Binder composition for non-aqueous secondary battery electrodes, slurry composition for non-aqueous secondary battery electrodes, electrodes for non-aqueous secondary batteries, and non-aqueous secondary batteries

Abstract

The purpose of the present invention is to provide a binder composition for a non-aqueous secondary battery electrode, which has excellent stability as a slurry composition and which is capable of forming an electrode having excellent peeling strength. This binder composition for a non-aqueous secondary battery electrode includes a particulate polymer comprising a random copolymer that includes: a structural unit derived from an aromatic vinyl monomer; a structural unit derived from a conjugated diene monomer; and a structural unit derived from an acid monomer. The aromatic vinyl monomer-derived structural unit content is 5%–40% by mass relative to 100% by mass of the particulate polymer. The structural unit derived from the conjugated diene monomer includes a structural unit derived from isoprene and the isoprene-derived structural unit content is at least 20% by mass relative to the total 100% by mass of the aromatic vinyl monomer-derived structural unit, the conjugated diene monomer-derived structural unit, and the acid monomer-derived structural unit.

Description

[Technical Field]

[0001] The present invention relates to a binder composition for a non-aqueous secondary battery electrode, a slurry composition for a non-aqueous secondary battery electrode, an electrode for a non-aqueous secondary battery, and a non-aqueous secondary battery. [Background technology]

[0002] Non-aqueous secondary batteries such as lithium ion secondary batteries (hereinafter sometimes simply referred to as "secondary batteries") are small, lightweight, have high energy density, and can be repeatedly charged and discharged, and are therefore used in a wide range of applications. Therefore, in recent years, improvements to battery components such as electrodes have been investigated with the aim of further improving the performance of non-aqueous secondary batteries.

[0003] Here, an electrode used in a secondary battery such as a lithium-ion secondary battery usually includes a current collector and an electrode mixture layer (positive electrode mixture layer or negative electrode mixture layer) formed on the current collector. This electrode mixture layer is formed, for example, by applying a slurry composition containing an electrode active material and a binder composition containing a binding agent onto the current collector and then drying the applied slurry composition.

[0004] Therefore, in recent years, attempts have been made to improve the binder composition used in forming the electrode mixture layer in order to achieve further improvements in the performance of secondary batteries. For example, Patent Documents 1 to 3 describe binder compositions for non-aqueous secondary battery electrodes that use aromatic vinyl / conjugated diene copolymers. Specifically, Patent Document 1 describes a composition containing a polymer obtained by sulfonating a styrene / isoprene copolymer. Patent Document 2 describes a binder composition for lithium ion secondary battery negative electrodes that contains an aromatic vinyl / aliphatic conjugated diene / ethylenically unsaturated carboxylic acid / (meth)acrylic acid particulate copolymer, such as a styrene / butadiene / ethylenically unsaturated carboxylic acid / (meth)acrylic acid particulate copolymer. Patent Document 3 describes a binder composition for non-aqueous secondary battery electrodes that contains a particulate polymer composed of a graft polymer in which hydrophilic graft chains are grafted onto core particles containing an aromatic vinyl / isoprene copolymer. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] International Publication No. 2011 / 024789 [Patent Document 2] International Publication No. 2015 / 098008 [Patent Document 3] International Publication No. 2019 / 172281 Summary of the Invention [Problem to be solved by the invention]

[0006] However, the above-mentioned conventional binder compositions for non-aqueous secondary battery electrodes using aromatic vinyl / conjugated diene copolymers have room for improvement in terms of improving the stability of slurry compositions using the binder compositions and the peel strength of electrodes formed using the binder compositions, thereby enabling secondary batteries to exhibit excellent performance.

[0007] Therefore, an object of the present invention is to provide a binder composition for a non-aqueous secondary battery electrode and a slurry composition for a non-aqueous secondary battery electrode that have excellent stability as a slurry composition and are capable of forming an electrode having excellent peel strength. Another object of the present invention is to provide an electrode for a non-aqueous secondary battery that can form a non-aqueous secondary battery that has excellent peel strength and exhibits excellent performance, and a non-aqueous secondary battery that has improved electrode peel strength and exhibits excellent performance. [Means for solving the problem]

[0008] The present inventors have conducted extensive research to solve the above problems, and have found that the use of a binder composition containing a particulate polymer made of an aromatic vinyl / conjugated diene random copolymer in which a conjugated diene containing isoprene is used and the content ratio of structural units derived from each monomer is within a predetermined range improves the stability of a slurry composition using the binder composition and the peel strength of an electrode formed using the binder composition, thereby enabling a secondary battery to exhibit excellent performance, thereby completing the present invention.

[0009] That is, the present invention has an object to advantageously solve the above-mentioned problems, and provides a binder composition for a non-aqueous secondary battery electrode, which comprises a particulate polymer consisting of a random copolymer containing structural units derived from an aromatic vinyl monomer, structural units derived from a conjugated diene monomer, and structural units derived from an acid monomer, wherein the content of the structural units derived from the aromatic vinyl monomer is more than 5% by mass and not more than 40% by mass relative to 100% by mass of the particulate polymer, the structural units derived from the conjugated diene monomer include structural units derived from isoprene, and the content of the structural units derived from the isoprene is 20% by mass or more relative to 100% by mass of the total of the structural units derived from the aromatic vinyl monomer, the structural units derived from the conjugated diene monomer, and the structural units derived from the acid monomer. By using a binder composition containing such a particulate polymer consisting of a random copolymer in which the structural units derived from a conjugated diene monomer include structural units derived from isoprene and the content ratio of the structural units derived from each monomer is within a predetermined range, the stability of a slurry composition using the binder composition and the peel strength of an electrode formed using the binder composition can be improved, and excellent performance can be achieved in a secondary battery. In the present invention, the "structural unit" of a polymer means "a repeating unit derived from a monomer contained in a polymer obtained using that monomer." In the present invention, the content ratio of the structural units derived from each monomer is 1 It can be measured using H-NMR.

[0010] In the binder composition for a non-aqueous secondary battery electrode of the present invention, the content of the structural unit derived from the acid monomer is preferably 3% by mass or more and 9% by mass or less relative to 100% by mass of the particulate polymer. If the content of the structural unit derived from the acid monomer is within the above range, it is possible to improve at least one of the stability as a slurry composition and the peel strength of the electrode.

[0011] In the binder composition for a non-aqueous secondary battery electrode of the present invention, the particulate polymer preferably has an average particle size of 60 nm to 300 nm, inclusive, which can improve the stability of the slurry composition.

[0012] Furthermore, the binder composition for a non-aqueous secondary battery electrode of the present invention preferably has a pH of 6 or more and 9 or less. If the pH is within the above range, the particulate polymer is stably maintained, which can contribute to improving the stability of the slurry composition.

[0013] Furthermore, the binder composition for a non-aqueous secondary battery electrode preferably contains an aqueous phase containing an acidic water-soluble polymer, and the weight-average molecular weight of the acidic water-soluble polymer is preferably from 10,000 to 100,000. When the weight-average molecular weight of the acidic water-soluble polymer contained in the aqueous phase is within the above range, the peel strength of the electrode can be improved while maintaining the coatability of the slurry composition.

[0014] The present invention also aims to advantageously solve the above-mentioned problems, and provides a slurry composition for a non-aqueous secondary battery electrode, characterized in that it contains the above-mentioned binder composition for a non-aqueous secondary battery electrode, an electrode active material, and at least one of a dispersant and a viscosity modifier. In this way, by including the above-mentioned binder composition for a non-aqueous secondary battery electrode, it is possible to form an electrode that is excellent in stability as a slurry composition and excellent in peel strength, and it is possible to achieve excellent performance in a secondary battery.

[0015] Furthermore, the present invention aims to advantageously solve the above-mentioned problems, and the non-aqueous secondary battery electrode of the present invention is characterized by comprising an electrode mixture layer formed using the above-mentioned slurry composition for a non-aqueous secondary battery electrode. In this way, by using the above-mentioned slurry composition for a non-aqueous secondary battery electrode, a non-aqueous secondary battery electrode having excellent peel strength and capable of forming a non-aqueous secondary battery exhibiting excellent performance can be obtained.

[0016] The present invention aims to advantageously solve the above-mentioned problems, and provides a nonaqueous secondary battery comprising a positive electrode, a negative electrode, a separator, and an electrolyte, wherein at least one of the positive electrode and the negative electrode is the above-described electrode for a nonaqueous secondary battery. Use of the above-described electrode for a nonaqueous secondary battery improves the peel strength of the electrode, resulting in a nonaqueous secondary battery that exhibits excellent performance. [Effects of the Invention]

[0017] According to the binder composition for a non-aqueous secondary battery electrode and the slurry composition for a non-aqueous secondary battery electrode of the present invention, an electrode having excellent stability as a slurry composition and excellent peel strength can be formed, and excellent performance can be achieved in the secondary battery. Furthermore, the electrode for a non-aqueous secondary battery of the present invention has excellent peel strength, and can form a non-aqueous secondary battery that exhibits excellent performance. Furthermore, according to the present invention, a non-aqueous secondary battery having improved electrode peel strength and exhibiting excellent performance can be obtained. DETAILED DESCRIPTION OF THE INVENTION

[0018] Hereinafter, embodiments of the present invention will be described in detail. The binder composition for a non-aqueous secondary battery electrode of the present invention can be used to prepare a slurry composition for a non-aqueous secondary battery electrode of the present invention, and can be prepared, for example, by the preparation method described herein. The slurry composition for a non-aqueous secondary battery electrode prepared using the binder composition for a non-aqueous secondary battery electrode of the present invention can be used to manufacture electrodes for non-aqueous secondary batteries such as lithium-ion secondary batteries. Furthermore, the non-aqueous secondary battery of the present invention is characterized by using a non-aqueous secondary battery electrode of the present invention formed using the slurry composition for a non-aqueous secondary battery electrode of the present invention. The binder composition for a non-aqueous secondary battery electrode, the slurry composition for a non-aqueous secondary battery electrode, and the electrode for a non-aqueous secondary battery of the present invention are preferably for use in a negative electrode, and the non-aqueous secondary battery of the present invention preferably uses the electrode for a non-aqueous secondary battery of the present invention as a negative electrode.

[0019] (Binder composition for non-aqueous secondary battery electrodes) The binder composition for a non-aqueous secondary battery electrode of the present invention comprises a particulate polymer composed of a random copolymer containing structural units derived from an aromatic vinyl monomer, structural units derived from a conjugated diene monomer, and structural units derived from an acid monomer, wherein the content of the structural units derived from the aromatic vinyl monomer is more than 5% by mass and not more than 40% by mass relative to 100% by mass of the particulate polymer, and the structural units derived from the conjugated diene monomer include structural units derived from isoprene, and the content of the structural units derived from the isoprene is 20% by mass or more relative to 100% by mass of the total of the structural units derived from the aromatic vinyl monomer, the structural units derived from the conjugated diene monomer, and the structural units derived from the acid monomer. The binder composition for a non-aqueous secondary battery electrode of the present invention typically further contains a dispersion medium such as water (aqueous phase). The binder composition for a non-aqueous secondary battery electrode of the present invention has the above-described composition, and therefore can improve the stability of a slurry composition using the binder composition and the peel strength of an electrode formed using the binder composition, thereby enabling the secondary battery to exhibit excellent performance.

[0020] <Particulate polymer> The particulate polymer is a component that functions as a binder, and in an electrode mixture layer formed using a slurry composition containing the binder composition, it holds components such as the electrode active material so that they do not detach from the electrode mixture layer. The particulate polymer is a water-insoluble particle formed by a predetermined random copolymer. In the present invention, the term "water-insoluble" for polymer particles means that when 0.5 g of the polymer is dissolved in 100 g of water at 25° C., the insoluble content is 90 mass % or more.

[0021] [Random copolymer] The random copolymer forming the particulate polymer is a random copolymer containing structural units derived from an aromatic vinyl monomer, structural units derived from a conjugated diene monomer, and structural units derived from an acid monomer, and the content of the structural units derived from the aromatic vinyl monomer is more than 5% by mass and not more than 40% by mass relative to 100% by mass of the particulate polymer, and the structural units derived from the conjugated diene monomer include structural units derived from isoprene, and the content of the structural units derived from the isoprene is 20% by mass or more relative to 100% by mass of the total of the structural units derived from the aromatic vinyl monomer, the structural units derived from the conjugated diene monomer, and the structural units derived from the acid monomer. By using a random copolymer as the polymer forming the particulate polymer, it is possible to further improve one or more of the stability as a slurry composition and the peel strength of the formed electrode.

[0022] -Structural units derived from aromatic vinyl monomers- Examples of structural units derived from aromatic vinyl monomers constituting the random copolymer include structural units derived from aromatic monovinyl compounds such as styrene, styrene sulfonic acid and its salts, α-methylstyrene, pt-butylstyrene, butoxystyrene, vinyltoluene, chlorostyrene, and vinylnaphthalene. Among these, structural units derived from styrene are preferred. These can be used alone or in combination of two or more, but it is preferred to use one alone.

[0023] The content of the structural units derived from the aromatic vinyl monomer in the random copolymer is more than 5% by mass, preferably 15% by mass or more, and 40% by mass or less, preferably 30% by mass or less, based on 100% by mass of the particulate polymer. If the content of the structural units derived from the aromatic vinyl monomer is greater than the above lower limit, the stability of the slurry composition can be further improved. On the other hand, if the content of the structural units derived from the aromatic vinyl monomer is equal to or less than the above upper limit, one or more of the peel strength of the formed electrode, the internal resistance characteristics of the secondary battery, and the cycle characteristics of the secondary battery can be further improved.

[0024] -Structural units derived from conjugated diene monomers- The structural units derived from conjugated diene monomers constituting the random copolymer include structural units derived from isoprene. That is, the structural units derived from conjugated diene monomers may be all structural units derived from isoprene, or may include structural units derived from isoprene and one or more structural units derived from conjugated diene monomers other than isoprene. Examples of structural units derived from conjugated diene monomers other than isoprene include structural units derived from aliphatic conjugated diene monomers such as 1,3-butadiene, 2-methyl-1,3-butadiene, 2,3-dimethyl-1,3-butadiene, 2-chloro-1,3-butadiene, substituted linear conjugated pentadiene, and substituted and side-chain conjugated hexadienes. Of these, structural units derived from 1,3-butadiene are preferred. It is preferred that all structural units derived from conjugated diene monomers are structural units derived from isoprene. When the particulate polymer contains a structural unit derived from isoprene, the cycle characteristics of the secondary battery can be improved, and the powder shedding characteristics during electrode formation and the peel strength of the formed electrode can be further improved.

[0025] The content of structural units derived from isoprene in the random copolymer is 20% by mass or more, preferably 50% by mass or more, relative to 100% by mass of the total of structural units derived from aromatic vinyl monomers, structural units derived from conjugated diene monomers, and structural units derived from acid monomers. The upper limit is not particularly limited, but may be, for example, 94% by mass or less, preferably 87% by mass or less. If the content of structural units derived from isoprene is equal to or greater than the above-mentioned lower limit, it is possible to further improve one or more of the powder shedding properties during electrode formation and the peel strength of the formed electrode.

[0026] -Structural units derived from acid monomers- The structural unit derived from the acid monomer constituting the random copolymer is preferably a structural unit derived from a monomer having a carbon-carbon double bond and an acidic group. Examples of the structural unit derived from the acid monomer include a structural unit derived from a carboxyl group-containing monomer, a structural unit derived from a sulfonic acid group-containing monomer, and a structural unit derived from a phosphoric acid group-containing monomer.

[0027] Here, examples of the "carboxyl group-containing monomer" in the "structural unit derived from a carboxyl group-containing monomer" include monocarboxylic acids and derivatives thereof, dicarboxylic acids and acid anhydrides thereof, and derivatives thereof. Examples of the monocarboxylic acid include acrylic acid, methacrylic acid, and crotonic acid. Examples of the monocarboxylic acid derivatives include 2-ethylacrylic acid, isocrotonic acid, α-acetoxyacrylic acid, β-trans-aryloxyacrylic acid, and α-chloro-β-E-methoxyacrylic acid. Examples of dicarboxylic acids include maleic acid, fumaric acid, and itaconic acid. Examples of dicarboxylic acid derivatives include methylmaleic acid, dimethylmaleic acid, phenylmaleic acid, chloromaleic acid, dichloromaleic acid, fluoromaleic acid, and maleic acid monoesters such as butyl maleate, nonyl maleate, decyl maleate, dodecyl maleate, octadecyl maleate, and fluoroalkyl maleates. Examples of the acid anhydrides of dicarboxylic acids include maleic anhydride, acrylic anhydride, methyl maleic anhydride, dimethyl maleic anhydride, and citraconic anhydride. Furthermore, as the carboxyl group-containing monomer, an acid anhydride that generates a carboxyl group upon hydrolysis can also be used. Furthermore, as the carboxyl group-containing monomer, ethylenically unsaturated polycarboxylic acids such as butenetricarboxylic acid, and partial esters of ethylenically unsaturated polycarboxylic acids such as monobutyl fumarate and mono-2-hydroxypropyl maleate can also be used.

[0028] Furthermore, examples of the "sulfonic acid group-containing monomer" in the "structural unit derived from a sulfonic acid group-containing monomer" include vinyl sulfonic acid (ethylene sulfonic acid), methyl vinyl sulfonic acid, (meth)allyl sulfonic acid, and 3-allyloxy-2-hydroxypropane sulfonic acid. In the present invention, "(meth)allyl" means allyl and / or methallyl. Taste.

[0029] Furthermore, examples of the "phosphate group-containing monomer" of the "structural unit derived from a phosphate group-containing monomer" include 2-(meth)acryloyloxyethyl phosphate, methyl-2-(meth)acryloyloxyethyl phosphate, and ethyl-(meth)acryloyloxyethyl phosphate. In the present invention, "(meth)acryloyl" means acryloyl and / or methacryloyl.

[0030] The structural unit derived from such an acid monomer may be one type alone or a combination of two or more types. The structural unit derived from such an acid monomer is preferably a structural unit derived from an acrylic acid monomer, a structural unit derived from a methacrylic acid monomer, or a structural unit derived from an itaconic acid monomer, and more preferably a structural unit derived from a methacrylic acid monomer.

[0031] The content of structural units derived from acid monomers in the random copolymer is not particularly limited, but is preferably 1% by mass or more, more preferably 3% by mass or more, and is preferably 20% by mass or less, more preferably 9% by mass or less, relative to 100% by mass of the particulate polymer.

[0032] -Structural units derived from other monomers- The random copolymer may optionally further contain structural units derived from other monomers. As structural units derived from such other monomers, structural units derived from monomers having carbon-carbon double bonds are preferred. Examples include structural units derived from nitrile group-containing monomers such as acrylonitrile and methacrylonitrile; structural units derived from (meth)acrylic acid ester monomer units such as alkyl acrylates and alkyl methacrylates; structural units derived from hydroxyl group-containing (meth)acrylic acid ester monomers having a hydroxyl group in the molecule such as 2-hydroxyethyl acrylate and 2-hydroxyethyl methacrylate; structural units derived from acrylamide monomers; structural units derived from hydroxyethylacrylamide monomers; structural units derived from vinyl acetate monomers; structural units derived from methoxy-polyethylene glycol acrylate monomers; and structural units derived from tetrahydrofurfuryl acrylate monomers. Note that, in this specification, "(meth)acrylic acid" refers to acrylic acid and / or methacrylic acid.

[0033] [Structure of particulate polymer] The particulate polymer may be a particle having a uniform structural unit composition (type and content ratio of structural units), or may be a particle having a non-uniform structural unit composition. Examples of particles having a non-uniform structural unit composition include particles having a core-shell structure in which the structural unit composition differs between the core and shell, and particles in which only the core portion has a different structural unit composition. Examples of particles having a core-shell structure include particles composed of a core portion that does not contain structural units derived from isoprene and a shell portion that contains structural units derived from isoprene. Furthermore, particles having a uniform structural unit composition but a core-shell structure with different crosslink densities may also be used.

[0034] The structural unit composition of the random copolymer (type and content of structural units) defined above refers to the structural unit composition of the entire particulate polymer contained in the binder composition for a non-aqueous secondary battery electrode. Therefore, for example, when the particulate polymer is a particle having a non-uniform structural unit composition such as a core-shell structure, the structural unit composition of the random copolymer refers to the structural unit composition of the entire particle including the core portion and the shell portion.

[0035] [Average particle size] The average particle size of the particulate polymer is preferably 60 nm or more, more preferably 90 nm or more, and is preferably 300 nm or less, more preferably 200 nm or less.

[0036] <Aqueous phase> The binder composition for a non-aqueous secondary battery electrode of the present invention usually contains water as a dispersion medium for the particulate polymer.

[0037] The pH of the aqueous phase is preferably 6.0 or higher, more preferably 7.0 or higher but not higher, preferably 9.0 or lower, and more preferably 8.0 or lower. If the pH is within the above range, the particulate polymer is stably maintained, which can contribute to improving the stability of the slurry composition. The pH may be adjusted by adding an alkali species to the aqueous phase. Examples of alkali species include lithium hydroxide, sodium hydroxide, potassium hydroxide, and aqueous ammonia. Ammonia water is preferred because it is less likely to cause aggregates due to addition shock during alkali neutralization.

[0038] The aqueous phase may contain an acidic water-soluble polymer. The acidic water-soluble polymer contained in the aqueous phase is polymerized as a by-product from the monomers that serve as raw materials for the particulate polymer during polymerization to produce the particulate polymer. Such an acidic water-soluble polymer is a polymer containing one or more structural units derived from an aromatic vinyl monomer that constitutes the particulate polymer, a structural unit derived from a conjugated diene monomer, and a structural unit derived from an acid monomer. The weight-average molecular weight of such an acidic water-soluble polymer is preferably 5,000 or more, more preferably 10,000 or more, and preferably 200,000 or less, more preferably 100,000 or less. If the weight-average molecular weight of the acidic water-soluble polymer is smaller than the above-mentioned lower limit, the peel strength decreases, so the weight-average molecular weight is preferably equal to or greater than the above-mentioned lower limit. Furthermore, if the weight-average molecular weight of the acidic water-soluble polymer is larger than the above-mentioned upper limit, the binder thickens, making coating impossible, so the weight-average molecular weight is preferably equal to or less than the above-mentioned upper limit.

[0039] The aqueous phase may contain additives such as antioxidants and preservatives.

[0040] Antioxidants include hindered phenol antioxidants (e.g., 4-[[4,6-bis(octylthio)-1,3,5-triazin-2-yl]amino]-2,6-di-tert-butylphenol, 2,6-di-tert-butyl-p-cresol, 3-(3,5-di-tert-butyl-4-hydroxyphenyl)stearyl propionate, pentaerythritol tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate], 2,4,6-tris(3',5'-di-tert-butyl-4'-hydroxybenzyl)mesitylene), oligomeric phenol antioxidants (e.g., WINGSTAY L), phosphite-based antioxidants (e.g., 3,9-bis(octadecyloxy)-2,4,8,10-tetraoxa-3,9-diphosphaspiro[5.5]undecane, 3,9-bis(2,6-di-tert-butyl-4-methylphenoxy)-2,4,8,10-tetraoxa-3,9-diphosphaspiro[5.5]undecane, 2,2-methylenebis(4,6-di-t-butylphenyl)2-ethylhexyl phosphite, tris(2,4-di-tert-butylphenyl)phosphite), sulfur-based antioxidants (e.g., didodecyl 3,3′-thiodipropionate), and the like. The amount of antioxidant added is preferably 0.1% by mass or more, more preferably 1% by mass or more, and is preferably 10% by mass or less, more preferably 5% by mass or less, relative to 100% by mass of the total of the structural units derived from the aromatic vinyl monomer, the structural units derived from the conjugated diene monomer, and the structural units derived from the acid monomer.

[0041] Examples of preservatives include known preservatives such as isothiazolinone compounds and 2-bromo-2-nitro-1,3-propanediol. Examples of isothiazolinone compounds include, but are not limited to, those described in JP 2013-211246 A, JP 2005-097474 A, and JP 2013-206624 A. Preservatives may be used singly or in combination of two or more. Preservatives preferably include 1,2-benzisothiazolin-3-one, 2-methyl-4-isothiazolin-3-one, 5-chloro-2-methyl-4-isothiazolin-3-one, and 2-bromo-2-nitro-1,3-propanediol, with 1,2-benzisothiazolin-3-one being more preferred. The amount of preservative contained in the binder composition is preferably 0.01 parts by mass or more, preferably 0.5 parts by mass or less, more preferably 0.4 parts by mass or less, and even more preferably 0.3 parts by mass or less per 100 parts by mass of binder. If the content of the preservative is 0.01 parts by mass or more per 100 parts by mass of binder, the formation of aggregates in the binder composition after long-term storage can be further suppressed, and if it is 0.5 parts by mass or less, the adhesion of the functional layer can be sufficiently improved.

[0042] <Method for preparing binder composition> The binder composition for a non-aqueous secondary battery electrode of the present invention can be prepared by polymerizing, in an emulsion, monomers (aromatic vinyl monomer, conjugated diene monomer, acid monomer, and optionally other monomers) that are the basis of the structural units contained in the particulate polymer. Examples of such a preparation method include a batch emulsion polymerization method, an emulsion (Em) prop method, and a seed polymerization method, with the batch emulsion polymerization method being preferred.

[0043] The batch emulsion polymerization method may be carried out, for example, by the following procedure: Monomers (aromatic vinyl monomer, conjugated diene monomer, acid monomer, and optionally other monomers) that constitute the structural units contained in the particulate polymer are mixed with water, an emulsifier, and a polymerization initiator. The mixture (emulsion) is heated to carry out a polymerization reaction. When a predetermined polymerization conversion rate is reached, the mixture is cooled to terminate the reaction, yielding a mixture containing the particulate polymer. Unreacted monomers are removed from the mixture. The pH of the mixture is adjusted to fall within the preferred pH range for the aqueous phase described above, and optionally, the additives described above (e.g., antioxidants) are added to obtain an aqueous dispersion as a binder composition for a non-aqueous secondary battery electrode. It is preferable to add the entire amount of the aromatic vinyl monomer and the conjugated diene monomer initially. The acid monomer and optionally other monomers may be added entirely at the beginning, or may be added in portions in stages. Heating may be carried out, for example, at 40°C or higher, 45°C or higher, 50°C or higher, 55°C or higher, or 60°C or higher, and 90°C or lower, 85°C or lower, 80°C or lower, 75°C or lower, or 70°C or lower. Unreacted monomers may be removed from the mixture by, for example, heated vacuum distillation or by blowing in steam. In the batch emulsion polymerization method, for example, a particulate polymer having a uniform composition of structural units derived from aromatic vinyl monomers and structural units derived from conjugated diene monomers can be obtained.

[0044] The Em Prop method may be carried out, for example, by the following procedure: A monomer for forming a core portion (one or more of an aromatic vinyl monomer, a conjugated diene monomer, an acid monomer, and optionally other monomers) is mixed with water, an emulsifier, a chain transfer agent, and a polymerization initiator. The mixture (emulsion) is heated and a polymerization reaction is carried out until a predetermined polymerization conversion rate is reached, thereby obtaining a mixture containing a seed particle polymer as the core portion. Next, the mixture is shellPolymerization was continued by continuously adding monomers for forming the particulate polymer (one or more of an aromatic vinyl monomer, a conjugated diene monomer, an acid monomer, and optionally other monomers), and optionally an emulsifier and water. The reaction was stopped by cooling when a predetermined polymerization conversion rate was reached, yielding a mixture containing a particulate polymer. Unreacted monomers were removed from the mixture. The pH of the mixture was adjusted to fall within the preferred pH range for the aqueous phase described above, and optionally, additives (e.g., antioxidants) were added to obtain an aqueous dispersion as a binder composition for a non-aqueous secondary battery electrode containing a particulate polymer having a core-shell structure.

[0045] In the seed polymerization method, for example, a seed particle polymer consisting of a polymer containing structural units derived from one or more monomers selected from the group consisting of an aromatic vinyl monomer, a conjugated diene monomer, an acid monomer, and optionally other monomers is mixed with a monomer for forming the particle polymer (an aromatic vinyl monomer, a conjugated diene monomer, an acid monomer, and optionally other monomers), water, an emulsifier, a chain transfer agent, and a polymerization initiator, and a polymerization reaction or the like is carried out in the same manner as described above, thereby obtaining an aqueous dispersion as a binder composition for a non-aqueous secondary battery electrode.

[0046] Examples of emulsifiers used in preparing the binder composition include alkyldiphenyl ether disulfonic acid, dodecylbenzenesulfonic acid, lauryl sulfuric acid, and salts thereof (eg, potassium salts, sodium salts). Examples of the polymerization initiator used in preparing the binder composition include potassium persulfate, n-butyllithium, and ammonium persulfate. Examples of chain transfer agents used in preparing the binder composition include α-methylstyrene dimer, tert-dodecyl mercaptan, and 3-mercapto-1,2-propanediol.

[0047] (Slurry composition for non-aqueous secondary battery electrodes) The slurry composition of the present invention is a composition used to form an electrode composite layer of an electrode, and contains the above-described binder composition, an electrode active material, and at least one of a dispersant and a viscosity modifier. That is, the slurry composition of the present invention contains the above-described particulate polymer and electrode active material, and further contains at least one of a dispersant and a viscosity modifier. Typically, the slurry composition of the present invention further contains a dispersion medium such as water (aqueous phase), and optionally, at least one selected from the group consisting of a phosphite-based antioxidant, a metal capture agent, and other components. Furthermore, because the slurry composition of the present invention contains the above-described binder composition, it is possible to form an electrode with excellent stability and peel strength, thereby enabling secondary batteries to exhibit excellent performance.

[0048] <Binder composition> As the binder composition, the above-described binder composition of the present invention is used, which contains a particulate polymer made of a random copolymer and usually further contains a dispersion medium such as water (aqueous phase). The amount of the binder composition in the slurry composition is not particularly limited. For example, the amount of the binder composition can be set so that the amount of the particulate polymer is 0.5 parts by mass or more and 15 parts by mass or less in terms of solid content per 100 parts by mass of the electrode active material.

[0049] <Electrode active material> The electrode active material is not particularly limited, and known electrode active materials used in secondary batteries can be used. Specifically, for example, the electrode active material that can be used in the electrode mixture layer of a lithium ion secondary battery, which is an example of a secondary battery, is not particularly limited, and the following electrode active materials can be used.

[0050] [Cathode active material] As the positive electrode active material blended in the positive electrode mixture layer of the lithium ion secondary battery, for example, a compound containing a transition metal, such as a transition metal oxide, a transition metal sulfide, a composite metal oxide of lithium and a transition metal, etc. can be used. Examples of the transition metal include Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Mo, etc. Specifically, the positive electrode active material is not particularly limited, and includes lithium-containing cobalt oxide (LiCoO2), lithium manganate (LiMn2O4), lithium-containing nickel oxide (LiNiO2), lithium-containing composite oxide of Co-Ni-Mn, lithium-containing composite oxide of Ni-Mn-Al, lithium-containing composite oxide of Ni-Co-Al, olivine-type lithium iron phosphate (LiFePO4), olivine-type lithium manganese phosphate (LiMnPO4), 1+x Mn 2-x Lithium-excess spinel compound represented by O4 (0 < X < 2), Li[Ni 0.17 Li 0.2 Co 0.07 Mn 0.56 O2, LiNi 0.5 Mn 1.5 O4, etc. In addition, the above-mentioned positive electrode active material may be used alone or in combination of two or more kinds.

[0051] [Negative electrode active material] As the negative electrode active material blended in the negative electrode mixture layer of the lithium ion secondary battery, for example, a carbon-based negative electrode active material, a metal-based negative electrode active material, and a negative electrode active material combining these are included. Here, the carbon-based negative electrode active material refers to an active material having carbon as the main skeleton into which lithium can be inserted (also referred to as "doped"). Specifically, the carbon-based negative electrode active material includes carbonaceous materials such as coke, mesocarbon microbeads (MCMB), mesophase pitch-based carbon fiber, pyrolytic vapor deposition carbon fiber, phenolic resin fired body, polyacrylonitrile-based carbon fiber, isotropic carbon, furfuryl alcohol resin fired body (PFA), and hard carbon, as well as graphite materials such as natural graphite and artificial graphite. Metal-based negative electrode active materials are active materials containing metals, typically active materials containing an element capable of intercalating lithium, and having a theoretical electrical capacity per unit mass of 500 mAh / g or more when lithium is intercalated. Examples of metal-based active materials include lithium metal, elemental metals capable of forming lithium alloys (e.g., Ag, Al, Ba, Bi, Cu, Ga, Ge, In, Ni, P, Pb, Sb, Si, Sn, Sr, Zn, Ti, etc.), and oxides, sulfides, nitrides, silicides, carbides, phosphides, etc. of these. Furthermore, oxides such as lithium titanate can be used. The above-mentioned negative electrode active materials may be used singly or in combination of two or more.

[0052] <Other ingredients> Other components that can be blended into the slurry composition are not particularly limited and include conductive materials and the same components as those that can be blended into the binder composition of the present invention. Note that the other components may be used alone or in combination of two or more in any ratio.

[0053] <Preparation of Slurry Composition> The method for preparing the slurry composition is not particularly limited. For example, a slurry composition can be prepared by mixing a binder composition, an electrode active material, at least one selected from a dispersant and a viscosity modifier, and other components used as needed in the presence of an aqueous phase (aqueous medium) that is usually contained in the binder composition. The mixing method is not particularly limited, but mixing can be carried out using a commonly used stirrer or disperser.

[0054] (Electrode for non-aqueous secondary batteries) The non-aqueous secondary battery electrode of the present invention includes an electrode mixture layer formed using the above-described slurry composition for a non-aqueous secondary battery electrode. The electrode mixture layer is composed of a dried product of the above-described slurry composition, and typically contains an electrode active material, a component derived from a particulate polymer, and at least one selected from the group consisting of a dispersant and a viscosity modifier. Optionally, the electrode mixture layer further contains at least one selected from the group consisting of a phosphite-based antioxidant, a metal capture agent, and other components. The components contained in the electrode mixture layer are the same as those contained in the above-described slurry composition for a non-aqueous secondary battery electrode, and the preferred ratios of the components are the same as the preferred ratios of the components in the slurry composition. The particulate polymer exists in particulate form in the slurry composition, but may be in particulate form or any other shape in the electrode mixture layer formed using the slurry composition. The electrode for a nonaqueous secondary battery of the present invention has an electrode mixture layer formed using the above-mentioned slurry composition for a nonaqueous secondary battery electrode, and therefore can form a nonaqueous secondary battery having excellent peel strength and exhibiting excellent performance. Furthermore, a secondary battery including such an electrode has improved peel strength and exhibits excellent performance.

[0055] <Production of electrodes for non-aqueous secondary batteries> The electrode mixture layer of the electrode for a non-aqueous secondary battery of the present invention can be formed, for example, by the following method. 1) A method in which the slurry composition of the present invention is applied to the surface of a current collector and then dried; 2) a method of immersing a current collector in the slurry composition of the present invention and then drying the same; and 3) A method in which the slurry composition of the present invention is applied to a release substrate, and dried to produce an electrode mixture layer, and the resulting electrode mixture layer is transferred to the surface of a current collector. Among these, the method 1) is particularly preferred because it allows for easy control of the thickness of the electrode mixture layer. Specifically, the method 1) includes a step of applying a slurry composition onto a current collector (application step) and a step of drying the slurry composition applied onto the current collector to form an electrode mixture layer on the current collector (drying step).

[0056] [Coating process] The method for applying the slurry composition to the current collector is not particularly limited, and known methods can be used. Specifically, examples of the application method include a doctor blade method, a dipping method, a reverse roll method, a direct roll method, a gravure method, an extrusion method, and a brush coating method. In this case, the slurry composition may be applied to only one side of the current collector, or may be applied to both sides. The thickness of the slurry film on the current collector after application and before drying can be appropriately set depending on the thickness of the electrode mixture layer obtained by drying.

[0057] Here, the current collector to which the slurry composition is applied is made of a material that is electrically conductive and electrochemically durable. Specifically, the current collector may be made of, for example, iron, copper, aluminum, nickel, stainless steel, titanium, tantalum, gold, platinum, etc. Note that one of the above materials may be used alone, or two or more may be used in combination in any ratio.

[0058] [Drying process] The method for drying the slurry composition on the current collector is not particularly limited and any known method can be used, such as drying with warm air, hot air, or low-humidity air, vacuum drying, or drying by irradiation with infrared rays or electron beams, etc. By drying the slurry composition on the current collector in this manner, an electrode mixture layer can be formed on the current collector, and a nonaqueous secondary battery electrode including the current collector and the electrode mixture layer can be obtained.

[0059] After the drying step, the electrode mixture layer may be subjected to a pressure treatment using a mold press, a roll press, or the like. The pressure treatment improves the adhesion between the electrode mixture layer and the current collector and further increases the density of the resulting electrode mixture layer. In addition, when the electrode mixture layer contains a curable polymer, it is preferable to cure the polymer after the electrode mixture layer is formed.

[0060] (Non-aqueous secondary battery) The nonaqueous secondary battery of the present invention includes a positive electrode, a negative electrode, an electrolyte, and a separator, and uses the above-described nonaqueous secondary battery electrode as at least one of the positive electrode and the negative electrode. Because the nonaqueous secondary battery of the present invention is manufactured using the above-described nonaqueous secondary battery electrode as at least one of the positive electrode and the negative electrode, it can exhibit excellent cycle characteristics. In the following, a case where the secondary battery is a lithium ion secondary battery will be described as an example, but the present invention is not limited to the following example.

[0061] <Electrode> Here, the electrodes other than the above-described nonaqueous secondary battery electrode of the present invention that can be used in the nonaqueous secondary battery of the present invention are not particularly limited, and known electrodes used in the manufacture of secondary batteries can be used. Specifically, the electrodes other than the above-described nonaqueous secondary battery electrode of the present invention can be electrodes formed by forming an electrode mixture layer on a current collector using a known manufacturing method.

[0062] <Electrolyte> As the electrolyte, an organic electrolyte solution in which a supporting electrolyte is dissolved in an organic solvent is usually used. For example, a lithium salt is used as the supporting electrolyte of a lithium ion secondary battery. Examples of lithium salts include LiPF6, LiAsF6, LiBF4, LiSbF6, LiAlCl4, LiClO4, CF3SO3Li, CF4F9SO3Li, CF3COOLi, (CF3CO)2NLi, (CF3SO2)2NLi, and (C2F5SO2)NLi. Among these, LiPF6, LiClO4, and CF3SO3Li are preferred because they are easily soluble in solvents and exhibit a high degree of dissociation. One type of electrolyte may be used alone, or two or more types may be used in combination at any ratio. Generally, the lithium ion conductivity tends to increase as the supporting electrolyte with a higher degree of dissociation is used, so the lithium ion conductivity can be adjusted by the type of supporting electrolyte.

[0063] The organic solvent used in the electrolyte is not particularly limited as long as it can dissolve the supporting electrolyte. Suitable examples include carbonates such as dimethyl carbonate (DMC), ethylene carbonate (EC), diethyl carbonate (DEC), propylene carbonate (PC), butylene carbonate (BC), ethyl methyl carbonate (EMC), and vinylene carbonate (VC); esters such as γ-butyrolactone and methyl formate; ethers such as 1,2-dimethoxyethane and tetrahydrofuran; and sulfur-containing compounds such as sulfolane and dimethyl sulfoxide. Mixtures of these solvents may also be used. Among these, carbonates are preferred due to their high dielectric constant and wide stable potential range. Generally, the lower the viscosity of the solvent used, the higher the lithium ion conductivity. Therefore, the lithium ion conductivity can be adjusted by the type of solvent. The concentration of the electrolyte in the electrolytic solution can be adjusted as appropriate, and known additives can be added to the electrolytic solution.

[0064] <Separator> The separator is not particularly limited, and can be, for example, one described in JP 2012-204303 A. Among these, a microporous film made of a polyolefin resin (polyethylene, polypropylene, polybutene, polyvinyl chloride) is preferred because it can reduce the overall separator thickness, thereby increasing the proportion of electrode active material in the secondary battery and increasing capacity per volume.

[0065] The secondary battery of the present invention can be produced, for example, by stacking a positive electrode and a negative electrode with a separator interposed therebetween, rolling or folding the stack as necessary according to the battery shape, placing the stack in a battery container, injecting an electrolyte into the battery container, and sealing the container. In the nonaqueous secondary battery of the present invention, the above-described nonaqueous secondary battery electrode is used as at least one of the positive electrode and negative electrode, preferably the negative electrode. The nonaqueous secondary battery of the present invention may be provided with a fuse, an overcurrent protection element such as a PTC element, an expanded metal, a lead plate, or the like, as necessary to prevent internal pressure buildup, overcharging and overdischarging, and the like within the secondary battery. The secondary battery may have any shape, such as a coin type, a button type, a sheet type, a cylindrical type, a rectangular type, or a flat type. [Example]

[0066] The present invention will be specifically described below based on examples, but the present invention is not limited to these examples. In the following description, "%" and "parts" representing amounts are based on mass unless otherwise specified. Furthermore, in a polymer produced by polymerizing multiple types of monomers, the proportion of structural units derived from each monomer formed by polymerizing the monomers in the polymer usually coincides with the ratio (feed ratio) of each monomer to the total monomers used in the polymerization of the polymer, unless otherwise specified. In the examples and comparative examples, the content ratio of structural units derived from each monomer in the polymer, the average particle size of the particulate polymer, the weight average molecular weight of the acidic water-soluble polymer contained in the aqueous phase, the viscosity stability of the slurry composition, the peel strength of the electrode, the powder shedding characteristics during electrode formation, the internal resistance of the secondary battery, and the cycle characteristics of the secondary battery were measured or evaluated by the following methods.

[0067] <Content ratio of structural units derived from each monomer> 1 The intensity ratio of the peaks derived from the structural units derived from each monomer was determined by 1 H-NMR (nuclear magnetic resonance) and converted into a mass ratio.

[0068] <Average particle size of particulate polymer> The average particle size of the particulate polymer was measured using a laser diffraction particle size distribution measuring device (manufactured by Shimadzu Corporation, product name "SALD-2300"). Specifically, a binder composition (aqueous dispersion of the particulate polymer) was prepared, and the particle size distribution (volume basis) was measured using the measuring device to determine the average particle size (μm).

[0069] <Method for measuring the molecular weight of an acidic water-soluble polymer in an aqueous phase> The aqueous phase was separated from the binder composition by centrifugation, and the acidic water-soluble polymer in the aqueous phase was measured by HPLC. Molecular weight measurement conditions Column: Tosoh Corporation TSKgel G2500PWXL Mobile phase: 100 mM sodium nitrate + 50 mM disodium hydrogen phosphate aqueous solution / acetonitrile = 80 / 20 Flow rate: 1.0mL / min Detector: RI detector Standard: Pullulan

[0070] <Viscosity stability of slurry composition> The viscosity η0 of the resulting slurry composition was measured using a Brookfield viscometer (manufactured by Toki Sangyo Co., Ltd., product name "TVB-10", rotor: No. 2, rotation speed: 60 rpm). Next, the slurry composition whose viscosity had been measured was stirred for 24 hours using a planetary mixer (rotation speed: 60 rpm), and the viscosity η1 of the slurry composition after stirring was measured using the same Brookfield viscometer (rotor: No. 2, rotation speed: 60 rpm) as above. The viscosity retention rate Δη of the slurry composition before and after stirring was calculated as Δη = η1 / η0 × 100 (%), and the viscosity stability of the slurry composition was evaluated according to the following criteria. The temperature during viscosity measurement was 25°C. The closer the viscosity retention rate Δη is to 100%, the better the viscosity stability of the slurry composition. A: Viscosity maintenance rate Δη is 90% or more and 110% or less B: Viscosity retention rate Δη is 80% or more and less than 90% C: Viscosity retention rate Δη is 70% or more and less than 80% D: Viscosity retention rate Δη is less than 70% or more than 110%

[0071] <Electrode peel strength> The prepared electrode was dried in a vacuum dryer at 100°C for 1 hour, and the dried electrode was cut into a rectangular shape measuring 100 mm in length and 10 mm in width to prepare a test specimen. This test specimen was placed with the electrode mixture layer surface facing down, and cellophane tape was attached to the surface of the electrode mixture layer. The cellophane tape used was specified in JIS Z1522. The cellophane tape was fixed to a test table. One end of the current collector was then pulled vertically upward at a pulling rate of 50 mm / min, and the stress when peeled was measured. This measurement was performed three times, and the average value was calculated. This average value was used as the peel strength and evaluated according to the following criteria. A higher peel strength indicates a stronger adhesive strength of the electrode mixture layer to the current collector, i.e., a higher adhesion strength. A: Peel strength is 30N / m or more B: Peel strength is 20N / m or more and less than 30N / m C: Peel strength is 10N / m or more and less than 20N / m D: Peel strength is less than 10 N / m

[0072] <Powder shedding characteristics during electrode formation> The powder shedding characteristics during electrode formation were evaluated by performing a cross-cut test on the electrodes as specified in JIS K 5600. Specifically, the electrodes were cut to a specified size, the weight of the cut electrodes was measured, a cut was made from the backside of the electrode using a cross-cutting tool, the powder that was produced during the cut was brushed off, the weight of the electrode was measured, and the amount of powder shedding was calculated from the difference in the weight of the electrode before and after the cut. The less the amount of powder shedding, the better the powder shedding characteristics. A: The amount of powder falling off is less than 0.5 mg B: Amount of powder falling off is 0.5 mg or more but less than 1 mg C: Powder fall-off amount is 1 mg or more but less than 2 mg D: Powder fall amount is 2 mg or more

[0073] <Internal resistance of secondary battery> To evaluate the internal resistance of the lithium-ion secondary battery, the IV resistance was measured as follows. A conditioning treatment was performed by charging at a charge rate of 0.1 C at 25°C until the voltage reached 4.2 V, resting for 10 minutes, and then discharging at a constant current (CC) rate of 0.1 C to 3.0 V three times. Subsequently, the battery was charged to 3.75 V at 1 C (C is a value expressed as rated capacity (mA) / hour (h)) in a −10°C atmosphere, and then charged and discharged for 20 seconds at 0.5 C, 1.0 C, 1.5 C, and 2.0 C, centered on 3.75 V. For each case, the battery voltage after 15 seconds on the charging side was plotted against the current value, and the slope was calculated as the IV resistance (Ω). The obtained IV resistance values ​​(Ω) were compared with the IV resistance of Comparative Example 4 and evaluated according to the following criteria. Note that a smaller IV resistance value indicates a lower internal resistance of the secondary battery. A: Less than 85% of the IV resistance of Comparative Example 4 B: 85% or more and less than 95% of the IV resistance of Comparative Example 4 C: 95% or more and less than 105% of the IV resistance of Comparative Example 4 D: 105% or more of the IV resistance of Comparative Example 4

[0074] <Cycle characteristics of secondary batteries> After injecting the electrolyte, the lithium-ion secondary batteries fabricated in the Examples and Comparative Examples were left standing at 25°C for 5 hours. Next, they were charged at 25°C and a constant current of 0.2C to a cell voltage of 3.65V, and then aged at 60°C for 12 hours. Then, they were discharged at 25°C and a constant current of 0.2C to a cell voltage of 3.00V. Then, they were subjected to constant current (CC)-constant voltage (CV) charging at a constant current of 0.2C (upper cell voltage: 4.20V), and CC discharging at a constant current of 0.2C to 3.00V. This 0.2C charge-discharge cycle was repeated three times. Thereafter, 100 cycles of charge / discharge were performed at a temperature of 25°C, a cell voltage of 4.20-3.00 V, and a charge / discharge rate of 1.0 C. The discharge capacity of the first cycle was defined as X1, and the discharge capacity of the 100th cycle as X2. Using the discharge capacities X1 and X2, the capacity change rate, ΔC'=(X2 / X1)×100(%), was calculated and evaluated according to the following criteria: The larger the capacity change rate ΔC', the better the cycle characteristics. A: ΔC' is 93% or more B: ΔC' is 90% or more and less than 93% C: ΔC' is 87% or more and less than 90% D: ΔC' is less than 87%

[0075] Example 1 <Preparation of binder composition containing particulate polymer (batch polymerization)> A 5 MPa pressure vessel A equipped with a stirrer was charged with 22 parts of styrene as an aromatic vinyl monomer, 72 parts of isoprene as an aliphatic conjugated diene monomer, 2 parts of methacrylic acid as an acid monomer, 0.6 parts of alkyl diphenyl ether disulfonate as an emulsifier, 137 parts of ion-exchanged water, and 0.3 parts of potassium persulfate as a polymerization initiator. After thorough stirring, the mixture was heated to 45°C to initiate polymerization and reacted for 20 hours. The mixture was then heated to 60°C and reacted for an additional 5 hours. Four parts of methacrylic acid were then added, and the reaction was continued for an additional 5 hours. When the polymerization conversion rate reached 97%, the mixture was cooled to terminate the reaction, yielding a mixture containing a particulate polymer. Unreacted monomer was then removed by heated, reduced-pressure distillation. A 1% aqueous ammonia solution was added to the mixture, adjusting the pH to 8. The mixture was then cooled, and 1 part of Wingstay L dispersion was added as an antioxidant, yielding an aqueous dispersion containing the desired particulate polymer as a binder composition for lithium-ion secondary battery negative electrodes. Using the obtained binder composition, the average particle size of the particulate polymer and the weight average molecular weight of the acidic water-soluble polymer produced as a by-product in the aqueous phase were measured. The results are shown in Table 1.

[0076] <Preparation of Slurry Composition for Non-Aqueous Secondary Battery Negative Electrode> In a planetary mixer with a disperser, artificial graphite (tap density: 0.85 g / cm) was used as the negative electrode active material. 3A mixture was obtained by adding 100 parts of a binder resin (capacity: 360 mAh / g), 1 part of carbon black (manufactured by TIMCAL, product name "Super C65") as a conductive material, and 1.2 parts (solids equivalent) of a 2% aqueous solution of carboxymethyl cellulose (manufactured by Nippon Paper Chemicals, product name "MAC-350HC") as a thickener. The resulting mixture was adjusted to a solids concentration of 60% with ion-exchanged water and then mixed at 25°C for 60 minutes. Next, the solids concentration was adjusted to 52% with ion-exchanged water and then mixed for an additional 15 minutes at 25°C to obtain a mixed solution. 2.0 parts (solids equivalent) of the binder composition prepared above and ion-exchanged water were added to the resulting mixed solution, and the final solids concentration was adjusted to 48%. After further mixing for 10 minutes, the mixture was degassed under reduced pressure to obtain a slurry composition for a negative electrode with good fluidity. The stability of the slurry composition for the negative electrode was evaluated during preparation, and the results are shown in Table 1.

[0077] <Formation of the negative electrode> The obtained negative electrode slurry composition was applied by a comma coater onto a copper foil having a thickness of 15 μm, which was used as a current collector, so that the weight of the negative electrode after drying was 11 mg / cm 2 The copper foil was dried by conveying it through an oven at 60°C for 2 minutes at a speed of 0.5 m / min, followed by heat treatment at 120°C for 2 minutes to obtain a negative electrode blank. The negative electrode raw material was then rolled with a roll press to make the density of the negative electrode composite layer 1.75 g / cm 3 A negative electrode of 1000 .mu.m was obtained. The powder shedding characteristics during negative electrode formation and the peel strength of the negative electrode were also evaluated. The results are shown in Table 1.

[0078] <Formation of the positive electrode> 100 parts of LiCoO2 with a median diameter of 12 μm as the positive electrode active material, 2 parts of acetylene black (manufactured by Denki Kagaku Kogyo Co., Ltd., product name "HS-100") as the conductive material, 2 parts of polyvinylidene fluoride (manufactured by Kureha Corporation, product name "#7208") as the binder in solids equivalent, and N-methylpyrrolidone as the solvent were mixed to a total solids concentration of 70%. These were mixed using a planetary mixer to obtain a positive electrode slurry composition. The obtained slurry composition for a positive electrode was coated on a 20 μm thick aluminum foil current collector using a comma coater so that the weight per unit area after drying was 23 mg / cm 2 The aluminum foil was dried by conveying it through an oven at 60°C for 2 minutes at a speed of 0.5 m / min, followed by heat treatment at 120°C for 2 minutes to obtain a positive electrode blank. The positive electrode raw material was then rolled with a roll press to make the density of the positive electrode composite layer 4.0 g / cm 3 A positive electrode of 1000 .mu.m was obtained.

[0079] <Preparing the separator> As a separator made of a separator substrate, a single-layer polypropylene separator (manufactured by Celgard Co., Ltd., product name "Celgard 2500") was prepared.

[0080] <Fabrication of lithium-ion secondary batteries> A laminate was obtained by sandwiching a separator (a 20 μm thick polypropylene microporous membrane) between the pressed lithium ion secondary battery positive electrode and pressed lithium ion secondary battery negative electrode prepared as described above in a separator / positive electrode / separator / negative electrode configuration. The electrode and separator laminate was then wound around a core with a diameter of 20 mm to obtain a wound body comprising a positive electrode, separator, and negative electrode. The wound body was then compressed in one direction at a speed of 10 mm / sec until it reached a thickness of 4.5 mm, thereby obtaining a flattened body. The obtained flattened body was elliptical in plan view, with a ratio of its major axis to its minor axis (major axis / minor axis) of 7.7. In addition, a non-aqueous electrolyte solution (LiPF6 solution with a concentration of 1.0 M, solvent: a mixed solvent of ethylene carbonate (EC) / ethyl methyl carbonate (EMC) = 3 / 7 (mass ratio), to which 2 vol% of vinylene carbonate (VC) was further added as an additive) was prepared. Next, the flat body was placed in an aluminum laminate case together with the nonaqueous electrolyte solution. After connecting the negative electrode lead and the positive electrode lead to their designated locations, the opening of the laminate case was thermally sealed to produce a laminated lithium-ion secondary battery as a nonaqueous secondary battery. The resulting secondary battery was a pouch-shaped battery measuring 35 mm wide, 48 mm high, and 5 mm thick, with a nominal capacity of 700 mAh. The battery resistance and cycle characteristics of this lithium-ion secondary battery were evaluated, and the results are shown in Table 1.

[0081] Example 2 A binder composition containing a particulate polymer was prepared in the same manner as in Example 1. A slurry composition for a non-aqueous secondary battery negative electrode, a negative electrode, a positive electrode, a separator, and a lithium ion secondary battery were produced or prepared in the same manner as in Example 1, except that the following active material 1 was used as the negative electrode active material when preparing the slurry composition for a non-aqueous secondary battery negative electrode. Evaluations were then performed in the same manner as in Example 1. The results are shown in Table 1. Active material 1: A mixture of 50 parts silicon-containing alloy (non-carbon-based negative electrode active material) and 50 parts artificial graphite (carbon-based negative electrode active material)

[0082] Example 3 A binder composition containing a particulate polymer was prepared in the same manner as in Example 1. A slurry composition for a non-aqueous secondary battery negative electrode, a negative electrode, a positive electrode, a separator, and a lithium ion secondary battery were produced or prepared in the same manner as in Example 1, except that the following active material 2 was used as the negative electrode active material when preparing the slurry composition for a non-aqueous secondary battery negative electrode. Evaluations were then performed in the same manner as in Example 1. The results are shown in Table 1. Active material 2: SiO x A mixture of 30 parts (non-carbon-based negative electrode active material) and 70 parts artificial graphite (carbon-based negative electrode active material)

[0083] (Example 4, Comparative Examples 3 and 4) A binder composition containing a particulate polymer, a slurry composition for a nonaqueous secondary battery negative electrode, a negative electrode, a positive electrode, a separator, and a lithium ion secondary battery were produced or prepared in the same manner as in Example 1, except that isoprene and / or 1,3-butadiene were used as the aliphatic conjugated diene monomer in the blending amounts shown in Table 1 when preparing the binder composition containing a particulate polymer. Evaluations were then performed in the same manner as in Example 1. The results are shown in Table 1.

[0084] (Examples 5 to 11, Comparative Examples 1 and 2) A binder composition containing a particulate polymer, a slurry composition for a nonaqueous secondary battery negative electrode, a negative electrode, a positive electrode, a separator, and a lithium ion secondary battery were produced or prepared in the same manner as in Example 1, except that, when preparing the binder composition containing a particulate polymer, the blending amounts of styrene and isoprene, the average particle size of the particulate polymer, the pH of the composition, and the molecular weight of the acidic water-soluble polymer contained in the aqueous phase were set as shown in Table 1. Evaluations were then performed in the same manner as in Example 1. The results are shown in Table 1.

[0085] Example 12 <Preparation of particulate polymers (Emprop polymerization)> To form the core portion, 4 parts of styrene as an aromatic vinyl monomer, 1 part of methacrylic acid as an acid monomer, 100 parts of ion-exchanged water, 0.7 parts of dodecylbenzenesulfonic acid as an emulsifier, 0.1 parts of α-methylstyrene dimer as a chain transfer agent, and 0.3 parts of potassium persulfate as a polymerization initiator were placed in a 5 MPa pressure vessel equipped with a stirrer and thoroughly stirred. The mixture was then heated to 60°C to initiate polymerization. The polymerization was continued until the polymerization conversion reached 98%, yielding a seed particle polymer for the core portion. Next, to the same pressure vessel, under stirring, 18 parts of styrene as an aromatic vinyl monomer, 72 parts of isoprene as an aliphatic conjugated diene monomer, 5 parts of methacrylic acid as an acid monomer, 0.3 parts of sodium dodecylbenzenesulfonate as an emulsifier, and 37 parts of ion-exchanged water were continuously added to continue polymerization. This aqueous dispersion was heated to 70°C, and when the polymerization conversion rate reached 97%, the reaction was stopped by cooling. A polymer serving as a shell was formed on the outer surface of the core, yielding a mixture containing a particulate polymer having a core-shell structure. One part of Wingsatay L dispersion was then added as an antioxidant to obtain an aqueous dispersion (binder composition for lithium-ion secondary battery negative electrodes) containing a particulate polymer having a core-shell structure in which the entire outer surface of the core was covered with a shell. The average particle size of the particulate polymer was measured using the resulting aqueous dispersion of the particulate polymer. Next, a nonaqueous secondary battery negative electrode slurry composition, a negative electrode, a positive electrode, a separator, and a lithium-ion secondary battery were fabricated or prepared in the same manner as in Example 1. Evaluations were then performed in the same manner as in Example 1. The results are shown in Table 1.

[0086] (Comparative Example 5) <Preparation of Particulate Polymers (Production of Block Copolymers by Solution Polymerization)> [Preparation of cyclohexane solution of block copolymer] A pressure-resistant reactor was charged with 233.3 kg of cyclohexane, 54.2 mmol of N,N,N',N'-tetramethylethylenediamine (TMEDA), and 25.0 kg of styrene as an aromatic vinyl monomer. While stirring at 40°C, 1806.5 mmol of n-butyllithium as a polymerization initiator was added, and the mixture was heated to 50°C and polymerized for 1 hour. The polymerization conversion of styrene was 100%. Subsequently, 75.0 kg of isoprene was continuously added to the pressure-resistant reactor over 1 hour while maintaining the temperature at 50-60°C. After the addition of isoprene was completed, the polymerization reaction was continued for another 1 hour. The polymerization conversion of isoprene was 100%. Next, 740.6 mmol of dichlorodimethylsilane as a coupling agent was added to the pressure-resistant reactor, and the coupling reaction was carried out for 2 hours. After that, 3612.9 mmol of methanol was added to the reaction solution to deactivate the active terminals, and the mixture was mixed thoroughly. Next, 100 parts of this reaction solution (containing 30.0 parts of the polymer component) were mixed with 0.05 parts of 4-[[4,6-bis(octylthio)-1,3,5-triazin-2-yl]amino]-2,6-di-tert-butylphenol (H1) as a hindered phenol-based antioxidant, 0.09 parts of 3,9-bis(octadecyloxy)-2,4,8,10-tetraoxa-3,9-diphosphaspiro[5.5]undecane (P1) as a phosphite-based antioxidant, and 0.03 parts of EDTA as a metal scavenger to obtain a block copolymer solution.

[0087] [Emulsification] Sodium alkylbenzenesulfonate was dissolved in ion-exchanged water to prepare a 5% aqueous solution. Then, 500 g of the obtained block copolymer solution and 500 g of the obtained aqueous solution were charged into a tank and stirred to perform premixing. Subsequently, the premix was transferred from the tank to a continuous high-efficiency emulsifying and dispersing machine (manufactured by Pacific Machinery Works, product name "Milder MDN303V") at a rate of 100 g / min using a metering pump, and stirred at a rotation speed of 15,000 rpm. Thus, the preliminary mixture was emulsified to obtain an emulsion. Next, the cyclohexane in the obtained emulsion was distilled off under reduced pressure using a rotary evaporator, and the distilled emulsion was then left to stand for one day in a chromatographic column equipped with a stopcock for separation, and the lower layer after separation was removed to concentrate the emulsion. Finally, the upper layer was filtered through a 100-mesh wire screen to obtain an aqueous dispersion (block copolymer latex) containing particulate block copolymers (core particles).

[0088] [Graft polymerization and crosslinking] To a polymerization reactor equipped with a stirrer, 675 parts of ion-exchanged water was added, followed by 20 parts of methacrylic acid. While stirring with the stirring blade of the polymerization reactor, 100 parts of the obtained block copolymer latex (calculated as block copolymer) was added to the polymerization reactor, and the atmosphere was replaced with nitrogen. The diluted block polymer latex was then heated to 30°C while stirring. In a separate container, a solution containing 7 parts of ion-exchanged water, 0.01 parts of ferrous sulfate (manufactured by Chubu Cherest Co., Ltd., trade name "Frost Fe") as a reducing agent, and 0.32 parts of sodium formaldehyde sulfoxylate (manufactured by Sumitomo Seika Chemicals Co., Ltd., trade name "SFS") was prepared. The resulting solution was added to a polymerization reaction vessel, and 0.35 parts of tert-butyl hydroperoxide (manufactured by NOF Corporation, trade name "Perbutyl H") as an oxidizing agent was added. The reaction was carried out at 30°C for 1 hour, followed by a further reaction at 70°C for 2 hours. The polymerization conversion rate was 99%. Then, an aqueous dispersion of a particulate polymer consisting of a graft polymer obtained by graft polymerizing and crosslinking the core particles containing the block copolymer was obtained.

[0089] The average particle size of the particulate polymer was measured using the obtained aqueous dispersion of the particulate polymer. Next, a slurry composition for a nonaqueous secondary battery negative electrode, a negative electrode, a positive electrode, a separator, and a lithium ion secondary battery were produced or prepared in the same manner as in Example 1. Evaluations were then performed in the same manner as in Example 1. The results are shown in Table 1.

[0090] [Table 1]

[0091] The abbreviations in the table have the following meanings: SIR: Styrene / isoprene random copolymer SBIR: Styrene / butadiene / isoprene random copolymer SIS block: styrene / isoprene block copolymer MAA: methacrylic acid Emprop: Emulsion prop method

[0092] Table 1 shows that in Examples 1 to 12, secondary batteries with excellent internal resistance and cycle characteristics were obtained, while the stability of the slurry composition, the peel strength of the electrode, and the powder shedding characteristics during electrode formation were further improved. Furthermore, in Comparative Examples 1 and 2, in which the content ratio of structural units derived from each monomer was outside the specified range, Comparative Examples 3 and 4, in which the copolymer did not contain structural units derived from isoprene, and Comparative Example 5, in which the copolymer was a block copolymer, it was shown that one or more of the stability of the slurry composition, the peel strength of the electrode, and the powder shedding characteristics during electrode formation were not good. [Industrial Applicability]

[0093] According to the binder composition for a non-aqueous secondary battery electrode and the slurry composition for a non-aqueous secondary battery electrode of the present invention, an electrode having excellent stability as a slurry composition and excellent peel strength can be formed, and excellent performance can be achieved in the secondary battery. Furthermore, the electrode for a non-aqueous secondary battery of the present invention has excellent peel strength, and can form a non-aqueous secondary battery that exhibits excellent performance. Furthermore, according to the present invention, a non-aqueous secondary battery having improved electrode peel strength and exhibiting excellent performance can be obtained.

Claims

1. The particulate polymer comprises a random copolymer containing structural units derived from an aromatic vinyl monomer, structural units derived from a conjugated diene monomer, and structural units derived from an acid monomer, the content of the structural unit derived from the aromatic vinyl monomer is more than 5% by mass and 40% by mass or less, based on 100% by mass of the particulate polymer; the structural units derived from the conjugated diene monomer include structural units derived from isoprene, and the content of the structural units derived from isoprene is 20% by mass or more relative to 100% by mass of the total of the structural units derived from the aromatic vinyl monomer, the structural units derived from the conjugated diene monomer, and the structural units derived from the acid monomer; The pH is 6 or more and 9 or less. A binder composition for non-aqueous secondary battery electrodes.

2. 2. The binder composition for a non-aqueous secondary battery electrode according to claim 1, wherein the content of the structural unit derived from the acid monomer is 3% by mass or more and 9% by mass or less relative to 100% by mass of the particulate polymer.

3. 3. The binder composition for a non-aqueous secondary battery electrode according to claim 1, wherein the particulate polymer has an average particle size of 60 nm or more and 300 nm or less.

4. 4. The binder composition for a non-aqueous secondary battery electrode according to claim 1, wherein the binder composition for a non-aqueous secondary battery electrode comprises an aqueous phase containing an acidic water-soluble polymer, and the weight-average molecular weight of the acidic water-soluble polymer is 10,000 or more and 100,000 or less.

5. A slurry composition for a non-aqueous secondary battery electrode, comprising the binder composition for a non-aqueous secondary battery electrode according to any one of claims 1 to 4, an electrode active material, and at least one of a dispersant and a viscosity modifier.

6. A non-aqueous secondary battery electrode comprising an electrode mixture layer formed using the slurry composition for a non-aqueous secondary battery electrode according to claim 5 .

7. a positive electrode, a negative electrode, a separator, and an electrolyte; A non-aqueous secondary battery, wherein at least one of the positive electrode and the negative electrode is the electrode for a non-aqueous secondary battery according to claim 6 .

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