Scraper and powder coating device

Abstract

A scraper moves relative to a substrate in a constant direction while forming a desired gap on one side, thereby uniformly smoothing the thickness of a powder layer composed of powder supplied to the substrate. The scraper includes: a first portion that vibrates in contact with the powder on the upstream side of the substrate relative to the scraper in the relative direction of movement; and a second portion that vibrates in contact with the powder on the downstream side of the substrate relative to the scraper in the relative direction of movement. The vibration directions of the first portion and the second portion are different.

Description

Technical Field

[0001] This disclosure relates to scrapers and powder coating apparatus. Background Technology

[0002] Previously, it was known that there were technologies for handling components such as metal foil and coating the surface of the components with powder.

[0003] For example, Patent Document 1 discloses a technique for coating the surface of a current collector, which is a strip of metal foil, with a composite material (powder) containing an active substance.

[0004] In addition, Patent Document 2 discloses a method for applying vibration at a frequency of 700 Hz to a cylindrical scraper in order to suppress powder retention.

[0005] Prior art literature

[0006] Patent documents

[0007] Patent Document 1: Japanese Patent Application Publication No. 2011-216504

[0008] Patent Document 2: Japanese Patent Application Publication No. 2014-198293 Summary of the Invention

[0009] According to one aspect of this disclosure, a scraper moves relative to a substrate in a constant direction while forming a desired gap on one side, thereby uniformly smoothing the thickness of a powder layer composed of powder supplied to the substrate. The scraper includes: a first portion that vibrates in contact with powder on an upstream side of the substrate relative to the scraper in the opposite direction of movement; and a second portion that vibrates in contact with powder on a downstream side of the substrate relative to the scraper in the opposite direction of movement, wherein the vibration direction of the first portion is different from that of the second portion. Attached Figure Description

[0010] Figure 1A This is a schematic diagram showing the powder coating apparatus 2 of Embodiment 1.

[0011] Figure 1B This is a schematic diagram showing the scraper 1 and powder coating device 2 of Embodiment 1.

[0012] Figure 2A It means in Figure 1B In this diagram, when part 5 vibrates in a direction where the angle between the vibration direction of part 5 and the surface 3a of substrate 3 is 90°, a vector diagram of the force applied to powder 4 upon contact with the surface 5a of part 5 is shown. Figure 2AThis is a vector diagram showing the force 111a (the resultant force of the force 104a of the powder 4 pressing the surface 5a of the part 5 when the surface 5a of the part 5 is close to the substrate 3) of the powder 4 pressing the surface 5a of the part 5.

[0013] Figure 2B It means to Figure 2A A vector diagram showing the force 111a of the powder 4 pressing part 5 surface 5a after decomposition, the force 105a of the vertically pressing part 5 surface 5a, and the force 112 of the powder 4 as the resistance of the force 105a from part 5.

[0014] Figure 2C This is a vector diagram showing the situation where part 5 is far from the substrate 3.

[0015] Figure 3 This is a schematic diagram of the scraper 1 and powder coating device 2 in Embodiment 2.

[0016] Figure 4A It means in Figure 3 In the case where the vibration direction of part 5 is not at an angle of 90° to the surface 3a of the substrate 3, but rather vibrates in a manner that approaches the upstream side of the relative movement direction 7 of the substrate 3 relative to the scraper 1 and moves away from the downstream side, a vector diagram of the force exerted on the powder 4 upon contact with the surface 5a of part 5 is shown. Figure 4A This is a vector diagram showing the force 111a of the powder 4 pressing the surface 5a of the part 5 when the surface 5a of the part 5 is close to the substrate 3 (the resultant force of the force 104a of the powder 4 pressing the surface 5a of the part 5 by being transported to the substrate 3 and the force 110a applied to the powder 4 from the vibrating part 5).

[0017] Figure 4B It means to Figure 4A A vector diagram showing the force 111a decomposed from the force on the surface 5a of the pressing part 5 of the powder 4, the force 105a of the vertically pressing part 5, and the force acting as resistance to the force 105a on the powder 4 from the part 5.

[0018] Figure 4C This is a vector diagram showing part 5 when it is far from the substrate 3.

[0019] Figure 5 This is a schematic diagram of the scraper 1 and powder coating device 2 as embodiments 3.

[0020] Figure 6A It means in Figure 5In this context, when part 5 is vibrated in a manner that brings it closer to the downstream side of the substrate 3 relative to the scraper 1 in the relative moving direction 7 and moves it away from the upstream side, a vector diagram of the force applied to the powder 4 by contacting the surface 5a of part 5 is shown. Here, Figure 6A It is a vector diagram showing the force 111a of the powder 4 pressing the surface 5a of the part 5 when the surface 5a of the part 5 approaches the substrate 3 in the downstream side of the relative movement direction 7 of the substrate 3 relative to the scraper 1 (the resultant force of the force 104a of the powder 4 pressing the surface 5a of the part 5 by transporting it to the substrate 3 and the force 110a applied to the powder 4 from the vibrating part 5).

[0021] Figure 6B It means to Figure 6A A vector diagram showing the force 111a of the powder 4 pressing the surface 5a of the part 5 after decomposition, the force 105a of the vertically pressing part 5 surface 5a, and the force acting as resistance to the force 105a on the powder 4 from the part 5.

[0022] Figure 6C This is a vector diagram showing the force 111a exerted by the powder 4 on the surface 5a of the part 5 when the part 5 is far from the substrate 3.

[0023] Figure 6D It means to Figure 6C The vector diagram of the force 111a of the powder 4 pressing part 5 surface 5a after decomposition, the force 105a of the vertically pressing part 5 surface 5a, and the force acting as a resistance force on the powder 4 from part 5.

[0024] Figure 7 This is a schematic diagram of the positive electrode mixture layer 10 as viewed from the top surface in an embodiment, and a diagram showing the location for film thickness measurement.

[0025] Figure 8 This is a cross-sectional view of a portion of the positive electrode compound layer 10 of an all-solid-state battery as an embodiment.

[0026] Figure 9 This is a schematic diagram of the prior art for using a blade-shaped scraper 100 on powder 4.

[0027] Figure 10 It is a vector diagram showing the force applied to powder 4 when it comes into contact with the blade-shaped scraper 100.

[0028] Figure 11 This is a schematic diagram of the prior art that shows the vibration of a cylindrical scraper 150.

[0029] Figure 12 It is a vector diagram representing the force applied to powder 4 when it comes into contact with a non-vibrating cylindrical scraper 150.

[0030] Figure 13AIt means in Figure 11 In this diagram, while maintaining the shortest distance 109 between the cylindrical scraper 150 vibrating in vibration direction A and the substrate 3, a vector diagram of the force applied to the powder 4 when it comes into contact with the cylindrical scraper 150 vibrating in vibration direction A (parallel to the moving direction 7) is shown. Figure 13A This is a vector diagram representing the force 111 (the resultant force of the force 104 generated by the transport of the substrate and the force 110 applied to the powder 4 by the vibrating scraper 150) when the scraper 150 moves in the opposite direction to the relative movement direction 7 of the substrate 3 relative to the scraper 150, as the scraper 150 vibrates and moves in one direction.

[0031] Figure 13B It means to Figure 13A A vector diagram showing a portion of the force 111 after the force 111 of the powder 4 pressing the scraper 150 is decomposed into the force 105 of the vertically pressing scraper 150 and the force 105 of the powder 4 as a force resistance from the scraper 150.

[0032] Figure 13C It is a vector diagram showing the cylindrical scraper 150 moving in the same direction as the relative movement direction 7 of the substrate 3 with respect to the scraper 150.

[0033] Figure 14A It means in Figure 11 In the diagram, the force exerted on the powder 4 by contact with the cylindrical scraper 150 vibrating in the vibration direction B is shown. Figure 14A This is a vector diagram showing the force 111 (the resultant force of the force 104 generated by the transport of the substrate 3 and the force 110 applied to the powder 4 by the vibrating scraper 150) when the cylindrical scraper 150 vibrates in a direction perpendicular to the relative movement direction 7 of the substrate 3, as observed from above (through the scraper 150).

[0034] Figure 14B This indicates that the view from the side is considered as... Figure 14A A vector diagram showing the resistance of the force 105 after the force 111 of the powder 4 pressing the scraper 150 is decomposed, and the force 107 of the powder 4 is subjected to by the scraper 150.

[0035] Figure 15 Table 1 shows the results of various embodiments of this disclosure.

[0036] Figure 16 Table 2 shows the results of comparative examples of existing technologies. Detailed Implementation

[0037] use Figure 9 and Figure 10 The topic of Patent Document 1 will be explained. Figure 9 This is a schematic diagram of prior art using the blade-shaped scraper 100 described in Patent Document 1. Additionally, Figure 10 It is a vector diagram showing the force applied to powder 4 when it comes into contact with the blade-shaped scraper 100.

[0038] Patent document 1 describes: such as Figure 9 As shown, after the powder 4 is supplied to the surface of the metal foil that serves as the substrate 3, the powder 4 is leveled using a blade-shaped scraper 100, thereby uniformly adjusting the thickness of the powder layer.

[0039] However, as Figure 10 As shown, when powder 4 comes into contact with the surface 101 of the scraper 100, it is resisted by the force 102 that presses the powder 4 perpendicularly against the contact surface (surface 101) of the scraper 100, and is subjected to a force 103 in the opposite direction to the direction of movement of powder 4 (the relative movement direction 7 of the substrate 3 (metal foil) relative to the scraper 100). Therefore, when the flowability of powder 4 is low, powder 4 tends to remain upstream of the substrate 3 (metal foil) in the relative movement direction 7 of the scraper 100. As a result, bridging is easily generated between the scraper 100 and the substrate 3 (metal foil).

[0040] In order to suppress the retention or arching of powder 4, it is important to reduce the force 103 that is received from scraper 100 in the opposite direction to the direction of movement of powder (the relative direction of movement of substrate 3 (metal foil) relative to scraper 100) as a resistance to the force 102 that presses the powder 4 vertically against the contact surface (surface 101 of scraper 100).

[0041] use Figure 11 , Figure 12 and Figures 13A-13C The topic of Patent Document 2 will be explained.

[0042] Figure 11 This is a schematic diagram illustrating a prior art method for vibrating the cylindrical scraper 150 described in Patent Document 2. Additionally, Figure 12 This is a vector diagram representing the force applied to powder 4 when it comes into contact with a non-vibrating cylindrical scraper 150. Additionally, Figures 13A-13C It means in Figure 11 In this diagram, while maintaining the shortest distance 109 between the cylindrical scraper 150 vibrating in vibration direction A and the substrate 3, a vector diagram of the force applied to the powder 4 when it comes into contact with the cylindrical scraper 150 vibrating in vibration direction A (parallel to the moving direction 7) is shown. Figure 13AThis is a vector diagram showing the force 111 exerted by the powder 4 on the scraper 150 when the scraper 150 moves in the opposite direction to the relative movement direction 7 of the substrate 3 relative to the scraper 150 during vibration (the resultant force of the force 104 generated by the substrate transport and the force 110 exerted on the powder 4 by the vibrating scraper 150). Additionally, Figure 13B It means to Figure 13A A vector diagram showing a portion of the force 111 after the force 111 of the powder 4 pressing against the scraper 150 is decomposed into the force 105 that vertically presses against the scraper 150 and the force 107 that the powder 4 experiences from the scraper 150 as a resistance force. Additionally, Figure 13C It is a vector diagram showing the movement of the cylindrical scraper 150 in the opposite direction of vibration, moving in the same direction as the relative movement direction 7 of the substrate 3 with respect to the scraper 150.

[0043] exist Figure 11 In the cylindrical scraper 150 described in Patent Document 2 as shown, and... Figure 9 The blade-shaped scraper 100 described in Patent Document 1 is different, as shown in the example. Figure 12 The force 104 exerted by the powder 4 on the scraper 150 as it is conveyed to the substrate 3 is decomposed into a force 105 that presses perpendicularly against the contact surface (scraper surface 151) of the scraper 150 and a force 106 that slides along the contact surface (scraper surface 151). As a resistance to the force 105 pressing perpendicularly against the contact surface (scraper surface 151) of the scraper 150, the powder 4 experiences a force 107 radially outward toward the cylinder (scraper 150). However, this radially outward force 107 includes a component 108 in the opposite direction to the relative movement direction 7 of the substrate 3. Therefore, when the powder 4 has low flowability, it tends to remain upstream of the substrate 3 relative to the cylindrical scraper 150 in the relative movement direction 7. This becomes a significant factor in the formation of arching between the cylindrical scraper 150 and the substrate 3 (metal foil).

[0044] In the cylindrical scraper 150, in order to suppress the retention and arching of the powder 4, it is important to reduce the resistance of the force 105 that presses the powder 4 vertically against the contact surface (scraper surface 151) of the scraper 150, and reduce the component of the force 107 that is received from the scraper 150 in the radially outward direction of the cylindrical scraper 150, that is, to reduce the force component in the opposite direction to the direction of movement of the powder 4 (relative movement direction 7 of the substrate 3).

[0045] In addition, to suppress the retention and arching of powder 4, it is also effective to increase the force 106 that slides on the contact surface (scraper surface 151) of scraper 150 after the force 104 of powder 4 pressing against scraper 150 by being transported to substrate 3 is decomposed. This is because by increasing the force 106, it is possible to promote the entry of powder 4 into the gap between scraper 150 and substrate 3.

[0046] Next, regarding maintaining the shortest distance 109 between the scraper 150 and the substrate 3, Figure 11 The cylindrical scraper 150 described in Patent Document 2 is along the relative movement direction 7 of the substrate 3 relative to the scraper 150 and its opposite direction. Figure 11 The vibration direction A is described similarly.

[0047] First, when the scraper 150 vibrates in the opposite direction to the relative moving direction 7 of the substrate 3, such as Figure 13A As shown, the combined force of the force 104 of the powder 4 pressing against the scraper 150 as the powder 4 is transported to the substrate 3 and the force 110 applied to the powder 4 from the vibrating scraper 150 becomes the force 111 of the powder 4 pressing against the scraper. Figure 13B As shown, the force 111 of the powder 4 pressing against the scraper 150 can be decomposed into a force 105 that presses perpendicularly against the contact surface (scraper surface 151) of the scraper 150 and a force 106 that slides on the contact surface (scraper surface 151). As a resistance to the force 105 that presses perpendicularly against the contact surface (scraper surface 151) of the scraper 150, the powder 4 is subjected to a force 107 radially outward toward the cylinder. Here, regarding force 107, although... Figure 12 The scraper 150 shown is relatively vibration-free, but because it includes a component 108 in the direction opposite to the relative movement direction 7 of the substrate 3, the powder 4 remains on the upstream side of the relative movement direction 7 of the substrate 3 when the powder 4 has low flowability. Therefore, this becomes a significant factor in the formation of arching between the cylindrical scraper 150 and the substrate 3 (metal foil). Furthermore, with Figure 12 Compared to the case where the scraper 150 is not vibrating, the force 106 sliding on the contact surface (scraper surface 151) of the scraper is smaller, thus failing to facilitate the entry of powder 4 into the gap between the scraper 150 and the substrate 3. Furthermore, with low flowability of powder 4, powder 4 remains on the upstream side in the relative movement direction 7 of the substrate 3. Therefore, this becomes a significant factor in the formation of arching between the cylindrical scraper 150 and the substrate 3 (metal foil).

[0048] Furthermore, when the cylindrical scraper 150 vibrates in the same direction as the relative movement direction 7 of the substrate 3, such as Figure 13CAs shown, since the scraper 150 moves away from the powder 4, the scraper 150 has no effect on suppressing the formation of retention and arching relative to the powder 4.

[0049] In this way, while maintaining the shortest distance 109 between the scraper 150 and the substrate 3, the cylindrical scraper 150 described in Patent Document 2 is positioned in the relative movement direction 7 of the substrate 3 and its opposite direction. Figure 11 In the case of vibration in direction A), repeat Figure 13B and Figure 13C The state shown is as follows. Therefore, although the force 107 applied from the scraper 150 to the powder 4 radially outward toward the cylinder is smaller than when the scraper 150 is not vibrating, it includes a component 108 in the direction opposite to the relative movement direction 7 of the substrate 3 relative to the scraper 150. Compared to the case where the scraper 150 is not vibrating, the force 106 sliding on the contact surface (scraper surface 151) of the scraper 150 is smaller. Therefore, it is difficult to promote the powder 4 to enter the gap between the scraper 150 and the substrate 3. Consequently, for example, in very small powders 4 with particle sizes of tens of μm to submicron, where agglomeration is easy and the powder 4 has low flowability, the effect of suppressing the retention and arching of the powder 4 is insufficient, making it difficult to uniformly level the powder layer in a way that ensures uniform powder layer thickness.

[0050] Next, regarding maintaining the shortest distance 109 between the scraper 150 and the substrate 3, the cylindrical scraper 150 described in Patent Document 2 is positioned in a direction perpendicular to the relative movement direction 7 of the substrate 3 relative to the scraper 150. Figure 11 Similarly, the vibration in direction B) will be described.

[0051] Figure 14A and Figure 14B It means in Figure 11 A vector diagram showing the force applied to powder 4 by contact between the powder 4 and the cylindrical scraper 150 vibrating in the vibration direction B.

[0052] Here, Figure 14A This is a vector diagram showing the force 111 (the resultant force of the force 104 generated by the transport of the substrate 3 and the force 110 applied to the powder 4 by the vibrating scraper 150) when the cylindrical scraper 150 vibrates in a direction perpendicular to the relative movement direction 7 of the substrate 3, as observed from above (through the scraper 150). Additionally, Figure 14B It means as a general Figure 14A The vector diagram showing the resistance of the force 105 after the force 111 of the powder 4 pressing the scraper 150 is decomposed, and the force 107 of the powder 4 is observed from the side of the scraper 150.

[0053] First, while maintaining the shortest distance 109 between the scraper 150 and the substrate 3, the scraper 150 vibrates in a direction perpendicular to the relative movement direction 7 of the substrate 3, such as Figure 14A As shown, the resultant force of the force 104 exerted by the powder 4 on the scraper 150 as it is conveyed to the substrate 3 and the force 110 exerted on the powder by the vibrating scraper 150 becomes the force 111 exerted by the powder 4 on the scraper. Here, as... Figure 14B As shown, when the force is decomposed into a force 105 that presses vertically against the contact surface (scraper surface 151) of the scraper 150 and a force 106 that slides on the contact surface (scraper surface 151) of the scraper 150, in essence, the force 110 applied to the powder 4 from the vibrating scraper 150 is ineffective; only the force 104 of the powder 4 pressing against the scraper 150 by being transported to the substrate 3 is effective. That is, it becomes as follows Figure 12 The situation shown is the same as when powder 4 contacts a non-vibrating cylindrical scraper 150. As a result, as a resistance to the force 105 pressing the contact surface (scraper surface 151) of the scraper 150 vertically, powder 4 experiences a force 107 radially outward toward the cylinder. This force 107 radially outward toward the cylinder includes... Figure 12 The component 108 shown is in the opposite direction to the relative movement direction 7 of the substrate 3, when the scraper 150 is not vibrating. Furthermore, regarding the force 106 sliding on the contact surface (scraper surface 151), relative to... Figure 12 The absence of vibration in the scraper 150 also fails to improve the situation. Consequently, when the powder 4 has low flowability, it remains upstream of the cylindrical scraper 150 in the relative movement direction 7 of the substrate 3. This becomes a significant factor in the formation of arching between the cylindrical scraper 150 and the substrate 3 (metal foil).

[0054] In addition, here we describe the case in which the cylindrical scraper 150 vibrates in a direction perpendicular to the relative movement direction 7 of the substrate 3 while maintaining the shortest distance 109 between the scraper 150 and the substrate 3. Since the case in which it vibrates in the opposite direction is also the same, the description here is omitted.

[0055] In this way, while maintaining the shortest distance 109 between the cylindrical scraper 150 and the substrate 3 as described in Patent Document 2, the scraper 150 is positioned in a direction perpendicular to the relative movement direction 7 of the substrate 3. Figure 11 In the case of vibration in direction B), it becomes Figure 14A and Figure 14BAs shown, the force 107 directed radially outward toward the cylinder includes a component 10g in the opposite direction to the relative movement direction 7 of the substrate 3, similar to the case where the scraper 150 is not vibrating. Furthermore, the force 106 sliding on the contact surface (scraper surface 151) of the scraper 150 is not improved relative to the case where the scraper 150 is not vibrating, and it is not possible to promote the entry of powder 4 into the gap between the scraper 150 and the substrate 3. As a result, for example, in very small powders 4 with particle sizes of tens of μm to submicron, the effect of suppressing the retention and arching of powder 4 is insufficient when the powder 4 is prone to agglomeration and has low flowability, making it difficult to flatten the powder layer in a uniform manner.

[0056] Therefore, the purpose of this disclosure is to provide a scraper and a powder coating apparatus capable of forming a powder layer with minimal film thickness deviation on the surface of a substrate.

[0057] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. Furthermore, the embodiments described below are all general or specific examples. The numerical values, shapes, materials, constituent elements, arrangement positions of constituent elements, connection methods, steps, and order of steps shown in the following embodiments are examples only and are not intended to limit this disclosure. Additionally, constituent elements in the following embodiments that are not described in the independent technical solution will be described as arbitrary constituent elements.

[0058] In addition, the figures are illustrative and may not be strictly representational. Furthermore, in the figures, substantially identical structures are labeled with the same reference numerals, and sometimes repeated descriptions are omitted or simplified.

[0059] It should be noted that the following terms describing the relationship between elements such as uniformity, parallelism, flatness, or orthogonality, as well as the terms describing the shape of elements such as powder, and numerical ranges do not only mean strict, but also include substantially equivalent ranges, such as differences of a few percent.

[0060] Furthermore, the embodiments will be described below with appropriate reference to the accompanying drawings, but sometimes necessary detailed descriptions will be omitted. For example, detailed descriptions of known matters and repetitive descriptions of substantially the same structures will sometimes be omitted. This is to avoid making the following description unnecessarily lengthy and to facilitate understanding by those skilled in the art.

[0061] (Implementation Method 1)

[0062] Figure 1A This is a schematic diagram showing the powder coating apparatus of Embodiment 1. Figure 1B This is a schematic diagram showing the scraper 1 and powder coating apparatus 2 of Embodiment 1. Additionally, in Figure 1BThe diagram illustrates the shortest distance 8 between part 5 and substrate 3 based on the vibration of part 5, and the shortest distance 9 between part 6 and substrate 3 based on the vibration of part 6. It should be noted that the shortest distance 8 between part 5 and substrate 3 may vary and is not limited to a constant value.

[0063] like Figure 1A As shown, the powder coating apparatus 2 is an apparatus that coats powder 4 onto the surface 3a of a sheet-like substrate 3 while simultaneously transporting the substrate 3 using a transport device that serves as a drive unit. More specifically, the powder coating apparatus 2 continuously supplies powder 4 onto the surface 3a of the substrate 3 using a powder supply unit 18 while transporting the substrate 3 using the transport device. Alternatively, the powder coating apparatus 2 can also combine the substrate 3 and the powder 4 on the substrate 3 together and continuously compress them using a roller press, thereby forming a powder layer on the surface of the substrate 3.

[0064] The powder coating apparatus 2 includes: a powder supply unit 18 that supplies powder 4 to the surface 3a of a substrate 3; a scraper 1 that is configured to form a gap with the substrate 3 to adjust the thickness of the powder layer formed by the powder 4 supplied to the substrate 3; and a drive unit 19 that moves the substrate 3 and the scraper 1 relative to each other in a constant direction.

[0065] By forming a desired gap with respect to the substrate 3 and moving it relative to the substrate 3 in a constant direction, such a scraper 1 can flatten (uniformly) the thickness of the powder layer composed of powder 4 supplied to the substrate 3. In addition, the vibration direction of the scraper 1 at the upstream side of the relative movement direction 7 of the substrate 3 relative to the scraper 1 where it contacts the powder 4 and vibrates is different from the vibration direction of the scraper 1 at the downstream side of the substrate 3 relative to the scraper 1 where it contacts the powder 4 and vibrates is different from the vibration direction of the scraper 1 at the downstream side of the substrate 3 relative to the scraper 1 where it contacts the powder 4 and vibrates.

[0066] The vibration direction of part 5 is the same as the direction of crushing powder 4. In addition, the vibration direction of part 6 is the same as the direction of flattening powder 4.

[0067] More specifically, the vibration direction of part 5 is the direction in which the surface 5a of part 5 vibrates in contact with the powder 4 approaches and moves away from the substrate 3. Furthermore, the vibration direction of part 6 is the direction in which vibration occurs while maintaining the shortest distance 9 between the surface 6a of part 6 vibrating in contact with the powder 4 and the substrate 3. For example, it can be parallel to the moving direction 7 of the substrate 3, as in vibration direction 13 of part 6, or orthogonal to the moving direction of the substrate 3, as in vibration direction 14 of part 6. That is, the scraper 1 can vibrate in different directions by parts 5 and parts 6. In this embodiment, the vibration direction of part 5 is orthogonal to the vibration direction of part 6.

[0068] In this embodiment, parts 5 and 6 are driven by the drive unit 19, but this is not a limitation. For example, the drive unit 19 may also include a vibration generator and a conveying device. The vibration generator causes parts 5 and 6 to vibrate in different directions. Specifically, the vibration generator imparts high-frequency vibrations near the ultrasonic band to parts 5 and 6 respectively, causing parts 5 and 6 to vibrate at high frequencies in a frequency band of 2 kHz to 300 kHz. In this way, the vibration generator imparts vibrations to parts 5 and 6 simultaneously or individually. The conveying device can convey the substrate 3 together with the powder 4 by moving the substrate 3 in a predetermined direction. The conveying device continuously feeds out the substrate 3 wound into a roller shape, or intermittently feeds out the substrate 3.

[0069] Part 5 vibrates in a direction (approaching and moving away) at an angle of 90° between the surface 3a of the substrate 3 and the vibration direction. That is, the vibration direction of part 5 is perpendicular to the substrate 3. Furthermore, part 6 vibrates while maintaining the shortest distance 9 between the surface 6a of part 6 and the surface 3a of the substrate 3, which is in contact with the powder 4. That is, part 6 vibrates in a direction parallel to the surface 3a of the substrate 3. Here, the shortest distance 9 refers to the distance of the narrowest portion of the gap between part 6 and the substrate 3.

[0070] In addition, the powder coating apparatus 2 of this embodiment includes: a powder supply unit 18 that continuously supplies powder 4 to the surface 3a of the substrate 3; a scraper 1 that is arranged to form a gap with the substrate 3 to adjust the thickness of the powder layer formed by the powder 4 supplied to the substrate 3; and a drive unit 19 that moves the substrate 3 and the scraper 1 relative to each other in a constant direction (the same or different directions).

[0071] The frequency at which parts 5 and 6 of scraper 1 vibrate is, for example, above 2 kHz and below 300 kHz.

[0072] Powder 4 can be any powdery substance; for example, the average particle size (D50) can be a particle group containing active material with a particle size of 0.005 μm or larger and 50 μm or smaller. It should be noted that the average particle size (D50) can also be the median particle size based on a volumetric standard calculated from particle size distribution measurements using laser diffraction / scattering methods. The average particle size (D50) can be measured using a commercially available laser analysis / scattering particle size distribution measuring device.

[0073] Figures 2A to 2C It means in Figure 1B In the diagram, when part 5 vibrates in a direction where the angle between the vibration direction of part 5 and the surface 3a of substrate 3 is 90°, the force applied to powder 4 by contacting the surface 5a of part 5 is shown. Figures 2A to 2CThe diagram illustrates a flat scraper 1, but the surface 5a of part 5, which is arc-shaped (R-shaped) / flat, can also be considered the same vector diagram. Later, for... Figures 4A to 4C , Figures 6A to 6D The same applies.

[0074] Here, Figure 2A This is a vector diagram showing the force 111a (the resultant force of the force 104a of the powder 4 pressing on the surface 5a of the part 5 when the surface 5a of the part 5 is close to the substrate 3 (when the scraper 1 moves in the first direction during vibration) of the powder 4 pressing on the surface 5a of the part 5. Additionally, Figure 2B It means to Figure 2A A vector diagram showing the decomposition of the force 111a on the surface 5a of the pressing part 5 of the powder 4, the force 105a perpendicularly pressing the surface 5a of the pressing part 5, and the force 112 acting as resistance to the force 105a on the powder 4 from the part 5. Additionally, Figure 2C This is a vector diagram showing the case where part 5 is far from the substrate 3 (the case where the scraper 1 moves in the direction opposite to the first direction, i.e., the second direction, when it vibrates).

[0075] In this embodiment, when the vibration direction of part 5 is made at a 90° angle with the surface 3a of the substrate 3, and the part 5 vibrates towards and away from the surface 3a of the substrate 3, when the surface 5a of part 5 is close to the substrate 3, as... Figure 2A As shown, the resultant force of the force 104a of the powder 4 pressing part 5 surface 5a by being transported to the substrate 3 and the force 110a applied to the powder 4 from the surface 5a of the vibrating part 5 becomes the force 111a of the powder 4 pressing part 5 surface 5a. Figure 2B As shown, the force 111a of the powder 4 pressing the surface 5a of the part 5 is decomposed into a force 105a in which the powder 4 presses perpendicularly against the contact surface of the part 5 and a force 106a in which it slides on the contact surface of the part 5. At this time, as a resistance to the force 105a that presses perpendicularly against the contact surface of the part 5, the powder 4 is subjected to a force 112 that is perpendicular to the contact surface of the part 5 and toward the outside of the part 5.

[0076] Here, if we consider the component 113 (the force in the opposite direction to the moving direction 7) of the force 112, which is perpendicular to the contact surface 5a of the part 5 and directed outwards from the part 5, then... Figure 12 Compared to the case where the scraper 150 is not vibrating, the component 113 ( Figure 12The scraper 150 is marked as cylindrical, but the scraper surface 151 is also considered to be arc-shaped / planar. Therefore, in this embodiment, the retention of powder 4 can be suppressed on the upstream side of the relative movement direction 7 of the substrate 3 relative to the scraper 1. That is, the effect of suppressing arching between the scraper 1 and the substrate 3 can be obtained.

[0077] Similarly, if we consider the force 106a that slides on the contact surface of the surface 5a of the part 5 after the force 111 of the powder 4 pressing part 5 is decomposed, then it is similar to... Figure 12 Compared to the case where the scraper 150 is not vibrating, the force can be increased by 106a. Therefore, in this embodiment, it is possible to achieve the effect of promoting the entry of powder 4 into the gap between the scraper 1 and the substrate 3.

[0078] Furthermore, when the surface 5a of part 5 moves away from the substrate 3 while the part 5 is vibrating, such as Figure 2C As shown, the surface 5a of part 5 moves away from the powder 4, so the surface 5a of part 5 does not act on the powder 4 and has no effect related to retention or arching.

[0079] Therefore, when the vibration direction of part 5 is made to form an angle of 90° with the surface 3a of the substrate 3, and the part 5 vibrates closer to and further away from the surface 3a of the substrate 3, the vibration of part 5 is performed in a manner that makes the vibration direction of the part 5 form an angle of 90° with the surface 3a of the substrate 3. Figure 12 Compared to the case where the scraper 150 is not vibrating, it is possible to suppress the retention and arching of powder 4 and promote the entry of powder 4 into the gap between the scraper 1 and the substrate 3. Therefore, even when... Figure 12 Even when the scraper 150 does not vibrate, which is difficult in the prior art for very small powders 4 such as tens of μm to submicron in size, which are prone to agglomeration and have low flowability, it is still possible to crush the powder 4 and flatten the powder layer in a way that the thickness of the powder layer is uniform.

[0080] In addition, such as Figure 13B and Figure 13C As shown, while maintaining the shortest distance 109 between the scraper 150 and the substrate 3, the relative movement direction 7 of the substrate 3 and its opposite direction ( Figure 11In the prior art of vibration in the vibration direction A), the component 108 (the force in the opposite direction to the relative movement direction 7 of the substrate 3) after decomposing the resistance force 107 applied to the powder 4 by the scraper 150 is smaller compared to the case where the scraper 150 does not vibrate. In addition, the component of the force 106 sliding on the contact surface (scraper surface 151) of the scraper 150 is smaller, so it is easy to agglomerate in very small powders 4, such as those with a particle size of tens of μm to submicron. When the flowability of the powder 4 is low, it is difficult to flatten the powder layer in a way that the powder layer thickness is uniform. However, in this embodiment, the vibration of the part 5 is performed such that the angle between the vibration direction of the part 5 and the surface 3a of the substrate 3 is 90°, so that the part 5 vibrates closer to and further away from the surface 3a of the substrate 3. This allows the powder 4 to be pulverized and the powder layer to be flattened in a way that the powder layer thickness is uniform.

[0081] Here, by vibrating part 5 at a 90° angle to the surface 3a of the substrate 3, moving part 5 closer to and further away from the surface 3a of the substrate 3, for example, by vibrating part 5 at a frequency of 2 kHz to 300 kHz, a reduction in frictional resistance between the powder particles 4 can be achieved. Furthermore, as a synergistic effect of the reduced frictional resistance, by allowing the powder particles 4 to flow into the gap between the scraper 1 and the substrate 3 from the powder storage section upstream of the relative movement direction 7 of the substrate 3 relative to the scraper 1 while narrowing the flow path, a higher pulverization / dispersion effect of the powder particles 4 can also be obtained. Thus, in addition to improving the uniformity of the powder layer thickness, the uniformity within the powder layer, which inhibits agglomeration and deviation, can also be improved.

[0082] Furthermore, in the scraper 1 of this embodiment, the scraper 5 vibrates towards and away from the surface 3a of the substrate 3 with the vibration direction of the scraper 5 forming an angle of 90° with the surface 3a of the substrate 3. This allows the scraper 6 to vibrate while maintaining the shortest distance 9 between the surface 6a of the scraper 6 and the substrate 3. Therefore, in the scraper 1 of this embodiment, the scraper 5 vibrates towards and away from the surface 3a of the substrate 3. Figure 12 Compared to the case where the scraper 150 does not vibrate, it is possible to suppress the retention and arching of powder 4, and to promote the entry of powder 4 into the gap between the scraper 1 and the substrate 3.

[0083] Here, the vibration direction of part 6 can be vibration direction 13, which is parallel to the relative movement direction 7 of the substrate 3 relative to the scraper 1, or it can be vibration direction 14 (inside and front of the paper) which is perpendicular to the movement direction 7.

[0084] Therefore, by making the vibration direction of part 5 at an angle of 90° to the surface 3a of the substrate 3, the part 5 vibrates closer to and further away from the surface 3a of the substrate 3, thereby suppressing the increase of film thickness deviation. This allows for the achievement of retention suppression effect, arching suppression effect, flowability imparting effect, and pulverization / dispersion effect, while also ensuring the uniformity of film thickness.

[0085] For example, by vibrating the scraper 1 at a frequency of 2 kHz or higher and 300 kHz or lower, the synergistic effect of reducing the frictional resistance between the powder particles 4 can further improve the planarization effect of the powder layer produced by vibrating the part 6 while maintaining the shortest distance 9 between the surface 6a of the part 6 and the substrate 3.

[0086] Furthermore, very small powder particles 4, such as those with particle sizes ranging from tens of μm to submicron, tend to agglomerate when left to stand, resulting in a decrease in the flowability of the powder particles 4. Therefore, in this embodiment, by continuously processing the powder particles 4 at multiple locations (locations 5 and 6) with different vibration directions, it is possible to maintain the flowability of the powder particles 4 while processing is performed at each location (locations 5 and 6) of the scraper 1. As a result, a variety of effects can be obtained, such as retention suppression, arching suppression, pulverization / dispersion, and uniformity of film thickness.

[0087] (Implementation Method 2)

[0088] Figure 3 This is a schematic diagram showing the scraper 1 and powder coating apparatus 2 as described in this embodiment.

[0089] In Embodiment 2, instead of vibrating in a direction where the vibration direction of part 5 forms a 90° angle with the surface 3a of the substrate 3, the scraper 1 is vibrated in such a way that the surface 5a of part 5 is close to the substrate 3 on the upstream side of the relative movement direction 7 of the substrate 3 relative to the scraper 1 and is far away on the downstream side. Otherwise, it is the same as Embodiment 1. Therefore, the differences from Embodiment 1 will be explained below.

[0090] Figures 4A to 4C It means in Figure 3 In the case where the vibration direction of part 5 is not at an angle of 90° to the surface 3a of the substrate 3, but rather vibrates in a manner that approaches the upstream side of the relative movement direction 7 of the substrate 3 relative to the scraper 1 and moves away from the downstream side, the vector diagram of the force applied to the powder 4 when it comes into contact with the surface 5a of part 5.

[0091] Here, Figure 4AThis is a vector diagram showing the force 111a (the resultant force of the force 104a of the powder 4 pressing against the surface 5a of the part 5 when the surface 5a of the part 5 is close to the substrate 3, and the force 110a applied to the powder 4 from the vibrating part 5) when the surface 5a of the part 5 is close to the substrate 3. Additionally, Figure 4B It means to Figure 4A The vector diagram shows the force 111a after decomposition of the force 111a on the surface 5a of the pressing part 5 of the powder 4, the force 105a perpendicularly pressing part 5, and the force acting on the powder 4 from part 5 as resistance to the force 105a. Additionally, Figure 4C This is a vector diagram showing part 5 when it is far from the substrate 3.

[0092] In this embodiment, where the vibration direction of part 5 is not at a 90° angle to the surface 3a of the substrate 3, but rather vibrates in a manner that approaches the upstream side of the substrate 3 relative to the scraper 1 in the relative moving direction 7 and moves away from the downstream side, when approaching the upstream side, as... Figure 4A As shown, the resultant force of the force 104a of the powder 4 pressing part 5 surface 5a by being transported to the substrate 3 and the force 110a applied to the powder 4 from the surface 5a of the vibrating part 5 becomes the force 111a of the powder 4 pressing part 5 surface 5a. Figure 4B As shown, the force 111a of the powder 4 pressing the surface 5a of the part 5 is decomposed into a force 105a that presses perpendicularly to the contact surface of the part 5 and a force 106a that slides on the contact surface of the part 5. The powder 4 is subjected to a resistance force 112 relative to the force 105a that presses perpendicularly to the contact surface of the part 5.

[0093] Here, if we focus on the component 113 of force 112, then with Figure 12 Compared to the case where the scraper 150 is not vibrating, the component 113 ( Figure 12 The scraper 150 is marked as cylindrical, but the scraper surface 151 is also considered to be arc-shaped / planar. Therefore, in this embodiment, the retention of powder 4 can be suppressed on the upstream side of the relative movement direction 7 of the substrate 3 relative to the scraper 1. That is, the effect of suppressing arching between the scraper 1 and the substrate 3 can be obtained.

[0094] Similarly, if we consider the force 106a that slides on the contact surface of the surface 5a of the part 5 after the force 111a that decomposes the force on the surface 5a of the powder 4 pressing part 5, then it is similar to... Figure 12 The condition of scraper 150 not vibrating as shown remains unchanged, and it is not easy to achieve the desired effect. Figure 13B It deteriorates in the same way as the existing technology shown.

[0095] Therefore, in this embodiment, by vibrating towards the upstream side of the substrate 3 relative to the scraper 1 in the relative moving direction 7 and away from the downstream side, it is thus in harmony with... Figure 13B and Figure 13C The prior art shown maintains the shortest distance 109 between the cylindrical scraper 150 and the substrate 3 while simultaneously moving the substrate 3 in the relative direction 7 and its opposite direction. Figure 11 Compared to vibration in the direction A), this method can suppress the retention and arching of powder 4, and promote the entry of powder 4 into the gap between the scraper 1 and the substrate 3. For example, even for very small powder 4 with a particle size of tens of μm to submicron, which is prone to agglomeration and has low flowability, the uniformity of the powder layer thickness is improved. In addition, the uniformity inside the powder layer can also be improved to suppress agglomeration and deviation. Thus, a homogeneous powder layer with small thickness deviation and suppressed agglomeration and deviation can be formed on the surface 3a of the substrate 3.

[0096] Furthermore, downstream of the relative movement direction 7 of the substrate 3 relative to the scraper 1, when the surface 5a of the portion 5 is far from the substrate 3, such as Figure 4C As shown, the surface 5a of part 5 moves away from the powder 4, so the surface 5a of part 5 has less effect on the powder 4 in suppressing retention and arching.

[0097] Furthermore, the shape, vibration, and effect of the portion 6 in Embodiment 2, which vibrates in contact with the powder 4 on the downstream side of the relative movement direction 7 of the substrate 3 relative to the scraper 1, are the same as those in Embodiment 1, so the description is omitted.

[0098] (Implementation Method 3)

[0099] Figure 5 This is a schematic diagram of the scraper 1 and powder coating device 2 as described in this embodiment.

[0100] In this embodiment, the vibration direction of part 5 is not at an angle of 90° to the surface 3a of the substrate 3, but rather vibrates towards the downstream side of the relative movement direction 7 of the substrate 3 relative to the scraper 1 and away from the upstream side. Otherwise, it is the same as in embodiment 1. Therefore, only the differences from embodiment 1 will be described below.

[0101] Figures 6A to 6D Indicates in Figure 5 In this context, the surface 5a of the portion 5 that vibrates in contact with the powder 4 on the upstream side of the relative movement direction 7 of the substrate 3 relative to the scraper 1 is not the direction in which the vibration direction of portion 5 forms a 90° angle with the surface 3a of the substrate 3. Furthermore, Figures 6A to 6DThis is a vector diagram showing the force applied to the powder 4 when the part 5 is vibrated in a manner that approaches the downstream side of the substrate 3 relative to the scraper 1 in the relative moving direction 7 and moves away from the upstream side, thus contacting the powder 4. Figure 6A This is a vector diagram showing the force 111a (the resultant force of the force 104a of the powder 4 pressing the surface 5a of the part 5 when the surface 5a of the part 5 approaches the substrate 3 in the downstream side of the relative movement direction 7 of the substrate 3 relative to the scraper 1) of the powder 4 pressing the surface 5a of the part 5. Additionally, Figure 6B It means to Figure 6A The vector diagram shows the force 111a after decomposition of the force 111a on the surface 5a of the pressing part 5 of the powder 4, the force 105a perpendicularly pressing part 5, and the force acting on the powder 4 from part 5 as resistance to the force 105a. Additionally, Figure 6C This is a vector diagram showing the force 111a exerted by the powder 4 on the surface 5a of the portion 5 when the portion 5 is away from the substrate 3. Additionally, Figure 6D It means to Figure 6C The vector diagram of the force 111a on the surface 5a of the pressing part 5 of the powder 4 after decomposition, the force 105a on the surface 5a of the pressing part 5 vertically after decomposition, and the force on the powder 4 from the part 5 as a force resistance.

[0102] In this embodiment, where the vibration direction of part 5 is not at a 90° angle to the surface 3a of the substrate 3, but rather vibrates towards the downstream side of the relative movement direction 7 of the substrate 3 and away from the upstream side, when approaching the downstream side, as... Figure 6A As shown, the resultant force of the force 104a of the powder 4 pressing part 5 surface 5a by being transported to the substrate 3 and the force 110a applied to the powder 4 from the surface 5a of the vibrating part 5 becomes the force 111a of the powder 4 pressing part 5 surface 5a. Figure 6B As shown, the force 111a of the powder 4 pressing the surface 5a of the part 5 is decomposed into a force 105a in which the powder 4 presses perpendicularly against the contact surface of the part 5 and a force 106a in which it slides on the contact surface of the part 5. Additionally, the powder 4 experiences a force 112 perpendicular to the contact surface of the part 5 and moving outward from the part 5, acting as resistance to the force 105a that presses perpendicularly against the contact surface of the part 5.

[0103] Here, if we focus on the force 106a that slides on the contact surface of the scraper 1 after the force 111a of the force on the surface 5a of the pressing part 5 of the powder 4 is decomposed, then it is related to... Figure 12 Compared to the case where the scraper 150 is not vibrating, it can achieve a much larger ( Figure 12The scraper 150 is marked as cylindrical, but the scraper surface 151 is also considered to be arc-shaped / planar. Therefore, in this embodiment, a significant effect can be obtained that promotes the entry of powder 4 into the gap between the scraper 1 and the substrate 3.

[0104] Similarly, as a resistance to the force 105a relative to the contact surface 5a of the vertically pressed portion 5, the powder 4 is subjected to a force 112 perpendicular to the contact surface 5a of the portion 5 and moving from the inside of the portion 5 outwards. Here, if we consider the component 113, which is opposite to the relative movement direction 7 of the substrate 3, then... Figure 12 The case of scraper 150 not vibrating is equivalent to the case where it is difficult to deteriorate. Figure 12 The scraper 150 is marked as cylindrical, but the scraper surface 151 is also considered to be arc-shaped / flat.

[0105] Furthermore, if the vibration direction of part 5 is not at an angle of 90° to the surface 3a of the substrate 3, but rather vibrates towards the downstream side of the relative movement direction 7 of the substrate 3 relative to the scraper 1 and away from the upstream side, then when it moves away from the upstream side, as... Figure 6C As shown, the resultant force of the force 104a of the powder 4 pressing part 5 surface 5a by being transported to the substrate 3 and the force 110a applied to the powder from the surface 5a of the vibrating part 5 becomes the force 111a of the powder 4 pressing part 5 surface 5a. Figure 6D As shown, the force 111a of the powder 4 pressing the surface 5a of the part 5 is decomposed into a force 105a that presses the surface 5a of the part 5 perpendicularly and a force 106a that slides on the surface 5a of the part 5. As a resistance to the force 105a that presses the surface 5a of the part 5 perpendicularly, the powder 4 is subjected to a force 112 that is perpendicular to the surface 5a of the part 5 and moves from the inside of the part 5 toward the outside.

[0106] Here, if we focus on the force 111a that decomposes the force 111a on the surface 5a of the powder 4 pressing part 5, and the force 106a that slides on the contact surface of the surface 5a of part 5, then it is related to... Figure 12 The size is smaller compared to the case where the scraper 150 does not vibrate.

[0107] Furthermore, if we consider the component 113 of the force 112 acting on the powder 4 as a resistance to the force 105a relative to the surface 5a of the vertically pressing part 5, then... Figure 12 The case of scraper 150 not vibrating is equivalent to the case where it is difficult to deteriorate. Figure 12 The scraper 150 is marked as cylindrical, but the scraper surface 151 is considered equally regardless of whether it is arc-shaped or flat.

[0108] Here, instead of vibrating in a direction where the angle between the vibration direction of part 5 and the surface 3a of the substrate 3 is 90°, the vibration is performed towards the downstream side of the relative movement direction 7 of the substrate 3 relative to the scraper 1 and away from the upstream side, repeating the vibration. Figure 6B and Figure 6D The state shown. Considering this condition, the force 106a that slides on the contact surface of the surface 5a of the part 5 after the force 111a that presses the powder 4 against the surface 5a is decomposed. When approaching the downstream side of the relative movement direction 7 of the substrate 3 relative to the scraper 1, the force 106a that allows sliding on the contact surface of the surface 5a of the part 5 is very large. In this case, a significant effect can be obtained that promotes the powder 4 to enter the gap between the scraper 1 and the substrate 3. When moving away from the upstream side of the relative movement direction 7 of the substrate 3 relative to the scraper 1, the force 106a that slides on the contact surface of the surface 5a of the part 5 becomes smaller, but in continuous vibration, a significant effect can be obtained that promotes the powder 4 to enter the gap between the scraper 1 and the substrate 3.

[0109] Furthermore, as a resistance to the force 105a relative to the contact surface 5a of the vertically pressing part 5, the component 113 of the force 112 experienced by the powder 4 in the opposite direction to the relative movement direction 7 of the substrate 3, during continuous vibration, is related to... Figure 12 The case of scraper 150 not vibrating is equivalent to the case where it is difficult to deteriorate. Figure 12 The scraper 150 is marked as cylindrical, but the scraper surface 151 is considered equally regardless of whether it is arc-shaped or flat.

[0110] Therefore, through repetition Figure 13B And in Figure 13, the component 108 of the radially outward force 107 acting on the powder 4 towards the cylinder, which is a resistance to the force 105 relative to the contact surface of the vertically pressing scraper 150, is compared with... Figure 12 Compared to the case where the scraper 150 does not vibrate, this can be reduced. Figure 11In the prior art shown, the force 106 after the powder 4 decomposes the force 111 of the pressing scraper 150 is smaller than when the scraper 150 does not vibrate, leading to deterioration. However, when the surface 5a of the portion 5 in this embodiment vibrates relative to the substrate 3, moving downstream of the substrate 3 in the relative movement direction 7 relative to the scraper 1 and moving away upstream, the force 106a sliding on the contact surface of the surface 5a of the portion 5 becomes very large. Therefore, it is possible to promote the powder 4 to enter the gap between the scraper 1 and the substrate 3, and on the upstream side of the relative movement direction 7 relative to the scraper 1 of the substrate 3, the retention of the powder 4 and the formation of arching are suppressed. As a result, even when the powder 4 is very small, such as tens of μm to submicron in size, is prone to agglomeration and has low flowability, in addition to improving the uniformity of the powder layer thickness, it is also possible to improve the uniformity of the powder layer inside by suppressing agglomeration and deviation. Therefore, a homogeneous powder layer with small thickness deviation and no agglomeration or deviation inside can be formed on the surface 3a of the substrate 3.

[0111] Furthermore, the shape, vibration, and effect of the portion 6 in Embodiment 3, which vibrates in contact with the powder 4 on the downstream side of the relative movement direction 7 of the substrate 3 relative to the scraper 1, are the same as those in Embodiment 1, so the description is omitted.

[0112] In one embodiment of this disclosure, as an example of powder 4, its average particle size (D50) is set to be 0.005 μm or more and 50 μm or less, but the same effect can be obtained in particle sizes other than these, and it is not limited thereto.

[0113] The embodiments of this disclosure will now be described in more detail using specific experimental examples. It should be noted that this invention is not limited to the following experimental examples and can be implemented with appropriate modifications without altering its spirit.

[0114] (Experimental Example)

[0115] As an experimental example, a positive electrode mixture layer 10, including a positive electrode active material 11 and a solid electrolyte 12 of an all-solid-state battery, was formed. The positive electrode active material 11 was LiNi1 / 3Co1 / 3Mn1 / 3 with an average particle size D50 of 5 μm, and the solid electrolyte was Li2S-P2S5 with an average particle size D50 of 0.8 μm. The mixture was formed by mixing the materials in a volume ratio of 7:3. Furthermore, the mixture was supplied to the substrate 3 upstream of the relative movement direction 7 of the substrate 3 relative to the scraper 1. The scraper 1 of this embodiment 1-3 was used to flatten the mixture, thereby forming a film on the aluminum foil that became the substrate 3 with a target coating width of 50 mm, a coating length of 200 mm, and a film thickness of 300 μm. The coating speed was 10 m / min. In addition, the vibration conditions are the same for the part 5 that vibrates in contact with the powder 4 on the upstream side of the relative movement direction 7 of the substrate 3 relative to the scraper 1 and the part 6 that vibrates in contact with the powder 4 on the downstream side, with the vibration frequency set to 35kHz and the amplitude set to 5μm.

[0116] Furthermore, in Embodiment 1, the vibration direction of the portion 5 that vibrates in contact with the powder 4 on the upstream side of the relative movement direction 7 of the substrate 3 relative to the scraper 1 is 90° with respect to the vibration direction. In Embodiment 2, the vibration direction of the portion 5 on the upstream side of the relative movement direction 7 of the substrate 3 relative to the scraper 1 is 45° with respect to the vibration direction of the substrate 3 and the portion 5. In Embodiment 3, the vibration direction of the portion 5 on the downstream side of the relative movement direction 7 of the substrate 3 relative to the scraper 1 is 45° with respect to the vibration direction of the substrate 3 and the portion 5.

[0117] Furthermore, in each embodiment, film formation is performed in cases where the vibration direction of the portion 6 that vibrates in contact with the powder 4 on the downstream side of the relative movement direction 7 of the substrate 3 relative to the scraper 1 is in the relative movement direction 7 of the substrate 3 relative to the scraper 1 and in the opposite direction, and in the case where it vibrates in the direction perpendicular to the relative movement direction 7 of the substrate 3 relative to the scraper 1.

[0118] Furthermore, as a comparative example, this is aimed at maintaining the shortest distance 109 between the scraper 150 and the substrate 3 while using... Figure 11 The prior art shown is that the cylindrical scraper 150 moves relative to the substrate 3 in the direction 7 of its relative movement and in the opposite direction. Figure 11 The case of vibration in the vibration direction A) (Comparative Example 1), and the case of maintaining the shortest distance 109 between the scraper 150 and the substrate 3 while making the cylindrical scraper 150 in a direction perpendicular to the relative movement direction 7 of the substrate 3 with respect to the scraper 150 ( Figure 11The film formation was performed in the same manner as in Comparative Example 2, where the vibration occurred in the direction B. Here, the vibration conditions of the scraper 150 were those disclosed in Patent Document 2, with the vibration frequency of the scraper 150 set to 700 Hz and the amplitude set to 5 μm.

[0119] Using a laser displacement meter, such as Figure 7 As shown, the in-plane film thickness deviation of the positive electrode mixture layer 10 was measured by transversely crossing the powder layer at 5mm intervals in both the coating width direction and the coating direction. For the maximum value of the film thickness deviation ((maximum film thickness - minimum film thickness) / (average film thickness)) in each powder layer, less than ±2.5% was set as "A", more than ±2.5% and less than ±5% was set as "B", and more than ±5% was set as "C".

[0120] In addition, measurement and observation Figure 8 The cross-sectional area of ​​the positive electrode compound layer 10 shown is 100 μm. 2 If the total area of ​​the aggregated portion of the solid electrolyte 12 is less than 2% relative to the cross-sectional area of ​​the positive electrode mixture layer 10, it is classified as "A"; if it is 2% or more but less than 10%, it is classified as "B"; and if it is 10% or more, it is classified as "C".

[0121] The results of various embodiments of this disclosure are shown in Figure 15 Table 1. Additionally, the results of comparative examples of the prior art are shown in Table 1. Figure 16 Table 2.

[0122] In experimental examples 1 to 6, which are embodiments of this disclosure, the vibration direction of the portion 5 that vibrates in contact with the powder 4 on the upstream side of the relative movement direction 7 of the substrate 3 relative to the scraper 1 and the vibration direction of the portion 6 that vibrates in contact with the powder 4 on the downstream side are different. Under any condition, it is possible to obtain both the effect of suppressing the retention and arching of the powder 4 and the effect of promoting the powder 4 to enter the gap between the scraper 1 and the substrate 3. It is possible to achieve both the reduction of film thickness deviation and the suppression of solid electrolyte 12 aggregation.

[0123] In contrast, in experimental examples 7 and 8, where the cylindrical scraper 150 (a prior art technique) was vibrated while maintaining the shortest distance 109 between the scraper 150 and the substrate 3, although not entirely satisfactory, film formation was achieved with a constant degree of film thickness deviation. However, it was not possible to simultaneously reduce film thickness deviation and suppress the aggregation of the solid electrolyte 12. This is because, in order to obtain a higher pulverization / dispersion effect of the powder 4, if conditions are set, for example, at a higher frequency, although an improvement trend is observed in the agglomeration state, a trend of worsening film thickness deviation is also observed. Conversely, in order to suppress film thickness deviation, if conditions are set, for example at a low frequency, although an improvement effect on film thickness deviation is observed, the agglomeration state tends to worsen.

[0124] Thus, in the prior art, which vibrates the cylindrical scraper 150 while maintaining the shortest distance 109 between the scraper 150 and the substrate 3, it is difficult to simultaneously ensure film thickness accuracy and film uniformity. In contrast, in this embodiment, the vibration direction of the portion 5 that vibrates in contact with the powder 4 on the upstream side of the relative movement direction 7 of the substrate 3 relative to the scraper 1 and the vibration direction of the portion 6 that vibrates in contact with the powder 4 on the downstream side are different, thus achieving both.

[0125] In this embodiment, powder 4 is an example of a group of particles containing active substances, but the same effect can be obtained in powders of other functional materials. There are no particular limitations on raw materials, composition, particle shape, or particle size.

[0126] Furthermore, powder 4 may contain only one type of powder or two or more types of powder. When powder 4 is a mixture of multiple powders, the dispersibility of the multiple powders 4 is improved when the powder 4 is planarized by applying high-frequency vibration near the ultrasonic band to the scraper 1. That is, the multiple powders 4 are easily dispersed, and it is difficult for specific types of powder 4 to form an uneven film on the substrate 3. This is because, through the high-frequency vibration near the ultrasonic band of the scraper 1, the high-frequency vibration near the ultrasonic band is transmitted to the powder 4 existing in a constant region before reaching the scraper 1, causing the multiple particles constituting the powder 4 to vibrate and flow, thereby mixing the multiple particles constituting the powder 4 with each other and improving the dispersibility.

[0127] Furthermore, the substrate 3 is a long, thin sheet that is rolled out from a wound state and then wound again after coating, but the substrate 3 is not limited to this method. The desired shape of the substrate 3 can also be moved relative to the scraper 1 by the drive unit 19, and after the coating of powder 4 is completed, a new substrate 3 can be intermittently moved relative to the scraper 1 by the drive unit 19. Alternatively, the substrate 3 may not be rolled into a roller shape. The substrate 3 is not limited to a sheet shape, as long as it has a shape that allows the powder 4 to be coated using the powder coating apparatus 2. In this embodiment, the substrate 3 is a current collector containing metal foil, but the material is not particularly limited; any substrate that allows the powder 4 to be coated using the powder coating apparatus 2 can be used.

[0128] (Other variations, etc.)

[0129] The present disclosure has been described above based on embodiments 1 to 3, but the present disclosure is not limited to these embodiments 1 to 3, etc.

[0130] Furthermore, various modifications conceived by those skilled in the art to implement embodiments 1 to 3, and any combination of the constituent elements and functions of embodiments 1 to 3 within the scope of this disclosure, are also included in this disclosure.

[0131] According to this disclosure, a powder layer with minimal thickness deviation can be formed on the surface of a substrate.

[0132] Industrial availability

[0133] The scraper and powder coating apparatus disclosed herein can produce powder layers with small and uniform thickness deviations without solvents, and therefore can also be applied to the formation of compound layers in high-quality energy devices (such as all-solid-state batteries).

[0134] Explanation of reference numerals in the attached figures:

[0135] 1. Scraper

[0136] 2 Powder Coating Device

[0137] 3. Substrate

[0138] 3a Surface of substrate

[0139] 4. Powder

[0140] 5 parts (first part)

[0141] Surface of part 5a

[0142] Part 6 (Second Part)

[0143] Surface of part 6a

[0144] 7. Relative movement direction of the substrate relative to the scraper

[0145] 8. Shortest distance between part 5 and the substrate

[0146] 9. Shortest distance between part 6 and the substrate

[0147] 10 Positive electrode mixture layer

[0148] 11 Positive electrode active material

[0149] 12 Solid electrolytes

[0150] 13. The vibration direction of the portion 6 parallel to the relative movement direction 7 of the substrate 3 relative to the scraper 1.

[0151] 14. Vibration direction of the portion 6 perpendicular to the relative movement direction 7 of the substrate 3 relative to the scraper 1.

[0152] 18. Powder Supply Department

[0153] 19 Drive Unit

[0154] 100 Blade-shaped scrapers in existing methods

[0155] 101 The surface of the blade-shaped scraper in the existing method

[0156] 102 The force of the powder pressing vertically against the contact surface of the scraper

[0157] 103 Force in the opposite direction to the direction of powder movement (the relative direction of movement of the substrate relative to the scraper (metal foil)).

[0158] 104 The force of the powder pressing scraper by transporting it to the substrate

[0159] 104a The force applied to the surface 5a of the powder 4 pressing part 5 by transporting it to the substrate 3

[0160] 105. The force applied vertically to the contact surface of the scraper.

[0161] 105a The force applied vertically to the contact surface 5a of part 5.

[0162] 106. Force sliding on the contact surface of the scraper

[0163] 106a The force of sliding on the contact surface of part 5, surface 5a

[0164] 107. Forces directed radially outward toward the cylinder

[0165] 108 The component in the direction opposite to the relative movement direction 7 of the substrate relative to the scraper.

[0166] 109 Shortest distance between scraper and substrate

[0167] 110 Force applied to powder from a vibrating scraper

[0168] 110a Force applied to powder 4 from the vibrating part 5

[0169] 111 The force 104 of the powder 4 pressing the scraper 150 by transporting it to the substrate 3 and the force 110 of the powder 4 applied to the powder 4 by the vibrating scraper 150 are the combined force of the powder 4 pressing the scraper 150.

[0170] 111a The force 104a of the powder 4 pressing part 5 surface 5a by the force 104a of the powder 4 being transported to the substrate 3 and the force 110a of the powder 4 being applied to the powder 4 from the surface 5a of the vibrating part 5 is the force of the powder 4 pressing part 5 surface 5a.

[0171] 112 As a resistance to the force 105a relative to the contact surface 5a of the vertically pressing part 5, a force perpendicular to the contact surface 5a of the part 5 and moving from the inside of the part 5 outwards.

[0172] 113 The component of force 112 that is perpendicular to the contact surface 5a of part 5 and moves from the inside of part 5 outward, and is in the opposite direction to the relative movement direction 7 of the substrate 3 relative to the scraper 1.

[0173] 150. Cylindrical scraper in existing methods

[0174] 151 The surface of the cylindrical scraper in the existing method.

Claims

1. A scraper that moves relative to a substrate in a constant direction while forming a desired gap on one side, thereby uniformly smoothing the thickness of a powder layer composed of powder supplied to the substrate, wherein, The scraper has the following features: The first part, which vibrates upon contact with the powder on the upstream side of the substrate in the relative movement direction of the scraper; and The second part vibrates in contact with the powder on the downstream side of the moving direction relative to the scraper. The vibration direction of the first part is different from that of the second part.

2. The scraper according to claim 1, wherein, The vibration direction of the first part is the direction of the pulverized powder. The vibration direction of the second part is the direction that flattens the powder.

3. The scraper according to claim 2, wherein, The vibration direction of the first part is the direction in which the surface of the first part, which is in contact with the powder, vibrates and approaches or moves away from the substrate. The vibration direction of the second part is the direction in which the surface of the second part vibrates while maintaining the shortest distance between the surface of the second part in contact with the powder and the substrate.

4. The scraper according to claim 3, wherein, The vibration direction of the first part is perpendicular to the substrate.

5. The scraper according to claim 3, wherein, The vibration direction of the second part is parallel to the movement direction of the substrate.

6. The scraper according to claim 3, wherein, The vibration direction of the second part is orthogonal to the movement direction of the substrate.

7. The scraper according to any one of claims 1 to 6, wherein, The frequency at which the first part and the second part vibrate is above 2kHz and below 300kHz.

8. A powder coating apparatus, wherein, The powder coating apparatus comprises: The powder supply unit supplies powder to the surface of the substrate; The scraper according to any one of claims 1 to 7, configured to form a gap with the substrate, adjusts the thickness of the powder layer composed of powder supplied to the substrate; and A drive unit that causes the substrate and the scraper to move relative to each other in a constant direction.

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