Manufacturing method of paste-layer-attached sheet and coating applicator

Patent metadata

Field	Value
Publication number	US-2018221908-A1
Application number	US-201815889313-A
Country	US
Kind code	A1
Filing date	Feb 6, 2018
Priority date	Feb 8, 2017
Publication date	Aug 9, 2018
Grant date	—

Abstract

At the time of forming a paste layer on a substrate sheet by use of three rolls placed at right angles, in order to offset a variation amount of a first gap due to thermal expansion of the rolls, a variation amount in a given detection period is calculated by use of outputs of a first sensor configured to detect a coating film surface of a second-roll coating film of a second roll and a second sensor configured to detect a second-roll surface, and the first roll is moved by use of a first-roll moving mechanism.

First claim

What is claimed is:

1 . A manufacturing method of a paste-layer-attached sheet in which a belt-shaped paste layer made of a paste is provided on a belt-shaped substrate sheet, the manufacturing method comprising:
forming the paste layer on the substrate sheet by use of a coating applicator, the coating applicator including
a first roll,
a second roll placed in parallel with the first roll via a first gap and configured to rotate in a second-roll rotation direction reverse to the first roll,
a third roll placed in parallel with the second roll via a second gap and configured to rotate in a reverse direction to the second roll so as to convey the substrate sheet passing through the second gap, the first roll, the second roll, and the third roll being placed such that a first virtual surface connecting a second-roll central axis of the second roll to a first-roll central axis of the first roll and a second virtual surface connecting the second-roll central axis of the second roll to a third-roll central axis of the third roll intersect with each other at right angles at the second-roll central axis and the second gap is formed in a part advanced by a quarter turn from the first gap in the second-roll rotation direction over a second-roll surface of the second roll,
a first sensor configured to detect a first radial position on a coating film surface of a second-roll coating film made of the paste applied to the second-roll surface, the first radial position being at a first angle position on the coating film surface of the second-roll coating film, the first angle position being advanced by a first angle from the first gap in the second-roll rotation direction over the second-roll surface, the first angle being larger than 0° but smaller than 90°,
a second sensor placed to be opposed to the first sensor across the second roll and configured to detect a second radial position on the second-roll surface of the second roll, the second radial position being at a second angle position on the second-roll surface, the second angle position being advanced from the first angle position by 180° in the second-roll rotation direction, and
a first-roll moving mechanism configured to move the first roll in a first direction connecting the second roll to the first roll,
the paste layer being formed such that the paste is supplied to the first gap and the second-roll coating film applied to the second-roll surface is passed through the second gap so as to be transferred onto the substrate sheet conveyed by the third roll; detecting, every detection period, a variation amount of a gap dimension of the first gap from the first radial position detected by the first sensor and the second radial position detected by the second sensor, the variation amount being caused during the detection period due to thermal expansion caused in the first roll and the second roll, the detection period being provided repeatedly; moving the first roll in the first direction by use of the first-roll moving mechanism so as to offset the detected variation amount of the first gap; and starting detection in a new detection period after the movement of the first roll by the first-roll moving mechanism is finished, and then, a second-roll rotation time during which the second roll rotates by the first angle elapses after a previous detection period is finished.

2 . The manufacturing method of the paste-layer-attached sheet, according to claim 1 , wherein
when the variation amount of the gap dimension of the first gap is detected, the variation amount of the first gap, caused during the detection period due to the thermal expansion, is acquired from a difference between a variation amount of the first radial position on the coating film surface of the second-roll coating film, the variation amount being caused during the detection period and detected by the first sensor, and a variation amount of the second radial position on the second-roll surface of the second roll, the variation amount being caused during the detection period and detected by the second sensor.

3 . The manufacturing method of the paste-layer-attached sheet, according to claim 1 , wherein:
the first sensor is a sensor configured to detect the first radial position on the coating film surface based on a preinitiation first radial position on the second-roll surface at the first angle position as a reference position, the preinitiation first radial position being measured by the first sensor before the supply of the paste to the first gap is started; the second sensor is a sensor configured to measure the second radial position on the second-roll surface based on a preinitiation second radial position on the second-roll surface at the second angle position as a reference position, the preinitiation second radial position being measured by the second sensor before the supply of the paste to the first gap is started; and the manufacturing method further comprises
measuring, by the first sensor, an initial first radial position on the coating film surface of the second-roll coating film based on the preinitiation first radial position as the reference position, after the second roll rotates by the first angle or more, but before the second roll makes a first predetermined number of rotations, counting from the start of the supply of the paste to the first gap at a time of starting a first detection period among the detection periods provided repeatedly,
measuring, by the second sensor, an initial second radial position on the second-roll surface based on the preinitiation second radial position as the reference position, after the second roll rotates by the first angle or more, but before the second roll makes a first predetermined number of rotations, counting from the start of the supply of the paste to the first gap at a time of starting a first detection period among the detection periods provided repeatedly,
measuring, by the first sensor, an end first radial position on the coating film surface of the second-roll coating film based on the preinitiation first radial position as the reference position at an end of each of the detection periods after the initial first radial position and the initial second radial position are measured,
measuring, by the second sensor, an end second radial position on the second-roll surface based on the preinitiation second radial position as the reference position at an end of each of the detection periods after the initial first radial position and the initial second radial position are measured, and
calculating a value of ΔG 1 , which is a variation amount of the first gap, caused due to the thermal expansion during each of the detection periods, by use of a relational expression of ΔG 1 =(L 12 −L 22 )−(L 11 −L 21 ), where L 11 indicates a value of the initial first radial position, L 21 indicates a value of the initial second radial position, L 12 indicates a value of the end first radial position, and L 22 indicates a value of the end second radial position.

4 . The manufacturing method of the paste-layer-attached sheet, according to claim 1 , wherein:
the first sensor includes a first-side first sensor and a second-side first sensor, and the second sensor includes a first-side second sensor and a second-side second sensor, such that the first-side first sensor and the first-side second sensor are placed to be opposed to each other via a first end of the second roll and the second-side first sensor and the second-side second sensor are placed to be opposed to each other via a second end of the second roll; the first-roll moving mechanism includes a first-side first-roll moving mechanism configured to move a first end of the first roll in the first direction, and a second-side first-roll moving mechanism configured to move a second end of the first roll in

Assignees

• Toyota Motor Co Ltd

Inventors

• ENOKIHARA Katsushi
• Ikeda Takenori

Classifications

• B05C1/0834

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

• B05D1/28

  performed by transfer from the surfaces of elements carrying the liquid or other fluent material, e.g. brushes, pads, rollers · CPC title

• H01M4/0404

  by coating on electrode collectors · CPC title

• B05C1/0865

  the cooperating element being a roller, e.g. a coating roller · 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