Dry electrode manufacturing system and method

Abstract

To provide a dry electrode manufacturing system and a manufacturing method with reduced operating cost and an improved efficiency.SOLUTION: A system includes: a first dry electrode material transport system configured to transport a dry electrode material; a first calendar roll; a second calendar roll; and a control part. The second calendar roll is configured to form a first nip between the first calendar roll and the second calendar roll. The first nip is configured to receive the dry electrode material from the first dry electrode material transport system and form the dry electrode material from the dry electrode material. The control part is configured to control a rotational speed of the second calendar roll to be greater than the rotational speed of the first calendar roll.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The described technology relates generally to energy storage devices, and in particular to The present invention relates to a simplified system and method for manufacturing dry electrodes for semiconductor devices. [Background technology]

[0002] Widely used to power electrical, electromechanical, electrochemical, and other useful devices The electrodes can be implemented in electrical energy storage cells that are used. Batteries such as electrochemical and secondary (rechargeable) batteries, fuel cells, ultracapacitors The electrodes can also be implemented in water purification systems. . Summary of the Invention [Problem to be solved by the invention]

[0003] It is desirable to reduce the operating costs and improve the efficiency of electrode manufacturing. [Means for solving the problem]

[0004] For purposes of summarizing the described technology, describe the specific objects and advantages of the described technology. Not all such objects or advantages may be achieved in any particular embodiment. Thus, for example, those skilled in the art may readily appreciate that the teachings herein may be of no use in implementing or practicing the techniques described. Any of the foregoing may be modified in a manner that achieves or optimizes any one advantage or group of advantages that are taught or suggested herein. It will be recognized that other objectives or advantages may not necessarily be achieved. .

[0005] One aspect of the invention is a system for manufacturing a dry electrode for an energy storage device. The system includes a first dry electrode material delivery system for delivering the dry electrode material. The calendering device includes a first calender roll, a second calender roll, and a control unit. The render roll is a first roller between the first and second calendar rolls. The first nip is configured to form a first dry electrode material transport system. and forming a dry electrode film from the dry electrode material. The control unit controls the rotation speed of the second calendar roll to be faster than that of the first calendar roll. The rotation speed of the roller is controlled to be faster than that of the roller.

[0006] In another aspect, the dry electrode film is not self-supporting.

[0007] In another embodiment, the system further comprises a third calender roll, A second nip is formed between the render roll and the adjacent upstream calender roll. The second nip is configured to receive the dry electrode film from the first nip. In another embodiment, the upstream adjacent calender roll is a second calender roll. In another embodiment, the control unit further controls the rotation speed of the third calender roll. The rotation speed of the first calendar roll is controlled to be higher than the rotation speed of the second calendar roll. In the system, a current collector supply source is provided to supply a current collector to the second nip, and the second nip is It is configured to receive a current collector and laminate it to a dry electrode film to form a dry electrode. In another embodiment, the system includes a second dry electrode film, In another aspect, the first nip is configured to convey the electrode material. receiving a second dry electrode material from the dry electrode material delivery system and transferring the first dry electrode material The dry electrode is formed from the first dry electrode material and the second dry electrode material. In the present embodiment, the first dry electrode material and the second dry electrode material are the same material. The system further includes a fourth calender roll, and the fourth calender roll and the fourth A third nip is formed between the calender roll and an adjacent calender roll on the downstream side of the calender roll. The third nip is configured to convey the second dry electrode material from the second dry electrode material conveying system. The electrode film is configured to receive the electrode material and form a second dry electrode film. In this embodiment, the downstream adjacent calender roll is a third calender roll. In this embodiment, the control unit controls the rotation speed of the third calender roll to be equal to the rotation speed of the fourth calender roll. In another aspect, the system is configured to control the rotation speed to be greater than the second a current collector supply source for supplying a current collector to the second nip, the second nip receiving the current collector; The current collector is laminated on a first electrode film and a second dry electrode film to form a double-sided dry electrode. This is a configuration in which an electrode is formed.

[0008] One aspect of the invention is a laminate for producing an intermittent electrode. The laminator includes a first calendar roll, a second calendar roll, and It includes one or more stacked actuators and one or more gap control actuators. For the multi-layer actuator, the first calender roll and the second calender roll are used during lamination of the intermittent electrodes. The one or more gaps are configured to apply a first force between the calender roll and the one or more calender rolls. A control actuator applies a second force to the first and second calender rolls, and the second force is configured to oppose and counter the first force.

[0009] In another aspect, the laminator further includes a sensor and a control unit. The control unit is configured to detect the uncovered area of ​​the electrode film. As the uncovered area passes between the first and second calender rolls, one or more The gap control actuator is configured to be interlocked.

[0010] Another aspect of the invention includes a method for manufacturing a dry electrode for an energy storage device. The method includes rotating a first calender roll at a first rotational speed; rotating the roll at a second rotational speed and rotating the first calender roll and the second calender roll. A dry electrode material is supplied to the nip between the render roll to form a dry electrode film. wherein the second rotational speed is greater than the first rotational speed.

[0011] In some embodiments, the dry electrode material is in the form of free-flowing particles. In this embodiment, the dry electrode film, as formed, adheres to the second calender roll.

[0012] Another aspect of the invention includes a method for manufacturing an intermittent electrode. The method includes manufacturing an intermittent electrode film and a collector. Preparing the current collector, the intermittent electrode film and the current collector are placed on a first calendar roll and a second calendar roll. The first calender roll and the second calender roll are conveyed between the calender rolls. applying a first force to the current collector between the first and second calendar rolls; and applying a second force to the first force, the second force being opposite to and opposing the first force.

[0013] In some embodiments, the first force presses the intermittent electrode film against the current collector; and when the uncoated area of ​​the intermittent electrode film is laminated by the second force, the first force is applied to the uncoated area of ​​the intermittent electrode film. and the second roll so that there is a fixed gap between them. [Brief explanation of the drawings]

[0014] [Figure 1] FIG. 1 is a block diagram illustrating the manufacturing process of a dry electrode for an energy storage device. [Figure 2] FIG. 2 shows an apparatus for forming a dry electrode film. [Figure 3A] FIG. 3A is a schematic side view of a multi-roll calender system. [Figure 3B] FIG. 3B shows the film formed by the calendar system. [Figure 4] FIG. 4 is an isometric view showing details of a multi-roll calender system. [Figure 5A] FIG. 5A illustrates the operational steps of the system shown in FIG. [Figure 5B] FIG. 5B illustrates the operational steps of the system shown in FIG. [Figure 5C] FIG. 5C illustrates the operational steps of the system shown in FIG. [Figure 6] FIG. 6 is a schematic side view of a combined calendar / laminator device for forming a dry electrode. [Figure 7] FIG. 7 is a schematic side view of an intermittently coated dry electrode according to one embodiment. [Figure 8A] FIG. 8A is a side view of the laminator arrangement. [Figure 8B] FIG. 8B is a front view of the laminator arrangement. [Figure 9] FIG. 9 shows a funnel-shaped filling hopper. [Figure 10] FIG. 10 shows the steps of calendering, including a scatter coating step, a continuous calendering step, a calendering step, and a winding step. DETAILED DESCRIPTION OF THE INVENTION

[0015] Energy storage devices such as lithium-ion batteries are used in many commercial and industrial applications. It is a trusted power source for consumer equipment, industrial equipment, and battery-powered vehicles, for example. However, the demands on energy storage devices are constantly and rapidly increasing. For example, the automotive industry is focusing on plug-in hybrid and pure electric vehicles. We are developing vehicles that rely on small, highly efficient energy storage such as lithium-ion batteries. Batteries are well suited to meet future demand.

[0016] The key element in the storage capacity of an energy storage device is the electrode. The capacity and efficiency of, for example, a battery electrode, is governed by various factors, such as the active material the dispersion of binders and additives; the physical properties of these materials, e.g., the particle size of the active material surface properties of the active material; and physical properties of the electrode film, e.g., density, porosity Dry processing systems and methods traditionally involve high shear and / or Alternatively, high pressure processing steps have been used to crush and mix the electrode film materials. The system and method offer structural advantages over wet electrode films. However, the self-supporting electrode film and the materials used to form the dry electrode The high process pressures and large equipment (and consequently large footprint) required leave room for improvement. It remains.

[0017] The systems and methods provided herein include dry electrodes for various energy storage devices. As provided herein, the present invention can be implemented to fabricate films and electrodes. The storage device is a capacitor, a lithium ion capacitor (LIC), It could be an ultracapacitor or a battery like a lithium-ion battery. However, a hybrid energy storage device that combines two or more of these aspects may also be used. good.

[0018] Various embodiments of the present systems and methods provide a drive for an energy storage device. The disclosed embodiments provide improvements to the manufacture of electrode films and dry electrodes. It is possible to provide a simplified and cost-effective manufacturing procedure for energy storage devices.

[0019] The materials and methods provided herein are directed to various applications for energy storage devices and / or water purification. As provided herein, the energy storage device can be implemented in a variety of forms, including capacitors, lithium ion batteries, and the like. Lithium-ion capacitors (LIC), ultracapacitors, or lithium-ion batteries It may be a battery like the one described above, or a hybrid battery that combines two or more of these aspects. In some embodiments, the drive may be a drive-on battery, as described herein. The method and apparatus for forming the light electrode film can be used to form continuous, multi-stripe, and intermittent This allows for electrodes of this type to be formed.

[0020] Embodiments of the present method and apparatus for forming a dry electrode film include: Some embodiments provide one or more of the following advantages: Some embodiments allow for the production of high precision, low tolerance films, both thin and thick. Ultracapacitor (UCAP), battery, Lcap, fuel cell electrode, water purification electrode, or electrode In some embodiments, this allows for a film that is a combination of: This reduces the need for material handling and the number of operators required, which is essential for calendering, lathing, and This is achieved by combining lamination, peeling and slitting in one machine. In some embodiments, one or more dry electrode material supply systems, such as powder transfer hoppers The use of a filter allows for multi-layer functionalized webs. Formulations that can be used to manufacture films and electrodes (such as self-supporting dry electrode films and dry electrodes) The variety of materials available increases. For example, lithium metal powder, silicon / silicon oxide anode and cathode active materials impregnated in porous conductive carbon, e.g., molten sulfur and active charcoal, solid electrolyte, or other air / moisture sensitive material.

[0021] Additional features or advantages provided by the present embodiments include a single electrode for forming the electrodes. The above layers are continuously wound / unwound from raw materials (powder, etc.) to form laminated electrodes. The dry electrode film formed by this system / method includes (at least It is not required to be self-supporting (either initially or throughout the process). At least part, if not all, of the process steps are arranged on the calendar rolls. For example, a dry electrode material and a current collector are laminated together to form a dry electrode. As the poles are formed, they are passed through the entire process in a multi-roll calendering system. The dry electrode film is rolled by at least one calendar roll, including the lamination process. It is supported by

[0022] The present multi-roll calender embodiment provides additional benefits not found in conventional calendering processes. The number of calendar nips can be set from 2 (3 rolls) to 6 ( It is possible to use more than 7 rolls, but this is only possible if the process pressure and force are weak. Each roll is individually Each robot is individually addressable and can be driven by a motor and gears. The line load in the roller calendering system is greater than that in a conventional calender. The system can achieve thinner dry films while still being able to lower the width The speed of each individual roll can be controlled, and the individual calender The gap between the rolls can be controlled. The temperature of each roll can also be controlled. In some embodiments, the final roll of a laminated multi-roll system is a dry electrode on a current collector. The film can be controlled to assist in lamination. Web manipulation is simple and easy. This allows for the reduction or elimination of idler rolls in the web path. In this case, the distance between adjacent roll sets (paired calendar nips or two adjacent nips) The bottoms of each of the frames (either one of them) can rotate at different speeds. The downstream set of rolls (e.g., the calender nip) is configured to rotate faster than the previous one. In addition, the individual rolls in a two-roll nip set can be The rolls in the nip set can be configured to rotate differently than the other rolls. The thickness allows for shear forces to be applied within the film and / or allows the film to adhere to any loosening. This can provide a force for better adhesion to the rod.

[0023] In some embodiments, gamma spectroscopy is used to control / measure film thickness or characteristic mass versus film thickness. A gauge such as a gage can be used. The rollers are fitted with a zero-play bearing. may be fixed in a specific position by a less bearing (oriented but captured) Oriented but captured bearings may be required. If tight tolerances can be achieved, tapered bearings or other bearing designs can be used on rolls with no play. The embodiment can be used to fix the same for each nip or roll within the nip. The roll surface finish may be a coating (e.g., chrome or hard It can be either a ceramic surface or patterned, as in the case of an embossed roll. It's okay to be there.

[0024] In some embodiments, two multi-roll calendars are placed end-to-end. The dry electrode film can be attached to the metal foil without first having to remove the film and transport it to another device. Therefore, the same equipment can be used to directly laminate the current collector. An electrode layer can be laminated on one or both sides of the substrate to form a single-sided electrode or a double-sided electrode. do.

[0025] In some embodiments, the laminated electrodes are either continuous web or intermittent electrode designs. Peeling the non-laminated film from the laminated web is also advantageous in terms of the continuous web and intermittent electrode configuration. In some embodiments, the current collector used in the system is an adhesive. Alternatively, the powder may be pre-coated with a separate powder on a multi-roll calender system. Adhesive may be supplied to one side of the film through a terminal hopper. It is possible to laminate directly to the foil without pre-coating. After the lamination process A slitter is added to cut the laminated web to the final electrode width and wind individual electrode rolls. In some embodiments, the device is self-webbing. For example, a continuous belt can be used under the roll to lift the webbing. This may ensure that the web is properly directed to the next roll nip.

[0026] FIG. 1 is a block diagram showing a process for fabricating dry electrodes for energy storage devices. The term "dry" as used herein refers to the mixing and coating of the electrodes in the process described herein. This means that no liquid solvents or additives are used in the final electrolysis process. The process shown in FIG. 1 begins with dry mixing 18, followed by dry active material impregnation. A dry mixture is formed from the material 12, the dry conductive particles 14 and the dry binder particles 16. Furthermore, the dry conductive particles 21 and the dry binder particles 23 are mixed 19. Alternatively, a dry mixture can be prepared and fed to the dry fiberizer 26 or 29. The mixture is then fiberized in a dry fiberization step 20, such as a jet mill (not shown). In the dry fiberization step 20, high shear force is applied to the dry mixture to physically stretch it. In the dry feed 22, the fibers are mixed together to form a fine web of fibers. The individual dry particle mixtures formed at 20 and 21 are then poured into respective containers (not shown). The dry film is then fed to a roll mill or is dry compressed and calendered by Calender 24, and embedded / intermixed dry film, or a self-supporting electrode film (or an electrochemically active free-standing film) The embedded / intermixed dry film is attached to a current collector (e.g., metal foil) 28. More detailed information on the manufacturing process of the embedded / intermixed dry film is available at The materials forming the current collector and the materials forming the film are all listed in U.S. Patent No. 7,352,555. 8, the entire contents of which are incorporated herein by cross-reference.

[0027] The self-supporting electrode film produced as described above is manufactured using a wet process. It may provide improved properties compared to typical electrode films. For example, The dry electrode film used has improved film strength, improved cohesion, and improved adhesion. This can provide one or more of the following: improved adhesion, improved electrical performance, or reduced defect generation. Defects include holes, cracks, and surface pits in the electrode film. Electrical performance is measured by the specific capacitance. The film strength may be a tensile strength.

[0028] FIG. 2 shows an apparatus for forming an electrode structure. The apparatus of FIG. 2 comprises three interconnected The system includes parts 100, 200, and 300. In 100, the dry particles are initially Stored in individual containers and fed as free-flowing dry particles into the high-pressure nip of the roll mill The separate streams of dry particles are mixed together and the dry particles are fed into the nip. As the body becomes more flexible, it begins to lose freedom of movement. The film exits component 100 and enters component 200. The compressed dry film , it must be self-supporting at the point where it exits 100 in order to proceed to part 200 without collapsing. To be self-supporting, the film exiting the roll of part 100 must be at the desired electrical conductivity. Therefore, the system portion 200 is self-supporting. The film is passed through a tension control system and then through a calendaring system (three large vertical The system repeatedly reduces the thickness of the dry film. The dry film has multiple nips to reduce the thickness and density to the desired level. It exits portion 200 and enters system portion 300. Portion 300 includes one or more idler rolls. , additional nips and / or take-up / storage rolls may be provided to further process the dry film. The final dry electrode film is wound at a winding station. The final rolled electrode film is transported to another device, where it is unwound and laminated onto a current collector. , a dry electrode is formed.

[0029] 3A and 3B are schematic side and side views, respectively, of a multi-roll calender system 310. The film 320 produced by the calendering system is shown. , including one or more dry electrode material delivery systems, such as powder delivery hoppers. Therefore, the system includes two powder hoppers, Powder Hopper #1 and Powder Hopper #2. The particle size, density, porosity, and / or material type and / or other The material properties are the same in powder hopper #1 and powder hopper #2. Good. Particle size, density, porosity, and / or material type and / or other material properties are , may be different from each other in powder hopper #1 and powder hopper #2.

[0030] The illustrated calendering device includes six rolls 330. However, more or fewer A roll 330B downstream along the web path may be provided. may be configured to rotate faster than the previous upstream roll 330A. The higher speed of the roll on the side generates shear forces in the film, while the roll At the nip, the film is attached to the faster rotating roll. The web can then be rotated much faster than before, thus completing the entire web path of the calender. Throughout the process, the film can remain attached to all rolls. By doing so, the film that is initially formed in FIG. 3A is formed from dry material. The film can be, but need not be, self-supporting. This is because the film This is because the rollers are attached to and supported by all the rollers. Reduce or completely eliminate the need for idler rolls between nips, as described above. Compared to other dry film devices, such as the device shown in Figure 2, The increased shear forces required to calender the film to the desired thickness The pressures and forces are also lower, and therefore the system is less complex and more flexible than that of FIG. A lower force (and therefore smaller) device can be used. The temperature of each roll can also be controlled individually. 3 shows a side view of a film 320 produced by a calendering system, - When the particles in powder hopper #1 are different in size from the particles in powder hopper #2.

[0031] Figure 4 shows a multi-roll calender system 400. The system has six rolls. 430 and one powder hopper 440, but this is for illustrative purposes and may include at most Along the web path, each of the six rolls is rotated relative to the previous roll. This is because the film adheres to the surface of the substrate, as mentioned above. FIG. 4 shows an individual motor 450 (e.g., a servo motor) and its speed, acceleration, and The timing and the like can be individually controlled by a control unit (not shown). The control system may be configured to control other aspects of the system, such as the gap distance between the rolls, The temperature of each roll and / or other system parameters may be controlled. The controller may be similarly implemented in other systems described herein.

[0032] 5A-C illustrate some of the operational steps of the multi-roll calender system 400 of FIG. In FIG. 5A, powder 445 is introduced into one roll nip of the calendar system. In FIG. 5B, film 420 is rolled onto roll 430 without the need for an idler roll. In Figure 5C, a doctor blade 460 removes the film from the last roll. The edges of the film are trimmed and then the film is peeled off from the core 4. It's wrapped around 70.

[0033] FIG. 6 shows a combined calendar / laminator system 600, which includes two dry electrodes. Films can be fabricated and laminated to current collectors to form double-sided electrodes. two dry electrode material transport systems shown as powder hoppers 602 and 603; There are four rolls 604, 605, 606 and 607. The current collector 610 is a current collector source. The first dry electrode film 620 is supplied from the powder delivery hopper 602. The particles are calendered through the nip formed between rolls 604 and 605. The second dry electrode film 621 may be formed by The particles from roll 603 are calendered through the nip formed between rolls 606 and 607. Both films 620 and 621 may be formed by coating. The film 620 may be laminated on the first and second opposing surfaces of the conductive body 601. and 621 and the current collector 610 are passed through a third nip formed between rolls 605 and 606. This may be achieved by compressing (e.g., calendering) the material between layers. The third nip provides additional calendering to the films 620 and 621 to adjust the film thickness. After lamination between rolls 605 and 606, the double-sided electrode can be further The rolls are collected, for example, at a winding station 609 for further processing. The calendering nips are sequentially positioned close to each other, allowing for continuous calendering and film thickness This provides a reduction in the amount of work required, reducing or completely eliminating the need for idler or dancer rolls. Each of the wheels is controlled for velocity, acceleration, speed, etc. as described elsewhere herein. Each successive roll rotates faster than the previous one, The film follows the roll to the end, then comes off the last roll and is unwound. It is wound onto a core at rewind station 609.

[0034] The system of FIG. 6 can also be implemented to fabricate single-sided electrodes. For example, the roll 607 and the hopper 603 are removed and the film 621 is not used. The wheels 604 and 607 are part of a belt calendar system as shown, and the belts , which provides a surface and support for application of dry electrode material thereon. One or more belts system (rollers like 604 and 607) or beltless system (605 and 60 6), or a combination thereof, in any of the embodiments of the present invention. can also be implemented.

[0035] 7 is a diagram illustrating an intermittently coated electrode according to one embodiment. The foil has an intermittent coated portion 702 with a coating gap X therebetween, and an uncoated foil portion 704. At least one uncoated foil portion 704 may be used to connect an electrode to another element, e.g. For example, it can be used to electrically connect to an electrode tab or the like.

[0036] 8A-B show side and front views of an embodiment of the laminator. The present invention can be implemented in a system such as system 600 of the present invention. The rolls in the laminator of FIGS. 8A-8B are similar to rolls 605 and 606 in FIG. The laminator may include one or more lamination actuators, For example, a current collector and an electrode film are laminated together to form an electrode. However, it may be a pressure cylinder 804 that provides the main force for the In laminating the intermittent electrodes as shown in FIG. 7, the uncoated (foil only) portion 704 is compressed. To reduce the impact of this collision, the laminator is designed to have more than one roll. For example, a gap control actuator may be provided to counter the force of the cylinder 804. The cylinder 802 is configured to maintain a constant gap even when laminating the uncoated portion. The sensor (Fig. 8A) was configured to detect uncoated and unlaminated areas. When an uncoated or unlaminated area is detected, the gap control cylinder 802 The gap is maintained and the roll is uncoated. This does not deform or damage the intermittently laminated web because it does not impact the area.

[0037] FIG. 9 illustrates a funnel-type filling hopper that can be implemented in embodiments of the systems and methods described herein. The hopper can be fed with bulk material by suction or a worm conveyor. Inside the filling hopper, the bulk material is uniformly dispersed and dispersed in the scattering process. The formation and destruction of cavities in the material is prevented by using a special mixer. A rotating metering roller is fixed to the bottom side of the filling hopper. The cell size of the metering roller is selected according to the particle size of the bulk material. The bulk material is held by a metering roller 2 and peeled off by a flexible doctor blade 3. The precisely metered bulk material is then conveyed to the vibrating brush device 4. After processing, the bulk material is inspected and transferred to the subsequent substrate line 5.

[0038] FIG. 10 shows a process including a scattering coating process, a continuous calendering process, a calendering process, and a winding process. The scattering coating device deposits a very thin layer of powder onto the belt. The thin layer can be calendered through the nip of a calender roll. As the powder is applied, a thin film is produced. The powder is collected in the groves or bristles of the main rotating drum. A secondary rotating brush then removes the powder from the glove or bristles, which then travels down the moving belt. Once the powder is compressed into a film in the first nip, the film The film moves through subsequent nips to achieve the desired thickness and / or density.

[0039] The energy storage devices provided herein can be in any desired configuration. Planar, spirally wound, button-shaped, interlocking, pouch-shaped, etc. The energy storage device can be a component of a system, e.g., a power generation system, an uninterruptible power generation system, Uninterruptible power source systems (UPS), photovoltaic systems, industry Energy recovery systems for machines and / or transportation, etc. Energy storage devices can be used to power various electronic devices and / or motor vehicles. For example, hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), and / or Electric vehicles (EVs), etc.

[0040] The terms "battery" and "capacitor" as used herein are used in accordance with the ordinary and customary understanding of those skilled in the art. The terms "battery" and "capacitor" are not mutually exclusive. Capacitors and batteries can also refer to electrochemical cells that operate independently. It can also refer to an electrochemical cell operating as a component of a multi-cell system.

[0041] Any feature, material, characteristic or group described in connection with a particular aspect, embodiment or example , any other aspect, embodiment or implementation described in this section or elsewhere herein. It is understood that the present invention is also applicable to the examples, except where incompatible. All features disclosed in the present application (including abstract and drawings) and / or any part so disclosed All steps of the method or process of any of the preceding claims may be combined in any combination, provided that: Except where at least some features and / or steps are mutually exclusive. Protection is granted to the fullest extent permitted by the present specification, including the accompanying claims, abstract and drawings. any novel feature or any combination of features disclosed in This includes any step or process, or any combination thereof.

[0042] Furthermore, certain features described in the disclosure in the context of separate implementations may be used interchangeably. Conversely, in the context of a single implementation, Various features described herein may be implemented separately in multiple implementations, or Furthermore, features may be implemented in any suitable subcombination. Although described above as working in combination, one of the claimed combinations One or more features may be excluded from the combination in some cases. , a subcombination or a variation of a subcombination.

[0043] Furthermore, the operations may be depicted in the drawings or described in the specification in a particular order. Such actions may be performed in the order shown or sequentially to achieve a result. It is not required that all operations be performed, nor is it required that all operations be performed. and the process may incorporate other operations not shown or described. For example, one or more actions can be performed before, after, simultaneously with, or between the actions described. Additionally, operations may be rearranged or reordered in other implementations. In some embodiments, in the processes shown and / or disclosed, It will be understood that the actual steps taken may differ from those shown in the diagram. In some embodiments, certain of the steps described above may be omitted and others may be added. Furthermore, the features and attributes of the specific embodiments disclosed above may be combined in different ways. Additional embodiments may be formed by combining the above and other elements, all of which are within the scope of this disclosure. In addition, the separation of the system components in the above-described embodiments does not affect any of the embodiments. In the present specification, such separation should not be understood as necessary. The elements are generally combined into a single product or packaged into multiple products. For example, the components of the energy storage system described in this application Any of the elements can be provided individually or integrated together (e.g., packaged together). They can also form an energy storage system (packaged or attached together). Cut.

[0044] For purposes of this disclosure, certain aspects, advantages and novel features are disclosed. However, this is not necessarily achieved in any particular embodiment. Those skilled in the art will appreciate that the present invention may be practiced without necessarily achieving the other advantages taught herein. Implementing or performing the disclosure in a manner that achieves one advantage or group of advantages as taught in You will realize that you can do this.

[0045] Conditional terms such as "can," "might," or "might" are used to specifically differentiate Unless expressly stated otherwise or understood in the context in which it is used, Certain embodiments may include certain features, elements and / or steps while other embodiments may not. Therefore, such conditional terms generally convey the characteristics, features, and It is not intended to imply that elements and / or steps are required for one or more particular embodiments. It is not intended to be limiting and one or more embodiments may be implemented in a particular manner, whether or not user input or prompting is required. It is understood that these features, elements and / or steps may or may not be included or performed in an embodiment. It is not intended to contain the logic behind the decision.

[0046] Conjunctive expressions such as the phrase "at least one of X, Y and Z" are particularly Unless otherwise specified, an item, term, etc. may be X, Y, or Z. This connective expression is understood in the context in which it is commonly used to convey: Certain embodiments require the presence of at least one X, at least one Y, and at least Z. It is not intended to imply that

[0047] Terms of degree used in this case, such as "approximately," "approximately," "generally," and "effectively," is a value, quantity, or characteristic that is close to the stated value, quantity, or characteristic and performs a desired function or fulfills a desired function. It is used to indicate that a desired result will be achieved.

[0048] The scope of the present disclosure extends beyond the specific disclosure of embodiments in this section or elsewhere herein. is not intended to be limited by, and should not be construed as limiting, any of the foregoing in any way whatsoever, including, but not limited to, any of the foregoing set forth in this section or elsewhere herein. The claim language may be defined in the claims or may be defined by the claims to come. The language used in this application shall be interpreted broadly and in accordance with the principles set forth herein or during prosecution of this application. The invention is not limited to the described examples, which are to be construed as non-exclusive.

[0049] Although specific embodiments have been described, these embodiments are presented by way of example only. and is not intended to limit the scope of the disclosure. The novel methods and systems described herein may be embodied in a variety of other forms. Various omissions, substitutions, and modifications of the described systems and methods may be made without departing from the spirit of the disclosure. The accompanying claims and their equivalents are believed to fall within the scope and spirit of the disclosure. It is intended to include all such forms or modifications as may be obtained. It is defined solely by reference to the scope of the appended claims.

Claims

1. 1. A system for manufacturing a dry electrode for an energy storage device, comprising: The method includes a first multi-roll calender, a second multi-roll calender, a lamination station, a current collector unwinding station, a winding station, and a control unit, the first multi-roll calender includes a first series of horizontally aligned rolls including a first roll, a second roll, and a third roll, and is configured to compress powder into a first film at a first nip formed by the first roll and the second roll of the first series, and to compress the first film into a compressed first film at a second nip formed by the second roll and the third roll of the first series; the second multi-roll calender includes a second series of horizontally aligned rolls including a first roll, a second roll, and a third roll, and is configured to compress powder into a second film at a first nip formed by the first roll and the second roll of the second series, and to compress the second film into a compressed second film at a second nip formed by the second roll and the third roll of the second series; the lamination station is configured to simultaneously laminate the first film to a first surface of a current collector and the second film to a second surface of the current collector; the current collector unwinding station is configured to supply the current collector to the lamination station; the winding station is configured to receive the stacked current collector from the lamination station and wind it into a roll; The control unit is configured to control a gap between the rolls.

2. The system of claim 1 , wherein the first roll and the second roll of the first series have the same diameter.

3. 3. The system of claim 2, wherein the third roll of the first series has a different diameter than the first roll and the second roll of the first series.

4. The system of claim 1 , wherein the first roll and the second roll of the first series have different diameters.

5. 10. The system of claim 1, wherein the second roll of the first series rotates at a faster speed than the first roll of the first series.

6. 6. The system of claim 5, wherein the third roll of the first series rotates at a faster speed than the second roll of the first series.

7. 10. The system of claim 1, further comprising a frame for the rolls of the first multi-roll calendar and a measuring unit attached to the frame for measuring a thickness of the first film or the compressed first film.

8. The system of claim 7 , wherein the first multi-roll calender is controlled based on the output of the metering unit.

9. The system of claim 7 , wherein the measurement unit uses high frequency electromagnetic radiation above visible light.

10. The system of claim 7 , wherein the metrology unit includes a gamma gauge.

11. 10. The system of claim 1, wherein one or more of the rolls of the first multi-roll calender include a surface finish that controls hardness on the outside of the roll.

12. 10. The system of claim 1, further comprising a doctor blade attached to the first multi-roll calender to assist in peeling the compressed first film from the rolls of the first multi-roll calender.

13. The system of claim 1 , further comprising an edge trim unit attached to the first multi-roll calender for trimming an edge of the compressed first film.

14. 2. The system of claim 1, wherein the first multi-roll calender comprises exactly three rolls and the second multi-roll calender comprises exactly three rolls.

15. the first multi-roll calender is composed of exactly six rolls, and the second multi-roll calender is composed of exactly six rolls; In the first multi-roll calendar, the third roll and the fourth roll form a third nip, the fourth roll and the fifth roll form a fourth nip, and the fifth roll and the sixth roll form a fifth nip; 2. The system of claim 1, wherein in the second multi-roll calendar, the third roll and the fourth roll form a third nip, the fourth roll and the fifth roll form a fourth nip, and the fifth roll and the sixth roll form a fifth nip.

16. the first multi-roll calender is composed of exactly seven rolls, and the second multi-roll calender is composed of exactly seven rolls; In the first multi-roll calendar, the third roll and the fourth roll form a third nip, the fourth roll and the fifth roll form a fourth nip, the fifth roll and the sixth roll form a fifth nip, and the sixth roll and the seventh roll form a sixth nip; 2. The system of claim 1, wherein in the second multi-roll calendar, the third roll and the fourth roll form a third nip, the fourth roll and the fifth roll form a fourth nip, the fifth roll and the sixth roll form a fifth nip, and the sixth roll and the seventh roll form a sixth nip.

17. 10. The system of claim 1, further comprising a first powder hopper supplying powder to the first nip of the first multi-roll calender and a second powder hopper supplying powder to the first nip of the second multi-roll calender.

18. 2. The system according to claim 1, wherein each roll of the first multi-roll calendar and each roll of the second multi-roll calendar are individually positionable and driven via a control system.

19. 10. The system of claim 1, further comprising: a gap sensor configured to detect a gap between two specific rolls; and a gap control system configured to control one or both of the two specific rolls based on a signal from the gap sensor.

20. 10. The system of claim 1, wherein the rolls of the first multi-roll calender are fixed.

21. 2. The system of claim 1, wherein the first multi-roll calender and the second multi-roll calender are both horizontally aligned.

22. The system described in claim 1, wherein the apparatus comprises the first multi-roll calender, the second multi-roll calender, the lamination station, the current collector unwinding station, and the winding station.

23. The system of claim 1 further comprising a slitter after the lamination station for slitting the laminated current collector to a final width.

24. The system of claim 1 , further comprising an edge trim unit configured to trim the compressed first film at the last roll of the first series.

25. 10. The system of claim 1, wherein the current collector web path begins at the current collector unwinding station and ends at the current collector take-up station.

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