The present invention relates to an electrical storage device, and in particular to a non-aqueous electrolyte storage device such as a lithium ion capacitor and a lithium ion battery having a large capacity.
Non-aqueous electrolyte storage devices such as lithium ion capacitors and lithium ion batteries advantageously have a high energy density, a low self-discharge rate, and good cycle performance. Therefore, in recent years, it has been expected to increase the size or the capacity of the non-aqueous electrolyte storage devices to use such storage devices as power sources for automobiles such as hybrid vehicles and electric vehicles. Some of the non-aqueous electrolyte storage devices used as power sources for automobiles are of a wound type in which a wound electrode group formed by winding positive and negative electrodes via a separator about an axial core is received together with an electrolyte in a bottomed cylindrical container. In the electrical storage devices of this type according to the related art, distal end portions of tabs (current collecting lead pieces) extending from the positive electrode and the negative electrode forming the wound electrode group are joined to current collecting members made of aluminum (positive electrode) or copper (negative electrode), for example.
When strong vibration or a strong impact is applied to the thus structured non-aqueous electrolyte storage device, the electrode group received in the container may be displaced with respect to the container. For a non-aqueous electrolyte storage device mounted on an automobile as a power source for the automobile, in particular, strong vibration and a strong impact applied to or produced by the body of the automobile may be applied to the electrical storage device over a long time. Therefore, in the non-aqueous electrolyte storage devices of the type discussed above in which the tabs are joined to the current collecting members, the joint between the tabs and the current collecting members may be broken to increase the resistance of the connection portion, which may result in degradation in electricity storage performance of the non-aqueous electrolyte storage devices. In some of the non-aqueous electrolyte storage devices according to the related art, an epoxy resin is injected from the bottom surface of the container to cover the current collecting member located close to the bottom surface of the container, as taught in JP 2010-141217 A (Patent Document 1).
In the structure according to the related art in which the electrodes and the current collecting members are connected to each other utilizing the tabs, however, the wound electrode group including the electrodes are not fixed to the current collecting members as opposed to the tabs which are fixed to the current collecting members. Therefore, the wound electrode group in the container may be vibrated to break the tabs if strong vibration is continuously applied to the electrical storage device from the outside. Partial breakage of the tabs increases the resistance between the electrode group and the current collecting members, and therefore the electrical storage device may not fully exercise its performance.
In the structure taught in Patent Document 1, in addition, an epoxy resin is injected into the bottom portion of the container for the purpose of electrical insulation. While it seems at a first glance that the electrode group is fixed to the bottom surface of the container, it has been revealed that the epoxy resin is decomposed through reaction with the non-aqueous electrolyte to reduce the reactivity of the non-aqueous electrolyte. Therefore, the epoxy resin taught in Patent Document 1 may not hinder displacement of the electrode group in the container for the electrode group.
An object of the present invention is to provide an electrical storage device that is resistant to vibration from the outside with its electrodes and current collecting members reliably fixed to each other.
Another object of the present invention is to provide a non-aqueous electrolyte storage device with its properties as an electrical storage device not degraded by enhancing its vibration resistance or impact resistance.
The present invention improves an electrical storage device including: an electrode group unit including a wound electrode group formed by winding a laminated member including a positive electrode in which a positive active material mixture is applied to a first metal foil, a negative electrode in which a negative active material mixture is applied to a second metal foil, and a separator, the positive electrode and the negative electrode being laminated via the separator, a positive current collecting member connected to the positive electrode at one end portion of the wound electrode group, and a negative current collecting member connected to the negative electrode at the other end portion of the wound electrode group; and a bottomed cylindrical container configured to form a terminal of one polarity and to receive the electrode group unit together with a non-aqueous electrolyte infiltrating the wound electrode group. The electrical storage device according to the present invention also includes fixing means for fixing the wound electrode group to the container, the fixing means being configured not to react with the non-aqueous electrolyte. Use of the fixing means that does not react with the non-aqueous electrolyte makes it possible to provide an electrical storage device with its vibration resistance and impact resistance enhanced by fixing the wound electrode group in the container and with its properties as an electrical storage device not degraded.
The electrical storage device according to the present invention includes an electrode group unit including a wound electrode group, a positive current collecting member, and a negative current collecting member, and a bottomed cylindrical container. The wound electrode group is formed by winding a laminated member including a positive electrode, a negative electrode, and a separator, the positive electrode having an applied layer formed by applying a positive active material mixture to a first metal foil and an unapplied portion on which the positive active material mixture is not applied along the applied layer of the positive active material mixture, the negative electrode having an applied layer formed by applying a negative active material mixture to a second metal foil and an unapplied portion on which the negative active material mixture is not applied along the applied layer of the negative active material mixture, and the positive electrode and the negative electrode being laminated via the separator such that the unapplied portion of the positive electrode and the unapplied portion of the negative electrode project in directions opposite to each other. The electrode group unit also includes the positive current collecting member welded to the unapplied portion of the positive electrode, the unapplied portion projecting beyond the separator at one end portion of the wound electrode group, and the negative current collecting member welded to the unapplied portion of the negative electrode, the unapplied portion projecting beyond the separator at the other end portion of the wound electrode group.
A container is configured to form a terminal of one polarity and to receive the electrode group unit. An annular projected portion is formed a predetermined distance away from an opening portion of the container toward a bottom portion of the container to be projected inwardly of the container over the entire periphery of the container. A lid member configured to form a terminal of the other polarity is disposed as electrically insulated from the container between an annular retaining portion and the annular projected portion, the retaining portion being formed by radially inwardly crimping an annular wall portion of the container adjacent to the opening portion.
In the electrical storage device according to the present invention, one of the positive current collecting member and the negative current collecting member that is electrically connected to the lid member is disposed near the annular projected portion and shaped and sized such that an outer peripheral portion of the one current collecting member is located closer to a peripheral wall portion of the container than a top portion of the annular projected portion is located. An electrically insulating member configured to electrically insulate the one current collecting member and the container from each other is disposed in a compressed state between an annular wall portion of the annular projected portion and the outer peripheral portion of the one current collecting member, and also between the peripheral wall portion continuous with the annular projected portion and the outer peripheral portion of the one current collecting member.
For example, if the lid member serves as the positive electrode, the current collecting member electrically connected to the lid member serves as the positive current collecting member. In this case, the positive current collecting member is disposed near the annular projected portion and shaped and sized such that an outer peripheral portion of the positive current collecting member is located closer to a peripheral wall portion of the container than a top portion of the annular projected portion is located. The electrically insulating member is disposed in a compressed state between an annular wall portion of the annular projected portion and the outer peripheral portion of the positive current collecting member, and also between the peripheral wall portion continuous with the annular projected portion and the outer peripheral portion of the positive current collecting member in order to electrically insulate the container forming the negative electrode and the positive current collecting member from each other.
According to this configuration, first, the area of one of the current collecting members that is electrically connected to the lid member can be increased. Therefore, the current collecting member and the unapplied portion of the wound electrode group can be directly welded to each other by semiconductor laser welding or the like without using tabs, which enables the electrode group unit to be handled as a substantially integral unit. Then, the current collecting member is fixed to the container with the electrically insulating member disposed in a compressed state, as a result of which the electrode group unit is reliably fixed in the container. Thus, according to the present invention, the electrode group unit in the container is not significantly vibrated even if vibration is applied from the outside, thereby obtaining an electrical storage device that is resistant to vibration.
The container may have any configuration on the bottom portion side. If the bottom portion of the container includes an annular bottom wall portion continuous with the peripheral wall portion of the container and a protruded portion continuous with the annular bottom wall portion and protruded in a direction away from the lid member in order to increase the strength of the container, the other of the positive current collecting member and the negative current collecting member that is electrically connected to the bottom portion is preferably shaped and sized such that an outer peripheral portion of the other current collecting member is located closer to the peripheral wall portion of the container than an inner edge portion of the annular bottom wall portion is located. According to this configuration, the electrode group unit is held between the annular projected portion discussed earlier and the annular bottom wall portion of the container. This improves resistance to external vibration.
The present invention improves an electrical storage device including an electrode group unit, a bottomed cylindrical container, a lid member, and a non-aqueous electrolyte. The electrode group unit includes a wound electrode group formed by winding a laminated member including a positive electrode with a plurality of tabs, a separator, and a negative electrode with a plurality of tabs, a positive current collecting member, and a negative current collecting member. The positive current collecting member is disposed close to one end of the wound electrode group and connected to the plurality of tabs of the positive electrode included in the wound electrode group. The negative current collecting member is disposed close to the other end of the wound electrode group and connected to the plurality of tabs of the negative electrode included in the wound electrode group. The container has an opening portion at one end portion and receives the electrode group unit inside. The lid member blocks the opening portion of the container. The non-aqueous electrolyte infiltrates the wound electrode group received in the container. In the present invention, at least an outer peripheral surface of the wound electrode group and an inner wall surface of the container are joined to each other by a resin material that does not react with the non-aqueous electrolyte. The outer peripheral surface of the wound electrode group and the inner wall surface of the container may be partially or entirely joined to each other by the resin material that does not react with the non-aqueous electrolyte. According to this configuration, the resin material between the outer peripheral surface of the wound electrode group and the inner wall surface of the container function as an adhesive to prevent the wound electrode group from being displaced with respect to the container. Therefore, the connection between the current collecting members fixed to the container and the tabs of the positive electrode or the tabs of the negative electrode is not broken. In addition, since the resin material used does not react with the non-aqueous electrolyte, the bonding strength of the joint portion made of the resin material is not reduced. Moreover, the reactivity of the non-aqueous electrolyte is not reduced, or the properties of the electrical storage device are not degraded. Thus, according to the present invention, an electrical storage device with its properties not degraded by enhancing its vibration resistance or impact resistance can be provided. The resin material that does not react with the non-aqueous electrolyte and which joins at least the outer peripheral surface of the wound electrode group and the inner wall surface of the container to each other can also be applied to electrical storage devices including a wound electrode group having no tabs in which the current collecting members and the unapplied portions of the wound electrode group are directly welded to each other.
A portion of the electrode group unit and the bottom portion of the container or the like may be further joined to each other by the resin material that does not react with the non-aqueous electrolyte. In this case, the resin material that does not react with the non-aqueous electrolyte is accumulated between a portion of the electrode group unit located close to the bottom portion of the container and the bottom portion of the container and also between the portion of the electrode group unit and a part of the inner wall surface of the container leading to the bottom portion of the container. Then, the resin material between the bottom portion of the container and a part of the inner wall surface of the container leading to the bottom portion of the container is cured. This increases the area over which the wound electrode group and the container are joined to each other by the resin material. In addition, since the resin material is cured, the wound electrode group is fixed by the cured resin. Thus, displacement of the wound electrode group with respect to the container can be further reduced.
The resin material may join a portion of the electrode group unit and the opening portion of the container or the like to each other. In this case, the resin material may be accumulated between a portion of the electrode group unit located close to the opening portion of the container and the opening portion and also between the portion of the electrode group unit and a part of the inner wall surface of the container leading to the opening portion to be cured.
The resin material that does not react with the non-aqueous electrolyte is preferably a fluorine-based resin material. The term “fluorine-based resin” refers to synthetic resins (fluorine resins) obtained by polymerizing an olefin containing fluorine and resins containing fluorine having similar nature. Studies by the inventors have revealed that the fluorine-based resin is a material that does not particularly react with the non-aqueous electrolyte, and that the fluorine-based resin is not degraded in durability even if immersed in the non-aqueous electrolyte after being cured. The fluorine-based resin, which does not react with the non-aqueous electrolyte, does not affect the properties of the electrical storage device. Therefore, use of the fluorine-based resin for joint makes it possible to obtain high vibration resistance and impact resistance, and to maintain the properties of the electrical storage device. Other examples of the resin material that does not react with the non-aqueous electrolyte include a polypropylene-based resin material, a polyethylene-based resin material, and polyphenylene sulfide.
In order to manufacture the electrical storage device according to the present invention, for example, an electrode group unit including a wound electrode group formed by winding a laminated member including a positive electrode with a plurality of tabs, a separator, and a negative electrode with a plurality of tabs, a positive current collecting member disposed close to one end of the wound electrode group and connected to the plurality of tabs of the positive electrode included in the wound electrode group, and a negative current collecting member disposed close to the other end of the wound electrode group and connected to the plurality of tabs of the negative electrode included in the wound electrode group is prepared in advance. In addition, a bottomed cylindrical container having an opening portion at one end portion and receiving the electrode group unit inside and a lid member that blocks the opening portion of the container are prepared in advance. First, a resin material that does not react with a non-aqueous electrolyte is applied to a part of an inner wall surface of the container. After the applying step, the electrode group unit is inserted into the container from the opening portion, and the resin material is cured. Then, one of the positive current collecting member and the negative current collecting member, and the container are electrically connected to each other, and the other of the positive current collecting member and the negative current collecting member, and the lid member are electrically connected to each other. After the completion of the electrically connecting steps, the opening portion is sealed with the lid member. After the sealing step, the non-aqueous electrolyte is injected from a liquid injection port. If the electrical storage device is manufactured in this way, when the electrode group unit is inserted into the container from the opening portion, the resin material applied to the inner wall surface of the container contacts the outer peripheral surface of the wound electrode group so that the resin material is spread between the inner wall surface of the container and the outer peripheral surface of the wound electrode group. If an increased amount of the resin material is applied to the inner wall surface of the container, the resin material is scraped down to a space around a portion of the electrode group unit located close to the bottom portion of the container. Then, the resin material which has been scraped down is accumulated between the bottom portion of the container and a part of the inner wall surface of the container leading to the bottom portion of the container. As a result, the resin material that does not react with the non-aqueous electrolyte can reliably join the inner wall surface of the container and the outer peripheral surface of the electrode group unit to each other, and the bottom portion of the container and a part of the inner wall surface of the container leading to the bottom portion of the container to each other.
Rather than the configuration in which the electrode group and the container are joined to each other by the resin material that does not react with the non-aqueous electrolyte, a portion across a part of the current collecting member and a part of the wound electrode group may be surrounded in a tightened state by a shrink tube formed from a material that does not react with the non-aqueous electrolyte. Specifically, a portion across a part of the positive current collecting member and a part of the wound electrode group is surrounded in a tightened state by a first shrink tube formed from a material that does not react with the non-aqueous electrolyte, and a portion across a part of the negative current collecting member and a part of the wound electrode group is surrounded in a tightened state by a second shrink tube formed from a material that does not react with the non-aqueous electrolyte. According to this configuration, a portion across a part of the current collecting member and a part of the wound electrode group is tightened by the shrink tube, and thus the tabs provided at an end portion of the wound electrode group are not moved away from the current collecting member. Thus, the connection between the current collecting member and the tabs of the positive electrode or the negative electrode is not easily broken. If a layer of a metal to be occluded by the positive electrode or the negative electrode in a pre-use process is disposed in the wound electrode group, in particular, a void is to be formed in a portion of the wound electrode group at which the occluded metal has been provided. When a void is formed in the wound electrode group, winding of the wound electrode group is loosened. Therefore, turns of the laminated member forming the wound electrode group become easily movable with respect to each other, and become easily displaceable with respect to the container. However, if a portion across a part of the current collecting member and a part of the wound electrode group is tightened by the shrink tube formed from a material that does not react with the non-aqueous electrolyte, the turns of the laminated member forming the wound electrode group are pressed by the shrink tube, and the void formed in the wound electrode group is eliminated. This makes it possible to prevent the turns of the laminated member forming the wound electrode group from being displaced with respect to the container, and thus the connection between the current collecting member and the tabs of the positive electrode or the tabs of the negative electrode is not easily broken.
The configuration in which a portion across a part of the positive current collecting member and a part of the wound electrode group is surrounded in a tightened state by the first shrink tube formed from a material that does not react with the non-aqueous electrolyte and in which a portion across a part of the negative current collecting member and a part of the wound electrode group is surrounded in a tightened state by the second shrink tube formed from a material that does not react with the non-aqueous electrolyte may also be applied to electrical storage devices having no tabs in which the current collecting members and the unapplied portions of the wound electrode group are directly welded to each other.
The resin material that does not react with the non-aqueous electrolyte may be a thermoplastic resin. The thermoplastic resin can be heated to be softened and cooled to be cured more rapidly than a solvent-based or two-part resin material, which facilitates manufacture of electrical storage devices to result in a high productivity.
The thermoplastic resin material that does not react with the non-aqueous electrolyte is preferably polypropylene, polyethylene, or a resin containing a high percentage of polypropylene or polyethylene. Studies by the inventors have revealed that addition agents such as oil and wax react with the non-aqueous electrolyte to be eluted or degraded in durability. Polypropylene, polyethylene, and a resin containing a high percentage of polypropylene or polyethylene do not react with the non-aqueous electrolyte, and therefore does not affect the properties of the electrical storage device. Therefore, use of polypropylene, polyethylene, or a resin containing a high percentage of polypropylene or polyethylene for joint makes it possible to provide a high productivity, to obtain high vibration resistance and impact resistance, and to maintain the properties of the electrical storage device. Other examples of the resin material that does not react with the non-aqueous electrolyte include polyphenylene sulfide.
If the positive electrode and the negative electrode each have a plurality of tabs, the thermoplastic resin material that does not react with the non-aqueous electrolyte may join the tabs of the positive electrode to each other, or may further join the tabs of the positive electrode and the positive current collecting member to each other. Alternatively, the thermoplastic resin material that does not react with the non-aqueous electrolyte may join the tabs of the negative electrode to each other, or may further join the tabs of the negative electrode and the negative current collecting member to each other. In this case, the tabs can be easily joined to each other, or the tabs and the current collecting member can be easily joined to each other, by softening the resin material around the tabs of the wound electrode group and thereafter solidifying the resin material. Consequently, the tabs are fixed as being surrounded by the resin material, thereby preventing the tabs from being broken.
In order to manufacture such an electrical storage device, an electrode group unit including a wound electrode group formed by winding a laminated member including a positive electrode with a plurality of tabs, a separator, and a negative electrode with a plurality of tabs, a positive current collecting member disposed close to one end of the wound electrode group and connected to the plurality of tabs of the positive electrode included in the wound electrode group, and a negative current collecting member disposed close to the other end of the wound electrode group and connected to the plurality of tabs of the negative electrode included in the wound electrode group is prepared in advance. In addition, a bottomed cylindrical container having an opening portion at one end portion and receiving the electrode group unit inside and a lid member that blocks the opening portion of the container are prepared in advance.
Then, the electrode group unit is inserted into the container from the opening portion. Next, one of the positive current collecting member and the negative current collecting member, and the container are electrically connected to each other, and the other of the positive current collecting member and the negative current collecting member, and the lid member are electrically connected to each other. Then, a thermoplastic resin material that does not react with a non-aqueous electrolyte is put into the container from the opening portion to dispose the thermoplastic resin material on an inner wall surface of the container and around a part of the wound electrode group and the tabs. After the putting step, the thermoplastic resin material is heated to soften the thermoplastic resin material, and the thermoplastic resin material is returned to normal temperature to solidify the thermoplastic resin material. Lastly, the opening portion is sealed with the lid member, and thereafter the non-aqueous electrolyte is injected from a liquid injection port. If the electrical storage device is manufactured in this way, the inner wall surface of the container and the electrode group unit and the tabs can be reliably joined to each other by the resin material that does not react with the non-aqueous electrolyte just by applying and radiating heat to and from the thermoplastic resin.
In order to manufacture an electrical storage device according to the present invention, a thermoplastic resin material that does not react with a non-aqueous electrolyte may be disposed at a bottom portion of the container. In this case, the electrode group unit is inserted into the container from the opening portion, and the bottom portion of the container is heated to soften the thermoplastic resin material. Then, one of the positive current collecting member and the negative current collecting member, and the container are electrically connected to each other, and the thermoplastic resin material that does not react with the non-aqueous electrolyte is returned to normal temperature to solidify the thermoplastic resin material. After that, the other of the positive current collecting member and the negative current collecting member, and the lid member are electrically connected to each other. Lastly, the opening portion is sealed with the lid member, and thereafter the non-aqueous electrolyte is injected from a liquid injection port.
A thermoplastic resin material that does not react with a non-aqueous electrolyte may be disposed at a bottom portion of the container. In this case, the electrode group unit is inserted into the container from the opening portion, and one of the positive current collecting member and the negative current collecting member, and the container are electrically connected to each other. Then, the bottom portion of the container is heated to soften the thermoplastic resin material that does not react with the non-aqueous electrolyte, and the thermoplastic resin material that does not react with the non-aqueous electrolyte is returned to normal temperature to solidify the thermoplastic resin material. Next, the other of the positive current collecting member and the negative current collecting member, and the lid member are electrically connected to each other. Lastly, the opening portion is sealed with the lid member, and thereafter the non-aqueous electrolyte is injected from a liquid injection port.
A cylindrical lithium ion capacitor according to a first embodiment of the present invention will be described below with reference to the drawings.
As shown in
As shown in
The divided positive electrodes 9A, 9B forming the positive electrode 9 have the same structure as each other except for the length. As shown in
The negative electrode 11 has a structure similar to that of the divided positive electrodes 9A and 9B shown in
The lithium metal support member 17 causes the negative active material (in the embodiment, amorphous carbon) of the negative electrode 11 to occlude (be doped with) lithium ions. As shown in
As shown in
The positive current collecting member 39 is made of aluminum (including an aluminum alloy), and has a ring shape in which a circular hole 41 is formed in the center portion as shown in
The negative current collecting member 45 is made of either nickel or a metal material obtained by plating copper with nickel. In the embodiment, the negative current collecting member 45 is made of a metal material obtained by plating copper with nickel. As shown in
Laser light is used to weld the unapplied portions 25 and 33 of the wound electrode group 5 and the current collecting members (positive current collecting member 39 and negative current collecting member 45) to each other. In the embodiment, a direct-collecting semiconductor laser device (DLL, not shown) that continuously generates laser light is used as a laser welding device. Welding of the negative current collecting member 45 will be described as an example. The negative current collecting member 45 is locally melted by continuously applying laser light generated by the direct-collecting semiconductor laser device along the grooves 49 of the negative current collecting member 45 from the outer peripheral side toward the center portion of the negative current collecting member 45, to weld the unapplied portion 33 of the copper foil 27 of the negative electrode and end portions of the support members 37 and the negative current collecting member 45 to each other with a molten metal. Performing laser welding using the direct-collecting semiconductor laser device as in the embodiment allows the negative current collecting member 45 to be efficiently melted, enables reliable welding, and reliably prevents an increase in resistance of the welded portion. Use of a fiber-guided semiconductor laser device in place of the direct-collecting semiconductor laser device also achieves good welding results.
The negative current collecting member 45 and the unapplied portion 33 of the negative electrode 11 are also welded to each other in the same manner. That is, the negative current collecting member 45 is melted to weld the unapplied portion 33 of the negative electrode 11 and the negative current collecting member 45 to each other with a molten metal. As discussed later, respective ends of the support members 37, 37 forming the lithium metal support member 17 are also welded to the negative current collecting member 45 in the same manner.
<Accommodation of Wound Electrode Group into Container>
As shown in
An insulating ring member 63 for electrical insulation between the positive current collecting member 39 and the container 3 is attached to the outer peripheral portion of the positive current collecting member 39. A drawing process is performed on a portion of the container 3 in the vicinity of the opening portion so that the electrode group unit 2 is fixed in the container 3 as shown in
The container lid 55 forming a positive electrode terminal is disposed above the positive current collecting member 39. The container lid 55 includes a lid body 57 disposed on the positive current collecting member 39, and a lid cap 59 combined with the lid body 57. The lid body 57 is made of aluminum, and the lid cap 59 is made of steel plated with nickel as with the container 3. The lid cap 59 includes an annular flat portion 59a and a projected portion 59b projected from the center portion of the flat portion 59a. The container lid 55 is formed by curling (crimping) the edge portion of the lid body 57 around the outer peripheral portion of the flat portion 59a of the lid cap 59. A void portion 61 is formed between the projected portion 59b of the lid cap 59 and the lid body 57.
A first end of the positive terminal portion 44A, which is one of two positive electrode terminal portions which are ribbon-like aluminum foils stacked over each other, is joined to the upper surface of the positive current collecting member 39. The other positive terminal portion 44B is welded to the outer bottom surface of the lid body 57 forming the container lid 55. Second ends of the two positive terminal portions 44A, 44B are joined to each other. This allows the lid body 57 to be electrically connected to one of the electrodes (positive electrode 9) of the wound electrode group 5.
The annular projected portion 3a is formed in the container which has been subjected to a drawing process as discussed above. The container lid 55 is disposed on the annular projected portion 3a via an insulating member 65 for electrical insulation between the container lid 55 and the container 3. Then, an annular wall portion 3b is curled (crimpled) toward the container lid 55. As a result, the container lid 55 is fixed between the annular wall portion 3b which has been subjected to a curling process and the annular projected portion 3a via the insulating member 65. This allows the internal space of the capacitor 1 to be tightly sealed. The insulating ring member 63 and the insulating member 65 may be integrated to reduce the number of components.
An amount of a non-aqueous electrolyte (not shown) that is enough to infiltrate the entire electrode group unit 2 is injected into the container 3. The non-aqueous electrolyte may be a solution obtained by dissolving lithium phosphate hexafluoride (LiPF6) as lithium salt in a solvent obtained by mixing ethylene carbonate (EC), dimethyl carbonate (DMC), and diethyl carbonate (DEC) at a volume ratio of 30:50:20, for example.
The separators 113 and 115 are formed using a cellulosic porous base material such as kraft paper. In the embodiment, the outer peripheral surface of the wound electrode group 105 is covered by an end portion of the separator 113 or 115. The end portion of the separator 113 or 115 is fixed by an adhesive tape (not shown) to prevent unwinding of the wound electrode group 105. The axial core 107 is formed from a polyphenylene resin. The specific configuration of the positive electrode 109, the negative electrode 111, and the separators 113 and 115 is not relevant to the gist of the present invention, and thus is not described here.
The positive current collecting member 139 made of aluminum and having a ring shape is disposed between the container lid 155 and an end portion of the wound electrode group 105 adjacent to the end portion of the wound electrode group 105. The plurality of tabs 126 of the positive electrode configured to collect electrical charges from the positive electrode 109 are connected to the positive current collecting member 139. The positive current collecting member 139 is fitted with the upper end portion of the axial core 107. The distal end portions of the tabs 126 of the divided positive electrodes 109A and 109B are joined to the outer peripheral surface of an annular portion of the positive current collecting member 139, which integrally extends from its periphery, by ultrasonic welding. The negative current collecting member 145 made of copper and having a ring shape is disposed between the bottom portion of the container 103 and an end portion of the wound electrode group 105 adjacent to the end portion of the wound electrode group 105. The plurality of tabs 130 of the negative electrode are connected to the negative current collecting member 145. The lower end portion of the axial core 107 is fitted with the inner peripheral surface of the negative current collecting member 145. The distal end portions of the tabs 130 of the negative electrode 111 are joined to the outer peripheral surface of an annular portion of the negative current collecting member 145 by ultrasonic welding. The specific configuration of the positive current collecting member 139 and the negative current collecting member 145 is not relevant to the gist of the present invention, and thus is not described here.
In the lithium ion capacitor according to the embodiment, as shown in
In the embodiment, in particular, the lithium metal plate 135 is disposed in the wound electrode group 105. The lithium metal plate 135 is ionized and occluded by a negative active material of the negative electrode 111 in a pre-use process. Therefore, in the lithium ion capacitor according to the embodiment, a void is formed in a portion of the wound electrode group 105 after being wound at which the lithium metal plate 135 has been disposed. When a void is formed in the wound electrode group 105, winding of the wound electrode group 105 is loosened. Therefore, turns of the laminated member forming the wound electrode group 105 become easily movable with respect to each other, and become easily displaceable with respect to the container 103. Among the turns of the laminated member forming the wound electrode group 105, inner turns close to the axial core 107 are not significantly displaced with respect to the container 103 because the axial core 107 is fixed to the container 103. Thus, the inner turns close to the axial core 107 are not significantly displaced with respect to the positive current collecting member 139 and the negative current collecting member 145 fixed to the container 103. Thus, the joint between the tabs 126 of the positive electrode for the inner turns close to the axial core 107 and the positive current collecting member 139 and the joint between the tabs 130 of the negative electrode for the inner turns close to the axial core 107 and the negative current collecting member 145 are not easily broken. However, outer turns far from the axial core 107 are significantly displaced with respect to the container 103. Therefore, the joint between the tabs 126 of the positive electrode for the outer turns and the positive current collecting member 139 and the joint between the tabs 130 of the negative electrode for the outer turns and the negative current collecting member 145 are more easily broken than such joints for the inner turns close to the axial core 107. In the lithium ion capacitor according to the embodiment, the fluorine-based resin F is accumulated between a portion of the electrode group unit 102 located close to the bottom portion of the container 103, that is, the negative current collecting member 145 and a part of the wound electrode group 105, and the bottom portion of the container 103 and a part of the inner wall surface of the container 103 leading to the bottom portion to be cured. Thus, the outer turns of the laminated member which are easily displaceable with respect to the container 103 are further fixed to the container 103 by the fluorine-based resin F. Thus, the joint between the positive current collecting member 139 fixed to the container 103 and the tabs 126 of the positive electrode for the outer turns and the joint between the negative current collecting member 145 fixed to the container 103 and the tabs 130 of the negative electrode for the outer turns are not broken.
In the embodiment, the outer peripheral surface of the wound electrode group 105 and the inner wall surface of the container 103 are entirely joined to each other by the fluorine-based resin F. However, the outer peripheral surface of the wound electrode group 105 and the inner wall surface of the container 103 may be partially joined to each other by the fluorine-based resin F as long as displacement of the wound electrode group 105 in the container 103 can be sufficiently restricted. Alternatively, the fluorine-based resin F may not be provided between the negative current collecting member 145 and a part of the wound electrode group 105, and the bottom portion of the container 103 and a part of the inner wall surface of the container 103 leading to the bottom portion as long as displacement of the wound electrode group 105 in the container 103 can be sufficiently restricted by only the joint between the outer peripheral surface of the wound electrode group 105 and the inner wall surface of the container 103.
In order to manufacture the lithium ion capacitor according to the embodiment, the electrode group unit 102, the container 103, and the container lid 155 are prepared in advance. The electrode group unit 102, the container 103, and the container lid 155 can be manufactured by the manufacturing method known in the art described in JP 2010-141217 A etc. Such a manufacturing method is not relevant to the gist of the present invention, and thus is not described here. First, the fluorine-based resin F that does not react with the non-aqueous electrolyte is applied to a part of the inner wall surface of the container 103 around the opening portion 104. After that, the electrode group unit 102 is inserted into the container 103 from the opening portion 104. When the electrode group unit 102 is inserted into the container 103 from the opening portion 104, the fluorine-based resin F applied to the inner wall surface of the container 103 around the opening portion 104 contacts the outer peripheral surface of the wound electrode group 105 of the electrode group unit 102 so that the fluorine-based resin F is spread between the inner wall surface of the container 103 and the outer peripheral surface of the wound electrode group 105. If an increased amount of the fluorine-based resin F is applied to the inner wall surface of the container 103 around the opening portion 104, the fluorine-based resin F is scraped down to a portion of the electrode group unit 102 located close to the bottom portion of the container 103, that is, the negative current collecting member 145 and an end portion of the wound electrode group 105 close to the bottom portion. Next, the fluorine-based resin F is cured. Then, the negative current collecting member 145 of the electrode group unit 102 and the container 103 are electrically connected to each other, and the positive current collecting member 139 and the container lid 155 are electrically connected to each other. Lastly, the opening portion 104 is sealed with the container lid 155, and the non-aqueous electrolyte is injected from a liquid injection port.
Although the fluorine-based resin is used in the embodiment described above, a polypropylene-based resin, a polyethylene-based resin, polyphenylene sulfide, etc. may also be used as the resin material that does not react with the non-aqueous electrolyte.
In the cylindrical lithium ion capacitor 201 according to the embodiment, as shown in
In order to verify the vibration resistance effect and the impact resistance effect of the present invention, the inventors conducted a vibration test for the lithium ion capacitors according to the embodiments of
In the experiment, the results of which are shown in
As seen from the results shown in
As seen from the results shown in
According to the results shown in
The lithium ion capacitors used in the test were unsealed after the vibration test to examine the state of the joint between the positive current collecting member and the tabs of the positive electrode and the state of the joint between the negative current collecting member and the tabs of the negative electrode. Then, for the lithium ion capacitor which used the fluorine-based resin, most of the joints were not broken. For the lithium ion capacitor which used the shrink tubes, almost 40% of the connections remained unbroken. For the lithium ion capacitor with no vibration resistance measures taken and the outer-lithium ion capacitor, most of the connections were broken.
In the lithium ion capacitor according to the embodiment, a solution obtained by dissolving lithium phosphate hexafluoride (LiPF6) as an electrolyte in a mixed solvent of ethylene carbonate, dimethyl carbonate, and diethyl carbonate is used as the non-aqueous electrolyte. However, it is a matter of course that any other non-aqueous electrolyte obtained by dissolving a common lithium salt as an electrolyte in an organic solvent may also be used. Examples of the electrolyte include LiClO4, LiAsF6, LiBF4, LiB(C6H5)4, CH3SO3L1, CF3SO3Li, etc., and a combination of these. Examples of the organic solvent include propylene carbonate, diethyl carbonate, 1,2-dimethoxyethane, 1,2-diethoxyethane, γ-butyrolactone, tetrahydrofuran, 1,3-dioxolane, 4-methyl-1,3-dioxolane, diethyl ether, sulfolane, methylsulfolane, acetonitrile, propionitrile, etc., and a combination of two or more of these. The mixing/compounding ratio is also not specifically limited.
In the embodiment described above, the present invention is applied to a cylindrical lithium ion capacitor. However, it is a matter of course that the present invention may also be applied to rectangular lithium ion capacitors, and to other non-aqueous electrolyte storage devices such as lithium ion batteries.
The separators 313 and 315 are formed using a cellulosic porous base material such as kraft paper. In the embodiment, the outer peripheral surface of the wound electrode group 305 is covered by an end portion of the separator 313 or 315. The end portion of the separator 313 or 315 is fixed by an adhesive tape (not shown) to prevent unwinding of the wound electrode group 305. The axial core 307 is formed from a polyphenylene resin. The specific configuration of the positive electrode 309, the negative electrode 311, and the separators 313 and 315 is not relevant to the gist of the present invention, and thus is not described here.
The positive current collecting member 339 made of aluminum and having a ring shape is disposed between the container lid 355 and an end portion of the wound electrode group 305 adjacent to the end portion of the wound electrode group 305. The plurality of tabs 326 of the positive electrode configured to collect electrical charges from the positive electrode 309 are connected to the positive current collecting member 339. The positive current collecting member 339 is fitted with the upper end portion of the axial core 307. The distal end portions of the tabs 326 of the divided positive electrodes 309A and 309B are joined to the outer peripheral surface of an annular portion of the positive current collecting member 339, which integrally extends from its periphery, by ultrasonic welding. The negative current collecting member 345 made of copper and having a ring shape is disposed between the bottom portion of the container 303 and an end portion of the wound electrode group 305 adjacent to the end portion of the wound electrode group 305. The plurality of tabs 330 of the negative electrode are connected to the negative current collecting member 345. The lower end portion of the axial core 307 is fitted with the inner peripheral surface of the negative current collecting member 345. The distal end portions of the tabs 330 of the negative electrode 311 are joined to the outer peripheral surface of an annular portion of the negative current collecting member 345 by ultrasonic welding. The specific configuration of the positive current collecting member 339 and the negative current collecting member 345 is not relevant to the gist of the present invention, and thus is not described here.
In the lithium ion capacitor according to the embodiment, as shown in
In the embodiment, in particular, the lithium metal plate 335 is disposed in the wound electrode group 305. The lithium metal plate 335 is ionized and occluded by a negative active material of the negative electrode 311 in a pre-use process. Therefore, in the lithium ion capacitor according to the embodiment, a void is formed in a portion of the wound electrode group 305 after being wound at which the lithium metal plate 335 has been disposed. When a void is formed in the wound electrode group 305, winding of the wound electrode group 305 is loosened. Therefore, turns of the laminated member forming the wound electrode group 305 become easily movable with respect to each other, and become easily displaceable with respect to the container 303. Among the turns of the laminated member forming the wound electrode group 305, inner turns close to the axial core 307 are not significantly displaced with respect to the container 303 because the axial core 307 is fixed to the container 303. Thus, the inner turns close to the axial core 307 are not significantly displaced with respect to the positive current collecting member 339 and the negative current collecting member 345 fixed to the container 303. Thus, the joint between the tabs 326 of the positive electrode for the inner turns close to the axial core 307 and the positive current collecting member 339 and the joint between the tabs 330 of the negative electrode for the inner turns close to the axial core 307 and the negative current collecting member 345 are not easily broken. However, outer turns far from the axial core 307 are significantly displaced with respect to the container 303. Therefore, the joint between the tabs 326 of the positive electrode for the outer turns and the positive current collecting member 339 and the joint between the tabs 330 of the negative electrode for the outer turns and the negative current collecting member 345 are more easily broken than such joints for the inner turns close to the axial core 307. In the lithium ion capacitor according to the embodiment, the thermoplastic resin R is accumulated between a portion of the electrode group unit 303 located close to the container lid 355 of the container 303, that is, the positive current collecting member 339 and a part of the wound electrode group 305, and a part of the inner wall surface of the container 303 to be cured. Thus, the outer turns of the laminated member which are easily displaceable with respect to the container 303 are further fixed to the container 303 by the thermoplastic resin R. Thus, the joint between the positive current collecting member 339 fixed to the container 303 and the tabs 326 of the positive electrode for the outer turns and the joint between the negative current collecting member 345 fixed to the container 303 and the tabs 330 of the negative electrode for the outer turns are not broken. The thermoplastic resin R is provided to join the plurality of tabs 326 of the positive electrode to each other, or to join the plurality of tabs 326 of the positive electrode and the positive current collecting member 339 to each other. Therefore, the plurality of tabs 326 of the positive electrode are fixed to each other, or the plurality of tabs 326 of the positive electrode and the positive current collecting member 339 are fixed to each other, as being surrounded by a thermoplastic resin material. Thus, the tabs 326 of the positive electrode can be prevented from being broken.
In order to manufacture the lithium ion capacitor according to the embodiment, for example, the electrode group unit 302, the container 303, and the container lid 355 are prepared in advance. The electrode group unit 302, the container 303, and the container lid 355 can be manufactured by the manufacturing method known in the art described in JP 2010-141217 A etc. Such a manufacturing method is not relevant to the gist of the present invention, and thus is not described here. First, the electrode group unit 302 is inserted into the container 303 from the opening portion 304. The negative current collecting member 345 of the electrode group unit 302 and the container 303 are electrically connected to each other, and the positive current collecting member 339 and the container lid 355 are electrically connected to each other. Then, an appropriate amount of the thermoplastic resin R prepared in advance is placed on the inner wall surface of the container 303 and a part of the electrode group unit 302 and the tabs 326 of the positive electrode from the opening portion 304 of the container 303. After that, the thermoplastic resin R is heated to be softened. The thermoplastic resin R which has been softened is partially entangled between the plurality of tabs 326 of the positive electrode, and between the plurality of tabs 326 of the positive electrode and the positive current collecting member 339. After that, heating of the thermoplastic resin R is stopped to return the thermoplastic resin R to normal temperature to be solidified. Lastly, the opening portion 304 is sealed with the container lid 355, and the non-aqueous electrolyte is injected from a liquid injection port.
In the embodiment described above, a resin containing 80 wt % of polypropylene and 20 wt % of polyethylene is used as the resin material that does not react with the non-aqueous electrolyte. However, a resin containing polypropylene and polyethylene at different content percentages, polypropylene alone, polyethylene alone, polyphenylene sulfide, etc. may also be used.
In the embodiment described above, the thermoplastic resin F is used to join the positive current collecting member 339 and the tabs 326 of the positive electrode and a part of the wound electrode group 305 and a part of the inner wall surface of the container 303. However, as in a fifth embodiment of the present invention shown in
In order to manufacture the lithium ion capacitor according to the embodiment, for example, an electrode group unit 402, the container 403, and a container lid 455 are prepared in advance. The electrode group unit 402, the container 403, and the container lid 455 can be manufactured by the manufacturing method known in the art described in JP 2010-141217 A etc. Such a manufacturing method is not relevant to the gist of the present invention, and thus is not described here. First, an appropriate amount of the thermoplastic resin R prepared in advance is placed on the bottom portion side of the container 403. After that, the electrode group unit 402 is inserted into the container 403. After that, the thermoplastic resin R is heated to be softened. The thermoplastic resin R which has been softened is partially entangled between the plurality of tabs 430 of the negative electrode, and between the plurality of tabs 430 of the negative electrode and the negative current collecting member 445. After that, heating of the thermoplastic resin R is stopped to return the thermoplastic resin R to normal temperature to be solidified. Then, the negative current collecting member 445 close to the bottom portion of the container 403 and the container 403 are electrically connected to each other. The process of electrically connecting the negative current collecting member 445 close to the bottom portion of the container 403 and the container 403 to each other may be performed before the process of softening and curing the thermoplastic resin R. After that, the positive current collecting member 439 and the container lid 455 are electrically connected to each other. Lastly, an opening portion 404 is sealed with the container lid 455, and the non-aqueous electrolyte is injected from a liquid injection port.
In the second to fifth embodiments, the present invention is applied to electrical storage devices including a wound electrode group having a positive electrode and a negative electrode with tabs. However, it is a matter of course that the inventions according to the second to fifth embodiments may also be applied to electrical storage devices including a wound electrode group having a positive electrode and a negative electrode with no tabs.
In order to verify the vibration resistance effect and the impact resistance effect of the present invention, the inventors conducted a vibration test for the lithium ion capacitors according to the embodiments of
In the experiment, the results of which are shown in
As seen from the results shown in
As seen from the results shown in
According to the results shown in
The lithium ion capacitors used in the test were unsealed after the vibration test to examine the state of the joint between the positive current collecting member and the tabs of the positive electrode and the state of the joint between the negative current collecting member and the tabs of the negative electrode. Then, for the lithium ion capacitor which used the thermoplastic resin, most of the joints were not broken. For the lithium ion capacitor with no vibration resistance measures taken, most of the connections were broken. For the lithium ion capacitor with no tabs, the joints were not affected. For the lithium ion capacitor with no vibration resistance measures taken, however, the mixtures applied to the current collectors were partially peeled off.
In the lithium ion capacitor according to the embodiment described above, a solution obtained by dissolving lithium phosphate hexafluoride (LiPF6) as an electrolyte in a mixed solvent of ethylene carbonate, dimethyl carbonate, and diethyl carbonate is used as the non-aqueous electrolyte. However, it is a matter of course that any other non-aqueous electrolyte obtained by dissolving a common lithium salt as an electrolyte in an organic solvent may also be used. Examples of the electrolyte include LiClO4, LiAsF6, LiBF4, LiB(C6H5)4, CH3SO3L1, CF3SO3Li, etc., and a combination of these. Examples of the organic solvent include propylene carbonate, diethyl carbonate, 1,2-dimethoxyethane, 1,2-diethoxyethane, γ-butyrolactone, tetrahydrofuran, 1,3-dioxolane, 4-methyl-1,3-dioxolane, diethyl ether, sulfolane, methylsulfolane, acetonitrile, propionitrile, etc., and a combination of two or more of these. The mixing/compounding ratio is also not specifically limited.
In the embodiments described above, the positive current collecting member is connected to the lid member, and the negative current collecting member is connected to the bottom portion of the container. However, it is a matter of course that the negative current collecting member may be connected to the lid member and the positive current collecting member may be connected to the bottom portion of the container.
In the embodiment described above, the present invention is applied to a cylindrical lithium ion capacitor. However, it is a matter of course that the present invention may also be applied to rectangular lithium ion capacitors, and to other non-aqueous electrolyte storage devices such as lithium ion batteries.
According to the present invention, an electrical storage device with its properties as a battery not degraded by enhancing its vibration resistance and impact resistance can be provided.
Number | Date | Country | Kind |
---|---|---|---|
2010-214049 | Sep 2010 | JP | national |
2010-252196 | Nov 2010 | JP | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/JP2011/071907 | 9/26/2011 | WO | 00 | 5/1/2013 |