Electrode manufacturing method, electrode, and secondary battery

An electrode having a laminated body comprising:

• an electrode active material layer comprising an electrode active material;
• and
• an insulating layer laminated directly on the electrode active material layer, the insulating layer comprising at least one of a polyolefin resin, a fluororesin, a polyacrylonitrile resin, a polystyrene resin, a polyvinyl acetal resin, a polyimide resin, a polyester resin, an acrylic resin, a polyether sulfone resin, a polysulfone resin, a polyamide resin, a polyamide-imide resin, a polyphenyl sulfone resin, an epoxy resin, a phenolic resin, a polyvinyl alcohol resin, a polyvinyl acetal resin, and carboxymethyl cellulose,
• wherein:
• a ratio (t/Rz) of a thickness value of the insulating layer to a surface roughness Rz value of the electrode active material layer is at least 2, and
• the surface roughness Rz value being a ten point average roughness as measured in accordance with JIS B0601 1994.

A method for manufacturing a secondary battery having a positive electrode, a negative electrode, and an insulating layer laminated between the positive electrode and the negative electrode, said method comprising:

• forming an electrode active material layer comprising an electrode active material;
• and
• laminating the insulating layer directly on the electrode active material layer of one of the positive electrode and the negative electrode, the insulating layer comprising at least one of a polyolefin resin, a fluororesin, a polyacrylonitrile resin, a polystyrene resin, a polyvinyl acetal resin, a polyimide resin, a polyester resin, an acrylic resin, a polyether sulfone resin, a polysulfone resin, a polyamide resin, a polyamide-imide resin, a polyphenyl sulfone resin, an epoxy resin, a phenolic resin, a polyvinyl alcohol resin, a polyvinyl acetal resin, and carboxymethyl cellulose,
• the insulating layer having a thickness value of at least twice a surface roughness Rz value of the electrode active material layer, and
• the surface roughness Rz value being a ten point average roughness as measured in accordance with JIS B0601 1994.

A secondary battery comprising:

• a positive electrode;
• a negative electrode facing the positive electrode;
• and
• an insulating layer laminated between the positive electrode and the negative electrode, wherein:
• at least one of the positive electrode and the negative electrode comprises an electrode active material layer comprising an electrode active material formed on a surface of the at least one of the positive electrode and the negative electrode,
• the insulating layer is positioned directly on the electrode active material layer,
• the insulating layer comprises at least one of a polyolefin resin, a fluororesin, a polyacrylonitrile resin, a polystyrene resin, a polyvinyl acetal resin, a polyimide resin, a polyester resin, an acrylic resin, a polyether sulfone resin, a polysulfone resin, a polyamide resin, a polyamide-imide resin, a polyphenyl sulfone resin, an epoxy resin, a phenolic resin, a polyvinyl alcohol resin, a polyvinyl acetal resin, and carboxymethyl cellulose, and
• a ratio (t/Rz) of the thickness value of the insulating layer to the surface roughness Rz value of the electrode active material layer is at least 2.