Apparatus for manufacturing dry electrode and method for manufacturing dry electrode

Abstract

An apparatus for manufacturing a dry electrode and a method of manufacturing a dry electrode are provided. An apparatus for manufacturing a dry electrode includes a lamination roller configured to laminate a self-supporting film on a first surface of a current collector. The apparatus further includes a first X-ray detector positioned adjacent to the lamination roller and configured to irradiate X-rays onto the self-supporting film and detect metallic material in the self-supporting film.

Description

Technical Field

[0001] This disclosure relates to an apparatus for manufacturing dry electrodes and a method for manufacturing dry electrodes. Background Technology

[0002] A rechargeable battery is a battery that can be charged and discharged.

[0003] Recently, there has been an increasing demand for devices that manufacture solvent-free dry electrodes for secondary batteries. According to related technologies, devices for manufacturing dry electrodes use calendering rollers or similar methods to calender fine powder comprising active materials, conductive materials, and binders into a self-supporting film, and then laminating the self-supporting film onto a current collector. Such devices require the detection of any unintentionally incorporated metallic materials in the self-supporting film laminated onto the current collector during the manufacturing process. Summary of the Invention

[0004] This disclosure provides an apparatus for manufacturing dry electrodes, which can improve the quality of dry electrodes and the stability of the manufacturing process by detecting the metallic material on the outer surface or inside of a self-supporting membrane laminated on a current collector.

[0005] This disclosure also provides a method for manufacturing a dry electrode, which can improve the quality of the dry electrode and the stability of the manufacturing process by detecting the metallic material on the outer surface or inside of the self-supporting membrane laminated on the current collector.

[0006] One aspect of this disclosure provides an apparatus for manufacturing dry electrodes, comprising: a laminating roller configured to laminate a self-supporting membrane onto the surface of a current collector; and an X-ray detector positioned adjacent to the laminating roller and configured to irradiate the self-supporting membrane with X-rays and detect metallic material in the self-supporting membrane.

[0007] The X-ray detector can be located on the front side of the laminating roller.

[0008] An X-ray detector may include: an X-ray source configured to irradiate a first self-supporting membrane with X-rays from above the self-supporting membrane; and a detector positioned corresponding to the X-ray source with the self-supporting membrane disposed between the detector and the X-ray source, and configured to detect X-rays.

[0009] The X-ray detector can be located on the back side of the laminating roller.

[0010] The X-ray source may be a first X-ray source, and the detector may be a first detector. The X-ray detector may include: a second X-ray source configured to irradiate the first self-supporting membrane and the current collector with X-rays from the upper side of the self-supporting membrane; and a second detector positioned corresponding to the second X-ray source and with the self-supporting membrane and the current collector disposed between the second X-ray source and the second detector, and configured to detect the X-rays irradiated from the second X-ray source.

[0011] The device may also include a marker spaced apart from the X-ray detector, located behind the laminating roller, and connected to the X-ray detector, the marker being configured to mark portions of the first self-supporting film at locations corresponding to the metallic material.

[0012] The laminating roller may be a first laminating roller, and the self-supporting film may be a first self-supporting film. The device may also include a second laminating roller configured to laminate a second self-supporting film onto a second surface of the current collector.

[0013] The apparatus may further include a third X-ray detector adjacent to the second laminating roller, the third X-ray detector being configured to irradiate the second self-supporting film with X-rays and detect the metallic material inside the second self-supporting film.

[0014] The third X-ray detector can be located in front of the second layer of pressure rollers.

[0015] The third X-ray detector may include: a third X-ray source configured to irradiate the second self-supporting membrane with X-rays from above; and a third detector positioned corresponding to the third X-ray source, with the second self-supporting membrane disposed between the third X-ray source and the third detector, and the third detector configured to detect X-rays irradiated from the third X-ray source.

[0016] The third X-ray detector can be located behind the second layer of pressure rollers.

[0017] The third X-ray detector may include: a fourth X-ray source configured to irradiate the second self-supporting membrane, the current collector, and the first self-supporting membrane with X-rays from below the second self-supporting membrane; and a fourth detector positioned corresponding to the fourth X-ray source with the second self-supporting membrane, the current collector, and the first self-supporting membrane disposed between the fourth X-ray source and the fourth detector, and configured to detect X-rays irradiated from the fourth X-ray source.

[0018] The device may further include a second marker spaced apart from the first and third X-ray detectors, located behind the second laminating roller, connected to the first and third X-ray detectors, and the second marker is configured to mark a portion of at least one of the first and second self-supporting films at a location corresponding to the metal material.

[0019] Furthermore, one aspect of this disclosure provides a method for manufacturing a dry electrode, the method comprising: laminating a first self-supporting film onto a first surface of a current collector; laminating a second self-supporting film onto a second surface of the current collector; and detecting a metallic material in at least one of the first and second self-supporting films by irradiating at least one of the first and second self-supporting films with X-rays.

[0020] The method may also include marking at least one of the first self-supporting membrane and the second self-supporting membrane at a location corresponding to the metal material.

[0021] The method may further include forming multiple electrode plates by slicing a dry electrode comprising a current collector, a first self-supporting membrane, and a second self-supporting membrane.

[0022] The method may also include excluding electrode plates that include markings from among multiple electrode plates.

[0023] Forming multiple electrode plates may include cutting into the excluding marked portions of the dry electrode.

[0024] Detection of the metallic material in at least one of the first and second self-supporting films can be performed by irradiating multiple electrode plates with X-rays.

[0025] The method may also include unmarked electrode plates in a stack of multiple electrode plates.

[0026] According to one embodiment, an apparatus for manufacturing dry electrodes is provided, which can improve both the quality of the dry electrodes and the stability of the manufacturing process by detecting the metallic material on the outer surface or inside of a self-supporting membrane laminated on a current collector.

[0027] According to another embodiment, a method for manufacturing a dry electrode is provided, which can improve both the quality of the dry electrode and the stability of the manufacturing process by detecting the metallic material on the outer surface or inside of the self-supporting membrane laminated on the current collector. Attached Figure Description

[0028] Figure 1 This is a side view of an apparatus for manufacturing dry electrodes according to one embodiment.

[0029] Figure 2 This is a plan view of an example of an apparatus for manufacturing a dry electrode according to one embodiment, showing portions of a first self-supporting membrane laminated on a current collector.

[0030] Figure 3 This is a side view of an apparatus for manufacturing dry electrodes according to another embodiment.

[0031] Figure 4 This is a flowchart of a method for manufacturing a dry electrode according to another embodiment.

[0032] Figure 5 This is a side view of an example apparatus for manufacturing a dry electrode, which performs a method for manufacturing a dry electrode according to another embodiment.

[0033] Figure 6This is a diagram illustrating an example of a method for manufacturing a dry electrode according to another embodiment.

[0034] Figure 7 This is a diagram illustrating another example of a method for manufacturing a dry electrode according to another embodiment.

[0035] Figure 8 This is a diagram illustrating another example of a method for manufacturing a dry electrode according to another embodiment.

[0036] Figure 9 This is a diagram illustrating another example of a method for manufacturing a dry electrode according to another embodiment. Detailed Implementation

[0037] Referring to the accompanying drawings, embodiments of this disclosure will now be described in detail so that those skilled in the art can implement this disclosure. This disclosure can be implemented in many different forms and is not limited to the embodiments set forth herein.

[0038] Throughout this specification, unless explicitly stated otherwise, the word “comprise” and variations such as “comprises” or “comprising” shall be understood to indicate that the mentioned elements are included without excluding any other elements.

[0039] In the following text, reference will be made to Figure 1 and Figure 2 This describes an apparatus for manufacturing dry electrodes according to one embodiment.

[0040] The apparatus for manufacturing a dry electrode according to one embodiment can be an apparatus for manufacturing a dry electrode for a secondary battery. However, this disclosure is not limited to this, and can be an apparatus for manufacturing various types of dry electrodes.

[0041] Figure 1 This is a side view of an apparatus for manufacturing dry electrodes according to one embodiment.

[0042] refer to Figure 1 According to one embodiment, an apparatus 1000 for manufacturing dry electrodes includes a first laminating roller 100, a second laminating roller 200, a first X-ray detector 300, a second X-ray detector 400, and a first marker 500.

[0043] The first laminating roller 100 laminates a first self-supporting film F1, which moves along a first direction, onto the first surface 11 of the current collector 10. The first laminating roller 100 may include various known laminating tools, and this disclosure is not limited thereto. The current collector 10 may move between the first laminating roller 100 and the second laminating roller 200 in a second direction intersecting the first direction. For example, the first direction may include a horizontal direction, and the second direction may include a vertical direction, but this disclosure is not limited thereto.

[0044] The first self-supporting film F1 can be formed by calendering fine powder using various known feeders and rollers. That is, fine powder supplied from the feeder to the rollers can be calendered into the first self-supporting film F1.

[0045] Fine powders can include a variety of known active substances, conductive materials, and binders. Fine powders can be prepared by mixing active substances, conductive materials, and binders into a mixture using a variety of known mixing tools. The mixture can be fiberized into a dry powder using a variety of known fiberizing tools, but this disclosure is not limited thereto.

[0046] Multiple rollers can calender fine powder supplied from a feeder into a first self-supporting film F1. The multiple rollers can be arranged in one direction, and the fine powder can be fed between the rollers and calendered into the first self-supporting film F1. The multiple rollers can calender the first self-supporting film F1 by rolling and stretching the fine powder, but this disclosure is not limited thereto. The multiple rollers can rotate at the same angular velocity, but are not limited thereto, and can rotate at different angular velocities. Each of the multiple rollers can rotate at a gradually increasing angular velocity toward the current collector 10. In other embodiments, each of the multiple rollers can rotate at a gradually decreasing angular velocity. A first laminating roller 100 can be positioned adjacent to the last roller of the multiple rollers.

[0047] The second laminating roller 200 laminates a second self-supporting film F2, which moves along a first direction, onto the second surface 12 of the current collector 10. The second laminating roller 200 may include various known laminating tools, and this disclosure is not limited thereto. The current collector 10 may also move between the second laminating roller 200 and the first laminating roller 100 along a second direction intersecting the first direction. In an example, the first direction may include a horizontal direction, and the second direction may include a vertical direction, but this disclosure is not limited thereto.

[0048] The second self-supporting film F2 can be formed by calendering fine powder using various known feeders and rollers. That is, fine powder supplied from the feeder to the rollers can be calendered into the second self-supporting film F2.

[0049] Fine powders can include a variety of known active substances, conductive materials, and binders. Fine powders can be prepared by mixing active substances, conductive materials, and binders into a mixture using a variety of known mixing tools. The mixture can be fiberized into a dry powder using a variety of known fiberizing tools, but this disclosure is not limited thereto.

[0050] Multiple rollers can calender fine powder supplied from a feeder into a second self-supporting film F2. The multiple rollers can be arranged in one direction, and the fine powder can be fed between the rollers and calendered into the second self-supporting film F2. The multiple rollers can calender the second self-supporting film F2 by rolling and stretching the fine powder, but this disclosure is not limited thereto. The multiple rollers can rotate at the same angular velocity, but are not limited thereto, and can rotate at different angular velocities. Each of the multiple rollers can rotate at a gradually increasing angular velocity toward the current collector 10. In other embodiments, the multiple rollers can rotate at a gradually decreasing angular velocity. A second laminating roller 200 can be positioned adjacent to the roller located at the rearmost end of the multiple rollers.

[0051] For example, the current collector 10 can move in one direction between the first laminating roller 100 and the second laminating roller 200, such that the first self-supporting film F1 can be laminated on the first surface 11 and the second self-supporting film F2 can be laminated on the second surface 12. The current collector 10 laminated with the first self-supporting film F1 and the second self-supporting film F2 can be wound by various known winding tools, but this disclosure is not limited thereto.

[0052] The first X-ray detector 300 is positioned adjacent to the first laminating roller 100. In particular, the first X-ray detector 300 is located on the front side of the first laminating roller 100. In this regard, the front side of the first laminating roller 100 may include, but is not limited to, the front side in the direction of movement of the first self-supporting membrane F1 that moves in one direction.

[0053] The first X-ray detector 300 can detect the metallic material inside the first self-supporting film F1 by irradiating it with X-rays (XR). For example, the first X-ray detector 300 can detect the metallic material on the outer surface of the first self-supporting film F1 by irradiating it with X-rays (XR). The first X-ray detector 300 may include a first X-ray source 310 and a first detector 320.

[0054] The first X-ray source 310 can irradiate X-rays (XR) that penetrate the first self-supporting membrane F1 from the upper side of the first self-supporting membrane F1 toward the first detector 320. The first X-ray source 310 can irradiate X-rays (XR) at various wavelengths and intensities.

[0055] The first detector 320 can correspond to the first X-ray source 310, and the first self-supporting membrane F1 is disposed between the first detector 320 and the first X-ray source 310. That is, the first detector 320 can face the first X-ray source 310, and the first self-supporting membrane F1 is disposed between the first detector 320 and the first X-ray source 310. The first detector 320 can detect X-rays (XR) irradiated from the first X-ray source 310 and penetrating the first self-supporting membrane F1, so as to detect metallic materials on the outer surface or inside the first self-supporting membrane F1.

[0056] The first X-ray detector 300 can detect metallic materials on the outer surface or inside the first self-supporting film F1 before the first self-supporting film F1 is laminated onto the current collector 10. This configuration prevents X-rays (XR) from being absorbed by the current collector 10. Therefore, the sensitivity of the X-ray detection image can be improved, thereby increasing the overall production speed of the dry electrode DE.

[0057] The first X-ray detector 300 can be connected to the first marker 500. Therefore, the coordinates (positions) in the first self-supporting membrane F1 can be transmitted to the first marker 500, at which the first detector 320 detects metallic material.

[0058] In another example, the first detector 320 of the first X-ray detector 300 can be connected to various known controllers, and the controllers can be connected to the first marker 500. The coordinates of the metallic material in the first self-supporting membrane F1 detected by the first detector 320 can be transmitted to the controller. Furthermore, the coordinates of the metallic material in the first self-supporting membrane F1 can be transmitted from the controller to the first marker 500.

[0059] The second X-ray detector 400 is positioned adjacent to the first laminating roller 100. The second X-ray detector 400 is located behind the first laminating roller 100. The rear side of the first laminating roller 100 may include, but is not limited to, the rear side in the direction of movement of the first self-supporting film F1.

[0060] The second X-ray detector 400 can detect the metallic material inside the first self-supporting film F1 by irradiating it with X-rays (XR). For example, the second X-ray detector 400 can detect the metallic material on the outer surface of the first self-supporting film F1 by irradiating it with X-rays (XR).

[0061] The second X-ray detector 400 can also detect the metallic material inside the second self-supporting film F2 by irradiating it with X-rays (XR). For example, the second X-ray detector 400 can detect the metallic material on the outer surface of the second self-supporting film F2 by irradiating it with X-rays (XR).

[0062] The second X-ray detector 400 may include a second X-ray source 410 and a second detector 420. The second X-ray source 410 may irradiate the second detector 420 with X-rays (XR) that penetrate the first self-supporting membrane F1, the current collector 10, and the second self-supporting membrane F2 from the upper side of the first self-supporting membrane F1 or the lower side of the second self-supporting membrane F2. The second X-ray source 410 may irradiate X-rays (XR) at various wavelengths and intensities.

[0063] The second detector 420 may correspond to the second X-ray source 410, and the first self-supporting film F1, the current collector 10, and the second self-supporting film F2 are disposed between the second detector 420 and the second X-ray source 410. The second detector 420 may face the second X-ray source 410, and the first self-supporting film F1, the current collector 10, and the second self-supporting film F2 are disposed between the second detector 420 and the second X-ray source 410. The second detector 420 can detect X-rays (XR) irradiated by the second X-ray source 410 and penetrating the first self-supporting film F1, the current collector 10, and the second self-supporting film F2, to detect metallic materials on or inside the outer surface of the first self-supporting film F1. The second detector 420 can also detect X-rays (XR) irradiated by the second X-ray source 410 and penetrating the first self-supporting film F1, the current collector 10, and the second self-supporting film F2, to detect metallic materials on or inside the outer surface of the second self-supporting film F2.

[0064] The current collector 10 may comprise a metallic material, but may be formed as a thin film that allows X-rays (XR) from the second X-ray source 410 to penetrate it. The current collector 10 may have various thicknesses to which X-rays (XR) of a given intensity can penetrate. The current collector 10 used in the apparatus 1000 for manufacturing dry electrodes may be moved via a roll-to-roll process, allowing the current collector 10 to have a thickness thinner than that of a current collector formed in the apparatus for manufacturing wet electrodes.

[0065] The second X-ray detector 400 can be connected to the first marker 500. In this way, the second detector 420 of the second X-ray detector 400 can set the coordinates (positions) of the metal material detected by the second detector 420 in the first self-supporting membrane F1 or set the coordinates of the metal material detected by the second detector 420 in the second self-supporting membrane F2 by transmitting the coordinates to the first marker 500.

[0066] In another example, the second detector 420 of the second X-ray detector 400 can be connected to various known controllers, and such controllers can be connected to the first marker 500. The coordinates of the metallic material in the first self-supporting membrane F1 detected by the second detector 420 or the coordinates of the metallic material in the second self-supporting membrane F2 detected by the second detector 420 can be transmitted to the controller, and then the coordinates can be transmitted from the controller to the first marker 500.

[0067] The first marker 500 is spaced apart from the first X-ray detector 300 and the second X-ray detector 400 and is located behind the first laminating roller 100. The first marker 500 can be connected to the first X-ray detector 300 and the second X-ray detector 400 to mark the portion of the metal material of the first self-supporting film F1 or the portion of the metal material of the second self-supporting film F2. The first marker 500 can include various known marking tools capable of marking films.

[0068] Using the above-mentioned device components, a dry electrode DE that has passed through the first marker 500 and includes a current collector 10, a first self-supporting film F1, and a second self-supporting film F2 can be manufactured.

[0069] Figure 2 It is a plan view showing an example of a device for manufacturing a dry electrode according to one embodiment, with portions of a first self-supporting membrane laminated on a current collector.

[0070] refer to Figure 2 The first marker 500 can mark a portion of the first self-supporting membrane F1, where the metal material MP is located inside the first self-supporting membrane F1 laminated on the current collector 10 of the dry electrode DE. The first marker 500 can display a mark directly on the portion of the first self-supporting membrane F1 or attach a label to the portion of the first self-supporting membrane F1.

[0071] Furthermore, the first marker 500 can mark a portion of the second self-supporting film F2, where the metallic material is located inside the second self-supporting film F2 laminated on the current collector 10 of the dry electrode DE. The first marker 500 can display the mark directly on the portion of the second self-supporting film F2, or attach a label to the portion of the second self-supporting film F2.

[0072] An apparatus 1000 for manufacturing a dry electrode according to one embodiment may include a first X-ray detector 300 and a second X-ray detector 400 to detect metallic material unintentionally included in the dry electrode on the outer surface or inside of the first self-supporting film F1 or the second self-supporting film F2 during the manufacturing process. Additionally, the apparatus 1000 for manufacturing a dry electrode according to one embodiment can detect metallic material unintentionally included in the dry electrode on the outer surface or inside of the first self-supporting film F1 or the second self-supporting film F2 during the manufacturing process, and mark the portion of the first self-supporting film F1 or the second self-supporting film F2 where the metallic material is detected with a first marker 500. The marked portion of the dry electrode can be excluded from various further processes, which improves the quality of the dry electrode and improves the stability of the process for manufacturing the dry electrode.

[0073] Therefore, according to various embodiments of the present disclosure, an apparatus 1000 for manufacturing dry electrodes is provided, which improves both the quality of the dry electrodes and the stability of the manufacturing process by detecting the metal material in or on the outer surface of the self-supporting film laminated on the current collector.

[0074] In the following text, reference will be made to Figure 3 An apparatus for manufacturing dry electrodes according to another embodiment is described.

[0075] Figure 3 This is a side view of an apparatus for manufacturing dry electrodes according to another embodiment.

[0076] refer to Figure 3 According to another embodiment, an apparatus 1002 for manufacturing dry electrodes includes a first laminating roller 100, a second laminating roller 200, a first X-ray detector 300, a third X-ray detector 600, a fourth X-ray detector 700, and a second marker 800.

[0077] The third X-ray detector 600 is positioned adjacent to the second laminating roller 200. In particular, the third X-ray detector 600 is located on the front side of the second laminating roller 200. The front side of the second laminating roller 200 may include, but is not limited to, the front side in the direction of movement of the second self-supporting film F2 that moves in one direction.

[0078] The third X-ray detector 600 can detect the metallic material inside the second self-supporting film F2 by irradiating it with X-rays (XR). Furthermore, the third X-ray detector 600 can detect the metallic material on the outer surface of the second self-supporting film F2 by irradiating it with X-rays (XR).

[0079] The third X-ray detector 600 may include a third X-ray source 610 and a third detector 620. The third X-ray source 610 may irradiate X-rays XR that penetrate the second self-supporting membrane F2 from above the third detector 620. The third X-ray source 610 may irradiate X-rays XR at various wavelengths and intensities.

[0080] The third detector 620 can correspond to the third X-ray source 610, and the second self-supporting membrane F2 is disposed between the third detector 620 and the third X-ray source 610. That is, the third detector 620 can face the third X-ray source 610, and the second self-supporting membrane F2 is disposed between the third detector 620 and the third X-ray source 610. The third detector 620 can detect X-rays (XR) irradiated from the third X-ray source 610 and penetrating the second self-supporting membrane F2, so as to detect metallic materials on the outer surface or inside the second self-supporting membrane F2.

[0081] The third X-ray detector 600 can detect metallic materials on the outer surface or inside the second self-supporting film F2 before the second self-supporting film F2 is laminated onto the current collector 10. This configuration prevents X-rays (XR) from being absorbed by the current collector 10. Therefore, the sensitivity of the X-ray detection image can be improved, thereby increasing the overall production speed of the dry electrode DE.

[0082] The third X-ray detector 600 can be connected to the second marker 800. The third detector 620 of the third X-ray detector 600 can thus transmit the coordinates (positions) of the metallic material in the second self-supporting membrane F2 detected by the third detector 620 to the second marker 800.

[0083] In another example, the third detector 620 of the third X-ray detector 600 can be connected to various known controllers, and such controllers can be connected to the second marker 800. The coordinates of the metal material in the second self-supporting membrane F2 detected by the third detector 620 can be transmitted to the controller, and the coordinates of the metal material in the second self-supporting membrane F2 that are transmitted to the controller can be transmitted to the second marker 800.

[0084] The fourth X-ray detector 700 is positioned adjacent to the second laminating roller 200. Specifically, the fourth X-ray detector 700 is located on the rear side of the second laminating roller 200. The fourth X-ray detector 700 may include a third X-ray detector. The rear side of the second laminating roller 200 may be, but is not limited to, on the rear side in the direction of movement of the second self-supporting film F2.

[0085] The fourth X-ray detector 700 can detect the metallic material inside the second self-supporting film F2 by irradiating it with X-rays (XR). The fourth X-ray detector 700 can also detect the metallic material on the outer surface of the second self-supporting film F2 by irradiating it with X-rays (XR). The fourth X-ray detector 700 can detect the metallic material inside the first self-supporting film F1 by irradiating it with X-rays (XR). The fourth X-ray detector 700 can also detect the metallic material on the outer surface of the first self-supporting film F1 by irradiating it with X-rays (XR).

[0086] For example, the fourth X-ray detector 700 may include a fourth X-ray source 710 and a fourth detector 720. The fourth X-ray source 710 may irradiate X-rays XR from the lower side of the second self-supporting membrane F2 or the upper side of the first self-supporting membrane F1 toward the fourth detector 720, and the X-rays XR may penetrate the second self-supporting membrane F2, the current collector 10, and the first self-supporting membrane F1. The fourth X-ray source 710 may irradiate X-rays XR at various wavelengths and intensities.

[0087] The fourth detector 720 can correspond to the fourth X-ray source 710, and the second self-supporting film F2, the current collector 10, and the first self-supporting film F1 are disposed between the fourth detector 720 and the fourth X-ray source 710. That is, the fourth detector 720 can face the fourth X-ray source 710, and the second self-supporting film F2, the current collector 10, and the first self-supporting film F1 are disposed between the fourth detector 720 and the fourth X-ray source 710. The fourth detector 720 can detect X-rays (XR) irradiated by the fourth X-ray source 710 and penetrating the second self-supporting film F2, the current collector 10, and the first self-supporting film F1, to detect metallic materials on or inside the outer surface of the second self-supporting film F2. The fourth detector 720 can also detect X-rays (XR) irradiated by the fourth X-ray source 710 and penetrating the second self-supporting film F2, the current collector 10, and the first self-supporting film F1, to detect metallic materials on or inside the first self-supporting film F1.

[0088] The current collector 10 may comprise a metallic material, and X-rays (XR) from the fourth X-ray source 710 can penetrate the current collector 10. The thickness of the current collector 10 allows X-rays (XR) to penetrate it. The current collector 10 used in the apparatus 1002 for manufacturing dry electrodes can be moved by a roll-to-roll process, thereby making the current collector 10 thinner than the current collector used in the apparatus for manufacturing wet electrodes.

[0089] The fourth X-ray detector 700 can be connected to the second marker 800. Thus, the fourth detector 720 of the fourth X-ray detector 700 can transmit the coordinates (positions) of the metal material in the second self-supporting membrane F2 detected by the fourth detector 720 or the coordinates of the metal material in the first self-supporting membrane F1 detected by the fourth detector 720 to the second marker 800.

[0090] In another example, the fourth detector 720 of the fourth X-ray detector 700 can be connected to various known controllers, and such controllers can be connected to the second marker 800. The coordinates of the metal material in the second self-supporting membrane F2 detected by the fourth detector 720 or the coordinates of the metal material in the first self-supporting membrane F1 detected by the fourth detector 720 can be transmitted to the controller, and the coordinates of the metal material in the second self-supporting membrane F2 and transmitted to the controller or the coordinates of the metal material in the first self-supporting membrane F1 and transmitted to the controller can be transmitted to the second marker 800.

[0091] The second marker 800 is spaced apart from the third X-ray detector 600 and the fourth X-ray detector 700 and is located behind the first laminating roller 100. The second marker 800 can be connected to the first X-ray detector 300, the third X-ray detector 600, and the fourth X-ray detector 700 to mark a portion of the first self-supporting film F1 containing metallic material, or a portion of the second self-supporting film F2 containing metallic material. The second marker 800 can include various known marking tools capable of marking self-supporting films.

[0092] For example, the second marker 800 can mark a portion of the first self-supporting film F1, where the metallic material is located inside the first self-supporting film F1 laminated on the current collector 10 of the dry electrode. The second marker 800 can display the mark directly on said portion of the first self-supporting film F1, or attach a label to said portion of the first self-supporting film F1. As another example, the second marker 800 can mark a portion of the second self-supporting film F2, where the metallic material is located inside the second self-supporting film F2 laminated on the current collector 10 of the dry electrode DE. The second marker 800 can display the mark directly on said portion of the second self-supporting film F2, or attach a label to said portion of the second self-supporting film F2.

[0093] According to another embodiment, an apparatus 1002 for manufacturing dry electrodes may include a first X-ray detector 300, a third X-ray detector 600, and a fourth X-ray detector 700 to detect metallic material on or inside the outer surface of the first self-supporting film F1 or the second self-supporting film F2 that is unintentionally included in the dry electrodes during the manufacturing process.

[0094] Furthermore, according to another embodiment, the apparatus 1002 for manufacturing dry electrodes can detect metallic material unintentionally included in the dry electrode during manufacturing on the outer surface or inside of the first self-supporting film F1 or the second self-supporting film F2. Moreover, the apparatus 1002 can use a second marker 800 to mark the portion of the first self-supporting film F1 or the second self-supporting film F2 where the metallic material is detected. The marked portion of the dry electrode can be excluded from various known subsequent processes. Therefore, the quality of the dry electrode can be improved, and the stability of the process for manufacturing the dry electrode can also be improved.

[0095] As described above, the apparatus 1002 for manufacturing dry electrodes improves both the quality of the dry electrodes and the stability of the manufacturing process by detecting the metallic material in or on the outer surface of the self-supporting membrane laminated on the current collector.

[0096] In the following text, reference will be made to Figures 4 to 9 A method for manufacturing a dry electrode according to an embodiment of the present disclosure is described.

[0097] The method for manufacturing dry electrodes can be performed using the apparatus for manufacturing dry electrodes according to the above embodiments, but is not limited thereto.

[0098] Figure 4 This is a flowchart of a method for manufacturing a dry electrode according to an embodiment of the present disclosure. Figure 5 This is a side view of an example apparatus for manufacturing a dry electrode, which performs a method for manufacturing a dry electrode according to an embodiment of the present disclosure.

[0099] refer to Figure 4 and Figure 5 A first self-supporting film F1 is laminated onto the first surface 11 of the current collector 10 (S100). The first self-supporting film F1 can be formed by calendering a fine powder comprising an active material, a conductive material, and a binder. The first self-supporting film F1 can be laminated onto the first surface 11 of the current collector 10 using a lamination tool such as a first lamination roller 100.

[0100] Next, a second self-supporting film F2 is laminated onto the second surface 12 of the current collector 10 (S200). The second self-supporting film F2 can be formed by calendering a fine powder comprising an active material, a conductive material, and a binder. The second self-supporting film F2 can be laminated onto the second surface 12 of the current collector 10 using a lamination tool such as a second lamination roller 200.

[0101] Next, by irradiating at least one of the first self-supporting film F1 and the second self-supporting film F2 with X-rays (XR), the metallic material in at least one of the first self-supporting film F1 and the second self-supporting film F2 is detected (S300). For example, the metallic material in at least one of the first self-supporting film F1 and the second self-supporting film F2 can be detected by irradiating at least one of the first self-supporting film F1 and the second self-supporting film F2 with X-rays (XR) using an X-ray detection tool such as a first X-ray detector 300 and a second X-ray detector 400.

[0102] Next, the portion of at least one of the first self-supporting membrane F1 and the second self-supporting membrane F2 containing metallic material is marked. For example, the portion of at least one of the first self-supporting membrane F1 and the second self-supporting membrane F2 containing metallic material can be marked using a marking tool such as a first marker 500 connected to an X-ray inspection tool.

[0103] A dry electrode DE having a metallic material located on at least one of a first self-supporting film F1 and a second self-supporting film F2 and having a marked portion can be notched into multiple electrode plates. The marked electrode plates among the multiple electrode plates can be excluded from subsequent processing steps such as electrode plate stacking processes. On the other hand, the unmarked electrode plates among the multiple electrode plates can undergo further processes such as electrode plate stacking processes.

[0104] A dry electrode DE having a metallic material located in at least one of a first self-supporting film F1 and a second self-supporting film F2 and having a marked portion can be formed into multiple jelly roll electrode assemblies by a winding process or the like. The marked electrode assemblies among the multiple jelly roll electrode assemblies can be excluded from further processing, and the unmarked electrode assemblies among the multiple jelly roll electrode assemblies can undergo further processing.

[0105] Figure 6 This is a diagram illustrating an example of a method for manufacturing a dry electrode according to another embodiment.

[0106] refer to Figure 6 As an example of a method for manufacturing dry electrodes, multiple electrode plates EP are formed by cutting into a dry electrode DE, which includes a current collector, a first self-supporting film, and a second self-supporting film.

[0107] For example, multiple electrode plates EP can be formed by cutting dry electrodes DE using various known electrode cutting tools. The dry electrodes DE have portions containing metallic material MP marked MA. Electrode plates EP including the MA mark can be excluded (OUT), and electrode plates EP EP excluding the MA mark can be moved (IN) to the next process.

[0108] Figure 7 This is a diagram illustrating another example of a method for manufacturing a dry electrode according to another embodiment.

[0109] refer to Figure 7 As another example of a method for manufacturing dry electrodes, multiple electrode plates EP are formed by slitting a dry electrode DE comprising a current collector, a first self-supporting film, and a second self-supporting film. Multiple electrode plates EP can be formed by slitting the dry electrode DE using various known electrode slitting tools. The dry electrode DE includes a portion marked MA, and a metallic material MP is located within the portion marked MA. When forming multiple electrode plates EP, multiple electrode plates EP can be formed by slitting the portion of the dry electrode DE excluding the portion marked MA, and the multiple electrode plates EP excluding the portion marked MA can be moved IN to the next process.

[0110] Figure 8 This is a diagram illustrating another example of a method for manufacturing a dry electrode according to another embodiment.

[0111] refer to Figure 8 As another example of a method for manufacturing dry electrodes, multiple electrode plates EP are formed by slitting a dry electrode DE comprising a current collector, a first self-supporting film, and a second self-supporting film. Multiple electrode plates EP can be formed by slitting the dry electrode DE using various known electrode slitting tools. At least one of the metal material MP inside the first and second self-supporting films of the multiple electrode plates EP can be detected by irradiating the multiple electrode plates EP with X-rays, and the electrode plates EP in which the metal material MP is detected can be marked MA. Electrode plates EP including the mark MA can be excluded (OUT), and electrode plates EP not including the mark MA can be moved IN to the next process.

[0112] Figure 9 This is a diagram illustrating another example of a method for manufacturing a dry electrode according to another embodiment.

[0113] refer to Figure 9As another example of a method for manufacturing dry electrodes, multiple electrode plates EP are formed by slitting a dry electrode DE comprising a current collector, a first self-supporting film, and a second self-supporting film. Multiple electrode plates EP can be formed by slitting the dry electrode DE using various known electrode slitting tools. X-rays penetrating each of the multiple electrode plates EP can be detected by an X-ray detector XD from an X-ray source XS, allowing the detection of metallic material MP in at least one of the first and second self-supporting films of the multiple electrode plates EP. The electrode plates EP in which metallic material MP is detected can be marked MA. Electrode plates EP in the multiple electrode plates EP that include the mark MA can be excluded OUT, and electrode plates EP in the multiple electrode plates EP that do not include the mark MA can be moved IN to the next process. Electrode plates EP in the multiple electrode plates EP that do not include the mark MA and are moved to the next process can be stacked into various known types of electrode assemblies.

[0114] The method for manufacturing a dry electrode according to this embodiment can use X-ray detection to detect metallic material on the outer surface or inside of each of the first self-supporting film F1 and the second self-supporting film F2, which is unintentionally included in the dry electrode during the manufacturing process. Furthermore, the method for manufacturing a dry electrode according to this embodiment can detect the metallic material unintentionally included in the dry electrode during the manufacturing process on the outer surface or inside of the first self-supporting film F1 and the second self-supporting film F2, and mark the portions of the first self-supporting film F1 and the second self-supporting film F2 where metallic material was detected. The marked portions of the dry electrode can then be excluded from various subsequent processes, thereby improving both the quality of the dry electrode and the stability of the manufacturing process.

[0115] According to this disclosure, a method for manufacturing a dry electrode is provided, which improves both the quality of the dry electrode and the stability of the manufacturing process by detecting the metallic material on the outer surface or inside of a self-supporting membrane laminated on a current collector.

[0116] Although embodiments of the present disclosure have been described in detail above, the scope of the disclosure is not limited thereto. Various modifications and improvements can be made by those skilled in the art to which this disclosure pertains.

[0117] <Explanation of Symbols>

[0118] First layer pressure roller 100, second layer pressure roller 200, first X-ray detector 300, second X-ray detector 400, first marker 500, third X-ray detector 600, fourth X-ray detector 700, second marker 800.

Claims

1. An apparatus for manufacturing a dry electrode, the apparatus comprising: a lamination roller configured to laminate a self-supporting film on a surface of a current collector; and an X-ray detector positioned adjacent to the lamination roller and configured to irradiate X-rays onto the self-supporting film and detect a metal material in the self-supporting film. 2.The apparatus of claim 1, wherein the X-ray detector is located at a front side of the lamination roller. 3.The apparatus of claim 2, wherein the X-ray detector comprises: a first X-ray source configured to irradiate the X-rays onto the self-supporting film from an upper side of the self-supporting film; and a first detector positioned to correspond to the first X-ray source with the self-supporting film disposed between the first detector and the first X-ray source, the first detector configured to detect the X-rays. 4.The apparatus of claim 1, wherein the X-ray detector is located at a rear side of the lamination roller. the X-ray detector comprises:

5. The apparatus of claim 4, wherein, a second X-ray source configured to irradiate the X-rays onto the self-supporting film and the current collector from an upper side of the self-supporting film; and a second detector positioned to correspond to the second X-ray source with the self-supporting film and the current collector disposed between the second detector and the second X-ray source, the second detector configured to detect the X-rays irradiated from the second X-ray source. 6.The apparatus of claim 1, further comprising a first marker spaced apart from the X-ray detector, located at a rear side of the lamination roller, and connected to the X-ray detector, the first marker configured to mark a portion of the self-supporting film at a position corresponding to the metal material. 7.The apparatus of claim 1, wherein the lamination roller is a first lamination roller and the self-supporting film is a first self-supporting film, and wherein the apparatus further comprises a second lamination roller configured to laminate a second self-supporting film on a second surface of the current collector. 8.The apparatus of claim 7, wherein the X-ray detector is a first X-ray detector and the apparatus further comprises a second X-ray detector positioned adjacent to the second lamination roller, the second X-ray detector configured to irradiate X-rays onto the second self-supporting film and detect a metal material inside the second self-supporting film. 9.The apparatus of claim 8, wherein, the second X-ray detector is located at a front side of the second lamination roller. the second X-ray detector comprises:

10. The apparatus of claim 9, wherein, a third X-ray source configured to irradiate the X-rays onto the second self-supporting film from an upper side of the second self-supporting film; and a third detector positioned to correspond to the third X-ray source with the second self-supporting film disposed between the third detector and the third X-ray source, the third detector configured to detect the X-rays irradiated from the third X-ray source. 11.The apparatus of claim 8, wherein the second X-ray detector is located at a rear side of the second lamination roller. ​ 12.The apparatus of claim 11, wherein the second X-ray detector further comprises: a fourth X-ray source configured to irradiate the X-rays onto the second self-supporting film, the current collector, and the first self-supporting film from a lower side of the second self-supporting film; and a fourth detector positioned to correspond to the fourth X-ray source, the second self-supporting film, the current collector, and the first self-supporting film being disposed between the fourth detector and the fourth X-ray source, the fourth detector being configured to detect the X-rays irradiated from the fourth X-ray source. 13.The apparatus of claim 8, further comprising: a second marker spaced apart from the first X-ray detector and the second X-ray detector, located at a rear side of the first lamination roller and the second lamination roller, connected to the first X-ray detector and the second X-ray detector, the second marker being configured to mark a portion of at least one of the first self-supporting film and the second self-supporting film at a position corresponding to the metal material. 14.A method of manufacturing a dry electrode, the method comprising: laminating a first self-supporting film on a first surface of a current collector; laminating a second self-supporting film on a second surface of the current collector; and detecting a metal material in at least one of the first self-supporting film and the second self-supporting film by irradiating X-rays onto the at least one of the first self-supporting film and the second self-supporting film. 15.The method of claim 14, further comprising marking a portion of at least one of the first self-supporting film and the second self-supporting film at a position corresponding to the metal material. 16.The method of claim 15, further comprising forming a plurality of electrode sheets by cutting the dry electrode including the current collector, the first self-supporting film, and the second self-supporting film.

17. The method of claim 16, further comprising: excluding an electrode sheet including a mark among the plurality of electrode sheets.

18. The method of claim 16, wherein, the forming a plurality of electrode sheets includes cutting a portion of the dry electrode excluding a mark.

19. The method of claim 16, wherein, the detecting a metal material in at least one of the first self-supporting film and the second self-supporting film is performed by irradiating X-rays onto the plurality of electrode sheets. 20.The method of claim 19, further comprising stacking electrode sheets excluding a mark among the plurality of electrode sheets.

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