Method for producing a metal sheet

Abstract

A method for producing a metal sheet (900, 1340), the method comprising: Extruding (200) a component along an extrusion axis (302, 402, 1104, 1304), the component having a wall (304, 404, 1108, 1308) at least partially defining an interior region (306, 406, 1110, 1310), the component comprising a metal; Cutting (208) the wall (304, 404, 1108, 1308) substantially parallel to the extrusion axis (302, 402, 1104, 1304), the wall (304, 404, 1108, 1308) defining a cross-section perpendicular to the extrusion axis (302, 402, 1104, 1304), the cross-section forming a closed curve prior to cutting (208); Unrolling (216) the wall (304, 404, 1108, 1308) to form a sheet precursor (800, 1140, 1320) having a first thickness (308, 408) and a first transverse dimension (310); and Rolling (224) the sheet precursor (800, 1140, 1320) along a rolling axis (904, 1144, 1334) to form the metal sheet (900, 1340), wherein the metal sheet (900, 1340) has a second thickness (910) perpendicular to the rolling axis (904, 1144, 1334), the second thickness being less than the first thickness, and a second transverse dimension (802) parallel to the rolling axis (904, 1144, 1334), the second transverse dimension (802) being greater than the first transverse dimension (310), wherein the cutting (208) is performed with a tool (1120) comprising a body (1122) defining a tool axis (1123) and a blade (1124) extending from the body (1122), the cutting (208) comprises moving one of the tool (1120) and the component with respect to the other of the tool (1120) and the component such that the body (1122) is at least partially located within the interior region (306, 406, 1110, 1310) and the blade (1124) cuts through the wall (304, 404, 1108, 1308), the body (1122) defines a cone or a truncated cone extending between a first end (1134) and a second end (1136), the second end (1136) including a base of the cone or truncated cone, and the first end (1134) enters the inner region (306, 406, 1110, 1310) before the second end (1136) during cutting (208).

Description

INITIATIONThe information provided in this section is intended to generally illustrate the context of the disclosure. Work of the present inventors, insofar as described in this introduction, as well as aspects of the description that may not otherwise be considered prior art at the time of filing, is neither expressly nor silently admitted as prior art against this disclosure.The present disclosure relates to methods of manufacturing a metal sheet.High energy density electrochemical cells, such as lithium ion batteries, can be used in a variety of consumer goods and vehicles, such as hybrid or electric vehicles. Battery-powered vehicles are promising as a transportation capability due to the continuous advances in battery performance and life. Batteries may include components made of or including metal sheets or foils.The document DE 28 38 980 A1 discloses a method for producing a metal strip, in which a tubular part is cast with a slit and subsequently bent up and flat rolled.It is an object of the invention to provide a method which enables the production of metal sheets of greater width without the use of complex installations.This object is achieved according to the invention by the features of claim 1. Advantageous further developments are evident from the dependent claims.BRIEF DESCRIPTION OF THE DRAWINGSThe present disclosure will become more fully understood from the detailed description and the accompanying drawings, wherein: FIG. 1 is a flow diagram illustrating a method of manufacturing a metal sheet according to various aspects of the present disclosure; FIG. 2 is a perspective view of an extruded cylinder according to various aspects of the present disclosure; FIG. 3 is a cross-sectional view of an extruded coil according to various aspects of the present disclosure; FIG. 4 is a perspective view of a cylinder formed by increasing a length of the cylinder of FIG. 2, in accordance with various aspects of the present disclosure; FIG. 5 is a perspective view of a cylinder formed by increasing a diameter of the cylinder of FIG. 2, in accordance with various aspects of the present disclosure; FIG. 6 is a perspective view of a cut cylinder formed by opening a wall of the cylinder of FIG. 2, in accordance with various aspects of the present disclosure; FIG. 7 is a perspective view of a sheet metal precursor formed by unrolling a wall of the cut cylinder of FIG. 6, in accordance with various aspects of the present disclosure; FIG. 8 is a schematic illustration of a method of rolling the sheet metal precursor of FIG. 7 in accordance with various aspects of the present disclosure; FIG. 9 is a perspective view of a metal sheet formed by the rolling of FIG. 8 ; FIG. 10 is a schematic view illustrating a method of manufacturing a metal sheet according to various aspects of the present disclosure; FIG. 11 is a perspective view of a cutting and lubricating tool according to various aspects of the present disclosure; and FIG. 12 is a schematic view illustrating a method of manufacturing a metal sheet according to various aspects of the present disclosure. In the drawings, reference numerals may be reused to identify similar and / or identical elements.DETAILED DESCRIPTIONFor a thorough disclosure, which will fully convey the scope to those skilled in the art, embodiments are provided. Numerous specific details are set forth, such as examples of specific compositions, components, devices, and methods, in order to provide a thorough understanding of the embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be used, that example embodiments may be embodied in many different forms, and that neither should be construed to limit the scope of the disclosure. In some embodiments, known processes, known device structures, and known techniques are not described in detail.The terminology used herein is for describing particular embodiments only and is not intended to be limiting. As used herein, the singular forms "a", "an / r / s", and "the" may also include the plural forms unless the context clearly indicates otherwise. The terms "comprise," "comprising," "include," and "have" are inclusive and thus indicate the presence of stated features, elements, compositions, steps, integers, operations, and / or components, but do not indicate the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. Although the open term "comprising" is to be understood as a non-limiting term that serves to describe and claim various embodiments set forth herein, in certain aspects, the term may alternatively be understood as a more limiting and restrictive term, such as "consisting of" or "consisting essentially of.". Therefore, for any given embodiment specifying compositions, materials, components, elements, features, integers, operations, and / or method steps, the present disclosure expressly includes also embodiments consisting of or consisting essentially of such specified compositions, materials, components, elements, features, integers, operations, and / or method steps. In the case of "consisting of", the alternative embodiment excludes any additional compositions, materials, components, elements, features, integers, operations, and / or process steps, while in the case of "consisting essentially of", any additional compositions, materials, components, elements, features, integers, operations, and / or process steps that materially affect the basic and novel characteristics are excluded from such an embodiment, but any compositions, materials, components, elements, features, integers, operations, and / or process steps that do not materially affect the basic and novel characteristics may be included in the embodiment.All method steps, processes, and operations described herein are not to be construed as necessarily requiring execution in the particular order discussed or illustrated, unless expressly characterized as the order of execution. It will also be appreciated that additional or alternative steps may be employed, unless otherwise indicated.When a component, element, or layer is referred to as being "on" or "engaged to" another element or layer, or as being "connected" or "coupled" to or the same, it may be directly on or engaged to or connected to or coupled to the other component, element, or layer, or intervening elements or layers may be present. On the other hand, when an element is referred to as being "directly on" or "directly engaged to" another element or layer, or as being "directly connected" or "directly coupled" to or the same, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between" versus "directly between," "adjacent," or "adjacent" versus "directly adjacent" or "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.Although the terms "first," "second," "third," etc. may be used herein to describe various steps, elements, components, regions, layers, and / or sections, these steps, elements, components, regions, layers, and / or sections are not intended to be limited by these terms unless otherwise specified. These terms may be used merely to distinguish one step, element, component, region, layer, or portion from another step, element, component, region, layer, or portion. Terms such as "first," "second," and other numerical terms, when used herein, do not imply a sequence or order unless the context clearly indicates. Thus, a first step, element, component, region, layer, or portion discussed below may be referred to as a second step, element, component, region, layer, or portion without departing from the teachings of the embodiments.Spatially or temporally relative terms such as "before," "after," "inner," "outer," "below," "under," "lower," "over," "upper," and the like may be used herein for convenience to describe the relationship of an element or feature to one or more other elements or features as illustrated in the figures. Spatially or temporally relative terms may be intended to include different orientations of the device or system in use or operation in addition to the orientation depicted in the figures.Throughout this disclosure, the numerical values represent approximate dimensions or limits for ranges to include minor deviations from the stated values and configurations that have approximately the stated value, as well as those values that have exactly the stated value. Unlike the working examples at the end of the detailed description, all numerical values of parameters (e.g., amounts or conditions) in this specification, including the appended claims, are to be understood as being modified in all instances by the term "about", regardless of whether or not "about" actually appears before the numerical value. "About" means that the numerical value indicated permits slight imprecision (with some approximation to the accuracy of the value, approximately or rather close to the value, fast). Where the imprecision given by "about" is not otherwise understood by this common meaning in the art, "about" as used herein means at least modifications that may result from common methods of measuring and using such parameters. For example, "about" may comprise a deviation of less than or equal to 5%, optionally less than or equal to 4%, optionally less than or equal to 3%, optionally less than or equal to 2%, optionally less than or equal to 1%, optionally less than or equal to 0.5%, and in certain aspects, optionally less than or equal to 0.1%.Moreover, the disclosure of ranges includes the disclosure of all values and further divided ranges within the entire range, including the endpoints and the sub-ranges indicated for the ranges.Referring now to the accompanying drawings, embodiments will be described in more detail.In various aspects, the present technique relates to rechargeable lithium-ion batteries that may be used in vehicles. A typical electrochemical cell includes a first electrode, such as a positive electrode or cathode, a second electrode, such as a negative electrode or anode, an electrolyte, and a separator. In a lithium ion battery pack, the electrochemical cells are often electrically connected into a stack to increase overall performance. Lithium ion electrochemical cells function by reversibly transferring lithium ions between the negative and positive electrodes. The separator and the electrolyte are disposed between the negative and positive electrodes. The electrolyte is suitable for conducting lithium ions and may be in liquid, gelled or solid form. The lithium ions move from a positive to a negative electrode when the battery is charged and in the opposite direction when the battery is discharged.Each of the negative and positive electrodes within a stack is typically electrically connected to a current collector (e.g., a metal such as copper for the negative electrode and aluminum for the positive electrode). During battery operation, the current collectors associated with the two electrodes are connected by an external circuit that allows the electron generated current to flow between the negative and positive electrodes to balance the transport of the lithium ions.The electrodes can generally be incorporated into various commercially available battery forms, for example prismatic cells, wound cylindrical cells, coin cells, pouch cells or other suitable cell forms. The cells may include a single electrode structure of each polarity or a stacked structure having a plurality of positive and negative electrodes arranged in electrical parallel and / or series connections. In particular, the battery may include a stack of alternating positive and negative electrodes with separators interposed therebetween. Although the positive electroactive materials may be used in batteries for primary use or single charge use, the resulting batteries generally have desirable cycle characteristics for secondary use over multiple cycles of the cells.Certain components of electrochemical cells, such as electrodes and / or current collectors, may be made from metal sheets or foils. In one example, a negative electrode includes metallic lithium and may be a lithium metal electrode ("LME"). The lithium ion battery may be a lithium metal battery or cell. Metallic lithium for use in the negative electrode of a rechargeable battery has various potential advantages, including the highest theoretical capacity and the lowest electrochemical potential. Thus, batteries with lithium metal anodes can have a higher energy density, which can double the storage capacity, so that the battery is only half as large.Sheet metal battery components, such as metal electrodes and current collectors for use in electrochemical cells (e.g., batteries), are typically made by extruding a sheet of metal (i.e., a substantially planar sheet) and then rolling the sheet until the desired thickness is reached. This can be carried out in a single-stage process, for example using an extrusion press. Standard extrusion presses are limited in sheet width (e.g., to about 100 mm width). Therefore, the resulting sheet widths are also limited without the use of more complex equipment in these methods.In various aspects, the present disclosure provides a method of manufacturing metal plates, for example for use in electrochemical cells. The method enables the production of metal sheets of greater width without the use of complex installations. The method generally includes extruding a three-dimensional ("3D") metal component having a wall that at least partially defines an interior region (e.g., a hollow cylinder, a spiral), derolling the wall of the 3D component to increase its width (e.g., in the case of a hollow cylinder, the original width is a diameter and the width after derolling is a π diameter), and then rolling the derolled wall to a desired thickness, thereby further increasing at least one transverse dimension. If the 3D component is a closed mold, e.g., a cylinder, the method also includes cutting or otherwise opening the wall prior to unrolling. The method may optionally include lubricating the wall prior to rolling, separating individual sheets prior to or after rolling, and / or expanding a dimension of the 3D shape prior to unrolling.Referring to FIG. 1, a method of making a metal sheet generally includes extruding a 3D component having a wall that at least partially defines an interior region at 200; selectively expanding one or more dimensions of the 3D component at 204; selectively opening the wall at 208 (i.e., when a cross-section of the 3D shape is a closed curve shape); selectively lubricating the wall at 212; unrolling the wall at 216; selectively forming one or more sheets at 220, for example, by cutting; rolling the wall / sheets to a desired thickness at 224; and optionally cutting the wall / sheets to form one or more sheets at 228. Each of these steps will be described in more detail below.At 200, the method includes extruding a 3D component having a wall that at least partially defines an interior region. A "3D component" is a component that has two dimensions (e.g., a width and a height) substantially perpendicular to the direction of extrusion that are of a similar order of magnitude (e.g., a difference in the order of magnitude less than or equal to about 2). In contrast to the 3D component according to certain aspects of the present disclosure, a sheet has a dimension (i.e., height / thickness) that is many orders of magnitude smaller than the other two dimensions (i.e., width, length). The 3D component is at least partially hollow such that it has a wall that at least partially defines an interior region. In certain aspects, the 3D component may be, for example, a cylinder, a spiral, a rectangular prism (e.g., a square prism), or an octagonal prism.The 3D component has a longitudinal axis that is parallel to the extrusion direction, as will be described in more detail below. The 3D component has a cross section which runs substantially parallel to its longitudinal axis and the extrusion direction. The cross section may be a closed or an open curve. Examples of closed curves are circles (see e.g. FIG. 2 ) and ellipses. An example of an open curve is a spiral (see, e.g., FIG. 3 ).The 3D component is formed of a metal, such as an elemental metal or an alloy. The metal may include lithium, magnesium, tin, indium, aluminum, copper, nickel, or any combination thereof. In certain aspects, the 3D component is substantially metal. In certain aspects, the metal may include one of the foregoing metals in combination with one or more other metals. In certain aspects, the metal may be provided in the form of an ingot or ingot prior to extrusion. The extrusion may be performed with a hydraulic press that forces the solid cylindrical ingot through a die and an embedded mandrel to create the cavity. Alternatively, the solid metal ingot may be slid around a mandrel held coaxial with the ingot, the wall thickness of the extrusion being defined by the difference between the outer dimension of the ingot and the outer dimension of the mandrel.Referring to FIG. 2, in various aspects, the 3D component is a cylinder 300. The barrel 300 may be extruded along an extrusion axis 302 aligned with a longitudinal axis 303 of the barrel 300. The cylinder 300 includes a wall 304. The wall 304 at least partially defines an interior region 306. The wall 304 may have a first thickness 308 of greater than or equal to about 2 mm, optionally greater than or equal to about 4 mm, optionally greater than or equal to about 6 mm, or optionally greater than or equal to about 8 mm. The first thickness 308 may be less than or equal to about 10 mm, optionally less than or equal to about 8 mm, optionally less than or equal to about 6 mm, or optionally less than or equal to about 4 mm. In certain aspects, the first thickness 308 may be greater than or equal to about 2 mm to less than or equal to about 10 mm, or optionally greater than or equal to about 4 mm to less than or equal to about 6 mm.The cylinder 300 defines a first dimension or length 310 that is substantially parallel to the extrusion axis 302. The cylinder 300 further defines a second dimension or height 312 and a third dimension or width 314 that is substantially perpendicular to the extrusion axis 302. The second and third dimensions 312, 314 may be substantially perpendicular to each other. In certain aspects, the first, second, and third dimensions 310, 312, 314 may be referred to as first, second, and third component dimensions, respectively. In certain aspects, the second and third dimensions 312, 314 may be discrete as the first dimension 310 continuously increases, e.g., in a continuous extrusion process. In certain aspects, the second and third dimensions 312, 314 are identical. For example, the cylinder 300 may be a straight, circular cylinder as shown, and the second and third dimensions 312, 314 may be a diameter. However, the second and third dimensions 312, 314 may be different. The second and third dimensions 312, 314 may each be greater than or equal to about 50 mm, optionally greater than or equal to about 100 mm, optionally greater than or equal to about 150 mm, optionally greater than or equal to about 200 mm, or optionally greater than or equal to about 250 mm. The second and third dimensions 312, 314 may each be less than or equal to about 300 mm, optionally less than or equal to about 250 mm, optionally less than or equal to about 200 mm, optionally less than or equal to about 150 mm, or optionally less than or equal to about 100 mm. In certain aspects, the second and third dimensions 312, 314 (e.g., the diameter) may be greater than or equal to about 50 mm to less than or equal to about 300 mm.Referring to FIG. 3, in various aspects, the 3D component is a scroll 400. The coil 400 may be extruded along an extrusion axis 402 that protrudes from the side. The scroll 400 includes a wall 404 that at least partially defines an interior region 406. The wall 404 may have a first thickness 408 of greater than or equal to about 2 mm, optionally greater than or equal to about 4 mm, optionally greater than or equal to about 6 mm, or optionally greater than or equal to about 8 mm. The first thickness 408 may be less than or equal to about 10 mm, optionally less than or equal to about 8 mm, optionally less than or equal to about 6 mm, or optionally less than or equal to about 4 mm. In certain aspects, the first thickness 408 may be greater than or equal to about 2 mm to less than or equal to about 10 mm, or optionally greater than or equal to about 4 mm to less than or equal to about 6 mm.The scroll 400 defines a first dimension (not shown) that is substantially parallel to the extrusion axis 402. The scroll 400 also defines a second dimension 412 (e.g., height) and a third dimension 414 (e.g., width) substantially parallel to the extrusion axis 402. The first dimension, the second dimension 412, and the third dimension 414 may be substantially the same as the first dimension 310, the second dimension 312, and the third dimension 314 of the cylinder 300 of FIG. 2 In one example, the scroll 400 may include an inner wrap 420 having an inner wrap diameter of about 100 mm and an outer wrap 422 having an outer wrap diameter of about 150 mm. The outer winding diameter may correspond to the second and / or third dimension 412, 414.Returning to FIG. 1, the method further optionally includes increasing one or more dimensions of the 3D component at 204. One or more dimensions of the 3D component may be increased after extrusion. In one example, a first dimension is increased substantially parallel to a longitudinal axis and / or extrusion axis (see, e.g., FIG. 4 ). In another example, a second and / or third dimension perpendicular to a longitudinal axis and / or extrusion axis is increased (see, e.g., FIG. 5 ). In another example, both the first dimension and the second and / or third dimension are increased. In certain other aspects, this step is omitted and the 3D shape is further processed without substantially changing the dimensions of the cylinder 300. Although the following examples are described in connection with the cylinder 300 (FIG. 2 ), dimensions of other 3D shapes may also be changed / increased.Referring to FIG. 4, a cylinder 500 is provided according to various aspects of the present disclosure. The cylinder 500 may be manufactured by increasing the length of the cylinder 300 of FIG. 2. The length may be increased, for example, by clamping the ends 502 of the cylinder 500 and stretching it. The cylinder 500 has a first dimension or length 510 that is greater than the first dimension 310 of the cylinder 300 of FIG. 2 ; accordingly, the cylinder 500 also has a thickness 518 that is less than the thickness 308 of the cylinder 300 of FIG. 2 The cylinder 500 may have substantially the same second and third dimensions 312, 314 as the cylinder 300 of FIG. 2 In certain aspects, this process may be referred to as "predilution.".Referring to FIG. 5, a cylinder 600 is provided in accordance with various aspects of the present disclosure. The cylinder 600 may be manufactured by increasing a diameter of the cylinder 300 of FIG. 2. The diameter may be increased, for example, by sliding a mandrel (not shown) having a diameter larger than the inner diameter of the cylinder 300 (FIG. 2 ) into the inner region 306. The cylinder 600 has a second dimension 612 and a third dimension 614 (i.e., a diameter) that are greater than the second and third dimensions 312, 314 of the cylinder 300 of FIG. 2 Accordingly, the cylinder 600 also has a thickness 618 that is less than the thickness 308 of the cylinder 300 of FIG. 2 The cylinder 600 may have substantially the same first dimension 310 as the cylinder 300 of FIG. 2.Returning to FIG. 1, at 208, the method optionally also includes opening a wall of the 3D component. This step is performed when the cross section of the 3D component is a closed waveform, such as a circle or an ellipse. Opening at 208 may occur after extruding at 208, even after selectively increasing a dimension at 204. In certain cases, opening at 208 may occur simultaneously with extruding at 200, as described further below in the discussions about FIG. 10. In certain aspects, opening the wall may also include slicing the wall.Referring to FIG. 6, in various aspects, an open component or cylinder 700 is provided in accordance with various aspects of the present disclosure. The open cylinder 700 is formed by opening the wall 304 of the cylinder 300. The wall 304 may be opened at a boundary 702 by cutting or other separation process. The boundary 702 separates the wall 304 to have a first edge 704 and a second edge 706 that converge at the boundary 702. The boundary 702 may extend through the entire thickness 308 of the wall 304. In certain cases, the boundary 702 may extend the entire length 310 of the wall. In certain cases, the cutting may be done with a blade, e.g., a straight blade (see, e.g., discussions about FIG. 10 ) or a roll blade; a laser such as a pulsed fiber laser; a saw; a heated wire; a spark cutter; or any combination thereof.Returning to FIG. 1, the method may also include lubricating the wall at 212. The wall lubrication at 208 may be performed anytime prior to the wall rolling at 224. For example, the wall can be lubricated at 212 after opening the wall at 208 and before unrolling the wall at 216, as shown. In certain cases, the wall lubrication at 212 may be performed simultaneously with the wall opening at 208 (see, e.g., discussions about FIG. 11 ).Lubricating the wall may facilitate rolling at 224. Depending on the rolling process to be used at 224, one or both sides of the wall may be lubricated. The lubricant may be applied by spraying, brush, sponge, dipping, or any combination thereof, for example. In certain cases, the lubricant may be applied through channels in a cutting tool (see, e.g., discussions about FIG. 11 ). The lubricant may include, for example, mineral oil, silicone oil, a solid lubricant (e.g., boron nitride, molybdenum disulfide, mica), or a combination thereof.At 216, the method includes unrolling the wall. The unrolling of the wall can be effected manually and / or with a tool, such as a downstream roll set for bending and unrolling sheets. After unrolling, the wall may be substantially planar; however, some curvature may remain until rolling is complete at 224. The unrolling can be carried out solely as an independent step. The unrolling can also take place simultaneously with the opening of the wall at 208 or the rolling at 224.Referring to FIG. 7, a sheet metal precursor 800 is provided according to various aspects of the present disclosure. The sheet precursor 800 is formed by unrolling the wall 304 of the open cylinder 700 of FIG. 6. The sheet precursor 800 defines the length 310, also referred to as the first transverse dimension, and the thickness 308. The sheet metal precursor 800 defines a second transverse dimension 802 that is substantially parallel to a deroll axis 804 and substantially perpendicular to the extrusion axis 302. The second transverse dimension 802 may be greater than or equal to about 100 mm, optionally greater than or equal to about 200 mm, optionally greater than or equal to about 300 mm, optionally greater than or equal to about 400 mm, optionally greater than or equal to about 500 mm, optionally greater than or equal to about 600 mm, optionally greater than or equal to about 700 mm, optionally greater than or equal to about 800 mm, optionally greater than or equal to about 900 mm, optionally greater than or equal to about 1,000 mm, or optionally greater than or equal to about 1,100 mm. The second transverse dimension 802 may be less than or equal to about 1,200 mm, optionally less than or equal to about 1,100 mm, optionally less than or equal to about 1,000 mm, optionally less than or equal to about 900 mm, optionally less than or equal to about 800 mm, optionally less than or equal to about 700 mm, optionally less than or equal to about 600 mm, optionally less than or equal to about 500 mm, optionally less than or equal to about 400 mm, optionally less than or equal to about 300 mm, or optionally less than or equal to about 200 mm. In certain aspects, the second transverse dimension 802 is greater than or equal to about 100 mm to less than or equal to about 1200 mm, optionally greater than or equal to about 500 mm to less than or equal to about 700 mm, or optionally about 600 mm. For example, if the 3D component is a cylinder, such as cylinder 300 of FIG. 2, second transverse dimension 802 is equal to π times (about 3.14 times) an outer diameter of cylinder 300 (i.e., second and third dimensions 312, 314). Accordingly, prior to rolling at 224 (FIG. 1 ), the sheet precursor 800 is substantially larger than methods where the sheet precursor is directly produced by extrusion.Unrolling may be similarly accomplished with open 3D components having other geometries, such as other open / cut closed curve cross-section components (e.g., an open elliptic cylinder), scroll 400 of FIG. 3, or other open curve cross-section shapes.Returning to FIG. 1, the method optionally includes forming one or more sheets at 220. The method may include forming one or more sheets to improve handling and / or facilitate rolling in a transverse direction that is not parallel to the extrusion axis (see, e.g., discussions about FIG. 12 ). Forming another sheet may include dividing a sheet precursor (e.g., the sheet precursor 800 of FIG. 7 ), such as by cutting.At 224, the method includes rolling the sheet precursor (i.e., the wall) to a desired thickness. Referring to FIG. 8, a rolling operation is provided according to various aspects of the present disclosure. The sheet precursor 800 may be rolled into a metal sheet 900. In certain aspects, the rolling may be performed with one or more roller pairs 902. The sheet metal precursor 800 can be guided between the roller pair 902 along a roller axis 904. The rollers 902 may be formed from and / or coated with an anti-stick material. The release material may include fluorinated polymers (e.g., per- and poly-fluoro-alkyl (PFAS)), diamond-like carbon, boron nitride, aluminum oxide (Al 2 O 3), titanium nitride, titanium carbide, tungsten, tungsten carbide, or any combination thereof. In certain aspects, the rolling process may use additional rolls, e.g., backup rolls configured to control elastic deformation. Moreover, the rolling process may include electronic controls configured to maintain the movement of the sheet precursor 800 through the rolls and to reduce or prevent the side-to-side movement. Cracking of the sheet precursor 800 during rolling may be reduced or prevented by optimizing the first thickness 308, a reduction ratio (between first and second thicknesses 308, 910), the tension, the diameter of the rolls 902, and the coefficient of friction.Prior to rolling, the sheet precursor 800 has the first thickness 308. After rolling, the metal sheet 900 has a second thickness 910. The second thickness 910 is less than the first thickness 308. The second thickness 910 may be greater than or equal to about 20 μm, optionally greater than or equal to about 40 μm, optionally greater than or equal to about 60 μm, or optionally greater than or equal to about 80 μm. The second thickness 910 may be less than or equal to about 100 μm, optionally less than or equal to about 80 μm, optionally less than or equal to about 60 μm, or optionally less than or equal to about 40 μm. In certain aspects, the second thickness 910 may be greater than or equal to about 20 μm to less than or equal to about 100 μm, or optionally greater than or equal to about 20 μm to less than or equal to about 40 μm.Referring to FIG. 9, the metal sheet 900 after rolling is provided according to various aspects of the present disclosure. The sheet 900 defines a third transverse dimension 1000 parallel to the rolling axis 904. The rolling axis 904 may be substantially parallel to the extrusion axis 302 (FIG. 2 ), as shown, the deroll axis 804 (FIG. 7 ), or another axis. When the rolling axis 904 is substantially parallel to the extrusion axis 302, the third transverse dimension 1000 is greater than the first transverse dimension 310 (FIG. 7 ). However, if a rolling axis is substantially parallel to a unrolling axis (see discussions about FIG. 12 ), a third dimension is greater than a second transverse dimension.The metal sheet 900 includes surfaces 1010. The surfaces 1010 may be in direct contact with the rollers 902 during rolling (FIG. 8 ). In certain aspects, each of the surfaces 1010 may have an average surface roughness (RA) of less than or equal to about 10 microinches, optionally less than or equal to about 8 microinches, or optionally less than or equal to about 4 microinches, for example. In certain aspects, the surfaces 1010 may be specular such that they are uniformly bright and have a diffuse to specular reflection ratio on the order of 0.005 in the rolling direction. The RA of the sheet 900 may be less than the RA of the sheet precursor 800 (FIG. 7 ). Accordingly, the rolling may facilitate a reduction of RA, e.g. by using a plurality of successive roller pairs whose roughness decreases stepwise.Returning to FIG. 1, at 228, the method may optionally include forming one or more individual sheets from the metal sheet 900 (FIG. 8 ). The method may optionally include further post-processing steps, such as trimming the edges (e.g., by wire cutting) to remove cracked portions of the sheet. In certain aspects, the metal sheet 900 may be a metal foil. The individual sheets can have dimensions, for example, which are suitable for use in an electrochemical cell. The individual sheets may be used as electrodes (e.g., a lithium metal electrode).While the panels and associated methods provided by the present technique are particularly suitable for use in components such as electrochemical cells of an automobile or other vehicle (e.g., motor cycles, boats, tractors, buses, motor cycles, trains, recreational vehicles, camera and tanks), they can also be used in a variety of other industries and applications, including aerospace components, consumer goods, equipment, buildings (e.g., houses, offices, scales, warehouses), office equipment and furniture, industrial machinery, agricultural equipment, or heavy machinery.Example 1In various aspects, extruding a 3D component at 200, opening a wall of the 3D component at 208, unrolling the wall at 216, and rolling the wall at 224 may be performed in a continuous process. Referring to FIG. 10, an example of a continuous process according to various aspects of the present disclosure is schematically depicted.The method includes extruding a barrel 1100 from an extruder 1102 along an extrusion axis 1104. The barrel 1100 may exit the extruder 1102 in an extrusion direction 1106 parallel to the extrusion axis 1104. The cylinder 1100 includes a wall 1108 that at least partially defines an interior region 1110.As the barrel 1100 moves in the extrusion direction 1106, it contacts a cutting tool 1120. The cutting tool 1120 includes a body 1122 and a cutting blade 1124. The body 1122 defines an axis 1123 that may be parallel to the extrusion axis 1104 during cutting. The body 1122 may have a frustoconical or conical shape (an optional cone tip is shown in dashed lines). The body 1122 may define an angle 1126 of greater than or equal to about 45°, optionally greater than or equal to about 60°, optionally greater than or equal to about 75°, optionally greater than or equal to about 90°, or optionally greater than or equal to about 105°. The angle 1126 can be less than or equal to about 120°, optionally less than or equal to about 105°, optionally less than or equal to about 90°, optionally less than or equal to about 75°, or optionally less than or equal to about 60°. In certain aspects, the angle 1126 is greater than or equal to about 45° to less than or equal to about 120°. The blade 1124 extends outwardly from the body 1122 and defines a cutting edge 1128. In certain aspects, the body 1122 may also define other shapes, e.g., when the 3D component has a non-circular cross-section.During cutting, at least one of the cylinder 1100 and the cutting tool 1120 displaces (e.g., along the extrusion axis) with respect to the other of the cylinder 1100 and the cutting tool 1120. For example, the cutting tool 1120 may remain stationary (i.e., be held rigidly in place) as the barrel 1100 is ejected from the extruder 1102 in the extrusion direction 1106. During displacement, the body 1122 is at least partially within the interior region 1110 of the cylinder 1100 and the cutting edge 1128 engages the wall 1108 of the cylinder 1100 to form a cut 1130 having edges 1132. A first (smaller) end 1134 of the cutting tool 1120 may enter the interior region 1110 before a second (larger) end 1136 of the cutting tool 1120. In certain aspects, an outer surface 1138 of the body 1122 may engage an inner surface 1139 of the cylinder 1100 to partially or fully unroll the cylinder 1100 and form a sheet metal precursor 1140.After unrolling, the sheet precursor is guided through one or more roll pairs 1142 along a roll axis 1144 in a rolling direction 1146 in order to produce a sheet 1150 having a desired thickness and roughness. The rolling axis 1144 and the extrusion axis 1104 may be aligned with each other. The use of multiple roller pairs 1142 may reduce or eliminate deflection and deformation of the sheet precursor 1140 and the sheet 1150. In certain aspects, each roller pair 1142 may allow for a further reduction in the thickness and / or roughness of the sheet precursor 1140.Example 2In various aspects, the present disclosure provides a cutting tool for simultaneously cutting, lubricating, and unrolling a wall. Referring to FIG. 11, a cutting tool 1200 according to various aspects of the present disclosure is provided. Unless otherwise described, the cutting tool 1200 may be similar to the cutting tool 1120 of FIG. 10. The cutting tool 1200 includes a body 1202 and a cutting blade 1204.The body 1202 may define a plurality of passageways. The passages may include, for example, holes or pores 1220, as shown, or channels. The pores 1220 may be provided over a portion of an outer surface 1222 of the body 1202 or over the entire outer surface 1222 of the body 1202. The pores 1220 may have any shape (e.g., circular, hexagonal, etc.) and may be provided in any pattern. If the passages include channels, the channels may be formed in an outer surface of a tool body and extend substantially transverse to a unrolling direction.In certain aspects, the body 1202 is at least partially hollow. The pores 1220 may be in fluid communication with an interior region 1224 of the body 1202. The interior region 1224 may receive a lubricant 1226, such as from a nozzle 1228. Lubricant 1226 may be directed through pores 1220 onto a surface of a wall of a 3D component as it is unrolled. In another example, the passages include channels formed in an outer surface of a cutting tool body transverse to a unrolling axis.Example 3In various aspects, the methods of the present disclosure may be performed using non-aligned extrusion and rolling axes. Referring to FIG. 12, a schematic example of such a method is provided in accordance with various aspects of the present disclosure. The method includes extruding a barrel 1300 from an extruder 1302 along an extrusion axis 1304. The barrel 1300 may exit the extruder 1302 in an extrusion direction 1306 parallel to the extrusion axis 1304. The cylinder 1300 includes a wall 1308 that at least partially defines an interior region 1310.The cylinder 1300 may be cut in a similar manner to the cylinder 1100 to form a sheet precursor 1320. The sheet precursor 1320 may be further cut or otherwise separated into one or more individual sheets 1330, such as at a boundary or cut 1331. Each of the individual sheets 1330 may be guided between one or more roller pairs 1332 along a rolling axis 1334 in a rolling direction 1336, to produce a metal sheet 1340. The rolling axis 1334 is not parallel to the extrusion axis 1304. In certain aspects, the rolling axis 1334 is substantially perpendicular to the extrusion axis 1304.

Claims

A method of making a metal sheet (900, 1340), the method comprising: extruding (200) a component along an extrusion axis (302, 402, 1104, 1304), the component having a wall (304, 404, 1108, 1308) at least partially defining an interior region (306, 406, 1110, 1310), and the component comprising a metal; cutting (208) the wall (304, 404, 1108, 1308) substantially parallel to the extrusion axis (302, 402, 1104, 1304), the wall (304, 404, 1108, 1308) defining a cross-section perpendicular to the extrusion axis (302, 402, 1104, 1304), the cross-section forming a closed curve prior to the cutting (208); A derolling (216) the wall (304, 404, 1108, 1308) to form a sheet precursor (800, 1140, 1320) having a first thickness (308, 408) and a first transverse dimension (310); and rolling (224) the sheet precursor (800, 1140, 1320) along a rolling axis (904, 1144, 1334) to form the metal sheet (900, 1340), wherein the metal sheet (900, 1340) has a second thickness (910) perpendicular to the rolling axis (904, 1144, 1334), wherein the second thickness is less than the first thickness, and a second transverse dimension (802) parallel to the rolling axis (904, 1144, 1334), wherein the second transverse dimension (802) is greater than the first transverse dimension (310), wherein the cutting (208) is performed with a tool (1120), a body (1122) defining a tool axis (1123) and comprising a blade (1124) extending from the body (1122), the cutting (208) comprising moving one of the tool (1120) and the component relative to the other of the tool (1120) and the component such that the body (1122) is at least partially located within the interior region (306, 406, 1110, 1310) and the blade (1124) intersects the wall (304, 404, 1108, 1308), the body (1122) defining a cone or frustum extending between a first end (1134) and a second end (1136), the second end (1136) including a base of the cone or frustum, and the first end (1134) enters the interior region (306, 406, 1110, 1310) before the second end (1136) during the cutting (208).The method of claim 1, further comprising: lubricating (212) a surface of the wall (304, 404, 1108, 1308) prior to rolling (224), wherein the lubricating (212) includes flowing lubricant (1226) through a passage defined in the body (1122) of the tool (1120).The method of claim 1, wherein the wall (304, 404, 1108, 1308) defines a cylinder (300, 500, 600, 700, 1100, 1300), the cylinder (300, 500, 600, 700, 1100, 1300) having an outer diameter of greater than or equal to about 50 mm to less than or equal to about 300 mm, wherein "about" comprises a deviation of less than or equal to 5%.The method of claim 1, wherein the wall defines a spiral (400).The method of claim 1, wherein the rolling axis (904, 1144, 1334) is substantially parallel to the extrusion axis (302, 402, 1104, 1304).The method of claim 1, wherein the second thickness (910) is greater than or equal to about 20 μm to less than or equal to about 100 μm, wherein "about" comprises a variation of less than or equal to 5%.The method of claim 1, wherein the metal comprises lithium, magnesium, tin, indium, aluminum, copper, and / or nickel.

Images