Apparatus for manufacturing rolled granular layer and method for manufacturing rolled granular layer using same

Abstract

An apparatus for manufacturing a rolled particle layer includes: a supply unit for supplying particles; a transport unit that transports the pellets supplied by the supply unit; a support unit that supports the pellets conveyed by the conveyance unit; a pressing part which is disposed on the support part with a gap therebetween and forms a particle layer by smoothing the particles; a pair of material guiding parts which stipulate the width of the granular layer; and a rolling section for rolling the granular layer to form a rolled granular layer, the pressing section having a thickness defining section closest to the support section, and the pair of guide sections each having: a parallel section including a surface parallel to an end surface of the pressing section, the parallel section including a surface parallel to the end surface of the pressing section; the thickness defining part is provided with an upstream side end part positioned on the upstream side of the thickness defining part and a downstream side end part positioned on the downstream side of the thickness defining part; and a protruding part which is disposed on the upstream side of the thickness defining part and protrudes toward the center of the pressing part in the width direction, and the distance between the parallel parts of each of the pair of guide parts is disposed so as to be equivalent to the width of the rolled particle layer.

Description

Technical Field

[0001] The present invention relates to an apparatus for manufacturing a calendered particle layer and a method for manufacturing a calendered particle layer using the same. Background Art

[0002] For example, there is known a technique in which a base material is conveyed, granulated particles containing an electrode active material and a binder material are supplied onto the conveyed base material, and after the granulated particles are leveled using a roller-shaped pressing portion, they are calendered using calender rolls (Patent Document 1).

[0003] Prior Art Documents

[0004] Patent Documents

[0005] Patent Document 1: Japanese Unexamined Patent Application Publication No. 2016-115569. Summary of the Invention

[0006] Problems to be Solved by the Invention

[0007] In the case of a manufacturing method including a step of forming a continuous strip-shaped particle layer by leveling granulated particles containing an electrode active material using a pressing portion, etc., sometimes the particles flow more toward the outside in the width direction of the particle layer than the target forming width of the calendered particle layer, and sometimes the smoothness (end smoothness) at the width direction end portion of the obtained calendered particle layer is insufficient.

[0008] The present inventors have found that in order to improve the end smoothness of the calendered particle layer, by disposing plate-shaped guide portions on both end face sides of the pressing portion, the end smoothness of the calendered particle layer can be improved.

[0009] On the other hand, the present inventors have found that if the above-described guide portions are disposed, there is a tendency that the mass of the calendered particles per unit area (unit area weight) at the width direction end portion of the calendered particle layer is greater than the unit area weight at the center portion in the width direction of the calendered particle layer.

[0010] If there is a deviation in the unit area weight in the width direction of the calendered particle layer, sometimes the characteristics in the width direction of the calendered particle layer are non-uniform. For example, in a laminate of a base material and a calendered particle layer, when there is a portion where the unit area weight of the calendered particles is smaller, the pressing pressure at that portion is lower, and as a result, the peel strength between the base material and the calendered particle layer at that portion may be small.

[0011] Therefore, it is preferable that the deviation in the unit area weight in the width direction of the calendered particle layer is small, and it is particularly preferable that the unit area weight at the width direction end portion of the calendered particle layer is close to the average unit area weight in the width direction of the calendered particle layer.

[0012] Therefore, there is a need for a manufacturing apparatus for a calendered particle layer capable of manufacturing a calendered particle layer with a small deviation in the weight per unit area in the width direction, and a manufacturing method for a calendered particle layer using the manufacturing apparatus for a calendered particle layer.

[0013] Solution to the problem

[0014] The inventors of the present invention conducted in-depth research to solve the above problems. As a result, it was found that by providing a prescribed protruding portion in the above-described guiding portion, the above problems can be solved, and thus the present invention was completed.

[0015] That is, the present invention provides the following solutions.

[0016] [1] A manufacturing apparatus for a calendered particle layer, comprising:

[0017] A supply unit that supplies particles;

[0018] A transport unit that transports the particles supplied by the supply unit;

[0019] A support unit that supports the particles transported by the transport unit;

[0020] An extrusion unit that is disposed on the support unit with a gap therebetween, flattens the particles to form a particle layer; a pair of guiding portions that define the width of the particle layer; and

[0021] A calendering unit that calenders the particle layer to form a calendered particle layer,

[0022] The extrusion unit has a thickness defining portion closest to the support unit,

[0023] Each of the pair of guiding portions has:

[0024] A parallel portion that includes a surface parallel to the end surface of the extrusion unit, and has an upstream end portion located on the upstream side of the thickness defining portion and a downstream end portion located on the downstream side of the thickness defining portion; and a protruding portion that is disposed on the upstream side of the thickness defining portion and protrudes toward the center in the width direction of the extrusion unit,

[0025] The distance W between the parallel portions respectively provided in the pair of guiding portions is configured to correspond to the width of the calendered particle layer.

[0026] [2] The manufacturing apparatus for a calendered particle layer according to [1], wherein the extrusion unit has a roll shape.

[0027] [3] The manufacturing apparatus for a calendered particle layer according to [1] or [2], wherein the protruding portion respectively provided in each of the pair of guiding portions has a first surface facing the support unit, and the support unit is separated from the first surface.

[0028] [4] The manufacturing apparatus for a calendered particle layer according to any one of [1] to [3], wherein the protruding portions respectively provided on the pair of guide portions are separated from the thickness regulating portion toward the upstream side.

[0029] [5] The manufacturing apparatus for a calendered particle layer according to [3], wherein the distance between the first surface of the protruding portion respectively provided on the pair of guide portions and the support portion is 0 mm or more and 20 mm or less.

[0030] [5-1] The manufacturing apparatus for a calendered particle layer according to [5], wherein the protruding portions respectively provided on the pair of guide portions are separated from the thickness regulating portion toward the upstream side.

[0031] [6] The manufacturing apparatus for a calendered particle layer according to [4], [5] or [5-1], wherein the distance between the protruding portions respectively provided on the pair of guide portions and the thickness regulating portion is 1 mm or more and 60 mm or less.

[0032] [7] The manufacturing apparatus for a calendered particle layer according to any one of [1] to [6], wherein the maximum thickness in the width direction of the extrusion portion of the protruding portions respectively provided on the pair of guide portions is 0.1% or more and 25% or less, or 0.5% or more and 25% or less with respect to the distance W.

[0033] [8] The manufacturing apparatus for a calendered particle layer according to any one of [1] to [7], wherein the maximum thickness in the width direction of the extrusion portion of the protruding portions respectively provided on the pair of guide portions is 1 mm or more and 100 mm or less.

[0034] [9] A method for manufacturing a calendered particle layer, wherein the manufacturing apparatus for a calendered particle layer according to any one of [1] to [8] is used, and the manufacturing method includes:

[0035] Step (A) of supplying the particles from the supply portion;

[0036] Step (B) of transporting the supplied particles;

[0037] Step (C) of arranging the transported particles on the support portion, flattening the particles using the extrusion portion, and forming the particle layer between the parallel portions of the pair of guide portions; and

[0038] Step (D) of calendering the particle layer using the calender portion to form the calendered particle layer.

[0039] Advantages of the Invention

[0040] According to the present invention, there can be provided a manufacturing apparatus for a calendered particle layer capable of manufacturing a calendered particle layer with a small deviation in the weight per unit area in the width direction, and a manufacturing method for a calendered particle layer using the manufacturing apparatus for a calendered particle layer. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] Figure 1 FIG. 1 is a side view schematically showing a manufacturing apparatus for a calendered particle layer according to a first embodiment of the present invention.

[0042] Figure 2 FIG. 2 is a top view schematically showing a feed section, an extrusion section, and a support section included in the manufacturing apparatus according to the first embodiment.

[0043] Figure 3-1 FIG. 3 is a side view schematically showing a feed section, an extrusion section, and a support section included in the manufacturing apparatus according to the first embodiment.

[0044] Figure 3-2 FIG. 4 is a partial enlarged view showing Figure 3-1 a part of FIG. 3.

[0045] Figure 4 FIG. 5 is a perspective view schematically showing an example of a feed section.

[0046] Figure 5 FIG. 6 is a perspective view schematically showing an example of a protrusion.

[0047] Figure 6 FIG. 7 is a perspective view schematically showing another example of a protrusion.

[0048] Figure 7 FIG. 8 is a side view schematically showing a manufacturing apparatus for a calendered particle layer according to a second embodiment of the present invention.

[0049] Figure 8 FIG. 9 is a side view schematically showing a feed section, an extrusion section, and a support disk included in the manufacturing apparatus according to the second embodiment.

[0050] Figure 9 FIG. 10 is a side view schematically showing a manufacturing apparatus for a calendered particle layer according to a third embodiment of the present invention.

[0051] Figure 10 FIG. 11 is a side view schematically showing a manufacturing apparatus for a calendered particle layer according to a fourth embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0052] Hereinafter, embodiments and examples will be used to describe the present invention in detail. However, the present invention is not limited to the embodiments and examples shown below, and can be arbitrarily changed within the scope not departing from the claims of the present invention and their equivalent scope. The components of the embodiments shown below can be appropriately combined. In addition, in the drawings, the same reference numerals are given to the same components, and the description thereof may be omitted sometimes.

[0053] In the following description, a "long strip" film refers to a film having a length 5 times or more that of the width, preferably 10 times or more, and specifically refers to a film having a length such that it can be wound into a roll for storage or transportation. The upper limit of the length of the film is not particularly limited. For example, it can be 100,000 times or less relative to the width.

[0054] In the following description, unless otherwise specified, within the range not impairing the effects of the present invention, the directions of components such as "parallel", "perpendicular", and "orthogonal" may also include errors within a range of, for example, ±5°, ±3°, ±2°, or ±1°.

[0055] In the following description, unless otherwise specified, the meanings of "upstream" and "downstream" are respectively the upstream and downstream in the conveying direction of the particles in the manufacturing apparatus of the calendered particle layer.

[0056] [1. Outline of the manufacturing apparatus of the calendered particle layer]

[0057] The manufacturing apparatus of the calendered particle layer according to an embodiment of the present invention includes:

[0058] A supply unit that supplies particles;

[0059] A conveying unit that conveys the particles supplied by the supply unit;

[0060] A supporting unit that supports the particles conveyed by the conveying unit;

[0061] An extrusion unit that is disposed on the supporting unit with a gap therebetween, flattens the particles to form a particle layer; a pair of guiding units that define the width of the particle layer; and

[0062] A calendering unit that calenders the particle layer to form a calendered particle layer,

[0063] The extrusion unit has a thickness defining portion closest to the supporting unit,

[0064] Each of the pair of guiding units has:

[0065] A parallel portion, which includes a surface parallel to the end surface of the extrusion portion, has an upstream end located on the upstream side of the thickness defining portion and a downstream end located on the downstream side of the thickness defining portion; and a protruding portion, which is disposed on the upstream side of the thickness defining portion and protrudes toward the center in the width direction of the extrusion portion.

[0066] The distance W between the parallel portions respectively provided in the pair of material guiding portions is configured to be equivalent to the width of the calendered particle layer.

[0067] The manufacturing apparatus for a calendered particle layer according to the present embodiment is preferably an apparatus that continuously conveys particles by a conveying portion, continuously forms a particle layer by an extrusion portion, continuously calenders the particle layer by a calendering portion, and continuously manufactures a strip-shaped calendered particle layer.

[0068] Unless otherwise specified, the "width of the particle layer" means the size of the particle layer in a direction perpendicular to the conveying direction and the thickness direction of the particle layer.

[0069] The supporting portion for supporting the particles can directly support the particles or indirectly support the particles (for example, indirectly through a substrate).

[0070] In the manufacturing apparatus for a calendered particle layer according to the present embodiment, the material guiding portion has a protruding portion, whereby the amount of particles flowing toward the width direction ends of the particle layer can be adjusted, and a calendered particle layer with a small deviation in the weight per unit area in the width direction can be manufactured.

[0071] Hereinafter, embodiments of the manufacturing apparatus for a calendered particle layer will be described in detail with reference to the drawings.

[0072] [2. First Embodiment of the Manufacturing Apparatus]

[0073] Figure 1 is a side view schematically showing the manufacturing apparatus for a calendered particle layer according to the first embodiment of the present invention. As Figure 1 shown, the manufacturing apparatus 100 for a calendered particle layer includes: a substrate feeder 121, a coating portion 180 for coating a bonding material coating liquid containing a bonding material on the substrate 1, a supply portion 110 for supplying particles 2, a supporting roller 130, an extrusion portion 140, a pair of material guiding portions 150, a calender roller 160 as a calendering portion, and a winder 170. The substrate feeder 121, the coating portion 180, the supply portion 110, the supporting roller 130, and the winder 170 are sequentially arranged from the upstream in the conveying direction of the particles 2.

[0074] The base material feeder 121 and the support roller 130 rotate in the same direction about their respective rotation axes to convey the base material 1. The particles 2 are supplied onto the conveyed base material 1. By the rotation of the base material feeder 121 and the support roller 130, the base material 1 conveys the particles 2 downstream. Accordingly, the base material feeder 121 and the support roller 130 cooperate to function as a conveyance unit that conveys the particles 2 supplied by the supply unit 110.

[0075] The support roller 130 functions as a conveyance unit that conveys the particles 2 and also functions as a support unit that supports the particles 2 conveyed while being carried on the base material 1.

[0076] The pressing unit 140 is disposed on the support roller 130 serving as a support unit with a gap therebetween to flatten the particles 2 and form a particle layer 3. In the manufacturing apparatus 100, the support roller 130 serving as a support unit and the pressing unit 140 are each cylindrical (roller-shaped) and configured to be rotatable about a rotation axis. The support roller 130 and the pressing unit 140 are disposed such that their respective rotation axes are parallel. In the manufacturing apparatus 100, the support roller 130 and the pressing unit 140 are rotated in the same direction with respect to each other, and the particles 2 are passed through the gap provided between the support roller 130 and the pressing unit 140, whereby the particles 2 on the base material 1 are flattened to form a particle layer 3 on the base material 1.

[0077] In other embodiments, the pressing unit 140 may be rotated in a direction opposite to the direction in which the support roller 130 rotates to convey the base material 1.

[0078] The calender roller 160 and the support roller 130 function as a calendering unit to calender the particle layer 3 formed on the base material 1 to form a calendered particle layer 4. That is, the support roller 130 also functions as a calender roller. The calender roller 160 and the support roller 130 are each configured to be rotatable about a rotation axis. The calender roller 160 and the support roller 130 are disposed such that their respective rotation axes are parallel. The calender roller 160 and the support roller 130 rotate in opposite directions with respect to each other to convey the calendered particle layer 4 downstream.

[0079] The laminate 5 of the calendered particle layer 4 conveyed downstream and the base material 1 is wound by a winder 170.

[0080] (Feeding section)

[0081] Figure 2 is a plan view schematically showing the feeding section, pressing section, and support section of the manufacturing apparatus according to the first embodiment. Figure 3-1 is a side view schematically showing the feeding section, pressing section, and support section of the manufacturing apparatus according to the first embodiment. Figure 3-2 Shows Figure 3-1 An enlarged view of a part of. Figure 4This is a perspective view schematically showing an example of a material guiding portion.

[0082] As Figure 2 shown, the material guiding portion 150 has a parallel portion 151 and a protruding portion 152.

[0083] The parallel portion 151 includes a surface 151P parallel to the end surface 140E of the extrusion portion 140.

[0084] The protruding portion 152 protrudes toward the center 140C in the width direction of the extrusion portion 140. Here, the width direction of the extrusion portion 140 is a direction perpendicular to the conveying direction x of the particles 2.

[0085] The parallel portions 151, 151 respectively provided in the pair of material guiding portions 150, 150 are arranged such that the distance W between them is equivalent to the width of the calendered particle layer 4. More specifically, the parallel portions 151, 151 are arranged such that the distance W between the surfaces 151P, 151P of the parallel portions 151, 151 is equivalent to the width of the calendered particle layer 4.

[0086] As Figure 3-1 shown, the extrusion portion 140 has a thickness regulating portion 141. The thickness regulating portion 141 is the portion of the extrusion portion 140 closest to the support roll 130 as the support portion. As Figure 2 shown, the thickness regulating portion 141 is linear.

[0087] The parallel portion 151 of the material guiding portion 150 has an upstream end portion 151E1 located on the upstream side in the conveying direction x of the particles 2 relative to the thickness regulating portion 141 and a downstream end portion 151E2 located on the downstream side in the conveying direction x of the particles 2 relative to the thickness regulating portion 141.

[0088] The upstream end portion 151E1 of the parallel portion 151 is located on the upstream side in the conveying direction x of the particles 2 relative to the upstream end portion 140E1 of the extrusion portion 140, and the downstream end portion 151E2 of the parallel portion 151 is located on the downstream side in the conveying direction x of the particles 2 relative to the downstream end portion 140E2 of the extrusion portion 140.

[0089] Here, the upstream end portion 140E1 of the extrusion portion 140 refers to the line ( Figure 3-1 140E1 in Figure 3-1 ) where the plane (L1 in Figure 3-1 ) including the rotation axis 130R of the support roll 130 as the support portion is tangent to the circumferential surface of the extrusion portion 140 on the upstream side. In addition, the downstream end portion 140E2 of the extrusion portion 140 refers to the line (Figure 3-1 in 140E2).

[0090] In this way, the upstream end portion 151E1 of the parallel portion 151 of the material guiding portion 150 is located on the upstream side in the conveying direction x of the particles 2, closer to the upstream side than the upstream end portion 140E1 of the extrusion portion 140, and the downstream end portion 151E2 of the parallel portion 151 is located on the downstream side in the conveying direction x of the particles 2, closer to the downstream side than the downstream end portion 140E2 of the extrusion portion 140. Therefore, it is possible to effectively suppress the flow of the particles 2 from between the parallel portions 151, 151 to the outside in the direction of the rotation axis 130R of the support roller 130. As a result, it is possible to effectively suppress the reduction in the end smoothness and the reduction in the yield of the particles 2.

[0091] The distances between the upstream end portion 151E1 and the downstream end portion 151E2 of the parallel portion 151 and the thickness defining portion 141 of the extrusion portion 140 can be appropriately selected according to the distance between the support roller 130 as the support portion and the extrusion portion 140, the shapes, sizes, and positional relationships of the support roller 130 and the extrusion portion 140, etc. The ratio (D1 / R140) of the distance D1 between the upstream end portion 151E1 of the parallel portion 151 and the thickness defining portion 141 to the radius R140 of the extrusion portion 140 can be, for example, 0.05 or more, can be 0.5 or more, can be 1.0 or more, and can also be greater than 1.0. For example, it can be 4.0 or less, can be 3.0 or less, and can be 2.0 or less. The ratio (D2 / R140) of the distance D2 between the downstream end portion 151E2 of the parallel portion 151 and the thickness defining portion 141 to the radius R140 of the extrusion portion 140 can be, for example, 0.05 or more, can be 0.5 or more, can be 1.0 or more, and can be greater than 1.0. For example, it can be 4.0 or less, can be 3.0 or less, and can be 2.0 or less.

[0092] As Figure 3-2 shown, the parallel portion 151 has a surface 151D facing the circumferential surface of the support roller 130 as the support portion. The surface 151D is preferably shaped along the surface of the facing support portion. In the manufacturing apparatus 100, the surface 151D is a curved surface along the circumferential surface of the support roller 130. In the cross-section when the parallel portion 151 and the support roller 130 are cut by a plane perpendicular to the rotation axis of the extrusion portion 140, the ratio (R1 / R0) of the radius of curvature R1 of the surface 151D to the radius of curvature R0 of the circumferential surface of the support roller 130 is, for example, 0.95 or more, preferably 0.98 or more, for example, 1.10 or less, preferably 1.05 or less. The ratio (R1 / R0) is ideally 1.00. In this case, the radius of curvature R0 of the circumferential surface of the support roller 130 is the same as the radius of curvature R1 of the surface 151D. In other embodiments, the surface 151D of the parallel portion 151 may also be a flat surface.

[0093] The parallel portion 151 of the guide portion 150 may be in direct contact with the support roller 130 as a support portion, or may be in indirect contact with other components (such as the substrate 1) or may be separated. In this embodiment, the parallel portion 151 is configured to be in indirect contact with the support roller 130 as a support portion via the substrate 1.

[0094] The degree to which the parallel portion 151 is brought into contact with the support roller 130 as a support portion can be appropriately adjusted in consideration of the effect that the contact between the parallel portion 151 and the support roller 130 may have on the support roller 130 or the substrate 1 .

[0095] For example, the ratio of the contact length of the parallel portion 151 to the circumference of the support roller 130 as the support portion is preferably 7.5% or more, more preferably 7.7% or more, further preferably 10% or more, preferably 17.5% or less, more preferably 17% or less, further preferably 13.5% or less, and particularly preferably 13% or less.

[0096] The parallel portion 151 preferably has a small friction with the substrate 1. Specifically, the static friction coefficient between the parallel portion 151 and the substrate 1 is preferably 0.50 or less, and more preferably 0.40 or less. The static friction coefficient between the parallel portion 151 of the guide portion 150 and the substrate 1 is ideally 0, and can be 0.04 or more as a lower limit. The static friction coefficient between the parallel portion 151 and the substrate 1 can be measured in accordance with JIS K7125.

[0097] The smaller the static friction coefficient between the parallel portion 151 and the substrate 1, the easier it is to reduce the adhesion between the particle 2 and the parallel portion 151. Therefore, the smaller the static friction coefficient between the parallel portion 151 and the substrate 1, the more effectively it is possible to suppress the reduction in the end smoothness caused by the particle 2 adhering to the parallel portion 151 of the guide portion 150.

[0098] In addition, the surface 151D of the parallel portion 151 and the support roller 130 as the support portion may also have a gap g. The size of the gap g is preferably adjusted to a degree that can suppress the outflow of the particles 2 from the gap g. For example, the size of the gap g is preferably 70% or less of the volume average particle size (D50) of the particles 2, more preferably 50% or less, preferably 10% or more, and more preferably 20% or more. By making the size of the gap g within the above range, the outflow of the particles 2 from the gap g can be reduced, and the influence on the substrate 1 can be reduced.

[0099] Among them, the volume average particle size (D50) of the particles 2 is the 50% volume average particle size measured and calculated by dry measurement based on a laser diffraction particle size distribution measuring device (for example, Microtrac MT3300EX II; manufactured by Microtrac Bels Co., Ltd.). The 50% volume average particle size is the particle size at the position where the cumulative frequency is 50% when cumulatively counted from the small diameter side in the obtained particle size distribution (volume basis). The average particle size in the examples is also the 50% volume average particle size (D50) measured and calculated by this method.

[0100] As Figure 3-2 and Figure 4 shown, the protruding portion 152 has a first surface 152D facing the circumferential surface of the support roller 130 as a support portion. In the present embodiment, the first surface 152D is rectangular. In addition, in the present embodiment, the first surface 152D is separated from the circumferential surface of the support roller 130. The first surface 152D is separated from the support roller 130 as a support portion, whereby the particles 2 are supplied to the gap between the first surface 152D and the circumferential surface of the support roller 130. As a result, a part of the particles 2 blocked by the protruding portion 152 flows toward the width direction end of the particle layer 3, and the supply amount of the particles 2 at the width direction end of the particle layer 3 becomes closer to uniform. Thereby, the deviation of the weight per unit area in the width direction of the calendered particle layer 4 can be effectively reduced.

[0101] In another embodiment, the first surface of the protruding portion may also be in contact with the circumferential surface of the support roller with a substrate interposed therebetween.

[0102] The distance D3 between the first surface 152D and the support roller 130 as a support portion can be appropriately adjusted according to the conveying speed (linear speed) of the substrate. For example, it is preferably 0 mm or more, more preferably 0.08 mm or more, further preferably 0.3 mm or more, preferably 20 mm or less, more preferably 15 mm or less, and further preferably 10 mm or less.

[0103] The first surface 152D of the protruding portion 152 may be a curved surface along the circumferential surface of the support roller 130 as a support portion, or may be a flat surface.

[0104] As Figure 3-2 shown, the protruding portion 152 is separated from the upstream side in the conveying direction x of the particles 2 from the thickness regulating portion 141. Thus, near the thickness regulating portion 141, the particles 2 flow to Figure 2 the surface 151P of the parallel portion 151 in. Therefore, the situation where the thickness at the width direction end of the particle layer 3 is smaller than the thickness at the width direction center of the particle layer 3 can be reduced. As a result, the deviation of the weight per unit area in the width direction of the calendered particle layer 4 can be reduced.

[0105] The distance D4 between the protruding portion 152 and the thickness regulating portion 141 is preferably less than the distance between the upstream end portion 151E1 of the parallel portion 151 and the thickness regulating portion 141. Thereby, near the thickness regulating portion 141, the amount of the particles 2 flowing to the surface 151P of the parallel portion 151 in Figure 2 is made an appropriate amount, and the situation where the thickness of the width direction end portion of the particle layer 3 is greater than the thickness of the width direction central portion of the particle layer 3 can be reduced. As a result, the deviation of the weight per unit area in the width direction of the calendered particle layer 4 can be reduced. Figure 2 Among them, the amount of the particles 2 on the surface 151P of the parallel portion 151 in Figure 2 is made an appropriate amount, and the situation where the thickness of the width direction end portion of the particle layer 3 is greater than the thickness of the width direction central portion of the particle layer 3 can be reduced. As a result, the deviation of the weight per unit area in the width direction of the calendered particle layer 4 can be reduced.

[0106] The distance D4 between the protruding portion 152 and the thickness regulating portion 141 is, for example, preferably 1 mm or more, more preferably 10 mm or more, further preferably 20 mm or more, preferably 60 mm or less, more preferably 55 mm or less, and further preferably 50 mm or less.

[0107] The maximum thickness Ws of the protruding portion 152 in the width direction of the extrusion portion 140 is preferably 1 mm or more, more preferably 5 mm or more, further preferably 8 mm or more, preferably 100 mm or less, more preferably 50 mm or less, and further preferably 30 mm or less.

[0108] The maximum thickness Ws of the protruding portion 152 in the width direction of the extrusion portion 140 with respect to the distance W between the parallel portions 151, 151 of the material guiding portion 150 (specifically, the distance between the surfaces 151P, 151P, that is, the width of the calendered particle layer) is, for example, preferably 0.1% or more, more preferably 0.5% or more, further preferably 1% or more, still more preferably 2% or more, preferably 25% or less, more preferably 15% or less, and further preferably 10% or less.

[0109] The thickness of the parallel portion 151 in the width direction of the extrusion portion 140 may also be such that the particles 2 can be held between the surfaces 151P, 151P of the parallel portions 151, 151. The thickness of the parallel portion 151 may be, for example, 10 mm or more and may be, for example, 30 mm or less.

[0110] (Deformation example of the protruding portion)

[0111] The protruding portion 152 provided in the material guiding portion 150 is not limited to Figure 4 the shape shown, and can be other shapes protruding toward the center 140C in the width direction of the extrusion portion 140.

[0112] Figure 5 is a perspective view schematically showing an example of the protruding portion. As Figure 5 shown, the shape of the surface 152aD of the protruding portion 152a facing the supporting portion is trapezoidal. In addition, the protruding portion 152a has a surface 152aS approaching the parallel portion downstream in the conveying direction x of the particles 2.

[0113] Figure 6 It is a perspective view schematically showing another example of the protruding portion. As Figure 6 shown, the shape of the surface of the protruding portion 152b facing the supporting portion has a curved portion 152bR approaching the parallel portion downstream in the conveying direction x of the particles 2. In addition, the protruding portion 152b has a curved surface 152bS approaching the parallel portion downstream in the conveying direction x of the particles 2.

[0114] The protruding portion has a surface approaching the parallel portion downstream in the conveying direction x of the particles 2. Thus, the supplied particles 2 flow more smoothly to the parallel portion, and therefore, the deviation of the weight per unit area in the width direction of the calendered particle layer 4 can be reduced more effectively.

[0115] The material constituting the material guiding portion is not particularly limited. Examples of the material of the material guiding portion include resins such as polytetrafluoroethylene (PTFE), acrylonitrile-butadiene-styrene copolymer (ABS), polypropylene (PP), polystyrene (PS), polyethylene (PE), ultra-high molecular weight polyethylene, monomer casting nylon (UMC), polyvinyl chloride (PVC), polyacetal, and methacrylic resin.

[0116] The parallel portion 151 and the protruding portion 152 may be formed as different members and assembled into an integrated material guiding portion 150, or may be formed as an integrated member.

[0117] (Calendering portion)

[0118] As the supporting roller (calendering roller) 130 and the calendering roller 160 of the calendering portion, the particle layer 3 is calendered to form a calendered particle layer 4. As the supporting roller 130 and the calendering roller 160 of the calendering roller, the particle layer 3 is calendered by applying pressure in a direction perpendicular to the surface direction of the particle layer 3 to form a calendered particle layer 4. By compressing the particles in the calendering portion, the adhesion between the particles can be improved, and the adhesion between the substances contained in the particles can be improved. As a result, the strength of the calendered particle layer 4 can be improved.

[0119] By adjusting the gap between the supporting roller 130 and the calendering roller 160 as the calendering roller, the pressing pressure on the particle layer 3 can be adjusted. For example, the pressing pressure can be adjusted by adjusting the difference between the gap size between the supporting roller 130 as the supporting portion and the extrusion portion 140 and the gap size between the supporting roller 130 and the calendering roller 160 as the calendering roller. In addition, the density of the calendered particle layer 4 can be adjusted thereby. The gap between the supporting roller 130 and the calendering roller 160 is usually adjusted to be narrower than the gap between the supporting roller 130 and the extrusion portion 140. For the specific distance, it can be appropriately adjusted according to the thickness and density of the calendered particle layer 4.

[0120] As the calender roll, examples of the material constituting the circumferential surfaces of the support roll 130 and the calender roll 160 include rubber, metal, and inorganic materials.

[0121] The calender roll 160 may also have a mechanism for heating its circumferential surface. Thereby, the particle layer 3 can be calendered while being heated. By calendering the particle layer 3 while heating, the binder material contained in the particles 2 can be softened or melted, and the particles 2 can be bonded to each other more firmly.

[0122] (Supply unit)

[0123] The supply unit 110 supplies the particles 2. In the present embodiment, a desired amount of the particles 2 is supplied onto the base material 1 transported by the base material feeder 121, which serves as a transport unit, and the support roll 130. As such a supply unit 110, for example, a hopper can be used. A hopper generally has a storage section for storing particles, an inlet for introducing particles into the storage section, and an outlet for discharging particles from the storage section.

[0124] The position of the supply unit 110 is generally on the upstream side of the extrusion unit 140 and is a position where the particles 2 can be supplied onto the transported base material 1. The supply unit 110 is preferably arranged so that the particles 2 can be supplied to the central region in the direction (width direction) orthogonal to the transport direction of the transported base material 1.

[0125] Specifically, it is preferable to arrange the outlet of the supply unit 110 within a range of a distance preferably 50% or less, more preferably 45% or less, or even more preferably 40% or less of the width of the base material 1 from the center in the width direction of the base material 1. The position of the end of the outlet of the supply unit 110 in the width direction of the base material 1 is preferably within a range of 40% or more and 50% or less of the width of the base material 1 from the center in the width direction of the base material 1.

[0126] In addition, the size of the outlet of the supply unit 110 in the width direction (length direction of the outlet) of the base material 1 is preferably 80% or more and preferably 100% or less of the width of the base material 1.

[0127] In other embodiments, the outlet of the supply unit 110 may be arranged within a range of a distance, for example, 40% or less of the width of the base material 1 from the center in the width direction of the base material 1, or within a range of a distance, for example, 30% or less of the width of the base material 1 from the center in the width direction of the base material 1.

[0128] The distance from the surface of the base material 1 to the outlet of the supply unit 110 can be appropriately selected according to the supply amount of the particles 2 and the width of the base material 1.

[0129] The supply unit 110 generally supplies the particles 2 such that the unit area weight of the produced calendered particle layer 4 is a desired amount.

[0130] (Coating section)

[0131] The coating section 180 coats the bonding material coating liquid on the substrate 1 to form a bonding material coating liquid layer. By supplying the particles 2 onto the bonding material coating liquid layer, the particles 2 can be further bonded to the substrate 1. As the coating section 180, for example, a slot die head, a gravure printing head, a rod coating head, a doctor blade coating head, etc. can be cited. In other embodiments, the manufacturing apparatus may not have a coating section.

[0132] (Recovery section)

[0133] The winder 170 as the recovery section is arranged on the downstream side of the support roller 130 and the calender roller 160 which are the calender section, and winds and recovers the substrate 1 formed with the calendered particle layer 4. In other embodiments, the manufacturing apparatus may not have a recovery section.

[0134] [3. Second Embodiment of the Manufacturing Apparatus]

[0135] Figure 7 is a side view schematically showing a manufacturing apparatus for a calendered particle layer according to the second embodiment of the present invention. Figure 8 is a side view schematically showing a feed section, an extrusion section, and a support disk included in the manufacturing apparatus according to the second embodiment.

[0136] As Figure 7 shown, the manufacturing apparatus 200 for a calendered particle layer includes a substrate feeder 121, a coating section 180, a supply section 110, a support disk 230 as a support section, an extrusion section 140, a pair of feed sections 250, calender rollers 260a, 260b as a calender section, and a winder 170. The substrate feeder 121, the coating section 180, the supply section 110, the support disk 230, and the winder 170 are arranged in order from the upstream in the transport direction of the particles 2.

[0137] The substrate feeder 121 and the calender rollers 260a, 260b rotate in the direction of transporting the substrate 1 downstream around their respective rotation axes. The particles 2 are supplied onto the substrate 1 and are transported together with the substrate 1. The substrate feeder 121 and the calender rollers 260a, 260b transport the particles 2 together with the substrate 1 downstream by rotation. Therefore, the substrate feeder 121 and the calender rollers 260a, 260b cooperate to function as a transport section for transporting the particles 2 supplied by the supply section 110.

[0138] The support disk 230 is plate-shaped and functions as a support section for supporting the particles 2. The extrusion section 140 is arranged on the support disk 230 as the support section with a gap therebetween, and levels the particles 2 to form a particle layer 3.

[0139] As Figure 8As shown, the parallel portion 251 of the guide portion 250 has an upstream end 251E1 located upstream of the thickness regulating portion 141 in the conveying direction x of the particles 2 and a downstream end 251E2 located downstream of the thickness regulating portion 141 in the conveying direction x of the particles 2.

[0140] The upstream end 251E1 of the parallel portion 251 is located upstream of the upstream end 140E1 of the extrusion portion 140 in the conveying direction x of the particles 2 , and the downstream end 251E2 of the parallel portion 251 is located downstream of the downstream end 140E2 of the extrusion portion 140 in the conveying direction x of the particles 2 .

[0141] The upstream end portion 140E1 of the extrusion portion 140 refers to a plane ( Figure 8 The line (L1 in FIG. 1 ) tangent to the peripheral surface of the extrusion portion 140 Figure 8 140E1 in the figure). In addition, the downstream end portion 140E2 of the extrusion portion 140 refers to a plane ( Figure 8 The line (L2 in FIG. 1 ) tangent to the peripheral surface of the extrusion portion 140 Figure 8 140E2 in the.

[0142] According to such a structure, similar to the guide portion 150, it is possible to effectively prevent the particles 2 from flowing outward in the width direction (the direction perpendicular to the conveying direction of the particles 2) of the support disk 230 as a support portion from between the parallel portions 251, 251. Thus, it is possible to effectively prevent the reduction in the smoothness of the end portions and the reduction in the yield of the particles 2.

[0143] The distances between the upstream end 251E1 and the downstream end 251E2 of the parallel portion 251 and the thickness regulating portion 141 of the extrusion portion 140 can be appropriately selected. The ratio (D1 / R140) of the distance D1 between the upstream end 251E1 of the parallel portion 251 and the thickness regulating portion 141 to the radius R140 of the extrusion portion 140, and the ratio (D2 / R140) of the distance D2 between the downstream end 251E2 of the parallel portion 251 and the thickness regulating portion 141 to the radius R140 of the extrusion portion 140 are as follows:

[0144] The parallel portion 251 may be in direct contact with the support plate 230 as the support portion, or may be in indirect contact with another member (for example, the substrate 1 ) interposed therebetween, or may be separated.

[0145] Similar to the parallel portion 151 of the first embodiment, the parallel portion 251 preferably has a small friction with the base material 1. The coefficient of static friction between the parallel portion 251 and the base material 1 can be the same as the examples and preferred examples of the coefficient of static friction between the parallel portion 151 and the base material 1.

[0146] Except for protruding from the parallel portion 251, the protruding portion 252 of the material guiding portion 250 can adopt the same structure as the protruding portion 152 protruding from the parallel portion 151 described in the manufacturing apparatus 100.

[0147] The calendering rollers 260a and 260b of the calendering portion calender the particle layer 3 formed on the base material 1 to form a calendered particle layer 4. The calendering rollers 260a and 260b are each configured to be rotatable about a rotation axis. The calendering rollers 260a and 260b are arranged such that their rotation axes are parallel. The calendering rollers 260a and 260b rotate in opposite directions to each other and convey the calendered particle layer 4 downstream.

[0148] The gap between the calendering roller 260a and the calendering roller 260b can be adjusted to be the same as the gap between the supporting roller 130 and the calendering roller 160.

[0149] Examples of the material constituting the calendering rollers 260a and 260b include the same examples as the material constituting the peripheral surface of the calendering roller 160. The calendering rollers 260a and 260b can also be the same as the calendering roller 160 and each have a mechanism for heating the peripheral surface.

[0150] [4. Third Embodiment of the Manufacturing Apparatus]

[0151] Figure 9 It is a side view schematically showing a manufacturing apparatus for a calendered particle layer according to the third embodiment of the present invention.

[0152] The manufacturing apparatus 300 includes a supply unit 110, a supporting roller 330, an extrusion unit 140, a pair of material guiding portions 150, a calendering roller 360, a base material feeder 121, a coating unit 180, and a winder 170. The supply unit 110, the supporting roller 330, and the winder 170 are arranged in sequence from the upstream in the conveying direction of the particles 2.

[0153] The base material 1 is fed out by the base material feeder 121 and conveyed downstream by the calendering roller 360.

[0154] The supporting roller 330 functions as a conveying unit for conveying the particles 2 supplied from the supply unit 110 and also functions as a supporting unit for supporting the particles 2. In addition, as will be described later, it also functions as a calendering unit for calendering the particle layer 3 in pairs with the calendering roller 360.

[0155] The particles 2 supported by the circumferential surface of the supported roller 330 are transported downstream by the rotation of the supported roller 330. When the particles 2 pass through the gap between the supported roller 330 and the pressing portion 140, the particles 2 are flattened by the pressing portion 140 to form a particle layer 3.

[0156] The particle layer 3 is calendered between the base material 1 transported by the calender roller 360 and the supported roller 330 to form a calendered particle layer 4, and the formed calendered particle layer 4 is transferred to the base material 1. The calendered particle layer 4 transferred to the base material 1 is wound and recovered by the winder 170 as a laminate 5 of the base material 1 and the calendered particle layer 4.

[0157] The manufacturing apparatus 300 can be the same as the content described for the manufacturing apparatus 100 except for the points described above.

[0158] [5. Fourth Embodiment of the Manufacturing Apparatus]

[0159] Figure 10 It is a side view schematically showing a manufacturing apparatus for a calendered particle layer according to a fourth embodiment of the present invention.

[0160] The manufacturing apparatus 400 includes a base material feeder 121, 422, a supply unit 110, a support disk 230, a pressing portion 140, a pair of guide portions 250, calender rollers 460a, 460b, a base material winder 470, and a winder 170.

[0161] The base material feeder 121, the supply unit 110, the support disk 230, and the winder 170 are arranged in order from the upstream in the transport direction of the particles 2.

[0162] The base material feeder 121 and the calender rollers 460a, 460b rotate in the direction of transporting the base material 1a downstream about their respective rotation axes. The particles 2 are supplied onto the base material 1a, and the particles 2 and the base material 1a are transported downstream together. Therefore, the base material feeder 121 and the calender rollers 460a, 460b cooperate to function as a transport unit for transporting the particles 2 supplied by the supply unit 110.

[0163] The base material 1b is sent out from the base material feeder 422 and transported downstream by the calender roller 460a.

[0164] The calender rollers 460a, 460b as a calendering portion calender the particle layer 3 formed on the base material 1a to form a calendered particle layer 4 and transfer it to the base material 1b. The calender rollers 460a, 460b are each configured to be rotatable about the rotation axis. The calender rollers 460a, 460b are arranged with their respective rotation axes parallel. The calender rollers 460a, 460b rotate in opposite directions to transport the calendered particle layer 4 downstream.

[0165] After the rolled particle layer 4 is transferred to the substrate 1b, the calender roller 460b transports the substrate 1a peeled from the rolled particle layer 4 to the downstream. The substrate 1a is wound up by the substrate winder 470 and recovered.

[0166] The rolled particle layer 4 transferred to the base material 1 b is conveyed downstream by the rolling rollers 460 a and 460 b , and is wound up by the winder 170 and recovered.

[0167] The manufacturing device 400 includes a support plate 230 and a pair of guides 250 as support parts, and in another embodiment, may include a support roller 130 and a pair of guides 150 as support parts. In addition, the manufacturing device 400 may include a coating part 180 .

[0168] [6. Method for producing a calendered particle layer]

[0169] A method for manufacturing a calendered particle layer according to one embodiment of the present invention is a method for manufacturing a calendered particle layer using the calendered particle layer manufacturing device, comprising:

[0170] Step (A), supplying the particles from the supply unit;

[0171] Step (B), transporting the supplied particles;

[0172] Step (C), placing the transported particles on the support portion, flattening the particles using the extrusion portion, and forming the particle layer between the parallel portions of the pair of guide portions; and

[0173] In step (D), the particle layer is rolled using the rolling section to form the rolled particle layer.

[0174] In the production method of the present embodiment, arranging the particles on the support portion includes arranging the particles in direct contact with the support portion and arranging the particles on the support portion via a substrate.

[0175] According to the production method of the present embodiment, it is possible to produce a rolled particle layer having a small variation in weight per unit area in the width direction.

[0176] The manufacturing method of the present embodiment preferably includes, for example, a step of supplying a substrate before step (A), and includes performing steps (A) to (D) on the substrate, that is, a manufacturing method using the manufacturing device for the rolled particle layer of the first embodiment or the second embodiment.

[0177] Hereinafter, each step of the production method according to the present embodiment will be described.

[0178] (Step (E): Substrate Supplying Step)

[0179] Step (E) is a step of supplying a base material before step (A), specifically, a step of supplying a base material from the upstream side of the supply unit of the manufacturing apparatus.

[0180] As the base material, a long strip of base material is usually supplied.

[0181] Specific examples of the base material include metal foils formed of aluminum, platinum, nickel, tantalum, titanium, stainless steel, copper, and other alloys; films containing conductive materials (e.g., carbon, conductive polymers); paper; cloths formed of natural fibers, polymer fibers, etc.; polymer resin films or sheets; etc., which can be appropriately selected according to the purpose. Examples of the polymers contained in the polymer resin films or sheets include polyesters such as polyethylene terephthalate and polyethylene naphthalate, polyimide, polypropylene, polyphenylene sulfide, polyvinyl chloride, aramid, PEN, PEEK, etc.

[0182] Among them, in the case of manufacturing an electrode tab for a lithium-ion battery electrode, as the base material, it is particularly preferable to be able to use a metal foil, a carbon film, or a conductive polymer film, and a metal foil is preferably used. Among them, from the viewpoints of conductivity and withstand voltage, it is particularly preferable to use a copper foil, an aluminum foil, or an aluminum alloy foil. In addition, treatments such as coating treatment, hole opening processing, polishing processing, sandblasting processing, and / or etching processing can also be performed on the surface of the base material.

[0183] The thickness of the base material is, for example, 1 μm or more, preferably 5 μm or more, for example, 1000 μm or less, preferably 800 μm or less. For the width of the base material, it can be any width.

[0184] (Step (A): Supply of Particles)

[0185] Step (A) is a step of supplying particles from the supply unit. Usually, particles are supplied onto the base material from the supply unit.

[0186] The particles are not particularly limited, and examples thereof include granulated particles containing an electrode active material and a binder. The granulated particles may also contain other dispersants, conductive materials, and / or additives as needed.

[0187] When the granulated particles contain an electrode active material, the electrode active material can be a positive electrode active material or a negative electrode active material. When the granulated particles are used as an electrode material for a lithium-ion battery, examples of the positive electrode active material include metal oxides that can reversibly dope and de-dope lithium ions. Examples of such metal oxides include lithium cobalt oxide (LiCoO 2 ), lithium nickel oxide (LiNiO 2 ), lithium manganate (LiMn 2 O 4 ), lithium iron phosphate (LiFePO4 ) A ternary active material obtained by replacing a part of lithium cobaltate with nickel and manganese (for example, LiCo 1 / 3 Ni 1 / 3 Mn 1 / 3 O 2 ), etc. The positive electrode active material of the above example can be used alone or in combination according to the use.

[0188] As the negative electrode active material which is the counter electrode of the positive electrode for a lithium ion battery, low-crystalline carbon (amorphous carbon) such as easily graphitizable carbon, hardly graphitizable carbon, and pyrolytic carbon can be cited; graphite (natural graphite, artificial graphite), alloy-based materials containing tin, silicon, etc.; oxides such as silicon oxide, tin oxide, and lithium titanate; etc. In addition, the electrode active materials of the above example can be used alone or in combination according to the use.

[0189] The electrode active material for a lithium ion battery electrode is preferably granulated into a granular shape. When the shape of the particles is spherical, a higher density electrode can be formed during electrode forming.

[0190] Regarding the volume average particle diameter (D50) of the electrode active material for a lithium ion battery electrode, both the positive electrode active material and the negative electrode active material are preferably 0.1 μm or more and 100 μm or less, more preferably 0.3 μm or more and 50 μm or less, and further preferably 0.5 μm or more and 30 μm or less.

[0191] As the binder material contained in the granulated particles, a compound capable of binding the electrode active materials to each other is preferred. A more preferred binder material is a dispersion-type binder material having the property of being dispersed in a solvent. As the dispersion-type binder material, for example, high molecular compounds such as silicone-based polymers, fluorine atom-containing polymers, conjugated diene-based polymers, acrylate-based polymers, polyimides, polyamides, and polyurethanes can be cited, and fluorine atom-containing polymers, conjugated diene-based polymers, and acrylate-based polymers are preferred, and conjugated diene-based polymers and acrylate-based polymers are more preferred.

[0192] The shape of the dispersion-type binder material is not particularly limited, and a granular shape is preferred. By being in a granular shape, good adhesiveness can be achieved, and in addition, deterioration of the fabricated electrode due to capacity reduction and repeated charge and discharge can be reduced. As the granular binder material, for example, an aqueous dispersion of binder material particles such as latex and granular binder material obtained by drying such an aqueous dispersion can be cited.

[0193] From the viewpoint of sufficiently ensuring the adhesion between the obtained electrode active material layer and the substrate and reducing the internal resistance, based on the dry mass basis, the amount of the binder material is usually 0.1 parts by mass or more and 50 parts by mass or less, preferably 0.5 parts by mass or more and 20 parts by mass or less, more preferably 1 part by mass or more and 15 parts by mass or less, relative to 100 parts by mass of the electrode active material.

[0194] The granulated particles may also use a dispersant as needed as described above. Specific examples of the dispersant include cellulose-based polymers such as carboxymethyl cellulose and methyl cellulose, and their ammonium salts or alkali metal salts. These dispersants can be used alone or in combination of two or more.

[0195] The granulated particles may also use a conductive material as needed as described above. Specific examples of the conductive material include conductive carbon blacks such as furnace black, acetylene black, and Ketjen black (registered trademark of Akzo Nobel Chemicals B.V.). Among them, acetylene black and Ketjen black are preferred. In addition, vapor-grown carbon fibers such as VGCF (registered trademark) and carbon nanotubes; graphite-based carbon materials such as expanded graphite and graphite; graphene; etc. can also be used. These conductive materials can be used alone or in combination of two or more.

[0196] The granulated particles are obtained, for example, by granulating using the electrode active material, the binder material, and other components such as the conductive material added as needed, and at least contain the electrode active material and the binder material. Each constituent component of the granulated particles does not exist as a separate and independent particle, and a particle is formed by two or more components including the electrode active material and the binder material as the constituent components. Specifically, it is preferable to combine each particle of two or more of the above components to form secondary particles, and to combine a plurality (preferably several to dozens) of electrode active materials with the binder material to form particles.

[0197] The manufacturing method of the granulated particles is not particularly limited, and can be manufactured by known granulation methods such as fluidized bed granulation method, spray drying granulation method, and rotary layer granulation method.

[0198] From the viewpoint of easily obtaining a calendered particle layer with a desired thickness, the volume average particle diameter (D50) of the particles is preferably 0.1 μm or more and 1000 μm or less, more preferably 1 μm or more and 500 μm or less, and further preferably 30 μm or more and 250 μm or less.

[0199] The volume average particle diameter (D50) of the particles is the 50% volume average particle diameter measured and calculated by a laser diffraction particle size distribution measuring device (for example, Microtrac MT3300EX II; manufactured by MicrotracBEL Corporation) by dry measurement. The 50% volume average particle diameter is the particle diameter at the position where the cumulative frequency accumulated from the small diameter side in the obtained particle size distribution (volume basis) is 50%.

[0200] The supply amount of the particles supplied from the supply unit can be appropriately adjusted according to the size of the substrate and the desired unit area weight.

[0201] (Step (B): Transportation step)

[0202] Step (B) is a step of transporting the supplied particles.

[0203] In the manufacturing method of the present embodiment, the particles are supplied onto the substrate, and the particles and the substrate are transported together. The transport speed of the particles, that is, the transport speed of the substrate, is preferably 1 m / minute or more, more preferably 5 m / minute or more, further preferably 10 m / minute or more, preferably 300 m / minute or less, more preferably 250 m / minute or less, and further preferably 200 m / minute or less.

[0204] (Step (C): Particle layer forming step)

[0205] Step (C) is a step of disposing the transported particles on the support portion, flattening the particles using the pressing portion, and forming a particle layer between the parallel portions of the pair of guide portions. In Step (C), by passing the particles transported by the transport portion through the gap between the support portion and the pressing portion, the particles are flattened to form a particle layer having a predetermined thickness. Further, in the manufacturing apparatus, since the pair of guide portions has parallel portions including surfaces parallel to the end surface of the pressing portion, a particle layer is formed between the parallel portions respectively provided on the pair of guide portions.

[0206] For the gap between the support portion and the pressing portion and the distance between the parallel portions of the pair of guide portions, they can be appropriately selected according to the desired thickness, size, etc. of the calendered particle layer.

[0207] (Step (D): Calendering step)

[0208] Step (D) is a step of calendering the particle layer using the calendering portion to form a calendered particle layer.

[0209] In Step (D), for example, by adjusting the distance between the pair of calender rolls, the pressure applied to the particle layer can be adjusted.

[0210] In the case where a pair of calender rolls is used as the calendering section, the pressing pressure on the particle layer can be adjusted by adjusting the distance between the respective calender rolls. For example, by adjusting the difference between the distance between the support section and the extrusion section in process (C) and the distance between the respective calender rolls, the density of the calendered particle layer can be adjusted. The distance between the respective calender rolls is usually adjusted to be narrower than the distance between the support section and the extrusion section. The specific distance can be appropriately adjusted according to the thickness and density of the calendered particle layer.

[0211] The thickness of the calendered particle layer obtained in process (D) is not particularly limited.

[0212] (Process (F): Coating process of the binder material coating liquid)

[0213] As an optional process, the manufacturing method of the present embodiment may also have a process of coating a binder material coating liquid containing a binder material on the surface of the base material before the process (A). In this case, in the process (A), the particles are supplied to the surface of the base material coated with the binder material coating liquid.

[0214] The binder material contained in the binder material coating liquid is preferably a compound capable of bonding the particles to the base material. In order to adjust the viscosity and wettability of the coating liquid, additives such as thickeners and surfactants may also be contained in the binder material coating liquid. As the thickener and surfactant, known components can be used. As the binder material, for example, styrene-butadiene rubber (SBR) aqueous dispersion, acrylate-based polymer aqueous dispersion, polyacrylic acid (PAA) aqueous solution, and polyvinylidene fluoride (PVDF) organic solvent-based solution can be cited. In addition, as the binder material coating liquid, for example, a dispersion liquid or solution containing a binder material that can be contained in the particles can be used.

[0215] In addition, in the manufacturing method of other embodiments, the following manufacturing method is preferred. After process (C), a process of supplying a base material is included. In process (D), a manufacturing method of transferring the calendered particle layer to the base material by calendering the particle layer formed on the support section between the supplied base material and the support section using the calendering section is included, that is, a manufacturing method using the manufacturing apparatus for manufacturing the calendered particle layer of the third embodiment.

[0216] In the manufacturing method using the manufacturing apparatus for manufacturing the calendered particle layer of the third embodiment, except that processes (A) to (C) are performed on the support section, a process of supplying a base material is further included after process (C), and in process (D), the calendered particle layer is transferred to the base material by calendering the particle layer formed on the support section between the base material and the support section using the calendering section, the content described in the manufacturing method using the manufacturing apparatus for manufacturing the calendered particle layer of the first embodiment can be the same.

[0217] In the manufacturing method of the present embodiment, as an arbitrary process, a process of coating a bonding material coating liquid containing a bonding material on the surface of the substrate may also be provided between the process of supplying the substrate and process (D).

[0218] The manufacturing method of another embodiment is preferably the following manufacturing method. Using the manufacturing apparatus of the fourth embodiment, processes (A) to (C) are performed on a first substrate as a transfer substrate. After process (C), a process of supplying a second substrate is further included. In process (D), it includes transferring the calendered particle layer to the second substrate by calendering the particle layer formed on the first substrate between the first substrate and the second substrate using a calender part.

[0219] [7. Calendered Particle Layer]

[0220] The manufacturing apparatus for the calendered particle layer of the present embodiment and the manufacturing method using the manufacturing apparatus can be used to calender arbitrary particles to manufacture a calendered particle layer.

[0221] The manufacturing apparatus for the calendered particle layer of the present embodiment and the manufacturing method using the manufacturing apparatus are not particularly limited, but can be used for manufacturing the electrode active material layer of various batteries. Among them, it is particularly preferably used for manufacturing the electrode active material layer of a lithium ion battery. In addition, when the substrate for forming the electrode active material layer is a conductive substrate, a substrate and an electrode active material layer can be obtained as an electrode (electrode tab).

[0222] According to the manufacturing apparatus for the calendered particle layer of the present embodiment and the manufacturing method using the manufacturing apparatus, a calendered particle layer with a small deviation in the weight per unit area in the width direction can be manufactured. By having a small coefficient of variation of the weight per unit area, it can be confirmed that the deviation in the weight per unit area is small.

[0223] The coefficient of variation of the weight per unit area in the width direction of the calendered particle layer is preferably, for example, 2% or less, more preferably 1.5% or less, further preferably 1.1% or less, still further preferably 1% or less. The smaller it is, the more preferable it is, but it can also be 0% or more.

[0224] The coefficient of variation of the weight per unit area in the width direction of the calendered particle layer can be measured in the following manner.

[0225] Measure the weight per unit area at a plurality of equally spaced positions (for example, 5 positions) along the width direction of the calendered particle layer. Among the measured plurality of positions, positions 5 mm inward in the width direction from the width direction end of the calendered particle layer are included. Based on the weight per unit area at these plurality of positions, the coefficient of variation of the weight per unit area in the width direction of the calendered particle layer can be obtained by the following formula.

[0226] Coefficient of variation (%) = (Standard deviation σ of the weight per unit area) / (Average value of the weight per unit area) × 100.

[0227] Examples

[0228] Hereinafter, the present invention will be specifically described with reference to examples. However, the present invention is not limited to the examples shown below, and can be arbitrarily modified within the scope of the claims of the present invention and its equivalent scope.

[0229] In the following description, unless otherwise specified, "%" and "parts" representing amounts are based on mass. In addition, unless otherwise specified, the operations described below are carried out under the conditions of normal temperature (20°C ± 15°C) and normal pressure (1 atm).

[0230] 〔Evaluation method〕

[0231] (Coefficient of variation of the weight per unit area)

[0232] The coefficient of variation of the weight per unit area in the width direction of the negative electrode active material layer as the calendered particle layer was determined as follows.

[0233] Using a manual punching machine (manufactured by Nogami Technology Co., Ltd.), circular test pieces with a diameter of 15.95 mm and an area of 2 cm 2 were punched out from the electrode plates obtained in the examples and comparative examples. Specifically, punching was carried out at 5 positions at equal intervals along the width direction of the electrode plate. The 5 positions included the position 5 mm inward in the width direction from the end in the width direction of the electrode plate.

[0234] The mass of each of the 5 punched test pieces was measured, and the mass of the negative electrode active material layer per 1 cm 2 was calculated (weight per unit area). Based on the following formula, the coefficient of variation of the weight per unit area at 5 positions was determined.

[0235] Coefficient of variation (%) = (Standard deviation σ of the weight per unit area) / (Average value of the weight per unit area) × 100.

[0236] The smaller the coefficient of variation, the smaller the deviation of the weight per unit area in the width direction of the negative electrode active material layer.

[0237] (Surface state of the electrode plate)

[0238] The electrode plates obtained in the examples and comparative examples were visually observed from the side of the negative electrode active material layer, and the presence or absence of linear unevenness and surface roughness was evaluated. The case without linear unevenness and surface roughness was evaluated as "good", and the case with linear unevenness and / or surface roughness was evaluated as "bad".

[0239] If the evaluation is "good", it is determined that there is no excessive or insufficient supply of particles in the base material.

[0240] [Examples 1 to 5]

[0241] (Preparation of slurry for granulated particles)

[0242] 97.7 parts of artificial graphite as the negative electrode active material (average particle size: 24.5 μm, graphite interlayer distance (lattice plane spacing (d value) of the (002) plane according to X-ray diffraction method): 0.354 nm), 1.6 parts of an acrylic binder in terms of solid content conversion, and 0.7 parts of carboxymethyl cellulose (CMC) as a water-soluble polymer (BSH-12; manufactured by Daiichi Kogyo Seiyaku Co., Ltd.) in terms of solid content conversion were mixed. Then, ion-exchanged water was added to make the solid content concentration 35% by mass, and the mixture was mixed and dispersed to obtain a slurry for granulated particles.

[0243] (Manufacture of granulated particles)

[0244] The above slurry for granulated particles was supplied to a spray dryer (manufactured by Okawara Chemical Industry Co., Ltd.) using a needle-type atomizer (diameter 84 mm) with a rotary disk method at a rate of 255 mL / minute, and spray drying granulation was carried out under the conditions of a rotation speed of 17,000 rpm, a hot air temperature of 150 °C, and a temperature at the particle recovery outlet of 90 °C to obtain granulated particles with an average particle size of about 70 μm.

[0245] (Manufacture of negative electrode active material layer)

[0246] Next, a binder coating liquid was prepared by dispersing the same acrylic binder as used for the above granulated particles in water. The properties of this binder coating liquid were as follows: solid content concentration 30% by mass, viscosity 6.7 mPa·s (25 ± 2 °C, 60 rpm), and surface tension 32 mN / m (Wilhelmy method). In addition, as the base material (negative electrode current collector), a long strip-shaped copper foil with a thickness of 10 μm and a width of 250 mm was prepared and placed in Figure 1 the electrode production line (manufacturing apparatus) shown. The linear velocity (transport speed of the base material) is shown in Table 1.

[0247] Strip-shaped current collector exposed portions were ensured at both ends in the width direction of the negative electrode current collector, and between these current collector exposed portions (central region in the width direction), a gravure coater ( Figure 1 coating section 180) was used to coat the prepared binder coating liquid at a coating amount of about 0.003 mg / cm 2 to form a binder coating liquid layer.

[0248] Then, the granulated particles prepared are supplied to the central region in the width direction of the transported negative electrode current collector by a powder supply device (supply unit) at a unit area weight (for each single side) of 28 mg / cm 2 in such a manner that. For the granulated particles supplied onto the negative electrode current collector, they are transported together with the negative electrode current collector to the calendering rollers ( Figure 1 the support roller 130 and the calendering roller 160 in) serving as a pair of calendering parts provided downstream, and the unevenness of the unit area weight is eliminated by a flattening roller ( Figure 1 the extrusion part 140 in), and the height in the vertical direction is made uniform in the width direction of the negative electrode current collector, resulting in a substantially uniform thickness.

[0249] At this time, by disposing a guide part ( Figure 1 the guide part 150 in) at both end faces of the flattening roller, the flow of the granulated particles in the width direction of the current collector is suppressed.

[0250] As the guide part, a member having a parallel part and a protruding part is used. The material of the guide part is polytetrafluoroethylene (PTFE).

[0251] The parallel part has a surface parallel to the end face of the flattening roller (extrusion part). The distance W between the surfaces of the parallel part parallel to the end face of the flattening roller (the distance W corresponds to the width of the negative electrode active material layer as the calendered particle layer) is 200 mm.

[0252] The protruding part is the distance D3 (gap D3) between the first surface (lower surface) facing the support roller and the circumferential surface of the support roller, which is the size shown in Table 1. In addition, the distance D4 (distance D4 from the thickness regulating part) between the protruding part and the thickness regulating part of the extrusion part is the size shown in Table 1. The maximum thickness (thickness Ws) in the width direction of the extrusion part of the protruding part is the size shown in Table 1. In addition, the percentage (Ws / W×100) of the thickness Ws with respect to the distance W is as shown in Table 1.

[0253] The radius R (curvature radius R0) of the calendering roller serving as the support part is the same as the curvature radius R1 of the surface of the parallel part ( Figure 3-2 the surface 151D in), the parallel part faces the circumferential surface of the support roller, the contact length of the current collector on the support roller with respect to the circumference of the support roller is 13.5%, and the gap with the current collector on the support roller is 0 mm.

[0254] In addition, the radius R of the support roller of the manufacturing device is 125 mm, and the radius of the extrusion part is 50 mm. In addition, the extrusion part and the guide part are arranged such that the upstream end of the parallel part of the guide part is upstream of the upstream end of the extrusion part, and the downstream end of the parallel part of the guide part is downstream of the downstream end of the extrusion part.

[0255] Next, by using the calendering roller arranged further downstream (Figure 1 In the middle is a calendering roll (160), which performs roll calendering on the granulated particle layer to form a negative electrode active material layer with a thickness of about 115 μm on the negative electrode current collector, serving as an electrode active material layer (calendered particle layer). Additionally, the calendering conditions are as described below.

[0256] The spacing between the supporting roll and the calendering roll of the calendering section: 100 μm

[0257] Linear pressure: 1 t / cm

[0258] Calendering temperature: 50 °C

[0259] For the laminate (electrode sheet) of the obtained negative electrode active material layer and the negative electrode current collector, evaluation is performed by the method described above.

[0260] 〔Comparative Example 1〕

[0261] As the material guiding section, a plate-shaped member having only a parallel section and no protruding section is used.

[0262] Except for the above matters, it is the same as in Example 1. A negative electrode active material layer is formed on the negative electrode current collector to obtain a laminate, and evaluation is performed by the method described above.

[0263] The manufacturing conditions and evaluation results of each example and comparative example are shown in the following table.

[0264] [Table 1]

[0265] Table 1

[0266]

[0267] In Table 1, "*1" indicates that the weight per unit area at the end in the width direction of the negative electrode active material layer is greater than the average weight per unit area in the width direction, and the end of the sheet is bent.

[0268] The above results show that by providing the material guiding section with a protruding section, the deviation of the weight per unit area in the width direction of the negative electrode active material layer as the calendered particle layer can be reduced. Furthermore, it can be known that by providing the material guiding section with a protruding section, an electrode sheet as a laminate of the calendered particle layer and the base material with a good surface state can be obtained.

[0269] Explanation of reference numerals

[0270] 1: Base material;

[0271] 1a: Base material;

[0272] 1b: Base material;

[0273] 2: Particles;

[0274] 3: Particle layer;

[0275] 4: Calendered particle layer;

[0276] 5: Laminate;

[0277] 100: Manufacturing device;

[0278] 110: Feeding section;

[0279] 121: Base material feeder (transport section);

[0280] 130: Support roll (transport section, support section, calendering section, calender roll);

[0281] 130R: Rotating shaft;

[0282] 140: Extrusion section;

[0283] 140C: Center in the width direction;

[0284] 140E: End face;

[0285] 140E1: Upstream end;

[0286] 140E2: Downstream end;

[0287] 141: Thickness regulating section;

[0288] 150: Guide section;

[0289] 151: Parallel section;

[0290] 151D: Surface;

[0291] 151E1: Upstream end;

[0292] 151E2: Downstream end;

[0293] 151P: Surface;

[0294] 152: Protrusion;

[0295] 152D: Surface;

[0296] 152a: Protrusion;

[0297] 152aD: Surface;

[0298] 152aS: Surface;

[0299] 152b: Protrusion;

[0300] 152bR: Curved section;

[0301] 152bS: Curved surface;

[0302] 160: Calender roll (calendering section);

[0303] 170: Winding machine (recovery section);

[0304] 180: Coating section;

[0305] 200: Manufacturing device;

[0306] 230: Support disk (support section);

[0307] 250: Material guiding section;

[0308] 251: Parallel section;

[0309] 251E1: Upstream end;

[0310] 251E2: Downstream end;

[0311] 252: Protruding section;

[0312] 260a, 260b: Calender roll (calendering section, conveying section);

[0313] 300: Manufacturing device;

[0314] 330: Support roll (conveying section, support section, calendering section);

[0315] 360: Calender roll;

[0316] 400: Manufacturing device;

[0317] 422: Base material feeder;

[0318] 460a, 460b: Calender roll (conveying section, calendering section);

[0319] 470: Base material winder.

Claims

1. A manufacturing apparatus for a calendered particle layer, comprising: A supply unit that supplies particles; A conveying unit that conveys the particles supplied by the supply unit; A supporting unit that supports the particles conveyed by the conveying unit; An extrusion unit that is disposed on the supporting unit with a gap therebetween, flattens the particles to form a particle layer; a pair of guiding units that define the width of the particle layer; And A calendering unit that calenders the particle layer to form a calendered particle layer, The extrusion unit has a thickness defining part closest to the supporting unit, Each of the pair of guiding units has: A parallel part that includes a surface parallel to the end face of the extrusion unit, and has an upstream end located on the upstream side of the thickness defining part and a downstream end located on the downstream side of the thickness defining part; And a protruding part that is disposed on the upstream side of the thickness defining part and protrudes toward the center in the width direction of the extrusion unit, The distance W between the parallel parts respectively provided in the pair of guiding units is configured to correspond to the width of the calendered particle layer.

2. The manufacturing apparatus for a calendered particle layer according to claim 1, Wherein, The extrusion unit is in the shape of a roll.

3. The manufacturing apparatus for a calendered particle layer according to claim 1, Wherein, The protruding part respectively provided in the pair of guiding units has a first surface facing the supporting unit, and the supporting unit is separated from the first surface.

4. The manufacturing apparatus for a calendered particle layer according to claim 1, Wherein, The protruding part respectively provided in the pair of guiding units is separated from the thickness defining part toward the upstream side.

5. The manufacturing apparatus for a calendered particle layer according to claim 3, Wherein, The distance between the first surface of the protruding part respectively provided in the pair of guiding units and the supporting unit is 0 mm or more and 20 mm or less.

6. The manufacturing apparatus for a calendered particle layer according to claim 4, Wherein, The distance between the protruding part respectively provided in the pair of guiding units and the thickness defining part is 1 mm or more and 60 mm or less.

7. The manufacturing apparatus for a calendered particle layer according to claim 1, Wherein, The maximum thickness of the protruding part respectively provided in the pair of guiding units in the width direction of the extrusion unit is 0.1% or more and 25% or less with respect to the distance W.

8. The manufacturing apparatus for a calendered particle layer according to claim 1, Wherein, The maximum thickness of the protruding part respectively provided in the pair of guiding units in the width direction of the extrusion unit is 1 mm or more and 100 mm or less.

9. A manufacturing method for a calendered particle layer, Wherein, Using the manufacturing apparatus for a calendered particle layer according to any one of claims 1 to 8, the manufacturing method includes: Step (A), supplying the particles from the supply unit; Step (B), conveying the supplied particles; Step (C), arranging the conveyed particles on the supporting unit, using the extrusion unit to flatten the particles, and forming the particle layer between the parallel parts of the pair of guiding units; and Step (D), using the calendering unit to calender the particle layer to form the calendered particle layer.

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