# US 8,785,041 B2 · Electrode and production method thereof

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- Number: US 8,785,041 B2
- Document ID: US8785041B2
- Status: Granted
- Kind: B2
- Application number: 13/126,106
- Filed: 2009-12-11
- Published: 2011-08-25
- Granted: 2014-07-22
- Earliest claimed: 2008-12-19
- Assignees: Nissan Motor Co., Ltd.
- Applicants: Shiho Inoue; Hideaki Horie; Kenji Hosaka; Osamu Shimamura; Shigeo Ibuka
- Inventors: Shiho Inoue; Hideaki Horie; Kenji Hosaka; Osamu Shimamura; Shigeo Ibuka
- Web page: https://patentgrep.com/patent/US8785041B2

## CPC

- H01M 4/043: {involving compressing or compaction}
- H01M 4/0433: {Molding}
- H01M 4/621: {Binders}
- H01M 4/622: {being polymers}
- H01M 4/623: {fluorinated polymers}
- H01M 4/667: {in the form of layers, e.g. coatings}
- H01M 4/668: {Composites of electroconductive material and synthetic resins}
- H01M 10/0418: {with bipolar electrodes}
- H01M 10/0585: of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators
- H01M 10/0525: Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
- Y02E 60/10: Energy storage using batteries
- Y02P 70/50: Manufacturing or production processes characterised by the final manufactured product
- Y10T 29/49108: Electric battery cell making
- Y10T 29/49114: including adhesively bonding
- Y10T 156/10: Methods of surface bonding and/or assembly therefor
- 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
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

An electrode includes a collector formed with a conductive resin layer and an active material layer formed on the conductive resin layer. The active material layer comprises an active material and a binder polymer, and the conductive resin layer is bonded by thermal fusion bonding to the active material layer.

## Claims

### Claim 1

A production method of an electrode, comprising:
preparing a collector consisting of a laminated material of three or more conductive resin layers each containing a polymer material, the collector including outermost resin layers and at least one inner layer interposed between the outermost resin layers;
forming an electrode laminate by laminating an active material layer on the collector, the active material layer containing a binder polymer having a melting point, wherein the polymer material of each of the three or more conductive resin layers has a softening point lower than the melting point of the binder polymer; and wherein the polymer material of one of the outermost resin layers disposed nearer to the active material layer than the other of the outermost resin layers has a softening point lower than that of the polymer material of the at least one inner layer; and
thermal fusion bonding the conductive resin layer to the active material layer in the electrode laminate at a thermal fusion bonding temperature selected to fuse the polymer material without melting the binder polymer.

### Claim 2 (depends on 1)

The production method of the electrode according to claim 1, wherein the binder polymer is a thermoplastic polymer; and wherein the thermal fusion bonding is performed at a thermal fusion bonding temperature T satisfying: Tb−10<T<Ta where Tb is a softening point of a polymer material of the conductive resin layer and Ta is a melting point of the binder polymer.

### Claim 3 (depends on 2)

The production method of the electrode according to claim 2, wherein the active material layer is formed on the resin layer by transferring or by applying a high viscosity precursor of the active material layer onto the resin layer, the high viscosity precursor having a viscosity in the range of 100 to 100,000 cps at 30 to 40° C.

### Claim 4 (depends on 1)

The production method of the electrode according to claim 1, wherein the binder polymer is a thermosetting polymer; and wherein the thermal fusion bonding is performed at a thermal fusion bonding temperature T′ satisfying: Tb′−10<T′ where Tb′ is a softening point of a polymer material of the conductive resin layer.

### Claim 5 (depends on 1)

The production method of the electrode according to claim 1, wherein thermally bonding the collector to the active material layer is performed at the thermal fusion bonding temperature that is higher than a softening point of the at least one inner resin layer.

### Claim 6

A production method of an electrode, comprising:
preparing a collector consisting of a laminated material of three or more conductive resin layers each containing a polymer material, the collector including outermost resin layers and at least one inner layer interposed between the outermost resin layers;
forming an electrode laminate by laminating an active material layer on the collector, the active material layer containing a binder polymer having a melting point, wherein the polymer material of each of the three or more conductive resin has a softening point lower than a melting point of the binder polymer; and wherein the polymer material of one of the outermost resin layers adjacent to the active material layer has a softening point lower than that of the polymer material of the at least one inner resin layer; and
thermal fusion bonding the conductive resin layer to the active material layer in the electrode laminate at a thermal fusion bonding temperature selected to fuse the polymer material without melting the binder polymer.