Bonding body manufacturing apparatus and bonding body manufacturing method

Abstract

The present invention provides a bonded body manufacturing apparatus and a bonded body manufacturing method. The roller conveyance unit (48) of the bonded body manufacturing apparatus (10) has a rotating unit (56) and a suction unit (58). The outer peripheral surface of the rotating unit (56) has a contact suction unit (88) that contacts the first back surface (38). The rotating unit (56) rotates while the contact suction unit (88) contacts the first back surface (38). The suction unit (58) sucks the second layer (14) through the pores of the first layer (12) from the contact suction unit (88), thereby forming a sucked portion (112) that is attracted to the contact suction unit (88) on the laminate of the first layer (12) and the second layer (14). The peeling unit (50) peels the cover film (46) from the second back surface (44) of the sucked portion (112) of the tape film bonded body (52). Accordingly, a high-quality bonded body can be efficiently manufactured.

Description

Technical Field

[0001] The present invention relates to an assembly manufacturing apparatus and an assembly manufacturing method. Background Art

[0002] For example, in Japanese Patent Application Laid-Open No. 2019-8995, an apparatus for manufacturing a membrane electrode assembly for a fuel cell by joining a porous electrode and a non-porous electrolyte membrane is proposed. Summary of the Invention

[0003] As described above, in the case of obtaining an assembly by joining a porous first layer and a non-porous second layer, it is required to improve the manufacturing efficiency of the assembly. Therefore, it is considered that the first joint surface of the first layer and the second joint surface of the second layer are continuously joined during the conveyance of the first layer and the second layer by a roller conveyance unit. In this case, for example, from the viewpoint of protecting the second layer, the second layer is supplied to the roller conveyance unit in a state where a covering film is peelably attached to the back surface of the second joint surface. The covering film temporarily protects the second layer and is not a constituent element of the assembly. Therefore, the covering film peels off from the second layer after the first joint surface and the second joint surface are joined.

[0004] However, as the covering film is peeled off from the second layer, the covering film stretches the second layer in a direction away from the first layer. At this time, forces in directions separating from each other act on the first joint surface and the second joint surface. When this force exceeds the joining force between the first joint surface and the second joint surface, for example, it is possible that the first joint surface and the second joint surface peel off, and the quality of the assembly deteriorates.

[0005] An object of the present invention is to solve the above-described technical problems.

[0006] One aspect of the present invention is a bonding body manufacturing apparatus that manufactures a bonding body from a porous first layer and a non-porous second layer. The first layer has a first bonding surface and a first back surface that is the back of the first bonding surface. The second layer has a second bonding surface and a second back surface that is the back of the second bonding surface. A covering film is peelably adhered to the second back surface. The bonding body manufacturing apparatus has a roll conveying unit and a peeling unit. The roll conveying unit continuously bonds the first bonding surface and the second bonding surface in a stacked state to form a film-bonded body during the conveyance of the first layer and the second layer. The peeling unit peels the covering film from the second back surface of the film-bonded body to obtain a bonding body. The roll conveying unit has a rotating unit and a suction unit. The outer peripheral surface of the rotating unit has a contact suction part that contacts the first back surface. The rotating unit rotates while the contact suction part contacts the first back surface. The suction unit sucks the second layer through the pores of the first layer via the contact suction part, thereby forming a sucked part attracted to the contact suction part on the laminate of the first layer and the second layer. The peeling unit peels the covering film from the second back surface of the sucked part of the film-bonded body.

[0007] Another aspect of the present invention is a bonding body manufacturing method that manufactures a bonding body from a porous first layer and a non-porous second layer. The first layer has a first bonding surface and a first back surface that is the back of the first bonding surface. The second layer has a second bonding surface and a second back surface that is the back of the second bonding surface. A covering film is peelably adhered to the second back surface. In the bonding body manufacturing method, during the conveyance of the first layer and the second layer by a roll conveying unit, the first bonding surface and the second bonding surface in a stacked state are continuously bonded to form a film-bonded body. Then, the covering film is peeled from the second back surface of the film-bonded body to manufacture a bonding body. The roll conveying unit has a rotating unit that rotates. The bonding body manufacturing method has the following steps: a step of rotating the rotating unit while the contact suction part provided on the outer peripheral surface of the rotating unit contacts the first back surface of the laminate of the first layer and the second layer; a step of forming a sucked part attracted to the contact suction part on the laminate of the first layer and the second layer by a suction unit that sucks the second layer through the pores of the first layer via the contact suction part; a step of peeling the covering film from the second back surface of the sucked part of the film-bonded body by a peeling unit.

[0008] In the present invention, while the first layer and the second layer are being conveyed by the roller conveyance unit, the first joint surface and the second joint surface in the stacked state are continuously joined to obtain a film laminate. The cover film is peeled off from the second back surface of the film laminate to manufacture the laminate. Therefore, the laminate can be efficiently manufactured while protecting the second layer with the cover film.

[0009] In addition, the rotating part of the roller conveyance unit rotates while the contact suction part is in contact with the first back surface. The suction part sucks the second layer through the pores of the first layer via the contact suction part. As a result, a sucked part that is attracted to the contact suction part is formed on the laminate of the first layer and the second layer. That is, on the sucked part, the second joint surface of the second layer is pressed against the first joint surface of the first layer by the suction force of the suction part.

[0010] The peeling part peels off the peeling film from the second back surface of the sucked part to obtain the laminate. In this case, even if the cover film stretches the second layer in a direction away from the first layer as the cover film is peeled off from the second back surface, it is possible to suppress the peeling of the first joint surface and the second joint surface. As a result, a high-quality laminate in which the first joint surface and the second joint surface are well joined can be obtained. Therefore, according to the present invention, a high-quality laminate can be efficiently manufactured.

[0011] The above objects, features, and advantages should be easily understood from the following description of the embodiments with reference to the drawings. Description of the Drawings

[0012] Figure 1 is a schematic structural diagram of a laminate manufacturing apparatus according to an embodiment of the present invention.

[0013] Figure 2 is along Figure 1 a cross-sectional view taken along the radial direction of the rotating part of.

[0014] Figure 3 is Figure 2 a cross-sectional view taken along the III-III direction of.

[0015] Figure 4A is by Figure 1 a schematic cross-sectional view of a laminate manufactured by the laminate manufacturing apparatus of. Figure 4B is having Figure 4A a schematic cross-sectional view of a membrane electrode assembly of a laminate of.

[0016] Figure 5 is a schematic structural diagram of a laminate manufacturing apparatus according to a modified example.

[0017] Figure 6 is along Figure 5 a cross-sectional view taken along the radial direction of the rotating part of.

[0018] Figure 7 It is a schematic structural diagram of a bonded body production apparatus according to another modified example.

[0019] Figure 8 It is along Figure 7 A radial cross-sectional view of a rotating portion.

[0020] Figure 9 yes Figure 8 A cross-sectional view taken along the IX-IX line. DETAILED DESCRIPTION

[0021] In the following drawings, the same reference numerals are given to components that are the same or that achieve similar functions and effects, and duplicate descriptions may be omitted.

[0022] Figure 1 The assembly manufacturing apparatus 10 according to the present embodiment shown in the figure manufactures an assembly 16 from a porous first layer 12 and a non-porous second layer 14. Preferred examples of the first layer 12 include a solid polymer fuel cell (not shown). Figure 4B The material of the anode electrode 18 or the cathode electrode 20 is preferably Figure 4B Therefore, in the following, an example in which the first layer 12 is a material of the anode electrode 18 and the second layer 14 is a material of the electrolyte membrane 22 will be described.

[0023] However, the first layer 12 is not limited to the material of the anode electrode 18. For example, the first layer 12 may also be the material of the cathode electrode 20. In addition, the first layer 12 may not be a component of the solid polymer fuel cell. As the first layer 12, various porous structures can be used. Porosity here means that it has air permeability by having a plurality of pores. The second layer 14 is not limited to the material of the electrolyte membrane 22. As the second layer 14, various non-porous structures can be used. Non-porosity here means that it has no air permeability or has an air permeability lower than that of the first layer 12.

[0024] like Figure 4B As shown, Figure 4A The joint body 16 is joined with the material of the cathode electrode 20 to form a membrane electrode assembly 24. The membrane electrode assembly 24 is clamped by separators not shown in the figure to form a power generation cell (single fuel cell). A fuel cell stack is formed by stacking a plurality of power generation cells. The fuel cell stack can be carried on a fuel cell vehicle such as a fuel cell electric vehicle. In addition, the fuel cell stack can also be carried on a carrier other than a fuel cell vehicle. In addition, the fuel cell stack can also be used as a fixed type.

[0025] like Figure 4BAs shown, the electrolyte membrane 22 is a solid polymer electrolyte membrane (cation exchange membrane) such as a thin film of perfluorosulfonic acid containing moisture. In the present embodiment, the electrolyte membrane 22 is made of an ionomer. In the membrane electrode assembly 24, the electrolyte membrane 22 is sandwiched between the anode electrode 18 and the cathode electrode 20. In addition to fluorine-based electrolytes, the electrolyte membrane 22 may also use HC (hydrocarbon)-based electrolytes.

[0026] The anode electrode 18 has a porous anode gas diffusion layer 26 and a porous anode electrode catalyst layer 28. The anode electrode catalyst layer 28 is joined to one surface of the anode gas diffusion layer 26 in a stacked state. For example, porous carbon particles supporting a platinum alloy on the surface are uniformly coated on the surface of the anode gas diffusion layer 26 together with an ion-conductive polymer binder. Thereby, the anode electrode catalyst layer 28 can be formed on one surface of the anode gas diffusion layer 26. In the present embodiment, the material of the anode electrode catalyst layer 28 contains an ionomer.

[0027] The cathode electrode 20 has a porous cathode gas diffusion layer 30 and a porous cathode electrode catalyst layer 32. The cathode electrode catalyst layer 32 is joined to one surface of the cathode gas diffusion layer 30 in a stacked state. For example, porous carbon particles supporting a platinum alloy on the surface are uniformly coated on the surface of the cathode gas diffusion layer 30 together with an ion-conductive polymer binder. Thereby, the cathode electrode catalyst layer 32 can be formed on one surface of the cathode gas diffusion layer 30. The cathode electrode catalyst layer 32 is preferably formed of a material containing an ionomer.

[0028] The cathode gas diffusion layer 30 and the anode gas diffusion layer 26 are each formed of a conductive porous sheet material such as carbon paper or carbon cloth. In addition, a porous layer (not shown) may be provided on at least one of the interfaces between the cathode electrode catalyst layer 32 and the cathode gas diffusion layer 30 and between the anode electrode catalyst layer 28 and the anode gas diffusion layer 26.

[0029] As Figure 4A shown, the joined body 16 is obtained by joining the first layer 12, which is the material of the anode electrode 18, and the second layer 14, which is the material of the electrolyte membrane 22. By joining this joined body 16 with the material of the cathode electrode 20, the membrane electrode assembly 24 as Figure 4B shown is obtained.

[0030] As Figure 1 shown, the first layer 12 is prepared in a state of being wound around the first core 34, for example, with a length capable of forming a plurality of anode electrodes 18. The first layer 12 has a first joining surface 36 and a first back surface 38 that is the back of the first joining surface 36. The first joining surface 36 is the surface of the material of the anode electrode catalyst layer 28. The first back surface 38 is the surface of the material of the anode gas diffusion layer 26.

[0031] The second layer 14 is, for example, of a length capable of forming a plurality of electrolyte membranes 22 and is prepared in a state of being wound around the second core 40. In the present embodiment, the second layer 14 is softened by heating. The second layer 14 has a second bonding surface 42 and a second back surface 44 that is the back surface of the second bonding surface 42. A covering film 46 is detachably pasted on the second back surface 44. In the present embodiment, the covering film 46 is in the form of a film that continuously covers the entire second back surface 44. Further, the covering film 46 is formed of, for example, a flexible resin or the like.

[0032] The covering film 46 is not a component of the joined body 16 and the membrane electrode assembly 24. The covering film 46 is pasted on the second back surface 44 in order to protect the second layer 14 during the period from the second layer 14 to the formation of the joined body 16. Therefore, the covering film 46 is peeled off from the second back surface 44 after the second layer 14 is joined to the first layer 12. Further, from the viewpoint of protecting the second layer 14 well, in the second layer 14 in a state of being wound around the second core 40, it is preferable that the second back surface 44 covered by the covering film 46 faces the outside in the radial direction of the second core 40.

[0033] While referring to Figures 1 - 3 , the joined body manufacturing apparatus 10 according to the present embodiment will be described. As Figure 1 shown, the joined body manufacturing apparatus 10 has a roll conveying unit 48 and a peeling unit 50. The roll conveying unit 48 continuously joins the first bonding surface 36 and the second bonding surface 42 in a stacked state during the conveyance of the first layer 12 and the second layer 14 to form a film-joined body 52. That is, the covering film 46 is pasted on the second back surface 44 of the film-joined body 52. The peeling unit 50 peels the covering film 46 from the second back surface 44 of the film-joined body 52 to obtain the joined body 16.

[0034] Specifically, the roll conveying unit 48 has a conveying mechanism 54, a rotating unit 56, a suction unit 58, and a heating unit 60. The conveying mechanism 54 has a first unwind roll 62, a second unwind roll 64, a first guide roll 66, a second guide roll 68, a joined body winding roll 70, and a third guide roll 72.

[0035] The first unwind roll 62 rotatably supports the first core 34. When the first unwind roll 62 rotates, the first layer 12 is supplied from the first core 34 to the rotating unit 56. In the present embodiment, the first layer 12 is supplied to the rotating unit 56 with the first bonding surface 36 facing upward and the first back surface 38 facing downward. The second unwind roll 64 rotatably supports the second core 40. When the second unwind roll 64 rotates, the second layer 14 is supplied from the second core 40 to the rotating unit 56. In the present embodiment, the second layer 14 is supplied to the rotating unit 56 with the second bonding surface 42 facing downward and the second back surface 44 covered by the covering film 46 facing upward.

[0036] The first guide roller 66 is interposed between the first unwinding roller 62 and the rotating portion 56 to guide the conveyance of the first layer 12. The second guide roller 68 is interposed between the second unwinding roller 64 and the rotating portion 56 to guide the conveyance of the second layer 14.

[0037] The bonded body winding roller 70 rotatably supports the third core 73. When the bonded body winding roller 70 rotates, the bonded body 16 obtained by the rotating portion 56 and the peeling portion 50 is wound around the third core 73. The third guide roller 72 is interposed between the rotating portion 56 and the bonded body winding roller 70 to guide the conveyance of the bonded body 16.

[0038] As Figure 2 and Figure 3 shown, the rotating portion 56 has a rotating portion main body 74 and a support shaft portion 76. As Figure 3 shown, the rotating portion main body 74 is substantially cylindrical and extends along the axial direction of the rotating portion main body 74. A hollow portion 78 is formed inside the rotating portion main body 74. One end surface in the axial direction of the rotating portion main body 74 is closed by a closing portion 80. A shaft portion 82 protruding toward the outside of the rotating portion main body 74 is provided at the radial center of the closing portion 80. The shaft portion 82 extends along the axial direction of the rotating portion main body 74. The shaft portion 82 is rotatably supported by a support mechanism (not shown) through a first bearing 84, for example.

[0039] A cylindrical protruding portion 86 is provided at the other end in the axial direction of the rotating portion main body 74. The outer diameter of the protruding portion 86 is smaller than the outer diameter of the rotating portion main body 74. In addition, the inner diameter of the protruding portion 86 is smaller than the inner diameter of the rotating portion main body 74. The inside of the protruding portion 86 communicates with the hollow portion 78.

[0040] The outer peripheral surface of the rotating portion main body 74 has a contact suction portion 88. When the roller conveyor portion 48 in Figure 1 conveys the first layer 12 and the second layer 14, the rotating portion main body 74 rotates while bringing the contact suction portion 88 into contact with the first back surface 38. In other words, when the outer peripheral surface of the rotating rotating portion main body 74 passes through the position where it is in contact with the first back surface 38, the outer peripheral surface of the rotating portion main body 74 constitutes the contact suction portion 88.

[0041] As Figure 3 shown, in the rotating portion main body 74, the outer diameter of the central portion in the axial direction of the contact suction portion 88 is smaller than the outer diameters of both end portions in the axial direction of the contact suction portion 88. Therefore, when viewed along the radial direction of the rotating portion 56, the contact suction portion 88 is curved in a direction in which the central portion of the contact suction portion 88 is recessed more than both end portions in the axial direction of the contact suction portion 88.

[0042] The rotating part main body 74 has a plurality of through holes 90 that communicate the inside and the outside of the hollow part 78. In addition, the number and shape of the through holes 90 are not particularly limited. In the present embodiment, the through holes 90 are formed along the entire circumferential direction of the rotating part main body 74. Further, the through holes 90 are formed along the entire axial direction of the contact suction part 88.

[0043] The support shaft part 76 supports the rotating part main body 74 in a rotatable manner. In addition, the rotating part main body 74 can be rotationally driven by a motor (not shown) or the like. Further, the rotating part main body 74 can also rotate, for example, by contacting the first back surface 38 of the first layer 12 conveyed by the conveying mechanism 54.

[0044] The support shaft part 76 has an insertion part 92 disposed inside the hollow part 78 of the rotating part main body 74. The insertion part 92 extends along the axial direction of the rotating part main body 74. The support shaft part 76 is supported by a support mechanism (not shown) in a non-rotating state. The insertion part 92 is provided at one end part in the extending direction of the support shaft part 76. The support shaft part 76 has a small-diameter part 94 extending from the insertion part 92. The small-diameter part 94 is disposed inside the protruding part 86 of the rotating part main body 74. The outer diameter of the small-diameter part 94 is smaller than the inner diameter of the protruding part 86. A second bearing 96 is provided between the outer peripheral surface of the small-diameter part 94 and the inner peripheral surface of the protruding part 86. Thus, the rotating part main body 74 is supported by the support shaft part 76 in a rotatable manner.

[0045] The insertion part 92 has a suction chamber 98 in a part that faces the contact suction part 88 from the inside of the hollow part 78. The suction chamber 98 is formed in a shape obtained by cutting the insertion part 92 in a direction from the outside in the radial direction of the insertion part 92 toward the center. Further, the suction chamber 98 communicates with a through hole 90 provided at the axial center part (a communication area 100 described later) of the contact suction part 88. In the axial direction of the insertion part 92, shielding parts 102 are provided outside both ends of the suction chamber 98. The outer diameter of the shielding parts 102 is set to be slightly smaller than the inner diameter of the rotating part main body 74. Therefore, the shielding parts 102 shield the communication between these through holes 90 and the suction chamber 98 by facing the through holes 90 provided at both end parts (a non-communication area 104 described later) in the axial direction of the contact suction part 88.

[0046] The insertion part 92 has a heating chamber 106 provided independently of the suction chamber 98. As Figure 2 shown, the heating chamber 106 is disposed at a position separated from the suction chamber 98 in a direction opposite to the rotation direction of the rotating part main body 74. The heating chamber 106 is formed in a shape obtained by cutting the insertion part 92 in a direction from the outside in the radial direction of the insertion part 92 toward the center. Further, as Figure 3As shown, the heating chamber 106 communicates with the through-hole 90 disposed along the entire axial direction of the rotating portion main body 74. Therefore, the length of the heating chamber 106 in the axial direction of the insertion portion 92 is longer than the length of the suction chamber 98 in the axial direction of the insertion portion 92.

[0047] The support shaft portion 76 also has a suction path 108 and a hot air supply path 110. The suction path 108 extends in such a manner as to pass through the inside of the small-diameter portion 94 from the suction chamber 98. In addition, as Figure 1 shown, the end portion of the suction path 108 opposite to the suction chamber 98 is connected to the suction portion 58 disposed outside the support shaft portion 76. That is, the suction path 108 communicates the suction chamber 98 with the suction portion 58. As Figure 3 shown, the hot air supply path 110 extends in such a manner as to pass through the inside of the small-diameter portion 94 from the heating chamber 106. In addition, as Figure 1 shown, the end portion of the hot air supply path 110 opposite to the heating chamber 106 is connected to the heating portion 60 disposed outside the support shaft portion 76. That is, the hot air supply path 110 communicates the heating chamber 106 with the heating portion 60.

[0048] As Figure 1 shown, when the first layer 12 and the second layer 14 separately conveyed by the conveying mechanism 54 reach the contact suction portion 88 of the rotating portion 56, the first layer 12 and the second layer 14 are in a state of a laminate formed by laminating the first joint surface 36 and the second joint surface 42. As Figure 2 and Figure 3 shown, the suction portion 58 sucks the second layer 14 through the pores of the first layer 12 via the contact suction portion 88, thereby forming a sucked portion 112 attracted to the contact suction portion 88 on the laminate of the first layer 12 and the second layer 14.

[0049] Specifically, the suction portion 58 sucks the suction chamber 98 via the suction path 108 to make it negative pressure. That is, the suction portion 58 forms a negative pressure portion 99 in the suction chamber 98 within the hollow portion 78. Thereby, in the contact suction portion 88, the laminate is sucked via the through-hole 90 communicating with the negative pressure portion 99, thereby forming the sucked portion 112. In addition, as the suction portion 58, for example, a known structure such as a suction pump can be used.

[0050] In the suctioned portion 112, the second layer 14 is sucked toward the contact suction portion 88 via the first layer 12 by the suction force of the suction portion 58. Therefore, in the suctioned portion 112, the second bonding surface 42 of the second layer 14 is pushed toward the first bonding surface 36 of the first layer 12. In this way, the membrane-attached bonded body 52 is formed by bonding the first bonding surface 36 and the second bonding surface 42 to which pressure is applied in the direction of approaching each other. In the bonded body manufacturing device 10, the bonding of the first bonding surface 36 and the second bonding surface 42 is mainly performed by the suction force of the suction portion 58. In this case, when the first bonding surface 36 and the second bonding surface 42 are bonded, it is possible to avoid the load applied to the first layer 12 and the second layer 14 from becoming too large to be greater than the required load. Therefore, for example, the membrane-attached bonded body 52 can be formed while reducing the load on the fibers and the like contained in the material of the anode gas diffusion layer 26 of the first layer 12.

[0051] As described above, the suction chamber 98 is connected to the through hole 90 provided at the central portion in the axial direction of the contact suction portion 88. In addition, the suction chamber 98 is not connected to the through holes 90 provided at both end portions in the axial direction of the contact suction portion 88. Therefore, the contact suction portion 88 is formed with a connecting area 100 connected to the negative pressure portion 99 via the through hole 90 and a non-connecting area 104 not connected to the negative pressure portion 99. The first back surface 38 of the suctioned portion 112 is in contact with both the connecting area 100 and the non-connecting area 104.

[0052] In addition, the plurality of fine pores of the first layer 12 are interconnected in various directions including the thickness direction and the width direction of the first layer 12. Therefore, when the suction chamber 98 is made to have a negative pressure by the suction portion 58, the entire second layer 14 stacked on the first layer 12 is sucked toward the contact suction portion 88 through the through-holes 90 of the communication region 100 and the fine pores of the first layer 12. As a result, the suctioned portion 112 contacts the entire contact suction portion 88 including the non-communication region 104. In addition, in the suctioned portion 112, the entire second bonding surface 42 is pressed toward the first bonding surface 36.

[0053] Here, the membrane-bonded body 52 composed of a plurality of layers tends to bend in a direction in which the central portion in the width direction of the first back surface 38 protrudes more than the two end portions in the width direction. In other words, the membrane-bonded body 52 tends to bend in a direction in which the central portion in the width direction of the first bonding surface 36 is recessed more than the two end portions in the width direction. Therefore, by bending the contact suction portion 88 as described above, the first back surface 38 and the contact suction portion 88 can be brought into good contact. Thus, the suction force of the suction portion 58 can be well transmitted to the suctioned portion 112. Furthermore, the state in which the second bonding surface 42 of the suctioned portion 112 is well pressed toward the first bonding surface 36 can be maintained.

[0054] Before the first joint surface 36 and the second joint surface 42 are joined, the heating unit 60 heats the second layer 14 to soften it. That is, the first layer 12 and the second layer 14 conveyed by the conveying mechanism 54 reach the position heated by the heating unit 60 before reaching the contact suction unit 88. In addition, in the present embodiment, at the time when the first layer 12 conveyed by the conveying mechanism 54 reaches the position heated by the heating unit 60, the second layer 14 is not laminated on the first layer 12.

[0055] The heating unit 60 supplies hot air to the heating chamber 106 via the hot air supply path 110. The hot air supplied from the heating unit 60 to the heating chamber 106 is discharged from the heating chamber 106 via the through holes 90. The hot air discharged from the heating chamber 106 via the through holes 90 passes through the pores of the first layer 12 to heat the second layer 14. As described above, the heating chamber 106 communicates with the through holes 90 provided in the entire axial direction of the rotating unit main body 74. Therefore, the second layer 14 can be heated and softened well using the entire axial direction of the rotating unit main body 74.

[0056] That is, in the bonded body manufacturing apparatus 10, the second layer 14 that has been softened by the heating unit 60 can be conveyed to the contact suction unit 88. As described above, in the present embodiment, both the first joint surface 36 and the second joint surface 42 contain ionomer. Therefore, it is easy to make the softened second joint surface 42 be in a state of being mixed with the first joint surface 36 in the contact suction unit 88. In addition, the softened second layer 14 can easily enter the concavo-convex structure of the porous first joint surface 36.

[0057] Thereby, in the contact suction unit 88, the first layer 12 and the second layer 14 can be quickly joined. In addition, since an anchoring effect can be generated between the joined first joint surface 36 and the second joint surface 42, the first layer 12 and the second layer 14 can be joined with high strength.

[0058] The hot air supplied from the heating unit 60 to the heating chamber 106 may be a gas at a temperature that can soften the second layer 14 (a temperature above the glass transition temperature). Examples of the hot air include heated air, heated inert gas, etc. In addition, from the viewpoint of quickly and stably joining the first joint surface 36 and the second joint surface 42, it is preferable that the hot air is humidified. Moreover, the hot air may be water vapor.

[0059] The peeling unit 50 peels the cover film 46 from the second back surface 44 of the sucked portion 112 of the tape-film bonded body 52. Specifically, the peeling unit 50 includes a cover film winding roller 114 and a guide unit 116. The cover film winding roller 114 rotatably supports the fourth core 118. When the cover film winding roller 114 rotates, the cover film 46 peeled from the tape-film bonded body 52 is wound around the fourth core 118.

[0060] The guide unit 116 guides the cover film 46 from the rotating unit 56 to the cover film winding roller 114. Specifically, the guide unit 116 is rotatably disposed at a position facing the sucked portion 112 on the side opposite to the rotating unit 56. In other words, the tape-film bonded body 52 is disposed between the contact suction unit 88 and the guide unit 116.

[0061] In addition, the guide unit 116 rotates in a direction opposite to the rotation direction of the rotating unit 56 in a state where the outer peripheral surface of the guide unit 116 is in contact with the cover film 46. That is, the cover film 46 remains adhered to the second back surface 44 until it reaches the contact suction unit 88 from the second unwinding roller 64. The cover film 46 that reaches the contact suction unit 88 changes its conveying direction to the direction of being peeled from the second back surface 44 and faces the cover film winding roller 114 by contacting the outer peripheral surface of the guide unit 116. Therefore, the peeling unit 50 peels the cover film 46 from the sucked portion 112 in a state where the second bonding surface 42 is pressed against the first bonding surface 36 by the suction of the suction unit 58.

[0062] In addition, as described above, when the second layer 14 is heated by the heating unit 60, the cover film 46 adhered to the second layer 14 is also heated. Therefore, the heated cover film 46 is conveyed to the peeling unit 50. Since the cover film 46 is heated and becomes easily deformable, the range of the conveying direction that the peeling unit 50 can change becomes wider. Such a cover film 46 can be easily peeled from the second back surface 44.

[0063] As described above, the bonded body 16 obtained by the peeling unit 50 is guided to the bonded body winding roller 70 by the third guide roller 72. Therefore, in the bonded body manufacturing apparatus 10, the bonded body 16 wound around the bonded body winding roller 70 can be obtained.

[0064] Hereinafter, a case where the bonded body manufacturing apparatus 10 is used will be described as an example to explain the bonded body manufacturing method according to the present embodiment. In this bonded body manufacturing method, first, the conveyance of the first layer 12 and the second layer 14 is started by the conveyance mechanism 54. As a result, the first layer 12 is conveyed from the first core 34 toward the rotating unit 56. The second layer 14 is conveyed from the second core 40 toward the rotating unit 56.

[0065] Next, a heating process is performed to heat and soften the second layer 14 being conveyed. In the heating process, hot air is supplied to the heating chamber 106 by the heating unit 60. The hot air is discharged from the through-hole 90 communicating with the heating chamber 106. Thereby, the second layer 14 can be heated and softened through the pores of the first layer 12. Further, in the heating process, it is preferable to heat and humidify the first layer 12 and the second layer 14 by supplying humidified hot air to the heating chamber 106, for example.

[0066] Next, the first layer 12 and the second layer 14 being conveyed are laminated to form a laminate. Next, while the contact suction part 88 of the rotating part 56 is brought into contact with the first back surface 38 of the laminate, the rotating part 56 is rotated. Next, the suction part 58 sucks the second layer 14 through the pores of the first layer 12 via the contact suction part 88. Thereby, a sucked part 112 attracted to the contact suction part 88 is formed on the laminate. In the sucked part 112, the second joint surface 42 is in a state of being pressed against the first joint surface 36. Therefore, the first joint surface 36 and the second joint surface 42 are joined to obtain a film-bonded body 52.

[0067] Next, the cover film 46 is peeled from the second back surface 44 of the sucked part 112 of the film-bonded body 52 by the peeling part 50. That is, the cover film 46 is peeled from the film-bonded body 52 in a state where the second joint surface 42 is pressed against the first joint surface 36 by the suction force of the suction part 58 to obtain a bonded body 16. The bonded body 16 is wound around the bonded body winding roller 70 via the third guide roller 72. The cover film 46 peeled from the second back surface 44 is wound around the cover film winding roller 114 via the guide part 116.

[0068] Thus, in the bonded body manufacturing apparatus 10 and the bonded body manufacturing method according to the present embodiment, during the conveyance of the first layer 12 and the second layer 14 by the roller conveyance part 48, the first joint surface 36 and the second joint surface 42 in the laminated state are continuously joined to obtain a film-bonded body 52. The cover film 46 is peeled from the second back surface 44 of the film-bonded body 52 to manufacture the bonded body 16. Therefore, the bonded body 16 can be efficiently manufactured while protecting the second layer 14 by the cover film 46.

[0069] Further, the rotating part 56 of the roller conveyance part 48 forms a sucked part 112 attracted to the contact suction part 88 on the laminate. On the sucked part 112, the second joint surface 42 is pressed against the first joint surface 36 by the suction force of the suction part 58. The peeling part 50 peels the peeling film from the second back surface 44 of the sucked part 112 to obtain the bonded body 16.

[0070] In this case, even when the covering film 46 is peeled off from the second back surface 44, and the covering film 46 stretches the second layer 14 in a direction away from the first layer 12, it is possible to suppress peeling between the first joint surface 36 and the second joint surface 42. As a result, a high-quality joined body 16 in which the first joint surface 36 and the second joint surface 42 are well joined can be obtained. Therefore, according to the joined body manufacturing apparatus 10 and the joining method according to the present embodiment, a high-quality joined body 16 can be efficiently manufactured.

[0071] In the above-described embodiment, the covering film 46 continuously covers the second back surface 44. The peeling portion 50 has a guiding portion 116 which is rotatably disposed at a position facing the suction portion 112 on the side opposite to the rotating portion 56. The guiding portion 116 rotates in a direction opposite to the rotation direction of the rotating portion 56 in a state where the outer peripheral surface of the guiding portion 116 is in contact with the covering film 46. In this case, by means of a simple structure in which the guiding portion 116 is provided as described above, the covering film 46 can be peeled off from the second back surface 44 of the suction portion 112 with high precision, and thus a high-quality joined body 16 can be obtained.

[0072] In the above-described embodiment, the outer diameter of the central portion in the axial direction of the contact suction portion 88 of the rotating portion 56 is smaller than the outer diameters of the both end portions in the axial direction of the contact suction portion 88. In a cross section of the rotating portion 56 along the axial direction, the contact suction portion 88 is bent in a direction in which it is recessed toward the central portion more than the both end portions in the axial direction of the contact suction portion 88. In this case, as described above, the first back surface 38 can be brought into good contact with the contact suction portion 88, and thus the suction force of the suction portion 58 can be well transmitted to the suction portion 112. As a result, the state in which the second joint surface 42 of the suction portion 112 is pressed against the first joint surface 36 can be maintained. As a result, the first joint surface 36 and the second joint surface 42 can be well joined. In addition, the covering film 46 can be peeled off while maintaining the state in which the first joint surface 36 and the second joint surface 42 are well joined. Furthermore, a high-quality joined body 16 can be efficiently obtained.

[0073] In the above-described embodiment, the rotating portion 56 has a rotating portion main body 74 which has an outer peripheral surface. A hollow portion 78 is formed inside the rotating portion main body 74. The rotating portion main body 74 has a through hole 90 that communicates the inside of the hollow portion 78 with the outside. The suction portion 58 forms a negative pressure portion 99 on at least a part of the hollow portion 78. The suction portion 58 forms the suction portion 112 via the negative pressure portion 99 and the through hole 90 that communicates with the negative pressure portion 99. In this case, by means of a simple structure in which the hollow portion 78 is suctioned by the suction portion 58, a high-quality joined body 16 can be efficiently obtained.

[0074] In the above-described embodiment, the contact suction portion 88 of the rotating portion main body 74 has a communication region 100 that communicates with the negative pressure portion 99 via the through hole 90 and a non-communication region 104 that does not communicate with the negative pressure portion 99. The non-communication region 104 is disposed outside both ends of the communication region 100 in the axial direction of the rotating portion main body 74. The first back surface 38 of the portion to be suctioned 112 contacts both the communication region 100 and the non-communication region 104.

[0075] Here, for example, when a through hole 90 that is not sufficiently covered by the first back surface 38 is generated in the communication region 100, a flow of gas that does not contribute to the suction of the portion to be suctioned 112 is generated from the outside to the inside of the negative pressure portion 99 via the through hole 90. In this case, the force for suctioning the portion to be suctioned 112 by the suction portion 58 may be reduced. In the contact suction portion 88 of the present embodiment, by providing the non-communication region 104 as described above, the entire communication region 100 is easily covered by the first back surface 38. Therefore, the portion to be suctioned 112 can be attracted to the contact suction portion 88 well. Furthermore, a joined body 16 in which the first joint surface 36 and the second joint surface 42 are joined well can be obtained.

[0076] In the above-described embodiment, the through hole 90 is formed in both the communication region 100 and the non-communication region 104. The rotating portion 56 has a support shaft portion 76 that supports the rotating portion main body 74 so as to be rotatable. The support shaft portion 76 has an insertion portion 92 disposed inside the hollow portion 78. The portion of the insertion portion 92 facing the communication region 100 forms a suction chamber 98 in the hollow portion 78. The suction portion 58 creates a negative pressure in the suction chamber 98 to form a negative pressure portion 99. The portion of the insertion portion 92 facing the non-communication region 104 (the blocking portion 102) blocks the communication between the through hole 90 disposed in the non-communication region 104 and the suction chamber 98.

[0077] In this case, by forming the suction chamber 98 in the insertion portion 92, the negative pressure portion 99 can be disposed at a desired position within the hollow portion 78. In addition, even if a through hole 90 is provided in the non-communication region 104, the communication between the through hole 90 in the non-communication region 104 and the suction chamber 98 (negative pressure portion 99) can be blocked by the portion of the insertion portion 92 other than the suction chamber 98 (the blocking portion 102). That is, the non-communication region 104 can be easily formed regardless of the presence or absence of the through hole 90. Therefore, for example, the communication region 100 and the non-communication region 104 can be accurately configured according to at least one of the configuration of the contact suction portion 88 in the rotating portion 56 and the dimensions of the first layer 12 and the second layer 14. As a result, the portion to be suctioned 112 can be attracted to the contact suction portion 88 even better, and thus a joined body 16 in which the first joint surface 36 and the second joint surface 42 are joined well can be obtained.

[0078] In the above-described embodiment, the roller conveyor section 48 has a heating section 60 that heats and softens the second layer 14 before the first joint surface 36 and the second joint surface 42 are joined. The insertion section 92 separately forms a heating chamber 106 in the hollow section 78 with respect to the suction chamber 98. The heating chamber 106 is arranged at a position separated from the suction chamber 98 in a direction opposite to the rotation direction of the rotating section main body 74. The heating section 60 supplies hot air to the heating chamber 106. The hot air supplied to the heating chamber 106 is discharged from the heating chamber 106 through the through holes 90, and thus the second layer 14 is heated through the pores of the first layer 12.

[0079] In this case, by forming the heating chamber 106 in the insertion section 92, the second layer 14 can be heated in the rotating section 56. Therefore, while suppressing the enlargement of the joint body manufacturing apparatus 10, the second layer 14 is heated to obtain the joint body 16 in which the first joint surface 36 and the second joint surface 42 are well joined. In addition, by supplying humidified hot air to the heating chamber 106, the first joint surface 36 and the second joint surface 42 can be humidified. Therefore, while suppressing the enlargement of the joint body manufacturing apparatus 10, the first joint surface 36 and the second joint surface 42 are humidified to obtain the joint body 16 in which the first joint surface 36 and the second joint surface 42 are well joined.

[0080] Furthermore, the present invention is not limited to the above-described embodiment, and various structures can be adopted without departing from the gist of the present invention.

[0081] In the above-described embodiment, at the time when the first layer 12 conveyed by the conveying mechanism 54 reaches the position heated by the heating section 60 (hereinafter, also referred to as the heating position), the second layer 14 is not laminated on the first layer 12. However, for example, as Figure 5 and Figure 6 shown, the first layer 12 may reach the heating position in a state where the first layer 12 and the second layer 14 conveyed by the conveying mechanism 54 are laminated. For example, as Figure 5 shown, by adjusting the relative positions of the first unwind roller 62, the first guide roller 66, the second unwind roller 64, and the second guide roller 68 with respect to the rotating section 56, etc., the laminate can be conveyed to the heating position.

[0082] In Figure 5 and Figure 6 the shown embodiment, the second layer 14 is further closer to the through holes 90 communicating with the heating chamber 106. Hot air can be supplied to the second layer 14 in this state through the pores of the first layer 12. Therefore, the second layer 14 can be heated more efficiently.

[0083] In the above-mentioned embodiment, the insertion part 92 forms the heating chamber 106 in the hollow part 78. However, the insertion part 92 may not form the heating chamber 106. That is, although not shown, the insertion part 92 may form only the suction chamber 98 in the hollow part 78. In this case, the heating part 60 may supply hot air to the second layer 14 before reaching the rotating part 56, for example, between the rotating part 56 and the second unwinding roller 64. In addition, the hot air is preferably humidified. In addition, the heating part 60 may heat the second layer 14 by a heater or the like instead of supplying hot air.

[0084] In the above-described embodiment, the rotating portion 56 has the supporting shaft portion 76. However, for example, Figures 7 - 9 As shown, the joint body manufacturing device 10 can also replace Figures 1 - 3 The rotating portion 56 is replaced with a rotating portion 120, and the rotating portion 120 does not have a supporting shaft portion 76. Figures 7 - 9 The rotating part 120 is mainly described with Figures 1 - 3 The different points of the rotating portion 56.

[0085] Figures 7 - 9 The rotating part body 122 of the rotating part 120 is provided with a third bearing 124 on the outer periphery of the protruding part 86. In addition, the rotating part body 122 is rotatably supported by a supporting mechanism (not shown) via the third bearing 124. The hollow part 78 formed inside the rotating part body 122 is connected to the suction part 58 via the inner side of the protruding part 86. Therefore, the hollow part 78 is sucked by the suction part 58, and the negative pressure part 99 is formed in the entire hollow part 78.

[0086] In the rotating portion main body 122, the through hole 90 is formed only in the central portion in the axial direction of the contact and suction portion 88. That is, the through hole 90 is formed only in the communication region 100 of the contact and suction portion 88. Since the non-communication region 104 of the contact and suction portion 88 does not have the through hole 90, it is not communicated with the negative pressure portion 99.

[0087] No hollow portion 78 of the rotating portion main body 122 is formed. Figures 1 - 3 Therefore, the heating section 60 does not Figures 1 - 3 The heating section 60 supplies hot air to the second layer 14 before reaching the rotating section 120, for example, between the rotating section 120 and the second unwinding roller 64. In addition, the hot air is preferably humidified. In addition, the heating section 60 may heat the second layer 14 by a heater or the like instead of supplying hot air.

[0088] In the above-mentioned Figures 7 - 9In the bonding body manufacturing apparatus 10, the hollow portion 78 can also be made into a negative pressure by the suction portion 58, so that the sucked portion 112 can be attracted to the contact suction portion 88. Therefore, even if the covering film 46 is peeled from the second back surface 44 by the peeling portion 50 and the covering film 46 stretches the second layer 14 in a direction away from the first layer 12, the peeling of the first bonding surface 36 and the second bonding surface 42 can be suppressed. As a result, a high-quality bonding body 16 can be efficiently manufactured. In addition, in Figures 7 - 9 the bonding body manufacturing apparatus 10, since it does not have Figure 2 and Figure 3 the support shaft portion 76, the structure of the rotating portion 120 can be simplified.

Claims

1. A bonded body manufacturing apparatus (10) manufactures a bonded body (16) from a porous first layer (12) and a non-porous second layer (14), characterized in that the first layer has a first bonding surface (36) and a first back surface (38) which is the back surface of the first bonding surface, the second layer has a second bonding surface (42) and a second back surface (44) which is the back surface of the second bonding surface, a covering film (46) is detachably attached to the second back surface, the bonded body manufacturing apparatus has a roll conveying section (48) and a peeling section (50), wherein the roll conveying section (48) continuously bonds the first bonding surface and the second bonding surface in a laminated state during the conveyance of the first layer and the second layer to form a film-bonded body (52); the peeling section (50) peels the covering film from the second back surface of the film-bonded body to obtain the bonded body (16), the roll conveying section has a rotating section (56) and a suction section (58), the outer peripheral surface of the rotating section has a contact suction section (88) that contacts the first back surface, the rotating section rotates while the contact suction section contacts the first back surface, the suction section sucks the second layer through the pores of the first layer via the contact suction section, thereby forming a sucked portion (112) attracted to the contact suction section on the laminate of the first layer and the second layer, the peeling section peels the covering film from the second back surface of the sucked portion of the film-bonded body.

2. The bonded body manufacturing apparatus according to claim 1, characterized in that the covering film continuously covers the second back surface, the peeling section has a guide section (116) which is rotatably arranged on the side opposite to the rotating section at a position facing the sucked portion, the guide section rotates in a direction opposite to the rotation direction of the rotating section in a state where the outer peripheral surface of the guide section contacts the covering film.

3. The bonded body manufacturing apparatus according to claim 1 or 2, characterized in that the outer diameter of the central portion in the axial direction of the contact suction section in the rotating section is smaller than the outer diameters of both end portions in the axial direction of the contact suction section, in the cross section along the axial direction of the rotating section, the contact suction section is curved in a direction where it is recessed toward the central portion compared to both end portions.

4. The bonded body manufacturing apparatus according to claim 1, characterized in that the rotating section has a rotating section main body (74) which has the outer peripheral surface, a hollow portion (78) is formed inside the rotating section main body, the rotating section main body has a through hole (90) that communicates the inside of the hollow portion with the outside, the suction section forms a negative pressure portion (99) on at least a part of the hollow portion, the suction section forms the sucked portion via the negative pressure portion and the through hole communicating with the negative pressure portion.

5. The bonded body manufacturing apparatus according to claim 4, characterized in that The contact suction part of the rotating part main body has a communication area (100) and a non-communication area (104), wherein the communication area communicates with the negative pressure part via the through hole, and the non-communication area does not communicate with the negative pressure part. The non-communication area is arranged outside both ends of the communication area in the axial direction of the rotating part main body. The first back surface of the part to be sucked contacts both the communication area and the non-communication area.

6. The bonding body manufacturing apparatus according to claim 5, wherein: The non-communication area does not have the through hole.

7. The bonding body manufacturing apparatus according to claim 1, wherein: The roller conveyor part has a heating part (60), and the heating part (60) heats and softens the second layer before the first joint surface and the second joint surface are joined.

8. The bonding body manufacturing apparatus according to claim 5, wherein: The through hole is formed in both the communication area and the non-communication area. The rotating part has a support shaft part (76), and the support shaft part (76) supports the rotating part main body in a rotatable manner. The support shaft part has an insertion part (92), and the insertion part (92) is arranged inside the hollow part. The part of the insertion part facing the communication area forms a suction chamber (98) in the hollow part. The suction part forms the negative pressure part by making the suction chamber into a negative pressure. The part of the insertion part facing the non-communication area blocks the communication between the through hole arranged in the non-communication area and the suction chamber.

9. The bonding body manufacturing apparatus according to claim 8, wherein: The roller conveyor part has a heating part, and the heating part heats and softens the second layer before the first joint surface and the second joint surface are joined. The insertion part forms a heating chamber (106) separately from the suction chamber in the hollow part. The heating chamber is arranged at a position separated from the suction chamber in the direction opposite to the rotation direction of the rotating part main body. The heating part supplies hot air to the heating chamber. The hot air supplied to the heating chamber is discharged from the heating chamber via the through hole, thereby heating the second layer through the pores of the first layer.

10. A method for manufacturing a bonded body, which manufactures a bonded body from a porous first layer and a non-porous second layer, wherein: The first layer has a first joint surface and a first back surface which is the back surface of the first joint surface. The second layer has a second joint surface and a second back surface which is the back surface of the second joint surface. A covering film is pasted on the second back surface in a peelable manner. In the method for manufacturing a bonded body: During the conveyance of the first layer and the second layer by a roller conveyor part, the first joint surface and the second joint surface in a stacked state are continuously joined to form a film-bonded body, and then the covering film is peeled off from the second back surface of the film-bonded body to manufacture a bonded body. The roller conveyor part has a rotating part that rotates. The method for manufacturing the bonded body has the following steps: A step of rotating the rotating portion while bringing the contact suction portion provided on the outer peripheral surface of the rotating portion into contact with the first back surface of the laminate of the first layer and the second layer; A step of forming a suction portion that sucks the second layer through the pores of the first layer via the contact suction portion, and forming a sucked portion that is attracted to the contact suction portion on the laminate of the first layer and the second layer; A step of peeling the cover film from the second back surface of the sucked portion of the film-bonded body through the peeling portion.

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