Manufacturing method for electrode

Abstract: A manufacturing method for electrode in which ultra fine particles of active material formed in gas by an evaporation method (1,2,3) are carried in gas flow (4) and blown (5) onto a surface of substrate (8), so that an electrode comprising a thin film of carbon material is formed on the surface of substrate (8). To form an electrode-electrolyte composite the substrate (8) is a film comprising a solid electrolyte. The electrode can be an anode or a cathode and can have an uniform thickness of under 10 microns. For an electrode-electrolyte there is good productivity, and adhesion of an ultra-thin electrode with the electrolyte is excellent.

Description: This invention relates to a manufacturing method for an electrode for use in a film type battery and a manufacturing method for an electrode-electrolyte composite. A conventional cathode for film type battery has been manufactured as a sheet-shaped thin film by mixing conductor, binder and positive active material. In this method, however, a thickness of the thin film has been dependent on the particle size and the charging rate of the positive active material. It has been hard to obtain a sub-micron particle size and it has been difficult to increase the charging rate, so that it has been not easy to obtain a thin film having a thickness of 10µm or less. Methods of utilizing lithium or lithium alloy for a anode have been proposed variously, but it has been difficult to obtain a thin film of uniform thickness composed of lithium. In a method for manufacturing a thin film by extruding lithium from a nozzle for example, a lower limit of thickness of the thin film has been 0.03 mm, below which the thickness is not uniform. In a method for obtaining thin films by rolling, a lower limit of thickness of the thin film has been 0.02 to 0.03 mm. Carbon electrodes have been manufactured as sheet-shaped thin films by mixing a carbon material and a binder. However, the thickness of the sheet is dependant on a charging rate of carbon material, and it has been difficult to obtain a thin film electrode having a thickness of 10µm or less. Thus, in the conventional methods it has been difficult to obtain an anode or a cathode composed of an ultra thin film having an uniform thickness of 10µm or lees, for example, with good productivity. Methods for manufacturing thin film electrodes by means of a vacuum coating method, sputtering method etc. have been proposed. In these methods, however, the film forming rate is small so that the method is suitable only for forming films of thickness less than several tens of nm. On the other hand, in order to improve the film forming rate, a method wherein ultra fine particles of metal are directly carried in gas flow to be deposited on a substrate at a high velocity has been proposed in JP-A-1/265450. However, this method has included such a disadvantage of incontinuous and inefficient film forming process. Obtaining active materials of multi-component systems by this method has provided bad productivity because of the expense of fine-particles of various metals and difficulty in mixing them uniformly. Moreover, it has been impossible to obtain active materials of multi-component systems having excellent property by this method. In recent years, study and development of secondary lithium batteries are flourishing. Using metallic lithium for the anode in the secondary lithium battery will cause troubles from the standpoint of deterioration of performance and safety accompanied by dendrite formation at time of charging. In order to overcome this problem, it has been proposed to use carbon capable of occlusion and emission of lithium as the anode material. In a lithium battery utilizing a normal lithium intercalation active material as the cathode and a carbon electrode as the anode, it is necessary to previously dope the lithium in the carbon electrode. For this reason, the carbon electrode has required a troublesome process ("doping process") before assembling a package. In order to eliminate the previous doping process for carbon electrodes it can be thought out that an active material having a structure reduced by lithium is synthesized to be used as the cathode active material. The manufacturing process can be simplified by this method. For example LiMn 2 0 4 , which is a spinel-related lithium manganese oxide compound, can be used as the cathode active material for a secondary lithium battery and can be synthesized easily. It is well known that the state of the cathode active material at the end of charging will change up to Li 2 Mn 2 0 4 when the battery is assembled using the above material together with a lithium-related anode material and discharged. Accordingly, if the spinel-related manganese compound expressed by the chemical formula of Li 2 Mn 2 0 4 can be synthesized, a secondary lithium battery can be composed by combining that compound and a carbon electrode which has not been doped. In the present situation, however, it requires further various studies to chemically synthesize the lithium reductant Li 2 Mn 2 0 4 , and a process of prior discharging becomes necessary to synthesize the reductant electro-chemically. In order to eliminate the previous doping process for carbon electrode, it can also be thought out to form a carbon electrode in which lithium has been doped previously. Further, the following literatures are known as the prior art: [1] "Surface Technology" 8 , 335,1987, M. Oda, 'Formation and Application of Ultra Fine particles by In-Gas Evaporation Method', [2] "Applied Physics" 54 , 687, 1985, C. Hayashi, 'Gas Deposition of Ultra Fine Particles', [3] "Japanese Journal of Applied Physics" 23 , L910, 1984, S. Kashu, E. Fuchita, T. Manabe, C. Hayashi, 'Deposition of Ultra Fine Particles Using a Gas Jet'. In one aspect, the invention provides a method of making a battery having a carbon electrode, in which the method of making the carbon electrode comprises pre-forming ultra-fine particles of carbon material mixing the previously prepared ultra-fine particles of carbon material with a gas flow and blowing said particles onto a substrate to form a thin film of carbon material thereon. Preferred properties of the carbon thin film are set out in claims 2 to 5. In a further aspect the invention provides a method of making an anode for a lithium battery comprising blowing ultra-fine particles of carbon material and ultra-fine particles of lithium simultaneously by gas flow onto a substrate surface to deposit carbon-lithium compound thereon, as well as a method of making a lithium battery having such an anode. Embodiments of the invention are now described with reference to the accompanying drawings, in which Figs. 1 and 2 are schematic views showing the basic components of a manufacturing device for use in the method described herein. Fig. 3 is a schematic view showing the basic elements of the manufacturing device as used in the specific example, and Fig. 4 is a graph showing the results of charge/discharge cycling tests for an electrode obtained in accordance with the specific example. Incidentally, it appears that the carbon electrode generally has a better volume energy efficiency with a decrease in porosity (an increase in charging density). To function as an electrode, however, the material of the electrode should properly contact the electrolyte so as to provide efficient transfer of ions through the interface between them. Therefore, it is required to use an electrode having a proper porosity, and the above-mentioned method will provide an electrode having a desired porosity by progressively adjusting the blowing velocity onto the substrate. The crystal of the formed carbon material has a pseudo-graphite structure having a spacing of at least 3.3. A perfect graphite structure means a structure in which two-dimensionally repeated perfect six-membered rings of carbon are stacked on one another in vertical direction, and its chemical composition is expressed by C. The distance between vertically stacked structures is called the spacing, and in a perfect graphite structure is 3.354; a value smaller than this can not exist. On the contrary, when -H group or other various groups are attached to carbon atom, the spacing will become larger than that of perfect graphite. Giving consideration to an application of this structure to a battery material using lithium ion as its medium, for instance, perfect graphite is not preferable for a graphitic structure having a lithium occlusion/emission ability; rather a structure having a larger spacing such as 3.4 to 3.5 is used. However, a retention ability of doped lithium lowers when the spacing becomes too large, and the graphitic substance can not maintain its structure when the spacing becomes further larger. A structure having a spacing ranging from 3.42 to 3.47x10 -10 m will develop the most excellent electro-chemical characteristic for a battery. On the other hand, crystal size (Lc) is expressed by multiplying (magnitude of spacing) by (stacked times of annular structure of graphite). When the stacked times are less than three, the crystal can not be set up and is not suitable for the battery material. Consequently, electrode Lc smaller than 10 -9 m can not be formed. Further, when Lc becomes larger, a crystallizability will become higher and an electro-chemical resersivility will become larger. However, when Lc exceeds 10 -7 m the material will become brittle and apt to rupture and will be peeled off by repeated cycles of charge/discharge. Therefore, a material having Lc of over 10 -7 m is not suitable for the electrode, so that it is desirable to use a carbon electrode having Lc ranging from 1 to 100nm (10 to 1000 angstroms.) Carbon, graphite, acetylene black etc. are used for the above-mentioned carbon material. The aerosol method is one in which previously prepared ultra fine particles of carbon material are mixed and carried by gas flow, as shown by Fig. 1. In Fig. 1, 31 is an evaporation chamber, 32 is a lead-in pipe which leads carrier gas into the evaporation chamber, 31, 34 is a delivery pipe and 41 is the previously prepared ultra fine particles of carbon material. There is a method in which organic substance becoming raw material for obtaining carbon material is supplied and subjected to treatment, such as heating, so as to form ultra fine particles of carbon material having a structure effective for the electrode, and the ultra fine particles are mixed and carried by gas flow in succession, as shown by Fig. 2. In Fig. 2, parts having symbols same as Fig. 1 represent corresponding parts, 42 is an organic substance and 43 is a heater. Description of a specific embodiment This embodiment relates to a manufacturing method for an anode for a lithium battery. Fig. 3 is the schematic view of a manufacturing device. In the figure, 50 is a spray chamber, 60 is an aerosol container, 70 is an evaporation chamber, 71 is a lead-in pipe for leading in carrier gas, 72 is a delivery pipe, 73 is a pump, 74 is a crucible, 75 is a heater, 76 is a heater power supply, 61 is a lead-in pipe for leading in carrier gas, 62 is a delivery pipe, 51 is a first nozzle at tip end of the delivery pipe 62, 52 is a second nozzle at tip end of the delivery pipe 72, 53 is a gas lead-in pipe, and 54 is a substrate. Tip end sizes of the both nozzles 51 & 52 are 0.8mm x 10µm. The nozzles 51 & 52 are both so installed as to blow gas onto the same spot of substrate. Pitch-related carbon material in a form of ultra fine particles having sizes of 0.1 to 0.3µm was put in the aerosol container 60 and a commercial metallic lithium was put in the crucible 74. Helium gas was led from the lead-in pipe 61 into the aerosol container 60, ultra fine particles 63 were carried by helium gas to be led through the delivery pipe 62 to the first nozzle 51, and then blow onto the surface of the substrate 54. At the same time, lithium 77 in the crucible 74 was converted into vapor by being heated, molten and vaporized in the heater 75. Ultra fine particles of lithium composed of the vapor condensing to sizes of 0.1 to 0.3µm were carried by helium gas, which were led from the lead-in pipe 71, to be led through the delivery pipe 72 to the second nozzle 52, and then blown onto the surface of the substrate 54. The quantity of ultra fine particles blown in this instance from both the nozzles 51, 52 was regulated by adjusting pressures in the aerosol container 60 and the evaporation chamber 70. A black or gray deposit i.e. an electrode comprising carbon lithium having a width of 10 mm, a length of 10 mm and a thickness of 100 µm was formed on the surface of the thickness of 100 µm was formed on the surface of the substrate 54. This deposit is rigid because it was obtained by the gas deposition method. The electrode thus formed was taken out in an atmosphere of inert gas and its weight was measured. A part of it was subjected to chemical analysis, and the remainder used for investigation of electrode characteristic. Whether or not a carbon-lithium compound electrode desirable for a battery electrode has been obtained can be judged firstly by a voltage which is developed by the electrode in an organic electrolyte, and secondly by a quantity of electricity which can take out or take in (de-doping and doping) lithium electro-chemically from or to that electrode in the organic electrolyte. Formed electrode cut out to a size of 1 cm 2 was used as a working electrode, metallic lithium was used as a counter electrode, metallic lithium was also used as a reference electrode, and a solution in which lithium arsenate hexafluoride was dissolved in a mixture of propylenecarbonate and ethylene-carbonate was used as an electrolyte; so that an electro-chemical cell was assembled. A performance of single battery was evaluated by this cell. A potential difference between the reference electrode and active electrode was 0.003 V. First, a current was made to flow between the working electrode and the counter electrode (i.e. de-doping) while monitoring an electric potential of the working electrode by the reference electrode, the quantity of electricity flowing until an electric potential of the reference electrode became 1.000 V was measured, and thereby the capacity of the electrode was measured. The result was 244 mAh/g. Then, a cycle test repeating doping/dedoping was carried out. The doping was done by connecting the working electrode and counter electrode using a lead wire and allowed the working electrode to stand until its electric potential became 0 V. The de-doping capacity was measured in the same manner as above and its change accompanied by cycle number was measured, and the result as shown in Fig. 4 was obtained. A capacity of 226 mAh/g is maintained at 80 cycles. As an electrode for a lithium battery, this result is not inferior to the electrode produced by the known sheeting method. The electrode capacity was then converted into a value per volume and evaluated. Measurement of electrode thickness was made by observing its section using an electron microscope. A capacity of first was 346 mAh/cm 3 . Since the capacity for the known sheeting method is 270 to 280 mAh/cm 3 , it can be understood that the capacity per volume of the electrode produced by the foregoing method is improved by a large margin. A volume energy efficiency of the carbon-lithium compound electrode generally has a better volume energy efficiency with a decrease in porosity (an increase in charging density). In order to have it function as an electrode, however, it is required that the material of electrode should properly contact with the electrolyte so as to provide efficient occlusion and emission of ion in the electrolyte. When the porosity is too small, an electrode having a good electro-chemical efficiency can not be obtained because the contact area with the electrolyte is limited. Consequently, there exists an optimum valve for the porosity. The carbon electrode of prior art has generally been manufactured by the method sheeting the ultra fine particles of carbon using the binder, and its porosity has been 40 to 60%. According to the above-mentioned method, however, the porosity can be controlled at will. That is, the velocity blowing the ultra fine particles onto the surface of the substrate 54 can be adjusted consecutively by regulating the pressure difference between the evaporation chamber 70 and the spray chamber 50, and the porosity can thus be reduced to approx. 0%. As described above, the foregoing method is of a dry type and pure because it does not require the use of binder. Further, the ultra thin lithium battery having an excellent volume efficiency and an uniform thickness can be manufactured by the foregoing method with good productivity. Moreover, its assembly process can also be simplified.

Claims: A method of making a battery having carbon electrode in which the method of making the carbon electrode comprises pre-forming ultra-fine particles of carbon material mixing the previously prepared ultra-fine particles of carbon material with a gas flow and blowing said particles onto a substrate to form a thin film of carbon material thereon. A method according to claim 1 in which carbon crystals in the thin film have pseudo-graphite structure with layer spacing of more than 3.354 x 10 -10 m. A method according to claim 2 in which the layer spacing is in the range from 3.4 to 3.5 x 10 -10 m. A method according to claim 3 in which the layer spacing is in the range from 3.42 to 3.47 x 10 -10 m. A method according to any one of the preceding claims in which carbon crystals in the thin film are from 1 to 100nm in size. A method of making an anode for a lithium battery comprising blowing ultra-fine particles of carbon material and ultra-fine particles of lithium simultaneously by gas flow onto a substrate surface to deposit carbon-lithium compound thereon. A method according to any one of the preceding claims in which the carbon material used is selected from carbon, graphite, acetylene black and pitch-related carbon materials. A method according to any one of claims 1 to 7 in which the ultra-fine particles of carbon material are prepared by heating an organic substance. A method of making a lithium battery, in which an anode for the battery is made by a method as defined in claim 6.

Inventors: IZUCHI SYUICHI, KATO SHIRO, MISHIMA HIROMISTU, NODA TOMOHIKO, TAKEUCHI KENICHI, YOSHIHISA YOUETSU, IZUCHI, SYUICHI, KATO, SHIRO, MISHIMA, HIROMISTU, NODA, TOMOHIKO, TAKEUCHI, KENICHI, YOSHIHISA, YOUETSU
Applicants: YUASA BATTERY CO LTD, YUASA CORPORATION
Application year: 1991
Main classification: H01M4
IPC codes: H01M4, H01M6, H01M10