Electrode manufacturing equipment

Abstract

The technical concept of the present invention provides an electrode manufacturing apparatus comprising: a plurality of guide rollers arranged along a movement path of an electrode sheet; a plurality of cameras positioned at a plurality of detection positions corresponding to the plurality of guide rollers; a control unit that detects physical defects in the electrode sheet based on signals transmitted from the plurality of cameras; and a plurality of actuators configured to move the plurality of guide rollers in the width direction of the electrode sheet.

Description

Technical Field

[0001] The present invention relates to an electrode manufacturing apparatus, and more particularly, to an electrode manufacturing apparatus for manufacturing electrodes of a secondary battery.

[0002] This application claims the benefit of priority based on Korean Patent Application No. 10-2023-0167378 filed on November 28, 2023, and all the contents disclosed in the literature of the Korean patent application are included as part of this specification.

Background Art

[0003] Due to the technological development and increasing demand for mobile devices, the demand for secondary batteries has also been rapidly increasing. Among them, lithium secondary batteries are widely used as an energy source for various mobile devices as well as a variety of electronic products because of their high energy density, operating voltage, and excellent storage and life characteristics. In recent years, as the application fields of secondary batteries have expanded, the demand for higher-capacity secondary batteries has been rapidly increasing.

[0004] Generally, when manufacturing a secondary battery, an electrode active material is coated on a current collector to manufacture an electrode sheet, and subsequent processes for the electrode sheet are performed. When a defect occurs in the electrode sheet during the process of handling the electrode sheet, the defective portion of the electrode sheet is removed, and the two separated portions of the electrode sheet are reconnected to perform the process for the electrode sheet.

Summary of the Invention

Problems to be Solved by the Invention

[0005] The technical problem to be achieved by the present invention is to provide an electrode manufacturing apparatus.

Means for Solving the Problems

[0006] To solve the above-mentioned problems, the technical concept of the present invention provides an electrode manufacturing apparatus that includes a plurality of guide rollers arranged along the movement path of an electrode sheet, a plurality of cameras arranged at a plurality of detection positions corresponding to the plurality of guide rollers, a control unit that detects physical defects in the electrode sheet based on signals transmitted from the plurality of cameras, and a plurality of actuators configured to move the plurality of guide rollers in the width direction of the electrode sheet.

[0007] In one exemplary embodiment, the electrode sheet includes a textured portion and a blank portion, and the control unit is configured to detect physical defects in the blank portion of the electrode sheet based on signals transmitted from the plurality of cameras.

[0008] In one exemplary embodiment, the control unit is configured to determine, based on signals transmitted from the plurality of cameras, a target guide roller among the plurality of guide rollers that is associated with a physical defect occurring in the electrode sheet.

[0009] In one exemplary embodiment, the control unit applies a control signal to a target actuator among the plurality of actuators that is responsible for moving the target guide roller, and the target actuator is configured to adjust the position of the target guide roller along the width direction of the electrode sheet based on the control signal from the control unit.

[0010] In one exemplary embodiment, each of the plurality of guide rollers includes a central portion having a flat surface, an outer portion having an inclined surface, and a stepped portion at the boundary between the central portion and the outer portion, and the target actuator is configured to adjust the position of the stepped portion of the target guide roller based on the control signal of the control unit.

[0011] In one exemplary embodiment, the target actuator is configured to adjust the position of the target guide roller such that the electrode sheet is located within the center of the target guide roller.

[0012] In one exemplary embodiment, the target actuator is configured to adjust the position of the target guide roller such that the electrode sheet does not overlap the stepped portion of the target guide roller.

[0013] In one exemplary embodiment, the control unit determines the guide roller among the plurality of guide rollers that is closest to the starting point of the physical defect occurring in the electrode sheet as the target guide roller.

[0014] In one exemplary embodiment, each of the plurality of actuators is configured to move a corresponding guide roller among the plurality of guide rollers based on a signal transmitted from the control unit.

[0015] In one exemplary embodiment, the electrode sheet includes a textured portion and a plain portion, and further comprises a notching device configured to remove a portion of the plain portion of the electrode sheet.

[0016] In one exemplary embodiment, the invention further includes an unwinder on which the electrode sheet is wound and a rewinder that retrieves and winds the electrode sheet, wherein the plurality of guide rollers are provided between the unwinder and the rewinder. [Effects of the Invention]

[0017] According to an exemplary embodiment of the present invention, since the occurrence of physical defects in the electrode sheet can be rapidly detected by multiple cameras positioned at multiple detection locations, the amount of electrode sheets discarded due to physical defects can be minimized, ultimately improving the productivity of the electrode manufacturing apparatus.

[0018] Furthermore, according to an exemplary embodiment of the present invention, physical defects in the electrode sheet can be detected by multiple cameras, and the position of the guide roller associated with the physical defect can be automatically adjusted based on the detection results of the physical defect. This reduces the time required to adjust the equipment settings due to the occurrence of physical defects in the electrode sheet, ultimately improving the productivity of the electrode manufacturing apparatus.

[0019] The effects that can be obtained from exemplary embodiments of the present invention are not limited to those described above, and other effects not mentioned can be clearly derived and understood by a person of ordinary skill in the art to which the exemplary embodiments of this disclosure belong, from the following description. That is, unintended effects associated with carrying out exemplary embodiments of this disclosure can also be derived by a person of ordinary skill in the art from exemplary embodiments of this disclosure. [Brief explanation of the drawing]

[0020] [Figure 1] This is a side view showing an electrode manufacturing apparatus according to an exemplary embodiment of the present invention. [Figure 2] This is a plan view showing an electrode manufacturing apparatus according to an exemplary embodiment of the present invention. [Figure 3] A perspective view showing a guide roller of an electrode manufacturing apparatus according to an exemplary embodiment of the present invention. [Figure 4a] This is a plan view showing an electrode manufacturing method for an electrode manufacturing apparatus according to an exemplary embodiment of the present invention. [Figure 4b] This is a plan view showing an electrode manufacturing method for an electrode manufacturing apparatus according to an exemplary embodiment of the present invention. [Modes for carrying out the invention]

[0021] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. On the premise that the terms and words used in this specification and the claims should not be construed as being limited to their ordinary or dictionary meanings, they can be construed as meanings and concepts consistent with the technical idea of the present invention based on the principle that the inventor can appropriately define the concept of the terms in order to explain the inventor's own invention in the best way.

[0022] Therefore, the embodiments described in this specification and the configurations shown in the drawings are only the most preferred embodiment of the present invention and do not represent all of the technical ideas of the present invention. Thus, there may be various equivalents and modifications that can replace them at the time of this application.

[0023] Also, in the description of the present invention, when it is determined that a specific description of a related known configuration or function may obscure the gist of the present invention, the detailed description thereof will be omitted.

[0024] The embodiments of the present invention are provided to more fully explain the present invention to an ordinary technician. Therefore, the shapes and sizes of the components in the drawings may be exaggerated, omitted, or shown schematically for a clearer explanation. Thus, the sizes and ratios of each component do not fully reflect the actual sizes and ratios.

[0025] (First Embodiment) FIG. 1 is a side view showing an electrode manufacturing apparatus 100 according to an exemplary embodiment of the present invention. FIG. 2 is a plan view showing the electrode manufacturing apparatus 100 according to an exemplary embodiment of the present invention. FIG. 3 is a perspective view showing a guide roller 130 of the electrode manufacturing apparatus 100 according to an exemplary embodiment of the present invention.

[0026] Referring to Figures 1 to 3, the electrode manufacturing apparatus 100 can be configured to move the electrode sheet 50 along a predetermined movement path and perform an electrode manufacturing process on the electrode sheet 50. The electrode manufacturing process may include a coating process, a rolling process, a slitting process, a notching process, and so on.

[0027] The electrode sheet 50 may include a substrate and an electrode slurry layer coated on at least one of the two surfaces of the substrate. The substrate is a current collector and may include, for example, copper or aluminum. The electrode slurry layer may include a positive electrode active material slurry or a negative electrode active material slurry.

[0028] The electrode sheet 50 may include a textured portion 51, which is an area coated with an electrode slurry layer, and a plain portion 53, which is not coated with the electrode slurry layer. In the textured portion 51 of the electrode sheet 50, the surface of the substrate may be covered by the electrode slurry layer and not exposed to the outside. In the plain portion 53 of the electrode sheet 50, the surface of the substrate may be exposed. For example, the plain portion 53 of the electrode sheet 50 may be located on both edges of the electrode sheet 50 along the width direction of the electrode sheet 50. The width direction of the electrode sheet 50 may be perpendicular to the movement direction MD of the electrode sheet 50. For example, when the movement direction MD of the electrode sheet 50 is parallel to the X direction, the width direction of the electrode sheet 50 may be parallel to the Y direction.

[0029] The electrode manufacturing apparatus 100 may include a roll-to-roll device 101 configured to move the electrode sheet 50 along a predetermined path. The roll-to-roll device 101 may include an unwider 110, a rewinder 120, a plurality of guide rollers 130, a plurality of actuators 150, a plurality of cameras 140, and a control unit 180.

[0030] The electrode sheet 50 extends between the unwinder 110 and the rewinder 120 and can move between the unwinder 110 and the rewinder 120. The electrode sheet 50 can be supplied wound onto the unwinder 110. The electrode sheet 50 supplied from the unwinder 110 moves along a predetermined path and can be retrieved by the rewinder 120. The rewinder 120 can rotate so that the electrode sheet 50 is wound onto it. The rewinder 120 can rotate in synchronization with the rotation of the unwinder 110. The rewinder 120 and the unwinder 110 can each be connected to a drive motor and configured to rotate around a rotation axis 139 by the driving force provided by the drive motor.

[0031] Multiple guide rollers 130 can be positioned on the movement path of the electrode sheet 50 provided between the rewinder 120 and the unwinder 110. The multiple guide rollers 130 can guide the movement of the electrode sheet 50 so that it moves along a predetermined movement path. Each guide roller 130 may be an idle roller or a drive roller. Figures 1 and 2 illustrate the arrangement of four guide rollers 130 between the unwinder 110 and the rewinder 120, but are not limited to this arrangement, and the roll-to-roll device 101 may include several to tens of guide rollers 130 to move the electrode sheet 50 along a predetermined movement path.

[0032] Each guide roller 130 may include a rotation shaft 139 and a rotating body 131 mounted on the rotation shaft 139. The rotation shaft 139 may be mounted on a frame 161. The rotating body 131 rotates with respect to the rotation shaft 139 and can provide a surface that contacts and supports the electrode sheet 50. The rotating body 131 may be configured to rotate with respect to the width direction of the electrode sheet 50, which is perpendicular to the direction of movement MD of the electrode sheet 50.

[0033] The rotating body 131 may include a central part 1311 aligned with the width direction of the electrode sheet 50 and a pair of outer parts 1313. The central part 1311 of the rotating body 131 may have a generally uniform thickness and a flat surface that supports the electrode sheet 50. The outer parts 1313 of the rotating body 131 may have a tapered shape, becoming thinner as they move away from the central part 1311. The outer parts 1313 of the rotating body 131 may include an inclined surface that is inclined with respect to the flat surface of the central part 1311 of the electrode sheet 50. A step portion 1315 may be provided between the central part 1311 and the outer parts 1313 of the rotating body 131.

[0034] Multiple actuators 150 can move multiple guide rollers 130 in the width direction of the electrode sheet 50 and adjust the position of the multiple guide rollers 130 along the width direction of the electrode sheet 50. Hereinafter, the position of the guide rollers 130 along the width direction of the electrode sheet 50 will be simply referred to as the position of the guide rollers 130. Each individual actuator 150 can linearly move a corresponding guide roller 130 from among the multiple guide rollers 130 and adjust the position of the corresponding guide roller 130. Each individual actuator 150 can linearly move the rotation axis 139 and the rotating body 131 of the corresponding guide roller 130. In an exemplary embodiment, each actuator 150 can linearly move a corresponding guide roller 130 along the width direction of the electrode sheet 50 or along the extending direction of the rotation axis 139 so that the stepped portion 1315 of the rotating body 131 of the corresponding guide roller 130 is located at a specified position.

[0035] Multiple cameras 140 can image the electrode sheet 50 at multiple detection positions in order to detect physical defects in the electrode sheet 50 as it moves guided by multiple guide rollers 130. Multiple cameras 140 may include at least one camera 140 for imaging one detection position of the electrode sheet 50. Multiple cameras 140 may include at least one image sensor configured to capture an image of the electrode sheet 50. Each of the multiple cameras 140 can transmit the image obtained by imaging the electrode sheet 50 to the control unit 180. Multiple cameras 140 can be arranged at multiple detection positions corresponding to the positions of the multiple guide rollers 130. Individual guide rollers 130 may be arranged around a corresponding guide roller 130 of the multiple guide rollers 130 and configured to image the portion of the electrode sheet 50 around the corresponding guide roller 130. In an exemplary embodiment, individual cameras 140 may be configured to image the blank portion 53 of the electrode sheet 50 in order to detect physical defects in the blank portion 53 of the electrode sheet 50. Physical defects in the plain portion 53 of the electrode sheet 50 may include visually identifiable defects such as wrinkles, creases, and cracks.

[0036] The control unit 180 can control the overall operation of the roll-to-roll device 101 based on signals DS transmitted from the multiple cameras 140. The control unit 180 can generate control signals CS for controlling the lateral position of the electrode sheets 50 of the multiple guide rollers 130 based on signals DS transmitted from the multiple cameras 140, and can apply the generated control signals CS to the multiple actuators 150. The control unit 180 may include at least one memory device configured to store data, and at least one processor configured to process data. For example, the control unit 180 can be implemented as a computer, a programmable logic controller (PLC), etc.

[0037] Multiple cameras 140 acquire images of the electrode sheet 50 at multiple detection points corresponding to the positions of multiple guide rollers 130, and the control unit 180 can determine whether or not a physical defect has occurred in the electrode sheet 50 based on the images of the electrode sheet 50 acquired at the multiple detection points. If it is determined that a physical defect has occurred in the electrode sheet 50, the control unit 180 can determine which of the multiple guide rollers 130 is associated with the physical defect that occurred in the electrode sheet 50, based on the images of the electrode sheet 50 acquired at the multiple detection points. Hereinafter, the guide roller 130 determined to be associated with the physical defect that occurred in the electrode sheet 50 will be referred to as the target guide roller.

[0038] When a target guide roller is determined, the control unit 180 applies a control signal CS to the target actuator among the plurality of actuators 150 that is responsible for moving the target guide roller. The target actuator can then adjust the position of the target guide roller by moving it in the width direction of the electrode sheet 50 in accordance with the control signal CS applied by the control unit 180.

[0039] In an exemplary embodiment, the control unit 180 can detect the occurrence of a physical defect in the blank portion 53 of the electrode sheet 50 based on images of the electrode sheet 50 acquired at multiple detection points, and can determine the target guide roller associated with the occurrence of the physical defect in the blank portion 53 of the electrode sheet 50. For example, if a continuous or discontinuous physical defect is detected in the blank portion 53 of the electrode sheet 50 along the movement direction MD of the electrode sheet 50, the control unit 180 can determine the guide roller 130 closest to the starting point of the physical defect as the target guide roller.

[0040] In an exemplary embodiment, the target actuator can move the target guide roller in response to a control signal CS from the control unit 180 so that the electrode sheet 50 is located within the center of the rotating body of the target guide roller. Alternatively, the target actuator can move the target guide roller in response to a control signal CS from the control unit 180 so that the electrode sheet 50 does not overlap the outer casing of the target guide roller.

[0041] In an exemplary embodiment, the target actuator can adjust the position of the stepped portion of the target guide roller along the width direction of the electrode sheet 50 based on a control signal CS from the control unit 180. For example, if the electrode sheet 50 overlaps the stepped portion of the target guide roller, the target actuator can move the target guide roller based on the control signal CS from the control unit 180 so that the electrode sheet 50 does not overlap the stepped portion of the target guide roller.

[0042] The electrode manufacturing apparatus 100 may include a notching device 190 positioned along the movement path of the electrode sheet 50. The notching device 190 can form electrode tabs 55 on the blank portion 53 of the electrode sheet 50 by removing a portion of the blank portion 53 of the electrode sheet 50. The notching device 190 may include a laser notching machine configured to remove a portion of the blank portion 53 of the electrode sheet 50 using a laser beam, or a press-based notching machine configured to remove a portion of the blank portion 53 of the electrode sheet 50 using a die cutting machine.

[0043] (Second Embodiment) Figures 4a and 4b are plan views showing an electrode manufacturing method of an electrode manufacturing apparatus 100 according to an exemplary embodiment of the present invention. The electrode manufacturing method of the electrode manufacturing apparatus 100 will be described below with reference to Figures 4a and 4b in conjunction with Figures 1 to 3.

[0044] Referring to Figure 4a in conjunction with Figures 1 to 3, the control unit 180 can detect physical defects 57 in the blank portion 53 of the electrode sheet 50 based on signals DS transmitted from multiple cameras 140. The physical defects 57 in the blank portion 53 may be crease defects. If the blank portion 53 of the electrode sheet 50 spans both the center 1311 and the outer casing 1313 of the rotating body 131 of the guide roller 130 located downstream of the electrode sheet 50 in the direction of movement MD, a crease defect originating from the downstream guide roller 130 may occur in the blank portion 53 of the electrode sheet 50.

[0045] As shown in Figure 4a, when a physical defect 57 is detected in the blank portion 53 of the electrode sheet 50, the control unit 180 can identify the target guide roller 130a associated with the physical defect 57 in the blank portion 53 of the electrode sheet 50 from among the multiple actuators 150, based on the signals DS transmitted from the multiple cameras 140. The target guide roller 130a is likely to be the one most adjacent to the starting point of the crease defect among the multiple guide rollers 130.

[0046] Referring to Figure 4b, the control unit 180 can adjust the position of the target guide roller 130a by applying a control signal CS to the target actuator 150a, which is responsible for moving the target guide roller 130a, among the plurality of actuators 150. The position of the target guide roller 130a can be adjusted so that physical defects 57 in the electrode sheet 50 caused by the target guide roller 130a are removed. In an exemplary embodiment, the adjustment of the position of the target guide roller 130a by the target actuator 150a can be performed while the movement of the electrode sheet 50 by the roll-to-roll device 101 is stopped. In an exemplary embodiment, the adjustment of the position of the target guide roller 130a by the target actuator 150a may be performed in parallel with the movement of the electrode sheet 50 in the movement direction MD by the roll-to-roll device 101.

[0047] In an exemplary embodiment, the control unit 180 calculates the positional movement value of the target guide roller 130a based on signals DS transmitted from a plurality of cameras 140, and the target actuator 150a can move the target guide roller 130a by the determined positional movement value in the width direction of the electrode sheet 50 based on the control signal CS applied from the control unit 180.

[0048] In an exemplary embodiment, the target actuator 150a can move the target guide roller 130a based on a control signal CS applied by the control unit 180 such that the electrode sheet 50 overlaps the center 1311a of the rotating body 131a of the target guide roller 130a, but does not overlap the outer casing 1313a of the rotating body 131a. In an exemplary embodiment, the target actuator 150a can move the target guide roller 130a based on a control signal CS applied by the control unit 180 such that the electrode sheet 50 does not overlap the stepped portion 1315a of the rotating body 131a of the target guide roller 130a. In an exemplary embodiment, the target actuator 150a can adjust the distance D1 between the frame 161 and the stepped portion 1315a of the target guide roller 130a based on a control signal CS from the control unit 180.

[0049] Generally, when a physical defect occurs in an electrode sheet, the electrode manufacturing process involves the steps of stopping the operation of the manufacturing equipment, resetting the manufacturing equipment to eliminate the cause of the physical defect, cutting out and removing the defective portion of the electrode sheet, reconnecting the two separated portions of the electrode sheet with tape, and restarting the operation of the manufacturing equipment. Since the defective portion of the electrode sheet is discarded, the later the physical defect is detected, the lower the productivity of the electrode sheet may become. In addition, in a typical electrode manufacturing process, there is a problem that it takes a long time to restart the manufacturing process, which reduces the utilization rate of the equipment.

[0050] According to an exemplary embodiment of the present invention, the occurrence of physical defects 57 in the electrode sheet 50 can be rapidly detected by multiple cameras 140 positioned at multiple detection locations, thereby minimizing the amount of electrode sheet 50 discarded due to physical defects 57, and ultimately improving the productivity of the electrode manufacturing apparatus 100.

[0051] Furthermore, according to an exemplary embodiment of the present invention, physical defects 57 in the electrode sheet 50 can be detected by multiple cameras 140, and the position of the guide roller 130 associated with the physical defects 57 can be automatically adjusted based on the detection results of the physical defects 57. This reduces the time required to adjust the equipment settings due to the occurrence of physical defects 57 in the electrode sheet 50, ultimately improving the productivity of the electrode manufacturing apparatus.

[0052] The present invention has been described in more detail above with reference to the drawings and embodiments. However, the configurations described in the drawings or embodiments of this specification are merely one embodiment of the present invention and do not represent the entire technical concept of the present invention. Therefore, there may be a variety of equivalents and modifications that can be substituted for them at the time of filing. [Explanation of Symbols]

[0053] 100 Electrode manufacturing equipment 130 Guide Roller 140 Cameras 150 Actuators

Claims

1. Multiple guide rollers arranged along the path of the electrode sheet, Multiple cameras arranged at multiple detection positions corresponding to the multiple guide rollers, A control unit that detects physical defects in the electrode sheet based on signals transmitted from the plurality of cameras, Multiple actuators configured to move the multiple guide rollers in the width direction of the electrode sheet, Electrode manufacturing equipment, including...

2. The electrode sheet includes a textured portion and a plain portion. The electrode manufacturing apparatus according to claim 1, wherein the control unit is configured to detect physical defects in the blank portion of the electrode sheet based on signals transmitted from the plurality of cameras.

3. The electrode manufacturing apparatus according to claim 2, wherein the control unit is configured to determine, based on signals transmitted from the plurality of cameras, a target guide roller among the plurality of guide rollers related to a physical defect occurring in the electrode sheet.

4. The control unit applies a control signal to the target actuator, which is responsible for moving the target guide roller, among the plurality of actuators. The electrode manufacturing apparatus according to claim 3, wherein the target actuator is configured to adjust the position of the target guide roller based on the control signal of the control unit.

5. Each of the plurality of guide rollers includes a central part having a flat surface, an outer part having an inclined surface, and a stepped part at the boundary between the central part and the outer part. The electrode manufacturing apparatus according to claim 4, wherein the target actuator is configured to adjust the position of the stepped portion of the target guide roller based on the control signal of the control unit.

6. The electrode manufacturing apparatus according to claim 5, wherein the target actuator is configured to adjust the position of the target guide roller such that the electrode sheet is located within the center of the target guide roller.

7. The electrode manufacturing apparatus according to claim 5, wherein the target actuator is configured to adjust the position of the target guide roller so that the electrode sheet does not overlap the stepped portion of the target guide roller.

8. The electrode manufacturing apparatus according to claim 3, wherein the control unit determines the guide roller among the plurality of guide rollers that is closest to the starting point of the physical defect occurring in the electrode sheet as the target guide roller.

9. The electrode manufacturing apparatus according to claim 1, wherein each of the plurality of actuators is configured to move a corresponding guide roller among the plurality of guide rollers based on a signal transmitted from the control unit.

10. The electrode sheet includes a textured portion and a plain portion. The electrode manufacturing apparatus according to claim 1, further comprising a notching device configured to remove a portion of the plain portion of the electrode sheet.

11. An unwinder on which the electrode sheet is wound, A rewinder that collects and winds up the electrode sheet, It further includes, The electrode manufacturing apparatus according to claim 1, wherein the plurality of guide rollers are provided between the unwinder and the rewinder.

Images