JP2006305967A - 電子部品ケース用包材の製造方法及び製造装置 - Google Patents

電子部品ケース用包材の製造方法及び製造装置 Download PDF

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Publication number
JP2006305967A
JP2006305967A JP2005133817A JP2005133817A JP2006305967A JP 2006305967 A JP2006305967 A JP 2006305967A JP 2005133817 A JP2005133817 A JP 2005133817A JP 2005133817 A JP2005133817 A JP 2005133817A JP 2006305967 A JP2006305967 A JP 2006305967A
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Japan
Prior art keywords
sheet
roll
electronic component
manufacturing
packaging material
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JP2005133817A
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JP4791755B2 (ja
Inventor
Hiroshi Hata
浩 畑
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Resonac Packaging Corp
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Showa Denko Packaging Co Ltd
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Priority to JP2005133817A priority Critical patent/JP4791755B2/ja
Application filed by Showa Denko Packaging Co Ltd filed Critical Showa Denko Packaging Co Ltd
Priority to CN200680015095A priority patent/CN100584586C/zh
Priority to DE112006001110T priority patent/DE112006001110T5/de
Priority to KR1020077025352A priority patent/KR101238150B1/ko
Priority to PCT/JP2006/308993 priority patent/WO2006118251A1/ja
Priority to US11/913,422 priority patent/US8221576B2/en
Publication of JP2006305967A publication Critical patent/JP2006305967A/ja
Application granted granted Critical
Publication of JP4791755B2 publication Critical patent/JP4791755B2/ja
Priority to US13/495,100 priority patent/US8486217B2/en
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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
    • 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
    • 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
    • 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
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    • 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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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • 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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    • 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
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    • 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

【課題】 設備コストを抑制できると共に、高速生産が可能な、電子部品ケース用包材の製造方法を提供する。
【解決手段】 この発明の製造方法は、熱可塑性樹脂未延伸フィルム層４の片面に熱可塑性接着樹脂層５が積層されてなる第１シート１と、耐熱性樹脂延伸フィルム層６の片面にアルミニウム箔層７が積層されてなる第２シート２とを、熱可塑性接着樹脂層５とアルミニウム箔層７とが接触する態様で一対のロール間１２、１３に挿通して、熱可塑性接着樹脂が溶融しない状態で加熱して挟圧することによって第１シート１と第２シート２とを仮接着して予備積層シート３を得る仮接着工程と、得られた予備積層シート３を加熱して熱可塑性接着樹脂を溶融せしめることによって、第１シート１と第２シート２とを接着一体化する本接着工程とを包含することを特徴とする。
【選択図】 図１

Description

この発明は、例えばリチウムイオン２次電池やキャパシター等の電子部品のケース用包材の製造方法に関する。
なお、この明細書において、「アルミニウム」の語は、アルミニウム及びその合金を含む意味で用いる。
リチウムイオン２次電池は、例えばノートパソコン、ビデオカメラ、携帯電話、電気自動車等の電源として広く用いられている。このリチウムイオン２次電池としては、電池本体の周囲をケースで包囲した構成のものが用いられている。このケース用包材としては、熱可塑性樹脂未延伸フィルムとアルミニウム箔とを熱接着性樹脂を用いて接着したものが公知であり、このような構成の包材を製造する方法としては、供給される熱可塑性樹脂未延伸フィルムとアルミニウム箔との間に、ポリオレフィンフィルム、変性ポリオレフィン樹脂フィルムを共押出してこれらを接着一体化する方法（特許文献１参照）、或いはアルミニウム箔の上に酸変性ポリオレフィンを固形分とするオルガノゾルを塗布した後、該オルガノゾルを乾燥して接着性皮膜を形成せしめ、次いで、ポリオレフィンフィルムと前記接着性皮膜とを圧着する方法（特許文献２参照）が知られている。
特開２００２−９６４１９号公報（請求項１、段落００１７） 特開２０００−６７８２３号公報（請求項１）
しかしながら、前者の共押出で接着一体化する方法では、複数台の押出機が必要となる上にヒートラミネート機も必要となるので、これら設備コストが多大なものになるという問題があった。即ち、製造コストが高くつくという問題があった。
また、後者の接着性皮膜を形成せしめる方法では、接着性皮膜を形成せしめるためにオルガノゾルを乾燥させる工程が必要であり、このために生産速度が遅いという問題があった。
この発明は、かかる技術的背景に鑑みてなされたものであって、設備コストを抑制できると共に、高速生産が可能な、電子部品ケース用包材の製造方法を提供することを目的とする。
前記目的を達成するために、本発明は以下の手段を提供する。
［１］熱可塑性樹脂未延伸フィルム層の片面に熱可塑性接着樹脂層が積層されてなる第１シートと、耐熱性樹脂延伸フィルム層の片面にアルミニウム箔層が積層されてなる第２シートとを、前記熱可塑性接着樹脂層と前記アルミニウム箔層とが接触する態様で一対のロール間に挿通して、前記熱可塑性接着樹脂が溶融しない状態で加熱して挟圧することによって前記第１シートと前記第２シートとを仮接着して予備積層シートを得る仮接着工程と、
得られた予備積層シートを加熱して前記熱可塑性接着樹脂を溶融せしめることによって、前記第１シートと前記第２シートとを接着一体化する本接着工程とを包含することを特徴とする電子部品ケース用包材の製造方法。
［２］前記仮接着工程において、前記一対のロールとして、ゴムロール及び加熱ロールを用いる前項１に記載の電子部品ケース用包材の製造方法。
［３］前記仮接着工程において、前記熱可塑性接着樹脂の融点（℃）を「Ｍ」とし、前記挟圧時の熱可塑性接着樹脂の温度（℃）を「Ｔ」としたとき、下記関係式
（Ｍ−６０）≦Ｔ≦（Ｍ−５）
を満足する前項１または２に記載の電子部品ケース用包材の製造方法。
［４］前記仮接着工程において、一対のロール間で挟圧することによって第１シートと第２シートとを仮接着したものを冷却ロールに沿わせて冷却して予備積層シートを得、前記本接着工程において、第１シートと第２シートとを接着一体化したものを冷却ロールに沿わせて冷却する前項１〜３のいずれか１項に記載の電子部品ケース用包材の製造方法。
［５］前記仮接着工程及び前記本接着工程において、前記加熱ロールの温度（℃）を「Ｘ」とし、前記冷却ロールの温度（℃）を「Ｙ」としたとき、下記関係式
（Ｘ−８０）≦Ｙ≦（Ｘ−１０）
を満足する前項４に記載の電子部品ケース用包材の製造方法。
［６］前記仮接着工程及び前記本接着工程において、前記加熱ロールの外周面の周方向における移動速度を「Ｗ」とし、前記冷却ロールの外周面の周方向における移動速度を「Ｚ」としたとき、下記関係式
１．０１Ｗ≦Ｚ≦１．３０Ｗ
を満足する前項４または５に記載の電子部品ケース用包材の製造方法。
［７］前記熱可塑性樹脂未延伸フィルムとして、ポリエチレン、ポリプロピレン、オレフィン系共重合体、これらの酸変性物およびアイオノマーからなる群より選ばれた少なくとも１種の熱可塑性樹脂からなる未延伸フィルムを用い、前記耐熱性樹脂延伸フィルムとして、ポリアミドまたはポリエステルからなる延伸フィルムを用いることを特徴とする前項１〜６のいずれか１項に記載の電子部品ケース用包材の製造方法。
［８］加熱ロールとゴムロールとからなる挟圧部と、冷却ロールとを備えた第１ラミネート装置と、加熱ロールおよび冷却ロールを備えた第２ラミネート装置とを含むことを特徴とする電子部品ケース用包材の製造装置。
［９］加熱ロールとゴムロールとからなる挟圧部と、冷却ロールとを備え、前記加熱ロールとゴムロールのうち少なくともいずれか一方のロールが他方のロールに対して離脱移動できるように構成されていることを特徴とする電子部品ケース用包材の製造装置。
［１］の発明では、熱可塑性接着樹脂が溶融しない状態（表面が一部溶融している状態も含む）で加熱して挟圧することによって第１シートと第２シートとを仮接着するので、重ね合わされた熱可塑性接着樹脂層とアルミニウム箔層との間にエアー（空気）が残存するのを効果的に防止することができる。即ち、熱可塑性接着樹脂層とアルミニウム箔層との間に気泡を存在させることなく第１シートと第２シートとを仮接着することができる。こうして仮接着された予備積層シートを加熱して熱可塑性接着樹脂を溶融せしめることによって第１シートと第２シートとを本接着（接着一体化）することができる。こうして重ね合わせ面に気泡のない包材を製造することができる。本製造方法では、接着剤の溶剤を乾燥させる乾燥工程を必要としないから、高速での生産を実現できる。
なお、本発明において、前記仮接着工程を省略して前記本接着工程を実施した場合には、第１シートと第２シートの重ね合わせ面に気泡が多く生じてしまうために高品質の包材を製造することができない。
［２］の発明では、ゴムロールと加熱ロールの間に、第１シートと第２シートを挿通して挟圧するので、重ね合わされた熱可塑性接着樹脂層とアルミニウム箔層との間にエアー（空気）が残存するのをより効果的に防止することができる。
［３］の発明では、熱可塑性接着樹脂の融点（℃）を「Ｍ」とし、挟圧時の熱可塑性接着樹脂の温度（℃）を「Ｔ」としたとき、関係式（Ｍ−６０）≦Ｔ≦（Ｍ−５）を満足する状態で製造するので、ある程度の接着強度でもって良好状態に仮接着することができる。
［４］の発明では、一対のロール間で挟圧することによって第１シートと第２シートとを仮接着したものを冷却ロールに沿わせて冷却して予備積層シートを得るから、良好な仮接着状態をそのまま保持させることができる。また、本接着工程において、第１シートと第２シートとを接着一体化したものを冷却ロールに沿わせて冷却するから、良好な本接着状態をそのまま保持させることができる。
［５］の発明では、加熱ロールの温度（℃）を「Ｘ」とし、冷却ロールの温度（℃）を「Ｙ」としたとき、関係式（Ｘ−８０）≦Ｙ≦（Ｘ−１０）を満足する状態で製造するので、仮接着工程及び本接着工程における膨張しわの発生を効果的に防止することができる。
［６］の発明では、加熱ロールの外周面の周方向における移動速度を「Ｗ」とし、冷却ロールの外周面の周方向における移動速度を「Ｚ」としたとき、関係式１．０１Ｗ≦Ｚ≦１．３０Ｗを満足する状態で製造するので、仮接着工程及び本接着工程における膨張しわの発生をより効果的に防止することができる。
［７］の発明では、耐熱性樹脂延伸フィルムとしてポリアミドまたはポリエステルからなる延伸フィルムを用いるから、成形性に優れた包材を製造できると共に、熱可塑性樹脂未延伸フィルムとして、ポリエチレン、ポリプロピレン、オレフィン系共重合体、これらの酸変性物およびアイオノマーからなる群より選ばれた少なくとも１種の熱可塑性樹脂からなる未延伸フィルムを用いるから、ヒートシール性及び耐電解液性、耐薬品性に優れた包材を製造することができる。
［８］の発明では、第１ラミネート装置において熱可塑性接着樹脂が溶融しない状態（表面が一部溶融している状態も含む）で加熱して挟圧することによって、熱可塑性接着樹脂層とアルミニウム箔層との間に気泡を存在させることなく第１シートと第２シートとを仮接着して予備積層シートを製造することができ、第２ラミネート装置において予備積層シートを加熱して熱可塑性接着樹脂を溶融せしめることによって本接着することができて、こうして重ね合わせ面に気泡のない包材を製造することができる。
［９］の発明の製造装置では、本製造装置１台で［８］の発明の第１ラミネート装置及び第２ラミネート装置の機能を具備したものとなるから、設備スペースを大幅に低減することができて設備の省スペース化を十分に図ることができる。
この発明の、電子部品ケース用包材の製造方法の好適例について図面を参照しつつ説明する。本製造方法は、仮接着工程と、本接着工程とを含むことを特徴とする。
まず、本製造方法で用いる製造装置（１０）について説明する。この製造装置（１０）は、図１、２に示すように、予熱ロール（１１）と、一対の挟圧ロール部（１２）（１３）と、冷却ロール（１４）とを備えている。本実施形態では、前記挟圧ロール部として、加熱ロール（１２）及びゴムロール（１３）が用いられている。また、前記ゴムロール（１３）は、前記加熱ロール（１２）に対して離脱移動できるように構成されている。即ち、仮接着工程では図１に示すように前記ゴムロール（１３）は前記加熱ロール（１２）に対して近接位置に配置されてシート体をこれらロール（１２）（１３）間で挟圧し得るものとなされる一方、本接着工程では図２に示すように前記ゴムロール（１３）は前記加熱ロール（１２）に対して離間した状態に配置される。
しかして、包材の製造に際しては、まず、熱可塑性樹脂未延伸フィルム層（４）の片面に熱可塑性接着樹脂層（５）が積層されてなる第１シート（１）と、耐熱性樹脂延伸フィルム層（６）の片面にアルミニウム箔層（７）が積層されてなる第２シート（２）を準備する。
図１に示すように、前記第１シート（１）と前記第２シート（２）とを、前記熱可塑性接着樹脂層（５）と前記アルミニウム箔層（７）とが重ね合わされて接触する態様で加熱ロール（１２）とゴムロール（１３）の間に挿通して、前記熱可塑性接着樹脂が溶融しない状態で加熱して挟圧することによって、第１シート（１）と第２シート（２）とを仮接着する（仮接着工程）。次いで、前記第１シート（１）と第２シート（２）とを仮接着してなるシートを冷却ロール（１４）の外周面に沿わせることによって徐冷して予備積層シート（３）を得、これを巻き取る。
前記熱可塑性接着樹脂が溶融しない状態での加熱挟圧は、例えば、前記熱可塑性接着樹脂を該熱可塑性接着樹脂の融点より低い温度に加熱した状態で挟圧することで実現できる。なお、加熱ロール（１２）の温度が熱可塑性接着樹脂の融点よりも高い温度であっても、加熱ロール（１２）及びゴムロール（１３）の回転速度が速い場合には、即ちロール（１２）（１３）間での挟圧時間が短い場合には、熱可塑性接着樹脂が溶融しない状態での加熱挟圧を実現することができる。また、前記「熱可塑性接着樹脂が溶融しない状態」には、熱可塑性接着樹脂層（５）の表面が一部溶融している状態も含まれる。即ち、前記熱可塑性接着樹脂層（５）の表面が一部溶融した状態で加熱挟圧しても該熱可塑性接着樹脂層（５）がゴムロール（１３）に溶着する恐れはない。また、ゴムロール（１３）に接している第１シート（１）の熱可塑性樹脂未延伸フィルム層（４）がゴムロール（１３）に溶着する恐れがある場合には、ＰＥＴ等の剥離シートを該熱可塑性樹脂未延伸フィルム層（４）の表面に介在させておいても良い。
前記仮接着工程では、熱可塑性接着樹脂が溶融しない状態（表面が一部溶融している状態も含む）で加熱して挟圧することによって第１シート（１）と第２シート（２）とを仮接着するので、重ね合わされた熱可塑性接着樹脂層（５）とアルミニウム箔層（７）との間にエアー（空気）が残存するのを効果的に防止することができる。即ち、熱可塑性接着樹脂層（５）とアルミニウム箔層（７）との間に気泡を存在させることなく第１シート（１）と第２シート（２）とを仮接着することができる。
前記ロールによる挟圧の際には次のような関係を満足する状態で挟圧するのが好ましい。即ち、熱可塑性接着樹脂の融点（℃）を「Ｍ」とし、ロールによる挟圧時の熱可塑性接着樹脂の温度（℃）を「Ｔ」としたとき、下記関係式
（Ｍ−６０）≦Ｔ≦（Ｍ−５）
を満足するのが好ましい。前記下限値以上とすることで仮接着に必要な接着強度を確保することができると共に、前記上限値以下とすることで熱可塑性接着樹脂の溶融によるエアー（空気）残存状態での接着を効果的に防止することができる。中でも、（Ｍ−３０）≦Ｔ≦（Ｍ−１０）の関係式を満足するのがより好ましい。
また、前記加熱ロール（１２）の温度（℃）を「Ｘ」とし、前記冷却ロール（１４）の温度（℃）を「Ｙ」としたとき、下記関係式
（Ｘ−８０）≦Ｙ≦（Ｘ−１０）
が成立する状態で冷却するのが好ましい。このような状態で冷却することにより、予備積層シート（３）における膨張しわの発生を効果的に防止することができる。中でも、（Ｘ−５０）≦Ｙ≦（Ｘ−３０）の関係式が成立するのが特に好ましい。
更に、前記加熱ロール（１２）の外周面の周方向における移動速度を「Ｗ」とし、前記冷却ロール（１４）の外周面の周方向における移動速度を「Ｚ」としたとき、下記関係式
１．０１Ｗ≦Ｚ≦１．３０Ｗ
を満足する状態で実施するのが好ましい。このような条件で実施することにより、予備積層シート（３）における膨張しわの発生を効果的に防止することができる。中でも、１．１Ｗ≦Ｚ≦１．１５Ｗの関係式が成立する状態で実施するのが特に好ましい。
なお、前記仮接着工程において、前記予熱ロール（１１）の温度は４０〜１００℃に設定されるのが好ましい。また、前記加熱ロール（１２）の温度は１００〜１８０℃に設定され、前記冷却ロール（１４）の温度は５０〜１３０℃に設定されるのが好ましい。また、前記加熱ロール（１２）の外周面の周方向における移動速度は３０〜５０ｍ／分に設定され、前記冷却ロール（１４）の外周面の周方向における移動速度３５〜７０ｍ／分に設定されるのが好ましい。
次に、前記巻き取られた予備積層シート（３）を取り外して、前記製造装置（１０）の図面左側の供給軸にセットすると共に、前記ゴムロール（１３）を上方向に離脱移動させて該ゴムロール（１３）を加熱ロール（１２）に対して離間した状態に配置する（図２参照）。しかして、この予備積層シート（３）を予熱ロール（１１）に沿わせることによって予備加熱した後、次の加熱ロール（１２）との接触により、予備積層シート（３）を加熱して接着樹脂を溶融せしめることによって前記第１シート（１）と前記第２シート（２）とを本接着（接着一体化）する（本接着工程）。この本接着工程では、前記ゴムロール（１３）は使用しない。
次いで、前記本接着されたシートを冷却ロール（１４）の外周面に沿わせることによって徐冷した後、これを巻き取る。こうして図４に示すような電子部品ケース用包材（９）が製造される。
前記本接着工程において、熱可塑性接着樹脂（５）の融点（℃）を「Ｍ」とし、加熱ロール（１２）との接触時の熱可塑性接着樹脂（５）の温度（℃）を「Ｕ」としたとき、下記関係式
（Ｍ＋１０）≦Ｕ≦（Ｍ＋６０）
を満足するのが好ましい。前記下限値以上とすることで十分な接着強度でもって本接着することができると共に、前記上限値以下とすることでエネルギーコストを抑制しつつ製造することができる。
また、前記本接着工程において、前記加熱ロール（１２）の温度（℃）を「Ｘ」とし、前記冷却ロール（１４）の温度（℃）を「Ｙ」としたとき、下記関係式
（Ｘ−８０）≦Ｙ≦（Ｘ−１０）
が成立する状態で冷却するのが好ましい。このような状態で冷却することにより、包材（９）における膨張しわの発生を効果的に防止することができる。
また、前記本接着工程において、前記加熱ロール（１２）の外周面の周方向における移動速度を「Ｗ」とし、前記冷却ロール（１４）の外周面の周方向における移動速度を「Ｚ」としたとき、下記関係式
１．０１Ｗ≦Ｚ≦１．３０Ｗ
を満足する状態で実施するのが好ましい。このような条件で実施することにより、包材（９）における膨張しわの発生を効果的に防止することができる。
なお、前記本接着工程において、前記予熱ロール（１１）の温度は４０〜１５０℃に設定されるのが好ましい。また、前記加熱ロール（１２）の温度は１８０〜２２０℃に設定され、前記冷却ロール（１４）の温度は５０〜１５０℃に設定されるのが好ましい。また、前記加熱ロール（１２）の外周面の周方向における移動速度は３０〜５０ｍ／分に設定され、前記冷却ロール（１４）の外周面の周方向における移動速度３５〜７０ｍ／分に設定されるのが好ましい。
前記例示した製造方法では、同一の製造装置（１０）で仮接着工程および本接着工程を実施するものとしているが、特にこのような製造方法に限定されるものではなく、例えば図３に示すように、仮接着工程を行うための第１ラミネート装置（２１）と、本接着工程を行うための第２ラミネート装置（２２）とを備えた製造装置（２０）を用いて、仮接着工程と本接着工程を連続して行うようにして製造しても良い。なお、図３に示す製造装置において、前記第１ラミネート装置（２１）は、予熱ロール（１１）と、一対の挟圧ロール部（１２）（１３）と、冷却ロール（１４）とを備える一方、前記第２ラミネート装置（２２）は、予熱ロール（１１）と、加熱ロール（１２）と、冷却ロール（１４）とを備えている。
この発明において、前記耐熱性樹脂延伸フィルム層（外側層）（６）は、包材として良好な成形性を確保する役割を主に担う部材である、即ち成形時のアルミニウム箔のネッキングによる破断を防止する役割を担うものである。前記耐熱性樹脂延伸フィルム（６）としては、特に限定されるものではないが、ポリアミドまたはポリエステルからなる延伸フィルムを用いるのが好ましい。前記耐熱性樹脂延伸フィルム層（６）の厚さは、１２〜５０μｍに設定されるのが好ましい。
前記熱可塑性樹脂未延伸フィルム層（内側層）（４）は、リチウムイオン二次電池等で用いられる腐食性の強い電解液などに対しても優れた耐薬品性を具備させると共に、包材にヒートシール性を付与する役割を担うものである。前記熱可塑性樹脂未延伸フィルム（４）としては、特に限定されるものではないが、ポリエチレン、ポリプロピレン、オレフィン系共重合体、これらの酸変性物およびアイオノマーからなる群より選ばれた少なくとも１種の熱可塑性樹脂からなる未延伸フィルムを用いるのが好ましい。前記熱可塑性樹脂未延伸フィルム層（４）の厚さは、２０〜８０μｍに設定されるのが好ましい。２０μｍ以上とすることでピンホールの発生を十分に防止できると共に、８０μｍ以下に設定することで樹脂使用量を低減できてコスト低減を図り得る。中でも、前記熱可塑性樹脂未延伸フィルム層（４）の厚さは３０〜５０μｍに設定されるのが特に好ましい。
なお、前記耐熱性樹脂延伸フィルム層（６）、前記熱可塑性樹脂未延伸フィルム層（４）は、いずれも単層であっても良いし、複層であっても良い。
前記アルミニウム箔層（７）は、包材に酸素や水分の侵入を阻止するガスバリア性を付与する役割を担うものである。アルミニウム箔（７）としては、純ＡｌまたはＡｌ−Ｆｅ系合金からなる厚さ５〜５０μｍの箔が好適に用いられる。
前記熱可塑性接着樹脂（５）としては、特に限定されないが、例えば、無水マレイン酸変性ポリエチレン、無水マレイン酸変性ポリプロピレン等の酸変性ポリオレフィンの他、ウレタン系樹脂、アクリル系樹脂、熱可塑性エラストマーを含有してなる樹脂等が挙げられる。前記熱可塑性接着樹脂層（５）の厚さは１０〜４０μｍに設定されるのが好ましい。これら熱可塑性接着樹脂層（５）は、例えば、前記熱可塑性樹脂未延伸フィルム層（４）の片面に熱可塑性接着樹脂フィルムがラミネートされて形成される。
この発明の製造方法で製造された電子部品ケース用包材（９）を深絞り成形または張り出し成形することにより、電子部品用ケースを得ることができる。しかして、リチウムイオン２次電池などの電池等の電子部品本体を、前記電子部品用ケースで包囲した構成とすることにより、電子部品が得られる。
次に、この発明の具体的実施例について説明する。
＜実施例１＞
（仮接着工程）
厚さ３５μｍのポリプロピレンフィルム（熱可塑性樹脂未延伸フィルム層）（４）の片面に厚さ１５μｍの無水マレイン酸変性ポリプロピレンフィルム（熱可塑性接着樹脂層）（５）が積層されてなる第１シート（１）と、厚さ２５μｍのポリアミドフィルム（耐熱性樹脂延伸フィルム層）（６）の片面に厚さ４０μｍのアルミニウム箔（７）が積層されてなる第２シート（２）とを、無水マレイン酸変性ポリプロピレンフィルム（５）とアルミニウム箔（７）とが接触する態様で、図１に示す製造装置（１０）の加熱ロール（１２）とゴムロール（１３）の間に挿通して挟圧して仮接着した後、冷却ロール（１４）の沿わせて徐冷することによって予備積層シート（３）を得、これを巻き取った。
前記仮接着工程では、予熱ロール（１１）の温度を７０℃に設定し、加熱ロール（１２）の温度を１３０℃に設定し、冷却ロール（１４）の温度を８０℃に設定した。無水マレイン酸変性ポリプロピレンフィルムの融点は１６８℃である。また、加熱ロール（１２）の外周面の周方向における移動速度は３６ｍ／分であり、冷却ロール（１４）の外周面の周方向における移動速度は４０ｍ／分であった。
（本接着工程）
次に、前記巻き取った予備積層シート（３）を、図２に示すように製造装置（１０）の図面左側の供給軸にセットすると共に、ゴムロール（１３）を上方向に離脱移動させた。しかして、図２に示すように、予備積層シート（３）を予熱ロール（１１）に沿わせることによって予備加熱した後、次の加熱ロール（１２）との接触により接着樹脂（無水マレイン酸変性ポリプロピレン）（５）を溶融させて第１シート（１）と第２シート（２）とを本接着した後、本接着されたシートを冷却ロール（１４）の外周面に沿わせて徐冷することによって、図４に示すような電子部品ケース用包材（９）を製造した。
なお、この本接着工程では、予熱ロール（１１）の温度を１００℃に設定し、加熱ロール（１２）の温度を２００℃に設定し、冷却ロール（１４）の温度を９０℃に設定した。また、加熱ロール（１２）の外周面の周方向における移動速度は３６ｍ／分であり、冷却ロール（１４）の外周面の周方向における移動速度は４０ｍ／分であった。
＜実施例２＞
仮接着工程において、加熱ロールの温度を１５０℃に設定し、冷却ロールの温度を９０℃に設定した以外は、実施例１と同様にして電子部品ケース用包材を製造した。
＜実施例３、４＞
表１に示す条件に設定した以外は、実施例１と同様にして電子部品ケース用包材を製造した。
＜比較例１＞
仮接着工程を省略するものとした以外は、実施例１と同様にして包材（９）を製造した。
上記のようにして得られた各包材について目視により気泡の有無及びしわの有無を調べて包材の外観を評価した。これらの結果を表１に示す。
Figure 2006305967
表１から明らかなように、この発明の製造方法で製造された実施例１〜４の電子部品ケース用包材は、気泡がない上にしわも殆どなくて外観が良好であった。これに対し、仮接着工程を省略した比較例１では気泡が発生していて外観不良であった。
この発明の製造方法で製造された電子部品ケース用包材は、例えば、リチウムイオン２次電池やキャパシター等の電子部品のケース用包材として用いられる。
第１シートと第２シートとを仮接着して予備積層シートを得る工程を示す側面図である。 予備積層シートを加熱して第１シートと第２シートとを本接着する工程を示す側面図である。 製造装置の一例を示す側面図である。 この発明の製造方法で製造された電子部品ケース用包材を示す断面図である。
符号の説明
１…第１シート
２…第２シート
３…予備積層シート
４…熱可塑性樹脂未延伸フィルム層（内側層）
５…熱可塑性接着樹脂層
６…耐熱性樹脂延伸フィルム層（外側層）
７…アルミニウム箔層
９…電子部品ケース用包材
１０…製造装置
１１…予熱ロール
１２…加熱ロール
１３…ゴムロール
１４…冷却ロール
２０…製造装置
２１…第１ラミネート装置
２２…第２ラミネート装置

Claims (9)

  1. 熱可塑性樹脂未延伸フィルム層の片面に熱可塑性接着樹脂層が積層されてなる第１シートと、耐熱性樹脂延伸フィルム層の片面にアルミニウム箔層が積層されてなる第２シートとを、前記熱可塑性接着樹脂層と前記アルミニウム箔層とが接触する態様で一対のロール間に挿通して、前記熱可塑性接着樹脂が溶融しない状態で加熱して挟圧することによって前記第１シートと前記第２シートとを仮接着して予備積層シートを得る仮接着工程と、
    得られた予備積層シートを加熱して前記熱可塑性接着樹脂を溶融せしめることによって、前記第１シートと前記第２シートとを接着一体化する本接着工程とを包含することを特徴とする電子部品ケース用包材の製造方法。
  2. 前記仮接着工程において、前記一対のロールとして、ゴムロール及び加熱ロールを用いる請求項１に記載の電子部品ケース用包材の製造方法。
  3. 前記仮接着工程において、前記熱可塑性接着樹脂の融点（℃）を「Ｍ」とし、前記挟圧時の熱可塑性接着樹脂の温度（℃）を「Ｔ」としたとき、下記関係式
    （Ｍ−６０）≦Ｔ≦（Ｍ−５）
    を満足する請求項１または２に記載の電子部品ケース用包材の製造方法。
  4. 前記仮接着工程において、一対のロール間で挟圧することによって第１シートと第２シートとを仮接着したものを冷却ロールに沿わせて冷却して予備積層シートを得、前記本接着工程において、第１シートと第２シートとを接着一体化したものを冷却ロールに沿わせて冷却する請求項１〜３のいずれか１項に記載の電子部品ケース用包材の製造方法。
  5. 前記仮接着工程及び前記本接着工程において、前記加熱ロールの温度（℃）を「Ｘ」とし、前記冷却ロールの温度（℃）を「Ｙ」としたとき、下記関係式
    （Ｘ−８０）≦Ｙ≦（Ｘ−１０）
    を満足する請求項４に記載の電子部品ケース用包材の製造方法。
  6. 前記仮接着工程及び前記本接着工程において、前記加熱ロールの外周面の周方向における移動速度を「Ｗ」とし、前記冷却ロールの外周面の周方向における移動速度を「Ｚ」としたとき、下記関係式
    １．０１Ｗ≦Ｚ≦１．３０Ｗ
    を満足する請求項４または５に記載の電子部品ケース用包材の製造方法。
  7. 前記熱可塑性樹脂未延伸フィルムとして、ポリエチレン、ポリプロピレン、オレフィン系共重合体、これらの酸変性物およびアイオノマーからなる群より選ばれた少なくとも１種の熱可塑性樹脂からなる未延伸フィルムを用い、
    前記耐熱性樹脂延伸フィルムとして、ポリアミドまたはポリエステルからなる延伸フィルムを用いることを特徴とする請求項１〜６のいずれか１項に記載の電子部品ケース用包材の製造方法。
  8. 加熱ロールとゴムロールとからなる挟圧部と、冷却ロールとを備えた第１ラミネート装置と、
    加熱ロールおよび冷却ロールを備えた第２ラミネート装置とを含むことを特徴とする電子部品ケース用包材の製造装置。
  9. 加熱ロールとゴムロールとからなる挟圧部と、冷却ロールとを備え、前記加熱ロールとゴムロールのうち少なくともいずれか一方のロールが他方のロールに対して離脱移動できるように構成されていることを特徴とする電子部品ケース用包材の製造装置。
JP2005133817A 2005-05-02 2005-05-02 電子部品ケース用包材の製造方法及び製造装置 Expired - Fee Related JP4791755B2 (ja)

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CN200680015095A CN100584586C (zh) 2005-05-02 2006-04-28 电子部件外壳用包装材料的制造方法及制造装置
US11/913,422 US8221576B2 (en) 2005-05-02 2006-04-28 Process for the production of packaging material for electronic component cases
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JP2008006612A (ja) * 2006-06-27 2008-01-17 Matsushita Electric Works Ltd 積層板の製造方法
JP2008006611A (ja) * 2006-06-27 2008-01-17 Matsushita Electric Works Ltd 積層板の製造方法
JP2008006610A (ja) * 2006-06-27 2008-01-17 Matsushita Electric Works Ltd 積層板の製造方法
JP2008155535A (ja) * 2006-12-25 2008-07-10 Matsushita Electric Works Ltd 積層板の製造方法
JP2008155536A (ja) * 2006-12-25 2008-07-10 Matsushita Electric Works Ltd 積層板の製造方法
JP2008155534A (ja) * 2006-12-25 2008-07-10 Matsushita Electric Works Ltd 積層体の巻き取り方法、銅張積層板の製造方法、及び保護テープ付き製品の製造方法
JP2009061670A (ja) * 2007-09-06 2009-03-26 Riken Technos Corp 多層フィルム
JP2009073010A (ja) * 2007-09-20 2009-04-09 Riken Technos Corp 複合多層フィルム
JP2009283382A (ja) * 2008-05-26 2009-12-03 Showa Denko Packaging Co Ltd 電池ケース用包材の製造方法
JP2010046863A (ja) * 2008-08-20 2010-03-04 Riken Technos Corp 多層フィルム
JP2011240714A (ja) * 2011-09-06 2011-12-01 Panasonic Electric Works Co Ltd 積層板の製造方法
JP2013092765A (ja) * 2011-10-07 2013-05-16 Sumitomo Chemical Co Ltd 偏光板の製造方法
KR20140088528A (ko) * 2011-10-04 2014-07-10 스미또모 가가꾸 가부시키가이샤 편광판의 제조 방법
KR20140088537A (ko) * 2011-10-07 2014-07-10 스미또모 가가꾸 가부시키가이샤 편광판의 제조 방법
JP2016225316A (ja) * 2016-09-15 2016-12-28 油化電子株式会社 電池外装用ラミネートフィルムの製造方法
JP2017045737A (ja) * 2016-12-09 2017-03-02 油化電子株式会社 電池外装用ラミネートフィルム及びその製造方法
JP2017069218A (ja) * 2016-12-05 2017-04-06 油化電子株式会社 電池外装用ラミネートフィルムの製造方法

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JP5959205B2 (ja) * 2012-01-17 2016-08-02 昭和電工パッケージング株式会社 電池用外装材、電池用外装材の成形方法及びリチウム二次電池
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JP2008006611A (ja) * 2006-06-27 2008-01-17 Matsushita Electric Works Ltd 積層板の製造方法
JP2008006610A (ja) * 2006-06-27 2008-01-17 Matsushita Electric Works Ltd 積層板の製造方法
JP2008006612A (ja) * 2006-06-27 2008-01-17 Matsushita Electric Works Ltd 積層板の製造方法
JP2008155535A (ja) * 2006-12-25 2008-07-10 Matsushita Electric Works Ltd 積層板の製造方法
JP2008155536A (ja) * 2006-12-25 2008-07-10 Matsushita Electric Works Ltd 積層板の製造方法
JP2008155534A (ja) * 2006-12-25 2008-07-10 Matsushita Electric Works Ltd 積層体の巻き取り方法、銅張積層板の製造方法、及び保護テープ付き製品の製造方法
JP2009061670A (ja) * 2007-09-06 2009-03-26 Riken Technos Corp 多層フィルム
JP2009073010A (ja) * 2007-09-20 2009-04-09 Riken Technos Corp 複合多層フィルム
JP2009283382A (ja) * 2008-05-26 2009-12-03 Showa Denko Packaging Co Ltd 電池ケース用包材の製造方法
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JP2011240714A (ja) * 2011-09-06 2011-12-01 Panasonic Electric Works Co Ltd 積層板の製造方法
KR20140088528A (ko) * 2011-10-04 2014-07-10 스미또모 가가꾸 가부시키가이샤 편광판의 제조 방법
KR101956953B1 (ko) 2011-10-04 2019-03-11 스미또모 가가꾸 가부시키가이샤 편광판의 제조 방법
JP2013092765A (ja) * 2011-10-07 2013-05-16 Sumitomo Chemical Co Ltd 偏光板の製造方法
KR20140088537A (ko) * 2011-10-07 2014-07-10 스미또모 가가꾸 가부시키가이샤 편광판의 제조 방법
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JP2016225316A (ja) * 2016-09-15 2016-12-28 油化電子株式会社 電池外装用ラミネートフィルムの製造方法
JP2017069218A (ja) * 2016-12-05 2017-04-06 油化電子株式会社 電池外装用ラミネートフィルムの製造方法
JP2017045737A (ja) * 2016-12-09 2017-03-02 油化電子株式会社 電池外装用ラミネートフィルム及びその製造方法

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US8221576B2 (en) 2012-07-17
KR20080003391A (ko) 2008-01-07
US20120273128A1 (en) 2012-11-01
DE112006001110T5 (de) 2008-03-27
JP4791755B2 (ja) 2011-10-12
CN100584586C (zh) 2010-01-27
KR101238150B1 (ko) 2013-02-28
WO2006118251A1 (ja) 2006-11-09

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