CN104054206A - 二次电池的制造方法、二次电池、熔接装置 - Google Patents

二次电池的制造方法、二次电池、熔接装置 Download PDF

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Publication number
CN104054206A
CN104054206A CN201380004985.9A CN201380004985A CN104054206A CN 104054206 A CN104054206 A CN 104054206A CN 201380004985 A CN201380004985 A CN 201380004985A CN 104054206 A CN104054206 A CN 104054206A
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Prior art keywords
refractory layer
barrier film
secondary cell
pressurization
shaking
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CN201380004985.9A
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CN104054206B (zh
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金泰元
久岛和实
泽田康宏
中井美由纪
木下晓子
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Envision AESC Japan Ltd
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Nissan Motor Co Ltd
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/46—Separators, membranes or diaphragms characterised by their combination with electrodes
    • 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
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • 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
    • B29C65/82—Testing the joint
    • B29C65/8207—Testing the joint by mechanical methods
    • B29C65/8215—Tensile tests
    • 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
    • B29C65/82—Testing the joint
    • B29C65/8207—Testing the joint by mechanical methods
    • B29C65/8223—Peel tests
    • 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
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
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    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/43—Joining a relatively small portion of the surface of said articles
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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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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/72—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
    • B29C66/723—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
    • B29C66/7232—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
    • B29C66/72324—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 inorganic materials not provided for in B29C66/72321 - B29C66/72322
    • B29C66/72325—Ceramics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/727—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 porous, e.g. foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • 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
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Abstract

对于隔着耐热层(49)层叠由树脂材料形成的隔膜层(48)、进而从其两侧层叠有外装材料(13)(层压板)的部分，利用加压加振部(111)和夹具受压部(112)进行夹持而加压，并且施加振动。在加压加振部(111)和夹具受压部(112)上形成有凸部(121)，由此，通过进行加压、加振，从而破坏耐热层(49)，在破坏部分(200)处隔膜层(48)的树脂熔化而熔接。根据本发明，能够提供一种二次电池的制造方法，其即使在设置有耐热层和由树脂材料形成的隔膜的二次电池中，也能够将带耐热层的隔膜和外装材料、以及带耐热层的隔膜之间可靠地熔接。

Description

二次电池的制造方法、二次电池、熔接装置
技术领域
本发明涉及二次电池的制造方法、二次电池、熔接装置。
背景技术
当前在二次电池中，存在具有隔着隔膜将正极和负极进行层叠而成的层叠电极体的二次电池。近些年，作为这种二次电池的一种，存在如下电池，即，为了提高二次电池内部的耐热性，如日本国专利公报专利3584583号(专利文献1)例示那样，采用在与一个电极(例如正极)相对的面上设置有耐热层的隔膜，按正极、带耐热层的隔膜、负极的顺序进行了层叠。
另外，作为二次电池的其他技术，如日本国专利公开公报特开2004-158344号(专利文献2)例示所示，存在如下电池，其为了防止隔膜在二次电池内部移动，以将隔膜的端部夹入外装材料中的方式，针对每个外装材料进行热熔接而进行固定。
发明内容
如果采用如专利文献1所示的带耐热层的隔膜，将如专利文献2所示的该带耐热层的隔膜的端部夹入外装部件并进行熔接，则耐热层耐热性强，在使由树脂材料形成的外装材料、隔膜热熔接程度的温度下也不会熔化。因此如果使用带耐热层的隔膜，则存在难于将端部与外装材料一起熔接并固定的问题。
根据本发明，能够提供一种二次电池的制造方法，其即使在设置有耐热层和由树脂材料形成的隔膜的二次电池中，也能够将带耐热层的隔膜和外装材料、以及带耐热层的隔膜之间可靠地熔接。
另外，根据本发明，能够提供一种二次电池，该二次电池通过利用该制造方法进行制造，从而使带耐热层的隔膜和外装材料、以及带耐热层的隔膜之间可靠地固定。并且，根据本发明，能够提供一种熔接装置，该熔接装置能够将带耐热层的隔膜和外装材料、以及带耐热层的隔膜之间可靠地熔接。
根据本发明技术层面，二次电池的制造方法采用熔接夹具，该熔接夹在加压加振部、和位于与该加压加振部相对位置的夹具受压部中的至少一个上具有凸部。并且，利用该加压加振部和加压加振部对具有在由树脂材料形成的多个隔膜层之间配置耐热层并层叠的构造的被熔接部分，从层叠方向夹持而加压且施加振动。通过该加压和振动，破坏位于被熔接部分中的耐热层，使在破坏部分接触的隔膜层的树脂熔接。
根据本发明的第2技术层面，二次电池利用上述二次电池的制造方法进行制造，该二次电池具有：外装材料，其在表面具有树脂层；以及发电要素，其由外装材料覆盖。并且，发电要素的正极和负极隔着带耐热层的隔膜而进行层叠，在外装材料的周边的一部分处，隔膜的端部的一部分被外装材料夹持。位于被该外装材料所夹持的部分的耐热层被破坏，在破坏部分外装材料的树脂层和隔膜的树脂熔接在一起。
根据本发明的第3技术层面，二次电池是利用上述二次电池的制造方法而制造的，具有袋装电极，该袋装电极是将正极、负极中的任一方的电极收容在形成为袋状的2片带耐热层的隔膜之间而形成的。在形成为该袋状的带耐热层的隔膜中，在与收容在带耐热层的隔膜中的电极相比更靠近外侧处，位于隔膜之间重合部分的一部分处的耐热层被破坏，在破坏部分隔膜的树脂熔接在一起。
根据本发明的第4技术层面，熔接装置具有：熔接夹具，其在加压加振部、和位于与该加压加振部相对位置的夹具受压部中的至少一个上具有凸部；以及超声波振动器，其至少使加压加振部振动。并且，该熔接装置通过利用加压加振部和夹具受压部，针对具有在由树脂材料形成的多个隔膜层之间配置耐热层并层叠的构造的被熔接部分，从层叠方向夹持而加压且施加振动，从而将位于被熔接部分中的耐热层破坏，将在破坏部分接触的隔膜层的树脂熔接。
附图说明
图1是表示本实施方式的二次电池的外观的斜视图。
图2是本实施方式的二次电池的分解斜视图。
图3是本实施方式的二次电池所采用的袋装正极(袋装电极)的说明图，(A)为俯视图、(B)为沿着(A)中的B-B线的剖面图。
图4是本实施方式的二次电池所采用的负极的俯视图。
图5是用于对本实施方式的二次电池的内部结构进行说明的图，图5(A)是用于说明本实施方式的二次电池的内部结构的要部剖面图，图5(B)是在(A)中示出的二次电池的端部的卡合部部分的放大剖面图。
图6是用于对本实施方式的超声波熔接装置进行说明的概略图，图6(A)为俯视图，图6(B)是从(A)中的箭头B方向观察的侧视图。
图7是表示上述超声波熔接装置所具有的加压加振部的工件抵接面的图，(A)为俯视图，(B)为从(A)中的箭头B方向观察的侧视图、(C)是从(A)中的箭头C方向观察的侧视图。
图8是表示将工件夹持在上述超声波熔接装置所具有的熔接夹具上的状态的放大剖面图，(A)是表示加压及加振前的状态的要部放大剖面图，(B)是表示加压及加振后的状态的要部放大剖面图。
图9是用于说明剥离试验的方法的概略图。
图10是表示剥离试验的结果的图表。
图11是表示将工件夹持在上述超声波熔接装置所具有的熔接夹具上的状态的放大剖面图，(A)是表示加压及加振前的状态的要部放大剖面图、(B)是表示加压及加振后的状态的要部放大剖面图。
具体实施方式
(实施例1)
下面，参照附图说明本发明的实施方式。此外，在附图的说明中，对相同的要素标注相同的标号，省略重复的说明。另外，为了说明的方便，附图中的各部件的大小、比例有时被夸大而与实际的大小、比例不同。
下面，首先说明本实施方式所涉及的二次电池，然后对用于制造该二次电池的熔接装置、和采用该装置的二次电池的制造方法以及袋装电极的制造方法进行说明。
(二次电池)
图1是表示本实施方式的二次电池的外观的斜视图。图2是本实施方式的二次电池的分解斜视图。图3是本实施方式的二次电池所采用的袋装正极(袋装电极)的说明图，图3(A)为俯视图、图3(B)为沿着(A)中的B-B线的剖面图。图4是本实施方式的二次电池所采用的负极的俯视图。图5是用于对本实施方式的二次电池的内部结构进行说明的图，图5(A)是用于对本实施方式的二次电池的内部结构进行说明的要部剖面图、图5(B)是在(A)中示出的二次电池的端部的卡合部部分的放大剖面图。
如图1所示，二次电池10具有扁平的矩形形状，从外装材料13的同一端部导出正极引线11及负极引线12。进行充放电反应的发电要素15收容在外装材料13的内部。
如图2所示，发电要素15由袋装正极20和负极30交替地层叠而形成。
如图3所示，袋装正极20形成为如下构造，即，将2片带耐热层的隔膜40的端部接合而形成袋状，并将正极22收容在其中。即，在由树脂材料形成的隔膜层48和正极22之间存在耐热层49。隔膜层48及耐热层49是预先将形成耐热层49的陶瓷(耐热材料)涂覆在由树脂材料形成的隔膜材料的两面而形成的3层构造。在此，将耐热层涂覆在该隔膜层的两面而形成的结构称为带耐热层的隔膜40。
隔膜层48例如由聚乙烯或聚丙烯等聚烯烃类的微多孔质树脂形成。
正极22为在极薄的片状的正极集电体21(集电箔)的两面形成正极活性物质层24而形成的矩形形状。正极22在正极耳片23以外的部分形成有正极活性物质层24。
2片带耐热层的隔膜40在端部通过接合部42相互接合而形成为袋状。因此，2片带耐热层的隔膜40均能够比正极22大(除了正极耳片23部分)。对该袋装正极20的制造方法进行后述。
另外，从袋状的带耐热层的隔膜40的形成为直线的边44A引出正极耳片23，在边44A的相反一侧的边44B上形成有局部凸出的卡合部43。卡合部43通过在外装材料13内与外装材料13卡合，从而具有将发电要素15相对于外装材料13进行固定的作用。
如图4所示，负极30形成为矩形形状，在极薄的片状的负极集电体31(集电箔)的两面形成有负极活性物质层34。负极30在负极耳片33以外的部分形成有负极活性物质层34。
发电要素15交替地层叠有负极30、袋装正极20。由此，如图5所示，形成为在负极30和正极22之间隔着带耐热层的隔膜40而进行层叠的构造。在图5(A)所示的端部，在对外装材料13进行封装时，在外装材料13之间夹持带耐热层的隔膜40的卡合部43而进行接合、封装。处于层叠状态的正极耳片23及负极耳片33，分别与正极引线11及负极引线12接合在一起(参照图2)。此外，在图5中，带耐热层的隔膜40的隔膜层48及耐热层49的构造省略了图示。
如果将负极30重叠在袋装正极20上，则负极活性物质层34形成为，在俯视观察时比正极22的正极活性物质层24大一圈。
在图5(A)所示的端部，带耐热层的隔膜40的卡合部43夹入并固定在外装材料13中。图5(B)是该卡合部43部分的放大剖面图。
外装材料13例如是层压板。如图示所示，层压板是将树脂层51涂覆在金属的基材50的两面而成。通常，利用热熔接进行这种外装材料13的封装。层压板的树脂层51通过加热而熔化，所重合的部分进行熔接。这点在关联技术(专利文献2)的情况下也相同，如果是没有耐热层的隔膜，则通过在其端部夹入至外装材料13的状态下进行加热，从而能够使得外装材料13的树脂层51与隔膜的树脂熔化而进行熔接。这些树脂在130～180℃左右熔化。
另一方面，耐热层49例如由多孔质陶瓷形成，虽然电解液可渗透该耐热层，但顾名思义，由于具有耐热性，因此在130～180℃左右不会熔化。另外，由于为多孔质，因此热传导率小、隔热性好。耐热层的耐热温度例如大于或等于800℃。
由此，无论施加多少热量，由于被耐热层49阻隔的隔膜层48的树脂和外装材料13的树脂层51、或者隔膜层48之间的树脂不接触，因此不能够进行熔接。
因此，在本实施方式中，通过对夹持带耐热层的隔膜40的卡合部43的外装材料13的部分(被熔接部分)一边加压一边施加振动，从而将耐热层49破坏而进行熔接。
下面，对一边施加压力和振动、一边由外装材料13将带耐热层的隔膜40的卡合部43夹入的被熔接部分的熔接进行说明。此外，除此之外，本实施方式所采用的将袋装正极20和负极30交替地层叠而制造锂离子二次电池的方法本身为普通的锂离子二次电池的制造方法，因此，省略详细的说明。
另外，由于锂离子二次电池所使用的正极活性物质、负极活性物质、集电箔等部件也采用普通的锂离子二次电池所使用的材料，因此，它们的详细的说明也省略。
(熔接装置)
对为了一边施加振动、一边对夹入了带耐热层的隔膜的卡合部的状态下的外装材料进行熔接所采用的装置进行说明。在此，由于是一边施加超声波振动、一边进行熔接的方式，因此将该装置称为超声波熔接装置。
图6是用于对本实施方式的超声波熔接装置进行说明的概略图，图6(A)为俯视图，图6(B)是从(A)中的箭头B方向观察的侧视图。
该超声波熔接装置100具有：工作台101，其载置工件；加振加压部111，其位于工作台101的上方，能够上下移动；夹具受压部112，其位于与加压加振部111相对的位置；以及超声波振动器130，其用于使加振加压部111振动。此外，将加压加振部111和夹具受压部112合起来称为熔接夹具110。
在此，工件是利用层压板将层叠有袋装正极20和负极30的发电要素15在它们层叠方向的两端进行夹入的对象，是处于将外装材料密封前的状态的二次电池。
并且，加压加振部111为了对该工件的外装材料13进行密封，在其周围移动而对作为外装材料13的树脂进行热熔接。该加压加振部111具有使加压加振部111振动的超声波振动器130。
加压加振部111的与工件的抵接面为凹凸面125，且形成有凸部121。图7是表示该加压加振部111的工件抵接面的图，(A)为主视图、(B)为从(A)中的箭头B方向观察的侧视图、(C)为从(A)中的箭头C方向观察的侧视图。
如图7所示，加压加振部111的工件抵接面为凹凸面125，具有多个凸部121。各凸部121的前端为圆弧形状、或进行了倒角加工。其如后所述，利用该圆角，将被破坏的耐热层49部分地排除，使树脂的隔膜层48之间易于接触。另外，这种圆弧形状、倒角加工还具有如下作用，即，在进行加压、加振时不会损伤外装材料13的表面。
各凸部121的大小(俯视观察时的长×宽)及高度根据熔接部分(被熔接部分)的厚度适当设定即可。在将外装材料13与多个带耐热层的隔膜40的卡合部43进行熔接的情况下，可以与它们的层叠厚度相同、或大于它们的层叠厚度。因此，如果该凸部121的高度大于或等于熔接部分的厚度，则可以设为易于构成(制作)装置的高度。大约为熔接部分的厚度的2倍左右就足够了。
作为凸部121的倒角加工，取决于凸部121的大小、高度，成为在如上述进行加压时能够按压被破坏的耐热层的大小。其原因在于，隔膜层48由于是树脂而具有柔软性，因此，较硬的耐热层48被破坏而形成的零落的碎片(粉碎碎片)，沿着凸部121的圆角受到按压，而被按向加压力相对小的凸部121的周边方向。考虑这种作用而对凸部121的倒角量进行确定。具体而言，例如，在对利用2片外装材料13夹持多片带耐热层的隔膜的部分进行熔接的情况下，如果总厚度设为700μm，则凸部121的倒角量优选为1～2mm左右。
关于加压加振部111整体的大小(与工件抵接部分的大小)，在对外装材料的周围进行熔接的情况下，为了不破坏位于外装材料内部的电极，需要比从外装材料13内部的电极端至外装材料的端部为止之间的距离小。此外，不会影响从外装材料13端部向外部伸出的部分。
在图6中，加压加振部111能够在工作台101上移动，以能够在工作台101上使加压加振部111和工件在沿着外装材料13的外周的方向上进行相对移动的方式，将外装材料13的外周封装。
另一方面，在工作台101上，在与加压加振部111相对的位置设置有夹具受压部111。该夹具受压部111的表面在与设置于加压加振部111的凸部121相对的位置处，形成有具有相同凸部121的凹凸面。设置在该夹具受压部112上的凸部121的大小、高度，与加压加振部111侧的凸部121相同，比熔接的部分的厚度大即可。夹具受压部111位于与加压加振部111相对的位置即可。因此，考虑到将外装材料13的外周全部熔接，也可以仅使加压加振部111移动，并在其轨迹上配置夹具受压部111。另外，也可以与加压加振部111的移动一起动作。在该情况下，例如为工件被固定在工作台上，使加压加振部111和夹具受压部112一起在工件周围移动的方式，或者为在被固定的加压加振部111和夹具受压部112之间，使固定在工作台上的工件连同工作台101一起移动的方式。其中，在后者的情况下，被熔接部分以从工作台伸出的方式被载置，利用加压加振部111和夹具受压部112将该伸出的外周部分夹入而进行熔接。
由此，工件的被熔接部分被加压加振部111及夹具受压部112夹入而加压并施加振动。
超声波振动器130至少使加压加振部111的与工件的抵接面振动。振动的方向为沿着工件的面的方向(称为横向)、以及对工件进行加压的方向(称为纵向)这2个方向。作为这种超声波振动器130，例如能够利用超声波熔接等所采用的超声波振动装置，但在本实施方式中，使其能够在如上所述的2个方向上进行振动。振动频率及振幅能够对由该加压加振部111加压加振的部分的耐热层进行破坏，且能够赋予利用因该振动引起的摩擦热量将树脂熔化程度的振动即可。
按照上述方式构成的超声波熔接装置100也能够在如下情况下利用，即，在制造袋装电极20时，在电极(在本实施方式中为正极22)的外侧，对2片带耐热层的隔膜40之间重合的部分进行熔接(参照图3的熔接部42)。在该情况下，由于熔接部分(被熔接部分)的厚度与对连同外装材料13一起进行熔接的情况不同，因此与被熔接部分匹配地对凸部121的高度、倒角量等进行变更。
对袋装电极20进行制造时的被熔接部分，只是将2片带耐热层的隔膜40之间重合。1片带耐热层的隔膜的厚度为20～30μm左右。因此，被熔接部分为40～60μm左右。因此，凸部121的高度至少大于或等于20μm即可。即，加压加振部111和夹具受压部112均大于或等于20μm，合计大于或等于40μm。关于上限，在该情况下也没有特别限定，只要是易于构成装置的大小即可，加压加振部111和夹具受压部112的凸部121的高度只要是分别使2片带耐热层的隔膜40之间重合的厚度的2倍左右就足够了。
关于倒角量，由于凸起的大小变小、且排除的耐热层的碎片也又薄又小，因此该倒角量较小即可。作为考虑上述凸部121的高度、且易于排除碎片的倒角量，优选其曲率半径为0.1～1mm左右。
如上所述，在用于袋装电极20的制造的情况下，加压加振部111整体的大小(与工件抵接的部分的大小)形成为比从电极端至2片带耐热层的隔膜40的端部为止之间的距离小，以使得不会对位于形成袋的2片带耐热层的隔膜40内部的电极造成破坏。此外，不会影响从2片带耐热层的隔膜40的端部向外伸出的部分。
(二次电池的制造方法)
对采用了上述超声波熔接装置100的二次电极的制造方法进行说明。
图8是表示将工件夹持在超声波熔接装置100的熔接夹具110中的状态的放大剖面图，图8(A)是表示加压及加振前的状态的要部放大剖面图，图8(B)是表示加压及加振后的状态的要部放大剖面图。图8所示的部分示出了一个凸部121(加压加振部111和夹具受压部112的各自的1个凸部121)，该凸部121对在2片外装材料13之间夹入多个带耐热层的隔膜40的卡合部46的部分进行加压。
在本实施方式中，首先，如图8(A)所示，在上述的超声波熔接装置100的加压加振部111和夹具受压部112之间设置工件的熔接的部分(被熔接部分)。在此，所谓工件的熔接部分(被熔接部分)是在2片外装材料13之间夹入有多个带耐热层的隔膜40的卡合部43的部分。
然后，如图8(B)所示，使加压加振部111下降，对该熔接的部分进行加压(图中箭头P)。此时，此时，在进行加压的同时，利用超声波振动器130向加压加振部111施加振动。由此，在从外装材料的两侧对其中的耐热层进行按压，并且施加振动。
利用该加压和振动，直至位于多个层叠的带耐热层的隔膜40的层叠方向中心部的耐热层49为止，在进行加压的微小区域中，耐热层49被破坏。
另外，利用此时的加压，凸部121将被破坏的耐热层49的碎片210向周围推出。
在该耐热层49被破坏的部分(破坏部分200)中，隔膜层48之间接触。并且，利用此时的振动，加压部分的外装材料13、带耐热层的隔膜40等相互摩擦而发热，外装材料13的树脂层51和隔膜层48的树脂熔化，它们熔接而接合。在接合部分的周边存在耐热层49的碎片210。
由此，完成熔接，由外装材料13夹持的卡合部43被可靠地紧固于外装材料13上。
这种熔接作用与普通的超声波熔接的接合作用不同。普通的超声波熔接，例如在对2片金属板、树脂材等进行超声波熔接的情况下，通过超声波熔接装置的焊头施加振动，使2片金属板、树脂材等彼此摩擦。利用此时的摩擦发热，并且在该摩擦的部分中，分子结合而进行接合。与其相对，根据本发明，如上所述，由于施加的振动具有将耐热层破坏的作用，因此，因该振动引起的摩擦、加压力不会促进接合部分的分子的结合。另外，在本实施方式中，通过振动而摩擦产生摩擦热量不具有利用其自身使摩擦面接合的作用，而该摩擦热量仅具有使树脂熔化的作用，在这点上也与普通的超声波熔接不同。
实际中，进行了将层叠有多片带耐热层的隔膜夹持在层压板之间并进行熔接的试验。
熔接部(包括外装材料和带耐热层的隔膜)的熔接前的厚度为700μm。利用具有与该熔接部的厚度相同高度的凸部121的加压加振部111进行了熔接。凸部121前端以曲率半径为1.0mm(R＝1.0mm)进行倒角加工。振动方向为横向和纵向2个方向。
针对进行了熔接的多个样品，进行了剥离试验。如图9所示，剥离试验是通过卡住外装材料13中的未熔接(接合)端的部分而向相互分离的方向拉伸而进行的。
图10是表示剥离试验的结果的图表，横轴为拉伸强度，纵轴为发生频率。
图表中，A～D为基于本实施方式而制作的样品，E为在未施加振动的情况下利用与工件的抵接面为平面的夹具进行了热熔接而成的样品。
如图表所示可知，与未施加振动的样品E相比，根据本实施方式制作的样品A～D的拉伸强度高。
(袋装电极的制造方法)
下面，对采用了上述的超声波熔接装置100的袋装电极的制造方法进行说明。虽然袋装电极的制造也包含在二次电池的制造方法中，但也可以单独地仅进行袋装电极的制造。
图11是表示将工件夹持在超声波熔接装置100的熔接夹具中的状态的放大剖面图，图11(A)是表示加压及加振前的状态的要部放大剖面图，图11(B)是表示加压及加振后的状态的要部放大剖面图。图11所示的部分是表示使2片带耐热层的隔膜40重合而对该部分进行加压的一个凸部121。
在本实施方式中，首先，如图11(A)所示，将工件的熔接部分(被熔接部分)设置在上述的超声波熔接装置100的加压加振部111和夹具受压部112之间。在此，所谓工件的熔接部分(被熔接部分)是将2片带耐热层的隔膜40重合在一起的部分。
然后，如图11(B)所示，使加压加振部111下降，对该熔接部分进行加压(图中箭头P)。此时，在进行加压的同时，利用超声波振动器130向加压加振部111施加振动。由此，从带耐热层的隔膜的两侧对其中的耐热层进行按压，并且，施加振动。通过该加压和振动，带耐热层的隔膜40的耐热层49在进行加压的微小区域被破坏。另外，根据此时的加压，凸部121将被破坏的耐热层49的碎片201向周围推出。
在该耐热层49被破坏的部分(破坏部分201)中，隔膜层48之间接触。并且，通过此时的振动，加压部分的带耐热层的隔膜40之间相互摩擦而发热，隔膜层48的树脂熔化，它们进行熔接(接合)。即，在摩擦的面状区域中产生的热量传递至隔膜层48而成为高温，树脂熔化并进行熔接。
由此，完成熔接，能够在成为袋装电极20的袋状的带耐热层的隔膜40的周围形成接合部42。
对于这种熔接作用，与上述的二次电池的制造方法的情况相同。
实际中，进行了使2片带耐热层的隔膜重合而进行熔接的试验。
熔接部(2片带耐热层的隔膜的合计)的熔接前的厚度为50μm。利用具有与该熔接部的厚度相同高度的凸部121的加压加振部111进行了熔接。凸部121的大小设为直径为0.5mm的圆筒形。凸部121前端以曲率半径0.1mm(R＝0.1mm)进行倒角加工。
针对进行了熔接的多个样品进行了剥离试验。剥离试验与图9所示的方式相同，是通过卡住2片带耐热层的隔膜40中的未熔接(接合)端的部分而向相互分离的方向拉伸进行的。
在表1中示出结果。在此，相对于使超声波振动的时间，对拉伸强度是否大于或等于规定值进行了验证。关于该规定值，将与对没有耐热层的隔膜进行热熔接(在不振动的情况下，仅利用与工件抵接的面为平面的夹具加热而进行熔接)的情况相同程度表示为OK，将比该情况低表示为LOW，将比该情况高表示为HIGH。即，在OK及HIGH的情况下，作为接合强度是足够的。振幅量是将与凸部121整体相当的移动量(即，移动量为0.5mm)设为100％时的相对的移动量。振动方向为横向和纵向2个方向(振幅均相同)。
[表1]
由表1可知，通过调整振动时间，能够获得与对没有耐热层的隔膜进行熔接的情况相同程度的足够的接合强度。
根据以上所说明的实施方式，能够实现下述效果。
(1)在本实施方式的二次电池的制造方法中，利用熔接夹具110对被熔接部分夹持而加压，并且施加振动，该熔接夹具110具有在与工件的抵接面上具有凸部121的加压加振部111和夹具受压部112。由此，在具有层叠有耐热层49和由树脂形成的隔膜层48的构造的被熔接部分中，不仅利用凸部121进行加压，还施加振动，耐热层49被破坏。并且，在该破坏部分接触的树脂由于振动产生的摩擦热量熔化而进行熔接。因此，即使是隔着耐热层49的被熔接部分，也能够可靠地进行熔接。
(2)在本实施方式的二次电池的制造方法中，将凸部121的前端设为圆弧形状或进行倒角加工后的形状。由此，通过加压振动而被破坏的耐热层49的碎片被按向凸部121的周围，在凸部121前端部分处，隔膜层48、外装材料13的树脂之间特别地易于接触，因此能够促进在该部分的熔接。
(3)在本实施方式的二次电池的制造方法中，将凸部121设置在加压加振部111及夹具受压部112的双方彼此相对的位置处。由此，能够从两侧对被熔接部分进行压入而加压、加振，因此，特别是在被熔接部分较厚的情况下，能够在直至层叠方向的中心部为止可靠地进行加压，并且施加振动。
(4)在本实施方式的二次电池的制造方法中，将利用外装材料13从层叠方向的两侧将多个带耐热层的隔膜40的卡合部43进行夹持的部分作为被熔接部分而进行了熔接。在此，多个带耐热层的隔膜40的层叠数量例如有时达到数十～数百层，即使在上述层叠数量多的情况下，通过加压并且施加振动，也能够可靠地进行熔接。
(5)在本实施方式的二次电池的制造方法中，在制造袋装电极时将重合有2片带耐热层的隔膜40的部分作为被熔接部分而进行了熔接。在制造袋装电极时，必须在由树脂形成的隔膜层48之间配置耐热层49，但通过在对该部分加压并且施加振动，能够将位于隔膜层48之间的耐热层49破坏，在该部分对隔膜层48的树脂进行熔接。
(6)在本实施方式的二次电池中，将利用外装材料13从层叠方向的两侧将多个带耐热层的隔膜40的卡合部43夹持的部分作为被熔接部分而进行了熔接。通过在该部分进行加压并且施加振动而进行熔接，耐热层49被破坏，在该部分树脂熔化而进行熔接。因此，带耐热层的隔膜40的卡合部43牢固地接合在外装材料13上，即使向二次电池施加振动、冲击，在外装材料13的内部也不会产生发电要素移动的现象。
(7)在本实施方式的二次电池中，在制造袋装电极时，将重合有2片带耐热层的隔膜40的部分作为被熔接部分而进行了熔接。通过在该被熔接部分中加压并且施加振动而进行熔接，使得耐热层49被破坏，在该部分树脂熔化而进行熔接。因此，成为袋状的带耐热层的隔膜40可靠地进行接合。
(8)本实施方式的熔接装置具有：熔接夹具110，其在加压加振部111、和位于与该加压加振部111相对位置处的夹具受压部112中的至少一方具有凸部121；以及超声波振动器，其至少使该加压加振部111振动。
并且，该装置能够在作为熔接夹具110部分的加压加振部111和夹具受压部112中对被熔接部分进行夹持而加压并且施加振动，该被熔接部分具有将耐热层49配置并层叠在由树脂材料形成的多个隔膜层48之间的构造。由此，能够将位于被熔接部分中的耐热层49破坏，将在该破坏部分接触的隔膜层48的树脂进行熔接，因此，通过采用该装置，即使是层叠有带耐热层的隔膜的结构，也能够可靠地进行熔接。
(9)本实施方式的熔接装置，将凸部121的前端形成为圆弧形状或进行倒角加工后的形状。由此，通过加压振动而被破坏的耐热层49的碎片被赶到凸部121的周围，在凸部121前端部分特别地易于隔膜层48、外装材料13的树脂之间进行接触，因此促进在该部分的熔接。
以上说明了适用于本发明的实施方式及实施例，但本发明并不限定于这些实施方式、实施例。
例如，作为袋装电极，以在袋中装入正极22的袋装正极20为例进行了说明，但作为位于袋装电极的内部的电极也可以是负极30。
另外，带耐热层的隔膜40可以不是耐热层49、隔膜层48、耐热层49的3层构造，而是仅在隔膜层48的单面具有耐热层49的2层构造。关于耐热层49的作用，如已说明所示，在发生了内部短路的情况下，即使由于其产生的热量而使隔膜层48熔化，也能够防止正极22和负极30在该部分直接接触。因此，只要利用仅在隔膜层48的单面具有耐热层49的2层构造的带耐热层的隔膜40，将正极22(或负极30)装袋并与负极30(或正极22)进行层叠，则在正极22和负极30之间必然存在耐热层49。因此，即使采用2层构造的带耐热层的隔膜40，也能够具有耐热层49的作用。但是，在采用2层构造的带耐热层的隔膜40的情况下，在接合部42中，以相向的方式进行接合(熔接)，以使得在2片隔膜层48之间具有耐热层49。即，在2片2层构造的带耐热层的隔膜40中，以使至少一方的耐热层49朝向电极侧的方式进行配置。但是，从防止因发热而使隔膜层48熔解的观点出发，作为这种带耐热层的隔膜40，优选设置在树脂的隔膜层48的两面。
另外，配置在隔膜层48和电极之间的耐热层49，可以不是预先在隔膜材料上涂覆耐热材料的结构，而是采用隔膜层48和耐热层49形成为不同部件的结构。
另外，凸部121也可以仅设置在加压加振部111或夹具受压部112的任一方。在该情况下，对于凸部121的高度，由于设置在一侧，因此仅该凸部121至少需要比被熔接部位的厚度大。此外，在连同外装材料13一起进行熔接的情况下，对应于该厚度，优选将凸部121设置在双方彼此相对的位置处。其为优选的原因在于，在连同外装材料13一起进行熔接的情况下，层叠方向的厚度增加，因此在双方具有凸部121的情况下，凸部121的嵌入可以通过双方实现，直至层叠方向中心部为止施加加压力及振动。
另外，在上述的实施方式中，利用因振动引起的摩擦热量使树脂熔化而进行熔接，在摩擦热量不足的情况下，为了使熔接夹具的与工件的抵接面过热，也可以在该部分设置发热体(电热器、感应加热器等)。
另外，在上述的实施方式中，作为二次电池，以锂离子二次电池为例进行了说明，但本发明并不限定于锂离子二次电池，能够适用于各种各样的二次电池。
除此之外，本发明能够基于权利要求书所记载的结构而进行各种各样的变化，这些当然也属于本发明的范畴。
根据本发明，在对被熔接部分进行加压的同时施加振动，该熔接部分具有由树脂材料形成的多个隔膜层隔着耐热层而进行层叠的构造。由于通过该加压和振动将位于被熔接部分的耐热层破坏，因此隔膜层的树脂通过该破坏部分相互接触，利用因振动产生的摩擦热量使树脂熔化而彼此熔接。因此，能够对具有耐热层的被熔接部分可靠地进行熔接。
(美国指定)
本国际专利申请涉及美国指定，针对在2012年1月12日申请的日本国专利申请第2012-004215号，援引基于美国专利法第119条(a)的优先权的利益，引用该公开内容。

Claims (9)

1.一种二次电池的制造方法，其特征在于，
利用熔接夹具，对具有在由树脂材料形成的多个隔膜层之间配置耐热层并层叠的构造的被熔接部分，从所述层叠方向夹持而加压且施加振动，从而破坏位于所述被熔接部分中的所述耐热层，使在该破坏部分处接触的所述隔膜层的树脂熔接，其中，该熔接夹具在加压加振部、和位于与该加压加振部相对位置的夹具受压部中的至少一个上具有凸部。
2.根据权利要求1所述的二次电池的制造方法，其特征在于，
所述凸部的前端为圆弧形状，或者进行了倒角加工。
3.根据权利要求1或2所述的二次电池的制造方法，其特征在于，
所述凸部设置在所述加压加振部以及所述夹具受压部这两者彼此相对的位置处。
4.根据权利要求1至3中任一项所述的二次电池的制造方法，其特征在于，
所述被熔接部分，在具有在由树脂材料形成的多个隔膜层之间配置耐热层并层叠的构造的部分的层叠方向的端部，还配置有在表面具有树脂层的外装材料，所述加压加振部及所述夹具受压部，从所述外装材料的所述层叠方向的外侧的面夹入而加压且施加振动。
5.根据权利要求1至3中任一项所述的二次电池的制造方法，其特征在于，
所述被熔接部分是具有将带耐热层的隔膜层叠多片的构造，该带耐热层的隔膜是在由树脂材料形成的多个隔膜层的两面涂覆有耐热层而成的，所述加压加振部及所述夹具受压部从所述层叠方向的外侧，将所述重合的所述带耐热层的隔膜之间夹入而加压且施加振动。
6.一种二次电池，其是利用权利要求4所述的二次电池的制造方法所制造的二次电池，其特征在于，具有：
外装材料，其在表面具有树脂层；以及
发电要素，其由所述外装材料覆盖，
作为所述发电要素，其正极和负极隔着带耐热层的隔膜而层叠，在所述外装材料的周边的一部分处，所述隔膜的端部的一部分被所述外装材料夹持，位于该夹持部分的所述耐热层被破坏，在该破坏部分处所述外装材料的树脂层和所述隔膜的树脂熔接在一起。
7.一种二次电池，其是利用权利要求5所述的二次电池的制造方法所制造的二次电池，其特征在于
具有袋装电极，该袋装电极是将正极或负极中任一个电极收容在形成为袋状的2片带耐热层的隔膜之间而形成的，
所述形成为袋状的带耐热层的隔膜，在与收容在带耐热层的隔膜中的电极相比的外侧，位于隔膜之间所重合的部分的一部分处的所述耐热层被破坏，在该破坏部分处所述隔膜的树脂熔接在一起。
8.一种熔接装置，其特征在于，具有：
熔接夹具，其在加压加振部、和位于与该加压加振部相对位置的夹具受压部中的至少一个上具有凸部；以及
超声波振动器，其至少使所述加压加振部振动，
利用所述加压加振部和所述夹具受压部，将具有在由树脂材料形成的多个隔膜层之间配置耐热层并层叠的构造的被熔接部分，从所述层叠方向夹持而加压且施加振动，从而将位于所述被熔接部分中的所述耐热层破坏，将在该破坏部分处接触的所述隔膜层的树脂熔接。
9.根据权利要求8所述的熔接装置，其特征在于，
所述凸部的前端为圆弧形状，或者进行了倒角加工。
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