This Nonprovisional application claims priority under 35 U.S.C. § 119 on Patent Application No. 2019-084520 filed in Japan on Apr. 25, 2019, the entire contents of which are hereby incorporated by reference.
The present invention relates to (i) a method for producing slit separators and (ii) an apparatus for producing slit separators.
Nonaqueous electrolyte secondary batteries such as lithium-ion secondary batteries are in wide use as batteries for personal computers, mobile telephones, portable information terminals, and the like. Lithium-ion secondary batteries, in particular, are drawing attention as batteries that help reduce CO2 emissions and that contribute to energy saving, as compared to conventional secondary batteries.
A process for producing a nonaqueous electrolyte secondary battery separator and other separators includes a separator inspecting step of detecting a defect in a separator (see Patent Literature 1).
A separator is commonly slit into a plurality of slit separators after being subjected to an inspection of a separator (e.g., a technique disclosed in Patent Literature 1).
The inventors of the present invention found the following. Specifically, in a process carried out after a separator is slit into slit separators, a defect may be developed in the slit separators in a case where a foreign object having adhered to a surface of a roller via which to transfer the slit separators is in contact with the slit separators. The inspection of a separator (e.g., the technique disclosed in Patent Literature 1) does not include an inspection carried out, on the assumption that a defect may be developed in slit separators, for detecting such a defect. Thus, even in a case where the inspection of a separator (e.g., the technique disclosed in Patent Literature 1) is carried out, slit separators in which the defect remains and which are low in quality unfortunately still may be shipped in a form of products.
An object of an aspect of the present invention is to allay a fear that slit separators that are low in quality may be shipped in a form of products.
In order to attain the object, a method for producing slit separators in accordance with an aspect of the present invention includes the steps of: a) preparing the slit separators by slitting a separator; b) transferring the slit separators via a roller; and c) inspecting, for a defect, the slit separators having been transferred via the roller.
In order to attain the object, an apparatus for producing slit separators in accordance with an aspect of the present invention includes: a slitting device for preparing the slit separators by slitting a separator; a roller via which to transfer the slit separators; and an inspection device for inspecting, for a defect, the slit separators having been transferred via the roller.
With the configuration, a defect in the slit separators which defect has been developed by a contact, with the slit separators, of a foreign object having adhered to a surface of the roller via which to transfer the slit separators can be detected in a process carried out after the separator is slit. This makes it possible to allay a fear that the slit separators in which the defect remains and which are low in quality may be shipped in a form of products.
An aspect of the present invention makes it possible to allay a fear that slit separators that are low in quality may be shipped in a form of products.
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Before discussing embodiments of the present invention, the following description will discuss a withstand voltage inspection carried out with respect to a separator for detecting a defect in the separator.
The separator 1 includes a base material 2 and a functional layer 3 provided to one of surfaces of the base material 2. Examples of the base material 2 include a porous film that contains polyolefin as a main component. Examples of the functional layer 3 include a heat-resistant film that contains aramid as a main component, a film that contains ceramic as a main component, and a film that contains polyvinylidene fluoride (PVdF) as a main component. Note that the functional layer 3 can be provided to each of the surfaces of the base material 2.
A defect may be produced in the separator 1 due to, for example, a foreign object produced during a process for producing the separator 1. This makes it necessary to carry out, during production of the separator 1, an inspection for detecting the defect.
Examples of the defect in the separator 1 include a slit 4, a pinhole 5, a recess 6, and a slit 7.
The slit 4 is a notch made in a thickness direction of the separator 1 so as not to be through the separator 1, and has a bottom part 8. In a case where one of surfaces of the separator 1 is viewed, the slit 4 (notch) has a length long enough to be in a circle having a diameter of not less than 50 μm and not more than 200 μm.
The pinhole 5 is a hole that is through the separator 1. The pinhole 5 has a diameter of not less than 5 μm and not more than 200 μm.
The recess 6 is provided to any of the surfaces of the separator 1 and is a depression having the bottom part 8. In a case where a surface of the separator 1 in which surface the recess 6 is provided is viewed, the recess 6 has a size large enough to be in a circle having a diameter of 10 μm.
In
The slit 7 is a notch made so as to be through the separator 1. In a case where one of the surfaces of the separator 1 is viewed, the slit 7 (notch) has a length long enough to be in a circle having a diameter of not less than 50 μm and not more than 200 μm.
An optical inspection has been conventionally carried out with respect to the separator 1 so that a defect in the separator 1 is detected. The optical inspection is carried out with respect to the separator 1 by capturing an image of the separator 1 with use of a camera so as to detect a defect in the separator 1 by the image thus captured. Note, however, that the optical inspection carried out with respect to the separator 1 has the following disadvantages (A) and (B).
(A) The optical inspection carried out with respect to the separator 1 is unsuitable for detecting a defect in the separator 1 while transferring the separator 1. The first reason is that, since a single period of image capture carried out with use of a camera is a relatively long time, the camera may fail to take a photograph of a defect in the separator 1 in a case where the separator 1 is transferred at a high speed. The second reason is that, in order that a captured image of an extremely small defect (e.g., the pinhole 5) in the separator 1 is prevented from being blurred, such a defect needs to be detected by (i) making a speed at which the separator 1 is transferred extremely low or (ii) stopping transfer of the separator 1.
(B) The optical inspection carried out with respect to the separator 1 is unsuitable for detecting the recess 6 provided to the separator 1. This is because of the following reason. Specifically, existence of the bottom part 8 may prevent the recess 6 from clearly existing in a captured image. In this case, the recess 6 is difficult to detect even by observing the captured image. Furthermore, the optical inspection carried out with respect to the separator 1 is unsuitable for detecting the slit 7 provided to the separator 1. This is because of the following reason. Specifically, the slit 7, which is not in a form of holes that are continuous in a vertical direction, may prevent the slit 7 from clearly existing in a captured image. In this case, the slit 7 is difficult to detect even by observing the captured image. The slit 4 having the bottom part 8 is more difficult to detect by the optical inspection.
Under the circumstances, it is possible to carry out a withstand voltage inspection with respect to the separator 1 in order to detect a defect in the separator 1.
Thus, in a case where (i) a voltage of the electric power source 9 is applied and (ii) the electrode 10 and the electrode 11 are electrically connected with each other while the separator 1 is sandwiched by the electrode 10 and the electrode 11, it is possible to detect that the defect 12 is produced in the part of the separator 1 which part is located between the electrode 10 and the electrode 11.
The above principle makes it possible to carry out the withstand voltage inspection with respect to the separator 1 in order to detect the defect 12 in the separator 1. Unlike the optical inspection carried out with use of a camera, the withstand voltage inspection carried out with respect to the separator 1 makes it unnecessary to capture an image of the defect 12. This allows the defect 12 that is extremely small (e.g., the pinhole 5 (see
A voltage value of the electric power source 9 is determined in accordance with, for example, a resistance value of the separator 1, an interval at which the electrode 10 and the separator 1 are spaced, and an interval at which the electrode 11 and the separator 1 are spaced. The voltage value of the electric power source 9, the interval at which the electrode 10 and the separator 1 are spaced, and the interval at which the electrode 11 and the separator 1 are spaced only need to be a condition under which the principle of the withstand voltage inspection can be embodied. Note, however, that the voltage value of the electric power source 9 can be set to, for example, not less than 1.8 kV and not more than 3 kV, and can alternatively be set to not less than 2.1 kV and not more than 2.4 kV. Note also that the electrode 10 and the electrode 11 are preferably spaced at an interval of approximately 100 μm. That is, it is possible to suitably employ a condition that the interval at which the electrode 10 and the electrode 11 are spaced is set to 100 μm and the voltage value of the electric power source 9 is set to not less than 1.8 kV and not more than 3 kV. Furthermore, since a voltage having a desired value is preferably continuously applied to each of the electrode 10 and the electrode 11, a direct-current voltage is more preferably applied to each of the electrode and the electrode 11 than an alternating-current voltage, as illustrated in
In
In a case where the electrode 10 and the separator 1 are not in contact with each other, it is possible to reduce damage to a surface of the electrode 10. This allows the electrode 10 to be durable. Same applies to a case where the electrode 11 and the separator 1 are not in contact with each other. In a case where the electrode 10 and the separator 1 are in contact with each other, it is unnecessary to consider an interval at which the electrode 10 and the separator 1 are spaced. This makes it easy to carry out the withstand voltage inspection with respect to the separator 1. Same applies to a case where the electrode 11 and the separator 1 are in contact with each other.
A method for producing the separator 1 in accordance with Embodiment 1 of the present invention includes an inspection step. In the inspection step, an inspection including at least the following first to sixth steps is carried out.
In the first step, the following processes are carried out. The separator 1 is transferred via a plurality of rollers 13. A winding device 14 is provided at a destination to which the separator 1 is transferred via the plurality of rollers 13. The winding device 14 includes a rotation mechanism 15 that rotates in a direction substantially parallel to a direction in which the separator 1 is transferred. To the rotation mechanism 15, a core 16 is provided. The winding device 14 causes the rotation mechanism 15 to rotate the core 16, so that the separator 1 is wound around the core 16. Thus, a roll 17 in which the separator 1 is wound around the core 16 is prepared.
Assume here that a foreign object adheres to a surface of a roller 13. In this case, the foreign object is in contact with a surface of the separator 1 to be transferred. This may develop a defect in the separator 1. According to Embodiment 1, a defect in the separator 1 which defect is caused by a foreign object having adhered to the surface of the roller 13 is referred to as a roller-derived defect. The foreign object having adhered to the surface of the roller 13 is in contact with the surface of the separator 1 per rotation of the roller 13. Thus, roller-derived defects are developed at regular intervals in the direction in which the separator 1 is transferred. In other words, in a case where a foreign object adheres to the surface of the roller 13, a plurality of roller-derived defects may be periodically developed in the separator 1 in a machine direction of the separator 1. Examples of a roller-derived defect include the slit 4 (see
In the second step, the following processes are carried out. A winding device 18 unwinds part of the separator 1 from the roll 17. The roll 17 is provided to a rotation mechanism 19 of the winding device 18. The rotation mechanism 19 rotates in a direction in which the separator 1 is sent out from the core 16. This causes the core 16 to unwind the separator 1. A part of the separator 1 which part has been unwound in the second step is referred to as an unwound part 20. A combination of the rotation mechanism 19 and the winding device 18 can be a combination of the rotation mechanism 15 and the winding device 14. Alternatively, the combination of the rotation mechanism 19 and the winding device 18 can be prepared separately from the combination of the rotation mechanism 15 and the winding device 14.
Note here that a length for which to unwind the separator 1 from the roll 17, i.e., a length of the unwound part 20 of the separator 1 which unwound part 20 extends in the machine direction of the separator 1 is preferably not less than a length of a circumference of a roller 13a that has a maximum diameter of the plurality of rollers 13. A reason for this will be described later.
In the third step, the following processes are carried out. An inspection performing device 21 is used to inspect at least part of the unwound part 20 for any defect such as a roller-derived defect.
Note here that the separator 1 that is unwound from the roll 17 in the second step for a length that is not less than the length of the circumference of the roller 13a that has a maximum diameter of the plurality of rollers 13 has the following advantages. In this case, a roller-derived defect that occurs in the separator 1 is easily located in the unwound part 20. In a case where a part of the unwound part 20 which part has a length as long as or longer than the circumference of the roller 13a is inspected as the inspected part 22 in the third step, a roller-derived defect is easily detected. This allows the inspection to be carried out in the third step with higher accuracy.
Without regarding the plurality of rollers 26 as rollers that are present in the process for producing the separator 1, Embodiment 1 discusses an example in which only the plurality of rollers 13 are present in the process for producing the separator 1. In view of the advantages described earlier, in a case where a roller that has a larger diameter than the roller 13a is present in the process for producing the separator 1, the separator 1 is preferably unwound from the roll 17 for a length that is not less than a length of a circumference of that roller. That is, the separator 1 is preferably unwound from the roll 17 for a length that is not less than a length of a circumference of a roller that has a maximum diameter of the rollers that are present in the process for producing the separator 1. The separator 1 can be unwound from the roll 17 for a length that is at least twice or at least three times a length of a circumference of a roller that has a maximum diameter of the rollers that are present in the process for producing the separator 1. In a case where the length for which the separator 1 is unwound from the roll 17 is set to at least twice a length of a circumference of a roller that has a maximum diameter, detected defects are easily regarded as periodic defects.
In the fourth step, the following processes are carried out. Quality of the roll 17 is determined in accordance with a result of the inspection carried out with respect to the inspected part 22 through the third step. For example, quality of the roll 17 is specifically determined such that (i) the roll 17 that has the separator 1 in which no defect has been detected in the inspected part 22 is regarded as a non-defective product and (ii) the roll 17 that has the separator 1 in which a defect has been detected in the inspected part 22 is regarded as a defective product.
According to the above-described mechanism through which the roller-derived defects are developed, the roller-derived defects are periodically developed in the separator 1 in the machine direction of the separator 1 in such an order as follows: defects 27 (1), 27 (2), . . . , 27 (n), 27 (n+1), . . . . According to the inspection carried out with respect to the inspected part 22 in the third step, the defects 27 (1), 27 (2), and 27 (3) can be detected. It is possible to estimate that the defects 27 (4), 27 (5), . . . are highly likely to be developed in a part, different from the inspected part 22, of the separator 1 in which the defects 27 (1), 27 (2), and 27 (3) have been detected in the inspected part 22, without the need to inspect that part. Thus, the separator 1 in which the defects 27 (1), 27 (2), and 27 (3) have been detected in the inspected part 22 can be regarded as a defective product that has roller-derived defects.
In the fifth step, the following processes are carried out. All the separator 1 of the roll 17 that has been regarded as a defective product in the fourth step is discarded. Furthermore, at least the inspected part 22 of the roll 17 that has been regarded as a non-defective product in the fourth step is cut with use of a cutting device 28 so as to be separated from another part of the separator 1, and a cut part is discarded. In a case where a foreign object has adhered to a surface of the roller 80 via which to transfer the inspected part 22, a defect that is unique to the inspected part 22 may be developed in the inspected part 22. In a case where the inspected part 22 is discarded, a part in which a defect may be developed due to a foreign object having adhered to the surface of the roller 80 can be removed from the separator 1. Furthermore, in a case where a change in physical property of the inspected part 22 may be caused by the inspection carried out in the third step, a part in which a change in physical property may be caused by the inspection can be removed from the separator 1 by discarding the inspected part 22. Note that a roller 26 is desirably a roller that is different in diameter from the rollers used in the other processes described above. In a case where the roller 26 is different in diameter from the other roller, even in a case where periodic defects occur from the roller 26, it is possible to determine, by measuring intervals at which the periodic defects occur in the machine direction, that a poor withstand voltage is caused by the roller 26.
In the fifth step, in a case where the unwound part that has been unwound from the roll 17 partially remains after the inspected part 22 is cut, the partially remaining unwound part 20 is wound back by the winding device 18. The rotation mechanism 19 rotates in a direction opposite to a direction in which the separator 1 is unwound in the second step. This causes the core 16 to wind back the unwound part 20.
In the sixth step, the following processes are carried out. To the roll 17 that has been regarded as a non-defective product in the fourth step, a label 29 indicating that the roll 17 is a non-defective product is attached. The label 29 can be attached to the roll 17 with use of a device or manually. To the roll 17 that has been regarded as a defective product in the fourth step, a label indicating that the roll 17 is a defective product can be attached. The label 29 includes information indicating whether the roll is a non-defective product. The label 29 can also include other information, e.g., information that is associated with a system (not illustrated) and is necessary for checking, in the system, the information indicating whether the roll 17 is a non-defective product. This makes it possible to understand, from the label 29, whether the roll 17 is a non-defective product.
The label 29 can further include information on the roll 17 which information has been revealed after the third step, such as a result of the inspection of the roll 17 and an overall length of the separator 1 of the roll 17. This makes it possible to specifically understand, from the label 29, information on the roll 17 which information has been revealed after the third step.
The sixth step can be carried out after the fourth step and before the fifth step.
According to the above method, defects that are periodically developed in the machine direction of the separator 1, such as roller-derived defects can be detected without the need to unwind all the separator 1 from the roll 17. This makes it possible to expect that periodic defects are developed in the separator 1 of the roll 17, so that the inspection step can be carried out with high efficiency.
An apparatus for producing the separator 1 in accordance with Embodiment 1 of the present invention includes an inspection device. The inspection device at least includes (i) the winding device 18 that unwinds the separator 1 from the roll 17, (ii) the inspection performing device 21 that inspects, for a defect, the separator 1 that has been unwound, and (iii) the cutting device 28 that cuts the separator 1 that has been inspected. The winding device 18 is configured to wind back, to the roll 17, a part of the separator 1 that has been unwound, the part being continuous with the roll 17 after the separator 1 is cut. Configurations of the apparatus for producing the separator 1 in accordance with Embodiment 1 of the present invention except for those of the winding device 18, the inspection performing device 21, and the cutting device 28 can be achieved by a known technique, and a specific description thereof is therefore omitted here. With the configuration, the separator 1 can be partially unwound from the roll 17 in a case where at least part of the unwound part 20 is inspected for a defect by partially unwinding the separator 1 from the roll 17. The configuration also allows the cutting device 28 to cut, from an uninspected part of the separator 1, the inspected part 22 to be discarded. This makes it possible to achieve an apparatus for producing the separator 1, the apparatus being suitable for a highly efficient inspection step. Note that it is possible to (i) combine, with use of, for example, a tape, (a) the inspected part 22 to be discarded and (b) the separator to be subsequently inspected, without discarding the inspected part 22 immediately after the inspected part 22 is inspected and (ii) use the inspected part 22 as a transfer separator piece to be used to carry out the withstand voltage inspection with respect to the subsequent separator. This reduces a feeding operation for transferring the subsequent separator, so that the withstand voltage inspection can be carried out with respect to the separator with high efficiency.
A method for producing slit separators 32 in accordance with Embodiment 2 of the present invention includes at least the following steps 1 to 3.
In the step 1, the following processes are carried out. A separator 1 is transferred via a plurality of rollers 33. A slitting device 34 is provided at a destination to which the separator 1 is transferred via the plurality of rollers 33. The slitting device 34 slits the separator 1 into the slit separators 32 in a direction in which the separator 1 is transferred, i.e., a machine direction of the separator 1.
In a transfer path of the separator 1, a preinspection device 35 is provided upstream of the slitting device 34. The preinspection device 35 inspects the separator 1 for a defect before the separator 1 is slit. The preinspection device 35 includes (i) a light source 36 that illuminates the separator 1, (ii) a camera 37 with which to capture an image of the separator 1 that is illuminated by the light source 36, and (iii) a detection section 38 configured to detect a defect in the separator 1 from the image that has been captured with the camera 37. The preinspection device 35 is a device for carrying out an optical inspection with respect to the separator 1 for detecting a defect in the separator 1.
In the step 2, the following processes are carried out. The slit separators 32 are transferred via a plurality of rollers 39. Assume here that a foreign object adheres to a surface of a roller 39. In this case, the foreign object is in contact with surfaces of the slit separators 32 to be transferred. This may develop a defect in the slit separators 32. According to Embodiment 2, a defect in the slit separators 32 which defect is caused by a foreign object having adhered to the surface of the roller 39 is referred to as a roller-derived defect. The foreign object having adhered to the surface of the roller 39 is in contact with the surfaces of the slit separators 32 per rotation of the roller 39. Thus, roller-derived defects are developed at regular intervals in a direction in which the slit separators are transferred. In other words, in a case where a foreign object adheres to the surface of the roller 39, a plurality of roller-derived defects may be periodically developed in the slit separators 32 in a machine direction of the slit separators 32. Examples of a roller-derived defect include the slit 4 (see
In the step 3, the following processes are carried out. An inspection device 40 inspects, for a defect such as a roller-derived defect, the slit separators 32 that have been transferred via the plurality of rollers 39.
An apparatus for producing the slit separators 32 in accordance with Embodiment 2 of the present invention includes (i) the slitting device 34 that prepares the slit separators 32 by slitting the separator 1, (ii) the (plurality of) rollers 39 via which to transfer the slit separators 32, and (iii) the inspection device 40 that inspects the slit separators 32 that have been transferred via the rollers 39. The apparatus for producing the slit separators 32 in accordance with Embodiment 2 of the present invention includes the preinspection device 35 that inspects the separator 1 before the separator 1 is slit. Configurations of the apparatus for producing the slit separators 32 in accordance with Embodiment 2 of the present invention except for those of the slitting device 34, the preinspection device 35, the rollers 39, and the inspection device 40 can be achieved by a known technique, and a specific description thereof is therefore omitted here.
Conventionally, a defect that has been developed in the separator 1 or in the slit separators 32 is not assumed to be detected downstream of the preinspection device 35 in a transfer path of the separator 1. According to the above method, it is possible to detect a defect such as a roller-derived defect by inspecting the slit separators 32 that have been transferred via the rollers 39. That is, a defect in the slit separators 32 which defect has been developed by a contact, with the slit separators 32, of a foreign object having adhered to surfaces of the rollers 39 via which to transfer the slit separators 32 can be detected in a process carried out after the separator 1 is slit. This makes it possible to allay a fear that the slit separators 32 in which the defect remains and which are low in quality may be shipped in a form of products. In addition, in a case where (i) the inspection carried out by the preinspection device 35 in the step 1 and (ii) the step 3 are combined, a defect that has been detected in the step 3 can be expected to be a roller-derived defect.
According to the above method, defects that are periodically developed in the machine direction of the slit separators 32, such as roller-derived defects can be detected without the need to unwind all the slit separators 32 from the roll 44. Thus, in a case where periodic defects are expected to be developed in the slit separators 32 of the roll 44, an inspection step can be carried out with high efficiency.
The following description discuss, by referring to
A method for producing the separator 1 that includes (i) a base material 2 and (ii) a functional layer 3 that is provided to at least one of surfaces of the base material 2 includes a withstand voltage inspection carried out with respect to the separator 1 for detecting a defect in the separator 1. The method for producing the separator 1 is regarded as the method for producing the separator 1 in accordance with Embodiment 3 of the present invention.
According to the method for producing the separator in accordance with Embodiment 3 of the present invention, it is possible to easily detect an extremely small defect of an order of not more than several hundred μm, the extremely small defect having been developed in the separator 1. Examples of the extremely small defect include a slit 4, a pinhole 5, a recess 6, a slit 7, and a defect 12. The roller-derived defects described earlier are also encompassed in the extremely small defect. In particular, an optical inspection carried out with respect to the separator 1 is unsuitable for detecting the recess 6 provided to the separator 1. Note, however, that the withstand voltage inspection carried out with respect to the separator 1 makes it easy to detect the recess 6.
The withstand voltage inspection is carried out with respect to the separator 1 by causing an electrode 10 and an electrode 11 that face each other across the separator 1 to be electrically connected with each other. In a part of the separator 1 which part is sandwiched by the electrode 10 and the electrode 11, a value of a voltage to be applied to each of the electrode 10 and the electrode 11 is determined so that (i) the electrode 10 and the electrode 11 are not electrically connected with each other in a case where no defect 12 is present and (ii) the electrode 10 and the electrode 11 are electrically connected with each other in a case where the defect 12 is present. This makes it possible to accurately detect an extremely small defect of an order of not more than several hundred μm, the extremely small defect having been developed in the separator 1, so that the recess 6 is easily detected.
A constant direct-current voltage is preferably applied to each of the electrode 10 and the electrode 11. This makes it possible to (i) continuously apply, to each of the electrode 10 and the electrode 11, a voltage having a desired value and (ii) allow the electrode 10 and the electrode 11 to be electrically connected with each other under a constant condition. Thus, the withstand voltage inspection can be carried out with respect to the separator 1 under a continuous and constant condition.
In the withstand voltage inspection carried out with respect to the separator 1, a hole or a depression that is provided to at least one of the base material 2 and the functional layer 3 is detected. Furthermore, in the withstand voltage inspection carried out with respect to the separator 1, the defect 12 is preferably detected in the separator 1 that includes, as the functional layer 3, a heat-resistant film that contains aramid as a main component, a film that contains ceramic as a main component, or a film that contains PVdF as a main component.
An apparatus for producing the separator 1 in accordance with Embodiment 3 of the present invention includes an electric power source 9, the electrode 10, and the electrode 11. Configurations of the apparatus for producing the separator 1 in accordance with Embodiment 3 of the present invention except for those of the electric power source 9, the electrode 10, and the electrode 11 can be achieved by a known technique, and a specific description thereof is therefore omitted here.
[Variation 1]
The inspection device 45 includes an electric power source 46, an electrode 47, and an electrode 48. The electric power source 46, the electrode 47, and the electrode 48 correspond to the electric power source 9 (see
The inspection device for inspecting the separator 1, the inspection device including the electric power source 9, the electrode 10, and the electrode 11, is configured such that the electrode 10 and the electrode 11 are fixed so that the separator 1 is moved. In contrast, the inspection device is configured such that the separator 1 and the electrode 48 are fixed so that the electrode 47 is moved. A constant direct-current voltage is preferably applied to each of the electrode 47 and the electrode 48 for a reason similar to a reason for which a constant direct-current voltage is preferably applied to each of the electrode 10 and the electrode 11. The electrode 47 is not limited to any particular electrode provided that the electrode 47 is an electric conductor that is hard enough to prevent a crack in the electrode 47. The electrode 47 can be made of stainless steel (SUS), tungsten, electrically conductive ceramic, or the like. In contrast, the electrode 48 is preferably an electrically conductive non-metallic sheet. For example, the electrode 48 is preferably an electrically conductive rubber sheet.
According to the inspection device 45, it is unnecessary to transfer the separator 1 during the withstand voltage inspection carried out with respect to the separator 1. This makes it easy to inspect the separator 1 that has a large area. In order to carry out the withstand voltage inspection with respect to the separator 1 with use of the inspection device 45, it is necessary to tightly place the separator 1 on the electrode 48 so that no wrinkle appears on the separator 1.
In the third step described earlier, a part of the separator 1 which part corresponds to an unwound part 20 (see
The inspection device 45 can be used to inspect an inspected part 22 or slit separators 32 instead of the separator 1.
[Variation 2]
The inspection device 49 includes an electric power source 50, an electrode 51, and an electrode 52. The electric power source 50, the electrode 51, and the electrode 52 correspond to the electric power source 9 (see
(a) of
The wall part 53 and the wall part 54 are each provided so as to be parallel to the electrode 52. The wall part 53 and the wall part 54 are provided so as to face each other across the electrode 52. An upper surface of the electrode 52, the wall part 53, and the wall part 54 form a groove 57. A part of the separator 1 which part is to be subjected to a withstand voltage inspection is provided in the groove 57. The electrode 52 has, from a wall part 53 side end thereof to a wall part 54 side end thereof, a length that is equal to or slightly larger than a width of the separator 1, the width extending in a transverse direction of the separator 1. A length, extending in a shorter side direction, of each of the electrode 51 and the electrode 52 is not limited to any particular length. Note, however, that, the electrode 51 can be made shorter in length extending in the shorter side direction than the electrode 52 as illustrated in (b) of
The mount part 55 mounts thereon the electrode 51. The electrode 51 is provided on an electrode 52 side of the mount part 55 so as to face the electrode 52. The electrode 51 has a size and a shape that allow the electrode 51 to be fitted in the groove 57. The lifting and lowering section 56 is a mechanism that lifts and lowers the mount part 55 that mounts thereon the electrode 51. In a case where the lifting and lowering section 56 lowers the mount part 55 while the electrode 51 is not fitted in the groove 57, the electrode 51, together with the mount part 55, is lowered and then fitted in the groove 57. In contrast, in a case where the lifting and lowering section 56 lifts the mount part 55 while the electrode 51 is fitted in the groove 57, the electrode 51, together with the mount part 55, is lifted and then left from the groove 57.
The withstand voltage inspection is carried out with respect to the separator 1 by placing the separator 1 on the upper surface of the electrode 52 so that the separator 1 is substantially precisely fitted in the groove 57. This determines a position of the separator 1 with respect to the electrode 52. By causing the lifting and lowering section 56 to lower the mount part 55 in such a state so that the electrode 51 is fitted in the groove 57, the separator 1 can be sandwiched by the electrode 51 and the electrode 52. In this case, a position of the electrode 51 in a direction parallel to a surface of the separator 1 is defined in advance by the mount part 55 and the lifting and lowering section 56. Thus, a position of the electrode 51 with respect to the separator 1 is determined when the mount part 55 finishes descending.
According to the inspection device 49 illustrated in
In a case where the wall part 53 and the wall part 54 are omitted from the inspection device 49 illustrated in
In a case where the lifting and lowering section 56 is omitted from the inspection device 49 illustrated in
(a) of
(a) of
The inspection device 49 can be used to inspect an inspected part 22 or slit separators 32 instead of the separator 1.
Aspects of the present invention can also be expressed as follows:
A method for producing slit separators in accordance with an aspect of the present invention includes the steps of: a) preparing the slit separators by slitting a separator; b) transferring the slit separators via a roller; and c) inspecting, for a defect, the slit separators having been transferred via the roller.
In order to attain the object, an apparatus for producing slit separators in accordance with an aspect of the present invention includes: a slitting device for preparing the slit separators by slitting a separator; a roller via which to transfer the slit separators; and an inspection device for inspecting, for a defect, the slit separators having been transferred via the roller.
With the configuration, a defect in the slit separators which defect has been developed by a contact, with the slit separators, of a foreign object having adhered to a surface of the roller via which to transfer the slit separators can be detected in a process carried out after the separator is slit. This makes it possible to allay a fear that the slit separators in which the defect remains and which are low in quality may be shipped in a form of products.
The method in accordance with an aspect of the present invention is configured such that in the step c), the slit separators are subjected to a withstand voltage inspection carried out for detecting a defect in the slit separators.
The apparatus in accordance with an aspect of the present invention is configured such that the inspection device subjects the slit separators to a withstand voltage inspection carried out for detecting a defect in the slit separators.
According to the configuration, it is possible to easily detect an extremely small defect having been produced in the slit separators and having not more than several hundred μm. Furthermore, the configuration allows an extremely small defect to be detected in the slit separators even in a case where the slit separators are transferred at a relatively high speed via the roller. Thus, the configuration is suitable for detecting a defect in the slit separators while transferring the slit separators.
A method in accordance with an aspect of the present invention further includes, before the step a), the step of: d) inspecting the separator for a defect.
The apparatus in accordance with an aspect of the present invention is configured such that the apparatus inspects the separator for a defect upstream of the slitting device in a transfer path of the separator.
A method in accordance with an aspect of the present invention further includes the steps of: e) preparing a roll by winding the slit separators; and f) unwinding part of the slit separators from the roll, in the step c), an inspection for a defect being carried out with respect to at least part of an unwound part of the slit separators.
According to the method, defects that are periodically developed in a machine direction of the slit separators can be detected without the need to unwind all the slit separators from the roll. Thus, in a case where periodic defects are expected to be developed in the slit separators of the roll, an inspection step can be carried out with high efficiency.
The present invention is not limited to the embodiments, but can be altered by a skilled person in the art within the scope of the claims. The present invention also encompasses, in its technical scope, any embodiment derived by combining technical means disclosed in differing embodiments.
Number | Date | Country | Kind |
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2019-084520 | Apr 2019 | JP | national |