System and method for manufacturing dry electrode

Abstract

The present disclosure provides a system for manufacturing a dry electrode and a method for manufacturing a dry electrode. The system for manufacturing a dry electrode according to the present disclosure comprises: a first supply unit for supplying a first electrode powder containing an active material; a first calendering unit for manufacturing a first electrode film by pressing the first electrode powder; an unwinding unit for supplying a current collector; and a first laminating unit for coupling the current collector and the first electrode film, wherein the unwinding unit may be disposed below the first calendering unit.

Description

System and method for manufacturing dry electrodes

[0001] The present disclosure relates to a system and method for manufacturing a dry electrode.

[0002] Secondary batteries, unlike non-rechargeable primary batteries, are rechargeable and dischargeable. Low-capacity secondary batteries are used in small, portable electronic devices such as smartphones, feature phones, laptops, digital cameras, and camcorders, while large-capacity secondary batteries are widely used as power sources for motor drives and power storage in hybrid and electric vehicles. These secondary batteries include an electrode assembly comprising a positive and negative electrode, a housing housing the electrode assembly, and electrode terminals connected to the electrode assembly.

[0003] The manufacturing process of these secondary batteries is largely divided into three stages: the electrode manufacturing process, the electrode assembly manufacturing process, and the formation process. Among them, the conventional electrode manufacturing process can be further divided into the electrode mixture mixing process, the electrode coating process, the drying process, the rolling process, the slitting process, and the winding process. The electrode mixture mixing process includes the process of mixing the electrode active material, which is an essential element of the electrode, and other additives such as conductive materials and fillers, a binder for inter-powder bonding and adhesion to the current collector, and a solvent for viscosity and powder dispersion, to manufacture it in the form of a slurry with fluidity in order to mix the components for forming the electrode active layer where the electrochemical reaction occurs in the electrode. The composition mixed in this way is also referred to as an electrode mixture in a broad sense.

[0004] Afterwards, an electrode coating process is performed to coat the slurry to apply the electrode mixture onto an electrically conductive current collector, and a drying process is performed to remove the solvent contained in the slurry. However, during this drying process, as the solvent contained in the slurry evaporates, defects such as pinholes and cracks are induced in the electrode active layer, and a powder floating phenomenon due to a difference in solvent evaporation rate occurs, that is, the powder in the area that dries first floats and forms a gap with the area that dries relatively later, which causes a deterioration in electrode quality.

[0005] Therefore, research on manufacturing dry electrodes that do not use solvents has been actively conducted recently.

[0006] The above-described information disclosed in the background technology of this invention is only intended to improve understanding of the background of the present invention, and therefore may include information that does not constitute prior art.

[0007] The problem to be solved by the present invention is to provide a system for manufacturing a dry electrode and a method for manufacturing a dry electrode to solve the above technical problem.

[0008] However, the technical problems to be solved by the present invention are not limited to the problems described above, and other problems not mentioned can be clearly understood by those skilled in the art from the description of the invention described below.

[0009] A dry electrode manufacturing system according to one embodiment of the present invention for solving the above technical problem includes a first supply unit for supplying a first electrode powder containing an active material, a first calendaring unit for pressurizing the first electrode powder to produce a first electrode film, an unwinding unit for supplying a current collector, and a first laminating unit for bonding the current collector and the first electrode film, wherein the unwinding unit can be arranged at the bottom of the first calendaring unit.

[0010] According to one embodiment of the present disclosure, the first laminating portion or the first calendaring portion may be disposed at the bottom of the first supply portion.

[0011] According to one embodiment of the present disclosure, the first electrode powder can be supplied from the first supply unit to the first calendaring unit perpendicular to the direction in which the first electrode film is calendared.

[0012] A dry electrode manufacturing system according to one embodiment of the present invention further includes a first cutting section for firing a first electrode film to have a specific width, and the first cutting section can be positioned spaced apart from the first calendaring section.

[0013] According to one embodiment of the present disclosure, the first cutting portion includes a trimming device, and the trimming device can be disposed at the lower end of the first calendaring portion.

[0014] A dry electrode manufacturing system according to one embodiment of the present disclosure further includes a first sensor for detecting bonding of the current collector and the first electrode film, wherein the first sensor can be disposed at the bottom of the first laminating portion.

[0015] According to one embodiment of the present disclosure, the first sensor may include a vision sensor or a thickness sensor.

[0016] A dry electrode manufacturing system according to one embodiment of the present disclosure may further include a second supply unit that supplies a second electrode powder including an active material, and a second calendaring unit that pressurizes the second electrode powder to produce a second electrode film.

[0017] A dry electrode manufacturing system according to one embodiment of the present disclosure may further include a second laminating portion that combines a current collector having a first electrode film and a second electrode film.

[0018] A dry electrode manufacturing system according to one embodiment of the present disclosure may further include a CPC (Center Position Control) for aligning the position of the second electrode film or the current collector before bonding the first electrode film and the current collector to which the second electrode film is bonded, and the first laminating part and the second laminating part may be arranged to be spaced apart from each other.

[0019] According to one embodiment of the present disclosure, the second electrode film can be bonded to correspond to the position of the first electrode film disposed on the current collector.

[0020] A dry electrode manufacturing system according to one embodiment of the present disclosure further includes a second cutting section for firing a second electrode film to have a specific width, wherein the cutting width of the second electrode film can correspond to the cutting width of the first electrode film.

[0021] A dry electrode manufacturing system according to one embodiment of the present disclosure may further include a rewinding unit for rewinding the dry electrode film applied to the current collector.

[0022] A dry electrode manufacturing system according to one embodiment of the present disclosure may further include a density measuring device that detects the bonding of the current collector to which the first electrode film is bonded and the second electrode film.

[0023] A dry electrode manufacturing method according to one embodiment of the present invention for solving a technical problem includes a step of supplying a first electrode powder containing an active material, a step of pressurizing the first electrode powder to produce a first electrode film, a step of supplying a current collector, and a step of combining the current collector and the first electrode film, wherein an unwinding unit supplying the current collector may be arranged below a first calendaring unit producing the first electrode film.

[0024] According to one embodiment of the present disclosure, the step of supplying the first electrode powder may include a step of supplying the first electrode powder perpendicularly to the progress direction of the process of producing the first electrode film by pressurizing the first electrode powder.

[0025] A method for manufacturing a dry electrode according to one embodiment of the present disclosure further includes a step of firing a first electrode film to have a specific width, and the step of firing the first electrode film can be performed separately from the step of manufacturing the first electrode film.

[0026] A method for manufacturing a dry electrode according to one embodiment of the present disclosure may further include a step of detecting the bonding of the current collector and the first electrode film.

[0027] A dry electrode manufacturing method according to one embodiment of the present disclosure may further include a step of supplying a second electrode powder including an active material and a step of pressurizing the second electrode powder to produce a second electrode film.

[0028] A method for manufacturing a dry electrode according to one embodiment of the present disclosure may further include a step of combining a current collector to which a first electrode film is combined and a second electrode film, and may further include a step of aligning a position of the second electrode film or the current collector before the step of combining the current collector and the second electrode film.

[0029] According to some embodiments of the present disclosure, foreign matter generated from the current collector supply device (unwinder) can be prevented from falling into the calendering section by appropriately positioning the current collector supply device. This simplifies the operation of process conditions for dry electrode manufacturing and optimizes the movement path of the electrode film.

[0030] According to some embodiments of the present disclosure, contamination of foreign substances due to friction and wear of a calendaring part during a cutting process of an electrode film in a dry electrode manufacturing system can be prevented, and quality defects occurring on the surface of an electrode film can be eliminated.

[0031] According to some embodiments of the present disclosure, in a process of laminating both sides of an electrode collector through a separately separated laminating unit, process conditions and alignment conditions can be simplified to provide a dry electrode of uniform quality.

[0032] However, the effects that can be obtained through the present invention are not limited to the effects described above, and other technical effects not mentioned can be clearly understood by those skilled in the art from the description of the invention described below.

[0033] The following drawings attached to this specification illustrate preferred embodiments of the present invention, and together with the detailed description of the invention described below, serve to further understand the technical idea of ​​the present invention, and therefore, the present invention should not be interpreted as being limited to matters described in such drawings.

[0034] FIG. 1 is a schematic diagram showing a dry electrode manufacturing system according to one embodiment of the present disclosure.

[0035] FIG. 2 is a drawing showing the relationship between a first supply unit and a first calendaring unit according to one embodiment of the present disclosure.

[0036] FIG. 3 is a drawing showing the periphery of a first supply section and a first calendaring section of a dry electrode manufacturing system according to one embodiment of the present disclosure.

[0037] FIG. 4 is a drawing showing the periphery of an unwinding section and a first laminating section of a dry electrode manufacturing system according to one embodiment of the present disclosure.

[0038] FIG. 5 is a schematic diagram showing a dry electrode manufacturing system according to one embodiment of the present disclosure.

[0039] FIG. 6 is a drawing showing the periphery of a second calendaring section and a second laminating section of a dry electrode manufacturing system according to one embodiment of the present disclosure.

[0040] FIG. 7 is a drawing showing a first electrode film and a second electrode film according to one embodiment of the present disclosure.

[0041] FIG. 8 is a drawing showing a dry electrode manufacturing system according to one embodiment of the present disclosure.

[0042] FIG. 9 is a flowchart illustrating an example of a method for manufacturing a dry electrode according to one embodiment of the present disclosure.

[0043] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the attached drawings. Prior to this, terms or words used in this specification and claims should not be interpreted as limited to their typical or dictionary meanings, and should be interpreted with meanings and concepts that conform to the technical spirit of the present invention based on the principle that the inventor can appropriately define the concept of a term to best explain his or her own invention. Therefore, the embodiments described in this specification and the configurations illustrated in the drawings are only some of the most preferred embodiments of the present invention and do not represent all of the technical spirit of the present invention. Therefore, it should be understood that various equivalents and modified examples may exist as substitutes for them at the time of filing this application.

[0044] Additionally, when used herein, the terms "comprise", "include" and / or "comprising", "including" specify the presence of stated features, numbers, steps, operations, elements, elements and / or groups thereof, but do not preclude the presence or addition of one or more other features, numbers, operations, elements, elements and / or groups thereof.

[0045] Additionally, to facilitate understanding of the invention, the attached drawings may not be drawn to scale and some components may be exaggerated in size. Furthermore, identical components may be assigned the same reference numbers in different embodiments.

[0046] The statement that two compared objects are "identical" means "substantially identical." Therefore, "substantially identical" may include deviations considered low in the art, such as deviations of less than 5%. Furthermore, uniformity of a parameter over a given region may also mean uniformity on average.

[0047] Although terms like "first" and "second" are used to describe various components, these components are not limited by these terms. These terms are used merely to distinguish one component from another, and unless otherwise specified, a "first" component may also be a "second" component.

[0048] Throughout the specification, unless otherwise specifically stated, each element may be singular or plural.

[0049] Any configuration being arranged "on the top (or bottom)" of a component or "on the upper (or lower) side" of a component may mean not only that any configuration is arranged in contact with the upper surface (or lower surface) of the component, but also that another configuration may be interposed between the component and any configuration arranged on (or under) the component. In addition, in the drawings, the portion between the upper and lower portions of the components depicted or the remaining portion excluding the upper and lower portions may be referred to as a "side" or a "side surface." Additionally, the direction toward the internal space of the component may be referred to as "inner," and the direction protruding into the open external space may be referred to as "outer." Relative terms such as "upper," "top," etc. may be used to describe the relationship between the configurations depicted in the drawings, and the present disclosure is not limited by such terms.

[0050] For ease of description, spatially relative terms such as "beneath," "below," "lower," "above," "upper," and the like may be used herein to describe the relationship of one element or feature to another element(s) or feature(s) as depicted in the drawings. It will be understood that spatially relative positions encompass different orientations of the device in use or operation in addition to the orientations depicted in the figures. For example, if the device in the drawings is turned over, an element described as "beneath" or "lower" another element would be understood to be "above" or "upper" the other element. Thus, the term "beneath" can encompass both the above and below orientations.

[0051] Additionally, when a component is described as being "on," "connected to," or "coupled to" another component, it should be understood that the components may be directly connected or coupled to one another, but that other components may also be "interposed" between the components, or that each component may be "connected," "coupled," or "connected" through other components.

[0052] As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. Furthermore, the use of "may" when describing embodiments of the present disclosure refers to "one or more embodiments of the present disclosure." The use of phrases such as "one or more" before a list of elements modifies the list as a whole and does not modify individual elements in the list.

[0053] When reference is made throughout the specification to “A and / or B,” this means A, B, or A and B, unless otherwise stated, and when reference is made to “C through D,” this means C or more and D or less, unless otherwise stated.

[0054] Although terms such as first, second, third, etc. may be used herein to describe various elements, components, regions, layers, and / or sections, these elements, components, regions, layers, and / or sections should not be limited by these terms. These terms are used to distinguish one element, component, region, layer, or section from another element, component, region, layer, or section. Thus, a first element, component, region, layer, or section discussed below could also be termed a second element, component, region, layer, or section without departing from the teachings of the exemplary embodiments.

[0055] The terminology used herein is for the purpose of describing embodiments of the present disclosure and is not intended to be limiting of the present disclosure.

[0056] FIG. 1 is a schematic diagram showing a dry electrode manufacturing system according to one embodiment of the present disclosure.

[0057] Referring to FIG. 1, a dry electrode manufacturing system (100) according to one embodiment of the present invention may include a first supply unit (110) that supplies a first electrode powder (112) containing an active material, a first calendaring unit (120) that pressurizes the first electrode powder (112) to produce a first electrode film (122), an unwinding unit (130) that supplies a current collector (132), and a first laminating unit (140) that combines the current collector (132) and the first electrode film (122).

[0058] The first supply unit (110) is not limited to any device that stores and supplies raw materials for a dry electrode. For example, the first supply unit (110) may be a hopper for storing and uniformly supplying powdered first electrode powder (112). The first electrode powder (112) may be formed by mixing within the first supply unit (110), or may be formed separately in an external mixer and then transferred to the first supply unit (110).

[0059] The first electrode powder (112) may be an irregular mixture in the form of a powder or a lump of powder combined. Specifically, the first electrode powder (112) may include a mixture of an active material (or electrode active material), a conductive material, and a binder. Here, the mixture is not limited to a dry mixture in which the active material, conductive material, and binder are mixed in powder form, and may be mixed by various methods. For example, the mixture may be manufactured by putting the materials into a device such as a blender or a kneader.

[0060] In one embodiment, the first electrode powder (112) may have undergone a fiberization process to fiberize the binder. For example, the fiberization process may include high shear mixing, such as jet milling. The fiberization process may be performed under high temperature conditions. Specifically, the fiberization process may include kneading the mixture at a temperature ranging from 60°C to 220°C, preferably from 90°C to 200°C.

[0061] Here, the active material may vary depending on the type of dry electrode to be manufactured. For example, if the dry electrode to be manufactured is a positive electrode, the active material may be a positive electrode active material.

[0062] A compound capable of reversible intercalation and deintercalation of lithium (a lithiated intercalation compound) can be used as a cathode active material. Specifically, one or more of a composite oxide of lithium and a metal selected from cobalt, manganese, nickel, and combinations thereof can be used.

[0063] The above composite oxide may be a lithium transition metal composite oxide, and specific examples thereof include lithium nickel-based oxide, lithium cobalt-based oxide, lithium manganese-based oxide, lithium iron phosphate-based compound, cobalt-free nickel-manganese-based oxide, or a combination thereof.

[0064] As an example, a compound represented by any one of the following chemical formulas may be used: Li a A 1-b X b O 2-c D c (0.90≤a≤1.8, 0≤b≤0.5, 0≤c≤0.05); Li a Mn 2-b X b O 4-c D c (0.90≤a≤1.8, 0≤b≤0.5, 0≤c≤0.05); Li a Ni 1-b-c Co b X c O 2-α D α (0.90≤a≤1.8, 0≤b≤0.5, 0≤c≤0.5, 0<α<2); Li a Ni 1-b-c Mn b X c O 2-α D α (0.90≤a≤1.8, 0≤b≤0.5, 0≤c≤0.5, 0<α<2); Li a Ni b Co c L 1 d G e O2(0.90≤a≤1.8, 0≤b≤0.9, 0≤c≤0.5, 0≤d≤0.5, 0≤e≤0.1); Li a NiG b O2(0.90≤a≤1.8, 0.001≤b≤0.1); Li a CoG b O2(0.90≤a≤1.8, 0.001≤b≤0.1); Li a Mn 1-b G b O2(0.90≤a≤1.8, 0.001≤b≤0.1); Li a Mn2G b O4(0.90≤a≤1.8, 0.001≤b≤0.1); Li a Mn 1-g G g PO4(0.90≤a≤1.8, 0≤g≤0.5); Li (3-f)Fe2(PO4)3(0≤f≤2); Li a FePO4(0.90≤a≤1.8).

[0065] In the above chemical formula, A is Ni, Co, Mn, or a combination thereof; X is Al, Ni, Co, Mn, Cr, Fe, Mg, Sr, V, a rare earth element, or a combination thereof; D is O, F, S, P, or a combination thereof; G is Al, Cr, Mn, Fe, Mg, La, Ce, Sr, V, or a combination thereof; L 1 is Mn, Al or a combination thereof.

[0066] For example, the cathode active material may be a high-nickel cathode active material in which the nickel content is 80 mol% or more, 85 mol% or more, 90 mol% or more, 91 mol% or more, or 94 mol% or more and 99 mol% or less, based on 100 mol% of metals excluding lithium in the lithium transition metal composite oxide. The high-nickel cathode active material can realize high capacity and thus can be applied to high-capacity, high-density lithium secondary batteries.

[0067] In one embodiment, if the dry electrode to be manufactured is a cathode, the active material may be a cathode active material.

[0068] The negative electrode active material includes a material capable of reversibly intercalating / deintercalating lithium ions, lithium metal, an alloy of lithium metal, a material capable of doping and dedoping lithium, or a transition metal oxide.

[0069] The material capable of reversibly intercalating / deintercalating the lithium ions may include a carbon-based negative electrode active material, for example, crystalline carbon, amorphous carbon, or a combination thereof. Examples of the crystalline carbon include graphite such as natural graphite or artificial graphite in an amorphous, plate-like, flake-like, spherical, or fibrous form, and examples of the amorphous carbon include soft carbon or hard carbon, mesophase pitch carbide, calcined coke, and the like.

[0070] As the above lithium metal alloy, an alloy of lithium and a metal selected from Na, K, Rb, Cs, Fr, Be, Mg, Ca, Sr, Si, Sb, Pb, In, Zn, Ba, Ra, Ge, Al, and Sn can be used.

[0071] As the material capable of doping and dedoping the lithium, a Si-based negative electrode active material or a Sn-based negative electrode active material may be used. The Si-based negative electrode active material may be silicon, a silicon-carbon composite, SiOx (0 < x < 2), a Si-Q alloy (wherein Q is selected from alkali metals, alkaline earth metals, Group 13 elements, Group 14 elements (excluding Si), Group 15 elements, Group 16 elements, transition metals, rare earth elements, and combinations thereof), or a combination thereof. The Sn-based negative electrode active material may be Sn, SnO2, a Sn-based alloy, or a combination thereof.

[0072] The silicon-carbon composite may be a composite of silicon and amorphous carbon. According to one embodiment, the silicon-carbon composite may be in the form of silicon particles and amorphous carbon coated on the surface of the silicon particles. For example, the composite may include secondary particles (cores) in which silicon primary particles are assembled and an amorphous carbon coating layer (shell) positioned on the surface of the secondary particles. The amorphous carbon may also be positioned between the silicon primary particles, such that, for example, the silicon primary particles may be coated with amorphous carbon. The secondary particles may be dispersed and present in an amorphous carbon matrix.

[0073] The silicon-carbon composite may further comprise crystalline carbon. For example, the silicon-carbon composite may comprise a core comprising crystalline carbon and silicon particles and an amorphous carbon coating layer positioned on the surface of the core. The Si-based negative electrode active material or the Sn-based negative electrode active material may be used in combination with a carbon-based negative electrode active material.

[0074] This is only an example, and any positive or negative active material commonly used in the industry can be used without limitation.

[0075] Conductive materials are used to impart conductivity to electrodes, and any material that does not cause chemical changes and is electronically conductive can be used in the battery. Examples of conductive materials include carbon-based materials such as natural graphite, artificial graphite, carbon black, acetylene black, Ketjen black, carbon fibers, carbon nanofibers, and carbon nanotubes; metallic materials containing copper, nickel, aluminum, silver, etc. in the form of metal powder or metal fibers; conductive polymers such as polyphenylene derivatives; or mixtures thereof.

[0076] The binder can play a role in adhering active material particles well to each other and the active material well to the current collector. For example, the binder may include, but is not limited to, polyvinyl alcohol, carboxymethyl cellulose, hydroxypropyl cellulose, diacetyl cellulose, polyvinyl chloride, carboxylated polyvinyl chloride, polyvinyl fluoride, a polymer containing ethylene oxide, polyvinyl pyrrolidone, polyurethane, polytetrafluoroethylene, polyvinylidene fluoride, polyethylene, polypropylene, styrene-butadiene rubber, (meth)acrylated styrene-butadiene rubber, epoxy resin, (meth)acrylic resin, polyester resin, nylon, etc.

[0077] According to one embodiment, the first electrode powder (112) may additionally include a filler, which is a component that suppresses expansion of the electrode. Here, the filler is not particularly limited as long as it is a fibrous material that does not cause a chemical change in the battery, and may include, for example, an olefin polymer such as polyethylene or polypropylene; a fibrous material such as glass fiber or carbon fiber.

[0078] In one embodiment of the present disclosure, the first calendaring unit (120) can pressurize the first electrode powder (112) to produce a first electrode film (122). Specifically, the first calendaring unit (120) can produce a first electrode film (122) of uniform thickness while performing a roll pressing process of passing the first electrode powder (112) between a plurality of rolling rollers (Calender rolls). In one embodiment, the rolling rollers can be heated to a temperature of 60° C. to 220° C. In one embodiment, the first electrode film (122) can be a free-standing dry electrode film produced from the first electrode powder (112).

[0079] The current collector (132) is not particularly limited as long as it has high conductivity without causing chemical changes. For example, the current collector (132) may include copper, aluminum, stainless steel, nickel, titanium, calcined carbon, or a combination thereof.

[0080] In one embodiment, the current collector (132) may be formed in the form of a metal foil or thin metal plate, such as copper, a copper alloy, nickel, or a nickel alloy. Alternatively, in another embodiment, the current collector (132) may be formed in the form of a metal foil or thin metal plate, such as aluminum or an aluminum alloy.

[0081] The current collector (132) can be supplied to the first laminating unit (140) by the unwinding unit (130). Here, the unwinding unit (130) can be arranged at the bottom of the first calendaring unit (120). If the unwinding unit (130) that supplies the current collector (132) is positioned above the first calendaring unit (120), the overall height of the dry electrode manufacturing system (100) may increase. This may limit the height of the ceiling when preparing a place to install the system (100), and may also cause limitations in the convenience of workers and operation and maintenance thereafter.

[0082] In addition, when the unwinding unit (130) that supplies the current collector (132) is located above the first calendaring unit (120), the movement path of the current collector (132) may interfere with the path that supplies the first electrode powder (112) of the first supply unit (110). In addition, when the unwinding unit (130) is driven above the first calendaring unit (120) that manufactures the first electrode film (122), foreign matter generated during the unwinding process of the current collector (132) may fall on the first calendaring unit (120), causing poor quality of the first electrode film (122).

[0083] Meanwhile, if the current collector (132) is supplied from the side of the first calendaring unit (120) to avoid interference between the movement path of the current collector (132) and the path supplying the first electrode powder (112) of the first supply unit (110), the first electrode powder (112) may be supplied unevenly in the width direction of the first electrode film (122), which may cause defects in the manufactured dry electrode.

[0084] In contrast, according to embodiments of the present disclosure, the unwinding unit (130) is arranged at the bottom of the first calendaring unit (120), thereby preventing such problems in advance.

[0085] The first laminating unit (140) can bond the current collector (132) and the first electrode film (122). Specifically, the first laminating unit (140) can include a pair of opposing presses or a pair of lamination rolls. The first laminating unit (140) can bond the current collector (132) and the first electrode film (122) by placing the current collector (132) and the first electrode film (122) between the pair of presses and pressing them, or by passing them between the pair of lamination rolls and pressing them. In one embodiment, the press or lamination roll can be heated to a temperature of 80° C. to 250° C. to thermally press-bond the current collector (132) and the first electrode film (122).

[0086] According to one embodiment, the first laminating unit (140) or the first calendaring unit (120) may be positioned at the bottom of the first supply unit (110).

[0087] According to some embodiments of the present disclosure, foreign matter generated during the manufacturing process of a dry electrode can be prevented from falling onto the first calendaring unit (120) by appropriately arranging the unwinding unit (130) that supplies the current collector (132). This simplifies the operation of process conditions for manufacturing a dry electrode and optimizes the movement path of the first electrode film (122).

[0088] FIG. 2 is a drawing showing the relationship between a first supply unit (110) and a first calendaring unit (120) according to one embodiment of the present disclosure.

[0089] Referring to FIG. 2, the first electrode powder (112) according to one embodiment of the present disclosure may be supplied from the first supply unit (110). The supply direction of the first electrode powder (112) may be perpendicular to the direction (D) in which the first electrode film (122) is calendered in the first calendering unit (120).

[0090] The first electrode powder (112) may be a mixture of various materials such as an active material, a conductive material, and a binder. Therefore, when the first electrode powder (112) is discharged from the first supply unit (110) and supplied to the first calendering unit (120), the composition ratio of the first electrode film (122) produced may differ depending on the angle (a) formed by the calendering direction (D) and the supply direction of the first electrode powder (112). Therefore, when the angle (a) formed by the calendering direction (D) and the supply direction of the first electrode powder (112) is 90 degrees, i.e., vertical, gravity is uniformly applied to all materials constituting the mixture, so that the first electrode film (122) may have a uniform composition ratio.

[0091] In one embodiment, before entering the first calendaring (120), the first electrode powder (112) may be pre-formed by being pressed by a pair of opposing forming rollers (210). Here, the forming rollers (210) may be heated to a temperature of 80° C. to 250° C. Through this pre-forming of the first electrode powder (112), the composition ratio of the first electrode film (122) can be made more uniform, and the surface can be smoothed, thereby preventing the occurrence of a cut section in the middle of the first electrode film (122).

[0092] FIG. 3 is a drawing showing the periphery of a first supply section and a first calendaring section of a dry electrode manufacturing system according to one embodiment of the present disclosure.

[0093] Referring to FIG. 3, a dry electrode manufacturing system (300) according to one embodiment of the present disclosure may further include a first cutting section (350) that fires the first electrode film (322) to have a specific width.

[0094] The first cutting section (350) may include a leading alignment roller (352), a trimming device (354), and a trailing alignment roller (356). The leading alignment roller (352) and the trailing alignment roller (356) may adjust the arrangement of the first electrode film (322) so that the trimming device (354) can cut an intended portion of the first electrode film (322), and may adjust the first electrode film (322) to pass through the first cutting section (350) at a constant speed.

[0095] In one embodiment, the trimming device (354) may include a pair of opposing blades or laser cutters. As the first electrode film (322) passes between the pair of blades or laser cutters, a portion of the first electrode film (322) exceeding a set width may be cut. The trimming device (354) may be positioned at the bottom of the first calendaring unit (320). The cut portion of the first electrode film (322) may be separated into scrap (358) and removed.

[0096] Here, "scrap" may refer to material removed during the cutting process or not part of the final product. Specifically, it may refer to a portion that is cut and discarded to form the first electrode film (322) into a specific shape or width. Therefore, although not shown, an additional process may be performed to collect and separately process the resulting scrap. Furthermore, although not shown, in one embodiment, a process may further include supplying cutting fluid to a portion of the first electrode film (322) before the first cutting unit (350) cuts the first electrode film (322).

[0097] In one embodiment, the first cutting portion (350) may be positioned spaced apart from the first calendaring portion (320). In contrast, when the first cutting portion (350), particularly the trimming device (354) for cutting the first electrode film (322), comes into contact with the first calendaring portion (320), the rolling roller of the first calendaring portion (320) may rotate and rub against the trimming device (354), thereby causing the trimming device (354) to wear out, or foreign matter that may cause a defect in the electrode may be generated during the friction process. In addition, when the trimming device (354) for cutting the first electrode film (322) does not come into contact with the first calendaring portion (320), a defect may occur in which the first electrode film (322) is not cut.

[0098] In one embodiment, the dry electrode manufacturing system (300) may further include a pre-cutting unit (359). Here, the pre-cutting unit (359) may perform a process of shaping the first electrode powder (312) supplied from the first supply unit (310). Specifically, the pre-cutting unit (359) may cut the pre-molded first electrode powder (312) before being supplied to the first calendaring unit (320) so that the pre-molded first electrode powder (312) has a more uniform shape on a pair of forming rollers (316). The configuration of the pre-cutting unit (359) may be the same as that of the first cutting unit (350). The configuration of the pair of forming rollers (316) may be the same as that of the forming roller (210) of FIG. 2.

[0099] According to some embodiments of the present disclosure, during the cutting process of the first electrode film (322) in the dry electrode manufacturing system (300), foreign matter contamination due to friction and wear of the first calendaring unit (320) can be prevented, and quality defects occurring on the surface of the first electrode film (322) can be eliminated.

[0100] FIG. 4 is a drawing showing the periphery of an unwinding section (430) and a first laminating section (440) of a dry electrode manufacturing system (400) according to one embodiment of the present disclosure.

[0101] Referring to FIG. 4, a dry electrode manufacturing system (400) according to one embodiment of the present disclosure may further include a first sensor (460) that detects the bonding of a current collector (432) and a first electrode film (422). Here, the first sensor (460) may be disposed at the bottom of the first laminating portion (440).

[0102] In one embodiment, the first sensor (460) may include a vision sensor or a thickness sensor. The vision sensor is a device that uses a camera and image processing software to inspect the appearance, size, surface condition, etc. of the current collector (432) and the first electrode film (422). The thickness sensor is a device that measures the thickness of the current collector (432) to which the first electrode film (422) is coupled in real time, thereby ensuring that the thickness is maintained uniformly. For example, the thickness sensor may include a laser thickness sensor, an ultrasonic thickness sensor, an optical thickness sensor, or a combination thereof.

[0103] A dry electrode manufacturing system (400) according to one embodiment of the present disclosure may further include a Center Position Control (CPC) (434) for aligning the position of a current collector (432) supplied from an unwinding unit (430). Specifically, the CPC (434) may control the relative arrangement of the current collector (432) with respect to the position of the first electrode film (422) before the current collector (432) is supplied to the first laminating unit (440).

[0104] In addition, the description of the configuration is the same as the description described above with reference to Fig. 1.

[0105] FIG. 5 is a schematic diagram illustrating a dry electrode manufacturing system (500) according to one embodiment of the present disclosure. FIG. 6 is also a diagram illustrating the periphery of a second calendaring section and a second laminating section of the dry electrode manufacturing system according to one embodiment of the present disclosure.

[0106] Referring to FIGS. 5 and 6, a dry electrode manufacturing system (500) according to one embodiment of the present disclosure may include a first supply unit (510) that supplies a first electrode powder (512) including an active material, a first calendaring unit (520) that pressurizes the first electrode powder (512) to produce a first electrode film (522), an unwinding unit (530) that supplies a current collector (532), and a first laminating unit (540) that combines the current collector (532) and the first electrode film (522). The description of each component is the same as the description given above with reference to FIGS. 1 to 4.

[0107] In one embodiment, the dry electrode manufacturing system (500) may further include a second supply unit (560) that supplies second electrode powder (562) including an active material, and a second calendaring unit (570) that pressurizes the second electrode powder (562) to produce a second electrode film (572). The composition of the second electrode powder (562) may be the same as that of the first electrode powder (512). The second calendaring unit (570) may include a plurality of rolling rollers (Calender rolls) for pressing the second electrode powder (562), similar to the first calendaring unit (520). The second electrode film (572) may be a free-standing dry electrode film produced from the second electrode powder (562).

[0108] A dry electrode manufacturing system (500) according to one embodiment may further include a second laminating unit (590) that combines a current collector (532) to which a first electrode film (522) is combined and a second electrode film (572).

[0109] Specifically, the second laminating unit (590) may include a pair of opposing presses or a pair of lamination rolls. The second laminating unit (590) may place the current collector (532) having the first electrode film (522) bonded thereto and the second electrode film (572) between the pair of presses and press the current collector (532) or pass the current collector (532) and the second electrode film (572) through the pair of lamination rolls to press the current collector (532) having the first electrode film (522) bonded thereto and the second electrode film (572). In one embodiment, the press or lamination roll may be heated to a temperature of 80° C. to 250° C. to thermally compress the current collector (532) and the second electrode film (572).

[0110] According to one embodiment, a dry electrode manufacturing system (500) may further include a CPC (Center Position Control) (634) for aligning the position of the current collector (532) to which the first electrode film (522) is bonded before bonding the current collector (532) to which the first electrode film (522) is bonded and the second electrode film (572). Specifically, the CPC (634) may control the relative arrangement of the current collector (532) to which the first electrode film (522) is bonded with respect to the position of the second electrode film (572) before the current collector (532) to which the first electrode film (522) is bonded is supplied to the second laminating unit (590). This will be described later with reference to FIG. 7.

[0111] Although not shown, alternatively or additionally, the dry electrode manufacturing system (500) may further include a second CPC (not shown) that aligns the position of the second electrode film (572) before bonding the first electrode film (522) to the current collector (532) and the second electrode film (572).

[0112] According to one embodiment, the dry electrode manufacturing system (500) may further include a second cutting unit (650) for sintering the second electrode film (572) to have a specific width. The second cutting unit (650) may include a leading alignment roller, a trimming device, and a trailing alignment roller, similar to the first cutting unit (350) of FIG. 3. The description of each component is the same as that described above with reference to FIG. 3. A portion of the cut second electrode film (572) may be separated into scrap (678) and removed. In addition, the cutting width of the second electrode film (572) may correspond to the cutting width of the first electrode film (522).

[0113] Here, the first laminating portion (540) and the second laminating portion (590) may be arranged spaced apart from each other. In contrast, in a manufacturing method in which dry electrode films (522, 572) are simultaneously laminated on both sides of a current collector (532), a highly difficult process of matching the alignment of the first electrode film (522) and the second electrode film (572) may be required.

[0114] In comparison, according to some embodiments of the present disclosure, in a process of sequentially laminating both sides of the current collector of an electrode through a separately separated laminating unit, process conditions and alignment conditions can be simplified to provide a dry electrode of uniform quality.

[0115] According to one embodiment, the dry electrode manufacturing system (500) may further include a second sensor (660) for detecting the bonding of the current collector (532) and the second electrode film (572). Here, the second sensor (660) may be positioned at the bottom of the second laminating unit (590). The second sensor (660) may include a vision sensor or a thickness sensor. Here, the vision sensor or the thickness sensor is as described above with reference to FIG. 3.

[0116] FIG. 7 is a drawing showing a first electrode film (722) and a second electrode film (772) according to one embodiment of the present disclosure.

[0117] Referring to FIG. 7, a second electrode film (772) according to one embodiment of the present disclosure can be coupled to correspond to the position of the first electrode film (722) disposed on the current collector (732).

[0118] Specifically, the CPC (734) can control the relative arrangement of the current collector (732) to which the first electrode film (722) is bonded with respect to the position of the second electrode film (772) before the current collector (732) to which the first electrode film (722) is bonded is supplied to the second laminating portion (not shown).

[0119] Here, the second electrode film (772) can be cut to have the same width as the first electrode film (722) by the second cutting portion (750), and the second electrode film (772) and the first electrode film (722) can face each other at the same position with the current collector (732) interposed therebetween after being combined. To this end, the first electrode film (722) and the second electrode film (772) can be laminated with the current collector (732) interposed at symmetrical positions.

[0120] FIG. 8 is a drawing showing a dry electrode manufacturing system according to one embodiment of the present disclosure.

[0121] Referring to FIG. 8, a dry electrode manufacturing system according to one embodiment of the present disclosure may further include a rewinding unit (820) for rewinding a dry electrode film (810) applied to a current collector (814). Here, the dry electrode film (810) may include a first electrode film (812) and a second electrode film (816).

[0122] The electrode can move in a constant direction and speed through the operation of the unwinding unit (803) that performs the function of unwinding the wound current collector (814) and the rewinding unit (820) that performs the function of rewinding the current collector (814) to which the first electrode film (812) and the second electrode film (816) are combined. Through this, the dry electrode manufacturing system can continuously perform the dry electrode manufacturing process.

[0123] A dry electrode manufacturing system according to one embodiment of the present disclosure may further include a density measuring device (830) that detects the bonding of the current collector (814) to which the first electrode film (812) is bonded and the second electrode film (816). For example, the density measuring device (830) may be a device that measures the density of the current collector (814) to which the first electrode film (812) and the second electrode film (816) are bonded using X-ray or Beta-ray. The density measuring device (830) can accurately measure and control the density of the dry electrode, thereby optimizing the performance of the dry electrode and maintaining consistent quality.

[0124] Although not shown, a dry electrode manufacturing system according to one embodiment of the present disclosure may include a plurality of dancers, guiders, and edge position controls (EPCs). The dancers can control the amount of tension applied to the electrodes so that the electrodes are supplied while maintaining a certain range of tension. For example, changes in the amount of tension applied to the electrodes supplied through the guiders create up-and-down or left-right movements of the dancers, and such movements can be detected by sensors or controllers to adjust the rotational speed and torque of the unwinding unit (803) and the rewinding unit (820).

[0125] EPC can detect the edge line of the electrode with an optical sensor, laser sensor, etc. during the movement of the electrode and adjust the position of the electrode to accurately maintain the alignment of the electrode.

[0126] Dancers, guides and EPCs may exist in various positions and arrangements depending on the manufacturing system, and may be equipped in multiples.

[0127] In addition, the description of the configuration is the same as the description described above with reference to FIGS. 1 to 7.

[0128] FIG. 9 is a flowchart illustrating an example of a method for manufacturing a dry electrode according to one embodiment of the present disclosure.

[0129] A dry electrode manufacturing method (900) according to one embodiment of the present disclosure may be initiated by supplying a first electrode powder containing an active material (S910). In one embodiment, the step of supplying the first electrode powder may include a step of supplying the first electrode powder perpendicular to the direction in which the process of pressurizing the first electrode powder to produce a first electrode film proceeds.

[0130] Afterwards, the first electrode powder can be pressurized to produce a first electrode film (S920).

[0131] After that, the entire house can be supplied (S930).

[0132] Afterwards, the current collector and the first electrode film can be combined (S940). The current collector and the first electrode film can be combined by heating by the laminating unit. Here, the unwinding unit that supplies the current collector can be positioned below the first calendaring unit that manufactures the first electrode film. A cooling and stabilization step can be performed on the current collector and the first electrode film that are heated and combined.

[0133] A dry electrode manufacturing method (900) according to one embodiment of the present disclosure further includes a step of firing a first electrode film to have a specific width, and the step of firing the first electrode film can be performed separately from the step of manufacturing the first electrode film.

[0134] A dry electrode manufacturing method (900) according to one embodiment of the present disclosure may further include a step of detecting the bonding of the current collector and the first electrode film.

[0135] A dry electrode manufacturing method (900) according to one embodiment of the present disclosure may further include a step of supplying a second electrode powder including an active material and a step of pressurizing the second electrode powder to produce a second electrode film.

[0136] A dry electrode manufacturing method (900) according to one embodiment of the present disclosure may further include a step of combining a current collector to which a first electrode film is combined and a second electrode film, and may further include a step of aligning a position of the second electrode film or the current collector before the step of combining the current collector and the second electrode film.

[0137] A secondary battery including a dry electrode manufactured according to one embodiment of the present disclosure may include a lithium battery cell, a sodium battery cell, and the like. However, the scope of the present disclosure is not limited thereto, and the secondary battery includes any battery capable of repeatedly providing electricity through charging and discharging. A secondary battery according to one embodiment may be applied to automobiles, mobile phones, and / or various types of electrical devices, and the present invention is not limited thereto.

[0138] Although the present invention has been described above with reference to limited embodiments and drawings, the present invention is not limited thereto, and various modifications and variations can be made by those skilled in the art within the scope of the technical idea of ​​the present invention and the equivalent scope of the claims to be described below. Those skilled in the art can make various substitutions, variations, and changes without departing from the technical idea of ​​the present invention, and therefore the present invention is not limited by the above-described embodiments and the attached drawings.

Claims

1. A first supply unit for supplying a first electrode powder containing an active material; A first calendaring unit that pressurizes the first electrode powder to produce a first electrode film; An unwinding section that supplies the entire collector; and A first laminating portion that combines the above-described collector and the first electrode film, A dry electrode manufacturing system, wherein the above unwinding section is positioned at the bottom of the first calendaring section.

2. In paragraph 1, A dry electrode manufacturing system, wherein the first laminating unit or the first calendaring unit is positioned at the bottom of the first supply unit.

3. In paragraph 2, A dry electrode manufacturing system, wherein the first electrode powder is supplied from the first supply unit to the first calendaring unit in a direction perpendicular to the direction in which the first electrode film is calendared.

4. In paragraph 1, Further comprising a first cutting section for firing the first electrode film to have a specific width, A dry electrode manufacturing system, wherein the first cutting portion is positioned spaced apart from the first calendaring portion.

5. In paragraph 4, The first cutting section includes a trimming device, A dry electrode manufacturing system, wherein the trimming device is disposed at the lower end of the first calendaring section.

6. In paragraph 1, Further comprising a first sensor for detecting the bonding of the above-mentioned collector and the first electrode film, A dry electrode manufacturing system, wherein the first sensor is positioned at the bottom of the first laminating portion.

7. In paragraph 6, A dry electrode manufacturing system, wherein the first sensor comprises a vision sensor or a thickness sensor.

8. In paragraph 1, A second supply unit for supplying a second electrode powder containing the above active material; and A second calendaring unit that pressurizes the second electrode powder to produce a second electrode film; A dry electrode manufacturing system further comprising:

9. In paragraph 8, A dry electrode manufacturing system further comprising a second laminating section that combines the current collector to which the first electrode film is combined and the second electrode film.

10. In paragraph 9, Before combining the current collector and the second electrode film to which the first electrode film is combined, a CPC (Center Position Control) is further included to align the position of the second electrode film or the current collector, A dry electrode manufacturing system, wherein the first laminating portion and the second laminating portion are spaced apart from each other.

11. In paragraph 10, A dry electrode manufacturing system, wherein the second electrode film is bonded to correspond to the position of the first electrode film disposed on the current collector.

12. In paragraph 8, Further comprising a second cutting section for firing the second electrode film to have a specific width, A dry electrode manufacturing system, wherein the cutting width of the second electrode film corresponds to the cutting width of the first electrode film.

13. In paragraph 1, A dry electrode manufacturing system further comprising a rewinding unit for rewinding the dry electrode film applied to the entire body.

14. In paragraph 9, A dry electrode manufacturing system further comprising a density measuring device that detects the bonding of the current collector and the second electrode film to which the first electrode film is bonded.

15. A step of supplying a first electrode powder containing an active material; A step of producing a first electrode film by pressurizing the first electrode powder; Step of supplying the entire house; and Including a step of combining the above-mentioned collector and the first electrode film, A dry electrode manufacturing method, wherein the unwinding unit supplying the above-mentioned current collector is positioned at the bottom of the first calendaring unit producing the first electrode film.

16. In paragraph 15, A dry electrode manufacturing method, wherein the step of supplying the first electrode powder includes a step of supplying the first electrode powder vertically compared to the progress direction of a process of producing the first electrode film by pressurizing the first electrode powder.

17. In paragraph 15, Further comprising a step of firing the first electrode film to have a specific width, A dry electrode manufacturing method, wherein the step of firing the first electrode film is performed separately from the step of manufacturing the first electrode film.

18. In paragraph 15, A dry electrode manufacturing method further comprising a step of detecting the bonding of the above-mentioned collector and the first electrode film.

19. In paragraph 15, A step of supplying a second electrode powder containing the above active material; and A step of producing a second electrode film by pressurizing the second electrode powder; A method for manufacturing a dry electrode, further comprising:

20. In paragraph 19, Further comprising a step of combining the current collector to which the first electrode film is combined and the second electrode film, A dry electrode manufacturing method, further comprising a step of aligning the position of the second electrode film or the current collector before the step of combining the current collector and the second electrode film.

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