Method for producing coating film and device for producing coating film

Abstract

This method for producing a coating film (17) includes: preparing a base material (1) in which a part of a surface (30) of the base material (1) is covered with a sheet-like covering material (4) that has an end surface extending in the X-axis direction in a plan view with respect to the surface (30); supplying a powder material (9) onto the surface (30) of the base material (1) along the end surface of the covering material (4); covering a powder material (12) and the covering material (4) with a protective material (13); compressing the powder material (12) via the protective material (13) so as to form the coating film (17); and collectively recovering the covering material (4) and the protective material (13) after the powder material (12) is compressed.

Description

Method for manufacturing a coating film and apparatus for manufacturing a coating film

[0001] This disclosure relates to a method for manufacturing a coating film and an apparatus for manufacturing a coating film.

[0002] Conventionally, a known technique for manufacturing coatings involves applying a liquid material to the surface of a substrate, creating a solid coating by drying, further fixing the coating material to the substrate surface through processes such as compression, and removing the excess coating. In coating manufacturing, it is necessary to form the coating into a desired shape. For example, coating manufacturing technology is used in the production of battery electrodes, and with the recent demand for miniaturization and high density of electronic devices, there is a need for improved dimensional accuracy in defining the position of the edges of the coating or the area of ​​the coating.

[0003] Patent Document 1 discloses a method for manufacturing a coating film in which tape is applied in advance to areas on the surface of a substrate before coating the coating material where coating film formation is unnecessary, and after going through the processes from coating to compression, the excess portion of the coating film along with the tape is removed to form a coating film in a shape that secures an area for joining current collector leads.

[0004] Japanese Patent Publication No. 2000-133250

[0005] However, the method for manufacturing a coating film as described in Patent Document 1 may be difficult to apply when compressing a coated powder material to produce a solid powder coating film.

[0006] For example, if excess paint film falls off and adheres to the surface of areas where the paint film should remain, it can lead to a decrease in the quality of the paint film. Furthermore, if the paint film is pressurized in subsequent processes after the removal of excess paint film, pressure will concentrate on the areas where the excess paint film adhered to the surface of areas where the paint film should remain, causing damage to the paint film. As a result, this leads to a further decrease in the quality of the paint film and a reduction in yield.

[0007] Therefore, this disclosure provides a method and apparatus for manufacturing a coating film that can produce a high-quality coating film in a desired shape.

[0008] A method for manufacturing a coating film according to an aspect of the present disclosure includes preparing a substrate having a part of its surface covered with a sheet-like covering material having an end face extending in a first direction in a plan view with respect to the surface of the substrate, supplying a powder material onto the surface of the substrate along the end face of the covering material, covering the powder material and the covering material with a protective material, compressing the powder material through the protective material to form a coating film, and collectively recovering the covering material and the protective material after the powder material is compressed.

[0009] A coating film manufacturing apparatus according to an aspect of the present disclosure includes a covering material installation unit that installs a sheet-like covering material having an end face extending in a first direction in a plan view with respect to the surface so as to cover a part of the surface of the substrate, a powder material supply unit that supplies a powder material onto the surface of the substrate along the end face of the covering material, a protective material installation unit that installs a protective material so as to cover the powder material and the covering material, a compression unit that compresses the powder material through the protective material to form a coating film, and a recovery unit that collectively recovers the covering material and the protective material after the powder material is compressed by the compression unit.

[0010] According to the present disclosure, a coating film of a desired shape and high quality can be manufactured.

[0011] Figure 1 is a schematic diagram of a coating film manufacturing apparatus according to an embodiment. Figure 2 is a flowchart of a coating film manufacturing method according to an embodiment. Figure 3 is a cross-sectional view illustrating a coating film manufacturing method according to an embodiment. Figure 4 is a cross-sectional view illustrating a coating film manufacturing method according to an embodiment. Figure 5 is a cross-sectional view illustrating a coating film manufacturing method according to an embodiment. Figure 6 is a cross-sectional view illustrating a coating film manufacturing method according to an embodiment. Figure 7 is a cross-sectional view illustrating a coating film manufacturing method according to an embodiment. Figure 8 is a cross-sectional view illustrating a coating film manufacturing method according to an embodiment. Figure 9 is a cross-sectional view illustrating a coating film manufacturing method according to an embodiment. Figure 10 is a cross-sectional view illustrating the details of the coating material. Figure 11 is a cross-sectional view illustrating a first modified example of the coating material. Figure 12 is a cross-sectional view illustrating a second modified example of the coating material. Figure 13 is a cross-sectional view illustrating a third modified example of the coating material. Figure 14 is a cross-sectional view illustrating a fourth modified example of the coating material. Figure 15 is a cross-sectional view illustrating a first modified example of the protective material. Figure 16 is a cross-sectional view showing the case where the protective material shown in Figure 14 and the coating material shown in Figure 15 are used in the manufacturing of a coating film according to an embodiment.

[0012] (Summary of this disclosure) An example of a method for manufacturing a coating film and a manufacturing apparatus related to this disclosure is shown below as an overview of this disclosure.

[0013] For example, a method for manufacturing a coating film according to a first aspect of the present disclosure includes: preparing a substrate wherein a portion of the surface of the substrate is covered with a sheet-like covering material having end faces extending in a first direction in a plan view with respect to the surface of the substrate; supplying a powder material onto the surface of the substrate along the end faces of the covering material; covering the powder material and the covering material with a protective material; compressing the powder material through the protective material to form a coating film; and recovering the covering material and the protective material together after the powder material has been compressed.

[0014] As a result, when forming a coating film by compressing the powder material, the powder material is compressed and spread, so that an excess portion of the coating film is generated between the coating material and the protective material. The excess portion is sandwiched and recovered by the coating material and the protective material that are recovered together. As a result, the shape of the coating film becomes the shape of the region on the surface of the base material that was not covered with the coating material, and the coating film can be formed into a desired shape by the coating material. In addition, since the excess portion of the coating film is sandwiched and recovered by the coating material and the protective material, it is possible to suppress the excess portion from spilling onto the coating film and suppress a decrease in the quality of the coating film. Therefore, according to this aspect, a coating film with a desired shape and high quality can be manufactured.

[0015] Further, for example, the method for manufacturing a coating film according to the second aspect of the present disclosure is the method for manufacturing a coating film according to the first aspect, wherein the coating material has a first surface that is a surface on the side opposite to the base material side and that is connected to the end surface. The first surface includes a first region that is a region including an end portion on the end surface side of the first surface and that approaches the base material as it moves away from the end surface.

[0016] As a result, a structure is formed in which the corner formed by the first surface and the end surface protrudes to the side opposite to the base material side. Therefore, a cut is generated between the coating film to be left on the surface of the base material and the excess portion of the coating film on the first surface of the coating material at the position of the corner. As a result, when the coating material and the protective material are recovered together, the coating film to be left on the surface of the base material and the excess portion of the coating film are easily separated. Therefore, it is possible to suppress the occurrence of damage to the coating film and a decrease in dimensional accuracy caused by a part of the coating film to be left on the surface of the base material being recovered together with the excess portion. In addition, it is possible to suppress the generation of chips of the coating film during the recovery of the excess portion and suppress the adhesion of the chips to the coating film.

[0017] Further, for example, the method for manufacturing a coating film according to the third aspect of the present disclosure is the method for manufacturing a coating film according to the second aspect, wherein the angle formed by the first region with respect to the end surface is 30° or more and 60° or less.

[0018] As a result, while suppressing damage to the corner formed by the first surface and the end surface, the corner makes it easier to separate the coating film and the excess portion of the coating film.

[0019] Furthermore, for example, the method for manufacturing a coating film according to the fourth aspect of this disclosure is the method for manufacturing a coating film according to the third aspect, wherein the angle that the first region makes with respect to the end face is 45°.

[0020] This suppresses damage to the corner formed by the first surface and the end surface, while also making it easier to separate the coating film from the excess portion of the coating film at the corner.

[0021] Furthermore, for example, a method for manufacturing a coating film according to a fifth aspect of the present disclosure is a method for manufacturing a coating film according to any one of the second to fourth aspects, wherein the maximum distance between the first region and the substrate in the thickness direction of the coating film is 60% or more and 80% or less of the thickness of the coating film.

[0022] This prevents damage to the corners formed by the first surface and the end surface due to the pressure during compression of the powder material, while also making it easier to separate the coating film from the excess portion of the coating film at the corners.

[0023] Furthermore, for example, a method for manufacturing a coating film according to a sixth aspect of the present disclosure is a method for manufacturing a coating film according to any one of the second to fifth aspects, further comprising peeling off the cushioning material covering the first surface from the first surface before covering it with the protective material.

[0024] This allows the first surface to be protected by the cushioning material.

[0025] Furthermore, for example, a method for manufacturing a coating film according to a seventh aspect of the present disclosure is a method for manufacturing a coating film according to any one of the second to sixth aspects, wherein the first surface is a second region located on the opposite side from the end face side of the first region, and includes a second region parallel to the surface of the substrate.

[0026] This makes it easier to sandwich the excess portion of the coating between the covering material and the protective material.

[0027] Furthermore, for example, the method for manufacturing a coating film according to the eighth aspect of this disclosure is the method for manufacturing a coating film according to the seventh aspect, wherein the first surface includes a roughened portion located in the second region, and the first region is not roughened.

[0028] As a result, the roughened areas increase the frictional force between the excess coating and the first surface, further suppressing the excess coating from spilling onto the coating. In addition, because the first region is not roughened, the excess coating is more likely to flow between the coating material and the protective material.

[0029] Furthermore, for example, the method for manufacturing a coating film according to the ninth aspect of this disclosure is a method for manufacturing a coating film according to any one of the first to eighth aspects, wherein the end face of the coating material is perpendicular to the surface of the substrate.

[0030] This allows the edges of the coating film to be perpendicular to the surface of the substrate.

[0031] Furthermore, for example, a method for manufacturing a coating film according to the tenth aspect of the present disclosure is a method for manufacturing a coating film according to any one of the first to ninth aspects, wherein the coating material has a first surface which is the surface opposite to the substrate side and which is connected to the end surface, and the minimum distance between the first surface and the substrate in the thickness direction of the coating film is less than 50% of the thickness of the coating film.

[0032] This prevents the coating material from interfering with the compression of the powder material, which could result in insufficient compression of the coating film.

[0033] Furthermore, for example, a method for manufacturing a coating film according to the 11th aspect of the present disclosure is a method for manufacturing a coating film according to any one of the first to tenth aspects, wherein the coating material has a first surface which is the surface opposite to the substrate side and which is connected to the end surface, and the first surface includes a portion that has been roughened.

[0034] As a result, the roughened surface increases the frictional force between the excess coating and the first surface, further suppressing the excess coating from spilling onto the coating.

[0035] Furthermore, for example, a method for manufacturing a coating film according to the twelfth aspect of the present disclosure is a method for manufacturing a coating film according to any one of the first to eleventh aspects, wherein the dimension of the protective material in the second direction perpendicular to the first direction in the plan view is greater than or equal to the dimension of the substrate in the second direction.

[0036] This allows the coating material and powder material on the surface of the substrate to be completely covered with a protective material.

[0037] Furthermore, for example, a method for manufacturing a coating film according to a thirteenth aspect of the present disclosure is a method for manufacturing a coating film according to any one of the first to twelfth aspects, wherein the protective material has a second surface which is the surface on the substrate side, and the second surface includes a roughened portion located in the region of the second surface that faces the coating material.

[0038] As a result, the roughened surface increases the frictional force between the excess coating and the second surface, further suppressing the excess coating from spilling onto the coating.

[0039] Furthermore, for example, a method for manufacturing a coating film according to a 14th aspect of the present disclosure is a method for manufacturing a coating film according to any one of the 1st to 13th aspects, wherein, in preparing the substrate, a substrate is prepared in which a part of the surface is covered by two coating materials that are spaced apart from each other so that their end faces face each other, and in supplying the powder material, the powder material is supplied onto the surface of the substrate between the two coating materials.

[0040] This allows the dimensions of the coating film in the direction in which the two coating materials are aligned to be defined by the two coating materials themselves.

[0041] Furthermore, for example, a method for manufacturing a coating film according to a 15th aspect of the present disclosure is a method for manufacturing a coating film according to any one of the 1st to 14th aspects, wherein the substrate is in the shape of a strip with a width direction that is perpendicular to the first direction in the plan view.

[0042] This allows the coating material to define the position of the edges of the coating film in the width direction of the substrate.

[0043] Furthermore, for example, the method for manufacturing a coating film according to the 16th aspect of this disclosure is the method for manufacturing a coating film according to the 15th aspect, wherein the supply of the powder material, the covering with the protective material, the formation of the coating film, and the collection of the covering material and the protective material together are performed while moving the substrate in the first direction.

[0044] This allows for the continuous production of coating films.

[0045] Furthermore, for example, a coating film manufacturing apparatus according to a 17th aspect of the present disclosure includes: a coating material installation unit for installing a sheet-like coating material having an end face extending in a first direction in a plan view with respect to the surface so as to cover a part of the surface of a substrate; a powder material supply unit for supplying powder material onto the surface of the substrate along the end face of the coating material; a protective material installation unit for installing a protective material so as to cover the powder material and the coating material; a compression unit for compressing the powder material via the protective material to form a coating film; and a recovery unit for recovering the coating material and the protective material together after the powder material has been compressed by the compression unit.

[0046] This makes it possible to manufacture a high-quality coating film in a desired shape, similar to the coating film manufacturing method according to the first embodiment.

[0047] The embodiments of this disclosure will be described below with reference to the drawings.

[0048] The embodiments described below are all comprehensive or specific examples. The numerical values, shapes, materials, components, arrangement and connection configurations of components, steps, and the order of steps shown in the following embodiments are examples only and are not intended to limit this disclosure. Furthermore, any components in the following embodiments that are not described in an independent claim will be described as optional components.

[0049] Furthermore, in this specification, terms indicating relationships between elements such as parallel and perpendicular, terms indicating the shape of elements such as rectangles, and numerical ranges do not represent only strict meanings, but also include substantially equivalent ranges, such as differences of a few percent.

[0050] Furthermore, each figure is a schematic diagram that has been appropriately emphasized, omitted, or had its proportions adjusted to illustrate this disclosure, and is not necessarily a strict representation of the actual shape, positional relationships, and proportions. In each figure, substantially identical components are denoted by the same reference numerals, and redundant explanations may be omitted or simplified.

[0051] Furthermore, in this specification, the terms "upper" and "lower" do not refer to the upward (vertically upward) and downward (vertically downward) directions in absolute spatial perception, but rather to terms defined by relative positional relationships. Terms such as "upper" and "lower" are used solely to specify the relative arrangement between constituent elements and are not intended to limit the orientation during the manufacturing of the coating film. In addition, the terms "upper" and "lower" apply not only when two constituent elements are spaced apart and another constituent element exists between them, but also when two constituent elements are placed in close contact with each other and touching. Furthermore, in this specification, "planar view" refers to a view from the direction normal to the surface of the substrate unless otherwise specified.

[0052] In this specification and in the drawings, the X, Y, and Z axes represent the three axes of a three-dimensional Cartesian coordinate system. Hereafter, the negative side of the Z axis is defined as "downward," and the positive side of the Z axis is defined as "upward." The Z-axis direction is the direction normal to the surface of the substrate during the manufacturing of the coating film, and is also the direction of the thickness of the coating film. The X-axis direction is an example of a first direction, and the Y-axis direction is an example of a second direction that is orthogonal to the first direction in a plan view.

[0053] (Embodiment) The following describes the manufacturing apparatus and manufacturing method for the coating film according to this embodiment.

[0054] [Apparatus for Manufacturing Coating Films] First, the apparatus for manufacturing coating films according to this embodiment will be described. Figure 1 is a schematic diagram of the apparatus 100 for manufacturing coating films 17 according to this embodiment. Figure 1 shows the apparatus 100 as viewed from the negative side of the Y-axis. Also, in Figure 1, a pattern has been added to parts other than the squeegee 11 for clarity.

[0055] As shown in Figure 1, the coating film manufacturing apparatus 100 according to this embodiment includes a conveying section 110 including a base material unwinding roll 2 and a base material winding roll 3, a coating material installation section 120 including a coating material unwinding roll 5, a cushioning material peeling section 130 including a cushioning material guide roll 7 and a cushioning material winding roll 8, a powder material supply section 10, a squeegee 11, a protective material installation section 140 including a protective material unwinding roll 14 and a protective material guide roll 15, a compression section 16, and a recovery section 150 including a coating material / protective material winding roll 18 and a coating material / protective material guide roll 19. The manufacturing apparatus 100 also further includes a drive device (not shown) for driving each roll. The manufacturing apparatus 100 may also further include a control device (not shown) for controlling the drive of the manufacturing apparatus 100.

[0056] The conveying unit 110 is a conveying device that moves the base material 1 in a predetermined direction. In the example shown in Figure 1, the conveying unit 110 is a roll-to-roll conveying device that continuously unwinds the base material 1 wound in a roll shape. In the example shown in Figure 1, the conveying unit 110 moves the base material 1 in the X-axis direction (the direction of the white arrow in Figure 1) using a base material unwinding roll 2 that unwinds the base material 1 and a base material winding roll 3 that winds up the base material 1. In the base material winding roll 3, for example, the base material 1 is wound up together with the coating film 17. The conveying unit 110 is not particularly limited as long as it is a device that can convey the base material 1. The conveying unit 110 may be, for example, a conveyor-type conveying device that has a conveyor on which the base material 1 is placed and moved.

[0057] The covering material installation unit 120 is a device for installing a sheet-like covering material 4 so as to cover a portion of the surface 30 of the base material 1. The covering material installation unit 120, for example, uses a covering material unwinding roll 5 that supplies the covering material 4 by unwinding it to attach the covering material 4 to the surface 30 of the base material 1.

[0058] The cushioning material peeling unit 130 is a device that peels off the cushioning material 6, which has been previously attached to the covering material 4 to protect the surface of the covering material 4, from the covering material 4. The cushioning material peeling unit 130 recovers the cushioning material 6 by winding it up with a cushioning material winding roll 8 while guiding the position of the cushioning material 6 with a cushioning material guide roll 7.

[0059] The powder material supply unit 10 supplies powder material 9 onto the surface 30 of the substrate 1. In the example shown in Figure 1, the powder material supply unit 10 is a hopper. The hopper stores powder material 9 inside and supplies powder material 9 onto the surface 30 of the substrate 1. The powder material supply unit 10 is positioned upstream of the squeegee 11 in the direction of movement of the substrate 1. The powder material supply unit 10 is not particularly limited as long as it is a device capable of supplying powder material 9 onto the surface 30 of the substrate 1. The powder material supply unit 10 may be, for example, a feeder.

[0060] The squeegee 11 makes the thickness of the powder material 9 supplied onto the surface 30 of the substrate 1 uniform. The powder material 9 becomes powder material 12 with adjusted thickness after passing through the squeegee 11. The squeegee 11 may adjust at least one of the basis weight and packing density of the powder material 9 supplied onto the surface 30 of the substrate 1. The squeegee 11 is a columnar structure extending in the Y-axis direction. The squeegee 11 may be configured to vibrate. The squeegee 11 is positioned, for example, above the substrate 1, so as to form a predetermined gap between it and the substrate 1. The squeegee 11 may also be installed so that the gap with the substrate 1 is adjustable.

[0061] The protective material installation unit 140 is a device for installing a sheet-like protective material 13 so as to cover the powder material 12 and the coating material 4. The protective material installation unit 140 supplies the protective material 13 to cover the surface of the powder material 12 after it has passed through the squeegee 11 by unwinding the protective material 13 using, for example, a protective material unwinding roll 14. A protective material guide roll 15 guides the protective material 13 and assists in aligning the protective material 13.

[0062] The compression unit 16 is a device that compresses the powder material 12 after it has passed through the squeegee 11 via the protective material 13. The compression unit 16 compresses the powder material 12 to form a coating film 17. In the example shown in Figure 1, the compression unit 16 is a roll press machine that compresses the powder material 12 via the protective material 13 and the base material 1. The compression unit 16 can be any compression device that is appropriate for the manufacturing method of the coating film 17. The compression unit 16 may be, for example, a flat plate press machine.

[0063] The recovery unit 150 is a device that recovers the coating material 4 and protective material 13 together after the powder material 12 has been compressed. The recovery unit 150 recovers the coating material 4 and protective material 13 by, for example, guiding them with a guide roll 19 for the coating material and protective material, and then winding them together with a winding roll 18 for the coating material and protective material.

[0064] As will be explained in detail later, when the powder material 12 is compressed, the excess portion of the coating film 17 is trapped between the coating material 4 and the protective material 13. The recovery unit 150 recovers the coating material 4 and the protective material 13 together, thereby recovering the coating material 4 and the protective material 13 while maintaining their relative positions. As a result, the excess portion is also recovered sandwiched between the coating material 4 and the protective material 13. Consequently, when the excess portion is removed, spillage onto the coating film 17 is suppressed, and a deterioration in the quality of the coating film 17 is suppressed. In addition, although the powder material 12 is spread out by the compression unit 16, the coating film 17 is not formed in the area of ​​the surface 30 of the base material 1 that was covered by the coating material 4, so the coating material 4 can form a coating film 17 of the desired shape.

[0065] [Method for Manufacturing the Coating Film] Next, a method for manufacturing the coating film 17 according to this embodiment will be described. Below, an example of manufacturing the coating film 17 using the above-described coating film manufacturing apparatus 100 will be described, but the apparatus and equipment for manufacturing the coating film 17 by the following manufacturing method are not particularly limited.

[0066] Figure 2 is a flowchart illustrating the method for manufacturing the coating film 17 according to this embodiment. Figures 3 to 9 are cross-sectional views illustrating the method for manufacturing the coating film 17 according to this embodiment. Figure 3 shows a cross-section at the position indicated by line III-III in Figure 1. Figure 4 shows a cross-section at the position indicated by line IV-IV in Figure 1. Figure 5 shows a cross-section at the position indicated by line V-V in Figure 1. Figure 6 shows a cross-section at the position indicated by line VI-VI in Figure 1. Figure 7 shows a cross-section at the position indicated by line VII-VII in Figure 1. Figure 8 shows a cross-section at the position indicated by line VIII-VIII in Figure 1. Figure 9 shows a cross-section at the position indicated by line IX-IX in Figure 1. Note that in Figure 9, the lengths in the Z-axis direction of the coating material 4, protective material 13, and excess portion 21 are shown in a shortened manner.

[0067] First, in the method for manufacturing the coating film 17, as shown in Figures 1 and 2, the transport unit 110 moves the sheet-like substrate 1 in the X-axis direction (step S11). Subsequent steps of the method for manufacturing the coating film 17 (steps S12 to S18) are performed while moving the substrate 1 in the X-axis direction. The substrate 1 is strip-shaped with the Y-axis direction as the width direction in a plan view. The width direction is the short-side direction of the substrate 1. The long-side direction of the substrate 1 is the X-axis direction, which is perpendicular to the width direction. Therefore, the substrate 1 is moved in the long-side direction of the substrate 1. The substrate 1 is made of, for example, metal or resin. In addition to the main body made of metal or resin, the substrate 1 may also have a film on its surface 30 made of a different material from the main body, such as a coating film or a plating film.

[0068] As will be described later, if the coating 17 is the positive electrode mixture layer or the negative electrode mixture layer of the battery, the substrate 1 may be a current collector such as metal foil. Also, as will be described later, if the coating 17 is the solid electrolyte layer of the battery, the substrate 1 may be an electrode plate in which the positive electrode mixture layer or the negative electrode mixture layer is laminated onto a current collector. Furthermore, the substrate 1 may be a resin support film that temporarily supports the coating 17 in order to transfer it.

[0069] Next, in the method for manufacturing the coating film 17, as shown in Figures 1, 2, and 3, the coating material installation section 120 covers a portion of the surface 30 of the base material 1 with the coating material 4 (step S12). This prepares a base material 1 in which a portion of the surface 30 is covered with the coating material 4. On the surface 30, the coating material 4 is in the form of a sheet with the Z-axis direction as the thickness direction. The coating material 4 is also, for example, a long length extending in the X-axis direction. Alternatively, instead of step S12, a base material 1 in which a portion of the surface 30 is covered with the coating material 4 may be prepared in advance.

[0070] The covering material 4 has an end face 40 extending in the X-axis direction in a plan view, and a first face 41 on the opposite side from the base material 1 and connected to the end face 40. In the examples shown in Figures 1 and 3, in step S12, a portion of the surface 30 of the base material 1 is covered with the covering material 4, whose first face 41 is covered with the cushioning material 6. The end face 40 is the end face of the covering material 4 in a direction perpendicular to the thickness direction of the sheet-like covering material 4 (in the example shown in Figure 3, the Y-axis direction). The end face 40 is, for example, perpendicular to the surface 30 of the base material 1.

[0071] Furthermore, in the example shown in Figure 3, in step S12, the covering material installation section 120 installs two covering materials 4 spaced apart from each other at both ends of the surface 30 of the base material 1 in the Y-axis direction, such that their end faces 40 face each other. Therefore, the end face 40 is the surface of each covering material 4 that is between the two covering materials 4. The two covering materials 4 are spaced apart from each other and arranged in the Y-axis direction on the surface 30 of the base material 1. At least one of the two covering materials 4 may be installed away from the end of the surface 30 of the base material 1 in the Y-axis direction. Also, there may be only one covering material 4 installed on the surface 30 of the base material 1, and only one end of the surface 30 of the base material 1 in the Y-axis direction may be covered by the covering material 4.

[0072] The covering material 4 is, for example, a tape made of metal or resin, and has an adhesive strength that allows it to be peeled off from the surface 30 of the base material 1.

[0073] The cushioning material 6 covers the first surface 41 of the covering material 4 from above, protecting the first surface 41. The cushioning material 6 is made of a material softer than the covering material 4. The material constituting the cushioning material 6 is, for example, resin or rubber. The Young's modulus of the cushioning material 6 is lower than, for example, the Young's modulus of the covering material 4. In the example shown in Figure 3, the entire first surface 41 of the covering material 4 is covered with the cushioning material 6. The width of the cushioning material 6 is the same as the width of the covering material 4, but it may be smaller or larger than the width of the covering material 4.

[0074] Next, in the method for manufacturing the coating film 17, as shown in Figures 1, 2, and 4, the cushioning material peeling unit 130 peels the cushioning material 6 from the first surface 41 and recovers the cushioning material 6 (step S13). Then, as shown in Figures 1, 2, and 5, the powder material supply unit 10 supplies the powder material 9 onto the surface 30 of the base material 1 along the end face 40 of the coating material 4 (step S14). Note that step S14 may be performed before step S13.

[0075] In the example shown in Figure 5, the powder material supply unit 10 supplies the powder material 9 onto the surface 30 of the base material 1 between the two coating materials 4. The supplied powder material 9 is in contact with the end faces 40 of the two coating materials 4 and the surface 30 of the base material 1. By supplying the powder material 9 between the two coating materials 4, it is possible to suppress the powder material 9 from flowing and spreading on the surface 30 in the width direction of the base material 1. In Figure 5, the powder material 9 is supplied so as not to be placed on the first surface 41, but it may also be supplied on the first surface 41.

[0076] The powder material 9 includes a powder composed of at least one type of particulate material. The median diameter (D50) of the particles of the powder material 9 is, for example, 0.005 μm or more and 50 μm or less. Furthermore, the powder material 9 is composed substantially of solid materials, excluding, for example, liquid components that are inevitably mixed in. The liquid component content in the powder material 9 is, for example, 50 ppm or less.

[0077] Next, in the method for manufacturing the coating film 17, as shown in Figures 1, 2, and 6, the squeegee 11 adjusts the thickness of the powder material 9 supplied onto the surface 30 of the substrate 1 (step S15). As a result, the powder material 9 becomes powder material 12 with an adjusted thickness after passing through the squeegee 11.

[0078] Next, in the method for manufacturing the coating film 17, as shown in Figures 1, 2, and 7, the protective material installation section 140 covers the powder material 12 and the coating material 4 with the protective material 13 from above (step S16). The powder material 12 and the two coating materials 4 are covered by the protective material 13 in their entirety in the Y-axis direction, for example, in a plan view.

[0079] In the example shown in Figure 7, the protective material 13 is in sheet form and covers the powder material 12 with the Z-axis direction being the thickness direction. The protective material 13 is also elongated and extends in the X-axis direction. The protective material 13 is made of resin or metal. The width W1 of the protective material 13, which is the dimension in the Y-axis direction, is, for example, greater than or equal to the width W2 of the base material 1, which is the dimension in the Y-axis direction. This allows the two coating materials 4 and the powder material 12 on the surface 30 of the base material 1 to be completely covered by the protective material 13. In the example shown in Figure 7, the width W1 of the protective material 13 is the same as the width W2 of the base material 1.

[0080] Next, in the manufacturing method of the coating film 17, as shown in Figures 1, 2, and 8, the compression section 16 compresses the powder material 12 via the protective material 13 to form the coating film 17 (step S17). At this time, as the powder material 12 is compressed and spread out, an excess portion 21 of the coating film 17 is created between the coating material 4 and the protective material 13. In step S17, the protective material 13 is compressed by the compression section 16 in its entirety in the Y-axis direction, for example. Furthermore, the dimensions of the coating film 17 in the Y-axis direction are defined by the end faces 40 of the two coating materials 4. In other words, the distance between the end faces 40 of the two coating materials 4 becomes the dimension of the coating film 17 in the Y-axis direction.

[0081] Finally, in the method for manufacturing the coating film 17, as shown in Figures 1, 2, and 9, the recovery unit 150 recovers the coating material 4 and the protective material 13 together (step S18). At this time, the two coating materials 4 are peeled off from the surface 30 of the substrate 1 while maintaining their positional relationship with the protective material 13. As a result, the excess portion 21 of the coating film 17 is sandwiched between the coating material 4 and the protective material 13 and recovered together with the coating material 4 and the protective material 13. As a result, the shape of the coating film 17 becomes the shape of the area on the surface 30 of the substrate 1 that was not covered by the two coating materials 4, and the coating film 17 can be formed into the desired shape by the two coating materials 4. In addition, since the excess portion 21 of the coating film 17 is sandwiched between the coating material 4 and the protective material 13 and recovered, spillage of the excess portion 21 onto the coating film 17 is suppressed, and a deterioration in the quality of the coating film 17 can be suppressed.

[0082] The coating film 17 is a powder coating film, and is, for example, a positive electrode mixture layer, a negative electrode mixture layer, or a solid electrolyte layer in an energy device such as an all-solid-state battery.

[0083] If the coating film 17 is a positive electrode mixture layer, the powder material 9 used to form the coating film 17 includes, for example, a positive electrode active material and an ion-conducting solid electrolyte. If the coating film 17 is a negative electrode mixture layer, the powder material 9 used to form the coating film 17 includes, for example, a negative electrode active material and an ion-conducting solid electrolyte. If the coating film 17 is a solid electrolyte layer, the powder material 9 used to form the coating film 17 includes an ion-conducting solid electrolyte.

[0084] Here, we will describe the details of the materials used in the positive electrode mixture layer, the negative electrode mixture layer, and the solid electrolyte layer.

[0085] The positive electrode active material is a material in which metal ions such as lithium (Li) are inserted into or removed from its crystal structure at a higher potential than the negative electrode, and oxidation or reduction occurs in conjunction with the insertion or removal of these metal ions. The type of positive electrode active material is appropriately selected according to the type of all-solid-state battery, and examples include oxide active materials and sulfide active materials.

[0086] For example, an oxide active material (lithium-containing transition metal oxide) is used as the positive electrode active material. ２ LiNiO２ , LiMn ２ O ４ , LiCoPO ４ , LiNiPO ４ , LiFePO ４ , LiMnPO ４ and compounds obtained by substituting the transition metals of these compounds with one or two different elements, etc. are included. Examples of compounds obtained by substituting the transition metals of the above compounds with one or two different elements include LiNi １／３ Co １／３ Mn １／３ O ２ , LiNi ０．８ Co ０．１５ Al ０．０５ O ２ , LiNi ０．５ Mn １．５ O ２ etc. Known materials are used. The positive electrode active material may be used alone or in combination of two or more kinds.

[0087] The negative electrode active material is a substance in which metal ions such as lithium are inserted or removed into or from the crystal structure at a potential lower than that of the positive electrode, and oxidation or reduction occurs with the insertion or removal of metal ions such as lithium.

[0088] Examples of the negative electrode active material include easily alloying metals with lithium such as lithium, indium, tin, and silicon, carbon materials such as hard carbon and graphite, and oxides such as Li ４ Ti ５ O １２ , SiO ｘ etc. Known materials such as oxide active materials are used. In addition, as the negative electrode active material, a composite obtained by appropriately mixing the above-mentioned negative electrode active materials may also be used.

[0089] The solid electrolyte may be appropriately selected according to the conduction ion species (for example, lithium ions). Examples of the solid electrolyte include sulfide-based solid electrolytes, oxide-based solid electrolytes, and halide-based solid electrolytes.

[0090] Examples of the sulfide-based solid electrolyte include, for example, Li ２ S - SiS ２ , LiI - Li ２S-SiS ２ LiI-Li ２ S-P ２ S ５ LiI-Li ２ S-P ２ O ５ LiI-Li ３ PO ４ -P ２ S ５ and Li ２ S-P ２ S ５ Examples include the above. In particular, from the viewpoint of excellent lithium ion conductivity, the sulfide-based solid electrolyte may contain Li, P, and S. The sulfide-based solid electrolyte may be used alone or in combination of two or more types. Furthermore, the sulfide-based solid electrolyte may be crystalline, amorphous, or glass ceramic. Note that the above "Li ２ S-P ２ S ５ The description of " is Li ２ S and P ２ S ５ This refers to a sulfide-based solid electrolyte using a raw material composition that includes [specific ingredient], and the same applies to other descriptions.

[0091] Examples of oxide-based solid electrolytes include LiPON and Li ３ PO ４ Li ２ SiO ２ Li ２ SiO ４ Li ０．５ La ０．５ TiO ３ Li １．３ Al ０．３ Ti ０．７ (PO ４ ) ３ La ０．５１ Li ０．３４ TiO ０．７４ Li １．５ Al ０．５ Ge １．５ (PO ４ ) ３ Examples include the following. The oxide-based solid electrolyte may be used individually or in combination of two or more types.

[0092] Furthermore, the coating 17 is not limited to its use in energy devices such as all-solid-state batteries; by selecting the powder material 9, it can be used in a variety of applications. For example, the coating 17 may be used as the dielectric layer of a capacitor.

[0093] [Coating Material] Next, the details of the coating material 4 used in the manufacture of the coating film 17 according to this embodiment will be described.

[0094] Figure 10 is a cross-sectional view illustrating the details of the coating material 4. Figure 10 shows a magnified view of the vicinity of one of the coating materials 4 in Figure 8. Therefore, Figure 10 shows the state after the coating film 17 has been formed by the compression of the powder material 12 in step S17.

[0095] As shown in Figure 10, the coating material 4 has a structure in which the corner portion 20 formed by the end face 40 and the first surface 41 protrudes upward (away from the base material 1). More specifically, the first surface 41 includes a first region 51 which is a region that includes the end of the first surface 41 on the end face 40 side and approaches the base material 1 as it moves away from the end face 40, so that the acute-angled corner portion 20 protrudes upward. The corner portion 20 can also be said to be the upper end of the end face 40 (the end of the end face 40 opposite to the base material 1 side). As a result, the corner portion 20 of the coating material 4 creates a cut between the coating film 17 that should be left on the surface 30 of the base material 1 and the excess portion 21 of the coating film 17. Therefore, when the coating material 4 and the protective material 13 are collected together in step S18, the coating film 17 and the excess portion 21 of the coating film 17 are easily separated. As a result, damage to the coating 17 and a decrease in dimensional accuracy caused by the collection of a portion of the coating 17 that should remain on the surface 30 of the substrate 1 together with the excess portion 21 can be suppressed. In addition, the generation of chips from the coating 17 can be suppressed when the excess portion 21 is collected, and the adhesion of chips to the coating 17 can be suppressed. Therefore, by using a coating material 4 having a first surface 41 including the first region 51, the quality of the coating 17 can be further improved. Note that the corner portion 20 may have a shape as if it has been rounded or chamfered. The expression "shape as if it has been rounded or chamfered" here is a description of the shape and does not mean that chamfering has actually been performed.

[0096] The corners 20 can be formed by processing the coating material 4. If the coating material 4 contains metal, for example, the coating material 4 is rolled so that the corners 20 are formed. If the coating material 4 contains resin, the coating material 4 is formed by molding so that the corners 20 are formed. Alternatively, the portion including the corners 20 may be formed separately and joined to the flat surface of the coating material 4.

[0097] As shown in Figure 10, the first region 51 in the coating material 4 is a planar region. That is, the first region 51 is a plane that is inclined to approach the base material 1 as it moves away from the end face 40. The angle θ that the first region 51 makes with respect to the end face 40 is not particularly limited, but for example, it is 30° or more and 60° or less. This suppresses damage to the corner 20, while making it easier for the coating film 17 and the excess portion 21 of the coating film 17 to be separated by the corner 20. The angle θ may also be 30° or more and 45° or less. This makes it even easier for the coating film 17 and the excess portion 21 of the coating film 17 to be separated by the corner 20. The angle θ may also be 45° or more and 60° or less. This further suppresses damage to the corner 20. The angle θ may also be 45°. Note that the first region 51 may include a plurality of planes with different inclinations. If the first region 51 includes multiple planes, the angle θ is the angle at the corner 20, that is, the angle between the plane closest to the end face 40 among the multiple planes of the first region 51 and the end face 40. Furthermore, the first region 51 may have a curved portion as long as the portion closest to the end face 40 is a plane.

[0098] Furthermore, the first surface 41 is a second region 52 located on the opposite side of the end face 40 of the first region 51, and further includes a second region 52 parallel to the surface 30 of the base material 1. This makes it easier for the excess portion 21 of the coating film 17 to be sandwiched between the coating material 4 and the protective material 13. In the example shown in Figure 10, the second region 52 is adjacent to the first region 51 and extends to the end of the first surface 41 on the opposite side of the end face 40. Also, the second region 52 is closer to the base material 1 than the first region 51.

[0099] The maximum distance t1 between the first region 51 and the substrate 1 in the thickness direction of the coating film 17 is, for example, 60% to 80% of the thickness T of the coating film 17. This suppresses damage to the corners 20 due to the pressure when the powder material 12 is compressed, while making it easier for the coating film 17 and the excess portion 21 of the coating film 17 to be separated by the corners 20. The distance t1 may also be 70% of the thickness T of the coating film 17. In the example shown in Figure 10, the distance t1 can also be said to be the height of the corner 20 from the surface 30 of the substrate 1. In other words, in the example shown in Figure 10, the corner 20 is the part of the coating material 4 furthest from the substrate 1.

[0100] The minimum distance t2 between the first surface 41 and the substrate 1 in the thickness direction of the coating film 17 is, for example, less than 50% of the thickness T of the coating film 17. This prevents the coating material 4 from interfering with the compression of the powder material 12, which would result in insufficient compression of the coating film 17. In the example shown in Figure 10, distance t2 is the distance between the substrate 1 and the second region 52. There is no particular lower limit to distance t2, but distance t2 is, for example, 0.1 μm or more.

[0101] The thickness T of the coating film 17 can be adjusted by, for example, the amount of powder material 9 supplied by the powder material supply unit 10, the height and filling rate of the powder material 12 after passing through the squeegee 11, and the compression pressure by the compression unit 16. For example, the thickness T of the coating film 17 can be confirmed in advance by forming the coating film 17 experimentally and used in the design of the dimensions of the coating material 4.

[0102] [Modified Forms of Coating and Protective Materials] Next, modified forms of coating and protective materials used in the manufacture of the coating film 17 will be described. In the following descriptions of modified forms of coating and protective materials, the differences from the above-mentioned coating 4 and protective material 13 will be the main focus, and the explanation of commonalities will be omitted or simplified.

[0103] First, a first modified example of the coating material will be described. Figure 11 is a cross-sectional view illustrating the first modified example of the coating material. In Figure 11, as with Figure 10 above, the state after the coating film 17 is formed by the compression of the powder material 12 in step S17 is shown. This is also the case in the cross-sectional views of other modified examples shown later.

[0104] The coating material 4A shown in Figure 11 differs from the coating material 4 mainly in that it has a first surface 41A including the first region 51A instead of a first surface 41 including the first region 51 and the second region 52.

[0105] The first surface 41A of the coating material 4A is a first region 51A, which is a region that approaches the base material 1 as it moves away from the end surface 40. This makes the corners 20 less susceptible to damage. Furthermore, the coating material 4A can be easily formed by simply processing the entire first surface 41 so that it becomes the first region 51A. In the example shown in Figure 11, the first region 51A is formed such that the end of the coating material 4A opposite to the end surface 40 has a predetermined thickness. Alternatively, the first region 51A may be formed such that the thickness of the end of the coating material 4A opposite to the end surface 40 is substantially zero.

[0106] Next, a second modified example of the covering material will be described. Figure 12 is a cross-sectional view illustrating the second modified example of the covering material.

[0107] The coating material 4B shown in Figure 12 differs from the coating material 4 mainly in that it has a first surface 41B that includes a first region 51B and a second region 52, instead of a first surface 41 that includes a first region 51 and a second region 52.

[0108] The first region 51B differs from the first region 51 described above in that it is a curved surface region rather than a planar region. This makes it easy to form the first region 51B. In particular, when the coating material 4B contains metal, the rolling process of the coating material 4B becomes easier. In the example shown in Figure 12, the first region 51B is a curved surface region where the base material 1 side is concave.

[0109] Next, a third modified example of the covering material will be described. Figure 13 is a cross-sectional view illustrating the third modified example of the covering material.

[0110] The coating material 4C shown in Figure 13 differs from the coating material 4 mainly in that it has a first surface 41C that includes the first region 51, the second region 52, and the third region 53, instead of a first surface 41 that includes the first region 51 and the second region 52.

[0111] The third region 53 is located on the opposite side of the end face 40 from the first region 51 and the second region 52, and is a region that moves away from the base material 1 as it moves away from the end face 40. This prevents the powder material 12 from spilling off the base material 1 when it is compressed after passing through the squeegee 11. In addition, the excess portion 21 of the coating film 17 can be wrapped by the covering material 4C and the protective material 13, further preventing the excess portion 21 of the coating film 17 from spilling onto the coating film 17. In the example shown in Figure 13, the third region 53 is a region that includes the end of the first surface 41C on the opposite side of the end face 40. Note that the covering material 4C may not include the second region 52, and the first region 51 and the third region 53 may be adjacent to each other. Also, in the example shown in Figure 13, the third region 53 is a planar region, but it may be a curved region or a region that includes both a planar and a curved surface.

[0112] Next, a fourth modified example of the covering material will be described. Figure 14 is a cross-sectional view illustrating the fourth modified example of the covering material.

[0113] The coating material 4D shown in Figure 14 differs from the coating material 4 mainly in that it includes a roughened portion 22.

[0114] The coating material 4D has a first surface 41D which includes a roughened portion 22. On the first surface 41D, the roughened portion 22 is located in a second region 52. In the example shown in Figure 14, the entire second region 52 is roughened. The roughened portion 22 increases the frictional force between the excess portion 21 of the coating film 17 and the first surface 41D, further suppressing the excess portion 21 of the coating film 17 from spilling onto the coating film 17. Also, in the example shown in Figure 14, the first region 51 on the first surface 41D is not roughened. This makes it easier for the excess portion 21 of the coating film 17 to flow between the coating material 4D and the protective material 13. Depending on the characteristics of the powder material 9 used to form the coating film 17, the first region 51 may also be roughened.

[0115] The surface roughening process is carried out, for example, by rubbing the first surface 41D with a file. The roughened portion 22 has a greater surface roughness than the unroughened portion of the coating material 4D.

[0116] Furthermore, the characteristics of each modified example of the coating material described above can be combined in any way. For example, the first surface of the coating material 4A, 4B, or 4C may be roughened. Also, for example, the first region of the coating material 4A, 4C, or 4D may be curved.

[0117] Next, a first modified example of the protective material will be described. Figure 15 is a cross-sectional view illustrating the first modified example of the protective material.

[0118] The protective material 13A shown in Figure 15 differs from the protective material 13 mainly in that it includes a roughened portion 23.

[0119] The protective material 13A has a second surface 42 which includes a roughened portion 23. The roughened portion 23 is located in the region of the second surface 42 that faces the coating material 4. In the example shown in Figure 15, the entire region of the second surface 42 that faces the coating material 4 is roughened. The roughened portion 23 increases the frictional force between the excess portion 21 of the coating film 17 and the second surface 42, further suppressing the excess portion 21 of the coating film 17 from spilling onto the coating film 17. Also, in the example shown in Figure 15, the region of the second surface 42 that does not face the coating material 4 is not roughened. This makes it easier for the excess portion 21 of the coating film 17 to flow between the coating material 4 and the protective material 13A. Depending on the characteristics of the powder material 9 used to form the coating film 17, the region of the second surface 42 that does not face the coating material 4 may also be roughened.

[0120] The surface roughening process is carried out, for example, by rubbing the second surface 42 with a file. The roughened portion 23 has a greater surface roughness than the unroughened portion of the protective material 13A.

[0121] In the example shown in Figure 15, the coating material 4 was used to manufacture the coating film 17 using the protective material 13A. However, the method is not limited to this, and the above-mentioned coating materials 4A, 4B, 4C, or 4D may be used instead of the coating material 4. An example of this case is shown in Figure 16. Figure 16 is a cross-sectional view showing the case in which the protective material 13A and the coating material 4D are used to manufacture the coating film 17 according to this embodiment. As shown in Figure 16, the coating film 17 may also be manufactured using the coating material 4D and the protective material 13A. This further suppresses the spillage of excess portions 21 of the coating film 17 onto the coating film 17.

[0122] (Other Embodiments) The methods and apparatus for manufacturing coating films according to the present disclosure have been described above based on embodiments, but the present disclosure is not limited to these embodiments. Without departing from the spirit of the present disclosure, various modifications to the embodiments that a person skilled in the art could conceive, and other forms constructed by combining some of the components of the embodiments are also included in the scope of the present disclosure.

[0123] For example, in the above embodiment, the substrate was in the form of a sheet, but it is not limited to this. The substrate may be in the form of a block, for example.

[0124] Furthermore, for example, in the above embodiment, the first surface of the coating material had a first region, but it is not limited to this. The first surface of the coating material may be, for example, an entire region parallel to the surface of the substrate, such as a second region.

[0125] Furthermore, in the above embodiment, for example, the thickness of the powder material supplied onto the surface of the substrate was adjusted by a squeegee, but this is not limited to this. The thickness of the powder material supplied onto the surface of the substrate does not need to be adjusted. Also, the thickness of the powder material supplied onto the surface of the substrate may be adjusted by a thickness adjuster other than a squeegee.

[0126] The coating film manufacturing apparatus and manufacturing method described herein can be used to form various coating films, such as the composite layer of an all-solid-state battery.

[0127] 1 Base material 2 Base material unwinding roll 3 Base material winding roll 4, 4A, 4B, 4C, 4D Coating material 5 Coating material unwinding roll 6 Cushioning material 7 Cushioning material guide roll 8 Cushioning material winding roll 9, 12 Powder material 10 Powder material supply section 11 Squeegee 13, 13A Protective material 14 Protective material unwinding roll 15 Protective material guide roll 16 Compression section 17 Coating film 18 Coating material / protective material winding roll 19 Coating material / protective material guide roll 20 Corner section 21 Excess portion 22, 23 Roughened portion 30 Surface 40 End face 41, 41A, 41B, 41C, 41D First surface 42 Second surface 51, 51A, 51B First region 52 Second region 53 Third Area 100 Manufacturing Equipment 110 Conveying Section 120 Covering Material Installation Section 130 Cushioning Material Removal Section 140 Protective Material Installation Section 150 Recovery Section

Claims

1. A method for manufacturing a coating film, comprising: preparing a substrate in which a portion of the surface is covered with a sheet-like covering material having end faces extending in a first direction in a plan view with respect to the surface of the substrate; supplying a powder material onto the surface of the substrate along the end faces of the covering material; covering the powder material and the covering material with a protective material; compressing the powder material through the protective material to form a coating film; and recovering the covering material and the protective material together after the powder material has been compressed.

2. The method for manufacturing a coating film according to claim 1, wherein the coating material has a first surface which is the surface opposite to the substrate side and is connected to the end surface, and the first surface includes a first region which is a region that includes the end of the first surface on the end surface side and approaches the substrate as it moves away from the end surface.

3. The method for manufacturing a coating film according to claim 2, wherein the angle formed by the first region with respect to the end face is 30° or more and 60° or less.

4. The method for manufacturing a coating film according to claim 3, wherein the angle formed by the first region with respect to the end face is 45°.

5. The method for manufacturing a coating film according to claim 2, wherein the maximum distance between the first region and the substrate in the thickness direction of the coating film is 60% or more and 80% or less of the thickness of the coating film.

6. The method for manufacturing a coating film according to claim 2, further comprising peeling off the cushioning material covering the first surface from the first surface before covering it with the protective material.

7. The method for manufacturing a coating film according to claim 2, wherein the first surface is a second region located on the opposite side from the end face side of the first region, and includes a second region parallel to the surface of the substrate.

8. The method for manufacturing a coating film according to claim 7, wherein the first surface includes a roughened portion located in the second region, and the first region is not roughened.

9. The method for manufacturing a coating film according to any one of claims 1 to 8, wherein the end face of the coating material is perpendicular to the surface of the substrate.

10. The method for manufacturing a coating film according to any one of claims 1 to 8, wherein the coating material has a first surface which is the surface opposite to the substrate side and which is connected to the end surface, and the minimum distance between the first surface and the substrate in the thickness direction of the coating film is less than 50% of the thickness of the coating film.

11. The method for manufacturing a coating film according to any one of claims 1 to 8, wherein the coating material has a first surface which is the surface opposite to the substrate side and which is connected to the end surface, and the first surface includes a portion that has been roughened.

12. The method for manufacturing a coating film according to any one of claims 1 to 8, wherein the dimension of the protective material in the second direction perpendicular to the first direction in the plan view is greater than or equal to the dimension of the substrate in the second direction.

13. The method for manufacturing a coating film according to any one of claims 1 to 8, wherein the protective material has a second surface which is the surface on the substrate side, and the second surface includes a roughened portion located in the region of the second surface that faces the coating material.

14. The method for manufacturing a coating film according to any one of claims 1 to 8, wherein by preparing the base material, a base material is prepared in which a portion of the surface is covered by two coating materials arranged spaced apart from each other so that their end faces face each other, and by supplying the powder material, the powder material is supplied onto the surface of the base material between the two coating materials.

15. The method for manufacturing a coating film according to any one of claims 1 to 8, wherein the substrate is in the shape of a strip with a width direction in a second direction perpendicular to the first direction in a plan view.

16. The method for manufacturing a coating film according to claim 15, wherein supplying the powder material, covering with the protective material, forming the coating film, and recovering the coating material and the protective material together are performed while moving the substrate in the first direction.

17. A coating film manufacturing apparatus comprising: a covering material installation unit for installing a sheet-like covering material having an end face extending in a first direction in a plan view with respect to the surface of a substrate so as to cover a portion of the surface of the substrate; a powder material supply unit for supplying powder material onto the surface of the substrate along the end face of the covering material; a protective material installation unit for installing a protective material so as to cover the powder material and the covering material; a compression unit for compressing the powder material through the protective material to form a coating film; and a recovery unit for recovering the covering material and the protective material together after the powder material has been compressed by the compression unit.

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