Laminator roller assembly for manufacturing dry electrodes for energy storage devices

Abstract

The invention relates to a laminating machine roller assembly for manufacturing a dry electrode of an energy storage device. The laminating machine roller assembly includes: a first roller; and a second roller disposed adjacent to the first roller, the first roller and the second roller configured to: receive a combined layer interposed between the first roller and the second roller while the first roller and the second roller rotate, the combined layer including a metal layer and an electrochemically active self-supporting film disposed on the metal layer, the electrochemical active self-supporting membrane is formed by a dry active material; and forming a plurality of membrane portions of the electrochemically active self-supporting membrane, the plurality of membrane portions being intermittently arranged on the metal layer in a longitudinal direction of the metal layer; and an output combination layer in which the metal layer is exposed by the plurality of film portions intermittently arranged.

Description

[0001] This application is a divisional application of the Chinese national phase application of the PCT application with an application date of November 7, 2019, an international application number of PCT / US2019 / 060257, and an invention name of "Intermittently coated dry electrode for energy storage device and method for manufacturing the same". The entry date of the Chinese national phase application into the Chinese national phase is July 7, 2021, and the application number is 201980088315.7. All the contents are incorporated herein by reference.

[0002] Related Applications

[0003] This application claims priority to U.S. Patent Application No. 16 / 675,012, filed on November 5, 2019, and the benefit of Provisional Application No. 62 / 757,609, filed in the U.S. Patent and Trademark Office on November 8, 2018, the entire contents of which are incorporated herein by reference. Technical Field

[0004] The described technology relates generally to energy storage devices, and in particular to methods for making discontinuously coated dry electrodes for energy storage devices and energy storage devices including the discontinuously coated dry electrodes. Background Art

[0005] Electrical energy storage cells are widely used to provide power to electronic, electromechanical, electrochemical and other useful devices, such as hybrid vehicles, plug-in hybrid vehicles and pure electric vehicles. Such cells include batteries such as primary chemical cells and secondary (rechargeable) batteries, fuel cells and various capacitors, including supercapacitors. Increasing the operating power and energy of energy storage devices, including capacitors and batteries, would be desirable to enhance energy storage, increase power capabilities and broaden real-world use cases. Summary of the invention

[0006] To summarize the described technology, certain objects and advantages of the described technology are described herein. Not all such objects or advantages may be achieved in any particular embodiment of the described technology. Thus, for example, those skilled in the art will recognize that the described technology may be implemented or performed in a manner that achieves or optimizes one advantage or a group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.

[0007] One inventive aspect is a discontinuously coated dry electrode for an energy storage device.

[0008] Another aspect is a method of making a discontinuously coated dry electrode for an energy storage device.

[0009] Another aspect is an energy storage device including a discontinuously coated dry electrode.

[0010] On the other hand is a method for manufacturing a dry electrode for an energy storage device, comprising: providing a metal layer; providing an electrochemically active self-supporting film formed of a dry active material; combining the electrochemically active self-supporting film and the metal layer to form a combined layer; and removing a portion of the electrochemically active self-supporting film from the combined layer so that the electrochemically active self-supporting film is intermittently formed on the metal layer along the longitudinal direction of the metal layer.

[0011] On the other hand is a dry electrode for an energy storage device, comprising: a metal layer; and an electrochemically active self-supporting film formed by a dry active material, wherein the electrochemically active self-supporting film comprises a plurality of film portions intermittently formed on the metal layer along a longitudinal direction of the metal layer to expose a portion of the metal layer.

[0012] On the other hand is an energy storage device, comprising: a first electrode; a second electrode; and an isolation member inserted between the first electrode and the second electrode, wherein each of the first electrode and the second electrode comprises: a metal layer; and an electrochemically active self-supporting film formed of a dry active material, wherein the electrochemically active self-supporting film comprises a plurality of film portions intermittently formed on the metal layer along a longitudinal direction of the metal layer to expose a portion of the metal layer.

[0013] On the other hand is a method for manufacturing a dry electrode for an energy storage device, comprising: providing a metal layer; providing a first electrochemically active self-supporting film formed of a dry active material; providing a second electrochemically active self-supporting film formed of a dry active material; combining the first electrochemically active self-supporting film and the second electrochemically active self-supporting film with the metal layer to form a combined layer, so that the metal layer is interposed between the first electrochemically active self-supporting film and the second electrochemically active self-supporting film; and removing a first portion of the first electrochemically active self-supporting film and a second portion of the second electrochemically active self-supporting film from the combined layer, so that each of the first electrochemically active self-supporting film and the second electrochemically active self-supporting film is intermittently formed on the metal layer along the longitudinal direction of the metal layer.

[0014] Any feature of one aspect is applicable to all aspects identified herein. In addition, any feature of one aspect may be combined with other aspects described herein independently, partially or completely in any manner, for example, one, two or three or more aspects may be combined in whole or in part. In addition, any feature of one aspect may be made optional for other aspects. Any aspect of a method for manufacturing a dry electrode for an energy storage device or an energy storage device may include another aspect of a dry electrode for an energy storage device or an energy storage device, and any aspect of a dry electrode for an energy storage device or an energy storage device may be configured to perform a method for manufacturing a dry electrode for an energy storage device or an energy storage device. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 is a block diagram illustrating a process for fabricating a dry electrode for an energy storage device.

[0016] Figure 2 An electrochemically active free-standing film is shown placed on a continuously adhesive-coated metal foil prior to applying heat and pressure thereto.

[0017] Figure 3 An electrochemically active free-standing film laminated to a continuously adhesive-coated metal foil after applying heat and pressure thereto is shown.

[0018] Figure 4 An example continuously coated dry electrode is shown.

[0019] Figure 5 An electrochemically active free-standing film is shown placed on a metal foil intermittently coated with adhesive prior to applying heat and pressure thereto.

[0020] Figure 6 An electrochemically active free-standing film is shown laminated to a metal foil intermittently coated with adhesive after applying heat and pressure thereto.

[0021] Figure 7 An example intermittently coated dry electrode is shown according to one embodiment.

[0022] Figure 8 An electrochemically active free active membrane according to one embodiment is shown.

[0023] Fig. 9 An example metal foil according to one embodiment is shown, the metal foil including metal foil portions intermittently coated with adhesive and uncoated metal foil portions.

[0024] Fig.10 A discontinuously coated dry electrode according to another embodiment is shown.

[0025] Fig.11 An electrochemically active free active film disposed on an example uncoated metal foil is shown according to another embodiment.

[0026] Fig.12 A laminator roll assembly is shown according to one embodiment that produces a discontinuously coated electrode laminate.

[0027] Fig.13 According to one embodiment, Fig.12 The laminator roller assembly produces the intermittently coated dry electrodes.

[0028] Fig.14An electrochemically active free active film disposed on an example uncoated metal foil is shown according to another embodiment.

[0029] Fig.15 A laminator roller assembly according to another embodiment is shown.

[0030] Fig.16 According to another embodiment, Fig.15 The laminator roller assembly produces the intermittently coated dry electrodes.

[0031] Fig.17 A laminator roller assembly is shown according to one embodiment, which produces a Fig.18 Asymmetric intermittent double-sided coated dry laminate shown.

[0032] Fig.18 According to one embodiment, Fig.17 A cross-sectional view of an asymmetrical intermittent double-sided coated dry laminate produced by a laminator roll assembly is shown.

[0033] Fig.19 A laminator roller assembly according to another embodiment is shown, which produces a laminator roller assembly Fig. 20 Asymmetric intermittent double-sided coated dry laminate shown.

[0034] Fig. 20 According to another embodiment, Fig.19 A cross-sectional view of an asymmetrical intermittent double-sided coated dry laminate produced by a laminator roll assembly is shown.

[0035] Fig.21 An intermittently coated dry electrode is shown to be connected to an electrode sheet according to one embodiment.

[0036] Fig. 22 An energy storage device according to one embodiment is shown.

[0037] Fig.23 A method of manufacturing a dry electrode for an energy storage device according to one embodiment is shown.

[0038] Fig.24 A method of manufacturing a dry electrode for an energy storage device according to another embodiment is shown. DETAILED DESCRIPTION

[0039] Various embodiments of dry electrodes for energy storage devices are provided herein. Specifically, in certain embodiments, the energy storage devices disclosed herein include intermittently coated dry electrodes. For example, the described technology can provide dry electrode coating capabilities to include intermittent patterns for cylindrical wound batteries, wherein current collection is designed to span the width of the electrode. Methods for manufacturing such intermittently coated dry electrodes are also provided. The disclosed embodiments can provide a simplified and cost-effective electrode coating process for energy storage devices.

[0040] Energy storage devices such as lithium-ion batteries have been relied upon as a power source in many commercial and industrial applications, such as in consumer devices, production devices, and battery-powered vehicles. However, the demand for energy storage devices continues to grow and grow rapidly. For example, the automotive industry is developing vehicles that rely on compact and efficient energy storage, such as plug-in hybrid vehicles and pure electric vehicles. Lithium-ion batteries are well suited to meet future needs.

[0041] The key components of energy storage devices for storing electrical potential are electrodes. The electrochemical capabilities of electrodes (e.g., the capacity and efficiency of battery electrodes) are controlled by various factors. For example, the distribution of active materials, binders, and additives; the physical properties of the materials, such as particle size and surface area of ​​the active materials; the surface properties of the active materials; and the physical properties of the electrode films, such as density, porosity, cohesion, and adhesion to conductive elements. Dry processing methods traditionally use high shear and / or high pressure processing steps to break down and mix electrode film materials, which can promote structural advantages over electrode films produced using wet processing.

[0042] Figure 1 1 is a block diagram illustrating a process 10 for making a dry electrode for an energy storage device. As used herein, the term "dry" means that no liquid phase solvents and additives are used in the mixing and coating of the electrode during the process steps described herein, except during the final impregnation electrolyte step. Figure 1The process 10 shown begins with dry mixing 18 dry active material particles 12, dry conductive particles 14 and dry binder particles 16 to form a dry mixture. In addition, dry conductive particles 21 and dry binder particles 23 are also dry mixed 19 to form a dry mixture, which can be provided to an optional dry fibrillation step 26 or 29. In the dry fibrillation step 20, the dry mixture is fibrillated using, for example, a jet mill (not shown). During the dry fibrillation step 20, high shear forces are applied to the dry mixture to physically stretch it and form a thin mesh fiber network. In the dry feed step 22 or 29, the corresponding separate mixtures of the dry particles formed in steps 19 and 20 are provided to the corresponding containers (not shown) to form dry films. Subsequently, the dry film is dry compacted and calendered by a roller mill or calender 24 to provide an embedded / mixed dry film or a self-supporting electrode film (or an electrochemically active self-supporting film). The embedded / mixed dry film is attached or bonded to a current collector (e.g., a metal foil) 28. A more detailed process for making an embedded / hybrid dry film including the type of material that forms the dry film and the material that forms the current collector is disclosed in US Pat. No. 7,352,558, the entire contents of which are incorporated herein by reference.

[0043] Relative to the typical electrode film manufactured using wet processing, the self-supporting dry electrode film manufactured above can provide improved properties. For example, the dry electrode film provided herein can provide one or more of improved film strength, improved cohesion, improved adhesion, improved electrical performance or reduced defect incidence. Defects can include holes, cracks, surface pits in the electrode film. Adhesion can be adhesion to the current collector. The electrical performance can be specific capacity. Film strength can be tensile strength.

[0044] The materials and methods provided herein can be implemented in various energy storage devices. As provided herein, the energy storage device can be a capacitor, a lithium ion capacitor (LIC), a supercapacitor, a battery (such as a lithium ion battery) or a hybrid energy storage device combining two or more of the foregoing aspects.

[0045] Figures 2 to 4 The process of manufacturing an example dry electrode is shown. The example dry electrode can be an anode or a cathode. Figure 2, the electrochemically active self-supporting film 34 is placed on the metal foil 30. The electrochemically active self-supporting film 34 can be formed by an electrochemically active material. The electrochemically active material can be an anode active material or a cathode active material. The anode active material can include, for example, graphite, silicon, tin, lithium titanate, lithium metal, lithium alloy compounds, or a composite derived from these compositions. The cathode active material can include, for example, nickel manganese cobalt oxide (NMC), nickel cobalt aluminum oxide (NCA), lithium cobalt oxide (LCO), lithium iron phosphate (LFP), activated carbon, lithium manganese oxide (LMO), lithium nickel manganese oxide (LNMO), iron sulfide, sulfur, or a composite derived from these compositions. The metal foil 30 can be formed by, for example, copper, aluminum, titanium, stainless steel, or a combination thereof. The description of this paragraph applies to the remaining embodiments.

[0046] The metal foil 30 includes a metal foil portion 32 continuously coated with an adhesive and an uncoated metal foil portion 36. The metal foil portion 32 continuously coated with an adhesive is continuously coated with an adhesive along the longitudinal direction of the metal foil 30. The electrochemically active self-supporting film 34 can be placed on most of the metal foil portion 32 coated with an adhesive. Figure 2 As shown, the active self-supporting film 34 may also be placed on a portion of the uncoated metal foil portion 36. In some embodiments, the active self-supporting film 34 may not be placed on any portion of the uncoated metal foil 36 (not shown). After applying heat and / or pressure to the active self-supporting film 34 and the adhesive-coated metal foil portion 32, the active self-supporting film 34 is laminated to the adhesive-coated metal foil portion 32 ( Figure 3 ). Figure 3 The laminated film includes areas of the electrochemically active self-supporting film 42 that are not attached and areas of the film laminated to the coated metal foil 44. The portion of the adhesive-coated metal foil 32 that is not directly attached to the active self-supporting film 34 can be removed by, for example, peeling or cutting. A continuously adhesive-coated dry electrode 46 ( Figure 4 ). Figure 4 The dry electrode 46 includes an uncoated metal foil portion 48, which can be used to electrically connect the dry electrode 46 to other electrical components located inside the final electrical device, such as an electrode sheet. The size or dimensions of the uncoated foil portion 48 generally constitutes a significant portion of the final dry electrode 46. Therefore, the size of the dry electrode 46 continuously coated with adhesive can be limited by the size of the uncoated portion 48.

[0047] Figures 5 to 7 A process for manufacturing an example intermittently coated dry electrode according to one embodiment is shown. Figure 5, the electrochemically active self-supporting film 56 is placed on the metal foil 58. The metal coil 58 is discontinuously or intermittently coated with an adhesive or adhesive layer (not shown) along its longitudinal direction. The adhesive layer can be formed by one or more of glue or thermoplastics such as polyethylene (PE), polyvinyl chloride (PVC), polystyrene (PS), acrylic resin, fluoropolymer, polyester, polyimide, polyamide, polyurethane, polycarbonate, carbon or its combination. The adhesive layer can be conductive (for example, a carbon adhesive layer). The coating weight of the conductive adhesive layer can be in the range of about 1 gram / square meter / face to about 5 grams / square meter / face, wherein the dry coating density is about 0.2 grams / square centimeter / face to about 1.1 grams / square centimeter / face. The above coating weight and density can provide the best balance between the mechanical robust attachment of the self-supporting active film and the lower cost. For example, the conductive adhesive layer can be thin (minimum load weight) and the density is as low as possible (using the least carbon adhesive material). These weight and density values ​​are only examples, and other weight and density values ​​are also possible. This applies to the remaining embodiments. The metal coil 58 includes a coated portion 52 (or a metal foil portion intermittently coated with an adhesive) and an uncoated portion 54 (or an uncoated metal foil portion). The uncoated portion 54 is interposed between the adhesive coated portions 52. The uncoated portion 54 may be placed around the middle of the metal foil 58 along the longitudinal direction of the metal foil 58, however the position of the uncoated portion 54 is not limited thereto. The discontinuously coated metal foil 58 may be produced by, for example, gravure roll coating or slot die coating or screen printing or laser jet printing.

[0048] After applying heat and / or pressure to the stack (58, 56), the active self-supporting film 56 is laminated to the adhesive coated metal foil portion 52 ( Figure 6 ). Figure 6 The laminated film includes areas of the electrochemically active self-supporting film 62 that are not attached and areas of the film that are laminated to the coated metal foil 64. Figure 6 As shown, the region of the electrochemically active self-supporting film 62 that is not attached includes the upper and middle portions of the active self-supporting film 56 (see Figure 6 The area of ​​the film laminated to the coated metal foil 64 includes the left and right portions of the active self-supporting film 56 that vertically overlap the adhesive-coated metal foil portion 52 (see FIG. Figure 6 The lower area of ​​the image is shown by two arrows).

[0049] After removing the portion of the active self-supporting film 56 vertically overlapping the uncoated metal foil portion 54, a discontinuously or intermittently coated dry electrode 72 ( Figure 7). The peeling / trimming or removal of the overlapping portions of the unattached self-supporting film 62 may be performed using, for example, an air knife and / or vacuum. Since the uncoated metal foil portions 54 are not coated with adhesive and are therefore not bonded to the corresponding portions of the active self-supporting film 56, the Figures 2 to 4 Compared to the electrode shown with a continuously coated adhesive, the overlapping self-supporting film portions can be removed more easily. The dry electrode 72 includes two active self-supporting film portions 64a and 64b formed discontinuously or intermittently relative to each other. The dry electrode 72 includes an uncoated foil portion 54 for electrically connecting the electrode 72 to other elements such as an electrode sheet. The size of the uncoated portion 54 can be substantially smaller than Figure 4 The uncoated portion 48 of the dry electrode 46 is continuously coated in the film. For example, the width of the uncoated foil portion 54 can be 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20 mm, or any width in a range between any two of these values. In other embodiments, the width of the uncoated foil portion 54 can be 5 to 10, 10 to 20, 20 to 30, 30 to 40, or 40 to 50 mm or more. Therefore, Figures 5 to 7 The illustrated embodiments may provide a simplified and cost-effective dry electrode manufacturing process for energy storage devices.

[0050] Figures 8 to 10 A process for manufacturing an example dry electrode according to another embodiment is shown. Figure 8 , an electrochemically active self-supporting film 80 is shown. The active self-supporting film 80 can be compared to Figure 2 The active self-supporting film 34 shown and Figure 5 The active free-standing film 56 shown is longer. Fig. 9 A metal foil 90 is shown. Fig. 9 As shown, the metal foil 90 is coated with adhesive discontinuously or intermittently along its longitudinal direction. The active self-supporting film 80 may be similar in size to the metal foil 90. The metal coil 90 includes a coated portion 92 (or a metal foil portion intermittently coated with adhesive) and an uncoated portion 94 (or an uncoated metal foil portion). Fig. 9 As shown, coated portions 92 and uncoated portions 94 are formed alternately relative to each other. The discontinuously coated metal foil portions 92 may be formed by intermittently applying an adhesive (as described above) to the metal foil 90 via, for example, gravure roll coating, slot die coating, screen printing, or laser jet printing.

[0051] exist Fig. 9 and Fig.10, x represents the width of each uncoated metal foil portion 94 measured along the longitudinal direction of the metal foil 90, and y represents the width of each coated metal foil portion 92 / 102 measured along the longitudinal direction. Fig. 9 Only three groups of coated portions 92 and uncoated portions 94 are shown, but more pairs of coated portions and uncoated portions (not shown) can be formed. More pairs of coated portions and uncoated portions can be formed alternately relative to each other. It should be appreciated that the ratio of x / y can be any value, wherein y is generally greater than x, so that the width of the coated portion is greater than the value of the uncoated portion. In one embodiment, as discussed more fully below, width y relates to the circumference of the final electrode winding, so that when the laminate film is wound into a roller electrode form, each uncoated portion 94 is aligned with each other.

[0052] Similar to Figure 5 and Figure 6 After placing the active self-supporting film 80 on the intermittently adhesive-coated metal foil portion 92 and the uncoated metal foil portion 94 of the metal foil 90, heat and / or pressure may be applied to the stacked layers (80, 90) so that the active self-supporting film 80 is laminated onto the adhesive-coated metal foil portion 92. Likewise, the active self-supporting film 80 may not adhere or be very weakly attached to the uncoated metal foil portion 94 on which no adhesive is formed. Fig. 9 Three uncoated metal foil portions 94 are provided, so that Fig.10 The laminated film 100 in the embodiment will initially include three portions (not shown) of the active self-supporting film 80 vertically overlapping (before removing the three portions) the three uncoated metal foil portions 94, respectively. After removing the overlapping portions of the active self-supporting film 80, a discontinuously or intermittently coated dry electrode 100 ( Fig.10 ). Figures 5 to 7 The peeling or removal of the overlapping portion of the active self-supporting film 80 is performed in the same manner as discussed in the embodiment of FIG.

[0053] The electrode 100 includes intermittently coated portions 102 and uncoated foil portions 94. At least one of the uncoated foil portions 94 can be used to electrically connect the electrode 100 to other components such as electrode sheets. The size of each uncoated portion 94 can be substantially smaller than Figure 4 The uncoated portion 48 of the dry electrode 46 is continuously coated. Figures 8 to 10 The illustrated embodiments may also provide a simplified and cost-effective dry electrode manufacturing process for energy storage devices.

[0054] Figures 11 to 13 A process for manufacturing an example dry electrode according to another embodiment is shown. Fig.11, an electrochemically active self-supporting film 110 and a metal foil 120 without a binder coating are shown. The active self-supporting film 110 may have Figure 8 The active self-supporting film 80 shown has the same dimensions. Fig.12 Prior to the laminator roll process in the embodiment, the active self-supporting film 110 is placed on and aligned with the uncoated metal foil 120. To illustrate both the active self-supporting film 110 and the uncoated metal foil 120, Fig.11 The two elements 110 and 120 are shown slightly misaligned with each other, however the elements 110 and 120 will be aligned prior to the laminator roll process.

[0055] refer to Fig.12 , the active self-supporting film 110 and the uncoated metal foil 120 are inserted into the laminator roller assembly 130 and laminated by the laminator roller assembly 130. The laminator roller assembly 130 includes a pair of rollers 132 and 134. The rollers 132 and 134 may have substantially the same diameter. The rollers 132 and 134 may be formed of the same material or different materials having the same or similar hardness levels, so that a substantially uniform pressure is applied to the stacked layers (110, 120) by both rollers 132 and 134. The rollers 132 and 134 have openings 136 and 138, respectively. The openings 136 and 138 may have the same size. In one embodiment, the openings 136 and 138 may have the same width or circumferential length (x) and the same depth. In another embodiment, the openings 136 and 138 may have the same width (x), but may have different depths. Each of the openings 136 and 138 has a diameter similar to Fig.13 The width of each uncoated metal foil portion 144 is shown to be the same width (x). The length (y) of the remaining portion of each of the rollers 132 and 134 is the same as Fig.13 Each of the intermittently coated portions 142 is shown to be of the same width.

[0056] Those skilled in the art will appreciate that each of the laminating rollers 132 and 134 may have different x and y dimensions depending on the desired dimensions of the intermittently coated portion 142 and the uncoated metal foil portion 144. For example, as the width (x) of each uncoated metal foil portion becomes larger, the circumferential length of the opening also becomes larger. Conversely, as the width (x) of each uncoated metal foil portion becomes smaller, the circumferential length of the opening also becomes smaller. Once the x dimension is defined, the dimensions of the remaining portion (y) may be automatically defined.

[0057] exist Fig.12 During the lamination process, rollers 132 and 134 are positioned adjacent to each other so that openings 136 and 138 are as shown in FIG. Fig.12When the stacked layers (110, 120) are inserted between the rollers 132 and 134, the two layers (110, 120) are laminated to each other except for the portions passing through the openings 136 and 138 because the stacked layers (110, 120) are not squeezed by the rollers 132, 134 in the openings 136 and 138. The unsqueezed portion of the active self-supporting film 110 can be peeled off to form a Fig.13 An intermittently coated dry electrode 140 is shown. The stripping process may be performed in the same manner as described above with respect to the previous embodiments.

[0058] although Fig.12 Each of the rollers 132 and 134 includes an opening, but only one of the rollers 132 and 134 may have an opening. In this embodiment, during the lamination roller process, only one of the two layers (110, 120) is in direct contact with the rollers 132 and 134 in the opening area.

[0059] In another embodiment, each of rollers 132 and 134 may include a plurality of openings (not shown). In this embodiment, each roller may have more than Fig.12 The size of the rollers 132 and 134 shown. For example, two or more openings spaced apart from each other are formed in each of the rollers 132 and 134. These rollers can have the same size and the same number of openings. In addition, during the lamination roller process, the openings of each roller can be aligned with each other on the circumference so that the same portion of the active self-supporting film 110 forming the x region is not directly squeezed by any roller. The length of each opening can be the same as the width (x) of each uncoated metal foil portion 144. The distance between adjacent openings can be the same as the width (y) of each intermittently coated portion 142. In this embodiment, the lamination process and the stripping process can be performed more effectively.

[0060] The above dry electrode manufacturing process can be applied to single-sided coated electrodes, double-sided coated electrodes and offset coated electrodes or asymmetric intermittent double-sided coated dry laminates (refer to Figures 17 to 20 A double-sided coated electrode having a different discontinuous pattern on one side than on the other side is described. In a double-sided coated electrode, the discontinuous pattern on one side may be symmetrical to the discontinuous pattern on the other side.

[0061] Figures 14 to 16 A process for manufacturing an example dry electrode according to another embodiment is shown. Fig.14 , an electrochemically active self-supporting film 150 and a metal foil 162 without a binder coating are shown. The active self-supporting film 150 may have Fig.11 The active self-supporting film 110 is shown to have the same dimensions. Fig.15Prior to the laminator roll process in , the active self-supporting film 150 is placed on and aligned with the uncoated metal foil 162 .

[0062] refer to Fig.15 , the active self-supporting film 150 and the uncoated metal foil 162 are inserted into and laminated by the laminator roller assembly 170. The laminator roller assembly 170 includes a pair of rollers 175 and 177. The rollers 175 and 177 may have substantially the same diameter. The rollers 175 and 177 may be formed of the same material or different materials having the same hardness level, so that a substantially uniform pressure is applied to the stacked layers (150, 162) by both rollers 175 and 177.

[0063] The relative positions (eg, vertical positions) of rollers 175 and 177 may be controlled such that the gap between rollers 175 and 177 is periodically closed or opened while rollers 175 and 177 rotate. Fig.15 In the embodiment, reference numerals 172 and 176 represent closed gaps, and reference numeral 174 represents an open gap. Fig.16 The intermittent cycle of the intermittently coated dry electrode 180 shown can be controlled by the duration of applying pressure to the two layers 150 and 162 to produce the dimensions x and y. In this embodiment, when the rollers 175 and 177 are closed (see Fig.15 172 and 176 ), resulting in dimension y where the self-supporting film 150 is attached to the metal foil 162 . Fig.16 The length (y) or width of each intermittently coated portion 184 shown may be proportional to the duration that the rollers 175 and 177 are closed (172, 176). For example, the longer the duration that the rollers 175 and 177 are closed, the greater the length y, and vice versa. In addition, when the rollers 175 and 177 are opened (see Fig.15 174 in the figure), resulting in a dimension x where the self-supporting film 150 is not attached to (but only placed on) the metal foil 162. The length (x) between adjacent intermittently coated portions 184 can be proportional to the duration that the rollers 175 and 177 are turned on (174). For example, the longer the duration that the rollers 175 and 177 are turned on (174), the greater the length x, and vice versa. In one embodiment, both rollers 175 and 177 are moved to open or close the gap between the rollers 175 and 177. In another embodiment, only one of the rollers 175 and 177 is moved to open or close the gap between the rollers 175 and 177.

[0064] When the gap between the rollers 175 and 177 is closed (172, 176), the stacked layers (150 and 162) are pressed by the rollers 175 and 177 and are thus laminated to each other. When the gap between the rollers 175 and 177 is opened (174), the stacked layers (150 and 162) are not pressed by the rollers 175 and 177 and are thus not laminated to each other (i.e., are merely placed on top of each other). The unpressed portion of the active self-supporting film 150 is removed, thereby forming a Fig.16 The intermittently coated dry electrode 180 is shown. The removal process can be performed in the same manner as described above with respect to the previous embodiment. Thus, the lamination process and the removal process can be performed more efficiently.

[0065] The above dry electrode manufacturing process can be applied to single-sided coated electrodes, double-sided coated electrodes and offset coated electrodes or asymmetric intermittent double-sided coated dry laminates (refer to Figures 17 to 20 Described is a double-sided coated electrode having a different intermittent pattern on one side than on the other side).

[0066] Fig.17 and Fig.18 A process for making an asymmetric intermittent double-sided coated dry laminate 300 using a laminator roll assembly 320 is shown according to one embodiment. Fig.17 A laminator roller assembly 320 is shown according to one embodiment, which produces a laminator roller assembly 320. Fig.18 An asymmetric intermittent double-sided coated dry laminate 300 is shown. Fig.18 According to one embodiment, Fig.17 A cross-sectional view of an asymmetric intermittent double-sided coated dry laminate 300 is shown produced by the laminator roll assembly 320. Figures 14 to 16 Brief description and Fig.18 As shown, the asymmetric discontinuous double-sided coated dry laminate 300 (or offset coated dry electrode) is a double-sided electrode having a different discontinuous pattern on one side than the other side.

[0067] refer to Fig.17 , the laminator roller assembly 320 includes an upper laminator roller 307 and a lower laminator roller 309. The roller assembly 320 receives the first film roll 304, the second film roll 306 and the adhesive metal foil roll 305. The first film roll 304 represents the Fig.18 The electrochemically active self-supporting film roll of the first intermittent dry laminate 301 is shown. The second film roll 306 represents the electrochemically active self-supporting film roll used for Fig.18 The electrochemically active self-supporting film roll of the second intermittent dry laminate 302 is shown. The adhesive metal foil roll 305 represents Fig.18A roll of adhesive metal foil 303 is shown which is coated asymmetrically and intermittently. When inserted into the roller assembly 320, the adhesive metal foil roll 305 is inserted between the first film roll 304 and the second film roll 306. When the film and metal layer are inserted between and squeezed by the upper roller 307 and the lower roller 309, the first film roll 304, the metal foil roll 305 and the second film roll 306 can be unwound simultaneously. Similar to Fig.15 In the process shown, the upper roller 307 is controlled to periodically press the first film roll 304 against the adhesive metal foil 305 to produce the first intermittent dry laminate 301. For example, the first film roll 304 is Fig.18 The first film roll 306 is pressed for a duration of length "a" as shown, and is not pressed for a duration of length "b". In addition, the lower roller 309 is controlled to periodically press the first second film roll 306 against the adhesive metal foil 305 to produce the second intermittent dry laminate 302. For example, the second film roll 306 is pressed for a duration of length "a" as shown, and is not pressed for a duration of length "b". Fig.18 The laminate layer 308 is compressed for a duration of length "c" as shown and is not compressed for a period of time of length "d". The uncompressed areas can be removed from the laminate layer 308 in the same manner as described above to produce Fig.18 The asymmetric intermittent double-sided coated dry laminate 300 shown. The removed portions may at least partially overlap each other vertically. Fig.18 As shown, the film portion of the first intermittent dry laminate 301 can at least partially vertically overlap the film portion of the second intermittent dry laminate 302.

[0068] refer to Fig.18 , the first intermittent dry laminate 301 and the second intermittent dry laminate 302 are asymmetrical to each other. For example, the length a of each laminated portion of the first intermittent dry laminate 301 is different from the length c of each laminated portion of the second intermittent dry laminate 302. In addition, the length b of the exposed portion of the upper surface of the metal foil 303 is also different from the length d of the exposed portion of the lower surface of the metal foil 303. In some embodiments, the length b is less than the distance d, such as Fig.18 In other embodiments, the length b is greater than the length d (not shown). In addition, in some embodiments, the length c is less than the length a, such as Fig.18 In other embodiments, the length c is greater than the length a (not shown).

[0069] although Fig.17 and Fig.18 The process of manufacturing an asymmetric intermittent double-sided coated dry laminate is shown, but a symmetric intermittent double-sided coated dry laminate can also be manufactured in the same manner except that the pressurization interval or duration is the same for the upper laminator roller 307 and the lower laminator roller 309. In addition, Fig.17 and Fig.18Only an example process for making an asymmetric intermittent double-sided coated dry laminate is shown, and other roll assembly configurations and / or other arrangements of film rolls and metal foil rolls are possible.

[0070] Fig.19 and Fig. 20 A process for making an asymmetric intermittent double-sided coated dry laminate 310 using a laminator roll assembly 340 is shown according to another embodiment. Fig.19 A laminator roller assembly 340 is shown according to another embodiment, which produces a laminator roller assembly 340. Fig. 20 An asymmetric intermittent double-sided coated dry laminate 310 is shown. Fig. 20 According to another embodiment, Fig.19 A cross-sectional view of an asymmetric intermittent double-sided coated dry laminate 310 produced by a laminator roll assembly 340 is shown. Fig.19 , the laminator roller assembly 340 includes a first laminator roller assembly 350 and a second laminator roller assembly 360. The first laminator roller assembly 350 includes a first pair of laminator rollers 317 and 321, and the second laminator roller assembly 360 includes a second pair of laminator rollers 323 and 318. Roller 317 has an opening 352 with a width or circumferential length (b). Roller 318 has an opening 354 with a width or circumferential length (d) different from the circumferential length (b).

[0071] The first roll assembly 350 receives the first film roll 314 and the uncoated metal foil roll 315. The first film roll 314 represents the Fig. 20 The electrochemically active self-supporting film roll of the first intermittent dry laminate 311 is shown. The second roller assembly 360 receives the first film roll 314, the uncoated metal foil roll 315 and the second film roll 316. The second film roll 316 represents the electrochemically active self-supporting film roll of the first intermittent dry laminate 311. Fig. 20 The electrochemically active self-supporting film roll of the second intermittent dry laminate 312 is shown. The uncoated metal foil roll 315 represents Fig. 20 A roll of asymmetrically intermittently coated adhesive metal foil 313 is shown. When inserted into the second roller assembly 360, the uncoated metal foil roll 315 is inserted between the first film roll 314 and the second film roll 316. In other embodiments, the second film roll 316 and the uncoated metal foil roll 315 can be inserted into the first roller assembly 350, while the first film roll 314 (together with the second film roll 316 and the uncoated metal foil roll 315) is inserted into the second roller assembly 360. In these embodiments, the roller 321 will have an opening with a circumferential length of d and the roller 323 will have an opening with a circumferential length of b. The first film roll 314 and the metal foil roll 315 can be unwound before the second film roll 316 is unwound.

[0072] Similar to Fig.17In the process shown, a first film roll 314 and an uncoated metal foil roll 315 are inserted into rollers 317 and 321 to produce a first laminated layer 330 when leaving a first roller assembly 350, and then the first laminated layer 330 and the second film roll 316 are inserted into rollers 323 and 318 to produce a second laminated layer 319 when leaving a second roller assembly 360. The three layers 314, 315, and 316 are laminated to each other except for the portions of the layers 314 and 316 that pass through the openings 352 and 354. The unpressed portion can be removed from the second laminated layer 319 to form a Fig. 20 An asymmetric intermittent double-sided coated dry laminate 310 is shown.

[0073] although Fig.19 and Fig. 20 The process of manufacturing an asymmetric intermittent double-sided coated dry laminate is shown, but a symmetric intermittent double-sided coated dry laminate can be manufactured in the same manner except that the width of the opening is the same for the upper laminator roller 317 and the lower laminator roller 318. Similarly, Fig.19 and Fig. 20 Only an example process for making an asymmetric intermittent double-sided coated dry laminate is shown, and other roll assembly configurations and / or other arrangements of film rolls and metal foil rolls are possible.

[0074] Fig.21 An intermittently coated dry electrode 198 to be connected to an electrode sheet according to one embodiment is shown. The intermittently coated dry electrode 198 includes laminated portions 192 and 194, wherein an electrochemically active self-supporting film is laminated to a metal foil. The intermittently coated dry electrode 198 further includes the uncoated metal foil portion 196 described above. The uncoated metal foil portion 196 is used to connect the dry electrode 198 to the electrode sheet (see Fig.21 ) or other electrical components for connection with an external device (not shown). Fig.21 A single uncoated metal foil portion 196 is shown, but an electrode sheet or other electrical component may be attached to one or more of the multiple uncoated metal foil portions, such as Fig.10 , Fig.13 and Fig.16 shown.

[0075] Fig. 22 An energy storage device 200 according to one embodiment is shown. The energy storage device 200 may be a battery, a capacitor, or a hybrid type combining a battery and a capacitor. The battery may include a liquid electrolyte battery or a polymer electrolyte battery or a solid-state battery. The polymer electrolyte may include a solid polymer electrolyte and a plasticized gel polymer electrolyte. The liquid electrolyte battery may include a lithium ion battery. The polymer electrolyte battery may include a lithium polymer battery. The battery may have a cylindrical shape, a prismatic shape, or a pouch shape.

[0076] The energy storage device 200 includes an electrode assembly 210. The electrode assembly 210 includes a first electrode 220, a second electrode 240, and a separator 230 located between the first electrode 220 and the second electrode 240. The separator 230 may be configured to electrically insulate the first electrode 220 and the second electrode 240 while allowing ionic communication between the two electrodes 220 and 240.

[0077] The first electrode 220 may be an anode ("negative electrode"), and the second electrode 240 may be a cathode ("positive electrode". Each of the anode electrode 220 and the cathode electrode 240 may be a Figures 5 to 19 The first electrode 220 and the second electrode 240 include uncoated metal foil portions 222 and 242, respectively, connected to corresponding electrode sheets 224 and 244 or other electrical components (not shown).

[0078] The energy storage device provided herein can have any suitable configuration, such as planar, spirally wound, button-shaped or bag-shaped. The energy storage device provided herein can be a component of a system, such as a power generation system, an uninterruptible power supply system (UPS), a photovoltaic power generation system, an energy recovery system for, for example, industrial machinery and / or transportation. The energy storage device provided herein can be used to power various electronic devices and / or motor vehicles (including hybrid electric vehicles (HEV), plug-in hybrid electric vehicles (PHEV) and / or electric vehicles (EV)).

[0079] Fig.23 A flowchart 2300 of a method of manufacturing a dry electrode for an energy storage device is shown according to one embodiment. Although the process flowchart 2300 is described herein with reference to a particular order, in various embodiments, the states herein may be performed in a different order or omitted, and additional states may be added. This may be applied to Fig.24 Flowchart 2400 is shown.

[0080] In state 2310, a metal layer is provided. For example, the metal layer may include Figure 5 , Fig. 9 , Fig.11 and Fig.14 In state 2320, an electrochemically active self-supporting film formed of a dry active material is provided. For example, the electrochemically active self-supporting film can be respectively as Figure 5 , Figure 8 , Fig.11 and Fig.14The electrochemically active dry film (56, 80, 110, 150) is shown. In state 2330, the electrochemically active self-supporting film and the metal layer are combined to form a combined layer. For example, the metal layer can be coated with an adhesive, the electrochemically active self-supporting film can be placed on the metal layer, and heat and / or pressure can be applied to the film and the metal layer to combine the two elements, as described with respect to Figure 6 and Fig. 9 As another example, the electrochemically active self-supporting film can be placed on the metal layer, inserted between an opposing set of rollers and squeezed by the rollers, as described with respect to Fig.12 and Fig.15 as described.

[0081] In state 2340, a portion of the electrochemically active self-supporting film is removed from the combined layer. Figure 7 , Fig.10 , Fig.13 and Fig.16 As described, the portion of the electrochemically active self-supporting film that is not attached with adhesive or not squeezed by the roller can be removed from the metal layer portion of the combined layer by peeling or cutting. In state 2350, the electrochemically active self-supporting film is intermittently formed on the metal layer along the longitudinal direction of the metal layer, for example, Figure 7 , Fig.10 , Fig.13 and Fig.16 As described above, the electrochemically active self-supporting film may be formed only on one surface or on opposite surfaces of the metal layer.

[0082] Fig.24 A flowchart 2400 of a method for manufacturing a dry electrode for an energy storage device according to another embodiment is shown. In state 2410, a metal layer is provided. For example, the metal layer may include Fig.17 and Fig.19 The metal foil rolls (305, 315) are shown. In state 2420, a first electrochemically active self-supporting film formed of a dry active material is provided. For example, the first electrochemically active self-supporting film may include Fig.17 and Fig.19 A first film roll (304, 314) is shown.

[0083] In state 2430, a second electrochemically active self-supporting film formed of a dry active material is provided. For example, the second electrochemically active self-supporting film may include Fig.17 and Fig.19In state 2440, the first electrochemically active self-supporting film and the second electrochemically active self-supporting film are combined with the metal layer to form a combined layer, such that the metal layer is interposed between the first electrochemically active self-supporting film and the second electrochemically active self-supporting film. For example, the rolls of the first electrochemically active self-supporting film and the second electrochemically active self-supporting film (wherein the metal layer is interposed between the first electrochemically active self-supporting film and the second electrochemically active self-supporting film) are squeezed by a set of opposing rollers (e.g., a pair of rollers or two pairs of rollers), as described with respect to Fig.17 and Fig.19 as described.

[0084] In state 2450, the first portion of the first electrochemically active self-supporting film and the second portion of the first electrochemically active self-supporting film are removed from the combined layer, as described with respect to Fig.18 and Fig. 20 In state 2460, a discontinuous electrochemically active self-supporting film is formed on the opposite surface of the metal layer, for example, Fig.18 and Fig. 20 shown.

[0085] As used herein, the terms "battery" and "capacitor" are given their ordinary and customary meanings to those of ordinary skill in the art. The terms "battery" and "capacitor" are not mutually exclusive. A capacitor or battery may refer to a single electrochemical cell that may operate alone or as a component of a multi-battery system.

[0086] Features, materials, characteristics or groups described in conjunction with a particular aspect, embodiment or example should be understood to be applicable to any other aspect, embodiment or example described in that section or elsewhere in this specification unless incompatible therewith. All features disclosed in this specification (including any accompanying claims, abstract and drawings) and / or all steps of any method or process so disclosed may be combined in any combination, except combinations where at least some of such features and / or steps are mutually exclusive. Protection is not limited to the details of any foregoing embodiments. The protection extends to any novel feature or any novel combination of features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel feature or any novel combination of steps of any method or process so disclosed.

[0087] In addition, certain features described in the present disclosure in the context of separate implementations may also be implemented in combination in a single implementation. In contrast, various features described in the context of a single implementation may also be implemented in multiple implementations individually or in any suitable subcombination. In addition, although the above features may be described as functioning in certain combinations, in some cases, one or more features from the claimed combination may be removed from the combination, and the combination may be claimed as a subcombination or a variation of the subcombination.

[0088] In addition, although the operations may be depicted in the drawings or described in a particular order in the specification, such operations do not need to be performed or all operations are performed in the particular order shown or in a sequential order to achieve the desired results. Other operations not depicted or described may be incorporated into the example methods and processes. For example, one or more additional operations may be performed before, after, at the same time, or between any of the operations. In addition, the operations may be rearranged or reordered in other implementations. It will be understood by those skilled in the art that in some embodiments, the actual steps taken in the process shown and / or disclosed may be different from the steps shown in the drawings. According to the embodiment, some of the above steps may be removed and other steps may be added. In addition, the features and attributes of the specific embodiments disclosed above may be combined in different ways to form additional embodiments, all of which fall within the scope of the present disclosure. In addition, the separation of various system components in the above implementations should not be understood as requiring such separation in all implementations, and it should be understood that the components and systems described may generally be integrated together in a single product or packaged into multiple products. For example, any component for an energy storage system described herein may be provided separately, or integrated together (e.g., packaged together, or attached together) to form an energy storage system.

[0089] For purposes of the present disclosure, certain aspects, advantages, and novel features are described herein. Not all of these advantages may be achieved according to any particular embodiment. Thus, for example, one skilled in the art will recognize that the present disclosure may be implemented or performed in a manner that achieves one advantage or a group of advantages as taught herein without necessarily achieving other advantages as taught or suggested herein.

[0090] Unless otherwise specifically stated or understood within the context of use, conditional language such as "can," "could," "might," or "may" is generally intended to convey that certain embodiments include certain features, elements, and / or steps while other embodiments do not. Thus, such conditional language is generally not intended to imply that features, elements, and / or steps are in any way required for one or more embodiments, or that one or more embodiments must include logic for determining, with or without user input or prompting, whether such features, elements, and / or steps are included in any particular embodiment or whether such features, elements, and / or steps will be performed in any particular embodiment.

[0091] Unless specifically stated otherwise, linking language such as the phrase "at least one of X, Y, and Z" is otherwise understood in context as generally used to convey that an item, term, etc. may be X, Y, or Z. Thus, such linking language is generally not intended to imply that certain embodiments require the presence of at least one of X, at least one of Y, and at least one of Z.

[0092] Language of degree as used herein, such as the terms “approximately,” “about,” “generally,” and “substantially” as used herein, indicates a value, amount, or characteristic that approaches the stated value, amount, or characteristic and still performs the desired function or achieves the desired result.

[0093] The scope of the present disclosure is not intended to be limited by the specific disclosure of the embodiments in this section or elsewhere in this specification, and may be limited by the claims presented or later presented in this section or elsewhere in this specification. The language of the claims is to be interpreted broadly based on the language employed in the claims, and not limited to the examples described in this specification or during the prosecution of the application, which examples are to be interpreted as non-exclusive.

[0094] Although certain embodiments have been described, these embodiments are presented only by way of example and are not intended to limit the scope of the present disclosure. In fact, the novel methods and systems described herein can be implemented in various other forms. In addition, various omissions, substitutions, and changes may be made to the systems and methods described herein without departing from the spirit of the present disclosure. The attached claims and their equivalents are intended to cover such forms or modifications that fall within the scope and spirit of the present disclosure. Therefore, the scope of the present invention is limited only by reference to the attached claims.

Claims

1. A laminator roller assembly for making a dry electrode for an energy storage device, comprising: First roller; as well as a second roller, disposed adjacent to the first roller, The first roller and the second roller are configured as follows: receiving a composite layer between the first roller and the second roller while the first roller and the second roller rotate, the composite layer comprising a metal layer and an electrochemically active self-supporting film disposed on the metal layer, the electrochemically active self-supporting film being formed of a dry active material; as well as forming a plurality of film portions of the electrochemically active self-supporting film, wherein the plurality of film portions are intermittently arranged on the metal layer along a longitudinal direction of the metal layer; as well as The combined layer is outputted, wherein the metal layer is exposed by the plurality of film portions arranged intermittently.

2. The laminator roller assembly according to claim 1, wherein: At least one of the first roller and the second roller includes an opening having a length.

3. The laminator roller assembly according to claim 2, wherein: The length of each opening is the same as a width of each portion of the metal layer exposed by the plurality of film portions arranged intermittently, and wherein the width is measured along the longitudinal direction.

4. The laminator roller assembly of claim 1, wherein: At least one of the first roller and the second roller is configured not to press the plurality of film portions that are intermittently arranged during rotation of the first roller and the second roller.

5. The laminator roller assembly of claim 1, wherein: The first roller and the second roller are configured to move relative to each other such that a gap between the first roller and the second roller is periodically closed and opened during rotation of the first roller and the second roller.

6. The laminator roller assembly according to claim 5, wherein: The gap is proportional to the width of the exposed portion of the metal layer.

7. The laminator roller assembly of claim 1, wherein: The first roller and the second roller are configured to output the combined layer such that the exposed portion of the metal layer is not coated with adhesive and extends in a direction crossing the longitudinal direction.

8. The laminator roll assembly of claim 1, wherein: The first roller and the second roller are configured to output the combined layer such that the plurality of film portions arranged intermittently are equally spaced apart from each other.

9. A laminator roller assembly for making a dry electrode for an energy storage device, comprising: The first roller assembly is configured to: receiving a first electrochemically active free-standing film and a metal layer; as well as outputting a first laminate layer, the first laminate layer comprising a first plurality of film portions of the first electrochemically active self-supporting film, the first plurality of film portions being intermittently arranged on a first side of the metal layer along a longitudinal direction of the metal layer; as well as A second roller assembly is spaced apart from the first roller assembly, the second roller assembly being configured as follows: receiving the first laminate layer and a second electrochemically active self-supporting film, and A second laminate layer is outputted, the second laminate layer comprising a second plurality of film portions of the second electrochemically active self-supporting film, the second plurality of film portions being intermittently arranged along the longitudinal direction on a second side of the metal layer opposite to the first side.

10. The laminator roller assembly of claim 9, wherein: The first plurality of membrane portions are spaced apart by a first distance, and wherein the second plurality of membrane portions are spaced apart by a second distance.

11. The laminator roller assembly of claim 10, wherein: The first distance is different from the second distance such that an asymmetric discontinuous double-sided coated dry laminate is formed.

12. The laminator roller assembly of claim 10, wherein: The first distance is the same as the second distance, so that a symmetrical intermittent double-sided coated dry laminate is formed.

13. The laminator roller assembly of claim 10, wherein: The first roller assembly includes a first roller and a second roller adjacent to each other, and wherein the first roller assembly is configured to receive the first electrochemically active self-supporting film and the metal layer between the first roller and the second roller during rotation of the first roller and the second roller.

14. The laminator roller assembly of claim 13, wherein: The first roller is disposed at a first side of the metal layer and includes a first opening formed on a circumferential portion of the first roller, and wherein a width of the first opening is the same as the first distance.

15. The laminator roller assembly of claim 14, wherein: The first roller is configured to not press the first electrochemically active self-supporting film against the metal layer on the first opening such that the first plurality of film portions of the first laminate layer are discontinuously arranged on the first side of the metal layer.

16. The laminator roll assembly of claim 10, wherein: The second roller assembly includes a third roller and a fourth roller adjacent to each other, and wherein the second roller assembly is configured to receive the first laminate layer and the second electrochemically active self-supporting film between the third roller and the fourth roller during rotation of the third roller and the fourth roller.

17. The laminator roller assembly of claim 16, wherein: The fourth roller is disposed at a second side of the metal layer and includes a second opening formed on a circumferential portion of the fourth roller, and wherein a width of the second opening is the same as the second distance.

18. The laminator roll assembly of claim 17, wherein: The fourth roller is configured to not press the second electrochemically active self-supporting film against the metal layer on the second opening such that the second plurality of film portions of the second laminate layer are discontinuously arranged on the second side of the metal layer.

19. The laminator roller assembly of claim 9, wherein: The first electrochemically active self-supporting film comprises a first roll of electrochemically active self-supporting film, wherein the second electrochemically active self-supporting film comprises a second roll of electrochemically active self-supporting film, and wherein the metal layer comprises a roll of metal foil.

20. The laminator roll assembly of claim 19, wherein: The first film roll and the metal foil roll are configured to be unwound before the second film roll is unwound.

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