Roll-to-roll machine and method for gauge repeatability and reproducibility

Abstract

A roll-to-roll machine and a method of gauge repeatability and reproducibility are provided. Disclosed are methods of testing and / or operating a roll-to-roll machine including a floating unwinder with its attached edge positioning sensor, and a floating rewinder with an attached edge positioning sensor.

Description

Technical Field

[0001] The technical field generally involves roll-to-roll machines and methods for repeatability and reproducibility. Background Technology

[0002] In a roll-to-roll machine, a substrate can be moved from the unwinding roller to the take-up roller, and various processes can be performed on the substrate during the process of moving from the unwinding roller to the take-up roller.

[0003] Accordingly, it is desirable to provide roll-to-roll machines and methods for testing and / or operating roll-to-roll machines, methods that allow for gauge repeatability and reproducibility using roll-to-roll machines. Furthermore, other desired features and characteristics of patentable variations will become apparent, taken in conjunction with the accompanying drawings and the foregoing introduction, based on the following detailed description and appended claims. Summary of the Invention

[0004] Multiple variations may include a method comprising: (a) moving a substrate marked with a plurality of sample locations on the substrate in a first longitudinal direction such that each of the plurality of sample locations moves past a sensor; (b) keeping the sensor in a constant position relative to a first side edge and a second side edge of the substrate as the plurality of sample locations move past the sensor; (c) using the sensor at each sample location to collect data about the properties of the substrate; (d) moving the substrate marked with the plurality of sample locations on the substrate in a second longitudinal direction opposite to the first longitudinal direction such that each of the plurality of sample locations moves past the sensor in the opposite direction; and (e) repeating action (ad).

[0005] Multiple variations may include a method in which multiple sample locations include at least five sample locations.

[0006] Multiple variations may include a method in which repeated action (ad) is performed multiple times, including repeated action (ad) eight times, to collect fifty data points about the properties of the substrate.

[0007] Multiple variations may include a method in which a sensor is configured and arranged to measure the thickness of a substrate.

[0008] Multiple variations may include a method in which the substrate comprises a battery electrode material.

[0009] Multiple variations may include a method in which each of a plurality of sample locations is identified by spaced-out pieces of tape or markers.

[0010] Multiple variations may include a method that further includes laterally moving the substrate when the substrate is moved in a first longitudinal direction.

[0011] Multiple variations may include a method in which the battery electrode material comprises a metal foil.

[0012] Multiple variations may include a method comprising: providing a roll-to-roll machine comprising: a floating unwinder including: an unwinding roller and an unwinding linear actuator for moving the unwinding roller in a first lateral direction and a second lateral direction; an unwinding motor coupled to the unwinding roller to rotate the unwinding roller in a first rotational direction and a second rotational direction opposite to the first rotational direction; a substrate partially wound on the unwinding roller; a first plurality of rollers for moving the substrate through the floating unwinder; a first edge positioning sensor attached to the floating unwinder for lateral movement therewith; a feeding unit having a second plurality of rollers for moving the substrate through the feeding unit; a second edge positioning sensor attached to the feeding unit, the feeding unit being fixed in position; an unloading unit having a third plurality of rollers for moving the substrate through the unloading unit; and a third edge positioning sensor. An edge positioning sensor is attached to an unwinding unit, which is fixed in position; a floating rewinder includes: a winding roller and a winding linear actuator for moving the winding roller in a first lateral direction and a second lateral direction; a winding motor coupled to the winding roller to rotate the winding roller in a first rotational direction and a second rotational direction opposite to the first rotational direction; a substrate wound on the winding roller; the floating rewinder includes a fourth plurality of rollers for moving the substrate through the floating rewinder; a fourth edge positioning sensor attached to the floating rewinder for lateral movement therewith; and an electronic controller including an electronic processor, a non-transitory storage medium having instructions stored thereon and executable by the electronic processor, the electronic controller being operatively connected to the unwinding linear actuator, the first edge positioning sensor, the second edge positioning sensor, the third edge positioning sensor, the fourth edge positioning sensor, the unwinding linear actuator, and the winding linear actuator;A portion of the substrate is moved from the floating unwinder to the floating rewinder, wherein the substrate passes a first edge positioning sensor and a second edge positioning sensor. An electronic controller uses data from the second edge positioning sensor to determine a first position of the substrate when it enters the feeding unit and issues a first command to the unwinding linear actuator to move the unwinding roller in a first or second lateral direction, thereby adjusting the substrate as it enters the feeding unit. The substrate passes through an unloading unit and a third and fourth edge positioning sensor. The electronic controller uses data from the fourth edge positioning sensor to determine a second position of the substrate when it enters the floating rewinder, and issues a second command to the rewinding linear actuator to move the rewinding roller in the first or second lateral direction, such that the substrate is wound onto the rewinding roller at a predetermined position on the rewinding roller. The substrate is moved from the floating take-up machine to the floating unwinder, wherein the substrate passes through a fourth edge positioning sensor and a third edge positioning sensor, wherein the electronic controller uses data from the third edge positioning sensor to determine a third position of the substrate when the substrate enters the unwinding unit, and issues a third command to the take-up linear actuator to move the take-up roller in a first lateral direction or a second lateral direction, thereby adjusting the substrate when it enters the unwinding unit, wherein the substrate passes through the feeding unit and the second edge positioning sensor and the first edge positioning sensor, and wherein the electronic controller uses data from the first edge positioning sensor to determine a fourth position of the substrate when the substrate enters the floating unwinder, and wherein the electronic controller issues a fourth command to the unwinding linear actuator to move the take-up roller in a first lateral direction or a second lateral direction, such that the substrate is wound onto the unwinding roller at a predetermined positioning position on the unwinding roller.

[0013] Multiple variations may include a method in which the substrate includes a plurality of sample locations marked on the substrate in a first longitudinal direction, such that when a portion of the substrate is moved from a floating unwinder to a floating rewinder, the plurality of sample locations move past a sensor.

[0014] Multiple variations may include a method that further includes maintaining the sensor in a constant position relative to a first and second side edge of the substrate as multiple sample positions move past the sensor.

[0015] Multiple variations may include a method in which multiple sample locations include at least five sample locations.

[0016] Multiple variations may include a method in which a sensor is configured and arranged to measure the thickness of a substrate.

[0017] Multiple variations may include a method in which the substrate comprises a battery electrode material.

[0018] Multiple variations may include a method in which each of a plurality of sample locations is identified by spaced-out pieces of tape or markers.

[0019] Multiple variations may include a system comprising: a roll-to-roll machine including: a floating unwinder including: an unwinding roller and an unwinding linear actuator for moving the unwinding roller in a first lateral direction and a second lateral direction; an unwinding motor coupled to the unwinding roller to rotate the unwinding roller in a first rotational direction and a second rotational direction opposite to the first rotational direction; a substrate partially wound on the unwinding roller; a first plurality of rollers for moving the substrate through the floating unwinder; a first edge positioning sensor attached to the floating unwinder for lateral movement therewith; a feeding unit having a second plurality of rollers for moving the substrate through the feeding unit; a second edge positioning sensor attached to the feeding unit, the feeding unit being fixed in position; an unloading unit having a third plurality of rollers for moving the substrate through the unloading unit; and a third edge positioning sensor. A positioning sensor is attached to an unloading unit, which is fixed in position; a floating rewinder includes: a take-up roller and a take-up linear actuator for moving the take-up roller in a first lateral direction and a second lateral direction; a take-up motor coupled to the take-up roller to rotate the take-up roller in a first rotational direction and a second rotational direction opposite to the first rotational direction; a substrate wound on the take-up roller; the floating rewinder includes a fourth plurality of rollers for moving the substrate through the floating rewinder; a fourth edge positioning sensor attached to the floating rewinder for lateral movement therewith; and an electronic controller including an electronic processor, a non-transitory storage medium having instructions stored thereon and executable by the electronic processor, the electronic controller being operatively connected to the unwind linear actuator, the first edge positioning sensor, the second edge positioning sensor, the third edge positioning sensor, the fourth edge positioning sensor, the unwind linear actuator, and the take-up linear actuator;The electronic controller is configured to perform the following actions: moving a portion of the substrate from a floating unwinder to a floating rewinder, wherein the substrate passes a first edge positioning sensor and a second edge positioning sensor; wherein the electronic controller uses data from the second edge positioning sensor to determine a first position of the substrate when the substrate enters the feeding unit, and issues a first command to the unwinding linear actuator to move the unwinding roller in a first lateral direction or a second lateral direction, thereby adjusting the substrate when it enters the feeding unit; wherein the substrate passes through an unloading unit and a third and a fourth edge positioning sensor; and wherein the electronic controller uses data from the fourth edge positioning sensor to determine a second position of the substrate when it enters the floating rewinder; and wherein the electronic controller issues a second command to the rewinding linear actuator to move the rewinding roller in the first lateral direction or the second lateral direction, such that the substrate is pre-positioned on the rewinding roller. The substrate is wound onto a take-up roller; the substrate is moved from a floating take-up machine to a floating unwinder, wherein the substrate passes a fourth edge positioning sensor and a third edge positioning sensor, wherein the electronic controller uses data from the third edge positioning sensor to determine a third position of the substrate when the substrate enters the unwinding unit, and issues a third command to the take-up linear actuator to move the take-up roller in a first lateral direction or a second lateral direction, thereby adjusting the substrate when the substrate enters the unwinding unit, wherein the substrate passes through a feeding unit and a second edge positioning sensor and a first edge positioning sensor, and wherein the electronic controller uses data from the first edge positioning sensor to determine a fourth position of the substrate when the substrate enters the floating unwinder, and wherein the electronic controller issues a fourth command to the unwinding linear actuator to move the take-up roller in a first lateral direction or a second lateral direction, such that the substrate is wound onto the unwinding roller at a predetermined positioning point on the unwinding roller.

[0020] Multiple variations may include a system in which a substrate includes a plurality of sample locations marked on the substrate in a first longitudinal direction, such that when a portion of the substrate is moved from a floating unwinder to a floating rewinder, the plurality of sample locations move past a sensor.

[0021] Multiple variations may include a system that further includes maintaining the sensor in a constant position relative to a first and second side edge of the substrate as multiple sample positions move past the sensor.

[0022] Multiple variations may include a system in which the substrate comprises battery electrode material.

[0023] Multiple variations may include a system in which the substrate comprises a metal foil. Attached Figure Description

[0024] The illustrative variations will be described below with reference to the following figures, wherein the same numerals denote the same elements, and wherein:

[0025] Figure 1 It is a schematic diagram of a substrate with multiple sample locations according to multiple variations, which can be identified by tape or markings;

[0026] Figure 2 This is a flowchart of a method based on multiple variations, which may include sensing multiple marker locations on a substrate;

[0027] Figure 3 It is a schematic diagram of a portion of a roll-to-roll machine, including a floating unwinder or a floating rewinder, based on multiple variations.

[0028] Figure 4 It is a schematic diagram of the unwinding machine and the feeding unit of a roll-to-roll machine based on multiple variations;

[0029] Figure 5 It is a schematic diagram of a portion of a roll-to-roll machine, including a floating rewinder and an exit unit, based on multiple variations.

[0030] Figure 6 It is a schematic diagram of a roll-to-roll machine operating in the forward direction according to several variations, wherein the substrate moves from a floating unwinder to a floating rewinder;

[0031] Figure 7 It is a schematic diagram of a roll-to-roll machine operating in reverse direction according to several variations, wherein the substrate moves from a floating take-up machine to a floating unwinder;

[0032] Figure 8 It is a schematic diagram of a feeding loop based on several variations, including an edge positioning sensor that provides data to an electronic controller that can issue commands to a lateral actuator.

[0033] Figure 9A and Figure 9B A flowchart of a method according to several variations is shown, which may include sensing multiple marked locations on a substrate. Detailed Implementation

[0034] The following detailed description is illustrative in nature only and is not intended to limit application or use. Furthermore, it is not intended to be bound by any express or implied theory presented in the foregoing introduction, description of the figures, summary of the invention, or the following detailed description.

[0035] refer to Figure 1Product 30 may include a substrate 32 having a plurality of sample locations 1, 2, 3, 4, 5, each of which may be identified in various ways, including but not limited to using a pair of spaced-apart tape pieces or markers 42. The substrate 32 may be generally flat and may have a first surface 34 and a second surface 36. The substrate 32 may have a first side edge 38 and a second side edge 40 opposite to the first side edge 38. The substrate 32 may be movable in a first longitudinal direction 46 or a second longitudinal direction 48 opposite to the first longitudinal direction 46. A sensor 44 may be used to determine the properties of the substrate 32 and may be held in a constant position relative to the first side edge 38 and the second side edge 40, for example, when the substrate 32 is moved in the first longitudinal direction 46. In various variations, the sensor 44 may be a property sensor, which may be a thickness gauge constructed and arranged to measure the thickness of the substrate 32 at each of the sample locations 1, 2, 3, 4, 5. For multiple passes of the substrate 32 moving in the first longitudinal direction 46, data can be collected from the sensor 44 using an electronic controller 96. For example, the substrate 32 can move in the first longitudinal direction 46 such that each sample position 1, 2, 3, 4, 5 passes the sensor 44. Subsequently, the substrate 32 can move in the second longitudinal direction 48 such that each of the sample positions moves in the opposite direction past the sensor 44. This process can then be repeated several times. For example, to collect fifty substrate thickness measurements, the process can be repeated nine times. Repeating this process to collect fifty thickness measurements can be used to verify the repeatability and reproducibility test standards / requirements for Type 3 gauges. The thickness of the substrate can be measured using any of a variety of thickness measurement sensors known to those skilled in the art. Thickness measurement sensors typically operate by measuring the distance between two surfaces of a material using methods such as laser triangulation, where a laser beam is projected onto the surface and the reflected light is analyzed to determine the distance. Thickness is calculated by subtracting the distance to the top surface from the distance to the bottom surface, usually achieved using two sensors located on opposite sides of the material. Other methods include capacitive sensing, where the change in capacitance between the sensor and the material is proportional to the thickness, or ultrasound, where the time required for an ultrasonic pulse to travel through the material is used to calculate the thickness.

[0036] refer to Figure 2The method may include a first action 50, which may include moving a substrate marked or labeled with a plurality of sample positions on the substrate in a first longitudinal direction, such that the plurality of sample positions move past a sensor. A second action 52 may include keeping the sensor in a constant position relative to a first side edge and a second side edge of the substrate as the plurality of sample positions move past the sensor. A third action may include using the sensor at each of the plurality of sample positions to collect data about the properties of the substrate. A fourth action may include moving the substrate marked with the plurality of sample positions in a second longitudinal direction opposite to the first direction, such that the plurality of sample positions move in the opposite direction past the sensor. Thereafter, the first action 50, the second action 52, the third action 54, and the fifth action 56 may be repeated in sequence multiple times. When the substrate 32 moves in the first longitudinal direction 46, the substrate may also move in a first transverse direction or a second transverse direction opposite to the first transverse direction. The sensor 44 remains in a constant position relative to a first side edge 38 and a second side edge 40 of the substrate. Thus, when the substrate moves in the first transverse direction or the second transverse direction, the sensor 44 may be positioned to move together with the substrate 32.

[0037] Now for reference Figure 3 Product 30 (which may be a roll-to-roll machine) may include a floating unwinder 58, which may include a motor 60 having a shaft 62 rotatably driven by the motor 60. Shaft 62 may be coupled to an unwinding roller 64 on which substrate 32 may be wound or unwound. An unwinding linear actuator 68 may be coupled to a housing 66 such that unwinding roller 64 may be movable in a first lateral direction 70 and a second lateral direction 72 opposite to the first lateral direction 70. Unwinding linear actuator 68 may be of any type known to those skilled in the art, including but not limited to rack and pinion linear actuators or ball screw linear actuators. Alternatively, unwinding linear actuator 68 may be positioned to move at least one of unwinding roller 64 or shaft 62. The floating unwinder may be configured such that at least unwinding roller 64 may be moved in the first lateral direction 70 and the second lateral direction 72 in response to data collected from an edge positioning sensor that measures the position of at least one of the first side edge 38 or the second side edge 40 of substrate 32 (e.g., ...). Figures 6-7(As shown). During testing or operation of the roll-to-roll machine 31, the substrate 32 may move laterally, which would cause the substrate 32 to be telescoping onto the unwinding roller 64, which is undesirable. The electronic controller can use data from the edge positioning sensor to command the unwinding linear actuator 68 to move the unwinding roller at a first lateral positioning or a second lateral positioning, so that the substrate 32 is properly wound onto the unwinding roller 64, rather than telescoping. Furthermore, the unwinding linear actuator 68 can be used to position the substrate 32 in the appropriate position so that the processing equipment can operate on the substrate 32, which may include, but is not limited to, pressing the substrate 32 to a thickness within a predetermined range.

[0038] Figure 4 The diagram shows a portion of the roll-to-roll machine 31, including a floating unwinder 58 and a feeding unit 80. The floating unwinder 58 may include a motor and a shaft (in...). Figure 3 The floating unwinder 58 may include a housing 66 and an unwinding linear actuator 68 connected thereto. The floating unwinder 58 may include a first plurality of rollers 74 for guiding the flow of the substrate 32 as it is unwound or wound onto the unwinding roller 64 of the floating unwinder 58. A first edge positioning sensor 76 is attached to the floating unwinder 58 and moves laterally with the floating unwinder 58. The first edge positioning sensor 76 is located along a first side edge 38 or a second side edge 40 of the substrate 32 (in the best visible position). Figure 3 Positioned (best visible in the center). The feeding unit 80 may include a second plurality of rollers 82 to guide the substrate 32. A second edge positioning sensor 78 may be attached to the feeding unit 80. The feeding unit 80 is fixed or may be fixed to the floor. The edge positioning sensor 78 and the feeding unit 80 are fixed together and are not expected to move relative to each other. Both the first edge positioning sensor 76 and the second edge positioning sensor 78 may be along the first side edge 38 or the second side edge 40 of the substrate 32 (in the best visible position). Figure 3 The first edge positioning sensor 76 and the second edge positioning sensor 78 are positioned between the floating unwinder 58 and the feed unit 80, wherein the first edge positioning sensor 76 is closer to the floating winding machine than the second edge positioning sensor 78.

[0039] Figure 5The diagram shows portions of a roll-to-roll machine 31 including an unloading unit 84 and a floating rewinder 92. The unloading unit 84 may include a third plurality of rollers 86 to guide the substrate 32. The unloading unit 84 is fixed or may be fixed to the floor. A third edge positioning sensor 88 and the unloading unit 84 are fixed together and are not expected to move relative to each other. The floating rewinder 92 may be constructed similarly to the floating unwinder 58. The floating rewinder 92 may include a motor 60 and a shaft 62 (in... Figure 3 The floating winder 92 may include a housing 66 and a winding linear actuator 69 connected thereto. The floating winder 92 may include a fourth plurality of rollers 94 for guiding the flow of the substrate 32 as it unwinds or winds onto the winding roller 65 of the floating winder 92. A fourth edge positioning sensor 90 is attached to the floating winder 92 and moves laterally with it. Both the third edge positioning sensor 88 and the fourth edge positioning sensor 90 may be along the first side edge 38 or the second side edge 40 (in the best visible position). Figure 3 The third edge positioning sensor 88 and the fourth edge positioning sensor 90 can be positioned between the floating winder 92 and the discharge unit 84, wherein the fourth edge positioning sensor 90 is closer to the floating winder 92 than the third edge positioning sensor 88.

[0040] refer to Figure 6 Product 30 (which may be a roll-to-roll machine) can be operated such that substrate 32 moves in a first longitudinal direction 46 from floating unwinder 58 toward floating rewinder 92. As substrate 32 moves in the first longitudinal direction 46, a second edge positioning sensor 78 attached to feed unit 80 is used to measure the position of substrate 32 before feed unit 80. Data from the first edge positioning sensor 76 is not needed when the substrate is unwound from floating unwinder 58. Substrate 32 moves past the second edge positioning sensor 78, through feed unit 80, into unwrap unit 84, and then past a third edge positioning sensor 88. Data from the third edge positioning sensor 88 is not needed when the substrate moves in the first longitudinal direction 46. Substrate 32 moves from the third edge positioning sensor 88 past a fourth edge positioning sensor 90. Data from the fourth edge positioning sensor is used to move the winding linear actuator 69 of the floating winding machine 92 in the lateral direction to properly wind the substrate 32 onto the winding roller 65 of the floating winding machine 92 and avoid winding the substrate 32 in a stacked manner.

[0041] refer to Figure 7The substrate 32 can move from the floating winder 92 to the floating unwinder 58 in the second longitudinal direction 48. The substrate 32 moves from the floating winder 92, passing the fourth edge positioning sensor 90 and the third edge positioning sensor 88. When the substrate 32 moves in the second longitudinal direction 48, data from the fourth edge positioning sensor 90 may not be used. Data from the third edge positioning sensor 88 is collected and used to determine the position of the substrate 32 when it enters the discharge unit 84. The substrate 32 moves from the discharge unit 84 to the feed unit 80. The substrate 32 moves from the feed unit 80, passing the second edge positioning sensor 78 and the first edge positioning sensor 76. When the substrate moves in the second longitudinal direction 48, data from the second edge positioning sensor 78 may not be collected. Data from the first edge positioning sensor 76 is used to move the roller in the lateral direction of the linear actuator of the floating unwinder 58 so that the substrate 32 is wound onto the unwinding roller 64 in a properly aligned manner and to avoid the substrate 32 being wound onto the unwinding roller 64 of the floating unwinder 58 in a stacked manner.

[0042] refer to Figure 8 The first edge positioning sensor 76, the second edge positioning sensor 78, the third edge positioning sensor 88, and the fourth edge positioning sensor 90 can be operatively connected so that data can be transmitted to the electronic controller 96, and commands can be issued to the unwinding linear actuator 68 of the floating unwinder 58 or the winding linear actuator 69 of the floating rewinder 92 (in Figures 6-7 (Best visible in the document). The electronic controller 96 may include an electronic processor 98 and a non-transitory computer-readable medium 100 on which instructions 102 are stored, which can be executed by the electronic processor 98 to perform any of the actions or methods disclosed herein.

[0043] Figure 9A and Figure 9BA flowchart of a method is shown, which may include providing action 120: providing a roll-to-roll machine comprising: a floating unwinder including: an unwinding roller and an unwinding linear actuator for moving the unwinding roller in a first lateral direction and a second lateral direction; an unwinding motor coupled to the unwinding roller to rotate the unwinding roller in a first rotational direction and a second rotational direction opposite to the first rotational direction; a substrate partially wound on the unwinding roller; a first plurality of rollers for moving the substrate through the floating unwinder; a first edge positioning sensor attached to the floating unwinder for lateral movement therewith; a feeding unit having a second plurality of rollers for moving the substrate through the feeding unit; a second edge positioning sensor attached to the feeding unit, the feeding unit being fixed in position; an unloading unit having a third plurality of rollers for moving the substrate through the unloading unit; and a third edge positioning sensor. A third edge positioning sensor is attached to an unloading unit, which is fixed in position; a floating rewinder includes: a rewinding roller and a rewinding linear actuator for moving the rewinding roller in a first lateral direction and a second lateral direction; a rewinding motor coupled to the rewinding roller to rotate the rewinding roller in a first rotational direction and a second rotational direction opposite to the first rotational direction; a substrate wound on the rewinding roller; the floating rewinder includes a fourth plurality of rollers for moving the substrate through the floating rewinder; a fourth edge positioning sensor is attached to the floating rewinder for lateral movement therewith; an electronic controller including an electronic processor and a non-transitory storage medium having instructions stored thereon and executable by the electronic processor; the electronic controller is operatively connected to the unwinding linear actuator, the first edge positioning sensor, the second edge positioning sensor, the third edge positioning sensor, the fourth edge positioning sensor, the unwinding linear actuator, and the rewinding linear actuator.Action 122: A portion of the substrate is moved from the floating unwinder to the floating rewinder, wherein the substrate passes a first edge positioning sensor and a second edge positioning sensor, wherein the electronic controller uses data from the second edge positioning sensor to determine a first position of the substrate when the substrate enters the feeding unit, and issues a first command to the unwinding linear actuator to move the unwinding roller in a first lateral direction or a second lateral direction, thereby adjusting the substrate when it enters the feeding unit, wherein the substrate passes an unloading unit and a third edge positioning sensor and a fourth edge positioning sensor, and wherein the electronic controller uses data from the fourth edge positioning sensor to determine a second position of the substrate when the substrate enters the floating rewinder, and wherein the electronic controller issues a second command to the rewinding linear actuator to move the rewinding roller in the first lateral direction or the second lateral direction, such that the substrate is wound onto the rewinding roller at a predetermined position on the rewinding roller. Action 124: Moving the substrate from the floating take-up machine to the floating unwinder, wherein the substrate passes the fourth edge positioning sensor and the third edge positioning sensor, wherein the electronic controller uses data from the third edge positioning sensor to determine the third position of the substrate when the substrate enters the unwinding unit, and issues a third command to the take-up linear actuator to move the take-up roller in the first lateral direction or the second lateral direction, thereby adjusting the substrate when the substrate enters the unwinding unit, wherein the substrate passes the feed unit and the second edge positioning sensor and the first edge positioning sensor, and wherein the electronic controller uses data from the first edge positioning sensor to determine the fourth position of the substrate when the substrate enters the floating unwinder, and wherein the electronic controller issues a fourth command to the unwinding linear actuator to move the take-up roller in the first lateral direction or the second lateral direction, such that the substrate is wound onto the unwinding roller at a predetermined positioning position on the unwinding roller.

[0044] While at least one variation has been presented in the foregoing detailed description, it should be understood that numerous variations exist. It should also be understood that one or more variations are merely examples and are not intended to limit the scope, applicability, or configuration of this disclosure in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient roadmap for implementing one or more illustrative variations. It should be understood that various changes can be made to the function and arrangement of the elements without departing from the scope of this disclosure as set forth in the appended claims and their legal equivalents.

Claims

1. A method comprising: (a) The substrate marked with a plurality of sample positions on the substrate is moved in a first longitudinal direction such that each of the plurality of sample positions moves past the sensor; (b) When the plurality of sample positions move past the sensor, the sensor is kept in a constant position relative to the first and second side edges of the substrate; (c) Use the sensor at each sample location to collect data on the properties of the substrate; (d) Moving the substrate marked with the plurality of sample positions on the substrate in a second longitudinal direction opposite to the first longitudinal direction, such that each of the plurality of sample positions moves in the opposite direction past the sensor; and (e) Repeated actions (ad).

2. The method according to claim 1, wherein the plurality of sample locations includes at least five sample locations.

3. The method of claim 1, wherein repeating action (ad) multiple times includes repeating action (ad) eight times to collect fifty data points regarding the properties of the substrate.

4. The method of claim 1, wherein the sensor is configured and arranged to measure the thickness of the substrate.

5. The method of claim 4, wherein the substrate comprises a battery electrode material.

6. The method of claim 1, wherein each of the plurality of sample locations is identified by spaced-out pieces of tape or markers.

7. The method of claim 1, further comprising moving the substrate laterally when the substrate moves in the first longitudinal direction.

8. The method of claim 5, wherein the battery electrode material comprises a metal foil.

9. A system comprising: A roll-to-roll machine, comprising: a floating unwinder, the floating unwinder including: an unwinding roller and an unwinding linear actuator for moving the unwinding roller in a first lateral direction and a second lateral direction; an unwinding motor coupled to the unwinding roller to rotate the unwinding roller in a first rotational direction and a second rotational direction opposite to the first rotational direction; a substrate partially wound on the unwinding roller; a first plurality of rollers for moving the substrate through the floating unwinder; a first edge positioning sensor attached to the floating unwinder for lateral movement therewith; a feeding unit having a second plurality of rollers for moving the substrate through the feeding unit; a second edge positioning sensor attached to the feeding unit, the feeding unit being fixed in position; an unloading unit having a third plurality of rollers for moving the substrate through the unloading unit; and a third edge positioning sensor attached to the unloading unit. The unloading unit is fixed in position; a floating rewinder includes: a take-up roller and a take-up linear actuator for moving the take-up roller in a first lateral direction and a second lateral direction; a take-up motor coupled to the take-up roller to rotate the take-up roller in a first rotational direction and a second rotational direction opposite to the first rotational direction; a substrate wound on the take-up roller; the floating rewinder includes a fourth plurality of rollers for moving the substrate through the floating rewinder; a fourth edge positioning sensor attached to the floating rewinder for lateral movement therewith; and an electronic controller including an electronic processor, a non-transitory storage medium having instructions stored thereon and executable by the electronic processor, the electronic controller being operatively connected to the unwind linear actuator, the first edge positioning sensor, the second edge positioning sensor, the third edge positioning sensor, the fourth edge positioning sensor, the unwind linear actuator, and the take-up linear actuator. The electronic controller is configured to perform actions including the following: A portion of the substrate is moved from the floating unwinder to the floating rewinder, wherein the substrate passes through the first edge positioning sensor and the second edge positioning sensor, wherein the electronic controller uses data from the second edge positioning sensor to determine a first position of the substrate when the substrate enters the feeding unit, and issues a first command to the unwinding linear actuator to move the unwinding roller in the first lateral direction or the second lateral direction, thereby adjusting the substrate when the substrate enters the feeding unit, wherein the substrate passes through the discharge unit and the third edge positioning sensor and the fourth edge positioning sensor, and wherein the electronic controller uses data from the fourth edge positioning sensor to determine a second position of the substrate when the substrate enters the floating rewinder, and wherein the electronic controller issues a second command to the rewinding linear actuator to move the rewinding roller in the first lateral direction or the second lateral direction, such that the substrate is wound onto the rewinding roller at a predetermined position on the rewinding roller; and The substrate is moved from the floating take-up machine to the floating unwinder, wherein the substrate passes the fourth edge positioning sensor and the third edge positioning sensor, wherein the electronic controller uses data from the third edge positioning sensor to determine a third position of the substrate when the substrate enters the discharge unit, and issues a third command to the take-up linear actuator to move the take-up roller in the first lateral direction or the second lateral direction, thereby adjusting the substrate when the substrate enters the discharge unit, wherein the substrate passes the feed unit and the second edge positioning sensor and the first edge positioning sensor, and wherein the electronic controller uses data from the first edge positioning sensor to determine a fourth position of the substrate when the substrate enters the floating unwinder, and wherein the electronic controller issues a fourth command to the unwind linear actuator to move the take-up roller in the first lateral direction or the second lateral direction, such that the substrate is wound onto the unwind roller at a predetermined positioning position on the unwind roller.

10. The system of claim 9, wherein the substrate includes a plurality of sample positions marked on the substrate in a first longitudinal direction, such that when a portion of the substrate is moved from the floating unwinder to the floating rewinder, the plurality of sample positions move past a sensor.

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