JP2014006965A - Manufacturing method and manufacturing apparatus of battery - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture a high performance three-dimensional battery having a nest structure.SOLUTION: A separator member 51 is molded into uneven shape copying that of an upstream side carriage 25. A negative electrode active material layer 52 is formed by supplying a negative electrode active material to a recess formed in one main surface of the separator member 51 molded into uneven shape, and a positive electrode active material layer 56 is formed by supplying a positive electrode active material to a recess formed in the other main surface of the separator member 51. Consequently, a high performance three-dimensional battery having a negative electrode 54 and a positive electrode 58 of nest structure is obtained, and the quality and performance of a battery can be enhanced.

Description

  The present invention relates to a technique for manufacturing a battery including a negative electrode, a separator (or a solid electrolyte layer) into which an electrolytic solution is injected, and a positive electrode.

  For example, Patent Document 1 describes a stacked lithium ion secondary battery including a flat electrode group in which a positive electrode, a separator, and a negative electrode are stacked and stacked. The positive electrode is composed of a positive electrode current collector and a positive electrode active material layer, and the negative electrode is composed of a negative electrode current collector and a negative electrode active material layer. The positive electrode and the negative electrode are disposed so that the positive electrode active material layer and the negative electrode active material layer face each other with the separator interposed therebetween. The electrode group configured as described above is inserted into the exterior case from the opening of the exterior case, and then an electrolyte is injected into the exterior case. Thereafter, the opening is welded while vacuuming the inside of the exterior case. Thus, the manufacture of the lithium ion secondary battery is completed.

Japanese Patent No. 4695170

  The current is realized by insertion / extraction of lithium ions in the positive electrode active material layer and the negative electrode active material layer. For this reason, the magnitude of the current is affected by the contact area between the electrolyte and the active material. That is, the increase in the contact area contributes to the increase in the amount of current. Therefore, it has been proposed to increase the contact area by finishing the active material layer into an uneven shape. In this case, the problem is the shape and molding of the separator. That is, the separator generally has a flat shape, but it is necessary to process the separator into a concavo-convex shape following the concavo-convex shape of the active material layer for the following reason. The reason is as follows.

  In a conventionally proposed battery, both of the positive electrode and the negative electrode have a structure having a series of comb-like parallel protrusions, and are arranged so as to mesh with each other while maintaining a certain gap. Therefore, in the battery, it is necessary to adopt a structure in which a separator is interposed in the gap between the positive electrode and the negative electrode. Moreover, in order to reduce the internal resistance of the electrolyte and the ion movement distance, it is necessary to finish the separator into an uneven shape corresponding to the uneven shape of the positive electrode and the negative electrode. Then, the positive electrode and the negative electrode are engaged with each other through the separator, whereby a three-dimensional battery having a nested structure is obtained. In addition, a battery composed of a negative electrode, a solid electrolyte layer, and a positive electrode has also been proposed to achieve a three-dimensional battery by finishing it in a nested structure.

  However, a manufacturing technique for successfully manufacturing a three-dimensional battery having such a nested structure has not yet been established.

  The present invention has been made in view of the above problems, and an object thereof is to provide a technique for manufacturing a high-quality and high-performance three-dimensional battery having a nested structure.

  In order to achieve the above object, according to a first aspect of the battery manufacturing method of the present invention, (a) a plurality of parallel mutually so as to satisfy the following arrangement conditions (a-1) to (a-3): An arrangement step of arranging a first mold member having a concavo-convex shape formed with linear projections and a second mold member having a plurality of projections parallel to each other; and (a-1) the first mold member is a line. (A-2) Separator member whose second mold member is opposite to the first main surface, the second mold member being positioned on the first main surface side of the separator member with the protruding portion facing the first main surface of the separator member (A-3) the protrusion of the second mold member faces the recess of the first mold member with the separator member interposed therebetween. (b) a molding step in which the separator member is sandwiched between the first mold member and the second mold member to mold the separator member into an uneven shape after the placing step; and (c) the second mold A first electrode forming step of supplying a first active material material to a recess formed in a second main surface of the separator member separated from the member; and (d) after the first electrode forming step, the first mold member is released. And a second electrode forming step of supplying a second active material material to a recess formed in the first main surface of the separator member.

  According to a first aspect of the battery manufacturing apparatus of the present invention, in order to achieve the above object, a first mold member having a concavo-convex shape formed with a plurality of linear protrusions parallel to each other and a plurality of parallel projections A second mold member having a protrusion, and the separator member is held by the first mold member and the second mold member in a state where the protrusion of the second mold member is opposed to the recess of the first mold member via the separator member. A molded part that sandwiches and forms the separator member into a concavo-convex shape, a first active material supply unit that supplies a first active material material to a concave portion on one main surface of the concavo-convex shaped separator member, and a concavo-convex shape. And a second active material supply unit that supplies the second active material to the recess on the other main surface of the separator member.

  In the invention configured as described above, the first mold member and the second mold member sandwich the separator member while the protrusion of the second mold member faces the recess of the first mold member via the separator member, and the separator member is It is formed into a concavo-convex shape following the concavo-convex shape of the first mold member. The first electrode is formed by supplying the first active material to the concave portion of the main surface (second main surface, one main surface) on one side of the separator member thus formed into a concavo-convex shape. In addition, the second active material is supplied to the concave portion of the other main surface (first main surface, other main surface) of the separator member on which the first electrode is formed, thereby forming the second electrode. As a result, both the first electrode and the second electrode have a nested structure.

  Here, when forming the first electrode, the first active material may be supplied while supporting the first main surface of the separator member formed into an uneven shape with the first mold member. . In this case, since the separator member is supported by the first mold member during the supply of the first active material, the supply can be stably performed.

  Further, when the first electrode is composed of the first active material layer composed of the first active material and the first current collector, the first active material layer and the first current collector are divided into the following two types: You may form in an aspect. For example, after forming the first active material layer by supplying the first active material material to the concave portion while exposing the top portion of the convex portion of the second main surface of the separator member, the first active material layer is formed on the top portion and the first active material layer. One current collector may be formed. Alternatively, the first current collector may be formed on the first active material layer after supplying the first active material material to the entire second main surface of the separator member to form the first active material layer.

  Further, when the second electrode is constituted by the second active material layer constituted by the second active material and the second current collector, the second electrode may be constituted in the same manner as the first electrode. For example, the second active material layer is formed by supplying the second active material to the recess while the top of the first main surface of the separator member is exposed, and then the second active material layer is formed on the top and the second active material layer. A current collector may be formed. Alternatively, the second current collector may be formed on the second active material layer after supplying the second active material material to the entire first main surface of the separator member to form the second active material layer.

  According to a second aspect of the battery manufacturing method of the present invention, in order to achieve the above object, (a) an electrolyte that supplies a solid electrolyte material to the concavo-convex surface of a first mold member having a plurality of parallel protrusions parallel to each other After the supplying step and (b) electrolyte supplying step, a second mold member having a plurality of protrusions parallel to each other is arranged so as to satisfy the following arrangement condition (b-1), and the first mold member is solid A molding step of forming an uneven solid electrolyte layer by sandwiching the electrolyte material; and (b-1) the protrusion of the second mold member faces the recess of the first mold member, and (c) spaced apart from the second mold member. A first electrode forming step of supplying a first active material material to a recess formed in the second main surface of the solid electrolyte layer, and (d) after the first electrode forming step, the first mold member is released to form a solid And a second electrode forming step of supplying a second active material material to a recess formed in the first main surface of the electrolyte layer, doing.

  According to a second aspect of the battery manufacturing apparatus of the present invention, in order to achieve the above object, the first mold member having a concavo-convex shape formed with a plurality of linear protrusions parallel to each other, the concavo-convex of the first mold member An electrolyte supply mechanism for supplying a solid electrolyte material to the surface, and a second mold member having a second mold member having a plurality of protrusions parallel to each other, with respect to the recess of the first mold member supplied with the solid electrolyte material The first mold member and the second mold member sandwich the solid electrolyte material between the first mold member and the second mold member so as to form a solid electrolyte layer having a concavo-convex shape, and a concave portion on one main surface of the solid electrolyte layer. A first active material supply unit that supplies an active material and a second active material supply unit that supplies a second active material to a recess on the other main surface of the solid electrolyte layer are provided.

  In the invention configured as described above, the first mold member and the second mold member with the protrusions of the second mold member facing the recesses of the uneven surface of the first mold member supplied with the solid electrolyte material. Forms a solid electrolyte layer having a concavo-convex shape following the concavo-convex shape of the first mold member by sandwiching the solid electrolyte material. And a 1st active material material is supplied to the recessed part of the one main surface (2nd main surface, one main surface) of a solid electrolyte layer, and a 1st electrode is formed. In addition, the second active material is supplied to the concave portion of the other main surface (the first main surface and the other main surface) of the solid electrolyte layer on which the first electrode is formed to form the second electrode. As a result, both the first electrode and the second electrode have a nested structure.

  Here, in forming the first electrode, the first active material may be supplied while supporting the first main surface of the solid electrolyte layer formed into an uneven shape with the first mold member. Good. In this case, since the solid electrolyte layer is supported by the first mold member during the supply of the first active material, the supply can be stably performed.

  Further, when the first electrode is composed of the first active material layer composed of the first active material and the first current collector, the first active material layer and the first current collector are in the first mode described above. You may form in the aspect similar to this invention. Further, when the second electrode is composed of the second active material layer composed of the second active material and the second current collector, the first mode described above is applied to the second active material layer and the second current collector. You may form in the aspect similar to the invention concerning.

  Moreover, in the invention concerning the 1st aspect mentioned above and the invention concerning the 2nd aspect, the comb-shaped metal mold | die which made the some linear projection part protrude from the flat 1st type | mold base material, for example as a 1st type | mold member. Can be used. Further, as the second mold member, for example, a comb-shaped mold having a plurality of protrusions protruding from a flat plate-shaped second mold substrate may be used, and the first mold member and the second mold member are engaged with each other. You may shape | mold so that it may adjoin.

  Further, as the second mold member, for example, a drum-shaped mold in which each protrusion is projected in an annular shape on the outer peripheral surface of a cylindrical or columnar second mold substrate may be used. In this case, while rotating the second mold member around the axis, the first mold member is moved relative to the second mold member, and the plurality of protrusions of the second mold member respectively correspond to the first mold members. You may shape | mold by making it enter into the recessed part of this.

  According to the first aspect of the present invention, after the separator member is formed into an uneven shape following the uneven shape of the first mold member using the first mold member and the second mold member, the recesses on the respective main surfaces of the separator member are formed. An active material is supplied to form an electrode having a nested structure. Thus, a high-quality and high-performance three-dimensional battery having a nested structure can be manufactured.

  According to the second aspect of the present invention, the solid electrolyte supplied to the uneven surface of the first mold member is formed by the second mold member, and the solid electrolyte layer is formed into an uneven shape following the uneven shape of the first mold member. Then, an active material is supplied to the concave portion of each main surface of the solid electrolyte layer to form an electrode having a nested structure. Thus, a high-quality and high-performance three-dimensional battery having a nested structure can be manufactured.

1 is a block diagram showing a battery manufacturing system as a first embodiment of a battery manufacturing apparatus according to the present invention. It is a figure which shows the structure of the manufacturing apparatus of the battery electrode group shown in FIG. It is a block diagram which shows the electrical structure of the manufacturing apparatus shown in FIG. It is a flowchart which shows the manufacturing method of the battery by the battery manufacturing system shown in FIG. It is a figure which shows the manufacturing process of a battery typically. It is a figure which shows the manufacturing process of a battery typically. It is a figure which shows the manufacturing process of a battery typically. It is a schematic diagram which shows 2nd Embodiment of the manufacturing method of the battery concerning this invention. It is a schematic diagram which shows 2nd Embodiment of the manufacturing method of the battery concerning this invention. It is a figure which shows the manufacturing apparatus which can perform 3rd Embodiment of the manufacturing method of the battery concerning this invention. It is a block diagram which shows the battery manufacturing system which is 4th Embodiment of the battery manufacturing apparatus concerning this invention. It is a figure which shows the structure of the manufacturing apparatus of the battery main body shown in FIG. It is a figure which shows the structure of the manufacturing apparatus of the battery main body employable with 5th Embodiment of the manufacturing apparatus of the battery concerning this invention.

<First Embodiment>
FIG. 1 is a block diagram showing a battery manufacturing system which is a first embodiment of a battery manufacturing apparatus according to the present invention. The battery manufacturing system 1 includes a manufacturing apparatus 2 and an injection / assembly apparatus 3 for manufacturing a battery electrode group, and manufactures a battery as follows. Here, the embodiment will be described by exemplifying a case of manufacturing a lithium ion secondary battery including a negative electrode, a separator member into which an electrolytic solution is injected, and a positive electrode.

  FIG. 2 is a diagram showing the configuration of the battery electrode group manufacturing apparatus shown in FIG. FIG. 3 is a block diagram showing an electrical configuration of the manufacturing apparatus shown in FIG. The battery electrode group manufacturing apparatus 2 includes a separator molding part 21, a negative electrode forming part 22, a transfer part 23, and a positive electrode forming part 24.

  In the manufacturing apparatus 2, two types of transfer tables 25 and 26 are provided. Among them, a plurality of transfer tables 25 are provided, and each transfer table 25 circulates and moves the separator forming unit 21, the negative electrode forming unit 22, and the transfer unit 23 in this order. On the other hand, a plurality of transfer tables 26 are also provided, and each transfer table 26 circulates and moves the transfer unit 23 and the positive electrode forming unit 24 in this order. In order to distinguish between the two types of transfer tables 25 and 26, the transfer tables 25 and 26 are hereinafter referred to as “upstream transfer table” and “downstream transfer table”, respectively.

  As shown in FIG. 2, each upstream-side transport platform 25 has a flat base portion 251 and a plurality of protrusions projecting upward from the base portion 251 in the vertical direction Z (hereinafter referred to as “vertically upward”). It has a linear protrusion 252 and has a function of conveying the separator member and the negative electrode as will be described later, and also functions as a lower mold for molding the separator member. In this embodiment, the base portion 251 is configured by a flat plate member having substantially the same plane size as the battery electrode group manufactured by the manufacturing apparatus 2. Each linear protrusion 252 has a line shape extending in the Y direction. These linear protrusions 252 are formed at equal intervals in the X direction on the upper surface of the base portion 251. Therefore, the upstream-side transport base 25 is finished in a concavo-convex shape in the XZ section, and has a so-called comb tooth shape. The width in the X direction of the convex portion (linear projection portion 252) of the upstream conveyance table 25 is narrower than the width of the concave portion (interval in the X direction between adjacent linear projection portions 252).

  The upstream conveyance table 25 can be moved intermittently in the Y direction, and the separator molding unit 21, the negative electrode formation unit 22, and the transfer unit 23 are arranged in this order along the movement path. Among these, the separator shaping | molding part 21 has the separator supply mechanism 211, the metal mold | die 212, and the metal mold | die raising / lowering mechanism 213 (FIG. 3).

  The separator supply mechanism 211 is provided above the separator supply position P11 of the separator molding unit 21. The separator supply mechanism 211 supplies the separator member 51 from vertically above the upstream conveyance table 25 while the upstream conveyance table 25 having the uneven shape as described above passes the separator supply position P11. That is, the separator supply mechanism 211 feeds the separator member 51 from the separator roll 511 mounted on a roll mounting shaft (not shown) in the continuous sheet (web) shape in the Y direction, and the upper surface of the upstream conveying table 25 at the separator supply position P11. To send. In this embodiment, the separator supply mechanism 211 is controlled by the control unit 27 that controls the entire apparatus 2, and intermittently feeds the separator member 51 in response to the intermittent movement of the upstream conveyance table 25. Thereby, the upstream conveyance stand 25 moves to the molding position P12 with the separator member 51 placed on the upper surface.

  At the molding position P <b> 12, the mold 212 is disposed vertically above the upstream conveyance platform 25 and the separator member 51. The mold 212 has a comb-like shape like the upstream conveyance table 25, and is disposed to face the upstream conveyance table 25 with the separator member 51 at the molding position P12 interposed therebetween. That is, the mold 212 has a flat base portion 2121 and a plurality of linear protrusion portions 2122 that protrude from the lower surface of the base portion 2121 in the vertical direction Z (hereinafter referred to as “vertically downward”). doing. The plurality of linear protrusions 2122 face the upper surface of the separator member 51, and the convex portion of the mold 212, that is, the linear protrusion portion 2122 faces the concave portion of the upstream conveyance table 25 via the separator member 51. As described above, the mold 212 is provided to be movable up and down.

  The mold 212 is connected to the mold lifting mechanism 213 (FIG. 3). Then, when a lowering command is given from the control unit 27 to the mold lifting mechanism 213 in a state where the upstream side conveyance platform 25 is stopped at the molding position P12, the mold lifting mechanism 213 is operated accordingly and the mold 212 is operated. Is moved vertically downward. As a result, the linear protrusion 2122 of the mold 212 pushes a part of the separator member 51 into the concave portion of the upstream conveying table 25 to form the separator member 51 into an irregular shape that follows the irregular shape of the upstream conveying table 25. . Following this, the mold lifting mechanism 213 is operated in accordance with the ascending command from the control unit 27 to retract the mold 212 vertically upward.

  In the negative electrode forming part 22 located on the downstream side (right hand side in FIG. 1) of the separator molding part 21, the negative electrode active material supply mechanism 221, the negative electrode current collector supply mechanism 222, and the negative electrode along the movement path of the upstream conveyance table 25. The cutting mechanism 223 and the negative electrode drying furnace 224 are arranged in this order. Among these, the negative electrode active material supply mechanism 221 includes a discharge nozzle 2211 provided with a plurality of discharge ports (not shown) for discharging a coating liquid containing a negative electrode active material along a horizontal direction X orthogonal to the Y direction. ing. The discharge nozzle 2211 is disposed vertically above the sheet-like separator member 51 that is conveyed in the Y direction while being supported by the upstream conveyance table 25, and each discharge port is directed to a concave portion of the separator member 51. And according to the discharge command from the control part 27, the said coating liquid is discharged on the surface of the separator member 51 from each discharge port of the discharge nozzle 2211 in the negative electrode active material supply position P21. As a result, the coating liquid containing the negative electrode active material is supplied to the recesses of the separator member 51 to form the negative electrode active material layer 52. The negative electrode active material supply mechanism 221 uses a so-called nozzle dispensing method, but other supply methods may be used.

  In the negative electrode current collector supply mechanism 222, the negative electrode current collector supply mechanism 222 is viewed from vertically above the separator member 51 having the negative electrode active material layer 52 while the upstream-side transport platform 25 passes through the negative electrode current collector supply position P <b> 22. A negative electrode current collector is supplied. In other words, the negative electrode current collector supply mechanism 222 uses a negative electrode current collector roll mounted on a roll mounting shaft (not shown) (in this embodiment, a metal foil functioning as a negative electrode current collector, for example, a copper foil 53). ) The copper foil 53 is fed out from the 531 in the Y direction into a continuous sheet (web) shape and fed onto the negative electrode active material layer 52. In this embodiment, the negative electrode current collector supply mechanism 222 is controlled by the control unit 27 in the same manner as the separator supply mechanism 211, and intermittently moves the copper foil 53 in response to the intermittent movement of the upstream conveyance table 25. Send it out. This also applies to the positive electrode current collector supply mechanism 242 described later.

  A negative electrode drying furnace 224 is provided downstream of the negative electrode current collector supply mechanism 222 in the transport direction Y. And the upstream conveyance stand 25 moves to the inside of the drying furnace 224 for negative electrodes in the state which laminated | stacked the separator member 51, the negative electrode active material layer 52 before drying, and the copper foil (negative electrode collector) 53 on the upper surface. The inside of the negative electrode drying furnace 224 is adjusted to a temperature according to the temperature command of the control unit 27. For this reason, the negative electrode active material layer 52 sandwiched between the separator member 51 and the copper foil 53 is subjected to a drying process to form a negative electrode.

  A negative electrode cutting mechanism 223 is provided between the negative electrode current collector supply mechanism 222 and the negative electrode drying furnace 224. The negative electrode cutting mechanism 223 has a pair of cutter members. Although only the upper cutter member is shown in FIG. 2, both cutter members are driven to open and close in response to an opening / closing command from the control unit 27. That is, the closing and opening of both the cutter members are executed in this order immediately after the rear end portion of the upstream conveyance table 25 passes the cutting position P23 of the negative electrode cutting mechanism 223. Thereby, the separator member 51 and the copper foil 53 are cut. Thereafter, the closing and opening of both cutter members is performed again in this order immediately before the leading end of the next upstream conveyance table 25 reaches the cutting position P23 of the negative electrode cutting mechanism 223. By these cutting operations, the separator member 51 and the copper foil 53 are trimmed to the same length in the Y direction as that of the upstream transport table 25. Then, as described above, the upstream conveying platform 25 passes through the negative electrode drying furnace 224, and the battery electrode in which the negative electrode 54 (= negative electrode active material layer 52 + copper foil 53) is integrally formed with the separator member 51, A so-called separator-integrated battery electrode 55 is formed on the upstream conveyance table 25. The battery electrode 55 is transported to the transfer unit 23 while being supported by the upstream transport platform 25.

  As illustrated in FIG. 3, the transfer unit 23 includes a reversing mechanism 231 and a transfer mechanism 232. The reversing mechanism 231 reverses the conveyed product (= upstream conveying table 25 + separator integrated battery electrode 55) conveyed from the negative electrode forming unit 22 up and down. As a result, the upstream-side transport base 25 covers the separator-integrated battery electrode 55. More specifically, the copper foil 53 is located at the lowermost position in the vertical direction Z, and the negative electrode active material layer 52, the separator member 51, and the upstream conveyance table 25 are stacked on the copper foil 53 in this order.

  The transfer mechanism 232 has a function of transferring the separator-integrated battery electrode 55 to the upper surface of the transfer table 26 as shown in FIG. 2 after removing the upstream transfer table 25 from the inverted transfer body. ing. Although not shown in the drawings, a transport mechanism is provided, and the removed upstream transport table 25 is turned upside down to return to the original posture and sent back to the separator molding unit 21 for upstream transport. It is used for circulating use of the table 25.

  Each downstream transport table 26 includes a flat base portion 261, and the upper surface of the base portion 261 can adsorb and hold the copper foil (negative electrode current collector) 53 of the separator-integrated battery electrode 55. . In addition, the holding method of the copper foil 53 by the downstream side conveyance stand 26 is not limited to the suction method, and other holding methods, for example, a mechanical chuck method may be adopted.

  In the positive electrode forming unit 24 located on the downstream side of the transfer unit 23, a positive electrode active material supply mechanism 241, a positive electrode current collector supply mechanism 242, a positive electrode cutting mechanism 243, and a positive electrode drying unit are arranged along the movement path of the downstream transport table 26. The furnaces 244 are arranged in this order. The positive electrode active material supply mechanism 241, the positive electrode current collector supply mechanism 242, the positive electrode cutting mechanism 243, and the positive electrode drying furnace 244 are the negative electrode active material supply mechanism 221, the negative electrode current collector supply mechanism 222, the negative electrode cutting mechanism 223, and the negative electrode, respectively. It has the same configuration as the drying furnace 224 and has a similar function. That is, the positive electrode active material supply mechanism 241 includes a discharge nozzle 2411 provided with a plurality of discharge ports (not shown) for discharging a coating liquid containing a positive electrode active material along the horizontal direction X orthogonal to the Y direction. Yes. The discharge nozzle 2411 is disposed vertically above the separator-integrated battery electrode 55 that is transported in the Y direction while being supported by the downstream transport platform 26, and each discharge port is directed to a recess of the separator member 51. Each concave portion is a portion that is formed into a concave shape by following the convex portion of the upstream conveyance table 25 by the separator molding portion 21.

  The positive electrode active material supply mechanism 241 discharges the coating liquid from the discharge ports of the discharge nozzle 2411 to the surface of the separator member 51 at the positive electrode active material supply position P41 in response to a discharge command from the control unit 27. As a result, the coating liquid containing the positive electrode active material is supplied to the recesses of the separator member 51, and the positive electrode active material layer 56 is formed. The positive electrode active material supply mechanism 241 uses the so-called nozzle dispensing method as in the negative electrode active material supply mechanism 221, but other supply methods may be used.

  In the positive electrode current collector supply mechanism 242 located on the downstream side of the positive electrode active material supply mechanism 241, the positive electrode current collector supply mechanism 242 operates while the positive electrode current collector supply mechanism 242 passes through the positive electrode current collector supply position P 42. The positive electrode current collector is supplied from vertically above the separator member 51 having the material layer 56. In other words, the positive electrode current collector supply mechanism 242 uses a positive electrode current collector roll mounted on a roll mounting shaft (not shown) (in this embodiment, a metal foil functioning as a positive electrode current collector, for example, an aluminum foil 57). ) The aluminum foil 57 is fed out in the Y direction from the 571 into a continuous sheet (web) shape and fed onto the positive electrode active material layer 56.

  A positive electrode drying furnace 244 is provided on the downstream side in the transport direction Y of the positive electrode current collector supply mechanism 242. And the downstream conveyance stand 26 moves to the inside of the drying furnace 244 for positive electrodes in the state which laminated | stacked the separator member 51, the positive electrode active material layer 56 before drying, and the aluminum foil (negative electrode collector) 57 on the upper surface. The inside of the positive electrode drying furnace 244 is adjusted to a temperature according to the temperature command of the control unit 27. For this reason, the positive electrode active material layer 56 sandwiched between the separator member 51 and the aluminum foil 57 is subjected to a drying process to form a positive electrode (= positive electrode active material layer 56 + aluminum foil 57).

  A positive electrode cutting mechanism 243 is provided between the positive electrode current collector supply mechanism 242 and the positive electrode drying furnace 244. The positive electrode cutting mechanism 243 has a pair of cutter members. Although only the upper cutter member is shown in FIG. 2, both cutter members are driven to open and close in response to an opening / closing command from the control unit 27. That is, the closing and opening of both cutter members are executed in this order immediately after the rear end portion of the downstream conveyance table 26 passes the cutting position P43 of the positive electrode cutting mechanism 243. Thereby, the separator member 51 and the aluminum foil 57 are cut. After that, the cutter members are closed and opened again in this order immediately before the leading end of the next downstream conveyance table 26 reaches the cutting position P43 of the positive electrode cutting mechanism 243. By these cutting operations, the aluminum foil 57 is cut and aligned to the same length in the Y direction as that of the downstream conveyance table 26. And the downstream conveyance stand 26 passes the positive electrode drying furnace 244 as mentioned above, and the flat battery electrode group formed by laminating | stacking the negative electrode, the separator, and the positive electrode is formed.

  In the battery manufacturing system 1, in addition to the battery electrode group manufacturing apparatus 2 described above, an injection / assembly apparatus 3 is provided. The injection / assembly device 3 has a function of inserting the battery electrode group manufactured by the manufacturing device 2 from the opening of the outer case into the outer case, a function of injecting an electrolyte into the outer case, and an inner portion of the outer case. It also has the function of welding the opening while vacuuming.

  Next, a method for manufacturing a battery by the battery manufacturing system 1 will be described with reference to FIGS. FIG. 4 is a flowchart showing a battery manufacturing method by the battery manufacturing system shown in FIG. 5 to 7 are diagrams schematically showing a battery manufacturing process. In the battery electrode group manufacturing apparatus 2, the control unit 27 controls each part of the apparatus (steps S1 to S6) to manufacture the battery electrode group 59. In the injection / assembly apparatus 3, the injection / assembly control unit (not shown). Controls each part of the apparatus (steps S7 to S9), and performs electrolyte injection and battery assembly. Hereinafter, each manufacturing process will be described in detail.

  In the separator molding unit 21 of the manufacturing apparatus 2, the separator member 51 is fed out from the separator roll 511 in the Y direction and sent to the separator supply position P11 in synchronization with the movement of the upstream conveyance platform 25 in the Y direction. As a result, as shown in FIG. 5A, the separator member 51 is placed on the upper surface of the upstream conveyance table 25, that is, on the top of the linear protrusion 252 at the separator supply position P <b> 11. Then, the upstream side carrier 25 moves from the separator supply position P11 to the molding position P12 and stops, while supporting the separator member 51. Thereby, as shown in FIG.5 (b), the upstream conveyance stand 25, the separator member 51, and the metal mold | die 212 are arrange | positioned as follows (step S1).

The upstream conveying platform 25 is positioned on the vertically lower side of the separator member 51 with the linear protrusion 252 facing the lower surface of the separator member 51;
The mold 212 is positioned vertically above the upstream conveying table 25 with the separator member 51 in between.
The linear protrusion 2122 of the mold 212 opposes the recess 253 of the upstream transfer table 25 via the separator member 51, and the linear protrusion 252 of the upstream transfer table 25 is separated from the recess 2123 of the mold 212. Opposing through the member 51.

  The mold 212 is driven to move downward by the mold lifting mechanism 213 while being placed in this manner. Then, the linear protrusion 2122 of the mold 212 first comes into contact with the upper surface of the separator member 51, and further pushes the contact portion into the concave portion 253 of the upstream conveyance table 25. Thereby, as shown in FIG.5 (c), the separator member 51 is shape | molded by the uneven | corrugated shape which followed the uneven | corrugated shape of the upstream conveyance stand 25 (step S2). Thereafter, the mold 212 is driven to move upward in the vertical direction, and is retracted from the separator member 51 and the upstream conveyance table 25, and the molding process of the separator member 51 is completed (FIG. 5D).

  Thereafter, the conveyance of the upstream conveyance table 25 is resumed. The upstream conveyance platform 25 is conveyed to the negative electrode active material supply mechanism 221 while supporting the lower surface of the separator member 51 formed into an uneven shape. Then, the negative electrode active material supply mechanism 221 includes the negative electrode active material from each discharge port of the discharge nozzle 2211 from the time when the leading end of the upstream side carrier 25 reaches the position immediately below the discharge nozzle 2211, that is, the negative electrode active material supply position P 21. The coating liquid is supplied to the recess 512 (see FIG. 5D) of the separator member 51. Thus, the supply of the coating liquid is performed in synchronization with the conveyance of the upstream conveyance table 25, and the coating liquid uniformly flows into the recess 512 of the separator member 51. In addition, the discharge flow rate of the coating liquid from each discharge port per unit time is controlled by the control unit 27 according to the transport speed of the upstream transport table 25, and the coating liquid fills the recess 512 of the separator member 51. In this way, as shown in FIG. 6A, a plurality of line patterns 521 extending in the Y direction are formed on the surface of the separator member 51. Although the negative electrode active material layer 52 is formed by these line-shaped patterns 521, the negative electrode active material layer 52 is in an undried state at this point.

  Following the formation of the negative electrode active material layer 52, the upstream-side transport platform 25 is transported in the Y direction. And while the upstream conveyance stand 25 passes the negative electrode current collector supply position P22 of the negative electrode current collector supply mechanism 222, the negative electrode current collector supply mechanism 222 is connected to the separator member 51 supported by the upstream conveyance table 25. Copper foil (negative electrode current collector) 53 is supplied from vertically above. Similarly to the separator supply mechanism 211, the negative electrode current collector supply mechanism 222 also changes the copper foil 53 from the negative electrode current collector roll (copper foil roll) 531 to the copper foil 53 in response to the intermittent movement of the upstream conveyance table 25. Is sent out intermittently. Thereby, as shown in FIG. 6B, the negative electrode active material layer 52 is entirely covered with the copper foil 53. In this state, the upstream side carrier 25 moves toward the negative electrode drying furnace 224.

  During the movement of the upstream conveyance table 25, both cutter members of the negative electrode cutting mechanism 223 are maintained in the open state. However, when the rear end portion of the upstream conveyance table 25 passes the cutting position P23 of the negative electrode cutting mechanism 223, the separator member 51 that has been supplied in a continuous sheet (web) state at the time when both the cutter members are closed and The copper foil 53 is cut. Further, when the leading end portion of the next upstream conveyance table 25 reaches the cutting position P23 of the negative electrode cutting mechanism 223, both the cutter members are closed and the separator member 51 and the copper foil 53 are cut. Thus, since the separator member 51 and the copper foil 53 are cut at the front end portion and the rear end portion of the upstream-side transport table 25, the separator member 51 and the copper foil 53 are cut into the size of the upstream-side transport table 25 in the Y direction. Can be aligned.

  While supporting the separator member 51 and the copper foil 53 that are trimmed in this way, the upstream-side transport platform 25 passes through the inside of the negative electrode drying furnace 224. During this passage, the line-shaped pattern 521 in the recess 512 of the separator member 51 is dried. As a result, as shown in FIG. 6B, a negative electrode 54 composed of the negative electrode active material layer 52 and the copper foil (negative electrode current collector) 53 is formed on the upper surface of the separator member 51 (step S3). In this way, the separator-integrated battery electrode 55 is formed in a state of being supported by the upstream-side transport base 25.

  The battery electrode 55 is transported to the transfer unit 23 while being supported by the upstream transport base 25, and then turned upside down together with the upstream transport base 25 by the reversing mechanism 231 (step S4). Subsequently, the upstream transport table 25 is removed by the transfer mechanism 232, and the battery electrode 55 is placed on the upper surface of the downstream transport table 26 alone and held by suction as shown in FIG. Step S5). As a result, the battery electrode 55 is supported by the downstream-side transport table 26 with the uneven surface 513 in contact with the upstream-side transport table 25 of the separator member 51 facing vertically upward. And the battery electrode 55 is conveyed by the downstream conveyance stand 26 to the positive electrode formation part 24 in the state, and positive electrode formation is performed (step S6).

  In this positive electrode forming portion 24, although the material used is different, basically the same as the negative electrode forming portion 22, the positive electrode 58 composed of the positive electrode active material layer 56 and the positive electrode current collector (aluminum foil) 57 is a separator. It is formed on the uneven surface 513 of the member 51. That is, the positive electrode active material supply mechanism 241 supplies the positive electrode active material from each discharge port of the discharge nozzle 2411 from the point in time when the tip of the downstream-side transport base 26 reaches a position immediately below the discharge nozzle 2411, that is, the positive electrode active material supply position P41. The coating liquid containing is supplied to the recessed part 514 (refer Fig.7 (a)) of the separator member 51. FIG. As a result, as shown in FIG. 7B, a plurality of line-shaped patterns 561 extending in the Y direction are formed on the uneven surface 513 of the separator member 51. The positive electrode active material layer 56 is formed by these line patterns 561. Subsequently, an aluminum foil (positive electrode current collector) is formed from vertically above the separator member 51 in which the positive current collector supply mechanism 242 is supported by the downstream transport table 26 while transporting the downstream transport table 26 in the Y direction. 57 is supplied. Then, both cutter members of the positive electrode cutting mechanism 243 are driven to open and close in synchronization with the movement of the downstream conveyance table 26 to cut the aluminum foil 57 at the front end portion and the rear end portion of the downstream conveyance table 26, thereby the downstream conveyance table. Cut to 26 size in Y direction.

  Furthermore, while supporting the aluminum foil 57, the positive electrode active material layer 56, the separator member 51, and the copper foil 53, the downstream conveyance table 26 passes through the positive electrode drying furnace 244. During this passage, the line-shaped pattern 561 is dried. As a result, as shown in FIG. 7C, a positive electrode 58 composed of the positive electrode active material layer 56 and the aluminum foil (positive electrode current collector) 57 is formed on the uneven surface 513 of the separator member 51 (step S6). ). Thus, as shown in FIG. 7D, the battery electrode group 59 is formed in a state of being supported by the downstream-side transport table 26.

  After that, the battery electrode group 59 is removed from the downstream transport table 26 and transported to the injection / assembly apparatus 3, and steps S7 to S9 are executed by the injection / assembly apparatus 3 in the same manner as in the prior art, so that a finished battery product is obtained. Manufactured. That is, the battery electrode group 59 is inserted into the exterior case from the opening of the exterior case (step S7). Subsequently, an electrolyte is injected into the exterior case from the case opening (step S8). Thereafter, the opening is welded while vacuuming the inside of the outer case (step S9).

Here, as a material constituting each layer, a known material can be used as a constituent material of the lithium ion battery. As the positive electrode active material, for example, a material mainly composed of LiCoO ₂ (LCO) is used. For example, those mainly composed of Li ₄ Ti ₅ O ₁₂ (LTO) can be used. In addition, for example, a polyethylene (PE) sheet can be used as the separator member 51, and an electrolytic solution such as an organic electrolytic solution or an ionic liquid can be used as the electrolyte. In addition, about the material of each functional layer, it is not limited to these, What is generally known as these functional materials can be used. For example, an LMO (M is Mn, Ni, Fe, or the like) -based material can be used as the positive electrode active material, and C, Si, or Sn can be used as the negative electrode active material. As the separator, a resin material such as polypropylene (PP) or polyolefin (PO) can be used. Examples of the organic electrolyte solution, it is possible to use those containing a lithium salt (e.g., _{LiClO 4, LiPF 6, LiBF 4} , LiCF 3 SO 3) and an organic solvent. Use organic solvents such as ethylene carbonate (EC), diethyl carbonate (DEC), propylene carbonate (PC), dimethyl carbonate (DMC), and ethyl methyl carbonate (EMC), or a mixture of these. Can do.

  As described above, in the first embodiment, the mold 212 is vertically downward while the linear protrusion 2122 of the mold 212 is opposed to the concave portion 253 formed on the upper surface of the upstream transport table 25 via the separator member 51. And the separator member 51 is sandwiched. As a result, the separator member 51 is formed into a concavo-convex shape following the concavo-convex shape of the upstream side carrier 25. Then, a negative electrode active material is applied to the concave portion 512 formed on one main surface of the separator member 51 formed into a concavo-convex shape to form the negative electrode active material layer 52 and formed on the other main surface of the separator member 51. The positive electrode active material layer 56 is formed by applying a positive electrode active material to the recesses 514. Thus, a three-dimensional battery having the nested negative electrode 54 and positive electrode 58 is obtained, and the quality and performance of the battery can be improved.

  In addition, since the negative electrode active material is supplied to the concave portion 512 while the separator member 51 formed into a concavo-convex shape is supported by the upstream conveyance platform 25, the negative electrode active material layer 52 is formed. The material material can be supplied stably, and a high-quality three-dimensional battery can be manufactured.

Second Embodiment
8 and 9 are schematic views showing a second embodiment of the battery manufacturing method according to the present invention. The second embodiment is greatly different from the first embodiment in the step of forming the negative electrode 54 and the positive electrode 58, and other configurations are basically the same as those in the first embodiment. Therefore, here, the formation of the negative electrode 54 (step S3) and the formation of the positive electrode 58 (step S6) in the second embodiment will be described in comparison with those in the first embodiment.

  In order to form the negative electrode active material layer 52, the negative electrode active material supply mechanism 221 of the nozzle dispensing system is used in the first embodiment. That is, as shown in FIG. 6A, the negative electrode active material is supplied only to the recess 512 to form a line pattern 521, and the negative electrode active material layer 52 is configured by these. In addition, as with the negative electrode active material layer 52, a line pattern 561 is formed on the positive electrode active material layer 56, and the positive electrode active material layer 56 is configured by these (see FIG. 7B). In the following description, an active material layer composed only of a line pattern is referred to as a “line-independent” active material layer.

  On the other hand, in the second embodiment, for example, a die coating type negative electrode active material supply mechanism 221 is used, and as shown in FIG. 8A, on the uneven surface of the separator member 51 supported by the upstream-side transport base 25. The negative electrode active material is supplied as a whole. For this reason, the negative electrode active material is supplied not only to the line-shaped pattern 521 but also to the convex portion of the separator member 51 to form the planar pattern 522. That is, the planar pattern 522 covers the line pattern 521 together with the separator member 51 and connects the line patterns 521 to each other (an active material layer having this structure is referred to as a “line connection type” active material layer). . Then, as shown in FIG. 4B, the copper foil 53 is supplied by the negative electrode current collector supply mechanism 222 to the upper surface of the line-connected negative electrode active material layer 52, that is, the planar pattern 522, so that the negative electrode 54 is Composed.

  Similarly to the negative electrode 54, for the positive electrode 58, for example, a die-coating positive electrode active material supply mechanism 241 is used, and as shown in FIG. 9B, a separator integrated battery supported by the downstream-side transport table 26. The positive electrode active material is supplied to the entire upper surface of the electrode 55, that is, the entire uneven surface of the separator member 51. For this reason, the line connection type positive electrode active material layer 56 having the line pattern 561 and the planar pattern 562 is formed. And the aluminum foil 57 is supplied with respect to the upper surface of the plane pattern 562 by the positive electrode collector supply mechanism 242, and the positive electrode 58 is comprised (the figure (c)).

  As described above, according to the second embodiment, the battery using the line-connected negative electrode active material layer 52 and the positive electrode active material layer 56 is also used in the first embodiment (line independent negative electrode active material layer 52 and Similarly to the battery manufacturing method and manufacturing apparatus using the positive electrode active material layer 56, the negative electrode 54 and the positive electrode 58 having a nested structure are obtained, and the quality and performance of the battery can be improved. In the first embodiment, both the negative electrode active material layer 52 and the positive electrode active material layer 56 have a line-independent structure, and in the second embodiment, both the negative electrode active material layer 52 and the positive electrode active material layer 56 have a line. Although the structure is a connected structure, the structure of the negative electrode active material layer 52 and the positive electrode active material layer 56 is not an essential part of the present invention, and each of the negative electrode active material layer 52 and the positive electrode active material layer 56 has a line-independent structure and a line. Any of a connection type structure may be sufficient. For example, the present invention is also applied to a manufacturing method and a manufacturing apparatus for manufacturing a battery in which one of the negative electrode active material layer 52 and the positive electrode active material layer 56 has a line-independent structure and the other has a line connection structure. be able to. These points are the same in the following embodiments.

<Third Embodiment>
FIG. 10 is a view showing a manufacturing apparatus capable of executing the third embodiment of the battery manufacturing method according to the present invention. The third embodiment is largely different from the first embodiment in the following three points. First, the first point is that the lengths in the Y direction of the carriages 25 and 26 are longer than those in the first and second embodiments, and the distance in the Y direction from the separator supply mechanism 211 to the negative electrode drying furnace 224. It is a point that is set longer than. The second point is that the separator member 51 is supplied, the separator member 51 is formed, the negative electrode active material is supplied, the copper foil (the negative electrode) while the upstream side carrier 25 moves from the separator supply mechanism 211 to the transfer unit 23. The current collector 53 is supplied and the negative electrode active material is dried continuously. Furthermore, the third point is that the supply of the positive electrode active material, the supply of the aluminum foil (positive electrode current collector) 57, the positive electrode active material, while the downstream side carrier 26 moves from the transfer unit 23 to the positive electrode drying furnace 244. The point is that the material is continuously dried. The basic configuration of the transport tables 25 and 26, the negative electrode active material supply mechanism 221, the negative electrode drying furnace 224, the positive electrode current collector supply mechanism 242 and the positive electrode drying furnace 244 are basically the same as those in the first embodiment. Hereinafter, the third embodiment will be described focusing on the differences, and the same components will be denoted by the same reference numerals and description thereof will be omitted.

  The upstream conveyance table 25 is continuously movable in the Y direction, and the separator molding unit 21, the negative electrode formation unit 22, and the transfer unit 23 are arranged in this order along the movement path. Among these, the separator supply mechanism 211 is provided at the separator supply position P11 of the separator molding unit 21. Unlike the first embodiment, the separator supply mechanism 211 has a separator storage portion 515 that stores a plurality of separator members 51 having the same length as the length of the transport bases 25 and 26 in the Y direction. The separator supply mechanism 211 sends out the separator members 51 one by one in synchronization with the conveyance of the upstream conveyance table 25 from the separator storage unit 515. In other words, the separator supply mechanism 211 starts to feed the separator member 51 at the same time as the leading end of the upstream conveyance table 25 reaches the separator supply position P11. In addition, at the same time as the rear end portion of the upstream conveyance table 25 passes the separator supply position P11, the separator supply mechanism 211 stops the feeding of the separator member 51. Instead of the separator storage portion 515, the separator member 51 may be sent out in a continuous sheet (web) state and the separator member 51 may be cut at an appropriate position as in the first embodiment. Conversely, in the first embodiment and the second embodiment, it is also possible to employ the delivery mode of the separator member 51 employed in the third embodiment.

  In the third embodiment, a drum-shaped mold in which a plurality of annular projections 2124 protrude from the outer peripheral surface of a cylindrical or columnar mold base 2123 is used as the mold 212. The drum-shaped mold 212 is disposed at the molding position P12 of the separator molding unit 21 and is disposed opposite to the upstream conveyance table 25 with the separator member 51 interposed therebetween. More specifically, the drum-shaped mold 212 is arranged in a state in which the lowest point in the vertical direction Z of the plurality of annular protrusions 2124 enters the concave portion of the upstream conveyance table 25. The drum-shaped mold 212 is rotatable around the rotation shaft 2125. Then, upon receiving a rotational driving force from a rotational driving mechanism (not shown), the drum-shaped mold 212 rotates at a peripheral speed substantially equal to the transport speed of the upstream-side transport base 25. For this reason, the separator member 51 supplied from the separator supply mechanism 211 to the uneven surface of the upstream conveyance table 25 is moved in the Y direction together with the upstream conveyance table 25, and is sandwiched between the upstream conveyance table 25 and the drum mold 212. Thus, it is formed into a concavo-convex shape following the concavo-convex shape of the upstream-side transport base 25.

  In the negative electrode forming unit 22 located on the downstream side (right hand side in FIG. 10) of the separator molding unit 21, the negative electrode active material supply mechanism 221, the negative electrode current collector supply mechanism 222, and the negative electrode are arranged along the movement path of the upstream conveyance table 25. The drying oven 224 is arranged in this order. Among these, the negative electrode active material supply mechanism 221 forms a negative electrode active material layer 52 by supplying a coating liquid containing a negative electrode active material to the recesses of the separator member 51 as in the first embodiment.

  Unlike the first embodiment, the negative electrode current collector supply mechanism 222 includes a copper foil storage portion 532 that stores a plurality of copper foils 53 having the same length as the length in the Y direction of the upstream conveyance platform 25. The negative electrode current collector supply mechanism 222 sends out the copper foils 53 one by one from the copper foil storage portion 532 in synchronization with the conveyance of the upstream conveyance table 25. In other words, the negative electrode current collector supply mechanism 222 starts to feed the copper foil 53 at the same time when the tip of the upstream transport platform 25 reaches the negative electrode current collector supply position P22. Further, at the same time as the rear end portion of the upstream conveyance table 25 passes through the negative electrode current collector supply position P22, the negative electrode current collector supply mechanism 222 stops the feeding of the copper foil 53. Instead of the copper foil storage portion 532, the copper foil 53 may be sent out in a continuous sheet (web) state in the same manner as in the first embodiment, and the copper foil 53 may be cut at an appropriate position. Conversely, in the first embodiment and the second embodiment, it is also possible to employ the delivery mode of the copper foil 53 employed in the third embodiment.

  On the downstream side of the negative electrode current collector supply mechanism 222 in the transport direction Y, a negative electrode drying furnace 224 is provided as in the first embodiment. Then, with the separator member 51, the negative electrode active material layer 52 before drying, and the copper foil (negative electrode current collector) 53 laminated on the upper surface, the upstream side carrier 25 moves into the negative electrode drying furnace 224, and the negative electrode active A drying process is performed on the material layer 52.

  Thus, a battery electrode in which the negative electrode 54 (= negative electrode active material layer 52 + copper foil 53) is integrally formed on the separator member 51, that is, a so-called separator-integrated battery electrode 55 is formed on the upstream side carrier 25. The battery electrode 55 is transported to the transfer unit 23 while being supported by the upstream transport platform 25.

  The transfer unit 23 is configured in the same manner as in the first embodiment, and after the product conveyed from the negative electrode forming unit 22 (= upstream transport table 25 + separator integrated battery electrode 55) is turned upside down, As shown in FIG. 10, only the separator-integrated battery electrode 55 is transferred to the upper surface of the downstream-side transport table 26.

  Similarly to the upstream transfer table 25, the downstream transfer table 26 can also move continuously in the Y direction, and the positive electrode active material supply mechanism 241 of the positive electrode forming unit 24, the positive electrode current collector, along the movement path. The body supply mechanism 242 and the positive electrode drying furnace 244 are arranged in this order. Among these, the positive electrode active material supply mechanism 241 supplies the coating liquid containing a positive electrode active material to the recessed part of the separator member 51 similarly to 1st Embodiment, and forms the positive electrode active material layer 56. FIG.

  Unlike the first embodiment, the positive electrode current collector supply mechanism 242 includes an aluminum foil storage portion 572 that stores a plurality of aluminum foils 57 having the same length as the length of the downstream-side transport base 26 in the Y direction. The positive electrode current collector supply mechanism 242 sends out the aluminum foils 57 one by one from the aluminum foil storage part 572 in synchronization with the conveyance of the downstream conveyance table 26. In other words, the positive electrode current collector supply mechanism 242 starts feeding the aluminum foil 57 at the same time as the leading end of the downstream side conveyance platform 26 reaches the positive electrode current collector supply position P42. Further, at the same time as the rear end portion of the downstream-side transport table 26 passes through the positive electrode current collector supply position P42, the positive electrode current collector supply mechanism 242 stops sending out the aluminum foil 57. Instead of the aluminum foil storage portion 572, the aluminum foil 57 may be sent out in a continuous sheet (web) state and cut at an appropriate position as in the first embodiment. Conversely, in the first embodiment and the second embodiment, it is also possible to adopt the delivery mode of the aluminum foil 57 employed in the third embodiment.

  As in the first embodiment, a positive electrode drying furnace 244 is provided on the downstream side in the transport direction Y of the positive electrode current collector supply mechanism 242. The downstream-side transport platform 26 is placed inside the positive electrode drying furnace 244 with the separator-integrated battery electrode 55, the positive electrode active material layer 56 before drying, and the aluminum foil (positive electrode current collector) 57 laminated on the upper surface. It moves and the drying process with respect to the positive electrode active material layer 56 is performed. Thus, the battery electrode group 59 is formed in a state where it is supported by the downstream-side transport table 26.

  Thereafter, as in the first embodiment, the battery electrode group 59 is removed from the downstream-side transport base 26 and transported to the injection / assembly apparatus 3, and a finished battery product is manufactured by the injection / assembly apparatus 3.

  As described above, also in the third embodiment, as in the first embodiment, a three-dimensional battery having the nested negative electrode 54 and positive electrode 58 is obtained, and the quality and performance of the battery can be improved. Yes. In addition, since the negative electrode active material is supplied to the recess 512 while supporting the separator member 51 formed into a concavo-convex shape by the upstream-side conveyance platform 25, the negative electrode active material is supplied to the recess 512 stably. And a high-quality three-dimensional battery can be manufactured.

  In the third embodiment, since the drum-shaped mold 212 is used, the following operational effects can be obtained. That is, in the first embodiment, since the plate-shaped mold 212 is used, it is necessary to perform the molding process in a state in which the conveyance of the upstream conveyance table 25 is temporarily stopped, whereas in the third embodiment, The molding process can be performed while the conveyance of the upstream conveyance table 25 is continued. Therefore, according to the third embodiment, the battery electrode group 59 can be efficiently manufactured, and as a result, the manufacturing efficiency of the battery can be increased.

  Further, in the first embodiment, since the flat metal mold 212 is moved up and down to perform the molding process, the size in the X direction and the Y direction of the area that can be molded by one molding process is the plane size of the mold 212. It depends. On the other hand, since the drum-shaped mold 212 is used in the third embodiment, the size in the Y direction is arbitrary. Therefore, according to the third embodiment, it is possible to manufacture battery electrodes 55 and battery electrode groups 59 of various sizes.

<Fourth embodiment>
By the way, in the said 1st Embodiment thru | or 3rd Embodiment, although the battery which inject | poured and impregnated electrolyte solution to the separator member 51 is manufactured, it replaces with electrolyte solution and manufactures the all-solid-state battery using a solid electrolyte. The present invention can also be applied to the technology to be performed. Hereinafter, a fourth embodiment of the present invention will be described with reference to FIGS. 11 and 12.

  FIG. 11 is a block diagram showing a battery manufacturing system which is a fourth embodiment of the battery manufacturing apparatus according to the present invention. The battery manufacturing system 1 according to the fourth embodiment includes a manufacturing apparatus 20 and an assembling apparatus 4 that manufacture a battery body, and manufactures a battery as follows. Here, the embodiment will be described by exemplifying a case where a lithium ion secondary battery including a negative electrode, a solid electrolyte layer, and a positive electrode is manufactured.

  FIG. 12 is a diagram showing the configuration of the battery body manufacturing apparatus shown in FIG. The battery body manufacturing apparatus 20 is provided with an electrolyte layer forming section 28 instead of the separator forming section 21 in the manufacturing apparatus 2 according to the first embodiment. Therefore, the negative electrode forming part 22 excluding the electrolyte layer forming part 28, the transfer part 23, the positive electrode forming part 24, the upstream transport table 25, and the downstream transport table 26 are the same as those in the first embodiment. Therefore, the same reference numerals are given and description of the configuration is omitted.

The electrolyte layer forming unit 28 includes an electrolyte supply mechanism 281, a mold 282, and a mold lifting mechanism (not shown). The electrolyte solution supply mechanism 281 includes a discharge nozzle 2811 provided with a plurality of discharge ports (not shown) for discharging the polymer electrolyte solution along a horizontal direction X orthogonal to the Y direction. The discharge nozzle 2811 is disposed vertically above the upstream transport table 25 that passes through the electrolytic solution supply position P <b> 11, and each discharge port is directed to a concave portion of the upstream transport table 25. Then, at the same time that the tip of the upstream side carrier 25 reaches the electrolyte supply position P11, the electrolyte supply mechanism 281 starts discharging the polymer electrolyte. In addition, at the same time as the rear end portion of the upstream conveyance table 25 passes through the electrolytic solution supply position P11, the electrolytic solution supply mechanism 281 stops the discharge of the coating solution. As a result, the polymer electrolyte is supplied to the concave portion of the upstream conveyance table 25, and although not shown in FIG. 12, an electrolyte layer is formed in the concave portion. In the fourth embodiment, the electrolyte supply mechanism 281 uses a so-called nozzle dispensing method, but other supply methods such as a die coating method may be used. This also applies to the fifth embodiment described later. In this case, the polymer electrolyte solution includes a polymer electrolyte material, for example, a copolymer of polyethylene oxide and polystyrene, LiPF ₆ (lithium hexafluorophosphate) as a supporting salt, and diethylene carbonate as a solvent, for example. The thing which mixed etc. can be used.

  The metal mold 282 is disposed vertically above the upstream-side transport platform 25 at the molding position P12. The mold 282 has the same shape as that of the mold 212 of the first embodiment, that is, a comb-like shape, and is disposed to face the upstream-side transport base 25 with the electrolyte layer interposed therebetween. Then, the mold lifting mechanism is actuated in a state where the upstream side conveyance platform 25 is stopped at the molding position P12, and the mold 282 is moved vertically downward. As a result, the linear protrusion 2822 of the mold 282 presses the electrolyte layer to form an uneven shape that follows the uneven shape of the upstream conveyance table 25. When the formation of the electrolyte layer is completed in this way, the mold lifting mechanism is operated to retract the mold 282 vertically upward.

In the battery body manufacturing apparatus 20 configured as described above, when the electrolyte layer having a concavo-convex shape is formed as described above, the following steps are performed as in the first embodiment:
-Formation of the negative electrode active material layer 52 in the concave portion of one main surface of the electrolyte layer,
Supply of the copper foil (negative electrode current collector) 53 on the convex portion of one main surface of the electrolyte layer and the negative electrode active material layer 52;
-Drying of the negative electrode active material layer 52,
-Cutting and removing excess copper foil 53,
Inverted up and down of the conveyed product from the negative electrode forming part 22 (= upstream conveying table 25 + battery electrode 55),
Transfer of the battery electrode 55 (= electrolyte layer + negative electrode active material layer 52 + copper foil 53) integrated with the electrolyte layer to the downstream side carrier 26;
-Formation of the positive electrode active material layer 56 in the recess of the other main surface of the electrolyte layer,
Supply of the aluminum foil (positive electrode current collector) 57 on the convex portion of the other main surface of the electrolyte layer and the positive electrode active material layer 56;
-Drying of the positive electrode active material layer 56,
-Cutting and removing excess aluminum foil 57,
Execute. Thus, a battery body having the negative electrode 54, the electrolyte layer, and the positive electrode 58 is manufactured.

  The battery main body is removed from the downstream conveyance table 26 and then conveyed to the assembling apparatus 4. Then, the battery body is inserted into the exterior case from the opening of the exterior case by the assembly device 4. Thereafter, the opening of the outer case is welded to form a battery.

  As described above, according to the fourth embodiment, the linear protrusion portion 2822 of the mold 282 enters the concave portion formed on the upper surface of the upstream conveyance table 25 and the electrolyte layer is formed in the uneven shape of the upstream conveyance table 25. Molded into a concavo-convex shape following the above. Then, a negative electrode active material is applied to a concave portion formed on one main surface of the electrolyte layer formed into a concavo-convex shape to form a negative electrode active material layer 52, and a concave portion formed on the other main surface of the electrolyte layer A positive electrode active material layer 56 is formed by applying a positive electrode active material. Thus, a three-dimensional battery having the nested negative electrode 54 and positive electrode 58 is obtained, and the quality and performance of the battery can be improved.

  In addition, since the negative electrode active material is supplied to the concave portion while supporting the electrolyte layer formed in the concavo-convex shape by the upstream conveyance platform 25 to form the negative electrode active material layer 52, the negative electrode active material material in the concave portion is formed. Supply can be performed stably and a high-quality three-dimensional battery can be manufactured.

<Fifth Embodiment>
FIG. 13 is a diagram showing a configuration of a battery main body manufacturing apparatus that can be employed in the fifth embodiment of the battery manufacturing apparatus according to the present invention. This battery body manufacturing apparatus 20 is provided with an electrolyte layer forming part 28 instead of the separator forming part 21 in the manufacturing apparatus 2 (FIG. 10) according to the third embodiment. Therefore, the negative electrode forming unit 22, the transfer unit 23, the positive electrode forming unit 24, the upstream transport table 25, and the downstream transport table 26 excluding the electrolyte layer forming unit 28 are the same as those in the third embodiment. Moreover, the electrolyte solution supply mechanism 281 of the electrolyte layer molding unit 28 is the same as that of the fourth embodiment, and the mold 282 of the electrolyte layer molding unit 28 has the same shape as the mold 212 of the third embodiment. Therefore, about the structure of each part of an apparatus, the same or equivalent code | symbol is attached | subjected and those structure description is abbreviate | omitted.

  In the battery body manufacturing apparatus 20 configured as described above, the electrolyte solution supply mechanism 281 supplies the electrolyte solution supply mechanism 281 to the concave portion of the upstream transport table 25 that passes through the electrolyte solution supply position P11, as in the fourth embodiment. Thereby, an electrolyte layer is formed in the recess.

  At the molding position P82 on the downstream side of the electrolyte supply position P11, the drum-shaped mold 212 is arranged such that the lowest point in the vertical direction Z of the plurality of annular projections 2824 enters the concave portion of the upstream transport table 25. Has been. The drum mold 282 rotates at a peripheral speed substantially equal to the transport speed of the upstream transport platform 25. For this reason, the electrolyte layer in the concave portion of the upstream conveyance table 25 from the separator supply mechanism 211 is sandwiched between the upstream conveyance table 25 and the drum mold 282 at the molding position P82 and follows the uneven shape of the upstream conveyance table 25. It is formed into an uneven shape.

And, in the battery body manufacturing apparatus 20, when the electrolyte layer having a concavo-convex shape is formed as described above, as in the third embodiment, the following steps are performed:
-Formation of the negative electrode active material layer 52 in the concave portion of one main surface of the electrolyte layer,
Supply of the copper foil (negative electrode current collector) 53 on the convex portion of one main surface of the electrolyte layer and the negative electrode active material layer 52;
-Drying of the negative electrode active material layer 52,
Inverted up and down of the conveyed product from the negative electrode forming part 22 (= upstream conveying table 25 + battery electrode 55),
Transfer of the battery electrode 55 (= electrolyte layer + negative electrode active material layer 52 + copper foil 53) integrated with the electrolyte layer to the downstream side carrier 26;
-Formation of the positive electrode active material layer 56 in the recess of the other main surface of the electrolyte layer,
Supply of the aluminum foil (positive electrode current collector) 57 on the convex portion of the other main surface of the electrolyte layer and the positive electrode active material layer 56;
-Drying of the positive electrode active material layer 56,
Execute. Thus, a battery body having the negative electrode 54, the electrolyte layer, and the positive electrode 58 is manufactured.

  The battery main body is removed from the downstream conveyance table 26 and then conveyed to the assembling apparatus 4. Then, the battery body is inserted into the exterior case from the opening of the exterior case by the assembly device 4. Thereafter, the opening of the outer case is welded to form a battery.

  As described above, also in the fifth embodiment, after the electrolyte layer is formed into a concavo-convex shape, the negative electrode active material layer 52 is formed in the recess formed in one main surface of the electrolyte layer, and the other main surface of the electrolyte layer is formed. The positive electrode active material layer 56 is formed in the recess formed in the step. Therefore, the same effect as the fourth embodiment can be obtained. In addition, since the electrolyte layer is formed in a concavo-convex shape using the drum-shaped mold 282, the same effect as the third embodiment can be obtained.

<Others>
In the first embodiment to the third embodiment, the separator member 51 is formed into an uneven shape following the uneven surface of the upstream transfer table 25 using the upstream transfer table 25 and the mold 212. Further, in the fourth and fifth embodiments, the electrolyte layer is formed into a concavo-convex shape following the concavo-convex surface of the upstream transport table 25 using the upstream transport table 25 and the mold 282. As described above, the upstream conveyance table 25 and the molds 212 and 282 function as the “first mold member” and the “second mold member” of the present invention, respectively. Further, the base portion 251 and the linear protrusion portion 252 constituting the upstream-side transport base 25 correspond to the “first mold base material” and the “linear protrusion portion” of the present invention, respectively. Further, the base portions 2121 and 2821 and the linear protrusion portions 2122 and 2822 constituting the flat plate molds 212 and 282 used in the first embodiment, the second embodiment, and the fourth embodiment are respectively “second”. It corresponds to “mold substrate” and “projection”. Further, the mold bases 2123 and 2823 and the annular projections 2124 and 2824 constituting the drum molds 212 and 282 used in the third embodiment and the fifth embodiment are the “second mold base” of the present invention. And “projection”. Furthermore, the negative electrode active material application mechanism 221 and the positive electrode active material application mechanism 241 function as a “first active material supply unit” and a “second active material supply unit”, respectively.

  The present invention is not limited to the above-described embodiment, and various modifications other than those described above can be made without departing from the spirit of the present invention. For example, in the above embodiment, after the negative electrode 54 is formed on one main surface of the separator member 51 and the electrolyte layer formed into an uneven shape, the positive electrode 58 is formed on the other main surface of the separator member 51 and the like. The positive electrode and the negative electrode may be interchanged.

  In the first embodiment and the second embodiment, the mold 212 is moved up and down, and in the fourth embodiment, the mold 282 is moved up and down to perform the molding process. However, instead of the molds 212 and 282, or the molds 212 and 282 and the molds 212 and 282 may be moved up and down, the molding process may be performed.

  Further, the materials such as the current collector, active material, and electrolyte exemplified in the above embodiment are only examples, and are not limited thereto, and other materials used as a constituent material of the lithium ion battery are used. Even when a lithium ion battery or a battery electrode is manufactured, the manufacturing method of the present invention can be preferably applied. Further, the present invention can be applied not only to lithium ion batteries but also to the manufacture of all three-dimensional batteries having a nested structure.

  The present invention can be applied to all techniques for manufacturing a battery including a negative electrode, a separator (or a solid electrolyte layer) into which an electrolytic solution is injected, and a positive electrode.

1. Battery manufacturing system (battery manufacturing equipment)
21 ... Separator molding part (molding part)
22 ... Negative electrode forming part 24 ... Positive electrode forming part 25 ... Upstream conveying table (first mold member)
27: Control unit 28 ... Electrolyte layer molding unit (molding unit)
51 ... Separator member 52 ... Negative electrode active material layer 53 ... Copper foil (negative electrode current collector, first current collector)
54 ... Negative electrode 55 ... Battery electrode 56 ... Positive electrode active material layer 57 ... Aluminum foil (positive electrode current collector, second current collector)
58 ... Positive electrode 59 ... Battery electrode group 211 ... Separator supply mechanism 212, 282 ... Mold 221 ... Negative electrode active material supply mechanism (first active material application part)
241 ... Positive electrode active material supply mechanism (second active material application unit)
252... Linear protrusion 281 (on the upstream conveyance table) 281 Electrolyte supply mechanism 2122, 2822... Linear protrusion 2123 ... Mold substrate 2124, 2824.

Claims (16)

(a) In order to satisfy the following arrangement conditions (a-1) to (a-3), a plurality of linear protrusions parallel to each other are formed, and the first mold member having an uneven shape is parallel to each other An arrangement step of arranging a second mold member having a plurality of protrusions;
(a-1) the first mold member is located on the first main surface side of the separator member in a state where the linear protrusion is directed to the first main surface of the separator member;
(a-2) the second mold member is located on the second main surface side of the separator member in a state where the protrusion is directed to the second main surface of the separator member opposite to the first main surface;
(a-3) The protrusion of the second mold member faces the recess of the first mold member via the separator member.
(b) After the placing step, a molding step of sandwiching the separator member by the first mold member and the second mold member and molding the separator member into an uneven shape;
(c) a first electrode forming step of supplying a first active material material to a recess formed in the second main surface of the separator member spaced apart from the second mold member;
(d) a second electrode forming step of supplying a second active material material to a recess formed in the first main surface of the separator member by releasing the first mold member after the first electrode forming step; ,
A method for producing a battery, comprising: A battery manufacturing method according to claim 1, comprising:
The first electrode forming step (c) is a step of supplying the first active material while supporting the first main surface of the separator member formed into a concavo-convex shape with the first mold member. Manufacturing method. It is a manufacturing method of the battery of Claim 1 or 2, Comprising:
The first electrode forming step (c) includes:
(c-1) forming the first active material layer by supplying the first active material to the concave portion while exposing the top of the convex portion of the second main surface of the separator member;
(c-2) A method for manufacturing a battery, comprising: forming a first current collector on the top and the first active material layer. It is a manufacturing method of the battery of Claim 1 or 2, Comprising:
The first electrode forming step (c) includes:
(c-1) supplying the first active material material to the entire second main surface of the separator member to form a first active material layer;
(c-2) A method of manufacturing a battery comprising a step of forming a first current collector on the first active material layer. A method for producing a battery according to any one of claims 1 to 4,
The second electrode forming step (d)
(d-1) forming the second active material layer by supplying the second active material material to the concave portion while exposing the top of the convex portion of the first main surface of the separator member;
(d-2) A method of manufacturing a battery, comprising: forming a second current collector on the top and the second active material layer. A method for producing a battery according to any one of claims 1 to 4,
The second electrode forming step (d)
(d-1) supplying the second active material material to the entire first main surface of the separator member to form a second active material layer;
(d-2) A method of manufacturing a battery comprising a step of forming a second current collector on the second active material layer. (a) an electrolyte supply step of supplying a solid electrolyte material to the uneven surface of the first mold member having a plurality of linear protrusions parallel to each other;
(b) After the electrolyte supply step, a second mold member having a plurality of protrusions parallel to each other is arranged so as to satisfy the following arrangement condition (b-1), and the solid electrolyte is formed with the first mold member A molding step of sandwiching the material and molding it into an uneven solid electrolyte layer;
(b-1) The protrusion of the second mold member faces the recess of the first mold member.
(c) a first electrode forming step of supplying a first active material to a recess formed in a second main surface of the solid electrolyte layer spaced from the second mold member;
(d) a second electrode forming step of supplying a second active material material to a recess formed in the first main surface of the solid electrolyte layer after the first mold member is released after the first electrode forming step; A method for producing a battery, comprising: A battery manufacturing method according to claim 7,
The first electrode forming step (c) is a step of supplying the first active material while supporting the first main surface of the solid electrolyte layer formed into a concavo-convex shape with the first mold member. Battery manufacturing method. A method of manufacturing a battery according to claim 7 or 8,
The first electrode forming step (c) includes:
(c-1) forming the first active material layer by supplying the first active material to the concave portion while exposing the top of the convex portion of the second main surface of the solid electrolyte layer;
(c-2) A method for manufacturing a battery, comprising: forming a first current collector on the top and the first active material layer. A method of manufacturing a battery according to claim 7 or 8,
The first electrode forming step (c) includes:
(c-1) supplying the first active material material to the entire second main surface of the solid electrolyte layer to form a first active material layer;
(c-2) A method of manufacturing a battery comprising a step of forming a first current collector on the first active material layer. A method for manufacturing a battery according to any one of claims 7 to 10,
The second electrode forming step (d)
(d-1) forming the second active material layer by supplying the second active material to the recess while exposing the top of the projection of the first main surface of the solid electrolyte layer;
(d-2) A method of manufacturing a battery, comprising: forming a second current collector on the top and the second active material layer. A method for manufacturing a battery according to any one of claims 7 to 10,
The second electrode forming step (d)
(d-1) supplying the second active material material over the first main surface of the solid electrolyte layer to form a second active material layer;
(d-2) A method of manufacturing a battery comprising a step of forming a second current collector on the second active material layer. A method for manufacturing a battery according to any one of claims 1 to 12,
The first mold member is a comb-shaped mold in which the plurality of linear protrusions protrude from a flat plate-shaped first mold base material, and the second mold member is formed of a flat plate-shaped second mold base material. A comb-like mold having the plurality of protrusions protruding;
The method of manufacturing a battery, wherein the forming step (b) is a step of forming the first mold member and the second mold member close to each other so as to mesh with each other. A method for manufacturing a battery according to any one of claims 1 to 12,
The first mold member is a comb-shaped mold in which the plurality of linear protrusions are protruded from a flat plate-shaped first mold base material, while the second mold member is a cylindrical or columnar second mold. A drum-shaped mold in which each protrusion is projected in an annular shape on the outer peripheral surface of the base material,
The molding step moves the first mold member relative to the second mold member while rotating the second mold member around an axis, and the plurality of protrusions of the second mold member. A method of manufacturing a battery, which is a step of forming the first mold member into a recess of the corresponding first mold member. A first mold member having a concavo-convex shape formed with a plurality of linear protrusions parallel to each other, and a second mold member having a plurality of protrusions parallel to each other, the protrusions of the second mold member being A molding section for sandwiching the separator member between the first mold member and the second mold member in a state of being opposed to the concave portion of the first mold member via the separator member, and molding the separator member into an uneven shape;
A first active material supply unit for supplying a first active material to a recess on one main surface of the separator member formed into an uneven shape;
A battery manufacturing apparatus comprising: a second active material supply unit configured to supply a second active material material to a concave portion on the other main surface of the separator member formed into an uneven shape. A first type member having a concavo-convex shape formed with a plurality of linear protrusions parallel to each other, an electrolyte supply mechanism for supplying a solid electrolyte material to the concavo-convex surface of the first type member, and a plurality of protrusions parallel to each other The first mold member and the second mold member in a state in which the protrusion of the second mold member is opposed to the recess of the first mold member to which the solid electrolyte material is supplied. A molding part that sandwiches the solid electrolyte material by a mold member and molds it into a concavo-convex solid electrolyte layer; and
A first active material supply unit for supplying a first active material to a recess on one main surface of the solid electrolyte layer;
A battery manufacturing apparatus comprising: a second active material supply unit configured to supply a second active material material to a recess on the other main surface of the solid electrolyte layer.

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