# US 12,603,391 B2 · All-in-one electrode stack unit, manufacturing method thereof, and lithium secondary battery including the same

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- Number: US 12,603,391 B2
- Document ID: US12603391B2
- Status: Granted
- Kind: B2
- Application number: 17/801,062
- Filed: 2021-12-16
- Published: 2023-03-16
- Granted: 2026-04-14
- Earliest claimed: 2021-02-05
- Assignees: LG Energy Solution, Ltd.
- Applicants: LG Energy Solution, Ltd.
- Inventors: Hyeok Jeong; Su Taek Jung; Seokhoon Jang; Soon Kwan Kwon; Byeong Kyu Lee
- Web page: https://patentgrep.com/patent/US12603391B2

## CPC

- H01M 50/461: {with adhesive layers between electrodes and separators}
- H01M 10/0585: of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators
- H01M 50/403: Manufacturing processes of separators, membranes or diaphragms
- H01M 50/414: Synthetic resins, e.g. thermoplastics or thermosetting resins
- H01M 50/42: Acrylic resins
- H01M 50/434: Ceramics
- H01M 50/446: Composite material consisting of a mixture of organic and inorganic materials
- H01M 50/449: having a layered structure
- H01M 50/457: comprising three or more layers
- H01M 50/46: Separators, membranes or diaphragms characterised by their combination with electrodes
- H01M 50/463: Separators, membranes or diaphragms characterised by their shape
- 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 50/491: Porosity
- 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

An all-in-one electrode stack unit includes a first electrode, a second electrode, and a separation layer interposed between the first electrode and the second electrode. The separation layer is a photocured PSA coating layer integrally formed on the first electrode. The separation layer has a strength of 30 to 50 MPa and an adhesive force to the second electrode of 70 gf/20 mm to 90 gf/20 mm. The first electrode, the separation layer, and the second electrode are laminated. The electrode stack unit is manufactured by a method. A lithium secondary battery includes the electrode stack unit.

## Claims

### Claim 1

An all-in-one electrode stack unit comprising:
a first electrode, a second electrode, and a separation layer interposed between the first electrode and the second electrode,
wherein the separation layer is a photocured pressure sensitive adhesive (PSA) coating layer integrally formed on the first electrode,
wherein the separation layer has a tensile strength of 30 to 50 MPa, and an adhesive force to the second electrode of 70 gf/20 mm to 90 gf/20 mm, and
wherein the first electrode, the separation layer, and the second electrode are laminated,
wherein the photocured PSA coating layer is a polymer coating layer containing ceramic particles,
wherein the polymer is an acrylate-based or epoxy-based monomer, an acrylate-based or epoxy-based oligomer, or a polymer of the monomer and the oligomer,
wherein the photocured PSA coating layer is obtained by curing a PSA solvent-free ink, and
wherein the PSA solvent-free ink contains 10 to 30% by weight of ceramic particles, 45 to 65% by weight of a monofunctional monomer, 10 to 15% by weight of a polyfunctional monomer, 5 to 10% by weight of an oligomer, and 0.1 to 0.8% by weight of an initiator.

### Claim 2 (depends on 1)

The all-in-one electrode stack unit according to claim 1, wherein:
the ceramic particles have an average diameter (D50) of 10 nm to 500 nm.

### Claim 3 (depends on 1)

The all-in-one electrode stack unit according to claim 1, wherein:
the ceramic particles contain at least one particle selected from the group consisting of AlN, BN, BeO, SrTiO3, SnO2, CeO2, MgO, NiO, CaO, ZnO, ZrO2, Y2O3, Al2O3, TiO2, and SiC.

### Claim 4 (depends on 1)

The all-in-one electrode stack unit according to claim 1, wherein:
the separation layer has a patterned structure.

### Claim 5 (depends on 1)

The all-in-one electrode stack unit according to claim 1, wherein:
the separation layer is composed of two or more layers, each separation layer has a patterned structure, and each separation layer has a pattern different from that of an adjacent separation layer.

### Claim 6 (depends on 5)

The all-in-one electrode stack unit according to claim 5, wherein:
each of the respective separation layers includes alternating coated and uncoated parts defining a line-type pattern, and an angle defined by lines formed by the patterns of the adjacent separation layers is 10 degrees to 90 degrees.

### Claim 7 (depends on 1)

The all-in-one electrode stack unit according to claim 1, wherein:
a total thickness of the separation layer is 1 μm to 5 μm.

### Claim 8 (depends on 1)

The all-in-one electrode stack unit according to claim 1, wherein:
a total porosity of the separation layer is 20 to 60%, and an average diameter (D50) of the pores is 0.01 μm to 1 μm.

### Claim 9 (depends on 1)

The all-in-one electrode stack unit according to claim 1, wherein:
the separation layer has an elongation of 20% to 50%.

### Claim 10 (depends on 1)

The all-in-one electrode stack unit according to claim 1, further comprising:
a separator on a surface of the first electrode that does not face the separation layer.

### Claim 11 (depends on 1)

A lithium secondary battery comprising the all-in-one electrode stack unit of claim 1.