CN100584586C - 电子部件外壳用包装材料的制造方法及制造装置 - Google Patents

电子部件外壳用包装材料的制造方法及制造装置 Download PDF

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Publication number
CN100584586C
CN100584586C CN200680015095A CN200680015095A CN100584586C CN 100584586 C CN100584586 C CN 100584586C CN 200680015095 A CN200680015095 A CN 200680015095A CN 200680015095 A CN200680015095 A CN 200680015095A CN 100584586 C CN100584586 C CN 100584586C
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sheet
sheet material
bonding process
mentioned
electronic component
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CN101171120A (zh
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畑浩
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Lishennoco Packaging Co ltd
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Showa Denko Packaging Co Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/76—Making non-permanent or releasable joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/40—Applying molten plastics, e.g. hot melt
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • B29C66/9192—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams
    • B29C66/91921—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature
    • B29C66/91931—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature in explicit relation to the fusion temperature or melting point of the material of one of the parts to be joined
    • B29C66/91933—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature in explicit relation to the fusion temperature or melting point of the material of one of the parts to be joined higher than said fusion temperature
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
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    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/45—Joining of substantially the whole surface of the articles
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    • B29C66/72321—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered comprising a non-plastics layer consisting of metals or their alloys
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/737—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
    • B29C66/7371—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined oriented or heat-shrinkable
    • B29C66/73711—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined oriented or heat-shrinkable oriented
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/834—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract

本发明的制造方法，其特征在于，包含下述工序：将在热塑性树脂未拉伸薄膜层(4)的一面上层叠热塑性粘合树脂层(5)而形成的第1片材(1)、和在耐热性树脂拉伸薄膜层(6)的一面上层叠铝箔层(7)而形成的第2片材(2)，以所述热塑性粘合树脂层(5)和所述铝箔层(7)相接触的形态在一对辊(12)(13)之间通过，在所述热塑性粘合树脂不熔融的状态下进行加热、夹压，由此将所述第1片材(1)和所述第2片材(2)进行假粘合，得到预叠层片(3)的假粘合工序；和通过将所得到的预叠层片(3)加热、使所述热塑性粘合树脂熔融，从而将所述第1片材(1)和所述第2片材(2)进行粘合一体化的真正粘合工序。根据该制造方法，在可以抑制设备成本的同时，可以进行高速生产。

Description

电子部件外壳用包装材料的制造方法及制造装置
技术领域
本发明涉及例如锂离子二次电池和电容器等电子部件的外壳用包装材料的制造方法。
再者，本说明书中，“铝”的用语是以包含锂及其合金的意思来使用的。
背景技术
锂离子二次电池被广泛用作为例如笔记本电脑、摄像机、便携电话、电动车等的电源。作为该锂离子二次电池，可以使用利用外壳包围电池本体周围的结构的电池。作为这种外壳用包装材料，公知的有利用热粘合性树脂将热塑性树脂未拉伸薄膜和铝箔粘合而形成的材料，作为制造这种结构的包装材料的方法，已知有：将聚烯烃薄膜、改性聚烯烃树脂薄膜共挤出到所供给的热塑性树脂未拉伸薄膜与铝箔之间，将它们粘合一体化的方法(参照专利文献1)，或者，在铝箔的上面涂布以酸改性聚烯烃为固体成分的有机溶胶后，将该有机溶胶干燥使之形成粘合性皮膜，接着，将聚烯烃薄膜和上述粘合性皮膜进行压合的方法(参照专利文献2)。
专利文献1：特开2002-96419号公报(权利要求1，段落0017)
专利文献2：特开2000-67823号公报(权利要求1)
发明内容
然而，采用前者的通过共挤出来进行粘合一体化的方法时，需要多台的挤出机，而且还需要热层压机，因此存在这些设备成本极大的问题。即，存在制造成本增高的问题。
另外，采用后者的形成粘合性皮膜的方法时，为了形成粘合性皮膜需要使有机溶胶干燥的工序，因此存在生产速度慢的问题。
本发明是鉴于所述技术背景而完成的，其目的在于，提供可以抑制设备成本，同时可高速生产的电子部件外壳用包装材料的制造方法。
为了达到上述目的，本发明提供以下的方案。
[1]一种电子部件外壳用包装材料的制造方法，其特征在于，包含下述工序：
将在热塑性树脂未拉伸薄膜层的一面上层叠热塑性粘合树脂层而形成的第1片材、和在耐热性树脂拉伸薄膜层的一面上层叠铝箔层而形成的第2片材，以上述热塑性粘合树脂层和上述铝箔层相接触的形态在一对辊间通过，在上述热塑性粘合树脂不熔融的状态下进行加热、夹压，由此将上述第1片材和上述第2片材进行假粘合(暂时粘合)，得到预叠层片的假粘合工序；和
通过将所得到的预叠层片加热、使上述热塑性粘合树脂熔融，从而将上述第1片材和上述第2片材进行粘合一体化的真正粘合工序。
[2]如前项1所述的电子部件外壳用包装材料的制造方法，其中在上述假粘合工序中，作为上述一对辊，使用橡胶辊和加热辊。
[3]如前项1或2所述的电子部件外壳用包装材料的制造方法，其中在上述假粘合工序中，将上述热塑性粘合树脂的熔点(℃)记为“M”、将上述夹压时的热塑性粘合树脂的温度(℃)记为“T”时，满足下述关系式：(M-60)≤T≤(M-5)。
[4]如前项1～3的任一项所述的电子部件外壳用包装材料的制造方法，其中，在上述假粘合工序中，使通过在一对辊间进行夹压而将第1片材和第2片材进行假粘合而形成的片跟随冷却辊而进行冷却，得到预叠层片；在上述真正粘合工序中，使将第1片材和第2片材粘合一体化而形成的片跟随冷却辊而进行冷却。
[5]如前项4所述的电子部件外壳用包装材料的制造方法，其中，在上述假粘合工序和上述真正粘合工序中，将上述加热辊的温度(℃)记为“X”、将上述冷却辊的温度(℃)记为“Y”时，满足下述关系式：(X-80)≤Y≤(X-10)。
[6]如前项4或5所述的电子部件外壳用包装材料的制造方法，其中，在上述假粘合工序和上述真正粘合工序中，将上述加热辊的外周面的周向的移动速度记为“W”、将上述冷却辊的外周面的周向的移动速度记为“Z”时，满足下述关系式：1.01W≤Z≤1.30W。
[7]如前项1～6的任一项所述的电子部件外壳用包装材料的制造方法，其特征在于，作为上述热塑性树脂未拉伸薄膜，使用由选自聚乙烯、聚丙烯、烯烃系共聚物、它们的酸改性物及离聚物中的至少1种热塑性树脂形成的未拉伸薄膜，作为上述耐热性树脂拉伸薄膜，使用由聚酰胺或聚酯形成的拉伸薄膜。
[8]一种电子部件外壳用包装材料，是采用前项1～7的任一项所述的制造方法制造的。
[9]一种电子部件外壳，是将前项8所述的电子部件外壳用包装材料进行深拉成型(深絞り成形)或凸肚成型(張り出し成形)而形成的。
[10]一种电子部件外壳用包装材料的制造装置，其特征在于，包含具备由加热辊和橡胶辊构成的夹压部、和冷却辊的第1层压装置、和具备加热辊和冷却辊的第2层压装置。
[11]一种电子部件外壳用包装材料的制造装置，其特征在于，具备由加热辊和橡胶辊构成的夹压部、和冷却辊，并且构成为：上述加热辊和橡胶辊中的至少任一方辊可相对于另一方辊进行脱离移动。
发明效果
[1]的发明，由于通过在热塑性粘合树脂不熔融的状态(也包括表面发生部分熔融的状态)下进行加热、夹压，从而将第1片材和第2片材进行假粘合，因此可有效地防止空气残留在重合的热塑性粘合树脂层与铝箔层之间。即，可使热塑性粘合树脂层与铝箔层之间不存在气泡而将第1片材和第2片材进行假粘合。通过将这样假粘合的预叠层片进行加热、使热塑性粘合树脂熔融，可以将第1片材和第2片材进行真正粘合(粘合一体化)。可以这样地制造在重合面上没有气泡的包装材料。本制造方法由于不需要使粘合剂的溶剂干燥的干燥工序，因此可实现在高速下的生产。
此外，本发明中，在省略上述假粘合工序来实施上述真正粘合工序的场合，会在第1片材与第2片材的重合面上产生较多的气泡，因此不能制造高品质的包装材料。
[2]的发明，由于使第1片材和第2片材在橡胶辊与加热辊之间通过而进行夹压，因此可以更有效地防止空气残留在重合的热塑性粘合树脂层与铝箔层之间。
[3]的发明，由于将热塑性粘合树脂的熔点(℃)记为“M”、将夹压时的热塑性粘合树脂的温度(℃)记为“T”时，在满足关系式(M-60)≤T≤(M-5)的状态下进行制造，因此可以按某种程度的粘合强度假粘合成良好状态。
[4]的发明，由于使通过在一对辊间进行夹压而将第1片材和第2片材假粘合而成的片跟随冷却辊而进行冷却，得到预叠层片，因此可使其原样地保持良好的假粘合状态，另外，在真正粘合工序中，由于使将第1片材和第2片材粘合一体化而成的片跟随冷却辊而进行冷却，因此可使其原样地保持良好的真正粘合状态。
[5]的发明，由于将加热辊的温度(℃)记为“X”、将冷却辊的温度(℃)记为“Y”时，在满足关系式(X-80)≤Y≤(X-10)的状态下进行制造，因此可有效地防止假粘合工序及真正粘合工序中的膨胀折皱的发生。
[6]的发明，由于将加热辊外周面的周向的移动速度记为“W”、将冷却辊外周面的周向的移动速度记为“Z”时，在满足关系式1.01W≤Z≤1.30W的状态下进行制造，因此可有效地防止假粘合工序和真正粘合工序中的膨胀折皱的发生。
[7]的发明，由于作为耐热性树脂拉伸薄膜，使用由聚酰胺或聚酯形成的拉伸薄膜，因此可制造成型性优异的包装材料，与此同时，由于作为热塑性树脂未拉伸薄膜，使用选自聚乙烯、聚丙烯、烯烃系共聚物、它们的酸改性物及离聚物之中的至少1种热塑性树脂形成的未拉伸薄膜，因此可以制造热封性及耐电解液性、耐化学性均优异的包装材料。
[8]的发明，能提供在重合面上没有气泡的低成本的电子部件外壳用包装材料。
[9]的发明，能提供锐利(Sharp)并且成型高度深的形状的电子部件外壳。
[10]的发明，通过在第1层压装置中，在热塑性粘合树脂不熔融的状态(也包含表面发生部分熔融的状态)下加热、进行夹压，可以使热塑性粘合树脂层与铝箔层之间不存在气泡而将第1片材和第2片材进行假粘合，来制造预叠层片，通过在第二层压装置中，对预叠层片进行加热，以使热塑性粘合树脂熔融，从而可进行真正粘合，可以这样制造在重合面上没有气泡的包装材料。
[11]的发明的制造装置，由于1台该制造装置具有[10]的发明的第1层压装置及第2层压装置的功能，因此可以大幅度降低设备空间，可充分地谋求设备节省空间。
附图说明
图1是表示将第1片材和第2片材进行假粘合以制得预叠层片的工序的侧面图。
图2是表示对预叠层片进行加热，将第1片材和第2片材进行真正粘合的工序的侧面图。
图3是表示制造装置的一例的侧面图。
图4是表示采用本发明的制造方法制造的电子部件外壳用包装材料的截面图。
符号说明
1：第1片材、2：第2片材、3：预叠层片、4：热塑性树脂未拉伸薄膜层(内侧层)、5：热塑性粘合树脂层、6：耐热性树脂拉伸薄膜层(外侧层)、7：铝箔层、9：电子部件外壳用包装材料、10：制造装置、11：预热辊、12：加热辊、13：橡胶辊、14：冷却辊、20：制造装置、21：第1层压装置、22：第2层压装置
具体实施方式
参照附图对本发明的、电子部件外壳用包装材料的制造方法的优选例进行说明。本制造方法其特征在于，包含假粘合工序和真正粘合工序。
首先，对本制造方法中使用的制造装置(10)进行说明。该制造装置(10)如图1、2所示，具有预热辊(11)、和一对夹压辊部(12)，(13)及冷却辊(14)。本实施方式中，作为上述夹压辊部，使用了加热辊(12)及橡胶辊(13)。另外，上述橡胶辊(13)被构成为可相对于上述加热辊(12)进行脱离移动。即，在假粘合工序中，如图1所示，上述橡胶辊(13)被配置在与上述加热辊(12)接近的位置，可将片体在这些辊(12)、(13)之间进行夹压，另一方面，在真正粘合工序中，如图2所示，上述橡胶辊(13)被配置成与上述加热辊(12)离间的状态。
另外，在制造包装材料时，首先准备在热塑性树脂未拉伸薄膜层(4)的一面上层叠热塑性粘合树脂层(5)而形成的第1片材(1)、和在耐热性树脂拉伸薄膜层(6)的一面上层叠铝箔层(7)而形成的第2片材(2)。
如图1所示，在上述热塑性粘合树脂层(5)与上述铝箔层(7)重合、进行接触的形态下使上述第1片材(1)和上述第2片材(2)在加热辊(12)与橡胶辊(13)之间通过，在上述热塑性粘合树脂不熔融的状态下进行加热、夹压，由此将第1片材(1)和第2片材(2)进行假粘合(假粘合工序)。接着，通过使将上述第1片材(1)和第2片材(2)假粘合而形成的片跟随冷却辊(14)的外周面来进行缓冷，得到预叠层片(3)，并将其卷绕。
在上述热塑性粘合树脂不熔融的状态下的加热夹压，例如可通过在将上述热塑性粘合树脂加热到比该热塑性粘合树脂的熔点低的温度的状态下进行夹压来实现。此外，即使加热辊(12)的温度为比热塑性粘合树脂的熔点高的温度，在加热辊(12)及橡胶辊(13)的旋转速度快的场合，即在辊(12)、(13)之间的夹压时间短的场合，也可以实现在热塑性粘合树脂不熔融状态下的加热夹压。另外，上述“热塑性粘合树脂不熔融的状态”也包含热塑性粘合树脂层(5)的表面发生部分熔融的状态。即，即使在上述热塑性粘合树脂层(5)发生部分熔融的状态下进行加热夹压也不用担心该热塑性粘合树脂层(5)与橡胶辊(13)熔合。另外，在与橡胶辊(13)接触的第1片材(1)的热塑性树脂未拉伸薄膜层(4)有可能与橡胶辊(13)熔合的场合，也可以使PET等的剥离片介于该热塑性树脂未拉伸薄膜层(4)的表面上。
上述假粘合工序，通过在热塑性粘合树脂不熔融的状态(也包含表面发生部分熔融的状态)下进行加热、夹压而将第1片材(1)和第2片材(2)进行假粘合，因此可有效地防止空气残留在所重合的热塑性粘合树脂层(5)与铝箔层(7)之间。即，可以使热塑性粘合树脂层(5)与铝箔层(7)之间不存在气泡而将第1片材(1)和第2片材(2)进行假粘合。
使用上述辊进行夹压时，优选在满足如下那样的关系的状态下进行夹压。即，将热塑性粘合树脂的熔点(℃)记为“M”、将采用辊进行夹压时的热塑性粘合树脂的温度(℃)记为“T”时，优选满足下述关系式：
(M-60)≤T≤(M-5)
通过规定为上述下限值以上，可确保假粘合所需的粘合强度，与此同时，通过规定为上述上限值以下，可有效地防止热塑性粘合树脂熔融所致的空气残留状态下的粘合。其中，更优选满足(M-30)≤T≤(M-10)的关系式。
另外，将上述加热辊(12)的温度(℃)记为“X”、将上述冷却辊(14)的温度(℃)记为“Y”时，优选在下述关系式：
(X-80)≤Y≤(X-10)
成立的状态下进行冷却。通过在这样的状态下进行冷却，可有效地防止预叠层片(3)的膨胀折皱发生。其中，特别优选(X-50)≤Y≤(X-30)的关系式成立。
此外，将上述加热辊(12)的外周面的周向的移动速度记为“W”、将上述冷却辊(14)的外周面的周向的移动速度记为“Z”时，优选在满足下述关系式：
1.01W≤Z≤1.30W
的状态下实施。通过在这样的条件下进行实施，可有效地防止预叠层片(3)的膨胀折皱发生。其中，特别优选在1.1W≤Z≤1.15W的关系式成立的状态下实施。
此外，优选在上述假粘合工序中，上述预热辊(11)的温度设定在40～100℃。另外，优选上述加热辊(12)的温度被设定在100～180℃、上述冷却辊(14)的温度被设定在50～130℃。另外，优选上述加热辊(12)的外周面的周向的移动速度被设定在30～50m/分、上述冷却辊(14)的外周面的周向的移动速度被设定在35～70m/分。
接着，卸下上述所卷绕的预叠层片(3)，安放在上述制造装置(10)的附图左侧的供给轴上，同时使上述橡胶辊(13)向上方方向脱离移动，将该橡胶辊(13)配置成与加热辊(12)离间的状态(参照图2)。然后，通过使该预叠层片(3)跟随预热辊(11)来进行预加热后，通过接下来的与加热辊(12)的接触，将预叠层片(3)加热，使粘合树脂熔融，由此将上述第1片材(1)和上述第2片材(2)进行真正粘合(粘合一体化)(真正粘合工序)。该真正粘合工序不使用上述橡胶辊(13)。
接着，通过使上述经真正粘合的片跟随冷却辊(14)的外周面来缓冷后，将其卷绕。这样可制造如图4所示的电子部件外壳用包装材料(9)。
上述真正粘合工序中，将热塑性粘合树脂(5)的熔点(℃)记为“M”、将与加热辊(12)接触时的热塑性粘合树脂(5)的温度(℃)记为“U”时，优选满足下述关系式：
(M+10)≤U≤(M+60)
通过规定为上述下限值以上，可以以足够的粘合强度进行真正粘合，同时，通过规定为上述上限值以下，可以一边抑制能量成本一边制造。
另外，上述真正粘合工序中，将上述加热辊(12)的温度(℃)记为“X”、将上述冷却辊(14)的温度(℃)记为Y时，优选在下述关系式：
(X-80)≤Y≤(X-10)
成立的状态下进行冷却。通过在这样的状态下进行冷却，可有效地防止包装材料(9)的膨胀折皱发生。
此外，上述真正粘合工序中，将上述加热辊(12)的外周面的周向的移动速度记为“W”、将上述冷却辊(14)的外周面的周向的移动速度记为“Z”时，优选在满足下述关系式：
1.01W≤Z≤1.30W
的状态下实施。通过在这样的条件下实施，可有效地防止包装材料(9)的膨胀折皱发生。
再者，上述真正粘合工序中，优选上述预热辊(11)温度被设定在40～150℃。另外，优选上述加热辊(12)的温度被设定在180～220℃、上述冷却辊(14)的温度被设定在50～150℃。另外，优选上述加热辊(12)的外周面的周向的移动速度被设定在30～50m/分、上述冷却辊(14)的外周面的周向的移动速度被设定在35～70m/分。
上述举出的制造方法为使用相同的制造装置(10)实施假粘合工序和真正粘合工序的方法，但并不特别限定于这样的制造方法，例如也可以如图3所示，使用具有用于进行假粘合工序的第1层压装置(21)和用于进行真正粘合工序的第2层压装置(22)的制造装置(20)连续地进行假粘合工序和真正粘合工序而制造。此外，图3表示的制造装置中，上述第1层压装置(21)具有预热辊(11)和一对夹压辊部(12)、(13)、及冷却辊(14)，而上述第2层压装置(22)具有预热辊(11)和加热辊(12)及冷却辊(14)。
本发明中，上述耐热性树脂拉伸薄膜层(外侧层)(6)，是主要起确保包装材料良好成型性作用的部件，即是起防止由成型时铝箔的缩幅而引起的断裂的作用的。作为上述耐热性树脂拉伸薄膜(6)没有特殊限定，优选使用由聚酰胺或聚酯形成的拉伸薄膜。优选上述耐热性树脂拉伸薄膜层(6)的厚度被设定在12～50μm。
上述热塑性树脂未拉伸薄膜层(内侧层)(4)是相对于在锂离子二次电池等中使用的腐蚀性强的电解液等也具有优异的耐化学性，同时起着对包装材料赋予热封性的作用的层。作为上述热塑性树脂未拉伸薄膜(4)没有特殊限定，但优选使用由选自聚乙烯、聚丙烯、烯烃系共聚物、它们的的酸改性物及离聚物之中的至少一种热塑性树脂形成的未拉伸薄膜。优选上述热塑性树脂未拉伸薄膜层(4)的厚度被设定在20～80μm。通过规定为20μm以上，可充分防止针孔的发生，同时，通过设定在80μm以下，可降低树脂使用量，可谋求成本降低。其中，特别优选上述热塑性树脂未拉伸薄膜层(4)的厚度被设定在30～50μm。
此外，上述耐热性树脂拉伸薄膜层(6)、上述热塑性树脂未拉伸薄膜层(4)均可以是单层，也可以是多层。
上述铝箔层(7)是起着对包装材料赋予阻止氧和水份侵入的气体阻隔性的作用的层。作为铝箔(7)，可优选作用由纯Al或Al-Fe系合金构成的厚度5-50μm的箔。
作为上述热塑性粘合树脂(5)没有特殊限定，例如除了马来酸酐改性聚乙烯、马来酸酐改性聚丙烯等的酸改性聚烯烃以外，还可举出含有聚氨脂系树脂、丙烯酸系树脂、热塑性弹性体而形成的树脂等。优选上述热塑性粘合树脂层(5)的厚度被设定在10～40μm。这些热塑性粘合树脂层(5)，例如在上述热塑性树脂未拉伸薄膜层(4)的一面上层叠热塑性粘合树脂薄膜而形成。
通过将采用本发明的制造方法制造的电子部件外壳用包装材料(9)进行深拉成型或凸肚成型，可制得电子部件用外壳。并且，通过形成为使用上述电子部件用外壳包围锂离子二次电池等电池等的电子部件本体的结构，可得到电子部件。
实施例
以下，对本发明的具体实施例进行说明。
<实施例1>
(假粘合工序)
将在厚度35μm的聚丙烯薄膜(热塑性树脂未拉伸薄膜层)(4)的一面上层叠厚度15μm的马来酸酐改性聚丙烯薄膜(热塑性粘合树脂层)(5)而形成的第1片材(1)、和在厚度25μm的聚酰胺薄膜(耐热性树脂拉伸薄膜层)(6)的一面上层叠厚度40μm的铝箔(7)而形成的第2片材(2)，以马来酸酐改性聚丙烯薄膜(5)和铝箔(7)相接触的形态，在图1所示的制造装置(10)的加热辊(12)与橡胶辊(13)之间通过，进行夹压、假粘合后，通过跟随冷却辊(14)来进行缓冷，得到预叠层片(3)，并将其卷绕。
上述假粘合工序中，将预热辊(11)的温度设定在70℃，将加热辊(12)的温度设定在130℃，将冷却辊(14)的温度设定在80℃。马来酸酐改性聚丙烯薄膜的熔点是168℃。另外，加热辊(12)的外周面的周向的移动速度是36m/分，冷却辊(14)的外周面的周向的移动速度是40m/分。
(真正粘合工序)
接着，将上述卷绕的预叠层片(3)，如图2所示，安放在制造装置(10)的图左侧的供给轴上，同时使橡胶辊(13)向上方方向脱离移动。并且，如图2所示，通过使预叠层片(3)跟随预热辊(11)来进行预加热后，通过与后面的加热辊(12)接触使粘合树脂(马来酸酐改性聚丙烯)(5)熔融，将第1片材(1)和第2片材(2)真正粘合后，通过使被真正粘合的片跟随冷却辊(14)的外周面来进行缓冷，制造出如图4所示的电子部件外壳用包装材料(9)。
此外，该真正粘合工序中，将预热辊(11)的温度设定在100℃，将加热辊(12)的温度设定在200℃，将冷却辊(14)的温度设定在90℃。另外，加热辊(12)的外周面的周向的移动速度是36m/分，冷却辊(14)的外周面的周向的移动速度是40m/分。
<实施例2>
在假粘合工序中，将加热辊的温度设定在150℃，将冷却辊的温度设定在90℃，除此以外，与实施例1同样地制造出电子部件外壳用包装材料。
<实施例3、4>
除了设定成表1表示的条件以外，与实施例1同样地制造出电子部件外壳用包装材料。
<比较例1>
除了省略假接合工序以外，与实施例1同样地制造出包装材料(9)。
对上述制得的各包装材料，通过目视来调查有无气泡及有无折皱，评价包装材料的外观，将这些评价结果示于表1
由表1看出，采用本发明的制造方法制造的实施例1～4的电子部件外壳用包装材料，没有气泡而且基本没有折皱，外观良好。与此相对，省略了假粘合工序的比较例1，产生气泡，外观不良。
本申请要求在2005年5月2日申请的日本国专利申请特愿2005-133817号的优选权，其所公开内容原样地构成本申请的一部分。
这里所使用的用语及说明，是为了说明本发明所述的实施方式而使用的，但本发明并不限于此。本发明，如果在发明内容的范围内，只要不脱离该精神，则也容许任何的设计变更。
工业实用性
采用本发明的制造方法制造的电子部件外壳用包装材料，例如，可以作为锂离子二次电池和电容器等电子部件的外壳用包装材料使用。
本发明中表示数值范围的“以上”和“以下”均包括本数。

Claims (7)

1.一种电子部件外壳用包装材料的制造方法，其特征在于，包含下述工序：
将在热塑性树脂未拉伸薄膜层的一面上层叠热塑性粘合树脂层而形成的第1片材、和在耐热性树脂拉伸薄膜层的一面上层叠铝箔层而形成的第2片材，以所述热塑性粘合树脂层和所述铝箔层相接触的形态在一对辊间通过，在所述热塑性粘合树脂不熔融的状态下进行加热、夹压，由此将所述第1片材和所述第2片材进行假粘合，得到预叠层片的假粘合工序；和
通过将所得到的预叠层片加热、使所述热塑性粘合树脂熔融，从而将所述第1片材和所述第2片材进行粘合一体化的真正粘合工序。
2.如权利要求1所述的电子部件外壳用包装材料的制造方法，其中在所述假粘合工序中，作为所述一对辊，使用橡胶辊和加热辊。
3.如权利要求1所述的电子部件外壳用包装材料的制造方法，其中在所述假粘合工序中，将所述热塑性粘合树脂的熔点(℃)记为“M”、将所述夹压时的热塑性粘合树脂的温度(℃)记为“T”时，满足下述关系式：(M-60)≤T≤(M-5)。
4.如权利要求1所述的电子部件外壳用包装材料的制造方法，其中，在所述假粘合工序中，使通过在一对辊间进行夹压而将第1片材和第2片材假粘合而形成的片跟随冷却辊而进行冷却，得到预叠层片；在所述真正粘合工序中，使将第1片材和第2片材粘合一体化而形成的片跟随冷却辊而进行冷却。
5.如权利要求4所述的电子部件外壳用包装材料的制造方法，其中，在所述假粘合工序和所述真正粘合工序中，将所述加热辊的温度(℃)记为“X”、将所述冷却辊的温度(℃)记为“Y”时，满足下述关系式：(X-80)≤Y≤(X-10)。
6.如权利要求4所述的电子部件外壳用包装材料的制造方法，其中，在所述假粘合工序和所述真正粘合工序中，将所述加热辊的外周面的周向的移动速度记为“W”、将所述冷却辊的外周面的周向的移动速度记为“Z”时，满足下述关系式：1.01W≤Z≤1.30W。
7.如权利要求1所述的电子部件外壳用包装材料的制造方法，其特征在于，作为所述热塑性树脂未拉伸薄膜，使用由选自聚乙烯、聚丙烯、烯烃系共聚物、它们的酸改性物及离聚物中的至少1种热塑性树脂形成的未拉伸薄膜；作为所述耐热性树脂拉伸薄膜，使用由聚酰胺或聚酯形成的拉伸薄膜。
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