Process for Production and Apparatus for Production of Laminate

• US 20080083499A1
• Filed: 10/19/2005
• Published: 04/10/2008
• Est. Priority Date: 10/21/2004
• Status: Abandoned Application

• Current Assignee: Sumitomo Chemical Company Limited
• Original Assignee: Sumitomo Chemical Company Limited
• Inventors: Nodono, Mitsunori
• Application Number:
  US11/665,371
• Publication Number:
  US 20080083499A1
• Time in Patent Office: Days
• US Class Current: 156/324
• CPC Class Codes: B32B 2037/243 Coating
• CPC Class Codes: B32B 2305/026 Porous
• CPC Class Codes: B32B 2323/04 Polyethylene
• CPC Class Codes: B32B 2367/00 Polyesters, e.g. PET, i.e. polyethylene terephthalate
• CPC Class Codes: B32B 2457/18 Fuel cells
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/36 comprising polyesters
• CPC Class Codes: B32B 37/0007 involving treatment or provisions in order to avoid deformation or air inclusion, e.g. to improve surface quality
• CPC Class Codes: B32B 37/0038 involving application of liquid to the layers prior to lamination, e.g. wet laminating B32B37/12 takes precedence
• CPC Class Codes: H01B 1/122 Ionic conductors
• CPC Class Codes: H01M 10/0565 Polymeric materials, e.g. gel-type or solid-type
• CPC Class Codes: H01M 2300/0082 Organic polymers
• CPC Class Codes: H01M 8/1018 Polymeric electrolyte materials
• CPC Class Codes: H01M 8/1023 having only carbon, e.g. polyarylenes, polystyrenes or polybutadiene-styrenes
• CPC Class Codes: H01M 8/1025 having only carbon and oxygen, e.g. polyethers, sulfonated polyetheretherketones [S-PEEK], sulfonated polysaccharides, sulfonated celluloses or sulfonated polyesters
• CPC Class Codes: H01M 8/1027 having carbon, oxygen and other atoms, e.g. sulfonated polyethersulfones [S-PES]
• CPC Class Codes: H01M 8/103 having nitrogen, e.g. sulfonated polybenzimidazoles [S-PBI], polybenzimidazoles with phosphoric acid, sulfonated polyamides [S-PA] or sulfonated polyphosphazenes [S-PPh]
• CPC Class Codes: H01M 8/1032 having sulfur, e.g. sulfonated-polyethersulfones [S-PES]
• CPC Class Codes: H01M 8/1034 having phosphorus, e.g. sulfonated polyphosphazenes [S-PPh]
• CPC Class Codes: H01M 8/1037 : having silicon, e.g. sulfonated crosslinked polydimethylsiloxanes
• CPC Class Codes: H01M 8/1039 : halogenated, e.g. sulfonated polyvinylidene fluorides
• CPC Class Codes: H01M 8/1053 : consisting of layers of polymers with at least one layer being ionically conductive
• CPC Class Codes: H01M 8/106 : characterised by the chemical composition of the porous support
• CPC Class Codes: H01M 8/1069 : characterised by the manufacturing processes
• CPC Class Codes: H01M 8/1081 : starting from solutions, dispersions or slurries exclusively of polymers
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02E 60/50 : Fuel cells
• CPC Class Codes: Y02P 70/50 : Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10T 156/1798 : with liquid adhesive or adhesive activator applying means

Abstract

A process for production of a laminate in which creasing is suppressed. The process for production of a laminate of the invention comprise a coating step for coating a porous membrane 1 with a coating liquid, and a laminating step for moving the porous membrane 1 coated with the coating liquid along the circumferential surface of a feed roller 14, moving the porous membrane 1 coated with the coating liquid along the circumferential surface of a lamination roller 30 together with a supporting substrate 2, and laminating the porous membrane 1 coated with the coating liquid and the supporting substrate 2 to obtain a laminate 3a,

wherein assuming the radius of the feed roller 14 is R1 (cm), the radius of the lamination roller 30 is R2 (cm), the distance between the central axes of the feed roller 14 and the lamination roller 30 is L (cm), the thickness of the porous membrane 1 is T1 (cm), and the thickness of the supporting substrate 2 is T2 (cm), a condition represented by the following expression (1) is satisfied.
R1+R2+T1+T2≦L≦R1+R2+100  (1)

Claims

1. A process for production of a laminate comprising:

a coating step for coating a porous membrane with a coating liquid, and

a laminating step for moving the porous membrane coated with the coating liquid along the circumferential surface of a feed roller, moving the porous membrane coated with the coating liquid along the circumferential surface of a lamination roller together with a supporting substrate, and laminating the porous membrane coated with the coating liquid and the supporting substrate to obtain a laminate,

wherein assuming the radius of the feed roller is R1 (cm), the radius of the lamination roller is R2 (cm), the distance between the central axes of the feed roller and the lamination roller is L (cm), the thickness of the porous membrane is T1 (cm), and the thickness of the supporting substrate is T2 (cm), a condition represented by the following expression (1) is satisfied.

R1+R2+T1+T2≦

L≦

R1+R2+100 

 

(1)

2. The process for production of a laminate of claim 1, wherein the laminate is formed so that the porous membrane coated with the coating liquid, rather than the supporting substrate, may come to the outer side on the circumferential surface of the lamination roller.

3. The process for production of a laminate of claim 2, wherein the central angle A1 (degrees) of an arc contacting with the lamination roller and the laminate satisfies a condition represented by the following expression (2).

10≦

A1≦

180 

 

(2)

4. The process for production of a laminate of claim 1, wherein the laminating step is further followed by a conveying step for moving the laminate along the circumferential surface of the conveying roller so that the porous membrane may come to the outer side.

5. The process for production of a laminate of claim 4, wherein the central angle A2 (degrees) of an arc contacting with the conveying roller and the laminate satisfies a condition represented by the following expression (3).

10≦

A2≦

180 

 

(3)

6. The process for production of a laminate of claim 1, wherein in the coating step and the laminating step, a tension F (kg/cm) is applied to satisfy a condition represented by the following expression (4) to the porous membrane in its conveying direction.

0.01≦

F≦

10 

 

(4)

7. The process for production of a laminate of claim 1, wherein the coating liquid is a liquid containing a polymer electrolyte.

8. An apparatus for production of a laminate comprising:

a coating means for coating a porous membrane with a coating liquid,

a feed roller for moving the porous membrane coated with the coating liquid along the circumferential surface, and

a lamination roller for moving the porous membrane after moving along the circumferential surface of the feed roller along the circumferential surface together with a supporting substrate, and laminating the porous membrane and the supporting substrate to obtain a laminate,

wherein assuming the radius of the feed roller is R1 (cm), the radius of the lamination roller is R2 (cm), the distance between the central axes of the feed roller and the lamination roller is L (cm), the thickness of the porous membrane is T1 (cm), and the thickness of the supporting substrate is T2 (cm), a condition represented by the following expression (1) is satisfied.

R1+R2+T1+T2≦

L≦

R1+R2+100 

 

(1)

9. The apparatus for production of a laminate of claim 8, wherein the central angle A1 (degrees) of an arc contacting with the lamination roller and the laminate satisfies a condition represented by the following expression (2).

10≦

A1≦

180 

 

(2)

10. The apparatus for production of a laminate of claim 8, further comprising a conveying roller for moving the laminate formed by the lamination roller along the circumferential surface so that the porous membrane may come to the outer side.

11. The apparatus for production of a laminate of claim 10, wherein the central angle A2 (degrees) of an arc contacting with the conveying roller and the laminate satisfies a condition represented by the following expression (3).

10≦

A2≦

180 

 

(3)

12. The apparatus for production of a laminate of claim 8, further comprising a tension applying means for applying a tension F (kg/cm) to satisfy a condition represented by the following expression (4) to the porous membrane in its conveying direction.

0.01≦

F≦

10 

 

(4)