Patent Publication Number: US-2023134433-A1

Title: Method of Producing Electrode and Electrode Production Apparatus

Description:
This nonprovisional application is based on Japanese Patent Application No. 2021-176370 filed on Oct. 28, 2021, with the Japan Patent Office, the entire contents of which are hereby incorporated by reference. 
     BACKGROUND 
     Field 
     The present disclosure relates to a method of producing an electrode, and to an electrode production apparatus. 
     Description of the Background Art 
     Japanese Patent Laying-Open No. 2018-192380 discloses an electrostatic powder coating device. 
     SUMMARY 
     Generally, an electrode is produced by forming an active material layer on a surface of a substrate. A method of forming an active material layer by electrostatic coating has been proposed. Into air, powder (an electrode material) is sprayed, for example. Corona discharge that occurs from a needle-shaped corona discharge electrode makes the powder be electrically charged. An electric field is formed to generate electrostatic force in a direction toward the substrate. Due to the electrostatic force, the powder is adhered onto the surface of the substrate, with the result that the active material layer can be formed. 
     However, a distance between the powder flying in air and the needle-shaped corona discharge electrode tends to be likely to be varied. When the distance between the powder (target to be charged) and the corona discharge electrode is varied, an amount of charges of the powder is also varied. The electrostatic force in the electric field is proportional to the amount of charges. Since the variation in the amount of charges is large, coating efficiency may be decreased. 
     It is an object of the present disclosure to reduce a variation in amount of charges. 
     Hereinafter, the technical configuration and effects of the present disclosure will be described. It should be noted that the action mechanism according to the present specification includes presumption. The action mechanism does not limit the technical scope of the present disclosure. 
     1. A method of producing an electrode includes the following (a) to (e). 
     (a) An aerosol including an active material, a binder and a gas is made. 
     (b) A film-like flow of the aerosol is formed. 
     (c) An electrically-charged region is formed by corona discharge. 
     (d) The film-like flow is allowed to pass through an electrically-charged region. 
     (e) The film-like flow is introduced into an electric field after passing through the electrically-charged region. 
     In the electric field, an active material layer is formed by adhering a solid component of the film-like flow onto a surface of a substrate by electrostatic force. 
     In the present disclosure, the film-like flow of the aerosol is formed. The film-like flow expands in the form of a film and flies. Since the charging target is planar, a variation in distance between the charging target and the corona discharge electrode is expected to be reduced, for example. That is, it is expected to reduce a variation in amount of charges. 
     2. The film-like flow has a flow direction and a width direction. The width direction is orthogonal to the flow direction. The electrically-charged region may be formed to pass through the film-like flow in the width direction. 
     The film-like flow has the flow direction, the width direction, and a thickness direction. The flow direction is a flight direction (traveling direction) of the aerosol. The width direction is orthogonal to the flow direction. The thickness direction is orthogonal to the flow direction and the width direction. 
     The electrically-charged region is formed by corona discharge. The electrically-charged region is formed to pass through the film-like flow in the width direction. Therefore, the film-like flow (aerosol) is expected to be uniformly charged in the width direction. That is, it is expected to reduce the variation in amount of charges in the width direction. 
     3. The corona discharge may occur from a corona discharge electrode. The corona discharge electrode may extend in a form of a line along the width direction. 
     For example, since the corona discharge electrode extends in the form of a line along the width direction, the electrically-charged region passing through the film-like flow may be formed. 
     4. In the width direction, the corona discharge electrode may have a width larger than a width of the film-like flow. 
     Since the corona discharge electrode has a width larger than that of the film-like flow, the electrically-charged region passing through the film-like flow may be formed. 
     5. The corona discharge electrode may include a plurality of protrusions. The plurality of protrusions are arranged side by side in the width direction. 
     Corona discharge is likely to occur at the tip of each protrusion. By arranging the plurality of protrusions side by side in the width direction, a charge density in the electrically-charged region is expected to become uniform. Thus, it is expected to reduce the variation in amount of charges. 
     6. In the (d), a gas may be blown toward the film-like flow in a direction in which the film-like flow is separated away from the corona discharge electrode. 
     When the film-like flow (aerosol) flies and is dispersed to the corona discharge electrode side, a material may be lost, with the result that coating efficiency may be decreased. By blowing the gas to separate the film-like flow away from the corona discharge electrode, it is expected to improve the coating efficiency. It should be noted that the coating efficiency represents a ratio of an amount (mass) of formation of the active material layer with respect to an amount (mass) of introduction of the material. 
     7. The method of producing the electrode may further include, for example, the following (f). 
     (f) At least one of heat and pressure is applied to the active material layer to fix the active material layer to the substrate. 
     8. The substrate may be, for example, in a sheet form. The flow direction and width direction of the film-like flow may be along the surface of the substrate. 
     Since the film-like flow flies along the surface of the substrate, the active material layer is expected to be formed smoothly. 
     9. An electrode production apparatus includes: a support part; an electric-field-forming apparatus; an aerosol-supplying part; and a charging apparatus. The support part is to support the substrate. The electric-field-forming apparatus is to form an electric field. The aerosol-supplying part is to form a film-like flow of an aerosol. The charging apparatus is to form an electrically-charged region by corona discharge. The film-like flow is introduced into the electric field after passing through the electrically-charged region. The aerosol includes an active material, a binder and a gas. In the electric field, an active material layer is formed by adhering a solid component of the film-like flow to the substrate by electrostatic force. 
     In the production apparatus of “9”, the production method of “1” can be performed. 
     10. The film-like flow has a flow direction and a width direction. The width direction is orthogonal to the flow direction. The electrically-charged region may be formed to pass through the film-like flow in the width direction. 
     In the production apparatus of “10”, the production method of “2” can be performed. 
     11. The charging apparatus may include a corona discharge electrode. The corona discharge electrode may extend in a form of a line along the width direction. 
     In the production apparatus of “11”, the production method of “3” can be performed. 
     12. The corona discharge electrode may include a plurality of protrusions. The plurality of protrusions are arranged side by side in the width direction. 
     In the production apparatus of “12”, the production method of “5” can be performed. 
     13. The aerosol-supplying part may include, for example, a flat nozzle. The flat nozzle has an ejection port expanding in the width direction. The film-like flow of the aerosol can be ejected from the ejection port. 
     For example, the flat nozzle is suitable for formation of the film-like flow. 
     14. In the width direction, the corona discharge electrode may have a width larger than a width of the ejection port. 
     In the production apparatus of “14”, the production method of “4” can be performed. 
     15. The electrode production apparatus may further include a blower apparatus. The blower apparatus may be to blow a gas toward the film-like flow in a direction in which the film-like flow is separated away from the corona discharge electrode. 
     In the production apparatus of “15”, the production method of “6” can be performed. 
     16. The electrode production apparatus may further include a fixing apparatus. The fixing apparatus may be to apply at least one of heat and pressure to the active material layer to fix the active material layer to the substrate. 
     In the production apparatus of “16”, the production method of “7” can be performed. 
     17. The support part may be in a roll form. The substrate may be in a sheet form. By rotation of the support part, the substrate may be transferred. 
     Since the support part is in the roll form, a roll-to-roll process can be applied. With the roll-to-roll process, productivity is expected to be improved. 
     18. In a cross section orthogonal to the rotation axis of the support part, the flow direction of the film-like flow may be along a tangential direction of the support part. 
     Since the film-like flow (aerosol) flies along the tangential direction of the roll, the active material layer is expected to be formed smoothly, for example. 
     The foregoing and other objects, features, aspects and advantages of the present disclosure will become more apparent from the following detailed description of the present disclosure when taken in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a schematic flowchart illustrating a method of producing an electrode according to the present embodiment. 
         FIG.  2    is a first conceptual diagram showing a process of producing the electrode. 
         FIG.  3    is a conceptual diagram showing an ejection port of a nozzle. 
         FIG.  4    is a conceptual diagram showing an exemplary corona discharge electrode. 
         FIG.  5    is a second conceptual diagram showing the process of producing the electrode. 
         FIG.  6    is a schematic cross sectional view showing a first production apparatus. 
         FIG.  7    is a schematic cross sectional view showing a second production apparatus. 
         FIG.  8    is a schematic cross sectional view showing a third production apparatus. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Definitions of Terms, Etc. 
     Next, an embodiment of the present disclosure (which may also be simply called “the present embodiment”) and an example of the present disclosure (which may also be simply called “the present example”) will be described. It should be noted that neither the present embodiment nor the present example limits the technical scope of the present disclosure. 
     Herein, expressions such as “comprise”, “include”, and “have”, and other similar expressions (such as “be composed of”, for example) are open-ended expressions. In an open-ended expression, in addition to an essential component, an additional component may or may not be further included. The expression “consist of” is a closed-end expression. However, even when a closed-end expression is used, impurities present under ordinary circumstances as well as an additional element irrelevant to the technique according to the present disclosure are not excluded. The expression “consist essentially of” is a semiclosed-end expression. A semiclosed-end expression tolerates addition of an element that does not substantially affect the fundamental, novel features of the technique according to the present disclosure. 
     Herein, expressions such as “may” and “can” are not intended to mean “must” (obligation) but rather mean “there is a possibility” (tolerance). 
     Herein, a singular form also includes its plural meaning, unless otherwise specified. For example, “a particle” may mean not only “one particle” but also “a collection of particles (powdery body, powder, particle group)”. 
     In the present specification, the order for implementing a plurality of steps, operations, processes, and the like included in each of various types of methods is not limited to the described order, unless otherwise specified. For example, a plurality of steps may proceed simultaneously. For example, a plurality of steps may be implemented in reverse order. 
     Herein, a numerical range such as “from m to n %” includes both the upper limit and the lower limit, unless otherwise specified. That is, “from m to n %” means a numerical range of “more than or equal to m % and less than or equal to n %”. Further, “more than or equal to m % and less than or equal to n %” includes “more than m % and less than n %”. Moreover, any numerical value selected from a certain numerical range may be used as a new upper limit or a new lower limit. For example, any numerical value from a certain numerical range may be combined with any numerical value described in another location of the present specification or in a table or a drawing, for example, to create a new numerical range. 
     Herein, all the numerical values are regarded as being modified by the term “about”. The term “about” may mean±5%, ±3%, ±1%, and/or the like, for example. Each numerical value can be an approximate value that can vary depending on the implementation configuration of the technique according to the present disclosure. Each numerical value can be expressed in significant figures. A measurement value can be an average value in multiple measurements. The number of measurements may be more than or equal to 3, more than or equal to 5, or more than or equal to 10. In general, as the number of measurements is larger, the reliability of the average value is expected to be improved. The measurement value can be rounded off based on the number of digits of the significant figure. The measurement value can include an error resulting from a detection limit of a measurement apparatus or the like, for example. 
     Herein, when a compound is represented by a stoichiometric composition formula such as “LiCoO 2 ”, for example, this stoichiometric composition formula is merely a typical example. Alternatively, the composition ratio may be non-stoichiometric. For example, when lithium cobalt oxide is represented as “LiCoO 2 ”, the composition ratio of lithium cobalt oxide is not limited to “Li/Co/O=1/1/2” but Li, Co, and O may be included in any composition ratio, unless otherwise specified. Further, doping with a trace element and/or substitution is also tolerated. 
     “Aerosol” herein refers to a dispersion system in which at least one of solid and liquid is dispersed in gas. Aerosol may also be called “fume”, for example. The appearance of aerosol may be described as cloud-like or smoke-like, for example. Aerosol can be also referred to as “cloud powder”. 
     “Electrically-charged region” herein refers to a region (space) in which a charge density is increased by corona discharge. The charge density can be measured by a suction-type Faraday cage. 
     “D50” herein is defined as a particle size in volume-based particle size distribution at which cumulative frequency of particle sizes accumulated from a small particle size side reaches 50%. 
     “Melting point” herein refers to the peak-top temperature for a melting peak (an endothermic peak) of a DSC (Differential Scanning calorimetry) curve. The DSC curve may be measured in accordance with “JIS K 7121”. “Near a melting point” may refer to the range of ±20° C. from the melting point, for example. 
     Any geometric term herein (such as “parallel”, “vertical”, and “perpendicular”, for example) should not be interpreted solely in its exact meaning. For example, “parallel” may mean a geometric state that is deviated, to some extent, from exact “parallel”. Any geometric term herein may include tolerances and/or errors in terms of design, operation, production, and/or the like. The dimensional relationship in each figure may not necessarily coincide with the actual dimensional relationship. The dimensional relationship (in length, width, thickness, and the like) in each figure may have been changed for the purpose of assisting the understanding of the technique according to the present disclosure. Further, a part of a configuration may have been omitted. 
     Herein, the expression “α is along β direction” means that an angle (acute angle) formed between a direction that α has (for example, a direction in which an electrode extends) and the β direction is 0 to 45°. The formed angle may be 0 to 30° or 0 to 15°, for example. A formed angle of 0° indicates that the direction that a has is parallel to the β direction. 
     “Electrode” herein is used as a generic term for a positive electrode and a negative electrode. The electrode may represent the positive electrode or the negative electrode, or may represent both the positive electrode and the negative electrode. 
     &lt;Method of Producing Electrode&gt; 
       FIG.  1    is a schematic flowchart illustrating a method of producing an electrode according to the present embodiment. Hereinafter, the “method of producing an electrode according to the present embodiment” may be simply called “the present production method”. The present production method includes “(a) making an aerosol”, “(b) forming a film-like flow”, “(c) forming an electrically-charged region”, “(d) charging” and “(e) electrostatic coating”. The present production method may further include, for example, “(f) fixing” or the like. It should be noted that an order of descriptions in the flowchart of  FIG.  1    is just for the sake of convenience. For example, “(b) forming a film-like flow” to “(d) charging” may be performed substantially simultaneously. 
     In the present production method, an electrode for a lithium-ion battery may be produced, for example. However, a lithium-ion battery is merely an example. The present production method may be applied to any battery system. In the present production method, a positive electrode may be produced or a negative electrode may be produced. 
     &lt;&lt;(a) Making Aerosol&gt;&gt; 
     The present production method includes making an aerosol including an active material, a binder and a gas. The aerosol can be made by mixing the active material, the binder, and the gas, for example. 
     &lt;Active Material&gt; 
     The active material may include active material particles. The active material may be a collection of active material particles. That is, the active material may be in powder form. Each active material particle may be an aggregate of primary particles (namely, may be a secondary particle). In the aerosol, individual active material particles (secondary particles) may not be aggregated any more but they may be rather dispersed and floating. In the aerosol, substantially all the active material particles (secondary particles) may not be aggregated any more but they may be rather dispersed and floating. In the aerosol, some of the active material particles may be aggregated. 
     The active material may also include a very small amount of a metal foreign object. For example, during production of the active material, the production apparatus may wear, causing a metal foreign object to enter into the active material powder. The metal foreign object may include stainless steel (SUS), iron (Fe), copper (Cu), and/or the like, for example. 
     A large metal foreign object may adversely affect battery performance. As the size of the metal foreign object is larger, the mass of the metal foreign object can be also larger. In the present production method, the aerosol flies. During the flight of the aerosol, the metal foreign object, which has a large mass, cannot fly, so that the metal foreign object is expected to be removed from the aerosol. 
     The active material may have a D50 from 1 to 30 μm, or may have a D50 from 1 to 20 μm, or may have a D50 from 1 to 10 μm, for example. 
     The active material particle causes electrode reaction. The active material particle may include an optional component. The active material particle may include a positive electrode active material, for example. For example, the active material particle includes at least one selected from a group consisting of LiCoO 2 , LiNiO 2 , LiMnO 2 , LiMn 2 O 4 , Li(NiCoMn)O 2 , Li(NiCoAl)O 2 , and LiFePO 4 . “(NiCoMn)” in “Li(NiCoMn)O 2 ”, for example, means that the constituents within the parentheses are collectively regarded as a single unit in the entire composition ratio. As long as (NiCoMn) is collectively regarded as a single unit in the entire composition ratio, the amounts of individual constituents are not particularly limited. Li(NiCoMn)O 2  may include, for example, Li(Ni 1/3 Co 1/3 Mn 1/3 )O 2 , Li(Ni 0.5 Co 0.2 Mn 0.3 )O 2 , Li(Ni 0.8 Co 0.1 Mn 0.1 )O 2 , or the like. 
     The active material particle may include a negative electrode active material, for example. The active material particle may include, for example, at least one selected from the group consisting of graphite, soft carbon, hard carbon, silicon, silicon oxide, silicon-based alloy, tin, tin oxide, tin-based alloy, and Li 4 Ti 5 O 12 . 
     &lt;Binder&gt; 
     The binder may be in powder form. The binder may bond a solid material to another solid material in the active material layer. The amount of the binder to be used may be, for example, from 0.1 to 10 parts by mass relative to 100 parts by mass of the active material. The binder may include an optional component. The binder may include, for example, at least one selected from the group consisting of polyvinylidene difluoride (PVdF), polytetrafluoroethylene (PTFE), vinylidene difluoride-hexafluoropropylene copolymer (PVdF-HFP), styrene-butadiene rubber (SBR), carboxymethylcellulose (CMC), polyimide (PI), polyamide-imide (PAI), and polyacrylic acid (PAA). 
     &lt;Gas&gt; 
     The gas is a dispersion medium for the aerosol. The gas may include an optional component. The gas may include, for example, at least one selected from the group consisting of air, nitrogen gas, and argon gas. For example, when the dispersoid (such as the active material and/or the solid electrolyte) in the aerosol is readily reacts with moisture in the air, an inert gas (such as nitrogen gas and/or argon gas) may be used. 
     &lt;Optional Component&gt; 
     The aerosol may further include a conductive material, for example. The conductive material may be in powder form. The conductive material may form an electron conduction path in the active material layer. The amount of the conductive material to be used may be from 0.1 to 10 parts by mass relative to 100 parts by mass of the active material. The conductive material may include an optional component. The conductive material may include a conductive carbon particle, a conductive carbon fiber, and/or the like, for example. The conductive material may include, for example, at least one selected from the group consisting of carbon black, vapor grown carbon fiber, carbon nanotube, and graphene flake. The carbon black may include, for example, at least one selected from the group consisting of acetylene black, furnace black, channel black, and thermal black. 
     The aerosol may further include a solvent, for example. The solvent is liquid. For example, the solvent may be in fume form. For example, the binder may absorb the solvent and be swollen. The solvent may include an optional component. The solvent may include, for example, at least one selected from the group consisting of water, N-methyl-2-pyrrolidone (NMP), and butyl butyrate. 
     The aerosol may further include a solid electrolyte, for example. That is, in the present production method, an electrode for an all-solid-state battery may also be produced. The solid electrolyte may be in powder form. The solid electrolyte may form an ion conduction path in the active material layer. The solid electrolyte may include an optional component. The solid electrolyte may include, for example, at least one selected from the group consisting of Li 2 S—P 2 S 5 , LiI—Li 2 S—P 2 S 5 , LiBr—Li 2 S—P 2 S 5 , and LiI—LiBr—Li 2 S—P 2 S 5 . 
     &lt;Composite Particles&gt; 
     The present production method may include forming composite particles, for example. Hereinafter, a collection of composite particles (powder) is also called “composite powder”. For example, the aerosol may be made by mixing the composite powder with the gas. 
     The composite particle includes an active material particle and other solid materials. For example, when the active material particle and these other solid materials are mixed under conditions where a strong shearing force is being applied, the composite particle may be formed. In the composite particle, a binder and a conductive material may be fixed to the surface of the active material particle, for example. 
     In the present embodiment, as described below, solid particles (an electrode material) fly and thereby an active material layer is formed. When specific gravities of the materials vary, a lighter material may fly preferentially. This may result in a non-uniform composition of the active material layer. In the configuration in which the active material particle, the conductive material, and the binder form the composite particles, a uniform active material layer is expected to be formed. 
     After the composite particles are formed, the composite particles may be subjected to heat treatment at, for example, a temperature near the melting point of the binder. Due to this heat treatment, the binder is softened, melted, and re-solidified. As a result, the binder, the conductive material, and the like are expected to be firmly fixed to the surface of the active material particle. When the fixation is not firm, the conductive material and the like may be peeled off from the surface of the active material particle while the composite particles are flying, for example. 
     For example, when the composite particle includes a plurality of the active material particles (more specifically, when the composite particle is an aggregate of the active material particles), the flying ability of the composite particle may be decreased. It may be because the mass of the composite particle is increased. For example, the composite particle may include a single active material particle. That is, the binder, the conductive material, and the like may adhere to a single active material particle to form a single composite particle. 
     &lt;&lt;(b) Forming Film-Like Flow&gt;&gt; 
     The production method includes forming a film-like flow of the aerosol. In the present production method, the film-like flow of the aerosol can be formed by any method. In the film-like flow, the gas included in the aerosol may transfer a solid component (such as the active material) in the flow direction. For example, the flow velocity of the gas or the like may be adjusted such that the film-like flow does not become a turbulent flow but becomes a laminar flow. 
       FIG.  2    is a first conceptual diagram showing a process of producing an electrode. For example, the aerosol may be ejected from a nozzle  30  in the form of a film, thereby forming a film-like flow  1 . Film-like flow  1  has an external appearance in the form of a film. Film-like flow  1  has an expanse in the form of a plane. That is, film-like flow  1  is formed to have a flow direction, a width direction, and a thickness direction. The flow direction corresponds to a Y-axis direction in  FIG.  2   . The width direction corresponds to an X-axis direction in  FIG.  2   . The width direction is orthogonal to the flow direction. The thickness direction corresponds to a Z-axis direction in  FIG.  2   . The thickness direction is orthogonal to the flow direction and the width direction. 
       FIG.  3    is a conceptual diagram showing an ejection port of the nozzle. The expanse (shape) of film-like flow  1  can be adjusted, for example, by the shape of ejection port  31  of nozzle  30 . Nozzle  30  may be, for example, a flat nozzle. The flat nozzle may have ejection port  31  expanding in the width direction (X-axis direction). Ejection port  31  may extend in the form of a line in the width direction. Film-like flow  1  of the aerosol may be ejected from ejection port  31 . Ejection port  31  may extend in the XZ plane in the form of a straight line, curved line, or wavy line. 
     Ejection port  31  may have, for example, a rectangular shape. The aspect ratio of ejection port  31  may be, for example, 5 to 100, 10 to 50, or 20 to 30. It should be noted that the “aspect ratio” indicates a ratio of the size in the width direction (X-axis direction) to the size in the thickness direction (Z-axis direction). The width of ejection port  31  can be adjusted in accordance with, for example, the width of a target active material layer. 
     &lt;&lt;(c) Forming Electrically-Charged Region&gt;&gt; 
     The present production method includes forming an electrically-charged region  40  by corona discharge. For example, electrically-charged region  40  may be formed to pass through film-like flow  1  in the width direction (X-axis direction). Thus, it is considered that variation in amount of charges in the width direction can be reduced. 
     For example, corona discharge occurs from a corona discharge electrode  41  (see  FIG.  2   ). In  FIG.  2   , dotted arrows indicate an irradiation direction of the corona discharge. Electrically-charged region  40  can be formed in the irradiation direction of the corona discharge. Electrically-charged region  40  has an expanse in the thickness direction (Z-axis direction) of film-like flow  1 . Electrically-charged region  40  may extend, for example, from corona discharge electrode  41  to a support part  10 . 
     For example, electrically-charged region  40  may extend in the width direction. Electrically-charged region  40  extending in the width direction can be formed by any method. For example, a plurality of needle-shaped electrodes may be arranged side by side in the width direction. For example, a wire electrode (line-shaped electrode) extending in the width direction may be used. 
       FIG.  4    is a conceptual diagram showing an exemplary corona discharge electrode. Corona discharge electrode  41  may extend in the form of a line along the width direction (X-axis direction), for example. In a top view (XY plane), corona discharge electrode  41  may extend in the form of a straight line, curved line, or wavy line, for example. Since corona discharge electrode  41  extends in the width direction, electrically-charged region  40  also extends in the width direction. In the width direction, corona discharge electrode  41  may have a width larger than that of film-like flow  1 . This is considered to facilitate formation of electrically-charged region  40  passing through film-like flow  1  in the width direction. 
     In the width direction, the width of corona discharge electrode  41  may be, for example, 1.01 to 2 times as large as the width of film-like flow  1 , or 1.1 to 1.5 times as large as the width of film-like flow  1 . The width of corona discharge electrode  41  in the width direction may be, for example, 1.01 to 2 times as large as the width of ejection port  31 , or 1.1 to 1.5 times as large as the width of ejection port  31 . 
     Corona discharge electrode  41  may include a plurality of protrusions  42 . Each of protrusions  42  may protrude, for example, in the thickness direction (Z-axis direction) of film-like flow  1 . Protrusion  42  may protrude toward support part  10 , for example. Protrusion  42  may be tapered toward the tip thereof. The plurality of protrusions  42  are arranged side by side in the width direction. Corona discharge electrode  41  may include, for example, 2 to 100 protrusions  42 . Corona discharge is likely to occur at the tip of each protrusion  42 . By arranging the plurality of protrusions  42  side by side in the width direction, it is expected to attain a uniform charge density in electrically-charged region  40 . Thus, it is expected to reduce variation in amount of charges. A space (pitch) between adjacent protrusions  42  may be, for example, 0.1 to 100 mm. 
     &lt;&lt;(d) Charging&gt;&gt; 
     The present production method includes allowing film-like flow  1  to pass through electrically-charged region  40 . Electrically-charged region  40  is formed in a flight path of film-like flow  1 . Since film-like flow  1  passes through electrically-charged region  40 , charges are injected into the solid component included in film-like flow  1 . That is, the solid component (active material or the like) is charged. In the present production method, electrically-charged region  40  may be formed to pass through film-like flow  1  in the width direction. Thus, it is considered that the solid component can be uniformly charged in the width direction. That is, it is considered that the variation in amount of charges in the width direction can be reduced. 
     The amount of charges of the solid component may be, for example, 100 nC/g or more, 500 nC/g or more, 1000 nC/g or more, or 1500 nC/g or more. As the amount of charges is larger, coating efficiency is expected to be improved. The amount of charges may be, for example, 3000 nC/g or less, or 2000 nC/g or less. 
     When film-like flow  1  passes through electrically-charged region  40 , a gas may be blown in a direction in which film-like flow  1  is separated away from corona discharge electrode  41 , for example. When the solid component of film-like flow  1  (aerosol) falls onto the corona discharge electrode  41  side, a material may be lost, with the result that the coating efficiency may be decreased. By blowing the gas to separate film-like flow  1  away from corona discharge electrode  41 , it is expected to improve the coating efficiency. The blown gas may be air, for example. The gas may be blown in the same direction as the thickness direction (Z-axis direction) of film-like flow  1 , for example. 
     &lt;&lt;(e) Electrostatic Coating&gt;&gt; 
     The present production method includes introducing film-like flow  1  into an electric field (E) after passing through electrically-charged region  40 . In the electric field, electrostatic force (F=qE) in a direction toward a substrate  2  acts on film-like flow  1 . With the electrostatic force, the solid component (the active material or the like) of film-like flow  1  is adhered onto a surface of substrate  2 . Thus, an active material layer  3  is formed. That is, an electrode  4  is produced. 
     Substrate  2  may be in sheet form, for example. Substrate  2  may be a current collector. Substrate  2  may include a metal foil, for example. Substrate  2  may include, for example, at least one selected from the group consisting of aluminum (Al) foil, Al alloy foil, Cu foil, Cu alloy foil, nickel (Ni) foil, Ni alloy foil, titanium (Ti) foil, and Ti alloy foil. Substrate  2  may have a thickness from 5 to 50 μm, or may have a thickness from 5 to 20 μm, for example. 
     For example, substrate  2  is supported by support part  10 . For example, DC voltage is applied between support part  10  and a counter electrode  22 . Thus, an electric field is formed between support part  10  and counter electrode  22 . The electric field is formed such that electrostatic force acts on film-like flow  1  in the direction toward substrate  2  (support part  10 ). The intensity of the electric field may be, for example, 50 to 500 V/mm. The intensity of the electric field is evaluated by dividing the DC voltage by a gap between support part  10  and counter electrode  22 . The DC voltage may be, for example, 500 to 1500 V. The gap may be, for example, 1 to 10 mm. 
     &lt;&lt;(f) Fixing&gt;&gt; 
     The present production method may include applying at least one of pressure and heat to active material layer  3  to fix active material layer  3  to substrate  2 . Fixing active material layer  3  is expected to enhance the peel strength of active material layer  3 , for example. 
       FIG.  5    is a second conceptual view showing a process of producing an electrode. The pressure and heat may be separately applied. The pressure and the heat may be applied substantially at the same time. For example, the active material layer may be compressed with a heated roll  60 , a heated plate, and/or the like. The temperature for heating active material layer  3  may be a temperature near the melting point of the binder, for example. The heating temperature may be from 80 to 200° C., or may be from 120 to 200° C., or may be from 140 to 180° C., for example. 
     The pressure may be adjusted depending on the target thickness, target density, and/or the like of active material layer  3 , for example. A pressure from 50 to 200 MPa may be applied to active material layer  3 , for example. 
     Active material layer  3  may be formed only on one surface of substrate  2 , or may be formed on each of both front and rear surfaces of substrate  2 . Active material layer  3  (after fixing) may have a thickness of 10 μm to 1 mm, or may have a thickness of 50 μm to 500 μm, for example. Active material layer  3  may have a density of 1 to 5 g/cm 3 , or may have a density of 2 to 4 g/cm 3 , for example. 
     &lt;First Production Apparatus&gt; 
       FIG.  6    is a schematic cross sectional view showing a first production apparatus. In a first production apparatus  100 , the present production method can be performed. First production apparatus  100  includes a support part  110 , an electric-field-forming apparatus  120 , an aerosol-supplying part  130 , and a charging apparatus  140 . First production apparatus  100  may further include, for example, a blower apparatus  150 , a fixing apparatus (not shown), a controller (not shown), and the like. The controller may control operation and cooperation of each apparatus, for example. In first production apparatus  100 , electrodes can be continuously produced. In each of  FIGS.  6  to  8   , each of arrows of alternate long and short dashed lines indicates the flow of each of the aerosol and the film-like flow. 
     &lt;&lt;Support Part&gt;&gt; 
     Support part  110  supports a substrate. Support part  110  is in a roll form. Support part  110  can also be referred to as “backup roll”. The substrate, which is in a sheet form, is supported on a surface of support part  110 . By rotation of support part  110 , the substrate is transferred. The substrate may be in a strip form. Support part  110  may have a width (size in the X-axis direction) larger than that of the substrate. Support part  110  may have a width larger than that of the film-like flow. 
     Support part  110  may have electric conductivity. A whole of support part  110  may have electric conductivity. A portion of support part  110  may have electric conductivity. For example, a portion thereof in contact with the substrate may have electric conductivity. For example, a surface layer of support part  110  may have electric conductivity. Support part  110  is electrically connected to a high-voltage power supply  121 . Support part  110  may be grounded. 
     &lt;&lt;Electric-Field-Forming Apparatus&gt;&gt; 
     Electric-field-forming apparatus  120  forms an electric field. Electric-field-forming apparatus  120  may include, for example, high-voltage power supply  121  and a counter electrode  122 . High-voltage power supply  121  applies DC voltage between support part  110  and counter electrode  122 . Thus, an electric field is formed between support part  110  and counter electrode  122 . The electric field has a direction from support part  110  toward counter electrode  122 . Electrostatic force acts on negative charges in the electric field in a direction toward substrate  2  (support part  110 ). Counter electrode  122  may have a width (size in the X-axis direction) larger than that of film-like flow  1 . 
     &lt;&lt;Aerosol-Supplying Part&gt;&gt; 
     Aerosol-supplying part  130  forms the film-like flow of the aerosol. Details of the aerosol are as described above. Aerosol-supplying part  130  may include, for example, a gas-supplying part  131 , a porous plate  132 , an aerosol-making part  133 , and a flat nozzle  134 . 
     Porous plate  132  partitions between gas-supplying part  131  and aerosol-making part  133 . The solid component (the active material or the like) of the aerosol can be placed on porous plate  132 . Porous plate  132  has a plurality of open pores formed in it. For example, the sieve opening of porous plate  132  may be adjusted so that the active material powder are not buried in the open pores. The sieve opening of porous plate  132  may be 0.5 to 2 times greater than the D50 of the active material powder, for example. The sieve opening of porous plate  132  may be from 5 to 20 μm, for example. Porous plate  132  may be formed with any material. For example, porous plate  132  may be a sintered material made of ceramic powder. Porous plate  132  may be made of alumina, for example. 
     Gas-supplying part  131  supplies a gas to aerosol-making part  133  through porous plate  132 . In aerosol-making part  133 , the gas can be mixed with the solid component, thereby making the aerosol. Since the gas passes through porous plate  132 , the flow of the gas in the in-plane direction is expected to become uniform. Thus, it is expected to stabilize the composition of the aerosol. Aerosol-making part  133  may include, for example, a stirring blade or the like. The stirring blade may mix the materials. For example, aerosol-making part  133  may be vibrated. The materials may be mixed by the vibration of aerosol-making part  133 . For example, the materials may be mixed by using both the stirring by the stirring blade and the vibration. 
     At an early stage of the making of the aerosol, the solid component (the active material or the like) in a stationary state is exposed to the gas flow on porous plate  132 . On this occasion, the solid component may be brought upward vigorously to leak from flat nozzle  134 . That is, part of the materials may be lost. For example, the internal volume (for example, the size in the Z-axis direction) of aerosol-making part  133  may be adjusted to avoid the leakage of the materials. 
     Details of flat nozzle  134  are as described above. Flat nozzle  134  has an ejection port having a flat shape. The ejection port extends in the width direction (X-axis direction). Flat nozzle  134  can convert the flow of the aerosol into the film-like flow. Flat nozzle  134  may eject the film-like flow in a tangential direction of support part  110 . That is, in a cross section orthogonal to the rotation axis of support part  110 , the flow direction of the film-like flow may be along the tangential direction of support part  110 . Since the film-like flow flies along the tangential direction of the roll, the flow direction and the width direction of the film-like flow are along the surface of the substrate. Since the film-like flow is along the surface of the substrate, the active material layer is expected to be formed smoothly. 
     In a cross section (YZ plane) orthogonal to the width direction of the film-like flow, the flow path in flat nozzle  134  may be tapered toward the tip thereof. With the tapered flow path, it is expected to facilitate the film-like flow to become a laminar flow, for example. 
     &lt;&lt;Charging Apparatus&gt;&gt; 
     Charging apparatus  140  forms the electrically-charged region by corona discharge. Charging apparatus  140  may include, for example, a corona discharge electrode  141 . Charging apparatus  140  may further include, for example, a housing  142 . Corona discharge electrode  141  may be accommodated in housing  142 . Details of corona discharge electrode  141  are as described above. Corona discharge electrode  141  may extend in the form of a line along the width direction (X-axis direction). Corona discharge electrode  141  may include, for example, protrusions (see  FIG.  4   ). Charging apparatus  140  may include a plurality of corona discharge electrodes  141 . The plurality of corona discharge electrodes  141  may be arranged side by side in the flow direction of the film-like flow, for example. In first production apparatus  100 , three rows of corona discharge electrodes  141  are disposed. For example, 1 to 10 rows of corona discharge electrodes  141  may be disposed. 
     The electrically-charged region can be formed by corona discharge that occurs from each corona discharge electrode  141 . A discharge voltage may be, for example, −100 to −1 kV. The film-like flow passes through the electrically-charged region and is introduced into the electric field (the gap between support part  110  and counter electrode  122 ). The solid component of the film-like flow is charged when passing through the electrically-charged region. By the electrostatic force in the electric field, the solid component of the film-like flow is attracted to the substrate (support part  110 ). The solid component is adhered to the surface of the substrate, thereby forming the active material layer. 
     &lt;&lt;Blower Apparatus&gt;&gt; 
     First production apparatus  100  may further include blower apparatus  150 . Blower apparatus  150  may be provided adjacent to corona discharge electrode  141 . Blower apparatus  150  blows a gas in the direction toward support part  110 . That is, blower apparatus  150  blows the gas in the direction in which the film-like flow is separated away from corona discharge electrode  141 . 
     &lt;&lt;Fixing Apparatus&gt;&gt; 
     First production apparatus  100  may further include the fixing apparatus. The fixing apparatus applies at least one of heat and pressure to the active material layer to fix the active material layer to the substrate. The fixing apparatus may include, for example, heated roll  60 , the heated press, or the like (see  FIG.  5   ). 
     &lt;Second Production Apparatus&gt; 
       FIG.  7    is a schematic cross sectional view showing a second production apparatus. Also in a second production apparatus  200 , the present production method can be performed. Second production apparatus  200  includes a support part  210 , an electric-field-forming apparatus  220 , an aerosol-supplying part  230 , and a charging apparatus  240 . Second production apparatus  200  may further include a blower apparatus  250 . Electric-field-forming apparatus  220  may include a high-voltage power supply  221  and a counter electrode  222 . Aerosol-supplying part  230  may include a gas-supplying part  231 , a porous plate  232 , an aerosol-making part  233 , and a flat nozzle  234 . Charging apparatus  240  may include a corona discharge electrode  241  and a housing  242 . Apparatuses and members having the same names may have the same functions between first production apparatus  100  and second production apparatus  200 . 
     Second production apparatus  200  is different from first production apparatus  100  in that the flow direction of the film-like flow ejected from flat nozzle  234  is oriented vertically downward. In second production apparatus  200 , the film-like flow and corona discharge electrode  241  are arranged side by side in the horizontal direction. Since corona discharge electrode  241  is not disposed vertically below the film-like flow, it is considered to reduce such a disadvantage that the solid component falls onto corona discharge electrode  241  due to gravity. 
     Reference Embodiment 
       FIG.  8    is a schematic cross sectional view showing a third production apparatus. A third production apparatus  300  is a production apparatus according to a reference embodiment. Third production apparatus  300  is different from first production apparatus  100  and second production apparatus  200  in terms of a charging method. Third production apparatus  300  includes a support part  310 , an electric-field-forming apparatus  320 , and an aerosol-supplying part  330 . Electric-field-forming apparatus  320  includes a high-voltage power supply  321  and an electrostatic screen  322 . Aerosol-supplying part  330  includes a gas-supplying part  331 , a porous plate  332 , an aerosol-making part  333 , and a stirring blade  335 . 
     High-voltage power supply  321  forms an electric field between support part  310  and electrostatic screen  322 . High-voltage power supply  321  supplies charges to electrostatic screen  322 . Electrostatic screen  322  is in a mesh form. In third production apparatus  300 , when the aerosol passes through electrostatic screen  322 , the solid component (particles) of the aerosol comes into contact with electrostatic screen  322 , thereby charging the solid component. However, some particles may pass through electrostatic screen  322  without coming into contact with electrostatic screen  322 . Therefore, third production apparatus  300  may be disadvantageous in terms of an amount of charges as compared with first production apparatus  100  and second production apparatus  200 . 
     EXAMPLES 
     &lt;Production of Electrode&gt; 
     First Production Example 
     In a first production example, a positive electrode was produced by the present production method. 
     The below materials were prepared. 
     Active material: Li(NiCoMn)O 2  (powder form) 
     Conductive material: acetylene black 
     Binder: PVdF 
     Substrate: Al foil (thickness, 12 μm) 
     A mixing apparatus “Multi-purpose Mixer” produced by Nippon Coke &amp; Engineering Co., Ltd. was prepared. This apparatus includes a round tank (a mixing tank). The convection-promoting effect of the round tank generates a strong shearing force, which is capable of combining the solid materials together. 
     The active material, the conductive material, and the binder were introduced into the round tank. The blending ratio of the materials was “(active material powder)/(conductive material)/binder=90/5/5 (mass ratio)”. The number of revolutions of the stirring blade was set at 10000 rpm. The materials were mixed for 10 minutes. Thus, composite powder was formed. The composite powder is a collection of composite particles. It seems that each composite particle includes a single active material particle. It seems that the binder and the conductive material are fixed to the surface of the active material particle. 
     A metal tray was prepared. On the tray, the composite powder was thinly spread. The tray was stored in an oven for heat treatment to be performed on the composite powder. The temperature of the oven was set at 160° C. The duration of the storage was 30 minutes. It seems that the heat treatment caused the binder and the conductive material to be fixed to the surface of the active material particle. 
     First production apparatus  100  was prepared (see  FIG.  6   ). A setting for each part is as follows. 
     Porous plate  132 : alumina porous plate (sieve opening, 10 μm; planar size, 75 mm×75 mm) 
     Corona discharge electrode  141 : −20 kV 
     Amount of gas from blower apparatus  150 : 3 L/min 
     Gap between corona discharge electrode  141  and support part  110 : 16 mm 
     Counter electrode  122 : −1000 V 
     Support part  110 : 0 V (GND) 
     Gap between support part  110  and counter electrode  122 : 4 mm 
     Electric field intensity: 250 V/mm 
     Transfer rate of substrate  2 : 1 m/min 
     Composite powder was supplied onto porous plate  132 . Vibration was applied to aerosol-making part  133 . The frequency of the vibration was 120 Hz, and the amplitude of the vibration was 0.13 mm. In a state in which aerosol-making part  133  was vibrated, gas-supplying part  131  supplied air to aerosol-making part  133  through porous plate  132 . An amount of the supplied air was 25 L/min. In this way, aerosol was made. The aerosol was ejected from flat nozzle  134 , thereby forming a film-like flow. An electrically-charged region was formed by corona discharge electrode  141 . The film-like flow passed through the electrically-charged region, thereby charging the film-like flow. The charged film-like flow was introduced into the electric field. An active material layer was formed at a rate of 1 m/min. That is, an electrode was produced. The active material layer had a planar size of 60 mm×200 mm. 
     The electrode was sandwiched between two heated plates (flat plates). The temperature of the heated plates was 160° C. By these heated plates, a load of 15 tf was applied to the active material layer. By this, the active material layer is supposed to be fixed to the substrate. 
     Second Production Example 
     In a second production example, a negative electrode was produced by the present production method. 
     The below materials were prepared. 
     Active material: amorphous coat graphite (powder form) 
     Binder: PVdF 
     Substrate: Cu foil (thickness, 8 μm) 
     With regard to the amorphous coat graphite, the surface of each graphite particle is coated with an amorphous carbon material. A mixing apparatus “High Speed Mixer” produced by Earthtechnica Co., Ltd. was prepared. This apparatus is capable of generating a relatively gentle shearing force during mixing. Into the mixing tank of the mixing apparatus, the active material and the binder were added. The blending ratio of the materials was “active material/binder=97.5/2.5 (mass ratio)”. The number of revolutions of the stirring blade was set at 4500 rpm. The materials were mixed for 2 minutes. Thus, composite powder was formed. Except these, the same procedure as in the first production example was carried out to produce an electrode. 
     Third Production Example 
     In a third production example, a positive electrode was produced by the production method according to the reference embodiment. Composite powder was prepared in the same manner as in the first production example. 
     Third production apparatus  300  was prepared (see  FIG.  8   ). A setting for each part was as follows. 
     Electrostatic screen  322 : mesh composed of SUS (sieve opening, 100 μm) 
     Porous plate  332 : alumina porous plate (sieve opening, 10 μm; planar size, 75 mm×75 mm) 
     Gap between electrostatic screen  322  and support part  310 : 4 mm 
     Electrostatic screen  322 : −1000 V 
     Support part  310 : 0 V (GND) 
     Electric field intensity: 250 V/mm 
     Onto porous plate  332 , the composite powder was supplied. By gas-supplying part  331 , air was supplied to the composite powder. An amount of the supplied air was 25 L/min. The composite powder and the air were stirred by stirring blade  335 , and thereby an aerosol was formed. The number of revolutions of stirring blade  335  was 120 rpm. 
     The aerosol was supplied to the electric field through electrostatic screen  322 , and thereby the active material layer was formed on the surface of the substrate. Except these, the same procedure as in the first production example was carried out to produce an electrode. 
     Fourth Production Example 
     An electrode (negative electrode) was produced in the same manner as in the third production example except that the composite powder of the second production example was used. 
     &lt;Evaluation Method&gt; 
     &lt;&lt;Quality of Active Material Layer&gt;&gt; 
     The quality (presence/absence of deficiencies or the like) of the active material layer was visually checked. 
     &lt;&lt;Amount of Charges&gt;&gt; 
     The aerosol after the charging was collected. An amount of charges was measured by a suction-type Faraday cage (produced by Nano Seeds Corporation). In accordance with the mass of the solid component of the aerosol and the amount of charges, an amount of charges per unit mass [nC/g] was found. 
     &lt;&lt;Coating Weight of Active Material Layer&gt;&gt; 
     With a punch, a specimen was sampled from the electrode. The specimen had a circular shape. The diameter of the specimen was 25 mm. By measuring the mass of the specimen, a coating weight of the active material layer was found. The coating weight represents a mass per unit area [mg/cm 2 ]. 
     
       
         
           
               
               
               
             
               
                 TABLE 1 
               
             
            
               
                   
               
               
                   
                   
                 Evaluation Results 
               
            
           
           
               
               
               
               
            
               
                   
                 Production  
                 Aerosol 
                 Active Material  
               
               
                   
                 Method 
                 (Solid 
                 Layer 
               
            
           
           
               
               
               
               
               
               
            
               
                   
                   
                 Produc- 
                 Component) 
                   
                 Coating  
               
               
                   
                   
                 tion 
                 Amount of 
                   
                 Weight 
               
               
                   
                   
                 Appar- 
                 Charges  
                   
                 [mg/ 
               
               
                   
                 Electrode 
                 atus 
                 [nC/g] 
                 Quality 
                 cm 2 ] 
               
               
                   
               
            
           
           
               
               
               
               
               
               
            
               
                 First 
                 Positive 
                 FIG. 6 
                 −1683 
                 Excel- 
                 24.8 
               
               
                 Produc- 
                 Electrode 
                   
                   
                 lent 
                   
               
               
                 tion 
                   
                   
                   
                   
                   
               
               
                 Example 
                   
                   
                   
                   
                   
               
               
                 Second 
                 Negative 
                 FIG. 6 
                 −1898 
                 Excel- 
                 30.3 
               
               
                 Produc- 
                 Electrode 
                   
                   
                 lent 
                   
               
               
                 tion 
                   
                   
                   
                   
                   
               
               
                 Example 
                   
                   
                   
                   
                   
               
               
                 Third 
                 Positive 
                 FIG. 8 
                 −64 
                 Excel- 
                 5.6 
               
               
                 Produc- 
                 Electrode 
                   
                   
                 lent 
                   
               
               
                 tion 
                   
                   
                   
                   
                   
               
               
                 Example 
                   
                   
                   
                   
                   
               
               
                 Fourth 
                 Negative 
                 FIG. 8 
                 −71 
                 Excel- 
                 6.1 
               
               
                 Produc- 
                 Electrode 
                   
                   
                 lent 
                   
               
               
                 tion 
                   
                   
                   
                   
                   
               
               
                 Example 
               
               
                   
               
            
           
         
       
     
     &lt;Evaluation Results&gt; 
     In each of the production examples, no deficiencies or the like were observed in the active material layer. That is, the quality of the active material layer was excellent. 
     In each of the third and fourth production examples, the amount of charges was smaller than that in each of the first and second production examples. It is considered that part of the solid component (particles) of the aerosol pass through the electrostatic screen without coming into contact with the electrostatic screen. 
     In each of the first and second production examples, the amount of charges was significantly larger than that in each of the third and fourth production examples. It is considered that the solid component is uniformly charged in the width direction of the aerosol (film-like flow). In each of the first and second production examples, the coating weight was also increased. It is considered that the coating efficiency is improved in response to the increased amount of charges. 
     The present embodiment and the present example are illustrative in any respect. The present embodiment and the present example are non-restrictive. The technical scope of the present disclosure encompasses any modifications within the meaning and the scope equivalent to the terms of the claims. For example, it is expected that certain configurations of the present embodiments and the present examples can be optionally combined.