Doctor blade and electrode manufacturing device including the same

Abstract

A doctor blade according to one embodiment of the present invention includes a first blade having a first tip with an inclined flat surface and a second blade having a second tip with a curved surface, the first blade and the second blade being in contact with each other, providing active material on a current collector, and being movable together or independently toward or away from a moving electrode.

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] This application claims the benefit of priority based on Korean Patent Application No. 10-2023-0024345, filed February 23, 2023, and Korean Patent Application No. 10-2024-0018641, filed February 7, 2024, and all contents disclosed in the documents of said Korean patent applications are incorporated herein by reference.

[0002] The present invention relates to a doctor blade, an electrode manufacturing apparatus including the same, and an electrode pattern forming method and an electrode manufacturing method, and more specifically to a doctor blade for neatly processing the boundary portion of a pattern when forming an electrode pattern in an electrode process and for making the thickness of an active material uniform, an electrode manufacturing apparatus including the same, and an electrode pattern forming method and an electrode manufacturing method. [Background technology]

[0003] In modern society, as the use of portable devices such as mobile phones, laptops, video cameras, and digital cameras has become commonplace, there has been active development of technologies related to these mobile devices. Furthermore, rechargeable secondary batteries are being used as power sources for electric vehicles (EVs), hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (P-HEVs), etc., as a solution to air pollution caused by existing gasoline-powered vehicles that use fossil fuels, and so there is an increasing need for development of secondary batteries.

[0004] Currently commercially available secondary batteries include nickel-cadmium batteries, nickel-metal hydride batteries, nickel-zinc batteries, and lithium secondary batteries. Of these, lithium secondary batteries are attracting attention because they have the advantages of being able to be charged and discharged freely since they have almost no memory effect compared to nickel-based secondary batteries, an extremely low self-discharge rate, and a high energy density.

[0005] The manufacturing process of such lithium secondary batteries is broadly divided into three stages: the electrode process, the assembly process, and the chemical formation process. The electrode process is further divided into the active material mixing process, the electrode coating process, the rolling process, the slitting process, and the winding process. Among these, the electrode coating process is divided into a wet process in which an active material slurry is provided to the electrode current collector, and a dry process in which the active material in a solid state is provided to the current collector.

[0006] A more effective method is needed to cleanly process the boundary portions of the pattern when forming an electrode pattern and to uniformly distribute the thickness of the active material provided on the current collector. Summary of the Invention [Problem to be solved by the invention]

[0007] The present invention provides a doctor blade, an electrode manufacturing apparatus including the same, an electrode pattern forming method, and an electrode manufacturing method, which aim to cleanly process the boundary areas of the pattern when forming the electrode pattern after providing an active material on an electrode current collector, and to make the thickness of the provided active material uniform.

[0008] However, the problems to be solved by the embodiments of the present invention are not limited to the above problems, and can be variously expanded within the scope of the technical ideas included in the present invention. [Means for solving the problem]

[0009] A doctor blade according to one embodiment of the present invention includes a first blade having a first tip with an inclined flat surface and a second blade having a second tip with a curved surface, and the first blade and the second blade are in contact with each other, provide active material on a current collector, and can move together or independently toward or away from a moving electrode.

[0010] The first blade may be located upstream of the second blade in the traveling direction of the electrode, and the inclined plane of the first tip of the first blade may be arranged to face in the opposite direction to the traveling direction of the electrode, and the curved surface of the second tip of the second blade may be arranged to face in the traveling direction of the electrode from the inclined plane.

[0011] The first blade may be positioned relatively closer to the electrode than the second blade so that the active material provided on the current collector of the traveling electrode is removed to form a pattern of exposed current collector areas, and an end of a first tip of the first blade may be maintained in contact with the current collector.

[0012] In order to flatten the thickness of the active material provided on the current collector of the moving electrode, the outer surfaces of the end of the first tip of the first blade and the end of the second tip of the second blade may be connected to each other and maintained at a predetermined distance from the current collector.

[0013] Only the first blade may move toward the traveling electrode, and an end of a first tip of the first blade may abut against the current collector so that the active material provided on the current collector of the traveling electrode is removed to form a pattern of exposed current collector areas.

[0014] The first blade, which has moved toward the traveling electrode, returns to its original position so as to flatten the thickness of the active material provided on the current collector of the traveling electrode, and the outer surfaces of the end of the first tip of the first blade and the end of the second tip of the second blade are connected to each other and can be maintained at a predetermined distance from the current collector.

[0015] The end of the first tip of the first blade may contact the current collector, removing the active material provided on the current collector of the moving electrode, and the exposed area of ​​the current collector may become an uncoated part of the electrode. The end of the first tip of the first blade and the end of the second tip of the second blade may be connected to each other, and the area where the active material is flattened may become a coated part of the electrode. The uncoated parts and the coated parts may be alternately arranged to form a pattern of the electrode.

[0016] The inclination angle of the inclined plane of the first blade may be any one selected from the range of more than 0 degrees and less than 90 degrees with respect to the traveling electrode.

[0017] The first blade and the second blade may each be positioned perpendicular to the traveling electrode.

[0018] The first tip of the first blade may further include a curved surface at an end thereof, and the curved surface of the first tip of the first blade and the inclined plane may be connected to each other.

[0019] The inclined plane of the first tip of the first blade may be made up of at least two planes having different inclination angles.

[0020] The second tip of the second blade may further include an inclined plane, and the curved surface of the second tip of the second blade may be disposed at an end of the second tip of the second blade, and the curved surface and the inclined plane may be connected to each other.

[0021] The inclined plane of the second tip of the second blade may be made up of at least two planes having different inclination angles.

[0022] The doctor blade may be used in a dry electrode process, and the active material may be provided as a powder on the current collector.

[0023] An electrode manufacturing apparatus according to one embodiment of the present invention may include a doctor blade according to the above-described embodiment, a feeder disposed in front of the doctor blade and supplying the active material to the current collector, and a rolling member disposed behind the doctor blade and rolling the electrode provided with the active material.

[0024] The electrode may further include an air blower disposed behind the doctor blade, and the air blower may blow air to remove the active material if the active material remains in the uncoated portion of the electrode.

[0025] A method for forming a pattern on an electrode using a doctor blade according to the above embodiment includes the steps of: moving the first blade downward to contact a surface of the current collector of the traveling electrode; maintaining the position of the first blade for a predetermined period of time so that active material provided on the current collector of the traveling electrode is removed; returning the first blade to its original position so that outer surfaces of an end of a first tip of the first blade and an end of a second tip of the second blade are connected to each other; and planarizing the active material of the electrode with the first tip of the first blade and the second tip of the second blade, wherein the end of the first tip of the first blade and the end of the second tip of the second blade may be maintained spaced a predetermined distance from the current collector.

[0026] An electrode manufacturing method performed in the electrode manufacturing apparatus according to the above embodiment includes the steps of: supplying active material onto a current collector of an electrode through a feeder; moving the first blade downward so that it abuts against the surface of the current collector of the traveling electrode; maintaining the position of the first blade for a predetermined period of time so that the active material provided on the current collector of the traveling electrode is removed; returning the first blade to its original position so that the outer surfaces of the end of the first tip of the first blade and the end of the second tip of the second blade are connected to each other; and flattening the active material of the electrode with the first tip of the first blade and the second tip of the second blade, wherein the end of the first tip of the first blade and the end of the second tip of the second blade can be maintained spaced a predetermined distance from the current collector.

[0027] If the active material remains in the uncoated portion of the electrode after the planarization of the active material, the method may further include the step of removing the active material by blowing air with an air blower.

[0028] The method may further include rolling the electrode, in which the active material has been planarized, with a rolling member. [Effects of the Invention]

[0029] According to an embodiment of the present invention, there are advantages in that the boundary portions of the pattern can be neatly processed when forming an electrode pattern in an electrode process, and the thickness of the provided active material can be planarized to make the thickness uniform.

[0030] Furthermore, by using the doctor blade and the electrode manufacturing apparatus including the same according to the embodiment of the present invention, defects in the electrodes manufactured thereby can be prevented or significantly reduced, thereby improving the performance of the batteries manufactured thereby. [Brief explanation of the drawings]

[0031] [Figure 1] 1 is a conceptual diagram of an electrode manufacturing apparatus according to an embodiment of the present invention. [Figure 2] 2 shows an embodiment of a doctor blade of the electrode manufacturing apparatus of FIG. 1. [Figure 3] 2A-2C illustrate various embodiments of the doctor blade of the electrode manufacturing apparatus of FIG. 1. [Figure 4] 1. Another embodiment of the doctor blade of the electrode manufacturing apparatus of FIG. 1 is shown. [Figure 5] FIG. 5 is a reference diagram for the doctor blade of FIG. [Figure 6] 1. Another embodiment of the doctor blade of the electrode manufacturing apparatus of FIG. 1 is shown. [Figure 7] 3 illustrates one embodiment of a process for forming an electrode pattern with the doctor blade of FIG. 2. [Figure 8] 8 is a flowchart of a method for manufacturing an electrode including a step of forming the electrode pattern of FIG. 7. [Figure 9] This shows a modified embodiment obtained by partially modifying FIG. [Figure 10] This shows a modified embodiment obtained by partially modifying FIG. DETAILED DESCRIPTION OF THE INVENTION

[0032] Hereinafter, various embodiments of the present invention will be described in detail with reference to the accompanying drawings so that those skilled in the art can easily carry out the embodiments. The present invention may be embodied in various different forms other than those described below, and the scope of the present invention is not limited to the embodiments described herein.

[0033] In order to clearly describe the present invention, parts not necessary for the explanation will be omitted, and the same reference numerals will be used throughout the specification to refer to the same or similar components.

[0034] Furthermore, the size and thickness of each component shown in the drawings are arbitrarily enlarged or reduced for the convenience of explanation, and it is obvious that the content of the present invention is not limited to those shown in the drawings. In the following drawings, the thickness of each layer is enlarged to clearly show various layers and regions. In the following drawings, the thickness of some layers and regions is exaggerated for the convenience of explanation.

[0035] Furthermore, when a layer, film, region, plate, or other portion is described as being "on" or "above" another portion, this should be interpreted as including not only the case where the layer, film, region, plate, or other portion is "directly above" the other portion, but also the case where there are other portions therebetween. Conversely, when a layer, film, region, plate, or other portion is described as being "directly above" the other portion, it means that there are no other portions therebetween. Furthermore, being "on" or "above" a reference portion means being located above or below the reference portion, and does not necessarily mean being located "on" or "above" the opposite direction of gravity. Meanwhile, similar to the description of being "on" or "above" another portion, the description of being "below" or "below" another portion should be understood with reference to the above content.

[0036] Additionally, because the top and bottom surfaces of a particular component may be determined differently depending on the reference direction, throughout this specification, "top" or "bottom" is defined to mean the two surfaces of the component that face each other along the z-axis.

[0037] Furthermore, throughout the specification, when a part is said to "comprise" a certain element, this does not mean that it excludes other elements, but that it may further include other elements, unless otherwise specified.

[0038] Furthermore, throughout the specification, the term "on a plane" means when the part in question is viewed from above, and the term "on a cross section" means when the part in question is cut vertically and viewed from the side.

[0039] An electrode manufacturing apparatus according to one embodiment of the present invention will be described below.

[0040] Fig. 1 is a conceptual diagram of an electrode manufacturing apparatus according to one embodiment of the present invention, showing a simplified front view of the electrode manufacturing apparatus. Fig. 2 shows a simplified front view of a doctor blade as one embodiment of the doctor blade of the electrode manufacturing apparatus of Fig. 1. Fig. 3 shows various embodiments of the doctor blade of the electrode manufacturing apparatus of Fig. 1.

[0041] 1, an electrode manufacturing apparatus according to an embodiment of the present invention mainly includes a feeder 10, a doctor blade 100, an air blower 20, and a rolling member 30. If necessary, a drying unit, an inspection unit, etc. may be further included, and the other components may include sub-components that are included in a typical electrode manufacturing apparatus.

[0042] A feeder 10 supplies the electrode active material 3 to the electrode current collector 2. In the case of a dry electrode manufacturing process, the active material 3 is supplied as a powder. The uncoated areas are areas on the electrode current collector 2 where the electrode active material 3 is not provided or where the active material 3 has been removed with a doctor blade, as described below. The air blower 20 blows air to blow away any remaining electrode active material 3 on the electrode current collector 2 where the electrode active material 3 is not provided or where the active material 3 has been removed with a doctor blade (i.e., uncoated areas), thereby preventing any electrode active material 3 from remaining on the current collector. The rolling member 30 may be, for example, a rolling roll, and rolls the electrode active material 3 provided on the electrode current collector 2. The electrode active material 3 supplied through the feeder 10 may be selectively mixed with a conductive material, an organic binder polymer, an additive, and the like, as needed. Furthermore, other specific details and features of the feeder 10, air blower 20, and rolling member 30 are the same as those of the feeder, air blower, and rolling member provided in a normal electrode manufacturing apparatus, and therefore a description thereof will be omitted.

[0043] 1 and 2, a doctor blade 100 according to one embodiment of the present invention includes a first blade 110 and a second blade 120, which form a set. The first blade 110 and the second blade 120 are arranged in a vertical line and are in contact with each other. In addition, the inclined flat surface 111a of the first blade 110 and the curved surface 121a of the second blade 120 are oriented in opposite directions.

[0044] During the electrode manufacturing process (electrode pattern formation), the first blade 110 and the second blade 120 may be arranged, for example, perpendicular to the running direction of the electrode 1. However, the present invention is not limited to this, and in some cases, the first blade 110 and the second blade 120 may have a slightly inclined shape as shown in Figure 9 or 10.

[0045] In addition, the first blade 110 and the second blade 120 are in contact with each other along the height direction and can move vertically independently. Figure 3(a) shows a case where the end of the first tip 111 of the first blade 110 and the end of the second tip 121 of the second blade 120 are aligned with each other. In other words, this shows a case where the outer surfaces of the end of the first tip 111 and the end of the second tip 121 of the second blade 120 are connected to each other.

[0046] 3(b) shows a case where the first blade 110 is positioned relatively lower than the second blade 120. In other words, this shows a case where the first tip 111 of the first blade 100 is positioned relatively lower than the second tip 121 of the second blade 120.

[0047] 3(c) shows a case where the second blade 120 is positioned relatively lower than the first blade 110. In other words, this shows a case where the second tip 121 of the second blade 120 is positioned relatively lower than the first tip 111 of the first blade 100.

[0048] First tip 111 of first blade 110 is made up of an inclined flat surface 111a, and second tip 121 of second blade 120 is made up of a curved surface 121a. The inclination angle θ of inclined flat surface 111a from electrode current collector 2 may be, for example, any angle selected from greater than 0 degrees and less than 90 degrees, or may be, for example, any angle selected from greater than 10 degrees and less than 80 degrees, or may be, for example, any angle selected from greater than 10 degrees and less than 45 degrees.

[0049] The first tip 111 of the first blade 110 has an inclined plane 111a, which provides a sharp edge, which is advantageous for forming an electrode pattern (i.e., forming a boundary region of the active material provided on the electrode current collector 2). The first blade 110 is positioned forward (upstream) of the second blade 120 in the traveling direction of the electrode 1. The inclined plane 111a of the first tip 111 of the first blade 110 faces in the opposite direction to the traveling direction of the electrode 1. That is, the inclined plane 111a of the first tip 111 of the first blade 110 faces the approaching electrode active material 3. This allows the first blade 110 alone (see FIG. 3(b)) to form an electrode pattern (i.e., form a boundary region of the active material provided on the electrode current collector 2). The first blade 110 is positioned relatively lower than the second blade 120.

[0050] When the end of the first tip 111 of the first blade 110 and the end of the second tip 121 of the second blade 120 are aligned, that is, when the outer surfaces of the end of the first tip 111 of the first blade 110 and the end of the second tip 121 of the second blade 120 are connected to each other (see FIG. 3(a)), it is advantageous to simultaneously flatten the thickness of the active material in the first tip 111 of the first blade 110 and the second tip 121 of the second blade 120, thereby making the thickness of the active material uniform. Therefore, when the end of the first tip 111 of the first blade 110 and the end of the second tip 121 of the second blade 120 are aligned, the thickness of the active material can be flattened and made uniform by the integrated first tip 111 of the first blade 110 and the second tip 121 of the second blade 120. In this case, the end of the first tip 111 of the first blade 110 and the end of the second tip 121 of the second blade 120 are spaced a predetermined distance from the current collector 2 of the running electrode 1. The distance may be, for example, the thickness of the active material 3 to be planarized, and is determined in advance according to the environment in which the present invention is embodied and / or the electrode to be manufactured.

[0051] Furthermore, since the second tip 121 of the second blade 120 has a curved surface, in some cases, if necessary, the thickness of the active material can be flattened and made uniform by using only the second tip 121 of the second blade 120 (see Figure 3(c)).

[0052] Fig. 4 shows another embodiment of the doctor blade of the electrode manufacturing apparatus of Fig. 1. More specifically, it shows the case where the first blade 110 shown in Fig. 3 is replaced with a first blade 110' shown in Fig. 4. The doctor blade 100' of Fig. 4 includes a first blade 110' and a second blade 120. Fig. 5 shows the first blade 110' of Fig. 4 in more detail.

[0053] The first blade 110' has a first tip 111' including at least one inclined flat surface 111a and one curved surface 111b. Among these, the curved surface 111b is located at the end of the first tip 111' of the first blade 110', and refers to the surface between P3 and P4 in FIG. 4, for example. In other words, the end of the first tip 111' of the first blade 110' is rounded. Because the end of the first tip 111' of the first blade 110' is formed with the curved surface 111b, excessive pressure concentration on the end of the tip when the end abuts against the current collector 2 or active material 3 of the electrode can be prevented, preventing the end from being worn or partially damaged.

[0054] The first tip 111' of the first blade 110' has an inclined plane 111a connected to a curved surface 111b located at its end. That is, the curved surface 111b and the inclined plane 111a are connected to each other. The inclined plane 111a may be a single plane, or may be two inclined planes 111a-1 and 111a-2 having different intersection angles θ1 and θ2, as shown in the present specification. In this case, the intersection angle θ2 of the inclined plane 111a-2, which is located closer to the end of the first tip 111' of the first blade 110' than the inclined plane 111a-1, is greater than the intersection angle θ1 of the inclined plane 111a-1. When the active material 3 is planarized, the first blade 110' contacts the active material 3, thereby further reducing the resistance it receives from the active material 3. This allows the active material 3 to be more effectively planarized.

[0055] 5, the intersection angle θ2 refers to the angle between an extension line connecting P1 and P2 corresponding to inclined plane 111a-1 in FIG. 4 and an extension line connecting P2 and P3 corresponding to inclined plane 111a-2. The intersection angle θ1 refers to the angle between an extension line connecting P1 and P2 corresponding to inclined plane 111a-1 and a line extending in the overall height (length) direction of first blade 110′. The intersection angle θ1 has a value selected from the range greater than 0 degrees and less than 45 degrees, and the intersection angle θ2 has a value selected from the range greater than 0 degrees and less than 90 degrees. In this case, the intersection angle θ2 may be greater than the intersection angle θ1.

[0056] Meanwhile, the number of inclined planes is not limited to the above and can be adjusted according to the environment in which the present invention is implemented, and the ratio of the size of the inclined planes is not limited to the above and can be adjusted according to the environment in which the present invention is implemented.

[0057] The curved surface 111b has a radius of curvature R and a central angle α, which can be variously adjusted according to the environment in which the present invention is implemented.

[0058] 4, second blade 120 and first blade 110' are also arranged vertically in a line and are in contact with each other. Furthermore, curved surface 111b and inclined planes 111a-1 and 111a-2 of first blade 110' and curved surface 121a of second blade 120 face in opposite directions. Furthermore, second blade 120 and first blade 110' are in contact with each other along the height direction and can move vertically independently.

[0059] The first blade 110' may form an electrode pattern alone (i.e., form a boundary portion of the active material provided on the electrode current collector 2). In this case, the first blade 110' is positioned relatively lower than the second blade 120. In addition, if the end of the first tip 111' of the first blade 110' coincides with the end of the second tip 121 of the second blade 120, the first tip 111' of the first blade 110' and the second tip 121 of the second blade 120 may simultaneously flatten the thickness of the active material, thereby making the thickness of the active material uniform. Of course, in some cases, the second tip 121 of the second blade 120 may also flatten the thickness of the active material alone, thereby making the thickness of the active material uniform.

[0060] The other explanations and process details regarding the second blade 120 and the first blade 110' overlap with the explanation regarding the doctor blade 100 in FIG. 3, so please refer to the explanations given above in FIGS.

[0061] FIG. 6 shows another embodiment of the doctor blade of the electrode manufacturing apparatus of FIG. 1. More specifically, it shows the case where the second blade 120 is replaced with a second blade 120′ shown in FIG. 6. In other words, the doctor blade 100″ of FIG. 6 includes a first blade 110 and a second blade 120′.

[0062] The second blade 120' in Figure 6 is bilaterally symmetrical to the first blade 110' in Figure 4, and has the same structure and shape as the first blade 110' in Figure 4. That is, the second blade 120' has a curved surface 121a at the end of the second tip 121' and at least one inclined flat surface 121b connected to the curved surface. The curved surface 121a and at least one inclined flat surface 121b of the second blade 120' in Figure 6 have a structure and shape that are bilaterally symmetrical to the curved surface 111b and at least one inclined flat surface 111a of the first blade 110' in Figures 4 and 5, respectively. Therefore, please refer to the above description and detailed description will be omitted to avoid duplication.

[0063] The first blade 110 alone can form the electrode pattern (i.e., form the boundary portion of the active material provided on the electrode current collector 2). In this case, the first blade 110 is positioned relatively lower than the second blade 120'. Also, if the end of the first tip 111 of the first blade 110 coincides with the end of the second tip 121' of the second blade 120', the first tip 111 of the first blade 110 and the second tip 121' of the second blade 120' can simultaneously flatten the thickness of the active material, thereby making the thickness of the active material uniform. Of course, in some cases, the second tip 121' of the second blade 120' alone can flatten the thickness of the active material, thereby making the thickness of the active material uniform.

[0064] On the other hand, the first blade 110 and the second blade 120' in Figure 6 are the same as the first blade 110 and the second blade 120' described above in Figures 1 to 5, so please refer to the description above in Figures 1 to 5 for other details.

[0065] FIG. 7 illustrates one embodiment of a method for forming an electrode pattern with the doctor blade of FIG.

[0066] A method for forming an electrode pattern using a doctor blade (see steps S120 to S150) and a method for manufacturing an electrode including the step of forming an electrode pattern (see steps S110 to S170) will be described with reference to Fig. 7. Fig. 8 is a flowchart of the method for manufacturing an electrode including the step of forming the electrode pattern of Fig. 7.

[0067] In step S110, an electrode active material 3 is supplied onto a current collector 2 of the electrode through a feeder 10 (see FIG. 1). At this time, the electrode 1 travels in the travel direction. Also, as shown in FIG. 7(a), a doctor blade 100 is positioned at a point where a pattern is to be formed on the active material 3 (for example, a point where a boundary between a coated area and an uncoated area is to be formed).

[0068] Among the methods for manufacturing electrodes, the method for forming an electrode pattern corresponds to steps S120 to S150 and is as follows.

[0069] As shown in FIG. 7(b), a step (S120) is performed in which the first blade moves toward the current collector 2 of the traveling electrode. For example, in step S120, the first tip 111 of the first blade 110 may descend to the surface of the current collector 2 of the electrode, and the first tip 111 (the end of the first tip) of the first blade 110 may abut on the current collector of the electrode. At this time, the first blade 110 is positioned relatively lower than the second blade 120. In step S120, the point where the first tip 111 of the first blade 110 abuts on the electrode 1 defines a boundary between a coated portion, which is a region on the current collector 2 where the active material 3 is provided, and an uncoated portion, which is a region on the current collector 2 from which the active material 3 provided thereon has been removed.

[0070] Next, as shown in FIG. 7(c), a step (S130) is performed in which the position of the first blade 110 lowered in FIG. 7(b) is maintained for a predetermined period of time. In step S130, the active material 3 is removed from the traveling electrode 1, forming an area where the current collector 2 is exposed. More specifically, the current collector 2 of the electrode 1 continues to travel in the traveling direction. However, the active material 3 of the electrode 1 is blocked by the first blade 110 and cannot travel. This is because, as described in step S120, the end of the first tip 111 of the first blade 110 abuts against the surface of the current collector 2 of the electrode. As a result, as shown in FIG. 7(c), the active material 3 is removed, forming an uncoated area where the current collector 2 is exposed.

[0071] Next, as shown in FIG. 7(d), a step (S140) is performed in which the first blade 110 is returned to its original position. That is, the first blade 110 moves upward in the opposite direction to the movement direction of the first blade 110 in step S120 and returns to its original position. As a result, the end of the first tip 111 of the first blade 110 and the end of the second tip 121 of the second blade 120 coincide with each other. That is, the outer surfaces of the end of the first tip 111 of the first blade 110 and the end of the second tip 121 of the second blade 120 are connected to each other. At this time, the end of the first tip 111 of the first blade 110 and the end of the second tip 121 of the second blade 120 are spaced a predetermined distance from the moving current collector 2 of the electrode 1. The distance may be, for example, the thickness of the active material 3 to be planarized and is predetermined depending on the environment in which the present invention is embodied and / or the electrode to be manufactured.

[0072] 7(d), that is, with the end of the first tip 111 of the first blade 110 and the end of the second tip 121 of the second blade 120 aligned, the process includes a step (S150) of flattening the active material 3 of the electrode 1 between the first tip 111 of the first blade 110 and the second tip 121 of the second blade 120. The flattened portions of the active material 3 of the electrode 1 in step S150 become ground portions. Through the above steps, a pattern in which ground portions and uncoated portions are alternately positioned is formed on the electrode 1.

[0073] While the electrode active material 3 is continuously supplied onto the electrode current collector 2 through the feeder 10 (see FIG. 1) as described above in step S110, step S120 is repeated again to form a boundary between the coated and uncoated portions of the electrode 1. Then, steps S130 through S150 are sequentially repeated. Repeating steps S120 through S150 several times in this manner produces an electrode 1 having a pattern in which coated and uncoated portions alternate.

[0074] If active material 3 remains in the uncoated portion of electrode 1 after the planarization of active material 3, the method further includes a step (S160) of removing the active material by blowing air using air blower 20 (see FIG. 1). The method also includes a step (S170) of rolling electrode 1 after the planarization of active material 3 with rolling member 30 (see FIG. 1). Step S160 may be performed between steps S150 and S170, as shown in FIG. 8, or may be performed after step S170. The electrode is then slit to manufacture an electrode assembly.

[0075] 9 and 10 each show a modified embodiment that is a partial modification of Fig. 7. As shown in Fig. 7, during the electrode manufacturing process (electrode pattern formation), the first blade 110 and the second blade 120 may be arranged, for example, perpendicular to the running direction of the electrode 1. However, the present invention is not limited to this, and in some cases, the first blade 110 and the second blade 120 may have a slightly inclined shape, as shown in Fig. 9 or 10.

[0076] 7 to 10 illustrate a process of forming a pattern on the electrode 1 using the doctor blade 100 of FIG. 2, but the present invention is not limited thereto and can be equally applied to a process of forming a pattern on the electrode 1 using the doctor blade 100′ shown in FIG. 4 or the doctor blade 100″ shown in FIG. 6.

[0077] The above-described embodiments of the present invention can be applied to, for example, the manufacturing process of dry electrodes.

[0078] The electrode according to the present invention may be a positive electrode or a negative electrode. That is, the manufacturing process of the electrode according to the present invention is not particularly limited to a positive electrode or a negative electrode, but can be easily applied to the manufacture of any electrode, and different electrodes can be manufactured depending on the material (e.g., positive electrode active material or negative electrode active material) used in the manufacture of each electrode. Therefore, the term "electrode" used in this specification, such as "electrode," "electrode active material 3," and "electrode current collector 2," can refer to both positive and negative electrodes unless otherwise defined.

[0079] In the process for producing a dry electrode of the present invention, the electrode active material 3, the binder polymer, and the like are dry-mixed to obtain a mixture.

[0080] Any material that contains lithium and can absorb and release lithium ions can be used as the positive electrode active material. For example, the positive electrode active material can be a layered compound such as lithium cobalt oxide (LiCoO2) or lithium nickel oxide (LiNiO2), or a compound substituted with one or more transition metals; 1+x Mn 2-x Lithium manganese oxides such as LiMnO4 (where x is 0 to 0.33), LiMnO3, LiMn2O3, and LiMnO2; lithium copper oxide (Li2CuO2); vanadium oxides such as LiV3O8, LiFe3O4, V2O5, and Cu2V2O7; and the chemical formula LiNi 1-x M x Ni-site lithium nickel oxide represented by the chemical formula LiMnO2 (where M=Co, Mn, Al, Cu, Fe, Mg, B, or Ga, and x=0.01 to 0.3). 2-x M x Lithium manganese composite oxides represented by Li2Mn3MO8 (where M=Co, Ni, Fe, Cr, Zn, or Ta, and x=0.01 to 0.1) or Li2Mn3MO8 (where M=Fe, Co, Ni, Cu, or Zn); LiNi x Mn 2-xExamples of the positive electrode include, but are not limited to, lithium manganese composite oxides with a spinel structure represented by the formula LiMnO4; LiMnO4 in which part of the Li in the chemical formula is replaced with an alkaline earth metal ion; disulfide compounds; and Fe(MoO4)3. The positive electrode may also include a positive electrode mixture layer containing lithium metal, a carbon material, a metal compound, or a mixture thereof. The metal compound may be a compound containing one or more metal elements selected from the group consisting of Si, Ge, Sn, Pb, P, Sb, Bi, Al, Ga, In, Ti, Mn, Fe, Co, Ni, Cu, Zn, Ag, Mg, Sr, and Ba, or a mixture thereof.

[0081] The negative electrode may be manufactured by providing a negative electrode active material on a negative electrode current collector and rolling the material, or may be manufactured by a dry method similar to the manufacturing process of the positive electrode described above. If necessary, the negative electrode may further include a conductive material, an organic binder polymer, an additive, and the like, as in the positive electrode.

[0082] The negative electrode active material may include, for example, a carbon material and a silicon material. The carbon material refers to a carbon material primarily composed of carbon atoms. Examples of such carbon materials include graphite, which has a completely layered crystalline structure like natural graphite; soft carbon having a low-crystalline graphene structure (a structure in which hexagonal honeycomb-shaped carbon planes are arranged in layers); hard carbon, in which such a structure is mixed with amorphous portions; artificial graphite; expanded graphite; carbon fiber; non-graphitizable carbon; carbon black; acetylene black; ketjen black; carbon nanotubes; fullerenes; activated carbon; and graphene. Preferably, the carbon material may include one or more selected from the group consisting of natural graphite, artificial graphite, and carbon nanotubes. More preferably, the carbon material may include natural graphite and / or artificial graphite, or may include at least one of carbon black and carbon nanotubes together with the natural graphite and / or artificial graphite. In this case, the carbon material may contain 0.1 to 10 parts by weight of carbon black and / or carbon nanotubes relative to 100 parts by weight of the total carbon material, more specifically, 0.1 to 5 parts by weight or 0.1 to 2 parts by weight of carbon black and / or carbon nanotubes relative to 100 parts by weight of the total carbon material.

[0083] The silicon material is a particle containing silicon (Si) as a metal component as a main component, and includes silicon (Si) particles and silicon oxide (SiO X , 1≦X≦2) particles. As one example, the silicon material may include silicon (Si) particles, silicon monoxide (SiO) particles, silicon dioxide (SiO2) particles, or a mixture of these particles.

[0084] In the present invention, the current collector is an electrically conductive material such as a metal plate, and any suitable material known in the field of secondary batteries can be used depending on the polarity of the current collector electrode.

[0085] In the present invention, the conductive material is not particularly limited as long as it has conductivity and does not induce chemical changes in the battery.

[0086] In the present invention, the binder resin is not particularly limited as long as it is a component that assists in bonding the active material to the conductive material and the like and in bonding to the current collector.

[0087] According to the embodiment of the present invention, when a pattern is to be formed on the surface of an electrode, an additional process for pattern formation is not required, thereby improving process efficiency. Furthermore, by using the electrode manufacturing apparatus according to the embodiment of the present invention, the specific surface area of ​​the electrode can be effectively increased, and more electrolyte ions can be stored during battery charging, thereby improving battery performance.

[0088] In this embodiment, terms indicating directions such as front, back, left, right, up, and down are used, but these terms are used only for convenience of explanation and may change depending on the position of the target object, the position of the observer, etc.

[0089] The electrode manufactured by applying the control method of the electrode manufacturing apparatus according to the present embodiment can be included in a secondary battery, and a plurality of such secondary batteries can be assembled to form a battery module. The battery module can be mounted with various control and protection systems, such as a BMS (Battery Management System) and a cooling system, to form a battery pack.

[0090] The secondary battery, battery module, or battery pack can be applied to various devices, specifically, but not limited to, transportation means such as electric bicycles, electric vehicles, and hybrid electric vehicles, and can be applied to various devices using secondary batteries.

[0091] Although the preferred embodiments of the present invention have been described in detail above, the scope of the present invention is not limited thereto, and various modifications and improvements made by those skilled in the art using the basic concept of the present invention defined in the following claims also fall within the scope of the present invention. [Explanation of symbols]

[0092] 1: Electrode 2: Current collector 3: Active material 10: Feeder 20: Air blower 30: Rolled member 100: Doctor Blade 110, 110': First blade 111, 111': First tip 111a: Inclined plane 111b: Curved surface 120, 120': Second blade 121, 121': Second tip 121a: Curved surface 121b: Tilted plane

Claims

1. a first blade having a first tip including an inclined flat surface; a second blade having a second tip including a curved surface; The first blade and the second blade are in contact with each other, provide active material on a current collector, and are movable together or individually toward or away from a traveling electrode.

2. the first blade is located upstream of the second blade in the traveling direction of the electrode, The inclined plane of the first tip of the first blade is arranged to face in a direction opposite to the traveling direction of the electrode, 2. The doctor blade according to claim 1, wherein the curved surface of the second tip of the second blade is arranged to face in the direction of travel of the electrode from the inclined plane of the first tip of the first blade.

3. 2. The doctor blade of claim 1, wherein the first blade is positioned relatively closer to the electrode than the second blade so that the active material provided on the current collector of the traveling electrode is removed to form a pattern of exposed areas of the current collector, and an end of a first tip of the first blade remains in contact with the current collector.

4. 2. The doctor blade of claim 1, wherein outer surfaces of an end of a first tip of the first blade and an end of a second tip of the second blade are connected to each other and maintained at a predetermined distance from the current collector so as to flatten the thickness of the active material provided on the current collector of the traveling electrode.

5. 2. The doctor blade of claim 1, wherein only the first blade moves toward the traveling electrode so that the active material provided on the current collector of the traveling electrode is removed, forming a pattern of exposed current collector areas, and an end of a first tip of the first blade abuts the current collector.

6. 6. The doctor blade of claim 5, wherein the first blade, which has moved toward the traveling electrode to flatten the thickness of the active material provided on the current collector of the traveling electrode, returns to its original position, and outer surfaces of the end of the first tip of the first blade and the end of the second tip of the second blade are connected to each other and maintained at a predetermined distance from the current collector.

7. an end of a first tip of the first blade abuts against the current collector, the active material provided on the current collector of the traveling electrode is removed, and the exposed area of ​​the current collector becomes an uncoated portion of the electrode; a region where the active material is flattened in a state where the outer surfaces of the end of the first tip of the first blade and the end of the second tip of the second blade are connected to each other becomes a ground portion of the electrode; 2. The doctor blade of claim 1, wherein the uncoated portions and the coated portions are arranged alternately to form the electrode pattern.

8. 2. The doctor blade according to claim 1, wherein the inclination angle of the inclined plane of the first blade is any one angle selected from the range of more than 0 degrees and less than 90 degrees with respect to the traveling electrode.

9. 2. The doctor blade of claim 1, wherein said first blade and said second blade are each positioned perpendicular to said traveling electrode.

10. the first tip of the first blade further includes a curved surface at a terminal end; 2. The doctor blade according to claim 1, wherein the curved surface of the first tip of the first blade and the inclined flat surface of the first tip of the first blade are connected to each other.

11. 11. The doctor blade according to claim 10, wherein the inclined plane of the first tip of the first blade comprises at least two planes having different inclination angles.

12. the second tip of the second blade further includes an inclined flat surface; the curved surface of the second tip of the second blade is disposed at an end of the second tip of the second blade; 2. The doctor blade according to claim 1, wherein the curved surface of the second tip of the second blade and the inclined flat surface of the second tip of the second blade are connected to each other.

13. 13. The doctor blade according to claim 12, wherein the inclined plane of the second tip of the second blade comprises at least two planes having different inclination angles.

14. 10. The doctor blade of claim 1, wherein the doctor blade is used in a dry electrode process and the active material is provided on the current collector as a powder.

15. The doctor blade of claim 1; a feeder disposed in front of the doctor blade to supply the active material to the current collector; a rolling member disposed behind the doctor blade and configured to roll the electrode on which the active material has been provided.

16. further comprising an air blower disposed behind the doctor blade; The electrode manufacturing apparatus according to claim 15 , wherein the air blower blows air onto an uncoated portion of the electrode to remove the active material if the active material remains therein.

17. 10. A method for forming a pattern on an electrode with a doctor blade according to claim 1, comprising: moving the first blade downward so as to contact a surface of a current collector of the traveling electrode; maintaining the position of the first blade for a predetermined period of time so that active material provided on the current collector of the traveling electrode is removed; returning the first blade to its original position so that the outer surfaces of the end of the first tip of the first blade and the end of the second tip of the second blade are joined together; and planarizing the active material of the electrode with a first tip of the first blade and a second tip of the second blade, wherein an end of the first tip of the first blade and an end of the second tip of the second blade are maintained spaced a predetermined distance from the current collector.

18. A method for manufacturing an electrode using the electrode manufacturing apparatus according to claim 15, comprising: Supplying an active material onto a current collector of an electrode through a feeder; moving the first blade downward so as to contact a surface of a current collector of the traveling electrode; maintaining the position of the first blade for a predetermined period of time so that active material provided on the current collector of the traveling electrode is removed; returning the first blade to its original position so that the outer surfaces of the end of the first tip of the first blade and the end of the second tip of the second blade are joined together; and planarizing the active material of the electrode with a first tip of the first blade and a second tip of the second blade, wherein an end of the first tip of the first blade and an end of the second tip of the second blade are maintained spaced a predetermined distance from the current collector.

19. The method according to claim 18, further comprising the step of removing the active material by blowing air with an air blower when the active material remains in the uncoated portion of the electrode after the planarization of the active material.

20. The method of claim 18 , further comprising the step of rolling the electrode after the planarization of the active material with a rolling member.

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