Coating film production method, coating film production apparatus, coating film, nonaqueous secondary battery electrode plate, and mobile body

Patent metadata

Field	Value
Publication number	US-2016082467-A1
Application number	US-201514788789-A
Country	US
Kind code	A1
Filing date	Jul 1, 2015
Priority date	Sep 18, 2014
Publication date	Mar 24, 2016
Grant date	—

Abstract

When a coating material is rolled between rolls to generate a a coating film, and the coating film is transferred onto the coating object, at first, a residual coating material layer based on a residual coating material is formed on each of the surfaces of the rolls, and supply of the coating material and transfer of the coating film are carried out in a state where the residual coating material layer is retained on each of the surfaces of the rolls, thereby suppressing abrasions between the rolls and the coating material.

First claim

What is claimed is:

1 . A coating film production method, comprising:
allowing a coating material to penetrate into a gap between a first roll and a second roll that rotates in an opposite direction to the first roll, to generate a coating film on a surface of the second roll; and transferring the coating film generated on the surface of the second roll onto a coating object running on a circumferential surface of a third roll that rotates in an opposite direction to the second roll, wherein a residual coating material, which is formed by a portion of the coating material remaining on each of circumferential surfaces of the first roll and the second roll before the circumferential surfaces move to the gap, is present thereon.

2 . The coating film production method according to claim 1 , wherein coating is carried out while allowing the residual coating materials to remain on the circumferential surfaces of the first roll and the second roll, the method comprising:
a first step of rolling, by a shearing force, the coating material that has penetrated into the gap between the first roll and the second roll, in a state where the surfaces of the first roll and the second roll are each covered with the residual coating material; a second step of transferring the coating material in the form of the coating film onto the second roll while allowing the residual coating material to remain on the surface of the first roll; a third step of rolling, by a shearing force, the coating material in the form of a coating film that has penetrated into a roll gap between the second roll and the coating object, in a state where the coating material in the form of a coating film is transferred onto the surface of the second roll; and a step of transferring the coating material in the form of the coating film onto the coating object while allowing the residual coating material to remain on the surface of the second roll.

3 . The coating film production method according to claim 1 , wherein a thickness of the residual coating material is 1 to 10 times or less as large as a mean particle diameter of coating particles.

4 . The coating film production method according to claim 1 , wherein arithmetic mean roughnesses Ra of the surfaces of the first roll and the second roll satisfy
0.05× D 10 <Ra< 50× D 90
wherein D 10 is a particle diameter where a cumulative distribution rate of the coating material is 10%, and D 90 is a particle diameter where the cumulative distribution rate is 90%.

5 . The coating film production method according to claim 1 , wherein the supplied coating material has a volume solvent content of 20 vol % or more to 62 vol % or less.

6 . The coating film production method according to claim 1 , wherein the coating object is supplied by the third roll, the coating film is transferred onto the coating object between the second roll and the third roll, a ratio of a circumferential speed of the second roll/a circumferential speed of the first roll is adjusted to larger than 1 to 30 or less, and a ratio of a circumferential speed of the third roll/the circumferential speed of the second roll is adjusted to 1 or more to 30 or less.

7 . The coating film production method according to claim 6 , wherein θ( 1 )≧θ( 2 )>θ( 3 ) where θ( 1 ) is a surface contact angle between the first roll and a solvent for the coating material, θ( 2 ) is a surface contact angle between the second roll and the solvent for the coating material, and θ( 3 ) is a surface contact angle between the third roll and a solvent for the coating material in the form of the coating film that is transferred onto the coating object.

8 . The coating film production method according to claim 7 , wherein 150°>θ( 1 ) and θ( 3 )>3°.

9 . A coating film production apparatus that coats a coating material including coating particles onto a coating object, the apparatus comprising:
a first roll and a second roll that roll the supplied coating material to generate the coating material in the form of a coating film; a third roll that supplies the coating object; and a residual coating material that remains on each of surfaces of the first roll and the second roll, wherein the coating material is supplied from a gap between the first roll and the second roll, the residual coating material is a portion of the supplied coating material that remains on each of the surfaces of the first roll and the second roll, and the coating material in the form of the coating film is transferred from the second roll onto the coating object running on the third roll.

10 . The coating film production apparatus according to claim 9 , wherein a thickness of the residual coating material is 1 to 10 times or less as large as a mean particle diameter of the coating particles.

11 . The coating film production apparatus according to claim 9 , wherein arithmetic mean roughnesses Ra of the surfaces of the first roll and the second roll satisfy
0.05× D 10 <Ra< 50× D 90
wherein D 10 is a particle diameter where a cumulative distribution rate of the coating material measured by a particle size analyzer is 10%, and D 90 is a particle diameter where the cumulative distribution rate is 90%.

12 . The coating film production apparatus according to claim 9 , wherein θ( 1 )≧θ( 2 )>θ( 3 ) where θ( 1 ) is a surface contact angle between the first roll and a solvent for the coating material, θ( 2 ) is a surface contact angle between the second roll and the solvent for the coating material, and θ( 3 ) is a surface contact angle between the third roll and a solvent for the coating material in the form of the coating film.

13 . The coating film production apparatus according to claim 12 , wherein 150°>θ( 1 ) and θ( 3 )>3°.

14 . A coating film produced by the production method according to claim 1 .

15 . A nonaqueous secondary battery electrode plate,
comprising the coating film according to claim 14 .

16 . A mobile body, comprising the nonaqueous secondary battery electrode plate according to claim 15 .

Assignees

• Panasonic Ip Man Co Ltd

Inventors

• Mikami Masateru
• Hamabe Masashi
• Kuromiya Takao

Classifications

• H01M10/0525

  Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries · CPC title

• B05C1/083

  being passed between the coating roller and one or more backing rollers · CPC title

• H01M4/0409

  by a doctor blade method, slip-casting or roller coating · CPC title

• B05C1/0834 Primary

  the coating roller co-operating with other rollers, e.g. dosing, transfer rollers · CPC title

• B05D1/26

  performed by applying the liquid or other fluent material from an outlet device in contact with, or almost in contact with, the surface · CPC title