Manufacturing apparatus for electrode laminate
10985408 · 2021-04-20
Assignee
Inventors
- Koichiro Fujiwake (Nagaokakyo, JP)
- Hideyasu Kamigawa (Nagaokakyo, JP)
- Takeshi Yamamoto (Nagaokakyo, JP)
- Sadao Nishida (Nagaokakyo, JP)
- Jiro Kamiura (Nagaokakyo, JP)
Cpc classification
H01M10/0585
ELECTRICITY
Y02E60/10
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y02P70/50
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
H01M4/82
ELECTRICITY
H01M10/0585
ELECTRICITY
Abstract
An electrode supply unit corrects an electrode target position based on a positional displacement amount of a first separator material, a first offset amount which is an actual positional displacement amount between the first separator material and an electrode when the first separator material is supplied in a manner that a positional displacement is not generated, and a movement amount in a lateral direction when an electrode supply region moves from a first position T1 to a second position T2 The electrode supply unit then supplies the electrode to the first separator material. A joining head corrects a joining target position based on a positional displacement amount of the electrode, a second offset amount which is an actual positional displacement amount which occurs when positions of the electrode and the joining head are adjusted so as not to cause positional displacement, and a movement amount in the lateral direction when the electrode supply region moves from the third position T3 to the fourth position T4. The joining head then joins the separator materials.
Claims
1. A manufacturing apparatus for an electrode laminate having a structure in which an electrode is sandwiched between first and second separators, the manufacturing apparatus comprising: a conveyor belt configured to convey elongated first and second separator materials along a longitudinal travelling direction of the conveyor belt; a first separator material supply configured to supply the first separator material onto the conveyor belt; a first image pickup configured to detect, as a first positional displacement amount, a positional displacement amount of the first separator material in a lateral direction orthogonal to the traveling direction of the conveyor belt with respect to a first reference position by capturing an image of the first separator material supplied onto the conveyor belt at a first position; an electrode supply unit configured to supply the electrode onto the first separator material, based on an electrode target position, at a second position located downstream of the first position in the traveling direction of the conveyor belt; a second image pickup unit configured to detect, as a second positional displacement amount, a positional displacement amount of the electrode relative to a second reference position as measured in the lateral direction by capturing an image of the electrode supplied onto the first separator material at a third position located downstream of the second position in the traveling direction of the conveyor belt; a second separator material supply unit configured to supply the second separator material onto the first separator material so as to sandwich the electrode between the first and second separator materials; a joining head configured to join together portions of the first and second separator materials around the electrode at a fourth position located downstream of the third position in the travelling direction of the conveyer belt; a cutter configured to cut the first separator material and the second separator material to obtain the electrode laminate; and a storage unit configured to store (a) information regarding a first movement amount of a first region of the conveyer belt in the lateral direction as it moves between the first and second positions and (b) information regarding a second movement amount of the first region of the conveyer belt in the lateral direction as it moves between the third and fourth positions; wherein: the electrode supply unit: (a) corrects the electrode target position based on: (i) the first positional displacement amount; (ii) a first offset amount which is a positional displacement amount in the lateral direction between the first separator material and the electrode when the first positional displacement amount is zero and the electrode is supplied based on the electrode target position; and (iii) the first movement amount obtained from the information regarding the first movement amount; and (b) supplies the electrode onto the first separator material based on the corrected electrode target position; and the joining head: (a) corrects the joining target position based on: (i) the second positional displacement amount; (ii) a second offset amount which is a positional displacement amount in the lateral direction of the joining head with respect to a position of the electrode when the second positional displacement amount is zero and the joining head is operated so as to join the first separator material and the second separator material at the joining target position; and (iii) the second movement amount obtained from information regarding the second movement amount; and (b) joins the first separator material and the second separator material at the corrected joining target position.
2. The manufacturing apparatus for an electrode laminate according to claim 1, wherein: the conveyer belt includes a plurality of regions; the electrode supply unit is configured to sequentially supply a plurality of electrodes to the conveyer belt, each electrode being applied to a respective one of the regions; and the storage unit stores information regarding the first and second movement amounts for each of the regions to which the electrodes are supplied on the conveyor belt.
3. The manufacturing apparatus for an electrode laminate according to claim 2, wherein: the storage unit stores, as information regarding the first movement amount, a positional displacement amount in the lateral direction at the first position and a positional displacement amount in the lateral direction at the second position for each of a plurality of regions to which the electrodes are supplied, and stores, as information regarding the second movement amount, a positional displacement amount in the lateral direction at the third position and a positional displacement amount in the lateral direction at the fourth position for each of a plurality of regions to which the electrodes are supplied.
4. The manufacturing apparatus for an electrode laminate according to claim 3, wherein: a positional displacement amount in the lateral direction at the first position is obtained by the first image pickup unit capturing an image of a region to which the electrode is supplied; a positional displacement amount in the lateral direction at the second position is obtained by the third image pickup unit, installed at the second position, capturing an image of a region to which the electrode is supplied; a positional displacement amount in the lateral direction at the third position is obtained by the second image pickup unit capturing an image of a region to which the electrode is supplied; and a positional displacement amount in the lateral direction at the fourth position is obtained by the fourth image pickup unit, installed at the fourth position, capturing an image of a region to which the electrode is supplied.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DESCRIPTION OF THE PREFERRED EMBODIMENTS
(10) Hereinafter, exemplary embodiments of the present invention will be shown to explain characteristics of the present invention more specifically.
(11) First, a structure of an electrode laminate will be briefly described, and then a method for manufacturing the electrode laminate will be described.
(12) As shown in
(13) The electrode 12 is either a positive or a negative electrode. When the electrode 12 is a positive electrode, it preferably includes a positive electrode current collector made of, for example, a metal foil, such as aluminum, and a positive electrode active material formed on both sides of the positive electrode current collector. When the electrode 12 is a negative electrode, it preferably includes a negative electrode current collector made of, for example, a metal foil, such as copper, and a negative electrode active material formed on both sides of the negative electrode current collector. A planar shape of the electrode 12 may be rectangular or non-rectangular.
(14) The first and second separators 11 and 13 can be made of the same material, and for example, can be constituted by a microporous thin film made of polypropylene having excellent insulation.
(15)
(16) The conveyor belt 30 is made of, for example, metal, and conveys the elongated first separator material 11A and an elongated second separator material 13A in a direction along the longitudinal direction of the conveyor belt (the horizontal direction as viewed in
(17) The conveyor belt 30 includes one or more suction hole (not shown). The first separator material 11A supplied onto the conveyor belt 30 is held on the conveyor belt 30 by being sucked downward through the suction hole. Further, the second separator material 13A is supplied onto the first separator material 11A and is sucked downward through the first separator material 11A to be held on the first separator material 11A.
(18) In
(19) Note that, the first and second positions T1 and T2 (as well as the second and third positions T2 and T3) are spaced apart by a distance (an electrode pitch) L, which will be described further below. Further, the distance between the third and fourth positions T3 and T4 is 3 L.
(20) At the first position T1, a first camera 22 captures an image of the first separator material 11A supplied onto the conveyor belt 30, so as to detect, as a first positional displacement amount, a positional displacement amount of the first separator material 11A in a lateral direction (Y-axis direction) that is orthogonal to the traveling direction (X-axis direction) of the conveyor belt 30 with respect to a first reference position Y1 (not shown). The first reference position Y1 is a reference position in the lateral direction and is an optional reference position set within a field of view of the first camera 22.
(21) As used herein, the “lateral”, and the “lateral direction” mean a direction (Y-axis direction) orthogonal to the traveling direction of the conveyor belt 30.
(22) At the second position T2, an electrode supply unit 23 supplies the electrode 12 onto the first separator material 11A based on an electrode target position. The electrode target position is a target position for determining a supply position of the electrode 12 in the lateral direction. That is, by supplying the electrode 12 to the electrode target position, the electrode 12 can be placed at a desired position on the first separator material 11A. The electrode target position is corrected by a method described below which compensates for lateral positional displacement due to meandering of the conveyor belt 30, and the like.
(23) Note that the electrode supply unit 23 supplies a respective electrode 12 to the first separator material at predetermined time intervals. Since the first separator material 11A is conveyed on the conveyor belt 30, the electrode 12 is supplied onto the first separator material 11A at predetermined intervals. Here, a distance shown by a reference symbol L in
(24) At the third position T3, a second camera 24 captures an image of the electrode 12 supplied onto the first separator material 11A, so as to detect, as a second positional displacement amount, a positional displacement amount of the electrode 12 in the lateral direction with respect to a second reference position Y2. The second reference position Y2 is a reference position in the lateral direction and is an optional reference position set within a field of view of the second camera 24.
(25) A second separator material supply unit 25 supplies the elongated second separator material 13A wound in a roll onto the conveyor belt 30, more specifically, at a predetermined position overlapping with the first separator material 11A, in such a manner that the electrode 12 is sandwiched between the second separator material 13A and the first separator material 11A. At this time, a supply rate of the second separator material 13A is controlled so that the second separator material 13A is appropriately supplied onto the conveyor belt 30 according to a traveling speed of the conveyor belt 30.
(26) A joining head 26 is provided with, for example, a heater, and is configured to be able to ascend and descend (move up and down as viewed in
(27) At the fifth position T5, in order to form an electrode laminate 10, a cutting unit 27 cuts the first separator material 11A and the second separator material 13A with a cutting blade 27a so as to cut a predetermined region including the electrode 12. In this manner, the electrode laminate 10 including the first separator 11, the electrode 12, and the second separator 13 is obtained.
(28) A storage unit 28 stores information regarding a first movement amount, which is an amount of lateral movement
(29) when a region to which the electrode 12 is supplied moves from the first position T1 to the second position T2 on the conveyor belt 30 when the conveyor belt 30 is driven, and information regarding a second movement amount, which is an amount of lateral movement when the region moves from the third position T3 to the fourth position T4.
(30) In the present embodiment, the conveyor belt 30 is divided into a plurality of regions according to supply positions of the electrode 12, and the storage unit 28 stores information regarding the first and second movement amounts for a plurality of the regions.
(31) In the present embodiment, the number of regions corresponds to the peripheral length of the conveyor belt 30 divided by the electrode pitch L. Here, an example will be described where the peripheral length of the conveyor belt 30 is 2142 mm, the electrode pitch is 102 mm, and the region on the conveyor belt 30 is divided into 21 regions (2142/102) regions S1 to S21. Thus,
(32) Here, the information regarding the first movement amount may be information indicating the first movement amount itself, or may be information necessary for obtaining the first movement amount. Similarly, the information regarding the second movement amount may be information indicating the second movement amount itself, or may be information necessary for obtaining the second movement amount.
(33) In the present embodiment, the information regarding the first movement amount is information necessary for obtaining the first movement amount, the information regarding the second movement amount is information required for obtaining the second movement amount. Specifically, the storage unit 28 stores, as the information regarding the first and second movement amounts, mapping data indicating the lateral positional displacement amount of the edge of the conveyor belt 30 as each of the regions S1 to S21 on the conveyor belt 30 move to the first position T1, the second position T2, the third position T3, and the fourth position T4 at the time the conveyor belt 30 is driven.
(34)
(35) Here, as shown in
(36) The first movement amount described above is obtained based on a difference between a positional displacement amount of the edge at the first position T1 and the positional displacement amount of the edge at the second position T2, and the second movement amount is obtained based on a difference between a positional displacement amount of the edge at the third position T3 and a positional displacement amount of the edge at the fourth position T4. The reference position Y0 for detecting a positional displacement amount of the edge of the conveyor belt 30 can be set to an optional position since only the first movement amount and the second movement amount need to be obtained.
(37) In the example shown in
(38) A method for creating the above-described mapping data will be described with reference to
(39) In order to create the mapping data, the conveyor belt 30 is driven, and images at a position of the edge of the conveyor belt 30 in the region S1 are captured by the first camera 22, the third camera 61, the second camera 24, and the fourth camera 62 sequentially. From the obtained images, positional displacement amounts in the lateral direction at the first position T1, the second position T2, the third position T3, and the fourth position T4 are obtained. By a similar method, a positional displacement amount of the edge of the conveyor belt 30 in each of the other regions S2 to S21 is also obtained. By such a method, with respect to each of the regions S1 to S21, the mapping data that defines a positional displacement amount of the edge of the conveyor belt 30 at the first position T1, the second position T2, the third position T3, and the fourth position T4 is created.
(40) According to the mapping data creation method described above, it is possible to use the first camera 22 and the second camera 24 of the manufacturing apparatus for an electrode laminate. Further, by providing the third camera 61 at the second position T2 and the fourth camera 62 at the fourth position T4, and capturing an image of the conveyor belt 30 being driven, it is possible to easily obtain the mapping data.
(41) However, the method for creating the mapping data is not limited to the above-described method, and the mapping data can be created by any other suitable creation method. Further, a positional displacement amount included in the mapping data may be a positional displacement amount of another reference position, for example, a center position in the lateral direction of the conveyor belt 30, instead of a positional displacement amount of the edge of the conveyor belt 30.
(42) Here, a method for correcting the electrode target position which is a target position when the electrode 12 is supplied will be described. The electrode target position is corrected based on the first positional displacement amount of the first separator material 11A detected by the first camera 22, a first offset amount, and the above-described first movement amount. The first offset amount is a lateral positional displacement amount (as measured in the Y-axis direction) between the first separator material 11A and the electrode 12 when the first positional displacement amount is zero and the electrode 12 is supplied to the electrode target position.
(43)
(44) Therefore, when the first positional displacement amount is zero and the distance between the electrode 12 and the one end E of the first separator material 11A when the electrode 12 is supplied to the electrode target position is H2, the distance H2−H1 is the first offset amount. The first offset amount is obtained in advance before manufacturing the electrode laminate 10.
(45) Note that, the distance between the upper edge of the electrode 12 and the upper end E of the first separator material 11A (again, as measured in the Y-axis direction) when the first positional displacement amount is zero and the electrode 12 is supplied to the electrode target position may be adjusted to H1. In this case, the first offset amount is zero.
(46) The corrected electrode target position is obtained by shifting the electrode target position before correction in the Y-axis direction by a distance obtained by adding together the first positional displacement amount of the first separator material 11A on a target region to which the electrode 12 is supplied, which is detected by the first camera 22, the first offset amount obtained in advance, and the first movement amount obtained from the information regarding the first movement amount stored in the storage unit 28. The first positional displacement amount of the first separator material 11A on a target region to which the electrode 12 is supplied is, for example, the first positional displacement amount of the first separator material 11A on the region S1 when the electrode 12 is supplied to the region S1.
(47) The electrode supply unit 23 corrects the electrode target position by the above-described method, and supplies the electrode 12 onto the first separator material 11A based on the corrected electrode target position.
(48) For example, when reference is made to the mapping data shown in
(49) It should be noted that the electrode target position may be corrected, for example, by a control unit (not shown) and the electrode supply unit 23 may supply the electrode 12 based on the corrected electrode target position. In that case, the control unit for correcting the electrode target position and the electrode supply unit 23 correspond to the electrode supply unit of the present invention.
(50) As described above, by correcting the electrode target position based on the first positional displacement amount, it is possible to correct the supply position of the electrode 12 based on the positional displacement amount of the first separator material 11A. Further, by correcting the electrode target position based on the first offset amount, a lateral positional relationship between the first separator material 11A and the electrode 12 can be set to an intended positional relationship.
(51) Further, in the present embodiment, the electrode target position is corrected based on the first movement amount which is an amount of lateral movement when a region to which the electrode 12 is supplied on the conveyor belt 30 moves from the first position T1 which is a position where a positional displacement amount of the first separator material 11A is detected to the second position T2 which is a position to which the electrode 12 is supplied. Accordingly, the electrode 12 can be supplied to an intended position on the first separator material 11A by eliminating the influence of meandering of the conveyor belt 30, and the like.
(52) In particular, since the storage unit 28 stores, as the mapping data, lateral positional displacement amounts of all the regions S1 to S21 on the conveyor belt 30, when the electrodes 12 are sequentially supplied onto the conveyor belt 30, it is possible to supply all the electrodes 12 to an intended position on the first separator material 11A by suppressing the influence of meandering of the conveyor belt 30 and the like.
(53) Further, since the first positional displacement amount of the first separator material 11A is detected at the first position T1 and the electrode 12 is supplied onto the first separator material 11A at the second position T2, by supplying a plurality of the electrodes 12 one after another on the first separator material 11A, detection of the first positional displacement amount and supply of the electrodes 12 can be performed at the same time, and manufacturing efficiency is improved.
(54) Next, a method for correcting the joining target position, which is a target position at the time of joining by the joining head 26, will be described. The joining target position is corrected based on the second positional displacement amount of the electrode 12 detected by the second camera 24, a second offset amount, and the above-described second movement amount.
(55) The second offset amount is a lateral positional displacement amount of the joining head 26 with respect to a position of the electrode 12 when the second positional displacement amount is zero and the joining head 26 is operated so as to perform joining at the joining target position. That is, the second offset amount is an actual positional displacement amount between the electrode 12 and the joining head 26 which is generated when the second positional displacement amount of the electrode 12 detected by the second camera 24 is zero and the joining head 26 is caused to descend to the joining target position. The second offset amount is obtained in advance before the electrode laminate 10 is manufactured.
(56) Note that a lateral descending position of the joining head 26 may be adjusted in advance so that the second offset amount becomes zero.
(57) The corrected joining target position is obtained by shifting the joining target position before correction in the Y-axis direction by a distance obtained by adding together the second positional displacement amount of the electrode 12 in a target region which is detected by the second camera 24, the second offset amount obtained in advance, and the second movement amount obtained from the information regarding the second movement amount stored in the storage unit 28. The above the second positional displacement amount of the electrode 12 in a target region is, for example, the second positional displacement amount of the electrode 12 on the region S1 when the region S1 is the target region, and portions around the electrode 12 on the region S1 are joined.
(58) The joining head 26 modifies the joining target position by the above-described method and joins a portion around the electrode 12 of the first separator material 11A and the second separator material 13A at the corrected joining target position.
(59) For example, when reference is made to the mapping data shown in
(60) It is to be noted that the joining target position is corrected by, for example, a control unit (not shown), so that the joining head 26 joins the first separator material 11A and the second separator material 13A at the corrected joining target position. In that case, the control unit for correcting the joining target position and the joining head 26 correspond to the joining head of the present invention.
(61) By correcting the joining target position based on the second positional displacement amount, it is possible to correct a position at which joining by the joining head 26 is performed based on a positional displacement amount of the electrode 12. Further, by correcting the joining target position based on the second offset amount, it is possible to join portions around the electrode 12 with high accuracy.
(62) Furthermore, in the present embodiment, the joining target position is corrected based on the second movement amount which is an amount of lateral movement when a region to which the electrode 12 is supplied on the conveyor belt 30 moves from the third position T3 which is a position where a positional displacement amount of the electrode 12 is detected to the fourth position T4 which is a position at which joining is performed by the joining head 26. Accordingly, the joining head 26 can join portions of the first separator material 11A and the second separator material 13A around the electrode 12 with high accuracy while the influence of meandering of the conveyor belt 30 and the like is suppressed.
(63) In particular, since the storage unit 28 stores, as the mapping data, lateral positional displacement amounts of all the regions S1 to S21 on the conveyor belt 30, even when the electrodes 12 are sequentially supplied onto the conveyor belt 30, it is possible to cause the joining head 26 to join portions around all the electrodes 12 with high accuracy while the influence of meandering of the conveyor belt 30 and the like is suppressed.
(64) Further, since the second positional displacement amount of the electrode 12 is detected at the third position T3 and portions around the electrode 12 are joined at the fourth position T4, by supplying a plurality of the electrodes 12 one after another, detection of the second positional displacement amount of the electrode 12 and joining of the first separator material 11A and the second separator material 13A can be performed at the same time, and manufacturing efficiency is improved.
(65) Note that the produced electrode laminate 10 is used for creating an electrode body of a battery. That is, an electrode body 50 as shown in
(66) The present invention is not limited to the above embodiment, and various applications and variations can be added within the scope of the present invention.
(67) For example, the method for joining portions of the first separator material 11A and the second separator material 13A around the electrode 12 by the joining head 26 is not limited to the thermocompression bonding method, and for example, it is also possible to use a high-frequency bonding method or a laser bonding method. Further, joining of portions around the electrode 12 includes not only a mode in which portions around the electrode 12 are completely joined but also a mode in which the portions around the electrode 12 are partially joined.
DESCRIPTION OF REFERENCE SYMBOLS
(68) 10: electrode laminate 11: first separator 11A: first separator material 12: electrode 13: second separator 13A: second separator material 14: second electrode 21: first separator material supply unit 22: First camera 23: electrode supply unit 24: Second camera 25: second separator material supply unit 26: Joining head 27: cutting unit 28: Storage unit 30: conveyor belt 50: electrode body 61: Third camera 62: Fourth camera T1: First position T2: Second position T3: Third position T4: Fourth position T5: Fifth position