# US 10,770,743 B2 · Electrode manufacturing method, electrode, and secondary battery > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,770,743 B2 - Document ID: US10770743B2 - Status: Granted - Kind: B2 - Application number: 15/539,368 - Filed: 2015-12-25 - Published: 2017-12-28 - Granted: 2020-09-08 - Earliest claimed: 2014-12-26 - Assignees: Sekisui Chemical Co., Ltd. - Applicants: Sekisui Chemical Co., Ltd. - Inventors: Rie Teranishi; Kenichi Shinmei; Masashi Kanoh; Akio Shokaku; Shinichiro Ito - Web page: https://patentgrep.com/patent/US10770743B2 ## CPC - H01M 10/058: Construction or manufacture - H01M 4/139: Processes of manufacture - H01M 50/409: Separators, membranes or diaphragms characterised by the material - H01M 50/489: Separators, membranes, diaphragms or spacing elements inside the cells, characterised by their physical properties, e.g. swelling degree, hydrophilicity or shut down properties - H01M 50/124: having a layered structure - Y02E 60/10: Energy storage using batteries - Y02P 70/50: Manufacturing or production processes characterised by the final manufactured product - H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract A method for manufacturing an electrode having a laminated body including an insulating layer laminated on an electrode active material layer, said method comprising: a step of laminating an insulating layer on an electrode active material layer formed on a base, such that a thickness value of the insulating layer is at least twice a surface roughness Rz value of the electrode active material layer, the surface roughness Rz value being a ten point average roughness as measured in accordance with JIS B0601 1994. ## Claims ### Claim 1 A method for manufacturing an electrode having a laminated body comprising an insulating layer laminated on an electrode active material layer, said method comprising: forming the electrode active material layer comprising an electrode active material; and laminating the insulating layer directly on the electrode active material layer formed on a base, 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, such that a thickness value of the insulating layer is at least twice a surface roughness Rz value of the electrode active material layer, the surface roughness Rz value being a ten point average roughness as measured in accordance with JIS B0601 1994. ### Claim 2 (depends on 1) The method according to claim 1, where the laminating the insulating layer directly on the electrode active material layer formed on a base comprises: laminating the insulating layer by coating a composition comprising an insulating material on the electrode active material layer, such that coating the composition such that a thickness value of the insulating layer is at least twice a surface roughness Rz value of the electrode active material layer. ### Claim 3 (depends on 1) The method according to claim 1, wherein the surface roughness Rz value is 35 μm or less. ### Claim 4 (depends on 2) The method according to claim 2, wherein the composition is coated such that the thickness value of the insulating layer is in a range of 2 μm to 35 μm. ### Claim 5 (depends on 2) The method according to claim 2, wherein the composition is coated by blade coating method. ### Claim 6 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. ### Claim 7 (depends on 6) The electrode according to claim 6, wherein the surface roughness Rz value is 35 μm or less. ### Claim 8 (depends on 6) The electrode according to claim 6, wherein the thickness value of the insulating layer is in a range of 2 μm to 35 μm. ### Claim 9 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. ### Claim 10 (depends on 9) The method according to claim 9, wherein the surface roughness Rz value of the electrode active material layer is 35 μm or less. ### Claim 11 (depends on 9) The method according to claim 9, wherein the thickness value of the insulating layer is in a range of 2 μm to 35 μm. ### Claim 12 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. ### Claim 13 (depends on 12) The secondary battery according to claim 12, wherein the surface roughness Rz value of the electrode active material layer is 35 μm or less. ### Claim 14 (depends on 12) The secondary battery according to claim 12, wherein the thickness value of the insulating layer is in a range of 2 μm to 35 μm. ### Claim 15 (depends on 12) The secondary battery according to claim 12, wherein the surface roughness Rz value of the electrode active material layer is 17.5 μm or less, and the thickness value of the insulating layer is in a range of 2 μm to 35 μm. ### Claim 16 (depends on 12) The secondary battery according to claim 12, which has a porous resin separator provided between the positive electrode and the negative electrode. ### Claim 17 (depends on 1) The method according to claim 1, wherein the thickness value of the insulating layer is at least 4 times the surface roughness Rz value of the electrode active material layer. ### Claim 18 (depends on 1) The method according to claim 1, wherein the thickness value of the insulating layer is at least 8 times the surface roughness Rz value of the electrode active material layer. ### Claim 19 (depends on 6) The electrode according to claim 6, wherein the ratio (t/Rz) is at least 4. ### Claim 20 (depends on 6) The electrode according to claim 6, wherein the ratio (t/Rz) is at least 8. ### Claim 21 (depends on 9) The method according to claim 9, wherein the insulating layer having the thickness value of at least 4 times the surface roughness Rz value of the electrode active material layer. ### Claim 22 (depends on 9) The method according to claim 9, wherein the insulating layer having the thickness value of at least 8 times the surface roughness Rz value of the electrode active material layer. ### Claim 23 (depends on 12) The secondary battery according to claim 12, wherein the ratio (t/Rz) of the thickness value to the surface roughness Rz value is at least 4. ### Claim 24 (depends on 12) The secondary battery according to claim 12, wherein the ratio (t/Rz) of the thickness value to the surface roughness Rz value is at least 8. ### Claim 25 (depends on 9) The method according to claim 9, further comprising: coating a gel electrolyte on one of the positive electrode and the negative electrode. ### Claim 26 (depends on 12) The secondary battery according to claim 12, further comprising: a gel electrolyte between the positive electrode and the negative electrode. ### Claim 27 (depends on 1) The method according to claim 1, wherein the insulating layer comprises 5% or more by volume of insulating fine particles having a specific average particle diameter that corresponds to 80% to 100% of a thickness of the insulating layer, an amount of the insulating fine particles being in a range of 15 to 95% by mass of a mass of the insulating layer, and the insulating fine particles including 5% by mass or more of organic fine particles. ### Claim 28 (depends on 1) The method according to claim 1, wherein the thickness value of the insulating layer is at least twice a surface roughness Rz value of the electrode active material layer and not more than 30 times the surface roughness Rz.