WO2016056379A1 - フィルム製造方法、フィルム製造装置、フィルム、及びフィルム捲回体 - Google Patents
フィルム製造方法、フィルム製造装置、フィルム、及びフィルム捲回体 Download PDFInfo
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- WO2016056379A1 WO2016056379A1 PCT/JP2015/076651 JP2015076651W WO2016056379A1 WO 2016056379 A1 WO2016056379 A1 WO 2016056379A1 JP 2015076651 W JP2015076651 W JP 2015076651W WO 2016056379 A1 WO2016056379 A1 WO 2016056379A1
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/89—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles
- G01N21/892—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles characterised by the flaw, defect or object feature examined
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
- B26D1/00—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor
- B26D1/01—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work
- B26D1/02—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a stationary cutting member
- B26D1/03—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a stationary cutting member with a plurality of cutting members
- B26D1/035—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor involving a cutting member which does not travel with the work having a stationary cutting member with a plurality of cutting members for thin material, e.g. for sheets, strips or the like
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
- B26D7/00—Details of apparatus for cutting, cutting-out, stamping-out, punching, perforating, or severing by means other than cutting
- B26D7/08—Means for treating work or cutting member to facilitate cutting
- B26D7/14—Means for treating work or cutting member to facilitate cutting by tensioning the work
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
- B26D7/00—Details of apparatus for cutting, cutting-out, stamping-out, punching, perforating, or severing by means other than cutting
- B26D7/26—Means for mounting or adjusting the cutting member; Means for adjusting the stroke of the cutting member
- B26D7/2614—Means for mounting the cutting member
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B65H16/10—Arrangements for effecting positive rotation of web roll
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- B65H18/08—Web-winding mechanisms
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Definitions
- the present invention relates to a film manufacturing method, a film manufacturing apparatus, a film, and a film winding body.
- a defect inspection apparatus for sheet-like products having an optical film is known (Patent Document 1).
- This defect inspection apparatus uses the defect information obtained from the protective film inspection unit as code data (two-dimensional code, QR code (registered trademark)) together with its position information and manufacturing identification information on one end surface of the PVA film original fabric. It is formed at a predetermined pitch.
- any film among the plurality of films obtained by cutting the sheet-like product along the longitudinal direction in the slit process includes the defect.
- the film which does not have a fault can be manufactured by giving appropriate measures, such as excising the location which has a fault, with respect to a film with a fault.
- any film among the plurality of films has a defect. Whether it is contained cannot be specified accurately, and it is determined that the film is a non-defective film even though it is a defective film having defects. As a result, an appropriate measure cannot be applied to the defective film, and in some cases, the defective film flows out as a non-defective film.
- An object of the present invention is to provide a film manufacturing method, a film manufacturing apparatus, a film, and a film winding that reduce a risk of determining a film having a defect as a non-defective film when a film is obtained by cutting the film raw material. To provide a body.
- a film manufacturing method includes a defect information acquisition step of acquiring defect information including position information of defects in a film original, and a slit along the longitudinal direction of the film original.
- a slit process in which a plurality of films are obtained by slitting in a line, and a defect determination of the film after slitting is performed based on the defect information regarding one defect, so that the film actually including the defect and the film are adjacent to the film.
- the film actually including the defect is determined not only as the defective film but also as another film adjacent to the film as a defective film. To do.
- the film that should originally contain the defect does not contain the defect, and another film adjacent to the film contains the defect. Even in this case, it is possible to reduce the risk of erroneously determining a film having a defect as a non-defective film.
- the defect information acquisition step as the defect information, information on the presence / absence of defects for each divided region obtained by dividing the surface area of the film original fabric into a plurality of regions arranged in the width direction.
- the determination step a film obtained by including the divided region having the defect and another film adjacent to the film based on the defect information related to the one divided region having the defect is a defective film. It may be a manufacturing method to be determined.
- the original film in the slit process, is slit with a slit line along the boundary line of the divided area.
- the boundary line of the divided area having the defect is formed. The manufacturing method which determines the said another film obtained including the division area adjacent to this division area as a defective film through this may be sufficient.
- the defect When slitting the original film with a slit line along the boundary line of the divided area having a defect, the defect is likely to be included in another film adjacent to the film that should originally contain the defect due to the shift of the slit position.
- the film obtained by slitting the original film with a slit line along the boundary line of the divided area and including the divided area adjacent to the divided area having a defect as a defective film can be appropriately determined as a defective film, and the risk of erroneously determining a film having a defect as a non-defective film can be reduced.
- the original film in the slitting process, is slit with a slit line along a boundary line of the divided region so as to obtain each film corresponding to a plurality of the divided regions,
- a divided region adjacent to the divided region is provided through a boundary line of the divided region located at an end portion of the plurality of divided regions corresponding to each of the films.
- the manufacturing method which determines the said another film obtained by including as a defective film may be sufficient.
- the film adjacent to the film corresponding to the divided area having a defect is likely to contain defects, and both adjacent films are regarded as defective films. It is necessary to judge.
- the original film in the slitting process, is slit with a slit line along a boundary line of the divided areas so as to obtain the films corresponding to the three divided areas.
- a divided region adjacent to the divided region is provided via a boundary line of the divided region located at an end of the three divided regions corresponding to the films and having the defect.
- the manufacturing method which determines the said another film obtained by including as a defective film may be sufficient.
- the film adjacent to the film corresponding to the three divided regions has a defect. Is not included, and it is not necessary to determine the film on both sides as a defective film. As a result, it is possible to reduce the number of films that are judged as defective films even though no defects are actually included.
- the film original fabric is slit by a slit line that divides the divided area, and in the determination process, an area formed by dividing the divided area having the defect is obtained.
- the manufacturing method which determines the two films obtained by including it as a defective film may be sufficient.
- the two films obtained including the area obtained by dividing the divided area having defects are likely to contain defects.
- the said two films with high possibility of including a defect can be determined as a defective film, and the risk of erroneously determining a film having a defect as a non-defective film is reduced. Can do.
- the defect information acquisition step as the defect information, a first divided region and a second divided region wider than the first divided region are alternately arranged. Information on the presence or absence of defects is obtained, and in the slitting process, the original film is slit with a slit line that divides the first divided area.
- the first divided area having the defect is The manufacturing method which determines two films obtained including the area
- the film manufacturing method which concerns on this invention is the defect information acquisition process which acquires the defect information containing the positional information on the defect in a film original fabric, and the said film original fabric in a longitudinal direction.
- the defect information acquisition process which acquires the defect information containing the positional information on the defect in a film original fabric, and the said film original fabric in a longitudinal direction.
- the two films divided by the slit line are determined as defective films.
- the film is likely to be included in another film adjacent to the film that should originally contain defects due to the shift of the slit position.
- two films adjacent to each other are judged as defective films, so that the film that should originally contain defects does not contain any defects, and another film adjacent to the films contains defects.
- the risk of erroneously determining a film having a defect as a non-defective film can be reduced.
- one film obtained including the divided area is determined as a defective film.
- a divided region having a defect is not slit by a slit line, even if the slit position is shifted, the possibility that the defect is included in another film adjacent to the film that should originally include the defect is low. Therefore, by determining that one film obtained including a divided region is a defective film, it is possible to reduce the number of films that are determined to be defective even though no defect is actually included.
- the film manufacturing method according to the present invention may be a manufacturing method including a defect information recording step for recording the defect information for each unit region having a predetermined length in the longitudinal direction of the film original fabric.
- the defect information for each unit area can be recorded collectively, and the manufacturing process can be simplified.
- the film manufacturing method according to the present invention may be a manufacturing method in which in the defect information recording step, information on the presence or absence of the defect for each of the divided regions in the unit region is recorded.
- the unit area can be further divided into divided areas and recorded together as information on the presence or absence of defects in each divided area, and the amount of information to be recorded can be reduced.
- the defect information recording step according to the number of defects in the unit area, as the defect information, information on the number of defects in the unit area, position information on each defect, and each A first mode for recording at least one information selected from the group consisting of defect size information, and the defect information for each of the divided areas in the unit area are recorded as the defect information. It may be a manufacturing method for switching between the second mode.
- the first mode for recording detailed defect information and the second mode for recording simple information can be switched according to the number of defects, the amount of information that can be recorded is increased.
- appropriate defect information can be recorded under the restriction of the information amount.
- a first mark indicating the position of the defect is given to the film that actually includes the defect, and a second mark is provided at a position corresponding to the first mark in the another film. It may be a manufacturing method including a defect mark applying step for applying a mark.
- the film manufacturing method provides, based on the defect information, a first mark indicating the position of the defect at a position corresponding to the film that actually includes the defect in the original film, and the film. Including the original defect defect applying step of applying the second mark to the position corresponding to the other film on the original fabric and moved in the width direction from the position of the first mark, the slit step Then, the manufacturing method which slits the said film original fabric provided with the said 1st mark and the said 2nd mark may be sufficient.
- a mark in order to give a mark with respect to the film raw material before a slit, compared with the case where a mark is provided with respect to the film after a slit, a mark can be provided to an exact position. .
- the film manufacturing method according to the present invention may be a manufacturing method in which the first mark and the second mark are applied so as not to overlap the slit line in the raw fabric defect mark applying step.
- the film manufacturing method according to the present invention may be a manufacturing method including a defect excision step of excising a part of the defective film based on the defect information.
- the film manufacturing apparatus which concerns on this invention has the defect information acquisition part which acquires the defect information containing the positional information on the defect in a film original fabric, and the said film original fabric in a longitudinal direction.
- a slit part that slits along a slit line along which a plurality of films are obtained, and a defect determination of the film after slitting based on the defect information related to one defect described above, the film actually including the defect and the film
- a determination unit that determines another adjacent film as a defective film.
- the film manufacturing apparatus which concerns on this invention has the defect information acquisition part which acquires the defect information containing the positional information on the defect in a film original fabric, and the said film original fabric in a longitudinal direction.
- the defect information acquisition part includes the defect information, Information on the presence or absence of a defect for each divided region obtained by dividing the surface area of the original film into a plurality of regions arranged in the width direction is obtained, and the determination unit overlaps the divided region where the defect exists with the slit line. If not, one film obtained including the divided area is determined as a defective film, and the divided area where the defect exists or its boundary line is the slit line. If the overlap is characterized by determining the two films being separated by the slit line as defective film.
- the film which concerns on this invention is the several film obtained corresponding to every area
- the film is obtained corresponding to a region adjacent to the region including the defect through the boundary line, and a mark is provided at a position facing the defect through the boundary line. It is characterized by.
- the film winding body according to the present invention is characterized in that the film is wound into a roll shape.
- the film is easy to handle and the position of the defect when the film is unwound. Can be recognized.
- FIG. 1 is a schematic diagram illustrating a cross-sectional configuration of a lithium ion secondary battery according to Embodiment 1.
- FIG. It is a schematic diagram which shows the detailed structure of the lithium ion secondary battery shown by FIG.
- FIG. It is a schematic diagram which shows the other structure of the lithium ion secondary battery shown by FIG.
- It is a schematic diagram for demonstrating the defect detection process and defect information recording process of the defect marking method of the said separator raw fabric.
- It is a figure for demonstrating the structure of the base-material defect inspection apparatus in the said defect detection process.
- It is a figure for demonstrating the structure of the coating defect inspection apparatus in the said defect detection process.
- FIG. 1 It is a schematic diagram which shows the structure of the slit apparatus which slits the said separator. It is an enlarged view, a side view, and a front view showing the configuration of the cutting device of the slit device shown in FIG. It is a schematic diagram for demonstrating the reading process of the said defect position identification method of the said separator, a mark provision process, and a winding-up process. It is a schematic diagram for demonstrating the mark detection process of the said defect position identification method of a separator, and a defect removal process. It is a schematic diagram for demonstrating the defect detection process and defect information recording process of the defect marking method of the separator original fabric which concerns on Embodiment 2.
- FIG. 1 It is a schematic diagram which shows the structure of the slit apparatus which slits the said separator. It is an enlarged view, a side view, and a front view showing the configuration of the cutting device of the slit device shown in FIG. It is a schematic diagram for demonstrating the reading process of the said defect
- FIG. 1 It is a schematic diagram for demonstrating the reading process of the said defect position identification method of the said separator, a mark provision process, and a winding-up process.
- FIG. 2 It is a top view of the separator original fabric for demonstrating the position which records a defect code
- FIG. It is a figure which illustrates the relationship between the division area containing a defect, a slit line, and a defect separator.
- Embodiment 1 As an example of the film according to the present invention, a separator for a battery such as a lithium ion secondary battery and a heat resistant separator will be described. Moreover, a separator manufacturing method and a separator manufacturing apparatus are demonstrated in order as an example of the film manufacturing method and film manufacturing apparatus which concern on this invention.
- Non-aqueous electrolyte secondary batteries represented by lithium ion secondary batteries have high energy density, and are therefore currently used for mobile devices such as personal computers, mobile phones, personal digital assistants, automobiles, airplanes, etc.
- As a battery it is widely used as a stationary battery that contributes to the stable supply of electric power.
- FIG. 1 is a schematic diagram showing a cross-sectional configuration of a lithium ion secondary battery 1.
- the lithium ion secondary battery 1 includes a cathode 11, a separator 12, and an anode 13.
- An external device 2 is connected between the cathode 11 and the anode 13 outside the lithium ion secondary battery 1. Then, electrons move in the direction A when the lithium ion secondary battery 1 is charged, and in the direction B when the lithium ion secondary battery 1 is discharged.
- the separator 12 is disposed between the cathode 11 that is the positive electrode of the lithium ion secondary battery 1 and the anode 13 that is the negative electrode thereof so as to be sandwiched between them.
- the separator 12 is a porous film that allows lithium ions to move between the cathode 11 and the anode 13 while separating them.
- the separator 12 includes, for example, polyolefin such as polyethylene and polypropylene as its material.
- FIG. 2 is a schematic diagram showing a detailed configuration of the lithium ion secondary battery 1 shown in FIG. 1, where (a) shows a normal configuration, and (b) shows a temperature rise of the lithium ion secondary battery 1. (C) shows a state when the temperature of the lithium ion secondary battery 1 is rapidly increased.
- the separator 12 is provided with a large number of holes P.
- the lithium ions 3 of the lithium ion secondary battery 1 can come and go through the holes P.
- the lithium ion secondary battery 1 may be heated due to an overcharge of the lithium ion secondary battery 1 or a large current caused by a short circuit of an external device.
- the separator 12 is melted or softened, and the hole P is closed. Then, the separator 12 contracts. Thereby, since the traffic of the lithium ion 3 stops, the above-mentioned temperature rise is also stopped.
- the separator 12 when the temperature of the lithium ion secondary battery 1 is rapidly increased, the separator 12 is rapidly contracted. In this case, as shown in FIG. 2C, the separator 12 may be broken. And since the lithium ion 3 leaks from the destroyed separator 12, the traffic of the lithium ion 3 does not stop. Therefore, the temperature rise continues.
- FIG. 3 is a schematic diagram showing another configuration of the lithium ion secondary battery 1 shown in FIG. 1, where (a) shows a normal configuration, and (b) shows that the lithium ion secondary battery 1 is abruptly changed. The state when the temperature is raised is shown.
- the lithium ion secondary battery 1 may further include a heat resistant layer 4.
- the heat-resistant layer 4 and the separator 12 form a heat-resistant separator 12a (separator).
- the heat-resistant layer 4 is laminated on one surface of the separator 12 on the cathode 11 side.
- the heat-resistant layer 4 may be laminated on one surface of the separator 12 on the anode 13 side, or may be laminated on both surfaces of the separator 12.
- the heat-resistant layer 4 is also provided with holes similar to the holes P.
- the lithium ions 3 come and go through the holes P and the holes of the heat-resistant layer 4.
- the heat resistant layer 4 includes, for example, wholly aromatic polyamide (aramid resin) as a material thereof.
- the heat-resistant layer 4 assists the separator 12.
- the shape of is maintained. Therefore, the separator 12 is melted or softened, and the hole P is only blocked. Thereby, since the traffic of the lithium ion 3 stops, the above-mentioned overdischarge or overcharge is also stopped. Thus, destruction of the separator 12 is suppressed.
- the manufacture of the heat-resistant separator 12a of the lithium ion secondary battery 1 is not particularly limited, and can be performed using a known method. In the following description, it is assumed that the separator 12 mainly contains polyethylene as its material. However, even when the separator 12 includes other materials, the heat-resistant separator 12a can be manufactured by the same manufacturing process.
- the separator 12 is a polyolefin separator formed from a polyethylene resin containing ultrahigh molecular weight polyethylene, the separator 12 can be manufactured by the following method.
- This method is (1) kneading to obtain a polyethylene resin composition by kneading ultrahigh molecular weight polyethylene and an inorganic filler (for example, calcium carbonate, silica) or a plasticizer (for example, low molecular weight polyolefin, liquid paraffin).
- a step, (2) a rolling step of forming a film using the polyethylene resin composition, (3) a removal step of removing the inorganic filler or plasticizer from the film obtained in step (2), and (4) It includes a stretching step of stretching the film obtained in the step (3) to obtain the separator 12.
- the said process (4) can also be performed between the said processes (2) and (3).
- a large number of micropores are provided in the film by the removing process.
- the micropores of the film stretched by the stretching process become the above-described holes P.
- the separator 12 which is a polyethylene microporous film having a predetermined thickness and air permeability is formed.
- 100 parts by weight of ultrahigh molecular weight polyethylene, 5 to 200 parts by weight of a low molecular weight polyolefin having a weight average molecular weight of 10,000 or less, and 100 to 400 parts by weight of an inorganic filler may be kneaded.
- the heat-resistant layer 4 is formed on the surface of the separator 12 in the coating process.
- an aramid / NMP (N-methyl-pyrrolidone) solution (coating solution) is applied to the separator 12 to form the heat-resistant layer 4 which is an aramid heat-resistant layer.
- the heat-resistant layer 4 may be provided only on one side of the separator 12 or on both sides. Moreover, you may apply the liquid mixture containing fillers, such as an alumina / carboxymethylcellulose, as the heat-resistant layer 4.
- a polyvinylidene fluoride / dimethylacetamide solution (coating liquid) is applied to the surface of the separator 12 (coating process) and solidified (coagulation process) to solidify the adhesive layer on the surface of the separator 12.
- the adhesive layer may be provided only on one side of the separator 12 or on both sides.
- the method of applying the coating liquid to the separator 12 is not particularly limited as long as it is a method that enables uniform wet coating, and a conventionally known method can be employed.
- a capillary coating method, a spin coating method, a slit die coating method, a spray coating method, a dip coating method, a roll coating method, a screen printing method, a flexographic printing method, a bar coater method, a gravure coater method, a die coater method, etc. Can do.
- the thickness of the heat-resistant layer 4 can be controlled by adjusting the thickness of the coating wet film, the solid content concentration represented by the sum of the binder concentration and the filler concentration in the coating solution, and the ratio of the filler to the binder.
- a resin film, a metal belt, a drum, or the like can be used as a support for fixing or conveying the separator 12 during coating.
- the heat-resistant separator original fabric 12b which is the separator original fabric 12c on which the heat-resistant layer 4 is laminated, can be manufactured (FIG. 4).
- the manufactured heat-resistant separator raw fabric 12b is wound around a cylindrical core 53 (FIG. 4).
- the object manufactured with the above manufacturing method is not limited to the heat-resistant separator raw fabric 12b. This manufacturing method does not need to include a coating process.
- the object to be manufactured is the separator raw 12c.
- a heat-resistant separator (film) having a heat-resistant layer as a functional layer will be mainly described as an example, but the same treatment is applied to a separator (film) having no functional layer and a separator original (film original). (Process) can be performed.
- ⁇ Defect detection process> In the manufacture of a heat-resistant separator used for a lithium ion secondary battery, when a defect is detected by an inspection device in a coating process for forming a heat-resistant separator original film in which a heat-resistant layer is applied to the separator original, the defect is present. A line is drawn with a marker on the original fabric to wind up the heat-resistant separator original fabric. And in the next slit process, the heat-resistant separator raw material is unwound. Thereafter, when the worker visually recognizes the line formed by the marker on the unrolled heat-resistant separator original fabric, the worker stops the unwinding operation of the heat-resistant separator original fabric.
- the worker visually confirms the position in the width direction of the heat-resistant separator original fabric of the defect corresponding to the line by the marker.
- a portion of the heat-resistant separator original fabric corresponding to the line formed by the marker is slit along the longitudinal direction by a cutting device to form a plurality of heat-resistant separators.
- the worker sticks the tape so as to protrude from the heat-resistant separator at a position corresponding to the defect of the heat-resistant separator corresponding to the position in the width direction of the defect corresponding to the line by the marker.
- the heat-resistant separator stuck so that the said tape may protrude may be wound up by a winding roller.
- the heat-resistant separator wound around the take-up roller is rewound from the take-up roller to the rewind roller in the rewinding step. Then, if an operator discovers in the middle of rewinding the tape stuck so that it may protrude from the heat-resistant separator, the rewinding operation is stopped. And an operator cuts and removes the location of the heat-resistant separator in which the defect corresponding to the said tape exists along the width direction. Next, the heat-resistant separator on the take-up roller side and the heat-resistant separator on the rewind roller side are joined together. Thereafter, the rewinding operation is restarted, and all the heat-resistant separators are wound around the rewinding roller.
- FIG. 4 is a schematic diagram for explaining a defect detection step and a defect information recording step of the defect marking method of the heat-resistant separator original fabric 12b
- FIG. 4 (a) is a front view of both steps.
- (B) is a plan view of both steps.
- FIG. 5 is a diagram for explaining the configuration of the substrate defect inspection apparatus 55 in the defect detection process.
- FIG. 6 is a diagram for explaining the configuration of the coating defect inspection apparatus 57 in the defect detection process.
- FIG. 7 is a diagram for explaining the configuration of the pinhole defect inspection apparatus 58 in the defect detection process.
- the heat-resistant separator original fabric 12b in which the heat-resistant layer is applied to the separator original fabric 12c by the coating unit 54 is wound around the core 53.
- the base material inspection process (defect detection process) for inspecting the defect D of the separator original fabric 12c is a base material defect inspection device 55 (defect detection section, disposed between the feeding process of the separator original fabric 12c and the coating process). Separator manufacturing apparatus).
- the substrate defect inspection device 55 is arranged such that the light source 55a and the detector 55b sandwich the separator original fabric 12c, and is emitted from the light source 55a in a direction perpendicular to the front and back surfaces of the separator original fabric 12c.
- the defect D existing in the separator raw 12c is inspected (the position of the defect D is specified) (defect detection step).
- the defects D present in the separator original fabric 12c include defects related to through holes (pinholes), defects related to film thickness irregularities, and defects related to foreign matters.
- the coating inspection process (defect detection process) for inspecting the defect D of the heat-resistant layer 4 applied to the separator raw 12 c is a coating defect inspection arranged between the coating process and the winding process by the core 53. It is implemented by the device 57 (defect detection unit, separator manufacturing device).
- the coating defect inspection device 57 includes a light source 57a and a detector 57b disposed on the heat-resistant layer 4 side of the heat-resistant separator raw 12b.
- the coating defect inspection device 57 detects the defect D existing in the heat-resistant layer 4 by detecting the reflected light emitted from the light source 57a and reflected by the heat-resistant layer 4 with the detector 57b (the position of the defect D is determined). Identify).
- the defects D present in the heat-resistant layer 4 include defects related to streaks, defects related to peeling, defects related to flip, and defects related to surface defects.
- the defect relating to the above-mentioned flipping is that the coating liquid is bounced from the surface of the separator raw 12c due to foreign matter, oil or the like, and the heat-resistant layer 4 is not locally formed, or even if formed, the thin heat-resistant layer 4 Means a defect.
- the defect related to the surface defect means a defect related to the film thickness defect of the heat-resistant layer 4.
- a pinhole inspection process (defect detection process) for inspecting defects D due to pinholes occurring in the heat-resistant separator original fabric 12 b is a pinhole defect inspection apparatus disposed between the coating defect inspection apparatus 57 and the defect information recording apparatus 56. 58 (defect detection unit, separator manufacturing apparatus).
- the pinhole defect inspection apparatus 58 includes a light source 58a disposed on the separator raw fabric 12c side of the heat resistant separator original fabric 12b, and light emitted from the light source 58a in a direction perpendicular to the front and back surfaces of the heat resistant separator original fabric 12b.
- the defect D due to the pinhole has a diameter of several hundred ⁇ m to several mm.
- a defect information recording device 56 is disposed between the pinhole defect inspection device 58 and the core 53.
- the defect information recording device 56 stores a defect code DC in which defect information such as position information of the defect D detected by the substrate defect inspection device 55, the coating defect inspection device 57, and the pinhole defect inspection device 58 is stored.
- the code data such as a dimension code and a QR code (registered trademark) is recorded on the end portion in the width direction of the heat-resistant separator original fabric 12b corresponding to the position of the defect D in the longitudinal direction of the heat-resistant separator original fabric 12b.
- the position information represents the position of the defect D in the longitudinal direction and the width direction of the heat-resistant separator raw fabric 12b.
- the position information may include information that can distinguish the type of the defect D.
- the type of the defect D is, for example, a structural defect of the base material to be inspected by the base material defect inspection device 55, a defect related to coating to be inspected by the coating defect inspection device 57, or a hole to be inspected by the pinhole defect inspection device 58. It is a flaw related to autumn.
- the film tension of the separator original fabric 12c and the heat-resistant separator original fabric 12b is usually 200 N / m or less, and preferably 120 N / m or less.
- film tension means the tension in the traveling direction applied per unit length in the width direction of the traveling film. For example, if the film tension is 200 N / m, a force of 200 N is applied to a film width of 1 m. If the film tension is higher than 200 N / m, wrinkles may occur in the running direction of the film and the accuracy of defect inspection may be reduced.
- the film tension is usually 10 N / m or more, preferably 30 N / m or more. If the film tension is lower than 10 N / m, the film may be slack or meander.
- a hole P is formed in the separator original fabric 12c and the heat-resistant separator original fabric 12b, and the film tension is smaller than the film tension of a film having no holes such as an optical film. Therefore, the separator original fabric 12c and the heat-resistant separator original fabric 12b have physical properties that are easier to stretch than films without holes such as optical films. For this reason, if the defect code DC is recorded at the end portion in the width direction of the heat-resistant separator original fabric 12b corresponding to the position of the defect D in the longitudinal direction of the heat-resistant separator original fabric 12b, The position in the longitudinal direction of the defect D and the position in the longitudinal direction of the defect code DC do not substantially deviate. Therefore, even if the heat-resistant separator raw fabric 12b extends in the longitudinal direction, the position of the defect D in the longitudinal direction can be easily specified.
- the heat-resistant separator original fabric 12b on which the defect code DC is recorded at the end is wound around the core 53.
- the core 53 on which the heat-resistant separator raw fabric 12b is wound is carried to the next slitting process.
- the defect information recording device 56 (FIG. 4) has a defect code DC representing the position information of the defect D at the end in the width direction of the heat-resistant separator original 12b corresponding to the position of the defect D in the longitudinal direction of the heat-resistant separator original 12b. Record.
- the distance LMD along the longitudinal direction between the defect D and the defect code DC is, for example, preferably 100 mm or less, and more preferably 30 mm or less.
- the distance L TD between the defect code DC and the end in the width direction of the heat-resistant separator original fabric 12b is, for example, preferably 100 mm or less, more preferably 30 mm or less.
- the distance LTD is 10 mm or more.
- a heat-resistant separator 12a (hereinafter referred to as “separator”) formed from a heat-resistant separator original fabric 12b (hereinafter referred to as “separator original fabric”) or a separator 12 formed from a separator original fabric 12c is applied to a lithium ion secondary battery 1 or the like.
- a width suitable for the product (hereinafter referred to as “product width”) is preferable.
- the separator web is manufactured such that its width is equal to or greater than the product width. Then, once manufactured, the separator stock is cut (slit) into the product width to form a separator.
- the “separator width” means the length of the separator in a direction parallel to the plane in which the separator extends and perpendicular to the longitudinal direction of the separator.
- a slit means cut
- the term “cut” means that the separator raw fabric or the separator is cut along a transverse direction (TD).
- the transverse direction (TD) means a direction (width direction) that is substantially perpendicular to the longitudinal direction (MD) and the thickness direction of the separator.
- FIG. 8 is a schematic diagram showing the configuration of the slit device 6 for slitting the separator original fabric 12b, where (a) shows the entire configuration, and (b) shows the configuration before and after slitting the separator original fabric 12b. .
- the slitting device 6 includes a cylindrical unwinding roller 61, rollers 62 to 65, and a plurality of winding rollers 69 that are rotatably supported.
- the slit device 6 is further provided with a cutting device 7 (FIG. 9) described later.
- a cylindrical core 53 around which the separator raw fabric 12 b is wound is fitted on the unwinding roller 61.
- the separator web 12 b is unwound from the core 53 to the path U or L.
- the unrolled separator blank 12b passes through the roller 63 and is conveyed to the roller 64 at a speed of 100 m / min, for example.
- the separator raw 12b is slit along the longitudinal direction in the plurality of separators 12a.
- a part of the plurality of separators 12a is wound around each core 81 (bobbin) fitted to the plurality of winding rollers 69, respectively.
- the other part of the plurality of separators 12 a is wound around each core 81 (bobbin) fitted to the plurality of winding rollers 69.
- the separator wound up in a roll shape is referred to as a “separator wound body (film wound body)”.
- FIG. 9 is a view showing the configuration of the cutting device 7 (slit portion) of the slit device 6 shown in FIG. 8A, wherein FIG. 9A is a side view of the cutting device 7, and FIG. It is a front view of the cutting device.
- the cutting device 7 includes a holder 71 and a blade 72.
- the holder 71 is fixed to a housing or the like provided in the slit device 6.
- the holder 71 holds the blade 72 so that the positional relationship between the blade 72 and the separator original fabric 12b to be conveyed is fixed.
- the blade 72 slits the raw material of the separator with a sharp edge.
- FIG. 10 is a schematic diagram for explaining a reading process (defect information acquiring process), a determining process, a mark applying process, and a winding process of the defect position specifying method of the separator 12a.
- the separator web 12b is unwound from the core 53 (FIG. 8) at a constant speed (for example, 80 m / min).
- the reading unit 73 (defect information acquisition unit) acquires defect information in the separator original fabric 12b by reading the defect code DC recorded at the end in the width direction of the separator original fabric 12b (defect information acquisition step).
- the determination device 75 determines that the separator having the defect D among the separators is a defective separator (defect film) based on the defect code DC read by the reading unit 73 (determination step). .
- the mark applying device 74 applies a mark L to a position corresponding to the defect D of the separator 12a determined by the determining device 75 as a defective separator (defect mark applying step).
- the determination device 75 determines that the plurality of separators 12a are defective separators.
- examples of the preferable mark L include a label
- examples of the preferable mark applying device 74 include a labeler.
- the mark L may be a mark drawn by a pen instead of a label, or a mark applied by an injector.
- the mark L may be a thermo label printed by heating the separator 12a made of resin, or the mark L may be formed by making a hole in the separator 12a with a laser.
- the plurality of separators 12a slit by the cutting device 7 are respectively wound around the plurality of cores 81 (winding step).
- the mark imparting device 74 uses the positional information in the length direction of the separator raw fabric 12b of the defect D represented by the defect code DC as the defect code DC2, and the outermost peripheral portion 86 around which the one specified separator 12a is wound up. And / or recorded in the core 81.
- FIG. 11 is a schematic diagram for explaining a mark detection step and a defect removal step of the defect position specifying method of the separator 12a
- FIG. 11 (a) is a schematic diagram for explaining the mark detection step
- FIG. 11B is a schematic diagram for explaining the defect removal step.
- the mark detection device 83 detects the mark L
- the mark detection device 83 stops the rewinding operation of the separator 12a.
- the defect removal device 84 removes the defect D from the separator 12a by cutting the upstream and downstream portions of the separator 12a corresponding to the mark L along the width direction (defect removal step).
- Such a defect removal step may be performed manually by an operator instead of the defect removal apparatus 84.
- the joining device 85 joins the cut separators 12a (joining step). Such a joining process may be performed manually by an operator instead of the joining device 85.
- the joining device 85 restarts the rewinding operation of the separator 12a. Then, the rewinding of the separator 12a from the core 81 to the core 82 is completed.
- the separator 12a divided into two parts may be wound around different cores without being connected. That is, the portion before being cut may be wound around the core 82, and the portion after being cut may be wound around a core other than the core 82.
- FIG. 12 is a schematic diagram for explaining a defect detection step and a defect information recording step of the defect marking method for the separator original fabric 12b according to the second embodiment.
- FIG. 13 is a schematic diagram for explaining a reading process, a mark applying process, and a winding process of the defect position specifying method of the separator 12a.
- the same reference numerals are assigned to the components described in the first embodiment. Therefore, detailed description of these components will not be repeated.
- the defect information recording device 56a (defect information recording unit, separator raw material manufacturing device) is the separator raw material 12c / 12b detected by the substrate defect inspection device 55, the coating defect inspection device 57, and the pinhole defect inspection device 58. Position information indicating the position of the existing defect D in the longitudinal direction and the width direction is recorded in the information storage device 91. Then, the reading unit 73a reads position information of the defect D in the longitudinal direction and the width direction from the information storage device 91 (reading process).
- the defect information recording device 56 has been described as recording the defect code DC at a position corresponding to the position of the defect D in the longitudinal direction of the separator blank 12b.
- the method of recording DC is not limited to this.
- FIG. 14 is a plan view of the original separator for explaining the position where the defect code DC is recorded.
- the defect information recording apparatus 56 corresponds to the defect D existing in each unit region 20 for each unit region 20 having a predetermined length in the longitudinal direction of the separator raw fabric 12 b.
- a defect code DC is recorded (formed) (defect information recording step).
- the length of the unit region 20 in the longitudinal direction of the separator original fabric 12b can be set to, for example, 250 mm.
- FIG. 14 illustrates six unit regions 20a to 20f arranged in the longitudinal direction of the separator raw fabric 12b, and the defect code DC corresponds to each unit region 20a, 20b, 20d, and 20f including the defect D. Is recorded.
- the defect information recording device 56 does not record the corresponding defect code DC in the unit area 20 where the defect D does not exist, such as the unit areas 20c and 20e.
- the defect information recording device 56 records one defect code DC representing the position information of the plurality of defects D in the unit area 20 where the plurality of defects D exist, such as the unit areas 20a and 20b.
- defect code DC representing the positional information of the plurality of defects D for each unit region 20
- recording is performed as compared with the case where one defect code DC is recorded for one defect D.
- the number of defect codes DC can be reduced, and the manufacturing process can be simplified.
- the defect information recording device 56 includes detailed information such as information on the number of defects D existing in the unit area 20, the type of the defect D, coordinates indicating the position of the defect D on the surface of the separator raw 12b, and the size of the defect D.
- the defect code DC including the is recorded.
- the defect information recording device 56 divides the unit area 20 into a plurality of divided areas 21 arranged in the width direction of the separator raw fabric 12b, and incorporates simple information such as the presence or absence of the defect D in each divided area 21. DC may be recorded.
- the unit region 20d including three defects D is divided into divided regions 21a to 21d arranged in the width direction of the separator raw fabric 12b, and the divided regions 21a to 21d are divided into the divided regions 21a to 21d.
- a defect code DC including information on the presence or absence of the defect D is recorded.
- the divided region 21a does not include the defect D
- the divided region 21b includes the defect D
- the divided region 21c does not include the defect D
- the divided region 21d includes the defect D. Records a defect code DC including simple information that the defect D is not included.
- the amount of information included in the defect code DC can be reduced.
- 14 is merely an example, and the number of the divided regions 21 arranged in the width direction of the separator raw fabric 12b and the width of each divided region 21 can be set as appropriate.
- the defect information recording device 56 records the first mode for recording the defect code DC including the detailed information and the defect code DC including the simple information according to the number of the defects D existing in the unit area 20.
- the second mode may be switched.
- defect code DC when there is a restriction on the amount of information that can be included in the defect code DC, it is possible to record the defect code DC including appropriate information under the restriction of the information amount.
- the determination device 75 (determination unit) has been described as specifying one defective separator based on one defect D.
- the determination process by the determination device 75 of the present embodiment is as follows. This is different from the determination step by the determination device 75 of the first and second embodiments.
- the reading unit 73 reads the defect code DC recorded on the separator original fabric 12b, the slit device 6 slits the separator original fabric 12b with a slit line along the longitudinal direction, and the determination device 75 is 1 Based on one defect D, the separator 12a that actually includes the defect D and another separator 12a adjacent to the separator 12a are determined as defective separators (defect determination).
- the mark provision apparatus 74 gives the mark L1 (1st mark) which shows the position of this defect D to the separator 12a which actually contains the defect D, and the mark L1 in another separator 12a adjacent to this separator 12a.
- a mark L2 (second mark) is applied to a position corresponding to (defect mark applying step).
- the other separator 12a is a separator obtained corresponding to a region formed by partitioning the surface of the separator raw fabric 12b with slit lines (boundary lines) along the longitudinal direction.
- a mark L2 is provided at a position opposite to.
- the slit device 6 slits the original separator 12b at a position shifted from a desired slit position, so that the separator 12a that should originally contain the defect D does not contain the defect D and is adjacent to the separator 12a. Even when the defect D is included in another separator 12a, the other separator 12a is determined as a defective separator 12a, and the outflow of the separator 12a having the defect D can be suppressed.
- the reading unit 73 reads the defect code DC including the simple information on the presence / absence of the defect for each divided region, and the determination device 75 is based on the divided region 21 having at least one defect D.
- the separator 12a obtained by including the divided region 21 having the defect D and another separator 12a adjacent to the separator 12a may be determined as a defective separator.
- the defect removing device 84 may cut out the defective portion of the defective separator based on the marks L1 and L2 (defect cutting step).
- FIG. 15 is a diagram exemplifying a relationship between a divided region including a defect, a slit line, and a defective separator.
- FIG. 15A is a diagram showing a slit line in which one divided region corresponds to one separator.
- B shows a case where the separator raw material is slit by a slit line in which two divided regions correspond to one separator, and
- c shows three divided regions corresponding to one separator.
- the case where the separator original fabric is slit by such a slit line is shown, and (d) shows the case where the separator original fabric is slit by a slit line dividing the divided region.
- the display of the defect code DC is omitted.
- the crosses in FIG. 15 indicate positions where the defect D included in the divided region may exist in the separator after the slit.
- the defect information recording device 56 records the defect code DC including the simple information in each of the divided regions 21a to 21d having a width equal to the width of the separator 12a.
- the reading unit 73 reads the defect code DC.
- the slitting device 6 obtains separators 12aa to 12ad corresponding to the divided regions 21a to 21d by slitting the separator raw sheet 12b with slit lines along the boundary lines of the divided regions 21a to 21d.
- the determination device 75 determines that the separator 12a obtained including the divided region 21 having the defect D is a defective separator, and adjacent divided regions via the boundary line of the divided region 21 having the defect D. Another separator 12a obtained by including 21 is determined as a defective separator.
- the determination device 75 determines that the separator 12ac obtained including the divided region 21c is a defective separator, The separator 12ab obtained including the divided area 21b adjacent through the boundary line of the divided area 21c and the separator 12ad obtained including the divided area 21d are determined as defective separators.
- the separator 12a that is likely to include a defect due to the shift of the slit position can be appropriately determined as a defective separator. Therefore, it is possible to reduce the risk of erroneously determining a defective separator as a good product separator.
- the defect information recording device 56 records a defect code DC including simple information in each of the divided regions 21aa to 21db having a width that is 1 ⁇ 2 of the width of the separator 12a.
- the reading unit 73 reads the defect code DC.
- the slit device 6 slits the separator raw sheet 12b with a slit line along one of the boundary lines of the divided regions 21aa to 21db. Thereby, the separator 12aa is obtained corresponding to the divided areas 21aa and 21ab, the separator 12ab is obtained corresponding to the divided areas 21ba and 21bb, and the separator 12ac is obtained corresponding to the divided areas 21ca and 21cb.
- a separator 12ad is obtained corresponding to 21da ⁇ 21db.
- the determination device 75 determines that the separator 12a obtained including the divided region 21 having the defect D is a defective separator, and also determines the divided region 21 adjacent to the divided region 21 having the defect D via the boundary line. Another separator 12a obtained by including is determined as a defective separator.
- the determination device 75 determines that the separator 12ac obtained including the divided area 21ca is a defective separator, Another separator 12ab obtained including the divided area 21bb adjacent to the divided area 21ca via the boundary line of the divided area 21ca is determined as a defective separator.
- one of the separators 12ab and 12ad adjacent to the separator 12ac obtained by including the divided region 21ca having the defect D one of the separators 12ad has the defect D. Is not included, and it is not necessary to determine the separator 12ad as the defective separator 12. Accordingly, it is possible to reduce the number of separators 12a that are determined to be defective separators 12 even though the defect D is not actually included.
- the defect information recording device 56 records the defect code DC including the simple information in each of the divided regions 21aa to 21dc having a width of 1/3 of the width of the separator 12a.
- the reading unit 73 reads the defect code DC.
- the slitting device 6 slits the separator raw material 12b with slit lines along the boundary lines of two of the boundary lines of the divided regions 21aa to 21dc.
- separators 12aa are obtained corresponding to the divided areas 21aa, 21ab, 21ac
- separators 12ab are obtained corresponding to the divided areas 21ba, 21bb, 21bc
- separators 12ac are obtained corresponding to the divided areas 21ca, 21cb, 21cc.
- separator 12ad corresponding to the divided areas 21da, 21db, and 21dc.
- the determination device 75 of the present embodiment determines that the separator 12a obtained including the divided region 21 having the defect D is a defective separator, and is adjacent to the divided region 21 having the defect D via the boundary line. Another separator 12a obtained by including 21 is determined as a defective separator.
- the determination device 75 determines that the separator 12ad obtained including the divided region 21da is a defective separator, Another separator 12ac obtained by including the divided area 21cc adjacent to the divided area 21da via the boundary line of the divided area 21da is determined as a defective separator. In other words, when the defect D is included in the divided region 21da, the determination device 75 determines that the two separators 12ac and 12ad divided by the slit line overlapping the boundary line of the divided region 21da are defective separators.
- the separator raw fabric 12b is slit so as to obtain one separator 12a corresponding to the two divided regions 21, it corresponds to the divided region 21 having the defect D.
- the separator 12a adjacent to the separator 12a is likely to include the defect D, and the adjacent separator 12a needs to be determined as a defective separator.
- two separators 12a are determined to be defective separators for one defect D.
- the separator 12ab adjacent to the separator 12aa obtained including the divided area 21ab includes the defect D. It is difficult to determine that the separator 12ab is a defective separator 12. Accordingly, it is possible to reduce the number of separators 12a that are determined to be defective separators 12 even though the defect D is not actually included.
- ⁇ Slit line that divides the divided area> 15 (a) to 15 (c) is an example in which the slit device 6 slits the separator raw material 12b with slit lines along the boundary lines of the divided areas 21, but the boundary lines of the divided areas 21 are not shown.
- the positional relationship between the slit line and the slit line is not limited to this.
- the defect information recording device 56 includes narrow divided areas 21aa, 21ba, 21ca, 21da, and 21ea (first divided areas) and wide divided areas 21ab that are alternately arranged.
- a defect code DC including simple information in 21bb, 21cb, and 21db (second divided area) is recorded.
- the reading unit 73 reads the defect code DC.
- the slit device 6 slits the separator web 12b with a slit line that divides a narrow divided area, thereby corresponding to each wide divided area and two divided narrow divided areas. Get ⁇ 12ad.
- the two separators 12a obtained including the region in which the divided region having the defect D is divided are highly likely to include the defect D. .
- the determination device 75 of the present embodiment determines that the two separators 12a obtained including the region where the divided region having the defect D is divided are defective separators. In other words, when the defect D is included in the divided area that overlaps the slit line, the determination device 75 determines that the two separators 12a that overlap the divided area are defective separators. Further, when the defect D is included in the wide divided area, one separator 12a obtained including the wide divided area is determined as a defective separator.
- the determination device 75 when the defect D is included in the divided area 21da, the determination device 75 includes two separators 12ac obtained including the area obtained by dividing the divided area 21da. ⁇ Determine 12ad as a defective separator. In other words, when the defect D is included in the divided region 21da, the determination device 75 determines that the two separators 12ac and 12ad divided by the slit line overlapping the divided region 21da are defective separators. Further, when the defect D is included in the divided region 21ab, the determination device 75 determines that one separator 12aa obtained including the divided region 21ab is a defective separator.
- the separator 12a that is likely to include defects can be appropriately determined as a defective separator. Therefore, it is possible to reduce the risk of erroneously determining a defective separator as a good product separator.
- the separator original fabric 12b is slit by the slit line that divides the narrow divided region, compared to the case where the separator original fabric 12b is slit by the slit line that divides the wide divided region, the divided region is divided. Since the possibility that defects are included is low, it is possible to reduce the number of separators that are determined as defective separators even though no defects are actually included.
- FIG. 16 is a schematic diagram for explaining a reading step, a mark applying step, and a winding step of the defect position specifying method of the separator 12a.
- the manufacturing method of the third embodiment is a manufacturing method in which the slit process and the mark imparting process are processed in this order, but the order of these processes is not limited to this.
- the manufacturing method of this embodiment is different from the manufacturing method of Embodiment 3 in that the mark applying step and the slitting step are processed in this order. This will be described in more detail below.
- the reading unit 73 reads the defect code DC recorded on the separator original fabric 12b (defect information acquisition step), and the determination device 75 is based on the defect code DC after the slit in the separator original fabric 12b. A portion that becomes a defective separator is specified (determination step), and the mark applying device 74 applies a mark L to a portion that becomes a defective separator with respect to the separator original fabric 12b (raw fabric defect mark applying step).
- the defect D in the separator original fabric 12b is affected by the positional deviation in the width direction of the separator 12a in the slit process.
- the position may not correspond to the position of the defect D in the separator 12a after the slit, and the position of the mark L applied to the defect D may be shifted.
- the mark L is given to the accurate position corresponding to the defect D by giving the mark L to the separator blank 12b before the slit based on the position information of the defect D in the separator blank 12b. be able to.
- the mark L1 and the mark L2 are preferably provided so as not to overlap the slit line. Thereby, it is possible to prevent the marks L1 and L2 from being cut in the slitting process and making it difficult to determine a defective separator.
- FIG. 17 is a perspective view showing a separator raw material or a separator provided with a mark at a position corresponding to a defect.
- FIG. 17A shows an original slit line with a broken line, and FIG. The slit line shifted from the position is illustrated by a broken line.
- FIG. 17 shows a defect code DC in which the defect information recording device 56 incorporates simple information in narrow divided areas and wide divided areas arranged alternately as shown in FIG. Is an example of a separator raw 12b on which is recorded.
- the determination device 75 is obtained including the region obtained by dividing the divided region 21ba.
- the two separators 12ab and 12aa are determined as defective separators.
- the mark imparting device 74 imparts a mark L1 to a portion corresponding to the separator 12ab determined to be a defective separator in the original separator 12b, and also applies a mark L2 to a portion corresponding to the separator 12aa determined to be a defective separator. .
- the marks L1 and L2 are provided around the corresponding defect D.
- the slit device 6 slits the separator web 12b to which the marks L1 and L2 are applied.
- the mark provision apparatus 74 is applied to separator 12aa.
- a mark L2 is given.
- the mark L1 is given to the part corresponding to the separator 12ab but also the mark L2 is given to the part corresponding to the separator 12aa.
- the mark L1 is given to the separator 12ab after the slit, and the mark L2 is given to the separator 12aa.
- a method for manufacturing a separator web according to the present invention includes a forming process for forming a separator web, and a defect detection process for detecting defects present in the separator web formed by the forming process. And a defect information recording step of recording defect information including positional information of the defects in the width direction of the separator original fabric.
- the “separator raw fabric” means a wide separator before being slit.
- the defect information including the position information of the defect in the width direction of the separator raw material is recorded, the defect existing in the separator raw material can be easily identified based on the recorded position information. Can do. Therefore, the defect which exists in a separator original fabric can be removed easily.
- the defect information further includes position information of the defect in the longitudinal direction of the separator original.
- the “longitudinal direction of the separator original fabric” corresponds to the direction in which the manufacturing object is conveyed in the manufacturing process of the separator.
- the defect can be easily found when the separator raw is unwound from the wound separator original based on the positional information of the defect in the longitudinal direction.
- the defect information is recorded at a location corresponding to the position of the defect in the longitudinal direction of the separator original.
- the position of the defect in the longitudinal direction of the separator original based on the position where the defect information is recorded.
- defect information is recorded at a location corresponding to the position of the defect in the longitudinal direction of the separator original fabric, even if the separator original fabric extends in the longitudinal direction, the longitudinal position between the defect and the defect information is substantially Don't slip. Therefore, even if the separator raw fabric extends in the longitudinal direction, the position in the longitudinal direction of the defect can be easily specified.
- a separator manufacturing method includes a forming step of forming a separator original fabric, a defect detecting step of detecting defects present in the separator original fabric formed by the forming step, A defect information recording step for recording defect information including positional information of the defect in the width direction of the separator original, and a separator original having a defect in which the position information is recorded by the defect information recording step A cutting process for forming a plurality of separators cut along the longitudinal direction, a reading process for reading the position information, and a plurality of separators cut by the cutting process based on the position information read by the reading process. And at least one of them includes a mark providing step for providing a mark for specifying the position of the defect.
- the separator since the mark for identifying the position of the defect is given to at least one of the plurality of separators cut by the cutting process based on the position information read by the reading process, the separator The defect part of the separator containing the said defect among the some separator which slit the original fabric can be removed easily.
- the winding step of winding up at least one of the plurality of separators provided with the mark for specifying the position of the defect by the mark applying step and the winding step.
- the defect removing step includes cutting the separator on both sides in the longitudinal direction of the defect along the width direction to remove the defect from the separator, and then cutting the separator. Are preferably joined together.
- the defect information recording step records the position information on an end portion of the separator original fabric in the width direction.
- the defective part can be recognized by reading the end of the separator in the width direction.
- the defect information recording step may record the position information in an information storage device.
- the defective part can be recognized by reading the information recorded in the information storage device.
- the mark applying step is performed by attaching a label.
- the separator raw according to the present invention is characterized in that position information in the width direction of its own defect is recorded at the end in the width direction.
- a separator raw fabric manufacturing apparatus includes a forming portion that forms a separator raw fabric, and a defect detection portion that detects a defect present in the separator raw fabric formed by the forming portion. And a defect information recording unit that records defect information including position information of the defect in the width direction of the separator original.
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Abstract
Description
以下、本発明に係るフィルムの一例として、リチウムイオン二次電池などの電池用のセパレータ及び耐熱セパレータについて説明する。また、本発明に係るフィルム製造方法およびフィルム製造装置の一例として、セパレータ製造方法およびセパレータ製造装置について順に説明する。
リチウムイオン二次電池に代表される非水電解液二次電池は、エネルギー密度が高く、それゆえ、現在、パーソナルコンピュータ、携帯電話、携帯情報端末等の機器、自動車、航空機等の移動体に用いる電池として、また、電力の安定供給に資する定置用電池として広く使用されている。
セパレータ12は、リチウムイオン二次電池1の正極であるカソード11と、その負極であるアノード13との間に、これらに挟持されるように配置される。セパレータ12は、カソード11とアノード13との間を分離しつつ、これらの間におけるリチウムイオンの移動を可能にする多孔質フィルムである。セパレータ12は、その材料として、例えば、ポリエチレン、ポリプロピレン等のポリオレフィンを含む。
図3は、図1に示されるリチウムイオン二次電池1の他の構成を示す模式図であって、(a)は通常の構成を示し、(b)はリチウムイオン二次電池1が急激に昇温したときの様子を示す。
リチウムイオン二次電池1の耐熱セパレータ12aの製造は特に限定されるものではなく、公知の方法を利用して行うことができる。以下では、セパレータ12がその材料として主にポリエチレンを含む場合を仮定して説明する。しかし、セパレータ12が他の材料を含む場合でも、同様の製造工程により、耐熱セパレータ12aを製造できる。
リチウムイオン二次電池に使用される耐熱セパレータの製造においては、セパレータ原反に耐熱層を塗工した耐熱セパレータ原反を形成する塗工工程において、検査装置により欠陥を検出すると、当該欠陥を有する原反にマーカにより線を描いて耐熱セパレータ原反を巻き取る。そして、次のスリット工程において耐熱セパレータ原反を巻出す。その後、巻き出された耐熱セパレータ原反に上記マーカによる線を作業員が視認したら、作業員は、上記耐熱セパレータ原反の巻出し動作を停止する。次に、作業員は、上記マーカによる線に対応する欠陥の耐熱セパレータ原反の幅方向の位置を目視確認する。次に、上記マーカによる線に対応する耐熱セパレータ原反の部分が、切断装置により長手方向に沿ってスリットされて複数の耐熱セパレータが形成される。その後、作業員は、上記マーカによる線に対応する欠陥の幅方向の位置に対応する耐熱セパレータの欠陥に対応する位置に、テープを当該耐熱セパレータからはみ出すように貼る。そして、上記テープをはみ出すように貼られた耐熱セパレータは巻き取りローラーに巻き取られる。
耐熱セパレータ原反12b(以下「セパレータ原反」)から形成される耐熱セパレータ12a(以下「セパレータ」)、又は、セパレータ原反12cから形成されるセパレータ12は、リチウムイオン二次電池1などの応用製品に適した幅(以下「製品幅」)であることが好ましい。しかし、生産性を上げるために、セパレータ原反は、その幅が製品幅以上となるように製造される。そして、一旦製造された後に、セパレータ原反は、製品幅に切断(スリット)されてセパレータとなる。
スリット装置6では、セパレータ原反12bを巻きつけた円筒形状のコア53が、巻出ローラー61に嵌められている。図8の(a)に示されるように、セパレータ原反12bは、コア53から経路U又はLへ巻き出される。巻き出されたセパレータ原反12bは、ローラー63を経由し、ローラー64へ例えば速度100m/分で搬送される。搬送される工程においてセパレータ原反12bは、複数のセパレータ12aに長手方向に沿ってスリットされる。
図8の(a)に示されるように、複数のセパレータ12aの一部は、それぞれ、複数の巻取ローラー69に嵌められた各コア81(ボビン)へ巻き取られる。また、複数のセパレータ12aの他の一部は、それぞれ、複数の巻取ローラー69に嵌められた各コア81(ボビン)へ巻き取られる。なお、ロール状に巻き取られたセパレータを「セパレータ捲回体(フィルム捲回体)」と称する。
図9は、図8の(a)に示されるスリット装置6の切断装置7(スリット部)の構成を示す図であって、(a)は切断装置7の側面図であり、(b)は切断装置7の正面図である。
次に、判定装置75(判定部)は、読み取り部73が読み取った欠陥コードDCに基づいて、セパレータのうち、欠陥Dを有するセパレータを不良セパレータ(不良フィルム)であると判定する(判定工程)。目印付与装置74は、判定装置75が不良セパレータであると判定したセパレータ12aの欠陥Dに対応する位置に目印Lを付与する(欠陥印付与工程)。なお、欠陥Dが複数個存在するときは、判定装置75は、複数個のセパレータ12aを不良セパレータであると判定する。ここで、好ましい目印Lとしては、ラベルが挙げられ、好ましい目印付与装置74としては、ラベラが挙げられる。
実施形態1では、セパレータ原反12bに存在する欠陥Dの位置情報をセパレータ原反12bの端部に記録する例を示した。しかしながら、本発明はこれに限定されない。欠陥Dの位置情報は、情報記憶装置に記録するように構成してもよい。
以下、本発明の他の実施形態について、図14~図15に基づいて説明する。なお、説明の便宜上、前記実施形態にて説明した部材と同じ機能を有する部材については、同じ符号を付記し、その説明を省略する。
図14は、欠陥コードDCを記録する位置を説明するためのセパレータ原反の平面図である。
欠陥情報記録装置56は、単位領域20に存在する欠陥Dの個数の情報、欠陥Dの種類、セパレータ原反12bの表面における欠陥Dの位置を表す座標、欠陥Dの大きさ、などの詳細情報を盛り込んだ欠陥コードDCを記録する。
実施形態1および実施形態2では、判定装置75(判定部)が、1つの欠陥Dに基づいて1つの不良セパレータを特定するものとして説明したが、本実施形態の判定装置75による判定工程は、実施形態1および実施形態2の判定装置75による判定工程とは異なる。
図15の(a)の例では、欠陥情報記録装置56は、セパレータ12aの幅に等しい幅を有する各分割領域21a~21dにおける簡易情報を盛り込んだ欠陥コードDCを記録する。読み取り部73は上記欠陥コードDCを読み取る。スリット装置6は、各分割領域21a~21dの境界線に沿ったスリットラインでセパレータ原反12bをスリットすることにより、各分割領域21a~21dに対応してセパレータ12aa~12adを得る。
図15の(b)の例では、欠陥情報記録装置56は、セパレータ12aの幅の1/2の幅を有する各分割領域21aa~21dbにおける簡易情報を盛り込んだ欠陥コードDCを記録する。読み取り部73は上記欠陥コードDCを読み取る。スリット装置6は、各分割領域21aa~21dbの境界線うち一つ飛ばしの境界線に沿ったスリットラインでセパレータ原反12bをスリットする。これにより、分割領域21aa・21abに対応してセパレータ12aaを得て、分割領域21ba・21bbに対応してセパレータ12abを得て、分割領域21ca・21cbに対応してセパレータ12acを得て、分割領域21da・21dbに対応してセパレータ12adを得る。
図15の(c)の例では、欠陥情報記録装置56は、セパレータ12aの幅の1/3の幅を有する各分割領域21aa~21dcにおける簡易情報を盛り込んだ欠陥コードDCを記録する。読み取り部73は上記欠陥コードDCを読み取る。スリット装置6は、各分割領域21aa~21dcの境界線うち二つ飛ばしの境界線に沿ったスリットラインでセパレータ原反12bをスリットする。これにより、分割領域21aa・21ab・21acに対応してセパレータ12aaを得て、分割領域21ba・21bb・21bcに対応してセパレータ12abを得て、分割領域21ca・21cb・21ccに対応してセパレータ12acを得て、分割領域21da・21db・21dcに対応してセパレータ12adを得る。
図15の(a)~(c)の例は、スリット装置6が各分割領域21の境界線に沿ったスリットラインでセパレータ原反12bをスリットする例であったが、分割領域21の境界線とスリットラインの位置関係はこれに限られない。
以下、本発明の他の実施形態について、図16~17に基づいて説明する。なお、説明の便宜上、前記実施形態にて説明した部材と同じ機能を有する部材については、同じ符号を付記し、その説明を省略する。
上記の課題を解決するために、本発明に係るセパレータ原反の製造方法は、セパレータ原反を形成する形成工程と、前記形成工程により形成したセパレータ原反に存在する欠陥を検出する欠陥検出工程と、前記セパレータ原反の幅方向における前記欠陥の位置情報を含む欠陥情報を記録する欠陥情報記録工程とを包含することを特徴とする。ここで、「セパレータ原反」とは、スリットされる前の幅広のセパレータを意味するものとする。
6 スリット装置(スリット部)
7 切断装置(切断機)
12 セパレータ(フィルム)
12a 耐熱セパレータ、セパレータ(フィルム)
12b 耐熱セパレータ原反、セパレータ原反(フィルム原反)
12c セパレータ原反
54 塗工部(フィルム原反製造装置)
55 基材欠陥検査装置(欠陥検出部、フィルム原反製造装置)
57 塗工欠陥検査装置(欠陥検出部、フィルム原反製造装置)
58 ピンホール欠陥検査装置(欠陥検出部、フィルム原反製造装置)
56、56a 欠陥情報記録装置(欠陥情報記録部、フィルム原反製造装置)
73 読み取り部
74 目印付与装置
75 判定装置(判定部)
81 コア
82 コア
83 目印検知装置
84 欠陥除去装置
85 繋ぎ合わせ装置
86 最外周部
91 情報記憶装置
D 欠陥
DC、DC2 欠陥コード
L 目印
Claims (19)
- フィルム原反における欠陥の位置情報を含む欠陥情報を取得する欠陥情報取得工程と、
上記フィルム原反を、長手方向に沿うスリットラインでスリットして複数のフィルムを得るスリット工程と、
1つの上記欠陥に関する上記欠陥情報に基づいてスリット後のフィルムの不良判定を行うことにより、実際に上記欠陥を含むフィルムおよび該フィルムに隣接する別のフィルムを不良フィルムと判定する判定工程と、を含むことを特徴とするフィルム製造方法。 - 上記欠陥情報取得工程では、上記欠陥情報として、上記フィルム原反の表面の領域を幅方向に並ぶ複数の領域に分けた分割領域ごとの欠陥の有無の情報を取得し、
上記判定工程では、上記欠陥を有する1つの上記分割領域に関する上記欠陥情報に基づいて、上記欠陥を有する上記分割領域を含んで得られるフィルムおよび該フィルムに隣接する別のフィルムを不良フィルムと判定することを特徴とする請求項1に記載のフィルム製造方法。 - 上記スリット工程では、上記分割領域の境界線に沿ったスリットラインで上記フィルム原反をスリットし、
上記判定工程では、上記欠陥を有する上記分割領域の境界線を介して該分割領域に隣接する分割領域を含んで得られる上記別のフィルムを不良フィルムと判定することを特徴とする請求項2に記載のフィルム製造方法。 - 上記スリット工程では、複数の上記分割領域に対応して各上記フィルムを得るように上記分割領域の境界線に沿ったスリットラインで上記フィルム原反をスリットし、
上記判定工程では、上記欠陥を有し、かつ、各上記フィルムに対応する上記複数の分割領域のうち端部に位置する上記分割領域の境界線を介して、該分割領域に隣接する分割領域を含んで得られる上記別のフィルムを不良フィルムと判定することを特徴とする請求項3に記載のフィルム製造方法。 - 上記スリット工程では、3つの上記分割領域に対応して各上記フィルムを得るように上記分割領域の境界線に沿ったスリットラインで上記フィルム原反をスリットし、
上記判定工程では、上記欠陥を有し、かつ、各上記フィルムに対応する上記3つの分割領域のうち端部に位置する上記分割領域の境界線を介して、該分割領域に隣接する分割領域を含んで得られる上記別のフィルムを不良フィルムと判定することを特徴とする請求項4に記載のフィルム製造方法。 - 上記スリット工程では、上記分割領域を分断するスリットラインで上記フィルム原反をスリットし、
上記判定工程では、上記欠陥を有する上記分割領域が分断されてなる領域を含んで得られる2つのフィルムを不良フィルムと判定することを特徴とする請求項2に記載のフィルム製造方法。 - 上記欠陥情報取得工程では、上記欠陥情報として、互いに交互に配列される第1の分割領域と上記第1の分割領域よりも幅広の第2の分割領域との欠陥の有無の情報を取得し、
上記スリット工程では、上記第1の分割領域を分断するスリットラインで上記フィルム原反をスリットし、
上記判定工程では、上記欠陥を有する上記第1の分割領域が分断されてなる領域を含んで得られる2つのフィルムを不良フィルムと判定することを特徴とする請求項6に記載のフィルム製造方法。 - フィルム原反における欠陥の位置情報を含む欠陥情報を取得する欠陥情報取得工程と、
上記フィルム原反を、長手方向に沿うスリットラインでスリットして複数のフィルムを得るスリット工程と、
上記欠陥情報に基づいてスリット後のフィルムの不良判定を行う判定工程と、を含み、
上記欠陥情報取得工程では、上記欠陥情報として、上記フィルム原反の表面の領域を幅方向に並ぶ複数の領域に分けた分割領域ごとの欠陥の有無の情報を取得し、
上記判定工程では、欠陥が存在する上記分割領域が上記スリットラインに重ならない場合には、該分割領域を含んで得られる1つのフィルムを不良フィルムと判定し、欠陥が存在する上記分割領域またはその境界線が上記スリットラインに重なる場合には、該スリットラインで分断される2つのフィルムを不良フィルムと判定することを特徴とするフィルム製造方法。 - 上記フィルム原反の長手方向に所定長さを有する単位領域ごとの上記欠陥情報を記録する欠陥情報記録工程を含むことを特徴とする請求項2~8の何れか1項に記載のフィルム製造方法。
- 上記欠陥情報記録工程では、上記単位領域における上記分割領域ごとの上記欠陥の有無の情報を記録することを特徴とする請求項9に記載のフィルム製造方法。
- 上記欠陥情報記録工程では、上記単位領域における欠陥の個数に応じて、
上記欠陥情報として、上記単位領域における欠陥の個数の情報、各欠陥の位置情報、および各欠陥の大きさの情報からなる群より選択される少なくとも何れか1つの情報を記録する第1モードと、
上記欠陥情報として、上記単位領域における上記分割領域ごとの上記欠陥の有無の情報を記録する第2モードと、を切り換えることを特徴とする請求項10に記載のフィルム製造方法。 - 上記実際に欠陥を含むフィルムに該欠陥の位置を示す第1の印を付与するとともに、
上記別のフィルムにおける上記第1の印に対応する位置に第2の印を付与する欠陥印付与工程を含むことを特徴とする請求項1~11の何れか1項に記載のフィルム製造方法。 - 上記欠陥情報に基づいて、上記フィルム原反における上記実際に欠陥を含むフィルムに対応する位置に上記欠陥の位置を示す第1の印を付与するとともに、上記フィルム原反における上記別のフィルムに対応する位置であって、上記第1の印の位置から幅方向に移動させた位置に第2の印を付与する原反欠陥印付与工程を含み、
上記スリット工程では、上記第1の印および上記第2の印が付与された上記フィルム原反をスリットすることを特徴とする請求項1~11の何れか1項に記載のフィルム製造方法。 - 上記原反欠陥印付与工程では、上記第1の印および上記第2の印を、上記スリットラインに重ならないように付与することを特徴とする請求項13に記載のフィルム製造方法。
- 上記欠陥情報に基づいて、上記不良フィルムの一部を切除する欠陥切除工程を含むことを特徴とする請求項1~14の何れか1項に記載のフィルム製造方法。
- フィルム原反における欠陥の位置情報を含む欠陥情報を取得する欠陥情報取得部と、
上記フィルム原反を、長手方向に沿うスリットラインでスリットして複数のフィルムを得るスリット部と、
1つの上記欠陥に関する上記欠陥情報に基づいてスリット後のフィルムの不良判定を行うことにより、実際に上記欠陥を含むフィルムおよび該フィルムに隣接する別のフィルムを不良フィルムと判定する判定部と、を備えていることを特徴とするフィルム製造装置。 - フィルム原反における欠陥の位置情報を含む欠陥情報を取得する欠陥情報取得部と、
上記フィルム原反を、長手方向に沿うスリットラインでスリットして複数のフィルムを得るスリット部と、
上記欠陥情報に基づいてスリット後のフィルムの不良判定を行う判定部と、を含み、
上記欠陥情報取得部は、上記欠陥情報として、上記フィルム原反の表面の領域を幅方向に並ぶ複数の領域に分けた分割領域ごとの欠陥の有無の情報を取得し、
上記判定部では、欠陥が存在する上記分割領域が上記スリットラインに重ならない場合には、該分割領域を含んで得られる1つのフィルムを不良フィルムと判定し、欠陥が存在する上記分割領域またはその境界線が上記スリットラインに重なる場合には、該スリットラインで分断される2つのフィルムを不良フィルムと判定することを特徴とするフィルム製造装置。 - 欠陥を有するフィルム原反の表面を長手方向に沿った境界線で区画してなる領域ごとに対応して得られる複数のフィルムのうちの一つのフィルムであって、
上記境界線を介して上記欠陥が含まれる領域に隣接する領域に対応して得られ、
上記境界線を介して上記欠陥に対向する位置に印が付与されていることを特徴とするフィルム。 - 請求項18に記載のフィルムがロール状に巻き取られてなるフィルム捲回体。
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