(12) United States Patent (10) Patent No.: US 9,118,062 B2 Yamaguchi Et Al

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(12) United States Patent (10) Patent No.: US 9,118,062 B2 Yamaguchi Et Al USOO91 18062B2 (12) United States Patent (10) Patent No.: US 9,118,062 B2 Yamaguchi et al. (45) Date of Patent: Aug. 25, 2015 (54) ANODE AND METHOD OF 4/136 (2013.01); H0IM 4/1397 (2013.01); MANUFACTURING THE SAME, AND H01 M 4/38 (2013.01); H0IM 6/164 (2013.01); BATTERY AND METHOD OF H0IM 10/0568 (2013.01); H0IM 10/0569 MANUFACTURING THE SAME (2013.01); H0IM 10/4235 (2013.01); HOIM (75) Inventors: Hiroyuki Yamaguchi, Fukushima (JP); 2004/027 (2013.01);s HOIM 2300/0034 Masayuki Ihara, Fukushima (JP); (2013.01); Y02E 60/122 (2013.01); Y10T Hideki Nakai, Fukushima (JP); Toru 29/491 15 (2015.01) Odani, Fukushima (JP); Tadahiko (58) Field of Classification Search Kubota, Kanagawa (JP) USPC ............... 29/623.5; 427/123; 429/218.1, 220, 429/221, 223, 229, 231.1, 231.3, 231.6, (73) Assignee: SONY CORPORATION, Tokyo (JP) 429/231.9, 231.95, 232 (*) Notice: Subject to any disclaimer, the term of this See application file for complete search history. patent is extended or adjusted under 35 U.S.C. 154(b) by 1368 days. (56) References Cited (21) Appl. No.: 12/135,572 U.S. PATENT DOCUMENTS 6,235,427 B1 5, 2001 Idota et al. (22) Filed: Jun. 9, 2008 6,337,159 B1* 1/2002 Peled et al. ................ 429,2314 6,743,877 B1 * 6/2004 Armand et al. ............... 526,258 (65) Prior Publication Data 6,790,563 B2 * 9/2004 Ishii et al. ..................... 429,347 US 2008/0311472A1 Dec. 18, 2008 (Continued) (30) Foreign Application Priority Data FOREIGN PATENT DOCUMENTS CN 1399363 2, 2003 Jun. 13, 2007 (JP) ................................. 2007-156410 CN 1710734. A 12/2005 (51) Int. Cl. (Continued) HOLM 4/02 (2006.01) OTHER PUBLICATIONS HOLM 4/04 (2006.01) HOLM 6/00 (2006.01) Yoshimura, JP 2007-027 105 JPO Abstract translation, Feb. 2007.* HOLM 4/1395 (2010.01) (Continued) HOLM 4/34 (2010.01) HOLM 4/36 (2010.01) HOLM 4/1397 (2010.01) Primary Examiner — Yun Qian HOLM 4/38 (2006.01) (74) Attorney, Agent, or Firm — Dentons US LLP HOLM 6/16 (2006.01) HIM I/0568 (2010.01) (57) ABSTRACT HIM I/0569 (2010.01) A coating on an anode active material that includes a metal HIM I/42 (2006.01) salt with two or more sulfonates or a metal salt of oxocarbonic (52) U.S. Cl. acid. CPC .......... H0IM 4/1395 (2013.01); H01 M 4/0416 (2013.01); H0IM 4/134 (2013.01); HOLM 14 Claims, 11 Drawing Sheets 1 2 3 N NTNTNT Y. Ya Ya Ya Y AN. Y. N. Ya Ya N. Y. Ya Ya Ya Ya / / / / / / / US 9,118,062 B2 Page 2 (56) References Cited JP 2006-294469 10, 2006 JP 2007-027105. A * 2/2007 U.S. PATENT DOCUMENTS JP 2007-149535 6, 2007 JP 2008-3O8421 12/2008 7,695,863 B2 * 4/2010 Abe et al. ...................... 429, 200 WO WO 2006/070546 * 7, 2006 ............ HOM 1040 2003. O152839 A1* 8, 2003 Kawai et al. ... 429,329 2004/0072072 A1* 4/2004 Suzuki et al. .............. 429,231.1 OTHER PUBLICATIONS 2006/00995.12 A1* 5, 2006 Nakai et al. ................... 429,246 2007/01 17024 A1* 5, 2007 Nakai et al. ... 429,246 Koch et al. Journal of Power Sources, 20, 1987, 287-291.* 2007/0122701 A1* 5/2007 Yamaguchi. 429,218.1 Korean Office Examination Report issued in connection with related 2007/0178379 A1* 8, 2007 Tamura et al. ................ 429, 200 Korean Patent Application No. 10-2008-55326 dated Oct. 8, 2014 with English translation. FOREIGN PATENT DOCUMENTS Chinese Office Examination Report issued in connection with related Chinese Patent Application No. 200810210393.3 dated Aug. 20. JP O2-262246 * 10, 1990 .............. HO1 M 4/50 2014. E. 995 3E Chinese Examination Report issued in connection with related coun JP 2002-056891 2, 2002 st CN Patent Application No. CN 200810210393.3 dated Apr. 1, JP 2003-132946 5, 2003 JP 2003-203673 T 2003 Japanese Office Action datedMar. 19, 2013 issued in connection with JP 2003-257479 9, 2003 counterpart Japanese Patent Application No. 2008-155787. JP 2005-332606 12/2005 JP 2006-86.058 3, 2006 * cited by examiner U.S. Patent Aug. 25, 2015 Sheet 1 of 11 US 9,118,062 B2 F.G. 1 U.S. Patent Aug. 25, 2015 Sheet 2 of 11 US 9,118,062 B2 F. G. 3 U.S. Patent Aug. 25, 2015 Sheet 3 of 11 US 9,118,062 B2 25 14 15A 15 a 1/A444/1 K) WS S. 37.2 SN 6 Ka www.xx. 77''''SS-22 Aaaaaa N raze a 4N 17 12 1 O 1 NLR)((((((( IR`N`(((((((?N 2 3 4 NÚTÍNÚŠNÚÑIÓNÚŠNÚÑ-ÍÑIŠTŠI?NÚŠTÍTNÝTÍSTÍN NÚINTSISTNIŠTISINISTIS(NOESIÑINTIÚN N 13 s ZZZZZX SIR)()()()()()()()()()()()()()l !!!!!!!!}ì?!!!!!!!!!!!!!! 26 NR)()()()()()()()()()()()()())? !————? FG. 4 U.S. Patent Aug. 25, 2015 Sheet 5 of 11 US 9,118,062 B2 FG. 7 U.S. Patent Aug. 25, 2015 Sheet 7 of 11 US 9,118,062 B2 7 YZ 7 7 7 7 7 7 7777 V Y"Y 7 / 7 NY YNNY, NYNNNNYN N N N N N N N Y 34 FIG. 9 U.S. Patent Aug. 25, 2015 Sheet 8 of 11 US 9,118,062 B2 Na YaYaNYa Ya Ya Ya Ya Ya Ya YaYa YaYa Ya Ya Ya Y77 / 7. Y 7/77 7 777 / Y 7 7 Y 7 7 34A 34B 34C 34D 34 F.G. 10 U.S. Patent Aug. 25, 2015 Sheet 9 of 11 US 9,118,062 B2 52 55 52A 52B 52C 53 NN Y N N KN kS:, 2 SS 3 3/D2, ( ( a N NeN N N N N N N N N Naga <) 56 54 51A 51B 56 - - 51 F.G. 11 U.S. Patent Aug. 25, 2015 Sheet 10 of 11 US 9,118,062 B2 52 55 52A 52B 52D 520 53 giNYN W (x^N///M-SN22 TzzazeezeCN (SN) 1S N432X2, (4 NJ424 U.S. Patent Aug. 25, 2015 Sheet 11 of 11 US 9,118,062 B2 1600 1400 1200 1000 800 300 295 290 285 ENERGY (eV) F.G. 13 US 9,118,062 B2 1. 2 ANODE AND METHOD OF lithium fluoride or lithium carbonate, or an oxide such as MANUFACTURING THE SAME, AND silicon oxide or aluminum oxide (for example, refer to Japa BATTERY AND METHOD OF nese Unexamined Patent Application Publication Nos. 2004 MANUFACTURING THE SAME 327211, H07-302617, H10-255800, H11-135153, 2005 026230, 2005-142156, 2005-166469 and 2006-185728). CROSS REFERENCES TO RELATED APPLICATIONS SUMMARY OF THE INVENTION The present invention contains Subject matter related to Japanese Patent Application JP 2007-156410 filed in the 10 However, with further enhancement of performance and Japanese Patent Office on Jun. 13, 2007, the entire contents of further expansion of functions in recent portable electronic which being incorporated herein by reference. devices, when charge and discharge of a secondary battery are frequently repeated, an electrolytic solution is decomposed, BACKGROUND OF THE INVENTION thereby a discharge capacity easily declines. The decompo 15 1. Field of the Invention sition of the electrolytic Solution accompanied with charge The present invention relates to an anode, a method of and discharge is likely to occur specifically in the case where manufacturing the anode, a battery including the anode, and a tin, silicon or the like having a high theoretical capacity is method of manufacturing the battery. used as an anode active material. Therefore, a further 2. Description of the Related Art improvement in the cycle characteristics of secondary batter In recent years, portable electronic devices such as camera ies is desired. integrated VTRs (videotape recorders), digital steel cameras, In view of the foregoing, it is desirable to provide an anode cellular phones, personal digital assistances or laptop com capable of improving cycle characteristics, a method of puters are widely used, and size and weight reduction in the manufacturing the anode, a battery including the anode, and a portable electronic devices and an increase in longevity of the 25 method of manufacturing the battery. portable electronic devices have been strongly demanded. According to an embodiment of the invention, there is Accordingly, as power sources for the portable electronic provided an anode including an anode current collector; an devices, the development of batteries, specifically light anode active material arranged on the anode current collector; weight secondary batteries capable of obtaining a high energy and a coating arranged on the anode active material layer, in density have been promoted. 30 which the coating includes at least one of a metal salt repre Among them, a secondary battery (a so-called lithium-ion sented by Chemical Formula 1 or a metal salt of oxocarbonic secondary battery) using insertion and extraction of lithium acid. Moreover, according to an embodiment of the invention, for charge-discharge reaction holds great promise, because there is provided a battery including the above-described the secondary battery is capable of obtaining a larger energy anode, a cathode and an electrolytic solution. density, compared to a lead-acid battery or a nickel-cadmium 35 battery. In the lithium-ion secondary battery, a carbon mate rial is widely used as an anode active material. Chemical Formula 1 Recently, with enhancement of performance in portable electronic devices, a further improvement in capacity is 8 desired, so it is considered to use tin, silicon or the like as an 40 O anode active material instead of a carbon material (for O -C SCO example, refer to U.S. Pat. No. 4,950,566). It is because the a R3 M theoretical capacities of tin (994 mAh/g) and silicon (41.99 R2-os, S 29 mAh/g) are much larger than the theoretical capacity of n graphite (372 mAh/g), so a remarkable improvement in bat 45 |YO-R1 O/ O d tery capacity is expected.
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