Non-aqueous secondary battery having an aggregation layer

A method of manufacturing a non-aqueous secondary battery, which comprises forming a positive electrode member by forming a positive electrode active material layer to at least one surface of a sheet-shaped positive electrode current collector, within the size of the current collector determined for an electrode plate laminate, such that a margin is present at a periphery of the current collector, forming an aggregation layer of insulating material particles formed by bonding insulating material particles to each other by a binder to the positive electrode member so as to cover a top surface and an end face of the positive electrode active material layer, then cutting the positive electrode member integrated with the aggregate layer of insulating material particles from the position of the margin of the positive electrode current collector in a direction perpendicular to a plane of the sheet-shaped positive electrode current collector to prepare a positive electrode having the aggregation layer of insulating material particles fixed thereon as a separator having an electrolyte solution permeability, and forming an electrode plate laminate by using the positive electrode and a negative electrode of a predetermined size having a negative electrode active material layer fixed to at least one surface of a sheet-shaped current collector, such that the positive electrode active material layer does not overhang the negative electrode active material layer paired therewith as a cell layer.

A method of manufacturing a non-aqueous secondary battery, which comprises forming a positive electrode member by forming a positive electrode active material layer to at least one surface of a sheet-shaped positive electrode current collector, within the size of the current collector determined for an electrode plate laminate, such that a margin is present at the periphery of the current collector, forming an aggregation layer of insulating material particles formed by bonding insulating material particles to each other by a binder to the positive electrode member so as to cover a top surface and an end face of the positive electrode active material layer, then integrating a negative electrode member having a negative electrode active material layer on at least one surface of a sheet-shaped negative electrode current collector on the aggregation layer of insulating material particles with the negative electrode active material layer being faced thereto and then cutting the integrated positive electrode member and the negative electrode member from the position of the margin of the positive electrode current collector in a direction perpendicular to a plane of the sheet-shaped positive electrode current collector, thereby forming an integrated layer which is formed by interposing the aggregation layer of insulating material particles as a separator having an electrolyte solution permeability between the active materials of both of the electrodes and integrating the separator and both of the electrodes, and laminating the integrated layer by one or more integrated layers to form an electrode plate laminate.

A method of manufacturing a non-aqueous secondary battery, which comprises forming a positive electrode member by forming a positive electrode active material layer to at least one surface of a sheet-shaped positive electrode current collector, within the size of the current collector determined for an electrode plate laminate, such that a margin is present at a periphery of the current collector, forming an aggregation layer of insulating material particles formed by bonding insulating material particles to each other by a binder to the positive electrode member so as to cover a top surface and an end face of the positive electrode active material layer, then forming a negative electrode active material layer on the aggregation layer of insulating material particles and then cutting the integrated positive electrode member and the negative electrode member from the position of the margin of the positive electrode current collector in a direction perpendicular to a plane of the sheet-shaped positive electrode current collector, thereby forming an integrated layer which is formed by interposing the insulation material particle aggregation layer as a separator having an electrolyte solution permeability between the active materials of both of the electrodes and integrating the separator and both of the electrodes, and laminating the integrated layer by one or more integrated layers to form an electrode plate laminate.

A non-aqueous secondary battery having, in a casing, an electrode plate laminate having at least a positive electrode and a negative electrode in which an active material layer is fixed to at least one surface of a current collector and a separator having an electrolyte solution permeability interposed between the active material layers of both of the electrodes, with a non-aqueous electrolyte solution being poured and sealed in the casing, wherein

• the separator is an aggregation layer of insulating material particles formed by bonding insulating material particles to each other by a binder and fixed to at least one of the positive electrode and the negative electrode,
• an end face of at least one of the positive electrode active material layer and the negative electrode active material layer is at least partially coated with the aggregation layer of insulating material particles,
• the insulating material particles constituting the aggregation layer of insulating material particles comprise an inorganic material, and
• an insulating layer interposed between the current collectors of both of the electrodes, and the insulating layer is fixed to at least one of the positive and negative current collectors and disposed so as to cover at least an entire surface of the positive electrode current collector opposed to the negative electrode current collector and so as not to overhang an end face of the positive electrode current collector.

A non-aqueous secondary battery having, in a casing, an electrode plate laminate having at least a positive electrode and a negative electrode in which an active material layer is fixed to at least one surface of a current collector and a separator having an electrolyte solution permeability interposed between the active material layers of both of the electrodes, with a non-aqueous electrolyte solution being poured and sealed in the casing, wherein

• the separator is an aggregation layer of insulating material particles formed by bonding insulating material particles to each other by a binder and fixed to at least one of the positive electrode and the negative electrode,
• an end face of at least one of the positive electrode active material layer and the negative electrode active material layer is at least partially coated with the aggregation layer of insulating material particles,
• the insulating material particles constituting the aggregation layer of insulating material particles comprise an inorganic material, and
• the electrode plate laminate comprises one or more of laminated integrated layers each of which is prepared by integrating both of the electrodes and the separator between the active material layers of both of the electrodes.

A non-aqueous secondary battery having, in a casing, an electrode plate laminate having at least a positive electrode and a negative electrode in which an active material layer is fixed to at least one surface of a current collector and a separator having an electrolyte solution permeability interposed between the active material layers of both of the electrodes, with a non-aqueous electrolyte solution being poured and sealed in the casing, wherein

• the separator is an aggregation layer of insulating material particles formed by bonding insulating material particles to each other by a binder and fixed to at least one of the positive electrode and the negative electrode,
• an end face of at least one of the positive electrode active material layer and the negative electrode active material layer is at least partially coated with the aggregation layer of insulating material particles,
• the insulating material particles constituting the aggregation layer of insulating material particles comprise an inorganic material,
• the electrode plate laminate comprises one or more of laminated integrated layers each of which is prepared by integrating both of the electrodes and the separator between the active material layers of both of the electrodes, and
• an insulating layer interposed between the current collectors of both of the electrodes, and the insulating layer is fixed to at least one of the positive and negative current collectors and disposed so as to cover at least the entire surface of the positive electrode current collector opposed to the negative electrode current collector and so as not to overhang an end face of the positive electrode current collector.