CURRENT COLLECTOR FOR SECONDARY BATTERY AND METHOD FOR MANUFACTURING SAME

The present invention relates to a current collector for a secondary battery and a method of preparing the same, and more specifically, comprises a conductive substrate comprising a first metal; and a coating layer coated on a surface of the conductive substrate. The coating layer comprises a second metal, carbon (C), phosphorus (P), and oxygen (O), and the second metal is different from the first metal, and a first water contact angle (A) of a surface of the coating layer is 1° to 45°.

TECHNICAL FIELD

The present invention relates to a current collector for a secondary battery, a method of preparing the current collector, an electrode for a secondary battery comprising the current collector, and a secondary battery comprising the current collector.

BACKGROUND ART

Batteries, which generate electrical energy through physical or chemical reactions of substances and supply power to the outside, are used when AC power cannot be supplied to the building or when DC power is required, depending on the living environment surrounded by various electrical and electronic devices.

Among these batteries, primary and secondary batteries, which are chemical batteries utilizing chemical reactions, are commonly used. Primary batteries are consumable batteries that collectively refer to dry batteries. On the other hand, secondary batteries are rechargeable batteries in which oxidation/reduction processes can be repeated at the positive and negative electrodes. The battery is charged by the reduction reaction on the positive electrode through the current, and the battery is discharged by the oxidation reaction on the positive electrode. In secondary batteries, this type of charge-discharge is performed repeatedly.

Recently, lithium secondary batteries have been used in electric vehicles and power storage devices. To ensure the stability of lithium secondary batteries, the performance of lead tabs, pouch packaging materials, and current collectors is being improved. In particular, various studies are being conducted to prevent corrosion, improve cohesion, and improve conductivity with electrode active materials for copper films, nickel-plated copper films, and aluminum films used as collectors.

DISCLOSURE

Technical Problem

The cohesion between the current collector and the active material layer of the secondary battery electrode has a great influence on the secondary battery performance, such as the battery life. The wettability of the surface of the current collector is a major factor in the cohesion between the current collector and the active material layer. Therefore, when producing aluminum foil used as a conductive substrate for a secondary battery current collector, to increase the wettability of the surface, a rolling process is performed on aluminum, followed by a degreasing process (annealing and/or washing). Since the degreasing process requires a lot of energy and time and generates wastewater, etc., a degreased substrate that has undergone the degreasing process is more expensive than a non-degreased substrate that has not undergone the degreasing process. Therefore, there is a problem of low economic efficiency when manufacturing electrodes and secondary batteries using the degreased substrate.

In order to solve the above problems, the present invention provides a current collector that has improved wettability even when using a non-degreased substrate.

Another problem that the present invention seeks to solve is to provide an electrode for a secondary battery with improved cohesion and conductivity with an active material layer by using the current collector.

Another problem that the present invention seeks to solve is to provide a secondary battery which can maintain cohesion between the current collector and the active material layer during charging and discharging and has improved performance.

Technical Solution

According to a concept of the present invention, a current collector for a secondary battery may comprise a conductive substrate comprising a first metal; and a coating layer coated on a surface of the conductive substrate. The coating layer may comprise a second metal, carbon (C), phosphorus (P), and oxygen (O), and the second metal may be different from the first metal, and a first water contact angle (A) of the surface of the coating layer may be 1° to 45°.

According to another concept of the present invention, an electrode for a secondary battery may comprise a current collector for a secondary battery; and an active material layer on the current collector.

According to another concept of the present invention, a secondary battery may comprise a cathode, an anode, a separator between the cathode and the anode, and an electrolyte. At least one of the cathode and the anode may comprise the electrode for a secondary battery.

According to another concept of the present invention, a current collector for a secondary battery may comprise a conductive substrate comprising a first metal; and a coating layer coated on a surface of the conductive substrate. The coating layer may comprise a second metal, carbon (C), phosphorus (P), and oxygen (O), and the second metal may be different from the first metal, the surface of the coating layer may have a first water contact angle (A), the surface of the conductive substrate may have a second water contact angle (B), and the difference (B−A) between the second water contact angle (B) and the first water contact angle (A) may be 10° to 140°.

A method of preparing a current collector for a secondary battery according to another concept of the present invention may comprise adding a metal compound, an inorganic acid, an organic acid, and a first conductive agent into a first solvent to prepare a coating composition; and coating the coating composition on a surface of a conductive substrate to form a coating layer. The conductive substrate may comprise a first metal, the second metal of the metal compound may be different from the first metal, and the surface of the coating layer may have a first water contact angle (A) of 1° to 45°.

Advantageous Effects

The current collector for a secondary battery according to the present invention can improve wettability through a coating layer on its surface. The current collector with improved wettability can have improved cohesion force and conductivity with an electrode active material. The current collector of the present invention can have high wettability through the coating layer even when a non-degreased substrate is used. Therefore, an electrode for a secondary battery with improved economic efficiency and performance can be provided.

The secondary battery according to the present invention can reduce the detachment of the active material layer from the current collector during charging and discharging. In addition, the cycle characteristics of the secondary battery can be improved due to the high conductivity of the electrode.

BEST MODE

In order to fully understand the configuration and effect of the present invention, preferred embodiments of the present invention will be described with reference to the attached drawings. However, the present invention is not limited to the embodiments disclosed below, but can be implemented in various forms and can be changed in various ways. However, these examples are provided so that the present invention may be fully disclosed through the description thereof, and a person having ordinary skill in the art to which the present invention pertains may fully understand the scope of the invention.

In this specification, when a certain component is mentioned as being on another component, it means that it can be formed directly on the other component or a third component can be interposed between them. In addition, in the drawings, the thickness of the components is exaggerated for effective explanation of the technical contents. Parts indicated by the same reference numerals throughout the specification represent the same components.

The embodiments described herein will be described with reference to cross-sectional and/or plan views, which are ideal exemplary drawings of the present invention. In the drawings, the thicknesses of the layers and regions are exaggerated for the effective explanation of the technical contents. Accordingly, the regions illustrated in the drawings have a schematic nature, and the shapes of the regions illustrated in the drawings are intended to illustrate specific forms of regions of the device and are not intended to limit the scope of the invention. Although the terms first, second, third, etc. have been used in various embodiments of the present invention to describe various components, these components should not be limited by these terms. These terms are only used to distinguish one component from another. The embodiments described and illustrated herein also include complementary embodiments thereof.

The terminology used herein is intended to describe embodiments and is not intended to limit the present invention. In the present invention, the singular includes the plural unless specifically stated otherwise. The terms “comprise(s)” and/or “comprising” as used in the present invention do not exclude the presence or addition of one or more other components.

FIG.1is a conceptual diagram briefly illustrating a lithium secondary battery according to embodiments of the present invention. Referring toFIG.1, the lithium secondary battery may include an anode100, a cathode200, an electrolyte300, and a separator400.

The anode100and the cathode200may be spaced apart from each other with the separator400interposed therebetween. The separator400may be placed between the anode100and the cathode200. The anode100, the cathode200, and the separator400may be in contact with the electrolyte300. The anode100, the cathode200, and the separator400may be impregnated into the electrolyte300.

The electrolyte300may be a medium for transferring lithium ions between the anode100and the cathode200. In the electrolyte300, the lithium ions may pass through the separator400and move toward the anode100or the cathode200.

Each of the anode100and the cathode200may include a current collector (COL) and an active material layer (AML) on the current collector (COL). The active material layer (AML) of the cathode200may include a cathode active material which is a source of lithium ions. The cathode active material may include two or more transition metals, as a lithium transition metal oxide. For example, the cathode active material may include a layered compound such as lithium cobalt oxide (LiCoO2) and lithium nickel oxide (LiNiO2) substituted with one or more transition metals; lithium manganese oxide substituted with one or more transition metals; lithium nickel-based oxide represented by the chemical formula LiNi1-yMyO2(wherein, M includes at least one element selected from the group consisting of Co, Mn, Al, Cu, Fe, Mg, B, Cr, Zn, and Ga, and 0.01≤y≤0.7); a lithium nickel cobalt manganese composite oxide represented by the chemical formula Li1+zNibMncCo1-(b+c+d)MdO(2-e)Ae(wherein, −0.5≤z≤0.5, 0.1≤b≤0.8, 0.1≤c≤0.8, 0≤d≤0.2, 0≤e≤0.2, b+c+d<1, M is Al, Mg, Cr, Ti, Si, or Y, and A is F, P, or Cl); or an olivine-based lithium metal phosphate represented by the chemical formula Li1+xM1-yM′yPO4-zXz(wherein, M is a transition metal such as Fe, Mn, Co or Ni, M′ is Al, Mg or Ti, X is F, S or N, and −0.5≤x≤+0.5, 0≤y≤0.5, 0≤z≤0.1). In one embodiment, the cathode active material may include primary particles and/or secondary particles in which primary particles are aggregated.

The active material layer (AML) of the anode (100) may include an anode active material. The anode active material may include at least one selected from the group consisting of carbon material, lithium metal or a lithium metal compound, silicon or a silicon compound, and tin or a tin compound. A metal oxide such as TiO2or SnO2having a potential of less than 2 V may also be used as the anode active material. The carbon material may include low-crystalline carbon and/or high-crystalline carbon.

The separator400may include a porous polymer film manufactured from a polyolefin-based polymer such as an ethylene homopolymer, a propylene homopolymer, an ethylene/butene copolymer, an ethylene/hexene copolymer, or an ethylene/methacrylate copolymer. The separator400may include a single porous polymer film or a laminate of a plurality of porous polymer films. In another embodiment of the present invention, the separator400may include a conventional porous nonwoven fabric, for example, a high-melting point glass fiber or a polyethylene terephthalate fiber.

In one embodiment of the present invention, the electrolyte300may be used by dissolving it in an organic solvent. The organic solvent may include propylene carbonate (PC), ethylene carbonate (EC), diethyl carbonate (DEC), dimethyl carbonate (DMC), dipropyl carbonate (DPC), dimethyl sulfoxide, acetonitrile, dimethoxyethane, diethoxyethane, tetrahydrofuran, N-methyl-2-pyrrolidone (NMP), ethyl methyl carbonate (EMC), γ-butyrolactone, or a mixture thereof.

The case of the secondary battery according to the embodiments of the present invention may adopt a type commonly used in the relevant technical field, and there is no limitation on the external shape according to the purpose of the battery. For example, the case of the secondary battery may include a cylindrical shape, a square shape, a pouch shape, a coin shape, etc.

FIG.2is a cross-sectional view schematically illustrating a current collector for a secondary battery according to embodiments of the present invention.

Referring toFIG.2, the current collector (COL) for a secondary battery may include a conductive substrate (MEL) and a coating layer (CTL) on the conductive substrate (MEL). The coating layer (CTL) may be a thin film coated on the surface (SUF) of the conductive substrate (MEL). The coating layer (CTL) may directly cover the surface (SUF) of the conductive substrate (MEL).

The conductive substrate (MEL) may include a first metal. For example, the first metal may be one or an alloy of two or more selected from the group consisting of aluminum, copper, stainless steel, nickel-plated copper, nickel, titanium, palladium, an iron alloy (e.g., an iron-nickel alloy), and an aluminum alloy (e.g., an aluminum-cadmium alloy), In another embodiment, the conductive substrate (MEL) may include calcined carbon. The conductive substrate (MEL) according to the present invention may be used without any particular limitation as long as it is a conductive material.

The conductive substrate (MEL) according to the present invention may use at least one of a degreased substrate that has undergone a rolling process and a degreasing process and a non-degreased substrate that has not undergone a degreasing process without limitation. The non-degreased substrate may refer to a metal substrate (e.g., a non-degreased aluminum substrate) that has undergone only a rolling process without a degreasing process. Rolling oil may remain on the surface of the non-degreased substrate. The conductive substrate (MEL) may include a metal substrate (e.g., a copper substrate or an iron alloy substrate) produced through an electrodeposition process rather than a rolling process.

It may be more preferable to use a non-degreased substrate as the conductive substrate (MEL) in order to improve the economic efficiency of the current collector. For example, the conductive substrate (MEL) may include a non-degreased aluminum substrate. The conductive substrate (MEL) may have a form such as a film, sheet, foil, mesh, net, porous body, foam, or non-woven fabric.

The coating layer (CTL) can improve the wettability of the surface of the current collector (COL). As a result, the coating layer (CTL) can improve the cohesion force between the active material layer (AML) and the current collector (COL) described inFIG.1. By improving the cohesion force between the active material layer (AML) and the current collector (COL), the conductivity of the electrode (100or200) can be increased and the internal resistance of the electrode (100or200) can be reduced. As a result, the current collector (COL) for a secondary battery according to the present invention can improve the life stability and battery characteristics of the secondary battery.

The coating layer (CTL) can include a second metal, carbon (C), phosphorus (P), and oxygen (O). The second metal can be different from the first metal of the conductive substrate (MEL). The second metal may include at least one selected from the group consisting of chromium (Cr), iron (Fe), cobalt (Co), manganese (Mn), nickel (Ni), zirconium (Zr), and titanium (Ti). For example, the second metal may be chromium (Cr).

The second metal may improve the corrosion resistance of the current collector (COL). Carbon (C) may improve the conductivity of the coating layer (CTL). Phosphorus (P) may form a phosphoric acid film on the surface (SUF) of the conductive substrate (MEL). The thickness of the coating layer (CTL) may be 10 nm to 5 μm. More specifically, the thickness of the coating layer (CTL) may be 100 nm to 3 μm.

When performing elemental analysis on the surface of the current collector (COL) using an energy dispersive spectrometer (EDX), the first metal, the second metal, carbon (C), phosphorus (P), and oxygen (O) may be detected. The first metal may be derived from the conductive substrate (MEL). Since the coating layer (CTL) is formed with a thin thickness of 5 μm or less, the first metal in the conductive substrate (MEL) may be detected as a result of EDX analysis. The second metal, carbon (C), phosphorus (P), and oxygen (O) may be elements constituting the coating layer (CTL). In other words, the coating layer (CTL) may include the second metal, carbon (C), phosphorus (P), and oxygen (O).

As a result of elemental analysis of the surface of the current collector (COL), the atomic fraction of the first metal may be greater than the sum of the atomic fractions of the remaining elements. For example, the first metal may have 40 at % to 90 at %, and the remaining elements (the second metal, carbon (C), phosphorus (P), and oxygen (O)) excluding the first metal may have 10 at % to 60 at %.

However, the current collector (COL) according to the present invention may have a relatively small atomic fraction of the first metal due to the coating layer (CTL) on the conductive substrate (MEL). More specifically, in the case of the conductive substrate (MEL) in which the coating layer (CTL) is omitted, the atomic fraction of the first metal may be detected to be greater than 90 at %. However, in the case of the current collector (COL) of the present invention, the atomic fraction of the first metal may be detected to be less than 90 at % due to the presence of the coating layer (CTL).

Hereinafter, the atomic fractions of the second metal, carbon (C), phosphorus (P), and oxygen (O), which constitute the coating layer (CTL) excluding the first metal, will be described. The atomic fraction of the second metal with respect to the total number of atoms of the second metal, carbon (C), phosphorus (P), and oxygen (O) may be 0.3 at % to 1 at %. The atomic fraction of carbon (C) with respect to the total number of atoms may be 5 at % to 25 at %. The atomic fraction of phosphorus (P) relative to the total number of atoms above may be 10 at % to 25 at %. Oxygen (O) may occupy the remaining atomic fraction.

In one embodiment of the present invention, the atomic fraction of phosphorus (P) may be greater than the atomic fraction of the second metal. The atomic fraction of carbon (C) may be greater than the atomic fraction of phosphorus (P). The atomic fraction of oxygen (O) may be greater than the atomic fraction of carbon (C). However, the content relationship between the components of the present invention is not limited as above.

The ratio of the atomic number of carbon (C) relative to the atomic number of the second metal may be 10 to 50. The ratio of the atomic number of phosphorus (P) relative to the atomic number of the second metal may be 15 to 35. The ratio of the atomic number of oxygen (O) relative to the atomic number of the second metal may be 85 to 150.

The coating layer (CTL) can improve the wettability of the surface of the current collector (COL) by including a second metal, carbon (C), phosphorus (P), and oxygen (O) in the ratios described above.

FIG.3Ashows a cross-sectional view for explaining the water contact angle of the surface of the collector according to embodiments of the present invention.FIG.3Bshows a cross-sectional view for explaining the water contact angle of the surface of the conductive substrate.

Referring toFIG.3A, a water droplet (DPL) can be provided on the surface (SUF′) of the collector (COL). The angle between the edge of the water droplet (DPL) and the surface (SUF′) of the collector (COL) can be obtained as the first water contact angle (A). The water contact angle described in the present invention can be obtained through a contact angle measuring device, for example, Phoenix 300.

The first water contact angle (A) of the surface (SUF′) of the collector (COL) according to the present invention can be 1° to 45°. More specifically, the first water contact angle (A) can be 3° to 30°. In other words, the wettability of the collector (COL) according to the present invention can be very high. This can be easily confirmed by the profile in which the water droplet (DPL) is widely spread on the surface (SUF′) of the current collector (COL).

Referring toFIG.3B, a water droplet (DPL) can be provided on the surface (SUF) of the conductive substrate (MEL) from which the coating layer (CTL) is omitted. The angle between the edge of the water droplet (DPL) and the surface (SUF) of the conductive substrate (MEL) can be obtained as the second water contact angle (B). The second water contact angle (B) of the surface (SUF) of the conductive substrate (MEL) can be 50° to 140°. In particular, in the case of a non-degreased substrate in which rolling oil remains, the second water contact angle (B) can be even larger. In other words, when the conductive substrate (MEL) from which the coating layer (CTL) is omitted is used as the current collector (COL), the wettability can be low. This can also be easily confirmed by the profile in which the water droplet (DPL) maintains a hemispherical shape (or spherical shape) on the surface (SUF) of the conductive substrate (MEL).

In one embodiment, the difference (B−A) between the second water contact angle (B) of the surface (SUF) of the conductive substrate (MEL) and the first water contact angle (A) of the surface (SUF′) of the current collector (COL) may be 10° to 140°. More specifically, the difference (B−A) may be 20° to 100°. The larger the difference (B−A), the more the wettability of the current collector (COL) according to the present invention is greatly improved.

The first water contact angle (A) of the surface (SUF′) of the current collector (COL) may be obtained for the current collector (COL) including the coating layer (CTL) according to the present invention. The second water contact angle (B) of the surface (SUF) of the conductive substrate (MEL) can be obtained for the conductive substrate (MEL) with the coating layer (CTL) omitted (i.e., the degreasing substrate or the non-degreased substrate). The conductive substrate (MEL) used for the measurement of the second water contact angle (B) inFIG.3Bis the same as the conductive substrate (MEL) used for the current collector (COL) ofFIG.3A.

The high wettability of the surface of the current collector (COL) according to the present invention can provide high cohesion force between the current collector (COL) and the active material layer (AML) described below. In addition, even if a non-degreased substrate with residual rolling oil is used as the conductive substrate (MEL), the cohesion force and conductivity between the current collector (COL) and the active material layer (AML) can be improved by having high wettability through the coating layer (CTL).

In one embodiment of the present invention, the above-described current collector (COL) can be used as an electrode of a lithium secondary battery. However, the present invention is not limited thereto, and the above-described current collector (COL) can be utilized as an electrode of various secondary batteries, such as a magnesium secondary battery or a sodium secondary battery.

FIG.4is a cross-sectional view schematically illustrating a secondary battery electrode according to embodiments of the present invention.

Referring toFIG.4, the secondary battery electrode may be the anode100or the cathode200ofFIG.1. The secondary battery electrode may include a current collector (COL) and an active material layer (AML) on the current collector (COL). The current collector (COL) may be the same as described above with reference toFIG.2.

The active material layer (AML) may include a binder, a second conductive agent, and an electrode active material. The electrode active material may be the anode active material described above when the secondary battery electrode ofFIG.4is the anode100. The electrode active material may be the cathode active material described above when the secondary battery electrode ofFIG.4is the cathode200. The electrode active material may be included in an amount of 80 wt % to 99 wt %, more specifically, 85 wt % to 98 wt %, based on the total weight of the active material layer (AML).

The second conductive agent may impart conductivity to the active material layer (AML). The second conductive agent may include at least one of a carbon-based material (e.g., graphite, carbon black, acetylene black, Ketjen black, channel black, furnace black, lamp black, summer black, or carbon fiber), a metal powder, a metal fiber, a conductive whisker, a conductive metal oxide, a conductive polymer, and a combination thereof. The second conductive agent may be included in an amount of 1 wt % to 30 wt % based on the total weight of the active material layer (AML).

The binder may improve cohesion between the electrode active material and the current collector (COL). For example, the binder may include at least one of polyvinylidene fluoride (PVDF), vinylidene fluoride-hexafluoropropylene copolymer (PVDF-co-HFP), polyvinyl alcohol, polyacrylonitrile, carboxymethyl cellulose (CMC), starch, hydroxypropyl cellulose, regenerated cellulose, polyvinyl pyrrolidone, polytetrafluoroethylene, polyethylene, polypropylene, ethylene-propylene-diene polymer (EPDM), sulfonated-EPDM, styrene butadiene rubber (SBR), fluoroelastomer, and combinations thereof. The binder may be included in an amount of 1 wt % to 30 wt % with respect to the total weight of the active material layer (AML).

FIG.5AandFIG.5Bare conceptual diagrams for schematically explaining a method for manufacturing a current collector for a secondary battery according to embodiments of the present invention.

Referring toFIG.5A, a coating composition (CCP) may be prepared. The coating composition (CCP) may include a metal compound, an inorganic acid, an organic acid, and a first conductive agent.

The metal compound may comprise at least one selected from the group consisting of: chromium potassium alum (KCr(SO4)2·12H2O), chromium chloride (CrCl3), chromium fluoride (CrF3), chromium hydroxide (Cr(OH)3), chromium nitrate (Cr(NO3)3), chromium phosphate (CrPO4), iron chromate (FeCr2O4) and hydrates thereof; cobalt chloride (CoCl2), cobalt acetate (Co(CH3COO)2·4H2O), cobalt sulfate (CoSO4), zinc sulfate (ZnSO4), manganese sulfate (MnSO4), nickel sulfate (NiSO4) and hydrates thereof; zirconium phosphate (Zr(HPO4)2), zirconium sulfate (Zr(SO4)2), zirconium nitrate (ZrO(NO3)2), zirconium hydroxide (Zr(OH)4); zirconium fluoride (H2ZrF6) and its soluble salts (Na2ZrF6, K2ZrF6, Zr(NH4)2F6); and titanium dioxide (TiO2).

The inorganic acid may include at least one selected from the group consisting of nitric acid (HNO3), sulfuric acid (H2SO4), phosphoric acid (H3PO4), boric acid (H3BO3), carbonic acid (H2CO3), and hydrogen halides (HI, HBr, HCl, and HF).

The organic acid may include a compound represented by R(COOH)n. The R may be an organic group, a hydroxyl group, or hydrogen bonded to carbon by a single bond or a double bond. The organic group may include an aliphatic group having 1 to 10 carbon atoms or an aromatic group having 1 to 10 carbon atoms. The n represents the number of carboxyl groups and may be an integer greater than or equal to 1. More specifically, the n may be an integer between 1 and 10.

The first conductive agent may include at least one selected from the group consisting of natural graphite, artificial graphite, carbon black, acetylene black, Ketjen black, channel black, furnace black, lamp black, summer black, graphene, and carbon fiber.

Preparing the coating composition (CCP) may include mixing the metal compound, the inorganic acid, the organic acid, and the first conductive agent in a first solvent. The metal compound may be added in an amount of 0.5 to 10 parts by weight, more specifically, 1 to 5 parts by weight, based on 100 parts by weight of the coating composition (CCP). The inorganic acid may be added in an amount of 0.05 to 10 parts by weight, more specifically 0.1 to 5 parts by weight, based on 100 parts by weight of the coating composition (CCP). The organic acid may be added in an amount of 1 to 20 parts by weight, more specifically 2 to 10 parts by weight, based on 100 parts by weight of the coating composition (CCP). The first conductive agent may be added in an amount of 0.01 to 5 parts by weight, more specifically 0.05 to 3 parts by weight, based on 100 parts by weight of the coating composition (CCP).

Referring toFIG.5B, a coating layer (CTL) may be formed by coating the coating composition (CCP) on a conductive substrate (MEL). The conductive substrate (MEL) may include at least one of the degreased substrate and the non-degreased substrate described above. More specifically, a non-degreased substrate may be used as the conductive substrate (MEL) to improve cost efficiency.

The coating composition (CCP) can be coated on the conductive substrate (MEL) by using spin coating, bar coating, gravure coating, roll coating, blade coating, slide die coating or dipping coating. The coating layer (CTL) can be formed to a thickness of 10 nm to 5 μm.

A drying process can be performed on the coating layer (CTL). The drying process can use an oven or hot air, and is not particularly limited. The drying process can be performed at a temperature of 80° C. to 300° C., more specifically 100° C. to 200° C., for 5 seconds to 1 hour, more specifically 5 seconds to 30 minutes. The conductive substrate (MEL) and the dried coating layer (CTL) can form a current collector (COL) ofFIG.2.

Hereinafter, a method for manufacturing a secondary battery electrode using a previously manufactured current collector (COL) will be described. An active material layer (AML) can be formed on a coating layer (CTL). Specifically, an electrode active material, a binder, and a second conductive agent can be dissolved or dispersed in a second solvent to manufacture a mixture. After applying the mixture on a current collector (COL), drying and rolling can be performed to manufacture a secondary battery electrode.

The second solvent can be a solvent generally used in the relevant technical field, and can include, for example, at least one of dimethyl sulfoxide (DMSO), isopropyl alcohol, N-methylpyrrolidone (NMP), acetone, water, and a combination thereof. The second solvent can be removed through the drying process.

In another embodiment, the mixture can be cast on a separate support to manufacture a film. The secondary battery electrode can be manufactured by laminating the film on a current collector (COL).

The electrode for a secondary battery according to the present invention can use a current collector formed by coating a coating composition (CCP) including a metal compound, an inorganic acid, an organic acid, and a first conductive agent on a conductive substrate (MEL). That is, the electrode for a secondary battery of the present invention can form an active material layer (AML) on a coating layer (CTL) rather than directly forming an active material layer on a conductive substrate such as aluminum. As a result, the interfacial cohesion between the current collector (COL) and the electrode active material can be improved. In addition, the detachment of the active material layer (AML) from the current collector (COL) can be prevented during charging and discharging of the secondary battery, and the performance of the secondary battery can be further improved due to the high conductivity of the electrode.

Example 1: Preparation of Surface-Coated Current Collector

Potassium chromium alum (KCr(SO4)2·12H2O) of 2 parts by weight was dissolved in 92.5 parts by weight of distilled water to prepare a solution, and then 0.5 parts by weight of phosphoric acid (OCI company, 85 wt %) was added. Then, 4.8 parts by weight of citric acid and 0.2 parts by weight of acetylene black (Lion corporation, EC 300J) were added to prepare a 100 parts by weight coating solution composition.

The coating composition manufactured in the above step 1 was coated on a non-degreased aluminum foil (thickness 12 μm) as a conductive substrate using a bar coating method, and then dried at 180° C. for 10 seconds. The thickness of the coating layer after drying was approximately 0.3 μm.

Comparative Example 1

A current collector made only of non-degreased aluminum foil without the coating layer of Example 1 was prepared.

Comparative Example 2

A current collector made only of degreased aluminum foil without the coating layer of Example 1 was prepared.

Example 2: Preparation of Cathode for Secondary Battery

LiNi0.6Mn0.2Co0.2O2of 92 parts by weight as a cathode active material, 4 parts by weight of acetylene black as a conductive material, and 4 parts by weight of polyvinylidene fluoride as a binder were mixed. The mixture was dispersed in N-methylpyrrolidone (NMP) to prepare a cathode active material slurry. The cathode active material slurry was applied on the coating layer of the current collector prepared in Example 1, dried, and then a roll press process was performed to prepare a cathode.

Comparative Example 3

A cathode was manufactured in the same manner as in Example 2, except that the current collector of Comparative Example 1 was used.

Comparative Example 4

A cathode was manufactured in the same manner as in Example 2, except that the current collector of Comparative Example 2 was used.

Example 3: Preparation of Lithium Secondary Battery

Carbon powder of 96.3 parts by weight as an anode active material, 1.0 parts by weight of acetylene black as a conductive material, and 1.5 parts by weight and 1.2 parts by weight of SBR and carboxymethyl cellulose (CMC) as a binder were mixed. The mixture was added to an NMP solvent to prepare an anode active material slurry. The negative active material slurry was applied to a copper (Cu) thin film as a current collector with a thickness of 10 μm, dried, and then roll pressed to manufacture an anode.

Ethylene carbonate (EC), dimethyl carbonate (DMC), and diethyl carbonate (DEC) were mixed in a volume ratio of 1:1:1 to manufacture a solvent. LiPF6was added to the solvent to prepare a 1M LiPF6non-aqueous electrolyte.

<Preparation of Lithium Secondary Battery>

After interposing a mixed separator of polyethylene and polypropylene between the cathode of Example 2 and the anode, a pouch-type battery was manufactured using a conventional method. The non-aqueous electrolyte was injected into the pouch to prepare a lithium secondary battery.

Comparative Example 5

A lithium secondary battery was prepared using the same method as Example 3, except that the cathode of Comparative Example 4 was used.

Experimental Example

The surface of the collector of Example 1 was analyzed using a scanning electron microscope (SEM), and the results are shown inFIG.6. The surface of the collector of Comparative Example 2 was analyzed using a scanning electron microscope (SEM), and the results are shown inFIG.7.

The water contact angles of the collector of Example 1, the collector of Comparative Example 1, and the collector of Comparative Example 2 were measured using Phoenix 300. The measurements were taken at two different surface areas and the average value was obtained. The results are shown in Table 1 below.

The measurement results of the water contact angle of the collector of Example 1 are shown inFIG.8. The measurement results of the water contact angle of the collector of Comparative Example 1 are shown inFIG.9. The measurement results of the water contact angle of the collector of Comparative Example 2 are shown inFIG.10.

As shown in the Table 1, it can be confirmed that the current collector of Example 1 has a very small average water contact angle of about 15°. On the other hand, the average water contact angle of Comparative Example 1 is very large, close to about 90°, and the average water contact angle of Comparative Example 2, in which a degreased substrate is used, is also very large compared to Example 1. The current collector including the coating layer according to the present invention can have greatly improved wettability compared to the current collector without the coating layer.

Each of the electrodes of Example 2, Comparative Example 3, and Comparative Example 4 was stamped into 15×100 mm. A tape was attached to the coating surface of the stamped electrode to manufacture a specimen. The force applied when the manufactured specimen was peeled off at a 180° angle was measured using a UTM cohesion force meter.

<Measurement of Conductivity of Cathode>

The conductivity of each of the electrodes of Example 2, Comparative Example 3, and Comparative Example 4 was measured. The conductivity of the electrode was measured using a milliohmmeter by punching out electrodes of 50×50 mm in size.

Each of the electrodes of Example 2, Comparative Example 3, and Comparative Example 4 was immersed in an 85° C. electrolyte for 24 hours. Afterwards, the expansion and peeling of the electrodes were visually checked.

The results of the above experiments are shown in Table 2 below.

As shown in the Table 2, it can be confirmed that the electrode of Example 2 has excellent cohesion force and conductivity between the active material layer and the current collector. In addition, it can be confirmed that the electrode of Example 2 has high resistance to the electrolyte. It can be confirmed that the electrode of Example 2 has higher cohesion force and conductivity than Comparative Example 4, which was manufactured with an expensive degreasing substrate. In other words, the electrode for secondary batteries according to the embodiments of the present invention can exhibit excellent cohesion force and conductivity even at a low production cost.

<Cycle Characteristics of Secondary Batteries>

In order to determine the life characteristics of the lithium secondary batteries of Example 3 and Comparative Example 5, an electrochemical evaluation experiment was performed as follows.

The lithium secondary batteries of Example 3 and Comparative Example 5 were charged at a constant current of 4.2 V at a current density of 1.0 C at 45° C., and then charged at a constant voltage to a current density corresponding to 0.05 C. The constant current discharge was performed to 2.5 V at a current density corresponding to 1.0 C. This cycle was repeated 60 times. The cycle characteristics were measured as a percentage by comparing the capacity after 60 cycles with the initial capacity. The results are shown in Table 3 below.

Referring to Table 3, it can be confirmed that the secondary battery of Example 3 has superior cycle characteristics compared to the secondary battery of Comparative Example 5.