Battery material manufacturing device, battery material manufacturing system, and battery material manufacturing method

Abstract

A battery material manufacturing device (100) is provided with an extension device (160), a monitoring device (180), and a control device (200). The extension device (160) receives a sheet-like molded article from the sheet molding device (140) at a first conveyance speed and feeds the received molded article at a second conveyance speed that is faster than the first conveyance speed, thereby reducing the thickness of the molded article, the molded article being obtained by kneading a base material and a filler, and the sheet molding device (140) being designed to continuously feed the molded article. A monitoring device (180) generates monitoring data by monitoring at least one of tension applied to the molded article at each of a plurality of different locations on the molded article, strain induced in the molded article, and thickness of the molded article in order to determine an extension condition in which no void is formed in the molded article, and outputting the generated monitoring data to a control device (200) designed to control the extension conditions.

Description

Technical Field

[0001] The present invention relates to an apparatus for manufacturing battery materials, a system for manufacturing battery materials, and a method for manufacturing battery materials. Background Art

[0002] In recent years, with the increasing demand for batteries in various fields, the development of next-generation batteries has progressed. As an example of such next-generation batteries, technologies have been proposed in which the material of the current collector is changed from metal to resin and a specific polymer is impregnated with an electrolyte.

[0003] For example, Patent Document 1 discloses a resin current collector for a lithium-ion battery, which includes a conductive resin layer containing a matrix resin, a conductive filler, and a conductive filler dispersant.

[0004] Patent Document 2 discloses a resin current collector for a positive electrode, in which a conductive filler is dispersed in a matrix resin containing a specific polymer.

[0005] Patent Document 3 discloses a negative electrode for a lithium-ion battery and a method for manufacturing such a negative electrode for a lithium-ion battery, which includes a current collector and a negative electrode composition layer provided on the surface of the current collector.

[0006] Citation List

[0007] Patent Documents

[0008] Patent Document 1: Japanese Unexamined Patent Application Publication JP 2021-068587;

[0009] Patent Document 2: Japanese Unexamined Patent Application Publication JP 2021-118046;

[0010] Patent Document 3: Japanese Unexamined Patent Application Publication JP 2021-125337. Summary of the Invention

[0011] However, in the inventions disclosed in the above patent documents, it is difficult to say that means for mass-producing lithium-ion batteries or battery materials have been established. In addition, when manufacturing a sheet-like battery material containing a filler, voids may be formed between the base material and the filler. Such voids cause a decrease in battery quality.

[0012] The present disclosure aims to solve such problems, and an object thereof is to provide an apparatus for manufacturing battery materials and the like that can continuously and efficiently manufacture battery materials while preventing voids from being formed in the battery materials.

[0013] The apparatus for manufacturing a battery material according to the present disclosure includes a stretching device and a monitoring device. The stretching device receives a sheet-shaped molded article from a sheet molding device at a first transfer speed and sends out the received molded article at a second transfer speed faster than the first transfer speed, thereby reducing the thickness of the molded article. The molded article is formed by kneading a base material and a filler, and the sheet molding device is designed to continuously send out the molded article. The monitoring device generates monitoring data by monitoring at least one of the tension applied to the molded article at each of a plurality of different positions on the molded article, the strain induced in the molded article, and the thickness of the molded article, in order to determine the stretching conditions under which voids will not be formed in the molded article, and outputs the generated monitoring data to a control device designed to control the stretching conditions.

[0014] In the method for manufacturing a battery material according to the present disclosure, the apparatus for manufacturing a battery material performs the following processes. The apparatus for manufacturing a battery material receives a sheet-shaped molded article from a sheet molding device at a first transfer speed. The molded article is formed by kneading a base material and a filler, and the sheet molding device is designed to continuously send out the molded article. The apparatus for manufacturing a battery material stretches the molded article by sending it out at a second transfer speed to reduce the thickness of the molded article. The apparatus for manufacturing a battery material obtains monitoring data from a monitoring device designed to monitor at least one of the tension applied to the molded article at each of a plurality of different positions on the molded article, the strain induced in the molded article, and the thickness of the molded article. The apparatus for manufacturing a battery material determines the stretching conditions under which voids will not be formed in the molded article based on the monitoring data. The apparatus for manufacturing a battery material controls the stretching device based on the stretching conditions.

[0015] According to the present disclosure, an apparatus for manufacturing a battery material or the like can be provided, which can continuously and effectively manufacture a battery material while preventing voids from being formed during the manufacture of the battery material. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 A structural diagram of a battery according to an embodiment;

[0017] Figure 2 An overall configuration diagram of a battery material manufacturing system according to an embodiment;

[0018] Figure 3 A block diagram of a battery material manufacturing system;

[0019] Figure 4 A diagram for explaining the state of a molded article;

[0020] Figure 5 A first graph showing the relationship between the strain and the tension of a molded article;

[0021] Figure 6 A second graph showing the relationship between the strain and the tension of a molded article;

[0022] Figure 7 A third curve graph showing the relationship between the strain and the tension of a molded product;

[0023] Figure 8 A flowchart of a method for manufacturing a material for a battery; and

[0024] Figure 9 A flowchart showing a control method of a stretching device. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0025] The present invention will be described below by way of embodiments of the present invention, but the present invention according to the claims is not limited to the embodiments shown below. In addition, all the components / structures described in the embodiments are not necessarily means for solving the technical problems. For the sake of clear illustration, parts of the following description and drawings are omitted and appropriately simplified. Note that the same reference numerals (or symbols) are assigned to the same elements in all the drawings, and redundant descriptions thereof are appropriately omitted.

[0026] <Embodiment>

[0027] A battery material manufacturing system according to an embodiment will be described below with reference to the drawings. The battery material manufacturing system according to the present embodiment manufactures materials for manufacturing a specific battery. The specific battery is, for example, a lithium-ion battery, which is a semi-solid battery.

[0028] Figure 1 It is a structural diagram of a battery according to the present embodiment. Figure 1 The battery P100 shown includes, from top to bottom, a current collector P10, a positive electrode layer P20, a separator P30, a negative electrode layer P40, and another current collector P10, all of which are stacked on top of each other in a layered structure.

[0029] Each current collector P10 includes, from top to bottom, a current collector P11 for the negative electrode, a current collector substrate P12, and a current collector P13 for the positive electrode, all of which are stacked on top of each other in a layered structure.

[0030] The current collector P11 for the negative electrode mainly consists of a matrix resin and conductive fillers dispersed in the matrix resin. The matrix resin is, for example, PP (polypropylene), PMMA (polymethylmethacrylate, acrylic resin) or PVC (polyvinylchloride). The conductive fillers are, for example, conductive powder materials such as titanium powder, nickel powder, aluminum powder or carbon black. The conductive fillers are not limited to the above examples and may also be conductive fiber materials such as carbon nanotubes, graphene or metal nanowires. The current collector P11 for the negative electrode may contain a dispersant. The composition and constitution of the dispersant are not limited to any specific composition and constitution as long as the dispersant is composed of a resin that can be formed into a film or sheet. The dispersant may be, for example, a copolymer of PP and PE (polyethylene).

[0031] In the above constitution and the like, when the conductive filler is a powder material, the particle size of the powder material is preferably 1 μm or more and 500 μm or less. In addition, the mass percentage of the conductive filler is preferably 5% or more and 85% or less, more preferably 20% or more and 80% or less. The conductive filler may form secondary particles. The secondary particles are aggregated particles formed by aggregating (clustering) primary particles having a particle size of 1 nm or more and less than 10 μm. The shape of the secondary particles does not necessarily have to be spherical or a spherical-like block, and may also be a shape connected in a bead-like manner or may have a portion branched in a dendritic shape.

[0032] In addition, when the conductive filler is a fiber material, the fiber diameter of the fiber material is 1 nm or more and 500 nm or less, and its fiber length is 1 μm or more and 500 μm or less. In addition, the mass percentage of the conductive filler is preferably 5% or more and 85% or less, more preferably 20% or more and 80% or less.

[0033] Note that the particle size can be appropriately measured by using a particle size distribution measuring device that utilizes laser diffraction and scattering. That is, the particle size can be the average value of the particle size distribution measured by the particle size distribution measuring device. In addition, the fiber diameter and fiber length can also be measured by using the above particle size distribution measuring device. In this case, since the particle size distribution pattern obtained by measurement has multiple peaks, the peak on the small diameter side can be determined as the fiber diameter, and the peak on the large diameter side can be determined as the fiber length.

[0034] The current collector substrate P12 is provided between the current collector P11 for the negative electrode and the current collector P13 for the positive electrode. The current collector substrate P12 contains, for example, PP, a copolymer of PP and PE, carbon black, graphite, etc.

[0035] The main components of the current collector P13 for the positive electrode include a matrix resin and conductive fillers dispersed in the matrix resin. The matrix resin is, for example, PP. In addition, the conductive fillers are, for example, carbon powder or carbon fiber. The form of the carbon powder is not limited to any specific form as long as the carbon powder is a powder material containing carbon as its main component. That is, the carbon powder can be graphite or carbon black. In addition, the form of the carbon fiber is not limited to any specific form as long as the carbon fiber is a fiber material containing carbon as its main component. That is, the carbon fiber can be a carbon nanotube or graphene. In addition, the current collector P13 for the positive electrode may contain a dispersant. The dispersant can be, for example, a copolymer of PP and PE.

[0036] In the above configurations and the like, when the conductive filler is a powder material, the particle size of the powder material is preferably 1 μm or more and 500 μm or less. In addition, the mass percentage of the conductive filler is preferably 5% or more and 85% or less, more preferably 20% or more and 80% or less. The conductive filler can form secondary particles. The secondary particles are aggregated particles formed by aggregating (clustering) primary particles having a particle size of 1 nm or more and less than 10 μm. The shape of the secondary particles does not necessarily have to be spherical or a spherical-like block shape, and can also be a shape connected in a bead-like shape, or can have a portion branched in a dendritic shape.

[0037] In addition, when the conductive filler is a fiber material, the fiber diameter of the fiber material is 1 nm or more and 500 nm or less, and its fiber length is 1 μm or more and 500 μm or less. In addition, the mass percentage of the conductive filler is preferably 5% or more and 85% or less, more preferably 20% or more and 80% or less. For the current collector P10 on the positive electrode side, the current collector P13 for the positive electrode is in contact with the positive electrode layer P20, and the current collector P11 for the negative electrode is provided on the opposite side.

[0038] The positive electrode layer P20 is provided between the current collector P13 for the positive electrode and the separator P30. The positive electrode layer P20 contains a gel-like polymer compound, a positive electrode active material, and a conductive filler. The gelled polymer compound can be a conductive resin.

[0039] The separator P30 is provided between the positive electrode layer P20 and the negative electrode layer P40. The separator P30 is, for example, a polyolefin (PO) microporous membrane or the like.

[0040] The negative electrode layer P40 is provided between the separator P30 and the current collector P11 for the negative electrode. The negative electrode layer P40 contains a gel-like polymer compound, negative electrode active material particles, and a conductive filler. The gelled polymer compound can be a conductive resin.

[0041] The current collector P10 is provided on the side of the negative electrode layer P40 opposite to the side in contact with the separator P30. For the current collector P10 on the negative electrode side, the current collector P11 for the negative electrode is in contact with the negative electrode layer P40, and the current collector P13 for the positive electrode is provided on the opposite side.

[0042] Although the structure of the battery P100 according to the present embodiment has been described above, in addition to the above structure, the battery P100 may include a structural material for maintaining the shape of the battery P100 and the like. In addition, the battery P100 may also be designed to stack a plurality of batteries P100 on top of each other to form a layered structure.

[0043] In the above battery P100, for example, the current collector P10 can be manufactured as follows. That is, the manufacturer first forms the current collector substrate P12 into a film. Next, the manufacturer applies the current collector P11 for the negative electrode to one of the surfaces of the formed current collector substrate P12 and dries the applied current collector P11 for the negative electrode. In addition, the manufacturer applies the current collector P13 for the positive electrode to the surface on the opposite side of the current collector substrate P12 and dries the applied current collector P13 for the positive electrode. The battery material manufacturing system according to this embodiment manufactures, for example, the above current collector substrate P12.

[0044] Next, reference will be made to Figure 2 Describe the battery material manufacturing system. Figure 2 is an overall configuration diagram of the battery material manufacturing system 10 according to the present embodiment. For Figure 2 the battery material manufacturing system 10 shown, for ease of understanding, each component and the like are schematically shown. The battery material manufacturing system 10 shown continuously manufactures, for example, the above current collector substrate P12. The battery material manufacturing system 10 includes a battery material manufacturing apparatus 100 as its main component. In addition, in addition to the battery material manufacturing apparatus 100, the battery material manufacturing system 10 further includes a raw material input section 110, an extruder 120, a pump section 130, a sheet forming apparatus 140, a casting roller 150, a rolling system 190, and a winding apparatus 170.

[0045] (Battery material manufacturing apparatus)

[0046] The battery material manufacturing apparatus 100 manufactures battery materials by receiving a sheet-shaped molded product obtained by kneading a substrate and a filler and stretching (i.e., pulling) the received sheet-shaped molded product. The main components of the battery material manufacturing apparatus 100 include a stretching apparatus 160, a monitoring apparatus 180, and a control apparatus 200.

[0047] The stretching device 160 receives the sheet-shaped molded product sent out from the sheet molding device 140, stretches the received molded product, and sends out the molded product whose thickness has been reduced by stretching. The molded product received by the stretching device 160 is a sheet-shaped molded product obtained by kneading a base material and a filler, and is continuously sent out by the sheet molding device 140. In addition, during this process, the stretching device 160 is controlled such that the conveyance speed on the downstream side, that is, the speed of conveying the molded product, is faster than the conveyance speed on the upstream side. For example, the stretching device 160 receives the molded product at a first conveyance speed and sends out the received molded product at a second conveyance speed faster than the first conveyance speed, thereby stretching, that is, elongating the molded product, and thus reducing its thickness. The above-mentioned first conveyance speed and second conveyance speed of the stretching device 160 are controlled by the control device 200.

[0048] The monitoring device 180 monitors at least one of the tension applied to the molded product, the strain induced in the molded product, and the thickness of the molded product at each of a plurality of different positions on the molded product to determine one or more stretching conditions under which voids will not be formed in the molded product. In addition, the monitoring device 180 generates monitoring data regarding at least one of the tension applied to the molded product, the strain induced in the molded product, and the thickness of the molded product, and outputs the generated monitoring data to the control device 200. The monitoring device 180 may include, for example, a tension sensor for measuring the tension applied to the molded product. In addition, the monitoring device 180 may further include a strain sensor for measuring the strain induced in the molded product. Note that the strain induced in the molded product can be calculated from the difference between the thickness on the upstream side and the thickness on the downstream side. In addition, the strain induced in the molded product can be calculated from the difference between the thickness on the upstream side and the thickness on the downstream side and the length by which the molded product is stretched, that is, elongated, in the conveyance direction. In this case, the monitoring device 180 can measure the thickness by using an optical dimension measuring device. In addition, the monitoring device 180 can calculate the length by which the molded product is stretched, etc., based on the difference between the conveyance speed on the upstream side and the conveyance speed on the downstream side. The monitoring device 180 may include an image sensor for monitoring dimensional changes by photographing the appearance of the molded product.

[0049] The monitoring device 180 may include an optical inspection device for determining the dispersion state of the filler contained in the molded product M2. The means for determining the dispersion state of the filler is not particularly limited. For example, it may include means for detecting the light intensity of the light passing through the molded product M2 when light having a single wavelength or multiple wavelengths passes through the molded product M2. The means for determining the dispersion state of the filler may, for example, include means for detecting light having a specific wavelength in the light scattered by the molded product M2 when light having a single wavelength or multiple wavelengths is applied to the molded product M2. The means for determining the dispersion state of the filler may, for example, include means for visually imaging the dispersion state of the filler by detecting at least one of the light passing through the molded product M2, the light reflected by the molded product M2, and the light scattered by the molded product M2 when light having a single wavelength or multiple wavelengths is applied to the molded product M2. In this case, the control device 200 determines the stretching condition based at least on the dispersion state of the filler in a plurality of different regions on the molded product M2. In this way, the battery material manufacturing system 10 can determine the stretching condition while appropriately determining whether voids are formed in the molded product in one or more stretching portions.

[0050] The monitoring device 180 may include a temperature inspection device for determining the temperature distribution on the molded product M2 (hereinafter also referred to as the temperature distribution). The means for determining the temperature distribution on the molded product M2 is not limited to any specific means, but may, for example, include means for detecting the intensity of the far-infrared light emitted from the molded product M2. In this case, the control device 200 determines the stretching condition based at least on the temperature distribution state of a plurality of different regions of the molded product M2.

[0051] The control device 200 determines the stretching condition in which voids are not formed in the molded product based on the output of the monitoring device 180, and controls the stretching device within the range in which voids are not formed in the molded product based on the determined stretching condition. In this way, the control device 200 controls the stretching device 160 based on the state of the molded product so that voids are not formed in the molded product. In addition, the stretching device 160 can stretch, that is, stretch the molded product while preventing voids from being formed in the molded product.

[0052] Note that in the battery material manufacturing apparatus 100, the stretching device 160 may include a plurality of stretching portions. Figure 2 The illustrated stretching device 160 includes a first stretching portion 161 and a second stretching portion 162.

[0053] In the stretching device 160, the first stretching portion 161 receives the molded product M2 at a conveying speed V5 and sends out the molded product M2 at a conveying speed V6. In addition, the second stretching portion 162 receives the molded product M2 sent out from the first stretching portion 161 and sends out the molded product M2 at a conveying speed V7. Note that the conveying speed V6 is faster than the conveying speed V5. In addition, the conveying speed V7 is faster than the conveying speed V6. In this case, the control device 200 controls the conveying speeds V5, V6, and V7 according to the output of the monitoring device 180 under the condition that voids are not formed in the molded product.

[0054] Figure 2 The stretching device 160 shown includes two stretching portions. However, the stretching device 160 may include three or more stretching portions. With the above configuration, the battery material manufacturing device 100 can perform multiple stretchings within the range where voids are not formed. In this way, the battery material manufacturing device 100 can manufacture a molded product with a desired thickness while maintaining a state where voids are not formed in the molded product.

[0055] In addition, in Figure 2 In the battery material manufacturing device 100 shown, the monitoring device 180 includes a first sensor 181 provided in the upstream region of the first stretching portion 161, a second sensor 182 provided in the intermediate region between the first stretching portion 161 and the second stretching portion 162, and a third sensor 183 provided in the downstream region of the second stretching portion 162. In this case, the control device 200 controls the stretching device 160 according to the outputs of the first sensor 181, the second sensor 182, and the third sensor 183. In this way, the battery material manufacturing device 100 can perform multiple stretchings in multiple stretching portions under stretching conditions where voids are not formed in the molded product.

[0056] The stretching device 160 includes stretching rollers for clamping the front and back surfaces of the molded product and thus stretching the molded product. In this case, the control device 200 controls the rotational speed of the stretching rollers. In this way, the stretching device 160 can appropriately stretch the molded product. Note that the stretching device 160 may include one or more guide rollers for guiding the molded product, etc.

[0057] In the battery material manufacturing device 100, the monitoring device 180 may include a sensor for measuring the tension applied to the molded product. More specifically, the tension sensor measures the force applied in the direction in which the molded product M2 is stretched in the stretching device 160 as the tension applied to the molded product. In this case, the control device 200 controls the stretching device 160 within the range where the above-mentioned tension does not exceed a predetermined threshold tension.

[0058] In the battery material manufacturing apparatus 100, the monitoring device 180 may include a sensor for monitoring strain induced in the molded product. In this case, the control device 200 controls the stretching device 160 within a range where the strain rate (or strain velocity) in the molded product does not exceed a predetermined threshold rate.

[0059] The battery material manufacturing device 100 has been described above. With the above configuration, the battery material manufacturing device 100 can perform stretching after appropriately determining one or more stretching conditions that do not form voids in the molded product in one or more extension portions. The battery material manufacturing device 100 stretches the molded product M2 received from the sheet molding device 140 so that its thickness is reduced to, for example, about 500 μm to 5 μm.

[0060] (Structure of battery material manufacturing system)

[0061] Next, other configurations of the battery material manufacturing system 10 will be described. The raw material input section 110 stores the raw material M1 and supplies it to the extruder 120 through the supply port. The raw material input section 110 may be a container called a hopper. The raw material input section 110 may include a rotary valve. The raw material M1 is a particle of a conductive resin obtained by mixing a resin as a base material and a conductive filler. The raw material M1 contains, for example, 50% by weight or more of a conductive filler as a filler. Note that the shape and size of the particles of the raw material M1 are not limited to any specific shape and size. In the case where the shape is blocky, the diagonal length is preferably 0.1 mm to 50 mm, more preferably 1 mm to 20 mm.

[0062] The extruder 120 receives the raw material M1, mixes the received raw material M1, and supplies the mixed material to the pump unit 130. The pump unit 130 supplies the mixed material received from the extruder 120 to the sheet forming device 140. The pump unit 130 is, for example, a gear pump. Through the above-mentioned structure, the extruder 120 can appropriately mix the raw material and supply (press-feed) the mixed material of the raw material M1 to the sheet forming device 140 at a predetermined pressure.

[0063] The sheet forming device 140 receives the mixture of the raw material M1 from the pump section 130 and continuously discharges the sheet-shaped molded product M2. Specifically, the sheet forming device 140 includes one or more molds called a T-die. The sheet forming device 140 includes a receiving port 141, an extending section 142, and a discharging port 143. The receiving port 141 receives the fluid mixture obtained by kneading the base material and the filler. The extending section 142 guides the mixture in the discharging direction while extending the mixture in a direction perpendicular to the discharging direction. The discharging port 143 is a slit-shaped opening through which the extended mixture can be continuously discharged as a molded product. The sheet forming device 140 supplies the sheet-shaped molded product M2 to the battery material manufacturing device 100 through the casting roller 150. Note that the thickness of the molded product M2 discharged from the discharging port 143 is about 1000 to 1500 microns.

[0064] In addition to the above structure, the sheet forming device 140 may further include a temperature control device. Further, the sheet forming device 140 may further include a degassing section. The degassing section extracts the gaseous bubbles contained in the raw material M1 inside the sheet forming device 140.

[0065] The main components of the degassing section include a branch portion, a branch pipe, a storage portion, and a lead-out pipe. The branch portion is a flow path provided in the component flow path in the sheet forming device 140. The purpose of the branch portion is to extract the gas contained in the raw material M1, such as air bubbles. Therefore, the branch portion can be provided at multiple positions in the sheet forming device 140.

[0066] The branch pipe is a pipe for guiding at least the gas contained in the raw material M1 from the branch portion. The cross-sectional area of the flow path of the branch pipe is not limited to any specific area, that is, any specific size, but the flow path preferably has a cross-sectional area according to the flow rate of the raw material M1 passing through the sheet forming device 140. Therefore, the branch pipe may include a valve for adjusting the cross-sectional area of the flow path of the branch pipe at at least one position on the flow path. Note that the valve preferably has a mechanism for adjusting its opening degree, that is, the opening size, according to an electric signal.

[0067] The storage portion is connected to the branch pipe, arranged above the branch portion, and is a predetermined space having a flow path cross-sectional area larger than the flow path cross-sectional area of the branch pipe. With the above structure, even when the raw material M1 itself flows from the branch portion into the branch pipe, the degassing section can prevent the raw material M1 from flowing back from the storage portion.

[0068] The lead-out pipe guides the gas accumulated in the storage portion to the outside of the sheet forming device 140. The lead-out pipe is connected to a vacuum pump, for example. In this way, the degassing section sucks the gas contained in the raw material M1. Note that the vacuum pump may be connected to multiple lead-out pipes. The storage portion may be connected to multiple branch pipes. With the above structure, the battery material manufacturing system 10 can prevent the formation of air bubbles in the battery material.

[0069] While rotating, the casting roll 150 receives the molded product M2 on its roll surface and sends out the received molded product M2 to the next process. The casting roll 150 contacts the molded product M2, and by doing so, cools and solidifies the molded product M2. The casting roll may include a temperature control unit for adjusting the temperature of the molded product M2 to a predetermined temperature. The casting roll 150 supplies the received molded product M2 to the battery material manufacturing apparatus 100. Note that the casting roll 150 may further include a rotation drive unit, a displacement drive unit, and a drive control unit, so as to be able to adjust the degree of solidification and the degree of extension of the molded product M2. In this case, for example, the casting roll 150 receives and winds the sheet-shaped molded product sent out from the delivery port at the fourth transfer speed, and at the same time, sends out the received molded product. In addition, the rotation drive unit rotationally drives the casting roll 150, so as to send out the molded product M2 at a fifth transfer speed faster than the fourth transfer speed. The casting roll 150, the rotation drive unit, the displacement drive unit, and the drive control unit may be collectively referred to as the casting block. With the above configuration, the casting roll 150 can cool the molded product M2 while extending the molded product M2.

[0070] The rotation drive unit and the drive control unit control, that is, adjust, the speed of the molded product on the surface of the casting roll 150 to a predetermined speed. For example, the casting roll sends out the molded product M2 received at the speed V1 at the speed V2. Note that the speed V2 is set to a value higher than the speed V1. Note that the rotation drive unit includes a motor for rotating the casting roll 150 and a sensor for measuring the rotation speed of the casting roll 150, etc.

[0071] The displacement drive unit is in Figure 2 the Z-axis direction (i.e., in the vertical direction) and in Figure 2Shift the casting roll 150 in the X-axis direction (i.e., in the horizontal direction or in the thickness direction of the molded product M2 fed out in the form of a sheet), that is, move the position of the casting roll 150. More specifically, the displacement driving unit includes, for example: linear tracks respectively along the Z-axis direction and the X-axis direction on which the casting roll 150 can move; bearings that engage with the linear tracks and support the casting roll 150; and a motor for driving the bearings along the linear tracks. The displacement driving unit displaces the casting roll 150 in response to a control signal received from the drive control unit. In this way, the casting roll 150 can appropriately adjust one or more conditions for curing and stretching the molded product M2. Specifically, the displacement driving unit adjusts the temperature of the molded product M2 in contact with the casting roll 150 by adjusting the position of the casting roll 150 in the vertical direction (Z-axis direction), thereby adjusting the degree of curing of the molded product M2. In addition, the displacement driving unit adjusts the position where the casting roll 150 contacts the molded product M2 by adjusting the position of the casting roll 150 in the horizontal direction (X-axis direction), thereby adjusting the degree of stretching of the molded product M2. Note that the displacement driving unit can change the position of the casting roll 150 according to the composition of the molded product M2.

[0072] The drive control unit includes a drive circuit for respectively driving the rotation drive unit and the displacement drive unit, and an arithmetic circuit for respectively driving the rotation drive unit and the displacement drive unit according to data on the rotation speed and position of the casting roll 150 received from the rotation drive unit and the displacement drive unit.

[0073] With the above configuration, the casting roll 150 stretches the molded product M2 fed out from the sheet molding device 140 and in a high-temperature and flowable state, while cooling the molded product M2. Generally, when resin is molded into a film and stretched, that is, drawn, the resin is stretched in a cured state. When the sheet-like molded product M2 containing a filler is stretched in a cured state, especially when a thick sheet (for example, a sheet with a thickness of 1 mm, such as the sheet just fed out from the sheet molding device 140) is stretched, there is a possibility that the sheet may break during stretching, such as being torn, or the thickness of the sheet may become uneven. To prevent such defects, etc., it is necessary to stretch the molded product at a relatively low speed subsequent to the sheet molding device 140. With the above configuration, the battery material manufacturing system 10 can perform a small amount of stretching in a molten state and can stretch the sheet-like molded product M2 into a sheet with a larger width uniformly at high speed. For example, with the above configuration, the casting roll 150 stretches the molded product M2 with a thickness of 1000 microns so that its thickness is reduced to 850 microns.

[0074] The main components of the rolling system 190 include a first rolling device 191, a second rolling device 192, and a third rolling device 193. The rolling system 190 receives the molded product M2 sent out from the casting roll 150 at a speed V2, and causes the first rolling device 191 to roll (i.e., extrude and stretch) the received molded product M2. The first rolling device 191 clamps the front and back surfaces of the molded product M2 with rolling rolls, and while compressing the molded product M2, sends out the molded product M2 at a speed V3.

[0075] The second rolling device 192 receives the molded product M2 rolled by the first rolling device 191 at a speed V3, and while further compressing the molded product M2, sends out the received molded product M2 at a speed V4. The third rolling device 193 receives the molded product M2 rolled by the second rolling device 192 at a speed V4, and while further compressing the molded product M2, sends out the molded product M2 at a speed V5.

[0076] Note that the delivery speed of the rolling device is not limited to any specific speed, but the delivery speed is preferably set such that the more downstream the rolling device is located, the higher the delivery speed of the rolling device. For example, the delivery speed is preferably set to V2 < V3 < V4 < V5. By controlling the speed of each rolling device of the rolling system 190 separately as described above, the rolling system 190 can superimpose the force for extruding and unfolding the molded product M2 in the thickness direction and the force for stretching the current collector P10 in the delivery direction on each other. Therefore, the use of the rolling system 190 enables the molded product M2 to be processed quickly and its thickness to be reduced. Therefore, the battery material manufacturing system 10 can improve productivity.

[0077] In addition to the above configuration, the rolling system 190 may further include a heating device. Moreover, it is sufficient for the rolling system 190 to have at least one rolling device. The rolling system 190 rolls, that is, reduces, the thickness of the molded product M2 received from the casting roll 150 to, for example, about 850 micrometers to 500 micrometers.

[0078] The winding device 170 receives the molded product M2 sent out from the battery material manufacturing device 100, and winds the received molded product M2 into a roll.

[0079] The configuration of the battery material manufacturing system 10 is as described above. In the above configuration, the battery material manufacturing system 10 extends the battery material that has been formed into a sheet in stages. In this way, the battery material manufacturing system 10 can continuously and effectively manufacture the battery material while preventing voids from being formed in the molded product.

[0080] Note that the battery material manufacturing system 10 may further include a process of manufacturing the shaped article M2 cut into sheets by cutting the shaped article M2 using a cutter or a cutting roll. Alternatively, the battery material manufacturing system 10 may further include a process of laminating a plurality of shaped articles M2 or a plurality of sheet-like battery materials, and / or a process of encapsulating them. That is, the battery material manufacturing system 10 may include a lamination molding system for manufacturing a laminate by laminating or stacking sheet-like objects to be laminated including at least one cut shaped article M2 on each other.

[0081] In addition, the battery material manufacturing system 10 may further include a lamination molding system for aligning and laminating a plurality of cut shaped articles M2 as objects to be laminated. The plurality of shaped articles M2 may have the same configuration or different configurations from each other. The plurality of shaped articles M2 may be, for example, a current collector P11 and a current collector substrate P12 for a positive electrode, or a current collector P10 and a current collector substrate P12. The sheet-like battery material is, for example, a resin such as a conductive polymer or a separator having fine voids. The sheet-like battery material is, for example, a metal such as aluminum foil or copper foil. Note that the process of encapsulating the battery material may be a process of encapsulating the battery material including the shaped article M2 with an outer packaging material made of a resin or a metal. In this case, the process of encapsulating the battery material may be a process of enhancing the adhesiveness of the outer packaging material by providing a frame-shaped thermosetting resin between a first metal foil and a second metal foil.

[0082] The process of bonding or encapsulating the battery material may be performed by the lamination molding system. The lamination molding system includes an upper and lower opening / closing type vacuum chamber and presses the objects to be laminated including the cut shaped article M2 in a reduced-pressure environment. Specifically, the lamination molding system receives, for example, a rectangular object to be laminated from one end thereof, and each object is cut into a side length of about 50 mm to 600 mm. Then, the lamination molding system closes the vacuum chamber so that the inside of the vacuum chamber is airtight, and then reduces the pressure inside the vacuum chamber to a predetermined air pressure using a vacuum pump or the like. The predetermined air pressure is, for example, 1 hPa or less. Then, in the vacuum chamber, a predetermined area on the object to be laminated is pressed at a predetermined pressure. The predetermined pressure is, for example, 0.1 MPa to 10 MPa. Finally, the lamination molding system sends out the object to be laminated from the other end thereof and receives the next object to be laminated from one end thereof. Note that the lamination molding system includes a control unit for controlling a series of operations and adjusting the atmosphere inside the vacuum chamber. The control unit may be included in the above-described control device 200.

[0083] The means for transporting the object to be laminated into the lamination forming system and for discharging the object to be laminated from the lamination forming system is not limited to any particular means. For example, such means can be appropriately achieved by placing the object to be laminated on a polyethylene terephthalate (PET) sheet inserted into a vacuum chamber and intermittently moving the sheet in combination with the operation of the vacuum chamber and the like. In addition, the pressing means of the lamination forming system is not limited to any particular means. For example, such means can be means in which an upper platen and a lower platen are hydraulically or electrically raised and lowered, or can be means including means for supplying gas to obtain a predetermined pressure. Alternatively, the pressing means can be means utilizing the expansion and contraction of a diaphragm-like flexible sheet made of a heat-resistant polymer. Note that in the case where a frame-shaped thermosetting resin is provided between a first metal foil and a second metal foil and the battery material as a laminate or stack including the molded product M2 is encapsulated, the battery material manufacturing system 10 preferably includes a frame-shaped pressing surface on one of the upper platen and the lower platen. In this case, due to electrode tabs and the like, there are protrusions and depressions at the place where the exterior material is adhered. Therefore, in order to conform to such protrusions and depressions, for example, the lower pressing surface is preferably formed of a mirror-finished metal plate, and the upper pressing surface is preferably formed of a metal plate including a frame-shaped heat-resistant resin or heat-resistant rubber.

[0084] In addition, the lamination forming system may include a temperature adjusting mechanism for adjusting the temperature of the object to be laminated, such as a heater or a heating medium. The temperature adjusting mechanism may be included in the mechanism for pressing the object to be laminated, or may be provided at other positions. The temperature adjusting mechanism adjusts the temperature of the object to be laminated to fall within a range of, for example, normal temperature to about 200 °C. In this way, the lamination forming system can appropriately bond or encapsulate the battery material.

[0085] As a result, the lamination forming system can prevent lamination defects such as residual bubbles in the gaps between the objects to be laminated, and can bond or encapsulate the battery material including the molded product M2 with satisfactory productivity.

[0086] Next, with reference to Figure 3 the functional configuration of the battery material manufacturing system 10 will be further described. Figure 3 is a block diagram of the battery material manufacturing system 10. The battery material manufacturing system 10 includes, as its main components, a battery material manufacturing apparatus 100, an extruder 120, a sheet forming apparatus 140, a casting roll 150, and a winding apparatus 170. Figure 3 The components shown are appropriately connected so that they can communicate. As Figure 3As shown, the extruder 120, the sheet forming device 140, the casting roller 150, and the winding device 170 are connected to the control device 200 of the battery material manufacturing device 100 so that they can communicate with it. That is, each of these components is controlled by the control device 200.

[0087] The stretching device 160 according to this embodiment may include a temperature control unit 163 for controlling the temperature of the molded product. The temperature control unit 163 controls the atmosphere of the stretching device 160 so that the molded product M2 has a predetermined temperature. The temperature control unit 163 cooperates with the control device 200 to control the temperature of the stretching device 160. Note that, in this case, the monitoring device 180 includes a temperature sensor. In addition, the control device 200 determines the stretching conditions based on the temperature of the molded product. In this way, the battery material manufacturing system 10 can set more effective and more robust stretching condition(s).

[0088] The control device 200 includes an arithmetic device such as a CPU (Central Processing Unit) or an MCU (Micro Controller Unit). The control device 200 includes an arithmetic unit 201 and a storage unit 202. The control device 200 determines the stretching conditions based on the data received from the monitoring device 180 that monitors the state of the molded product, and controls the stretching device so that voids are not formed in the molded product.

[0089] The arithmetic unit 201 determines the stretching conditions based on the data received from the monitoring device 180, and selects or calculates parameters for controlling each component of the battery material manufacturing system 10 according to the determination result. For example, the arithmetic unit 201 calculates the yield time and the completion time. The yield time is the time when at least a part of the monitored portion provided in the molded product reaches the yield tension after the start of stretching, and the completion time is the time when the stretching process is completed in the monitored portion. In this case, when the yield time is earlier than the completion time, the control device 200 controls the stretching device to change the stretching speed. On the other hand, when the yield time is later than the completion time, the control device 200 controls the stretching device to maintain the stretching speed.

[0090] In addition, the control device 200 is connected to each component of the battery material manufacturing system 10 so as to be able to communicate therewith, and has a function of controlling each component. In this way, the battery material manufacturing system 10 can cooperate with the sheet forming device 140 and the battery material manufacturing device 100, so that it can manufacture battery materials more effectively. Note that the means for connecting to enable communication can be wireless communication or wired communication. In addition, the control device 200 preferably includes a display for visually displaying the control status of each component of the battery material manufacturing system 10. In addition, the control device 200 can visually display the status of each component of the battery material manufacturing system 10 on a medium other than the display provided in the control device 200 through wireless communication. The medium other than the display provided in the control device 200 can be, for example, a personal computer, a tablet computer, or a smart phone. In this case, the battery material manufacturing system 10 is more preferably capable of remotely executing, changing, or stopping the control of each component of the battery material manufacturing system 10 through such a medium or software installed on such a medium.

[0091] The storage unit 202 is a storage device that at least includes a non-volatile memory such as a flash memory or an SSD (Solid State Drive). Programs executed by the control device 200 are at least stored in the storage unit 202. In addition, data related to the extension conditions determined by the control device 200 is also stored in the storage unit 202. That is, the control device 200 controls the extension device 160 by referring to the data received from the monitoring device 180 and the data related to the extension conditions stored in the storage unit 202. In addition, the storage unit 202 may further include an interface for electronically or visually outputting past data to the outside.

[0092] The functional configuration of the battery material manufacturing system 10 has been described above. With the above configuration, the battery material manufacturing device 100 can extend the molded product while preventing voids from being formed in the molded product. Therefore, the battery material manufacturing system 10 can continuously manufacture battery materials. Note that the battery material manufacturing system 10 may include two or more control devices 200. In this case, the battery material manufacturing system 10 can control the battery material manufacturing system 10 by connecting multiple control devices to each other so that they can communicate with each other and cooperate with each other.

[0093] Next, the state of the molded product before and after extension will be described with reference to Figure 4 the following. Figure 4 FIG. for illustrating the state of the molded product. The molded product M2 before extension is shown on the Figure 4 left side. Note that in the molded product M2 before extension, the filler F2 is dispersed in the base material F1.

[0094] The molded product M2 after stretching under stretching condition C1 is shown in the upper right part of Figure 4 . Stretching condition C1 is a condition for forming voids in the molded product. Therefore, in the stretched molded product M2, voids F3 are formed around the dispersed filler F2.

[0095] The molded product M2 after stretching under stretching condition C2 is shown in the lower right part of Figure 4 . Stretching condition C2 is a condition for not forming voids in the molded product. Therefore, in the stretched molded product M2, voids F3 are not formed around the dispersed filler F2.

[0096] As described above, depending on the stretching condition, voids may or may not be formed in the molded product M2 after stretching. Therefore, the battery material manufacturing apparatus 100 determines the stretching condition for not forming voids, and then stretches the molded product under the determined stretching condition.

[0097] Next, with reference to Figure 5 , the stretching condition will be described with reference to the relationship between the strain and the tension of the molded product. Figure 5 is the first curve graph showing the relationship between the strain and the tension of the molded product. In the curve graph shown in Figure 5 , the horizontal axis represents the strain (S), and the vertical axis represents the tension (T).

[0098] In this curve graph, the data of the sample M11 is plotted by a dotted line. In the data of the sample M11, the point R11 represented by a circle is the boundary for forming voids. That is, when a tension greater than the tension T11 is applied, voids are formed in the sample M11.

[0099] In addition, in this curve graph, the data of the sample M12 is shown by a solid line below the data of the sample M11. In the data of the sample M12, the point R12 represented by a circle is the boundary for forming voids. That is to say, when a tension greater than the tension T12 is applied, voids are formed in the sample M12.

[0100] As Figure 5 shown, the data plotted according to the samples varies. Therefore, when stretching the molded product while monitoring the tension applied to the molded product, the battery material manufacturing apparatus 100 sets, for example, the threshold tension Tth to a value lower than the tension T12. In this way, the battery material manufacturing apparatus 100 can stretch the molded product while applying a tension lower than the threshold tension Tth under the condition of not forming voids.

[0101] Next, changes in the stretching conditions will be described. At point R12 of sample M12, the inclined straight line represented by the thick double-dotted line indicates the rate of change dT / dS between strain S and tension T. Although the tension applied to sample M11 when voids are formed is different from the tension applied to sample M12 when voids are formed, their rates of change dT / dS between strain S and tension T are approximately the same. Therefore, the battery material manufacturing apparatus 100 can, for example, set a threshold value for the rate of change dT / dS between strain S and tension T. In this way, the battery material manufacturing apparatus 100 can stretch the molded product while monitoring the rate of change dT / dS between strain S and tension T.

[0102] Next, with reference to Figure 6 , the temperature during stretching of the molded product and the strain rate (strain velocity) of the molded product will be described. Figure 6 is the second graph showing the relationship between the strain and tension of the molded product. Similar to the graph shown in Figure 5 , in the graph shown in Figure 6 , the horizontal axis represents strain and the vertical axis represents tension. In addition, Figure 6 the graph in

[0103] shows the case where the atmosphere or temperature (stretching temperature) of the molded product during stretching is 50°C. Figure 6 In -1 , the data at a strain rate of 1.0 s -1 is plotted with a thick solid line. In this case, when the molded product is subjected to a strain greater than the strain at point R21, voids are formed in the molded product. In addition, the data at a strain rate of 0.5 s -1 is plotted with a thick dashed line below the data at a strain rate of 1.0 s -1 is plotted with a thin solid line below the data at a strain rate of 0.5 s -1 In this case, within the strain range shown in this figure, no voids are formed in the molded product.

[0104] As described above, when the stretching temperature is 50°C and the strain rate in the molded product is different, the conditions (i.e., stretching conditions) for forming voids in the molded product are different.

[0105] Figure 7 is the third graph showing the relationship between the strain and tension of the molded product. Similar to the above graph, in the graph shown in Figure 7 , the horizontal axis represents strain and the vertical axis represents tension. In addition, Figure 7 the graph shown in

[0106] exist Figure 7 The thick solid line is used to draw the strain rate of 1.0s -1 In this case, when the molded product is subjected to a strain greater than the strain at point R31, voids are formed in the molded product. In addition, the strain rate is 0.5s -1 The data at a strain rate of 1.0 s are plotted with a thick dashed line. -1 In this case, when the molded product is subjected to a strain greater than the strain at point R32, voids are formed in the molded product. In addition, the strain rate is 0.1s -1 The data at the strain rate of 0.5 s are plotted as thin solid lines. -1 In this case, when the molded product is subjected to a strain greater than the strain at point R33, voids are formed in the molded product.

[0107] As described above, when the molded product is extended, the condition for forming a gap depends on the extension temperature. In addition, when the molded product is extended, the condition for forming a gap also depends on the strain rate. Therefore, in the battery material manufacturing device 100, the control device 200 receives these data from the monitoring device 180, determines the extension condition based on the received data, and controls the extension device 160 under the determined extension condition. In this way, the battery material manufacturing device 100 can effectively perform the extension of the molded product while preventing the formation of gaps in the molded product.

[0108] Next, see Figure 8 The processing performed by the battery material production system 10 will be described. Figure 8 It is a flow chart of a method for manufacturing battery materials.

[0109] First, the battery material manufacturing system 10 adjusts the temperature of each component according to the operation performed by the user (step S10). Note that in this case, in addition to the temperature of the battery material manufacturing device 100, the battery material manufacturing system 10 also adjusts the temperature of the sheet forming device 140, the casting roll 150, etc.

[0110] Subsequently, the battery material manufacturing system 10 starts driving each component and supplies the raw material (step S20). Specifically, the battery material manufacturing system 10 starts driving, for example, the stretching roller of the stretching device 160. Alternatively, the battery material manufacturing system 10 starts driving the screw provided in the extruder 120. Then, the battery material manufacturing system 10 supplies the raw material M1 to the extruder 120.

[0111] Then, the battery material manufacturing system 10 causes the sheet molding device 140 to deliver the molded product M2 molded from the kneaded material (step S30 ). Furthermore, the battery material manufacturing system 10 supplies the molded product M2 to the battery material manufacturing device 100 , thereby stretching the molded product M2 (step S40 ).

[0112] Next, the battery material manufacturing system 10 winds the molded product sent out from the battery material manufacturing device 100 by the winding device 170 to collect the molded product (step S50).

[0113] Subsequently, refer to Figure 9 A description will be given of the processing performed by the battery material manufacturing device 100. Figure 9 It is a flowchart showing a method for controlling the stretching device. Figure 9 The flowchart shown shows Figure 8 The details of step S40 shown.

[0114] First, the battery material manufacturing device 100 starts receiving the molded product M2 (step S41). More specifically, the battery material manufacturing device 100 receives the sheet-shaped molded product M2 from the sheet molding device 140 that continuously sends out the sheet-shaped molded product M2 obtained by kneading the base material and the filler via the casting roller 150. Note that the battery material manufacturing device 100 stretches the received molded product M2 to reduce its thickness. Specifically, for example, the battery material manufacturing device 100 receives the molded product M2 at a first transfer speed, and while conveying the received molded product M2, sends out the molded product M2 at a second transfer speed. In this way, the molded product M2 is stretched to reduce its thickness.

[0115] Subsequently, the control device 200 receives data from the monitoring device 180 (step S42). Note that among the above various data, the monitoring device 180 generates data conforming to the method for determining the predetermined stretching conditions and provides the generated data to the control device 200. In addition, when performing the above process, the control device 200 receives data conforming to the method for determining the predetermined stretching conditions from the monitoring device 180. That is, the control device 200 obtains monitoring data from the monitoring device 180, and the monitoring device 180 monitors at least one of the tension applied to the molded product, the strain caused in the molded product, and the thickness of the molded product at each of a plurality of different positions on the molded product.

[0116] Next, the control device 200 determines the delivery speed V when sending out the molded product M2 in the stretching device 160 OUT whether it is faster than the receiving speed V when receiving the molded product M2 IN (step S43). When it is determined that the delivery speed V OUT is faster than the receiving speed V IN (step S43: Yes), the battery material manufacturing device 100 proceeds to step S44. When it is determined that the delivery speed V OUT is not faster than the receiving speed V IN (step S43: No), the battery material manufacturing device 100 proceeds to step S46.

[0117] In step S44, the control device 200 determines whether the monitoring data received from the monitoring device 180 is within the range of the stretching conditions. When it is within the range of the stretching conditions, no voids are formed in the molded product M2. On the other hand, when it is not within the range of the stretching conditions, there is a possibility that voids are formed in the molded product M2. Therefore, when the control device 200 determines that the monitoring data is within the range of the stretching conditions (step S44: Yes), the battery material manufacturing device 100 proceeds to step S45. On the other hand, when the control device 200 does not determine that the monitoring data is within the range of the stretching conditions (step S44: No), the battery material manufacturing device 100 proceeds to step S46.

[0118] In step S45, the control device 200 determines the thickness B of the molded product M2 at the position where it is sent out by the stretching device 160 OUT whether it is within the required product specifications. More specifically, the control device 200 determines whether the thickness B of the molded product M2 received from the monitoring device 180 OUT is equal to or greater than the thickness B1 and less than the thickness B2 (step S45). When the control device 200 determines that the thickness B of the molded product M2 OUT is equal to or greater than the thickness B1 and less than the thickness B2 (step S45: Yes), the battery material manufacturing device 100 returns to step S43 and continues to monitor the stretching conditions. On the other hand, when the control device 200 does not determine that the thickness B of the molded product M2 OUT is equal to or greater than B1 and less than B2 (step S45: No), the battery material manufacturing device 100 proceeds to step S46.

[0119] In step S46, the control device 200 controls the stretching device 160 (step S46). Note that the control of the stretching device 160 is changed according to the state of the monitoring data and the like. The control device 200 changes at least one of, for example, the transfer speed and the stretching temperature of the stretching device 160. After the control device 200 controls the stretching device 160, the battery material manufacturing device 100 returns to step S43 and continues to monitor the molded product M2 and control the stretching device 160.

[0120] As described above, the control device 200 determines the stretching conditions under which no voids are formed in the molded product M2 based on the monitoring data, and controls the stretching device 160 based on the determined stretching conditions. In this way, the battery material manufacturing device 100 can continuously and effectively manufacture battery materials while preventing voids from being formed in the molded product.

[0121] Note that in the above configuration of the battery material manufacturing system, the shape of the roller is not limited to a cylindrical or columnar shape, and can also be a polyhedral shape or a gear shape. In addition, the roller can be oscillated or vibrated by a motor or the like, and at the same time, their amplitude or frequency can be controlled to a predetermined amplitude or frequency. In this way, the battery material manufacturing system 10 can appropriately cure, roll, stretch, and wind the molded product M2.

[0122] Although the present invention has been described above with reference to exemplary embodiments, the present invention is not limited to the above exemplary embodiments. Various modifications understandable to those skilled in the art can be made to the configuration and details of the present invention within the scope and spirit of the present invention.

[0123] This application is based on and claims the priority of Japanese Patent Application JP 2022-188312 filed on November 25, 2022, the entire disclosure of which is incorporated herein by reference.

[0124] List of Reference Numerals

[0125] 10 Battery material manufacturing system

[0126] 100 Battery material manufacturing apparatus

[0127] 110 Raw material input section

[0128] 120 Extruder

[0129] 130 Pump section

[0130] 140 Sheet forming apparatus

[0131] 141 Receiving port

[0132] 142 Stretching section

[0133] 143 Delivery port

[0134] 150 Casting roller

[0135] 160 Stretching device

[0136] 161 First stretching section

[0137] 162 Second stretching section

[0138] 163 Temperature control section

[0139] 170 Winding device

[0140] 180 Monitoring device

[0141] 181 First sensor

[0142] 182 Second sensor

[0143] 183 Third sensor

[0144] 190 Rolling system

[0145] 191 First rolling device

[0146] 192 Second rolling device

[0147] 193 Third rolling device

[0148] 200 Control device

[0149] 201 Operation unit

[0150] 202 Storage unit

[0151] F1 Substrate

[0152] F2 Filler

[0153] F3 Void

[0154] M1 Raw material

[0155] M2 Molded product

[0156] P10 Current collector

[0157] P11 Current collector for positive electrode

[0158] P12 Current collecting substrate

[0159] P13 Current collector for negative electrode

[0160] P20 Positive electrode layer

[0161] P30 Separator

[0162] P40 Negative electrode layer

[0163] P100 Battery

Claims

1. Battery material manufacturing device, comprising: An extension device designed to receive a sheet-shaped molded product from a sheet molding device at a first transfer speed and send out the received molded product at a second transfer speed faster than the first transfer speed, thereby reducing the thickness of the molded product. The molded product is obtained by kneading a base material and a filler, and the sheet molding device is designed to continuously send out the molded product; and A monitoring device designed to generate monitoring data by monitoring at least one of the tension applied to the molded product, the strain induced in the molded product, and the thickness of the molded product at multiple different positions on the molded product, so as to determine the extension conditions under which voids will not be formed in the molded product, and output the generated monitoring data to a control device designed to control the extension conditions.

2. The battery material manufacturing device according to claim 1, wherein, It further includes a control device, which is designed to determine the extension conditions under which voids will not be formed in the molded product according to the output of the monitoring device, and control the extension device based on the determined extension conditions.

3. The battery material manufacturing device according to claim 2, wherein, The extension device includes: a first extension part and a second extension part. The first extension part is designed to receive the molded product at the first transfer speed and send out the molded product at the second transfer speed, and the second extension part is designed to receive the molded product sent out from the first extension part and send out the molded product at a third transfer speed faster than the second transfer speed, and The control device controls the first transfer speed, the second transfer speed, and the third transfer speed according to the output of the monitoring device.

4. The battery material manufacturing device according to claim 3, wherein, The monitoring device includes a first sensor, a second sensor, and a third sensor. The first sensor is arranged in the upstream area of the first extension part, the second sensor is arranged in the intermediate area between the first extension part and the second extension part, the third sensor is arranged in the downstream area of the second extension part, and The control device controls the extension device according to the outputs of the first sensor, the second sensor, and the third sensor.

5. The battery material manufacturing device according to any one of claims 2 to 4, wherein, The monitoring device includes a sensor designed to measure the tension applied to the molded product, and The control device controls the extension device within a range such that the measured tension does not exceed a predetermined threshold tension.

6. The battery material manufacturing device according to any one of claims 2 to 4, wherein, The monitoring device includes a sensor designed to monitor the strain induced in the molded product, and The control device controls the extension device within a range such that the strain rate in the molded product does not exceed a predetermined threshold rate.

7. The battery material manufacturing device according to any one of claims 2 to 4, wherein, The monitoring device includes a sensor designed to monitor the stretching speed of the molded product and the tension applied to the molded product, and the control device includes an arithmetic unit designed to calculate a yield time, which is the time when at least a part of the monitoring portion provided in the molded product reaches a yield tension after the start of stretching, and a completion time, which is the time when the stretching process is completed in the monitoring portion. When the yield time is earlier than the completion time, the control device controls the stretching device to change the stretching speed. When the yield time is later than the completion time, the control device controls the stretching device to maintain the stretching speed.

8. The battery material manufacturing device according to any one of claims 2 to 4, wherein, the monitoring device includes an optical inspection device designed to determine the dispersion state of the filler, and the control device determines the stretching conditions based at least on the dispersion states in a plurality of different regions.

9. The battery material manufacturing device according to any one of claims 2 to 4, wherein, the stretching device includes a temperature control unit designed to control the temperature of the molded product, the monitoring device includes a temperature sensor, and the control device determines the stretching conditions according to the temperature of the molded product.

10. A battery material manufacturing system, comprising: a sheet molding device designed to continuously feed a sheet-shaped molded product to a stretching device, and including: a receiving port, a stretching portion, and a discharging port. The receiving port is designed to receive a fluid-state kneaded product obtained by kneading a base material and a filler. The stretching portion is designed to stretch the kneaded product in a direction perpendicular to the feeding direction while guiding the kneaded product in the feeding direction. The discharging port is a slit-shaped opening, and the sheet molding device can continuously discharge the stretched kneaded product as a molded product through the opening; and the battery material manufacturing device according to claim 1.

11. The battery material manufacturing system according to claim 10, wherein, it further includes a casting block, which includes a casting roll and a rotation driving unit. The casting roll is designed to receive and wind the sheet-shaped molded product discharged from the discharging port at a fourth conveying speed, and discharge the received molded product while rotating the casting roll, so as to discharge the molded product at a fifth conveying speed faster than the fourth conveying speed.

12. The battery material manufacturing system according to claim 10, wherein, it further includes a rolling system designed to clamp the front and back surfaces of the sheet-shaped molded product discharged from the discharging port and roll the molded product.

13. The battery material manufacturing system according to claim 12, wherein, the rolling system includes a rolling roll designed to clamp the front and back surfaces of the molded product and roll the molded product, and the control device controls the rotation speed of the rolling roll.

14. The battery material manufacturing system according to claim 10, wherein, it further includes: A cutting device, which is designed to cut the molded product and thus manufacture a molded product cut into a sheet shape; and A lamination molding system, which is designed to manufacture a laminate by laminating sheet-like objects to be laminated, and the sheet-like objects include at least one cut molded product.

15. The battery material manufacturing system according to claim 14, wherein, It further includes a lamination molding system, and the lamination molding system includes a frame-shaped pressing surface to laminate at least a part of the exterior material and encapsulate the laminate, and the exterior material is composed of at least any one of a metal foil and a resin.

16. The battery material manufacturing system according to claim 14 or 15, wherein, It further includes a vacuum chamber designed to perform lamination in a reduced-pressure environment.

17. The battery material manufacturing system according to claim 10, wherein, The receiving port receives the mixture containing 50 wt% or more of the conductive filler as the filler.

18. A method for manufacturing a battery material, wherein, The following processes are performed by a battery material manufacturing device having an extending device: Receiving a sheet-shaped molded product from a sheet molding device at a first conveying speed, the molded product being kneaded from a base material and a filler, and the sheet molding device being designed to continuously feed out the molded product; Extending the molded product by feeding out the molded product at a second conveying speed to reduce the thickness of the molded product; Obtaining monitoring data from a monitoring device, the monitoring device being designed to monitor at least one of the tension applied to the molded product, the strain induced in the molded product, and the thickness of the molded product at each of a plurality of different positions on the molded product; Determining an extension condition in which voids will not be formed in the molded product based on the monitoring data; and Controlling the extending device based on the extension condition.

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