds the thickness of the electrode sheet S1 to be thicker than that of a conventional electrode sheet and is made of a rectangular parallelepiped plate so that if the electrode assembly is embedded in a bag, the rounding of the bag is minimized to achieve a large capacity design. The rectangular electrode sheet S1 is conducive to the management of the negative-positive ratio (N / P ratio).

[0079] Hereinafter, various embodiments of the present disclosure will be described. Descriptions of the same configurations as those of the first embodiment and the previously described embodiments will be omitted, and descriptions of different configurations will be described.

[0080] Figure 6 is a cross-sectional view of an injection mold for injecting and molding an electrode sheet using an electrode mixture in a method for manufacturing an electrode of a rechargeable battery according to one or more embodiments of the present disclosure, Figure 7 According to one or more embodiments Figure 6 A top view of the interior of the lower mold of the injection mold, and Figure 8 For use according to one or more embodiments Figure 6Side view of the injection mold for injection-molded electrode sheets.

[0081] See also Figure 6 to Figure 8 , the injection mold 60 used in the first step ST1' in the manufacturing method according to one or more embodiments includes an upper mold 21 and a lower mold 62. The lower mold 62 may include a plate forming area 621 formed into a shape corresponding to a plate by rectangular parallelepiped carving, and may include a convex circular area 622 at a corner of the internal space. For example, the curvature radius of the convex circular area 622 may be in the range of 0 mm to 30 mm.

[0082] In the first step ST1', the chamfer S11 of the electrode sheet S1' may be formed by a convex circular area 622 at a corner of the lower mold 62 of the injection mold 60, where the thickness may gradually become thinner on an outer portion of one surface of the electrode sheet S1'. The chamfer S11 may further prevent defects from occurring at the corner of the electrode sheet S1'.

[0083] Fig. 9 2 is a cross-sectional view of laminating electrode sheets on both sides of a metal substrate in a method for manufacturing an electrode of a rechargeable battery according to one or more embodiments of the present disclosure. Fig. 9 In the manufacturing method according to one or more embodiments, in the third step ST3", the metal substrate S2" can be unwound on the unwinding reel R1 and continuously supplied to the pressing device 30. The electrode sheet S1 can be laminated on both surfaces of the metal substrate S2" in the pressing device 30, and the metal substrate S2" laminated with the electrode sheet S1 is rewound on the rewinding reel R2.

[0084] The unwinding reel R1 can supply the metal substrate S2", and the rewinding reel R2 can rewind the electrode sheets S1 laminated on both surfaces of the metal substrate S2". The metal substrate S2" realizes a continuous process, which can implement the efficiency of the process of laminating the electrode sheets S1, and the metal substrate S2" allows a core type electrode assembly to be formed together with the laminated electrode sheets S1.

[0085] Embodiments of the present disclosure provide a method for manufacturing an electrode for a rechargeable battery, capable of eliminating or reducing the loss and defect rate of an electrode mixture (including an active material) and a metal substrate.

[0086] According to an embodiment, the injection mold can be manufactured into the shape of an electrode sheet to reduce the loss of an electrode mixture containing an active material, and the molded electrode sheet can be laminated with a metal substrate to prevent defects caused by wrinkling of the uncoated area and minimize the loss of the metal substrate caused by shearing of the edges.

[0087] According to an embodiment, different electrode sheets can be injection molded by replacing the injection mold, thereby reducing material loss and time loss when converting electrode specifications. In addition, according to an embodiment, the thickness of the electrode sheet can be molded to be thicker than the thickness of the electrode sheet manufactured by a conventional method and the bag can be implemented in a more right-angled shape, thereby realizing a large-capacity design of a rechargeable battery and a favorable management of a negative-positive ratio (N / P ratio). In this way, the quality of the electrode in the secondary battery can be improved.

[0088] While the disclosure has been described in connection with what are presently considered to be practical embodiments, it is to be understood that the disclosure is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

[0089] Example embodiments have been disclosed herein, and although specific terms are employed, they are used and interpreted in a general and descriptive sense only, and not for purposes of limitation. In some cases, as would be apparent to one of ordinary skill in the art at the time of filing this application, features, characteristics, and / or elements described in conjunction with a particular embodiment may be used alone or in combination with features, characteristics, and / or elements described in conjunction with other embodiments, unless otherwise specifically indicated. Therefore, those skilled in the art will appreciate that various changes may be made in form and detail without departing from the scope of the invention as set forth in the claims.

[0090] <Description of Reference Numerals>

[0091] 10: Injection device 11: Hopper

[0092] 12: Screw 13: Discharge port

[0093] 14: Heater 20: Injection into mold

[0094] 21: Upper mold 22: Lower mold

[0095] 30: Pressing device 40: Electrode for rechargeable battery

[0096] 60: injection mold 62: lower mold

[0097] 211: Plate forming area 212: Injection hole

[0098] 221: Plate forming area 621: Plate forming area

[0099] 622: Circular area M: Electrode mixture

[0100] P: Pressure S1: Electrode sheet

[0101] S2: Metal substrate S11: Chamfer

[0102] S1': electrode sheet S2": metal substrate

Claims

1. A method for manufacturing an electrode for a rechargeable battery, the method comprising: In the first step, the electrode mixture input into the injection device is injected into the injection mold to form a plate-shaped electrode sheet to obtain a formed electrode sheet; The second step is to move the formed electrode sheet onto a metal substrate; as well as The third step is to laminate the metal substrate and the formed electrode sheet.

2. The method for manufacturing an electrode for a rechargeable battery according to claim 1, wherein: In the third step, The metal substrate is cut, In a pressing device, the molded electrode sheet is laminated on one surface of the metal substrate, and The molded electrode sheet is laminated on the other surface of the metal substrate.

3. The method for manufacturing an electrode for a rechargeable battery according to claim 1, wherein: In the third step, The metal substrate is cut, and In the pressing device, the molded electrode sheets are disposed on both surfaces of the metal substrate and laminated.

4. The method for manufacturing an electrode for a rechargeable battery according to claim 1, wherein: For the positive electrode, the electrode mixture comprises a positive electrode active material, a binder, a conductive material and a curing agent, and The ratio of positive electrode active material: binder: conductive material: curing agent is 96.9:1.8:2:

2.

5. The method for manufacturing an electrode for a rechargeable battery according to claim 1, wherein for a positive electrode or a negative electrode, based on 100 wt% of the electrode mixture, the electrode mixture comprises: 85.0wt% to 98.5wt% of electrode active material, 0.5wt% to 5.0wt% of a binder, 0.5 wt% to 5.0 wt% of a conductive material, and 0.5wt% to 5.0wt% of curing agent.

6. The method for manufacturing an electrode for a rechargeable battery according to claim 5, wherein: The binder helps the electrode active material and the conductive material to be bonded to the metal substrate, and It is formed from one of polyvinylidene fluoride, polyvinyl alcohol, carboxymethyl cellulose, starch, hydroxypropyl cellulose, regenerated cellulose, polyvinyl pyrrolidone, tetrafluoroethylene, polyethylene, polypropylene, ethylene-propylene-diene terpolymer, sulfonated ethylene-propylene-diene terpolymer, styrene-butadiene rubber and fluororubber. 7 . The method of manufacturing an electrode for a rechargeable battery according to claim 5 , wherein the conductive material comprises a nonlinear first conductive material and a linear second conductive material.

8. The method for manufacturing an electrode for a rechargeable battery according to claim 7, wherein the nonlinear first conductive material comprises at least one of Denka black and a carbon-based material, wherein the Denka black and the carbon-based material comprise carbon black, acetylene black, Ketjen black, channel black, furnace black, lamp black, thermal black and conductive carbon black.

9. The method for manufacturing an electrode for a rechargeable battery according to claim 8, wherein: The nonlinear first conductive material has an average particle size of 50 nm to 110 nm. The linear second conductive material is a linear carbon nanotube manufactured by a wet grinding process, and The average length of the linear carbon nanotubes is 1 μm to 5 μm.

10. The method of manufacturing an electrode for a rechargeable battery according to claim 4 or 5, wherein the curing agent comprises one of an epoxy-based resin and a phenol-based resin.

11. The method for manufacturing an electrode for a rechargeable battery according to claim 10, wherein the epoxy resin comprises at least one of bisphenol A epoxy resin, bisphenol F epoxy resin, bisphenol S epoxy resin, bisphenol epoxy resin, novolac epoxy resin, cresol novolac epoxy resin, bisphenol A novolac epoxy resin, bisphenol F novolac epoxy resin, novolac salicylic acid novolac epoxy resin, alicyclic epoxy resin, aliphatic chain epoxy resin, glycidyl ester type epoxy resin and modified resins thereof.

12. The method of manufacturing an electrode for a rechargeable battery according to claim 10, wherein the phenolic resin comprises at least one of bisphenol F, bisphenol A, bisphenol S, polyvinylphenol, phenol, cresol, alkylphenol, catechol, novolac resin and halogenated substitutes thereof.

13. The method of manufacturing an electrode for a rechargeable battery according to claim 1, wherein in the second step, the electrode sheet that is molded and separated from the injection mold and then freely falls or is moved with a jig is moved onto the metal substrate.

14. The method for manufacturing an electrode for a rechargeable battery according to claim 1, wherein in the first step, A rectangular space is formed using the upper mold and the lower mold of the injection mold, and The electrode sheet is formed into a plate-shaped rectangular parallelepiped. 15 . The method of manufacturing an electrode for a rechargeable battery according to claim 14 , wherein in the first step, an overall thickness of the electrode sheet is formed uniformly.

16. A method for manufacturing an electrode for a rechargeable battery according to claim 1, wherein in the first step, the chamfer of the electrode sheet is formed by a convex circular area at the corner of the internal space of the lower mold in the upper mold and the lower mold of the injection mold, and at the chamfer, the thickness gradually becomes thinner on the outer part of one surface of the electrode sheet.

17. The method for manufacturing an electrode for a rechargeable battery according to claim 1, wherein in the third step, The metal substrate is unwound and continuously supplied to a pressing device, and The electrode sheets are laminated on both surfaces of the metal substrate in the pressing device, and the metal substrate laminated with the electrode sheets is rewound.

Images