Patent Description:
The present invention relates to a pressing apparatus including a fluid and a pressing method using the same, and more particularly to a pressing apparatus including a pressure adjustment portion having a fluid contained therein, whereby pressure applied to target object to be pressed is changed depending on the shape of the target object, and a pressing method using the same.

With recent development of alternative energies due to air pollution and energy depletion caused as the result of use of fossil fuels, demand for secondary batteries capable of storing electrical energy that is produced has increased. The secondary batteries, which are being capable of being charged and discharged, are intimately used in daily life. For example, the secondary batteries are used in mobile devices, electric vehicles, and hybrid electric vehicles.

Secondary batteries used as energy sources of various kinds of electronic devices inevitably used in modern society have been used in a state of being mounted in various kinds of devices, such as mobile devices and electric vehicles. Various shapes of battery cells are required in response to user demand and variety in shape of devices in which secondary batteries are mounted.

Various shapes of battery cells may be generally formed by receiving, in a curved or bent case, an electrode having a shape corresponding to the shape of the case or an electrode assembly constituted by stacking electrodes. In order to form various shapes of electrodes, an electrode active material is applied to one surface or opposite surfaces of an electrode current collector formed so as to have a uniform shape, and is then pressed. In addition, for various shapes of electrode assemblies, various shapes of electrodes and separators are stacked, and a lamination process is performed in order to increase the force of coupling therebetween.

<FIG> is a schematic view of a conventional pressing apparatus.

In order to press a target object <NUM> to be pressed, a pressing portion of the conventional pressing apparatus <NUM>, which is a portion configured to come into contact with the target object <NUM>, is flat. However, the pressing apparatus <NUM> having the flat pressing portion cannot apply uniform force to a target object <NUM> having various heights or shapes.

That is, stronger force is applied to a portion of the target object <NUM> that protrudes farther than the other portions of the target object, and weaker force is applied to a portion of the target object <NUM> that is depressed farther than the other portions of the target object, whereby the target object <NUM> is not uniformly laminated. In order to solve the above problem, an additional pressing process may be performed with respect to the portion of the target object <NUM> that is not properly laminated. In this case, however, process time is lengthened and related cost is increased as a result of performing such an additional process.

In Patent Document <NUM>, a pattern is formed on the surface of a roll member such that compression force that is transmitted to an electrode and a separator is applied only to some regions thereof. However, there is a problem in that only a portion of a target object is compressed, whereby the entirety of the target object is not uniformly pressed at once.

In order to solve the above problem, it is necessary to consider a method capable of uniformly pressing a target object while reducing process time.

(Patent Document <NUM>) <CIT>). <CIT> discloses a pressing apparatus according to the preamble of claim <NUM>. <CIT> and <CIT> disclose various pressing apparatuses.

The present invention has been made in view of the above problems, and it is an object of the present invention to provide a pressing apparatus capable of applying uniform pressing force to a target object to be pressed.

It is another object of the present invention to easily produce various shapes of electrodes or electrode assemblies using the pressing apparatus. It is a further object of the present invention to simplify an electrode and electrode assembly manufacturing process and to reduce a defect rate, whereby it is possible to reduce production cost.

In order to accomplish the above objects, a pressing apparatus according to claim <NUM> and an electrode and electrode assembly manufacturing method according to claim <NUM> is provided.

In addition, the contact portion has a pattern configured to change a pressure applied to the target object depending on the shape of the target object.

The pattern may be an oblique pattern, an X-shaped pattern, or a dot type pattern having a plurality of micro-scale protrusions.

The contact portion may have a plurality of protrusions configured to be individually movable.

The pressure adjustment portion may be individually connected to the contact portion.

In addition, the pressing portion may be individually or integrally connected to the pressure adjustment portion.

The fluid of the pressure adjustment portion may be connected to the plurality of protrusions.

In addition, the fluid of the pressure adjustment portion may occupy less than <NUM>% of the pressure adjustment portion.

In addition, the pressing apparatus may include an upper roll including the contact portion, the pressing portion, and the pressure adjustment portion and a lower roll having the same identical construction as the upper roll.

The present invention provides an electrode and electrode assembly manufacturing method including (S1) preparing an electrode or an electrode assembly that is the target object to be pressed, (S2) disposing the target object in the pressing apparatus, and (S3) pressing the target object using the pressing apparatus.

In step (S3), the pressing apparatus may be deformed depending on the shape of the target object or a pressing force applied to the contact portion, configured to come into contact with the target object, may be changed depending on the shape of the target object.

The present invention provides a unit cell including the above-mentioned electrode or electrode assembly. In addition, the present invention provides a battery module or a battery pack including the unit cell. In addition, the present invention provides a device having the unit cell, the battery module, or the battery pack mounted therein.

In the present invention, one or more constructions that do not conflict with each other may be selected and combined from among the above constructions.

As is apparent from the above description, a pressing apparatus according to the present invention includes a contact portion having a shape changeable depending on the shape of a target object to be pressed, a pressing portion configured to apply uniform force to the contact portion, and a pressure adjustment portion configured to adjust the force applied from the pressing portion differently depending on the shape of the target object in order to change the shape of the contact portion, whereby it is possible to apply uniform pressing force to the target object irrespective of the shape of the target object.

In addition, the target object, to which uniform pressing force is applied irrespective of the shape of the target object, may be uniformly laminated while the uniform shape of the target object is maintained. As a result, all parts of the target object are uniformly laminated, whereby it is possible to obtain a target object, the uniform shape of which is maintained. Furthermore, defects of the target object at a specific part thereof are remarkably reduced.

In addition, it is not necessary to perform an additional process for uniform lamination, whereby it is possible to reduce time and cost incurred in the process, which is economical.

In the case in which one part is said to be connected to another part in the entire specification, not only may the one part be directly connected to the other part, but also, the one part may be indirectly connected to the other part via a further part.

<FIG> is a schematic view of a pressing apparatus according to the present invention, <FIG> is a schematic view of the pressing apparatus according to the present invention configured to have a pressing roll type structure, <FIG> is a schematic view showing the interior of a pressing apparatus according to a first embodiment of the present invention, and <FIG> is a schematic view showing the interior of a pressing apparatus according to a second embodiment of the present invention.

The pressing apparatus <NUM> according to the present invention is characterized in that uniform pressure is applied to a target object <NUM> irrespective of the shape of the target object <NUM>.

The target object <NUM> may be an electrode having an active material applied to one surface or opposite surfaces of an electrode current collector or an electrode assembly including electrodes, each of which is formed as described above, i.e. a positive electrode and a negative electrode, which are stacked in the state in which a separator is interposed therebetween.

The positive electrode includes a positive electrode active material layer applied to at least one surface of a positive electrode current collector. The positive electrode active material layer may be manufactured by applying a positive electrode mixture of a positive electrode active material, a conductive agent, and a binder. A filler may be further added to the positive electrode mixture as needed.

In general, the positive electrode current collector is manufactured so as to have a thickness of <NUM> to <NUM>. The positive electrode current collector is not particularly restricted as long as the positive electrode current collector exhibits high conductivity while the positive electrode current collector does not induce any chemical change in a battery to which the positive electrode current collector is applied. For example, the positive electrode current collector may be made of stainless steel, aluminum, nickel, or titanium. Alternatively, the positive electrode current collector may be made of aluminum or stainless steel, the surface of which is treated with carbon, nickel, titanium, or silver. Specifically, aluminum may be used. The positive electrode current collector may have a micro-scale uneven pattern formed on the surface thereof so as to increase the force of adhesion to the positive electrode active material layer. The positive electrode current collector may be configured in any of various forms, such as a film, a sheet, a foil, a net, a porous body, a foam body, or a non-woven fabric body.

The positive electrode active material may be constituted, for example, by a layered compound, such as a lithium nickel oxide (LiNiO<NUM>), or a compound substituted with one or more transition metals; a lithium manganese oxide represented by the chemical formula Li<NUM>+xMn<NUM>-xO<NUM> (where x = <NUM> to <NUM>) or a lithium manganese oxide, such as LiMnO<NUM>, LiMn<NUM>O<NUM>, or LiMnO<NUM>; a lithium copper oxide (Li<NUM>CuO<NUM>); a vanadium oxide, such as LiV<NUM>O<NUM>, LiV<NUM>O<NUM>, V<NUM>O<NUM>, or Cu<NUM>V<NUM>O<NUM>; an Ni-sited lithium nickel oxide represented by the chemical formula LiNi<NUM>-xMxO<NUM> (where M = Co, Mn, Al, Cu, Fe, Mg, B, or Ga, and x = <NUM> to <NUM>); a lithium manganese composite oxide represented by the chemical formula LiMn<NUM>-xMxO<NUM> (where M = Co, Ni, Fe, Cr, Zn, or Ta, and x = <NUM> to <NUM>) or the chemical formula Li<NUM>Mn<NUM>MO<NUM> (where M = Fe, Co, Ni, Cu, or Zn); LiMn<NUM>O<NUM> in which a portion of Li in the chemical formula is replaced by alkaline earth metal ions; a disulfide compound; or Fe<NUM>(MoO<NUM>)<NUM>. However, the present invention is not limited thereto.

The conductive agent is generally added so that the conductive agent accounts for <NUM> weight% to <NUM> weight% based on the total weight of the mixture including the positive electrode active material. The conductive agent is not particularly restricted as long as the conductive agent exhibits high conductivity without inducing any chemical change in a battery to which the conductive agent is applied. For example, graphite, such as natural graphite or artificial graphite; carbon black, such as carbon black, acetylene black, Ketjen black, channel black, furnace black, lamp black, or thermal black; conductive fiber, such as carbon fiber or metallic fiber; carbon fluoride powder; metallic powder, such as aluminum powder, or nickel powder; conductive whisker, such as a zinc oxide or potassium titanate; a conductive metal oxide, such as a titanium oxide; or a conductive material, such as a polyphenylene derivative, may be used as the conductive agent.

The binder, which is included in the positive electrode, is a component assisting in binding between the active material and the conductive agent and in binding with the current collector. The binder is generally added in an amount of <NUM> weight% to <NUM> weight% based on the total weight of the mixture including the positive electrode active material. As examples of the binder, there may be used polyvinylidene fluoride, polyvinyl alcohol, carboxymethylcellulose (CMC), starch, hydroxypropylcellulose, regenerated cellulose, polyvinyl pyrrolidone, tetrafluoroethylene, polyethylene, polypropylene, ethylenepropylene-diene terpolymer, sulfonated ethylene-propylenediene monomer, styrene butadiene rubber, fluoro rubber, and various copolymers.

The negative electrode is manufactured by applying a negative electrode active material to one surface or opposite surfaces of a negative electrode current collector and drying the same, whereby a negative electrode active material layer is provided at one surface of the negative electrode. The above-described components may be selectively further included as needed.

Since the negative electrode is provided as a single-sided negative electrode having a negative electrode active material layer provided only at one surface of a negative electrode current collector, the space of a pouch-shaped secondary battery occupied by the negative electrode is reduced, whereby the capacity of the pouch-shaped secondary battery is increased.

As the negative electrode active material, for example, there may be used carbon, such as a non-graphitizing carbon or a graphite-based carbon; a metal composite oxide, such as LixFe<NUM>O<NUM> (<NUM>≤x≤<NUM>), LixWO<NUM> (<NUM>≤x≤<NUM>), or SnxMe<NUM>-xMe'yOz (Me: Mn, Fe, Pb, Ge; Me': Al, B, P, Si, Group <NUM>, <NUM> and <NUM> elements of the periodic table, halogen; <NUM><x≤<NUM>; <NUM>≤y≤<NUM>; <NUM>≤z≤<NUM>); lithium metal; lithium alloy; a silicon-based alloy; a tin-based alloy; a metal oxide, such as SnO, SnO<NUM>, PbO, PbO<NUM>, Pb<NUM>O<NUM>, Pb<NUM>O<NUM>, Sb<NUM>O3, Sb<NUM>O<NUM>, Sb<NUM>O<NUM>, GeO, GeO<NUM>, Bi<NUM>O<NUM>, Bi<NUM>O<NUM>, or Bi<NUM>O<NUM>; a conductive polymer, such as polyacetylene; or a Li-Co-Ni based material.

The separator is interposed between the positive electrode and the negative electrode, and an insulative thin film that exhibits high ion permeability and mechanical strength is used as the separator. The separator generally has a pore diameter of <NUM> to <NUM> and a thickness of <NUM> to <NUM>. As the material for the separator, for example, a sheet or non-woven fabric made of an olefin-based polymer, such as polypropylene, which exhibits chemical resistance and hydrophobicity, glass fiber, or polyethylene is used. In the case in which a solid electrolyte, such as a polymer, is used as an electrolyte, the solid electrolyte may also function as the separator.

The electrode assembly may be a stacked type electrode assembly constituted by unit cells, each of which is configured to have a structure in which a rectangular positive electrode and a rectangular negative electrode are stacked in the state in which a separator is interposed therebetween, or a laminated/stacked type electrode assembly, which is configured to have a structure in which unit cells are stacked so as to be attached to each other in the state in which a separator is interposed between therebetween, but the present invention is not limited thereto. However, it is preferable for the electrode assembly not to be a jelly-roll type electrode assembly, which is configured to have a structure in which a long sheet type positive electrode and a long sheet type negative electrode are wound in the state in which a separator is interposed therebetween, or a stacked and folded type electrode assembly, which is configured to have a structure in which unit cells are wound using a long separation film, which reduces impregnability of an electrolyte solution.

The pressing apparatus according to the present invention presses the positive electrode, the negative electrode, or the electrode assembly in a stacking direction.

When describing the pressing apparatus <NUM> with reference to <FIG>, the pressing apparatus <NUM> includes a pressing portion <NUM> configured to apply uniform force in the pressing apparatus, a contact portion <NUM> configured to come into direct contact with the target object <NUM>, and a pressure adjustment portion <NUM> located between the pressing portion and the contact portion, the pressure adjustment portion having a fluid contained therein.

The pressing apparatus <NUM> is moved toward the target object <NUM> by the pressing portion <NUM>, and the contact portion <NUM> of the pressing apparatus <NUM> may come into contact with the entirety of the outer surface of the target object <NUM>.

Also, in the pressing roll type pressing apparatus shown in <FIG>, the pressing portion <NUM> may not be connected to the pressure adjustment portion but may be connected to another region at which the pressure adjustment portion and the contact portion <NUM> can be pressed at once, as shown in <FIG>.

As shown in <FIG>, the pressing portion <NUM> may be configured to be in contact with the pressure adjustment portion <NUM>. Alternatively, as shown in <FIG>, the pressing portion may be configured to press a roll including a contact portion <NUM> and a pressure adjustment portion (not shown). The roll may be configured such that the contact portion is located at the outer surface of the roll and the pressure adjustment portion is disposed in the contact portion.

The pressing portion <NUM> may be configured to move the pressing apparatus <NUM> using physical mechanical force, or may be located in the pressing apparatus so as to move members constituting the pressing apparatus, such as the contact portion <NUM> and the pressure adjustment portion <NUM>, using hydraulic pressure in order to perform pressing.

In general, the pressing portion <NUM> may apply a pressing force of <NUM>/mm to <NUM>/mm to the contact portion <NUM> so as to come into contact with the target object <NUM>; however, the pressing force may be changed depending on the thickness of the target object <NUM>, elastic force of the target object <NUM>, and a purpose to be achieved by pressing.

The contact portion <NUM>, which is configured to come into direct contact with the target object <NUM>, may be deformed depending on the shape of the target object <NUM>. For example, the contact portion <NUM> may be made of an elastic material. Even in the case in which the outer surface of the target object includes a curved or bent portion, therefore, the contact portion may be deformed so as to come into tight contact with the entirety of the outer surface of the target object.

As an example, as shown in <FIG>, the shape of the contact portion <NUM> may be changed depending on the shape of the target object <NUM>. As can be seen from <FIG>, the shape of the contact portion <NUM> is changed so as to correspond to the shape of the target object <NUM> by force applied by the pressing portion <NUM>. The pressure adjustment portion <NUM> has a fluid contained therein. Consequently, pressure applied by the pressing portion <NUM> is distributed depending on the shape of the target object <NUM>, whereby the shape of the contact portion <NUM> is changed so as to correspond to the external shape of the target object <NUM>. At this time, late pressing force F2 applied by the pressure adjustment portion <NUM> is generated as a result of early pressing force F1 applied by the pressing portion <NUM> being appropriately dispersed by the fluid contained in the pressure adjustment portion <NUM> depending on the shape of the target object <NUM>, whereby the contact portion <NUM> presses the entire surface of the target object <NUM>.

As another example, as shown in <FIG> and <FIG>, the height of the contact portion <NUM> may be changed. That is, the shape of the pressure adjustment portion <NUM> having the fluid contained therein may be changed to adjust projection or depression of the contact portion.

Specifically, the pressing apparatus <NUM> according to the first embodiment shown in <FIG> may be configured to have a structure in which a single pressure adjustment portion <NUM> is connected to a plurality of contact portions <NUM>. That is, the pressure adjustment portion <NUM> may be a single member connected to a contact portion <NUM> constituted by a plurality of protrusions, and a fluid may be contained in the pressure adjustment portion.

At this time, the fluid may be contained in the pressure adjustment portion so as to account for a percentage of less than <NUM>%, whereby the fluid may be moved by the pressing portion <NUM> and the contact portion <NUM>.

At this time, the contact portion <NUM> may be operated in a manner in which the contact portion <NUM> projects out of the pressing apparatus <NUM> or is depressed into the pressing apparatus through one surface thereof as a result of the members constituting the pressing apparatus <NUM>, i.e. the contact portion <NUM>, the pressing portion <NUM>, and the pressure adjustment portion <NUM>, moving together, as shown in <FIG>.

In the pressing apparatus <NUM> according to the second embodiment shown in <FIG>, pressure adjustment portions <NUM> may be individually connected to contact portions <NUM>. That is, the pressure adjustment portions <NUM> may be individually connected to the contact portions <NUM>, which form a pattern, in order to adjust the shape or position of the contact portions <NUM>.

At this time, pressing portions <NUM> may be connected to the pressure adjustment portions <NUM> individually, i.e. one to one, as shown in <FIG>, or a plurality of pressing portions <NUM> may be integrally connected to a single pressure adjustment portion <NUM>, as shown in <FIG>.

In the case in which the pressure adjustment portions <NUM> are individually connected to the contact portions <NUM>, a movement range or a deformation range of each of the contact portions <NUM> may be further increased.

The contact portion <NUM> may be formed separately from the pressure adjustment portion <NUM>, or the contact portion <NUM> and the pressure adjustment portion <NUM> may be integrated.

As shown in <FIG>, the contact portion <NUM> is constituted by a plurality of protrusions configured to be individually movable, whereby movement ranges of the protrusions may be different from each other depending on the shape of the target object <NUM>.

At this time, the contact portion <NUM> may be configured to have a pattern in which the heights of the protrusions are different from each other depending on the shape of the target object <NUM>.

<FIG> is a photograph showing the shape of the pattern of the contact portion according to the present invention.

As can be seen from <FIG>, the contact portion <NUM> according to the present invention may have an oblique pattern (a), an X-shaped pattern (b), or a dot type pattern (c) having a plurality of micro-scale protrusions.

The oblique pattern may be used in the case in which the shape of the target object <NUM> is the same oblique shape as the pattern of the contact portion <NUM> while having a uniform height or in the case in which the target object has the same shape as the pattern of the contact portion based on a specific reference line.

In addition, the X-shaped pattern (b) may be used in the case in which a target object <NUM> having a changed height while having a uniform pattern is pressed, and the dot type pattern (c) may be used in the case in which an amorphous target object <NUM> is pressed.

The interval or the size of the pattern may be changed depending on the shape of the target object <NUM>. In general, however, it is preferable for the interval of the pattern to be <NUM> to <NUM>. In the case in which the interval of the pattern is less than the above range, it may be difficult to perform a fine adjustment or form a contact portion <NUM> having a pattern by a fluid. In the case in which the interval of the pattern is greater than the above range, it may be difficult to achieve uniformity in lamination through uniform pressing force, which must be achieved in the present invention.

The contact portion <NUM> may simultaneously perform heating while performing pressing. As a result, it is possible to easily achieve lamination for increasing coupling force of the positive electrode, the negative electrode, or the electrode assembly.

The pressing apparatus according to the first embodiment may be configured to have a structure in which a single pressure adjustment portion <NUM> is connected to a plurality of contact portions <NUM>, as shown in <FIG>. That is, the pressure adjustment portion <NUM> may be constituted by a single fluid layer connected to a contact portion <NUM> constituted by a plurality of protrusions.

At this time, a fluid may be contained in the fluid layer so as to account for a percentage of less than <NUM>%, whereby the fluid may be moved by the pressing portion <NUM> and the contact portion <NUM>.

In the pressing apparatus according to the second embodiment, pressure adjustment portions <NUM> may be individually connected to contact portions <NUM>, as shown in <FIG>. That is, the pressure adjustment portions <NUM> may be individually connected to the contact portions <NUM>, which form a pattern, in order to adjust the shape or position of the contact portions <NUM>.

At this time, pressing portions <NUM> may be individually connected to the pressure adjustment portions <NUM> or may be integrally connected to the pressure adjustment portions <NUM>.

Also, in the pressing roll type pressing apparatus shown in <FIG>, the pressing portion <NUM> may not be connected to the pressure adjustment portion <NUM>.

Although the pressing apparatus <NUM> according to the present invention may press the target object <NUM> only in one direction depending on the shape of the target object <NUM>, the pressing apparatus <NUM> may be constituted by an upper roll and a lower roll, each of which includes the pressing portion <NUM>, the contact portion <NUM>, and the pressure adjustment portion <NUM>, in order to press a three-dimensional target object <NUM>.

An electrode and electrode assembly manufacturing method according to the present invention includes a step (S1) of preparing an electrode or an electrode assembly as a target object to be pressed, a step (S2) of disposing the target object in the pressing apparatus described above, and a step (S3) of pressing the target object using the pressing apparatus.

The pressing apparatus may press one surface or opposite surfaces of the target object. At this time, the direction in which the pressing apparatus presses the target object may be changed depending on the shape of the target object.

In order to uniformly press the target object while maintaining the shape of the target object, the pressing apparatus may be deformed depending on the shape of the target object, or pressing force applied to the contact portion that comes into contact with the target object may be changed depending on the shape of the target object. Since the pressing apparatus has a shape changed depending on the shape of the target object, as described above, it is possible to apply uniform pressure to the target object. As a result, the target object may be uniformly laminated, whereby a defect rate of the target object may be reduced and various shapes of target objects may be formed.

The device may be an electronic device including a large-capacity battery, such as an electric vehicle, a hybrid electric vehicle, or a plug-in hybrid electric vehicle.

Claim 1:
A pressing apparatus (<NUM>) comprising:
a contact portion (<NUM>) having a shape or position configured to be changed depending on a shape of a target object (<NUM>) to be pressed so that the pressing apparatus (<NUM>) comes into contact with the entirety of the outer surface of the target object (<NUM>);
a pressing portion (<NUM>) configured to apply uniform force to the contact portion (<NUM>); and
a pressure adjustment portion (<NUM>) located between the contact portion (<NUM>) and the pressing portion (<NUM>), the pressure adjustment portion (<NUM>) having a fluid contained therein;
and wherein the contact portion (<NUM>) of the pressing apparatus (<NUM>) is configured to press the entire surface of the target object (<NUM>) characterized in that the contact portion (<NUM>) has a plurality of protrusions configured to be individually movable.