3D structures with embedded active materials and method thereof

Abstract

The present disclosure provides a method of creating 3D structures (108) with integrated materials. In particular, the present disclosure provides that a 3D structure is received, wherein the 3D structure is porous. A first film (106) comprising active material particles is also received and aligned with the 3D structure. The aligned 3D structure and first film is fed through a nip formed by a first roll (102) and a second roll (104). The first film is calendered into the 3D structure, using the first roll and the second roll, wherein the first roll and the second roll apply a pre-determined pressure to the first film and the 3D conductive structure.

Description

1 Jones Day MW60006PCTMatthews International GmbH Gutenbergstrasse 1-3 48691 Vreden Germany3D STRUCTURES WITH EMBEDDED ACTIVE MATERIALS AND METHOD _ THEREOFBACKGROUNDTechnical Field

[0001] The present disclosure relates generally to the 3D structures and more particularly to porous 3D structures with active materials calendering into the structure and method of making such structures.Technical Description

[0002] 3D structures are used for many purposes, including heat dissipation, insulation, cooling, impact absorption, sound absorption, filtration, and energy production. Materials can be embedded into 3D structures. In some cases, active materials can be embedded into 3D structures to increase the active area. One way to embed active material into a 3D structure is to calender the material into the structure.SUMMARY

[0003] The present disclosure provides a 3D structure with embedded active materials and method thereof. In particular, the present disclosure provides a method of creating 3D structures with integrated material comprising receiving a 3-D structure, wherein the 3-D structure is porous, receiving a first film comprising active material particles, aligning the 3-D structure and the first film, feeding the aligned 3-D structure and first film through a nip formed by a first roll and a second roll; and calendering the first film into the 3-D structure, using a first roll and a second roll, wherein the first roll and the second roll apply a pre-determined pressure and / or nip width to the first film and 3-D conductive structure.

[0004] In some embodiments, the method further receives a second film comprising the active material particles, aligns the second film to the 3D structure, feeds the second film through the nip and calenders the second film into the 3D conductive from an opposite side as the first film, using the first roll and the second roll.

[0005] In some embodiments, the method further receives a second film comprising the active material particles, aligns the second film to the 3D structure, feeds the second film throughNAI-5004559019vl2 Jones Day MW60006PCT the nip and calenders the second film into the 3D conductive from an same side as the first film, using the first roll and the second roll.

[0006] In some embodiments, the first film is received through a hopper, wherein the first film is a powder.

[0007] In some embodiments, the first film is supported by the first roll.

[0008] In some embodiments, the particles of the first film are smaller than or the same size as the size of particles of the second film.

[0009] In some embodiments, the 3D structure is a metal wool or metal mesh.

[0010] In some embodiments, the 3D structure is conductive and the active material particles comprise electrode material.

[0011] In some embodiments, the first film is a dry film.

[0012] In some embodiments, the 3D structure is coated with a conductive adhesive.

[0013] These and other features and characteristics of the present disclosure, as well as the methods of operation and functions of the related elements of structures and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the disclosure. Hence, specific dimensions and other physical characteristics related to the embodiments disclosed herein are not to be considered as limiting. Further, it is to be understood that the disclosure may assume various alternative variations and step sequences, except where expressly specified to the contrary.BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Additional advantages and details of non-limiting embodiments or aspects are explained in greater detail below with reference to the exemplary embodiments that are illustrated in the accompanying schematic figures, in which:

[0015] FIG. l is a diagram of a 2-roll calender system depicting a film and 3D structure;

[0016] FIG. 2 is a diagram of a 2-roll calender system depicting a film and embedded 3D structure;

[0017] FIG. 3 is a diagram of a 2-roll calender system depicting two films and a 3D structure;NAI-5004559019vl3 Jones Day MW60006PCT

[0018] FIG. 4 is a diagram of a 2-roll calender system depicting a supported film and a 3D structure;

[0019] FIG. 5 is a diagram of a multi-roll calender system with a supported film and a 3D structure; and

[0020] FIG. 6 is a diagram of a 2-roll calender system with a hopper.

[0021] It should be appreciated by those skilled in the art that any block diagrams herein represent conceptual views of illustrative systems embodying the principles of the present subject matter. While each of the figures illustrates a particular embodiment for purposes of illustrating a clear example, other embodiments may omit, add to, reorder, and / or modify any of the elements shown in the figures. Further, when practical, similar reference numbers denote similar structures, features, or elements.DETAILED DESCRIPTION

[0022] For purposes of the description hereinafter, the terms “end,” “upper,” “lower,” “right,” “left,” “vertical,” “horizontal,” “top,” “bottom,” “lateral,” “longitudinal,” and derivatives thereof shall relate to the disclosure as it is oriented in the drawing figures. However, it is to be understood that the disclosure may assume various alternative variations and step sequences, except where expressly specified to the contrary.

[0023] All numbers and ranges used in the specification and claims are to be understood as being modified in all instances by the term “about”. The term “about” means plus or minus 25% of the stated value, such as plus or minus 10% of the stated value. However, this should not be considered as limiting to any analysis of the values under the doctrine of equivalents.

[0024] The terms “first,” “second,” and the like are not intended to refer to any particular order or chronology, but refer to different conditions, properties, or elements.

[0025] The term “at least” is synonymous with “greater than or equal to”.

[0026] The terms “comprises,” “comprising,” or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, device, or method that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup, device, or method. In other words, one or more elements in a system or apparatus proceeded by “comprises ... a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or method.

[0027] The terms “includes,” “including,” or any other variations thereof are intended to cover a non-exclusive inclusion such that a setup, device, or method that includes a list ofNAI-5004559019vl4 Jones Day MW60006PCT components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup, device, or method. In other words, one or more elements in a system or apparatus preceded by “includes ... a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or method.The terms “an embodiment,” “embodiment,” “embodiments,” “the embodiment,” “the embodiments,” “one or more embodiments,” “some non-limiting embodiments or aspects,” and “one embodiment” mean “one or more (but not all) embodiments of the invention(s),” unless expressly specified otherwise. A description of an embodiment with several components in communication with each other does not imply that all such components are required. On the contrary, a variety of optional components is described to illustrate the wide variety of possible embodiments of the disclosure.

[0028] In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration specific embodiments in which the disclosure may be practiced. It should be understood, however, that it is not intended to limit the disclosure to the forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the spirit and the scope of the disclosure. It is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.

[0029] 3D structures can be used in a variety of industries for different uses. 3D structures are porous and can have numerous interconnected pores. Examples of 3D structures include 3D foams and mesh. Materials can be embedded into the 3D structures, such that the material fills the pores and / or coats the internal surfaces. 3D structures with materials embedded can be used for heat dissipation, insulation, cooling, impact absorption, sound absorption, filtration, and energy production. When active materials are embedded into a 3D structure, they can fill the internal surfaces of the structure, which creates a larger surface area for the active material compared to a 2D surface. Moreover, more active material and a thicker active layer can be used to calender the material.

[0030] Discussion of specific use cases of the present disclosure are non-limiting. These non-limiting examples include air filtration systems that have active carbon embedded into 3D matrices, thermal management systems that use phase change materials, energy storage devices comprising electrode material embedded into metal mesh, and biosensors that utilize biological recognition elements into 3D structures to detect biomarkers. In each of these examples, theNAI-5004559019vl5 Jones Day MW60006PCT use of the 3D structure can provide an increase in the active area where the specific active processes occur.

[0031] The present disclosure provides systems and methods for calendering active material into 3D structures to enhance the active area. In some cases, the systems and methods described herein may calender free-standing or supported active film into the 3D structure. In other cases, the systems and methods described herein may also calender free-flowing dry powder into the porous 3D structure.

[0032] With reference to FIG. 1, a calender system 100 is illustrated in accordance with some embodiments of the present disclosure. The system 100 includes at least two rolls 102 and 104. Each roll 102 and 104 may be controlled independently. The rolls may be heated and can be heated to the same or different temperatures. The speed of the rolls may also be the same or different. Further, in some embodiments, the rolls may have the same diameter. In other embodiments, the rolls may have different diameters. The rolls may also be horizontally collinear, as shown in FIG. 1. In other embodiments, the rolls may be offset from one another. The rolls may also be supported on a common frame structure or different frame structures. Further, the gap between the first roll 102 and the second roll 104 may be fixed or it may vary. In some embodiments, the gap may be controlled by a gap control system that can alter the gap manually or automatically. The gap may be altered for a variety of reasons. For example, the gap may be adjusted to accommodate the thickness of the material being received.

[0033] With continued reference to Fig. 1, the first roll 102 and the second roll 104 form a nip. A film 106 and a 3D structure 108 are received at the nip. The film 106 may comprise active materials. Active materials are any materials that participate in the primary function of an apparatus. Examples of active materials include activated carbon, electrode material, fluorinated materials, polymers, phase change materials, and biological recognition elements (e.g., enzymes and antibodies). In some cases, the film may be a dry film. A dry film is a film that is manufactured without the use of wet processes. In other cases, the film may be created using wet processes. 3D structures may be a material with a three-dimensional porous or interconnected matrix. In some embodiments, the 3D structure may have openings, depressions, or comparable structures that enable an active material to be absorbed into the substrate. Preferably, not only the surface of the substrate has a porous nature, but also openings, depressions, pores or comparable structures are formed within the substrate. In particular, the three-dimensional structure may be formed throughout the substrate. For example, the substrate may be formed like a sponge, foam, net, mesh, braid, or wool, or mayNAI-5004559019vl6 Jones Day MW60006PCT have a honeycomb or matrix structure. Thus, the substrate may be or have an open-pored support material.

[0034] These pores throughout the structure can be designed to provide an increased surface area, enhanced heat transfer and / or structural support. The 3D structure 108 may be composed of metals, polymers, ceramics, or composite materials. Examples of metals include copper, aluminum, nickel, stainless steel, and titanium. In some cases, the 3D structure may be provided in the form of a film, foil, or sheet, such that the thickness of the 3D structure is less than a width or length of the 3D structure.

[0035] It may be advantageous if an open porosity or useful porosity is as large as possible, i.e. that as many cavities as possible within the substrate are in communication with each other and with the environment. Thus, an open porosity of the substrate can be at least 5%, preferably at least 10%, particularly preferably at least 20%. The pore structure may have a pore density in a range of 25 to 150 pores per inch (ppi), preferably in a range of 35 to 100 ppi, particularly preferably in a range of 45 to 65 ppi. In some embodiments, the specific gravity of the 3D structure 108 may be between 50 and 500 g / m2In further embodiments, it may be preferable for the specific gravity to be between 75 and 250 g / m2, preferably between 100 and 175 g / m2.

[0036] In some embodiments, the particles of the film 106 may be smaller than or the same size as the pores. In other embodiments, the particles may be larger than the size of the pores. Preferably, an average particle size of the active material is at most as large as an average size of an element of the three-dimensional structure. Thus, the invention enables advantageous incorporation of the active material into the three-dimensional structure of the substrate. This is because if the substrate has a three-dimensional structure that is too fine and / or the active material has particles that are too large, very high forces are required to introduce the active material into the substrate. However, this leads to increased technical demands on a device for carrying out the process and / or can lead to damage, in particular to the substrate.

[0037] Further, the porosity, geometry, and composition of the 3D structure can be customized to the specific function it is being manufactured for. In some embodiments, the 3D structures may be pre-coated with adhesive to reduce contact resistance between the active material and 3D structure. For example, when manufacturing 3D structures for use in electrodes, the 3D structures may be coated with conductive adhesive.

[0038] In some embodiments, there may be a guiding mechanism ensuring that the 3D structure and the film are precisely positioned and aligned before they enter the nip. The guiding mechanism may comprise one or more idle rolls that guide the film and / or the 3D structure. In other embodiments, the guiding mechanism may comprise alignment rails toNAI-5004559019vl7 Jones Day MW60006PCT ensure the film and 3D structure are properly aligned. In further embodiments, the guiding mechanism may comprise a feeding belt conveyor. In further embodiments, the guidance is a structure in the rolls. For example, one roll may have an indent and the other roll may have a protrusion. This would allow the rolls to guide the foil and / or film.

[0039] With continued reference to FIG. 1, the first roll 102 and the second roll 104 assert pressure on the film 106. The pressure applied by the rolls 102 and 104 compresses the film 106 into the porous matrix of the 3D structure 108, ensuring that the material is distributed throughout the structure’s pores. An even distribution of material through the pores is preferable. Preferably, at least 50% of the active material is introduced into the substrate, particularly preferably at least 75% of the active material.

[0040] In some embodiments, the rolls may apply a pre-determined pressure on the film 106 and the 3D structure 108. The process can be controlled to achieve the desired penetration of active material from film 108 into the 3D structure. The process parameters, such as roll speed, applied pressure, and roll temperature can be adjusted depending on the properties of the active material and the 3D structure 108. Increasing the roll temperature may lead to better flow of the active material into the 3D structure.

[0041] In some embodiments, a vacuum (not shown) may be configured to remove any debris created during the compression process. For example, when using dry film, the vacuum can suction up any debris created when the film 106 is compressed into the 3D structure 108. Some of the particles from the film may be released into the environment. The vacuum creates a controlled environment that prevents the accumulation or introduction of debris during the compression step. Airborne particles, dust, and other contaminants can be removed using a vacuum. The vacuum may also allow for less energy consumption, reduced force of the rolls, and / or increased process speed. For example, the vacuum can lead to less air molecules in the gap and / or the 3D-structure. Therefore, the air molecules don’t need to be pushed out of the 3D structure while the active material is pushed into the 3D structure. This leads to less pressing force, which in turn requires less energy. The absence of all or most of the air molecules can also allow the process to run faster.

[0042] In some cases, the vacuum is applied prior to the compression phase, while in others, it is applied during the compression phase. The vacuum may be configured near the nip, where the compression step occurs.

[0043] With reference to FIG. 2, in some embodiments, a 3D structure 202 with active material already embedded within and a film 204 are received by a first roll 102 and a second roll 104. The 3D structure 202 may be similar and / or the same in structure and material as 3DNAI-5004559019vl8 Jones Day MW60006PCT structure 108 described above. The 3D structure 202 includes active material that may have been calendering in at an early step or have been embedded into the 3D structure 202 using a different method. The film 204 may be the same active material, a different active material, or a different non-active material. The film 204 is calendering into the 3D structure 202 using the first and second rolls 102 and 104 with the same methods described in FIG. 1. Guiding mechanism may also be used to align the film 204 and the 3D structure 202.

[0044] With reference to FIG. 3, in some embodiments, a 3D structure 302, a first film 304, and a second film 306 are received by a first roll 102 and a second roll 104. The first roll 102 and the second roll 104 compress the first film 304 and the second film 306 into the 3D structure 302. The first film 304 is compressed into a first side of the 3D structure 302 and the second film 306 is compressed into a second side of the 3D structure 302. The first film 304 and the second film 306 may be the same material or a different material. The first film 304 and the second film 306 may be active materials or non-active materials. The 3D structure 302 may be similar and / or the same in structure and material as 3D structure 108 described above. Guiding mechanism may also be used to align the films 304, 306 and the 3D structure 302.

[0045] With reference to FIG. 4, in some embodiments, the film 404 is supported by a first roll 102. A supported film 404 refers to a film that maintains contact with a roll. The roll provides mechanical support to the film. A film may be supported for part of the calendering process or for the whole process. The supported film 404 and a 3D structure 402 are received at a nip formed by the first roll 102 and a second roll 104. The supported film 404 is compressed into the 3D structure 402. The 3D structure 402 may be similar and / or the same in structure and material as 3D structure 108 described above. Guiding mechanism may also be used to align the films 404 and the 3D structure 402.

[0046] With reference to FIG. 5, in some embodiments, a multi-roll calender system 500 may be utilized to embed a film 504 into a 3D structure 502. As shown in FIG. 5, the multiroll calender system has four rolls — 510, 512, 514, and 516. In other embodiments, the multiroll calender system 500 may have more than four rolls. In further embodiments, the multi-roll calender system may have three rolls. Each roll 510, 512, 514, and 516 may be controlled independently. The rolls may be heated and can be heated to the same or different temperatures. The speed / surface velocities of the rolls may also be the same or different. Further, in some embodiments, the rolls may have the same diameter. In other embodiments, the rolls may have different diameters. The rolls may also be horizontally collinear, as shown in FIG. 5. In other embodiments, the rolls may be offset from one another. The rolls may also be supported on a common frame structure or different frame structures.NAI-5004559019vl9 Jones Day MW60006PCT

[0047] With continued reference to FIG. 5, the film 504 is supported by the rolls 510, 512, and 514. Further, the film 504 may be compressed at each nip Nl, N2, and / or N3. Nip N1 is formed by rolls 510 and 512; nip N2 is formed by rolls 512 and 514; and nip N3 is formed by rolls 514 and 516. As the film is compressed at one or more nips, the thickness of the film may decrease. The supported film 504 and the 3D structure 502 are received by rolls 514 and 516 at nip N3. The supported film 504 is compressed into the 3D structure 502, using the techniques discussed in this disclosure. Guiding mechanism may also be used to align the films 504 and the 3D structure 502.

[0048] With reference to FIG. 6, in some embodiments, a first roll 102 and a second roll 104 receive powder 604 from a hopper 606. The first roll 102 and the second roll 104 also receive a 3D structure 602 and compress the powder 604 into the 3D structure. The hopper 606 is positioned above the nip between the rolls and is configured to dispense active material powder 604. In some embodiments, the hopper 606 may have a control mechanism to ensure the powder to be delivered in a control manner. The control mechanism may comprise integrated sensors positioned within the hopper. The sensors may monitor the powder level and ensure that the hopper is filled to maintain a steady flow of active material. If the powder level drops below a certain threshold, the sensor can send a signal to a control system or a person to replenish the powder. This can prevent interruptions in the calendering process. In other embodiments, the sensor may be positioned above the nip formed by rolls 102 and 104 to monitor the delivery of powder to the 3D structure 602. If the sensor detects that the powder is being unevenly distributed, it can communicate with a control system or a person to adjust the powder flow rate or pause the calendering process to troubleshoot any issues. In some embodiments, an automatic control system may adjust the powder feed rate of the hopper in real-time based on feedback from sensors. In other embodiments, the control mechanism may signal an alert for a person to manually resolve the issues. The hopper may be designed to distribute powder evenly across the width of the rolls, ensuring consistent loading of active material into the 3D structure.

[0049] Once the powder 604 is delivered between the nip, the rolls apply pressure to the powder 604 and the 3D structure 602, compressing the powder into the porous matrix of the 3D structure. In some embodiments, the rolls may adjust the pressure applied based on the characteristics of the powder and / or the 3D structure.

[0050] The methods and embodiments described herein can apply to created 3D structures embedded with active material for a variety of industries. For example, in the field of air filtration, the active material may be activated carbon that is embedded in a 3D matrix for useNAI-5004559019vl10 Jones Day MW60006PCT in air filtration systems. Calendering active carbon or other active filtration materials into a 3D matrix allows for increased surface area to enhance the filtration efficiency to trap harmful substances. As another example, for thermal management and insulation, phase change materials (PCMs) can be used in heat exchangers for improved thermal management. The phase change materials or other thermally conducive materials can be calendered into a metal or ceramic foam. The increase in active area would allow for more efficient heat transfer.

[0051] As a further example, these systems and methods could be used for manufacturing energy storage devices, such as a capacitor, a lithium-ion capacitor (LIC), an ultracapacitor, a battery such as a lithium-ion battery, or a hybrid energy storage device that combines aspects of two or more of the foregoing. The active materials would include lithium-based compounds, anode material, cathode material, or other conductive polymers. The active materials for an electrodes may depend on whether it is a dry process and a wet process. The dry powder may comprise an active material, a conductive additive and / or a suitable binder. Compared to processes used in wet processes, materials that are sensitive to moisture can also be used in particular. For example, a dry powder can be used that includes or comprises polytetrafluoroethylene, a conductive additive, such as carbon nanotubes, porous carbon, a transition metal oxide, and / or sulfur. For a carbon / sulfur cathode, the dry powder mixture may include porous carbon, for example porous carbon black or carbon nanotubes, sulfur, polytetrafluoroethylene, and optionally another conductive additive. For a lithium ion electrode, in addition to polytetrafluoroethylene and an additional conductive additive, an active material, preferably lithium iron phosphate (LFP), lithium manganese oxide (LMO), nickel-manganese-cobalt (NMC), nickel-rich lithium-nickel-manganese-cobalt oxide (NMC 622 or NMC 811), lithium-nickel-cobalt-aluminum oxide (NCA), lithium-cobalt oxide (LCO), lithium-manganese-nickel oxide (LMNO), and resp. or lithium titanate (LTO) can be used.

[0052] These materials could be directly embedded into 3D structures, such as carbon or metal foams, increasing the active area. As the active area for these electrode materials increases, the performance and capacity of the energy storage devices also increases. Examples of 3D structures include metal foams, copper wool, aluminum wool, expanded metal, braided metal, woven metal, etched metal and conductive polymer fabrics. In some cases, the 3D structures may be coated with a conductive adhesive.

[0053] The embodiments described herein are not mutually exclusive and may be combined in various ways to achieve desired results. Features from one embodiment may be incorporated into another embodiment, and such combinations are within the scope of the present invention. Further, the specific embodiments discussed may be used individually or inNAI-5004559019vl11 Jones Day MW60006PCT any suitable combination to provide further variations of the inventions. Similarly, examples described herein are illustrative and non-exhaustive. There may be other examples and variations of the invention that have not been specifically described.NAI-5004559019vl

Claims

12 Jones Day MW60006PCTClaimsWhat is claimed:

1. A method of creating 3D structures with integrated material comprising: receiving a 3D structure, wherein the 3D structure is porous; receiving a first film comprising active material particles; aligning the 3D structure and the first film; feeding the aligned 3D structure and first film through a nip formed by a first roll and a second roll; and calendering the first film into the 3D structure, using a first roll and a second roll, wherein the first roll and the second roll apply a pre -determined pressure to the first film and3D structure.

2. The method of claim 1, further comprising: receiving a second film comprising the active material particles; aligning the second film to the 3D structure; feeding the second film through the nip; calendering the second film into the 3D structure from an opposite side as the first film, using the first roll and the second roll.

3. The method of claim 1, further comprising: receiving a second film comprising the active material particles; aligning the second film to the 3D structure; feeding the second film through the nip; calendering the second film into the 3D structure from the same side as the first film, using the first roll and the second roll.

4. The method of claim 1, further comprising: receiving the first film through a hopper, wherein the first film is a powder.

5. The method of claim 1, wherein the first film is supported by the first roll.NAI-5004559019vl13 Jones Day MW60006PCT6. The method of claim 1, wherein the particles of the first film are smaller than or the same size as the size of the particles of the second film.

7. The method of claim 1, wherein the 3D structure is a metal wool or metal mesh.

8. The method of claim 1, wherein the 3D structure is conductive and the active material particles comprise electrode material.

9. The method of claim 8, wherein the first film is a dry film.

10. The method of claim 8, wherein the 3D structure is coated with a conductive adhesive.

11. The method of claim 8, wherein a vacuum is used at the nip.

12. An article of manufacture comprising: a 3D structure with an interconnected porous matrix; and an active material embedded within the porous matrix of the 3D structure, wherein the active material is compressed into the 3D structure, resulting in an increased surface area for interaction between the active material and the 3D structure.

13. The article of manufacturing of claim 12, wherein the 3D structure is configured to be used in an energy storage device.

14. The article of manufacturing of claim 12, wherein the 3D structure comprises a metal foam, metal mesh, ceramic foam, or polymer foam.

15. The article of manufacturing of claim 12, wherein the active material is embedded into the 3D structure using a calendering process.NAI-5004559019vl

Images