Method of manufacturing current collector electrode sheet, current collector electrode sheet, and battery

1. A method of manufacturing a current collector electrode sheet in which an active material is applied to both surfaces of a sheet-shaped metal foil, the method comprising:

an application step of alternately forming a slurry application area, on which an active material layer is continuously present, and a slurry non-application area in a winding direction of the metal foil having a strip shape by intermittently applying and drying a slurry containing the active material over the metal foil having a strip shape;

a first detection step of detecting a length of a tailing portion at a terminal end of each application area formed in the application step;

a compression step of continuously compressing the slurry application area and the non-application area using a pair of compression rollers in a thickness direction of the metal foil on which the active materiel layer is formed; and

a cutting step of continuously cutting the slurry application area and the non-application area to be parallel with the winding direction of the metal foil on which the active material layer is formed through the first detection step and the compression step,

wherein the first detection step includes

detecting the tailing portion which is formed continuously from the terminal end of the slurry application area to the non-application area and which satisfies the following Equation (A),

x ≤(2 rt min− t min 2 ) 1/2 −y max −z max −w max   Equation (A),

wherein, x is a maximum value of the length of the tailing portion at the terminal end of each application area in the application step, r is a roll diameter of the compression roller used in the compression step, t min is a minimum value of an assumed thickness acquired after pressurizing compression is performed in a central portion of each application area successively formed in the application step, y max is a maximum value of a discrepancy amount of an application start position between both surfaces of the metal foil in the winding direction of the metal foil, z max is a maximum value of a discrepancy amount of an application length of the active material on both surfaces of the metal foil in the winding direction of the metal foil, and w max is a maximum value of a distance from a coating terminal end of the active material on both surfaces of the metal foil to a portion where a thickness of a coating film becomes the same as a center of a coating area.

2. The method of manufacturing the current collector electrode sheet according to claim 1 ,

wherein, in the detection step, a position, at which the tailing portion is detected, includes a position where cutting processing is performed in the cutting step and a peripheral portion of the position.

3. The method of manufacturing the current collector electrode sheet according to claim 1 ,

wherein the detection step is a step which is performed between the application step and the cutting step and includes a step of forming a protective layer for the tailing portion detected in the detection step.

4. The method of manufacturing the current collector electrode sheet according to claim 1 , further comprising:

a step, subsequent to the detection step, of performing marking processing on the application area including the tailing portion detected in the detection step.

5. The method of manufacturing the current collector electrode sheet according to claim 4 , further comprising:

a second detection step of detecting a position of the marking before producing an electrochemical device using an electrode produced through the cutting step; and

a step of excluding the electrode, which includes a marking detected in the second detection step and is acquired after the cutting step, from a target member for producing the electrochemical device.

6. The method of manufacturing the current collector electrode sheet according to claim 1 ,

wherein the current collector electrode sheet is produced using a lithium metal composite oxide as the active material.

7. The method of manufacturing the current collector electrode sheet according to claim 1 ,

wherein, in a case where a thickness of the metal foil is denoted by d,

particles are arranged in order from a particle having a smallest particle diameter among measured active material particles when measurement is performed using a particle size analyzer, and a diameter of the particle corresponding to 90% of the measured particles is denoted by D90, the current collector electrode sheet is produced using the metal foil and the active material which satisfy a relationship of D90≥d.

8. The method of manufacturing the current collector electrode sheet according to claim 1 ,

wherein, in the compression step, a load applied to a central portion of the application area in the metal foil, on which the active material layer is formed, exceeds 1.5 ton/cm.

9. The method of manufacturing the current collector electrode sheet according to claim 2 ,

wherein the detection step is a step which is performed between the application step and the cutting step and includes a step of forming a protective layer for the tailing portion detected in the detection step.

10. The method of manufacturing the current collector electrode sheet according to claim 3 , further comprising:

a step, subsequent to the detection step, of performing marking processing on the application area including the tailing portion detected in the detection step.

11. The method of manufacturing the current collector electrode sheet according to claim 10 , further comprising:

a second detection step of detecting a position of the marking before producing an electrochemical device using an electrode produced through the cutting step; and

a step of excluding the electrode, which includes a marking detected in the second detection step and is acquired after the cutting step, from a target member for producing the electrochemical device.

12. A method of manufacturing a current collector electrode sheet in which an active material is applied to both surfaces of a sheet-shaped metal foil, the method comprising:

an application step of alternately forming a slurry application area, on which an active material layer is continuously present, and a slurry non-application area in a winding direction of the metal foil having a strip shape by intermittently applying and drying a slurry containing the active material over the metal foil having a strip shape;

a detection step of detecting a length of a tailing portion at a terminal end of each application area formed in the application step;

a compression step of continuously compressing the slurry application area and the non-application area using a pair of compression rollers in a thickness direction of the metal foil on which the active materiel layer is formed through the application step and the detection step; and

a cutting step of continuously cutting the slurry application area and the non-application area to be parallel with the wingding direction of the metal foil on which the active material layer is formed through the detection step and the compression step,

wherein the compression step includes

performing compression using a compression roller having a roll radius r that satisfies the following Equation (B),

r≥t min /2+( x max +y max +z max +w max ) 2 /(2 t min )  Equation (B),

wherein, t min is a minimum value of an assumed thickness after pressurizing compression is performed at a central portion of each application area successively formed in the application step, X max is a maximum value of the length of the tailing portion at the terminal end of each application area successively formed in the application step, the length of the tailing portion being detected in the detection step, y max is a maximum value of a discrepancy amount of an application start position of the active material between both surfaces of the metal foil, z max is a maximum value of a discrepancy amount of an application length of the active material on both surfaces of the metal foil in the winding direction of the metal foil, and w max is a maximum value of a distance from a coating terminal end of the active material on both surfaces of the metal foil to a portion where a thickness of a coating film becomes the same as a center of a coating area.

13. The method of manufacturing the current collector electrode sheet according to claim 12 ,

wherein the current collector electrode sheet is produced using a lithium metal composite oxide as the active material.

14. The method of manufacturing the current collector electrode sheet according to claim 12 ,

wherein, in a case where a thickness of the metal foil is denoted by d,

particles are arranged in order from a particle having a smallest particle diameter among measured active material particles when measurement is performed using a particle size analyzer, and a diameter of the particle corresponding to 90% of the measured particles is denoted by D90, the current collector electrode sheet is produced using the metal foil and the active material which satisfy a relationship of D90≥d.

15. The method of manufacturing the current collector electrode sheet according to claim 12 ,

wherein, in the compression step, a load applied to a central portion of the application area in the metal foil, on which the active material layer is formed, exceeds 1.5 ton/cm.