Induction heater for calender roll

Abstract

An induction heater system for manufacturing electrodes for various energy storage devices may include a generator configured to generate power. The system may also include an induction heating coil disposed adjacent an end of at least one of the first roller or the second roller and configured to generate an electromagnetic field based on the power. The system may also include a heater plate surrounding an end of at least one of the first or second rollers, the heater plate configured to receive the electromagnetic field and generate an eddy current, the eddy current generating heat on the heater plate based on induction of the electromagnetic field, the generated heat is transferred to one end or both ends of at least one of the first roller or the second roller via heat conduction.

Description

Priority requirements

[0001] This application claims priority to U.S. Application Serial No. 63 / 516,322, filed on July 28, 2023, which is incorporated herein by reference in its entirety. Background Technology

[0002] Energy storage devices, such as batteries and capacitors, are integrated into a wide range of applications, from consumer electronics to electric vehicles and renewable energy systems. The performance and efficiency of these devices are significantly affected by the quality and uniformity of their electrodes. The manufacturing processes for these electrodes typically involve forming thin layers of material on a substrate using rollers. These methods seek to ensure consistent material properties and dimensions for reliable and efficient energy storage. Variations in the manufacturing process can lead to inconsistencies in electrode thickness and properties, which can affect the overall performance of the energy storage device. Technical Field

[0003] This disclosure relates to induction heaters for manufacturing electrodes for various energy storage devices. Related technical descriptions

[0004] Calendering rolls or laminating rolls can be used to form films or material layers on a substrate by rolling materials between them. Substrates with the formed films or material layers can be used for various purposes, such as energy storage battery electrodes. Attached Figure Description

[0005] The foregoing and other features of this disclosure will become more fully apparent from the accompanying drawings, the following description, and the appended claims. It should be understood that these drawings depict several examples according to this disclosure and should not be considered as limiting its scope, but rather will be used to describe the disclosure with additional features and details.

[0006] Figure 1A and Figure 1B This illustrates how thermal protrusions on a laminating or calendering roll result in a thicker film at the ends of the roll.

[0007] Figure 2 yes Figure 1A Enlarged view of the roller.

[0008] Figure 3 An example induction heating system is shown based on some examples.

[0009] Figure 4 This is a conceptual diagram illustrating induction heating based on some examples.

[0010] Figure 5A The diagram illustrates how an induction heating coil (around a heater plate) can be mounted into an end cap on one side of a roller, according to some examples.

[0011] Figure 5B and Figure 5C An example configuration of an induction heating coil is shown, based on some examples.

[0012] Figure 5D The diagram illustrates how an induction heating coil (facing the heater plate) can be mounted into an end cap on one side of a roller, according to some examples.

[0013] Figure 5E The illustration shows how, according to some examples, an induction heating coil (around a heater plate) is mounted into an end cap on the opposite side of a roller.

[0014] Figure 6 One aspect of the subject matter according to one embodiment is shown.

[0015] Figure 7 This is an exploded view showing an example heater plate or ring assembly to be installed on one or both end caps of a roller, according to some examples.

[0016] Figure 8 This is an example flowchart illustrating how induction heating is performed based on some examples.

[0017] Figure 9 One aspect of the subject matter according to one embodiment is shown.

[0018] Figure 10 One aspect of the subject matter according to one embodiment is shown.

[0019] Figure 11 The thickness distribution of materials formed by rollers using induction heating and rollers not using induction heating is shown.

[0020] Figure 12A The roll flatness distribution obtained by using the material thickness of the roll without induction heating is shown.

[0021] Figure 12B The following are examples of roll flatness distributions obtained by using a roll with induction heating, based on the material thickness.

[0022] Figure 13A The laser thickness distribution of a material formed by a roller without induction heating is shown.

[0023] Figure 13B The laser thickness distribution of materials formed using induction-heated rollers is shown according to some examples.

[0024] Figure 14 It is a graphical representation of a machine in the form of a computer system, based on some examples, within which a set of instructions can be executed to cause the machine to perform any one or more methods discussed herein.

[0025] Embodiments of the invention and their advantages can be best understood by referring to the following detailed description. It should be understood that the same reference numerals are used to identify the same elements shown in one or more of the figures, which are shown in the figures to illustrate examples of the present disclosure and not to limit the disclosure. Detailed Implementation

[0026] This article provides various examples of induction heaters for manufacturing electrodes with substantially uniform or consistent thickness for various energy storage devices. Some examples include induction heaters configured to heat the end portions of electrode manufacturing rolls (e.g., calendering or laminating rolls) such that the roll diameter can be substantially uniform along the length of the roll, or otherwise at least modified. Some examples include stationary induction heaters mounted to bearing housings facing (but not in contact with) the ends of rotating rolls, which generate electromagnetic fields that produce eddy currents that can heat the ends of the rolls to compensate for inherent heat losses. This can be done in a non-contact heating process, avoiding, for example, electrical slip rings in the limited space between the bearing housing and the ends of the rolls.

[0027] An example can be used to address thermal bulges in calender rolls. Thermal bulges in calender rolls are the phenomenon where the roll diameter increases at the center due to temperature variations. This is because different parts of the roll experience varying temperatures during operation, resulting in uneven thermal expansion. For example, due to friction between the roll and the material being processed, the central area of ​​the roll may heat up more than the edges. This uneven expansion causes a slight bulge or "bump" effect at the center of the roll.

[0028] Uneven thermal expansion can be influenced by the material properties of the rolls, such as their thermal conductivity. Metals typically used for rolls have varying thermal conductivity, which can exacerbate the bulging effect. For example, radial heat flow is relatively slow in steel rolls, causing the temperature to rise more at the center than at the edges. This phenomenon is further complicated by operating conditions such as roll speed and applied loads, which can generate more heat due to friction, leading to a more significant thermal gradient and thus more pronounced bulging.

[0029] The journal bearings at the ends of the roll can also function as radiators, influencing the temperature distribution along the roll. These bearings support the shaft with a thin layer of oil, preventing metal-to-metal contact and providing damping characteristics. The lubricant in the journal bearings not only reduces friction but also removes heat from the bearing surface, effectively acting as a partial radiator. This cooling effect at the ends of the roll creates a temperature gradient, where the ends are cooler than the center, promoting a heat-promoting effect.

[0030] Increasing the diameter at the center of the roll causes several problems. One such problem is uneven pressure distribution on the roll surface. Uneven pressure can lead to defects such as wrinkles, folds, and inconsistent thickness in the processed material, thus impairing product quality. Additionally, if thermal protrusions are not adequately controlled, they can cause excessive wear and tear on the roll, reducing its service life and increasing maintenance costs.

[0031] To manage and control temperature, and thus control thermal protrusion on the calender rolls, oil passages in the heater can be used. These systems circulate hot oil through the rolls, maintaining a uniform temperature on the roll surface. Hot oil heated in a boiler is pumped through internal channels of the rolls, seeking a uniform heat distribution. While this helps mitigate the temperature gradients that cause thermal protrusion, it is insufficient to maintain consistent thermal expansion and preserve the desired roll distribution.

[0032] Some examples discussed here include stationary induction heaters, which include one or more induction coils and are mounted on a stationary or fixed component, such as a bearing housing facing (but not in contact with) the end of a rotating roller (e.g., a roller made of steel or other ferrous material). As described above, the induction heater generates an electromagnetic field that produces eddy currents, which can heat the end of the roller to compensate for inherent heat loss. This can be done in a non-contact heating process, avoiding, for example, electrical slip rings in the limited space between the bearing housing and the end of the roller. The heating process seeks a consistent temperature distribution along the length of the roller to prevent thermal bulges and ensure a uniform diameter. A uniform diameter can contribute to obtaining a uniform material layer on the substrate, which improves the quality and efficiency of the electrodes or other products manufactured.

[0033] Some examples include heater plates or ring assemblies fixed to the ends of the roller. The heater plate may comprise a stack of two annular plates (e.g., flat rings or circular washers) stacked on the ends of the roller. The annular plate closest to the induction heating coil may be made of steel or other ferrous materials to better promote eddy current generation, thereby improving heating efficiency. Adjacent copper plates may serve as heat transfer plates to effectively conduct heat. Although copper is used as an example, other materials with relatively high thermal conductivity compared to steel / iron materials can be used.

[0034] The copper plate can make direct or indirect thermal contact with the end of the steel roll and is designed with recessed areas to prevent heat transfer into the roll's internal oil heating lines. As mentioned above, these oil heating lines are part of a loop that circulates heating oil (or other fluid) within the roll to distribute heat along its length. Adding induction heating to the end of the heated roll is superior to other heated rolls, such as electrically heated rolls, because the former can transfer more heat, is significantly simpler in structure and operation, and is therefore cheaper and more reliable than the latter.

[0035] To outline the advantages of the described techniques and their superiority over conventional techniques, this document describes certain objectives and advantages of the described techniques. Not all of these objectives or advantages can be achieved in any particular example of the described techniques. Therefore, those skilled in the art will recognize, for example, that the described techniques can be implemented or performed in a manner that achieves or optimizes one or more advantages as taught herein without necessarily achieving other objectives or advantages as taught or suggested herein.

[0036] Figure 1A and Figure 1B The thermal protrusions on laminating or calendering rolls 102 and 104 are shown to result in a thicker film at the ends of rolls 102 and 104. Figure 2 yes Figure 1A An enlarged view of the rollers. The journal bearings 110 in rollers 102 and 104 can be water-cooled, allowing longitudinal heat migration to occur towards the cooler ends of rollers 102 and 104. Due to reduced thermal expansion as heat is lost to the journal bearings 110, the diameter (D1) of the middle portion 112 of each roller 102 and 104 can be larger than the diameter (D2) of the end portion of each roller. The end portion of each roller with a reduced diameter (D2) can result in a thicker film 114 forming on the electrode because the end portion of the roller squeezes the electrode less than the center portion. This can lead to potential yield problems and reduced electrode cell efficiency. The industrial term for this phenomenon is hot roll protrusion or “hot bump.” For example, oil-heated rollers are primarily used in calendering rollers. Due to the hot bump at the ends, the entire length of the roller may not be fully utilized, and doing so results in a greater film thickness measured on the outer channel. Depending on the process temperature, yield losses can be as high as approximately 25%. This is an industrial-scale problem because rollers typically have journal bearings 110 that function as heat sinks (e.g., because they are water-cooled and / or designed for heat dissipation).

[0037] To provide further context, as stated above, thermal bulges in calender rolls are the phenomenon where the roll's diameter increases at the center due to temperature variations. This is because different parts of the roll experience varying temperatures during operation, resulting in uneven thermal expansion. For example, due to friction between the roll and the material being processed, the central region of the roll may be hotter than the edges. This uneven expansion causes a slight bulge or "bump" effect at the center of the roll.

[0038] Uneven thermal expansion can be influenced by the material properties of the rolls, such as their thermal conductivity. Metals typically used for rolls have varying thermal conductivity, which can exacerbate the bulging effect. For example, radial heat flow is relatively slow in steel rolls, causing the temperature to rise more at the center than at the edges. This phenomenon is further complicated by operating conditions such as roll speed and applied loads, which can generate more heat due to friction, leading to a more significant thermal gradient and thus more pronounced bulging.

[0039] The journal bearings at the ends of the roll can also function as radiators, influencing the temperature distribution along the roll. These bearings support the shaft with a thin layer of oil, preventing metal-to-metal contact and providing damping characteristics. The lubricant in the journal bearings not only reduces friction but also removes heat from the bearing surface, effectively acting as a partial radiator. This cooling effect at the ends of the roll can create a temperature gradient, where the ends are cooler than the center, promoting a heat-promoting effect.

[0040] Increasing the diameter at the center of the roll causes several problems that can affect production output. One such problem is uneven pressure distribution on the roll surface. Uneven pressure can lead to defects such as wrinkles, folds, and inconsistent thickness in the processed material, thus impairing product quality. Additionally, if thermal protrusions are not adequately controlled, they can cause excessive wear and tear on the roll, reducing its service life and increasing maintenance costs.

[0041] To manage and control temperature, and thus control thermal protrusion on the calender rolls, oil passages in the heater can be used, as described above. These systems circulate hot oil through the rolls, maintaining a uniform temperature on the roll surface. Hot oil heated in a boiler is pumped through internal channels of the rolls, seeking a uniform heat distribution. While this helps mitigate the temperature gradient that causes thermal protrusion, it is insufficient to maintain consistent thermal expansion and preserve the desired roll distribution.

[0042] Some examples discussed here include stationary induction heaters, which include one or more induction coils and are mounted on a stationary or fixed component, such as a bearing housing facing (but not in contact with) the end of a rotating roller (e.g., a roller made of steel or other ferrous material). As described above, the induction heater generates an electromagnetic field that produces eddy currents, which can heat the end of the roller to compensate for inherent heat loss. This can be done in a non-contact heating process, avoiding, for example, electrical slip rings in the limited space between the bearing housing and the end of the roller. The heating process seeks a consistent temperature distribution along the length of the roller to prevent thermal bulges and ensure a uniform diameter. A uniform diameter can contribute to obtaining a uniform material layer on the substrate, which improves the quality and efficiency of the electrodes or other products manufactured.

[0043] Some examples include heater plates or ring assemblies fixed to the ends of the roller. The heater plate may comprise a stack of two annular plates (e.g., flat rings or circular washers) stacked on the ends of the roller. The annular plate closest to the induction heating coil may be made of steel or other ferrous materials to better promote eddy current generation, thereby improving heating efficiency. Adjacent copper plates may serve as heat transfer plates to effectively conduct heat. Although copper is used as an example, other materials with relatively high thermal conductivity compared to steel / iron materials can be used.

[0044] The copper plate can make direct or indirect thermal contact with the end of the steel roll and is designed with recessed areas to prevent heat transfer into the roll's internal oil heating lines. As mentioned above, these oil heating lines are part of a loop that circulates heating oil (or other fluid) within the roll to distribute heat along its length. Adding induction heating to the end of a heated roll can be advantageous compared to other heated rolls (such as electrically heated rolls) because the former can transfer more heat, is significantly simpler in structure and operation, and is therefore cheaper and more reliable than the latter.

[0045] To outline the advantages of the described techniques and their superiority over conventional techniques, this document describes certain objectives and advantages of the described techniques. Not all of these objectives or advantages can be achieved in any particular example of the described techniques. Therefore, those skilled in the art will recognize, for example, that the described techniques can be implemented or performed in a manner that achieves or optimizes one or more advantages as taught herein without necessarily achieving other objectives or advantages as taught or suggested herein.

[0046] Figure 3 This is a schematic diagram showing a side view of a roller system 302 according to some examples.

[0047] The roller system 302 includes a roller 326, such as another roller (not shown), located near an opposing member. The roller 326 is configured to laminate material onto a substrate inserted therebetween. The roller 326 is made of various steel alloys and may be cast steel or forged steel.

[0048] In some examples, roller 326 may have a complex internal structure to accommodate a closed-loop hot oil system. This system is connected to a rotary joint at the end of the roller, and channels within the roller distribute the hot oil for heat transfer. The use of various steel alloys in the roller structure can provide enhanced thermal properties and mechanical strength.

[0049] The composition and manufacturing method of rolls 326 (e.g., cast steel or forged steel) can affect their thermal properties and response to induction heating systems. A variety of steel alloys can be selected for use in roll structures to balance factors such as thermal conductivity, heat capacity, and resistance to thermal expansion.

[0050] The outer surface of the roller 326, which contacts the material layer and the substrate, may be made of a specific steel alloy selected for its wear resistance and surface finish characteristics. The outer layer may be engaged with the heater plate 308, particularly the second ring 404, which is responsible for transferring heat to the roller.

[0051] Roll system 302 includes a journal bearing 110 supporting the journal 316 of roller 326. The journal bearing 110 can function as a radiator, influencing the temperature distribution along roller 326. The journal bearing 110 can incorporate additional features to manage heat distribution. For example, it can include internal cooling channels through which a coolant (e.g., water) circulates. The cooling system helps regulate the temperature at the roller ends, working in conjunction with the induction heating system to achieve optimal temperature distribution.

[0052] The roller system 302 includes a generator 304 configured to generate power. The generator 304 can be connected to the roller system 302 wirelessly or via a wired connection. The generator 304 can be controlled by a control unit 314.

[0053] The roller system 302 includes one or more induction heating coils 306 disposed adjacent to one or both ends of the roller 326. The induction heating coils 306 are configured to generate a magnetic field 320 based on power supplied by the generator 304. In some examples, the induction heating coils 306 may be fixed while the roller 326 rotates. For example, the induction heating coils 306 may be fixed or mounted to the journal bearing 110 or other fixed components of the roller system 302.

[0054] Heater plate 308 is thermally coupled to end cap 310 of roller 326. Heater plate 308 is configured to receive magnetic field 320 from induction heating coil 306 and generate eddy currents in response. Eddy currents generate heat on heater plate 308 based on electromagnetic field induction. The generated heat is then transferred to the end of roller 326 via thermal conduction.

[0055] In some examples, heater plate 308 may include a first ring 402 made of a ferromagnetic material (e.g., steel) to generate eddies and heat, and a second ring 404 made of a thermally conductive material (e.g., copper) to transfer heat from the first ring 402 to roller 326.

[0056] Roller system 302 includes a control unit 314 connected to generator 304. Control unit 314 operably controls the heating of roller 326. Control unit 314 includes temperature control 328, which can dynamically adjust the heating using inputs from one or more temperature sensors 322, which measure the temperature along the roller.

[0057] The online metering device 332 may be included to measure at least one of the thickness or load density of the material layer formed by the roller 326. The control unit 314 may implement closed-loop proportional-integral-derivative (PID) control 330 to control the generator 304 based on feedback from the temperature sensor 322 and the online metering device 332.

[0058] As a further detail, in some examples, the induction heating coil 306 can be divided into two parts to accommodate the journal 316 of the roller 326. This configuration allows for easier installation and maintenance of the system.

[0059] The generator 304 is capable of generating various types of power, including alternating current (AC power 324) transmitted to the induction heating coil 306. The induction heating coil 306, in turn, generates radio frequency power (RF power) in the form of a magnetic field 320. The frequency of the RF power can be optimized for the specific materials and dimensions of the heater plate 308 and the roller 326 to maximize heating efficiency.

[0060] Induction heating coil 306:

[0061] The induction heating coils 306 can be designed with specific geometries to optimize the distribution of the magnetic field 320. In some examples, these coils can be shaped to surround approximately one quadrant of the circumference of the bearing housing facing the roll end. This configuration allows for efficient heating while minimizing interference with other components of the roll system 302.

[0062] The design of the induction heating coil 306 can incorporate various advanced geometries to further enhance the magnetic field distribution 320 and heating efficiency. For example, the coil can use a helical or spiral configuration, where the number of turns and pitch are calculated to generate a uniform magnetic field along the length of the heater plate 308. This helical design helps ensure uniform heating across the entire surface of the heater plate.

[0063] In some examples, the induction heating coil 306 can be constructed using stranded wire, which consists of multiple strands of insulated wire twisted or braided together. Using stranded wire can help reduce skin effect and proximity effect losses at high frequencies, improving the overall efficiency of the induction heating system.

[0064] The induction heating coil 306 can also be combined with flux concentrators made of ferrite or other high-permeability materials. These concentrators can be strategically placed around the coil to focus and enhance the magnetic field 320 in specific areas of the heater plate 308, thereby allowing for more precise control of the heating mode.

[0065] To accommodate the journal 316 of the roller 326, the induction heating coil 306 can be designed in a split configuration. This can include two semi-circular coil segments that can be mounted around the roller journal 316 without disassembling the entire roller system. The split design also facilitates coil maintenance and replacement when needed.

[0066] In some examples, the induction heating coils 306 can be combined with an active cooling system to maintain their efficiency during extended operation. This may involve internal channels for liquid cooling or forced air cooling, ensuring that the coils remain at their optimal operating temperature even when high-intensity magnetic fields are generated.

[0067] The positioning of the induction heating coil 306 relative to the heater plate 308 can be adjustable to allow for fine-tuning of the heating profile. This adjustability can be achieved through a mounting system that allows for small variations in the distance and angle between the coil and the heater plate, thus providing an additional means to optimize the heating process for different roll configurations or operating conditions.

[0068] Heater plate 308:

[0069] For example, a first ring 402 made of steel or other ferromagnetic materials is designed to generate eddy currents when exposed to a magnetic field 320 generated by an induction heating coil 306. The ferromagnetic properties of steel allow it to respond strongly to an alternating magnetic field, resulting in the generation of local currents within the material. These eddy currents generate heat through resistive losses, effectively converting electromagnetic energy into thermal energy.

[0070] For example, a second ring 404 made of copper or other highly thermally conductive materials serves as an effective heat transfer medium. The high thermal conductivity of copper (approximately 400 W / m·K) allows it to effectively distribute the heat generated in the first ring 402 to the roller 326. This dual-ring design helps to separate the heat generation and heat transfer functions, potentially allowing for more precise control of the heating process.

[0071] The dimensions and geometry of the two rings can be designed to optimize their respective functions. For example, the first ring 402 can have an outer diameter of approximately 693 mm and an inner diameter of approximately 490 mm, while the second ring 404 can have the same outer diameter but a smaller inner diameter of approximately 350 mm. This configuration allows the second ring 404 to have a larger surface area in contact with the roller 326, facilitating more efficient heat transfer.

[0072] In some examples, one or each of the first ring 402 and the second ring 404 can be divided into two halves for ease of installation and maintenance. The two halves of each ring can be assembled offline and then installed to the roll end using existing mounting points (such as M16 holes typically used for roll end caps). This split ring design allows for convenient retrofitting of existing roll systems without requiring complete disassembly.

[0073] The interface between the first ring 402 and the second ring 404 is designed to ensure effective heat transfer. Thermal paste or other highly conductive materials can be applied between the rings to minimize thermal resistance at the interface. Alternatively, the rings can be mechanically coupled using flathead screws or other fasteners, which maintain good thermal contact while allowing for thermal expansion.

[0074] This double-ring configuration of the heater plate 308 allows for targeted heating of the roll ends, which helps to compensate for heat losses typically experienced at these locations, for example, due to the cooling effect of the journal bearing 110.

[0075] The heater plate 308 may include additional features to enhance its performance. For example, the second ring 404 may include oil bypass cavities 702 aligned with the hot oil path in the roll 326. These oil bypass cavities 702 are designed to minimize heat transfer to the hot oil system while directing heat towards the core or center of the roll. This configuration can help maintain a more uniform temperature distribution along the length of the roll.

[0076] Temperature sensor 322:

[0077] Temperature sensor 322 can be used to measure temperature using various techniques. In some examples, non-contact infrared (IR) sensors can be used to monitor the surface temperature of heater plate 308 or roller 326. These sensors can provide real-time temperature data without requiring physical contact, reducing wear and maintenance requirements.

[0078] Although non-contact IR sensors have been discussed, the roller system 302 can also be adapted to other temperature measurement techniques. For example, in some applications, contact sensors or embedded sensors can be used within the roller 326.

[0079] Online metering device 332

[0080] The online metering device 332 can combine various measurement technologies to evaluate the quality of the material layer formed by the roller 326. These can include laser thickness gauges, beta or gamma ray thickness sensors, X-ray fluorescence analyzers, optical sensors, or capacitance / inductance sensors integrated into the production line. The combination of these technologies allows for comprehensive monitoring of material properties.

[0081] Control Unit 314:

[0082] As described above, the control unit 314 includes a temperature control 328, which can dynamically adjust the heating using inputs from one or more temperature sensors 322, which measure the temperature along the roller.

[0083] The temperature control 328 within the control unit 314 can implement algorithms to manage the heating process based on real-time temperature data from the temperature sensors 322. These sensors can be strategically placed along the length of the roller 326 to provide a comprehensive temperature distribution.

[0084] Dynamic regulation of heating can involve modulating the power output from generator 304 to induction heating coil 306. This modulation can be achieved through techniques such as pulse width modulation (PWM) or frequency regulation of the AC power 324 supplied to the coil.

[0085] The control unit 314 can implement a predictive algorithm for anticipated temperature changes based on historical data and current operating conditions. This predictive capability allows the system to proactively adjust heating parameters to maintain the optimal temperature distribution along the roll 326.

[0086] Furthermore, temperature control 328 can work in conjunction with PID control 330 and inputs from online metering device 332 to produce a multivariable control system. This integrated approach allows the system to consider not only temperature but also material thickness or density when adjusting heating parameters, potentially leading to more precise control over the quality of the final product.

[0087] The system can also incorporate an adaptive control mechanism, which adjusts control parameters in real time based on changes in processing conditions or roller characteristics over time. This adaptability helps maintain optimal performance even when system components age or operating conditions change.

[0088] In some examples, the induction heater system 334, including, for example, induction heating coil 306, heater plate 308, generator 304, and control unit 314, can be designed as a modification kit for existing roll systems. This can include a split-ring configuration for the heater plate 308 and a modular design for the induction heating coil 306, allowing for easy installation on a wide range of roll sizes and configurations. The modification design enables manufacturers to upgrade existing equipment to address thermal bulge issues without completely replacing the system.

[0089] Figure 4 This is a conceptual diagram illustrating how induction heating is performed according to some examples. An induction heating coil 306 can generate an electromagnetic field based on the supplied power (e.g., AC power 324). The electromagnetic field can generate eddy currents in a first steel ring 402, where heat can be generated. The generated heat can be transferred from the first steel ring 402 to a second copper ring 404 via thermal conduction, and then from the second copper ring 404 to the roller end cap 310.

[0090] Based on some examples, Figure 5AThe diagram illustrates how an induction heating coil 306 (surrounding a heater plate 308) is mounted on a journal bearing 110 on one side of the roll system 302. The induction heating coil 306 is positioned near the heater plate 308, which is mounted on an end cap 310 of the roll system 302. The induction heating coil 306 generates an electromagnetic field that induces eddy currents in the heater plate 308, thereby generating heat. This heat is then transferred to the roll end to compensate for heat loss and maintain a consistent temperature distribution along the roll length.

[0091] Figure 5B and Figure 5C An example configuration of an induction heating coil 306 is shown according to some examples. Figure 5B and Figure 5C This shows the view from view A (see Figure 5A The image shows a simplified view of the heating coil configuration. The heating coil assembly can be divided into two parts to accommodate the journal 316 of the roller 326 during installation. In some examples, a composite heating coil arrangement with two (or even more) independent semicircular induction coils can be provided, such as... Figure 5B As shown (Option A). This configuration allows the coil to be easily installed around the journal 316 of the roller without requiring disassembly of the roller system 302.

[0092] In some examples, a single heating coil can have an incomplete circle, such as Figure 5C As shown (Option B). This design accommodates the roller's journal 502 by leaving a gap in the induction heating coil 306, thus allowing it to be positioned without interference around the journal 316. Although Figure 5B and Figure 5C The specific locations and dimensions of the separate heating coils are shown, but the invention is not limited thereto, and other separate locations and dimensions are also possible. The flexibility in the design of the induction heating coils 306 ensures that they can be adapted to various roller configurations and installation requirements.

[0093] The separate design of the induction heating coil 306 can be used for a variety of purposes. For example, it allows the installation of the induction heater system 334 without the need for complete disassembly of the roller system 302. This is particularly advantageous for refurbishing existing roller systems or for facilitating maintenance and coil replacement.

[0094] In the composite heating coil assembly (Option A), each semicircular coil can be powered and controlled independently. This configuration allows for more precise control of the heating mode, enabling adjustments to compensate for any asymmetry in the heat distribution of the rollers. Independent control also allows for more efficient power utilization by allowing different power levels to be applied to each coil segment as needed.

[0095] An incomplete circular shape (Option B) offers a simpler design that can be more cost-effective to manufacture and easier to install. This configuration is particularly suitable for applications with lower heating requirements or greater space constraints.

[0096] Both designs take into account practical considerations for working with large industrial equipment. The ability to install heating coils without disassembling the roller system 302 reduces downtime and installation costs.

[0097] The flexibility of the coil design also allows for optimization based on the specific thermal characteristics of different roll configurations. For example, the size and location of the slits or gaps can be adjusted to provide more intense heating to areas of the rolls experiencing greater heat loss, such as those near the journal bearings.

[0098] Furthermore, the separate design facilitates the use of flux concentrators or other magnetic field shaping elements, which can be positioned around the coil to focus and enhance the magnetic field in specific areas. This results in more efficient and targeted heating at the roll ends.

[0099] The adaptability of induction heating coil design extends to the manufacturing process. Coils can be customized for specific roller sizes and configurations, ensuring optimal performance across a wide range of applications.

[0100] Figure 5D The diagram illustrates how, according to some examples, an induction heating coil 306 (facing the heater plate 308) is mounted into the roller system 302 by fixing it to the end plate. Figure 5E The illustration shows how, according to some examples, induction heating coils 306 and 312 (around heater plate 308) are mounted on end caps 310 on opposite sides of roller system 302. Figure 5D An example is shown where induction heating coils 306 and 312 surround heater plate 308; induction heating coils 306 and 312 may face heater plate 308, as shown. Figure 5D As shown. Induction heating coils 306 and 312 may face and completely or at least partially surround heater plate 308 without physical contact with heater plate 308.

[0101] In some examples where induction heating coils 306 and 312 surround heater plate 308, such as Figure 5A As shown, induction heating coils 306 and 320 can be directly coupled to the roller end cap 310 via coupling members such as screws, bushings, etc., without physically contacting the heater plate 308. In some examples, each of induction heating coils 306 and 312 may have an inner diameter larger than the outer diameter of the heater plate 308. In some examples, each of induction heating coils 306 and 312 may not need to have an inner diameter larger than the outer diameter of the heater plate 308.

[0102] Each of induction heating coils 306 and 312 may include one or more induction heating coils. Although Figure 5A , Figure 5D and Figure 5E The illustration shows that each of induction heating coils 306 and 312 includes two induction heating coils, but the invention is not limited thereto. For example, each of induction heating coils 306 and 312 may include only one induction heating coil. As another example, each heating coil 306 / 312 may include two or more induction heating coils. As another example, each of induction heating coils 306 and 312 may include three or more induction heating coils. As yet another example, one of induction heating coils 306 and 312 may include only one induction heating coil, while the other of heating coils 306 and 312 may include two or more induction heating coils.

[0103] In some examples, only one of the induction heating coils 306 and 312 is operable to heat the corresponding end of the roller system 302. In these examples, the induction heating coils 306 or 312 may include only one induction heating coil or two or more induction heating coils.

[0104] In some examples, the roller system 302 may include an induction heating coil only on one end side. For example, the roller system 302 may include only the left induction heating coil 306. The left induction heating coil 306 may include only one induction heating coil, or two or more induction heating coils. As another example, the roller system 302 may include only the right induction heating coil 312. The right induction heating coil 312 may include only one induction heating coil, or two or more induction heating coils.

[0105] The roller system 302 may include induction heating coils on both end sides. The left induction heating coil 306 and the right induction heating coil 312 may have the same configuration. For example, induction heating coils 306 and 312 may have the same number of turns, the same dimensions, and / or include the same material, etc. Alternatively, the left induction heating coil 306 and the right induction heating coil 312 may have different configurations. For example, induction heating coils 306 and 312 may have different numbers of turns, different dimensions, and / or include different materials, etc.

[0106] The left induction heating coil 306 and the right induction heating coil 312 can be controlled in the same manner (e.g., synchronously) or independently of each other. For example, induction heating coils 306 and 312 can receive the same amount of voltage, current, or RF power to generate the same amount of induced current (e.g., eddy current). Alternatively, induction heating coils 306 and 312 can receive different amounts of power to generate different amounts of induced current. The left and right induction heating coils 306 and 312 can operate at different times or for different durations. For example, voltage, current, or RF power can be applied to the left induction heating coil 306 for a first duration (e.g., 5-10 minutes), while voltage, current, or RF power can be applied to the right induction heating coil 312 for a second duration different from the first duration (e.g., 7-12 minutes).

[0107] The amount of power can vary depending on the duration. For example, the longer the duration, the less power can be applied. As a non-limiting example, if 1 kW of RF power is applied to an induction heating coil for about 10 minutes, then 2 kW of RF power can be applied to the same induction heating coil for less than about 10 minutes, such as about 5 minutes. These times are merely examples, and other times can be used (e.g., about 30 seconds, about 1 minute, about 2 minutes, about 3 minutes, about 4 minutes, about 5 minutes, about 6 minutes, about 7 minutes, about 8 minutes, about 9 minutes, about 10 minutes, or any other time in between, or any other time around them, etc.). Furthermore, voltage, current, or RF power can be applied for less than about 30 seconds or more than about 10 minutes, depending on the example.

[0108] One of the left induction heating coil 306 and the right induction heating coil 312 may receive power before the other of the left induction heating coil 306 and the right induction heating coil 312 receives voltage, current, or RF power (delayed heating). For example, the left induction heating coil 306 may receive power approximately 30 seconds to approximately 5 minutes before the right induction heating coil 312 receives voltage, current, or RF power. As another example, the right induction heating coil 312 may supply power approximately 30 seconds to approximately 5 minutes before the left induction heating coil 310 receives voltage, current, or RF power. These times are merely examples, and other delay times of less than approximately 30 seconds or greater than approximately 5 minutes may also be used.

[0109] At least one of the left induction heating coil 306 and the right induction heating coil 312 can receive power constantly. For example, at least one of the left induction heating coil 306 and the right induction heating coil 312 can receive power continuously while the roller is operating. At least one of the left induction heating coil 310 and the right induction heating coil 320 can receive power intermittently. For example, one or both of the left induction heating coil 306 and the right induction heating coil 312 can receive power every five minutes after the roller starts operating. In some examples, one of the left induction heating coil 310 and the right induction heating coil 320 can receive power every five minutes, while the other of the left induction heating coil 306 and the right induction heating coil 312 can receive voltage, current, or RF power every three minutes. These times are merely examples, and other intermittent times may also be used.

[0110] At least one of the left induction heating coil 306 and the right induction heating coil 312 may receive power before the roller system 302 is operated (preheated). For example, one or both of the left induction heating coil 306 and the right induction heating coil 312 may receive power approximately 5 to 10 minutes before the roller system 302 is operated to preheat the roller ends. By preheating the roller ends, the diameter of the roller can thermally expand to be closer to or match the diameter of the middle portion. This thermal expansion helps to maintain a consistent roller diameter along its entire length, which in turn helps to create a consistent material layer on the substrate. These times are merely examples, and other preheating times may be used. The preheating time may vary depending on the amount of power.

[0111] In some examples, as described above, the roll temperature can be monitored to determine whether the roll is sufficiently heated before or during operation. For example, the temperature at which the roll is sufficiently heated can be in the range of about 100 degrees Celsius to about 200 degrees Celsius. Temperature sensor 322 can be used to determine the roll temperature. The temperature sensor can be positioned near the end of the roll to detect the temperature at the roll end. The degree of roll heating can be monitored or controlled in various ways. For example, a predetermined amount of power (e.g., RF power) and / or the power application time can be used to control the heating level or temperature of the roll. The roll diameter can be continuously measured while induction heating is applied to the roll end cap. In some examples, a feedback loop can be used to determine a specific temperature of the roll end cap or the diameter of the roll end portion.

[0112] In some examples, only one of the two rollers can be heated by an induction heating coil. For example, one of the upper or lower rollers can be heated only via induction heating. In other examples, both the upper and lower rollers, or adjacent rollers, can be heated by induction heating coils. In either case, one or both sides of each roller can be heated by the induction heating coils as described above. In some examples, both the upper and lower rollers, or adjacent rollers, can be heated to a temperature lower than that where only one of the two rollers is heated.

[0113] Figure 6 This is a perspective view of a roller system with a dual-coil induction heating configuration, based on some examples.

[0114] The roller system includes roller 326, which is configured to rotate during operation. Roller 326 has end caps 310, which are secured to the roller using multiple fasteners. End caps 310 serve as mounting points for heater plate 308 and other components of the induction heating assembly.

[0115] The heater plate 308 comprises two main components: a first ring 402 and a second ring 404. The first ring 402 is made of a ferromagnetic material such as steel. The ring is designed to generate eddy currents in response to an electromagnetic field. The second ring 404 is made of a thermally conductive material such as copper. Its main function is to transfer the heat generated by the eddy currents to the roller 326. The first ring 402 and the second ring 404 are coupled together and mounted to the end cap 310.

[0116] The induction heating assembly incorporates two or more induction heating coils 306. These coils are positioned adjacent to the heater plate 308. Multi-coil configurations offer advantages including installation flexibility, independent or combined control, and enhanced heating accuracy.

[0117] The induction heating coil 306 generates an electromagnetic field based on the supplied power (e.g., RF power). The electromagnetic field induces eddy currents in the first ring 402, thereby generating heat. The heat is then transferred from the first ring 402 to the second ring 404, and subsequently to the roller 326 via thermal conduction.

[0118] The separate design of the semi-circular independent induction heating coils 306 allows for easy installation around the journal of the roller without disassembling the roller system. This configuration facilitates improvements to existing roller systems and simplifies coil maintenance or replacement. The separate coils can be connected in series to function as a single coil while maintaining high circumferential coverage of the heating area.

[0119] Each semicircular coil can be independently powered and controlled, enabling precise adjustment of the heating mode. This independent control allows for compensation of asymmetry in the heat distribution of the roller by applying different power levels to each coil segment as needed. Alternatively, the coils can be controlled in combination to provide consistent heating when required. A control unit 314, including temperature control 328 and PID control 330, processes information from temperature sensor 322 and online metering device 332 to determine the optimal or desired power distribution to the coils.

[0120] In some examples, the roller system 302 may incorporate more than two coils, such as three or four semi-circular coils, to provide greater flexibility and precision in heating control. The number of coils can be determined based on the specific requirements of the roller system, the desired level of heating control, and the size of the roller. For example, larger rollers or rollers requiring more precise temperature control may benefit from additional coils.

[0121] The induction heating coil 306 can be shaped to surround approximately one quadrant of the circumference of the bearing housing facing the roll end. This design increases the magnetic field distribution while minimizing interference with other components of the roll system. The coil is mounted on a fixed journal bearing 110 or bearing housing, ensuring that it remains stationary as the roll rotates.

[0122] The power supplied to the induction heating coil 306 is generated by a generator 304, which converts the AC input power into RF energy. The RF energy is then emitted by the induction coil to induce heat in the heat distribution plate (heater plate 308). The control unit 314 adjusts the power output based on real-time feedback from temperature sensors and material thickness or density measurements, thereby ensuring optimal heating performance throughout the roll operation.

[0123] The induction heating coil 306 is mounted on the fixed journal bearing 110. This mounting arrangement ensures that the coil remains stationary while the roller 320 rotates. The non-contact design of the induction heating coil 306 allows for effective heating without physical contact with the heater plate 308. This design feature reduces wear and precision requirements.

[0124] Figure 7 This is an exploded view showing an example heater plate 308 (or ring assembly) to be mounted on one or both end caps of a roller, according to some examples. The heater plate 308 may include a first ring 402 and a second ring 404, as referenced above. Figure 3 As stated above.

[0125] As mentioned above Figure 5E The induction heating coil 306 may surround (e.g., without contact) the circumferential edge of the heater plate 308. The induction heating coil 306 may surround at least one of a first ring 402 or a second ring 404. For example, the induction heating coil 306 may surround the first ring 402 to inductively transfer eddy currents to or inductively generate eddy currents on the first ring 402. However, the induction heating coil 306 may surround the second ring 404 or both the first ring 402 and the second ring 404, as long as eddy currents can be inductively generated in the first ring 402.

[0126] Heater plate 308 can be mounted to each of the two end caps 310 of the rotating roller (see...) Figure 3 The induction heating coil 306 can be mounted to the fixed journal bearing 110 and can face the rotating heater plate 308, providing effective non-contact heating of the first ring 402. The second ring 404 can transfer heat from the first ring 402 to the central journal of the roller 326 to compensate for heat otherwise lost to the cooling circuit of the journal bearing 110. The induction heating coil 306 can be fixed while the heater plate 308 rotates with the roller.

[0127] The first ring 402 and the second ring 404 may have substantially the same outer diameter. For example, the outer diameter may be in the range of about 670 mm to about 710 mm, such as about 670 mm, about 680 mm, about 690 mm, about 700 mm, about 710 mm, or any diameter between them. These diameters are merely examples, and this disclosure is not limited thereto. For example, other outer diameters less than about 670 mm or greater than about 710 mm may also be used.

[0128] The inner diameter of the first ring 402 can be larger than the inner diameter of the second ring 404. The inner diameter of the first ring 402 can be in the range of about 470 mm to about 510 mm, such as about 470 mm, about 480 mm, about 490 mm, about 500 mm, about 510 mm, or any diameter between them. These diameters are merely examples, and this disclosure is not limited thereto. For example, the first ring 402 can have other inner diameters that are less than about 470 mm or greater than about 510 mm.

[0129] The inner diameter of the second ring 404 can be in the range of about 330 mm to about 370 mm, such as about 330 mm, about 340 mm, about 350 mm, about 360 mm, about 370 mm, or any diameter between them. These inner diameters of the second ring are merely examples, and this disclosure is not limited thereto. For example, the second ring 404 may have other inner diameters less than about 330 mm or greater than about 370 mm.

[0130] The first ring 402 and the second ring 404 can be formed of or comprise different materials, such that the first ring 402 can generate heat based on an induced current, and the second ring 404 can transfer the heat to the end of the roll via conduction. The first ring 402 can be formed of or comprise steel, and the second ring 404 can be formed of or comprise copper. These materials are merely examples, and other materials can be used as long as they generate heat and conduct it to the end of the roll.

[0131] The second ring 404 may include one or more oil bypass cavities 702 aligned with the hot oil path and capable of preventing or minimizing heat transfer to the radially outer region of the second ring 404. In the roll system 302, hot oil can circulate through internal oil heating lines to maintain a constant temperature along the length of the roll. These oil heating lines are part of a loop that circulates heated oil (or another fluid) within the roll to distribute heat evenly. However, the presence of these oil heating lines can also lead to unintended heat dissipation, especially if heat generated by the induction heating system is transferred into the oil path. This will result in ineffective heating and potential thermal imbalances within the roll.

[0132] The oil bypass cavities 702 in the second ring 404 are designed to address this problem. These cavities are cutouts or recesses aligned with the hot oil path, creating a thermal barrier that prevents heat transfer into the oil heating line. By doing so, the cavities ensure that the heat generated by the induction heating coils is directed to the roll ends, where heat loss due to bearing cooling circuitry needs to be compensated. This directional heating helps maintain a consistent temperature distribution along the roll length, prevents thermal bulging, and ensures consistent roll diameter.

[0133] Without these cavities, the heat generated by the induction heating system may be absorbed by the circulating oil, resulting in inefficient heating and potential thermal gradients within the roll. This could further compromise the effectiveness of the induction heating system and potentially lead to uneven material thickness during rolling. By incorporating the oil bypass cavity 702, the design of the second ring 404 effectively transfers heat to the roll ends.

[0134] Each of the first ring 402 and the second ring 404 may include two or more separate components (e.g., two halves). A first half of the first ring 402 may be coupled to a corresponding first half of the second ring, such as... Figure 7 As shown. The second half of the first ring 402 can be coupled to the corresponding second half of the second ring, as follows. Figure 7 As shown. These halves can be coupled to each other using coupling members such as rivets or flathead screws. Other coupling members or mechanisms can also be used, such as adhesives, magnets, welding, etc. These halves can be coupled to each other before they are coupled to the roller end caps.

[0135] like Figure 7 As shown, the first half of the first ring 402 can be arranged asymmetrically relative to the first half of the second ring 404 for easy coupling. Figure 7 As shown, the second half of the first ring 402 can be arranged asymmetrically relative to the second half of the second ring 404 to facilitate coupling.

[0136] Fasteners can be used to secure the dividing ring assembly to the roller end. For example, holes such as 7×M16 holes (for coupling roller end caps) can be used. However, this disclosure is not limited to this, and other types or sizes of holes or fasteners can be used. 7×M16 screws can preload a sealing washer to seal the roller end. The M16 screws may have internal threads, which provide a mounting point while maintaining the washer preload.

[0137] The heater plate 308 can be coupled to the roll end using a coupling member. For example, an M8 flathead cap screw (FHCS) and one or more bushings can be used to fasten the heater plate 308 to the roll end cap. One or more bushings can be screwed into the back of the heater plate 308. The M8 fasteners and bushings can compress the first ring 402 (e.g., a steel ring) to preload the joint, and hot grease can be applied between the joints. The one or more fasteners can be flush or sub-flush fasteners. Furthermore, the coupling members or mechanisms described above are merely examples, and this disclosure is not limited thereto.

[0138] Figure 8 This is a flowchart illustrating a method 800 for induction heating rollers according to some examples. Figure 8 This is merely an example flowchart, and you can remove some boxes, add other boxes, combine two or more boxes, or divide a box into multiple boxes according to specifications and requirements.

[0139] In block 802, the induction heater system 334 can be mounted to a side end portion of the roller (e.g., an end cap). In block 804, power such as RF power can be generated by generator 304 and the generated power can be supplied to one or more induction heating coils 306.

[0140] In block 806, one or more induction heating coils 306 can generate an electromagnetic field based on the supplied power. The electromagnetic field can induce a current (e.g., eddy current) in the first steel ring 402 of the heater plate 308.

[0141] In frame 808, the steel first ring 402 of heater plate 308 can generate heat based on eddy currents and transfer the heat to the end portion of the roller.

[0142] In block 810, it is determined whether the end of the roller is sufficiently heated. As described above, various methods can be used to determine whether the end of the roller is sufficiently heated. For example, the temperature on the end portion of the roller can be sensed, and it can be determined that the end of the roller is sufficiently heated in response to the sensed temperature exceeding a threshold temperature or in response to the sensed temperature being within a certain temperature range. As another example, one or more of the following can be used to determine whether the end of the roller is sufficiently heated: i) the power of one or more induction heating coils 306, ii) the number of heating coils, iii) the number of turns of each heating coil, or iv) the duration of power delivery.

[0143] If it is determined that the end of the roller is not sufficiently heated, steps 806 and 808 can be repeated until the end of the roller is sufficiently heated.

[0144] A feedback loop for at least one of temperature, power quantity, or power application time can be used to determine whether the end of the roller is sufficiently heated as described above.

[0145] If it is determined in box 810 that the end of the roller is sufficiently heated, then the roller operation (box 812) can be performed. The roller operation may include, but is not limited to, forming a film or material layer on a substrate by rolling the roller relative to the substrate on the film or material layer.

[0146] During roll operation, the roll temperature can be continuously monitored using temperature sensors strategically placed near the roll's end. These sensors provide real-time data on the roll temperature, ensuring the roll maintains the desired temperature range throughout operation. If the temperature at the roll end begins to drop below the optimal range, an induction heating system can be activated to intermittently heat the roll end in real time. This intermittent heating helps compensate for any heat loss and maintains a consistent temperature distribution along the roll's length.

[0147] Real-time monitoring and intermittent heating are controlled by a feedback loop system. The feedback loop continuously compares the sensed temperature with a predetermined threshold. If the temperature drops below the threshold, the system triggers the induction heating coil to generate an electromagnetic field, thereby inducing eddy currents in the heater plate 308. The generated heat is then conducted to the roll end, restoring the temperature to the desired level. Once the temperature returns to the optimal range, the induction heating system can be temporarily stopped until further heating is required. This dynamic and responsive heating method aims to ensure that the roll maintains a uniform diameter and temperature.

[0148] Figure 9 This is a flowchart illustrating a method 900 for controlling an induction heating system used to manufacture rollers for electrodes of an energy storage device, according to some examples. Although the example methods describe a particular sequence of operations, this sequence can be changed without departing from the scope of this disclosure. For example, some of the described operations may be performed in parallel or in different orders that do not substantially affect the functionality of the method. In some examples, different components of the example device or system implementing the method may perform their functions substantially simultaneously or in a specific order.

[0149] In frame 902, the induction heater system 334 initiates the preheating phase. The control unit 314 can activate the induction heating system to begin heating the roll ends before roll operation begins.

[0150] In box 904, the induction heater system 334 generates and supplies power to one or more induction heating coils. A generator can generate radio frequency (RF) power that is transmitted to the induction heating coils.

[0151] In frame 906, induction heating coil 306 generates an electromagnetic field based on the provided power. The electromagnetic field interacts with a heater plate connected to the end of the roller.

[0152] In box 908, heater plate 308 generates eddy currents in response to an electromagnetic field. In some examples, the steel ring component of the heater plate may be primarily responsible for generating these eddy currents.

[0153] In frame 910, eddy currents generate heat in heater plate 308. The heat is primarily generated in the steel ring component.

[0154] In frame 912, the generated heat is conducted from heater plate 308 to the roll end. In some examples, the copper ring component of heater plate 308 can facilitate efficient heat transfer to the roll end.

[0155] In decision box 914, the induction heater system 334 determines whether the roll end is sufficiently heated. This determination may include using a non-contact infrared sensor to measure the temperature of the heater plate or the roll end.

[0156] If the roll end is not sufficiently heated, method 900 returns to frame 904 to continue heating. If the roll end is sufficiently heated, the process proceeds to frame 918.

[0157] In box 916, the induction heater system 334 switches to operating heating mode. In this mode, the roller begins its operation of forming electrode material.

[0158] In frame 918, the induction heater system 334 monitors the temperature at the roller end and the thickness or load density of the formed material layer. This monitoring may involve using a non-contact infrared sensor for temperature measurement and an online metering device for material layer properties.

[0159] In decision box 920, the induction heater system 334 determines whether heating adjustment is needed based on the monitored parameters. This decision can be made using a closed-loop proportional-integral-derivative (PID) control system.

[0160] In block 928, if heating regulation is required, the induction heater system 334 modifies the power supplied to the induction heating coil. This regulation may involve changing the amount of RF power or the duration of power application.

[0161] If heating regulation is not required, then in box 922. The induction heater system 334 continues to monitor while maintaining the current heating level.

[0162] In decision box 924, the induction heater system 334 determines whether the roller operation is complete. If not, the process returns to box 918 for continued monitoring and adjustment as needed. If the operation is complete, the process ends at closed loop box 926.

[0163] Method 900 allows for control of roll temperature, compensation for heat loss at the roll ends, and maintenance of a consistent diameter along the roll length. The system can continuously adjust heating based on real-time feedback from temperature sensors and material quality measurements, ensuring consistent electrode production throughout the manufacturing process.

[0164] Figure 10This is a flowchart illustrating a method 1000 for manufacturing and installing a kit according to some examples, the kit being used to modify a roller system to reduce thermal protrusion. Although the example methods describe a specific sequence of operations, the sequence can be changed without departing from the scope of this disclosure. For example, some of the described operations can be performed in parallel or in different orders that do not substantially affect the functionality of the method. In some examples, different components of the example device or system implementing the method can perform their functions substantially simultaneously or in a specific order.

[0165] In block 1002, method 1000 begins by providing an induction heating system configured to generate a magnetic field. This may include constructing one or more induction heating coils, which are designed to be placed adjacent to one or both ends of a roller.

[0166] At block 1004, method 1000 proceeds to providing a heater assembly configured to be coupled to the roll. The heater assembly is designed to receive a magnetic field from an induction heating system and, in response, generate heat to thermally expand at least a portion of the roll upon coupling.

[0167] In block 1006, method 1000 relates to providing a first component of a heater assembly made of a ferromagnetic material. This component is configured to generate eddy currents in response to receiving a magnetic field. In some examples, the first component may be a steel ring.

[0168] In block 1008, method 1000 relates to providing a second component of a heater assembly made of a thermally conductive material. This component is configured to transfer heat generated by eddies to the roller upon coupling. In some examples, the second component may be a copper ring.

[0169] In box 1010, the first and second components of the heater assembly are coupled together. This coupling may include fastening the steel half and the copper half together using flathead screws.

[0170] In block 1012, method 1000 relates to configuring one or more non-contact infrared sensors to monitor the temperature of the heater assembly. These sensors may be positioned to measure the surface temperature of a heat distribution plate mounted on a roller end cap.

[0171] At block 1014, control unit 314 is configured to control the induction heating system based on feedback from one or more temperature sensors. This may include programming the control unit to implement a closed-loop proportional-integral-derivative (PID) control system.

[0172] In block 1016, control unit 314 is also programmed to adjust heating based on at least one of the thickness of the material layer or the load density measured by an online metering device. This device may include a laser thickness gauge, beta or gamma ray thickness sensor, X-ray fluorescence analyzer, optical sensor, or capacitance / inductance sensor integrated into the production line.

[0173] In box 1018, a heater assembly is assembled to compensate for disproportionate heat loss from the ends of the roll during coupling. This design aims to maintain a substantially uniform temperature distribution along the length of the roll.

[0174] In block 1020, method 1000 may include mounting a heater assembly having cutouts aligned with the hot oil path in the roll. These cutouts are designed to minimize heat transfer to the hot oil system while directing heat to the core or center of the roll.

[0175] In block 1022, method 1000 may involve mounting the heater assembly in a split-ring configuration for easy installation on an existing roller. This may include forming two halves of each ring, which can be assembled offline and then mounted to the roller end.

[0176] This method of manufacturing modification kits allows for the creation of systems that can be applied to existing roll systems to address hot extrusion problems. The kits are designed to provide targeted heating to the roll ends, compensate for heat loss, and maintain a more consistent temperature distribution along the roll length, which in turn helps to maintain a consistent roll diameter and improve the quality of the manufactured materials.

[0177] Figure 11 An example thickness distribution of material formed using induction-heated rollers and without induction-heated rollers is shown. Figure 11 Three thickness distributions, 1102, 1102, 1104, and 1106, are shown, indicating the thickness distribution from the center of the material (in... Figure 11 The center roller is indicated as "center roller" to the side (in Figure 11 The thickness of a material (e.g., a film) is measured across the material (indicated by "Line 1" and "Line 8").

[0178] Thickness distribution 1102 represents the thickness of the material formed on the substrate (e.g., an electrode) when induction heating is not used. Thickness distribution 1104 represents the thickness of the material when one of the two rollers is heated by one or more induction heating coils. Thickness distribution 1106 represents the thickness of the material when both rollers are heated by one or more induction heating coils.

[0179] like Figure 11As shown, compared to thickness distribution 1102, the laser thickness distribution has a reduced film thickness on the side. Furthermore, compared to thickness distributions 1102 and 1104, thickness distribution 1106 has a reduced film thickness on the side. Thickness distribution 1106 has a substantially similar or uniform film thickness along the axial length of the roller.

[0180] Figure 12A The roll flatness distribution 1202 is obtained by using the material thickness of the roll without induction heating. Figure 12B This is based on some examples of roller flatness distribution 1204 obtained by using the material thickness of rollers employing induction heating. For example... Figure 12A and Figure 12B As shown, compared to the roll flatness distribution 1202 without induction heating, the roll flatness distribution 1204 using induction heating is substantially uniform along the entire length of the roll. That is, by providing an induction heating application to heat the two end caps of the roll with eddy current electromagnetic heating, so that the diameter of each end cap thermally expands and maintains substantially equal or similar outer diameters along the axial length of the roll, various examples can make the surface distribution of thermally raised calendering rolls or laminating rolls smoother.

[0181] Laser thickness profiling is a measurement technique used to determine the thickness of a material layer (such as a film or coating) applied to a substrate. This technique uses a laser-based sensor to scan the surface of the material and generate a detailed distribution of its thickness at different points. Figure 13A The laser thickness distribution 1302 of a material formed by a roller without induction heating is shown. Figure 13B The laser thickness distribution 1304 of a material formed using an induction-heated roller is shown according to some examples. Reference Figure 13A The middle portion 1306 of the coated electrode can be used for an acceptable coating thickness, while the side portions or upper and lower portions 712 / 714 of the coated electrode cannot be used due to poor coating thickness. The middle portion 1306 of the coated electrode can constitute approximately 80% of the entire coated electrode, while the upper portions 1308 and lower portions 1310 can constitute approximately 20%. Conversely, refer to... Figure 13B The coating can cover virtually the entire electrode (approximately 100%) with an acceptable coating thickness. Therefore, from Figure 13A and Figure 13B It can be seen that the laser thickness distribution 1304 obtained by induction heating has a better yield than the laser thickness distribution 1302 without induction heating.

[0182] Figure 14This is a graphical representation of machine 1400, in which instructions 1410 (e.g., software, programs, applications, applets, or other executable code) can be executed to cause machine 1400 to perform any one or more of the methods discussed herein. In some examples, machine 1400 may be control unit 314 of induction heater system 334.

[0183] Instruction 1410 can cause machine 1400 to perform any one or more of the methods described herein. Instruction 1410 transforms a general, unprogrammed machine 400 into a specific machine 1400 programmed to perform the described and illustrated functions in the manner described. Machine 1400 can operate as a standalone device or be coupled (e.g., networked) to other machines. In a networked deployment, machine 1400 can operate within the capabilities of a server machine or client machine in a server-client network environment, or as a peer machine in a peer-to-peer (or distributed) network environment. Machine 1400 can be, but is not limited to, server computers, client computers, personal computers (PCs), tablet computers, laptop computers, netbooks, set-top boxes (STBs), entertainment media systems, cellular phones, smartphones, mobile devices, wearable devices (e.g., smartwatches), smart home devices (e.g., smart devices), other smart devices, network application devices, network routers, network switches, bridges, or any machine capable of sequentially or otherwise executing instructions 1410 specifying the actions to be taken by machine 1400. Furthermore, although a single machine 1400 is shown, the term "machine" can include a collection of machines that individually or jointly execute instructions 1410 to perform any one or more methods discussed herein.

[0184] Machine 1400 may include processor 1404, memory 1406, and I / O components 1402, which may be configured to communicate via bus 1440. In some examples, processor 1404 (e.g., a central processing unit (CPU), a reduced instruction set computing (RISC) processor, a complex instruction set computing (CISC) processor, a graphics processing unit (GPU), a digital signal processor (DSP), an application-specific integrated circuit (ASIC), a radio frequency integrated circuit (RFIC), a tensor processing unit (TPU), a neural processing unit (NPU), a vision processing unit (VPU), a machine learning accelerator (MLA), a cryptographic accelerator processor, a field-programmable gate array (FPGA), a quantum processor, another processor, or any suitable combination thereof) may include, for example, processor 1408 and processor 1412 that execute instruction 1410.

[0185] Although Figure 14Multiple processors 1404 are shown, but machine 1400 may include a single processor with a single core, a single processor with multiple cores (e.g., a multi-core processor), multiple processors with a single core, multiple processors with multiple cores, or any combination thereof. Modern processor architectures include superscalar, very long instruction word (VLIW), vector processors, multi-core, many-core, neuromorphic, and quantum architectures.

[0186] Memory 1406 includes main memory 1414, static memory 1416, and memory cell 1418, all of which are accessible by processor 1404 via bus 1440. Main memory 1406, static memory 1416, and memory cell 1418 store instructions 1410 that implement any one or more methods or functions described herein. During execution of instructions 1410 by machine 1400, instructions 1410 may also reside wholly or partially in main memory 1414, static memory 1416, machine-readable medium 1420 within memory cell 1418, processor 1404 (e.g., processor cache memory), or any suitable combination thereof.

[0187] I / O component 1402 may include various components to receive input, provide output, generate output, send information, exchange information, or capture measurements. The specific I / O component 1402 included in a particular machine depends on the type of machine. For example, a portable machine such as a mobile phone may include a touch input device or other such input mechanism, while a headless server machine may not include such a touch input device. I / O component 1402 may include... Figure 14 Many other components are not shown. In various examples, I / O component 1402 may include output component 1426 and input component 1428. Output component 1426 may include visual components (e.g., a display such as a plasma display panel (PDP), a light-emitting diode (LED) display, a liquid crystal display (LCD), a projector, or a cathode ray tube (CRT)), acoustic components (e.g., a speaker), haptic components (e.g., a vibration motor, a resistive mechanism), or other signal generators. Input component 1428 may include alphanumeric input components (e.g., a keyboard, a touchscreen configured to receive alphanumeric input, an optoelectronic keyboard, or other alphanumeric input components), point-based input components (e.g., a mouse, a touchpad, a trackball, a joystick, a motion sensor, or other pointing instruments), haptic input components (e.g., physical buttons, a touchscreen or other haptic input component that provides position and / or force for a touch or touch gesture), audio input components (e.g., a microphone), etc.

[0188] Motion component 1432 includes an acceleration sensor component (e.g., an accelerometer), a gravity sensor component, and a rotation sensor component (e.g., a gyroscope). Environmental component 1434 includes, for example, one or more cameras, an illumination sensor component (e.g., a photometer), a temperature sensor component (e.g., one or more thermometers for detecting ambient temperature), a humidity sensor component, a pressure sensor component (e.g., a barometer), an acoustic sensor component (e.g., one or more microphones for detecting background noise), a proximity sensor component (e.g., an infrared sensor for detecting nearby objects), a gas sensor (e.g., a gas detection sensor for detecting hazardous gas concentrations or measuring pollutants in the atmosphere for safety purposes), or other components that can provide indications, measurements, or signals corresponding to the surrounding physical environment. Position component 1436 includes a position sensor component (e.g., a Global Positioning System (GPS) receiver component), an altitude sensor component (e.g., an altimeter or barometer from which altitude can be derived), an orientation sensor component (e.g., a magnetometer), etc.

[0189] Various technologies can be used to implement communication. I / O component 1402 also includes a communication component 1438 operable to couple machine 1400 to network 1422 or device 1424 via appropriate coupling or connection. For example, communication component 1438 may include a network interface component or another suitable device interfaced with network 1422. In other examples, communication component 1438 may include a wired communication component, a wireless communication component, a cellular communication component, a near field communication (NFC) component, or Bluetooth. ® Components (e.g., Bluetooth) ® Low energy), Wi-Fi ® Components and other communication components that provide communication via other modes. Device 1424 may be any of another machine or a variety of peripheral devices (e.g., peripheral devices coupled via USB).

[0190] Furthermore, the communication component 1438 may detect identifiers or include components that can be used to detect identifiers. For example, the communication component 1438 may include a radio frequency identification (RFID) tag reader component, an NFC smart tag detection component, an optical reader component (e.g., an optical sensor for detecting one-dimensional barcodes (e.g., Universal Product Code (UPC) barcodes), multi-dimensional barcodes (e.g., Quick Response (QR) codes, Aztec codes, Data Matrix, Data glyphs, Maxi codes, PDF417, Ultra codes, UCCRSS-2D barcodes, and other optical codes)), or an acoustic detection component (e.g., a microphone for identifying tagged audio signals). Additionally, various information can be derived via the communication component 1438, such as location via Internet Protocol (IP) geolocation, location via Wi-Fi® signal triangulation, or location via detection of NFC beacon signals indicating a specific location.

[0191] Various memories (e.g., main memory 1414, static memory 1416, and / or the memory of processor 1404) and / or storage units 1418 may store one or more sets of instructions and data structures (e.g., software) embodied or used by any one or more methods or functions described herein. These instructions (e.g., instruction 1410) cause various operations to implement the disclosed examples when executed by processor 1404.

[0192] Instructions 1410 can be sent or received over network 1422 using a transmission medium, via a network interface device (e.g., a network interface component included in communication component 1438) and using any of several known transmission protocols (e.g., Hypertext Transfer Protocol (HTTP)). Similarly, instructions 1410 can be sent or received using a transmission medium via coupling (e.g., peer-to-peer coupling) to device 1424.

[0193] The aforementioned induction heater can be used in roller systems for forming material layers on a substrate to manufacture battery electrodes. Rollers may include, but are not limited to, calendering rolls, laminating rolls, or other material forming rolls. Furthermore, the aforementioned induction heater can be used in any calendering / laminating / material forming roll application employing oil heating. Various examples are applicable to the manufacture of paper, textiles, rubber tires, plastic sheets, or specialty polymers, such as Teflon. Induction heating can be used for directly heating electrode films, etc.

[0194] Features, materials, properties, or groups described in connection with a particular aspect or example shall be construed as applicable to any other aspect or example described elsewhere in this section or specification, unless incompatible therewith. All features disclosed in this specification (including any appended claims, abstract, and drawings) and / or all steps of any method or process so disclosed may be combined in any combination, except for combinations in which at least some such features and / or steps are mutually exclusive. Protection is not limited to the details of any of the foregoing examples. Protection extends to any novel feature or any novel combination of features disclosed in this specification (including any appended claims, abstract, and drawings), or to any novel step or any novel combination of steps of any method or process so disclosed.

[0195] Furthermore, some features described in this disclosure in the context of a single implementation may also be implemented in combination in a single implementation. Conversely, various features described in the context of a single implementation may also be implemented individually or in any suitable sub-combination in multiple implementations. Moreover, although features may be described above as functioning in certain combinations, in some cases, one or more features from a claimed combination may be removed from said combination, and said combination may be claimed as a sub-combination or a variation of a sub-combination.

[0196] Furthermore, although operations may be depicted in the accompanying drawings or described in the specification in a specific order, such operations need not be performed in the specific order shown or sequentially, or all operations need to be performed to achieve the desired result. Other operations not depicted or described may be incorporated into the example methods and processes. For example, one or more additional operations may be performed before, after, simultaneously with, or between any of the stated operations. Furthermore, in other implementations, operations may be rearranged or reordered. Those skilled in the art will understand that in some examples, the actual steps employed in the illustrated and / or disclosed methods may differ from those shown in the accompanying drawings. Depending on the example, some of the steps described above may be removed, and other steps may be added. Furthermore, features and properties of the specific examples disclosed above may be combined in different ways to form additional examples, all of which fall within the scope of this disclosure. Moreover, the separation of various system components in the above embodiments should not be construed as requiring such separation in all embodiments, and it should be understood that the described components and systems can generally be integrated together in a single product or packaged into multiple products. For example, any component of the energy storage system described herein may be provided separately or integrated together (e.g., packaged together or connected together) to form an energy storage system.

[0197] For the purposes of this invention, certain aspects, advantages, and novel features are described herein. Not all of these advantages can necessarily be achieved according to any particular example. Thus, by way of example, those skilled in the art will recognize that the invention may be implemented or practiced in a manner that achieves one or more advantages taught herein without necessarily achieving the other advantages taught or suggested herein.

[0198] Conditional language, such as “can,” “able,” “may,” or “may,” unless otherwise specified or understood in the context in which it is used, is generally intended to convey that some examples include certain features, elements, and / or steps, while other examples do not include certain features, elements, and / or steps. Therefore, such conditional language is generally not intended to imply that one or more examples in any way require features, elements, and / or steps, or that one or more examples must include logic for determining whether such features, elements, and / or steps are included in or to be performed in any particular example, with or without user input or prompts.

[0199] Unless otherwise explicitly stated, a compound phrase such as “at least one of X, Y, and Z” should be understood in context as generally used to express items, terms, etc., that can be X, Y, or Z. Therefore, such a compound phrase is generally not intended to imply that certain examples require the presence of at least one of X, at least one of Y, and at least one of Z.

[0200] The degree language used in this document, such as the terms “approximately,” “about,” “generally,” and “substantially,” indicates a value, quantity, or characteristic that is close to the stated value, quantity, or characteristic and still performs the desired function or achieves the desired result.

[0201] The scope of this disclosure is not intended to be limited by the specific disclosures of embodiments in this section or elsewhere in this specification, and may be defined by the claims set forth or to be laid forth in this section or elsewhere in this specification. The language of the claims should be interpreted broadly based on the language used in the claims and is not limited to the examples described in this specification or in the course of the application, which should be interpreted as non-exclusive.

[0202] While certain embodiments have been described, these embodiments are presented by way of example only and are not intended to limit the scope of this disclosure. In fact, the novel methods and systems described herein can be implemented in a variety of other forms. Furthermore, various omissions, substitutions, and changes can be made to the systems and methods described herein without departing from the spirit of this disclosure. The appended claims and their equivalents are intended to cover these forms or modifications that fall within the scope and spirit of this disclosure. Therefore, the scope of the invention is defined only by the appended claims. Example

[0203] Example 1 is a roller system for forming a material layer on a substrate. The roller system includes: a first roller configured to rotate; and a second roller configured to rotate near the first roller. The first and second rollers are together configured to laminate the material onto a substrate inserted therebetween. At least one of the first rollers or the second roller includes an induction heater. The induction heater includes: a generator configured to generate power; one or more induction heating coils positioned adjacent to one or both ends of at least one of the first rollers or the second roller and configured to generate an electromagnetic field based on the power; and a heater plate surrounding one or both ends of at least one of the first rollers or the second roller. The heater plate is configured to: receive the electromagnetic field from the one or more induction heating coils; and generate eddy currents based on the electromagnetic field. The eddy currents are configured to generate heat on the heater plate based on the electromagnetic field induction, such that the generated heat is transferred via thermal conduction to one or both ends of at least one of the first rollers or the second roller, so as to thermally expand the diameter of one or both ends of at least one of the first rollers or the second roller.

[0204] In Example 2, which is based on the subject of Example 1, the generated heat is configured to maintain a substantially similar outer diameter of at least one of the first or second rollers over the entire axial length of the rollers before or during operation of the rollers.

[0205] In Example 3, which is based on the subject of Examples 1-2, one or more induction heating coils are disposed at both ends of each of the first and second rollers.

[0206] In Example 4, which is based on the subject of Examples 1-3, one or more induction heating coils include a pair of heating coils spaced apart from each other.

[0207] In Example 5, which is based on the subject of Examples 1-4, a heater plate is disposed between the end of the roller and one or more induction heating coils.

[0208] In Example 6, which is based on the subject matter of Examples 1-5, the electric power includes at least one of voltage, current, or radio frequency (RF) power.

[0209] In Example 7, which is based on the subject of Examples 1-6, one or more induction heating coils are fixed as the first and second rollers rotate.

[0210] In Example 8, which is based on the subject of Examples 1-7, one or more induction heating coils do not contact the heater plate.

[0211] Example 9 is a roll heating system for heating one or more rolls, comprising: a generator configured to generate power; one or more induction heating coils configured to be placed adjacent to one or both ends of at least one of a first roll or a second roll and configured to generate an electromagnetic field based on the power; and a heater plate configured to: at least partially surround one or both ends of at least one of the first roll or the second roll; receive the electromagnetic field from the one or more induction heating coils; and generate eddy currents based on the electromagnetic field, the eddy currents generating heat on the heater plate based on the electromagnetic field induction, such that the generated heat is transferred via thermal conduction to one or both ends of at least one of the first roll or the second roll to thermally expand the diameter of one or both ends of at least one of the first roll or the second roll.

[0212] In Example 10, which is based on the subject matter of Example 9, the generated heat is configured to maintain substantially similar outer diameters of at least one of the first or second rollers over the entire axial length of the rollers before or during operation of the rollers.

[0213] In Example 11, based on the subject matter of Examples 9-10, one or more induction heating coils face the heater plate without contacting it.

[0214] In Example 12, which is based on the subject matter of Examples 9-11, one or more induction heating coils are included, which surround the circumferential edge of the heater plate without contacting the heater plate.

[0215] Example 13 is a roll heating system for heating one or more calender rolls, comprising: an RF generator for generating RF power; and one or more induction heating coils placed at one or both ends of at least one of a first roll or a second roll, the one or more induction heating coils being configured to: receive RF power from the RF generator; and generate an electromagnetic field based on the RF power, the electromagnetic field being configured to generate eddy currents, the eddy currents generating heat to be transferred via thermal conduction to one or both ends of at least one of the first roll or the second roll, so as to thermally expand the diameter of one or both ends of at least one of the first roll or the second roll.

[0216] Example 14 is a heater plate for heating one or more material forming rollers, comprising: a first ring having a first inner diameter and a first outer diameter; and a second ring having a second inner diameter smaller than the first inner diameter and a second outer diameter substantially the same as the first outer diameter, the first ring and the second ring being coupled to each other such that the first outer diameter and the second outer diameter are substantially aligned, the coupled first ring and the second ring being configured to couple to and heat the end of at least one of the one or more material forming rollers, the first ring and the second ring comprising different materials.

[0217] In Example 15, which is based on the subject of Example 14, it includes a first ring comprising steel and a second ring comprising copper.

[0218] In Example 16, which is based on the subject of Examples 14-15, each of the first ring and the second ring includes a first half and a second half, wherein the first half of the first ring is coupled to the first half of the second ring, and wherein the second half of the first ring is coupled to the second half of the second ring.

[0219] In Example 17, which is based on the subject of Examples 14-16, it includes a first half of the first ring arranged asymmetrically with respect to the first half of the second ring, and a second half of the first ring arranged asymmetrically with respect to the second half of the second ring.

[0220] In Example 18, which is based on the subject matter of Examples 14-17, the coupled first and second rings are configured to receive an electromagnetic field and generate eddy currents, which generate heat to be transferred via thermal conduction to the end of at least one of the one or more material forming rollers so as to thermally expand the diameter of the end.

[0221] In Example 19, which is based on the subject of Example 18, a first ring is configured to generate eddies and transfer the generated heat to a second ring, and the second ring is configured to transfer the received heat to an end portion of at least one of the material forming rollers.

[0222] Example 20 is a method of manufacturing an electrode for an energy storage device using one or more rollers, comprising: providing one or more rollers; providing one or more induction heating coils to a side end of at least one of the one or more rollers, wherein a heater plate is coupled to the side end of at least one of the one or more rollers; generating power and supplying power to the one or more induction heating coils; generating an electromagnetic field via the one or more induction heating coils to generate eddy currents in the heater plate, the eddy currents generating heat on the heater plate; thermally conducting heat from the heater plate to the side end of at least one of the one or more rollers; determining whether the side end of at least one of the one or more rollers is sufficiently heated; and performing roller operation to form an electrode in response to determining that the side end of at least one of the one or more rollers is sufficiently heated.

[0223] In Example 21, which is based on the subject matter of Example 20, the roller operation includes depositing a thin film on an electrode; rotating at least one of one or more rollers; and pressing the thin film against the electrode with at least one of the rotating rollers, such that the thin film is formed on the electrode.

[0224] In Example 22, which is based on the subject matter of Examples 20-21, the conduction includes thermally expanding the diameter of the side end of at least one of the rollers such that at least one of the rollers maintains a substantially similar outer diameter over the entire axial length of at least one of the rollers before or during roller operation.

[0225] In Example 23, which is based on the subject matter of Examples 20-22, determining whether a side end of at least one of the rollers is sufficiently heated includes: sensing a temperature on a side end of at least one of the rollers; determining whether the sensed temperature is greater than a threshold temperature; and determining that a side end of at least one of the rollers is sufficiently heated in response to determining that the sensed temperature is greater than the threshold temperature.

[0226] Example 24 is a system for mitigating thermal protrusions in a calender roll, the system comprising: a heater assembly to be mounted on an end of a calender roll; and an induction heating mechanism that generates eddy currents to heat the heater assembly, wherein the heater assembly includes a first component made of a ferromagnetic material and a second component made of a thermally conductive material, the heater assembly facilitating directional heat transfer toward the end of the roll to achieve a substantially uniform temperature distribution along the length of the roll.

[0227] In Example 25, which is based on the subject of Example 24, it includes the fact that the ferromagnetic material is steel.

[0228] In Example 26, which is based on the subject of Examples 24-25, the thermally conductive material is copper.

[0229] In Example 27, which is based on the subject of Examples 24-26, a heater assembly is included, wherein the heater assembly is configured to be mounted to the end of a roller having an air gap.

[0230] In Example 28, which is based on the subject of Examples 24-27, a control unit is included for independently controlling the heating of each end of the roller.

[0231] In Example 29, which is based on the subject of Example 28, the control unit utilizes input from temperature sensors distributed along the roller to dynamically adjust the heating.

[0232] In Example 30, which is based on the subject matter of Examples 24-29, the induction heating mechanism includes an induction coil positioned adjacent to the end of a roller on a fixed bearing housing.

[0233] In Example 31, which is based on the subject of Example 30, the induction coil is shaped to surround approximately one quadrant of the circumference of the bearing housing facing the roller end.

[0234] In Example 32, which is based on the subject matter of Examples 24-31, the heater assembly includes an electromagnetic shielding component to prevent interference with the operation of the sensor due to inductive heating.

[0235] In Example 33, which is based on the subject matter of Examples 24-32, a thermal interface material is incorporated at the joint of the heater assembly to improve thermal contact and uniform heat distribution.

[0236] In Example 34, which is based on the subject of Examples 24-33, a heater assembly is included, wherein the heater assembly is adjustable to accommodate different roller sizes and configurations.

[0237] In Example 35, which is based on the subject of Examples 24-34, an induction heating mechanism is included, wherein the intensity of the generated eddy current is changed.

[0238] In Example 36, which is based on the subject of Examples 28-35, the heater assembly includes a sensor for detecting the temperature at the end of the roller and providing feedback to the control unit.

[0239] In Example 37, which is based on the subject of Examples 28-36, the control unit is programmable to follow a heating curve based on the roller material properties and operating parameters.

[0240] Example 38 is at least one machine-readable medium including instructions that, when executed by processing circuitry, cause the processing circuitry to perform operations to implement any one of Examples 1-37.

[0241] Example 39 is an apparatus that includes means for implementing any one of Examples 1-37.

[0242] Example 40 is a system for implementing any of Examples 1-37.

[0243] Example 41 is a method for implementing any of Examples 1-37.

[0244] Example 42 is a roller system for forming a material layer on a substrate, comprising an induction generator for generating a magnetic field, a counter member, and a roller adjacent to the counter member. The roller and the counter member are configured to laminate the material onto the substrate inserted therebetween. The roller includes a heater plate thermally coupled to the roller, the heater plate being configured to receive the magnetic field from the induction generator and, in response, generate eddy currents and heat a portion of the roller to thermally expand the diameter of the roller.

[0245] In Example 43, which is based on the subject of Example 42, the heater plate includes a first ring and a second ring, the first ring being used to generate eddies and heat, and the second ring being thermally coupled to the first ring to transfer heat from the first ring to a portion of the roller.

[0246] In Example 44, which is based on the subject of Examples 42-43, the first ring comprises a ferromagnetic material configured to generate eddy currents in response to receiving a magnetic field.

[0247] In Example 45, which is based on the subject of Examples 42-44, the second ring includes a thermally conductive material configured to transfer heat generated by the eddies to the roller.

[0248] In Example 46, which is based on the subject of Examples 42-45, the heater plate is configured to be fixed to the end portion of the roller.

[0249] In Example 47, which is based on the subject of Examples 42-46, the induction generator includes one or more induction heating coils disposed adjacent to the end of the roller.

[0250] In Example 48, which is based on the subject of Examples 42-47, one or more induction heating coils are fixed as the roller rotates.

[0251] In Example 49, which is based on the subject of Examples 42-48, a control unit is further included, which is coupled to the induction generator and operably controls the heating of a portion of the roller.

[0252] In Example 50, which is based on the subject of Examples 42-49, the control unit uses input from at least one temperature sensor to dynamically adjust the heating of a portion of the roller, the at least one temperature sensor measuring the temperature along the roller.

[0253] In Example 51, which is based on the subject of Examples 42-50, the control unit uses a closed-loop proportional-integral-derivative (PID) control system to control the induction generator based on at least one of the thickness of the material layer or the load density measured by an online metering device.

[0254] Example 52 is a kit for retrofitting a roll system to reduce thermal congestion, comprising an induction heating system for generating a magnetic field and a heater assembly configured to be thermally coupled to the roll. The heater assembly is configured to receive the magnetic field from the induction heating system and generate heat in response to receiving the magnetic field to cause at least a portion of the roll to thermally expand when thermally coupled to the roll.

[0255] In Example 53, which is based on the subject of Example 52, the heater assembly includes a first component and a second component, the first component being made of a ferromagnetic material to generate eddy currents in response to receiving a magnetic field, and the second component being made of a thermally conductive material to transfer the heat generated by the eddy currents to the roller.

[0256] In Example 54, which is based on the subject of Examples 52-53, the induction heating system includes one or more induction heating coils, which are configured to be placed adjacent to one or both ends of the roller.

[0257] In Example 55, which is based on the subject of Examples 52-54, one or more induction heating coils are configured to be fixed to a plurality of bearing seats supporting the roller as the roller rotates.

[0258] In Example 56, which is based on the subject of Examples 52-55, one or more induction heating coils are divided into two parts to accommodate the journal of the roller.

[0259] In Example 57, which is based on the subject of Examples 52-56, one or more temperature sensors are further included to monitor the temperature of the roller, and a control unit is configured to control the induction heating system based on feedback from the one or more temperature sensors.

[0260] In Example 58, which is based on the subject of Examples 52-57, the control unit controls the induction heating system based on at least one of the thickness of the material layer or the load density.

[0261] In Example 59, which is based on the subject of Examples 52-58, the heater assembly includes a first ring having a first inner diameter and a first outer diameter, and a second ring having a second inner diameter smaller than the first inner diameter and a second outer diameter substantially the same as the first outer diameter, the first ring and the second ring being coupled to each other such that the first and second outer diameters are substantially aligned.

[0262] In Example 60, which is based on the subject of Examples 52-59, the first ring and the second ring each include a first half and a second half, wherein the first half of the first ring is coupled to the first half of the second ring, and wherein the second half of the first ring is coupled to the second half of the second ring.

[0263] Example 61 is a method for manufacturing electrodes for an energy storage device using a roller system, the roller system including an induction heating system and a heater assembly coupled to the roller, the method comprising: generating a magnetic field using the induction heating system; receiving the magnetic field at the heater assembly coupled to the roller; generating heat in the heater assembly in response to receiving the magnetic field; thermally expanding at least a portion of the roller using the generated heat; determining that the roller is sufficiently heated; and performing roller operation to form electrodes in response to determining that the roller is sufficiently heated.

[0264] In Example 62, which is based on the subject of Example 61, the roller operation includes depositing a thin film on the electrode, rotating the roller, and pressing the thin film against the electrode while the roller is rotating, such that the thin film is formed on the electrode; and determining whether the roller is sufficiently heated includes sensing the temperature of the heater assembly using one or more non-contact infrared sensors and comparing the sensed temperature with a threshold temperature.

[0265] In Example 63, which is based on the subject matter of Examples 61-62, the method further includes: monitoring the temperature of the heater assembly using one or more temperature sensors; controlling the induction heating system using a closed-loop proportional-integral-derivative (PID) control system based on feedback from one or more temperature sensors; and adjusting the heating based on at least one of the thickness or load density of the material layer measured by an online metering device.

[0266] In Example 64, which is based on the subject matter of Examples 61-63, the heater assembly includes a first part made of steel and a second part made of copper; generating heat in the heater assembly includes generating eddy currents in the first part in response to receiving a magnetic field; and causing at least a portion of the roller to thermally expand includes transferring the heat generated by the eddy currents from the second part to the roller.

[0267] In Example 65, which is based on the subject matter of Examples 61-64, the method further includes: compensating for disproportionate heat loss from the ends of the roll by maintaining a substantially uniform temperature distribution along the length of the roll; maintaining a substantially similar outer diameter over the entire axial length of the roll before or during roll operation; and laminating material onto a substrate inserted between the roll and the opposing member of the adjacent roll.

[0268] Example 66 is a method of manufacturing a kit for retrofitting a roller system to reduce thermal bulges, the method comprising: providing an induction heating system configured to generate a magnetic field; providing a heater assembly configured to be coupled to the roller, the heater assembly being configured to receive the magnetic field from the induction heating system and generate heat in response to receiving the magnetic field to thermally expand at least a portion of the roller upon coupling; and configuring a control unit to control the induction heating system based on feedback from one or more temperature sensors.

[0269] In Example 67, which is based on the subject matter of Example 66, the provision of the heater assembly includes: providing a first component made of a ferromagnetic material, the first component being configured to generate eddy currents in response to receiving a magnetic field; providing a second component made of a thermally conductive material, the second component being configured to transfer heat generated by these eddy currents to the roller upon coupling; and coupling the first component to the second component; and providing an induction heating system includes: constructing one or more induction heating coils, the one or more induction heating coils being configured to be placed adjacent to one or both ends of the roller.

[0270] In Example 68, which is based on the subject matter of Examples 66-67, the method further includes: configuring one or more non-contact infrared sensors to monitor the temperature of the heater assembly; programming the control unit to implement a closed-loop proportional-integral-derivative (PID) control system based on at least one of the thickness of the material layer or the load density measured by an online metering device; and designing the heater assembly to compensate for disproportionate heat loss from the ends of the roll during coupling, thereby maintaining a substantially uniform temperature distribution along the length of the roll.

Claims

1. A roller system for forming a material layer on a substrate, the roller system comprising: An induction generator is used to generate a magnetic field; Relative components; as well as A roller adjacent to the opposing member, wherein the roller and the opposing member are configured to laminate the material onto the substrate, the substrate being inserted between the roller and the opposing member, the roller comprising: A heater plate, thermally coupled to the roller, is configured such that: Receive the magnetic field from the induction generator; as well as In response to receiving the magnetic field, eddy currents are generated and a portion of the roller is heated to thermally expand the diameter of the roller.

2. The roller system of claim 1, wherein the heater plate comprises: A first ring, the first ring being used to generate the vortex and heat; as well as A second ring is thermally coupled to the first ring and transfers the heat from the first ring to the portion of the roller.

3. The roller system of claim 2, wherein the first ring comprises a ferromagnetic material configured to generate the eddy currents in response to receiving the magnetic field.

4. The roller system of claim 2, wherein the second ring comprises a thermally conductive material configured to transfer heat generated by the eddy current to the roller.

5. The roller system of claim 1, wherein the heater plate is configured to be fixed to an end portion of the roller.

6. The roller system of claim 5, wherein the induction generator includes one or more induction heating coils disposed adjacent to an end of the roller.

7. The roller system of claim 6, wherein the one or more induction heating coils are fixed as the roller rotates.

8. The roller system of claim 1 further includes a control unit coupled to the induction generator and operable to control the heating of portions of the roller.

9. The roller system of claim 8, wherein the control unit dynamically adjusts the heating of the portion of the roller using input from at least one temperature sensor that measures temperature along the roller.

10. The roller system of claim 8, wherein the control unit controls the induction generator using a closed-loop proportional-integral-derivative (PID) control system based on at least one of the thickness or load density of the material layer measured by an online metering device.

11. A kit for retrofitting a roller system to reduce thermal protrusions, comprising: Induction heating system, used to generate a magnetic field; as well as Heater assembly, configured to be thermally coupled to the roller, the heater assembly being used for: Receive the magnetic field from the induction heating system; as well as In response to receiving the magnetic field, heat is generated when thermally coupled to the roller to thermally expand at least a portion of the roller.

12. The kit of claim 11, wherein the heater assembly comprises: A first component, made of a ferromagnetic material, generates eddy currents in response to receiving the magnetic field; as well as The second component, made of a thermally conductive material, transfers the heat generated by the eddy current to the roller.

13. The kit of claim 11, wherein the induction heating system comprises one or more induction heating coils configured to be placed adjacent to one or both ends of the roller.

14. The kit of claim 13, wherein the one or more induction heating coils are configured to be fixed to a bearing housing supporting the roller as the roller rotates.

15. The kit of claim 13, wherein the one or more induction heating coils are divided into two parts to accommodate the journal of the roller.

16. The kit of claim 11, further comprising: One or more temperature sensors are used to monitor the temperature of the roller; as well as The control unit is configured to control the induction heating system based on feedback from the one or more temperature sensors.

17. The kit of claim 16, wherein the control unit controls the induction heating system based on at least one of the thickness of the material layer or the load density.

18. The kit of claim 11, wherein the heater assembly comprises: The first ring has a first inner diameter and a first outer diameter; and The second ring has a second inner diameter smaller than the first inner diameter and a second outer diameter substantially the same as the first outer diameter. The first ring and the second ring are coupled to each other such that the first outer diameter and the second outer diameter are substantially aligned.

19. The kit of claim 18, wherein the first ring and the second ring each comprise a first half and a second half, wherein the first half of the first ring is coupled to the first half of the second ring, and wherein the second half of the first ring is coupled to the second half of the second ring.

20. A method of manufacturing electrodes for an energy storage device using a roller system, the roller system including an induction heating system and a heater assembly coupled to the roller, the method comprising: The induction heating system is used to generate a magnetic field; The magnetic field is received at the heater assembly coupled to the roller; Heat is generated in the heater assembly in response to receiving the magnetic field; The generated heat causes at least a portion of the roller to thermally expand; Ensure that the roller is sufficiently heated; as well as In response to determining that the roller is sufficiently heated, roller operation is performed to form the electrode.

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