Powder film forming device

Abstract

The objective is to provide a powder film forming apparatus capable of forming a powder film at a predetermined position on a substrate. [Solution] A powder film forming apparatus comprising a supply unit for supplying and depositing powder onto a substrate, and a press mechanism for pressing and compressing a portion of the powder deposited on the substrate to form a powder film and press it onto the substrate, wherein the press mechanism is configured to press the powder deposited on the substrate at a predetermined position on the substrate, and a removal mechanism is provided to remove powder present in the unpressed area on the substrate that was not pressed by the press mechanism.

Description

Technical Field

[0001] The present invention relates to a powder film forming apparatus for forming a powder film on a substrate.

Background Art

[0002] In the manufacturing process of lithium ion batteries, an electrode sheet is formed by depositing a powder of an electrode material on a sheet-like substrate such as an aluminum foil or a copper foil that is conveyed roll-to-roll, and pressing it to form a powder film.

[0003] Such a powder film forming apparatus used in the manufacturing process of lithium ion batteries includes a conveyance mechanism for conveying a substrate roll-to-roll, a supply unit for supplying and depositing powder on the substrate during conveyance, and a pressing mechanism for pressing the powder deposited on the substrate. Then, powder is supplied from the supply unit onto the substrate conveyed by the conveyance mechanism, and the powder deposited on the substrate is pressed by the pressing mechanism to form a powder film.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] In such a powder film forming apparatus, in order to improve productivity and reduce loss of electrode material, there is a demand for the development of means for forming a powder film at a predetermined position on the substrate, such as intermittently forming a powder film on the substrate. Therefore, an object of the present invention is to provide a powder film forming apparatus having a new technical means capable of forming a powder film at a predetermined position on the substrate.

Means for Solving the Problems

[0006] The powder film forming apparatus of the present invention, which solves the above problems, comprises a supply unit for supplying and depositing powder onto a substrate, and a press mechanism for forming a powder film and pressing it onto the substrate by pressing and compressing a portion of the powder deposited on the substrate, wherein the press mechanism is configured to press the powder deposited on the substrate at a predetermined position on the substrate, and a removal mechanism is provided to remove powder present in the non-pressed area on the substrate that was not pressed by the press mechanism.

[0007] According to the above-described powder film forming apparatus, a pressing mechanism presses and compresses the powder deposited on the substrate at a predetermined position on the substrate, and a removal mechanism removes the powder present in the non-pressed areas on the substrate, i.e., the powder that was not pressed and compressed onto the substrate by the pressing mechanism, thereby forming a powder film at a predetermined position on the substrate.

[0008] Furthermore, the system may also include a conveying mechanism for continuously transporting the substrate, and the supply unit, the press mechanism, and the removal mechanism may be arranged in this order along the direction of transport of the substrate by the conveying mechanism.

[0009] This configuration allows for continuous processing of powder by the supply unit, press mechanism, and removal mechanism on a substrate being transported by the conveying mechanism, thereby enabling the efficient formation of a powder film at a predetermined location on the substrate.

[0010] Furthermore, the press mechanism may have a press roll section that rotates with a rotation axis parallel to the width direction which is perpendicular to the transport direction in the in-plane direction of the substrate, and a press section that is provided so as to protrude from the outer circumferential surface of the press roll section and presses the powder deposited on the substrate, and a plurality of press sections may be provided so as to be arranged at predetermined intervals along the circumferential direction of the roll section.

[0011] With this configuration, multiple pressing sections are provided on the outer surface of the press roll section so as to be arranged at predetermined intervals along the circumferential direction of the press roll section, allowing the powder deposited on the substrate to be intermittently pressed along the conveying direction of the substrate, thereby enabling the intermittent formation of a film on the substrate.

[0012] Furthermore, the press mechanism may have a press roll section that rotates with an axis of rotation parallel to the width direction which is perpendicular to the transport direction in the in-plane direction of the substrate, and a press section that is provided so as to protrude from the outer circumferential surface of the press roll section and presses the powder deposited on the substrate, and a plurality of press sections may be provided so as to be arranged at predetermined intervals in the width direction.

[0013] With this configuration, multiple pressing sections are provided on the outer surface of the press roll section so as to be arranged at predetermined intervals in the width direction, allowing the powder deposited on the substrate to be pressed at multiple locations along the width direction. This makes it possible to form multiple films side by side on the substrate in the width direction.

[0014] Furthermore, the removal mechanism may be configured to include a posture adjustment unit that adjusts the posture of the substrate so that the powder present in the non-pressed area falls, thereby separating the powder from the substrate.

[0015] With this configuration, the posture adjustment unit adjusts the posture of the substrate so that powder present in the non-pressed area falls off, thereby allowing the powder present in the non-pressed area to fall off the substrate, leaving only the powder contained in the film on the substrate. Furthermore, since the powder present in the non-pressed area can be removed without contact, it is possible to suppress damage to the substrate and film that may occur due to contact between the removal mechanism and the film, while also suppressing the adhesion of foreign matter to the substrate and film.

[0016] Furthermore, the removal mechanism may be configured to include a suction section for sucking up the powder present in the non-pressed area.

[0017] With this configuration, the suction unit can remove powder present in the non-pressed area from the substrate, thus leaving only the powder contained in the film on the substrate. Furthermore, since the powder present in the non-pressed area can be removed without contact, it is possible to suppress damage to the substrate and film that may occur if the removal mechanism comes into contact with the film, while also suppressing the adhesion of foreign matter to the substrate and film.

[0018] Furthermore, the removal mechanism may be configured to include an air blowing section that blows air onto the substrate to blow away the powder present in the non-pressed area and separate it from the substrate.

[0019] With this configuration, the air blowing section blows away the powder present in the non-pressed area, thereby removing the powder from the substrate, and leaving only the powder contained in the film on the substrate. Furthermore, since the powder present in the non-pressed area can be removed without contact, it is possible to suppress damage to the substrate and film that may occur if the removal mechanism comes into contact with the film, while also suppressing the adhesion of foreign matter to the substrate and film.

[0020] Furthermore, the removal mechanism may be configured to include a vibration-applying unit that vibrates the substrate, thereby causing the powder present in the non-pressed area to flow and separate from the substrate.

[0021] With this configuration, the vibration unit vibrates the substrate, causing the powder present in the non-pressed area to flow and fall from the substrate, thus leaving only the powder contained in the film on the substrate.

[0022] Furthermore, the powder may contain an adhesive, and the press mechanism may be configured to further include a heating section for heating the pressing section.

[0023] According to this configuration, by heating the pressing part with the heating part, the powder on the base material can be pressed while melting the adhesive contained in the powder, so that the adhesive force between the powders contained in the film and the adhesive force between the base material and the film can be increased. Thereby, it is possible to suppress the removal of the powder contained in the film by the removal mechanism.

[0024] Further, it may be configured to adjust the time for which the pressing part presses the powder deposited on the base material by the relative speed difference between the base material conveyed by the conveying mechanism and the pressing part rotated by the pressing roll part.

[0025] According to this configuration, since the time for which the pressing part presses the powder deposited on the base material is adjusted by the relative speed difference between the base material conveyed by the conveying mechanism and the pressing part rotated by the pressing roll part, it becomes possible to adjust the shape of the powder film formed on the base material. Specifically, the slower the rotation speed of the pressing part compared to the conveyance speed of the base material, the longer the time for which the pressing part presses the powder deposited on the base material. Therefore, the powder film formed on the base material becomes longer in dimension in the conveyance direction of the base material as the rotation speed of the pressing part is slower compared to the conveyance speed of the base material. Also, the faster the rotation speed of the pressing part compared to the conveyance speed of the base material, the shorter the time for which the pressing part presses the powder deposited on the base material. Therefore, the powder film formed on the base material becomes shorter in dimension in the conveyance direction of the base material as the rotation speed of the pressing part is faster compared to the conveyance speed of the base material.

[0026] Further, it may be configured to further include an inspection part provided on the downstream side of the pressing mechanism for inspecting the state of the powder film formed on the base material.

[0027] According to this configuration, the inspection unit inspects the state of the powder film formed by pressing the powder deposited on the base material by the pressing mechanism, so it is possible to inspect whether there is an abnormality in the powder film, such as foreign matter adhering to the surface of the powder film. When it is found as a result of the inspection by the inspection unit that there is an abnormality in the powder film, it becomes possible to perform measures such as maintenance of the pressing mechanism and not using the powder film with an abnormality as a product.

Effect of the Invention

[0028] According to the powder film forming apparatus of the present invention, a powder film can be formed at a predetermined position on a base material.

Brief Description of the Drawings

[0029] [Figure 1] It is a diagram showing a powder film forming apparatus in the first embodiment of the present invention. [Figure 2] It is a diagram for explaining a press roll part in the first embodiment of the present invention. [Figure 3] It is a diagram showing a state where a powder film is formed on a base material by a powder film forming apparatus in an embodiment of the present invention. [Figure 4] It is a diagram showing a powder film forming apparatus in the second embodiment of the present invention. [Figure 5] It is a diagram showing one variation of a pressing mechanism in an embodiment of the present invention.

Mode for Carrying Out the Invention

[0030] 〔First Embodiment〕 The powder film forming apparatus in this embodiment will be described while referring to the drawings. In the following description, the three axes of the orthogonal coordinate system are denoted as X, Y, and Z, the horizontal direction is expressed as the X-axis direction and the Y-axis direction, and the direction perpendicular to the XY plane (that is, the vertical direction) is expressed as the Z-axis direction.

[0031] Figure 1 shows a powder film deposition apparatus 100 according to a first embodiment of the present invention. Figure 2 is a diagram illustrating the press roll section 52 according to a first embodiment of the present invention. Figure 3 shows a state in which a film 12 of powder 11 has been formed on a substrate 1 by the powder film deposition apparatus 100 according to one embodiment of the present invention.

[0032] As shown in Figure 1, the powder film forming apparatus 100 includes a conveying mechanism 2 for conveying a substrate 1, a supply unit 3 for supplying and depositing powder 11 onto the substrate 1, a squeegee unit 4 for leveling the powder 11 deposited on the substrate 1, and a press mechanism 5 for pressing a portion of the powder 11 leveled by the squeegee unit 4. The powder 11 supplied and deposited by the supply unit 3 onto the substrate 1 being conveyed by the conveying mechanism 2 and leveled by the squeegee unit 4 is then pressed and compressed by the press mechanism 5 to form a film 12 of the powder 11 (hereinafter referred to as film 12) and press it onto the substrate 1.

[0033] The base material 1 is a metal foil that serves as the electrode plate for a lithium-ion battery. When forming the positive electrode, aluminum foil or the like is used, and when forming the negative electrode, copper foil or the like is used. This base material 1 is a long, strip-shaped sheet and is transported by the transport mechanism 2 so as to pass through each part that makes up the powder film deposition apparatus 100.

[0034] The powder 11 is a powdery material in which at least a portion of the surface of the electrode active material is coated with a non-aqueous binder. This powder 11 is supplied onto the substrate 1 by the supply unit 3, leveled by the squeegee unit 4, and then pressed by the press mechanism 5 to form a film 12. This forms the positive or negative electrode of a lithium-ion battery.

[0035] The conveying mechanism 2 is for continuously conveying the base material 1 in its longitudinal direction. This conveying mechanism 2 includes an unwinding roll (not shown) for unwinding the base material 1, a winding roll (not shown) for winding the base material 1, and a plurality of conveying rolls 21 that the base material 1, unwinded by the unwinding roll, passes through before being wound onto the winding roll. By rotating these rolls, the base material 1 is conveyed so as to pass through each part of the powder film forming apparatus 100.

[0036] The supply unit 3 is for supplying powder 11 onto the substrate 1. This supply unit 3 is formed to be long in one direction, and is long along the width direction (Y-axis direction shown in Figure 1) which is perpendicular to the transport direction of the substrate 1 in the in-plane direction of the substrate 1. The supply unit 3 is positioned directly above the substrate 1 that is transported by the transport mechanism 2. In the following description, the width direction which is perpendicular to the transport direction of the substrate 1 in the in-plane direction of the substrate 1 will also be referred to as the width direction in the description of the supply unit 3, etc.

[0037] Furthermore, the supply unit 3 has a discharge port 31 for discharging the powder 11 and a storage unit connected to the discharge port 31 for accumulating the powder 11. The discharge port 31 is an opening for discharging the powder 11 and is formed to be long in the width direction. The storage unit is a space for accumulating the powder 11 formed within the supply unit 3 and is formed to be open at the lower end of the supply unit 3. The open end of this storage unit is the discharge port 31, and the powder 11 accumulated in the storage unit is discharged from the discharge port 31 by gravity. This makes it possible to supply and accumulate the powder 11 over the width direction on the substrate 1 conveyed by the conveying mechanism 2. In this embodiment, the dimensions of the discharge port 31 and the storage unit in the width direction are equal.

[0038] The squeegee section 4 is for leveling the powder 11 that has been supplied onto the substrate 1 by the supply section 3 and deposited thereon, and is located downstream of the supply section 3 in the conveying direction of the substrate 1. In this embodiment, the squeegee section 4 is a roll having a rotation axis parallel to the width direction and is positioned directly above the substrate 1 at a predetermined distance from the substrate 1. When the substrate 1, which is conveyed by the conveying mechanism 2, passes under the squeegee section 4, the powder 11 deposited on the substrate 1 comes into contact with the squeegee section 4, and the thickness of the powder 11 deposited on the substrate 1 is leveled to the predetermined distance.

[0039] The press mechanism 5 is used to press and compress a portion of the powder 11 leveled by the squeegee section 4, thereby forming a film 12 and pressing it onto the substrate 1. It is located downstream of the squeegee section 4 in the conveying direction of the substrate 1. In this embodiment, the press mechanism 5 has a set of roll sections 51 that press the powder 11 on the substrate 1 by sandwiching the substrate 1 from above and below.

[0040] Each set of rolls 51 includes a press roll section 52 positioned above the base material 1 with a gap between them, and a support roll section 53 positioned below the base material 1 so as to contact it. The rotation axes of each section are arranged parallel to the width direction. The base material 1, transported by the transport mechanism 2, passes between the press roll section 52 and the lower roll 53, thereby pressing the powder 11 accumulated on the base material 1. This forms a film 12 on the base material 1, which is then pressed onto the base material 1.

[0041] Here, the powder film deposition apparatus 100 is configured to form a film 12 at a predetermined position on the substrate 1. Specifically, the powder film deposition apparatus 100 is configured such that a press mechanism 5 presses the powder 11 deposited on the substrate 1 at a predetermined position on the substrate 1, and a removal mechanism 6 is provided to remove the powder 11 present in the non-pressed area 13 on the substrate 1 that was not pressed by the press mechanism 5. In other words, the powder film deposition apparatus 100 forms a powder film 12 at a predetermined position on the substrate 1 by pressing the film 12 only at a predetermined position on the substrate 1 using the press mechanism 5 and pressing it onto the substrate 1, and by removing the powder 11 that was not pressed onto the substrate 1 by the removal mechanism 6.

[0042] The following will provide a specific explanation using an example of intermittently forming multiple films 12 on a substrate 1. Intermittently forming films 12 on a substrate 1 means continuously forming films 12 on the substrate 1 such that there is a certain gap between each film 12 formed in the transport direction of the substrate 1, as shown in Figure 3. Forming multiple films 12 on a substrate 1 means forming multiple films 12 on the substrate 1 in the width direction such that there is a certain gap between each film 12 in the width direction, as shown in Figure 3.

[0043] As shown in Figure 2, the press mechanism 5 in this embodiment has a press section 54 that protrudes from the outer circumferential surface of the press roll section 52 and presses the powder 11 deposited on the substrate 1. In this embodiment, the contact surface of the press section 54 that contacts the powder 11 is formed in a rectangular shape. When the powder 11 on the substrate 1 is pressed by this press section 54, a film 12 with the same shape as the contact surface of the press section 54 is formed on the substrate 1. The distance between the contact surface of the press section 54 and the powder 11 deposited on the substrate 1 is smaller than the distance between the squeegee section 4 and the powder 11 deposited on the substrate 1.

[0044] Multiple press sections 54 are provided so as to be arranged at predetermined intervals along the circumferential direction of the press roll section 52. Therefore, when the substrate 1 being transported by the transport mechanism 2 passes between the press roll section 52 and the support roll section 53, the powder 11 deposited on the substrate 1 is intermittently pressed along the transport direction of the substrate 1 by each of the multiple press sections 54 provided on the outer surface of the press roll section 52 so as to be arranged at predetermined intervals along the circumferential direction of the press roll section 52. As a result, a film 12 is intermittently formed on the substrate 1 and pressed onto the substrate 1.

[0045] Furthermore, multiple press sections 54 are provided so as to be arranged at predetermined intervals in the width direction. Therefore, when the substrate 1 conveyed by the conveying mechanism 2 passes between the press roll section 52 and the support roll section 53, the powder 11 deposited on the substrate 1 is pressed at multiple locations along the width direction by each of the multiple press sections 54 provided on the outer surface of the press roll section 52 so as to be arranged at predetermined intervals in the width direction. As a result, a film 12 is formed on the substrate 1 in a line along the width direction and pressed onto the substrate 1.

[0046] The removal mechanism 6 is for removing powder 11 present in the non-pressing area 13 and is located downstream of the press mechanism 5 in the conveying direction of the base material 1. That is, the supply unit 3, the press mechanism 5, and the removal mechanism 6 are arranged in this order along the conveying direction of the base material 1.

[0047] In this embodiment, the removal mechanism 6 has a posture adjustment unit 61 that separates the powder 11 from the substrate 1 by adjusting the posture of the substrate 1 so that the powder 11 present in the non-pressed area 13 falls. In this embodiment, the conveying roll 21 is the posture adjustment unit 61, and as shown in Figure 1, it is positioned to form a conveying path for the substrate 1 so that the substrate 1 is conveyed vertically downward after passing through the press mechanism 5. In this way, by adjusting the posture of the substrate 1 with the posture adjustment unit 61 so that the substrate 1 is conveyed vertically downward, the powder 11 present in the non-pressed area 13 can be made to fall from the substrate 1 by gravity, as shown in Figure 1. As a result, only the powder 11 contained in the film 12 can be left on the substrate 1. Therefore, the film 12 can be formed intermittently and in multiple strips on the substrate 1.

[0048] Furthermore, in this embodiment, the posture adjustment unit 61 can remove the powder 11 present in the non-pressing area 13 without contact, thereby suppressing scratches on the substrate 1 and the film 12, and the adhesion of foreign matter, which may occur when the removal mechanism 6 comes into contact with the film 12.

[0049] Furthermore, the press mechanism 5 in this embodiment further includes a heating unit (not shown) that heats the press section 54. The heating unit is a heater and is provided within the press roll section 52. By heating the press section 54 with this heating unit, the binder contained in the powder 11 can be melted while pressing the powder 11 on the substrate 1, thereby increasing the adhesive force between the powder particles 11 contained in the film 12 due to the binder and the adhesive force between the substrate 1 and the film 12. This makes it possible to suppress the removal of the powder 11 contained in the film 12 by the removal mechanism 6.

[0050] Furthermore, it is preferable that the powder film deposition apparatus 100 in this embodiment is provided with a powder receiving section (not shown) that receives the powder 11 that falls from the substrate 1 whose orientation has been adjusted by the orientation adjustment section 61. By providing this powder receiving section, it becomes possible to collect the powder 11 that has fallen from the substrate 1 and supply it again to the substrate 1 from the supply section 3, thereby reducing the loss of powder 11.

[0051] Furthermore, in this embodiment, the powder film forming apparatus 100 adjusts the shape of the film 12 formed on the substrate 1 by adjusting the time the press section 54 presses the powder 11 deposited on the substrate 1 based on the relative speed difference between the substrate 1 conveyed by the conveying mechanism 2 and the press section 54 rotated by the press roll section 52.

[0052] Specifically, the powder film forming apparatus 100 in this embodiment adjusts at least one of the following: the rotational speed of the press roll section 52 by the press mechanism 5 and the conveying speed of the substrate 1 by the conveying mechanism 2. The slower the rotational speed of the press section 54 is compared to the conveying speed of the substrate 1, the longer the time the press section 54 presses the powder 11 deposited on the substrate 1. As a result, the length of the film 12 formed on the substrate 1 in the conveying direction of the substrate 1 increases as the rotational speed of the press section 54 is slower compared to the conveying speed of the substrate 1.

[0053] Furthermore, by adjusting the rotational speed of the press roll section 52 by the press mechanism 5 and adjusting the transport speed of the base material 1 by the transport mechanism 2, the faster the rotational speed of the press section 54 is made compared to the transport speed of the base material 1, the shorter the time the press section 54 spends pressing the powder 11 deposited on the base material 1. As a result, the film 12 formed on the base material 1 becomes shorter in the transport direction of the base material 1 as the rotational speed of the press section 54 is increased compared to the transport speed of the base material 1.

[0054] Here, between the supply unit 3 and the press roll unit 52 in the conveying direction of the substrate 1, there is a preheating unit (not shown) that preheats the powder 11 deposited on the substrate 1. The preheating unit is, for example, an infrared heater. By preheating the powder 11 deposited on the substrate 1 on the front side of the press roll unit 52 with this preheating unit, it is possible to suppress a decrease in the adhesive strength between the powder 11 contained in the film 12 due to the binder, and the adhesive strength between the substrate 1 and the film 12, due to insufficient heating of the powder 11 deposited on the substrate 1 when the rotation speed of the press unit 54 is faster than the conveying speed of the substrate 1. As a result, even when the rotation speed of the press unit 54 is faster than the conveying speed of the substrate 1, it is possible to suppress the removal of the powder 11 contained in the film 12 by the removal mechanism 6.

[0055] Furthermore, the powder film forming apparatus 100 in this embodiment is further provided with an inspection unit 71 located downstream of the press mechanism 5, which inspects the state of the film 12 formed on the substrate 1. The inspection unit 71 in this embodiment is a camera for imaging the film 12 and is positioned directly above the substrate 1. This inspection unit 71 images the film 12 formed by pressing the powder 11 deposited on the substrate 1 by the press mechanism 5.

[0056] Then, by checking the image of the film 12 obtained by the inspection unit 71, it becomes possible to inspect whether or not there is any abnormality in the film 12, such as foreign matter adhering to the surface of the film 12. If the inspection unit 71 finds that there is an abnormality in the film 12 as a result of the inspection, processing is carried out to resolve the abnormality. For example, if it is found that the abnormality in the film 12 is that wear particles from the press mechanism 5 are adhering to the surface of the film 12, then measures such as maintenance of the press mechanism 5 or not using the film 12 with the wear particles attached as a product will be taken.

[0057] Furthermore, the inspection unit 71 may be connected to a general-purpose computer device (not shown), and the inspection unit 71 may transmit an image of the film 12 to the computer device, which then inspects whether or not there is an abnormality in the film 12 based on the image of the film 12 it receives. If the inspection result indicates that there is an abnormality in the film 12, the computer device stores which of the multiple films 12 formed on the substrate 1 had the abnormality. This makes it easy to check which film 12 on the wound substrate 1 had the abnormality even after the substrate 1 has been wound onto the winding roll, and makes it easier to discard the abnormal film 12 so that it is not used as a product. Note that abnormalities in the film 12 include not only foreign matter adhering to the surface of the film 12, but also defects in the shape and thickness of the film 12, and delamination between the substrate 1 and the film 12.

[0058] In this manner, the powder film forming apparatus 100 in the above embodiment can form a film 12 at a predetermined position on the substrate 1 by pressing and compressing the powder 11 deposited on the substrate 1 at a predetermined position on the substrate 1 using the pressing mechanism 5, and by removing the powder 11 present in the non-pressed area 13 on the substrate 1, that is, the powder 11 that was not pressed and compressed by the pressing mechanism 5, using the removal mechanism 6.

[0059] Furthermore, in the above embodiment, the supply unit 3, the press mechanism 5, and the removal mechanism 6 are arranged in this order along the conveying direction of the substrate 1, making it possible to continuously process the powder 11 by the supply unit 3, the press mechanism 5, and the removal mechanism 6 on the substrate 1 being conveyed by the conveying mechanism 2. This makes it possible to efficiently form a film 12 at a predetermined position on the substrate 1.

[0060] [Second Embodiment] Next, the powder film deposition apparatus 100 in the second embodiment of the present invention will be described with reference to Figure 4. The powder film deposition apparatus 100 in this embodiment differs from the first embodiment in that the removal mechanism 6 has a suction section 62. In the following description, specific details of points that are the same as in the first embodiment will be omitted, and the differences will be described in detail.

[0061] Figure 4 is a diagram illustrating the powder film deposition apparatus 100 in this embodiment. As shown in Figure 4, the removal mechanism 6 in this embodiment has a suction unit 62 that sucks up the powder 11 present in the non-press area 13. The suction unit 62 is not particularly limited as long as it has a suction force capable of sucking up the powder 11 and a suction port with a diameter larger than the particle size of the powder 11. By sucking up the powder 11 present in the non-press area 13 with the suction unit 62, the powder 11 present in the non-press area 13 can be removed from the substrate 1, so that only the powder 11 contained in the film 12 can be left on the substrate 1. In addition, since the powder 11 present in the non-press area 13 can be removed without contact, scratches on the substrate 1 and the film 12 that may occur due to the removal mechanism 6 coming into contact with the film 12, and the adhesion of foreign matter can be suppressed.

[0062] [Third Embodiment] Next, a powder film deposition apparatus 100 according to a third embodiment of the present invention will be described. The powder film deposition apparatus 100 in this embodiment differs from the first and second embodiments in that the removal mechanism 6 has an air blowing section (not shown). In the following description, specific details of points similar to those in the first and second embodiments will be omitted, and the differences will be the focus of the description.

[0063] The removal mechanism 6 in this embodiment has an air blowing section that blows air onto the substrate 1 to blow away the powder 11 present in the non-pressed area 13 and separate it from the substrate 1. The air blowing section is not particularly limited as long as it is capable of blowing air with an air volume and force sufficient to blow away the powder 11 onto the substrate 1. By blowing away the powder 11 present in the non-pressed area 13 with the air blowing section, the powder 11 present in the non-pressed area 13 can be removed from the substrate 1, so that only the powder 11 contained in the film 12 can be left on the substrate 1. In addition, since the powder 11 present in the non-pressed area 13 can be removed without contact, scratches on the substrate 1 and the film 12 that may occur due to contact between the removal mechanism 6 and the film 12, and the adhesion of foreign matter can be suppressed.

[0064] [Fourth Embodiment] Next, a powder film deposition apparatus 100 according to the fourth embodiment of the present invention will be described. The powder film deposition apparatus 100 in this embodiment differs from the first, second, and third embodiments in that the removal mechanism 6 has a vibration-applying part (not shown). In the following description, specific details of points similar to those in the first, second, and third embodiments will be omitted, and the differences will be the focus of the description.

[0065] The removal mechanism 6 in this embodiment has a vibration-applying unit that vibrates the substrate 1, thereby causing the powder 11 present in the non-pressed area 13 to flow and separate from the substrate 1. The vibration application may be, for example, ultrasonic vibration of the substrate 1, or vibration by striking the substrate 1, and is not particularly limited as long as it is possible to vibrate the substrate 1. By vibrating the substrate 1 with the vibration-applying unit, the powder 11 present in the non-pressed area 13 can be caused to flow and fall from the substrate 1, so that only the powder 11 contained in the film 12 can be left on the substrate 1.

[0066] Although embodiments of the present invention have been described in detail above with reference to the drawings, the configurations and combinations thereof in the above embodiments are merely examples, and additions, omissions, substitutions, and other modifications to the configurations are possible without departing from the spirit of the present invention. For example, in the above embodiments, an example in which the powder 11 includes a binder was described, but it does not have to be a binder as long as it is an adhesive that can bond the powders 11 together and the powders 11 together with the substrate 1.

[0067] Furthermore, although the above embodiment describes an example in which the press mechanism 5 has a press roll section 52, it is not limited to this. For example, as shown in Figure 5, the press mechanism 5 may have a stamp section 55 that moves vertically to press the powder 11 on the substrate 1, thereby pressing the powder 11.

[0068] Furthermore, although the above embodiment describes an example in which the contact surface of the press portion 54 is rectangular, it is not limited to this and may be appropriately changed according to the shape of the film 12 to be formed. For example, it may be circular.

[0069] Furthermore, although examples have been described in each of the above embodiments in which the removal mechanism 6 has a posture adjustment unit 61, a suction unit 62, an air blowing unit, and a vibration applying unit, it may have multiple units. In this case, the powder 11 present in the non-pressing area 13 can be removed more reliably.

[0070] Furthermore, although the above embodiment describes an example where the inspection unit 71 is a camera, it is not limited to this and may be a sensor, for example. [Explanation of Symbols]

[0071] 100 Powder film forming equipment 1 Base material 11 Powder 12 membrane 13 Non-press area 2. Conveying mechanism 21 Conveyor Rolls 3 Supply section 31 Discharge port 4. Squeegee section 5 Press mechanism 51 Roll section 52 Press Roll Section 53 Support Roll Section 54 Press Department 55 Stamp section 6 Removal mechanism 61 Posture adjustment part 62 Suction part 71 Inspection Department

Claims

1. A supply unit that supplies and deposits powder onto a substrate, A powder film forming apparatus comprising a pressing mechanism that presses and compresses a portion of the powder deposited on a substrate to form a powder film and press it onto the substrate, The aforementioned pressing mechanism is configured to press powder deposited on the substrate at a predetermined position on the substrate, A powder film forming apparatus characterized by being provided with a removal mechanism for removing powder present in the unpressed areas on the substrate that were not pressed by the aforementioned pressing mechanism.

2. It is further equipped with a conveying mechanism for continuously transporting the substrate, The powder film forming apparatus according to claim 1, characterized in that the supply unit, the press mechanism, and the removal mechanism are arranged in this order along the direction of transport of the substrate by the transport mechanism.

3. The press mechanism includes a press roll section that rotates with a rotation axis parallel to the width direction, which is perpendicular to the transport direction in the in-plane direction of the substrate, It has a press section that protrudes from the outer surface of the press roll section and presses the powder deposited on the substrate, The powder film forming apparatus according to claim 2, characterized in that a plurality of the pressing sections are provided so as to be arranged at predetermined intervals along the circumferential direction of the pressing roll section.

4. The press mechanism includes a press roll section that rotates with a rotation axis parallel to the width direction, which is perpendicular to the transport direction in the in-plane direction of the substrate, It has a press section that protrudes from the outer surface of the press roll section and presses the powder deposited on the substrate, The powder film forming apparatus according to claim 2, characterized in that a plurality of the pressing sections are provided so as to be arranged at predetermined intervals in the width direction.

5. The powder film forming apparatus according to any one of claims 1 to 4, characterized in that the removal mechanism has a posture adjustment unit that separates the powder from the substrate by adjusting the posture of the substrate so that the powder present in the non-pressed area falls.

6. The powder film forming apparatus according to any one of claims 1 to 4, characterized in that the removal mechanism has a suction unit for sucking up powder present in the non-pressing area.

7. The powder film forming apparatus according to any one of claims 1 to 4, characterized in that the removal mechanism has an air blowing section that blows air onto the substrate to blow away the powder present in the non-pressed area and separate it from the substrate.

8. The powder film forming apparatus according to any one of claims 1 to 4, characterized in that the removal mechanism has a vibration-applying unit that vibrates the substrate to cause the powder present in the non-press region to flow and separate from the substrate.

9. The powder contains adhesive. The powder film forming apparatus according to claim 3 or 4, characterized in that the pressing mechanism further includes a heating section for heating the pressing section.

10. The powder film forming apparatus according to claim 3 or 4, characterized in that the time for which the press section presses the powder deposited on the substrate is adjusted by the relative speed difference between the substrate conveyed by the conveying mechanism and the press section rotated by the press roll section.

11. The powder film forming apparatus according to any one of claims 1 to 4, further comprising an inspection unit provided downstream of the press mechanism for inspecting the state of the powder film formed on the substrate.

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