JP5778938B2 - Separator manufacturing equipment - Google Patents

Description

  The present invention relates to a separator manufacturing apparatus.

  A separator having a nanofiber layer has high insulation and dendrite resistance because the fibers are thin and the voids are fine and uniform compared to a separator having a general fiber layer. For this reason, it is possible to increase the ion conductivity by reducing the thickness of the separator while maintaining high insulation and high dendrite resistance. In addition, the separator having a nanofiber layer has a higher porosity compared to a separator having a general fiber layer, and thus has a high electrolyte solution retention property, which also makes it possible to increase ion conductivity. It becomes. For this reason, the separator which has a nanofiber layer turns into a separator which has high insulation, high dendrite tolerance, and high ionic conductivity. Such a separator can be suitably used for a battery (including a primary battery and a secondary battery), a capacitor (also referred to as a capacitor), and the like.

  Conventionally, a nanofiber provided with a transport device having a transport mechanism for transporting a long sheet, and an electrospinning device that forms a nanofiber layer by depositing nanofibers on one side of the long sheet from below using an upward nozzle. A manufacturing apparatus is known (for example, refer to Patent Document 1). It is conceivable to manufacture a separator having a nanofiber layer using such a nanofiber manufacturing apparatus as a separator manufacturing apparatus.

  FIG. 10 is a view for explaining a conventional nanofiber manufacturing apparatus 900. FIG. 10A is a front view of the nanofiber manufacturing apparatus 900, and FIG. 10B is a perspective view of the periphery of the upward nozzle 920. FIG. As shown in FIGS. 10 (a) and 10 (b), the conventional nanofiber manufacturing apparatus 900 has a plurality of upwards that discharge a polymer solution (a polymer material or the like dissolved in a solvent) upward from the discharge port. A nozzle unit 910 having a nozzle 920, a collector 950 disposed above the nozzle unit 910, and a power supply device 960 that applies a high voltage between the plurality of upward nozzles 920 and the collector 950 are provided.

  According to the conventional nanofiber manufacturing apparatus 900, the polymer solution is discharged from the discharge ports of a plurality of upward nozzles 920 to electrospin the nanofibers, so that a drop as seen in the case of a separator manufacturing apparatus using a downward nozzle is used. A separator having a nanofiber layer can be produced without causing a letting phenomenon (a phenomenon in which a lump of polymer solution that has not been spun from a downward nozzle adheres to a long sheet or a base material layer as it is).

  The “separator” in the present invention refers to a non-conductive separator. In the present invention, the “nanofiber” refers to a fiber made of a polymer material and having an average diameter of several nm to several thousand nm.

Japanese Patent No. 4414458

  By the way, in the battery and capacitor industry, a separator having a structure in which nanofiber layers are formed on both surfaces of a base material layer (for example, a structure in which nanofiber layers are formed on both surfaces of a base material layer having high mechanical strength). May be required. Such a separator has high mechanical strength in addition to high insulation, high dendrite resistance and high ionic conductivity.

  However, since the conventional nanofiber manufacturing apparatus uses an upward nozzle as a nozzle, the direction in which the nanofiber layer can be formed is limited, and the nanofiber layer is formed on both sides of the base material layer. In order to manufacture a separator, a nanofiber layer is formed on one surface of a long sheet serving as a base layer by one nanofiber manufacturing apparatus 900, and then a long sheet is formed in another nanofiber manufacturing apparatus 900. It is necessary to form a nanofiber layer on the other surface of the long sheet after re-installing. For this reason, in the conventional nanofiber manufacturing apparatus, there exists a problem that the separator which has the structure where the nanofiber layer was formed on both surfaces of the base material layer cannot be mass-produced with high productivity.

  Therefore, the present invention has been made to solve the above problems, and mass-produces separators having a structure in which nanofiber layers are formed on both sides of a base material layer with high productivity without causing a droplet phenomenon. An object of the present invention is to provide a separator manufacturing apparatus capable of performing the above.

[1] The separator manufacturing apparatus of the present invention is a separator manufacturing apparatus that manufactures a separator in which a first nanofiber layer is formed on one surface of a base material layer and a second nanofiber layer is formed on the other surface. The transport mechanism for transporting the long sheet serving as the base material layer, and the direction of the one surface of the long sheet and the direction of the other surface are reversed while the long sheet is being transported. A conveying device having a long sheet reversing mechanism for reversing the long sheet, and a first nanofiber that is disposed in front of the long sheet reversing mechanism and deposits the first nanofibers on the one surface from below using an upward nozzle. A first electrospinning apparatus for forming the first nanofiber layer, and a second nanofiber deposited on the other surface from below by using an upward nozzle, and disposed at a stage subsequent to the long sheet reversing mechanism. The second nanofiber layer Characterized in that it comprises a second electrospinning apparatus for forming.

  Therefore, according to the separator manufacturing apparatus of the present invention, since the above-described long sheet reversing mechanism is provided, after the nanofiber layer is formed on one surface of the long sheet by the electrospinning apparatus (first electrospinning apparatus), It becomes possible to form a nanofiber layer on the other side of the long sheet without re-installing the long sheet in another electrospinning apparatus (second electrospinning apparatus). The separator having the nanofiber layer formed on the other surface) can be mass-produced with high productivity.

  Moreover, according to the separator manufacturing apparatus of the present invention, since the long sheet reversing mechanism is provided, both the first electrospinning apparatus and the second electrospinning apparatus are the same as in the case of the conventional nanofiber manufacturing apparatus. In addition, since it becomes possible to electrospin nanofibers by discharging a polymer solution from the discharge ports of a plurality of upward nozzles, a droplet phenomenon as seen in a separator manufacturing apparatus using downward nozzles is generated. There is nothing.

  Therefore, the separator manufacturing apparatus of the present invention is capable of mass-producing a separator having a structure in which nanofiber layers are formed on both surfaces of a base material layer with high productivity without causing a droplet phenomenon. It becomes.

  Note that the first nanofiber spinning device and the second nanofiber spinning device may have the same configuration or different configurations. Also, the first nanofiber layer and the second nanofiber layer may have the same configuration (material, average diameter, thickness, density, etc.), or may have different configurations. It can select suitably according to the separator to manufacture.

[2] In the separator manufacturing apparatus of the present invention, the second electrospinning device is disposed above the first electrospinning device, and the long sheet reversing mechanism is positioned at a height position of the second electrospinning device. It is preferable to reverse the long sheet from the first electrospinning apparatus in accordance with the above.

  By setting it as such a structure, it becomes possible to manufacture the separator which has the structure where the nanofiber layer was formed in both surfaces of the base material layer, without enlarging the installation area of a separator manufacturing apparatus so much.

[3] In the separator manufacturing apparatus of the present invention, the second electrospinning device is disposed below the first electrospinning device, and the long sheet reversing mechanism is positioned at a height position of the second electrospinning device. It is preferable to reverse the long sheet from the first electrospinning apparatus in accordance with the above.

  Even with such a configuration, it is possible to manufacture a separator having a structure in which nanofiber layers are formed on both surfaces of a base material layer without enlarging the installation area of the separator manufacturing apparatus.

[4] In the separator manufacturing apparatus of the present invention, the second electrospinning device is disposed at the same height position as the first electrospinning device, and the long sheet reversing mechanism changes the height position. It is preferable to reverse the long sheet.

  By setting it as such a structure, it becomes possible to manufacture the separator which has a structure in which the nanofiber layer was formed in both surfaces of the base material layer, without making the height of a separator manufacturing apparatus so much.

  In the case of the above [4], as the long sheet reversing mechanism, a long sheet is twisted without changing the conveying direction of the long sheet (see Modification 1 and FIG. 8 described later) or long. What twists a long sheet so that the conveyance direction of a long sheet may be bent 90 degree | times (refer the modification 2 mentioned later and FIG. 9) etc. can be used.

  In addition, “the same height position” does not indicate only the exact same height position, but also includes being handled as substantially the same height position. Further, “not changing the height position” does not only indicate that the height position is not strictly changed, but also includes that the height position can be handled substantially without being changed.

[5] In the separator manufacturing apparatus of the present invention, a first air permeability measuring device that is arranged downstream of the first electrospinning device and measures the air permeability of the long sheet on which the first nanofiber layer is formed. And a second air permeability measuring device that is disposed downstream of the second electrospinning device and measures the air permeability of the long sheet on which the first nanofiber layer and the second nanofiber layer are formed, Based on the air permeability measured by the first air permeability measuring device, “the first transport speed that is the transport speed of the long sheet when the long sheet passes through the first electrospinning device” is controlled, Based on the air permeability measured by the second air permeability measuring device, “the second transport speed that is the transport speed of the long sheet when the long sheet passes through the second electrospinning device” is controlled. Conveying speed control device It is preferably provided.

  By adopting such a configuration, it becomes possible to control the first transport speed and the second transport speed based on the air permeability measured by the first air permeability measuring device and the second air permeability measuring device. Even if the spinning conditions fluctuate in the electrospinning process for a long time and the air permeability fluctuates, it is possible to appropriately control the conveying speed to keep the air permeability fluctuation amount within a predetermined range. It becomes possible to mass-produce separators in which the nanofiber layer and the second nanofiber layer each have uniform air permeability.

  The control of the first transport speed and the second transport speed by the transport speed control device is, for example, a deviation amount between the air permeability measured by the first transport speed measuring device and the second transport speed measuring device and a predetermined target air permeability. Can be done based on. In the above case, the control of the first transport speed and the second transport speed by the transport speed control device can be performed in consideration of the time change rate of the deviation amount.

  In addition, from the viewpoint of operating the separator manufacturing apparatus continuously for a long time, it is preferable that the speed difference between the first transport speed and the second transport speed is as small as possible.

[6] In the separator manufacturing apparatus of the present invention, the first thickness measuring device is arranged at the rear stage of the first electrospinning device and measures the thickness of the long sheet on which the first nanofiber layer is formed. And a second thickness measuring device that is disposed downstream of the second electrospinning device and measures the thickness of the long sheet on which the first nanofiber layer and the second nanofiber layer are formed, and Based on the thickness measured by the first thickness measuring device, "the first conveying speed that is the conveying speed of the long sheet when the long sheet passes through the first electrospinning apparatus" is controlled, Based on the thickness measured by the second thickness measuring device, “the second conveying speed that is the conveying speed of the long sheet when the long sheet passes the second electrospinning device” is controlled. It is preferable to have a transport speed control device. Arbitrariness.

  By adopting such a configuration, it becomes possible to control the first transport speed and the second transport speed based on the thickness measured by the first thickness measuring device and the second thickness measuring device, Even if the spinning conditions fluctuate in the electrospinning process for a long time and the thickness fluctuates, it is possible to appropriately control the conveying speed to keep the variation in thickness within a predetermined range. It becomes possible to mass-produce separators in which the nanofiber layer and the second nanofiber layer each have a uniform thickness.

  The control of the first transport speed and the second transport speed by the transport speed control device is based on, for example, the amount of deviation between the thickness measured by the first transport speed measuring device and the second transport speed measuring device and a predetermined target thickness. Can be done. In the above case, the control of the first transport speed and the second transport speed by the transport speed control device can be performed in consideration of the time change rate of the deviation amount.

[7] In the separator manufacturing apparatus of the present invention, the separator manufacturing apparatus is disposed between the first electrospinning apparatus and the second electrospinning apparatus, and absorbs a speed difference between the first conveying speed and the second conveying speed. A speed difference absorbing device is further provided, and the transport device transports the long sheet at the first transport speed, and a second drive device transports the long sheet at the second transport speed. It is preferable to further comprise.

  By adopting such a configuration, even when the first conveyance speed and the second conveyance speed are different, it becomes possible to prevent the long sheet from being cut or loosened. It becomes possible to continue driving continuously.

[8] In the separator manufacturing apparatus of the present invention, it is preferable that the speed difference absorbing device includes a plurality of speed difference absorbing rollers capable of changing a distance between each other.

  By setting it as such a structure, it becomes possible to absorb the difference between a 1st conveyance speed and a 2nd conveyance speed by changing the space | interval of a speed difference absorption roller.

[9] The separator manufacturing apparatus of the present invention preferably further includes a spinning condition changing device capable of independently changing the spinning conditions of the first electrospinning device and the spinning conditions of the second electrospinning device. .

  By adopting such a configuration, it is possible to prevent the difference between the first conveyance speed and the second conveyance speed from becoming large by independently changing the spinning conditions. As a result, the separator manufacturing apparatus can be continuously operated for a longer time.

  Examples of the “spinning conditions” include voltage, distance between the upward nozzle and the long sheet, composition of the polymer solution, temperature and humidity in the spinning area, and the like.

1 is a front view of a separator manufacturing apparatus 1 according to Embodiment 1. FIG. It is a figure for demonstrating the 1st electrospinning apparatus 20 in Embodiment 1. FIG. It is a figure for demonstrating the speed difference absorption apparatus 40 in Embodiment 1. FIG. 6 is a diagram for explaining a method for manufacturing a separator in Embodiment 1. FIG. It is a front view of the separator manufacturing apparatus 2 which concerns on Embodiment 2. FIG. It is a front view of the separator manufacturing apparatus 3 which concerns on Embodiment 3. FIG. It is a front view of the separator manufacturing apparatus 4 which concerns on the modification 1. FIG. It is a figure for demonstrating the elongate sheet inversion mechanism 15c in the modification 2. FIG. It is a figure for demonstrating the elongate sheet inversion mechanism 15d in the modification 3. FIG. It is a front view of the conventional separator manufacturing apparatus 900.

  Hereinafter, the separator manufacturing apparatus of this invention is demonstrated based on embodiment shown in a figure.

1. Configuration of Separator Manufacturing Apparatus 1 According to Embodiment 1 First, the configuration of the separator manufacturing apparatus 1 according to Embodiment 1 will be described.
FIG. 1 is a front view of a separator manufacturing apparatus 1 according to the first embodiment. In FIG. 1, some members are shown as cross-sectional views. The same applies to FIGS. 2 and 5 to 7 described later.
FIG. 2 is a diagram for explaining the first electrospinning apparatus 20 according to the first embodiment. 2A is a front view of the first electrospinning apparatus 20, and FIG. 2B is a view of the nozzle block 110 viewed from the collector 150 side. In FIG. 2B, components (upward nozzle 120 and the like) arranged below the long sheet W are also illustrated. The auxiliary belt 172 is not shown.
FIG. 3 is a diagram for explaining the speed difference absorbing device 40 according to the first embodiment. FIG. 3A is a diagram when the first conveyance speed and the second conveyance speed are the same, and FIG. 3B is a diagram when the first conveyance speed is faster than the second conveyance speed. FIG. 3C is a diagram when the first transport speed is slower than the second transport speed.

  As shown in FIGS. 1 to 3, the separator manufacturing apparatus 1 according to Embodiment 1 includes a transport device 10, a first electrospinning device 20, a first air permeability measuring device 30, a speed difference absorbing device 40, and Second electrospinning device 22, second air permeability measuring device 32, transport speed control device 50 (not shown), spinning condition changing device 60 (not shown), and main control device 70 (shown). Not shown.). The separator manufacturing apparatus 1 is a separator in which a first nanofiber layer NL1 is formed on one surface of a base material layer and a second nanofiber layer NL2 is formed on the other surface (see FIG. 4D described later). It is a separator manufacturing apparatus for manufacturing.

  The separator manufacturing apparatus 1 according to Embodiment 1 includes one electrospinning apparatus 20 as the first electrospinning apparatus. Further, one electrospinning device 22 is provided as the second electrospinning device.

  As shown in FIG. 1, the conveying device 10 is configured to convey a long sheet W serving as a base material layer from the first electrospinning device 20 to the second electrospinning device 22. When the first electrospinning device 20 forms the first nanofiber layer NL1 (see FIG. 4B described later), the conveying device 10 moves the long sheet in the first direction (direction A1 in FIG. 1). ) And the long sheet W from the height position of the first electrospinning device 20 to the height position of the second electrospinning device 22 in a second direction (A2 direction) substantially perpendicular to the first direction. When the second electrospinning device 22 forms the second nanofiber layer NL2 (see FIG. 4D described later), the long sheet W is in the third direction opposite to the first direction. It is conveyed in the direction of A3.

  The conveying device 10 includes a feeding roller 11 that feeds out the long sheet W, a take-up roller 12 that winds up the long sheet W, a tension roller 13 that adjusts the tension of the long sheet W, and the long sheet W as the first. The first driving roller 14 that transports at the transport speed, the first reversing roller 16a that directs the transport direction of the long sheet W from the first electrospinning device 20, and the long sheet W from the first reversing roller 16a. A second reversing roller 16b that directs the conveying direction toward the second electrospinning device 22, a second driving roller 17 that conveys the long sheet W at a second conveying speed, and an auxiliary roller 18 that assists the conveyance.

  Among these, the feeding roller 11, the take-up roller 12, the tension roller 13, the first driving roller 14, the second driving roller 17, and the auxiliary roller 18 are transporting mechanisms that transport the long sheet W (reference numerals are not shown). Configure. The first drive roller 14 is a first drive device that transports the long sheet W at the first transport speed. The second drive roller 17 is a second drive device that transports the long sheet W at the second transport speed.

The first reversing roller 16a and the second reversing roller 16b move the long sheet W so that the direction of one surface of the long sheet W and the direction of the other surface are opposite while the long sheet W is being conveyed. A long sheet reversing mechanism 15a for reversing is configured. The long sheet reversing mechanism 15 a reverses the long sheet W from the first electrospinning device 20 in accordance with the height position of the second electrospinning device 22.
The feeding roller 11, the take-up roller 12, the first drive roller 14, and the second drive roller 17 are each configured to be rotated by a drive motor (not shown). The rollers other than those described above may also be configured to be rotationally driven by a drive motor or the like.

  The first transport speed and the second transport speed are ideally the same speed, but are controlled independently by the transport speed control device 50 based on the measured air permeability as will be described later. The first transport speed may be slightly faster than the second transport speed, or the first transport speed may be slightly slower than the second transport speed.

As shown in FIGS. 1 and 2, the first electrospinning apparatus 20 is disposed in front of the long sheet reversing mechanism 15a and is formed on one side of the long sheet W from below using an upward nozzle 120 (described later). First nanofibers are deposited to form a first nanofiber layer NL1. The second electrospinning device 22 is disposed downstream of the long sheet reversing mechanism 15a, and deposits second nanofibers on the other surface of the long sheet W from below by using an upward nozzle to form a second nanofiber layer NL2. Form.
The second electrospinning device 22 is disposed above the first electrospinning device 20 located in the preceding stage.

Hereinafter, the configuration of the first electrospinning apparatus 20 will be described in detail.
As shown in FIG. 2, the first electrospinning device 20 includes a housing 100, a nozzle unit 110, a polymer solution supply unit 130 (not shown), a collector 150, a power supply device 160, and an auxiliary belt device. 170. The first electrospinning device 20 discharges the first polymer solution from the discharge ports of a plurality of upward nozzles 120 described later while overflowing, and electrospins the first nanofibers.

The housing 100 is made of a conductor.
The nozzle unit 110 has a plurality of upward nozzles 120.
Nozzle units having various sizes and shapes can be used in the separator manufacturing apparatus of the present invention, but the nozzle unit 110 has a rectangular shape (a square having a side of 0.5 m to 3 m when viewed from above. It has a block-like shape with a visible size.

  The upward nozzle 120 is a nozzle that discharges “a first polymer solution that is a raw material of the first nanofibers” supplied from a polymer solution supply unit 130 (not shown) from a discharge port. The upward nozzle 120 discharges the first polymer solution upward from the discharge port. As a material constituting the upward nozzle 120, a conductor can be used. For example, copper, stainless steel, aluminum, or the like can be used.

  The upward nozzles 120 are arranged at a pitch of 1.5 cm to 6.0 cm, for example. The number of upward nozzles 120 can be, for example, 36 (6 × 6 when arranged in the same vertical and horizontal directions) to 21904 (148 × 148 when arranged in the same vertical and horizontal directions).

The collector 150 is disposed above the nozzle unit 110. The collector 150 is made of a conductor and is attached to the housing 100 via an insulating member 152 as shown in FIG.
The power supply device 160 applies a high voltage between the upward nozzle 120 and the collector 150. The positive electrode of the power supply device 160 is connected to the collector 150, and the negative electrode of the power supply device 160 is connected to the nozzle unit 110 via the housing 100.

  The auxiliary belt device 170 includes an auxiliary belt 172 that rotates in synchronization with the conveyance speed of the long sheet W, and five auxiliary belt rollers 174 that assist the rotation of the auxiliary belt 172. Of the five auxiliary belt rollers 174, one or more auxiliary belt rollers are drive rollers, and the remaining auxiliary belt rollers are driven rollers. Since the auxiliary belt 172 is disposed between the collector 150 and the long sheet W, the long sheet W is smoothly conveyed without being attracted to the collector 150 to which a positive high voltage is applied. become.

  The second electrospinning device 22 is basically the same as the first electrospinning device 20 except that it handles “the second polymer solution that is the raw material of the second nanofiber” and “electrospins the second nanofiber”. Since it has the configuration, the description of the configuration of the first electrospinning device 20 is replaced with the description of the second electrospinning device 22. However, this does not indicate that the first electrospinning apparatus and the second electrospinning apparatus need to have the same configuration. Within the scope of the present invention, the first electrospinning device and the second electrospinning device may have different configurations.

As shown in FIG. 1, the first air permeability measuring device 30 is arranged at the rear stage of the first electrospinning device 20 and measures the air permeability of the long sheet W on which the first nanofiber layer NL1 is formed.
The second air permeability measuring device 32 is arranged at the subsequent stage of the second electrospinning device 22 and measures the air permeability of the long sheet W on which the first nanofiber layer NL1 and the second nanofiber layer NL2 are formed.
As the first air permeability measuring device 30 and the second air permeability measuring device 32, a general air permeability measuring device can be used. The first air permeability measuring device 30 and the second air permeability measuring device 32 each transmit a measurement result to the conveyance speed control device 50.

  The speed difference absorbing device 40 is disposed between the first electrospinning device 20 and the second electrospinning device 22, and absorbs the speed difference between the first transport speed and the second transport speed. As shown in FIG. 3, the speed difference absorbing device 30 includes a plurality of speed difference absorbing rollers 42 that can change the interval between them.

Here, operation | movement of the speed difference absorption apparatus 40 is demonstrated using FIG.
First, when the first transport speed and the second transport speed are the same, as shown in FIG. 3A, the distance between the speed difference absorbing rollers 42 remains constant.
On the other hand, when the second transport speed is higher than the first transport speed, as shown in FIG. 3B, the second transport speed moves above the speed difference absorbing roller 42 positioned below, and the speed between the first transport speed and the second transport speed. Absorb the difference.
Further, when the second transport speed is slower than the first transport speed, as shown in FIG. 3C, the speed difference absorbing roller 42 located below moves downward, and the first transport speed and the second transport speed are reduced. Absorbs the speed difference.

  The conveyance speed control device 50 is based on the air permeability measured by the first air permeability measuring device 30, “This is the conveyance speed of the long sheet W when the long sheet W passes through the first electrospinning device 20. The “first conveying speed” is controlled, and “the conveying speed of the long sheet W when the long sheet W passes through the second electrospinning device 22 based on the air permeability measured by the second air permeability measuring device 32. Is controlled. " For example, if the spinning conditions fluctuate in a direction that increases the air permeability during a long electrospinning process, the air permeability is reduced by increasing the amount of nanofibers deposited per unit area by slowing the conveying speed. . On the other hand, if the spinning conditions fluctuate in the direction of decreasing the air permeability during the long-time electrospinning process, the air permeability is increased by increasing the conveyance speed and reducing the amount of nanofibers deposited per unit area. . This is performed independently at the first transport speed and the second transport speed.

  The spinning condition changing device 60 can independently change the spinning conditions of the first electrospinning device 20 and the spinning conditions of the second electrospinning device 22. The spinning condition changing device 60 is based on the “air permeability of the long sheet W on which the first nanofiber layer NL1 is formed” measured by the first air permeability measuring device 30, and the spinning conditions of the first electrospinning device 20. (Voltage, the distance between the upward nozzle and the long sheet, the composition of the polymer solution, the temperature and the humidity of the spinning area, etc.) are changed so that the fluctuation of the first conveying speed becomes small. Further, the spinning condition changing device 60 is based on “the air permeability of the long sheet W on which the first nanofiber layer NL1 and the second nanofiber layer NL2 are formed” measured by the second air permeability measuring device 32. The spinning condition of the second electrospinning device 22 is changed so that the fluctuation of the second transport speed is reduced.

  The main controller 70 is “conveying device 10, first electrospinning device 20, first air permeability measuring device 30, speed difference absorbing device 40, second electrospinning device 22, second air permeability measuring device 32, conveying speed control. The apparatus 50 and the spinning condition changing apparatus 60 "are controlled.

2. Method for Producing Separator Using Separator Production Apparatus 1 According to Embodiment 1 Hereinafter, a method for producing a separator using the separator production apparatus 1 according to Embodiment 1 will be described.

  FIG. 4 is a diagram for explaining a method of manufacturing a separator in the first embodiment. 4A to 4D are process diagrams.

a) Preparation for Spinning / Conveying Long Sheet W A first polymer solution and a second polymer solution are prepared and supplied to the nozzle block 110 of the first electrospinning device 20 and the second electrospinning device 22. Subsequently, the long sheet W is set on the conveying device 10, and the long sheet W (see FIG. 4A) is conveyed from the feeding roller 11 toward the take-up roller 12.

b) Electrospinning (1)
Next, the first nanofiber layer NL1 is formed on one surface of the long sheet W by the first electrospinning apparatus 20 while the long sheet W is being transported at the first transport speed (see FIG. 4B). .
The air permeability of the long sheet W on which the first nanofiber layer NL1 is formed is measured by the first air permeability measuring device 30, and the transport speed control device 50 controls the first transport speed based thereon. Further, the spinning condition changing device 60 changes the spinning conditions of the first electrospinning device 20 so that the fluctuation of the first transport speed becomes small.

c) Reversal of the long sheet W Next, the direction of the one surface of the long sheet W so that the other surface is on the lower side by the long sheet reversing mechanism 15a (the first reversing roller 16a and the second reversing roller 16b). And the direction of the other surface are reversed (see FIG. 4C).

d) Electrospinning (2)
Finally, the second nanofiber layer NL2 is formed on the other surface of the long sheet W by the second electrospinning device 22 while the long sheet W on which the first nanofiber layer NL1 is laminated is transported at the second transport speed. (See FIG. 4D.)
The air permeability of the long sheet W on which the first nanofiber layer NL1 and the second nanofiber layer NL2 are formed is measured by the second air permeability measuring device 32, and the transport speed control device 50 determines the second transport speed based on the measured air permeability. To control. Further, the spinning condition changing device 60 changes the spinning conditions of the second electrospinning device 22 so that the fluctuation of the second transport speed is reduced.
A separator can be manufactured by the above method.

  Below, the spinning conditions in Embodiment 1 are shown as an example.

  As a polymer used as a raw material of the first nanofiber and the second nanofiber, for example, polylactic acid (PLA), polypropylene (PP), polyvinyl acetate (PVAc), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), Polyethylene naphthalate (PEN), polyamide (PA), polyurethane (PUR), polyvinyl alcohol (PVA), polyacrylonitrile (PAN), polyetherimide (PEI), polycaprolactone (PCL), polylactic glycolic acid (PLGA), Silk, cellulose, chitosan and the like can be used.

  Examples of the solvent used in the first polymer solution and the second polymer solution include dichloromethane, dimethylformamide, dimethyl sulfoxide, methyl ethyl ketone, chloroform, acetone, water, formic acid, acetic acid, cyclohexane, and THF. A plurality of types of solvents may be mixed and used. The polymer solution may contain an additive such as a conductivity improver.

  As long sheet W, the nonwoven fabric which can be used as a separator, a textile fabric, a knitted fabric, paper etc. can be used. The long sheet W may have a thickness of, for example, 3 μm to 50 μm. The length of the long sheet W can be, for example, 10 m to 10 km.

  The first transport speed and the second transport speed can be set to, for example, 0.2 m / min to 100 m / min. The voltage applied between the collector 150 and the nozzle block 110 can be set to 10 kV to 80 kV, and is preferably set to around 50 kV.

  The temperature of the spinning zone can be set to 10 ° C. to 40 ° C., for example. The humidity of the spinning area can be set to 20% to 60%, for example.

3. Effect of Separator Manufacturing Apparatus 1 According to Embodiment 1 According to the separator manufacturing apparatus 1 according to Embodiment 1, since the above-described long sheet reversing mechanism 15a is provided, it is long by an electrospinning apparatus (first electrospinning apparatus 20). After forming the nanofiber layer on one surface of the sheet, the nanofiber layer is formed on the other surface of the long sheet without re-installing the long sheet in another electrospinning apparatus (second electrospinning apparatus 22). Therefore, it is possible to mass-produce a separator having a nanofiber layer formed on both surfaces (one surface and the other surface) of the base material layer with high productivity.

  Moreover, according to the separator manufacturing apparatus 1 which concerns on Embodiment 1, in order to provide the above-mentioned long sheet inversion mechanism 15a, in any case of the 1st electrospinning apparatus 20 and the 2nd electrospinning apparatus 22, the conventional nanofiber As in the case of the manufacturing apparatus 900, the nanofibers can be electrospun by discharging a polymer solution from the discharge ports of a plurality of upward nozzles, so that it can be seen in the case of a separator manufacturing apparatus using a downward nozzle. Does not cause an excessive droplet phenomenon.

  Therefore, the separator manufacturing apparatus 1 according to Embodiment 1 can mass-produce a separator having a structure in which nanofiber layers are formed on both surfaces of a base material layer with high productivity without causing a droplet phenomenon. Separator manufacturing equipment.

  Further, according to the separator manufacturing apparatus 1 according to the first embodiment, the second electrospinning device 22 is disposed above the first electrospinning device 20, and the long sheet reversing mechanism 15 a is configured to be connected to the second electrospinning device 22. In order to reverse the long sheet W from the first electrospinning device 20 according to the height position, the nanofiber layers were formed on both surfaces of the base material layer without increasing the installation area of the separator manufacturing device so much. It becomes possible to manufacture a separator having a structure.

  Moreover, according to the separator manufacturing apparatus 1 which concerns on Embodiment 1, since the 1st air permeability measurement apparatus 30, the 2nd air permeability measurement apparatus 32, and the conveyance speed control apparatus 50 are provided, a 1st air permeability measurement apparatus and Since the first transport speed and the second transport speed can be controlled based on the air permeability measured by the second air permeability measuring device, the spinning conditions fluctuate in the long-time electrospinning process, and the air permeability is reduced. Even if it fluctuates, it becomes possible to appropriately control the conveyance speed to keep the variation amount of the air permeability within a predetermined range. As a result, the first nanofiber layer and the second nanofiber layer have uniform air permeability. It becomes possible to mass-produce the separator which has.

  Moreover, according to the separator manufacturing apparatus 1 which concerns on Embodiment 1, it arrange | positions between the 1st electrospinning apparatus 20 and the 2nd electrospinning apparatus 22, and absorbs the speed difference of a 1st conveyance speed and a 2nd conveyance speed. Since the speed difference absorbing device 40 is provided, even when the first transport speed and the second transport speed are different, it becomes possible to prevent the long sheet from being cut or loosened. It becomes possible to continue driving for hours.

  Moreover, according to the separator manufacturing apparatus 1 which concerns on Embodiment 1, since the speed difference absorption apparatus 40 is provided with the speed difference absorption roller 42 which can change a space | interval, it is 1st by changing the space | interval of a speed difference absorption apparatus. It becomes possible to absorb the difference between the transport speed and the second transport speed.

  In addition, the separator manufacturing apparatus 1 according to the first embodiment includes the spinning condition changing device 60 that can independently change the spinning conditions of the first electrospinning device 20 and the spinning conditions of the second electrospinning device 22. Therefore, by independently changing the spinning conditions, it is possible to prevent the difference between the first transport speed and the second transport speed from becoming large. As a result, the separator manufacturing apparatus can be continuously operated for a longer time.

[Embodiment 2]
FIG. 5 is a front view of the separator manufacturing apparatus 2 according to the second embodiment.

  The separator manufacturing apparatus 2 according to the second embodiment has basically the same configuration as the separator manufacturing apparatus 1 according to the first embodiment, but the arrangement position of the electrospinning apparatus is the separator manufacturing apparatus 1 according to the first embodiment. Is different. Accordingly, the configuration of the transport device and the arrangement of the first air permeability measuring device and the second air permeability measuring device are also different from the separator manufacturing apparatus 1 according to the first embodiment.

  In the separator manufacturing apparatus 2, as shown in FIG. 5, the second electrospinning apparatus 22 is disposed below the first electrospinning apparatus 20 located in the subsequent stage. Further, the long sheet reversing mechanism 15b of the conveying device 19 includes a first reversing roller 16c and a second reversing roller 16d, and is arranged from the first electrospinning device 20 in accordance with the height position of the second electrospinning device 22. The long sheet W is reversed.

  As described above, the separator manufacturing apparatus 2 according to the second embodiment is different from the separator manufacturing apparatus 1 according to the first embodiment in the arrangement position of the electrospinning apparatus, but the long sheet reversal for reversing the long sheet W is performed. A transport device 19 having a mechanism 15b, a first electrospinning device 20 that forms a first nanofiber layer NL1 by depositing first nanofibers on one surface from below using an upward nozzle 120, and an upward nozzle Since the second electrospinning device 22 for forming the second nanofiber layer NL2 by depositing the second nanofibers on the other surface from below is provided, as in the case of the separator manufacturing device 1 according to the first embodiment, Separator manufacturing apparatus capable of mass-producing a separator having a structure in which nanofiber layers are formed on both sides of a layer with high productivity without causing a droplet phenomenon It made.

  Further, according to the separator manufacturing apparatus 2 according to the second embodiment, the second electrospinning device 22 is disposed below the first electrospinning device 20, and the long sheet reversing mechanism 15 b has a height higher than that of the second electrospinning device 22. In order to reverse the long sheet W from the first electrospinning device 20 in accordance with the position, the configuration of the base material layer can be reduced without increasing the installation area of the separator manufacturing device by such a configuration. It becomes possible to manufacture a separator having a structure in which nanofiber layers are formed on both sides.

  The separator manufacturing apparatus 2 according to the second embodiment has basically the same configuration as that of the separator manufacturing apparatus 1 according to the first embodiment except for the arrangement position of the electrospinning apparatus. Of the effects that the separator manufacturing apparatus 1 has, the corresponding effects are provided as they are.

[Embodiment 3]
FIG. 6 is a front view of the separator manufacturing apparatus 3 according to the third embodiment.

  The separator manufacturing apparatus 3 according to the third embodiment has basically the same configuration as the separator manufacturing apparatus 1 according to the first embodiment, except that the number of electrospinning apparatuses is the separator manufacturing apparatus 1 according to the first embodiment. Is different. That is, the separator manufacturing apparatus 3 according to Embodiment 3 includes two first electrospinning apparatuses 20 and 21 and two second electrospinning apparatuses 22 and 23 as shown in FIG. The first electrospinning device 20 and the first electrospinning device 21 have the same configuration, and the second electrospinning device 22 and the second electrospinning device 23 have the same configuration.

  Thus, the separator manufacturing apparatus 3 according to the third embodiment is different from the separator manufacturing apparatus 1 according to the first embodiment in the number of electrospinning apparatuses, but the long sheet reversing mechanism 15b that reverses the long sheet W. A first electrospinning device 20, 21 for forming a first nanofiber layer NL1 by depositing first nanofibers on one surface from below using an upward nozzle 120, and an upward nozzle Since the second electrospinning devices 22 and 23 for forming the second nanofiber layer NL2 by depositing the second nanofibers on the other side from below, as in the case of the separator manufacturing device 1 according to the first embodiment, Separator manufacturing capable of mass production of separators having a structure in which nanofiber layers are formed on both sides of a base material layer without causing droplet phenomenon with high productivity The location.

  The separator manufacturing apparatus 3 according to the third embodiment has basically the same configuration as the separator manufacturing apparatus 1 according to the first embodiment except for the number of electrospinning apparatuses, and thus the separator according to the first embodiment. It has the corresponding effect as it is among the effects of the manufacturing apparatus 1.

  As mentioned above, although this invention was demonstrated based on said embodiment, this invention is not limited to said embodiment. The present invention can be implemented in various forms without departing from the spirit thereof, and for example, the following modifications are possible.

(1) The number, positional relationship, and size of each component in each of the above embodiments are examples, and the present invention is not limited to this.

(2) The separator manufacturing apparatus according to each of the above embodiments includes an air permeability measuring device (a first air permeability measuring device and a second air permeability measuring device), but the present invention is limited to this. is not. For example, a thickness measuring device (a first thickness measuring device and a second thickness measuring device) may be provided. In this case, the transport speed control device controls the first transport speed and the second transport speed based on the thicknesses measured by the first thickness measurement device and the second thickness measurement device. By adopting such a configuration, it becomes possible to control the first transport speed and the second transport speed based on the thickness measured by the first thickness measuring device and the second thickness measuring device, Even if the spinning conditions fluctuate in the electrospinning process for a long time and the thickness fluctuates, it is possible to appropriately control the conveyance speed accordingly to keep the fluctuation amount of the thickness within a predetermined range. In addition, it is possible to mass-produce separators in which the first nanofiber layer and the second nanofiber layer each have a uniform thickness.

(3) In the third embodiment, the separator manufacturing apparatus of the present invention has been described by taking the separator manufacturing apparatus 3 having the same configuration of the electrospinning apparatuses 20 and 21 and the electrospinning apparatuses 22 and 23 as an example. It is not limited to this. The present invention can also be applied to separator manufacturing apparatuses having different electrospinning apparatus configurations.

(4) In the third embodiment, the separator manufacturing apparatus of the present invention has been described by taking the separator manufacturing apparatus 3 having the same number (two) of the first electrospinning apparatus and the second electrospinning apparatus as an example. However, the present invention is not limited to this. FIG. 7 is a front view of the separator manufacturing apparatus 4 according to the first modification. For example, the present invention can also be applied to a separator manufacturing apparatus in which the number of first electrospinning apparatuses and the number of second electrospinning apparatuses are not the same as in the separator manufacturing apparatus 4 shown in FIG. In addition, the separator manufacturing apparatus of this invention is not restricted to what was described in FIG. 7, The 1st electrospinning apparatus may be equipped with 1 unit | set or 3 units | sets or 2 or more 2nd electrospinning unit units | sets. May be.

(5) In each of the above embodiments, the long sheet reversing mechanism for reversing the long sheet W from the first electrospinning device 20 according to the height position of the second electrospinning device 22 is used. The invention is not limited to this. For example, a long sheet reversing mechanism that reverses the long sheet without changing the height position may be used. In this case, the second electrospinning device is preferably disposed at the same height as the first electrospinning device. By setting it as such a structure, it becomes possible to manufacture the separator which has a structure in which the nanofiber layer was formed in both surfaces of the base material layer, without making the height of a separator manufacturing apparatus so much.

FIG. 8 is a view for explaining the long sheet reversing mechanism 15c in the second modification. FIG. 9 is a view for explaining the long sheet reversing mechanism 15d in the third modification. 8 and 9 are schematic views of the long sheet reversing mechanism as viewed from above.
As shown in FIG. 8, the long sheet reversing mechanism 15c includes three twist rollers 16e, 16f, and 16g, and reverses the long sheet so as to twist it without changing the conveying direction of the long sheet. is there. Further, as shown in FIG. 9, the long sheet reversing mechanism 15d includes one torsion roller 16h, and reverses the long sheet so as to bend so that the conveying direction of the long sheet is bent by 90 degrees. is there. The long sheet reversing mechanism as described above may be used.

(6) In the separator manufacturing apparatus of the present invention, a nozzle block having a block shape is used as the nozzle unit, but the present invention is not limited to this. As the nozzle unit, a nozzle unit composed of a plurality of tubes each having a plurality of upward nozzles may be used.

(7) In each of the above embodiments, the separator manufacturing apparatus of the present invention has been described using an electrospinning apparatus in which the positive electrode of the power supply device 160 is connected to the collector 150 and the negative electrode of the power supply device 160 is connected to the nozzle unit 110. However, the present invention is not limited to this. For example, the present invention can be applied to a separator manufacturing apparatus including an electrospinning apparatus in which a positive electrode of a power supply device is connected to a nozzle unit and a negative electrode of the power supply device is connected to a collector.

(8) In each of the above embodiments, the present invention has been described using the separator manufacturing apparatus 1 in which one nozzle unit is disposed in one electrospinning apparatus, but the present invention is not limited to this. . For example, the present invention can be applied to a separator manufacturing apparatus in which two or more nozzle units are disposed in one electrospinning apparatus.

  In this case, the nozzle arrangement pitch can be made the same for all nozzle units, or the nozzle arrangement pitch can be made different for each nozzle unit. Moreover, the height position of a nozzle unit can also be made the same by all the nozzle units, and the height position of a nozzle unit can also be varied by each nozzle unit.

1, 2, 3, 4 ... Separator manufacturing device, 10, 19 ... Conveying device, 11 ... Feeding roller, 12 ... Winding roller, 13 ... Tension roller, 14 ... First drive roller, 15a, 15b, 15c, 15d ... Long sheet reversing mechanism, 16a, 16c ... first reversing roller, 16b, 16d ... second reversing roller, 16e, 16f, 16g, 16h ... twisting roller, 17 ... second driving roller, 18 ... auxiliary roller, 20, 21 ... 1st electrospinning device, 22, 23 ... 2nd electrospinning device, 30, 32 ... Air permeability measuring device, 40 ... Speed difference adjusting device, 42 ... Speed difference absorbing roller, 100 ... Housing, 110 ... Nozzle unit, 120 ... Upward nozzle, 150 ... Collector, 152 ... Insulator, 160 ... Power supply device, 170 ... Auxiliary belt device, 172 ... Auxiliary belt, 1 4 ... auxiliary belt rollers, NL1 ... first nanofiber layer, NL2 ... second nanofiber layer, W ... long sheet

Claims (5)

A separator manufacturing apparatus for manufacturing a separator in which a first nanofiber layer is formed on one surface of a base material layer and a second nanofiber layer is formed on the other surface,
The transport mechanism that transports the long sheet serving as the base material layer, and the long sheet so that the direction of one surface of the long sheet and the direction of the other surface are opposite while the long sheet is being transported. A conveying device comprising a long sheet reversing mechanism for reversing the long sheet;
A first electrospinning apparatus that is arranged in front of the long sheet reversing mechanism and deposits first nanofibers on the one surface from below using an upward nozzle to form the first nanofiber layer;
A second electrospinning device disposed behind the long sheet reversing mechanism and depositing second nanofibers on the other surface from below using an upward nozzle to form the second nanofiber layer. In separator manufacturing equipment,
A first air permeability measuring device that is arranged downstream of the first electrospinning device and measures the air permeability of the long sheet on which the first nanofiber layer is formed;
A second air permeability measuring device that is arranged downstream of the second electrospinning device and measures the air permeability of the long sheet on which the first nanofiber layer and the second nanofiber layer are formed;
Based on the air permeability measured by the first air permeability measuring device, “the first transport speed that is the transport speed of the long sheet when the long sheet passes through the first electrospinning device” is controlled. , Based on the air permeability measured by the second air permeability measuring device, “the second transport speed that is the transport speed of the long sheet when the long sheet passes through the second electrospinning device” is controlled. A separator manufacturing apparatus, further comprising a conveying speed control device. A separator manufacturing apparatus for manufacturing a separator in which a first nanofiber layer is formed on one surface of a base material layer and a second nanofiber layer is formed on the other surface,
The transport mechanism that transports the long sheet serving as the base material layer, and the long sheet so that the direction of one surface of the long sheet and the direction of the other surface are opposite while the long sheet is being transported. A conveying device comprising a long sheet reversing mechanism for reversing the long sheet;
A first electrospinning apparatus that is arranged in front of the long sheet reversing mechanism and deposits first nanofibers on the one surface from below using an upward nozzle to form the first nanofiber layer;
A second electrospinning device disposed behind the long sheet reversing mechanism and depositing second nanofibers on the other surface from below using an upward nozzle to form the second nanofiber layer. In separator manufacturing equipment,
A first thickness measuring device that is disposed downstream of the first electrospinning device and measures the thickness of the long sheet on which the first nanofiber layer is formed;
A second thickness measuring device that is disposed downstream of the second electrospinning device and measures the thickness of the long sheet on which the first nanofiber layer and the second nanofiber layer are formed;
Based on the thickness measured by the first thickness measuring device, the control unit controls “the first conveying speed that is the conveying speed of the long sheet when the long sheet passes through the first electrospinning device”. Based on the thickness measured by the second thickness measuring device, the control unit controls the “second conveying speed that is the conveying speed of the long sheet when the long sheet passes through the second electrospinning device”. A separator manufacturing apparatus, further comprising a conveying speed control device. In the separator manufacturing apparatus according to claim 1 or 2 ,
A speed difference absorbing device that is disposed between the first electrospinning device and the second electrospinning device and absorbs a speed difference between the first transport speed and the second transport speed;
The transport device further includes a first drive device that transports the long sheet at the first transport speed, and a second drive device that transports the long sheet at the second transport speed. Separator manufacturing equipment. In the separator manufacturing apparatus according to claim 3 ,
The said speed difference absorption apparatus is provided with the several speed difference absorption roller which can change a mutual space | interval, The separator manufacturing apparatus characterized by the above-mentioned. In the separator manufacturing apparatus in any one of Claims 1-4 ,
A separator manufacturing apparatus, further comprising: a spinning condition changing device capable of independently changing a spinning condition of the first electrospinning device and a spinning condition of the second electrospinning device.

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