Manufacturing method and manufacturing device for stacked battery

Abstract

To provide a manufacturing method for a laminate battery with which it is possible to realize improvement in productivity while maintaining highly accurate quality; and a manufacturing device for conducting such a method.SOLUTION: Included are: a lamination step S02 for zigzag-folding an elongate strip-shaped separator 103, and each time the separator 103 is folded, alternately placing, in order on the folded separator 103, a predetermined number of positive electrode sheets 101 and the predetermined number of negative electrode sheets 102, each arranged together and arranged side-by-side in a longitudinal direction of the separator 103, to form an electrode laminated body group 110 comprising a plurality of the positive electrode sheets 101 and the negative electrode sheets 102, the predetermined number thereof being laminated on one another with the separator 103 interposed therebetween; and a dividing step S03 for cutting the formed electrode laminated body group 110 by means of heat cutting in a laminating direction of the positive electrode sheets 101 and the negative electrode sheets 102, to divide the electrode laminated body group into electrode laminated bodies 110A each comprising a plurality of the positive electrode sheets 101 and the negative electrode sheets 102 laminated singly with the separator 103 interposed therebetween.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing a stacked battery and an apparatus for manufacturing a stacked battery that implements the manufacturing method. [Background technology]

[0002] 2. Description of the Related Art Conventionally, stacked batteries have been known which are formed by alternately stacking a plurality of electrode plates, for example, positive and negative electrode plates, with separators interposed between each of them. Various methods have been proposed for manufacturing the stacked battery. For example, Patent Document 1 discloses a method for manufacturing the stacked battery in which a stacked sheet is formed by bonding a first separator and a second separator in the form of a long strip to both sides of a negative electrode sheet made of a long strip-shaped negative electrode core coated with a negative electrode active material layer, via an adhesive layer made of an adhesive or a bonding agent, and the like; the formed stacked sheet is then cut into a predetermined shape; and the cut stacked sheets (negative electrode plates sandwiched between two separators) are alternately stacked with a plurality of pre-prepared positive electrode plates, thereby stacking a plurality of positive electrode plates and negative electrode plates alternately with separators interposed therebetween. Furthermore, for example, Patent Document 2 discloses a method for manufacturing the above-mentioned stacked battery, in which a long strip-shaped separator is folded zigzag, and each time the separator is folded back, a plurality of positive electrode plates and negative electrode plates are alternately stacked one by one on the separator, so that a plurality of positive electrode plates and negative electrode plates are alternately stacked with separators interposed therebetween. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] International Publication No. 2018 / 021263 [Patent Document 2] Japanese Patent Application Laid-Open No. 2017-16946 Summary of the Invention [Problem to be solved by the invention]

[0004] In recent years, the demand for stacked batteries having such a configuration has been increasing, and there has been an increasing demand for improved productivity (the number of stacked batteries manufactured per unit time) in the manufacturing process of such stacked batteries. However, in the manufacturing method of Patent Document 1, a negative electrode plate sandwiched between two separators is prepared in advance by cutting a laminated sheet. Therefore, although some improvement in productivity can be expected compared to, for example, stacking a plurality of positive electrode plates and negative electrode plates and a plurality of separators one by one in an alternating order, it still takes time to perform positioning and the like each time a plurality of positive electrode plates and negative electrode plates are stacked, making it difficult to obtain sufficient effects that meet the above-mentioned demands. Furthermore, in the manufacturing method of Patent Document 2, the separators interposed between each of a plurality of positive electrode plates and negative electrode plates, which are stacked alternately one by one, are arranged in a zigzag manner. Therefore, compared to the manufacturing method of Patent Document 1, at least the work of cutting the laminated sheets can be omitted, and further improvement in productivity can be expected. However, even with this manufacturing method, it was difficult to obtain sufficient effects that met the above-mentioned demands.

[0005] The present invention has been made in consideration of the current problems described above, and an object of the present invention is to provide a method for manufacturing a stacked battery that can improve productivity while maintaining high-precision quality, and a manufacturing apparatus for carrying out the method. [Means for solving the problem]

[0006] The problem to be solved by the present invention is as described above, and the means for solving this problem will now be described.

[0007] That is, the manufacturing method of a stacked battery according to the present invention is a manufacturing method of a stacked battery in which a plurality of positive electrode plates and negative electrode plates are alternately stacked and separators are interposed between the plurality of positive electrode plates and negative electrode plates, and is characterized by comprising: a lamination step of zigzag folding a long, strip-shaped separator, and each time the separator is folded back by zigzag folding, placing a predetermined number of positive electrode plates and a predetermined number of negative electrode plates collectively and alternately on the folded back separator in a state where they are aligned along the longitudinal direction of the separator, thereby forming an electrode stack group made up of a predetermined number of positive electrode plates and negative electrode plates stacked together with separators interposed therebetween; and a division step of cutting the electrode stack group formed by the lamination step by heat cutting in the stacking direction of the positive electrode plates and the negative electrode plates, and dividing it into electrode stacks made up of a plurality of positive electrode plates and negative electrode plates stacked one by one with separators interposed therebetween. Furthermore, a manufacturing apparatus for a stacked battery according to the present invention is a manufacturing apparatus for a stacked battery in which a plurality of positive and negative electrode plates are alternately stacked and separators are interposed between the plurality of positive and negative electrode plates, and is characterized by comprising: a zigzag folding device that folds a long, strip-shaped separator in a zigzag manner; an electrode plate mounting device that, each time the separator is folded back by the zigzag folding device, collectively and alternately mounts a predetermined number of positive and negative electrode plates and a predetermined number of negative electrode plates on the folded separator in a state where they are lined up along the longitudinal direction of the separator; and a dividing device that cuts, by heat cutting, an electrode stack group formed by the zigzag folding device and the electrode plate mounting device, which consists of a plurality of positive and negative electrode plates stacked in predetermined numbers with separators interposed between them, in the stacking direction of the positive and negative electrode plates, and divides the electrode stack group into electrode stacks each consisting of a plurality of positive and negative electrode plates stacked one by one with separators interposed between them. As described above, in the manufacturing method and manufacturing apparatus for a stacked battery according to the present invention, a predetermined number of positive electrode plates and negative electrode plates, each formed in a predetermined shape, are alternately stacked with a zigzag-folded separator interposed therebetween to form an electrode stack group, and then the electrode stack group is cut by heat cutting to separate it into electrode stacks each made of a plurality of positive electrode plates and negative electrode plates stacked one by one with a separator interposed therebetween. Therefore, compared to conventional stacked battery manufacturing devices in which positive and negative electrode plates formed in advance to a predetermined shape are alternately stacked one by one, with a separator that is zigzag folded each time interposed therebetween, it is possible to reduce at least the number of times the separator is zigzag folded and shorten the process, thereby improving the productivity of the manufactured stacked batteries. Furthermore, as described above, the formed electrode layer stack group is cut by heat cutting and divided into individual electrode stacks, and therefore the separators interposed between each positive electrode plate and negative electrode plate are welded together in a bag-like shape at the cut ends at the same time as being cut, without using, for example, an adhesive sheet or adhesive. Therefore, the shape of each divided electrode stack is sufficiently maintained by the plurality of cut separators interposed between each positive electrode plate and negative electrode plate, which prevents, for example, the stacked positive electrode plates and negative electrode plates from collapsing, and allows a high-quality stacked battery to be obtained.

[0008] Furthermore, in the manufacturing method of the stacked battery according to the present invention, it is preferable that in the stacking step, the predetermined number of positive electrode plates and the predetermined number of negative electrode plates are arranged along the longitudinal direction of the separator with a predetermined interval between them, and that in the dividing step, the electrode stack group is cut at a position between adjacent positive electrode plates or adjacent negative electrode plates. Furthermore, in the manufacturing apparatus for a stacked battery according to the present invention, it is preferable that the electrode plate mounting device mounts the predetermined number of positive electrode plates and the predetermined number of negative electrode plates in a line along the longitudinal direction of the separator, with the plates spaced apart at a predetermined interval, and the dividing device cuts the electrode stack group at positions between adjacent positive electrode plates or adjacent negative electrode plates while heating them in the stacking direction. With this configuration, when the formed electrode layer stack group is cut by heat cutting, only the separator can be reliably cut without accidentally cutting the positive electrode plate and the negative electrode plate at the same time, and the cut end portions of the separator can be welded, thereby making it possible to stably obtain a high-quality stacked battery.

[0009] In the manufacturing method of the stacked battery according to the present invention, it is preferable that in the stacking step, the predetermined interval between the predetermined number of positive electrode plates and the predetermined number of negative electrode plates is 4 mm or more and 6 mm or less. In addition, in the laminated battery manufacturing apparatus according to the present invention, it is preferable that in the electrode plate mounting device, the predetermined intervals between the predetermined number of positive electrode plates and the predetermined number of negative electrode plates are 4 mm or more and 6 mm or less. With this configuration, when the formed electrode layer stack group is cut by heat cutting, it is possible to more reliably cut only the separator without accidentally cutting the positive electrode plate and the negative electrode plate at the same time, and to weld the cut end portions of the separator, thereby more reliably obtaining a high-quality stacked battery.

[0010] Furthermore, in the manufacturing method of the stacked battery according to the present invention, it is preferable that the negative electrode plate has a strip-shaped negative electrode core extending in one direction and a negative electrode active material layer coated on both the front and back surfaces of the negative electrode core, and that in the stacking step, the negative electrode plate is placed on the separator so as to be perpendicular to the longitudinal direction of the separator, and that the dimension of the separator in the width direction perpendicular to the longitudinal direction is larger than the dimension of the negative electrode active material layer of the negative electrode plate in the extension direction of the negative electrode core. Furthermore, in the manufacturing apparatus for a stacked battery according to the present invention, it is preferable that the negative electrode plate has a strip-shaped negative electrode core extending in one direction and a negative electrode active material layer coated on both the front and back surfaces of the negative electrode core, the electrode plate mounting device mounts the predetermined number of negative electrode plates on the separator so as to be perpendicular to the longitudinal direction of the separator, and the dimension of the separator in the width direction perpendicular to the longitudinal direction is larger than the dimension of the negative electrode active material layer of the negative electrode plate in the extension direction of the negative electrode core. Generally, the coating area of ​​the negative electrode active material layer on the negative electrode substrate of the negative electrode plate is set slightly larger than the coating area of ​​the positive electrode active material layer on the positive electrode substrate of the positive electrode plate. Therefore, as in the present invention, by setting the width dimension of the separator to be larger than the dimension in the extension direction of the negative electrode active material layer of the negative electrode plate, the positive electrode active material layer of the positive electrode plate and the negative electrode active material layer of the negative electrode plate can be reliably separated via the separator, thereby preventing short circuits from occurring between the positive electrode plate and the negative electrode plate.

[0011] Furthermore, it is preferable that the manufacturing apparatus for a stacked battery according to the present invention includes a stacking area in which the zigzag folding device and the electrode plate placing device are arranged and the electrode stack group is formed, and a dividing area in which the dividing device is arranged and the electrode stack group is divided into the individual electrode stacks, and further includes a positive electrode-side conveying device that continuously transports a plurality of positive electrode plates in one direction and supplies the positive electrode plates to the stacking area, a negative electrode-side conveying device that continuously transports a plurality of negative electrode plates in one direction and supplies the negative electrode plates to the stacking area, and a moving device that moves the electrode stack group between the stacking area and the dividing area. In this way, by separately providing a stacking area where the stacking step is carried out to form an electrode stack group and a dividing area where the dividing step is carried out to divide the electrode stack group into individual electrode stacks, it is possible to carry out the dividing step even during the stacking step, or it is possible to carry out the stacking step even during the dividing step, thereby further improving the productivity of the manufactured stacked battery.

[0012] In the laminated battery manufacturing apparatus according to the present invention, the moving device is preferably configured as a rotary table. With this configuration, the layout of the stacked battery manufacturing equipment can be made more compact than when the moving device is configured using, for example, a shuttle conveyor that enables reciprocating transport via transport surfaces arranged parallel to the vertical direction.

[0013] In the stacked battery manufacturing apparatus according to the present invention, it is preferable that the positive electrode side transport device and the negative electrode side transport device are arranged in parallel to each other in a plan view. By having such a configuration, it is possible to more reliably achieve a compact layout of the components in the stacked battery manufacturing apparatus, compared to when the positive electrode side conveying device and the negative electrode side conveying device are arranged in a straight line with the stacking area in between in a plan view, for example. [Effects of the Invention]

[0014] The present invention has the following effects. That is, the manufacturing method and manufacturing apparatus for a stacked battery according to the present invention can improve productivity of stacked batteries while maintaining high-precision quality. [Brief explanation of the drawings]

[0015] [Figure 1] 1A to 1C are process diagrams showing a method for manufacturing a stacked battery according to the present invention in chronological order. [Figure 2] 1A and 1B are diagrams showing the procedure for forming individual electrode bodies from a long strip-shaped electrode core, where FIG. 1A is a schematic diagram showing a positive electrode plate, and FIG. 1B is a schematic diagram showing a negative electrode plate. [Figure 3] 1A to 1E are schematic cross-sectional views showing the steps of forming a stacked battery by stacking a plurality of positive and negative electrode plates while folding a long strip-shaped separator in a zigzag manner, and sequentially showing the various states of the formed stacked battery. [Figure 4] 1 is a plan view showing the overall configuration of a manufacturing apparatus for a stacked battery according to the present invention. [Figure 5] 3A and 3B are diagrams showing the overall configuration of a laminated battery manufacturing apparatus according to the present invention, in which (a) is a front view seen in the direction of arrow X1 in FIG. 2, and (b) is a front view seen in the direction of arrow X2 in FIG. 2. [Figure 6] FIG. 4 is a plan view showing the overall configuration of a manufacturing apparatus for a stacked battery according to a first alternative embodiment. [Figure 7]7 is a diagram showing the overall configuration of a manufacturing apparatus for a stacked battery according to a first alternative embodiment, and is a front view seen in the direction of arrow X3 in FIG. 6. FIG. [Figure 8] FIG. 10 is a plan view showing the overall configuration of a manufacturing apparatus for a stacked battery according to a second alternative embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0016] Next, one embodiment of the present invention will be described with reference to FIGS. For the sake of convenience, in the following description, the front-rear direction, left-right direction, and up-down direction of the stacked battery manufacturing apparatus 1 in this embodiment and the stacked battery manufacturing apparatuses 201 and 301 in other embodiments will be defined and described using the directions of the arrows shown in Figures 3 to 8. 4 to 8, the conveying direction of the positive electrode plate 101 is defined by an arrow A1, the conveying direction of the negative electrode plate 102 is defined by an arrow A2, and the direction of the electrode stack group 110 is defined by an arrow A3. Furthermore, in FIG. 3, the external size, thickness, etc. of each component constituting the stacked battery 100 (or the electrode stack group 110) are exaggerated for ease of understanding, and may differ from the components in the actual implementation.

[0017] [Laminated battery manufacturing method] First, a method for manufacturing a stacked battery embodied in this embodiment will be described with reference to FIGS. 1 to 3. FIG.

[0018] The manufacturing method of a stacked battery in this embodiment (hereinafter simply referred to as the "manufacturing method") is a method for manufacturing a stacked battery 100 in which a plurality of positive electrode plates 101·101··· and negative electrode plates 102·102··· are alternately stacked one by one, and separators 103·103··· are interposed between the plurality of positive electrode plates 101·101··· and negative electrode plates 102·102···.

[0019] The laminated battery 100 manufactured here may be, for example, a repeatedly chargeable and dischargeable lithium ion secondary battery provided as a power source for driving the motor of an electric vehicle (EV) or a hybrid electric vehicle (HEV).

[0020] The stacked battery 100 is not limited to lithium-ion secondary batteries installed in electric vehicles or hybrid electric vehicles, but may be any of a variety of stacked batteries installed in homes, solar panels, electronic devices, or the like, for example.

[0021] As shown in FIG. 1, the manufacturing method of this embodiment mainly includes a supplying step S01, a stacking step S02, a dividing step S03, and the like, which are carried out in sequence over time.

[0022] The supplying process S01 is a process of forming a positive electrode plate 101 and a negative electrode plate 102, which are electrode bodies of a predetermined shape, from long strip-shaped electrode cores (more specifically, a positive electrode core 101a and a negative electrode core 102a), and supplying the formed positive electrode plate 101 and negative electrode plate 102 to a predetermined working area (a stacking area Z1, described later; see Figure 4).

[0023] As shown in FIG. 2(a), the positive electrode plate 101 includes a sheet-like positive electrode core 101a made of, for example, aluminum, a positive electrode active material layer 101b coated on both the front and back surfaces of the positive electrode core 101a, and a positive electrode tab 101c that is part of the positive electrode core 101a and protrudes to one side with the positive electrode active material layer 101b in an uncoated state. The positive electrode active material layer 101b is made of a positive electrode active material such as lithium cobalt oxide, and a positive electrode mixture slurry containing a conductive agent and a binder.

[0024] The positive electrode plates 101 are then formed continuously in the following manner. That is, first, the long strip-shaped positive electrode substrate 101a wound in a roll is pulled out in the longitudinal direction Y1 and cut into strips extending in one direction along a predetermined cutting line L1 by the positive electrode side fixed length cutting device 22 described later. The positive electrode substrate 101a has a positive electrode active material layer 101b coated on both its front and back surfaces in advance, except for one end portion in the width direction Y2 (the direction perpendicular to the longitudinal direction Y1 in a plan view).

[0025] Thereafter, the position of each positive electrode substrate 101a cut into strips is accurately determined by an image detection means, and then the positive electrode substrate 101a is fused along predetermined cutting lines L2 and L3 by a positive electrode side laser cutting device 23, which will be described later. As a result, a positive electrode tab 101c is formed at one end where the positive electrode active material layer 101b is not coated, and both corners are removed at the other end opposite to the one end, thereby forming a positive electrode plate 101 of a predetermined shape.

[0026] On the other hand, as shown in FIG. 2(b), the negative electrode plate 102 has a sheet-shaped negative electrode core 102a made of, for example, copper, a negative electrode active material layer 102b coated on both the front and back surfaces of the negative electrode core 102a, and a negative electrode tab 102c that is part of the negative electrode core 102a and protrudes to one side with the negative electrode active material layer 102b in an uncoated state. The negative electrode active material layer 102b is made of a negative electrode active material such as graphite, or a negative electrode mixture slurry containing a conductive agent and a binder.

[0027] Then, like the positive electrode plate 101 described above, the negative electrode plate 102 is also formed continuously according to the following procedure. That is, first, the long strip-shaped negative electrode core 102a wound in a roll is pulled out in the longitudinal direction Y3 and cut into strips extending in one direction along a predetermined cutting line L4 by the negative electrode side fixed length cutting device 25 described later. The negative electrode substrate 102a has both the front and back surfaces coated in advance with the negative electrode active material layer 102b, except for one end portion in the width direction Y4 (the direction perpendicular to the longitudinal direction Y3 in a plan view).

[0028] Thereafter, the negative electrode substrate 102a cut into strips has its position accurately determined by an image detection means, and is then fused along predetermined cutting lines L5 and L6 by a negative electrode side laser cutting device 26, which will be described later. As a result, a negative electrode tab 102c is formed at one end where the negative electrode active material layer 102b is not coated, and both corners are removed at the other end opposite to the one end, thereby forming a negative electrode plate 102 of a predetermined shape.

[0029] In this embodiment, the positive electrode plate 101 and the negative electrode plate 102 are continuously formed according to the above-described procedure while being transported in predetermined directions by a positive electrode-side transport device 21 and a negative electrode-side transport device 24, which will be described later. The formed positive electrode plate 101 and negative electrode plate 102 are then continuously transported by the positive electrode side transport device 21 and the negative electrode side transport device 24, respectively, to predetermined waiting positions P1 and P2 (see Figure 4) located near the stacking area Z1, and are then supplied to the stacking area Z1.

[0030] As shown in FIG. 3 , the stacking process S02 is a process in which, for example, on a horizontally arranged movable pallet 120, a long strip-shaped separator 103 is zigzag folded, and each time the separator 103 is zigzag folded, a predetermined number (for example, six in this embodiment) of positive electrode plates 101·101··· and a predetermined number of negative electrode plates 102·102··· are placed together in a group and in an alternating order on the folded separator 103, in a state where they are aligned along the longitudinal direction of the separator 101 (i.e., the folding direction of the separator 103), thereby forming an electrode stack group 110 consisting of a plurality of positive electrode plates 101·101··· and negative electrode plates 102·102···, stacked in predetermined numbers (six plates) with separators 103 interposed therebetween.

[0031] Specifically, as shown in FIG. 3(a), first, the leading end of the separator 103 wound in a roll shape is clamped by a pair of movable rollers 31c·31c described later and gradually unwound downward until it reaches the upper surface of the movable pallet 120.

[0032] When the leading end of the separator 103 reaches the upper surface of the movable pallet 120, the pair of movable rollers 31c·31c move to one side in the horizontal direction (one side in the longitudinal direction Y5 (in this embodiment, the left side) relative to the separator 103 on the movable pallet 120) while unwinding the leading end of the separator 103. As a result, the leading end of the separator 103 is laid on the upper surface of the movable pallet 120 by a predetermined length.

[0033] When the tip of the separator 103 is laid out on the upper surface of the movable pallet 120 by a predetermined length, a predetermined number of negative electrode plates 102·102··· (or positive electrode plates 101·101···) formed by the above-mentioned supply process S01 are supplied together on the laid out separator 103 and arranged (placed) along the longitudinal direction Y5 of the separator 101, spaced apart from each other by a predetermined distance d.

[0034] Specifically, a predetermined number of negative electrode plates 102·102··· are placed on the separator 103 so that they are perpendicular to the longitudinal direction Y5 of the laid separator 103 in a plan view, and are spaced apart from each other at a predetermined interval d.

[0035] When a predetermined number of negative electrode plates 102·102··· are placed on the separator 103 on the movable pallet 120, as shown in Figure 3(b), the pair of movable rollers 31c·31c move to the other side in the horizontal direction (the other side in the longitudinal direction Y5 (in this embodiment, the right side) relative to the separator 103 on the movable pallet 120) while unwinding the leading end of the separator 103. As a result, the leading end of the separator 103 is folded back, and a predetermined length of the separator 103 is laid on the upper surfaces of the predetermined number of negative electrode plates 102.

[0036] When the tip of the folded separator 103 is laid on the top surface of the specified number of negative electrode plates 102·102··· by a specified length, the specified number of positive electrode plates 101·101··· (or negative electrode plates 102·102···) formed in the supply process S01 are supplied together on top of the laid separator 103 and are placed in the same position as the specified number of negative electrode plates 102·102··· that have already been placed when viewed in a plane. That is, the predetermined number of positive electrode plates 101 are arranged (placed) on the folded separator 103 along the longitudinal direction Y5 of the separator 103, with the plates spaced apart from each other at predetermined intervals d.

[0037] Specifically, a predetermined number of positive electrode plates 101·101··· are placed on the separator 103 so that they are perpendicular to the longitudinal direction Y5 of the separator 103 when viewed in a plane, and are spaced apart from each other at a predetermined interval d.

[0038] Here, the coating area of ​​the negative electrode active material layer 102b in the negative electrode core 102a of the negative electrode plate 102 (see Figure 2(b)) is generally set to be slightly larger than the coating area of ​​the positive electrode active material layer 101b in the positive electrode core 101a of the positive electrode plate 101 (see Figure 2(a)). In this embodiment, however, the dimension in the width direction perpendicular to the longitudinal direction Y5 of the separator 103 is set to be larger than the dimension in the extension direction of the negative electrode active material layer 102b of the negative electrode plate 102.

[0039] With this configuration, the positive electrode active material layer 101b of the positive electrode plate 101 and the negative electrode active material layer 102b of the negative electrode plate 102 are reliably isolated from each other via the separator 103, thereby preventing a short circuit from occurring between the positive electrode plate 101 and the negative electrode plate 102.

[0040] When a predetermined number of positive electrode plates 101·101··· are placed on the folded separator 103, the pair of moving rollers 31c·31c move to one side in the horizontal direction (one side (left side) in the longitudinal direction Y5) while again unwinding the leading end of the separator 103. As a result, the leading end of the separator 103 is folded back again, and a predetermined length of the separator 103 is laid on the upper surfaces of the predetermined number of positive electrode plates 101.

[0041] When the tip of the separator 103 that has been folded back again is laid on top of the above-mentioned predetermined number of positive electrode plates 101·101··· by a predetermined length, the predetermined number of negative electrode plates 102·102··· (or positive electrode plates 101·101···) formed in the above-mentioned supply process S01 are supplied together on top of the laid separator 103 and are placed in the same position as the predetermined number of positive electrode plates 101·101··· that have already been placed when viewed in a plane. That is, the predetermined number of negative electrode plates 102 are arranged (placed) on the separator 103 that has been folded back again, spaced apart from each other at predetermined intervals d, along the longitudinal direction Y5 of the separator 103.

[0042] By repeating this procedure, the long strip-shaped separator 103 is folded zigzag on the movable pallet 120, and each time the separator 103 is folded, a predetermined number of positive electrode plates 101·101··· and negative electrode plates 102·102··· are stacked in order on the folded separator 103.

[0043] Then, as shown in Figure 3(c), when a predetermined number of positive electrode plates 101·101··· and a predetermined number of negative electrode plates 102·102··· are stacked in a predetermined number of layers (a total of four layers in this embodiment), the separator 103 is cut downstream in the payout direction relative to the pair of moving rollers 31c·31c. As a result, as shown in FIG. 3(d), an electrode stack group 110 is formed, which is made up of a plurality of positive electrode plates 101·101··· and negative electrode plates 102·102···, stacked together in predetermined numbers with separators 103 interposed therebetween.

[0044] In this embodiment, as described above, a predetermined number of negative electrode plates 102·102··· are placed on the separator 103 placed on the movable pallet 120 in order, but this is not limited to this, and a predetermined number of positive electrode plates 101·101··· may be placed in order. However, as described above, the coating area of ​​the negative electrode active material layer 102b on the negative electrode plate 102 (more specifically, the negative electrode core 102a) is generally set to be slightly larger than the coating area of ​​the positive electrode active material layer 101b on the positive electrode plate 101 (more specifically, the positive electrode core 101a). Therefore, it is more preferable to first place a predetermined number of negative electrode plates 102·102··· and then place a predetermined number of positive electrode plates 101·101···, as this makes it easier to grasp the position of the negative electrode plates 102 that have already been placed when viewed from the front.

[0045] The dividing step S03 is a step of cutting the electrode stack group 110 formed in the stacking step S02 by heat cutting in the stacking direction of the positive electrode plates 101 and the negative electrode plates 102 (vertical direction in this embodiment) to divide it into a plurality of electrode stacks 110A·110A···, (for example, six in this embodiment) each consisting of a plurality of positive electrode plates 101·101··· and negative electrode plates 102·102··· stacked one by one with separators 103 interposed therebetween.

[0046] Specifically, as shown in FIG. 3(d), the electrode stack group 110 is placed on a movable pallet 120 and transported to a predetermined work area (a division area Z2 described later; see FIG. 4), where it is cut (heat-cut) by a dividing device 41 described later along a predetermined cutting line L7 set at a position between adjacent positive electrode plates 101, 101, or adjacent negative electrode plates 102, 102. As a result, along the cutting line L7, the cut separators 101·101··· are welded together in a bag-like shape at the cut ends while being interposed between each positive electrode plate 101 and negative electrode plate 102, thereby forming a plurality of electrode stacks 110A·110A··· (for example, six in this embodiment) consisting of a plurality of positive electrode plates 101·101··· and negative electrode plates 102·102···, stacked one by one with each separator 103 interposed therebetween.

[0047] In this embodiment, as will be described later, the stacked battery 100 is constructed by winding the separator 103a around each divided electrode stack 110A several times so as to constrain the stacked structure, but this is not limited to this, and the stacked battery 100 may be constructed with each divided electrode stack 110A without the separator 103a.

[0048] Furthermore, in this embodiment, as described above, in the stacking step S02, a predetermined number (six) of positive electrode plates 101·101··· and a predetermined number (six) of negative electrode plates 102·102··· are arranged together along the longitudinal direction Y5 of the folded separator 103, with the plates spaced apart at a predetermined distance d. However, this is not limited to this, and for example, the predetermined number (six) of positive electrode plates 101·101··· and the predetermined number (six) of negative electrode plates 102·102··· may be arranged together in close proximity to each other (with no gaps between them).

[0049] However, by arranging a predetermined number (six) of positive electrode plates 101·101··· and a predetermined number (six) of negative electrode plates 102·102··· in a group while spaced apart at a predetermined distance d in this manner, when the formed electrode layer stack group 110 is cut by heat cutting in the subsequent division step S03, it is possible to reliably cut only the separators 103 without accidentally cutting the positive electrode plates 101 and the negative electrode plates 102 at the same time, and to weld the cut ends of the separators 103 together in a bag-like shape, thereby enabling a stable, high-quality electrode stack 110A (stacking battery 100) to be obtained.

[0050] Furthermore, in this embodiment, the stacking process S02 is performed such that the predetermined distance d between the predetermined number (6) of positive electrode plates 101·101··· and the predetermined number (6) of negative electrode plates 102·102··· when they are arranged together is set to be 4 mm or more and 6 mm or less (4 mm≦d≦6 mm).

[0051] With this configuration, even if the position of the cutting blade of the dividing device 41 is slightly misaligned with the set cutting line L7 when the formed electrode layer laminate group 110 is cut by heat cutting in the subsequent dividing step S03, it is possible to more reliably cut only the separator 103 without accidentally cutting the positive electrode plate 101 and the negative electrode plate 102 at the same time, and to weld the cut ends of the separator 101 together in a bag-like shape, thereby making it possible to obtain a more stable, high-quality electrode laminate 110A (stacked battery 100).

[0052] As described above, the manufacturing method in this embodiment includes at least the laminating step S02 and the dividing step S03. Then, in the stacking process S02, the long strip-shaped separator 103 is folded zigzag, and each time the separator 103 is folded back by zigzag folding, a predetermined number (6) of positive electrode plates 101·101··· and a predetermined number (6) of negative electrode plates 102·102··· are placed together in a group and in an alternating order on the folded separator 103, in a state where they are aligned along the longitudinal direction Y5 of the separator 103, thereby forming an electrode stack group 110 consisting of a plurality of positive electrode plates 101·101··· and negative electrode plates 102·102···, stacked in predetermined numbers (6 plates) with the separator 103 interposed therebetween. In the dividing step S03, the electrode stack group 110 formed in the stacking step S02 is cut by heat cutting in the stacking direction of the positive electrode plates 101 and the negative electrode plates 102. The electrode stack 110A is divided into a plurality of positive electrode plates 101 and negative electrode plates 102, which are stacked one by one with separators 103 interposed therebetween.

[0053] As described above, in the manufacturing method of the stacked battery 100 of this embodiment, a plurality of positive electrode plates 101·101··· and negative electrode plates 102·102···, each formed in a predetermined shape, are alternately stacked in groups of a predetermined number (six plates) with zigzag-folded separators 103 interposed therebetween to form an electrode stack group 110, and then the electrode stack group 110 is cut by heat cutting to separate it into electrode stacks 110A each consisting of a plurality of positive electrode plates 101·101··· and negative electrode plates 102·102···, stacked one by one with separators 103 interposed therebetween.

[0054] Therefore, compared to conventional manufacturing devices for stacked batteries, in which positive electrode plates 101 and negative electrode plates 102 formed in advance to a predetermined shape are alternately stacked one by one, with separators 103 that are zigzag folded each time interposed therebetween, it is possible to reduce at least the number of times that zigzag folding of the separators 103 is performed, shorten the process, and improve the productivity of the stacked battery 100 that is manufactured.

[0055] Furthermore, as described above, the formed electrode layer laminate group 110 is cut by heat cutting and divided into each electrode laminate 110A, and therefore the separators 103 interposed between each positive electrode plate 101 and negative electrode plate 102 are welded together in a bag-like shape at the cut ends at the same time as being cut, without using, for example, an adhesive sheet or adhesive. Therefore, the shape of each divided electrode stack 110A is sufficiently maintained by the multiple cut separators 103, 103, interposed between each positive electrode plate 101 and negative electrode plate 102, which prevents, for example, the stacked positive electrode plates 101 and negative electrode plates 102 from collapsing, and allows for the production of a high-quality stacked battery 100.

[0056] [Configuration of stacked battery manufacturing apparatus 1 (present embodiment)] Next, the configuration of the stacked battery manufacturing apparatus 1 embodied in this embodiment will be described with reference to FIGS.

[0057] In this embodiment, the stacked battery manufacturing apparatus 1 (hereinafter simply referred to as "manufacturing apparatus 1") is an apparatus that carries out the above-mentioned manufacturing method, and is an apparatus that manufactures a stacked battery 100 in which a plurality of positive electrode plates 101·101··· and negative electrode plates 102·102··· are alternately stacked one by one, and separators 103·103··· are interposed between the plurality of positive electrode plates 101·101··· and negative electrode plates 102·102···.

[0058] As shown in FIG. 4, the manufacturing apparatus 1 is provided with a lamination area Z1, which is a work area for carrying out the lamination step S02 and in which the above-mentioned electrode stack group 110 is formed, and a division area Z2, which is a work area for carrying out the division step S03 and in which the formed electrode stack group 110 is divided into each of the electrode stacks 110A·110A···.

[0059] The formed electrode stack group 110 is placed on a movable pallet 120, which is moved back and forth between the stacking area Z1 and the division area Z2 by a moving device 11 described later, and is moved from the stacking area Z1 to the division area Z2.

[0060] As described above, in the present embodiment, the stacking area Z1 where the stacking step S02 is carried out to form the electrode stack group 110 and the dividing area Z2 where the dividing step S03 is carried out to divide the electrode stack group 110 into each of the electrode stacks 110A·110A··· are provided separately. Therefore, the dividing step S03 can be carried out even during the stacking step S02, or the stacking step S02 can be carried out even during the dividing step S03, thereby further improving the productivity of the manufactured stacked battery.

[0061] The manufacturing apparatus 1 mainly includes a moving device 11 that moves a moving pallet 120 back and forth between the stacking area Z1 and the dividing area Z2, a supply unit 2 that continuously forms positive electrode plates 101 and negative electrode plates 102 and supplies the formed positive electrode plates 101 and negative electrode plates 102 to the stacking area Z1, a stacking unit 3 that forms an electrode stack group 110 in the stacking area Z1, a dividing unit 4 that divides the formed electrode stack group 110 into individual electrode stacks 110A·110A··· in the dividing area Z2, and a winding unit 5 that winds a finishing separator 103a around each divided electrode stack 110A.

[0062] In this embodiment, the moving device 11 is, for example, configured as a shuttle conveyor or the like that extends horizontally in one direction (in this embodiment, the front-to-back direction) and has conveying paths that are arranged parallel to each other in the vertical direction, and the upper conveying path is configured to convey the moving pallet 120 from the stacking area Z1 to the division area Z2, and the lower conveying path is configured to convey the moving pallet 120 from the division area Z2 to the stacking area Z1. In addition, at both ends of the moving device 11 in the extension direction, a first lifting section 11a and a second lifting section 11b are provided between the upper and lower conveying paths, respectively, to raise and lower the moving pallet 120.

[0063] Then, the movable pallet 120 is raised by the first lifting section 11a and moved from the lower conveying path to the upper conveying path, and is transported via the upper conveying path to the stacking area Z1 and the division area Z2 in that order, before reaching the second lifting section 11b. When the movable pallet 120 reaches the second lifting section 11b, it is lowered by the second lifting section 11b, moved from the upper conveying path to the lower conveying path, and then conveyed via the lower conveying path to the first lifting section 11a. Thereafter, when the movable pallet 120 reaches the first lifting section 11a, it is lifted again by the first lifting section 11a and moved from the lower conveying path to the upper conveying path. In this way, the moving pallet 120 is moved back and forth between the stacking area Z1 and the dividing area Z2 by the moving device 11.

[0064] The supply unit 2 includes a positive electrode side conveying device 21, a positive electrode side fixed size cutting device 22, and a positive electrode side laser cutting device 23 that continuously form positive electrode plates 101, as well as a negative electrode side conveying device 24, a negative electrode side fixed size cutting device 25, and a negative electrode side laser cutting device 26 that continuously form negative electrode plates 102.

[0065] The positive electrode side transport device 21 includes a first upstream conveyor 21A and a first downstream conveyor 21B, which are formed of, for example, belt conveyors. In addition, the first upstream conveyor 21A and the first downstream conveyor 21B are arranged in a straight line from the upstream side to the downstream side of the conveying direction (direction of arrow A1), with one side of the horizontal direction (in this embodiment, the left side) as the conveying direction.

[0066] The positive electrode side transport device 21 is disposed so that the stacking area Z1 is located near the downstream end of the first downstream conveyor 21B in the transport direction (direction of arrow A1).

[0067] Here, as shown in Figure 5(a), on the upstream side of the conveying direction (direction of arrow A1) of the first upstream conveyor 21A, a long strip-shaped positive electrode core 101a wound in a roll shape is arranged with its axial direction perpendicular to the conveying direction when viewed from above. In addition, between the first upstream conveyor 21A and the roll-shaped positive electrode core 101a, multiple (two in this embodiment) guide rollers 6·6 and a pair of pay-out rollers 7·7 are arranged parallel to the positive electrode core 101a in order from the upstream side to the downstream side in the conveying direction (direction of arrow A1).

[0068] The leading end pulled out from the roll-shaped positive electrode substrate 101a is guided by guide rollers 6·6 to a pair of pay-out rollers 7·7, and is paid out by the pay-out rollers 7·7 to the first upstream conveyor 21A.

[0069] The positive electrode-side fixed-length cutting device 22 is a device that continuously cuts the long strip-shaped positive electrode substrate 101a fed onto the first upstream conveyor 21A into predetermined strip shapes extending in one direction.

[0070] The positive electrode side constant length cutting device 22 is disposed between the upstream end of the first upstream side conveyor 21A in the conveying direction (direction of arrow A1) and the pair of feed rollers 7.7. The positive electrode side fixed length cutting device 22 includes a base plate 22b that extends in the width direction of the positive electrode core 101a (a direction perpendicular to the conveying direction (the direction of arrow A1) in a plan view) for the positive electrode core 101a fed out by a pair of feed rollers 7·7 and supports the underside of the positive electrode core 101a, and a cutting blade 22a that is movable up and down above the base plate 22b and extends in the width direction.

[0071] The tip of the positive electrode substrate 101a fed from the pair of feed rollers 7·7 is cut into a predetermined strip shape by the positive electrode side fixed length cutting device 22, and then supplied to the first upstream conveyor 21A, and transported by the first upstream conveyor 21A to the first downstream conveyor 21B.

[0072] The positive electrode side laser cutting device 23 is a device that uses a laser to melt and cut the positive electrode core 101a cut into strips to form a positive electrode tab 101c (see Figure 2(a)) and other parts, thereby forming the positive electrode plate 101 in its final form.

[0073] The positive electrode side laser cutting device 23 has an image detection means (not shown) and is placed directly above the first upstream conveyor 21A, in the center of the conveying direction (direction of arrow A1), with the laser irradiation port facing downward.

[0074] Then, as the positive electrode core 101a cut into strips passes directly below the positive electrode side laser cutting device 23 while being transported by the first upstream conveyor 21A, its position is accurately determined by the image detection means, and the positive electrode side laser cutting device 23 melt-cuts it into a positive electrode plate 101 of a predetermined shape.

[0075] In this way, the long strip-shaped positive electrode substrate 101a wound into a roll is unwound by a pair of unwound rollers 7, 7, and then cut into strips by a positive electrode side fixed length cutting device 22. Thereafter, the strips are transported by a first upstream conveyor 21A and pass through a positive electrode side laser cutting device 23, whereby they are continuously formed into positive electrode plates 101 of a predetermined shape. The successively formed positive electrode plates 101 are then continuously transported by the first upstream conveyor 21A and transferred in order to the first downstream conveyor 21B.

[0076] In addition, an image inspection device 8 is provided near the downstream side of the positive electrode side laser cutting device 23 in the conveying direction (direction of arrow A1) of the first upstream conveyor 21A, and the positive electrode plate 101 formed by the positive electrode side laser cutting device 23 is inspected for quality (e.g., external size, shape, etc.) by the image inspection device 8, and if it does not meet the desired quality, it is ejected from the first upstream conveyor 21A.

[0077] The positive electrode plates 101 transferred onto the first downstream conveyor 21B are transported by the first downstream conveyor 21B toward the stacking area Z1. Then, when the number of positive electrode plates 101·101··· being transported in sequence by the first downstream conveyor 21B reaches a predetermined number (for example, six in this embodiment) from the waiting position P1 located near the stacking area Z1 (i.e., the downstream end of the first downstream conveyor 21B in the conveying direction (direction of arrow A1)) toward the upstream side in the conveying direction (direction of arrow A1), the electrode plate mounting device 32 described later operates, and the predetermined number of positive electrode plates 101·101··· are supplied together to the stacking area Z1. That is, the positive electrode side transport device 21 continuously transports the plurality of positive electrode plates 101 in one direction (the direction of arrow A1) and supplies these plurality of positive electrode plates 101 to the stacking area Z1.

[0078] The negative electrode side transport device 24 includes a second upstream conveyor 24A and a second downstream conveyor 24B, which are formed of, for example, belt conveyors. In addition, the second upstream conveyor 24A and the second downstream conveyor 24B are each arranged in a straight line from the upstream side to the downstream side of the conveying direction (direction of arrow A2), with one side of the horizontal direction (in this embodiment, the right side) being the conveying direction.

[0079] As shown in Figure 4, the negative electrode side conveying device 24 is arranged so that the stacking area Z1 is located near the downstream end of the second downstream conveyor 24B in the conveying direction (direction of arrow A2), and is arranged in a straight line with the above-mentioned positive electrode side conveying device 21, with the stacking area Z1 sandwiched between them.

[0080] Here, as shown in Figure 5(a), on the upstream side of the conveying direction (direction of arrow A2) of the second upstream conveyor 24A, a long strip-shaped negative electrode substrate 102a wound in a roll shape is arranged with its axial direction perpendicular to the conveying direction in a plan view. In addition, between the second upstream conveyor 24A and the roll-shaped negative electrode core 102a, multiple (two in this embodiment) guide rollers 6·6 and a pair of payout rollers 7·7 are arranged parallel to the negative electrode core 102a in order from the upstream side to the downstream side in the conveying direction (direction of arrow A2).

[0081] The leading end pulled out from the roll-shaped negative electrode substrate 102a is guided by guide rollers 6·6 to a pair of pay-out rollers 7·7, and is then paid out onto the second upstream conveyor 24A by the pay-out rollers 7·7.

[0082] The negative electrode fixed length cutting device 25 is a device that continuously cuts the long strip-shaped negative electrode substrate 102a fed onto the second upstream conveyor 24A into predetermined strip shapes extending in one direction. The negative electrode side constant length cutting device 25 has the same configuration as the positive electrode side constant length cutting device 22 described above, and therefore a detailed description thereof will be omitted.

[0083] The negative electrode side laser cutting device 26 is a device that uses a laser to melt-cut the negative electrode core 102a cut into strips to form the negative electrode tab 102c (see Figure 2(b)) and other parts, thereby forming the negative electrode plate 102 in its final form. The negative electrode side laser cutting device 26 has the same configuration as the positive electrode side laser cutting device 23 described above, and therefore a detailed description thereof will be omitted.

[0084] In this way, the long strip-shaped negative electrode substrate 102a wound into a roll is, like the above-mentioned positive electrode substrate 101a, unwound by a pair of unwound rollers 7, 7, and then cut into strips by a negative electrode side fixed length cutting device 25. Thereafter, the strips are conveyed by a second upstream conveyor 24A and pass through a negative electrode side laser cutting device 26, whereby they are continuously formed into negative electrode plates 102 of a predetermined shape. The successively formed negative electrode plates 102 are then continuously transported by the second upstream conveyor 24A and transferred in order to the second downstream conveyor 24B.

[0085] In the negative electrode side conveying device 24, as in the above-mentioned positive electrode side conveying device 21, an image inspection device 8 is provided near the downstream side of the conveying direction of the second upstream conveyor 24A relative to the negative electrode side laser cutting device 26, and the quality (e.g., external size, shape, etc.) of the negative electrode plate 102 formed by the negative electrode side laser cutting device 26 is inspected by the image inspection device 8, and if it does not meet the desired quality, it is ejected from the second upstream conveyor 24A.

[0086] The negative electrode plates 102 transferred onto the second downstream conveyor 24B are transported by the second downstream conveyor 24B toward the stacking area Z1. Then, when the number of negative electrode plates 102, 102, etc. being transported in sequence by the second downstream conveyor 24B reaches a predetermined number (for example, six in this embodiment) from the waiting position P2 located near the stacking area Z1 (i.e., the downstream end of the second downstream conveyor 24B in the conveying direction (direction of arrow A2)) toward the upstream side in the conveying direction (direction of arrow A2), the electrode plate mounting device 32 operates, and the predetermined number of negative electrode plates 102, 102, etc. are supplied together to the stacking area Z1. That is, the negative electrode-side transport device 24 continuously transports the plurality of negative electrode plates 102 in one direction (the direction of arrow A2) and supplies these plurality of negative electrode plates 102 to the stacking area Z1.

[0087] The supply section 2 having such a configuration carries out the aforementioned supply step S01, and positive electrode plates 101 and negative electrode plates 102 are continuously formed from long strip-shaped electrode cores (positive electrode core 101a and negative electrode core 102a), and the formed positive electrode plates 101 and negative electrode plates 102 are supplied to the stacking area Z1.

[0088] The stacking unit 3 is disposed in the stacking area Z1 and includes a zigzag folding device 31 for forming the electrode stack group 110, an electrode plate placing device 32, and the like.

[0089] The zigzag folding device 31 is a device that folds the long strip-shaped separator 103 zigzag on the top surface of the moving pallet 120 that is conveyed to the stacking area Z1 by the moving device 11 and stopped in the stacking area Z1. The zigzag folding device 31 is made up of a plurality of (three in this embodiment) guide rollers 31a, a pair of feed rollers 31b, and a pair of moving rollers 31c.

[0090] The multiple guide rollers 31a·31a·31a and the pair of feed rollers 31b·31b are each arranged above the moving pallet 120 stopped in the stacking area Z1, with their axial direction perpendicular to the conveying direction of the positive electrode side conveying device 21 (direction of arrow A1) or the conveying direction of the negative electrode side conveying device 24 (direction of arrow A2) in a planar view. In addition, a pair of movable rollers 31c·31c are arranged above the movable pallet 120 and below the guide rollers 31a and the feed rollers 31b·31b, with their axial direction perpendicular to the conveying direction of the positive electrode side conveying device 21 (direction of arrow A1) or the conveying direction of the negative electrode side conveying device 24 (direction of arrow A2) in a planar view. Furthermore, the pair of moving rollers 31c are configured to be able to move back and forth together along the transport direction (the direction of arrow A1 or arrow A2).

[0091] The long strip-shaped separator 103 wound in a roll is placed above the stacking area Z1 with its axial direction perpendicular to the transport direction (the direction of arrow A1 or arrow A2) in a plan view. Furthermore, the leading end pulled out from the separator 103 is guided by a plurality of guide rollers 31a, 31a, 31a, and led between a pair of feed rollers 31b, 31b, passes between the pair of feed rollers 31b, 31b, hangs down, and is then clamped by a pair of movable rollers 31c, 31c, and placed on the upper surface of the movable pallet 120 stopped in the stacking area Z1.

[0092] In this state, the pair of feed rollers 31b·31b feeds out the leading end of the roll-shaped separator 103, and each time the length of the fed leading end reaches a predetermined length, the pair of movable rollers 31c·31c moves alternately in sequence toward one side and the other side of the conveying direction (the direction of arrow A1 or arrow A2), whereby the separator 103 is folded zigzag on the upper surface of the movable pallet 120.

[0093] It is also possible to arrange an unused separator 103 wound in a roll in advance near the separator 103 to be zigzag folded.

[0094] The electrode plate placing device 32 is a device that places a predetermined number (6) of positive electrode plates 101·101··· and a predetermined number (6) of negative electrode plates 101·101··· on the folded separator 103 in a group, alternately in order, in a state where they are aligned along the longitudinal direction of the separator 103, each time the separator 103 is folded by the zigzag folding device 31. The electrode plate mounting device 32 includes a moving frame 32a, a positive electrode side suction portion 32b, a negative electrode side suction portion 32c, and the like that are supported by the moving frame 32a so as to be able to move up and down.

[0095] As shown in FIG. 4, the moving frame 32a is made of a U-shaped member in a plan view, and a pair of support portions 32a1-32a1 arranged parallel to each other are configured to be simultaneously positioned above the first downstream conveyor 21B and stacking area Z1, or above the second downstream conveyor 24B and stacking area Z1.

[0096] The moving frame 32a is configured to be reciprocally movable along the transport direction (the direction of the arrow A1 or A2) by a drive mechanism (not shown).

[0097] The positive electrode side suction portion 32b has, in a plan view, a plurality of suction pads 32b1·32b1··· arranged to overlap a predetermined number of positive electrode plates 101·101···, and a plurality of support materials 32b2·32b2··· that support these plurality of suction pads 32b1·32b1···, and is arranged to be able to move up and down on the underside of the support portion 32a1 located on the positive electrode side conveying device 21 side (in this embodiment, the right side).

[0098] Similarly to the positive electrode side adsorption portion 32b, the negative electrode side adsorption portion 32c also has a plurality of adsorption pads 32c1·32c1··· arranged to overlap a predetermined number of negative electrode plates 102·102··· in a planar view, and a plurality of support materials 32c2·32c2··· that support these plurality of adsorption pads 32c1·32c1···, and is arranged so as to be able to move up and down on the underside of the support portion 32a1 located on the negative electrode side conveying device 24 side (in this embodiment, the left side).

[0099] As shown in FIG. 5, the electrode plate mounting device 32 is configured so that, with the pair of support portions 32a1·32a1 positioned above the first downstream conveyor 21B and the stacking area Z1, respectively, the positive electrode side suction portion 32b and the negative electrode side suction portion 32c are raised and lowered to simultaneously perform the operations of removing a predetermined number of positive electrode plates 101·101··· from the first downstream conveyor 21B and placing a predetermined number of negative electrode plates 102·102··· on the upper surface of a moving pallet 120 stopped in the stacking area Z1. In addition, the electrode plate mounting device 32 is configured so that, when the pair of support portions 32a1·32a1 are positioned above the second downstream conveyor 24B and the stacking area Z1, respectively, the positive electrode side suction portion 32b and the negative electrode side suction portion 32c are raised and lowered to simultaneously perform the operations of removing a predetermined number of negative electrode plates 102·102··· from the second downstream conveyor 24B and placing a predetermined number of positive electrode plates 101·101··· on the upper surface of the moving pallet 120 that stops in the stacking area Z1.

[0100] The stacking unit 3 having such a configuration performs the stacking step S02 described above, and an electrode stack group 110 (see FIG. 3(d)) is formed on the upper surface of the moving pallet 120 in the stacking area Z1.

[0101] As shown in FIG. 4, the dividing section 4 is arranged in the dividing area Z2 and includes a dividing device 41 that divides the electrode stack group 110 formed in the stacking area Z1 into individual electrode stacks 110A.

[0102] The dividing device 41 is composed of a heat cutting device that performs cutting work (heat cutting) using electric heat, and when viewed in a plane, has an electric heating blade 41a, etc. that extends in a direction perpendicular to the conveying direction (the direction of arrow A1 or arrow A2) (in this embodiment, the front-to-back direction). In addition, the electric heating blade 41a is configured to be able to move up and down and to move back and forth along the conveying direction (the direction of arrow A1 or arrow A2), and is always kept heated to a predetermined temperature by a heater not shown.

[0103] The dividing device 41 then cuts the electrode stack group 110, which is formed by the zigzag folding device 31 and the electrode plate placing device 32 and is made up of a plurality of positive electrode plates 101·101··· and negative electrode plates 102·102···, stacked in a predetermined number (six plates) with separators 103 interposed between them, in the stacking direction of the positive electrode plates 101 and the negative electrode plates 102 (in the vertical direction in this embodiment), by heat cutting, thereby dividing the electrode stack group 110 into electrode stacks 110A, which are made up of a plurality of positive electrode plates 101·101··· and negative electrode plates 102·102···, stacked one by one with separators 103 interposed between them.

[0104] Specifically, the electrode stack group 110 formed in the stacking area Z1 is placed on a movable pallet 120 and transported to the division area Z2 by the moving device 11, and when the electrode stack group 110 reaches the division area Z2, the dividing device 41 intermittently moves the electric heating blade 41a toward one side (the right side in this embodiment) of the above-mentioned transport direction (the direction of arrow A1 or arrow A2), and cuts (heat cuts) the electrode stack group 110 along each of the predetermined plurality of cutting lines L7·L7··· (see Figure 3(d)) using the electric heating blade 41a.

[0105] The dividing section 4 having such a configuration carries out the above-mentioned dividing step S03, and multiple electrode stacks 110A·110A·· are formed by dividing the electrode stack group 110 on the upper surface of the movable pallet 120 in the dividing area Z2.

[0106] The winding section 5 includes, for example, a winder device 51 that winds a finishing separator 103a around each formed electrode laminate 110A, and a transfer robot 52 that supplies the electrode laminate 110A formed in the divided area Z2 to the winder device 51.

[0107] As shown in Figure 5(b), the winder device 51 has a turret 51a with its axial direction in the horizontal direction, multiple (three in this embodiment) guide rollers 51b·51b·51b arranged on one side (right side in this embodiment) of the turret 51a, and a cutting blade 51c arranged near the axis of the turret 51a. In addition, the winder device 51 holds the finishing separator 103a wound in a roll on the side opposite the turret plate 51a (the right side in this embodiment) relative to the multiple guide rollers 51b·51b·51b so that the axial direction is parallel to the axis of the turret plate 51a. Furthermore, the turret board 51a holds the pair of electrode stacks 110A in a state where they face each other in the radial direction (the left-right direction in this embodiment) of the turret board 51a.

[0108] The tip portion pulled out from the separator 103a is guided to the turret plate 51a via a plurality of guide rollers 51b, 51b, 51b, and is held so as to cover one side surface (in this embodiment, the upper surface) of the pair of electrode stacks 110A, 110A held by the turret plate 51a.

[0109] In this state, first, of the pair of electrode laminates 110A, one electrode laminate 110A located on the side away from the separator 103a (the left side in this embodiment) is rotated several times, and the separator 103a is wrapped around the electrode laminate 110A. Then, the separator 103a is cut near one of the electrode stacks 110A by the cutting blade 51c, and after the turret 51a rotates half a turn around its axis, the other electrode stack 110A is rotated several times, and the separator 103a is wrapped around the electrode stack 110A.

[0110] Thereafter, the separator 103a is cut by the cutting blade 51c near the other electrode stack 110A, and the pair of electrode stacks 110A are removed from the turret board 51a. As a result, the finishing separator 103a is wound around the laminated battery 100 as a final product.

[0111] As mentioned above, the winding unit 5 is not an essential component, and may not be provided in the manufacturing apparatus 1 of this embodiment. In this case, the stacked battery 100 may be made up of each electrode stack 110A divided at the division areas Z2, without having the finishing separator 103a.

[0112] [Laminated Battery Manufacturing Apparatus (First Alternative Embodiment)] Next, the configuration of a laminated battery manufacturing apparatus 201 according to the first alternative embodiment will be described with reference to FIGS.

[0113] In the first alternative embodiment, a stacked battery manufacturing apparatus 201 (hereinafter simply referred to as "manufacturing apparatus 201") has a configuration substantially equivalent to that of the manufacturing apparatus 1 in the present embodiment described above, but differs from the manufacturing apparatus 1 mainly in the configuration of the moving device 211. Therefore, in the following description, differences from the manufacturing apparatus 1 described above will be mainly described. Description of the same configuration as that of the manufacturing apparatus 1 will be omitted.

[0114] As shown in FIG. 6, the manufacturing apparatus 201 mainly includes a moving device 211 that moves the moving pallet 120 back and forth between the stacking area Z1 and the dividing area Z2, a supply unit 202 that continuously forms positive electrode plates 101 and negative electrode plates 102 and supplies the formed positive electrode plates 101 and negative electrode plates 102 to the stacking area Z1, a stacking unit 203 that forms an electrode stack group 110 in the stacking area Z1, a dividing unit 204 that divides the formed electrode stack group 110 into individual electrode stacks 110A·110A··· in the dividing area Z2, and a winding unit 205 that winds a finishing separator 103a around each divided electrode stack 110A.

[0115] The supply section 202, stacking section 203, dividing section 204, and winding section 205 have the same configuration as the supply section 2, stacking section 3, dividing section 4, and winding section 5 in the manufacturing apparatus 1 described above, respectively, and therefore detailed explanations thereof will be omitted.

[0116] The moving device 211 is configured by a rotary table, and as shown in FIG. 7, has a rotary disk 211a that can rotate around a vertical axis G1. As shown in FIG. 6, a pair of movable pallets 120 are placed on the rotating table 211a.

[0117] The turntable 211a is in a standby state with a pair of movable pallets 120-120 positioned in the stacking area Z1 and the dividing area Z2, respectively, and rotates half a turn around the axis G1 at a predetermined timing (for example, at the end of the stacking process S02 in the stacking area Z1 and / or at the end of the dividing process S03 in the dividing area Z2), thereby moving the movable pallet 120 positioned in the stacking area Z1 to the dividing area Z2, and simultaneously moving the movable pallet 120 positioned in the dividing area Z2 to the stacking area Z1.

[0118] According to the manufacturing apparatus 201 of the first alternative embodiment in which the moving device 211 is configured by a rotary table, the layout of the components in the manufacturing apparatus for stacked batteries can be made more compact than when the moving device 11 is configured by a shuttle conveyor or the like that enables reciprocating transport via transport surfaces arranged parallel to the vertical direction, as in the manufacturing apparatus 1 of the present embodiment described above.

[0119] [Laminated Battery Manufacturing Apparatus (Second Alternative Embodiment)] Next, the configuration of a laminated battery manufacturing apparatus 301 according to a second alternative embodiment will be described with reference to FIG.

[0120] The manufacturing apparatus 301 of a stacked battery in the second alternative embodiment (hereinafter simply referred to as "manufacturing apparatus 301") has a configuration substantially equivalent to that of the manufacturing apparatus 1 in the present embodiment described above, but differs from the manufacturing apparatus 1 mainly in the positions of the positive electrode side conveying device 321 and the negative electrode side conveying device 324, and the configurations of the moving device 311 and the electrode plate mounting device 332. Therefore, in the following description, differences from the manufacturing apparatus 1 described above will be mainly described, and a description of the same configuration as the manufacturing apparatus 1 will be omitted.

[0121] The manufacturing apparatus 301 mainly includes a moving device 311 that moves the moving pallet 120 back and forth between the stacking area Z1 and the division area Z2, a supply unit 302 that continuously forms positive electrode plates 101 and negative electrode plates 102 and supplies the formed positive electrode plates 101 and negative electrode plates 102 to the stacking area Z1, a stacking unit 303 that forms an electrode stack group 110 in the stacking area Z1, a dividing unit 304 that divides the formed electrode stack group 110 into individual electrode stacks 110A·110A··· in the division area Z2, and a winding unit 305 that winds a finishing separator 103a around each of the divided electrode stacks 110A.

[0122] In addition, the zigzag folding device 331, the dividing unit 304, and the winding unit 305 provided in the stacking unit 303 have the same configuration as the zigzag folding device 31, the dividing unit 4, and the winding unit 5 in the manufacturing apparatus 1 described above, respectively, so detailed explanations will be omitted. Moreover, the moving device 311 has the same configuration as the moving device 211 in the second alternative embodiment described above, and therefore a detailed description thereof will be omitted.

[0123] The supply section 302 includes a positive electrode side conveying device 321, a positive electrode side fixed size cutting device 322, and a positive electrode side laser cutting device 323 that continuously form the positive electrode plates 101, as well as a negative electrode side conveying device 324, a negative electrode side fixed size cutting device 325, and a negative electrode side laser cutting device 326 that continuously form the negative electrode plates 102.

[0124] The positive electrode side fixed size cutting device 322, the positive electrode side laser cutting device 323, the negative electrode side fixed size cutting device 325, and the negative electrode side laser cutting device 326 have the same configuration as the positive electrode side fixed size cutting device 22, the positive electrode side laser cutting device 23, the negative electrode side fixed size cutting device 25, and the negative electrode side laser cutting device 26 in the manufacturing apparatus 1 described above, and therefore detailed explanations thereof will be omitted.

[0125] The positive electrode side transport device 321 includes a third upstream conveyor 321A and a third downstream conveyor 321B, which are formed of, for example, a belt conveyor. In addition, the third upstream conveyor 321A and the third downstream conveyor 321B are each arranged in a straight line from the upstream side to the downstream side of the conveying direction (the direction of arrow A1 in Figure 8), with one side in the horizontal direction (in this embodiment, approximately the front side) being the conveying direction.

[0126] The positive electrode side transport device 321 is disposed so that the stacking area Z1 is located near the downstream end of the third downstream conveyor 321B in the transport direction (direction of arrow A1).

[0127] On the other hand, the negative electrode side transport device 324 has a fourth upstream conveyor 324A and a fourth downstream conveyor 324B, which are made up of, for example, belt conveyors. In addition, the fourth upstream conveyor 324A and the fourth downstream conveyor 324B are arranged in a straight line from the upstream side to the downstream side of the conveying direction (the direction of arrow A2 in Figure 8), with one side in the horizontal direction (in this embodiment, approximately the front side) being the conveying direction.

[0128] Similarly to the positive electrode side transport device 321, the negative electrode side transport device 324 is also arranged so that the stacking area Z1 is located near the downstream end of the downstream conveyor 324B in the transport direction (direction of arrow A2). That is, in a plan view, the positive electrode side transport device 321 and the negative electrode side transport device 324 are arranged substantially parallel to each other.

[0129] In addition, between the third downstream conveyor 321B and the fourth downstream conveyor 324B, there is arranged an electrode plate placing device 332 having a movable frame 332a that is L-shaped in a plan view, and a positive electrode side adsorption portion 332b and a negative electrode side adsorption portion 332c that are supported by the movable frame 332a so that they can be raised and lowered, and the electrode plate placing device 332 is configured to supply a predetermined number (6 sheets) of positive electrode plates 101·101··· and negative electrode plates 102·102··· collectively to the stacking area Z1.

[0130] According to the manufacturing apparatus 301 of the second alternative embodiment, in which the positive electrode side conveying device 321 and the negative electrode side conveying device 324 are arranged in approximately parallel, the layout of the components in the manufacturing apparatus for stacked batteries can be made more compact than, for example, when the positive electrode side conveying device 21 and the negative electrode side conveying device 24 are arranged in a straight line with the stacking area Z1 sandwiched between them, as in the manufacturing apparatus 1 of the present embodiment described above.

[0131] The above describes one embodiment of the present invention, but the present invention is not limited to such an embodiment, which is merely an example, and it goes without saying that the present invention can be embodied in various other forms without departing from the gist of the present invention. The scope of the present invention is indicated by the claims, and further includes the meaning of equivalents set forth in the claims, and all modifications within the scope of the claims. [Explanation of symbols]

[0132] 1, 201, 301 Stacked battery manufacturing equipment 11, 211, 311 Mobile devices 21, 321 Positive electrode side transport device 24, 324 Negative electrode side transport device 31, 331 Zigzag folding device 32, 332 Electrode plate mounting device 41 Splitting device 100 Stacked battery 101 Positive electrode plate 102 negative electrode plate 102a Negative electrode core 102b Negative electrode active material layer 103 Separator 110 Electrode laminate group 110A electrode stack d. predetermined interval S02 Lamination process S03 Splitting process Z1 stacking area Z2 division area

Claims

1. A method for manufacturing a stacked battery, which is formed by alternately stacking a plurality of positive electrode plates and negative electrode plates and interposing separators between the plurality of positive electrode plates and negative electrode plates, comprising: A long strip-shaped separator is folded zigzag, and each time the separator is folded back by zigzag folding, a predetermined number of positive electrode plates and a predetermined number of negative electrode plates are placed together and alternately in order on the folded back separator in a state where they are aligned along the longitudinal direction of the separator, a stacking step of forming an electrode stack group consisting of a plurality of positive electrode plates and negative electrode plates stacked in predetermined numbers with separators interposed therebetween; The electrode stack group formed in the stacking step is cut by heat cutting in the stacking direction of the positive electrode plates and the negative electrode plates, and a dividing step of dividing the electrode stack into an electrode stack composed of a plurality of positive electrode plates and negative electrode plates stacked one by one with separators interposed therebetween.

1. A method for manufacturing a stacked battery comprising:

2. In the lamination step, the predetermined number of positive electrode plates and the predetermined number of negative electrode plates are arranged along the longitudinal direction of the separator while being spaced apart at predetermined intervals, In the dividing step, The electrode stack group is cut at a position between adjacent positive electrode plates or adjacent negative electrode plates.

2. The method for manufacturing a stacked battery according to claim 1.

3. In the lamination step, The predetermined intervals between the predetermined number of positive electrode plates and the predetermined number of negative electrode plates are: 4 mm or more and 6 mm or less, 3. The method for manufacturing a stacked battery according to claim 2.

4. The negative electrode plate is a strip-shaped negative electrode core body extending in one direction; a negative electrode active material layer coated on both the front and back surfaces of the negative electrode core, In the lamination step, The separator is placed on the substrate so as to be perpendicular to the longitudinal direction of the separator, The dimension of the separator in the width direction perpendicular to the longitudinal direction is The negative electrode active material layer of the negative electrode plate has a dimension larger than the dimension in the extending direction of the negative electrode core.

4. The method for manufacturing a stacked battery according to claim 1, wherein the stacked battery is a laminated battery.

5. 1. An apparatus for manufacturing a stacked battery in which a plurality of positive electrode plates and negative electrode plates are alternately stacked and separators are interposed between the plurality of positive electrode plates and negative electrode plates, a zigzag folding device that folds a long strip-shaped separator zigzag; an electrode plate mounting device that, each time the separator is folded back by the zigzag folding device, collectively mounts a predetermined number of positive electrode plates and a predetermined number of negative electrode plates on the folded back separator in a state in which the plates are aligned along the longitudinal direction of the separator, in an alternating order; an electrode stack group formed by the zigzag folding device and the electrode plate mounting device, the electrode stack group being made up of a plurality of positive electrode plates and negative electrode plates stacked in predetermined numbers with separators interposed therebetween, is cut by heat cutting in the stacking direction of the positive electrode plates and the negative electrode plates; and a dividing device for dividing the positive electrode plate and the negative electrode plate into an electrode stack composed of a plurality of positive electrode plates and negative electrode plates stacked one by one with separators interposed therebetween. A manufacturing apparatus for a stacked battery.

6. The electrode plate mounting device is The predetermined number of positive electrode plates and the predetermined number of negative electrode plates are arranged along the longitudinal direction of the separator, with the plates spaced apart at a predetermined interval; The dividing device cutting the electrode stack group at a position between adjacent positive electrode plates or adjacent negative electrode plates; 6. The laminated battery manufacturing apparatus according to claim 5,

7. In the electrode plate mounting device, The predetermined intervals between the predetermined number of positive electrode plates and the predetermined number of negative electrode plates are: 4 mm or more and 6 mm or less, 7. The laminated battery manufacturing apparatus according to claim 6,

8. The negative electrode plate is a strip-shaped negative electrode core body extending in one direction; a negative electrode active material layer coated on both the front and back surfaces of the negative electrode core, The electrode plate mounting device is The predetermined number of negative electrode plates are placed on the separator so as to be perpendicular to the longitudinal direction of the separator, The dimension of the separator in the width direction perpendicular to the longitudinal direction is The negative electrode active material layer of the negative electrode plate has a dimension larger than the dimension in the extending direction of the negative electrode core.

8. The laminated battery manufacturing apparatus according to claim 5, wherein:

9. a stacking area in which the zigzag folding device and the electrode plate mounting device are arranged and in which the electrode stack group is formed; a dividing area in which the dividing device is disposed and which divides the electrode stack group into each of the electrode stacks; a positive electrode-side conveying device that continuously conveys a plurality of positive electrode plates in one direction and supplies the positive electrode plates to the stacking area; a negative electrode-side conveying device that continuously conveys a plurality of negative electrode plates in one direction and supplies the negative electrode plates to the stacking area; a moving device that moves the electrode stack group between the stacking area and the division area, 8. The laminated battery manufacturing apparatus according to claim 5, wherein:

10. The moving device is constituted by a rotary table.

10. The laminated battery manufacturing apparatus according to claim 9,

11. In plan view, The positive electrode side transport device and the negative electrode side transport device are arranged in parallel with each other.

10. The laminated battery manufacturing apparatus according to claim 9,

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