JP2022142813A - Electrostatic film forming apparatus and electrostatic film forming method - Google Patents

Abstract

To provide a technology that can obtain high film-forming efficiency in an electrostatic film forming apparatus.SOLUTION: An electrostatic film forming apparatus includes a magnet roller having a magnetic pole, and attracting a carrier having magnetism to which electrode particles as a film forming material are attached by a magnetic force, and a backup roller spaced apart from the magnet roller, and having a film-forming surface on which the electrode particles separated from the carrier are formed, and inside the backup roller, a repelling magnetic pole member having a repelling magnetic pole that repels the magnetic pole of the magnet roller, and causing a change in the magnetic field in a flying region located between the magnet roller and the backup roller is provided.SELECTED DRAWING: Figure 3

Description

The present disclosure relates to technology of an electrostatic film forming apparatus and an electrostatic film forming method.

Conventionally, in a developing device, toner is transferred onto the surface of a photosensitive drum facing the developer carrier by carrying the developer on the surface of the developer carrier having a magnet roller as a magnetic field generating means inside and conveying the toner. A technique for developing an image is known (Patent Document 1). The developer includes toner and a magnetic carrier. In this technique, triboelectrically charged toner is electrostatically bound by the carrier while the carrier is bound by the magnetic flux of the magnet roller to form magnetic brushes. Then, the toner image is developed by bringing the magnetic brush into contact with the photosensitive drum and supplying toner to the photosensitive drum.

JP 2017-129607 A

As a technique for forming electrodes used in lithium ion batteries and the like, for example, there is a wet film forming method in which a paste containing electrode particles is applied to the surface of a strip-shaped metal foil and dried. The inventors of the present application have studied application of the technique of developing a toner image with a developing device having a magnetic field generating means described in Japanese Patent Application Laid-Open No. 2002-300001 to electrode film formation. When the technique described in Patent Document 1 is applied to electrode film formation, it may be difficult to separate the electrode particles from the carrier, making it impossible to obtain high film formation efficiency. Therefore, there is a demand for a technique capable of increasing the film formation efficiency by causing more electrode particles to fly from the magnet roller.

The present disclosure can be implemented as the following forms.

(1) According to one aspect of the present disclosure, an electrostatic deposition apparatus is provided. This electrostatic film forming apparatus includes a magnet roller having a magnetic pole, and a magnet roller for attracting a carrier having magnetism to which electrode particles as a film forming material are adhered by a magnetic force, and the magnet roller being spaced from the magnet roller. a backup roller having a film-forming surface on which the electrode particles separated from the carrier are film-formed; a repelling magnetic pole member having a repulsive magnetic pole that is located between the magnet roller and the backup roller, the repelling magnetic pole member generating a magnetic field change in a flight region located between the magnet roller and the backup roller. According to this configuration, in the flight region, a magnetic field change is caused by the magnetic poles and the repelling magnetic poles. Therefore, the carrier to which the electrode particles are attached can be vibrated by changing the magnetic field. Since the electrode particles electrostatically bound to the carrier can be easily separated from the carrier by this vibration, the film forming efficiency can be improved.
(2) In the above aspect, the magnet roller has a cylindrical member that attracts the carrier to which the electrode particles are attached, and a magnetic pole member that is provided inside the cylindrical member and has the magnetic pole. The repelling magnetic pole member may be rotatable such that the magnetic pole and the repelling magnetic pole periodically face each other. According to this aspect, the periodic rotation of the repulsive magnetic pole member can easily cause a change in the magnetic field.
(3) In the above aspect, the number of times the magnetic pole and the repelling magnetic pole face each other per second may be 20 times or more and 270 times or less. According to this aspect, the film formation efficiency can be further improved.
(4) In the above aspect, the backup roller may have a rotating shaft, and the repelling magnetic pole member may be positioned between the rotating shaft and the magnet roller in the interior. According to this aspect, the size of the repulsive magnetic pole member can be reduced compared to the case where the repulsive magnetic pole member is provided throughout the inside of the backup roller. As a result, the number of rotations of the repelling magnetic pole member per unit time for the same driving force can be efficiently increased.
(5) According to another aspect of the present disclosure, an electrostatic deposition method is provided. This electrostatic film forming method includes (a) a step of attracting the carrier, which is a carrier having magnetism and to which electrode particles as a film forming material are adhered, to a magnet roller by the magnetic force of the magnetic poles; a step of separating the electrode particles and adhering the electrode particles to a film-forming surface of a backup roller, wherein the step (b) is performed by a repelling magnetic pole that repels the magnetic pole inside the backup roller. and vibrating the carrier by generating a change in the magnetic field in a flight area located between the magnet roller and the backup roller. According to this configuration, in the flight region, the magnetic poles and the repelling magnetic poles repel each other to cause periodic magnetic field changes. Therefore, the carrier to which the electrode particles are attached can be vibrated by changing the magnetic field. Since the electrode particles electrostatically bound to the carrier can be easily separated from the carrier by this vibration, the film forming efficiency can be improved.
The present disclosure can be realized in various forms other than the above-described electrostatic film forming apparatus and electrostatic film forming method. For example, it can be realized in the form of a manufacturing method of an electrostatic film forming apparatus, a control method of the electrostatic film forming apparatus, a computer program for realizing the control method, a non-temporary recording medium recording the computer program, or the like.

1 is a diagram showing a schematic configuration of an electrostatic film forming apparatus according to this embodiment; FIG. FIG. 4 is a diagram for explaining the positional relationship of each component in the film forming section of the embodiment; FIG. 4 is a diagram for explaining the behavior of electrode particles and carriers in a film forming section; 4 is a graph showing the relationship between the amount of electrode particles deposited and the magnetic frequency.

A. Embodiment:
FIG. 1 is a diagram showing a schematic configuration of an electrostatic film forming apparatus 1 of this embodiment. FIG. 1 shows the state when the electrostatic film forming apparatus 1 is viewed from the side. The electrostatic film forming apparatus 1 attracts the magnetic carrier C to which the electrode particles E, which are film forming materials, are attached by the magnetic force of the magnet roller 20, and uses the magnetic field change to remove the carrier C to which the electrode particles E are attached. vibrate. By this vibration and the centrifugal force caused by the rotation of the magnet roller 20, the electrostatic film forming apparatus 1 separates the electrode particles E from the carrier C, thereby forming an electrode as an aggregate of the electrode particles E. As shown in FIG. The electrostatic film forming apparatus 1 forms, for example, a sheet-like electrode. A sheet-shaped electrode is used as an electrode for secondary batteries, such as a lithium ion battery, for example. The electrostatic film forming apparatus 1 includes a supply section 2 , a film forming section 3 , a collecting section 4 , an adjusting section 5 , a fixing section 6 and a control device 7 . The electrode particles E are transported to the supply section 2, the film formation section 3, the adjustment section 5, and the fixing section 6 in this order. In other words, in the present embodiment, the supply section 2 is the upstream side in the transport direction of the electrode particles E. As shown in FIG. Further, the fixing section 6 is the downstream side in the conveying direction of the electrode particles E. As shown in FIG. In the following description, the direction of gravity is defined as the lower side, and the direction opposite to the direction of gravity is defined as the upper side.

The supply unit 2 is provided upstream of the film forming unit 3 in the conveying direction of the electrostatic film forming apparatus 1 . The supply unit 2 supplies the electrode particles E and the carrier C to the film forming unit 3, which will be described later. The supply unit 2 includes a mixture storage chamber 200 and three supply chambers 211 , 212 and 213 . First, the electrode particles E and the carrier C will be described below.

The electrode particles E are diamagnetic and are not attracted by the magnetic force of the magnetic pole member 21 and the repulsive magnetic pole member 60, which will be described later. Furthermore, the electrode particles E have electronic conductivity and contain an active material. When forming a positive electrode, the electrode particles E contain a positive electrode active material. Various oxides such as lithium-cobalt composite oxides and lithium-manganese composite oxides are used as the positive electrode active material. Moreover, when forming a negative electrode into a film, the electrode particles E contain a negative electrode active material. Carbon-based materials, lithium titanate-based materials, oxide-based materials, alloy-based materials, and lithium metal-based materials are used as the negative electrode active material, for example. It should be noted that the electrode particles E constituting the electrode are not limited to those disclosed in the present disclosure, and may be those having electronic conductivity. Moreover, the electrode particles E may contain two or more active materials of the same polarity.

The carrier C is configured by coating ferrite particles, which are magnetic substances, with a resin, which is a non-metal. The nonmetallic resin coating preferably has conductivity. Since the carrier C has magnetism, it is attracted by the magnetic force of the magnet roller 20, which will be described later, and is attracted to the surface of the cylindrical member 30, which will be described later.

The electrode particles E and the carrier C are mixed by a stirring device, and supplied to the electrostatic film forming apparatus 1 in a state in which the electrode particles E adhere to the carrier C to form a mixture EC. Specifically, the electrode particles E are negatively charged by friction with the carrier C, and electrostatically adhere to the surface of the carrier C in a dispersed state, thereby forming the mixture EC. In addition, since the mixture EC contains the carrier C having magnetism, it functions as a magnetic material.

Next, each component of the supply section 2 and its function will be described. The mixed material storage chamber 200 is provided upstream of a first supply chamber 211 (to be described later) in the supply section 2 . The mixture storage chamber 200 stores the mixture EC. The mixture EC is supplied to the mixture storage chamber 200 through a passage (not shown). Furthermore, the mixture EC is supplied from the mixture storage chamber 200 to a first supply chamber 211 described later through a communication port 201 that communicates the mixture storage chamber 200 and a first supply chamber 211 described later.

The supply chambers 211 , 212 , 213 are provided in this order on the downstream side of the mixture storage chamber 200 in the supply section 2 . The supply chambers 211, 212, and 213 convey the mixture EC supplied from the mixture storage chamber 200 toward the film forming section 3, which will be described later, and supply it to the film forming section 3, which will be described later. The three supply chambers 211, 212, and 213 are hereinafter referred to as the first supply chamber 211, the second supply chamber 212, and the third supply chamber 213, respectively.

The first supply chamber 211 receives the mixture EC supplied from the mixture storage chamber 200 and supplies it to the second supply chamber 212 . The first supply chamber 211 is provided downstream of the mixture storage chamber 200 and upstream of the second supply chamber 212 . The first supply chamber 211 has a semi-cylindrical shape with an open top. A first wall portion 215 higher than a second wall portion 216 described later is formed on the side of the first supply chamber 211 where the communication port 201 of the mixture storage chamber 200 is located. The first supply chamber 211 has a first rotor 221 having a plurality of blades. In this embodiment, the first rotor 221 has six blades. The six blades of the first rotor blade 221 form a shape that radiates from a central axis (not shown). Also, the first rotor blade 221 rotates around a central axis (not shown) under the control of the control device 7, which will be described later. The rotation direction of the first rotor blade 221 is the direction in which the mixture EC can be supplied to the second supply chamber 212 . In FIG. 1, the first rotor blade 221 is rotating in the same direction as the conveying direction. Thereby, the mixture EC supplied from the mixture storage chamber 200 is supplied to the second supply chamber 212 by the rotation of the first rotor blade 221 in the first supply chamber 211 .

The second supply chamber 212 receives the mixture EC supplied from the first supply chamber 211 and supplies it to the film forming section 3 . The second supply chamber 212 is provided downstream of the first supply chamber 211 and upstream of the third supply chamber 213 . In this embodiment, of the supply chambers 211, 212, and 213, the second supply chamber 212 is positioned closest to the later-described pumping magnetic pole N1. The second supply chamber 212 has a semi-cylindrical shape with an open top. A second wall portion 216 is formed between the first supply chamber 211 and the second supply chamber 212 as a partition separating the two. The second supply chamber 212 includes a second rotor blade 222 having the same shape as the first rotor blade 221 . The second rotor blade 222 is preferably rotated in a direction in which the mixture EC can be well supplied depending on the positional relationship between the second supply chamber 212 and the film forming section 3 . In this embodiment, the second rotor blade 222 rotates in the same direction as the first rotor blade 221 about a central axis (not shown) under the control of the control device 7, which will be described later. Thereby, the mixture EC supplied from the first supply chamber 211 is supplied to the film forming section 3 by the rotation of the second rotor blade 222 in the second supply chamber 212 . The mixture EC supplied to the film forming section 3 is attracted by the magnetic force of a drawing-up magnetic pole N1, which is one of the magnetic poles of the magnet roller 20 described later, and is attracted to the surface of the cylindrical member 30 described later. At this time, a part of the mixture EC supplied from the second supply chamber 212 is not adsorbed on the surface of the cylindrical member 30 and returns into the second supply chamber 212. and flows into the third supply chamber 213 .

The third supply chamber 213 receives the mixture EC that has flowed into the third supply chamber 213 over a third wall portion 217 to be described later due to the rotation of the second rotor blade 222 , and supplies the mixture to the second supply chamber 212 . The third supply chamber 213 has a semi-cylindrical shape with an open top. A third wall portion 217 is formed between the second supply chamber 212 and the third supply chamber 213 as a partition separating the two. A fourth wall portion 218 is formed between the third supply chamber 213 and a recovery chamber 420, which will be described later, to separate them. The third supply chamber 213 includes a third rotor blade 223 having the same shape as the first rotor blade 221 . The third rotor blade 223 is preferably rotated in a direction opposite to the direction of rotation of the second rotor blade 222 . In this embodiment, the third rotor blade 223 rotates in the opposite direction to the second rotor blade 222 about a central axis (not shown) under the control of the control device 7, which will be described later. As a result, the mixture EC that has flowed into the third supply chamber 213 over the third wall portion 217 due to the rotation of the second rotor blade 222 can be supplied to the second supply chamber 212 .

The film forming unit 3 is provided upstream of the supply unit 2 and downstream of the adjusting unit 5 described later in the electrostatic film forming apparatus 1 . In the film forming unit 3, a step of attracting the mixture EC supplied from the supply unit 2 to a magnet roller 20 described later and a step of conveying the mixture EC toward a position facing a backup roller 50 described later are performed. Further, in the film-forming section 3, a step of separating the electrode particles E from the carrier C in the flight region 300 described later and forming a film of the electrode particles E on the film-forming surface 68 described later is executed. A detailed configuration of the film forming unit 3 will be described later.

FIG. 2 is a diagram for explaining the positional relationship of each component in the film forming section 3 of this embodiment. FIG. 2 schematically shows a state when the film forming unit 3 of the electrostatic film forming apparatus 1 is viewed from the front. FIG. 2 also schematically shows the internal configuration of the electrostatic film forming apparatus 1 . The film forming section 3 includes a magnet roller 20, a backup roller 50, a repelling magnetic pole member 60, a ground member 80 shown in FIG. 1, and a pedestal 18 serving as a base for these. Below, each component in the film-forming part 3 and its positional relationship are demonstrated. The behavior of the electrode particles E and the carrier C in the film forming section 3 will be described later. First, each component of the film forming section 3 and the positional relationship thereof will be described below.

The magnet roller 20 includes a tubular member 30, a magnetic pole member 21 as magnetic field generating means, a regulating member 25 shown in FIG. 1, a voltage supply section (not shown), and electrical wiring (not shown).

The cylindrical member 30 has a surface that attracts and conveys the mixture EC by the magnetic force of the magnetic pole member 21, which will be described later. The cylindrical member 30 has a cylindrical shape. The tubular member 30 is made of a conductive non-magnetic material, such as aluminum or non-magnetic stainless steel. The longitudinal direction of the tubular member 30 is a direction horizontal to the base 18 . The tubular member 30 is composed of a tubular member main body 31 and a first shaft portion 32 . The tubular member main body 31 includes a magnetic pole member 21, which will be described later. The first shaft portion 32 forms a cylinder rotation axis O<b>1 that is the rotation axis of the tubular member 30 . The first shaft portion 32 is rotatably supported by a first support member 33 erected vertically from the pedestal 18 , thereby supporting the tubular member 30 . The cylindrical member 30 rotates around the cylinder rotation axis O1 under the control of the control device 7, which will be described later. As shown in FIG. 3 to be described later, in this embodiment, the rotation direction of the tubular member 30 is opposite to the rotation direction of the second rotor blade 222 . is. Further, in the present embodiment, the direction in which the cylinder rotation axis O1 extends is the horizontal direction.

The magnetic pole member 21 is provided inside the tubular member 30 . The magnetic pole member 21 is composed of a magnetic pole member body 21 a having a diameter smaller than that of the cylindrical member 30 and a second shaft portion 22 . Like the cylindrical member 30, the longitudinal direction of the magnetic pole member 21 is the horizontal direction.

The magnetic pole member main body 21a is composed of a plurality of magnets, each having magnetic poles N1, S1, N2, S2 and N3. The magnetic pole member main body 21a is radially formed around a second shaft portion 22, which will be described later. Details of the magnetic pole member body 21a will be described later with reference to FIG.

The second shaft portion 22 is provided so as to have a smaller diameter than the magnetic pole member main body 21a. The magnetic pole member 21 is fixed inside the tubular member 30 by supporting the second shaft portion 22 of the magnetic pole member 21 with the first support member 33 . In addition, in this embodiment, the magnetic pole member 21 is fixed without rotating. Note that the magnetic pole member 21 only needs to be fixed inside the cylindrical member 30 without rotating, and the position and number of supporting the magnetic pole member 21 are not limited to the present disclosure.

The regulating member 25 removes excess of the mixture EC attracted to the surface of the tubular member 30 by the magnetic force of the magnetic pole member 21 . Details of the restricting member 25 will be described later with reference to FIG.

The voltage supply section includes a voltage supply device (not shown) that supplies voltage to the magnet roller 20 , particularly the tubular member 30 . The magnet roller 20 and the voltage supply unit (not shown) are connected by electric wiring (not shown). A predetermined voltage is applied to the magnet roller 20 from a voltage supply unit via electric wiring (not shown). A mode of voltage application to the magnet roller 20 during film formation of the electrode particles E will be described later. It should be noted that the shape, formation position, size, and manner of rotation of each component in the magnet roller 20 are not limited to the present disclosure.

The backup roller 50 has a film-forming surface 68 on the surface of the backup roller 50, and conveys a foil F, which will be described later. The backup roller 50 is provided apart from the magnet roller 20 . In the example shown in FIG. 2 , the backup roller 50 is provided above the magnet roller 20 . In FIG. 2, a portion of the surface of the magnet roller 20 and a portion of the surface of the backup roller 50 face each other. The backup roller 50 has a cylindrical shape. The backup roller 50 is made of a conductive material such as metal, for example, aluminum. The longitudinal direction of the backup roller 50 is the horizontal direction.

The backup roller 50 is composed of a backup roller main body 51 and a third shaft portion 52 . The backup roller main body 51 includes a repelling magnetic pole member 60, which will be described later. The backup roller 50 has a third shaft portion 52 that forms the backup roller rotation axis O3. In FIG. 2 , the third shaft portion 52 is provided so as to have a diameter smaller than that of the backup roller main body 51 . The third shaft portion 52 is rotatably supported by a third support member 53 erected vertically from the pedestal 18 , thereby supporting the backup roller 50 . The backup roller 50 rotates around a backup roller rotation axis O3, which is the central axis of the backup roller 50, under the control of the control device 7, which will be described later. In this embodiment, the rotation direction of the backup roller 50 is opposite to the rotation direction of the magnet roller 20 . Further, in the present embodiment, the direction in which the backup roller rotation axis O3 extends is the horizontal direction.

The backup roller 50 has a film formation surface 68 on which the electrode particles E separated from the carrier C are formed at a position facing the magnet roller 20 on the surface of the backup roller 50 . In this embodiment, as shown in FIG. 1, a long foil F is continuously supplied along the film-forming surface 68 . That is, the electrode particles E separated from the carrier C are not deposited directly on the film-forming surface 68 but are deposited on the foil F supplied onto the film-forming surface 68 . The foil F is made of a conductive material such as metal, for example aluminum. The foil F functions as a base for the sheet-shaped electrodes. The foil F and the pre-formed electrode I as the electrode particles E deposited on the foil F are pressed in a fixing section 6 described later, and the foil F and the electrode particles E are brought into close contact with each other to be integrated. A sheet-like electrode is produced.

The backup roller 50 only needs to have a larger diameter than the repulsive magnetic pole member 60, and the shape, formation position, size, and rotation mode of each component of the backup roller 50 are not limited to the present disclosure. .

The repelling magnetic pole member 60 is provided inside the backup roller 50 between the backup roller rotating shaft O<b>3 and the magnet roller 20 . In this embodiment, the repelling magnetic pole member 60 is provided below the backup roller rotation axis O3. The repulsive magnetic pole member 60 is magnetic field generating means. The repelling magnetic pole member 60 has a facing position where the later-described opposing magnetic pole N2 of the magnetic pole member 21 faces the repelling magnetic pole N of the repelling magnetic pole member 60, and a non-facing position where the later-described opposing magnetic pole N2 and the repelling magnetic pole N do not face each other. , and are configured to be displaceable. In this embodiment, by rotating a repelling magnetic pole member 60 having a repelling magnetic pole N with respect to a later-described opposing magnetic pole N2 that exists at a fixed position, it can be displaced between a facing position and a non-opposing position. The repulsion magnetic pole member 60 has a repulsion magnetic pole member main body 60a and a fourth shaft portion 62 that forms a repulsion magnetic pole rotation axis O4. The longitudinal direction of the repelling magnetic pole member 60 is horizontal, like the backup roller 50 .

The repulsion magnetic pole member main body 60a is composed of a plurality of magnets. As shown in FIG. 1, the magnets forming the repulsive magnetic pole member body 60a each have a repulsive magnetic pole N. As shown in FIG. As shown in FIGS. 1 and 2, the plurality of magnets forming the repulsion magnetic pole member main body 60 a are plate-shaped and supported by the fourth shaft portion 62 .

The fourth shaft portion 62 is rotatably supported inside the backup roller 50 . At this time, the repulsion magnetic pole member main body 60a rotates around the repulsion magnetic pole rotation axis O4 under the control of the control device 7, which will be described later. In this embodiment, the repelling magnetic pole member 60 rotates in the direction opposite to the magnet roller 20 . The direction in which the repulsion magnetic pole rotation axis O4 extends is the horizontal direction. The number and positions of the magnets forming the repulsive magnetic pole member main body 60a are not limited to this. The repelling magnetic pole member main body 60a may have a repelling magnetic pole N that opposes and repels a later-described opposing magnetic pole N2. The repelling magnetic pole member main body 60a may be composed of, for example, five magnets and have five magnetic poles. Details of the repulsion magnetic pole member body 60a will be described later with reference to FIG.

The shape, formation position, size, manner of rotation, and displacement means between the opposed position and the non-opposed position of each component of the repulsive magnetic pole member 60 are not limited to those described above. The repelling magnetic pole member 60 is provided with a diameter smaller than that of the backup roller 50, and is displaced between a facing position where the opposing magnetic pole N2 and the repelling magnetic pole N face each other and a non-facing position where the opposing magnetic pole N2 and the repelling magnetic pole N do not face each other. It is sufficient if it is configured to be possible.

Returning to FIG. 1, other components included in the electrostatic film forming apparatus 1 will be described. The recovery unit 4 recovers the detached mixture EC when the mixture EC adsorbed to the surface of the cylindrical member 30 is detached by the magnetic force of the magnetic pole member 21 . The collection unit 4 includes a discharge member 410 and a collection chamber 420 .

The discharge member 410 receives the separated mixture EC as described above and guides it to the recovery chamber 420 . Hereinafter, the side of the ejecting member 410 on which the magnet roller 20 is positioned is referred to as the leading end side. In addition, the portion located on the side opposite to the distal end side of the ejection member 410 is defined as the proximal end side. The tip end side of the discharging member 410 is between a later-described separating magnetic pole N3 and a pumping magnetic pole N1 among the plurality of magnetic poles N1, S1, N2, S2, and N3 possessed by the magnetic pole member 21, and is located on the surface of the cylindrical member 30. provided to face the The base end side of the discharge member 410 is provided at a portion of the fourth wall portion 218 that abuts on a portion of the recovery chamber 420 and is fixed to a portion of the recovery chamber 420 . Note that the shape of the discharge member 410 is not limited to the present disclosure. The discharge member 410 may have any shape as long as it can guide the mixture EC separated from the magnet roller 20 to the collection chamber.

The recovery chamber 420 is provided on the proximal end side of the discharge member 410 . The recovery chamber 420 is a space for recovering the mixture EC supplied along the discharge member 410 . In this manner, the recovery section 4 recovers the carrier C and the electrode particles E that have not been separated from the carrier C in the film forming section 3 . The electrode particles E and carriers C collected in the collection chamber 420 may be supplied to the supply section 2 by a connecting member (not shown). By doing so, the electrode particles E and the carrier C collected in the collection chamber 420 can be easily reused.

The adjustment unit 5 checks the state of the pre-formed electrode I as the electrode particles E formed on the foil F in the film formation unit 3, and adjusts the thickness of the film. The adjustment section 5 includes a thickness correction member 510 , a pressing member 520 , a sensor 530 and a carrier removal device 540 . In this embodiment, the thickness correction member 510, the pressing member 520, the sensor 530, and the carrier removing device 540 are provided in this order in the transport direction of the electrostatic film forming apparatus 1. FIG. Note that each component of the adjustment unit 5 and the order in which the components are arranged are not limited to the present disclosure. For example, the components listed in the adjustment section 5 are not essential, and the adjustment section 5 may additionally include other components. Also, each component may be arranged in an order different from that of the present embodiment.

The thickness correction member 510 regulates the thickness of the preformed electrode I formed on the foil F on the film formation surface 68 . The thickness correction member 510 is a so-called scraper. The tip of the thickness correction member 510 is provided so as to face the outer surface of the electrode I before molding. Further, the thickness correction member 510 is provided at a position separated from the film formation surface 68 by a predetermined distance in the thickness direction from the film formation surface 68 to the outer surface of the electrode I before molding. Here, while the backup roller 50 rotates, the tip of the thickness correction member 510 comes into contact with the surface of the preformed electrode I, thereby scraping off the portion exceeding the predetermined thickness. That is, the thickness correction member 510 regulates the thickness of the preformed electrode I formed on the foil F on the film formation surface 68 to a predetermined thickness.

The pressing member 520 presses the pre-molding electrode I deposited on the foil F on the deposition surface 68 to make the thickness of the deposited electrode particles E constant. In this embodiment, the pressing member 520 has a roll-like shape that rotates around a central axis (not shown) under the control of the control device 7, which will be described later. In this embodiment, the rotating direction of the pressing member 520 is the same as the rotating direction of the backup roller 50 . The pressing member 520 is made of an insulating material, such as rubber. The pressing member 520 has a contact surface that contacts the pre-molding electrode I on the film-forming surface 68 of the backup roller 50 . A contact surface of the pressing member 520 is provided in parallel so as to face the surface of the backup roller 50 . The pressing member 520 contacts the surface of the preformed electrode I while rotating around a central axis (not shown). In this embodiment, the pressing member 520 rotates in a direction opposite to the rotating direction of the backup roller 50 . Here, in the thickness direction of the electrode I before molding, the distance between the pressing member 520 and the surface of the electrode I before molding is preferably shorter than the distance between the thickness correction member 510 and the surface of the electrode I before molding. In this way, when the pre-shaped electrode I on the foil F, which is regulated to a predetermined thickness by the thickness correction member 510, is brought into contact with the contact surface of the pressing member 520, the thickness of the pre-shaped electrode I is uniform. become.

The sensor 530 detects the state of the pre-molding electrode I deposited on the foil F on the film-forming surface 68, for example, the unevenness and thickness of the surface, the presence or absence of carrier C contamination, the presence or absence of foreign matter contamination, and the like. Sensor 530 transmits detected information to control device 7 .

The carrier removal device 540 removes the carrier C from the pre-molding electrode I when the carrier C is mixed in the pre-molding electrode I during film formation in the film forming section 3 . The carrier removing device 540 is composed of, for example, a magnet and provided so as to face the pre-molding electrode I. As shown in FIG. When the pre-shaped electrode I is transported in the transport direction together with the foil F, and the pre-shaped electrode I on the foil F faces the carrier removing device 540, the magnetic carrier C mixed in the pre-shaped electrode I is removed from the carrier removing device 540. It is attracted to the carrier removal device 540 by magnetic force. On the other hand, the foil F in the present embodiment is made of aluminum and does not have magnetism, and the electrode particles E constituting the preformed electrode I are diamagnetic. Therefore, the foil F and the preformed electrode I are not attracted by the magnetic force of the carrier removing device 540 and are not attracted to the carrier removing device 540 . By doing so, the carrier C mixed in the preformed electrode I can be removed, and the purity of the electrode particles E on the foil F can be improved. When a magnetic metal foil is used as the foil F, a roller may be provided to prevent the foil F from floating due to the magnetic force of the carrier removing device 540 . In this case, for example, a pair of rollers are provided upstream and downstream of the carrier removing device 540 in the direction in which the foil F is conveyed. Note that the carrier removing device 540 may recognize information about the carrier C mixed in the pre-molding electrode I, such as the mixed location and the mixed amount, using a sensor and acquire the information via the control device 7 .

The fixing unit 6 presses the foil F and the pre-molding electrode I formed on the foil F to bring the foil F and the pre-molding electrode I into close contact and integrate them. The fixing section 6 is provided downstream of the adjustment section 5 in the transport direction. The fixing section 6 includes fixing rollers 610 and 620 . The fixing rollers 610 and 620 are a pair of rollers that sandwich the foil F and the pre-molding electrode I formed on the foil F in the conveying direction. That is, the fixing rollers 610 and 620 are provided on one surface located on the foil F side and on the other surface located on the opposite side to the one surface and on the pre-molding electrode I side. The fixing rollers 610 and 620 are rotated in synchronism with the transport speed of the foil F under the control of the control device 7, which will be described later, and heat the foil F and the preformed electrode I by a heating device (not shown). The fixing unit 6 applies pressure and heat when the foil F and the pre-molded electrode I pass between a pair of fixing rollers 610 and 620 to fix the pre-molded electrode I to the foil F. to settle. As a result, the foil F and the preformed electrode I are integrated to produce a sheet-like electrode.

The grounding member 80 renders the conductive backup roller 50 and the foil F uncharged. The grounding member 80 is grounded (earthed). The grounding member 80 contacts the backup roller main body 51 of the backup roller 50 and keeps the backup roller 50 in an uncharged state.

The control device 7 applies a driving force to each component of the electrostatic film forming apparatus 1 described above to control them. In FIG. 1, among the constituent elements of the electrostatic film forming apparatus 1 that are electrically connected to and controlled by the control device 7, a part of the electrical connection mode is schematically illustrated as a representative. . Specifically, the control device 7 controls the first rotor blade 221, the second rotor blade 222, the third rotor blade 223, the tubular member 30, the backup roller 50, the repelling magnetic pole member 60, and the pressing member. 520 and fixing rollers 610 and 620 are provided with a driving force. Thereby, each component 221, 222, 223, 30, 50, 60, 520, 610, 620 of the electrostatic film forming apparatus 1 rotates. The control device 7 includes a motor (not shown). The control device 7 and each component 221, 222, 223, 30, 50, 60, 520, 610, 620 are connected by electrical wiring. The rotation speed of each component 221 , 222 , 223 , 30 , 50 , 60 , 520 , 610 , 620 of the electrostatic film forming apparatus 1 is controlled by the rotation speed of the motor of the controller 7 .

Based on the electrostatic film forming apparatus 1 described above, the details of each component in the film forming unit 3 and the behavior of the electrode particles E and the carrier C will be described.

FIG. 3 is a diagram for explaining the behavior of the electrode particles E and the carrier C in the film forming section 3. As shown in FIG. FIG. 3 schematically shows a state of the film forming unit 3 of the electrostatic film forming apparatus 1 viewed from the side. In addition, FIG. 3 schematically shows only a portion of the elongated foil F conveyed to the film formation surface 68 that contacts the backup roller 50 . First, the configuration of each of the magnetic poles N1, S1, N2, S2, and N3 that the magnetic pole member 21 has will be described below.

As described above, in the magnetic pole member 21, the magnetic pole member main body 21a functioning as a magnetic field generating means is composed of a plurality of magnets, each having magnetic poles N1, S1, N2, S2 and N3. In this embodiment, the magnetic pole member body 21a is composed of five magnets. That is, the number of magnetic poles of the magnetic pole member main body 21a is five. As shown in FIG. 3 , the five magnets are plate-shaped and form a shape that spreads radially around the second shaft portion 22 . Hereinafter, the portion where each magnet constituting the magnetic pole member main body 21a and the second shaft portion 22 abut is referred to as a first base end portion. A portion of each magnet located on the side opposite to the first base end portion, that is, a portion facing the inner surface of the cylindrical member 30 is defined as a first tip portion. The magnetic poles N1, S1, N2, S2, and N3 of the magnetic pole member main body 21a are located at the first tip of each magnet.

The magnetic poles N1, S1, N2, S2, N3 of the magnetic pole member main body 21a are a pumping magnetic pole N1, a first transfer magnetic pole S1, a facing magnetic pole N2, a second transfer magnetic pole S2, and a detachment magnetic pole N3. The pumping magnetic pole N1, the first transport magnetic pole S1, the opposing magnetic pole N2, the second transport magnetic pole S2, and the detachment magnetic pole N3 are provided inside the tubular member 30 in this order.

The pumping magnetic pole N1 is provided at a position facing the second supply chamber 212 on the upper side of the second supply chamber 212, as shown in FIG. In this embodiment, the polarity of the pumping magnetic pole N1 is north pole.

The opposing magnetic pole N2 is provided at a position facing the repulsive magnetic pole member 60. As shown in FIG. That is, the opposing magnetic pole N2 faces the film-forming surface 68 of the backup roller 50 and the foil F supplied to the film-forming surface 68 . In this embodiment, the polarity of the opposing magnetic pole N2 is N pole.

The first transport magnetic pole S1 is provided between the pumping magnetic pole N1 and the opposing magnetic pole N2. In this embodiment, the polarity of the first transport magnetic pole S1 is an S pole different from that of the pumping magnetic pole N1 and the opposing magnetic pole N2.

The separating magnetic pole N3 is provided at a position adjacent to the pumping magnetic pole N1 and closer to the second transport magnetic pole S2 than the position where the surface of the cylindrical member 30 and the tip of the discharging member 410 face each other. In this embodiment, the polarity of the separating magnetic pole N3 is the same N pole as the pumping magnetic pole N1 adjacent to the separating magnetic pole N3.

The second transport magnetic pole S2 is provided between the opposing magnetic pole N2 and the separating magnetic pole N3. In this embodiment, the polarity of the second transport magnetic pole S2 is an S pole different from that of the opposing magnetic pole N2 and the separating magnetic pole N3.

The positions and number of the plurality of magnetic poles N1, S1, N2, S2, and N3 included in the magnetic pole member main body 21a are not limited to these. The magnetic pole of the magnetic pole member main body 21a has an opposing magnetic pole N2 having the same polarity as the repulsive magnetic pole N described later at a position facing the repulsive magnetic pole N described later. should be positioned so that their magnetic poles are adjacent to each other.

Next, the functions of the magnetic poles N1, S1, N2, S2, and N3 of the magnetic pole member main body 21a and the behavior of the electrode particles E and the carrier C when the mixture EC is conveyed by the magnet roller 20 will be described.

First, the mixture EC is attracted to the magnet roller 20 . The manner in which the mixture EC is attracted to the magnet roller 20 is as follows. As shown in FIG. 1, the supply unit 2 is supplied with a mixture EC in which negatively charged electrode particles E are electrostatically adhered to a carrier C. As shown in FIG. This mixture EC is conveyed to the second supply chamber 212 via the mixture storage chamber 200 and the first supply chamber 211 . The mixture EC transported to the second supply chamber 212 is pushed up by the plurality of blades of the second rotor 222 due to the rotation of the second rotor 222 and approaches the magnet roller 20 . At this time, the magnetic pole closest to the second supply chamber 212 is the pumping magnetic pole N1. The polarity of the pumping magnetic pole N1 is the N pole, and the N pole has the property of attracting the magnetic material by magnetic force. Moreover, the mixture EC, which is a mixture of the magnetic carrier C and the electrode particles E, functions as a magnetic material as described above. Therefore, when a magnetic force is applied, the mixture EC is in a state of being attracted or repulsed by the applied magnetic force, and its behavior follows the lines of magnetic force. The magnetic lines of force referred to here are lines that virtually represent the distribution of the magnetic field generated around each magnetic pole. As a result, the mixture EC pushed up by the second rotor blades 222 of the second supply chamber 212 is drawn toward the magnet roller 20 by the magnetic force of the drawing magnetic pole N1 located closest to the second supply chamber 212 . Further, the mixture EC attracted to the pumping magnetic pole N1 is attracted to a position facing the pumping magnetic pole N1 on the surface of the cylindrical member 30 forming the outer shape of the magnetic pole member 21. FIG.

The mixture EC attracted to the surface of the cylindrical member 30 forms a shape that follows the direction of the magnetic lines of force. Specifically, the mixture EC attracted to the position facing the pumping magnetic pole N1 rises in a direction away from the position where the pumping magnetic pole N1 and the cylindrical member 30 face each other, as shown in FIG. At this time, the mixture EC forms a rice ear-shaped magnetic ear in which the electrode particles E are attached to the carrier C with the carrier C as an axis. That is, the cob in the ear of rice corresponds to the carrier C in this embodiment. In addition, the husks in the ears of rice correspond to the electrode particles E in this embodiment. In the example shown in FIG. 3, the mixture EC attracted to the position facing the pumping magnetic pole N1 is in a state in which a plurality of electrode particles E are attached to seven carriers C. As shown in FIG. At this time, as the tubular member 30 rotates, the mixture EC is adsorbed to the surface of the tubular member 30, and while changing the shape of the ear of rice into a shape that follows the lines of magnetic force, as shown in FIG. It is conveyed in the direction of rotation of the magnet roller 20 .

A regulating member 25 is provided between the pumping magnetic pole N1 and the first transport magnetic pole S1. At this time, in the conveying process of the magnet roller 20, in order to regulate the length of the mixture EC attracted to the magnet roller 20 to a predetermined length, the regulation member 25 is predetermined from the surface of the tubular member 30. spaced apart by a distance. In addition, since the regulating member 25 is provided so that the front end thereof faces the surface of the tubular member 30, when the tubular member 30 rotates, the mixture EC attracted to the magnet roller 20 moves toward the front end of the regulating member 25. come into contact with Then, the carrier C and the electrode particles E, which are excessively adsorbed over a predetermined length, come into contact with the tip side of the regulating member 25 and are detached and dropped. As a result, the mixture EC attracted to the magnet roller 20 is transported toward the first transport magnetic pole S1 in a state where the length of the mixture EC is made uniform. Of the mixture EC attracted to the magnet roller 20, the electrode particles E and the carrier C separated and dropped by the regulating member 25 are received in the supply chambers 211 to 213 and supplied again to the pumped-up magnetic pole N1. . Note that the shape and formation position of the regulating member 25 are not limited to those of the present disclosure. The regulating member 25 may be provided at a position facing the mixture EC attracted to the magnet roller 20 between the pumping magnetic pole N1 and the opposing magnetic pole N2 in the rotational direction of the tubular member 30 . The regulating member 25 may be positioned, for example, between the first transport magnetic pole S1 and the opposing magnetic pole N2.

Furthermore, due to the rotation of the cylindrical member 30, the mixture EC attracted to the magnet roller 20 is conveyed to the first conveying magnetic pole S1 while making its shape follow the lines of magnetic force. The pumping magnetic pole N1 and the first transport magnetic pole S1 have different magnetic pole polarities. If the magnetic pole positioned at the first conveying magnetic pole S1 is the same N pole as the scooping magnetic pole N1, a repulsive magnetic field is generated between the scooping magnetic pole N1 and the adjacent magnetic pole, and the mixture EC attracted to the magnet roller 20 separates from the magnet roller 20. On the other hand, in the present embodiment, by providing the first transport magnetic pole S1 having a polarity different from that of the pumping magnetic pole N1, the mixture EC is transported while being reversed. On the surface of the tubular member 30, near the center between the pumping magnetic pole N1 and the first transport magnetic pole S1, the mixture EC has a bow-like curved shape following the lines of magnetic force. In other words, the base end and the front end of the mixture EC are reversed between the time when the mixture EC is attracted to the position facing the pumping magnetic pole N1 and the time when it is attracted to the position facing the first transport magnetic pole S1.

The mixture EC conveyed to the position facing the first conveying magnetic pole S1 is further conveyed toward the position where the magnet roller 20 and the backup roller 50 face each other, and on the surface of the cylindrical member 30, the opposite magnetic pole N2. Reach nearby areas. In the region between the magnet roller 20 and the backup roller 50 containing the opposing magnetic pole N2, the electrode particles E are separated from the carrier C and fly to adhere to the foil F. As shown in FIG. Therefore, this area located between the magnet roller 20 and the backup roller 50 is also called a flying area 300 . The first transport magnetic pole S1 and the opposing magnetic pole N2 have different magnetic pole polarities. Therefore, the manner in which the mixture EC attracted to the magnet roller 20 is conveyed from the first conveying magnetic pole S1 to the opposing magnetic pole N2 is the same as the conveying manner described above.

As described above, in the repulsive magnetic pole member 60, the repulsive magnetic pole member main body 60a functioning as the magnetic field generating means is composed of a plurality of magnets, each of which has a repulsive magnetic pole N. As shown in FIG. In this embodiment, the repulsion magnetic pole member main body 60a is composed of four magnets. That is, the repulsion magnetic pole member main body 60a of this embodiment has four repulsion magnetic poles N. As shown in FIG. Since the functions of the four repulsive magnetic poles N in the repulsive magnetic pole member main body 60a are the same, they are given the same reference numerals in FIG. As shown in FIG. 3, the four magnets forming the repulsion magnetic pole member body 60a are plate-shaped and spread radially around the fourth shaft portion 62. As shown in FIG. In this embodiment, the four magnets forming the repulsive magnetic pole member main body 60a are provided at regular intervals. Hereinafter, the portion where each magnet constituting the repelling magnetic pole member main body 60a and the fourth shaft portion 62 abut is referred to as a second base end portion. A portion of each magnet located on the side opposite to the second base end portion, that is, a portion facing the inner surface of the cylindrical member 30 is defined as a second tip portion. The four repulsive magnetic poles N of the repulsive magnetic pole member body 60a are located at the second tip of each magnet.

The repelling magnetic pole N is a magnetic pole that opposes and repels the opposing magnetic pole N2. That is, since the opposing magnetic pole N2 has the N pole, the repelling magnetic pole N is also the same N pole as the opposing magnetic pole N2. An electrostatic film forming method using the electrostatic film forming apparatus 1, the behavior of the mixture EC in the flying region 300, and the film forming mode of the electrode particles E will be described below.

In the mixture EC conveyed to the flying region 300, some of the electrode particles E forming the mixture EC are separated from the carrier C by the following two forces.

The first force is centrifugal force. Specifically, part of the electrode particles E forming the mixture EC is separated from the carrier C by the centrifugal force accompanying the rotation of the tubular member 30 . In the separation mode by centrifugal force, electrostatic restraint of the electrode particles E and the carrier C in the mixture EC rather than the film formation in which the electrode particles E electrostatically adhere to the foil F on the film formation surface 68 to be described later. tends to take precedence. That is, the electrostatically bound electrode particles E are difficult to separate from the carrier C. Therefore, in the film formation of the electrode particles E, a case may arise in which high film formation efficiency cannot be obtained.

On the other hand, the electrostatic film forming apparatus 1 of this embodiment additionally generates the second force described below. The second force is a force that causes periodic magnetic field changes in the flying region 300 to cause the carrier C to vibrate. Specifically, it is as follows. The opposing magnetic pole N2 and the repulsive magnetic pole N are N poles of the same polarity. When the opposing magnetic pole N2 and the repulsive magnetic pole N face each other, the magnetic fields formed by the magnetic forces generated by the two collide with each other, and repulsion occurs between the two. A magnetic field is generated in the direction of Here, the magnetic pole member 21 is fixed without rotating, and the repulsive magnetic pole member 60 rotates around the repulsive magnetic pole rotation axis O4. As a result, in the flight region 300, the repelling magnetic pole N periodically opposes the opposing magnetic pole N2 existing at a fixed position.

Consider a case where the opposing magnetic pole N2 and the repulsive magnetic pole N are separated from each other by the rotation of the repulsive magnetic pole member 60 from the position where the opposing magnetic pole N2 and the repulsive magnetic pole N face each other. In this case, the strength of the magnetic field in the repelling direction generated between the opposing magnetic pole N2 and the repelling magnetic pole N becomes weaker in proportion to the distance between the opposing magnetic pole N2 and the repelling magnetic pole N than in the case of the opposing position. . Among the non-opposing positions described above, when the distance between the opposing magnetic pole N2 and the repelling magnetic pole N is the greatest, the strength of the magnetic field in the repelling direction generated between them is minimized. On the other hand, when the repulsion magnetic pole member 60 rotates further, the distance between the opposing magnetic pole N2 and the repulsion magnetic pole N becomes closer again. At this time, the strength of the magnetic field in the repelling direction generated between the opposing magnetic pole N2 and the repulsive magnetic pole N increases as the repulsive magnetic pole N approaches the opposing magnetic pole N2. Then, when the opposing magnetic pole N2 and the repelling magnetic pole N again come to the opposing positions, the strength of the magnetic field in the repelling direction generated between them becomes maximum. In this manner, the electrostatic film forming apparatus 1 causes periodic magnetic field changes in the flying region 300 .

When considering the effects of magnetic field changes on the mixture EC, it is easier to understand using magnetic lines of force that virtually represent the distribution of the magnetic field generated around the opposing magnetic pole N2 and the repelling magnetic pole N. As described above, when a periodic magnetic field change is caused, the mixture EC attracted to the magnet roller 20 follows changes in magnetic lines of force caused by the periodic magnetic field change, and the shape of the mixture EC changes. . Specifically, when the opposing magnetic pole N2 and the repelling magnetic pole N face each other, that is, when the strength of the magnetic field in the repelling direction is maximum, the magnetic field in the repelling direction formed between them separates them. It is drawn with magnetic lines of force such as Therefore, the mixture EC attracted to the magnet roller 20 follows this line of magnetic force, and the carrier C forming the axis of the mixture EC falls down. In FIG. 3, the solid line schematically shows the shape of the mixture EC when the intensity of the magnetic field in the repelling direction is maximized at the opposing position. On the other hand, when the distance between the opposing magnetic pole N2 and the repelling magnetic pole N is the greatest, that is, when the strength of the magnetic field in the repelling direction is minimum, the lines of magnetic force of both exist without blocking each other. In other words, a magnetic field that separates the opposing magnetic pole N2 and the repelling magnetic pole N is not generated. Therefore, in the mixture EC attracted to the magnet roller 20, when the distance between the opposing magnetic pole N2 and the repelling magnetic pole N is the greatest among the non-opposing positions, the carrier C forming the axis in the mixture EC rises. become a state. In FIG. 3, the dotted line schematically shows the shape of the mixture EC when the intensity of the magnetic field in the repelling direction is minimized at the non-facing position. In this manner, the mixture EC attracted to the magnet roller 20 falls down and rises as if by beating dust, with the carrier C forming the axis of the mixture EC, along with the periodical change of the magnetic field. repeat. That is, the mixture EC vibrates while being attracted to the magnet roller 20 as the magnetic field periodically changes. In FIG. 3, in the flying region 300, the double-headed arrow schematically shows the vibration when the carrier C forming the axis of the mixture EC shakes due to this vibration. Here, since the mixture EC is a magnetic material, the vibration of the mixture EC accompanying periodic magnetic field changes can also be said to be magnetic vibration.

Here, the mixture EC is a state in which the electrode particles E are attached to the carrier C. As shown in FIG. Therefore, as described above, in the flight region 300, magnetic vibration is propagated to the entire mixture EC due to the magnetic vibration of the carrier C accompanying the periodic magnetic field change. As a result, some of the electrode particles E are separated from the carrier C. As shown in FIG. At this time, the mode in which some of the electrode particles E are separated from the carrier C by the magnetic vibration of the mixture EC is a state in which the electrode particles E adhering to the carrier C constituting the mixture EC are shaken off by the magnetic vibration. . That is, when some of the electrode particles E are separated from the carrier C by magnetic vibration, it can be said that some of the electrode particles E separated from the carrier C fly toward the foil F on the film formation surface 68 . In the example shown in FIG. 3, the electrode particles E separated from the carrier C and flew in the flying region 300 are shown as flying electrode particles E1.

The repelling magnetic pole member 60 in this embodiment is provided inside the backup roller 50 between the backup roller rotating shaft O<b>3 and the magnet roller 20 . By doing so, the size of the repulsive magnetic pole member 60 can be reduced as compared with the case where the repulsive magnetic pole member 60 is provided in the entire inside of the backup roller 50 . As a result, the number of rotations of the repulsion magnetic pole member 60 per unit time for the same driving force can be efficiently increased. That is, by miniaturizing the repulsive magnetic pole member 60, the magnetic frequency, which will be described later, can be efficiently increased.

Subsequently, the flying electrode particles E1 as the electrode particles E separated from the carrier C are conveyed to the film formation surface 68 by at least one of the centrifugal force and the magnetic vibration force as the two forces described above. The manner in which a film is formed on the film will be described.

The magnet roller 20 is connected to a voltage supply section (not shown) for supplying voltage to the magnet roller 20, as described above. In this embodiment, a voltage supply section (not shown) applies a DC voltage of 2550 V to the magnet roller 20 . On the other hand, the backup roller 50 is connected to the grounding member 80 as described above. In this embodiment, the voltage of the backup roller 50 is 0V because it is grounded by the grounding member 80 . Thereby, the electrostatic film forming apparatus 1 is in a state in which a potential difference is provided between the magnet roller 20 and the backup roller 50 . The voltage applied to the magnet roller 20 is not limited to this, and for example, a voltage obtained by superimposing an AC voltage on a DC voltage may be applied.

As described above, in the electrostatic film forming apparatus 1, a potential difference is provided between the magnet roller 20 that attracts and conveys the mixture EC and the backup roller 50 that has the film forming surface 68 on its surface. Therefore, the negatively charged flying electrode particles E1 receive an electrostatic force (Coulomb force) from the magnet roller 20 toward the backup roller 50 . Specifically, when the negatively charged flying electrode particles E1 approach the backup roller 50, positive charges gather on the surface of the backup roller 50 due to electrostatic induction. At this time, the backup roller 50 is grounded (earthed) by the grounding member 80 . Therefore, the negative charges on the backup roller 50 flow to the ground, the positive charges of the free electrons from the ground and the negative charges on the backup roller 50 are neutralized, and the negative charges on the backup roller 50 disappear as if they flowed to the ground. do. As a result, the surface of the backup roller 50 is positively charged. As a result, the flying electrode particles E1 separated from the carrier C due to at least one of the centrifugal force and the magnetic vibration force fly toward the film-forming surface 68 of the backup roller 50 by electrostatic force. A film is formed by adhering to the foil F which is conveyed to the surface 68 .

It should be noted that the electrostatic force generated between the magnet roller 20 and the backup roller 50 is generated not only by the step of forming the flying electrode particles E1 as the electrode particles E separated from the carrier C on the foil F, but also by the electrode particles from the carrier C. It also contributes to the process of separating E. That is, among the two forces that separate the electrode particles E adhering to the carrier C, the electrostatic force generated between the magnet roller 20 and the backup roller 50 works in the direction of promoting the separation of the electrode particles E from the carrier C. .

The mixture EC transported to the flight region 300 is further transported to the second transport magnetic pole S2 by the rotation of the cylindrical member 30. As shown in FIG. Subsequently, the mixture EC transported to the second transport magnetic pole S2 is transported to the detachment magnetic pole N3 by the rotation of the tubular member 30. As shown in FIG. The transporting mode of the mixture EC at this time is the same as the transporting mode in which the mixture EC is transported from the pumping magnetic pole N1 to the opposing magnetic pole N2 via the first transporting magnetic pole S1, and therefore the description thereof is omitted.

The mixture EC conveyed to the separating magnetic pole N3 is conveyed in the direction in which the pumping magnetic pole N1 is positioned due to the rotation of the cylindrical member 30 . In this transfer process, since the separating magnetic pole N3 and the pumping magnetic pole N1 have the same polarity, a magnetic field is formed between the separating magnetic pole N3 and the pumping magnetic pole N1 in a repelling direction. The magnetic field in the repelling direction that is formed so as to separate the separating magnetic pole N3 and the pumping magnetic pole N1 forms a non-magnetic zone at the boundary between the two. As a result, the mixture EC attracted to the magnet roller 20 is separated from the magnet roller 20 .

According to the electrostatic film forming apparatus 1 described above, the magnetic pole member 21 is provided inside the magnet roller 20 that attracts and conveys the mixture EC. The magnetic pole member 21 includes an opposing magnetic pole N2 as a magnetic pole positioned in the flying region 300 among the plurality of magnetic poles N1, S1, N2, S2, and N3 provided in the magnetic pole member main body 21a. On the other hand, the backup roller 50 having the film-forming surface 68 has the repelling magnetic pole member 60 inside. The repelling magnetic pole member 60 has a repelling magnetic pole N as a magnetic pole that opposes and repels the opposing magnetic pole N2. The opposing magnetic pole N2 and the repelling magnetic pole N periodically face each other, so that the electrostatic film forming apparatus 1 causes a periodic magnetic field change. That is, in the state of being attracted to the magnet roller 20, the electrostatic film forming apparatus 1 causes the mixture EC to magnetically vibrate due to the change in the magnetic field in addition to the centrifugal force associated with the rotation of the cylindrical member 30, thereby moving the carrier C from the electrode. A force is generated that shakes off the particles E.

The change in the film thickness of the electrode particles E was measured by changing the number of rotations of the repulsion magnetic pole member 60 . FIG. 4 is a graph showing the relationship between the film formation amount of the electrode particles E and the magnetic frequency (rotational speed). FIG. 4 shows the relationship between the magnetic frequency at the time of measurement and the value of the film formation amount corresponding to the magnetic frequency at the time of measurement as the result of this measurement. The vertical axis of the graph in FIG. 4 represents the weight of the electrode particles E formed per 1 cm ² as the film formation amount of the electrode particles E formed on the foil F conveyed to the film formation surface 68. ing. The horizontal axis of the graph in FIG. 4 indicates the magnetic frequency. Also, the film formation efficiency was calculated from the results of this measurement. The film formation efficiency referred to here is a value obtained by dividing the weight of the electrode particles E formed on the foil F transported to the film formation surface 68 by the supply amount of the electrode particles E to the film formation unit 3. . That is, the film formation efficiency is a value that indicates the weight of the electrode particles E formed per cm ² of the foil F with respect to the supply amount of the electrode particles E to the film formation section 3 . In this measurement, (weight of electrode particles E deposited on foil F)/(weight of electrode particles E collected without being deposited + weight of electrode particles E deposited on foil F) A film formation efficiency was calculated. In this measurement, the unit of the weight of the film-formed electrode particles E is expressed in milligrams (mg). The unit of film formation efficiency in this measurement is mg/cm ² .

As a prerequisite for creating the graph of FIG. 4, the closest distance between the cylindrical member 30 forming the outer shape of the magnet roller 20 and the backup roller 50 having the film-forming surface 68 on its surface was 6 to 10 mm. A DC voltage of 2,550 V was applied to the magnet roller 20, and 0 V was set to 0 V by bringing a grounded member 80 into contact with the backup roller 50, creating a potential difference of 2,550 V between the two. The carrier C and the electrode particles E were supplied to the supply section 2 so as to have a weight ratio of 10:1. In this measurement, the supply amount of the mixture EC supplied to the film forming unit 3 was approximately 30 mg/cm ² . Specifically, the supply amount of the mixture EC is 29.27 mg/cm ² when the magnetic frequency described later is 0 Hz, 29.29 mg/cm ² when the magnetic frequency is 20 Hz, 29.22 mg/cm ² when the magnetic frequency is 200 Hz, and 267 Hz. At that time, it was 29.31 mg/cm ² . In this measurement, the circumferential speeds of the cylindrical member 30 and the backup roller 50, which are the rotational speeds, were set to predetermined values, which were constant regardless of the magnetic frequency. In addition, the peripheral speed as the rotational speed of the repulsive magnetic pole member 60 was controlled by the motor constituting the control device 7 so as to match the magnetic frequency to be measured, and the rotational speed of the repulsive magnetic pole member 60 was controlled. The results of this measurement under the above conditions are shown in FIG.

The magnetic frequency in this measurement represents the number of times the opposing magnetic pole N2 and the repelling magnetic pole N face each other per second. That is, the magnetic frequency is also the number of magnetic vibrations per second caused by the opposing magnetic pole N2 and the repelling magnetic pole N facing each other. In the following, the unit of magnetic frequency in this measurement is hertz (Hz). The magnetic frequency in this embodiment depends on the number of magnets included in the repulsive magnetic pole member 60, the number of repulsive magnetic poles N attached thereto, and the number of rotations of the repulsive magnetic pole member 60. FIG. At this time, the number of rotations of the repulsive magnetic pole member 60 is adjusted by the rotational speed of the repulsive magnetic pole member 60 . In this measurement, the number of repulsive magnetic poles N is kept constant at four, and the magnetic frequency is adjusted by varying the rotational speed of the repulsive magnetic pole member 60 .

In this measurement, measurements were performed at four different magnetic frequencies in order to compare changes in film formation efficiency that accompany changes in the magnetic frequency. The four types of magnetic frequencies that were measured are 0 Hz, 20 Hz, 200 Hz, and 267 Hz, as shown in FIG. Here, when the magnetic frequency is 0 Hz, the repulsion magnetic pole member 60 is not rotated, that is, the mixture EC is not magnetically vibrating without generating a periodic magnetic field change. In the following, the case where the magnetic frequency is 0 Hz is compared with the case where the mixture EC is somewhat magnetically vibrated (magnetic frequencies of 20 Hz, 200 Hz, and 267 Hz).

First, as shown in FIG. 4, when the magnetic frequency was 0 Hz, the film formation amount of the electrode particles E was 4.39 mg/cm ² , and the film formation efficiency at this time was approximately 15.0%. On the other hand, when the magnetic frequency is 20 Hz, that is, when the opposing magnetic pole N2 and the repelling magnetic pole N face each other 20 times per second, the amount of film formation of the electrode particles E is 4.98 mg/cm ² . The film formation efficiency at this time was about 17.0%. As a result, the film formation amount of the electrode particles E increased when the mixture EC was magnetically oscillated, compared to when the mixture EC was not magnetically oscillated. Accompanying this, when the mixture EC was magnetically oscillated, the film formation efficiency was improved by about 2.0% compared to the case where the mixture EC was not magnetically oscillated.

Furthermore, when the magnetic frequency is 200 Hz, that is, when the opposing magnetic pole N2 and the repulsive magnetic pole N are opposed 200 times per second, the film formation amount of the electrode particles E is 5.26 mg/cm ² . The film formation efficiency was about 18.0%. That is, by increasing the magnetic frequency, that is, by increasing the number of times the opposing magnetic pole N2 and the repelling magnetic pole N face each other per second, the amount of the electrode particles E deposited increases. An improvement in membrane efficiency was observed. Specifically, when the mixture EC was magnetically oscillated at a magnetic frequency of 200 Hz, the film formation efficiency was improved by about 3.0% compared to the case where the mixture EC was not magnetically oscillated. Furthermore, when the mixture EC was magnetically oscillated at a magnetic frequency of 200 Hz, the film formation efficiency was improved by about 1.0% compared to the case where the mixture EC was magnetically oscillated at a magnetic frequency of 20 Hz. From this, it was possible to improve the film formation efficiency by generating a periodic magnetic field change and magnetically oscillating the mixture EC. Furthermore, when the magnetic frequency was increased to 200 Hz, a further improvement in deposition efficiency was achieved.

Here, when the magnetic frequency is increased from 200 Hz to 267 Hz, that is, when the opposing magnetic pole N2 and the repelling magnetic pole N face each other 267 times per second, the film formation amount of the electrode particles E is 5.13 mg/cm ² . , and the film formation efficiency at this time was about 17.5%. Specifically, when the mixture EC is magnetically oscillated at a magnetic frequency of 267 Hz, the film formation efficiency is about 0.5% compared to the case where the mixture EC is magnetically oscillated at a magnetic frequency of 200 Hz. Decreased. In other words, the magnetic oscillation of the mixture EC due to the periodic magnetic field change contributes to the improvement of the film formation amount of the electrode particles E and the associated film formation efficiency. However, when the magnetic frequency exceeds a specific value (hereinafter referred to as a threshold value), the film formation amount and film formation efficiency of the electrode particles E tend to decrease. That is, the magnetic frequency is an index for achieving the effect of improving the film formation amount and the film formation efficiency of the electrode particles E, and the threshold value can be said to be its maximum value.

From the above results, when the mixture EC was magnetically oscillated, the film formation amount was improved by up to about 19.8% compared to the case where the mixture EC was not magnetically oscillated. Accompanying this, when the mixture EC was magnetically oscillated, the film formation efficiency was improved by up to about 3.0% compared to the case where the mixture EC was not magnetically oscillated. That is, when the mixture EC is magnetically oscillated by a periodic magnetic field change caused by periodically opposing the opposing magnetic pole N2 and the repelling magnetic pole N, the amount of film formation and growth of the electrode particles E on the film formation surface 68 are increased. Membrane efficiency is improved.

Furthermore, from the above results, it is preferable that the magnetic frequency in the electrostatic film forming apparatus 1 that forms a film of particles such as the electrode particles E using a magnet roller as a magnetic field generating means is 20 Hz or higher. Moreover, the magnetic frequency in the electrostatic film forming apparatus 1 is preferably 270 Hz or less, more preferably 267 Hz or less. In other words, in the electrostatic deposition apparatus 1, the number of times the opposing magnetic pole N2 and the repelling magnetic pole N as a magnetic pole opposing and repelling the opposing magnetic pole N2 face each other is preferably 20 times or more per second. In the electrostatic film forming apparatus 1, the number of times the opposing magnetic pole N2 and the repelling magnetic pole N face each other per second is preferably 270 times or less, more preferably 267 times or less.

In addition, when the magnetic frequency exceeds the threshold value, the following factors are conceivable as factors for the decrease in the film formation amount of the electrode particles E and the associated film formation efficiency. First, due to the magnetic field in the direction of repulsion generated between the opposing magnetic pole N2 and the repelling magnetic pole N due to their opposition, the mixture EC cannot stand up with the carrier C as an axis, and is arranged along the surface side of the tubular member 30. It will be in a state of falling down. In this way, after the mixture EC falls down, the distance between the opposing magnetic pole N2 and the repelling magnetic pole N increases as the repelling magnetic pole member 60 rotates. In this process, when the magnetic frequency is equal to or less than the threshold, the strength of the magnetic field in the repulsive direction generated between the opposing magnetic pole N2 and the repulsive magnetic pole N weakens, and the mixture EC gradually rises with the carrier C as its axis. . Furthermore, in the process in which the distance between the opposing magnetic pole N2 and the repelling magnetic pole N approaches again, the strength of the magnetic field in the repelling direction generated between them increases, causing the mixture EC to collapse again. The mixture EC magnetically oscillates. However, when the magnetic frequency exceeds the threshold, the magnetic frequency is equal to or less than the threshold in the interval from when the opposing magnetic pole N2 and the repelling magnetic pole N face each other until the opposing magnetic pole N2 and the repelling magnetic pole N again face each other. shorter than the case. As a result, after the mixture EC falls down due to the magnetic field in the repelling direction formed between the opposing magnetic pole N2 and the repelling magnetic pole N as described above, it repels the opposing magnetic pole N2 again before it rises with the carrier C as its axis. A magnetic field is generated in a direction in which the magnetic pole N opposes and repels the magnetic pole N, so that the mixture EC continues to lie down. That is, when the magnetic frequency exceeds the threshold, it is conceivable that the mixture EC will not follow the change in the magnetic field produced by the opposing magnetic pole N2 and the repelling magnetic pole N.

According to the above-described embodiment, the electrostatic film forming apparatus 1 includes the magnet roller 20 that attracts and conveys the mixture EC as the carrier C to which the electrode particles E are attached. A magnetic pole N2 and a repelling magnetic pole N located inside the backup roller 50 having the film-forming surface 68 and opposing and repelling the opposing magnetic pole N2. The opposing magnetic pole N2 and the repelling magnetic pole N periodically face each other, so that the electrostatic film forming apparatus 1 causes a periodic magnetic field change. That is, in the state of being attracted to the magnet roller 20 , the electrostatic film forming apparatus 1 causes the mixture EC to magnetically vibrate due to the change in the magnetic field in addition to the centrifugal force accompanying the rotation of the cylindrical member 30 . As a result, in the film formation technique using the magnet roller 20 as the magnetic field generating means, the separation of the carrier C and the electrode particles E electrostatically bound to the carrier C can be facilitated. In other words, the electrostatic film forming apparatus 1 can easily separate the electrode particles E electrostatically bound to the carrier C from the carrier C. As shown in FIG. As a result, film formation efficiency can be improved.

Further, according to the above-described embodiment, when the mixture EC is magnetically oscillated by generating a periodic magnetic field change, the number of electrode particles E per unit area is greater than when the mixture EC is not magnetically oscillated. Increased film yield and concomitant deposition efficiency. As a result, the electrostatic film forming apparatus 1 can easily separate the particles electrostatically bound to the carrier C from the carrier C by causing a periodic magnetic field change.

Further, according to the above embodiment, by controlling the motor, the number of times the opposing magnetic pole N2 and the repelling magnetic pole N face each other per second, that is, the magnetic frequency can be controlled. This controllable magnetic frequency correlates with the amount of electrode particles E deposited. Thus, by controlling the magnetic frequency, the electrostatic film forming apparatus 1 can further improve the film forming amount of the electrode particles E and the associated film forming efficiency.

B. Other embodiments:
B-1. Alternative Embodiment 1:
In the above-described embodiment, the entire backup roller 50 is kept in an uncharged state by the grounding member 80 . That is, the electrode particles E separated from the carrier C were deposited on the foil F conveyed to the film-forming surface 68 located on the surface of the backup roller 50 . However, the present disclosure is not limited to this. Instead of the grounding member 80, a charging roller that uniformly charges the backup roller 50 and a laser device that renders a part of the film formation surface 68 uncharged may be provided. For example, the charging roller negatively charges the surface of the backup roller 50 . Further, the laser device is provided at a position separated from the backup roller 50, for example, like laser irradiation in toner development, and removes static electricity by irradiating a predetermined region of the film formation surface 68 with a laser beam, An uncharged region is formed in part of the film formation surface 68 . Even in such a form, the electrostatic film forming apparatus 1 includes the opposing magnetic pole N2 and the repelling magnetic pole N, and by periodically opposing the two, a periodic magnetic field change is generated. As a result, in the film formation technique using the magnet roller 20 as the magnetic field generating means, the separation of the carrier C and the electrode particles E electrostatically bound to the carrier C can be facilitated. That is, film formation efficiency can be improved. Furthermore, with such a form, the area and the film formation width of the electrode particles E can be controlled on the film formation surface 68 .

B-2. Alternative Embodiment 2:
In the above embodiment, by rotating the repulsive magnetic pole member 60 formed by a plurality of magnets having the repulsive magnetic poles N with respect to the opposed magnetic pole N2 existing at a fixed position, it is displaced between the opposed position and the non-opposed position. It was possible. However, the present disclosure is not limited to this. The repelling magnetic pole member 60 may be formed by a single magnet having a repelling magnetic pole N, and instead of rotating, moves horizontally inside the backup roller 50 to displace between opposed and non-opposed positions. It may be possible. Even in such a form, the electrostatic film forming apparatus 1 includes the opposing magnetic pole N2 and the repelling magnetic pole N, and is displaceable between the opposing position and the non-opposing position. C can be oscillated by magnetic field changes. Since the electrode particles E electrostatically bound to the carrier C can be easily separated from the carrier C by this vibration, the film forming efficiency can be improved.

B-3. Alternative Embodiment 3:
In the above embodiment, by rotating the repulsive magnetic pole member 60 formed by a plurality of magnets having the repulsive magnetic poles N with respect to the opposed magnetic pole N2 existing at a fixed position, it is displaced between the opposed position and the non-opposed position. It was possible. However, the present disclosure is not limited to this. The magnetic pole member 21 and the repelling magnetic pole member 60 may be electromagnets. Even in such a form, the electrostatic film forming apparatus 1 is provided with the opposing magnetic pole N2 and the repulsive magnetic pole N. The opposing state in which the opposing magnetic pole N2 and the repulsive magnetic pole N face each other, and the non-facing state in which they do not face each other. and can be made displaceable. As a result, the carrier C to which the electrode particles E are attached can be vibrated by changing the magnetic field. That is, since the electrode particles E electrostatically bound to the carrier C can be easily separated from the carrier C by this vibration, the film forming efficiency can be improved.

B-4. Alternative Embodiment 4:
In the above-described embodiment, the number of magnets constituting the repulsion magnetic pole member main body 60a is four, and the magnets are plate-shaped. Further, since the magnets forming the repulsive magnetic pole member main body 60a each have a repulsive magnetic pole N, the number of repulsive magnetic poles N included in the repulsive magnetic pole member 60 is four. On the other hand, the present disclosure is not limited to this, and the shape, number and size of the magnets forming the repulsive magnetic pole member 60 and the number of repulsive magnetic poles N can be arbitrary. The repulsive magnetic pole member 60 may include a repulsive magnetic pole N that opposes and repels the opposing magnetic pole N2 located inside the magnet roller 20 that attracts and conveys the carrier C to which the electrode particles E are attached. Even in such a form, the electrostatic film forming apparatus 1 includes the opposing magnetic pole N2 and the repelling magnetic pole N, which are periodically opposed to each other to generate a periodic magnetic field change. As a result, in the film formation technique using the magnet roller 20 as the magnetic field generating means, the separation of the carrier C and the electrode particles E electrostatically bound to the carrier C can be facilitated. That is, film formation efficiency can be improved. Furthermore, with such a configuration, the size of the backup roller 50 can be reduced by adjusting the shape, number, and size of the magnets included in the repulsive magnetic pole member 60 .

The present disclosure is not limited to the embodiments described above, and can be implemented in various configurations without departing from the scope of the present disclosure. For example, the technical features of the embodiments corresponding to the technical features in each form described in the outline of the invention are used to solve some or all of the above-mentioned problems, or to achieve some of the above-mentioned effects. Alternatively, replacements and combinations can be made as appropriate to achieve all. Also, if the technical features are not described as essential in this specification, they can be deleted as appropriate.

DESCRIPTION OF SYMBOLS 1... Electrostatic film-forming apparatus 2... Supply part 3... Film-forming part 4... Recovery part 5... Adjusting part 6... Fixing part 7... Control device 18... Base 20... Magnet roller 21... Magnetic pole member 21a Magnetic pole member main body 22 Second shaft portion 25 Regulation member 30 Tubular member 31 Tubular member main body 32 First shaft portion 33 First support member 50 Backup roller 51 Backup roller main body 52 Third shaft 53 Third support member 60 Repulsion magnetic pole member 60a Repulsion magnetic pole member main body 62 Fourth shaft 68 Film-forming surface 80... Grounding member 200... Mixture storage chamber 201... Communication port 211... First supply chamber 212... Second supply chamber 213... Third supply chamber 215... First wall 216... Second wall Section 217 Third wall 218 Fourth wall 221 First rotor 222 Second rotor 223 Third rotor 300 Flight area 410 Ejection member 420 Recovery Chamber 510 Thickness correction member 520 Pressing member 530 Sensor 540 Carrier removal device 610, 620 Fixing roller C Carrier E Electrode particles E1 Flying electrode particles EC Mixture F... Foil, I... Electrode before forming, N... Repulsion magnetic pole, N1... Drawing up magnetic pole, N2... Opposing magnetic pole, N3... Detachable magnetic pole, O1... Cylinder rotary shaft, O3... Backup roller rotary shaft, O4... Repulsive magnetic pole rotary shaft, S1... First transport magnetic pole, S2... Second transport magnetic pole

Claims (5)

An electrostatic deposition apparatus,
A magnet roller having a magnetic pole, the magnet roller attracting a carrier having magnetism to which electrode particles as a film forming material are attached by a magnetic force;
A backup roller provided apart from the magnet roller, the backup roller having a film-forming surface on which the electrode particles separated from the carrier are formed,
Inside the backup roller is a repelling magnetic pole member having a repelling magnetic pole that repels the magnetic pole of the magnet roller, the repelling magnetic pole member causing a magnetic field change in a flying region located between the magnet roller and the backup roller. An electrostatic deposition apparatus provided with a magnetic pole member. The electrostatic film forming apparatus according to claim 1,
The magnet roller includes a cylindrical member that attracts the carrier to which the electrode particles are attached;
a magnetic pole member provided inside the cylindrical member and having the magnetic pole,
The electrostatic film forming apparatus, wherein the repulsion magnetic pole member is rotatable so that the magnetic pole and the repulsion magnetic pole periodically face each other. The electrostatic film forming apparatus according to claim 2,
The electrostatic film forming apparatus, wherein the number of times the magnetic pole and the repelling magnetic pole face each other is 20 times or more and 270 times or less per second. The electrostatic film forming apparatus according to any one of claims 1 to 3,
The backup roller has a rotating shaft,
The electrostatic film forming apparatus, wherein the repelling magnetic pole member is positioned between the rotating shaft and the magnet roller within the interior. An electrostatic deposition method,
(a) a step of attracting the carrier, which is a carrier having magnetism and to which electrode particles as a film forming material are attached, to a magnet roller by the magnetic force of the magnetic pole;
(b) separating the electrode particles from the carrier and adhering the electrode particles to a film-forming surface of a backup roller;
In the step (b), a magnetic field change is generated in a flying region located between the magnet roller and the backup roller by a repelling magnetic pole that repels the magnetic pole inside the backup roller to vibrate the carrier. An electrostatic deposition method, comprising steps.

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