JP2009087803A - ELECTROCHEMICAL DEVICE, ITS MANUFACTURING METHOD, AND ITS MANUFACTURING DEVICE - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an electrochemical element having high capacity in which the discharge capacity of the electrochemical element is increased by enhancing utilization factor of an active material in the electrochemical element by uniformizing a condition of absorbing and impregnating an electrolyte in a positive electrode material. <P>SOLUTION: A positive electrode material 3, a negative electrode material 5, a separator 2 interposed between the positive electrode material 3 and the negative electrode material 5, and an electrolyte are housed in a bottomed case 4, irregularities are formed so as to retain the electrolyte at the beginning of housing of the separator 2 in the bottomed case 4, the irregularities are made almost flat by impregnation of the electrolyte, and then an opening part of the bottomed case 4 is sealed with a sealing body 7 to form the electrochemical element. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to an electrochemical element improved in a separator interposed between a positive electrode material and a negative electrode material of an electrochemical element such as a battery or a capacitor, a manufacturing method thereof, and a manufacturing apparatus thereof.

  In recent years, high-functional electronic devices with large power consumption such as digital cameras and portable music players that require high-load discharge performance have become popular in the market. Along with this, there is an increasing demand for electrochemical elements typified by alkaline manganese dry batteries used in these electronic devices. In order to improve the functionality of such electronic devices, higher capacity and higher performance electrochemical elements are required than ever, improving production efficiency, and providing high quality and reliable large capacity discharge performance. There is a need for improved high power electrochemical devices.

  For alkaline manganese batteries, which are conventional electrochemical devices, as an effort to improve discharge performance, the positive electrode material is compression-molded to accommodate as much active material as possible by effectively using the limited internal volume in the bottomed case. In this case, the pressure force was set high to produce a high-density positive electrode material, and the amount of the positive electrode material could be increased. However, because of the high-density positive electrode material, the void volume inside the mold was reduced. It took a long time to impregnate the electrolytic solution, and the amount of impregnated electrolytic solution tended to decrease.

  As a result, the electrolyte in the bottomed case becomes insufficient, so that the effective utilization rate of the active material enclosed in the bottomed case is flat or tends to decrease, and the utilization rate of the active material decreases. As a result, there is a problem that the high-load discharge performance is deteriorated.

In order to solve the problem, as a method of absorbing and impregnating a large amount of electrolytic solution for improving discharge performance, the utilization rate of the active material in the electrochemical element is increased by impregnating the positive electrode material with a large amount of electrolytic solution. In order to increase the utilization rate of the active material of the positive and negative electrode materials and provide a material having good electrochemical device performance, in particular, discharge performance, as shown in FIG. 9B, between the positive electrode material 102 and the negative electrode material 103. As shown in the cross section of FIG. 9A, the separator 101 processed so that the entire surface is corrugated is sandwiched between the positive electrode material 102 and the negative electrode material 103, and the separator 101 and There has been proposed a device devised so that an electrolyte solution necessary for a discharge reaction can be supplied by providing a space for holding an electrolyte solution between the positive electrode materials 102 and holding the electrolyte solution in this space. (For example, patents Document reference 1).
JP 7-326370 A

  However, the conventional technology such as Patent Document 1 described above has a structure in which a separator is processed and a space for holding an electrolytic solution is provided between the positive electrode material and the separator. Therefore, since the volume occupied by the separator in the electrolytic chemical element increases, there is a problem that the volume of the negative electrode material decreases.

  The present invention has been made in view of the above-described conventional problems. It improves the conditions for absorbing and impregnating the electrolyte into the positive electrode material, and improves the utilization rate of the active material in the electrochemical device. An object of the present invention is to provide a high-capacity electrochemical device having improved discharge performance of the chemical device.

In order to achieve the above object, the electrochemical device of the present invention includes a positive electrode material, a negative electrode material, a separator interposed between the positive electrode material and the negative electrode material, and an electrolyte in a bottomed case. In an electrochemical element whose opening is sealed with a sealing body, a concavo-convex part is formed that retains the electrolytic solution when the separator is initially stored in the bottomed case, and the concavo-convex part is made substantially flat by impregnation with the electrolytic solution. It is characterized by using a composition.

  In the electrochemical device of the present invention, the separator is formed with a concavo-convex portion for retaining the electrolyte solution at the beginning of storage in the bottomed case, and the electrolyte solution is retained in the gap formed by the concavo-convex portion with the positive electrode material. Thus, after the positive electrode material comes into direct contact with the electrolytic solution and the liquid absorption impregnation is promoted, the separator impregnated with the electrolytic solution becomes a substantially flat state, and the volume occupied by the separator is also reduced without reducing the capacity of the negative electrode material. In addition, it is possible to improve the discharge performance of the electrochemical device by suppressing the electrolyte solution of the positive electrode material from dying during discharge and improving the utilization factor of the active material in the bottomed case.

  In the first aspect of the present invention, the positive electrode material, the negative electrode material, the separator interposed between the positive electrode material and the negative electrode material, and the electrolytic solution are accommodated in the bottomed case, and the opening of the bottomed case is sealed with the sealing body. In the electrochemical device, the separator was formed so that the uneven portion for retaining the electrolytic solution was formed at the beginning of storage in the bottomed case, and the uneven portion was made substantially flat by impregnation with the electrolytic solution. The electrolyte solution is retained in the gap between the positive electrode material and the positive electrode material, and the positive electrode material comes into direct contact with the electrolyte solution and the liquid absorption impregnation is promoted, and then the separator impregnated with the electrolyte solution is substantially flat. Therefore, by reducing the volume occupied by the separator, the capacity of the negative electrode material is not reduced, and the electrolyte of the positive electrode material is prevented from withstanding during discharge, and the utilization rate of the active material in the bottomed case is improved. Improve device discharge performance Rukoto is possible.

  In the second invention of the present invention, by forming a plurality of concave and convex portions connected to the separator, it is possible to retain a large amount of electrolytic solution, promote liquid absorption impregnation into the positive electrode material, and perform electrolysis of the positive electrode material during discharge. The liquid does not wither, and the utilization factor of the active material can be improved to improve the discharge performance of the electrochemical device.

  In the third invention of the present invention, an electrolytic solution poured from the opening of the bottomed case by forming the uneven portion formed in the separator so as to communicate with the end of the separator in the direction of the opening of the bottomed case Can be easily retained, and by retaining the electrolyte solution, impregnation of the positive electrode material can be promoted, and the utilization rate of the active material can be improved to improve the discharge performance of the electrochemical device. it can.

  In the fourth aspect of the present invention, the unevenness formed on the separator is formed at an inclined angle with respect to the end of the separator, so that the resistance when the unevenness of the separator impregnated with the electrolyte extends can be reduced. The separator is efficiently in a substantially flat state, and the decrease in the negative electrode material can be suppressed.

  In the fifth invention of the present invention, since the uneven portion formed in the separator is in contact with the positive electrode material, the electrolyte solution can be in direct contact with the positive electrode material, so that the electrolyte solution of the positive electrode material is absorbed and impregnated, and And the resistance at the time of the uneven part of a separator extending can be reduced.

  In the sixth aspect of the present invention, since the height of the concavo-convex portion formed on the separator becomes lower as it approaches the end of the separator, the resistance when the concavo-convex portion of the separator impregnated with the electrolyte extends is increased. It can be reduced and it becomes easy to become a substantially flat state.

In the seventh aspect of the present invention, since the separator has an uneven portion on the opening side of the bottomed case, the electrolytic solution can directly contact the portion of the positive electrode material that is difficult to absorb and impregnate, and the impregnation of the absorbent is positive. It is promoted evenly throughout the material.

  In the eighth aspect of the present invention, the uneven surface of the separator impregnated with the electrolyte extends by providing a smooth surface without the uneven portion on the winding end side of the separator wound so as to form a cylinder. As a result, the separator is effectively in a substantially flat state, and the decrease in the negative electrode material can be suppressed.

  In the ninth aspect of the present invention, since the electrochemical element is a battery, the positive electrode material comes into direct contact with the electrolytic solution, the liquid absorption impregnation is promoted, and the capacity of the negative electrode material is reduced by reducing the occupied volume of the separator. Therefore, it is possible to improve the discharge performance of the battery by suppressing the electrolyte solution of the positive electrode material from dying during discharge and improving the utilization factor of the active material in the bottomed case.

  In the tenth aspect of the present invention, since the battery is a dry battery, it is possible to cope with a high-performance electronic device that requires a heavy load discharge performance, and the production efficiency is improved and the quality is high and the reliability is improved. A high-power battery with high capacity and improved discharge performance.

  In an eleventh aspect of the present invention, a positive electrode material, a negative electrode material, a separator is interposed between the positive electrode material and the negative electrode material in the bottomed case, and is stored together with the electrolyte, and the opening of the bottomed case is sealed with a sealing body. In the manufacturing method of the electrochemical element that is sealed through, the concave and convex portions for holding the electrolytic solution are formed in the separator, and then stored in the bottomed case, and the electrolytic solution is injected and liquid-absorbed and impregnated to form the separator. Electrochemical element that can reduce the impregnation time of the positive electrode material, suppress the decrease of the capacity of the negative electrode material, improve the production efficiency, and improve the discharge performance by forming the uneven part to be almost flat Can be manufactured.

  In the twelfth aspect of the present invention, after injecting the electrolytic solution, the inside of the bottomed case is evacuated and impregnated with the electrolytic solution. Time can be reduced.

  In the thirteenth aspect of the present invention, since the electrochemical element is a battery, the time for impregnating the positive electrode material with liquid can be reduced, and a battery with improved production efficiency can be manufactured.

  In the fourteenth aspect of the present invention, since the battery is a dry battery, it is possible to promote the liquid material impregnation of the electrolyte into the positive electrode material, and the liquid absorption impregnation time can be reduced.

  In the fifteenth aspect of the present invention, a hollow battery-formed positive electrode material is housed in a bottomed case, and an uneven portion for retaining an electrolyte solution is formed on a separator, and then wound into a cylindrical shape to form a bottomed case After being accommodated in the hollow part of the positive electrode material accommodated in the inside, the electrolyte solution is injected, the positive electrode material and the separator are impregnated with liquid absorption, and the concavo-convex part formed on the separator is shaped to be substantially flat, By containing the negative electrode material and sealing the opening of the bottomed case with an insulating gasket with a sealing plate equipped with a negative electrode current collector, production efficiency can be improved, and high quality and reliability are achieved. It is possible to manufacture an electrochemical device as a high-power dry battery having a large capacity and improved discharge performance.

In the sixteenth aspect of the present invention, the positive electrode material formed in a hollow cylindrical shape from the opening of the bottomed case and the gelled negative electrode material are stored together with the electrolytic solution through the cylindrical separator, and then the bottomed case opening is opened. In an electrochemical device manufacturing apparatus in which a sealing body is placed and sealed by caulking, a loading portion for carrying a bottomed case containing a positive electrode material, a turntable for holding the carried bottomed case, and a turntable A drive unit that drives the separator, a molding unit that molds the concavo-convex part for retaining the liquid in the separator, a winding unit that molds the separator into a cylindrical shape from the strip-shaped separator, and an insertion unit that inserts the separator into the bottomed case And a dry cell with improved discharge performance, which can reduce the liquid material impregnation time of the positive electrode material, can suppress the decrease in the capacity of the negative electrode material, and can improve the production efficiency. Electrochemical element It is possible to elephants.

  In the seventeenth aspect of the present invention, the molding part is composed of a feed roller that feeds the strip-shaped separator and a molding roller that molds the concavo-convex part for retaining the liquid in the strip-shaped separator. Thus, it is possible to form the uneven portion on the separator.

  Hereinafter, an electrochemical element according to an embodiment of the present invention will be described with reference to the drawings, taking an alkaline manganese dry battery as an example. In addition, about the electrochemical element of this invention, batteries other than an alkaline manganese battery, a capacitor, etc. correspond.

  Further, the embodiment described below is an example embodying the present invention, and an example is shown as LR6, which is an alkaline manganese dry battery having an outer diameter of 14 mm and a height of 50 mm, for example, for explaining the present invention. However, it does not limit the technical scope of the present invention.

(Embodiment 1)
Hereinafter, the configuration of an alkaline manganese dry battery according to an embodiment of the present invention will be described with reference to the drawings. As shown in FIG. 1, a hollow cylindrical shape in contact with the inner peripheral surface of the bottomed case 4 is provided on the bottomed case 4 integrally formed with the bottom of the positive terminal, which is provided with a convex portion that becomes the positive terminal 1 at the bottomed portion. The positive electrode material 3 obtained by compression-molding a powdered positive electrode mixture is accommodated in the cathode, and an electrolyte solution (not shown) and a gel-like negative electrode separated by a bottom separator 8 and a cylindrical separator 2 in the hollow portion of the positive electrode material 3 The material 5 is accommodated.

  Further, the cylindrical separator 2 is formed with an uneven portion for retaining the electrolytic solution at the beginning of storage, impregnated with the electrolytic solution, and the uneven portion formed on the cylindrical separator is extended into a substantially flat state. By accommodating the negative electrode material 5, the negative electrode material 5 is in close contact between the positive electrode material 3 and the negative electrode material 5.

  Further, the opening of the bottomed case 4 is sealed by a sealing plate 7 through an insulating gasket 9, and a sealing plate 7 to which a negative electrode current collector rod 6 inserted into the negative electrode material 5 is connected and becomes a negative electrode terminal is attached. A cylindrical alkaline manganese dry battery 10 is configured.

  The positive electrode material 3 stored according to the type of the alkaline manganese dry battery 10 includes a plurality of positive electrode materials 3 formed by compressing and forming a powdered positive electrode mixture into a hollow cylindrical shape. For example, 2 to 6 positive electrode materials 3 may be accommodated.

  The positive electrode mixture was prepared by mixing a mixture of manganese dioxide and graphite in a weight ratio of 90:10 and an alkaline electrolyte in a weight ratio of 100: 3, sufficiently stirring, and then compression-molding into flakes. did. In addition, a 40% by weight sodium hydroxide aqueous solution is used as the alkaline electrolyte, and the flaky positive electrode mixture is pulverized and powdered and classified by sieving. The pelletized positive electrode material 3 was obtained by compression molding. In the embodiment of the present invention, four positive electrode materials 3 are accommodated in the bottomed case 4.

  Next, as shown in FIG. 2, the cylindrical separator 2 is produced by forming the concave and convex portions 11 for retaining the electrolytic solution in the cylindrical separator 2 in the vertical direction and winding the cylindrical separator 2 in a cylindrical shape. Further, the concavo-convex portion 11 communicates with the end portion of the cylindrical separator 2. Further, the number of windings of the cylindrical separator 2 is determined by the type of the alkaline manganese dry battery 10, and in the embodiment of the present invention, the cylindrical separator 2 having three windings is used.

The cylindrical separator 2 uses regenerated cellulose as a microporous film that allows only ions to pass through, and a nonwoven fabric made of chemical fibers is laminated on both sides thereof, and the thickness is preferably 0.02 mm to 0.3 mm. Moreover, it is good also as a shape which becomes low as the height of the uneven | corrugated | grooved part 11 shape | molded in the cylindrical separator 2 approaches the edge part of the cylindrical separator 2, ie, the terminal end side wound. As a result, when the concavo-convex portion 11 is extended, it can be easily extended.

  Next, the cylindrical separator 2 is stored along the inner periphery of the hollow portion of the positive electrode material 3 in a state where the cylindrical separator 2 is wrapped with a bottom separator 8 formed into a square having a width larger than the diameter of the cylindrical separator 2. In the same manner as the cylindrical separator 2, the bottom separator 8 uses regenerated cellulose as a microporous film that transmits only ions, and a nonwoven fabric made of chemical fibers is laminated on both sides thereof.

  FIG. 3A shows a cross-sectional view of the bottomed case 4 in which the cylindrical separator 2 is housed in the hollow portion of the positive electrode material 3. A gap 13 is formed between the uneven portion 11 formed on the cylindrical separator 2 and the positive electrode material 3, and an electrolyte (not shown) is poured into the gap 13 and the hollow portion of the cylindrical separator 2. And is allowed to stand for a time during which the positive electrode material 3 is impregnated with the electrolyte.

  In the prior art, an electrolytic solution is injected inside a cylindrical separator, and the positive electrode material and the electrolytic solution are not in direct contact with each other, and the electrolytic solution impregnated in the separator is in contact with the positive electrode material and impregnated in the positive electrode material. It was. In particular, since the entire separator is impregnated with the electrolytic solution using the capillary phenomenon, there is a problem that the impregnated state of the electrolytic solution is poor in a portion where the separator and the electrolytic solution are not in direct contact.

  In the present invention, as described above, the electrolytic solution is injected and retained in the gap portion 13, so that the electrolytic solution and the positive electrode material 3 are in direct contact with each other, and the liquid material impregnation into the positive electrode material 3 is promoted. The

  FIG. 3B shows a cross-sectional view of the bottomed case 4 in which the gelled negative electrode material 5 is accommodated after being allowed to stand for the liquid absorption impregnation time. The cylindrical separator 2 impregnated with the electrolytic solution has increased flexibility, and the electrolytic solution in the concavo-convex portion 11 formed on the cylindrical separator 2 is impregnated into the positive electrode material 2 to absorb the concavo-convex portion 11 and the positive electrode material 3. The electrolyte solution in the gap portion 13 formed therebetween decreases and is pressed by the electrolyte solution stored in the hollow portion of the cylindrical separator 2 from the hollow portion side, so that the concavo-convex portion 11 extends and becomes substantially flat.

  In this state, the negative electrode material 5 having a gel-like viscosity is accommodated in the hollow part of the cylindrical separator 2, so that pressure is applied in the outer peripheral direction from the hollow part side of the cylindrical separator 2, and the cylindrical separator 2 is molded. The concavo-convex portion 11 is further deformed and extended further, becomes a substantially flat state, and the outer periphery of the cylindrical separator 2 is in close contact with the inner periphery of the positive electrode material 3. Moreover, since the uneven part 11 is in contact with the inner periphery of the positive electrode material 3, the contact resistance for extending the uneven part 11 is reduced.

  Note that the gelled negative electrode material 4 comprises sodium polyacrylate as a gelling agent, a 40 wt% aqueous sodium hydroxide solution as an alkaline electrolyte, and zinc powder as a negative electrode active material in a weight ratio of 1:33:66. Mixed.

  After that, as shown in FIG. 1, the insulating gasket 9 is attached to the periphery, and the negative electrode current collector rod 6 at the center of the sealing plate 7 serving as the negative electrode terminal is inserted into the negative electrode material 5 and attached to the opening of the bottomed case 4. Then, the opening of the bottomed case 4 was bent inward to be caulked and sealed to produce an alkaline manganese dry battery 10 that was sealed.

  The positive electrode material 3 impregnated and impregnated with a lot of electrolytic solution uses the active material without draining the electrolytic solution during discharge. As a result, the effective utilization rate of the active material is improved, and an alkaline manganese dry battery with improved high-load discharge performance is obtained.

  Hereinafter, although the manufacturing method and manufacturing apparatus of the alkaline manganese dry battery concerning one embodiment of this invention are demonstrated in detail, referring a figure, this invention is not limited only to these.

  As shown in FIG. 4, a carry-in conveyor 31, which is a carry-in portion for carrying the bottomed case 4, is connected to the turntable 32. The bottom separator 8 is held on the turntable 32 and the cylindrical separator 2 is placed in the bottomed case 4. An insertion portion 36 to be inserted therein is disposed.

  Further, a winding part configured to form the cylindrical tubular separator 2 by winding the forming part 34 for forming the concavo-convex part 11 on the strip separator 30 that is the base of the cylindrical separator 2 and the strip separator 30 connected to the forming part 34. A part 35 is provided on the insertion part 36. By passing the strip-shaped separator 30 through the molding portion 34 and the winding portion 35, the cylindrical separator 2 in which the concavo-convex portion 11 capable of retaining the electrolytic solution is formed.

  Here, the shaping | molding part 34 and the winding part 35 are demonstrated, referring a figure further. As shown in FIG. 5, the belt-like separator 30 is attached to the molding part 34 and the winding part 35. In the molding part 34, the belt-like separator 30 was fed to the molding roller 42 by the feed roller 41, and irregularities were formed on the surface of the molding roller 42, and the irregular part 11 was molded on the belt-like separator 30 that passed through the molding roller 42.

  In FIG. 5, the uneven portion 11 only in the vertical direction is molded. However, the oblique uneven portion 11 is formed on the strip separator 30 by forming the uneven portion on the surface of the forming roller 42 obliquely. Further, the range and length of the concavo-convex portion 11 can define the concavo-convex portion 11 of the strip separator 30 by changing the concavo-convex portion of the forming roller 42.

  Further, the belt-like separator 30 having the concavo-convex portion 11 is wound between the auxiliary roller 44 and the winding guide by the winding pin 43 of the winding portion 35. In addition, although the frequency | count of winding of the cylindrical separator 2 is determined by the kind of the alkaline manganese dry battery 10, it is set as the cylindrical separator 2 which has the frequency | count of winding of 3 windings in one Embodiment of this invention. After winding, the cylindrical separator 2 in which the concavo-convex portion 11 was formed by cutting with a cutting cutter 46 was produced.

  Next, as shown in FIG. 4, in a state where the cylindrical separator 2 is wrapped by the bottom separator 8 held by the rotating disk 33, the winding pin 43 is moved and inserted into the hollow portion of the positive electrode material 3 and attached. Thereafter, the turntable 32 is driven by the drive unit 33 to convey the bottomed case 4 containing the positive electrode material 3 with the cylindrical separator 2 mounted in the hollow portion to the exit of the turntable 33, and a conveyer 37 serving as a transfer unit. In the next process.

  An electrolyte is poured into the bottomed case 4 transported to the next step, and the positive electrode material 3 is left for a period of time during which the electrolyte solution is impregnated. Then, the gelled negative electrode material 5 is accommodated, and the opening of the bottomed case 4 is opened. Was sealed by caulking through a sealing plate 7 equipped with an insulating gasket 9, and an alkaline manganese dry battery according to an embodiment of the present invention was produced.

  In addition, after accommodating the cylindrical separator 2 in the hollow part of the positive electrode material 3, the electrolytic solution may be injected, transported to the outlet of the rotating plate 33, and transported to the next process by the transport conveyor 37. Further, when the positive electrode material 3 is impregnated with the electrolyte, the bottomed case 4 is evacuated, and the air held in the cylindrical separator 2, the bottom separator 8, and the positive electrode material 3 is removed. The electrolytic solution enters the air space, and the time for impregnating the liquid can be further shortened.

(Embodiment 2)
In Embodiment 2 of the present invention, the cylindrical separator 2 in which the concave and convex portion 11 of the cylindrical separator 2 is formed at an inclined angle with respect to the end portion 15 of the cylindrical separator 2 as shown in FIG. 1 is an alkaline manganese dry battery having the same configuration as that of the first embodiment except that it is housed in the hollow portion of the positive electrode material 3 as shown in FIG.

First, as shown in FIG. 5, the strip-shaped separator 30 fed by the feeding roller 41 in the molding unit 34 molded the uneven part 11 by the molding roller 42. In FIG. 5, the surface of the forming roller 42 is provided with unevenness in the vertical direction. However, in the case of the unevenly inclined portion 11 shown in FIG. 6, the surface of the forming roller 42 with respect to the central axis of the forming roller 42 Inclined irregularities were provided.

  After winding the strip-shaped separator 30 in which the concavo-convex portion 11 was formed into a cylindrical shape with the winding portion 35, the cylindrical separator 2 in which the concavo-convex portion 11 having an inclined angle was formed by cutting was produced.

  The inclined angle of the concavo-convex portion 11 formed on the cylindrical separator 2 is preferably 60 ° or less with respect to the end portion 15, and most preferably 45 °. When tilted at an angle exceeding 60 °, a remarkable effect is exerted on the retention of the electrolytic solution. However, when pressure is applied in the direction in which the electrolytic solution is impregnated and the concavo-convex portion 11 is extended by the negative electrode material 5, The state where the concavo-convex portion 11 of the separator 2 becomes flat is poor, and the occupied volume of the cylindrical separator 2 in the bottomed case 4 increases. As a result, the storage capacity of the negative electrode material 5 is reduced.

  Next, as shown in FIG. 3A, the cylindrical separator 2 in which the uneven portion 11 having the inclined angle is formed is housed in the hollow portion of the positive electrode material 3 together with the bottom separator 8, and the gap portion 13 and the hollow portion of the cylindrical separator 2 are hollow. An electrolytic solution (not shown) is poured into the part, and the positive electrode material 3 is left for a period of time during which the electrolytic solution absorbs liquid. The inner periphery of the positive electrode material 3 is in direct contact with the electrolytic solution, so that the liquid electrolyte impregnation of the positive electrode material 3 is promoted.

  Thereafter, as shown in FIG. 3B, the gelled negative electrode material 5 is accommodated, and the uneven portion 11 having an inclined angle of the cylindrical separator 2 is extended into a substantially flat state, and the inner periphery and the cylindrical shape of the positive electrode material 3 are formed. The outer periphery of the separator 2 adhered. Further, the opening of the bottomed case 4 was caulked and sealed through a sealing plate 7 equipped with an insulating gasket 9 to produce an alkaline manganese dry battery 10 according to an embodiment of the present invention.

(Embodiment 3)
In Embodiment 3 of the present invention, the concavo-convex portion 11 is formed on the winding end side of the tubular separator 2 wound so that the concavo-convex portion 11 of the tubular separator 2 is formed into a tubular shape as shown in FIG. The alkaline manganese dry battery has the same configuration as that of the first embodiment except that there is no smooth surface 12.

  First, as shown in FIG. 5, the strip-shaped separator 30 fed by the feeding roller 41 in the molding unit 34 molded the uneven part 11 by the molding roller 42. After winding the strip-shaped separator 30 having the concavo-convex portion 11 into a cylindrical shape with the winding portion 35, when cutting, the end portion of the concavo-convex portion 11 is cut without leaving the smooth surface 12, and wound. A cylindrical separator 2 having a smooth surface 12 having no concavo-convex portion 11 on the end side is prepared.

  Next, as shown in FIG. 3A, the cylindrical separator 2 is housed in the hollow portion of the positive electrode material 3 together with the bottom separator 8, and an electrolytic solution (not shown) is placed in the gap portion 13 and the hollow portion of the cylindrical separator 2. The solution is poured and allowed to stand for a time during which the positive electrode material 3 is impregnated with the electrolyte.

  After that, the gelled negative electrode material 5 is accommodated as shown in FIG. 3B, and when the uneven portion 11 of the cylindrical separator 2 is extended, the smooth surface 12 without the uneven portion 11 extends in the direction in which the uneven portion 11 extends. It played the role of a guide so that it might become easy, and it was easy to become a substantially flat state, and the outer periphery of the positive electrode material 3 and the outer periphery of the cylindrical separator 2 adhered. Further, the opening of the bottomed case 4 was caulked and sealed through a sealing plate 7 equipped with an insulating gasket 9 to produce an alkaline manganese dry battery 10 according to an embodiment of the present invention.

(Embodiment 4)
In Embodiment 4 of this invention, the uneven | corrugated | grooved part 11 which retains the electrolyte solution of the cylindrical separator 2 is shown in FIG.
As shown in (a) and (b), the first embodiment is the same as the first embodiment except that an uneven portion is formed on the opening side of the bottomed case, that is, formed so as to extend from the intermediate portion of the cylindrical separator 2 to the end face. This is an alkaline manganese dry battery having the same configuration as the above.

  First, as shown in FIG. 5, the strip-shaped separator 30 fed by the feeding roller 41 in the molding unit 34 molded the uneven part 11 by the molding roller 42. In FIG. 5, the surface of the forming roller 42 is provided with vertical unevenness. However, in the case of the uneven portion 11 formed from the intermediate portion of the cylindrical separator 2 shown in FIGS. 8A and 8B to the end surface. The surface of the molding roller 42 was provided with unevenness from the middle portion to the end portion of the molding roller 42.

  The strip separator 30 having the concavo-convex portion 11 is wound into a cylindrical shape by the winding portion 35 and then cut and cut into a cylindrical separator 2 having the concavo-convex portion 11 formed from the intermediate portion of the cylindrical separator 2 to the end face. Produced. In addition, you may provide the smooth surface 12 as shown in FIG.

  As shown in FIG. 3 (a), the bottom separator 8 is housed in the hollow portion of the positive electrode material 3, and an electrolytic solution (not shown) is injected into the gap portion 13 and the hollow portion of the cylindrical separator 2. The electrolyte solution is left for a period of time for impregnation with the liquid.

  As the electrolyte injected into the inside of the cylindrical separator 2 crawls in the direction of the opening of the bottomed case 4 due to capillary action, the electrolyte directly contacts the inner periphery of the positive electrode material 3 on the opening side. The liquid material impregnation into the positive electrode material 3 is promoted.

  Thereafter, as shown in FIG. 3B, the gelled negative electrode material 5 is accommodated, and the concavo-convex portion 11 of the cylindrical separator 2 is extended into a substantially flat state, and the inner periphery of the positive electrode material 3 and the outer periphery of the cylindrical separator 2 are obtained. Stuck. Further, the opening of the bottomed case 4 was caulked and sealed through a sealing plate 7 equipped with an insulating gasket 9 to produce an alkaline manganese dry battery 10 according to an embodiment of the present invention.

  As described above, the separator 2 after being impregnated with the electrolytic solution has a smaller space occupied by the separator 21 than before the impregnation, so that a high-capacity alkaline manganese dry battery that can effectively use the space in which the negative electrode material 5 can be stored can be obtained. become. The separator 2 in the present invention may be composed of two or more separators. Furthermore, you may use combining the separator which provided the uneven | corrugated | grooved part 11, and the flat separator which does not provide the uneven | corrugated | grooved part 11. FIG.

  As described above, according to the present invention, the positive electrode material and the separator can be efficiently impregnated with the electrolytic solution, and the space occupied by the separator after impregnating the electrolytic solution can be reduced. As a result, it is possible to provide a high-capacity electrochemical device and a method for producing the same, and it is useful as a power source for highly functional electronic devices that require high load discharge performance, such as digital cameras and portable music players.

The half cross-sectional front view of the electrochemical element in one embodiment of this invention The schematic diagram of the cylindrical separator in one embodiment of this invention (A) Schematic cross-sectional view of the separator before storing the negative electrode material in one embodiment of the present invention, (b) Schematic cross-sectional view of the separator after storing the negative electrode material in one embodiment of the present invention. The schematic diagram of the manufacturing apparatus of the electrochemical element in one embodiment of this invention The schematic diagram of the winding part and shaping | molding part of the manufacturing apparatus in one embodiment of this invention The schematic diagram of the another cylindrical separator in one embodiment of this invention The schematic diagram of the another cylindrical separator in one embodiment of this invention (A) Schematic diagram of a cylindrical separator in which a vertical concavo-convex portion is formed in the intermediate portion in one embodiment of the present invention, (b) Schematic diagram of a cylindrical separator formed by inclining the concavo-convex portion in the same intermediate portion. (A) Schematic cross-sectional view of a conventional alkaline manganese dry battery, (b) Schematic vertical cross-sectional view of a conventional alkaline manganese dry battery

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Positive electrode terminal 2 Cylindrical separator 3 Positive electrode material 4 Case with bottom 5 Negative electrode material 6 Negative electrode current collecting rod 7 Sealing plate 8 Bottom separator 9 Insulating gasket 10 Alkali manganese dry cell 11 Uneven portion 12 Smooth surface 13 Gap portion 15 End portion 30 Strip separator 31 Carry-in conveyor 32 Turntable 33 Drive unit 34 Molding unit 35 Winding unit 36 Insertion unit 37 Conveyor 41 Feed roller 42 Molding roller 43 Winding pin 44 Auxiliary roller 45 Winding guide 46 Cutting cutter

Claims (17)

  In an electrochemical device in which a positive electrode material, a negative electrode material, a separator interposed between the positive electrode material and the negative electrode material, and an electrolyte are stored in a bottomed case, and an opening of the bottomed case is sealed with a sealing body, The separator is formed with a concave and convex portion for retaining an electrolytic solution at the beginning of storage in the bottomed case, and the concave and convex portion is configured to be substantially flat by impregnation with the electrolytic solution. Electrochemical element to do.   The electrochemical element according to claim 1, wherein a plurality of concave and convex portions connected to the separator are formed.   The electrochemical device according to claim 1, wherein the uneven portion formed in the separator is formed so as to communicate with an end portion of the separator in a direction toward the opening of the bottomed case.   The electrochemical device according to claim 1, wherein the uneven portion formed on the separator is formed at an inclined angle with respect to the end portion of the separator.   The electrochemical device according to claim 1, wherein the uneven portion formed in the separator is in contact with the positive electrode material.   The electrochemical element according to claim 2, wherein the height of the concavo-convex portion formed on the separator becomes lower as it approaches the end of the separator.   The electrochemical device according to claim 1, wherein the separator has an uneven portion formed on the opening side of the bottomed case.   The electrochemical device according to any one of claims 1 to 7, wherein a smooth surface without an uneven portion is formed on a terminal end side of the separator wound so as to form a cylinder.   The electrochemical device according to claim 1, wherein the electrochemical device is a battery.   The electrochemical device according to claim 9, wherein the battery is a dry battery.   An electrochemical element in which a positive electrode material, a negative electrode material, a separator is interposed between the positive electrode material and the negative electrode material, and is stored together with an electrolyte, and the opening of the bottomed case is sealed through a sealing body in a bottomed case. In the manufacturing method, after forming an uneven portion for retaining the electrolytic solution in the separator, the recessed portion is accommodated in the bottomed case, poured into the electrolyte, impregnated with liquid, and the uneven portion formed on the separator is substantially omitted. A method for producing an electrochemical element, wherein the electrochemical element is shaped to be flat.   The method for producing an electrochemical element according to claim 11, wherein after injecting the electrolytic solution, the inside of the bottomed case is evacuated and impregnated with the electrolytic solution.   The method for producing an electrochemical element according to claim 11, wherein the electrochemical element is a battery.   The method for producing an electrochemical element according to claim 13, wherein the battery is a dry battery. The positive electrode material for a dry battery formed into a hollow shape is housed in the bottomed case, and after forming an uneven portion for retaining an electrolyte solution in the separator, it is wound into a cylindrical shape and stored in the bottomed case. After being accommodated in the hollow portion of the positive electrode material, the electrolyte solution is injected to impregnate the positive electrode material and the separator with liquid, and the uneven portion formed on the separator is formed to be substantially flat, 15. The electrochemical device according to claim 14, wherein the negative electrode material is accommodated, and the opening of the bottomed case is caulked and sealed with an insulating gasket with a sealing plate having a negative electrode current collector. Method.   After storing the positive electrode material and the gel-like negative electrode material formed in a hollow cylindrical shape from the opening of the bottomed case together with the electrolyte solution through a cylindrical separator, a sealing body is placed on the opening of the bottomed case. In the electrochemical element manufacturing apparatus for caulking and sealing, a carry-in unit for carrying in the bottomed case containing the positive electrode material, a turntable for holding the carried bottomed case, and a drive unit for driving the turntable; A molding part for forming an uneven part for retaining liquid in the separator, a winding part for molding the separator into a tubular shape from a strip-shaped separator, and an insertion part for inserting the separator into the bottomed case, An apparatus for manufacturing an electrochemical element, characterized in that it comprises a transfer section for transferring to the next process.   17. The apparatus for producing an electrochemical element according to claim 16, wherein the forming part is constituted by a feed roller for feeding a strip-shaped separator and a forming roller for forming a concavo-convex part for retaining liquid in the strip-shaped separator. .

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