Gravure roll, method of fabricating a separator, and separator

Patent metadata

Field	Value
Publication number	US-2016226047-A1
Application number	US-201414888115-A
Country	US
Kind code	A1
Filing date	Oct 15, 2014
Priority date	Oct 16, 2013
Publication date	Aug 4, 2016
Grant date	—

Abstract

A gravure roll, in which the outside peripheral surface of a metal roll main body has a plurality of oblique line shaped protrusions forming a prescribed angle with the center axis of the roll main body and the coating liquid can be held in a plurality of oblique line shaped recesses formed between each of the plurality of protrusions, is configured such that the roll main body has a diamond-like carbon layer on the entire outer peripheral surface thereof, a head part for each of the plurality of protrusions is cut down, and each of the plurality of protrusions has a trapezoidal cross-sectional shape that becomes gradually narrower in width moving in direction toward the head part. A separator with a uniform weight per unit area can be manufactured wherein the coating liquid is coated onto a base material film using this gravure roll.

First claim

We claim:

1 - 11 . (canceled)

12 . A gravure roll including:
a roll body composed of a metal, a plurality of protrusions formed on an outer surface of the roll body, and obliquely extending at a predetermined angle relative to a central axis of the roll body, and a diamond-like carbon (DLC) layer entirely covering an outer surface of the roll body therewith, a plurality of obliquely extending recesses being formed between the adjacent protrusions, each of the recesses retaining a coating liquid therein, each of the obliquely extending protrusions having a cross-section including a head portion comprised of a flat surface, and a pair of sidewalls having a width gradually reducing towards the head portion.

13 . The gravure roll as set forth in claim 12 , wherein the cross-section is trapezoidal.

14 . The gravure roll as set forth in claim 12 , wherein the DLC layer is water-repellent.

15 . The gravure roll as set forth in claim 12 , wherein the DLC layer has a thickness equal to or greater than 0.1 micrometer, but equal to or smaller than 3.0 micrometers.

16 . The gravure roll as set forth in claim 12 , wherein the gravure roll further includes an intermediate layer between the outer surface of the roll body and the DLC layer.

17 . The gravure roll as set forth in claim 16 , wherein the intermediate layer is composed of hard chromium.

18 . The gravure roll as set forth in claim 17 , wherein the intermediate layer has a thickness equal to or greater than 10 micrometers, but equal to or smaller than 30 micrometers.

19 . The gravure roll as set forth in claim 12 , wherein each of the obliquely extending recesses has a trapezoidal cross-section.

20 . A method of fabricating a separator, including:
a first step of operating the gravure roll defined in claim 12 ; and a second step of coating a coating liquid onto a base film through the use of the gravure roll.

21 . The method as set forth in claim 20 , wherein the coating liquid contains inorganic fillers therein.

22 . The method as set forth in claim 21 , wherein, in the second step, the coating liquid containing inorganic fillers therein is coated onto the base film for forming a heat-resistant layer containing inorganic fillers therein on a surface of the base film such that a difference between a maximum and a minimum in a weight per unit area of the separator in a length-wise direction thereof, measured every 100 meters interval, is equal to or smaller than 2 grams/m 2 .

23 . A separator including a base film, and a heat-resistant layer containing inorganic fillers therein and formed on a surface of the base film,
a difference between a maximum and a minimum in a weight per unit area of the separator in a length-wise direction thereof, measured every 100 meters interval, being equal to or smaller than 2 grams/m 2 .

Assignees

• Sumitomo Chemical Co

Inventors

• Watanabe Koichiro
• Wang Jian
• Minemoto Yasutoshi
• Kimura Shinya

Classifications

• B05C1/027 Primary

  only at particular parts of the articles (at particular parts of work of indefinite length B05C1/16) · CPC title

• B05C1/0808 Primary

  Details thereof, e.g. surface characteristics · CPC title

• B05C1/083

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

• B05C1/0817

  characterised by means for removing partially liquid or other fluent material from the roller, e.g. scrapers (coating roller co-operating with dosing rollers B05C1/0834) · CPC title

• B41N1/20

  made of metal {or similar inorganic compounds, e.g. plasma coated ceramics, carbides} · CPC title