Method for producing current collector foil with resin film

Abstract

This method for producing a current collector foil with a resin film comprises: a step (A) in which a metal foil for a current collector foil is cut into single pieces; b, the moving table adsorbs the cut metal foils one by one, and the moving table moves the adsorbed metal foils to the resin film; and a step C in which the metal foil and the resin film are brought into contact with each other so as to thermally fuse the metal foil and the resin film, the moving table including a plate-shaped body having a heating and adsorption region, the area of the heating and adsorption region being smaller than the area of the metal foil to be cut.

Description

Technical Field

[0001] The present invention relates to a method for producing a collector foil with a resin film. Background Art

[0002] In recent years, various technologies related to quasi-solid-state batteries (also called semi-solid-state batteries) and all-solid-state batteries are being studied. Regarding the technology for continuously and / or semi-continuously manufacturing semi-solid electrodes and batteries assembled with semi-solid electrodes, a method is described in Japanese Patent Publication No. 2021-530829, which includes the following steps: continuously distributing a semi-solid electrode slurry onto a current collector; separating the semi-solid electrode slurry into independent parts; and cutting the current collector to form a finished electrode.

[0003] Japanese Patent Publication No. 2018-524759 describes a method for manufacturing an electrochemical cell, the method comprising: a process of disposing a first current collector on a first portion of a bag material; a process of disposing a first electrode material on the first current collector; a process of disposing a second current collector on a second portion of the bag material; a process of disposing a second electrode material on the second current collector; a process of disposing a separator on at least one of the first electrode material and the second electrode material; a process of folding the bag material along a folding line between the first portion and the second portion of the bag; and a process of sealing the bag material to form a bag for accommodating an electrochemical cell.

[0004] On the other hand, as a technology for bonding multiple films with poor self-supporting properties, a method for bonding films is described in Japanese Patent Gazette No. 08-224785, which is characterized in that in the method of bonding two or more films, one of the films is suctioned and fixed on a bonding table having multiple suction holes, an adhesive is applied to at least two opposite sides of the film, and after another film to be bonded is stacked on the film coated with the adhesive, the two films are charged and fixed by static electricity, and are crimped by a roller from above the fixed film. Summary of the invention

[0005] Technical issues to be solved by the invention

[0006] In the manufacture of quasi-solid-state batteries, a collector foil with a resin film is sometimes used, which is formed by laminating and cutting a plurality of metal foils into a predetermined shape at predetermined intervals on a continuous resin film. As one method for manufacturing such a collector foil with a resin film, the following manufacturing method can be cited: cutting a metal foil into a predetermined shape, preparing a stacked body having a plurality of metal foils stacked thereon, peeling the metal foil from the stacked body, moving the metal foil on a continuous resin film, and then heat-melting the resin film and the metal foil. In addition, when a battery cell is assembled into a so-called bag type using a collector foil with a resin film, since the electrical wiring is taken out from the outside of the bag, it is also required that there is an area (also called a "pole ear portion") between the collector foil and the resin film where the two are not heat-melted.

[0007] However, it was found that in the manufacturing method as described above, in a laminate formed by overlapping multiple sheets of metal foil, the metal foils are fixed to each other due to burrs and charging at the ends of the metal foils, making it difficult to peel off the metal foils piece by piece, and wrinkles are generated when the resin film and the metal foil are heat-fused after the metal foil is stacked on the resin film, and it is difficult to prevent a specified portion of the metal foil from being heat-fused to the resin film.

[0008] An embodiment of the present invention aims to provide a method for producing a collector foil with a resin film, which can bond a metal foil to a predetermined position on a resin film with high accuracy and can obtain a collector foil with a resin film in which wrinkles are suppressed.

[0009] Means for solving technical problems

[0010] The present invention includes the following aspects.

[0011] <1> A method for producing a collector foil with a resin film, comprising:

[0012] Step A, cutting the collector foil into individual pieces using metal foil;

[0013] Step B: the moving stage absorbs the cut metal foil piece by piece, and the moving stage moves the absorbed metal foil onto the resin film; and

[0014] Step C, bringing the metal foil into contact with the resin film to thermally fuse the metal foil and the resin film,

[0015] The moving stage comprises a plate-shaped body having a heating and adsorption region, and the area of ​​the heating and adsorption region is smaller than the area of ​​the cut metal foil.

[0016] <2> The method for producing a current collector foil with a resin film according to <1>, wherein:

[0017] In step C, the metal foil moved by the moving table is brought into contact with the resin film wrapped around the roller, and the roller and the moving table are relatively moved to thermally fuse the metal foil and the resin film.

[0018] <3> The method for producing a collector foil with a resin film according to <1> or <2>, wherein:

[0019] In step C, a region not thermally fused to the resin film is formed on a part of the metal foil, and after step C, there is step D of pressing the region not thermally fused to the resin film in the metal foil against the resin film to flatten it.

[0020] <4> The method for producing a collector foil with a resin film according to any one of <1> to <3>, wherein

[0021] The thickness of the resin film is 4 μm to 50 μm.

[0022] <5> The method for producing a collector foil with a resin film according to <4>, wherein:

[0023] The resin film includes a heat-sealing layer and a plastic base material, and the thickness of the heat-sealing layer and the thickness of the plastic base material satisfy the relationship represented by the following formula 1.

[0024] Formula 1: 0.1≤[thickness of heat-welding layer]÷[thickness of plastic substrate]≤1.00

[0025] <6> The method for producing a collector foil with a resin film according to any one of <1> to <5>, wherein

[0026] The plate-like body having the heated adsorption area included in the moving stage has a plurality of adsorption holes, and the thickness of the metal foil and the average opening diameter of the adsorption holes satisfy the relationship shown in the following formula 2.

[0027] Formula 2: 0.005 ≤ [thickness of metal foil] ÷ [average opening diameter of adsorption holes] ≤ 0.1

[0028] <7> The method for producing a current collector foil with a resin film according to any one of <1> to <6>, wherein

[0029] The metal foil is copper foil or aluminum foil.

[0030] Effects of the Invention

[0031] According to one embodiment of the present invention, a method for producing a collector foil with a resin film can be provided, which can laminate a metal foil to a predetermined position on a resin film with high accuracy and can obtain a collector foil with a resin film in which wrinkles are suppressed. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1A This is a schematic diagram for explaining the cutting of the metal foil in step A.

[0033] Figure 1B This is a schematic diagram for explaining the cutting of the metal foil in step A.

[0034] Figure 1C This is a schematic diagram for explaining the cutting of the metal foil in step A.

[0035] Figure 1D This is a diagram showing an example of a moving stage on which cut metal foil is sucked.

[0036] Figure 2 This is a plan view for explaining an example of a metal foil cut into a collector foil shape.

[0037] Figure 3A This is a schematic diagram for explaining the adsorption and movement of the metal foil on the moving stage in step B.

[0038] Figure 3B It is a schematic cross-sectional view showing a moving station according to one embodiment.

[0039] Figure 3C It is a schematic cross-sectional view showing a moving station according to another embodiment.

[0040] Figure 4 This is a process diagram for explaining an example of a method of thermally fusing a metal foil and a resin film.

[0041] Figure 5 This is a schematic diagram for explaining one embodiment of a method for producing a current collector foil with a resin film.

[0042] Figure 6 This is a diagram showing an example of a collector foil with a resin film.

[0043] Figure 7 It is a diagram for explaining distances a, b, and c. DETAILED DESCRIPTION

[0044] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. The present invention is not limited to the following embodiments and can be implemented with appropriate changes within the scope of the purpose of the present invention. Constituent elements represented by the same symbols in the various drawings refer to the same constituent elements. The description of the constituent elements and symbols repeated in the various drawings may sometimes be omitted. The dimensional ratios in the drawings do not necessarily represent the ratios of the actual dimensions.

[0045] In the present invention, when the embodiments are described with reference to the drawings, the structure of the embodiments is not limited to the structure shown in the drawings. In addition, the sizes of the components in the drawings are conceptual, and the relative relationship between the sizes of the components is not limited thereto.

[0046] In the present invention, the numerical range represented by "to" refers to a range including the numerical values ​​recorded before and after "to" as the lower limit and the upper limit. In the numerical range recorded in stages in the present invention, the upper limit or lower limit recorded in a certain numerical range can be replaced by the upper limit or lower limit of the numerical range recorded in other stages. Moreover, in the numerical range recorded in the present invention, the upper limit or lower limit recorded in a certain numerical range can be replaced by the value shown in the embodiment.

[0047] In the present invention, the term "process" includes not only an independent process but also a process that cannot be clearly distinguished from other processes as long as the intended purpose of the process can be achieved.

[0048] [Method for producing current collector foil with resin film]

[0049] The manufacturing method of the collector foil with resin film of the present invention (hereinafter also referred to as "the manufacturing method of the present invention") includes: step A, cutting the collector foil into single pieces with metal foil; step B, the movable table adsorbs the cut metal foil piece by piece, and the movable table moves the adsorbed metal foil onto the resin film; and step C, bringing the metal foil into contact with the resin film to thermally weld the metal foil and the resin film, the movable table includes a plate-like body having a heated adsorption area, and the area of ​​the heated adsorption area is smaller than the area of ​​the cut metal foil.

[0050] According to the production method of the present invention, a collector foil with a resin film can be obtained by bonding a metal foil to a predetermined position on a resin film with high accuracy and suppressing the occurrence of wrinkles.

[0051] The reason why the above-mentioned effect is exerted is not clear, but is presumed as follows.

[0052] In the manufacturing method of the present invention, in step A, the collector foil is cut into individual pieces by a metal foil, and in step B, the movable table absorbs the cut metal foil piece by piece, and the movable table moves the absorbed metal foil onto the resin film. In this way, in the manufacturing method of the present invention, since the cut metal foil can be moved onto the resin film without being stacked, the metal foils will not adhere to each other. In addition, in the manufacturing method of the present invention, the movable table used in step B includes a plate-like body having a heated absorption area, and when the movable table moves the metal foil onto the resin film, the heated absorption area heats the metal foil, so that in step C, the resin film and the metal foil can be quickly thermally welded.

[0053] Therefore, it is presumed that the resin film is not overheated, thereby effectively suppressing the generation of wrinkles. In addition, by making the area of ​​the heating adsorption region on the moving table used in step B smaller than the area of ​​the cut metal foil, an area where the metal foil and the resin film are not heat-fused can be formed at a predetermined position of the metal foil.

[0054] On the other hand, the following is recorded in Japanese Patent Table 2021-530829 Gazette: In several embodiments thereof, the current collector can be arranged on an electrically insulating material (e.g., a laminated bag material) in direct contact with the insulating material. Japanese Patent Table 2018-524759 Gazette records the following: In an anode assembly or a cathode assembly, a plurality of current collectors are arranged on a bag film (e.g., a PE / PP film). However, neither Japanese Patent Table 2021-530829 Gazette nor Japanese Patent Table 2018-524759 Gazette records the processes corresponding to process A, process B, and process C included in the manufacturing method of the present invention.

[0055] Furthermore, the laminating stage with suction holes used in the method described in Japanese Patent Application Laid-Open No. 08-224785 is a component different from the moving stage involved in the present invention. Originally, the method described in Japanese Patent Application Laid-Open No. 08-224785 is a method for laminating thin film lens sheets such as Fresnel lenses or biconvex lenses, and the method described in the document does not consider thermally fusing metal foil and resin film.

[0056] The collector foil with resin film obtained by the manufacturing method of the present invention also has the additional effect of excellent adhesion between the metal foil and the resin film. The excellent adhesion between the metal foil and the resin film has a tendency to improve the reliability of the battery using the collector foil with resin film. That is, for example, when manufacturing a quasi-solid-state battery, a composition comprising a positive electrode active material or a negative electrode active material and a conductive auxiliary agent is applied to the surface of the collector foil to form a positive electrode or a negative electrode, so the excellent adhesion between the metal foil as the collector foil and the resin film makes the base for forming the positive electrode or the negative electrode firm, so it is preferred.

[0057] Hereinafter, one embodiment of the production method of the present invention will be described with reference to the drawings as appropriate.

[0058] (Process A)

[0059] The manufacturing method of the present invention includes a step A of cutting a metal foil for a current collector foil into individual pieces.

[0060] The cutting may be performed using a cutting mechanism. The metal foil to be cut is preferably a strip-shaped metal foil. The strip-shaped metal foil can be used as a roll.

[0061] Figure 1A , Figure 1B and Figure 1C This is a schematic diagram for explaining one embodiment of step A.

[0062] like Figure 1A As shown, in step A, first, a desired amount of strip-shaped metal foil 10 is pulled out from a roll of metal foil 10 in the direction of arrow X.

[0063] like Figure 1B As shown, the metal foil 10 is pulled out onto the cutting table 14 so as to cover the cutting table 14 , and is fixed to the cutting table 14 by the holding portion 12 .

[0064] Then, if Figure 1B As shown, the cutting unit 20 disposed at a position opposite to the surface of the cutting table 14 is moved in the direction of arrow A1 to cut the metal foil 10 into the shape of the target collector foil. Thus, a single piece of cut metal foil (collector foil) having the target shape is obtained. In addition, the cutting unit 20 is provided with a cutting mechanism (not shown).

[0065] In addition, a protective member such as a cutting mat may be disposed on the surface of the cutting table 14 with which the cutting mechanism of the cutting member 20 abuts.

[0066] Then, if Figure 1C As shown, the cutting member 20 is moved in the direction of arrow A2 to separate the cutting member 20 from the cutting table 14. The cut metal foil 11 is sucked by a moving table (not shown) moved to the cutting table 14 and is separated from the cutting table 14.

[0067] As in the above embodiment, the metal foil is preferably cut on a cutting table. The cutting table may be a plate-shaped member that is detachably provided with a movable table. Figure 1A As shown, it may be a plate-shaped member having a flat surface, or it may be a flat plate member having a through portion corresponding to the cut shape of the collector foil.

[0068] like Figure 1A As shown, as long as the cutting table is a plate-shaped member having a flat surface, the cut metal foil may be sucked by moving the moving table disposed on the upper side in the vertical direction of the cutting table downward in the vertical direction. Figure 1D 1 is a schematic diagram showing an example of a moving stage 16 on which the metal foil according to this embodiment is sucked. The metal foil 11 is sucked on the lower side of the moving stage 16 in the vertical direction.

[0069] Furthermore, as long as the cutting table is a flat plate member having a through portion corresponding to the cut shape of the collector foil, the moving table can be arranged below the through portion to suck the cut metal foil that has passed through the through portion. Matters related to the sucking of the metal foil are described in detail in the description of step B.

[0070] The cutting means provided in the cutting device may be any cutting mechanism capable of cutting the metal foil to be cut into a predetermined shape, and examples thereof include a Thomson blade, an engraving blade, and a laser cutter.

[0071] The pressing force required for cutting the metal foil may be any pressure that can cut the metal foil to be cut. The pressing force may be, for example, 50 kgf (0.5 kN) to 10000 kgf (100 kN), preferably 100 kgf (1 kN) to 1000 kgf (10 kN).

[0072] Examples of a pressing mechanism that can be used for cutting the metal foil include a servo press and an air cylinder.

[0073] The cut shape of the metal foil may be any shape as long as it is a desired shape of the collector foil. For example, the cut shape of the metal foil is preferably a rectangular shape corresponding to the collector foil having a lug portion protruding from a main body portion. Figure 2 This is a plan view showing an example of a metal foil constituting a current collector foil portion in a current collector foil with a resin film obtained by the production method of the present invention.

[0074] exist Figure 2 In the example shown, the metal foil 11 is an example of a cut product cut from the strip-shaped metal foil 10 as a cutting object, and the reference numerals 11A and 11B respectively represent the parts corresponding to the main body and the lug part of the collector foil. Figure 2 In the example shown, the size of the metal foil 11 can be set according to the size of the target collector foil.

[0075] exist Figure 2 In the example shown, the size of the metal foil 11 can be, for example, 100 mm to 2000 mm in length L1×100 mm to 2000 mm in width L2, and 15 mm to 50 mm in length L3×20 mm to 50 mm in width L4. The position of the reference numeral 11B corresponding to the lug portion is not limited to the illustrated form as long as it can function as the lug portion.

[0076] The thickness of the metal foil (ie, the current collector foil obtained by cutting) is preferably 3 μm or more, more preferably 5 μm or more, and further preferably 10 μm or more.

[0077] From the viewpoint of flexibility and lightness, the thickness of the metal foil is preferably 100 μm or less, more preferably 70 μm or less, and further preferably 50 μm or less.

[0078] The metal foil can be a metal foil containing a known metal material for a collector foil. Examples of the metal material include aluminum, aluminum alloys, copper, copper alloys, stainless steel, nickel, and titanium. The type of metal material can be selected based on whether the collector foil is a positive electrode collector foil or a negative electrode collector foil.

[0079] In one embodiment, copper foil or aluminum foil can be preferably used as the metal foil. The collector foil using copper foil or aluminum foil sometimes has poor adhesion to the resin material, but the collector foil with resin film obtained by the manufacturing method of the present invention has excellent adhesion to the resin film even when copper foil or aluminum foil is used.

[0080] (Process B)

[0081] The manufacturing method of the present invention includes: step B, the moving stage sucks the cut metal foil piece by piece, and the moving stage moves the sucked metal foil onto the resin film. In step B, the metal foil sucked by the moving stage is moved onto the resin film while heating a predetermined area.

[0082] The moving stage includes a plate-shaped body having a heated adsorption area.

[0083] The heated adsorption region is a region having both an adsorption mechanism and a heating mechanism. When the metal foil is moved onto the resin film in step B, the heated adsorption region heats the metal foil while maintaining the metal foil adsorbed onto the surface of the moving stage.

[0084] In step B, the portion in contact with the heat adsorption region of the metal foil is heated to a temperature at which the metal foil can be thermally fused to the resin film. By heating only the metal foil in step B, thermal deformation of the resin film due to overheating in step C can be effectively suppressed.

[0085] The area of ​​the heated adsorption region is smaller than the area of ​​the cut metal foil. Therefore, when the metal foil is heated, the temperature of the portion of the metal foil that is not in contact with the heated adsorption region can be lower than that of the portion in contact with the heated adsorption region. By adjusting the temperature of the portion of the metal foil that is not in contact with the heated adsorption region to a temperature at which the metal foil and the resin film are not thermally fused, in step C, a region between the metal foil and the resin film that is not thermally fused can be formed.

[0086] The method in which the moving stage adsorbs the metal foil is not particularly limited as long as the metal foil can be held on the moving stage.

[0087] In one embodiment, when the metal foil is cut on the moving stage, the adsorption mechanism provided in the heating adsorption area is operated from the vertical lower side of the cut metal foil to adsorb the metal foil onto the moving stage.

[0088] In one embodiment, the movable stage is moved to the upper side in the vertical direction of the cutting stage on which the cut metal foil is placed, so that the heating adsorption area of ​​the movable stage faces the metal foil, and the heating adsorption area is aligned with the heated portion of the metal foil. Then, the adsorption mechanism of the heating adsorption area is operated, and after the movable stage adsorbs the metal foil, it moves in a predetermined direction. Figure 3A This is a schematic diagram for explaining an example of this method.

[0089] like Figure 3A As shown, a moving stage 110 having a heating mechanism 111 and an adsorption mechanism 112 is mounted on a moving mechanism 116, and the moving stage 110 is moved to a position corresponding to the cut metal foil 113 by the moving mechanism 116. Next, the moving stage 110 is lowered in the A3 direction, and the adsorption mechanism 112 is operated, so that the metal foil 113 is adsorbed on the surface of the adsorption mechanism 112 side of the moving stage 110. Next, the moving stage with the metal foil 113 adsorbed is raised in the A4 direction, and the moving stage 110 is moved in the A5 direction by the moving mechanism 116, thereby transferring the metal foil 113 onto a resin film (not shown).

[0090] Next, in step C described later, after the metal foil 113 and the resin film are thermally fused, the movable stage 110 is moved in the A6 direction and returned to the cutting stage.

[0091] The adsorption mechanism of the heated adsorption area is not particularly limited as long as it has a function of adsorbing the metal foil cut in step A to the surface of the moving table. The adsorption mechanism may be composed of, for example, a plurality of adsorption holes provided on the surface of the moving table and an air suction component (for example, an air suction pipe) connected to the moving table and a vacuum pump. By sucking the air inside the adsorption holes provided on the surface of the moving table by the air suction component and making the inside of the holes a decompressed state, the retention of the metal foil on the surface of the moving table can be improved.

[0092] The adsorption mechanism may release the metal foil when the suction from the air suction member stops, or may maintain the metal foil for a certain period of time by maintaining the reduced pressure inside the adsorption holes provided on the surface of the moving stage.

[0093] When the moving stage is a plate-like body having a plurality of adsorption holes, the shape of the openings of the adsorption holes is not particularly limited, but is preferably a circular or elliptical shape.

[0094] The number of adsorption holes can be set to the number of metal foil adsorbed on the surface of the moving stage. 2 The number of adsorption holes present is, for example, 1 to 10,000.

[0095] The opening diameter of the adsorption hole can be set to, for example, 10 μm to 2000 μm. The opening diameter is the diameter of the opening when the shape of the adsorption hole opening is a perfect circle, and is the average value of the maximum and minimum inner diameters of the opening when the shape is not a perfect circle.

[0096] In one embodiment, preferably, the plate-like body having the heating adsorption region included in the moving stage has a plurality of adsorption holes, and the thickness of the metal foil and the average opening diameter of the adsorption holes satisfy the relationship shown in the following formula 2.

[0097] Formula 2: 0.005 ≤ [thickness of metal foil] ÷ [average opening diameter of adsorption holes] ≤ 0.1

[0098] If the value obtained by dividing the thickness of the metal foil by the average opening diameter of the adsorption holes is 0.005 or more, it is difficult for the adsorption holes to be attached to the metal foil, and the adhesion between the metal foil and the resin film during heat welding is further improved. In addition, if the value obtained by dividing the thickness of the metal foil by the average opening diameter of the adsorption holes is 0.1 or less, when the cut collector foil is moved to the resin film, the collector foil can be transferred without positional displacement.

[0099] In the present invention, the "thickness of the metal foil" refers to a value measured in accordance with Japanese Industrial Standard JIS K7130:1999.

[0100] In the present invention, the “average opening diameter of adsorption pores” is a value measured by the following method.

[0101] The surface of the plate-like body having a plurality of adsorption holes is observed with an electron microscope, and 20 adsorption holes are randomly selected. The opening diameters of the selected 20 adsorption holes are measured, and the measured values ​​are arithmetic averaged to calculate the "average opening diameter".

[0102] The heating mechanism of the heated adsorption region is not particularly limited as long as it is a mechanism capable of heating the metal foil. Examples of the heating mechanism include resistance heating, arc heating, induction heating, dielectric heating, infrared heating, laser heating, and heat pump heating. From the perspective of lightweighting the device, resistance heating and induction heating are preferred as the heating mechanism.

[0103] The heating mechanism is preferably operated when the heating absorption area on the moving stage absorbs the metal foil. The heating mechanism can also be operated after the moving stage absorbs the metal foil.

[0104] The heating temperature may be set according to the metal foil and the resin film.

[0105] The heating temperature may be a temperature at which the metal foil and the resin film can be thermally fused in step C, and may be, for example, 50°C to 300°C, preferably 60°C to 200°C, and more preferably 70°C to 100°C.

[0106] The time for which the metal foil is heated may be the time required for the moving stage to move the cut metal foil onto the resin film, and can be, for example, 0.1 to 60 seconds, preferably 1 to 30 seconds, and more preferably 2 to 15 seconds.

[0107] The mobile platform can be moved by the moving mechanism.

[0108] The moving mechanism is not particularly limited, and examples thereof include a single-axis robot, an air cylinder, and a conveyor.

[0109] The material constituting the moving stage is not particularly limited, and examples thereof include aluminum, stainless steel, and phenolic plastic.

[0110] The thickness of the moving stage is not particularly limited, and can be set to 1 mm to 50 mm, for example, from the viewpoint of transportability.

[0111] Figure 3B FIG. 1 is a schematic cross-sectional view showing an embodiment of a moving stage and a method of adsorption between the moving stage and the metal foil. Figure 3B As shown, the heating mechanism 111 and the adsorption mechanism 112a are stacked together to form a moving platform 110A. A plurality of adsorption holes 114 are provided on the surface of the adsorption mechanism 112a on the side opposite to the heating mechanism 111. In the moving platform 110A, the entire surface of the adsorption mechanism 112a on the side opposite to the heating mechanism 111 is a heating adsorption area.

[0112] When the moving stage 110A is used, the portion of the cut metal foil 113 where heating is to be suppressed (ie, the lug portion of the collector foil) is positioned outside the surface of the suction mechanism 112 a .

[0113] Figure 3C FIG. 2 is a schematic cross-sectional view showing another embodiment of a moving stage and a method of adsorption between the moving stage and the metal foil. Figure 3C As shown, the heating mechanism 111 and the adsorption mechanism 112b are stacked together to form a moving table 110B. A plurality of adsorption holes 114 are provided on the surface of the adsorption mechanism 112b on the side opposite to the heating mechanism 111. In addition, a portion of the surface of the adsorption mechanism 112b on the side opposite to the heating mechanism 111 is formed of a heat insulating material d.

[0114] As the heat insulating material, for example, expanded polystyrene, polyurethane foam, silicone, etc. can be applied.

[0115] In the moving stage 110B, the surface of the adsorption mechanism 112 b that is on the opposite side to the heating mechanism 111 and is not formed of the heat insulating material d serves as a heating adsorption region.

[0116] When the moving stage 110B is used, the portion of the cut metal foil 113 where heating is to be suppressed (ie, the tab portion of the collector foil) is positioned in the region formed of the heat insulating material d on the surface of the suction mechanism 112b.

[0117] (Process C)

[0118] The production method of the present invention includes step C of bringing the metal foil and the resin film into contact with each other to thermally fuse the metal foil and the resin film.

[0119] In step B, the portion of the metal foil in contact with the heated adsorption region is heated to a temperature at which the metal foil can be thermally fused to the resin film. Therefore, in step C, when the metal foil is brought into contact with the resin film, the metal foil is rapidly thermally fused to the resin film, thereby suppressing thermal deformation of the resin film due to overheating, thereby suppressing the generation of wrinkles.

[0120] The resin film is a film including a plastic substrate, and is preferably a laminated film including a heat-sealed layer and a plastic substrate. The resin film may be formed only of a plastic substrate.

[0121] In the present invention, the plastic substrate refers to a substrate containing a thermoplastic resin as a main component and having a glass transition temperature (Tg) of 100° C. or higher.

[0122] In the present invention, the heat-sealing layer refers to a layer containing a thermoplastic resin as a main component and having a glass transition temperature (Tg) of 50° C. or higher. The heat-sealing layer is configured as a layer having a lower glass transition temperature (Tg) than the plastic base material.

[0123] The glass transition temperature (Tg) can be measured using a differential scanning calorimeter.

[0124] Furthermore, the main component of the plastic base material or the heat-sealing layer refers to the component with the largest content (mass %) among the components contained in the plastic base material or the heat-sealing layer.

[0125] Examples of the thermoplastic resin contained in the plastic substrate include at least one selected from polyethylene terephthalate, triacetyl cellulose, acrylic resin, polycarbonate, polyethylene and polyimide, preferably polyethylene terephthalate or polyethylene, and more preferably polyethylene terephthalate.

[0126] As the thermoplastic resin contained in the heat-sealing layer, for example, common materials used for heat sealing can be cited, preferably polyethylene, polypropylene, ethylene vinyl acetate, ionomer, EVA (ethylene-vinyl acetate resin) and EMMA (copolymer resin of ethylene and methyl methacrylate), and more preferably at least one selected from EVA (ethylene-vinyl acetate resin) and EMMA (copolymer resin of ethylene and methyl methacrylate).

[0127] The plastic base material and the heat-sealing layer may contain desired additives (epoxy resin, nylon, etc.) in addition to the thermoplastic resin.

[0128] The content of the thermoplastic resin relative to the total mass of the heat-sealing layer is not particularly limited, and may be 50% by mass or more, 70% by mass or more, 90% by mass or more, or 100% by mass.

[0129] The resin film is preferably a long strip-shaped resin film.

[0130] From the viewpoint of suppressing the generation of wrinkles, the thickness of the resin film is preferably 4 μm or more, more preferably 4 μm to 50 μm, and further preferably 4 μm to 20 μm. The upper limit of the thickness of the resin film is not particularly limited, but from the viewpoint of ease of winding the collector foil with the resin film, it is, for example, 1 mm.

[0131] The thickness of the resin film is the thickness of the plastic base material when the resin film is formed only of the plastic base material, and is the thickness of the plastic base material plus the thickness of the thermal welding layer when the resin film is formed of the plastic base material and the thermal welding layer.

[0132] In one embodiment, the resin film includes a heat-sealing layer and a plastic substrate. Preferably, the thickness of the heat-sealing layer and the thickness of the plastic substrate satisfy the relationship represented by the following formula 1.

[0133] Formula 1: 0.1≤[thickness of heat-welding layer]÷[thickness of plastic substrate]≤1.00

[0134] When the value obtained by dividing the thickness of the heat-sealed layer by the thickness of the plastic substrate satisfies the range of Formula 1, the energy density of a battery incorporating the obtained current collector foil with a resin film is more excellent.

[0135] The thickness of the heat-sealed layer and the thickness of the plastic substrate more preferably satisfy the relationship represented by the following formula 1A.

[0136] Formula 1A: 0.25<[thickness of heat-sealed layer]÷[thickness of plastic substrate]<2.00

[0137] In the present invention, the thicknesses of the heat-sealed layer and the plastic base material are values ​​measured by the following method.

[0138] The resin film is cut in the thickness direction using any cutting mechanism (e.g., a slicer). The cross section is magnified using a laser microscope, and the thickness of the heat-welding layer and the plastic substrate are measured respectively. The measurement is performed at 10 locations, and the thickness of the heat-welding layer or the plastic substrate is the arithmetic mean of the measured values ​​at the 10 locations.

[0139] The metal foil and the resin film may be thermally welded by bringing the metal foil and the resin film into contact with each other and, if necessary, pressing the contact portion between the metal foil and the resin film.

[0140] In one embodiment, from the viewpoint of suppressing the generation of wrinkles, it is preferred that the metal foil is brought into contact with the resin film wrapped around the roller, and the roller and the moving table are relatively moved to thermally fuse the metal foil and the resin film. Figure 4 (A) to (D) of the present invention describe thermal fusion bonding between the metal foil and the resin film.

[0141] From the viewpoint of suppressing the generation of wrinkles, the time for which the metal foil and the resin film are in contact is preferably 1 to 10 seconds, and more preferably 2 to 5 seconds.

[0142] Figure 4 This is a process diagram showing an example of a process of bringing a metal foil into contact with a resin film wrapped around a roller, and relatively moving the roller and a moving stage to thermally fuse the metal foil and the resin film.

[0143] exist Figure 4 As shown in (A), in step B, the moving table 32 holding the metal foil 30 by suction stops at a predetermined position facing the resin film 34. The resin film 34 is supported by two rollers 36. Reference numeral 38 denotes a holding roller.

[0144] A predetermined area of ​​the metal foil 30 is heated by a heating adsorption area (not shown) of the moving stage 32. The adsorption of the metal foil 30 by the moving stage 32 is released after the moving stage 32 reaches a predetermined position on the resin film 34 and before the heat fusion process starts.

[0145] Then, in Figure 4 In the embodiment, as shown in (B), the holding roller 38 is moved in the direction of the metal foil 30 in a manner of wrapping the resin film 34 at an angle (wrapping angle) represented by θ1, so that the metal foil 30 is in contact with the resin film 34. The angle θ1 can be set to 90°≤θ1<180°. The angle θ1 can be 90°. The distance between the movable table 32 and the resin film 34 is preferably set so that the angle θ1 is within the above range.

[0146] Then, in Figure 4 In the embodiment, as shown in (C), the holding roller 38 is rotated in the direction of arrow C2 while being moved in the direction of arrow C1, so that the holding roller 38 is separated from the movable table 32. Figure 4 In the diagram, the metal foil 30 and the resin film 34 are thermally fused and bonded to each other in a portion of the region surrounded by the one-dot chain line in (D).

[0147] (Process D)

[0148] Since the area of ​​the heating and adsorption region of the moving stage used in the manufacturing method of the present invention is smaller than the area of ​​the cut metal foil, in step C, a region which is not thermally fused to the resin film is formed in a part of the metal foil.

[0149] The area of ​​the metal foil not thermally fused to the resin film functions as a lug portion for pulling out electric wiring in the collector foil with resin film. Therefore, bending of the metal foil not thermally fused to the resin film tends to significantly impair the product value of the collector foil with resin film.

[0150] From this viewpoint, in the manufacturing method of the present invention, it is preferred that after step C, there is a step D of pressing the area of ​​the metal foil that is not thermally fused to the resin film against the resin film to flatten it. By performing step D, the occurrence of bending of the metal foil in the area that is not thermally fused to the resin film can be effectively suppressed.

[0151] As a method of pressing the region of the metal foil that is not thermally fused to the resin film against the resin film to flatten it, a pressing mechanism such as a roller may be used, or a winding pressure when winding the collector foil with the resin film into a roll may be used.

[0152] When the coiling pressure is used for pressing, the collector foil with the resin film is preferably coiled so that the metal foil bonded to the resin film by thermal fusion is located on the outer side in the circumferential direction of the roll body.

[0153] (Other processes)

[0154] The manufacturing method of the present invention may include other steps in addition to step A, step B, step C, and step D. Examples of other steps include a step of punching holes in the resin film and a step of shaping the collector foil thermally fused to the resin film by laser.

[0155] The manufacturing method of the present invention preferably uses a long strip-shaped resin film as the resin film, and repeatedly and continuously performs a series of steps including any steps such as step A, step B, step C, and step D. By repeatedly and continuously performing the above series of steps, a collector foil with a resin film can be manufactured in which a plurality of metal foils are bonded to the resin film at a constant interval on the resin film.

[0156] Figure 5 This is a schematic diagram showing a configuration example of a production apparatus for carrying out a series of steps including step A, step B, step C, and step D of the production method according to the present invention.

[0157] Figure 5 The manufacturing apparatus of the example shown is composed of a cutting section (A), a moving section (B), and an attaching section (C).

[0158] like Figure 5As shown, in the cutting section (A), the metal foil 40 is pulled out from the roll body of the metal foil 40 in the X direction and covered on the cutting table 42, and then the metal foil 40 is fixed on the cutting table 42 by a fixing member such as a holding portion 41. Then, the cutting member 43 is moved in the A1 direction to cut the metal foil 40 into a predetermined shape. (Process A)

[0159] Next, the moving stage 44 absorbs the cut metal foil 40, and heats it while moving it onto the resin film 45 in the moving section (B). The moving stage 44 absorbs and heats the metal foil 40 in a heating absorption region (not shown). In this example, the moving stage 44 absorbs the cut metal foil 40 at the lower side in the figure after the cutting member 43 moves in the A2 direction.

[0160] In the attaching section (C), the resin film 45 is continuously transported in the Y direction from the roll body of the resin film 45 by the transport roller pair 48 .

[0161] The movable table 44 to which the cut metal foil 40 is adsorbed moves the movable part (B) in the B1 direction, and in the attachment part (C), when the metal foil 10 is moved to a specified position on the upper side of the continuously conveyed resin film 45 in the figure, the adsorption is released. Next, the holding and pressing rollers 47 wrap around the resin film 45 so that the resin film 45 supported by two rollers 46 from the lower side in the figure contacts the metal foil 10, thereby thermally fusing the resin film 45 to the metal foil 40. Thus, a collector foil S with a resin film is obtained. After the resin film 45 and the metal foil 40 are thermally fused, the movable table 44 moves in the B2 direction. The collector foil S with a resin film is conveyed to the downstream side in the Y direction and becomes a roll body that is wound up in a manner such that the metal foil 40 faces circumferentially outward. (Process B and process C)

[0162] In addition, as another embodiment of the attaching portion (C), the following structure may be adopted: Figure 4 (A)~ Figure 4 In the same manner as the process shown in (D), two rollers 46 support the resin film 45 from the lower side in the figure, the movable table 44 moves the metal foil 10 to the specified position on the upper side of the resin film 45 in the figure, and the pressing roller 47 wraps the resin film 45 from the upper side in the figure to make the resin film 45 contact with the metal foil 10, thereby thermally melting the resin film 45 and the metal foil 40.

[0163] In this example, in the attachment portion (C), after the resin film 45 and the metal foil 40 are heat-fused, the portion of the metal foil 40 that is not heat-fused to the resin film is pressed by the pressure of the conveying roller pair 48 arranged on the downstream side in the Y direction and the winding pressure when the collector foil S with the resin film is wound as a roll body, thereby flattening. (Step D)

[0164] In addition, Figure 5In the example shown, when the collector foil S with a resin film is used, a punching member 49 is disposed on the upstream side in the Y direction in order to provide an opening 49 a for pulling out the lug portion of another collector foil.

[0165] Figure 6 It is shown in Figure 5 An example of a collector foil with a resin film obtained by the manufacturing method of the embodiment shown. Figure 6 2 shows an example of a collector foil with a resin film in which three metal foils are arranged at equal intervals on a resin film. However, it is a matter of course that the collector foil with a resin film according to the present invention is not limited to this example.

[0166] like Figure 6 As shown in the figure, regarding the collector foil 50 with resin film, three metal foils 52 are bonded to the resin film 54 at equal intervals. The portion indicated by the symbol 52a represents the portion of the metal foil 52 that is not thermally fused to the resin film 54 (i.e., the metal foil that is not thermally fused to the resin film). The collector foil 50 with resin film is formed with an opening 56 for pulling out the lug portion of the other collector foil.

[0167] Example

[0168] Hereinafter, the above-mentioned embodiment will be described in more detail with reference to Examples, but the above-mentioned embodiment is not limited to these Examples.

[0169] <Metal Foil>

[0170] As the metal foil, aluminum foil was prepared.

[0171] The thickness M (μm) of the metal foil used in each of the Examples and Comparative Examples is shown in Table 1. The thickness was measured by the above-mentioned measurement method.

[0172] <Resin film>

[0173] As the resin film, a roll of a long film (width: 270 mm) composed of two layers of the following plastic base material and a heat-sealed layer was prepared.

[0174] Plastic substrate: Polyethylene terephthalate substrate

[0175] Thermal bonding layer: EMMA (copolymer resin of ethylene and methyl methacrylate) layer

[0176] Regarding the resin films used in the examples and comparative examples, the thickness A of the heat-sealed layer (unit: μm), the thickness B of the plastic substrate (unit: μm), and the total thickness C of the resin film (A+B, unit: μm) are shown in Table 1. The thickness was measured by the above-mentioned measurement method.

[0177] <Mobile station>

[0178] As a moving stage, a moving stage (size: length 203 mm×width 147 mm×thickness 30 mm) including a plate-like body having adsorption holes was prepared. The plate-like body having adsorption holes had a thickness of 15 mm and was made of aluminum.

[0179] The movable stage has a heating adsorption area on one surface. The heating adsorption area includes an adsorption mechanism composed of a plurality of adsorption holes and an air suction pipe connected to the movable stage and a vacuum pump, and a heating mechanism of a resistance heating method.

[0180] Table 1 shows the average opening diameter N (unit: mm) of the adsorption pores.

[0181] [Examples 1 to 11, Comparative Example 1]

[0182] <Manufacturing equipment>

[0183] Prepared with Figure 5 However, the following changes were made to Examples 1, 2, 3 and Comparative Example 1. The shape of the collector foil with the resin film was set to the following structure: Figure 6 Similarly, in the collector foil 50 with resin film shown, a single collector foil is thermally fused to the resin film at a constant interval, and the interval between adjacent collector foils is set to 40 mm.

[0184] The metal foil constituting the collector foil portion has a main body portion and a tab portion for extracting wiring, and its shape is similar to Figure 2 The following are the dimensions of each part. Figure 2 The symbols L1, L2, L3 and L4 correspond to each other.

[0185] L1: 205mm, L2: 149mm, L3: 33mm, L4: 30mm.

[0186] Embodiment 1:

[0187] In the step C of the laminating portion (C), the metal foil and the resin film are thermally fused without wrapping the resin film around the holding roll 47 (wrapping angle θ1 = 0). In Table 1, it is described as "directly laid flat" (the same applies hereinafter).

[0188] In the laminating section (C), step D is not performed. That is, after the metal foil and the resin film are thermally fused, they are cut and overlapped without being pressed or rolled up by the transport roller pair 48 .

[0189] Embodiment 2:

[0190] In the laminating section (C), step D is not performed. That is, after the metal foil and the resin film are thermally fused, they are cut and overlapped without being pressed or rolled up by the transport roller pair 48 .

[0191] Embodiment 3:

[0192] In the laminating section (C), after the metal foil and the resin film are thermally fused, as step D, only pressing by the transport roller pair 48 is performed, and the film is cut and overlapped without being wound into a roll.

[0193] Comparative Example 1:

[0194] In the cutting section (A), step A is not performed. That is, a stacked body in which metal foils cut in advance into a predetermined shape are stacked is used. In the moving section (B), the metal foil is sucked from the stacked body onto a moving table and moved.

[0195] When the metal foil and the resin film are thermally fused to each other during the step C of the laminating portion (C), the metal foil and the resin film are thermally fused to each other without wrapping the resin film around the holding roll 47 (wrapping angle θ1 = 0).

[0196] In the laminating section (C), step D is not performed. That is, after the metal foil and the resin film are thermally fused, they are cut and overlapped without being pressed or rolled up by the transport roller pair 48 .

[0197] <Manufacturing of current collector foil with resin film>

[0198] (Process A)

[0199] The metal foil (aluminum foil) wound into a roll shape is fixed on a cutting table.

[0200] The fixed metal foil was cut by sliding a Thomson blade capable of punching out in a desired size using a servo press. At this time, the set pressure of the servo press was set to 600 kgf (5880 N).

[0201] (Process B)

[0202] After the cut metal foil was sucked onto the moving stage by activating a vacuum pump, the metal foil was moved to a predetermined position facing the resin film by a uniaxial robot while being heated. The movement was completed within 3 seconds. The heating setting temperature was set to 110°C.

[0203] (Process C)

[0204] The resin film was brought into contact with the metal foil moved in step B by the holding and pressing rolls. Then, the metal foil and the resin film were thermally fused and bonded to each other by rotating the holding and pressing rolls at a speed of 3 m / min.

[0205] Ten consecutive metal foils were heat-fused to the resin film while keeping the interval between the metal foils at 40 mm.

[0206] Table 1 shows the values ​​of the angle θ in the example in which the wrap angle θ was set by the wrapping roll.

[0207] (Process D)

[0208] In step C, a pair of rollers is arranged above and below the resin film at a position just after the aluminum foil and the resin film are attached. The gap between the pair of rollers is set to be less than the thickness of the resin film. The laminate of the aluminum foil and the resin film after step C is conveyed between the gaps. Thus, the area of ​​the aluminum foil that is not thermally fused with the resin film is pressed by the pair of rollers.

[0209] After step D, the collector foil with the resin film was further conveyed at 1 m / min and wound into a roll.

[0210] As described above, the current collector foils with resin films of Examples and Comparative Examples were produced.

[0211] [Matters related to Formula 1]

[0212] The value of [thickness A (mm) of the heat-sealed layer] ÷ [thickness B (mm) of the plastic base material] was calculated for the resin films used in Examples and Comparative Examples.

[0213] [Matters related to Formula 2]

[0214] The value of [thickness M (mm) of metal foil] ÷ [average opening diameter N (mm) of adsorption holes] was calculated for the metal foil and the moving stage used in Examples and Comparative Examples.

[0215]

[0216] [evaluate]

[0217] The collector foils with resin films obtained in the examples and comparative examples were evaluated for positional deviation, wiring extraction suitability, wrinkles, bending of the metal foil portion not thermally fused to the resin film, and yield rate.

[0218] In addition, the current collector foil with resin film obtained in each example was evaluated in terms of energy density and adhesion between the metal foil and the resin film.

[0219] The evaluation method and evaluation criteria are as follows.

[0220] As the evaluation sample, a collector foil with resin film was used in which the roll of the collector foil with resin film obtained above was cut into 10 pieces and the metal foil was thermally fused to the resin film at intervals of 40 mm.

[0221] A quasi-solid-state battery was prepared using the current collector foil with the resin film obtained above and evaluated for ease of wiring access and energy density. The quasi-solid-state battery was prepared as follows.

[0222] (Fabrication of Quasi-Solid-State Batteries)

[0223] <<Preparation of positive electrode composition>>

[0224] (1) After 13.4 g of a 0.9 mol / L LiPF6 solution (electrolyte) was mixed with a mixed solution of 45 g of ethylene carbonate, 10 g of propylene carbonate and 45 g of diethyl carbonate, 2.3 g of vinylene carbonate (VC) was further mixed to prepare an electrolyte solution X1.

[0225] (2) Using a stirrer (Awatori Rentaro ARE-310, manufactured by THINKY CORPORATION), 2 g of a conductive aid (Ketjen black: "Carbon ECP600JD" manufactured by Lion Specialty Chemicals Co., Ltd.) and 174 g of a positive electrode active material (iron phosphate: "LFP NCO M121" manufactured by Aleees) were stirred at 1500 rpm (revolutions per minute, the same below) for 30 seconds to prepare a kneaded product Y1 (176 g).

[0226] (3) Electrolyte X1 (64 g) was added to kneaded product Y1 (176 g), and the mixture was stirred at 1500 rpm for 120 seconds using Awatori Rentaro (manufactured by THINKY CORPORATION) to obtain a positive electrode composition.

[0227] <<Preparation of negative electrode composition>>

[0228] (1) An electrolyte solution X1 (64 g) was prepared that was the same as the electrolyte solution used in the preparation of the positive electrode composition.

[0229] (2) A kneaded material Z1 was prepared by stirring 152.5 g of a conductive additive (carbon black: "C-NERGY SUPER C45" manufactured by Imerys Graphite & Carbon) and 6.5 g of a negative electrode active material ("MESOPHASE GRAPHITE POWDER A (MGP-A)" manufactured by China Steel Chemical Corporation) at 900 rpm for 18 seconds using Awatori Rentaro (manufactured by THINKY CORPORATION).

[0230] (3) Electrolyte X1 (64 g) was added to kneaded product Z1 (159 g), and the mixture was stirred at 900 rpm for 30 seconds using Awatori Rentaro (manufactured by THINKY CORPORATION) to obtain a negative electrode composition.

[0231] <<Production of Quasi-Solid-State Batteries>>

[0232] Ten quasi-solid-state batteries were produced using the evaluation samples obtained in the examples and comparative examples. The production method is as follows.

[0233] The evaluation sample was cut between the metal foils to prepare collector foils to be used as positive electrode collector foils and negative electrode collector foils.

[0234] The positive electrode composition was applied to the surface of the main body of the positive electrode collector foil to form a positive electrode having a thickness of 600 μm.

[0235] The negative electrode composition was applied to the surface of the main body of the negative electrode current collector foil to form a negative electrode having a thickness of 500 μm.

[0236] As a separator, a polyethylene separator (thickness 20 μm, manufactured by W-SCOPE Corporation, COD-20-A) was prepared.

[0237] The separator was sandwiched between the positive electrode and the negative electrode, and pressurized by flat plate pressing to obtain a battery.

[0238] (Evaluation (1): Position deviation)

[0239] In each of the examples and comparative examples, the distance a [mm] from the short side of the metal foil to the end of the resin film, the distance b [mm] between the vertices of the metal foils, and the distance c [mm] were measured for 10 metal foils heat-sealed to the resin film. The details of the distances a, b, and c are shown in Figure 7 middle.

[0240] In addition, for the two pieces of metal foil located at the two ends of the evaluation sample among the 10 pieces, the distance b [mm] and the distance c [mm] to the adjacent one collector foil were measured, and for the other 8 pieces of metal foil, the distance b [mm] and the distance c [mm] to the adjacent two metal foils were measured.

[0241] The number of metal foils whose distance a, distance b, and distance c were all within the range of 16 [mm] ± 1 [mm] for distance a and 40 [mm] ± 1 [mm] for distance b and distance c was counted.

[0242] The results are shown in Table 2. The most excellent evaluation result was "0 pieces".

[0243] (Evaluation (2): Wiring extraction suitability)

[0244] The number of batteries (10) of the prepared quasi-solid-state batteries of the examples and comparative examples in which the metal foil of each of the positive electrode collector foil and the negative electrode collector foil was not exposed outside the resin film (i.e., bag) was counted. Batteries in which the metal foil was not exposed outside the bag were batteries from which the wiring was easily removed. Batteries in which the metal foil was exposed outside the bag were batteries from which the wiring was poorly removed.

[0245] The results are shown in Table 2. The most excellent evaluation result was "0 pieces".

[0246] (Rating (3): Wrinkles)

[0247] In each of the evaluation samples of the examples and comparative examples, the number of metal foils having one or more wrinkles having a length of 1 mm or more and a height of 0.1 mm or more was counted.

[0248] The results are shown in Table 2. The most excellent evaluation result was "0 pieces".

[0249] (Evaluation (4): Bending of the metal foil portion not thermally fused to the resin film)

[0250] In each evaluation sample of the example and the comparative example, the number of pieces of metal foil in which the metal foil portion not thermally fused to the resin film did not maintain a rectangular shape and was bent was counted.

[0251] The results are shown in Table 2. The most excellent evaluation result was "0 pieces".

[0252] In Table 2, "bend of the metal foil portion that is not thermally fused to the resin film" is described as "bend".

[0253] (Evaluation (5): Yield)

[0254] For each of the Examples and Comparative Examples, the yield rate was calculated by the following formula (X) based on the results of each of the evaluations (1) to (4) described above, and the evaluation was performed according to the following evaluation criteria. The results are shown in Table 2. In addition, the yield rate of each Example and Comparative Example is shown in parentheses recorded together with the evaluation results.

[0255] The most excellent evaluation result is "A", and A, B, C, and D are regarded as pass levels.

[0256] =Evaluation Method=

[0257] Yield rate = ([Total number of batteries produced] - [Number of collector foils with resin film that have any positional deviation / wiring extraction failure / wrinkles / bends]) ÷ [Total number of batteries produced] ... Formula (X)

[0258] =Evaluation Criteria=

[0259] A: 1.0

[0260] B: 0.8 or more and less than 1.0

[0261] C: 0.6 or more and less than 0.8

[0262] D: 0.5 or more and less than 0.6

[0263] E: less than 0.5

[0264] [Table 2]

[0265]

[0266] As shown in Table 2, in the current collector foil with resin film produced in Examples, the metal foil was bonded to a desired position on the resin film with high accuracy, and the generation of wrinkles was suppressed.

[0267] The collector foil with resin film produced in the examples was excellent in each evaluation of suitability for wiring extraction and bending of the metal foil portion that was not thermally fused to the resin film.

[0268] In comparison between the collector foils with resin films produced in Examples and the collector foils with resin films produced in Comparative Examples, the yield rate was high in all cases.

[0269] (Evaluation (6): Energy density)

[0270] The energy density (Wh / L) of the produced quasi-solid-state battery of the example was measured as follows, and evaluated based on the following evaluation criteria.

[0271] The most excellent evaluation grade was "A".

[0272] =Measurement method=

[0273] One battery was randomly selected from the ten batteries produced in each example, and a resin film (ie, bag) was bonded to the battery at the ends in the longitudinal direction and the width direction using a vacuum laminator.

[0274] The total capacity and total volume of each battery were confirmed by a predetermined method. The energy density (Wh / L) of each battery of the example and the comparative example was determined by dividing the total capacity of each battery by the total volume.

[0275] =Evaluation Criteria=

[0276] A: 94.5 [Wh / L] or above

[0277] B: 93 [Wh / L] or more and less than 94.5 [Wh / L]

[0278] C: 89 [Wh / L] or more and less than 93 [Wh / L]

[0279] D: less than 89 [Wh / L]

[0280] (Evaluation (7): Adhesion between metal foil and resin film)

[0281] =Evaluation Method=

[0282] One metal foil was randomly selected from the evaluation samples obtained in each Example, and the adhesion between the metal foil and the resin film was evaluated by the cross-hatch test described in JIS K 5600-5-6:1999.

[0283] The results are shown in Table 3. The most excellent evaluation rank was "A".

[0284] In addition, in Table 3, "Adhesion between metal foil and resin film" is described as "Adhesion".

[0285] =Evaluation Criteria=

[0286] A: The metal foil was not peeled off.

[0287] B: The metal foil was peeled off by one square.

[0288] C: The metal foil was peeled off by 2 or more squares.

[0289] [Table 3]

[0290]

[0291] (Explanation of symbols)

[0292] 10, 40-metal foil (metal foil to be cut), 11, 30, 52, 113-metal foil (metal foil to be cut), 11A-main body, 11B-ear portion, 12, 41-gripping portion, 14, 42-cutting table, 16, 32, 44-moving table, 20, 43-cutting member, 34, 45, 54-resin film, 18, 36, 46-roller, 38, 47-holding roller, 48-conveying roller pair, 49-punching member, 49a, 56-opening, 50, S-collector foil, 52a-not connected with resin film Heat-fused metal foil, 110, 110A, 110B-moving table, 111-heating mechanism, 112a, 112b-adsorption mechanism, 114-adsorption hole, 116-moving mechanism, d-thermal insulation material, L1-longitudinal dimension, L2-lateral dimension, L3-longitudinal dimension, L4-lateral dimension, θ1-angle (wrapped angle), A1-A1 direction, A2-A2 direction, A3-A3 direction, A4-A4 direction, A5-A5 direction, A6-A6 direction, C1-C1 direction, C2-C2 direction, XX direction.

[0293] The entire contents of the disclosure of Japanese Patent Application No. 2022-159487 filed on October 3, 2022 are incorporated into this specification by reference.

[0294] All documents, patent applications, and technical specifications described in this specification are incorporated by reference into this specification to the same extent as if each document, patent application, or technical specification was specifically and individually indicated.

Claims

1. A method for manufacturing a collector foil with a resin film, comprising: Step A, cutting the collector foil into individual pieces using metal foil; In step B, the moving stage absorbs the cut metal foil piece by piece, and the moving stage moves the absorbed metal foil onto the resin film; and Step C, bringing the metal foil into contact with the resin film to thermally fuse the metal foil and the resin film, The moving stage comprises a plate-shaped body having a heating and adsorption region, and the area of ​​the heating and adsorption region is smaller than the area of ​​the cut metal foil.

2. The method for producing a collector foil with a resin film according to claim 1, wherein: In step C, the metal foil moved by the moving table is brought into contact with the resin film wrapped around the roller, and the roller and the moving table are relatively moved to thermally fuse the metal foil and the resin film.

3. The method for producing a collector foil with a resin film according to claim 1 or 2, wherein: In step C, a region not thermally fused to the resin film is formed on a part of the metal foil, and after step C, there is step D of pressing the region not thermally fused to the resin film in the metal foil against the resin film to flatten it.

4. The method for producing a collector foil with a resin film according to claim 1 or 2, wherein: The thickness of the resin film is 4 μm to 50 μm.

5. The method for producing a collector foil with a resin film according to claim 4, wherein: The resin film includes a heat-sealing layer and a plastic substrate, and the thickness of the heat-sealing layer and the thickness of the plastic substrate satisfy the relationship shown in the following formula 1: Formula 1: 0.1≤[thickness of the heat-welding layer]÷[thickness of the plastic substrate]≤1.

00.

6. The method for producing a collector foil with a resin film according to claim 1 or 2, wherein: The plate-like body having the heating adsorption area included in the mobile station has a plurality of adsorption holes, and the thickness of the metal foil and the average opening diameter of the adsorption holes satisfy the relationship shown in the following formula 2: Formula 2: 0.005≤[thickness of metal foil]÷[average opening diameter of adsorption holes]≤0.

1.

7. The method for producing a collector foil with a resin film according to claim 1 or 2, wherein: The metal foil is copper foil or aluminum foil.

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