Nip Roller Adjustment

Abstract

An apparatus and method for forming a film having a uniform thickness across the entire width of the film is disclosed. A film is also disclosed. The apparatus for forming the film includes a first nip roller and a second nip roller, each of which is configured to compress powder when passing between the first nip roller and the second nip roller to thereby form a film, such that the first nip roller deflects more than the second nip roller in the absence of a force opposing the pressure of the powder passing between the first nip roller and the second nip roller. Additionally, the first nip roller and the second nip roller are each associated with one or more eccentric bearings that rotate to apply a force vector to the first nip roller and the second nip roller.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 275,857, filed November 4, 2021, the entire contents of which are incorporated herein by reference.

[0002] The present disclosure relates to an integrated roller bending device, and more particularly, to a device that can counteract deflections at any angle perpendicular to the central axis of the device, ensuring the production of films of uniform thickness.

[0003] Accurate formation of films, alternatively referred to in the art as sheets, webs, or substrates, is an industrial challenge. Accurate formation of films is particularly difficult when there is limited physical space available for the film-forming equipment, when the film-forming equipment itself is responsible for the initial incorporation of the components that form the film, when high pressure must be applied to the components during film formation, or when more than one of the above requirements exist. In each of these situations, the skilled artisan will generally need to select nip rollers with small diameters. Thus, when these and other design requirements exist, deflection of one or more nip rollers will result in a resulting film profile that is overly convex, overly concave, or otherwise undesirable. In order to maintain the desired perfectly flat film profile, the deflection of each of the one or more nip rollers must be independently controlled within the design constraints of the overall roller apparatus.

[0004] The precise thickness of the film profile is also important, especially in the field of manufacturing electrochemical cells such as lithium ion cells. The thickness of the film must be uniform throughout its length. This is because during the manufacturing of lithium ion cells, such as cylindrical, prismatic, or pouch type cells, the entire endless laminate film is cut to a predetermined length after the electrode film is manufactured and laminated to other layers such as separators and current collectors. The cut laminate film is then wound to form the lithium ion cell. Any deviation in the thickness of the film throughout its length will result in a change in the size of the wound layers of film resulting from the above process, which may result in an incomplete winding that cannot be used to form a cylindrical, prismatic, or pouch type cell. For the above reasons, there is a need for improved systems, methods, and apparatus to ensure the precision of the film thickness. Summary of the Invention

[0005] A roller apparatus is provided that includes one or more nip rollers that maintain alignment at any angle perpendicular to the central axis of the nip roller through the use of eccentric bearings that can rotate independently of one another to counteract deflection of the nip rollers.

[0006] In some embodiments, the technology described herein relates to an apparatus for forming a film having a uniform thickness from a powder, the apparatus including a first nip roller and a second nip roller, each of the first nip roller and the second nip roller configured to compress the powder as it passes between the first nip roller and the second nip roller to thereby form a film, whereby the first nip roller deflects more than the second nip roller in the absence of a force opposing the pressure of the powder passing between the first nip roller and the second nip roller, the first nip roller and the second nip roller each associated with one or more eccentric bearings that rotate to apply a force vector to the first nip roller and the second nip roller.

[0007] In some embodiments, the technology described herein relates to an apparatus configured such that a first contact area between the film and a first nip roller is smaller than a second contact area between the film and a second nip roller.

[0008] In some embodiments, the technology described herein relates to an apparatus in which an eccentric bearing is configured to apply a greater magnitude of force resulting from a force vector to the second nip roller than to the first nip roller.

[0009] In some aspects, the technology described herein relates to an apparatus in which eccentric bearings are configured to apply different force vectors to each side of the same nip roller.

[0010] In some embodiments, the technology described herein relates to an apparatus further including a position sensor configured to determine a position of at least one of the eccentric bearings.

[0011] In some embodiments, the technology described herein relates to an apparatus in which the first nip roller and the second nip roller are each configured to independently apply a force of between about 1 kN and about 75 kN, such force being attributable solely to the action of the eccentric bearings and being separate from any additional forces applied to the first nip roller and the second nip roller by other parts of the apparatus.

[0012] In some embodiments, the technology described herein relates to an apparatus capable of imparting a uniform thickness to a film, with thickness variations of about 10 μm or less across the width of the film.

[0013] In some embodiments, the technology described herein relates to a method of forming a film having a uniform thickness from a powder, the method including compressing and passing the powder between a first nip roller and a second nip roller, thereby forming a film, whereby the first nip roller deflects more than the second nip roller due to the passage of the film in the absence of a force opposing the pressure of the passage of the powder between the first nip roller and a second opposing force, and adjusting the deflection of the first nip roller, the second nip roller, or both, by rotating one or more eccentric bearings associated with the first nip roller and the second nip roller to apply a force vector to the first nip roller and the second nip roller.

[0014] In some embodiments, the technology described herein relates to methods where an eccentric bearing applies a greater magnitude of force resulting from a force vector to the second nip roller than to the first nip roller.

[0015] In some aspects, the technology described herein relates to how eccentric bearings apply different force vectors to each side of the same nip roller.

[0016] In some embodiments, the technology described herein relates to a method further including determining a position of at least one of the eccentric bearings using a position sensor.

[0017] In some embodiments, the technology described herein relates to methods in which the magnitude of the force vector applied by rotating one or more eccentric bearings is between about 1 kN and about 75 kN.

[0018] In some embodiments, the technology described herein relates to methods in which the thickness variation across the width of the film is about 10 μm or less.

[0019] In some embodiments, the technology described herein relates to a film having a uniform thickness, the film having a thickness variation of about 10 μm or less across its width, the film being formed by compressing and passing a powder between first and second nip rollers, the first and second nip rollers being coordinated by one or more eccentric bearings associated with and applying a force vector to the first and second nip rollers.

[0020] In some embodiments, the technology described herein relates to a film, where the film is one or more of an anode film, a cathode film, a separator film, a current collector film, an interlayer film, an adhesive film, a primer film, or a laminate of one or more of the preceding films.

[0021] Aspects, features, benefits, and advantages of the embodiments described herein will become apparent with reference to the following description, the appended claims, and the accompanying drawings. [Brief description of the drawings]

[0022] [Figure 1] 1 illustrates an eccentric bearing used to maintain alignment at any angle perpendicular to the central axis of the nip rollers, according to one embodiment.

[0023] [Diagram 2] 1 illustrates potential deflections caused by rotation of an eccentric bearing relative to a stationary state, according to one embodiment.

[0024] [Diagram 3] FIG. 2 illustrates the position of the nip rollers relative to the backup rollers in an integrated rolling system according to one embodiment.

[0025] [Figure 4]1 illustrates alignment of the nip of the nip rollers without sagging, according to one embodiment.

[0026] [Figure 5A] 13 illustrates the interaction of eccentric bearings causing inward horizontal deflection according to one embodiment.

[0027] [Figure 5B] 13 illustrates the interaction of an eccentric bearing causing an outward horizontal deflection according to one embodiment.

[0028] [Figure 5C] FIG. 13 illustrates the interaction of eccentric bearings to induce vertical deflection according to one embodiment.

[0029] [Figure 5D] 13 illustrates the interaction of eccentric bearings to induce vertical deflection according to one embodiment.

[0030] [Figure 6A] FIG. 2 illustrates how the nip rollers are aligned with the backup rollers according to one embodiment.

[0031] [Figure 6B] FIG. 1 illustrates a nip roller aligned with a backup roller through which a film is formed by powder application according to one embodiment.

[0032] [Figure 7A] 1 illustrates improper thickness tolerance created by nip roller deflection, according to one embodiment.

[0033] [Figure 7B] 1 illustrates improper thickness tolerance created by nip roller deflection, according to one embodiment.

[0034] [Figure 8A]1 illustrates the proper uniform film thickness produced by properly aligned nip rollers, according to one embodiment.

[0035] [Figure 8B] 1 illustrates the proper uniform film thickness produced by properly aligned nip rollers, according to one embodiment.

[0036] [Figure 9A] 1 illustrates the formation of a film, according to one embodiment.

[0037] [Figure 9B] 3 shows another view of the formation of a film, according to one embodiment.

[0038] [Figure 10] 1 illustrates a cross section of a nip roller with an eccentric bearing according to one embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0039] The disclosure is not limited to the particular systems, devices, and methods described, which may vary, and the terminology used herein is for the purpose of describing particular variations or embodiments only, and is not intended to limit the scope.

[0040] The singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. Nothing in this disclosure should be construed as an admission that the embodiments described in this disclosure are not entitled to antedate such disclosure by virtue of prior invention. As used in this document, the term "including" means "including, but not limited to."

[0041] This disclosure describes an apparatus for maintaining the alignment of integral nip rollers to ensure that the film produced by the nip rollers has a uniform thickness. The independent rotation of at least two eccentric bearings attached to the nip rollers can create a counter deflection that eliminates any deflection at any angle perpendicular to the central axis of the roller caused by various pressure sources.

[0042] As used herein, "backup roller" or "calender roller" refers to a roller that is not a nip roller but is located in another portion of the apparatus. The backup roller or rollers may have a variety of designs and functional purposes. Depending on the path of the film moving through the apparatus, it is understood that the backup roller may be a calender roller that applies one or more of heat, pressure, or other physical conditions to the film. Alternatively, the backup roller may be an idler roller that serves the function of facilitating transport or handling of the film.

[0043] For purposes of this specification, the term "static" is used to refer to a roller that has no net deflection in both the horizontal and vertical directions. For example, one embodiment of a static state includes a nip roller that is in perfect vertical and horizontal alignment with a backup roller.

[0044] roller FIG. 1 shows an eccentric bearing 100 used to maintain alignment at any angle perpendicular to the central axis of the nip rollers, according to one embodiment. The bearing includes a first outer bearing 101 with an inner hollow circle eccentric to the entire part. The bearing further includes a second inner bearing 102 with an inner hollow circle concentric to the entire part when the roller is undeflected. The outer bearing is further configured to rotate to provide a deflection to the roller and counter deflection caused by external pressure. The inner bearing is also further configured to rotate eccentrically to provide a deflection to the roller that can counter deflection caused by external pressure.

[0045] 2 illustrates the potential deflections caused by rotation of eccentric bearing 201 relative to the stationary state of nip roller 202, according to one embodiment, including the depiction of bearing 203 rotating to cause roller 204 to deflect downward, bearing 205 rotating to cause roller 206 to deflect in the negative x-direction, bearing 207 rotating to cause roller 208 to deflect upward, and bearing 209 rotating to cause roller 210 to deflect in the positive x-direction.

[0046] 3 is a diagram illustrating the position of nip roller 301 relative to backup roller 302 in an integrated rolling system according to one embodiment, which includes a horizontally aligned sequence of at least one backup roller, two nip rollers, at least two backup rollers, two nip rollers, and at least one backup roller. The diagram further includes a separator layer 303 located in the center of the row of rollers to ensure that the film created by the nip rollers is adhered to both sides of the separator layer.

[0047] 4 shows a nip alignment of nip rollers with no deflection, according to one embodiment, where one nip roller 401 is positioned adjacent to a second nip roller 402, with the vertical centers of the rollers lying in the same plane of the x-axis.

[0048] Figures 5A-5D show the interaction of nip roller bearings in nip alignment. Figure 5A shows one nip roller 501 aligned with a second nip roller 502, with the first nip roller bearing 503 aligned to deflect in the positive x-direction and the second nip roller bearing 504 aligned to deflect in the negative x-direction. Figure 5B shows one nip roller 511 aligned with a second nip roller 512, with the first nip roller bearing 513 aligned to deflect in the negative x-direction and the second nip roller bearing 514 aligned to deflect in the positive x-direction. Figure 5C shows one nip roller 521 aligned with a second nip roller 522, with the first nip roller bearing 523 aligned to deflect downwards and the second nip roller bearing 524 aligned to deflect upwards. Figure 5D shows one nip roller 531 aligned with a second nip roller 532, with the first nip roller bearing 533 aligned to deflect downwards and the second nip roller bearing 534 aligned to deflect upwards.

[0049] 6A-6B show the alignment of the nip and backup rollers and how the rollers are used to create a film. This includes a series of adjacent rollers including backup roller 601, nip roller 603, nip roller 604, and backup roller 602, all aligned in a row. In one embodiment, a series of adjacent rollers including backup roller 611, nip roller 615, nip roller 614, and nip roller 612, all aligned in a row, are provided, where a dry powder mixture is added between the nip rollers from above, and the rollers rotate to create a film 613 from the powder.

[0050] 7A-7B show improper thickness tolerances created by nip roller deflection, according to one embodiment. This includes a system with a series of adjacent rollers including backup roller 701, nip roller 703, nip roller 704, and nip roller 702 all in line, where a dry powder mixture is added between the nip rollers from above and two of the nip rollers deflect upwards, leading to the creation of a film 705 with improper thickness tolerance. In one embodiment, a system with a series of adjacent rollers including backup roller 711, nip roller 713, nip roller 714, and nip roller 712 all in line, where a dry powder mixture is added between the nip rollers from above and one of the two nip rollers deflects upwards, leading to the creation of a film 715 with improper thickness tolerance.

[0051] 8A-8B show the proper uniform film thickness created by properly aligned nip rollers according to one embodiment. This includes a system with a series of adjacent rollers including backup roller 801, nip roller 803, nip roller 804, and nip roller 802 all aligned in line, where the dry powder mixture is added between the nip rollers from above and the two nip rollers are properly aligned so that no net deflection occurs, resulting in the creation of film 805 with the proper thickness tolerance. In one embodiment, a system with a series of adjacent rollers including backup roller 811, nip roller 813, nip roller 814, and nip roller 812 all aligned in line, where the dry powder mixture is added between the nip rollers from above and the two nip rollers are properly aligned so that no net deflection occurs, resulting in the creation of film 815 with the proper thickness tolerance, allowing backup roller 811 to properly control the transport of the film.

[0052] During operation, the nip rollers deflect to accommodate the film formed as the dry powder mixture passes through the nip rollers. The amount of deflection is not limited, but is selected depending on various factors that will be apparent to the skilled artisan. In some embodiments, the amount of deflection is about 5 μm, about 10 μm, about 15 μm, about 20 μm, about 25 μm, about 30 μm, about 35 μm, about 40 μm, about 45 μm, about 50 μm, about 55 μm, about 60 μm, about 65 μm, about 70 μm, about 75 μm, about 80 μm, about 85 μm, about 90 μm, about 95 μm, or about 100 μm, all based on a roller having a diameter of about 200 mm. Alternatively, the amount of deflection can be expressed as a ratio selected based on the overall dimensions of the nip rollers. In one embodiment, the ratio of deflection is about 2.5×10 based on the amount of roller displacement divided by the diameter of the roller. -5 ~ about 0.0005, about 5 × 10-5 to about 0.0005, or about 7.5 × 10 -5~ about 0.0005. The above values ​​are based on a 200 mm diameter nip roller, but the roller diameter is not limited thereto. It is recognized that larger nip rollers may provide additional deflection.

[0053] The deflection of the nip rollers is continuously adjustable in any direction. As shown in Figure 2, by rotating one or more of the eccentric bearings 201, 203, 205, 207, and 209, the nip roller 202 is deflected in any direction. The bending is indicated by reference characters 204, 206, 208, and 210. Again, it will be understood that the rotation of the eccentric bearings is not limited, and therefore the amount and direction of roller deflection is not limited.

[0054] In addition to the amount and direction of roller deflection, the nip rollers can each be individually controlled by rotating only the eccentric bearing associated with each individual roller. This allows the user to further control the amount of space between the rollers and thus the thickness of the film passing between them. The direction of rotation is not restricted and each eccentric bearing can be individually rotated any amount. Additionally, because each individual eccentric bearing associated with a particular nip roller can be adjusted, further control over the deflection of each roller is possible.

[0055] In some embodiments, the nip rollers have a crown that helps further increase the accuracy and precision that the rollers impart to the film. The crown ensures that the contact footprint, and therefore the film profile and film thickness, remain flat and accurate even as the rollers deflect or undergo other manipulations. The amount of crown is not limited and is selected based on the requirements of the particular film and the deflection selected for each roller. In some embodiments, the crown of the nip rollers has a crown of about 3 μm, about 4 μm, about 5 μm, about 6 μm, about 7 μm, about 8 μm, about 9 μm, about 10 μm, or any range of the above values, such as about 3 μm to about 10 μm, about 4 μm to about 9 μm, or about 4 μm to about 8 μm.

[0056] The film formed by the disclosed nip roller is not limited and may be metal, polymer, paper, ceramic, or a mixture or laminate of one or more of the above. In a particular embodiment, the film formed is formed from a dry powder that is then formed as part of a lithium ion battery. When the film is formed from a dry powder, it is formed into a cathode or anode for the manufacture of a lithium ion battery.

[0057] The nip rollers of the present disclosure can achieve both high levels of accuracy and precision with respect to the film formed. In some embodiments, the crown is about 5 μm, about 10 μm, about 15 μm, about 20 μm, about 25 μm, about 30 μm, about 35 μm, about 40 μm, about 45 μm, about 50 μm, about 55 μm, about 60 μm, about 65 μm, about 70 μm, about 75 μm, about 80 μm, about 85 μm, about 90 μm, about 95 μm, or about 100 μm, or any range formed by two or more of the preceding values ​​as endpoints. The crown may be about 30 μm to about 50 μm.

[0058] In addition to controlling the thickness of the film by adjusting the gap between the nip rollers, the disclosed nip rollers and eccentric bearings can also be used to adjust the amount of pressure applied to the film. The magnitude of the force applied by the first nip roller or the second nip roller resulting from adjustment by the eccentric bearing alone, without any external structure or device, can be up to about 75 kN, up to about 50 kN, up to about 25 kN, from about 1 kN to about 75 kN, from about 1 kN to about 50 kN, from about 10 kN to about 50 kN, from about 10 kN to about 40 kN, from about 10 kN to about 30 kN, or any combination of one or more of the aforementioned ranges. In this manner, the first nip roller and the second nip roller can each be independently adjusted to apply greater pressure to the powder or film. It is understood that the aforementioned pressure results solely from adjustment by the eccentric bearing, and that the first nip and the second nip can each apply additional force based on other structures of the apparatus.

[0059] Alternatively, the precision of the eccentric bearings and associated nip rollers is measured by the uniformity of the film formed by the nip rollers. In some embodiments, the cathode or anode films formed by the nip rollers of the present disclosure have a measured thickness that varies by about 10 μm or less, about 8 μm or less, about 6 μm or less, about 4 μm or less, about 3 μm or less, about 2 μm or less, about 1 μm or less, about 1-10 μm, about 1-8 μm, about 1-6 μm, about 1-4 μm, about 1-3 μm, or about 1-2 μm. The above values ​​are measured across the width of the film required for the form factor of the battery being manufactured.

[0060] In the preceding paragraphs describing the precision of the nip roller in relation to the eccentric bearing as measured by the crown of the nip roller, the amount of force applied to the nip roller, and the uniformity of the film, these are again measured against the width required for the form factor of the battery, such as a lithium ion battery, that is produced by the apparatus. Examples of form factors include, but are not limited to, cylindrical batteries 10440 or 1044 (10 mm diameter x 44 mm length), 14500 or 1450 (14 mm diameter x 50 mm length), 16340 or 1634 or CR123A (16 mm diameter x 34 mm length), 18650 or 1865 (18 mm diameter x 65 mm length), 21700 or 2170 (21 mm diameter x 70 mm length), 26650 or 2665 (26 mm diameter x 65 mm length), 32650 or 3265 (32 mm diameter x 65 mm length), and 4680 (46 mm diameter x 80 mm length). Prismatic and pouch style batteries are also contemplated, and there is no limit to the dimensions contemplated.

[0061] The disclosed apparatus further includes one or more position sensors associated with the eccentric bearing, the nip roller, or both. The position sensors determine the amount of rotation of the eccentric bearing or the amount of rotation of the nip roller and provide a digital or analog signal corresponding to the amount of rotation of the nip roller or the eccentric bearing. Such position sensors include, but are not limited to, potentiometric sensors, capacitive position sensors, or optical position sensors. Optical position sensors can operate by measuring with any light, such as ultraviolet (UV), visible light, infrared, etc. In a particular embodiment, the light selected for the optical position sensor is a laser of one of the aforementioned bandwidths.

[0062] In yet other embodiments, or in combination with the provided position sensor, one or more film thickness sensors may be provided. Film thickness sensors include, but are not limited to, optical sensors, such as laser sensors. The film thickness sensor determines the thickness of the film formed by the nip rollers by measuring the thickness of the film at least at one point on the film. In some embodiments, there are one or more film thickness sensors configured to measure the thickness at multiple points across the width of the film. The thickness sensor provides a digital or analog signal corresponding to the thickness of the film.

[0063] Purpose The applications of the nip rollers and associated components of the present disclosure are not limited, but certain applications are desirable. In some embodiments, a production line is constructed that includes the nip rollers of the present disclosure and various other components known to those skilled in the art. The nip rollers are incorporated to precisely control the thickness of the films produced throughout the production line. Examples of films that are configured to be formed on or that use the nip rollers and associated components of the present disclosure include one or more of anode films, cathode films, separator films, current collector films, interlayer films, adhesive films, primer films, or laminates that include two or more of the above films.

[0064] Although the disclosed nip rollers and associated components have been disclosed as being useful for forming films from powders, they have other applications, for example, it is contemplated that the nip rollers and associated components can form films from liquids or non-Newtonian fluids such as slurries. EXAMPLES

[0065] 9A and 9B show one particularly advantageous embodiment of the present disclosure. According to Fig. 9A and 9B, the apparatus 900 includes a first nip roller 901 and a second nip roller 902 disposed in close proximity to a powder mill hopper 904 for receiving an electrode material 905. Furthermore, a first calender roller 906 and a second calender roller 907 are disposed on one side of the first nip roller 901 and the second nip roller 902.

[0066] In use, the electrode material 905, typically a powder for a dry electrode, is compressed by the first nip roller 901 and the second nip roller 902 to form a dry electrode film 908. The dry electrode film 908 passes through the first nip roller 901 and the second nip roller 902 and is shaped under pressure before being wrapped around the first calendar roller 906 and the second calendar roller 907. As the dry electrode film 908 moves, it is compressed and exerts equal and opposite forces on the first nip roller 901 and the second nip roller 902, except that the first nip roller 901 and the second nip roller 902 are configured to respond differently. The first nip roller 901 experiences a large deflection and must be appropriately accommodated by an eccentric bearing (not shown). However, the second nip roller 902 is surrounded by the dry electrode 908 and therefore exerts pressure on the opposite side. Therefore, the second nip roller 902 does not require the same degree of adjustment as the first nip roller 901. Additionally, the second nip roller 902 is disposed adjacent to, and therefore supported to some extent by, calender rollers 906 and 907, which have a diameter larger than that of the second nip roller 902.

[0067] 9B, the first nip roller 901 and the second nip roller 902 are adjusted by one or more eccentric bearings (not shown), such that the magnitude of the adjustment force exerted by the eccentric bearing of the first nip roller 901 is greater than the magnitude of the adjustment force exerted by the eccentric bearing of the second nip roller 902. Thus, a uniform and precisely controlled gap between the first nip roller 901 and the second nip roller 902 is ensured during the passage of the dry electrode film 908.

[0068] It should be noted that although the first nip roller 901 is supported by the support roller 909, the formed film 908 continues to exert a force on the roller, resulting in a larger displacement force on the first nip roller 901. This is shown by the exaggerated bending of the first nip roller 901 in FIG. 9B and must be corrected by the force exerted by the eccentric bearing of the first nip roller 901.

[0069] FIG. 10 shows a cross section of a nip roller 1001, an outer eccentric bearing 1002, and an inner eccentric bearing 1003 mounted on the nip roller 1001. The nip roller 1001 is mounted on a machine frame 1004 that includes a hollow shaft 1005 and a cylindrical bushing that houses the nip roller 1001. The inner eccentric bearing 1003 and the outer eccentric bearing 1002 are arranged such that the inner eccentric bearing 1003 is located inside and overlaps the outer eccentric bearing 1002. The outer eccentric bearing 1002 is axially rotatable by a first radial bearing 1006. The inner eccentric bearing 1003 is axially rotatable by a second radial bearing 1007. The nip roller 1001 is axially movable by a third radial bearing 1008. In the view of Figure 10, the outer eccentric bearing 1002 and the inner eccentric bearing 1003 are in a starting position with the nip roller 1001 in the center and no deflection. The outer eccentric bearing 1002 and the inner eccentric bearing 1003 are independently adjustable.

[0070] In the above detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, like symbols typically identify like components unless the context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not intended to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. It will be readily understood that the aspects of the present disclosure, as generally described herein and illustrated in the drawings, can be arranged, substituted, combined, separated, and designed in a wide variety of configurations, as expressly contemplated herein.

[0071] The present disclosure is not limited to the specific embodiments described in this application, but are intended as examples of various aspects. As will be apparent to those skilled in the art, many modifications and variations can be made without departing from the spirit and scope thereof. Functionally equivalent methods and apparatuses encompassed within the scope of the present disclosure, as well as those recited herein, will be apparent to those skilled in the art from the above description. Such modifications and variations are intended to be included within the scope of the appended claims. The present disclosure is limited only by the terms of the appended claims, and the full scope of equivalents to which such claims are entitled. It is to be understood that the present disclosure is not limited to specific methods, reagents, compounds, compositions, or biological systems, which can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting.

[0072] With respect to the use of substantially any plural and / or singular term herein, those skilled in the art can convert from plural to singular and / or from singular to plural as appropriate to the context and / or application. For clarity, various singular / plural permutations may be explicitly set forth herein.

[0073] Those skilled in the art will understand that the terms used in the specification, in general, and in the claims, in particular (e.g., the body of the claims), are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "including" should be interpreted as "including but not limited to," etc.). While various components, methods, and devices are described in terms of "comprising" (interpreted as meaning "including but not limited to") various components or steps, compositions, methods, and devices may also "essentially comprise" or "consist of" various components and steps, and such terms should be interpreted as defining an essentially closed collection of elements. Those skilled in the art will further understand that if a specific number of claim recitations are intended to be introduced, such intent will be explicitly recited in the claim, and the absence of such recitation is not an indication that such intent is not presented.

[0074] For example, as an aid to understanding, the following appended claims may include the use of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed as implying that introducing a claim recitation with the indefinite article "a" or "an" limits any particular statement that includes such an introduced claim recitation to embodiments that include only one such statement, even when that same claim includes the introductory phrases "one or more" or "at least one" and an indefinite article such as "a" or "an" (e.g., "a" and / or "an" should be construed to mean "at least one" or "one or more"); the same applies to the use of definite articles used to introduce claim recitations.

[0075] In addition, when a specific number of claim recitations is explicitly recited, one of ordinary skill in the art will understand that such recitation should be interpreted to mean at least the recited number (e.g., a minimum recitation of "two recitations" without other modifiers means at least two recitations, or two or more recitations). Furthermore, when a rule similar to "at least one of A, B, and C, etc." is used, such an interpretation is generally intended in the sense that one of ordinary skill in the art would understand the rule (e.g., "a system including at least one of A, B, and C" includes, but is not limited to, systems having only A, only B, only C, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). In cases where a rule similar to "at least one of A, B, or C, etc." is used, such an interpretation is generally intended in the sense that one of skill in the art would understand the rule (e.g., "a system including at least one of A, B, C" includes, but is not limited to, systems having only A, only B, only C, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). Furthermore, one of skill in the art will appreciate that virtually any disjunction and / or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibility of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" is understood to include the possibilities of "A" or "B" or "A and B."

[0076] Additionally, when features or aspects of the disclosure are described in a Markush group, one of skill in the art will understand that the disclosure is also thereby described in terms of any individual component or subgroup of components of that Markush group.

[0077] It will be appreciated by those of skill in the art that for any and all purposes, particularly in terms of providing a written description, all ranges disclosed herein encompass any and all possible subranges and combinations of subranges of that range. Any range listed can be readily recognized as fully descriptive and capable of dividing the same range into at least equal halves, thirds, quarters, fifths, tenths, etc. As a non-limiting example, each range described herein can be easily broken down into a lower third, middle third, upper third, etc. Also, as will be appreciated by those of skill in the art, all terms such as "up to," "at least," etc. can refer to ranges that are inclusive of the recited numbers and can then be subdivided into subranges as described above. Finally, it will be appreciated by those of skill in the art that a range includes each of the individual elements. Thus, for example, a group having 1-3 components refers to a group having 1, 2, or 3 components. Similarly, a group having 1-5 cells refers to a group having 1, 2, 3, 4, or 5 components.

[0078] Various of the above-disclosed and other features and functions, or alternatives thereof, may be combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements thereof, each of which are intended to be encompassed by the disclosed embodiments, may subsequently be made by those skilled in the art.

Claims

1. 1. An apparatus for forming a film having a uniform thickness from a powder, comprising: a first nip roller and a second nip roller, each of the first nip roller and the second nip roller configured to compress the powder as it passes between the first nip roller and the second nip roller to thereby form the film, such that in the absence of a force opposing the pressure of the powder passing between the first nip roller and the second nip roller, the first nip roller deflects more than the second nip roller; the first nip roller and the second nip roller are each associated with one or more eccentric bearings that rotate to apply a force vector to the first nip roller and the second nip roller.

2. 2. The apparatus of claim 1, configured such that a first contact area between the film and the first nip roller is less than a second contact area between the film and the second nip roller.

3. The apparatus of claim 1 , wherein the eccentric bearing is configured to apply a greater magnitude of force resulting from the force vector to the second nip roller than to the first nip roller.

4. The apparatus of claim 1 , wherein the eccentric bearings are configured to apply different force vectors to each side of the same nip roller.

5. The apparatus of claim 1 , further comprising a position sensor configured to determine a position of at least one of the eccentric bearings.

6. 2. The apparatus of claim 1, wherein the first nip roller and the second nip roller are each configured to independently apply a force of between about 1 kN and about 75 kN, such force being attributable solely to action of the eccentric bearing and being separate from any additional forces applied to the first nip roller and the second nip roller by other parts of the apparatus.

7. 10. The apparatus of claim 1, capable of imparting a uniform thickness to the film, the thickness varying by about 10 μm or less across the width of the film.

8. 1. A method for forming a film having a uniform thickness from a powder, comprising: compressing and passing the powder between a first nip roller and a second nip roller, thereby forming a film, whereby the passage of the film causes the first nip roller to deflect more than the second nip roller in the absence of a force opposing the pressure of the passage of the powder between the first nip roller and the second opposing force; adjusting the deflection of the first nip roller, the second nip roller, or both by rotating one or more eccentric bearings associated with the first nip roller and the second nip roller to apply a force vector to the first nip roller and the second nip roller.

9. The method of claim 8 , wherein the eccentric bearing exerts a greater magnitude of force resulting from the force vector on the second nip roller than on the first nip roller.

10. The method of claim 8 , wherein the eccentric bearings apply different force vectors to each side of the same nip roller.

11. The method of claim 8 further comprising determining a position of at least one of the eccentric bearings with a position sensor.

12. The method of claim 8, wherein the force vector applied by rotating the one or more eccentric bearings has a magnitude of about 1 kN to about 75 kN.

13. The method of claim 8 , wherein the film has a thickness variation across its width of about 10 μm or less.

14. 1. A film having a uniform thickness, the film having a thickness variation of about 10 μm or less across its width, the film being formed by compressing and passing a powder between first and second nip rollers, the first and second nip rollers being coordinated by one or more eccentric bearings associated with and applying a force vector to the first and second nip rollers.

15. 15. The film of claim 14, wherein the film is one or more of an anode film, a cathode film, a separator film, a current collector film, an interlayer film, an adhesive film, a primer film, or a laminate of one or more of the foregoing films.

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