Electrode assembly and method of manufacturing electrode assembly

Abstract

The invention relates to an electrode assembly and a method of manufacturing an electrode assembly. The electrode assembly includes: an electrode plate including a coated portion in which an active material is coated on both sides of a composite substrate and an uncoated portion in which the active material is not provided on the composite substrate; a conductor coupled to the uncoated portion; and an insulating layer covering at least a portion of each of the uncoated portion, the coated portion, and the conductor. The uncoated portion is coupled to a first side of the conductor, and the insulating layer is disposed on a second side of the conductor opposite the first side of the conductor.

Description

Technical Field

[0001] This disclosure relates to electrode assemblies and methods for manufacturing electrode assemblies. Background Technology

[0002] Unlike primary batteries, which are not designed to be (re)chargeable, secondary (or rechargeable) batteries are designed to be discharged and recharged. Low-capacity secondary batteries are used in portable small electronic devices such as smartphones, feature phones, laptops, digital cameras, and camcorders, while high-capacity secondary batteries are widely used as power sources for drive motors in hybrid and electric vehicles, as well as for energy storage (e.g., residential and / or utility-scale energy storage). A secondary battery typically comprises an electrode assembly consisting of positive and negative electrodes, a housing containing the electrode assembly, and electrode terminals connected to the electrode assembly.

[0003] There is a need to reduce the weight of secondary batteries used in portable IT devices, automobiles, and other applications. To achieve this, conventional technologies have been developed to make materials used in secondary batteries thinner (such as substrates, separators, and external materials) or to improve the physical properties of active materials to increase energy density. However, some of these developments have led to reduced safety of secondary batteries.

[0004] The information disclosed in this background section is intended to enhance the understanding of the background of this disclosure, and therefore may contain information that does not constitute related technology (or prior art). Summary of the Invention

[0005] Embodiments of this disclosure provide electrode assemblies and methods for manufacturing electrode assemblies.

[0006] These and other aspects and features of this disclosure will be described in or will be apparent from the following description of embodiments of this disclosure.

[0007] The electrode assembly disclosed herein includes: an electrode plate including a coated portion in which an active material is coated on both sides of a composite substrate and an uncoated portion in which no active material is provided on the composite substrate; a conductor connected to the uncoated portion; and an insulating layer covering at least a portion of each of the uncoated portion, the coated portion, and the conductor, wherein the uncoated portion is connected to a first side of the conductor, and the insulating layer is disposed on a second side of the conductor opposite to the first side of the conductor.

[0008] According to an embodiment, the composite substrate includes: a polymer substrate; a first metal layer on a first surface of the polymer substrate; and a second metal layer on a second surface of the polymer substrate, wherein the first metal layer and the second metal layer are formed of the same material.

[0009] According to one embodiment, the conductor includes a region connected to an uncoated portion, and when viewed in a direction perpendicular to a second side of the conductor, this region is located inside an insulating layer.

[0010] According to the embodiment, this area is spaced apart from the coated portion.

[0011] According to an embodiment, the distance between this area and the coated portion is at least 0.3 mm.

[0012] According to the embodiment, the upper end of the insulating layer is located at a height of at least 0.5 mm above the upper end of the region.

[0013] According to an embodiment, the portion of the conductor covered by the insulating layer is a first insulating layer, and the insulating layer further includes a second insulating layer connected to the first insulating layer and covering the uncoated portion located between the region and the coated portion.

[0014] According to an embodiment, the insulating layer further includes a third insulating layer that is connected to the second insulating layer and covers at least a portion of the coated portion.

[0015] According to the embodiment, the lower end of the third insulating layer is located at least 0.3 mm lower than the upper end of the coated portion.

[0016] According to the embodiment, the polarity of the composite substrate is positive, and the longitudinal length of the region is 1.5mm to 5.5mm.

[0017] According to the embodiment, the composite substrate has a negative polarity, and the longitudinal length of the region is 2.0 mm to 6.0 mm.

[0018] According to an embodiment, the conductor includes: a first conductor connected to a first metal layer; and a second conductor connected to a second metal layer; and the first conductor includes: a first region connected to the first metal layer; and a second region connected to the second conductor.

[0019] According to the implementation method, the second region is separated from the first region.

[0020] According to an embodiment, the insulating layer includes: a first insulating layer, wherein a first region is located inside the first insulating layer when viewed in a direction perpendicular to a second side of the conductor; and a second insulating layer, connected to the first insulating layer, wherein the second region is located inside the second insulating layer when viewed in a direction perpendicular to a second side of the conductor.

[0021] According to the embodiment, the longitudinal length of the second insulating layer is at least 0.25 times the longitudinal length of the first insulating layer.

[0022] According to the implementation method, the end of the second conductor corresponds to the end of the second region.

[0023] According to an embodiment, the insulating layer includes at least one of alumina and boehmite.

[0024] According to an embodiment, the insulating layer comprises a ceramic material and an adhesive, and the ratio of the adhesive to the ceramic material is 15wt% to 45wt%.

[0025] The method of manufacturing an electrode assembly disclosed herein includes: preparing a plurality of electrode plates, each electrode plate including a coated portion in which an active material is coated on both sides of a composite substrate and an uncoated portion in which no active material is provided on the composite substrate; connecting a conductor to the uncoated portion of each electrode plate; providing an insulating layer to cover at least a portion of the uncoated portion of each electrode plate, the coated portion of each electrode plate, and each of the conductors; and laminating the plurality of electrode plates connected to the conductors and having the insulating layer disposed thereon and a diaphragm inserted between the plurality of electrode plates.

[0026] According to an embodiment, the composite substrate includes: a polymer substrate; a first metal layer disposed on a first surface of the polymer substrate; and a second metal layer disposed on a second surface of the polymer substrate; wherein the first metal layer and the second metal layer are formed of the same material.

[0027] According to embodiments of this disclosure, by including a polymer substrate, the weight of the composite substrate can be reduced. Accordingly, the energy density of the secondary battery including the composite substrate can be improved.

[0028] According to some embodiments of this disclosure, the region where the attached conductor is disposed and the region where the insulating layer is disposed may not be spaced apart from each other, and the region where the attached conductor is disposed and the region where the insulating layer is disposed may overlap. Accordingly, the length of the uncoated portion required for the attached conductor can be reduced, and the energy density of the electrode assembly can be improved.

[0029] According to some embodiments of this disclosure, because the first conductor and the second conductor are connected to both sides of the composite substrate and are firmly combined, the composite substrate and the conductor can conduct electricity more stably. Accordingly, the defect rate of the electrode assembly can be reduced.

[0030] According to some embodiments of this disclosure, the second conductor connected to one side of the composite substrate can be provided only in the amount required for conductivity. Accordingly, because the amount of conductor connected to the strip terminals can be reduced in each of the plurality of electrode plates, it becomes easier to solder the conductors and the strip terminals.

[0031] However, the aspects and features of this disclosure are not limited to those described above, and those skilled in the art will clearly understand from the detailed description below that other aspects and features not mentioned will be apparent. Attached Figure Description

[0032] The following drawings illustrate embodiments of the present disclosure and, together with the detailed description of the present disclosure, further describe aspects and features of the present disclosure. Therefore, the present disclosure should not be construed as being limited to the drawings.

[0033] Figure 1 A secondary battery according to an embodiment of the present disclosure is explained.

[0034] Figure 2 A diagram of a composite substrate according to an embodiment of the present disclosure.

[0035] Figure 3 This is a cross-sectional view of a portion of an electrode assembly according to an embodiment of the present disclosure.

[0036] Figure 4 This is a top view taken from above of an electrode assembly in accordance with an embodiment of the present disclosure, wherein a portion of the insulating layer has been omitted.

[0037] Figure 5 This is a diagram of a conductor connected to a composite substrate according to an embodiment of the present disclosure.

[0038] Figure 6 This is a diagram of a conductor connected to a composite substrate according to an embodiment of the present disclosure.

[0039] Figure 7 This is a diagram of an electrode assembly according to an embodiment of the present disclosure, in which the insulating layer is omitted.

[0040] Figure 8 This is a diagram of an electrode assembly according to an embodiment of the present disclosure, in which the insulating layer is omitted.

[0041] Figure 9 This is a flowchart of a method for manufacturing an electrode assembly according to an embodiment of the present disclosure.

[0042] Explanation of reference numerals in the attached figures

[0043] 10: Secondary batteries

[0044] 110: Shell

[0045] 122: Cover plate

[0046] 124: Exhaust section

[0047] 126: Sealing plug

[0048] 130_1: Positive electrode terminal

[0049] 130_2: Negative electrode terminal Detailed Implementation

[0050] In the following description, embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. The terms or words used in this specification and claims should not be construed as limited to their ordinary or dictionary meanings, and should be interpreted, based on the principle that the inventor can define the concepts of terms appropriately as a lexicographer, to best interpret his / her invention in a meaning and concept consistent with the technical spirit of the present disclosure.

[0051] The embodiments described in this specification and the configurations shown in the accompanying drawings are only some embodiments of this disclosure and do not represent all the technical ideas, aspects, and features of this disclosure. Accordingly, it should be understood that various equivalent solutions and modifications may be made to replace or modify the embodiments described herein at the time of filing this application.

[0052] It will be understood that when a layer (or element) is referred to as being "between" two layers (or elements), it can be the only layer (or element) between the two layers (or elements), or there may be one or more intermediary layers (or elements). It will be understood that when an element or layer is referred to as being "on" another element or layer, "connected to," or "linked to" another element or layer, it can be directly on, directly connected to, or directly linked to the other element or layer, or there may be one or more intermediary elements or layers. When an element or layer is referred to as being "directly on" another element or layer, "directly connected to," or "directly linked to" another element or layer, there are no intermediary elements or layers. For example, when a first element is described as being "linked" or "connected" to a second element, the first element can be directly linked or directly connected to the second element, or the first element can be indirectly linked or indirectly connected to the second element via one or more intermediary elements.

[0053] In the figures, the dimensions of various elements, layers, etc., may be enlarged for clarity of explanation. The same reference numerals denote the same elements. The term “and / or” as used herein includes any and all combinations of one or more of the associated enumerated items. Furthermore, when describing embodiments of this disclosure, the use of “may” means “one or more embodiments of this disclosure.” Expressions such as “at least one of…” and “any one of…” when following a list of elements modify the entire list of elements and not individual elements of the list. When phrases such as “at least one of A, B, and C,” “at least one selected from the group of A, B, and C,” or “at least one selected from A, B, and C” are used to refer to a list of elements A, B, and C, the phrase may refer to any and all suitable combinations or subsets of A, B, and C, such as A, B, C, A and B, A and C, B and C, or A and B and C. The terms “use,” “using,” and “used” as used herein may be considered synonymous with the terms “utilize,” “utilizing,” and “utilized,” respectively. The terms “substantially,” “about,” and similar terms used herein are used as approximate terms and not as terms of degree, and are intended to explain the inherent biases of measurements or calculations that a person skilled in the art would recognize.

[0054] It will be understood that although the terms “first,” “second,” “third,” etc., may be used herein to describe various elements, components, areas, layers, and / or portions, these elements, components, areas, layers, and / or portions should not be limited by these terms. These terms are used to distinguish one element, component, area, layer, or portion from another element, component, area, layer, or portion. Therefore, without departing from the teachings of the exemplary embodiments, the first element, component, area, layer, or portion discussed below may be referred to as the second element, component, area, layer, or portion.

[0055] For ease of description, spatial relative terms such as “below,” “under,” “down,” “above,” and “above” may be used herein to describe the relationship between one element or feature as illustrated in the figures and another element(s). It will be understood that, in addition to the orientation depicted in the figures, the spatial relative terms are also intended to cover different orientations of the device in use or operation. For example, if the device in the figures is flipped, an element described as “below” or “under” other elements or features will subsequently be oriented “above” or “above” other elements or features. Therefore, the term “below” can encompass both the above and below orientations. The device may be oriented in other ways (rotated 90 degrees or otherwise), and the spatial relative descriptors used herein should be interpreted accordingly.

[0056] The terminology used herein is for the purpose of describing embodiments of this disclosure and is not intended to limit this disclosure. The singular forms “a” and “an” as used herein are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “includes,” “including,” “comprises,” and / or “comprising,” when used in this specification, indicate the presence of the described features, integers, steps, operations, elements, components, and / or groups thereof, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0057] Furthermore, any numerical range disclosed and / or set forth herein is intended to include all subranges containing the same numerical precision within the set forth range. For example, the range “1.0 to 10.0” is intended to include all subranges between the set forth minimum value of 1.0 and the set forth maximum value of 10.0 (and inclusive), i.e., a minimum value equal to or greater than 1.0 and a maximum value equal to or less than 10.0, such as, for example, 2.4 to 7.6. Any maximum numerical limit set forth herein is intended to include all lower numerical limits contained therein, and any minimum numerical limit set forth in this specification is intended to include all higher numerical limits contained therein. Accordingly, the applicant reserves the right to amend this specification (including the claims) to expressly set forth any subranges contained within the range expressly set forth herein. All such ranges are intended to be described inherently in this specification such that any amendment to expressly set forth any such subrange will comply with the requirements of local patent law.

[0058] When comparing two elements, features, etc., that are “identical,” it can mean that they are “substantially identical.” Therefore, the phrase “substantially identical” can include cases with deviations considered small in the art (e.g., 5% or less). Additionally, when a parameter is said to be uniform in a given region, it can mean that it is uniform in an average sense.

[0059] Throughout this specification, unless otherwise stated, each element may be singular or plural.

[0060] Placing any element "above (or below)" or "above (below)" another element means that the arbitrary element can contact the upper (or lower) surface of the other element, and other elements can also be inserted between the other element and the arbitrary element placed on (or below) the other element.

[0061] Additionally, it will be understood that when a component is referred to as “linked,” “coupled,” or “connected” to another component, these components can be directly “linked,” “coupled,” or “connected” to each other, or another component can “insert” between these components.

[0062] Throughout this specification, when “A and / or B” is stated, it means A, B, or A and B, unless otherwise stated. That is, “and / or” includes any or all of the listed items. When “C~D” is stated, it means C or greater and D or less, unless otherwise indicated.

[0063] In this disclosure, for clarity of explanation, the dimensions of the layers and regions shown in the accompanying drawings and their relative dimensions may be enlarged. That is, the dimensions shown in the drawings are for convenience only, and this disclosure is not limited thereto. Furthermore, throughout the specification, the same reference numerals refer to the same components.

[0064] In this disclosure, the "longitudinal length" can be measured in an electrode plate comprising coated portions in which active material is coated on both sides of a substrate and uncoated portions in which no active material is coated on the substrate, based on the direction of extension of the uncoated portions. That is, the height or longitudinal length of a particular configuration can be measured when viewed in a direction perpendicular to the direction in which the uncoated portions extend. In this disclosure, the upper side of a drawing may be referred to as the "upper" or "top" of the structure illustrated in the drawing, and the lower side may be referred to as the "lower" or "bottom" of the structure illustrated in the drawing. In this case, the longitudinal length can be measured based on the direction from the top to the bottom of the structure illustrated in the drawing. Such relative terms including "upper," "top," etc., are used to describe relationships in the structures shown in the drawings, and this disclosure is not limited to those terms.

[0065] Figure 1 A secondary battery 10 according to an embodiment of this disclosure is explained. (See reference...) Figure 1 The secondary battery 10 according to one or more embodiments of the present disclosure may include at least one electrode assembly wound with a separator, which is an insulator, between the positive electrode and the negative electrode, a housing 110 containing (or accommodating) the electrode assembly, and a cover plate 122 connected to an opening of the housing 110.

[0066] The secondary battery 10 according to one or more embodiments will now be described as an example of a prismatic lithium-ion secondary battery. However, this disclosure is not limited thereto, and the appropriate aspects, features, and principles described herein can be applied to a variety of other types of batteries, such as lithium polymer batteries and / or cylindrical batteries.

[0067] Each of the positive and negative electrodes may include a current collector made of a thin metal foil having a coated portion thereon coated with an active material and an uncoated portion thereon uncoated with an active material.

[0068] A diaphragm, which serves as an insulator, is inserted between the positive and negative electrodes and then wound up. However, this disclosure is not limited thereto, and the electrode assembly may have a structure in which the positive and negative electrodes (each made of multiple sheets) are stacked alternately and the diaphragm is inserted therebetween.

[0069] The housing 110 forms the overall appearance of the secondary battery 10 and can be made of a conductive metal such as aluminum, aluminum alloy, or nickel-plated steel. In addition, the housing 110 provides space for accommodating the electrode assembly.

[0070] The cover assembly may include a cover plate 122 that covers an opening in the housing 110, and the housing 110 and the cover plate 122 may be made of a conductive material. Positive electrode terminals 130_1 and negative electrode terminals 130_2, which are electrically connected to positive and negative electrodes respectively, may be mounted to penetrate (or extend through) the cover plate 122 and thereby protrude outward.

[0071] Additionally, the outer peripheral surfaces (e.g., circumferential surfaces) of the upper supports of the positive electrode terminal 130_1 and the negative electrode terminal 130_2 protruding outward from the cover plate 122 may be threaded and can be secured to the cover plate 122 by using nuts.

[0072] However, this disclosure is not limited thereto, and the positive electrode terminal 130_1 and the negative electrode terminal 130_2 may have a riveted structure and may be riveted or welded to the cover plate 122.

[0073] Additionally, the cover plate 122 may be made of a thin plate and may be connected to an opening in the housing 110, and an electrolyte injection port (with a sealing plug 126 positioned therein) and a venting portion 124 with a notch may be installed in the cover plate 122.

[0074] In one embodiment, the secondary battery 10 may include an electrode assembly. The electrode assembly may include an electrode plate comprising a coated portion in which active material is coated on both sides of a composite substrate, and an uncoated portion in which no active material is provided on the composite substrate. A conductor may be coupled to the uncoated portion, and an insulating layer may cover at least a portion of each of the uncoated portion, the coated portion, and the conductor. Reference is made below. Figure 2 Examples of composite substrates are described in detail.

[0075] The uncoated portion can be connected to the first side of the conductor. Additionally, an insulating layer can be applied to the second side of the conductor opposite the first side. See below for reference. Figures 3-8 A detailed description of an example of this conductor and insulating layer.

[0076] Figure 2 A diagram of a composite substrate 210 according to an embodiment of the present disclosure. Electrode plates (e.g., for...) Figure 1 The aforementioned electrode plate may include a coated portion 240 in which an active material 220 is applied to both sides of the composite substrate 210, and an uncoated portion 230 in which no active material is applied to the composite substrate 210. The composite substrate 210 may include: a polymer substrate 212; a first metal layer 214 disposed on one surface of the polymer substrate 212; and a second metal layer 216 disposed on the other surface of the polymer substrate 212. Here, the first metal layer 214 and the second metal layer 216 disposed on the polymer substrate 212 may be formed of the same material. In some examples, the polymer substrate 212 may include PET (polyethylene terephthalate), and the first metal layer 214 and the second metal layer 216 may include aluminum (Al) or copper (Cu). However, this disclosure is not limited to these examples.

[0077] In one embodiment, the first metal layer 214 and the second metal layer 216 disposed on the surface of the polymer substrate 212 may comprise aluminum (Al). In this configuration, the active material 220 disposed on the first metal layer 214 may be a positive electrode active material, and the electrode plate may be used as a positive electrode plate. In other embodiments, the first metal layer 214 and the second metal layer 216 may comprise copper (Cu). In this configuration, the active material 220 disposed on the first metal layer 214 may be a negative electrode active material, and the electrode plate may be used as a negative electrode plate.

[0078] The positive electrode active material may include compounds capable of intercalating and deintercalating lithium (lithiation intercalation compounds). Specifically, a composite oxide of at least one lithium with a metal selected from cobalt, manganese, nickel, and combinations thereof may be used.

[0079] The composite oxide can be a lithium transition metal composite oxide. Specific examples of composite oxides may include lithium nickel oxides, lithium cobalt oxides, lithium manganese oxides, lithium iron phosphate compounds, cobalt-free nickel manganese oxides, or combinations thereof.

[0080] As an example, a compound represented by any of the following chemical formulas can be used: Li a A 1-b X b O 2-c D c (0.90≤a≤1.8, 0≤b≤0.5, 0≤c≤0.05); Li a Mn 2-b X b O 4-c D c (0.90≤a≤1.8, 0≤b≤0.5, 0≤c≤0.05); Lia Ni 1-b-c Co b X c O 2-α D α (0.90≤a≤1.8, 0≤b≤0.5, 0≤c≤0.5, 0<α<2); Li a Ni 1-b- c Mn b X c O 2-α D α (0.90≤a≤1.8, 0≤b≤0.5, 0≤c≤0.5, 0<α<2); Li a Ni b Co c L 1 d G e O2 (0.90≤a≤1.8, 0≤b≤0.9, 0≤c≤0.5, 0≤d≤0.5, 0≤e≤0.1); Li a NiG b O2 (0.90≤a≤1.8, 0.001≤b≤0.1); Li a CoG b O2 (0.90≤a≤1.8, 0.001≤b≤0.1); Li a Mn 1-b G b O2 (0.90≤a≤1.8, 0.001≤b≤0.1); Li a Mn2G b O4 (0.90≤a≤1.8, 0.001≤b≤0.1); Li a Mn 1-g G g PO4 (0.90≤a≤1.8, 0≤g≤0.5); Li (3-f) Fe2(PO4)3 (0≤f≤2); and Li a FePO4 (0.90≤a≤1.8).

[0081] In the above chemical formulas, A is Ni, Co, Mn, or a combination thereof; X is Al, Ni, Co, Mn, Cr, Fe, Mg, Sr, V, rare earth elements, or a combination thereof; D is O, F, S, P, or a combination thereof; G is Al, Cr, Mn, Fe, Mg, La, Ce, Sr, V, or a combination thereof; and L 1 It is Mn, Al, or a combination thereof.

[0082] The positive electrode for a rechargeable lithium battery may include a positive electrode current collector and a positive electrode active material layer on the positive electrode current collector. The positive electrode active material layer may include a positive electrode active material and may further include a binder and / or a conductive material (e.g., a conductive material).

[0083] Based on 100 wt% of the positive electrode active material layer, the amount of the positive electrode active material may be about 90 wt% to about 99 wt%. Based on 100 wt% of the positive electrode active material layer, the amounts of the binder and the conductive material may be about 0.5 wt% to about 5 wt% respectively.

[0084] The positive electrode current collector may be an aluminum (Al) foil, but is not limited thereto.

[0085] The negative electrode active material may include a material that reversibly intercalates / deintercalates lithium ions, lithium metal, a lithium metal alloy, a material capable of doping / de-doping lithium, or a transition metal oxide.

[0086] The material that reversibly intercalates / deintercalates lithium ions may include a carbon-based negative electrode active material, such as, for example, crystalline carbon, amorphous carbon, or a combination thereof. The crystalline carbon may be graphite, such as amorphous, flaky, platelet, spherical, or fibrous natural graphite or artificial graphite. The amorphous carbon may be soft carbon, hard carbon, mesophase pitch carbonized product, calcined coke, etc.

[0087] The material capable of doping / de-doping lithium may be a silicon (Si)-based negative electrode active material or a tin (Sn)-based negative electrode active material. The Si-based negative electrode active material may include silicon, a silicon-carbon composite, SiO x (0 < x ≤ 2), a Si-Q alloy (where Q is selected from alkali metals, alkaline earth metals, group 13 elements, group 14 elements (excluding Si), group 15 elements, group 16 elements, transition metals, rare earth elements, and combinations thereof).

[0088] The silicon-carbon composite may be a composite of silicon and amorphous carbon. According to an embodiment, the silicon-carbon composite may be in the form of silicon particles and amorphous carbon coated on the surface of the silicon particles.

[0089] The silicon-carbon composite may further include crystalline carbon. For example, the silicon-carbon composite may include a core containing crystalline carbon and silicon particles, and an amorphous carbon coating on the surface of the core. <>

[0090] By including a polymer substrate therein, the weight of the composite substrate can be reduced. Accordingly, the energy density of the secondary battery including the composite substrate can be improved.

[0091] Figure 3 It is a cross-sectional view of a part of an electrode assembly according to an embodiment of the present disclosure. Figure 4This is a top view taken from above, according to an embodiment of the present disclosure, of an electrode assembly in which a portion of the insulating layer is omitted. The electrode assembly may include an electrode plate having a portion of the insulating layer within a composite substrate (e.g., Figure 2 The composite substrate 210 has an uncoated portion 310 without active material, a coated portion 320 with active material coated on both sides, a conductor 330 connected to the uncoated portion 310, and an insulating layer 340. Here, the insulating layer 340 may cover at least a portion of each of the uncoated portion 310, the coated portion 320, and the conductor 330.

[0092] In an example compared to embodiments of this disclosure, the region where the uncoated portion and the conductor are connected can be separated from the region where the insulating layer is provided. For example, the insulating layer can be formed separately below the region where the uncoated portion and the conductor are connected (i.e., below the conductor connected to the uncoated portion). In this case, the length of the uncoated portion can be increased for both the region where the uncoated portion and the conductor are connected and the region where the insulating layer is provided. Accordingly, the energy density of the electrode assembly decreases due to the increased length of the uncoated portion.

[0093] In embodiments of this disclosure, a first side of the conductor 330 may be connected to an uncoated portion 310. For example, the first side of the conductor 330 may be connected to the uncoated portion 310 by means of ultrasonic welding or the like. However, this disclosure is not limited to this type of connection. Furthermore, an insulating layer 340 may be disposed on a second side of the conductor 330 opposite to the first side of the conductor 330. That is, the conductor 330 may be located between at least a portion of the uncoated portion 310 and at least a portion of the insulating layer 340.

[0094] Conductor 330 may include a first region 332 connected to the uncoated portion 310. Insulating layer 340 may include a first insulating layer 342 covering the first region 332 of conductor 330. Here, when viewed in a direction perpendicular to the second side of conductor 330, the first region 332 may be located inside the first insulating layer 342.

[0095] The insulating layer 340 may include a second insulating layer 344 connected to the first insulating layer 342 and a third insulating layer 346 connected to the second insulating layer 344. Here, the second insulating layer 344 may cover a portion of the uncoated portion 310 located between the first region 332 and the coated portion 320. The third insulating layer 346 may cover at least a portion of the coated portion 320. Accordingly, the insulating layer 340 may cover at least a portion of each of the uncoated portion 310, the coated portion 320, and the conductor 330.

[0096] The area of ​​the first insulating layer 342 may be larger than the area of ​​the first region 332. (See reference) Figure 3 and Figure 4The horizontal length of the first insulating layer 342 and the horizontal length of the first region 332 can be the same. The longitudinal length h2 of the first insulating layer 342 can be greater than the longitudinal length h1 of the first region 332. Specifically, the upper end of the first insulating layer 342 can be at least 0.5 mm higher than the upper end of the first region 332. That is, the longitudinal length h2 of the first insulating layer 342 can be at least 0.5 mm longer than the longitudinal length h1 of the first region 332.

[0097] The first zone 332 may be spaced apart from the coated portion 320. (Reference) Figure 3 and Figure 4 The distance (longitudinal length h3) between the first region 332 and the coated portion 320 can be at least 0.3 mm. In this arrangement, the second insulating layer 344 can cover the uncoated portion located between the first region 332 and the coated portion 320.

[0098] The third insulating layer 346 may cover at least a portion of the coated portion 320. (See reference) Figure 3 and Figure 4 The lower end of the third insulating layer 346 may be located at least 0.3 mm lower than the upper end of the coated portion 320. That is, the longitudinal length h4 of the third insulating layer 346 covering the coated portion 320 may be at least 0.3 mm.

[0099] use Figure 3 and Figure 4 The configuration depicted in the diagram allows the region where the attached conductor is disposed and the region where the insulating layer is disposed to be non-spaced apart from each other, and allows the region where the attached conductor is disposed and the region where the insulating layer is disposed to overlap. Accordingly, the length of the uncoated portion required for the attached conductor can be reduced, thus improving the energy density of the electrode assembly.

[0100] Figure 5 This diagram illustrates a conductor connected to a composite substrate 510 according to an embodiment of the present disclosure. The conductor may be connected to an uncoated portion of the composite substrate 510 where no active material is provided. The composite substrate 510 may include: a polymer substrate 512; a first metal layer 514 disposed on a first surface of the polymer substrate 512; and a second metal layer 516 disposed on a second surface of the polymer substrate 512. The first metal layer 514 and the second metal layer 516 may be formed of the same material.

[0101] The conductor may include a first conductor 520 connected to a first metal layer 514 and a second conductor 530 connected to a second metal layer 516. The first conductor 520 may include a first region 522 connected to the first metal layer 514 and a second region 524 connected to the second conductor 530. The second region 524 may be located above the first region 522. That is, the first conductor 520 and the second conductor 530 may be connected at the upper part of the composite substrate 510. The first region 522 and the second region 524 may be formed by using ultrasonic welding or the like, but this disclosure is not limited thereto.

[0102] The insulating layer may cover at least a portion of the uncoated portion (i.e., the composite substrate 510) and each of the conductors. For example, the insulating layer may be disposed on a second side of the first conductor 520, which faces away from the first side of the first conductor 520 in which the first region 522 and the second region 524 are formed. Specifically, when viewed in a direction perpendicular to the second side of the first conductor 520, the insulating layer may include: a first insulating layer 542, in which the first region 522 is located; and a second insulating layer 544, in which the second region 524 is located. The second insulating layer 544 may be connected to the upper portion of the first insulating layer 542.

[0103] The longitudinal length h1 of the first insulating layer 542 may be greater than the longitudinal length h3 of the second insulating layer 544. In a specific embodiment, the longitudinal length h3 of the second insulating layer 544 may be at least 0.25 times the longitudinal length h1 of the first insulating layer 542. Furthermore, the longitudinal length h3 of the second insulating layer 544 may be greater than the longitudinal length h2 of the second region 524. For example, the upper end of the second insulating layer 544 may be located at least 0.5 mm higher than the upper end of the second region 524. However, this disclosure is not limited to these exemplary configurations.

[0104] The insulating layer 340 may comprise a ceramic material, which may include at least one of alumina and boehmite. The average particle size (D) of the ceramic material in the insulating layer 340 is... 50 The thickness can be less than 3 μm. Additionally, the insulating layer 340 may further include an adhesive, and the ratio of the adhesive to the ceramic material can be 15 wt% to 45 wt%.

[0105] exist Figure 5 The coating portion where active materials are applied to both sides of the composite substrate 510 is omitted, but all configurations can be referenced. Figure 3 and Figure 4 Therefore, the insulating layer may further include a third insulating layer 546 connected to the underside of the first insulating layer 542 and covering the uncoated portion. The insulating layer may further include a fourth insulating layer (not shown) connected to the underside of the third insulating layer 546 and covering the coated portion.

[0106] Figure 5 The second conductor 530 shown has a similar configuration to the first conductor 520. That is, the insulating layer covers the second conductor 530 in the same manner as the insulating layer covering the first conductor 520 as described above.

[0107] Because the first and second conductors are connected to both sides of the composite substrate and are firmly bonded, the composite substrate and conductors can conduct electricity more stably. Consequently, the defect rate of the electrode assembly can be reduced.

[0108] Figure 6 This diagram illustrates a conductor connected to a composite substrate 610 according to an embodiment of the present disclosure. The conductor may be connected to an uncoated portion of the composite substrate 610 where no active material is provided. The composite substrate 610 may include: a polymer substrate 612; a first metal layer 614 disposed on a first surface of the polymer substrate 612; and a second metal layer 616 disposed on a second surface of the polymer substrate 612. The first metal layer 614 and the second metal layer 616 may be formed of the same material.

[0109] The conductor may include a first conductor 620 connected to a first metal layer 614 and a second conductor 630 connected to a second metal layer 616. Here, the first conductor 620 may include a first region 622 connected to the first metal layer 614 and a second region 624 connected to the second conductor 630. The second region 624 may be located above the first region 622. That is, the first conductor 620 and the second conductor 630 may be connected at the upper part of the composite substrate 610. Such a first region 622 and a second region 624 may be formed by using ultrasonic welding or the like, but this disclosure is not limited to these examples.

[0110] The insulating layer may cover at least a portion of the uncoated portion (i.e., the composite substrate 610) and each of the conductors. For example, the insulating layer may be disposed on a second side of a first conductor 620, which faces away from a first side of the first conductor 620 in which a first region 622 and a second region 624 are formed. When viewed in a direction perpendicular to the second side of the first conductor 620, the insulating layer may include: a first insulating layer 642, with the first region 622 located inside the first insulating layer 642; and a second insulating layer 644, with the second region 624 located inside the second insulating layer 644. The second insulating layer 644 may be connected to the upper portion of the first insulating layer 642.

[0111] exist Figure 6 In the embodiment depicted, the length of the second conductor 630 is shorter than the length of the first conductor 620. To create this configuration, after the second conductor 630 is joined to the first conductor 620, the second conductor 630 can be cut such that the end of the second conductor 630 corresponds to the end of the second region 624. A third insulating layer 650 covering the second conductor 630 may cover the end of the second conductor 630.

[0112] use Figure 6 In the configuration depicted, the second conductor connected to one side of the composite substrate can be provided only in the amount required for conductivity. Accordingly, because the amount of conductor connected to the strip terminals can be reduced in each of the multiple electrode plates, it becomes easier to solder the conductors and strip terminals.

[0113] Figure 7 This is a diagram of an electrode assembly according to an embodiment of the present disclosure, wherein an insulating layer is omitted. The electrode assembly may include an electrode plate comprising elements thereof in a composite substrate (e.g., Figure 2 The composite substrate has a coated portion on both sides of a portion to which an active material is applied and an uncoated portion on which no active material is applied. A conductor may be connected to the uncoated portion, and an insulating layer may cover at least a portion of each of the uncoated portion, the coated portion, and the conductor. Depending on the polarity of the composite substrate, the electrode plates may include a positive electrode plate 710 and a negative electrode plate 720. The electrode assembly can be manufactured by laminating the positive electrode plate 710, the negative electrode plate 720, and a separator 730 inserted between the positive electrode plate 710 and the negative electrode plate 720. Such an electrode assembly may be included in a secondary battery for an electronic device. However, this disclosure is not limited to the specific configuration or use of the electrode assembly mentioned above.

[0114] The positive electrode plate 710 may include a first uncoated portion (not shown) and a first coated portion 714. A first conductor 712 may be coupled to the first uncoated portion at a first region 716. Here, the first region 716 may be the region in which the first uncoated portion is soldered and coupled to the first conductor 712. A first insulating layer (not shown) may cover at least a portion of each of the first uncoated portion, the first coated portion 714, and the first conductor 712.

[0115] The negative electrode plate 720 may include a second uncoated portion (not shown) and a second coated portion 724. A second conductor 722 may be coupled to the second uncoated portion at a second region 726. Here, the second region 726 may be a region in which the second uncoated portion is soldered and coupled to the second conductor 722. A second insulating layer (not shown) may cover at least a portion of each of the second uncoated portion, the second coated portion 724, and the second conductor 722.

[0116] The first insulating layer may cover the first region 716. That is, the area of ​​the first insulating layer may be larger than the area of ​​the first region 716. Similarly, the second insulating layer may cover the second region 726. That is, the area of ​​the second insulating layer may be larger than the area of ​​the second region 726.

[0117] The longitudinal length h1 of the first region 716 of the positive electrode plate 710 may be different from the longitudinal length h2 of the second region 726 of the negative electrode plate 720. Specifically, the longitudinal length h1 of the first region 716 may be 1.5mm to 5.5mm, while the longitudinal length h2 of the second region 726 may be 2.0mm to 6.0mm.

[0118] Figure 8 This is a diagram of an electrode assembly according to an embodiment of the present disclosure, wherein an insulating layer is omitted. The electrode assembly may include an electrode plate comprising elements thereof in a composite substrate (e.g., Figure 2 The composite substrate has a coated portion on both sides of a portion 210 where active material is applied and an uncoated portion where no active material is provided on the composite substrate. A conductor may be connected to the uncoated portion, and an insulating layer may cover at least a portion of each of the uncoated portion, the coated portion, and the conductor. Depending on the polarity of the composite substrate, the electrode plates may include a positive electrode plate 810 and a negative electrode plate 820. The electrode assembly can be manufactured by laminating the positive electrode plate 810, the negative electrode plate 820, and a separator 830 inserted between the positive electrode plate 810 and the negative electrode plate 820. Such an electrode assembly may be included in a secondary battery requiring high output power, such as a secondary battery for an electric vehicle. However, this disclosure is not limited to this example.

[0119] The positive electrode plate 810 may include a first uncoated portion (not shown) and a first coated portion 814. A first conductor 812 may be coupled to the first uncoated portion at a first region 816. That is, the first region 816 may be a region in which the first uncoated portion is soldered and coupled to the first conductor 812. A first insulating layer (not shown) may cover at least a portion of each of the first uncoated portion, the first coated portion 814, and the first conductor 812.

[0120] The negative electrode plate 820 may include a second uncoated portion (not shown) and a second coated portion 824. A second conductor 822 may be coupled to the second uncoated portion at a second region 826. That is, the second region 826 may be a region in which the second uncoated portion is soldered and coupled to the second conductor 822. A second insulating layer (not shown) may cover at least a portion of each of the second uncoated portion, the second coated portion 824, and the second conductor 822.

[0121] The first insulating layer may cover the first region 816. That is, the area of ​​the first insulating layer may be larger than the area of ​​the first region 816. Similarly, the second insulating layer may cover the second region 826. That is, the area of ​​the second insulating layer may be larger than the area of ​​the second region 826.

[0122] Figure 9This is a flowchart of a method 900 for manufacturing an electrode assembly according to an embodiment of the present disclosure. The method 900 for manufacturing an electrode assembly may begin by preparing a plurality of electrode plates, each electrode plate including a coated portion in which an active material is coated on both sides of a composite substrate and an uncoated portion in which no active material is provided on the composite substrate (step S910). The composite substrate may include: a polymer substrate; a first metal layer disposed on a first surface of the polymer substrate; and a second metal layer disposed on a second surface of the polymer substrate. The first metal layer and the second metal layer may be formed of the same material.

[0123] Next, conductors can be connected to the uncoated portion of each of the plurality of electrode plates (step S920). An insulating layer can be provided to cover the uncoated portion of each electrode plate, the coated portion of each electrode plate, and at least a portion of each of the conductors (step S930). Then, an electrode assembly can be manufactured by laminating the plurality of electrode plates connected to the conductors and having the insulating layer disposed thereon, and a diaphragm inserted between the plurality of electrode plates (step S940).

[0124] The conductor may include a first region connected to the uncoated portion, and the insulating layer may include a first insulating layer covering the first region of the conductor. When viewed in a direction perpendicular to a second side of the conductor, the first region may be located inside the first insulating layer.

[0125] The first region may be spaced apart from the coated portion. For example, the distance between the first region and the coated portion may be at least 0.3 mm. And the upper end of the first insulating layer may be located at least 0.5 mm higher than the upper end of the first region. However, this disclosure is not limited to this example.

[0126] The insulating layer may include a second insulating layer connected to the first insulating layer and covering the uncoated portion located between the first region and the coated portion. The insulating layer may also include a third insulating layer connected to the second insulating layer and covering at least a portion of the coated portion. The lower end of the third insulating layer may be located, for example, at least 0.3 mm lower than the upper end of the coated portion.

[0127] The composite substrate can be positively polarized. In this configuration, the longitudinal length of the first region can be 1.5 mm to 5.5 mm. In another embodiment, the composite substrate can be negatively polarized. In this configuration, the longitudinal length of the first region can be 2.0 mm to 6.0 mm.

[0128] The conductor may include a first conductor connected to a first metal layer and a second conductor connected to a second metal layer. The first conductor may include a first region connected to the first metal layer and a second region connected to the second conductor. Here, the second region may be located above the first region.

[0129] The insulating layer may include: a first insulating layer, wherein a first region is located inside the first insulating layer when viewed in a direction perpendicular to the second side of the conductor; and a second insulating layer connected to the first insulating layer. The second region may be located inside the second insulating layer when viewed in a direction perpendicular to the second side of the conductor. The longitudinal length of the second insulating layer may be at least 0.25 times the longitudinal length of the first insulating layer. The end of the second conductor may correspond to the end of the second region.

[0130] The insulating layer may include at least one of alumina and boehmite. In some examples, the insulating layer includes a ceramic material and an adhesive, and the ratio of the adhesive to the ceramic material may be 15 wt% to 45 wt%.

[0131] Although the present disclosure has been described above by way of embodiments thereof, the present disclosure is not limited thereto. Various modifications and variations may be made thereto by those skilled in the art within the spirit and scope of the present disclosure.

Claims

1. An electrode assembly, the electrode assembly comprising: An electrode plate includes a coated portion in which an active material is coated on both sides of a composite substrate and an uncoated portion in which the active material is not provided on the composite substrate; Conductor, connected to the uncoated portion; as well as An insulating layer covering at least a portion of each of the uncoated portions, the coated portions, and the conductors. The uncoated portion is connected to the first side of the conductor, and The insulating layer is disposed on a second side of the conductor opposite to the first side of the conductor.

2. The electrode assembly according to claim 1, wherein the composite substrate comprises: Polymer substrate; A first metal layer is disposed on a first surface of the polymer substrate; as well as A second metal layer is disposed on the second surface of the polymer substrate, and The first metal layer and the second metal layer are formed of the same material.

3. The electrode assembly of claim 1, wherein the conductor includes a region connected to the uncoated portion. When viewed in a direction perpendicular to the second side of the conductor, the region is located inside the insulating layer.

4. The electrode assembly of claim 3, wherein the region is spaced apart from the coating portion.

5. The electrode assembly of claim 4, wherein the distance between the area and the coated portion is at least 0.3 mm.

6. The electrode assembly of claim 3, wherein the upper end of the insulating layer is located at least 0.5 mm higher than the upper end of the region.

7. The electrode assembly of claim 3, wherein the portion of the insulating layer covering the region of the conductor is a first insulating layer, and The insulating layer further includes a second insulating layer connected to the first insulating layer and covering the uncoated portion located between the area and the coated portion.

8. The electrode assembly of claim 7, wherein the insulating layer further comprises a third insulating layer connected to the second insulating layer and covering at least a portion of the coated portion.

9. The electrode assembly of claim 8, wherein the lower end of the third insulating layer is located at least 0.3 mm lower than the upper end of the coated portion.

10. The electrode assembly of claim 3, wherein the polarity of the composite substrate is positive, and The longitudinal length of the region is 1.5mm to 5.5mm.

11. The electrode assembly of claim 3, wherein the polarity of the composite substrate is negative, and The longitudinal length of the region is 2.0 mm to 6.0 mm.

12. The electrode assembly of claim 2, wherein the conductor comprises: A first conductor is connected to the first metal layer; and the second conductor, connected to the second metal layer, and The first conductor includes: a first region connected to the first metal layer; And the second region, connected to the second conductor.

13. The electrode assembly of claim 12, wherein the second region is spaced apart from the first region.

14. The electrode assembly of claim 12, wherein the insulating layer comprises: A first insulating layer, wherein the first region is inside the first insulating layer when viewed in a direction perpendicular to the second side of the conductor; as well as The second insulating layer is connected to the first insulating layer, and When viewed in a direction perpendicular to the second side of the conductor, the second region is located inside the second insulating layer.

15. The electrode assembly of claim 14, wherein the longitudinal length of the second insulating layer is at least 0.25 times the longitudinal length of the first insulating layer.

16. The electrode assembly of claim 12, wherein the end of the second conductor corresponds to the end of the second region.

17. The electrode assembly of claim 1, wherein the insulating layer comprises at least one of alumina and boehmite.

18. The electrode assembly of claim 1, wherein the insulating layer comprises a ceramic material and a binder, and The ratio of the binder to the ceramic material is 15wt% to 45wt%.

19. A method of manufacturing an electrode assembly, the method comprising: Multiple electrode plates are prepared, each electrode plate including a coated portion in which an active material is coated on both sides of a composite substrate and an uncoated portion in which the active material is not provided on the composite substrate; Connect the conductor to the uncoated portion of each electrode plate; An insulating layer is provided to cover the uncoated portion of each electrode plate, the coated portion of each electrode plate, and at least a portion of each of the conductors; and The plurality of electrode plates are laminated and connected to the conductor, and the insulating layer is disposed thereon, and a diaphragm is inserted between the plurality of electrode plates.

20. The method of claim 19, wherein the composite substrate comprises: polymer substrate, A first metal layer is disposed on a first surface of the polymer substrate, and A second metal layer is disposed on the second surface of the polymer substrate, and The first metal layer and the second metal layer are formed of the same material.

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