Actual gap and minimum gap methods for calendering dry electrode films, and the system thereof.

Abstract

This invention provides a calendering method and system for accurately and / or precisely calendering dry electrode films. [Solution] The method and system can control the calender nip and / or calendering distance between calender rollers, with or without the presence of electrode film and / or electrode powder mixture, so as to reduce variations in calendering distance.

Description

[Technical Field]

[0001] [Cross-reference of related applications] This application claims priority to U.S. Patent Application No. 18 / 926,060, filed on 24 October 2024, entitled "REAL GAP AND MINIMUM GAP METHODS OF CALENDERING A DRY ELECTRODE FILM, AND SYSTEMS THEREOF," which is incorporated herein by reference in its entirety for all purposes.

[0002] This disclosure relates to calendering electrode films in general, and more particularly to accurately calendering dry electrode films. [Background technology]

[0003] Electrodes implemented in energy storage devices can be manufactured by wet and dry processes. Wet-processed electrodes utilize slurry casting to form and control the physical properties of the electrode film, but such methods may not be applicable to dry-processed electrode films that can be formed using calendering systems. Therefore, improved methods and systems for manufacturing electrode films would be desirable. [Overview of the Initiative] [Means for solving the problem]

[0004] For the purpose of summarizing the advantages achieved beyond the present invention and the prior art, specific purposes and advantages of the present invention are described herein. Not all such purposes or advantages can be achieved in any particular embodiment of the present invention. Therefore, for example, those skilled in the art will recognize that the present invention can be embodied or practiced in a manner that achieves or optimizes one or a group of advantages taught herein, without necessarily achieving other purposes or advantages that can be taught or suggested herein.

[0005] All of these embodiments are intended to be within the scope of the invention disclosed herein. These and other embodiments will be readily apparent to those skilled in the art from the following detailed description of preferred embodiments with reference to the accompanying drawings, and the invention is not limited to any particular preferred embodiment disclosed.

[0006] In a first embodiment, a method for calendering a dry electrode film is disclosed. The method is a step of rotating a first calender roll including a first roller surface and a first roller journal, wherein the first roller journal is located within a first bearing block assembly including a first bearing and a second bearing; a step of rotating a second calender roll including a second roller surface and a second roller journal, wherein the second roller journal is located within a second bearing block assembly including a third bearing and a fourth bearing, the calendering distance between the first roller surface and the second roller surface defines a calender nip, the first and fourth bearings are non-corresponding bearings, and the second and third bearings are non-corresponding bearings; and during the rotation of each of the first and second calender rolls A calendering step of a dry electrode film in a calender nip, the calendering step of applying a deflection force of about 25 to 450 kN to each of a first and a second bearing block; applying a first pressing / tensile force between a first bearing and a fourth bearing and a second pressing / tensile force between a second bearing and a third bearing, thereby controlling the accuracy of the calendering distance to a maximum of about 30 μm, wherein each of the first and second pressing / tensile forces applied is about 25 to 450 kN; and exiting the calendering step of the dry electrode film from the calender gap, wherein the first and second calender rolls continue to rotate after the dry electrode film has exited the calender nip, and the calendering distance after the dry electrode film has exited the calender nip is at least about 1 μm.

[0007] In another embodiment, a method for calendering a dry electrode film is disclosed. The method comprises the steps of: rotating a first calender roll including a first roller surface and a first roller journal, wherein the first roller journal is located within a first bearing block assembly including a first bearing and a second bearing; and rotating a second calender roll including a second roller surface and a second roller journal, wherein the second roller journal is located within a second bearing block assembly including a third bearing and a fourth bearing, and calendering between the first roller surface and the second roller surface. The distance includes the steps of defining a calender nip, wherein the first and fourth bearings are non-corresponding bearings, and the second and third bearings are non-corresponding bearings; calendering a dry electrode film within the calender nip during the rotation of each of the first and second calender rolls; and applying a first pressing / tensile force between the first and fourth bearings and a second pressing / tensile force between the second and third bearings, thereby controlling the accuracy of the calendering distance to a maximum of approximately 50 μm.

[0008] In some embodiments, the first pressing / tensile force is a pressing force, and the second pressing / tensile force is a tensile force. In some embodiments, the calendering distance is at least about 1 μm. In some embodiments, the calendering distance is the minimum distance at which the first calender roll and the second calender roll do not collide. In some embodiments, the accuracy of the calendering distance is about 1 to 30 μm. In some embodiments, calendering applies a deflection force of about 25 to 450 KN to each of the first and second bearing blocks. In some embodiments, each of the first and second pressing / tensile forces applied is about 25 to 450 KN. In some embodiments, the method further includes the dry electrode film exiting the calender nip. In some embodiments, the calendering distance after the dry electrode film has exited the calender nip is at least about 1 μm. In some embodiments, the first and second calender rolls continue to rotate after the dry electrode film has exited the calender nip. In some embodiments, the calendering distance of the dry electrode film before calendering is at least about 1 μm. In some embodiments, the dry electrode film is self-supporting and substantially free of solvent residue. In some embodiments, the dry electrode film contains a fibrillation binder. In some embodiments, the dry electrode film contains an active material.

[0009] In another embodiment, a calendar system is disclosed. The calendar system includes a first calendar roll including a first roller surface and a first journal, and a first bearing block assembly including a first bearing and a second bearing, wherein the first bearing includes a first bearing position, the second bearing includes a second bearing position, and the first journal is located within the first bearing block assembly, and a second calendar roll including a second roller surface and a second journal, and a second bearing block assembly including a third bearing and a fourth bearing, wherein the third bearing includes a third bearing position, and the fourth bearing A second bearing block assembly is provided, wherein the journal includes a fourth bearing position, the first and fourth bearings are non-corresponding bearings, the second and third bearings are non-corresponding bearings, and the second journal is located within the second bearing block assembly; a feedback control system is configured to apply a first pressing / tensile force between the first and fourth bearings and a second pressing / tensile force between the second and third bearings; and a controller is electrically connected to the feedback control system, wherein the calendering distance between the first roller surface and the second roller surface defines the calendering nip.

[0010] In some embodiments, the feedback control system includes a hydraulic system, a servo motor system, a magnetic levitation system, a pneumatic system, and a combination thereof. In some embodiments, the system further includes bearing sensors configured to electrically communicate with a controller and detect first and second bearing positions. In some embodiments, the bearing sensors include mechanical sensors, optical sensors, electromagnetic sensors, capacitive sensors, or a combination thereof. In some embodiments, the system further includes a nip sensor configured to electrically communicate with a controller and detect calendering distance. In some embodiments, the nip sensor includes mechanical sensors, optical sensors, electromagnetic sensors, capacitive sensors, mathematical models, or a combination thereof. [Brief explanation of the drawing]

[0011] The present invention will be described with reference to the accompanying drawings, in which similar reference numerals refer to similar elements.

[0012] [Figure 1] This is a schematic diagram of a roller system according to several embodiments.

[0013] [Figure 2] This is a flowchart of a method for calendering a dry electrode film according to several embodiments.

[0014] [Figure 3A] This graph shows experimental stiffness and force results for calendar bearings in several embodiments.

[0015] [Figure 3B] This graph shows experimental compression and force results for calendar bearings in several embodiments.

[0016] [Figure 4A]A graph showing the results of the experimental lever action and tensile force of a calendar bearing according to some embodiments.

[0017] [Figure 4B] Another graph showing the results of the experimental lever action and tensile force of a calendar bearing according to some embodiments.

[0018] [Figure 4C] A graph showing the results of the experimental lever action and pressing force of a calendar bearing according to some embodiments.

[0019] [Figure 4D] Another graph showing the results of the experimental lever action and pressing force of a calendar bearing according to some embodiments.

[0020] [Figure 5] A bar graph showing the experimental improvement of calendar nip accuracy under various operating conditions of pressing force and tensile force according to some embodiments. Detailed Description of the Invention

[0021] The following detailed description of specific embodiments presents various descriptions of specific embodiments. However, the technological innovations described herein can be embodied in many different ways, for example, as defined and encompassed by the claims. In this description, reference is made to the drawings that can show like reference numerals and / or terms for the same or functionally similar elements. It will be understood that the elements shown in the drawings are not necessarily drawn to scale. Further, it will be understood that specific embodiments can include more elements than shown in the drawings and / or a subset of the elements shown in the drawings. Additionally, some embodiments can incorporate any suitable combination of features from two or more of the drawings. The headings are provided for convenience only and do not affect the scope or meaning of the claims.

[0022] A calendering method and system for precisely and / or accurately calendering a dry electrode film is described. The method and system can control the calender nip and / or calendering distance between calender rollers, with or without the presence of the electrode film and / or electrode powder mixture, so as to reduce variations in the calendering distance. In some embodiments, the method and system can control the calender nip and / or calendering distance between calender rollers, with or without the presence of the electrode film and / or electrode powder mixture, so as to reduce the calendering distance to zero, thereby preventing the calender rollers from colliding with each other. In some embodiments, the calendering distance between calender rollers is the minimum distance such that the distance between two calender rollers is the minimum allowable space between the two calender rollers before they collide with each other.

[0023] Such methods and systems can enable precise control of the thickness of the dry electrode film, which cannot be adjusted after the calendering process. Furthermore, the described methods and systems can enable higher throughput and manufacturing efficiency by allowing the transfer of the electrode film between calender rollers without the need to start and stop the calender rollers due to the presence or absence of electrode film between the nip.

[0024] Figure 1 is a schematic diagram of the roller system 100. The roller system 100 includes a first calender roll 102A and a second calender roll 102B adjacent to each other. The first calender roll 102A includes a first roller surface 104A and a first roller journal 110A, and the second calender roll 102B includes a second roller surface 104B and a second roller journal 110B. The calendering distance 106 between the first roller surface 104A and the second roller surface 104B defines a calender nip 108. The first roller journal 110A is located in the first bearing block assembly 112A at the first bearing position, and the second roller journal 110B is located in the second bearing block assembly 112B at the second bearing position. The first bearing block assembly 112A includes a first bearing 113A and a second bearing 115A, and the second bearing block assembly 112B includes a third bearing 113B and a fourth bearing 115B. The first bearing 113A and the third bearing 113B are corresponding bearings in that they contact and apply force to the same, similar, or substantially similar surfaces of the first and second roller journals 110A and 110B, respectively, and the second bearing 115A and the fourth bearing 115B are corresponding bearings in that they contact and apply force to the same, similar, or substantially similar surfaces of the first and second roller journals 110A and 110B, respectively. The first bearing 113A and the fourth bearing 115B are non-corresponding bearings in that they contact and apply force to different or substantially different surfaces of the first and second roller journals 110A and 110B, respectively, and the second bearing 115A and the third bearing 113B are non-corresponding bearings in that they contact and apply force to different or substantially different surfaces of the first and second roller journals 110A and 110B, respectively.The feedback control system 114 is shown to be located between the first bearing block assembly 112A and the second bearing block assembly 112B, and to apply a first pressing / tensile force 116 and a second pressing / tensile force 118 to each of the first bearing block assembly 112A and the second bearing block assembly 112B, respectively. Specifically, the feedback control system 114 is configured to apply the first pressing / tensile force 116 to the non-corresponding first and fourth bearings 113A and 115B, and to apply the second pressing / tensile force 118 to the non-corresponding second and third bearings 113B and 115A. The bearing sensor 120 is positioned and configured to detect and / or measure the position (e.g., deflection) and / or force applied thereto (e.g., compression, tension) of the first, second, third, and fourth bearings 113A, 115A, 113B, and 115B, specifically the first, second, third, and fourth bearings 113A, 115A, 113B, and 115B. The bearing sensor 120 is positioned and configured to indirectly detect and / or measure the calendering distance 106. The nip sensor 122 is positioned and configured to directly detect and / or measure the calendering distance 106. The controller 124 is configured to electrically communicate with the feedback control system 114 and control the compression force 116 and / or tension force 118, and also communicates electrically with the bearing sensor and the nip sensor.

[0025] In some embodiments, the roll system includes one or more additional calender rolls and additional bearing block assemblies. In some embodiments, one or more additional calender rolls and bearing block assemblies may be upstream and / or downstream of the roller system 100 shown in Figure 1, and may form a first and / or second calender roll and / or additional calender rolls and an additional nip. In some embodiments, a dispensing device is located above the nip and is configured to dispense a dry electrode film mixture into the nip to form a dry electrode. In some embodiments, the calender roll is configured to rotate down to the downstream nip while carrying the dry electrode on its surface. In some embodiments, the roll system is configured to laminate the dry electrode film onto a current collector to form a dry electrode.

[0026] In some embodiments, the feedback control system includes a hydraulic system, a servo motor system, a magnetic levitation system, a pneumatic system, and a combination thereof. In some embodiments, the feedback control system is a system that can apply pressing and / or tensile forces to adjust the gap distance between two calender rollers based on communication from a controller. In some embodiments, the bearing sensor and / or nip sensor includes a mechanical sensor, an optical sensor, an electromagnetic sensor, a capacitive sensor, or a combination thereof. In some embodiments, the optical sensor includes a laser sensor. In some embodiments, the nip sensor includes a model for determining the calendering distance.

[0027] In some embodiments, the bearing sensor is configured to measure the gap of the calendar nip. In some embodiments, the bearing sensor and / or nip sensor communicate electrically with a feedback control system via a controller. In some embodiments, the bearing sensor includes a model for determining the calendar machining distance. In some embodiments, the model is a linear regression model or a nonlinear parametric model that estimates the deflection of the bearing from tensile / compressive forces and bearing stiffness. In some embodiments, the model equation includes the following: g r =g m -g d g r = Distance between roller surfaces g m =Measurement values ​​from bearing sensor g d =Bearing deflection estimated from tensile and compressive forces In some embodiments, the bearing sensor may be configured to provide a feedback signal to the control system to improve control of the calendering distance during the operation of the roller system.

[0028] A bearing block assembly includes bearings, and the journals are configured to be located within and / or held by the bearings. In some embodiments, the bearings are configured to contact the journals and / or apply force to the journals to hold the calender rolls in place and / or counteract the deflection of the calender rolls (e.g., deflection caused by the material being calendered by the roller system). In some embodiments, a bearing block assembly includes 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 bearings. In some embodiments, a bearing block assembly includes multiple bearings, some of which are configured to apply force to the journals from different directions (e.g., opposing directions) to reduce deflection and / or variation in calendering distance. In some embodiments, a bearing may be configured to contact and / or force against a journal at an angle relative to the normal, or approximately, of 0°, 23°, 45°, 77°, 90°, 112°, 135°, 158°, 180°, 202°, ​​225°, 247°, 270°, 292°, 315°, or 337°, or any range of values ​​in between. Bearings in the same and / or different bearing block assemblies having the same or substantially similar contact angles and / or force angles are corresponding bearings. Bearings in the same and / or different bearing block assemblies having different or substantially different contact angles and / or force angles are non-corresponding bearings.

[0029] Bearing block assemblies (e.g., adjacent bearing block assemblies) and their bearings can communicate physically with each other via a feedback control system. In some embodiments, the feedback control system is configured to apply compressive and / or tensile forces (i.e., compressive / tensile forces) between some or all unmatched bearings. In some embodiments, the feedback control system is configured to apply compressive and tensile forces simultaneously, and / or alternately apply compressive or tensile forces between some or all unmatched bearings. In some embodiments, the feedback control system is configured to apply compressive forces between a first set of unmatched bearings and tensile forces between a second set of unmatched bearings.

[0030] Figure 2 is a flowchart of method 200 for calendering a dry electrode film. Method 200 includes the steps of rotating a first calender roll and a second calender roll, calendering the dry electrode film, applying compressive and tensile forces to the first and second bearing block assemblies, and the electrode film 208 emerging from the calender nip. The first and second calender rolls are shown rotating throughout method 200, and a gap is shown between the surface of the first calender roll and the surface of the second calender roll.

[0031] In some embodiments, the calendering distances of the electrode film before and / or before it exits the nip, and / or afterward, are 1 μm, 2 μm, 3 μm, 5 μm, 10 μm, 15 μm, 20 μm, 25 μm, 30 μm, 40 μm, 50 μm, 60 μm, 75 μm, 100 μm, 125 μm, 150 μm, 175 μm, 200 μm, 250 μm, 300 μm, 400 μm, 500 μm, 600 μm, 700 μm, 800 μm, 900 μm, or 1000 μm, or any range between them, about these, at least these, or at least about these values. In some embodiments, the calendering process applies deflection forces of approximately 5KN, 10KN, 15KN, 20KN, 25KN, 30KN, 40KN, 50KN, 60KN, 75KN, 100KN, 125KN, 150KN, 175KN, 200KN, 250KN, 300KN, 350KN, 400KN, 450KN, 500KN, 550KN, 600KN, or 700KN, or any range in between, to the first and / or second bearing blocks. In some embodiments, the first and / or second bearing blocks are subjected to compressive and / or tensile forces of approximately 5KN, 10KN, 15KN, 20KN, 25KN, 30KN, 40KN, 50KN, 60KN, 75KN, 100KN, 125KN, 150KN, 175KN, 200KN, 250KN, 300KN, 350KN, 400KN, 450KN, 500KN, 550KN, 600KN, or 700KN, or any range in between. In some embodiments, the calendering of the electrode film is performed with calendering distance accuracy of 1 μm, 2 μm, 3 μm, 4 μm, 5 μm, 8 μm, 10 μm, 13 μm, 15 μm, 17 μm, 20 μm, 22 μm, 25 μm, 30 μm, 40 μm, 50 μm, 60 μm, or any range between them, with an accuracy of approximately these, at least these, or at least approximately these.In some embodiments, the calendering distance accuracy of the electrode film during calendering is performed with a biasing force of about these, at most these, at most about these, at least these, or at least about these, of 5 KN, 10 KN, 15 KN, 20 KN, 25 KN, 30 KN, 40 KN, 50 KN, 60 KN, 75 KN, 100 KN, 125 KN, 150 KN, 175 KN, 200 KN, 250 KN, 300 KN, 350 KN, 400 KN, 450 KN, 500 KN, 550 KN, 600 KN or 700 KN, or any range of values therebetween. In some embodiments, the first and second calender rolls continue to rotate before, and / or simultaneously with, and / or after the dry electrode film enters and / or exits the calender nip.

[0032] · Electrode Materials, Electrode Films, Electrodes and Energy Storage Devices In some embodiments, the electrode film is a positive electrode film or a negative electrode film. The active material (e.g., positive electrode active material, negative electrode active material) may be used in the preparation of the electrode film and / or electrode for an energy storage device. In some embodiments, the electrode includes a current collector and an electrode film.

[0033] In some embodiments, the active material is a positive electrode active material. In some embodiments, the positive electrode active material is selected from at least one of metal oxides, metal sulfides, sulfur-carbon composites, lithium metal oxides, and sulfur-containing substances. In some embodiments, the positive electrode active material is lithium iron phosphate (i.e., LiFePO4 or "LFP"), lithium manganese iron phosphate (e.g., LiMn 0.6 Fe 0.4 PO4 or "LMFP"), lithium nickel manganese cobalt oxide (i.e., LiNi x Mn y Co 1-x-y O2 or "NMC"), lithium nickel cobalt aluminum oxide (i.e., LiNi x Co y Al zThe cathode active material is selected from O2 (or "NCA"), lithium manganese oxide ("LMO"), lithium nickel manganese oxide ("LNMO"), lithium cobalt oxide ("LCO"), lithium titanate ("LTO"), or a combination thereof. In some embodiments, the cathode active material includes at least two of LFP, LMFP, NMC, NCA, LMO, LNMO, LCO, LTO, and combinations thereof. In some embodiments, the cathode active material is an iron phosphate-based active material. In some embodiments, the iron phosphate-based active material is LiFePO4 (i.e., "lithium iron phosphate" and "LFP") and LiMn 1-x Fe x PO4 (i.e., "lithium iron manganese phosphate" and "LMFP") (e.g., LiMn 0.6 Fe 0.4 PO4 or LiMn 0.8 Fe 0.2 It includes PO4). In some embodiments, the iron phosphate active material includes LFP. In some embodiments, the iron phosphate active material includes LMFP. In some embodiments, the iron phosphate active material includes LFP and / or LMFP.

[0034] In some embodiments, the active material is the anode active material. In some embodiments, the anode active material may include, for example, insert materials (such as carbon, graphite, and / or graphene), alloying / dealloying materials (e.g., silicon, silicon oxide, tin, and / or tin oxide), metallic alloys or compounds (e.g., Si-Al and / or Si-Sn), and / or conversion materials (e.g., manganese oxide, molybdenum oxide, nickel oxide, and / or copper oxide). The anode active material may be used alone or mixed together to form a multilayer material (such as Si-C, Sn-C, SiOx-C, SnOx-C, Si-Sn, Si-SiOx, Sn-SnOx, Si-SiOx-C, Sn-SnOx-C, Si-Sn-C, SiOx-SnOx-C, Si-SiOx-Sn, or Sn-SiOx-SnOx). Negative electrode active materials include common natural graphite, synthetic or artificial graphite, surface-modified graphite, spherical graphite, flake graphite, and blends or combinations of these types of graphite, metal elements and their compounds, as well as metal-C composites for negative electrodes.

[0035] In some embodiments, the electrode film contains an active material in amounts of 70% by weight, 75% by weight, 80% by weight, 85% by weight, 86% by weight, 87% by weight, 88% by weight, 89% by weight, 90% by weight, 91% by weight, 92% by weight, 93% by weight, 94% by weight, 95% by weight, 96% by weight, 97% by weight, 98% by weight, 98.5% by weight, 99% by weight, 99.5% by weight, 99.8% by weight, or 99.9% by weight, or any range of values ​​between them, in amounts of at least these, or at least about these.

[0036] In some embodiments, the electrode film includes a carbon material configured to reversibly intercalate lithium ions. In some embodiments, the carbon intercalating lithium is selected from graphitic carbon, graphite, hard carbon, soft carbon, and combinations thereof. For example, the electrode film of an electrode may include a binder material, one or more of graphitic carbon, graphite, graphene-containing carbon, hard carbon, and soft carbon, as well as a conductivity-enhancing material. In some embodiments, the electrode is mixed with lithium metal and / or lithium ions. In some embodiments, the electrode includes a total amount of carbon material in approximately these, at most these, or at most these, in values ​​of 20% by weight, 15% by weight, 10% by weight, 9% by weight, 8% by weight, 7% by weight, 6% by weight, 5% by weight, 4% by weight, 3% by weight, 2% by weight, 1% by weight, or any range between these.

[0037] In some embodiments, the electrode film includes a conductive additive. In some embodiments, the conductive additive may include a conductive carbon additive such as carbon black. In some embodiments, the conductive carbon additive may include carbon black, carbon nanotubes, such as single-walled carbon nanotubes (SWCNTs) and multi-walled carbon nanotubes (MWCNTs). In some embodiments, the electrode film includes a total amount of the conductive additive in approximately these, at most these, or at most these, of values ​​such as 10% by weight, 9% by weight, 8% by weight, 7% by weight, 6% by weight, 5% by weight, 4% by weight, 3% by weight, 2% by weight, 1% by weight, 0.5% by weight, 0.25% by weight, 0.1% by weight, or any range between these. In some embodiments, each of the conductive additives is in amounts of 10% by weight, 9% by weight, 8% by weight, 7% by weight, 6% by weight, 5% by weight, 4% by weight, 3% by weight, 2% by weight, 1% by weight, 0.5% by weight, 0.25% by weight, 0.1% by weight, or any range between these amounts, in amounts of approximately these, at most these, or at most approximately these. In some embodiments, the conductive additive is carbon black.

[0038] In some embodiments, the electrode film includes a binder. In some embodiments, the binder may include polytetrafluoroethylene (PTFE), polyolefins, polyalkylenes, polyethers, styrene-butadiene, polysiloxane and polysiloxane copolymers, branched polyethers, polyvinyl ethers, carboxymethylcellulose (CMC), copolymers thereof, and / or combinations thereof. In some embodiments, the polyolefin may include polyethylene (PE), polypropylene (PP), polyvinylidene fluoride (PVDF), copolymers thereof, and / or combinations thereof. For example, the binder may include polyvinyl chloride, poly(phenylene oxide) (PPO), polyethylene-block-poly(ethylene glycol), poly(ethylene oxide) (PEO), poly(phenylene oxide) (PPO), polyethylene-block-poly(ethylene glycol), polydimethylsiloxane (PDMS), polydimethylsiloxane-coalkylmethylsiloxane, copolymers thereof, and / or combinations thereof. In some embodiments, the binder may include a thermoplastic material. In some embodiments, the binder includes a fibrillable and / or fibrillated polymer. In certain embodiments, the binder includes, is essentially, or consists of a single fibrillable and / or fibrillated binder such as PTFE. In some embodiments, the electrode film includes about these, at most these, or at most about these binders, including values ​​of 1% by weight, 2% by weight, 3% by weight, 4% by weight, 5% by weight, 6% by weight, 7% by weight, 8% by weight, 9% by weight, 10% by weight, or any range between them.

[0039] In some embodiments, the electrode film may be a wet-processed electrode film. In some embodiments, the electrode film is prepared by a wet or slurry-based electrode manufacturing process. In some embodiments, the electrode film of the Disclosure may be a dry-processed electrode film. In some embodiments, the electrode film is prepared by a dry electrode manufacturing process. As used herein, a dry electrode manufacturing process may refer to a process of forming a dry electrode film without the use of a solvent, or substantially without the use of a solvent. For example, the components of an active layer or electrode film, including a carbon material and a binder, may include, consist of, or essentially consist of dry particles. A combination of dry particles for forming an active layer or electrode film can provide a dry particle active layer mixture. In some embodiments, the active layer or electrode film may be formed from a dry particle active layer mixture such that the weight percentage of the components of the active layer or electrode film is substantially the same as the weight percentage of the components of the dry particle active layer mixture. In some embodiments, an active layer or electrode film formed from a dry particle active layer mixture using a dry manufacturing process may not contain, or substantially contain, any processing additives such as solvents and solvent residues arising therefrom. In some embodiments, the resulting active layer or electrode film is a self-supporting film formed from a dry particle mixture using a dry process. In some embodiments, the resulting active layer or electrode film is a freestanding film formed from a dry particle mixture using a dry process. The process for forming the active layer or electrode film may include fibrillating a fibrillable binder component so that the film contains a fibrillating binder. In further embodiments, the freestanding active layer or electrode film may be formed in the absence of a current collector. In further embodiments, the active layer or electrode film may include a fibrillated polymer matrix so that the film is self-supporting. It is conceivable that a matrix, grid, or web of fibrils can be formed to provide a mechanical structure to the electrode film.

[0040] In some embodiments, the electrode film is placed on a current collector to form an electrode. In some embodiments, the current collector may include a metallic material such as aluminum, nickel, copper, or a combination thereof. In some embodiments, the current collector may include a pure metal. In some embodiments, the current collector may include a metallized polymer film or a metal-coated polymer film. In some embodiments, the polymer may include polyethylene terephthalate (PET), biaxially oriented polypropylene (BOPP), or a combination thereof. In some embodiments, the metal coating may include aluminum. In some embodiments, coating the final electrode film mixture may involve forming a uniform electrode film mixture coating. In some embodiments, the current collector may include thicknesses of approximately 200 μm, 100 μm, 50 μm, 40 μm, 30 μm, 20 μm, 15 μm, 10 μm, 5 μm, or any range between these values.

[0041] In some embodiments, the electrode is a double-sided electrode. In some embodiments, the double-sided electrode includes two electrode films. In some embodiments, the double-sided electrode may include a current collector, an upper electrode film, and a lower electrode film. In some embodiments, each of the two electrode films may have any preferred shape, size, and thickness.

[0042] In some embodiments, the energy storage device includes a separator, a negative electrode, a positive electrode, an electrolyte, and a housing, wherein the electrolyte, separator, negative electrode, and positive electrode are arranged within the housing, and the separator is positioned between the negative electrode and the positive electrode. In some embodiments, the energy storage device is formed by arranging the electrolyte, separator, negative electrode, and positive electrode described herein within the housing, and the separator is positioned between the negative electrode and the positive electrode.

[0043] The electrode assembly includes a positive electrode, a negative electrode, and a separator located between the negative and positive electrodes. In some embodiments, the electrode assembly is a wound electrode (i.e., rolled electrode) assembly (e.g., a jelly roll). In some embodiments, the energy storage device is selected from the group consisting of cylindrical energy storage devices, laminated prism energy storage devices, and helically wound prism energy storage devices.

[0044] The electrodes disclosed herein can be used in energy storage devices. In some embodiments, the energy storage device comprises a separator, a negative electrode, a positive electrode, an electrolyte, and a housing, wherein the electrolyte, separator, negative electrode, and positive electrode are arranged within the housing, and the separator is located between the negative electrode and the positive electrode. In some embodiments, the energy storage device is formed by arranging the electrolyte, separator, negative electrode, and positive electrode described herein within the housing, with the separator located between the negative electrode and the positive electrode. In some embodiments, the energy storage device includes a negative electrode located between two positive electrodes. In some embodiments, the negative electrode and / or positive electrode comprises a molded electrode film. In some embodiments, the energy storage device is a lithium-ion battery. In some embodiments, the energy storage device may be a battery, a capacitor, a capacitor-battery hybrid, a fuel cell, or a combination thereof. In some embodiments, the energy storage system or energy storage device may be used in electromobility. In some embodiments, the energy storage device can be used in automobiles including hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), and / or electric vehicles (EVs). In some embodiments, energy storage devices used in vehicles, including hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), and / or electric vehicles (EVs), reduce greenhouse gas emissions.

[0045] In some embodiments, the energy storage device is charged with a suitable lithium-containing electrolyte. For example, the energy storage device may contain a lithium salt and a solvent such as a non-aqueous solvent or an organic solvent. Generally, the lithium salt contains a redox-stable anion. In some embodiments, the anion may be monovalent. In some embodiments, the lithium salt can be selected from lithium hexafluorophosphate (LiPF6), lithium bis(trifluoromethanesulfonyl)imide (LiFSI), lithium tetrafluoroborate (LiBF4), lithium perchlorate (LiClO4), lithium bis(trifluoromethanesulfonyl)imide (LiN(SO2CF3)2), lithium trifluoromethanesulfonate (LiSO3CF3), lithium bis(oxalato)borate (LiB(C2O4)2), lithium bis(fluorosulfonyl)imide (LiN(SO2F)2), lithium difluoro(oxalato)borate (LiC2BF2O4), and combinations thereof. In some embodiments, the electrolyte may include a quaternary ammonium cation and an anion selected from the group consisting of hexafluorophosphate, tetrafluoroborate, and iodide. In some embodiments, the salt concentration may be about 0.1 mol / L(M) to about 5 M, about 0.2 M to about 3 M, or about 0.3 M to about 2 M. In further embodiments, the salt concentration of the electrolyte may be about 0.7 M to about 2 M. In certain embodiments, the salt concentration of the electrolyte may be about 0.2 M, about 0.3 M, about 0.4 M, about 0.5 M, about 0.6 M, about 0.7 M, about 0.8 M, about 0.9 M, about 1 M, about 1.1 M, about 1.2 M, 1.3 M, 1.4 M, 1.5 M, or values ​​in between.

[0046] In some embodiments, the energy storage device may contain a liquid solvent. The solvent does not need to dissolve all components of the electrolyte, nor does it need to completely dissolve any component. In further embodiments, the solvent may be an organic solvent. In some embodiments, the solvent may contain one or more functional groups selected from dioxathiolane (e.g., 1,3,2-dioxathiolane-2,2-dioxide (i.e., "DTD")), carbonates, ethers and / or esters. In some embodiments, the solvent may contain a carbonate. In further embodiments, the carbonate may be selected from cyclic carbonates, e.g., ethylene carbonate (EC), propylene carbonate (PC), vinylethylene carbonate (VEC), vinylene carbonate (VC), fluoroethylene carbonate (FEC), and combinations thereof, or acyclic carbonates, e.g., dimethyl carbonate (DMC), diethyl carbonate (DEC), ethyl methyl carbonate (EMC), 1,3-propensultone (PRS), and combinations thereof. In some embodiments, the solvent may include an ester. In some embodiments, the ester is selected from methyl acetate (MA), methyl propionate (MP), ethyl acetate (EA), methyl butyrate (MB), and combinations thereof. In some embodiments, the solvent may include EC, PC, VEC, VC, FEC, DMC, DEC, EMC, MA, MP, EA, MB, and combinations thereof. In some embodiments, the solvent may include EC, DMC, DEC, EMC, MA, and combinations thereof. In some embodiments, the solvent may include EC, DMC, EMC, and combinations thereof. In some embodiments, the solvent may include EC:DMC:EMC ratios of 10-30:0-90:0-70.

[0047] In some embodiments, one or more solvents can be used in concentrations of 30% by weight, 35% by weight, 40% by weight, 45% by weight, 50% by weight, 55% by weight, 60% by weight, 65% by weight, 70% by weight, 75% by weight, 80% by weight, 85% by weight, or 90% by weight, or any range in between, at least these concentrations, or at least about these concentrations. In some embodiments, the solvent is used as an additive in the electrolyte system and can be used in concentrations of approximately these, at most these, or at most these, or at most approximately these, in values ​​of 0.1% by weight, 0.2% by weight, 0.3% by weight, 0.4% by weight, 0.5% by weight, 0.6% by weight, 0.7% by weight, 0.8% by weight, 0.9% by weight, 1% by weight, 1.1% by weight, 1.2% by weight, 1.3% by weight, 1.4% by weight, 1.5% by weight, 1.6% by weight, 1.7% by weight, 1.8% by weight, 1.9% by weight, 2% by weight, 2.1% by weight, 2.2% by weight, 2.3% by weight, 2.4% by weight, 2.5% by weight, 2.6% by weight, 2.7% by weight, 2.8% by weight, 2.9% by weight, 3% by weight, 4% by weight, 5% by weight, 6% by weight, 7% by weight, 8% by weight, 9% by weight, or 10% by weight, or any range in between. For example, in some embodiments, the amount of additive in the electrolyte is within the following ranges or approximately one of the following ranges: 0.1–10% by weight, 1–6% by weight, 2–5% by weight, 0.1–6% by weight, 2–8% by weight, 2–3% by weight, or 1–4% by weight.

[0048] In some embodiments, the energy storage device is constructed such that one electrode (e.g., the negative electrode) is larger than and overhangs the other electrode (e.g., the positive electrode). One electrode may overhang the other in the winding direction and / or non-winding direction of the electrode assembly. Such electrode overhangs can avoid yield losses. In some embodiments, where the separator and the molded electrode film (e.g., the positive electrode film) do not overlap, or substantially do not overlap, and / or do not mix, it is easier to identify the boundaries of the molded electrode film, and therefore the ability to form a counter electrode (e.g., the negative electrode) with an overhang is improved. [Examples]

[0049] Exemplary embodiments of the present disclosure, including processes, materials, and / or resulting products, are described in the following examples.

[0050] Adjacent calendars in the calendar system were in contact and in force control mode, and the compressive and tensile forces on each bearing varied with the action of stiffness, compression, and leverage, and were recorded for each bearing. Figure 3A is a graph showing the results for stiffness and force, Figure 3B is a graph showing the results for compression and force, and Figures 4A to 4D are graphs showing the results for leverage and compressive / tensile force. Figure 5 is a bar graph showing the experimental gap variation under various tensile and compressive force operating conditions. Figures 3A to 5 show that the experimentally tested system and method can control the calendaring distance of the roller to within 30 μm over a wide force range of 25 to 450 KN.

[0051] While specific embodiments have been described, these embodiments are presented only as examples and are not intended to limit the scope of this disclosure. In fact, the novel methods and systems described herein can be embodied in a variety of other forms. Furthermore, various omissions, substitutions, and modifications can be made to the systems and methods described herein without departing from the spirit of this disclosure. The appended claims and their equivalents are intended to encompass such forms or modifications that may fall within the scope and spirit of this disclosure.

[0052] Features, materials, properties, or groups described in relation to a particular aspect, embodiment, or example should be understood to be applicable to any other aspect, embodiment, or example described in this section or elsewhere in this specification, unless they are incompatible. All features disclosed herein (including the appended claims, abstract, and drawings) and / or all steps of any method or process disclosed herein may be combined in any combination, except for any combination in which at least some of such features and / or steps are mutually exclusive. Protection is not limited to the details of any of the aforementioned embodiments. Protection extends to any novel features or any novel combination of features disclosed herein (including the appended claims, abstract, and drawings), or any novel steps of any method or process disclosed herein.

[0053] Furthermore, certain features described in this disclosure in the context of separate implementations may be implemented in combination in a single implementation. Conversely, various features described in the context of a single implementation may be implemented separately in multiple implementations or in any preferred subcombination. Moreover, features may be described above as acting in a particular combination, but one or more features from a claimed combination may, in some cases, be removed from the combination, and the combination may be claimed as a subcombination or a variation of a subcombination.

[0054] Furthermore, while operations may be shown in the drawings or described herein in a specific order, such operations do not need to be performed in a specific or sequential order shown, or not all operations need to be performed, in order to achieve the desired result. Other operations not shown or described may be incorporated into exemplary methods and processes. For example, one or more additional operations may be performed before, after, simultaneously with, or in between any of the described operations. Furthermore, operations may be rearranged or rearranged in other implementations. Those skilled in the art will understand that in some embodiments, the actual steps performed in the illustrated and / or disclosed processes may differ from those shown in the drawings. Depending on the embodiment, some of the steps described above may be omitted, and other steps may be added. Furthermore, the features and attributes of the particular embodiments disclosed above may be combined in different ways to form additional embodiments, all of which are included within the scope of this disclosure. Also, the separation of various system components in the above implementations should not be understood as requiring such separation in all implementations, and it should be understood that the components and systems described can generally be integrated together in a single product or packaged in multiple products. For example, any of the components of the energy storage systems described herein may be provided separately or may be integrated together (e.g., packaged together or mounted together) to form an energy storage system.

[0055] For the purposes of this disclosure, certain aspects, advantages, and novel features are described herein. Not all such advantages can necessarily be achieved according to any particular embodiment. Therefore, for example, a person skilled in the art will recognize that this disclosure can be embodied or implemented in a manner that achieves one or a group of advantages as taught herein, without necessarily achieving other advantages that can be taught or suggested herein.

[0056] Conditional statements such as “can,” “could,” “might,” or “may,” unless otherwise specified, or understood to have a different meaning in the context in which they are otherwise used, are generally intended to convey that a particular embodiment includes certain features, elements, and / or steps, while other embodiments do not. Therefore, such conditional statements are generally not intended to suggest that features, elements, and / or steps are required in some way in one or more embodiments, or that one or more embodiments necessarily include logic for determining, with or without user input or prompting, whether these features, elements, and / or steps should be included in or performed in any particular embodiment.

[0057] Conjunctional phrases such as "at least one of X, Y, and Z," are understood separately from the contexts in which they are commonly used to indicate that an item, term, etc., may be one of X, Y, or Z, unless otherwise specified. Therefore, such conjunctional phrases are not generally intended to suggest that a particular embodiment requires the presence of at least one X, at least one Y, and at least one Z.

[0058] As used herein, the terms expressing degree, such as “approximately,” “about,” “generally,” and “substantially,” refer to values, quantities, or characteristics close to the stated values, quantities, or characteristics that still perform the desired function or achieve the desired result. For example, the terms “approximately,” “about,” “generally,” and “substantially” may refer to quantities less than 10%, less than 5%, less than 1%, less than 0.1%, and less than 0.01% of the stated quantity, depending on the desired function or desired result.

[0059] The scope of this disclosure is not intended to be limited by any specific disclosure of preferred embodiments in this section or elsewhere in this specification, but may be defined by the claims, as presented in this section or elsewhere in this specification, or as may be presented in the future. The language of the claims should be interpreted broadly on the basis of the language used in the claims, and should be interpreted as non-exclusive, not limited to the examples described herein or during the examination of this application.

[0060] The headings provided herein, where present, are for convenience only and do not necessarily affect the scope or meaning of the devices and methods disclosed herein.

Claims

1. A method for calendering a dry electrode film, A step of rotating a first calender roll, which includes a first roller surface and a first roller journal, wherein the first roller journal is located within a first bearing block assembly, which includes a first bearing and a second bearing. A step of rotating a second calender roll, which includes a second roller surface and a second roller journal, wherein the second roller journal is located within a second bearing block assembly which includes a third bearing and a fourth bearing, the calendering distance between the first roller surface and the second roller surface defines a calender nip, the first bearing and the fourth bearing are non-corresponding bearings, and the second bearing and the third bearing are non-corresponding bearings, and A calendering step of calendering a dry electrode film within the calender nip during the rotation of each of the first and second calender rolls, wherein the calendering step is to apply a deflection force of 25 to 450 kN to each of the first and second bearing blocks. A step of applying a first pressing / tensile force between the first bearing and the fourth bearing, and a second pressing / tensile force between the second bearing and the third bearing, thereby controlling the accuracy of the calendering distance to a maximum of 30 μm, wherein each of the first and second pressing / tensile forces applied is 25 to 450 kN. Steps include: discharging the dry electrode film from the calender gap, wherein the first and second calender rolls continue to rotate after the dry electrode film has exited the calender nip, and the calendering distance of the dry electrode film after it has exited the calender nip is at least 1 μm; Methods that include...

2. A method for calendering a dry electrode film, A step of rotating a first calender roll, which includes a first roller surface and a first roller journal, wherein the first roller journal is located within a first bearing block assembly, which includes a first bearing and a second bearing. A step of rotating a second calender roll, which includes a second roller surface and a second roller journal, wherein the second roller journal is located within a second bearing block assembly which includes a third bearing and a fourth bearing, the calendering distance between the first roller surface and the second roller surface defines a calender nip, the first bearing and the fourth bearing are non-corresponding bearings, and the second bearing and the third bearing are non-corresponding bearings, and The steps include calendering a dry electrode film within the calender nip while each of the first and second calender rolls is rotating, The steps include applying a first pressing / tensile force between the first bearing and the fourth bearing, and applying a second pressing / tensile force between the second bearing and the third bearing, thereby controlling the accuracy of the calendering distance to a maximum of 50 μm, Methods that include...

3. The method according to claim 2, wherein the first pressing / tensile force is a pressing force and the second pressing / tensile force is a tensile force.

4. The method according to claim 2 or 3, wherein the calendering distance is at least 1 μm.

5. The method according to claim 2 or 3, wherein the calendering distance is the minimum distance that does not cause the first calender roll and the second calender roll to collide.

6. The method according to claim 2 or 3, wherein the accuracy of the calendering distance is 1 to 30 μm.

7. The method according to claim 2 or 3, wherein the calendering process applies a deflection force of 25 to 450 kN to each of the first and second bearing blocks.

8. The method according to claim 2 or 3, wherein each of the first and second pressing / tensile forces applied is 25 to 450 kN.

9. The method according to claim 2 or 3, further comprising the dry electrode film exiting the calender nip.

10. The method according to claim 9, wherein the calendering distance of the dry electrode film after it exits the calender nip is at least 1 μm.

11. The method according to claim 9, wherein the first and second calender rolls continue to rotate after the dry electrode film has exited the calender nip.

12. The method according to claim 9, wherein the calendering distance of the dry electrode film before calendering is at least 1 μm.

13. The method according to claim 2 or 3, wherein the dry electrode film is self-supporting and substantially free of solvent residue.

14. The method according to claim 2 or 3, wherein the dry electrode film comprises a fibrillation binder.

15. The method according to claim 2 or 3, wherein the dry electrode film contains an active material.

16. It is a calendar system, A first calender roll including a first roller surface and a first journal, A first bearing block assembly comprising a first bearing and a second bearing, wherein the first bearing includes a first bearing position, the second bearing includes a second bearing position, and the first journal is disposed within the first bearing block assembly. A second calender roll including a second roller surface and a second journal, A second bearing block assembly comprising a third bearing and a fourth bearing, wherein the third bearing includes a third bearing position, the fourth bearing includes a fourth bearing position, the first and fourth bearings are non-corresponding bearings, the second and third bearings are non-corresponding bearings, and the second journal is disposed within the second bearing block assembly. A feedback control system configured to apply a first pressing / tensile force between the first bearing and the fourth bearing, and a second pressing / tensile force between the second bearing and the third bearing, A controller that communicates electrically with the aforementioned feedback control system, Equipped with, A calendering system in which the calendering distance between the first roller surface and the second roller surface defines a calendering nip.

17. The system according to claim 16, wherein the feedback control system includes a hydraulic system, a servo motor system, a magnetic levitation system, a pneumatic system, and a combination thereof.

18. The system according to claim 16 or 17, further comprising bearing sensors configured to electrically communicate with the controller and to detect the positions of the first and second bearings.

19. The system according to claim 18, wherein the bearing sensor includes a mechanical sensor, an optical sensor, an electromagnetic sensor, a capacitive sensor, or a combination thereof.

20. The system according to claim 16 or 17, further comprising a nip sensor configured to electrically communicate with the controller and detect the calendering distance.

21. The system according to claim 20, wherein the nip sensor includes a mechanical sensor, an optical sensor, an electromagnetic sensor, a capacitive sensor, a mathematical model, or a combination thereof.

Images