Multi-layer electrode structure, and method of manufacturing same

A battery containing a positive electrode and a spaced negative electrode and a liquid or non-liquid electrolyte between said positive and negative electrodes, at least one of said positive and negative electrodes comprising a plurality of electrode layers at least composed of a binder made of a macromolecular substance and an electrode material and coated on a current-collecting member, each of said electrode layers including a macromolecular substance, wherein a first electrode layer in contact with said current-collecting member and a second electrode layer in contact with said first electrode layer are formed of different constituents or have different proportions of the same constitutent.

A double-layer capacitor with spaced first and second electrodes and a liquid or non-liquid electrolyte between the said electrodes, at least one of said first and second electrodes comprising a plurality of electrode layers at least composed of a binder made of a macromolecular substance and an electrode material and coated on a current-collecting member, each of said electrode layers including a macromolecular substance, wherein a first electrode layer in contact with said current-collecting member and a second electrode layer in contact with said first electrode layer are formed of different constituents or have different proportions of the same constitutent.

A method of manufacturing a multi-layer electrode structure comprising a plurality of electrode layers coated on a current-collecting member, said method comprising the steps of:

• forming a first electrode layer on said current-collecting member by coating a first mixture comprising a macromolecular binder, an electrode substance, and a solvent onto said current-collecting member and drying said first mixture;
• and
• forming a second electrode layer by coating a second mixture containing a macromolecular binder, an electrode substance and a solvent on said first electrode layer and drying said second mixture.

A multi-layer electrode structure comprised of a plurality of electrode layers at least composed of a binder made of a macromolecular substance and an electrode material coated on a current-collecting member, wherein the first electrode layer formed in contact with the current-collecting member and a second electrode layer formed on the first electrode layer are formed of different constituents and/or have different proportions of the same constituent.

A multi-layer electrode structure comprised of a plurality of electrode layers at least composed of a binder made of a macromolecular substance and an electrode material, coated on a current-collecting member, wherein the binder of the first electrode layer formed in contact with the current-collecting member has a stronger adhesive strength than the second electrode layer formed on the first electrode layer.

A multi-layer electrode structure comprised of a plurality of electrode layers at least composed of a binder made of a macromolecular substance, an electrode material, and a powdered electrically-conducting substance coated on a current-collecting member, wherein the first electrode layer formed in contact with a current-collecting member, has a higher electrical conduction rate than the second electrode layer formed on the first electrode layer.

A battery containing at least one electrode comprised of a multi-layer electrode structure coated on a current-colleting layer, each layer at least composed of a binder made of a macromolecular substance, an electrode material, and a powdered electrically-conducting substance, wherein the battery further includes a liquid or non-liquid electrolyte between the electrodes, and wherein the first electrode layer formed in contact with a current-collecting member has a binder of stronger adhesive strength and a higher electrical conduction rate than the second electrode layer formed on the first electrode layer.

A double-layer capacitor with at least one electrode comprised of a multi-layer electrode structure coated on a current-collecting member, each layer at least composed of a binder made of a macromolecular substance, an electrode material, and a powdered electrically-conducting substance, wherein the double-layer capacitor further includes a liquid or non-liquid electrolyte between the electrodes, wherein the first electrode layer formed in contact with the current-collecting member has a binder of stronger adhesive strength and a higher electrical conduction rate than the second electrode layer formed on the first electrode layer.

A method of manufacturing a multi-layer electrode structure comprised of a plurality of electrode layers at least composed of a binder made of a macromolecular substance and an electrode material coated on a current-collecting member, the method comprising the steps of forming a first electrode layer by coating a mixed material containing a macromolecular binder, an electrode substance, and a solvent onto a current-collecting member and drying the mixed material, forming a second electrode layer by coating a mixed material containing a macromolecular binder, an electrode substance, and a solvent on top of the first electrode layer and drying the mixed material to form an electrode of multiple layers, and wherein the macromolecular binders used are such that the binding strength of the first electrode layer is stronger than the second electrode layer.

A method of manufacturing a multi-layer electrode structure comprised of a plurality of electrode layers at least composed of a binder made of a macromolecular substance, an electrode material, and a powdered electrically-conducting substance coated on a current-collecting member, the method comprising the steps of forming a first electrode layer by coating a mixed material containing a macromolecular binder, an electrode substance, a solvent, and a powdered electrically-conducting substance onto a current-collecting member and drying the mixed material, forming a second electrode layer by coating a mixed material containing a macromolecular binder, an electrode substance, a solvent, and a powdered electrically-conducting substance on top of the first electrode layer and drying the mixed material to form an electrode of multiple layers, and using powdered electrically-conducting substances such that the electrical conduction rate of the first electrode layer is higher than the second electrode layer.

A method of manufacturing a multi-layer electrode structure comprised of a plurality of electrode layers at least composed of a binder made of a macromolecular substance and an electrode material coated on a current-collecting member, the method comprising the steps of forming a first electrode layer by coating a mixed material containing a macromolecular binder, an electrode substance, and a solvent onto a current-collecting member and drying the mixed material, forming a second electrode layer by coating a mixed material containing a macromolecular binder, an electrode substance, and a solvent on top of the first electrode layer and drying the mixed material to form an electrode of multiple layers, and wherein the macromolecular binders used are such that the binding strength of the first electrode layer is stronger than the second electrode layer, wherein a mixed material containing macromolecular binder, electrode substance, and solvent are mixed and coated onto the second electrode layer and drying the mixed material to form an electrode layer such that the third electrode layer has a stronger bonding force than the second electrode layer, and the electrode material for at least one electrode layer is coated with an ion-conducting polymer.

A method of manufacturing a multi-layer electrode structure comprised of a plurality of electrode layers at least composed of a binder made of a macromolecular substance and an electrode material coated on a current-collecting member, the method comprising the steps of forming a first electrode layer by coating a mixed material containing a macromolecular binder, an electrode substance, and a solvent onto a current-collecting member and drying the mixed material, forming a second electrode layer by coating a mixed material containing a macromolecular binder, an electrode substance, and a solvent on top of the first electrode layer and drying the mixed material to form an electrode of multiple layers, and wherein the macromolecular binders used are such that the binding strength of the first electrode layer is stronger than the second electrode layer, wherein a mixed material containing macromolecular binder, electrode substance, and solvent are mixed and coated onto the second electrode layer and drying the mixed material to form an electrode layer such that the third electrode layer has a stronger bonding force than the second electrode layer, and the macromolecular binder for at least one electrode layer other than the first electrode layer uses a binder polymer easily prone to form fibrils.

A method of manufacturing a multi-layer electrode structure comprised of a plurality of electrode layers at least composed of a binder made of a macromolecular substance and an electrode material coated on a current-collecting member, the method comprising the steps of forming a first electrode layer by coating a mixed material containing a macromolecular binder, an electrode substance, and a solvent onto a current-collecting member and drying the mixed material, forming a second electrode layer by coating a mixed material containing a macromolecular binder, an electrode substance, and a solvent on top of the first electrode layer and drying the mixed material to form an electrode of multiple layers, and wherein the macromolecular binders used are such that the binding strength of the first electrode layer is stronger than the second electrode layer, wherein a mixed material containing macromolecular binder, electrode substance, and solvent are mixed and coated onto the second electrode layer and drying the mixed material to form an electrode layer such that the third electrode layer has a stronger bonding force than the second electrode layer, and the powdered electrically-conducting substance of the first electrode layer contains support electrolytic salts

A method of manufacturing a battery with at least one electrode comprised of a multi-layer electrode structure at least composed of a binder made of a macromolecular substance, an electrode material, and a powdered electrically-conducting substance coated on a current-collecting member, wherein the battery further comprises a liquid or non-liquid electrolyte between the electrodes, the method comprising forming a first electrode layer by coating a mixed material containing a macromolecular binder, an electrode substance, a solvent, and a powdered electrically-conducting substance onto a current-collecting member and drying the mixed material, forming a second electrode layer by coating a mixed material containing a macromolecular binder, an electrode substance, a solvent, and a powdered electrically-conducting substance on top of the first electrode layer and drying the mixed material to form an electrode of multiple layers, and using macromolecular binders such that the bonding force of the first electrode layer is stronger than the bonding force of the second electrode layer and using powdered electrically-conducting substances so that the electrical conduction rate of the first electrode layer is higher than the second electrode layer.

A method of manufacturing a double-layer capacitor with an electrode comprised of a multi-layer electrode structure at least composed of a binder made of a macromolecular substance, an electrode material, and a powdered electrically-conducting substance coated on a current-collecting member, wherein the double-layer capacitor comprises a liquid or non-liquid electrolyte between the electrodes, the method comprising forming a first electrode layer by coating a mixed material containing a macromolecular binder, an electrode substance, a solvent, and a powdered electrically-conducting substance onto a current-collecting member and drying the mixed material, forming a second electrode layer by coating a mixed material containing a macromolecular binder, an electrode substance, a solvent, and a powdered electrically-conducting substance on top of the first electrode layer and drying the mixed material to form an electrode of multiple layers, and using macromolecular binders such that the bonding force of the first electrode layer is stronger than the binding force of the second electrode layer and using powdered electrically-conducting substances such that the electrical conduction rate of the first electrode layer is higher than that of the second electrode layer.