System and method for extracting active material residue from assembly in which electrode is coated with 5 layers of active material, and corresponding assembly, method for manufacturing electrode, electrode and battery

Abstract

A system for extracting an active material residue from a component coated with an electrode with an active material layer, the system comprising: a mobile tank configured to contain an active material residue; a conduit attached to the mobile tank and connectable to the assembly; and a pumping device configured to apply a negative pressure to the mobile tank to draw an active material residue from the assembly through the conduit.

Description

Technical Field

[0001] The present disclosure relates to systems and methods for extracting active material residues from assemblies having electrodes coated with an active material layer, and to corresponding assemblies configured to allow extraction of the active material. The present disclosure also relates to methods for manufacturing electrodes in assemblies having electrodes coated with active material residues, and to corresponding electrodes and batteries. Background Art

[0002] In modern society, with the widespread use of portable devices such as mobile phones, laptops, camcorders, and digital cameras, the development of battery technology has become increasingly important. Furthermore, rechargeable / dischargeable secondary batteries have become an indispensable power source for electric vehicles (EVs), hybrid electric vehicles (HEVs), and plug-in hybrid electric vehicles (P-HEVs), aiming to address air pollution caused by existing fossil fuel combustion engine vehicles and reduce carbon dioxide emissions. Consequently, there is a growing demand for improved secondary batteries.

[0003] Currently commercially available secondary batteries include nickel-cadmium batteries, nickel-metal hydride batteries, nickel-zinc batteries, and lithium secondary batteries. Among them, lithium secondary batteries have attracted much attention due to various advantages. For example, compared with nickel-based secondary batteries, they exhibit almost no memory effect and can be freely charged and discharged. They also have very low self-discharge rates and high energy density.

[0004] Secondary batteries can be classified based on the shape of the battery case into cylindrical batteries with an electrode assembly mounted in a cylindrical metal can, prismatic batteries with an electrode assembly mounted in a prismatic metal can, and pouch-type batteries. Pouch-type secondary batteries generally house an electrode assembly having a structure in which electrodes and separators are alternately arranged within a pouch-shaped case made of laminated aluminum sheets.

[0005] In addition, secondary batteries can be classified based on the structure in which the positive electrode and the negative electrode are stacked and the separator is inserted between the positive electrode and the negative electrode. Generally, there may be a stacked (laminated) type structure (in which a plurality of positive electrodes and negative electrodes cut into a predetermined unit size are stacked sequentially and the separator is inserted between the positive electrode and the negative electrode) and the like. In recent years, in order to solve the problems caused by the core-roll type electrode assembly and the stacked type electrode assembly, a stacked / folded type electrode assembly has been developed. This stacked / folded type battery assembly is a combination of a core-roll type electrode assembly and a stacked type electrode assembly. This stacked type electrode assembly may also be referred to as an electrode stack assembly.

[0006] Electrodes (i.e., positive and negative electrodes) are typically formed by processing a metal foil web material into an electrode web material (electrode, for short) by coating it with a layer of active material and subsequently separating the individual electrodes from the coated metal foil web material. Production assemblies typically include large, stationary tanks configured to hold a large amount of active material for processing. This amount of active material must be no less than the amount required for coating, resulting in the stationary tanks often containing residual active material. When a production assembly is changed from coating a first type of electrode to coating a different, second type of electrode, for example, from a positive electrode to a negative electrode, the active material powder used for coating must be changed accordingly. These changes typically occur according to a schedule, but sometimes occur unexpectedly, resulting in a change in the amount of residual material. For example, when a coating operation for manufacturing a positive electrode is completed, residual positive electrode active material invariably remains in the assembly. Before the same assembly is used in another coating operation for a different negative electrode or positive electrode (typically using a different active material), the residual material must be removed from the assembly; otherwise, the residual material may remain and become an undesirable impurity during subsequent electrode manufacturing. Removal of active electrode material is cumbersome, associated with undesirable assembly downtime, and, if not done correctly, can result in poor product in subsequent electrode fabrication. Summary of the Invention

[0007] Technical issues

[0008] The object of the present disclosure is to overcome the disadvantages of the prior art and in particular to improve components and methods with regard to economic and / or ecological aspects.

[0009] Technical Solution

[0010] The subject matter according to the independent claims solves one or more problems known from the prior art. Detailed description of the invention is given by the features of the dependent claims.

[0011] Therefore, the present disclosure relates to a system for extracting active material residues (particularly powder residues) from an assembly of an electrode coated with an active material layer. The system includes a mobile storage tank, a conduit, and a pumping device. It should be understood that the system can be configured to be releasably attached to one or more (preferably, several) assemblies of electrodes coated with an active material layer. Preferably, the system is movable so as to be movable from a first assembly coating an electrode with a first active material (e.g., a positive electrode active material) to a second assembly coating another electrode with a second active material (e.g., a negative electrode active material). The mobile storage tank can be provided with a carriage. The carriage can include wheels, rollers, slides, etc., to enable movement between different locations spaced apart in a manufacturing facility. The carriage can be movable on a flat surface, rails, ropes, chains, etc. The mobile storage tank can be moved horizontally and / or vertically between different locations spaced apart in a manufacturing facility. The mobile storage tank can be moved manually. Alternatively or additionally, the mobile storage tank can be provided with at least one engine and a transmission system configured to move the mobile storage tank. The mobile storage tank is preferably equipped with an electric engine. Although the component is preferably rigidly attached to a support structure (such as a building structure), the mobile storage tank is movable relative to the support structure. The system is preferably configured so that it can be attached to and released from the first component, the second component and possible further components in the manufacturing site. Preferably, the system according to the present disclosure does not constitute part of the component that coats the electrode with the active material during the normal coating operation of the component. That is, it can preferably be that the system according to the present disclosure is different from and separate from the component during the normal operation of the component. The system can in particular be attached to the component only after the normal coating operation of the component that coats the electrode with the active material layer has been interrupted (preferably terminated). More specifically, the system can be configured to be attached to the first component after the component has terminated its coating operation and to be released from the first component before the component preferably starts another normal coating operation using another active material different from the previous one.

[0012] The mobile storage tank is configured to accommodate active material residues. A conduit is attached to or can be attached to the mobile storage tank and is releasably connected or releasably connectable to a component. The conduit can be adapted according to the requirements of one or more components to which the system can be attached. The form and shape of the conduit can preferably be selected and / or adapted relative to the system and one or more components interacting therewith. For example, the length of the conduit can be appropriately selected. The conduit or a portion thereof can be integrally formed with the mobile storage tank. In some embodiments, the conduit or a portion thereof can be implemented as a tube, pipe, short pipe, etc. The conduit can be attached to the mobile storage tank, preferably integrally formed with the mobile storage tank. In one example, the conduit or a portion thereof can include or consist of a flexible hose. Such a flexible hose can be attached to or attached to the mobile storage tank. The flexible hose can be releasably connectable or connectable to a component. In some embodiments, the conduit can include a first section (such as a pipe or short pipe or hole thereof) integrally formed with the mobile storage tank, and a tubing (such as a flexible hose) forming a second section of the conduit.

[0013] The volume of the mobile storage tank can be at least 50L, in particular at least 100L, preferably at least 250L, and / or no more than 2000L, in particular no more than 1000L, preferably no more than 750L. The mobile storage tank can, for example, have a volume of approximately 500L. The mobile storage tank can, for example, have a volume of 380L. In particular, the funnel section can have a volume of 280L. The mobile storage tank can be selectively closed or closable in an airtight manner. In particular, one or more valves can be selectively closed to close the mobile storage tank, or selectively opened to form a fluid connection between the interior of the mobile storage tank and the components, pumping device, storage container, etc. Leakage can be avoided by allowing the mobile storage tank to be tightly sealed during the pumping action, which is used to transfer the active material (in particular, active material powder residue) from the component to the system and to controllably release the active material residue (in particular, active material powder residue) from the mobile storage tank (preferably, to the storage container). A control valve may be provided between the conduit and the mobile storage tank.Preferably, the mobile storage tank comprises a control valve configured to open and / or close a connection between the mobile storage tank and a component to which the system is attachable or to which it is attached.

[0014] The pumping device of the system is configured to apply negative pressure to the mobile storage tank to suck the active material residue from the component through the conduit. The pumping device may include a pneumatic drive (in particular, a pneumatic drive connected to the pneumatic supply line of the system). The pumping device is used to propel air or another suitable transmission medium, wherein the transmission medium can be a liquid or a gas, so as to push the active material residue (in particular, the active material residue powder) through the conduit. When the system is attached to the first component, wherein the conduit is attached to the mobile storage tank on the one hand and is releasably connected to the first component on the other hand (connected state), the pumping device can be operated to suck the active material residue from the component. In the connected state, the pumping device can be configured to transfer the active material residue from the component to the mobile storage tank.

[0015] As used herein, the term "negative pressure" refers to a pressure that is lower than ambient pressure and / or lower than the pressure existing within the assembly when the system is connected to the assembly. The term "negative pressure" should be understood as meaning that the pumping device is configured to generate a pressure differential between the assembly and the system to which it is connected, so as to propel a transport medium, such as ambient air, nitrogen, etc., along with the active material (preferably active material residue powder) from the assembly through a conduit into a mobile tank. The term "negative pressure" should preferably be understood as referring to the difference between the assembly on the one hand and the mobile tank of the system on the other hand. In other words, negative pressure should be understood to refer to a pressure that is lower than (or negative relative to) a reference pressure, particularly at the inlet of a conduit that can be connected to or is connected to the assembly from which the active material residue (particularly, powder residue) is to be extracted. In some cases, negative pressure can be referred to as vacuum pressure. The pumping device can particularly be configured to generate a pressure differential between the assembly and the mobile tank of not less than 0.01 MPa, preferably not less than 0.1 MPa, and more preferably not less than 0.5 MPa. The pumping device can optionally be configured to generate a pressure difference of no more than 10 MPa, in particular no more than 5 MPa, preferably no more than 1 MPa between the assembly and the mobile storage tank. In some embodiments, the pressure difference can be between 0.5 MPa and 0.7 MPa, in particular approximately 0.6 MPa. Additionally or alternatively, the pumping device can be configured to generate a flow of at least 1 kg / min, in particular at least 5 kg / min, preferably at least 10 kg / min, more preferably at least 25 kg / min of active material residue through the conduit (preferably determined at the interface of the conduit and the mobile storage tank). Additionally or alternatively, the pumping device can be configured to generate a flow of at least 100 NL / min, in particular at least 1000 NL / min, preferably at least 2000 NL / min, more preferably at least 2400 NL / min of the transport medium through the conduit (preferably determined at the interface of the conduit and the mobile storage tank). Further additionally or alternatively, the pumping device can be configured to generate a flow of the transport medium through the conduit of no more than 10,000 NL / Min, particularly no more than 5,000 NL / Min, preferably no more than 4,000 NL / Min, and more preferably no more than 3,500 NL / Min. "NL" or normal liter refers to a unit of mass of a gas equal to 1 liter at a pressure of 1 atmosphere (101.325 kPa) and a standard temperature of 20°C. In some embodiments, the system can include a pumping device that generates a relatively higher pressure in the component, a pumping device that generates a relatively lower pressure in the system, or both.

[0016] The system according to the present disclosure allows collecting active material residues (in particular, powder residues) from an assembly coated with an electrode mesh with an active material layer in order to clean the assembly for subsequent operations, preferably using different active materials, and / or collecting active material residues (in particular, powder residues) for future use in the same assembly or a different assembly coated with an electrode mesh with an active material layer. By using this system, the assembly can be particularly well prepared for future operations, in particular operations using different kinds of active materials, which otherwise might be affected by impurities generated by the active material residues. This allows a subsequent coating operation to be started quickly with a second active material that is different from, and in particular incompatible with, the first active material previously in the assembly. When an electrode mesh coated with an active material layer contains impurities that have a negative impact on performance, the electrode or even a battery containing the electrode may in some cases not pass quality requirements, which can result in defective products.

[0017] Removing or extracting active material residues from the assembly and collecting them in mobile tanks provides a basis for possible future use of the active material residues. Typically, during electrode manufacturing, active material residues are considered waste to be discarded. For economic and ecological reasons, distributing active material residues is undesirable. The system according to the present disclosure allows for assemblies or components of electrode meshes coated with active material layers to have a significantly improved economic and ecological footprint.

[0018] In one embodiment, the pumping device is arranged at the mobile storage tank. The pumping device can be rigidly attached to the mobile storage tank. For example, the pumping device can be attached to a cover vertically above the funnel section (or alternatively, an optional cylindrical section attached to the funnel section).

[0019] In some embodiments, the system may further include a storage container that is attachable to and detachable from the mobile storage tank. In other words, the storage container is releasably attachable to the mobile storage tank. The storage container is configured to receive and store active material residue. Preferably, the storage container is appropriately selected to store active material residue (preferably, active material powder residue). The storage container may preferably be selected to be physically and / or chemically compatible with the active material residue to be stored therein. The system may include multiple storage containers, each configured for a different type of active material residue. For example, the system may include a first storage container for a first active material, a second storage container for a second active material, and so on. In particular, the storage container may be configured to be chemically non-reactive with the active material to be stored therein. Preferably, the storage container includes or is composed of a material that is chemically inert with respect to the active material to be stored therein. In a preferred embodiment, the storage container is implemented using a transport packaging material, wherein the active material residue extracted from the assembly is initially provided to the assembly as active material. Preferably, the storage container is attachable to the underside of the mobile storage tank. In particular, the storage container can be arranged vertically below the mobile storage tank. The storage container can be connected or connectable to the lower side of the mobile storage tank (in particular, the bottom of the mobile storage tank). The bottom of the mobile storage tank can be at least partially enclosed by the storage container. The lower side can generally refer to a portion of the mobile storage tank in the vertical lower half of the mobile storage tank, in particular in the vertical lower third or lower quarter of the mobile storage tank. The storage container can be attached to the bottom end of the mobile storage tank, or alternatively, to a section near the bottom end of the mobile storage tank, in particular, to a section extending upward from the bottom end of the mobile storage tank.

[0020] In a preferred embodiment of the system, the mobile storage tank may include a cylinder section and a funnel section. In particular, the mobile storage tank includes a funnel section and / or a discharge valve located on the lower side of the mobile storage tank. The funnel can realize the bottom of the mobile storage tank, thereby forming the lower side of the mobile storage tank. The cylinder section can be arranged vertically above the funnel section. Preferably, the cylinder section is complementary to the wide end shape of the funnel section. The diameter of the narrow end of the funnel section can be at least as large as the diameter of the conduit and / or the diameter of one or more pressure supply lines used in the system, preferably larger than the diameter of the conduit and / or the diameter of one or more pressure supply lines used in the system. The pressure supply line can be used to operate a pumping device. For example, the pumping device can have a supply line with a diameter of 1 inch (2.54 cm). In a preferred embodiment, the width of the narrow end of the funnel section (in particular, the width of the discharge valve) is between 2 inches (5 cm) and 20 inches (50 cm), preferably between 6 inches (15 cm) and 12 inches (30 cm), for example 8 inches (20 cm). The funnel section and / or the barrel section may have a diameter at the wide end of the funnel section of between 250 mm and 2500 mm, in particular between 500 mm and 1500 mm, and operationally between 1000 mm and 1200 mm.

[0021] A funnel section may be provided to facilitate the discharge of the active material residue from the mobile storage tank, preferably into a storage container. Providing a discharge valve on the underside of the mobile storage tank (particularly, at the lower (narrow) end of the funnel section) may facilitate the operation of the system or method for extracting the active material residue.

[0022] In some embodiments, the mobile storage tank comprises a vibrator and / or a flow digger, which is configured to facilitate the discharge of active material residues from the mobile storage tank, in particular into a storage container. Preferably, the flow digger and / or vibrator comprises a corresponding pneumatic drive, in particular a pneumatic drive connected to a pneumatic supply line of the system. The vibrator and / or flow digger for discharging active material can be particularly arranged in a system for extracting active material powder residues from a component. The flow digger and / or vibrator can increase the rate at which active material residues can be discharged from the mobile storage tank. Thus, the system or method for digging and extracting active material can be operated quickly and therefore particularly efficiently.

[0023] In some embodiments that may be combined with the above embodiments, the pumping device is a vacuum conveyor comprising a vacuum pump. The pumping device as a vacuum conveyor may further comprise a filter between the pumping device (in particular the vacuum conveyor) and the mobile storage tank. The filter may be used to protect the vacuum pump from absorbing active material residues, in particular active material residues in powder form. Additionally or alternatively, the system (in particular its pumping device) comprises a dust collector that is particularly connected to the exhaust port of the pumping device. The dust collector protects the environment from dust from active material powder residues. The pumping device comprising the vacuum conveyor is preferably attached to the mobile storage tank so as to be operated to allow the second active material residue to pass from the assembly through the conduit into the mobile storage tank.

[0024] In a preferred embodiment of the system according to the present disclosure, which may be combined with the above-described embodiments, the conduit is configured to be directly connectable or connected to a fixed tank, hopper, scale, mixer and / or die coater of the component. Preferably, the conduit is configured to be directly connectable or connected to a hopper of the component or a conveyor directly connected to the hopper. It may be preferred that the mixer and / or die coater together with the active material slurry (including liquid components, such as binders and / or solvents used in combination with the active material powder) are removed before the active material powder residue is extracted from the component. In addition, it may be preferred that the scale for measuring and / or metering the active material is removed before attaching the system, or that at least the scale, i.e., another metering device, is sealed from the system before operating the system to extract the active material (powder) residue from the component to avoid causing measurement errors of the scale. It may be particularly preferred to configure the system to be connected or connectable to a subsystem of an assembly for coating an electrode with an active material layer, the subsystem comprising a stationary tank and / or hopper for the active material (powder) and optionally a conveyor for transferring the active material powder from the tank and / or hopper to a scale and / or mixer, etc. By such attachment, the amount of active material (powder) residue that may remain inside the assembly after extraction using a system according to the present disclosure can be minimized. In addition, using the system and connecting the system in this manner, active material residue can be quickly and efficiently cleared from the assembly before starting a subsequent coating operation with another active material.

[0025] The present disclosure also relates to an assembly for coating an electrode with an active material layer. The assembly includes a fixed storage tank, a die coater, and a conveyor. The assembly may include additional assembly components, preferably fixed assembly components. The fixed storage tank can be rigidly attached to a holding structure (such as a building structure). Preferably, the die coater and / or conveyor are rigidly attached to a holding structure (e.g., a building structure). The fixed storage tank is configured to store a supply of active materials for processing in the assembly. The volume of the fixed storage tank can be at least 500L, particularly at least 1000L, preferably at least 2500L, and / or no more than 100,000L, particularly no more than 50,000L, preferably no more than 20,000L. A system for extracting active material residues from the assembly (e.g., the system described above) can be attachable or attached to the assembly, and in this case, the mobile storage tank of the extraction system can preferably be no larger than the fixed storage tank of the coating assembly, and more preferably, the volume of the mobile storage tank can be less than the volume of the fixed storage tank, particularly less than half the volume of the fixed storage tank. The die-coater is configured to supply an active material onto the metal foil mesh material to form an active material layer. The stationary storage tank may be disposed vertically above the die-coater. The stationary storage tank is preferably immovable. A conveyor is configured to transfer the active material from the stationary storage tank to the die-coater. The conveyor may include at least one conduit for fluid communication between the die-coater and the stationary storage tank.

[0026] According to the present disclosure, the assembly further comprises an outlet member. Preferably, the outlet member is a fixed component of the assembly. The outlet member is configured to selectively close or open an outlet opening for ejecting active material from the assembly. A system for extracting active material residue from the assembly, in particular the system described above, can be releasably attached to or attached to the outlet member. In particular, the system comprises a conduit releasably connectable to the assembly. The conduit of the system can preferably be connectable to the outlet opening of the assembly.

[0027] In an embodiment of the assembly, the outlet member has a closed state and an open state. Preferably, the outlet member is configured to selectively close or open the outlet orifice depending on the open or closed state of the outlet member. In the closed state of the outlet member, the active material is free to flow from the stationary reservoir to the die coater. Furthermore, in the closed state, the active material is inhibited from exiting the assembly through the outlet orifice, while in the open state, the outlet orifice is in fluid communication with the stationary reservoir, allowing the active material to exit the assembly through the outlet orifice. In particular, when the system is attached to the assembly, in the open state, the stationary reservoir can be in fluid communication with the system, preferably with a mobile reservoir of the system, through the open outlet orifice.

[0028] According to a further development of the assembly, the outlet member is configured such that, in the open state, the active material is inhibited from traveling from the stationary reservoir to the die-coater. In the closed state of the outlet member, the outlet member can separate the stationary reservoir and / or the outlet opening from the die-coater. Preferably, in the closed state of the outlet member, the outlet member forms a liquid-tight and / or air-tight barrier between the stationary reservoir on the one hand and the scale and / or mixer of the assembly on the other hand. Additionally or alternatively, in the closed state of the outlet member, the outlet member forms a liquid-tight and / or air-tight barrier between the outlet opening on the one hand and the scale and / or mixer of the assembly on the other hand.

[0029] In a preferred embodiment of the assembly, which can be combined with and further developed from the above embodiments, the outlet member comprises a T-piece. In particular, the outlet member can comprise a branched T-valve and / or a 3-way piston.

[0030] In an embodiment of the assembly which may be combined and further developed with the preceding embodiments, the outlet member is arranged below the stationary tank, so that extraction of the active material from the assembly to the system can be assisted by gravity.

[0031] Additionally or alternatively, some embodiments of the assembly further include a hopper attached to and positioned at the bottom of the stationary storage tank. Preferably, the stationary storage tank is provided with the hopper to improve the flow of active material from the stationary storage tank through the conveyor to the die coater. An outlet member is positioned below the hopper. Thus, additionally or alternatively, the hopper can assist in extracting active material from the stationary storage tank into the system.

[0032] The assembly may include a scale for measuring and / or metering the active material. Alternatively or additionally, the assembly may include a mixer configured to combine the active material with other components (particularly liquid components) to form a slurry. The scale and / or mixer is arranged between the stationary storage tank and the die coater. Preferably, the scale is arranged upstream of the mixer. The outlet member is arranged upstream of the scale and / or mixer. The conveyor can be divided into a powder conveying section and a slurry conveying section by the mixer, wherein the outlet member is preferably arranged in the powder conveying section.

[0033] The present disclosure also relates to a method for extracting active material residue from a component having an electrode coated with an active material layer, particularly using the system and / or assembly described above. Preferably, the method is performed to extract the active material residue from a first component and subsequently inject the active material residue into another component, or to reintroduce the active material residue into the first component.

[0034] An assembly for coating an electrode with an active material layer may include: a stationary tank in which the active material may be stored for processing; a conveyor configured to transport the active material (powder) through the assembly; a scale or other metering device for measuring the amount of active material to be processed for coating; and a mixer configured to combine the active material powder with other components (particularly liquid components) to form a slurry. The other components may in particular include a binder, a conductive material and / or a solvent. The assembly for coating the active material layer onto the electrode includes at least one die coater, wherein the active material slurry that can be prepared in the mixer is supplied to the electrode in the shape of an electrode mesh so as to form the active material layer thereon.

[0035] Additionally or alternatively, the assembly may comprise one or more conveyors for the active material (in particular, for active material powder and / or for active material slurry). The conveyor of the assembly for coating the electrode with the active material layer may comprise a vacuum conveyor. It should be clear that the pumping means of the system according to the present disclosure (in particular, the vacuum conveyor) is preferably a separate unit from the conveyor of the assembly. Preferably, in the case where the system according to the present disclosure is connected to the assembly, the combination of the system and the assembly may comprise two different vacuum conveyors, one implementing the pumping means of the system and the other being a conveyor of the assembly operable for normal coating operations. Alternatively, in the case where the assembly is ready to be connected to the system according to the present disclosure by separating two or more subsystems from the assembly, the system including its pumping means (which may be a vacuum conveyor) may be connected to a first subsystem of the assembly and the second subsystem of the assembly includes a vacuum conveyor of the assembly which is different from the pumping means of the system.

[0036] A method for extracting active material residues from an assembly of electrodes coated with active material, preferably from an assembly as described above, comprises the steps of providing a mobile tank; attaching a conduit to the mobile tank; connecting the conduit to the assembly; and sucking the active material residues from the assembly into the mobile tank through the conduit.

[0037] In the method for extracting active material residues, it is preferred that the conduit be first attached to the mobile storage tank. This attachment can be permanent, for example, by welding. The conduit is preferably connected to the assembly after the conduit is attached to the mobile storage tank. The conduit is preferably connected to the assembly in a detachable manner.

[0038] After the conduit has been attached to the mobile tank and connected to the assembly (preferably its outlet port), the active material residue is extracted from the assembly. Before extracting the active material, it is conceivable to test whether the fluid system, including the conduit in the mobile tank, the assembly, and / or its subsystem (from which the active material residue is to be extracted), is sealed in an airtight manner so that the transport medium (such as air, nitrogen, etc.) used to deposit the active material residue in the assembly does not leak. In the case of using ambient air as the transport medium, it would be appropriate to controllably open at least one port (e.g., an air inlet) of the assembly or its subsystem (from which the active material residue is to be extracted) before commencing the extraction of the active material residue from the assembly.

[0039] In an embodiment of the method for extracting active material residue, a step may be provided including opening a selectively closable outlet member of the assembly to allow the active material residue to pass from the assembly through an outlet aperture of the outlet member to the mobile tank. The outlet member is operable to switch between at least a closed state, in which the active material residue is inhibited from passing from the stationary tank to the mobile tank through the outlet aperture, and an open state, in which the active material residue can pass from the stationary tank to the mobile tank through the outlet aperture.

[0040] In a preferred embodiment of the method for extracting active material residues, a further step comprises discharging the active material residues from the mobile storage tank to a storage container. Prior to discharging the active material residues from the tank to the container, the storage container may be releasably connected to the mobile storage tank, in particular releasably connected to the mobile storage tank in an airtight manner. Discharging the active material residues from the mobile storage tank to the storage container may be assisted by discharging the material into the storage container through a downward-facing funnel section of the mobile storage tank. Alternatively or additionally, the mobile storage tank may be provided with a vibrator and / or a stream excavator configured to facilitate the discharge of the active material residues from the mobile storage tank. It may be preferred that the stream excavator and / or vibrator associated with the fixed storage tank is operated (in particular intermittently or continuously) while the active material residues are being discharged from the mobile storage tank to the storage container. In some preferred embodiments, a discharge valve may be provided to the mobile storage tank. It may be preferred that the discharge valve is operated to start and / or stop the discharge of the active material from the mobile storage tank to the storage container. In a preferred embodiment, the active material residue can be discharged from the mobile tank to a storage container through a discharge valve.

[0041] In a particularly preferred embodiment of the method for extracting active material residues from an assembly for coating an electrode, which embodiment can be combined with the above-described embodiments, connecting the conduit to the assembly comprises connecting the conduit directly to one of a stationary tank, a hopper, a scale, a mixer and / or a die coater of the assembly, in particular directly to the hopper.

[0042] The present disclosure also relates to a method for manufacturing an electrode in an assembly in which the electrode is coated with an active material layer, the method using a mixture of an active material and an active material residue. For ease of understanding, the mixture may be referred to as a mixture of a first active material and a second active material. In the method according to the present disclosure, the second active material is composed of an active material residue. The mixture of the first active material and the second active material can be produced in a mixer of the assembly before, during, or after mixing the first active material and / or the second active material with a fluid component, which may particularly include a binder and / or a solvent. In some embodiments, the mixing of the first active material and the second active material can be performed as a dry blend of a first active material powder and a second active material powder. The dry blending of the first active material powder and the second active material powder can be performed within the assembly, for example, within a stationary storage tank, hopper, and / or conveyor of the assembly. According to another embodiment of the method, the dry blending of the active material powders can be performed before the mixture of the first active material powder and the second active material powder is introduced into the assembly (particularly a stationary storage tank and / or hopper of the assembly). Preferably, the first active material (powder) is different from the second active material (powder). The first active material may include a first marker to distinguish the first active material from the second active material. Alternatively or additionally, the second active material may include a marker, particularly a second marker, which is preferably used to distinguish the second active material from the first active material. Preferably, both the first active material and the second active material include their respective first and second markers. In some preferred embodiments, only the second active material (the extracted active material residue) includes the marker.

[0043] Preferably, the method for manufacturing an electrode uses the above-mentioned method for extracting active material residues to provide active material residues. Preferably, with respect to the components of the method for manufacturing an electrode, the active material residues are extracted from the same or different components.

[0044] In a further development of the method for manufacturing an electrode, a mixture comprising 0.01 wt% to 25 wt% of active material residues is prepared. In particular, the preparation can produce a mixture comprising 0.1 wt% to 10 wt% of active material residues. As previously described, it may be preferred that the mixture is a powder mixture comprising an active material powder (first active material powder) and an active material residue powder (second active material powder), wherein the content of the active material residues can be determined relative to the total weight of the powder mixture. In the case of a wet active material mixture comprising a liquid component (e.g., a solvent, a binder, etc.), the content of the second active material can be determined relative to the total dry content of the wet mixture.

[0045] In the method for manufacturing an electrode, the content of active material residues in the mixture can be constant over the duration of the coating operation. In a preferred embodiment of the method for manufacturing an electrode in an assembly in which an electrode is coated with an active material using a mixture of active material and active material residues, it can be preferred to reduce the active material residue content. In particular, the active material residue content can be reduced from an initial value of about 10 wt%, in particular 20 wt% or more to a second active material residue content of less than 10 wt%, in particular less than 5 wt%. In the method for manufacturing an electrode, the active material residue content can be reduced to a final active material residue content of less than 1%, in particular less than 0.1%, preferably less than 0.01% by weight (wt%).

[0046] The present disclosure also relates to a method for manufacturing a battery using a mixture of an active material and an active material residue. The battery may be, for example, a pouch-type battery or a jelly-roll-type battery. The battery may include a stacked or wound (particularly rolled) electrode assembly comprising a positive electrode (which may include an active material residue), a negative electrode (which may include a second active material residue), and a separator between the positive and negative electrodes.

[0047] The present disclosure also relates to an electrode including a pellet-shaped electrode and an active material layer coated on the pellet-shaped electrode, wherein the active material layer includes a mixture of an active material and an active material residue.

[0048] Additionally, the present disclosure relates to a battery comprising the electrode as described above.

[0049] Battery

[0050] A battery typically includes two electrodes of opposite polarity, namely a negative electrode and a positive electrode. These electrodes are arranged together with a separator in a common container. The separator separates the container so that the negative electrode and the positive electrode are not in close contact with each other, thereby avoiding short circuits. In addition, the common container is filled with an electrolyte solution that allows ions to pass from the positive electrode to the negative electrode to allow a chemical reaction to release electrical energy. The electrodes of the battery may each include a corresponding foil. The foil may include or consist of a conductive material. In particular, the foil may consist of or include a metal or a metal alloy, including, for example, aluminum or copper, or consisting of, for example, aluminum or copper. Preferably, at least one electrode of the battery is implemented as a foil coated with an active electrode material (abbreviated as: active material).

[0051] For example, an electrode configured to function as a negative electrode may be provided with an active material layer configured to receive and / or store (preferably releasably store) ions. The active material (particularly, the active material of the negative electrode) may include graphite as its primary component. An electrode configured to function as a positive electrode may be provided with an active material configured to release ions. The active material, particularly the active material for the positive electrode, may contain or consist of a metal oxide (e.g., lithium oxide). The active material may, for example, include or consist of LCO (LiCoO2), NCM (Li(NiCoMn)O2), NCA (Li(NiCoAl)O2), LMO (LiMn2O), and / or LFP (LiFePO4). The active material slurry or layer may include a conductive additive, a binder, a filler, and other components. The active positive electrode material can be configured to be replenishable. The process of releasing ions from the positive electrode active material and receiving ions through the negative electrode active material can be called discharging. The process of releasing ions from the negative electrode active material and replenishing the positive electrode active material with ions can generally be called charging or recharging. The active materials used in the electrodes of the battery are considered to be essential to determining the properties of the battery (such as its capacity, voltage and memory effect).

[0052] In the present disclosure, the positive electrode active material coated on the positive electrode sheet and the negative electrode active material coated on the negative electrode sheet may include, but are not limited to, any known active material in the art to which the present disclosure pertains. The electrode sheet may be made by cutting sections from an electrode mesh.

[0053] The term "mesh material" is to be understood as a general term referring to mesh-like materials (e.g., films, sheets, foils, meshes, porous materials such as sieves, foams, and nonwoven fabrics). The mesh material has a mesh length dimension that is substantially greater than a mesh width dimension, wherein the mesh width dimension is substantially greater than a mesh thickness dimension. For example, the mesh thickness dimension of the metal foil mesh material to be processed can be configured within a range of between 1 μm and 100 μm, preferably between 3 μm and 30 μm, and more preferably between 5 μm and 15 μm. For example, the mesh width dimension of the metal foil mesh material to be processed can be configured within a range of between 1 mm and 5000 mm, preferably between 10 mm and 1000 mm, and more preferably between 50 mm and 500 mm. For example, the mesh length dimension of the metal foil mesh material to be processed can be configured within a range of between 10 m and 100 km, preferably between 100 m and 50 km, and more preferably between 500 m and 25 km. Typical rates at which the web material moves during processing, particularly during the coating step, may be of the order of 100 m / min.

[0054] positive electrode

[0055] The positive electrode preferably includes active material powder, in particular positive electrode active material powder. Specifically, the positive electrode includes a positive electrode current collector and a positive electrode active material layer formed on the positive electrode current collector, wherein the positive electrode active material layer includes positive electrode active material powder.

[0056] In one example, the positive electrode active material may include a x M y ]O 2+z An alkali metal compound represented by (A includes at least one of Li, Na or K; M includes at least one selected from Ni, Co, Mn, Ca, Mg, Al, Ti, Si, Fe, Mo, V, Zr, Zn, Cu, Al, Mo, Sc, Zr, Ru and Cr; x ≥ 0, 1 ≤ x + y ≤ 2, -0.1 ≤ z ≤ 2; the stoichiometric coefficients x, y and z are selected to maintain the electrical neutrality of the compound).

[0057] In another example, the positive active material may be an alkali metal compound xLiM 1 O2-(1x)Li2M 2 O3(M 1 comprising at least one element having an average oxidation state of trivalent; M 2 It preferably includes at least one element having an average tetravalent oxidation state (0≤x≤1) disclosed in US Pat. No. 6,677,082 and US Pat. No. 6,680,143.

[0058] In yet another example, the positive electrode active material may be of the formula Li aM 1 x Fe 1-x M 2 y P 1-y M 3 z O 4-z (M 1 comprises at least one selected from Ti, Si, Mn, Co, Fe, V, Cr, Mo, Ni, Nd, Al, Mg, and Al; M 2 comprises at least one selected from Ti, Si, Mn, Co, Fe, V, Cr, Mo, Ni, Nd, Al, Mg, Al, As, Sb, Si, Ge, V, and S; M 3 comprises a halogen group element optionally including F; 0 < a ≤ 2, 0 ≤ x ≤ 1, 0 ≤ y < 1, 0 ≤ z < 1; the stoichiometric coefficients a, x, y, and z are selected to maintain the electro-neutrality of the compound) or a lithium metal phosphate represented by Li3M2(PO4)3 [M comprises at least one selected from Ti, Si, Mn, Fe, Co, V, Cr, Mo, Ni, Al, Mg, and Al].

[0059] Preferably, the positive electrode active material may include primary particles and / or secondary particles formed by aggregation of the primary particles.

[0060] In one example, the negative electrode active material may include a carbon material, a lithium metal or a lithium metal compound, silicon or a silicon compound, tin or a tin compound. Metal oxides having a potential of less than 2V (such as TiO2 and SnO2) can be used as the negative electrode active material. The carbon material may include low-crystalline carbon and high-crystalline carbon. <00001​​​​​​Conductive materials are used to impart conductivity to the electrodes. Any conductive material that does not cause chemical changes in the battery and exhibits conductivity can be used without particular limitation. Specific examples include: graphite, such as natural graphite and artificial graphite; carbon-based materials, such as carbon black, acetylene black, Ketjen black, channel black, furnace black, lamp black, thermal black, and carbon fiber; metal powders or fibers, such as copper, nickel, aluminum, and silver; conductive tubes, such as carbon nanotubes; conductive whiskers, such as zinc oxide and potassium titanate; conductive metal oxides, such as titanium oxide; and conductive polymers, such as polyphenylene derivatives, which can be used alone or in combination of two or more. The conductive material may be included in an amount of 0.1 to 15 wt% relative to the total weight of the positive electrode active material layer.

[0064] The binder is used to enhance the cohesive force between the positive electrode active material particles and the adhesion between the positive electrode active material and the current collector. Specific examples of binders include polyvinylidene fluoride (PVDF), polyvinylidene fluoride-hexafluoropropylene copolymer (PVDF-co-HFP), polyvinyl alcohol, polyacrylonitrile, polymethyl methacrylate, carboxymethyl cellulose (CMC), starch, hydroxypropyl cellulose, regenerated cellulose, polyvinyl pyrrolidone, polytetrafluoroethylene, polyethylene, polypropylene, ethylene-propylene-diene polymer (EPDM), sulfonated EPDM, styrene-butadiene rubber (SBR), fluororubber, polyacrylic acid, polymers in which hydrogen has been replaced by Li, Na or Ca, and various copolymers thereof, which can be used alone or in combination of two or more thereof. The binder may be included in an amount of 0.1 to 15 wt% relative to the total weight of the positive electrode active material layer.

[0065] The positive electrode can be manufactured by a typical method for manufacturing a positive electrode, wherein positive electrode active material powder is used. Specifically, a positive electrode slurry composition prepared by dissolving or dispersing the positive electrode active material powder and an optional binder, a conductive material, and a dispersant in a solvent is applied to a positive electrode current collector and dried and roll-pressed to manufacture the positive electrode.

[0066] The solvent may be a commonly used solvent in the art, examples of which include dimethyl sulfoxide (DMSO), isopropyl alcohol, N-methylpyrrolidone (NMP), dimethylformamide (DMF), acetone, water, and the like. These materials may be used alone or in combination of two or more. Considering the thickness of the slurry to be coated and the manufacturing yield, it is sufficient as long as the amount of solvent used is sufficient to dissolve and disperse the positive electrode active material, the conductive material, the binder, and the dispersant and to allow for a viscosity that exhibits excellent thickness uniformity when coating the positive electrode.

[0067] negative electrode

[0068] The negative electrode preferably includes active material powder, in particular negative electrode active material powder. Specifically, the negative electrode includes a negative electrode current collector and a negative electrode active material layer formed on the negative electrode current collector, and the negative electrode active material layer includes negative electrode active material powder.

[0069] In a battery (particularly, a lithium secondary battery), the negative electrode includes a negative electrode current collector and a negative electrode active material layer located on the negative electrode current collector.

[0070] The negative electrode current collector is not particularly limited as long as it does not cause chemical changes in the battery and has high conductivity. For example, copper, stainless steel, aluminum, nickel, titanium, heat-treated carbon, copper or stainless steel, aluminum-cadmium alloy, etc. whose surfaces have been treated with carbon, nickel, titanium, silver, etc., can be used. In addition, the negative electrode current collector may generally have a thickness of 3 μm to 500 μm. In addition, like the positive electrode current collector, the negative electrode current collector may have tiny irregularities formed on its surface to increase the adhesion of the negative electrode active material. For example, the negative electrode current collector may be used in any of various forms (such as, a film, a sheet, a foil, a mesh, a porous material, a foam, a non-woven fabric, etc.).

[0071] The negative electrode active material layer includes a negative electrode active material and optionally a binder and a conductive material.

[0072] As the negative electrode active material, a compound that can achieve reversible insertion and extraction of lithium can be used. Specific examples include: carbonaceous materials such as artificial graphite, natural graphite, graphitized carbon fiber, amorphous carbon, etc.; metal compounds that can be alloyed with lithium, such as Si, Al, Sn, Pb, Zn, Bi, In, Mg, Ga, Cd, Si alloys, Sn alloys, Al alloys, etc.; metal oxides that can be doped and dedoped with lithium, such as SiOβ (0<β<2), SnO2, vanadium oxide, and lithium vanadium oxide; and composite materials including metal compounds and carbonaceous materials, such as Si-C composite materials and Sn-C composite materials, which can be used alone or in combination of two or more thereof. In addition, a lithium metal film can be used as the negative electrode active material. In addition, as the carbon material, both low crystallinity carbon and high crystallinity carbon can be used. Representative examples of low-crystallinity carbon include soft carbon and hard carbon, and representative examples of high-crystallinity carbon include amorphous, plate-like, flaky, spherical or fibrous natural graphite or artificial graphite, agglomerated graphite (Kish graphite), cracked carbon, mesophase pitch-type carbon fibers, meso-carbon microbeads, mesophase pitch and high-temperature calcined carbon (such as coke derived from petroleum or coal tar pitch), etc.

[0073] The negative active material may be included in an amount of 80 wt % to 99 wt % with respect to the total weight of the negative active material layer.

[0074] The binder is used to assist in the bonding between the conductive material, the active material, and the current collector, and is generally included in an amount of 0.1 wt % to 10 wt % relative to the total weight of the negative electrode active material layer. Examples of binders include polyvinylidene fluoride (PVDF), polyvinyl alcohol, carboxymethyl cellulose (CMC), starch, hydroxypropyl cellulose, regenerated cellulose, polyvinyl pyrrolidone, polytetrafluoroethylene, polyethylene, polypropylene, ethylene-propylene-diene polymer (EPDM), sulfonated EPDM, styrene-butadiene rubber, nitrile rubber, fluororubber, and various copolymers thereof.

[0075] The conductive material is a component for enhancing the conductivity of the negative electrode active material and can be included in an amount of 10 wt% or less, and preferably 5 wt% or less, relative to the total weight of the negative electrode active material layer. Such a conductive material is not particularly limited as long as it does not cause chemical changes in the battery and has conductivity. For example, the following can be used: graphite, such as natural graphite, artificial graphite, etc.; carbon black, such as acetylene black, Ketjen black, channel black, furnace black, lamp black, thermal black, etc.; conductive fibers, such as carbon fibers, metal fibers, etc.; carbon fluoride; metal powder containing aluminum, nickel, etc.; conductive whiskers, such as zinc oxide, potassium titanate, etc.; conductive metal oxides, such as titanium oxide, etc.; or conductive materials, such as polyphenylene derivatives, etc.

[0076] The negative electrode can be manufactured by a typical method for manufacturing a negative electrode, wherein a negative electrode active material powder is used. Specifically, a negative electrode slurry composition prepared by dissolving or dispersing the negative electrode active material powder and an optional binder, a conductive material, and a dispersant in a solvent is applied to a negative electrode current collector and dried and roll-pressed to manufacture the negative electrode.

[0077] The negative electrode active material layer may be formed by coating a negative electrode slurry composition prepared by dissolving or dispersing the negative electrode active material and optionally a binder and a conductive material in a solvent onto a negative electrode collector and drying it; or by laminating a film obtained by casting the negative electrode slurry composition on a separate support and removing it from the support onto the negative electrode collector.

[0078] Active material powder

[0079] The active material powder may include an active material powder containing a metal oxide (for example, a lithium composite transition metal oxide) in the form of a single particle consisting of one nodule and / or in the form of a pseudo-single particle composed of 30 or fewer nodules, preferably 2 to 20 nodules, and more preferably 2 to 10 nodules. Since the active material powder containing a metal oxide (for example, a lithium composite transition metal oxide) in the form of a single particle and / or a pseudo-single particle has a higher particle strength than a conventional lithium composite transition metal oxide in the form of secondary particles (in which tens to hundreds of primary particles are aggregated), the particles are less likely to break during rolling.

[0080] In addition, since the active material powder in the form of single particles or pseudo-single particles containing metal oxides (for example, including lithium composite transition metal oxides) has a small number of sub-parts (i.e., nodules) constituting the single particles and / or pseudo-single particles, the changes caused by the volume expansion / contraction of the sub-parts (i.e., nodules) during charge and discharge are small, and therefore, the generation of cracks within the particles is significantly reduced.

[0081] In the present disclosure, a "single particle" is a particle composed of a single nodule. In the present disclosure, a "pseudo-single particle" refers to a particle that is a composite formed of 30 or fewer nodules. A "nodule" according to the present disclosure refers to the particle unit body that constitutes a single particle and a pseudo-single particle. A nodule may be a single crystal lacking any crystalline grain boundaries, or alternatively, may be a polycrystal in which no grain boundaries appear when observed in a field of view of 5000X to 20000X using a scanning electron microscope (SEM).

[0082] In the present disclosure, "secondary particles" refer to particles formed by the aggregation of tens to hundreds of primary particles. More specifically, the secondary particles are aggregates of 50 or more primary particles.

[0083] In the present disclosure, when "particles" are described, any one or all of single particles, pseudo single crystals, primary particles, nodules, and secondary particles may be encompassed.

[0084] In this disclosure, “D mean ” refers to the average particle size of nodules measured using an electron backscatter diffraction (EBSD) pattern analyzer. EBSD analysis is performed as follows: an electrode is manufactured using a positive electrode active material powder to be measured; the electrode is cut by ion milling (HITACHI IM-500, accelerating voltage: 6 kV) before a roll pressing process to obtain a cross section; and the cross section is measured using a FE-SEM apparatus (JEOL JSM-7900F). In this case, the measurement is performed under the conditions of an accelerating voltage of 15 kV and a WD of 15 mm on a scale (130) of about 400±10 primary particles. The active material powder may include an average particle size (D mean) is a nodule of 0.5 to 3.5 μm. Specifically, D mean may be 0.5 μm or greater, 1.0 μm or greater, or 1.5 μm or greater, and D mean It can be 3.5 μm or less, 3 μm or less, 2.5 μm or less, or 2.0 μm or less. When the average particle size of the nodules (D mean ) is less than 0.5 μm, the specific surface area of ​​the entire positive electrode active material increases, and thus the side reaction with the electrolyte may increase. On the other hand, when D mean When it exceeds 3.5 μm, the (lithium) mobility in the positive electrode active material decreases, and thus the output characteristics of the battery may be deteriorated.

[0085] In this disclosure, “D 50 ” refers to the particle size corresponding to 50% of the cumulative volume in the particle size distribution of the active material powder. The average particle size (D 50 ) can be measured by a laser diffraction method. For example, the average particle size can be measured by dispersing the positive electrode active material powder in a dispersion medium and inputting the resultant into a commercial laser.

[0086] The active material powder may have D 50 , which is a value of 2 to 10 μm corresponding to 50% of the cumulative volume in the powder particle size distribution. Specifically, D 50 may be 2 μm or greater, 3 μm or greater, 4 μm or greater, 5 μm or greater, or 6 μm or greater, and D 50 It can be 10 μm or less, 9 μm or less, 8 μm or less, or 7 μm or less. 50 When the D is less than 2 μm, the specific surface area of ​​the entire positive electrode active material increases, and thus the side reaction with the electrolyte may increase. On the other hand, when D 50 When it exceeds 10 μm, lithium mobility in the positive electrode active material decreases, and thus the output characteristics of the battery may be deteriorated.

[0087] The active material powder may include one or more markers. The markers may be used to distinguish between a first active material powder and a second active material powder. In particular, the markers may be used to distinguish between original active material powder and active material residue. The one or more markers are preferably selected so as not to adversely affect the active material. Preferably, the active material powder, in particular the active material powder residue, may contain 0.01 wt% to 5 wt%, in particular 0.02 wt% to 2 wt%, and preferably 0.05 wt% to 1 wt% of the marker. In some preferred embodiments, the active material powder, in particular the active material powder residue, contains less than 1 wt%, in particular less than 0.5 wt%, and preferably less than 0.2 wt% or less than 0.1 wt% of the marker. A positive electrode marker may be provided to distinguish between different positive electrode active material powders. The positive electrode marker may preferably include or consist of a material other than the positive electrode active material. A negative electrode marker may be provided to distinguish between different negative electrode active material powders. The negative electrode marker may preferably include or consist of a material other than the negative electrode active material.

[0088] In some embodiments, the marker may include or consist of a metal oxide, for example, lithium oxide, such as LiCoO2, Li(NiCoMn)O2, Li(NiCoAl)O2, LiMn2O and / or LiFePO4. Alternatively or additionally, the marker may specifically include or consist of one or more of the following: a carbonaceous material, such as artificial graphite, natural graphite, graphitized carbon fiber, amorphous carbon, etc.; a metal compound capable of alloying with lithium, such as Si, Al, Sn, Pb, Zn, Bi, In, Mg, Ga, Cd, Si alloy, Sn alloy, Al alloy, etc.; a metal oxide, such as SiO β (0<β<2), SnO2, vanadium oxide and lithium vanadium oxide; and composite materials including metal compounds and carbonaceous materials, such as Si-C composites and Sn-C composites, which can be used alone or in combination of two or more thereof.

[0089] However, the problems to be solved by the embodiments of the present disclosure are not limited to the above-mentioned problems, and can be variously extended within the scope of the technical concept included in the present disclosure.

[0090] Beneficial effects

[0091] According to embodiments, a system and method for extracting active material residues from an assembly in which an electrode (web) is coated with an active material layer can be provided, thereby allowing the active material to be saved and reused for operating the assembly in an economically and ecologically improved manner. According to embodiments, economic and ecological advantages can be exploited in batteries, electrodes, and methods for manufacturing electrodes using a mixture of (original) active material and active material residues.

[0092] The effects of the present disclosure are not limited to the above-described effects, and other additional effects not described above will be clearly understood by those skilled in the art from the description of the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0093] Figure 1 is a schematic diagram of an assembly for coating an electrode with a layer of active material;

[0094] Figure 2 is a schematic diagram of a system for extracting active material residues from components connected to its subsystems;

[0095] Figure 3 is a schematic diagram of a system for extracting active material residues from a component; and

[0096] Figure 4 is another schematic diagram of a system for extracting active material residues. DETAILED DESCRIPTION

[0097] Hereinafter, various embodiments of the present disclosure will be described in detail with reference to the accompanying drawings so that those skilled in the art can easily perform the embodiments. The present disclosure can be modified in various ways and is not limited to the embodiments set forth herein.

[0098] In order to clearly describe the present disclosure, parts that are not relevant to the description will be omitted, and the same reference numerals represent the same elements throughout the specification. The marker is preferably different from the main component of the active material powder. The marker can preferably be introduced into the extracted active material residue in the system (particularly in a mobile tank or in a storage container). In some embodiments, the marker can be formed in the active material residue during extraction from the component and / or during storage in the mobile tank and / or storage container. In some embodiments, the marker can be added to the active material during the preparation of the active material before the active material as the active material residue is extracted from the component.

[0099] In addition, in the drawings, for the sake of convenience of description, the size and thickness of each element are arbitrarily shown, and the present disclosure is not necessarily limited to those shown in the drawings. In the drawings, the thickness of layers, regions, etc. are exaggerated for clarity. In the drawings, the thickness of some layers and regions are exaggerated for the sake of convenience of description.

[0100] In addition, it should be understood that when an element such as a layer, film, region, or plate is referred to as being "on" or "above" another element, it can be directly on the other element, or there can be an intervening element. Conversely, when an element is referred to as being "directly on" another element, this means that there are no other intervening elements. In addition, the words "on..." or "above..." mean to be disposed on or below the referenced portion, and do not necessarily mean to be disposed on the upper end of the referenced portion in the opposite direction of gravity. In addition, similar to the case where it is described as being "higher than another portion," "on another portion," or "above another portion," the case where it is described as being "lower than another portion," "below another portion," or "below another portion" will also be understood with reference to the above.

[0101] Furthermore, throughout the specification, when referred to as a “plane”, this means observing the target portion from the upper side, and when referred to as a “cross section”, this means observing the target portion from one side of a cross section cut vertically.

[0102] Throughout the specification, when a part is referred to as "including" or "comprising" a certain component, it means that the part may also include other components, and does not exclude other components, unless otherwise specified. Throughout the specification, unless otherwise specified, each element may be single or plural.

[0103] Additionally, when an element is referred to as being “connected,” “coupled,” or “linked” to another element, it may be directly connected or coupled to the other element, but it should be understood that intermediate elements may exist between the elements, or the elements may be “connected,” “coupled,” or “linked” to each other through another element.

[0104] Throughout the specification, unless expressly stated otherwise, "A and / or B" means A or B or both A and B, and unless expressly stated otherwise, "C to D" means C or greater and D or less.

[0105] Hereinafter, a system and method for extracting active material residues, a method for coating an electrode with an active material layer for manufacturing a battery, and corresponding components are described with reference to the accompanying drawings.

[0106] For illustrative purposes, Figure 1 1 shows an assembly 100 configured to perform a process of processing a metal foil mesh material 101 into an electrode mesh material 102. In other words, Figure 1The normal coating operation mode of the assembly 100 is shown. The metal foil mesh material 101 typically has a thickness of only a few μm, a width of a few dm, and a length that can reach one kilometer or more. The metal foil mesh material 101 is provided from a supply source and transported through the assembly 100 according to a transport direction T indicated by an arrow. The metal foil mesh material 101 passes through a die coater 110, which is configured and operated to supply an active material layer 103 to the metal foil mesh material, thereby forming an electrode or electrode mesh material 102. Downstream of the die coater 110, an oven for curing the active material layer 103 to stabilize the electrode mesh material 102 (not shown) may be provided.

[0107] exist Figure 1 In the schematic diagram of the assembly 100 shown, only one die coater 110 is shown, thereby coating only the first side of the metal foil mesh material 101. Preferably, the metal foil mesh material 101 is then fed through a second die coater to coat the opposite second side of the metal foil mesh material to produce an electrode mesh (not shown) supplied with an active material layer on both sides of the metal foil mesh material. Downstream of the one or more die coaters 110, one or more separation devices may be provided to cut individual sheets from the electrode mesh material 102 (not shown). Such separation devices can be operated to produce individual electrode sheets to be used in batteries.

[0108] The assembly 100 includes a conveyor 120 for the active material slurry prepared in the mixer 130. The conveyor 120 brings the active material slurry from the mixer 130 to the die coater 110, where the slurry is dispensed onto the metal foil mesh material 101 to produce the active material layer 103 coating the electrode 102. A predetermined amount of active material powder is supplied to the mixer 130 by a check scale 150 or other metering device. The mixer 130 may also include one or more ports 140 to include additional materials in the active material slurry. The port 140 may be provided to introduce active material residue extracted from another assembly. The port 140 may be provided to introduce one or more liquid components, such as a binder or solvent.

[0109] A conveyor 160, which may be a vacuum conveyor, is disposed between the hopper 170 and the scale 150. The hopper 170 may contain active material powder, or a dry mixture of active material powder and active material residue powder. The hopper 170 may be implemented with or combined with a stationary storage tank 180 for the active material powder or the dry mixture of active material powder and active material residue powder.

[0110] Assembly 100 may include a T-valve (not shown). The T-valve may be arranged in conveyor 160 between stationary storage tank 180 and die coater 110. Preferably, the T-valve may be arranged below stationary storage tank 180, in particular at the lower end of hopper 170 provided to stationary storage tank 180. The T-valve may have an outlet hole to which a conduit may be attached. The T-valve may be operable to close the outlet hole and provide a connection between stationary storage tank 180 and die coater 110 via conveyor 160, or to open the outlet hole so that active material residue can be extracted from assembly 100 (in particular, stationary storage tank 180) through the outlet hole.

[0111] Figure 2 A system 1 for extracting active material residue from an assembly in combination with a subsystem of assembly 100 is shown, the subsystem comprising a hopper 170 and a conveyor 160 attached to the hopper. When the system 1 is attached to the assembly 100, the assembly is in an extraction mode in which any active material (powder) residue can be removed from the assembly 100 or its subassemblies using the system 1.

[0112] Figure 2 The system 1 shown includes a mobile storage tank 3, a conduit 5, and a pumping device 7. The conduit 5 is attached to the mobile storage tank 3 and is connected to the hopper 170 via the conveyor 160 of the assembly 100. The pumping device 7 is securely attached to the mobile storage tank 3. The pumping device 7 of the system 1 is operable to generate a negative pressure for sucking the active material residue out of the assembly 100 (particularly a subsystem or subassembly of the assembly 100 including the hopper 170). Figure 2 As shown, the system 1 may include a storage container 9, which may be a reusable transfer bag that has been previously used to provide raw active material powder to the assembly 100. The storage container 9 may be connected to the mobile tank 3 to receive the active material residue extracted by the system 1.

[0113] System 1 may include a carriage or frame 2 including rollers or wheels 21 configured to enable system 2, including its mobile tank 3, to be moved to and from one or more components 1 at a manufacturing site. Mobile tank 3 is rigidly attached to frame 2. Pumping device 7 is rigidly attached to frame 2 and / or mobile tank 3. Conduit 5 may be attached, or preferably is attached, to mobile tank 3 and, therefore, to frame 2. Pneumatic supply line 4 may be mounted to frame 2.

[0114] Figure 3An exemplary embodiment of a system 1 for extracting active material residues is shown. A mobile storage tank 3 includes a downwardly tapering funnel section 31 and a cylindrical section 32 directly above the funnel section 31, providing the mobile storage tank 3 with a large capacity. A lid 36 is placed directly on top of the cylindrical section 32. A conduit 5 is attached to the mobile storage tank 3. The attachment of the conduit 5 to the mobile storage tank 3 is arranged below the lid 36. The attachment of the conduit 5 to the mobile storage tank 3 is in the peripheral wall of the cylindrical section 32. The conduit 5 may be a flexible hose.

[0115] A control valve 35 is provided at the junction of the conduit 5 and the mobile storage tank 3. The control valve 35 is operable to close to seal the mobile storage tank 3 from the conduit 5 and the component 100 that can be attached to the conduit 5. The control valve 35 is operable to open to establish a fluid connection between the mobile storage tank 3 and the conduit 5, in particular, to establish a fluid connection between the system 1 and the component that coats the electrode with the active material layer.

[0116] The system 1 may be provided with a pneumatic supply line 4 to power and / or control one or more components of the system (e.g., the pumping device 7). One or more components of the system 1 (e.g., the control valve 35, the discharge valve 33, the vibrator 77, the flow excavator 78) may be connected to the pneumatic supply line 4.

[0117] The system 1 is provided with a storage container 9 that can be releasably attached to the mobile tank 3. The storage container 9 can be attached to the bottom of the mobile tank 3 to receive the active material residue from the mobile tank 3 by gravity. To enhance the distribution of the active material residue from the mobile tank 3 into the storage container, a vibrator 77 and / or a stream scraper 78 can be provided. During the extraction mode, the vibrator 77 and / or the stream scraper 78 can be turned off. The vibrator 77 and / or the stream scraper 78 can each include a corresponding drive, in particular a pneumatic drive powered by the pneumatic supply line 4 of the assembly.

[0118] The funnel section 31 of the mobile tank 3 tapers toward the dispensing opening to which the storage container 9 is attached. The storage container 9 can be sealingly attached to the mobile tank 3, for example, using a cuff 39, to prevent spillage of active material residue during dispensing. The mobile tank 3 has a drain valve 33 arranged at the dispensing opening. This drain valve can be closed, for example, to allow removal or replacement of the storage container 9 and / or to seal the mobile tank 3 during extraction mode.

[0119] The pumping device 7 is securely attached to the top of the mobile storage tank 3. The pumping device 7 is attached to the cover 36. In the embodiment shown, the pumping device 7 includes a vacuum conveyor 71 using a vacuum pump. A filter 73 is arranged between the mobile storage tank 3 and the vacuum conveyor 71 to protect the vacuum device 7 from residual powder of the active material or other particles. The system (preferably, its pumping device) may also include a dust collector 75 provided at the exhaust port of the vacuum device to protect the environment from dust particles handled by the vacuum pump, etc.

[0120] The system 1 is provided with a control panel 10 having a user interface for interacting with an operator. The system 1 includes a control device 11 operatively coupled to one or more components of the system. The control device 11 can be coupled to the control panel 10 so that the system 1 can be turned on or off, and optionally used to control one or more operating parameters of the system (such as the negative pressure, mass flow rate, and / or volume flow rate of the pumping device 7). Alternatively or additionally, the control device 11 can be coupled to one or more sensors of the system 1, such as pressure sensors, for example, sensors associated with the supply line 4, the vibrator 77, the flow excavator 78, and / or the pumping device 7.

[0121] Figure 4 Another exemplary embodiment of a system 1 for extracting active material residues is shown. The mobile tank 3 has a cover 36 directly on top of the funnel section 31 .

[0122] Reference Signs List

[0123] 1 System

[0124] 2 racks

[0125] 3 Mobile storage tanks

[0126] 4 Pneumatic supply lines

[0127] 5 Catheter

[0128] 7 Pumping device

[0129] 9 Storage Containers

[0130] 10 Control Panel

[0131] 11 Control device

[0132] 21 rounds

[0133] 31 Funnel Segment

[0134] 32 cylindrical sections

[0135] 33 Discharge valve

[0136] 35 Control Valve

[0137] 36 Cover

[0138] 39 cuffs

[0139] 71 Vacuum pump

[0140] 73 Filter

[0141] 75 dust collector

[0142] 77 Vibrator

[0143] 78 Stream Miner

[0144] 100 components

[0145] 101 Metal Foil Mesh Material

[0146] 102 electrodes

[0147] 103 Active material layer

[0148] 110 Die Coater

[0149] 120 Teleporter

[0150] 130 Mixer

[0151] Port 140

[0152] 150 scales

[0153] 160 Teleporter

[0154] 170 Hopper

[0155] 180 Fixed storage tank

Claims

1. A system (1) for extracting active material residues from an assembly (100) coating an electrode (102) with an active material layer (103), the system (1) comprising: a mobile storage tank (3), the mobile storage tank (3) being configured to contain the active material residue; a conduit (5) attachable to the mobile storage tank (3) and releasably connectable to the assembly (100); as well as A pumping device (7) is configured to apply negative pressure to the mobile storage tank (3) to suck the active material residue from the assembly (100) through the conduit (5).

2. The system (1) according to claim 1, wherein The pumping device (7) is arranged at the mobile storage tank (3).

3. The system (1) according to claim 1 or 2, further comprising: A storage container (9) is attachable to and detachable from the mobile storage tank (3), and is configured to receive and store the active material residue.

4. System (1) according to any one of the preceding claims, wherein The mobile storage tank (3) includes a funnel section (31) and / or a discharge valve (33) located on the lower side of the mobile storage tank (3).

5. System (1) according to any one of the preceding claims, wherein The mobile storage tank (3) includes a vibrator (77) and / or a stream dredge (78), the vibrator (77) and / or the stream dredge (78) being configured to facilitate discharge of the active material residue from the mobile storage tank (3).

6. The system (1) according to any one of the preceding claims, further comprising a filter (73) between the pumping device (7) and the mobile tank (3).

7. System (1) according to any one of the preceding claims, wherein The conduit (5) is configured to be directly connectable to a stationary storage tank (180), a hopper (170), a scale (150), a mixer (130) and / or a die coater of the assembly (100).

8. An assembly (100) of an electrode (102) coated with a layer (103) of active material, the assembly (100) comprising: a stationary storage tank (180) configured to store a supply of active material for processing in the assembly (100); a die coater (110) configured to supply the active material onto a metal foil mesh material (101) to form the active material layer (103); a conveyor (120, 160) configured to transfer the active material from the stationary storage tank (180) to the die coater (110); as well as an outlet member configured to selectively close or open an outlet hole for ejecting the active material from the assembly (100), Therein, a system (1) for extracting active material residues from the assembly (100) is attached to the outlet member or is releasably attachable to the outlet member.

9. The assembly (100) according to claim 8, wherein The outlet member has: a closed state in which active material is free to flow from the stationary reservoir (180) to the die coater (110) and in which the active material is inhibited from exiting the assembly through the outlet orifice; as well as - an open state in which the outlet opening is in fluid communication with the stationary reservoir (180), such that the active material can exit the assembly (100) through the outlet opening.

10. Assembly (100) according to claim 8 or 9, wherein The outlet member includes a T-piece.

11. A method for extracting active material residues from an assembly (100) comprising an electrode (102) coated with an active material layer (103), the method comprising the steps of: -Provide mobile storage tanks (3); - attaching a conduit (5) to the mobile tank (3); - connecting the conduit (5) to the assembly (100); - The active material residues are sucked from the assembly (100) into the mobile tank (3) through the conduit (5).

12. The method according to claim 11, further comprising the steps of: The selectively closable outlet member of the assembly (100) is opened to allow active material residue from the assembly to travel to the mobile storage tank (3) through the outlet aperture of the outlet member.

13. A method of manufacturing an electrode (102) in an assembly (100) in which the electrode (102) is coated with a layer (103) of active material, the method using a mixture of active material and active material residue.

14. The method of claim 13, comprising preparing the mixture comprising 0.01 wt% to 25 wt% of the active material residue.

15. A method of manufacturing a battery using a mixture of an active material and an active material residue.

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