Additive manufacturing method and manufacturing apparatus for electrochemical devices

Abstract

The invention relates to a production method for the additive production of at least one component of an electrochemical device, preferably an electrochemical energy store, in particular a battery, preferably a lithium ion battery, and / or an electrolytic cell, the invention relates to a method for producing, at least in part, a construction material in the form of powder, by applying layer by layer and subsequently, in particular, selectively curing, preferably, a construction material in the form of powder, comprising the following steps: providing a carrier device in the form of a carrier tape, in particular comprising or consisting of a carrier film, preferably a metal; applying at least one layer of construction material to the carrier tape; feeding the construction material into an irradiation region (19) of at least one preferably fixed irradiation unit (10) and at least partially, in particular selectively, curing the construction material on the carrier tape by means of the at least one irradiation unit.

Description

Field of the Invention

[0001] The present invention relates to a manufacturing method and a manufacturing apparatus for manufacturing at least one component of an additive manufacturing electrochemical device, the electrochemical device being preferably an electrochemical energy storage device, in particular a storage battery, preferably a lithium-ion storage battery, and / or an electrolytic cell. Background Art

[0002] Manufacturing apparatuses and corresponding methods for manufacturing components (additively) by layer-by-layer application and local selective curing of a construction material are generally known from the prior art. For layer-by-layer application, there is usually at least one corresponding coating unit. For local selective curing, there is usually at least one corresponding irradiation unit (for example, including at least one laser). These features can also be implemented partially or fully in the present invention.

[0003] In principle, it has also been proposed to use such an additive manufacturing method in the manufacture of batteries. For example, US2020 / 0411838 A1 describes a manufacturing method for a component of an electrical energy storage system, in which a substrate is coated with a particulate construction material and the construction material is cured by a laser unit after coating. Then, additional layers are applied and cured in a conventional manner, respectively. This processing method, which is oriented towards conventional processing methods and similar processing methods in the field of laser sintering, is considered to be relatively complex and partially limited (especially slow and costly) in the large-scale manufacture of battery components in particular. Summary of the Invention

[0004] Therefore, an object of the present invention is to provide a manufacturing method and a corresponding manufacturing apparatus, by which an electrochemical device to be manufactured can be manufactured in a relatively simple and still precise manner and form (especially also in large quantities and / or also with a high output measured, for example, by the area manufactured per minute), the electrochemical device being preferably an electrochemical energy storage device, in particular a storage battery, preferably a lithium-ion storage battery, and / or an electrolytic cell.

[0005] The object is achieved in particular by the features of claim 1.

[0006] In particular, the object is achieved according to a first aspect by a production method for the additive production of at least one component of an electrochemical device (device for electrochemical applications), in particular an electrochemical cell, preferably an electrochemical energy storage device, in particular a battery, preferably a lithium-ion battery, (e.g. a battery cell structure and / or an electrode structure of a battery or a battery cell, in particular a lithium-ion battery), and / or (at least one component of) an electrolytic cell, at least partially by layer-by-layer application and subsequent, in particular selective, curing of a preferably powdered construction material, preferably by (in particular selective) irradiation, preferably by irradiation with at least one laser, the method comprising the following steps:

[0007] - providing a (preferably at least partially flexible) carrier device in the form of a (preferably at least partially flexible) carrier tape (or comprising such a carrier tape), the carrier device in particular comprising a preferably metallic (in particular with at least 30 wt.%, preferably at least 50 wt.%, further preferably at least 80 wt.%) carrier film or being formed from such a carrier film,

[0008] - applying at least one (especially dry) layer of a building material to a carrier tape,

[0009] - (gradually, preferably continuously) supplying the building material into the irradiation region of at least one first, preferably stationary, irradiation unit and at least partially curing, in particular selectively curing, the building material on the carrier tape by means of the at least one first irradiation unit.

[0010] One idea of ​​the first aspect is that for the (additive) manufacturing method, a (preferably flexible) carrier device is used, which is preferably in the form of a carrier tape or comprises a carrier tape, which is (gradually) introduced into the irradiation area of ​​the irradiation unit. In this way, in particular relatively flat electrochemical components or component parts (in particular battery components) can be produced in a simple manner and form. In addition, the movement or irradiation can be carried out relatively quickly. In particular, one or more layers with a special structure (for example, oriented porosity and / or a special chemical composition) can be produced. For example, after the (corresponding) layer is cured, the carrier material (for example formed by the carrier device or carrier film) can be further moved so that the area of ​​the carrier material covered with the cured building material is guided out of the irradiation area, and in this case, preferably at the same time, another section of the carrier material (on which no cured building material is yet located) is moved into the irradiation area. In this way, a large area of ​​the carrier material can be provided (in particular printed) with the cured building material (gradually, preferably continuously).

[0011] Generally, a large area can be structured in a simple and rapid manner and form, or a large number of parts of a component to be manufactured can be achieved (e.g., by separating and splitting individual segments of a solidified construction material and / or a carrier material carrying the solidified material).

[0012] The object is achieved according to a second (usually independent, but preferably combined with the first aspect) aspect, in particular by a manufacturing method for additive manufacturing of at least one component of an electrochemical device, preferably for manufacturing an electrochemical energy storage device, in particular a storage battery, preferably a lithium-ion storage battery, and / or an electrolytic cell (at least one component thereof), the manufacturing method being at least partially manufactured by layer-by-layer application and subsequent, in particular selective, curing of a preferably powdery construction material, the method comprising the following steps:

[0013] - Applying at least one layer of the construction material to a carrier device,

[0014] - At least partially curing, in particular selectively curing, the construction material on the carrier device by means of at least one first irradiation unit, the first irradiation unit having a plurality of individual radiation outlet segments, preferably arranged in at least one row and / or (particularly preferably: and) at least one column, in particular a plurality of laser diodes and / or radiation guide ends. If the arrangement in rows or columns is described here and below, preferably there are at least 5 rows or at least 10 rows or at least 50 rows and / or there are at least 5 columns or at least 10 columns or at least 50 columns.

[0015] One idea of the second aspect is that for the (additive) manufacturing method, curing is carried out by means of a (first) irradiation unit having a plurality of radiation outlet segments (e.g., at least 5 or at least 10 or at least 50 radiation outlet segments). The radiation outlet segment preferably refers to a segment of the corresponding (e.g., first) irradiation unit on which the beam (e.g., in particular the light of a laser) finally leaves the irradiation unit. Here, "finally leaving" preferably means that the beam (light) no longer comes into contact (or interacts) with a solid before hitting the construction material to be cured (at this time, at least a transparent intermediate structure that does not significantly affect the light path is preferably not considered). Above and below, the corresponding radiation is preferably electromagnetic radiation, in particular visible light and / or infrared light, preferably the radiation of a laser and / or a laser diode.

[0016] In principle, a plurality of radiation outlet segments can be realized by a plurality of radiation sources (e.g., laser diodes) and / or by splitting the beam of a (common) radiation source.

[0017] The end of the radiation director preferably refers to the end of a (physical) radiation director, such as an optical conductor. The plurality of radiation outlet sections can also be realized by means of at least one prism and / or at least one lens, in particular a microlens, and / or at least one mirror, in particular a micromirror.

[0018] Generally, through the special configuration of the irradiation unit according to the second aspect, it is possible (especially even when the construction material is at least one metal) to structure a large area in a simple and rapid manner and form, or (by separating and splitting individual sections of the cured construction material and / or the carrier material carrying the cured material) to achieve a large number of pieces for a determined component to be manufactured (similar to the situation in the first aspect). Therefore, especially by combining the first and second aspects, it is possible to achieve improved manufacturing in a synergistic manner and form in this regard. Here, it is particularly advantageous that by using a plurality of radiation outlet sections and by using a carrier tape moving forward, a larger area can be irradiated and (selectively) cured (simultaneously), and at this time, by using the carrier tape, the construction material to be cured can be replenished in a simple manner.

[0019] The following description (as long as not otherwise indicated by the corresponding context) relates to the first and second aspects (as corresponding optional improvements of the first or second aspect, or as an improvement of the combination of these two aspects).

[0020] An additional (second) irradiation unit can be provided but is not necessary.

[0021] (The corresponding) carrier device preferably includes a carrier material, which can be formed, for example, by a carrier tape, in particular a carrier film. The carrier device can be at least partially supported by a base. The base can have a belt (such as a conveyor belt) and / or a processing and / or carrier table and / or at least one roller and / or at least one support sheet, preferably a plurality, such as at least 5 or at least 10 or at least 20 support sheets. (The corresponding) carrier device especially refers to such a device onto which the construction material is (directly) applied. (The corresponding) carrier device can be configured as single-layer or multi-layer. (The corresponding) carrier device can be configured as one-piece, if necessary as an integral whole, or as multi-piece. As an alternative or in addition to the carrier tape, a (possibly non-flexible or conventional) construction platform can also be used as the carrier device. For example, the length of such a construction platform can be less than 10 times the width or less than 2 times the width. Here, the length (here and below) preferably should refer to the longest extension dimension along the axis of symmetry in a top view (observed isometrically from a vertical perspective from above) or (if no axis of symmetry is formed) should refer to the distance between the pair of points with the largest spacing among all pairs of points, and here the width should refer to the (maximum) extension dimension perpendicular to the length.

[0022] (The corresponding) carrier device, preferably a carrier film, can be at least partially or completely additively manufactured, for example in order to obtain a porous structure and in order to reduce the weight if necessary.

[0023] In principle, only one layer of the construction material can be applied to the carrier device (in particular the carrier material) and then cured (here). However, the step of applying one layer of the construction material and subsequent (at least partial) curing, in particular selective curing, can be repeated at least once, and if necessary at least 2 times or at least 5 times (here, the carrier device or the carrier material can continue to move for this purpose or can remain in the same position, and accordingly the underlying layer is also cured in this position, which will be explained in more detail below).

[0024] The curing process is preferably a (selective) laser sintering method or a laser melting method.

[0025] The flexible carrier material is preferably a shape-unstable material, for example a material that can be laid around a straight cylinder with a diameter of 20 cm at 20 °C without breaking, and preferably (after such an arrangement) does not leave the straight cylinder due to an elastic restoring force. Alternatively or additionally, the flexible carrier material can be a material for which, when a square piece with a side length of 10 cm of the material is supported on two support lines (the support lines extending along two opposite sides of the square), the square piece sags by at least 1 mm or at least 1 cm due to its own weight. If the resulting flexibility is not uniform over the carrier material, this condition should apply in particular to at least one square piece (side length 10 cm), preferably to the following corresponding square pieces, which in total cover at least 50% of the area of the carrier material (if necessary over the entire carrier material or all corresponding pieces). The (flexible) carrier material preferably can have a thickness of less than 2.0 mm, preferably less than 1.00 mm, more preferably less than 0.50 mm, if necessary less than 0.050 mm or less than 0.015 mm or less than 0.008 mm or even less than 0.004 mm. Alternatively or additionally (as long as it is not logically excluded by the previous upper limit values), a thickness of at least 0.001 mm, preferably at least 0.005 mm, if necessary at least 0.010 mm can be present. Each of the said upper limits and each of the said lower limit values can be combined into a corresponding range (as long as it is not logically excluded).

[0026] The carrier material is in particular a (metal) film (carrier film). The carrier material (in particular the carrier film) preferably contains aluminum (in particular at least 50 wt.% or at least 80 wt.%), preferably for making the cathode, and / or contains copper (in particular at least 50 wt.% or at least 80 wt.%), preferably for making the anode.

[0027] The additively manufactured component can be, for example, a (functional) layer of an electrochemical device and / or, for example, an anode and / or a cathode and / or a separator of a storage battery.

[0028] In some embodiments, for example, at least 10 wt.%, preferably at least 30 wt.%, and optionally at least 60 wt.% of an electrochemical device (such as a storage battery) can be manufactured or have been manufactured by the manufacturing method according to the present invention.

[0029] The electrochemical device (English: electrochemical device) can be an electrochemical device, an electrochemical element, and / or an electrochemical component, in particular an electrochemical cell, preferably a battery cell, a fuel cell, and / or an electrolytic cell.

[0030] In principle, the carrier material (or carrier film) can be (partially or completely) a component of the additively manufactured component (or remain in or on the component or the corresponding member), for example, a component of an electrode (cathode or anode) of a storage battery, or the carrier material can be removed (at least partially) at a later time point (i.e., in particular only used as a transport base or transport film, or at least partially only used as a transport base or transport film).

[0031] Selective curing is preferably carried out (so that not the entire corresponding layer is cured). Alternatively, however, during curing, the entire layer of the construction material can be cured by the irradiation unit. Optionally, the uncured part of the construction material can be removed from the cured component in a subsequent step (for example, by suction, in particular suction by means of at least one suction nozzle).

[0032] In the (optionally selective) cured area, all the material in the corresponding layer can be melted or only a part of the material can be melted. If there is a material mixture, for example, only one component of the material mixture can be melted, for example, the binder (in particular a polymer binder) can be melted, for example, for connecting metal particles that do not melt (at least not completely) themselves (in particular particles having at least 50 wt.% or at least 80 wt.% of metal).

[0033] The binder, in particular the aforementioned binder (in particular a polymer binder), is preferably configured such that the binder adheres to the carrier device, in particular the carrier film, when melted and is thereby connected thereto.

[0034] Generally, the uncured construction material can be guided back into the cycle, preferably for manufacturing new layers or new batteries, preferably pouch cells and / or cylindrical cells. The backhaul of the unused powder (construction material) can include, for example, pneumatic conveyance and, if necessary, incorporation of new powder.

[0035] The curing step can also include the step of binding the construction material to a carrier material, which is particularly advantageous when the carrier material is to be part of a component of an electrochemical device (or a corresponding electrochemical element). However, even if the carrier material is removed from the construction material in a subsequent manufacturing step, a (at least loose) binding can be advantageous, for example for further conveyance. If necessary, in this case (or also generally) an intermediate layer can be provided between the carrier material and the construction material, which facilitates subsequent detachment of the construction material from the carrier material.

[0036] Relative movement preferably occurs between the carrier device and the coating unit (during coating) and / or between the carrier material and the irradiation unit (during irradiation). For this purpose, the carrier device can move forward, and the coating unit or the irradiation unit can remain stationary, or vice versa. Alternatively, both the coating unit or the irradiation unit and the carrier device can move forward. If movement (forward movement) is mentioned here and below without a clear contrary indication, it is preferably (as long as no other situation results from the context) to be understood as movement perpendicular to the construction direction (z-direction).

[0037] A fixed irradiation unit in particular refers to an irradiation unit that has no (optionally no overall) movement during the curing of the construction material (absolutely speaking, in particular no movement relative to a reference point that is part of the base in use and on which the manufacturing equipment is set up). The radiation for curing (for example, the corresponding laser beam) can (also absolutely speaking) move, or can remain stationary (in both cases, the (optionally additional) relative movement relative to the construction material can be achieved by the forward movement of the construction material).

[0038] Optionally, one (corresponding) radiation outlet section (optionally multiple radiation outlet sections) of the irradiation unit can always irradiate the same (sub)area of an irradiation area. If, for example, individual radiation outlet sections are switched on and individual radiation outlet sections (optionally multiple radiation outlet sections) are switched off, this does not necessarily apply to the entire irradiation unit.

[0039] In any case, the irradiation itself can (optionally) move locally forward, for example in such a way that the laser beam is moved, in particular deflected (e.g. in a grid-like manner). The laser beam can be moved, for example, by means of MEMs (MEM = microelectromechanical mirror).

[0040] The manufacturing method is preferably a continuous method, in particular a conveyor belt method. For this purpose, a corresponding continuous / ring-shaped carrier can be provided. Alternatively or additionally, the manufacturing method can also be carried out discontinuously (in the form of a hybrid method), so that, for example, the construction material is built up on a (single) carrier (or cured here), and then it (together with the carrier device or at least some parts of the carrier device) is removed from the area where curing takes place, and then another (new) carrier device is brought into the irradiation area, and the construction material is provided here again (the construction material is cured here).

[0041] According to this embodiment, in the initial state, the length of the carrier material (or carrier belt or carrier film) is preferably at least 2 times, preferably at least 5 times, more preferably at least 10 times and / or at most 100,000 times the width.

[0042] The carrier material is preferably provided in strip form (in the form of a belt, preferably a film belt).

[0043] According to this embodiment, the carrier material (or carrier belt and / or its carrier film) is preferably provided in at least partially (optionally completely in the initial state) rolled-up state. Alternatively or additionally, the carrier material (or carrier belt and / or its carrier film) can be provided in a folded state (e.g. folded at least 2 times or at least 5 times or at least 10 times), or can also be provided in a state of being partially rolled up and partially folded. Thereby, the carrier material can be provided in a space-saving manner and form.

[0044] The carrier material (or carrier belt and / or its carrier film) can be at least partially rolled up and / or folded (after the construction material has been cured), optionally together with the construction material (or at least some parts of the construction material), or rolled up and / or folded without the construction material.

[0045] In particular, when the carrier material is to be a component of an electrochemical device, it is advantageous to roll up or fold it together with the construction material. But when the carrier material (or carrier belt and / or its carrier film) is not a component of the construction material, a common roll-up or fold can also be carried out first (e.g. for transport and / or storage purposes).

[0046] In some embodiments, the structural material may preferably be transferred, after curing, from the carrier material, preferably formed by a carrier film, of the carrier tape - hereinafter also referred to as the first carrier material - to a further optionally flexible second carrier material by a roll-to-roll process, or remain on the first carrier material. Alternatively, the structural material may also remain beside / on the (first) carrier material (and become part of the electrochemical device to be manufactured). The second carrier material may optionally have the properties as described in connection with the first carrier material (above and / or below).

[0047] Alternatively or additionally, a layer structure (sandwich structure), in particular comprising the carrier material (carrier film) of the carrier tape or the carrier tape itself and the (cured) structural material, may be cut into at least two (smaller) strips or divided into individual (e.g., rectangular) plates (in particular for pouch cells).

[0048] Preferably, the back side of the carrier tape and / or its carrier film is also provided with a (in particular selectively) cured layer of the structural material. In order to be able to irradiate the back side with the irradiation unit, a deflection roller may be provided, for example. At this time, a storage battery (cell) can be manufactured in a particularly effective manner and form.

[0049] In some embodiments, the application may be carried out with a stationary coating unit. Alternatively or additionally, curing may be carried out with a stationary irradiation unit (in particular as defined above).

[0050] A stationary coating unit in particular refers to a unit that does not move (itself) during the coating process, so that, for example, the coating is carried out in such a way that the carrier material (or the carrier tape or at least its carrier film) moves forward under the coating unit. Alternatively, the coating unit may also move (at least partially), in particular the coating arm of the coating unit may move.

[0051] The irradiation unit may have a plurality of individual radiation outlet segments, preferably arranged in at least one row and / or at least one column, in particular a plurality of laser diodes and / or radiation guide ends.

[0052] Specifically, the irradiation unit may have an array consisting of radiation outlet segments. If a plurality of radiation outlet segments are provided, an array of hit points can be achieved, where each hit point is in particular assigned to a corresponding radiation outlet segment (here, the hit point is the area of the structural material or the structural region irradiated by the corresponding radiation outlet segment).

[0053] When a plurality of hit points are successively arranged in the longitudinal direction (or the forward movement direction of the construction material), these hit points can be aligned (in the longitudinal direction; with at least one nearest neighboring point). However, in this case, it is advantageous that there can also be an offset in the width direction with at least one neighboring point (especially such an offset that at least two hit points successively arranged in the longitudinal direction are not aligned with each other in the longitudinal direction). A corresponding situation can also apply to the radiation exit section, where there is not necessarily a mandatory association (for example, if the angles of the beams respectively assigned to the radiation exit section are different from each other, such that although there is no offset in the width direction for the radiation exit section, there is an offset for the hit points). Generally, for at least 30% or at least 50% of all hit points and / or radiation exit sections, they are arranged offset with respect to at least one nearest (front and / or rear in the longitudinal direction) neighboring point and / or section in the longitudinal direction.

[0054] In the presence of such an offset, steps (step portions) can be reduced or avoided in a simple and thus advantageous manner and form, especially when a plurality of radiation exit sections irradiate the same line (in the longitudinal direction), the steps will be generated.

[0055] The corresponding radiation exit section can preferably be configured for constant (fixed) irradiation.

[0056] Preferably, the carrier material (or carrier tape) moves forward during the irradiation by the irradiation unit. In this case, the forward movement of the carrier tape or carrier material is used in a synergistic manner and form in a twofold way, that is, on the one hand, for continuously transporting the carrier material, and on the other hand, for being able to introduce the structure (selectively) into the construction material. Alternatively, the carrier material can also be stationary during the irradiation (relative to the irradiation unit or exposure unit). For example, the corresponding (selective) structure is achieved by turning on or off individual radiation exit sections (such as laser diodes) and / or (in a conventional way and form) by scanning with one or more laser beams (the same is true when the carrier material moves forward).

[0057] The irradiation unit preferably includes at least one laser. Further preferably, the irradiation unit includes at least one VCSEL (Vertical-Cavity Surface-Emitting Laser) and / or VECSEL (Vertical External Cavity Surface-Emitting Laser). Further preferably, the irradiation unit includes a VCSEL and / or VECSEL component, which preferably includes a plurality of VCSELs and / or VECSEL diodes in an array arrangement form having multiple rows and multiple columns. The wavelength of the corresponding laser diode is 405 - 1400 nm, preferably 900 - 1000 nm, and particularly preferably 940 - 980 nm. Further preferably, the wavelength of the absorption spectral band of the construction material can be adaptively adjusted.

[0058] Alternatively or additionally, the irradiation unit may further include one or more lasers that move (in a raster pattern) over the construction area or irradiation area, for example, by means of a plurality of (polygonal) scanners.

[0059] Preferably, in addition to the first irradiation unit having a plurality of individual radiation outlet sections (preferably arranged in at least one row and / or at least one column), an auxiliary irradiation unit (preferably at least one, especially a scanning auxiliary laser unit) is also used, such as a CO laser, a CO2 laser, a fiber laser, and / or a Nd:YAG laser.

[0060] The scanning can be carried out especially by means of a scanning galvanometer (galvanometer scanner) and / or a polygonal scanner and / or a micromirror array. Alternatively or additionally, the beam can be moved over the construction area or irradiation area by means of a uniaxial or multi-axial linear actuator. Generally, microelectromechanical systems (MEM) can be used.

[0061] For certain applications (component structures), it may be advantageous to not only perform irradiation / curing in a raster pattern (with a constant or variable raster size), as achieved by, for example, an array exposure device or a polygonal scanner, but also to form curved curing tracks, for example, by means of a galvanometer mirror. Alternatively or additionally, a light conductor (possibly a light conductor row or a light conductor array) can be provided, which can be moved relative to the construction area in the x / y direction by means of a two-axis linear actuator (this can be achieved, for example, by a separate movement or by the cooperation with the movement of the carrier device).

[0062] In addition, structuring (for example, introducing local holes) may be of interest. Specifically, the laser beam can move from one position to another and stay at a location for a determined short time.

[0063] The above-mentioned auxiliary irradiation unit (or complementary irradiation unit, especially complementary lasers) can be, for example, a CO2 laser or a Nd:YAG laser (e.g., having a scanner-based controller), especially for melting metals and / or polymers whose wavelengths and / or powers using VCSEL and / or VECSEL or other diode lasers cannot be melted, for example, due to insufficient absorption of input energy. The emission wavelength of a CO laser (in the mid-infrared range of 4.8 - 8.3 μm) and / or the emission wavelength of a CO2 laser (in the mid-infrared range of especially 9.4 to 10.6 μm) is especially suitable for processing (curing) metal-containing, especially lithium-containing ceramics and oxides. When adding, for example, conductive carbon black as an absorber, it may also not be possible to satisfactorily melt all conceivable construction materials (without taking such measures).

[0064] Preferably (especially in the second aspect, and if necessary also in the first aspect), it is applied by a movable coating unit. Alternatively or additionally, (especially in the second aspect, and if necessary also in the first aspect), it is cured by a movable irradiation unit. A movable coating unit preferably means that the coating unit (as a whole), i.e., for example, not only the coating arm can move in such a way that the coating unit can be set on different areas (e.g., different individual construction areas), for example, in order to apply multiple components (of the same or different shapes) on a plane. The movement preferably occurs translationally in one direction, particularly preferably alternately / reciprocally between two end positions located at or near the ends of the construction area.

[0065] If necessary, the coating unit can move in such a way that different layers (e.g., arranged at the same height) can be applied. This mobility is not (only) limited to moving for the purpose of applying layers. However, the coating unit can generally be a unit that moves (if necessary only) for the purpose of applying layers. The (movable) irradiation unit can preferably be configured such that the irradiation unit can move (as a whole), for example, in order to (selectively) cure the juxtaposed layers applied by the coating unit as described above. By means of such a movable coating unit and / or such a movable irradiation unit, a relatively large area of the carrier material can be provided with (selectively) cured construction material. Then separation can be achieved, for example, by splitting the carrier material (including the construction material) or splitting the construction material.

[0066] The construction area for curing is preferably rectangular, circular, circular-arc-shaped, circular-sector-shaped, annular, or annular-segment-shaped.

[0067] In some embodiments, rotational (continuous) coating is performed. For example, a rotational coating device can be configured for this purpose. Thereby, spiral curing can be achieved.

[0068] The coating unit for applying the construction material preferably includes at least one roller (exactly two or exactly three or more rollers if necessary), and preferably a drive unit is provided for at least one of the possible multiple rollers. In addition, preferably, the circumferential speed of the (corresponding) roller can be adjusted relative to the (relative) movement speed of the substrate material with respect to the corresponding roller. For example, the circumferential speed of the roller can be equal to the movement speed of the substrate material with respect to the corresponding roller. Alternatively, the circumferential speed of the roller can be different from (lower or higher than) the movement speed of the substrate material with respect to the corresponding roller. The movement of the circumference of the (corresponding) roller in the section facing the substrate material is preferably adjustable. For example, it can be carried out in the same or opposite direction along the movement of the substrate material.

[0069] The (corresponding) roller of the coating unit can have a diameter of 10 mm - 200 mm. The direction of rotation and the rotational speed should also be mentioned.

[0070] Two rollers can be arranged at different z-height levels. The roller for application can form a planar layer with a first height from the metered powder. The roller for compaction in the subsequent operation can compress the leveled layer because this roller is set lower. In the alternating operation (alternating application), these two rollers can exchange their height positions layer by layer.

[0071] (The corresponding) roller can be configured as a rolling mill (especially for compacting the applied layer).

[0072] (The corresponding) roller (rolling mill) can have an anti-sticking agent to reduce the adhesion of the construction material on the roller surface.

[0073] At least one roller can extend at least substantially over the entire width of the carrier material, especially over at least 70% or at least 90% or at least 99% of the width.

[0074] (The corresponding) roller can vibrate during coating or at least be placed in a vibrating state.

[0075] A scraping member can be provided for the (corresponding) roller to scrape off the construction material adhering to the roller.

[0076] In addition, the (corresponding) roller can have a fluidizing device, which includes channels for supplying gas (under pressure if necessary), for example. Thus, for example, powder bridges can be loosened and / or the construction material (powder) can be allowed to flow again.

[0077] The spacing between at least one roller and the carrier material (or carrier film) can be adjustable, for example, adjustable in the range of 5 - 500 μm, preferably in the range of 10 - 100 μm, and particularly preferably in the range of 50 - 70 μm. Thus, the layer thickness can be adjusted in a simple manner and form.

[0078] The coating unit can be configured as a multi-chamber coater (for example, for locally and specifically metering and applying at least two structural materials). The coating unit can have at least one metering unit, which preferably includes at least one chamber meter and / or one or more controllable outlets. The metering unit can extend at least substantially (i.e., especially over at least 70% or at least 90% or at least 99% of the width) over the entire width of the carrier material. The metering unit can vibrate (at least locally) during coating or can at least be placed in vibration. Alternatively or additionally, the metering unit can have a fluidization device, which for example includes a plurality of channels through which a gas (especially under pressure) can be supplied.

[0079] When the metering unit includes a plurality of controllable outlets, these outlets can preferably be opened (or can be selectively - partially or fully - closed) so that the metering can be changed or can be changed over the width of the carrier material.

[0080] Curing can be carried out in a processing chamber. The process gas atmosphere (especially the process gas atmosphere in the processing chamber) can be substantially oxygen-free (for example, having an oxygen content of less than 10000 ppm, preferably less than 1000 ppm, further preferably less than 500 ppm, and particularly preferably less than 200 ppm). Alternatively or additionally, the process gas atmosphere can contain at least one inert gas, such as nitrogen, and / or contain at least one noble gas, such as Ar or He, in an amount of at least 50 vol.%, preferably at least 90 vol.%, and further preferably at least 99 vol.%.

[0081] The process air flow (especially the protective air flow) on the separately applied structural material layer can preferably be achieved at least substantially perpendicular to the conveying direction of the structural material and / or the coating direction of the structural material.

[0082] A monitoring unit can be configured, which can identify, for example, defects and / or abnormalities or deviations, such as delamination.

[0083] Such a monitoring unit can preferably be based on optical tomography, i.e., based on a spatially resolved measurement of the thermal radiation emitted by the construction area. The monitoring unit can, for example, also be designed for the selective curing of (primarily by weight) metallic and (primarily by weight) polymeric construction materials, and for this purpose, it can ensure, especially in a lower temperature range, a correspondingly high sensitivity. It is also conceivable to operate with two separate monitoring units or to form a monitoring unit with a common optical device, which can be connected by two lines (Strang) for processing signals (the lines are, for example, optimized for a higher temperature range in one case and for a lower temperature range in another case, and / or have different band-pass filters).

[0084] Alternatively or additionally, active tomography can be used, especially to check the adhesion on the carrier film. Here, energy (e.g., a flash) can be applied to the carrier film and the layer can be recorded with a thermal imager. At all positions where the layer is not properly connected, the layer will heat up because the layer cannot release the energy to the substrate / membrane.

[0085] The carrier material or carrier tape can extend completely or partially within the processing chamber or the process gas atmosphere. For example, the carrier material or carrier tape can be introduced into the processing chamber on one side of the processing chamber and withdrawn again on the other side.

[0086] The irradiation unit can include at least one radiation source, especially at least one laser device, which is configured to emit a collimated radiation that locally hits the construction material. This especially refers to such an irradiation in which no mask is used to enable only the widely dispersed irradiation to selectively hit the construction material.

[0087] Preferably, at least one curing zone where the construction material is cured can be (indirectly or directly) heated or cooled, and more preferably, the heating or cooling is carried out by heating or cooling the carrier device and / or by heating or cooling the base (such as a carrier stage) for the carrier device and / or by heating or cooling the carrier material, for example, by means of radiation, if necessary, by means of an irradiation unit for curing and / or another irradiation unit, such as an infrared radiation source or a certain number of VCSEL radiators. Alternatively or additionally, the heating can also be carried out by means of at least one resistance heating device, for example, for heating the base.

[0088] By heating (raising the temperature) and / or cooling, especially when using the same irradiation unit, corresponding differences can be compensated for in a simple manner and form, especially in the case of using different materials (for example in different layers), such as differences in melting point. For example, when melting the first layer, additional thermal irradiation can be carried out for heating (temperature adjustment), and when melting the second layer, this irradiation can be stopped or only weakly implemented, and / or cooling can be carried out. The first layer can contain (at least 30 wt.%, or at least 50 wt.%, or at least 70 wt.%, or at least 90 wt.%) metal, and the second layer can contain (at least 30 wt.%, or at least 50 wt.%, or at least 70 wt.%, or at least 90 wt.%) polymer; or vice versa. Heating (raising the temperature) or cooling preferably refers to active heating or cooling. (Active) heating can be achieved, for example, by at least one resistance heater and / or radiation heater. Alternatively or additionally, (active) heating and / or cooling can be achieved, for example, by means of at least one heat pump and / or by means of at least one Peltier element.

[0089] For example, the corresponding construction material can be heated to a temperature slightly below the melting point (for example, if the temperature is expressed in °C, heated to a maximum of 10% below the melting point). Here (above and below), the melting point should in particular refer to such a temperature at which the corresponding construction material has a viscosity of less than 25,000 mPas, and optionally less than 5,000 mPas (preferably measured in accordance with EN ISO 3219 valid as of the priority date or filing date).

[0090] Especially for an irradiation unit having a plurality of (especially individually controllable) radiation outlet sections (such as a single laser diode), the power of the individual radiation outlet sections (laser diodes) can be controlled such that only heating of the construction material is carried out, and at this time, especially the other radiation outlet sections can also be controlled such that melting is achieved (at least in cooperation with the other radiation outlet sections or laser diodes).

[0091] After (initially) applying and (optionally selectively) curing the construction material and optionally before (optionally selectively) applying additional construction material, the construction material can be selectively removed, especially by suction, further preferably by means of at least one suction unit, preferably by means of a suction nozzle assembly. At this time, the suction nozzle assembly preferably includes a plurality of suction nozzles preferably arranged in rows and / or columns, and / or the suction unit is preferably arranged on the coating unit.

[0092] Specifically, a suction nozzle row and / or an array can be provided for targeted (local) suction of uncured construction material. Particularly preferably, additional (especially different) construction material can be applied in the area where the construction material has already been (locally) suctioned away, so that different construction materials can be (selectively) cured in the same plane (or layer) if necessary.

[0093] The suction resolution of the suction device in the longitudinal direction and / or width direction and / or vertical direction is preferably at most 100 times, further preferably at most 20 times, further preferably at most 5 times, further preferably at most 2 times, and even further preferably at most 1 time the resolution of the irradiation unit.

[0094] The construction material can be applied or coated (spread) in a dry state. The construction material can include particles or be formed from especially at least substantially dry powder. The particles of the construction material can have an (average) particle size of at least 1 nm, preferably at least 100 nm, further preferably at least 1 μm, and / or at most 200 μm, preferably at most 10 μm, further preferably at most 5 μm.

[0095] The particle size or grain size can be determined, if necessary, by laser diffraction (especially by laser diffraction measurement according to ISO 13320 or ASTM B822). Alternatively or additionally, the particle size can be determined by measurement (e.g., by means of a microscope) and / or by using dynamic image analysis (preferably according to ISO 13322-2, if necessary with the XT from Retsch Technology GmbH). If the particle size is determined from a two-dimensional image (e.g., by a microscope, especially an electron microscope, if necessary a scanning electron microscope), the corresponding diameter (maximum diameter or equivalent diameter) obtained from the two-dimensional image is preferably used.

[0096] The (average) particle size or grain size of the individual particles of the construction material is preferably the d50 particle size. For the average particle size, the expression d (value) represents the number of particles (by mass percentage and / or volume percentage) that are less than or equal to the given particle size or grain size (i.e., when d50 is 50 μm, 50% of the particles have a size ≤ 50 μm). The particle size is preferably determined by the diameter of the individual particles, which can in turn be the corresponding maximum diameter (the maximum of all distances between every two points in the particle), or the sieve diameter, or the (especially volume-related) equivalent spherical diameter. When the particles are at least partially agglomerated, in particular, the size of the individual particles in the corresponding agglomerate (original particle size) should be used as the corresponding particle size (grain size).

[0097] Individual particles of the construction material may have (at least approximately) the same size, or a particle size distribution may be present.

[0098] Specifically, the construction material may include powders and / or particulate suspensions (nanoparticle suspensions).

[0099] Alternatively or additionally, the construction material may be present (at least in part) in liquid form in its initial state, for example, consisting of a synthetic resin, or be pasty.

[0100] Alternatively or additionally, the construction material may include at least one coherent body (optionally pre-cured by pressure, for example, during coating).

[0101] The construction material may be provided and used in different variants (cumulatively or separately individually).

[0102] The construction material may be a metal-containing construction material and may contain at least one pure metal and / or contain at least one compound containing at least one metal element. The metal-containing construction material preferably contains lithium, for example, in the form of pure lithium and / or LFP (lithium iron phosphate), LCO (lithium cobalt oxide), and / or NMC (lithium nickel manganese cobalt oxide), and / or NCA (lithium nickel cobalt aluminum oxide), and / or LAGP (lithium aluminum germanium phosphate), and / or LATP (lithium aluminum titanium oxide), and / or LLTO (lithium lanthanum titanium oxide), and / or LLZO (lithium lanthanum zirconium oxide), all of these materials optionally in the form of metal-containing solid electrolyte ceramics. In addition, the metal-containing construction material may also be aluminum, for example, in the form of pure aluminum, and / or cobalt, for example, in the form of pure cobalt, and / or nickel, for example, in the form of pure nickel, and / or copper, for example, in the form of pure copper. Such a metal-containing construction material may include at least 30 wt.%, or 50 wt.%, or 70 wt.%, or 90 wt.%, or at least close to 100 wt.% of at least one metal and / or a compound containing at least one metal.

[0103] The construction material may be a polymer-containing construction material and include at least one polymer, preferably PVDF (polyvinylidene fluoride) and / or PVDF-HFP (polyvinylidene fluoride-hexafluoropropylene copolymer) and / or PEO (polyethylene oxide) and / or Nafion, optionally in the form of a solid electrolyte polymer. At least one polymer in the polymer-containing construction material may in particular be an adhesive, such as PVDF. Such a polymer-containing construction material may contain at least one polymer in an amount of at least 50 wt.%, or at least 70 wt.%, or at least 90 wt.%, or at least close to 100 wt.%.

[0104] The structural material may be a structural material with low metal and polymer content and may contain non-metallic elements and / or semiconductor (elements) and / or ceramics and / or oxides (except oxides containing metal elements). The structural material with low metal and polymer content preferably may contain carbon, for example in the form of conductive carbon black and / or graphite, and / or contain silicon, for example in the form of pure (elemental) silicon and / or in the form of silicon oxide. Such a structural material with low metal and polymer content may be at least substantially non-metallic and at least substantially free of polymers (preferably at least 50 wt.%, or at least 70 wt.%, or at least 90 wt.%, or at least nearly 100 wt.% consists of non-metallic and non-polymeric materials, such as consisting of ceramics and / or oxides and / or carbon and / or silicon). Particularly preferably, the structural material with low metal and polymer content contains carbon (at least 50 wt.%, or at least 70 wt.%, or at least 90 wt.%, or at least nearly 100 wt.%). In the case of a structural material with low metal and polymer content, "carbon" refers to carbon in a pure form (for example present as graphite and / or conductive carbon black, i.e., not bonded in a molecular form such as in a polymer).

[0105] In addition, the structural material may include a metal-containing structural material and / or a polymer-containing structural material and / or a structural material with low metal and polymer content. If the structural material includes a plurality of structural materials with different compositions respectively, these structural materials with different compositions respectively are also referred to as structural material components hereinafter. This means that the structural material may contain a metal-containing component and / or a polymer-containing component and / or a component with low metal and polymer content, and the metal-containing, polymer-containing, and metal- and polymer-containing structural material components respectively correspondingly form a metal-containing, polymer-containing, and structural material with low metal and polymer content. Hereinafter, especially for components of an electrochemical device, the active material is also described. The active material is a component of the electrochemical device obtained by processing the structural material and / or the structural material component (for example by curing through irradiation). For example, a metal-containing active material is obtained by processing a metal-containing structural material or a metal-containing structural material component (the same applies to the other structural materials or structural material components mentioned above and the corresponding active materials).

[0106] The structural material may include additives (such as anti-caking agents and / or absorbents), and the additives may exist in the form of separate particles and / or fibers, or as part of composite particles. The structural material especially may include a binder, and the binder is optionally part of the polymer-containing structural material.

[0107] The structural material may include particles that at least partially have metal and polymer components and / or ceramic and polymer components or metal and ceramic components (e.g., metal particles coated with a polymer binder). For example, metal particles and polymer particles (granules) and particles that do not contain metal and polymer may preferably be mixed together in the weight ratios mentioned above. Instead of or in combination with particles, fibers may be used, such as carbon fibers and / or ceramic fibers and / or oxide fibers.

[0108] The metal-containing structural material (or metal-containing structural material component) may include particles that are at least partially composed of pure metals (e.g., lithium, copper, aluminum, cobalt, nickel) and / or particles that are at least partially composed of compounds containing at least one metal element (e.g., LFP, NMC, NCA, LCO, LAGP, LATP, LLTO, LLZO) and particles composed of non-metal and / or polymer materials, and these particles may be mixed with each other in the weight ratios given above. Alternatively or additionally, the metal-containing structural material may include particles that are at least partially composed of pure metals (e.g., lithium, copper, aluminum, cobalt) and / or particles that are at least partially composed of compounds containing at least one metal element (e.g., LFP, NMC, NCA, LCO, LAGP, LATP, LLTO, LLZO), and these particles may additionally include non-metal and / or polymer materials. For example, the metal-containing particle core may be coated with non-metal and / or polymer materials. Conversely, the non-metal and / or polymer particle core may be coated with metal-containing materials. The metal-containing part (metal-containing particle core or metal-containing coating) and the non-metal and / or polymer part (non-metal and / or polymer particle core or non-metal and / or polymer coating) preferably exist in the weight ratios given above with respect to each other.

[0109] The polymer-containing structural material (or polymer-containing structural material component) may include particles that are at least partially composed of polymer materials (e.g., PVDF, PEO, Nafion) and particles composed of non-metal and / or metal-containing materials, and these particles may be mixed with each other in the weight ratios given above. Alternatively or additionally, the polymer-containing structural material may include particles that are at least partially composed of polymers (e.g., PVDF, PEO, Nafion), and these particles may additionally contain non-metal and / or metal-containing materials. For example, the polymer particle core may be coated with non-metal materials and / or metal-containing materials. Conversely, the non-metal and / or metal-containing particle core may be coated with polymer materials. The polymer-containing component (polymer particle core or polymer coating) and the non-metal and / or metal-containing component (non-metal and / or metal-containing particle core or non-metal and / or metal-containing coating) exist in the weight percentages given above with respect to each other.

[0110] Structural materials with low metal and polymer content (or components of structural materials with low metal and polymer content) may include particles at least partially composed of materials with low metal and polymer content (such as ceramics, oxides other than metal-containing oxides, carbon, especially conductive carbon black and / or graphite, silicon), and particles composed of polymers and / or metal-containing materials, and these particles can be mixed with each other according to the weight ratios given above. Alternatively or additionally, structural materials with low metal and polymer content may include particles at least partially composed of materials with low metal and polymer content (such as ceramics, oxides other than metal-containing oxides, carbon, especially conductive carbon black and / or graphite, silicon), and these particles may additionally contain polymer and / or metal-containing materials. For example, a metal-free and polymer-free particle core can be coated with a polymer material and / or a metal-containing material. Conversely, a polymer and / or metal-containing particle core can be coated with a material with low metal and polymer content. The metal-free and polymer-free components (metal-free and polymer-free particle cores or metal-free and polymer-free coatings) and the polymer and / or metal-containing components (polymer and / or metal-containing particle cores or polymer and / or metal-containing coatings) are present relative to each other according to the weight percentage ratios given above.

[0111] Alternatively or additionally, the structural material may include at least one active material specific to a component / part of an electrochemical device, especially:

[0112] Cathode active materials (such as LFP, NMC, NCA, and / or LCO), optionally a binder (such as PVDF, especially 2 - 15 wt.%, preferably 3 - 5 wt.%), and conductive carbon black (especially 0.1 - 10 wt.%, preferably 0.1 - 5 wt.%), and / or

[0113] Anode active materials (usually graphite, optionally with silicon in a proportion of, for example, 1 - 60 wt.%, optionally 10 - 15 wt.%, and / or optionally at least substantially pure silicon), a binder (such as PVDF, especially 5 - 15 wt.%), and conductive carbon black (especially 0.1 - 10 wt.%, preferably 0.1 - 5 wt.%), and / or

[0114] Anode active materials for solid-state batteries (such as lithium, especially lithium powder, preferably without a binder), and / or

[0115] Solid electrolyte materials (such as polymer-containing solid electrolytes, including PVDF-HFP, PEO, and / or Nafion, and / or solid electrolytes, including LAGP, LATP, LLTO, and / or LLZO).

[0116] Alternatively or additionally, the structural material may include: a separator, especially a separator for (conventional) batteries. The separator may be configured as a (thin) polymer film. The polymer may comprise (at least 50 wt.% or 80 wt.% when necessary) polyolefins such as polyethylene and / or polypropylene, and / or polyamides such as PA 6 and / or PA 12 and / or PA 6.6, and / or polyesters.

[0117] When using a solid electrolyte polymer, for example, when a lithium metal anode expands, it can be expected to achieve better ionic conductivity, good processability, and high flexibility. When, for example, the anode expands, preferably, the separator (e.g., composed of one or more solid electrolyte polymers) can absorb force and yield flexibly.

[0118] Solid electrolyte ceramics or corresponding oxides have the advantages of high stability over time and better performance. On the other hand, in order to achieve (at least partial) melting within the range of (selective) curing, a relatively high energy input is required. The above-mentioned and subsequent measures (such as heating a powder bed and / or an auxiliary irradiation device, such as an auxiliary laser, and / or an adhesive) can offset this inherently existing disadvantage.

[0119] Generally, it is preferably to use an adhesive having a relatively high lithium ion conductivity.

[0120] (Especially for manufacturing a cathode structure) the carrier material may be aluminum foil (e.g., with a thickness of 5 - 50 μm, especially 10 - 15 μm, and when necessary, also less than 8 μm or even less than 5 μm). Alternatively, the carrier material may be copper foil, which has a thickness of 5 - 20 μm, especially 10 - 15 μm, such as approximately at least 10 μm, and when necessary, also less than 8 μm or even less than 5 μm.

[0121] It is also possible to apply at least one additional layer composed of the structural material to the (at least partially) cured (first) layer, and also cure the additional layer (completely or selectively). This can be repeated at least once (or any number of times).

[0122] The structural material of the corresponding (additional) layer may be different from that of the first layer (or the layer applied before or after), especially in terms of chemical composition and / or structure, or may be configured to be the same as this structural material. The additional layer may be applied by another and / or the same coating unit (the first layer has also been applied using this coating unit). The additional layer may be cured by another or the same irradiation unit (the first or other layers have also been cured using this irradiation unit). Thus, the corresponding layer can be influenced in terms of its properties and / or its structure. For example, directional porosity and / or varying porosity on the layer can be generated.

[0123] By repeating coating and irradiation (exposure), layers that are higher or thicker and / or of different types, for example composed of the same material, can be applied in a simple manner. Alternatively, by applying a thicker or higher layer of construction material and curing the layer by using correspondingly adjusted energy input parameter values of the irradiation unit, a higher or thicker layer can be produced.

[0124] In an (additive) manufacturing process, the uncured construction material can be guided back into the manufacturing method and used in a further curing process. Before using the construction material in a further curing process, it can be processed and / or mixed with new powder if necessary. The curing of the construction material, especially the polymer-containing construction material and / or the construction material including polymer-containing construction material components, is preferably achieved by (selectively) melting at least one polymer material. The curing of the construction material is particularly preferably achieved by (selectively) melting the binder. By melting and gradually solidifying the binder or polymer material, other (originally not, at least not completely) melted (especially metal-containing and / or non-metal-containing and / or low metal and polymer content) material components can be connected to and / or interconnected with the binder or polymer material.

[0125] Curing the construction material by melting the polymer material or binder can be particularly advantageous because the chemical and / or physical properties (such as conductivity, electron and / or ion transport ability, crystal and / or lattice structure) of other construction materials, especially metal-containing construction materials and / or construction materials with low metal and polymer content, remain unchanged. A change (deterioration) in its chemical and / or physical properties may occur due to the (partial) melting (phase change) of especially metal-containing and / or construction materials with low metal and polymer content.

[0126] In some embodiments, the application of layers of at least one metal-containing construction material, at least one polymer-containing construction material, and at least one construction material with low metal and polymer content is carried out at least partially by means of the same coating unit.

[0127] Alternatively or additionally, the curing of at least one metal-containing construction material, at least one polymer-containing construction material, and at least one construction material without metal and polymer is carried out at least partially by means of the same irradiation unit, preferably a laser unit, and / or by using radiation with the same wavelength.

[0128] The coating unit or the irradiation unit is particularly preferably configured such that at least two of the metal-containing construction materials, the polymer-containing construction materials, and the construction materials with low metal and polymer content can be processed by means of the same respective unit. If necessary, additional measures can be taken for this purpose, such as, for example, using an auxiliary irradiation unit, heating (raising the temperature) or cooling the construction materials and / or using adhesives. This deviates from the conventional processing method, in which significantly different configurations are used for additive manufacturing for different materials (such as metals and polymers).

[0129] The coating direction preferably corresponds to the irradiation direction (or is opposite to the irradiation direction). The coating direction particularly refers to the following direction, which corresponds to the movement direction of the coating unit relative to the construction material (for example, when the construction material itself moves, this does not mean that the coating unit must move absolutely). The irradiation direction can particularly refer to the advancing direction of the radiation hit area relative to the construction material (also relatively speaking). The term "irradiation direction" can relate to the average direction along which a region of the cross-section of the member to be cured is scanned with a beam. That is to say, it does not necessarily relate to the direction of a single curing path or scanning vector. In particular, when the irradiation unit is coupled with a corresponding scanner / beam deflection unit or other drive, this direction can be transverse to, for example, perpendicular to the coating direction in some cases. If the exposure direction (irradiation direction) is the same as the coating direction, particularly precise (selective) curing can be achieved.

[0130] Preferably, the adhesion of the layers for additive manufacturing made of different materials is achieved, which is assisted by the mechanical interlocking caused by the surface treatment if necessary.

[0131] The component (of the electrochemical device) is preferably made of at least one metal-containing construction material and / or at least one polymer-containing construction material and / or at least one construction material with low metal and polymer content. Here, for at least one layer made of a polymer-containing construction material and / or for at least one layer made of a metal-containing construction material and / or for at least one layer made of a construction material with low metal and polymer content, different layer thicknesses can preferably be set.

[0132] Porosity can be introduced into the component in a targeted manner by means of the curing. The porosity can be adjusted (at least locally) in a targeted manner. The porosity can have a gradient. Specifically, the quantity (or density, i.e., the number of pores per unit volume) and / or the size (such as the total volume or the average pore size) can be adjusted, particularly (locally) changed.

[0133] However, alternatively, for example, in an electrochemical device in which lithium ions are conducted in a solid electrolyte, porosity may not be introduced (intentionally) (except for very small porosity that is common within the scope of additive manufacturing methods).

[0134] The gradient of the porosity introduced in a targeted manner preferably extends in the z-direction (i.e., along the surface normal to the surface plane of the carrier device or carrier material; the construction direction).

[0135] Porosity can be introduced (in the desired distribution) by, for example, changing process parameter values such as scanning speed, beam power or laser power, scanning vector spacing, and / or beam shaping. Alternatively or additionally, porosity can be introduced post hoc by laser (e.g., by a polygon scanner). The laser can generate a large number of small pores in the layer to increase tortuosity and thereby achieve improved lithium ion transport.

[0136] Preferably, the component is made of a first construction material and at least one second construction material, and preferably, the material with a higher melting point (i.e., the material having a higher melting point) is applied and irradiated before the material with a lower melting point. In this way, the risk that the layer of the construction material with a lower melting point located beneath it melts again (undesirably) when the construction material with a higher melting point melts can be reduced in a simple manner and form.

[0137] For example, after an electrode for a storage battery (preferably mainly by weight) comprising a metal-containing and / or low metal and polymer content and / or polymer-containing construction material, a separator mainly containing a polymer (preferably by weight) can be printed. In this way, damage to the separator structure due to a possibly higher laser intensity required to melt the metal can be prevented in a simple manner and form (especially when the separator has porosity that should be retained in its structure or distribution). In this case, the separator material is preferably coated only after the electrode (cathode or anode) has been cured. The opposite can also be advantageous when, for example, a separator made of ceramic (or at least 50 wt.% ceramic) is used.

[0138] Preferably, the forward speed of the carrier material is controlled according to the exposure time (irradiation time) and / or the power of the irradiation unit (and / or vice versa). Thereby, the forward speed of the construction material can be adapted to the exposure time (irradiation time) or power.

[0139] Alternatively or additionally, the switching speed of the laser device (laser diode) can be considered for the forward speed, or the forward speed of the construction material can be adapted to the (maximum) switching speed and / or controlled according to the switching speed.

[0140] Furthermore, the above object is achieved in particular by a manufacturing device for additive manufacturing of at least one component of an electrochemical energy storage device, which manufacturing device is preferably configured to carry out the above-described manufacturing method, and the electrochemical device is in particular a storage battery, preferably a lithium-ion storage battery.

[0141] Manufacturing is carried out at least in part by layer-by-layer application and subsequent in particular selective curing of preferably powdery construction material. The manufacturing device comprises: a receiving unit for receiving a carrier device, which carrier device is in the form of a carrier tape, which carrier tape is in particular formed by or comprises a carrier film; a coating unit for applying a layer of construction material to the carrier tape; an irradiation unit for at least partially curing, in particular selectively curing, the construction material on the carrier tape; and a conveying unit for moving the carrier tape relative to at least one preferably stationary first irradiation unit.

[0142] Alternatively or additionally, the above object is achieved in particular by a manufacturing device for additive manufacturing of at least one component of an electrochemical energy storage device, which manufacturing device in particular has the features of the immediately preceding paragraph, which manufacturing device is preferably configured to carry out the manufacturing method described above, and the electrochemical energy storage device is in particular a storage battery, preferably a lithium-ion storage battery, and is manufactured at least in part by layer-by-layer application and subsequent in particular selective curing of preferably powdery construction material. The manufacturing device comprises: a carrier device; a coating unit for applying a layer of construction material to the carrier device; an irradiation unit for at least partially curing, in particular selectively curing, the construction material on the carrier device, which irradiation unit has a plurality of individual preferably arranged radiation outlet segments in at least one row and / or at least one column, in particular a plurality of laser diodes and / or radiation guide ends.

[0143] The coating unit preferably comprises:

[0144] at least one, in particular two or more, rollers, preferably a drive unit is assigned to at least one of the possible plurality of rollers, and further preferably the circumferential speed and / or the direction of rotation is adjusted or adjustable, the circumferential speed being equal to or higher or lower than the relative movement speed of the base material relative to the respective roller, and / or at least one roller extends at least substantially over the entire width of the carrier material and / or vibrates or can at least be placed in vibration, and / or

[0145] at least one metering unit, which metering unit preferably comprises a chamber meter and / or one or more controllable outlets, and / or the metering unit extends at least substantially over the entire width of the carrier material and / or vibrates at least in part or can at least be placed in vibration.

[0146] The corresponding roller and / or metering unit may have a fluidizing device for fluidizing the construction material, as described in connection with the method above.

[0147] Alternatively or additionally, the metering unit may furthermore have a cell wheel gate.

[0148] Alternatively or in addition to one or more rollers, at least one squeegee and / or at least one wiper blade and / or at least one brush and / or at least one rake may be provided.

[0149] Furthermore, the metering unit may also have a stirring mechanism and / or a scraping member in order to be able to continue to convey the adhering construction material.

[0150] The irradiation unit may have a plurality of individual radiation outlet sections (light outlet sections), preferably arranged in at least one row and / or at least one column, in particular a plurality of laser diodes and / or radiation guide ends.

[0151] Preferably, in addition to the (first) irradiation unit, a plurality of individual radiation outlet sections, auxiliary irradiation units, preferably at least one, in particular a scanning auxiliary laser unit, such as a CO laser, a CO2 laser, a fiber laser and / or a Nd:YAG laser, preferably arranged in at least one row and / or at least one column, are provided.

[0152] The scanning auxiliary laser unit may be configured as described above in connection with the method and may in particular be coupled to a scanning galvanometer and / or a polygon scanner and / or a micromirror array.

[0153] The manufacturing device preferably has at least one common coating unit configured for applying a layer of at least one metal-containing construction material and / or at least one polymer-containing construction material and / or at least one construction material with a low metal and polymer content.

[0154] Alternatively or additionally, the manufacturing device has a common irradiation unit, preferably a laser unit, configured for curing at least one metal-containing construction material and / or at least one polymer-containing construction material and / or at least one construction material with a low metal and polymer content.

[0155] For example, a filter device (for reducing the power of the radiation when hitting the construction material) or a beam splitter with a beam collector may be assigned to the (common) irradiation device. For example, when a material with a lower melting point should be melted, it may be preferably selectively introduced into the optical path.

[0156] The manufacturing device may include at least one (additional) coating unit for applying additional layers of construction material and / or at least one additional irradiation unit for curing the additional / said additional layers.

[0157] For example, two coating units can be provided before and after the (corresponding) irradiation unit. Thus, when the irradiation unit reciprocates, irradiation can be performed or a new layer can be (selectively) cured each time it passes by.

[0158] The manufacturing apparatus preferably includes at least one control and / or monitoring unit configured to control and / or monitor at least one parameter during manufacturing, in particular the flatness and / or packing density and / or temperature or temperature distribution of the construction material applied to the carrier device, and / or the flatness and / or density and / or porosity and / or temperature or temperature distribution of the components, where the construction material preferably includes a polymer-containing construction material component and / or at least one metal-containing construction material component and / or at least one construction material component with a low metal and polymer content.

[0159] The manufacturing apparatus preferably includes at least one (active) heating and / or cooling unit for directly or indirectly regulating the temperature, in particular heating or cooling, of the curing zone, for example by radiation, where the construction material cures in the curing zone, preferably by heating or cooling the carrier device and / or by heating or cooling the base of the carrier device and / or by heating or cooling the construction material, and the heating and / or cooling unit is optionally provided at least in part by the irradiation unit for curing and / or a heating unit provided in addition to the irradiation unit, such as an additional irradiation unit, such as an infrared radiation source.

[0160] The temperature regulation is preferably carried out to, for example, a constant temperature (temperature plateau) or a temperature according to a predefined curve, in particular to achieve uniform temperature conditions for all components to be manufactured (same material). By means of the heating and / or cooling unit, in particular when different materials are used (for example in different layers), the corresponding differences (for example in terms of melting point) can be compensated in a simple manner. For example, when melting a layer made of a metal-containing construction material, additional thermal irradiation for heating (temperature regulation) can be carried out, and when melting a layer made of a polymer-containing construction material, this irradiation can be stopped or only weakly implemented, or cooling can be carried out. Alternatively, when melting a layer made of a polymer-containing construction material, additional thermal irradiation for heating (temperature regulation) can also be carried out, and when melting a layer made of a metal-containing construction material, this irradiation can be stopped or only weakly implemented, or cooling can be carried out.

[0161] The gas (process gas) preferably travels in a circulating operation mode (as a closed system).

[0162] Preferably, the oxygen content is monitored. Alternatively or additionally, the laser smoke can be filtered. For this purpose, preferably, there can be provided: a corresponding pipeline, a filtration chamber with a memory filter and / or a cleanable filter (which is preferred), a blower for circulation, and an oxygen sensor, a temperature sensor, a pressure sensor, and / or a volume flow sensor.

[0163] The manufacturing device can have at least one suction unit, preferably a suction nozzle assembly, which includes a plurality of suction nozzles, and these suction nozzles are preferably arranged in rows and / or columns.

[0164] Alternatively or additionally, at least one suction unit can be provided, and the suction unit is configured to be fixed (absolutely speaking, especially with reference to a reference point that is part of a base on which the manufacturing device is arranged during use). Alternatively or additionally, the suction unit can be configured to be fixed relative to the coating unit and / or the irradiation unit. Within the method described above, the suction unit can be correspondingly configured to be fixed (absolutely speaking), or remain fixed in this sense during the manufacturing method. Alternatively or additionally, in the manufacturing method described above, the suction unit can remain fixed relative to the coating unit and / or the irradiation unit during the manufacturing method.

[0165] Other features of the manufacturing device are derived from the description of the method above. The method steps described above can be implemented by corresponding devices configured to implement the corresponding method steps. In addition, the manufacturing device can include the carrier material (described above and / or hereinafter) and / or the structural material (described above and / or hereinafter).

[0166] In addition, the above-mentioned object is particularly achieved by a system including the above-mentioned manufacturing device and the carrier material and / or the structural material.

[0167] In addition, the above-mentioned object is also achieved by the application of the above-mentioned manufacturing device and / or the above-mentioned system to at least one component for additive manufacturing of an electrochemical device, and the electrochemical device is preferably an electrochemical energy storage device, especially a storage battery, preferably a lithium-ion storage battery, and / or an electrolytic cell.

[0168] Preferably, at least 10 wt.%, preferably at least 30 wt.%, optionally at least 50 wt.% or at least 90 wt.% of the corresponding electrochemical device is manufactured additively.

[0169] Other features are obtained from the dependent claims. Description of the Drawings

[0170] The present invention will be described below in detail with reference to the embodiments described with reference to the accompanying drawings. Among them:

[0171] Figure 1Show a manufacturing apparatus according to the present invention with schematic views;

[0172] Figure 2 Show a schematic diagram of a method for manufacturing a structured, three - dimensional layer composite structure;

[0173] Figure 3 Show a schematic diagram of additive manufacturing (such as a solid - state battery cell);

[0174] Figure 4 Show an example of manufacturing an electrochemical device;

[0175] Figure 5 Show another example of manufacturing an electrochemical device; and

[0176] Figure 6 Show another example of manufacturing an electrochemical device. DETAILED DESCRIPTION

[0177] Figure 1 Show a manufacturing apparatus for manufacturing a component with a schematic side view. The manufacturing apparatus includes an irradiation unit 10 and a coating unit 11. The coating unit 11 includes a meter 12, a coating roll (roller) 13, and a counter roll 14. Through the meter 12, a (e.g., powdery) structural material can be metered and output in the direction of the coating roll 13 and the counter roll 14. The coating roll 13 is set or operated such that the coating roll adjusts the thickness of the material application of the structural material 15 on the carrier material 16. The carrier material 16 is a tape (especially a film tape) that can be unwound from a reel (storage reel) 17. Steering can be achieved, for example, by (optionally driven) deflection rollers 18. The steering function is not mandatory. The thickness of the material application can be determined by adjusting the height of the coating unit 11 or the spacing between the coating roll 13 and the carrier material 16. Additionally, the density of the material application can be determined by the relationship between the circumferential speed of the coating roll 13 and the moving speed of the carrier material (see below, e.g., adjustable by the rotational speed of the reel 20). The circumferential speed of the coating roll 13 is preferably greater than the moving speed of the carrier material 16. Thereby, a higher density can be advantageously achieved. Alternatively or additionally, the movement (rotation direction) of the circumference of the coating roll 13 is adjustable. In Figure 1Among them, the movement of the circumference of the coating roller 13 is in the same direction as the movement (moving direction) of the carrier material 16. Preferably, the circumference of the coating roller 13 moves (rotates) in the direction opposite to the movement (moving direction) of the carrier material 16. Thereby, a higher density can be advantageously achieved. Then, the structural material 15 on the carrier material 16 is irradiated in the irradiation area 19 and cured (selectively). Then, the carrier material 16 together with the (selectively) cured structural material 15 thereon can be wound up on another reel 20. A (optionally heatable) processing table 22 is provided between the turning roller 18 and another reel 21.

[0178] The exposure unit (irradiation unit) 10 is preferably a VCSEL exposure device. With the VCSEL exposure device, the adhesive and / or other materials can be melted or structured relatively quickly. Electrodes with shape constraints (for battery manufacturing) can be printed in a simple manner and form. This enables the realization of new battery geometries, which can, for example, be adapted to the structural space and / or can have an integrated cooling device in the battery.

[0179] In Figure 1 The manufacturing device shown is preferably used for manufacturing an electrochemical cell, which comprises or consists of the following:

[0180] - A preferably porous cathode, which consists of a metal-containing active material obtained by processing a metal-containing structural material by (by means of irradiation), the structural material mainly (especially in an amount of 75 - 97.9 wt.%, preferably 90 - 96 wt.%) comprises at least one metal-containing material (such as LFP, NMC, NCA, and / or LCO) and conductive carbon black (especially in an amount of 0.1 - 10 wt.%, preferably 1 - 5 wt.%), and optionally further comprises a (polymeric) binder (such as PVDF, especially in an amount of 2 - 15 wt.%, preferably 3 - 5 wt.%).

[0181] - A separator, especially for a (conventional) battery. The separator can be configured as a (thin) polymer film. The polymer can contain (if necessary, at least 50 wt.% or 80 wt.%) polyolefins, such as polyethylene and / or polypropylene, and / or polyamides, such as PA 6 and / or PA 12 and / or PA 6.6, and / or polyesters.

[0182] -Preferably, a porous anode, especially an anode with a porosity of at least 20 vol.%, and optionally at least 40 vol.%, is composed of a metal and a low-metal and polymer active material. The low-metal and polymer active material is obtained by processing a low-metal and polymer structural material (by means of irradiation). The low-metal and polymer active material mainly includes carbon, preferably carbon in the form of conductive carbon black and / or graphite (especially preferably in the form of graphite particles), and / or includes a binder (such as PVDF, especially 5-15 wt.%). The active material preferably contains 0.1-10 wt.%, especially preferably 1-5 wt.%, of conductive carbon black in the carbon component. In addition, preferably, the active material contains a certain proportion (0.1-60 wt.%, especially preferably 10-15 wt.%) of silicon in the carbon component. The silicon is in the form of at least substantially pure (elemental) silicon and / or silicon oxide, such as in the form of silicon particles and / or SiO2 particles. Optionally, the carbon component can be at least substantially replaced by a silicon and / or SiO2 component, so that the low-metal and polymer active material mainly contains silicon and / or silicon oxide, preferably at least 60 wt.%, especially preferably at least 90 wt.%, and / or contains a binder (such as PVDF, especially 5-20 wt.%), and / or conductive carbon black (especially 5-20 wt.%).

[0183] According to Figure 1 Preferably, a (conventional) electrochemical lithium-ion battery or its components can be manufactured. Such a battery can have one or more porous layers and / or a liquid electrolyte.

[0184] Such an electrochemical cell can be manufactured based on a film strip including an aluminum layer (as the first current collector). The cathode, and then in turn the separator and the anode, can be mounted (especially the cathode and the anode) and / or applied (especially the separator) on the aluminum layer (current collector). Next, a copper layer (as the second current collector) can be applied to the thus-formed electrochemical cell. Alternatively, the aluminum layer and / or the copper layer (current collector) can be additively manufactured by an irradiation unit (10) from a metal-containing structural material, especially a structural material containing at least substantially pure aluminum or copper. The manufacture of a layer (current collector) substantially composed of pure metal (aluminum or copper) can be carried out by means of a heat conduction welding method, a deep welding method, and / or a combination thereof, especially in order to achieve a determined material density and / or crystal structure and / or porosity.

[0185] The following process is considered as conduction welding, in which the radiation power introduced into the construction material by radiation per unit area is too low to cause evaporation of the construction material. The energy diffuses into the construction material by heat conduction, which results in a small expansion of the molten pool generated by radiation in the direction perpendicular to the surface. In contrast, in the deep welding process, a sufficiently high radiation power per unit area is achieved, whereby material transport also occurs in the direction perpendicular to the surface. This means that the construction material is evaporated and at the same time the material that has been processed (solidified) during the previous exposure process is remelted (this results in the formation of a so-called "keyhole"). In particular, when a high surface quality (evenness) and / or a uniform crystal structure must be achieved, the construction material can be advantageously processed using the conduction welding process, while when a firm bond must be achieved between the layers of an electrochemical cell (with each other and / or on a substrate), the construction material can be advantageously processed using the deep welding process. This firm bond is achieved by simultaneously melting different layers / construction materials.

[0186] Figure 2 A method for manufacturing a structured three-dimensional layer composite structure is shown in a schematic manner and form, and the layer composite structure is formed into an electrochemical device (such as a pouch battery or also a battery in the form of a cylindrical structure) using a continuous process. First, a (for example, strip-shaped) carrier material 16 (substrate) is introduced into a processing chamber (not shown). For this purpose, for example, a movable table or a (conveyor) belt can be used. Alternatively or additionally, the carrier material 16 itself can be constructed additively (for example, in the processing chamber). Arrow 23 indicates the direction of movement (transport direction) of the carrier material 16 (and thus also the other layers constructed thereon step by step). On the Figure 2 left side, first, a first construction material 15a is applied to the carrier material 16, and it is leveled with the aid of a first leveling device (such as a squeegee) 24a (the layer thickness can be adjusted simultaneously).

[0187] The applied layer of the first construction material 15a is selectively cured by a first irradiation unit 10a (wherein the uncured construction material can be sucked away, especially selectively, which is in Figure 2(not shown in the figure). Then, the second construction material 15b is applied to the carrier material 16 and the first construction material 15a, leveled (or the layer thickness is adjusted accordingly) by means of the second leveling device 24b, and selectively cured by means of the second irradiation unit 10b. For the third construction material 15c and the fourth construction material 15d, these steps are successively repeated by means of the third and fourth leveling devices 24c and 24d and the third and fourth irradiation devices 10c and 10d. Here, the subsequent construction materials can be applied above and / or beside the previously applied construction materials and selectively cured (when, for example, suction is performed, such as selective suction). At the end of this process, a structured three-dimensional body can exist in which, for example, five different materials (separately in themselves) have been selectively cured in particular.

[0188] (Corresponding) irradiation units 10a - 10d can be, for example, irradiation units that apply a plurality of laser beams side by side (in the Y and / or X direction). The X direction is preferably the movement direction of the construction material (relative to the corresponding irradiation unit). The Z direction is the construction direction. The Y direction is the direction perpendicular to the X direction and the Z direction.

[0189] Different from the shown 4 - level structure, fewer (for example two or three) or more (for example 5 or more) levels (with corresponding leveling devices or coating devices and irradiation units) can also be provided. For example, when corresponding sections of the carrier material 16 enter the irradiation area of the corresponding irradiation unit multiple times (which can be achieved, for example, by retracting the carrier material 16 or using a surrounding carrier material 16), different layers can also be cured or other construction materials can be cured in separate processes using a corresponding irradiation unit (such as the first irradiation unit 10a).

[0190] Figure 3 Schematic diagram showing additive manufacturing (such as a solid battery cell). The coating unit 11 and the irradiation unit 10 can move within the processing chamber 30. The corresponding movement directions are indicated by arrows 31. The coating unit 11 and the irradiation unit 10 can preferably move along corresponding guiding structures (especially linear guiding structures) 32.

[0191] The processing chamber can be filled with an inert gas (such as argon) by means of an inert gas supply device 42. The gas in the processing chamber can leave the processing chamber via the gas outlet 33. Optionally, sensors can be provided, such as a pressure sensor 34, an oxygen detection sensor 35, and a temperature sensor 36, in order to measure different parameters inside the processing chamber (such as the pressure, oxygen content, and / or temperature of the gas in the processing chamber). Optionally, a monitoring unit 39 is constituted, which can identify defects and / or anomalies or deviations, such as delamination.

[0192] Here, the coating unit 11 (exemplarily) includes three metering units 12a, 12b, and 12c, so that different construction materials 15a - 15c can be applied. The layer composite structure is gradually applied to the construction platform 37 (which can be adjusted according to height) (and by irradiation by means of the irradiation unit 10 immediately after the corresponding coating process). The irradiation unit 10 can have a plurality of radiation outlet sections 38. Optionally, corresponding suction devices 43a, 43b are provided on the side of the coating unit 11. These suction devices enable the removal of unmelted powder again.

[0193] In a preferred embodiment, there are two coating units (not shown in Figure 3 ), and the irradiation unit 10 can be located between these two coating units 11, so that exposure can be carried out more efficiently. For example, the corresponding coating cavities or multi - cavity coaters can be filled in the end positions.

[0194] In Figure 3 The manufacturing device shown is preferably used for manufacturing an electrochemical cell, which includes or consists of the following:

[0195] - A first current collector, for example based on aluminum (especially for a composite cathode). Such an aluminum - based current collector can be formed by processing a preferably powdered construction material mainly composed of pure aluminum (by irradiation curing).

[0196] - A cathode, which includes at least one or at least or exactly two metal - containing active materials, and the active materials are obtained by processing a metal - containing construction material (by irradiation). At least one metal - containing first active material can include LATP and / or LLTO and / or LLZO, and / or at least one metal - containing second active material can include LFP and / or NMC and / or NCA and / or LCO. The cathode preferably mainly (75 - 99 wt.%, preferably 90 - 95 wt.%) consists of one or more of the above - mentioned materials. Optionally, the cathode active material can contain at least one binder (such as PVDF, and if necessary, 1 - 25 wt.% or preferably 5 - 10 wt.%).

[0197] - An electrolyte material, especially a polymer - containing electrolyte material, such as including PVDF - HFP, PEO, and / or Nafion, and / or especially a metal - containing, preferably lithium - containing electrolyte material, such as LAGP, LATP, LLTO, and / or LLZO. Optionally, the electrolyte material can be made based on polymer - containing and metal - containing construction materials, that is, made from a construction material including polymer - containing and metal - containing construction material components. The electrolyte material is preferably configured as a solid - state electrolyte material. This especially means that the electrolyte material has a very small porosity.

[0198] - For example, a lithium-based anode. Such a lithium-based anode can be formed by processing a metal-containing, preferably powdered, construction material mainly composed of pure lithium (by means of radiation curing). The anode is preferably configured as a solid-state battery anode; this particularly means that the anode has a very small porosity.

[0199] - For example, a copper-based second current collector. Such a copper-based current collector can be formed by processing a metal-containing, preferably powdered, construction material mainly composed of pure copper (by means of radiation curing).

[0200] Figure 3 It can be particularly preferably used in ceramic-based solid-state batteries. Such a solid-state battery can be configured without porosity in individual / single active layers. Alternatively or additionally, the anode can have (pure) lithium or be formed of lithium. Due to its reactivity with air, it is advantageously processed under an inert gas (pure) lithium, which can be achieved in a simple manner in the Figure 3 equipment. Alternatively or additionally, the cathode can be a composite material composed of a lithium-ion conductor and a lithium-ion storage material (active material).

[0201] Alternatively or additionally, the construction material can include a separator, especially a separator for (conventional) batteries. The separator can be configured as a (thin) polymer film. The polymer can contain (if necessary at least 50 wt.% or 80 wt.%) for example polyethylene and / or polypropylene, and / or polyamide, such as PA 6 and / or PA 12 and / or PA 6.6, and / or polyester. In some applications, the separator can especially replace the solid electrolyte material. The manufacture of components of an electrochemical cell mainly composed of pure metal (such as lithium, aluminum or copper) can be carried out by a heat conduction welding method, a deep welding method and / or a combination thereof, especially in order to achieve a determined material density and / or crystal structure and / or porosity. In particular, when a high surface quality (uniformity) and / or a uniform crystal structure must be achieved, the construction material can advantageously be processed by a heat conduction welding process, while when a firm bond must be achieved between the layers (components) of the electrochemical cell, the processing of the construction material by a deep welding process may be advantageous. Such a firm bond is especially achieved when melting different layers / construction materials simultaneously.

[0202] Figures 4 - 6 Shows different examples for the manufacture of an electrochemical device, specifically a storage battery. In Figure 4In this case, for example, a plurality of cathode structures 41 (e.g., LFP, e.g., having a thickness of 45 μm) are fabricated onto a carrier film 40 (e.g., an aluminum carrier film, e.g., having a thickness of 12 μm). Curing can be carried out, for example (locally), by means of a certain number of VCSEL exposure units, e.g., already having the shape of a (subsequent) pouch cell. If necessary, the unmelted material can be suctioned off and in some cases returned.

[0203] Figure 5 Corresponding to the embodiment according to Figure 4 there are the following differences. In Figure 5 continuous exposure is carried out to fabricate cathode strips for manufacturing (subsequent) cylindrical battery cells. The corresponding irradiation (exposure) can be carried out continuously.

[0204] In a subsequent step, irradiation (exposure) can be carried out, if necessary, on the back side (in principle in the same manner and form), calendering can be carried out if necessary, and then optionally cut into "daughter rolls (Tochterrollen)".

[0205] Figure 6 shows an embodiment that also corresponds to Figure 4 with the following differences. As shown in Figure 6 by the manufacturing method proposed here, different (more complex) shapes can be selected for the cathode structure 41. Thereby, ergonomic and space-saving manufacturing can be achieved. For example, a cooling device can also be integrated.

[0206] It should be noted here that all the components or functions described above, individually as well as in any combination, especially the details shown in the drawings, are claimed as important parts of the present invention. Modifications thereto are well known to those skilled in the art.

[0207] In addition, it should be noted that the broadest possible scope of protection is desired. In this regard, the disclosure contained in the claims can also be specified by features described with other features (even if such other features are not compulsorily included). It should be clearly noted that the parentheses and the expression "in particular" should emphasize the optional nature of the features in their respective contexts (which should not mean, in the opposite case, that a feature is considered mandatory in the corresponding case if there is no such indication).

[0208] List of reference numerals 10a - d Irradiation unit (exposure unit) 11 Coating unit

[0209] 12a - c Meter (metering device) 13 Coating roller

[0210] 14 Corresponding roller

[0211] 15a-d Structural material

[0212] 16 Carrier material

[0213] 17 Roller

[0214] 18 (Steering) roller

[0215] 19 Irradiation area

[0216] 20 Reel

[0217] 21 Reel

[0218] 22 Processing table

[0219] 23 Direction of movement

[0220] 24a-d Levelling device

[0221] 25 Current collector

[0222] 26 Cathode

[0223] 27 Solid-state electrolyte

[0224] 28 Anode

[0225] 29 Current collector

[0226] 30 Irradiation unit

[0227] 31 Direction of movement

[0228] 32 Guide structure

[0229] 33 Gas outlet

[0230] 34 Pressure sensor

[0231] 35 Oxygen detection sensor

[0232] 36 Temperature sensor

[0233] 37 Structural platform

[0234] 38 Radiation outlet section

[0235] 39 Monitoring unit

[0236] 40 Carrier film

[0237] 41 Cathode structure

[0238] 42 Inert gas supply device

[0239] 43a, 43b Suction device.

Claims

1. A method for manufacturing at least one component of an electrochemical device for additive manufacturing, wherein the electrochemical device is preferably an electrochemical energy storage device, in particular a storage battery, preferably a lithium-ion storage battery, and / or an electrolytic cell. The manufacturing method is carried out at least in part by layer-by-layer application and subsequent, in particular selective, curing of a preferably powdery construction material. The manufacturing method comprises the following steps: - Providing a carrier device in the form of a carrier tape, which carrier tape in particular comprises or is formed by a carrier film, which carrier film is preferably metallic. - Applying at least one layer of the construction material to the carrier tape. - Supplying the construction material into the irradiation area (19) of at least one preferably stationary first irradiation unit (10), and at least partially curing, in particular selectively curing, the construction material on the carrier tape by means of the at least one first irradiation unit.

2. A method for manufacturing at least one component of an electrochemical device for additive manufacturing, preferably the manufacturing method according to claim 1, wherein the electrochemical device is preferably an electrochemical energy storage device, in particular a storage battery, preferably a lithium-ion storage battery, and / or an electrolytic cell. The manufacturing method is carried out at least in part by layer-by-layer application and subsequent, in particular selective, curing of a preferably powdery construction material. The manufacturing method comprises the following steps: - Applying at least one layer of the construction material to the carrier device. - At least partially curing, in particular selectively curing, the construction material on the carrier device by means of at least one first irradiation unit (10), which first irradiation unit (10) has a plurality of individual radiation outlet segments preferably arranged in at least one row and / or at least one column, in particular a plurality of laser diodes and / or radiation guide ends.

3. The manufacturing method according to any one of the preceding claims, characterized in that, The manufacturing method is a continuous method.

4. The manufacturing method according to any one of the preceding claims, characterized in that, The carrier tape and / or its carrier film are provided in an at least partially rolled-up and / or folded state.

5. The manufacturing method according to any one of the preceding claims, characterized in that, After curing the construction material, the carrier tape and / or its carrier film are at least partially rolled up and / or folded, optionally together with the construction material or without the construction material.

6. The manufacturing method according to any one of the preceding claims, characterized in that, After curing, the construction material is transferred from the carrier material of the carrier tape, preferably formed by the carrier film - hereinafter also referred to as the first carrier material - to a further optionally flexible second carrier material, preferably in a roll-to-roll process, or left on the first carrier material.

7. The manufacturing method according to any one of the preceding claims, characterized in that, The back side of the carrier tape and / or its carrier film is also provided with a layer of construction material that is in particular selectively cured.

8. The manufacturing method according to any one of the preceding claims, wherein, Application is carried out by means of a stationary coating unit and / or curing is carried out by means of a stationary irradiation unit (10).

9. The manufacturing method according to any one of the preceding claims, characterized in that, The irradiation unit (10) has a plurality of individual radiation outlet segments preferably arranged in at least one row and / or at least one column, in particular a plurality of laser diodes and / or radiation guide ends.

10. The manufacturing method according to any one of the preceding claims, characterized in that, When irradiated by the irradiation unit (10), the carrier tape moves forward.

11. The manufacturing method according to any one of the preceding claims, wherein, The irradiation unit comprises at least one VCSEL and / or VECSEL.

12. The manufacturing method according to any one of the preceding claims, wherein, An additional irradiation unit is attached to the first irradiation unit having a plurality of individual radiation exit segments preferably arranged in at least one row and / or at least one column, and an auxiliary irradiation unit is also used, preferably at least one, in particular a scanning auxiliary laser unit, such as a CO laser, a CO2 laser, a fiber laser and / or a Nd:YAG laser.

13. The manufacturing method according to any one of the preceding claims, wherein, Application is carried out by a movable coating unit and / or curing is carried out by a movable irradiation unit.

14. The manufacturing method according to any one of the preceding claims, wherein, The construction area for curing is rectangular, circular, circular arc-shaped, circular sector-shaped, annular or annular segment-shaped.

15. The manufacturing method according to any one of the preceding claims, wherein, Rotary coating is carried out.

16. The manufacturing method according to any one of the preceding claims, characterized in that, The coating unit (11) for applying the construction material includes: At least one, in particular two, preferably three or more rollers (13, 14), preferably a drive unit is assigned to at least one of the possibly multiple rollers (13), further preferably the circumferential speed of at least one roller is adjusted or adjustable, the circumferential speed being equal to or different from the relative movement speed of the carrier belt relative to the corresponding roller, and / or at least one roller extends at least substantially over the entire width of the carrier belt and / or vibrates or at least can be placed in vibration and / or has a fluidization device, and / or At least one metering unit (12) for metering the construction material onto the carrier device, the metering unit preferably includes a chamber meter and / or one or more controllable outlets, and / or the metering unit extends at least substantially over the entire width of the carrier belt and / or vibrates at least partially or at least partially can be placed in vibration and / or has a fluidization device.

17. The manufacturing method according to any one of the preceding claims, wherein, Curing is carried out in a processing chamber and / or in a process gas atmosphere preferably substantially free of oxygen, the process gas atmosphere including, for example, nitrogen and / or at least one noble gas, such as in particular argon and / or helium, and the carrier belt preferably extends completely or only partially in the processing chamber or the process gas atmosphere.

18. The manufacturing method according to any one of the preceding claims, characterized in that, The irradiation unit includes at least one radiation source, in particular at least one laser device, which is configured to emit a focused radiation that locally hits the construction material.

19. The manufacturing method according to any one of the preceding claims, characterized in that, For example, by means of radiation, if necessary with the aid of the irradiation unit for curing and / or another irradiation unit, such as an infrared radiation source, preferably by heating or cooling the carrier device and / or by heating or cooling the base for the carrier device and / or by heating or cooling the carrier material, the curing section where the construction material is cured is indirectly or directly heated or cooled.

20. The manufacturing method according to any one of the preceding claims, characterized in that, After the initial application and, if necessary, selective curing of the construction material, and optionally before the optional selective application of additional construction material, the construction material is selectively removed, preferably by suction, further preferably by means of at least one suction unit, preferably by means of a suction nozzle assembly, the suction nozzle assembly preferably including a plurality of suction nozzles, the plurality of suction nozzles preferably being arranged in rows and / or columns, and / or the suction unit is arranged on the coating unit.

21. The manufacturing method according to any one of the preceding claims, characterized in that, The structural material includes particles, and the particles of the structural material preferably have an average particle size of at least 1 nm, preferably at least 100 nm, more preferably at least 1 μm and / or a maximum of 200 μm, preferably a maximum of 10 μm, more preferably a maximum of 5 μm. The structural material includes in particular powders and / or particulate suspensions (nanoparticle suspensions), and / or The structural material is liquid in its initial state, for example composed of a synthetic resin, or is pasty, and / or The structural material includes at least one coherent, optionally pre-cured mass.

22. The manufacturing method according to any one of the preceding claims, wherein, The structural material contains specific active materials, preferably including: Cathode active materials (such as LFP, NMC, NCA and / or LCO), optionally including a binder (such as PVDF, especially 2-15 wt.%, preferably 3-5 wt.%) and conductive carbon black (especially 0.1-10 wt.%, preferably 0.1-5 wt.%), and / or Anode active materials (usually graphite, optionally with a small proportion of, for example, 10-15 wt.% of silicon, and / or silicon), binder (such as PVDF, especially 5-15 wt.%) and conductive carbon black (especially 0.1-10 wt.%, 0.1-5 wt.%), and / or Solid-state battery anode active materials (such as lithium, especially lithium powder, preferably without a binder), and / or Solid-state electrolyte materials (such as solid-state electrolyte polymers, such as PVDF-HFP, PEO and / or Nafion, and / or solid-state electrolyte ceramics and / or solid-state electrolyte oxides, such as LAGP, LATP, LLTO and / or LLZO).

23. The manufacturing method according to any one of the preceding claims, wherein, At least one additional layer composed of the structural material is also applied to at least a partially cured layer, hereinafter also referred to as the first layer. The structural material of the additional layer can be different from that of the first layer or can be configured to be the same as that of the first layer; and / or the additional layer can be applied by an additional and / or the same coating unit (11); and / or the additional layer can be cured by an additional or the same irradiation unit (10).

24. The manufacturing method according to any one of the preceding claims, wherein, The uncured structural material is guided back into the manufacturing method and used in a further curing process.

25. The manufacturing method according to any one of the preceding claims, wherein, The curing is carried out by melting the polymer-containing structural material, preferably the binder.

26. The manufacturing method according to any one of the preceding claims, wherein, The application of at least one metal-containing structural material and / or at least one polymer-containing structural material and / or a structural material with low metal and polymer content is carried out at least in part by means of the same coating unit, and / or the curing of at least one metal-containing structural material and / or at least one polymer-containing structural material and / or a structural material with low metal and polymer content is carried out at least in part by means of the same irradiation unit, preferably a laser unit, and / or using radiation of the same wavelength.

27. The manufacturing method according to any one of the preceding claims, wherein, The coating direction corresponds to the irradiation direction.

28. The manufacturing method according to any one of the preceding claims, wherein, The adhesion of layers for additive manufacturing made of different materials is carried out, and the adhesion is assisted if necessary by the interlocking of surface process bands.

29. The manufacturing method according to any one of the preceding claims, wherein, The component is made of at least one metal-containing construction material and / or at least one polymer-containing construction material and / or at least one construction material with low metal and polymer content, and different layer thicknesses are provided for at least one layer constructed of a metal-containing construction material and / or for at least one layer constructed of a polymer-containing construction material and / or for at least one layer constructed of a metal- and polymer-free construction material.

30. The manufacturing method according to any one of the preceding claims, wherein, Porosity is introduced into the component in a targeted manner by means of the curing and / or the porosity is adjusted at least locally in a targeted manner, and the porosity preferably has a gradient.

31. The manufacturing method according to any one of the preceding claims, wherein, The component is made of at least one first construction material and at least one second construction material, and the material with a higher melting point is irradiated before the material with a lower melting point.

32. A manufacturing apparatus for manufacturing at least one component of an additive manufactured electrochemical device, preferably a manufacturing apparatus configured to implement the manufacturing method according to any one of the preceding claims, the electrochemical device preferably being an electrochemical energy storage device, in particular a storage battery, preferably a lithium-ion storage battery, and / or an electrolytic cell, which is manufactured at least in part by layer-by-layer application and subsequent, in particular selective, curing of preferably powdery construction materials, the manufacturing apparatus comprising: A receiving unit for receiving a carrier device in the form of a carrier tape, the carrier tape being formed in particular by a carrier film or including a carrier film; A coating unit (11) for applying a layer of construction material to the carrier tape; an irradiation unit for at least partially curing, in particular selectively curing, the construction material on the carrier tape; And a conveying unit for moving the carrier tape relative to at least one preferably stationary first irradiation unit (10).

33. A manufacturing device for manufacturing at least one component of an electrochemical device by additive manufacturing, preferably the manufacturing device according to claim 32 and / or configured to implement the manufacturing method according to any one of the preceding claims, the electrochemical device preferably being an electrochemical energy storage device, in particular a storage battery, preferably a lithium-ion storage battery, and / or an electrolytic cell, and being manufactured at least partially by successively applying and subsequently, in particular selectively curing, preferably powdered construction materials, the manufacturing device comprising; a carrier device; a coating unit (11) for applying a layer of construction material to the carrier device; an irradiation unit for at least partially curing, in particular selectively curing, the construction material on the carrier device, the irradiation unit (10) having a plurality of individual radiation outlet sections, preferably arranged in at least one row and / or at least one column, in particular a plurality of laser diodes and / or radiation guide ends.

34. The manufacturing apparatus according to claim 32 or 33, characterized in that, The coating unit (11) comprises: at least one, in particular two or three or more rollers (13, 14), preferably a drive unit is assigned to at least one of the possibly multiple rollers (13), and further preferably the circumferential speed and / or the direction of rotation of at least one roller is adjusted or adjustable, the circumferential speed being equal to or higher or lower than the relative movement speed of the carrier tape relative to the respective roller, and / or at least one roller extends at least substantially over the entire width of the carrier tape and / or vibrates or can at least be placed in vibration, and / or At least one metering unit (12), the metering unit preferably comprising a chamber meter and / or one or more controllable outlets and / or one or more rows and / or columns of controllable outlets, and / or the metering unit extends at least substantially over the entire width of the carrier tape and / or vibrates at least partially or can at least partially be placed in vibration.

35. The manufacturing apparatus according to any one of claims 32 to 34, wherein, Attached to a first irradiation unit having a plurality of individual radiation outlet sections, preferably arranged in at least one row and / or at least one column, there is an auxiliary irradiation unit, preferably at least one, in particular a scanning auxiliary laser unit, such as a CO laser, a CO2 laser, a fiber laser, and / or a Nd:YAG laser.

36. The manufacturing apparatus according to any one of claims 32 to 35, wherein, There is a common coating unit configured for the application of layers of at least one metal-containing construction material and / or at least one polymer-containing construction material and / or a construction material with low metal and polymer content, and / or there is a common irradiation unit, preferably a laser unit, configured for curing at least one construction material containing at least 50 wt.% of metal and at least one construction material containing at least 50 wt.% of polymer.

37. The manufacturing apparatus according to any one of the preceding claims 32 to 36, said manufacturing apparatus including at least one additional coating unit for applying additional layers of construction material and / or at least one additional irradiation unit for curing one / the additional layer.

38. The manufacturing apparatus according to any one of the preceding claims 32 to 37, said manufacturing apparatus including at least one control and / or monitoring unit configured for controlling and / or monitoring at least one parameter during manufacturing, in particular the flatness and / or packing density and / or temperature or temperature distribution of the construction material applied to the carrier device and / or the flatness and / or density or porosity and / or temperature or temperature distribution of the component, the construction material preferably comprising at least one metal-containing construction material component and / or at least one polymer-containing construction material component and / or at least one construction material component with low metal and polymer content.

39. The manufacturing apparatus according to any one of the preceding claims 32 to 38, characterized in that, There is at least one heating and / or cooling unit for directly or indirectly conditioning, in particular heating or cooling, the curing zone where the construction material is cured, for example by heating or cooling the carrier device preferably by means of radiation and / or by heating or cooling the base for the carrier device and / or by heating or cooling the construction material, the heating and / or cooling unit optionally being at least partially provided by the irradiation unit for curing and / or a heating unit provided in addition to the irradiation unit, such as an additional irradiation unit, such as an infrared radiation source.

40. The manufacturing apparatus according to any one of claims 32 to 39 described above, characterized in that, There is at least one suction unit, preferably a suction nozzle assembly, the suction nozzle assembly preferably including a plurality of suction nozzles, the suction nozzles preferably being arranged in rows and / or columns, and / or the suction unit is preferably arranged on the coating unit.

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