JP6845024B2 - Assembly manufacturing method and assembly - Google Patents

Description

The present invention relates to a method for manufacturing an assembly and an assembly for assembling a wound body (roll) in which a film is wound.

Inside the lithium ion secondary battery, the positive electrode and the negative electrode are separated by a porous separator. In the manufacture of a lithium ion secondary battery, a separator wound body in which this separator is wound around a cylindrical core is used.

In the manufacture of lithium-ion secondary batteries, the inclusion of dust is fatal, so the separator winding body is packaged so that dust does not invade or dust that becomes dust is not generated. Further, in order to improve the efficiency of the transportation and packaging process, a plurality of separator wound bodies are inserted into the same core material and assembled into one roll assembly.

For example, in the configuration described in Patent Document 1, a plurality of rolls, a protective sheet for protecting the end faces of the rolls, and a spacer inserted between the rolls are inserted into a cylindrical core and wrapped with a packaging film. Has been done. In addition, as a protective sheet that protects the end face of the roll, Patent Documents 2 to 3 describe one that directly engages with the shaft hole of the core of the roll.

Further, for example, in the configuration described in Patent Document 4, a plurality of roll cores are inserted into a branch pillar portion provided so as to project laterally from the plate-shaped portion, and a cushioning material is screwed on the end surface of the branch pillar portion. By being stopped, the roll is prevented from falling off from the branch pillar portion.

Japanese Unexamined Patent Publication No. 2010-274922 (published on December 09, 2010) Japanese Unexamined Patent Publication No. 2006-298455 (published on November 02, 2006) International Publication WO2008 / 123124 (International Release on October 16, 2008) Utility model registration No. 3195120 (issued on December 25, 2014)

However, the above-mentioned conventional techniques have the following problems.

In the configuration described in Patent Document 1, the protective sheet and the core are engaged with each other by penetrating the core through the opening provided in the center of the protective sheet. Therefore, there is a problem that the core is dropped from the opening due to the vibration during transportation, and the assembly is easily disassembled. In order to solve this problem, if the core is lengthened so as not to fall out of the opening, the roll assembly becomes bulky, which causes another problem that the transportation efficiency is lowered.

In the configuration described in Patent Document 4, the cushioning material is screwed by screwing a male screw jig with a knob into the female screw portion provided on the end surface of the branch pillar portion. Therefore, due to the vibration during transportation, collision and friction occur between the screw groove and the screw thread of the female screw portion and the male screw jig with a knob. Since both the branch pillar portion and the male screw jig with a knob are made of a hard material, there is a problem that dust is likely to be generated due to collision and friction.

The present invention has been made in view of the above-mentioned problems, and an object of the present invention is to prevent the core material from falling off from the side plate that protects the end face of the wound body, and to prevent wear debris from being generated. The purpose is to realize a manufacturing method.

In order to solve the above problems, a manufacturing method of assembly according to one embodiment of the present invention, the length of the first convex portion protruding from among plate-shaped first base portion of the first side plate and L _4, the core Assuming that the length of the core material in the insertion direction when the core material is inserted into the wound body in which the film is wound and the plate-shaped member is L ₃ , the first convex portion where _{L 3} > L ₄ The total length of the one or more winding bodies in the first insertion step and the insertion direction is L _{1, sum,} and the length of the one or more plate-shaped members is defined as L 1, sum. If the sum of the sums is L _{2, sum} , then one or more of the winding bodies and one or more of the plate-like members so that L ₃ + L ₄ > L _{1, sum} + L _{2, sum} > L ₃ Including an insertion step of inserting the core material.

Also, another method for manufacturing the assembly according to one embodiment of the present invention, the length of the first convex portion protruding from among plate-shaped first base portion of the first side plate and L _4, a film core wound Assuming that the length of the core material in the insertion direction when the core material is inserted into the wound body is L ₃ , _{the first convex portion having L 3} > L ₄ is inserted into one end of the core material. Assuming that the total length of one or more winding bodies in one insertion step and the insertion direction is L _{1, sum} , one or one or more so that L ₃ + L ₄ > L _{1, sum} > L _3. The insertion step of inserting the core material into the plurality of wound bodies is included.

According to the above two methods, since the first convex portion is inserted into one end of the core material, the core material is unlikely to fall off from the first side plate. Further, the other end on the opposite side of one end of the core material can be prevented from protruding from the inserted wound body or the inserted wound body and the plate-shaped member. Therefore, the first base portion can be separated from the end face of one end of the core material. Therefore, since the first base portion and the end face of the core material do not rub against each other, it is possible to prevent the generation of wear debris.

In the method for manufacturing an assembly according to one aspect of the present invention, assuming that the length of the second convex portion protruding from the plate-shaped second base portion of the second side plate is L ₅ , L _{1, sum} + L _{2, sum.} A second insertion step of inserting the second convex portion into the other end of the core material opposite to the one end so that _{−L 4} > L ₅ > L _{1, sum} + L _{2, sum} −L ₃ Is preferably included.

In another manufacturing method of the assembly according to one aspect of the present invention, assuming that the length of the second convex portion protruding from the plate-shaped second base portion of the second side plate is L ₅ , L _{1, sum-} L It is preferable to include a second insertion step of inserting the second convex portion into the other end of the core material opposite to the one end so that ₄ > L ₅ > L _{1, sum} −L _3.

According to the above two methods, the second base portion can be separated from the end face of one end of the core material. Therefore, since the second base portion and the end face of the core material do not rub against each other, it is possible to prevent the generation of wear debris. Even if the position of the core material is biased inside the inserted wound body and the plate-shaped member, or inside the inserted wound body, at least a part of the second convex portion must be covered. It can be inserted into the other end of the core material. Therefore, the core material is unlikely to fall off from the second side plate. Further, since the first side plate is engaged with one end of the core material and the second side plate is engaged with the other end, the core material supporting the wound body can be suspended by the first and second side plates. Become.

In the method for manufacturing an assembly according to one aspect of the present invention, it is preferable to insert the core material alternately between the wound body and the plate-shaped member in the insertion step. According to the above method, one plate-shaped member can always be sandwiched between the wound bodies. Therefore, the minimum number of plate-shaped members can prevent or alleviate the collision between the wound body and the wound body.

In the method for manufacturing an assembly according to one aspect of the present invention, it is preferable that the plate-shaped member is a plurality of the plate-shaped members, and the core material is inserted into the plate-shaped member at the beginning and the end in the insertion step. According to the above method, at least one plate-shaped member can be surely sandwiched between the first side plate and the wound body and between the second side plate and the wound body. Therefore, the collision between the wound body and the first side plate and the collision between the wound body and the second side plate can be prevented or alleviated.

In the method for manufacturing an assembly according to one aspect of the present invention, it is preferable that at least one of the plate-shaped members is a spacer that is not deformed by an external force. When a spacer is used, the distance between the first side plate and the wound body, between the second side plate and the wound body, and between the wound bodies, while the spacer is sandwiched, can be separated. it can. Such a separation can prevent a collision between the first side plate and the wound body, between the second side plate and the wound body, or between the wound bodies.

In the method for manufacturing an assembly according to one aspect of the present invention, at least one of the plate-shaped members is a cushioning material that is deformed by an external force, and the L _{2, sum} is a cushioning material that is deformed by an external force. It is preferable that it is the total length in the non-cushioned state. When a cushioning material is used, the impact of collision between the first side plate and the wound body, between the second side plate and the wound body, and between the wound bodies while the cushioning material is sandwiched between them. Can be absorbed by the cushioning material. Such absorption can alleviate collisions between the first side plate and the wound body, between the second side plate and the wound body, and between the wound bodies.

When a cushioning material is used, in the method for manufacturing an assembly according to one aspect of the present invention, the total length of the plate-shaped members in the insertion direction in which the cushioning material is deformed by an external force is L _{2. , Sum, deformed} , the second convex portion can be inserted into the other end of the core material so that _{L 1, sum} + L _{2, sum, deformed} ≧ L _{3 in} the second insertion step. preferable. According to the method, a surface of the first base portion in which the first convex portion projects, the distance between the second base portion of the surface the second convex portion projects is, the length of the core L ₃ or more Is also far away. Therefore, the end faces at both ends of the core material are unlikely to rub against the first and second base portions. As a result, wear debris is less likely to be generated from the end faces at both ends of the core material and the first and second base portions.

In the method for manufacturing an assembly according to one aspect of the present invention, it is preferable that the insertion direction is the direction of gravity in the insertion step. According to the method, the inserted wound body and the plate-shaped member, or the inserted wound body are stacked in the direction of gravity. Due to gravity, they can be easily stacked so that there is no gap between the core of the wound body and the plate-shaped member, between the cores of the wound body, and between the plate-shaped members. As a result, in the assembled assembly, there is little room for the wound body to move. Therefore, it is possible to prevent the wound bodies from colliding with each other or with the first or second side plate.

In the method for manufacturing an assembly according to one aspect of the present invention, after the first insertion step, the insertion step, and the second insertion step, the first side plate and the second side plate are attached to each other. It is preferable to include a winding step of winding with a band-shaped member. According to the method, since the distance between the first and second side plates is limited, it is possible to prevent the core material from falling off from the first or second side plate. As a result, it is possible to prevent a gap from being generated between the core of the wound body and the plate-shaped member, between the cores of the wound body, or between the plate-shaped members.

When a cushioning material is used, in the method for manufacturing an assembly according to one aspect of the present invention, after the first insertion step, the insertion step, and the second insertion step, the first side plate and the said. It is preferable to include a winding step of winding the second side plate with each other _{with a band-shaped member so that L 1, sum} + L _{2, sum, deformed} ≧ L _3. According to the method, since the distance between the first and second side plates is limited, it is possible to prevent the core material from falling off from the first or second side plate. As a result, it is possible to prevent a gap from being generated between the core of the wound body and the plate-shaped member, between the cores of the wound body, or between the plate-shaped members. Further, according to the above method, the distance between the surface of the first base portion on which the first convex portion protrudes and the surface of the second base portion on which the second convex portion protrudes is the length L _{3 of the core material.} It's farther away. Therefore, the end faces at both ends of the core material are unlikely to rub against the first and second base portions. As a result, wear debris is less likely to be generated from the end faces at both ends of the core material and the first and second base portions.

In the method for manufacturing an assembly according to one aspect of the present invention, in the winding step, the band-shaped member is provided with a first engaging portion provided by the first side plate and a second engaging portion provided by the second side plate. It is preferable to engage with. According to the above method, since the band-shaped member is engaged with the first and second engaging portions, the band-shaped member is unlikely to come off from the first and second side plates. Further, when the first and second engaging portions also serve as guiding portions for guiding the strip-shaped member to an appropriate position, the strip-shaped member can be easily wound so as not to loosen.

In the method for manufacturing an assembly according to one aspect of the present invention, the strip-shaped member is preferably a stretch film. According to the above method, since a stretch film is used, it can be easily torn by a human hand without using a device such as scissors. This makes it easier to disassemble the assembly, and the assembled wound body can be easily taken out.

In the method for manufacturing an assembly according to one aspect of the present invention, it is preferable that the number of wound bodies is a plurality. According to the above method, the wound body can be assembled into one assembly.

In the method for manufacturing an assembly according to one aspect of the present invention, the film is preferably a battery separator. The assembly according to the method for manufacturing an assembly according to the present invention is particularly suitable for storage and transportation of a wound body in which a battery separator is wound, because wear debris that becomes dust is unlikely to be generated.

The assembly according to one embodiment of the present invention, the length of the first convex portion protruding from among plate-shaped first base portion of the first side plate and L _4, wound body and the plate was wound the film to the core Assuming that the length of the core material in the insertion direction when the core material is inserted into the member is L ₃ , _{the first convex portion having L 3} > L ₄ is inserted at one end of the core material. Assuming that the total length of one or more winding bodies in the insertion direction is L _{1, sum} and the total length of one or more plate-shaped members is L _{2, sum} , L ₃ + L ₄ The core material is inserted through the one or more winding bodies and the one or more plate-shaped members so that> L _{1, sum} + L _{2, sum} > L _3.

Another assembly according to one embodiment of the present invention, the length of the first convex portion protruding from among plate-shaped first base portion of the first side plate and L _4, the wound is wound a film core Kaitai Assuming that the length of the core material in the insertion direction when the core material is inserted is L ₃ , _{the first convex portion having L 3} > L ₄ is inserted at one end of the core material, and the insertion direction. Assuming that the total length of the one or more winding bodies in the above is L _{1, sum} , the one or more winding bodies are L ₃ + L ₄ > L _{1, sum} > L ₃ . It is inserted through the core material.

According to the above two configurations, since the first convex portion is inserted into one end of the core material, the core material is unlikely to fall off from the first side plate. Further, the other end on the opposite side of one end of the core material can be prevented from protruding from the inserted wound body or the inserted wound body and the plate-shaped member. Therefore, the first base portion can be separated from the end face of one end of the core material. Therefore, since the first base portion and the end face of the core material do not rub against each other, it is possible to prevent the generation of wear debris.

INDUSTRIAL APPLICABILITY In the method of manufacturing an assembly for assembling a wound body, the present invention has an effect that the core material is less likely to fall off from a side plate that protects an end surface of the wound body and an effect that wear debris is less likely to be generated.

It is a schematic diagram which shows the cross-sectional structure of a lithium ion secondary battery. It is a schematic diagram which shows the detailed structure of the lithium ion secondary battery shown in FIG. It is a schematic diagram which shows the other detailed structure of the lithium ion secondary battery shown in FIG. It is a schematic diagram which shows the structure of the slit device which slits a separator. It is a figure which shows the structure of the cutting device of the slit device shown in FIG. It is a schematic diagram which shows the structure of the separator wound body of embodiment of this invention. It is a schematic diagram which shows the structure of the cushioning material of embodiment of this invention. It is a schematic diagram which shows the structure of the core material of embodiment of this invention. It is a schematic diagram which shows the structure of the protector of embodiment of this invention. It is a schematic diagram which shows an example of the assembly process of the roll assembly of embodiment of this invention. It is a schematic diagram which shows the cross-sectional structure of the roll assembly of embodiment of this invention. It is a schematic diagram which shows the cross-sectional structure of the modified example of the roll assembly of embodiment of this invention.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. However, the dimensions, materials, shapes, relative arrangements, processing methods, etc. of the configurations described in this embodiment are merely one embodiment, and the scope of the present invention should not be construed as limited by these. Furthermore, the drawings are schematic, and the ratio of dimensions and the shape are different from the actual ones.

[Basic configuration]
Regarding the battery separator wound around the separator winding body which is the assembly target of the embodiment of the present invention, as a basic configuration, a lithium ion secondary battery, a separator, a heat-resistant separator, a method for manufacturing a separator / heat-resistant separator, a slit device, and the like. The cutting device will be described in order.

(Lithium-ion secondary battery)
Non-aqueous electrolyte secondary batteries represented by lithium ion secondary batteries have a high energy density. Therefore, at present, non-aqueous electrolyte secondary batteries are used as batteries for personal computers, mobile phones, devices such as personal digital assistants, mobile bodies such as automobiles and aircraft, and as stationary batteries that contribute to the stable supply of electric power. , Widely used.

FIG. 1 is a schematic view showing a cross-sectional configuration of the lithium ion secondary battery 1. As shown in FIG. 1, the lithium ion secondary battery 1 includes a cathode 11, a separator 12 (film, battery separator), and an anode 13. Outside the lithium ion secondary battery 1, an external device 2 is connected between the cathode 11 and the anode 13. Then, the 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.

(Separator)
The separator 12 is arranged so as to be sandwiched between the cathode 11 which is the positive electrode of the lithium ion secondary battery 1 and the anode 13 which is the negative electrode thereof. The separator 12 is a porous film that allows the movement of lithium ions between the cathode 11 and the anode 13 while separating them. The separator 12 is a porous film containing a polyolefin resin as a main component. With respect to the porous film containing a polyolefin resin as a main component, the proportion of the polyolefin resin component in the porous film is usually 50% by volume or more, preferably 90% by volume or more, more preferably 90% by volume or more of the entire porous film. Means that it is 95% by volume or more. The polyolefin resin porous film, it preferably contains high molecular weight components of the weight average molecular weight ranging from ^{5 × 10 5 ~15 × 10 6} . Since the polyolefin-based resin of the porous film contains a polyolefin-based resin having a weight average molecular weight of 1 million or more, the porous film, that is, the entire separator for a non-aqueous electrolyte secondary battery, and the porous film and the porous film described later are porous. It is more preferable that a polyolefin-based resin having a weight average molecular weight of 1 million or more is contained because the strength of the entire laminated separator for a non-aqueous electrolyte secondary battery including a quality layer is increased.

Examples of the polyolefin-based resin include high-molecular-weight homopolymers (for example, polyethylene, polypropylene, and polybutene) obtained by polymerizing ethylene, propylene, 1-butene, 4-methyl-1-pentene, 1-hexene, and the like, or copolymers. Polymers (eg, ethylene-propylene copolymers) can be mentioned. The porous film containing a polyolefin-based resin as a main component is a layer containing one kind of these polyolefin-based resins, or a layer containing two or more kinds of these polyolefin-based resins. In particular, among the polyolefin-based resins, a high-molecular-weight polyethylene-based resin mainly composed of ethylene is preferable in terms of being able to prevent (shut down) the flow of an excessive current at a lower temperature. The porous film does not prevent the porous film from containing components such as additives other than the polyolefin resin as long as the function of the layer is not impaired. Examples of the additive include an organic compound (organic additive), and the organic compound may be an antioxidant (organic antioxidant) or a lubricant.

Examples of the polyethylene-based resin include low-density polyethylene, high-density polyethylene, linear polyethylene (ethylene-α-olefin copolymer), ultra-high molecular weight polyethylene having a weight average molecular weight of 1 million or more, and among them, weight. Ultra-high molecular weight polyethylene having an average molecular weight of 1 million or more is more preferable.

2A and 2B are schematic views showing a detailed configuration of the lithium ion secondary battery 1 shown in FIG. 1, in which FIG. 2A shows a normal configuration and FIG. 2B shows a temperature rise of the lithium ion secondary battery 1. The state at the time is shown, and (c) shows the state at the time when the temperature of the lithium ion secondary battery 1 suddenly rises. As shown in FIG. 2A, the separator 12 is provided with a large number of holes P. Normally, the lithium ions 3 of the lithium ion secondary battery 1 can come and go through the holes P.

Here, for example, the temperature of the lithium ion secondary battery 1 may rise due to overcharging of the lithium ion secondary battery 1, a large current caused by a short circuit of an external device, or the like. In this case, as shown in FIG. 2B, the separator 12 is melted or softened, and the hole P is closed. Then, the separator 12 shrinks. As a result, the movement of the lithium ion 3 is stopped, so that the above-mentioned temperature rise is also stopped.

However, when the temperature of the lithium ion secondary battery 1 rises sharply, the separator 12 shrinks sharply. In this case, as shown in FIG. 2 (c), the separator 12 may be destroyed. Then, since the lithium ion 3 leaks from the destroyed separator 12, the movement of the lithium ion 3 does not stop. Therefore, the temperature rise continues.

(Heat-resistant separator)
3A and 3B are schematic views showing another configuration of the lithium ion secondary battery 1 shown in FIG. 1, in which FIG. 3A shows a normal configuration and FIG. 3B shows the lithium ion secondary battery 1 suddenly. The state when the temperature is raised is shown. As shown in FIG. 3A, the separator 12 may be a heat-resistant separator including the porous film 5 and the heat-resistant layer 4. The heat-resistant layer 4 is laminated on one side of the porous film 5 on the cathode 11 side. The heat-resistant layer 4 may be laminated on one side of the porous film 5 on the anode 13 side, or may be laminated on both sides of the porous film 5. The heat-resistant layer 4 is also provided with a hole similar to the hole P. Usually, the lithium ions 3 come and go through the pores P and the pores of the heat-resistant layer 4. The heat-resistant layer 4 is made of, for example, a polyolefin such as polyethylene, polypropylene, polybutene, and an ethylene-propylene copolymer; a fluorine-containing resin such as polyvinylidene fluoride (PVDF) and polytetrafluoroethylene; vinylidene fluoride-hexa. Fluorophilic rubber such as fluoropropylene-tetrafluoroethylene copolymer and ethylene-tetrafluoroethylene copolymer; aromatic polyamide; total aromatic polyamide (aramid resin); styrene-butadiene copolymer and its hydride, methacrylic acid Rubbers such as ester copolymers, acrylonitrile-acrylic acid ester copolymers, styrene-acrylic acid ester copolymers, ethylene propylene rubber, and vinyl acetate; polyphenylene ether, polysulfone, polyether sulfone, polyphenylene sulfide, polyether Resins such as imide, polyamideimide, polyetheramide, polyester, and polyesteramide having a melting point and a glass transition temperature of 180 ° C. or higher; polyvinyl alcohol, polyethylene glycol, cellulose ether, sodium alginate, polyacrylic acid, polyacrylamide, and polymethacryl. Water-soluble polymers such as acids; and the like.

Specific examples of the aromatic polyamide include poly (paraphenylene terephthalamide), poly (metaphenylene isophthalamide), poly (parabenzamide), poly (metabenzamide), and poly (4,4'. -Benzanilide terephthalamide), poly (paraphenylene-4,4'-biphenylenedicarboxylic acid amide), poly (metaphenylene-4,4'-biphenylenedicarboxylic acid amide), poly (paraphenylene-2,6-naphthalenedicarboxylic acid) Acid amide), poly (metaphenylene-2,6-naphthalenedicarboxylic acid amide), poly (2-chloroparaphenylene terephthalamide), paraphenylene terephthalamide / 2,6-dichloroparaphenylene terephthalamide copolymer, metaphenylene Examples thereof include terephthalamide / 2,6-dichloroparaphenylene terephthalamide copolymer. Of these, poly (paraphenylene terephthalamide) is more preferable.

Among the above resins, polyolefins, fluororesins, aromatic polyamides, and water-soluble polymers are more preferable. Above all, when the porous layer is arranged so as to face the positive electrode of the non-aqueous electrolytic solution secondary battery, a fluororesin is particularly preferable. When a fluororesin is applied, it is easy to maintain various performances such as rate characteristics and resistance characteristics (liquid resistance) of the non-aqueous electrolyte secondary battery due to acidic deterioration during operation of the non-aqueous electrolyte secondary battery. As the water-soluble polymer, water can be used as a solvent for forming the porous layer, so that it is more preferable from the viewpoint of process and environmental load, cellulose ether and sodium alginate are more preferable, and cellulose ether is particularly preferable.

Specific examples of the cellulose ether include carboxymethyl cellulose (CMC), hydroxyethyl cellulose (HEC), carboxyethyl cellulose, methyl cellulose, ethyl cellulose, cyanethyl cellulose, and oxyethyl cellulose, which are less likely to deteriorate after long-term use. CMC and HEC, which are excellent in chemical stability, are more preferable, and CMC is particularly preferable.

The heat-resistant layer more preferably contains a filler. Therefore, when the heat-resistant layer contains a filler, the resin has a function as a binder resin. The filler is not particularly limited, and may be a filler made of an organic substance or a filler made of an inorganic substance.

Specific examples of the filler made of an organic substance include homopolymers of monomers such as styrene, vinyl ketone, acrylonitrile, methyl methacrylate, ethyl methacrylate, glycidyl methacrylate, glycidyl acrylate, and methyl acrylate, or two or more kinds of fillers. Copolymer; Fluorine-containing resin such as polytetrafluoroethylene, tetrafluoroethylene-6 fluoride propylene copolymer, tetrafluoroethylene-ethylene copolymer, polyfluorinated vinylidene; melamine resin; urea resin; polyethylene; Examples thereof include fillers composed of polypropylene; polyacrylic acid, polymethacrylic acid; and the like.

Specific examples of the filler composed of an inorganic substance include calcium carbonate, talc, clay, kaolin, silica, hydrotalcite, diatomaceous soil, magnesium carbonate, barium carbonate, calcium sulfate, magnesium sulfate, barium sulfate, and aluminum hydroxide. Examples thereof include fillers made of inorganic substances such as boehmite, magnesium hydroxide, calcium oxide, magnesium oxide, titanium oxide, titanium nitride, alumina (aluminum oxide), aluminum nitride, mica, zeolite, and glass. Only one type of filler may be used, or two or more types may be used in combination.

Among the above fillers, fillers made of inorganic substances are preferable, and fillers made of inorganic oxides such as silica, calcium oxide, magnesium oxide, titanium oxide, alumina, mica, zeolite, aluminum hydroxide, and boehmite are more preferable. At least one filler selected from the group consisting of magnesium oxide, titanium oxide, aluminum hydroxide, boehmite and alumina is more preferred, with alumina being particularly preferred. Alumina has many crystalline forms such as α-alumina, β-alumina, γ-alumina, and θ-alumina, and any of them can be preferably used. Of these, α-alumina is most preferred because of its particularly high thermal and chemical stability.

The shape of the filler varies depending on the method for producing the organic or inorganic material as the raw material, the dispersion conditions of the filler when preparing the coating liquid for forming the heat-resistant layer, etc., and is spherical, oval, short, or gourd. The shape may be any shape, such as an irregular shape having no specific shape.

When the heat-resistant layer contains a filler, the content of the filler is preferably 1 to 99% by volume, more preferably 5 to 95% by volume of the heat-resistant layer. By setting the content of the filler in the above range, the voids formed by the contact between the fillers are less likely to be blocked by the resin or the like, sufficient ion permeability can be obtained, and per unit area. The basis weight can be set to an appropriate value.

As shown in FIG. 3B, the heat-resistant layer 4 assists the porous film 5 even if the lithium ion secondary battery 1 rapidly heats up and the porous film 5 melts or becomes flexible. Therefore, the shape of the porous film 5 is maintained. Therefore, the porous film 5 is melted or softened, and the pores P are only closed. As a result, the movement of the lithium ion 3 is stopped, so that the above-mentioned over-discharge or over-charge is also stopped. In this way, the destruction of the separator 12 is suppressed.

(Manufacturing process of separator / heat-resistant separator)
The production of the separator and the heat-resistant separator of the lithium ion secondary battery 1 is not particularly limited, and can be carried out by using a known method. Hereinafter, the case where the porous film 5 mainly contains polyethylene as its material will be described. However, even when the porous film 5 contains other materials, the separator 12 (heat-resistant separator) can be manufactured by the same manufacturing process.

For example, a method in which an inorganic filler or a plasticizer is added to a thermoplastic resin to form a film, and then the inorganic filler and the plasticizer are washed and removed with an appropriate solvent can be mentioned. For example, when the porous film 5 is a polyolefin separator formed of a polyethylene resin containing ultra-high molecular weight polyethylene, it can be produced by the method shown below.

In this method, (1) ultra-high molecular weight polyethylene is kneaded with an inorganic filler (for example, calcium carbonate, silica) or a plasticizer (for example, low molecular weight polyolefin, liquid paraffin) to obtain a polyethylene resin composition. Steps, (2) a rolling step of forming a film using a polyethylene resin composition, (3) a removing step of removing an inorganic filler or a plasticizer from the film obtained in step (2), and (4). The stretching step of stretching the film obtained in the step (3) to obtain a porous film 5 is included. The step (4) can also be performed between the steps (2) and (3).

The removal step provides a large number of micropores in the film. The fine pores of the film stretched by the stretching step become the above-mentioned pores P. As a result, a porous film 5 (separator 12 having no heat-resistant layer), which is a polyethylene microporous film having a certain thickness and air permeability, can be obtained.

In the kneading step, 100 parts by weight of ultra-high molecular weight polyethylene, 5 to 200 parts by weight of 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.

Then, in the coating process, the heat-resistant layer 4 is formed on the surface of the porous film 5. For example, an aramid / NMP (N-methyl-pyrrolidone) solution (coating liquid) is applied to the porous film 5 to form a heat-resistant layer 4 which is an aramid heat-resistant layer. The heat-resistant layer 4 may be provided on only one side of the porous film 5 or may be provided on both sides. Further, the heat-resistant layer 4 may be coated with a mixed solution containing a filler such as alumina / carboxymethyl cellulose.

Further, in the coating step, a polyvinylidene fluoride / dimethylacetamide solution (coating solution) is applied (coating step) on the surface of the porous film 5, and the porous film 5 is coagulated (coagulated step) to form the porous film 5. An adhesive layer can also be formed on the surface. The adhesive layer may be provided on only one side of the porous film 5 or may be provided on both sides.

The method of applying the coating liquid to the porous film 5 is not particularly limited as long as it can be uniformly wet-coated, and a conventionally known method can be adopted. For example, 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 and the like can be adopted. The thickness of the heat-resistant layer 4 can be controlled by the thickness of the coating wet film and the solid content concentration in the coating liquid.

As the support for fixing or transporting the porous film 5 at the time of coating, a resin film, a metal belt, a drum, or the like can be used.

As described above, the separator 12 (heat-resistant separator) in which the heat-resistant layer 4 is laminated on the porous film 5 can be manufactured. The manufactured separator is wound around a cylindrical core. The target manufactured by the above manufacturing method is not limited to the heat-resistant separator. This manufacturing method does not have to include a coating step. In this case, the object to be manufactured is a separator having no heat-resistant layer. Further, an adhesive separator having another functional layer (for example, an adhesive layer described later) instead of the heat-resistant layer may be manufactured by the same manufacturing method as the heat-resistant separator.

(Slit device)
The heat-resistant separator or the separator having no heat-resistant layer (hereinafter referred to as “separator”) preferably has a width suitable for an applied product such as the lithium ion secondary battery 1 (hereinafter referred to as “product width”). However, in order to increase productivity, the separator is manufactured so that its width is equal to or larger than the product width. Then, once manufactured, the separator is cut (slit) to the product width.

The "separator width" means the length of the separator in a direction substantially perpendicular to the longitudinal direction and the thickness direction of the separator. In the following, the wide separator before being slit is referred to as "original fabric", and the slit separator is particularly referred to as "slit separator". Further, the slit means to cut the separator along the longitudinal direction (the flow direction of the film in manufacturing, MD: Machine direction), and the cut means to cut the separator along the transverse direction (TD). Means to disconnect. The transverse direction (TD) means a direction substantially perpendicular to the longitudinal direction (MD) and the thickness direction of the separator.

FIG. 4 is a schematic view showing the configuration of a slit device 6 for slitting a separator. FIG. 4A shows the overall configuration, and FIG. 4B shows the configuration before and after slitting the original fabric. As shown in FIG. 4A, the slit device 6 includes a rotatably supported cylindrical winding roller 61, rollers 62 to 69, and a plurality of winding rollers 70U / 70L. .. The slit device 6 is further provided with a cutting device 7, which will be described later.

(Before the slit)
In the slit device 6, a cylindrical core c around which the original fabric is wound is fitted to the unwinding roller 61. As shown in FIG. 4B, the raw fabric is unwound from the core c into the path U or L. The unwound raw fabric is conveyed to the roller 68 via the rollers 63 to 67. In the process of being conveyed, the raw fabric is slit into a plurality of separators. The roller 67 may not be provided. At this time, the original fabric is conveyed from the roller 66 to the roller 68.

(After slit)
As shown in FIG. 4B, a part of the plurality of slit separators is wound around each cylindrical core u (bobbin) fitted in the winding roller 70U. Further, the other part of the plurality of slit separators is wound around each cylindrical core l (bobbin) fitted in the winding roller 70L, respectively. The one piece of the slit separator and the core u ・ l wound in a roll shape is referred to as a “winding body”.

(Cutting device)
FIG. 5 is a diagram showing a configuration of a cutting device 7 of the slit device 6 shown in FIG. 4A. FIG. 5A is a side view of the cutting device 7, and FIG. 5B is a front view of the cutting device 7. As shown in FIGS. 5A and 5B, 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 original fabric of the separator to be conveyed is fixed. The blade 72 slits the original fabric of the separator by a sharply sharpened edge.

[Embodiment]
The separator winding body to be assembled according to the embodiment of the present invention, and the cushioning material, the core material, and the protector to be assembled together will be described in order.

<Structure of separator winding body>
FIG. 6 is a diagram showing a configuration of a separator winding body 10 which is an assembly target of the embodiment of the present invention. FIG. 6A is a front view showing a state before the separator 12 is unwound from the core 8, and FIG. 6B is a side view of FIG. 6A. As shown in FIGS. 6A to 6B, the separator winding body 10 includes a core 8 in which the separator 12 is wound. The separator 12 is not a raw fabric, but a slit separator slit from the raw fabric as described above.

(core)
The core 8 includes an outer cylindrical portion 81, an inner cylindrical portion 82, and a plurality of ribs 83 (support members), and has the same functions as the above-mentioned cores u and l. The core 8 is provided with a shaft hole H centered on the central shaft CA of the core 8.

The outer cylindrical portion 81 is a cylindrical member for winding the separator 12 around the outer peripheral surface thereof. The inner cylindrical portion 82 is a cylindrical member arranged inside the outer cylindrical portion 81 and surrounding the shaft hole H. The rib 83 is eight support members that support between the outer cylindrical portion 81 and the inner cylindrical portion 82 and are spaced apart from each other. The core 8 is formed with a through hole h surrounded by an outer cylindrical portion 81, an inner cylindrical portion 82, and a rib 83.

The material of the core 8 contains ABS resin. However, the material of the core used in the embodiment of the present invention is not limited to this. In addition to ABS resin, the core material according to the embodiment of the present invention may contain resins such as polyethylene resin, polypropylene resin, polystyrene resin, and vinyl chloride resin. The core material is preferably not metal, paper or fluororesin. Since the paralator winding body 10 in which the separator 12 is wound around the core 8 is subjected to stress due to the winding of the separator 12, the core 8 is preferably provided with rigidity in order to suppress deformation of the core 8 due to the stress due to the winding. The core material according to the embodiment of the present invention is not limited to the above, and may be any material as long as it has such rigidity.

The length in the direction along the central axis CA of the core 8 is the width L _{1 of} the core 8, the outer diameter of the outer cylindrical portion 81 on the plane orthogonal to the central axis CA of the core 8 is the outer diameter of the core 8, and the center of the core 8. the inner diameter phi ₂ of the inner peripheral diameter (shaft hole diameter H) the core 8 of the inner cylindrical portion 82 in the plane perpendicular to the axis _CA, and respectively. Is. The core width L ₁ , outer diameter and inner diameter φ ₂ are not particularly limited. Further, the width L _{1 of the} core 8 included in the separator winding body 10 is defined as the width of the separator winding body 10.

(Separator)
The outer peripheral diameter of the wound a separator 12 in a plane perpendicular to the central axis CA of the separator wound body 10 and the outside diameter phi ₁ of the separator wound body 10. Outer diameter phi ₁ of the separator wound body 10 depends on the length of the outer diameter of the separator 12 of the core 8 is not particularly limited.

<Composition of cushioning material>
The plate-shaped member in the present invention can be a cushioning material.

FIG. 7 is a schematic view showing the configuration of the cushioning material (plate-shaped member) 160 according to the embodiment of the present invention. FIG. 7A is a front view, and FIG. 7B is a side view of FIG. 7A.

The cushioning material 160 is flexible, easily deformed by an external force, and has independence. For example, the cushioning material 160 is a porous body of a sponge-like resin such as urethane foam. The cushioning material 160 has, for example, a flat ring shape, and includes a shaft hole 162 centered on the central shaft 161 of the cushioning material 160. Outer diameter phi ₃ of the buffer material 160 central axis thickness _{L 2} of the cushioning material 160 direction of length along the 161, buffer material 160 central axis 161 cushioning material 160 to the outer peripheral diameter of the plane perpendicular to the the cushioning material to the inner diameter phi ₄ of the central axis 161 cushioning material 160 to the inner peripheral diameter (diameter of the shaft hole 162) in the plane perpendicular to, respectively. _{The thickness L 2} of the cushioning material 160, the outer diameter φ ₃ and the inner diameter φ ₄ are not particularly limited. In the present embodiment, for the sake of simplicity, the shape of the cushioning material 160 is a flat ring shape, but the shape of the cushioning material according to one aspect of the present invention is not limited to this. The shape of the cushioning material may be a shape having undulations or irregularities on the surface, or one or both of the inner peripheral shape and the outer peripheral shape of the cushioning material may be a shape other than circular, and the inner circumference of the cushioning material The center of and the center of the outer circumference may be different.

Since the cushioning material 160 is flexible, the assembled roll assembly absorbs the vibration and the impact of collision of the separator winding body 10 assembled together when the assembled roll assembly is changed in posture or transported. Thereby, the cushioning material 160 can protect the separator 12 wound around the separator winding body 10 from vibration and collision.

The above dimensions (thickness L ₂ , outer diameter φ ₃ , inner diameter φ ₄ of the cushioning material 160) are dimensions in a state where the cushioning material 160 is not deformed by an external force. Specifically, the dimensions are measured with the cushioning material 160 placed flat on a flat horizontal plane so that the central axis 161 is parallel to the direction of gravity. Further, in the present specification, unless otherwise specified, each dimension of each member is a dimension in a state where each member is not deformed by an external force.

_{The thickness L 2} of the cushioning material 160 is preferably a thickness that can absorb vibration during transportation so that the side surface of the separator winding body 10 can be protected. _{The thickness L 2} of the cushioning material 160 is preferably a thickness that can absorb the impact of collision due to vibration so that the side surface of the separator winding body 10 can be protected.

As can protect the entire side surface of the separator wound body 10, the outer diameter phi ₃ of the cushioning material 160 is preferably larger than the outer diameter phi ₁ of the separator wound body 10. Inner diameter phi ₄ of the cushioning material 160, to facilitate inserting the core member 150 to be described later to the buffer material 160 is preferably slightly larger than the outside diameter phi ₅ of the core 150.

<Core material>
8A and 8B are schematic views showing the configuration of the core material 150 according to the embodiment of the present invention, in which FIG. 8A is a front view and FIG. 8B is a side view of FIG. 8A.

The material of the core material 150 may be any material that can support the weight of the object through which it is inserted (the total weight of the separator winding body 10 inserted through the core material 150 and the cushioning material 160). The material of the core material 150 is, for example, a hard resin, but the material is not limited to this. The above-mentioned weight is, for example, the sum of the weights of the four separator winding bodies 10 and the five cushioning materials 160. The material of the core material 150 may include, for example, a resin such as ABS resin, polyethylene resin, polypropylene resin, polystyrene resin, and vinyl chloride resin, or may be paper.

The core material 150 is a cylindrical pipe, and includes a shaft hole 152 centered on the central shaft 151 of the core material 150. The length in the direction along the central axis 151 of the core material 150 is the length L _{3 of} the core material 150, and the outer diameter on the surface orthogonal to the central axis 151 of the core material 150 is the outer diameter φ _{5 of} the core material 150 and the core material. inner diameter phi ₆ of the inner circumferential diameter at the plane perpendicular to the central axis 151 (diameter of the shaft hole 152) core 150, respectively. _{The thickness L 3} of the core material 150, the outer diameter φ ₅ and the inner diameter φ ₆ are not particularly limited. In the present embodiment, the shape of the core material 150 is a cylindrical shape for the sake of simplicity, but the shape of the core material according to one aspect of the present invention is not limited to this. The shape of the core material may be a tubular shape with corners, or the inner peripheral shape and the outer peripheral shape of the core material may be different from each other. The outer peripheral shape of the core material is preferably a shape corresponding to the inner peripheral shape (shape of the shaft hole) of the inner cylindrical portion of the core used in the embodiment of the present invention.

The length L ₃ of the core member 150, when the core member 150 is inserted into the separator winding body 10 of the desired number and desired number of buffer material 160, a separator wound body 10 is inserted through the cushioning material 160 It is sufficient that the end of the core material 150 does not protrude from the core material 150. In other words, the length L ₃ of the core material 150 may be shorter than the sum of the total _{width L 1} of the separator winding body 10 to be inserted and the total thickness L _{2 of the cushioning material 160 to be inserted.} .. For example, when the four separator winding bodies 10 and the five cushioning materials 160 are alternately inserted into the core material 150, L ₃ <4L ₁ + 5L ₂ may be sufficient.

The core material 150 is inserted into the separator winding body 10 described above so as to penetrate the shaft hole H. Further, the core material 150 is inserted into the cushioning material 160 so as to penetrate the shaft hole 162. Therefore, the outer diameter φ ₅ of the core material 150 may be smaller than the diameter φ ₂ of the shaft hole H and the diameter φ _{4 of the shaft hole 162.} Further, conversely, so that the diameter phi ₂ than the outside diameter phi ₅ of the core material 150 is increased, may be provided a shaft hole H to the core 8, the diameter phi than the outside diameter phi ₅ of the core material 150 _A shaft hole 162 may be provided in the cushioning material 160 so that 4 becomes larger. Further, as inserted through a separator wound body 10 is stabilized, the outside diameter phi ₅ of the core material 150 is preferably close to the inside diameter phi ₂ of the core 8.

Inner diameter phi ₆ of the core material 150, if supporting the weight by the object to the core member 150 is inserted itself may be less. In order to reduce the weight, the core material 150 may be thinned or lightened.

The shaft hole 152 of the core material 150 comes into contact with the convex portion 142 of the protector 140, which will be described later. Therefore, the wall surface of the shaft hole 152 is formed smoothly so that wear debris is less likely to be generated even if they rub against each other.

<Protector>
The first side plate and the second side plate in the present invention can be protectors for protecting the separator winding body.

9A and 9B are schematic views showing the protectors (first side plate, second side plate) 140 of the embodiment of the present invention, (a) is a front view, and (b) is a rear view of (a). , (C) is a side view of (a).

The material of the protector 140 is a material capable of suspending the core material 150 that supports the above-mentioned weight (the total weight of the separator winding body 10 inserted through the core material 150 and the cushioning material 160) with two protectors 140. It suffices, for example, a hard resin. The material of the protector 140 may include, for example, a resin such as ABS resin, polyethylene resin, polypropylene resin, polystyrene resin, and vinyl chloride resin, or may be paper.

The protector 140 includes a convex portion (first convex portion, second convex portion) 142 on the inner side surface of the base portion (first base portion, second base portion) 141, and a plurality of foot portions 145 on the outer surface of the base portion 141. The outer edge portion of the base portion 141 is provided with a plurality of notch grooves (first engaging portion, second engaging portion) 143, and a shaft hole 146 centered on the central shaft 144 of the base portion 141.

(base)
The base portion 141 has a plate-like substantially octagonal shape. When the protector 140 is attached to the core material 150 of the base portion 141, the main surface on the side closer to the separator winding body 10 is the inner side surface, and the main surface on the side farther from the separator winding body 10 is the outer surface. is there. The distance between the opposite sides in a plane perpendicular to the central axis 144 of the base 141, the external dimensions phi ₇ of the base 141.

The shape of the base portion 141 is not limited to this, and may be a curved shape, an asymmetrical shape, or another substantially regular polygonal shape such as a substantially quadrangular shape or a substantially hexagonal shape.

The thickness of the base portion 141 may be such that the core material 150 that supports the above-mentioned load can be suspended, and the base portion 141 may be thinned or lightened in order to reduce the weight.

Outer dimensions phi ₇ of the base 141, a core 150 which separator 12 is inserted into the separator wound body 10 so as not to ground to allow the suspension, the outer dimensions phi ₇ of the base 141, the outer diameter of the separator wound body 10 It is preferably larger than φ _1. Also, as can be suspended a core 150 which separator 12 and the buffer material 160 has been inserted into the separator wound body 10 so as not to ground the cushioning material 160, outer dimensions phi ₇ of the base 141, the separator winding body 10 is preferably larger than the outer diameter phi ₃ of the outer diameter phi ₁ and the cushioning material 160.

(Convex part)
The convex portion 142 projects from the inner side surface of the base portion 141 with the central axis 144 of the base portion 141 as the center. The length from the inner side surface of the base portion 141 in the direction along the central axis 144 of the convex portion 142 is the height L ₄ (L ₅ ) of the convex portion 142, and the outer peripheral diameter on the plane orthogonal to the central axis 144 of the convex portion 142. outer diameter phi ₈ of the convex portions 142, and respectively.

_{The height L 4} of the convex portion 142 is such that when the core material 150 is inserted into the desired number of separator winding bodies 10 and the desired number of cushioning materials 160, even if the core material 150 is biased, the convex portion 142 It suffices if it can be fitted into the shaft hole 152 of the core material 150. Therefore, the height L ₄ of the convex portion 142 is the length of the core material 150 from the sum of the total _{width L 1} of the separator winding body 10 to be inserted and the total thickness L _{2 of the cushioning material 160 to be inserted.} it is larger than the value obtained by subtracting the L _{3. In other words, the sum of the length L 3} of the core material 150 and the height L ₄ of the convex portion 142 is the sum of the width L ₁ of the separator winding body 10 to be inserted and the thickness L of the cushioning material 160 to be inserted. _It should be larger than the sum of the sum of 2. For example, when the four separator winding bodies 10 and the five cushioning materials 160 are alternately inserted into the core material 150, L ₃ + L ₄ <4L ₁ + 5L ₂ may be sufficient.

Of course, in order to fit the protectors 140 to both ends of the core material 150, when the convex portion 142 is inserted into one end of the core material 150, another protector is attached to the other end opposite to one end of the core material 150. _{The height L 4} of the convex portion 142 needs to be smaller than _{the length L 3} of the core material 150 so that the convex portion 140 of the 142 can be inserted. Further, the inner surface of the protector 140 must be _{2L 4} <4L ₁ + 5L ₂ so that the inserted cushioning material 160 and the separator winding body 10 can be pressed. When the protector 140 is fitted only to one end of the core material 150, it does not have to protrude from the inserted cushioning material 160 and the parator winding body 10, so L ₄ <4L ₁ + 5L ₂ may be used.

Outer diameter phi ₈ of the convex portion 142, the protrusion 142 may be able to engage the core 150. Therefore, the outer diameter φ ₈ of the convex portion 142 may be the inner diameter φ ₆ or less of the core material 150. Note that, as the resistance between the shaft hole 152 of the protrusion 142 and the core material 150 of the protector 140 occurs, the outside diameter phi ₈ of the convex portion 142 is preferably close to the inside diameter phi ₆ of the core 150.

In the present embodiment, the convex portion 142 is formed of resin integrally with the base portion 141, but the present invention is not limited to this, and the convex portion 142 may be formed separately from the base portion 141 and assembled so as to be integrated with the base portion 141. Further, in the present embodiment, the convex portion 142 is one component having a cylindrical shape, but may be composed of a plurality of components. In the present embodiment, for the sake of simplicity, the shape of the convex portion 142 is a cylindrical shape. The shape of the convex portion of the protector according to one aspect of the present invention is not limited to this. The shape of the convex portion may be any shape that can be inserted into the shaft hole of the core material, and preferably has a shape corresponding to the shape of the shaft hole of the core material.

As described above, the convex portion 142 comes into contact with the shaft hole 152 of the core material 150. Therefore, the side surface of the convex portion 142 is formed smoothly so that wear debris is less likely to be generated even if they rub against each other.

(Foot)
A plurality of foot portions 145 are provided on the outer peripheral portion of the outer surface of the base portion 141. In the present embodiment, the foot portions 145 are provided at the center of the sides, every other eight sides of the base portion 141 having a substantially octagonal shape. Not limited to this, the foot portion 145 may be provided at the eight corners of the base portion 141 having a substantially octagonal shape, or may have another arrangement. In the present embodiment, the foot portion 145 is integrally formed of resin with the base portion 141, but the present invention is not limited to this, and the foot portion 145 may be formed separately from the base portion 141 and assembled so as to be integrated with the base portion 141.

(Notch groove)
The notch groove 143 is an engaging portion that engages the binding band with the protector 140 when the protectors 140 fitted to both ends of the core material 150 are bound by the binding band. Since the binding band is caught in the notch groove 143, the binding band and the protector 140 are engaged with each other, and the binding band is difficult to loosen after binding.

As opposed interval phi ₉ substantially notched groove 143 of the distance between the groove bottom of the octagonal notched groove 143 provided to each other in opposite sides of the base portion 141 of strapping the binding band does not contact the separator wound body 10 , so as to separate, opposing distance phi ₉ of notched groove 143 may be greater than the outer diameter phi ₁ of the separator wound body 10.

The notch groove 143 is also a guide portion that guides the binding band so that it is bound at an appropriate position. The notch groove 143 guides the binding band to an appropriate position for binding, so that the binding band is less likely to loosen after binding.

A plurality of notch grooves 143 are provided at the outer edge portion of the base portion 141. In the present embodiment, the notch grooves 143 are provided every other eight sides of the substantially octagonal base portion 141 so as to cut out the central portion of the side on the side where the foot portion 145 is not provided. There is. Not limited to this, the engaging portion for engaging the binding band with the protector 140 may be a groove provided in an X shape on the outer surface of the base portion 141, or may be a protrusion or the like.

<Assembly process>
An example of the assembly process according to the embodiment of the present invention will be described in order. Unless otherwise specified, in the description of the assembly process, "above" means above in the direction of gravity, and "below" means below in the direction of gravity.

FIG. 10 is a schematic view showing an example of an assembly process of the roll assembly (assembly) 180 according to the embodiment of the present invention.

First, as shown in FIG. 10A, the protector 140 is laid flat on a substantially flat substantially horizontal plane with the outer surface facing down. Therefore, the protector 140 stands on a substantially horizontal plane by the foot portion 145, and the convex portion 142 faces upward. Further, the central axis 144 (see FIG. 9) of the protector 140 is substantially vertical.

Next, as shown in FIG. 10B, the convex portion 142 of the protector 140 is inserted into the core material 150 (first insertion step), and the core material 150 is approximately the central axis 151 (see FIG. 8). Stand vertically. Specifically, one end of the core material 150 is directed downward, the other end opposite to one end is directed upward, the central axis of the core material 150 is substantially aligned with the central axis of the protector 140, and the convex portion of the protector 140 is provided. The 142 is inserted into the shaft hole 152 at one end of the core material 150. As a result, one end of the core material 150 is engaged with the protector 140.

At this time, in order to make the core material 150 stand up stably, it is preferable that the convex portion 142 is deeply inserted into the shaft hole 152. Therefore, the inner surface of the base portion 141 of the protector 140 is in contact with the end surface of the lower end (one end) of the core material 150. Further, in order to make the core material 150 stand up stably, it is preferable that the central axis 151 (see FIG. 8) of the core material 150 is substantially vertical.

Then, as shown in FIG. 10 (c), the core material 150 is inserted into the cushioning material 160 (insertion step). Specifically, the central axis of the cushioning material 160 is substantially aligned with the central axis of the core material 150 so that the core material 150 passes through the shaft hole of the cushioning material 160, and the lower end from the upper end (the other end) of the core material 150. The cushioning material 160 is moved along the direction of the central axis (insertion direction) to (one end). Next, the core material 150 is inserted into the separator winding body 10 (insertion step). Specifically, the central axis of the separator winding body 10 is substantially aligned with the central axis of the core material 150 so that the core material 150 passes through the shaft hole of the separator winding body 10, and the core material 150 is from the upper end to the lower end. , The separator winding body 10 is moved along the direction of the central axis (insertion direction). Similarly, as shown in FIG. 10D, the core material 150 is alternately inserted into the three cushioning materials 160 and the three separator winding bodies 10, and finally, one cushioning material 160 is inserted. The core material 150 is inserted.

At this time, since the core material 150 stands substantially vertically, the core material 150 can be smoothly inserted into the cushioning material 160 and the separator winding body 10 without resistance. Further, since the center of gravity is always on the substantially central axis of the core material 150, the center of gravity is stable, and the cushioning material 160 and the separator winding body 10 can be stably inserted. Further, since the core material 150 stands substantially vertically, the cushioning material 160, the core 8 of the separator winding body 10, and the protector 140 can be easily stacked without a gap by gravity.

Then, as shown in FIG. 10 (e), another protector 140 is placed flat on the uppermost cushioning material 160 with the outer surface facing upward, and the convex portion 142 is inserted into the core material 150. (Second insertion step). Specifically, the central axis of the protector 140 is substantially aligned with the central axis of the core material 150, and a part of the convex portion 142 of the protector 140 is inserted and engaged with the shaft hole 152 at the upper end of the core material 150.

At this time, the total _{width L 1} of the core 8 of the four inserted separator winding bodies 10 is _{4L 1 , the total thickness L 2} of the five inserted cushioning materials 160, and the total 5 L ₂ of the inserted core material. The length L _{3 of 150 and the height L 4} of the convex portion 142 of the protector 140 to be inserted satisfy the following inequality (Equation 1).

L ₄ > 4L ₁ + 5L _2- L ₃ (> 0) ……… (Equation 1)
Therefore, at least a part of the convex portion 142 can be always inserted into the shaft hole 152.

At this time, it is preferable that the end surface of the upper end of the core material 150 does not protrude above the cushioning material 160 at the uppermost stage. In other words, the inner surface of the lower side of the protector 140, such that the distance between the inner surface of the upper side protector 140 becomes the length L ₃ or more core material 150, the insertion convex portion 142 in the shaft hole 152 It is preferable to do so. More preferably, the distance between the inner surface of the lower side of the protector 140, the inner surface of the upper side protector 140 is greater than the length L ₃ of the core 150. The weight of the stacked cushioning material 160 and the separator winding body 10, the weight of the protector 140 inserted into the upper end of the core material 150, and the pressure of inserting the protector 140 into the upper end of the core material 150 act as external forces on the cushioning material 160. Join. Therefore, the following relationship (Equation 2) may be satisfied while the cushioning material 160 is deformed by an external force.

4L ₁ + L _{2, sum, deformed} ≧ L ₃ ……… (Equation 2)
The L _{2, sum, and deformed} are sandwiched between the inner peripheral portions of the cushioning material 160 in the deformed state (near the shaft hole 162, between the cores 8 or between the core 8 and the protector 140). It is the sum of the thicknesses (lengths in the direction along the central axis 161) of the portions).

Further, the number of separator winding bodies 10 inserted through the core material 150 is not limited to four, and the number of cushioning materials 160 inserted through the core material 150 is not limited to five. The number of the separator winding bodies 10 to be inserted is m (m: natural number), and the number of cushioning materials 160 to be inserted is n (n: natural number), and the inequality of the following (Equation 3) may be satisfied. Further, it is preferable that the relationship is n = m + 1, that is, one cushioning material is arranged between the protector 140 and the separator winding bodies 10 and between the separator winding bodies 10.

L ₄ > mL ₁ + nL _2- L ₃ (> 0) ……… (Equation 3)
Therefore, taking into consideration the number m of the separator winding body 10 to be inserted, the core width L _{1 of the} separator winding body 10 to be inserted, and the number n and the thickness L _{2 of the cushioning material 160 to be inserted.} , The length L ₃ of the core material and the height L ₄ of the convex portion may be determined.

In this way, the roll assembly 180 is formed by integrally assembling the two protectors 140, the one core material 150, and the five cushioning materials 160.

Then, the posture of the roll assembly 180 is changed from a standing posture in which the central axis of the core material 150 is vertical to a lying posture in which the central axis of the core material 150 is horizontal. Specifically, the orientation of the roll assembly is changed so that the central axes of the core material 150 are horizontal so that the two protectors 140 do not fall off from the core material 150.

In the roll assembly 180 in a lying position, the base 141 of either protector 140 can be separated without contacting the end face of the core 150. In the standing posture, the cushioning material 160 is crushed by the load of the separator winding body 10 above itself and the protector 140. On the other hand, in the lying posture, no external load is applied to the cushioning material 160. Therefore, the thickness of the cushioning material 160 is restored by letting it lie down. Then, since the protector 140 on the lower side is pushed by the cushioning material 160 to be restored and moves a little, the base portion 141 that was in contact with the end face of one end of the core material 150 is separated from the end face of one end of the core material 150. obtain.

Further, in the lying posture, only the outer edge portion of the protector 140 is in contact with the ground, and the core material 150 is suspended from both sides by the protector 140. Therefore, the cushioning material 160 and the separator winding body 10 are supported so as to float in the air by the inserted core material 150.

Then, as shown in FIG. 10 (f), the binding band (belt-shaped member) 170 is hung on the protector 140 in an X shape in one roll and fastened (winding step). The protectors 140 on both sides bind the roll assembly 180 by winding it with a binding band 170.

At this time, it is preferable to bind the core material 150 so that the distance between the inner side surfaces of the protectors 140 on both sides is L _{3 or more.} Furthermore, the distance between the inner surfaces of both sides of protector 140, to be greater than the length L ₃ of the core 150, it is preferable to unity. The tension of the binding band 170 transmitted via the protector 140 is applied to the cushioning material 160 as an external force. Therefore, the relationship (Equation 2) may be satisfied while the cushioning material 160 is deformed by an external force.
4L ₁ + L _{2, sum, deformed} ≧ L ₃ ……… (Equation 2)
As in the case of inserting the protector 140 into the upper end of the core material 150, L _{2, sum, and deformed} are the total thicknesses of the inner peripheral portions of the cushioning material 160 in the deformed state.

Further, the binding band 170 is engaged with the notch groove 143 of the protector 140 so that the binding band 170 does not come off from the roll assembly 180. Further, the binding band 170 is bound to the roll assembly 180 so that a gap is not formed between the separator winding body 10 and the cushioning material 160 or between the protector 140 and the cushioning material 160. In other words, the distance between the inner surfaces of the protectors 140 on both sides is the total width of the core 8 of the inserted separator winding body 10 (4L ₁ ) and the total thickness of the inserted cushioning material 160 (5L _2). ), The binding band 170 is bound so that the binding band 170 is not loosened.

Since the roll assembly 181 in which the roll assembly 180 is bound by the binding band 170 is bound, it is difficult to disassemble and is stable. Since the distance between the two protectors 140 is limited by the binding, the protector 140 does not fall off from the core material 150. Further, a gap is unlikely to occur between the protector 140 and the cushioning material 160 and between the core 8 of the separator winding body 10 and the cushioning material 160. Therefore, there is little room for the separator winding bodies 10 to move with respect to each other, and the separator winding bodies 10 are unlikely to collide with each other. Further, there is little room for the separator winding body 10 to move with respect to the protector 140, and the separator winding body 10 is unlikely to collide with the protector 140. Further, by cutting the binding band 170, the roll assembly 181 can be easily disassembled and the separator winding body 10 can be used.

In the present embodiment, a PP band made of polypropylene (PP) resin is used as the binding band 170, and the PP band is bound by heat adhesion. Not limited to this, other binding bands may be used, or other binding methods may be used. Further, the method of hanging the binding band 170 is not particularly limited.

<Structure of roll assembly>
The configuration of the roll assembly 180 assembled by the above-mentioned assembly step will be described in order. The structure of the roll assembly 181 in which the roll assembly 180 is bound by the binding band 170 is the same as that of the roll assembly 180 except for the binding band 170, and the binding by the binding band is a well-known technique, so the description thereof is omitted. To do.

(Axial direction)
11A and 11B are schematic views showing a cross-sectional configuration of the roll assembly 180 according to the embodiment of the present invention, in which FIG. 11A is a vertical sectional view and FIG. 11B is a cross-sectional view.

FIG. 11A shows a vertical cross section cut by a plane passing through the central axis of the core material 150.

In the roll assembly 180, the central axis of the core material 150 is substantially the same as the central axis of the separator winding body 10 and the core 8, the central axis of the cushioning material 160, and the central axis 144 of the protector 140. ..

The convex portion 142 of the protector 140 is inserted into the shaft hole 152 of the core material 150 so as to satisfy the inequality relationship of (Equation 1). Therefore, even when the core material 150 sways due to vibration during transportation or the like, the convex portions 142 of the protectors 140 on both sides are still inserted into the shaft holes 152 of the core material 150. Therefore, the core material 150 does not fall off from the protector 140.
L ₄ > 4L ₁ + 5L _2- L ₃ (> 0) ……… (Equation 1)
L ₄ > mL ₁ + nL _2- L ₃ (> 0) ……… (Equation 3)
More broadly speaking, when the number of separator winding bodies 10 to be inserted is m and the number of cushioning materials 160 to be inserted is n, if the inequality of (Equation 3) is satisfied, the protector The core material 150 does not fall off from 140. Further, it is preferable that the relationship is n = m + 1, that is, one cushioning material is arranged between the protector 140 and the separator winding bodies 10 and between the separator winding bodies 10. Of course, the inner surface of the protector 140 must be _{2L 4} <mL ₁ + nL ₂ so that the inserted cushioning material 160 and the separator winding body 10 can be pressed.

Further, when the outer diameter φ ₈ of the convex portion 142 is close to the inner diameter φ ₆ of the core material 150, the relative position does not change between the convex portion 142 of the protector 140 and the shaft hole 152 of the core material 150. Resistance is generated. The core material 150 will not fall off from the protector 140 unless a large force is applied to pull out the convex portion 142 from the core material 150 due to the resistance force. Therefore, it is easy to change or move the posture of the roll assembly in the middle of the assembly process. Since this resistance is weak, it is preferable that the roll assembly is bound like the roll assembly 181 when vibration is applied as in the case of transportation.

Further, (a) of FIG. 11 shows an ideal state in which the cushioning material 160 is not compressed, but in the actual roll assembly 180, the cushioning material 160 may be slightly compressed. When the cushioning material 160 is compressed, the restoring force that restores the shape of the compressed cushioning material 160 is the protector 140 and the core material so that the convex portion 142 of the protector 140 does not fall off from the shaft hole 152 of the core material 150. The resistance generated between 150 and 150 is balanced.

Further, in order to facilitate understanding of the inequality relationship of (Equation 1), (a) of FIG. 11 is shown as if the end face of the core material 150 is in contact with one protector 140, but the actual roll. In the assembly 180, as described above, both end faces of the core member 150 are generally separated from the protector 140.

The cushioning material 160 is sandwiched between the separator winding body 10 and the protector 140 and between the separator winding bodies 10. The cushioning material 160 absorbs the vibration of the separator winding body 10 and alleviates the vibration and the impact of the vibration. Further, even when the separator winding body 10 is tilted, the cushioning material 160 does not cause the separators 12 to directly collide with each other, and the impact of the collision is alleviated. In this way, the cushioning material 160 protects the separator 12 wound around the separator winding body 10.

There is no gap between the cushioning material 160, the core 8 of the separator winding body 10, and the protector 140. Therefore, there is little room for the separator winding body 10 to move between the protectors 140 on both sides. This prevents the separator winding bodies 10 from colliding with each other or with the protector 140.

(Diameter direction)
FIG. 11B shows a cross section taken along the line CC of FIG. 11A.

To protect the separator 12 are wound with the separator winding body 10, as shown, the outer dimension phi ₇ of the base portion 141 of the protector 140, the outside diameter phi ₃ of the cushioning material 160, Kai wound separator the outer diameter phi ₁ of the body 10, preferably satisfies the inequality relation of the following equation (4).
φ ₇ > φ ₃ > φ ₁ (> 0) ……… (Equation 4)
Further, when the notch groove 143 is provided on the outer edge portion of the protector 140, _{it is preferable that the facing interval φ 9} of the notch groove 143 further satisfies the following inequality (Equation 5).
φ ₇ ＞ φ ₉ ＞ φ ₃ ＞ φ ₁ (> 0) ………… (Equation 5)
As core material 150 passes through the shaft hole of the core 8, in order to inserting the core material into the separator winding body 10, as illustrated, the outer diameter φ5 of the core 150, the inner diameter phi ₂ of the core 8 And is preferably satisfied with the following relationship (Equation 6).
φ ₂ > φ ₅ (> 0) ……… (Equation 6)
Hereinafter, various modifications of the embodiment of the present invention will be described.

<Modification example 1>
_{The length L 3} of the core material 150 _{is the sum of the total width L 1} of the core 8 of the separator winding body to be inserted and the total thickness L ₂ of the cushioning material 160 to be inserted. It is preferable that the end faces of both ends of the 150 are close to each other as long as they are separated from each other without contacting the base 141 of the protector 140. When the core material 150 is long as described above, the inserted separator winding body 10 is likely to be stable. However, the core material 150 may be short.

Since the core material 150 is short, it becomes easy to assemble the roll assemblies 180 and 181 so that the end faces of both ends of the core material 150 are separated from the base portion 141 of the protector 140.
L _{1, sum} + L _{2, sum, deformed} > L ₃ (> 0) ……… (Equation 7)
In other words, the total width of each core 8 of the plurality of separator winding bodies 10 to be inserted is L _{1, sum,} and the total thickness of the inner peripheral portion of the cushioning material 160 to be inserted in the deformed state. L _{2, sum, deformed and the length L 3} of the core material 150 to be inserted easily satisfy the inequality of the above (Equation 7).

The shortness of the core material 150 is not particularly limited, but for example, the following inequality relationship (Equation 8) may be satisfied.
L _{1, sum} > L ₃ (> 0) ………… (Equation 8)
When the inequality of the equation (8) is satisfied, the inequality of the equation (7) is always satisfied. Specifically, four separator winding bodies 10 in which the separator 12 is wound around the core 8 _{having a width L 1} of 70 mm are inserted into the core material 150, and five cushioning materials 160 having a _{thickness L 2 of 1 mm are inserted into the core material 150.} When the core material 150 is used, the length L ₃ of the core material 150 may be 278 mm, which is shorter than 280 mm (4 × 70 mm).

<Modification 2>
The plate-shaped member in the present invention can also be a spacer.

Instead of the cushioning material 160, or in addition to the cushioning material 160, a spacer may be sandwiched between the separator winding body 10 and the protector 140 and / or between the separator winding bodies 10. When a spacer is used together with the cushioning material 160, the cushioning material 160 may be integrated with the spacer or may be a separate body.

The spacer is less likely to be deformed by an external force than the cushioning material 160. By sandwiching the spacer, the separator winding body 10 and the protector 140 or the separator winding bodies 10 are separated from each other. By separating the intervals in this way, for example, when the roll assembly 181 is transported, even if the separator winding body 10 is tilted with respect to the core material 150 due to vibration, the separator winding body 10 is wound around the separator winding body 10. It is possible to prevent the separator 12 from colliding with the protector 140 or another separator winding body 10. In particular, when the cushioning material 160 and the spacer are used at the same time, the cushioning material is inserted between the separator winding body 10 and the separator winding body 10, and the spacer is inserted between the protector 140 and the separator winding body 10 (roll assembly). It may be inserted into the end of the solid 180). By arranging a spacer that is not easily deformed by an external force at the end of the roll assembly 180 and arranging a cushioning material 160 that is easily deformed by an external force between the separator winding bodies 10, the spacer winding body 10 is wound around the separator winding body 10. The separated separator 12 can be protected from vibration and collision.

Of course, even when the spacer is sandwiched, the core material 150 may be short as in the above-mentioned modification 1.

<Modification example 3>
The cores 8 of the plurality of separator winding bodies 10 inserted through the core material 150 may have different widths from each other. Similarly, when a plurality of cushioning materials 160 are used, the plurality of cushioning materials 160 to be inserted may have different thicknesses from each other, and when a plurality of spacers are used, the plurality of spacers to be inserted have a thickness. They may be different from each other. When the cushioning material 160 and the spacer are used, the thickness of the cushioning material 160 and the thickness of the spacer may be different from each other.

In this case, the total width of each of the cores 8 of the plurality of separator winding bodies to be inserted is L _{1, sum,} and the total thickness of the cushioning material 160 to be inserted and the spacer is L _{2, sum} . It suffices if the following (Equation 9) inequality relationship is satisfied.
L ₄ > mL ₁ + nL _2- L ₃ (> 0) ……… (Equation 3)
L ₄ > L _{1, sum} + L _{2, sum} −L ₃ (> 0) ………… (Equation 9)
(Equation 9) is an equation in which mL ₁ and nL ₂ of (Equation 3) are replaced with _{L 1, sum} and L _{2, sum} , respectively.

In this case as well, it goes without saying that the core material 150 may be short as in the above-mentioned modification 1. Of course, the inner surface of the protector 140 must be _{2L 4} <L _{1, sum} + L _{2, sum} so that the inserted cushioning material 160, the separator winding body 10, and the spacer can be held down. is there.

<Modification example 4>
FIG. 12 is a schematic view showing a cross-sectional configuration of a modified example of the roll assembly 180 according to the embodiment of the present invention.

Neither the cushioning material 160 nor the spacer is an essential component in the assembly of the separator winding body 10. Therefore, if it is not necessary to protect the separator 12 wound around the separator winding body 10, as shown in FIG. 12, only the separator winding body 10 is attached to the core material 150 without sandwiching the cushioning material 160 or the spacer. May be inserted.

When only m separator winding bodies 10 are inserted through the core material 150, the following inequality relationship (Equation 10) may be satisfied.
L ₄ > mL ₁ + nL _2- L ₃ (> 0) ……… (Equation 3)
L ₄ > mL _1- L ₃ (> 0) ……… (Equation 10)
(Equation 10) is an equation in which n = 0 in (Equation 3).

Also in this case, if the inequality of the following (Equation 11) is satisfied, the width of the core 8 of the plurality of separator winding bodies 10 inserted through the core material 150 as in the above-described modification 3. Of course, may be different from each other.
L ₄ > L _{1, sum-} L ₃ (> 0) ………… (Equation 11)
Further, it goes without saying that the core material 150 may be short as in the above-mentioned modification 1. Of course, _{the inner surface of the protector 140 must be 2L 4} <L _{1, sum} so that the inserted cushioning material 160 can be held down.

<Modification 5>
In the roll assembly 181, a stretch film may be used instead of the binding band 170 that binds the roll assembly 180. Since the stretch film is thin, it can be easily torn by human hands without using scissors or other equipment. Therefore, the roll assembly can be easily disassembled, and the assembled separator winding body 10 can be easily taken out.

Further, since the stretch film has elasticity, when it is wound around the roll assembly 180, it deforms along the shape of the protector 140. Since the deformed stretch film is engaged with the protector 140, it is not necessary to provide the protector 140 with an engaging portion such as the notch groove 143.

Of course, in the above-mentioned modifications 1 to 4, a stretch film may be used instead of the binding band 170.

<Modification 6>
In the roll assembly 180, protectors 140 having the same shape are inserted at both ends of the core material 150, but protectors having different shapes may be used. For example, when the protector 140 is inserted into one end of the core material 150 _{and another protector having a convex portion having a height L 5} protruding from the base is inserted into the other end, (Equation 9) and the following (Equation 9) are inserted. In addition to the two inequality relations of ´), the inequality relation of the following (Equation 12) may be satisfied.

L ₄ > L _{1, sum} + L _{2, sum} −L ₃ (> 0) ………… (Equation 9)
L ₅ > L _{1, sum} + L _{2, sum} −L ₃ (> 0) ……… (Equation 9')
L ₄ + L ₅ <L _{1, sum} + L _{2, sum} ……… (Equation 12) (Equation 9 ′) is an equation in which L ₄ in (Equation 9) is replaced with _{L 5.} When the two inequality between (Equation 9) and (Equation 12) is satisfied, the height L ₅ of the convex portion of another protector is shorter than the length L _{3 of} the core material 150, so that one end of the core material 150 is used. The convex portion 142 of the protector 140 can always be inserted. Similarly, when the two inequality between (Equation 9') and (Equation 12) is satisfied, the height L _{4 of the convex portion 142 of the protector 140 is shorter than the length L 3} of the core material 150, so that the core material The convex portion of another protector can always be inserted into the other end of the 150.

<Effect>
According to the above configuration, the height L ₄ of the convex portion 142 of the protector 140 is the sum (L _{1, sum ) of the width L 1} of the core 8 of the separator winding body 10 inserted through the core material 150 and the core material. It is larger than the sum of the total _{thickness L 2} of the cushioning material 160 inserted through 150 _{(L 2, sum} ) minus the length L _{3 of the core material 150.} Therefore, even if the position of the core material 150 is biased inside the shaft hole between the inserted separator winding body 10 and the cushioning material 160, at least a part of the convex portion 142 is always the core material 150. It is inserted inside the shaft hole 152 of.

Therefore, in the assembly process, even if one protector 140 is inserted into one end of the core material 150 until the end face of the core material 150 contacts the base portion 141 of the protector 140, the other protector 140 is inserted into the other end of the core material 150. Can be inserted. Further, both protectors 140 are engaged with the core material 150 even if the position of the core material 150 is displaced when the posture of the roll assembly 180 is changed or the roll assembly 181 is transported.

As described above, since the core material 150 does not fall off from the protector 140, the roll assemblies 180 and 181 are structurally stable. Therefore, it is possible to prevent the separator winding bodies 10 from colliding with each other due to rattling vibration.

According to the above configuration, since the convex portion 142 of the protector 140 is inserted into one end of the core material 150 and the other end on the opposite side of one end, the protector 140 engages with both ends of the core material 150. Therefore, the core material 150 that supports the inserted separator winding body 10 can be suspended from both sides by the protector 140. By suspending in this way, a space can be provided on the outer periphery of the separator winding body 10, so that the wound separator 12 can be protected.

According to the above configuration, the separator winding body 10 and the cushioning material 160 are inserted into the core material 150 from the top to the bottom in the direction of gravity. Since the insertion direction is along the direction of gravity, the separator winding body 10 and the cushioning material 160 are easily stacked so that a gap is not formed between the core 8 of the separator winding body 10 and the cushioning material 160. be able to.

According to the above configuration, the length L ₃ of the core material 150 is the sum (L _{1, sum} ) _{of the width L 1} of the core 8 of the separator winding body 10 inserted through the core material 150 and the core material 150. It is smaller than the _{sum of the thickness L 2} of the cushioning material 160 and the sum (L _{2, sum).} Therefore, both end faces of the core material 150 can be separated from each other without contacting the inner side surface of the base portion 141 of the protector 140.

_{In order to separate them in this way, the total thickness (L 2, sum, deformed} ) of the cushioning material 160 inserted through the core material 150 deformed by an external force and the separator wound body inserted through the core material 150 It is necessary to assemble the roll assemblies 180 and 181 so that the _{sum of the width L 1} of the core 8 of 10 and the sum (L _{1, sum} ) is larger than the length of the core material 150 (L _3).

When a plurality of members rub against each other and are both formed of a hard material, wear debris is likely to be generated from the contact surface of each member. Therefore, since both the core material 150 and the protector 140 are formed of a hard material, it is preferable that there are few surfaces that rub against each other, and the end surface of the core material 150 and the inner surface of the base 141 of the protector 140 are separated from each other. It is preferable to have.

Further, the core material 150 is often obtained by cutting the long pipe-like material to a length L _3. When the end surface of the core material 150 is a cut surface in this way, the cut surface is rough and the core material 150 is hard, so that the end surface of the core material 150 rubs against other hard surfaces, so that the core material 150 Wear debris is particularly likely to be generated from the end face of the. Further, since the end surface of the core material 150 damages the other hard surfaces that rub against each other, wear debris is likely to be generated from the other surfaces that rub against each other. Therefore, it is particularly preferable that both end faces of the core material 150 do not come into contact with the base portion 141 of the protector 140.

By not making contact, the end face of the core material 150 does not rub against the protector 140, so that wear debris is less likely to be generated. Invasion of dust is fatal in the battery manufacturing process. Therefore, it is extremely important for the separator 12, which is a battery member, that dust is less likely to be generated from the roll assemblies 180 and 181. Therefore, the above-described configuration in which wear debris that becomes dust is less likely to be generated is suitable for assembling, storing, and transporting the separator winding body 10.

According to the above configuration, as shown in FIG. 11, the protector 140 is inserted into the core material 150 so that the convex portion 142 of the protector 140 is inserted into the shaft hole 152 of the core material 150. Therefore, the wall surface of the shaft hole 152 of the core material 150 comes into contact with the side surface of the convex portion 142. However, since the wall surface of the shaft hole 152 of the core material 150 and the side surface of the convex portion 142 are smooth, dust is unlikely to be generated even if they rub against each other.

According to the above configuration, as shown in FIG. 11A, the cushioning material 160 comes into contact with the base 141 of the protector 140. However, since the cushioning material 160 is not hard, wear debris is unlikely to be generated even if the cushioning material 160 and the protector 140 rub against each other. Invasion of dust is fatal in the battery manufacturing process. Therefore, it is extremely important for the separator 12, which is a battery member, that wear debris is less likely to be generated from the roll assemblies 180 and 181. Therefore, the above-described configuration, which is less likely to generate abrasion debris as dust, is suitable for assembling, storing, and transporting the separator winding body 10.

According to the above configuration, the separator winding body 10 and the cushioning material 160 are alternately inserted into the core material 150. By alternately inserting the cushioning materials 160, one cushioning material 160 is always sandwiched between the separator winding bodies 10. The minimum number of cushioning materials 160 can alleviate or prevent collisions between the separator winding bodies 10. Similarly, when a spacer is used, it is preferable that the separator winding body 10 and the spacer are alternately inserted into the core material 150.

According to the above configuration, in the step of inserting the separator winding body 10 and the cushioning material 160 into the core material 150, the cushioning material 160 is inserted into the core material 150 at the beginning and the end. Therefore, the cushioning material 160 is always sandwiched between the protector 140 and the separator winding body. The sandwiched cushioning material 160 can alleviate or prevent the separator winding body 10 from colliding with the protector 140. Similarly, when a spacer is used, it is preferable that the spacer is inserted through the core material 150 at the beginning and the end.

According to the above configuration, the protector 140 that engages with one end of the core material 150 is the same as the protector 140 that engages with the other end of the core material 150. Therefore, the number of members constituting the roll assemblies 180 and 181 can be suppressed, and the inventory cost can be suppressed. Further, when the roll assemblies 180 and 181 are disassembled, they may be removed from either of the two protectors 140, so that the roll assemblies 180 and 181 can be easily disassembled.

The present invention is not limited to the above-described embodiments, and various modifications can be made within the scope of the claims, and the embodiments obtained by appropriately combining the technical means disclosed in the different embodiments. Is also included in the technical scope of the present invention.

The present invention can be used for assembling a wound body in which a film is wound around a core.

1 Lithium-ion secondary battery 2 External equipment 3 Lithium-ion 4 Heat-resistant layer 5 Porous film 6 Slit device 7 Cutting device 8, c, u ・ l core 10 Separator winding body (winding body)
11 Cathode 12 Separator (film, battery separator)
13 Anode 61 Unwinding Roller 62, 63, 66, 67, 68, 69 Roller 70L, 70U, 70U / 70L Winding Roller 71 Holder 72 Blade 81 Outer Cylindrical Part 82 Inner Cylindrical Part CA Central Shaft H Shaft Hole 83 Rib 140 Protector (1st side plate, 2nd side plate)
141 base (1st base, 2nd base)
142 Convex part (1st convex part, 2nd convex part)
143 Notch groove (engagement part)
144 Central shaft 145 Foot 146 Shaft hole 150 Core material 151 Central shaft 152 Shaft hole 160 Cushioning material (plate-shaped member)
161 Central shaft 162 Shaft hole 170 Cable tie (belt-shaped member)
180 roll assembly (assembly)
181 roll assembly (assembly)
A, B direction U, L path P hole h Through hole

Claims (14)

One of the same or different pair of side plates and the first side plate, the length of the first convex portion protruding from among plate-shaped first base portion of said first side plate and L _4, wound by winding the film on the core Assuming that the length of the core material in the insertion direction when the core material is inserted into the rotating body and the plate-shaped member is L ₃ , _{the first convex portion having L 3} > L ₄ is attached to one end of the core material. The first insertion process to insert and
Assuming that the total length of one or more winding bodies in the insertion direction is L _{1, sum} and the total length of one or more plate-shaped members is L _{2, sum} , L ₃ + L ₄ An insertion step of inserting the core material into one or more of the wound bodies and one or more of the plate-shaped members so that> L _{1, sum} + L _{2, sum} > L ₃ .
Assuming that the other side of the pair of side plates is the second side plate and the length of the second convex portion protruding from the plate-shaped second base portion of the second side plate is L ₅ , L _{1, sum} + L _{2, sum} − A second insertion step of inserting the second convex portion into the other end of the core material opposite to the one end so that _{L 4} > L ₅ > L _{1, sum} + L _{2, sum} −L ₃ Manufacturing method of the assembly including. The method for manufacturing an assembly according to claim 1 , wherein in the insertion step, the core material is inserted alternately between the wound body and the plate-shaped member. There are a plurality of the plate-shaped members,
The method for manufacturing an assembly according to claim 1 or 2 , wherein in the insertion step, the core material is inserted into the plate-shaped member at the beginning and the end. The method for manufacturing an assembly according to any one of claims 1 to 3 , wherein at least one of the plate-shaped members is a spacer that is not deformed by an external force. At least one of the plate-shaped members is a cushioning material that is deformed by an external force.
The method for manufacturing an assembly according to any one of claims 1 to 4 , wherein L _{2 and sum} are the total lengths of the cushioning materials in a state where they are not deformed by an external force. Assuming that the total length of the plate-shaped members in which the cushioning material is deformed by an external force in the insertion direction is L _{2, sum, deformed} .
The assembly according to claim 5 , wherein the second convex portion is inserted into the other end of the core material so that _{L 1, sum} + L _{2, sum, deformed} ≥ L ₃ in the second insertion step. Production method. The method for manufacturing an assembly according to any one of claims 1 to 6 , wherein in the insertion step, the insertion direction is the direction of gravity. Claims 1 to 7 including a winding step of winding the first side plate and the second side plate with each other with a band-shaped member after the first insertion step, the insertion step, and the second insertion step. The method for manufacturing an assembly according to any one of the above items. After the first insertion step, the insertion step, and the second insertion step, the first side plate and the second side plate are L _{1, sum} + L _{2, sum, deformed} ≧ L ₃ , respectively. The method for manufacturing an assembly according to claim 6 , further comprising a winding step of winding with a strip-shaped member. The assembly according to claim 8 or 9 , wherein in the winding step, the strip-shaped member is engaged with a first engaging portion included in the first side plate and a second engaging portion included in the second side plate. Manufacturing method. The method for manufacturing an assembly according to claim 8 or 9 , wherein the strip-shaped member is a stretch film. The method for manufacturing an assembly according to any one of claims 1 to 11, wherein the wound body is a plurality. The method for manufacturing an assembly according to any one of claims 1 to 12 , wherein the film is a battery separator. One of the same or different pair of side plates and the first side plate, the length of the first convex portion protruding from among plate-shaped first base portion of said first side plate and L _4, wound by winding the film on the core Assuming that the length of the core material in the insertion direction when the core material is inserted into the rotating body and the plate-shaped member is L ₃ , _{the first convex portion where L 3} > L ₄ is formed at one end of the core material. Has been inserted and
Assuming that the total length of one or more winding bodies in the insertion direction is L _{1, sum} and the total length of one or more plate-shaped members is L _{2, sum} , L ₃ + L ₄ The core material is inserted through the one or more winding bodies and the one or more plate-shaped members so that> L _{1, sum} + L _{2, sum} > L ₃ .
Assuming that the other side of the pair of side plates is the second side plate and the length of the second convex portion of the second side plate protruding from the plate-shaped second base is L ₅ , L _{1, sum} + L _{2, sum} − An assembly in which the second convex portion is inserted into the other end of the core material opposite to the one end so that L ₄ > L ₅ > L _{1, sum} + L _{2, sum} −L _3.

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