Abstract:
A method of manufacturing a battery is provided. The steps are as follows: forming an anode material and a cathode material on a first side and a second side of an isolation film, respectively, wherein the first side is opposite to the second side; forming a first protection layer on the first side of the isolation film; forming a first metal layer on the second side of the isolation film; forming a second protection layer on the first metal layer; removing the first protection layer; forming a second metal layer on the first side of the isolation film; and removing the second protection layer.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the priority benefit of Taiwan application Ser. No. 105101650, filed on Jan. 20, 2016. The entirety of the above-mentioned patent application is hereby incorporated by reference herein and made a part of this specification. 
       BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The invention relates to a method of manufacturing a battery. 
         [0004]    2. Description of the Related Art 
         [0005]    Lithium ion batteries have a high energy density without the memory effect. In addition, when the lithium ion batteries are not in used, the power lost is less. Therefore, the lithium-ion batteries are widely used in notebook computers, mobile phones, cameras, PDA, Bluetooth headsets and wireless  3 C products and other consumer electronics. 
         [0006]    Within the trend that the electronic products become lighter, smaller and thinner. The lithium ion batteries manufactured by the conventional methods which has large in size is no longer applicable. 
       BRIEF SUMMARY OF THE INVENTION 
       [0007]    According to one aspect of the disclosure, a method of manufacturing a battery, comprises: forming an anode material and a cathode material on a first side and a second side of an isolation film, respectively, wherein the first side is opposite to the second side; forming a first protection layer on the first side of the isolation film; forming a first metal layer on the second side of the isolation film; forming a second protection layer on the first metal layer; removing the first protection layer; forming a second metal layer on the first side of the isolation film; and removing the second protection layer. 
         [0008]    These and other features, aspects and advantages of the invention will become better understood with regard to the following embodiments and accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1A  to  FIG. 1E  shows cross-section diagrams of a process of manufacturing a battery in an embodiment. 
       
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0010]    To produce a battery by the method of the present application discloses,  FIG. 1A  to  FIG. 1E  shows cross-section diagrams step by step in an embodiment. 
         [0011]    Refer to  FIG. 1 , first, an isolation film is provided. The isolation film includes a first side S 1  and a second side S 2  opposite to each other. In an embodiment, the material of the isolation film  100  is made of an insulating material. In embodiments, the insulating material is made of polypropylene (PP), polyethylene (PE), or a combination thereof. In  FIG. 1A , the first side S 1  is under the second side S 2 , which is not limited herein. In another embodiment, the first side Si is above the second side S 2 . 
         [0012]    Then, the anode material  102  is formed at the first side S 1  of the isolation film  100 , and the cathode material  104  is formed on the second side S 2  of the isolation film  100 . In another embodiment, the cathode material  104  is formed at the first side S 1  of the isolation film  100 , and the anode material  102  is formed at the second side S 2  of the isolation film  100 , which is not limited herein. In an embodiment, the anode material  102  is lithium cobalt oxide, lithium nickel cobalt manganese oxide, lithium nickel titanium oxide, lithium manganese oxide, lithium phosphate iron oxide, lithium nickel manganese oxide, or combinations thereof The cathode material  104  is graphite composites, such as graphite, silicon carbide (SiC), silicon oxide (SiO), tin oxide (SnO), or combinations thereof. In an embodiment, the method of forming the anode material  102  and the cathode material  104  is a wet deposition method. The wet deposition method is, in an embodiment, a screen printing method, an embossing method, a relief printing method, a lithography method, or a combination thereof. 
         [0013]    In addition, in an embodiment, before the cathode material  102  and the cathode material  104  are formed, the sealing material is selectively formed on the surface of the insulation film  100  (including the surfaces of the first side S 1  and the second side S 2 ). The sealing material includes a ceramic material in an embodiment. The ceramic material includes titanium dioxide, silicon dioxide, or a combination thereof. The method of forming the sealing material includes a wet coating method such as a brush coating method, a spray coating method, a screen printing method, a lamination method, a roll coating method, a bonding method, or a combination thereof. The sealing material improves the mechanical properties of the insulation film  100  and prevents the short circuit of the battery due to the direct contact between the anode and the cathode under heat environment, which ensures the battery safety. 
         [0014]    The steps of forming the cathode material  102  and the cathode material  104  are continuous steps or non-continuous steps. In an embodiment, the cathode material  102  and the cathode material  104  are formed in a same process (that is the continuous step), which saves time. In an embodiment, the anode material  102  and the cathode material  104  are formed in different processes (that is the non-continuous step). In an embodiment, the anode material  102  is formed by one process, and the cathode material  104  is formed by another process. In an embodiment, the thickness of the anode material  102  and that of the cathode material  104  which are formed by the non-continuous step are uniform. 
         [0015]    Please refer to  FIG. 1A  and  FIG. 1B . A drying process is performed on the insulation film  100 . The drying process is, in an embodiment, performed at 25° C. to 90° C. Then, a bonding process is performed on the anode material  102  and the cathode material  104 . In an embodiment, the bonding process is performed with a double roller. After the bonding process, the thickness of the anode material  102   a  and the cathode material  104   a  is thinner. 
         [0016]    Please refer to  FIG. 1B  and  FIG. 1C . A first protective layer  106  is formed on the anode material  102   a.  In an embodiment, the material of the first protective layer  106  is a strippable material, such as a resin material. In an embodiment, the first protective layer  106  is formed by a wet deposition method, such as one or a combination of a brush coating method, a spray coating method, a printing method. 
         [0017]    Then, a first metal layer  108  (such as a cathode plate) is formed on the cathode material  104   a.  In an embodiment, the material of the first metal layer  108  is aluminum, copper, nickel, or combinations thereof. In an embodiment, the first metal layer  108  is formed by a dry deposition process or a wet deposition process. In an embodiment, the dry deposition method is a physical vapor deposition (PVD) method, an atomic layer deposition (ALD) method, or a combination thereof. In an embodiment, the wet deposition method is electroplating, chemical plating, or a combination thereof 
         [0018]    Please refer to  FIG. 1C  and  FIG. 1D . A second protective layer  110  is formed on the first metal layer  108 . In an embodiment, the material of the second protective layer  110  is a strippable material. In an embodiment, the strippable material is a resin material formed by a wet deposition method. In an embodiment, the wet deposition method is a brush coating method, a spray coating method, a printing method, or a combination thereof. 
         [0019]    Next, the first protective layer  106  is removed by stripping. Then, a second metal layer  112  (such as an anode plate) is formed on the anode material  102   a.  In an embodiment, the material of the second metal layer  112  is aluminum, copper, nickel, or combinations thereof. In an embodiment, the second metal layer  112  is formed by a dry deposition method or a wet deposition method. In an embodiment, the dry deposition method is a physical vapor deposition (PVD) method, an atomic layer deposition (ALD) method, or a combination thereof. In an embodiment, the wet deposition method is electroplating, chemical plating, or a combination thereof. 
         [0020]    In different types of batteries, the material of the first metal layer  108  and the second metal layer  112  are the same or different. In an embodiment, in a lithium ion battery, the anode plate material is aluminum, and the cathode plate material is copper, which is not limited herein. The oxidation potential difference should exist between the anode plate material and the cathode plate material. In the nickel-hydrogen battery, nickel is used as the anode plate material. 
         [0021]    Please refer to  FIG. 1D  and  FIG. 1E . The second protective layer  110  is stripped to form a partial battery structure  10  (as shown in  FIG. 1E ). In one embodiment, the thickness T 1  of the combination of the second metal layer  112  and the anode material  102   a  (such as anode plate) is between 0.3 μm and 2.0 μm. The thickness T 2  of the combination of the first metal layer  108  and the cathode material  104   a  (such as cathode plate) is between 0.3 μm and 2.0 μm. 
         [0022]    In an embodiment, the battery has a stacked partial battery structures  10 . The anode plate, the isolation film, the cathode plate, the isolation film, and the anode plate are sequentially stacked. The stacked partial battery structure  10  is immersed in an electrolyte solution. Therefore, when the thickness of an anode plate or a cathode plate in the embodiment becomes thin, the overall thickness of the stacked partial battery structure  10  is reduced. In an embodiment, the main component of the electrolyte solution is a conductive salt such as Lithium Hexafluorophosphate or Lithium Hexafluoroarsenate. 
         [0023]    In the embodiment in  FIG. 1C  to  FIG. 1E , the first metal layer  108  is formed on the cathode material  104   a  first. In another embodiment, the second metal layer  112  is formed on the anode material  102   a  before the first metal layer  108 . 
         [0024]    In sum, an anode material and a cathode material are formed on opposite sides of an isolation film. Next, a metal layer (used as an electrode plate) is formed on the anode material and the cathode material, respectively. the method of manufacturing the battery in embodiments further reduces the thickness of the electrode plate, and the battery production is improved. In addition, the method of manufacturing the battery is a continuous process or a one-time operation in different embodiments, which can further reduce the manufacturing cost. 
         [0025]    Although the invention includes been disclosed with reference to certain embodiments thereof, the disclosure is not for limiting the scope. Persons having ordinary skill in the art may make various modifications and changes without departing from the scope of the invention. Therefore, the scope of the appended claims should not be limited to the description of the embodiments described above.