Electrode manufacturing apparatus, battery manufacturing apparatus, electrode manufacturing method, and battery manufacturing method

Abstract

The electrode manufacturing apparatus of the present invention aims to apply a liquid composition that corresponds to the surface state of an object to which the liquid composition has been applied. [Solution] The device includes a dispensing unit that dispenses a liquid composition capable of forming a resin layer or inorganic layer on a substrate or on a functional layer provided on a substrate, a dispensing control unit that controls the dispensing unit, and a surface image acquisition unit that acquires a surface image of the dispensed liquid composition or the resin layer or inorganic layer formed by the dispensed liquid composition. The dispensing control unit changes the amount of the liquid composition dispensed by the dispensing unit by changing the dispensing pattern based on the surface image acquired by the surface image acquisition unit.

Description

Technical Field

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

Background Art

[0002] Examples of electrochemical devices include lithium-ion secondary batteries, electric double layer capacitors, lithium-ion capacitors, redox capacitors, and the like. Among them, in particular, secondary batteries that can repeatedly charge and discharge have strong requirements regarding safety and reliability due to their applications. These requirements regarding safety and reliability are also demanded for the electrodes of electrochemical devices. It is necessary to strictly maintain the manufacturing quality in the manufacturing process so that problems such as ignition do not occur. For this reason, it is similarly necessary to maintain the manufacturing quality for the electrodes, which are the materials of electrochemical devices.

[0003] In Patent Document 1, a position information acquisition step of acquiring identification information of an electrode material to be used in assembly and position information of a planned use portion in the electrode material to be used in assembly, a quality information acquisition step of acquiring quality information of the planned use portion in the electrode material based on the acquired identification information and position, and a used portion determination step of determining a portion actually used in assembly in the electrode material based on the acquired quality information are disclosed for a method of manufacturing a secondary battery.

Summary of the Invention

Problems to be Solved by the Invention

[0004] The electrode manufacturing apparatus of the present invention aims to apply a liquid composition corresponding to the surface state of a non-application target to which the liquid composition has been applied.

Means for Solving the Problems

[0005] The electrode manufacturing apparatus of the present invention comprises: an application unit that applies a liquid composition capable of forming a resin layer or an inorganic layer on a substrate or on a functional layer provided on a substrate; an application control unit that controls the application unit; and a surface image acquisition unit that acquires a surface image of the applied liquid composition or the resin layer or the inorganic layer formed by the applied liquid composition. The application control unit is characterized in that, based on the surface image acquired by the surface image acquisition unit, it changes the amount of the liquid composition applied by the application unit by changing the application pattern. [Effects of the Invention]

[0006] The electrode manufacturing apparatus of the present invention can apply a liquid composition corresponding to the surface state of an object to which a liquid composition has been applied. [Brief explanation of the drawing]

[0007] [Figure 1] This is an example of an overall configuration diagram of the electrode manufacturing apparatus according to this embodiment. [Figure 2] This is a functional block diagram of the electrode manufacturing apparatus and the electrode manufacturing apparatus control unit. [Figure 3] This is a hardware configuration diagram of the electrode manufacturing apparatus control unit according to this embodiment. [Figure 4] A flowchart illustrating an example of the discharge volume control process. [Figure 5] This is a conceptual diagram of the formation of an insulating layer by the discharge of a liquid composition. [Figure 6] This is a plan view of an electrode manufacturing apparatus illustrating how streaky defects occur. [Figure 7] This is another example of the overall configuration diagram of the electrode manufacturing apparatus according to this embodiment. [Figure 8] This is an example of an optical system for a surface detection unit. [Figure 9] This is an example of the detection result from the surface detection unit. [Figure 10] This is a flowchart for defect detection. [Figure 11] This is a flowchart for adjusting the discharge volume based on the output of defect location information. [Figure 12] This is one example of a method for adjusting the discharge volume. [Figure 13] This is a flowchart showing a method for adjusting the discharge volume in stages. [Modes for carrying out the invention]

[0008] In the electrode manufacturing apparatus of the present invention, a surface detection unit detects the surface state of the insulating layer after the application of the liquid composition during the electrode manufacturing process, and the application control unit can control the application unit based on the detected surface state.

[0009] The electrode manufacturing apparatus of the present invention will be described in detail below with reference to the drawings.

[0010] <<Electrode manufacturing equipment 1>> (Overall structure) Figure 1 is an example of an overall configuration diagram of the electrode manufacturing apparatus according to this embodiment.

[0011] As shown in Figure 1, the electrode manufacturing apparatus 1 of this embodiment consists of an unwinding unit 10 and a winding unit 11, which are responsible for transporting the material; a discharge unit 5, which is an example of a liquid composition application unit; a curing device 6; a heater 7; a surface detection unit 8; an electrode substrate 9; a functional layer 12 provided on the electrode substrate; and a system control unit 3. Details of the system control unit 3 will be described separately.

[0012] Figure 1 shows the inside of the electrode manufacturing apparatus 1 as viewed through from the electrode substrate, which is the material to be extruded, or from a direction Y perpendicular to the transport direction X of the electrode substrate.

[0013] The surface detection unit 8 is positioned downstream in the transport direction, which is the direction in which the material to be discharged, from which the liquid composition has been discharged by the discharge unit 5, is transported. The order in which the surface detection unit 8 is positioned relative to the curing device 6 and heater 7 does not matter.

[0014] This electrode manufacturing apparatus 1 forms an insulating layer 21, which is a resin layer 22 or an inorganic layer 23, using a liquid composition 24 that is a material for forming the insulating layer 21, and forms the resin layer 22 or the inorganic layer 23 as the insulating layer 21 so as to cover the surface of the electrode substrate 9 or the functional layer 12 provided on the electrode substrate. The surface state of the insulating layer 21, which is the resin layer 22 or the inorganic layer 23, is detected by a surface detection unit 8 provided downstream of the discharge unit 5.

[0015] (Transportation) The electrode manufacturing apparatus 1 conveys the material to be discharged by an unwinding unit 10 and a winding unit 11, and the discharge unit 5 discharges the liquid composition 24 onto the material to be discharged, and forms the insulating layer 21, which is a resin layer 22 or an inorganic layer 23, so as to cover the surface of the material to be discharged, that is, the surface of the electrode substrate 9 or the functional layer 12 provided on the electrode substrate.

[0016] In this embodiment, the unwinding unit 10 is used as the means for unwinding the material to be discharged, and the winding unit 11 is used as the means for winding up the material to be discharged. The unwinding unit 10 supplies the material to be discharged to the conveyance path of the electrode manufacturing apparatus 1 by rotating the material to be discharged stored in a roll shape. The winding unit 11 winds up the material to be discharged onto which the liquid composition 24 has been discharged and the insulating layer 21 has been formed, and stores it in a roll shape. Although it is also related to other processes, the coating speed in the electrode manufacturing apparatus 1 is preferably 30 [m / min] to 100 [m / min]. Thereby, it can also be suitably used when high-speed formation of the insulating layer 21 is required.

[0017] The material to be discharged is a continuous base material along the conveyance direction X. The base material is the electrode substrate 9 or the functional layer 12 provided on the electrode substrate in this example. The electrode manufacturing apparatus 1 conveys the material to be discharged along the conveyance path between the unwinding unit 10 and the winding unit 11. Also, the length of the material to be discharged along the conveyance direction X is at least longer than the conveyance path between the unwinding unit 10 and the winding unit 11. The electrode manufacturing apparatus 1 can continuously perform the formation of the insulating layer 21 on the continuously conveyed material to be discharged.

[0018] (Material to be discharged) The electrode substrate 9 according to this embodiment is a conductive foil having a planar shape and can be suitably used in secondary batteries, capacitors, and especially lithium-ion secondary batteries, which are generally energy storage devices. As the conductive foil, aluminum foil, copper foil, stainless steel foil, titanium foil, and etched foil obtained by etching them to create fine holes, or perforated electrode substrates used in lithium-ion capacitors can be used. For this electrode substrate 9, non-woven or woven carbon paper fibrous electrodes used in power generation devices such as fuel cells can be made into a planar shape, or perforated electrode substrates with fine holes can be used.

[0019] (Functional layer provided on the electrode substrate) The functional layer 12 provided on the electrode substrate according to this embodiment is a layer containing an active material. The functional layer 12 provided on the electrode substrate is formed by dispersing and / or dissolving a powdered active material or catalyst composition in a liquid, and then coating, fixing, and drying it on the electrode substrate.

[0020] To form the functional layer 12 on the electrode substrate, methods such as spraying, dispensing, die coating, and pull coating are used, and the functional layer 12 is formed on the electrode substrate by drying the applied liquid composition after coating. The functional layer 12 on the electrode substrate is formed by dispersing and / or dissolving powdered active substances or catalyst compositions in a liquid, and then coating, fixing, and drying the liquid on the electrode substrate.

[0021] The positive electrode active material is not particularly limited as long as it is a material that can reversibly intercept and release alkali metal ions. Typically, alkali metal-containing transition metal compounds can be used as positive electrode active materials. For example, lithium-containing transition metal compounds include composite oxides containing lithium and at least one element selected from the group consisting of cobalt, manganese, nickel, chromium, iron, and vanadium. Examples include lithium-containing transition metal oxides such as lithium cobaltate, lithium nickelate, and lithium manganate, olivine-type lithium salts such as LiFePO4, chalcogen compounds such as titanium disulfide and molybdenum disulfide, and manganese dioxide. Lithium-containing transition metal oxides are metal oxides containing lithium and a transition metal, or metal oxides in which a portion of the transition metal in the metal oxide is substituted with a heterogeneous element. Examples of heterogeneous elements include Na, Mg, Se, Y, Mn, Fe, Co, Ni, Cu, Zn, Al, Cr, Pb, Sb, and B, with Mn, Al, Co, Ni, and Mg being particularly preferred. The different elements may be one or two or more. These positive electrode active materials can be used individually or in combination of two or more. Examples of the above active materials in nickel-metal hydride batteries include nickel hydroxide.

[0022] The negative electrode active material is not particularly limited as long as it is a material capable of reversibly intercalating and releasing alkali metal ions. Typically, carbon materials containing graphite having a graphite-type crystal structure can be used as the negative electrode active material. Examples of such carbon materials include natural graphite, spherical or fibrous artificial graphite, non-graphitizable carbon (hard carbon), and easily graphitizable carbon (soft carbon). Lithium titanate is an example of a material other than carbon. Furthermore, from the viewpoint of increasing the energy density of lithium-ion batteries, high-capacity materials such as silicon, tin, silicon alloys, tin alloys, silicon oxide, silicon nitride, and tin oxide can also be suitably used as negative electrode active materials. Examples of the above active materials in nickel-metal hydride batteries include AB2 or A2B hydrogen storage alloys represented by Zr-Ti-Mn-Fe-Ag-V-Al-W and Ti15Zr21V15Ni29Cr5Co5Fe1Mn8.

[0023] For the positive or negative electrode binder, for example, PVDF, polytetrafluoroethylene (PTFE), polyethylene, polypropylene, aramid resin, polyamide, polyimide, polyamide-imide, polyacrylonitrile, polyacrylic acid, polymethyl polyacrylate, polyethyl polyacrylate, polyhexyl polyacrylate, polymethacrylic acid, polymethyl polymethacrylate, polyethyl polymethacrylate, polyhexyl polymethacrylate, polyvinyl acetate, polyvinylpyrrolidone, polyether, polyethersulfone, hexafluoropolypropylene, styrene-butadiene rubber, carboxymethylcellulose, etc. may be used. Alternatively, copolymers of two or more materials selected from tetrafluoroethylene, hexafluoroethylene, hexafluoropropylene, perfluoroalkyl vinyl ether, vinylidene fluoride, chlorotrifluoroethylene, ethylene, propylene, pentafluoropropylene, fluoromethyl vinyl ether, acrylic acid, and hexadiene may be used. Alternatively, two or more selected materials may be mixed and used.

[0024] Examples of conductive materials used in electrodes include graphites such as natural graphite and artificial graphite, carbon blacks such as acetylene black, Ketjen black, channel black, furnace black, lamp black, and thermal black, conductive fibers such as carbon fibers and metal fibers, metal powders such as carbon fluoride and aluminum, conductive whiskers such as zinc oxide and potassium titanate, conductive metal oxides such as titanium oxide, and organic conductive materials such as phenylene derivatives and graphene derivatives. In fuel cells, the active material generally used as a catalyst for the cathode or anode electrode is a metal nanoparticle such as platinum, ruthenium, or platinum alloy supported on a catalyst support such as carbon. To support catalyst particles on the surface of the catalyst support, for example, the catalyst support is suspended in water, and a precursor of the catalyst particles is added (using alloy components such as chloroplatinic acid, dinitrodiaminoplatinum, dic platinum chloride, platinum monochloride, bisacetylacetonate platinum, dichlorodiammineplatinum, dichlorotetramineplatinum, dic platinum sulfate ruthenium chloride, iridium chloride, rhodium chloride, ferric chloride, cobalt chloride, chromium chloride, gold chloride, silver nitrate, rhodium nitrate, palladium chloride, nickel nitrate, iron sulfate, copper chloride, etc.) and dissolved in the suspension. An alkali is then added to generate metal hydroxides, and a catalyst support is obtained with the catalyst particles supported on the surface of the catalyst support. This catalyst support is then coated onto an electrode and reduced under a hydrogen atmosphere to obtain an electrode with catalyst particles (active material) coated on its surface.

[0025] (Resin layer or inorganic layer) In this embodiment, a resin layer 22 or an inorganic layer 23 is formed on a functional layer 12 provided on an electrode substrate by discharging a liquid composition 24 from a discharging unit 5. The liquid composition 24 is not particularly limited, as long as it has a viscosity that can be dispensed by the discharging unit 5 and a surface tension that can form the functional layer 12 provided on the electrode substrate.

[0026] (Dispensing section for liquid composition) As shown in Figure 1, the electrode manufacturing apparatus 1 is equipped with a discharge unit 5 as a means for dispensing a liquid composition 24. The discharge unit 5 has multiple nozzle rows in which multiple nozzles are arranged along the width direction (Y) of the material to be discharged. The electrode manufacturing apparatus 1 is equipped with a liquid composition discharge unit 5 such that the direction of discharge of the liquid composition 24 from the nozzles is directed toward the material to be discharged. In the discharge unit 5, the means for applying a stimulus to the liquid composition 24 to discharge the liquid composition 24 can be appropriately selected according to the purpose, and may be any of the following: a piezo method using a piezoelectric element, a thermal method using a heater, or a valve method using a pressurizing device.

[0027] The discharge unit 5 includes a discharge unit for the liquid composition 24, which is not shown in Figure 1. The discharge unit for the liquid composition 24 is an assembly of functional components and mechanisms related to the discharge of the liquid composition 24 from the discharge unit 5. The discharge unit for the liquid composition 24 includes a combination of the discharge unit 5 with at least one of the components of a supply mechanism, a maintenance and recovery mechanism, and a liquid discharge head movement mechanism.

[0028] The control related to the discharge of the liquid composition 24 from the discharge unit 5 is performed by the discharge control unit 40, which is an example of a control unit within the system control unit 3 shown in Figure 1. The discharge control unit 40 controls the discharge timing of the liquid composition 24, the discharge position of the liquid composition 24 droplets, and the droplet size of each droplet.

[0029] (Surface detection unit) The surface detection unit 8 is an example of a detection means that observes and outputs the surface condition of the insulating layer 21 (resin layer 22 or inorganic layer 23) formed on the material to be extruded. The electrode manufacturing apparatus 1 can acquire quality information of the insulating layer 21 (resin layer 22 or inorganic layer 23) formed on the material to be extruded based on the observation results output by the surface detection unit 8.

[0030] Details of the detection method in the surface detection unit 8 will be explained separately.

[0031] As shown in Figure 2, the electrode manufacturing apparatus 1 has a system control unit 3. The system control unit 3 controls the operation of the entire electrode manufacturing apparatus 1.

[0032] The system control unit 3 also includes an operation unit 34, a storage unit 35, a storage / reading unit 39, and a discharge control unit 40.

[0033] The control unit 34 consists of a touch panel or the like, and accepts user input for the electrode manufacturing apparatus 1, as well as displays the status and settings of the electrode manufacturing apparatus 1 on the screen.

[0034] The discharge control unit 40 controls the discharge unit 5 for the discharge of the liquid composition 24.

[0035] (System Control Unit) As shown in Figure 2, the electrode manufacturing apparatus 1 includes a system control unit 3.

[0036] The system control unit consists of an operation unit 34, a storage unit 35, a storage / reading unit 39, a processing unit 36, a surface detection image acquisition unit 51, a defect determination unit 52, a discharge instruction creation unit 53, a result output unit 54, a transport control unit 33, and a discharge control unit 40. The functions of each block will be described separately.

[0037] The system control unit 3 can be installed at any location inside or outside the electrode manufacturing apparatus 1. If installed outside, it will exchange control signals and data via various communication networks. The communication network can be the Internet, a mobile communication network, a LAN (Local Area Network), etc. The communication network may include not only wired communication but also wireless communication networks such as 3G (3rd Generation), WiMAX (Worldwide Interoperability for Microwave Access), and LTE (Long Term Evolution). Furthermore, the electrode manufacturing apparatus 1 can communicate using short-range communication technologies such as NFC (Near Field Communication) (registered trademark).

[0038] <<Hardware Configuration>> Next, we will explain the hardware configuration of the system control unit 3 using Figure 3.

[0039] <Hardware configuration of the system control unit> Figure 3 is a hardware configuration diagram of the system control unit.

[0040] As shown in Figure 3, the system control unit 3 includes a CPU (Central Processing Unit) 301, ROM (Read Only Memory) 302, RAM (Random Access Memory) 303, HD (Hard Disk) 304, HDD (Hard Disk Drive) 305, media 306, media I / F 307, display 308, network I / F 309, keyboard 311, mouse 312, CD-RW (Compact Disc Rewritable) drive 314, and bus line 31 It has 0.

[0041] Of these, the CPU 301 controls the operation of the entire system control unit 3. The ROM 302 stores the program used to drive the CPU 301. The RAM 303 is used as the work area for the CPU 301. The HD 304 stores various data such as programs. The HDD 305 controls the reading or writing of various data to the HD 304 according to the control of the CPU 301. The media I / F 307 controls the reading or writing (storage) of data to the media 306, such as flash memory. The display 308 displays various information such as cursors, menus, windows, characters, or images. The network I / F 309 is an interface for data communication using the communication network 100. The keyboard 311 is a type of input means equipped with multiple keys for inputting characters, numbers, and various instructions. The mouse 312 is a type of input means for selecting and executing various instructions, selecting processing targets, moving the cursor, etc. The CD-RW drive 314 controls the reading or writing of various data to the CD-RW (image management server) 313, which is an example of a removable recording medium.

[0042] Note that the CD-RW drive 314 may be replaced with a DVD-R drive or the like. Also, the system control unit 3 may be constructed by multiple computers, each of which is divided and arbitrarily assigned.

[0043] <<Configuration, Functions, and Detailed Operation of the System Control Unit>> Figure 2, a functional block diagram of the electrode manufacturing apparatus 1, also shows a functional block diagram of the system control unit 3. The operation of the system control unit 3 will be explained below using Figures 2 and 3.

[0044] As shown in Figure 2, the system control unit 3 includes an operation unit 34, a storage unit 35, a storage / reading unit 39, a processing unit 36, a surface detection image acquisition unit 51, a defect determination unit 52, a discharge instruction creation unit 53, a result output unit, a transport control unit 33, and a discharge control unit 40.

[0045] Each of these components is a function or means of functioning, which is realized by any of the components shown in Figure 3 operating according to instructions from the CPU 301 that follow a program deployed from HD 304 onto RAM 303. The system control unit 3 also has a storage unit 35 constructed from RAM 303 and HD 304 as shown in Figure 3.

[0046] The operation unit 34 is primarily implemented by instructions from the CPU 301 shown in Figure 3, and accepts various user operations by receiving signals from the keyboard 311 or mouse 312 operated by the user. The operations thus accepted are then implemented by instructions from the CPU 301 shown in Figure 3, and various images and screens are displayed on the display 308 located on the operation unit 34.

[0047] The processing unit 36 ​​is implemented by instructions from the CPU 301 shown in Figure 3 and performs overall control of the electrode manufacturing apparatus 1.

[0048] The storage / reading unit 39 is executed by instructions from the CPU 301 shown in Figure 3, as well as by the HDD 305, media I / F 307, and CD-RW drive 314, and performs processes such as storing various data in the storage unit 35, media 306, and CD-RW 313, and reading various data from the storage unit 35, media 306, and CD-RW 313.

[0049] The discharge control unit 40 controls the discharge unit 5, primarily based on information detected by the surface detection unit 8, as part of the control of the electrode manufacturing apparatus 1. The transport control unit 33 controls the unwinding unit 10 and the winding unit 11, controlling the discharge timing and discharge amount of the liquid composition 24. These functions are implemented by electrical circuits, and some of these functions can also be implemented by software (CPU; Central Processing Unit). These functions may also be implemented by multiple circuits or multiple software programs. The transport control unit 33 controls the start and stop of transport of the material to be discharged by the unwinding unit 10 and the winding unit 11, as well as the transport speed, etc.

[0050] When the surface detection image acquisition unit 51 acquires a surface detection image from the surface detection unit 8, the defect determination unit 52 starts defect determination. The defect determination unit 52 determines whether there is a defect. A defect refers to a defect that causes a decrease in the material properties of the functional layer, such as streaks, pinholes, unevenness, foreign matter, and insufficient film thickness. The user can set in advance which items from the quality information should be considered defects, as well as parameters such as size. Figure 6, which will be described later, will focus on streaky defects. If there is no defect, the discharge instruction creation unit 53 creates a log indicating that no change in the discharge amount was necessary, and the result output unit 54 instructs the discharge control unit 40 to that effect. If there is a defect, the discharge instruction creation unit 53 creates an instruction to increase the discharge amount, and the result output unit 54 instructs the discharge control unit 40 to that effect.

[0051] Figure 4 is a flowchart showing an example of a discharge volume control process.

[0052] First, the surface detection image acquisition unit 51 acquires a surface detection image from the surface detection unit 8 (S001).

[0053] Subsequently, the defect detection unit 52 begins to determine whether or not there is a defect (S002).

[0054] The defect detection unit 52 determines whether or not there are streak-like defects (S003), and if there are no defects, it creates a log indicating that no change in the discharge amount is necessary (S004).

[0055] If a defect is found, the defect detection unit 5 instructs the creation of a discharge instruction (S005), and the discharge instruction creation unit 53 creates an instruction to increase the discharge amount (S006).

[0056] Finally, the result of the determined instruction is output from the result output unit 54 to the discharge control unit 40 (S007).

[0057] <Detailed operation of electrode manufacturing apparatus 1>

[0058] (Formation of an insulating layer) Figure 5 is a conceptual diagram of the formation of an insulating layer by the discharge of a liquid composition.

[0059] Figures 5(a) and 5(b) illustrate the process of forming an insulating layer in the electrode manufacturing apparatus 1 according to the first embodiment.

[0060] Figure 5(a) shows a side view of the electrode manufacturing apparatus 1 as seen from the Y direction, and Figure 5(b) shows a top view of the electrode manufacturing apparatus 1 as seen from the Z direction.

[0061] Note that in Figure 2, the unwinding section 10, winding section 11, curing device 6, and heater 7 are not shown.

[0062] The electrode manufacturing apparatus 1 uses a liquid composition 24 to form an insulating layer, which is either a resin layer 22 or an inorganic layer 23, to form an insulating layer, which is either a resin layer 22 or an inorganic layer 23, so as to cover the surface of the electrode substrate 9 or a functional layer 12 provided on the electrode substrate. A surface detection unit 8 provided downstream of the discharge unit 5 detects the surface state of the insulating layer, which is either a resin layer 22 or an inorganic layer 23. Here, the electrode substrate 9 or the functional layer 12 provided on the electrode substrate is not limited to a continuous pattern across the entire surface, but may also have an intermittent coating or a free shape. Furthermore, the printed shape of the formed insulating layer 21, which is either a resin layer 22 or an inorganic layer 23, is not limited to a continuous pattern across the entire surface, but may also have an intermittent coating or a free shape.

[0063] Figure 6 is a plan view of an electrode manufacturing apparatus illustrating how streak-like defects occur.

[0064] Figures 6(a) to (c) illustrate how streak-like defects 59 occur during the extrusion of the insulating resin layer 22 or inorganic layer 23.

[0065] Figure 6(a) shows a state in which a streak-like defect 59 occurs during the dispensing of the insulating resin layer 22 or inorganic layer 23. As long as the streak-like defect 59 occurs during the dispensing of the dispensing unit 5 and the streak-like defect 59 does not reach the surface detection unit 8, only a log indicating that the dispensing amount does not need to be changed by the dispensing unit 5 (S004) is created.

[0066] Figure 6(b) shows a state in which a streak-like defect occurs during the dispensing of the insulating resin layer 22 or inorganic layer 23, and the streak-like defect 59 reaches the surface detection unit 8. When the streak-like defect 59 reaches the surface detection unit 8, the dispensing instruction creation unit 53 creates an instruction to increase the dispensing amount (S006). The instruction to increase the dispensing amount is sent from the dispensing instruction creation unit 53 to the dispensing control unit 40 via the result output unit 54, and the dispensing amount of the liquid composition 24 by the dispensing unit 5 is increased.

[0067] Figure 6(c) shows the state after the discharge instruction generation unit 53 sends a discharge amount increase instruction to the discharge control unit 40 via the result output unit 54, and the discharge amount of the liquid composition 24 by the discharge unit 5 is increased. By increasing the discharge amount of the liquid composition 24, the streaky defects 59 can be filled in, and the occurrence of new streaky defects can be suppressed.

[0068] (Regarding the location of the inspection equipment) Figure 7 shows another example of the overall configuration diagram of the electrode manufacturing apparatus according to this embodiment.

[0069] Figure 7(a) shows an electrode manufacturing apparatus 1 in which a curing device 6 is not used because the liquid composition 24 that forms the resin layer 22 or inorganic layer 23, which is the insulating layer 21, does not require a curing process.

[0070] As shown in Figure 7(b), the surface detection unit 8 may be provided upstream of the heater 7. If the surface detection unit 8 can detect the surface state of the liquid composition 24 before drying, it is preferable that the surface detection unit 8 be provided as the next step after the discharge unit 5 for reasons described later.

[0071] Furthermore, even when a curing device 6 is required as shown in Figure 7(c), if the surface detection unit 8 can detect the surface state of the liquid composition 24 before drying, it is preferable for the surface detection unit 8 to be provided in the next step after the dispensing unit 5 for reasons described later.

[0072] The present invention offers unique advantages when the surface detection unit 8 is provided immediately after the ejection unit 5, i.e., as the next step. While the present invention primarily has the effect of suppressing the occurrence of streak-like defects 59, the period from the occurrence of the streak-like defects 59 shown in Figure 6(a) to the detection of the streak-like defects 59 in Figure 6(b) and the suppression of the streak-like defects 59 in Figure 6(c) results in a defective product. Therefore, the shorter the distance from the ejection unit 5 where defects occur to the surface detection unit 8 where defects are detected, the greater the improvement in productivity due to the reduction in the defect rate. Thus, when defects can be detected before the ink dries, it is preferable to provide the surface detection unit 8 immediately after the ejection unit 5, i.e., as the next step after the ejection unit.

[0073] On the other hand, if the liquid composition 24 before drying by the heater 7 or curing by the curing device 6 is, for example, transparent and difficult to detect with a specular reflection camera or the like, it is preferable to install the surface detection unit 8 downstream of the heater 7 or curing device 6.

[0074] (Surface detection unit) Figure 8 shows an example of the optical system of the surface detection unit 8.

[0075] The surface detection unit 8 includes, as an illumination system, a visible light source 62 that irradiates the upper surface of the object to be detected 64 with visible light, and an IR / UV light source 63 that irradiates at least one of ultraviolet light or infrared light. Of course, either one of the light sources may be used.

[0076] Here, the object to be detected 64, which is the object to be detected by the surface detection unit 8, refers to the electrode substrate 9 on which the aforementioned insulating layer 21, which is either a resin layer 22 or an inorganic layer 23, is extruded, or the functional layer 12 provided on the electrode substrate.

[0077] Furthermore, the surface detection unit 8 is configured to include a visible light camera 61 as part of the measurement system, but an IR / UV light camera may be used instead of the visible light camera 61. The IR / UV light camera is not shown in the diagram, but it will have a similar arrangement to the visible light camera.

[0078] In such a measurement system, the surface detection unit 8 detects streak-like defects in the object to be detected 64 based on the output signal of the visible light camera 61 or the output signal of the IR / UV light camera.

[0079] Figure 9(a) shows an example of how the image detected by the surface detection unit 8 and acquired by the surface detection image acquisition unit 51 is displayed on the operation unit 34.

[0080] This example displays the defective area image 72, along with the defect type information 71, the defective area line 73, and the defect output signal graph 74 (the output is a graph showing the change in brightness value or brightness ratio), which are the results of the analysis by the defect determination unit 52.

[0081] By outputting information about these defects, users can gain a concrete understanding of the nature of the defects that have occurred.

[0082] Figures 9(b) and (c) show the cases where the brightness value is high and low, respectively. By accumulating experimental data for each type of anomaly that can actually occur, the presence or absence of defects and the level of defects can be accurately identified based on the correspondence between these types of changes in brightness value (increase or decrease) and the types of anomalies.

[0083] Figure 10 is a flowchart of the defect detection process.

[0084] First, the detection system is adjusted (S301) when no object to be detected 64 is present. As an example, a blue visible light source 31 is turned on, and the imaging device 4 captures visible light. This adjustment ensures that the brightness of the light directly incident on the visible light camera 61 is equal to or substantially equal to the upper limit of the measurable range.

[0085] Next, detection is initiated. The object to be detected 64 is photographed, and its output signal is taken into the surface detection image acquisition unit 51. At this time, white shading processing is applied to the signal for one line (for example, 4096 pixels), and a brightness value is generated (step S302).

[0086] Subsequently, the defect detection unit 52 detects and determines the location of abnormalities. For example, the defect detection unit 52 detects a region (group of pixels) consisting of pixels whose brightness value is greater than a predetermined threshold from the acquired image, and determines that the region is a "defective location" if the area of ​​the region exceeds a predetermined value. Here, the location of the defect (Y direction) and the transport timing at which the defect was detected are also acquired (S303).

[0087] If it is determined that a defect has been detected, the process proceeds to step S305. On the other hand, if no defect is detected, this routine terminates. (S304) If a defect is detected, the type of defect is determined (S305), and the defect type and location information are output (S306).

[0088] (Change in discharge volume) Figure 11 is a flowchart showing the adjustment of the discharge volume based on the output of defect location information.

[0089] First, the surface detection unit 8, the surface detection image acquisition unit 51, and the defect determination unit 52 detect information about the location of defects (S401).

[0090] Furthermore, the surface detection image acquisition unit 51 and the defect determination unit 52 identify the location of the defect (position in the Y-axis direction) (S402).

[0091] Subsequently, the ejection instruction creation unit 53 determines an appropriate ejection amount for the defect (for example, increasing the ejection amount) and a method for changing that ejection amount (for example, changing the ejection pattern or changing the print resolution) (S403).

[0092] Furthermore, the discharge instruction creation unit 53 creates instructions related to discharge, and the result output unit 54 outputs these instructions to the discharge control unit 40 (S404).

[0093] The discharge control unit 40 then controls the discharge at the specified location according to the specified discharge amount and discharge method (S405).

[0094] Figure 12 shows an example of how to change the discharge volume.

[0095] The print resolution is changed from Figure 12(a) to Figure 12(b). This is an example of how changing the print resolution can increase the discharge volume of the liquid composition 24.

[0096] In this example, the print resolution per unit area is changed from 3x3 as shown in Figure 12(a) to 4x4 as shown in Figure 12(b). By changing the print resolution from 3x3 to 4x4 without changing the size of the printed dots, the total amount of liquid composition imprinted per unit area can be increased.

[0097] The printing pattern is changed from Figure 12(c) to Figure 12(d). This is an example of how changing the printing pattern can increase the discharge volume of the liquid composition 24.

[0098] In this example, although the print resolution per unit area remains unchanged at 3x3, the total amount of liquid composition injected per unit area can be increased by changing the print density from approximately 56% in (c) to 100% in (d).

[0099] Of course, another common method for changing the discharge volume is to increase the energy input to the drive source of the nozzle of the discharge unit 5, thereby increasing the volume of the liquid composition 24 discharged from the nozzle.

[0100] At this point, the discharge volume can be increased across the entire discharge area to fill the streak-like defects 59, or it may be increased only around the area of ​​the streak-like defects 59. The surface detection image acquisition unit 51 and the defect determination unit 52 acquire defect position information in the Y direction and add this defect position information in the Y direction when creating a discharge instruction from the discharge instruction creation unit 53. In this case, the discharge volume outside the streak-like defect area does not need to be changed, thus minimizing the impact on the overall film thickness.

[0101] Furthermore, the defect location information is determined by combining the Y-direction position information with the transport information (such as transport speed and time information) of the electrode substrate 9 or the functional layer 12 provided on the electrode substrate, which is the object being transported. This allows the location of the defect on the transported object to be identified, just as in a normal manufacturing line.

[0102] (Step-by-step repair of defects) Figure 13 shows a flowchart illustrating a method for adjusting the discharge rate in stages.

[0103] The operation of adjusting the discharge volume in stages will be explained according to the flowchart in Figure 13.

[0104] Specifically, first, the defect is detected and its location (the streak-like defect 59 in Figure 6) is identified. As mentioned above, the location of the streak-like defect 59 on the electrode substrate 9 or the functional layer 12 provided on the electrode substrate can be identified from its position in the Y direction and the transport speed in the transport direction (S501).

[0105] Next, the amount of liquid composition discharged to the identified defect location is increased by a certain amount (S502). When this is done, the amount of liquid composition 24 can be small. In fact, using a small amount prevents the amount of liquid composition 24 used to fill the defect from becoming too large.

[0106] When the defective portion with increased discharge volume (streak-like defect 59 in Figure 6) is transported and reaches the surface detection unit 8, the defective portion with increased discharge volume is re-detected (S503).

[0107] In this case, the defect determination unit 52 determines whether the detected defect is below a specified value (i.e., whether it is at a level where it does not need to be treated as a defect) (S504).

[0108] If the defect is not below a specified value, that is, if the defect has not been repaired despite the increased discharge amount, the defect determination unit 52, via the discharge instruction creation unit 53, the result output unit 54, and the discharge control unit 40, again increases the discharge amount of the liquid composition to the defect location by a certain amount (S502).

[0109] If the defect still persists, this process is repeated. (S504:NO) If the defect falls below the specified value (S504: YES), it is assumed that the defect has been repaired as a result of increasing the discharge rate, and the increase in the discharge rate is stopped (S505). ●Summary

[0110] An electrode manufacturing apparatus 1 according to one embodiment of the present invention includes a discharge unit 5 that forms an insulating layer 21 by discharging a liquid composition 24 onto an electrode substrate 9 or a functional layer 12 provided on the electrode substrate, a discharge control unit 40 that controls the discharge unit 5, and a surface detection unit 8 that detects the surface state of the insulating layer 21 after the liquid composition 24 has been discharged by the discharge unit 5. The discharge control unit 40 controls the discharge unit 5 based on the surface state detected by the surface detection unit 8.

[0111] Due to these features, the surface detection unit 8 detects the surface state of the insulating layer 21 after the liquid composition 24 is dispensed, and the dispensing control unit 40 controls the dispensing unit 5 based on the detected surface state. Therefore, subsequent dispensing control on the surface of the insulating layer 21 can be performed in accordance with the detected surface state.

[0112] The insulating layer 21 of the electrode manufacturing apparatus 1 according to one embodiment of the present invention is a resin layer 22.

[0113] Due to these features, the surface detection unit 8 detects the surface state of the resin layer 22 after the liquid composition 24 is dispensed, and the dispensing control unit 40 controls the dispensing unit 5 based on the detected surface state. Therefore, subsequent dispensing control of the resin layer 22 can be performed in accordance with the detected surface state.

[0114] The insulating layer 21 of the electrode manufacturing apparatus 1 according to one embodiment of the present invention is an inorganic layer 23.

[0115] Due to these features, the surface detection unit 8 detects the surface state of the inorganic layer 23 after the liquid composition 24 is dispensed, and the dispensing control unit 40 controls the dispensing unit 5 based on the detected surface state. Therefore, subsequent dispensing control of the inorganic layer 23 can be performed in accordance with the detected surface state.

[0116] In the electrode manufacturing apparatus 1 according to one embodiment of the present invention, the information based on the surface state detected by the surface detection unit 8 is information based on defects, and the discharge control unit 40 increases the amount of liquid composition 24 discharged from the discharge unit 5 so as to eliminate the defects.

[0117] Due to these characteristics, if information based on defects on the surface of the insulating layer 21 after the liquid composition 24 has been dispensed is detected, the amount of liquid composition 24 can be increased to eliminate the defect in question, thereby eliminating the defect on the surface of the insulating layer 21 thereafter.

[0118] Information based on defects in the electrode manufacturing apparatus 1 according to one embodiment of the present invention is information regarding the location of the defects.

[0119] Due to these characteristics, the amount of liquid composition 24 can be increased to eliminate the target defect based on information about the location of the defect, which is information based on defects on the surface of the insulating layer 21 after the liquid composition 24 has been dispensed. Therefore, defects can be efficiently eliminated in the areas where there are defects on the surface of the insulating layer 21 thereafter.

[0120] The discharge control unit 40 of the electrode manufacturing apparatus 1 according to one embodiment of the present invention gradually increases the amount of liquid composition 24 ejected from the discharge unit 5 so that defects are eliminated step by step.

[0121] Due to these characteristics, the amount of liquid composition 24 is increased to eliminate defects on the surface of the insulating layer 21 after the liquid composition 24 is dispensed. In this process, the amount of liquid composition 24 dispensed from the dispensing section 5 is increased in stages so that the defects are eliminated gradually, thereby preventing the amount of liquid composition 24 dispensed from becoming excessively large, beyond what is needed to compensate for the defects.

[0122] One means by which the electrode manufacturing apparatus 1 according to one embodiment of the present invention increases the amount of liquid composition 24 is to change the printing resolution.

[0123] These features allow for easy control of surface defects in the insulating layer 21 by increasing the discharge volume of the liquid composition 24 by changing the printing resolution.

[0124] A means of increasing the amount of liquid composition 24 in the electrode manufacturing apparatus 1 according to one embodiment of the present invention is to change the discharge pattern.

[0125] Due to these characteristics, the amount of liquid composition 24 discharged can be increased by changing the discharge pattern, thereby eliminating surface defects of the insulating layer 21 with simple control. [Explanation of Symbols]

[0126] 1 Electrode manufacturing equipment 3. System Control Unit 5. Discharge section (an example of a dispensing section) 6 Curing equipment 7 Heater 8 Surface detection unit 9 Electrode base Volume 10 11 Winding section 12 Functional layer provided on electrode substrate 21 Insulating layer 22 Resin layer 23 Inorganic layer 24 Liquid composition 33 Transport Control Unit 34 Control section 35 Storage section 36 Processing Unit 39 Memory / readout section 40 Discharge control unit (an example of a dispensing control unit) 51 Surface detection image acquisition unit 52 Defect detection unit 53 Discharge instruction creation unit 54 Result Output Section 59. Stripe-like defects 61 Visible light camera 62 Visible light source 63 IR / UV light source 64. Detected object 71. Information on Defect Types 72 Images of defective areas 73 Defect Location Line 74 Defective Output Signal Graph 301 CPU 302 ROM 303 RAM 304 HD 305 HDD 306 Media 307 Media I / F 308 displays 309 Network I / F 310 Bus Line 311 keyboard 312 mice 313 CD-RW 314 CD-RW drive [Prior art documents] [Patent Documents]

[0127] [Patent Document 1] Japanese Patent Publication No. 2009-266739

Claims

1. An electrode manufacturing apparatus, A dispensing unit that applies a liquid composition capable of forming a resin layer or inorganic layer on a substrate or on a functional layer provided on a substrate, A granting control unit that controls the granting unit, A surface image acquisition unit that acquires a surface image of the applied liquid composition or the resin layer or inorganic layer formed by the applied liquid composition, It has, The application control unit changes the amount of the liquid composition applied by the application unit by changing the application pattern, based on the surface image acquired by the surface image acquisition unit. An electrode manufacturing apparatus characterized by the following features.

2. The application control unit increases the amount of the liquid composition applied by the application unit by changing the application pattern without changing the print resolution, based on the surface image acquired by the surface image acquisition unit. The electrode manufacturing apparatus according to claim 1.

3. A battery manufacturing apparatus, A dispensing unit that applies a liquid composition capable of forming a resin layer or inorganic layer on a substrate or on a functional layer provided on a substrate, A granting control unit that controls the granting unit, A surface image acquisition unit that acquires a surface image of the applied liquid composition or the resin layer or inorganic layer formed by the applied liquid composition, It has, The application control unit changes the amount of the liquid composition applied by the application unit by changing the application pattern, based on the surface image acquired by the surface image acquisition unit. A battery manufacturing apparatus characterized by the following features.

4. The application control unit increases the amount of the liquid composition applied by the application unit by changing the application pattern without changing the print resolution, based on the surface image acquired by the surface image acquisition unit. The battery manufacturing apparatus according to claim 3.

5. The application control unit changes the amount of the liquid composition applied by the application unit based on defect information obtained from the surface image. The battery manufacturing apparatus according to claim 3 or 4.

6. The aforementioned defect information is information regarding the location of the defect. The battery manufacturing apparatus according to claim 5.

7. The aforementioned defect information indicates a defect that causes a decrease in the material property values ​​of the functional layer. The battery manufacturing apparatus according to claim 5.

8. The information indicating the defect is information indicating at least one of the following: streaks, pinholes, unevenness, foreign matter, and insufficient film thickness. The battery manufacturing apparatus according to claim 7.

9. The system further includes a logging unit that generates a log indicating that it is unnecessary to change the amount of the liquid composition applied by the application unit if no information about the defect is obtained from the surface image. A battery manufacturing apparatus according to any one of claims 5 to 8.

10. A method for manufacturing electrodes, A step of applying a liquid composition capable of forming a resin layer or inorganic layer on a substrate or on a functional layer provided on a substrate, A dispensing control step for controlling the application of the liquid composition, A surface image acquisition step of acquiring a surface image of the applied liquid composition or the resin layer or inorganic layer formed by the applied liquid composition, Includes, The application control step modifies the amount of the liquid composition applied by the application step by changing the application pattern, based on the surface image acquired by the surface image acquisition step. A method for manufacturing electrodes characterized by the following features.

11. The application control step increases the amount of the liquid composition applied by the application step by changing the application pattern without changing the print resolution, based on the surface image acquired by the surface image acquisition step. The electrode manufacturing method according to claim 10.

12. A method for manufacturing a battery, A step of applying a liquid composition capable of forming a resin layer or inorganic layer on a substrate or on a functional layer provided on a substrate, A dispensing control step for controlling the application of the liquid composition, A surface image acquisition step of acquiring a surface image of the applied liquid composition or the resin layer or inorganic layer formed by the applied liquid composition, Includes, The application control step modifies the amount of the liquid composition applied by the application step by changing the application pattern, based on the surface image acquired by the surface image acquisition step. A battery manufacturing method characterized by the following features.

13. The application control step increases the amount of the liquid composition applied by the application step by changing the application pattern without changing the print resolution, based on the surface image acquired by the surface image acquisition step. The battery manufacturing method according to claim 12.

14. The application control step changes the amount of the liquid composition applied by the application step based on defect information obtained from the surface image. The battery manufacturing method according to claim 12 or 13.

15. The aforementioned defect information is information regarding the location of the defect. The battery manufacturing method according to claim 14.

16. The aforementioned defect information indicates a defect that causes a decrease in the material property values ​​of the functional layer. The battery manufacturing method according to claim 14.

17. The information indicating the defect is information indicating at least one of the following: streaks, pinholes, unevenness, foreign matter, and insufficient film thickness. The battery manufacturing method according to claim 16.

18. If information about the defects is not obtained from the surface image, the process further includes a logging step to create a log indicating that it is unnecessary to change the amount of the liquid composition applied in the application step. A battery manufacturing method according to any one of claims 14 to 17.

19. The aforementioned application control step changes the amount of the liquid composition applied by the application step by changing the printing rate. A battery manufacturing method according to any one of claims 12 to 18.

20. The application control step changes the amount of the liquid composition applied by the application step by gradually changing the amount of the liquid composition. A battery manufacturing method according to any one of claims 12 to 19.

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