Electrode calendering with rollers with controllable sleeves

Abstract

The invention relates to electrode rolling with rollers with controllable sleeves. An electrode calendering system for reducing electrode wrinkling after calendering includes at least one roller configured to compress an electrode and a sleeve. The roller is defined by an outer surface configured to contact the electrode. The outer surface has a first edge portion at a first side of the roller and a second edge portion at a second side of the roller opposite the first side. When the electrode contacts the roller, the first and second edge portions of the roller are aligned with the first and second outer edges of the electrode. A sleeve is disposed around the outer surface of the roller along the first edge portion, the sleeve having a controllable thickness to adjust a pressure between the first outer edge of the electrode and the sleeve. Other example systems and methods for reducing post-calendering electrode corrugation are also disclosed.

Description

[0001] introduction

[0002] The information provided in this section is for the purpose of generally presenting the context of the present disclosure. To the extent described in this section, the works of the presently named inventors and aspects of the description that may not constitute prior art at the time of filing are neither explicitly nor impliedly admitted to be prior art to the present disclosure. Technical Field

[0003] The present disclosure relates to electrode calendering with rollers having a controllable sleeve, and more particularly to electrode calendering with rollers having a sleeve whose thickness is actively and / or passively adjusted to reduce wrinkling of the electrode. Background Art

[0004] An electric power source, such as a battery for a vehicle, includes an anode electrode and a cathode electrode. The anode electrode may include lithium. In such an example, the lithium metal anode may be formed by applying a layer of lithium material to a layer of copper material to form a stack, and then cold rolling (or calendering) the stack between a pair of rollers. Summary of the Invention

[0005] An electrode calendaring system for reducing electrode wrinkling after calendaring includes at least one roller configured to compress an electrode and a sleeve. The roller is defined by an outer surface configured to contact the electrode. The outer surface has a first edge portion on a first side of the roller and a second edge portion on a second side of the roller opposite the first side. When the electrode contacts the roller, the first and second edge portions of the roller align with the first and second outer edges of the electrode. A sleeve is disposed around the outer surface of the roller along the first edge portion, the sleeve having a controllable thickness to adjust the pressure between the first outer edge of the electrode and the sleeve.

[0006] In other features, the sleeve is a first sleeve, the electrode calendaring system further includes a second sleeve disposed on the outer surface of the roller along the second edge portion, and the second sleeve has a controllable thickness to adjust the pressure between the second outer edge of the electrode and the second sleeve.

[0007] In other features, the thickness of the sleeve is passively adjusted to regulate the pressure between the first outer edge of the electrode and the sleeve.

[0008] In other features, the sleeve includes a plurality of knitted courses, each knitted course having loops that interlock with loops of adjacent ones of the plurality of knitted tapes.

[0009] In other features, one or more of the knit courses includes an inlay element knitted therein.

[0010] In other features, the sleeve includes a plurality of inlay elements having a sinusoidal shape in a circumferential direction relative to the roller.

[0011] In other features, the plurality of knit courses includes a first set of courses formed from the smart material and a second set of courses formed from the non-smart material, and the first set of courses and the second set of courses are juxtaposed or alternate within the sleeve.

[0012] In other features, the sleeve includes a smart material element.

[0013] In other features, the smart material element includes a superelastic shape memory alloy.

[0014] In other features, the sleeve includes a support layer and a smart material element integrated into the support layer.

[0015] In other features, the support layer is a first support layer, and the sleeve includes a second support layer disposed along a surface of the first support layer such that a portion of the layer of smart material is positioned between the first support layer and the second support layer.

[0016] In other features, the electrode calendering system also includes at least one optical sensor disposed downstream of the roller, a control module in communication with the optical sensor, and the control module is configured to receive a signal from the optical sensor and control a temperature control device based on the signal from the optical sensor to adjust the temperature of the sleeve, thereby adjusting the pressure between the first outer edge of the electrode and the sleeve.

[0017] In other features, the thickness of the sleeve is actively controlled to adjust the pressure between the first outer edge of the electrode and the sleeve.

[0018] In other features, the electrode calendering system also includes a force or pressure sensor arranged between the sleeve and the roller, a temperature control device adjacent to the sleeve, and a control module in communication with the force or pressure sensor and the temperature control device, the control module being configured to receive a signal from the force or pressure sensor and to control the temperature control device based on the signal to adjust the temperature of the sleeve, thereby adjusting the pressure between the first outer edge of the electrode and the sleeve.

[0019] An electrode calendaring method for reducing electrode wrinkling after calendaring includes receiving an electrode at a roller. The roller is defined by an outer surface configured to contact the electrode. The outer surface has a first edge portion on a first side of the roller and a second edge portion on a second side of the roller opposite the first side. When the electrode contacts the roller, the first and second edge portions of the roller align with first and second outer edges of the electrode. The electrode calendaring method further includes controlling the thickness of a sleeve disposed around the outer surface of the roller along the first edge portion to adjust a pressure between the first outer edge of the electrode and the sleeve.

[0020] In other features, controlling the thickness of the sleeve includes passively adjusting the thickness of the sleeve to regulate a pressure between the first outer edge of the electrode and the sleeve.

[0021] In other features, controlling the thickness of the sleeve includes actively controlling the thickness of the sleeve to adjust a pressure between the first outer edge of the electrode and the sleeve.

[0022] In other features, the sleeve includes a plurality of knit courses, each knit course having loops interlocked with loops of an adjacent knit course in the plurality of knit courses, and one or more of the knit courses includes an inlay knitted therein.

[0023] In other features, the sleeve includes a smart material.

[0024] In other features, the electrode calendaring method further includes: receiving a signal from a force or pressure sensor disposed between the sleeve and the roller; and controlling a temperature control device to adjust a temperature of the sleeve based on the signal.

[0025] The present invention provides the following technical solutions.

[0026] Technical Solution 1. An electrode calendering system for reducing electrode wrinkling after calendering, the electrode calendering system comprising:

[0027] at least one roller configured to compress an electrode, the roller defined by an outer surface configured to contact the electrode, the outer surface having a first edge portion at a first side of the roller and a second edge portion at a second side of the roller opposite the first side, the first and second edge portions of the roller being aligned with the first and second outer edges of the electrode when the electrode contacts the roller; and

[0028] A sleeve is disposed around the outer surface of the roller along the first edge portion, the sleeve having a controllable thickness to adjust the pressure between the first outer edge of the electrode and the sleeve.

[0029] Technical Solution 2. The electrode rolling system according to Technical Solution 1, wherein:

[0030] The sleeve is a first sleeve;

[0031] The electrode calendaring system further includes a second sleeve disposed around the outer surface of the roller along the second edge portion; and

[0032] The second sleeve has a controllable thickness to adjust the pressure between the second outer edge of the electrode and the second sleeve.

[0033] Technical Solution 3. An electrode rolling system according to Technical Solution 1, wherein the thickness of the sleeve is passively adjusted to regulate the pressure between the first outer edge of the electrode and the sleeve.

[0034] Technical Solution 4. An electrode calendering system according to Technical Solution 1, wherein the sleeve includes a plurality of knitted rows, each knitted row having coils that are interlocked with coils of adjacent knitted bands among the plurality of knitted bands.

[0035] Technical Solution 5. An electrode calendering system according to Technical Solution 4, wherein one or more of the knitted rows include inlaid elements woven therein.

[0036] Technical Solution 6. An electrode rolling system according to Technical Solution 4, wherein the sleeve includes a plurality of inlaid elements, and the plurality of inlaid elements have a sinusoidal shape in the circumferential direction relative to the roller.

[0037] Technical Solution 7. The electrode rolling system according to Technical Solution 4, wherein:

[0038] The plurality of knit courses includes a first set of courses formed from a smart material and a second set of courses formed from a non-smart material; and

[0039] The first set of rows and the second set of rows are juxtaposed or alternate within the sleeve.

[0040] Technical Solution 8. An electrode rolling system according to Technical Solution 1, wherein the sleeve includes a smart material element.

[0041] Technical Solution 9. An electrode rolling system according to Technical Solution 8, wherein the smart material element includes a superelastic shape memory alloy (SE-SMA).

[0042] Technical Solution 10. An electrode calendering system according to Technical Solution 8, wherein the sleeve includes a support layer and the smart material element integrated into the support layer.

[0043] Technical Solution 11. The electrode rolling system according to Technical Solution 10, wherein:

[0044] The support layer is a first support layer; and

[0045] The sleeve includes a second support layer disposed along a surface of the first support layer such that a portion of the layer of smart material is positioned between the first support layer and the second support layer.

[0046] Technical Solution 12. The electrode rolling system according to Technical Solution 1, wherein:

[0047] The electrode calendering system further comprises: at least one optical sensor disposed downstream of the roller;

[0048] the control module in communication with the optical sensor; and

[0049] The control module is configured to receive a signal from the optical sensor and control the temperature control device based on the signal from the optical sensor to adjust the temperature of the sleeve, thereby adjusting the pressure between the first outer edge of the electrode and the sleeve.

[0050] Technical Solution 13. An electrode rolling system according to Technical Solution 1, wherein the thickness of the sleeve is actively controlled to adjust the pressure between the first outer edge of the electrode and the sleeve.

[0051] Technical Solution 14. The electrode rolling system according to Technical Solution 1 further includes:

[0052] a force or pressure sensor disposed between the sleeve and the roller;

[0053] a temperature control device adjacent to the sleeve; and

[0054] a control module in communication with the force or pressure sensor and the temperature control device, the control module being configured to receive a signal from the force or pressure sensor and control the temperature control device based on the signal to adjust the temperature of the sleeve, thereby adjusting the pressure between the first outer edge of the electrode and the sleeve.

[0055] Technical Solution 15. An electrode calendering method for reducing electrode wrinkling after calendering, the electrode calendering method comprising:

[0056] receiving an electrode at a roller, the roller being defined by an outer surface configured to contact the electrode, the outer surface having a first edge portion at a first side of the roller and a second edge portion at a second side of the roller opposite the first side, the first and second edge portions of the roller being aligned with the first and second outer edges of the electrode when the electrode contacts the roller; and

[0057] A thickness of a sleeve disposed around the outer surface of the roller along the first edge portion is controlled to adjust a pressure between the first outer edge of the electrode and the sleeve.

[0058] Technical Solution 16. An electrode rolling method according to Technical Solution 15, wherein controlling the thickness of the sleeve includes passively adjusting the thickness of the sleeve to adjust the pressure between the first outer edge of the electrode and the sleeve.

[0059] Technical Solution 17. An electrode rolling method according to Technical Solution 15, wherein controlling the thickness of the sleeve includes actively controlling the thickness of the sleeve to adjust the pressure between the first outer edge of the electrode and the sleeve.

[0060] Technical Solution 18. The electrode rolling method according to Technical Solution 15, wherein:

[0061] The sleeve includes a plurality of knit courses, each knit course having loops interlocked with loops of an adjacent knit course of the plurality of knit courses; and

[0062] One or more of the knit courses includes an inlay knitted therein.

[0063] Technical Solution 19. An electrode rolling method according to Technical Solution 15, wherein the sleeve comprises a smart material.

[0064] Technical Solution 20. The electrode rolling method according to Technical Solution 19 further comprises:

[0065] receiving a signal from a force or pressure sensor disposed between the sleeve and the roller; and

[0066] A temperature control device is controlled based on the signal to adjust the temperature of the sleeve.

[0067] Further areas of applicability of the present disclosure will become apparent from the detailed description, claims and drawings.The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0068] The present disclosure will become more fully understood from the detailed description and accompanying drawings, in which:

[0069] Figure 1 is a diagram of an electrode calendaring system for reducing electrode wrinkling after calendaring according to the present disclosure;

[0070] Figure 2 According to the present disclosure Figure 1 A diagram of electrodes and rollers of an electrode calendaring system, wherein a sleeve is wrapped around the rollers;

[0071] Figure 3 According to the present disclosure Figure 2 A side view of one of the sleeves and the roller;

[0072] Figure 4 is an isometric view of an example sleeve including smart materials according to the present disclosure;

[0073] Figures 5 to 7According to the present disclosure Figure 4 Examples of some parts of the sleeve;

[0074] Figure 8 is a graph plotting the stress-strain response of a smart material according to the present disclosure;

[0075] Figure 9 is a side view of a portion of an example sleeve having a single-layer design with integrated smart materials according to the present disclosure;

[0076] Figure 10 According to the present disclosure Figure 9 Isometric view of the sleeve;

[0077] Figure 11 The roller and Figure 9 A side view of the sleeve;

[0078] Figure 12 is a side view of a portion of an example sleeve having a dual-layer design with integrated smart materials according to the present disclosure;

[0079] Figure 13 is a front view of a portion of an example sleeve having a knitted band of material according to the present disclosure;

[0080] Figure 14 is a front view of a portion of an example sleeve according to the present disclosure having a knitted band of material and an inlay woven between loops of the knitted band;

[0081] Figure 15 According to the present disclosure Figure 14 A cross-sectional view of one of the knitted belts;

[0082] Figure 16 The roller and Figure 14 Isometric view of the sleeve;

[0083] Figure 17 According to the present disclosure Figure 16 A side view of the roller and sleeve;

[0084] Figure 18 is a diagram of an electrode calendaring system for reducing electrode wrinkling after calendaring according to the present disclosure; and

[0085] Figure 19 is a flow chart of an example process for reducing electrode wrinkling after calendaring according to the present disclosure.

[0086] In the drawings, reference numerals may be repeated to identify similar and / or identical elements. DETAILED DESCRIPTION

[0087] During the production of battery electrodes, defects such as surface, internal and interface type defects may appear and / or exist in the electrode material. For example, during the electrode calendaring process, significant wrinkling of the battery cell electrodes may occur. More specifically, battery cell electrodes are typically formed of a foil having an inner coated area and an uncoated exposed edge on the opposite side of the inner coated area. During the calendaring process, very high compressive forces between the rollers are typically required to produce a higher electrode density. The compressive force is typically applied only to the inner coated area. In some examples, this configuration of applying force on the foil results in wrinkling and other failures of the uncoated foil (at both edges).

[0088] The electrode calendering system and method according to the present disclosure provide a solution to reduce electrode wrinkling after calendering by controlling the contact pressure between the uncoated edge of the electrode and (multiple) calendering rollers. In various embodiments, and as further explained below, the solution includes providing a sleeve around the outer curved surface of the roller along the outer edge portion of the calendering roller. Each sleeve is passively and / or actively changed (for example, in the absence or presence of sensing and feedback signals during the process) to control or adjust the thickness of the sleeve and adjust or regulate the contact pressure between the outer edge of the electrode and the sleeve. In various embodiments, the thickness of the sleeve can be adjusted by a few microns or up to about 30 microns if necessary.

[0089] Now refer to Figure 1 , a block diagram of an example electrode calendaring system 100 for reducing electrode wrinkling after calendaring is presented. Figure 1 The electrode calendaring system 100 and / or any other example systems and methods herein may be suitable for manufacturing battery cell electrodes (eg, anode electrodes and cathode electrodes) for vehicle applications and / or any other suitable application that includes electrodes.

[0090] like Figure 1 As shown in FIG, the electrode calendaring system 100 generally includes a plurality of rollers 104, 106, 108, 110, 112, 114, 116, 118, 120, 122 and an electrode 102 (shown as a dashed line). Figure 1 In the example of FIG, the rollers have various sizes for compressing and moving the electrode 102 through a cabinet 124 that houses the rollers. The rollers can include idler rollers with fixed positions and dancer rollers that can be adjusted (e.g., vertically up and down).

[0091] exist Figure 1 In the example of , the electrode 102 can be conventional. For example, the electrode 102 can be formed from foil or another suitable conductive material. In addition, the electrode 102 can have multiple regions. For example, Figure 2 Depicts Figure 1 An example of roller 114 and electrode 102. Figure 2As shown in FIG, the electrode 102 generally includes an inner region (e.g., a coated region) 202 and outer edges (e.g., uncoated, exposed edges) 204, 206 on opposite sides of the inner region 202. In some examples, the outer edges 204, 206 can have the same width (e.g., as shown in FIG. Figure 2 ) or different widths, depending on, for example, the design of the electrode 102. In such an example, both outer edges 204, 206 can be uncoated, exposed edges. In other examples, only one of the outer edges 204, 206 can be an uncoated, exposed edge, while the other outer edge 204, 206 can be coated (e.g., similar to the inner region 202).

[0092] Figure 1 Each roller 104, 106, 108, 110, 112, 114, 116, 118, 120, 122 is cylindrical and defined by an outer surface for contacting (and sometimes compressing) the electrode 102. For example, Figure 3 Depicts Figures 1 to 2 An example of roller 114. Figures 1 to 3 , the roller 114 includes an outer surface 126 that contacts the electrode 102 as the electrode 102 passes over the roller 114. In this example, the outer surface 126 has edge portions 128, 130 at opposite sides (or ends) 132, 134 of the roller 114. As shown, when the electrode contacts the roller 104, the edge portions 128, 130 of the roller 114 are substantially aligned with the outer edges 204, 206 of the electrode 102.

[0093] In various embodiments, the Figure 1 One or more sleeves are provided on the outer surface of any one of the rollers 104, 106, 108, 110, 112, 114, 116, 118, 120, 122. In such an example, the sleeve(s) may be provided around the outer surface of the roller in a circumferential direction. Figures 2 to 3 As shown in FIG, two sleeves 208, 210 are disposed around the outer surface 126 of the roller 114 along the edge portions 128, 130 of the roller 114. In such an example, when the electrode contacts the roller 104, the sleeves 208, 210 are aligned with the outer edges 204, 206 of the electrode 102, as shown in FIG. Figure 2 Although Figures 2 to 3 The example of roller 114 is described as having two sleeves 208, 210 wrapped around its outer surface 126, but it should be appreciated that roller 114 may include more or fewer sleeves as desired, depending on, for example, the possible wrinkle locations of the electrode. Additionally, in various embodiments, other rollers may include one or more sleeves as disclosed herein. For example, Figure 1Roller 116 may have one or more sleeves corresponding to the one or more sleeves on roller 114 .

[0094] Figures 2 to 3 The sleeves 208, 210 can include various properties. For example, and as further explained herein, the sleeves 208, 210 can include different types of materials, different shapes, etc. to reduce post-calendering wrinkling of the electrode (e.g., electrode 102). This wrinkling reduction is typically achieved by controlling the thickness of the sleeves 208, 210 to adjust the contact pressure between the outer edges 204, 206 of the electrode 102 and the sleeves 208, 210. For example, the stiffness of each sleeve 208, 210 can be adjusted (e.g., sometimes in real time) to control the thickness of the sleeves 208, 210 when the sleeves contact the corresponding outer edges 204, 206 of the electrode 102. By adjusting the stiffness and, therefore, the thickness of the sleeves 208, 210, the contact pressure between the electrode 102 and the sleeves 208, 210 wrapped around the roller 114 can be controlled to ensure that a desired force is applied to the outer edges 204, 206 of the electrode 102. In this way, non-uniformities in the electrode 102 and / or roller 114 (e.g., roller gap, electrode coating variations, etc.) can be eliminated while applying compressive force to the outer edges 204, 206, thereby reducing (and sometimes eliminating) wrinkling defects along the outer edges 204, 206 of the electrode 102.

[0095] In various embodiments, the thickness of each sleeve 208, 210 can be passively or actively adjusted. For example, the stiffness of each sleeve 208, 210 can be passively adjusted without in-process sensing and feedback signals. In such an example, the sleeves 208, 210 can include desired components (e.g., materials, components, etc.), have a desired shape, be formed in a desired manner, etc., to cause the thickness of the sleeves 208, 210 to change, as further explained below. In other examples, the stiffness of each sleeve 208, 210 can be actively adjusted with in-process sensing and feedback signals to cause the thickness of the sleeves 208, 210 to change, as further explained below.

[0096] For example, the sleeve herein may be formed at least partially of a smart material. In such an example, the sleeve may include a base of an inactive material and a smart material. Such a material configuration exhibits elastic properties, thereby allowing the sleeve to be stretched to slide on and off the roller. As an example, Figure 4 Describes what can be used as Figures 2 to 3 The sleeve 400 of any one of the sleeves 208, 210 shown in FIG. Figure 4 In the example of FIG. 4 , the sleeve 400 includes a base 402 defining an opening 404. With this configuration, the base 402 (and more generally, the sleeve 400) can be positioned around a roller (e.g., Figures 1 to 3The roller 114) is positioned so that the sleeve 400 contacts the outer surface of the roller and the roller extends through the opening 404.

[0097] exist Figure 4 In one example, sleeve 400 includes at least one smart (or active) material to adaptively adjust the thickness / stiffness of sleeve 400 and / or the contact pressure between the electrode and sleeve 400 without requiring a sensing signal during the process. For example, in one embodiment, sleeve 400 can take the form of a braided tape comprising one or more yarns made of an inactive / non-smart material (e.g., polyester, etc.) and an active / smart element made of a superelastic shape memory alloy (SE-SMA). In such an example, the inactive yarns constitute a matrix that contains the SE-SMA elements and positions them in appropriate locations within the tape. Due to, for example, the braided construction, the properties of the inactive yarns, or both, the matrix is ​​elastic (e.g., can undergo large elastically recoverable strains). SE-SMA materials exhibit large recoverable strains due to, for example, reversible, stress-driven solid-state phase transitions within the SE-SMA material. Additionally, the geometry of the SE-SMA elements can also allow them to undergo recoverable deformations. Because both components of the sleeve 400 (e.g., the base and the SE-SMA element) exhibit large recoverable strains, the sleeve 400 itself can withstand large (e.g., 2-10%) strains, which makes it possible for the sleeve 400 to be stretched to assemble it to or disassemble it from a roller.

[0098] In such examples, shape memory alloys (SMAs) can be metallic materials with unique properties that allow the material to be trained to move (e.g., stretch, bend, etc.) and return to its original shape. As an example, SMA components can be based on nickel-titanium alloys (e.g., Nitinol, etc.). In other examples, SMA components can be copper-based alloys, gold-based alloys, etc.

[0099] Figures 5 to 7 Describes the formation Figure 4 The various sleeve portions 500, 502, 504, 600, 700 of a portion of the sleeve 400. For example, in Figure 5 , sleeve portion 500 includes a strand of yarn 512 (e.g., a non-active / non-intelligent material such as polyester) and an active / intelligent element 510 (e.g., formed of SE-SMA), sleeve portion 502 includes two strands of yarn 522 and a plurality of active / intelligent elements 520, and sleeve portion 504 includes a strand of yarn 532 and a strand of active / intelligent elements 530. In addition, as Figure 6 As shown in FIG, the sleeve portion 604 includes a strand of yarn 612 and a strand of active / intelligent element 610. Figure 7 In FIG, the sleeve portion 704 includes a strand of yarn 712 and a strand of active / smart element 710 .

[0100] In various embodiments, SE-SMA materials generally exhibit a plateau in their stress-strain response. For example, Figure 8 A graph 800 is depicted, plotting the stress-strain response of an SE-SMA material relative to stress (y-axis) and strain (x-axis). Graph 800 includes line 802 representing the forward transition (e.g., loading) of the SE-SMA material and line 804 representing the reverse transition (e.g., unloading) of the SE-SMA material. As shown, the SE-SMA material generally exhibits a plateau between the vertical dashed lines. In this region, both the forward transition line 802 and the reverse transition line 804 have less positive slopes than other regions along lines 804, 804. In this way, the material response can be exploited to create a passive SE-SMA element that applies a nearly constant force (stress) over a strain range of approximately 2%-8%. Consequently, this design ensures a constant pressure of the sleeve 400 on the calendering roller (e.g., roller 114), which can easily accommodate roll gap and / or electrode coating variations of up to 15 microns or more, which is more than sufficient for production purposes, where variations of 10 microns or less are typical.

[0101] In various embodiments, the sleeves herein can be formed of an integrated passive SE-SMA material. In such examples, the stiffness of the sleeve can be greater than the stiffness of the sleeve 400 explained above (e.g., including any of the sleeve portions 500, 502, 504, 600, 700). This can result in the ability to better control the stresses applied at the corners and edges of the electrode. For example, Figures 9 to 11 Depicted is a sleeve 900 of single layer design that can be used as Figures 2 to 3 Any of the sleeves 208, 210 shown in FIG and wrapped around the roller 114. Figures 9 to 11 In an example of the embodiment, the sleeve 900 includes a support layer 902, a smart material element 904 integrated into the support layer 902, and an optional protective layer 910. In such an example, the protective layer 910 can be disposed on the outer surface of the sleeve 900 so that it is interposed between the smart material element 904 and the electrode to improve the surface finish of the electrode. Alternatively, the support layer 902 can be a strip formed of rubber, elastomer, leather, polymer, cork, etc. The smart material element 904 can include the SE-SMA material as explained above and be in the form of a wire, strip, mesh, etc. In some examples, set screws or other suitable fastening devices can be used to secure the opposing ends of the smart material element 904 and the support layer 902 to the roller.

[0102] In other examples, the sleeves herein may be formed from an integrated passive SE-SMA material of a dual-layer design. For example, Figure 12Depicted is a dual layer design sleeve 1200 that can be used as Figures 2 to 3 Any one of the sleeves 208, 210 shown in FIG. Figure 12 In the example of Figures 9 to 11 The sleeve 1200 includes a support layer 902, a smart material element 904, and an optional protective layer 910. In addition, the sleeve 1200 includes a support layer 1202 disposed along a bottom surface of the support layer 902 such that a portion of the smart material element 904 of the smart material is positioned between the support layers 902, 904. Figure 9 In such an example, the sleeve 1200 can be positioned so that the bottom surface of the support layer 1202 substantially contacts the roller (e.g., Figures 1 to 3 In various embodiments, a coating (e.g., a high-friction coating, etc.) can be disposed along the bottom surface of the support layer 1202 (e.g., the surface opposite the support layer 902) and disposed between the support layer 1202 and the outer surface of the roller when the sleeve 1200 is placed on the roller.

[0103] In various embodiments, the sleeves herein may be formed from a knitted strip of material having radially compliant properties. In such examples, each knitted strip may be formed from smart and / or non-smart materials. A strip or band of knitted material may be constructed from a set of stitches (a small patch of stitches). A small patch of stitches for a simple "plain" knit may be formed from a set of stitches (a small patch of stitches). Figure 13 The knitting block 1300 can be repeated in the circumferential direction and the radial direction to construct Figures 2 to 3 Any one of the sleeves 208, 210 shown in FIG. Figure 13 In the example of FIG. 1 , the knit block 1300 includes three rows 1302, 1304, 1306 of material 1308, 1310, 1312, respectively, knitted together. Figure 13 The knitting block 1300 is shown as including three courses, but it will be appreciated that other embodiments may include more or fewer courses if desired to create the appropriate final geometry of the band.

[0104] In such an example, the standard knit material may be composed of yarn loops that interlock with adjacent yarn courses above and / or below it. Figure 13 As shown in FIG, course 1302 has loops formed from material 1308 that interlock with loops of an adjacent strip 1304 formed from material 1310. Similarly, course 1304 has loops formed from material 1310 that interlock with loops of an adjacent course 1306 formed from material 1312. This construction creates a uniform layer of material in which the yarns overlap at the stitch loops.

[0105] Materials 1308, 1310, 1312 may be of the same or different types, such as a mixture of smart and non-smart materials. For example, rows 1302, 1304, 1306 may include alternating types of materials, rows 1302, 1304 may have the same material and row 1306 may have a different material, or rows 1302, 1304, 1306 may have the same material. Figure 13 In the example of FIG. 1 , materials 1308 , 1312 are non-smart materials, while material 1310 is a smart material (eg, a SE-SMA material as explained above), thereby providing an alternating situation within the sleeve.

[0106] In some examples, additional machine operations such as inlaying can be used to introduce other materials into the knitted strip of material. In such examples, the inlay elements can be woven between the loops of the knitted strip. For example, Figure 14 A knitting block 1400 is depicted, which may be used to construct Figures 2 to 3 Any one of the sleeves 208, 210 shown in FIG. Figure 14 In the example of the knitting block 1400, the knitting block 1400 includes the knitting block 1400 of the embodiment of the present invention. Figure 13 The three rows 1402, 1404, 1406 of material 1408, 1410, 1412 are knitted together in a similar manner to the rows 1302, 1304, 1306. Figure 14 In the example of FIG, materials 1408, 1410, 1412 are formed of the same type of material, such as a non-smart material or a smart material (eg, juxtaposed within a sleeve). Figure 14 The knitting block 1400 is shown as including three rows, but it should be appreciated that the knitting block 1400 in other embodiments may include more or fewer rows, if desired.

[0107] like Figure 14 As shown in FIG, each knit course 1402, 1404, 1406 includes an inlaid element 1414, 1416, 1418 woven therein. For example, knit course 1402 includes inlaid element 1414 woven between adjacent loops of material 1408. In this example, inlaid element 1414 passes in front of one loop and then passes behind the adjacent loop. Knit courses 1404, 1406 and inlaid elements 1416, 1418 are similarly configured. While knit courses 1402, 1404, 1406 are shown with inlaid elements 1414, 1416, 1418 woven between adjacent loops, it should be appreciated that the frequency of the forward and backward transitions of inlaid elements 1414, 1416, 1418 relative to knit courses 1402, 1404, 1406 can be varied to control the radial compliance characteristics of knit block 1400.

[0108] In various embodiments, when the knit courses 1402, 1404, 1406 are formed into a tubular structure for wrapping around a roller, the inlaid spirals of yarn can form a wave spring-like structure that imparts radial compliance to the knit block 1400. For example, Figure 15 Depicts Figure 14 14 is a cross-sectional view of knit course 1402 along line 1430. As shown, inlay elements 1414 create a sinusoidal shape (or more generally a wavy shape).

[0109] Figures 16 and 17 Depicts including Figures 1 to 3 Roller 114 and Figures 14 and 15 The assembly 1600 of the knitting block 1400. As described above with respect to Figures 14 and 15 As shown, knit block 1400 includes knit courses 1402, 1404, 1406, wherein inlay elements 1414, 1416, 1418 are knitted into materials 1408, 1410, 1412. Figures 16 and 17 , knit block 1400 has a sinusoidal shape in the circumferential direction relative to roller 114. In such an example, if fitted to an appropriate calendar roll diameter and knitted with a suitable material, tubular knit courses 1402, 1404, 1406 can serve as a carrier for the helical wave spring structure created by inlay elements 1414, 1416, 1418. The carrier knit imparts a bumpy pattern to inlay elements 1414, 1416, 1418, thereby creating a compliant surface on roller 114.

[0110] In various embodiments, Figures 13 to 17The knitted courses 1302, 1304, 1306, 1402, 1404, 1406 can form a self-folding structure. For example, the knitted courses 1302, 1304, 1306, 1402, 1404, 1406 can be formed from a basic plain knit textile with interconnected loops linking adjacent courses of the fabric as explained above. The overlap of stitch loops can be consistent on a simple textile, but a stitch can loop behind (front) or in front (back) of a loop in the next course. In some embodiments, due to this stitch structure, the plain knit fabric has a tendency to curl, but the direction of this curl is determined by how the loops overlap. For example, a stitch looped on the back (front) may curl in one direction, while a stitch looped on the front (back) may curl in the opposite direction. Thus, knit courses 1302, 1304, 1306, 1402, 1404, 1406 can be designed to produce a bowed surface with dramatically increased compliance when placed on a cylindrical surface, such as roller 114. Furthermore, stitch length, spacing, and tightness can make this curling effect more or less pronounced; denser, tighter knits typically curl more. Increasing the stiffness of the material can also amplify curling, creating "turns" in textiles with only a few knit courses.

[0111] In other examples, the sleeves described herein can be actively controlled using sensing and feedback signals. For example, if a passively designed sleeve is insufficient, an actively controlled sleeve can be employed. In various embodiments, the sleeve can be formed from a smart material, such as the SE-SMA material explained above. In such examples, the plateau stress of the SE-SMA material can be controlled by adjusting the temperature of the smart material. For example, for a near-isoatomic SMA, the plateau in the stress-strain response may increase by approximately 10.5 MPa for every degree increase in the smart material's temperature. This also applies in the opposite direction. For example, the plateau stress or transition stress may decrease by 10.5 MPa for every degree decrease in the material's temperature. There may be limits to how high or low a temperature can be applied to a material without compromising its properties. For example, the maximum or upper limit of the temperature may be below the recrystallization temperature of the SE-SMA material. The lower limit of the temperature is generally less critical. This temperature dependence can be used to actively adjust the clamping pressure on an electrode (eg, electrode 102 ) by using a directed, non-contact heating / cooling source to control the local temperature of the smart material in the region where the electrode tab is clamped by the sleeve.

[0112] For example, Figure 18 An example electrode calendaring system 1800 for reducing electrode wrinkling after calendaring is depicted. Figure 18 The electrode calendaring system 1800 is basically similar to Figure 1The electrode calendaring system 100 of FIG. 1800 includes a control component for actively controlling the sleeve. For example, the system 1800 includes Figure 1 1800 and the electrode 102. In addition, the system 1800 includes a control module 1802, sensors 1804, 1806, temperature control devices 1808, 1810, and an optional optical sensor 1812. In various embodiments, each sensor 1804, 1806 can include a pressure sensor, a force sensor, and / or any other suitable sensor. As shown, the sensors 1804, 1806, the temperature control devices 1808, 1810, and the optical sensor 1812 are in communication with the control module 1802.

[0113] exist Figure 18 In the example of FIG. 1 , sensors 1804 and 1806 are generally disposed between the sleeve and the roller to measure (e.g., in real time) the contact pressure distribution for feedback to control module 1802. For example, rollers 114 and 116 may include one or more sleeves (e.g., any of the sleeves described herein), which are not shown for clarity. In such an example, sensor 1804 is disposed between a sleeve wrapped around roller 114 and roller 114, and sensor 1806 is disposed between a sleeve wrapped around roller 116 and roller 116. In some examples, sensors 1804 and 1806 may include an array of sensors.

[0114] In various embodiments, temperature control devices 1808, 1810 are adjacent to the sleeves wrapped around rollers 114, 116. In such examples, one or both temperature control devices 1808, 1810 can be controlled (e.g., individually or collectively) to heat or cool one or more of the sleeves. In some examples, temperature control devices 1808, 1810 can be a heating / cooling source (e.g., an HVAC module) having one or more fans, heaters, air conditioners, infrared (IR) lamps, etc., for heating or cooling the sleeves without contacting the sleeves.

[0115] exist Figure 18 In this embodiment, the optical sensor 1812 is typically positioned downstream of the rollers 114, 116. In such an example, the optical sensor 1812 may include one or more cameras or other suitable devices for capturing images of the electrode 102 downstream of the rollers 114, 116. In this manner, the optical sensor 1812 may capture images of the electrode 102 after calendaring.

[0116] In various embodiments, the control module 1802 receives one or more signals from one or both of the sensors 1804, 1806. In such an example, the signals may indicate a force or pressure value between the corresponding sleeve and the roller. Based on the received signals, the control module 1802 may then control one or both of the temperature control devices 1808, 1810 to adjust the temperature of the sleeve, thereby adjusting the pressure between the electrode 102 and the sleeve.

[0117] In some examples, the control module 1802 can receive one or more signals from the optical sensor 1812. In such examples, the signal provides data indicating whether the electrode 102 has wrinkles after calendaring. In such examples, the control module 1802 can control one or both of the temperature control devices 1808, 1810 based on the signal from the optical sensor 1812 to adjust the temperature of the sleeve, thereby adjusting the pressure between the electrode 102 and the sleeve. For example, the control module 1802 can adjust the control of the temperature control devices 1808, 1810 based on data from the optical sensor 1812 and the sensors 1804, 1806. In some examples, the control module 1802 can initiate control based on signal feedback in response to data from the optical sensor 1812 indicating wrinkling of the electrode 102.

[0118] Figure 19 An example process 1900 for reducing electrode wrinkling after calendaring is illustrated. Figure 19 Although shown and described as including specific steps, it should be appreciated that process 1900 is an example of variations that can be implemented, and in other embodiments, process 1600 and / or other example processes may include different steps, more or fewer steps, etc. Additionally, although process 1900 is relative to Figure 18 The system 1800 is described, but the process 1900 may be employed by any suitable system.

[0119] As shown, process 1900 begins at 1902, where control determines whether the electrode calendaring process has been activated. For example, control may sense (e.g., using a motion sensor, etc.) whether an electrode (e.g., electrode 102) has been received by a machine including rollers. In other examples, a user may select an input once the electrode has been received. If "No" at 1902, control returns to 1902. Otherwise, if "Yes" at 1902, control continues to 1904.

[0120] At 1904, the control module 1802 receives data from one or more post-calendering sensors. For example, the control module 1802 may receive a signal from the optical sensor 1812 indicating whether the electrode has wrinkles after passing through one or more rollers. Control then proceeds to 1906, where the control module 1802 determines whether the electrode has a defect (e.g., wrinkles along the edge of the electrode), as explained herein. If the control module 1802 determines that a defect is present, control proceeds to 1908. Otherwise, if the control module 1802 determines that a defect is not present, control may return to 1902 as shown or may end.

[0121] At 1908, control module 1802 receives one or more force or pressure values. For example, and as explained above, control module 1802 may receive one or more force or pressure signals from one or both of sensors 1804, 1806 located between the roller sleeve(s) and the roller. In such an example, the force or pressure signals may indicate a contact pressure distribution. Control then proceeds to 1910.

[0122] At 1910, control module 1802 determines a temperature adjustment for the sleeve(s) based on the force or pressure values. For example, and as explained above, the plateau stress of the smart material in the sleeve(s) can be controlled by adjusting the material's temperature. For example, to increase the plateau stress (e.g., the applied force) of the smart material in the sleeve(s), the material's temperature can be increased. Conversely, to decrease the plateau stress of the smart material in the sleeve(s), the material's temperature can be decreased. In such an example, the temperature adjustment (e.g., an increase or decrease in temperature) can be determined based on the received force or pressure values. Control then proceeds to 1912.

[0123] At 1912, the control module 1802 generates and sends one or more control signals to one or more temperature control devices. For example, the control module 1802 may generate and send a control signal based on the determined temperature adjustment to one or more temperature control devices. Figure 18 In such an example, the control module 1802 can send a control signal to initiate cooling or heating of the sleeve(s) using the temperature control devices 1808, 1810. In this way, the thickness of the sleeve(s) can be controlled to adjust the pressure between the electrode and the sleeve(s), as explained herein. The control can then be as follows: Figure 19 , or returns to another appropriate step, such as step 1908, if necessary.

[0124] The foregoing description is merely illustrative in nature and is in no way intended to limit the present disclosure, its application or use. The broad teachings of the present disclosure can be implemented in many forms. Therefore, although the present disclosure includes specific examples, the true scope of the present disclosure should not be so limited, because after studying the drawings, the description and the appended claims, other modifications will become apparent. It should be understood that one or more steps in the method can be performed in a different order (or simultaneously) without changing the principles of the present disclosure. In addition, although each of the embodiments is described above as having certain features, any one or more of those features described with respect to any embodiment of the present disclosure can be implemented in any other embodiment and / or combined with the features of any other embodiment, even if the combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and the arrangement of one or more embodiments with each other is still within the scope of the present disclosure.

[0125] Various terms are used to describe spatial and functional relationships between elements (e.g., between modules, circuit elements, semiconductor layers, etc.), including “connected,” “engaged,” “coupled,” “adjacent,” “immediately next to,” “on top of,” “above,” “below,” and “disposed on.” Unless explicitly described as “directly,” when describing a relationship between a first element and a second element in the above disclosure, the relationship can be a direct relationship with no other intervening elements between the first element and the second element, but can also be an indirect relationship (spatially or functionally) with one or more intervening elements between the first element and the second element. As used herein, the phrase “at least one of A, B, and C” should be interpreted to mean a logical (A or B or C) using a non-exclusive logical “OR” and should not be interpreted to mean “at least one of A, at least one of B, and at least one of C.”

[0126] In the accompanying drawings, the direction of an arrow, as indicated by the arrow head, generally indicates the flow of information (such as data or instructions) of interest to the diagram. For example, when component A and component B exchange various information, but the information transmitted from component A to component B is relevant to the diagram, an arrow may point from component A to component B. This unidirectional arrow does not mean that no other information is transmitted from component B to component A. In addition, for information sent from component A to component B, component B may send a request for the information or an acknowledgment of receipt to component A.

[0127] In this application, including the definitions below, the term "module" or the term "controller" may be replaced with the term "circuit". The term "module" may refer to, be a part of, or include: an application-specific integrated circuit (ASIC); a digital, analog, or mixed analog / digital discrete circuit; a digital, analog, or mixed analog / digital integrated circuit; a combinational logic circuit; a field-programmable gate array (FPGA); a processor circuit (shared, dedicated, or group) that executes code; a memory circuit (shared, dedicated, or group) that stores code executed by the processor circuit; other suitable hardware components that provide the described functionality; or a combination of some or all of the above, such as in a system on a chip.

[0128] The module may include one or more interface circuits. In some examples, the interface circuit may include a wired or wireless interface connected to a local area network (LAN), the Internet, a wide area network (WAN), or a combination thereof. The functionality of any given module of the present disclosure may be distributed across multiple modules connected via the interface circuits. For example, multiple modules may allow for load balancing. In another example, a server (also referred to as a remote or cloud) module may perform certain functions on behalf of a client module.

[0129] As used above, the term "code" may include software, firmware and / or microcode, and may refer to programs, routines, functions, classes, data structures and / or objects. The term "shared processor circuitry" encompasses a single processor circuit that executes some or all code from multiple modules. The term "group processor circuitry" encompasses a processor circuit that, in combination with additional processor circuits, executes some or all code from one or more modules. References to multiple processor circuits encompass multiple processor circuits on discrete dies, multiple processor circuits on a single die, multiple cores of a single processor circuit, multiple threads of a single processor circuit, or a combination of the foregoing. The term "shared memory circuitry" encompasses a single memory circuit that stores some or all code from multiple modules. The term "group processor circuitry" encompasses a memory circuit that, in combination with additional memory, stores some or all code from one or more modules.

[0130] The term "memory circuit" is a subset of the term computer-readable medium. As used herein, the term "computer-readable medium" does not encompass transient electrical or electromagnetic signals propagated through a medium (such as a carrier wave); thus, the term "computer-readable medium" may be considered to be both tangible and non-transitory. Non-limiting examples of non-transitory tangible computer-readable media are non-volatile memory circuits (such as flash memory circuits, erasable programmable read-only memory circuits, or mask read-only memory circuits), volatile memory circuits (such as static random access memory circuits or dynamic random access memory circuits), magnetic storage media (such as analog or digital magnetic tape or hard drives), and optical storage media (such as CDs, DVDs, or Blu-ray discs).

[0131] The apparatus and methods described in this application may be implemented in part or in whole by a special-purpose computer, which is created by configuring a general-purpose computer to perform one or more specific functions embodied in a computer program. The functional blocks, flow chart components, and other elements described above serve as software specifications that can be translated into computer programs by a skilled technician or programmer through routine work.

[0132] A computer program includes processor-executable instructions stored on at least one non-transitory, tangible computer-readable medium. A computer program may also include or rely on stored data. A computer program may include a basic input / output system (BIOS) that interacts with the hardware of a special-purpose computer, device drivers that interact with specific devices of the special-purpose computer, one or more operating systems, user applications, background services, background applications, etc.

[0133] A computer program may include: (i) descriptive text to be parsed, such as HTML (Hypertext Markup Language), XML (Extensible Markup Language), or JSON (JS Object Notation), (ii) assembly code, (iii) object code generated by a compiler from source code, (iv) source code executed by an interpreter, (v) source code compiled and executed by a just-in-time compiler, etc. By way of example only, the source code may be written using the syntax of a language including: C, C++, C#, Objective-C, Swift, Haskell, Go, SQL, R, Lisp, Fortran, Perl, Pascal, Curl, OCaml, HTML5 (Hypertext Markup Language Version 5), Ada, ASP (Active Server Pages), PHP (PHP: Hypertext Preprocessor), Scala, Eiffel, Smalltalk, Erlang, Ruby, Visual Lua, MATLAB, SIMULINK, and

Claims

1. An electrode calendering system for reducing electrode wrinkling after calendering, the electrode calendering system comprising: at least one roller configured to compress an electrode, the roller defined by an outer surface configured to contact the electrode, the outer surface having a first edge portion at a first side of the roller and a second edge portion at a second side of the roller opposite the first side, the first and second edge portions of the roller being aligned with first and second outer edges of the electrode when the electrode contacts the roller; and A sleeve is disposed around the outer surface of the roller along the first edge portion, the sleeve having a controllable thickness to adjust the pressure between the first outer edge of the electrode and the sleeve.

2. The electrode rolling system according to claim 1, wherein: The sleeve is a first sleeve; The electrode calendaring system further includes a second sleeve disposed around the outer surface of the roller along the second edge portion; and The second sleeve has a controllable thickness to adjust the pressure between the second outer edge of the electrode and the second sleeve.

3. The electrode rolling system according to claim 1, wherein: The thickness of the sleeve is passively adjusted to regulate the pressure between the first outer edge of the electrode and the sleeve.

4. The electrode rolling system according to claim 1, wherein: The sleeve includes a plurality of knit courses, each knit course having loops that interlock with loops of adjacent ones of the plurality of knit bands.

5. The electrode rolling system according to claim 4, wherein: One or more of the knit courses include inlay elements knitted therein.

6. The electrode rolling system according to claim 4, wherein: The sleeve includes a plurality of inlay elements having a sinusoidal shape in a circumferential direction relative to the roller.

7. The electrode rolling system according to claim 4, wherein: The plurality of knit courses includes a first set of courses formed from a smart material and a second set of courses formed from a non-smart material; and The first set of rows and the second set of rows are juxtaposed or alternate within the sleeve.

8. The electrode rolling system according to claim 1, wherein: The sleeve includes a smart material element.

9. The electrode rolling system according to claim 8, wherein: The smart material element includes a super elastic shape memory alloy (SE-SMA).

10. An electrode calendering method for reducing electrode wrinkling after calendering, the electrode calendering method comprising: receiving an electrode at a roller, the roller defined by an outer surface configured to contact the electrode, the outer surface having a first edge portion at a first side of the roller and a second edge portion at a second side of the roller opposite the first side, the first and second edge portions of the roller being aligned with first and second outer edges of the electrode when the electrode contacts the roller; and A thickness of a sleeve disposed around the outer surface of the roller along the first edge portion is controlled to adjust a pressure between the first outer edge of the electrode and the sleeve.

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