Film-like functional material and method for producing same

Abstract

To provide a film-like functional material for use as an electrode applied to electrical energy storage devices, and a method for producing the film-like functional material.SOLUTION: In a film-like functional material 1, a carrier medium 2 including a total carrier volume and having a cross-sectional extent 7 less than or equal to 100 μm is arranged; a strip-shaped extent is formed from linear carrier elements 3a and node-like carrier elements 3b; the linear carrier elements and node-like carrier elements form the ingredient components of the carrier medium and pass throughout the total carrier volume; and the strip-shaped extent has interconnected partial volumes 5 present therein. The carrier elements 3 are coated to be sheathed with a first functional ingredient, and the remaining volume of the total carrier volume formed by the partial volumes is filled with at least one second functional ingredient.SELECTED DRAWING: Figure 2D

Description

[Technical Field]

[0001] The present invention relates to film-like functional materials that fulfill at least one predetermined function and can therefore be used for targeted specific physical, chemical, physicochemical, biological or other technical or scientific purposes.

[0002] A functional film material in the sense of the present invention is always a composite material, i.e., a material consisting of three or more connected raw materials, where at least one of these raw materials is a structural raw material and at least two of these raw materials are functional raw materials. These functional raw materials serve, in particular, to fulfill a critical and characteristic function for a specific targeted physical, chemical, physicochemical, biological, or other technical or scientific application. A functional film material as a whole has properties different from those of the raw materials that compose it. It can therefore be used to achieve a targeted function, specifically in a manner different from that of its individual raw materials.

[0003] In this context, functional raw materials are a subgroup of raw materials in the sense of materials science. Among raw materials, a distinction is generally made between structural raw materials and functional raw materials, whereby functional raw materials, unlike structural raw materials, are not primarily characterized by their mechanical resistance and the resulting mechanical stability, but are characterized in particular by electrical, mechanical, magnetic, acoustic, optical, or biochemical properties that can be specifically influenced to change the properties of components. Functional raw materials focus on the properties, intended use, and application of the functional raw materials, rather than the structural design of the component, but functional raw materials can also have mechanical resistance.

[0004] The present invention relates in particular to a film-like functional material for use as an electrode in an electrical energy storage device, and to a method for producing the film-like functional material. Nevertheless, the present invention also allows for functional materials that can be used for functions other than as an electrode in an electrical energy storage device.

[0005] For the purposes of this description, the term film-like material is used. Film-like materials generally have many properties consistent with films. In addition, they also have some notable differences compared to films.

[0006] As is known, a film is a thin material in sheet or web form, often made of plastic or metal, but also of other materials, that is very thin and has a large area. Typical film thicknesses are in the range of less than 0.4 millimeters. Films are generally produced in a continuous web, rolled, and then often cut into pieces suitable for each application. Although a film is characterized by a large area, it is a three-dimensional solid material characterized by Δx and Δy >> Δz (Δx is the length, Δy is the width, and Δz is the thickness of the film), where x and y characterize the surface dimensions of the film and z is the thickness of the film. Another characteristic is that the components of the material, i.e., the raw materials that make up the film, macroscopically fill this three-dimensional solid material without exception, i.e., there is no other raw material or macroscopically free space anywhere within the solid material. Only the raw materials that make up the film fill the three-dimensional space spanned by the solid material. Any other material that looks, behaves, and can be used like a film, but lacks the above characteristics, is a film-like material. Unfortunately, these materials are often also referred to as films, although this is not strictly accurate.

[0007] Much like films, film-like materials are thin materials in sheet or web form that have two major dimensions and a relatively small dimension in the third. Film-like materials are also typically manufactured as continuous webs, rolled up, and often subsequently cut into suitable sections. They differ from films in that film-like materials are similarly characterized by x, y, and z, where x and y characterize the surface dimensions of the object and z characterizes the direction of the transverse dimension of the film-like material, representing the measurable distance from one side of the object to the other side of the object, with Δx being the length, Δy being the width, and Δz being the transverse dimension. While film-like materials are indeed continuous within their dimensions, they are not space-fillingly continuous; i.e., the raw materials that make up the film-like material do not completely fill the three-dimensional space that the object spans. Accordingly, discontinuous or interconnected partial volumes (also called free volumes) permeate the object. A discrete subvolume, also called an independent subvolume, is a hollow space or volume or cavity that is free space within certain boundaries. These boundaries are formed by the raw materials, boundary layers or structures that make up the film-like material.

[0008] A film-like functional material is a composition of interconnected raw materials, in which a partial volume surrounded or defined by one raw material or a structural raw material formed as a carrier medium is permeated with one or more other raw materials, or even completely filled with one or more other raw materials, i.e., the carrier medium, that define the partial volume.

[0009] For this reason, the variety of film-like functional materials is correspondingly great.

[0010] An example of a structural raw material formed as a carrier medium is expanded polytetrafluoroethylene, also known as ePTFE, a specially engineered form of polytetrafluoroethylene. It can be formed into a film-like material. During the processing process, it is referred to as multidirectional ePTFE. The resulting material is characterized by a porous structure with PTFE molecular fibers permeating the material and up to 70 percent open, fillable volume.

[0011] Flat textile structures, such as woven fabrics, warp knitted fabrics, weft knitted fabrics, braided fabrics, nonwoven fabrics, and felted raw materials, can also serve as carrier media for film-like materials. The main component of all textile products is textile fiber, i.e., fiber that can be processed in textile manufacturing processes, especially spinnable fiber. These are linear structures, i.e., structures with a length-to-diameter ratio essentially greater than 1, with sufficient length and flexibility and flexibility as prerequisites for their processability. Depending on their shape, fibers can be distinguished into staple fibers, which refer to fibers with a limited length, and filaments, which refer to continuous fibers.

[0012] A special type of textile fabric is one made of metal wire. Textile fabrics made of metal wire are called metal cloth or wire cloth. Metal cloth is also produced on a loom.

[0013] For use in electrical energy storage devices, electrode films are used as positive or negative electrodes or as anode or cathode films, which fulfill active and non-active functions. In the case of an electrode film, charge carrier storage is the active function in all its aspects. In contrast, the non-active function is the electrical conduction function for the supply and release of charge carriers, i.e., the connection function for the functional raw materials that fulfill the active function. In the case of known electrode films, the functional raw materials often also serve or essentially contribute to the mechanical stability of the electrode film.

[0014] Electrical energy storage devices are based, for example, on the spontaneous conversion of chemical energy into electrical energy, thus the so-called Galvanic cell, or on the storage of electrical energy in chemicals, where the reaction partners are present in a dissolved form in a solvent, for example in redox flow batteries. Alternatively, electrical energy storage devices can be based on the principle of statically storing energy in an electric field. This principle is particularly used in capacitors, such as electrolytic capacitors, supercapacitors, such as double-layer capacitors, pseudocapacitors, or hybrid capacitors. To achieve the highest possible capacity of the energy storage device in a small construction volume, the thickness of the electrode film should be as thin as possible. In this case, structural materials in the form of carrier films or textile three-dimensional flat structures are used to ensure the mechanical stability of the electrode film.

[0015] In electrode films, metals in the form of metal films are often used as raw materials. In most cases, metal films do not require additional metal coatings or metal films, because the metal film itself can ensure mechanical stability as well as the electrical conduction function for transporting charge carriers. In this context, the term stability includes the strength of the raw material against mechanical and thermal influences on the material, such as mechanical and thermal stress, bending, stretching, twisting, folding, and shape changes.

[0016] The thickness of the metal film in the z-direction depends on the required mechanical stability and the ability to fabricate the metal film. To ensure the required mechanical stability, the metal film cannot be made as thin as desired. On the other hand, a much thinner metal film may be sufficient to ensure electrical conductivity.

[0017] The mechanical stability of the film must generally allow for the manufacturing process of the electrode film. Furthermore, the electrode film must ensure the functionality of all film parts in the component assembly. This requires sufficiently good adhesion with the applied layers and components.

[0018] Electrode films are also known that comprise dielectric raw materials, such as polymer films, metallized on one or both sides. The metallization must be shaped and dimensioned to ensure the transport of charge carriers. This requires sufficient electrical conductivity to support the spontaneously occurring current density. The thickness of these metal layers is usually greater than one or two micrometers, and the metal coating is performed chemically, electrochemically, or by vacuum techniques, making the production of the composites correspondingly more cost-intensive than the production of pure metal films. Furthermore, the presence of a dielectric between two separate metal layers is a disadvantage in double-sided metallization. Additional process steps are required to join these metal layers together, i.e., to short-circuit them.

[0019] For example, to produce electrolytic capacitors, electrically conductive aluminum films that are as thin as possible are used. Electrically conductive films made of high-purity aluminum with a film thickness of less than 100 μm may be difficult to process using conventional, i.e., state-of-the-art, processing processes, such as those used to produce anode films for electrolytic capacitors, due to their insufficient mechanical stability.

[0020] In lithium-ion batteries, the thickness of the aluminum film for the positive current collector, which must also ensure the mechanical stability of the electrode, is typically between 25 and 15 μm. The goal here is to use a film with a thickness of approximately 10 μm. The thickness of the copper film for the negative current collector, which must also ensure the mechanical stability of the electrode, is typically between 15 and 10 μm. The goal is to use a film with a thickness of approximately 6 μm. One of the major problems is the film's insufficient mechanical stability, especially during the electrode film manufacturing process. For this reason, there are limitations on how thin the film can be.

[0021] DE 10 2010 011 413 A1 (Patent Document 1) discloses a cathode electrode having a carrier containing a metal material, in particular aluminum, and having a thickness of 15 to 45 μm. EP 1 455 404 A2 (Patent Document 2) describes an electrode unit having a porous carrier structure made of metal wires.

[0022] To improve the mechanical stability of metal films, DE 10 2012 000 508 A1 (Patent Document 3) discloses a method for producing so-called GLARE components, in which aluminum sheets and prepreg sheets are alternately stacked and then glued or pressed together. The layers are arranged so that the aluminum sheets are positioned on the outside. Prepreg sheets are understood to mean pre-cured sheets of glass fiber-reinforced epoxy resin. However, mechanically stabilized metal films produced according to this method are not suitable for applications requiring a film with good electrical conductivity.

[0023] Metal-coated textiles are also used in clothing. What is particularly important here is the breathability of the textile. DE 10196402 T1 (Patent Document 4) describes gold-laminated textiles and a method for their production. Breathability is ensured due to the openings between the metal-coated carrier elements.

[0024] DE 10 2013 108 808 B4 (Patent Document 5) discloses a method for producing a carbon-metal composite material and a semiconductor device. In this case, a carbon fiber fabric with a strip-shaped carrier element is coated with a metal, which can then be used to dissipate heat from a semiconductor component. To secure the semiconductor component, a soft solder is introduced into the interstices of the metal-coated carbon fiber fabric, structurally connecting the coated carbon fiber fabric to the semiconductor component. Thus, the first metal layer applied to the carbon fiber fabric primarily serves to dissipate heat from the component, and the subsequently introduced soft solder primarily fulfills the function of structurally securing the component to be cooled. In this case, the strip-shaped carrier element occupies a large portion of its total volume to ensure effective heat dissipation. In contrast, the soft solder occupies only a small portion of the total volume, which is sufficient for securing a heat sink to the semiconductor component. This results in the fact that the volume of the carbon fiber fabric constitutes a large portion of the total volume of the heat sink. [Prior art documents] [Patent documents]

[0025] [Patent Document 1] DE102010011413A1 [Patent Document 2] EP1455404A2 [Patent Document 3] DE102012000508A1 [Patent Document 4] DE10196402T1 [Patent Document 5] DE102013108808B4 Summary of the Invention [Problem to be solved by the invention]

[0026] The object of the present invention is to provide a film-like functional material comprising a carrier medium formed from a structural raw material in the sense of a support substrate, and at least two functional raw materials combined with the carrier medium, wherein the carrier medium formed from the structural raw material should have sufficient mechanical stability for use of the film-like functional material, and occupy only a small volume relative to the volume of the entire film-like functional material. [Means for solving the problem]

[0027] This problem is solved by a product and a method with the features according to the independent claims. Developments are set out in the dependent claims.

[0028] In particular, the above-mentioned problem is solved by a film-like functional material that fulfills at least one predetermined function and can therefore be used for physical, chemical, physicochemical, biological, or other technical or scientific applications. In the film-like functional material, a film-like medium formed from at least one structural raw material, comprising a carrier total volume and having a cross-sectional dimension of ≦100 μm, is arranged, which can be considered as a matrix, i.e., a substrate in which further raw materials are embedded. The carrier medium is composed of linear and nodular carrier elements (hereinafter, for short, referred to as linear and nodular carrier elements), which form the raw material components of the carrier medium and are distributed throughout the carrier total volume, and the strip-like medium has a partial volume of the carrier total volume that is connected to each other and is defined by the adjacent carrier elements. In this case, the linear and nodular carrier elements are coated with a first functional material that fulfills a first function, and the remaining volume of the total carrier volume formed by the interconnected partial volumes is filled with at least one second functional material that fulfills a second function different from the first function. DETAILED DESCRIPTION OF THE INVENTION

[0029] When the remaining volume of the total volume of the carrier formed by the interconnected partial volumes is filled with more than one second functional ingredient, each second functional ingredient fulfills at least one function different from the first function.

[0030] It is also within the scope of the present invention that further functions may be fulfilled by a second or further functional material introduced into the partial volume. Furthermore, it should always be understood that the second or further functional material introduced into the partial volume does not necessarily fulfill just one function, but may also fulfill several functions, with at least one active or passive function of the functional material introduced into the partial volume being different from the active or passive function of the first functional material coated around the carrier element.

[0031] The carrier medium consists of a multitude of individual carrier elements, which can be linear, i.e., large in one dimension but small in two other dimensions, or can be configured as nodules. A linear carrier element, in the sense of the present invention, is a carrier element in which the dimensions of the linear carrier element are small and are approximately equal in two dimensions. In this case, the ratio of the larger dimension to the two smaller dimensions is at least 50:1. In this case, the ratio between the dimensions of the two smaller dimensions is greater than 1:5 and less than 5:1. Therefore, linear carrier elements differ from stop-shaped carrier elements. The above-mentioned limits for linear carrier elements can also be exceeded if the spacing between the linear carrier elements is at least partially large.

[0032] The linear carrier elements have at least partially large spacings between each other, so that their planar effect based on the geometric plane in which the surfaces of the linear carrier elements lie is negligible, so that the partial volumes defined by the linear carrier elements are not almost completely separated from each other.

[0033] Here, large spacing is understood to mean that the ratio of the spacing between the individual linear carrier elements to the larger of the two smaller dimensions of the linear carrier elements is greater than 5:1, where the ratio of the two smaller dimensions can exceed the aforementioned limits.

[0034] In the sense of the present invention, a carrier element is nodular if it has similar dimensions in all dimensions, in particular all dimensions being small relative to the larger dimensions of the linear carrier element. If two or more linear carrier elements come into contact, the carrier medium has nodular carrier elements at the contact points.

[0035] The total carrier volume, in the sense of the present invention, denotes the volume that includes all the carrier elements and therefore the entire carrier medium.

[0036] A body has a strip-shaped extent in the sense of the present invention when its size in one dimension is small compared to its size in two other dimensions.

[0037] The carrier element is circumferentially coated with a first functional ingredient, and at contact points of the carrier element, the circumferential coating may have imperfections, provided that all areas of the coating connect to one another and form a coherent layer.

[0038] The carrier elements covering the entire volume of the carrier are partially spaced apart from one another such that partial volumes are defined between adjacent carrier elements. The defined partial volumes are configured as open, interconnected free spaces. These partial volumes are not filled with carrier elements, thus forming fillable gaps between the carrier elements coated with the first functional ingredient. In the present invention, these partial volumes, i.e., gaps, are filled with at least one second functional ingredient.

[0039] Furthermore, the term "first functional ingredient" should always be understood as the functional ingredient with which the linear and nodular carrier elements are coated, and the term "second functional ingredient" should always be understood as the functional ingredient introduced into, i.e., filling, the open, interconnected free partial volumes defined by the carrier elements. In this case, the second functional ingredient fills the interconnected free partial volumes of the openings defined by the carrier elements completely, but not densely. This means that within the second functional ingredient, not only relatively small volumes, which may be open and interconnected, for example in the form of pores, but also additional second functional ingredients may be present.

[0040] In the present invention, a carrier element is coated with a first functional material, which fulfills at least one active or inactive function. The matrix form of the coated film-like carrier medium is maintained. This means that a large portion of the free interconnected partial volumes present in the carrier medium are also maintained, but are reduced by the volume of the first functional material surrounding the carrier element. In particular, within the carrier medium, the total volume of the free partial volumes is not smaller than the total volume of the carrier element coated with the first functional material. Preferably, the ratio of the total volume of the free partial volumes to the total volume of the carrier element coated with the first functional material is at least 2:1 or at least 5:1, particularly preferably at least 10:1.

[0041] In one advantageous design, when the linear carrier elements are arranged in parallel, the ratio between the dimension of the smaller dimension of the linear carrier elements and their spacing in the carrier medium is at least 1:1, preferably at least 1:2 or at least 1:3 or at least 1:5.

[0042] One or more second functional raw materials fulfilling not only an active function but also a non-active function can be introduced into the partial volume of the film-like functional material, and the upper and lower surfaces of the film-like functional material can be coated with the second functional raw materials in a strongly adherent state. In this case, at least one second functional raw material fulfills at least one active or non-active function, which is different from the active or non-active function fulfilled by the first functional raw material.

[0043] Particularly when the film-like functional material is used as an electrode for an electrical energy storage device, there are interconnected spaces in the form of open holes inside the second functional raw material or multiple second functional raw materials.

[0044] That is, a film-like functional material is a composite material whose constituents or raw materials perform one or more additional functions in order to enable it to serve its intended purpose, such as storing electrical energy, or a catalytic process, or as a fuel, in addition to the original specific function characteristic of the use of the functional material. For this reason, it is often necessary for the functional raw materials to fulfill both active and non-active functions.

[0045] Here, an active function is understood to mean that the functional raw material fulfills a function corresponding to the purpose or conditions for use of the film-like functional material, i.e., a function characteristic for the use of the film-like functional material.

[0046] By non-active function, it is understood that the functional material fulfills the function necessary to enable the active function for the purpose or conditions for use of the film-like material.For this reason, both active and non-active functions are very important.In this case, the functional raw material can fulfill one or more functions, which can be active or non-active.

[0047] In this regard, the carrier medium, or the structural raw materials forming the carrier medium, also fulfill a non-active function, namely the mechanical stability of the film-like functional material.

[0048] It may be advantageous for the application of the film-like functional material that the at least one second functional raw material covers the upper surface and / or the lower surface of the film-like functional material in a strongly adherent state.

[0049] The film-like functional material is advantageously configured such that the linear carrier elements of the carrier medium form a woven fabric in which warp and weft threads running perpendicular to each other are interwoven. In a preferred embodiment, the warp and weft threads are made of a plurality of filaments. Alternatively, the warp and weft threads can be made of monofilaments.

[0050] In the construction of the film-like functional material, the first functional raw material, i.e., the functional raw material that is coated around the carrier element, is a metal.

[0051] In one preferred form of the film-like functional material, the carrier medium is a glass fiber cloth strip, or a carbon fiber cloth strip, or a mineral wool fiber cloth strip, or a polymer fiber cloth strip, or a wire mesh strip.

[0052] In one preferred form of the film-like functional material, the second functional raw material comprises one of substance mixtures from the group consisting of lithium / nickel oxide, lithium / manganese oxide, lithium / cobalt oxide, and lithium / iron phosphate, and optionally further additives, preferably carbon black.

[0053] The above object is also achieved by a method for producing a film-like functional material, which comprises the following steps: coating a carrier medium around a carrier element by dispensing a first functional ingredient onto the carrier element, the first functional ingredient fulfilling a first function; and filling the remaining volume of the total volume of the carrier formed by the interconnected partial volumes with at least one second functional ingredient fulfilling a second function different from the first function, Includes.

[0054] In this case, the coating of the carrier element can be effected by metallizing the carrier element.

[0055] Preferably, the metal coating of the carrier element of the carrier medium is carried out by physical vapor deposition of the metal in a vacuum coating apparatus, preferably by thermal evaporation, or by electron beam physical vapor deposition, or by pulsed laser deposition, or by arc evaporation, or by sputtering, or by ion beam assisted deposition.

[0056] Thermal evaporation, in the sense of the present invention, is a process in which a material is evaporated or atomized by the input of thermal energy and is consequently deposited on a carrier element of a carrier medium. In order to ensure that the carrier element is as completely covered as possible, i.e., all sides are covered with the first material, it is advantageous to use several different deposition angles, i.e., more than two, during the thermal evaporation process.

[0057] Any of the other deposition methods mentioned herein proceed appropriately, where they differ essentially by the method of energy input into the first material.

[0058] In one advantageous embodiment of the method, the coating of the carrier element with the first functional raw material is carried out by thermal spraying, preferably by flame wire spraying, or by powder flame spraying, or by high velocity flame spraying, or by high velocity wire flame spraying, or by arc flame spraying, or by plasma spraying, or by cold gas spraying, or by hot metal spraying.

[0059] Even when thermal spraying is used, the carrier element of the carrier medium is completely coated therearound with the first material over the entire surface and under a plurality of different spray angles, i.e., more than two.

[0060] Instead of thermal evaporation or spraying at multiple different deposition or spray angles, i.e., more than two, the thermal evaporation or spraying to coat the carrier element with the first functional raw material can be performed by thermal evaporation or spraying at one or two deposition or spray angles, preferably 180° apart, in combination with a subsequent heat treatment. In this heat treatment, heat is supplied to the first functional raw material applied to the carrier element of the carrier medium by thermal evaporation or spraying within a specified short period of time or at a specified time interval so that the deformability of the applied first functional raw material increases until it begins to flow and coats the carrier element. In this case, the heat input must be carried out at a time interval such that the first functional raw material coats the carrier element but does not drip off. This method can be used to coat the first material on the carrier element with a cross-sectional dimension of up to 10 μm.

[0061] Preferably, the heat input is pulsed with a pulse duration in the range of 1 ms to 100 s, with the temperature of the heat source being up to 500 K higher than the melting temperature of the applied first functional raw material. Therefore, the effect of the heat input can be considered as shock heating.

[0062] If the first functional raw material is an electrically conductive raw material and the thickness of the functional raw material layer applied to the carrier element is less than 1 micrometer, the heat input can be achieved by using microwaves, in which case the electrically conductive first functional raw material applied to the carrier element is exposed to microwave radiation, the microwave energy being determined such that the resulting heating changes the deformability of the first functional raw material, as already mentioned, so that the carrier element is coated with the first functional raw material.

[0063] For irradiation with a 2.45 GHz magnetron up to about a 1 μm thick layer of applied first functional raw material, the radiation power is 1 Ws / cm for an exposure time of 0.1 to 150 s. 2 ~10000Ws / cm 2To optimize the heat input, the microwave irradiation power can be supplied using a pulse sequence, with pulse widths ranging from 0.01 seconds to several seconds.

[0064] When the first functional raw material is a metal, the metallization of the carrier element of the carrier medium can be performed by chemical metallization in a two-step process, where the metallization of the carrier element of the carrier medium comprises the following steps: The seeding process, and Metallic coating process.

[0065] Alternatively, the metallization of the carrier element of the carrier medium can be carried out by electrochemical metallization in a three-step process, in which case the metallization of the carrier element of the carrier medium comprises the following steps: Seeding process, Metallization processes, and Metal layer strengthening process.

[0066] In yet another possible embodiment, the metallization of the carrier element of the carrier medium is carried out by hot-dipping the carrier medium in a molten metal bath.

[0067] A preferred use of the film-like functional material according to the present invention is in the formation of an electrode film for use in an electrical energy storage device. In reality, the term electrode film should not be used in this context, because in the context of the present invention, this is a film-like electrode material. However, since the term electrode film is customary not only for films in practice but also for film-like materials, it should also be used here, but always with the proviso that the use according to the present invention is specifically a film-like electrode material.

[0068] Conceptually, an electrode film consists of a film-like functional material having a carrier medium, which can be considered a matrix, whose carrier elements are coated with a first electrically conductive functional raw material, preferably a metal, such as aluminum, copper, silver, gold, brass, or other metal or metal alloy. In special cases, other electrically conductive functional raw materials, such as conductive polymers, can also be used to form the electrically conductive layer that coats the carrier elements. This electrically conductive functional raw material layer, which the carrier medium coats around the carrier elements, has the function of charge carrier transport, i.e., the transport of charge carriers into and out of the electrode film, a non-active but still important function for the electrode film. Because substantially all of the carrier elements of the carrier medium are connected to each other, the inflow and outflow of charge carriers in the x-, y-, and z-directions, and therefore current flow to the contacts of the electrode film, are possible. In this case, the metal-coated carrier medium, which can be considered a metal-coated matrix, has a thickness of ≦100 μm. As the carrier medium, particularly, a textile three-dimensional planar structure having a cross-sectional dimension of ≦100 μm is proposed. To form the electrode film, it is further necessary to introduce a second functional raw material that fulfills at least one second function into the existing partial volume of the carrier medium defined by the metal-coated carrier element. The second function fulfilled by the second functional raw material is an active function characteristic of the electrode film used for energy or charge carrier storage, i.e., electrical energy storage devices. The second functional raw material introduced into the partial volume can also fulfill a function other than the aforementioned characteristic function. This can be an inactive function, such as an electrical conduction function. The second functional raw material can also contribute to the mechanical stability of the electrode film. The upper and lower surfaces of the electrode film can be advantageously coated with the second functional raw material in a strongly adherent manner.

[0069] By using the present invention, a film-like functional material is provided in which the ratio of functional raw materials that fulfill active functions characteristic of use as an electrode film in an electrical energy storage device is high relative to the remaining raw materials contained in the film-like functional material, i.e., the structural raw materials and the first functional raw materials.

[0070] A carrier medium consisting of structural raw materials formed in the form of a three-dimensional textile flat element can be considered a matrix within the meaning of the present invention. This can be made of textile raw materials, especially in the form of yarns, or metal in the form of metal threads called wires. All raw materials manufactured or processed according to any textile technology are called textile raw materials. Here, the yarns are again made of individual long filaments, i.e., monofilaments. Besides natural fibers, other materials such as glass fibers, carbon fibers, mineral wool fibers, polymer fibers, or wires can also be used as materials for the yarns. Wires are themselves monofilaments. Within the meaning of the present invention, filaments also refer to fibers or wires. In this case, yarns and wires can be processed into textile strips, especially fabric strips in which individual warp and weft threads are interwoven. Therefore, such carrier mediums can be, for example, woven fabrics, weft-knitted fabrics, or warp-knitted fabrics.

[0071] For the use according to the invention of woven, weft-knitted or warp-knitted fabrics, the thread density should be as small as possible, precisely so that the technical processing requirements regarding carrier and stabilizing functions are still possible.

[0072] Coating the carrier elements of the carrier medium with the first functional raw material can result in increased mechanical stability of the carrier medium, which can facilitate performing a fabrication step.

[0073] Processing of the carrier medium can be advantageously carried out in a roll-to-roll process.

[0074] The film-like functional material can also be configured for other applications, in which case it is a composite of other raw materials suitable for the corresponding application, for example, for use in catalysts or in heatable plastic mats with micro-ventilation, to name just two further examples.

[0075] Further details, features and advantages of embodiments of the invention will become apparent from the following description of examples with reference to the associated drawings. [Brief explanation of the drawings]

[0076] [Figure 1] Figure 1: Schematic diagram of the cross section of a film-like functional material. [Figure 2A] FIG. 2A: Schematic of the matrix in its simplest structural form. [Figure 2B] FIG. 2B: Schematic of the matrix in a more disordered structural morphology than that shown in FIG. 2A. [Figure 2C] Figure 2C: Scanning electron micrograph of expanded polytetrafluoroethylene film (ePTFE) as a form of matrix that serves as a carrier medium for film-like functional materials. [Figure 2D] Figure 2D: Schematic diagram of a single-layer woven fabric as a form of carrier medium for film-like functional materials. [Figure 2E] Figure 2E: Schematic diagram of a single-layer knitted fabric as a form of carrier medium for film-like functional materials. [Figure 2F] Figure 2F: Scanning electron micrograph of a textile braid as a form of carrier medium for film-like functional materials. [Figure 3A] FIG. 3A: Schematic diagram of the principle of the cross section of a film-like functional material with glass fabric. [Figure 3B] FIG. 3B: Principal schematic diagram of a cross section of an electrode film according to the prior art. [Figure 3C] Figure 3C: A relatively detailed schematic diagram of the cross section of a film-like functional material. [Figure 4A]FIG. 4A: Schematic of a cross-sectional view of an anode film of an aluminum electrolytic capacitor with glass fabric as the carrier medium. [Figure 4B] FIG. 4B: Scanning electron micrograph of a cross section of an anode film of an aluminum electrolytic capacitor as a representative of a functional film according to the prior art. [Figure 5A] FIG. 5A: Scanning electron micrograph of a cross section of a conventional electrode for a lithium-ion battery according to the prior art. [Figure 5B] FIG. 5B: Schematic of a cross section of a film electrode for a lithium-ion battery having a textile carrier medium coated such that the carrier element is surrounded by aluminum. [Figure 6] Figure 6: Schematic of the cross section of a filmy graphite electrode for a lithium-ion battery with copper-plated steel wire fabric as the carrier medium.

[0077] FIG. 1 shows the basic structure of a functional film 1 in cross section. The functional film 1 comprises a carrier medium 2 made of a structural material in the form of a matrix. Its carrier elements 3, formed as linear carrier elements 3a and nodular carrier elements 3b, are coated with a first functional raw material 4, which fulfills a first function. A partial volume 5 is defined by the carrier elements 3a and 3b, which is filled with a second functional raw material 6, which fulfills at least one second function different from the first function. Depending on the application, the functional film 1 can also be referred to as a film electrode material 1, a film anode material 1 or anode film 1, or a film cathode material or cathode film 1. The upper and / or lower surfaces of the functional film 1 are completely covered with the second functional raw material 6.

[0078] FIG. 2A shows a simplified, principled embodiment of the carrier medium 2. The linear carrier elements 3a and nodular carrier elements 3b are present only in mutually perpendicular planes. The carrier elements 3a and 3b are connected to each other and define a free partial volume 5 that is open on all sides. The carrier medium 2 is formed like a film, i.e., its dimensions in the x and y directions are much greater than its dimension in the z direction, referred to as the transverse dimension 7 of the carrier medium 2. This condition always applies within the scope of the present invention, even if the figures do not always clearly show this. The carrier medium 2 always consists of two different types of carrier elements 3a and 3b, including all structural elements made of structural raw materials contained in the carrier medium 2. The linear carrier elements 3a are, for example, threads in textile products or polymer threads in drawn polymers, or linear structures, molecular fibers, spun fibers, textile fibers, filaments, or other linear structures. The nodular carrier elements 3b are, for example, crossed warp and weft threads in a textile fabric, intertwined threads, dense collections of thread-like elements of the structural raw material, point-like clusters of elements of the structural raw material (e.g., in drawn polymers), three-dimensional accumulations of the structural raw material, or the like. The carrier elements 3 open out partial volumes 5, which are connected to each other and open to the sides, in particular to the top and bottom surfaces of the carrier medium 2. In the special case of the carrier medium 2 in Figure 2A, the linear carrier elements 3a and the nodular carrier elements 3b always lie in parallel planes that are perpendicular to each other.

[0079] In this case, the carrier medium 2 is referred to as a carrier medium 2 when it has a three-dimensional extent. Thus, although all the carrier elements 3 are essentially in one plane, they are already referred to as a carrier medium 2 when they no longer represent a two-dimensional surface but have a three-dimensional extent.

[0080] 2B shows a schematic diagram of a relatively disordered arrangement of carrier medium 2, as compared with carrier medium 2 in FIG. 2A, which is one of the more typical forms of carrier medium 2 for film-like functional materials. This schematic diagram shows that carrier medium 2 is not necessarily required to have a regular structure. The distribution of linear carrier elements 3a and nodular carrier elements 3b can in fact be disordered. In the case of FIG. 2B, carrier elements 3a and 3b are also connected to each other and open free partial volumes 5 on all sides.

[0081] FIG. 2C shows a top view of a scanning electron microscope (hereinafter simply referred to as an REM photograph) of an expanded polytetrafluoroethylene film, i.e., ePTFE, as the carrier medium 2. The linear carrier elements 3a and the nodular carrier elements 3b are disordered. The linear carrier elements 3a are oriented molecular fibers, and the nodular carrier elements 3b are point-like accumulations of polytetrafluoroethylene raw material components. The oriented molecular fibers, i.e., the linear carrier elements 3a and the nodular carrier elements 3b, define partial volumes 5. The partial volumes 5 are connected to each other.

[0082] FIG. 2D shows a schematic representation of a carrier medium 2 in the form of a textile fabric. The linear carrier elements 3a are threads or wires referred to as warp and weft threads. The nodular carrier elements 3b are the areas where the warp and weft threads intersect. This carrier medium 2 formed as a textile fabric shown in FIG. 2D is an example of a case where all carrier elements 3 lie substantially in one plane, yet the carrier medium 2 has a three-dimensional extent. A partial volume 5 of the opening is defined between the linear carrier elements 3a, i.e., the warp and weft threads, and their intersection points, the nodular carrier elements 3b. The distance resulting from the intersection of the warp and weft threads corresponds to the transverse dimension 7 of the carrier medium 2.

[0083] 2E shows a schematic diagram of a top view of a knitted textile as carrier medium 2. Such film-like textile formations can be industrially produced from yarn systems by forming meshes on a knitting machine and belong to the knitting family. The linear carrier elements 3a are, in this case, textile yarns, and the nodular carrier elements 3b are formed from intertwined yarns. An open partial volume 5 is defined between the linear carrier elements 3a formed from textile yarns and the nodular carrier elements 3b, which are their intertwined overlapping portions of the textile yarns. The distance resulting from the intertwined overlapping portions of the textile yarns corresponds to the transverse dimension 7 of the carrier medium 2.

[0084] 2F shows an REM photograph of a top view of the braid as carrier medium 2. Linear carrier elements 3a are formed from textile yarns, and nodular carrier elements 3b are formed from intersections or accumulations of textile yarns. In this example, the distribution of linear carrier elements 3a and nodular carrier elements 3b is statistical. An open subvolume 5 is defined between the nodular carrier elements 3b, which are multiple intersecting textile yarns, and the linear carrier elements 3a, which make up a relatively large proportion of the textile yarns.

[0085] FIG. 3A shows a schematic cross-sectional view of a film material 1 made of a textile carrier medium 2. The textile carrier medium 2 includes linear carrier elements 3a, which are the textile warp and weft yarns, and their intersection regions, which are nodular carrier elements 3b. A first functional raw material 4, which fulfills a first function, is coated around the textile carrier medium 2. A partial volume 5 is filled with a functional raw material 6, which fulfills at least one second function different from the first function. The upper and lower surfaces of the carrier medium 2 are covered with the second functional raw material 6. The carrier medium 2 is a glass fabric, the basic structure of which is shown in FIG. 2D. The first functional raw material 4, which fulfills the first function, is applied both to the linear carrier element 3a and to the nodular carrier element 3b. The first functional raw material 4, which fulfills the first function, is coated around the linear and nodular carrier elements 3a and 3b. Aindicates a transverse dimension 7 of the carrier medium 2, the carrier element 3 of which is coated therearound with the first functional ingredient 4. D VfFM represents the thickness of the film-shaped functional material 1 whose upper and lower surfaces are coated with the second functional raw material 6.

[0086] 3B shows a cross section of a conventional electrode film according to the prior art, which has a metal film 2' or a metal-coated film, preferably a metal-coated polymer film, as a carrier medium 2', as a comparison with the film-like functional material 1 shown in FIG. 3A. The same functional raw material 6 as that filling the partial volume 5 of the film-like functional material 1 according to FIG. 3A and coating the upper and lower surfaces in a strongly adhesive manner is applied to both sides of the carrier medium 2'. In this case, D TF corresponds to the thickness of the metal film 2' that not only functions as a carrier medium but also fulfills the functions of charge transport and discharge. VF corresponds to the thickness of the electrode film. VF is the thickness D of the film-like functional material 1 of FIG. 3A coated on both sides with the second functional raw material 6. VfFM This corresponds to D VfFM Therefore, D VfFM =D VF is.

[0087] 3C shows a detailed schematic cross-sectional view of the film-shaped functional material 1 shown in FIG. 3A. In this case, the second functional raw material 6 fulfills at least one active function and at least one non-active function. The second functional raw material 6 has an open pore 8 as an internal structure, which does not correspond to the partial volume 5.

[0088] In principle, the film-like functional material 1 according to the present invention is characterized by a large volume or mass proportion of the second functional raw material 6 based on the total volume or mass of the film-like functional material 1. This is crucial for the use of the film-like functional material 1, since it allows a large proportion of the total volume or mass of the film-like functional material 1 to be occupied by the second functional raw material 6 that fulfills the active function.

[0089] FIG. 4A shows a cross-section of a functional film 1 for use as an anode film 1, i.e., an electrode, for an aluminum electrolytic capacitor. The carrier medium 2 is a glass fabric, as shown in FIG. 2D. The carrier element 3 is coated with aluminum as a first functional raw material 4. The layer thickness can range from 0.2 μm to 4 μm, depending on the type of electrode. A highly porous aluminum is introduced into the subvolume 5 as a second functional raw material 6. This highly porous aluminum is present on both the upper and lower surfaces of the carrier medium 2. The enlarged cross-section shown on the right side of FIG. 4A reveals that the highly porous aluminum consists of a highly porous aluminum body 9, an aluminum oxide layer 10 formed on the surface of the highly porous aluminum body 9, and open pores 8. The open pores 8 in the second functional raw material 6 serve to capture electrolyte when the functional film 1 is used as an electrode for an electrical energy storage device. The aluminum oxide layer 10 is produced by anodization on the surface of the highly porous aluminum body 9 and serves as the dielectric layer of the aluminum electrolytic capacitor. The highly porous aluminum body fulfills the inactive function, i.e., charge carrier transport and discharge. The aluminum oxide layer 10 fulfills the active function of charge carrier storage, i.e., charge carrier storage, which is a characteristic function of the use of the film-like functional material 1 as an anode film 1 for aluminum electrolytic capacitors. The open pores 8 are filled with electrolyte. In this sense, they fulfill the inactive function by providing a capacitance for the electrolyte. The introduction of the highly porous aluminum into the partial volume 5 and the application of the carrier medium 2 to the upper and lower surfaces are preferably carried out by a vacuum coating method.

[0090] The amount of aluminum as the first functional raw material 4 coated around the carrier element 3 must have dimensions sufficient to meet the electrical conductivity requirements. Typically, this corresponds to an aluminum layer having a thickness between 0.2 μm and 4 μm. To meet this requirement, for example, a glass fabric having 22 warp and weft threads per centimeter is used as the carrier medium 2. The fabric is flattened. The compression results in warp and weft threads with a width of 180 μm and a thread height of 15.5 μm. The first functional raw material 4 in the form of an aluminum layer is applied to these threads in a coating manner, which is characterized by excellent electrical conductivity properties. Therefore, the carrier medium is metallized with the first functional raw material 4, i.e., aluminum. The thickness of the aluminum layer applied to the warp and weft threads in a coating manner is approximately 2.5 μm on average. Therefore, the cross-sectional dimension 7 of the metallized carrier medium 2 is 36 μm. In a partial volume 5 of the metal-coated carrier medium 2, i.e., in the interstices of the glass fabric, highly porous aluminum was deposited as a second functional raw material 6. Similarly, highly porous aluminum was deposited on the top and bottom surfaces of the film-like functional material 1, each with a layer thickness of 32 μm. The total thickness of the anode film 1 was 100 μm.

[0091] The aluminum-metallized carrier medium 2 as the first functional raw material 4 has an area of ​​0.00156 cm based on one square centimeter of the base area of ​​the anode film 1. 3 The total volume of anode film 1 based on a base area of ​​1 square centimeter is 0.01 cm 3 Therefore, the volume fraction of the carrier medium 2 and the first functional raw material is about 15.6%, and the volume fraction of the second functional raw material 6, i.e., highly porous aluminum, is about 84.4%.

[0092] In contrast, in a conventional anode film 1', the carrier medium 2' occupies a significantly larger proportion of the total volume of the anode film 1'. One possible embodiment of such a conventional anode film 1' according to the prior art is shown in cross section in FIG. 4B. This anode film 1' is fabricated from a high-purity aluminum film by electrochemical etching, leaving the inner portion unprocessed. This portion is the carrier medium 2' of the anode film 1'. For a conventional anode film 1' with a thickness of 100 μm, as shown in the REM photograph in FIG. 4B, the thickness of the carrier medium 2' that has not been electrochemically etched is approximately 28.6 μm, and the thickness of the electrochemically etched region is approximately 71.4 μm, corresponding to a thickness of this region of approximately 35.7 μm per side. The anode film 1' is formed after a so-called forming process, electrochemical or anodizing. The carrier medium 2' performs the carrier function and simultaneously supplies and discharges charge carriers. The electrochemically etched area performs the actual capacitor function, i.e., the accumulation of charge carriers. The thickness D between the carrier medium 2′ and the layer performing the actual capacitor function is TF The ratio can be determined to be approximately 1:2 and 1 / 2, or 1:2.5.

[0093] The carrier medium 2' of the conventional anode film 1' has an area of ​​0.00286 cm based on one square centimeter. 3 This corresponds to about 28.6% of the total volume of the conventional anode film 1' according to the prior art. The area of ​​the conventional anode film 1' that performs the capacitor function is 0.0032 cm2 based on 1 square centimeter of the base area. 3 This corresponds to approximately 71.4% of the total volume, whereas in the solution according to the invention 84.4% of the total volume is available for performing the capacitor function, i.e. for storing charge carriers.

[0094] In the case of an anode film 1 for an aluminum electrolytic capacitor, for example, by further reducing the number of warp and weft threads or by using threads with filaments having a diameter of 4 μm instead of threads with filaments having a diameter of 5 μm, the proportion of the volume of the second functional raw material 6 available for performing the capacitor function can be further increased to 94%.

[0095] Figure 5A shows a cross-sectional SEM image of a cathode 1' of a conventional lithium-ion battery. The term "cathode" should always be understood in the context of a discharged battery. This electrode belongs to the so-called lithium-metal oxide electrode family. Such conventional cathodes 1' consist of an essentially poorly electrically conductive active material, such as lithium and nickel oxide, lithium and manganese oxide, lithium and cobalt oxide, or lithium and iron phosphate, as well as a series of additives, fulfilling the non-active function. One important additive for achieving electrical conductivity is carbon black. An aluminum film serves as the carrier medium 2'.

[0096] The anode of the lithium-ion battery, not shown, is made of graphite and is therefore also referred to as a graphite electrode. The carrier medium 2' for the cathode, also referred to as a current collector, is an aluminum film 2', and for the anode, not shown, it is a copper film. In the application shown in FIG. 5A, the carrier medium 2' is also an aluminum film 30 μm thick. The use of such an aluminum film can be considered prior art. Furthermore, there are solutions in the prior art where the carrier medium 2' is an aluminum film 15 μm thick. The use of a 10 μm thick aluminum film as the carrier medium 2' is contemplated. The total thickness of the cathode film is approximately 194 μm.

[0097] FIG. 5B shows a schematic cross-sectional view of the application of the film-like functional material 1 as a cathode 1 in a lithium-ion battery. The film-like functional material 1 has a three-dimensional textile flat structure as a carrier medium 2 in the form of a glass fabric with 18 warp threads and 18 weft threads per cm. The warp and weft threads, which form linear carrier elements 3a, have roughly circular cross sections with a diameter of approximately 35 μm. The intersections of the warp and weft threads form nodular carrier elements 3b. Aluminum, acting as a first functional raw material 4, is applied to the carrier elements 3a and 3b so as to coat them. The applied aluminum layer has a thickness of approximately 7 μm. A partial volume 5 of the metal-coated carrier medium 2, i.e., the interstitial spaces 5 between the warp and weft threads, is filled with a second functional raw material 6. The top and bottom surfaces of the film-like functional material 1 are additionally coated with the second functional raw material 6, each with a thickness of 55 μm. The second functional raw material 6 is composed of a mixture of lithium iron phosphate, conductive carbon black, a solvent, a binder, and an additive. The novel cathode 1 is calendered. Calendering means that the film-like functional material 1 is passed through the gap between a plurality of successively arranged heated and polished rolls, thereby causing the film-like functional material 1, i.e., the cathode 1, to be compacted and strengthened. The thickness D of the cathode 1 is VfFM is 194 μm after this process, which allows easy comparison with the solution shown in FIG. 5A from the prior art.

[0098] The carrier medium 2' in the form of an aluminum film of the prior art cathode 1' shown in FIG. 5A has an area of ​​0.003 cm based on one square centimeter. 3 This corresponds to about 15.5% of the total volume of the cathode 1'. The second functional raw material 6 applied to both sides of the carrier medium 2' has a volume of 0.0164 cm2 based on one square centimeter of the base area. 3 This is equivalent to approximately 84.5% of the total volume.

[0099] When a 15 μm thick aluminum film is used as the carrier medium 2′, the volume of the second functional raw material 6 is about 0.018 cm 3 This corresponds to about 92.3% of the total volume of the cathode 1'. When a 10 μm thick aluminum film is used as the carrier medium 2', the volume of the second functional raw material 6 is about 0.0184 cm 3 This would correspond to about 94.85% of the total volume of the cathode 1'.

[0100] In the solution shown in Figure 5B for cathode 1 using a film-like functional material, the volume of carrier medium 2, on which carrier element 3 is coated so that first functional raw material 4 is wrapped around it, accounts for approximately 4.7% of the total volume of cathode 1. The volume fraction of second functional material 6 is therefore approximately 95.3% of the total volume of cathode 1. In contrast, in the prior art solution shown in Figure 5A, even when using a 10 μm thick aluminum film as carrier medium 2', which was previously technically unrealizable, the maximum possible fraction of second functional raw material 6 in the total volume of cathode 1' is only 94.85%.

[0101] FIG. 6 shows a schematic cross-sectional view of an anode 1 for a lithium-ion battery using a film-like functional material. The anode 1 has a steel wire woven fabric as a carrier medium 2, each with 20 warp threads and 20 weft threads per centimeter. The warp and weft threads are therefore monofilament and have a diameter of approximately 15 μm. A dense copper layer having a thickness of approximately 4 μm is applied to the carrier elements 3 (wires as linear carrier elements 3a and their intersections as nodular carrier elements 3b) as a first functional raw material 4, covering them. The partial volume 5 defined by the carrier elements 3 is filled with a second functional raw material 6. The upper and lower surfaces of the film-like functional material 1 are coated with the second functional raw material 6 having a thickness of 75 μm, respectively. The second functional raw material is open-pore graphite. The anode 1 was calendered as is customary in the prior art. The thickness D of the anode 1 was approximately 1 μm.VfFM is 188 μm after calendering.

[0102] A prior art anode for a lithium ion battery comparable to anode 1 shown in Figure 6 consists of graphite applied to a copper film in a strongly adherent manner. When a 15 μm thick copper film is used, this corresponds to an area of ​​0.0015 cm based on a square centimeter. 3 This corresponds to about 8.0% of the total volume of the anode. The graphite, i.e., second functional raw material 6, applied in a strongly adherent state onto the copper film occupies a volume of 0.0173 cm based on one square centimeter of the anode base area. 3 This corresponds to approximately 92.0% of the total volume of the anode. If a 6 μm thick copper film is used, this is 0.0006 cm2 based on a 1 square centimeter anode base area. 3 This corresponds to about 3.2% of the total volume of the anode. The graphite, i.e., second functional raw material 6, applied in a strongly adherent state onto the copper film occupies a volume of 0.0182 cm based on one square centimeter of the anode base area. 3 This corresponds to approximately 96.8% of the total volume of the anode.

[0103] In contrast, in the solution shown in FIG. 6, the carrier element 3 is coated with a dense copper layer about 4 μm thick around its periphery. The carrier medium 2 has an area of ​​about 0.0002 cm based on one square centimeter of anode base area. 3 The second functional raw material 6, i.e., graphite, occupies a volume of about 0.0186 cm based on a square centimeter of the anode base area. 3 Therefore, the proportion of the second functional raw material 6 in the total volume of the anode 1 is 98.9%.

[0104] The production of the cathode 1 or anode 1 according to the invention using a film-like functional material can be carried out as follows: A woven textile fabric is used as the carrier medium 2. The carrier elements 3, i.e., the warp and weft threads as linear carrier elements 3a and the intersection areas of the warp and weft threads as nodular carrier elements 3b, are coated with a first functional raw material 4, an electrically conductive metal, such as aluminum or copper, depending on the intended use, in a strongly adhesive manner. The layer thickness is between 1 μm and 4 μm. In the context of the present invention, the carrier medium 2 contributes to the mechanical stability of the film-like functional material 1, while the first functional raw material 4 fulfills the passive function of transporting charge carriers. Nevertheless, the first functional raw material 4 can also contribute to improving the mechanical stability of the film-like functional material 1. The coating of the carrier element 3 with the first functional raw material 4 can be achieved using vacuum-technical PVD or thermal spraying methods (where, depending on the method implementation, a thermal post-treatment can optionally be carried out as already described), by the chemical and electrochemical methods described above, or by hot-dip plating of the carrier medium in a molten metal bath (where the melting temperature of the metal must be below that which would lead to destruction of the textile fabric). The partial volume 5 defined by the carrier element 3 coated all around with the first functional raw material 4 is then filled with a second functional raw material 6. This results in a film-like functional material 1, which can then be further processed into a cathode 1 or anode 1 using methods known from the prior art.

[0105] To produce the cathode 1 or anode 1, the upper and lower surfaces of the film-like functional material 1 are coated with a second functional raw material 6. The second functional raw material 6 is, for example, a coating composition (called a slurry) known from the prior art. The second functional raw material fulfills the active function of charge carrier storage and the inactive function of transporting charge carriers to and from storage sites in the second functional raw material 6. It may also contribute to mechanical stabilization. The coating composition is placed in a tank, which also allows mixing of the components, and is applied to both sides of the film-like functional material 1 by means of an application device, i.e., an application tool.

[0106] Subsequent processes after coating, such as drying, can be carried out according to the prior art.

[0107] A textile fabric suitable as a carrier medium 2 for the film-like functional material 1 according to the present invention should not necessarily feature a high density of warp and weft threads, but should have a sufficiently large partial volume 5 opened up by the warp and weft threads as linear carrier elements 3a and their intersections as nodular carrier elements 3b, provided that the mechanical stability of the textile fabric is sufficiently high for the carrier function.

[0108] This means that a textile fabric suitable as carrier medium 2 does not necessarily have to feature an especially small transverse dimension 7 or an especially small mesh width.

[0109] However, it often makes sense to make the diameter of the filaments constituting the warp and weft threads for the carrier medium 2 as small as possible, thereby keeping the volume fraction of the carrier medium 2 relative to the total volume of the film-like functional material 1 sufficiently small, provided, of course, that the mechanical stability of the textile fabric is sufficiently high for the carrier function.

[0110] The following describes anode films for aluminum electrolytic capacitors: The anode film has a thickness of 100 μm. The carrier medium 2 is a glass fabric (EC5 5.5 1×0 5 5.5 1×0). The glass fabric has a thread density of 22 warp threads and 22 weft threads per cm. The warp and weft threads each consist of filaments with a diameter of 5 μm, with a thread width of 160 μm and a thread height of 17.5 μm. A 2.5 μm thick aluminum layer is applied to the warp and weft threads as the first functional raw material 4. The metal-coated glass fabric is characterized by the following geometric dimensions: The transverse dimension 7 of the metal-coated fabric is 0.004 cm, i.e., 40 μm. The mesh size of the metallized glass fabric is approximately 0.031 x 0.31 cm. Metallized glass fabric has a glass fabric base area of ​​1cm 2 Approximately 0.004 cm based on 3 is the volume of. Approximately 38.36% of the volume of the film-like functional material 1 is occupied by the metal-coated glass fabric, and the sum of the interconnected partial volumes 5 of the openings defined by the linear and nodular carrier elements is 61.64% of this volume of the film-like functional material 1.

[0111] The partial volume 5 is filled with highly porous aluminum as a second functional raw material 6. This results in a film-like functional material 1. To form an anode film, the upper and lower surfaces of this film-like functional material 1 are also coated with highly porous aluminum. The completed anode film 1 is characterized by the following geometric dimensions: The total volume of the highly porous aluminum applied to the upper and lower surfaces of the film-like functional material 1, i.e., the second functional raw material, is 0.006 cm 2 based on 1 square centimeter of the anode film base area. 3 is. The total volume of the highly porous aluminum, the second functional raw material that fulfills the charge carrier storage function characteristic of electrolytic capacitors, is 0.0085 cm2 based on 1 square centimeter of the anode film base area. 3 is. Highly porous aluminum accounts for 85% of the total volume of the anode film.

[0112] Another anode film for aluminum electrolytic capacitors uses a glass woven fabric as the carrier medium 2, with warp and weft threads consisting of approximately 102 5 μm diameter filaments and a thread density of 15 to 20 threads per cm. By compressing the cross-section of the threads and stretching them biaxially to straighten the yarns, a significant reduction in the transverse dimension 7 is achieved. It can be between 25 μm and 35 μm, with a mesh size in the range of 325 μm to 550 μm by 325 μm to 550 μm. In this anode film, the volume fraction of the film-like functional material 1 occupied by the metal-coated glass woven carrier medium 2 can be reduced to 13.5%.

[0113] Another anode film for aluminum electrolytic capacitors uses a glass woven fabric as the carrier medium 2, with warp and weft threads consisting of approximately 51 4 μm diameter filaments and a thread density of 20 to 25 threads per cm. By compressing the cross-section of the threads and stretching them biaxially to straighten the yarns, a significant reduction in the transverse dimension 7 is achieved, between 10 μm and 18 μm, with a mesh size in the range of 300 μm to 425 μm by 300 μm to 425 μm. In this anode film, the volume fraction of the film-like functional material 1 occupied by the metal-coated glass woven carrier medium 2 can be reduced to 5.5%.

[0114] The following describes positive and negative electrodes for lithium-ion batteries: The carrier medium 2 is a textile fabric having warp and weft threads consisting of approximately 102 5 μm diameter filaments and a thread density of between 12 and 18 threads per cm. The transverse dimension 7 of the carrier medium 2 can be up to 100 μm. The mesh size can be within the range of 400 μm to 725 μm x 400 μm x 725 μm. The carrier elements 3 of the carrier medium 2, i.e., the intersection areas of the warp and weft threads as linear carrier elements 3a and the warp and weft threads as nodular carrier elements 3b, are strongly and adhesively coated with an electrically conductive metal, i.e., aluminum or copper, corresponding to the intended positive or negative electrode, as the first functional raw material 4. The volume fraction occupied by the metal-coated carrier elements 3 is approximately 6% of the total volume defined by the carrier medium 2.

[0115] Using yarns consisting of 51 filaments with a diameter of 4 μm and having a generally circular cross section, a carrier medium 2 consisting of a textile fabric with a thread density of between 17 and 22 threads per cm can be formed, which has a transverse dimension 7 of up to 65 μm. The mesh size is in the range of 425 μm to 600 μm x 425 μm x 600 μm. In this case, the volume fraction occupied by the metal-coated carrier element 3 is approximately 3% of the total volume defined by the carrier medium 2.

[0116] This application is directed to the invention set forth in the claims, but the disclosure of this application also includes:

[0117] 1. A film-like functional material (1) that fulfills at least one predetermined function and can therefore be used for physical, chemical, physicochemical, and biological applications, a film-like carrier medium (2) formed from at least one structural raw material, comprising the entire carrier volume and having a transverse dimension (7) of ≦100 μm, disposed therein; The film-like carrier medium (2) can be considered as a matrix and comprises a strip-shaped extension of linearly shaped carrier elements (3a) and nodularly shaped carrier elements (3b); The linearly shaped carrier elements (3a) and the nodularly shaped carrier elements (3b) form the raw material components of the carrier medium (2) and are distributed throughout the entire volume of the carrier; and the strip-shaped extension has a partial volume (5) of the total volume of the carrier that is connected to each other, the partial volume (5) being defined by adjacent carrier elements (3); A film-like functional material (1), The linearly shaped carrier element (3a) and the nodularly shaped carrier element (3b) are coated with a first functional raw material (4) that fulfills a first function, and The remaining volume of the entire volume of the carrier, constituted by the partial volumes (5) connected to each other, is filled with at least one second functional raw material (6) that fulfills a second function different from the first function, in the film-like functional material (1).

[0118] 2. The film-shaped functional material (1) described in 1 above, characterized in that at least one second functional raw material (6) covers the upper and / or lower surface of the carrier medium (2).

[0119] 3. The film-like functional material (1) according to 1. or 2., characterized in that the linearly formed carrier elements (3a) of the carrier medium (2) are interwoven warp and weft threads running perpendicular to each other that constitute a woven fabric.

[0120] 4. The film-shaped functional material (1) according to any one of the above 1. to 3., characterized in that the first functional raw material (4) is a metal.

[0121] 5. The film-like functional material (1) according to any one of 1. to 4. above, characterized in that the carrier medium (2) is a glass fiber cloth strip, a carbon fiber cloth strip, a mineral wool fiber cloth strip, a polymer fiber cloth strip, or a wire mesh strip.

[0122] 6. The film-like functional material (1) according to any one of 1. to 5. above, characterized in that the at least one second functional raw material (6) contains one of substance mixtures from the group consisting of lithium / nickel oxide, lithium / manganese oxide, lithium / cobalt oxide and lithium / iron phosphate, and optionally further additives, preferably carbon black.

[0123] 7. A method for producing the film-shaped functional material (1) described in any one of 1. to 6., comprising the steps of: - coating the carrier medium (2) around the carrier element (3) by applying a first functional raw material (4) that fulfills a first function onto the carrier element (3); and filling the remaining volume of the total volume of the carrier, formed by the interconnected partial volumes (5), with at least one second functional ingredient (6) fulfilling a second function different from the first function, The method comprising:

[0124] 8. The method according to claim 7, characterized in that the coating of the carrier element (3) is carried out by metallizing the carrier element (3).

[0125] 9. The method according to claim 7 or 8, wherein the carrier medium (2) is a cloth strip.

[0126] 10. The method according to claim 9, wherein the carrier medium (2) is a glass fiber cloth strip, a carbon fiber cloth strip, a mineral wool fiber cloth strip, or a wire mesh strip.

[0127] 11. The method according to any one of items 8 to 10 above, characterized in that the metal coating of the carrier element (3) is carried out by physical vapor deposition of the metal in a vacuum coating device, by thermal spraying, or by hot-dip plating of the carrier medium (2) in a molten metal bath.

[0128] 12. The metallization of the carrier element (3) is carried out by chemical metallization in a two-stage process, in which the metallization of the carrier element (3) is carried out in the following steps: The seeding process, and Metal coating process, Contains or Alternatively, the metallization of the carrier element (3) can be carried out in a three-stage process, in which the metallization of the carrier element (3) comprises the following steps: Seeding process, Metal coating processes, and Metal layer strengthening process, The method according to any one of items 8 to 10 above, comprising: [Explanation of symbols]

[0129] 1. Film-like functional materials, film-like anode materials or anode films, film-like cathode materials or cathode films 1' Conventional electrode film according to the prior art, anode or cathode according to the prior art, film-like functional material according to the prior art, anode film for electrolytic capacitor according to the prior art 2. Carrier medium 2' Carrier media in the prior art: metal carrier films, metal-coated polymer films, aluminum films in the prior art 3. Career Elements 3a Linear carrier element 3b Nodular carrier element 4. The first functional material, the first functional raw material 5 Partial volume, space of fabric weave 6 Second functional materials; Second functional raw materials 7 Transverse dimension of carrier medium 2 8 Opening hole 9. Aluminum body 10 Aluminum oxide layer D A Transverse dimension of carrier medium 2 D VfFM Thickness of the coated film-like functional material 1 D TF Carrier film 2' thickness D VF Electrode film thickness

Claims

1. A film-like functional material (1) that fulfills at least one predetermined function and can therefore be used for physical, chemical, physicochemical, and biological applications, a film-like carrier medium (2) formed from at least one structural raw material, comprising the entire carrier volume and having a transverse dimension (7) of ≦100 μm, is disposed therein; The film-like carrier medium (2) can be considered as a matrix and comprises a strip-shaped extension of linearly shaped carrier elements (3a) and nodularly shaped carrier elements (3b), the linearly shaped carrier element (3a) is formed to be large in one dimension (the large dimension) and small in two other dimensions (two smaller dimensions), wherein the ratio of the large dimension to the two smaller dimensions is at least 50:1, and the ratio between the two smaller dimensions is 1:5 or more but not more than 5:1; The linearly shaped carrier elements (3a) and the nodularly shaped carrier elements (3b) form the raw material components of the carrier medium (2) and are distributed throughout the entire volume of the carrier; and the strip-shaped extension has a partial volume (5) of the total volume of the carrier present therein, the partial volume (5) being defined by adjacent carrier elements (3); A film-like functional material (1), the linear carrier elements (3 a) have at least partially large spacings between each other, which means that the ratio of the linear carrier elements (3 a) to the larger of the two smaller dimensions is greater than 5:1; The linearly shaped carrier element (3a) and the nodularly shaped carrier element (3b) are coated with a single layer of a first functional raw material (4) that fulfills a first function, the remaining volume of the total volume of the carrier, constituted by the interconnected partial volumes (5), is completely but not densely filled with at least one second functional ingredient (6) fulfilling a second function different from the first function; and The carrier medium (2) is a nonwoven fabric. The film-like functional material (1).

2. 2. The film-like functional material (1) according to claim 1, characterized in that at least one second functional raw material (6) covers the upper and / or lower surface of the carrier medium (2).

3. 3. The film-like functional material (1) according to claim 1 or 2, characterized in that the first functional raw material (4) is a metal.

4. 4. The film-like functional material (1) according to claim 1, wherein the carrier medium (2) consists of natural fibers or carbon fibers, each in the form of a monofilament.

5. The film-like functional material (1) according to any one of claims 1 to 4, characterized in that the at least one second functional raw material (6) comprises one of a mixture of substances from the group consisting of lithium / nickel oxide, lithium / manganese oxide, lithium / cobalt oxide and lithium / iron phosphate, or graphite.

6. A film-like functional material (1) as described in claim 5, characterized in that at least one second functional raw material (6) additionally contains further additives.

7. A film-like functional material (1) as described in claim 6, characterized in that the further additive is carbon black.

8. A method for producing a film-like functional material (1) according to any one of claims 1 to 7, comprising the following steps: - coating the carrier medium (2) around the carrier element (3) by applying a single layer of a first functional raw material (4) that fulfills a first function onto the carrier element (3); and filling the remaining volume of the total volume of the carrier, formed by the interconnected partial volumes (5), with at least one second functional ingredient (6) fulfilling a second function different from the first function; and the carrier medium (2) is a nonwoven fabric.

9. 9. The method according to claim 8, characterized in that the coating of the carrier element (3) is carried out by metallizing the carrier element (3).

10. 10. The method according to claim 9, characterized in that the metal coating of the carrier element (3) is carried out by physical vapor deposition of the metal in a vacuum coating device, or by thermal spraying, or by hot-dip plating of the carrier medium (2) in a molten metal bath.

11. The metallization of the carrier element (3) is carried out by chemical metallization in a two-stage process, in which the metallization of the carrier element (3) comprises the following steps: The seeding process, and - Metal coating process, Contains or Alternatively, the metallization of the carrier element (3) can be carried out in a three-stage process, in which the metallization of the carrier element (3) comprises the following steps: - seeding process, Metal coating processes, and - Metal layer consolidation process, 10. The method of claim 9, comprising:

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