Device and method for coating a battery film

Abstract

The invention relates to a device (BV) for coating a battery film, comprising: - a nozzle (D) which is designed to apply a coating material (BM) to the battery film (BF), - a first unit (DEV1) for deforming the battery film (BF) and / or a second unit (DEV2) for deforming a nozzle shape of the nozzle (D), and - a controller (R) which controls the first unit (DEV1) for deforming the battery film and / or the second unit (DEV2) for deforming the nozzle shape, wherein the battery film (BF) is deformed by the respective deforming unit (DEV1) in accordance with a first predefined deformation parameter and / or the nozzle shape is deformed by the respective deforming unit (DEV2) in accordance with a second predefined deformation parameter such that the coating material (BM), after being applied, has a predefined layer thickness (MD) on the battery film perpendicular to a coating direction. In particular, the first and / or second deformation parameter can be optimised by means of a simulation of the coating process.

Description

[0001] 202412292 Foreign version 24 Jul 2025

[0002] 1

[0003] Description

[0004] Device and method for coating a battery foil

[0005] The invention relates to a device and a method for coating a battery foil.

[0006] The production of batteries, such as lithium-ion batteries, is based on coating the battery electrodes. Electrode coating involves applying a coating material, known as a slurry, to a film to create a layer of active material that is as homogeneous and consistent as possible. This coating can be applied, for example, using a nozzle coating process. In this process, the coating material is applied to the film through a nozzle. The material flows continuously from the nozzle, with the film passing underneath it. Due to the surface tension of the slurry, the application of this viscous material to the film can lead to undesirable irregularities in the coating thickness, such as raised areas at the edges of the battery film.An inhomogeneous thickness of the foil coating can have a negative effect on the conductivity of the electrode.

[0007] It is therefore an object of the invention to enable a coating of the film with the slurry thickness to be as constant as possible.

[0008] The problem is solved by the measures described in the independent claims. Advantageous embodiments of the invention are described in the dependent claims.

[0009] According to a first aspect, the invention relates to a device for coating a battery foil, comprising: a nozzle configured to apply a coating material to the battery foil, a first unit for deforming the battery foil and / or a second unit for deforming a nozzle shape, and a controller that actuates the first unit for deforming the battery foil and / or the second unit for deforming the nozzle shape, wherein the battery foil is deformed by the respective deforming unit according to a first predetermined deformation parameter and / or the nozzle shape according to a second predetermined deformation parameter such that the coating material is applied according to the 202412292 Foreign version 24 Jul 2025

[0010] 2

[0011] Applying the coating perpendicular to a coating direction results in a predetermined layer thickness on the battery foil.

[0012] According to a second aspect, the invention relates to a method for coating a battery foil comprising the following process steps:

[0013] Deformation of the battery foil by a first deformation unit, wherein the battery foil is deformed according to a first predetermined deformation parameter such that the coating material has a predetermined layer thickness on the battery foil after application perpendicular to a coating direction, and / or deformation of a nozzle shape by a second deformation unit, wherein the nozzle is configured to apply a coating material to the battery foil, wherein the nozzle shape is deformed according to a second predetermined deformation parameter such that the coating material has a predetermined layer thickness on the battery foil after application perpendicular to a coating direction, and

[0014] Applying a coating material to the battery foil.

[0015] An advantage of the present invention is that a coating of the battery foil with a uniform layer thickness within a predetermined tolerance can be achieved, and irregularities in the layer thickness can be avoided or counteracted. In particular, this prevents rejects and / or improves the quality of the foil coating.

[0016] In an advantageous embodiment, the device can include a simulation unit configured to simulate the coating of the battery foil with the coating material using a computer-aided simulation model, depending on the specified first and / or second deformation parameter.

[0017] Thus, the coating process can be simulated using a computer. Among other things, the simulation results can include the expected layer thickness of the coating material. The coating process can be carried out from the outset without a lengthy, manual adjustment of the control parameters. This significantly reduces rejects. Furthermore, the use of such a simulation can shorten the commissioning time for the coating equipment. 202412292 Foreign version 24 Jul 2025

[0018] 3

[0019] In a further advantageous embodiment, the device can include an optimization unit configured to determine an optimized first and / or second deformation parameter by means of simulating the coating and to provide the optimized deformation parameters to the controller.

[0020] An optimization goal could be, for example, a predetermined homogeneous layer thickness of the coating.

[0021] In another embodiment, the computer-aided simulation model can be a 3D CFD simulation model (Computational Fluid Dynamics simulation).

[0022] This allows, in particular, the flow properties of the coating material to be simulated using computer technology.

[0023] In an alternative embodiment, the device can comprise a sensor and an analysis unit, wherein the sensor is configured to continuously measure the layer thickness of the coating material on the battery foil perpendicular to the coating direction, and the analysis unit is configured to determine the first and / or the second deformation parameter based on the measured layer thickness.

[0024] This allows for adjustments to the deformation of the nozzle shape and / or the battery foil during the coating process.

[0025] In one embodiment, the first and / or the second deformation parameter can be determined on the basis of artificial intelligence, wherein the artificial intelligence is trained to determine a first and / or second deformation parameter depending on a layer thickness perpendicular to the coating direction and / or a coating parameter.

[0026] This allows, in particular, for rapid control of the coating process.

[0027] In one embodiment, the first deformation parameter can be a deformation of a battery foil.

[0028] In particular, the first deformation parameter determines a deformation in a defined edge region of the battery foil. 202412292 Foreign version 24 Jul 2025

[0029] 4

[0030] In one embodiment, the second deformation parameter can determine a deformation of a cross-section of a nozzle exit surface of the nozzle.

[0031] Exemplary embodiments of the invention are shown in the drawings and are explained in more detail below. The drawings show:

[0032] Fig. 1A-C: a coating device from the prior art;

[0033] Fig. 2A-B: a first embodiment of the device according to the invention for coating a battery foil;

[0034] Fig. 3: a second embodiment of the device according to the invention for

[0035] Coating a battery foil; and

[0036] Fig. 4: an embodiment of the inventive method for coating a battery foil.

[0037] Corresponding parts are marked with the same reference symbols in all figures.

[0038] In particular, the following embodiments merely show exemplary implementation possibilities of how such implementations of the teaching according to the invention could look, since it is impossible and also not helpful or necessary for understanding the invention to name all these implementation possibilities.

[0039] Furthermore, a person skilled in the art, with knowledge of the method claim(s), will of course be aware of all the possibilities for realizing the invention that are customary in the prior art, so that in particular there is no need for a separate disclosure in the description.

[0040] Figure 1 shows the prior art. Figure 1A shows a cross-section along the coating direction of a prior art coating device for battery foils. The coating device comprises at least two rollers W1, W2, between which a battery foil BF is passed. Downstream, the coating device includes a nozzle D that applies a coating material BM to the coating foil. Figure 1B shows a top view of the battery foil after the coating material has been applied. Figure 1C shows a cross-section perpendicular to the 202412292 Foreign version 24 Jul 2025

[0041] 5

[0042] Longitudinal direction of the battery foil BF, along the section axis AA in Fig. 1B. When applying the coating material BM to the battery foil BF by a known coating device, irregularities in the coating material BM, in particular elevations at the edge of the coating foil BF, can occur.

[0043] Figure 2 shows a first embodiment of a device BV according to the invention for coating a battery foil. The invention can also be used, in particular, for coating foils of other types, wherein a foil is coated with a viscous material.

[0044] The coating device BV preferably comprises at least two rollers W1, W2, between which a battery foil BF is passed. The coating device BV further comprises at least one nozzle D, which is configured to apply coating material BM to the coating foil BF. The nozzle is preferably located downstream of the rollers W1, W2 in the coating device BV. After coating by the nozzle D, the coating material BM has a layer thickness MD perpendicular to the coating direction BR. The coating direction BR in Figure 2A is indicated by an arrow. The layer thickness MD is thus to be understood, in particular, as a layer thickness perpendicular to the surface of the battery foil BF or parallel to the surface of the battery foil and in each case perpendicular to the coating direction BR.

[0045] In particular, irregularities such as raised areas at the edges (i.e., variable layer thickness perpendicular to the film surface) and / or varying layer widths of the coating material BM transverse to the coating direction can occur during the application of the coating material BM through the nozzle D due to the material's toughness and surface tension (see Fig. 1). To avoid this, the coating device BV according to the invention comprises a first unit DEV1 for forming the battery film BF and / or a second unit DEV2 for forming a nozzle shape of the nozzle D. The forming units DEV1 and DEV2 are each controlled by a controller R.

[0046] The controller R controls the first unit DEV1 for deforming the battery foil BF as a function of a predetermined first deformation parameter P1, so that the battery foil BF is deformed according to the first predetermined deformation parameter P1, such that the coating material BM, after application perpendicular to the coating direction BR, has a predetermined layer thickness MD on the battery foil. The first unit DEV1 for deforming the battery foil BF is preferably located in the coating device BV.

[0047] 6 of the nozzle is arranged so that deformation of the battery foil BF occurs before coating.

[0048] Preferably, the battery foil BF is deformed only locally in a predetermined section BF' to compensate for irregularities in the application of the coating material BM in this section. For example, the battery foil BF is bent transversely to the coating direction BR so that the edges of the battery foil point downwards or upwards with respect to the nozzle D, as shown in Figure 1B. This locally lengthens or shortens the distance between the nozzle D and the battery foil BF, causing the coating material BM to be stretched or compressed during application. This results in a reduced or increased layer thickness.

[0049] The first unit DEV1 for deforming the battery foil BF can be configured as follows, for example. To deform the battery foil BF, one or more punches DEV1 can be positioned upstream of the nozzle. The punches DEV1 can be arranged, for example, below the foil BF. For instance, the punches are arranged in a row transverse to the coating direction BR. The punches can be moved vertically perpendicular to the foil surface, thus deforming the foil surface BF' at specific points so that, for example, no material ridges are created when the coating compound is applied. In other words, the deformed foil surface BF' is passed under the nozzle D. The material BM comes into contact with the deformed foil surface, thus compensating for any ridges or depressions in the applied material BM. The first deformation parameter P1 can, in particular, include the positioning of a punch DEV1.

[0050] The controller R also or alternatively controls the second unit DEV2 for deforming the nozzle shape of the nozzle D, wherein the nozzle shape is deformed by the unit DEV2 according to a second predetermined deformation parameter P2 such that the coating material BM has a predetermined layer thickness MD on the battery foil BF after application perpendicular to the coating direction BR through the nozzle deformed in this way.

[0051] For deforming the nozzle shape, a second deforming unit DEV2 is provided, for example an actuator, such as a piezo actuator, which can exert tension or pressure on the nozzle shape and thus influence the nozzle and the nozzle outflow.

[0052] Consequently, the film / film surface can be selectively deformed, or the nozzle shape can be chosen so that a homogeneous application of the coating material with a predetermined 202412292 Foreign version 24 Jul 2025

[0053] 7

[0054] The coating thickness is achieved by changing the shape of the nozzle, thus altering the volume flow across the nozzle cross-section, allowing for a reduced or increased layer thickness.

[0055] The first deformation parameter P1 and / or the second deformation parameter P2 are preferably provided in advance and passed via the controller R of the respective unit for deformation DEV1, DEV2.

[0056] The first deformation parameter P1, for example, determines a deformation in a defined edge region of the battery foil. In particular, the first deformation parameter P1 can include the position of a punch.

[0057] The second deformation parameter P2, for example, determines a deformation of a cross-section of a nozzle outlet surface of the nozzle D. For example, the second deformation parameter P2 specifies at what pressure and at which point on the nozzle the actuator should be applied.

[0058] Preferably, the first and / or the second deformation parameter P1, P2, is selected such that the coating material BM, after application perpendicular to the coating direction BR, has a layer thickness MD on the surface of the battery foil BF, wherein the layer thickness MD in a predetermined region of the surface of the battery foil BF has a value within a predetermined tolerance range. In other words, the first and / or the second deformation parameter P1, P2, are preferably dependent on a predetermined layer thickness MD of the coating material BM.

[0059] Preferably, the first deformation unit DEV1 and / or the second deformation unit DEV2 can be dynamically controlled by the controller R, so that in the event of parameter changes of the coating process, such as changes in ambient temperature, a corresponding deformation of the film and / or the nozzle can be adjusted.

[0060] The coating device BV can, in particular, include a simulation unit SIM, which is configured to simulate the coating of the battery foil BF with the coating material BM in the coating device BV using a computer-aided simulation model of the coating process, depending on the specified first deformation parameter P1 and / or second deformation parameter P2. The computer-aided simulation model can simulate the flow of the 202412292 Foreign version 24 Jul 2025

[0061] 8

[0062] The simulation model describes the application of coating material to the moving, possibly deformed, battery foil. The simulation model preferably comprises a CFD simulation model. Preferably, the computer simulation models the coating of the battery foil BF as a function of the first deformation parameter P1 and / or the second deformation parameter P2, as well as other predefined coating parameters, such as roller rotation speed, temperature, coating material properties, nozzle shape, etc. Thus, the computer simulation can be used to determine the expected coating thickness MD of the coating material for a given setting of the coating device BV. Furthermore, the positioning of the stamps DEV1 can be determined in advance using CFD simulation.

[0063] The coating device BV can further include an optimization unit OPT, which is configured to determine an optimized first deformation parameter P1 and / or second deformation parameter P2 by means of coating simulation and to provide the optimized deformation parameters P1opt, P2opt to the controller R. For example, an optimal position of each individual punch DEV1 can be determined using the optimization algorithm.

[0064] The coating can thus be simulated for various deformation parameters using computer software, and a simulation result, including at least one resulting layer thickness of the coating material, can be output for each scenario. From this, an optimized first and / or second deformation parameter, P1opt and P2opt, can be determined. The optimized first deformation parameter, P1opt, and / or the optimized second deformation parameter, P2opt, can then be passed to the controller, R, to regulate the coating process.

[0065] Figure 3 shows a further embodiment of the device BV according to the invention for coating a battery foil BF. Analogous to Figure 1A, Figure 2 schematically shows a coating device BV in cross-section along the coating direction BR. The coating device BV preferably comprises at least two rollers W1, W2, between which a battery foil BF is passed, and at least one nozzle D for coating the battery foil BF. After coating through the nozzle D, the coating material BM has a layer thickness MD perpendicular to the coating direction BR.

[0066] The coating device BV further comprises a first unit DEV1 for forming the battery foil BF / BF'. Additionally or alternatively, the coating device BV can also comprise a second unit DEV2 for forming a nozzle shape of the nozzle D. The two forming units DEV1 and DEV2 are controlled by a controller R depending on the respective forming parameters P1 and P2, as explained with reference to Figure 1. 202412292 Foreign version 24 Jul 2025

[0067] 9

[0068] The coating device BV also includes a sensor SE, such as a scanner or line sensor, which can determine the layer thickness MD of the coating material BM perpendicular to the coating direction on the battery foil BF. This enables measurement of the layer thickness MD during operation of the coating device BV. The measured layer thickness MD is transmitted to an analysis unit AE of the coating device BV. The analysis unit AE is configured to determine the first and / or the second deformation parameters P1 and P2 based on the measured layer thickness. For example, the position of a punch and / or the nozzle shape can be determined using the determined layer thickness MD.

[0069] The first and / or second deformation parameters P1, P2 can also be determined using artificial intelligence (AI). For example, the coating device BV includes a computing unit for executing the AI. The AI ​​can, for example, be an artificial neural network. The AI ​​is preferably trained on training data to determine a first and / or second deformation parameter P1, P2 depending on a determined (e.g., measured or simulated) layer thickness MD (perpendicular to the coating direction BR) and / or depending on a coating parameter, such as roller speed, distance between nozzle and film, processing temperature, coating material properties, nozzle shape, etc.

[0070] Figure 4 shows an embodiment of a method according to the invention for coating a battery foil with the following process steps:

[0071] Reading SO of a first and / or a second deformation parameter, deformation S1 of the battery foil by a first deformation unit controlled by a controller, wherein the battery foil is deformed according to the first deformation parameter such that the coating material has a predetermined layer thickness on the battery foil after application perpendicular to a coating direction, and / or deformation S2 of a nozzle shape by a second unit for deforming the nozzle shape, wherein the second unit is controlled by the controller, wherein the nozzle is configured to apply a coating material to the battery foil, wherein the nozzle shape is deformed according to the second deformation parameter such that the coating material has a predetermined layer thickness on the battery foil after application perpendicular to a coating direction, and

[0072] Application of a coating material (S3) to the battery foil. 202412292 Foreign version 24 Jul 2025

[0073] 10

[0074] All described and / or illustrated features can be advantageously combined within the scope of the invention. The invention is not limited to the described embodiments.

Claims

202412292 Foreign version 24 Jul 2025 11 Patent claims 1. Device (BV) for coating a battery foil, comprising: a nozzle (D) configured to apply a coating material (BM) to the battery foil (BF), a first unit (DEV1) for deforming the battery foil (BF) and / or a second unit (DEV2) for deforming a nozzle shape of the nozzle (D), and a controller (R) controlling the first unit (DEV1) for deforming the battery foil and / or the second unit (DEV2) for deforming the nozzle shape, wherein the battery foil (BF) is deformed by the respective deforming unit (DEV1, DEV2) according to a first predetermined deformation parameter (P1) and / or the nozzle shape according to a second predetermined deformation parameter (P2) such that the coating material (BM) has a predetermined layer thickness (MD) on the battery foil after application perpendicular to a coating direction. - a simulation unit (SIM) configured to simulate the coating of the battery foil (BF) with the coating material (BM) using a computer-aided simulation model as a function of the specified first deformation parameter (P1) and / or second deformation parameter (P2), and - an optimization unit (OPT) configured to determine an optimized first deformation parameter (P1) and / or second deformation parameter (P2) by means of coating simulation and to provide the optimized deformation parameters (P1opt, P2opt) to the controller (R).

2. Device according to claim 1, wherein the computer-aided simulation model is a 3D CFD simulation model.

3. Device according to claim 1, further comprising a sensor (SE) for continuously measuring the layer thickness (MD) of the coating material (BM) on the battery foil (BF) perpendicular to the coating direction and an analysis unit (AE) configured to determine the first and / or the second deformation parameter based on the measured layer thickness (MD).

4. Device according to one of the preceding claims, wherein the first and / or the second deformation parameter is determined on the basis of artificial intelligence (AI), wherein the 202412292 Foreign version 24 Jul 2025 12 artificial intelligence (AI) is trained to determine a first and / or second deformation parameter depending on a layer thickness (MD) perpendicular to the coating direction and / or a coating parameter.

5. Device according to one of the preceding claims, wherein the first deformation parameter determines a deformation of the battery foil.

6. Device according to one of the preceding claims, wherein the second deformation parameter determines a deformation of a cross-section of a nozzle exit surface of the nozzle.

7. Method for coating a battery foil using a device according to one of the preceding claims comprising the following method steps: Deformation (S1) of the battery foil by a first deformation unit (DEV1), wherein the battery foil is deformed according to a first predetermined deformation parameter such that the coating material has a predetermined layer thickness on the battery foil after application perpendicular to a coating direction, and / or deformation (S2) of a nozzle shape of a nozzle (D) by a second deformation unit (DEV2), wherein the nozzle (D) is configured to apply a coating material to the battery foil, wherein the nozzle shape is deformed according to a second predetermined deformation parameter such that the coating material has a predetermined layer thickness on the battery foil after application perpendicular to a coating direction, and Application (S3) of a coating material to the battery foil.

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