Non-aqueous electrolyte secondary battery, negative electrode, and method of manufacturing negative electrode

Abstract

Graphite material capable of absorbing and desorbing lithium is used in the negative electrode material of a non-aqueous electrolyte secondary battery. The negative electrode material is bound by at least one type of material selected from the group consisting of ethylene-propylene-acrylic acid copolymers, ethylene-propylene-acrylate copolymers, ethylene-propylene-methyl acrylic acid copolymers, ethylene-propylene-methacrylic acid copolymers, ethylene-propylene-methacrylate copolymers, and ethylene-propylene-methyl methacrylic acid copolymers, in which the ethylene-propylene content of the binder is the range of 70-95%. A non-aqueous electrolyte secondary battery with a high anti-peeling strength of the electrode mix, superiority in the ease of handling, a high reliability in mass production, a superior low-temperature discharge characteristic and cycle characteristic is provided by using the negative electrode in combination with a rechargeable positive electrode and a non-aqueous liquid electrolyte.

Description

FIELD OF THE INVENTION

[0002] The present invention relates to a non-aqueous electrolyte secondary battery, a negative electrode therefor, and method of manufacturing the negative electrode.

BACKGROUND OF THE INVENTION

[0003] In recent years, non-aqueous electrolyte secondary batteries have been drawing attention as high output, high energy-density power sources and many research works are being conducted.

[0004] Among the non-aqueous electrolyte secondary batteries, lithium secondary batteries have heretofore been drawing attention and studied. Lithium secondary batteries employ as the positive active material lithiated transition metal oxides such as LiCoO2, LiNiO2 and chalcogen compounds such as MoS2. These materials have a layer structure in which lithium ions can be reversibly inserted and detached. On the other hand, as the negative active material, metallic lithium has been employed. However, when metallic lithium is employed in the negative active material, lithium dissolution and deposition reaction is repeated with the repetition of charge and discharge, resulting in the formation of dendritic lithium on the surface of lithium. The formation of dendritic lithium causes problems of decreasing charge-discharge efficiency and a possible risk of causing short circuit by piercing the separator and getting in contact with the positive electrode.

[0005] In order to solve these problems, lithium alloy plate, metal powders, graphite or other carbon based (amorphous) materials, metal oxides, or metal sulfides, which can reversibly absorb and desorb lithium are being studied as an alternative negative electrode material to metallic lithium.

[0006] However, with the use of a lithium alloy plate, there has been a problem that charge-collecting capability of the alloy decreases with repetition of deep charge and discharge due to becoming fine of the alloy thus lowering the charge-discharge cycle life characteristic. On the other hand, when metal powders and powders of carbon materials, metal oxides or metal sulfides are employed, binders are usually added as an electrode can not be formed with these materials alone. Regarding carbon materials, for example, a method of forming an electrode by adding an elastic rubber-based polymer as the binder is disclosed in Japanese Laid-Open Patent Application No. Hei 4-255670. With metal oxides and metal sulfides, an electrically conducting material is also added to increase conductivity in addition to adding a binder.

[0007] When using a carbon material as the negative electrode, the carbon material is usually pulverized into powder and an electrode is formed by using a binder. When a highly crystalline graphite material is used as the carbon material, a battery with a higher capacity and higher voltage is obtained compared with a battery using other carbon materials. However, when a graphite material is pulverized, the powder tends to show flaky configuration. When a negative electrode is formed using this material, as the planar portions of the flaky graphite particles that are not involved in the insertion-detaching reaction of lithium are oriented in parallel to the plane of the electrode, the high-rate discharge characteristic declines. Furthermore, when a conventional rubber-based polymer material is employed as the binder, the binder covers the graphite particles thus hindering lithium insertion-detaching reaction, drastically lowering the high-rate discharge characteristic of the battery, especially the discharge characteristic at low temperatures.

[0008] Also, as the force of binding with the metallic core material is weak, it is necessary to add a large quantity of the binder, which further declines the high-rate discharge characteristic. Conversely, when the quantity of addition of the binder is reduced, problems arise such as an increase in the failure rate due to peeling of the electrode mix in the manufacturing process as the force of binding is weak, or a poor charge-discharge cycle characteristic due to low resistance to liquid electrolyte of the rubber-based polymer binder, and a sufficient characteristic has not yet been achieved.

[0009] Also, during the pressing process of an electrode, there is a problem in that the graphite particles slide in the direction of pressing thus breaking bonds of the binder and decreasing the strength of the electrode.

[0010] The present invention addresses these problems and provides batteries having a superior high-rate discharge characteristic, especially the discharge characteristic at low temperatures, and a superior charge-discharge cycle characteristic in a large quantity and with stability.

SUMMARY OF THE INVENTION

[0011] An object of the present invention is to provide a negative electrode which is strong against peeling of the negative electrode mix, superior in the ease of handling, high in reliability during mass production process, and further, superior in low-temperature discharge characteristic and cycle characteristic, and to provide a non-aqueous electrolyte secondary battery employing the negative electrode.

[0012] In accomplishing the object, in a negative electrode for a non-aqueous electrolyte secondary battery, the negative electrode comprising a carbon material which can reversibly absorb and desorb lithium and a binder, the present invention employs as the binder of the above negative electrode material at least one type of material selected from the group consisting of polyethylene, polypropylene, ethylene-vinyl acetate copolymers, ethylene-propylene copolymers, and ethylene-propylene-vinyl acetate copolymers. The present invention further provides a non-aqueous electrolyte secondary battery comprising a rechargeable positive electrode, a non-aqueous liquid electrolyte, and employing the above-described negative electrode.

[0013] Also, the present invention employs as the binder of the above negative electrode material at least one type of material selected from the group consisting of polyethylene, polypropylene, polyacrylic acid, acrylate, polymethyl acrylic acid, polymethacrylic acid, methacrylate, and polymethyl methacrylic acid. The present invention further provides a non-aqueous electrolyte secondary battery comprising a rechargeable positive electrode and a non-aqueous liquid electrolyte, and employing the above-described negative electrode.

[0014] Further, the present invention employs as the binder of the above-described negative electrode material at least one type of material selected from the group consisting of polyethylene, polypropylene, ethylene-acrylic acid copolymers, ethylene-acrylate copolymers, ethylene-methylacrylic acid copolymers, ethylene-methacrylic acid copolymers, ethylene-methacrylate copolymers, and ethylene-methylmethacrylic acid copolymers. The present invention further provides a non-aqueous electrolyte secondary battery comprising a rechargeable positive electrode and a non-aqueous liquid electrolyte, and employing the above-described negative electrode.

[0015] Also, the present invention employs as the binder of the above-described negative electrode material at least one type of material selected from the group consisting of polyethylene, polypropylene, ethylene-propylene-acrylic acid copolymers, ethylene-propylene-acrylate copolymers, ethylene-propylene-methylacrylic acid copolymers, ethylene-propylene-methacrylic acid copolymers, ethylene-propylene-methacrylate copolymers, and ethylene-propylene-methyl methacrylic acid copolymers. The present invention further provides a non-aqueous electrolyte secondary battery comprising a rechargeable positive electrode and a non-aqueous liquid electrolyte, and employing the above-described negative electrode.

[0016] Yet further, the present invention employs as the binder of the above-described negative electrode material at least one type of material selected from the group consisting of polyethylene, polypropylene, ethylene-acrylic acid-styrene copolymers, ethylene-acrylate-styrene copolymers, ethylene-methyl acrylic acid-styrene copolymers, ethylene-methacrylic acid-styrene copolymers, ethylene-methacrylate-styrene copolymers, ethylene-methyl methacrylic acid-styrene copolymers, ethylene-propylene-acrylic acid-styrene copolymers, ethylene-propylene-acrylate-styrene copolymers, ethylene-propylene-methylacrylic acid-styrene copolymers, ethylene-propylene-methacrylic acid-styrene copolymers, ethylene-propylene-methacrylate-styrene copolymers, and ethylene-propylene-methyl methacrylic acid-styrene copolymers. The present invention further provides a non-aqueous electrolyte secondary battery comprising a rechargeable positive electrode and a non-aqueous liquid electrolyte, and employing the above-described negative electrode.

[0017] In a preferred embodiment of the present invention wherein the negative electrode material of a non-aqueous electrolyte secondary battery comprises a carbon material which is capable of absorbing and desorbing lithium and a binder, the carbon material is high-crystallinity graphite and at least one type of material selected from the group consisting of polyethylene, polypropylene, ethylene-vinyl acetate copolymers, ethylene-propylene copolymers, and ethylene-propylene-vinyl acetate copolymers is employed as the binder of the negative electrode.

[0018] In other preferred embodiment of the present invention, as the binder of the negative electrode material at least one type of material selected from the group consisting of polyethylene, polypropylene, polyacrylic acid, acrylate, polymethyl acrylic acid, polymethacrylic acid, methacrylate, and polymethyl methacrylic acid is used. Additionally, by substituting a part or the whole of —COOH radical of the acrylic acid and methacrylic acid with —COO−Na+, K+ and the like to obtain acrylate and methacrylate, a negative electrode with a further superior electrode strength can be obtained.

[0019] In a yet other preferred embodiment of the present invention, as the binder of the negative electrode material, at least one type of material selected from the group consisting of polyethylene, polypropylene, ethylene-acrylic acid copolymers, ethylene-acrylate copolymers, ethylene-methyl acrylic acid copolymers, ethylene-methacrylic acid copolymers, ethylene-methacrylate copolymers, and ethylene-methyl methacrylic acid copolymers is used. Additionally, by substituting a part or the whole of the —COOH radical of the acrylic acid and methacrylic acid with —COO−Na+, K+ and the like to obtain acrylate and methacrylate, a negative electrode with a further superior electrode strength can be obtained.

[0020] In a still further preferred embodiment of the present invention, as the binder of the negative electrode material, at least one type of material selected from the group consisting of polyethylene, polypropylene, ethylene-propylene-acrylic acid copolymers, ethylene-propylene-acrylate copolymers, ethylene-propylene-methyl acrylic acid copolymers, ethylene-propylene-methacrylic acid copolymers, ethylene-propylene-methacrylate copolymers, and ethylene-propylene-methyl methacrylic acid copolymers is used. Additionally, by substituting a part or the whole of the —COOH radical of the acrylic acid and methacrylic acid with —COO−Na+, K+ and the like to obtain acrylate and methacrylate, a negative electrode with a further superior electrode strength can be obtained.

[0021] In a still further preferred embodiment of the present invention, as the binder of the negative electrode material, at least one type of material selected from the group consisting of polyethylene, polypropylene, ethylene-acrylic acid-styrene copolymers, ethylene-acrylate-styrene copolymers, ethylene-methyl acrylic acid-styrene copolymers, ethylene-methacrylic acid-styrene copolymers, ethylene-methacrylate-styrene copolymers, ethylene-methyl methacrylic acid-styrene copolymers, ethylene-propylene-acrylic acid-styrene copolymers, ethylene-propylene-acrylate-styrene copolymers, ethylene-propylene-methyl acrylic acid-styrene copolymers, ethylene-propylene-methacrylic acid-styrene copolymers, ethylene-propylene-methacrylate-styrene copolymers, and ethylene-propylene-methyl methacrylic acid-styrene copolymers is used. Additionally, by substituting a part or the whole of the —COOH radical of the acrylic acid and methacrylic acid with —COO−Na+, K+ and the like to obtain acrylate and methacrylate, a negative electrode with a further superior electrode strength can be obtained.

[0022] In the present invention, when an ethylene-acrylic acid (or acrylate) copolymer, ethylene-methyl acrylic acid copolymer, ethylene-methacrylic acid (or methacrylate) copolymer or ethylene-methyl methacrylic acid copolymer is employed as the binder, it is preferable to make the ethylene content in the range 70%-95%. This is because when the ethylene content is less than 70%, the low-temperature discharge characteristic declines significantly, and the strength of the electrode decreases when the ethylene content exceeds 95%.

[0023] The preferred range of the average particle size of the graphite material to be used as the negative material of the present invention is 5-30 μm. This is because when the average particle size is 5 μm or smaller, the irreversible capacity of the graphite material increases thus decreasing the battery capacity, and when the average particle size is greater than 30 μm, the low-temperature discharge characteristic declines.

[0024] Furthermore, the preferred content ratio of the binder to 100 parts by weight of the carbon material is between 0.5 to 8 parts by weight. This is because when the content ratio of the binder is below 0.5, sufficient electrode strength is not obtained whereas the low-temperature discharge characteristic declines when the ratio is beyond 8.

[0025] Also, the negative electrode of the present invention is rendered more superior and desirable in the electrode strength by heat treatment at a temperature between the melting point and the decomposition temperature of the binder after a mixture of the carbon material and the binder has been coated on a current collector, dried, and pressed, or by pressing at a temperature between the melting point and the decomposition temperature of the binder. This is because the binder of the negative electrode of the present invention melts during pressing or during heat treatment after pressing and solidifies again thus enhancing the binding property. The effect is more pronounced especially when heat treated during pressing because of the applied pressure. This effect has not been observed with the conventional rubber-based polymers.

[0026] In configuring a non-aqueous electrolyte secondary battery employing the negative electrode of the present invention, lithiated transition metal oxides such as LiCoO2, LiNiO2, LiMn2O4, etc., can be used as the positive electrode material. As the liquid electrolyte, a solution prepared by dissolving an electrolyte salt such as LiPF6, LiBF4, etc., into a mixed solvent of a cyclic carbonate such as ethylene carbonate and a chain carbonate such as ethylmethyl carbonate and the like may be used.

[0027] As has been described above, the present invention provides a negative electrode which is superior in low-temperature discharge characteristic and in non-peeling strength of the electrode mix and, by using the negative electrode, it provides a non-aqueous electrolyte secondary battery which is superior in the ease of handling during mass production, high in reliability, and superior in discharge characteristic.

BRIEF DESCRIPTION OF THE DRAWING

[0028] FIG. 1 is a vertical cross-sectional view of a non-aqueous electrolyte secondary battery in an embodiment of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0029] Referring to the drawing, a description of exemplary embodiments of the present invention will be given in the following.

EXAMPLE 1

[0030] FIG. 1 shows a vertical cross sectional view of a cylindrical battery used in the present invention. In the figure, a positive electrode 1 is prepared by mixing LiCoO2 as the active material and acetylene black as an electrically conducting agent, and additionally, polytetrafluoroethylene as a binder at a weight ratio of 100:3:7, making paste by using a thickener, coating the paste on both sides of an aluminum foil, drying, and pressing, then cutting to predetermined dimensions (37 mm×350 mm). In addition, an aluminum lead 2 is welded to a positive electrode 1. Negative electrode 3 is prepared by mixing flaky graphite as the carbon material and polyethylene as a binder at a predetermined ratio, coating paste made by using a thickener on both sides of a copper foil, drying, and pressing, then cutting to predetermined dimensions (39 mm×425 mm). Flaky graphite having average particle sizes of 1, 5, 20, 30, and 40 μm was used. The mixing ratios of polyethylene as the binder were 0.5, 5, 8, and 10 parts by weight relative to 100 parts by weight of the carbon material. A nickel lead 4 is welded to the negative electrode 3, too. A separator 5 made of a microporous polyethylene film is interposed between the positive electrode 1 and negative electrode 3, all of which are spirally wound to form an electrode group. After disposing insulating plates 6 and 7 made of polypropylene respectively on the top and bottom ends of the electrode group, the electrode group is inserted into a case 8 made of nickel-plated iron. Subsequently, a positive lead 2 and a negative lead 4 are respectively welded to a seal plate 9 provided with a safety vent and to the bottom of the case 8. Further, a liquid electrolyte prepared by dissolving lithium hexafluorophosphate as an electrolyte into a 1:3 volume ratio mixed solvent of ethylene carbonate and ethylmethyl carbonate to a concentration of 1.5 mol/L is added, sealed with the seal plate 9 with the intervention of a gasket 10 to obtain battery A1 of the present invention. Numeral 11 is the positive terminal of the battery and the case 8 is also serving as the negative terminal. The battery measures 17 mm in diameter and 50 mm in height.

[0031] The negative electrode was pressed at two temperature points of 25 degrees C. and 130 degrees C., and was subsequently dried at 130 degrees C.

EXAMPLE 2

[0032] Battery A2 of the present invention was fabricated in the same manner as in Example 1 with the exception of using ethylene-vinyl acetate copolymer as the negative electrode binder.

EXAMPLE 3

[0033] Battery A3 of the present invention was fabricated in the same manner as in Example 1 with the exception of using ethylene-propylene copolymer as the negative electrode binder.

EXAMPLE 4

[0034] Battery A4 of the present invention was fabricated in the same manner as in Example 1 with the exception of using ethylene-propylene-vinyl acetate copolymer as the negative electrode binder.

EXAMPLE 5

[0035] Battery A5 of the present invention was fabricated in the same manner as in Example 1 with the exception of using polypropylene as the negative electrode binder.

EXAMPLE 6

[0036] Battery B1 of the present invention was fabricated in the same manner as in Example 1 with the exception of using polyacryl acid as the negative electrode binder.

EXAMPLE 7

[0037] Battery B2 of the present invention was fabricated in the same manner as in Example 1 with the exception of using polymethyl acrylic acid as the negative electrode binder.

EXAMPLE 8

[0038] Battery B3 of the present invention was fabricated in the same manner as in Example 1 with the exception of using polymethacrylic acid as the negative electrode binder.

EXAMPLE 9

[0039] Battery B4 of the present invention was fabricated in the same manner as in Example 1 with the exception of using polymethyl methacrylic acid as the negative electrode binder.

EXAMPLE 10

[0040] Battery C1 of the present invention was fabricated in the same manner as in Example 1 with the exception of using ethylene-acrylic acid copolymer as the negative electrode binder.

EXAMPLE 11

[0041] Battery C2 of the present invention was fabricated in the same manner as in Example 1 with the exception of using ethylene-methyl acrylic acid copolymer as the negative electrode binder.

EXAMPLE 12

[0042] Battery C3 of the present invention was fabricated in the same manner as in Example 1 with the exception of using ethylene-methacrylic acid copolymer as the negative electrode binder.

EXAMPLE 13

[0043] Battery C4 of the present invention was fabricated in the same manner as in Example 1 with the exception of using ethylene-methyl methacrylic acid copolymer as the negative electrode binder.

EXAMPLE 14

[0044] Battery D1 of the present invention was fabricated in the same manner as in Example 1 with the exception of using ethylene-propylene-acrylic acid copolymer as the negative electrode binder.

EXAMPLE 15

[0045] Battery D2 of the present invention was fabricated in the same manner as in Example I with the exception of using ethylene-propylene methyl acrylic acid copolymer as the negative electrode binder.

EXAMPLE 16

[0046] Battery D3 of the present invention was fabricated in the same manner as in Example 1 with the exception of using ethylene-propylene-methacrylic acid copolymer as the negative electrode binder.

EXAMPLE 17

[0047] Battery D4 of the present invention was fabricated in the same manner as in Example 1 with the exception of using ethylene-propylene-methyl methacrylic acid copolymer as the negative electrode binder.

EXAMPLE 18

[0048] Battery E1 of the present invention was fabricated in the same manner as in Example 1 with the exception of using ethylene-acrylic acid-styrene copolymer as the negative electrode binder.

EXAMPLE 19

[0049] Battery E2 of the present invention was fabricated in the same manner as in Example 1 with the exception of using ethylene-methyl acrylic acid-styrene copolymer as the negative electrode binder.

EXAMPLE 20

[0050] Battery E3 of the present invention was fabricated in the same manner as in Example 1 with the exception of using ethylene-methacrylic acid-styrene copolymer as the negative electrode binder.

EXAMPLE 21

[0051] Battery E4 of the present invention was fabricated in the same manner as in Example 1 with the exception of using ethylene-methyl methacrylic acid-styrene copolymer as the negative electrode binder.

EXAMPLE 22

[0052] Battery E5 of the present invention was fabricated in the same manner as in Example 1 with the exception of using ethylene-propylene-acrylic acid-styrene copolymer as the negative electrode binder.

EXAMPLE 23

[0053] Battery E6 of the present invention was fabricated in the same manner as in Example 1 with the exception of using ethylene-propylene-methyl acrylic acid-styrene copolymer as the negative electrode binder.

EXAMPLE 24

[0054] Battery E7 of the present invention was fabricated in the same manner as in Example 1 with the exception of using ethylene-propylene-methacrylic acid-styrene copolymer as the negative electrode binder.

EXAMPLE 25

[0055] Battery E8 of the present invention was fabricated in the same manner as in Example 1 with the exception of using ethylene-propylene-methyl methacrylic acid-styrene copolymer as the negative electrode binder.

COMPARATIVE EXAMPLE

[0056] Comparative Example battery F of the present invention was fabricated in the same manner as in Example 1 with the exception of using styrene-butadiene copolymer as the negative electrode binder.

[0057] Comparison of the low-temperature discharge characteristic, electrode strength of the negative electrode, and charge-discharge cycle characteristic was carried out on the above 26 types of batteries, namely, A1 -A5, B1-B4, C1-C4, D1-D4, E1-E8, and F each using a different negative electrode binder.

[0058] Battery capacity was determined by discharging at a constant discharge current of 180 mA until a discharge termination voltage of 3.0 V is reached after a constant-current constant-voltage charging at a charging current of 630 mA at a charging voltage of 4.2 V for a charging time of 2 hours in a 20 degrees C. environment. The low-temperature discharge characteristic was assessed by discharging at a constant discharge current of 900 mA until a discharge termination voltage of 3.0 V is reached after a constant-current constant-voltage charging at a charging current of 630 mA at a charging voltage of 4.2 V for a charging time of 2 hours in a −20 degrees C. environment. Strength of the negative electrode was tested by applying 1.5 cm-square cellophane adhesive tape on the surface of the negative electrode and measuring the force required to peel off the negative electrode mix, which force is then compared with that of Comparative Example battery F which is defined to be unity. The relative values thus obtained are shown in Table 1 as the electrode strength. The larger the electrode strength is, the stronger the negative electrode mix is against peeling. The charge-discharge cycle test was carried out in a 20 degrees C. environment by repeating constant-current constant-voltage charging at a charging current of 630 mA at a charging voltage of 4.2 V for a charging time of 2 hours and constant-current discharging at a discharging current of 900 mA until a discharge termination voltage of 3.0 V is reached, and obtaining the number of cycles reached until the discharge capacity decreased to 50% of the initial battery capacity.

[0059] Table 1 shows the low-temperature discharge capacity, electrode strength, and charge-discharge cycle characteristic of Example batteries A1-A5 and Comparative Example battery F. The data is for the case of an average particle size of flaky graphite of 20 μm and a binder content of 5 parts by weight relative to 100 parts by weight of the carbon material.

TABLE 1
Battery	A1	A2	A3
Rolling Temperature	25	130	25	130	25	130
(deg C.)
Discharge Capacity at	282	355	307	360	273	340
−20 deg C. (mAh)
Electrode Strength	1	2	1	2	1	2
Number of Cycles	721	736	508	511	711	720
(cycles)
Battery	A4	A5	F
Rolling Temperature	25	130	25	130	25	130
(deg C.)
Discharge Capacity at	310	355	285	359	44	47
−20 deg C. (mAh)
Electrode Strength	1	2	2	3	1	1
Number of Cycles	515	522	702	713	447	430
(cycles)

[0060] As indicated in Table 1, all of the Example batteries A1-A5 were superior to Comparative Example battery F in the low-temperature discharge characteristic. This may be attributable to a lower degree of carbon particle coverage with the binder compared with Comparative Example battery F. In other words, the styrene-butadiene copolymer used in Comparative Example battery F as the binder has a high film-forming ability as its glass transition temperature is as low as 0 degree C. or below and its particle size is on the order of sub-μm, and, as a result, the binder has a tendency of thinly covering the entire carbon particle even though the mixing ratio is the same when compared with the negative electrode binder of the present invention.

[0061] With regard to the electrode strength, all of the Example batteries A1-A5 of the present invention showed equal or better strength than Comparative Example battery F. Furthermore, in the case pressing was performed at 130 degrees C., a negative electrode with a further superior electrode strength was obtained because the binder of the present invention melts during pressing and solidifies again under the state of being pressed.

[0062] With regard to the charge-discharge cycle characteristic, Example batteries A1-A5 showed a characteristic superior to Comparative Example battery F. This may be attributable to superior liquid electrolyte-resistance of the binder used in these batteries as it does not contain double bonds in the primary chain of the polymer and is chemically less reactive with the liquid electrolyte compared with the styrene-butadiene copolymer binder used in the Comparative Example battery F.

[0063] Table 2 shows the relationships between the average particle size of flaky graphite and battery capacity and between the average particle size of flaky graphite and low-temperature discharge characteristic in Example batteries A1-A5 of the present invention and Comparative Example battery F. The data is for the case of a binder content of 5 parts by weight to 100 pats by weight of the carbon material. Pressing was carried out at 25 degrees C.

TABLE 2
	Average Particle Size of	Battery	Discharge Capacity
	Flaky Graphite	Capacity	at −20 deg C.
Battery	(μm)	(mAh)	(mAh)
A1	1	872	321
	5	920	301
	20	932	282
	30	938	271
	40	943	119
A2	1	852	332
	5	910	322
	20	925	307
	30	930	290
	40	941	120
A3	1	879	319
	5	916	302
	20	936	273
	30	942	260
	40	951	111
A4	1	846	329
	5	900	319
	20	919	310
	30	925	286
	40	938	119
A5	1	876	330
	5	919	318
	20	939	285
	30	942	272
	40	949	115
F	1	859	79
	5	913	61
	20	935	44
	30	938	20
	40	945	3

[0064] As can be seen in Table 2, when the average particle size of the flaky graphite is smaller than 5 μm, the battery capacity decreases remarkably as the irreversible capacity of the carbon material of the negative electrode increases, and when greater than 30 μm, the low-temperature discharge characteristic declines, suggesting that an average particle size of flaky graphite in the range 5-30 μm is preferable.

[0065] Table 3 shows the relationships between the binder content in parts by weight relative of 100 parts by weight of the carbon material of the negative electrode and the low-temperature discharge characteristic and between the binder content in parts by weight relative to 100 parts by weight of the carbon material of the negative electrode and the electrode strength of Example batteries A1-A5 of the present invention and Comparative Example battery F. The data is for the case of an average flaky graphite particle size of 20 μm. Pressing was carried out at 25 degrees C.

TABLE 3
		Discharge Capacity at
		−20 deg C.
Battery	Binder Content	(mAh)	Electrode Strength
A1	0.5	320	<1
	5	282	1
	8	269	3
	10	144	4
A2	0.5	339	<1
	5	307	1
	8	291	3
	10	145	3
A3	0.5	315	<1
	5	273	1
	8	254	3
	10	152	4
A4	0.5	345	<1
	5	310	1
	8	298	2
	10	146	3
A5	0.5	326	1
	5	285	2
	8	256	4
	10	150	4
F	0.5	58	= 0
	5	44	1
	8	19	2
	10	2	2

[0066] It can be seen from Table 3 that when the content in parts by weight of the binder relative to 100 parts by weight of the carbon material is greater than 8 in the Examples of the present invention, the low-temperature discharge characteristic remarkably declines, and when it is less than 0.5 the electrode strength decreases not necessarily to zero, resulting in electrode failure such as peeling of the electrode mix. Therefore, it is preferable to make the content of the binder in parts by weight relative to 100 parts by weight of the carbon material in the range 0.5 to 8.

[0067] Additionally, when the temperature of heat treatment after pressing of the negative electrode is equal to or below the melting point of the negative electrode binder, enough electrode strength can not be obtained because the binder does not melt, and at or above the decomposition temperature of the binder, the binder decomposes and the electrode strength decreases. As a result, by heat treatment of the negative electrode at a temperature between the melting point and the decomposition temperature of the binder, an electrode with a superior electrode strength can be obtained. Same thing is applicable to the temperature of pressing of the negative electrode.

[0068] Though use of one type of binder has been shown in each of the examples of the present invention, it is apparent that use of a mixture of two or more types of binder will give similar result.

[0069] Table 4 shows the low-temperature discharge characteristic, electrode strength and charge-discharge cycle characteristic of Example batteries B1-B4 of the present invention and Comparative Example battery F. The data is for the case of an average flaky graphite particle size of 20 μm and the binder content of 5 parts by weight relative to 100 parts by weight of the carbon material.

TABLE 4
Battery	B1	B2	B3
Rolling Temperate	25	130	25	130	25	130
(deg C.)
Discharge Capacity at	105	143	110	147	108	146
−20 deg C. (mAh)
Electrode Strength	5	6	5	6	5	6
Number of Cycles	508	515	550	559	543	553
(cycles)
	Battery	B4	F
	Rolling Temperature	25	130	25	130
	(deg C.)
	Discharge Capacity at	106	150	44	47
	−20 deg C. (mAh)
	Electrode Strength	5	6	1	1
	Number of Cycles	526	531	447	430
	(cycles)

[0070] As shown in Table 4, all of Example batteries B1-B4 of the present invention were superior to Comparative Example battery F in the low-temperature discharge characteristic. This is considered to be due to a lower degree of carbon particle coverage with the binder compared with Comparative Battery F.

[0071] With regard to the electrode strength, too, all of Example batteries B1-B4 of the present invention were superior to Comparative Example battery F. Furthermore, in the case pressing was performed at 130 degrees C., a negative electrode with a further superior electrode strength was obtained because the binder melts during pressing and solidifies again under the state of being pressed. Also, the reason why the negative electrode of Example batteries B1-B4 of the present invention showed especially high values of strength is considered to be due to the fact that the negative electrode has a highly polar radical, —COOH or —COOCH3, and has hence an enhanced adhesiveness with the metal current collector. Furthermore, it was confirmed that when a part or the whole of —COOH or —COOCH3 radical is substituted with —COO−Na+, K+ to make acrylate and methacrylate, adhesiveness with the core material is enhanced.

[0072] Example batteries of the present invention also showed a charge-discharge cycle characteristic which is superior to the Comparative Example battery F. This is considered to be due to the fact that the binder of these batteries does not have double bonds in the primary chains of the polymer and is chemically less reactive to liquid electrolyte thus superior in resistance to liquid electrolyte compared with styrene-butadiene copolymer of the binder used in Comparative Example battery F.

[0073] Table 5 shows the relationships between the average particle size of flaky graphite and battery capacity and between the average particle size of flaky graphite and low-temperature discharge characteristic in Example batteries B1-B4 of the present invention and Comparative Example battery F. The data is for the case of a binder content of 5 parts by weight to 100 parts by weight of the carbon material. Pressing was carried out at 25 degrees C.

TABLE 5
	Average Particle Size of	Battery	Discharge Capacity at
	Flaky Graphite	Capacity	−20 deg C.
Battery	(μm)	(mAh)	(mAh)
B1	1	868	210
	5	908	155
	20	924	105
	30	931	95
	40	940	30
B2	1	871	205
	5	911	150
	20	926	110
	30	933	95
	40	943	35
B3	1	869	208
	5	909	149
	20	924	108
	30	932	93
	40	941	33
B4	1	866	211
	5	904	153
	20	919	106
	30	926	91
	40	938	32
F	1	859	79
	5	913	61
	20	935	44
	30	938	20
	40	945	3

[0074] As can be seen from Table 5, when the average particle size of the flaky graphite is smaller than 5 μm, the battery capacity decreases significantly as the irreversible capacity of the negative electrode carbon material increases, and when greater than 30 μm, the low-temperature discharge characteristic declines, suggesting that an average particle size range of 5-30 μm of the flaky graphite is preferable.

[0075] Table 6 shows the relationships between the binder content in parts by weight in the negative electrode relative to 100 parts by weight of the carbon material and the low-temperature discharge characteristic and between the binder content in parts by weight in the negative electrode relative to 100 parts by weight of the carbon material and the electrode strength of Example batteries B1-B4 of the present invention and Comparative Example battery F. The data is for the case of an average flaky graphite particle size of 20 μm. Pressing was carried out at 25 degrees C.

TABLE 6
		Discharge Capacity at
		−20 deg C.
Battery	Binder Content	(mAh)	Electrode Strength
B1	0.5	175	3
	5	105	5
	8	90	7
	10	38	10
B2	0.5	180	3
	5	110	5
	8	96	8
	10	37	10
B3	0.5	178	3
	5	108	5
	8	94	7
	10	37	10
B4	0.5	175	3
	5	106	5
	8	90	8
	10	34	10
F	0.5	58	= 0
	5	44	1
	8	19	2
	10	2	2

[0076] As can be seen from Table 6, when the binder content in parts by weight relative to 100 parts by weight of the carbon material was larger than 8, a significant decline in the low-temperature discharge characteristic was observed, and at 0.5, there was a decrease in the electrode strength. Therefore, the preferable range of the binder content in parts by weight relative to 100 parts by weight of the carbon material is 0.5-8.

[0077] Now, with regard to the temperature of heat treatment of the negative electrode after pressing, enough electrode strength is not obtained at or below the melting point of the negative electrode binder as the binder does not melt, and the electrode strength decreases at or above the decomposition temperature of the binder as the binder decomposes. Therefore, an electrode with a superior electrode strength can be obtained by heat treatment at a temperature between the melting point and decomposition temperature of the binder. Same thing applies to the pressing temperature of the negative electrode.

[0078] Though a description has been made of use of one type of binder in each Example of the present invention, it is obvious that similar result will be obtained by using a mixture of two or more types. It is also obvious that similar result will be obtained when the binder is used blended with polyethylene and polypropylene.

[0079] Table 7 shows the low-temperature discharge characteristic, electrode strength, and charge-discharge cycle characteristic of the Example batteries C1-C4 of the present invention and Comparative battery F. The data is for the case of an average flaky graphite particle size of 20 μm and the binder content of 5 parts by weight relative to 100 parts by weight of the carbon material.

TABLE 7
Battery	C1	C2	C3
Rolling Temperature	25	130	25	130	25	130
(deg C.)
Discharge Capacity at	170	204	185	225	170	200
−20 deg C. (mAh)
Electrode Strength	3	4	4	5	4	5
Number of Cycles	516	527	530	540	522	531
(cycles)
	Battery	C4	F
	Rolling Temperature	25	130	25	130
	(deg C.)
	Discharge Capacity at	180	223	44	47
	−20 deg C. (mAh)
	Electrode Strength	4	4	1	1
	Number of Cycles	521	539	447	430
	(cycles)

[0080] As shown in Table 7, all of Example batteries C1-C4 of the present invention exhibited a characteristic superior to Comparative Example battery F in the low-temperature discharge characteristic. This is considered to be due to a lower degree of coverage of the carbon particles with the binder compared with Comparative Example battery F.

[0081] With regard to the electrode strength, too, all of Example batteries C1-C4 of the present invention were superior to Comparative Example battery F. Furthermore, in the case pressing was performed at 130 degrees C., a negative electrode with a further superior electrode strength was obtained because the negative binder of the present invention melts during pressing and solidifies again under the state of being pressed thus enhancing the binding property. Also, the reason why the negative electrode of Example batteries C1-C4 of the present invention showed especially high values of strength is considered to be due to the fact that the negative electrode has a highly polar radical, —COOH or —COOCH3. Furthermore, it was confirmed that when a part or the whole of —COOH or —COOCH3 radical is substituted with —COO−Na+, K+ to make acrylate and methacrylate, adhesiveness with the core material is further enhanced.

[0082] Example batteries of the present invention also showed a charge-discharge cycle characteristic which is superior to Comparative Example battery F. This is considered to be due to the fact that the binder of these batteries does not have double bonds in the primary chains of the polymer and is chemically less reactive to liquid electrolyte thus superior in resistance compared with styrene-butadiene copolymer of the binder used in Comparative Example battery F.

[0083] Table 8 shows the low-temperature discharge characteristic and electrode strength for various ethylene contents of the ethylene-acrylic acid copolymer in Example batteries C1-C4 of the present invention. The data is for the case of an average particle size of 20 μm of the flaky graphite and a binder content of 5 parts by weight relative to 100 parts by weight of the carbon material. Pressing was carried out at 25 degrees C.

TABLE 8
		Discharge Capacity at
	Ethylene Content	−20 deg C.
Battery	(%)	(mAh)	Electrode Strength
C1	60	102	5
	70	161	3
	80	170	3
	95	230	2
	98	256	1
C2	60	105	5
	70	167	4
	80	185	4
	95	234	2
	98	268	1
C3	60	98	5
	70	159	4
	80	170	4
	95	228	3
	98	254	1
C4	60	102	5
	70	162	4
	80	180	4
	95	234	2
	98	266	1

[0084] As shown in Table 8, though the low-temperature discharge capacity increased with increasing ethylene content, the electrode strength decreased conversely. Consequently, it is preferable to keep the ethylene content of the ethylene-acrylic acid copolymer in the range 70-95%.

[0085] Table 9 shows the relationships between the average particle size of flaky graphite and battery capacity and between the average particle size of flaky graphite and low-temperature discharge characteristic in Example batteries C1-C4 of the present invention and Comparative Example battery F. The data is for the case of a binder content of 5 parts by weight relative to 100 parts by weight of the carbon material. Pressing was carried out at 25 degrees C.

TABLE 9
	Average Particle Size of	Battery	Discharge Capacity at
	Flaky Graphite	Capacity	−20 deg C.
Battery	(μm)	(mAh)	(mAh)
C1	1	863	218
	5	914	200
	20	922	170
	30	932	155
	40	944	71
C2	1	867	230
	5	921	205
	20	930	185
	30	934	159
	40	941	75
C3	1	866	211
	5	921	195
	20	933	170
	30	935	158
	40	944	69
C4	1	866	233
	5	922	208
	20	933	180
	30	938	155
	40	946	72
F	1	859	79
	5	913	61
	20	935	44
	30	938	20
	40	945	3

[0086] As can be seen from Table 9, when the average particle size of the flaky graphite is smaller than 5 μm, the battery capacity decreases significantly as the irreversible capacity of the negative electrode carbon material increases, and when greater than 30 μm, the low-temperature discharge characteristic declines, suggesting that an average particle size range of 5-30 μm of the flaky graphite is preferable.

[0087] Table 10 shows the relationships between the binder content in parts by weight in the negative electrode relative to 100 parts by weight of the carbon material and the low-temperature discharge characteristic and between the binder content in parts by weight of the negative electrode relative to 100 parts by weight of the carbon material and the electrode strength of Example batteries C1-C4 of the present invention and Comparative Example battery F. The data is for the case of an average flaky graphite particle size of 20 μm. Pressing was carried out at 25 degrees C.

TABLE 10
		Discharge Capacity at
		−20 deg C.
Battery	Binder Content	(mAh)	Electrode Strength
C1	0.5	198	2
	5	170	3
	8	158	5
	10	93	8
C2	0.5	210	3
	5	185	4
	8	168	7
	10	100	10
C3	0.5	201	3
	5	170	4
	8	160	7
	10	98	10
C4	0.5	205	3
	5	180	4
	8	164	6
	10	97	9
F	0.5	58	= 0
	5	44	1
	8	19	2
	10	2	2

[0088] As can be seen from Table 10, when the binder content in parts by weight relative to 100 parts by weight of the carbon material was larger than 8, a significant decline in the low-temperature discharge characteristic was observed, and at 0.5 there was a decrease in the electrode strength. Therefore, the preferable range of the binder content in parts by weight relative to 100 parts by weight of the carbon material is 0.5-8.

[0089] Now, with regard to the temperature of heat treatment of the negative electrode after pressing, enough electrode strength is not obtained at or below the melting point of the negative electrode binder as the binder does not melt, and the electrode strength decreases at or above the decomposition temperature of the binder as the binder decomposes. Therefore, an electrode with a superior electrode strength can be obtained by heat treatment at a temperature between the melting point and decomposition temperature of the binder. Same thing applies to the pressing temperature of the negative electrode.

[0090] Though a description has been made of use of one type of binder in each Example of the present invention, it is obvious that similar result will be obtained by using a mixture of two or more types. It is also obvious that similar result will be obtained when the binder is used blended with polyethylene and polypropylene.

[0091] Table 11 shows the low-temperature discharge characteristic, electrode strength, and charge-discharge cycle characteristic of the Example batteries D1-D4 of the present invention and Comparative Battery F. The data is for the case of an average flaky graphite particle size of 20 μm and the binder content of 5 parts by weight relative to 100 parts by weight of the carbon material.

TABLE 11
Battery	D1	D2	D3
Rolling Temperature	25	130	25	130	25	130
(deg C.)
Discharge Capacity at	173	208	187	224	175	200
−20 deg C. (mAh)
Electrode Strength	4	4	4	5	4	4
Number of Cycles	535	540	527	540	531	529
(cycles)
	Battery	D4	F
	Rolling Temperature	25	130	25	130
	(deg C.)
	Discharge Capacity at	186	222	44	47
	−20 deg C. (mAh)
	Electrode Strength	4	5	1	1
	Number of Cycles	537	547	447	430
	(cycles)

[0092] As shown in Table 11, all of the Example batteries D1-D4 of the present invention exhibited a characteristic superior to Comparative Example battery F in the low-temperature discharge characteristic. This is considered to be due to a lower degree of coverage of the carbon particles with the binder compared with Comparative Example battery F.

[0093] With regard to the electrode strength, too, all of Example batteries D1-D4 of the present invention were superior to Comparative Example battery F. Furthermore, in the case pressing was performed at 130 degrees C., a negative electrode with a further superior electrode strength was obtained because the negative binder of the present invention melts during pressing and solidifies again under the state of being pressed thus enhancing the binding property. Also, the reason why the negative electrode of Example batteries D1-D4 of the present invention showed especially high values of strength is considered to be due to the fact that the negative electrode has a highly polar radical, —COOH or —COOCH3. Furthermore, it was confirmed that when a part or the whole of —COOH or —COOCH3 radicals is substituted with —COO−Na+, K+ to make acrylate and methacrylate, adhesiveness with the core material is further enhanced.

[0094] Example batteries of the present invention also showed a charge-discharge cycle characteristic which is superior to the Comparative Example battery F. This is considered to be due to the fact that the binder of these batteries does not have double bonds in the primary chain of the polymer and is chemically less reactive to liquid electrolyte thus superior in resistance to liquid electrolyte compared with styrene-butadiene copolymer of the binder used in Comparative Example battery F.

[0095] Table 12 shows the relationships between the average particle size of flaky graphite and battery capacity and between the average particle size of flaky graphite and low-temperature discharge characteristic in Example batteries D1-D4 of the present invention and Comparative Example battery F. The data is for the case of a binder content of 5 parts by weight relative to 100 parts by weight of the carbon material. Pressing was carried out at 25 degrees C.

TABLE 12
	Average Particle Size of	Battery	Discharge Capacity at
	Flaky Graphite	Capacity	−20 deg C.
Battery	(μm)	(mAh)	(mAh)
D1	1	863	207
	5	920	195
	20	930	173
	30	936	141
	40	946	70
D2	1	861	217
	5	919	202
	20	929	187
	30	932	154
	40	940	80
D3	1	868	209
	5	921	196
	20	938	175
	30	940	147
	40	945	75
D4	1	870	220
	5	922	204
	20	937	186
	30	942	155
	40	948	79
F	1	859	79
	5	913	61
	20	935	44
	30	938	20
	40	945	3

[0096] As can be seen from Table 12, when the average particle size of the flaky graphite is smaller than 5 μm, the battery capacity decreases significantly as the irreversible capacity of the negative electrode carbon material increases, and when greater than 30 μm, the low-temperature discharge characteristic declines suggesting that an average particle size range of 5-30 μm of the flaky graphite is preferable.

[0097] Table 13 shows the relationships between the binder content in parts by weight relative to 100 parts by weight of the carbon material of the negative electrode and the low-temperature discharge characteristic and between the binder content in parts by weight relative to 100 parts by weight of the carbon material of the negative electrode and the electrode strength of Example batteries D1-D4 of the present invention and Comparative Example battery F. The data is for the case of an average particle size of flaky graphite of 20 μm. Pressing was carried out at 25 degrees C.

TABLE 13
		Discharge Capacity at
		−20 deg C.
Battery	Binder Content	(mAh)	Electrode Strength
D1	0.5	206	3
	5	173	4
	8	162	7
	10	99	9
D2	0.5	219	3
	5	187	4
	8	171	7
	10	105	9
D3	0.5	207	3
	5	175	4
	8	166	8
	10	100	10
D4	0.5	220	3
	5	186	4
	8	170	8
	10	103	10
F	0.5	58	= 0
	5	44	1
	8	19	2
	10	2	2

[0098] As can be seen from Table 13, when the binder content in parts by weight relative to 100 parts by weight of the carbon material was greater than 8, a significant decline in the low-temperature discharge characteristic was observed, and at 0.5 there was a decrease in the electrode strength, suggesting that the preferable range of the ration between the carbon material and the binder is 0.5-8 parts by weight relative to 100 parts by weight of the carbon material.

[0099] Now, with regard to the temperature of heat treatment of the negative electrode after pressing, enough electrode strength is not obtained at or below the melting point of the negative electrode binder as the binder does not melt, and the electrode strength decreases at or above the decomposition temperature of the binder as the binder decomposes. Therefore, an electrode with a superior electrode strength can be obtained by heat treatment at a temperature between the melting point and decomposition temperature of the binder. Same thing applies to the pressing temperature of the negative electrode.

[0100] Though a description has been made of use of one type of binder in each Example of the present invention, it is obvious that similar result will be obtained by using a mixture of two or more types. It is also obvious that similar result will be obtained by using the binder blended with polyethylene and polypropylene.

[0101] Table 14 shows the low-temperature discharge characteristic, electrode strength, and charge-discharge cycle characteristic of the Example batteries E1-E8 of the present invention and Comparative Battery F. The data is for the case of a average flaky graphite particle size of 20 μm and the binder content of 5 parts by weight relative to 100 parts by weight of the carbon material.

TABLE 14
Battery	E1	E2	E3
Rolling Temperature	25	130	25	130	25	130
(deg C.)
Discharge Capacity at	190	227	187	214	178	203
−20 deg C. (mAh)
Electrode Strength	4	5	4	4	4	5
Number of Cycles	341	329	335	341	322	309
(cycles)
Battery	E4	E5	E6
Rolling Temperature	25	130	25	130	25	130
(deg C.)
Discharge Capacity at	183	212	178	205	181	218
−20 deg C. (mAh)
Electrode Strength	4	4	3	4	4	5
Number of Cycles	339	343	317	333	321	338
(cycles)
Battery	E7	E8	F
Rolling Temperature	25	130	25	130	25	130
(deg C.)
Discharge Capacity at	177	209	175	211	44	47
−20 deg C. (mAh)
Electrode Strength	4	5	3	4	1	1
Number of Cycles	304	308	315	322	447	430
(cycles)

[0102] In the low-temperature discharge characteristic, all of Example batteries E1-E8 of the present invention exhibited a characteristic superior to Comparative Example battery F as shown in Table 14. This is considered to be due to a lower degree of coverage of the carbon particles with the binder compared with Comparative Example battery F.

[0103] With regard to the electrode strength, too, all of Example batteries E1-E8 of the present invention were superior to Comparative Example battery F. Furthermore, in the case pressing was performed at 130 degrees C., a negative electrode with a further superior electrode strength was obtained because the negative binder of the present invention melts during pressing and solidifies again under the state of being pressed thus enhancing the binding property. Also, the reason why the negative electrode of Example batteries E1-E8 of the present invention showed especially high values of strength is considered to be due to the fact that the negative electrode has a highly polar radical, —COOH or —COOCH3. Furthermore, it was confirmed that when a part or the whole of —COOH or —COOCH3 radical is substituted with —COO−Na+, K+ to make acrylate and methacrylate, adhesiveness with the core material is further enhanced.

[0104] Example batteries of the present invention showed a charge-discharge cycle characteristic which is inferior to the Comparative Example battery F. While the reason is not clear, it is assumed that, in view of the superiority of the binder in the resistance to liquid electrolyte, elasticity of the resin has decreased by copolymerization of styrene causing a physical stress due to expansion and shrinkage of the carbon material.

[0105] Table 15 shows the relationships between the average particle size of flaky graphite and battery capacity and between the average particle size of flaky graphite and low-temperature discharge characteristic in Example batteries E1-E8 of the present invention and Comparative Example battery F. The data is for the case of a binder content of 5 parts by weight to 100 parts by weight of the carbon material. Pressing was carried out at 25 degrees C.

TABLE 15
	Average Particle Size of	Battery	Discharge Capacity at
	Flaky Graphite	Capacity	−20 deg C.
Battery	(μm)	(mAh)	(mAh)
E1	1	874	234
	5	922	214
	20	930	190
	30	938	165
	40	947	79
E2	1	873	230
	5	918	209
	20	927	187
	30	935	164
	40	944	78
E3	1	872	212
	5	923	199
	20	936	178
	30	942	159
	40	945	77
E4	1	875	229
	5	920	205
	20	930	183
	30	937	163
	40	948	74
E5	1	873	222
	5	922	203
	20	931	178
	30	939	159
	40	948	69
E6	1	871	227
	5	919	208
	20	928	181
	30	936	169
	40	946	74
E7	1	877	220
	5	924	201
	20	932	177
	30	938	167
	40	947	71
E8	1	875	216
	5	922	197
	20	929	175
	30	936	163
	40	943	68
F	1	859	79
	5	913	61
	20	935	44
	30	938	20
	40	945	3

[0106] As can be seen from Table 15, when the average particle size of the flaky graphite is smaller than 5 μm, the battery capacity decreases significantly as the irreversible capacity of the negative electrode carbon material increases, and when greater than 30 μm, the low-temperature discharge characteristic declines, suggesting that an average particle size range of 5-30 μm of the flaky graphite is preferable.

[0107] Table 16 shows the relationships between the binder content in parts by weight relative to 100 parts by weight of the carbon material of the negative electrode and the low-temperature discharge characteristic and between the binder content in parts by weight relative to 100 parts by weight of the carbon material of the negative electrode and the electrode strength of Example batteries E1-E8 of the present invention and Comparative Example battery F. The data is for the case of an average flaky graphite particle size of 20 μm. Pressing was carried out at 25 degrees C.

TABLE 16
		Discharge Capacity
Battery	Binder Content	at −20 degC. (mAh)	Electrode Strength
E1	0.5	231	3
	5	190	4
	8	176	6
	10	104	9
E2	0.5	226	3
	5	187	4
	8	171	6
	10	100	10
E3	0.5	213	3
	5	178	4
	8	166	6
	10	87	10
E4	0.5	222	3
	5	183	4
	8	169	6
	10	98	9
E5	0.5	216	2
	5	178	3
	8	164	4
	10	92	8
E6	0.5	221	3
	5	181	4
	8	168	5
	10	94	9
E7	0.5	220	3
	5	177	4
	8	169	6
	10	96	10
E8	0.5	211	2
	5	175	3
	8	162	4
	10	92	7
F	0.5	58	=0
	5	44	1
	8	19	2
	10	2	2

[0108] As can be seen from Table 16, when the binder content in parts by weight relative to 100 parts by weight of the carbon material is larger than 8, a significant decrease in the low-temperature discharge characteristic was observed, and at 0.5, there was a decrease in the electrode strength. Therefore, the preferable range of the binder content in parts by weight relative to 100 parts by weight of the carbon material is 0.5-8.

[0109] Table 17 shows the low-temperature discharge characteristics and electrode strength for various ethylene-propylene contents of the copolymer in Example batteries D1-D4 of the present invention. The data is for the case of an average particle size of 20 μm of the flaky graphite and a binder content of 5 parts by weight relative to 100 parts by weight of the carbon material. Pressing was carried out at 25 degrees C.

TABLE 17
	Ethylene-	Discharge Capacity
Battery	Propylene Content	at −20 degC. (mAh)	Electrode Strength
D1	60%	94	5
	70%	157	4
	80%	173	4
	95%	226	2
	98%	246	1
D2	60%	97	5
	70%	163	4
	80%	187	4
	95%	230	3
	98%	258	1
D3	60%	90	5
	70%	155	4
	80%	175	4
	95%	223	3
	98%	248	1
D4	60%	94	5
	70%	163	4
	80%	186	4
	95%	229	2
	98%	256	1

[0110] Table 18 shows the low-temperature discharge characteristics and electrode strength for various ethylene to propylene ratios of the copolymer in Example battery D2 of the ethylene-propylene content 80%. The data is for the case of an average particle size of 20 μm of the flaky graphite and a binder content of 5 parts by weight relative to 100 parts by weight of the carbon material. Pressing was carried out at 25 degrees C.

	TABLE 18
	Ethylene	Propylene	Discharge Capacity	Electrode
	Content	Content	at −20 degC. (mAh)	Strength
	100%	0%	185	4
	80%	20%	185	4
	50%	50%	187	4
	20%	80%	171	4
	10%	90%	143	4
	0%	100%	111	4

[0111] As shown in Table 17, though the low-temperature discharge capacity increased with increasing ethylene and propylene content, the electrode strength decreased conversely. Consequently, it is preferable to keep the ethylene-propylene weight content in the range of 70-95%.

[0112] In addition, as shown in Table 18, the low-temperature discharge capacity decreased with decreasing ethylene ratio less than 20%. This may come form the decrease in negative electrode reactivity due to the steric hindrance of propylene.

[0113] Consequently, it is preferable to keep the ethylene to propylene weight % in the range of 100:0 to 20:80. (i.e., 20-100% ethylene to 0-80% propylene).

[0114] Now, with regard to the temperature of heat treatment of the negative electrode after pressing, enough electrode strength is not obtained at or below the melting point of the negative electrode binder as the binder does not melt, and the electrode strength decreases at or above the decomposition temperature of the binder as the binder decomposes. Therefore, an electrode with a superior electrode strength can be obtained by heat treatment at a temperature between the melting point and decomposition temperature of the binder. Same thing applies to the pressing temperature of the negative electrode.

[0115] Though a description has been made of use of one type of binder in each Example of the present invention, it is obvious that similar result will be obtained by using a mixture of two or more types. It is also obvious that similar result will be obtained when the binder is used blended with polyethylene and polypropylene.

[0116] In the examples of the present invention, though flaky graphite was used as the negative electrode carbon material, similar effects were obtained irrespective of the type and configuration of the carbon materials.

[0117] Also, while LiCoO2 was employed as the positive active material, similar effects were obtained by employing other positive active material such as LiNiO2 or LiMn2O4.

Industrial Application

[0118] As has been described above, the present invention provide a negative electrode which is superior in the low-temperature discharge characteristic and in the strength against peeling of the electrode mix, and, through use of the negative electrode, it also provides a non-aqueous electrolyte secondary battery which is superior in the ease of handling in mass production, high in reliability, and superior in discharge characteristic.

Claims

1. A non-aqueous electrolyte secondary battery comprising a rechargeable positive electrode, a non-aqueous liquid electrolyte, a negative electrode comprising a negative electrode material; in which: the negative electrode material comprises: (1) a carbon material that is capable of absorbing and desorbing lithium, and (2) a binder; the carbon material is a graphite material; the binder is at least material selected from the group consisting of ethylene-propylene-acrylic acid copolymers, ethylene-propylene-acrylate copolymers, ethylene-propylene-methyl acrylic acid copolymers, ethylene-propylene-methacrylic acid copolymers, ethylene-propylene-methacrylate copolymers, and ethylene-propylene-methyl methacrylic acid copolymers; and the ethylene-propylene content of the binder is the range of 70-95%.

2. The non-aqueous electrolyte secondary battery of claim 1 wherein the carbon material is a graphite material having an average particle size in the range 5-30 μm.

3. The non-aqueous electrolyte secondary battery claim 1 wherein the ratio between the carbon material and binder is such that the binder content is in the range 0.5-8 parts by weight relative to 100 parts by weight of the carbon material.

4. The non-aqueous electrolyte secondary battery of claim 1 wherein the positive electrode comprises a positive active material selected from the group consisting of LiCoO2, LiNiO2, and LiMn2O4.

5. The non-aqueous electrolyte secondary battery of claim 1 wherein the binder comprises —COO−Na+ or —COO−K+ groups.

6. The non-aqueous electrolyte secondary battery claim 1 wherein the ethylene to propylene weight % content of the binder is between 100:0 to 20:80.

7. The non-aqueous electrolyte secondary battery of claim 6 wherein the carbon material is a graphite material having an average particle size in the range 5-30 μm.

8. The non-aqueous electrolyte secondary battery claim 6 wherein the ratio between the carbon material and binder is such that the binder content is in the range 0.5-8 parts by weight relative to 100 parts by weight of the carbon material.

9. The non-aqueous electrolyte secondary battery of claim 6 wherein the positive electrode comprises a positive active material selected from the group consisting of LiCoO2, LiNiO2, and LiMn2O4.

10. The non-aqueous electrolyte secondary battery of claim 6 wherein the binder comprises —COO−Na+ or —COO−K+ groups.

11. A method of manufacturing a non-aqueous electrolyte secondary battery negative electrode employing as the negative electrode material a carbon material which is capable of absorbing and desorbing lithium and at least one type of binder selected from the group consisting of ethylene-propylene-acrylic acid copolymers, ethylene-propylene-acrylate copolymers, ethylene-propylene-methylacrylic acid copolymers, ethylene-propylene-methacrylate copolymers, ethylene-propylene-methacrylate copolymers, and ethylene-propylene-methyl methacrylic acid copolymers; wherein the ethylene-propylene content of the binder is the range of 70-95%; wherein a mixture of said carbon material and a binder is coated on a current collector, dried, and pressed followed by heat treatment at a temperature between the melting point and the decomposition temperature of said binder, or pressing at a temperature between the melting point and the decomposition temperature of said binder.

12. The method of claim 11 wherein the ethylene to propylene weight % content of the binder is between 100:0 to 20:80.

13. The method of claim 12 wherein the carbon material is a graphite material having an average particle size in the range 5-30 μm.

14. The method claim 12 wherein the ratio between the carbon material and binder is such that the binder content is in the range 0.5-8 parts by weight relative to 100 parts by weight of the carbon material.

15. The method of claim 12 wherein the binder comprises —COO−Na+ or —COO−K+ groups.