Coating processes – Nonuniform coating – Metal – glass – or ceramic base
Patent
1994-12-20
1996-12-10
Bareford, Katherine
Coating processes
Nonuniform coating
Metal, glass, or ceramic base
4271261, 427116, 427428, 118247, 118249, 118253, 118261, 118263, B05D 500, B05C 108
Patent
active
055828680
DESCRIPTION:
BRIEF SUMMARY
This application is a national stage application of PCT/JP94/00319, filed Feb. 28, 1994.
BACKGROUND OF THE INVENTION
The present invention relates to a process and an apparatus for coating a slurry coating material onto a continuous base sheet at a given thickness, and particularly to a process and an apparatus for intermittently coating a slurry coating material to alternately form coated areas and uncoated areas, each having a predetermined length on a base sheet.
In mass production of, for example, spiral electrode type lithium batteries, the following intermittent coating technique is employed. A band-shaped hoop material of a copper or an aluminum foil approximately 400 mm wide and 10 .mu.m thick is employed as a base sheet for current collectors for such batteries. Slurry mixture containing electrode active material as a main component is used as a coating material. The coating material is applied onto the base sheet, for example, over areas each having a length of 30 cm at a certain thickness, in such a manner that the coating material is not applied at all to subsequent areas, each having a length of 5 cm. Thereby, the coated areas and the uncoated areas, each having the above-mentioned lengths, are alternately formed on the continuous base sheet. Finally, the base sheet is cut at the uncoated areas into a plurality of electrode sheets for the batteries. Each electrode sheet is wound with another electrode sheet constituting another electrode, with a separator therebetween. Then, the resultant wound electrode body is assembled in a battery case.
One known process for carrying out such an intermittent coating operation employs a coating apparatus called a reverse roll coater as shown in FIGS. 10 to 12.
In FIG. 10, the coating apparatus includes, as principal portions, a supplying drum 10 for supplying a base sheet 3, an intermittent coating portion 20 for intermittently applying coating material 6 onto the base sheet 3, a drying furnace 21 for drying the coated material 6 and a take-up roll 22 for taking up the base sheet 3 having passed through the drying furnace 21. As shown in FIG. 11, the base sheet 3 supplied form the supplying drum 10 is guided to the intermittent coating portion 20 by guide rolls 11a, 11b, feed rolls 9 and a guide roll 8.
In the intermittent coating portion 20, as shown in FIG. 12, a coating roll 1 (hereinafter referred to as a C-roll) is rotated at a predetermined speed in a direction indicated by an arrow a, whereas a backing roll 2 (hereinafter referred to as a B-roll) is rotated in a direction opposite to that of the C-roll 1 (i.e., in a direction indicated by an arrow b). The base sheet 3 is allowed to travel in a direction indicated by an arrow c along the B-roll 2 and to pass between the C-roll 1 and the B-roll 2.
An adjuster called a doctor roll 4 (hereinafter referred to as a D-roll) is fixedly (i.e., non-rotatably) mounted above the C-roll 1 and spaced a predetermined distance from the C-roll 1. The coating material 6 accumulated in a hopper 5 is deposited onto a peripheral surface of the C-roll 1, then passes through a region of minimum distance between the C-roll 1 and the D-roll 4, whereby the amount of the coating material 6 applied to the base sheet 3 is controlled at a certain value (in other words, thickness) corresponding to the minimum distance.
A coating layer 6a controlled to the predetermined thickness by the distance between the C-roll 1 and the D-roll 4 is transferred onto the base sheet 3 when the base sheet 3 passes between the B-roll 2 and the C-roll 1. In this manner, a coating layer 6b is continuously formed on the base sheet 3 at a controlled constant thickness.
In order to form uncoated areas intermittently, there is mounted an intermittent moving mechanism for moving the B-roll 2 in a direction perpendicular to a rotational axis thereof. Thus, the B-roll 2 is displaced in a direction indicated by an arrow d at given intervals, until it is sufficiently spaced apart from the C-roll 1 so that the coating layer 6a is not transferred from the C-r
REFERENCES:
patent: 4704296 (1987-11-01), Leanna et al.
Harada Yoshiro
Hironaka Kazuhiko
Kobara Hiroshi
Matsui Eiji
Okada Kaoru
Bareford Katherine
Fuji Electrochemical Co. Ltd.
Hirano Tecseed Co., Ltd.
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