Electrode manufacturing method and electrode manufacturing apparatus

Abstract

To provide an electrode manufacturing method and an electrode manufacturing apparatus that can prevent scattering of a powdery active material in a process of manufacturing an active material layer from the active material.SOLUTION: In a method for manufacturing an electrode including an active material layer, the active material layer is manufactured through a step of supplying a cray-like long-size body that is a mixture of an active material forming the active material layer and an electrolyte, a step of rolling the long-size body into a belt-like body, and a step of cutting, from the belt-like body, an active material layer in a predetermined length in a direction in which the long-size body is fed out.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing an electrode and an apparatus for manufacturing an electrode.

Background Art

[0002] When manufacturing an active material layer included in an electrode of a lithium ion battery, a powdery active material is compacted. Such a method and apparatus for manufacturing an electrode are described in Patent Document 1.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in such a manufacturing method, since the active material is in powder form, it is difficult to handle, and the active material may spill and scatter during the manufacturing process of the active material layer.

[0005] In view of the above circumstances, at least one embodiment of the present disclosure aims to provide a method for manufacturing an electrode and an apparatus for manufacturing an electrode capable of preventing the active material from scattering during the process of manufacturing the active material layer from the powdery active material.

Means for Solving the Problems

[0006] To achieve the above object, a method for manufacturing an electrode according to the present disclosure is a method for manufacturing an electrode including an active material layer, the active material layer being manufactured by a step of supplying a clay-like elongated body that is a mixture of an active material and an electrolytic solution constituting the active material layer, a step of rolling the elongated body so as to form a strip, and a step of cutting the active material layer having a predetermined length in a direction in which the elongated body is fed out from the strip.

[0007] Moreover, the electrode manufacturing apparatus according to the present disclosure is an apparatus for manufacturing an electrode provided with an active material layer, and includes a long body supply unit that supplies a clay-like long body that is a mixture of an active material and an electrolytic solution constituting the active material layer, a rolling unit that rolls the long body into a strip shape, and a cutting unit that cuts the active material layer having a predetermined length in the direction in which the long body is fed out from the strip.

Advantages of the Invention

[0008] According to the electrode manufacturing method and the electrode manufacturing apparatus of the present disclosure, since the active material layer is manufactured by rolling a clay-like long body that is a mixture of an active material and an electrolytic solution into a strip shape and cutting the active material layer from the strip, it is possible to prevent the active material from scattering during the process of manufacturing the active material layer from the powdered active material.

Brief Description of the Drawings

[0009]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Mode for Carrying Out the Invention

[0010] Hereinafter, a method for manufacturing an electrode and a manufacturing apparatus for an electrode according to an embodiment of the present disclosure will be described with reference to the drawings. The embodiments described below show one aspect of the present disclosure, do not limit this disclosure, and can be arbitrarily changed within the scope of the technical idea of this disclosure.

[0011] (Embodiment 1) As shown in FIG. 1, the electrode 1 is a positive electrode or a negative electrode of a lithium ion battery, and includes a frame body 2, an active material layer 3 housed in the frame body 2, a separator 4 provided so as to be in contact with one end face 2a of the frame body 2, and a current collector 5 provided so as to be in contact with the other end face 2b of the frame body 2.

[0012] FIG. 2 shows a schematic configuration of the manufacturing apparatus 10 for the electrode 1. The manufacturing apparatus 10 includes a long body supply unit 11 that supplies a clay-like long body 14 that is a mixture of a powdery active material (an aggregate of active material particles) and an electrolytic solution, a rolling unit 12 that rolls the long body 14 into a strip 15, and a cutting unit 13 that cuts an active material layer 3 having a predetermined length in the direction in which the long body 14 is fed out from the strip 15.

[0013] The configuration of the long body supply unit 11 is not particularly limited, but the long body supply unit 11 may include, for example, a mixer 11a that mixes the active material and the electrolytic solution, and a supply nozzle 11b that causes the mixture in the mixer 11a to flow out of the mixer 11a as the long body 14.

[0014] The configuration of the rolling unit 12 is not particularly limited, but the rolling unit 12 may include, for example, at least a pair of press rollers 17, 17. When the rolling unit 12 includes two or more pairs of press rollers, the rolling unit 12 may include a pair of main press rollers 17a, 17a and at least a pair of pre-press rollers 17b, 17b. The rolling unit 12 is provided between a pair of main press rollers 17a, 17a and on both sides of the elongated body 14 in the width direction of the elongated body 14, and may further include a pair of side rollers 17c, 17c that press the elongated body 14 during rolling from both sides in its width direction.

[0015] The configuration of the cutting unit 13 is not particularly limited, but the cutting unit 13 may include, for example, a cutter 13a that faces, preferably orthogonally, the conveying direction of the strip 15 and is movable up and down.

[0016] The manufacturing apparatus 10 may further include a base material supply unit 18 for placing the elongated body 14 supplied from the elongated body supply unit 11 and supplying a base material 19 for conveying the elongated body 14 and the strip 15. The base material 19 may be a thin cloth, film, or the like. The configuration of the base material supply unit 18 is not particularly limited, but the base material supply unit 18 may have a configuration including, for example, a base material coil 18a around which the base material 19 is wound and a device 18b for pulling the tip of the base material 19 fed out from the base material coil 18a.

[0017] As described later, the manufacturing apparatus 10 manufactures the active material layer 3 with the above-described configuration, but the manufacturing apparatus 10 may include an assembly unit 20 for assembling the electrode 1 by combining the manufactured active material layer 3, the frame body 2, the separator 4, and the current collector 5. The assembly unit 20 may not be included in the manufacturing apparatus 10 and may be installed at another location, and may be configured to bring the active material layer 3 manufactured by the manufacturing apparatus 10 into the assembly unit 20 to form the electrode 1.

[0018] The configuration of the assembly unit 20 is not particularly limited. However, as shown in FIG. 3 for example, the assembly unit 20 may include a conveyor 23 that conveys the current collector 5. Further, the assembly unit 20 may have a configuration in which a frame supply unit 24, a separator supply unit 25, and a pressing unit 26 are sequentially arranged above the conveyor 23 and along the conveyance direction of the conveyor 23. The configuration of the frame supply unit 24 is not particularly limited. However, the frame supply unit 24 may include, for example, a mechanism that can hold or release the frame 2 and a device that raises or lowers this mechanism. The configuration of the separator supply unit 25 is not particularly limited. However, the separator supply unit 25 may include, for example, a mechanism that can hold or release the separator 4 and a device that raises or lowers this mechanism. The configuration of the pressing unit 26 is not particularly limited. However, the pressing unit 26 may include, for example, at least one roller 26a that applies pressure toward the conveyor 23.

[0019] Next, based on FIGS. 2 and 3, a method for manufacturing an electrode according to Embodiment 1 of the present disclosure will be described. First, in the long body supply unit 11, a clay-like mixture formed by mixing an active material and an electrolytic solution input into the mixer 11a is caused to flow out from the mixer 11a through the supply nozzle 11b and supplied to the rolling unit 12 as the long body 14. When the manufacturing apparatus 10 includes the base material supply unit 18, the long body 14 that has flowed out from the long body supply unit 11 is placed on the base material 19 sent out from the base material supply unit 18 and supplied to the rolling unit 12.

[0020] In the rolling section 12, the long body 14 is rolled to form a strip 15 having a predetermined width and a predetermined thickness in a direction orthogonal to the direction in which the long body 14 is fed out. When the long body 14 is placed on the base material 19, it is rolled in a state where the long body 14 is placed on the base material 19. The width and thickness of the strip 15 can be set to the above-mentioned predetermined width and predetermined thickness by adjusting the supply amount of the long body 14 from the base material supply section 18 and the rolling strength in the rolling section 12. When the rolling section 12 is provided with a pair of side rollers 17c, 17c, the shape of the strip 15 can be adjusted so that the width of the strip 15 becomes the distance between the side rollers 17c, 17c. Subsequently, the cutting section 13 cuts the strip 15 to a predetermined length, and the active material layer 3 is cut from the strip 15. When the long body 14 is rolled in a state where it is placed on the base material 19, the base material 19 is also cut by the cutting section 13, so that the active material layer 3 placed on the base material 19 having a predetermined length is obtained.

[0021] The thus obtained active material layer 3, the frame body 2, the separator 4, and the current collector 5 are assembled in the assembly section 20 to form the electrode 1. In the assembly section 20 having the above-described configuration, the current collector 5 placed on the conveyor 23 is being conveyed. The active material layer 3 is placed on the conveyed current collector 5. When the active material layer 3 placed on the base material 19 is brought into the assembly section 20, after peeling the base material 19 from the active material layer 3, the active material layer 3 is placed on the current collector 5. While the active material layer 3 placed on the current collector 5 is being conveyed, the frame body 2 is placed on the current collector 5 so that the active material layer 3 is fitted into the frame body 2 by the frame body supply section 24, and the separator 4 is placed on the end face 2a of the frame body 2 by the separator supply section 25, and the pressing section 26 presses the separator 4 toward the active material layer 3. Through such an operation, the electrode 1 is assembled.

[0022] According to the method for manufacturing an electrode according to Embodiment 1, since the clay-like long body 14, which is a mixture of an active material and an electrolytic solution, is rolled into a strip 15 and the active material layer 3 is cut from the strip 15, the active material can be prevented from scattering in the process of manufacturing the active material layer 3 from the powdery active material.

[0023] (Modification of Embodiment 1) In Embodiment 1, the supply amount of the long body 14 and the rolling strength in the rolling unit 12 were determined in advance so that the width and thickness of the strip 15 would be predetermined values. However, in order to make it possible to change the width during manufacturing, as shown in FIG. 2, the long body supply unit 11 may include a supply amount adjusting device 11c for adjusting the outflow amount (supply amount) of the long body 14 from the mixer 11a. The configuration of the supply amount adjusting device 11c is not particularly limited. For example, the supply amount adjusting device 11c may include a conveying screw for conveying the mixture in the mixer 11a to the outside of the mixer 11a and a device for adjusting the rotation speed of the conveying screw, or may include an extrusion piston for extruding the mixture in the mixer 11a to the outside of the mixer 11a and a device for adjusting the moving speed of the extrusion piston. Further, instead of the device for adjusting the moving speed of the conveying screw or the extrusion piston in the above-described exemplary configuration, a configuration including a device for adjusting the opening area of the outlet of the supply nozzle 11b may be provided. According to such a configuration, the width of the strip 15 can be changed by adjusting the supply amount of the long body 14 supplied to the rolling unit 12. For example, in order to reduce the width of the strip 15, the supply amount of the long body 14 may be reduced.

[0024] In addition to the above-described configuration, a camera 21 for photographing an image or video of the strip 15 in a plan view and a control device 22 such as a computer configured to be capable of wired communication or wireless communication with each of the supply amount adjusting device 11c and the camera 21 may be further provided. According to such a configuration, based on the image or video of the strip 15 photographed by the camera 21, the control device 22 can calculate the width of the strip 15, calculate the deviation from each predetermined value of the width, and determine an appropriate supply amount of the long body 14 based on this dissociation. By operating the supply amount adjusting device 11c by the control device 22 so that the supply amount of the long body 14 becomes the above-described determined value, the width of the strip 15 can be automatically and appropriately adjusted.

[0025] In Embodiment 1, the rolling in the rolling unit 12 was assumed to be cold rolling in which rolling is performed without applying heat. However, the rolling is not limited to cold rolling, and hot rolling in which rolling is performed with heat applied may be used. Since the surface of the active material layer 3 obtained by rolling the long body 14 by hot rolling becomes hard, the handleability during the subsequent processes is improved. Also, since the surface becomes smooth, it becomes easier to conform to the separator 4 and the current collector 5.

[0026] In Embodiment 1, the active material layer 3 is manufactured by rolling the long body 14, which is a clay-like mixture of the active material and the electrolytic solution. However, since the amount of the electrolytic solution with respect to the active material is small, it may be necessary to add the electrolytic solution to the active material layer 3 in the assembling unit 20. In the assembling unit 20 having the configuration shown in FIG. 3, an electrolytic solution supply unit may be provided between the frame supply unit 24 and the separator supply unit 25, and the electrolytic solution may be supplied to the upper surface of the active material layer 3 accommodated in the frame 2. However, when the electrolytic solution is supplied in such a manner, when the electrolytic solution penetrates into the active material layer 3, the air pre-existing in the active material layer 3 must escape. However, if the active material layer 3 is fitted into the frame 2 without gaps, there is no passage for the air in the active material layer 3 to escape, so the air cannot escape, and the electrolytic solution may stay on the upper surface of the active material layer 3 and evaporate as it is.

[0027] The assembling unit 20 may be modified as follows with respect to the above-described configuration so that the electrolytic solution can be efficiently supplied to the active material layer 3. As shown in FIG. 4, in the assembling unit 20', the frame supply unit 24 is configured to place the frame 2 on the current collector 5 placed on the conveyor 23 before the active material layer 3 is conveyed to the assembling unit 20'. The assembling unit 20' includes an electrolytic solution supply unit 27 that supplies the electrolytic solution 28 into the frame 2. When the electrolytic solution 28 is supplied from the electrolytic solution supply unit 27 into the frame 2, the electrolytic solution 28 is stored in the frame 2 placed on the current collector 5. In the assembling unit 20', the active material layer 3 is configured to be fitted into the frame 2 in which the electrolytic solution 28 is stored. The configurations of the components on the downstream side thereof, that is, the separator supply unit 25 and the pressing unit 26, are the same as those of the above-described assembling unit 20.

[0028] In the assembly section 20', since the active material layer 3 is fitted inside the frame body 2 in which the electrolytic solution 28 is stored, the electrolytic solution 28 is absorbed from the lower surface of the active material layer 3, and on the other hand, the air in the active material layer 3 can escape from the upper surface of the active material layer 3. That is, when the electrolytic solution soaks into the active material layer 3, a passage for the air to escape from inside the active material layer 3 is secured. As a result, the electrolytic solution 28 can be efficiently absorbed into the active material layer 3. Also, in such a method of adding the electrolytic solution 28, since a liquid film of the electrolytic solution 28 is formed on the entire inner surface of the frame body 2 placed on the current collector 5, the electrolytic solution 28 can be brought into contact with the entire lower surface of the active material layer 3 uniformly, so that the electrolytic solution 28 can be absorbed uniformly throughout the active material layer 3. With respect to such a method of adding the electrolytic solution, if the electrolytic solution 28 is to be applied to the upper surface of the active material layer 3 after the active material layer 3 is fitted into the frame body 2, a part of the electrolytic solution 28 may adhere to the upper surface of the frame body 2, which may have an adverse effect when the separator 4 is welded to the upper surface of the frame body 2. If an attempt is made to apply the electrolytic solution 28 uniformly to the entire upper surface of the active material layer 3 while avoiding such a possibility, the application operation of the electrolytic solution 28 to the boundary between the upper surface of the frame body 2 and the upper surface of the active material layer 3 becomes difficult. However, with such a method of adding the electrolytic solution, the electrolytic solution 28 can be absorbed uniformly throughout the active material layer 3 while avoiding such difficult operations. Further, with such a method of adding the electrolytic solution, since no liquid pool of the electrolytic solution 28 is formed on the surface of the active material layer 3, it is possible to move on to the next process without worrying about the time for the electrolytic solution 28 to impregnate the active material layer 3, which can contribute to speeding up the manufacturing process.

[0029] In Embodiment 1, the rolling unit 12 was described by taking as an example a configuration in which the rolling unit 12 includes at least a pair of press rollers 17, 17. However, as shown in FIG. 5, the rolling unit 12 may have a configuration including a pair of endless belts 16, 16. If the long body 14 is rolled by the rolling unit 12 having such a configuration, since the rollers do not directly contact the long body 14, it is possible to reduce the risk of unevenness being formed on the surface of the belt-like body 15. Also, in the pressing unit 26 (see FIG. 3) of the assembling unit 20 (see FIG. 3), instead of at least one roller 26a (see FIG. 3), an endless belt may be provided so that the endless belt presses the separator 4 toward the active material layer 3.

[0030] (Embodiment 2) Next, a method for manufacturing an electrode and an electrode manufacturing apparatus according to Embodiment 2 of the present disclosure will be described. The method for manufacturing an electrode and the electrode manufacturing apparatus according to Embodiment 2 are modifications of Embodiment 1 such that the long body 14 is rolled while being sandwiched between two cover films. In Embodiment 2, components that are the same as those in Embodiment 1 are denoted by the same reference numerals, and detailed descriptions thereof are omitted. Also, unless otherwise specified and as long as there is no structural contradiction, each modified form of Embodiment 1 may also be applied in Embodiment 2.

[0031] As shown in FIG. 6, in the manufacturing apparatus 10 according to Embodiment 2, the rolling unit 12 includes a cover film supply unit 30 that supplies two cover films 31, 31 so as to sandwich the long body 14 supplied from the long body supply unit 11. For this reason, the manufacturing apparatus 10 according to Embodiment 2 does not include the base material supply unit 18 (see FIG. 2) of the manufacturing apparatus 10 of Embodiment 1. The configuration of the cover film supply unit 30 is not particularly limited. For example, it may be a configuration including two cover film coils 30a around which the cover film 31 is wound, and a device 30b that pulls the leading ends of the cover films 31, 31 sent out from the cover film coil 30a. The cutting unit 13 in Embodiment 2 may have a configuration including a cutter 13a (see FIG. 2) as in Embodiment 1, or may have a configuration including a laser cutter 13b in order to easily cut the cover film 31. Other configurations can be the same as those in Embodiment 1. Although not limited, instead of the side roller 17c (see FIG. 2) in Embodiment 1, a non-rotating side guard 17d may be provided.

[0032] Next, a method for manufacturing an electrode according to Embodiment 2 of the present disclosure will be described. When the long body 14 is supplied from the long body supply unit 11 to the rolling unit 12 in the same manner as in Embodiment 1, two cover films 31, 31 are supplied from the cover film supply unit 30 toward the long body 14 before the long body 14 flows into the rolling unit 12, so that the long body 14 is sandwiched between the two cover films 31, 31. In the rolling unit 12, since the long body 14 is rolled while being sandwiched between the two cover films 31, 31, a strip 15 sandwiched between the two cover films 31, 31 is formed. Subsequently, the cutting unit 13 cuts the strip 15 together with the two cover films 31, 31 to a predetermined length, so that the active material layer 3 sandwiched between the two cover films 31, 31 is cut from the strip 15.

[0033] In Embodiment 2, since the active material layer 3 is sandwiched between two cover films 31, 31, after peeling the two cover films 31, 31 from the active material layer 3 in the assembly portion 20, in the same manner as in Embodiment 1, the active material layer 3, the frame body 2 (see FIG. 3), the separator 4 (see FIG. 3), and the current collector 5 (see FIG. 3) are assembled to form the electrode 1 (see FIG. 3).

[0034] The active material constituting the active material layer 3 contains a metal component, but the metal component may be oxidized when it comes into contact with oxygen in the air. In contrast, in Embodiment 2, since the active material layer 3 sandwiched between the two cover films 31, 31 can be obtained, the contact between the metal component and oxygen can be suppressed by the cover film 31. Thereby, it is possible to suppress the metal component from being oxidized until the electrode 1 is assembled in the assembly portion 20. Further, since it can also be expected to suppress the corrosion of the metal material of each roller in the rolling portion 12 by the electrolytic solution, special processing such as corrosion countermeasures and maintenance corresponding to corrosion prevention are not required for each roller, so it is expected that the rolling portion 12 will have a cheaper configuration. Also, in Embodiment 2, since the long body 14 is rolled while being sandwiched between the two cover films 31, 31, these serve as reinforcing materials for the long body 14 and the belt-like body 15, making it easier to handle the long body 14 and the belt-like body 15 during conveyance.

[0035] (Modification of Embodiment 2) In Embodiment 2, the long body 14 was rolled while being sandwiched between two cover films 31, 31, but it may be rolled with the long body 14 placed on one cover film 31. In this case, the cover film supply unit 30 of the manufacturing apparatus 10 only needs to include one cover film coil 30a. According to the manufacturing method of this modified form, an active material layer 3 in a state where the cover film 31 is attached only to one of the surfaces of the active material layer 3 can be obtained. The active material layer 3 with the cover film 31 attached only to one surface is inferior in terms of the effect of facilitating the handling during the conveyance of the long body 14 and the strip 15, the effect of suppressing the oxidation of the metal components in the active material constituting the active material layer 3, and the cost for suppressing the corrosion of the metal materials of the rollers in the rolling unit 12 compared to the active material layer 3 sandwiched between two cover films 31, 31. However, compared to the active material layer 3 with no cover film 31 attached to either surface, it is easier to handle the long body 14 and the strip 15 during conveyance, the oxidation of the metal components can be suppressed, and it is also expected to reduce the cost for suppressing the corrosion of the rollers by the electrolytic solution.

[0036] (Embodiment 3) Next, a method for manufacturing an electrode and an apparatus for manufacturing an electrode according to Embodiment 3 of the present disclosure will be described. The method for manufacturing an electrode and the apparatus for manufacturing an electrode according to Embodiment 3 are modifications of Embodiment 2 such that two cover films are peeled off from the strip 15 before cutting the active material layer 3 from the strip 15. In Embodiment 3, the same components as those in Embodiment 2 are denoted by the same reference numerals, and detailed descriptions thereof are omitted. Also, unless otherwise specified and as long as there is no structural contradiction, the modified forms of Embodiment 2 may also be applied in Embodiment 3.

[0037] As shown in FIG. 7, in the manufacturing apparatus 10 according to Embodiment 3, the rolling unit 12 includes a cover film peeling unit 32 that peels the two cover films 31, 31 from the strip 15 sandwiched between the two cover films 31, 31. The configuration of the cover film peeling unit 32 is not particularly limited. For example, it may be a configuration including two cover film winding coils 32a, 32a that wind the two cover films 31, 31 respectively. In Embodiment 3, since the cover film 31 supplied from the cover film coil 30a is wound around the cover film winding coil 32a, the cover film supply unit 30 of Embodiment 3 does not need to include the device 30b (see FIG. 6) unlike Embodiment 2. Although not shown in FIG. 7, it is preferable that a conveyor for placing and conveying the strip 15 from which the two cover films 31, 31 have been peeled is provided downstream of the rolling unit 12. Other configurations can be the same as those in Embodiment 2.

[0038] In Embodiment 3, the configuration of the cutting unit 13 can be made different from those in Embodiments 1 and 2 respectively. For example, the cutting unit 13 may cut the active material layer 3 from the strip 15 by punching. In this case, the cutting unit 13 may include a die 13c for punching and a roller 13d provided so as to cross the strip 15 in its width direction.

[0039] Next, a method for manufacturing an electrode according to Embodiment 3 of the present disclosure will be described. Similar to Embodiment 2, the long body 14 supplied from the long body supply unit 11 to the rolling unit 12 is rolled while being sandwiched between the two cover films 31, 31 supplied from the cover film supply unit 30, and a strip 15 sandwiched between the two cover films 31, 31 is formed. The two cover films 31, 31 are peeled from the strip 15 sandwiched between the two cover films 31, 31, and each of the two cover films 31, 31 is wound around each of the two cover film winding coils 32a, 32a. The strip 15 from which the two cover films 31, 31 have been peeled is conveyed to the cutting unit 13.

[0040] In the case where the cutting portion 13 includes the die 13c and the roller 13d, the die 13c forms a cut 33 corresponding to the periphery of the active material layer 3 in the strip 15. The strip 15 with the cut 33 formed therein can have its direction changed by the roller 13d in a direction perpendicular to the direction in which it is carried out from the rolling portion 12. However, the portion surrounded by the cut 33 is pressed by the roller 13d while passing through the roller 13d, so the conveying direction cannot be changed. On the other hand, only the portion outside the cut 33 can have its conveying direction changed. As a result, the portion surrounded by the cut 33 is removed from the strip 15, and the active material layer 3 is cut from the strip 15. The strip 15 from which the active material layer 3 has been cut may be recycled to the mixer 11a (see FIG. 6) of the long body supply unit 11.

[0041] In Embodiment 3, during rolling, the long body 14 is sandwiched between two cover films 31, 31, which facilitates the handling of the long body 14 during conveyance. When cutting the active material layer 3 from the strip 15, the strip 15 is not sandwiched between two cover films 31, 31, which facilitates cutting. Further, by performing the cutting of the active material layer 3 from the strip 15 by punching, the dimensions of the active material layer 3 can be made accurate.

[0042] (Modification of Embodiment 3) In Embodiment 3, when one cover film 31 is supplied from the cover film supply unit 30, that is, in a configuration where the cover film supply unit 30 includes one cover film coil 30a, the cover film peeling unit 32 may be configured to include one cover film winding coil 32a.

[0043] (Embodiment 4) Next, a method for manufacturing an electrode and an apparatus for manufacturing an electrode according to Embodiment 4 of the present disclosure will be described. The method for manufacturing an electrode and the apparatus for manufacturing an electrode according to Embodiment 4 are modified such that, with respect to Embodiment 3, the elongated body 14 is rolled in a state where a conductive mesh-like thin film body is interposed between one of the two cover films 31, 31 and the elongated body 14. In Embodiment 4, the same components as those in Embodiment 3 are denoted by the same reference numerals, and detailed descriptions thereof are omitted. Further, unless otherwise specified and as long as there is no structural contradiction, the modified forms of Embodiment 3 may also be applied in Embodiment 4.

[0044] As shown in FIG. 8, in the manufacturing apparatus 10 according to Embodiment 4, the rolling unit 12 includes a mesh-like thin film body supply unit 40 that supplies a conductive mesh-like thin film body 41 between one of the two cover films 31, 31 and the elongated body 14. The configuration of the mesh-like thin film body supply unit 40 is not particularly limited. For example, the mesh-like thin film body supply unit 40 may include a mesh-like thin film body coil 40a around which the mesh-like thin film body 41 is wound. Other configurations are the same as those in Embodiment 3.

[0045] As the mesh-like thin film body supply unit 40, a woven fabric (conductive woven fabric) made of fibers coated with a conductive material such as metal can be used. As such a woven fabric, for example, product number Sui-40-9027 (a woven fabric made of polyethylene terephthalate (PET) fibers coated with copper and nickel) and product number Su-4X-25030 (a woven fabric made of PET fibers coated with copper and Black Surface) commercially available from Seiren Co., Ltd. can be used. Note that the mesh-like thin film body supply unit 40 is not limited to a conductive woven fabric, and may be a conductive non-woven fabric or the like.

[0046] Next, a method for manufacturing an electrode according to Embodiment 4 of the present disclosure will be described. The long body 14 supplied from the long body supply unit 11 to the rolling unit 12 is sandwiched between two cover films 31, 31 from the cover film supply unit 30, and the mesh-like thin film body 41 supplied from the mesh-like thin film body supply unit 40 is disposed between one of the two cover films 31, 31 and the long body 14 and then rolled. A strip 15 is formed which is sandwiched between two cover films 31, 31 and in which the mesh-like thin film body 41 is disposed between one of the two cover films 31, 31 and the long body 14.

[0047] Next, in the same manner as in Embodiment 3, when the two cover films 31, 31 are peeled off from the strip 15, the strip 15 with the mesh-like thin film body 41 attached to one surface is conveyed to the cutting unit 13. At the cutting unit 13, cut lines 33 are formed in both the strip 15 and the mesh-like thin film body 41 by a die 13c. When the strip 15 with the mesh-like thin film body 41 attached to one surface passes through the roller 13d, according to the principle described in Embodiment 3, the active material layer 3 with the mesh-like thin film body 41 attached to one surface, that is, the active material layer 3 lined with the mesh-like thin film body 41, is cut from the strip 15.

[0048] If the active material layer 3 is not reinforced by the base material 19 (see FIG. 2) or the cover film 31, it is difficult to convey the active material layer 3 to the assembly unit 20 or handle the active material layer 3 at the assembly unit 20. However, the active material layer 3 manufactured by the manufacturing method of Embodiment 4 is reinforced by being lined with the mesh-like thin film body 41, so its handling becomes easy. Further, even if it is lined with a thin mesh-like thin film body 41 having conductivity, it does not inhibit the conductivity of lithium ions and electrons. Therefore, the active material layer 3 lined with the mesh-like thin film body 41 can be directly fitted into the frame body 2 (see FIG. 3) to assemble the electrode 1 (see FIG. 3).

[0049] (Embodiment 5) Next, a method for manufacturing an electrode and an apparatus for manufacturing an electrode according to Embodiment 5 of the present disclosure will be described. The method for manufacturing an electrode and the apparatus for manufacturing an electrode according to Embodiment 4 are those in which the configuration of the cutting portion 13 is changed with respect to Embodiment 3. In Embodiment 5, the same components as those in Embodiment 3 are denoted by the same reference numerals, and detailed descriptions thereof are omitted. Further, unless otherwise specified and as long as there is no contradiction in the configuration, the modified forms of Embodiment 3 may also be applied in Embodiment 4.

[0050] As shown in FIG. 9, in the manufacturing apparatus 10 according to Embodiment 5, the cutting portion 13 includes a conveyor 50 disposed on the downstream side of the cover film peeling portion 32 in the conveying direction of the strip 15, and an adjusting device 51 for adjusting the conveying speed of the strip 15 by the conveyor 50. A protrusion 53 is provided on either one of the pair of press rollers 17, 17 of the rolling portion 12, preferably on either one of the pair of main press rollers 17a, 17a located on the most downstream side at the conveying speed of the strip 15 so as to extend in the longitudinal direction of the one main press roller 17a.

[0051] Although not an essential configuration in Embodiment 5, the cutting portion 13 may further include a camera 52 provided between the cover film peeling portion 32 and the conveyor 50 and configured to capture an image or picture of the strip 15 in a plan view, and a control device 22 such as a computer configured to be capable of wired communication or wireless communication with each of the adjusting device 51 and the camera 52. Other configurations are the same as those in Embodiment 3.

[0052] Next, a method for manufacturing an electrode according to Embodiment 5 of the present disclosure will be described. Similar to Embodiment 3, in the rolling section 12, the long body 14 sandwiched between two cover films 31, 31 is rolled. When the belt-like body 15 is formed by being rolled by a pair of main press rollers 17a, 17a, grooves 54 extending in the width direction of the belt-like body 15 are formed in the belt-like body 15 at regular intervals in the conveyance direction of the belt-like body 15 by the protrusions 53. Then, in the same manner as in Embodiment 3, after the two cover films 31, 31 are peeled off from the belt-like body 15 sandwiched between the two cover films 31, 31, the belt-like body 15 is transferred onto the conveyor 50 and conveyed by the conveyor 50.

[0053] At an appropriate timing, for example, when the camera 52 is provided, based on the video or image of the belt-like body 15 taken by the camera 52, at the timing when the control device 22 detects the groove 54 formed in the belt-like body 15, the control device 22 uses the adjusting device 51 to adjust the conveyance speed of the belt-like body 15 by the conveyor 52 so that the moving speed of the belt-like body 15 on the side opposite to the long body 14 with respect to the groove 54 is greater than the moving speed of the belt-like body 15 on the long body 14 side with respect to the groove 54. Then, due to the difference in the conveyance speed of the belt-like body 15 on both sides of the groove 54 in the conveyance direction of the belt-like body 15, the belt-like body 15 on the side opposite to the long body 14 with respect to the groove 54 is cut in the groove 54 as the active material layer 3 from the belt-like body 15 on the long body 14 side with respect to the groove 54.

[0054] According to the manufacturing method of Embodiment 5, since the active material layer 3 is cut from the belt-like body 15 in the groove 54 formed to extend in the width direction of the belt-like body 15, the active material layer 3 can be manufactured without generating waste.

Explanation of Reference Numerals

[0055] 1 Electrode, 2 Frame body, 3 Active material layer, 4 Separator, 5 Current collector, 10 Manufacturing apparatus, 11 Long body supply unit, 12 Rolling unit, 13 Cutting unit, 14 Long body, 15 Band-shaped body, 16 Endless belt, 17 Press roller, 30 Cover film supply unit, 31 Cover film, 32 Cover film peeling unit, 40 Mesh-like thin film body supply unit, 41 Mesh-like thin film body, 50 Conveyor, 51 Adjustment device, 53 Protrusion, 54 Groove.

Claims

1. A method for manufacturing an electrode comprising an active material layer, comprising: The active material layer is: Supplying a clay-like elongated body that is a mixture of an active material and an electrolytic solution constituting the active material layer; Rolling the elongated body so as to form a strip; Cutting the active material layer of a predetermined length in the direction in which the elongated body is fed from the strip A method for manufacturing an electrode manufactured thereby.

2. The method for manufacturing an electrode according to claim 1, wherein the elongated body is rolled while being placed on a single cover film.

3. The method for manufacturing an electrode according to claim 1, wherein the elongated body is rolled while being sandwiched between two cover films.

4. The method for manufacturing an electrode according to claim 3, wherein the active material layer is cut from the strip while being sandwiched between the two cover films.

5. Including a step of peeling the two cover films from the strip after the elongated body is rolled while being sandwiched between the two cover films, After the step of peeling the two cover films from the strip, a step of cutting the active material layer from the strip is performed, and the step of cutting the active material layer from the strip is performed by punching. The method for manufacturing an electrode according to claim 3.

6. The elongated body is rolled with a conductive mesh-like thin film body interposed between one of the two cover films and the elongated body, The method for manufacturing an electrode according to claim 5, wherein the active material layer lined with the mesh-like thin film body is cut from the strip by punching.

7. Including a step of peeling the two cover films from the strip after the elongated body is rolled while being sandwiched between the two cover films, In the step of rolling the elongated body, at regular intervals in the direction in which the elongated body is fed, grooves perpendicular to the direction in which the elongated body is fed are formed in the strip, After the step of peeling the two cover films from the strip, a step of cutting the active material layer from the strip is performed. In the step of cutting the active material layer from the strip, the moving speed of the strip on the side opposite to the elongated body with respect to the groove is made greater than the moving speed of the strip on the elongated body side with respect to the groove, thereby cutting the active material layer from the strip. The method for manufacturing an electrode according to claim 3.

8. The method for manufacturing an electrode according to any one of claims 1 to 7, wherein the step of rolling the long body is performed by hot rolling the long body.

9. The electrode includes a frame into which the active material layer fits, a current collector and a separator installed so as to sandwich the frame with the active material layer fitted therein and further includes The manufacturing method includes a step of placing the active material layer on the current collector, a step of fitting the active material layer placed on the current collector into the frame, and a step of placing the separator on the frame with the active material layer fitted therein and pressing the separator toward the active material layer and further includes the method for manufacturing an electrode according to any one of claims 1 to 7.

10. The electrode includes a frame into which the active material layer fits, a current collector and a separator installed so as to sandwich the frame with the active material layer fitted therein and further includes The manufacturing method includes a step of placing the frame on the current collector, a step of storing an electrolytic solution inside the frame placed on the current collector, and a step of fitting the active material layer into the inside of the frame with the electrolytic solution stored therein and further includes the method for manufacturing an electrode according to any one of claims 1 to 7.

11. An electrode manufacturing apparatus including an active material layer, comprising a long body supply unit that supplies a clay-like long body that is a mixture of an active material and an electrolytic solution constituting the active material layer, a rolling unit that rolls the long body into a strip shape, and a cutting unit that cuts the active material layer having a predetermined length in the direction in which the long body is fed out from the strip and is an electrode manufacturing apparatus.

12. The electrode manufacturing apparatus according to claim 11, wherein the rolling unit includes a cover film supply unit that supplies one cover film so as to place the long body thereon.

13. The electrode manufacturing apparatus according to claim 12, wherein the rolling unit includes a cover film peeling unit that peels the cover film from the strip after rolling the long body.

14. The electrode manufacturing apparatus according to claim 13, wherein the rolling unit includes a mesh-like thin film body supply unit that supplies a conductive mesh-like thin film body between the cover film and the long body.

15. The electrode manufacturing apparatus according to claim 11, wherein the rolling unit includes a cover film supply unit that supplies two cover films so as to sandwich the long body.

16. The rolling unit of the electrode manufacturing apparatus according to claim 15 includes a cover film peeling section that peels the two cover films from the strip after rolling the long body.

17. The rolling unit of the electrode manufacturing apparatus according to claim 16 includes a mesh-like thin film body supply section that supplies a conductive mesh-like thin film body between one of the two cover films and the long body.

18. The rolling unit of the electrode manufacturing apparatus according to any one of claims 11 to 17 includes a pair of endless belts arranged to sandwich the long body.

19. The rolling unit includes at least a pair of press rollers arranged to sandwich the long body, and one of the at least a pair of press rollers includes a protrusion extending in the longitudinal direction of the one press roller. The cutting section is arranged downstream of the cover film peeling section in the conveying direction of the strip, and includes a conveyor that conveys the strip, and an adjusting device that adjusts the conveying speed of the strip by the conveyor. The electrode manufacturing apparatus according to claim 13 or 16 includes the above components.

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