Electrode manufacturing apparatus, electrode manufacturing method, and battery

Abstract

To pressure-bond powder onto a base material uniformly.SOLUTION: An electrode manufacturing apparatus 1 comprises a feed section 10, a facing section 20, a guide section 30, and a flow channel configuration section 60. The feed section 10 feeds powder to a sheet-like base material 2. The facing section 20 extends in a width direction of the base material 2, substantially orthogonal to a conveyance direction in which the base material 2 is to be conveyed. The facing section 20 presses the powder fed by the feed section 10 onto the base material 2. The guide section 30 is arranged on upstream in a conveyance direction DR1 of the facing section 20 to guide the powder P fed from the feed section 10 to the base material 2. The flow channel configuration section 60 is provided between the facing section 20 and the guide section 30 and configures a flow channel for the powder P existing between the facing section 20 and the guide section 30.SELECTED DRAWING: Figure 10

Description

Technical Field

[0001] The present invention relates to an electrode manufacturing apparatus, an electrode manufacturing method, and a battery.

Background Art

[0002] A technique of pressing a powder material onto a base material using a rolling roll is disclosed in, for example, Patent Document 1.

Prior Art Document

Patent Document

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The powder material supplied to the base material as described in Patent Document 1 is not uniformly pressed onto the base material with the same thickness. Therefore, it is required to press the powder material onto the base material as uniformly as possible.

[0005] An example of the object of the present invention is to uniformly press a powder onto a base material.

Means for Solving the Problems

[0006] The invention according to claim 1 is a supply unit that supplies a powder to a sheet-like base material, a facing portion that extends in the width direction of the base material, which is substantially orthogonal to the conveyance direction in which the base material is conveyed, and presses the powder supplied by the supply unit against the base material, a guide portion that is disposed on the upstream side in the conveyance direction with respect to the facing portion and guides the powder supplied from the supply unit to the base material, An electrode manufacturing apparatus comprising a flow path setting unit provided between the facing part and the guide part and setting a flow path for the powder existing between the facing part and the guide part.

[0007] The invention according to claim 7 is A battery having an electrode manufactured using the electrode manufacturing apparatus according to claim 1 or 2.

Advantages of the Invention

[0008] According to the above aspect of the present invention, the powder can be uniformly pressure-bonded to the base material.

Brief Description of the Drawings

[0009]

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Embodiments for Carrying Out the Invention

[0010] Hereinafter, embodiments of the present invention will be described with reference to the drawings. In all the drawings, the same components are denoted by the same reference numerals, and the description will be omitted as appropriate.

[0011] <First Embodiment> (Electrode Manufacturing Apparatus 1) FIG. 1 is a schematic cross-sectional view of an electrode manufacturing apparatus 1 according to the first embodiment. FIG. 2 is an enlarged schematic cross-sectional view of a portion A shown in FIG. 1. The manufacturing apparatus 1 will be described with reference to FIGS. 1 and 2. The manufacturing apparatus 1 is an apparatus for manufacturing an electrode used in a battery. In the first embodiment, the sheet-like base material 2 is used for manufacturing a positive electrode and a negative electrode of the battery. In the first embodiment, the manufacturing apparatus 1 conveys the base material 2 having an adhesive layer 3 (e.g., undercoat) in the conveyance direction DR1, attaches the powder P described later to the adhesive layer 3 (base material 2), and presses it with a pair of press rolls 90 to manufacture an electrode.

[0012] (Supply unit 10) As shown in FIG. 2, the manufacturing apparatus 1 includes a supply unit 10, a facing unit 20, and a guide unit 30. The supply unit 10 according to the first embodiment has a housing in which the powder P is stored. The powder P according to the first embodiment is a granule, and the particle size of the granule is 15 [μm] or more and 110 [μm] or less. More preferably, it is in the range of 60 [μm] ± 30 [μm]. The supply unit 10 supplies the powder P to the conveyed base material 2.

[0013] (Facing unit 20) The facing unit 20 according to the first embodiment has a cylindrical or columnar shape. The facing unit 20 has a shape extending in the width direction DR2 of the base material 2. The width direction DR2 is a direction substantially orthogonal to the conveyance direction DR1 in which the base material 2 is conveyed, and is the width direction of the base material 2. In this specification, the fact that the conveyance direction DR1 and the width direction DR2 are substantially orthogonal means that the angle formed by the conveyance direction DR1 and the width direction DR2 is -5 [°] or more and 5 [°] or less. The roll-shaped facing unit 20 rotates in the direction opposite to the conveyance direction DR1 in a plane orthogonal to the width direction DR2.

[0014] In the first embodiment, the facing unit 20 faces the press roll 90 with the base material 2 interposed therebetween. The facing unit 20 presses the powder P supplied by the supply unit 10 against the base material 2. The facing unit 20 presses the powder P against the base material 2 to make the thickness of the powder P attached to the base material 2 uniform.

[0015] (Guide section 30) In the first embodiment, the guide section 30 has a plate-like shape. The guide section 30 guides the powder P supplied from the supply section 10 to the base material 2 being conveyed in the conveyance direction DR1. The powder P is carried to the base material 2 being conveyed along the surface of the guide section 30. The guide section 30 is disposed on the upstream side of the facing section 20 in the conveyance direction DR1. The guide section 30 is disposed on the upstream side of the supply section 10 in the conveyance direction DR1.

[0016] (Adjustment section 40) FIG. 3 is a schematic plan view when the manufacturing apparatus 1 shown in FIG. 2 is viewed from above. In FIG. 3, the description of the supply section 10 and the guide section 30 is omitted. The manufacturing apparatus 1 according to the first embodiment further includes an adjustment section 40. The adjustment section 40 is provided at the end 21 of the facing section 20 in the width direction DR2 and adjusts the amount of the powder P guided to the end 21.

[0017] In the first embodiment, the adjustment section 40 may include a hinge 41, a plate-like rotating section 42, and a plate-like fixing section 43. The fixing section 43 is provided at the end 21. The rotating section 42 is rotatable via the hinge 41 with respect to the direction in which the fixing section 43 extends (conveyance direction DR1). In FIG. 3, the rotating section 42 is rotating at a rotation angle of θ1 toward the inside of the width direction DR2. Thus, the adjustment section 40 according to the first embodiment is configured to be rotatable with respect to the conveyance direction DR1.

[0018] FIG. 4 is a schematic plan view showing the state of the adjustment section 40 when the rotating section 42 is open toward the outside of the width direction DR2. The adjustment section 40 according to the first embodiment may adjust the amount of the powder P guided to the end 21 according to the amount of the powder P covering the base material 2. Specifically, the adjustment section 40 may adjust the amount of the powder P guided to the vicinity of the end 21 according to the so-called deposition (the amount of the powder P per unit area of the surface of the base material 2) in the vicinity of the end 21. That is, the adjustment section 40 according to the first embodiment may adjust the rotation angle of the rotating section 42 according to the deposition in the vicinity of the end 21.

[0019] For example, as shown in FIG. 4, when the rotating portion 42 is opened at a rotation angle θ2 toward the outside in the width direction DR2, the amount of powder P guided to the end portion 21 increases. And, for example, as shown in FIG. 3, when the rotating portion 42 is opened at a rotation angle θ1 toward the inside in the width direction DR2, the amount of powder P guided to the end portion 21 decreases. In this way, the adjusting portion 40 may adjust the amount of powder P guided to the end portion 21 by adjusting the angle at which the rotating portion 42 opens. Note that if the rotation angle θ in the direction in which the rotating portion 42 closes toward the inside in the width direction DR2 is positive and the rotation angle in the direction in which the rotating portion 42 opens toward the outside in the width direction DR2 is negative, the range of the rotation angle θ of the rotating portion 42 is preferably -1.0 [°] ≦ θ ≦ 1.0 [°].

[0020] (Function and Effect) As described above, the manufacturing apparatus 1 according to the first embodiment includes the supply unit 10, the opposing unit 20, and the adjusting unit 40. The adjusting unit 40 is provided at the end portion 21 of the opposing unit 20 in the width direction DR2 and adjusts the amount of powder P guided to the end portion 21. Generally, compared with the portions other than the vicinity of the end portion of the opposing unit, the variation in deposition (the amount of powder per unit area of the surface of the substrate) in the vicinity of the end portion of the opposing unit is large. However, in the first embodiment, by providing the adjusting unit 40, the amount of powder P guided to the end portion 21 can be adjusted, so that the variation in deposition in the vicinity of the end portion 21 of the opposing unit 20 can be suppressed. Thereby, the powder P can be uniformly adhered to the substrate 2. Therefore, the powder P can be uniformly pressure-bonded to the substrate 2.

[0021] Furthermore, the adjusting unit 40 may be configured to be rotatable with respect to the transport direction DR1. Thereby, the mechanism for adjusting the amount of powder P guided to the end portion 21 can be simply configured.

[0022] Furthermore, the adjusting unit 40 may adjust the amount of powder P guided to the end portion 21 according to the amount of powder P covering the substrate 2. By measuring the amount of powder P (deposition) covering the substrate 2 and adjusting the amount of powder P guided to the end portion 21, the powder P can be more accurately and uniformly adhered to the substrate 2.

Example

[0023] The following is an explanation of the example. In order to calculate the appropriate range of the rotation angle θ, the following conditions were evaluated.

[0024] <Implementation Conditions> With the rotation angle when closing towards the inside in the width direction (θ1 in FIG. 3) being positive and the rotation angle when opening towards the outside of the width direction DR2 (θ2 in FIG. 4) being negative, the relationship between the rotation angle θ and the amount of powder near the end was evaluated.

[0025] <Evaluation Results> FIG. 5 is a graph plotting the relationship between the amount of powder at the end and the rotation angle. The horizontal axis in FIG. 5 indicates the amount of powder at the end, and the vertical axis indicates the rotation angle of the optimal rotating part with respect to the amount of powder at the end. Note that the "amount of powder at the end" indicates the ratio between the average value of the amount of powder adhering to the substrate when viewed over the entire substrate and the amount of powder adhering to the substrate near the end. For example, in the graph of FIG. 5, when the amount of powder at the end is 0.9 (90%), it means that the amount of powder near the end is 10% less than the above average value. And the graph of FIG. 5 shows that when the amount of powder at the end is 0.9, the optimal rotation angle is approximately -1.0 [°].

[0026] As an example, as shown in FIG. 5, it can be seen that when the rotation angle θ is -1.0 [°] ≤ θ ≤ 1.0 [°], the ratio between the amount of powder near the end and the above average value is within ±10%. To control the amount of powder more precisely, preferably, -0.2° ≤ θ ≤ 0.2°. When the implementation conditions are different, the optimal amount of powder can be obtained by appropriately adjusting the rotation angle, etc. <Second Embodiment> FIG. 6 is a schematic cross-sectional view of an electrode manufacturing apparatus 1 according to the second embodiment. FIG. 7 is a plan view of the manufacturing apparatus 1 shown in FIG. 6 when viewed from above. In FIG. 7, the description of the guide portion 30 and the supply portion 10 is omitted. Different from the first embodiment, the manufacturing apparatus 1 according to the second embodiment includes a stirring portion 50.

[0027] As shown in FIG. 6, the stirring portion 50 according to the second embodiment is provided between the opposing portion 20 and the guide portion 30. The stirring portion 50 according to the second embodiment stirs the powder P1 existing between the opposing portion 20 and the guide portion 30 by rotating. In the second embodiment, the stirring portion 50 rotates counterclockwise.

[0028] As shown in FIG. 7, the stirring portion 50 according to the second embodiment has a shape extending in the width direction DR2. The stirring portion 50 according to the second embodiment may include a driving portion 51 and blade portions 52. The powder P is stirred by the driving portion 51 rotating the blade portions 52. As shown in FIG. 7, the blade portions 52 may be configured in a direction in which the powder P moves toward the inside in the width direction DR2.

[0029] As described above, the manufacturing apparatus 1 according to the second embodiment includes a supply portion 10, an opposing portion 20, a guide portion 30, and a stirring portion 50. By providing the stirring portion 50, it is possible to suppress the formation of powder lumps of the powder P in the region R between the opposing portion 20 and the guide portion 30. Thereby, the powder P can be adhered to the base material 2 without unevenness. Therefore, the powder P can be uniformly crimped to the base material 2.

[0030] Furthermore, the stirring portion 50 may adjust the degree of stirring according to the amount of the powder P covering the base material 2. More specifically, for example, the rotation speed of the stirring portion 50 may be adjusted according to the deposition (the amount of the powder P per unit area of the surface of the base material 2). Thereby, the powder P can be more accurately and uniformly crimped to the base material 2.

[0031] (Modification example) FIG. 8 is a schematic cross-sectional view of the electrode manufacturing apparatus 1 in the modified example. FIG. 9 is a plan view when the manufacturing apparatus 1 shown in FIG. 8 is viewed from above. As shown in FIG. 8, a flat plate 80 may be provided between the press roll 90 and the opposing portion 20. Then, in the modified example, the opposing portion 20 may press the plate 80 via the base material 2 and attach the powder P to the base material 2.

[0032] Also, as shown in FIG. 9, the stirring unit 50 in the modified example may include a plurality of driving units 51. Further, the blade portion 52 in the modified example may have a spiral shape.

[0033] <Third Embodiment> FIG. 10 is a schematic cross-sectional view of the manufacturing apparatus 1 according to the third embodiment. The manufacturing apparatus 1 according to the third embodiment includes a flow path setting unit 60, which is different from the first embodiment. The flow path setting unit 60 according to the third embodiment is provided between the opposing portion 20 and the guide portion 30 and sets the flow path of the powder P1 existing between the opposing portion 20 and the guide portion 30. The flow path setting unit 60 according to the third embodiment has a plate-like shape extending in the width direction DR2.

[0034] By providing the flow path setting unit 60, the region R between the opposing portion 20 and the guide portion 30 is divided into a region R1 and a region R2. That is, a region R1 is formed between the guide portion 30 and the flow path setting unit 60, and a region R2 is formed between the opposing portion 20 and the flow path setting unit 60.

[0035] The region R1 is a storage portion where the powder P supplied from the supply unit 10 is stored. The powder P supplied from the supply unit 10 first lands on the storage portion. In the vertical direction DR3 (= the direction in which gravity acts, the up-down direction), the height of the upper edge 61 of the flow path setting unit is higher than the height of the upper surface 63 of the powder P stored in the storage portion (region R1).

[0036] Region R2 is a backflow path where the powder P supplied to the base material 2 flows back. The flow of the powder P supplied to the base material 2 will be described. The supply unit 10 according to the third embodiment first supplies the powder P to the storage unit (region R1). Then, the powder P supplied to the region R1 is conveyed to the base material 2 along the D1 direction. A part of the powder P conveyed to the base material 2 is conveyed as it is in the conveyance direction DR1. Another part of the powder P conveyed to the base material 2 is conveyed by the opposing part 20 to the upper end edge 61 of the flow path setting part 60 along the D2 direction. That is, the powder P flows back toward the upper end edge 61. Then, the powder P that has reached the upper end edge 61 gets over the flow path setting part 60 and lands on the upper surface 63 (see arrow D3).

[0037] Also, in a cross-section orthogonal to the width direction DR2, the first interval t1 between the flow path setting part 60 and the opposing part 20 is larger than the second interval t2 between the opposing part 20 and the base material 2. The first interval t1 is the shortest distance between the flow path setting part 60 and the opposing part 20. The second interval t2 is the shortest distance between the opposing part 20 and the base material 2 (adhesive layer 3).

[0038] Also, in a cross-section orthogonal to the width direction DR2, the second interval t2 is smaller than the third interval t3 between the lower end edge 62 of the flow path setting part 60 and the base material 2 (adhesive layer 3) in the vertical direction DR3. The third interval t3 is the shortest distance between the lower end edge 62 and the base material 2 (adhesive layer 3).

[0039] As described above, the electrode manufacturing apparatus 1 according to the third embodiment includes a supply unit 10, an opposing part 20, a guide part 30, and a flow path setting part 60. By providing the flow path setting part 60, it is possible to suppress the formation of powder lumps of the powder P in the region R between the opposing part 20 and the guide part 30. Thereby, the powder P can be adhered to the base material 2 without unevenness. Therefore, the powder P can be uniformly crimped to the base material 2.

[0040] Furthermore, in the vertical direction DR3, the height of the upper end edge 61 of the flow path setting portion 60 may be higher than the height of the upper surface 63 of the powder P stored in the storage portion (region R1). Thereby, since the powder P flowing back from the reverse flow path (region R2) can be poured again into the storage portion (region R1), the powder P can be effectively reused.

[0041] Furthermore, the manufacturing apparatus 1 for an electrode according to the third embodiment may include a suction portion 70 (not shown) that sucks the powder P accumulated in the reverse flow path (region R2). Thereby, even if no limit is provided for the height of the upper end edge 61 as described above, the powder P can be effectively reused.

[0042] Note that the conveyance path of the base material shown in FIG. 1 is an example. For example, the base material 2 is drawn out from a winding portion, and in order to form a predetermined conveyance path for the base material, conveyance rolls may be further added in the middle of the path of the base material 2. The conveyance rolls include, but are not limited to, driven rolls, feed rolls, suction rolls, and the like. Note that the base material 2 on which the powder P is formed (hereinafter, the base material 2 on which the powder P is formed may be simply referred to as the base material 2) may be further pressed by a second pressing apparatus 100 having second pressing rolls 100a and 100b as shown in FIG. 11. The configuration of further pressing by the above-described conveyance rolls and the second pressing rolls 100a and 100b can also be applied to the first to third embodiments described above.

[0043] Also, as an example, the gap between the pair of second pressing rolls 100a and 100b described above is 50 μm or more and 200 μm or less. Also, as an example, the diameter of the second pressing rolls 100a and 100b is Φ500 mm or more and Φ800 mm or less.

[0044] The second pressing rolls 100a and 100b rotate in the moving direction of the base material 2 and further press the powder P pressed by the pressing roll 90 against the base material 2. The peripheral speed of the second pressing rolls 100a and 100b is the same as the traveling speed of the base material 2, and is, for example, 20 m / min or more and 130 m / min or less.

[0045] In addition, the pressure applied to the base material 2 from the second press rolls 100a and 100b is, for example, 1 ton / cm or more and 5 ton / cm or less. Since the powder P is pressed by the press roll 90 at a higher linear pressure than during the pressing by the press roll 90, an active material layer having a desired density and a predetermined thickness can be formed. Further, after the active material layer is pressed onto both sides by the second press rolls 100a and 100b, the weight per unit area of the base material 2 is, for example, 10 mg / cm 2 or more and 30 mg / cm 2 or less when the negative electrode active material layer is formed. Further, when the positive electrode active material layer is formed, it is, for example, 10 mg / cm 2 or more and 50 mg / cm 2 or less.

[0046] In addition, the material of the second press rolls 100a and 100b is not particularly limited, but those having high wear resistance are preferable. Specifically, for example, those in which a coating material is coated on the surface of a cylindrical or columnar roll made of SUS material can be used, but the present invention is not limited thereto.

[0047] [Base material 2] The base material 2 according to these embodiments is, for example, a general current collector foil. As an example, when the powder P is composed of a negative electrode active material, a foil mainly composed of copper is preferable. Further, when the powder P is composed of a positive electrode active material, the current collector foil is preferably a foil mainly composed of aluminum. Further, the width of the base material 2 is not particularly limited, but is, for example, 1300 mm or less. Further, the length of the base material 2 is, for example, 50 m or more and 10000 m or less, but the present invention is not limited thereto. The configuration regarding the above base material 2 can also be applied to the first to third embodiments described above.

[0048] [Powder P] As the powder P according to these embodiments, for example, a granulated body obtained by granulating either a negative electrode active material or a positive electrode active material can be used.

[0049] As the positive electrode active material, one or a combination of two or more selected from lithium-nickel composite oxides, lithium-cobalt composite oxides, lithium-nickel-cobalt-aluminum composite oxides, lithium-nickel-manganese-cobalt composite oxides (NMC), etc., which are composite oxides of lithium and transition metals; transition metal sulfides such as TiS2, FeS, MoS2; MnO, V2O5, V6O 13 , transition metal oxides such as TiO2; and one or a combination of two or more selected from olivine-type lithium phosphate oxides, etc. can be used. As the positive electrode active material, it is preferable to use a lithium-nickel-manganese-cobalt composite oxide having an average particle size of 3 μm or more and 15 μm or less. Further, some of the elements of the above compounds may be partially substituted with other elements.

[0050] As the negative electrode active material, one or a combination of two or more selected from natural graphite, artificial graphite, hard carbon, soft carbon, and carbon black, etc. can be used. Further, the surfaces of the particles of natural graphite and artificial graphite may be coated with amorphous carbon, and they may be primary particles, or particles in which primary particles are aggregated to form secondary particles, and mixtures of these particles. Also, SiO, SiO2 containing silicon, a composite of silicon and carbon, etc. can be used, and these may be mixed with carbon.

[0051] Further, the powder P preferably further contains a conductive assistant and a binder. As the conductive assistant, one or a combination of two or more selected from carbon blacks such as acetylene black and ketjen black, activated carbon, graphite, mesoporous carbon, fullerenes, carbon nanotubes, carbon nanofibers, carbon nanobrushes, etc., which are carbon fibers, can be used. Also, as the binder, one or a combination of two or more selected from fluororesins such as PVDF, PTFE, and PVF, conductive polymers such as polyacrylic acid, polyanilines, and polythiophenes, synthetic rubbers such as SBR, etc. can be used.

[0052] In addition, when the powder P contains a conductive assistant and a binder, it is preferable that the conductive assistant is 0.02 parts by mass or more and 5 parts by mass or less, and the binder is 1 part by mass or more and 5 parts by mass or less with respect to 100 parts by mass of the entire powder P.

[0053] In the cumulative frequency distribution curve based on volume measured using a laser diffraction particle size distribution measuring device for the powder P, the particle diameter D50 at which the cumulative frequency is 50% is preferably 40 μm or more, more preferably 45 μm or more, and even more preferably 50 μm or more. Further, for the powder P, the particle diameter D50 is preferably 120 μm or less, more preferably 110 μm or less, even more preferably 100 μm or less, and even more preferably 90 μm or less. The measurement of D50 above is performed, for example, in accordance with JIS Z 8825. The configuration regarding the powder P above can also be applied to the first to third embodiments described above.

[0054] Next, a flowchart of the method for manufacturing the electrode according to these embodiments is shown in FIG. 12. First, the powder P is disposed on the base material 2 (step S10). Next, the disposed powder P is leveled by the opposing portion 20 (step S20). Next, the leveled powder P is temporarily pressure-bonded by the press roll 90 (step S30). Then, the base material 2 is attached to the second press roll device 100, and the powder P pressure-bonded to both surfaces is pressed by the press rolls 100a and 100b. Note that steps S10 to S30 are performed on each side in the steps shown in the first embodiment and the second embodiment, and thus are performed on both sides in two separate operations. Further, as described above, the configuration of further pressing by the second press roll 100 can also be applied to the first to third embodiments described above, and in that case, the steps shown in the above flowchart can be applied.

[0055] In addition, the electrode manufactured by the manufacturing apparatus 1 described in the first to third embodiments can be used for manufacturing a secondary battery according to a known method. Specifically, the electrode can be used for either the positive electrode plate or the negative electrode plate, and a battery element can be obtained by laminating or winding the positive electrode plate and the negative electrode plate so as to face each other with a separator interposed therebetween. This battery element is housed in a container together with an electrolyte, and one end of a positive electrode terminal electrically connected to the positive electrode plate of the battery element and one end of a negative electrode terminal electrically connected to the negative electrode plate are arranged outside the container. The container is not limited to being composed of a rectangular or cylindrical metal case made of hard aluminum, iron, etc., or a film-like pouch case containing aluminum. As the electrolyte, any liquid that dissolves an electrolyte may be used, such as carbonates such as ethylene carbonate, propylene carbonate, butylene carbonate, dimethyl carbonate, diethyl carbonate, methyl ethyl carbonate, vinylene carbonate, lactones such as γ-butyrolactone, ethers, sulfoxides, oxolanes, nitrogen-containing compounds, organic acid esters, sulfones such as 1,3-propane sultone and 1,4-butane sultone, etc., but not limited thereto, and these may be used alone or in combination of two or more. The electrolyte includes, but is not limited to, LiPF6, LiBF6, LiFSI, etc. Examples of the separator include, but are not limited to, those in the form of a film, a film, a non-woven fabric, etc. containing polypropylene-based, polyethylene, aromatic polyamide, etc.

[0056] <Fourth Embodiment> Next, the fourth embodiment will be described. FIG. 13 is an example of a schematic plan view of the manufacturing apparatus 1 for an electric foil in this embodiment as viewed from the side of the base material 2, that is, in the DR2 direction.

[0057] As shown in FIG. 13, the opposing portion 20 may be located farther away from the supply portion 10. Specifically, when viewed in the DR2 direction, the opposing portion 20 may be away from the supply portion 10 within a range of an arbitrary angle θ in a range where the opposing portion 20 does not touch each of the pair of pressing rolls 90 with respect to the DR3 direction of the straight line connecting the center of the opposing portion 20 and the center of the pressing roll 90.

[0058] Also, in the present embodiment, the rotation speed of the opposing portion 20 may be 0% or more and 10% or less with respect to the traveling speed of the base material 2. The negative sign here means that the traveling direction of the base material 2 and the traveling direction of the surface of the opposing portion 20 facing the base material 2 are opposite. The configuration regarding the rotation of the opposing portion 20 described above can also be applied to the first to third embodiments described above.

[0059] Next, the flow path setting portion 60 in the present embodiment will be described. FIG. 14 shows a first example of the flow path setting portion 60 as viewed from the DR2 direction. In FIG. 14, for convenience of explanation, the flow path setting portion 60 is described as a rectangle, but it is not limited thereto. Each vertex of the flow path setting portion 60 does not need to be chamfered and have an acute angle, each corner may be rounded, each surface may be a curved surface, and it may have a shape along the opposing portion 20 as described in FIG. 13, and it may be arranged along the width direction DR2.

[0060] In the present embodiment, the flow path setting portion 60 is provided between the opposing portion 20 and the guide portion 30 in the same manner as in the third embodiment, and sets the flow path of the powder P1 existing between the opposing portion 20 and the guide portion 30. The flow path setting portion 60 may be inclined at an angle within 30° from the vertical direction. Also, the flow path setting portion 60 may be flat or bent. Further, the upper end edge 61 of the flow path setting portion 60 is an inclined surface that is inclined in a direction opposite to the moving direction of the base material 2 (in other words, in the upstream direction) with respect to the horizontal plane. Thereby, more powder P moves beyond the flow path setting portion 60 toward the supply portion 10 side. Also, the angle θ of the inclined surface with respect to the horizontal direction is not particularly limited as long as the powder falls upstream, but it is preferably 0° or more and 45° or less, and more preferably 10° or more and 45° or less.

[0061] The first interval t1 between the flow path setting portion 60 and the opposing portion 20 does not necessarily have to be constant, as long as the powder that could not pass through the second interval t2 between the opposing portion 20 and the base material 2 does not clog between the flow path setting portion 60 and the opposing portion 20. Preferably, it is adjusted alone or together with the rotation speed of the opposing portion 20 so that a flow is generated such that the powder that could not pass through the second interval t2 between the opposing portion 20 and the base material 2 falls upstream beyond the flow path setting portion 60. The third interval t3 between the lower end edge 62 of the flow path setting portion 60 and the base material 2 is not particularly limited, but is preferably equal to or greater than the second interval t2.

[0062] The lower end edge 62 of the flow path setting portion 60 is preferably parallel to the base material 2. However, as shown in FIG. 13, this is not the case when it has a shape along the opposing portion 20 as described in FIG. 13.

[0063] Also, the height of the flow path setting portion 60 in the DR3 direction, that is, the vertical distance W1 from the lower end to the upper end of the flow path setting portion 60 is not particularly limited, and the powder located between the flow path setting portion 60 and the first interval t1 with the opposing portion 20 may be adjusted alone or together with the rotation speed of the opposing portion 20 so that it falls upstream beyond the upper end of the flow path setting portion. The thickness W2 of the flow path setting portion 60 in the DR1 direction is not particularly limited as long as it does not deform under the pressure received from the powder. For example, when acrylic is used, it is 3 mm or more and 10 mm or less.

[0064] Next, FIG. 15 shows a second example of the flow path setting portion 60 as viewed from the DR2 direction. Also in FIG. 15, for the sake of convenience of explanation, the vertices of the flow path setting portion are described in shapes such as acute angles, right angles, and obtuse angles. However, similar to FIG. 14, each vertex may be chamfered, each corner may be rounded, each surface may be a curved surface, or it may have a shape along the opposing portion as described in FIG. 13. As shown in FIG. 15, the upper part of the flow path setting portion 60 includes a stepped portion 65 and an inclined portion 64 on the upstream side of the stepped portion 65. And the upper end edge 61 in the inclined portion 64 is an inclined surface. The stepped portion 65 includes the upper end of the flow path setting portion 60, and the thickness in the advancing direction of the base material 2 is narrower than other portions of the flow path setting portion 60. The upper surface of the stepped portion 65 is arranged to be horizontal or inclined so that the powder falls toward the upstream side. The inclined portion 64 is a portion connecting the lower end of the stepped portion 65 and other portions of the flow path setting portion 60. The inclination direction of the inclined surface of the inclined portion 64 is the same as the inclination direction of the upper end edge 61 of the flow path setting portion 60 shown in FIG. 14. The angle of the inclined portion 64 with respect to the parallel direction only needs to be inclined so that the upstream side is lower, and it is preferably larger than the angle of the upper surface of the stepped portion 65 with respect to the horizontal direction. By doing so, even when the flow path setting portion is tilted with respect to the vertical direction, the powder easily falls to the upstream side. Note that the thickness W3 of the stepped portion 65 in the advancing direction of the base material 2, that is, the DR1 direction, is not particularly limited as long as it does not deform under the pressure received from the powder.

[0065] Next, FIG. 16 is an example of the flow path setting portion 60 as viewed from the DR1 direction corresponding to the flow path setting portion 60 in FIG. 14. However, FIG. 16 schematically shows the configuration when the upper surface of the flow path setting portion in FIG. 14 is substantially horizontal (the angle θ in FIG. 14 is almost 0°). The flow path setting portion 60 shown in FIG. 16 is concave when viewed from the DR1 direction. In other words, the upper end edge 61 of the flow path setting portion 60 has a region where the height decreases as it approaches an arbitrary reference point O (the central portion in the DR2 direction in the example shown in FIG. 16) which is a part of the upper end edge 61 in the width direction of the base material 2 when viewed from the DR1 direction. Hereinafter, this shape is described as a concave shape. Thereby, it is possible to suppress the powder P from gathering at the end of the base material 2.

[0066] Note that the position of the reference point O is not limited to the central part in the DR2 direction and may be deviated from the central part. However, in the width direction of the base material 2, the distance between the reference point O and the center of the base material 2 is 1 / 3 or less, preferably 1 / 5 or less of the width of the base material 2. The difference W5 between the height of the highest position (the end in FIG. 16) of the flow path setting portion 60 and the height of the reference point O is, for example, 0.5 mm or more and 20 mm or less.

[0067] Next, FIG. 17 is another example of the flow path setting portion 60 viewed from the DR1 direction corresponding to the flow path setting portion 60 in FIG. 14. However, FIG. 17 schematically shows the configuration when the upper end edge of the flow path setting portion is not horizontal in FIG. 14. The upper end edge 61 of the flow path setting portion 60 has a concave shape when viewed from the DR1 direction, similar to FIG. 16. Further, the slope of the upper end edge 61 is shown in FIG. 17.

[0068] FIG. 18(a) shows the A-A' cross-section, which is the cross-section at a position outside the reference point O in FIG. 17, and FIG. 18(b) shows the B-B' cross-section, which is the cross-section at the reference point O. As shown in FIG. 18, the inclination angle θ1 of the upper end edge 61 in the A-A' cross-section is larger than the inclination angle θ2 of the upper end edge 61 in the B-B' cross-section outside the reference point O. Also, the downstream height W1 and the upstream height W1' in the A-A' cross-sectional view are higher than the downstream height W1 and the upstream height W1' in the B-B' cross-sectional view, respectively. However, the inclination angle θ2 may be larger than the inclination angle θ1. Also, in cross-sectional view, the inclined surface may be a curved surface.

[0069] According to the above structure, the powder P passing over the flow path setting portion 60 can be brought closer to the reference point O side.

[0070] Next, FIG. 19 shows an example of the flow path setting portion 60 as viewed from the DR1 direction, corresponding to the flow path setting portion 60 in FIG. 15. In FIG. 19, the inclined portion 64 and the stepped portion 65 are shown. The upper edge in the vertical direction of the stepped portion 65 is horizontal with the DR2 direction. Thereby, the height of the powder P positioned between the flow path setting portion 60 and the opposing portion 20 becomes constant, that is, the force exerted by the weight of the powder P positioned in the first interval t1 on the gap between the opposing portion 20 and the substrate becomes constant, and the powder P can be stably transferred to the substrate. On the other hand, since the inclination 64 shown in FIG. 19 inclines so that the height in the vertical direction becomes lower toward the reference point O, the powder flows more to the center side, and it is possible to suppress the powder P from gathering at the end of the base material 2. FIG. 20(a) shows the A-A' cross section which is a cross section at a position outside the reference point O in FIG. 19, and FIG. 20(b) shows the B-B' cross section which is a cross section at the reference point O. As shown in FIG. 20, the inclination angle θ1 of the upper edge 61 of the inclined portion 64 in the A-A' cross section may be larger than the inclination angle θ2 of the upper edge 61 of the inclined portion 64 in the B-B' cross-sectional view. Also, the upstream height W1' in the A-A' cross-sectional view is higher than the upstream height W1' in the B-B' cross-sectional view. On the other hand, the downstream height W1 is the same in the A-A' cross-sectional view and the B-B' cross-sectional view. Also, the height W4 of the stepped portion 65 in the A-A' cross-sectional view is lower than the height W4 of the stepped portion 65 in the B-B' cross-sectional view. However, the inclination angle θ2 may be larger than the inclination angle θ1. The inclined surface may be a curved surface in cross-sectional view.

[0071] Next, a third example of the flow path setting unit 60 will be described. FIG. 21 is a schematic view of the electrode manufacturing apparatus 1 including the flow path setting unit 60 in the third example according to the present embodiment as viewed from the DR3 direction, that is, from above. As shown in FIG. 21, the flow path setting unit 60 is curved in a top view so that the position of an arbitrary reference point O2 is located on the supply unit 10 side. In other words, the portion of the reference point O2 is on the most downstream side, and it becomes the upstream side toward the outside. Also by this, it is possible to suppress the powder P from gathering at the end of the base material 2. Note that the position of the reference point O2 is not limited to the central portion in the DR2 direction, and it may be deviated from the central portion. The difference W6 in the DR1 direction between the end of the flow path setting unit 60 and the portion of the reference point O2 of the flow path setting unit 60 is not particularly limited, but as an example, it is 1 mm or more and 20 mm or less, and it may be 10 mm or more and 20 mm or less. Further, the flow path setting unit 60 in this example may have the configurations in the above-described first example and second example combined.

[0072] Also, in FIG. 21, a pair of side walls 45 fix the flow path setting unit 60 and the opposing unit 20. Further, the side walls 45 cover at least a part of the base material 2 as viewed from the DR3 direction. And the powder P (not shown in FIG. 21) is arranged at the position between the pair of side walls 45 of the base material 2. In other words, the width of the position where the powder P is arranged is determined by the distance between the pair of side walls 45. However, the adjustment unit 40 in the first embodiment may be configured together with the pair of side walls 45.

[0073] As described above, according to the electrode manufacturing apparatus 1 according to the present embodiment, it is possible to suppress the powder P from staying in front of the opposing unit 20. Further, it is possible to suppress the powder P from gathering at the end of the base material 2.

[0074] Also, the electrode manufactured by the manufacturing apparatus 1 described in the fourth embodiment can be used for manufacturing a secondary battery according to a known method, similarly to the electrodes manufactured by the manufacturing apparatus 1 described in the first to third embodiments described above.

[0075] The embodiments of the present invention have been described above with reference to the drawings. These are examples of the present invention, and various configurations other than the above can also be adopted.

[0076] In the embodiment, the opposing portion 20 may have a plate-like shape instead of a cylindrical or columnar shape.

[0077] In the first embodiment, the electrode manufacturing apparatus 1 may further include a stirring portion 50 in addition to the adjusting portion 40.

[0078] In the first embodiment, the electrode manufacturing apparatus 1 may further include a flow path setting portion 60 in addition to the adjusting portion 40.

[0079] Examples of reference embodiments are appended below. 1. A supply unit that supplies powder to a sheet-like base material, An opposing portion that extends in the width direction of the base material, which is substantially orthogonal to the conveyance direction in which the base material is conveyed, and presses the powder supplied by the supply unit against the base material, A guide portion that is disposed upstream of the opposing portion in the conveyance direction and guides the powder supplied from the supply unit to the base material, An electrode manufacturing apparatus including a flow path setting portion that is provided between the opposing portion and the guide portion and sets a flow path of the powder existing between the opposing portion and the guide portion. 2. In the electrode manufacturing apparatus according to 1., In a cross-section orthogonal to the width direction, a first interval between the flow path setting portion and the opposing portion is larger than a second interval between the opposing portion and the base material. An electrode manufacturing apparatus. 3. In the electrode manufacturing apparatus according to 1. or 2., A storage portion for storing the powder supplied from the supply unit is formed between the guide portion and the flow path setting portion, In the vertical direction, the height of the upper end edge of the flow path setting portion is higher than the height of the upper surface of the powder stored in the storage portion. An electrode manufacturing apparatus. 4. In the electrode manufacturing apparatus according to any one of 1. to 3., In a cross-section orthogonal to the width direction, the second interval between the facing portion and the base material is smaller than the third interval between the lower end edge of the flow path setting portion in the vertical direction and the base material. An electrode manufacturing apparatus. 5. In the electrode manufacturing apparatus according to any one of 1. to 4., A backflow path is formed between the flow path setting portion and the facing portion, through which the powder supplied to the base material flows back. An electrode manufacturing apparatus further comprising a suction portion for sucking the powder accumulated in the backflow path. 6. In the electrode manufacturing apparatus according to any one of 1. to 5., The facing portion has a cylindrical or columnar shape. An electrode manufacturing apparatus. A battery having an electrode manufactured using the electrode manufacturing apparatus according to any one of 1. to 6.

Explanation of symbols

[0080] 1 Manufacturing apparatus 2 Base material 3 Adhesive layer 10 Supply portion 20 Facing portion 21 End portion 30 Guide portion 40 Adjustment portion 41 Hinge 42 Rotating portion 43 Fixed portion 50 Stirring portion 51 Driving portion 52 Blade portion 60 Flow path setting portion 80 Plate 90 Press roll 100 Second press roll device 100a, 100b Second press roll DR1 Conveying direction DR2 Width direction DR3 Vertical direction P Powder

Claims

1. A supply unit that supplies powder to a sheet-shaped base material, An opposing part that extends in the width direction of the base material, which is substantially orthogonal to the conveyance direction in which the base material is conveyed, and presses the powder supplied by the supply unit against the base material, A guide part that is disposed upstream of the opposing part in the conveyance direction and guides the powder supplied from the supply unit to the base material, An electrode manufacturing apparatus comprising: a flow path setting part that is provided between the opposing part and the guide part and sets a flow path of the powder existing between the opposing part and the guide part.

2. In the electrode manufacturing apparatus according to Claim 1, In a cross section orthogonal to the width direction, a first interval between the flow path setting part and the opposing part is larger than a second interval between the opposing part and the base material. An electrode manufacturing apparatus.

3. In the electrode manufacturing apparatus according to Claim 1 or 2, A storage part for storing the powder supplied from the supply part is formed between the guide part and the flow path setting part, In the vertical direction, the height of the upper end edge of the flow path setting part is higher than the height of the upper surface of the powder stored in the storage part. An electrode manufacturing apparatus.

4. In the electrode manufacturing apparatus according to Claim 1 or 2, In a cross section orthogonal to the width direction, a second interval between the opposing part and the base material is smaller than a third interval between the lower end edge of the flow path setting part in the vertical direction and the base material. An electrode manufacturing apparatus.

5. In the electrode manufacturing apparatus according to Claim 1 or 2, A backflow path through which the powder supplied to the base material flows back is formed between the flow path setting part and the opposing part, An electrode manufacturing apparatus further comprising a suction part that sucks the powder accumulated in the backflow path.

6. In the electrode manufacturing apparatus according to Claim 1 or 2, The opposing part has a cylindrical or columnar shape. An electrode manufacturing apparatus.

7. A battery having an electrode manufactured using the electrode manufacturing apparatus according to Claim 1 or 2.

8. A supply unit that supplies powder to a base material, An opposing part that is provided downstream of the supply unit in the moving direction of the base material, the lower end of which is separated from the base material and the lower end of which contacts the powder on the base material, A flow path setting part that is provided between the opposing part and the supply unit, is lower than the opposing part, the lower end of which is separated from the base material and the lower end of which contacts the powder on the base material, Comprising An electrode manufacturing apparatus, wherein an upper end of the flow path setting portion has a region where the height decreases as it approaches a reference point in the width direction of the base material.

9. In the flow path setting portion, the position of an arbitrary reference point is located on the supply unit side in a top view. The electrode manufacturing apparatus according to claim 8.

10. The upper end of the flow path setting portion has an inclined surface that slopes downward in at least a part of the width direction of the base material, in a direction opposite to the moving direction of the base material. The electrode manufacturing apparatus according to claim 8 or 9.

11. The distance between the opposing portion and the base material is smaller than the distance between the lower edge of the flow path setting portion and the base material. The electrode manufacturing apparatus according to claim 8 or 9.

12. The base material is an electrode used in a secondary battery, and the powder contains an active material of the electrode. The electrode manufacturing apparatus according to claim 8 or 9.

13. An electrode manufacturing method for manufacturing an electrode using the electrode manufacturing apparatus according to claim 12.

14. A battery having an electrode manufactured using the electrode manufacturing method according to claim 13.

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