U.S. patent application number 13/064675 was filed with the patent office on 2011-09-08 for nonaqueous electrolyte secondary battery.
Invention is credited to Yoshio Kato, Shigeki Matsuta, Keiji Saisho, Hidekazu Yamamoto.
Application Number | 20110217599 13/064675 |
Document ID | / |
Family ID | 37070907 |
Filed Date | 2011-09-08 |
United States Patent
Application |
20110217599 |
Kind Code |
A1 |
Yamamoto; Hidekazu ; et
al. |
September 8, 2011 |
Nonaqueous electrolyte secondary battery
Abstract
Disclosed is a nonaqueous electrolyte secondary battery which
has a negative electrode containing silicon as a negative active
material, a positive electrode containing a positive active
material, a nonaqueous electrolyte and a separator.
Characteristically, an additive which retards oxidation of silicon
during operation of the battery is contained either in an interior
or surface portion of the positive electrode, or in an interior or
surface portion of the negative electrode, or in an interior or
surface portion of the separator.
Inventors: |
Yamamoto; Hidekazu;
(Kobe-city, JP) ; Saisho; Keiji; (Kobe-city,
JP) ; Kato; Yoshio; (Hirakata-city, JP) ;
Matsuta; Shigeki; (Kobe-city, JP) |
Family ID: |
37070907 |
Appl. No.: |
13/064675 |
Filed: |
April 7, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11385836 |
Mar 22, 2006 |
7923148 |
|
|
13064675 |
|
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Current U.S.
Class: |
429/306 ;
429/188 |
Current CPC
Class: |
H01M 10/052 20130101;
H01M 10/0567 20130101; Y02E 60/10 20130101; H01M 4/1391 20130101;
H01M 4/386 20130101; H01M 4/0426 20130101; H01M 50/449 20210101;
H01M 4/134 20130101; H01M 4/1395 20130101; H01M 50/46 20210101;
H01M 4/131 20130101; H01M 50/409 20210101; H01M 4/13 20130101; H01M
4/62 20130101 |
Class at
Publication: |
429/306 ;
429/188 |
International
Class: |
H01M 10/02 20060101
H01M010/02 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 31, 2005 |
JP |
102733/2005 |
Mar 31, 2005 |
JP |
102734/2005 |
Mar 31, 2005 |
JP |
102735/2005 |
Claims
1. A nonaqueous electrolyte secondary battery which includes a
negative electrode containing silicon as a negative active
material, a positive electrode containing a positive active
material, a nonaqueous electrolyte and a separator; said battery
being characterized in that an additive which retards oxidation of
said silicon during battery operation is contained either in an
interior or surface portion of said positive electrode, or in an
interior or surface portion of said negative electrode, or in an
interior or surface portion of said separator; wherein said
additive is selected from the group consisting of acetic anhydride;
oxalic acid, malonic acid, succinic acid, glutaric acid, adipic
acid, pimelic acid, suberic acid, azelaic acid, sebacic acid,
phthalic acid and fumaric acid, and their salts and esters; hydroxy
acids; lithium carbonate; lithium nitrate; lithium sulfonate;
acrylic acid and its derivatives; and methacrylic acid and its
derivatives; and said nonaqueous electrolyte contains a film former
which forms a film on a surface of said negative electrode, said
film former comprising vinylene carbonate.
2. The nonaqueous electrolyte secondary battery as recited in claim
1, characterized in that said additive is contained in said
interior or surface portion of the positive electrode.
3. The nonaqueous electrolyte secondary battery as recited in claim
1, characterized in that said additive is contained in said
interior or surface portion of the negative electrode and a film
former which forms a film on a surface of the negative electrode is
contained in said nonaqueous electrolyte.
4. The nonaqueous electrolyte secondary battery as recited in claim
1, characterized in that said additive is contained in said
interior or surface portion of the separator.
5. The nonaqueous electrolyte secondary battery as recited in claim
1, characterized in that said negative electrode is an electrode
fabricated by depositing a thin film of silicon or silicon alloy on
a current collector.
6. The nonaqueous electrolyte secondary battery as recited in claim
5, characterized in that said thin film has such a columnar
structure that it is divided into columns by gaps formed therein
and extending in its thickness direction.
7. The nonaqueous electrolyte secondary battery as recited in claim
1, characterized in that said negative active material comprises an
alloy of silicon and other metal.
8. The nonaqueous electrolyte secondary battery as recited in claim
1, characterized in that said additive in the nonaqueous
electrolyte exists in the solid form.
9. The nonaqueous electrolyte secondary battery as recited in claim
1, characterized in that said additive has a mean particle size
within a particle size distribution of said positive or negative
active material.
10. The nonaqueous electrolyte secondary battery as recited in
claim 1, characterized in that said additive is held within a
support material.
11. The nonaqueous electrolyte secondary battery as recited in
claim 10, characterized in that said support material comprises
solid fine particles (fillers).
12. The nonaqueous electrolyte secondary battery as recited in
claim 10, characterized in that said support material is
electronically conductive.
Description
[0001] This application is a divisional application of application
Ser. No. 11/385,836, filed Mar. 22, 2006, which claims priority
based on Japanese Patent Application Nos. 2005-102733, 2005-102734
and 2005-102735, each filed Mar. 31, 2005, and which are
incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a nonaqueous electrolyte
secondary battery.
[0004] 2. Description of the Related Art
[0005] The recent years have seen a marked reduction in size and
weight of portable electric devices. Also, the increase of their
functions pushes up their power consumption. This has led to a
strong demand for further improvements of secondary lithium
batteries which serve as a power source of those devices, in terms
of weight reduction and capacity increase.
[0006] As a measure to meet such a demand, the use of silicon as an
electrode material has been recently proposed which shows superior
charge/discharge capacity, both per unit mass and unit volume,
compared to a carbon electrode.
[0007] In conventional secondary lithium batteries using a silicon
thin film as a negative active material, an electrode has been
proposed including a thin film of active material which is divided
into columns by gaps formed therein and extending in its thickness
direction. The provision of such a columnar structure lessens a
stress engendered due to expansion and shrinkage of the active
material, prevents separation of the active material from a current
collector and thereby improves charge-discharge cycle
characteristics.
[0008] It is however known that, in the negative electrode using
such a silicon thin film, the active material changes in properties
and increases in porosity with repeated charge-discharge cycling.
As will be described later, the inventors of this application have
discovered that such a change in properties of the active material
results from oxidation of silicon during operation of a battery.
The present invention is based on such a knowledge of the
inventors.
[0009] Japanese Patent Laying-Open No. 2004-349079 proposes the use
of a pH control agent in order to retard oxidation of silicon in
the manufacture of an electrode. However, in Japanese Patent
Laying-Open No. 2004-349079, neither disclosure nor suggestion is
provided as to oxidation of silicon during charge-discharge
cycles.
[0010] Japanese Patent Laying-Open No. 2004-6188 describes that
incorporation of a saturated dicarboxylic acid in an interior
portion of a negative electrode improves charge-discharge cycle
characteristics. Japanese Patent Laying-Open No. 2004-335379
describes that incorporation of an organic acid in an interior
portion of a negative electrode improves cycle characteristics.
However, neither of these prior art references provides disclosure
as to improvement of charge-discharge cycle characteristics by
retarding oxidation of silicon.
SUMMARY OF THE INVENTION
[0011] It is an object of the present invention to provide a
nonaqueous electrolyte secondary battery including silicon as a
negative active material, which shows suppressed expansion of the
negative active material containing silicon and improved
charge-discharge cycle characteristics.
[0012] The present invention provides a nonaqueous electrolyte
secondary battery which has a negative electrode containing silicon
as a negative active material, a positive electrode containing a
positive active material, a nonaqueous electrolyte and a separator.
Characteristically, an additive which can retard oxidation of
silicon during operation of the battery is contained either in an
interior or surface portion of the positive electrode, or in an
interior or surface portion of the negative electrode, or in an
interior or surface portion of the separator.
[0013] In the present invention, due to the inclusion of the
additive capable of retarding oxidation of silicon during operation
of the battery either in an interior or surface portion of the
positive electrode, or in an interior or surface portion of the
negative electrode or in an interior or surface portion of the
separator, expansion of the negative active material containing
silicon as a result of deterioration thereof is suppressed so that
charge-discharge cycle characteristics can be improved.
[0014] In the present invention, examples of additives which retard
oxidation of silicon during operation of the battery include acids,
weak alkalis, acid anhydrides and lithium salts of acids. As will
be described later, the inventors of this application have found
that oxidation of silicon during battery operation is promoted by a
reaction similar to a reaction involving OH.sup.-. Such oxidation
of silicon by an alkali can be retarded if an atmosphere
surrounding silicon is rendered weak-alkaline or acidic.
Accordingly, the additive for use in the present invention is a
material by which an atmosphere surrounding silicon can be rendered
weak-alkaline or acidic.
[0015] Specific examples of additives for use in the present
invention include acid anhydrides such as succinic anhydride and
acetic anhydride; carboxylic and dicarboxylic acids such as oxalic
acid, malonic acid, succinic acid, glutaric acid, adipic acid,
pimelic acid, suberic acid, azelaic acid, sebacic acid, phthalic
acid and fumaric acid, and their salts and esters; hydroxy acids;
carbonates such as lithium carbonate; nitrates such as lithium
nitrate; sulfonates such as lithium sulfonate; acrylic acid and its
derivatives; methacrylic acid and its derivatives; compounds which
generate free fluorine in an electrolyte; salts formed via a
reaction between a strong acid and a weak alkali; and the like.
[0016] In a first aspect of the present invention, the additive is
contained in an interior or surface portion of a positive
electrode. It is known that a reaction product in a battery shows a
general trend of adhering onto a surface of a negative electrode.
Inclusion of the additive in an interior or surface portion of the
positive electrode, in accordance with the first aspect of the
present invention, suppresses such adherence of the reaction
product and retards oxidation of silicon more effectively.
[0017] In the first aspect of the present invention, the additive
is preferably contained in the amount of 0.01-10% by weight, based
on the weight of the positive active material. If its content
exceeds 10% by weight, the additive in some cases decomposes on a
positive electrode side in an initial stage of battery fabrication
to result in the formation of a deposit on a surface of the
positive electrode. This reduces an initial capacity of the battery
and, as a result, reduces an energy density. On the other hand, if
its content falls below 0.01% by weight, the effect of the present
invention that improves charge-discharge cycle characteristics may
not be obtained sufficiently.
[0018] The inclusion of the additive in an interior or surface
portion of the positive electrode, in accordance with the first
aspect of the present invention, assures a steady supply of the
additive to the electrolyte near the surface of silicon as a
negative active material. This causes continuous consumption of a
component which may oxidize silicon and accordingly retards
oxidation of silicon without interruption.
[0019] In a second aspect of the present invention, the additive is
contained in an interior or surface portion of the negative
electrode. In the second aspect of the present invention, the
additive is preferably contained in the amount of 0.01-10% by
weight, based on the weight of the negative active material. If its
content exceeds 10% by weight, the additive in some cases
decomposes on a negative electrode side in an initial stage of
battery fabrication to result in the formation of a deposit on a
surface of the negative electrode. This reduces an initial capacity
of the battery and, as a result, reduces an energy density. On the
other hand, if its content falls below 0.01% by weight, the effect
of the present invention that improves charge-discharge cycle
characteristics may not be obtained sufficiently.
[0020] In the second aspect of the present invention, the following
method can be utilized to incorporate the additive in an interior
portion of a negative electrode. For example, in the case where the
additive is used in the powder form, it is first mixed with a
binder and active material to form an anode mix. Then, a solvent is
added to the mix to form a slurry which is subsequently coated and
dried. As a result, a plate having the additive contained in an
interior portion of the negative electrode can be obtained.
[0021] Also in the second aspect of the present invention, the
following method can be utilized to incorporate the additive in a
surface portion of a negative electrode. A solid-form additive is
subdivided into powder particles. A suspension of these powder
particles is sprayed on a surface of an electrode. A vacuum
treatment is subsequently carried out to remove a solvent,
resulting in uniform dispersion of the additive on the surface. As
a result, the additive is incorporated uniformly in a surface
portion of the negative electrode.
[0022] In the other case where the additive is used in the liquid
form, the additive may be sprayed onto a surface of an electrode.
This enables uniform incorporation of the additive in a surface
portion of the negative electrode.
[0023] The inclusion of the additive in an interior or surface
portion of the negative electrode, in accordance with the second
aspect of the present invention, assures a steady supply of the
additive to the electrolyte near the surface of silicon as a
negative active material. This causes continuous consumption of a
component which may oxidize silicon and accordingly retards
oxidation of silicon without interruption.
[0024] In a third aspect of the present invention, the additive is
contained in the separator. Accordingly, the additive can be
incorporated in the battery without causing any problem, even when
the negative or positive electrode contains a compound which easily
reacts with the additive.
[0025] In the third aspect of the present invention, the additive
is contained in the separator in the amount of
1.times.10.sup.-6-1.times.10.sup.-3 g per cm.sup.2 of the
separator. If the amount of the additive exceeds 1.times.10.sup.-3
g per cm.sup.2 of the separator, an initial capacity of the battery
may decrease to result in the reduced energy density. This is
probably because the increase in amount of the additive disturbs
diffusion of lithium ions through the separator. On the other hand,
if the amount of the additive falls below 1.times.10.sup.-6 g per
cm.sup.2 of the separator, the effect of the present invention that
improves charge-discharge cycle characteristics may not be obtained
sufficiently.
[0026] The type of the separator is not particularly specified so
long as it is useful for lithium secondary batteries. It may
preferably comprise a microporous film of polyolefin such as
polyethylene or polypropylene, a composite film thereof, a
microporous film of polyamide, or a nonwoven fabric made of fine
fibers such as a glass fiber, for example.
[0027] Also in the third aspect of the present invention, the
following method can be utilized to incorporate the additive in a
separator. A solid-form additive is subdivided into powder
particles. A suspension of these powder particles is sprayed onto a
surface of the separator. A vacuum treatment is then carried out to
remove a solvent, resulting in uniform dispersion of the additive
on the separator surface. As a result, the additive is incorporated
uniformly in a surface portion of the separator.
[0028] Alternatively, a solution containing the additive dissolved
therein may be impregnated into a separator and then a solvent is
removed by vacuum drying. This enables the separator to hold the
additive in its interior portion.
[0029] Inclusion of the additive in an interior or surface portion
of the separator, in accordance with the third aspect of the
present invention, assures a steady supply of the additive to the
electrolyte near a surface of silicon as a negative active
material. This causes continuous consumption of a component which
may oxidize silicon and accordingly retards oxidation of silicon
without interruption.
[0030] The matters common to the first through third aspects of the
present invention may be described below as those of the "present
invention".
[0031] The negative electrode in the present invention is
preferably formed by depositing a thin film of silicon or silicon
alloy onto a current collector. Such a thin film can be deposited
by various processes including sputtering, CVD, vapor deposition
and thermal spraying. Presumably, expansion of this thin film in a
thickness direction during a charge reaction causes a protective
film to partly come away from the active material, eases contact of
the electrolyte with the exposed fresh surface of the active
material and, as a result, causes oxidation of silicon. If
oxidation of silicon under such circumstances is retarded, swelling
of the active material during charge-discharge cycles can be
suppressed to thereby restrain an increase in thickness of a layer
of the active material.
[0032] Preferably, the aforesaid thin film of silicon or silicon
alloy has such a columnar structure that it is divided into columns
by gaps formed therein and extending in its thickness direction.
The provision of such a columnar structure lessens a stress
engendered when the active material expands and shrinks as lithium
is inserted and deinserted from the active material, and
effectively prevents delamination or falling-off of the active
material layer from the current collector. By retarding oxidation
of silicon present in the active material that repeats such
expansion and shrinkage, swelling of silicon and cycle
deterioration can be suppressed.
[0033] In order to form the gaps that extend in the thickness
direction of the thin film, irregularities are preferably formed on
a surface of the thin film. In order to form such irregularities on
the surface of the thin film of active material, a
surface-roughened copper foil or the like is preferably used as a
negative current collector. A typical example of such a copper foil
is an electrolytic copper foil. The electrolytic copper foil may be
obtained according to the following procedure, for example: A
metallic drum is immersed in an electrolyte solution containing
copper ions dissolved therein. The introduction of current while
the drum is rotated results in the deposition of copper on a
surface of the drum. The electrolytic copper foil is then obtained
by removing the deposited copper from the drum. A metal may be
deposited on both or either surface of the electrolytic copper foil
by an electrolytic process to impart surface roughness thereto.
Alternatively, a metal may be deposited on a surface of a rolled
foil by an electrolytic process to impart surface roughness
thereto.
[0034] In the present invention, the negative active material may
comprise an alloy of silicon and another metal. Examples of such
metals include cobalt, zirconium, zinc and iron. An alloy of
silicon and cobalt is particularly useful. By the addition of
cobalt, charge-discharge cycle characteristics can be further
improved. Preferably, the alloy of silicon and another metal
contains at least 50 atomic % of silicon.
[0035] In the present invention, the additive preferably remains in
a solid state in a nonaqueous electrolyte solution. That is, the
additive in the present invention preferably comprises a material
that hardly dissolves into a nonaqueous electrolyte solution.
Because the additive is consumed via a reaction with a component in
the electrolyte solution that acts to increase the amount of
silicon oxide, it is preferred that the additive constantly exists
in the electrolyte solution. If the additive is soluble in the
electrolyte solution, an excess amount of the additive readily
dissolves into the electrolyte solution. In such a case, the
additive may be consumed by a reaction with lithium or others
present in silicon and possibly exhaust in a later charge-discharge
cycle.
[0036] The additive, if present in a solid state in the nonaqueous
electrolyte solution, dissolves gradually into the electrolyte
solution. Only a part of the additive that dissolved therein takes
part in the reaction. Accordingly, the amount of the additive that
is consumed by the side reaction is minimized. It is thus believed
that the additive can be used effectively and exhibit the effect
that depends on the amount of the additive.
[0037] In the first and second aspects of the present invention,
the additive preferably has a mean particle size within a particle
size distribution of the positive or negative active material. This
enables uniform dispersion of the additive in an interior portion
of the positive or negative electrode.
[0038] In the present invention, the nonaqueous electrolyte
solution preferably contains a film former. This film former, when
subjected to reductive decomposition, forms a film which is
believed to improve homogeneity of a deinsertion-insertion reaction
of lithium on a surface of the negative electrode, suppress
development of local deterioration and reduce the occurrence of the
side reaction, effectively. However, this type of film is
insufficient to retard oxidation of a silicon surface. Also, the
effectiveness of the film is lost when the film former in the
battery exhausts. As silicon is oxidized, swelling of the negative
active material advances and its surface area enlarges. Then, an
increasing proportion of the film is destroyed to increase the
consumption of the film former. This reduces the number of
charge-discharge cycles during which the effect of adding the film
former is obtained. Accordingly, if the effect of adding the film
former is to continue, swelling of the negative active material
must be suppressed. Therefore, the simultaneous use of the additive
and the film former, in accordance with the present invention,
permits them to exhibit their individual advantages efficiently by
a synergistic effect. This results in obtaining improved cycle
characteristics.
[0039] Specific examples of film formers include vinylene carbonate
(VC) and vinylethylene carbonate (VEC). Under high temperature
circumstances, ethylene carbonate (EC) also serves as the film
former.
[0040] The film former is preferably added in the amount of
0.01-10% by weight, more preferably 0.1-10% by weight, based on the
weight of the nonaqueous electrolyte solution.
[0041] In the present invention, the additive may be held in a
support material. Any material, either inorganic or organic, which
has internal open spaces and is stable in the battery can be
suitably used as the support material. Examples of specific support
materials include solid inorganic fillers such as alumina, titania
and silica.
[0042] Also, the additive may be encapsulated by an outer shell
which gradually dissolves into the electrolyte solution.
Particularly when the liquid-form additive is used, the same result
is obtained by using a high-molecular polymer which can retain the
additive by swelling. The additive, if retained by the support
material, dissolves into the electrolyte solution in a more
controlled fashion. The additive, if solid, may be held within
internal open spaces of the support material and, if liquid, may be
impregnated into the support material.
[0043] Also in the third aspect of the present invention, the
support material preferably comprises solid fine particles. The use
of such a support material enhances strength of the separator which
can then be formed into a thinner film, and thus permits the
separator to retain the additive therein without reduction of an
energy density.
[0044] Also in the first and second aspects of the present
invention, the support material is preferable electronically
conductive. The use of such a support material eliminates the need
of using a conductive aid and thus permits the additive to be held
in the positive or negative electrode without reduction of an
energy density.
[0045] Examples of nonaqueous solvents for use in the nonaqueous
electrolyte solution in the present invention include cyclic
carbonates, chain carbonates, lactone compounds (cyclic
carboxylates), chain carboxylates, cyclic ethers, chain ethers and
sulfur-containing organic solvents. Preferred among them are cyclic
carbonates with a carbon number of 3-9, chain carbonates, lacton
compounds (cyclic carboxylates), chain carboxylates, cyclic ethers
and chain ethers. Particularly preferred nonaqueous solvents
contain one or both of a cyclic carbonate having a carbon number of
3-9 and a chain carbonate.
[0046] Examples of useful solutes for the nonaqueous electrolyte
solution in the present invention include lithium salt compounds
generally used in lithium secondary batteries.
[0047] The positive active material for use in the present
invention may be suitably chosen from those useful for lithium
secondary batteries. Examples of positive active materials include
lithium cobaltate, lithium manganate, lithium nickelate and lithium
transition metal complex oxides containing oxides thereof. These
oxides may be used alone or in combination.
[0048] (Concerning Oxidation of Silicon During Battery
Operation)
[0049] Descriptions are below given as to oxidation of silicon
during battery operation.
[0050] FIG. 1 is a secondary electron image, showing a rupture
surface of an electrode of the silicon thin film before charge and
discharge. This electrode of the silicon thin film is an electrode
formed by sputter depositing a thin film of silicon onto an
electrolytic copper foil as a current collector.
[0051] FIG. 2 is a secondary electron image, showing the electrode
in its state after the first-cycle charge. FIG. 3 is a secondary
electron image, showing the electrode in its state after the
first-cycle discharge.
[0052] As can be clearly seen from FIGS. 2 and 3, the silicon thin
film, when brought to a charged state by insertion of lithium
thereinto, expands to at least twice its initial thickness. By the
following discharge, cracks are formed in a thickness direction of
the silicon thin film. As a result, the silicon thin film assumes a
columnar structure and expands to at least 1.5 times its initial
thickness before charge and discharge. Such a columnar structure of
the silicon thin film is effective to lessen a stress engendered
due to expansion and shrinkage of the active material and thus
prevents shedding of the active material from the current
collector.
[0053] With the use of such a negative electrode of the silicon
thin film, a discharge capacity retention rate declines with
repeated charge-discharge cycling, as shown in FIG. 4.
[0054] FIGS. 5-7 are microscopic images when taken with a scanning
ion microscope, showing sections of an electrode of the silicon
thin film in its state before charge and discharge, before
deterioration of discharge capacity (after 10 cycles) and after
deterioration of discharge capacity (after 100 cycles),
respectively. Specifically, a tungsten protective film is deposited
on a surface of an active material layer, followed by cutting with
a focused ion-beam device. The exposed columns of the active
material are then observed with a scanning ion microscope to obtain
each microscopic image. FIGS. 5-7, an arrow at an end of a
single-dotted chain line indicates a tungsten protective film.
[0055] In FIGS. 5-7, an arrow at an end of a solid line indicates a
modified portion which appears bright relative to an interior of
the columnar active material. This portion is a region where the
active material underwent a property change. An arrow at an end of
a dotted line indicates an unmodified portion which appears dark.
This portion is an interior region of the column where the active
material remains unchanged in property.
[0056] As can be clearly seen from FIGS. 5-7, the modified portion
of the active material is small both before charge and discharge
and before deterioration of discharge capacity but becomes larger
after deterioration of discharge capacity. In a region of the
modified portion, the active material decreases in bulk density
(swells) as a result of formation of open spaces therein and
accordingly the layer of active material increases in thickness.
However, the active material is observed to remain unpowdered. No
appreciable shedding thereof from the current collector is
observed.
[0057] The negative electrode was cleaned with dimethyl carbonate,
dried under vacuum and then subjected to X-ray photoelectron
spectroscopy (XPS) combining sputtering by an argon ion beam, in
which the negative active material was analyzed along its depth for
oxygen and silicon present in its interior and surface
portions.
[0058] In FIGS. 8-10, the silicon and oxygen concentrations, in
terms of atomic percent, are shown versus sputtering time. FIGS.
8-10 show the data for the active material before charge and
discharge, before deterioration of discharge capacity and after
deterioration of discharge capacity, respectively. A rate of
sputtering is 10 nm/min, in terms of SiO.sub.2.
[0059] As can be clearly seen from FIGS. 8-10, before charge and
discharge and before deterioration of discharge capacity, oxygen is
only concentrated at the utmost surface. However, after
deterioration of discharge capacity, oxygen exists in the
concentration of at least 20 atomic % to the depth of sputtering
time of 80 minutes (800 nm depth from the utmost surface). This
demonstrates that oxidation of silicon advances with
charge-discharge cycling.
[0060] Accordingly, the modified portion shown by an arrow at an
end of a solid line in FIGS. 5-7 is believed to constitute a region
where a high concentration of oxygen exists in the form of silicon
oxide. On the other hand, in the unmodified portion shown by an
arrow at an end of a dotted line, silicon is believed to remain in
the unoxidized state.
[0061] In the X-ray photoelectron spectroscopy (XPS) analysis, a
valence of silicon is known to be related to the binding energy
position of an XSP Si(2p) spectrum by 0-valent silicon: about 99
eV, 2-valent silicon: about 101 eV and 4-valent silicon: about 103
eV.
[0062] FIG. 11 shows XPS Si-2p spectra for the silicon thin film of
the negative electrode at the utmost surface and after sputtered
for 1 minute, 10 minutes, 20 minutes, 40 minutes and 80 minutes. As
can be clearly seen from FIG. 11, 2-valent silicon is concentrated
in the surface portion and 0-valent silicon is concentrated in the
interior portion of the silicon thin film.
[0063] FIGS. 12-14 shows XPS profiles for the silicon thin film of
the negative electrode before charge and discharge (FIG. 12),
before deterioration of discharge capacity (FIG. 13) and after
deterioration of discharge capacity (FIG. 14), wherein a peak area
of the XPS Si(2p) spectrum is divided by 0-valent silicon and
oxidized silicon (2-valent silicon plus 4-valent silicon) and their
concentrations, in terms of atomic percent, are plotted.
[0064] As can be clearly seen from FIGS. 12-14, before charge and
discharge and before deterioration of discharge capacity, silicon
oxide only exists at the utmost surface. However, after
deterioration of discharge capacity, silicon oxide exists in the
concentration of at least 20 atomic % to the depth of sputtering
time of 80 minutes.
[0065] As discussed above, it has been confirmed that, as silicon
is oxidized with charge-discharge cycling, the active material
swells increasingly to increase its thickness. The following is
believed to describe one reason for the deterioration of discharge
capacity. As the active material is oxidized at its surface and
swells, its electric conduction decreases at the surface and its
resistance increases when lithium is stored and released. Silicon
may be oxidized by the following reactions:
Si+2Li.sup.++2OH.sup.-.fwdarw.Si(OLi)H.sub.2.uparw. (1)
2Si+6OH.sup.-.fwdarw.3SiO.sub.2.sup.2-+3H.sub.2.uparw. (2)
[0066] These reaction formulas are generally known in the aqueous
solution system. In the aqueous solution system, silicon is
oxidized by a reaction with OH.sup.-.
[0067] However, little OH.sup.- is transferred in an organic
solution for use as a nonaqueous electrolyte solution. In this
case, an alkaline lithium-containing compound, such as LiOH, ROLi,
Li.sub.2O, ROCO.sub.2Li or RCO.sub.2Li, is believed to cause
silicon to undergo reactions similar to those involving OH.sup.- in
the above formulas (1) and (2) to increase silicon oxide.
[0068] Under the presence of lithium, water present in the system
may also react with lithium via the following reaction to produce
OH.sup.- that causes oxidation of silicon:
2Li+2H.sub.2O.fwdarw.2Li--OH+H.sub.2.uparw. (3)
[0069] A component which increases production of silicon oxide in
the battery is considered to be a substance that causes the
following reactions (i) and (ii):
[0070] (i) a reaction by which silicon changes its oxidation number
from 0 to 2 or 4, i.e., an oxidation reaction of silicon; and
[0071] (ii) a reaction by which a compound having a silicon-oxygen
bond is produced.
[0072] The foregoing demonstrate that deterioration of silicon as
an active material occurs as a result of an oxidation reaction of
silicon. In this invention, the additive which retards oxidation of
silicon is incorporated in an interior or surface portion of the
separator, based on such finding of the inventors of this
application, to thereby suppress deterioration of silicon and, as a
result, improve charge-discharge cycle characteristics.
[0073] Inclusion of the additive capable of retarding oxidation of
silicon during battery operation either in an interior or surface
portion of the positive electrode, or in an interior or surface
portion of the negative electrode or in an interior or surface
portion of the separator, in accordance with the present invention,
suppresses deterioration and thus expansion (swelling) of the
active material containing silicon, resulting in obtaining improved
charge-discharge cycle characteristics.
BRIEF DESCRIPTION OF THE DRAWINGS
[0074] FIG. 1 is a secondary electron image, showing a rupture
surface of an electrode of a silicon thin film before charge and
discharge;
[0075] FIG. 2 is a secondary electron image, showing a rupture
surface of an electrode of a silicon thin film in a conventional
battery in its state after the first-cycle charge;
[0076] FIG. 3 is a secondary electron image, showing a rupture
surface of an electrode of a silicon thin film in a conventional
battery in its state after the first-cycle discharge;
[0077] FIG. 4 is a graph, showing charge-discharge cycle
characteristics for a conventional battery;
[0078] FIG. 5 is an image when taken with a scanning ion
microscope, showing a section of an electrode of a silicon thin
film in its state before charge;
[0079] FIG. 6 is an image when taken with a scanning ion
microscope, showing a section of an electrode of a silicon thin
film in a conventional battery in its state before discharge
capacity deterioration;
[0080] FIG. 7 is an image when taken with a scanning ion
microscope, showing a section of an electrode of a silicon thin
film in a conventional battery in its state after discharge
capacity deterioration;
[0081] FIG. 8 is an XPS profile, showing silicon and oxygen
concentrations in a surface portion of a silicon thin film before
charge and discharge;
[0082] FIG. 9 is an XPS profile, showing silicon and oxygen
concentrations in a surface portion of a negative electrode of a
silicon thin film in a conventional battery before discharge
capacity deterioration;
[0083] FIG. 10 is an XPS profile, showing silicon and oxygen
concentrations in a surface portion of a negative electrode of a
silicon thin film in a conventional battery after discharge
capacity deterioration;
[0084] FIG. 11 is an XPS Si(2p) spectrum profile for a surface
portion of a negative electrode of a silicon thin film in a
conventional battery after discharge capacity deterioration;
[0085] FIG. 12 is an XPS profile, showing concentrations of
O-valent silicon and silicon oxide present in a surface portion of
a negative electrode of a silicon thin film before charge and
discharge;
[0086] FIG. 13 is an XPS profile, showing concentrations of
O-valent silicon and silicon oxide present in a surface portion of
a negative electrode of a silicon thin film in a conventional
battery before discharge capacity deterioration;
[0087] FIG. 14 is an XPS profile, showing concentrations of
O-valent silicon and silicon oxide present in a surface portion of
a negative electrode of a silicon thin film in a conventional
battery after discharge capacity deterioration;
[0088] FIG. 15 is a photograph taken with a scanning electron
microscope, showing a condition of a negative electrode in a
battery of Example 1 in accordance with the present invention after
delivery of 80 cycles;
[0089] FIG. 16 is a photograph taken with a scanning electron
microscope, showing a condition of a negative electrode in a
battery of Example 2 in accordance with the present invention after
delivery of 80 cycles;
[0090] FIG. 17 is a photograph taken with a scanning electron
microscope, showing a condition of a negative electrode in a
battery of Comparative Example 1 while in an initial stage of a
charge-discharge cycle test;
[0091] FIG. 18 is a photograph taken with a scanning electron
microscope, showing a condition of a negative electrode in a
battery of Comparative Example 1 after delivery of 80 cycles;
[0092] FIG. 19 is a photograph taken with a scanning electron
microscope, showing a condition of a negative electrode in a
battery of Comparative Example 2 after delivery of 80 cycles;
[0093] FIG. 20 is a photograph taken with a scanning electron
microscope, showing a condition of a negative electrode in a
battery of Example 5 in accordance with the present invention after
delivery of 80 cycles;
[0094] FIG. 21 is a photograph taken with a scanning electron
microscope, showing a condition of a negative electrode in a
battery of Comparative Example 3 while in an initial stage of a
charge-discharge cycle test;
[0095] FIG. 22 is a photograph taken with a scanning electron
microscope, showing a condition of a negative electrode in a
battery of Comparative Example 3 after delivery of 80 cycles;
[0096] FIG. 23 is a photograph taken with a scanning electron
microscope, showing a condition of a negative electrode in a
battery of Comparative Example 4 after delivery of 80 cycles;
[0097] FIG. 24 is a photograph taken with a scanning electron
microscope, showing a condition of a negative electrode in a
battery of Comparative Example 5 after delivery of 80 cycles;
[0098] FIG. 25 is a photograph taken with a scanning electron
microscope, showing a condition of a negative electrode in a
battery of Example 7 in accordance with the present invention after
delivery of 80 cycles;
[0099] FIG. 26 is a photograph taken with a scanning electron
microscope, showing a condition of a negative electrode in a
battery of Example 8 in accordance with the present invention after
delivery of 80 cycles;
[0100] FIG. 27 is a photograph taken with a scanning electron
microscope, showing a condition of a negative electrode in a
battery of Comparative Example 6 while in an initial stage of a
charge-discharge cycle test;
[0101] FIG. 28 is a photograph taken with a scanning electron
microscope, showing a condition of a negative electrode in a
battery of Comparative Example 6 after delivery of 80 cycles;
and
[0102] FIG. 29 is a photograph taken with a scanning electron
microscope, showing a condition of a negative electrode in a
battery of Comparative Example 7 after delivery of 80 cycles.
DESCRIPTION OF THE PREFERRED EXAMPLES
[0103] The present invention is below described by way of specific
examples but is not intended to be limiting thereof.
Example 1
Fabrication of Positive Electrode
[0104] Lithium cobaltate as a positive active material, ketchen
black as a conductive aid and a fluororesin as a binder were mixed
in the ratio by mass of 90:5:5 and then dissolved in
N-methyl-2-pyrrolidone (NMP). Succinic anhydride was further added
in the amount of 1.0% by weight, based on the weight of lithium
cobaltate as the positive active material, to prepare a cathode mix
paste.
[0105] The cathode mix paste was uniformly coated on both sides of
a 20 .mu.m thick aluminum foil by a doctor blade process, heat
treated under vacuum in a heating drier at a temperature of
100-150.degree. C. to remove NMP and then rolled by a pressure roll
to a thickness of 0.16 mm to fabricate a positive electrode.
[0106] (Fabrication of Negative Electrode)
[0107] An electrolytic copper foil having a thickness of 18 .mu.m
and a surface roughness Ra of 0.188 .mu.m was used as a current
collector. A 5 .mu.m thick silicon film was deposited on this
electrolytic copper foil by an RF sputtering process under the
following conditions: a sputtering gas (Ar) flow rate of 100 sccm,
an ambient substrate temperature (not heated), a reaction pressure
of 0.133 Pa (1.0.times.10.sup.-3 Torr.) and 200 W RF power. The
resulting silicon thin film was analyzed by Raman spectroscopy
which detected the presence of a peak around 480 cm.sup.-1 but the
absence of a peak around 520 cm.sup.-1. This revealed an amorphous
nature of the silicon thin film.
[0108] Formation of such a silicon thin film on both sides of the
current collector, as described above, resulted in fabrication of a
negative electrode.
[0109] (Preparation of Nonaqueous Electrolyte Solution)
[0110] 1 mole/liter of LiPF.sub.6 as an electrolyte salt was
dissolved in a mixed solvent containing ethylene carbonate (EC) and
diethyl carbonate (DEC) at a 3:7 ratio by volume to prepare an
electrolyte solution.
[0111] (Construction of Secondary Battery)
[0112] Each of the positive and negative electrodes was cut into a
predetermined size. A current collecting tab was attached to its
current collector. A 20 .mu.m thick separator made of a microporous
polyolefin film was interposed between the positive and negative
electrodes. This combination was wound and then fastened at an
outermost periphery by a tape to provide a spirally-wound electrode
assembly which was subsequently pressed into a flat shape. This
electrode assembly was then inserted into an inner space of an
outer casing made of a laminated material such as having layers of
PET and aluminum. After introduction of the electrolyte solution,
the outer casing was sealed such that a distal end of each tab
extended from an outer edge of the outer casing, thereby
constructing a lithium secondary battery.
Comparative Example 1
[0113] The procedure of Example 1 was followed, except that
succinic anhydride was excluded from the cathode mix paste, to
construct a lithium secondary battery.
[0114] (Evaluation of Cycle Characteristics)
[0115] The batteries obtained in Example 1 and Comparative Example
1 were evaluated for cycle characteristics. Each battery was
subjected to charge-discharge cycling under the following
conditions until reaching the 50th cycle to measure an initial
discharge capacity and a discharge capacity after 50 cycles and
calculate a discharge capacity retention (initial discharge
capacity/discharge capacity after 50 cycles.times.100). The results
are shown in Table 2.
[0116] Charging condition: constant current at 250 mA--constant
voltage at 4.2 V to a final current of 12 mA
[0117] Discharging condition: constant current at 250 mA to a final
voltage of 2.75 V
[0118] (Thickness Measurement of Active Material Layer)
[0119] Each battery was subjected to charge-discharged cycling
under the above-specified conditions until reaching the 80th cycle
to measure a thickness change of the active material layer after 80
cycles. Specifically, the negative electrode was removed from the
battery prior to and subsequent to the above charge-discharge test
and observed with a scanning electron microscope (SEM) to measure a
thickness of the active material layer and calculate its thickness
change.
[0120] FIG. 15 is an SEM photograph, showing the negative electrode
of the battery of Example 1 after 80 cycles. FIGS. 17 and 18 are
SEM photographs, showing the negative electrode of Comparative
Example 1 before the charge-discharge test and after 80 cycles,
respectively. The thickness of the active material layer was
determined using dotted lines shown in each Figure (positions shown
by arrows) as standards.
[0121] The measurement results are shown in Table 2.
[0122] (Measurement of Oxygen/Silicon Ratio at Negative Electrode
Surface)
[0123] After 80 cycles, the negative electrode was removed, cleaned
with dimethyl carbonate and analyzed using an electron microprobe
for its surface to measure an oxygen/silicon ratio at the surface.
The measurement results are shown in Table 2.
TABLE-US-00001 TABLE 1 Loading Additive (weight %) Comparative None
-- Example 1 Example 1 Succinic 1 Anhydride
TABLE-US-00002 TABLE 2 Oxygen/Sili- con Ratio (Ra- Thickness
Discharge tio of Numbers Change of Capacity Discharge of Atoms) at
Active After 50 Capacity Negative Elec- Material Initially Cycles
Retention trode Surface Layer (mAh) (mAh) (%) Comparative 1.7 16
.mu.m 247 180 72.8 Example 1 Example 1 1.6 12 .mu.m 241 202
83.9
[0124] As can be clearly seen from the results shown in Table 2,
the addition of succinic anhydride as an additive capable of
retarding oxidation of silicon, in accordance with the present
invention, not only results in the increased discharge capacity
retention and the improved cycle characteristics but also
suppresses increase in thickness of the active material layer.
Example 2
[0125] The procedure of Example 1 was followed, except that
vinylene carbonate (VC) was added to the nonaqueous electrolyte
solution in the amount of 2% by weight, to construct a lithium
secondary battery.
Comparative Example 2
[0126] The procedure of Example 2 was followed, except that
succinic anhydride was excluded from the cathode mix paste, to
construct a lithium secondary battery.
TABLE-US-00003 TABLE 3 Film Former Additive Type of Loading Type of
Loading Film Former (weight %) Additive (weight %) Comparative None
-- None -- Example 1 Comparative VC 2 None -- Example 2 Example 1
None -- Succinic 1 Anhydride Example 2 VC 2 Succinic 1
Anhydride
[0127] (Measurement of Charge-Discharge Cycle Characteristics and
Thickness Change of Active Material Layer of Negative
Electrode)
[0128] Charge-discharge cycle characteristics of each battery were
evaluated in the same manner as in Example 1. Its discharge
capacity retention is shown in Table 4. Also, a thickness change of
an active material layer of the negative electrode was measured in
the same manner as in Example 1. The results are shown in Table 4.
FIG. 16 is an SEM photograph, showing the negative electrode of the
battery of Example 2 after 80 cycles. FIG. 19 is an SEM photograph,
showing the negative electrode of the battery of Comparative
Example 2 after 80 cycles. In Table 4, the results of Example 1 and
Comparative Example 1 are also shown.
TABLE-US-00004 TABLE 4 Thickness Change of Negative Active
Discharge Capacity Material Layer Retention (%) Comparative 16
.mu.m 72.8 Example 1 Comparative 16 .mu.m 89.8 Example 2 Example 1
12 .mu.m 83.9 Example 2 8 .mu.m 90.6
[0129] As can be clearly seen from the results shown in Table 4,
addition of vinylene carbonate to the nonaqueous electrolyte
solution, as well as incorporation of succinic anhydride in the
positive electrode, results in the marked improvements in
charge-discharge cycle characteristics and suppression of electrode
swelling.
Example 3
[0130] In Fabrication of Positive Electrode in Example 1, succinic
anhydride was not incorporated in the cathode mix slurry. Instead,
the cathode mix slurry, exclusive of succinic anhydride, was coated
to prepare a positive electrode. Then, succinic anhydride was
dispersed over a surface of the positive electrode in the amount of
1% by weight. Dispersing was carried out by a method wherein a
suspension of subdivided powder-form succinic anhydride in DEC was
sprayed onto the electrode surface and subjected to a vacuum
treatment to remove a solvent so that succinic anhydride was
uniformly dispersed over the electrode surface. The procedure of
Example 2 using the nonaqueous electrolyte solution containing VC
was followed, except that the above-prepared positive electrode was
used, to construct a lithium secondary battery.
Example 4
[0131] In the fabrication of negative electrode in Example 3, a
thin film of a silicon-cobalt alloy, instead of the silicon thin
film, was deposited. Otherwise, the procedure of Example 3 was
followed to construct a lithium secondary battery. The cobalt
content of the silicon-cobalt alloy thin film was 20% by
weight.
TABLE-US-00005 TABLE 5 Negative Active Additive to Material
Negative Active Material Example 3 Si None Example 4 Si Co
[0132] (Evaluation of Charge-Discharge Cycle Characteristics)
[0133] Charge-discharge cycle characteristics of the lithium
secondary batteries obtained in Examples 3 and 4 were evaluated
according to the previously outlined procedure. A discharge
capacity retention for each battery was shown in Table 6.
TABLE-US-00006 TABLE 6 Discharge Capacity Retention (%) Example 3
81.9 Example 4 84.6
[0134] As can be clearly seen from the results shown in Table 6,
the use of the silicon-cobalt alloy as an active material further
improves cycle characteristics. Also in the case where succinic
anhydride was incorporated in a surface portion of the positive
electrode, the effect of the present invention was similarly
obtained.
Example 5
Fabrication of Positive Electrode
[0135] Lithium cobaltate as a positive active material, ketchen
black as a conductive aid and a fluororesin as a binder were mixed
in the ratio by mass of 90:5:5 and then dissolved in
N-methyl-2-pyrrolidone (NMP) to prepare a cathode mix paste.
[0136] The cathode mix paste was uniformly coated on both sides of
a 20 .mu.m thick aluminum foil by a doctor blade process, heat
treated under vacuum in a heating drier at a temperature of
100-150.degree. C. to remove NMP and then rolled by a pressure roll
to a thickness of 0.16 mm to fabricate a positive electrode.
[0137] (Fabrication of Negative Electrode)
[0138] An electrolytic copper foil having a thickness of 18 .mu.m
and a surface roughness Ra of 0.188 .mu.m was used as a current
collector. A 5 .mu.m thick silicon film was deposited on this
electrolytic copper foil by an RF sputtering process under the
following conditions: a sputtering gas (Ar) flow rate of 100 sccm,
an ambient substrate temperature (not heated), a reaction pressure
of 0.133 Pa (1.0.times.10.sup.-3 Torr.) and 200 W RF power. The
resulting silicon thin film was analyzed by Raman spectroscopy
which detected the presence of a peak around 480 cm.sup.-1 but the
absence of a peak around 520 cm.sup.-1. This revealed an amorphous
nature of the silicon thin film.
[0139] Formation of such a silicon thin film on each side of the
current collector, as described above, resulted in fabrication of a
negative electrode. Thereafter, succinic anhydride was incorporated
in a surface portion of the negative electrode. Specifically, a
suspension of subdivided powder-form succinic anhydride in DEC was
sprayed over a surface of the electrode. A vacuum treatment is
subsequently carried out to remove DEC. As a result, the negative
electrode was obtained having a surface portion in which succinic
anhydride was uniformly dispersed.
[0140] (Preparation of Nonaqueous Electrolyte Solution)
[0141] 1 mole/liter of LiPF.sub.6 as an electrolyte salt was
dissolved in a mixed solvent containing ethylene carbonate (EC) and
diethyl carbonate (DEC) at a 3:7 ratio by volume. Vinylene
carbonate (VC) was further added in the amount of 2% by weight to
prepare an electrolyte solution.
[0142] (Construction of Secondary Battery)
[0143] Each of the positive and negative electrodes was cut into a
predetermined size. A current collecting tab was attached to its
current collector. A 20 .mu.m thick separator made of a microporous
polyolefin film was interposed between the positive and negative
electrodes. This combination was wound and then fastened at an
outermost periphery by a tape to provide a spirally-wound electrode
assembly which was subsequently pressed into a flat shape. This
electrode assembly was then inserted into an inner space of an
outer casing made of a laminated material such as having layers of
PET and aluminum. After introduction of the electrolyte solution,
the outer casing was sealed such that a distal end of each tab
extended from an outer edge of the outer casing, thereby
constructing a lithium secondary battery.
Comparative Example 3
[0144] The procedure of Example 5 was followed, except that
succinic anhydride was not incorporated in the surface portion of
the negative electrode and vinylene carbonate (VC) was excluded
from the electrolyte solution, to construct a lithium secondary
battery.
[0145] (Evaluation of Cycle Characteristics)
[0146] The batteries obtained in Example 5 and Comparative Example
3 were evaluated for cycle characteristics. Each battery was
subjected to charge-discharge cycling under the following
conditions until reaching the 50th cycle to measure an initial
discharge capacity and a discharge capacity after 50 cycles and
calculate a discharge capacity retention (initial discharge
capacity/discharge capacity after 50 cycles.times.100). The results
are shown in Table 8.
[0147] Charging condition: constant current at 250 mA--constant
voltage at 4.2 V to a final current of 12 mA
[0148] Discharging condition: constant current at 250 mA to a final
voltage of 2.75 V
[0149] (Thickness Measurement of Active Material Layer)
[0150] Each battery was subjected to charge-discharge cycling under
the above-specified conditions until reaching the 80th cycle to
measure a thickness change of the active material layer after 80
cycles. Specifically, the negative electrode was removed from the
battery prior to and subsequent to the above charge-discharge test
and observed with a scanning electron microscope (SEM) to measure a
thickness of the active material layer and calculate its thickness
change.
[0151] FIG. 20 is an SEM photograph, showing the negative electrode
of the battery of Example 5 after 80 cycles. FIGS. 21 and 22 are
SEM photographs, showing the negative electrode of Comparative
Example 3 before the charge-discharge test and after 80 cycles,
respectively. The thickness of the active material layer was
determined using dotted lines shown in each Figure (positions shown
by arrows) as standards. The measurement results are shown in Table
8.
TABLE-US-00007 TABLE 7 Additive Film Former Type of Loading Type of
Film Loading Additive (weight %) Former (weight %) Comparative None
-- None -- Example 3 Example 5 Succinic 1 VC 2 Anhydride
TABLE-US-00008 TABLE 8 Thickness Change of Discharge Capacity
Discharge Active Mate- Initially After 50 Capacity rial Layer (mAh)
Cycles (mAh) Retention (%) Comparative 16 .mu.m 247 180 72.8
Example 3 Example 5 12 .mu.m 247 226 91.4
[0152] As can be clearly seen from the results shown in Table 8,
the incorporation of succinic anhydride as an additive capable of
retarding oxidation of silicon in the surface portion of the
negative electrode and the inclusion of VC in the electrolyte
solution, in accordance with the present invention, not only
results in the increased discharge capacity retention and the
improved cycle characteristics but also suppresses increase in
thickness of the active material layer.
Comparative Example 4
[0153] The procedure of Comparative Example 3 was followed, except
that vinylene carbonate (VC) was added to the nonaqueous
electrolyte solution in the amount of 2% by weight, to construct a
lithium secondary battery.
Comparative Example 5
[0154] The procedure of Comparative Example 3 was followed, except
that succinic anhydride was incorporated in a surface portion of
the negative electrode, to construct a lithium secondary
battery.
TABLE-US-00009 TABLE 9 Additive Film Former Type of Loading Type of
Film Loading Additive (weight %) Former (weight %) Comparative None
-- None -- Example 3 Comparative None -- VC 2 Example 4 Comparative
Succinic 1 None -- Example 5 Anhydride Example 5 Succinic 1 VC 2
Anhydride
[0155] (Measurement of Charge-Discharge Cycle Characteristics and
Thickness Change of Active Material of Negative Electrode)
[0156] Charge-discharge cycle characteristics of each battery were
evaluated in the same manner as in Example 5. Its discharge
capacity retention is shown in Table 10. Also, a thickness change
of an active material layer of the negative electrode was measured
in the same manner as in Example 5 and shown in Table 10. FIG. 23
is an SEM photograph, showing the negative electrode of the battery
of Comparative Example 4 after 80 cycles. FIG. 24 is an SEM
photograph, showing the negative electrode of the battery of
Comparative Example 5 after 80 cycles. In Table 10, the results of
Example 5 and Comparative Example 3 are also shown.
TABLE-US-00010 TABLE 10 Thickness Change of Negative Active
Discharge Capacity Material Layer Retention (%) Comparative 16
.mu.m 72.8 Example 3 Comparative 16 .mu.m 89.8 Example 4
Comparative 16 .mu.m 78.6 Example 5 Example 5 12 .mu.m 91.4
[0157] As can be clearly seen from the results shown in Table 10,
the incorporation of vinylene carbonate in the nonaqueous
electrolyte solution, as well as the inclusion of succinic
anhydride in the surface portion of the negative electrode, results
in the marked improvements in charge-discharge cycle
characteristics and suppression of electrode swelling.
Example 6
[0158] In the fabrication of negative electrode in Example 5, a
thin film of a silicon-cobalt alloy, instead of the silicon thin
film, was deposited. Otherwise, the procedure of Example 5 was
followed to construct a lithium secondary battery. The cobalt
content of the silicon-cobalt alloy thin film was 20% by
weight.
TABLE-US-00011 TABLE 11 Negative Active Additive to Material
Negative Active Material Example 5 Si None Example 6 Si Co
[0159] (Evaluation of Charge-Discharge Cycle Characteristics)
[0160] Charge-discharge cycle characteristics of the lithium
secondary batteries obtained in Examples 5 and 6 were evaluated
according to the previously outlined procedure. A discharge
capacity retention for each battery was shown in Table 12.
TABLE-US-00012 TABLE 12 Discharge Capacity Retention (%) Example 5
91.4 Example 6 92.7
[0161] As can be clearly seen from the results shown in Table 12,
the use of the silicon-cobalt alloy as an active material further
improves cycle characteristics.
Example 7
Fabrication of Positive Electrode
[0162] Lithium cobaltate as a positive active material, ketchen
black as a conductive aid and a fluororesin as a binder were mixed
in the ratio by mass of 90:5:5 and then dissolved in
N-methyl-2-pyrrolidone (NMP) to prepare a cathode mix paste.
[0163] The cathode mix paste was uniformly coated on both sides of
a 20 .mu.m thick aluminum foil by a doctor blade process, heat
treated under vacuum in a heating drier at a temperature of
100-150.degree. C. to remove NMP and then rolled by a pressure roll
to a thickness of 0.16 mm to fabricate a positive electrode.
[0164] (Fabrication of Negative Electrode)
[0165] An electrolytic copper foil having a thickness of 18 .mu.m
and a surface roughness Ra of 0.188 .mu.m was used as a current
collector. A 5 .mu.m thick silicon film was deposited on this
electrolytic copper foil by an RF sputtering process under the
following conditions: a sputtering gas (Ar) flow rate of 100 sccm,
an ambient substrate temperature (not heated), a reaction pressure
of 0.133 Pa (1.0.times.10.sup.-3 Torr.) and 200 W RF power. The
resulting silicon thin film was analyzed by Raman spectroscopy
which detected the presence of a peak around 480 cm.sup.-1 but the
absence of a peak around 520 cm.sup.-1. This revealed an amorphous
nature of the silicon thin film.
[0166] Formation of such a silicon thin film on each side of the
current collector, as described above, resulted in fabrication of a
negative electrode.
[0167] (Fabrication of Separator)
[0168] Silica powder having surfaces to which ester was adsorbed
and polyethylene powder were mixed and melt extruded into a 200
.mu.m thick sheet. The resulting sheet was immersed in a 20 wt. %
aqueous solution of sodium hydroxide and an organic solvent to
remove the silica powder and ester. The sheet was further cleaned
with water, dried and then drawn both in the MD (machine direction)
and TD (transverse direction) to obtain a separator comprised of a
20 .mu.m thick, microporous polyethylene film having internal
micropores.
[0169] Succinic anhydride was dissolved in diethyl carbonate to
prepare a solution containing 1 mole/liter of succinic anhydride.
The separator was immersed in this solution sufficiently and then
vacuum dried to remove diethyl carbonate, so that succinic
anhydride was uniformly dispersed throughout micropores of the
separator. The succinic anhydride content of the separator was
determined by measuring the weight of the separator prior to and
subsequent to inclusion of the succinic anhydride. The succinic
anhydride content was 1.times.10.sup.-5 g/cm.sup.2.
[0170] (Preparation of Nonaqueous Electrolyte Solution)
[0171] 1 mole/liter of LiPF.sub.6 as an electrolyte salt was
dissolved in a mixed solvent containing ethylene carbonate (EC) and
diethyl carbonate (DEC) at a 3:7 ratio by volume to prepare an
electrolyte solution.
[0172] (Construction of Secondary Battery)
[0173] Each of the positive and negative electrodes was cut into a
predetermined size. A current collecting tab was attached to its
current collector. The separator as fabricated above was interposed
between the positive and negative electrodes. This combination was
wound and then fastened at an outermost periphery by a tape to
provide a spirally-wound electrode assembly which was subsequently
pressed into a flat shape. This electrode assembly was then
inserted into an inner space of an outer casing made of a laminated
material such as having layers of PET and aluminum. After
introduction of the electrolyte solution, the outer casing was
sealed such that a distal end of each tab extended from an outer
edge of the outer casing, thereby constructing a lithium secondary
battery.
Comparative Example 6
[0174] The procedure of Example 7 was followed, except that
succinic anhydride as an additive was not incorporated in the
separator, to construct a lithium secondary battery.
[0175] (Evaluation of Cycle Characteristics)
[0176] The batteries obtained in Example 7 and Comparative Example
6 were evaluated for cycle characteristics. Each battery was
subjected to charge-discharge cycling under the following
conditions until reaching the 50th cycle to measure an initial
discharge capacity and a discharge capacity after 50 cycles and
calculate a discharge capacity retention (initial discharge
capacity/discharge capacity after 50 cycles.times.100). The results
are shown in Table 14.
[0177] Charging condition: constant current at 250 mA--constant
voltage at 4.2 V to a final current of 12 mA
[0178] Discharging condition: constant current at 250 mA to a final
voltage of 2.75 V
[0179] (Thickness Measurement of Active Material Layer)
[0180] Each battery was subjected to charge-discharged cycling
under the above-specified conditions until reaching the 80th cycle
to measure a thickness change of the active material layer after 80
cycles. Specifically, the negative electrode was removed from the
battery prior to and subsequent to the above charge-discharge test
and observed with a scanning electron microscope (SEM) to measure a
thickness of the active material layer and calculate its thickness
change.
[0181] FIG. 25 is an SEM photograph, showing the negative electrode
of the battery of Example 7 after 80 cycles. FIGS. 27 and 28 are
SEM photographs, showing the negative electrode of Comparative
Example 6 before the charge-discharge test and after 80 cycles,
respectively. The thickness of the active material layer was
determined using dotted lines shown in each Figure (positions shown
by arrows) as standards. The measurement results are shown in Table
14.
[0182] (Measurement of Oxygen/Silicon Ratio at Negative Electrode
Surface)
[0183] After 80 cycles, the negative electrode was removed, cleaned
with dimethyl carbonate and analyzed using an electron microprobe
for elements to measure an oxygen/silicon ratio at the surface of
the negative electrode. The measurement results are shown in Table
14.
TABLE-US-00013 TABLE 13 Content Additive (.times.10.sup.-5
g/cm.sup.2) Comparative None -- Example 6 Example 7 Succinic 1
Anhydride
TABLE-US-00014 TABLE 14 Oxygen/Sili- con Ratio (Ra- Thickness
Discharge tio of Numbers Change of Capacity Discharge of Atoms) at
Active After 50 Capacity Negative Elec- Material Initially Cycles
Retention trode Surface Layer (mAh) (mAh) (%) Comparative 1.7 16
.mu.m 247 180 72.8 Example 6 Example 7 1.6 12 .mu.m 239 198
82.8
[0184] As can be clearly seen from the results shown in Table 14,
the inclusion of succinic anhydride as an additive capable of
retarding oxidation of silicon, in accordance with the present
invention, not only results in the increased discharge capacity
retention and the improved cycle characteristics, but also
suppresses increase in thickness of the active material layer.
Example 8
[0185] The procedure of Example 7 was followed, except that
vinylene carbonate (VC) was added to the nonaqueous electrolyte
solution in the amount of 2% by weight, to construct a lithium
secondary battery.
Comparative Example 7
[0186] The procedure of Example 8 was followed, except that
succinic anhydride was not incorporated in the separator, to
construct a lithium secondary battery.
TABLE-US-00015 TABLE 15 Film Former Additive Type of Loading Type
of Content Film Former (weight %) Additive (.times.10.sup.-5
g/cm.sup.2) Comparative None -- None -- Example 6 Comparative VC 2
None -- Example 7 Example 7 None -- Succinic 1 Anhydride Example 8
VC 2 Succinic 1 Anhydride
[0187] (Measurement of Charge-Discharge Cycle Characteristics and
Thickness Change of Active Material Layer of Negative
Electrode)
[0188] Charge-discharge cycle characteristics of each battery were
evaluated in the same manner as in Example 7. Its discharge
capacity retention is shown in Table 16. Also, a thickness change
of an active material layer of the negative electrode was measured
in the same manner as in Example 7 and shown in Table 16. FIG. 26
is an SEM photograph, showing the negative electrode of the battery
of Example 8 after 80 cycles. FIG. 29 is an SEM photograph, showing
the negative electrode of the battery of Comparative Example 7
after 80 cycles. In Table 16, the results of Example 7 and
Comparative Example 6 are also shown.
TABLE-US-00016 TABLE 16 Thickness Change of Negative Active
Discharge Capacity Material Layer Retention (%) Comparative 16
.mu.m 72.8 Example 6 Comparative 16 .mu.m 89.8 Example 7 Example 7
12 .mu.m 82.8 Example 8 8 .mu.m 90.6
[0189] As can be clearly seen from the results shown in Table 16,
the incorporation of vinylene carbonate in the nonaqueous
electrolyte solution, as well as the inclusion of succinic
anhydride in the separator, results in the marked improvements in
charge-discharge cycle characteristics and suppression of electrode
swelling.
Example 9
[0190] As contrary to the procedure of Example 7, 1.times.10.sup.-5
g/cm.sup.2 of succinic anhydride was incorporated in a surface
portion of the separator by dispersing succinic anhydride over a
surface of the separator. Dispersing was carried out by a method
wherein a suspension of subdivided powder-form succinic anhydride
in DEC was sprayed onto the separator surface and then subjected to
a vacuum treatment to remove DEC so that the additive was uniformly
dispersed over the separator surface. This resulted in the uniform
incorporation of the additive in the surface portion of the
separator. The procedure of Example 8 using the nonaqueous
electrolyte solution containing VC was then followed, except that
the above-fabricated separator was used, to construct a lithium
secondary battery.
Example 10
[0191] In the fabrication of negative electrode in Example 9, a
thin film of a silicon-cobalt alloy, instead of the silicon thin
film, was deposited. Otherwise, the procedure of Example 9 was
followed to construct a lithium secondary battery. The cobalt
content of the silicon-cobalt alloy thin film was 20% by
weight.
TABLE-US-00017 TABLE 17 Negative Active Additive to Material
Negative Active Material Example 9 Si None Example 10 Si Co
[0192] (Evaluation of Charge-Discharge Cycle Characteristics)
[0193] Charge-discharge cycle characteristics of the lithium
secondary batteries obtained in Examples 9 and 10 were evaluated
according to the previously outlined procedure. A discharge
capacity retention for each battery was shown in Table 18.
TABLE-US-00018 TABLE 18 Discharge Capacity Retention (%) Example 9
81.2 Example 10 84.6
[0194] As can be clearly seen from the results shown in Table 18,
the use of the silicon-cobalt alloy as an active material further
improves cycle characteristics. Also in the case where succinic
anhydride was incorporated in a surface portion of the separator,
the effect of the present invention was similarly obtained.
* * * * *