Electrode active material layer manufacturing apparatus

Abstract

This apparatus for manufacturing an electrode active material layer comprises: a support unit; a supply unit that supplies predetermined granulated particles over or above the support unit; a first transport unit; a squeegee unit; a predetermined first stock guide; a second stock guide; a first positioning unit capable of measuring a distance D1; a second positioning unit capable of measuring a distance D2; a rolling unit; a first gap amount adjustment unit that adjusts a gap amount G1; a second gap amount adjustment unit that adjusts a gap amount G2; and a control unit. The control unit causes the first gap amount adjustment unit to adjust the gap amount G1 on the basis of a difference between the gap amount G1 obtained on the basis of the distance D1 and a gap amount threshold value T1, and causes the second gap amount adjustment unit to adjust the gap amount G2 on the basis of a difference between the gap amount G2 obtained on the basis of the distance D2 and a gap amount threshold value T2.

Description

Technical Field

[0001] The present invention relates to an apparatus for manufacturing an electrode active material layer.

Background Art

[0002] An electrode sheet, which is a component of a battery such as a lithium-ion secondary battery, may include an electrode active material layer. The electrode active material layer is usually formed on a base material that is a current collector. As an apparatus for forming an electrode active material layer, an apparatus that deposits granulated particles containing an electrode active material in layers on a base material and rolls the layer of granulated particles is known. In order to make the thickness of the layer of granulated particles constant, an electrode active material layer manufacturing apparatus is provided with a member (squeegee part) that levels the granulated particles deposited at the center in the width direction of the layer of granulated particles and guides them to both ends in the width direction. And, in order to reduce the conveyance of the granulated particles guided to both ends in the width direction beyond the defined width of the layer of granulated particles to the downstream in the conveyance direction of the layer of granulated particles, techniques are known (see Patent Documents 1 to 4).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Patent Document 3

Patent Document 4

Summary of the Invention

Problems to be Solved by the Invention

[0004] Granulated particles, leveled by the squeegee and guided to both ends of the granulated particle layer in the width direction, may be transported downstream beyond the width direction of the squeegee under certain manufacturing conditions, such as when the supply of granulated particles is excessive. Excess granulated particles transported downstream may be mixed into the rolling mechanism, such as the rolling rolls, causing defects in the molding of the electrode active material layer. To remove excess granulated particles transported downstream, the manufacturing apparatus in Patent Document 1 is provided with a jig and a dust collection device for removing both ends of a layer of granulated particles formed beyond a specified width, and the manufacturing apparatus in Patent Document 2 is provided with an air purging device for removing granulated particles by blowing gas onto both ends of the layer.

[0005] However, even with the manufacturing apparatus described in Patent Document 1 and Patent Document 2, there are excess granulated particles that are transported downstream beyond both ends in the width direction of the squeegee, making it difficult to stably produce the electrode active material layer. Furthermore, the generation of excess granulated particles increases manufacturing costs.

[0006] In the manufacturing apparatus described in Patent Documents 3 and 4, guide members are provided to form areas where granulated particles are not deposited. However, these guide members are in physical contact with the surface on which the granulated particles are deposited. Therefore, for example, when granulated particles are deposited on a substrate, if the relative position of the substrate and the guide member in the width direction shifts due to tension fluctuations during transport of the substrate, the substrate may become distorted and break. Also, for example, when granulated particles are deposited directly on a support part such as a roll, the support part and the guide member may come into contact, causing wear on the guide part, and the gap between the substrate part and the guide part may increase, rendering the guide part unable to perform its function. As a result, it was sometimes difficult to stably manufacture the electrode active material layer.

[0007] Therefore, there is a need for manufacturing equipment that can stably produce electrode active material layers. [Means for solving the problem]

[0008] The inventors, after diligently studying to solve the aforementioned problems, discovered that the problems could be solved by a manufacturing apparatus including a specific stock guide and control unit, and thus completed the present invention. In other words, the present invention provides the following:

[0009] [1] Support part and, A supply unit that supplies granulated particles containing electrode active material and binder to the support unit or above the support unit, A first conveying unit for conveying the granulated particles supplied above or above the support unit, A squeegee section for leveling the conveyed granulated particles to form a granulated particle layer, A plate-shaped first stock guide having a first surface facing the support portion and arranged parallel to the first end face of the squeegee portion, A plate-shaped second stock guide having a second surface facing the support portion and arranged parallel to the second end face of the squeegee portion, A rolling section that rolls the granulated particle layer to form an electrode active material layer, An apparatus for manufacturing an electrode active material layer containing, The manufacturing apparatus further includes a first positioning unit fixed to the first stock guide, a second positioning unit fixed to the second stock guide, a first gap adjustment unit, a second gap adjustment unit, and a control unit. The first stock guide and the second stock guide are arranged such that the distance between the main surface of the first stock guide and the main surface of the second stock guide corresponds to the width of the electrode active material layer. The first positioning unit can measure the distance D1 between the first positioning unit and the surface of the first stock guide that is opposite to the first surface and to which the granulated particles are supplied. The second positioning unit can measure the distance D2 between the second positioning unit and the surface of the second stock guide that is opposite to the second surface and to which the granulated particles are supplied. The first gap adjustment unit can adjust the gap amount G1 between the first surface of the first stock guide and the surface to which the granulated particles are supplied. The second gap adjustment unit can adjust the gap amount G2 between the second surface of the second stock guide and the surface to which the granulated particles are supplied. The control unit, Based on the difference between the gap amount G1 obtained from the distance D1 and the gap amount threshold T1 set to be greater than 0 μm, the first gap amount adjustment unit is instructed to adjust the gap amount G1. Based on the difference between the gap amount G2 obtained from the distance D2 and the gap amount threshold T2 set to be greater than 0 μm, the second gap amount adjustment unit is instructed to adjust the gap amount G2. A manufacturing apparatus for electrode active material layers. [2] The first positioning unit is fixed to the first end face of the first stock guide, which is on the opposite side of the first surface of the first stock guide, The first stock guide has a first through hole, the first through hole extending from the first end face to the first face of the first stock guide to which the first positioning unit is fixed. The first positioning unit is configured to measure the distance D1 from the first through hole, The second positioning unit is fixed to the second end face of the second stock guide, which is on the opposite side of the second surface of the second stock guide. The second stock guide has a second through hole, the second through hole extending from the second end face to the second face of the second stock guide to which the second positioning unit is fixed. The second positioning unit is configured to measure the distance D2 from the second through hole. [1] Apparatus for manufacturing the electrode active material layer described above. [3] The rolling section further includes a second conveying section for conveying the base material, The apparatus for manufacturing an electrode active material layer according to [1] or [2], wherein the rolling section rolls the granulated particle layer that has been placed on the conveyed substrate. [4] The support unit further includes a third transport unit for transporting a base material, The support portion supports the substrate, The supply unit supplies the granulated particles onto the base material supported by the support unit. The first positioning unit is configured to measure the distance D1 between the first positioning unit and the main surface of the base material facing the first surface of the first stock guide. The second positioning unit is configured to measure the distance D2 between the second positioning unit and the main surface of the base material facing the second surface of the second stock guide. The control unit obtains the gap amount G1 based on the distance D1, and based on the difference from the gap amount threshold value T1 set so that the distance between the first surface of the first stock guide and the main surface of the base material is greater than 0 μm, causes the first gap amount adjustment unit to adjust the gap amount G1. obtains the gap amount G2 based on the distance D2, and based on the difference from the gap amount threshold value T2 set so that the distance between the second surface of the second stock guide and the main surface of the base material is greater than 0 μm, causes the second gap amount adjustment unit to adjust the gap amount G2. The manufacturing apparatus for an electrode active material layer according to [1] or [2]. [5] The manufacturing apparatus for an electrode active material layer according to any one of [1] to [4], wherein the support unit and the first conveyance unit are a single roll. [6] The support unit is a rotatable roll. The control unit acquires a data set A1 of the distance D1 while the support unit rotates two or more times, analyzes the data set A1 to predict the distance D1 that varies due to the rotation of the support unit, and based on the predicted distance D1, causes the first gap amount adjustment unit to adjust the gap amount G1. and the control unit acquires a data set A2 of the distance D2 while the support unit rotates two or more times, analyzes the data set A2 to predict the distance D2 that varies due to the rotation of the support unit, and based on the predicted distance D2, causes the second gap amount adjustment unit to adjust the gap amount G2. The manufacturing apparatus for an electrode active material layer according to any one of [1] to [5].

Advantages of the Invention

[0010] According to the present invention, an apparatus for manufacturing an electrode active material layer can be provided that can stably produce the electrode active material layer. [Brief explanation of the drawing]

[0011] [Figure 1] Figure 1 is a schematic diagram showing a manufacturing apparatus for an electrode active material layer according to the first embodiment. [Figure 2] Figure 2 is a schematic top view showing a part of the manufacturing apparatus according to the first embodiment. [Figure 3] Figure 3 is a schematic side view showing a part of the manufacturing apparatus according to the first embodiment. [Figure 4] Figure 4 is a schematic diagram showing the configuration of the control unit of the manufacturing apparatus according to the first embodiment. [Figure 5] Figure 5 is a flowchart illustrating the processing performed by the control unit according to the first embodiment. [Figure 6] Figure 6 is a flowchart illustrating the processing performed by the control unit according to the first embodiment. [Figure 7] Figure 7 is a schematic diagram showing the configuration of a control unit including a distance prediction unit according to the first embodiment. [Figure 8] Figure 8 is a flowchart illustrating the processing performed by the control unit, which includes the distance prediction unit. [Figure 9] Figure 9 is a flowchart illustrating the processing performed by the control unit, which includes the distance prediction unit. [Figure 10] Figure 10 is a schematic diagram showing a manufacturing apparatus for an electrode active material layer according to the second embodiment. [Figure 11] Figure 11 is a schematic diagram showing a manufacturing apparatus for an electrode active material layer according to the third embodiment. [Figure 12] Figure 12 is a schematic top view showing a part of the manufacturing apparatus according to the third embodiment. [Figure 13] Figure 13 is a schematic side view showing a part of the manufacturing apparatus according to the third embodiment. [Figure 14]Figure 14 is a schematic diagram showing a manufacturing apparatus according to a modified example of the third embodiment. [Modes for carrying out the invention]

[0012] The present invention will be described in detail below with reference to embodiments and examples. However, the present invention is not limited to the embodiments and examples shown below, and can be modified and implemented as appropriate without departing from the scope of the claims and equivalents of the present invention. The components of the embodiments shown below can be combined as appropriate. In addition, in the figures, the same reference numerals are used for the same components, and their descriptions may be omitted.

[0013] In the following description, "long film" refers to a film having a length of five times or more its width, preferably 10 times or more its width, and specifically a film long enough to be rolled up for storage or transport. There is no particular upper limit to the length of the film; for example, it may be 100,000 times or less its width.

[0014] In the following description, the orientation of the elements being "parallel," "perpendicular," and "orthogonal" may include errors within a range that does not impair the effects of the present invention, for example, within a range of ±3°, ±2°, or ±1°, unless otherwise specified.

[0015] In the following explanation, "above" or "above" an element includes both direct and indirect connections to that element.

[0016] An electrode active material layer produced by a manufacturing apparatus according to one embodiment of the present invention is obtained by rolling a layer of granulated particles. The electrode active material layer is preferably formed on a substrate. The substrate is preferably elongated.

[0017] Examples of substrates include metal foils made of aluminum, platinum, nickel, tantalum, titanium, stainless steel, copper, and other alloys; films containing conductive materials (e.g., carbon, conductive polymers); paper; fabrics made of natural fibers, synthetic fibers, etc.; and resin films containing polymers. Examples of polymers that may be included in resin films include polyesters such as polyethylene terephthalate and polyethylene naphthalate; polyimide; polypropylene; polyphenylene sulfide; polyvinyl chloride; aramid; PEN; and PEEK. These can be appropriately selected depending on the purpose.

[0018] Among these, the substrates are preferably metal foil, films containing carbon material, and films containing conductive polymer material, more preferably metal foil, and even more preferably copper foil, aluminum foil, and aluminum alloy foil from the viewpoint of conductivity and voltage resistance. These substrates are suitable for manufacturing electrode sheets for lithium-ion batteries.

[0019] The substrate may have undergone surface treatments such as coating, drilling, buffing, sandblasting, or etching, and may have undergone multiple surface treatments.

[0020] The thickness of the substrate is not particularly limited, but is preferably 1 μm or more, more preferably 5 μm or more, preferably 1000 μm or less, and more preferably 800 μm or less. The substrate may have any width.

[0021] Granulated particles typically contain electrode active material and binder, and may optionally contain other components such as dispersants, conductive materials, and additives.

[0022] The electrode active material contained in the granulated particles may be either a positive electrode active material or a negative electrode active material. Examples of positive and negative electrode active materials include materials that can be used as electrode active materials in lithium-ion batteries. Examples of positive electrode active materials include metal oxides that can be reversibly doped and dedoped with lithium ions. Examples of such metal oxides include lithium cobalt oxide (LiCoO2), lithium nickel oxide (LiNiO2), lithium manganese oxide (LiMn2O4), lithium iron phosphate (LiFeO4), and ternary active materials in which part of lithium cobalt oxide is replaced with nickel and manganese (for example, LiCo 1 / 3 Ni 1 / 3 Mn 1 / 3 O2 is one example. The positive electrode active material may be used alone or in combination of multiple types.

[0023] Examples of negative electrode active materials include low-crystallinity carbon (amorphous carbon) (e.g., easily graphitizable carbon, poorly graphitizable carbon, pyrolytic carbon); graphite (e.g., natural graphite, artificial graphite); alloy materials containing tin, silicon, etc.; oxides (e.g., silicon oxide, tin oxide, lithium titanate); and the like. The negative electrode active material may be used alone or in combination of multiple types.

[0024] The electrode active material is preferably granular. When the particles are granular, the electrode active material can be molded to form a high-density electrode.

[0025] The volume-average particle size (D50) of the electrode active material is preferably 0.1 μm or more and 100 μm or less, more preferably 0.3 μm or more and 50 μm or less, and even more preferably 0.5 μm or more and 30 μm or less. When the volume-average particle size (D50) of the electrode active material is within the above range, it can be suitably used as a material for lithium-ion battery electrodes.

[0026] The binder contained in the granulated particles is preferably a compound that can bind the electrode active materials together. The binder is more preferably a dispersible binder that disperses in a solvent. Examples of dispersible binders include polymer compounds such as silicon atom-containing polymers, fluorine atom-containing polymers, conjugated diene polymers, acrylate polymers, polyimides, polyamides, and polyurethanes.

[0027] The shape of the dispersed binder is not particularly limited, but it is preferably particulate. Being particulate improves the binding properties and can reduce the decrease in capacity and degradation of the fabricated electrode due to repeated charging and discharging. Examples of particulate binders include aqueous dispersions of binder particles such as latex, and particulate binders obtained by drying such aqueous dispersions.

[0028] From the viewpoint of ensuring sufficient adhesion between the resulting electrode active material layer and the substrate, and lowering the internal resistance, the amount of binder is preferably 0.1 parts by weight or more and 50 parts by weight or less, more preferably 0.5 parts by weight or more and 20 parts by weight or less, and even more preferably 1 part by weight or more and 15 parts by weight or less, based on dry weight, per 100 parts by weight of electrode active material.

[0029] Granulated particles may contain a dispersant as an optional component. Examples of dispersants include cellulosic polymers such as carboxymethylcellulose and methylcellulose, and their ammonium salts or alkali metal salts. These dispersants may be used individually or in combination.

[0030] Granulated particles may contain conductive materials as optional components. Examples of conductive materials include conductive carbon blacks such as furnace black, acetylene black, and Ketjenblack (a registered trademark of AkzoNobel Chemicals Sloten Fennotschap), with acetylene black and Ketjenblack being preferred. Other conductive materials that can be used include vapor-grown carbon fibers such as VGCF® and carbon nanotubes; graphite-based carbon materials such as expanded graphite and graphite; and graphene. These conductive materials may be used individually or in combination.

[0031] Granulated particles can be produced by granulating electrode active material and binder, as well as optional components that may be included as needed. Examples of methods for producing granulated particles are not particularly limited and include known granulation methods such as fluidized bed granulation, spray drying granulation, and rolling bed granulation.

[0032] Preferably, each granulated particle is in the form of a secondary particle formed by the aggregation of multiple primary particles. Specifically, it is preferable that the secondary particles are formed by binding multiple (preferably several to several dozen) electrode active materials and optional components together with a binder.

[0033] The volume-average particle diameter (D50) of the granulated particles is preferably 0.1 μm or more, more preferably 1 μm or more, even more preferably 20 μm or more, even more preferably 30 μm or more, preferably 1000 μm or less, more preferably 500 μm or less, and even more preferably 250 μm or less, from the viewpoint of easily obtaining an electrode active material layer of the desired thickness.

[0034] The volume-average particle diameter (D50) of granulated particles is the 50% volume-average particle diameter calculated by dry measurement using a particle size distribution analyzer based on laser scattering and diffraction (e.g., Microtrac MT3300EX II; manufactured by Microtrac-Bell Co., Ltd.). The 50% volume-average particle diameter is the particle diameter at the point where the cumulative frequency, calculated from the smallest diameter side, reaches 50% in the obtained particle size distribution (volume-based).

[0035] The number-average particle diameter of granulated particles, as described later, is the particle diameter calculated by dry measurement using a particle size distribution analyzer based on laser scattering and diffraction (e.g., Microtrac MT3300EX II; manufactured by Microtrac-Bell Co., Ltd.). For example, the 50% number-average particle diameter (D50) is the particle diameter at the point where the cumulative frequency, accumulated from the smallest diameter side, reaches 50% in the obtained particle size distribution (number-based).

[0036] [1. First Embodiment] The manufacturing apparatus for the electrode active material layer according to the first embodiment will be described below with reference to the figures. Figure 1 is a schematic diagram showing a manufacturing apparatus for an electrode active material layer according to the first embodiment. Figure 2 is a schematic top view showing a part of the manufacturing apparatus according to the first embodiment. Figure 3 is a schematic side view showing a part of the manufacturing apparatus according to the first embodiment. Figure 4 is a schematic diagram showing the configuration of the control unit of the manufacturing apparatus according to the first embodiment.

[0037] As shown in Figure 1, the manufacturing apparatus 100 according to this embodiment includes a forming roll 101, a supply unit 103, a third transport unit 104, a squeegee roll 105 as a squeegee unit, a first stock guide 110a, a second stock guide 110b, a first positioning unit 120a, a second positioning unit 120b, a rolling roll 130a, a first gap adjustment unit 131a, a second gap adjustment unit 131b, and a control unit 140. The forming roll 101 functions as a support unit, as a first transport unit, and as a rolling unit 130 together with the rolling roll 130a.

[0038] In this embodiment, the manufacturing apparatus 100 has one squeegee roll and two stock guides. In another embodiment, the manufacturing apparatus has two or more n squeegee rolls and n+1 stock guides, where the n squeegee rolls and n+1 stock guides are arranged alternately, with one stock guide at each end of the squeegee roll. This allows for the stable production of a striped electrode active material layer.

[0039] The molding roll 101 is a cylindrical member and is rotatably supported in the direction DR101 around an axis R101. The third conveying unit 104 conveys the base material 1 to the molding roll 101, which acts as a support, and the molding roll 101 conveys the base material 1 downstream while rotating in the direction DR101. The third conveying unit 104 is, for example, a conveying roll.

[0040] The supply unit 103 supplies granulated particles P to the main surface of the substrate 1 supported by the molding roll 101, above the molding roll 101. Any powder supply device may be used as the supply unit 103. Examples of powder supply mechanisms include pressure feed type, rotary blade type, screw type, and rotary drum type. The supply unit 103 of this embodiment includes a hopper section equipped with a granulated particle inlet and a granulated particle outlet. Granulated particles P are introduced from the granulated particle inlet and supplied from the granulated particle outlet onto the main surface of the substrate 1 supported by the molding roll 101. In other words, in this embodiment, the surface to which the granulated particles P are supplied is the main surface of the substrate 1.

[0041] The molding roll 101, which serves as the first conveying unit, rotates in direction DR101 to convey the granulated particles P supplied onto the main surface of the substrate 1 downstream together with the substrate 1.

[0042] The squeegee roll 105, which serves as the squeegee portion, is a cylindrical member and is rotatably supported around axis R105 in the direction DR105, which is opposite to the direction DR101. A drive device (not shown) is attached to the squeegee roll 105 to rotate the squeegee roll 105 in the direction DR105. As the squeegee roll 105 rotates in the opposite direction DR105 to the conveying direction of the substrate 1, the granulated particles P supplied and conveyed onto the main surface of the substrate 1 supported by the molding roll 101 are leveled to a predetermined thickness, forming a granulated particle layer 2.

[0043] The squeegee roll 105 is provided with a position adjustment mechanism (not shown) that allows adjustment of the distance between the circumferential surface of the squeegee roll 105 and the circumferential surface of the forming roll 101, which serves as the first conveying section. By adjusting this distance, the thickness of the granulated particle layer 2 can be adjusted, and as a result, the weight per unit area (basis weight) of the electrode active material layer 3 obtained by rolling the granulated particle layer 2 can be adjusted.

[0044] As shown in Figure 2, the squeegee roll 105 has a first end face 105E1 and a second end face 105E2 that are perpendicular to the axis R105. A plate-shaped first stock guide 110a is positioned parallel to the first end face 105E1 of the squeegee roll 105. A plate-shaped second stock guide 110b is positioned parallel to the second end face 105E2 of the squeegee roll 105.

[0045] The distance W110 between the main surface of the first stock guide 110a on the squeegee roll 105 side and the main surface of the second stock guide 110b on the squeegee roll 105 side corresponds to the width of the electrode active material layer 3 to be manufactured.

[0046] The materials constituting the first stock guide 110a and the second stock guide 110b are not particularly limited. Examples of stock guide materials include resins such as tetrafluoroethylene (PTFE), acrylonitrile butadiene styrene (ABS), polypropylene (PP), polystyrene (PS), polyethylene (PE), ultra-high molecular weight polyethylene, monomer casting nylon (UMC), polyvinyl chloride (PVC), polyacetal, and methacrylic resin; and metals such as aluminum and stainless steel. Resins are preferred as stock guide materials because they can reduce the coefficient of dynamic friction of the stock guide, and fluororesins such as PTFE are more preferred.

[0047] It is preferable that the first stock guide 110a and the second stock guide 110b have low dynamic friction with the base material 1. Specifically, the dynamic friction coefficient of the first stock guide 110a and the second stock guide 110b is preferably 0.50 or less, preferably 0.40 or less. Ideally, the dynamic friction coefficient of the first stock guide 110a and the second stock guide 110b is 0, and can take a lower limit of 0.04 or more. The dynamic friction coefficient between the first stock guide 110a and the second stock guide 110b and the base material 1 can be measured in accordance with JIS K7125. Furthermore, the smaller the coefficient of dynamic friction of the stock guide, the less likely it is that the adhesion between the granulated particles and the stock guide will decrease. This can suppress the reduction in edge smoothness of the electrode active material layer caused by the adhesion of granulated particles to the stock guide. Furthermore, the stock guide may be surface-treated to reduce the coefficient of dynamic friction. Examples of such surface treatments include fluororesin coating, lubricant application, and plating.

[0048] A fixing device may be attached to each end of the squeegee device, which consists of a first stock guide 110a, a second stock guide 110b, and a squeegee roll 105, to restrict the movement of the first stock guide 110a and the second stock guide 110b in the axial direction of the rotation axis. The fixing device may be configured to include, for example, a fixing plate fixed to the rotation axis and an elastic member equipped with an elastic body such as a helical spring, a leaf spring, or a rubber plate. Specifically, the elastic member may press the first stock guide 110a and the second stock guide 110b, which are positioned at both ends of the squeegee roll 105, toward the axial center of the squeegee roll 105, thereby fixing the first stock guide 110a and the second stock guide 110b so that they do not move in the axial direction of the rotation axis. By configuring the fixing device in this way, the first stock guide 110a and the second stock guide 110b can be freely rotated about the rotation axis. The fixing device secures the first stock guide 110a and the second stock guide 110b so that they can rotate freely around the axis of rotation, but do not move in the axial direction of the axis of rotation. As a result, the position of each of the first stock guide 110a and the second stock guide 110b in the longitudinal direction of the squeegee device is less likely to fluctuate due to vibrations during manufacturing. Consequently, fluctuations in the distance between the main surfaces of the first stock guide 110a and the second stock guide 110b are suppressed, and an electrode active material layer 3 having a predetermined width can be manufactured stably.

[0049] The fixture may be configured to be detachable from the rotating shaft, allowing the first stock guide 110a, the second stock guide 110b, and the squeegee roll 105 to be removed from the squeegee device as needed. This makes it easy to replace only the parts that need replacing if the first stock guide 110a, the second stock guide 110b, or the squeegee roll 105 needs to be replaced due to wear or other reasons. As a result, the effort required for part replacement is reduced, the continuous operation period of the manufacturing apparatus 100 can be extended, and the electrode active material layer 3 can be manufactured stably.

[0050] As shown in Figure 3, the first stock guide 110a has a first surface 111a that faces the circumferential surface of the molding roll 101, which serves as a support, via the base material 1. The second stock guide 110b also has a second surface 111b that faces the circumferential surface of the molding roll 101, which serves as a support, via the base material 1. Both the first surface 111a and the second surface 111b have a shape that conforms to the circumferential surface of the molding roll 101, which serves as a support. In this embodiment, the first surface 111a and the second surface 111b are concave curved surfaces having a radius of curvature that is approximately the same as the radius of curvature of the molding roll 101, preferably 95% to 110% of the radius of curvature of the molding roll 101. Because the first surface 111a and the second surface 111b have a shape that conforms to the circumferential surface of the molding roll 101, it is possible to reduce leakage of granulated particles P supplied above the molding roll 101 outward in the direction of the axis R101 of the molding roll 101 from the gap between the first surface 111a of the first stock guide 110a and the main surface of the base material 1 supported by the circumferential surface of the molding roll 101, and from the gap between the second surface 111b of the second stock guide 110b and the main surface of the base material 1 supported by the circumferential surface of the molding roll 101. Here, the gap amount G1 between the first surface 111a of the first stock guide 110a and the main surface of the substrate 1 to which the granulated particles P are supplied, and the gap amount G2 between the second surface 111b of the second stock guide 110b and the main surface of the substrate 1 to which the granulated particles P are supplied, can be adjusted by the first gap amount adjustment unit 131a and the second gap amount adjustment unit 131b, which will be described later.

[0051] A first positioning unit 120a is fixed to the first end face 112a of the first stock guide 110a, which is opposite to the first surface 111a. A second positioning unit 120b is fixed to the second end face 112b of the second stock guide 110b, which is opposite to the second surface 111b. The first positioning unit 120a and the second positioning unit 120b may be measuring instruments such as laser displacement meters. Because the first positioning unit 120a is fixed to the first stock guide 110a, when the first gap adjustment unit 131a (described later) raises or lowers the first stock guide 110a, the first positioning unit 120a also raises or lowers together with the first stock guide 110a. Similarly, since the second positioning unit 120b is fixed to the second stock guide 110b, when the second gap adjustment unit 131b (described later) raises or lowers the second stock guide 110b, the second positioning unit 120b also raises or lowers together with the second stock guide 110b. Therefore, the first positioning unit 120a can measure the distance (distance D1) corresponding to the gap amount G1. The second positioning unit 120b can measure the distance (distance D2) corresponding to the gap amount G2.

[0052] The first stock guide 110a is provided with a first slit 113a, which serves as a first through-hole, extending from the first end face 112a to which the first positioning unit 120a is fixed, to the first surface 111a. The first slit 113a is positioned parallel to the main surface of the first stock guide 110a. In this embodiment, the first positioning unit 120a emits a laser from a laser irradiation port (not shown), and the emitted laser passes through the first slit 113a and is reflected by the surface to which the granulated particles P are supplied, which is opposite the first surface 111a. In another embodiment, the first slit 113a does not have to be parallel to the main surface of the first stock guide 110a. The reflected laser passes through the first slit 113a and is received by a light-receiving unit (not shown) of the first positioning unit 120a, so that the distance D1 between the first positioning unit 120a and the surface to which the granulated particles P are supplied can be measured. The second stock guide 110b, like the first stock guide 110a, is provided with a second through-hole, a second slit 113b, that penetrates from the second end face 112b to which the second positioning unit 120b is fixed, to the second face 111b. The second slit 113b is positioned parallel to the main surface of the second stock guide 110b. The second positioning unit 120b can measure the distance D2 between the second positioning unit 120b and the surface to which the granulated particles P are supplied. In another embodiment, the second slit 113b does not have to be parallel to the main surface of the second stock guide 110b.

[0053] In this embodiment, the first through-hole and the second through-hole are slit-shaped, but in another embodiment, the first through-hole and the second through-hole may be cylindrical.

[0054] By fixing the first positioning unit 120a and the second positioning unit 120b to the first stock guide 110a and the second stock guide 110b, respectively, and providing the first slit 113a and the second slit 113b to measure distances D1 and D2, the rattle of the first positioning unit 120a and the second positioning unit 120b can be reduced, thereby improving the measurement accuracy of distances D1 and D2.

[0055] The first positioning unit 120a and the second positioning unit 120b are each electrically connected to the control unit 140, which will be described later.

[0056] As shown in Figure 1, the first stock guide 110a is provided with a first gap adjustment section 131a for adjusting the gap amount G1. The second stock guide 110b is also provided with a second gap adjustment section 131b for adjusting the gap amount G2. Any mechanism can be used to adjust the gap amount G1 or the gap amount G2, such as a lifting mechanism equipped with a servo motor and a ball screw. In this embodiment, nuts are fixed to both the first stock guide 110a and the second stock guide 110b. The ball screw paired with the nut is positioned to align with a direction perpendicular to the axis R101 of the forming roll 101. A servo motor is attached to the end of the ball screw so as to rotate the ball screw.

[0057] As described above, the squeegee roll 105 is provided with a position adjustment mechanism so that the gap between the circumferential surface of the squeegee roll 105 and the circumferential surface of the forming roll 101, which serves as the first conveying section, can be adjusted. The first gap adjustment section 131a and the second gap adjustment section 131b are configured to adjust the gap amounts G1 and G2 independently of adjusting the gap between the circumferential surface of the squeegee roll 105 and the circumferential surface of the forming roll 101.

[0058] The first gap adjustment unit 131a and the second gap adjustment unit 131b are each electrically connected to a control unit 140, which will be described later. The first gap adjustment unit 131a and the second gap adjustment unit 131b each receive control signals from the control unit 140. Based on the signals from the control unit 140, the first gap adjustment unit 131a adjusts the gap amount G1, and the second gap adjustment unit 131b adjusts the gap amount G2. In this embodiment, the first gap adjustment unit 131a, which is a servo motor, rotates the ball screw in a predetermined direction and amount of rotation based on the signals from the control unit 140, and the second gap adjustment unit 131b, which is a servo motor, rotates the ball screw in a predetermined direction and amount of rotation based on the signals from the control unit 140. As a result, the first stock guide 110a and the second stock guide 110b can be raised and lowered independently, and the gap amounts G1 and G2 can be adjusted independently.

[0059] The rolling section 130 consists of a forming roll 101 that functions as a rolling roll and a rolling roll 130a. The rolling roll 130a is a cylindrical member and is rotated at a constant speed around its axis R130a in the direction of transporting the base material 1 and the granulated particle layer 2 downstream. Axis R101 and axis R130a are arranged to be parallel to each other. A gap is provided between the circumferential surface of the forming roll 101 and the circumferential surface of the rolling roll 130a. The granulated particle layer 2 is guided into the gap between the forming roll 101 and the rolling roll 130a. In this embodiment, the granulated particle layer 2 is formed on the base material 1, and the laminate of the base material 1 and the granulated particle layer 2 is guided into the gap between the forming roll 101 and the rolling roll 130a. The granulated particle layer 2, laminated on the base material 1, is rolled as it passes through the gap between the molding roll 101 and the rolling roll 130a, becoming tightly attached to the base material 1, and an electrode active material layer 3 having a predetermined thickness is formed on the base material 1.

[0060] The gap (distance) between the circumferential surface of the forming roll 101 and the circumferential surface of the rolling roll 130a can be appropriately adjusted according to the desired thickness and porosity of the electrode active material layer 3.

[0061] Examples of materials that make up the circumferential surfaces of the forming roll 101 and the rolling roll 130a include rubber, metal, and inorganic materials.

[0062] The rolling roll 130a may have a mechanism for heating its circumferential surface. This allows the granulated particle layer 2 to be rolled while being heated. By rolling the granulated particle layer 2 while heating it, the binder contained in the granulated particles P can be softened or melted, thereby binding the granulated particles P more firmly to each other.

[0063] As shown in Figure 4, the control unit 140 is electrically connected to the first positioning unit 120a, the second positioning unit 120b, the first gap adjustment unit 131a, and the second gap adjustment unit 131b. Figures 5 and 6 are flowcharts illustrating the processes performed by the control unit 140 according to the first embodiment.

[0064] As shown in Figure 4, the control unit 140 includes a data acquisition unit 141, a gap amount calculation unit 142, a storage unit 143, a gap amount adjustment amount determination unit 144, an adjustment determination unit 145, and a gap amount adjustment instruction unit 146.

[0065] The data acquisition unit 141 acquires distance D1 data from the first positioning unit 120a (step S11). The gap amount calculation unit 142 calculates the gap amount G1 between the first surface 111a of the first stock guide 110a and the main surface of the base material 1, which is the surface to which the granulated particles P are supplied, based on the distance D1 data and the dimensional data of the first stock guide 110a stored in the storage unit 143 (step S12). The void amount adjustment amount determination unit 144 determines the adjustment amount ΔG1 of the void amount G1 based on the difference between the calculated void amount G1 and the void amount threshold T1 stored in the storage unit 143 (step S13). The void amount threshold T1 is set to a value greater than 0 μm. The adjustment determination unit 145 determines whether the adjustment amount ΔG1 of the gap amount G1 is 0 or not (whether adjustment of the gap amount G1 is necessary or not) (step S14). If ΔG1 is 0 (step S14: Yes), the process returns to step S11. If ΔG1 is not 0 (Step S14: No), the gap amount adjustment instruction unit 146 instructs the first gap amount adjustment unit 131a to adjust by the determined adjustment amount ΔG1 (Step S15). The first gap adjustment unit 131a adjusts the gap amount G1 by raising or lowering the first stock guide 110a based on the instructed adjustment amount ΔG1 (step S16).

[0066] Similarly, the data acquisition unit 141 acquires distance D2 data from the second positioning unit 120b (step S21). The gap amount calculation unit 142 calculates the gap amount G2 between the second surface 111b of the second stock guide 110b and the main surface of the base material 1, which is the surface to which the granulated particles P are supplied, based on the distance D2 data and the dimensional data of the second stock guide 110b stored in the storage unit 143 (step S22). The void amount adjustment amount determination unit 144 determines the adjustment amount ΔG2 of the void amount G2 based on the difference between the calculated void amount G2 and the void amount threshold T2 stored in the storage unit 143 (step S23). The void amount threshold T2 is set to a value greater than 0 μm. The adjustment determination unit 145 determines whether the adjustment amount ΔG2 of the gap amount G2 is 0 or not (whether adjustment of the gap amount G2 is necessary or not) (step S24). If ΔG2 is 0 (step S24: Yes), the process returns to step S21. If ΔG2 is not 0 (Step S24: No), the gap amount adjustment instruction unit 146 instructs the second gap amount adjustment unit 131b to adjust the determined adjustment amount ΔG2 (Step S25). The second gap adjustment unit 131b adjusts the gap amount G2 by raising or lowering the second stock guide 110b based on the instructed adjustment amount ΔG2 (step S26).

[0067] The control unit 140 may perform the process of causing the first gap amount adjustment unit 131a to adjust the gap amount G1 and the process of causing the second gap amount adjustment unit 131b to adjust the gap amount G2 in parallel or sequentially.

[0068] The control unit 140 may include a distance prediction unit 150. Figure 7 is a schematic diagram showing the configuration of a control unit 140 including a distance prediction unit 150 according to the first embodiment. The control unit 140 includes a data acquisition unit 141, a gap amount calculation unit 142, a storage unit 143, a gap amount adjustment amount determination unit 144, an adjustment determination unit 145, a gap amount adjustment instruction unit 146, and further includes a distance prediction unit 150. The control unit 140 is electrically connected to a first positioning unit 120a, a second positioning unit 120b, a first gap amount adjustment unit 131a, and a second gap amount adjustment unit 131b.

[0069] The distance prediction unit 150 includes a data set acquisition unit 151, a data set analysis unit 152, and a predicted distance data storage unit 153. Figures 8 and 9 are flowcharts illustrating the processes performed by the control unit 140, which includes the distance prediction unit 150.

[0070] The data acquisition unit 151 acquires a data set A1 of the distance D1 during which the forming roll 101, which serves as the support, rotates two or more times (step S101). The data set analysis unit 152 analyzes the acquired data set A1 to predict the distance D1 that fluctuates due to the rotation of the molding roll 101 (step S102). The predicted distance data storage unit 153 stores the predicted distance D1 in the storage unit 143 (step S103). The gap amount calculation unit 142 calculates the gap amount G1 between the first surface 111a of the first stock guide 110a and the main surface of the base material 1, which is the surface to which the granulated particles P are supplied, based on the predicted distance D1 data stored in the storage unit 143 and the dimensional data of the first stock guide 110a (step S104). The void amount adjustment amount determination unit 144 determines the adjustment amount ΔG1 of the void amount G1 based on the difference between the calculated void amount G1 and the void amount threshold T1 stored in the storage unit 143 (step S105). The void amount threshold T1 is set to a value greater than 0 μm. The adjustment determination unit 145 determines whether the adjustment amount ΔG1 of the gap amount G1 is 0 or not (whether or not adjustment of the gap amount G1 is necessary) (step S106). If ΔG1 is 0 (step S106: Yes), the process returns to step S104. If ΔG1 is not 0 (step S106: No), the gap amount adjustment instruction unit 146 instructs the first gap amount adjustment unit 131a to adjust by the determined adjustment amount ΔG1 (step S107). The first gap adjustment unit 131a adjusts the gap amount G1 by raising or lowering the first stock guide 110a based on the instructed adjustment amount ΔG1 (step S108).

[0071] The data acquisition unit 151 acquires a data set A2 of the distance D2 during which the forming roll 101, which serves as the support, rotates two or more times (step S201). The data set analysis unit 152 analyzes the acquired data set A2 to predict the distance D2 that fluctuates due to the rotation of the molding roll 101 (step S202). The predicted distance data storage unit 153 stores the predicted distance D2 in the storage unit 143 (step S203). The gap amount calculation unit 142 calculates the gap amount G2 between the second surface 111b of the second stock guide 110b and the main surface of the base material 1, which is the surface to which the granulated particles P are supplied, based on the predicted distance D2 data stored in the storage unit 143 and the dimensional data of the second stock guide 110b (step S204). The void amount adjustment amount determination unit 144 determines the adjustment amount ΔG2 of the void amount G2 based on the difference between the calculated void amount G2 and the void amount threshold T2 stored in the storage unit 143 (step S205). The void amount threshold T2 is set to a value greater than 0 μm. The adjustment determination unit 145 determines whether the adjustment amount ΔG2 of the gap amount G2 is 0 or not (whether or not adjustment of the gap amount G2 is necessary) (step S206). If ΔG2 is 0 (step S206: Yes), the process returns to step S204. If ΔG2 is not 0 (step S206: No), the gap amount adjustment instruction unit 146 instructs the second gap amount adjustment unit 131b to adjust the determined adjustment amount ΔG2 (step S207). The second gap adjustment unit 131b adjusts the gap amount G2 by raising or lowering the second stock guide 110b based on the instructed adjustment amount ΔG2 (step S208).

[0072] The control unit 140 includes a distance prediction unit 150 to predict fluctuating distances D1 and D2, and based on the predicted distances D1 and D2, causes the first gap adjustment unit 131a to adjust the gap amount G1 and the second gap adjustment unit 131b to adjust the gap amount G2. This makes it easy to make the adjustment amounts ΔG1 and ΔG2 follow the fluctuations in distances D1 and D2. This reduces leakage of granulated particles P supplied above the molding roll 101 outwards in the direction of the molding roll 101 axis R101 from the gap between the first surface 111a of the first stock guide 110a and the main surface of the substrate 1 supported by the circumferential surface of the molding roll 101, and from the gap between the second surface 111b of the second stock guide 110b and the main surface of the substrate 1 supported by the circumferential surface of the molding roll 101. Furthermore, by ensuring that the gaps G1 and G2 do not become 0 μm, the first stock guide 110a and the second stock guide 110b come into contact with the substrate 1, reducing the amount of strain that occurs in the substrate 1. As a result of reducing the strain in the substrate 1, fracture of the substrate 1 can be suppressed, and the manufacturing stability of the electrode active material layer 3 can be improved.

[0073] The control unit 140 may perform the distance D1 prediction process and the distance D2 prediction process in parallel or sequentially.

[0074] The analysis of data set A1 or data set A2 by the data set analysis unit 152 can be performed by conventionally known methods. Examples of analysis methods include time series analysis. By analyzing the acquired data set A1 or data set A2 with the circumference of the forming roll 101 as the unit of repetition, the fluctuating distance D1 or distance D2 can be predicted.

[0075] The predicted distances D1 and D2 may be predicted, for example, as a function of the rotation angle of the forming roll 101.

[0076] The functions of the control unit 140 can be realized by a computer including an input interface, an output interface, a CPU (Central Processing Unit), and a storage device (ROM (Read Only Memory), RAM (Random Access Memory), etc.). The input interface is connected to the first positioning unit 120a and the second positioning unit 120b. The output interface is connected to the first gap adjustment unit 131a and the second gap adjustment unit 131b. The CPU and the storage device are connected by a bus. The storage device stores a program. The CPU executes the program stored in the storage device.

[0077] The manufacturing apparatus 100 is configured such that the gap G1 between the first surface 111a of the first stock guide 110a and the surface to which the granulated particles P are supplied (in this embodiment, the main surface of the substrate 1), and the gap G2 between the second surface 111b of the second stock guide 110b and the surface to which the granulated particles P are supplied (in this embodiment, the main surface of the substrate 1), are both greater than 0 μm. This reduces the contact between the first stock guide 110a and the second stock guide 110b and the substrate 1, thereby reducing the strain on the substrate 1. As a result of reducing the strain on the substrate 1, fracture of the substrate 1 can be suppressed, and the manufacturing stability of the electrode active material layer 3 can be improved.

[0078] The void threshold T1 and void threshold T2 can each be set to any value greater than 0 μm. For example, the void threshold T1 and void threshold T2 can each be preferably less than or equal to the 10% number average particle diameter (D10) of the granulated particle P, more preferably less than or equal to the 5% number average particle diameter (D5), and even more preferably less than or equal to the 3% number average particle diameter (D3). The lower limit is usually greater than 0% of the volume average particle diameter (D50) of the granulated particle P.

[0079] By setting the gap threshold T1 and gap threshold T2 to less than or equal to the upper limit, it is possible to effectively reduce leakage of granulated particles P supplied above the molding roll 101 outward in the direction of the molding roll 101 axis R101 through the gap between the first surface 111a of the first stock guide 110a and the main surface of the substrate 1 supported by the circumferential surface of the molding roll 101, and through the gap between the second surface 111b of the second stock guide 110b and the main surface of the substrate 1 supported by the circumferential surface of the molding roll 101. As a result, it is possible to effectively reduce the amount of leaked granulated particles P that are carried to the rolling section 130 and rolled together with the granulated particle layer 2. This effectively suppresses molding defects in the resulting electrode active material layer 3. Furthermore, since leakage of granulated particles P can be effectively reduced, the yield of granulated particles P can be improved, and the manufacturing cost of the electrode active material layer 3 can be reduced.

[0080] In another embodiment, the manufacturing apparatus may further include a height sensor upstream of the squeegee device for measuring the height of the supplied granulated particles, and a control unit for adjusting the amount of granulated particles supplied from the supply unit based on information from the height sensor. This reduces variations in the weight per unit area (basis weight) of the electrode active material layer 3 obtained by rolling the granulated particle layer 2, and allows for highly accurate adjustment of the basis weight.

[0081] (Optional configuration) In addition to the above-described configuration, the manufacturing apparatus according to the present invention may include any other configurations as needed.

[0082] For example, an optional configuration may include a coating section located upstream of the supply section of the manufacturing apparatus, which applies a binder coating liquid onto the substrate. When the manufacturing apparatus includes a coating section, a binder coating liquid layer can be formed by applying the binder coating liquid onto the substrate, and granulated particles can be supplied onto the binder coating liquid layer, thereby allowing the granulated particles to adhere closely to the substrate. The coating section may include, for example, a slot die head, a gravure head, a bar coat head, or a knife coat head.

[0083] Furthermore, the manufacturing apparatus may include a recovery section downstream of the rolling section for recovering the substrate on which the electrode active material layer has been formed. The recovery section could be, for example, a roll for winding the substrate.

[0084] [2. Second Embodiment] Next, a manufacturing apparatus for the electrode active material layer according to the second embodiment will be described. Figure 10 is a schematic diagram showing a manufacturing apparatus for an electrode active material layer according to the second embodiment. The manufacturing apparatus 200 according to this embodiment includes a forming roll 201, a supply unit 103, a second conveying unit 202, a squeegee roll 105 as a squeegee unit, a first stock guide 110a, a second stock guide 110b, a first positioning unit 120a, a second positioning unit 120b, a rolling roll 230b, a first gap adjustment unit 131a, a second gap adjustment unit 131b, and a control unit 140. The forming roll 201 functions as a support unit, a first conveying unit, and a rolling unit.

[0085] The supply unit 103 supplies granulated particles P onto the molding roll 201 of the manufacturing apparatus 200, specifically onto the circumferential surface of the molding roll 201, which serves as a support unit. The molding roll 201, acting as a first conveying unit, conveys the granulated particles P downstream by rotating in direction DR201. The squeegee roll 105 rotates in direction DR105, opposite to direction DR201, so that the granulated particles P supplied and conveyed onto the circumferential surface of the molding roll 201 are leveled to a predetermined thickness, forming a granulated particle layer 2.

[0086] The forming roll 201, in conjunction with the rolling roll 230b, constitutes the rolling section 230. The rolling roll 230b is a cylindrical member and is rotated at a constant speed around its axis R230b in a direction that conveys the base material 1 and the granulated particle layer 2 downstream. The axis R201 of the forming roll 201 and the axis R230b of the rolling roll 230b are arranged to be parallel to each other. A gap is provided between the circumferential surface of the forming roll 201 and the circumferential surface of the rolling roll 230b. The granulated particle layer 2, conveyed by the circumferential surface of the forming roll 201, is guided into the gap between the forming roll 201 and the rolling roll 230b as the forming roll 201 rotates. The second conveying section 202 is, for example, a conveying roll, which conveys the base material 1 to the rolling section 230. More specifically, it conveys the base material 1 to the circumferential surface of the rolling roll 230b that constitutes the rolling section 230, and as the rolling roll 230b rotates, the base material 1 is guided into the gap between the forming roll 201 and the rolling roll 230b. The granulated particle layer 2 and the base material 1 are guided and stacked in the gap between the forming roll 201 and the rolling roll 230b, and are rolled as they pass through the gap between the forming roll 201 and the rolling roll 230b, forming an electrode active material layer 3 having a predetermined thickness on the base material 1.

[0087] The gap between the circumferential surface of the forming roll 201 and the circumferential surface of the rolling roll 230b can be appropriately adjusted according to the desired thickness and porosity of the electrode active material layer 3. Examples of materials constituting the circumferential surface of the rolling roll 230b include the materials exemplified in the description of the rolling roll 130b. The rolling roll 230b may have a mechanism for heating its circumferential surface.

[0088] Similar to the manufacturing apparatus 100, the manufacturing apparatus 200 is configured such that the gap G1 between the first surface 111a of the first stock guide 110a and the surface to which the granulated particles P are supplied (in this embodiment, the circumferential surface of the molding roll 201 as a support) and the gap G2 between the second surface 111b of the second stock guide 110b and the surface to which the granulated particles P are supplied (in this embodiment, the circumferential surface of the molding roll 201 as a support) are both greater than 0 μm. This reduces wear of the first stock guide 110a and the second stock guide 110b due to contact with the molding roll 201. As a result, the manufacturing stability of the electrode active material layer 3 can be improved.

[0089] The manufacturing apparatus 200 is equipped with a first stock guide 110a, a second stock guide 110b, a first positioning unit 120a, a second positioning unit 120b, a first gap adjustment unit 131a, a second gap adjustment unit 131b, and a control unit 140, all configured similarly to the manufacturing apparatus 100. Therefore, similar to the manufacturing apparatus 100, it can effectively reduce leakage of granulated particles P supplied onto the molding roll 201 outward in the direction of the molding roll 201 axis R201 from the gap between the first surface 111a of the first stock guide 110a and the circumferential surface of the molding roll 201, and from the gap between the second surface 111b of the second stock guide 110b and the circumferential surface of the molding roll 201. As a result, it can effectively reduce the amount of granulated particles P that have leaked out and are carried to the rolling unit 230 and rolled together with the granulated particle layer 2. This effectively suppresses molding defects in the resulting electrode active material layer 3. Furthermore, since leakage of granulated particles P can be effectively reduced, the yield of granulated particles P can be improved, thereby reducing the manufacturing cost of the electrode active material layer 3.

[0090] [3. Third Embodiment] Next, a manufacturing apparatus for the electrode active material layer according to the third embodiment will be described. Figure 11 is a schematic diagram showing a manufacturing apparatus for an electrode active material layer according to the third embodiment. Figure 12 is a schematic top view showing a part of the manufacturing apparatus according to the third embodiment. Figure 13 is a schematic side view showing a part of the manufacturing apparatus according to the third embodiment.

[0091] The manufacturing apparatus 300 according to this embodiment includes a support section 301, a supply section 103, a third conveying section 104, a pair of rolling rolls 330a and 330b as the first conveying section and rolling section, a squeegee roll 105 as the squeegee section, a first stock guide 310a, a second stock guide 310b, a first positioning section 120a, a second positioning section 120b, a first gap adjustment section 131a, a second gap adjustment section 131b, and a control section 140.

[0092] In this embodiment, the support portion 301 is disc-shaped. The supply portion 103 is above the support portion 301 and supplies granulated particles P onto the main surface of the substrate 1 supported by the support portion 301. That is, the surface to which the granulated particles P are supplied is the main surface of the substrate 1. The rolling rolls 330a and 330b, which serve as the first conveying portion, rotate in opposite directions to each other, thereby conveying the substrate 1 and the granulated particles P supplied onto the main surface of the substrate 1 downstream.

[0093] The squeegee roll 105 is configured such that the distance between the circumferential surface of the squeegee roll 105 and the support portion 301 can be adjusted.

[0094] As shown in Figure 12, a plate-shaped first stock guide 310a is positioned parallel to the first end face 105E1 of the squeegee roll 105. A plate-shaped second stock guide 310b is also positioned parallel to the second end face 105E2 of the squeegee roll 105. The distance W310 between the main surface of the first stock guide 310a on the squeegee roll 105 side and the main surface of the second stock guide 310b on the squeegee roll 105 side corresponds to the width of the electrode active material layer 3 to be manufactured.

[0095] As shown in Figure 13, the first stock guide 310a has a first surface 311a that faces the main surface of the support portion 301 via the base material 1. The second stock guide 310b also has a second surface 311b that faces the main surface of the support portion 301 via the base material 1. Both the first surface 311a and the second surface 311b have a planar shape that is aligned with the main surface of the support portion 301. The first stock guide 310a and the second stock guide 310b are provided such that the first surface 311a and the second surface 311b are parallel to the main surface of the support portion 301, respectively.

[0096] The first stock guide 310a is provided with a first slit 313a, which serves as a first through-hole, extending from the first end face 312a to which the first positioning unit 120a is fixed, to the first surface 311a. The first slit 313a is positioned parallel to the main surface of the first stock guide 310a. Similarly to the first stock guide 310a, the second stock guide 310b is provided with a second slit 313b, which serves as a second through-hole, extending from the second end face 312b to which the second positioning unit 120b is fixed, to the second surface 311b. The second slit 313b is positioned parallel to the main surface of the second stock guide 310b. By fixing the first positioning unit 120a and the second positioning unit 120b to the first stock guide 310a and the second stock guide 310b, respectively, and providing the first slit 313a and the second slit 313b to measure distances D1 and D2, the rattle of the first positioning unit 120a and the second positioning unit 120b can be reduced, thereby improving the measurement accuracy of distances D1 and D2.

[0097] In this embodiment, the first through-hole and the second through-hole are slit-shaped, but in another embodiment, the first through-hole and the second through-hole may be cylindrical.

[0098] In another embodiment, the first slit 313a does not have to be parallel to the main surface of the first stock guide 310a. Similarly, the second slit 313b does not have to be parallel to the main surface of the second stock guide 310b.

[0099] The pair of rolling rolls 330a and 330b are configured to function as both a first conveying section and a rolling section. The pair of rolling rolls 330a and 330b are arranged such that their respective axes of rotation R330a and R330b are parallel to each other. In this embodiment, the support section 301 and the pair of rolling rolls 330a and 330b are arranged such that the planes containing the axis of rotation R330a of rolling roll 330a and the axis of rotation R330b of rolling roll 330b are perpendicular to the plane containing the main surface of the support section 301.

[0100] Similar to the manufacturing apparatus 100, the manufacturing apparatus 300 is configured such that the gap G1 between the first surface 311a of the first stock guide 310a and the surface to which the granulated particles P are supplied (in this embodiment, the main surface of the substrate 1), and the gap G2 between the second surface 311b of the second stock guide 310b and the surface to which the granulated particles P are supplied (in this embodiment, the main surface of the substrate 1), are both greater than 0 μm. This reduces the contact between the first stock guide 310a and the second stock guide 310b and the substrate 1, thereby reducing the strain on the substrate 1. As a result of reducing the strain on the substrate 1, fracture of the substrate 1 can be suppressed, and the manufacturing stability of the electrode active material layer 3 can be improved.

[0101] [4. Modified Examples of the Third Embodiment] Next, a manufacturing apparatus for an electrode active material layer according to a modified example of the third embodiment will be described. Figure 14 is a schematic diagram showing a manufacturing apparatus according to a modified example of the third embodiment. In the manufacturing apparatus 400, the support section 301 and the pair of rolling rolls 330a and 330b are arranged such that the planes containing the axis of rotation R330a of the rolling roll 330a and the axis of rotation R330b of the rolling roll 330b are parallel to the plane containing the main surface of the support section 301. In the manufacturing apparatus 400, as in the manufacturing apparatus 300, the first stock guide 310a and the second stock guide 310b contact the substrate 1, reducing the amount of strain that occurs in the substrate 1. As a result of reducing the strain in the substrate 1, fracture of the substrate 1 can be suppressed, and the manufacturing stability of the electrode active material layer 3 can be improved. [Explanation of Symbols]

[0102] 1: Base material 2: Granulated particle layer 3: Electrode active material layer P: Granulated particles 100: Manufacturing equipment 101: Forming roll (support section, first conveying section, or rolling section) R101: Axis DR101: Direction 103: Supply department 104: Third transport section 105: Squeegee Roll (Squeegee Part) 105E1: First end face 105E2: Second end face R105: Axis DR105: Direction 110a: First Stock Guide 110b: Second Stock Guide W110:Distance 111a: First side 111b: Second side 112a: First end face 112b: Second end face 113a: First slit (first through hole) 113b: Second slit (second through hole) 120a: First positioning unit 120b: Second positioning unit 130: Rolling section 130a: Rolling mill rolls 131a: First gap adjustment section 131b: Second gap adjustment section 140: Control Unit 141: Data Acquisition Unit 142: Gap amount calculation part 143: Storage section 144: Gap amount adjustment amount determination section 145:Adjustment judgment section 146: Gap amount adjustment instruction section 150: Distance prediction unit 151: Data set acquisition unit 152: Data Set Analysis Unit 153: Predicted distance data storage unit 201: Forming Roll R201: Axis DR201: Direction 202: Second transport section 230: Rolling section 230b: Rolling mill rolls R230b: Axis 301: Support part 310a: First Stock Guide 310b: Second Stock Guide 330a: Rolling mill rolls 330b: Rolling mill rolls R330a: Shaft R330b: Axis W310:Distance 311a: First side 311b: Second side 312a: First end face 312b: Second end face 313a: First slit (first through hole) 313b: Second slit (second through hole)

Claims

1. Support part and A supply unit that supplies granulated particles containing electrode active material and binder to the support unit or above the support unit, A first conveying unit for conveying the granulated particles supplied above or above the support unit, A squeegee section for leveling the conveyed granulated particles to form a granulated particle layer, A plate-shaped first stock guide having a first surface facing the support portion and arranged parallel to the first end face of the squeegee portion, A plate-shaped second stock guide having a second surface facing the support portion and arranged parallel to the second end face of the squeegee portion, A rolling section that rolls the granulated particle layer to form an electrode active material layer, An apparatus for manufacturing an electrode active material layer containing, The manufacturing apparatus further includes a first positioning unit fixed to the first stock guide, a second positioning unit fixed to the second stock guide, a first gap adjustment unit, a second gap adjustment unit, and a control unit. The first stock guide and the second stock guide are arranged such that the distance between the main surface of the first stock guide and the main surface of the second stock guide corresponds to the width of the electrode active material layer. The first positioning unit can measure the distance D1 between the first positioning unit and the surface of the first stock guide that is opposite to the first surface and to which the granulated particles are supplied. The second positioning unit can measure the distance D2 between the second positioning unit and the surface of the second stock guide that is opposite to the second surface and to which the granulated particles are supplied. The first gap adjustment unit can adjust the gap amount G1 between the first surface of the first stock guide and the surface to which the granulated particles are supplied. The second gap adjustment unit can adjust the gap amount G2 between the second surface of the second stock guide and the surface to which the granulated particles are supplied. The control unit, Based on the difference between the gap amount G1 obtained based on the distance D1 and the gap amount threshold T1 set to be greater than 0 μm, the first gap amount adjustment unit is instructed to adjust the gap amount G1. Based on the difference between the gap amount G2 obtained from the distance D2 and the gap amount threshold T2 set to be greater than 0 μm, the second gap amount adjustment unit is instructed to adjust the gap amount G2. A manufacturing apparatus for electrode active material layers.

2. The first positioning unit is fixed to the first end face of the first stock guide, which is on the opposite side of the first surface of the first stock guide. The first stock guide has a first through hole, the first through hole extending from the first end face to the first face of the first stock guide to which the first positioning unit is fixed. The first positioning unit is configured to measure the distance D1 from the first through hole, The second positioning unit is fixed to the second end face of the second stock guide, which is on the opposite side of the second surface of the second stock guide. The second stock guide has a second through hole, the second through hole extending from the second end face to the second face of the second stock guide to which the second positioning unit is fixed. The second positioning unit is configured to measure the distance D2 from the second through hole. The apparatus for manufacturing an electrode active material layer according to claim 1.

3. The rolling section further includes a second conveying section for conveying the base material, The apparatus for manufacturing an electrode active material layer according to claim 1, wherein the rolling section rolls the granulated particle layer that has been placed on the conveyed substrate.

4. The support unit further includes a third transport unit for transporting the base material, The support portion supports the substrate, The supply unit supplies the granulated particles onto the substrate supported by the support unit, The first positioning unit is configured to measure the distance D1 between the first positioning unit and the main surface of the substrate facing the first surface of the first stock guide. The second positioning unit is configured to measure the distance D2 between the second positioning unit and the main surface of the substrate facing the second surface of the second stock guide. The control unit, Based on the distance D1, the gap amount G1 is obtained, and based on the difference between this and the gap amount threshold T1, which is set so that the distance between the first surface of the first stock guide and the main surface of the substrate is greater than 0 μm, the first gap amount adjustment unit is made to adjust the gap amount G1. Based on the distance D2, the gap amount G2 is obtained, and the gap amount G2 is adjusted by the second gap amount adjustment unit based on the difference between this gap amount G2 and the gap amount threshold T2, which is set so that the distance between the second surface of the second stock guide and the main surface of the substrate is greater than 0 μm. The apparatus for manufacturing an electrode active material layer according to claim 1.

5. The apparatus for manufacturing an electrode active material layer according to claim 1, wherein the support section and the first transport section are a single roll.

6. The support part is a rotatable roll, The control unit, A data set A1 of the distance D1 during the rotation of the support part two or more times is acquired, the data set A1 is analyzed to predict the distance D1 that will fluctuate due to the rotation of the support part, and the first gap amount adjustment unit is instructed to adjust the gap amount G1 based on the predicted distance D1. Furthermore, the control unit, A data set A2 of the distance D2 during the rotation of the support part two or more times is acquired, the data set A2 is analyzed to predict the distance D2 that will fluctuate due to the rotation of the support part, and the second gap amount adjustment unit is instructed to adjust the gap amount G2 based on the predicted distance D2. The apparatus for manufacturing an electrode active material layer according to claim 1.

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