Battery

Abstract

The invention relates to a battery. A battery having a laminate in which a first current collector layer, a first electrode active material layer, an electrolyte layer, and a second electrode active material layer are laminated in this order, and a hard member, the laminate being in contact with the hard member at at least one end of the laminate, the tip of the first electrode active material layer, the tip of the electrolyte layer, and the tip of the second electrode active material layer are present further inside than the tip of the hard member, and the second surface of the hard member is in contact with the first electrode active material layer and / or is present between the surface of the second electrode active material layer and the first contact surface of the first current collector layer. The angle between the tangential direction at the tip of the second electrode active material layer and the planar direction of the surface of the first current collector layer is 60-120 DEG.

Description

Technical Field

[0001] This disclosure relates to batteries. Background Technology

[0002] As shown in, for example, Japanese Patent Application Publication No. 2019-139921, batteries are manufactured by cutting the ends of a laminate. Furthermore, in this laminate, electrode paste or similar materials are generally coated onto the surface of the current collector layer to form various layers. In the electrode active material layer obtained by coating the electrode paste, the ends of the electrode paste coating film wet and spread until the electrode paste coating film dries, thereby sometimes creating so-called drap portions in the electrode active material layer. Therefore, manufacturing apparatuses and coating apparatuses that suppress the formation of drap portions in the electrode active material layer are known, for example, in Japanese Patent Application Publication Nos. 2022-139404 and 2015-020098.

[0003] Japanese Patent Application Publication No. 2019-139921 discloses a method for manufacturing an all-solid-state battery. This method includes: a step of coating an electrode slurry comprising an electrode active material, a glassy solid electrolyte material, and a solvent onto a current collector foil along a coating direction, followed by drying to form a positive electrode and a negative electrode; a step of forming a solid electrolyte layer comprising the glassy solid electrolyte material on the surface of at least one of the positive electrode, the negative electrode, and a carrier; a step of stacking the positive electrode and the negative electrode with the solid electrolyte layer sandwiched between them, and pressing them from the stacking direction to form a laminate; and a step of cutting the laminate at a cutting angle of 10° or more and 40° or less relative to the coating direction. According to the all-solid-state battery manufacturing method of Japanese Patent Application Publication No. 2019-139921, compared with conventional manufacturing methods, it reduces material waste, simplifies the manufacturing process, and improves the productivity of all-solid-state batteries.

[0004] Japanese Patent Application Publication No. 2022-139404 discloses a manufacturing apparatus for a battery that coats an active material paste onto a substrate. The apparatus includes a coating section having a discharge port for discharging the swellable active material paste. The discharge port has first narrowing portions at both ends in its extending direction, reducing its length in a direction orthogonal to the extending direction. The discharge port discharges the active material paste at a low shear viscosity at its central portion located between the first narrowing portions, and at a high shear viscosity at the first narrowing portions. According to the battery manufacturing apparatus of Japanese Patent Application Publication No. 2022-139404, the utilization rate of the active material in the battery can be improved.

[0005] Japanese Patent Application Publication No. 2015-020098 discloses a coating apparatus that includes a die for applying the coating liquid to a foil, with lips formed on both sides of a slit from which the coating liquid is discharged as one end. The width direction of the lips is inclined relative to the width direction of the foil. According to the coating apparatus of Japanese Patent Application Publication No. 2015-020098, in a coating apparatus that uses a die to apply the coating liquid to a foil, fluctuations in the unit area weight of the coating area caused by sagging can be suppressed. Summary of the Invention

[0006] For example, in a battery where a first electrode active material layer, an electrolyte layer, and a second electrode active material layer are sequentially coated onto a first current collector layer, to prevent short circuits—specifically, to prevent the second electrode active material layer from contacting the first current collector layer and the first electrode active material layer—it is necessary to consider the flow portions of each layer and coat the composite slurry forming each layer. In such a battery, the flow portions of each layer are multi-segmented, reducing the battery's volumetric efficiency.

[0007] In order to improve the volumetric efficiency of the battery, it is considered to cut away the sloughed portions of the electrode active material layer and the electrolyte layer. However, in such a battery, although it is desirable for the first current collector layer to extend to connect with the outside, cutting away the aforementioned sloughed portions may not only cut away the sloughed portions but also potentially cut away the first current collector layer.

[0008] Therefore, the purpose of this disclosure is to provide a battery that leaves a first current collector layer and improves volumetric efficiency.

[0009] The above objectives are achieved by means of the following methods.

[0010] Option 1

[0011] A battery comprising a stack of a first current collector layer, a first electrode active material layer, an electrolyte layer, and a second electrode active material layer, and a rigid member, wherein at least one end of the stack is in contact with the rigid member, the top ends of the first electrode active material layer, the top ends of the electrolyte layer, and the top ends of the second electrode active material layer are located inside the top end of the rigid member, the rigid member has a first surface on the side of the first current collector layer and a second surface opposite to the first surface, the first current collector layer has a first contact surface in contact with the first electrode active material layer, the second surface of the rigid member is in contact with the first electrode active material layer and / or exists between the surface of the second electrode active material layer and the first contact surface of the first current collector layer, and the angle between the tangent direction at the top end of the second electrode active material layer and the surface direction of the surface of the first current collector layer is 60° or more and 120° or less.

[0012] Option 2

[0013] According to the battery described in Scheme 1, the top end of the second electrode active material layer is a cut surface.

[0014] Option 3

[0015] According to the battery described in Scheme 1 or 2, the top end of the second electrode active material layer is flush with the top end of the electrolyte layer.

[0016] Option 4

[0017] According to any one of Schemes 1 to 3, the rigid component is selected from alumina, zirconium oxide, silicon carbide, titanium, and combinations thereof.

[0018] Option 5

[0019] The method for manufacturing a battery according to any one of claims 1 to 4 includes the following steps:

[0020] The rigid component is formed in the first current collector layer, and then the first electrode active material layer is formed, or the rigid component and the first electrode active material layer are formed simultaneously in the first current collector layer.

[0021] The electrolyte layer and the second electrode active layer are sequentially stacked on the surface of the first electrode active material layer to provide a pre-stacked body; and

[0022] The second electrode active material layer of the pre-stacked body is cut on the rigid component to form the stacked body.

[0023] According to the battery disclosed herein, the first current collector layer remains, and the volumetric efficiency of the battery is improved. Attached Figure Description

[0024] The features, advantages, and technical and industrial significance of exemplary embodiments of the present invention will now be described with reference to the accompanying drawings, wherein like reference numerals denote like elements, and wherein:

[0025] Figure 1A A schematic cross-sectional view for illustrating the battery of this disclosure and batteries in the prior art;

[0026] Figure 1B A schematic cross-sectional view for illustrating the battery of this disclosure and batteries in the prior art;

[0027] Figure 2A A schematic cross-sectional view for illustrating the battery of this disclosure;

[0028] Figure 2B A schematic cross-sectional view for illustrating the battery of this disclosure;

[0029] Figure 3A This is a schematic diagram used to illustrate tangents;

[0030] Figure 3B This is a schematic diagram used to illustrate tangents;

[0031] Figure 4A A schematic diagram illustrating the method of manufacturing the battery according to this disclosure;

[0032] Figure 4B A schematic diagram illustrating the method of manufacturing the battery according to this disclosure;

[0033] Figure 4C A schematic diagram illustrating the method of manufacturing the battery according to this disclosure;

[0034] Figure 4D A schematic diagram illustrating the method of manufacturing the battery according to this disclosure;

[0035] Figure 5A A schematic diagram illustrating the method of manufacturing the battery according to this disclosure;

[0036] Figure 5B A schematic diagram illustrating the method of manufacturing the battery according to this disclosure;

[0037] Figure 5C A schematic diagram illustrating the method of manufacturing the battery according to this disclosure;

[0038] Figure 5D A schematic diagram illustrating the method of manufacturing the battery according to this disclosure;

[0039] Figure 6A A schematic diagram illustrating the method of manufacturing the battery according to this disclosure;

[0040] Figure 6B A schematic diagram illustrating the method of manufacturing the battery of this disclosure; and

[0041] Figure 6C This is a schematic diagram illustrating the method of manufacturing the battery according to the present disclosure. Detailed Implementation

[0042] The embodiments of this disclosure are described in detail below. It should be noted that this disclosure is not limited to the following embodiments, and various modifications can be made within the scope of the spirit of this disclosure. Furthermore, in the description of the drawings, the same reference numerals are used to denote the same elements, and repeated descriptions are omitted.

[0043] Battery; First Option

[0044] The battery disclosed herein comprises a stacked body consisting of a first current collector layer, a first electrode active material layer, an electrolyte layer, and a second electrode active material layer stacked sequentially, and a rigid member. At at least one end of the stacked body, the stacked body is in contact with the rigid member. The top ends of the first electrode active material layer, the electrolyte layer, and the second electrode active material layer are located inside the top end of the rigid member. The rigid member has a first surface on the side of the first current collector layer and a second surface opposite to the first surface. The first current collector layer has a first contact surface that contacts the first electrode active material layer. The second surface of the rigid member contacts the first electrode active material layer. The angle between the tangent direction at the top end of the second electrode active material layer and the surface direction of the first current collector layer is 60° or more and 120° or less.

[0045] According to the battery disclosed herein, the first current collector layer remains, and the volumetric efficiency of the battery is improved.

[0046] While not limited by theory, the battery disclosed herein has a first electrode active material layer on a rigid member. Therefore, for example, when a portion of the electrode active material layer or the like is vertically cut away from the surface of the second electrode active material layer, the presence of the rigid member prevents the first current collector layer from being cut. This leaves the first current collector layer intact, and the volumetric efficiency of the battery is improved.

[0047] Figure 1A This is a schematic cross-sectional view illustrating one embodiment of the battery disclosed herein, but is not limited to this case. Furthermore, Figure 1B This is a schematic cross-sectional view of one embodiment of a battery in the prior art, but is not limited to this case.

[0048] Figure 1A The battery 10 illustrated in the figure has a laminate 100 in which a first current collector layer 110, a first electrode active material layer 120, an electrolyte layer 130, and a second electrode active material layer 140 are sequentially stacked. At one end of the laminate 100, the laminate 100 contacts a rigid member 200. Furthermore, the top ends 120a of the first electrode active material layer, 130a of the electrolyte layer, and 140a of the second electrode active material layer are located inside the rigid member, compared to the top end 200a. The rigid member 200 has a first surface 200b on the side of the first current collector layer 110 and a second surface 200c opposite to the first surface 200b. Figure 1A In the illustrated battery 10, the second surface 200c of the rigid member 200 contacts the first electrode active material layer 120, and the tangent 140b at the top of the second electrode active material layer is perpendicular to the angle 140e of the surface direction of the first current collector layer 110. Figure 1AAs shown in the figure, a first electrode active material layer 120 is present on the rigid member 200. Therefore, for example, when a portion of the electrode active material layer or the like is vertically cut away from the surface of the second electrode active material layer on the rigid member, the presence of the rigid member prevents the first current collector layer 110 from being cut. This leaves the first current collector layer intact and improves the volumetric efficiency of the battery.

[0049] Figure 1B The illustrated prior art battery is, for example, a battery obtained by sequentially coating, drying, and forming a laminate of electrode composite slurry and solid electrolyte composite slurry, with each layer having a drip portion. Specifically, Figure 1B The illustrated battery 10 has a laminate 100 in which a first current collector layer 110, a first electrode active material layer 120, an electrolyte layer 130, and a second electrode active material layer 140 are sequentially stacked. The end face 120b of the first electrode active material layer forms an inclined surface close to the first current collector layer 110, facing the top tip 120a of the first electrode active material layer. The end faces 130d of the electrolyte layer and 140d of the second electrode active material layer also form inclined surfaces similar to those of the end face 120b of the first electrode active material layer. Each inclined surface is stepped, forming a so-called drip portion (…). Figure 1B (The area within the dashed box in the diagram). Because of this sag, the volumetric efficiency of the battery is reduced. Furthermore, if this sag is cut away, it is possible to cut the first current collector layer 110.

[0050] Battery; Second Option

[0051] The battery disclosed herein comprises a stacked body consisting of a first current collector layer, a first electrode active material layer, an electrolyte layer, and a second electrode active material layer stacked sequentially, and a rigid member. At at least one end of the stacked body, the stacked body is in contact with the rigid member. The top ends of the first electrode active material layer, the electrolyte layer, and the second electrode active material layer are located inside the top end of the rigid member. The rigid member has a first surface on the side of the first current collector layer and a second surface opposite to the first surface. The first current collector layer has a first contact surface that contacts the first electrode active material layer. The second surface of the rigid member exists between the surface of the second electrode active material layer and the first contact surface of the first current collector layer. The angle between the tangent direction at the top end of the second electrode active material layer and the surface direction of the surface of the first current collector layer is 60° or more and 120° or less.

[0052] According to the battery disclosed herein, the first current collector layer remains, and the volumetric efficiency of the battery is improved.

[0053] While not theoretically limited, in the battery disclosed herein, the rigid member contacts the laminate at a predetermined position. Therefore, for example, when cutting away a portion of the electrode active material layer from the surface of the second electrode active material layer, the cutting stop position is controlled by the position of the second surface of the rigid member, preventing the first current collector layer existing beneath the rigid member from being cut. This leaves the first current collector layer intact and improves the volumetric efficiency of the battery.

[0054] Figure 2A This is a schematic cross-sectional view of one embodiment of the battery disclosed herein, but is not limited to this case.

[0055] Figure 2A The illustrated battery 10 has a laminate 100, at one end of which the laminate 100 contacts a rigid member 200. A first current collector layer 110 has a first contact surface 110a that contacts a first electrode active material layer 120. Figure 2A In the illustrated battery 10, the second surface 200c of the rigid member 200 exists between the surface 140c of the second electrode active material layer and the first contact surface 110a of the first current collector layer 110, more specifically, it exists within the second electrode active material layer 140. The tangent 140b at the top of the second electrode active material layer is perpendicular to the angle 140e of the surface direction of the first current collector layer 110. Figure 2A In the illustrated battery 10, the rigid member 200 contacts the laminate 100 at a predetermined position. Therefore, for example, when a portion of the electrode active material layer, etc., is vertically cut away from the surface of the second electrode active material layer on the rigid member, the portion of the second electrode active material layer 140 is cut off without cutting the first current collector layer 110 existing beneath the rigid member 200. This leaves the first current collector layer intact and improves the volumetric efficiency of the battery.

[0056] There are no particular limitations on the battery disclosed herein. The electrolyte layer has a second contact surface that contacts the second electrode active material layer, and the second surface of the rigid member may exist between the second contact surface of the electrolyte layer and the first contact surface of the first current collector layer.

[0057] Figure 2B This is a schematic cross-sectional view of one embodiment of the battery disclosed herein, but is not limited to this case.

[0058] Figure 2B The illustrated battery 10 has a laminate 100, at one end of which the laminate 100 contacts a rigid member 200. The electrolyte layer 130 has a second contact surface 130c that contacts the second electrode active material layer 140. Figure 2BIn the illustrated battery 10, the second surface 200c of the rigid member 200 exists between the second contact surface 130c of the electrolyte layer 130 and the first contact surface 110a of the first current collector layer 110, more specifically, it exists within the electrolyte layer 130. Figure 2B In the illustrated battery 10, the rigid member 200 contacts the laminate 100 at a predetermined position. Therefore, for example, when a portion of the electrode active material layer, etc., is vertically cut away from the surface of the second electrode active material layer on the rigid member, the portions of the second electrode active material layer 140 and the electrolyte layer 130 are cut away, without cutting the first current collector layer 110 existing beneath the rigid member 200. This leaves the first current collector layer intact, and the volumetric efficiency of the battery is improved.

[0059] The shape of the stacked body

[0060] The laminate consists of a first current collector layer, a first electrode active material layer, an electrolyte layer, and a second electrode active material layer, stacked sequentially. The shapes of each layer constituting the laminate are described below.

[0061] In the battery disclosed herein, the first current collector layer is not particularly limited, and can extend and protrude compared to the first electrode active material layer, the electrolyte layer, and the second electrode active material layer.

[0062] The aforementioned Figure 1A The laminate 100 comprises a first current collector layer 110, a first electrode active material layer 120, an electrolyte layer 130, and a second electrode active material layer 140, which are stacked sequentially. The first current collector layer 110 extends and protrudes compared to the first electrode active material layer 120, the electrolyte layer 130, and the second electrode active material layer 140.

[0063] In the battery disclosed herein, the top end of the second electrode active material layer is not particularly limited and can be a cut surface. Similarly, the top end of the electrolyte layer is not particularly limited and can be a cut surface. Furthermore, the top end of the first electrode active material layer is also not particularly limited and can be a cut surface.

[0064] In the above Figure 1A In this battery, the top end 140a of the second electrode active material layer, the top end 130a of the electrolyte layer, and the top end 120a of the first electrode active material layer can each be a cut surface. For a battery in which the end face of each layer is a cut surface, for example on a rigid component, the sloughed portion of the electrode active material layer, etc., can be vertically cut away from the surface of the second electrode active material layer. Figure 2A , Figure 2B The same applies to China.

[0065] In the battery disclosed herein, there are no particular limitations on the top ends of the second electrode active material layer and the electrolyte layer; they can be flush. Furthermore, there are no particular limitations on the top ends of the electrolyte layer and the first electrode active material layer; they can be flush.

[0066] The above Figure 1A In this battery, the top end 140a of the second electrode active material layer is flush with the top end 130a of the electrolyte layer. Furthermore, the top end 130a of the electrolyte layer is flush with the top end 120a of the first electrode active material layer. For a battery where the end faces of each layer are flush, for example on a rigid component, the battery can be obtained by vertically cutting away the excess portion of the electrode active material layer from the surface of the second electrode active material layer.

[0067] In the battery disclosed herein, the angle between the tangent direction at the tip of the second electrode active material layer and the surface direction of the first current collector layer is 60° or more and 120° or less. There is no particular limitation on the aforementioned angle, which can be 60° or more, 65° or more, 70° or more, 75° or more, 80° or more, 85° or more, or 90° or more. The aforementioned angle can be 120° or less, 115° or less, 110° or less, 105° or less, 100° or less, 95° or less, or 90° or less.

[0068] In the above Figure 1A In this context, angle 140e is the angle formed by the tangent 140b at the top of the second electrode active material layer and the surface direction of the first current collector layer 110. It should be noted that the term "tangent" in this disclosure will be described later.

[0069] In the battery disclosed herein, the angle between the tangent at the top of the electrolyte layer and the surface direction of the first current collector layer is not particularly limited, and can be 60° or more, 65° or more, 70° or more, 75° or more, 80° or more, 85° or more, or 90° or more. The angle between the tangent at the top of the electrolyte layer and the surface direction of the first current collector layer can be 120° or less, 115° or less, 110° or less, 105° or less, 100° or less, 95° or less, or 90° or less.

[0070] In the above Figure 2B In this context, angle 130e is the angle formed by the direction of the tangent 130b at the top of the electrolyte layer and the surface direction of the first current collector layer 110. It should be noted that the term "tangent" in this disclosure will be described later.

[0071] In this disclosure, "tangent" means a tangent in a section that is perpendicular to the surface direction of each layer and perpendicular to the line formed by the top of each layer.

[0072] Figure 3A and Figure 3BThis is a schematic diagram used to illustrate "tangents", but it is not limited to this case. Figure 3B To view from the surface side of the active material layer of the second electrode Figure 3A A rough sketch.

[0073] For example, Figure 3A The tangent 120c of the first electrode active material layer, illustrated by dashed lines, is a cross-section perpendicular to the surface direction of the first electrode active material layer 120 and perpendicular to the line formed by the top tip 120a of the first electrode active material layer. Specifically, in... Figure 3B The tangent line in the cross-section is shown by the dotted line indicating the cutting position. The same applies to the tangent lines in other layers.

[0074] Battery manufacturing method; First scheme

[0075] The battery disclosed herein can be manufactured using a manufacturing method that includes the following steps:

[0076] The rigid component is formed on the surface of the first current collector layer, and then the first electrode active material layer is formed.

[0077] The electrolyte layer and the second electrode active layer are sequentially stacked on the surface of the first electrode active material layer to provide a pre-stacked body; and

[0078] The second electrode active material layer of the pre-stacked body is cut on the rigid component to form the stacked body.

[0079] According to the battery manufacturing method disclosed herein, it is possible to manufacture a battery that leaves a first current collector layer and improves volumetric efficiency.

[0080] Figures 4A to 4D This diagram illustrates a schematic representation of one method for manufacturing the battery according to the present disclosure, but is not limited to that approach.

[0081] First, such as Figure 4A As shown in the figure, the surface of the first current collector layer 110 is processed to form a hard component 200. Next, as... Figure 4B As illustrated, at least a portion of the rigid component 200 is covered to form a first electrode active material layer 120. Then, as shown... Figure 4CAs illustrated, an electrolyte layer 130 and a second electrode active material layer 140 are sequentially stacked on the surface of the first electrode active material layer 120 to form a pre-stacked body 101. Then, on a rigid member 200, the second electrode active material layer 140 and the electrolyte layer 130 of the pre-stacked body 101 are vertically cut from the surface 140c of the second electrode active material layer using a cutting blade 300 to form a stacked body 100. Due to the presence of the rigid member, for example, even when the sag portion of the electrode active material layer is cut off, the first current collector layer is not cut off, thereby enabling the manufacture of a battery that retains the first current collector layer and improves volumetric efficiency.

[0082] Figures 5A to 5D This diagram illustrates a schematic representation of one method for manufacturing the battery according to the present disclosure, but is not limited to this approach.

[0083] First, such as Figure 5A As illustrated, a rigid member 200 is formed by coating the surface of the first current collector layer 110 with a paste, for example, containing a rigid member. Next, a first electrode active material layer 120 is formed in contact with the rigid member 200. Then, as shown... Figure 5C As illustrated, an electrolyte layer 130 and a second electrode active material layer 140 are sequentially stacked on the surface of the first electrode active material layer 120 to form a pre-stacked body 101. Then, on a rigid member 200, the second electrode active material layer 140 and the electrolyte layer 130 of the pre-stacked body 101 are vertically cut from the surface 140c of the second electrode active material layer using a cutting blade 300 to form a stacked body 100. Due to the presence of the rigid member, for example, when cutting away the sloughed portions of the electrode active material layer, the first current collector layer is not cut, thereby enabling the manufacture of a battery that retains the first current collector layer and improves volumetric efficiency.

[0084] Battery manufacturing method; second option

[0085] The battery disclosed herein can be manufactured using a manufacturing method that includes the following steps:

[0086] The rigid component and the first electrode active material layer are simultaneously formed on the surface of the first current collector layer;

[0087] The electrolyte layer and the second electrode active layer are sequentially stacked on the surface of the first electrode active material layer to provide a pre-stacked body; and

[0088] The second electrode active material layer of the pre-stacked body is cut on the rigid component to form the stacked body.

[0089] According to the battery manufacturing method disclosed herein, it is possible to manufacture a battery that leaves a first current collector layer and improves volumetric efficiency.

[0090] Figures 6A to 6C This diagram illustrates a schematic representation of one method for manufacturing the battery according to the present disclosure, but is not limited to this approach.

[0091] First, such as Figure 6A As shown, by simultaneously coating the surface of the first current collector layer 110 with, for example, a paste containing a rigid component and a composite paste forming the first electrode active material, the rigid component 200 and the first electrode active material layer 120 are simultaneously formed. Secondly, as... Figure 6B As shown, an electrolyte layer 130 and a second electrode active material layer 140 are sequentially stacked on the surface of the first electrode active material layer 120 to form a pre-stacked body 101. Then, on a rigid member 200, the second electrode active material layer 140 and the electrolyte layer 130 of the pre-stacked body 101 are vertically cut from the surface 140c of the second electrode active material layer using a cutting blade 300 to form a stacked body 100. Due to the presence of the rigid member, for example, when cutting away the excess portion of the electrode active material, the first current collector layer is not cut, thereby enabling the manufacture of a battery that retains the first current collector layer and improves volumetric efficiency.

[0092] Methods for forming rigid components

[0093] There is no particular limitation on the method for forming the rigid component. For example, methods for forming the rigid component include coating a paste containing the rigid component onto the surface of the first current collector layer to form the rigid component, transferring the rigid component onto the surface of the first current collector layer, electrostatically coating the rigid component onto the surface of the first current collector layer, etching the first current collector layer, and then embedding the rigid component, etc., but are not limited to these.

[0094] Cutting method for pre-stacked bodies

[0095] There are no particular limitations on the cutting method for the pre-electrode stack. Methods such as cutting with a cutting blade can be listed, but it is not limited to this case.

[0096] Batteries and their manufacturing methods; components

[0097] The following describes the components of a battery and its manufacturing process.

[0098] The battery disclosed herein can be a liquid battery containing an electrolyte as the electrolyte layer, or a solid battery having a solid electrolyte layer as the electrolyte layer. It should be noted that, in the context of this disclosure, "solid battery" means a battery that uses at least a solid electrolyte as the electrolyte; therefore, a solid battery can use a combination of solid and liquid electrolytes as the electrolyte. Furthermore, the battery disclosed herein can be an all-solid battery, that is, a battery that uses only a solid electrolyte as the electrolyte.

[0099] Regarding this disclosure, "composite material" means a composition that can form a positive electrode active material layer, etc., either in its original form or by further containing other components. Furthermore, regarding this disclosure, "composite material slurry" means a slurry that, in addition to "composite material," also contains a dispersion medium, thereby enabling coating and drying to form a positive electrode active material layer, etc.

[0100] The battery disclosed herein has rigid components.

[0101] rigid components

[0102] In this disclosure, there are no particular limitations on the rigid component. Materials selected from alumina, zirconium oxide, silicon carbide, titanium, and combinations thereof can be cited as examples of rigid components, but are not limited to these. While there are no particular limitations on the material of the rigid component, from the viewpoint of coating formation, materials that are easily particle-formed, such as alumina, are preferred.

[0103] Regarding rigid components, for example, they can be formed by coating a slurry containing the rigid component as described above. There are no particular limitations on the slurry containing the rigid component, and it may contain an adhesive. As an adhesive, a material that does not react with a solid electrolyte is preferred. Specifically, examples of such materials include polyvinylidene fluoride (PVDF), acrylic butadiene rubber (ABR), and styrene-butadiene rubber (SBR), but these are not limited to.

[0104] The total mass of the slurry containing rigid components is set at 100%. There is no particular limitation on the content of rigid components; it can be more than 1%, more than 5%, or more than 10%, or less than 99%, less than 95%, or less than 90%.

[0105] There is no particular limitation on the Young's modulus of the rigid component. From the viewpoint of protecting the first current collector layer, the Young's modulus of the rigid component relative to the first electrode active material layer can be 5 times, 6 times, or 7 times or more. From the viewpoint of preventing wear of the aforementioned cutting tool, the Young's modulus of the rigid component can be 10 times or less, 9 times or less, or 8 times or less. It should be noted that the Young's modulus can be obtained according to JIS K 7161-1 (2014).

[0106] From the viewpoint of protecting the first current collector layer, the Young's modulus of the rigid component can be 5 times, 6 times, or 7 times or more relative to the second electrode active material layer. From the viewpoint of preventing wear of the aforementioned cutting blade, the Young's modulus of the rigid component can be 10 times or less, 9 times or less, or 8 times or less. It should be noted that the Young's modulus can be obtained according to JIS K 7161-1 (2014).

[0107] In the battery disclosed herein, a stacked body comprises a first current collector layer, a first electrode active material layer, an electrolyte layer, and a second electrode active material layer stacked sequentially. There is no particular limitation on the stacked body, and a second current collector layer may be included. Specifically, in the stacked body, the first current collector layer, the first electrode active material layer, the electrolyte layer, and the second electrode active material layer may be stacked sequentially; the second electrode active material layer, the electrolyte layer, the first electrode active material layer, the first current collector layer, the first electrode active material layer, the electrolyte layer, and the second electrode active material layer may be stacked sequentially; the first current collector layer, the first electrode active material layer, the electrolyte layer, the second electrode active material layer, and the second current collector layer may be stacked sequentially; or the second current collector layer, the second electrode active material layer, the electrolyte layer, the first electrode active material layer, the first current collector layer, the first electrode active material layer, the electrolyte layer, the second electrode active material layer, and the second current collector layer may be stacked sequentially.

[0108] First collector layer

[0109] The first current collector layer can be either a negative current collector layer or a positive current collector layer. There is no particular limitation on the first current collector layer, but it is preferably a negative current collector layer.

[0110] Materials used for the first current collector layer include, but are not limited to, Cu, Ni, Cr, Au, Pt, Ag, Al, Fe, Ti, Zn, Co, and stainless steel. The shape of the first current collector layer can be, for example, foil, plate, or mesh.

[0111] First electrode active material layer

[0112] The first electrode active material layer contains at least an electrode active material, and may optionally contain a solid electrolyte, a conductive additive, and a binder. When the first electrode active material layer is a positive electrode active material layer, it contains a positive electrode active material as the electrode active material. Conversely, when the first electrode active material layer is a negative electrode active material layer, it contains a negative electrode active material as the electrode active material. There is no particular limitation on the first electrode active material layer, but a negative electrode active material layer is preferred.

[0113] Positive electrode active material

[0114] As positive electrode active materials, they can be, for example, lithium cobalt oxide (LiCoO2), lithium manganese oxide (LiMn2O4), and lithium nickel / cobalt / manganese oxide (NCM:LiCO3). 1 / 3 Ni 1 / 3 Mn 1 / 3 (O2), but not limited to these. The shape of the positive electrode active material can be, for example, particulate.

[0115] Negative electrode active material

[0116] There are no particular limitations on the materials used for the negative electrode active material; it can be metallic lithium or any material capable of absorbing and releasing lithium ions or other metal ions. Examples of materials capable of absorbing and releasing lithium ions or other metal ions include alloy-based negative electrode active materials containing Si and Sn, carbon materials such as graphite, or lithium titanate (Li4Ti5O4). 12 Examples of negative electrode active materials include, but are not limited to, particles or sheets.

[0117] solid electrolyte

[0118] There are no particular limitations on the materials used for solid electrolytes; they can be sulfide solid electrolytes, oxide solid electrolytes, or polymer electrolytes, etc. Examples of sulfide solid electrolytes include the Li₂S-P₂S₅ system (Li₇P₃S₅). 11 Examples of oxide solid electrolytes include Li3PS4, Li8P2S9, etc., but are not limited to these. Examples of oxide solid electrolytes include Li7La3Zr2O. 12 Li 7-x La3Zr 1-x Nb x O 12 Examples of polymer electrolytes include, but are not limited to, polyethylene oxide (PEO).

[0119] Conductive additives

[0120] Conductive additives may include, but are not limited to, vapor-grown carbon fiber (VGCF), acetylene black (AB), Ketjen black (KB), etc.

[0121] adhesive

[0122] The adhesive may be, for example, polyvinylidene fluoride (PVdF), styrene-butadiene rubber (SBR), etc., but is not limited to these.

[0123] Electrolyte layer - solid electrolyte layer

[0124] The battery disclosed herein can be a solid-state battery, meaning it can have a solid electrolyte layer as the electrolyte layer. The solid electrolyte layer contains at least a solid electrolyte and may include conductive additives, binders, etc., as needed. For details regarding the solid electrolyte, conductive additives, and binders, please refer to the description in the "First Electrode Active Material Layer" above.

[0125] Electrolyte layer - separator layer

[0126] The battery disclosed herein can be a liquid battery, that is, it can have an electrolyte, particularly an electrolyte held in a separator layer as an electrolyte layer.

[0127] electrolyte

[0128] There are no particular limitations on the electrolyte, but it is preferable to contain a supporting salt and a solvent. Examples of supporting salts include LiPF6 and LiCF3SO2, but the electrolyte is not limited to these. Examples of solvents used in the electrolyte include ethylene carbonate (EC) and diethyl carbonate (DEC), but the electrolyte is not limited to these.

[0129] Separator

[0130] There are no particular limitations on the separator; nonwoven fabrics such as polyolefin, polyamide, and polyimide can be used.

[0131] Second electrode active material layer

[0132] The second electrode active material layer contains at least an electrode active material, and may optionally contain a solid electrolyte, a conductive additive, and a binder. When the first electrode active material layer is a positive electrode active material layer, a negative electrode active material is included in the second electrode active material layer. Conversely, when the first electrode active material layer is a negative electrode active material layer, a positive electrode active material is included in the second electrode active material layer. There are no particular limitations on the second electrode active material layer, but a positive electrode active material layer is preferred.

[0133] Regarding the electrode active material, solid electrolyte, conductive additives and binders that may be contained in the second electrode active material layer, please refer to the description in the above-mentioned "First Electrode Active Material Layer".

[0134] Second collector layer

[0135] The first current collector layer can be either a negative current collector layer or a positive current collector layer. There are no particular limitations on the second current collector layer, but a positive current collector layer is preferred. Regarding the material used for the second current collector layer, please refer to the description in the section "<First Current Collector Layer>" above.

[0136] Uses of batteries, etc.

[0137] There are no particular limitations on the battery used in this disclosure; it can be a lithium-ion rechargeable battery. The battery used in this disclosure can be, for example, a vehicle battery, or can be used as a power source for mobile bodies other than vehicles (such as railways, ships, and aircraft), or as a power source for electrical products such as information processing devices.

[0138] The present disclosure describes embodiments of the battery, and those skilled in the art will understand that variations are possible without departing from the patent claims.

Claims

1. A battery having a stack of a first current collector layer, a first electrode active material layer, an electrolyte layer, and a second electrode active material layer stacked sequentially, and a rigid member, wherein at least one end of the stack is in contact with the rigid member, the top ends of the first electrode active material layer, the top ends of the electrolyte layer, and the top ends of the second electrode active material layer are located inside the top end of the rigid member, the rigid member has a first surface on the side of the first current collector layer and a second surface opposite to the first surface, the first current collector layer has a first contact surface in contact with the first electrode active material layer, the second surface of the rigid member is in contact with the first electrode active material layer and / or exists between the surface of the second electrode active material layer and the first contact surface of the first current collector layer, and the angle between the tangent direction at the top end of the second electrode active material layer and the surface direction of the surface of the first current collector layer is 60° or more and 120° or less.

2. The battery according to claim 1, wherein, The top of the active material layer of the second electrode is a cut surface.

3. The battery according to claim 1, wherein, The top of the second electrode active material layer is flush with the top of the electrolyte layer.

4. The battery according to claim 1, wherein, The rigid component is selected from alumina, zirconium oxide, silicon carbide, titanium, and combinations thereof.

5. A method for manufacturing a battery according to any one of claims 1 to 4, comprising the following steps: The rigid component is formed in the first current collector layer, and then the first electrode active material layer is formed, or the rigid component and the first electrode active material layer are formed simultaneously in the first current collector layer. The electrolyte layer and the second electrode active layer are sequentially stacked on the surface of the first electrode active material layer to provide a pre-stacked body; and The second electrode active material layer of the pre-stacked body is cut on the rigid component to form the stacked body.

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