阅读说明：本技术 二次电池用层叠体的制造装置和制造方法 (Apparatus and method for manufacturing secondary battery laminate ) 是由 大森弘士 铃木成实 于 2019-03-20 设计创作，主要内容包括：本发明提供一种制造装置(100),其具有：凸部形成构件配置机构(90)、作为贴合机构的张力缓冲器(70)、加速装置(80)、金属辊(30)和橡胶辊(40)、以及切断机构(50)。而且,使间隔件卷料(20)和电极卷料(10)在夹着凸部形成构件(35)的状态下接合,在配置有凸部形成构件(35)的部分使间隔件卷料(20)弯曲并贴合。(The present invention provides a manufacturing apparatus (100) having: a convex part forming member arranging mechanism (90), a tension buffer (70) as a bonding mechanism, an accelerating device (80), a metal roller (30) and a rubber roller (40), and a cutting mechanism (50). The separator roll (20) and the electrode roll (10) are joined with the convex portion forming member (35) therebetween, and the separator roll (20) is bent and bonded at the portion where the convex portion forming member (35) is disposed.)

1. An apparatus for manufacturing a secondary battery laminate, comprising:

an electrode roll formed by rolling a long electrode roll material into a roll shape;

a separator roll formed by rolling a long separator roll material into a roll shape;

a convex portion forming member arranging mechanism that arranges a convex portion forming member on at least one of a main surface of a spacer roll paid out from the spacer roll and a main surface of an electrode roll paid out from the electrode roll;

a bonding mechanism that bonds the separator roll and the electrode roll with the projection forming member interposed therebetween, bends or bends the separator roll at a portion where the projection forming member is disposed to form a projection extending over the entire width of the separator roll, and bonds the separator roll and the electrode roll; and

and a cutting mechanism that cuts at least the electrode roll portion of the bonded body of the separator roll and the electrode roll at a portion where the convex portion is provided.

2. The manufacturing apparatus of a laminate for a secondary battery according to claim 1, wherein,

the projection forming member arranging mechanism has a plurality of projection forming members having different surface areas, and arranges the projection forming members such that the surface area of each projection forming member gradually increases or gradually decreases toward the direction of conveyance of the spacer roll and the electrode roll.

3. The manufacturing apparatus of a laminate for a secondary battery according to claim 1 or 2, wherein,

a removing mechanism for removing the projection forming member is further provided between the bonding mechanism and the cutting mechanism.

4. The manufacturing apparatus of a laminate for a secondary battery according to claim 3, wherein,

the removing mechanism has a removing portion for removing the projection forming member by removing the projection forming member.

5. The manufacturing apparatus of a laminate for a secondary battery according to claim 3, wherein,

the convex portion forming member is formed of a material that can be dissolved, melted, or sublimated, and the removing mechanism has a removing portion that dissolves, melts, or sublimates the convex portion forming member to remove.

6. The manufacturing apparatus of a laminate for a secondary battery according to any one of claims 1 to 5, wherein,

the bonding mechanism includes a crimping machine that clamps and bonds the spacer roll and the electrode roll by a spacer roll side pressing member and an electrode roll side pressing member, the spacer roll side pressing member has a lower elastic modulus than the convex portion forming member, and the electrode roll side pressing member has a higher elastic modulus than the convex portion forming member.

7. The manufacturing apparatus of a laminate for a secondary battery according to claim 6, wherein,

the spacer roll-to-roll pressing member and the electrode roll-to-roll pressing member are pressure contact rollers.

8. The manufacturing apparatus of a laminate for a secondary battery according to any one of claims 1 to 7, wherein,

the projections have first and second projections extending across the width of the spacer roll, and a valley between the first and second projections.

9. A method for manufacturing a laminate for a secondary battery, comprising:

a step (A) for disposing a projection forming member on at least one of a main surface of a separator roll discharged from a separator roll formed by winding a long separator roll into a roll and a main surface of an electrode roll discharged from an electrode roll formed by winding a long electrode roll into a roll;

a step B of joining the separator roll and the electrode roll with the projection forming member interposed therebetween, bending or curving the separator roll at a portion where the projection forming member is disposed to form a projection extending over the entire width of the separator roll, and bonding the separator roll and the electrode roll; and

and a step C of cutting at least the electrode roll portion of the bonded body of the separator roll and the electrode roll obtained in the step B at a portion where the convex portion is provided.

10. The method for producing a laminate for a secondary battery according to claim 9, wherein,

the method further comprises a step D of removing the projection forming member after the step B and before the step C.

11. The method for producing a laminate for a secondary battery according to claim 10, wherein,

in the step D, the projection forming member is pulled out and removed.

12. The method for producing a laminate for a secondary battery according to claim 10, wherein,

the convex portion forming member is formed of a material capable of being dissolved, melted or sublimated,

in the step D, the projection forming member is dissolved, melted, or sublimated and removed.

13. The method for manufacturing a laminate for a secondary battery according to any one of claims 9 to 12, wherein,

in the step B, an electrode roll-side pressing member having a higher elastic modulus than the projection forming member and a spacer roll-side pressing member having a lower elastic modulus than the projection forming member are used to sandwich and bond the spacer roll and the electrode roll.

14. The method for producing a laminate for a secondary battery according to claim 13, wherein,

the spacer roll-to-roll pressing member and the electrode roll-to-roll pressing member are pressure contact rollers.

15. The method for manufacturing a laminate for a secondary battery according to any one of claims 9 to 14, wherein,

in the step a, the plurality of projection forming members having different surface areas are arranged such that the surface area of each projection forming member gradually increases or gradually decreases in the direction in which the spacer web and the electrode web are conveyed, and in the step B, the plurality of projections are formed such that the surface area of each projection gradually increases or gradually decreases in the direction in which the spacer web is conveyed.

16. The method for manufacturing a laminate for a secondary battery according to any one of claims 9 to 15, wherein,

the projections have first and second projections extending across the width of the spacer roll, and a valley between the first and second projections.

Technical Field

The present invention relates to an apparatus for manufacturing a secondary battery laminate and a method for manufacturing a secondary battery laminate.

Background

Secondary batteries such as lithium ion secondary batteries are small and lightweight, have high energy density, and are capable of repeated charge and discharge, and are used in a wide range of applications. In general, a secondary battery includes a battery member such as a positive electrode, a negative electrode, and a separator for separating the positive electrode and the negative electrode from each other to prevent a short circuit between the positive electrode and the negative electrode.

Here, as the structure of the secondary battery, a laminate type in which a positive electrode, a separator, and a negative electrode are alternately laminated, and a winding type in which a long positive electrode, a long separator, and a long negative electrode are laminated and wound in concentric circles are known. In recent years, attention has been particularly paid to a laminated secondary battery from the viewpoint of excellent energy density, safety, quality, and durability.

As a method for manufacturing a laminated secondary battery, for example, a method of alternately laminating a first electrode and a second electrode, which are wrapped with a spacer, has been proposed (for example, see patent document 1). Specifically, in patent document 1, a laminated secondary battery is manufactured by sandwiching a first strip-shaped electrode web from both sides with a strip-shaped spacer roll having a plurality of folded portions formed in the short-side direction, bonding the first strip-shaped electrode web and the contact portion of the strip-shaped spacer roll, then cutting the first strip-shaped electrode web and the strip-shaped spacer roll at the folded portions, sealing the cut pieces (first electrodes) of the first strip-shaped electrode web at the folded portions of the spacers, and alternately laminating the obtained spacer seal of the first electrode and the second electrodes.

Disclosure of Invention

Problems to be solved by the invention

However, in the method for manufacturing a laminated secondary battery described in patent document 1, a first strip-shaped electrode roll and a strip-shaped separator roll having a folded portion, which are prepared in advance and have substantially the same length in the longitudinal direction, are bonded and cut to prepare a laminate of a first electrode and a separator. Therefore, in the technique described in patent document 1, when a plurality of stacked bodies are required to continuously manufacture the stacked secondary battery, the preparation, bonding, and cutting of each member (coil stock) need to be alternately repeated, and the stacked secondary battery cannot be continuously and efficiently manufactured.

In order to solve such a problem, it is conceivable to manufacture a laminate of an electrode and a separator by a roll-to-roll (roll) method using a long electrode roll wound in a roll and a long separator roll wound in a roll. However, in the laminated secondary battery, a laminate having a larger spacer size than the electrode is generally required from the viewpoint of safety such as prevention of short-circuiting, and when the laminate is manufactured by a roll-to-roll method, since the stacked electrode roll and spacer roll are cut, there is a problem that the sizes of the electrode and the spacer between the cut positions are the same.

Accordingly, an object of the present invention is to provide an apparatus and a method for manufacturing a secondary battery laminate for efficiently manufacturing a secondary battery laminate having a separator and an electrode, which can continuously and efficiently manufacture a laminated secondary battery.

Means for solving the problems

The present invention is directed to advantageously solve the above problems, and an apparatus for manufacturing a laminate for a secondary battery according to the present invention includes: an electrode roll formed by rolling a long electrode roll material into a roll shape; a separator roll formed by rolling a long separator roll material into a roll shape; a convex portion forming member arranging mechanism that arranges a convex portion forming member on at least one of a main surface of a spacer roll paid out from the spacer roll and a main surface of an electrode roll paid out from the electrode roll; a bonding mechanism that bonds the separator roll and the electrode roll with the projection forming member interposed therebetween, bends or bends the separator roll at a portion where the projection forming member is disposed to form a projection extending over the entire width of the separator roll, and bonds the separator roll and the electrode roll; and a cutting mechanism that cuts at least the electrode roll material portion of the bonded body of the separator roll material and the electrode roll material at the portion where the convex portion is provided. In this manner, by providing the bonding mechanism and the cutting mechanism, and bonding and cutting the separator roll discharged from the separator roll and the electrode roll discharged from the electrode roll, it is possible to continuously manufacture the secondary battery laminate. In addition, the lamination mechanism laminates the separator roll material and the electrode roll material with the convex portions (bent portions or curved portions) formed on the separator roll material, and the cutting mechanism cuts at least the electrode roll material portion at the portion where the convex portions are provided, thereby obtaining a laminate for a secondary battery having a larger size of the separator than the electrode. Therefore, the laminate for secondary batteries can be efficiently produced, and the laminated secondary batteries can be continuously and efficiently produced.

In the apparatus for manufacturing a secondary battery laminate according to the present invention, it is preferable that the convex portion forming member arranging means has a plurality of convex portion forming members having different surface areas, and the convex portion forming member arranging means arranges the convex portion forming members such that the surface areas of the convex portion forming members gradually increase or decrease in the direction in which the separator roll and the electrode roll are conveyed. By using the convex portion forming member arranging means for arranging the convex portion forming members such that the surface area of the convex portion forming members gradually increases or gradually decreases in the direction of conveyance of the separator roll and the electrode roll, a laminate can be obtained in which a plurality of electrodes are bonded to a long separator and the distance between the electrodes gradually increases or gradually decreases. Moreover, the laminated secondary battery can be efficiently and easily manufactured using the laminate.

In the apparatus for manufacturing a secondary battery laminate according to the present invention, it is preferable that a removing mechanism for removing the projection forming member is further provided between the bonding mechanism and the cutting mechanism. If the structure further including a removing mechanism for removing the projection forming member is adopted, the manufacturing time can be shortened as compared with the case where the projection forming member is removed after the bonded body is cut with the projection forming member interposed therebetween.

In the apparatus for manufacturing a secondary battery laminate according to the present invention, it is preferable that the removing means includes a removing portion that removes the projection forming member by removing. If the convex portion forming member is removed by pulling out the removing means, the manufacturing time can be further shortened, and the convex portion forming member can be reused.

Alternatively, in the apparatus for manufacturing a secondary battery laminate according to the present invention, it is preferable that the convex portion forming member is formed of a material that can be dissolved, melted, or sublimated, and the removing means has a removing portion that dissolves, melts, or sublimates the convex portion forming member and removes the same. If the projection forming member is formed of a material that can be dissolved, melted, or sublimated, and the projection forming member is dissolved, melted, or sublimated and removed by the removing mechanism, the projection forming member can be easily removed without applying a mechanical load to the bonded body.

In the apparatus for manufacturing a secondary battery laminate according to the present invention, it is preferable that the bonding means includes a bonding machine for bonding the separator roll and the electrode roll by sandwiching the separator roll and the electrode roll by a separator roll side pressing member and an electrode roll side pressing member, the separator roll side pressing member has a lower elastic modulus than the convex portion forming member, and the electrode roll side pressing member has a higher elastic modulus than the convex portion forming member. By providing the crimping machine having the spacer roll-side pressing member with a lower elastic modulus than the convex portion forming member and the electrode roll-side pressing member with a higher elastic modulus than the convex portion forming member, the spacer roll can be bent or curved along the outer shape of the convex portion forming member in a satisfactory manner.

In the apparatus for manufacturing a secondary battery laminate according to the present invention, the separator roll-side pressing member and the electrode roll-side pressing member are preferably pressure contact rollers. By using the pressure-bonding roller, the separator roll and the electrode roll can be continuously bonded more efficiently.

In the apparatus for manufacturing a secondary battery laminate according to the present invention, the convex portions include first convex portions and second convex portions extending over the entire width of the separator roll, and valley portions located between the first convex portions and the second convex portions. If the convex portion has a first convex portion, a second convex portion, and a valley portion, the bonded body of the separator roll material and the electrode roll material can be easily cut at the valley portion.

In addition, an object of the present invention is to advantageously solve the above-mentioned problems, and a method for manufacturing a laminate for a secondary battery according to the present invention includes: a step (A) for disposing a projection forming member on at least one of a main surface of a separator roll discharged from a separator roll formed by winding a long separator roll into a roll and a main surface of an electrode roll discharged from an electrode roll formed by winding a long electrode roll into a roll; a step B of joining the separator roll and the electrode roll with the projection forming member interposed therebetween, bending or curving the separator roll at a portion where the projection forming member is disposed to form a projection extending over the entire width of the separator roll, and bonding the separator roll and the electrode roll; and a step C of cutting at least the electrode roll portion of the bonded body of the separator roll and the electrode roll obtained in the step B at a portion where the convex portion is provided. In this manner, the separator roll discharged from the separator roll and the electrode roll discharged from the electrode roll are bonded and cut, and the secondary battery laminate can be continuously manufactured. In step B, the separator roll is bonded to the electrode roll with the projections (bent portions or bent portions) formed thereon, and in step C, at least the electrode roll is cut at the portions where the projections are provided, whereby a laminate for a secondary battery having a larger spacer size than the electrode can be obtained. Therefore, the laminate for secondary batteries can be efficiently produced, and the laminated secondary batteries can be continuously and efficiently produced.

Here, the method for producing a secondary battery laminate according to the present invention preferably further includes a step D of removing the projection forming member after the step B and before the step C. If the step D of removing the projection forming member is further provided, the manufacturing time can be shortened.

In the step D, the projection forming member is preferably removed by pulling out. If the projection forming member is removed by pulling out, the manufacturing time can be further shortened, and the projection forming member can be reused.

In the case where the projection forming member is formed of a material that can be dissolved, melted, or sublimated, it is preferable that the projection forming member be dissolved, melted, or sublimated and removed in the step D.

In the method for producing a laminate for a secondary battery according to the present invention, it is preferable that in the step B, an electrode roll-side pressing member having a higher elastic modulus than the projection forming member and a spacer roll-side pressing member having a lower elastic modulus than the projection forming member are used, and the spacer roll and the electrode roll are sandwiched and bonded. By using the electrode roll-material-side pressing member having a higher elastic modulus than the convex portion forming member and the spacer roll-material-side pressing member having a lower elastic modulus than the convex portion forming member, the spacer roll material and the electrode roll material are sandwiched and bonded to each other, and the spacer roll material can be bent or curved along the outer shape of the convex portion forming member.

In the method for producing a laminate for a secondary battery according to the present invention, the separator roll-side pressing member and the electrode roll-side pressing member are preferably pressure contact rollers. If the pressure-bonding roller is used, the separator roll and the electrode roll can be continuously bonded more efficiently.

In the method for producing a secondary battery laminate according to the present invention, it is preferable that, in the step a, the plurality of projection forming members having different surface areas are arranged such that the surface area of each projection forming member gradually increases or gradually decreases in the direction in which the separator roll and the electrode roll are conveyed, and in the step B, the plurality of projections are formed such that the surface area of each projection gradually increases or gradually decreases in the direction in which the separator roll is conveyed. In the step a, the plurality of projection forming members having different surface areas are arranged such that the surface area of each projection forming member gradually increases or gradually decreases in the direction of transport of the separator roll and the electrode roll, and in the step B, the plurality of projections are formed such that the surface area of each projection gradually increases or gradually decreases in the direction of transport of the separator roll, whereby a laminate in which the plurality of electrodes are bonded to the long separator and the distance between the electrodes gradually increases or gradually decreases can be obtained. Moreover, if the laminate is used, a laminate type secondary battery can be manufactured efficiently and easily.

In the method for producing a secondary battery laminate according to the present invention, it is preferable that the convex portions include first convex portions and second convex portions extending over the entire width of the separator roll, and valley portions located between the first convex portions and the second convex portions. If the convex portion has the first convex portion, the second convex portion, and the valley portion, the bonded body of the separator roll material and the electrode roll material can be easily cut at the valley portion in step C.

Effects of the invention

According to the present invention, it is possible to efficiently manufacture a secondary battery laminate having a separator and an electrode by using a manufacturing apparatus and a manufacturing method for a secondary battery laminate which can continuously and efficiently manufacture a laminate type secondary battery.

Drawings

Fig. 1 (a) is a cross-sectional view along the longitudinal direction of a first example of a bonded body of a separator roll and an electrode roll, fig. 1 (b) is a cross-sectional view along the longitudinal direction of a second example of a bonded body of a separator roll and an electrode roll, and fig. 1 (c) is a cross-sectional view along the longitudinal direction of a third example of a bonded body of a separator roll and an electrode roll.

Fig. 2 (a) is a cross-sectional view along the stacking direction of a first example of a secondary battery laminate, and fig. 2 (b) is a cross-sectional view along the stacking direction of a second example of a secondary battery laminate.

Fig. 3 is a cross-sectional view along the longitudinal direction of a third example of a laminate for a secondary battery.

Fig. 4 is an explanatory diagram illustrating a structure of an example of an electrode structure formed using the secondary battery laminate shown in fig. 2.

Fig. 5 is an explanatory diagram illustrating a process of forming an electrode structure using the secondary battery laminate shown in fig. 3.

Fig. 6 (a) to (c) are cross-sectional views along the longitudinal direction of the spacer roll, showing the shape of a modification of the convex portion formed by bending or curving the spacer roll.

Fig. 7 is an explanatory view showing a schematic configuration of a first example of an apparatus for manufacturing a secondary battery laminate.

Fig. 8 (a) is an explanatory view showing a schematic configuration of a first example of the projection forming member arranging mechanism, fig. 8 (b) is an explanatory view showing a schematic configuration of a second example of the projection forming member arranging mechanism, and fig. 8 (c) is an explanatory view showing a schematic configuration of a third example of the projection forming member arranging mechanism.

Fig. 9 is a perspective view showing a modification of the pressure roller shown in fig. 7.

Fig. 10 is an explanatory view showing a schematic configuration of a second example of an apparatus for manufacturing a secondary battery laminate.

Detailed Description

The method for producing a secondary battery laminate of the present invention can be used, for example, when producing a secondary battery laminate using the apparatus for producing a secondary battery laminate of the present invention. The produced laminate for a secondary battery is suitable for use in the production of a laminate-type secondary battery.

Here, in the apparatus and method for manufacturing a secondary battery laminate according to the present invention, a secondary battery laminate is generally continuously manufactured using an electrode roll in which a long electrode material is wound into a roll and a separator roll in which a long separator is wound into a roll. Specifically, in the manufacturing apparatus and the manufacturing method of the present invention, for example, the separator roll fed out from the separator roll and the electrode roll fed out from the electrode roll are bonded to each other so that the convex portion is positioned on the opposite side to the electrode roll side in a state where the convex portion extending over the entire width of the separator roll is formed by bending or curving the separator roll by using the bonding mechanism, thereby manufacturing the bonded body of the separator roll and the electrode roll. Then, for example, by using a cutting mechanism, both the separator roll and the electrode roll or only the electrode roll can be cut at the portion where the convex portion is provided, whereby a laminate for a secondary battery can be manufactured.

< electrode roll Material >

The electrode roll is not particularly limited, and for example, an electrode roll in which an electrode composite material layer containing an electrode active material and a binder is formed on one surface or both surfaces of a long current collector can be used. Also, known materials can be used as the materials of the current collector and the electrode composite layer.

< roll spacer >

The separator roll is not particularly limited, and a long porous member made of an organic material such as a microporous film or a nonwoven fabric containing a resin such as a polyolefin resin (for example, polyethylene, polypropylene, or the like) or an aromatic polyamide resin can be used.

The tensile modulus of elasticity of the spacer roll in the direction in which the spacer roll is unwound from the spacer roll (the transport direction) is preferably 400MPa or more and 4500MPa or less. The thickness of the spacer roll is usually 0.5 μm or more, preferably 1 μm or more, usually 40 μm or less, preferably 30 μm or less, and more preferably 20 μm or less. Here, in the present invention, "tensile elastic modulus of a spacer roll" means a tensile elastic modulus at a temperature of 23 ℃ measured according to JIS K7127.

< bonded body >

In the manufacturing apparatus and the manufacturing method of the present invention, the bonded body formed from the electrode roll and the spacer roll is not particularly limited, and has, for example, a structure showing a cross section in the longitudinal direction as shown in fig. 1 (a) to (c).

Here, the bonded body 1 shown in fig. 1a has a structure in which a separator roll 20 is bonded to one surface (upper side in fig. 1 a) of an electrode roll 10, the electrode roll 10 is formed by forming electrode composite material layers 12 on both surfaces of a current collector 11, and the separator roll 20 is formed by forming a plurality of projections (bent portions) 21 extending in a semicircular arc shape in cross section over the entire width at predetermined intervals.

The bonded body 1A shown in fig. 1 (b) has a structure in which a separator roll 20 is bonded to both surfaces of an electrode roll 10, the electrode roll 10 is formed by forming electrode composite material layers 12 on both surfaces of a current collector 11, and the separator roll 20 is formed by forming a plurality of projections (bent portions) 21 extending across the entire width and having a semicircular arc shape in cross section at predetermined intervals. In the bonded body 1A, the formation positions of the convex portions 21 of the spacer roll 20 bonded to the first surface of the electrode roll 10 are matched with the formation positions of the convex portions 21 of the spacer roll 20 bonded to the second surface of the electrode roll 10. That is, the convex portions 21 of the spacer roll 20 bonded to the first surface of the electrode roll 10 and the convex portions 21 of the spacer roll 20 bonded to the second surface of the electrode roll 10 face each other across the electrode roll 10. Further, the portions between the projections 21 of the separator roll 20 are bonded to the electrode roll 10.

Furthermore, the bonded body 1B shown in fig. 1c has a structure in which a separator roll 20 is bonded to one surface (the upper side of fig. 1 c) of an electrode roll 10, the electrode roll 10 being formed by forming electrode composite material layers 12 on both surfaces of a current collector 11, and the separator roll 20 being formed by forming a plurality of projections (bent portions) 21 extending in a semicircular arc shape in cross section over the entire width at predetermined intervals. In addition, in the bonded body 1B, a pattern (for example, a pattern configured by a combination of three convex portions 21A, 21B, and 21C which are sequentially enlarged in the drawing) in which the size of the convex portion 21 is gradually increased from the first side (the left side of (C) in fig. 1) to the second side (the right side of (C) in fig. 1) in the longitudinal direction is repeatedly provided. The portions of the separator roll 20 between the projections 21A, 21B, 21C are bonded to the electrode roll 10.

In fig. 1 (a) to (c), the electrode roll 10 has the electrode composite material layers 12 on both surfaces of the current collector 11, but the electrode roll may have the electrode composite material layers formed only on one surface of the current collector.

In fig. 1 (a) to (c), the projection 21 is illustrated as having a semicircular arc shape in cross section, but the shape of the projection may be any shape such as the shape illustrated in fig. 6 (a) to (c). Here, the convex portion 21D shown in fig. 6 (a) is triangular, the convex portion 21E shown in fig. 6 (b) is quadrangular, and the convex portion 21F shown in fig. 6 (c) is shaped to have a first convex portion 21a and a second convex portion 21c, and a valley portion 21b located between the first convex portion 21a and the second convex portion 21 c. In particular, if a shape having a first convex portion 21a and a second convex portion 21c adjacent to each other and a trough portion 21b located between the first convex portion 21a and the second convex portion 21c is adopted as shown in fig. 6 (c), the spacer roll 20 can be easily cut in the trough portion 21 b.

< laminate for Secondary Battery >

In the manufacturing apparatus and the manufacturing method of the present invention, the laminate for a secondary battery obtained by cutting at least the electrode roll portion of the laminate at the portion provided with the convex portion has the following configuration: the separator formed of a cut piece of the separator and having a size larger than that of the electrode is bonded to one surface or both surfaces of the electrode formed of the cut piece of the electrode roll, or a plurality of electrodes formed of the cut piece of the electrode roll are bonded to one surface of a long separator formed of the cut piece of the separator roll. Specifically, the secondary battery laminate is not particularly limited, and has, for example, a structure showing a cross section in the lamination direction in (a) and (b) in fig. 2, or a structure showing a cross section in the longitudinal direction in fig. 3.

Here, the laminate 2 for a secondary battery shown in fig. 2 (a) can be obtained, for example, by cutting the electrode roll 10 and the separator roll 20 of the laminate 1 shown in fig. 1 (a) at a position substantially in the center (top) of the convex portion 21. The secondary battery laminate 2 further includes: an electrode 10a formed by cutting a roll 10 of the electrode, and having electrode composite material layers 12a provided on both surfaces of a current collector 11 a; and a spacer 20a formed of a cut piece of the spacer roll 20, having a size larger than that of the electrode 10a, and attached to one surface (upper side of fig. 2 (a)) of the electrode 10 a.

In fig. 2 (a), the lengths of the portions of the spacers 20a protruding from the ends of the electrode 10a are approximately 1/2, which are the difference between the length of the protruding portion 21 cut in the bonded body 1 and the length of the electrode roll 10 at the position where the protruding portion 21 faces each other.

The laminate 2A for a secondary battery shown in fig. 2 (b) can be obtained by cutting the electrode roll 10 and the separator roll 20 of the laminate 1A shown in fig. 1 (b) at a position substantially in the center (top) of the convex portion 21, for example. The secondary battery laminate 2A further includes: an electrode 10a formed by cutting a roll 10 of the electrode, and having electrode composite material layers 12a provided on both surfaces of a current collector 11 a; and a spacer 20a formed of a cut piece of the spacer roll 20, having a size larger than that of the electrode 10a, and attached to both surfaces of the electrode 10 a.

In fig. 2 (b), the lengths of the portions of the spacers 20a protruding from the ends of the electrode 10a are approximately 1/2, which are the difference between the length of the protruding portion 21 cut in the bonded body 1A and the length of the electrode roll 10 at the position where the protruding portion 21 faces each other.

Further, if the secondary battery laminate 2 and the secondary battery laminate 2A are used, for example, as shown in fig. 4, lamination is performed, whereby an electrode structure usable for a laminate-type secondary battery can be produced.

In fig. 4, reference numeral 2 'denotes a negative electrode laminate, 10 a' denotes a negative electrode, 11a 'denotes a negative electrode current collector, 12 a' denotes a negative electrode composite material layer, 2 "denotes a positive electrode laminate, 10 a" denotes a positive electrode, 11a "denotes a positive electrode current collector, 12 a" denotes a positive electrode composite material layer, and 20a denotes a separator. In this example, the size of the positive electrode 10a ″ is made smaller than that of the negative electrode 10 a' in order to improve the safety of the secondary battery. Further, 11b is a positive electrode collector with a current lead-out terminal, and 11c is a negative electrode collector with a current lead-out terminal.

Further, the laminate 2B for a secondary battery shown in fig. 3 can be obtained by: for example, in the bonded body 1B shown in fig. 1 (C), the electrode roll 10 and the spacer roll 20 are cut at the substantially central (top) position of the convex portion 21A, and only the electrode roll 10 is cut at the position facing the substantially central (top) position of the convex portion 21B and the convex portion 21C. The secondary battery laminate 2B has the following structure: a plurality of (three in the drawing) electrodes 10a are bonded to one surface of a long separator 20a formed from cut pieces of a separator roll 20, the electrodes 10a are formed from the cut pieces of the electrode roll 10, and electrode composite material layers 12a are provided on both surfaces of a current collector 11 a.

In fig. 3, the distances L1 and L2 of the electrode 10a correspond to the lengths of the projections 21B and 21C that are not cut in the bonded body 1B, respectively.

Further, if the secondary battery laminate 2B is used, an electrode structure usable for a laminated secondary battery can be produced by laminating and winding as shown in fig. 5, for example. The electrode structure has a structure in which n first electrodes (negative electrodes or positive electrodes; negative electrodes 10 a' in the drawing) and n-1 second electrodes (positive electrodes or negative electrodes; positive electrodes 10a "in the drawing) are alternately laminated, and has a structure in which a first laminate in which n-1 first electrodes are bonded to one surface of a long spacer at predetermined intervals, and a second laminate in which n-1 second electrodes are bonded to one surface of the long spacer at predetermined intervals, and one first electrode is bonded to the other surface of the spacer so that the second electrode faces the other end side in the longitudinal direction are laminated and wound around the other end side in the longitudinal direction so that the spacer of the first laminate is positioned on one end side in the longitudinal direction of the first laminate and the second electrode faces the other end side in the longitudinal direction of the second laminate And (4) preparing the composition.

In other words, the electrode structure shown in fig. 5 includes: the first laminate is formed by bonding a plurality of first electrodes to one surface of an elongated first spacer while being separated from each other in the longitudinal direction of the first spacer, and the second laminate is formed by bonding a plurality of second electrodes to one surface of an elongated second spacer while being separated from each other in the longitudinal direction of the second spacer, and bonding one first electrode to the other surface of the second spacer so as to face a second electrode located on one end side in the longitudinal direction of the second spacer. The first spacer and the second spacer are wound around the first electrode of the second laminate as a winding center.

In the case of forming an electrode structure, the spacer may be loosened or tightened during winding, but the "predetermined interval" between adjacent electrodes generally means a length at which the first electrode and the second electrode can be vertically aligned, which is equal to or greater than the total thickness of all the electrodes and the spacer sandwiched between the electrodes during winding.

In fig. 5, reference numeral 2 'denotes a negative electrode laminate, 10 a' denotes a negative electrode, 2 ″ denotes a positive electrode laminate, 10a ″ denotes a positive electrode, and 20a denotes a separator. In this example, the negative electrode 10 a' located on one end side of the positive electrode laminate 2 ″ and facing the positive electrode 10a ″ with the separator 20a interposed therebetween can be disposed on the separator 20a by any method used in the production of secondary batteries. The distance between the electrodes (negative electrode 10a ', positive electrode 10a ") may be equal to or greater than the total thickness of the negative electrode 10a ', positive electrode 10 a", and separator 20a interposed between the electrodes during winding, and the length of the negative electrode 10a ' and positive electrode 10a "may be aligned in the vertical direction. In this example, the size of the positive electrode 10a ″ is smaller than that of the negative electrode 10 a' from the viewpoint of improving the safety of the secondary battery.

< apparatus and method for producing laminate for secondary battery >

The secondary battery laminate described above can be manufactured using, for example, the manufacturing apparatus 100 shown in fig. 7.

The manufacturing apparatus 100 shown in fig. 7 includes: an electrode roll 10' formed by rolling a long electrode roll 10 into a roll shape; a separator roll 20' formed by rolling a long separator roll 20 into a roll shape; a projection forming member arranging mechanism 90 that arranges the projection forming member 35 on the main surface of the electrode roll 10 fed out from the electrode roll 10'; a metal roller 30 and a rubber roller 40 as pressure contact rollers that nip and pressure contact the electrode roll 10 and the spacer roll 20; a removing mechanism 95 that removes the convex portion forming member 35; and a cutting mechanism 50 for cutting the bonded body of the separator roll 20 and the electrode roll 10. The removing mechanism 95 has a pulling-out portion (not shown) for pulling out the projection forming member 35. The manufacturing apparatus 100 further includes a transport roller 60 that transports the electrode roll 10 and the spacer roll 20, a tension buffer 70 that adjusts the tension of the spacer roll 20, and an acceleration device 80 that increases the transport speed of the spacer roll 20. The tension damper 70, the accelerator 80, the metal roller 30, and the rubber roller 40 function as a bonding means, and the separator roll 20 fed out from the separator roll 20 'and the electrode roll 10 fed out from the electrode roll 10' are bonded with the convex portion forming member 35 interposed therebetween, and the separator roll 20 is bent at a portion where the convex portion forming member 35 is disposed to form the convex portion 21 extending over the entire width of the separator roll 20, and in this state, the convex portion 21 is bonded so as to be positioned on the opposite side to the electrode roll 10 side. In the bonding mechanism, the metal roller 30 and the rubber roller 40 function as a crimping machine, the metal roller 30 is an electrode roll 10 side pressing member of the crimping machine, and the rubber roller 40 is a spacer roll 20 side pressing member of the crimping machine. Further, the metal roller 30 has a higher elastic modulus than the convex portion forming member 35, and the rubber roller 40 has a lower elastic modulus than the convex portion forming member 35. In the pressure-contact roller including the metal roller 30 and the rubber roller 40, when sandwiching the electrode roll 10, the projection forming member 35, and the spacer roll 20, the rubber roller 40 changes its shape according to the shape of the projection forming member 35 without substantially deforming the metal roller 30, and thereby the spacer roll 20 can be bent at the portion where the projection forming member 35 is arranged to form the projections 21 extending over the entire width of the spacer roll 20.

Here, the convex portion forming member 35, the convex portion forming member arranging mechanism 90, and the removing mechanism 95 will be specifically described with reference to the drawings and fig. 8 that have been described above.

Fig. 8 (a) to (c) are explanatory views showing schematic configurations of the first to third examples of the projection forming member arranging mechanism 90.

First, description is made with reference to fig. 8 (a). The projection forming member arranging mechanism includes an arranging portion 15 for arranging the projection forming member 35 on the main surface of the electrode roll 10. In this example, the convex portion forming member 35 is disposed on the main surface of the electrode roll 10 while the disposing part 15 moves at the same speed as the electrode roll 10, but in the manufacturing apparatus of the present invention, the convex portion forming member 35 may be disposed on the main surface of the electrode roll 10 in a state where the conveyance of the electrode roll 10 and the spacer roll 20 is stopped.

The protrusion forming member 35 has a protrusion having a shape (semi-circular arc shape) corresponding to the protrusion 21 of the bonded body 1 formed and cut in the manufacturing apparatus 100. As shown in fig. 8 (a), the projection forming member 35 is disposed over the entire width of the electrode roll 10. The projection forming member 35 is made of a material having a surface that is difficult to adhere, such as teflon (registered trademark), or a material having a coating that is difficult to adhere applied to the surface.

The removing mechanism 95 has a removing portion (not shown) for removing the projection forming member 35 by pulling. The protruding portion forming member 35 is pulled out by the pulling-out portion, and the protruding portion forming member 35 between the spacer roll 20 and the electrode roll 10 is removed. In addition, the removed convex portion forming member 35 can be reused in the convex portion forming member arranging mechanism 90. The removal unit 35 may be configured to include, for example, a linear guide, a ball screw, a table having a motor for rotating the ball screw, and a linear servo motor for operating the table.

Then, according to the manufacturing apparatus 100, for example, the bonded body 1 shown in fig. 1 (a) is formed and cut by the cutting mechanism 50, and the secondary battery laminate 2 shown in fig. 2 (a) can be obtained.

According to this manufacturing apparatus 100, the convex portion forming member 35 can be disposed on the main surface of the electrode roll 10 fed out from the electrode roll 10' (step (a)). The separator roll 20 and the electrode roll 10 can be joined with the projection forming member 35 interposed therebetween, and the projection 21 extending over the entire width of the separator roll 20 can be formed by bending the separator roll 20 at the portion where the projection forming member 35 is disposed, and in this state, the projection 21 can be bonded so as to be positioned on the opposite side of the electrode roll 10 (step (B)). The laminate of the separator roll 20 and the electrode roll 10 obtained in the step (B) is cut at the portion where the convex portion 21 is provided, whereby the laminate 2 for a secondary battery shown in fig. 2 (a) can be obtained (step (C)). Further, after the step (B) and before the step (C), the convex portion forming member 35 can be removed (step (D)). Therefore, a secondary battery laminate having a larger separator size than the electrode can be continuously produced. As a result, the laminated secondary battery can be continuously and efficiently manufactured.

Here, in the manufacturing apparatus 100, the convex portion forming member arranging mechanism 90 is used in order to manufacture the laminate 2 for a secondary battery shown in fig. 2 (a) so that the bonded body 1 shown in fig. 1 (a) can be formed and cut by the cutting mechanism 50, but in the case of manufacturing the laminate 2B for a secondary battery shown in fig. 3 by forming the bonded body 1B shown in fig. 1 (c), the convex portion forming member arranging mechanism shown in fig. 8 may be used instead of the convex portion forming member arranging mechanism 90.

Next, description will be given with reference to fig. 8 (b). The projection forming member arranging mechanism has a plurality of (4 in the drawing) projection forming members 35A, 35B, 35C, 35D. The surface areas of the projection forming members 35A, 35B, 35C, and 35D disposed on the main surface of the electrode roll 10 gradually decrease toward the conveying direction of the electrode roll 10. That is, the surface areas of the projection forming members 35A, 35B, 35C, and 35D arranged on the main surface of the electrode roll 10 are sequentially increased in size.

When the multilayer body 2B for a secondary battery shown in fig. 3 is manufactured using the projection forming member arrangement mechanism shown in fig. 8 (B), for example, the separator roll 20 and the electrode roll 10 shown in fig. 7 are joined with the projection forming members 35A, 35B, 35C, and 35D interposed therebetween. Namely, the following operations are repeated: the projection forming members 35A, 35B, 35C, 35D are sequentially arranged on the main surface of the electrode roll 10 at predetermined intervals, for example, and the spacer roll 20 is bent at the portions where the projection forming members 35A, 35B, 35C, 35D are arranged to form projections extending over the entire width of the spacer roll 20, and bonded. Further, after the projection forming members 35A, 35B, 35C, 35D are arbitrarily removed, the cutting mechanism 50 cuts the electrode roll 10 and the spacer roll 20 at the portions where the projections having the smallest surface area size formed by the projection forming member 35A are located, and the cutting mechanism 50 cuts only the electrode roll 10 at the portions where the projections formed by the projection forming members 35B, 35C, 35D are located. In this way, the secondary battery laminate 2B shown in fig. 3 can be efficiently obtained, and the electrode structure shown in fig. 5 can be produced, whereby the laminated secondary battery can be continuously and efficiently produced.

The cutting mechanism 50 can cut the electrode roll 10 by, for example, providing a cutting blade (not shown) on the opposite side of the electrode roll 10 from the spacer roll 20 and moving the cutting blade to a position between the electrode roll 10 and the convex portion of the spacer roll 20.

In the case where the laminate 2 for a secondary battery shown in fig. 2 (a) is manufactured by forming a bonded body having the convex portion 21F having the shape shown in fig. 6 (c), the convex portion forming member arranging mechanism shown in fig. 8 (c) may be used instead of the convex portion forming member arranging mechanism 90 shown in fig. 7.

Next, description will be given with reference to (c) of fig. 8. The projection forming member arranging mechanism has a projection 35F, and the projection 35F has: the first and second convex portions 35a and 35c having shapes corresponding to the first and second convex portions 21a and 21c shown in fig. 6 (c), and the groove portion 35b having a shape corresponding to the valley portion 21b shown in fig. 6 (c) and located between the first and second convex portions 35a and 35c adjacent to each other.

When the laminate 2 for a secondary battery shown in fig. 2 (a) is manufactured by forming a bonded body having the convex portions 21F of the shape shown in fig. 6 (c) using the convex portion forming member arranging mechanism shown in fig. 8 (c), for example, the separator roll 20 and the electrode roll 10 are joined with the convex portion forming member 35F interposed therebetween, the separator roll 20 is bent at the portion where the convex portion forming member 35F is arranged to form the convex portions extending over the entire width of the separator roll 20 and bonded together, and the cutting mechanism cuts the electrode roll 10 and the separator roll 20 at the positions of the valley portions 21b of the convex portions 21F. In this way, the secondary battery laminate 2 having a larger spacer size than the electrode can be continuously manufactured. As a result, the laminated secondary battery can be continuously and efficiently manufactured.

In the above description, the case of manufacturing the secondary battery laminate 2 in which the convex portions are formed using the convex portion forming member 35 disposed on the main surface of the electrode roll 10 has been described, but for example, in the manufacturing apparatus 100, the secondary battery laminate shown in fig. 1 and the like can be manufactured by using the metal roller 40A shown in fig. 9 instead of the rubber roller 40.

Here, the description will be specifically made with reference to fig. 1, 7, and 9. The metal roller 40A has a concave portion 41 having a shape (semi-circular arc shape) corresponding to the convex portion 21 of the bonded body 1 formed and cut in the manufacturing apparatus 100. As shown in fig. 9, the concave portion 41 of the metal roller 40A is provided over the entire width of the metal roller 40A.

The tension damper 70, the accelerator 80, the metal roller 30, and the metal roller 40A function as a bonding means, and the separator roll 20 fed out from the separator roll 20 'and the electrode roll 10 fed out from the electrode roll 10' are bonded so that the convex portions 21 are positioned on the opposite side of the electrode roll 10 side in a state where the convex portions 21 extending over the entire width of the separator roll 20 are formed by pressing and bending the separator roll 20 into the concave portions 41 of the metal roller 40A by using the convex portion forming member 35.

According to the manufacturing apparatus having the metal roller 40A, the spacer roll 20 fed out from the spacer roll 20 'shown in fig. 7 and the electrode roll 10 fed out from the electrode roll 10' can be bonded so that the convex portion 21 is positioned on the opposite side to the electrode roll 10 side in a state where the spacer roll 20 is bent using the concave portion 41 and the convex portion forming member 35 of the metal roller 40A to form the convex portion 21 extending over the entire width of the spacer roll 20. The obtained laminate of the separator roll 20 and the electrode roll 10 is cut at the portion where the convex portion 21 is provided, whereby the secondary battery laminate 2 shown in fig. 2 (a) can be obtained. Therefore, a secondary battery laminate having a larger separator size than the electrode can be continuously produced. As a result, the laminated secondary battery can be continuously and efficiently manufactured.

In the above description, the case where the laminate for a secondary battery in which the separator is bonded to one surface of the electrode roll 10 by bonding the separator roll 20 to form the bonded body and the separator is bonded to one surface of the electrode by cutting with the cutting mechanism has been described, for example, the manufacturing apparatus 100A shown in fig. 10 can be used in the case where the laminate for a secondary battery 2A shown in fig. 2 (b) is manufactured by bonding the separator roll 20 to both surfaces of the electrode roll 10 to form the bonded body.

In fig. 10, the same reference numerals as in fig. 7 are assigned to members having the same configurations as in fig. 7, and the description thereof will be omitted.

Further, according to the manufacturing apparatus 100A, the convex portion forming members 35 can be disposed on both the principal surfaces of the electrode roll 10 discharged from the electrode roll 10' (step (a)). The separator roll 20 and the electrode roll 10 are joined with the projection forming member 35 interposed therebetween by using a pressure-contact roller composed of two rubber rollers 40, and the separator roll 20 is bent at a portion where the projection forming member 35 is disposed to form the projections 21 extending over the entire width of the separator roll 20, and then the projections 21 are bonded so as to be positioned on the opposite side of the electrode roll 10 (step (B)). The laminate of the separator roll 20 and the electrode roll 10 obtained in the step (B) is cut at the portion where the convex portion 21 is provided, whereby the laminate 2 for a secondary battery shown in fig. 2 (B) can be obtained (step (C)). Further, after the step (B) and before the step (C), the convex portion forming member 35 can be removed (step (D)). Therefore, a secondary battery laminate having a larger separator size than the electrode can be continuously produced. As a result, the laminated secondary battery can be continuously and efficiently manufactured.

In the manufacturing apparatus 100A, the bonded body having the convex portions 21 on both surfaces is conveyed without particular limitation, and for example, it can be conveyed by using a lift-type conveying mechanism such as a conveying roller or an air-lift roller having a concave portion with a shape corresponding to the shape of the convex portion 21.

The apparatus and the method for manufacturing a secondary battery laminate according to the present invention have been described above by way of example, but the apparatus and the method for manufacturing a secondary battery laminate according to the present invention are not limited to the above examples.

For example, the convex portion forming member may be formed of a material that can dissolve, melt, or sublimate the convex portion forming member, and any removing mechanism that removes the convex portion forming member may be configured to have a removing portion that dissolves, melts, or sublimates the convex portion forming member to remove. In this case, as a material for forming the projection forming member, for example, a material having a surface which is difficult to adhere such as teflon (registered trademark) or a material having a coating which is difficult to adhere applied to the surface, dry ice or the like can be given. In addition, as a method for dissolving, melting, or sublimating the projection forming member, there are a method in which the projection forming member is fed into an immersion tank together with an electrode roll and a separator roll joined to each other with the projection forming member therebetween, and immersed in a solvent such as an electrolytic solution (ethylene carbonate), a method in which the projection forming member is fed into a heating furnace together with the electrode roll and the separator roll joined to each other with the projection forming member therebetween, and heated, and the like. In these methods, the convex portion forming member can be removed without applying mechanical loads such as stress and friction to the spacer roll and the electrode roll at the time of pulling out, as compared with the case of pulling out the convex portion forming member.

The pressure-contact roller usable as the bonding means is not limited to the above-described configuration, and any roller may be used in combination as long as the roller positioned on the separator roll side is changed in accordance with the shape of the protrusion-forming member and the roller positioned on the electrode roll side is not substantially deformed when the electrode roll, the protrusion-forming member, and the spacer roll are sandwiched, and the protrusion extending over the entire width of the spacer roll is formed by bending the spacer roll at the portion where the protrusion-forming member is arranged.

Further, the following method is also possible: for example, the projection forming member is constituted by a first member arranged on the main surface of the spacer and a second member arranged on the main surface of the electrode roll, and the first member and the second member case constitute the projection forming member only when the spacer roll and the electrode roll are joined.

For example, a die or the like may be used as a crimping machine for sandwiching and bonding the spacer roll and the electrode roll.

Further, when the bonded body is difficult to form, convey, and cut while maintaining the shape of the convex portion because the spacer roll is soft, such as when the tensile elastic modulus in the conveyance direction of the spacer roll is 400MPa to 4500MPa, and/or when the thickness of the spacer roll is 0.5 μm to 40 μm, the spacer roll may be heated in the concave portion to apply a crease. The convex portion forming member is not removed, and may be taken out when the electrode roll 10 is cut by the cutting mechanism, or may be cut together with the electrode roll and the spacer roll 20. Further, the removing means of the present invention may be provided downstream of the cutting means, not between the bonding means and the cutting means. In this way, when cutting is performed by the cutting mechanism, the convex portion forming member is interposed between the separator roll and the electrode roll, and thus no hollow portion exists between the separator roll and the electrode roll, which facilitates cutting. In addition, when the projection forming member is removed by dissolution or the like, the cutting is facilitated because the hollow member does not exist as described above, and the influence of the burr can be avoided by preventing the metal burr on the cross section at the time of cutting.

Industrial applicability

According to the manufacturing apparatus and the manufacturing method of the present invention, it is possible to continuously and efficiently manufacture the laminated secondary battery, and it is possible to efficiently manufacture the laminated body for the secondary battery having the separator and the electrode.

Description of the reference numerals

1. 1A, 1B: bonded body

2. 2A, 2B: laminate for secondary battery

2': negative electrode laminate

2": positive electrode laminate

10: electrode coil stock

10 a: electrode for electrochemical cell

10 a': negative electrode

10 a': positive electrode

10': electrode roll

11: current collector

11 a: current collector

11 a': negative electrode current collector

11 a': positive electrode current collector

11 b: positive electrode collector with current leading-out terminal

11 c: negative electrode collector with current leading-out terminal

12: electrode composite layer

12 a: electrode composite layer

12 a': negative electrode composite material layer

12 a': positive electrode composite material layer

15: arrangement part

20: spacer roll

20 a: spacer member

20': spacer roll

21: convex part

21A, 21B, 21C, 21D, 21E, 21F: convex part

21 a: first convex part

21 b: trough part

21 c: second convex part

30: metal roller

35: convex part forming member

35 a: first convex part

35 b: trough part

35 c: second convex part

40A: metal roller

41 a: first concave part

41 c: second concave part

50: cutting mechanism

60: transfer roll

70: tension buffer

80: accelerating device

90: convex part forming member arranging mechanism

95: removing mechanism

100. 100A: manufacturing apparatus