U.S. patent application number 12/599941 was filed with the patent office on 2010-08-26 for lithium ion rechargeable battery and process for producing the lithium ion rechargeable battery.
This patent application is currently assigned to NAMICS CORPORATION. Invention is credited to Mamoru Baba, Takayuki Fujita, Shoichi Iwaya, Hitoshi Masumura, Noriyuki Sakai, Hiroshi Sasagawa, Hiroshi Sato.
Application Number | 20100216032 12/599941 |
Document ID | / |
Family ID | 40031737 |
Filed Date | 2010-08-26 |
United States Patent
Application |
20100216032 |
Kind Code |
A1 |
Baba; Mamoru ; et
al. |
August 26, 2010 |
LITHIUM ION RECHARGEABLE BATTERY AND PROCESS FOR PRODUCING THE
LITHIUM ION RECHARGEABLE BATTERY
Abstract
Conventional ion rechargeable batteries having an electrode
layer on an electrolyte layer suffer from an impurity layer formed
at the interface, degrading performance. Conventional batteries
with no such impurity layer have a problem of weak interface
bonding. In the present invention, in a baking process step after
an electrode layer is laminated on an electrolyte layer, materials
for an electrode layer and an electrolyte layer are selected such
that an intermediate layer formed of a reaction product
contributing to charging and discharging reactions is formed at the
interface of the electrode layer and the electrolyte layer. In
addition, a paste that an active material is mixed with a
conductive material at a predetermined mixing ratio is used to form
a positive electrode layer and a negative electrode layer.
Reductions in electrode resistance and interface resistance and
improvement of charging and discharging cycle characteristics are
made possible.
Inventors: |
Baba; Mamoru; (Iwate,
JP) ; Iwaya; Shoichi; (Niigata, JP) ;
Masumura; Hitoshi; (Niigata, JP) ; Sakai;
Noriyuki; (Niigata, JP) ; Fujita; Takayuki;
(Niigata, JP) ; Sasagawa; Hiroshi; (Niigata,
JP) ; Sato; Hiroshi; (Niigata, JP) |
Correspondence
Address: |
YOUNG & THOMPSON
209 Madison Street, Suite 500
Alexandria
VA
22314
US
|
Assignee: |
NAMICS CORPORATION
Niigata-shi
JP
|
Family ID: |
40031737 |
Appl. No.: |
12/599941 |
Filed: |
May 9, 2008 |
PCT Filed: |
May 9, 2008 |
PCT NO: |
PCT/JP2008/058616 |
371 Date: |
December 30, 2009 |
Current U.S.
Class: |
429/322 ;
29/623.3 |
Current CPC
Class: |
B29C 65/02 20130101;
H01M 4/366 20130101; H01M 4/505 20130101; H01M 4/485 20130101; H01M
10/0562 20130101; H01M 10/0525 20130101; H01M 4/624 20130101; Y10T
29/49112 20150115; Y02E 60/10 20130101 |
Class at
Publication: |
429/322 ;
29/623.3 |
International
Class: |
H01M 6/18 20060101
H01M006/18; H01M 10/04 20060101 H01M010/04 |
Foreign Application Data
Date |
Code |
Application Number |
May 11, 2007 |
JP |
2007-127443 |
May 11, 2007 |
JP |
2007-127444 |
Claims
1-26. (canceled)
27. A multilayer all solid state lithium ion rechargeable battery
characterized by comprising: a multilayered product having a
positive electrode layer containing a positive active material
laminated on a negative electrode layer containing a negative
active material through an electrolyte layer containing a solid
electrolyte, wherein an intermediate layer formed of a substance
that functions as an active material or an electrolyte is included
at an interface of the positive electrode layer and/or the negative
electrode layer and the electrolyte layer, the intermediate layer
is a layer formed from a reaction and/or diffusion between the
positive active material and/or the negative active material and
the solid electrolyte.
28. The lithium ion rechargeable battery according to claim 27,
characterized in that the positive electrode layer and/or the
negative electrode layer has a structure in which an active
material is supported in a conductive matrix formed of a conductive
material.
29. The lithium ion rechargeable battery according to claim 28,
characterized in that an area ratio between the positive active
material and/or the negative active material and the conductive
material in a cross section of the positive electrode layer and/or
the negative electrode layer is within a range of 20:80 to
65:35.
30. The lithium ion rechargeable battery according to claim 27,
characterized in that the intermediate layer is a layer formed from
a reaction between the positive active material and/or the negative
active material and the solid electrolyte.
31. A multilayer all solid state lithium ion rechargeable battery
characterized by comprising: a multilayered product having a
positive electrode layer containing a positive active material
laminated on a negative electrode layer containing a negative
active material through an electrolyte layer containing a solid
electrolyte, wherein a part or all of the positive electrode layer
is formed of a sintered compact produced from a reaction and/or
diffusion between a starting material for the positive active
material contained in the positive electrode layer before baked and
a starting material for the solid electrolyte contained in the
electrolyte layer before baked.
32. A multilayer all solid state lithium ion rechargeable battery
characterized by comprising: a multilayered product having a
positive electrode layer containing a positive active material
laminated on a negative electrode layer containing a negative
active material through an electrolyte layer containing a solid
electrolyte, wherein a part or all of the negative electrode layer
is formed of a sintered compact produced from a reaction and/or
diffusion between a starting material for the negative active
material contained in the negative electrode layer before baked and
a starting material for the solid electrolyte contained in the
electrolyte layer before baked.
33. A multilayer all solid state lithium ion rechargeable battery
characterized by comprising: a multilayered product having a
positive electrode layer containing a positive active material
laminated on a negative electrode layer containing a negative
active material through an electrolyte layer containing a solid
electrolyte, wherein a part or all of the electrolyte layer is
formed of a sintered compact produced from a reaction and/or
diffusion between a starting material for the positive active
material contained in the positive electrode layer before baked a
starting material for the solid electrolyte contained in the
electrolyte layer before baked, and/or formed of a sintered compact
produced from a reaction and/or diffusion between a starting
material for the negative active material contained in the negative
electrode layer before baked and a starting material for the solid
electrolyte contained in the electrolyte layer before baked.
34. The lithium ion rechargeable battery according to claim 31,
characterized in that the positive electrode layer and/or the
negative electrode layer has a structure in which an active
material is supported in a conductive matrix formed of a conductive
material.
35. The lithium ion rechargeable battery according to claim 34,
characterized in that an area ratio between the positive active
material and/or the negative active material and the conductive
material in a cross section of the positive electrode layer and/or
the negative electrode layer is within a range of 20:80 to
65:35.
36. The lithium ion rechargeable battery according to claim 27,
characterized in that the positive electrode layer, the negative
electrode layer, and/or the electrolyte layer is formed of a
substance that functions as an active material or an electrolyte
formed from a reaction between a starting material for the positive
active material and/or a starting material for the negative active
material and a starting material for the solid electrolyte.
37. The lithium ion rechargeable battery according to claim 27,
characterized in that an oxide containing no lithium is not
included in a substance forming the intermediate layer or the
sintered compact.
38. The lithium ion rechargeable battery according to claim 27,
characterized in that a starting material for the solid electrolyte
contains at least a complex oxide of lithium and a IV group
element.
39. The lithium ion rechargeable battery according to claim 27,
characterized in that a starting material for the solid electrolyte
contains at least a lithium silicate.
40. The lithium ion rechargeable battery according to claim 27,
characterized in that a starting material for the solid electrolyte
contains at least a lithium silicate and a lithium phosphate.
41. The lithium ion rechargeable battery according to claim 40,
characterized in that a mixing ratio between the lithium silicate
and the lithium phosphate is within a range of 4:6 to 6:4.
42. The lithium ion rechargeable battery according to claim 27,
characterized in that the thickness of the electrolyte layer is 30
.mu.m or below.
43. The lithium ion rechargeable battery according to claim 27,
characterized in that a starting material for the positive active
material or the negative active material contains a substance or a
plurality of substances selected from a substance group of a
lithium manganese oxide, lithium nickel oxide, lithium cobalt
oxide, lithium vanadium oxide, lithium titanium oxide, manganese
dioxide, titanium oxide, niobium oxide, vanadium oxide, and
tungsten oxide.
44. The lithium ion rechargeable battery according to claim 43,
characterized in that a starting material for the positive active
material contains a lithium manganese oxide.
45. The lithium ion rechargeable battery according to claim 44,
characterized in that a starting material for the positive active
material contains Li.sub.xMn.sub.yO.sub.z (where x=1 to 2, y=1 to
2, and z=2 to 4).
46. The lithium ion rechargeable battery according to claim 43,
characterized in that a starting material for the negative active
material contains a lithium titanium oxide.
47. The lithium ion rechargeable battery according to claim 46,
characterized in that a starting material for the positive active
material contains Li.sub.xTi.sub.yO.sub.z (where x=1 to 2, y=1 to
5/3, and z=2 to 4).
48. A method of manufacture of a lithium ion rechargeable battery
characterized by comprising the steps of: alternately laminating a
positive electrode layer green sheet and a negative electrode layer
green sheet through at least an electrolyte layer green sheet to
form a multilayered product; and collectively baking the
multilayered product to form a sintered multilayered product,
wherein a starting material for the electrolyte layer contains at
least a complex oxide of lithium and a IV group element.
49. A method of manufacture of a lithium ion rechargeable battery
characterized by comprising the steps of: dispersing at least a
solid electrolyte material in a binder and a solvent to form a
solid electrolyte layer paste; coating and drying the solid
electrolyte layer paste to form a solid electrolyte layer green
sheet; mixing an active material with a conductive material, and
dispersing the materials in a binder and a solvent to form a
positive electrode layer paste and/or a negative electrode layer
paste; coating and drying the positive electrode layer paste and/or
the negative electrode layer paste to form a positive electrode
layer green sheet and/or a negative electrode layer green sheet;
alternately laminating the positive electrode layer green sheet and
the negative electrode layer green sheet through the solid
electrolyte layer green sheet to form a multilayered product; and
collectively baking the multilayered product to form a sintered
multilayered product, wherein a starting material for the
electrolyte layer contains at least a complex oxide of lithium and
a IV group element.
50. The method of manufacture of a lithium ion rechargeable battery
according to claim 49, characterized in that a mixing ratio of
mixing the active material with the conductive material is within a
range of 20:80 to 65:35 in a volume ratio.
51. The method of manufacture of a lithium ion rechargeable battery
according to claim 48, characterized in that a baking temperature
in the baking step ranges from temperatures of 600.degree. C. or
greater to 1100.degree. C. or below.
52. The method of manufacture of a lithium ion rechargeable battery
according to claim 48, characterized in that a baking temperature
in the baking step ranges from temperatures of 800.degree. C. or
greater to 1050.degree. C. or below.
Description
TECHNICAL FIELD
[0001] The present invention relates to a multilayer all solid
state lithium ion rechargeable battery including a multilayered
product formed of a positive electrode layer, an electrolyte layer,
and a negative electrode layer, and a method of manufacture of the
same.
BACKGROUND ART
[0002] Patent Document 1: JP 2007-5279 A
[0003] Patent Document 2: JP 2000-164252 A
[0004] Patent Document 3: JP 2004-281316 A
[0005] Patent Document 4: JP H06-9141 B
[0006] Patent Document 5: JP 2001-210360 A
[0007] Patent Document 6: JP 2001-351615 A
[0008] Non-Patent Document 1: J. Power Sources, 81-82, (1999),
853
[0009] Non-Patent Document 2: J. Electrochem. Soc., 124, (1977),
1240-1242
[0010] In recent years, the development of electronics appliances
are being reduced in size, weight, and thickness, and are provided
with multiple functions. With these trends, batteries, which are
power supplies of electronic appliances, are strongly demanded to
reduce in size and weight and to improve reliability. In order to
meet these demands, a multilayer lithium ion rechargeable battery
was proposed, in which multiple positive electrode layers and
negative electrode layers are laminated thorough an electrolyte
layer. Because the multilayer lithium ion rechargeable battery is
assembled by laminating a battery cell having a thickness of a few
.mu.m, reductions in size, weight, and thickness of the battery can
be readily realized. The all solid state lithium ion rechargeable
battery using a solid electrolyte instead of a liquid electrolyte
is free from the leakage and exhaustion of the electrolyte, and
highly reliable. Moreover, because the battery uses lithium, the
battery can obtain high voltage and high energy density.
[0011] An all solid state lithium battery using an inorganic solid
electrolyte for the electrolyte layer is prepared by in turn
laminating the positive active material layer and the negative
active material layer through the electrolyte layer to form a
multilayered product. In this all solid state lithium battery,
various problems have been reported in the past.
[0012] For example, in Non-Patent Document 1, it is reported that
when LiCoO.sub.2, which is a positive active material, and
LiTi.sub.2(PO.sub.4).sub.3, which is a solid electrolyte, are
laminated and baked, both react with each other in the baking
process to produce an impurity layer formed of a compound such as
CaTiO.sub.3, CO.sub.2TiO.sub.4, or LiCaPO.sub.4, which is not
contribute to charging and discharging reactions, at the interface
of the positive electrode layer and the electrolyte layer. This
impurity layer is formed to cause a problem that energy loss is
large, or the product does not function as a battery, because the
interface resistance is high.
[0013] In Patent Document 1, a technique is disclosed in which
specific materials are used for an active material and a solid
electrolyte, whereby the above-described formation of the impurity
layer is suppressed, an active material/solid electrolyte interface
is formed, which is electrochemically active, and an all solid
lithium ion rechargeable battery having a small internal resistance
and high capacitance is provided. Preferably, the following
materials are used as materials for the active material and the
solid electrolyte:
[0014] positive active material: LiMPO.sub.4
(where M is at least one kind selected from a group formed of Mn,
Fe, Co, and Ni)
[0015] solid electrolyte:
Li.sub.1+xM.sup.III.sub.xTi.sup.IV.sub.2-x(PO.sub.4).sub.3
(where M.sup.III is at least one kind selected from a group formed
of Al, Y, Ga, In, and La, 0.ltoreq.X.ltoreq.0.6)
[0016] negative active material: FePO.sub.4,
Li.sub.3Fe.sub.2(PO.sub.4).sub.3, and LiFeP.sub.2O.sub.7.
Patent Document 1 describes that when a multilayered product having
the positive active material layer, the electrolyte layer, and the
negative active material layer formed of these materials laminated
is analyzed by X-ray diffractometry, any components other than the
components forming the active material layer and the electrolyte
layer are not detected.
[0017] FIG. 12 is a cross section depicting a lithium ion
rechargeable battery before described in Patent Document 1, showing
an interface of a positive electrode layer and an electrolyte
layer. The battery shown in FIG. 12 is produced according to a
process described below. A positive active material powder formed
of LiCoPO.sub.4 and a solid electrolyte powder formed of
Li.sub.1.3Al.sub.0.3Ti.sub.1.7(PO.sub.4).sub.3 are prepared, they
are separately mixed with a binder, a solvent, and a plasticizer to
form slurries to prepare green sheets. After the prepared positive
active material green sheet and the solid electrolyte green sheet
are laminated, the sheets are baked at a temperature of 900.degree.
C. to form a multilayered product formed of an electrolyte layer
103 and a positive electrode layer 102, and gold is sputtered onto
the surface of the positive electrode layer 102 to form a metal
layer 101.
[0018] In the lithium ion rechargeable battery produced according
to Patent Document 1, no impurity layer interfering with the
charging and discharging reactions of the battery is formed at the
interface of the positive electrode layer 102 and the electrolyte
layer 103. In addition, also at an interface of a negative
electrode layer and an electrolyte layer, not shown, no impurity
layer is formed. Moreover, including the impurity layers
interfering with charging and discharging reactions, an area formed
of a reaction product is not formed at the interface of the
electrode layer and the electrolyte layer. On this account, the
interface bonding between the electrode layer and the electrolyte
layer is not strong, and it is incapable of providing a
sufficiently large contact area at the interface of the electrode
layer and the electrolyte layer. Therefore, there is a problem that
excellent charging and discharging cycle characteristics cannot be
obtained because of the occurrence of delamination caused by long
time use of the battery to increase internal resistance.
DISCLOSURE OF THE PRESENT INVENTION
Problems that the Present Invention is to Solve
[0019] It is an object of the present invention to provide a
multilayer all solid state lithium ion rechargeable battery having
a positive electrode layer, an electrolyte layer, and a negative
electrode layer laminated on each other, the lithium ion
rechargeable battery capable of reducing the internal resistance
and improving charging and discharging cycle characteristics of the
battery by strengthening the interface bonding of a multilayered
product and reducing electrode resistance and interface resistance
at the same time, and a method of manufacture of the same.
Means for Solving the Problems
[0020] An invention (1) is a multilayer all solid state lithium ion
rechargeable battery characterized by including: a multilayered
product having a positive electrode layer containing a positive
active material laminated on a negative electrode layer containing
a negative active material through an electrolyte layer containing
a solid electrolyte, wherein an intermediate layer formed of a
substance that functions as an active material or an electrolyte is
included at an interface of the positive electrode layer and/or the
negative electrode layer and the electrolyte layer and the
intermediate layer is a layer formed from a reaction and/or
diffusion between the positive active material and/or the negative
active material and the solid electrolyte.
[0021] An invention (2) is the lithium ion rechargeable battery
according to the invention (1), characterized in that the positive
electrode layer and/or the negative electrode layer has a structure
in which an active material is supported in a conductive matrix
formed of a conductive material.
[0022] An invention (3) is the lithium ion rechargeable battery
according to the invention (2), characterized in that an area ratio
between the positive active material and/or the negative active
material and the conductive material in a cross section of the
positive electrode layer and/or the negative electrode layer is
within a range of 20:80 to 65:35.
[0023] An invention (4) is the lithium ion rechargeable battery
according to any one of the inventions (1) to (3), characterized in
that the intermediate layer is a layer formed from a reaction
between the positive active material and/or the negative active
material and the solid electrolyte.
[0024] An invention (5) is a multilayer all solid state lithium ion
rechargeable battery characterized by including: a multilayered
product having a positive electrode layer containing a positive
active material laminated on a negative electrode layer containing
a negative active material through an electrolyte layer containing
a solid electrolyte, wherein a part or all of the positive
electrode layer is formed of a sintered compact produced from a
reaction and/or diffusion between a starting material for the
positive active material contained in the positive electrode layer
before baked and a starting material for the solid electrolyte
contained in the electrolyte layer before baked.
[0025] An invention (6) is a multilayer all solid state lithium ion
rechargeable battery characterized by including: a multilayered
product having a positive electrode layer containing a positive
active material laminated on a negative electrode layer containing
a negative active material through an electrolyte layer containing
a solid electrolyte, wherein a part or all of the negative
electrode layer is formed of a sintered compact produced from a
reaction and/or diffusion between a starting material for the
positive active material contained in the positive electrode layer
before baked and a starting material for the solid electrolyte
contained in the electrolyte layer before baked.
[0026] An invention (7) is a multilayer all solid state lithium ion
rechargeable battery characterized by including: a multilayered
product having a positive electrode layer containing a positive
active material laminated on a negative electrode layer containing
a negative active material through an electrolyte layer containing
a solid electrolyte, wherein a part or all of the electrolyte layer
is formed of a sintered compact produced from a reaction and/or
diffusion between a starting material for the positive active
material contained in the positive electrode layer before baked and
a starting material for the solid electrolyte contained in the
electrolyte layer before baked, and/or formed of a sintered compact
produced from a reaction and/or diffusion between a starting
material for the negative active material contained in the negative
electrode layer before baked and a starting material for the solid
electrolyte contained in the electrolyte layer before baked.
[0027] An invention (8) is the lithium ion rechargeable battery
according to any one of the inventions (5) to (7), characterized in
that the positive electrode layer and/or the negative electrode
layer has a structure in which an active material is supported in a
conductive matrix formed of a conductive material.
[0028] An invention (9) is the lithium ion rechargeable battery
according to the invention (8), characterized in that an area ratio
between the positive active material and/or the negative active
material and the conductive material in a cross section of the
positive electrode layer and/or the negative electrode layer is
within a range of 20:80 to 65:35.
[0029] An invention (10) is the lithium ion rechargeable battery
according to any one of the inventions (1) to (9), characterized in
that the positive electrode layer, the negative electrode layer,
and/or the electrolyte layer is formed of a substance that
functions as an active material or an electrolyte formed from a
reaction between a starting material for the positive active
material and/or a starting material for the negative active
material and a starting material for the solid electrolyte.
[0030] An invention (11) is the lithium ion rechargeable battery
according to any one of the inventions (1) to (10), characterized
in that an oxide containing no lithium is not included in a
substance forming the intermediate layer or the sintered
compact.
[0031] An invention (12) is the lithium ion rechargeable battery
according to any one of the inventions (1) to (11), characterized
in that a starting material for the solid electrolyte contains at
least a complex oxide of lithium and a IV group element.
[0032] An invention (13) is the lithium ion rechargeable battery
according to any one of the inventions (1) to (12), characterized
in that a starting material for the solid electrolyte contains at
least a lithium silicate.
[0033] An invention (14) is the lithium ion rechargeable battery
according to any one of the inventions (1) to (13), characterized
in that a starting material for the solid electrolyte contains at
least a lithium silicate and a lithium phosphate.
[0034] An invention (15) is the lithium ion rechargeable battery
according to the invention (14), characterized in that a mixing
ratio between the lithium silicate and the lithium phosphate is
within a range of 4:6 to 6:4.
[0035] An invention (16) is the lithium ion rechargeable battery
according to any one of the inventions (1) to (15), characterized
in that the thickness of the electrolyte layer is 30 .mu.m or
below.
[0036] An invention (17) is the lithium ion rechargeable battery
according to any one of the inventions (1) to (16), characterized
in that a starting material for the positive active material or the
negative active material contains a substance or a plurality of
substances selected from a substance group of a lithium manganese
oxide, lithium nickel oxide, lithium cobalt oxide, lithium vanadium
oxide, lithium titanium oxide, manganese dioxide, titanium oxide,
niobium oxide, vanadium oxide, and tungsten oxide.
[0037] An invention (18) is the lithium ion rechargeable battery
according to the invention (17), characterized in that a starting
material for the positive active material contains a lithium
manganese oxide.
[0038] An invention (19) is the lithium ion rechargeable battery
according to the invention (18), characterized in that a starting
material for the positive active material contains
Li.sub.xMn.sub.yO.sub.z (where x=1 to 2, y=1 to 2, and z=2 to
4).
[0039] An invention (20) is the lithium ion rechargeable battery
according to the invention (17), characterized in that a starting
material for the negative active material contains a lithium
titanium oxide.
[0040] An invention (21) is the lithium ion rechargeable battery
according to the invention (20), characterized in that a starting
material for the positive active material contains
Li.sub.xTi.sub.yO.sub.z (where x=1 to 2, y=1 to 5/3, and z=2 to
4).
[0041] An invention (22) is a method of manufacture of a lithium
ion rechargeable battery characterized by including the steps of:
alternately laminating a positive electrode layer green sheet and a
negative electrode layer green sheet through at least an
electrolyte layer green sheet to form a multilayered product; and
collectively baking the multilayered product to form a sintered
multilayered product, wherein a starting material for the
electrolyte layer contains at least a complex oxide of lithium and
a IV group element.
[0042] An invention (23) is a method of manufacture of a lithium
ion rechargeable battery characterized by including the steps of:
dispersing at least a solid electrolyte material in a binder and a
solvent to form a solid electrolyte layer paste; coating and drying
the solid electrolyte layer paste to form a solid electrolyte layer
green sheet; mixing an active material with a conductive material,
and dispersing the materials in a binder and a solvent to form a
positive electrode layer paste and/or a negative electrode layer
paste; coating and drying the positive electrode layer paste and/or
the negative electrode layer paste to form a positive electrode
layer green sheet and/or a negative electrode layer green sheet;
alternately laminating the positive electrode layer green sheet and
the negative electrode layer green sheet through the solid
electrolyte layer green sheet to form a multilayered product; and
collectively baking the multilayered product to form a sintered
multilayered product, wherein a starting material for the
electrolyte layer contains at least a complex oxide of lithium and
a IV group element.
[0043] An invention (24) is the method of manufacture of a lithium
ion rechargeable battery according to the invention (23),
characterized in that a mixing ratio of mixing the active material
with the conductive material is within a range of 20:80 to 65:35 in
a volume ratio.
[0044] An invention (25) is the method of manufacture of a lithium
ion rechargeable battery according to any one of the inventions
(22) to (24), characterized in that a baking temperature in the
baking step ranges from temperatures of 600.degree. C. or greater
to 1100.degree. C. or below.
[0045] An invention (26) is the method of manufacture of a lithium
ion rechargeable battery according to any one of the inventions
(22) to (24), characterized in that a baking temperature in the
baking step ranges from temperatures of 800.degree. C. or greater
to 1050.degree. C. or below.
ADVANTAGE OF THE PRESENT INVENTION
[0046] According to the present invention (1), or (5) to (7), or
(10), and (22), the interface bonding of the multilayered product
of the lithium ion rechargeable battery is strengthened, and the
interface resistance is reduced at the same time, whereby battery
internal resistance can be reduced, and charging and discharging
cycle characteristics can be improved.
[0047] According to the invention (2), (3), (8), (9), (23), or
(24), the following advantages are exerted.
1. The mixing ratio between the active material and the conductive
material is within a range of 20:80 to 65:35 in the area ratio,
whereby the electrode structure is the structure in which the
active material is supported in the conductive matrix, and the
conductive matrix assists the active material of a low electric
conductivity to carry current. Thus, the present invention is
advantageous in improving battery performance such as a reduction
in impedance and an increase in ampere-hour capacity. 2. Because
the electrode layer functions as the active material layer and the
current collector layer before in a single layer, no current
collector layer is necessary, and the present invention is
advantageous in a simplified process steps, reductions in
manufacture costs, prevention of sheet attack, and the like. 3. The
electrode is formed in the structure in which the active material
is supported in the conductive matrix, whereby the active material
and the conductive material are entangled with each other. Thus,
expansion caused by charging and discharging and the removal of the
active material and the conductive material because of contraction
can be suppressed, and the present invention is advantageous in
improving charging and discharging cycle characteristics. 4. The
active material, which is difficult to be adopted in the past
because of its too small electric conductivity, is supported in the
conductive matrix, whereby the active material can be adopted as an
excellent active material for the electrode material of the lithium
ion rechargeable battery.
[0048] According to the inventions (11) to (13), at the interface
of the electrode layer and the electrolyte layer, the formation of
a useful reaction product that functions as the active material or
the electrolyte can be promoted.
[0049] According to the invention (14), the ionic conductance in
the electrolyte layer can be improved.
[0050] According to the invention (15), the ionic conductance in
the electrolyte layer can be made optimum.
[0051] According to the invention (16), a small-sized lithium ion
rechargeable battery of large capacity with low internal resistance
and high performance can be produced.
[0052] According to the inventions (17) to (21), a useful
intermediate layer contributing to the charging and discharging
reactions of the battery can be formed at the interface of the
electrode layer and the electrolyte layer.
[0053] According to the invention (25), a useful intermediate layer
can be formed, and problems such as the melting of the solid
electrolyte, structural changes in the positive active material and
the negative active material, and the deformation of the
multilayered product can be prevented.
[0054] According to the invention (26), the present invention is
effective for compacting the electrode layer and the electrolyte
layer and a reduction in battery internal resistance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0055] FIGS. 1(a) and 1(b) are cross sections depicting a lithium
ion rechargeable battery according to according to a specific
embodiment of the present invention before baked and after
baked;
[0056] FIG. 2 shows cross sectional SEM photographs of a lithium
ion rechargeable battery;
[0057] FIG. 3 is a work flowchart depicting a study experiment to
study reactions between an electrolyte material and an active
material;
[0058] FIG. 4 shows XRD patterns of samples prepared in which a
solid electrolyte was mixed with a positive active material and
then baked;
[0059] FIG. 5 shows XRD patterns of samples prepared in which a
solid electrolyte was mixed with a negative active material and
then baked;
[0060] FIG. 6 is a graph depicting the dependency of ionic
conductivity of lithium silicophosphate on electrolyte material
compositions;
[0061] FIGS. 7(a) to 7(e) are cross sections depicting the lithium
ion rechargeable battery according to a specific embodiment of the
present invention and graphs depicting concentration
distributions;
[0062] FIG. 8 shows graphs depicting the dependencies of electric
conductivity and ampere-hour capacity on the positive active
material volume ratio;
[0063] FIG. 9 shows graphs depicting the dependencies of electric
conductivity and ampere-hour capacity on the negative active
material volume ratio;
[0064] FIG. 10 shows XRD patterns of samples prepared in which a
solid electrolyte was mixed with an active material and then
baked;
[0065] FIG. 11 shows XRD patterns of samples prepared in which a
solid electrolyte was mixed with an active material and then baked;
and
[0066] FIG. 12 is a cross section depicting a lithium ion
rechargeable battery before.
DESCRIPTION OF REFERENCE NUMERALS AND SIGNS
[0067] 1: positive electrode layer [0068] 2: electrolyte layer
[0069] 3: negative electrode layer [0070] 4: intermediate layer
formed at a positive electrode layer/electrolyte layer interface
[0071] 5: intermediate layer formed at a negative electrode
layer/electrolyte layer interface [0072] 6, 9: electrolyte layer
[0073] 7, 10: intermediate layer [0074] 8, 11: negative electrode
layer [0075] 21: positive electrode layer [0076] 22: electrolyte
layer [0077] 23: negative electrode layer [0078] 24: intermediate
layer formed at a positive electrode layer/electrolyte layer
interface [0079] 25: intermediate layer formed at a negative
electrode layer/electrolyte layer interface [0080] 26: positive
active material concentration [0081] 27: electrolyte the
concentration [0082] 28: negative active material concentration
[0083] 29, 32: reaction product layer that functions as a positive
electrode [0084] 30, 34: reaction product layer that functions as a
negative electrode [0085] 31, 33: reaction product layer that
functions as an electrolyte [0086] 101: metal layer [0087] 102:
positive electrode layer [0088] 103: electrolyte layer
BEST MODE FOR CARRYING OUT THE PRESENT INVENTION
[0089] Hereinafter, the best mode of the present invention will be
described. A lithium ion rechargeable battery according to the
present invention is a lithium ion rechargeable battery formed of a
multilayered product having a positive electrode layer and a
negative electrode layer alternately laminated through an
electrolyte layer in which an intermediate layer formed from
reactions by baking the multilayered product is provided at an
interface of the electrolyte layer and any one of the positive
electrode layer and the negative electrode layer, or both at an
interface of the positive electrode layer and the electrolyte layer
and an interface of the negative electrode layer and the
electrolyte layer. Moreover, a material for the electrolyte layer
is properly selected to allow the intermediate layer to function as
an active material or an electrolyte.
[0090] The present inventors used a plurality of active materials
and a plurality of solid electrolyte materials to produce lithium
ion rechargeable batteries, and compared and studied the batteries.
As the result, they found that when a starting material containing
a complex oxide of lithium and a IV group element such as a lithium
silicate and a lithium germanium oxide is used, no impurity layer
is formed at the interface of the electrode layer and the
electrolyte layer (hereinafter, a layer formed of a reaction
product that does not function as either an active material or an
electrolyte is referred to as "an impurity layer") in the baking
process, and the active material and the solid electrolyte react
with each other to produce a layer formed of a useful reaction
product contributing to charging and discharging reactions
(hereinafter, such a layer formed of a useful reaction product that
functions as an active material or an electrolyte is referred to as
"an intermediate layer"). Methods of preparing individual layers of
the positive electrode layer, the electrolyte layer, and the
negative electrode layer were conducted in which powders for the
individual layers were each dispersed in a solvent and a binder to
form pastes, each of the pastes was coated and dried on a sheet to
form a green sheet, and the sheets were laminated and then baked.
It was found that substances forming the intermediate layer do not
include an oxide containing no lithium and only substances that
function as the active material or the electrolyte in the lithium
ion rechargeable battery are produced.
[0091] In addition, it was found that when only a phosphoric acid
material such as a lithium phosphate widely used is used for a
solid electrolyte of a lithium ion rechargeable battery, no
reaction product is produced at the interface. It can be considered
that this is because a phosphate such as a lithium phosphate is a
single salt and it is hard to react with the active material. In
contrast to this, it is estimated that lithium silicate
Li.sub.4SiO.sub.4, for example, is a complex oxide of Li.sub.2O and
SiO.sub.2, and highly reactive Li.sub.2O, isolated by baking,
reacts with the active material.
[0092] Moreover, the present inventors found that a material having
an active material mixed with a conductive material is used for the
material forming the positive electrode layer and/or the negative
electrode layer, whereby the impedance of the electrode can be
reduced. In addition, they found that the mixing ratio between an
active material and a conductive material forming the electrode is
changed to produce and evaluate batteries, and as the result, when
both of the mixing ratio between a positive active material and a
conductive material, which are materials for a paste, and the
mixing ratio between a negative active material and a conductive
material range from 20:80 to 65:35, such batteries having excellent
characteristics of high electric conductivity and large ampere-hour
capacity can be produced. It was found from the results of
observing the cross sections of batteries produced under the
optimum conditions by SEM and EDS that the area ratio between the
active material and the conductive material in the electrode cross
section ranges from 20:80 to 65:35 as similar to the volume ratio.
In addition, it was found that when the mixing ratio of the
conductive material is 35% or greater in the volume ratio, the
conductive material continues in a matrix in the cross section and
the active material is supported in the matrix-like conductive
material. It was also found that in order to form such a matrix
structure, it is necessary to bake a multilayered product at a high
temperature of 600.degree. C. or greater.
[0093] Here, in the present application, the term "conductive
matrix", or "matrix-like conductive material" means a structure
that conductive material particles three-dimensionally continue and
contact with one another. When the conductive material is a metal,
the term "metal matrix" is sometimes used. In addition, the
expression "a structure that an active material is supported in a
conductive matrix" means a structure that active material particles
are distributed among conductive material particles, which are
three-dimensionally continue and contact with one another. The
active material particles may be continuously distributed, or may
be discontinuously distributed. However, preferably, the active
material particles are uniformly distributed in the electrode. In
addition, the expression "to be three-dimensionally continuous"
means that even though a partially discontinuing portion exists on
a two-dimensional cross section, it is considered to be
three-dimensionally continuous when a continuing area exists at
least in the other cross sections.
[0094] In addition, even though a slight amount of an additive is
added as an electrode material in addition to an active material
and a conductive material, the mixing ratio between the active
material and the conductive material to be a paste material is set
in the range of 20:80 to 65:35 to form the electrode structure into
a conductive matrix in which an active material is supported, and
excellent batteries having a low impedance and a large ampere-hour
capacity can be produced, as long as the amount of the additional
additive does not greatly reduce an amount of the active material
or the conductive material.
[0095] The lithium ion rechargeable battery according to the
present invention is highly advantageous in producing batteries of
high performance even though the positive electrode layer and/or
the negative electrode layer is unnecessarily formed in the
structure in which an active material is supported in a conductive
matrix as long as a useful reaction layer is formed from a reaction
between the positive electrode layer and/or the negative electrode
layer and the solid electrolyte layer. In addition, the positive
electrode layer and/or the negative electrode layer are formed in
the structure in which an active material is supported in a
conductive matrix, whereby batteries of higher performance can be
prepared.
[0096] [Structure of a Battery]
[0097] FIGS. 1(a) and 1(b) are cross sections depicting a lithium
ion rechargeable battery according to a specific embodiment of the
present invention before baked and after baked. In addition, FIGS.
1(a) and 1(b) are cross sections depicting a secondary battery
having the most basic structure of a multilayered product. The
multilayered product has a structure in which a positive electrode
layer 1 is laminated on a negative electrode layer 3 through an
electrolyte layer 2.
[0098] For a positive active material forming the positive
electrode layer 1, LiMn.sub.2O.sub.4, for example, is used. For a
solid electrolyte forming the electrolyte layer 2,
Li.sub.3.5Si.sub.0.5P.sub.0.5O.sub.4, for example, is used. For a
negative active material forming the negative electrode layer 3,
Li.sub.4/3Ti.sub.5/3O.sub.4, for example, is used.
[0099] Although Li.sub.3.5Si.sub.0.5P.sub.0.5O.sub.4 used for the
solid electrolyte is a solid solution of Li.sub.3PO.sub.4 and
Li.sub.4SiO.sub.4, it was found from experimental results that
Li.sub.4SiO.sub.4 greatly contributes to reactions with the active
material in Li.sub.3PO.sub.4 and Li.sub.4SiO.sub.4 forming the
electrolyte. When the multilayered product shown in FIG. 1(a) is
baked at a temperature of 600.degree. C. or greater, as shown in
FIG. 1(b), an intermediate layer 4 is formed at the interface of
the positive electrode layer 1 and the electrolyte layer 2, and an
intermediate layer 5 is formed at the interface of the negative
electrode layer 3 and the electrolyte layer 2. The intermediate
layer 4 contains substances such as LiMnO.sub.2, Li.sub.2MnO.sub.3,
and Li.sub.1.4Mn.sub.1.7O.sub.4. LiMnO.sub.2 and
Li.sub.1.4Mn.sub.1.7O.sub.4 function as active materials, and
Li.sub.2MnO.sub.3 functions as an electrolyte. The intermediate
layer 5 contains substances such as LiTiO.sub.2 and
Li.sub.2TiO.sub.3. LiTiO.sub.2 functions as an active material, and
Li.sub.2TiO.sub.3 functions as an electrolyte.
[0100] For example, it is considered that the formation of the
intermediate layer at the negative electrode side interface occurs
by the reactions below.
2 Li 3.5 Si 0.5 P 0.5 O 4 .fwdarw. Li 4 SiO 4 + Li 3 PO 4 .fwdarw.
2 Li 2 O + SiO 2 + Li 3 PO 4 SiO 2 + 2 Li 2 O .fwdarw. Li 4 SiO 4 6
Li 4 / 3 Ti 5 / 3 O 4 + Li 2 O .fwdarw. 10 LiTiO 2 + 5 / 2 O 2
.uparw. 3 Li 4 / 3 Ti 5 / 3 O 4 + 3 Li 2 O .fwdarw. 5 Li 2 TiO 3
##EQU00001##
[0101] Moreover, it was found that as the baking temperature is
increased, the reaction product at the positive electrode side
interface changes from LiMn.sub.2O.sub.4 to more Li-rich compounds,
Li.sub.1.4Mn.sub.1.7O.sub.4, Li.sub.1.6Mn.sub.1.6O.sub.4,
LiMnO.sub.2, and Li.sub.2MnO.sub.3, and the reaction product at the
negative electrode side interface changes from
Li.sub.4/3Ti.sub.5/3O.sub.4 to more Li-rich compounds, LiTiO.sub.2
and Li.sub.2TiO.sub.3
[0102] FIG. 2 shows cross sectional SEM photographs of a lithium
ion rechargeable battery. The photographs shown in FIG. 2 show the
interface of the negative electrode layer and the electrolyte layer
of the battery shown in FIG. 1(a), and the battery was produced in
which the temperature was increased to a temperature of 870.degree.
C. at a rate of temperature rise of 200.degree. C./hr, and then the
battery was held for two hours and allowed to stand to cool. It is
seen from the photograph shown in the left that an intermediate
layer 7 is formed between an electrolyte layer 6 and a negative
electrode layer 8. It is seen from the photograph that the
thickness of the intermediate layer is about 10 .mu.m. The
photograph shown on the right is a photograph that partially
enlarges the areas of the individual layers in the photograph shown
in the left, showing an electrolyte layer 9, an intermediate layer
10, and a negative electrode layer 11. It is seen that the
intermediate layer 10 exists, which is clearly different from the
electrolyte layer 9 and the negative electrode layer 11, the
electrolyte layer 6 is strongly bonded to the intermediate layer 7,
and the intermediate layer 7 is strongly bonded to the negative
electrode layer 8. In across sectional photograph of a battery
using materials to form no intermediate layers, such strong bonding
is not conformed. It was found from the analysis results that
substances forming the intermediate layer include substances such
as LiTiO.sub.2 and Li.sub.2TiO.sub.3 as described above. It is
known that LiTiO.sub.2 functions as an active material, and
Li.sub.2TiO.sub.3 functions as an electrolyte.
[0103] Similar SEM observations were made to the interface of the
electrolyte layer and the negative electrode layer as well as to
the interface of the electrolyte layer and the positive electrode
layer, and it was found that an intermediate layer existed. The
positive electrode layer was strongly bonded to the electrode layer
through the intermediate layer also at the positive electrode side
interface. In addition, it was found from the analysis results that
the positive electrode side intermediate layer contained substances
such as LiMnO.sub.2, Li.sub.2MnO.sub.3, and
Li.sub.1.4Mn.sub.1.7O.sub.4 as described above. It is known that
LiMnO.sub.2 and Li.sub.1.4Mn.sub.1.7O.sub.4 functions as active
materials, and Li.sub.2MnO.sub.3 functions as an electrolyte.
[0104] In addition, it was confirmed from the analysis results that
the intermediate layer had no impurities that do no function as
either an active material or an electrolyte. Because the
intermediate layer formed in the baking process strengthened
bonding between the positive electrode layer, the negative
electrode layer and the electrolyte layer and the contact area
between the active material and the electrolyte was dramatically
increased in the intermediate layer at the same time, a substantial
reduction in interface resistance was implemented. Because the
bonding strength of the interface was strong even though charging
and discharging are repeated for a long time, the intermediate
layer was also advantageous in improving charging and discharging
cycle characteristics.
[0105] When the thicknesses of the layers forming the battery
become thinner, the battery internal resistance is more affected
from the ion conductance at the interface of the electrode layer
and the electrolyte layer than the electronic conductivity in the
electrode layer and the ionic conductance in the electrolyte layer.
The development of the lithium ion rechargeable battery is being
advanced for further reductions in size and provisions of larger
capacity and high output voltage, and the thicknesses of the
electrode layer and the electrolyte layer tend to be much thinner.
Because the technique according to the present invention can
substantially decrease interface resistance, significant advantages
can be particularly obtained when the technique is adapted to a
battery having a thickness of its electrolyte layer being 30 .mu.m
or below.
[0106] In the battery according to the specific embodiment shown in
FIGS. 1(a) and 1(b), a battery formed of a single battery cell is
shown in which a single positive electrode layer is laminated on a
single negative electrode layer as a single electrolyte layer is
sandwiched between these layers. However, batteries are generally
produced as a large number of battery cells are laminated on each
other. In other words, a battery has a multilayered product in
which a plurality of positive electrode layers and a plurality of
negative electrode layers are alternately laminated through an
electrolyte layer. It is without saying that the technique
according to the present invention is also applicable to such
batteries and exerts excellent advantages. When the number of the
battery cells is increased and the number of the interfaces is
grown, the advantages of the present invention are more
significantly exerted. In order to fully enjoy the merits of the
technique according to the present invention, preferably, the
number of battery cells ranges from 2 to 500 cells, and more
preferably, 5 to 500 cells. In addition, the structure of the
lithium ion rechargeable battery according to the present invention
may be a structure in which a current collector layer is not
laminated on the electrode layer, or may be a structure in which a
current collector layer is laminated on the electrode layer.
[0107] [Materials of the Battery]
[0108] (Materials for the Active Material)
[0109] For the active material forming the electrode layer of the
lithium ion rechargeable battery according to the present
invention, preferably, materials that efficiently release and
attract lithium ions are used. For example, preferably, transition
metal oxides and transition metal complex oxides are used. More
specifically, preferably, lithium manganese complex oxides, lithium
nickel complex oxides, lithium cobalt complex oxides, lithium
vanadium complex oxides, lithium titanium complex oxides, manganese
dioxides, titanium oxides, niobium oxides, vanadium oxides,
tungsten oxides, and the like are used. Moreover, because lithium
manganese complex oxides and lithium titanium complex oxides
particularly have small changes in the volume caused by the
attraction and release of lithium ions and hardly cause fine
powders and removal of electrodes, these oxides can be more
preferably used for the active material.
[0110] Here, there is no clear distinction between the positive
active material and the negative active material. The potentials of
two kinds of compounds are compared, the compound showing higher
potential can be used for the positive active material, and the
compound showing lower potential can be used for the negative
active material. For the positive active material, lithium
manganese oxides are particularly preferably used. For the negative
active material, lithium titanium oxides are particularly
preferably used.
[0111] In addition, for supplementary explanations, the term
"complex oxide" means an oxide containing two kinds of elements or
greater in addition to oxygen, and the term "lithium manganese
oxide", for example, is referred to as "lithium manganese complex
oxide". Oxides containing only a single element in addition to
oxygen are simply referred to as "oxides". However, the term
"oxide" means a higher-level concept including the term "complex
oxide". Therefore, the term "lithium manganese complex oxide" means
the same substance as "lithium manganese oxide".
[0112] (Materials for the Conductive Material)
[0113] The structure of the lithium ion rechargeable battery
according to the present invention may be a structure in which a
current collector layer formed of a conductive material is
laminated on an electrode layer. In addition, the positive
electrode layer and/or the negative electrode layer may be formed
in a structure in which an active material is supported in a
conductive matrix formed of a conductive material. For such
conductive materials, preferably, a material having a large
electric conductivity is used. For example, preferably, a metal or
an alloy of high oxidation resistance is used.
[0114] Here, a metal or an alloy of high oxidation resistance is a
metal or an alloy having an electric conductivity of
1.times.10.sup.1 S/cm or greater after baked under atmosphere. More
specifically, for the metal, silver, palladium, gold, platinum,
aluminum, or the like is preferably used. For the alloy, an alloy
formed of two kinds of metals or greater selected from silver,
palladium, gold, platinum, copper, and aluminum is preferably used.
For example, AgPd is preferably used. For AgPd, a powder mixture of
Ag powder and Pd powder or AgPd alloy powder is preferably
used.
[0115] A conductive material that is mixed with an active material
for preparing an electrode layer may be the same in the positive
electrode and the negative electrode, or may be different. In other
words, preferably, the material, mixing ratio, and manufacture
conditions of the conductive material are suitably individually
selected for the positive electrode and the negative electrode.
[0116] (Materials for the Solid Electrolyte)
[0117] For the solid electrolyte forming the electrolyte layer of
the lithium ion rechargeable battery according to the present
invention, materials having a small electronic conductivity and a
high lithium ion conductance are preferably used. In addition,
preferably, materials are inorganic materials that can be baked in
atmosphere. In addition, preferably, a complex oxide of lithium and
a IV group element such as a lithium silicate is used for forming a
reaction product contributing to charging and discharging. For
example, preferably, at least one kind of material selected from a
group formed of lithium silicophosphate
(Li.sub.3.5Si.sub.0.5P.sub.0.5O.sub.4), phosphoric acid germanium
lithium Li.sub.3.5Ge.sub.0.5P.sub.0.5O.sub.4, Li.sub.2O--SiO.sub.2,
Li.sub.2O--V.sub.2O.sub.5--SiO.sub.2, and Li.sub.2O--GeO.sub.2 is
used. Particularly, preferably, a lithium silicophosphate is used.
A lithium silicophosphate is a complex oxide of a lithium phosphate
and a lithium silicate, which is sometimes expressed by
Li.sub.3PO.sub.4--Li.sub.4SiO.sub.4. A lithium silicate having
effect on generating a substance useful for charging and
discharging reactions is mixed with a lithium phosphate having high
ionic conductivity, whereby the ionic conductivity of the
electrolyte layer is advantageously improved. FIG. 6 is a graph
depicting the dependency of the ionic conductivity of lithium
silicophosphate on the composition (mixing ratio) of
Li.sub.3PO.sub.4 and Li.sub.4SiO.sub.4, plotted based on data
described in Non-Patent Document 2. It is seen that the ionic
conductivity becomes the highest when the mixing ratio between
Li.sub.3PO.sub.4 and Li.sub.4SiO.sub.4 is in the range of 4:6 to
6:4 in a mol ratio.
[0118] For the solid electrolyte material, such materials may be
used that these materials are doped with different kinds of
elements, Li.sub.3PO.sub.4, LiPO.sub.3, Li.sub.4SiO.sub.4,
Li.sub.2SiO.sub.3, LiBO.sub.2, or the like. In addition, the
material for the electrolyte layer may be any of crystalline
substances, amorphous substances, and vitreous substances.
[0119] [Method of Manufacture of the Battery]
[0120] The multilayered product configuring the multilayer all
solid state lithium ion rechargeable battery according to the
present invention is fabricated in which materials for the positive
electrode layer, the electrolyte layer, and the negative electrode
layer forming the multilayered product and a given protective layer
are individually formed into pastes, the pastes are coated and
dried to prepare green sheets, these green sheets are laminated on
each other, and a prepared multilayered product is collectively
compressed for baking.
[0121] Here, for the materials individually used to form the pastes
of the positive active material, the negative active material, and
the solid electrolyte, calcined inorganic salts and the like, which
are raw materials for these materials, can be used. For the
materials for the solid electrolyte, preferably, materials
containing a complex oxide of a IV group element and lithium such
as a lithium silicate are used. From the viewpoint that calcination
advances the chemical reactions between the raw materials to
sufficiently exert their functions after the multilayered product
is collectively baked, preferably, the calcination temperatures of
all of the positive active material, the negative active material,
and the solid electrolyte are temperatures of 600.degree. C. or
greater.
[0122] Although pasting methods are not restricted particularly,
for example, a powder of each material is mixed with an organic
solvent and a binder carrier to obtain a paste. For example,
LiMn.sub.2O.sub.4 powder, the positive active material, is
dispersed into a solvent and a carrier to prepare a positive
electrode paste. By the similar methods, an electrolyte layer paste
and a negative electrode paste are prepared.
[0123] In addition, for example, when an electrode formed of a
material having an active material mixed with a conductive
material, a powder of each of the materials is mixed with an
organic solvent and a binder carrier to obtain a paste. For
example, LiMn.sub.2O.sub.4 powder, the positive active material, is
mixed with a mixture of a metal powder of Ag and Pd, the conductive
material, at a predetermined volume ratio, and the resulting
mixture is dispersed into a solvent and a carrier to prepare a
positive electrode paste.
[0124] Preferably, the particle diameters (particle size) of the
active material powder and the conductive material powder are 3
.mu.m or below for any of the positive active material, the
negative active material, and the conductive material. In addition,
for the particle size ratio between the active material powder and
the conductive material powder, preferably, the ratio between the
active material and the conductive material is in the range of 1:50
to 50:1 for both of the positive active material and the negative
active material. Because a conductive matrix is properly formed in
the electrode by baking and the active material is properly
supported in the matrix as long as the particle size and the
particle size ratio are in the above-described ranges, it is
effective to improve battery performance such as a reduction in
impedance and an increase in ampere-hour capacity. Preferably, the
volume ratio of mixing the active material powder with the
conductive material powder ranges from 20:80 to 65:35. When AgPd is
used for the conductive material, in addition to a metal powder
mixture of Ag and Pd, a composite powder prepared by Ag--Pd
coprecipitation process, or Ag--Pd alloy powder can be used. By
this method, the positive electrode layer paste, the solid
electrolyte layer paste, and the negative electrode paste are
prepared.
[0125] The prepared pastes are coated on a base material such as
PET in desired order and dried as necessary, and then the base
material is removed to prepare a green sheet. Paste coating methods
are not limited particularly, and publicly known methods such as
screen printing, coating, transfer, and doctor blading can be
adopted.
[0126] The prepared green sheets for the positive electrode layer
the electrolyte layer, and the negative electrode layer are
laminated on each other in desired order and the desired number of
layers, aligned as necessary, and cut to prepare a multilayered
product.
[0127] The prepared multilayered product is collectively
compressed. Although the prepared multilayered product is
compressed while heated, the heating temperature is at temperatures
of 40 to 70.degree. C., for example. The compressed multilayered
product is heated and baked under atmosphere, for example. Here,
the term "baking" referred to as heat treatment for the purpose of
sintering. The term "sintering" is referred to as a phenomenon that
when a solid powder aggregate is heated at a temperature lower than
the melting point, the solid powder aggregate is compacted to be a
dense product called a sintered compact.
[0128] In manufacture of the lithium ion rechargeable battery
according to the present invention, preferably, the baking
temperature ranges from temperatures of 600 to 1100.degree. C. This
is because such problems arise that when the temperature is below a
temperature of 600.degree. C., no intermediate layer is formed at
the interface of the electrode layer and the electrolyte layer,
whereas when the temperature exceeds a temperature of 1100.degree.
C., the solid electrolyte is melt, the structures of the positive
active material and the negative active material are changed, and
the multilayered product is deformed. Moreover, preferably, the
baking temperature ranges from temperatures of 800 to 1050.degree.
C. This is because the electrode layer and the electrolyte layer
become more compact in the range of temperatures of 800 to
1050.degree. C., which is effective to reduce battery internal
resistance.
[0129] For the rate of temperature rise and holding time in the
baking process, preferably, conditions suited for compacting the
electrode layer and the electrolyte layer and forming the
intermediate layer are selected and set depending on baking
temperatures. In addition, preferably, the rate of temperature rise
ranges from 60.degree. C./hr to 600.degree. C./hr, for example, in
consideration of a faster rate of temperature rise and a shorter
holding time are advantageous to productivity. In addition,
preferably, the holding time ranges from 30 minutes to 10
hours.
[0130] As a first specific embodiment of a method of manufacture, a
method of manufacture of a multilayer all solid state lithium ion
rechargeable battery including process steps (1) to (5) described
below is provided.
Process step (1): A positive electrode paste containing a metal
powder and a positive active material, a negative electrode paste
containing a metal powder and a negative active material, and a
solid electrolyte paste containing a solid electrolyte powder are
prepared. Process step (2): The solid electrolyte paste is coated
and dried on a PET base material to prepare a solid electrolyte
sheet. Hereinafter, the green sheet is simply called a sheet.
Subsequently, the positive electrode paste is coated and dried on
the solid electrolyte sheet to prepare a positive electrode sheet.
In addition, the negative electrode paste is coated and dried on a
solid electrolyte sheet to prepare a negative electrode sheet.
Process step (3): A positive electrode unit having the positive
electrode sheet laminated on the solid electrolyte sheet is removed
from the PET base material. In addition, a negative electrode unit
having the negative electrode sheet laminated on the solid
electrolyte sheet is removed from the PET base material.
Subsequently, the positive electrode unit and the negative
electrode unit are alternately laminated on each other to prepare a
multilayered product in which the positive electrode sheet and the
negative electrode sheet are alternately laminated on each other
through the sol id electrolyte sheet. At this time, the positive
electrode unit and the negative electrode unit are aligned and
laminated on each other such that the negative electrode sheet is
not exposed in one side surface of the multilayered product and the
positive electrode sheet is not exposed in the other side surface,
as necessary. Process step (4): The multilayered product is
compressed and baked to prepare a sintered multilayered product.
Process step (5): On the side surfaces of the multilayered product,
a positive electrode terminal is formed to connect to the positive
electrode layer, and a negative electrode terminal is formed to
connect to the negative electrode layer. The electrode terminal
(lead electrode) can be formed and provided in such a way that a
lead electrode paste is coated on the both side surfaces of the
battery and then baked at temperatures of 500 to 900.degree. C.,
for example. A protective layer, not shown in the drawing, is
formed on the outermost part of the multilayered product as
necessary, and then the battery is completed.
[0131] When a battery having a structure in which a current
collector layer is laminated on an electrode layer is produced, as
a method of manufacture of a second specific embodiment, a method
of manufacture of a multilayer all solid state lithium ion
rechargeable battery including process steps (1') to (5') described
below is provided.
Process step (1'): A positive electrode paste containing a positive
active material, a negative electrode paste containing a negative
active material, and a solid electrolyte paste containing a solid
electrolyte powder are prepared. Process step (2'): The pastes are
coated on a PET base material in order of the solid electrolyte
paste, the positive electrode paste, a positive current collector
paste, and the positive electrode paste, and dried as the case may
be, and the base material is removed to prepare a positive
electrode unit. The pastes are coated on a base material in order
of the solid electrolyte paste, the negative electrode paste, a
negative current collector paste, and the negative electrode paste,
and dried as the case may be, and then the base material is removed
to prepare a negative electrode unit. Process step (3'): The
positive electrode unit and the negative electrode unit are
alternately laminated on each other to prepare a multilayered
product in which a positive electrode sheet and a negative
electrode sheet are alternately laminated on each other through a
solid electrolyte sheet. At this time, the positive electrode unit
and the negative electrode unit are aligned and laminated on each
other such that the negative electrode sheet is not exposed in one
side surface of the multilayered product and the positive electrode
sheet is not exposed in the other side surface, as necessary.
Process step (4'): The multilayered product is compressed and baked
to prepare a sintered multilayered product. Process step (5'): On
the side surfaces of the multilayered product, a positive electrode
terminal is formed to connect to the positive electrode layer, and
a negative electrode terminal is formed to connect to the negative
electrode layer. The electrode terminal (lead electrode) can be
formed and prepared in such a way that a lead electrode paste is
coated on the both side surfaces of the battery and then baked at
temperatures of 500 to 900.degree. C., for example. A protective
layer, not shown in the drawing, is formed on the outermost part of
the multilayered product as necessary, and then the battery is
completed.
[0132] In addition, as a third specific embodiment of a method of
manufacture, a method of manufacture of a multilayer all solid
state lithium ion rechargeable battery including process steps (i)
to (iii) described below is also provided.
Process step (i): A positive electrode paste containing a metal
powder and a positive active material, a negative electrode paste
containing a metal powder and a negative active material, and a
solid electrolyte paste containing a lithium ion conductive
inorganic powder are prepared. Process step (ii): The pastes are
coated in order of the positive electrode paste, the solid
electrolyte paste, the negative electrode paste, and the solid
electrolyte paste, and the pastes are dried to prepare a
multilayered product formed of green sheets. At this time, the
sheets are aligned and laminated such that the negative electrode
sheet is not exposed in one side surface of the multilayered
product and the positive electrode sheet is not exposed in the
other side surface, as necessary. Process step (iii): A base
material used for preparing the green sheet is removed as
necessary, and the multilayered product is compressed and baked to
prepare a sintered multilayered product. Process step (iv): On the
side surfaces of the multilayered product, a positive electrode
terminal is formed to connect to the positive electrode layer, and
a negative electrode terminal is formed to connect to the negative
electrode layer. A protective layer is formed on the outermost part
of the multilayered product as necessary, and then the battery is
completed.
[0133] [Mixing Ratio of the Electrode Materials]
[0134] (Electric Conductivity and Ampere-Hour Capacity)
[0135] The mixing ratio between the active material and the
conductive material forming the electrode was changed to produce
and evaluate batteries. The detail will be described below.
[0136] For the electrode layer forming pastes of the prepared
battery, an active material powder was mixed with a conductive
material powder at a predetermined volume ratio, and the powders
were dispersed in a solvent and a binder to prepare the pastes. For
the positive active material to be the material for the electrode
layer, LiMn.sub.2O.sub.4 was used. For the negative active
material, Li.sub.4/3Ti.sub.5/3O.sub.4 was used. For the conductive
material to be mixed, AgPd at a weight ratio 85/15 was used. On the
other hand, the solid electrolyte layer forming paste was prepared
by dispersing Li.sub.3.5Si.sub.0.5P.sub.0.5O.sub.4 in a solvent and
a binder.
[0137] First, the evaluation results of the electric conductivity
and ampere-hour capacity of the battery will be described.
[0138] FIG. 8 is a graph depicting the dependencies of electric
conductivity and ampere-hour capacity on a positive active material
volume ratio. Evaluations were made that the volume ratio was a
parameter because the volume ratio was considered to contribute to
electric conductivity more than a weight ratio did. As the results
of varying the mixing ratio between the positive active material
and the conductive particles ranging from 0:100 to 100:0, it was
found that when the volume ratio of the positive active material
was in the range of 20 vol % or greater to 65 vol % or below, the
electric conductivity was sufficiently high, the battery impedance
was effectively reduced, and the ampere-hour capacity was also
sufficiently increased. At the volume ratios of these optimum
conditions, the electric conductivity was 1.times.101 S/cm or
greater. When the volume ratio of the active material was below 20
vol %, the electric conductivity became high, but the ampere-hour
capacity was decreased because of a small amount of the active
material. In addition, it was found that when the volume ratio of
the active material exceeded 65 vol %, the electric conductivity
was suddenly dropped.
[0139] FIG. 9 is a graph depicting the dependencies of electric
conductivity and ampere-hour capacity on a negative active material
volume ratio. As the result of varying the mixing ratio between the
negative active material and the conductive particles ranging from
0:100 to 100:0, as similar to the cases of the positive active
material, when the volume ratio of the negative active material was
in the range of 20 vol % or greater to 65 vol % or below, it was
found that the electric conductivity was sufficiently high, the
battery impedance was effectively reduced, and the ampere-hour
capacity was also sufficiently increased. In the volume ratios of
these optimum conditions, the electric conductivity was 1.times.101
S/cm or greater as well.
[0140] [Comparisons to Similar Prior Art Techniques]
[0141] Patent Document 2 discloses a technique "a solid electrolyte
battery having a solid electrolyte between a pair of electrodes, in
which an intermediate layer having a reaction interface of the
solid electrolyte with an electrode active material is provided
between the electrode and the solid electrolyte". An object of this
technique is to reduce battery internal resistance.
[0142] In the technique disclosed in Patent Document 2, a paste
formed of a material that the active material and the solid
electrolyte are mixed, baked and synthesized is coated and dried on
an electrode layer to form the intermediate layer. Moreover, a
solid electrolyte layer is coated, dried, and formed on the
intermediate layer to prepare the battery. No baking is conducted
after the electrode layer and the electrolyte layer are laminated.
This method is different from the method according to the present
invention in which pastes for forming the positive electrode layer,
the electrolyte layer, and the negative electrode layer are coated
and dried to form green sheets, and the green sheets are laminated
and then baked.
[0143] Moreover, Patent Document 2 has no descriptions that a
complex oxide formed of a IV group element and lithium is
preferable for an electrolyte material. Therefore, it cannot be
said that a useful reaction product is not always formed on the
intermediate layer. In addition, even though interface resistance
between the active material and the electrolyte is reduced inside
the intermediate layer, it cannot be said that because the product
is not baked after laminated, the interface resistance or adhesion
between the intermediate layer and the electrode layer or the
intermediate layer and the electrolyte layer is not improved, and
the overall electric characteristics and mechanical characteristics
of the battery are not improved. In addition, because of the
necessities of conducting process steps of coating and drying the
intermediate layer, problems arise that process steps are
complicated and manufacture costs are expensive.
[0144] Therefore, the patentability of the present invention is not
rejected over the technique disclosed in Patent Document 2.
[0145] Patent Document 3 discloses a technique "a battery using a
solid electrolyte, in which at an interface of at least one of
electrodes and an electrolyte, an area is formed, in which one
element of the electrode and one element of the electrolyte form a
compound". An objet of this technique is to reduce internal
resistance and to suppress the occurrence of delamination at the
interface.
[0146] The technique disclosed in Patent Document 3 describes a
method having a scheme of forming the area layer in which a film is
deposited and then allowed to stand in a moisture containing Ar
atmosphere, for example. Although it is also described that it is
possible to form the area layer by heat treatment, there are no
detailed descriptions of the method.
[0147] It is described that the area layer is an oxide, nitride, or
hydroxide, the thickness of the area layer ranges from 0.01 to 300
nm, and charging and discharging are inhibited when the thickness
is greater than 300 nm. Therefore, it is estimated that the
substance forming the area layer does not function as the active
material or the electrolyte. Moreover, no description is made that
a complex oxide formed of a IV group element and lithium is
preferable for the electrolyte material.
[0148] Therefore, the patentability of the present invention is not
rejected over the technique disclosed in Patent Document 3.
[0149] Patent Document 4 discloses a technique in which "an
electrolyte material uses an electrolyte material having a
.gamma."-lithium phosphate crystal structure and a positive
electrode and an electrolyte are laminated and then collectively
baked". An object of this technique is to reduce contact resistance
at the interface.
[0150] In the technique disclosed in Patent Document 4, electrolyte
pellets formed by pressurizing and molding powder are sintered, and
the pellets and an active material are put in a mold, pressurized,
molded, and then collectively baked to form a battery. This method
is different from the present invention in which the positive
electrode layer, the electrolyte layer, and the negative electrode
layer are laminated in the state of green sheets before baked, and
then baked to form the intermediate layer formed of a useful
reaction product. Moreover, an object of the technique disclosed in
Patent Document 4 is to reduce contact resistance between active
material and electrolyte particles, not for reducing resistance by
forming a novel useful reaction product like the present
invention.
[0151] Therefore, the patentability of the present invention is not
rejected over the technique disclosed in Patent Document 4.
[0152] Patent Document 5 discloses an all solid secondary battery
using Li.sub.2O--B.sub.2O.sub.3--SiO.sub.2--ZnO as an option for a
solid electrolyte material. In the technique disclosed in Patent
Document 5, a product having an electrode layer laminated on an
electrolyte layer is microwave heated and baked. The product is
baked for a short time, whereby the filling factors of the
electrode and the solid electrolyte are increased to improve ionic
conductance, while reactions between individual particles in the
electrode and the solid electrolyte are suppressed. In other words,
it is not a technique to form a reaction layer. The technique is
different from the technique according to the present invention in
which materials for the electrodes and the electrolyte are selected
to constructively form a useful intermediate layer by baking,
whereby bonding strength is improved and interface resistance is
reduced.
[0153] Therefore, the patentability of the present invention is not
rejected over the technique disclosed in Patent Document 5.
[0154] Patent Document 6 discloses a lithium secondary battery
using Li.sub.4SiO.sub.4 as an option for a solid electrolyte
material. In the technique disclosed in Patent Document 6, a
battery is produced in which an inorganic solid electrolyte film is
formed on a lithium metal foil to be a negative electrode by
sputtering, and a positive electrode formed by coating a mixture of
a positive active material and carbon on an aluminum foil is bonded
on the electrolyte film. The electrode layer and the electrolyte
layer are not baked after laminated. In other words, it is not the
technique to form a useful intermediate layer by baking.
[0155] Therefore, the patentability of the present invention is not
rejected over the technique disclosed in Patent Document 6.
[0156] [Specific Embodiments of the Battery Structure]
[0157] FIGS. 7(a) to 7(e) are cross sections depicting lithium ion
rechargeable batteries according to specific embodiments of the
present invention, and graphs depicting concentration
distributions.
[0158] In FIG. 7(a), in an intermediate layer 24 formed at the
interface of a positive electrode layer 21 and an electrolyte layer
22, the positive active material and the electrolyte exist in
concentration distributions with slopes. Similarly, in an
intermediate layer 25 formed at the interface of a negative
electrode layer 23 and the electrolyte layer 22, the negative
active material and the electrolyte exist in concentration
distributions with slopes.
[0159] It may be possible that the film thickness before baked and
the baking conditions are controlled to allow the positive
electrode layer, the electrolyte layer, and/or the negative
electrode layer to partially react as well as allow the layers to
entirely react after baked, and then a reaction product layer is
formed. Also in this case, these layers are formed such that the
concentration distributions of the positive active material, the
electrolyte, and the negative active material become in turn
dominant, whereby an excellent battery of high bonding strength and
small internal resistance can be produced.
[0160] FIG. 7(b) is a cross section depicting the case in which a
positive electrode layer was all turned into a reaction product
layer by baking. In a reaction product layer 29, the positive
active material is dominant in the composition after baked.
[0161] FIG. 7(c) is a cross section depicting the case in which a
negative electrode layer was all turned into a reaction product
layer by baking. In a reaction product layer 30, the negative
active material is dominant in the composition after baked.
[0162] FIG. 7(d) is a cross section depicting the case in which an
electrolyte layer was all turned into a reaction product layer by
baking. In a reaction product layer 31, the electrolyte is dominant
in the composition after baked.
[0163] FIG. 7(e) is a cross section depicting the case in which a
positive electrode layer, an electrolyte layer, and a negative
electrode layer were all turned into reaction product layers by
baking. In a reaction product layer 32, the positive active
material is dominant in the composition after baked, in a reaction
product layer 33, the electrolyte is dominant in the composition
after baked, and in a reaction product layer 34, the negative
active material is dominant in the composition after baked.
[0164] As described above, a specific embodiment of the lithium ion
rechargeable battery according to the present invention is a
multilayer all solid state lithium ion rechargeable battery
characterized by including: a multilayered product having a
positive electrode layer containing a positive active material
laminated on a negative electrode layer containing a negative
active material through an electrolyte layer containing a solid
electrolyte, wherein a part or all of the positive electrode layer
is formed of a sintered compact produced from a reaction between a
starting material for the positive active material and a starting
material for the solid electrolyte.
[0165] In addition, another specific embodiment of the lithium ion
rechargeable battery according to the present invention is a
multilayer all solid state lithium ion rechargeable battery
characterized by including: a multilayered product having a
positive electrode layer containing a positive active material
laminated on a negative electrode layer containing a negative
active material through an electrolyte layer containing a solid
electrolyte, wherein a part or all of the negative electrode layer
is formed of a sintered compact produced from a reaction between a
starting material for the negative active material and a starting
material for the solid electrolyte.
[0166] Moreover, still another specific embodiment of the lithium
ion rechargeable battery according to the present invention is a
multilayer all solid state lithium ion rechargeable battery
characterized by including: a multilayered product having a
positive electrode layer containing a positive active material
laminated on a negative electrode layer containing a negative
active material through an electrolyte layer containing a solid
electrolyte, wherein a part or all of the electrolyte layer is
formed of a sintered compact produced by a reaction between a
starting material for the electrolyte substance and a starting
material for the negative active material and/or a starting
material for the positive active material.
[0167] As defined above, the term "sintered compact" means a dense
product (solid) formed by baking (sintering) a solid powder
aggregate at a temperature lower than the melting point. The states
before and after sintered can be distinguished by observing a cross
section of a solid. In the cross sectional structure before
sintered, solid powder particles are gathered as separated in
almost uniform forms, whereas after sintered, (1) a neck (joining
part) is formed between particles, (2) the neck between particles
grows, (3) a reduction in voids (pores) caused by grain growth
(growth of particles and a reduction in the number of particles)
and compacting are observed, and individual particles take various
forms depending on the degree of sintering. The size of particles
and the presence of voids are observed to determine the presence of
sintering and the degree of progress of sintering.
[0168] In addition, the ratio of the sintered compact can be
controlled by controlling baking conditions (the baking
temperature, rate of temperature rise, holding time, and baking
atmosphere). Particularly, control of the baking temperature is
effective.
[0169] The ratio of the sintered compact can be evaluated from the
equation:
(density of sintered compact)/(true density, which is inherent
density of sintered compact material).times.100
Alternatively, the voidage is evaluated from the observation of
cross sections, whereby the ratio of the sintered compact can be
evaluated. For the voidage, preferably, in the solid electrolyte,
ions more tend to pass as the number of voids is small, and in the
active material, energy density becomes higher as the number of
voids is small. More specifically, preferably, in the solid
electrolyte, the voidage ranges from 0% or greater to 10% or below.
Preferably, in the active material, the voidage ranges from 0% or
greater to 10% or below. For example, the baking temperature is set
to a temperature of 1000.degree. C., whereby a sintered compact of
high density with few voids can be obtained.
EXAMPLES
Example 1
[0170] Hereinafter, examples are used to describe the present
invention in detail. In addition, the expression "parts" means
parts by weight, unless otherwise specified.
[0171] (Preparation of a Positive Electrode Paste)
[0172] For the positive active material, LiMn.sub.2O.sub.4 prepared
by a method described below was used.
[0173] Li.sub.2CO.sub.3 and MnCO.sub.3 were used as starting
materials, and weighted to be at a mol ratio 1:4, water was used as
a solvent to conduct wet blending in a ball mill for 16 hours, and
then the mixture was dewatered and dried. The resulting powder was
calcined in the air for two hours at a temperature of 800.degree.
C. The calcined product was roughly crushed, water was used as a
solvent to conduct wet blending in a ball mill for 16 hours, and
then the mixture was dewatered and dried to obtain a positive
active material powder. The BET value of this powder was 13.4
m.sup.2/g. An X-ray diffraction device was used to confirm that the
composition of the prepared powder was LiMn.sub.2O.sub.4.
[0174] For a positive electrode paste, 100 parts of a mixture that
Ag/Pd powder at a weight ratio 85/15 used as metal powders in
advance was mixed with LiMn.sub.2O.sub.4 used as the positive
active material powder at a volume ratio 60:40, 15 parts of
ethylcellulose as a binder, and 65 parts of dihydroterpinenol as a
solvent were added, mixed, and dispersed by a triple roll mill, and
then a positive electrode paste was prepared. Here, for Ag/Pd
powder at a weight ratio 85/15, a mixture of Ag powder (average
particle size is 0.3 .mu.m) and Pd powder (average particle size is
1.0 .mu.m) was used.
[0175] (Preparation of a Negative Electrode Paste)
[0176] For a negative active material, Li.sub.4/3Ti.sub.5/3O.sub.4
prepared by a method described below was used.
[0177] Li.sub.2CO.sub.3 and TiO.sub.2 were used as starting
materials, and weighted to be at a mol ratio 2:5, water was used as
a solvent to conduct wet blending in a ball mill for 16 hours, and
then the mixture was dewatered and dried. The resulting powder was
calcined in the air for two hours at a temperature of 800.degree.
C. The calcined product was roughly crushed, water was used as a
solvent to conduct wet blending in a ball mill for 16 hours, and
then the mixture was dewatered and dried to obtain a negative
active material powder. The BET value of this powder was 6.3
m.sup.2/g. An X-ray diffraction device was used to confirm that the
composition of the prepared powder was
Li.sub.4/3Ti.sub.5/3O.sub.4
[0178] For a negative electrode paste, 100 parts of a mixture that
Ag/Pd powder at a weight ratio 85/15 used as metal powders in
advance was mixed with Li.sub.4/3Ti.sub.5/3O.sub.4 used as a
negative active material powder at a volume ratio 60:40, 15 parts
of ethylcellulose as a binder, and 65 parts of dihydroterpinenol as
a solvent were added, mixed, and dispersed by a triple roll mill,
and then a negative electrode paste was prepared. Here, for Ag/Pd
powder at a weight ratio 85/15, a mixture of Ag powder (average
particle size is 0.3 .mu.m) and Pd powder (average particle size is
1.0 .mu.m) was used.
[0179] (Preparation of a Solid Electrolyte Sheet)
[0180] For a solid electrolyte,
Li.sub.3.5Si.sub.0.5P.sub.0.5O.sub.4 prepared by a method described
below was used.
[0181] Li.sub.2CO.sub.3, SiO.sub.2 and Li.sub.3PO.sub.4 were used
as starting materials, and weighted to be at a mol ratio 2:1:1,
water was used as a solvent to conduct wet blending in a ball mill
for 16 hours, and then the mixture was dewatered and dried. The
resulting powder was calcined in the air for two hours at a
temperature of 950.degree. C. The calcined product was roughly
crushed, water was used as a solvent to conduct wet blending in a
ball mill for 16 hours, and then the mixture was dewatered and
dried to obtain a lithium ion conductive inorganic powder. The BET
value of this powder was 14.0 m.sup.2/g. An X-ray diffraction
device was used to confirm that the composition of the prepared
powder was Li.sub.3.5Si.sub.0.5P.sub.0.5O.sub.4.
[0182] Subsequently, 100 parts of ethanol and 200 parts of toluene
were added to 100 parts of this powder in a ball mill for wet
blending. After that, 16 parts of a polyvinyl butyral binder and
4.8 parts of benzylbutylphthalate are further added, and mixed to
prepare a lithium ion conductive inorganic paste. This lithium ion
conductive inorganic paste was shaped into a sheet by doctor
blading as a PET film was used for a base material, and then a
lithium ion conductive inorganic sheet having a thickness of 13
.mu.m was obtained.
[0183] (Preparation of a Lead Electrode Paste)
[0184] 100 parts of Ag powder was mixed with 5 parts of a glass
frit, 10 parts of ethylcellulose as a binder and 60 parts of
dihydroterpinenol as a solvent were added, mixed, and dispersed by
a triple roll mill, and then a lead electrode paste was
prepared.
[0185] (Preparation of a Positive Electrode Unit)
[0186] On the opposite surface of the PET film of the
above-described lithium ion conductive inorganic sheet having a
thickness of 13 .mu.m, the positive electrode paste was printed by
screen printing in a thickness of 8 .mu.m. Subsequently, the
printed positive electrode paste was dried for 5 to 10 minutes at
temperatures of 80 to 100.degree. C. As described above, a sheet of
a positive electrode unit having the positive electrode paste
printed on the lithium ion conductive inorganic sheet was
obtained.
[0187] (Preparation of a Negative Electrode Unit)
[0188] On the opposite side of the PET film of the above-described
lithium ion conductive inorganic sheet having a thickness of 13
.mu.m, the negative electrode paste was printed by printing in a
thickness of 8 .mu.m. As described above, a sheet of a negative
electrode unit having the negative electrode paste printed on the
lithium ion conductive inorganic sheet was obtained.
[0189] (Preparation of a Multilayered Product)
[0190] The PET film was removed from each of the positive electrode
unit and the negative electrode unit, and then these two units were
alternately laminated through the lithium ion conductive inorganic
substance. At this time, the positive electrode unit was displaced
from the negative electrode unit, and laminated such that the
positive current collector was extended only on one end surface and
the negative current collector was extended only on the other end
surface. After that, this product was shaped at a temperature of
80.degree. C. at pressure of 1000 kgf/cm.sup.2, and then cut to
prepare a multilayered block. After that, the multilayered block
was baked to obtain a multilayered product. For baking, the
temperature was increased in the air to a temperature of
1000.degree. C. at the rate of temperature rise of 200.degree.
C./hour, the temperature was kept at the temperature for two hours,
and the product was naturally cooled after baked. In the
multilayered product after sintered thus obtained, the thickness of
the lithium ion conductive inorganic substance was 7 .mu.m, the
thickness of a unit of the positive electrode was 5 .mu.m, and the
thickness of a unit of the negative electrode was 6 .mu.m. In
addition, the length, width, and height of the multilayered product
were 8 mm.times.8 mm.times.0.1 mm, respectively.
[0191] (Formation of a Lead Electrode)
[0192] The lead electrode paste was coated on the end surfaces of
the multilayered product and baked at a temperature of 800.degree.
C. to form a pair of lead electrodes, and then an all solid lithium
ion rechargeable battery was obtained.
Example 2
[0193] XRD analysis was used to study reactions between the solid
electrolyte, the positive active material, and the negative active
material by baking and to identify the reaction product.
[0194] FIG. 3 is a work flowchart depicting a study experiment to
study reactions between the solid electrolyte material and the
active material.
[0195] A study method was conducted according to the process steps
shown below.
(1) The solid electrolyte, the positive active material, and the
negative active material were mixed in a mortar. (2) The mixed
powders were shaped in a mold to prepare a disk. (3) The
temperature of the prepared disk was increased to a set temperature
at the rate of temperature rise of 200.degree. C./hr, kept for two
hours, and then allowed to stand to cool. The set temperature was
temperatures of 500, 600, 700, 800, 900, 960, 1000, and
1050.degree. C. (4) The baked disk was crushed in a mortar to form
a sample. (5) Substances were identified by XRD.
[0196] FIG. 4 shows XRD patterns of samples that the solid
electrolyte and the positive active material were mixed and then
baked. It is seen that in the pattern before baked and the pattern
of baking at a temperature of 500.degree. C., only the peak of
LiMn.sub.2O.sub.4 used as the positive active material is observed,
whereas in the patterns of baking at temperatures of 600.degree. C.
or greater, the peaks of LiMnO.sub.2, Li.sub.2MnO.sub.3, and
Li.sub.1.4Mn.sub.1.7O.sub.4, which are reaction products, are
observed.
[0197] FIG. 5 shows XRD patterns of samples that the solid
electrolyte and the negative active material were mixed and then
baked. It is seen that in the pattern before baked and the pattern
of baking at a temperature of 500.degree. C., only the peak of
Li.sub.4/3Ti.sub.5/3O.sub.4 used as the negative active material is
observed, whereas in the patterns of baking at temperatures of
600.degree. C. or greater, the peaks of LiTiO.sub.2, and
Li.sub.2TiO.sub.3, which are reaction products, are observed.
Example 3
[0198] XRD analysis was conducted by a method similar to that of
Example 2, reactions between the solid electrolyte and the active
material by baking were studied, and reaction products were
identified.
[0199] FIG. 10 shows XRD patterns of samples that a solid
electrolyte Li.sub.3.5Si.sub.0.5P.sub.0.5O.sub.4 and an active
material LiMn.sub.1.5Co.sub.0.5O.sub.4 were mixed and then baked.
It is seen that in the pattern before baked and the pattern of
baking at a temperature of 600.degree. C., only the peaks of the
solid electrolyte Li.sub.3.5Si.sub.0.5P.sub.0.5O.sub.4 and the
active material LiMn.sub.4.5Co.sub.0.5O.sub.4 are observed, whereas
in the patterns of baking at temperatures of 700.degree. C. or
greater, the peak of LiMnCoO.sub.4, which is a reaction product, is
observed. LiMnCoO.sub.4 is a substance that functions as the active
material.
[0200] FIG. 11 shows XRD patterns of samples that a solid
electrolyte Li.sub.3.5Si.sub.0.5P.sub.0.5O.sub.4 and an active
material LiMn.sub.1.5Ni.sub.0.5O.sub.4 were mixed and then baked.
It is seen that in the pattern before baked and the patterns of
baking at temperatures of 600.degree. C. and 700.degree. C., only
the peaks of the solid electrolyte
Li.sub.3.5Si.sub.0.5P.sub.0.5O.sub.4 and the active material
LiMn.sub.1.5Ni.sub.0.5O.sub.4 are observed, whereas in the patterns
of baking at temperatures of 800.degree. C. or greater, the peak of
LiMn.sub.1.82Ni.sub.0.18O.sub.4, which is a reaction product, is
observed. LiMn.sub.1.82Ni.sub.0.18O.sub.4 is a substance that
functions as the active material.
INDUSTRIAL APPLICABILITY
[0201] As discussed above, the lithium ion rechargeable battery
according to the present invention and the method of manufacture of
the same are advantageous in a reduction in the internal resistance
of the lithium ion rechargeable battery and improvement of the
charging and discharging cycle characteristics. A small-sized
battery of high performance and large capacity is provided to make
significant contributions in the field of electronics in
particular.
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