Patent Description:
Exemplary electrochemical devices include a lithium-ion secondary battery, an electric double layer capacitor, a lithium-ion capacitor, and a redox capacitor. Among others, the secondary battery, which is repeatedly chargeable and dischargeable, is severely required to be desirable in safety and reliability because of uses of the secondary battery. Desirability in safety and reliability is also required of electrodes of electrochemical devices.

In order not to cause problems including ignition, the quality of manufacture needs to be strictly maintained in manufacturing processes. Consequently, the quality of manufacture also needs to be maintained for an electrode as a material of an electrochemical device.

<CIT> discloses a secondary battery manufacturing method including: acquiring, as position information, identification information on an electrode material used for assembly and a position of a portion expected for use of the electrode material used for assembly; acquiring quality information on the portion expected for use of the electrode material, based on the identification information and position as acquired; and deciding a portion of the electrode material that is to be actually used for assembly, based on the quality information as acquired.

An electrode manufacturing apparatus includes: an applier configured to apply a liquid composition to form an insulating layer onto an electrode base or a functional layer on the electrode base; a controller configured to control the applier; and a surface detector configured to detect a surface condition of the liquid composition or the insulating layer on the electrode base or the functional layer, wherein the controller is configured to control the applier based on the surface condition of the liquid composition or the insulating layer detected by the surface detector, characterized in that the controller is configured to change a pattern to be formed on the electrode base or the functional layer to increase an amount of the liquid composition to be applied onto the electrode base or the functional layer.

A more complete application of embodiments of the present disclosure and many of the attendant advantages and features thereof can be readily obtained and understood from the following detailed description with reference to the accompanying drawings, wherein:.

In an electrode manufacturing apparatus of the present disclosure, in electrode manufacturing processes, a surface detector detects a surface condition of an insulating layer after application of a liquid composition and an application controller controls an applier based on the detected surface condition.

In the following, the electrode manufacturing apparatus of the present disclosure is described in detail using the drawings.

<FIG> is an example of a diagram illustrating a general arrangement of an electrode manufacturing apparatus according to an embodiment of the present disclosure.

As illustrated in <FIG>, an electrode manufacturing apparatus <NUM> of the present embodiment includes a winding off part <NUM> and a winding up part <NUM> that bear a conveying function, a discharger <NUM> as an example of an applier of a liquid composition, a curing device <NUM>, a heater <NUM>, a surface detector <NUM>, an electrode base <NUM>, a functional layer <NUM> provided on the electrode base <NUM>, and a system control section <NUM>. The details of the system control section <NUM> will be described later.

<FIG> illustrates the electrode base <NUM>, which is a discharge target material as an object of application, or the inside of the electrode manufacturing apparatus <NUM> as viewed in a Y direction orthogonal to a conveyance direction X of the electrode base <NUM>.

The surface detector <NUM> is arranged on a downstream side in the conveyance direction X, which is a direction where the discharge target material with the liquid composition discharged by the discharger <NUM> to the discharge target material is conveyed. The surface detector <NUM> is arranged with the curing device <NUM> and the heater <NUM> in any order.

The electrode manufacturing apparatus <NUM> uses a liquid composition <NUM> that is a material for forming an insulating layer <NUM> as a resin layer <NUM> or an inorganic layer <NUM>, to form the insulating layer <NUM> as the resin layer <NUM> or the inorganic layer <NUM> so that the insulating layer <NUM> may cover a surface of the electrode base <NUM> or a surface of the functional layer <NUM> provided on the electrode base <NUM>, and detects a surface condition of the insulating layer <NUM> as the resin layer <NUM> or the inorganic layer <NUM> with the surface detector <NUM> provided downstream of the discharger <NUM>.

The electrode manufacturing apparatus <NUM> conveys the discharge target material by the winding off part <NUM> and the winding up part <NUM> and discharges, with the discharger <NUM>, the liquid composition <NUM> to the discharge target material being conveyed, so as to form the insulating layer <NUM> as the resin layer <NUM> or the inorganic layer <NUM> so that the insulating layer <NUM> may cover a surface of the discharge target material, that is to say, the surface of the electrode base <NUM> or the surface of the functional layer <NUM> provided on the electrode base <NUM>.

In the present embodiment, the winding off part <NUM> is used as a means for winding off the discharge target material, and the winding up part <NUM> is used as a means for winding up the discharge target material. The winding off part <NUM> rotates the discharge target material stored in a roll form, so as to feed the discharge target material to a conveyance path of the electrode manufacturing apparatus <NUM>. The winding up part <NUM> winds up the discharge target material, to which the liquid composition <NUM> has been discharged so as to form the insulating layer <NUM>, and stores the discharge target material in a roll form. Also in relation to other processes, the coating speed on the electrode manufacturing apparatus <NUM> is preferably <NUM> [m/min. ] to <NUM> [m/min. Such coating speed allows the electrode manufacturing apparatus <NUM> to be suitably used even if the insulating layer <NUM> needs to be formed at a high speed.

The discharge target material is a base material continuing in the conveyance direction X. In this instance, the base material includes the electrode base <NUM> and the functional layer <NUM> provided on the electrode base <NUM>. The electrode manufacturing apparatus <NUM> conveys the discharge target material along the conveyance path between the winding off part <NUM> and the winding up part <NUM>. The length in the conveyance direction X of the discharge target material is at least larger than the length of the conveyance path between the winding off part <NUM> and the winding up part <NUM>. The electrode manufacturing apparatus <NUM> is to successively form the insulating layer <NUM> on the discharge target material, which continues in the conveyance direction X.

The electrode base <NUM> according to the present embodiment includes an electroconductive foil with planarity that is, in general, suitably used for a power storage device such as a secondary battery and a capacitor, among others a lithium-ion secondary battery. Examples of the electroconductive foil to be used include an aluminum foil, a copper foil, a stainless steel foil, a titanium foil, an etched foil obtained by etching any of such foils so as to make minute holes, and a perforated electrode base used for a lithium-ion capacitor. A carbon paper-fibrous electrode for a power generation device such as a fuel cell, which electrode is made nonwoven or woven and planar, and a perforated electrode base whose holes are minute are usable as the electrode base <NUM>.

The functional layer <NUM> provided on the electrode base <NUM> according to the present embodiment includes a layer containing an active material. A powdery active material or catalyst composition is dispersed or dissolved in liquid, and the resultant liquid is coated, fixed, and dried on the electrode base <NUM> so as to form the functional layer <NUM> provided on the electrode base <NUM>.

In order to form the functional layer <NUM> provided on the electrode base <NUM>, a spray, a dispenser, a die coater, a lift coating technique or the like is used, and the liquid composition <NUM> as coated is dried after coating so as to form the functional layer <NUM> provided on the electrode base <NUM>. A powdery active material or catalyst composition is dispersed or dissolved in liquid, and the resultant liquid is coated, fixed, and dried on the electrode base <NUM> so as to form the functional layer <NUM> provided on the electrode base <NUM>.

A cathode active material is not particularly limited as long as the material reversibly occludes and releases alkali metal ions. Typically, an alkali metal-containing transition metal compound is used as an active material for cathode. For instance, a complex oxide containing at least one element selected from the group consisting of cobalt, manganese, nickel, chromium, iron, and vanadium, and lithium is mentioned as a lithium-containing transition metal compound. The alkali metal-containing transition metal compound is exemplified by a lithium-containing transition metal compound such as lithium cobalt oxide, lithium nickel oxide, and lithium manganese oxide, an olivine type lithium salt such as LiFePO<NUM>, a chalcogenide such as titanium disulfide and molybdenum disulfide, manganese dioxide, and the like. The lithium-containing transition metal compound refers to a metal oxide containing lithium and a transition metal or the metal oxide, in which the transition metal is partially substituted with a hetero element. Examples of the hetero element include Na, Mg, Se, Y, Mn, Fe, Co, Ni, Cu, Zn, Al, Cr, Pb, Sb, and B, with Mn, Al, Co, Ni, and Mg being especially preferred. The hetero element may be one or two or more in kind. The above cathode active materials may be used alone or in combination of two or more. Examples of the active material for a nickel-hydrogen battery include nickel hydroxide.

An anode active material is not particularly limited as long as the material reversibly occludes and releases alkali metal ions. Typically, a carbon material including graphite having a graphitic crystal structure is used as an anode active material. Such carbon material is exemplified by natural graphite, spherical or fibrous synthetic graphite, hardly graphitizable carbon (hard carbon), readily graphitizable carbon (soft carbon), and the like. Other suitable materials than the carbon material include lithium titanate. From the viewpoint of raise in energy density of a lithium-ion battery, a high capacitance material, such as silicon, tin, a silicon alloy, a tin alloy, silicon oxide, silicon nitride, and tin oxide, is also used suitably as an anode active material. A hydrogen-occluding alloy usable as an anode active material for the nickel-hydrogen battery is exemplified by an AB2 type or A2B type hydrogen-occluding alloy that is typified by Zr-Ti-Mn-Fe-Ag-V-Al-W, Ti<NUM>Zr<NUM>V<NUM>Ni<NUM>Cr<NUM>Co<NUM>Fe<NUM>Mn<NUM>, and the like.

A substance usable for a binding agent for a cathode or an anode is exemplified by polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), polyethylene, polypropylene, an aramid resin, polyamide, polyimide, polyamide imide, polyacrylonitrile, polyacrylic acid, polymethyl acrylate ester, polyethyl acrylate ester, polyhexyl acrylate ester, polymethacrylic acid, polymethyl methacrylate ester, polyethyl methacrylate ester, polyhexyl methacrylate ester, polyvinyl acetate, polyvinylpirroridone, polyether, polyethersulfone, polyhexafluoropropylene, styrene-butadiene rubber, carboxymethyl cellulose, and the like. A copolymer of two or more materials selected from among tetrafluoroethylene, hexafluoroethylene, hexafluoropropylene, perfluoroalkyl vinyl ether, vinylidene fluoride, chlorotrifluoroethylene, ethylene, propylene, pentafluoropropylene, fluoromethyl vinyl ether, acrylic acid, and hexadiene may also be used. Two or more selected from such substances may be mixed together and used as such.

Examples of a substance used for an electroconductive agent to be contained in an electrode include graphite such as natural graphite and synthetic graphite, carbon black such as acetylene black, Ketjen black, channel black, furnace black, lamp black, and thermal black, electroconductive fibers such as carbon fibers and metal fibers, fluorocarbon, metal powder such as aluminum powder, electroconductive whiskers of zinc oxide, potassium titanate or the like, an electroconductive metal oxide such as titanium oxide, and an organic electroconductive material such as a phenylene derivative and a graphene derivative.

An active material in a fuel cell normally uses, as a catalyst for the cathode or the anode, fine particles of metal, such as platinum, ruthenium, and a platinum alloy, carried by a catalyst carrier such as carbon. For instance, the catalyst carrier is suspended in water, a catalyst particle precursor is added to and dissolved in the suspension (using a substance containing an alloy component, such as chloroplatinic acid, dinitrodiaminoplatinum, platinic chloride, platinous chloride, bisacetylacetonatoplatinum, dichlorodiammine platinum, dichlorotetramine platinum, platinic sulphate chlororuthenic acid, iridium chloride acid, rhodium chloride acid, ferric chloride, cobalt chloride, chromium chloride, gold chloride, silver nitrate, rhodium nitrate, palladium chloride, nickel nitrate, iron sulphate, and copper chloride), then an alkali is added to the solution so as to produce a metal hydroxide and allow the catalyst carrier to support the metal hydroxide on a surface of the catalyst carrier. The resultant catalyst carrier is coated onto the electrode and reduction is caused in a hydrogen atmosphere or the like so as to achieve the electrode, which has the catalyst particles (active material) coated to a surface of the electrode.

(Resin Layer or Inorganic Layer) In the present embodiment in particular, the liquid composition <NUM> is discharged by the discharger <NUM> to the functional layer <NUM> provided on the electrode base <NUM> so as to form the resin layer <NUM> or the inorganic layer <NUM>. The liquid composition <NUM> is not particularly limited as long as the liquid composition <NUM> has a viscosity allowing the discharge by the discharger <NUM> or a surface tension allowing the formation on the functional layer <NUM> provided on the electrode base <NUM>.

(Discharger of Liquid Composition) As illustrated in <FIG>, the electrode manufacturing apparatus <NUM> includes the discharger <NUM> as a means for discharging the liquid composition <NUM>. The discharger <NUM> includes multiple nozzle arrays each having multiple nozzles arranged in a width direction of the discharge target material (the Y direction). In the electrode manufacturing apparatus <NUM>, the discharger <NUM> of the liquid composition <NUM> is provided so that the liquid composition <NUM> may be discharged through the nozzles toward the discharge target material. In the discharger <NUM>, a means for stimulating the liquid composition <NUM> so as to discharge the liquid composition <NUM> is selected appropriately to the purpose, so that it does not matter whether the means is of a piezoelectric type using a piezoelectric element, of a thermal type using a heater, of a valve type using a pressure device, or of some other type.

The discharger <NUM> includes a discharge unit for the liquid composition <NUM>. The discharge unit for the liquid composition <NUM> includes an aggregation of functional parts and mechanisms involved in the discharge of the liquid composition <NUM> from the discharger <NUM>. The discharge unit for the liquid composition <NUM> includes at least one out of configurations of a supply mechanism, a maintenance mechanism, and a liquid discharging head movement mechanism, as combined with the discharger <NUM>.

Control of the discharger <NUM> in relation to the discharge of the liquid composition <NUM> is exerted by a discharge control unit <NUM> as an example of an application controller in the system control section <NUM> illustrated in <FIG>. The "discharge control unit <NUM>" may be also referred to as a "controller".

The discharge control unit <NUM> controls the timing of discharge of the liquid composition <NUM>, the position where a droplet of the liquid composition <NUM> is to be discharged, and the size of each droplet.

The surface detector <NUM> is an example of a detection means that observes and outputs the surface condition of the insulating layer <NUM> (the resin layer <NUM> or the inorganic layer <NUM>) formed on the discharge target material. The electrode manufacturing apparatus <NUM> acquires quality information on the insulating layer <NUM> (the resin layer <NUM> or the inorganic layer <NUM>) formed on the discharge target material, based on an observation result output by the surface detector <NUM>.

A method of detection by the surface detector <NUM> will be detailed later.

As illustrated in <FIG>, the electrode manufacturing apparatus <NUM> includes the system control section <NUM>. The system control section <NUM> controls operations of the whole electrode manufacturing apparatus <NUM>.

The system control section <NUM> includes an operation unit <NUM>, a storage unit <NUM>, a storage and reading unit <NUM>, and the discharge control unit <NUM>.

The operation unit <NUM> includes a touch panel, accepts an operation input by a user of the electrode manufacturing apparatus <NUM>, and displays a state and settings of the electrode manufacturing apparatus <NUM> on a screen.

The discharge control unit <NUM> controls the discharger <NUM> in relation to the discharge of the liquid composition <NUM>.

As illustrated in <FIG>, the electrode manufacturing apparatus <NUM> includes the system control section <NUM>.

The system control section <NUM> includes the operation unit <NUM>, the storage unit <NUM>, the storage and reading unit <NUM>, a processing unit <NUM>, a surface detection image acquisition unit <NUM>, a defect determination unit <NUM>, a discharge instruction preparation unit <NUM>, a result output unit <NUM>, a conveyance control unit <NUM>, and the discharge control unit <NUM>. Functions of the respective units will be described later.

The system control section <NUM> is arranged in any position inside or outside the electrode manufacturing apparatus <NUM>. If the system control section <NUM> is arranged outside, exchange of control signals and data is carried out over various communications networks. The communications networks include the Internet, a mobile communication network, and a local area network (LAN). In addition to a wired communications network, a network based on wireless communication, such as the third generation mobile communication system (<NUM>), the worldwide interoperability for microwave access (WiMAX), and the long term evolution (LTE),may be included in the communications networks. The electrode manufacturing apparatus <NUM> sends and receives communications by a short range communication technology such as the near field communication (NFC) (registered trademark).

Using <FIG>, a hardware configuration of the system control section <NUM> is described below.

<FIG> is a diagram illustrating a hardware configuration of the system control section <NUM>.

As illustrated in <FIG>, the system control section <NUM> includes a central processing unit (CPU) <NUM>, a read-only memory (ROM) <NUM>, a random access memory (RAM) <NUM>, a hard disk (HD) <NUM>, a hard disk drive (HDD) <NUM>, a medium <NUM>, a media interface (I/F) <NUM>, a display <NUM>, a network I/F <NUM>, a keyboard <NUM>, a mouse <NUM>, a compact disc rewritable (CD-RW) drive <NUM>, and a bus line <NUM>.

The CPU <NUM> controls operations of the whole system control section <NUM>. The ROM <NUM> stores a program used to drive the CPU <NUM>. The RAM <NUM> is used as a work area of the CPU <NUM>. The HD <NUM> stores various kinds of data such as a program. The HDD <NUM> controls reading or writing of various kinds of data from or on the HD <NUM> in accordance with the control by the CPU <NUM>. The media I/F <NUM> controls reading or writing (storing) of data from or on the medium <NUM> such as a flash memory. The display <NUM> displays various kinds of information such as a cursor, a menu, a window, a letter, and an image. The network I/F <NUM> is an interface for using a communications network <NUM> to perform data communication. The keyboard <NUM> is an example of input means provided with multiple keys for inputting letters, numerical values, various instructions, and the like. The mouse <NUM> is an example of input means for selecting and executing various instructions, selecting an object of processing, moving a cursor, and so forth. The CD-RW drive <NUM> controls reading or writing of various kinds of data from or on a CD-RW (image management server) <NUM> as an example of a removable recording medium.

The CD-RW drive <NUM> may be replaced by a digital versatile disc recordable (DVD-R) drive. The system control section <NUM> may include multiple computers that the respective units (functions, means or storages) are dividedly and optionally assigned to.

<FIG> as a function block diagram of the electrode manufacturing apparatus <NUM> includes a function block diagram of the system control section <NUM>. Using <FIG> and <FIG>, operations of the system control section <NUM> are described below.

As illustrated in <FIG>, the system control section <NUM> includes the operation unit <NUM>, the storage unit <NUM>, the storage and reading unit <NUM>, the processing unit <NUM>, the surface detection image acquisition unit <NUM>, the defect determination unit <NUM>, the discharge instruction preparation unit <NUM>, the result output unit <NUM>, the conveyance control unit <NUM>, and the discharge control unit <NUM>.

The above units each represent a function realized, or a means functioning, based on the fact that one of the components illustrated in <FIG> operates in line with a command from the CPU <NUM> following a program developed from the HD <NUM> onto the RAM <NUM>. The system control section <NUM> includes the storage unit <NUM>, which includes the RAM <NUM> and the HD <NUM> illustrated in <FIG>.

The operation unit <NUM> is chiefly realized by a command from the CPU <NUM> illustrated in <FIG>, and receives a signal from the keyboard <NUM> or the mouse <NUM> operated by the user, so as to accept various operations by the user. The operations thus accepted are each realized by a command from the CPU <NUM> illustrated in <FIG>, so as to cause various images or screens to be displayed on the display <NUM> provided on the operation unit <NUM>.

The processing unit <NUM> is realized by a command from the CPU <NUM> illustrated in <FIG>, and performs total control of the electrode manufacturing apparatus <NUM>.

The storage and reading unit <NUM> is realized by a command from the CPU <NUM> illustrated in <FIG>, as well as the HDD <NUM>, the media I/F <NUM>, and the CD-RW drive <NUM>, and performs a process for storing various kinds of data in the storage unit <NUM>, the medium <NUM>, and the CD-RW <NUM> and a process for reading various kinds of data from the storage unit <NUM>, the medium <NUM>, and the CD-RW <NUM>.

Among controls exerted on the electrode manufacturing apparatus <NUM>, the discharge control unit <NUM> exerts control on the discharger <NUM> chiefly based on information detected by the surface detector <NUM>. The conveyance control unit <NUM> controls the winding off part <NUM> and the winding up part <NUM>. The timing of discharge and the discharge amount of the liquid composition <NUM> are controlled. Such control functions are realized by an electric circuit, and part of the functions may be realized by software (a CPU). The functions may also be realized by multiple circuits or multiple software programs. The conveyance control unit <NUM> controls the start and stop of conveyance of the discharge target material by the winding off part <NUM> and the winding up part <NUM>, or the conveyance speed and the like.

If the surface detection image acquisition unit <NUM> acquires a surface detection image from the surface detector <NUM>, the defect determination unit <NUM> starts defect distinction. The defect determination unit <NUM> distinguishes defects. The defect refers to a fault causing fall of a material characteristic value of the functional layer <NUM>, such as a streak, a pinhole, unevenness, foreign matter, and a shortage of film thickness. An item in the quality information that should be regarded as a defect and such parameters as the size of a defect are assumed to be set by the user in advance. In a statement about <FIG> to be given later, a streak-like defect is taken up.

If no defects are present, a log notifying that change in discharge amount is unnecessary is prepared in the discharge instruction preparation unit <NUM>, and the result output unit <NUM> sends an instruction with such contents to the discharge control unit <NUM>. If a defect is present, an instruction to increase the discharge amount is prepared in the discharge instruction preparation unit <NUM> and sent from the result output unit <NUM> to the discharge control unit <NUM>.

<FIG> is a flowchart illustrating an example of processing for controlling the discharge amount.

Initially, the surface detection image acquisition unit <NUM> acquires a surface detection image from the surface detector <NUM> (step S001).

Then, the defect determination unit <NUM> starts to distinguish between the presence and the absence of a defect (step S002).

The defect determination unit <NUM> determines whether a streak-like defect is present (step S003), and, if the defect is not present, the log notifying that the change in discharge amount is unnecessary is prepared (step S004).

If the defect is present, the defect determination unit <NUM> instructs to prepare a discharge instruction (step S005), and the discharge instruction preparation unit <NUM> prepares an instruction to increase the discharge amount (step S006).

In the end, a result with contents of the decided instruction is output from the result output unit <NUM> to the discharge control unit <NUM> (step S007).

<FIG> are conceptual diagrams of formation of the insulating layer <NUM> by the discharge of the liquid composition <NUM>.

Referring to <FIG>, a process for forming the insulating layer <NUM> in the electrode manufacturing apparatus <NUM> according to the present embodiment is described.

<FIG> is a side view of the electrode manufacturing apparatus <NUM> as viewed in the Y direction, and <FIG> is a plan view of the electrode manufacturing apparatus <NUM> as viewed in a Z direction.

In <FIG>, the winding off part <NUM>, the winding up part <NUM>, the curing device <NUM>, and the heater <NUM> illustrated in <FIG> is omitted for simplicity.

The electrode manufacturing apparatus <NUM> uses the liquid composition <NUM> for forming the resin layer <NUM> or the inorganic layer <NUM> as the insulating layer <NUM> to form the resin layer <NUM> or the inorganic layer <NUM> as the insulating layer <NUM> so that the surface of the electrode base <NUM> or the surface of the functional layer <NUM> provided on the electrode base <NUM> may be covered, and detects the surface condition of the resin layer <NUM> or the inorganic layer <NUM> as the insulating layer <NUM> with the surface detector <NUM> provided downstream of the discharger <NUM>. The electrode base <NUM> or the functional layer <NUM> provided on the electrode base <NUM> does not merely have a running pattern spread over the entire surface but may be formed by intermittent coating or in a free shape. In addition, a printing shape of the resin layer <NUM> or the inorganic layer <NUM> as the insulating layer <NUM>, which is to be formed, is not limited to a running pattern spread over the entire surface but may be achieved by intermittent coating or as a free shape.

<FIG> are plan views of the electrode manufacturing apparatus <NUM>, illustrating how a streak-like defect is produced.

Using <FIG>, description is made how a streak-like defect <NUM> is produced in the course of formation of the resin layer <NUM> or the inorganic layer <NUM> as the insulating layer <NUM>.

<FIG> illustrates a state where the streak-like defect <NUM> has been produced in the course of formation of the resin layer <NUM> or the inorganic layer <NUM> as the insulating layer <NUM>. If the streak-like defect <NUM> has been produced in the course of discharge by the discharger <NUM>, a log notifying that change in amount of discharge by the discharger <NUM> is unnecessary is only prepared (step S004) until the streak-like defect <NUM> reaches the surface detector <NUM>.

<FIG> illustrates a state where the streak-like defect <NUM> as produced in the course of formation of the resin layer <NUM> or the inorganic layer <NUM> as the insulating layer <NUM> has reached the surface detector <NUM>. If the streak-like defect <NUM> reaches the surface detector <NUM>, an instruction to increase the discharge amount is prepared by the discharge instruction preparation unit <NUM> (step S006). The instruction to increase the discharge amount is sent from the discharge instruction preparation unit <NUM> to the discharge control unit <NUM> through the result output unit <NUM> so as to increase the amount of discharge of the liquid composition <NUM> by the discharger <NUM>.

<FIG> illustrates a state after the instruction to increase the discharge amount is sent from the discharge instruction preparation unit <NUM> to the discharge control unit <NUM> through the result output unit <NUM> and the amount of discharge of the liquid composition <NUM> by the discharger <NUM> is increased. The discharge amount of the liquid composition <NUM> is increased so as to embed the streak-like defect <NUM> and suppress the production of another streak-like defect.

<FIG> are each another example of the diagram illustrating the general arrangement of the electrode manufacturing apparatus <NUM> according to the present embodiment.

<FIG> illustrates the electrode manufacturing apparatus <NUM>, which does not include the curing device <NUM> because the liquid composition <NUM> for forming the resin layer <NUM> or the inorganic layer <NUM> as the insulating layer <NUM> does not need a curing process.

As illustrated in <FIG>, the surface detector <NUM> may be provided on an upstream side of the heater <NUM>.

If the surface detector <NUM> is to detect the surface condition before drying of the liquid composition <NUM>, the surface detector <NUM> is preferably provided at a stage next to the discharger <NUM> for the reason to be stated later.

Even if the curing device <NUM> is required as illustrated in <FIG>, the surface detector <NUM> is preferably provided at the stage next to the discharger <NUM> for the reason to be stated later if the surface detector <NUM> is to detect the surface condition before the drying of the liquid composition <NUM>.

Providing the surface detector <NUM> immediately after the discharger <NUM>, that is to say, at the stage next to the discharger <NUM> brings about a merit inherent to the present disclosure. While the present disclosure is chiefly effective at suppressing the production of the streak-like defect <NUM>, the insulating layer <NUM> after the production of the streak-like defect <NUM> illustrated in <FIG> is deemed to be faulty until the streak-like defect <NUM> is detected as illustrated in <FIG> and suppressed as illustrated in <FIG>. Therefore, the improvement in productivity attendant on the decrease in fraction defective is effected to a larger extent as the distance from the discharger <NUM> producing a defect to the surface detector <NUM> detecting a defect is shorter. Consequently, if a defect is detected before the drying of the liquid composition <NUM>, it is desirable to provide the surface detector <NUM> immediately after the discharger <NUM>, that is to say, at the stage next to the discharger <NUM>.

In the case where detection with a specular reflection light-type camera or the like is difficult, such as the case where the liquid composition <NUM> before being dried by the heater <NUM> or being cured by the curing device <NUM> is transparent, for instance, it is desirable to provide the surface detector <NUM> on a downstream side of the heater <NUM> or the curing device <NUM>.

<FIG> illustrates an example of an optical system of the surface detector <NUM>.

The surface detector <NUM> includes, as an illumination system, a visible light source <NUM> that irradiates an upper face of a detection target <NUM> with a visible light, and an infrared/ultraviolet (IR/UV) light source <NUM> that emits at least one of an ultraviolet light or an infrared light. As a matter of course, the surface detector <NUM> may only include one of the light sources.

The detection target <NUM> as an object of detection by the surface detector <NUM> refers to the electrode base <NUM> or the functional layer <NUM> provided on the electrode base <NUM>, on which the resin layer <NUM> or the inorganic layer <NUM> as the insulating layer <NUM> is being formed.

The surface detector <NUM> includes a visible light camera <NUM> as a measurement system, and the visible light camera <NUM> may be replaced by an IR/UV light camera. The IR/UV light camera is to be arranged similarly to the visible light camera <NUM>.

The surface detector <NUM> detects a streak-like defect contained in the detection target <NUM>, based on an output signal from the visible light camera <NUM> or the IR/UV light camera in such measurement system.

<FIG> illustrates an example of a state where an image acquired by the surface detection image acquisition unit <NUM> after the detection of a defect by the surface detector <NUM> is displayed in the operation unit <NUM>.

In this example, in addition to a defect spot image <NUM>, defect type information <NUM> that is a result of analysis with the defect determination unit <NUM>, a defect spot line <NUM>, and a defect output signal graph <NUM> (graph representing the change in output luminance value or luminance ratio) are collectively displayed.

Outputting such information concerning a defect spot allows the user to specifically grasp the details of the defect as produced.

<FIG> illustrate a case where the luminance value is high and a case where the luminance value is low, respectively. A correspondence relation between the pattern of such change (increase or decrease) in luminance value and the type of abnormality allows an accurate determination of the presence or absence of a defect and the level of a defect as a result of accumulation of experimental data for each type of abnormality that can actually occur.

<FIG> is a flowchart of defect detection.

Initially, a detection system is adjusted in a state where the detection target <NUM> is not arranged (step S301). As an example, a blue visible light source <NUM> is lit so as to perform image capturing with a visible light by an image capturing device <NUM>. As a result of such adjustment, the luminance of light that directly enters the visible light camera <NUM> is so adjusted as to be the same or essentially the same as the upper limit of a measurable range.

Next, detection is begun. An image of the detection target <NUM> is captured, and an output signal of the image is taken into the surface detection image acquisition unit <NUM>. During the taking in of the output signal, signals for one line (<NUM> pixels, for instance) are subjected to white shading so as to generate the luminance value (step S302).

Thereafter, the defect determination unit <NUM> detects and determines a spot of abnormality. As an example, the defect determination unit <NUM> detects, from the image as acquired, a region (a group of pixels) formed of pixels with luminance values exceeding a specified threshold and determines the region as a "defect spot" if the region has an area exceeding a specified value. In this example, the position (in the Y direction) of a defect and the timing of conveyance, with which the defect has been detected, are also acquired (step S303).

If it is determined that a defect has been detected (step S304), the processing proceeds to step S305. If it is determined that no defects have been detected (step S304), this routine is terminated.

If a defect has been detected, the type of the defect as detected is determined (step S305), and the type of the defect and defect spot information are output (step S306).

<FIG> is a flowchart of discharge amount regulation based on defect spot information output.

Initially, the surface detector <NUM>, the surface detection image acquisition unit <NUM>, and the defect determination unit <NUM> detect the defect spot information (step S401).

Further, the surface detection image acquisition unit <NUM> and the defect determination unit <NUM> specify the position (position in a y-axis direction) of the defect (step S402).

Then, the discharge instruction preparation unit <NUM> decides a discharge amount appropriate to the defect (an increased discharge amount, for instance) and a method for changing the discharge amount (change in discharge pattern or change in printing resolution, for instance) (step S403).

The discharge instruction preparation unit <NUM> prepares an instruction as to the discharge, and the result output unit <NUM> outputs the instruction to the discharge control unit <NUM> (step S404).

The discharge control unit <NUM> controls the discharge with respect to the special position as instructed, based on the discharge amount and the discharge method as instructed (step S405).

<FIG> illustrate examples of the method for changing the discharge amount.

The printing resolution in <FIG> is changed to the printing resolution in <FIG>. Such change in printing resolution is an exemplary method for increasing the discharge amount of the liquid composition <NUM>.

In this instance, the printing resolution per unit area is changed from <NUM> × <NUM> in <FIG> × <NUM> in <FIG>. The printing resolution is changed from <NUM> × <NUM> to <NUM> × <NUM> without changing the size of dots to be printed, so as to increase the total discharge amount per unit area of the liquid composition <NUM>.

A printing pattern in <FIG> is changed to a printing pattern in <FIG>. Such change in printing pattern is another exemplary method for increasing the discharge amount of the liquid composition <NUM>.

In this instance, although a printing resolution per unit area of <NUM> × <NUM> is not changed, the coverage rate is changed from about <NUM>% in <FIG> to <NUM>% in <FIG> so as to increase the total discharge amount per unit area of the liquid composition <NUM>.

Naturally, it is common as another method for changing the discharge amount to increase energy input to a drive source for a nozzle of the discharger <NUM> so as to increase the volume itself of the liquid composition <NUM> discharged through the nozzle.

The discharge amount may be increased over the entire region of discharge so as to embed the streak-like defect <NUM> or may be only increased on the periphery of a region of the streak-like defect <NUM>. The surface detection image acquisition unit <NUM> and the defect determination unit <NUM> acquire information on the position in the Y direction of a defect, and the information on the position in the Y direction of a defect is additionally used by the discharge instruction preparation unit <NUM> to prepare a discharge instruction. In such case, the discharge amount does not need to be changed in a region other than the region of the streak-like defect <NUM>, so that the film thickness is less affected as a whole.

In addition to the information on the position in the Y direction as defect position information, conveyance information (containing the conveyance speed and time information) on the electrode base <NUM> or the functional layer <NUM> provided on the electrode base <NUM>, which is an object of conveyance, is considered to specify the position of a defect on the object of conveyance, as is the case with a normal production line.

<FIG> is a flowchart of a method for gradually regulating the discharge amount.

Following the flowchart of <FIG>, an operation to gradually regulate the discharge amount is described.

Specifically, a defect is detected first and the position of the defect (the streak-like defect <NUM> in <FIG>) is specified. As described above, the position of the streak-like defect <NUM> on the electrode base <NUM> or the functional layer <NUM> provided on the electrode base <NUM> is specified from the position in the Y direction and the conveyance speed in the conveyance direction X (step S501).

Then, the discharge amount of the liquid composition <NUM>, which is to be discharged to the specified position of the defect, is increased in a specified amount (step S502). In this regard, a small amount will be fine as an increment of the liquid composition <NUM>. Such small amount can further prevent the liquid composition <NUM>, to fill (make up) a defect part, from being applied to the defect part in an amount larger than the amount for properly filling the defect part.

When the defect part (the streak-like defect <NUM> in <FIG>) with an increased discharge amount of the liquid composition <NUM> is conveyed and reaches the surface detector <NUM>, the defect part with an increased discharge amount of the liquid composition <NUM> is re-detected (step S503).

At this time, the defect determination unit <NUM> determines whether the defect as detected is of a value equal to or smaller than a defined value (that is to say, is ignorable as a defect) (step S504).

If it is determined that the defect is not of a value equal to or smaller than the defined value, that is to say, is not remedied in spite of the increase in discharge amount, the defect determination unit <NUM> increases again the discharge amount of the liquid composition <NUM>, which is to be discharged to the position of the defect, in the specified amount through the discharge instruction preparation unit <NUM>, the result output unit <NUM>, and the discharge control unit <NUM> (step S502).

Thereafter, if the defect is still not remedied (NO in step S504), the above process is repeated.

If it is determined that the defect is of a value equal to or smaller than the defined value (YES in step S504), the defect is considered as remedied as a result of the increase in discharge amount, so that the increase in discharge amount is stopped (step S505).

The electrode manufacturing apparatus <NUM> according to an embodiment of the present disclosure includes the discharger <NUM>, which discharges the liquid composition <NUM> onto the electrode base <NUM> or the functional layer <NUM> provided on the electrode base <NUM> so as to form the insulating layer <NUM>, the discharge control unit <NUM>, which controls the discharger <NUM>, and the surface detector <NUM>, which detects the surface condition of the insulating layer <NUM> after the discharge of the liquid composition <NUM> by the discharger <NUM>. The discharge control unit <NUM> controls the discharger <NUM> based on the surface condition detected by the surface detector <NUM>.

According to such features, the surface detector <NUM> detects the surface condition of the insulating layer <NUM> after the discharge of the liquid composition <NUM> and the discharge control unit <NUM> controls the discharger <NUM> based on the detected surface condition, so that discharge control corresponding to the detected surface condition is thereafter carried out with respect to the surface of the insulating layer <NUM>.

The insulating layer <NUM> in the electrode manufacturing apparatus <NUM> according to an embodiment of the present disclosure includes the resin layer <NUM>.

According to such feature, the surface detector <NUM> detects the surface condition of the resin layer <NUM> after the discharge of the liquid composition <NUM> and the discharge control unit <NUM> controls the discharger <NUM> based on the detected surface condition, so that discharge control for the resin layer <NUM> that corresponds to the detected surface condition is thereafter carried out with respect to the surface of the resin layer <NUM>.

The insulating layer <NUM> in the electrode manufacturing apparatus <NUM> according to an embodiment of the present disclosure includes the inorganic layer <NUM>.

According to such feature, the surface detector <NUM> detects the surface condition of the inorganic layer <NUM> after the discharge of the liquid composition <NUM> and the discharge control unit <NUM> controls the discharger <NUM> based on the detected surface condition, so that discharge control for the inorganic layer <NUM> that corresponds to the detected surface condition is thereafter carried out with respect to the surface of the inorganic layer <NUM>.

In the electrode manufacturing apparatus <NUM> according to an embodiment of the present disclosure, information based on the surface condition detected by the surface detector <NUM> includes information based on a defect, and the discharge control unit <NUM> increases the amount of the liquid composition <NUM> discharged by the discharger <NUM> so that the defect may be eliminated.

According to such features, if information based on a defect produced at the surface of the insulating layer <NUM> after the discharge of the liquid composition <NUM> has been detected, the amount of the liquid composition <NUM> is increased in order to eliminate the defect as a target, and the defect is thereafter eliminated from the surface of the insulating layer <NUM>.

In the electrode manufacturing apparatus <NUM> according to an embodiment of the present disclosure, the information based on a defect includes information about the position of a defect.

According to such feature, the amount of the liquid composition <NUM> is increased in order to eliminate a defect as a target, based on the information about the position of a defect, which is the information based on a defect produced at the surface of the insulating layer <NUM> after the discharge of the liquid composition <NUM>. Consequently, the defect is thereafter efficiently eliminated from a spot on the surface of the insulating layer <NUM> where the defect is present.

The discharge control unit <NUM> in the electrode manufacturing apparatus <NUM> according to an embodiment of the present disclosure gradually increases the amount of the liquid composition <NUM> discharged by the discharger <NUM> so that a defect may gradually be eliminated.

According to such feature, the amount of the liquid composition <NUM> is increased in order to eliminate a defect produced at the surface of the insulating layer <NUM> after the discharge of the liquid composition <NUM>. On this occasion, since the amount of the liquid composition <NUM> discharged by the discharger <NUM> is gradually increased so that the defect may gradually be eliminated, the discharge amount of the liquid composition <NUM> is prevented from being too large for making up the defect.

In the electrode manufacturing apparatus <NUM> according to an embodiment of the present disclosure, the printing resolution is changed to increase the amount of the liquid composition <NUM>.

According to such feature, the printing resolution is changed to increase the discharge amount of the liquid composition <NUM>, so that a defect produced at the surface of the insulating layer <NUM> is eliminated by a simple control.

In the electrode manufacturing apparatus <NUM> according to an embodiment of the present disclosure, the discharge pattern is changed to increase the amount of the liquid composition <NUM>.

Claim 1:
An electrode manufacturing apparatus (<NUM>) comprising:
an applier (<NUM>) configured to apply a liquid composition (<NUM>) to form an insulating layer (<NUM>) onto an electrode base (<NUM>) or a functional layer (<NUM>) on the electrode base (<NUM>);
a controller (<NUM>) configured to control the applier (<NUM>); and
a surface detector (<NUM>) configured to detect a surface condition of the liquid composition (<NUM>) or the insulating layer (<NUM>) on the electrode base (<NUM>) or the functional layer (<NUM>),
wherein the controller (<NUM>) is configured to control the applier (<NUM>) based on the surface condition of the liquid composition (<NUM>) or the insulating layer (<NUM>) detected by the surface detector (<NUM>), characterized in that
the controller (<NUM>) is configured to change a pattern to be formed on the electrode base (<NUM>) or the functional layer (<NUM>) to increase an amount of the liquid composition (<NUM>) to be applied onto the electrode base (<NUM>) or the functional layer (<NUM>).