Patent Description:
As in-vehicle batteries, for example, laminate-type batteries have been developed. Such a battery has a structure in which a container contains a laminated electrode assembly, in which multiple positive electrode plates and multiple negative electrode plates are alternatively laminated with a separator in between, and an electrolyte. For example, patent literature <NUM> discloses a device to manufacture such a laminate-type battery whereby individual pieces of electrode plates and separators are sucked by a suction pad by vacuum suction, conveyed to a lamination stage, and layered on the stage. The document <CIT> discloses an article lamination device, the document <CIT> discloses a battery material stacking device and the document <CIT> discloses a transfer mechanism.

In laminate-type batteries, it is desirable to reduce misalignment of electrode plates as much as possible from the perspective of increasing the battery performance.

(e.g., higher capacity, higher energy density). In particular, it is required that the positive electrode plate does not protrude from the opposite negative electrode plate in a lithium-ion secondary battery.

In the related-art laminating device, it sometimes happen that the suction pad or the lamination stage is vibrated due to the inertia when the suction pad is stopped on the lamination stage. If a laminating action is performed under the vibration, a position gap may be created between the electrode plate, etc. sought to be laminated and the electrode plate, etc. on the stage. It was therefore necessary to postpone the laminating action until the vibration subsides. However, providing a standby time could inhibit increase in the throughput of the laminating device. Further, the above-described issue is also of a concern when sheet members other than electrode plates and separators are laminated.

The present disclosure addresses the issue described above, and a purpose thereof is to provide a technology of increasing the throughput of a laminating device.

An aspect of the present disclosure relates to a laminating device adapted to laminate a plurality of sheet members on a lamination stage. The device includes: the lamination stage, a plurality of laminating heads that each has a curved holding surface for holding the sheet member; a drum section in which the plurality of laminating heads are arranged in a circumferential direction, the drum section holding each laminating head such that the holding surface is swingable, and rotation of the drum section causing each laminating head to advance to a laminating position facing a planar lamination surface provided in the lamination stage; and a rolling motion mechanism that rolls the holding surface on the lamination surface so that a delivery point of the sheet member formed between the holding surface and the lamination surface moves from a rear end to a front end of the sheet member in a rotational direction of the drum section while each laminating head is caused to move by the rotation of the drum section.

Optional combinations of the aforementioned constituting elements, and implementations of the present disclosure in the form of methods, devices, systems, etc. may also be practiced as additional modes of the present disclosure.

According to the present disclosure, the throughput of a laminating device is improved.

Hereinafter, the present disclosure will be described based on preferred embodiments with reference to the accompanying drawings. The embodiments are not intended to limit the scope of the present disclosure but exemplify the present disclosure. Not all of the features and the combinations thereof described in the embodiments are necessarily essential to the present disclosure. Identical or like constituting elements, members, processes shown in the drawings are represented by identical symbols and a duplicate description will be omitted as appropriate. The scales and shapes shown in the figures are defined for convenience's sake to make the explanation easy and shall not be interpreted limitatively unless otherwise specified. Terms like "first", "second", etc. used in the specification and claims do not indicate an order or importance by any means unless specified otherwise and are used to distinguish a certain feature from the others. Those of the members that are not important in describing the embodiment are omitted from the drawings.

<FIG> is a schematic view of a laminated electrode assembly manufacturing device <NUM>. By way of one example, the laminated electrode assembly manufacturing device <NUM> is a continuous drum-type manufacturing device in which multiple drums are combined. Performing each process of cutting, heating, bonding, laminating, and the like of electrode bodies and separators on the drums enables highspeed and continuous manufacturing of laminated electrode assemblies. The laminated electrode assemblies may be used, for example, for lithium-ion secondary batteries.

The laminated electrode assembly manufacturing device <NUM> includes a first electrode cutting drum <NUM>, a first electrode heating drum <NUM>, a second electrode cutting drum <NUM>, a second electrode heating drum <NUM>, a bonding drum <NUM>, a separator cutting drum <NUM>, and a laminating drum <NUM>.

The first electrode cutting drum <NUM> cuts a continuous sheet (continuous body) of multiple first electrode plates into multiple individual first electrode plates and conveys the plates. In the present embodiment, the first electrode is a negative electrode. To the first electrode cutting drum <NUM>, a strip-shaped first electrode continuous sheet N as the continuous sheet of multiple first electrode plates is supplied. The first electrode continuous sheet N includes a first electrode current collector and a first electrode active material layer. The first electrode active material layer is laminated on the first electrode current collector. In the present embodiment, the first electrode active material layer is laminated on both sides of the first electrode current collector, but the first electrode active material layer may be laminated on only one side of the first electrode current collector.

Each of the first electrode current collector and the first electrode active material layer can be made of a publicly-known material and has a publicly-known structure. The first electrode current collector may be, for example, constituted by foil or a porous body made of copper, aluminum, or the like. The first electrode active material layer may be formed by applying, onto a surface of the first electrode current collector, first electrode mixture slurry containing a first electrode active material, a binder, a dispersant, and the like and by drying and rolling the applied film. The thickness of the first electrode current collector may be in the range from <NUM> to <NUM> inclusive, for example. Also, the thickness of the first electrode active material layer may be in the range from <NUM> to <NUM> inclusive, for example.

The first electrode cutting drum <NUM> includes multiple holding heads arranged in a circumferential direction of the drum, and a cutting blade that cuts the first electrode continuous sheet N. Each of the multiple holding heads includes a holding surface that sucks and holds the first electrode continuous sheet N. The holding surface of each holding head faces outward from the first electrode cutting drum <NUM>. The first electrode continuous sheet N supplied to the first electrode cutting drum <NUM> is conveyed by the rotation of the first electrode cutting drum <NUM> while being sucked and held by the holding surfaces of the multiple holding heads.

Each of the multiple holding heads rotates around the central axis of the first electrode cutting drum <NUM> and can also move in a circumferential direction of the drum independently of other holding heads. Relative movement of each holding head is achieved by mounting thereon a motor that is different from the motor used to rotate the first electrode cutting drum <NUM>. The independent driving of the holding heads enables adjustment of the positions of cutting by the cutting blade in the first electrode continuous sheet N and also enables adjustment of the positions of the individually divided first electrode plates, for example.

The first electrode cutting drum <NUM> sucks and holds the first electrode continuous sheet N supplied and rotates to convey the first electrode continuous sheet N. At a cutting position <NUM> schematically illustrated in <FIG>, the first electrode cutting drum <NUM> cuts the first electrode continuous sheet N. The first electrode continuous sheet N is cut by the cutting blade at a position between adjacent holding heads, so that multiple individual first electrode plates are obtained. Each first electrode plate thus obtained is conveyed while being sucked and held by each holding head. The positions of the multiple produced first electrode plates are monitored by a camera or the like.

The first electrode heating drum <NUM> is located at close proximity to the first electrode cutting drum <NUM>. Before the proximity position between the first electrode cutting drum <NUM> and the first electrode heating drum <NUM>, the speed of a holding head of the first electrode cutting drum <NUM> is temporarily increased or decreased until it becomes substantially identical with the linear velocity of the first electrode heating drum <NUM>. As a result, the relative speed of the holding head with respect to the first electrode heating drum <NUM> becomes substantially zero. At the time when the relative speed becomes substantially zero, the holding head transfers, to the first electrode heating drum <NUM> side, the first electrode plate that the holding head has sucked and held.

The first electrode heating drum <NUM> rotates while sucking and holding the first electrode plates transferred from the first electrode cutting drum <NUM> and preheats the first electrode plates with a built-in heater. The preheating is performed to thermally bond a first electrode plate and a separator in the subsequent bonding process. Although the first electrode plates are heated at a heating position <NUM> in the present embodiment, the position is not limited thereto. For example, the first electrode plates may be heated in the entire circumferential area of the first electrode heating drum <NUM>.

The second electrode cutting drum <NUM> is a drum for cutting a continuous sheet of multiple second electrode plates into multiple individual second electrode plates and conveying the plates. In the present embodiment, the second electrode is a positive electrode. To the second electrode cutting drum <NUM>, a strip-shaped second electrode continuous sheet P, which is the continuous sheet of multiple second electrode plates, is supplied. The second electrode continuous sheet P includes a second electrode current collector and a second electrode active material layer. The second electrode active material layer is laminated on the second electrode current collector. In the present embodiment, the second electrode active material layer is laminated on both sides of the second electrode current collector, but the second electrode active material layer may be laminated on only one side of the second electrode current collector.

Each of the second electrode current collector and the second electrode active material layer can be made of a publicly-known material and has a publicly-known structure. The second electrode current collector is constituted by, for example, foil or a porous body made of stainless steel, aluminum, or the like. The second electrode active material layer is formed by applying, onto a surface of the second electrode current collector, second electrode mixture slurry containing a second electrode active material, a binder, a dispersant, and the like and by drying and rolling the applied film. The thickness of the second electrode current collector is in the range from <NUM> to <NUM> inclusive, for example. Also, the thickness of the second electrode active material layer may be in the range from <NUM> to <NUM> inclusive, for example.

The second electrode cutting drum <NUM> has multiple holding heads arranged in a circumferential direction of the drum and a cutting blade that cuts the second electrode continuous sheet P. Each of the multiple holding heads has a holding surface that sucks and holds the second electrode continuous sheet P. The holding surface of each holding head faces outward from the second electrode cutting drum <NUM>. The second electrode continuous sheet P supplied to the second electrode cutting drum <NUM> is conveyed by the rotation of the second electrode cutting drum <NUM> while being sucked and held by the holding surfaces of the multiple holding heads.

Each of the multiple holding heads rotates around the central axis of the second electrode cutting drum <NUM> and can also move in a circumferential direction of the drum independently of other holding heads. Relative movement of each holding head is achieved by mounting thereon a motor that is different from the motor used to rotate the second electrode cutting drum <NUM>. The independent driving of the holding heads enables adjustment of the positions of cutting by the cutting blade in the second electrode continuous sheet P and also enables adjustment of the positions of the individually divided second electrode plates.

The second electrode cutting drum <NUM> sucks and holds the supplied second electrode continuous sheet P and rotates to convey the second electrode continuous sheet P. At a cutting position <NUM> schematically illustrated in <FIG>, the second electrode cutting drum <NUM> cuts the second electrode continuous sheet P. The second electrode continuous sheet P is cut by the cutting blade at a position between adjacent holding heads, so that multiple individual second electrode plates are obtained. Each second electrode plate thus obtained is conveyed while being sucked and held by each holding head. The positions of the multiple produced second electrode plates are monitored by a camera or the like.

The second electrode heating drum <NUM> is located at close proximity to the second electrode cutting drum <NUM>. Before the proximity position between the second electrode cutting drum <NUM> and the second electrode heating drum <NUM>, the speed of a holding head of the second electrode cutting drum <NUM> is temporarily increased or decreased until it becomes substantially identical with the linear velocity of the second electrode heating drum <NUM>. As a result, the relative speed of the holding head with respect to the second electrode heating drum <NUM> becomes substantially zero. At the time when the relative speed becomes substantially zero, the holding head transfers, to the second electrode heating drum <NUM> side, the second electrode plate that the holding head has sucked and held.

The second electrode heating drum <NUM> rotates while sucking and holding the second electrode plates transferred from the second electrode cutting drum <NUM> and preheats the second electrode plates with a built-in heater. The preheating is performed to thermally bond a second electrode plate and a separator in the subsequent bonding process. Although the second electrode plates are heated at a heating position <NUM> in the present embodiment, the position is not limited thereto. For example, the second electrode plates may be heated in the entire circumferential area of the second electrode heating drum <NUM>.

The bonding drum <NUM> is a drum that forms a continuous laminated sheet <NUM> (continuous laminated body) in which multiple laminated sheets (unit laminated bodies) are continuous. Each laminated sheet is constituted by a first separator, a first electrode plate, a second separator, and a second electrode plate. To the bonding drum <NUM>, a strip-shaped first separator continuous sheet S1, in which multiple first separators are continuously arranged, and a strip-shaped second separator continuous sheet S2, in which multiple second separators are continuously arranged, are supplied. On a surface of each of the first separator continuous sheet S1 and the second separator continuous sheet S2, a thermal bonding layer is provided. The thermal bonding layer has a property of developing no adhesiveness at room temperature but developing adhesiveness when heated. The thermal bonding layer may be, for example, a thermoplastic layer containing a thermoplastic polymer, which develops adhesiveness based on plastic deformation of the thermoplastic polymer caused by heating.

Further, the bonding drum <NUM> is located at close proximity to the first electrode heating drum <NUM> and the second electrode heating drum <NUM>. Then, to the bonding drum <NUM>, multiple first electrode plates are supplied from the first electrode cutting drum <NUM> via the first electrode heating drum <NUM>, and multiple second electrode plates are supplied from the second electrode cutting drum <NUM> via the second electrode heating drum <NUM>. A first electrode plate is rotationally conveyed while being preheated on the first electrode heating drum <NUM> and is transferred, to the bonding drum <NUM> side, at the proximity position between the first electrode heating drum <NUM> and the bonding drum <NUM>. A second electrode plate is rotationally conveyed while being preheated on the second electrode heating drum <NUM> and is transferred, to the bonding drum <NUM> side, at the proximity position between the second electrode heating drum <NUM> and the bonding drum <NUM>.

The first separator continuous sheet S1, each first electrode plate, the second separator continuous sheet S2, and each second electrode plate are supplied to the bonding drum <NUM> at positions provided in the enumerated order from the upstream side of the rotational direction of the bonding drum <NUM>. Accordingly, the first separator continuous sheet S1 is supplied to the bonding drum <NUM> first at a certain position. The first separator continuous sheet S1 is sucked and held by the bonding drum <NUM> and rotationally conveyed. Subsequently, at a position on the downstream side of the supply position of the first separator continuous sheet S1, the first electrode plates are supplied from the first electrode heating drum <NUM> to the bonding drum <NUM> and placed on the first separator continuous sheet S1. The multiple first electrode plates are arranged on the first separator continuous sheet S1 at predetermined intervals in the conveying direction of the first separator continuous sheet S1.

Subsequently, at a position on the downstream side of the supply position of the first electrode plates, the second separator continuous sheet S2 is supplied to the bonding drum <NUM> and placed over the multiple first electrode plates. Thereafter, the first separator continuous sheet S1, multiple first electrode plates, and second separator continuous sheet S2 are pressurized by a thermocompression bonding roller <NUM>, at a position on the downstream side of the supply position of the second separator continuous sheet S2. Accordingly, the first separator continuous sheet S1, each first electrode plate, and the second separator continuous sheet S2 are bonded together. Subsequently, at a position on the downstream side of the position of pressure bonding by the thermocompression bonding roller <NUM>, the second electrode plates are supplied from the second electrode heating drum <NUM> to the bonding drum <NUM> and placed on the second separator continuous sheet S2. The multiple second electrode plates are arranged on the second separator continuous sheet S2 at predetermined intervals in the conveying direction of the second separator continuous sheet S2. Also, the multiple second electrode plates are bonded to the second separator continuous sheet S2 by the pressing force of the second electrode heating drum <NUM>.

Through the process described above, the first separator continuous sheet S1, multiple first electrode plates, second separator continuous sheet S2, and multiple second electrode plates are laminated in this order and bonded to each other, forming a continuous laminated sheet <NUM>. The continuous laminated sheet <NUM> has a structure in which the laminated sheets, which each are constituted by a first separator, a first electrode plate, a second separator, and a second electrode plate, are continuously connected by the first separator continuous sheet S1 and the second separator continuous sheet S2. The continuous laminated sheet <NUM> is conveyed from the bonding drum <NUM> to the separator cutting drum <NUM>. By halting the supply of the second electrode plates from the second electrode cutting drum <NUM> side, three-layered laminated sheets without the second electrode plates may be produced after every fixed number of pieces. The electrode plates of which supply is halted may also be the first electrode plates.

The separator cutting drum <NUM> is a drum that cuts the first separator continuous sheet S1 and the second separator continuous sheet S2 in the continuous laminated sheet <NUM> to obtain multiple individual laminated sheets. The separator cutting drum <NUM> has multiple holding heads arranged in a circumferential direction of the drum and a cutting blade that cuts the continuous laminated sheet <NUM>. Each of the multiple holding heads has a holding surface that sucks and holds the continuous laminated sheet <NUM>. The holding surface of each holding head faces outward from the separator cutting drum <NUM>. The continuous laminated sheet <NUM> supplied to the separator cutting drum <NUM> is conveyed by the rotation of the separator cutting drum <NUM> while being sucked and held by the holding surfaces of the multiple holding heads.

Each of the multiple holding heads rotates around the central axis of the separator cutting drum <NUM> and can also move in a circumferential direction of the drum independently of other holding heads. Relative movement of each holding head is achieved by mounting thereon a motor that is different from the motor used to rotate the first electrode cutting drum <NUM>. The independent driving of the holding heads enables adjustment of the positions of cutting by the cutting blade in the continuous laminated sheet <NUM> and also enables adjustment of the positions of the individually divided laminated sheets, for example.

At a cutting position <NUM> schematically illustrated in <FIG>, the separator cutting drum <NUM> cuts the continuous laminated sheet <NUM>. The continuous laminated sheet <NUM> is cut at a position between adjacent holding heads, so that multiple individual laminated sheets are obtained. At the time, in the continuous laminated sheet <NUM>, the first separator continuous sheet S1 and the second separator continuous sheet S2 are cut at a position between electrode plates that are adjacent in the conveying direction of the continuous laminated sheet <NUM>. Each laminated sheet thus obtained is conveyed while being sucked and held by each holding head. A holding head transfers, to the laminating drum <NUM> side, a laminated sheet that the holding head has sucked and held. The positions of the multiple produced laminated sheets are monitored by a camera or the like.

The laminating drum <NUM> is a drum that laminates multiple laminated sheets on a lamination stage <NUM> to form a laminated electrode assembly. The laminating drum <NUM> includes multiple laminating heads arranged in a circumferential direction of the drum. Each laminating head includes a holding surface that sucks and holds a laminated sheet. The holding surface of each laminating head faces outward from the laminating drum <NUM>. Each of the multiple laminating heads rotates around the central axis of the laminating drum <NUM> and advances sequentially to a laminating position facing the lamination stage <NUM>. The laminating head reaching the laminating position transfers, onto the lamination stage <NUM>, a laminated sheet that the laminating head has been holding.

The lamination stage <NUM> is located immediately beneath the laminating drum <NUM>. On the lamination stage <NUM>, the laminated sheets transferred from each laminating head of the laminating drum <NUM> are sequentially laminated. Thus, a laminated electrode assembly is formed. The lamination stage <NUM> can be driven in an X-axis direction and a Y-axis direction perpendicular to each other. Also, a tilt angle on an X-Y plane of the lamination stage <NUM> can be adjusted. This enables adjustment of the positions in the X-axis direction and the Y-axis direction and the tilt angle of a laminated sheet transferred from the laminating drum <NUM>, with respect to a laminated sheet already laminated on the lamination stage <NUM>.

The laminating drum <NUM> is composed of a laminating device <NUM> according to the present embodiment. <FIG> is a front view showing a part of the laminating device <NUM> according to the embodiment on an enlarged scale. <FIG> shows that a drum section <NUM> is provided toward the front and a fixed plate <NUM> is provided away from the back. <FIG> shows a transparent view of a laminating head <NUM> and the drum section <NUM>.

The laminating device <NUM> is a device that laminates a plurality of sheet members W on the lamination stage <NUM>. By way of one example, the sheet member W includes at least one of an electrode plate or a separator of a battery. The sheet member W of the present embodiment is a laminated sheet in which an electrode plate and a separator are laminated. The laminating device <NUM> includes multiple laminating heads <NUM>, the drum section <NUM>, a rolling motion mechanism <NUM>, and a displacement mechanism <NUM>.

Each of the laminating heads <NUM> has a holding surface <NUM> for holding the sheet member W. The holding surface <NUM> has a curved shape. Each holding surface <NUM> is curved along the circumferential direction of the drum section <NUM>. The holding surface <NUM> of the present embodiment sucks and holds the sheet member W by sucking an atmosphere gas such as air. The holding surface <NUM> includes multiple suction holes (not shown) arranged in the circumferential direction of the drum section <NUM>.

Further, the holding surface <NUM> includes at least a first suction part 110a and a second suction part 110b. The holding surface <NUM> of the present embodiment is organized into two regions including the first suction part 110a and the second suction part 110b. The first suction part 110a is provided more toward the front than the second suction part 110b in the rotational direction D1 of the drum section <NUM>. The multiple suction holes are respectively allocated to the first suction part 110a and the second suction part 110b. A first suction nozzle 112a is connected to each suction hole of the first suction part 110a. A second suction nozzle 112b is connected to each suction hole of the second suction part 110b.

Each suction nozzle is connected to a vacuum pump (not shown) via a vacuum pipe (not shown). When the vacuum pump connected to the first suction nozzle 112a is driven, the atmosphere gas is sucked from the suction hole of the first suction part 110a via the vacuum pipe and the first suction nozzle 112a. This causes the sheet member W to be sucked by the first suction part 110a. Similarly, when the vacuum pump connected to the second suction nozzle 112b is driven, the atmosphere gas is sucked from the suction hole of the second suction part 110b via the vacuum pipe and the second suction nozzle 112b. This causes the sheet member W to be sucked by the second suction part 110b. The first suction part 110a and the second suction part 110b can switchably generate a suction force and cancel a suction force in a mutually independent manner.

It should be noted that it is sufficient that the first suction part 110a and the second suction part 110b can switchably generate a suction force and cancel a suction force in a mutually independent manner. Therefore, the vacuum pipe connected to the first suction part 110a and the vacuum pipe connected to the second suction part 110b are not necessarily independent. For example, the mechanism for holding the sheet member W may be comprised of a vacuum pipe connected to both the first suction part 110a and the second suction part 110b, a vacuum pump connected to the vacuum pipe, and a valve provided in the vacuum pipe. The valve can switchably establish and interrupt communication between the vacuum pump and the first suction part 110a and switchably establish and interrupt communication between the vacuum pump and the second suction part 110b in a mutually independent manner. According to this configuration, the first suction part 110a and the second suction part 110b can switchably generate a suction force and cancel a suction force in a mutually independent manner in accordance with the valve operation.

The multiple laminating heads <NUM> are held by the drum section <NUM>. The drum section <NUM> is a cylindrical drum (see also <FIG>), and the multiple laminating heads <NUM> are arranged in the circumferential direction at predetermined intervals. The holding surface <NUM> of the laminating heads <NUM> arranged in the drum section <NUM> faces outward in the radial direction D2 of the drum section <NUM>. Further, the drum section <NUM> includes multiple elongated holes <NUM> extending in the radial direction D2. The multiple elongated holes <NUM> are arranged in the circumferential direction of the drum section <NUM> at predetermined intervals.

Each laminating head <NUM> includes a rocking shaft <NUM>, a base plate <NUM>, and a rocking part <NUM>. The rocking shaft <NUM> is inserted into the elongated hole <NUM>. The elongated hole <NUM> permits displacement of the rocking shaft <NUM> in the radial direction D2. Further, the rocking shaft <NUM> is rotatable around its own axis in the elongated hole <NUM>. In other words, the rocking shaft <NUM> is capable of spinning.

The base plate <NUM> has a shape elongated in the radial direction D2 and is slidably supported by the drum section <NUM> in the radial direction D2. Further, the rocking shaft <NUM> is coupled to the inward end of the base plate <NUM> in the radial direction D2. The base plate <NUM> can slide the rocking shaft <NUM> in the radial direction D2 by sliding in the radial direction D2 in itself. The rocking shaft <NUM> is rotatably coupled to the base plate <NUM>.

The rocking part <NUM> has a shape elongated in the radial direction D2 and has the inward end thereof in the radial direction D2 fixed to the rocking shaft <NUM>. In other words, the rocking part <NUM> is coupled to the rocking shaft <NUM> so as not to be rotatable. The holding surface <NUM> is fixed to the outward end of the rocking part <NUM> in the radial direction D2. When the rocking shaft <NUM> is rotated around its own axis, therefore, the rocking part <NUM> and the holding surface <NUM> are rotated along with the rocking shaft <NUM>. This displaces the rocking part <NUM> and the holding surface <NUM> relative to the base plate <NUM> and, ultimately, the drum section <NUM>. With the above-described configuration, each laminating head <NUM> is held by the drum section <NUM> such that the holding surface <NUM> is swingable.

A driving mechanism (not shown) such as a motor is coupled to the center of the drum section <NUM>. Accordingly, the drum section <NUM> is rotated in the rotational direction D1 to turn the multiple laminating heads <NUM>. The rotation of the drum section <NUM> causes each laminating head <NUM> to advance to a laminating position facing the planar lamination surface 30a provided in the lamination stage <NUM>.

The rolling motion mechanism <NUM> is a mechanism for rolling the holding surface <NUM> on the lamination surface 30a. Since the holding surface <NUM> has a curved shape and the lamination surface 30a has a planar shape, the holding surface <NUM> and the lamination surface 30a facing each other are formed such that the respective portions that approach closest to each other are formed in the respective surfaces in a localized manner. A delivery point <NUM> (see <FIG>, etc.) of the sheet member W is formed at the position of closest approach. The delivery point <NUM> is a position at which the sheet member W on the holding surface <NUM> comes into contact with the lamination surface 30a. Strictly speaking, the delivery point <NUM> is a straight line parallel to the axial direction of the drum section <NUM>. The interval between the holding surface <NUM> and the lamination surface 30a at the delivery point <NUM> is substantially equal to the thickness of the sheet member W.

The rolling motion mechanism <NUM> rolls the holding surface <NUM> so that the delivery point <NUM> moves from the rear end to the front end of the sheet member W in the rotational direction D1 of the drum section <NUM> while each laminating head <NUM> is caused to move by the rotation of the drum section <NUM>. The rolling motion mechanism <NUM> of the present embodiment realizes the rolling motion of the holding surface <NUM> by means of a cam mechanism. More specifically, the rolling motion mechanism <NUM> includes a first cam <NUM> and a first cam follower <NUM> and rolls the holding surface <NUM> by means of the first cam <NUM> and the first cam follower <NUM>.

The first cam <NUM> is provided in the circular fixed plate <NUM> that does not follow the rotation of the drum section <NUM>. The fixed plate <NUM> is arranged such that the center thereof is aligned with the rotational center of the drum section <NUM>. The first cam <NUM> extends in the circumferential direction of the drum section <NUM> and the fixed plate <NUM>. By way of one example, the first cam <NUM> is a groove cam provided on the principal surface of the fixed plate <NUM>.

The first cam follower <NUM> is provided on the side of each laminating head <NUM> and slidably comes into contact with the first cam <NUM>. Therefore, the first cam follower <NUM> moves along the first cam <NUM> in association with the movement of each laminating head <NUM> based on the rotation of the drum section <NUM>. The first cam follower <NUM> is fixed to the rocking shaft <NUM> via a link member <NUM>.

The rolling motion mechanism <NUM> of the present embodiment includes two first cams <NUM> and two first cam followers <NUM>. One of the first cams <NUM> is more inward in the radial direction D2 than the other first cam <NUM> and extends in the circumferential direction of the fixed plate <NUM>. Therefore, the two first cam followers <NUM> are substantially arranged in the radial direction D2. Also, the two first cam followers <NUM> are arranged to be displaced relative to the rocking shaft <NUM> in the rotational direction D1. The link member <NUM> by way of one example is substantially triangular, and the rocking shaft <NUM> and the two first cam followers <NUM> are fixed to the respective corners of the triangle. The rocking shaft <NUM> and the two first cam followers <NUM> are coupled to the link member <NUM> so as not to be rotatable with respect to the link member <NUM>.

The two first cams <NUM> have a shape based on a circle concentric with the drum section <NUM>. However, the portion of the first cam <NUM> extending in a region including the laminating position is displaced from the base circle to permit the rolling motion of the holding surface <NUM>. In the present embodiment, the relative positions of the two first cam followers <NUM> change and the orientation of the link member <NUM> changes accordingly as at least one of the two first cams <NUM> is displaced from the baes circle. Consequently, the rocking shaft <NUM> is rotated, and the holding surface <NUM> is swung around the rocking shaft <NUM> to roll on the lamination surface 30a.

The orientation of the holding surface <NUM> taken when the first cam <NUM> is on the base circle of the first cam <NUM> is defined as a reference orientation. The laminating head <NUM> not engaged in a laminating action moves in the circumferential direction of the drum section <NUM> while the holding surface <NUM> is in the reference orientation. When the holding surface <NUM> is in the reference orientation, the circumferential positions of the inward first cam follower <NUM> and the outward first cam follower <NUM> are substantially aligned. In other words, the straight line extending from the center of the drum section <NUM> to the center of the inward first cam follower <NUM> and the straight line extending from the center of the drum section <NUM> to the center of the outward first cam follower <NUM> are substantially aligned.

The displacement mechanism <NUM> is a mechanism for displacing the entirety of the holding surface <NUM> in the radial direction D2 of the drum section <NUM>. The displacement mechanism <NUM> of the present embodiment realizes displacement of the holding surface <NUM> by means of a cam mechanism. More specifically, the displacement mechanism <NUM> includes a second cam <NUM> and a second cam follower <NUM> and displaces the holding surface <NUM> by means of the second cam <NUM> and the second cam follower <NUM>. The second cam <NUM> is provided in the fixed plate <NUM> that does not follow the rotation of the drum section <NUM>. The second cam <NUM> extends in the circumferential direction of the drum section <NUM> and the fixed plate <NUM>. By way of one example, the second cam <NUM> is a groove cam provided on the principal surface of the fixed plate <NUM>. Further, the second cam <NUM> of the present embodiment is provided more outward than the two first cams <NUM> in the radial direction D2.

The second cam follower <NUM> is provided on the side of each laminating head <NUM> and slidably comes into contact with the second cam <NUM>. Therefore, the second cam follower <NUM> moves along the second cam <NUM> in association with the movement of each laminating head <NUM> based on the rotation of the drum section <NUM>. The second cam follower <NUM> is fixed to the outward end of the base plate <NUM> in the radial direction D2.

The second cams <NUM> has a shape based on a circle concentric with the drum section <NUM>. However, the portion of the second cam <NUM> extending in a region including the laminating position is displaced from the base circle to displace the holding surface <NUM> in the radial direction D2. The second cam <NUM> of the present embodiment is curved at the laminating position in a direction away from the center of the base circle. Therefore, the second cam follower <NUM> passing through this portion is displaced outward in the radial direction D2 of the drum section <NUM>. Consequently, the base plate <NUM> slides outward in the radial direction D2, and the entirety of the holding surface <NUM> approaches the lamination surface 30a.

<FIG>, <FIG>, <FIG> are schematic diagrams for explaining the operation of the laminating device <NUM>. In the figures, illustration of the sheet member W is omitted. A description will be given below of the lamination operation for laminating the sheet member W performed by the laminating device <NUM>, highlighting a particular laminating head 102a.

As shown in <FIG>, the laminating head 102a arrives at the laminating position at which the lamination surface 30a extends while the holding surface <NUM> is in the reference orientation. The laminating head 102a then begins to perform the laminating operation for laminating the sheet member W. As shown in <FIG>, the laminating operation for laminating the sheet member W is performed such that the rolling motion mechanism <NUM> first swings the holding surface <NUM> in the reference orientation forward in the rotational direction D1, causing the rear end of the holding surface <NUM> to approach the lamination surface 30a.

Displacement of the holding surface <NUM> can be realized by the first cam <NUM> and the first cam follower <NUM>. More specifically, the rocking shaft <NUM> is rotated around its own axis in the rotational direction D1 in association with the displacement of the track of the first cam <NUM> in the radial direction D2. The rocking part <NUM> is fixed to the rocking shaft <NUM> and is coupled to the base plate <NUM> so as to be rotatable around the rocking shaft <NUM>. Therefore, the rocking part <NUM> is rotated along with the rocking shaft <NUM> and changes its orientation with respect to the base plate <NUM>. This swings the holding surface <NUM> forward (i.e., the holding surface <NUM> accelerates in the rotational direction D1).

The laminating device <NUM> of the present embodiment includes two sets of a combination of the first cam <NUM> and the first cam follower <NUM>. By rotating the rocking part <NUM> by means of two sets of the first cam <NUM> and the first cam follower <NUM> in this way, the pressure angle between the first cam <NUM> and the first cam follower <NUM> is configured to be small. By configuring the pressure angle to be small, the load applied to the first cam <NUM> and the first cam follower <NUM> is reduced. The number of combinations of the first cam <NUM> and the first cam follower <NUM> is not limited to two. One combination or three or more combinations may be used.

When the laminating head 102a advances in this state, the rear end of the sheet member W comes into contact with the lamination surface 30a, and the delivery point <NUM> of the sheet member W is formed between the holding surface <NUM> and the lamination surface 30a, as shown in <FIG>. When the delivery point <NUM> is formed, the vacuum pump connected to the second suction nozzle 112b stops being driven, and the second suction part 110b cancels the suction force. This initiates the delivery of the portion of the sheet member W held by the second suction part 110b to the lamination surface 30a.

As shown in <FIG>, the laminating head 102a then advances further in association with the rotation of the drum section <NUM>. Further, the rolling motion mechanism <NUM> rolls the holding surface <NUM> on the lamination surface 30a rearward in the rotational direction D1. This causes the delivery point <NUM> located at the rear end of the sheet member W to move toward the front end of the sheet member W. The portion of the sheet member W passing through the delivery point <NUM> is successively delivered to the lamination surface 30a.

As in the case of the displacement of the holding surface <NUM> shown in <FIG>, the rolling of the holding surface <NUM> can be realized by the first cam <NUM> and the first cam follower <NUM>. More specifically, the rocking shaft <NUM> is rotated around its own axis in a direction opposite to the rotational direction D1 in association with the displacement of the track of the first cam <NUM> in the radial direction D2. The rocking part <NUM> is rotated along with the rocking shaft <NUM> and changes its orientation with respect to the base plate <NUM>. This swings the holding surface <NUM> rearward (i.e., the holding surface <NUM> decelerates in the rotational direction D1).

The holding surface <NUM> leaves the state of being swung forward in the rotational direction D1 and approaches the reference orientation. The holding surface <NUM> undergoing the reference orientation is gradually swung rearward in the rotational direction D1. As the holding surface <NUM> leaves the state of being swung forward and approaches the reference orientation, the displacement mechanism <NUM> displaces the entirety of the holding surface <NUM> outward in the radial direction D2. Further, the displacement mechanism <NUM> displaces the entirety of the holding surface <NUM> inward in the radial direction D2 as the holding surface <NUM> is swung rearward from the reference orientation.

If the holding surface <NUM> is rolled without providing the displacement mechanism <NUM>, the distance of the portion of the holding surface <NUM> closest to the lamination surface 30a (i.e., the portion that could form the delivery point <NUM>) to the lamination surface 30a will be largest when the holding surface <NUM> is at the reference position, and the distance will be smaller as the amount of swinging of the holding surface <NUM> (i.e., the amount of displacement around the rocking shaft <NUM>) is increased. If the holding surface <NUM> in a state in which the holding surface <NUM> is swung forward in the rotational direction D1 to form the delivery point <NUM> at the rear end of the sheet member W starts to be rolled, the distance between the holding surface <NUM> and the lamination surface 30a at the delivery point <NUM> will be increased as the holding surface <NUM> approaches the reference orientation, making it difficult to deliver the sheet member W.

This is addressed by the displacement mechanism <NUM> which brings the entirety of the holding surface <NUM> closer to the lamination surface 30a as the holding surface <NUM> approaches the reference orientation and distancing the entirety of the holding surface <NUM> away from the lamination surface 30a as the holding surface <NUM> is swung rearward. This makes it possible to move the delivery point <NUM> parallel to the lamination surface 30a. In other words, it is possible to maintain the delivery point <NUM> more properly than otherwise until the delivery of the sheet member W is completed.

The displacement of the holding surface <NUM> is realized by the cam structure in which the second cam <NUM> protrudes outward in the radial direction D2. In this case, the second cam follower <NUM> is displaced outward in the radial direction D2 of the drum section <NUM> until the second cam follower <NUM> travels from the base end of the second cam <NUM> to the apex thereof. This causes the base plate <NUM> to slide outward in the radial direction D2, causing the entirety of the holding surface <NUM> to approach the lamination surface 30a. Further, the second cam follower <NUM> is displaced inward in the radial direction D2 of the drum section <NUM> until the second cam follower <NUM> returns from the apex of the second cam <NUM> to the base end thereof. This causes the base plate <NUM> to slide inward in the radial direction D2, causing the entirety of the holding surface <NUM> to be distanced from the lamination surface 30a.

Subsequently, the delivery point <NUM> arrives at the boundary between the first suction part 110a and the second suction part 110b, and the vacuum pump connected to the first suction nozzle 112a stops being driven to cause the first suction part 110a to cancel the suction force. In other words, the sheet member W is delivered from the holding surface <NUM> to the lamination surface 30a such that the second suction part 110b cancels the suction force and then the first suction part 110a cancels the suction force. This initiates the delivery of the portion of the sheet member W held by the first suction part 110a to the lamination surface 30a. It is also possible to cancel the suction force of each of the first suction part 110a and the second suction part 110b without stopping the vacuum pump. For example, the vacuum pipe may be provided with an open end that communicates with the atmosphere, and a valve for blocking the open end may be provided. According to this configuration, the suction force of each suction part can be canceled by opening the valve to cause the vacuum pipe to communicate with the atmosphere, even while the vacuum pump is being driven. By closing the valve, the suction force of each suction part is restored.

Then, as shown in <FIG>, as the laminating head 102a advances further and the rolling motion mechanism <NUM> rolls the holding surface <NUM> further rearward, the delivery point <NUM> arrives at the front end of the sheet member W. This completes the delivery of the sheet member W from the holding surface <NUM> to the lamination surface 30a. Subsequently, the laminating head 102a advances further and leaves the laminating position, as shown in <FIG>. Further, the rolling motion mechanism <NUM> returns the holding surface <NUM> in the state of being swung rearward in the rotational direction D1 to the reference position. The laminating head 102a turns around the drum section <NUM>, receives the sheet member W from the separator cutting drum <NUM>, and is forwarded to the laminating position again.

This displacement of the holding surface <NUM>, like the displacement of the holding surface <NUM> shown in <FIG> and the rolling of the holding surface <NUM> shown in <FIG>, is realized by the first cam <NUM> and the first cam follower <NUM>. More specifically, the rocking shaft <NUM> is rotated in the rotational direction D1 in association with the displacement of the track of the first cam <NUM> in the radial direction D2. The rocking part <NUM> is rotated along with the rocking shaft <NUM> and changes its orientation with respect to the base plate <NUM>. This swings the holding surface <NUM> forward and returns it to the reference position.

The shape of the cams constituting the rolling motion mechanism <NUM> and the displacement mechanism <NUM> can be set as appropriate based on geometric calculation, simulation, etc. by the designer in accordance with the position and orientation taken by the holding surface <NUM>. Further, the workpiece W is not limited to a component constituting a battery such as the electrode plate, the separator, and the laminated sheet. The regions of the holding surface <NUM> in which the suction force is adjustable in a mutually independent manner may not be limited to the two regions, namely, the first suction part 110a and the second suction part 110b. One such region may be provided, or three or more such regions may be provided. Where there are multiple regions, they are preferably arranged in the rotational direction D1.

The first cam <NUM> and the first cam follower <NUM> may be provided one each. The second cam <NUM> may be provided more inward in the radial direction D2 than the first cam <NUM>. The laminating device <NUM> may not be provided with the displacement mechanism <NUM>. In this case, parallel translation of the delivery point <NUM> can be realized by displacing the lamination stage <NUM>.

As described above, a laminating device <NUM> according to the present embodiment includes: a plurality of laminating heads <NUM> that each has a curved holding surface <NUM> for holding the sheet member W; a drum section <NUM> in which the plurality of laminating heads <NUM> are arranged in a circumferential direction, the drum section <NUM> holding each laminating head <NUM> such that the holding surface <NUM> is swingable, and rotation of the drum section <NUM> causing each laminating head <NUM> to advance to a laminating position facing a planar lamination surface 30a provided in the lamination stage <NUM>; and a rolling motion mechanism <NUM> that rolls the holding surface <NUM> on the lamination surface 30a so that a delivery point <NUM> of the sheet member W formed between the holding surface <NUM> and the lamination surface 30a moves from a rear end to a front end of the sheet member W in a rotational direction of the drum section <NUM> while each laminating head <NUM> is caused to move by the rotation of the drum section <NUM>.

If the laminating head <NUM> is viewed as a foot of a person, the movement of the holding surface <NUM> brought about by the rolling motion mechanism <NUM> is equivalent to movement of raising the toe and landing the foot on the lamination surface <NUM> from the heel (this forms the delivery point <NUM>), moving the point of contact (the delivery point <NUM>) with the lamination surface 30a from the heel to the toe, and causing the toe to leave from the lamination surface 30a.

The laminating device <NUM> of the present embodiment delivers the sheet member W gradually to the lamination surface 30a, starting at the rear end in the rotation direction D1, by rolling the curved holding surface <NUM> on the lamination surface 30a by means of the rolling motion mechanism <NUM>. The delivery operation can be performed without stopping the laminating head <NUM> at the laminating position. It is therefore not necessary to postpone the delivery operation until the vibration generated by stopping the laminating head <NUM> subsides. Accordingly, the throughput of the laminating device <NUM> is increased.

Further, the sheet member W can be laminated without generating vibration caused by stopping the laminating head <NUM> so that the precision of lamination of the sheet member W is increased and the quality of laminated sheet is increased. Further, the risk of applying a load such as a shear force to the sheet member W moving from a curved surface to a planar surface is reduced by rolling the holding surface <NUM> and delivering the sheet member W to the lamination surface 30a. Further, the the sheet member W of the present embodiment includes at least one of an electrode plate or a separator of a battery. Accordingly, the productivity and quality of laminated electrode assemblies and batteries are improved.

The rolling motion mechanism <NUM> of the present embodiment includes: a first cam <NUM> that does not follow the rotation of the drum section <NUM> and extends in the circumferential direction of the drum section <NUM>; and a first cam follower <NUM> that is provided in each laminating head <NUM> and that comes into contact with the first cam <NUM> and moves along the first cam <NUM> in association with movement of each laminating head <NUM>, wherein the first cam <NUM> and the first cam follower <NUM> roll the holding surface <NUM>. By configuring the rolling motion mechanism <NUM> using a cam mechanism, the structure of the rolling motion mechanism <NUM> is prevented from becoming complicated and the number of components is prevented from being increased.

Further, the laminating device <NUM> of the present embodiment includes the displacement mechanism <NUM> that displaces the holding surface <NUM> in the radial direction D2 of the drum section <NUM> and moves the delivery point <NUM> parallel to the lamination surface 30a. By moving the delivery point <NUM> parallel to the lamination surface 30a, the delivery point <NUM> is maintained until the delivery of the sheet member W is completed. This makes it possible to deliver the sheet member W more properly than otherwise. Further, the load applied to the sheet member W being delivered from the holding surface <NUM> to the lamination surface 30a is further suppressed. Further, the structure required to realize parallel translation of the delivery point <NUM> is prevented from becoming complicated and the number of components is prevented from being increased more successfully than in the case of displacing the lamination stage <NUM>.

Further, the displacement mechanism <NUM> according to the present embodiment includes: a second cam <NUM> that does not follow the rotation of the drum section <NUM> and extends in the circumferential direction of the drum section <NUM>; and a second cam follower <NUM> that is provided in each laminating head <NUM> and that comes into contact with the second cam <NUM> and moves along the second cam <NUM> in association with movement of each laminating head <NUM>, wherein the second cam <NUM> and the second cam follower <NUM> displace the holding surface <NUM>. By configuring the displacement mechanism <NUM> using a cam mechanism, the structure of the displacement mechanism <NUM> is prevented from becoming complicated and the number of components is prevented from being increased.

Further, the holding surface <NUM> of the present embodiment includes at least a first suction part 110a and a second suction part 110b that suck the sheet member W. The first suction part 110a and the second suction part 110b are adapted to switchably generate a suction force and cancel a suction force in a mutually independent manner. Further, the first suction part 110a is provided more toward the front than the second suction part 110b in the rotational direction D1 of the drum section <NUM>. The sheet member W is delivered from the holding surface <NUM> to the lamination surface 30a such that the second suction part 110b cancels a suction force and then the first suction part 110a cancels a suction force. This makes it possible to transfer the sheet member W in multiple separate stages. It is therefore possible to laminate the sheet member W on the lamination surface 30a with a higher positional accuracy.

Embodiments of the present disclosure have been described above in detail. The embodiments described above are merely specific examples of practicing the present disclosure. The details of the embodiments shall not be construed as limiting the technical scope of the present disclosure. A number of design modifications such as modification, addition, deletion, etc. of constituting elements may be made to the extent that they do not depart from the scope of the invention defined by the claims.

The present disclosure can be used in laminating devices.

Claim 1:
A laminating device (<NUM>) adapted to laminate a plurality of sheet members (W) on a lamination stage (<NUM>), comprising:
the lamination stage (<NUM>),
a plurality of laminating heads (<NUM>) that each has a holding surface (<NUM>) for holding the sheet member (W);
a drum section (<NUM>) in which the plurality of laminating heads (<NUM>) are arranged in a circumferential direction, the drum section (<NUM>) holding each laminating head (<NUM>) such that the holding surface (<NUM>) is swingable, and rotation of the drum section (<NUM>) causing each laminating head (<NUM>) to advance to a laminating position facing a planar lamination surface (30a) provided in the lamination stage (<NUM>); and
characterized in that :
the holding surface (<NUM>) is curved, and
the laminating device (<NUM>) further comprises :
a rolling motion mechanism (<NUM>) that rolls the holding surface (<NUM>) on the lamination surface (30a) so that a delivery point (<NUM>) of the sheet member (W) formed between the holding surface (<NUM>) and the lamination surface (30a) moves from a rear end to a front end of the sheet member (W) in a rotational direction (D1) of the drum section (<NUM>) while each laminating head (<NUM>) is caused to move by the rotation of the drum section (<NUM>).