JP6848876B2 - Electrode sheet manufacturing equipment and electrode sheet manufacturing method - Google Patents

Description

The present invention relates to an electrode sheet manufacturing apparatus and a method for manufacturing an electrode sheet.

Japanese Unexamined Patent Publication No. 2015-72834 discloses a cutting device for electrodes. This electrode cutting device has a laser at a predetermined position, and is configured to cut out the electrode sheet from the coating sheet with the laser. The coating sheet is based on a strip-shaped metal foil, and the metal foil has an active material coated region and a non-coated region. The coated area and the uncoated area are alternately provided in the longitudinal direction of the metal foil and extend in the width direction of the metal foil, respectively.

The electrode cutting device has a pair of transport means. Both transport means have an area corresponding to each coating area of the coating sheet. Both transporting means can transport the coating sheet in the transport direction along the longitudinal direction thereof while sucking each coating area individually, and the arrangement order of the transport directions can be freely exchanged with each other. Both transporting means move in turn from the initial position where suction and transport of each coating area are started to the collection position where the electrode sheet after cutting is collected, and transport the coating sheet. The laser is installed at a cutting position between the initial position and the recovery position.

Both transport means temporarily stop the transport of the coated sheet at the timing when each non-coated region of the coated sheet reaches the cutting position. In this transport stopped state, the laser cuts the uncoated area at the cutting position over the width direction and cuts out the electrode sheet from the coated sheet.

In Japanese Patent Application Laid-Open No. 2015-72834, when the electrode sheet is cut out from the coating sheet, the transportation of the coating sheet is temporarily stopped. Therefore, a time loss occurs in the transportation of the coating sheet.

Conventionally, it has been required to continuously cut out an electrode sheet from the coating sheet without stopping the transportation of the coating sheet.

In order to solve the above problems, the present invention takes the following means.

According to one feature of the present invention, the electrode sheet manufacturing apparatus uses a laser to cut out an electrode sheet from a coating sheet in which a coating layer is formed on a strip-shaped metal foil. The coating sheet is provided adjacent to the coating area, which is a region in which the coating layer is continuously formed in the longitudinal direction of the metal foil, and the coating region in the width direction of the metal foil, and is made of metal. It has a non-painted region which is a region continuous in the longitudinal direction in a state where the foil is exposed. The electrode sheet has a rectangular current collecting portion and a tab portion having a shape protruding from the tab forming side, which is one side of the current collecting portion, without the back side active material layer being formed. The electrode sheet manufacturing apparatus is arranged so as to face the non-coated region, and the upstream transport device that transports the non-coated region in the transport direction along the longitudinal direction and the non-painted transport device toward the upstream transport device. The upstream suction device that sucks the area and the upstream suction device are arranged so as to face the coating area and are arranged on the downstream side in the transport direction with respect to the upstream transport device, and transport the coating area in the transport direction. The downstream transport device, the downstream suction device that sucks the coating area toward the downstream transport device, the space adjacent to the upstream transport device in the width direction, and the downstream transport device. A laser device that irradiates a coating sheet with a laser along a virtual contour that is a contour of an electrode sheet virtually set on the coating sheet in the upstream laser space, which is a space in series in the transport direction. In the downstream laser space, which is a space adjacent to the downstream transport device in the width direction and in series with the upstream transport device in the transport direction, a virtual on the coating sheet. It has a laser device that irradiates a coating sheet with a laser along the remaining virtual contour excluding a portion of the virtual contour that is the contour and the laser device irradiates the laser in the upstream laser space.

In the above configuration, an upstream laser space serving as a passing space for the coated area is provided at a position adjacent to the upstream transport device for transporting the non-coated area in the width direction of the coating sheet. Further, a downstream laser space serving as a passing space for the non-painted region is provided at a position adjacent to the downstream transport device for transporting the coated region in the width direction of the coating sheet. Therefore, by first cutting the coated area in the upstream laser space and then cutting the non-coated area in the downstream laser space, the coated area is continuously formed in the longitudinal direction. In the coating sheet, the electrode sheet can be continuously cut out from the coating sheet without stopping the transportation of the coating sheet.

According to another feature, the front surface of the coating sheet is a region in which the front coating layer as the coating layer is continuously formed in the longitudinal direction with respect to the front coating region and the front coating region. It has a front side non-painted region which is a region which is provided adjacent to each other in the width direction and is continuous in the longitudinal direction in a state where the metal foil is exposed. The back surface of the coating sheet is a region facing the front coating region with the metal foil sandwiched between them, and is a region in which the back coating layer as a coating layer is formed. It has a back side non-painted region which is a region facing the front side non-painted region and which is a region which is continuous in the longitudinal direction in a state where the metal foil is exposed. The rectangular current collecting portion has a tab forming side, a tab facing side which is a side facing the tab forming side, and a tab parallel side which is two sides excluding the tab forming side and the tab facing side. The front side coating area and the back side coating area have a width corresponding to at least the length of the tab parallel sides. The front side non-painted area and the back side non-painted area have a width corresponding to at least the length of the tab portion in the protruding direction. The upstream-side transport device has a width equal to or less than the width of the back-side non-painted region, is arranged so as to face the back-side non-coating region, and transports the back-side non-coating region in the transport direction. The upstream suction device sucks the backside unpainted area toward the upstream transfer device. The downstream side transport device has a width equal to or less than the width of the back side coating area, is arranged so as to face the back side coating area, and conveys the back side coating area in the transport direction. The downstream suction device sucks the back coating area toward the downstream transfer device.

In the above configuration, the backside unpainted area is sucked toward the upstream side transport device by the upstream side suction device. Therefore, the transport of the backside non-coated area by the upstream transport device is stable. Further, the back side coating area is sucked toward the downstream side transport device by the downstream side suction device. Therefore, the transfer of the back coating area by the downstream transfer device is stable.

According to other features, the front coating layer is formed by a front active material layer and a front insulating material layer that covers the front active material layer, or is formed only by the front active material layer, or , Formed only by the front insulating material layer. The back coating layer is formed by a back active material layer and a back insulating material layer covering the back active material layer, or is formed only by the back active material layer, or only the back insulating material layer. Is formed by.

In the above configuration, for example, when the front side active material layer is covered with the front side insulating material layer, the polarity is ensured on the front side of the electrode sheet and the insulating property is ensured on the front side. Similarly, when the back side active material layer is covered with the back side insulating material layer, the polarity is ensured on the back side of the electrode sheet and the insulating property is ensured on the back side.

According to another feature, the intensity of the laser irradiated in the upstream laser space is set to the coating layer cutting intensity capable of cutting the front coating layer, the metal leaf and the back coating layer, and the downstream laser. The intensity of the laser irradiated in the space is set to a metal leaf cutting intensity that is smaller than the coating layer cutting intensity and is capable of cutting the metal leaf.

In the above configuration, in the upstream laser space, the front coating layer, the metal leaf, and the back coating layer of the front coating region and the back coating region passing through the upstream laser space can be cut, and the downstream side can be cut. In the laser space, the metal leaf of the front side non-coated area and the back side non-coated area passing through the downstream laser space can be cut.

According to another feature, the laser apparatus irradiates the laser at a position corresponding to the tab facing side and the tab parallel side at least in the virtual contour in the upstream laser space. Further, the laser device irradiates a laser at a position corresponding to a tab portion in at least a virtual contour in the downstream laser space.

In the above configuration, in the upstream laser space, the tab facing side and both side sides can be cut out on the front side coating area and the back side coating area passing through the upstream side laser space, and the downstream side laser space can be cut out. The tab portion can be cut out on the front side non-painted area and the back side non-painted area passing through the downstream laser space.

According to other features, the laser device is an upstream laser device that irradiates an upstream laser, which is a laser, toward a virtual contour in the upstream laser space, and a laser toward a virtual contour in the downstream laser space. It is composed of a downstream laser device that irradiates a downstream laser.

In the above configuration, since laser devices are individually provided corresponding to each laser space, the type and intensity of the laser (for example, continuous wave or pulse wave) are passed through each laser space. It can be set individually according to the type of area.

According to another feature, the front side uncoated area has a first front side uncoated area and a second front side uncoated area on both sides of the front side coated area in the width direction of the metal foil. The first front-side non-coated area is a region adjacent to the front-side coated area and continuous in the longitudinal direction with respect to the inner first front-side non-coated area and the inner first front-side non-coated area. It has an outer first front side non-painted region which is a region continuous in the longitudinal direction on the side opposite to the front side coated region in the width direction. The second front-side non-coated area is a region adjacent to the front-side coated area and continuous in the longitudinal direction with respect to the inner second front-side non-coated area and the inner second front-side non-coated area. It has an outer second front side non-painted region which is a region continuous in the longitudinal direction on the side opposite to the front side coated region in the width direction. The back side non-coated area has a first back side non-coated area and a second back side non-coated area on both sides of the back side coated area in the width direction of the metal foil. The first backside non-coated area is a region adjacent to the backside coated area and continuous in the longitudinal direction with respect to the inner first backside non-coated area and the inner first backside non-coated area. It has an outer first backside non-painted region which is a region continuous in the longitudinal direction on the side opposite to the backside coated region in the width direction. The second backside non-coated area is a region adjacent to the backside coated area and continuous in the longitudinal direction with respect to the inner second backside non-coated area and the inner second backside non-coated area. It has an outer second backside non-painted region which is a region continuous in the longitudinal direction on the side opposite to the backside coated region in the width direction. The upstream transport device has a width equal to or less than the width of the first backside non-coated region, is arranged so as to face the first backside non-coated region, and has the first backside non-coated region in the transport direction. The first upstream transport device to be transported has a width equal to or less than the width of the second backside non-coated area, and is in contact with the second back non-coated region so as to face and parallel to the first upstream transport device. It is composed of a second upstream side transport device which is arranged in the above and transports the second backside uncoated area in the transport direction along the longitudinal direction. The upstream suction device includes a first upstream suction device that sucks the first backside unpainted area toward the first upstream transfer device and a second backside unpainted area toward the second upstream transfer device. It is composed of a second upstream suction device for suction. Further, the electrode sheet manufacturing apparatus has a width equal to or less than the width of the outer first backside non-coated region, and is arranged so as to face the outer first backside non-coated region and to be in parallel with the downstream transfer apparatus. The first auxiliary downstream transport device that transports the outer first backside non-coated area in the transport direction, and the outer second backside non-coated region having a width equal to or less than the width of the outer second backside non-coated region and the outer second backside non-coated region. It has a second auxiliary downstream side transporting device which is arranged so as to face each other and in parallel with the downstream side transporting device and transports the outer second backside uncoated area in the transporting direction. Further, the electrode sheet manufacturing apparatus includes a first auxiliary downstream suction device that sucks the outer first backside unpainted area toward the first auxiliary downstream transport device, and an outer first auxiliary downstream suction device toward the second auxiliary downstream transport device. It has a second auxiliary downstream suction device that sucks the backside unpainted area. The upstream laser space is a space sandwiched between the first upstream transport device and the second upstream transport device, and is a space close to the first upstream transport device, and is a first upstream laser space and a first space. It has a second upstream laser space, which is a space sandwiched between the first upstream transport device and the second upstream transport device and is a space close to the second upstream transport device. The downstream laser space is sandwiched between the first downstream laser space, which is a space sandwiched between the downstream transport device and the first auxiliary downstream transport device, and the downstream transport device and the second auxiliary downstream transport device. It has a second downstream laser space, which is a space. The upstream side laser device is an electrode virtually set from the center in the width direction to the side of the first front side non-painted region on the coating sheet in the first upstream side laser space and the second upstream side laser space. The first virtual contour, which is the contour of the sheet, and the second virtual contour, which is the contour of the electrode sheet virtually set from the center in the width direction to the side of the second front side non-painted area on the coated sheet, Along the way, the upstream laser is applied to the coating sheet supported by the first upstream transfer device and the second upstream transfer device. The downstream laser apparatus is the remaining first virtual contour on the coating sheet in the first downstream laser space, excluding the portion of the first virtual contour irradiated with the upstream laser. Along the way, the downstream laser is applied to the coating sheet supported by the downstream transfer device and the first auxiliary downstream transfer device. Further, the downstream laser device is the remaining second virtual contour excluding the portion of the second virtual contour on the coating sheet and irradiated with the upstream laser in the second downstream laser space. Along the contour, the downstream laser is applied to the coating sheet supported by the downstream transfer device and the second auxiliary downstream transfer device.

According to the above configuration, when the upstream laser is irradiated toward both upstream laser spaces, both sides of the coating sheet are supported by the first upstream transport device and the second upstream transport device. There is. Further, when the downstream laser is irradiated toward the first downstream laser space, both sides of the coating sheet are supported by the downstream transport device and the first auxiliary downstream transport device. Further, when the downstream laser is irradiated toward the second downstream laser space, both sides of the coating sheet are supported by the downstream transfer device and the second auxiliary downstream transfer device. Therefore, the coating sheet is irradiated with the laser in a stable position. Therefore, it is possible to prevent the laser irradiation position from deviating from the virtual contour on the coating sheet.

According to another feature, the coating sheet is transported at a predetermined transport height by the upstream transport device and the downstream transport device. Then, the electrode sheet manufacturing apparatus is located at a position adjacent to the downstream transport device in the width direction and in series with the inner first backside non-coated region in the transport direction, in the transport direction. Along there is a first guide member having an inclined surface that goes from a position lower than the transport height to a position close to the transport height. Further, the electrode sheet manufacturing apparatus is located at a position adjacent to the downstream transport device in the width direction and in series with the inner second backside non-coated region in the transport direction, in the transport direction. Along there is a second guide member having an inclined surface that goes from a position lower than the transport height to a position close to the transport height.

In the above configuration, the inclined surfaces of both guide members scoop up the cut out tab portion from the hanging state and guide it to a position close to the transport height. Therefore, it is possible to prevent the tab portion that has been cut out from being torn due to a burden on the tab portion.

According to one feature of the present invention, in the method for manufacturing an electrode sheet, an electrode sheet is cut out from a coating sheet in which a coating layer is formed on a strip-shaped metal foil by using a laser. The coating sheet is provided adjacent to the coating area, which is a region in which the coating layer is continuously formed in the longitudinal direction of the metal foil, and the coating region in the width direction of the metal foil, and is made of metal. It has a non-painted region which is a region continuous in the longitudinal direction in a state where the foil is exposed. The electrode sheet has a rectangular current collecting portion and a tab portion having a shape protruding from a tab forming side which is one side of the current collecting portion. The method for manufacturing the electrode sheet is that when the contour of the electrode sheet defines a virtual contour that is virtually set on the coated sheet, the coated sheet is conveyed along the longitudinal direction while supporting the non-coated area. A coating area cutting process in which a portion of the virtual contour in the coating area adjacent to the supporting non-coating area is cut out by a laser while being conveyed in the direction, and a coating area is supported and coated. It has a non-coated area cutting step in which a portion of a virtual contour in a non-coated area adjacent to a supported coated area is cut out by a laser while the sheet is conveyed in the conveying direction.

In the above configuration, when the non-coated area is supported, the laser is irradiated toward the coated area adjacent to the non-coated area, and the coated area is supported. The laser is radiated toward the unpainted area adjacent to. Therefore, each region of the coating sheet is irradiated with the laser in a stable position. Therefore, it is possible to prevent the laser irradiation position from deviating from the virtual contour on the coating sheet.

According to another feature, the front surface of the coating sheet is a region in which the front coating layer as the coating layer is continuously formed in the longitudinal direction with respect to the front coating region and the front coating region. It has a front side non-painted region which is a region which is provided adjacent to each other in the width direction and is continuous in the longitudinal direction in a state where the metal foil is exposed. The back surface of the coating sheet is a region facing the front coating region with the metal foil sandwiched between them, and is a region in which the back coating layer as a coating layer is formed. It has a back side non-painted region which is a region facing the front side non-painted region and which is a region which is continuous in the longitudinal direction in a state where the metal foil is exposed. The rectangular current collecting portion has a tab forming side, a tab facing side which is a side facing the tab forming side, and a tab parallel side which is two sides excluding the tab forming side and the tab facing side. The front side coating area and the back side coating area have a width corresponding to at least the length of the tab parallel sides. The front side non-painted area and the back side non-painted area have a width corresponding to at least the length of the tab portion in the protruding direction. In the coating area cutting step, while supporting the backside non-coating area and transporting the coating sheet in the transport direction, the virtual contour in the backside coating area adjacent to the supporting backside non-coating area. In the non-coating area cutting step, the portion is adjacent to the supporting backside coating area while supporting the backside coating area and transporting the coating sheet in the transport direction. The part of the virtual contour in the backside unpainted area is cut out with a laser.

In the above configuration, in the state where the back side non-painted area is supported, the laser is irradiated toward the back side coated area adjacent to the back side non-painted area and the front side coated area facing the back side coated area. In a state where the back side coating area is supported, the laser is irradiated toward the back side non-coating area adjacent to the back side coating area and the front side non-coating area facing the back side non-coating area. Therefore, each region of the coating sheet is irradiated with the laser in a stable position. Therefore, it is possible to prevent the laser irradiation position from deviating from the virtual contour on the coating sheet.

According to other features, the front coating layer is formed by a front active material layer and a front insulating material layer that covers the front active material layer, or is formed only by the front active material layer, or , Formed only by the front insulating material layer. The back coating layer is formed by a back active material layer and a back insulating material layer covering the back active material layer, or is formed only by the back active material layer, or only the back insulating material layer. Is formed by.

In the above configuration, for example, when the front side active material layer is covered with the front side insulating material layer, the polarity is ensured on the front side of the electrode sheet and the insulating property is ensured on the front side. Similarly, when the back side active material layer is covered with the back side insulating material layer, the polarity is ensured on the back side of the electrode sheet and the insulating property is ensured on the back side.

It is a perspective view of the power storage device. It is sectional drawing of the electrode assembly. It is a perspective view of a positive electrode sheet, a separator, and a negative electrode sheet. It is a perspective view of the positive electrode sheet. It is a perspective view of the negative electrode sheet. It is a flowchart which showed the manufacturing process of an electrode sheet. It is a schematic side view of a coating dryer. It is a top view of the front side of a coating sheet. It is a top view of the back side of a coating sheet. It is a side view of the electrode sheet manufacturing apparatus. It is a perspective view of the electrode sheet manufacturing apparatus. It is a top view of the electrode sheet manufacturing apparatus. It is a perspective view of the transport device. It is a top view of the transport device. It is a top view of a belt. It is a perspective view of the laser apparatus on the front side of a coating sheet. It is a perspective view of the laser apparatus on the back side of a coating sheet. It is sectional drawing of the coating sheet in a cut state. It is a top view which showed the modification example of a coating sheet. It is a perspective view which showed the modification example of the electrode sheet manufacturing apparatus. It is a top view which showed the modification example of a coating sheet. It is sectional drawing which showed the example that the outer edge of a negative electrode sheet approached the side of a positive electrode sheet. It is a perspective view which showed the modification example of a laser apparatus by correspondence with FIG. It is a perspective view which showed the modification example of a laser apparatus by correspondence with FIG. It is a top view which showed the modification example of a coating sheet. It is a perspective view which showed the modification example of the electrode sheet manufacturing apparatus. It is a top view which showed the modification example of the electrode sheet manufacturing apparatus. It is a perspective view which showed the modification example of a transport device. It is a top view which showed the modification example of a transport device. It is a perspective view which showed the modification example of the positive electrode sheet. It is a perspective view which showed the modification example of the negative electrode sheet. It is a top view which showed the modification example of a coating sheet. It is a schematic side view which showed the modification example of a coating dryer. It is a schematic side view of a press machine. It is a schematic side view of the coating dryer for an insulating substance. It is a perspective view which showed the modification example of the positive electrode sheet. It is a top view which showed the modification example of the positive electrode sheet. It is sectional drawing of XXXVIII-XXXVIII of FIG. 37 in the arrow-viewing direction. It is a perspective view which showed the modification example of the negative electrode sheet. It is a top view which showed the modification example of the negative electrode sheet. It is sectional drawing of XXXXI-XXXXI of FIG. 40 in the arrow-viewing direction. It is a top view which showed the modification example of a coating sheet. It is a schematic side view which showed the coating dryer in the case of performing intermittent coating. It is a schematic side view of the coating dryer for an insulating substance.

Hereinafter, embodiments for carrying out the present invention will be described with reference to the drawings. The power storage device 1 shown in FIG. 1 is, for example, a lithium ion secondary battery. The case 10 of the power storage device 1 has a bottomed rectangular parallelepiped case body 12 and a flat plate-shaped lid 11 that closes the opening of the case body 12. The lid 11 has external connection terminals 14 and 16. The external connection terminals 14 and 16 penetrate the lid 11 in the thickness direction.

As shown in FIG. 1, the power storage device 1 has an electrode assembly 20 and an electrolytic solution (not shown) inside the case 10. The electrode assembly 20 is connected to the external connection terminals 14 and 16 via a positive electrode tab portion 32b and a negative electrode tab portion 42b, which will be described later. The electrode assembly 20 supplies electric power to the outside of the power storage device 1 (discharge) through the external connection terminals 14 and 16 and supplies power from the outside of the power storage device 1 (charge).

As shown in FIGS. 2 and 3, the electrode assembly 20 is configured by alternately laminating a positive electrode sheet 30 (electrode sheet) and a negative electrode sheet 40 (electrode sheet). A separator 28 is provided between the positive electrode sheet 30 and the negative electrode sheet 40. The separator 28 is made of a thin-film porous resin. The area of the separator 28 is larger than the area of the negative electrode current collector 42a, which will be described later.

As shown in FIGS. 2, 3 and 4, the positive electrode sheet 30 is based on the positive electrode current collecting foil 32 (current collecting foil). The positive electrode current collecting foil 32 is a metal foil, for example, an aluminum foil. The positive electrode current collecting foil 32 has a rectangular positive electrode current collecting portion 32a (current collecting portion) and a positive electrode tab portion 32b (tab portion) having a shape protruding from one side of the positive electrode current collecting portion 32a. The positive electrode current collector 32a has a front side positive electrode active material layer 34 (front side active material layer) which is a front side positive electrode coating layer 21 (front side coating layer or coating layer) on the surface of the front side 32c (see FIG. 2). Have. The positive electrode current collector 32a has a back side positive electrode active material layer 36 (back side active material layer) which is a back side positive electrode coating layer 22 (back side coating layer or coating layer) on the surface of the back side 32d. Both positive electrode active material layers 34 and 36 cover substantially the entire area of the positive electrode current collector 32a, for example. Both positive electrode active material layers 34 and 36 are composed of, for example, a lithium-containing metal oxide. As shown in FIG. 4, the positive electrode current collector 32a and both positive electrode active material layers 34 and 36 (both positive electrode coating layers 21 and 22) constitute a positive electrode base portion 38.

The positive electrode tab portion 32b does not have the front side positive electrode active material layer 34 and the back side positive electrode active material layer 36, and the positive electrode current collecting foil 32 is exposed. The positive electrode tab portions 32b of each positive electrode sheet 30 are overlapped with each other and welded to one of the external connection terminals 14 (see FIG. 1), for example. In the present specification, the side of the positive electrode current collecting unit 32a where the positive electrode tab portion 32b is provided is referred to as a positive electrode tab forming side 38a (tab forming side). The side facing the positive electrode tab forming side 38a is referred to as the positive electrode tab facing side 38b. Further, the two sides excluding the positive side tab forming side 38a and the positive side tab facing side 38b are referred to as a first positive side tab parallel side 38c (tab parallel side) and a second positive side tab parallel side 38d (tab parallel side).

As shown in FIGS. 2, 3 and 4, the front positive electrode active material layer 34 has a positive electrode front side tapered portion 34a (front side tapered portion). The positive electrode front side tapered portion 34a is provided along each of the positive electrode tab facing side 38b, the first positive electrode tab parallel side 38c, and the second positive electrode tab parallel side 38d. Each positive electrode front side tapered portion 34a is inclined inward from the corresponding sides 38b, 38c, 38d on the front side 32c surface of the positive electrode current collecting portion 32a, for example, linearly inclined. There is. The position of each edge portion 34EG (see FIG. 2) of each positive electrode front side tapered portion 34a substantially coincides with the position of the edge portion of the positive electrode current collector 32a. Each positive electrode front side tapered portion 34a has a positive electrode front side inclination angle θ1A (see FIG. 2).

As shown in FIGS. 2 and 4, the back side positive electrode active material layer 36 has a positive electrode back side tapered portion 36a (back side tapered portion). The positive electrode back side tapered portion 36a is provided along each of the positive electrode tab facing side 38b, the first positive electrode tab parallel side 38c, and the second positive electrode tab parallel side 38d. The tapered portion 36a on the back side of each positive electrode is inclined inward from the corresponding sides 38b, 38c, 38d on the surface of the back side 32d of the positive electrode current collecting portion 32a, for example, linearly inclined. There is. The position of each edge portion 36EG (see FIG. 2) of each positive electrode backside tapered portion 36a substantially coincides with the position of the edge portion of the positive electrode current collector 32a. Each positive electrode backside tapered portion 36a has a positive electrode backside inclination angle θ1B (see FIG. 2).

As shown in FIGS. 2, 3 and 5, the negative electrode sheet 40 is based on the negative electrode current collecting foil 42 (current collecting foil). The negative electrode current collecting foil 42 is a metal foil, for example, a copper foil. The negative electrode current collecting foil 42 has a rectangular negative electrode current collecting portion 42a (current collecting portion) and a negative electrode tab portion 42b (tab portion) having a shape protruding from one side of the negative electrode current collecting portion 42a. The area of the negative electrode current collector 42a is equal to or larger than the area of the positive electrode current collector 32a described above. The negative electrode current collector 42a has a front negative electrode active material layer 44 (front side active material layer) which is a front side negative electrode coating layer 23 (front side coating layer or coating layer) on the surface of the front side 42c (see FIG. 2). Have. The negative electrode current collector 42a has a back side negative electrode active material layer 46 (back side active material layer) which is a back side negative electrode coating layer 24 (back side coating layer or coating layer) on the surface of the back side 42d. Both negative electrode active material layers 44 and 46 cover substantially the entire area of, for example, the negative electrode current collector 42a. Both negative electrode active material layers 44 and 46 are made of, for example, carbon. As shown in FIG. 5, the negative electrode current collector 42a and both negative electrode active material layers 44 and 46 (both negative electrode coating layers 23 and 24) constitute a negative electrode base portion 48.

The negative electrode tab portion 42b does not have the front negative electrode active material layer 44 and the back negative electrode active material layer 46, and the negative electrode current collecting foil 42 is exposed. The negative electrode tab portions 42b of each negative electrode sheet 40 are overlapped with each other and welded to one of the external connection terminals 16 (see FIG. 1), for example. In the present specification, the side of the negative electrode current collecting portion 42a where the negative electrode tab portion 42b is provided is referred to as a negative electrode tab forming side 48a (tab forming side). The side facing the negative electrode tab forming side 48a is referred to as the negative electrode tab facing side 48b. Further, the two sides excluding the negative electrode tab forming side 48a and the negative electrode tab facing side 48b are referred to as a first negative electrode tab parallel side 48c (tab parallel side) and a second negative electrode tab parallel side 48d (tab parallel side).

As shown in FIGS. 2, 3 and 5, the front negative electrode active material layer 44 has a negative electrode front tapered portion 44a (front tapered portion). The negative electrode front side tapered portion 44a is provided along each of the negative electrode tab facing side 48b, the first negative electrode tab parallel side 48c, and the second negative electrode tab parallel side 48d. Each negative electrode front side tapered portion 44a is inclined inward from the corresponding sides 48b, 48c, 48d on the front side 42c surface of the negative electrode current collecting portion 42a, for example, linearly inclined. There is. The position of each edge portion 44EG (see FIG. 2) of each negative electrode front side taper portion 44a substantially coincides with the position of the edge portion of the negative electrode current collector portion 42a. Each negative electrode front side tapered portion 44a has a negative electrode front side inclination angle θ2A (see FIG. 2).

As shown in FIGS. 2 and 5, the back side negative electrode active material layer 46 has a negative electrode back side tapered portion 46a (back side tapered portion). The negative electrode back side tapered portion 46a is provided along each of the negative electrode tab facing side 48b, the first negative electrode tab parallel side 48c, and the second negative electrode tab parallel side 48d. The tapered portion 46a on the back side of each negative electrode is inclined inward from the corresponding sides 48b, 48c, 48d on the surface of the back side 42d of the negative electrode current collecting portion 42a, for example, linearly inclined. There is. The position of each edge portion 46EG (see FIG. 2) of each negative electrode backside tapered portion 46a substantially coincides with the position of the edge portion of the negative electrode current collector 42a. Each negative electrode backside tapered portion 46a has a negative electrode backside tilt angle θ2B (see FIG. 2).

Generally, in the electrode assembly 20, a load is likely to be applied to the outer edge portions of the positive electrode sheet 30 and the negative electrode sheet 40. Therefore, the positive electrode sheet 30 and the negative electrode sheet 40 may be in contact with each other (internal short circuit) due to the separator 28 being torn between the outer edge portions of each other. As shown in FIG. 2, in the electrode assembly 20, the positive electrode front side tapered portion 34a and the positive electrode back side tapered portion 36a are provided on the outer edge portion of the positive electrode sheet 30. Further, a negative electrode front side tapered portion 44a and a negative electrode back side tapered portion 46a are provided on the outer edge portion of the negative electrode sheet 40. Therefore, a gap is formed between the outer edge portions of the positive electrode sheet 30 and the negative electrode sheet 40 by the amount of each of these tapered portions 34a, 36a, 44a, 46a, and even if the separator 28 is torn, the inside Short circuits are avoided. For example, as shown in FIG. 22, even when the separator 28 is torn and the outer edge of the negative electrode sheet 40 approaches the side of the positive electrode sheet 30, the inside is by the amount of the gap S corresponding to the tapered portion 34a on the front side of the positive electrode. Short circuits are avoided.

Next, a method for manufacturing the positive electrode sheet 30 and the negative electrode sheet 40 will be described. The manufacturing methods of both sheets 30 and 40 are the same. Therefore, in the following, both sheets 30 and 40 will be referred to as electrode sheets 80, and a method for manufacturing the electrode sheets 80 will be described. The materials of the metal foil 52 of the coating sheet 50 and the active material layers 54 and 56, which will be described later, are changed according to the positive electrode sheet 30 and the negative electrode sheet 40, respectively.

The tab portions 82, 82AT, 82BT, 382b, and 482b, which will be described later, correspond to the positive electrode tab portion 32b and the negative electrode tab portion 42b. The tab forming sides 88a, 388a, and 488a, which will be described later, correspond to the positive electrode tab forming side 38a and the negative electrode tab forming side 48a. The tab facing sides 88b, 388b, and 488b, which will be described later, correspond to the positive electrode tab facing side 38b and the negative electrode tab facing side 48b. The first tab parallel sides 88c, 388c, and 488c, which will be described later, correspond to the first positive electrode tab parallel side 38c and the first negative electrode tab parallel side 48c. The second tab parallel sides 88d, 388d, and 488d, which will be described later, correspond to the second positive electrode tab parallel side 38d and the second negative electrode tab parallel side 48d. The front taper portion 54a, which will be described later, corresponds to the positive electrode front taper portion 34a and the negative electrode front taper portion 44a. The back side tapered portion 56a, which will be described later, corresponds to the positive electrode back side tapered portion 36a and the negative electrode back side tapered portion 46a. The base portion 88 corresponds to the positive electrode base portion 38 and the negative electrode base portion 48.

As shown in FIG. 6, the method for manufacturing the electrode sheet 80 includes a coating sheet preparation step S1 and an electrode sheet cutting step S2. In the coating sheet preparation step S1, the coating sheet 50 in which the active material layers 54 and 56 are formed on both surfaces of the strip-shaped metal foil 52 is prepared. In the electrode sheet cutting step S2, the electrode sheet 80 is cut out from the coating sheet 50 using a laser.

In the coating sheet preparation step S1, as shown in FIG. 7, the coating dryer 170 is used. The coating dryer 170 includes a supply roller 171, a coating machine 172, a dryer 173, a press roller 174, and a take-up roller 176. The metal leaf 52 is unwound from the supply roller 171 and passes through the coating machine 172, the dryer 173, and the press roller 174 in this order. The metal leaf 52 is coated with an active material on both sides of the metal leaf 52 by a coating machine 172. As a result, the front side active material layer 54 is formed on the front side 60 surface of the metal foil 52, and the back side active material layer 56 is formed on the back side 70 surface. The biactive material layers 54 and 56 are dried by the dryer 173 and compressed in the thickness direction by the press roller 174. In this way, the coating sheet 50 in which the active material layers 54 and 56 are formed on both the front and back surfaces of the metal foil 52 is produced. The coating sheet 50 is wound by the take-up roller 176 in a state of being stretched by each roller 177.

In the coating machine 172 shown in FIG. 7, the front side coating machine 172a for coating the surface of the front side 60 of the metal foil 52 with the active material and the back side coating for coating the surface of the back side 70 of the metal foil 52 with the active material. Machine 172b and the machine 172b face each other. As will be described later, both coating machines 172a and 172b do not have to face each other.

The coating sheet 50 will be described in detail. In the following description, the longitudinal direction of the metal foil 52 is referred to as the X direction, and the width direction of the metal foil 52 is referred to as the Y direction. The coating sheet 50 has a front side coating area 62 (coating area) and a front side non-coating area 64 (non-coating area) on the surface of the front side 60 (see FIG. 8). The front side coating region 62 is an region in which the front side active material layer 54, which is the front side coating layer 18 (coating layer), is continuously formed in the X direction. The width of the front coating area 62 corresponds to approximately twice the length of the first tab parallel side 388c in the first virtual contour R1 described later. The front side non-coated area 64 is provided adjacent to the front side coated area 62 in the Y direction, and is continuous in the X direction with the metal foil 52 exposed without forming the front active material layer 54. Area to do.

The front side non-painted area 64 has a first front side non-painted area 66 and a second front side non-painted area 68 on both sides of the front side coated area 62 in the Y direction. The first front side non-painted area 66 has an inner first front side non-painted area 66a and an outer first front side non-painted area 66b. The first front-side non-coated area 66a is an area adjacent to the front-side coated area 62 in the Y direction and continuous in the X direction. The width of the inner first front side unpainted area 66a substantially coincides with the length of the tab portion 382b in the first virtual contour R1 described later in the protruding direction. The outer first front side non-painted area 66b is located on the side opposite to the front side coated area 62 with respect to the inner first front side non-painted area 66a in the Y direction, and is a region continuous in the X direction.

The second front side non-painted area 68 has an inner second front side non-painted area 68a and an outer second front side non-painted area 68b. The inner second front side non-painted area 68a is an area adjacent to the front side coated area 62 in the Y direction and continuous in the X direction. The width of the inner second front side unpainted area 68a substantially coincides with the length of the tab portion 482b in the second virtual contour R2 described later in the protruding direction. The outer second front side non-painted area 68b is located on the side opposite to the front side coated area 62 with respect to the inner second front side non-painted area 68a in the Y direction, and is a region continuous in the X direction.

The coating sheet 50 has a back side coating area 72 (coating area) and a back side non-coating area 74 (non-coating area) on the surface of the back side 70 (see FIG. 9). The back side coating area 72 is a region facing the front side coating area 62 (see FIG. 8) with the metal foil 52 interposed therebetween, and is a back side coating layer 19 (coating layer), which is a back side active material layer 56 (FIG. 9). (See) is the area where it was formed. The back side non-coated area 74 is an area facing the front side non-coated area 64 (see FIG. 8) with the metal foil 52 sandwiched therein, and the metal foil is formed without forming the back side active material layer 56 (see FIG. 9). 52 is the exposed area.

As shown in FIG. 9, the back side non-painted area 74 has a first back side non-painted area 76 and a second back side non-painted area 78 on both sides of the back side coated area 72 in the Y direction. The first back side non-painted region 76 has an inner first back side non-painted region 76a and an outer first back side non-painted region 76b. The inner first back side non-painted area 76a is an area facing the inner first front side non-painted area 66a with the metal foil 52 sandwiched between them. The outer first back side non-painted region 76b is a region facing the outer first front side non-painted region 66b with the metal leaf 52 interposed therebetween.

The second backside non-painted region 78 has an inner second backside non-painted region 78a and an outer second backside non-painted region 78b. The inner second back side non-painted region 78a is a region facing the inner second front side non-painted region 68a with the metal foil 52 sandwiched between them. The outer second back side non-painted region 78b is a region facing the outer second front side non-painted region 68b with the metal leaf 52 sandwiched between them.

The electrode sheet cutting step S2, which will be described later, is carried out on the coating sheet 50 assuming that the virtual contours R shown in FIGS. 8 and 9 are defined. The virtual contour R is a virtual contour of the electrode sheet 80 set on the coating sheet 50. In FIGS. 8 and 9, the first virtual contour R1 is indicated by a alternate long and short dash line, and the second virtual contour R2 is indicated by a alternate long and short dash line. Both virtual contours R1 and R2 are defined so that the shapes of the electrode sheets after cutting out are the same. The first virtual contour R1 is set on the coating sheet 50 from the center in the Y direction to the side of the first front side non-coating region 66. The second virtual contour R2 is set on the coating sheet 50 from the center in the Y direction to the side of the second front side non-coating area 68. A plurality of both virtual contours R1 and R2 are continuously set in the X direction.

As shown in FIG. 8, the first virtual contour R1 has tab facing sides 388b and both tab parallel sides 388c and 388d set on the front side coating area 62, and the tab forming side 388a and the tab portion 382b are inside. It is set on the first front side non-painted area 66a. A part of each of the parallel sides 388c and 388d of both tabs protrudes to the side of the inner first non-painted area 66a. The first tab parallel side 388c and the second tab parallel side 388d of the first virtual contour R1 adjacent to each other in the X direction coincide with each other.

In the second virtual contour R2, the tab facing side 488b and both tab parallel sides 488c and 488d are set on the front side coating area 62, and the tab forming side 488a and the tab portion 482b are the inner second front side non-painting area. It is set on 68a. A part of each of the parallel sides 488c and 488d of both tabs protrudes to the side of the inner second non-painted area 68a. The first tab parallel side 488c and the second tab parallel side 488d of the second virtual contour R2 adjacent to each other in the X direction coincide with each other. The tab facing sides 388b and 488b of both virtual contours R1 and R2 are in agreement. The positions of both virtual contours R1 and R2 face each other on the front side 60 (see FIG. 8) and the back side 70 (see FIG. 9) of the coating sheet 50.

As shown in FIG. 6, the electrode sheet cutting step S2 is performed after the coating sheet preparation step S1. The electrode sheet cutting step S2 includes a coated region cutting step T1, a non-coated region cutting step T2, and a recovery step T3. The coating area cutting step T1 includes a front side coating area cutting step T1a and a back side coating area cutting step T1b.

In the electrode sheet cutting step S2, the electrode sheet manufacturing apparatus 280 shown in FIGS. 10 and 11 is used. The electrode sheet manufacturing apparatus 280 is an apparatus for cutting out the electrode sheet 80 from the coating sheet 50 while transporting the coating sheet 50 in the transport direction M along the X direction at the transport height HT. The coating sheet 50 is unwound from the supply roller 81. The electrode sheet manufacturing device 280 includes a transfer device 282, a laser device 284, a recovery device 286, and a controller 288. All operations of the electrode sheet manufacturing apparatus 280 are controlled by the controller 288. In FIG. 11, the recovery device 286 (see FIG. 10) is omitted. In FIGS. 8 to 17 and 19 to 21, the direction pointed to by the X axis coincides with the transport direction M.

As shown in FIGS. 13 and 14, the transport device 282 includes an upstream transport device 90, a downstream transport device 92, an auxiliary downstream transport device 94, a guide member 96, an upstream suction device 98, and a downstream suction device 100. It has an auxiliary downstream suction device 102.

As shown in FIGS. 13 and 14, the upstream transfer device 90 is composed of a first upstream transfer device 90a and a second upstream transfer device 90b. Both upstream side transport devices 90a and 90b have a configuration in which a belt BT is stretched on two rollers RL1 and RL2, respectively. The first upstream side transport device 90a has a first upstream side suction device 98a in the inner peripheral region of the belt BT. The second upstream suction device 98b has a second upstream suction device 98b in the inner peripheral region of the belt BT. As shown in FIG. 15, the belt BT has a plurality of holes BH. Each hole BH has a circular shape and penetrates the belt BT in the thickness direction.

As shown in FIG. 12, the first upstream side transport device 90a has a width equal to or less than the width of the first back side non-coated area 76a of the coating sheet 50, and faces the inner first back side non-coated area 76a. However, it is arranged so as to be in contact with the inner first back side non-painted area 76a. The first upstream side transport device 90a is in a state where the inner first back side non-painted area 76a is sucked onto the upper surface of the first upstream side transport device 90a by the suction force of the first upstream side suction device 98a, and the inner first back side thereof. The uncoated area 76a is transported in the transport direction M. In FIG. 12, the laser device 284 and the recovery device 286 shown in FIG. 10 are omitted.

As shown in FIG. 12, the second upstream transfer device 90b has a width equal to or less than the width of the inner second back side non-painted area 78a, faces the inner second back side non-painted area 78a, and is inner. It is arranged so as to be in contact with the second backside non-coated area 78a. Further, the second upstream side transport device 90b is arranged so as to be in parallel with the first upstream side transport device 90a. The second upstream side transport device 90b is in a state where the inner second back side unpainted area 78a is sucked onto the upper surface of the second upstream side transport device 90b by the suction force of the second upstream side suction device 98b, and the inner second back side is the same. The uncoated area 78a is transported in the transport direction M. An upstream laser space 104 is formed between the first upstream transfer device 90a and the second upstream transfer device 90b.

As shown in FIG. 13, the downstream transfer device 92 has a configuration in which a belt BT is stretched on two rollers RL1 and RL2. The downstream transfer device 92 has a downstream suction device 100 in the inner peripheral region of the belt BT. As shown in FIG. 15, the belt BT has a plurality of holes BH. Each hole BH has a circular shape and penetrates the belt BT in the thickness direction.

As shown in FIG. 12, the downstream side transport device 92 has a width equal to or less than the width of the back side coating area 72 of the coating sheet 50. The downstream side transport device 92 is arranged on the downstream side in the transport direction M with respect to the upstream side transport device 90. The coating sheet conveying portion 92a, which is an upstream portion of the downstream side conveying device 92, is arranged so as to face the back side coating area 72 and to be in contact with the back side coating area 72. The electrode sheet transport portion 92b, which is a middle stream portion and a downstream portion of the downstream side transport device 92, is arranged so as to face the back surface of the cut-out electrode sheet 80 and to be in contact with the back surface. The coating sheet transporting section 92a conveys the backside coating area 72 in a state where the backside coating area 72 of the coating sheet 50 is sucked onto the upper surface of the coating sheet transporting section 92a by the suction force of the downstream suction device 100. Transport in direction M. The electrode sheet transport section 92b transports the electrode sheet 80 in the transport direction M in a state where the back surface of the electrode sheet 80 is sucked onto the upper surface of the electrode sheet transport section 92b by the suction force of the downstream suction device 100. Both sides of the coating sheet transport portion 92a in the Y direction are downstream laser spaces 106.

As shown in FIGS. 13 and 14, the auxiliary downstream side transport device 94 is composed of a first auxiliary downstream side transport device 94a and a second auxiliary downstream side transport device 94b. Both auxiliary downstream side transport devices 94a and 94b have a configuration in which a belt BT is stretched on two rollers RL1 and RL2, respectively. The first auxiliary downstream side transport device 94a has a first auxiliary downstream side suction device 102a in the inner peripheral region of the belt BT. The second auxiliary downstream side transport device 94b has a second auxiliary downstream side suction device 102b in the inner peripheral region of the belt BT. As shown in FIG. 15, the belt BT has a plurality of holes BH. Each hole BH has a circular shape and penetrates the belt BT in the thickness direction.

As shown in FIG. 12, the first auxiliary downstream side transport device 94a has a width equal to or less than the width of the outer first back side non-coated area 76b of the coating sheet 50, and has a width equal to or less than the width of the outer first back side non-coated area 76b. It is arranged so as to face each other and to be in contact with the outer first back side non-painted area 76b. Further, the first auxiliary downstream side transport device 94a is arranged so as to be in parallel with the coating sheet transport portion 92a of the downstream side transport device 92. The first auxiliary downstream side transport device 94a is outside in a state where the outer first back side non-painted area 76b is sucked onto the upper surface of the first auxiliary downstream side transport device 94a by the suction force of the first auxiliary downstream side suction device 102a. The first backside uncoated area 76b is conveyed in the transfer direction M.

As shown in FIG. 12, the second auxiliary downstream side transport device 94b has a width equal to or less than the width of the outer second back side non-painted area 78b, faces the outer second back side non-painted area 78b, and It is arranged so as to be in contact with the outer second back side non-painted area 78b. Further, the second auxiliary downstream side transport device 94b is arranged so as to be in parallel with the coating sheet transport portion 92a of the downstream side transport device 92. The second auxiliary downstream side transport device 94b is outside in a state where the outer second back side unpainted area 78b is sucked onto the upper surface of the second auxiliary downstream side transport device 94b by the suction force of the second auxiliary downstream side suction device 102b. The second backside uncoated area 78b is transported in the transport direction M.

As shown in FIGS. 13 and 14, the upstream laser space 104 is a space adjacent to the upstream transfer device 90 in the Y direction and a space serialized with the downstream transfer device 92 in the transfer direction M. Is. The upstream laser space 104 is a space sandwiched between the first upstream transfer device 90a and the second upstream transfer device 90b. The upstream laser space 104 is composed of a first upstream laser space 104a and a second upstream laser space 104b. The first upstream side laser space 104a is a space on the side close to the first upstream side transfer device 90a. The second upstream laser space 104b is a space on the side close to the second upstream transfer device 90b. As shown in FIG. 12, the front side coating area 62 and the back side coating area 72 of the coating sheet 50 pass through the upstream side laser space 104.

As shown in FIGS. 13 and 14, the downstream laser space 106 is a space adjacent to the downstream transfer device 92 in the Y direction, and the transfer direction M with respect to both the upstream transfer devices 90a and 90b, respectively. It is a space that is in series with. The downstream laser space 106 is composed of a first downstream laser space 106a and a second downstream laser space 106b. The first downstream laser space 106a is a space sandwiched between the downstream transfer device 92 and the first auxiliary downstream transfer device 94a. The second downstream laser space 106b is a space sandwiched between the downstream transfer device 92 and the second auxiliary downstream transfer device 94b. As shown in FIG. 12, the first front side non-painted region 66a and the inner first back side non-painted region 76a of the coating sheet 50 pass through the first downstream side laser space 106a. The inner second front side non-painted region 68a and the inner second back side non-painted region 78a pass through the second downstream side laser space 106b.

As shown in FIGS. 12, 13, and 14, the guide member 96 is composed of a first guide member 96a and a second guide member 96b. The first guide member 96a is located adjacent to the electrode sheet transport portion 92b of the downstream transport device 92 in the Y direction, and extends the first backside non-coating region 76a of the coating sheet 50 in the transport direction M. It is placed in the correct position. The first guide member 96a extends linearly along the transport direction M. The first guide member 96a has an inclined surface 95 and a tab holding surface 97. As shown in FIG. 10, the inclined surface 95 is inclined from a position lower than the transport height HT to a position closer to the transport height HT along the transport direction M. The tab holding surface 97 extends in the transport direction M at a position substantially matching the transport height HT. As shown in FIG. 11, the inclined surface 95 scoops up the tab portion 82AT of the first electrode sheet 80A cut out from the coating sheet 50 and brings it closer to the transport height HT. The tab holding surface 97 guides the tab portion 82AT at the transport height HT.

As shown in FIG. 12, the second guide member 96b is located adjacent to the electrode sheet transporting portion 92b of the downstream transporting device 92 in the Y direction, and is the second backside non-coated region 78a of the coating sheet 50. Is arranged at a position extended in the transport direction M. The second guide member 96b extends linearly along the transport direction M. The second guide member 96b has an inclined surface 95 and a tab holding surface 97. Since the configurations and functions of the inclined surface 95 and the tab holding surface 97 are the same as those of the first guide member 96a, duplicate description will be omitted.

As shown in FIG. 11, the laser device 284 includes a front upstream side laser device 180, a back upstream side laser device 190, a first downstream side laser device 210, and a second downstream side laser device 220. The front upstream side laser device 180 and the back upstream side laser device 190 constitute an upstream side laser device. The first downstream side laser device 210 and the second downstream side laser device 220 constitute a downstream side laser device.

As shown in FIG. 10, the front upstream side laser device 180 is arranged above the coating sheet 50 (front side 60 of the coating sheet 50). The back upstream side laser device 190 is arranged below the coating sheet 50 (the back side 70 of the coating sheet 50). As shown in FIG. 11, the front upstream side laser device 180 irradiates the front upstream side laser 180L (front side laser) toward the first virtual contour R1 and the second virtual contour R2 in the upstream side laser space 104. The back upstream side laser device 190 irradiates the back upstream side laser 190L (back side laser) toward the first virtual contour R1 and the second virtual contour R2 in the upstream side laser space 104. In FIG. 11, the first virtual contour R1 is indicated by the alternate long and short dash line, and the second virtual contour R2 is indicated by the alternate long and short dash line.

As shown in FIG. 16, the front upstream side laser device 180 has a laser head 182 and an XY-axis robot 184. The laser head 182 is supplied with a laser beam from a laser oscillator (not shown). Then, the laser head 182 irradiates the front upstream side laser 180L toward the first virtual contour R1 and the second virtual contour R2 in the front side coating area 62. In FIG. 16, the first virtual contour R1 is indicated by a long-dashed line, and the second virtual contour R2 is indicated by a long-dashed line. The laser head 182 is attached to the XY-axis robot 184. The XY-axis robot 184 moves the laser head 182 in the X and Y directions. The XY-axis robot 184 has, for example, a Y-axis member 184a that movably supports the laser head 182 in the Y direction, and an X-axis member 184b that movably supports the Y-axis member 184a in the X direction. The XY-axis robot 184 moves the laser head 182 according to the program stored in the controller 288. In FIG. 11, the XY-axis robot 184 (see FIG. 16) is omitted.

As shown in FIG. 17, the back-upstream laser device 190 has a laser head 192 and an XY-axis robot 194. The XY-axis robot 194 has a Y-axis member 194a and an X-axis member 194b. Since the laser head 192 and the XY-axis robot 194 function in the same manner as the respective devices 182 and 184 of the front upstream side laser device 180, duplicate description will be omitted. The laser head 192 irradiates the back upstream side laser 190L toward the first virtual contour R and the second virtual contour R2 of the back side coating region 72. In FIG. 17, the first virtual contour R1 is indicated by a alternate long and short dash line, and the second virtual contour R2 is indicated by a alternate long and short dash line. In FIG. 11, the XY-axis robot 194 (see FIG. 17) is omitted.

Both laser heads 182 and 192 have lenses 182a and 192a, respectively, as shown in FIG. With these lenses 182a and 192a, both upstream lasers 180L and 190L are focused toward the focal points P1 and P2 set at predetermined positions on the coating sheet 50. The focal points P1 and P2 are located near the center of thickness of the metal foil 52, for example, within the thickness of the metal foil 52. Alternatively, the focal points P1 and P2 are located in the front side active material layer 54 in the vicinity of the metal foil 52, or in the back side active material layer 56 in the vicinity of the metal foil 52. The focal points P1 and P2 may be set at the same position or may be set at different positions.

The front upstream side laser 180L has an output intensity capable of cutting at least the front side active material layer 54 in the thickness direction. The back upstream side laser 190L has an output intensity capable of cutting at least the back side active material layer 56 in the thickness direction. At least one of the two upstream lasers 180L and 190L has an output strength capable of cutting the metal foil 52 in addition to the front active material layer 54 or the back active material layer 56. That is, the front upstream side laser 180L has an output intensity capable of cutting the front side active material layer 54 and the metal foil 52 in the thickness direction, and the back upstream side laser 190L has an output capable of cutting only the back side active material layer 56. It may have strength. Further, the front upstream side laser 180L has an output intensity capable of cutting only the front side active material layer 54, and the back upstream side laser 190L has an output capable of cutting the back side active material layer 56 and the metal foil 52 in the thickness direction. It may have strength. Further, the front upstream side laser 180L has an output strength capable of cutting the front side active material layer 54 and the metal foil 52 in the thickness direction, and the back upstream side laser 190L has the back side active material layer 56 and the metal foil 52. It may have an output strength capable of cutting in the thickness direction. For example, the front upstream side laser 180L has an output intensity capable of cutting the front side active material layer 54 and a part of the metal foil 52 in the thickness direction, and the back upstream side laser 190L has the back side activity with the remaining part of the metal foil 52. It may have an output strength capable of cutting the material layer 56. In this way, both upstream lasers 180L and 190L combine the two to obtain an output strength (coating layer cutting strength) capable of cutting the front active material layer 54, the metal foil 52, and the back active material layer 56. Have.

The output intensities of both upstream lasers 180L and 190L will be described in more detail. The output intensity of the front upstream side laser 180L is set to an intensity capable of cutting from the surface of the front side active material layer 54 to a predetermined front side laser arrival position. The front side laser arrival position is set to a predetermined position within a range from the surface of the front side 52a of the metal foil 52 to the inside of the back side active material layer 56. The output intensity of the back upstream side laser 190L is set to an intensity capable of cutting from the surface of the back side active material layer 56 to a predetermined back side laser arrival position. The back side laser arrival position is set to a predetermined position within a range from the surface of the back side 52b of the metal foil 52 to the inside of the front side active material layer 54.

As described above, the output intensities of the lasers 180L and 190L on both upstream sides are weaker than the intensities of cutting the active material layers 54 and 56 and the metal foil 52 together. Therefore, in both the upstream lasers 180L and 190L, the amount of melting the amphoteric material layers 54 and 56 is reduced due to their thermal influence. As a result, in the electrode sheet 80 after cutting out, a decrease in the capacity of the active material can be suppressed. Further, when the coating sheets 50 are irradiated with the lasers 180L and 190L on both upstream sides, the scattering of foreign substances due to the melting of the active material layers 54 and 56 is suppressed.

As shown in FIG. 18, both upstream lasers 180L and 190L are irradiated so that their respective optical axes J1 and J2 are perpendicular to the coating sheet 50. Therefore, the lasers 180L and 190L on both upstream sides have the shortest linear distance through which each of the lasers 180L and 190L passes through the coating sheet 50 in the thickness direction, unlike the case where each of them is irradiated obliquely with respect to the coating sheet 50. Become. Therefore, the output intensities of both upstream lasers 180L and 190L can be set weakly. As a result, the amount of the active material layers 54 and 56 melted by the thermal influence of the lasers 180L and 190L on both upstream sides can be reduced, the decrease in the capacity of the active material on the electrode sheet 80 after cutting out can be suppressed, and both upstream sides can be suppressed. When the lasers 180L and 190L are applied to the coating sheet 50, the scattering of foreign substances due to the melting of the active material layers 54 and 56 is suppressed. The optical axis J1 is a straight line passing through the center of the lens 182a and the focal point P1. Similarly, the optical axis J2 is a straight line passing through the center of the lens 192a and the focal point P2.

As shown in FIG. 18, the front upstream side laser 180L forms front side tapered portions 54a on both sides of the front side active material layer 54 when the front side active material layer 54 is cut. When the back side active material layer 56 is cut, the back upstream side laser 190L forms back side tapered portions 56a on both sides of the laser 190L.

Both upstream lasers 180L and 190L are continuous wave lasers. The wavelengths of both upstream lasers 180L and 190L are preferably set within the range of 300 to 1100 nm. The spot diameters of both upstream lasers 180L and 190L are preferably set within the range of 1 to 100 μm. The cutting speed of the coating sheet 50 by both upstream lasers 180L and 190L is preferably set within the range of 1 to 3 m / s. The output intensities of both upstream lasers 180L and 190L are preferably set within the range of 0.005 to 5.0 kW.

Both downstream side laser devices 210 and 220 are arranged above the coating sheet 50 (front side 60 of the coating sheet 50) as shown in FIG. The first downstream laser device 210 irradiates the first downstream laser 210L (laser for metal leaf) toward the first virtual contour R1 in the first downstream laser space 106a. The second downstream laser device 220 irradiates the second downstream laser 220L (laser for metal leaf) toward the second virtual contour R2 in the second downstream laser space 106b.

As shown in FIG. 16, the first downstream laser device 210 includes a laser head 212 and an XY-axis robot 214. The XY-axis robot 214 has a Y-axis member 214a and an X-axis member 214b. The second downstream laser device 220 has a laser head 222 and an XY-axis robot 224. The XY-axis robot 224 has a Y-axis member 224a and an X-axis member 224b. Both laser heads 212 and 222 and both XY-axis robots 214 and 224 function in the same manner as the respective devices 182 and 184 of the front upstream side laser device 180, respectively. The laser head 212 irradiates the first downstream side laser 210L toward the first virtual contour R1 in the inner first front side unpainted area 66a. The laser head 222 irradiates the second downstream side laser 220L toward the second virtual contour R2 in the inner second front side unpainted area 68a. In FIG. 11, both XY-axis robots 214 and 224 (see FIG. 16) are omitted.

Both the laser heads 212 and 222 have a lens (not shown) like the laser head 182. Both downstream lasers 210L and 220L are focused by the lens toward their respective focal points set at predetermined positions on the coating sheet 50. The focal points of the lasers 210L and 220L on both downstream sides are located near the center of thickness of the metal foil 52, for example, within the thickness of the metal foil 52. Both downstream side lasers 210L and 220L are irradiated so that their respective optical axes are perpendicular to the coating sheet 50, for example. As described above, the optical axis is a straight line passing through the center and focal point of the lens.

Both downstream lasers 210L and 220L are pulse wave lasers, respectively. It is preferable that the wavelengths of the lasers 210L and 220L on both downstream sides are set within the range of 300 to 1100 nm, respectively. It is preferable that the spot diameters of the lasers 210L and 220L on both downstream sides are set within the range of 1 to 100 μm, respectively. It is preferable that the cutting speed of the coating sheet 50 by the lasers 210L and 220L on both downstream sides is set within the range of 1 to 3 m / s, respectively. The output intensities of both downstream lasers 210L and 220L are preferably set within the range of 0.1 to 100W, respectively. The output intensities of the lasers 210L and 220L on both downstream sides are set to the intensities that can cut the metal leaf 52 (metal leaf cutting intensity), respectively. The pulse widths of the lasers 210L and 220L on both downstream sides are preferably set to be smaller than 20 ps (picoseconds), respectively. It is preferable that the repetition frequencies of the lasers 210L and 220L on both downstream sides are set within the range of 0.1 to 1 MHz, respectively.

The electrode sheet cutting step S2 is performed by the electrode sheet manufacturing apparatus 280 described above. As shown in FIG. 6, the electrode sheet cutting step S2 includes a coated region cutting step T1, a non-coated region cutting step T2, and a recovery step T3. The non-painted area cutting step T2 is performed after the coated area cutting step T1. The recovery step T3 is performed after the uncoated area cutting step T2. As described above, the electrode sheet cutting step S2 is carried out assuming that the virtual contour R of the electrode sheet 80 is defined on the coating sheet 50.

In the coating area cutting step T1, as shown in FIG. 11, both upstream side lasers 180L and 190L are applied to the front side coating area 62 and the back side coating area 72 of the coating sheet 50 conveyed in the transfer direction M. Irradiation is performed to cut out the locations of the first virtual contour R1 and the second virtual contour R2 on both the coating areas 62 and 72. In the coating sheet 50, the inner first back side non-coating area 76a and the inner second back side non-coating area 78a are supported by the first upstream side transfer device 90a and the second upstream side transfer device 90b, respectively. It is being transported in the transport direction M in the state of being.

The coating area cutting step T1 includes a front side coating area cutting step T1a and a back side coating area cutting step T1b (see FIG. 6). In the front side coating area cutting step T1a, as shown in FIGS. 11 and 16, the front upstream side laser 180L is irradiated from the front side 60 of the coating sheet 50. The front upstream side laser 180L has a portion of the first virtual contour R1 on the front side coating area 62 passing through the first upstream side laser space 104a and a front side coating area passing through the second upstream side laser space 104b. It is irradiated along the portion of the second virtual contour R2 on 62. That is, the front upstream side laser 180L is irradiated along both the first tab parallel sides 388c and 488c and the tab facing sides 388b and 488b. The front upstream side laser 180L continuously irradiates the parallel sides 388c and 488c of both first tabs. As described above, the first tab parallel side 388c is also the second tab parallel side 388d. Similarly, the second tab parallel side 488c is also the second tab parallel side 488d.

In the back side coating area cutting step T1b, as shown in FIGS. 11 and 17, the back upstream side laser 190L is irradiated from the back side 70 of the coating sheet 50. The back upstream side laser 190L has a portion of the first virtual contour R1 on the back side coating area 72 passing through the first upstream side laser space 104a and a back side coating area passing through the second upstream side laser space 104b. It is irradiated along the portion of the second virtual contour R2 on 72. As in the case of the front upstream side laser 180L, the back upstream side laser 190L is irradiated along both the first tab parallel sides 388c and 488c and the tab facing sides 388b and 488b. The back upstream side laser 190L continuously irradiates the parallel sides 388c and 488c of both first tabs.

The front side coating area cutting step T1a and the back side coating area cutting step T1b are performed at the same time. Then, both upstream lasers 180L and 190L are simultaneously irradiated to the respective positions of both virtual contours R1 and R2. As a result, at the irradiation positions of the two upstream lasers 180L and 190L, the heats of the two upstream lasers 180L and 190L can complement each other. Therefore, both the upstream lasers 180L and 190L can cut the amphoteric material layers 54 and 56 and the metal foil 52 of the coating sheet 50 even if the output intensities are set to be weak, respectively. Therefore, in both upstream lasers 180L and 190L, the amount of melting of the active material layers 54 and 56 is reduced due to their thermal influence, and as a result, the reduction in the capacity of the active material is suppressed in the electrode sheet 80 after cutting out. At the same time, when the coating sheets 50 are irradiated with the lasers 180L and 190L on both upstream sides, the scattering of foreign substances due to the melting of the active material layers 54 and 56 is suppressed.

By carrying out the front side coating area cutting step T1a and the back side coating area cutting step T1b, both first tab parallel sides 388c and 488c, both second tab parallel sides 388d and 488d, and both tab facing sides 388b and 488b. Is cut out. After that, the coating sheet 50 reaches the downstream side transport device 92 without hanging downward, and is transported in the transport direction M by the downstream side transport device 92. In the tab parallel sides 388c, 388d, 488c, and 488d, the portions protruding from the front side coating area 62 and the back side coating area 72 are cut out in the non-coating area cutting step T2 described later.

In the non-coating area cutting step T2, as shown in FIG. 11, the coating sheet 50 transported in the transport direction M is irradiated with the first downstream side laser 210L and the second downstream side laser 220L, and both are irradiated. The uncut portion in the virtual contours R1 and R2 is cut. The first downstream laser 210L cuts the uncut portion of the first virtual contour R1. The second downstream laser 220L cuts the uncut portion of the second virtual contour R2. The first downstream laser 210L includes a coating sheet transport portion 92a (see FIG. 13) of the downstream transport device 92 and a first auxiliary downstream transport device 94a in a back coating region 72 and an outer first back non-coating region. The coating sheet 50 is irradiated toward the coating sheet 50 on which 76b and 76b are supported, respectively. The second downstream side laser 220L is a coating sheet in which the back side coating area 72 and the outer second back side non-coating area 78b are supported by the coating sheet transfer portion 92a and the second auxiliary downstream side transfer device 94b, respectively. It is irradiated toward 50.

As shown in FIGS. 11 and 16, the first downstream laser 210L is irradiated from the front side 60 of the coating sheet 50. The first downstream laser 210L is irradiated along the portion of the first virtual contour R1 on the first front side unpainted region 66a that passes through the first downstream laser space 106a. That is, the first downstream laser 210L has a tab forming side 388a, a tab portion 382b, and a part of the first tab parallel side 388c (second tab parallel side 388d) (first tab parallel side 388c) of the first virtual contour R1. Is irradiated toward the portion protruding into the non-coated area 66a on the front side of the first surface). As a result, each side 388a, 388b, 388c, 388d and the tab portion 382b of the first virtual contour R1 are all cut out to produce the first electrode sheet 80A. The portion of the first front side non-coated region 66 (first back side non-coated region 76) that did not become the first electrode sheet 80A is separated from the electrode sheet 80A.

As shown in FIGS. 11 and 16, the second downstream laser 220L is irradiated from the front side 60 of the coating sheet 50. The second downstream side laser 220L is irradiated along the portion of the second virtual contour R2 on the inner second front side unpainted area 68a passing through the second downstream side laser space 106b. That is, the second downstream laser 220L has a tab forming side 488a, a tab portion 482b, and a part of the first tab parallel side 488c (second tab parallel side 488d) (first tab parallel side 488c) of the second virtual contour R2. Is irradiated toward the portion protruding into the non-coated area 68a on the second front side of the above. As a result, each side 488a, 488b, 488c, 488d and the tab portion 482b of the second virtual contour R2 are all cut out to produce the second electrode sheet 80B. The portion of the second front side non-coated area 68 (second back side uncoated area 78) that did not become the second electrode sheet 80B is separated from the electrode sheet 80B.

After the uncoated area cutting step T2, the recovery step T3 is performed. The first electrode sheet 80A and the second electrode sheet 80B are transported in the transport direction M by the electrode sheet transport portion 92b of the downstream transport device 92. As shown in FIG. 11, the tab portion 82AT of the first electrode sheet 80A is scooped up by the inclined surface 95 of the first guide member 96a. After that, the tab portion 82AT is guided by the inclined surface 95 to a position close to the transfer height HT shown in FIG. 10, and is conveyed on the tab holding surface 97. Similarly, the tab portion 82BT of the second electrode sheet 80B is scooped up by the inclined surface 95 of the second guide member 96b, and then is conveyed on the tab holding surface 97. In this way, the inclined surfaces 95 of the guide members 96a and 96b scoop up the tab portions 82AT and 82BT, thereby preventing the tab portions 82AT and 82BT from being left hanging. Therefore, both tab portions 82AT and 82BT are burdened, and both tab portions 82AT and 82BT are prevented from being torn from the respective electrode sheets 80A and 80B.

When both electrode sheets 80A and 80B reach the downstream portion of the downstream transfer device 92, they are collected by the collection device 286. As shown in FIG. 10, the recovery device 286 has, for example, a suction hand 286a and a recovery box 286b. The suction hand 286a sucks the second electrode sheet 80B and moves it to the recovery box 286b. The suction hand 286a releases the suction of the second electrode sheet 80B above the collection box 286b, and collects the second electrode sheet 80B in the collection box 286b. The recovery device 286 also collects the first electrode sheet 80A in the recovery box 286b in the same manner. Two recovery devices 286 may be provided corresponding to the double electrode sheets 80A and 80B, respectively. Further, both electrode sheets 80A and 80B may be dropped directly downward from the downstream end of the downstream transfer device 92 and collected in the collection box 286b without using the suction hand 286a. The above is the manufacturing method of the electrode sheet in the present embodiment.

In the above configuration, an upstream laser space 104 that serves as a passage space for the front coating area 62 and the back coating area 72 of the coating sheet 50 is provided at a position adjacent to the upstream transfer device 90 in the Y direction. (See FIG. 11). Further, a non-coated area on the front side of the coating sheet 50 is located at a position in series with the upstream transport device 90 on the downstream side in the transport direction M and adjacent to the downstream transport device 92 in the Y direction. A downstream laser space 106 that serves as a passage space for 64 and the backside unpainted area 74 is provided. Therefore, first, in the upstream laser space 104, the front side coating area 62 and the back side coating area 72 are irradiated with the upstream side lasers 180L and 190L, and the tab facing sides 388b and 488b and the tab parallel sides 388c, 388d and 488c, 488d is cut out, and then the front side non-painted area 64 and the back side non-painted area 74 are irradiated with the downstream lasers 210L and 220L in the downstream laser space 106 to cut out the tab portions 382b and 482b and the tab forming sides 388a and 488a. As a result, in the coating sheet 50 in which the front side coating area 62 and the back side coating area 72 are continuously formed in the longitudinal direction, the coating sheet 50 is continuously formed without stopping the transportation of the coating sheet 50. The electrode sheet 80 can be cut out from.

In the above configuration, when both upstream lasers 180L and 190L are irradiated toward the first virtual contour R1 and the second virtual contour R2 of the upstream laser space 104, the coating sheet 50 is conveyed to the first upstream side. Both sides are supported by the device 90a and the second upstream transfer device 90b. Further, when the first downstream side laser 210L is irradiated toward the first virtual contour R1 of the first downstream side laser space 106a, the coating sheet 50 is subjected to the downstream side transfer device 92 and the first auxiliary downstream side transfer device 94a. Both sides are supported by. Further, when the second downstream side laser 220L is irradiated toward the second virtual contour R2 of the second downstream side laser space 106b, the coating sheet 50 is subjected to the downstream side transfer device 92 and the second auxiliary downstream side transfer device 94b. Both sides are supported by. Therefore, the coating sheet 50 is irradiated with the lasers 180L, 190L, 210L, and 220L in a stable position. As a result, the lasers 180L, 190L, 210L, and 220L are suppressed from being irradiated to positions deviating from the first virtual contour R1 and the second virtual contour R2.

In the above configuration, individual laser devices correspond to the upstream laser space 104 that cuts the metal foil 52 and the active material layers 54 and 56 and the downstream laser space 106 that cuts only the metal foil 52. Is provided. Therefore, the type of laser (for example, continuous wave or pulse wave) and the output intensity can be set individually corresponding to the respective laser spaces 104 and 106.

In the above configuration, the front side active material layer 54 and the back side active material layer 56 are individually cut by using the front upstream side laser 180L and the back upstream side laser 190L. From this, the output intensities of the two upstream lasers 180L and 190L are higher than those in the case where the active material layers 54 and 56 are cut together by either of the two upstream lasers 180L and 190L, respectively. The output intensity of the above can be set weakly, and the amphibious material layers 54 and 56 can be cut quickly, respectively. Therefore, the amount of the amphoteric material layers 54 and 56 melted by the thermal influence of the lasers 180L and 190L on both upstream sides can be reduced. As a result, in the electrode sheet 80 after cutting out, a decrease in the volume of the active material is suppressed. Further, when the coating sheets 50 are irradiated with the lasers 180L and 190L on both upstream sides, the scattering of foreign substances due to the melting of the active material layers 54 and 56 is suppressed.

Although one embodiment for carrying out the present invention has been described above in relation to the drawings, the present invention can also be carried out in other embodiments. The tab forming sides 388a and 488a of both virtual contours R1 and R2 may be set on the front side coating area 62 and the back side coating area 72. In this case, both tab forming sides 388a and 488a are cut out in the upstream laser space 104.

As for the virtual contour R, only one of the two virtual contours R1 and R2 may be abolished and only one may be set in the Y direction on the coating sheet 50. FIG. 19 shows an example of a coating sheet 50a when the virtual contour R is only the first virtual contour R1. When this coating sheet 50a is adopted, for example, the electrode sheet 80A is cut out from the coating sheet 50a by the electrode sheet manufacturing apparatus 280a shown in FIG. In this electrode sheet manufacturing apparatus 280a, the second downstream side laser apparatus 220 shown in FIG. 11 is abolished. Further, in the transport device 282a, the second auxiliary downstream side transport device 94b, the second auxiliary downstream side suction device 102b, and the second guide member 96b shown in FIG. 11 are abolished. The width of the downstream transfer device 92 is set to a width that is the sum of the width of the front side coated area 62 and the width of the second front side non-coated area 68. The width of the second front-side non-painted area 68 shown in FIG. 20 substantially coincides with the width of the inner second front-side coated area 68a shown in FIG. 11, for example. The first upstream side transfer device 90a and the first auxiliary downstream side transfer device 94a have a first upstream side suction device 98a (see FIG. 13) and a first auxiliary downstream side suction device 102a (see FIG. 13), respectively, which are not shown. In FIGS. 19 and 20, the parts having the same or substantially the same configuration and function as those in FIGS. 1 to 18 are designated by the same reference numerals as those in FIGS. 1 to 18 to omit duplicate description.

As in the coating sheet 50b shown in FIG. 21, the position of the tab portion 382b of the first virtual contour R1 and the position of the tab portion 482b of the second virtual contour R2 may be displaced in the longitudinal direction. Note that, in FIG. 21, parts having the same or substantially the same configuration and function as those in FIG. 8 are designated by the same reference numerals as those in FIG. 8, and duplicate description will be omitted.

The front side coating area cutting step T1a and the back side coating area cutting step T1b may be performed separately. That is, both upstream lasers 180L and 190L (see FIG. 11) may irradiate each position of the virtual contour R separately without irradiating them at the same time.

Both downstream side lasers 210L and 220L may be irradiated from the back side 70 of the coating sheet 50. In this case, both downstream side laser devices 210 and 220 are arranged below the coating sheet 50 (the back side 70 of the coating sheet 50). Even if one of the two downstream side laser devices 210 and 220 is abolished and the laser is irradiated from the single downstream side laser device toward the virtual contour R in the both downstream side laser spaces 106a and 106b. Good.

The optical axes of the lasers 180L, 190L, 210L, and 220L do not have to be perpendicular to the coating sheet 50.

The laser device 284 may be a scanner type as shown in the examples of FIGS. 23 and 24. The front upstream side laser device 180a shown in FIG. 23 has a support member 186 fixed at a predetermined position and a scanner 187 fixed at a predetermined position of the support member 186. The scanner 187 has a mirror 188. The angle of the mirror 188 can be freely changed. A laser beam is supplied to the scanner from a laser oscillator (not shown). The mirror 188 reflects the supplied laser beam. This reflected laser beam is the front upstream side laser 180L. The mirror 188 can change the irradiation position of the front upstream side laser 180L three-dimensionally by changing the angle of the mirror 188. The laser beam reflected by the mirror 188 is focused by a lens (not shown). The angle of the mirror 188 is controlled by, for example, a controller 288.

Similar to the front upstream laser device 180a, the first downstream laser device 210a has a support member 216 and a scanner 217 with a mirror 218. The second downstream laser device 220a includes a support member 226 and a scanner 227 provided with a mirror 228. The back-upstream laser device 190a shown in FIG. 24 includes a support member 196 and a scanner 197 provided with a mirror 198. Since each of the laser devices 190a, 210a, 220a functions in the same manner as the front upstream side laser device 180a, duplicate description will be omitted. In addition, in FIGS. 23 and 24, the parts having the same or substantially the same configuration and function as those in FIGS. 16 and 17 are designated by the same reference numerals as those in FIGS.

The inclined surface 95 of the first guide member 96a may be extended to the lower side of the first downstream side laser space 106a so as to face the inner first back side uncoated area 76a. Similarly, the inclined surface 95 of the second guide member 96a may be extended to the lower side of the second downstream side laser space 106b so as to face the inner second back side unpainted area 78a.

In the electrode sheet manufacturing apparatus 280, the recovery apparatus 286 may be abolished. In this case, in the electrode sheet cutting step S2, the recovery step T3 is abolished.

The electrode sheet cut out from the coating sheet 50 may have a long rectangular shape in which the tab forming side and the tab facing side are longer than the positive electrode sheet 30 and the negative electrode sheet 40 shown in the example of FIG. This long electrode sheet constitutes, for example, a winding type power generation element disclosed in Patent Document 2.

The positive electrode front side tapered portion 34a shown in FIG. 4 may be provided on all four sides 38a, 38b, 38c, 38d of the positive electrode current collecting portion 32a, or at least one side of these four sides 38a, 38b, 38c, 38d. It may be provided in. Similarly, the positive electrode back side tapered portion 36a may be provided on all four sides 38a, 38b, 38c, 38d of the positive electrode current collector 32a, or on at least one of these four sides 38a, 38b, 38c, 38d. It may be provided. The negative electrode front side tapered portion 44a shown in FIG. 5 may be provided on all four sides 48a, 48b, 48c, 48d of the negative electrode current collecting portion 42a, or at least one side of these four sides 48a, 48b, 48c, 48d. It may be provided in. Similarly, the negative electrode back side tapered portion 46a may be provided on all four sides 48a, 48b, 48c, 48d of the negative electrode current collector 42a, or on at least one of these four sides 48a, 48b, 48c, 48d. It may be provided.

The positive electrode front side inclination angle θ1A and the positive electrode back side inclination angle θ1B shown in FIG. 2 can be freely set. The positive electrode front side inclination angle θ1A and the positive electrode back side inclination angle θ1B may be individually set on each side 38a, 38b, 38c, 38d of the positive electrode current collector 32a. The negative electrode front side inclination angle θ2A and the negative electrode back side inclination angle θ2B can be freely set. The negative electrode front side inclination angle θ2A and the negative electrode back side inclination angle θ2B may be individually set on each of the sides 48a, 48b, 48c, and 48d of the negative electrode current collector 42a.

One of the two upstream laser devices 180 and 190 is abolished, and the both active material layers 54 and 56 and the metal foil 52 are cut together by only one of the two upstream lasers 180L and 190L. It may be configured. In this case, the laser is a continuous wave laser. The wavelength of the laser is preferably set in the range of 300 to 1100 nm. The spot diameter of the laser is preferably set within the range of 1 to 100 μm. The cutting speed of the laser is preferably set within the range of 0.5 to 3 m / s. The output intensity of the laser is preferably set within the range of 0.01 to 5.0 kW. For example, when the back upstream side laser device 190 (see FIG. 17) is abolished, the upstream side laser device is only the front upstream side laser device 180 (see FIG. 16), and the laser device 284 is the three laser devices shown in FIG. It is composed of 180, 210 and 220. The same applies to the scanner type laser device shown in FIGS. 23 and 24.

As in the coating sheet 50c shown in FIG. 25, for example, four virtual contours R may be set in the Y direction. The coating sheet 50c has a configuration in which two coating sheets 50b shown in FIG. 21 are continuous in the Y direction. Both coating sheet portions 50c1 and 50c2 correspond to the coating sheet 50b shown in FIG. 21, respectively. The portion where both coating sheet portions 50c1 and 50c2 overlap is a front side center non-coating area 67 (front side non-coating area) on the front side 60 of the coating sheet 50c, and on the back side 70 of the coating sheet 50c. It is the back side center non-painted area 77 (back side non-painted area). The front center non-coating area 67 also serves as an inner second front side coating area in the first coating sheet portion 50c1 and an inner first front side coating area in the second coating sheet portion 50c2. Similarly, the back side central non-coating area 77 also serves as an inner second back side coating area in the first coating sheet portion 50c1 and an inner first front side coating area in the second coating sheet portion 50c2. .. In FIG. 25, parts having the same or substantially the same configuration / function as those in FIGS. 1 to 24 are designated by the same reference numerals as those in FIGS. 1 to 24, thereby omitting duplicate description. In the coating sheet, the metal foil may be expanded in the Y direction, and four or more virtual contours R may be set in the Y direction. In the coating sheet, three virtual contours R may be set in the Y direction.

When the coating sheet 50c shown in FIG. 25 is adopted, the electrode sheet 80 is cut out from the coating sheet 50c by, for example, the electrode sheet manufacturing apparatus 280b shown in FIGS. 26 and 27. The transfer device 282b (see FIGS. 26 to 29) of the electrode sheet manufacturing device 280b has a configuration in which two transfer devices 282 shown in FIGS. 13 and 14 are arranged in parallel in the Y direction. The first transfer device 282b1 and the second transfer device 282b2 correspond to the transfer devices 282 shown in FIGS. 13 and 14, respectively. The first transport device 282b1 transports the first coating sheet portion 50c1 in the transport direction M. The second transport device 282b2 transports the second coating sheet portion 50c2 in the transport direction M. The central upstream side transport device 90c, the central upstream side suction device 98c, the central downstream side laser space 106c, and the central guide member 96c are arranged in the portion where the two transport devices 282b1,282b2 overlap.

The central upstream side transfer device 90c also serves as a second upstream side transfer device of the first transfer device 282a and a first upstream side transfer device of the second transfer device 282b. The central upstream side suction device 98c also serves as a second upstream side suction device of the first transfer device 282a and a first upstream side suction device of the second transfer device 282b. The center upstream side transport device 90c sucks the back side central non-painted area 77 onto the upper surface of the center upstream side transport device 90c by the suction force of the center upstream side suction device 98c, and transports the back side center non-painted area 77 in the transport direction. Transport to M.

The central downstream side laser space 106c also serves as a second downstream side laser space of the first transfer device 282a and a first downstream side laser space of the second transfer device 282b. In the central downstream side laser space 106c, the downstream side laser 210L is irradiated toward the front side central non-painted area 67 and the back side central non-painted area 77 (see later).

The central guide member 96c also serves as a second guide member of the first transfer device 282a and a first guide member of the second transfer device 282b. The central guide member 96c guides the tab portion 82BT of the second electrode sheet 80B cut out from the first coating sheet portion 50c1 and the tab portion 82AT of the first electrode sheet 80A cut out from the second coating sheet portion 50c2. To do.

The electrode sheet manufacturing apparatus 280b has a front upstream side laser apparatus 180a and a back upstream side laser apparatus 190a corresponding to both the conveying apparatus 282b1,282b1. The front upstream side laser 180L and the back upstream side laser 190L corresponding to the first transfer device 282b1 are both virtual contours R1 set on the front side coating area 62 and the back side coating area 72 in the first coating sheet portion 50c1. The portion of R2 (the first tab parallel sides 388c, 488c and the tab facing sides 388b, 488b of both virtual contours R1 and R2) is irradiated. The front upstream side laser 180L and the back upstream side laser 190L corresponding to the second transfer device 282b are set on both the front side coating area 62 and the back side coating area 72 in the second coating sheet portion 50c2. The portion of R2 (the first tab parallel sides 388c, 488c and the tab facing sides 388b, 488b of both virtual contours R1 and R2) is irradiated.

The electrode sheet manufacturing apparatus 280b has a first downstream laser apparatus 210a corresponding to both the conveying apparatus 282a and 282b, respectively. The scanners 217 of both first downstream laser devices 210a are arranged in the center of the corresponding downstream transfer devices 92 in the Y direction. In the electrode sheet manufacturing apparatus 280b, the downstream side laser apparatus is composed of only the first downstream side laser apparatus 210a, and the second downstream side laser apparatus is abolished.

The first downstream laser 210L corresponding to the first transport device 282b1 is irradiated toward the first downstream laser space 106a and the central downstream laser space 106c of the first transport device 282b1. The first downstream laser 210L irradiates the uncut portion of both virtual contours R1 and R2 in the first coating sheet portion 50c1. In detail, the uncut portion includes a tab portion 382b, a tab forming side 388a, and a tab portion 382b of the first virtual contour R1 set in the inner first front side unpainted area 66a and the inner first back side unpainted area 76a. The first tab parallel side 388c, the tab portion 482b, the tab forming side 488a, and the first tab parallel side 488c of the second virtual contour R2 set in the front side center non-painted area 67 and the back side center non-painted area 77. ,.

The first downstream laser 210L corresponding to the second transfer device 282b2 is irradiated toward the central downstream laser space 106c and the second downstream laser space 106b of the second transfer device 282b2. The first downstream laser 210L irradiates the uncut portion of both virtual contours R1 and R2 in the second coating sheet portion 50c2. In detail, the uncut portion includes the tab portion 382b, the tab forming side 388a, and the first tab parallel to the first virtual contour R1 set in the front side central non-painted area 67 and the back side central non-painted area 77. The tab portion 482b, the tab forming side 488a, and the first tab parallel side 488c of the side 388c and the second virtual contour R2 set in the inner second front side unpainted area 68a and the inner second back side unpainted area 78a. ,.

The recovery devices (not shown) already described are arranged at the rear portions of both transport devices 282b1,282b2. In FIGS. 26 to 29, parts having the same or substantially the same configuration / function as those in FIGS. 1 to 25 are designated by the same reference numerals as those in FIGS. 1 to 25, thereby omitting duplicate description.

In the positive electrode plate 30 shown in FIG. 4, the front side positive electrode coating layer 21 was formed only by the front side positive electrode active material layer 34, and the back side positive electrode coating layer 22 was formed only by the back side positive electrode active material layer 36. Instead of this form, as shown in the positive electrode plate 30a shown in FIG. 30, the front side positive electrode coating layer 21a (front side coating layer or coating layer) is provided with the front side positive electrode active material layer 34 and the front side positive electrode active material layer 34. It may be formed by the front side insulating material layer 25 that covers it. Further, the back side positive electrode coating layer 22a (back side coating layer or coating layer) may be formed by the back side positive electrode active material layer 36 and the back side insulating material layer 26 covering the back side positive electrode active material layer 36. The front side positive electrode active material layer 34 and the back side positive electrode active material layer 36 cover substantially the entire area of the positive electrode current collector 32a. The front side insulating material layer 25 covers substantially the entire area of the front side positive electrode active material layer 34. The back-side insulating material layer 26 covers substantially the entire area of the back-side positive electrode active material layer 36. Both insulating material layers 25 and 26 may have heat resistance. In both insulating material layers 25 and 26, for example, ceramic particles such as alumina and a binder are mixed. The positive electrode front side tapered portion 34a is continuous from the front side positive electrode active material layer 34 to the front side insulating material layer 25. The positive electrode back side tapered portion 36a is continuous from the back side positive electrode active material layer 36 to the back side insulating material layer 26. The positive electrode base portion 38a1 is composed of a positive electrode current collecting portion 32a and both positive electrode coating layers 21a and 22a. In FIG. 30, parts having the same or substantially the same configuration and function as those in FIG. 4 are designated by the same reference numerals as those in FIG. 4, and duplicate description will be omitted. The insulating material layer may be formed only on either the front surface or the back surface of the positive electrode plate.

In the negative electrode plate 40 shown in FIG. 5, the front negative electrode coating layer 23 was formed only of the front negative electrode active material layer 44, and the back negative electrode coating layer 24 was formed only of the back negative electrode active material layer 46. Instead of this form, as shown in the negative electrode plate 40a shown in FIG. 31, the front negative electrode coating layer 23a (front side coating layer or coating layer) is provided with the front negative electrode active material layer 44 and the front negative electrode active material layer 44. It may be formed by the front side insulating material layer 25 that covers it. Further, the back side negative electrode coating layer 24a (back side coating layer or coating layer) may be formed by the back side negative electrode active material layer 46 and the back side insulating material layer 26 covering the back side negative electrode active material layer 46. The front negative electrode active material layer 44 and the back negative electrode active material layer 46 cover substantially the entire area of the negative electrode current collector 42a. The front side insulating material layer 25 covers substantially the entire area of the front side negative electrode active material layer 44. The back-side insulating material layer 26 covers substantially the entire area of the back-side negative electrode active material layer 46. The negative electrode front side tapered portion 44a is continuous from the front side negative electrode active material layer 44 to the front side insulating material layer 25. The negative electrode back side tapered portion 46a is continuous from the back side negative electrode active material layer 46 to the back side insulating material layer 26. The negative electrode base portion 48a1 is composed of a negative electrode current collecting portion 42a and both negative electrode coating layers 23a and 24a. In FIG. 31, parts having the same or substantially the same configuration / function as those in FIGS. 5 and 30 are designated by the same reference numerals as those in FIGS. 5 and 25, thereby omitting duplicate description. The insulating material layer may be formed only on either the front surface or the back surface of the negative electrode plate.

When the positive electrode sheet 30a (see FIG. 30) or the negative electrode sheet 40a (see FIG. 31) is manufactured as the electrode sheet 80, the coating sheet 50d shown in FIG. 32 is produced in the coating sheet preparation step S1. Although FIG. 32 shows an example of a coating sheet when four virtual contours R are set in the Y direction, the number of virtual contours R set in the Y direction in the coating sheet can be freely changed. ..

On the coating sheet 50d (see FIG. 32), two rows of front coating regions 62 are formed in parallel in the Y direction. Both front side coating regions 62 are regions in which the front side coating layers 18a are continuously formed in the X direction. The front coating layer 18a is formed by a front active material layer 54 and a front insulating material layer 25 covering the front active material layer 54. Both the front active material layer 54 and the front insulating material layer 25 are continuous in the X direction. The width of the front insulating material layer 25 is substantially the same as the width of the front active material layer 54, for example. The width of the front insulating material layer 25 may be larger than the width of the front active material layer 54. The back coating area 72 is formed at a position facing the front coating area 62. The back coating area 72 is formed in two rows in parallel in the Y direction. Backside coating layers 19a are continuously formed in the X direction in both backside coating regions 72. The back side coating layer 19a is formed by a back side active material layer 56 and a back side insulating material layer 26 that covers the back side active material layer 56. The back side active material layer 56 and the back side insulating material layer 26 are both continuous in the X direction. The back side active material layer 56 is formed at a position facing the front side active material layer 54. The back side insulating material layer 26 is formed at a position facing the front side insulating material layer 25. Note that FIG. 32 shows a state in which the front side insulating material layer 25 and the back side insulating material layer 26 are partially peeled off. In FIG. 32, parts having the same or substantially the same configuration / function as those in FIGS. 1 to 31 are designated by the same reference numerals as those in FIGS. 1 to 31 to omit duplicate description.

When producing the coating sheet 50d, first, the active material coating sheet 50d1 (see FIG. 33) is produced. The active material coating sheet 50d1 is produced, for example, by using the coating dryer 170a shown in FIG. 33. In the coating dryer 170a, the front coating machine 172a is arranged on the upstream side of the back coating machine 172b in the transport direction of the metal leaf 52. The front coating machine 172a faces, for example, the tension roller 175. The front side coating machine 172a coats the surface of the front side 60 of the metal foil 52 with the active material continuously in the longitudinal direction of the metal foil 52. The back side coating machine 172b coats the surface of the back side 70 of the metal foil 52 with the active material continuously in the longitudinal direction of the metal foil 52. After this, the active material is dried by the dryer 173. In this way, the active material coating sheet 50d1 in which the front side active material layer 54 and the back side active material layer 56 are formed on both sides 60 and 70 of the metal foil 52 is produced. The active material coating sheet 50d1 is wound by a winding roller 176. The front side coating machine 172a coats the active material in two rows in the width direction of the metal foil 52 with the width of the front side central non-coating area 67 (see FIG. 32) widened. The back side coating machine 172b coats the back side 70 of the metal foil 52 with the active material in two rows in the width direction of the metal foil 52 so as to face the active material on the front side 60 of the metal foil 52.

The active material coating sheet 50d1 is wound by the take-up roller 176 and then set in the supply roller 174S of the press machine 170b (see FIG. 34). Then, in the active material coating sheet 50d1, both active material layers 54 and 56 are compressed in the thickness direction by the press roller 174. After that, the active material coating sheet 50d1 is wound up by the winding roller 174R. After that, the active material coating sheet 50d1 is set on the supply roller 178a of the insulating material coating dryer 178 shown in FIG. 35. The active material coating sheet 50d1 is unwound from the supply roller 178a. After that, the surface of the front side 60 of the active material coating sheet 50d1 is coated with an insulating material by the front side coating machine 178c1, which is a coating machine 178c. The front side coating machine 178c1 coats the insulating material in two rows in the width direction of the active material coating sheet 50d1 so as to cover the front side active material layer 54. The front side coating machine 178c1 continuously coats the insulating material in the longitudinal direction of the active material coating sheet 50d1. After that, the back side 70 surface of the active material coating sheet 50d1 is coated with an insulating material by the back side coating machine 178c2 which is a coating machine 178c. The back side coating machine 178c2 coats the insulating material in two rows in the width direction of the active material coating sheet 50d1 so as to cover the back side active material layer 56. The back side coating machine 178c2 continuously coats the insulating material in the longitudinal direction of the active material coating sheet 50d1. After that, the insulating material is dried by the dryer 173 on both sides 60 and 70 of the active material coating sheet 50a1. In this way, the coating sheet 50d in which the front side active material layer 54 is covered with the front side insulating material layer 25 and the back side active material layer 56 is covered with the back side insulating material layer 26 is completed. The coating sheet 50d is wound by a winding roller 178b. After that, the coating sheet 50d is sent to the electrode sheet cutting step S2. In FIGS. 33 to 35, parts having the same or substantially the same configuration / function as those in FIGS. 1 to 32 are designated by the same reference numerals as those in FIGS. 1 to 32, thereby omitting duplicate description.

The output intensities of the lasers 180L and 190L on both upstream sides when the coating sheet 50d is cut in the electrode sheet cutting step S2 will be described. The front upstream side laser 180L has an output intensity capable of cutting at least the front side insulating material layer 25 and the front side active material layer 54 in the thickness direction. The back upstream side laser 190L has an output strength capable of cutting at least the back side insulating material layer 26 and the back side active material layer 56 in the thickness direction. Then, at least one of both upstream lasers 180L and 190L can cut the metal foil 52 in addition to the front side insulating material layer 25 and the front side active material layer 54, or the back side insulating material layer 26 and the back side active material layer 56. Has output strength. That is, the front upstream side laser 180L has an output strength capable of cutting the front side insulating material layer 25, the front side active material layer 54, and the metal foil 52 in the thickness direction, and the back upstream side laser 190L has the back side insulating material layer 26. It may have an output strength capable of cutting only the backside active material layer 56. Further, the front upstream side laser 180L has an output strength capable of cutting only the front side insulating material layer 25 and the front side active material layer 54, and the back upstream side laser 190L has the back side insulating material layer 26, the back side active material layer 56 and the metal foil. It may have an output strength capable of cutting 52 and 52 in the thickness direction. Further, the front upstream side laser 180L has an output strength capable of cutting the front side insulating material layer 25, the front side active material layer 54, and the metal foil 52 in the thickness direction, and the back upstream side laser 190L has the back side insulating material layer 26. And the back side active material layer 56 and the metal foil 52 may have an output strength capable of cutting in the thickness direction. For example, the front upstream side laser 180L has an output strength capable of cutting the front side insulating material layer 25, the front side active material layer 54, and a part of the metal foil 52 in the thickness direction, and the back upstream side laser 190L has the metal foil 52. It may have an output strength capable of cutting the remaining portion, the back side active material layer 56, and the back side insulating material layer 26. In this way, the two upstream lasers 180L and 190L combine the two to cut the front insulating material layer 25, the front active material layer 54, the metal foil 52, the back active material layer 56, and the back insulating material layer 26. Has possible output strength (coating layer cutting strength).

As the positive electrode plate, the positive electrode plate 30b shown in FIGS. 36 to 38 may be adopted. In the positive electrode plate 30b, the front positive electrode active material layer 34 is formed only in the central region 32aC of the positive electrode current collector 32a, and includes the front positive electrode active material layer 34 so as to cover substantially the entire front side 32c of the positive electrode current collector 32a. The front side insulating material layer 25 is formed on the surface. Further, in the positive electrode plate 30b, the back side positive electrode active material layer 36 is formed only in the central region 32aC of the positive electrode current collector 32a, and includes the back side positive electrode active material layer 36 to cover substantially the entire back side 32d of the positive electrode current collector 32a. The back side insulating material layer 26 is formed so as to cover it. As shown in FIG. 38, in the central region 32aC of the positive electrode current collector 32a, the front side positive electrode coating layer 21b (front side coating layer or coating layer) is the front side positive electrode active material layer 34 and the front side positive electrode active material layer 34. It is formed by a front side insulating material layer 25 that covers the surface. Further, in the central region 32aC of the positive electrode current collector 32a, the back side positive electrode coating layer 22b (back side coating layer or coating layer) covers the back side positive electrode active material layer 36 and the back side positive electrode active material layer 36. It is formed by the layer 26. In the outer peripheral region 32aT of the positive electrode current collector 32a, the front side positive electrode coating layer 21b (front side coating layer or coating layer) is formed only by the front side insulating material layer 25. Further, in the outer peripheral region 32aT of the positive electrode current collector 32a, the back side positive electrode coating layer 22b is formed only by the back side insulating material layer 26. The positive electrode base portion 38a2 is composed of a positive electrode current collecting portion 32a and both positive electrode coating layers 21b and 22b. In the positive electrode plate 30b, the front side positive electrode active material layer 34 and the back side positive electrode active material layer 36 are not formed in the outer peripheral region 32aT of the positive electrode current collector 32. Therefore, for example, when the positive electrode plates 30b are alternately laminated with the negative electrode plates to produce the electrode assembly 20, even if any side of the positive electrode current collecting portion 32a hits the wall surface of the laminated box (not shown), this side It is prevented that the active material is separated from the outer peripheral region 32aT corresponding to the above. The central region 32aC of the positive electrode current collector 32a is a rectangular region in the center of the positive electrode current collector 32a. The outer peripheral region 32aT of the positive electrode current collector 32a is a frame-shaped region along the four sides of the positive electrode current collector 32a. In FIGS. 36 to 38, parts having the same or substantially the same configuration and function as those in FIGS. 1 to 35 are designated by the same reference numerals as those in FIGS. 1 to 35, thereby omitting duplicate description.

As the negative electrode plate, the negative electrode plate 40b shown in FIGS. 39 to 41 may be adopted. In the negative electrode plate 40b, the front negative electrode active material layer 44 is formed only in the central region 42aC of the negative electrode current collector 42a, and includes the front negative electrode active material layer 44 so as to cover substantially the entire front side 42c of the negative electrode current collector 42a. The front side insulating material layer 25 is formed on the surface. Further, in the negative electrode plate 40b, the back side negative electrode active material layer 46 is formed only in the central region 42aC of the negative electrode current collector 42a, and includes the back side negative electrode active material layer 46 to cover substantially the entire back side 42d of the negative electrode current collector 42a. The back side insulating material layer 26 is formed so as to cover it. As shown in FIG. 41, in the central region 42aC of the negative electrode current collector 42a, the front negative electrode coating layer 23b (front negative coating layer or coating layer) is the front negative electrode active material layer 44 and the front negative electrode active material layer 44. It is formed by a front side insulating material layer 25 that covers the surface. Further, in the central region 42aC of the negative electrode current collector 42a, the back side positive electrode coating layer 24b (back side coating layer or coating layer) covers the back side negative electrode active material layer 46 and the back side negative electrode active material layer 46. It is formed by the layer 26. In the outer peripheral region 42aT of the negative electrode current collector 42a, the front negative electrode coating layer 23b (front coating layer or coating layer) is formed only by the front insulating material layer 25. Further, in the outer peripheral region 42aT of the negative electrode current collector 42a, the back side negative electrode coating layer 24b is formed only by the back side insulating material layer 26. The negative electrode base portion 48a2 is composed of a negative electrode current collecting portion 42a and both negative electrode coating layers 23b and 24b. In the negative electrode plate 40b, the front negative electrode active material layer 44 and the back negative electrode active material layer 46 are not formed in the outer peripheral region 42aT of the negative electrode current collector 42. Therefore, for example, when the negative electrode plates 40b are alternately laminated with the positive electrode plates to produce the electrode assembly 20, even if any side of the negative electrode current collector 42a hits the wall surface of the laminated box (not shown), this side It is prevented that the active material is separated from the outer peripheral region 42aT corresponding to the above. The central region 42aC of the negative electrode current collector 42a is a rectangular region in the center of the negative electrode current collector 42a. The outer peripheral region 42aT of the negative electrode current collector 42a is a frame-shaped region along the four sides of the negative electrode current collector 42a. In FIGS. 39 to 41, parts having the same or substantially the same configuration / function as those in FIGS. 1 to 38 are designated by the same reference numerals as those in FIGS. 1 to 38, thereby omitting duplicate description.

When the positive electrode sheet 30b (see FIGS. 36 to 38) or the negative electrode sheet 40b (see FIGS. 39 to 41) is manufactured as the electrode sheet 80, the coating sheet 50e shown in FIG. 42 is produced in the coating sheet preparation step S1. Will be done. Although FIG. 42 shows an example of a coating sheet when four virtual contours R are set in the Y direction, the number of virtual contours R set in the Y direction in the coating sheet can be freely changed. ..

On the coating sheet 50e, two rows of front coating regions 62 are formed in parallel in the Y direction. Both front side coating regions 62 are regions in which the front side coating layers 18b are continuously formed in the X direction. The front side coating layer 18b is a front side insulation that integrally covers a plurality of front side active material layers 54k arranged in two rows in the Y direction with a width direction coating interval K1 and each front side active material layer 54k in these two rows. It is formed of a material layer 25. Each front side active material layer 54k is formed in a rectangular shape, for example. Each front side active material layer 54k is formed with a predetermined longitudinal coating interval K2 in the X direction. In the place where each front side active material layer 54k is formed, the front side coating layer 18b is formed by each of these front side active material layers 54k and the front side insulating material layer 25. Between the front active material layers 54k, the front coating layer 18b is formed only by the front insulating material layer 25. The front coating area 62 corresponds to the area where the front insulating material layer 25 is formed.

On the coating sheet 50e, two rows of backside coating regions 72 are formed in parallel in the Y direction. Both back side coating areas 72 face both front side coating areas 62. Both backside coating regions 72 are regions in which the backside coating layers 19b are continuously formed in the X direction. The back side coating layer 19b integrally covers a plurality of back side active material layers 56k arranged in two rows in the Y direction with a width direction coating interval K1 and each back side active material layer 56k in these two rows. It is formed of a material layer 26. Each backside active material layer 56k is formed, for example, in a rectangular shape. Each backside active material layer 56k is formed with a predetermined longitudinal coating interval K2 in the X direction. Each back side active material layer 56k is formed at a position facing each front side active material layer 54k. The back side insulating material layer 26 is formed at a position facing the front side insulating material layer 25. In the place where each back side active material layer 56 is formed, the back side coating layer 19b is formed by each of the back side active material layers 56k and the back side insulating material layer 26. Between the backside active material layers 56k, the backside coating layer 19b is formed only by the backside insulating material layer 26. The back coating area 72 corresponds to the area where the back insulating material layer 26 is formed.

Each first virtual contour R1 set on the coating sheet 50e individually surrounds each front side active material layer 54k (each back side active material layer 56k). The tab facing sides 388b and the tab parallel sides 388c and 388d of each first virtual contour R1 are located between the front side active material layers 54 (each back side active material layer 56). Each second virtual contour R2 set on the coating sheet 50e individually surrounds each front side active material layer 54 (each back side active material layer 56). The tab facing sides 488b and the tab parallel sides 488c and 488d of each second virtual contour R2 are located between the front side active material layers 54 (each back side active material layer 56). In FIG. 42, parts having the same or substantially the same configuration / function as those in FIGS. 1 to 41 are designated by the same reference numerals as those in FIGS. 1 to 41, thereby omitting duplicate description.

When producing the coating sheet 50e, first, the active material coating sheet 50e1 is produced. As shown in FIG. 43, the metal foil 52 is unwound from the supply roller 171. After that, the metal foil 52 is coated with the active material by the front side coating machine 172a. The front side coating machine 172a coats the surface of the front side 60 of the metal foil 52 with the active material. The front side coating machine 172a intermittently coats the active material in the longitudinal direction of the metal foil 52 with a longitudinal coating interval K2. The front side coating machine 172a coats the active material in four rows in the width direction of the metal foil corresponding to the coating sheet 50e shown in FIG. 42. After that, the metal foil 52 is coated with the active material by the backside coating machine 172b. The back side coating machine 172b coats the surface of the back side 70 of the metal foil 52 with the active material. The back side coating machine 172b intermittently coats the active material in the longitudinal direction of the metal foil 52 with a longitudinal coating interval K2. The back side coating machine 172b coats the active material in four rows in the width direction of the metal foil 52. The back side coating machine 172b coats the back side 70 of the metal foil 52 with the active material so as to face the active material coated on the front side 60 of the metal foil 52. After that, the active material is dried by the dryer 173 on both sides 60 and 70 of the metal foil 52. As a result, the active material coating sheet 50e1 in which the front side active material layer 54k and the back side active material layer 56k are formed on both sides 60 and 70 of the metal foil 52 is produced. After that, the active material coating sheet 50e1 is wound up by the winding roller 176. After that, the active material coating sheet 50e1 is set in a press machine (not shown) having a press roller. Then, the biactive material layers 54 and 56 of the active material coating sheet 50e1 are compressed in the thickness direction.

After that, the active material coating sheet 50e1 is set on the supply roller 178a of the insulating material coating dryer 178 shown in FIG. 44. The active material coating sheet 50e1 is unwound from the supply roller 178a. After that, the surface of the front side 60 of the active material coating sheet 50e1 is coated with an insulating material by the front side coating machine 178c1. The front side coating machine 178c1 continuously coats the insulating material in the longitudinal direction of the active material coating sheet 50e1. The front side coating machine 178c1 coats the insulating material so as to cover the space between the front side active material layer 54k and each front side active material layer 54k. The front side coating machine 172c1 coats the insulating material in two rows in the width direction of the material coating sheet 50e1 with the width of the front side center non-coating area 67 widened. After that, the active material coating sheet 50e1 is coated with an insulating material by the backside coating machine 178c2. The back side coating machine 178c2 coats the surface of the back side 70 of the active material coating sheet 50e1 with an insulating material. The back side coating machine 178c2 continuously coats the insulating material in the longitudinal direction of the active material coating sheet 50e1. The back side coating machine 178c2 coats the insulating material so as to cover the space between each back side active material layer 56k and each back side active material layer 56k. The back side coating machine 172c2 coats the insulating material in two rows in the width direction of the material coating sheet 50e1 with the width of the back side central non-coating area 77 widened. The back side coating machine 178c2 coats the back side 70 of the active material coating sheet 50e1 with the insulating material so as to face the insulating material coated on the front side 60 of the active material coating sheet 50e1. After that, the insulating material is dried by the dryer 173 on both sides 60 and 70 of the active material coating sheet 50a1. In this way, the space between the front side active material layer 54 and each front side active material layer 54 is covered with the front side insulating material layer 25, and the space between the back side active material layer 56 and each back side active material layer 56 is covered with the back side insulating material layer 26. The coating sheet 50e is completed. The coating sheet 50e is wound by the winding roller 178b. In FIGS. 43 and 44, parts having the same or substantially the same configuration / function as those in FIGS. 1 to 42 are designated by the same reference numerals as those in FIGS. 1 to 42, thereby omitting duplicate description. The coating sheet 50e is sent to the electrode sheet cutting step S2.

The output intensities of the lasers 180L and 190L on both upstream sides when the coating sheet 50e is cut in the electrode sheet cutting step S2 will be described. The front upstream side laser 180L has an output intensity capable of cutting at least the front side insulating material layer 25 in the thickness direction. The back upstream side laser 190L has an output intensity capable of cutting at least the back side insulating material layer 26 in the thickness direction. At least one of both upstream lasers 180L and 190L has an output strength capable of cutting the metal foil 52 in addition to the front insulating material layer 25 or the back insulating material layer 26. That is, the front upstream side laser 180L has an output intensity capable of cutting the front side insulating material layer 25 and the metal foil 52 in the thickness direction, and the back upstream side laser 190L has an output capable of cutting only the back side insulating material layer 26. It may have strength. Further, the front upstream side laser 180L has an output strength capable of cutting only the front side insulating material layer 25, and the back upstream side laser 190L has an output capable of cutting the back side insulating material layer 26 and the metal foil 52 in the thickness direction. It may have strength. Further, the front upstream side laser 180L has an output strength capable of cutting the front side insulating material layer 25 and the metal foil 52 in the thickness direction, and the back upstream side laser 190L has the back side insulating material layer 26 and the metal foil 52. It may have an output strength capable of cutting in the thickness direction. For example, the front upstream side laser 180L has an output strength capable of cutting the front side insulating material layer 25 and a part of the metal foil 52 in the thickness direction, and the back upstream side laser 190L has the back side insulation with the remaining part of the metal foil 52. It may have an output strength capable of cutting the material layer 26. In this way, both upstream lasers 180L and 190L combine the two to obtain an output strength (coating layer cutting strength) capable of cutting the front insulating material layer 25, the metal leaf 52, and the back insulating material layer 26. Have. As described above, the active material layer is not formed on the coating sheet 50e. Therefore, when cutting the coating sheet 50e, both upstream side lasers 180L and 190L need only have the strength to cut the front side insulating material layer 25, the metal foil 52, and the back side insulating material layer 26, and the active material layer. It is not necessary to have the strength to cut. Therefore, the output intensities of both upstream lasers 180L and 190L are reduced.

In the above embodiment, the positive electrode tab portion 32b and the negative electrode tab portion 42b may not be completely exposed, and even if the active material layers are partially extended and coated. Good. Further, the laser apparatus does not necessarily have to be arranged on the front side and the back side, and may be arranged only on the front side. Further, a plurality of upstream laser devices may be arranged. Further, it does not mean that the front side coating area 62 and the area where the front side insulating material layer 25 is formed only completely coincide with each other, and the type of active material to be coated, the basis weight, the coating conditions, and the drying conditions. Depending on the case, they may not match exactly.

Claims (12)

An electrode sheet manufacturing device that cuts out an electrode sheet using a laser from a coating sheet in which a coating layer is formed on a strip-shaped metal foil.
The coating sheet is provided adjacent to a coating region, which is a region in which the coating layer is continuously formed in the longitudinal direction of the metal foil, and the coating region in the width direction of the metal foil. It has a non-coated area which is a continuous area in the longitudinal direction in a state where the metal foil is exposed.
The electrode sheet has a rectangular current collecting portion and a tab portion having a shape protruding from a tab forming side which is one side of the current collecting portion.
An upstream transport device arranged so as to face the non-coated region and transporting the non-coated region in a transport direction along the longitudinal direction.
An upstream suction device that sucks the uncoated area toward the upstream transfer device,
A downstream transfer device that is arranged so as to face the coating area and is arranged on the downstream side of the upstream transfer device in the transfer direction to convey the coating area in the transfer direction.
A downstream suction device that sucks the coating area toward the downstream transfer device,
Virtually on the coating sheet in the upstream laser space, which is a space adjacent to the upstream transport device in the width direction and a space serialized in the transport direction with respect to the downstream transport device. A space that is a laser device that irradiates the coating sheet with the laser along the virtual contour that is the contour of the electrode sheet set to, and is adjacent to the downstream transfer device in the width direction. In the downstream laser space, which is a space in series with the upstream transport device in the transport direction, the virtual contour on the coating sheet and the laser device is said in the upstream laser space. It has the laser apparatus for irradiating the coating sheet with the laser along the remaining virtual contour excluding the portion of the virtual contour irradiated with the laser.
Electrode sheet manufacturing equipment. The electrode sheet manufacturing apparatus according to claim 1.
The front surface of the coating sheet has a front coating region, which is a region in which the front coating layer as the coating layer is continuously formed in the longitudinal direction, and a width thereof with respect to the front coating region. It has a front side non-painted area which is a region which is provided adjacent to each other in the direction and which is a continuous region in the longitudinal direction in a state where the metal foil is exposed.
The back surface of the coating sheet is a region facing the front coating region with the metal foil sandwiched between the coating sheet and a back coating region in which the back coating layer as the coating layer is formed. The back side non-coated region, which is a region facing the front non-coated region with the metal foil sandwiched therein and is a region continuous in the longitudinal direction with the metal foil exposed.
The rectangular current collecting portion is a tab parallel side which is two sides excluding the tab forming side, the tab facing side which is the side facing the tab forming side, and the tab forming side and the tab facing side. And have
The front side coating area and the back side coating area have a width corresponding to at least the length of the tab parallel side.
The front side non-painted area and the back side non-painted area have a width corresponding to at least the length of the tab portion in the protruding direction.
The upstream-side transport device has a width equal to or less than the width of the back-side non-painted region, is arranged so as to face the back-side non-coating region, and transports the back-side non-coating region in the transport direction. And
The upstream side suction device sucks the back side unpainted area toward the upstream side transport device.
The downstream side transport device has a width equal to or less than the width of the back side coating area, is arranged so as to face the back side coating area, and conveys the back side coating area in the transport direction.
The downstream suction device sucks the back coating area toward the downstream transfer device.
Electrode sheet manufacturing equipment. The electrode sheet manufacturing apparatus according to claim 2.
The front coating layer is formed by a front active material layer and a front insulating material layer covering the front active material layer, or is formed only by the front active material layer, or the front side. It is formed only by the insulating material layer and
The back side coating layer is formed by a back side active material layer and a back side insulating material layer covering the back side active material layer, or is formed only by the back side active material layer, or the back side. Formed only by the insulating material layer,
Electrode sheet manufacturing equipment. The electrode sheet manufacturing apparatus according to claim 2 or 3.
The intensity of the laser irradiated in the upstream laser space is set to a coating layer cutting intensity capable of cutting the front coating layer, the metal foil, and the back coating layer.
The intensity of the laser irradiated in the downstream laser space is set to a metal leaf cutting intensity that is smaller than the coating layer cutting intensity and is capable of cutting the metal leaf.
Electrode sheet manufacturing equipment. The electrode sheet manufacturing apparatus according to claim 4.
The laser device is
In the upstream laser space, at least a portion corresponding to the tab facing side and the tab parallel side in the virtual contour is irradiated with the laser.
In the downstream laser space, at least a portion corresponding to the tab portion in the virtual contour is irradiated with the laser.
Electrode sheet manufacturing equipment. The electrode sheet manufacturing apparatus according to claim 1.
The laser device includes an upstream laser device that irradiates the upstream laser, which is the laser, toward the virtual contour in the upstream laser space, and the laser toward the virtual contour in the downstream laser space. It is composed of a downstream laser device that irradiates a certain downstream laser.
Electrode sheet manufacturing equipment. The electrode sheet manufacturing apparatus according to any one of claims 2 to 5.
The laser device includes an upstream laser device that irradiates the upstream laser, which is the laser, toward the virtual contour in the upstream laser space, and the laser toward the virtual contour in the downstream laser space. It is composed of a downstream laser device that irradiates a certain downstream laser.
Electrode sheet manufacturing equipment. The electrode sheet manufacturing apparatus according to claim 7.
The front-side non-coated area has a first front-side non-coated area and a second front-side non-coated area on both sides of the front-side coated area in the width direction of the metal foil.
The first front-side non-painted area includes an inner first front-side non-painted area which is adjacent to the front-side coated area and continuous in the longitudinal direction, and the inner first front-side non-painted area. It has an outer first front side non-coated area which is a region continuous in the longitudinal direction on the side opposite to the front side coated area in the width direction with respect to the region.
The second front-side non-painted area includes an inner second front-side non-painted area which is adjacent to the front-side coated area and continuous in the longitudinal direction, and the inner second front-side non-painted area. It has an outer second front side non-painted area, which is a region continuous in the longitudinal direction on the side opposite to the front side coated area in the width direction with respect to the area.
The back side non-coated area has a first back side non-coated area and a second back side non-coated area on both sides of the back side coated area in the width direction of the metal foil.
The first backside non-coated area includes an inner first backside non-coated area which is adjacent to the backside coated area and continuous in the longitudinal direction, and the inner first backside non-coated area. It has an outer first backside unpainted region which is a region continuous in the longitudinal direction on the side opposite to the backside coated region in the width direction with respect to the region.
The second backside non-coating area includes an inner second backside non-coating area which is adjacent to the backside coating area and continuous in the longitudinal direction, and the inner second backside non-coating area. It has an outer second backside unpainted region which is a region continuous in the longitudinal direction on the side opposite to the backside coated region in the width direction with respect to the region.
The upstream-side transport device has a width equal to or less than the width of the first back-side non-painted region, is arranged so as to face the first back-side non-coating region, and has the first back-side non-coating region. The first upstream transport device that transports in the transport direction has a width equal to or less than the width of the second backside non-coated region, and is in contact with the second backside non-coated region so as to face the first upstream. It is composed of a second upstream transport device which is arranged in parallel with the side transport device and transports the second backside uncoated area in the transport direction along the longitudinal direction.
The upstream suction device includes a first upstream suction device that sucks the first backside unpainted area toward the first upstream transfer device, and the second back side toward the second upstream transfer device. It is composed of a second upstream suction device that sucks the uncoated area.
It has a width equal to or less than the width of the outer first backside non-coated area, is arranged so as to face the outer first backside non-coated area and in parallel with the downstream transfer device, and is arranged so as to be in parallel with the downstream transfer device. A first auxiliary downstream transport device that transports the first backside non-coated area in the transport direction, and
It has a width equal to or less than the width of the outer second backside non-coated area, is arranged so as to face the outer second backside uncoated area and in parallel with the downstream transfer device, and is arranged so as to be in parallel with the downstream side transport device. A second auxiliary downstream transport device that transports the second backside non-coated area in the transport direction, and
The first auxiliary downstream suction device that sucks the outer first back side unpainted area toward the first auxiliary downstream side transport device, and the outer second back side unpainted device toward the second auxiliary downstream side transport device. It has a second auxiliary downstream suction device that sucks the work area.
The upstream laser space is a space sandwiched between the first upstream transfer device and the second upstream transfer device, and is a space on the side close to the first upstream transfer device. A space and a second upstream laser space, which is a space sandwiched between the first upstream transfer device and the second upstream transfer device and is close to the second upstream transfer device, are provided. Have and
The downstream laser space includes a first downstream laser space, which is a space sandwiched between the downstream transfer device and the first auxiliary downstream transfer device, and the downstream transfer device and the second auxiliary downstream transfer device. It has a second downstream laser space, which is a space sandwiched between the devices.
The upstream laser device is
In the first upstream side laser space and the second upstream side laser space, the electrode sheet virtually set on the coating sheet from the center in the width direction to the side of the first front side non-coating region. The first virtual contour which is the contour of the electrode sheet and the second virtual contour which is the contour of the electrode sheet virtually set from the center in the width direction to the side of the second front side non-painted region on the coating sheet. Along the above, the upstream laser is applied to the coating sheet supported by the first upstream transfer device and the second upstream transfer device.
The downstream laser device is
In the first downstream laser space, the remaining first virtual contour excluding the portion of the first virtual contour on the coating sheet that is irradiated with the upstream laser. Along the way, the downstream laser is applied to the coating sheet supported by the downstream transfer device and the first auxiliary downstream transfer device.
In the second downstream laser space, the remaining second virtual contour on the coating sheet, excluding the portion of the second virtual contour irradiated with the upstream laser. Along the way, the downstream laser is applied to the coating sheet supported by the downstream transfer device and the second auxiliary downstream transfer device.
Electrode sheet manufacturing equipment. The electrode sheet manufacturing apparatus according to claim 8.
The coating sheet is conveyed at a predetermined transfer height by the upstream side transfer device and the downstream side transfer device.
At a position adjacent to the downstream transport device in the width direction and in series with the inner first backside non-coated region in the transport direction, the transport is performed along the transport direction. It has a first guide member having an inclined surface from a position lower than the height to a position close to the transport height.
At a position adjacent to the downstream transport device in the width direction and in series with the inner second backside non-coated region in the transport direction, the transport is performed along the transport direction. It has a second guide member having an inclined surface from a position lower than the height to a position close to the transport height.
Electrode sheet manufacturing equipment. A method for manufacturing an electrode sheet, in which an electrode sheet is cut out from a coating sheet in which a coating layer is formed on a strip-shaped metal foil using a laser.
The coating sheet is provided adjacent to a coating region, which is a region in which the coating layer is continuously formed in the longitudinal direction of the metal foil, and the coating region in the width direction of the metal foil. It has a non-coated area which is a continuous area in the longitudinal direction in a state where the metal foil is exposed.
The electrode sheet has a rectangular current collecting portion and a tab portion having a shape protruding from a tab forming side which is one side of the current collecting portion.
When the contour of the electrode sheet defines a virtual contour that is virtually set on the coating sheet,
While supporting the non-coated area and transporting the coated sheet in a transport direction along the longitudinal direction, the virtual contour in the coated area adjacent to the supporting non-coated area. The coating area cutting process that cuts out the part with the laser and
While transporting the coating sheet in the transport direction while supporting the coating region, the laser is used to determine a portion of the virtual contour in the non-coating region adjacent to the supporting coating region. Has a non-painted area cutting process, which is cut out in
A method for manufacturing an electrode sheet. The method for manufacturing an electrode sheet according to claim 10.
The front surface of the coating sheet has a front coating region, which is a region in which the front coating layer as the coating layer is continuously formed in the longitudinal direction, and a width thereof with respect to the front coating region. It has a front side non-painted area which is a region which is provided adjacent to each other in the direction and which is a continuous region in the longitudinal direction in a state where the metal foil is exposed.
The back surface of the coating sheet is a region facing the front coating region with the metal foil sandwiched between the coating sheet and a back coating region in which the back coating layer as the coating layer is formed. The back side non-coated region, which is a region facing the front non-coated region with the metal foil sandwiched therein and is a region continuous in the longitudinal direction with the metal foil exposed.
The rectangular current collecting portion is a tab parallel side which is two sides excluding the tab forming side, the tab facing side which is the side facing the tab forming side, and the tab forming side and the tab facing side. And have
The front side coating area and the back side coating area have a width corresponding to at least the length of the tab parallel side.
The front side non-painted area and the back side non-painted area have a width corresponding to at least the length of the tab portion in the protruding direction.
In the coating area cutting step, the backside coating area adjacent to the supporting backside non-coating area while supporting the backside non-coating area and transporting the coating sheet in the transport direction. The part of the virtual contour in the inside is cut out by the laser.
In the non-coating area cutting step, the backside non-coating area adjacent to the supporting backside coating area while supporting the backside coating area and transporting the coating sheet in the transport direction. The part of the virtual contour in the region is cut out by the laser.
A method for manufacturing an electrode sheet. The method for manufacturing an electrode sheet according to claim 11.
The front coating layer is formed by a front active material layer and a front insulating material layer covering the front active material layer, or is formed only by the front active material layer, or the front side. It is formed only by the insulating material layer and
The back side coating layer is formed by a back side active material layer and a back side insulating material layer covering the back side active material layer, or is formed only by the back side active material layer, or the back side. Formed only by the insulating material layer,
A method for manufacturing an electrode sheet.

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