Patent Application
20200339331
The present invention relates to a film packaged body and a method of manufacturing a film packaged body.
In the related art, for example, a film material including a laminate film, a metal foil or the like is used for packages of products such as cosmetics and an exterior body of a lithium ion secondary battery (for example, refer to Patent Literatures 1 and 2). When an object to be packaged, for example, cosmetics or a battery cell, is packaged using such a film material, a method in which such an object to be packaged is interposed between a pair of film materials and then peripheral portions of the film materials are sealed through adhesion or heat scaling under a reduced pressure environment is used.
In addition, as a method of manufacturing a film material for packaging a battery cell as an object to be packaged, for example, a method in which a film material is interposed between molds including a punch (a male mold) and a die (a female mold), and a concave portion for accommodating a battery cell is formed in advance is proposed (for example, refer to Patent Literature 3). As in the technology described in Patent Literature 3, when the concave portion is formed in the film material in advance, an effect of improving productivity when a battery cell is packaged with a film material is obtained. However, when a concave portion corresponding to properties of an overall shape, for example, a size of a battery cell, is formed to accommodate the battery cell as in Patent Literature 3, there is a problem in that a manufacturing cost increases since large manufacturing equipment such as a mold to be used is necessary.
Japanese Unexamined Patent Application, First Publication No. 2014-037261
Japanese Unexamined Patent Application, First Publication No. 2004-055171
Japanese Unexamined Patent Application, First Publication No. 2000-133216
Here, when the object to be packaged described above is packaged, it is conceivable that a concave portion and the like are not formed in a film material, the object to be packaged is wrapped in a fiat sheet state as it is, peripheral portions are sealed under a reduced pressure environment in this state, and thus a laminated film packaged body is formed, which is also investigated. In this manner, when the film material in the flat sheet state is used as it is to package the object to be packaged, there is no need to use large and expensive manufacturing equipment. In addition, it is possible to obtain an effect of improving productivity since a process of forming a concave portion corresponding to an overall shape of the object to be packaged can be omitted.
However, if a film material is used in a flat sheet state as it is to package an object to be packaged, for example, when vacuum suction is performed for laminate processing, wrinkles may be generated in the film material which originate from the vicinity of an edge of a portion for accommodating the object to be packaged. In particular, as a thickness of the object to be packaged increases, wrinkles are more likely to be formed (for example, refer to
The present invention has been made in view of the above problems and provides a film packaged body and a method of manufacturing a film packaged body through which it is possible to inhibit generation of wrinkles in a film when an object to be packaged is packaged and scaled.
The invention according to a first aspect is a film packaged body formed by superimposing a pair of film molded articles in which a plurality of concave or convex embossed portions disposed apart from each other are formed on a surface of a film, wherein the film is made of a plastic material capable of adding a shape according to plastic deformation, wherein the plurality of embossed portions are disposed on the surface of the film such that an enclosed region surrounded by the plurality of embossed portions and imaginary lines that connect the plurality of embossed portions is formed, and the plurality of embossed portions are disposed at four areas on the surface of the film to form the enclosed region with rectangular shape, when an object is packaged by the film molded article, the plurality of embossed portions and imaginary lines forming the enclosed region are freely folded according to a shape or a size of the object to be packaged, and become a concave accommodating portion for accommodating the object to be packaged, wherein an object to be packaged is disposed in the enclosed region formed on the film molded article, the pair of film molded articles are superimposed to cover the object to be packaged, and the object to be packaged is a lithium ion secondary battery cell.
When an object is packaged by superimposing the film molded article of the present invention and an unprocessed sheet or when an object to be packaged is packaged by superimposing a pair of the film molded articles of the present invention, positions of the plurality of embossed portions and imaginary lines forming the enclosed region are freely folded according to a shape or a size of the object to be packaged and thus it is possible to inhibit generation of wrinkles in the film.
In addition, since the film packaged body is obtained by superimposing the pair of film molded articles having the configuration, positions of the plurality of embossed portions and imaginary lines forming the enclosed region are freely folded according to a shape or a size of the object to be packaged, and thus it is possible to inhibit generation of wrinkles in the film.
In addition, since plastic deformation is caused in the film through pressing, engraving or the like using a simple manufacturing device, a desired shape is obtained and thus film molded articles having various shapes can be realized.
In addition, when the lithium ion secondary battery cell is packaged, the film packaged body can be configured as a lithium ion secondary battery having good scalability and appearance characteristics without wrinkles being generated in the film and having high battery performance.
The invention according to a second aspect is the film packaged body according to the first aspect, wherein the embossed portion has a semicircular shape, a triangular shape, a linear shape, a polygonal line shape, a curvilinear shape, a rectangular shape, a circular shape, or a point shape is a plan view.
According to the present invention, when the embossed portion has the above shape, it is possible to secure a stable shape for the enclosed region. In addition, when an object to be packaged is packaged by superimposing a pair of film molded articles, it is possible to inhibit generation of wrinkles in the film more effectively.
The invention according to a third aspect is the film packaged body according to the first aspect, wherein the embossed portion has a shape that changes in multiple stages in a thickness direction from the surface of the film.
According to the present invention, when the embossed portion has a shape that changes in multiple stages, it is possible to flexibly have compatibility with objects to be packaged having various shapes.
The invention according to a fourth aspect is the film packaged body according to the first aspect, wherein the film is made of a heat-sealable laminate material.
According to the present invention, when the heat-sealable laminate material is used for the film, it is possible to improve productivity and it is possible to perform sealing while inhibiting generation of wrinkles in the film.
The invention according to a fifth aspect is the film packaged body according to the first aspect, wherein the film is a laminate film of a metal material and a resin.
According to the present invention, when the laminate film of metal material and resin used for the film, it is possible to improve productivity and it is possible to perform scaling while inhibiting generation of wrinkles in the film more effectively.
The invention according to a sixth aspect is the film packaged body according to the fifth aspect, wherein the metal material comprises at least one selected from the group consisting of aluminum, stainless steel, and brass.
According to the present invention, when the laminate film of metal material comprises at least one selected from the group consisting of aluminum, stainless steel, and brass used for the film, it is possible to improve productivity and it is possible to perform sealing while inhibiting generation of wrinkles in the film more effectively.
The invention according to a seventh aspect is the film packaged body according to the fifth aspect, wherein the film is a laminate film of an aluminum and a nylon resin.
According to the present invention, when the laminate film of aluminum and nylon resin used for the film, it is possible to improve productivity and it is possible to perform sealing while inhibiting generation of wrinkles in the film more effectively.
The invention according to an eighth aspect is a film packaged body according to the first aspect, wherein a peripheral portions of the film molded articles are sealed.
According to the present invention, since the film packaged body is obtained by superimposing the pair of film molded articles having the configuration, positions of the plurality of embossed portions and imaginary lines forming the enclosed region are freely folded according to a shape or a size of the object to be packaged and sealing peripheral portions of the pair of film molded articles after the pair of film molded articles are superimposed, thus it is possible to inhibit generation of wrinkles in the film.
The invention according to a ninth aspect is a method of manufacturing a film packaged body by superimposing a pair of film molded articles, including on the surface of the film to forming a concave or convex embossed portion to product the film molded articles, causing plastic deformation in the film by adding a shape to at least a part of the surface of the film using a mold, forming a plurality of the embossed portions to be disposed apart from each other on the surface of the film, the plurality of embossed portions is forming to four areas on the surface of the film to form the enclosed region with rectangular shape, securing formation of an enclosed region surrounded by the plurality of embossed portions and imaginary lines that connect the plurality of embossed portions is formed, when an object is packaged by the film molded article, the plurality of embossed portions and imaginary lines forming the enclosed region are freely folded according to a shape or a size of the object to be packaged, and the enclosed region become a concave accommodating portion for accommodating the object to be packaged, disposing an object to be packaged in the enclosed region formed in one film molded article between the pair of film molded articles, subsequently, superimposing the other film molded article on the one film molded article while the object to be packaged is covered in the enclosed region formed in the other film molded article, and wherein a lithium ion secondary battery cell is used as the object to be packaged.
According to the present invention, in the method, in this method, since a pair of film molded articles having the configuration are superimposed to cover an object to be packaged in the enclosed region formed in the film molded article, positions of the plurality of embossed portions and imaginary lines forming the enclosed region are freely folded according to a shape or a size of the object to be packaged and thus it is possible to inhibit generation of wrinkles in the film.
In addition, in the method, by adding a shape to the surface of the film using a mold, the plurality of embossed portions are formed to secure an enclosed region surrounded by the embossed portions and imaginary lines that connect the embossed portions, and thus it is possible to manufacture a film molded article with favorable productivity at low cost without using a large manufacturing device.
In addition, when the lithium ion secondary battery cell is packaged, the film packaged body can be manufactured as a lithium ion secondary battery having good sealability and appearance characteristics without wrinkles being generated in the film and having high battery performance.
The invention according to a tenth aspect is the method of manufacturing a film molded article according to the ninth aspect, wherein the mold includes a punch and a die, and a tip portion in contact with the surface of the film in the punch is formed in a semicircular shape, or a triangular shape in plan view, and wherein a shape is added to the surface of the film using the mold, and thus a plurality of the embossed portions having a semicircular shape, or a triangular shape in plan view are formed on the surface of the film.
According to the present invention, the mold includes a punch and a die, a tip portion of the punch is optimized, and thus it is possible to form an embossed portion having a desired shape on the surface of the film with a simple device and procedure.
The invention according to an eleventh aspect is a method of manufacturing a film packaged body according to the first aspect, including sealing peripheral portions of the pair of film molded articles, after the pair of film molded articles are superimposed.
According to the present invention, in this method, since a pair of film molded articles having the configuration are superimposed to cover an object to be packaged in the enclosed region formed in the film molded article, positions of the plurality of embossed portions and imaginary lines forming the enclosed region are freely folded according to a shape or a size of the object to be packaged and sealing peripheral portions of the pair of film molded articles after the pair of film molded articles are superimposed, thus it is possible to inhibit generation of wrinkles in the film more effectively.
The invention according to a twelfth aspect is a film packaged body obtained by the method according to the ninth aspect.
According to the present invention, since the film packaged body is obtained by the method, the plurality of embossed portions are freely folded according to a shape or a size of an object to be packaged, and thus it is possible to inhibit generation of wrinkles in the film.
Note that, when it is described that “a shape is added using a mold” in the present invention, various molding methods using a mold, for example, engraving a surface of a film using a mold and performing vacuum molding, are used.
According to the film packaged body of the present invention, a configuration in which a plurality of embossed portions are formed on a surface of a film and the embossed portions are connected by imaginary lines to secure an enclosed region is used. Therefore, it is possible to achieve favorable productivity at low cost without using a large manufacturing device. More specifically, according to the film packaged body of the present invention, since the position of the imaginary lines are not pressed with the manufacturing device (Bending machine), thus, energy during manufacturing can be reduced, and the manufacturing device can be downsized.
In addition, according to the film packaged body of the present invention, when the pair of film molded articles are superimposed to package an object to be packaged, positions of the plurality of embossed portions and imaginary lines forming the enclosed region are freely folded according to a shape or a size of the object to be packaged and thus it is possible to inhibit generation of wrinkles in the film. Therefore, good scalability and appearance characteristics are obtained. Additionally, according to the film packaged body of the present invention, the entire enclosed region including the embossed portion becomes the receptacle part as is, and each peripheral portion can be sealed without wrinkling in the film more effectively.
In addition, according to a method of manufacturing a film packaged body of the present invention, when a shape is added to a surface of a film using a mold, a plurality of embossed portions are formed such that an enclosed region surrounded by the embossed portions and imaginary lines that connect the embossed portions is secured. Therefore, it is possible to manufacture a film molded article with favorable productivity at low cost without using a large manufacturing device. Also, according to a method of manufacturing a film packaged body of the present invention, since the position of the imaginary lines are not pressed with the manufacturing device, thus, energy during manufacturing can be reduced, and the manufacturing device can be downsized.
In addition, according to a method of manufacturing a film packaged body of the present invention, in the method, a pair of film molded articles having the configuration are superimposed to cover an object to be packaged in the enclosed region formed in the film molded article. Therefore, positions of the plurality of embossed portions and imaginary lines forming the enclosed region are freely folded according to a shape or a size of the object to be packaged. Accordingly, it is possible to inhibit generation of wrinkles in the film and it is possible to manufacture a film packaged body having good scalability and appearance characteristics. Further, according to a method of manufacturing a film packaged body of the present invention, the entire enclosed region including the embossed portion becomes the receptacle part as is, and each peripheral portion can be sealed without wrinkling in the film more effectively.
Hereinafter, a film packaged body, and a method of manufacturing a film packaged body according to embodiments of the present invention will be described with reference to drawings.
The film packaged body (11) according to embodiments of the present invention, the film packaged body (11) formed by superimposing a pair of film molded articles (1).
The film molded article (1) has a plurality of concave or convex embossed portions (3) disposed apart from each other are formed on a surface (2a) of a film (2).
The film (2) is made of a plastic material capable of adding a shape according to plastic deformation.
The plurality of embossed portions (3) are disposed on the surface of the film (2) to form an enclosed region (4) surrounded by the plurality of embossed portions (3) and imaginary lines (4a) that connect the plurality of embossed portions (3) is formed, and the plurality of embossed portions (3) are disposed at four areas on the surface (2a) of the film (2) to form the enclosed region (4) with rectangular shape.
In addition, in a film packaged body (11) of the present invention, when an object is packaged by the film molded article (1), the plurality of embossed portions (3) and imaginary lines (4a) forming the enclosed region (4) are freely folded according to a shape or a size of the object to be packaged (5), and become a concave accommodating portion (4A) for accommodating the object to be packaged (5).
Furthermore, in a film packaged body (11) of the present invention, the object to be packaged (5) is disposed in the enclosed region (4) formed on the film molded article (1), the pair of film molded articles (1) are superimposed to cover the object to be packaged (5).
Moreover, in a film packaged body (11) of the present invention, the object to be packaged (5) is a lithium ion secondary battery cell.
The method of manufacturing a film packaged body (11) according to embodiments of the present invention, the method of manufacturing a film packaged body (11) by superimposing a pair of film molded articles (1), includes the following steps.
First, on the surface (2a) of the film (2) to forming a concave or convex embossed portion (3) to product the film molded articles (1). At this step, causing plastic deformation in the film (2) by adding a shape to at least part of the surface (2a) of the film (2) using a mold, forming a plurality of the embossed portions (3) to be disposed apart from each other on the surface (2a) of the film (2), and the plurality of embossed portions (3) is forming to four areas on the surface (2a) of the film (2) to form the enclosed region (4) with rectangular shape.
In addition, in the method of manufacturing a film packaged body (11) of the present invention, securing formation of an enclosed region (4) surrounded by the plurality of embossed portions (3) and imaginary lines (4a) that connect the plurality of embossed portions (3) is formed, when an object is packaged by the film molded article (1), the plurality of embossed portions (3) and imaginary lines (4a) forming the enclosed region (4) are freely folded according to a shape or a size of the object to be packaged (5), and the enclosed region (4) become a concave accommodating portion for accommodating the object to be packaged (5).
Next, disposing an object to be packaged (5) in the enclosed region (4) formed in one film molded article (1) between the pair of film molded articles (1).
Subsequently, superimposing the other film molded article (1) on the one film molded article (1) while the object to be packaged (5) is covered in the enclosed region (4) formed in the other film molded article (1).
Then, in the method of manufacturing a film packaged body (11) of the present invention, a lithium ion secondary battery cell is used as the object to be packaged (5).
Hereinafter, a film molded article 1 used in a film packaged body (11) and a method of manufacturing the same according to this embodiment will be described with reference to
As shown in
The film molded article 1 of this embodiment can be applied as, for example, a package of a product such as cosmetics and an exterior body of a lithium ion secondary battery.
The film 2 can utilize, for example, metal materials such as aluminum, stainless steel, and brass and various sheet materials such as a polymer film. In addition, the film 2 may be formed as a laminated film of a metal and a resin, a laminated film of aluminum and a nylon resin, or a laminated film of stainless steel and a polypropylene resin. Also, a film having a thickness of about 10 to 800 μm can be used as the film 2.
The film 2 used in this embodiment is preferably made of a plastic material that can add a desired shape according to plastic deformation. This is because, according to a method such as engraving and pressing using a mold to be described below, it is easy to add a desired shape to the surface 2a of the film 2 and film molded articles having various shapes can be formed. Further, as a method of adding 3 shape to the film 2 made of a plastic material, methods such as pressure molding, heat pressure molding, vacuum molding, and heat vacuum molding known in the related art can be used.
In addition, a sealable laminate material is preferably used for the film 2. In this manner, when the sealable laminate material is used for the film, a sealing process performed when the film molded articles 1 are superimposed to form a film packaged body is simplified, productivity is improved, and it is possible to significantly inhibit generation of wrinkles in the film 2 (a peripheral portion 1a) as will be described below.
As described above, as the sealable laminate material, a laminate material capable of heat sealing or pressure-sensitive sealing can be exemplified.
Examples of the heat sealable laminate material include hot melt resins formed of a polyethylene resin, a polypropylene resin, a polyester resin, and the like.
Examples of the laminate material capable of pressure-sensitive sealing include a binding material formed of an acrylic resin, a silicone resin, and the like and an adhesive material formed of an acrylic resin, a silicone resin, an epoxy resin and the like.
As shown in
Also, along an imaginary line 4a fiat connects an embossed portion 3 and another embossed portion 3, one or more embossed portions (not shown) may be formed.
The embossed portions 3 are portions that serve as edge portions in a portion for accommodating an object to be packaged when the pair of film molded articles 1 are superimposed to form a film packaged body to be described below and as will be described below in detail, when the object to be packaged is interposed and sealed, the portions are freely folded and thus a concave accommodating portion is formed between the pair of film molded articles 1. In addition, the accommodating portion has a size that substantially matches the enclosed region 4 described above in plan view.
Also, a region further outward that the enclosed region 4 in the film molded article 1 is the peripheral portion 1a when the pair of film molded articles 1 are superimposed to form a film packaged body to be described below.
A size of projection (convex) front the surface 2a of the film 2 of the embossed portion 3 and a size of a depth (concave) are not particularly limited, but may be determined in consideration of ease of bending (in particular, a thickness of an object to be packaged) when the pair of film molded articles 1 are superimposed, an object to be packaged is interposed therebetween, and an accommodating portion is formed, and for example, may be about 0.1 to 20 mm.
Also, in the film molded article 1 shown in
In addition, the embossed portion can have a shape including a linear shape, a polygonal line shape, a curvilinear shape, a rectangular shape, a circular shape, or a point shape in plan view, and the shape is not particularly limited.
In addition, in the film molded article 1 shown in
Further, in this embodiment as in a film molded article 100 shown in
Moreover, in this embodiment, the embossed portion 3B formed in a trapezoidal shape in plan view may have a configuration in which a region surrounded by the trapezoidal shape on the surface 200a of the film 200 is formed in a concave shape or a convex shape. In the shown example, the embossed portion 3B is formed as a planar concave portion that is recessed downward from the surface 200a of the film 200 (downward in a vertical direction in
Here, similarly to the embossed portions 3 included in the film molded article 1 shown in
In addition, in the film molded article of this embodiment, although details are omitted, the embossed portion may be formed in a shape that changes in multiple stages in a thickness direction from a surface of a film, for example, a size in the thickness direction may change in a stepwise manner. Accordingly, when a film packaged body to be described below is manufactured by superimposing a pair of film molded articles, for example, when objects to be packaged having various shapes are packaged, it is possible to flexibly have compatibility therewith.
Next, a method of manufacturing the film molded article 1 having the above configuration will be described with reference to
A method of manufacturing the film molded article 1 of this embodiment is a method of forming the concave or convex embossed portions 3 on the surface 2a of the film 2 as shown in
Specifically, as shown in
Next, the punch 20 is moved in a direction D, and the surface 2a of the film 2 is engraved at a scheduled formation position of the embossed portion 3. Accordingly, the embossed portion 3 is formed at one area of the surface 2a of the film 2, the punch 20 is then moved to another scheduled formation position of the embossed portion 3 on the film 2, and engraving is performed in the same manner as described above to form the embossed portion 3. In this embodiment, by repeating such procedures, the plurality of embossed portions 3 are sequentially formed. Here, while a state in which the embossed portions 3 are formed at two areas of the surface 2a of the film 2 is shown in
Note that, in this embodiment, a position in which the embossed portion 3 is formed and the number thereof formed are not limited, and can be appropriately determined in consideration of a shape, a size of an object to be packaged and the like when a film packaged body to be described below is formed. For example, while the embossed portions 3 are formed at a total of four areas in the example shown in
In addition, while the embossed portions 3 are disposed at four areas and the enclosed region 4 having an approximately rectangular shape in plan view is formed in the shown example, the present invention is not limited thereto. For example, a plurality of embossed portions may be disposed to form an enclosed region having an approximately triangular shape. Moreover, a plurality of embossed portions may be disposed to form an enclosed region having an approximately circular shape.
The film molded article 1 of this embodiment has a configuration in which the plurality of embossed portions 3 are formed on the surface 2a of the film 2 and the embossed portions 3 are connected by the imaginary lines 4a to secure the enclosed region 4. Thus, it is possible to manufacture the film molded article 1 using a mold and the like including the small punch 20 as described above without using a large manufacturing device. Accordingly, it is possible to manufacture the film molded article 1 with high productivity at low cost. In addition, when the pair of film molded articles 1 of this embodiment are superimposed to package an object to be packaged and a film packaged body to be described below is formed, positions of the plurality of embossed portions 3 and the imaginary lines 4a forming the enclosed region 4 are freely folded according to a shape or a size of an object to be packaged, and thus it is possible to obtain a film packaged body without generating wrinkles in the film 2.
While a method in which a shape of the tip portion 21 is an approximately L shape in plan view as shown in
Alternatively, in this embodiment, as shown in
In the manufacturing method of this embodiment, as described above, the mold includes the punch 20 (30 and 40) and the die (not shown), and a shape of the tip portion 21 (31 and 41) of the punch 20 (30 and 40) is optimized. Therefore, it is possible to form an embossed portion having a desired shape on a surface of a film with a simple device and procedure.
Also, in this embodiment, as described above, in the method of manufacturing the film molded article 1 using the mold including the small punch 20, for example, a position of the surface 2a of the film 2 that is engraved by the punch 20 is appropriately changed, and thus it is possible to easily change a position of the embossed portion 3 to be formed. Accordingly, it is possible to easily change a size of the enclosed region 4 that is secured when the embossed portions 3 are connected by the imaginary lines 4a. Thus, for example, when the pair of film molded articles 1 are superimposed to form a film packaged body to be described below, it is possible to flexibly correspond to a size and a shape of an object to be packaged.
In addition, in this embodiment, in a method of manufacturing the film molded article 1 using a mold including the small punch 20 without using a large manufacturing device, for example, in a process of manufacturing a film packaged body by packaging an object to be packaged to be described below, it is easy to incorporate a process of manufacturing the film molded article in-line. Accordingly, it is possible to improve productivity in the process of manufacturing the film molded article and reduce a manufacturing cost.
Further, in this embodiment, as in the film molded article 100 shown in
As shown in
The mold 50 shown in
In addition, in the base plate 50A of the mold 50, holes 52 into which a guide rod (not shown) for slidingly moving the base plate 50A to perform an engraving operation is inserted are provided at a total of four areas.
In addition, in the base plate 50A of the mold 50, a pin hole 53 that can be used for alignment of the film 200 is provided.
In addition, although not shown, in the mold 50, on a side that faces the base plate 50A with the film 200 therebetween, a die member in which a concave portion entered by a shape of the protrusion 51 is formed is included.
Therefore, when a concave embossed portion is formed on live surface 200a of the film 200 using the mold 50, first, the elongated film 200 drawn from a roll portion (not shown) wound in a roll shape is introduced into the mold 50 such that the elongated film 200 is inserted between the base plate 50A and a die member (not shown).
Next, the base plate 50A guided by the guide rod (not shown) is slidingly moved along the guide rod, the protrusion 51 is brought in contact with the surface 200a, and the surface 200a is thus engraved at a scheduled formation position of an embossed portion. In this case, two areas on the surface 200a of the film 200 are engraved according to the protrusions 51A and 51B, and the embossed portions 3B (refer to
Next, the base plate 50A is moved so as to slide apart from the film 200.
Next, the film 200 is cut at an intermediate position between two embossed portions (corresponding to positions of the protrusions 51A and 51B in
Then, the cut film 200 is conveyed in a direction of an arrow Y shown in
Then, by repeating the procedures described above, the embossed portions 3B shown in
Here, when the film molded article 100 shown in
In addition, a method of manufacturing the film molded article 100 shown in
The mold 60 shown in
In addition, although not shown, similarly to the mold 50 described above, in the mold 60, on a side that faces the base plate 60A with the film 200 therebetween, a die member in which a concave portion entered by a shape of the protrusion 61 is formed is included.
Therefore, when a concave embossed portion is formed on the surface 200a of the film 200 using the mold 60, similarly to the above case, first, the elongated film 200 is inserted between the base plate 50A and a die member (not shown).
Next, the protrusion 61 is brought in contact with the surface 200a of the film 200 and the surface 200a is thus engraved at a scheduled formation position of an embossed portion so that the embossed portion 3B (refer to
Next, the base plate 60A is rotated by a rotation mechanism (not shown), and the base plate 60A is thus moved to a vacuum side of the film 200 (refer to an arrow R shown in
Then, the rotated base plate 60A is moved to the film 200 side, the protrusion 61 is brought in contact with the surface 200a of the film 200, and engraving is performed at a scheduled formation position of an embossed portion to form the embossed portion. Therefore, it is possible to manufacture the film molded article 100 shown in
In the above manufacturing method, while an exemplary method in which a surface of a film is engraved by a mold (a punch) has been described, the present invention is not limited thereto. For example, methods such as vacuum forming described above can be used without limitation.
Hereinafter, a film packaged body 11 and a method of manufacturing the same according to this embodiment will be described with reference to
The film packaged body 11 of this embodiment is a film packaged body 11 obtained by superimposing the pair of film molded articles 1 of this embodiment described above. Therefore, the film packaged body 11 is schematically configured such that the object to be packaged 5 is disposed in the enclosed region 4 formed on the film molded article 1, the pair of film molded articles 1 are superimposed to cover the object to be packaged 5, and the peripheral portions 1a of the film molded article 1 are sealed.
The object to be packaged 5 accommodated and packaged in the film packaged body 11 of this embodiment includes, for example, cosmetics and a lithium secondary battery cell as described above, but various other objects to be packaged can be applied without limitation.
Here, when a lithium secondary battery cell is applied as the object to be packaged 5 and the film packaged body 11 is configured as a lithium ion secondary battery, the lithium secondary battery cell to be used is not particularly limited. For example, although details are omitted, as the lithium secondary battery cell to be applied as the object to be packaged 5, a laminated body in which a positive electrode sheet in which a positive electrode active material layer is provided on a positive electrode current collector and a negative electrode sheet in which a negative electrode active material layer is provided on a negative electrode current collector are laminated with a separator therebetween can be used. In addition, when the laminated body is used as the object to be packaged 5, a nonaqueous electrolyte (not shown) is accommodated inside the film packaged body 11 together with the laminated body.
Also, when the peripheral portions 1a of the pair of film molded articles 1 are sealed, a method, for example, adhesion and heat sealing, can be used. However, a method in which a heat-sealable laminate material is used for the film 2 and the peripheral portions 1a are thermally sealed as described above is preferable in consideration of scalability and productivity.
Next, a method of manufacturing the film packaged body 11 having the above configuration will be described with reference to
In a method of manufacturing the film packaged body 11 of this embodiment, first, between a pair of film molded articles 1 (1A and 1B), the object to be packaged 5 is disposed in the enclosed region 4 that is formed in one film molded article 1A. More specifically, for example, the object to be packaged 5 shown in
Next, as shown in
Then, while the object to be packaged 5 is interposed between the pair of film molded articles 1 (1A and 1B), the peripheral portions 1a of the pair of film molded articles 1 (1A and 1B) are sealed under vacuum reduced pressure. In this case, as a method of sealing the peripheral portions 1a, a method in which the peripheral portions 1a are heated, pressed and fused using a vacuum laminator, a roller and a vacuum packing device can be used. In addition, when the peripheral portions 1a are sealed while the object to be packaged 5 is interposed therebetween, a position of the enclosed region 4 in which the object to be packaged 5 is disposed is formed as an accommodating portion 4B having a concave shape when viewed from a surface side on which the pair of film molded articles 1 (1A and 1B) are bonded to each other.
In this embodiment, the object to be packaged 5 is packaged using the pair of film molded articles 1 in which a shape is not added at positions of the imaginary lines 4a that connect the concave or convex embossed portions 3. In this case, while positions of the plurality of embossed portions 3 and the imaginary line 4a forming the enclosed region 4 are freely folded according to a shape or a size of an object to be packaged, the peripheral portions 1a of the pair of film molded articles 1 (1A and 1B) are sealed. Accordingly, for example, even if a battery cell having a thick laminated body is packaged and the peripheral portions 1a are sealed, it is possible to inhibit generation of wrinkles in the peripheral portions 1a which originate from the vicinity of an edge of an accommodating space of the object to be packaged 5.
As described above, for example, when a lithium ion secondary battery cell is packaged as the object to be packaged 5 and the film packaged body 11 is configured as a lithium ion secondary battery, a lithium ion secondary battery having good sealability and appearance characteristics, and high battery performance without wrinkles being generated in the peripheral portion 1a (the film 2) is obtained. In addition, when the pair of film molded articles 1 are used to configure a lithium ion secondary battery, a center portion of the enclosed region 4 serving as an accommodating space becomes inflatable, for example, even if a temperature of a lithium ion secondary battery cell packaged inside increases and the lithium ion secondary battery cell inflates. Accordingly, in particular, in the vicinity of the center of the lithium ion secondary battery cell (in the vicinity of the center of the object to be packaged 5 in plan view), it is easy to maintain a distance between electrodes and thus battery characteristics do not easily deteriorate.
Also, when the film packaged body 11 of this embodiment is applied to a lithium ion secondary battery cell, it is necessary to inject a nonaqueous electrolyte thereinto as described above. In such a case, for example, a method in which, after three portions among four peripheral portions 1a in
Hereinafter, other examples of the above-described film molded article and film packaged body according to the present invention will be described below with reference to
In this embodiment, for example, an elongated film molded article 110 as shown in
In addition, in this embodiment, for example, like a film molded article 120 shown in
In addition, like a film molded article 130 shown in
Alternatively, like a film molded article 140 shown in
Further, like a film molded article 150 shown in
According to the film molded articles 110, 120, 130, 140, and 150 shown in
Hereinafter, effects obtained when the film molded article 1 of this embodiment is used to form the film packaged body 11 will be described with reference to production examples shown in
As shown in
On the other hand, as shown in
Based on the results of the above production experiment, in the film packaged body 11 in which the pair of film molded articles 1 in which the embossed portion 3 of this embodiment is provided are superimposed to package the object to be packaged 5, it is apparent that it is possible to inhibit generation of wrinkles during sealing.
The configurations in the above-described embodiment and combinations thereof are examples. Additions, omissions, substitutions and other modifications of the configuration can be made without departing from the spirit and scope of the present invention. In addition, the present invention is not limited to the embodiments and the examples, and is limited by only the scope of the appended claims.
110, 100, 110, 120, 130, 140, 150 Film molded article
1
a Peripheral portion
2, 25, 200, 112, 122, 132, 142, 152 Film
2
a,
25
a,
200
a,
112
a,
122
a,
132
a,
142
a,
152
a Surface
3, 3A, 3B, 3C, 3D, 3E, 3F, 3G Embossed portion
3
a Tip
4, 4A, 4C Enclosed region
4
a,
4
b Imaginary line
4B Accommodating portion
5 Object to be packaged
11 Film packaged body
20, 30, 40 Punch (mold)
21, 31, 41 Tip portion
50, 60 Mold
51, 61 Protrusion
S Wrinkles
| Number | Date | Country | Kind |
|---|---|---|---|
| 2014-153763 | Jul 2014 | JP | national |
| 2015-059854 | Mar 2015 | JP | national |
This application is a Continuation-in-Part of application Ser. No. 15/327,372, filed Jan. 18, 2017, which is a national stage of PCT/JP2015/071501, filed Jul. 29, 2015, which claims priority to Japanese Application No. 2014-153763, filed Jul. 29, 2014, and Japanese Patent Application No. 2015-059854 filed Mar. 23, 2015. The entire contents of the prior applications are hereby incorporated by reference herein in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 15327372 | Jan 2017 | US |
| Child | 16925213 | US |
