Electrode manufacturing apparatus

Abstract

The technical idea of the present invention provides an electrode manufacturing apparatus comprising: a plurality of guide rollers arranged along a moving path of an electrode sheet; a plurality of cameras disposed at a plurality of detection locations corresponding to the plurality of guide rollers; a control unit for detecting a physical defect of the electrode sheet on the basis of a signal transmitted from the plurality of cameras; and a plurality of actuators configured to move the plurality of guide rollers in the width direction of the electrode sheet.

Description

Electrode manufacturing device

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

[0002] This application claims the benefit of priority from Republic of Korea Patent Application No. 10-2023-0167378, filed November 28, 2023, and all contents of the document in that Republic of Korea patent application are incorporated herein by reference.

[0003] With technological advancements and growing demand for mobile devices, the demand for secondary batteries is also rapidly increasing. Among these, lithium secondary batteries are widely used as a power source for various mobile devices and electronic products due to their high energy density, high operating voltage, and excellent storage and lifespan characteristics. Recently, as the application areas for secondary batteries have expanded, the demand for higher-capacity secondary batteries has skyrocketed.

[0004] Typically, during the manufacture of secondary batteries, electrode sheets are manufactured by coating a current collector with an electrode active material, and subsequent processes are performed on the electrode sheets. If a defect occurs in the electrode sheet during handling, the defective portion is removed, the two separated portions are reconnected, and subsequent processes are performed on the electrode sheet.

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

[0006] In order to solve the above-described problem, the technical idea of ​​the present invention provides an electrode manufacturing device including: a plurality of guide rollers arranged along a movement path of an electrode sheet; a plurality of cameras arranged at a plurality of detection positions corresponding to the plurality of guide rollers; a control unit that detects a physical defect of the electrode sheet based on signals transmitted from the plurality of cameras; and a plurality of actuators configured to move the plurality of guide rollers in the width direction of the electrode sheet.

[0007] In exemplary embodiments, the electrode sheet includes a holding portion and a non-holding portion, and the control portion is configured to detect a physical defect in the non-holding portion of the electrode sheet based on signals transmitted from the plurality of cameras.

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

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

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

[0011] In exemplary embodiments, the target actuator is characterized in that it is configured to adjust the position of the target guide roller such that the electrode sheet is positioned within the center of the target guide roller.

[0012] In exemplary embodiments, the target actuator is characterized in that it is configured to adjust the position of the target guide roller such that the electrode sheet does not overlap the step portion of the target guide roller.

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

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

[0015] In exemplary embodiments, the electrode sheet comprises a retaining portion and a non-retaining portion, and further comprises a notching device configured to remove a portion of the non-retaining portion of the electrode sheet.

[0016] In exemplary embodiments, the present invention further includes an unwinder in which the electrode sheet is wound; and a rewinder for recovering and winding the electrode sheet; wherein the plurality of guide rollers are provided between the unwinder and the rewinder.

[0017] According to exemplary embodiments of the present invention, since the occurrence of a physical defect in an electrode sheet can be quickly detected by a plurality of cameras arranged at a plurality of detection locations, the amount of electrode sheets discarded due to physical defects in the electrode sheet can be minimized, and ultimately, the productivity of an electrode manufacturing device can be improved.

[0018] In addition, according to exemplary embodiments of the present invention, since a physical defect of an electrode sheet can be detected by a plurality of cameras and the position of a guide roller related to the physical defect can be automatically adjusted based on the detection result of the physical defect, the time for adjusting the setting of equipment due to the occurrence of a physical defect of an electrode sheet can be reduced, and ultimately, the productivity of an electrode manufacturing device can be improved.

[0019] The effects that can be obtained from the exemplary embodiments of the present invention are not limited to the effects mentioned above, and other effects not mentioned can be clearly derived and understood by those skilled in the art to which the exemplary embodiments of the present disclosure pertain from the following description. In other words, unintended effects resulting from practicing the exemplary embodiments of the present disclosure can also be derived by those skilled in the art from the exemplary embodiments of the present disclosure.

[0020] FIG. 1 is a side view showing an electrode manufacturing device according to exemplary embodiments of the present invention.

[0021] FIG. 2 is a plan view showing an electrode manufacturing device according to exemplary embodiments of the present invention.

[0022] FIG. 3 is a perspective view showing a guide roller of an electrode manufacturing device according to exemplary embodiments of the present invention.

[0023] FIGS. 4A and 4B are plan views showing an electrode manufacturing method of an electrode manufacturing device according to exemplary embodiments of the present invention.

[0024] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the attached drawings. Prior to this, it should be noted that the terms and words used in this specification and claims should not be construed as limited to their conventional or dictionary meanings. Based on the principle that the inventor can appropriately define the concepts of terms to best explain his or her invention, they should be interpreted in a way that aligns with the technical spirit of the present invention.

[0025] Accordingly, the embodiments described in this specification and the configurations illustrated in the drawings are merely the most preferred embodiments of the present invention and do not represent all of the technical ideas of the present invention. Therefore, it should be understood that there may be various equivalents and modified examples that can replace them at the time of filing this application.

[0026] In addition, when describing the present invention, if it is determined that a detailed description of a related known configuration or function may obscure the gist of the present invention, the detailed description is omitted.

[0027] Since the embodiments of the present invention are provided to more fully explain the present invention to those skilled in the art, the shapes and sizes of components in the drawings may be exaggerated, omitted, or schematically illustrated for clearer explanation. Accordingly, the sizes and proportions of each component do not fully reflect the actual sizes or proportions.

[0028]

[0029] (Example 1)

[0030] Fig. 1 is a side view illustrating an electrode manufacturing device (100) according to exemplary embodiments of the present invention. Fig. 2 is a plan view illustrating an electrode manufacturing device (100) according to exemplary embodiments of the present invention. Fig. 3 is a perspective view illustrating a guide roller (130) of an electrode manufacturing device (100) according to exemplary embodiments of the present invention.

[0031] Referring to FIGS. 1 to 3, the electrode manufacturing device (100) may be configured to move an electrode sheet (50) along a predetermined movement path and perform an electrode manufacturing process on the electrode sheet (50). The electrode manufacturing process may include a coating process, a rolling process, a slitting process, a notching process, etc.

[0032] The electrode sheet (50) may include a substrate and an electrode slurry layer applied to at least one of both surfaces of the substrate. The substrate may serve as a current collector and may include, for example, copper or aluminum. The electrode slurry layer may include a positive electrode active material slurry or a negative electrode active material slurry.

[0033] The electrode sheet (50) may include a holding portion (51) where an electrode slurry layer is applied, and a non-conductive portion (53) where the electrode slurry layer is not applied. In the holding portion (51) of the electrode sheet (50), the surface of the substrate may be covered with the electrode slurry layer and not exposed to the outside. In the non-conductive portion (53) of the electrode sheet (50), the surface of the substrate may be exposed. For example, the non-conductive portion (53) of the electrode sheet (50) may be located at both edges of the electrode sheet (50) along the width direction of the electrode sheet (50). The width direction of the electrode sheet (50) may be perpendicular to the moving direction (MD) of the electrode sheet (50). For example, when the moving direction (MD) of the electrode sheet (50) is parallel to the X direction, the width direction of the electrode sheet (50) may be parallel to the Y direction.

[0034] The electrode manufacturing device (100) may include a roll-to-roll device (101) configured to move an electrode sheet (50) along a predetermined path. The roll-to-roll device (101) may include an unwinder (110), a rewinder (120), a plurality of guide rollers (130), a plurality of actuators (150), a plurality of cameras (140), and a control unit (180).

[0035] The electrode sheet (50) extends between the unwinder (110) and the rewinder (120) and can move between the unwinder (110) and the rewinder (120). The electrode sheet (50) can be wound and provided to the unwinder (110). The electrode sheet (50) supplied from the unwinder (110) moves along a predetermined movement path and can be recovered from the rewinder (120). The rewinder (120) can rotate so that the electrode sheet (50) is wound. The rewinder (120) can rotate in synchronization with the rotation of the unwinder (110). The rewinder (120) and the unwinder (110) are each connected to a driving motor and can be configured to rotate about a rotation axis (139) by a driving force provided by the driving motor.

[0036] A plurality of guide rollers (130) may be arranged on a movement path of an electrode sheet (50) provided between a rewinder (120) and an unwinder (110). The plurality of guide rollers (130) may guide the movement of the electrode sheet (50) so that the electrode sheet (50) moves along a predetermined movement path. Each guide roller (130) may be an idle roller or a drive roller. In FIGS. 1 and 2, four guide rollers (130) are arranged between the unwinder (110) and the rewinder (120), but the present invention is not limited thereto, and the roll-to-roll device (101) may include several to several tens of guide rollers (130) for moving the electrode sheet (50) along a predetermined movement path.

[0037] Each guide roller (130) may include a rotation shaft (139) and a rotation body (131) mounted on the rotation shaft (139). The rotation shaft (139) may be mounted on a frame (161). The rotation body (131) may rotate about the rotation shaft (139) and provide a surface that contacts and supports the electrode sheet (50). The rotation body (131) may be configured to rotate about a width direction of the electrode sheet (50) that is perpendicular to a movement direction (MD) of the electrode sheet (50).

[0038] The above-described rotating body (131) may include a central portion (1311) and a pair of peripheral portions (1313) in the width direction of the electrode sheet (50). The central portion (1311) of the rotating body (131) may have a generally uniform thickness, and the central portion (1311) of the rotating body (131) may have a flat surface that supports the electrode sheet (50). The peripheral portion (1313) of the rotating body (131) may have a tapered shape in which the thickness becomes smaller as it gets farther away from the central portion (1311) of the rotating body (131). The peripheral portion (1313) of the rotating body (131) may include an inclined surface that is inclined with respect to the flat surface of the central portion (1311) of the electrode sheet (50). A step (1315) may be provided between the center (1311) and the outer portion (1313) of the rotating body (131).

[0039] A plurality of actuators (150) can move a plurality of guide rollers (130) in the width direction of the electrode sheet (50) and adjust the positions of the plurality of guide rollers (130) along the width direction of the electrode sheet (50). Hereinafter, the positions of the guide rollers (130) along the width direction of the electrode sheet (50) are simply referred to as the positions of the guide rollers (130). Each actuator (150) can linearly move a corresponding guide roller (130) among the plurality of guide rollers (130), thereby adjusting the positions of the corresponding guide rollers (130). Each actuator (150) can linearly move the rotational axis (139) and the rotational body (131) of the corresponding guide roller (130) together. In exemplary embodiments, each actuator (150) can linearly move the corresponding guide roller (130) along the width direction of the electrode sheet (50) or the extension direction of the rotational axis (139) so that the step (1315) of the rotating body (131) of the corresponding guide roller (130) is positioned at a designated position.

[0040] A plurality of cameras (140) can capture images of the electrode sheet (50) at a plurality of detection locations of the electrode sheet (50) to detect physical defects of the electrode sheet (50) that is guided and moved by a plurality of guide rollers (130). The plurality of cameras (140) can include at least one camera (140) for capturing an image of one detection location of the electrode sheet (50). The plurality of cameras (140) can include at least one imaging element configured to capture an image of the electrode sheet (50). The plurality of cameras (140) can each capture an image of the electrode sheet (50) and transmit the obtained image to the control unit (180). The plurality of cameras (140) can be arranged at a plurality of detection locations corresponding to the positions of the plurality of guide rollers (130). Each guide roller (130) may be arranged around a corresponding guide roller (130) among the plurality of guide rollers (130) and configured to capture an image of a portion of the electrode sheet (50) around the corresponding guide roller (130). In exemplary embodiments, each camera (140) may be configured to capture an image of the uncoated portion (53) of the electrode sheet (50) to detect a physical defect in the uncoated portion (53) of the electrode sheet (50). The physical defect in the uncoated portion (53) of the electrode sheet (50) may include a defect that is identifiable in appearance, such as a wrinkle, a burr, or a crack.

[0041] The control unit (180) can control the overall operation of the roll-to-roll device (101) based on signals (DS) transmitted from a plurality of cameras (140). The control unit (180) can generate a control signal (CS) for controlling the lateral positions of the electrode sheets (50) of the plurality of guide rollers (130) based on the signals (DS) transmitted from the plurality of cameras (140), and can apply the generated control signal (CS) to a plurality of actuators (150). The control unit (180) can include at least one memory device configured to store data and at least one processor configured to process data. For example, the control unit (180) can be implemented by a computer, a programmable logic controller (PLC), etc.

[0042] A plurality of cameras (140) acquire images of the electrode sheet (50) at a plurality of detection points corresponding to the positions of the plurality of guide rollers (130), and the control unit (180) can determine whether a physical defect has occurred in the electrode sheet (50) based on the images of the electrode sheet (50) acquired at the plurality of detection points. If it is determined that a physical defect has occurred in the electrode sheet (50), the control unit (180) can determine which of the plurality of guide rollers (130) is related to the physical defect that occurred in the electrode sheet (50) based on the images of the electrode sheet (50) acquired at the plurality of detection points. Hereinafter, the guide roller (130) determined to be related to the physical defect that occurred in the electrode sheet (50) is referred to as a target guide roller.

[0043] When the target guide roller is determined, the control unit (180) applies a control signal (CS) to the target actuator (150) among the plurality of actuators (150) that is responsible for moving the target guide roller, and the target actuator moves the target guide roller in the width direction of the electrode sheet (50) according to the control signal (CS) applied from the control unit (180), thereby adjusting the position of the target guide roller.

[0044] In exemplary embodiments, the control unit (180) may detect the occurrence of a physical defect in the uncoated portion (53) of the electrode sheet (50) based on images of the electrode sheet (50) acquired at multiple detection points, and determine the target guide roller associated with the occurrence of the physical defect in the uncoated portion (53) of the electrode sheet (50). For example, when the occurrence of a continuous or discontinuous physical defect along the moving direction (MD) of the electrode sheet (50) is detected in the uncoated portion (53) of the electrode sheet (50), the guide roller (130) closest to the starting point of the occurrence of the physical defect may be determined as the target guide roller.

[0045] In exemplary embodiments, the target actuator may move the target guide roller so that the electrode sheet (50) is positioned within the center of the rotating body of the target guide roller in accordance with a control signal (CS) of the control unit (180). Alternatively, the target actuator may move the target guide roller so that the electrode sheet (50) does not overlap with the outer portion of the target guide roller in accordance with the control signal (CS) of the control unit (180).

[0046] In exemplary embodiments, the target actuator can adjust the widthwise position of the electrode sheet (50) of the step portion of the target guide roller based on a control signal (CS) of the control unit (180). For example, when the electrode sheet (50) overlaps the step portion of the target guide roller, the target actuator can move the target guide roller so that the electrode sheet (50) does not overlap the step portion of the target guide roller based on the control signal (CS) of the control unit (180).

[0047] The electrode manufacturing device (100) may include a notching device (190) arranged in a moving path of the electrode sheet (50). The notching device (190) may form an electrode tab (55) on the uncoated portion (53) of the electrode sheet (50) by removing a portion of the uncoated portion (53) of the electrode sheet (50). The notching device (190) may include a laser notching machine configured to remove a portion of the uncoated portion (53) of the electrode sheet (50) using a laser beam, or a press-based notching machine configured to remove a portion of the uncoated portion (53) of the electrode sheet (50) using a mold cutting machine.

[0048]

[0049] (Example 2)

[0050] FIGS. 4A and 4B are plan views illustrating an electrode manufacturing method of an electrode manufacturing device (100) according to exemplary embodiments of the present invention. Hereinafter, the electrode manufacturing method of the electrode manufacturing device (100) will be described with reference to FIGS. 4A and 4B together with FIGS. 1 to 3.

[0051] Referring to FIG. 4a together with FIGS. 1 to 3, the control unit (180) can detect a physical defect (57) in the uncoated portion (53) of the electrode sheet (50) based on signals (DS) transmitted from multiple cameras (140). The physical defect (57) in the uncoated portion (53) may be a nick defect. While the electrode sheet (50) is in contact with the center (1311) of the rotating body (131) of the guide roller (130) located on the upstream side in the moving direction (MD) of the electrode sheet (50), if the uncoated portion (53) of the electrode sheet (50) is overlapping both the center (1311) and the outer portion (1313) of the rotating body (131) of the guide roller (130) located on the downstream side in the moving direction (MD) of the electrode sheet (50), a nick defect originating from the guide roller (130) located on the downstream side may occur in the uncoated portion (53) of the electrode sheet (50).

[0052] As illustrated in Fig. 4a, when a physical defect (57) is detected in the uncoated portion (53) of the electrode sheet (50), the control unit (180) can identify a target guide roller (130a) related to the physical defect (57) in the uncoated portion (53) of the electrode sheet (50) among a plurality of actuators (150) based on signals (DS) transmitted from a plurality of cameras (140). The target guide roller (130a) can be closest to the starting point of the nick defect among the plurality of guide rollers (130).

[0053] Referring to FIG. 4B, the control unit (180) can apply a control signal (CS) to the target actuator (150a) among the plurality of actuators (150) that is responsible for moving the target guide roller (130a), thereby adjusting the position of the target guide roller (130a). The position of the target guide roller (130a) can be adjusted so that a physical defect (57) of the electrode sheet (50) caused by the target guide roller (130a) is removed. In exemplary embodiments, the position adjustment of the target guide roller (130a) by the target actuator (150a) can be performed while the movement of the electrode sheet (50) by the roll-to-roll device (101) is stopped. In exemplary embodiments, position adjustment of the target guide roller (130a) by the target actuator (150a) may be performed in parallel with movement of the electrode sheet (50) in the movement direction (MD) by the roll-to-roll device (101).

[0054] In exemplary embodiments, the control unit (180) calculates a position movement value of the target guide roller (130a) based on a signal (DS) transmitted from a plurality of cameras (140), and the target actuator (150a) can move the target guide roller (130a) in the width direction of the electrode sheet (50) by the determined position movement value based on a control signal (CS) applied from the control unit (180).

[0055] In exemplary embodiments, the target actuator (150a) may move the target guide roller (130a) based on a control signal (CS) applied from the control unit (180) so that the electrode sheet (50) overlaps the center portion (1311a) of the rotating body (131a) of the target guide roller (130a) but does not overlap the outer portions (1313a) of the rotating body (131a). In exemplary embodiments, the target actuator (150a) may move the target guide roller (130a) based on a control signal (CS) applied from the control unit (180) so that the electrode sheet (50) does not overlap the step portions (1315a) of the rotating body (131a) of the target guide roller (130a). In exemplary embodiments, the target actuator (150a) can adjust the distance (D1) between the frame (161) and a step portion (1315a) of the target guide roller (130a) based on a control signal (CS) of the control unit (180).

[0056] Typically, when a physical defect occurs in an electrode sheet, the electrode manufacturing process is performed through the following steps: stopping the operation of the manufacturing equipment; resetting the manufacturing equipment to remove the cause of the physical defect in the electrode sheet; cutting and removing the physically defective portion of the electrode sheet; reconnecting the two separated portions of the electrode sheet with tape; and restarting the operation of the manufacturing equipment. Since the portion of the electrode sheet where the physical defect occurs is discarded, the productivity of the electrode sheet may decrease as the detection of the physical defect in the electrode sheet is delayed. In addition, in the case of a typical electrode manufacturing process, there is a problem that it takes a long time to restart the manufacturing process, which lowers the operating rate of the equipment.

[0057] According to exemplary embodiments of the present invention, since the occurrence of a physical defect (57) in an electrode sheet (50) can be quickly detected by a plurality of cameras (140) arranged at a plurality of detection locations, the amount of electrode sheets (50) discarded due to physical defects (57) in the electrode sheets (50) can be minimized, and ultimately, the productivity of an electrode manufacturing device (100) can be improved.

[0058] In addition, according to exemplary embodiments of the present invention, a physical defect (57) of an electrode sheet (50) can be detected by a plurality of cameras (140), and the position of a guide roller (130) related to the physical defect (57) can be automatically adjusted based on the detection result of the physical defect (57), so that the time for adjusting the setting of equipment due to the occurrence of a physical defect (57) of an electrode sheet (50) can be reduced, and ultimately, the productivity of an electrode manufacturing device (100) can be improved.

[0059] The present invention has been described in more detail through drawings and examples. However, the configurations described in the drawings or examples described in this specification are merely embodiments of the present invention and do not represent all of the technical ideas of the present invention. Therefore, it should be understood that various equivalents and modified examples may exist as of the time of this application.

Claims

1. A plurality of guide rollers arranged along the movement path of the electrode sheet; A plurality of cameras arranged at a plurality of detection positions corresponding to the plurality of guide rollers; A control unit that detects a physical defect in the electrode sheet based on signals transmitted from the plurality of cameras; and A plurality of actuators configured to move the plurality of guide rollers in the width direction of the electrode sheet; An electrode manufacturing device comprising:

2. In paragraph 1, The above electrode sheet includes a maintenance portion and a non-maintaining portion, An electrode manufacturing device, characterized in that the control unit is configured to detect a physical defect in the non-conductive portion of the electrode sheet based on signals transmitted from the plurality of cameras.

3. In paragraph 2, An electrode manufacturing device, characterized in that the control unit is configured to determine a target guide roller related to a physical defect occurring in the electrode sheet among the plurality of guide rollers based on signals transmitted from the plurality of cameras.

4. In paragraph 3, The above control unit applies a control signal to a target actuator among the plurality of actuators responsible for moving the target guide roller, An electrode manufacturing device, characterized in that the target actuator is configured to adjust the position of the target guide roller based on the control signal of the control unit.

5. In paragraph 4, Each of the above plurality of guide rollers includes a central portion having a flat surface, an outer portion having an inclined surface, and a stepped portion at a boundary between the central portion and the outer portion. An electrode manufacturing device, characterized in that the target actuator is configured to adjust the position of the step portion of the target guide roller based on the control signal of the control unit.

6. In paragraph 5, An electrode manufacturing device, characterized in that the target actuator is configured to adjust the position of the target guide roller so that the electrode sheet is positioned within the center of the target guide roller.

7. In paragraph 5, An electrode manufacturing device, characterized in that the target actuator is configured to adjust the position of the target guide roller so that the electrode sheet does not overlap the step portion of the target guide roller.

8. In paragraph 3, An electrode manufacturing device characterized in that the control unit determines the guide roller closest to the starting point of the physical defect occurring in the electrode sheet among the plurality of guide rollers as the target guide roller.

9. In paragraph 1, An electrode manufacturing device, characterized in that each of the plurality of actuators is configured to move a corresponding guide roller among the plurality of guide rollers based on a signal transmitted from the control unit.

10. In paragraph 1, The above electrode sheet includes a maintenance portion and a non-maintaining portion, An electrode manufacturing apparatus characterized by further comprising a notching device configured to remove a portion of the non-conductive portion of the electrode sheet.

11. In paragraph 1, An unwinder in which the above electrode sheet is wound; and A rewinder for recovering and winding the above electrode sheet; Including more, An electrode manufacturing device characterized in that the plurality of guide rollers are provided between the unwinder and the rewinder.

Images