Electrode manufacturing apparatus

Abstract

An electrode manufacturing apparatus according to one embodiment of the present invention comprises: a plurality of rolls sequentially arranged; a first squeezer disposed on a preceding roll among the plurality of rolls, the first squeezer flattening a first electrode active material provided on a current collector to form a first electrode active material layer; and a second squeezer disposed on a following roll among the plurality of rolls, the second squeezer flattening a second electrode active material provided on the current collector or the first electrode active material to form a second electrode active material layer.

Description

Electrode manufacturing device

[0001] Cross-citation with related application(s)

[0002] This application claims the benefit of priority based on Korean Patent Application No. 10-2024-0131928 filed September 27, 2024, and all contents disclosed in the document of said Korean patent application are incorporated herein as part of this specification.

[0003] The present invention relates to an electrode manufacturing apparatus, and more specifically, to an electrode manufacturing apparatus having a plurality of layer structures.

[0004] In modern society, as the use of portable devices such as mobile phones, laptops, camcorders, and digital cameras, as well as energy storage systems (ESS), has become commonplace, the development of technologies in related fields is becoming active. Furthermore, rechargeable secondary batteries are being utilized as power sources for electric vehicles (EVs), hybrid electric vehicles (HEVs), and plug-in hybrid electric vehicles (P-HEVs) as a solution to address air pollution caused by conventional gasoline vehicles using fossil fuels; consequently, the need for the development of secondary batteries is increasing.

[0005] Currently commercialized rechargeable batteries include nickel-cadmium, nickel-hydrogen, nickel-zinc, and lithium-ion batteries. Among these, lithium-ion batteries are receiving the most attention due to their advantages of free charging and discharging, low self-discharge rate, and high energy density.

[0006] These lithium secondary batteries primarily use lithium-based oxides and carbon materials as the positive and negative active materials, respectively. The lithium secondary battery comprises an electrode assembly in which a positive plate and a negative plate, each coated with the positive and negative active materials, are arranged with a separator in between, and an outer casing, namely a battery case, that seals and houses the electrode assembly together with an electrolyte.

[0007] Generally, lithium secondary batteries can be classified according to the shape of the casing into can-type secondary batteries, in which the electrode assembly is embedded in a metal can, and pouch-type secondary batteries, in which the electrode assembly is embedded in a pouch of aluminum laminate sheet.

[0008] The manufacturing process of such lithium secondary batteries is broadly divided into three stages: electrode process, assembly process, and formation process. The electrode process is further divided into active material mixing process, electrode coating process, rolling process, slitting process, and winding process. Among these, the electrode coating process is divided into a wet process that provides an active material slurry to the electrode current collector and a dry process that provides the active material to the current collector in a solid state.

[0009] There is a need for a method to manufacture multiple layers of electrode active material by sequentially providing different types of electrode active materials in the electrode process.

[0010] The present invention aims to manufacture an electrode active material layer into a plurality of layers in an electrode process.

[0011] However, the problems that the embodiments of the present invention aim to solve are not limited to the problems described above and can be expanded in various ways within the scope of the technical ideas included in the present invention.

[0012] An electrode manufacturing apparatus according to one embodiment of the present invention may include: a plurality of rolls arranged in sequence; a first squeezer disposed on a leading roll among the plurality of rolls, which flattens a first electrode active material provided on a current collector to form a first electrode active material layer; and a second squeezer disposed on a trailing roll among the plurality of rolls, which flattens a second electrode active material provided on the current collector or the first electrode active material to form a second electrode active material layer.

[0013] The plurality of rolls includes a first roll, a second roll, and a third roll arranged in sequence, the first squeezer is located on the first roll, the second squeezer is located on the third roll, the second roll is interposed between the first roll and the third roll, and the first electrode active material layer and the current collector formed on the first roll can pass between the first roll and the second roll, then pass through the surface of at least a portion of the lower semicircle of the second roll, and then pass between the second roll and the third roll.

[0014] The above second roll may be provided as one or more.

[0015] The first squeezer may be positioned forward at a first predetermined angle based on an extension line connecting the center of the first roll to the uppermost surface of the first roll, and the second squeezer may be positioned forward at a second predetermined angle based on an extension line connecting the center of the third roll to the uppermost surface of the third roll.

[0016] The first predetermined angle above may be 0 degrees or more and 50 degrees or less, and the second predetermined angle above may be 0 degrees or more and 50 degrees or less.

[0017] The first electrode active material layer formed on the first roll can be calendered at least in one of passing between the first roll and the second roll and passing between the second roll and the third roll.

[0018] The above second roll may be a heating roll.

[0019] The second roll mentioned above may be a guide roll.

[0020] The plurality of rolls further include a fourth roll following the third roll, and the first electrode active material layer and the second electrode active material layer can be calendered while passing between the third roll and the fourth roll.

[0021] The apparatus further includes a first feeder for supplying the first electrode active material and a second feeder for supplying the second electrode active material, wherein the first feeder is located on an extension line connecting the center of the first roll to the uppermost surface of the first roll, or between an extension line connecting the center of the first roll to the uppermost surface of the first roll and an extension line connecting the center of the first roll to the squeezer, and the second feeder may be located on an extension line connecting the center of the third roll to the uppermost surface of the third roll, or between an extension line connecting the center of the third roll to the uppermost surface of the third roll and an extension line connecting the center of the third roll to the squeezer.

[0022] The plurality of rolls includes a first roll, a second roll, and a third roll arranged in sequence, the first squeezer is located on the first roll, the second squeezer is located on the second roll, and the first electrode active material layer and the current collector formed on the first roll can be moved to the uppermost surface of the second roll, spaced apart from the upper semicircle of the first roll.

[0023] The first squeezer may be located on an extension line connecting the center of the first roll to the uppermost surface of the first roll, or at a third predetermined angle relative to the extension line, and the second squeezer may be located forward at a second predetermined angle relative to an extension line connecting the center of the second roll to the uppermost surface of the second roll.

[0024] The third predetermined angle above may be -20 degrees or greater and 0 degrees or greater and 20 degrees or less, and the second predetermined angle above may be 0 degrees or greater and 50 degrees or less.

[0025] The first electrode active material layer and the second electrode active material layer can be calendered when passing between the second roll and the third roll.

[0026] The plurality of rolls further include a fourth roll following the third roll, and the first electrode active material layer and the second electrode active material layer can be calendered when passing between the third roll and the fourth roll.

[0027] The apparatus further includes a guide member interposed between the first roll and the second roll, and the first electrode active material layer formed in the first roll and the current collector can move to the second roll by passing through the guide member.

[0028] The apparatus further includes a first feeder for supplying the first electrode active material and a second feeder for supplying the second electrode active material, wherein the first feeder is positioned rearward at a fourth predetermined angle relative to an extension line connecting the center of the first roll to the uppermost surface of the first roll, and the second feeder may be positioned on an extension line connecting the center of the second roll to the uppermost surface of the second roll, or between an extension line connecting the center of the second roll to the uppermost surface of the second roll and an extension line connecting the center of the second roll to the squeezer.

[0029] At least one of the first squeezer and the second squeezer may include a roller.

[0030] The particle size of the first electrode active material and the particle size of the second electrode active material may be different.

[0031] The particle size of the first electrode active material may be larger than the particle size of the second electrode active material.

[0032] The composition of the first electrode active material and the composition of the second electrode active material may be different.

[0033] Each of the first electrode active material and the second electrode active material may be an electrode active material powder for a dry electrode manufacturing process.

[0034] According to the present invention, the electrode active material layer can be manufactured into a plurality of layers in an electrode process.

[0035] In addition, according to the present invention, an electrode active material layer having a more uniform porosity can be manufactured in a dry electrode process, and the quality of the electrode and electrode assembly manufactured accordingly can also be improved.

[0036] The effects of the present invention are not limited to those mentioned above, and other unmentioned effects will be clearly understood by those skilled in the art from the description in the claims.

[0037] FIG. 1 is a schematic diagram of an electrode manufacturing apparatus according to one embodiment of the present invention.

[0038] Figure 2 illustrates a modified embodiment of Figure 1.

[0039] FIG. 3 is a schematic diagram of an electrode manufacturing apparatus according to another embodiment of the present invention.

[0040] Figure 4 illustrates a modified embodiment of Figure 3.

[0041] Figure 5 is a partial enlarged view of Figure 3.

[0042] FIG. 6 illustrates another modified embodiment of FIG. 3.

[0043] Fig. 7 illustrates another modified embodiment of Fig. 3.

[0044] FIG. 8 illustrates a modified embodiment of FIG. 7.

[0045] FIG. 9 is a vertical cross-sectional view of the first electrode active material layer (11) and current collector (10) manufactured in the embodiments of FIG. 1 to 8.

[0046] FIG. 10 is a vertical cross-sectional view of an electrode (1) manufactured in the embodiments of FIG. 1 to 8.

[0047] FIG. 11 is a reference diagram relating to the feeder in the embodiments of FIG. 1 to 8.

[0048] Hereinafter, various embodiments of the present invention will be described in detail with reference to the attached drawings so that those skilled in the art can easily implement the present invention. The present invention may be embodied in various different forms and is not limited to the embodiments described herein.

[0049] To clearly explain the present invention, parts unrelated to the explanation have been omitted, and the same reference numerals are used for identical or similar components throughout the specification.

[0050] Furthermore, the size and thickness of each component shown in the drawings are depicted arbitrarily for convenience of explanation, and thus the present invention is not necessarily limited to what is illustrated. Thicknesses have been enlarged in the drawings to clearly represent various layers and regions. Additionally, for convenience of explanation, the thickness of some layers and regions has been exaggerated in the drawings.

[0051] Furthermore, when a part such as a layer, membrane, region, or plate is said to be "on" or "on" another part, this includes not only the case where it is "directly above" the other part, but also the case where there is another part in between. Conversely, when a part is said to be "directly above" another part, it means that there is no other part in between. Also, saying that a part is "on" or "on" a reference part means that it is located above or below the reference part, and does not necessarily mean that it is located "on" or "on" facing the opposite direction of gravity.

[0052] Furthermore, throughout the specification, when a part is described as "including" a certain component, this means that, unless specifically stated otherwise, it does not exclude other components but may include additional components.

[0053] Additionally, throughout the specification, "planar" means when the subject part is viewed from above, and "cross-sectional" means when the cross-section obtained by vertically cutting the subject part is viewed from the side.

[0054] Hereinafter, embodiments of the present invention will be described with reference to the drawings.

[0055] FIG. 1 is a schematic diagram of an electrode manufacturing apparatus (100) according to one embodiment of the present invention. FIG. 3 is a schematic diagram of an electrode manufacturing apparatus (100) according to another embodiment of the present invention.

[0056] Referring to FIGS. 1 and FIGS. 3, the electrode manufacturing apparatus (100) includes a plurality of rolls arranged in sequence. According to the present invention, among the plurality of rolls arranged in sequence, a first electrode active material (1) is provided in a preceding roll, and a second electrode active material (2) is provided in a succeeding roll.

[0057] To elaborate, a current collector (10) is provided to a plurality of rolls arranged sequentially in an electrode manufacturing device (100). In the preceding roll, a first electrode active material (1) is provided on the current collector (10) to form a first electrode active material layer (11) (see FIG. 9). Additionally, in the subsequent roll, a second electrode active material (2) is provided on the current collector (10) or the first electrode active material (1) to form a second electrode active material layer (12) (see FIG. 10).

[0058] To elaborate, the second electrode active material (2) is provided on the first electrode active material layer (11), so that the electrode (1) can be formed in the order of the current collector (10), the first electrode active material layer (11), and the second electrode active material layer (12) (see FIG. 10). However, the present invention is not necessarily limited thereto, and various modifications and changes are possible to suit the electrode (1) to be manufactured in the electrode manufacturing device (100) of the present invention.

[0059] For example, in a preceding roll, a first electrode active material layer (11) may be primarily provided on a current collector (10), but for a certain purpose or function, a portion of the current collector (10) may not have the first electrode active material (1) provided and may form an exposed portion of the current collector (10), and in a subsequent roll, a second electrode active material (2) may be provided on the exposed portion of the current collector (10) to form a second electrode active material layer (12), and various modifications and changes are possible.

[0060] In addition, the present invention is not limited to cases where only two active material layers, a first electrode active material layer (11) and a second electrode active material layer (12), are provided on the current collector (10) as illustrated, but can be applied in various ways, such as cases where at least three active material layers are formed.

[0061] A plurality of rolls includes at least a first roll (110), a second roll (120), and a third roll (130), and in some cases, may additionally include a fourth roll (140). A plurality of rolls are arranged sequentially, for example, in the order of the first roll (110), the second roll (120), the third roll (130), and additionally the fourth roll (140), as illustrated exemplarily in FIGS. 1 and FIGS. 3.

[0062] Among a plurality of rolls, a first electrode active material (1) is provided on a current collector (10) in a preceding roll, and the first electrode active material (1) is flattened by a first squeezer (160) to form a first electrode active material layer (11). In addition, a second electrode active material (2) is provided on a current collector (10) in a succeeding roll, and the second electrode active material (2) is flattened by a second squeezer (180) to form a second electrode active material layer (12). Each of the first squeezer (160) and the second squeezer (180) may be in the form of a roller as shown in FIGS. 1 and FIGS. 3, but the present invention is not limited to what is shown, and it is sufficient to have a structure and shape capable of flattening each of the first electrode active material layer (11) and the second electrode active material (12).

[0063]

[0064] First, an embodiment of FIG. 1 is described. FIG. 2 is a modified embodiment of FIG. 1. According to the embodiment of FIG. 1, the first roll (110) is a leading roll for forming a first electrode active material layer (11), and the third roll (130) is a trailing roll for forming a second electrode active material layer (12). Additionally, at least one second roll (120) is interposed between the leading roll and the trailing roll, and the first electrode active material layer (11) formed in the first roll (110), which is the leading roll, passes over at least a portion of the surface of the lower semicircle of the at least one second roll (120) before entering the third roll (130), which is the trailing roll.

[0065] First, a first feeder (150) and a first squeezer (160) that provide a first electrode active material (1) are positioned on a first roll (110).

[0066] The first feeder (150) stores the first electrode active material (1) inside and supplies the first electrode active material (1) onto a current collector (10) passing over the surface of the first roll (110). The first electrode active material (1) supplied onto the current collector (10) on the first roll (110) is flattened as it passes between the first roll (110) and the first squeezer (160). Accordingly, a layer of the first electrode active material (11) is formed on the current collector (10).

[0067] Additionally, a second feeder (170) and a second squeezer (180) that provide the second electrode active material (2) are located on the third roll (130).

[0068] The second feeder (170) stores the second electrode active material (2) inside and supplies the second electrode active material (2) onto the current collector (10) passing over the surface of the third roll (130). The second electrode active material (2) supplied onto the current collector (10) on the third roll (130) is flattened as it passes between the third roll (130) and the second squeezer (180). Accordingly, a second electrode active material layer (12) is formed on the current collector (10).

[0069] In the specification of the present invention, the phrase “a second electrode active material layer (12) is formed on a current collector (10)” is not limited to cases where the second electrode active material layer (12) is formed by direct contact with the current collector (10) without interposing another layer, but also includes cases where the second electrode active material layer (12) is formed by interposing another layer on the current collector (10). For example, when the second electrode active material (2) is supplied when the current collector (10) and the first electrode active material layer (11) formed thereon pass over the third roll (130), the second electrode active material layer (12) is formed on the first electrode active material layer (11).

[0070] The first feeder (150) is positioned on the first roll (110). At this time, the first roll (110) serves as a leading roll for forming the first electrode active material layer (11). The first squeezer (160) is spaced apart from the first feeder (150) and positioned in front of the first feeder (150). Additionally, the second feeder (170) is positioned on the third roll (130). At this time, the third roll (130) serves as a trailing roll for forming the second electrode active material layer (12). The second squeezer (180) is spaced apart from the second feeder (170) and positioned in front of the second feeder (170).

[0071] In the specification of the present invention, “forward” means positioned in the direction of travel of the electrode, and “backward” means positioned in the opposite direction to the direction of travel of the electrode.

[0072] Additionally, referring to FIG. 11, the meaning of “the feeder is positioned on the roll” in the specification of the present invention includes, but is not limited to, the case where it is positioned on the extension line (vertical axis) connecting the center of the roll to the top surface of the roll as shown in FIG. 11 (a), and is located near the extension line connecting the center of the roll to the top surface of the roll, in the front (Fig. 11 (b)) or rear (Fig. 11 (c)), and it is sufficient if it is positioned in a location where it can supply electrode active material onto the roll.

[0073] In the embodiment of FIG. 1, the first squeezer (160) is located in front of the first roll (110).

[0074] The extension line connecting the center of the first roll (110) to the first squeezer (160) has a first predetermined angle (θ1) based on the extension line (vertical axis) connecting the center of the first roll (110) to the uppermost surface of the first roll (110). The first predetermined angle (θ1) may be, for example, 0 degrees or more and 50 degrees or less, or, for example, 5 degrees or more and 45 degrees or less, or, for example, 5 degrees or more and 30 degrees or less. In addition, the first squeezer (160) is positioned at a first predetermined angle (θ1) tilted forward based on the extension line (vertical axis) connecting the center of the first roll (110) to the uppermost surface of the first roll (110).

[0075] Additionally, as described above, the first feeder (150) is positioned on the first roll (110). More specifically, for example, the first feeder (150) may be positioned on an extension line (vertical axis) connecting the uppermost surface of the first roll (110), or between the extension line (vertical axis) connecting the uppermost surface of the first roll (110) and the extension line connecting the center of the first roll (110) to the first squeezer (160).

[0076] The first electrode active material (1) supplied onto the current collector (10) which is placed on the surface of the first roll (110) and passes through the outlet of the first feeder (150) is accumulated between the outlet of the first feeder (150) and the first squeezer (160) and is flattened as it passes between the first roll (110) and the first squeezer (160).

[0077] Additionally, as described above, the first electrode active material layer (11) formed in the first roll (110) passes over at least a portion of the surface of the lower semicircle of at least one second roll (120) before entering the third roll (130). The second roll (120) may be a single roll as shown in FIG. 1, but in some cases, as shown in FIG. 2, a plurality of second rolls (120; 120-1, 120-2) may be provided, and various modifications and changes are possible to suit the environment in which the present invention is implemented.

[0078] The first electrode active material layer (11) formed in the first roll (110) moves along the surface of at least a portion of the upper quarter of the first roll (110) and passes between the first roll (110) and the second roll (120). At this time, the first electrode active material layer (11) can be calendered while passing between the first roll (110) and the second roll (120). That is, the second roll (120) may be a calendering roll.

[0079] However, the present invention is not limited thereto, and depending on the case, the first electrode active material layer (11) does not necessarily have to be calendered while passing between the first roll (110) and the second roll (120), and the second roll (120) may have a guide function (a guide function for the current collector (10) and the first electrode active material layer (11) formed thereon to enter the third roll (130), and may have a heating function, and various modifications and changes are possible.

[0080] Meanwhile, as the first electrode active material layer (11) moves along the lower semicircle of the second roll (120), there may be a risk of point defects, such as voids, occurring. To prevent this, the first roll (110) and / or the second roll (120) may be heated to soften the first electrode active material layer (11), or the first electrode active material (1) stored inside the first feeder (150) may be heated to make the first electrode active material (1) flexible.

[0081] Alternatively, as shown in FIG. 2, if a plurality of second rolls (120) are provided, abrupt bending of the first electrode active material layer (11) passing through at least a portion of the lower semicircle of the second roll (120) may be prevented.

[0082] Next, the first electrode active material layer (11) passing over the surface of at least the lower semicircle of the second roll (120) passes between the second roll (120) and the third roll (130). At this time, if necessary, calendering may be performed while passing between the second roll (120) and the third roll (130), but the present invention is not limited thereto and various modifications and changes are possible.

[0083] In addition, in the embodiment of FIG. 1, the second squeezer (180) is located in front of the third roll (130).

[0084] The extension line connecting the center of the third roll (130) to the second squeezer (180) has a second predetermined angle (θ2) based on the extension line (vertical axis) connecting the center of the third roll (130) to the uppermost surface of the third roll (130). The second predetermined angle (θ2) may be, for example, 0 degrees or more and less than 50 degrees, or, for example, 5 degrees or more and less than 45 degrees. To elaborate, the second squeezer (180) is positioned at a second predetermined angle (θ2) tilted forward based on the extension line (vertical axis) connecting the center of the third roll (130) to the uppermost surface of the third roll (130).

[0085] Additionally, as described above, the second feeder (170) is positioned above the third roll (130). More specifically, for example, the second feeder (170) may be positioned between an extension line (vertical axis) connecting the uppermost surface of the third roll (130) and an extension line connecting the center of the third roll (130) to the second squeezer (180).

[0086] The second electrode active material (2) supplied onto the current collector (10) which is placed on the surface of the third roll (130) and passes through the outlet of the second feeder (170) is accumulated between the outlet of the second feeder (170) and the second squeezer (180) and is flattened as it passes between the third roll (130) and the second squeezer (180).

[0087] In addition, in the embodiment of FIG. 1, the second electrode active material layer (12) formed on the surface of the third roll (130) passes between the third roll (130) and the fourth roll (140). At this time, the second electrode active material layer (12) can be calendered while passing between the third roll (130) and the fourth roll (140). That is, the fourth roll (140) can be a calendering roll. Also, at this time, the first electrode active material layer (11) can also be additionally calendered.

[0088] However, the present invention is not limited thereto, and in some cases, the second electrode active material layer (12) does not necessarily have to be calendered while passing between the third roll (130) and the fourth roll (140), but may be calendered in a subsequent process. In such cases, various modifications and changes are possible, such as the fourth roll (140) having a guide function (a guide function for entering the device of the subsequent process) or a heating function.

[0089]

[0090] Next, an embodiment of FIG. 3 will be described. FIG. 4 is a modified embodiment of FIG. 3. FIG. 5 is a partial enlarged view of FIG. 3. FIG. 6 is another modified embodiment of FIG. 3.

[0091] According to the embodiment of FIG. 3, the first roll (110) becomes a leading roll for forming the first electrode active material layer (11), and the second roll (120) becomes a trailing roll for forming the second electrode active material layer (12). In the embodiment of FIG. 3, unlike the embodiment of FIG. 1, the first electrode active material layer (11) formed in the leading roll does not pass over the surface of at least a portion of the lower semicircle of at least one roll interposed between the leading roll and the trailing roll, and moves to the trailing roll.

[0092] First, a first feeder (150) and a first squeezer (160) that provide a first electrode active material (1) are positioned on a first roll (110). Meanwhile, in the embodiment of FIG. 3, a second feeder (170) and a second squeezer (180) that provide a second electrode active material (2) are positioned on a second roll (120).

[0093] The first feeder (150) stores the first electrode active material (1) inside and supplies the first electrode active material (1) onto a current collector (10) passing over the surface of the first roll (110). The first electrode active material (1) supplied onto the current collector (10) on the first roll (110) is flattened as it passes between the first roll (110) and the first squeezer (160). Accordingly, a layer of the first electrode active material (11) is formed on the current collector (10).

[0094] The second feeder (170) stores the second electrode active material (2) inside and supplies the second electrode active material (2) onto the current collector (10) or the first electrode active material layer (11) passing over the surface of the second roll (120). The second electrode active material (2) supplied onto the current collector (10) on the second roll (120) is flattened as it passes between the second roll (120) and the second squeezer (180). Accordingly, the second electrode active material layer (12) is formed on the current collector (10).

[0095] As described above in FIG. 1, the specification of the present invention states that “a second electrode active material layer (12) is formed on a current collector (10)” is not limited to cases where the second electrode active material layer (12) is formed by direct contact with the current collector (10) without interposing another layer, but also includes cases where the second electrode active material layer (12) is formed by interposing another layer on the current collector (10).

[0096] The first feeder (150) is positioned above the first roll (110). For reference, possible positions of the first feeder (150) refer to (a) or (c) of FIG. 11. The first squeezer (160) is spaced apart from the first feeder (150) and positioned in front of the first feeder (150).

[0097] Additionally, the second feeder (170) is positioned above the second roll (120). The second squeezer (180) is spaced apart from the second feeder (170) and is positioned in front of the second feeder (170).

[0098] Meanwhile, in the embodiment of FIG. 3, the first squeezer (160) is located on or near the uppermost surface of the first roll (110) (on the extension line (vertical axis) connecting the center of the first roll (110) to the uppermost surface of the first roll (110).

[0099] To elaborate, it is preferable that the first squeezer (160) be positioned on the uppermost surface of the first roll (110). This is because the first electrode active material layer (11) and the current collector (10), which are flattened while passing between the first roll (110) and the first squeezer (160), move to the subsequent roll while being spaced apart from the surface of the upper semicircle of the first roll (110) at the position in front of the first roll (110).

[0100] However, depending on the type and composition ratio of the first electrode active material (1) or the radius of the first roll (110) or other process conditions, if the adhesion between the first squeezer (160) and the current collector (10) is good, the first squeezer (160) may be positioned near the front of the extension line connecting the center of the first roll (110) to the uppermost surface of the first roll (110), as shown in FIG. 4 (a). At this time, the third predetermined angle (θ3) may be, for example, 0 degrees or more and 20 degrees or less with respect to the extension line (vertical axis) connecting the center of the first roll (110) to the uppermost surface of the first roll (110).

[0101] Alternatively, as illustrated in FIG. 4(b), the first squeezer (160) may be positioned near the rear of the extension line connecting the center of the first roll (110) to the uppermost surface of the first roll (110). In this case, the third predetermined angle (θ3) may be, for example, 0 degrees or more and -20 degrees or less with respect to the extension line (vertical axis) connecting the center of the first roll (110) to the uppermost surface of the first roll (110). In summary, the third predetermined angle (θ3) may be 20 degrees or more and 20 degrees or less.

[0102] Referring again to FIG. 3, the first feeder (150) is positioned on the first roll (110). More specifically, the first feeder (150) may be positioned on an extension line (vertical axis) connecting the uppermost surface of the first roll (110), or positioned behind the extension line (vertical axis) connecting the uppermost surface of the first roll (110).

[0103] Referring to the partial enlarged view of FIG. 5, the first feeder (150) is positioned behind the extension line (vertical axis) connecting the center of the first roll (110) to the uppermost surface of the first roll (110). With respect to the extension line (vertical axis) connecting the center of the first roll (110) to the uppermost surface of the first roll (110), the extension line connecting the center of the first roll (110) to the first feeder (150) has a fourth predetermined angle (θ4). The fourth predetermined angle (θ4) may be, for example, between -50 degrees and 5 degrees, or, for example, between -45 degrees and -5 degrees, or, for example, between -30 degrees and -5 degrees.

[0104] Meanwhile, to prevent the first electrode active material (1) supplied from the first feeder (150) onto the current collector (10) from unintentionally flowing down to the rear of the first roll (110) along the inclined current collector (10), it may be implemented in a modified embodiment as shown in FIG. 6.

[0105] As illustrated in FIG. 6(a), a blocking member (151) may be additionally provided. By additionally providing a blocking member (151) on the first roll (110), the first electrode active material (1) supplied from the first feeder (150) can be prevented from flowing out of the first roll (110) along the curved surface of the first roll (110).

[0106] Alternatively, as shown in FIG. 6(b), this problem may be prevented by adjusting the supply angle of the current collector (10).

[0107] The first electrode active material (1) supplied onto the current collector (10) which is placed on the surface of the first roll (110) and passes through the outlet of the first feeder (150) is accumulated between the outlet of the first feeder (150) and the first squeezer (160) and is flattened as it passes between the first roll (110) and the first squeezer (160).

[0108] In addition, in the embodiment of FIG. 3, the first electrode active material layer (11) formed in the first roll (110) is spaced apart from the surface of the upper quarter of the first roll (110) and moves to a subsequent roll to form a second electrode active material layer (12). As described above, in the embodiment of FIG. 3, the second roll (120) becomes the subsequent roll to form the second electrode active material layer (12).

[0109] The current collector (10) and the first electrode active material layer (11) above it, which are moved apart from the surface of the upper rear quadrant of the first roll (110), move to the uppermost surface of the second roll (120).

[0110] In addition, in the embodiment of FIG. 3, the second squeezer (180) is located in front of the second roll (120).

[0111] The extension line connecting the center of the second roll (120) to the second squeezer (180) has a second predetermined angle (θ2) based on the extension line (vertical axis) connecting the center of the second roll (120) to the uppermost surface of the second roll (120). The second predetermined angle (θ2) may be, for example, 0 degrees or more and 50 degrees or less, or, for example, 5 degrees or more and 45 degrees or less, or, for example, 5 degrees or more and 30 degrees or less. In addition, the second squeezer (180) is positioned at a second predetermined angle (θ2) tilted forward based on the extension line (vertical axis) connecting the center of the second roll (120) to the uppermost surface of the second roll (120).

[0112] Additionally, as described above, the second feeder (170) is positioned on the second roll (120). More specifically, for example, the second feeder (170) may be positioned between an extension line (vertical axis) connecting the uppermost surface of the second roll (120) and an extension line connecting the center of the second roll (120) to the second squeezer (180). Refer to (a) to (c) of FIG. 11 for the position of the second feeder (170).

[0113] The second electrode active material (2) supplied onto the current collector (10) which is placed on the surface of the second roll (120) and passes through the outlet of the second feeder (170) is stacked between the outlet of the second feeder (170) and the second squeezer (180) and is flattened as it passes between the second roll (120) and the second squeezer (180).

[0114] Additionally, in the embodiment of FIG. 3, the second electrode active material layer (12) formed on the surface of the second roll (120), the first electrode active material layer (11), and the current collector (10) pass between the second roll (120) and the third roll (130). At this time, the first electrode active material layer (11) and the second electrode active material layer (12) can be calendered while passing between the second roll (120) and the third roll (130). That is, the third roll (130) may be a calendering roll.

[0115] However, the present invention is not limited thereto, and depending on the case, the second electrode active material layer (12) does not necessarily have to be calendered while passing between the second roll (120) and the third roll (130), and the third roll (130) may have a guide function (in which case calendering may be performed at a subsequent roll of the third roll (130)), or may have a heating function, and various modifications and changes are possible.

[0116] Meanwhile, as the first electrode active material layer (11) and / or the second electrode active material layer (12) moves along the lower semicircle of the third roll (130), there may be a risk of point defects, such as voids, occurring. To prevent this, the first roll (110) and / or the second roll (120) and / or the third roll (130) may be heated to soften the first electrode active material layer (11) and / or the second electrode active material layer (12), or the first electrode active material (1) and / or the second electrode active material (2) originally stored inside the first feeder (150) may be heated to soften the first electrode active material (1) and / or the second electrode active material (2) originally stored inside the second feeder (150).

[0117] Next, the second electrode active material layer (12), the first electrode active material layer (11), and the current collector (10) may pass between the second roll (120) and the third roll (130), and then additionally pass between the third roll (130) and the fourth roll (140). At this time, if necessary, calendering may be performed while passing between the third roll (130) and the fourth roll (140), but the fourth roll (140) may only serve as a guide to a subsequent process, and the present invention is not limited thereto and various modifications and changes are possible.

[0118] Referring to FIG. 7, FIG. 7 illustrates another modified embodiment of FIG. 3, wherein at least one guide member (190) is further included between the first roll (110) and the second roll (120) in the embodiment of FIG. 3. The guide member (190) may be in the form of, for example, one or a plurality of small guide rollers as shown in FIG. 7. When the distance between the first roll (110) and the second roll (120) increases during the path of the current collector (10) and the first electrode active material layer (11) above it moving from the first roll (110) to the second roll (120), the current collector (10) and the first electrode active material layer (11) above it may sag downward. By providing at least one guide member (190) between the first roll (110) and the second roll (120), such concerns can be prevented.

[0119] FIG. 8 is a modified embodiment of FIG. 7, wherein the guide member (190) may be a roll having a diameter substantially equal to the diameter of the first roll (110) and / or the diameter of the second roll (120). The difference between the guide member (190) of FIG. 8 and the second roll (120, FIG. 1) positioned secondly in FIG. 1 is whether the first electrode active material layer (11) formed in the first roll (110) passes over the surface of at least a portion of the upper semicircle of the roll or over the surface of at least a portion of the lower semicircle.

[0120] Meanwhile, the guide member (190) of the present invention is not limited to what is illustrated and can be modified or changed to suit the environment in which the present invention is implemented. Although not illustrated in the specification of the present invention, it may be in the form of a conveyor, and it is sufficient if it can transfer the current collector (10) and the first electrode active material layer (11) thereon from the first roll (110) to the second roll (120), and various modifications or changes are possible to suit the environment in which the present invention is implemented.

[0121] Additionally, the guide member (190) may be one or multiple, and there is no limit to the number of guide members (190).

[0122]

[0123] FIG. 9 is a vertical cross-sectional view of the first electrode active material layer (11) and current collector (10) manufactured in the embodiments described above. It corresponds to an enlarged conceptual view of the part labeled A in FIG. 1 and FIG. 3.

[0124] FIG. 10 is a vertical cross-sectional view of the electrode (1) manufactured in the above-described embodiment. It corresponds to an enlarged conceptual view of the part labeled B in FIG. 1 and FIG. 3.

[0125] The electrode (1) manufactured in the above-described embodiments comprises a plurality of electrode active material layers on a current collector (10). For example, as shown in FIG. 10, the electrode (1) comprises a first electrode active material layer (11) and a second electrode active material layer (12) formed on the current collector (10).

[0126] In the embodiments described above, the first electrode active material layer (11) is manufactured in a preceding roll, and the second electrode active material layer (12) is manufactured in a succeeding roll. The second electrode active material layer (12) may be formed on the first electrode active material layer (11), but in some cases, the second electrode active material layer (12) may be formed on the current collector (1) without interposing the first electrode active material layer (11) in some regions of the electrode (1).

[0127] Meanwhile, in the electrode (1) having a plurality of layer structures, each layer may be a layer having a different particle size, for example. That is, the plurality of electrode active material layers may have the same composition but different particle sizes.

[0128] For example, the particle size of the first electrode active material (1) forming the first electrode active material layer (11) may be larger than the particle size of the second electrode active material (2) forming the second electrode active material layer (12).

[0129] In conventional technology, a single layer of electrode active material was fabricated on a current collector in a single step. In this conventional technology, when the electrode active material provided on the current collector passes through a squeezer, small particles are mainly located close to the bottom surface of the current collector, while large particles are mainly coated on the upper surface of the electrode active material layer. Consequently, in the conventional technology, the electrode active material layer did not have a uniform porosity when viewed in a vertical cross-section, which caused a degradation in the quality of the electrode.

[0130] On the other hand, in the case of the present invention, a first electrode active material (1) having a relatively larger particle size is first supplied onto a current collector (10) from a first feeder (150), and a second electrode active material (2) having a relatively smaller particle size is supplied onto it from a second feeder (170), so that the electrode active material layer of the electrode (1) that has passed through the second squeezer (180) can ultimately have a more uniform porosity.

[0131] Meanwhile, the present invention is not limited to the above description, and in accordance with the specifications of the electrode to be manufactured, in the opposite case to the above description, a first electrode active material (1) having a relatively smaller particle size is first supplied onto a current collector (10) from a first feeder (150), and a second electrode active material (2) having a relatively larger particle size is supplied onto it from a second feeder (170).

[0132] Alternatively, in some cases, the first electrode active material (1) and the second electrode active material (2) may be a mixture having different compositions.

[0133] In addition, the first electrode active material (1) and the second electrode active material (2) may each be, for example, an electrode active material powder used in a dry electrode manufacturing process.

[0134] That is, the embodiments of the present invention described above can be applied, for example, to a manufacturing process of a dry electrode.

[0135] The electrode according to the present invention may be an anode or a cathode. That is, the manufacturing process of the electrode according to the present invention is not particularly limited to an anode or a cathode and can be easily applied to the manufacture of any electrode, and different electrodes can be manufactured depending on the material used in the manufacture of each electrode (e.g., an anode active material or a cathode active material). Accordingly, the term "electrode" used in the electrode, electrode active material, electrode current collector, etc. in this specification may mean both an anode and a cathode unless specifically defined otherwise.

[0136] In the manufacturing process of the dry electrode of the present invention, an electrode active material and a binder polymer, etc. are dry-mixed to obtain a mixture.

[0137] Any material containing lithium capable of absorbing and releasing lithium ions can be used as the cathode active material. For example, the cathode active material may be a layered compound such as lithium cobalt oxide (LiCoO2) or lithium nickel oxide (LiNiO2), or a compound substituted with one or more transition metals; chemical formula Li 1+x Mn 2-x Lithium manganese oxides such as O4 (where x is 0 to 0.33), LiMnO3, LiMn2O3, LiMnO2, etc.; lithium copper oxide (Li2CuO2); vanadium oxides such as LiV3O8, LiFe3O4, V2O5, Cu2V2O7, etc.; chemical formula LiNi 1-x M x Ni-site type lithium nickel oxide represented by O2 (where M = Co, Mn, Al, Cu, Fe, Mg, B, or Ga, and x = 0.01 ~ 0.3); chemical formula LiMn 2-x M x Lithium manganese composite oxide represented by O2 (where M = Co, Ni, Fe, Cr, Zn, or Ta, and x = 0.01 to 0.1) or Li2Mn3MO8 (where M = Fe, Co, Ni, Cu, or Zn); LiNi x Mn2-x It may include, but is not limited to, a lithium manganese composite oxide with a spinel structure represented by O4; LiMn2O4 in which a portion of the Li in the chemical formula is substituted with an alkaline earth metal ion; a disulfide compound; Fe2(MoO4)3, etc. Additionally, the anode may have an anode composite layer comprising lithium metal, a carbon material, a metal compound, and a mixture thereof. The metal compound may be a compound containing one or more metal elements selected from the group consisting of Si, Ge, Sn, Pb, P, Sb, Bi, Al, Ga, In, Ti, Mn, Fe, Co, Ni, Cu, Zn, Ag, Mg, Sr, and Ba, or a mixture thereof.

[0138] The cathode can be manufactured by providing a cathode active material on a cathode current collector and rolling it, or by manufacturing it dry, as in the manufacturing process of the anode described above, and optionally additionally may include a conductive material, an organic binder polymer, an additive, etc., as in the anode.

[0139] In addition, the cathode active material may include, for example, a carbon material and a silicon material. The carbon material refers to a carbon material having carbon atoms as its main component. Such carbon materials may include graphite, which has a completely layered crystal structure like natural graphite; soft carbon, which has a low-crystallinity layered crystal structure (graphene structure; a structure in which hexagonal honeycomb-shaped planes of carbon are arranged in layers); hard carbon, in which such structures are mixed with amorphous portions; artificial graphite; expanded graphite; carbon fiber; non-graphitized carbon; carbon black; acetylene black; ketjen black; carbon nanotubes; fullerene; activated carbon; graphene; carbon nanotubes; and, preferably, one or more selected from the group consisting of natural graphite, artificial graphite, and carbon nanotubes. More preferably, the carbon material may include natural graphite and / or artificial graphite, and together with natural graphite and / or artificial graphite, one or more of carbon black and carbon nanotubes. In this case, the carbon material may comprise 0.1 to 10 parts by weight of carbon black and / or carbon nanotubes per 100 parts by weight of the total carbon material, and more specifically, 0.1 to 5 parts by weight; or 0.1 to 2 parts by weight of carbon black and / or carbon nanotubes per 100 parts by weight of the total carbon material.

[0140] In addition, silicon material is a particle containing silicon (Si) as the main component as a metallic component, comprising silicon (Si) particles and silicon oxide (SiO₂). X It may include one or more of the particles (1≤X≤2). As one example, the silicon material may include silicon (Si) particles, silicon monoxide (SiO) particles, silicon dioxide (SiO2) particles, or a mixture of these particles.

[0141] In addition, in the present invention, the current collector may be a metal plate or the like that exhibits electrical conductivity, and may be appropriate depending on the polarity of the current collector electrode known in the field of secondary batteries.

[0142] In addition, the conductive material in the present invention is not particularly limited as long as it has conductivity without causing chemical changes in the battery.

[0143] In addition, in the present invention, the binder resin is not particularly limited as long as it is a component that assists in the bonding of the active material and the conductive material, and the bonding to the current collector.

[0144] According to these embodiments of the present invention, when a pattern is to be formed on the surface of an electrode, no additional process for pattern formation is required, thereby improving process efficiency. Furthermore, by using an electrode manufacturing apparatus according to the embodiments of the present invention, the specific surface area of ​​the electrode can be effectively increased, allowing more electrolyte ions to be stored during battery charging, thus improving the performance of the battery.

[0145] In this embodiment, terms indicating directions such as front, back, left, right, up, and down have been used; however, these terms are for convenience of explanation only and may vary depending on the location of the object or the observer.

[0146] The electrode manufactured by applying the control method of the electrode manufacturing device according to the embodiment described above may be included in a secondary battery, and such secondary batteries may be assembled in multiple numbers to form a battery module. The battery module may be mounted together with various control and protection systems, such as a Battery Management System (BMS) and a cooling system, to form a battery pack.

[0147] Secondary batteries, battery modules, or battery packs can be applied to various devices. Specifically, they can be applied to means of transportation such as electric bicycles, electric vehicles, and hybrids, but are not limited to these; they can be applied to various devices capable of using secondary batteries.

[0148]

[0149] Although preferred embodiments of the present invention have been described in detail above, the scope of the present invention is not limited thereto, and various modifications and improvements by those skilled in the art using the basic concept of the present invention as defined in the following claims also fall within the scope of the present invention.

[0150] [Explanation of the symbol]

[0151] 1: Electrode

[0152] 10: The whole house

[0153] 11: First electrode active material layer

[0154] 12: Second electrode active material layer

[0155] 100: Electrode manufacturing device

[0156] 110: 1st Roll

[0157] 120: Second Roll

[0158] 130: 3rd Roll

[0159] 140: The 4th Roll

[0160] 150: 1st Feeder

[0161] 160: 1st Squeezer

[0162] 170: 2nd Feeder

[0163] 180: The 2nd Squeezer

[0164] 190: Absence of guide

Claims

1. Multiple rolls arranged in sequence; A first squeezer disposed on a preceding roll among the plurality of rolls, which flattens a first electrode active material provided on a current collector to form a first electrode active material layer; and An electrode manufacturing apparatus comprising a second squeezer disposed on a subsequent roll among the plurality of rolls, the second squeezer which flattens a second electrode active material provided on the current collector or the first electrode active material to form a second electrode active material layer.

2. In Paragraph 1, The plurality of rolls above include a first roll, a second roll, and a third roll arranged in sequence, and The first squeezer is positioned on the first roll, and The second squeezer is positioned on the third roll, and An electrode manufacturing apparatus in which the second roll is interposed between the first roll and the third roll, and the first electrode active material layer and the current collector formed on the first roll pass between the first roll and the second roll, then pass through the surface of at least a portion of the lower semicircle of the second roll, and then pass between the second roll and the third roll.

3. In Paragraph 2, The electrode manufacturing device, wherein the above-mentioned second roll is provided in one or multiple numbers.

4. In Paragraph 2, An electrode manufacturing device in which the first squeezer is positioned forward at a first predetermined angle based on an extension line connecting the center of the first roll to the uppermost surface of the first roll, and the second squeezer is positioned forward at a second predetermined angle based on an extension line connecting the center of the third roll to the uppermost surface of the third roll.

5. In Paragraph 4, The above-mentioned first predetermined angle is 0 degrees or more and 50 degrees or less, and An electrode manufacturing device in which the second predetermined angle is 0 degrees or more and 50 degrees or less.

6. In Paragraph 2, An electrode manufacturing apparatus in which the first electrode active material layer formed on the first roll is calendered at least one of passing between the first roll and the second roll and passing between the second roll and the third roll.

7. In Paragraph 2, The above second roll is a heating roll, an electrode manufacturing device.

8. In Paragraph 2, The above second roll is a guide roll, an electrode manufacturing device.

9. In Paragraph 2, The plurality of rolls further include a fourth roll following the third roll, and An electrode manufacturing apparatus in which the first electrode active material layer and the second electrode active material layer are calendered while passing between the third roll and the fourth roll.

10. In Paragraph 2, It further includes a first feeder for supplying the first electrode active material and a second feeder for supplying the second electrode active material, The first feeder is located on an extension line connecting the center of the first roll to the uppermost surface of the first roll, or is located between the extension line connecting the center of the first roll to the uppermost surface of the first roll and the extension line connecting the center of the first roll to the squeezer. The electrode manufacturing device wherein the second feeder is located on an extension line connecting the center of the third roll to the uppermost surface of the third roll, or between the extension line connecting the center of the third roll to the uppermost surface of the third roll and the extension line connecting the center of the third roll to the squeezer.

11. In Paragraph 1, The plurality of rolls above include a first roll, a second roll, and a third roll arranged in sequence, and The first squeezer is positioned on the first roll, and The second squeezer is positioned on the second roll, and An electrode manufacturing apparatus in which the first electrode active material layer formed on the first roll and the current collector are spaced apart from the upper semicircle of the first roll and moved to the uppermost surface of the second roll.

12. In Paragraph 11, The first squeezer is located on an extension line connecting the center of the first roll to the uppermost surface of the first roll, or is located at a third predetermined angle relative to the extension line. The electrode manufacturing device, wherein the second squeezer is positioned forward at a second predetermined angle based on an extension line connecting the center of the second roll to the uppermost surface of the second roll.

13. In Paragraph 12, The above third predetermined angle is -20 degrees or greater and 0 degrees or greater and 20 degrees or less, and An electrode manufacturing device in which the second predetermined angle is 0 degrees or more and 50 degrees or less.

14. In Paragraph 11, An electrode manufacturing apparatus in which the first electrode active material layer and the second electrode active material layer are calendered as they pass between the second roll and the third roll.

15. In Paragraph 11, The plurality of rolls further include a fourth roll following the third roll, and An electrode manufacturing apparatus in which the first electrode active material layer and the second electrode active material layer are calendered as they pass between the third roll and the fourth roll.

16. In Paragraph 11, It further includes a guide member interposed between the first roll and the second roll, An electrode manufacturing apparatus in which the first electrode active material layer and the current collector formed in the first roll move to the second roll passing through the guide member.

17. In Paragraph 11, It further includes a first feeder for supplying the first electrode active material and a second feeder for supplying the second electrode active material, The first feeder is positioned rearward at a fourth predetermined angle based on the extension line connecting the center of the first roll to the uppermost surface of the first roll, and The electrode manufacturing device wherein the second feeder is located on an extension line connecting the center of the second roll to the uppermost surface of the second roll, or between the extension line connecting the center of the second roll to the uppermost surface of the second roll and the extension line connecting the center of the second roll to the squeezer.

18. In Paragraph 2, An electrode manufacturing device comprising at least one of the first squeezer and the second squeezer including a roller.

19. In Paragraph 1, An electrode manufacturing apparatus in which the particle size of the first electrode active material and the particle size of the second electrode active material are different.

20. In Paragraph 19, An electrode manufacturing apparatus in which the particle size of the first electrode active material is larger than the particle size of the second electrode active material.

21. In Paragraph 1, An electrode manufacturing apparatus in which the composition of the first electrode active material and the composition of the second electrode active material are different.

22. In Paragraph 1, An electrode manufacturing apparatus in which each of the first electrode active material and the second electrode active material is an electrode active material powder for a dry electrode manufacturing process.

Images