Device and method for producing a dry film, a dry film, a substrate and an energy storage or energy converter system

Abstract

This invention relates to an apparatus for manufacturing a dry film, comprising a feeder for dry powder, a powder mill, and a roller assembly. The powder mill has a first body and a second body arranged such that they provide a first gap between the first body and the second body, wherein at least one of the first body or the second body is designed to rotate, and the first gap is formed to receive dry powder from the feeder and process it into a dry film. The roller assembly comprises at least one roller, wherein the roller assembly is designed to receive the dry film from the powder mill. The powder mill and the roller assembly are decoupled from each other.

Description

Technical Field

[0001] This invention relates to a calendering roll, and more particularly, to a calendering roll having an inner inner roll core and an outer coating arranged and covering the inner inner roll core. Prior Technology

[0002] In manufacturing battery electrodes, extremely thin layers, ranging from 50 to 100 micrometers in thickness, must be coated onto a metallic conductor (i.e., a current collector) at high speeds. This can be accomplished using either wet or dry techniques, depending on existing technology. Wet techniques require the use of solvents, which are often not completely removed, negatively impacting the electrode's lifespan. Furthermore, the subsequent drying process increases energy consumption and complicates the process further.

[0003] For example, drying methods known from U.S. Patent US7,352,558 B2, German Patent DE 10 2017 208 220 A1, and International Patent WO 2020 / 148410 A2 involve pressing dry powder into a powder mill having two rotating bodies (particularly rollers). In currently used apparatuses, the dry film is further processed in a roller assembly following the powder milling. The multiple rollers in the roller assembly can be adjusted to achieve the desired dry film density and quality.

[0004] However, these devices have two drawbacks: First, processing dry powder in the first roll gap requires a specific material temperature, which can affect further processing of the dry film, especially at excessively high temperatures. However, the rolls in a powder mill are generally not adjustable to the specific material temperature required for processing dry powder. Therefore, only the first roll in the roll assembly can have a different temperature, particularly a lower one. However, there is still a suboptimal temperature in the gap between the first roll of the roll assembly and the powder mill.

[0005] Furthermore, processing dry powder requires very high shear forces in the gap between the two rotating bodies of the powder mill. This generates vibrations that are transmitted to the subsequent roller assembly. For example, this makes precise adjustment of the gap distance difficult and / or may cause the unit to generate natural frequency excitations, potentially leading to a decrease in dry film quality and / or emergency shutdowns. Summary of the Invention

[0006] One object of the present invention is to develop an apparatus and method for manufacturing a dry film to improve process control. This object can be achieved by: an apparatus for manufacturing a dry film having the features of claim 1, a method for manufacturing a dry film having the features of claim 30, a dry film having the features of claim 35, a substrate having the features of claim 36, and an energy storage or energy conversion system having the features of claim 37. Advantageous embodiments of the invention correspond to the subject matter of their respective appendices.

[0007] An apparatus for manufacturing a dry film according to the present invention, for coating a substrate, particularly a current collector, comprises a dry powder feeder, a powder mill, and a roller assembly. The powder mill has a first body and a second body, with a first gap between the first and second bodies, wherein at least one of the first or second bodies can function as a rotating body. The first gap is used to receive dry powder from the feeder and process it into a dry film. The roller assembly has at least one roller for receiving the dry film from the powder mill. The powder mill and the roller assembly are decoupled / separated from each other.

[0008] By decoupling or separating the powder mill from the roller assembly, the present invention avoids or at least reduces the adverse effects on further processing of the dry film, such as in the roller assembly, during the process of processing dry powder into a dry film in the powder mill, particularly compared to known devices in the prior art. Specifically, the powder mill and roller assembly can be arranged mechanically and / or thermally separated, meaning that the inherent rigidity and (if necessary) vibration of the powder mill can be separated from the roller assembly, avoiding or reducing the transmission of vibration between the powder mill and the roller assembly. Decoupling also prevents or at least reduces the transfer of heat. This, in turn, allows the dry film to be further processed at a suitable process temperature and / or avoids or reduces dry film defects caused by unnecessary vibration. Furthermore, emergency shutdowns can be avoided or their frequency reduced.

[0009] The term "body" as used herein refers to an object or component suitable for providing a gap with a second body. In particular, the body has material properties that allow dry powder to be processed into a dry film.

[0010] A rotating body is defined as an object or component that rotates about one of its axes or is guided by circular motion, preferably fixed or supported so as not to translate, thereby keeping the rotating body stationary. In one embodiment, the rotating body may be a roller or a band.

[0011] The rotation direction of at least one rotating body can be configured such that the motion direction of the rotating body surface facing the first gap is aligned with the feed direction of the dry powder. Preferably, at least one rotating body is designed as a first roller. Preferably, the powder mill and the roller assembly are separate. This at least reduces vibration transmission and heat transfer between the powder mill and the roller assembly. This reduces defects in the dry film and allows for faster setting of the dry film temperature suitable for the process. The distance between the powder mill and the roller assembly is at least twice the first gap, preferably at least three times, and most preferably at least five times.

[0012] Powder mills and roller units can have independent suspension systems. This can significantly reduce the transmission of vibrations. These suspension systems are generally understood as accessories and / or supports. If the powder mill and roller units are independently suspended, vibration transmission is highly unlikely due to their structural decoupling. Furthermore, or alternatively, the floor or wall can have damping properties and / or damping elements to further reduce vibration transmission.

[0013] Preferably, the powder mill is positioned above the roller assembly. This allows the dry film produced in the powder mill to be gravity-fed to the roller assembly for further processing. In particular, the powder mill can be adjusted relative to the roller assembly. This adjustment can be translation and / or rotation. The powder mill can be adjusted relative to the roller assembly so that the position of the dry film contacting the roller assembly is adjustable. Therefore, the present invention allows the residence time of the dry film on at least one roller of the roller assembly to be adjusted, thereby controlling the heat input in the dry film. This allows for subsequent adjustment of temperature fluctuations during the dry film production process and the achievement of consistent film quality.

[0014] If translational and rotational adjustments of the powder mill relative to the roller assembly are provided, the dry film length between the contact point of the powder mill and at least one roller on the roller assembly can be kept constant or varied as needed. Furthermore, for example, if a higher production speed is required, and the rotational speed of at least one rotating body of the powder mill and / or at least one roller of the roller assembly is increased, the present invention makes it possible to adjust the residence time of the dry film on at least one roller of the roller assembly by adjusting the powder mill relative to the roller assembly.

[0015] Furthermore, by adjusting the powder mill relative to the roller assembly, the maximum wrapping rate of the dry film around the first rotating body of the powder mill and / or at least one roller of the roller assembly can be greater than 10%, preferably greater than 25%, and particularly greater than 50%. This can further influence the temperature control of the dry film. This is because a higher wrapping rate results in a larger heat transfer area. In particular, the wrapping of the upper circumferential portion of at least one preferably heatable roller of the roller assembly allows for adjustable temperature preheating of the dry film, for example, adjustable according to the production speed. Here, the wrapping rate refers to the proportion of the surface, particularly the side surface, of the first rotating body or at least one roller of the roller assembly in contact with the dry film.

[0016] The first or second body of the powder mill can also be designed as a stationary body. A stationary body design allows for reduced technical input because bearings can be omitted, and a drive unit is not required. Furthermore, the rotational speed of at least one rotating body can be chosen to be lower than the rotational speed in a powder mill with two rollers, which reduces drive power. This is because the rotational speed of at least one rotating body is always necessarily greater than the rotational speed of the stationary body, and the relative speed between the stationary body and at least one rotating body is crucial for film formation.

[0017] A stationary body is defined as an object or component that is mounted or placed in a stationary position. The absence of motion characteristic specifically means that a stationary body does not undergo regular and / or continuous motion, particularly rotation. A stationary body may include a wall, a portion of a wall, or a part mounted on a wall.

[0018] Preferably, the stationary body has at least one flat surface, and the first gap is disposed between the at least one flat surface and the first rotating body. Therefore, the present invention allows for a sufficient contact area for forming the film.

[0019] Preferably, the feeder is received or formed within a stationary body. Therefore, this invention allows for very efficient use of available space. The first feeder may be a hopper.

[0020] Furthermore, the profile of the surface of the stationary body facing the first gap can be adjusted, at least within the region. This design allows for influencing the production of the dry film during the ongoing manufacturing process. For example, if the dry film is to have a specific material profile, the profile of the stationary body surface can be adjusted accordingly. Preferably, the apparatus includes a device for measuring the profile of the dry film. Based on the measurement results, the profile of the stationary body surface can be adjusted to correct the profile of the dry film. Therefore, the variable profile of the stationary body surface can be used for closed-loop control.

[0021] To regionally modify the profile of a stationary body's surface, the stationary body may include at least one control element. Preferably, the at least one control element is a cylinder. Regionally changing the profile of a stationary body's surface can replace a roller bending unit in at least one rotating body or roller device, and is easier to control.

[0022] The first and / or second body of the powder mill can also be designed as a belt. This makes guiding the dry powder easier. The belt can be guided by at least two guide rollers. Preferably, the belt is guided by three guide rollers to provide sufficient belt tension. The apparatus may also include a back pressure element located on the side of the belt facing away from the first gap region. The back pressure element is designed to provide sufficient belt tension to allow the dry powder to be processed into a dry film in the first gap.

[0023] The dry film can be self-standing before being received by the roller assembly. This reduces or eliminates the need for deflection or compensation rollers.

[0024] Preferably, the powder mill and the roller assembly can be temperature-controlled independently. Therefore, the temperature in the powder mill can be adapted to the processing of the dry film, while the temperature in the roller assembly can be adapted to further processing.

[0025] The temperature of a single rotating body can also be controlled by providing a temperature control device. For example, in some embodiments, the last roller or the last few rollers of the roller assembly can be temperature controlled to support the lamination of the dry film onto the current collector.

[0026] Preferably, at least one roller of the first and / or second body and / or roller assembly of the powder mill is adjustable. This allows for adjustment of the width of the first gap or subsequent gaps in the roller assembly, for example, to produce dry films of different thicknesses. This also allows for adjustment of the dry film based on thickness measured during production to obtain a dry film of the desired thickness.

[0027] Furthermore, it is conceivable to adjust the rotational speed of at least one rotating body of the powder mill and / or the rotational speed of at least one roller of the roller assembly. This can affect the shear force within the dry film and adjust the density, thickness, or porosity of the dry film by possible material stretching. This also improves the adhesion of the dry film to subsequent rollers or rotating bodies to facilitate the transfer of the dry film, particularly by the downstream roller rotating at a speed greater than that of the upstream roller.

[0028] Preferably, the device has at least one temperature sensor designed to detect the dry film temperature, preferably in the area between the powder mill and the roller assembly, particularly in the area before the roller assembly. This allows the temperature of the dry film to be detected immediately before it enters the roller assembly. The temperature control of the roller assembly can be adjusted based on the recorded temperature. Here, "immediately" means that the temperature measured by the temperature sensor is within a range of up to ten times the width of the first gap from the roller assembly, preferably up to five times, and particularly preferably up to two times.

[0029] In addition, the device may have at least one detector for detecting the quality and / or thickness of the dry film, preferably in the area between the powder mill and the roller assembly. This may include detecting density, porosity, aggregates, hard foreign matter, or powder hardening. For example, these particles or aggregates may damage the roller assembly and may not be detected in adjacent dry films. However, these particles or aggregates can be identified by measuring in the area where the dry film is not in contact with the rollers or powder mill body. When such defects are detected, it is preferable to stop the process or open the roll gap in the roller assembly. This prevents roller damage and costly roller replacements.

[0030] Preferably, the roller assembly includes at least one additional downstream roller, and at least two rollers are arranged such that they provide a first roll gap between the roller assembly, wherein the first roll gap is formed to receive dry film from the upstream roller of the roller assembly. This allows the roller assembly to continue dry film processing, for example, producing dry film with a desired density or thickness.

[0031] In this context, "upstream" refers to the direction of dry film transport; therefore, for example, the powder mill is located upstream of the roller assembly. This is because the roller assembly receives the dry film from the powder mill. Consequently, at least one roller that transfers the dry film to the further rollers of the roller assembly is located upstream of the further rollers. This is also how the term "downstream" is understood.

[0032] Preferably, the diameter of the upstream roller in the roller assembly is larger than the diameter of the downstream roller. By using the larger diameter of the upstream roller, the residence time of the dry film can be extended at the same surface velocity.

[0033] The apparatus preferably includes a substrate supply unit, particularly a substrate supply unit for a current collector. This supply unit is designed to feed the substrate into a first or further roller gap, and the first or further roller gap is formed to pick up the substrate and coat the dry film onto it. In particular, the supply unit can be designed to feed the substrate into the last gap of the roller assembly. The advantage of coating the dry film only into the last gap of the roller assembly is that the dry film typically only possesses the desired properties, such as density, thickness, porosity, and / or strength, at the end of the roller assembly.

[0034] By means of a device with a supply unit, the present invention allows dry film to be directly laminated onto a substrate, such as the metal foil of a current collector, without first removing the dry film and transporting it to a separate machine. Therefore, the same device can directly laminate electrode layers onto the current collector to form electrodes.

[0035] Laminated electrodes can be continuous or intermittent electrode designs. The substrate used can be pre-coated with adhesive, or the adhesive can be applied to one side of the substrate via a separate powder container, allowing for direct lamination of the substrate. After lamination, a roll cutter can be provided to cut the laminated substrate to the final electrode width and wind it into a single electrode roll.

[0036] Dry powder can contain active materials, conductive additives, and / or suitable binders. Compared to wet processes, moisture-sensitive materials can also be used. For example, dry powder containing or having polytetrafluoroethylene (PTFE), conductive additives (such as carbon nanotubes, porous carbon, transition metal oxides, and / or sulfur) can be used. For carbon / sulfur cathodes, the dry powder mixture can contain porous carbon, such as porous soot, graphene, and / or carbon nanotubes, sulfur, PTFE, and other suitable conductive additives. For lithium-ion electrodes, in addition to PTFE and additional conductive additives, active materials can be used, preferably lithium iron phosphate (LFP), lithium manganese oxide (LMO), nickel manganese cobalt (NMC), nickel-rich lithium nickel manganese cobalt oxide (NMC 622 or NMC 811), nickel cobalt aluminum oxide (NCA), lithium cobalt oxide (LCO), lithium manganese nickel oxide (LMNO), and / or lithium titanate (LTO).

[0037] Preferably, the device includes a control unit designed and configured to regulate the rotational speed of at least one roller of at least one rotating body and / or roller assembly of the powder mill. The control unit may also be designed and equipped to regulate the temperature of at least one roller of the first and / or second body and / or roller assembly of the powder mill, and / or adjust the position of the powder mill relative to the roller assembly, at least one roller of the first and / or second body and / or roller assembly of the powder mill.

[0038] The control unit is preferably designed and configured to acquire recorded dry film temperature, quality and / or thickness from the detector, and based on the received information, set the rotational speed of at least one roller of at least one rotating body and / or roller assembly of the powder mill, the temperature of at least one roller of the first and / or second body and / or roller assembly of the powder mill, and / or the position of the powder mill relative to the roller assembly, and at least one roller of the first and / or second body and / or roller assembly of the powder mill.

[0039] For example, a temperature sensor can measure the dry film temperature immediately before the roller assembly. The control unit can receive the measured temperature from the temperature sensor and, based on the measured temperature, actively control the residence time of the dry film on at least one roller of the roller assembly by adjusting the position of the powder mill relative to the roller assembly. This allows for near real-time adjustment and / or correction of the dry film temperature without changing the roller temperature. Compared to changing the roller temperature, this also has the advantage of faster adjustment speed, as there is a time delay, especially when lowering the roller temperature.

[0040] Alternatively, the control unit can be designed and configured to acquire measurement data from the detector to detect the quality of the dry film, identify defects based on the measurement data, and if a defect is identified, stop the roller assembly or at least open the roller gap, for example by adjusting at least one roller of the roller assembly. This can be used to avoid roller damage and costly roller replacements, or at least reduce the frequency of replacements.

[0041] Further apparatus embodiments may have other features. For example, a second dry powder feeder may be provided, which supplies the apparatus with dry powder having the same or different composition. The feeder may also be located in the first gap or downstream position. If the dry powder composition of the second feeder is different from that of the first feeder, this allows for the production of dry films with different properties on opposite sides.

[0042] Furthermore, a mirrored arrangement can be configured. This means, for example, producing two dry films in separate units, each with a powder mill and a roller assembly. Additionally, such a mirrored arrangement can have a substrate feeder, preferably a current collector, designed to feed the substrate into a gap in the laminating unit, and the gap in the laminating unit is formed to pick up the substrate and coat the two mirrored dry films onto the substrate.

[0043] Therefore, this invention allows for the parallel production of two dry films. Furthermore, these two dry films can be directly laminated onto a substrate, such as the metal foil of a current collector, without first removing the two dry films and transporting them to a separate machine. Thus, the same apparatus can directly laminate single-sided or double-sided electrode layers onto a current collector to form single-sided or double-sided electrodes.

[0044] Each rotating element, such as a roller or belt, can be driven and controlled individually, for example, by means of a motor and gears. A control unit can be designed and equipped to control or regulate the individual rotational speeds. Furthermore, the gap distance between the individual rotating elements can also be controlled or adjusted relative to the stationary body of the powder mill.

[0045] Another aspect of the invention relates to a method for manufacturing a dry film, preferably for coating a substrate, particularly a current collector, wherein the dry powder is processed by an apparatus having a powder mill and roller device, and preferably formed into a dry film by an innovative apparatus, comprising the following steps:

[0046] Provide dry powder; and

[0047] Dry powder is processed in the device to form a dry film;

[0048] The powder mill and roller assembly are arranged in a decoupled manner, which is a better mechanical and / or thermal decoupling.

[0049] This method enables advantageous production of dry films because the decoupled arrangement of the powder mill and roller assembly prevents or at least reduces defects in the dry film, while still providing a dry film temperature suitable for process control.

[0050] The method preferably includes the steps of providing a substrate and coating a dry film onto the substrate. Therefore, this method allows for the production of electrodes by laminating a dry film onto a substrate.

[0051] Preferably, the method may include further adjusting the position of the powder mill relative to the roller assembly. For example, the residence time of the dry film on at least one roller of the roller assembly may be set and / or the wrapping rate of the dry film around at least one roller of the roller assembly or the rotating body of the powder mill may be adjusted. In this way, the heat input to the dry film from at least one roller of the roller assembly or the rotating body of the powder mill can be controlled.

[0052] Preferably, the adjustment steps are based on recorded dry film temperature, quality, and / or thickness. This allows the method to be performed in a closed loop. In particular, the method can be adjusted during operation to at least reduce the yield of dry film with undesirable properties.

[0053] The present invention also relates to dry films provided by the apparatus according to the invention and / or produced by the method according to the invention. Due to the decoupling of the powder mill and the roller assembly, this can result in better material properties than dry films in the prior art, where the dry film temperature is not optimal for processing the dry film in the roller assembly, and / or defects in the dry film result from vibrations transmitted from the powder mill to the roller assembly. In particular, the dry film can have the desired density, thickness, or porosity. The thickness of the dry film can be less than 500 micrometers, preferably less than 250 micrometers, and particularly less than 150 micrometers.

[0054] The present invention also relates to a substrate having a dry film according to the invention, preferably a current collector.

[0055] The substrate can be made of or contain metallic materials. In particular, it can be a metal foil, such as containing aluminum or copper. Another aspect of the invention relates to an energy storage or energy conversion system having a dry film according to the invention.

[0056] Energy storage or conversion systems can be capacitors, lithium-ion capacitors (LIC), supercapacitors, batteries (such as lithium-ion batteries), or hybrid energy storage devices that combine two or more of the above characteristics. Simple Explanation of the Diagram

[0057] Further details regarding this invention will be explained using the following figures. [Figure 1] shows a schematic side view of an apparatus for producing dry film in the prior art. [Figure 2] shows an embodiment of the apparatus according to the invention, wherein the powder mill can be translated relative to the roller assembly for producing dry film. [Figure 3] shows another embodiment of the apparatus according to the invention, wherein the powder mill can be translated relative to the roller assembly for producing dry film. [Figure 4] shows an embodiment of the apparatus according to the invention, wherein the powder mill can be translated and rotated relative to the roller assembly for producing dry film. [Figure 5] shows another embodiment of the apparatus according to the invention, wherein the powder mill can be translated and rotated relative to the roller assembly for producing dry film. Implementation

[0058] Figure 1 exemplarily illustrates a dry film manufacturing apparatus 100 in the prior art. This dry film manufacturing apparatus 100 has a total of six rollers 101, 201, 301, 401, 501, and 601, with a gap provided between each pair of rollers. A first gap 102, provided by the first roller 101 and the second roller 201, is designed to process the dry powder 105 supplied by the feeder 104 into a dry film 103. In subsequent gaps, such as gaps 202 and 302, the dry film 103 is further processed. Once the final density and quality are achieved, the dry film 103 is collected on a rewinder 701. For further details on the dry film manufacturing apparatus 100, see WO 2020 / 148410 A2.

[0059] However, the apparatus shown in Figure 1 has two drawbacks. Processing the dry powder 105 into a dry film 103 in the first roll gap 102 requires a specific material temperature. However, this temperature is not necessarily the ideal temperature for further processing of the dry film 103. Since rollers 101 and 201 must be maintained at the process temperature for producing the dry film 103, roller 301 can initially be driven at a lower temperature. Therefore, there are no optimal processing conditions in the gap 202.

[0060] Furthermore, very high shear forces must be applied in gap 102 to process the dry powder 105 into dry film 103. This partially causes vibration, which can be transmitted throughout the dry film manufacturing apparatus 100 due to the continuously arranged rollers 101, 201, 301, 401, 501, and 601. This can also make gap adjustment difficult, especially accurate gap distance adjustment. This results in frequent oscillations in the dry film manufacturing apparatus 100, potentially leading to emergency shutdowns.

[0061] Therefore, there is a need for an apparatus for producing dry films to achieve improved process control. Figure 2 shows a dry film manufacturing apparatus 200 for producing dry film 203, here used for coating substrate 209, specifically a current collector, comprising:

[0062] Feeder 204 for dry powder 205;

[0063] The powder mill 210 has a first body configured as a first roller 101 and a second body configured as a second roller 201, arranged in such a way that they provide a first gap 102 between the first roller 101 and the second roller 201. The first gap 102 is formed to receive dry powder 205 from the feeder 204 and process it into a dry film 203; and

[0064] Roller assembly 220, having a third roller 301 and subsequent fourth roller 401, fifth roller 501 and sixth roller 601, is designed to receive dry film 203 from powder mill 210.

[0065] The powder mill and roller assembly 220 are arranged in a decoupled configuration. Decoupling is achieved by separating the rollers 101, 201 of the powder mill 210 from the roller assembly 220, i.e., by independent suspension. This at least reduces vibration excitation because the powder mill 210 and the roller assembly 220 are not mechanically connected by a common mounting device.

[0066] Furthermore, heat transfer between the powder mill 210 and the roller assembly 220 can be reduced. As shown in Figure 2, there is a certain distance 207 between the rollers 101 and 201 of the powder mill 210 and the roller assembly 220. This distance is at least twice the first gap 102, but can also be larger. The powder mill 210 and the roller assembly 220 are thus mechanically and thermally decoupled from each other.

[0067] The powder mill 210 is located above the third roller 301. This allows the production of a self-supporting film using two rollers 101 and 201 of the powder mill 210, which is then guided to the third roller 301. In addition to decoupling, the powder mill 210 can also move freely on roller 301, here for translational adjustment. This translational adjustment allows for adjustment of the residence time of the dry film 203 on roller 301, thereby adjusting the heat entering the dry film. This allows for the adjustment of temperature fluctuations during the dry film production process and the achievement of consistent film quality.

[0068] Furthermore, this arrangement enables optimal process control in terms of temperature, speed, and / or material density during the production of the dry film 203. In particular, the powder mill 210 can be designed to be translationally adjustable relative to the roller assembly 220, so that the position of the dry film 203 in contact with the roller assembly 220 is adjustable. For example, as the production speed increases, and thus the surface speed of the roller 301 increases, the residence time of the dry film 203 on the roller 301 can be extended by adjusting the powder mill 210, so that the heat input remains substantially constant.

[0069] This is shown in Figure 3, where the powder mill 210 of device 200 is translated so that the dry film 203 contacts the roller 301 of roller device 220 at different positions. Therefore, the contact area between the dry film 203 and roller 301 in the arrangement shown in Figure 3 is greater than the contact area in the arrangement shown in Figure 2. This corresponds to an increased wrapping rate, because the dry film 203 in Figure 3 wraps the roller 301 more tightly than in Figure 2. In the arrangement shown in Figure 3, the roller 301 inputs more heat to the dry film 203 than in the arrangement shown in Figure 2. Therefore, by translating the powder mill 210, the temperature control of the dry film 203 can be directly affected.

[0070] The rotation directions 106 and 206 of the first roller 101 and the second roller 201 are adjusted such that the movement direction of the surfaces of the two rollers 101 and 201 facing the first gap 102 is aligned with the feeding direction of the dry powder 205, which is from top to bottom. Furthermore, the rotation directions 306, 406, 506, and 606 of the rollers 301, 401, 501, and 601 of the roller assembly 220 are shown. The rotation directions 406, 506, and 606 of the downstream rollers 401, 501, and 601 are always opposite to the rotation directions 306, 406, and 506 of the corresponding upstream rollers 301, 401, and 501.

[0071] Furthermore, the rotational speeds of subsequent rollers 401, 501, and 601 may be greater than those of upstream rollers 301, 401, and 501. These different rotational speeds can provide shear forces within the dry film 203 and / or generate forces that improve the adhesion of the dry film 203 to the subsequent rollers 401, 501, and 601. This allows the dry film 203 to be transported on the subsequent rollers 401, 501, and 601 without requiring the dry film 203 to be freely loaded or self-supporting starting from roller 301.

[0072] In the gap 502 between the last rollers 501 and 601, the dry film 203 can be laminated onto the substrate 209, here serving as a backing film, for example, to obtain electrodes. For this purpose, the apparatus 200 may have a supply unit for the carrier film 209, designed to feed the carrier film 209 into the last roller gap 502 of the roller assembly 220. The last roller gap 502 of the roller assembly 220 is formed to receive the carrier film 209 and coat the dry film 203 onto it.

[0073] The apparatus 200 shown in Figures 2 and 3 is therefore suitable for a method of producing dry film 203, comprising the following steps:

[0074] Provides dry powder 205; and

[0075] Dry powder 205 is processed in apparatus 200 to form a dry film 203;

[0076] In an alternative exemplary embodiment, the first or second body of the powder mill 210 can also be configured as a stationary body. Due to the relative velocity difference between at least one rotating body 101, 201 and the stationary body, the device 200 allows dry powder 205 to be processed into a dry film 203 in the first gap 102. This is because the basic mechanism of dry film formation is friction between two surfaces of material, and the relative velocity difference is the main influencing factor. Compared to the devices shown in Figures 2 and 3, the design with a stationary body reduces technical input. This is because bearings are omitted or simplified compared to rollers, and a drive device is not required.

[0077] Figure 4 shows a dry film manufacturing apparatus 300, in which the powder mill 310 is translatably and rotatably adjustable relative to the roller assembly 320. Rotational adjustment is performed along a circular path 308 concentric with the third roller 301 of the roller assembly 320. Translational adjustment can be performed in the x-direction and / or y-direction. Adjustment in the x-direction allows for changing the contact point between the dry film 303 and the third roller 301, while adjustment in the y-direction allows for adjusting the distance between the powder mill 310 and the roller assembly 320.

[0078] The rotational adjustment of the powder mill 310 relative to the roller assembly 320, for example by rotation, allows the length between the contact point of the dry film 303 and the roller 301 to remain constant or vary as needed, even when the powder mill 310 is simultaneously undergoing translational motion. This has the advantage that the length can be adjusted according to the characteristics of the dry film 303 (such as strength) to avoid possible tearing or at least reduce the probability of tearing.

[0079] The diameter of roller 301 is increased compared to the diameters of the other rollers 101, 201, 401, 501, and 601. This allows for a longer residence time of the dry film 303 on the third roller 301 at the same surface speed. Therefore, the device 300 provides additional possibilities for adjusting the heat input of roller 301 to the dry film 303.

[0080] The apparatus 300 also includes a temperature sensor 801 in the area between the powder mill 310 and the roller assembly 320 (here, the area before the roller assembly 320). This sensor is designed to record the temperature of the dry film 303, thereby allowing control of the residence time of the dry film 303 on the roller 301 based on the recorded temperature. This allows for near real-time adjustment and / or correction of the dry film temperature without changing the roller temperature.

[0081] In addition, the device 300 includes another detector 802 for detecting aggregates, hard foreign objects, or powder hardening. These particles or aggregates can damage the roller assembly 320 and are undetectable in the dry film 303 (e.g., on rollers 101, 201, 301, 401, 501, 601). However, measurements on the self-standing dry film 303 between the powder mill 310 and the roller assembly 320 allow for the detection of these particles or aggregates. If such defects are detected, the roller assembly 320 can be stopped or at least one gap in the roller assembly 320 can be opened. This prevents roller damage and costly roller replacements.

[0082] The apparatus 300 shown in Figure 5 demonstrates the further advantage of the rotational and translational adjustability of the powder mill 310 relative to the roller assembly 320. By means of the rotational movement of the powder mill 310 around the roller 301, a very high dry film 303 encapsulation rate can be achieved around the roller 201 and / or roller 301. This allows for maximum temperature control and heat transfer by utilizing the roller 201 of the powder mill 210 and the roller 301 of the roller assembly to transfer heat to the dry film 303. In the embodiment shown here, the encapsulation rate is close to 50%, but encapsulation rates greater than 75% can also be achieved.

[0083] In other examples not shown here, the powder mills 210 and 310 and the roller assemblies 220 and 320 can be configured to have independent temperature control. Furthermore, the first roller 101 and / or the second roller 201 of the powder mills 210 and 310 and / or at least one roller 301, 401, or 501 of the roller assemblies 220 and 320 can be adjusted. The rotational speed of at least one roller 101 or 201 of the powder mills 210 and 310 and / or the rotational speed of at least one roller 301, 401, or 501 of the roller assemblies 220 and 320 can also be adjusted.

[0084] In particular, the apparatuses 200 and 300 may include a control unit designed and equipped to adjust the rotational speed of at least one roller 101, 201 of the powder mill 210 and 310 and / or at least one roller 301, 401, 501 of the roller assembly 220 and 320, the temperature of the first roller 101 and / or the second roller 201 of the powder mill 210 and 310 and / or at least one roller 301, 401, 501 of the roller assembly 220 and 320, and / or the position of the powder mill 210 and 310 relative to the roller assembly 220 and 320, the first roller 101 and / or the second roller 201 of the powder mill 210 and 310 and / or at least one roller 301, 401, 501 of the roller assembly 220 and 320.

[0085] Preferably, the control unit can make these settings or adjustments based on the temperature, quality, and / or thickness of the dry films 203 and 303 recorded by the detectors 801 and 802. For example, such a control unit can execute a method that further includes adjusting the position of the powder mills 210 and 310 relative to the roller assemblies 220 and 320 based on the recorded temperature, quality, and / or thickness of the dry films 203 and 303. Therefore, the present invention allows for automatic adjustment of the production of the dry films 203 and 303 during operation.

[0086] The inventive features disclosed in the foregoing textual description, drawings, and claims are substantially important for individual implementations and combinations of the invention.

[0087] 100, 200, 300: Dry film manufacturing equipment 101: First Roller 102: First gap 106: Rotation direction of the first roller 201: Second Roller 202: Second gap 103, 203, 303: Dry film 104, 204, 304: Feeder 105, 205, 305: Dry powder 206: Rotation direction of the second roller 207, 307: Distance between the powder mill and the roller assembly 209,309:Substrate 210, 310: Powder mill 220, 320: Roller assembly 301: Third Roller 302: Third gap 306: Rotation direction of the third roller 308: Concentric Circle Path 401: Fourth Roller 406: Rotation direction of the fourth roller 501: Fifth Roll 506: Rotation direction of the fifth roller 502: Fifth gap 601: Sixth Roller 606: Rotation direction of the sixth roller 701: Rewinder 801: Temperature Detector 802: Other Detectors

[0088] none

Claims

1. An apparatus (200, 300) for manufacturing a dry film (203, 303) for coating a substrate, the apparatus comprising: a feeder (204, 304) for feeding a dry powder (205, 305); a powder mill (210, 310) having a first roller (101) and a second roller (201) forming a first gap (102) between the first roller (101) and the second roller (201), wherein one of the first roller (101) or the second roller (201) is a rotating body, and the first gap (102) is for receiving the dry powder (205, 305) from the feeder (204, 304) and processing the dry powder (205, 305) into a dry film (203, 303). 303); and a roller assembly (220, 320) comprising at least one third roller (301), wherein the roller assembly (220, 320) is for receiving the dry film (203, 303) from the powder mill (210, 310), wherein, During the operation of the device (200, 300), the position of the dry film (203, 303) in contact with one of the roller devices (220, 320) is adjustable.

2. The apparatus (200, 300) as claimed in claim 1, wherein the powder mill (210, 310) and the roller assembly (220, 320) are mechanically and / or thermally decoupled from each other.

3. The apparatus (200, 300) as claimed in claim 1, wherein the powder mill (210, 310) and the roller assembly (220, 320) are spaced apart from each other.

4. The apparatus (200, 300) as claimed in claim 2, wherein the distance (207, 307) between the powder mill (210, 310) and the roller assembly (220, 320) is at least twice the first gap (102).

5. The apparatus (200, 300) as claimed in claim 1, wherein the powder mill (210, 310) and the roller assembly (220, 320) each have independent suspension devices.

6. The apparatus (200, 300) as claimed in claim 1, wherein the powder mill (210, 310) is disposed above the roller assembly (220, 320).

7. The apparatus (200, 300) as claimed in claim 1, wherein the powder mill (210, 310) is positionally adjustable relative to the roller assembly (220, 320).

8. The apparatus (200, 300) as claimed in claim 6, wherein the powder mill (210, 310) is translatably adjustable relative to the roller assembly (220, 320).

9. The apparatus (200, 300) as claimed in claim 7, wherein the position in which the dry film (203, 303) contacts the roller assembly (220, 320) is adjustable by means of translational adjustment of the powder mill (210, 310) relative to the roller assembly (220, 320).

10. The apparatus (200, 300) as claimed in claim 6, wherein the powder mill (210, 310) is rotatably adjustable relative to the roller assembly (220, 320).

11. The apparatus (200, 300) as claimed in claim 9, wherein the powder mill (210, 310) is rotatably adjustable along a concentric circular path (308) centered on the third roller (301) of the roller assembly (220, 320).

12. The apparatus (200, 300) as claimed in claim 6, wherein by adjusting the position of the powder mill (210, 310) relative to the roller assembly (220, 320), the maximum encapsulation rate of the dry film (203, 303) around the first roller (101) or the second roller (201) which is a rotating body in the powder mill (210, 310), and / or the third roller (301) of the roller assembly (220, 320) is greater than 10%.

13. The apparatus (200, 300) as claimed in claim 1, wherein the first roller (101) or the second roller (201) of the powder mill (210, 310) is a stationary body.

14. The apparatus (200, 300) as claimed in claim 13, wherein the surface profile of the stationary body facing the first gap (102) is adjustable in at least a portion of the area.

15. The apparatus (200, 300) as claimed in claim 1, wherein the first roller (101) or the second roller (201) of the powder mill (210, 310) is a band.

16. The apparatus (200, 300) as claimed in claim 1, wherein the first roller (101) and the second roller (201) are both rotating bodies.

17. The apparatus (200, 300) as claimed in claim 1, wherein the dry film (203, 303) is freestanding before being received by the roller apparatus (220, 320).

18. The apparatus (200, 300) as claimed in claim 1, wherein the powder mill (210, 310) and the roller assembly (220, 320) are each capable of independent temperature control.

19. The apparatus (200, 300) as claimed in claim 1, wherein the first roller (101) or the second roller (201) of the powder mill (210, 310), and / or the third roller (301) of the roller assembly (220, 320) is adjustable.

20. The apparatus (200, 300) as claimed in claim 1, wherein the rotational speed of the first roller (101) or the second roller (201) serving as a rotating body in the powder mill (210, 310), and / or the third roller (301) of the roller assembly (220, 320) is adjustable.

21. The apparatus (200, 300) as claimed in claim 1 further includes at least one temperature sensor (801) for detecting the temperature of the dry film (203, 303) and disposed between the powder mill (210, 310) and the roller assembly (220, 320).

22. The apparatus (200, 300) as claimed in claim 1 further includes at least one detector (802) for detecting the quality and / or thickness of the dry film (203, 303), and is disposed between the powder mill (210, 310) and the roller assembly (220, 320).

23. The apparatus (200, 300) as claimed in claim 1, wherein the roller assembly (220, 320) includes a downstream fourth roller (401), and a second gap (302) is formed between the third roller (301) and the fourth roller (401), the second gap (302) being for receiving the dry film (203, 303) from the third roller (301).

24. The apparatus (200, 300) as claimed in claim 23, wherein the diameter of the third roller (301) is greater than the diameter of the fourth roller (401).

25. The apparatus (200, 300) as claimed in claim 1, further comprising a supply unit for a substrate (209, 309), wherein the supply unit is configured to feed the substrate (209, 309) into a second gap (302) or a downstream gap (402, 502) of the roller assembly (220, 320), and the second gap (302) or the downstream gap (402, 502) for receiving the substrate (209, 309) is configured to adhere the dry film (203, 303) to the substrate (209, 309).

26. The apparatus (200, 300) as claimed in claim 1, wherein the dry powder (205, 305) comprises an active material, a conductive additive, or a suitable binder.

27. The apparatus (200, 300) as claimed in claim 1 further includes a control unit designed to adjust the rotational speed of the first roller (101) or the second roller (201) that is a rotating body in the powder mill (210, 310), and / or the third roller (301) of the roller assembly (220, 320).

28. The apparatus (200, 300) as claimed in claim 1 further includes a control unit designed to adjust the temperature of the first roller (101) or the second roller (201) of the powder mill (210, 310), and / or the third roller (301) of the roller assembly (220, 320).

29. The apparatus (200, 300) as claimed in claim 1 further includes a control unit designed to adjust the position of the powder mill (210, 310) relative to the roller assembly (220, 320).

30. The apparatus (200, 300) as described in claim 21 or claim 22 further includes a control unit configured to acquire detection data from the temperature sensor or the sensor (801, 802) regarding the temperature, quality, and / or thickness of the dry film (203, 303), and based on the detection data, perform at least one of the following adjustments: adjusting the rotational speed of the first roller (101) or the second roller (201) serving as a rotating body in the powder mill (210, 310), and / or the third roller (301) of the roller assembly (220, 320); adjusting the temperature of the first roller (101) or the second roller (201) of the powder mill (210, 310), and / or the third roller (301) of the roller assembly (220, 320); or adjusting the temperature of the powder mill (210, 310). 310) Position relative to the roller assembly (220, 320).

31. A method for manufacturing a dry film (203, 303) obtained from a dry powder (205, 305) and used for coating a substrate (209, 309), the method comprising the steps of: providing the dry powder (205, 305); and processing the dry powder (205, 305) in an apparatus (200, 300) as described in claim 1 to manufacture the dry film (203, 303).

32. The method as described in claim 31 further comprises the steps of: providing the substrate (209, 309); and coating the dry film (203, 303) onto the substrate (209, 309).

33. The method as described in claim 31 further comprises the step of: adjusting the position of the powder mill (210, 310) relative to the roller assembly (220, 320).

34. The method as described in claim 33, wherein the adjustment step is based on the temperature, quality and / or thickness of the detected dry film (203, 303).

35. The method as described in claim 31 further comprises the steps of: detecting the quality of the dry film (203, 303); and if the detection result indicates that the dry film (203, 303) is defective, adjusting at least one roller (301, 401, 501, 601) of the roller assembly (220, 320), or interrupting the manufacturing of the dry film (203, 303).

36. A dry film (203, 303) provided by the apparatus (200, 300) as described in claim 1, or produced by the method as described in claim 31.

37. A substrate (209, 309) having a dry film (203, 303) as described in claim 36.

38. An energy storage or energy conversion system comprising a dry film as described in claim 36, or a substrate as described in claim 37.

39. An apparatus (200, 300) for manufacturing a dry film (203, 303), the apparatus comprising: a feeder (204, 304) for feeding a dry powder (205, 305); a powder mill (210, 310) having a first roller (101) and a second roller (201) forming a first gap (102) between the first roller (101) and the second roller (201), wherein one of the first roller (101) or the second roller (201) is a rotating body, and the first gap (102) is for receiving the dry powder (205, 305) and processing it into a dry film (203, 303); and a roller assembly (220, 320) comprising at least three horizontally arranged rollers (301, 401, 501), the ... 320) is designed to receive the dry film (203, 303) and guide the dry film (203, 303) sequentially through the gaps formed between adjacent pairs of rollers in the roller assembly (220, 320), wherein the powder mill (210, 310) and the roller assembly (220, 320) are mechanically and / or thermally decoupled from each other.

40. An apparatus (200, 300) for manufacturing a dry film (203, 303), the apparatus comprising: a feeder (204, 304) for feeding a dry powder (205, 305); a powder mill (210, 310) having a first roller (101) and a second roller (201) forming a first gap (102) between the first roller (101) and the second roller (201), wherein one of the first roller (101) or the second roller (201) is a rotating body, and the first gap (102) is for receiving the dry powder (205, 305) and processing it into a dry film (203, 303); and a roller assembly (220, 320) comprising at least one third roller (301), the ... 320) is designed to receive the dry film (203, 303), wherein, During the operation of the device (200, 300), the position of the powder mill (210, 310) relative to the roller device (220, 320) is adjustable.

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