Method for producing a dry film, system for producing a dry film, dry film, and battery including the dry film

Abstract

A method for producing a dry film, a system for producing a dry film, a dry film, and a battery including the dry film are provided. The method and system are characterized in that at least two processing devices are used, each positioned facing an outer segment of the carrier roll in a direction perpendicular to the carrier roll rotation axis, and each of the at least two processing devices is suitable for removing a region of the dry film supported on the carrier roll at the outer segment of the carrier roll. The method and system enable the rapid and energy-efficient production of segmented strip-shaped dry films with very high edge accuracy.

Description

[Technical Field]

[0001] A method for producing a dry film, a system for producing a dry film, a dry film, and a battery including the dry film are provided. The method and system are characterized in that at least two processing devices are used, each positioned facing an outer segment of the carrier roll in a direction perpendicular to the carrier roll rotation axis, and each of the at least two processing devices is suitable for removing a region of the dry film supported on the carrier roll at the outer segment of the carrier roll. The method and system enable the rapid and energy-efficient production of segmented strip-shaped dry films with very high edge accuracy. [Background technology]

[0002] In the prior art, it is known to coat conductive arrester foils of battery electrodes using a slurry method (i.e., a wet chemical method) with a slurry film containing an electrode active material, a binder, and a conductive additive. For efficient production, increasingly wider films are coated onto conductive arrester foil as a substrate. In many cases, a coating width that is a multiple of the width of the dimensions of the electrode to be made from the film-bearing substrate is desired. For example, a 300 mm film width is specified here, and 100 mm long pieces are cut from this width film to produce an electrode format, for example, 300 mm wide x 100 mm long. For example, slot dies with shims are used to produce electrodes with segmented coatings (zebra coatings). These slot dies enable coating over a wide width and prevent the slurry from leaking from the slot die in the masked areas, creating uncoated areas through the shims. By controlling the flow of slurry through the nozzle opening, it is also possible to produce so-called intermittent coatings with uncoated areas at regular intervals along the coating direction.

[0003] Furthermore, the prior art is known to coat the conductors of battery electrodes by a dry film process (i.e., dry chemical or dry process) using a dry film containing the electrode active material, conductive additive, and binder. In this case, a dry mixture and / or dry powder mixture containing particles of the active material, conductive additive, and binder is used. Dry film refers to a coating or a free-standing, self-supporting film obtained from a film-forming process in which no solvent is used. The resulting layer or film generally has a thickness of 10 μm to 1000 μm and is composed of particles. Free-standing dry films can be applied with a resistance of 100 N / m along the layer surface. 2 It has a mechanical tensile strength (nominal tension) of over 100N / m, which allows the dry film to be self-supporting. 2 If the thickness is less than 100 μm, the dry film is not self-supporting and must be mechanically stabilized by rolling, a substrate film, or other means. In the region of the battery electrodes, the dry film has properties (layer thickness, porosity, composition, conductivity) comparable to layers made using a slurry process. Methods for making dry films are very important for future battery manufacturing because they can be performed faster and more energy-efficiently than slurry processes (e.g., there is no need to evaporate the slurry liquid, which means that smaller systems with lower energy requirements can be realized). However, the dry film process still has disadvantages compared to the slurry process.

[0004] For example, to produce electrodes with segmented coatings (zebra coatings), individual free-standing films can be fabricated and laminated in parallel onto a target substrate, but this involves a significant expenditure of time and equipment and a large amount of waste (offcuts).

[0005] It is also known to fabricate electrodes with segmented coatings using a primer layer to produce a targeted, localized transfer of the dry film onto a substrate. For example, a dry film is fabricated on a roll, and this dry film is transferred to the substrate only at the points where the substrate is provided with an adhesion-promoting primer layer. Thus, the pattern of the primer layer applied to the substrate also determines the layout of the dry film layer on the substrate. While this works well for some materials, it is often observed that the cohesion or mechanical stability of the dry film layer fabricated on the roll makes it impossible to achieve a transfer with neat edges.

[0006] In addition, Patent Document 1 discloses a method for producing an electrode having a segmented coating by first preparing a dry film carried on a first roll, which forms a calender nip together with a second roll, and the second roll carries a release film suitable for removing a portion of the dry film from the first roll by applying pressure to the calender nip, thereby forming a striped dry film (zebra pattern) on the first roll. The problem with this method is that the use of the release film increases costs because it must be replaced, and that the release film undergoes a specific meandering motion within the calender nip, i.e., a specific motion in a direction parallel to the rotation axes of the first and second rolls, resulting in two boundary lines of each dry film web being wavy in at least some areas in the longitudinal direction of the dry film. In other words, in this method, two separate dry film segments are removed. The boundaries cannot be made to extend along the length as strictly parallel lines, and therefore the dry film produced has edge accuracy that could be improved.

[0007] Patent Document 2 discloses a multi-roll device for producing dry films, in which the edges of the dry film are trimmed on the last roll of the multi-roll device at the end of the process. Edge trimming on the last roll of the multi-roll device has several drawbacks. First, the dry film is already very dense at this point, so edge trimming requires more energy and causes greater wear on the cutting tool. Second, the distance of the cutting device to the first calender nip of the multi-roll device is very large, which extends the transport path (e.g., of the cut dry film material) from the cutting device to the first calender nip. Third, there is a risk that the unevenly formed edges of the dry film (low parallelism or frayed areas) may fold over during transport, resulting in different layer thicknesses or layer compaction, and then the uneven edges may be trimmed.

[0008] A further difficulty with the dry film process is that due to the large coating width (i.e., at least 300 mm width perpendicular to the longitudinal direction of the dry film), the rolls used after calendering (consolidation) must be very large and sturdy to withstand the correspondingly higher line loads for wider coatings than for narrower coatings. [Prior art documents] [Patent documents]

[0009] [Patent Document 1] US Patent Application Publication No. 2017 / 040591A1 [Patent Document 2] International Publication No. 2020 / 148410A2 Summary of the Invention [Problem to be solved by the invention]

[0010] Based on this, it is an object of the present invention to provide a method for producing a dry film, a system for producing a dry film, a dry film, and a battery including a dry film that overcomes at least one, and preferably all, of the drawbacks of the prior art. [Means for solving the problem]

[0011] This object is achieved by a method having the features of claim 1, a system having the features of claim 10, a dry film having the features of claim 19, and a battery having the features of claim 29. Advantageous developments are described in the dependent claims.

[0012] According to the present invention, there is provided a method for producing a dry film, comprising feeding a dry powder mixture and / or the dry mixture to a first calender nip formed by a carrier roll and a first counter roll, wherein the carrier roll rotates about its rotation axis at a first peripheral speed in a first rotation direction, and the counter roll rotates about its rotation axis at a second peripheral speed lower than the first peripheral speed in a second rotation direction opposite to the first rotation direction, and the dry powder mixture and / or the dry mixture passes through the first calender nip in a conveying direction, thereby forming a dry film supported on at least a portion of the carrier roll. A method is provided in which at least one first processing device is used, arranged opposite a first outer segment of the carrier roll in a direction perpendicular to the carrier roll rotation axis, and at least one second processing device is used, arranged opposite a second outer segment of the carrier roll in a direction perpendicular to the carrier roll rotation axis, the carrier roll having an inner segment between the first outer segment and the second outer segment in a direction parallel to the carrier roll rotation axis, and the first and second processing devices are each suitable for removing (preferably at least by cutting, more preferably further by removal, for example, by a removal unit) an area of ​​the dry film supported on the carrier roll at the outer segment of the carrier roll.

[0013] The dry powder mixture may be in the form of a free-flowing powder. The dry mixture may exist as a cohesive, non-flowing bulk material, as a flat agglomerate, or (already) as a dry film (e.g., a dry film in ribbon form). In principle, the dry powder mixture and the dry mixture are not considered to be two different substances, but rather the dry powder mixture is considered to be a special embodiment of the dry mixture. In this case, the term "dry powder mixture and / or dry mixture" can be simplified to the term "dry mixture," where the dry powder mixture is a special form (species) of the dry mixture (genus). In this case, the dry mixture (because it can be a dry powder mixture) can also be in the form of a free-flowing powder.

[0014] The method (dry film process) according to the invention makes it possible to provide segmented strip-shaped dry films with very high edge accuracy at high speed and in an energy-saving manner. High edge accuracy is understood to mean that the web formed by the dry film (or the entire web formed by the dry film) is defined by two boundary lines in the longitudinal direction of the web, the boundary lines being substantially straight and substantially parallel to each other. "Substantially straight and substantially parallel to each other" is understood to mean that the distance between each two boundary lines along the longitudinal direction varies by 1000 μm or less, preferably 500 μm or less, particularly preferably 200 μm or less. According to the invention, the dry film is particularly suitable for use with non-self-supporting coatings or layers (with a coating surface resistance of 100 N / m 2 or a free-standing self-supporting film (tensile strength of 100 N / m on the coated surface) 2 tensile strength of greater than 1000 MPa), which means that it is obtained from a film-forming process in which no solvent is used, i.e. in particular no solvent is used in the method according to the invention.

[0015] The method according to the invention is relevant for the preparation of layers of battery electrodes (lithium-ion batteries, solid-state batteries, lithium-sulfur batteries, sodium-ion batteries), but also for other coatings for energy storage devices (e.g. supercapacitors, fuel cells), electrochemical components (e.g. for electrolysis or catalytic layers) or adsorbent layers formed from porous materials.

[0016] In a preferred embodiment of the method, the first and second processing devices are each suitable for removing, without movement of their own, an area of ​​the dry film supported on the carrier roll at the outer segment of the carrier roll, at least by cutting (preferably also by removal, for example, by a removal unit of the system), where it is particularly meant that in the method, the first and second processing devices remain stationary (i.e., do not move relative to the carrier roll). The same can be applied to other, preferably all, processing devices used in the method according to the invention. This embodiment can further increase the high edge precision, i.e., the strict linearity and parallelism of the two boundary lines of the dry film produced by the method.

[0017] In this method, the dry film can be transferred to a carrier roll without a substrate. This method can be used to create a free-standing dry film, i.e., a dry film that is not stored on a substrate. In a downstream step of this method, the free-standing dry film can be applied to a substrate. The substrate can have a three-dimensional structure (e.g., fabric, fleece, or expanded metal). Furthermore, the substrate can be textured (e.g., etched, sandblasted, laser treated). In addition, the substrate can include or consist of a porous layer (e.g., an electrode layer or a particle layer). The layer applied to the substrate can be applied to the substrate using a slurry process or a dry film process. A primer layer can be present between the substrate and the dry film, and this primer layer can support (i.e., strengthen) the adhesion of the dry film to the substrate.

[0018] Alternatively, a dry film can be laminated onto a substrate during the method according to the present invention. This method can be used to produce a dry film laminated onto a substrate. In this case, the substrate can have a three-dimensional structure (e.g., fabric, fleece, or expanded metal). Furthermore, the substrate can be textured (e.g., etched, sandblasted, or laser-treated). In addition, the substrate can comprise or consist of a porous layer (e.g., an electrode layer or a particle layer). The layer applied to the substrate can be applied to the substrate using a slurry process or a dry film process. To support adhesion of the dry film to the substrate, the substrate can have a primer layer before the dry film is laminated. However, in this embodiment, it is also possible, in principle, to remove the dry film from the substrate again (at the end of the process) to provide a free-standing dry film. Removing the substrate from the dry film can be useful (e.g., for use in a battery) if the substrate to which the dry film is laminated during the method according to the present invention does not comprise or consist of any conductive material, i.e., is not suitable as a substrate for use in, for example, a battery.

[0019] The substrate may be free of or made of a conductive material, or may comprise or made of a conductive material, where the conductive material is preferably selected from the group consisting of metal, carbon, and combinations thereof. The term "metal" also includes metal alloys.

[0020] To enhance adhesion of the dry film, the substrate can have a primer layer in at least some areas. The primer layer can comprise or consist of a polymer (or binder, e.g., a thermoplastic material) and a conductive material (e.g., a carbon-containing material such as carbon black or graphite). The primer layer preferably has a thickness of less than 10 μm, particularly preferably less than 2 μm. Preferably, the primer layer is disposed on the substrate in a direction perpendicular to the carrier roll rotation axis, in an area facing the inner segment of the carrier roll. The primer layer has the advantage of enhancing adhesion of the dry film to the area of ​​the substrate provided with the primer layer. Activation of the polymer in the primer layer, for example, heating (e.g., by a heated roll or an external heat source such as an infrared radiator) in the case of a thermoplastic polymer material, softens the primer layer. In this way, the particles of the dry film are pressed into the primer layer, increasing the contact area between the particles of the dry film and the primer layer. When the primer layer cools (exits the heating zone or turns off the heat source), it solidifies and adheres to the substrate provided with the primer layer due to the increased contact area with the particles of the dry film pressed against the primer layer. In areas of the substrate not provided with a primer layer, the interface is not increased, and therefore the adhesion to the dry film is not increased, which means that the dry film preferably does not adhere to these areas. As a result, the primer layer can further improve the edge precision of the dry film produced and also enables intermittent coating.

[0021] Similar to the primer layer, roughened or three-dimensional substrates (e.g., fleece, wire mesh, expanded metal, and / or textured substrates, such as etched, sandblasted, or laser-treated substrates) can also be used. The surface of the substrate (e.g., a textured surface, such as an etched, sandblasted, or laser-treated surface) can result in a local increase in adhesion and thus improved edge precision. In this case, adhesion is improved when the surface roughness Ra is 1 μm or more, preferably greater than 5 μm, and particularly preferably greater than 10 μm, while areas of the substrate with poor adhesion to the dry film have a roughness Ra of less than 1 μm.

[0022] The substrate may have or consist of a three-dimensional structure in at least certain areas, where the substrate preferably comprises or consists of a woven fabric, a nonwoven fabric, and / or an expanded metal.

[0023] Furthermore, the substrate can have texturing in at least some areas, preferably produced by etching, sandblasting, and / or laser processing. The texturing is particularly present on the surface of the substrate facing the dry film. The texturing can result in a local increase in the adhesion of the dry film and therefore improved edge precision.

[0024] Furthermore, the substrate may comprise or consist of a porous layer in at least some areas, preferably comprising an electrode layer and / or a particle layer. The porous layer onto which the dry film is applied can provide a local increase in adhesion of the dry film and thus improved edge accuracy. The layer applied to the substrate may have been applied to the substrate using a slurry process or a dry film process.

[0025] Additionally, improved adhesion of the dry film, and therefore improved edge accuracy, can be achieved by adding particulate adhesion promoters to the dry powder mixture and / or defined areas of the dry mixture.

[0026] The dry powder mixture and / or the dry mixture may comprise the active material of the battery's electrodes. The dry powder mixture and / or the dry mixture may comprise the active material in a mass fraction of more than 50 wt. %, preferably more than 70 wt. %, particularly preferably more than 90 wt. %, based on the total mass of the dry powder mixture and / or the dry mixture. The dry powder mixture may be in the form of a free-flowing powder. The dry mixture may be present as a cohesive, non-flowing bulk material, as a flat agglomerate, or (already) as a dry film (e.g., a dry film in ribbon form). The active material is preferably selected from the group consisting of the active material for the battery's cathode and the active material for the battery's anode. The battery may preferably be a lithium or sodium battery. The cathode active material may be selected from the group consisting of lithium iron phosphate (LFP), lithium manganese iron phosphate (LMFP), lithium manganese oxide (LMO), lithium nickel manganese cobalt oxide (NMC), nickel-rich lithium nickel manganese cobalt oxide (NMC622, NMC811, or related NMC materials), lithium nickel cobalt aluminum oxide (NCA), lithium cobalt oxide (LCO), lithium manganese nickel oxide (LMNO), high-voltage spinel (HVS), carbon, sulfur, and combinations thereof. The anode active material may be selected from the group consisting of graphite, hard carbon, silicon, carbon, tin, silicon oxide, lithium, lithium indium titanate (LTO), and combinations thereof. Additionally, these may be sodium-containing compounds based on metal oxides, polyanions (vanadates and / or phosphates), and analogs of Berlin blue.

[0027] In addition, the dry powder mixture and / or the dry mixture may contain a conductive additive, preferably selected from the group consisting of carbon nanotubes, carbon (e.g., carbon black, carbon nanotubes, and / or carbon fiber), graphite, graphene, porous carbon (e.g., activated carbon), and combinations thereof. The dry powder mixture and / or the dry mixture may contain the conductive additive in a proportion of 0.1 to 10 wt %, preferably 0.5 to 5 wt %, particularly preferably 1 to 4 wt %, based on the total mass of the dry powder mixture and / or the dry mixture.

[0028] Furthermore, the dry powder mixture and / or dry mixture (as a binder or binder component) may contain a material that exhibits a binder effect in a non-fibrillated state (i.e., a "binder"). The material is preferably selected from the group consisting of non-fibrillizable fluoropolymers (preferably polyvinylene fluoride (PVDF), ethylene tetrafluoroethylene (ETFE), and / or polytetrafluoroethylene (PTFE)), carboxymethylcellulose (CMC), styrene-butadiene rubber (SBR), biopolymers, polyolefins (e.g., polyethylene, preferably polyethylene with a molecular weight greater than 1,000,000 g / mol), polypeptides (e.g., sericin), polyamides, polyacrylates, and mixtures thereof. In this case, the binder effect does not depend on the formation of a fibril network (non-fibrillizable binder). The dry powder mixture and / or dry mixture may contain this material in a proportion of 0.1 to 10 wt. %, preferably 0.5 to 5 wt. %, and particularly preferably 0.5 to 4 wt. % based on the total mass of the dry powder mixture and / or dry mixture.

[0029] In particular, the dry powder mixture and / or dry mixture (as a binder or binder component) may contain a fibrillizable material that can fibrillate under the action of mechanical, thermal, and / or physicochemical influences and also exhibit a binder effect (i.e., can also be a "binder"). The material is preferably selected from the group consisting of polypeptides (e.g., sericin), plastics (e.g., fluoropolymers such as PTFE and / or polyolefins with a molecular weight greater than 1,000,000 g / mol, such as polyethylene with a molecular weight greater than 1,000,000 g / mol), and mixtures and combinations thereof (fibrillizable binders). The mechanical shear force of the calendar nip allows the material to form fibrils, which form a stabilizing network and thus increase the mechanical stability of the dry film. The term "fibril" particularly refers to thread-like structures, preferably having a diameter in the range of 0.001 μm to 1 μm and / or a length in the range of 1 μm to 100 μm. The dry powder mixture and / or dry mixture may contain fibrillizable material in a proportion of up to 10% by weight, preferably up to 5% by weight, particularly preferably up to 2% by weight, very particularly preferably 0.3 to 2% by weight, optionally 1 to 2% by weight, based on the total mass of the dry powder mixture and / or dry mixture.

[0030] By storing the prepared dry film in a roll, the binder can be present in the dry powder mixture and / or dry mixture in a proportion of 10% by weight or less, preferably 5% by weight or less, particularly preferably 2% by weight or less, very particularly preferably 0.3 to 2% by weight, and optionally 1 to 2% by weight, based on the total weight of the dry powder mixture and / or dry mixture. Optionally, the proportion of the binder in the dry powder mixture and / or dry mixture is 0.1% by weight or more, based on the total weight of the dry powder mixture and / or dry mixture.

[0031] The activation of the binder effect (such as the formation of fibrils in PTFE or the punctate binder effect in PVDF or polyolefins) can occur thermally, mechanically, and / or chemically. The activation process can be preformed in an upstream process step or can be generated for the first time in the calendering process.

[0032] For upstream activation, grinding or mixing processes can be used in which shear forces are exerted on the dry powder mixture and / or the dry mixture, especially the binder, by collisions between particles or with mechanical elements. For this purpose, mills such as pin mills, jet mills, impact mills, ball mills, beater mills, mortar mills, roller mills, or mixers such as planetary mixers, Eirich mixers, kneaders, single-screw extruders and / or twin-screw extruders can be used.

[0033] Activation of the binder (e.g., fibrillation or softening, formation of physical or chemical bonds, or a combination thereof) can also be achieved by thermal or chemical activation in addition to or instead of the dry powder mixture and / or shear forces introduced into the dry mixture.

[0034] For thermoplastic binders such as PVDF or polyolefins, activation by heating near or above the softening temperature can be used. If heat is used in addition to mechanical activation, heating well below the softening temperature may be sufficient for activation. For activation of fibrillizable binders such as PTFE, a transition temperature must be observed. For fibrillizable PTFE (e.g., 10 6 g / mol, preferably greater than 10 7Emulsion-polymerized PTFE (with a high molecular weight of more than 1000 g / mol) has a softening temperature above 300°C. However, fibril formation of such PTFE can be thermally activated when subjected to mechanical stress at temperatures above 18°C. Thus, thermal activation combined with the application of mechanical force can be achieved between 18°C ​​and 330°C, preferably between 25°C and 200°C, particularly preferably between 60°C and 180°C, and very particularly preferably between 80°C and 120°C.

[0035] Conversely, processing below 18°C ​​allows for mechanical processing (mixing, homogenization, grinding, etc.) without fibrillation. This means that the binder effect is not present at these low temperatures, which means that the mixture does not tend to clump and has good injectability. After the binder is activated, the dry powder mixture and / or dry mix may tend to clump and may no longer be free-flowing. This can be detrimental to further process control if the dry powder mixture and / or dry mix must be free-flowing for dosing processes or transportation and delivery. For example, when activating PTFE in a jet mill, fine dry powder mixtures and / or dry mixes are produced, which must be processed directly; otherwise, the activated binder will cause clumping, making certain subsequent process steps unfeasible.

[0036] It is also possible to recycle dry film material that is generated as waste during coating production by using an upstream process for the dry powder and / or dry mix processing. The reject material (waste) is fed back into the dry powder and / or dry mix, and the rate of reject material added is controlled using a controlled dosing unit.

[0037] Shear forces also occur in the film-forming calender nip between the carrier roll and the counter roll, which may allow for mechanical activation of the binder independently of or in addition to the dry powder mix pretreatment and / or dry mix pretreatment. Shear forces, and therefore film formation, can be achieved even when the same peripheral speed of the two rolls is used. Preferably, for this purpose, dry powder mixes and / or dry mixes are used in which the binder has already been pre-activated (e.g., PTFE fibrillation has been performed in an upstream process). In the case of fibrillated PTFE, fibrils may already be present in the dry powder mix and / or dry mix (and therefore distributed in all spatial directions within the resulting layer). By combining different types of activation, both free-flowing dry powder mixes and less flowable, agglomerated dry powder mixes and / or dry mixes (e.g., ribbon-shaped dry films) can be used for film formation.

[0038] Preferably, film formation is achieved by using different peripheral speeds for the carrier roll and the counter roll. The greater the difference in peripheral speeds, the greater the additional shear force acting on the dry powder mixture and / or dry mixture in the nip, further supporting binder activation. This can result in anisotropically oriented fibrils in the dry film. Preferably, a peripheral speed ratio between the carrier roll and the counter roll is used that is greater than 1:1, preferably greater than 2:1, particularly preferably greater than 3:1, and most preferably greater than 4:1. Preferably, a peripheral speed ratio between the carrier roll and the counter roll is used that is less than 20:1. The shear force introduced by the rolls rotating at different speeds can achieve higher compaction of the dry film (=lower porosity) with the same pressing force as pure pressing (the rolls have the same rotational speed and a rotational speed ratio of 1:1). In this case, a porosity greater than 60% results in a film formation step with the same pressing force, and therefore, strong recompression or higher pressing force must be used during the film formation step, which can result in particle damage. However, when forming films according to the invention at different peripheral speeds, it is directly possible to achieve porosities of less than 40% at the same pressing force, which reduces the risk of particle damage.

[0039] The nip width used between the carrier roll and the counter roll may be between 5 μm and 1000 μm, preferably between 10 μm and 1000 μm, particularly preferably between 20 μm and 150 μm, especially preferably between 30 μm and 100 μm, and very preferably between 40 μm and 70 μm.

[0040] The method according to the present invention allows the use of a lower linear load during film formation compared to pure pressure. The linear load used can be less than 500 kN / cm (e.g., a linear load between 1 N / cm and 200 kN / cm), preferably 10 kN / cm or less (e.g., a linear load between 10 N / cm and 10 kN / cm). Because a low linear load can avoid roll deformation, the carrier roll and / or counter roll (film-forming roll) can have a smaller roll diameter and / or roll width.

[0041] The diameter of the carrier roll and / or counter roll (film-forming roll) may be 100 cm or less (e.g., between 10 cm and 100 cm), particularly preferably 50 cm or less (e.g., between 10 cm and 50 cm), and especially less than 30 cm. The roll diameters of the carrier roll and counter roll may be different. A smaller roll diameter has the advantage that a lower dry film thickness can be achieved during film formation. Thus, the process and system according to the present invention can achieve a dry film thickness of between 5 μm and 1000 μm, preferably between 10 μm and 1000 μm, particularly preferably between 20 μm and 150 μm, especially preferably between 30 μm and 100 μm, and very particularly preferably between 40 μm and 70 μm.

[0042] The width (ie the extent perpendicular to the roll axis) of the carrier roll and / or counter roll may be more than 30 cm, preferably more than 60 cm, particularly preferably more than 100 cm (especially up to 300 cm).

[0043] This effect can also be enhanced by using heated rolls (for example, heated to a temperature between 18°C ​​and 330°C, preferably between 25°C and 200°C, particularly preferably between 60°C and 180°C, and very particularly preferably between 80°C and 120°C). This means that non-preactivated dry powder mixtures and / or non-preactivated dry mixes can also be used for film formation. However, it is also possible to use non-flowable or low-flowable dry powder mixtures and / or dry mixes (for example, ribbon-shaped dry mixes).

[0044] When dry powder mixtures and / or dry mixtures are mixed and / or pretreated using an extruder, such as a twin-screw extruder, and the PTFE is activated by applying shear and thermal activation, free-flowing agglomerated extrudates can be obtained. These extrudates can have particle sizes ranging from 50 μm to 5000 μm, preferably from 200 μm to 2000 μm, and particularly preferably from 250 μm to 750 μm. In contrast to fine dry powder mixtures and / or fine dry mixtures pretreated in a jet mill, the particles are significantly larger and have a much lower tendency to further agglomerate. In this way, storable dry powder mixtures and / or dry mixtures can be obtained, which can be transferred to a calendering machine without further processing to form a film. By avoiding excessive activation of the binder (processing at temperatures below 150°C, preferably below 120°C, and residence times in the shear-applying kneading zone of the extruder of less than 60 seconds, preferably less than 10 seconds), the extrudate can have a relatively low hardness, allowing for good processing in the calender nip at relatively low pressing forces.

[0045] Furthermore, the dry powder mixture and / or the dry mixture may contain an ion-conducting substance, preferably an ion-conducting solid (solid electrolyte). The ion-conducting material is preferably selected from the group consisting of an ion-conducting solid (solid electrolyte), a gel-like ion conductor, a salt-like ion conductor, and a mixture thereof (preferably Li-ion conductive and / or Na-ion conductive). The ion-conducting solid is preferably selected from the group consisting of a sulfide solid ion conductor (e.g., lithium thiophosphate, LPS, argyrodite, LPSCl and / or LGPS, or a corresponding Na-ion conductive sulfide solid ion conductor), a glassy solid ion conductor (e.g., LiAlSiO4 or NaAlSiO4), a polymer solid ion conductor (e.g., PEO), a ceramic solid ion conductor (e.g., LLZO or a corresponding Na-ion conductive ceramic solid ion conductor), and a mixture thereof. The dry powder mixture and / or the dry mixture may contain the solid electrolyte in a proportion of 1 to 99% by weight, preferably 5 to 30% by weight, particularly preferably 10 to 20% by weight, based on the total mass of the dry powder mixture.

[0046] The dry powder mix and / or dry blend may have a liquid content of 1% or less by volume, based on the total volume of the dry powder mix and / or dry blend.

[0047] In this method, the inner segment, the first outer segment, and the second outer segment of the carrier roll can each be defined by two mutually parallel boundary lines around the circumference of the carrier roll. Preferably, at least one boundary line of the inner segment is located on the boundary line of the first outer segment and / or the second outer segment. In other words, the inner segment is directly connected to, i.e., in contact with, the first and / or second outer segments.

[0048] The inner segment of the carrier roll may have, in at least a portion thereof, a surface finish to which a dry film adheres (e.g., an adhesive coating on the surface of the carrier roll and / or surface texturing of the carrier roll, e.g., texture optionally generated periodically or irregularly by etching, sandblasting, and / or laser processing), while the first outer segment and / or the second outer segment of the carrier roll have a surface finish to which a dry film does not adhere, preferably designed as a smooth surface of the carrier roll. The smooth surface may have a central roughness value Ra that is 50% or less of the central roughness value of the inner segment of the carrier roll. The smooth surface has a central roughness value Ra in the range of 0.001 μm to 1 μm. The surface of the inner segment of the carrier roll may have a central roughness value Ra that is more than 50% of the central roughness value Ra of the smooth surface of the carrier roll, preferably between 0.1 μm and 10 μm. An advantage of this embodiment is that the adhesion of the dry film to the carrier roll is reduced in areas where the dry film should not adhere to the carrier roll. In other words, the first and second processing devices only need to remove a smaller amount of dry film from the carrier roll, at least by cutting. That is, the unadhered dry film becomes available again earlier in the process and is returned to the first calender nip (as a dry powder mixture and / or a dry mixture), which may make the process more efficient and shorten maintenance intervals for the processing devices.

[0049] Furthermore, the inner segment of the carrier roll may have, in at least a portion thereof, a surface finish to which a dry film adheres (e.g., an adhesive coating on the surface of the carrier roll and / or a surface texturing of the carrier roll, e.g., a texturing optionally generated periodically or irregularly by etching, sandblasting, and / or laser treatment), while the first outer segment of the counter roll, which is arranged opposite the first outer segment of the carrier roll in a direction perpendicular to the carrier roll rotation axis, and / or the second outer segment of the counter roll, which is arranged opposite the second outer segment of the carrier roll in a direction perpendicular to the carrier roll rotation axis, has a surface finish to which a dry film does not adhere. Preferably, the surface finish of the first outer segment of the counter roll and / or the second outer segment of the counter roll is designed as a concave surface of the counter roll, and the concave surface preferably has a radius of 99.9% or less, preferably 99% or less, particularly preferably 95% or less, and in particular 90% or less of the radius of the counter roll in the first region of the inner segment of the counter roll. The surface finish of the first outer segment of the counter roll and / or the second outer segment of the counter roll to which the dry film does not adhere can further be designed as a coating (e.g., a coating including or consisting of DLC and / or PTFE) on the first outer segment of the counter roll and / or the second outer segment of the counter roll, thereby reducing adhesion to the counter roll (preferably at least 1% by weight less dry film, especially at least 10% by weight less dry film, than the inner segment of the carrier roll), and preferably resulting in no adhesion at all. Alternatively or additionally, the surface finish of the inner segment of the carrier roll to which the dry film adheres can be designed as a coating and / or texturing of the inner segment of the carrier roll, which results in adhesion to the carrier roll. The coating can also be an adhesive coating on the surface of the inner segment of the carrier roll.The texturing may be created by etching, sandblasting, and / or laser treatment (optionally periodically or irregularly). The surface of the inner segment of the carrier roll may have a median roughness value Ra greater than 50% of the median roughness value Ra of the surface of the first outer segment of the counter roll and / or the second outer segment of the counter roll, preferably between 0.1 μm and 10 μm. The coating of the inner segment of the carrier roll and / or the first outer segment of the counter roll and / or the second outer segment of the counter roll may comprise or consist of a material selected from the group consisting of PTFE, DLC, tungsten carbide, hard chrome, and combinations thereof. An advantage of this embodiment is that the adhesion of the dry film to the carrier roll is reduced in areas where the dry film should not adhere to the carrier roll. In other words, the first and second processing devices only need to remove a smaller amount of dry film from the carrier roll by at least cutting. That is, the unattached dry film becomes available again earlier in the process and can be returned to the first calender nip (as a dry powder mix and / or dry mix), which can make the process more efficient and shorten maintenance intervals for the processing device.

[0050] Optionally, the carrier roll has at least one second region of the inner segment shaped similarly to the first and / or second outer segments of the carrier roll, i.e., the concave surface of the second region preferably has a radius that is 99.9% or less, preferably 99% or less, particularly preferably 95% or less, and especially 90% or less of the radius that the counter roll has in the first region of the inner segment.

[0051] The first and second processing devices may each have a cutting unit used to separate by cutting the region of the dry film supported on the carrier roll at the respective outer segments of the carrier roll from the region of the dry film supported on the carrier roll at the inner segments of the carrier roll (i.e., cutting of the dry film occurs in the web direction in which the dry film is transported on the carrier roll). The advantage of separating by cutting compared to separating by applying pressure via a moving stripper film (e.g., the method of Patent Document 1) is that it is possible to highly reliably prevent the boundary line of the dry film (i.e., the edge of the dry film) from extending in a wavy shape or fraying in the longitudinal direction of the dry film, at least in some regions. In other words, it can be highly reliably guaranteed that the edges of the dry film extend straight and parallel to each other along their length. This improves the edge precision of the produced dry film.

[0052] The cutting unit is preferably selected from the group consisting of a rolling knife, an air nozzle, a laser, and a combination thereof. A rolling knife and a laser can also be used to cut dry films with strong adhesive properties. The rolling knife can include a material (e.g., brass as the rolling knife material) with a lower Vickers hardness (e.g., HV10) than the material of the surface of the carrier roll (e.g., chromium as the carrier roll surface material). This has the advantage of reducing wear on the carrier roll. An air nozzle is particularly suitable when cutting areas of the dry film on roll segments (e.g., the first and / or second outer segments) that have a surface finish to which the dry film does not adhere, because the lower cutting force of the air nozzle can be sufficient to cut dry film residues that adhere to the carrier roll despite the non-adhesive surface finish of the carrier roll. Further advantages of air nozzles are that they can be operated with low maintenance, the air speed can be easily adjusted to accommodate dry film of different thicknesses, and, unlike rolling knives, no material accumulates near the cutting edge (e.g., dry film material accumulates on the blade of a rolling knife), thereby preventing damage to the formation or structure of the dry film. Lasers have the advantage of enabling non-contact cutting and therefore being gentler on the surface of the carrier roll than, for example, rolling knives, which may allow the process to run longer and more economically. Furthermore, lasers can also prevent the accumulation of dry film material near the cutting edge, preventing damage to the formation or structure of the dry film. In this method, the switching on, switching off, and effective force of the cutting unit of each processing device (e.g., the pressing force of the rolling knife, the air flow intensity of the air nozzle, and / or the radiation intensity of the laser) can be controlled.

[0053] The cutting unit may comprise a positioning system. This may improve edge accuracy and, for example, positioning of the cutting unit on the substrate film. The positioning system may comprise a detector for detecting the positioning. Furthermore, the positioning system may comprise a crossing unit for positioning the cutting unit. Furthermore, the positioning system may comprise a control unit (separate from the system according to the invention) configured to control or adjust the positioning system, preferably the crossing unit of the positioning system. Alternatively or additionally, the control unit of the system according to the invention may be configured to control or adjust the positioning system, preferably the crossing unit of the positioning system. Adjustment may be made via feedback of information from the detector of the positioning system (a "feedback" mechanism).

[0054] Additionally, each of the first and second processing devices may include a removal unit used to remove an area of ​​the dry film supported on the carrier roll at a respective outer segment of the carrier roll.

[0055] Furthermore, the first and second processing devices may each comprise a further removal unit that is used to remove areas of the dry film perpendicular to the coating direction to achieve an intermittent coating in the coating direction.

[0056] The removal unit is preferably selected from the group consisting of an air nozzle, a scraper, a brush, a suction device, and combinations thereof. Scrapers and brushes have the advantage that they can also remove dry film that is strongly adhered to the carrier roll. Air nozzles or suction devices are particularly suitable when cutting dry film areas on roll segments (e.g., the first and / or second outer segments) that have a surface finish to which dry film does not adhere, because the lower removal force of the air nozzle or suction device can then be sufficient to cut off dry film residues that adhere to the carrier roll despite its non-adhesive surface finish. The extractor has the additional advantage that the extracted dry film material (in the suction channel) can be easily transported back to the calender nip (recovery of the dry film material), thereby avoiding waste of dry film material and making the process more economical. Because the processing device with the removal unit is positioned opposite the first outer segment of the carrier roll in a direction perpendicular to the carrier roll rotation axis, the transport path of the removed dry film material to the calender nip of the carrier roll is also very short, making the transport faster and more energy-efficient. In this method, the switching on, switching off and effective force (e.g., air flow strength of an air nozzle, pressing force of a brush, and / or suction flow strength of a suction device) of the removal unit of each processing device on the carrier roll can be controlled.

[0057] The distance unit and / or the further distance unit can have a positioning system. This can improve edge accuracy and, for example, positioning of the removal unit on the substrate film. The positioning system can have a detector for detecting the positioning. Furthermore, the positioning system can have a traversing unit for positioning the distance unit. Furthermore, the positioning system can have a control unit (separate from the system according to the invention) configured to control or adjust the positioning system, preferably the traversing unit of the positioning system. Alternatively or additionally, the control unit of the system according to the invention can be configured to control or adjust the positioning system, preferably the traversing unit of the positioning system. The adjustment can be made via feedback of information from the detector of the positioning system (a "feedback" mechanism).

[0058] The inner segment of the carrier roll can be subdivided into at least two inner segment regions by at least 2n mutually parallel boundary lines around the circumference of the carrier roll, where n is an integer (e.g., 1, 2, 3, 4, 5, or 6), with an intermediate region disposed between each two adjacent inner segment regions, the boundaries of which are defined in the direction of the rotation axis of the carrier roll by two opposing boundary lines in each case among the 2n boundary lines. At least two inner segment regions can have a surface finish to which a dry film adheres, and the intermediate region preferably has a surface finish to which a dry film does not adhere. An advantage here is that a dry film can also be produced on an inner segment of a carrier roll having a striped pattern (zebra pattern).

[0059] In a preferred embodiment, a further processing device may be used in each case facing each intermediate region of the inner segment in a direction perpendicular to the rotation axis of the carrier roll, and this further processing device is suitable for removing at least a region of the dry film supported on the carrier roll in each intermediate region of the carrier roll by cutting (i.e., cutting of the dry film is performed in the web direction in which the dry film is transported on the carrier roll). The advantage of this is that a dry film can also be produced in the inner segment of the carrier roll with a striped pattern (zebra pattern). By removing by cutting, the dry film can have high edge precision.

[0060] Each of the further processing devices may include a cutting unit used to separate by cutting the region of the dry film supported on the carrier roll in the respective intermediate region of the carrier roll from the portion of the dry film supported on the carrier roll in the inner segment of the carrier roll. The cutting unit is preferably selected from the group consisting of a rolling knife, an air nozzle, a laser, and combinations thereof. In the method, the switching on, switching off, and effective force (e.g., the pressing force of the rolling knife, the air flow strength of the air nozzle, and / or the radiation intensity of the laser) of the cutting unit of each further processing device can be controlled. The cutting unit can optionally have a positioning system having at least one of the above-mentioned features.

[0061] Furthermore, each of the further processing devices may include a removal unit used to remove a region of the dry film supported on the carrier roll at the inner segment of the carrier roll, and the removal unit is preferably a roll. In this method, a roll is preferably used as the further processing device, and the rotation axis of the roll is attached parallel to the rotation axis of the carrier roll, and the width of the roll corresponds to the width of the inner segment or inner segment region. When the roll contacts the carrier roll, the dry film is transferred across the entire width of the roll for further processing or coating, and the outer segment remains on the carrier roll. The outer segment can then be removed from the outer segment of the carrier roll using a removal unit (preferably selected from the group consisting of an air nozzle, a scraper, a brush, an extractor, and combinations thereof). Multiple such rolls can also be arranged along the same rotation axis to, for example, remove at least two inner segment regions of the inner segment of the carrier roll from the carrier roll and transfer those regions to a roll.

[0062] Furthermore, each further processing device may comprise a removal unit used to remove a region of the dry film supported on the carrier roll in the respective intermediate region of the carrier roll, the removal unit preferably being selected from the group consisting of an air nozzle, a scraper, a brush, an extractor, and combinations thereof. In this method, the switching on, switching off, and effective force (e.g., the air flow strength of the air nozzle, the pressing force of the brush, and / or the suction flow strength of the suction device) of the removal unit of each processing device on the carrier roll can be controlled.

[0063] A removal unit, and optionally further removal units, can be used to deliver separate areas of the dry film to the first calender nip, the advantage here being that the dry film material is recycled, thus making the process more economical.

[0064] The removal unit and / or the further removal unit may optionally comprise a positioning system with at least one of the features described above.

[0065] The removed area of ​​the dry film can be fed to a dry mix, for example, which is processed to form a dry powder mixture, which is then fed to a first calender nip. The processing to form a dry powder mixture preferably includes a process selected from the group consisting of an extruder process, a jet mill, a pin mill, an impact mill, a mortar mill, a roll mill, and combinations thereof.

[0066] Alternatively, the removed area of ​​the dry film can be fed to a dry powder mixture, which is then fed to a first calender nip. The proportion of the added removed area of ​​the dry film relative to the total proportion of the dry powder mixture can be preferably at least 0.1% by weight, particularly preferably at least 1% by weight, and particularly preferably at least 10% by weight.

[0067] The dry powder mix and / or dry mix may be delivered to the calender pin using a feeding and / or dosing device (eg, a gravimetric dosing chute).

[0068] The first calender nip can have a width (i.e., the extent in one direction along the carrier roll rotation axis or the distance between the two end faces of the roll) of at least 300 mm, preferably at least 600 mm, particularly preferably at least 1200 mm. Optionally, the first calender nip has a maximum width of 3000 mm. The wider the first calender nip, the more dry film can be produced per unit time, increasing the throughput of the method according to the invention. These dimensions can also be applied to other calender trains.

[0069] Furthermore, the first calender nip may have a mask and / or funnel arranged above the calender nip. The funnel or mask has the advantage of being able to specifically apply the dry powder mixture and / or dry mixture to the area on the carrier roll intended to form a dry film on the carrier roll. For example, the mask or funnel can reduce the amount of dry powder mixture and / or dry mixture applied to at least the two opposite outer segments of the carrier roll, and optionally also to the middle segment of the carrier roll. Thus, the area to be coated is predefined, and the material adheres less to the area of ​​the carrier roll that should not be coated, making the method more efficient.

[0070] Laminating the dry film to the substrate can include the following steps. i) A step of transporting the dry film on the carrier roll to a second calender nip formed by the carrier roll and a second counter roll, wherein the second counter roll rotates in a third rotation direction around the second counter roll rotation axis at a second peripheral speed higher than the first peripheral speed of the carrier roll, and the third rotation direction is opposite to the first rotation direction. ii) Optionally, a step of transporting the dry film together with the substrate through at least a third calender nip, preferably also at least a fourth calender nip, particularly preferably also at least a fifth calender nip, and in particular also at least a sixth calender nip. iii) Optionally, a step of conveying the substrate-free dry film through at least a third calender nip, preferably at least a fourth calender nip, particularly preferably at least a fifth calender nip, in particular at least a sixth calender nip by transfer at an increased peripheral speed (the speed increase between the rolls can be in the range of 1 to 1000%, preferably in the range of 5 to 100%, particularly preferably in the range of 10 to 50%).

[0071] At least one third calender nip, at least one fourth calender nip, at least one fifth calender nip, and at least one sixth calender nip may each be formed by two rolls rotating in opposite rotational directions at different peripheral speeds. Different calender rolls may have different diameters. The rolls may be arranged linearly next to each other. The rolls may also be arranged at an angle to each other.

[0072] The advantage of this embodiment is that the dry film is recompressed. The counter roll, and optionally at least one additional roll, are used to induce transfer of the dry film by applying additional shear force to each calender nip, achieving additional compaction of the dry film. This eliminates the need for downstream calendering or high pressing forces, and therefore large roll diameters in the first and / or second calender nip. Thus, film formation and re-densification or lamination can be spatially decoupled with respect to the assembly. This allows for the use of low-stiffness or low-solidity assemblies and the design of angled structures instead of linear structures, where changes in the calender nip opening risk affecting the nip opening of adjacent nips.

[0073] The method may further comprise a step (preferably at the end of the method) in which the dry film is removed from the substrate to which it has been applied during the method, in which case a free-standing dry film may also be obtained from the dry film that was initially laminated to the substrate (during the process).

[0074] In accordance with the present invention, there is provided a system for producing a dry film, comprising: a) a device configured to produce a dry film from a dry powder mixture and / or the dry mixture, the device comprising a carrier roll and a first counter roll, the carrier roll and the counter roll forming a first calender nip for supplying the dry powder mixture and / or the dry mixture, the carrier roll adapted to rotate about a carrier roll rotation axis, and the counter roll adapted to rotate about a counter roll rotation axis; b) a control unit configured at least to rotate the carrier roll in a first rotation direction about the carrier roll rotation axis at a first peripheral speed and to rotate the counter roll in a second rotation direction about the counter roll rotation axis at a second peripheral speed lower than the first peripheral speed, the second rotation direction being opposite to the first rotation direction, the control unit being configured in particular to set the nip width and / or the contact pressure between the carrier roll and the first counter roll; Equipped with The system comprises at least one first treatment device arranged opposite a first outer segment of the carrier roll in a direction perpendicular to the rotation axis of the carrier roll and at least one second treatment device arranged opposite a second outer segment of the carrier roll in a direction perpendicular to the rotation axis of the carrier roll, the carrier roll having an inner segment between the first outer segment and the second outer segment in a direction parallel to the rotation axis of the carrier roll, the first and second treatment devices each being suitable for removing by at least cutting (and preferably also by removal, e.g., by a removal unit) an area of ​​the dry film supported on the carrier roll at the outer segment of the carrier roll. A system is also provided.

[0075] The system according to the present invention is capable of providing segmented strip-shaped dry film with very high edge accuracy at high speed and in an energy-efficient manner.

[0076] The dry powder mixture may be in the form of a free-flowing powder. The dry mixture may exist as a cohesive, non-flowing bulk material, as a flat agglomerate, or (already) as a dry film (e.g., a dry film in ribbon form). In principle, the dry powder mixture and the dry mixture are not considered to be two different substances, but rather the dry powder mixture is considered to be a special embodiment of the dry mixture. In this case, the term "dry powder mixture and / or dry mixture" can be simplified to the term "dry mixture," where the dry powder mixture is a special form (species) of the dry mixture (genus). In this case, the dry mixture (because it can be a dry powder mixture) can also be in the form of a free-flowing powder.

[0077] The control unit may be configured to control the individual peripheral rotational speeds of the individual rolls and / or further the ratio of the peripheral rotational speeds of the rolls relative to one another.

[0078] Furthermore, the system may comprise a unit configured to control the individual roll spacing (i.e., the nip opening and / or the pressing force occurring at the nip).

[0079] The control unit and / or units may be configured to couple the controller with process monitoring devices, such that the controller adjusts system parameters such as peripheral speed, nip opening, and / or pressing force based on process monitoring values ​​(e.g., regarding coating thickness, load, homogeneity, defects, and / or edge accuracy) to maintain within a predetermined coating result having a specified tolerance range.

[0080] In a preferred embodiment of the system, the first and second treatment devices are each suitable for removing, without independent movement, at least by cutting (and preferably also by removal, e.g., by a removal unit of the system), an area of ​​the dry film supported on the carrier roll at the outer segment of the carrier roll, which in particular means that in the system the first and second treatment devices remain stationary (i.e., are not configured to move relative to the carrier roll). The same may apply to other, preferably all, treatment devices comprised by the system according to the invention.

[0081] If the system includes a dry powder mix and / or dry mix, the dry powder mix and / or dry mix may have at least one of the characteristics described above.

[0082] In a preferred embodiment, the system includes a substrate and is configured to laminate the dry film to the substrate, the substrate preferably including a primer layer in at least some areas to enhance adhesion of the dry film. When the system includes a substrate, the substrate may include at least one of the characteristics described above.

[0083] The primer layer may comprise or consist of a binder and a conductive material.

[0084] The primer layer may have a thickness in the range of less than 10 μm, preferably less than 2 μm.

[0085] Additionally, the primer layer may be disposed on the substrate in an area facing the inner segment of the carrier roll in a direction perpendicular to the axis of rotation of the carrier roll.

[0086] The inner segment, first outer segment, and second outer segment of the carrier roll can each be defined by two parallel boundary lines around the circumference of the carrier roll. Preferably, at least one boundary line of the inner segment is located on the boundary line of the first outer segment and / or the second outer segment. In other words, the inner segment is directly connected to, i.e., in contact with, the first and / or second outer segments.

[0087] The inner segment of the carrier roll may have, in at least a portion thereof, a surface finish to which a dry film adheres (e.g., an adhesive coating on the surface of the carrier roll and / or surface texturing of the carrier roll, e.g., texture optionally generated periodically or irregularly by etching, sandblasting, and / or laser processing), while the first outer segment and / or the second outer segment of the carrier roll have a surface finish to which a dry film does not adhere, preferably designed as a smooth surface of the carrier roll. The smooth surface may have a central roughness value Ra that is 50% or less of the central roughness value of the inner segment of the carrier roll. The smooth surface has a central roughness value Ra in the range of 0.005 μm to 1 μm. The surface of the inner segment of the carrier roll may have a central roughness value Ra that is more than 50% of the central roughness value Ra of the smooth surface of the carrier roll, preferably between 0.1 μm and 10 μm.

[0088] Furthermore, the inner segment of the carrier roll may have, in at least a portion thereof, a surface finish to which a dry film adheres (e.g., an adhesive coating on the surface of the carrier roll and / or a surface texturing of the carrier roll, e.g., a texturing optionally generated periodically or irregularly by etching, sandblasting, and / or laser treatment), while the first outer segment of the counter roll, which is arranged opposite the first outer segment of the carrier roll in a direction perpendicular to the carrier roll rotation axis, and / or the second outer segment of the counter roll, which is arranged opposite the second outer segment of the carrier roll in a direction perpendicular to the carrier roll rotation axis, has a surface finish to which a dry film does not adhere. Preferably, the surface finish of the first outer segment of the counter roll and / or the second outer segment of the counter roll is designed as a concave surface of the counter roll, and the concave surface preferably has a radius of 99.9% or less, preferably 99% or less, particularly preferably 95% or less, and in particular 90% or less of the radius of the counter roll in the first region of the inner segment of the counter roll. Alternatively or additionally, the surface finish of the first outer segment of the counter roll and / or the second outer segment of the counter roll can be designed as a coating (e.g., a coating comprising or consisting of DLC and / or PTFE) on the first outer segment of the counter roll and / or the second outer segment of the counter roll, thereby reducing adhesion to the counter roll (preferably at least 1% by weight less dry film, particularly at least 10% by weight less dry film, than the inner segment of the carrier roll), preferably eliminating adhesion altogether, the inner segment of the carrier roll optionally having a coating to which the dry film adheres. The coating can also be an adhesive coating on the surface of the inner segment of the carrier roll. The coating can also be a textured coating on the inner segment of the carrier roll (e.g., a textured coating, optionally periodically or irregularly generated by laser texturing and / or sandblasting).The surface of the inner segment of the carrier roll may have a median roughness value Ra of more than 50% of the median roughness value Ra of the surface of the first outer segment of the counter roll and / or the second outer segment of the counter roll, which preferably have a median roughness value Ra of between 0.1 μm and 10 μm. The coating particularly preferably comprises or consists of a material selected from the group consisting of PTFE, DLC, tungsten carbide, hard chrome, and combinations thereof.

[0089] Optionally, the carrier roll has at least one second region of the inner segment shaped similarly to the first and / or second outer segments of the carrier roll, i.e., the concave surface of the second region preferably has a radius that is 99.9% or less, preferably 99% or less, particularly preferably 95% or less, and especially 90% or less of the radius that the counter roll has in the first region of the inner segment.

[0090] The first and second processing devices may each have a cutting unit configured to cut and separate a region of the dry film supported on the carrier roll at the respective outer segment of the carrier roll from a region of the dry film supported on the carrier roll at the inner segment of the carrier roll (i.e., cutting of the dry film occurs in the web direction in which the dry film is transported on the carrier roll). The cutting unit is preferably selected from the group consisting of a rolling knife, an air nozzle, a laser, and combinations thereof. The control unit of the system may further be configured to control the switching on, switching off, and effective force (e.g., the pressing force of the rolling knife, the air flow intensity of the air nozzle, and / or the radiation intensity of the laser) of the cutting unit of each processing device.

[0091] The cutting unit may comprise a positioning system. This may improve edge accuracy and, for example, positioning of the cutting unit on the substrate film. The positioning system may comprise a detector for detecting the positioning. Furthermore, the positioning system may comprise a crossing unit for positioning the cutting unit. Furthermore, the positioning system may comprise a control unit (separate from the system according to the invention) configured to control or adjust the positioning system, preferably the crossing unit of the positioning system. Alternatively or additionally, the control unit of the system according to the invention may be configured to control or adjust the positioning system, preferably the crossing unit of the positioning system. Adjustment may be made via feedback of information from the detector of the positioning system (a "feedback" mechanism).

[0092] Furthermore, the first and second processing devices may include a removal unit configured to remove a region of the dry film supported on the carrier roll at each outer segment of the carrier roll. The removal unit is preferably selected from the group consisting of an air nozzle, a scraper, a brush, a suction device, and combinations thereof. The control unit of the system may further be configured to control the switching on, switching off, and effective force (e.g., the air flow strength of the air nozzle, the pressing force of the brush, and / or the suction flow strength of the suction device) of the removal unit of each processing device on the carrier roll.

[0093] Additionally, the first and second processing devices may comprise further removal units configured to remove areas of the dry film perpendicular to the coating direction to achieve an intermittent coating in the coating direction.

[0094] The distance unit and / or the further distance unit can have a positioning system. This can improve edge accuracy and, for example, positioning of the removal unit on the substrate film. The positioning system can have a detector for detecting the positioning. Furthermore, the positioning system can have a traversing unit for positioning the distance unit. Furthermore, the positioning system can have a control unit (separate from the system according to the invention) configured to control or adjust the positioning system, preferably the traversing unit of the positioning system. Alternatively or additionally, the control unit of the system according to the invention can be configured to control or adjust the positioning system, preferably the traversing unit of the positioning system. The adjustment can be made via feedback of information from the detector of the positioning system (a "feedback" mechanism).

[0095] The inner segment of the carrier roll may be subdivided into at least two inner segment regions by at least 2n mutually parallel boundary lines around the circumference of the carrier roll, where n is an integer, and an intermediate region is arranged between each two adjacent inner segment regions, the boundaries of the intermediate region being defined in the direction of the rotation axis of the carrier roll by in each case two opposing boundary lines of the 2n boundary lines.

[0096] At least two of the inner segment regions can have a surface finish to which the dry film will adhere, and the middle region preferably has a surface finish to which the dry film will not adhere.

[0097] Furthermore, the system can have a further processing device in each case opposite each intermediate region of the inner segment in a direction perpendicular to the carrier roll rotation axis, said further processing device being in each case suitable for removing, by at least cutting, an area of ​​the dry film supported on the carrier roll in the intermediate region of the carrier roll.

[0098] Each of the further processing devices may have a cutting unit configured to cut and separate the region of the dry film supported on the carrier roll in the respective intermediate region of the carrier roll from the region of the dry film supported on the carrier roll in the inner segment of the carrier roll (i.e., cutting of the dry film is performed in the web direction in which the dry film is transported on the carrier roll). The cutting unit is preferably selected from the group consisting of a rolling knife, an air nozzle, a laser, and combinations thereof. The control unit of the system may further be configured to control the switching on, switching off, and effective force (e.g., the pressing force of the rolling knife, the air flow strength of the air nozzle, and / or the radiation intensity of the laser) of the cutting unit of each further processing device on the carrier roll. The cutting unit may optionally have a positioning system comprising at least one of the above-mentioned features.

[0099] Furthermore, each of the further processing devices may include a removal unit configured to remove a region of the dry film supported on the carrier roll at the inner segment of the carrier roll, and the removal unit is preferably a roll. In this system, a roll is preferably used as the further processing device, and the rotation axis of the roll is attached parallel to the rotation axis of the carrier roll, and the width of the roll corresponds to the width of the inner segment or inner segment region. When the roll contacts the carrier roll, the dry film is transferred across the entire width of the roll for further processing or coating, and the outer segment remains on the carrier roll. The outer segment can then be removed from the outer segment of the carrier roll using a removal unit (preferably selected from the group consisting of an air nozzle, a scraper, a brush, an extractor, and combinations thereof). Multiple such rolls can also be arranged along the same rotation axis to, for example, remove at least two inner segment regions of the inner segment of the carrier roll from the carrier roll and transfer them to a roll.

[0100] Furthermore, each of the further processing devices may include a removal unit configured to remove a region of the dry film supported on the carrier roll in a respective intermediate region of the carrier roll. The removal unit is preferably selected from the group consisting of an air nozzle, a scraper, a brush, a suction device, and combinations thereof. The control unit of the system may further be configured to control the switching on, switching off, and effective force (e.g., the air flow strength of the air nozzle, the pressing force of the brush, and / or the suction flow strength of the suction device) of the removal unit of each of the further processing devices on the carrier roll.

[0101] The removal unit, and optionally further removal units, can be configured to feed the discrete areas of the dry film to the first calender nip. Preferably, the control unit of the system is configured to control the feeding of the discrete areas of the dry film to the first calender nip.

[0102] The removal unit and / or the further removal unit may optionally comprise a positioning system with at least one of the features described above.

[0103] Optionally, the removal unit, preferably the further removal unit, can be configured to first feed the removed area of ​​the dry film to a dry mix, and the processing device of the system is configured to process the dry mix into a dry powder mix and feed the dry powder mix to the first calender nip. The processing device is preferably selected from the group consisting of an extruder, a jet mill, a pin mill, an impact mill, a mortar mill, a roller mill, and combinations thereof.

[0104] Alternatively, the removal unit, preferably the further removal unit, can be configured to first feed the removed area of ​​the dry film to the dry powder mixture, and the system is configured to feed the dry powder mixture to the first calender nip, and the proportion of the fed removed area of ​​the dry film relative to the total proportion of the dry powder mixture is preferably at least 0.1 wt.%, particularly preferably at least 1 wt.%, and very particularly preferably at least 10 wt.%.

[0105] The system may comprise a feeding and / or dosing device (eg, a gravimetric dosing chute) suitable for feeding the dry powder mix and / or dry mix into the calender nip.

[0106] The first calender nip can have a width of at least 300 mm, preferably at least 600 mm, particularly preferably at least 1200 mm. Optionally, the first calender nip has a maximum width of 3000 mm. The wider the first calender nip, the more dry film can be produced per unit time, increasing the throughput of the method according to the present invention. These dimensions can also be applied to other calender trains in the system.

[0107] The nip width between the carrier roll and the counter roll may be between 5 μm and 1000 μm, preferably between 10 μm and 1000 μm, particularly preferably between 20 μm and 150 μm, especially preferably between 30 μm and 100 μm, and very preferably between 40 μm and 70 μm.

[0108] The system according to the present invention also allows for the use of lower linear loads during film formation compared to pure pressure. The control unit of the system can be configured to apply a linear load of less than 500 kN / cm (e.g., a linear load between 1 N / cm and 200 kN / cm), preferably 10 kN / cm or less (e.g., a linear load between 10 N / cm and 10 kN / cm). Because low linear loads can avoid roll deformation, the carrier roll and / or counter roll (film-forming roll) can have a smaller roll diameter and / or roll width.

[0109] The diameter of the carrier roll and / or counter roll (film-forming roll) may be 100 cm or less (e.g., between 10 cm and 100 cm), particularly preferably 50 cm or less (e.g., between 10 cm and 50 cm), and especially less than 30 cm. The roll diameters of the carrier roll and counter roll may be different. A smaller roll diameter has the advantage that a lower dry film thickness can be achieved during film formation. Thus, the process and system according to the present invention can achieve a dry film thickness of between 5 μm and 1000 μm, preferably between 10 μm and 1000 μm, particularly preferably between 20 μm and 150 μm, especially preferably between 30 μm and 100 μm, and very particularly preferably between 40 μm and 70 μm.

[0110] The width (ie the extent perpendicular to the roll axis) of the carrier roll and / or counter roll may be more than 30 cm, preferably more than 60 cm, particularly preferably more than 100 cm (especially up to 300 cm).

[0111] The system may be configured to heat the roll (e.g., by a heating element of the system). The control unit of the system may be configured to heat the roll to a temperature between 18°C ​​and 330°C, preferably between 25°C and 200°C, particularly preferably between 60°C and 180°C, and very preferably between 80°C and 120°C. This means that non-preactivated dry powder mixtures and / or non-preactivated dry mixtures can also be used for film formation. However, it is also possible to use non-flowable or low-flowable or low-free-flowable dry powder mixtures and / or dry mixtures (e.g., ribbon-shaped dry mixtures).

[0112] Furthermore, the first calender nip may have a mask and / or a funnel arranged above the calender nip. Preferably, the mask is suitable for reducing the amount of dry powder mixture and / or dry mixture applied to at least two opposite outer segments of the carrier roll, and optionally also to at least one intermediate region of an inner segment of the carrier roll.

[0113] The system may include a second counter roll forming a second calender nip together with the carrier roll, the system being configured to transport the dry film on the carrier roll to the second calender nip, and the control unit being configured to rotate the second counter roll in a third rotational direction about the second counter roll rotation axis at a second peripheral speed higher than the first peripheral speed of the carrier roll, the third rotational direction being opposite to the first rotational direction.

[0114] The system may also comprise at least one third roll, preferably also at least one fourth roll, particularly preferably also at least one fifth roll, most preferably at least one sixth roll, and in particular at least one seventh roll.

[0115] Furthermore, the system can be configured to transport the dry film together with the substrate through at least a third calender nip, preferably also at least a fourth calender nip, particularly preferably also at least a fifth calender nip, and in particular also at least a sixth calender nip, each of which is formed by two rolls. At least one third calender nip, at least one fourth calender nip, at least one fifth calender nip, and at least one sixth calender nip can each be formed by two rolls rotating in opposite rotational directions at different peripheral speeds. Optionally, the two rolls can be arranged linearly or at an angle to each other. An angled arrangement has the advantage that the assembly for film formation and lamination is decoupled. In addition, the radii of the two rolls can be different sizes, which has the advantage that a higher pressing force can be exerted on the calender nip (by the roll with a larger radius). In particular, the control unit of the system is configured to set the nip width of the calender nip between the two rolls in each case and / or to set the contact pressure at the calender nip between the two rolls in each case.

[0116] Furthermore, the system can be configured to transport the dry film together with the substrate through at least a third calender nip, preferably also at least a fourth calender nip, particularly preferably also at least a fifth calender nip, and in particular also at least a sixth calender nip, the calender nip being formed in each case by two rolls. At least one third calender nip, at least one fourth calender nip, at least one fifth calender nip, and at least one sixth calender nip can each be formed by two of these rolls rotating in opposite rotational directions at different peripheral speeds. The dry film can be transferred to the substrate at the third nip, the fourth nip, the fifth nip, or the sixth nip.

[0117] Furthermore, the system may be configured to transport the substrate-free dry film through at least a third calender nip, preferably at least a fourth calender nip, particularly preferably at least a fifth calender nip, and especially at least a sixth calender nip, by transfer at an increasing peripheral speed.

[0118] Furthermore, a roll arrangement can be provided in which two dry films are simultaneously produced in two first calender nips. Both dry films can be transferred to a third, fourth, fifth, or sixth calender nip and / or transferred to a substrate therefrom. This allows for simultaneous coating on both sides or multi-layer coating.

[0119] The device may also be configured to remove the dry film from a substrate to which it has been applied by the device. The control unit of the system may be configured to initiate the removal of the dry film from the substrate. In this case, the system may also create a free-standing dry film from the dry film laminated on the substrate.

[0120] In a preferred embodiment, the system is configured to carry out the method according to the invention, and therefore may have at least one feature or at least one configuration required to carry out the method according to the invention.

[0121] The present invention further provides a dry film arranged on a substrate as at least one web, preferably several parallel webs, wherein at least one web, preferably several parallel webs in each case, is defined in the longitudinal direction of the web by two boundary lines, characterized in that the boundary lines are essentially linear and extend essentially parallel to one another. By "substantially linear and essentially parallel to one another" is understood that the distance between each two boundary lines along the longitudinal direction varies by not more than 1000 μm, preferably not more than 500 μm, particularly preferably not more than 200 μm.

[0122] At least one web, preferably each of the plurality of parallel webs, may have a length in the longitudinal direction of the web of at least 0.05 m, preferably at least 0.5 m, particularly preferably at least 1 m, most preferably at least 5 m, especially at least 10 m.

[0123] Furthermore, at least one web, preferably each of the plurality of parallel webs, may have a width perpendicular to the longitudinal direction of the web of at least 200 mm and / or at most 6000 mm, preferably in the range of 250 mm to 1300 mm, and particularly preferably in the range of 550 mm to 1250 mm. In certain embodiments, at least one web, preferably each of the plurality of parallel webs, may have a width perpendicular to the longitudinal direction of the web of at least 1 mm and at most 50 mm.

[0124] In a preferred embodiment, the dry film is arranged on the substrate as at least two parallel webs, preferably as at least three parallel webs, particularly preferably as at least four parallel webs, and in particular as at least five parallel webs.

[0125] The substrate onto which the dry film is disposed may have or consist of a three-dimensional structure, and preferably comprises or consists of a woven fabric, a nonwoven fabric, and / or an expanded metal.

[0126] Furthermore, the substrate may preferably have texturing produced by etching, sandblasting, and / or laser treatment, the texturing being particularly present on the surface of the substrate facing the dry film.

[0127] Additionally, the substrate may comprise or consist of a porous layer, which preferably comprises or consists of an electrode layer and / or a particle layer. The layers applied to the substrate may be applied to the substrate using a slurry process or a dry film process.

[0128] The substrate on which the dry film is disposed preferably comprises or consists of a conductive material, which is preferably selected from the group consisting of metal, carbon, and combinations thereof, the term "metal" also including metal alloys.

[0129] A primer layer may be disposed in at least a portion of the region between the dry film and the substrate, and the primer layer contacts both the dry film and the substrate. The primer layer may comprise or consist of a polymer (or binder) and a conductive material. The primer layer preferably has a thickness of less than 10 μm, particularly preferably less than 2 μm. Preferably, the primer layer is disposed on the substrate in a region facing the inner segment of the carrier roll in a direction perpendicular to the carrier roll rotation axis. The primer layer has the advantage of increasing the adhesion of the dry film to the region of the substrate provided with the primer layer. As a result, the primer layer can further improve the edge precision of the produced dry film.

[0130] The dry film may comprise or consist of an active material for a battery electrode. The dry film may comprise the active material in a mass fraction of more than 50 wt %, preferably more than 70 wt %, and particularly preferably more than 90 wt %, based on the total mass of the dry film. The active material is preferably selected from the group consisting of an active material for a battery cathode and an active material for a battery anode. The battery may preferably be a lithium battery or a sodium-ion battery. The active material for the cathode may be a material selected from the group consisting of lithium iron phosphate (LFP), lithium manganese iron phosphate (LMFP), lithium manganese oxide (LMO), lithium nickel manganese cobalt oxide (NMC), nickel-rich lithium nickel manganese cobalt oxide (NMC622, NMC811, or related NMC materials), lithium nickel cobalt aluminum oxide (NCA), lithium cobalt oxide (LCO), lithium manganese nickel oxide (LMNO), high-voltage spinel (HVS), carbon, sulfur, and combinations thereof. The active material for the dry film anode may be a material selected from the group consisting of graphite, hard carbon, silicon, carbon, tin, silicon oxide, lithium, lithium indium titanate (LTO), and combinations thereof. Additionally, the dry film may contain metal oxides, polyanions (vanadates and / or phosphates), and sodium-containing compounds based on analogs of Berlin Blue.

[0131] Furthermore, the dry film may contain a conductive additive, which is preferably selected from the group consisting of carbon nanotubes, carbon particles (e.g., carbon black, carbon nanofibers, and / or carbon fibers), graphite, graphene, porous carbon (e.g., activated carbon), and combinations thereof. The dry film may contain the conductive additive in an amount of 0.1 to 10 wt %, preferably 0.5 to 5 wt %, and particularly preferably 1 to 4 wt %, based on the total mass of the dry film.

[0132] Furthermore, the dry film (as a binder or a component of a binder) may contain a non-fibrillating material that exhibits a binder effect, preferably selected from the group consisting of fluoropolymers (preferably polyvinylidene fluoride (PVDF), ethylene tetrafluoroethylene (ETFE), or polytetrafluoroethylene (PTFE)), carboxymethylcellulose (CMC), styrene-butadiene rubber (SBR), biopolymers, polyolefins (e.g., polyethylene, preferably polyethylene having a molecular weight greater than 1,000,000 g / mol), polypeptides (e.g., sericin), polyamides, polyacrylates, and mixtures thereof. The dry film may contain this material in a proportion of 0.1 to 10 wt. %, preferably 0.5 to 5 wt. %, and particularly preferably 0.5 to 1 wt. %, based on the total mass of the dry film.

[0133] In particular, the dry film (as a binder or component of a binder) may comprise a fibrillating material (or fibrils) that exerts a binder effect, where the material is preferably selected from the group consisting of polypeptides (e.g., sericin), fibrillating plastics (e.g., fluoropolymers such as PTFE, and / or polyolefins having a molecular weight of more than 1,000,000 g / mol, e.g., polyethylene having a molecular weight of more than 1,000,000 g / mol), and mixtures and combinations thereof. For example, the dry film may comprise a 10 6 g / mol, preferably greater than 10 7The dry film may contain fibrillizable PTFE having a molecular weight of more than 10 ...

[0134] The dry film may further comprise an ion-conducting material, preferably an ion-conducting solid (solid electrolyte). The ion-conducting material is preferably selected from the group consisting of ion-conducting solids, gel-like ion conductors, salt-like ion conductors, and mixtures thereof. The ion-conducting solid is particularly preferably from the group consisting of sulfide solid ion conductors (e.g., lithium thiophosphates, LPS, argyrodite, LPSCl, and / or LGPS, or sodium analogs), glassy solid ion conductors (e.g., LiAlSiO4 or NaAlSiO4), polymeric solid ion conductors (e.g., PEO), ceramic solid ion conductors (e.g., LLZO, Lisocon, and / or Nasicon, or corresponding sodium-ion-conducting ceramic solid ion conductors), and mixtures thereof. The dry film may comprise a solid electrolyte in a proportion of 1 to 99 wt. %, preferably 5 to 30 wt. %, and particularly preferably 10 to 20 wt. % based on the total mass of the dry film.

[0135] The dry film can have a thickness (i.e., the thickness in the direction perpendicular to the maximum surface of the dry film) in the range of 5 μm to 500 μm, preferably in the range of 10 μm to 150 μm, particularly preferably in the range of 30 μm to 100 μm, and very preferably in the range of 40 μm to 70 μm.

[0136] The dry film may have a liquid content of 1% or less by volume, based on the total volume of the dry film.

[0137] The method of the present invention can produce a dry film having a porosity of 15 to 80%, preferably 20 to 50%, and particularly preferably 25 to 35%. After subsequent compaction, the dry film can have a porosity of 0.1 to 25%, preferably 0.1 to 10%, and particularly preferably 0.1 to 5%.

[0138] According to the method of the present invention, the dry film may have a wave-like pattern extending in the longitudinal direction of the dry film web and extending perpendicular to the longitudinal direction of the web (i.e., transversely) between substantially linear and substantially mutually parallel boundaries of the (each) dry film web, and preferably the waves of the wave-like pattern have a periodic spacing in the transverse direction of the (each) web within a range of more than 0 mm to less than 10 mm, preferably more than 0 mm to less than 5 mm. This wave-like pattern can be generated by different peripheral speeds. The periodic spacing of the wave pattern can vary depending on the absolute peripheral speeds of the carrier roll and counter roll, as well as the nip used. This correlation occurs in combination with the rheological properties of the dry mix used. When the difference in peripheral speed is larger, the pattern can be more pronounced and the individual strips can be spaced further apart than when the difference in peripheral speed is smaller.

[0139] The dry film can be produced by the method according to the invention, and therefore can have at least one characteristic that results from carrying out the method according to the invention.

[0140] According to the present invention, a) an electrode comprising or consisting of the dry film according to the present invention; b) a counter electrode; c) an electrolyte, preferably a liquid or solid electrolyte, disposed between the electrode and the counterelectrode; A battery comprising: [Brief explanation of the drawings]

[0141] [Figure 1] 1 illustrates an embodiment of a method or system for making a dry film according to the present invention. [Figure 2] 1 illustrates a further embodiment of a method or system for making a dry film according to the present invention. [Figure 3] 1 illustrates a further embodiment of a method or system for making a dry film. [Figure 4] The carrier roll 3 of the embodiment of FIG. 3 is shown together with part of the processing device in a direction perpendicular to the carrier roll rotation axis TR. [Figure 5] 1 illustrates a further embodiment of a method or system for making a dry film according to the present invention. [Figure 6] 1 illustrates a further embodiment of a method or system for making a dry film according to the present invention. [Figure 7] 1 illustrates a further embodiment of a method or system for making a dry film according to the present invention. [Figure 8] 1 shows a photographic image of a web of dry film according to the present invention having a wavy pattern. [Figure 9] 1 shows a schematic top view of a portion of a dry film according to the present invention formed in the form of two segments on a current conductor foil. DETAILED DESCRIPTION OF THE INVENTION

[0142] The subject matter of the present invention will be explained in more detail based on the following figures, without wishing to limit the subject matter of the present invention to the particular embodiments shown therein.

[0143] FIG. 1 illustrates an embodiment of a method or system for producing a dry film according to the present invention. The upper view shows a view of a carrier roll 3 and a counter roll 4 along the carrier roll rotation axis TR, while the lower view shows a view perpendicular to the carrier roll rotation axis TR on the side where processing devices 7, 8, 15, and 16 are located. A dry powder mixture is fed into a first calender nip 2 formed by the carrier roll 3 and a first counter roll 4. The carrier roll 3 rotates about the carrier roll rotation axis TR at a first peripheral speed in a first rotation direction 5, and the counter roll 4 rotates about the counter roll rotation axis GR at a second peripheral speed lower than the first peripheral speed in a second rotation direction 6, where the second rotation direction 6 is opposite to the first rotation direction 5. The dry powder mixture passes through the first calender nip 2 in the conveying direction, forming a dry film at least partially supported on the carrier roll 3. At least one first processing device 7 is used, which is arranged opposite a first outer segment 9 of the carrier roll 3 in a direction perpendicular to the carrier roll rotation axis TR, and at least one second processing device 8 is used, which is arranged opposite a second outer segment 10 of the carrier roll 3 in a direction perpendicular to the carrier roll rotation axis TR. The carrier roll 3 has an inner segment 11 between the first outer segment 9 and the second outer segment 10 in a direction parallel to the carrier roll rotation axis TR. The first processing device 7 and the second processing device 8 are each suitable for removing, at least by cutting, areas of the dry film attached to the carrier roll 3 at the outer segments 9, 10 of the carrier roll 3. To laminate the dry film onto a substrate, the dry film is guided through a second calender nip 17 formed by the third roll and the carrier roll 3. The embodiment shown in FIG. 1 is a symmetrical arrangement of a first pair of carrier rolls 3 and counter rolls 4 and a second pair of carrier rolls 3 and counter rolls 4, so that the third roll of the first pair is formed by the second pair of carrier rolls, and the third roll of the second pair is formed by the first pair of carrier rolls.In the second calender nip 17, the dry film can be laminated / transferred to a substrate (not shown), and the substrate together with the dry film is advanced through the second calender nip 17. Due to the symmetrical arrangement of the two pairs of carrier rolls 3 and counter rolls 4, the dry film can be laminated on both sides of the substrate (double-sided lamination). In the illustrated embodiment, the carrier roll 3 also has two further processing devices 15, 16, which are respectively arranged opposite the middle region 14 of the inner segment 11 in a direction perpendicular to the carrier roll rotation axis TR. These two processing devices make it possible to divide the dry film into two individual dry film tapes or dry film strips.

[0144] 2 shows a further embodiment of a method or system for producing a dry film according to the present invention, which is substantially identical to the embodiment shown in FIG. 1. The upper view shows the view of the carrier roll 3 and the counter roll 4 along the carrier roll rotation axis TR, the middle view shows the view perpendicular to the carrier roll rotation axis TR on the side where the processing devices 7, 8, 15, and 16 are located, and the lower view shows the view perpendicular to the carrier roll rotation axis TR on the side where the dry powder mixture 1 is fed to the first calender nip 2. The difference from the embodiment of FIG. 1 is that the second calender nip 17 is not formed by the carrier roll 3 of the first roll pair and the carrier roll 3 of the second roll pair, but by the respective carrier roll 3 and a third roll 19 or second counter roll in each case, which rotates around its second counter roll rotation axis 2GR in a third rotation direction 20 opposite to the first rotation direction 5. Due to the symmetrical arrangement, each third roll 19 forms a third calender nip 18 that can laminate the dry film onto a substrate (not shown). The advantage of using two third rolls 19 is that the dry film is subjected to additional compaction and pressure by the second calender nip 17 before being laminated to the substrate by the third calender nip 18, which can make the dry film more mechanically stable.

[0145] FIG. 3 shows a further embodiment of a method or system for producing a dry film according to the present invention, which is substantially identical to the embodiment shown in FIG. 1. The upper view shows the view of the carrier roll 3 and the counter roll 4 along the carrier roll rotation axis, and the lower view shows the view perpendicular to the carrier roll rotation axis TR on the side where the processing devices 7 and 8 are located. The difference from the embodiment of FIGS. 1 and 2 is that there are no additional processing devices 15 and 16, and therefore it is not possible to split the dry film into two separate dry film tapes or strips; i.e., only a single dry film tape or strip is produced. A further difference is that the carrier roll 3 has a first surface finish 12 on an inner segment of the carrier roll 3, which adheres the dry film to the carrier roll 3, and further has a second surface finish 13 on first and second outer segments of the carrier roll, which does not adhere the dry film. Here, the second surface finish is designed as a smooth surface of the carrier roll, which has a central roughness value Ra that is 50% or less of the central roughness value that the carrier roll has on its inner segments. This embodiment has the advantage that the dry film is prevented from adhering to segments of the carrier roll 3 where it should not be adhered in the first place. The dry film that is not adhered to these segments of the carrier roll 3 can be fed back to the first calender nip 2 (as a dry powder mixture), which makes the process more efficient and may also shorten the maintenance intervals for the processing devices 7, 8.

[0146] 4 shows the carrier roll 3 of the embodiment of FIG. 3 together with a part of the processing device in a direction perpendicular to the carrier roll rotation axis TR. The carrier roll 3 has a second surface finish 13 on the first outer segment and the second outer segment, which surface finish 13 prevents the dry film 3 from adhering thereto. This has the advantage that the cutting unit 23 (here, an air nozzle) can cut the dry film more easily and with less energy consumption (i.e., with lower air flow intensity), and the removing unit 24 (here, an extractor) can remove the cut dry film residue from the carrier roll 3 more easily and with less energy consumption (i.e., with lower suction flow intensity).

[0147] FIG. 5 shows a further embodiment of a method or system for producing a dry film according to the present invention, which is substantially identical to the embodiment shown in FIG. 1. The upper view is a view along the carrier roll rotation axis toward the carrier roll 3 and counter roll 4, and the lower view is a view toward the side where the processing devices 7 and 8 are located. One difference from the embodiment shown in FIG. 1 is the absence of additional processing devices 15 and 16. A further difference is that the first outer segment 25 of the counter roll 4, which is positioned opposite the first outer segment of the carrier roll 3 in a direction perpendicular to the carrier roll rotation axis TR, and the second outer segment 26 of the counter roll, which is positioned opposite the second outer segment of the carrier roll 3 in a direction perpendicular to the carrier roll rotation axis TR, have a surface finish to which a dry film does not adhere. Here, the surface quality of the first outer segment 25 of the counter roll 4 and / or the second outer segment 26 of the counter roll 4 is configured as a concave surface of the counter roll 4, which preferably has a radius that is 99.9% or less of the radius of the counter roll 4 in the first region 27 of the inner segment of the counter roll 4. This embodiment has the advantage that the dry film is prevented from adhering to segments of the carrier roll 3 where it should not be adhered from the beginning. The dry film that is not adhered to these segments of the carrier roll 3 can be fed back to the first calender nip 2 (as a dry powder mixture), which makes the process more efficient and shortens the maintenance intervals for the processing devices 7, 8. In the illustrated embodiment, the carrier roll also has a second region 28 of the inner segment, which is shaped similarly to the first and / or second outer segments of the carrier roll, i.e., in particular has a concave surface with a radius that is 99.9% or less of the radius of the counter roll 4 in the first region 27 of the inner segment of the counter roll 4. This allows the dry film to be split into two separate dry film tapes or strips, ie two parallel dry film tapes or strips can be created.

[0148] Figure 6 shows a further embodiment of a method or system for making a dry film according to the present invention, which is substantially identical to the embodiment shown in Figure 2. The illustration shows the orientation of the carrier roll 3, counter roll 4, and second counter roll 19 along the carrier roll rotation axis. One difference from the embodiment shown in Figure 2 is that the second counter roll 19 is positioned at an angle relative to each other. This has the advantage of decoupling the assemblies for film formation and lamination.

[0149] 7 shows a further embodiment of a method or system for producing a dry film according to the present invention. This figure shows, along the rotation axis of the carrier rolls, a carrier roll 3, a counter roll 4, a second counter roll 19, a third counter roll 29, and a fourth counter roll 30. In this embodiment, the radii of the second counter roll 19 and the third counter roll 29 are larger than the radii of the carrier roll 3 and the fourth counter roll 30, which advantageously allows a higher pressing force to be exerted on the second calender nip 17 and the fourth calender nip 33.

[0150] 8 shows a photographic image of a dry film web according to the present invention having a wavy pattern extending longitudinally (from left to right in FIG. 8) and perpendicularly to the longitudinal direction of the dry film web (from top to bottom in FIG. 8, i.e., across the web) between substantially straight and substantially parallel boundaries of the dry film web, where each wave of the wavy pattern has a periodic spacing of about 3 mm across the web.

[0151] 9 shows a schematic top view of a portion of a dry film according to the present invention formed in the form of two segments on a current conductor foil. The checkered area indicates the substrate (current conductor foil), and the hatched area indicates the coating (dry film). The interrupted lines (white portions) shown above and below indicate that this is part of a longer band, i.e., a band extending in the direction from the top to the bottom of FIG. 9 (or in the opposite direction). [Explanation of symbols]

[0152] 1 dry powder mixture 2. First Calendar Nip 3 Carrier Roll 4 Counter Roll 5 First rotation direction 6 Second Rotation Direction 7. First processing device (comprising a cutting unit and a removing unit) 8. Second processing device (comprising a cutting unit and a removing unit) 9 First outer segment of carrier roll 10 Second outer segment of carrier roll 11 Inner segment of carrier roll 12 First surface finish of carrier roll (adheres to dry film) 13 Second surface finish of carrier roll (does not adhere to dry film) 14 Intermediate region within the inner segment of the carrier roll 15 Further processing device (comprising cutting unit and removal unit) 16 Further processing device (comprising cutting unit and removal unit) 17 Second Calendar Nip 18 The Third Calendar Nip 19 Third Roll (or Second Counter Roll) 20 Third rotation direction (Rotation direction of the third roll) 21 Dry film (first) web 22 Second web of dry film 23 Cutting unit (e.g. air nozzle) 24 Removal unit (e.g., suction device) 25 First outer segment of the counter roll with a small radius 26 Second outer segment of the counter roll with a smaller radius 27 First area of ​​the inner segment of the counter roll with a large radius 28 Second area of ​​the inner segment of the counter roll with a small radius 29 Fourth Roll (or Third Counter Roll) 30 5th Roll (or 4th Counter Roll) 31 Fourth rotation direction (fourth roll rotation direction) 32 Fifth rotation direction (fifth roll rotation direction) 33 The Fourth Calendar Nip 34 The 5th Calendar Nip TR Carrier roll rotation axis GR counter roll rotation axis 2GR Second counter roll rotation axis (e.g., second carrier roll rotation axis) 3GR Third counter roll rotation axis (e.g., rotation axis of the third counter roll) 4GR Fourth counter roll rotation axis (e.g., the rotation axis of the fourth counter roll)

Claims

1. A method for producing a dry film, comprising: feeding a dry powder mixture and / or a dry mixture to a first calender nip formed by a carrier roll and a first counter roll, wherein the carrier roll rotates in a first rotational direction at a first peripheral speed about a carrier roll rotation axis, and the counter roll rotates in a second rotational direction at a second peripheral speed about the counter roll rotation axis that is lower than the first peripheral speed, the second rotational direction being opposite to the first rotational direction, the dry powder mixture and / or the dry mixture passing through the first calender nip in a conveying direction, and a dry film supported on at least a portion of the carrier roll is formed; a first processing device arranged opposite a first outer segment of the carrier roll in a direction perpendicular to the carrier roll rotation axis; and a second processing device arranged opposite a second outer segment of the carrier roll in a direction perpendicular to the carrier roll rotation axis, the carrier roll having an inner segment between the first outer segment and the second outer segment in a direction parallel to the carrier roll rotation axis, the first and second processing devices each being suitable for removing a region of the dry film supported on the carrier roll at the outer segment of the carrier roll.

2. The dry film is laminated onto a substrate during the method, the substrate preferably having, at least in some areas, a primer layer, a three-dimensional structure, texturing, and / or a porous layer to enhance adhesion of the dry film, particularly preferably i) the primer layer comprises or consists of a polymer and a conductive material, has a thickness in the range of less than 10 μm, preferably less than 2 μm, and / or is disposed on the substrate in an area facing the inner segment of the carrier roll in a direction perpendicular to the carrier roll rotation axis; and / or ii) the substrate comprises or consists of a woven fabric, a nonwoven fabric, and / or an expanded metal as a three-dimensional structure; and / or iii) the texturing has been produced by etching, sandblasting and / or laser treatment, and the texturing is present in particular on the surface of the substrate facing the dry film; and / or iv) The porous layer includes an electrode layer and / or a particle layer, or consists of an electrode layer and / or a particle layer.

2. The method of claim 1 .

3. the inner segment of the carrier roll has, in at least some areas, a surface finish to which the dry film adheres; i) the first outer segment and / or the second outer segment of the carrier roll has a surface finish to which the dry film does not adhere, the surface finish preferably being configured as a smooth surface of the carrier roll, the smooth surface preferably having a central roughness value Ra of not more than 50% of the central roughness value of the inner segments of the carrier roll, the smooth surface particularly preferably having a central roughness value Ra in the range of 0.005 μm to 1 μm; and / or ii) a first outer segment of the counter roll arranged opposite the first outer segment of the carrier roll in a direction perpendicular to the rotation axis of the carrier roll, and / or a second outer segment of the counter roll arranged opposite the second outer segment of the carrier roll in a direction perpendicular to the rotation axis of the carrier roll, have a surface finish to which the dry film does not adhere, and the surface finish of the first outer segment of the counter roll and / or the second outer segment of the counter roll is preferably a) formed as a concave surface of the counter roll, which preferably has a radius of at most 99.9%, preferably at most 99%, particularly preferably at most 95%, in particular at most 90% of the radius of the counter roll in the first region of the inner segment of the counter roll; and / or b) the coating of the first outer segment of the counter roll and / or the second outer segment of the counter roll is preferably formed as a coating comprising or consisting of DLC and / or PTFE, which results in at least 1% by weight less dry film, in particular at least 10% by weight less dry film, adhering to the counter roll than the inner segment of the counter roll, preferably no dry film adhering to the counter roll, the inner segment of the counter roll optionally having a coating and / or a texture treatment to which the dry film adheres, the coating particularly preferably comprising or consisting of a material selected from the group consisting of PTFE, DLC, tungsten carbide, hard chromium and combinations thereof, the carrier roll optionally having at least one second region of the inner segment configured similarly to the first and / or second outer segments of the carrier roll; 3. The method according to claim 1 or 2.

4. the first and second processing devices each i) a cutting unit used to separate by cutting the regions of the dry film supported on the carrier roll at the respective outer segments of the carrier roll from the regions of the dry film supported on the carrier roll at the inner segments of the carrier roll, the cutting unit preferably being selected from the group consisting of a rolling knife, an air nozzle, a laser, and combinations thereof; and / or ii) a removal unit used to remove areas of the dry film supported on the carrier roll at each outer segment of the carrier roll, the removal unit preferably being selected from the group consisting of an air nozzle, a scraper, a brush, a suction device, and combinations thereof; and / or iii) a further removal unit is used to remove areas of the dry film perpendicular to the coating direction to achieve an intermittent coating in the coating direction.

4. The method according to claim 1, wherein the first and second electrodes are connected to a first electrode.

5. the inner segment of the carrier roll is subdivided into at least two inner segment areas by at least 2n mutually parallel boundary lines around the circumference of the carrier roll, where n is an integer, and in each case an intermediate area is arranged between two adjacent inner segment areas, the boundaries of the intermediate area being defined in the direction of the rotation axis of the carrier roll by in each case two opposing boundary lines of the 2n boundary lines, i) the at least two inner segment regions have a surface finish to which the dry film adheres, and the intermediate regions preferably each have a surface finish to which the dry film does not adhere; and / or ii) facing each intermediate region of the inner segments in a direction perpendicular to the carrier roll rotation axis, a further processing device is used in each case, which further processing device is in each case suitable for removing by at least cutting an area of ​​the dry film supported on the carrier roll in the intermediate region of the carrier roll, each further processing device being particularly preferably a cutting unit used to separate by cutting the regions of the dry film supported on the carrier roll in the respective intermediate regions of the carrier roll from the regions of the dry film supported on the carrier roll in the inner segments of the carrier roll, the cutting unit preferably being selected from the group consisting of a rolling knife, an air nozzle, a laser, and combinations thereof; and / or a removal unit used to remove the region of the dry film supported on the carrier roll in the respective intermediate regions of the carrier roll, the removal unit preferably being selected from the group consisting of an air nozzle, a scraper, a brush, a suction device, and combinations thereof; 5. The method according to claim 1, wherein the first and second electrodes are connected to a first electrode.

6. The removal unit, optionally also the further removal unit, is used to feed the removed area of ​​the dry film to the first calender nip, optionally first i) feeding to a dry mix, said dry mix being processed to form a dry powder mix, said dry powder mix then being fed to said first calender nip, said processing to form said dry powder mix preferably comprising a process selected from the group consisting of extruder processing, jet mill, pin mill, impact mill, mortar mill, roll mill, and combinations thereof; or ii) feeding a dry powder mixture and / or dry mixture, which is then fed to the first calender nip, and the proportion of the removed area of ​​the fed dry film is preferably at least 0.1% by weight, particularly preferably at least 1% by weight, and very particularly preferably at least 10% by weight, based on the total proportion of the dry powder mixture and / or dry mixture.

6. The method according to claim 4 or 5.

7. The first calendar nip comprises: i) has a length of at least 300 mm, preferably at least 600 mm, particularly preferably at least 1200 mm, optionally up to 3000 mm; and / or ii) having a mask and / or funnel arranged above the calender nip, the mask preferably reducing the amount of dry powder mixture and / or dry mixture applied to at least the two opposite outer segments of the carrier roll, and optionally also to at least one intermediate region of the inner segment of the carrier roll; 7. The method according to any one of claims 1 to 6.

8. The carrier roll and / or counter roll are a) has a diameter of 100 cm or less, optionally between 10 cm and 100 cm, particularly preferably 50 cm or less, optionally between 10 cm and 50 cm, in particular less than 30 cm; and / or b) in a direction perpendicular to the roll axis of the carrier roll and / or counter roll, has a width of more than 30 cm, preferably more than 60 cm, particularly preferably more than 100 cm, in particular up to 300 cm 8. The method according to any one of claims 1 to 7.

9. The lamination of the dry film onto a substrate comprises: i) transporting the dry film on the carrier roll to a second calender nip formed by the carrier roll and a second counter roll, wherein the second counter roll rotates in a third rotation direction around a second counter roll rotation axis at a second peripheral speed equal to or greater than the first peripheral speed of the carrier roll, and the third rotation direction is opposite to the first rotation direction; ii) optionally transporting the dry film together with the substrate through at least a third calender nip, preferably also at least a fourth calender nip, particularly preferably also at least a fifth calender nip, in particular also at least a sixth calender nip; iii) optionally conveying said substrate-free dry film by transfer at an increasing peripheral speed through at least a third calender gap, preferably at least a fourth calender gap, particularly preferably at least a fifth calender gap, in particular at least a sixth calender gap; Including, A substrate laminated with dry film is created 9. The method according to any one of claims 1 to 8.

10. 1. A system for producing a dry film, comprising: a) a device configured to produce a dry film from a dry powder mixture and / or a dry mixture, the device comprising a carrier roll and a first counter roll, the carrier roll and the counter roll forming a first calender nip for supplying the dry powder mixture and / or the dry mixture, the carrier roll adapted to rotate about a carrier roll rotation axis, and the counter roll adapted to rotate about a counter roll rotation axis; b) a control unit configured at least to rotate the carrier roll in a first rotation direction about the carrier roll rotation axis at a first peripheral speed and to rotate the counter roll in a second rotation direction about the counter roll rotation axis at a second peripheral speed lower than the first peripheral speed, the second rotation direction being opposite to the first rotation direction, the control unit being configured in particular to set a nip width of the calender nip and / or a contact pressure of the calender nip between the carrier roll and the first counter roll; Equipped with the system comprises at least one first processing device disposed opposite a first outer segment of the carrier roll in a direction perpendicular to the carrier roll rotation axis, and at least one second processing device disposed opposite a second outer segment of the carrier roll in a direction perpendicular to the carrier roll rotation axis, the carrier roll having an inner segment between the first outer segment and the second outer segment in a direction parallel to the carrier roll rotation axis, the first and second processing devices each being adapted to remove by at least cutting a region of the dry film supported on the carrier roll at the outer segment of the carrier roll.

9. The method according to any one of claims 1 to 8.

11. The system is configured to include a substrate and to laminate the dry film onto the substrate, the substrate preferably having, at least in some areas, a primer layer, a three-dimensional structure, texturing, and / or a porous layer to enhance adhesion of the dry film, and particularly preferably: i) the primer layer comprises or consists of a polymer and a conductive material, has a thickness in the range of less than 10 μm, preferably less than 2 μm, and / or is disposed on the substrate in an area facing the inner segment of the carrier roll in a direction perpendicular to the carrier roll rotation axis; and / or ii) the substrate comprises or consists of a woven fabric, a nonwoven fabric, and / or an expanded metal as a three-dimensional structure; and / or iii) the texturing is produced by etching, sandblasting and / or laser treatment; and / or iv) The porous layer includes an electrode layer and / or a particle layer, or consists of an electrode layer and / or a particle layer. The system of claim 10.

12. the inner segment of the carrier roll has, in at least some areas, a first surface finish to which the dry film adheres; i) the first outer segment and / or the second outer segment of the carrier roll has a second surface finish to which the dry film does not adhere, the surface finish preferably being configured as a smooth surface of the carrier roll, the smooth surface preferably having a central roughness value Ra of not more than 50% of the central roughness value of the inner segments of the carrier roll, the smooth surface particularly preferably having a central roughness value Ra in the range of 0.001 μm to 1 μm; and / or iii) a first outer segment of the counter roll arranged opposite the first outer segment of the carrier roll in a direction perpendicular to the rotation axis of the carrier roll, and / or a second outer segment of the counter roll arranged opposite the second outer segment of the carrier roll in a direction perpendicular to the rotation axis of the carrier roll, have a surface finish to which the dry film does not adhere, and the surface finish of the first outer segment of the counter roll and / or the second outer segment of the counter roll is preferably a) formed as a concave surface of the counter roll, which preferably has a radius of at most 99.9%, preferably at most 99%, particularly preferably at most 95%, in particular at most 90% of the radius of the counter roll in the first region of the inner segment of the counter roll; and / or b) the coating of the first outer segment of the counter roll and / or the second outer segment of the counter roll is preferably formed as a coating comprising or consisting of DLC and / or PTFE, which results in at least 1% by weight less dry film, in particular at least 10% by weight less dry film, adhering to the counter roll than the inner segment of the counter roll, preferably no dry film adhering to the counter roll, the inner segment of the counter roll optionally having a coating and / or a texture treatment to which the dry film adheres, the coating particularly preferably comprising or consisting of a material selected from the group consisting of PTFE, DLC, tungsten carbide, hard chromium and combinations thereof, the carrier roll optionally having at least one second region of the inner segment configured similarly to the first and / or second outer segments of the carrier roll; 12. The system according to claim 10 or 11.

13. the first and second processing devices in each case: i) a cutting unit used to separate by cutting the regions of the dry film supported on the carrier roll at the respective outer segments of the carrier roll from the regions of the dry film supported on the carrier roll at the inner segments of the carrier roll, the cutting unit preferably being selected from the group consisting of a rolling knife, an air nozzle, a laser, and combinations thereof; and / or ii) a removal unit used to remove areas of the dry film supported on the carrier roll at each outer segment of the carrier roll, the removal unit preferably being selected from the group consisting of an air nozzle, a scraper, a brush, a suction device, and combinations thereof; and / or iii) a further removal unit configured to remove a region of the dry film perpendicular to the coating direction to achieve an intermittent coating in the coating direction. The system according to any one of claims 10 to 12.

14. the inner segment of the carrier roll is subdivided into at least two inner segment areas by at least 2n mutually parallel boundary lines around the circumference of the carrier roll, where n is an integer, and in each case an intermediate area is arranged between two adjacent inner segment areas, the boundaries of the intermediate area being defined in the direction of the rotation axis of the carrier roll by in each case two opposing boundary lines of the 2n boundary lines, i) the at least two inner segment regions have a surface finish to which the dry film adheres, and the intermediate regions preferably each have a surface finish to which the dry film does not adhere; and / or ii) the system has in each case a further treatment device opposite each intermediate region of the inner segment in a direction perpendicular to the carrier roll rotation axis, the further treatment device being in each case suitable for removing by at least cutting an area of ​​the dry film supported on the carrier roll in the intermediate region of the carrier roll, wherein each further treatment device is particularly preferably a cutting unit configured to separate by cutting the regions of the dry film supported on the carrier roll at the respective intermediate regions of the carrier roll from the regions of the dry film supported on the carrier roll at the inner segments of the carrier roll, the cutting unit preferably being selected from the group consisting of a rolling knife, an air nozzle, a laser, and combinations thereof; and / or a removal unit configured to remove a region of the dry film supported on the carrier roll at each intermediate region of the carrier roll, the removal unit preferably being selected from the group consisting of a scraper, a brush, an extractor, and combinations thereof. The system according to any one of claims 10 to 13.

15. The removal unit, and optionally also the further removal unit, is configured to feed the removed area of ​​the dry film to the first calender nip, optionally first feeding a dry mixture to be processed into a dry powder mixture, wherein a processing device of the plant is configured to process the dry mixture into a dry powder mixture and feed the dry powder mixture to the first calender nip, wherein the processing device is preferably selected from the group consisting of an extruder, a jet mill, a pin mill, an impact mill, a mortar mill, a roll mill, and combinations thereof; or The removed area of ​​the dry film is first fed to a dry powder mixture and / or dry mix, and the system is configured to feed the dry powder mixture and / or dry mix to the first calender gap, and the proportion of the fed removed area of ​​the dry film relative to the total proportion of the dry powder mixture and / or dry mix is ​​preferably at least 0.1 wt. %, particularly preferably at least 1 wt. %, and very particularly preferably at least 10 wt. %.

15. The system according to claim 13 or 14.

16. The first calender gap comprises: i) has a width of at least 300 mm, preferably at least 600 mm, particularly preferably at least 1200 mm, and / or ii) having a mask and / or funnel arranged above the calender nip, the mask preferably being suitable for reducing the amount of dry powder mixture and / or dry mixture applied to at least the two opposite outer segments of the carrier roll, and optionally also to at least one intermediate region of the inner segment of the carrier roll. The system according to any one of claims 10 to 15.

17. The carrier roll and / or counter roll are a) has a diameter of 100 cm or less, optionally between 10 cm and 100 cm, particularly preferably 50 cm or less, optionally between 10 cm and 50 cm, in particular less than 30 cm; and / or b) in a direction perpendicular to the roll axis of the carrier roll and / or counter roll, has a width of more than 30 cm, preferably more than 60 cm, particularly preferably more than 100 cm, in particular up to 300 cm The system according to any one of claims 10 to 16.

18. The system comprises: i) the system includes a second counter roll forming a second calender nip together with the carrier roll, the system being configured to transport the dry film on the carrier roll to the second calender nip, and the control unit being configured to rotate the second counter roll in a third rotation direction about a second counter roll rotation axis at a second peripheral speed that is higher than or equal to the first peripheral speed of the carrier roll, the third rotation direction being opposite to the first rotation direction; ii) optionally further comprising at least one third roll, preferably further at least one fourth roll, particularly preferably further at least one fifth roll, very particularly preferably further at least one sixth roll, in particular further at least one seventh roll, iii) optionally configured to transport the dry film together with the substrate through at least a third calender nip, preferably also at least a fourth calender nip, particularly preferably also at least a fifth calender nip, in particular also at least a sixth calender nip, the calender nip being formed in each case by two rolls, the two rolls optionally being arranged linearly or at an angle to each other and / or having radii of different sizes, the control unit of the system being configured in particular to set in each case the nip width of the calender nip between the two rolls and / or to set in each case the contact pressure at the respective calender nip between the two rolls, and iv) Optionally, the dry film without a substrate is transported by transfer at an increasing peripheral speed through at least a third calender nip, preferably at least a fourth calender nip, particularly preferably at least a fifth calender nip, and especially at least a sixth calender nip. The system according to any one of claims 10 to 17.

19. A dry film arranged as at least one web, preferably a plurality of parallel webs, on a substrate, wherein the at least one web, preferably the plurality of parallel webs, is in each case defined by two boundary lines in the longitudinal direction of the web, the boundary lines being essentially straight and extending essentially parallel to one another, and the distance between each of the two boundary lines varies along the longitudinal direction by not more than 1000 μm, preferably not more than 500 μm, particularly preferably not more than 200 μm.

20. said at least one web, preferably each of said plurality of parallel webs, i) has a length in the longitudinal direction of the web of at least 0.1 m, preferably at least 0.5 m, particularly preferably at least 1 m, very particularly preferably at least 5 m, in particular at least 10 m; and / or ii) perpendicular to the longitudinal direction of the web, has a width of at least 200 mm and / or at most 1200 mm, preferably in the range from 250 mm to 650 mm, particularly preferably in the range from 250 mm to 350 mm; and / or iii) a wave pattern extending in the longitudinal direction of the web of dry film and extending perpendicular to the longitudinal direction of the web between the substantially straight and substantially mutually parallel boundaries of the web of dry film, preferably wherein the waves of the wave-like pattern have a periodic spacing in the transverse direction of the web within a range of greater than 0 mm and less than 10 mm, preferably greater than 0 mm and less than 5 mm; The dry film is optionally arranged on the substrate as at least two parallel webs, preferably as at least three parallel webs, particularly preferably as at least four parallel webs, in particular as at least five parallel webs. The dry film according to claim 19 .

21. A primer layer is disposed in at least a portion of the region between the dry film and the substrate, and the primer layer contacts both the dry film and the substrate, and preferably: i) the primer layer comprises or consists of a polymer and a conductive material and / or has a thickness in the range of less than 10 μm, particularly preferably in the range of less than 2 μm, and / or ii) the substrate has or consists of a three-dimensional structure, preferably comprising or consisting of a woven fabric, a nonwoven fabric and / or an expanded metal; and / or iii) the substrate has a texturing, preferably produced by etching, sandblasting and / or laser treatment, said texturing being present in particular on the surface of the substrate facing the dry film; and / or iv) The substrate comprises or consists of a porous layer, and the porous layer preferably comprises or consists of an electrode layer and / or a particle layer.

21. The dry film according to claim 19 or 20.

22. The dry film comprises an active material for a battery electrode, and the active material is preferably i) selected from the group consisting of active materials for the cathode of a battery and active materials for the anode of a battery, the active materials being particularly preferably selected from the group consisting of lithium iron phosphate, lithium manganese iron phosphate, lithium manganese oxide, lithium nickel manganese cobalt oxide, nickel-rich lithium nickel manganese cobalt oxide, lithium nickel cobalt aluminum oxide, lithium cobalt oxide, lithium manganese nickel oxide, high-voltage spinel, carbon, sulfur, graphite, hard carbon, silicon, tin, silicon oxide, lithium, lithium indium titanate, sodium-containing compounds based on metal oxides, polyanions, analogues of Berlin blue, and combinations thereof; and / or ii) contained in the dry film in a mass fraction of more than 50 wt. %, preferably more than 70 wt. %, particularly preferably more than 90 wt. %, based on the total mass of the dry film; i) having a liquid content of 1% by volume or less, based on the total volume of the dry film; The dry film according to any one of claims 19 to 21.

23. The dry film includes a conductive additive, and the conductive additive preferably comprises: i) selected from the group consisting of carbon nanotubes, carbon particles, graphite, graphene, porous carbon, and combinations thereof; and / or ii) The dry film contains the inorganic filler in a mass fraction of 0.1 to 10 wt %, preferably 0.5 to 5 wt %, particularly preferably 1 to 4 wt %, based on the total mass of the dry film. The dry film according to any one of claims 19 to 22.

24. The dry film comprises a non-fibrillating material that exhibits a binder effect, the material preferably comprising: i) selected from the group consisting of fluoropolymers, carboxymethylcellulose, styrene butadiene rubber, biopolymers, polyolefins, polypeptides, polyamides, polyacrylates, and mixtures thereof; and / or ii) The dry film contains the inorganic filler in a mass fraction of 0.1 to 10% by weight, preferably 0.5 to 5% by weight, and particularly preferably 0.5 to 4% by weight, based on the total mass of the dry film. The dry film according to any one of claims 19 to 23.

25. The dry film comprises a fibrillating material that exhibits a binder effect, and the fibrillating material preferably comprises: i) selected from the group consisting of fibrillating polypeptides, fibrillating plastics, and mixtures and combinations thereof, said fibrillating material being particularly preferably fibrillizable PTFE having a molecular weight of more than 10 g / mol, most preferably more than 10 g / mol; and / or ii) present in the dry film in a mass fraction of more than 1 wt. %, preferably more than 10 wt. %, particularly preferably more than 50 wt. %, relative to the total mass of the dry film; and / or iii) comprising or consisting of a filament structure having a diameter in the range of 0.001 μm to 1 μm and / or having a length in the range of 1 μm to 100 μm; and / or iv) isotropically distributed in the dry film; and / or v) anisotropically distributed in the dry film The dry film according to any one of claims 19 to 24.

26. The dry film includes an ion-conductive material, and the ion-conductive material is preferably i) selected from the group consisting of ionically conducting solids, gel-like ion conductors, salt-like ion conductors, and mixtures thereof, wherein said ionically conducting solids are preferably selected from the group consisting of sulfide solid ion conductors, glassy solid ion conductors, polymeric solid ion conductors, ceramic solid ion conductors, and mixtures thereof; and / or ii) present in the dry film in a mass fraction of 1 to 99% by weight, preferably 5 to 30% by weight, particularly preferably 10 to 20% by weight, based on the total weight of the dry film; The dry film according to any one of claims 19 to 25.

27. The dry film is i) have a layer thickness in the range of 5 μm to 500 μm, preferably in the range of 10 μm to 150 μm, particularly preferably in the range of 30 μm to 100 μm, very particularly preferably in the range of 40 μm to 70 μm, and / or ii) having a liquid content of 1% or less by volume, based on the total volume of the dry film; and / or iii) a porosity of 15 to 80%, preferably 20 to 50%, particularly preferably 25 to 35%, or a porosity of 0.1 to 25%, preferably 0.1 to 10%, particularly preferably 0.1 to 5%. The dry film according to any one of claims 19 to 26.

28. The dry film according to any one of claims 19 to 27, which is produced by the method according to any one of claims 1 to 9.

29. a) an electrode comprising or consisting of the dry film according to any one of claims 19 to 28; b) a counter electrode; and c) an electrolyte, preferably a solid electrolyte, disposed between the electrode and the counter electrode; A battery comprising:

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