Method for manufacturing laminated film

Abstract

The method for manufacturing a laminated film according to the present disclosure is a manufacturing method performed by a molding machine. The manufacturing method includes a step of forming a recess in a laminated film by pressing a front end portion of a punch onto the laminated film placed on a mold with an adjustment mechanism; a step of thermally welding, by means of a heater provided in the mold, a corner portion of the recessed portion formed in the laminated film and a spacer disposed at a corner portion of the tip portion of the punch; and separating the spacer thermally welded to the laminated film from the corner portion of the tip portion of the punch by separating the tip portion of the punch from the mold by the adjustment mechanism.

Description

Technical Field

[0001] This invention relates to a method for manufacturing laminated films. Background Technology

[0002] Japanese Patent Application Publication No. 2004-039271 discloses a method for manufacturing a battery module that can suppress wrinkles in the laminated film during depressurization. Specifically, in Japanese Patent Application Publication No. 2004-039271, when sealing the power generation element by joining the opposing surfaces of the periphery of the laminated film, an insulating spacer is disposed inside the corner of a recess in one of the laminated films. This insulating spacer is embedded in the space between the power generation element and the corner. Therefore, when the laminated films are sealed together under depressurization, the shape of the recess is maintained, preventing wrinkles from forming at the corners of the laminated film. Summary of the Invention

[0003] In the technology described in Japanese Patent Application Publication No. 2004-039271, a spacer is placed inside the corner of the recess of the laminated film housing the power generation element by means of equipment such as a transfer robot or a human hand.

[0004] In recent years, there has been a pursuit of high capacity and high density batteries, exemplified by BEVs (Battery Electronic Vehicles). To achieve this high efficiency, large-scale battery modules are being developed. However, with the increasing size of battery modules, in technologies such as Japanese Patent Application Publication No. 2004-039271, where spacers are configured using transfer robots, gaps arise between the corners of the recessed portion of the laminate and the spacers due to factors such as assembly precision, forming tolerances, and component tolerances. Therefore, a problem arises where the laminate wrinkles when depressurization occurs.

[0005] In view of such problems, the purpose of this disclosure is to provide a method for manufacturing a laminated film that can suppress wrinkling of the laminated film when sealing it under reduced pressure.

[0006] The method for manufacturing the laminated film disclosed herein is performed by a molding machine, said molding machine comprising:

[0007] Mold, for placing the laminated film;

[0008] A punch forms a recess in the laminate by pressing its front end onto the laminate placed in the mold.

[0009] An adjustment mechanism is used to adjust the relative positions of the mold and the punch.

[0010] Spacer, a portion including a corner, disposed at the front end of the punch; and

[0011] Heater, configured in the mold,

[0012] The method for manufacturing the laminated film includes:

[0013] The step of forming a recess in the laminate by pressing the front end of the punch onto the laminate placed on the mold using the adjustment mechanism;

[0014] The step of heat-melting the spacer formed in the corner of the recess of the laminated film and the corner disposed at the front end of the punch by means of the heater;

[0015] The steps of moving the front end of the punch away from the mold and separating the spacer that is hot-melt-applied to the laminate from the corner of the front end of the punch by means of the adjustment mechanism.

[0016] In the method for manufacturing the laminated film disclosed herein, further,

[0017] The spacer is disposed on the edge of the front end of the punch, including the corner portion.

[0018] In the method for manufacturing the laminated film disclosed herein, further,

[0019] The spacer is disposed at the corner of the front end of the punch.

[0020] In the method for manufacturing the laminated film disclosed herein, further,

[0021] The spacer is disposed on the periphery of the front end of the punch, including the corner portion.

[0022] According to this disclosure, a method for manufacturing a laminated film can be provided, which can suppress wrinkles generated in the laminated film when sealing it under reduced pressure. Attached Figure Description

[0023] The features, advantages, and technical and industrial significance of exemplary embodiments of the present invention will be described below with reference to the accompanying drawings, wherein like reference numerals denote like elements, wherein:

[0024] Figure 1 This is a side view showing an example of the structure of the molding machine according to the first embodiment.

[0025] Figure 2 This is a perspective view showing an example of the front end of the punch of the molding machine according to the first embodiment.

[0026] Figure 3 This is a diagram showing the relationship between the position of the heater provided in the recess of the mold in the molding machine of the first embodiment and the position of the spacer when the bottom stop is reached.

[0027] Figure 4 This is a diagram illustrating an example of the operation of the molding machine according to the first embodiment.

[0028] Figure 5A This is a diagram showing the laminate formed by the molding machine of the first embodiment.

[0029] Figure 5B This is a diagram showing the laminate formed by the molding machine of the first embodiment.

[0030] Figure 5C This is a diagram showing the laminate formed by the molding machine of the first embodiment.

[0031] Figure 6A This is a perspective view showing an example of the front end of the punch of a molding machine in a modified example of the first embodiment.

[0032] Figure 6B This is a perspective view showing an example of the front end of the punch of a molding machine in a modified example of the first embodiment. Detailed Implementation

[0033] In the following, embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. In the drawings, the same or corresponding elements are labeled with the same reference numerals, and repeated descriptions are omitted as necessary for clarity.

[0034] (First Implementation)

[0035] First, use Figure 1 The structure of the molding machine 100 according to the first embodiment will be described. Figure 1 This is a side view showing an example of the structure of the molding machine 100 according to the first embodiment.

[0036] like Figure 1 As shown, the molding machine 100 is a device for molding the laminated film X. The laminated film X is an outer casing used to house the power generation elements and spacers of a battery module. The laminated film X is, for example, a metal laminated film with resin layers formed on both sides of a metal layer, having a laminated structure with stacked metal layers and resin layers. The metal layer is, for example, made of aluminum foil. The resin layers on both sides are, for example, made of PP, PET, or nylon. In order to facilitate the heat-sealing of the laminated film X with the spacers 4a and 4b (described later), preferably, the heat-sealing portion of the laminated film X with the spacers 4a and 4b, or the entire laminated film X, is made of a resin with a relatively low melting point (e.g., PP). The thickness of the laminated film X is preferably 50 to 500 μm.

[0037] The molding machine 100 includes a mold 1, a punch 2, an adjustment mechanism 3, spacers 4a and 4b, and heaters 5a and 5b.

[0038] Mold 1 is a component used to hold the laminated film X.

[0039] The punch 2 is a component used to form a recess in the laminated film X by pressing its front end 21 onto the laminated film X placed in the mold 1. The front end 21 of the punch 2 is inserted into the recess 11 provided in the mold 1.

[0040] Spacers 4a and 4b are components used to assemble into the corners of the recesses formed on the laminated film X via the front end 21 of the punch 2. Spacers 4a and 4b are made of resins such as PE, PP, PVC, ABS, or PET (classified as general-purpose plastics) and POM, PEEK, PPS, or PTFE (classified as engineering plastics or super engineering plastics). Alternatively, spacers 4a and 4b can be composed of a combination of multiple resins. Spacers 4a and 4b can be made of raw materials with added reinforcing materials such as glass fiber or carbon fiber to suppress warping and the difference in linear expansion coefficient with the laminated film X. For easy heat-sealing of spacers 4a and 4b with the laminated film X (described later), preferably, the heat-sealing portion of spacers 4a and 4b with the laminated film X, or the entire spacers 4a and 4b, is made of a resin with a relatively low melting point (e.g., PP).

[0041] Spacers 4a and 4b are respectively disposed at the front end portion 21 of the punch 2. For example, spacers 4a and 4b are respectively adsorbed onto the front end portion 21 of the punch 2 in a manner that prevents them from falling off by an adsorption portion (not shown) provided at the front end portion 21. Alternatively, the punch 2 may have a holding portion (not shown) at the front end portion 21 instead of an adsorption portion (not shown), and the holding portion holds spacers 4a and 4b respectively.

[0042] The specific shapes and configurations of spacers 4a and 4b are as follows: Figure 2 As shown. Figure 2 This is a perspective view showing an example of the front end portion 21 of the punch 2 in the molding machine 100 of the first embodiment. (See diagram below.) Figure 2 As shown, spacers 4a and 4b are disposed on the corner portions of the front end portion 21 of the punch 2. More specifically, the front end portion 21 of the punch 2 has four corner portions. Spacer 4a is disposed on the side portion of the front end portion 21 of the punch 2 on the other side (negative x-direction side) that includes two corner portions. Spacer 4b is disposed on the side portion of the front end portion 21 of the punch 2 on one side (positive x-direction side) that includes two corner portions. Furthermore, the number of corner portions of the front end portion 21 of the punch 2 is not limited to four and can be varied in various ways. The number and shape of spacers 4a and 4b can be varied depending on the number of corner portions of the front end portion 21 of the punch 2.

[0043] The adjusting mechanism 3 adjusts the relative position of the mold 1 and the punch 2. Specifically, the adjusting mechanism 3 causes the punch 2 to rise or fall. Here, the position where the laminated film X pressed by the front end 21 of the punch 2 reaches the bottom surface of the recess 11 of the mold 1 becomes the lower stop point of the front end 21 of the punch 2 and the spacers 4a and 4b. In addition, a demolding device 31 is provided in the adjusting mechanism 3, which holds the laminated film X when the front end 21 of the punch 2 presses against the laminated film X during the descent of the punch 2.

[0044] Heaters 5a and 5b are respectively used for heat-melting the corner portion of the recess in the laminated film X formed by the front end portion 21 of the punch 2 and the spacers 4a and 4b disposed on the front end portion 21 of the punch 2. Heaters 5a and 5b are respectively disposed in the recess 11 of the mold 1.

[0045] The specific configurations of heaters 5a and 5b are as follows: Figure 3 As shown. Figure 3 This is a diagram showing the relationship between the positions of the heaters 5a and 5b provided in the recess 11 of the mold 1 in the molding machine 100 of the first embodiment and the positions of the spacers 4a and 4b when the lower stop point is reached. Figure 3 It also means from Figure 1 A diagram showing the relationship between the positions of heaters 5a and 5b and the positions of spacers 4a and 4b when viewed from the upper side of the vertical direction (positive z-direction).

[0046] like Figure 3 As shown, one or more (four in this embodiment) heaters 5a are provided near the lower stop point of the spacer 4a in the bottom surface of the recess 11 of the mold 1. Similarly, one or more (four in this embodiment) heaters 5b are provided near the lower stop point of the spacer 4b in the bottom surface of the recess 11 of the mold 1. Here, the heaters 5a and 5b are preferably disposed on the bottom surface near the corners of the recess 11 of the mold 1. Furthermore, the structure of the heaters 5a and 5b is not limited to... Figure 3 For example, the heaters 5a and 5b are not limited to the bottom of the recess 11 of the mold 1, but can also be located on the side of the recess 11 of the mold 1. Furthermore, the heaters 5a and 5b may not be fixed to the bottom surface of the recess 11 of the mold 1, and can be moved up and down by means of a cylinder or the like. In addition, the number, length, and heat-sealing shape of the heaters 5a and 5b can be varied in various ways.

[0047] The molding machine 100 includes a computer (not shown) with a processor and memory. The processor may be, for example, a microprocessor, an MPU (Micro Processing Unit), or a CPU (Central Processing Unit). Multiple processors may be included. The memory consists of a combination of volatile and non-volatile memory. The memory may include storage devices located remotely from the processor. In this case, the processor can access the memory via an I / O interface (not shown). The processor executes one or more programs including sets of commands to the regulating mechanism 3, heaters 5a and 5b, adsorption section, etc. The program includes sets of commands (or software code) used to cause the computer to perform one or more functions described in the embodiments when read into the computer. The program may be stored on a non-transitory computer-readable medium or a physical storage medium. By way of example, and not limitation, computer-readable media or physical storage media include RAM (random-access memory), ROM (read-only memory), flash memory, SSD (solid-state drive) or other storage technologies, CD-ROM, DVD (digital versatile disc), Blu-ray (registered trademark) disc or other optical disc storage, cassette tape, magnetic tape, disk storage, or other magnetic storage devices. Programs may be transmitted on temporary computer-readable media or communication media. By way of example, and not limitation, temporary computer-readable media or communication media include electrical, optical, acoustic, or other forms of propagation signals.

[0048] Next, use Figure 4 The operation of the molding machine 100 according to the first embodiment will be explained. Figure 4 This is a diagram illustrating an example of the operation of the molding machine 100 of the first embodiment (i.e., the method for manufacturing the laminated film X).

[0049] First, before step S1, spacers 4a and 4b are respectively arranged at the front end 21 of the punch 2 of the molding machine 100. Specifically, the molding machine 100 begins to adsorb the spacers 4a and 4b from the adsorption section to the front end 21 of the punch 2.

[0050] Next, in step S1, the molding machine 100 uses the adjusting mechanism 3 to lower the front end 21 of the punch 2, pressing the front end 21 of the punch 2 onto the laminated film X placed on the mold 1. By doing so, the molding machine 100 forms a recess on the laminated film X.

[0051] Next, in step S2, the molding machine 100 uses heaters 5a and 5b to heat-melt the corner of the recess formed on the laminate X with the spacers 4a and 4b disposed on the front end 21 of the punch 2. For example, if the heat-melting surfaces of the spacers 4a and 4b and the laminate X are all PP and the thickness of the laminate X is approximately 150 μm, then the heat-melting temperature is 200°C and the heat-melting time is approximately 15 seconds. Alternatively, at a heat-melting temperature of 230°C, the heat-melting time is approximately 5 seconds.

[0052] Next, in step S3, the forming machine 100 uses the adjusting mechanism 3 to move the front end 21 of the punch 2 away from the recess 11 of the mold 1, thereby separating the spacers 4a and 4b that are heat-melted onto the laminated film X from the corners of the front end 21 of the punch 2. For example, at a predetermined time after step S1, the forming machine 100 stops adsorbing the spacers 4a and 4b onto the front end 21 of the punch 2 through the adsorption part. By doing so, in step S3, the forming machine 100 can move the front end 21 of the punch 2 away from the recess 11 of the mold 1 using the adjusting mechanism 3, thereby separating the spacers 4a and 4b that are heat-melted onto the laminated film X from the corners of the front end 21 of the punch 2.

[0053] Furthermore, in step S3, the laminated film X finally adheres to the recess 11 side of the mold 1. However, depending on the draft angle of the recess 11 of the mold 1 and the front end 21 of the punch 2, after the front end 21 of the punch 2 is moved away from the recess 11 of the mold 1 by the adjustment mechanism 3, the laminated film X may still adhere to the front end 21 side of the punch 2. In this case, in step S3, after the front end 21 of the punch 2 is moved away from the recess 11 of the mold 1 by the adjustment mechanism 3, it is sufficient to stop the adsorption of the spacers 4a and 4b to the front end 21 of the punch 2 by the adsorption part.

[0054] Figure 5A , 5B , Figure 5C This is a diagram showing the laminate X formed by the molding machine 100 of the first embodiment. Figure 5A This diagram shows the back side (convex side) of the laminate X after the spacers 4a and 4b have been removed from the recess. Figure 5B It means Figure 5A A diagram of the surface of the laminate X. Figure 5C This diagram shows the state in which spacers 4a and 4b are heat-fused onto the recesses of the laminated film X after molding. Figure 5A and 5B In the middle, the spacers 4a and 4b were not heat-fused.

[0055] like Figure 5A and Figure 5BAs shown, at the location where spacer 4a is removed from the formed laminate X (within the area surrounded by dotted lines), the surface roughness of spacer 4a is increased to transfer the shape of spacer 4a, i.e., a wrinkle-like pattern. Additionally, a step is transferred at this location to the connection between spacer 4a and the front end 21 of punch 2. The same process is performed at the location where spacer 4b is removed from the formed laminate X. Therefore, it is shown that the laminate X is formed according to the shapes of spacers 4a and 4b.

[0056] The structure and operation of the molding machine 100 according to the first embodiment have been described above.

[0057] When the spacer is placed in the corner of the recess of the laminate by means of equipment such as a transfer robot, as described in Japanese Patent Application Publication No. 2004-039271, a gap is generated between the corner of the recess of the laminate and the spacer due to the influence of assembly accuracy, molding tolerances and component tolerances.

[0058] However, in the manufacturing method of the laminated film X performed by the forming machine 100 of the first embodiment, the laminated film X is formed by the spacers 4a and 4b disposed at the front end 21 of the punch 2. By doing so, in this manufacturing method, the shape of the spacers 4a and 4b matches the shape of the corner of the recessed portion of the laminated film X after forming. Therefore, this manufacturing method can prevent gaps from forming between the corner of the recessed portion of the laminated film X and the spacers 4a and 4b, and can suppress wrinkles generated in the laminated film X when sealing it under reduced pressure. Furthermore, in this manufacturing method, the spacers 4a and 4b are thermally bonded to the laminated film X. Therefore, this manufacturing method can prevent gaps from forming between the corner of the recessed portion of the laminated film X and the spacers 4a and 4b due to positional deviations of the spacers 4a and 4b, and can further suppress wrinkles generated in the laminated film X when sealing it under reduced pressure.

[0059] (A variation of the first embodiment)

[0060] In the first embodiment described above, spacers 4a and 4b are provided at the front end 21 of the punch 2 of the forming machine 100 (see reference). Figure 1 and Figure 2 The shapes of spacers 4a and 4b are not limited to this example.

[0061] Figure 6A , Figure 6B This is a perspective view of an example of the front end portion 21 of the punch 2 of the molding machine 100, which is a modified example of the first embodiment.

[0062] Figure 6A This is a perspective view of the front end portion 21 of the punch 2 of the molding machine 100 in a modified example of the first embodiment. Figure 6AAs shown, each of the spacers 6a, 6b, 6c, and 6d is respectively disposed at the four corners of the front end 21 of the punch 2, replacing the spacers 4a and 4b. Figure 6B This is a perspective view of the front end portion 21 of the punch 2 of the forming machine 100 in another variation of the first embodiment. (See diagram below.) Figure 6B As shown, spacer 7 is disposed on the periphery of the front end portion 21 of the punch 2, including the four corners, replacing spacers 4a and 4b. Furthermore, the number of corners of the front end portion 21 of the punch 2 is not limited to four and can be varied. Depending on the number of corners of the front end portion 21 of the punch 2, the number and shape of spacers 6a, 6b, 6c, 6d, and spacer 7 can be changed. In addition, the placement and number of heaters 5a and 5b in the first embodiment described above can also be appropriately changed according to the shape of spacers 6a, 6b, 6c, 6d, and spacer 7.

[0063] In addition, such as Figure 2 , Figure 6A and Figure 6B As shown, the shapes of the surfaces of spacers 4a, 4b, 6a, 6b, 6c, 6d, and spacer 7 in the molding machine 100, especially the shapes (e.g., patterns) of the surfaces pressed against the laminated film X, are not limited to the embodiments described above, and can be set individually. By making the shapes of the surfaces of spacers 4a and 4b pressed against the laminated film X characteristic, it becomes easier to detect damage.

[0064] In addition, such as Figure 1 As shown, in the molding machine 100 of the above embodiment, the punch 2 is disposed on the upper side of the mold 1. However, in the modified molding machine 100, it may be configured such that the punch 2 and the mold 1 are reversed and the punch 2 is disposed on the lower side of the mold 1.

[0065] The present disclosure has been described above with reference to the embodiments described above, but the present disclosure is not limited to the embodiments described above. Within the scope of the present disclosure, various changes that can be understood by those skilled in the art can be made to the structure and details of the present disclosure. Each embodiment can be appropriately combined with other embodiments.

[0066] The accompanying drawings are merely illustrative of one or more embodiments. Each drawing may be associated not only with a specific embodiment but also with one or more other embodiments. As those skilled in the art will understand, various features or steps illustrated with reference to any of the drawings can be combined with features or steps shown in one or more other figures to create embodiments not explicitly illustrated or described. Features or steps shown in any of the figures for the purpose of illustrating illustrative embodiments are not essential, and some features or steps may be omitted. The order of steps described in any figure may also be appropriately changed.

Claims

1. A method for manufacturing a laminated film, performed by a molding machine, said molding machine comprising: Mold, for placing the laminated film; A punch forms a recess in the laminate by pressing its front end onto the laminate placed in the mold. An adjustment mechanism is used to adjust the relative positions of the mold and the punch. A spacer, disposed at the front end portion of the punch, including the corner portion; as well as Heater, configured in the mold, The method for manufacturing the laminated film includes: The step of forming a recess in the laminate by pressing the front end of the punch against the laminate placed on the mold using the adjustment mechanism; The step of heat-melting the spacer formed at the corner of the recess in the laminated film and the corner disposed at the front end of the punch using the heater; and The steps of moving the front end of the punch away from the mold and separating the spacer that is heat-melted onto the laminate from the corner of the front end of the punch by means of the adjustment mechanism.

2. The method for manufacturing a laminated film according to claim 1, wherein, The spacer is disposed on the edge of the front end of the punch, including the corner portion.

3. The method for manufacturing a laminated film according to claim 1, wherein, The spacer is disposed at the corner of the front end of the punch.

4. The method for manufacturing a laminated film according to claim 1, wherein, The spacer is disposed on the periphery of the front end of the punch, including the corner portion.

Images