Dry electrode coating system and method

Abstract

The present invention relates to a dry electrode coating system and method, the system comprising: a dry mixing unit for producing an active material by mixing precursor materials; a complex mixing unit for producing an electrode by mixing the active material with a conductive material and a binder; a dry coating unit for thickly applying the produced electrode to a current collector; and a winder for winding the coated current collector.

Description

Dry electrode coating system and method

[0001] The present invention relates to a dry electrode coating system and method, and more specifically, to a dry electrode coating system and method that enables process simplification, reduction of manufacturing costs, and mass production application by introducing a precursor material in a dry mixing process to produce a granulated active material, powdering a binder in a composite mixing process and introducing it to produce an electrode, or introducing it as is and producing an electrode through a homogeneous grinding and extrusion process, and applying a thick film coating to a current collector.

[0002] Currently, technological capabilities among leading companies in the battery materials sector are leveling up, and China's CATL is rapidly catching up with ternary battery technologies, such as NCM (nickel, cobalt, manganese), which were considered the strength of Korean battery companies. Consequently, process innovations like dry electrodes are required to secure global leadership in the battery market.

[0003] Dry electrodes are recognized as an eco-friendly technology that can not only increase battery productivity and expand energy capacity but are also a versatile technology applicable to thick-film electrodes and all-solid-state batteries.

[0004] The drying process is the section that requires the most cost and space in the wet process to date, and since the coating and drying equipment ranges in length from tens to 100 meters, the technology of eliminating this drying process and directly coating the active material, conductive material, and powder onto the current collector is the dry electrode. Since the dry electrode eliminates the drying process, it has the advantage of simplifying the manufacturing process and reducing equipment investment costs.

[0005] Conventionally, to commercialize dry electrode processes, advanced materials such as carbon nanotubes (CNT) have been introduced to optimize electrode performance, and technologies have been developed to ensure that electrode films are safely attached even under high cycle and thermal stress conditions in order to improve adhesion between the electrode film and the current collector.

[0006] However, conventional processes have the inconvenience of requiring regular optimization of each process step approximately every six months, and in the event of an unexpected error, the operator must stop production and correct the error according to a manual generated based on data accumulated through regular optimization, and the manual must also be updated frequently, resulting in a structure where this process is inevitably repeated.

[0007] In addition, conventional processes have limitations in that they lack a process for systematically generating active materials and performing composite mixing, as they involve introducing dry composite materials such as active materials, conductive materials, and binders and then mixing all the introduced composite materials.

[0008] Prior art literature

[0009] Patent documents

[0010] Korean Published Patent No. 10-2024-0099048

[0011] The present invention aims to solve the aforementioned problems by providing a dry electrode coating system and method that enables process simplification, reduction of manufacturing costs, and mass production application by introducing a precursor material during a dry mixing process to produce a granulated active material, powdering a binder during a composite mixing process and introducing it to produce an electrode, or introducing it as is and producing an electrode through a homogeneous grinding and extrusion process, and applying a thick film coating to a current collector.

[0012] A dry electrode coating system (100) according to one embodiment of the present invention may include a dry mixing unit (110) for producing an active material by mixing precursor materials, a composite mixing unit (120) for producing an electrode by mixing a conductive material and a binder with the active material, a dry coating unit (130) for thick-film coating the produced electrode onto a current collector, and a winder (140) for winding the coated current collector.

[0013] According to one embodiment of the present invention, the dry mixing unit (110) can produce a granulated active material by mixing the precursor material using an intensive mixer.

[0014] According to one embodiment of the present invention, the dry mixing unit (110) can inspect the particle size of the granulated active material and, if it is determined that it does not meet the set size, remixing can be performed using the intensive mixer.

[0015] A dry mixing unit (110) according to one embodiment of the present invention may be configured to repeat the process of remixing using the intensive mixer until the particle size inspection result of the active material matches the set size, and may be configured to automatically change the remixing time during the repetition process.

[0016] According to one embodiment of the present invention, the composite mixing unit (120) mixes the active material by introducing a conductive material and a binder, and the binder introduced can be powdered before introduction.

[0017] The composite mixing unit (120) according to one embodiment of the present invention can pulverize the introduced binder using an auxiliary milling process.

[0018] According to one embodiment of the present invention, the composite mixing unit (120) can obtain a granulated electrode by mixing the active material, conductive material, and powdered binder using an intensive mixer.

[0019] According to one embodiment of the present invention, the composite mixing unit (120) can inspect the particle size of the granulated electrode and, if it is determined that it does not meet the set size, perform remixing using the intensive mixer.

[0020] According to one embodiment of the present invention, the composite mixing unit (120) may be configured to repeat the process of remixing using the intensive mixer until the particle size inspection result of the electrode matches the set size, and may be configured to automatically change the remixing time during the repetition process.

[0021] According to one embodiment of the present invention, the composite mixing unit (120) mixes the active material by introducing a conductive material and a binder, but introduces the binder without pulverizing it so that a mixture in an initial fiberized state can be secured.

[0022] According to one embodiment of the present invention, the composite mixing unit (120) homogeneously grinds the mixture and can obtain an extruded electrode using an extruder process.

[0023] In one embodiment of the present invention, the composite mixing unit (120) can inspect the particle size of the ground material during the homogeneous grinding process of the mixture, and if it is determined that the ground material does not meet the set size, the ground material can be re-ground.

[0024] According to one embodiment of the present invention, the composite mixing unit (120) can inspect the viscosity of the extruded electrode during the extrusion molding process using the extruder process, and if it is determined that the extruded electrode does not meet the set viscosity, the extruded electrode can be re-extruded using the extruder process.

[0025] In the process of complex mixing, a compression heating process can be utilized as one example.

[0026] According to one embodiment of the present invention, the dry coating unit (130) can thick-film coat the secured electrode, and inspect the thickness and image of the coating result coated on the current collector, and if it is determined that it does not conform to the set thickness or set image, the coating result can be determined as defective and a processing signal can be output.

[0027]

[0028] A dry electrode coating method according to another embodiment of the present invention may include the steps of: mixing a precursor material to produce an active material through a dry mixing unit; mixing a conductive material and a binder with the active material through a composite mixing unit to produce an electrode; thick-film coating the produced electrode onto a current collector through a dry coating unit; and winding the coated current collector through a winder.

[0029] According to one embodiment of the present invention, a granulated active material is produced by introducing a precursor material in a dry mixing process, and an electrode is produced by introducing a binder powder in a composite mixing process and then introducing it, or by introducing it as is and then producing an electrode through a homogeneous grinding and extrusion process and applying a thick film coating to a current collector, thereby having the advantages of process simplification, reduced manufacturing costs, and mass production application.

[0030] In addition, according to the present invention, the development period can be shortened compared to conventional processes, and there is an advantage of easy adaptation to model changes.

[0031] In addition, according to the present invention, it is easy to develop battery-related parts and materials for non-battery manufacturers, and has the advantage of facilitating quality control through process simplification.

[0032] In addition, according to the present invention, mass production quality management is facilitated through real-time quality inspection, and quality history management and measures are facilitated through the digitization of manufacturing information.

[0033] In addition, according to the present invention, manufacturing costs can be reduced through the stable mass production application of the dry process, and it has advantages for early and expanded application.

[0034] FIG. 1 is a schematic diagram showing the overall configuration of a dry electrode coating system (100) according to one embodiment of the present invention.

[0035] FIG. 2 is a diagram schematically showing the overall process of a dry electrode coating system (100) according to one embodiment of the present invention.

[0036] FIG. 3 is a flowchart showing a dry electrode coating method according to one embodiment of the present invention in a series of sequences.

[0037] FIG. 4 is a schematic diagram showing the overall process of another embodiment of a dry electrode coating system (200) according to one embodiment of the present invention.

[0038] FIG. 5 is a diagram showing a structure according to one embodiment for feeding a composite mixture at a constant feed amount through an extrusion molding section (250).

[0039] FIG. 6 is a diagram showing a structure according to another embodiment for feeding a composite mixture at a constant feed amount through an extrusion molding section (250).

[0040] FIG. 7 is a diagram showing a structure according to another embodiment for feeding a composite mixture at a constant feed amount through an extrusion molding section (250).

[0041] FIG. 8 is a schematic diagram showing the configuration of the dry electrode forming part (260) illustrated in FIG. 4.

[0042] FIG. 9 is a drawing showing a double rolling device of a dry electrode forming unit (260).

[0043] FIG. 10 is a schematic diagram showing the hardware configuration of a dry electrode coating system (200) according to one embodiment of the present invention.

[0044] Hereinafter, specific details for implementing the present invention will be described in detail with reference to the attached drawings. However, in the following description, specific descriptions regarding widely known functions or configurations will be omitted if there is a risk that the gist of the present invention may be unnecessarily obscured.

[0045] In the attached drawings, identical or corresponding components are given the same reference numerals. Additionally, in the description of the following embodiments, the description of identical or corresponding components may be omitted. However, even if a description of a component is omitted, it is not intended that such component is not included in any embodiment.

[0046] The advantages and features of the invented embodiments and the methods for achieving them will become clear by referring to the embodiments described below together with the accompanying drawings. However, the present invention is not limited to the embodiments described below but can be implemented in various different forms, and these embodiments are provided merely to make the present invention complete and to fully inform a person skilled in the art of the scope of the invention.

[0047] The terms used in this specification will be briefly explained, and the invented embodiments will be described in detail. The terms used in this specification have been selected to be as generally used as possible, taking into account their functions in the present invention; however, these terms may vary depending on the intent of those skilled in the relevant field, case law, the emergence of new technologies, etc. Additionally, in specific cases, terms have been arbitrarily selected by the applicant, and in such cases, their meanings will be described in detail in the relevant description of the invention. Therefore, the terms used in this invention should be defined not merely by their names, but based on the meanings they possess and the content of the invention as a whole.

[0048] In this specification, singular expressions include plural expressions unless the context clearly specifies them as singular. Additionally, plural expressions include singular expressions unless the context clearly specifies them as plural. 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.

[0049] Additionally, the terms 'module' or 'part' as used in the specification refer to software or hardware components, and the 'module' or 'part' performs certain roles. However, the meaning of 'module' or 'part' is not limited to software or hardware. The 'module' or 'part' may be configured to reside in an addressable storage medium or configured to run on one or more processors. Thus, as an example, the 'module' or 'part' may include components such as software components, object-oriented software components, class components, and task components, and at least one of processes, functions, attributes, procedures, subroutines, segments of program code, drivers, firmware, microcode, circuits, data, databases, data structures, tables, arrays, or variables. The components and the functions provided within the 'module' or 'part' may be combined into a smaller number of components and 'modules' or 'parts', or further separated into additional components and 'modules' or 'parts'.

[0050] FIG. 1 is a schematic diagram showing the overall configuration of a dry electrode coating system (100) according to one embodiment of the present invention, and FIG. 2 is a schematic diagram showing the overall process of a dry electrode coating system (100) according to one embodiment of the present invention.

[0051] Referring to FIGS. 1 and 2, a dry electrode coating system (100) according to one embodiment of the present invention may largely include a dry mixing unit (110), a composite mixing unit (120), a dry coating unit (130), and a winder (140).

[0052] The dry mixing unit (110) can produce an active material by mixing precursor materials. Here, the dry mixing unit (110) can produce a granulated active material by mixing precursor materials using an intensive mixer. To this end, the dry mixing unit (110) may include an input device (not shown) for introducing precursor materials into the intensive mixer. Here, the input device can automatically introduce precursor materials of a preset weight into the intensive mixer.

[0053] In addition, in one embodiment, the dry mixing unit (110) can inspect the particle size of the granulated active material and, if it is determined that it does not meet the set size, remixing can be performed using an intensive mixer.

[0054] In addition, during this process, the dry mixing unit (110) repeats the process of remixing using an intensive mixer until the particle size inspection result of the active material meets the set size, and the remixing time can be set to automatically change during the repetition.

[0055] In addition, during this process, the dry mixing unit (110) can be set to automatically change the operating time of the intensive mixer or the rotation speed of the intensive mixer while repeating the mixing process using the intensive mixer.

[0056] The granulated active material through the dry mixing unit (110) can be introduced into the composite mixing unit (120).

[0057] The composite mixing unit (120) can produce an electrode by introducing and mixing a conductive material and a binder into the active material produced through the dry mixing unit (110).

[0058] In the process of mixing the conductive material and the binder by introducing them into the active material, the binder to be introduced may be powdered and introduced, or it may be homogeneously ground after introduction without being powdered.

[0059] First, let's look at the process of powdering and adding the binder as follows.

[0060] The composite mixing unit (120) can pulverize the binder being introduced during the process of introducing and mixing a conductive material and a binder into an active material. At this time, the composite mixing unit (120) can pulverize the binder using an auxiliary milling process.

[0061] In addition, the composite mixing unit (120) can produce and secure a granulated electrode by mixing an active material, a conductive material, and a powdered binder using an intensive mixer.

[0062] At this time, the composite mixing unit (120) can inspect the particle size of the granulated electrode and, if it is determined that it does not meet the set size, remixing can be performed using an intensive mixer.

[0063] In addition, during this process, the composite mixing unit (120) repeats the process of remixing using an intensive mixer until the particle size inspection result of the electrode meets the set size, and can be set to automatically change the remixing time during the repetition.

[0064] In addition, during this process, the composite mixing unit (120) can be configured to automatically change the operating time of the intensive mixer or the rotation speed of the intensive mixer while repeating the mixing process using the intensive mixer.

[0065] In the process of complex mixing, a compression heating process can be utilized as one example.

[0066] Next, we will look at the process of homogeneously grinding the binder after adding it as is without pulverizing it.

[0067] In the process of mixing the conductive material and binder by introducing them into the active material, the composite mixing unit (120) can ensure that the binder is introduced without being powdered, thereby securing a mixture in an initial fibrous state.

[0068] In addition, the composite mixing unit (120) homogeneously grinds the mixture (mixture of active material, conductive material, and binder) and can obtain an extruded electrode using an extruder process.

[0069] In this process, the composite mixing unit (120) can inspect the particle size of the crushed material and, if it is determined that it does not meet the set size, re-crush the crushed material.

[0070] In addition, the composite mixing unit (120) can inspect the viscosity of the extruded electrode during the extrusion molding process using the extruder process, and if it is determined that the viscosity does not meet the set viscosity, it can re-extrude the extruded electrode using the extruder process.

[0071] In one embodiment, the dry electrode coating system (100) according to the present invention may further include a plasma surface treatment device that improves the adhesion between the electrode and the current collector by performing plasma surface treatment on the current collector adhesive surface for electrode coating after the mixing process of the active material, conductive material, and binder through the composite mixing unit (120).

[0072] A plasma surface treatment device can improve electrode durability by applying plasma surface treatment to the adhesive surface of the current collector, thereby enhancing the adhesion between the electrode and the current collector.

[0073] The dry coating unit (130) can apply a thick film coating of the electrode produced through the composite mixing unit (120) described above to the current collector, and the winder (140) can wind the current collector that has been coated.

[0074] In addition, in one embodiment, the dry coating unit (130) thick-films the secured electrode, and inspects the thickness and image of the coating result thick-films coated on the current collector. If it is determined that the coating result does not conform to the set thickness or set image, the coating result is determined to be defective and a processing signal is output. Accordingly, the management terminal can identify the coating state defect based on this processing signal.

[0075] Next, we will examine the overall process of performing dry electrode coating using the dry electrode coating system (100) according to the present invention described above in order.

[0076] FIG. 3 is a flowchart showing a dry electrode coating method according to one embodiment of the present invention in a series of sequences.

[0077] Referring to FIG. 3, first, a precursor material is introduced into a dry mixing unit (110) (S201), and the dry mixing unit (110) mixes the introduced precursor material using an intensive mixer to produce a granulated active material (S202).

[0078] At this time, the dry mixing unit (110) inspects the particle size of the granulated active material (S203), and if it meets the set size, it is fed into the composite mixing unit (120), and if it is determined that it does not meet the set size, it is remixed using an intensive mixer.

[0079] Next, the composite mixing unit (120) adds a conductive material and a binder to the active material introduced from the dry mixing unit (110) (S204).

[0080] In this process, the composite mixing unit (120) determines whether to powderize the binder to be introduced (S205).

[0081] If it is decided to pulverize and feed, the composite mixing unit (120) uses an auxiliary milling process to pulverize the binder and feed it (S205').

[0082] Additionally, the composite mixing unit (120) mixes the input active material, conductive material, and binder using an intensive mixer to obtain a granulated electrode (S206), and the composite mixing unit (120) inspects the particle size of the granulated electrode (S207). At this time, if it does not meet the set size, the composite mixing unit (120) performs re-mixing using an intensive mixer, and if it meets the set size, the dry coating unit (130) thickly coats the produced electrode onto a current collector (S208).

[0083] Meanwhile, in the S205 process, if it is decided not to powder the binder being introduced, the composite mixing unit (120) homogeneously grinds the introduced active material, conductive material, and binder (S206-1), and obtains an extruded electrode using an extruder process for the ground material (S207-1).

[0084] In addition, the composite mixing unit (120) introduces the extruded electrode into the dry coating unit (130) (S208-1), and the electrode is coated with a thick film on the current collector in the dry coating unit (130).

[0085] Next, we will examine a configuration according to an embodiment different from the dry electrode coating system (100) previously examined, and a dry electrode coating method using the same.

[0086] FIG. 4 is a schematic diagram showing the overall process of another embodiment of a dry electrode coating system (200) according to one embodiment of the present invention.

[0087] Referring to FIG. 4, a dry electrode coating system (200) according to one embodiment of the present invention may largely include a precursor input section (210), a primary mixing section (220), a conductive material and binder input section (230), a secondary mixing section (240), an extrusion molding section (250), and a dry electrode forming section (260).

[0088] The precursor input section (210) can input precursor materials corresponding to the precursor materials in a set amount. Here, the precursor material may mean nickel (Ni), cobalt (Co), or manganese (Mn), and the precursor input section (210) can input each of the precursor materials corresponding to nickel (Ni), cobalt (Co), or manganese (Mn) into the hopper in an 8:1:1 ratio.

[0089] The first mixing section (220) can mix the precursor materials (NCM) previously introduced through the precursor input section (210) for a set time to form spherical shapes.

[0090] More specifically, the primary mixing unit (220) can mix the introduced precursor materials and granulate them into spherical bodies having a particle size of 10 μm. At this time, an intensive mixer may be applied to the primary mixing unit (220).

[0091] An intensive mixer is a high-performance mixing device used to evenly mix materials in the form of solid particles or powders, and can be applied to uniformly mix battery materials, such as precursors (NCM), for use in the manufacture of dry electrodes.

[0092] These intensive mixers achieve very high rotational speeds during mixing through high-speed rotation, allowing powder particles to be mixed rapidly and materials to be mixed uniformly. Additionally, the mixer can apply strong shear force to precursor particles through rotating blades or rotors. This allows for the decomposition of large particles into smaller ones or the strengthening of bonds between particles, thereby increasing the homogeneity of the mixture.

[0093] In addition, the intensive mixer further includes a heat dissipation device (not shown) to cool the heat generated during high-speed mixing of precursor particles, conductive material, and binder with rapid rotation and strong shear force, thereby preventing quality degradation caused by heat.

[0094] Such intensive mixers offer fast mixing speeds and excellent reproducibility. They are suitable for applications where uniformity of particle size and distribution is critical, such as in battery electrodes, and provide excellent fine particle dispersion, offering advantageous benefits for manufacturing high-performance battery electrode materials.

[0095] Additionally, in one embodiment, the primary mixing unit (220) is connected to the precursor input unit (210) via a two-way branch pipe and may include first and second primary mixing units (221, 222) that mix and spheroidize the precursor materials introduced through the two-way branch pipe.

[0096] Accordingly, the precursors mixed and spherical through each of the first and second primary mixing sections (221, 222) can be collected and fed into the conductive material and binder input section (230) described later.

[0097] In addition, in one embodiment, the primary mixing unit (220) can inspect the particle size of the spherical bodies and, if it is determined that they do not meet the set size, remixing can be performed using an intensive mixer.

[0098] For example, the primary mixing unit (220) further includes an inspection device (not shown) capable of inspecting whether the particle size of the spherical body corresponds to 10 μm, and if the particle size does not correspond to 10 μm, re-mixing can be performed using an intensive mixer.

[0099] The conductive material and binder input section (230) can input the conductive material and binder in a set amount to the precursor sphericalized to a particle size of 10 μm through the primary mixing section (220).

[0100] More specifically, the conductive material and binder input section (230) may include a conductive material input section (230a) for inputting carbon black (Cb), which is a conductive material having a particle size of 1 μm, and a binder input section (230b) for inputting polytetrafluoroethylene (PTFE), which is a binder having a particle size of 1 mm.

[0101] These conductive material and binder input sections (230) can be divided into a first conductive material and binder input section (231) and a second conductive material and binder input section (132) according to the structure of the secondary mixing section (240) that is separated from each other.

[0102] The secondary mixing unit (240) is connected to the conductive material and binder input unit (230), and can form a composite mixture by mixing the conductive material and binder and the precursor introduced through the conductive material and binder input unit (230). At this time, the secondary mixing unit (240) can homogeneously grind the precursor, conductive material and binder after mixing them to form a composite mixture having a particle size of 50 to 500 μm.

[0103] Additionally, in one embodiment, the secondary mixing unit (240) is connected to the primary mixing unit (220) by a two-way branch pipe and may include first and second secondary mixing units (241, 242) that mix the spherical precursor, conductive material, and binder, respectively, introduced through the two-way branch pipe.

[0104] At this time, the first secondary mixing unit (241) can receive the conductive material and binder from the first conductive material and binder input unit (231), and the second secondary mixing unit (242) can receive the conductive material and binder from the second conductive material and binder input unit (231).

[0105] Meanwhile, in the process of mixing the conductive material and binder in the conductive material and binder input section (230) and the secondary mixing section (240) by inputting the conductive material and binder into the precursor, the binder to be input may be powdered and input, or it may be homogeneously ground after input without being powdered.

[0106] First, the process of pulverizing and introducing the binder in the conductive material and binder input section (230) is as follows.

[0107] The conductive material and binder input section (230) can pulverize and input the binder during the process of inputting the conductive material and binder into the precursor. At this time, the conductive material and binder input section (230) can pulverize the binder to have a particle size of 1 mm using an auxiliary milling process.

[0108] In addition, the secondary mixing section (240) can form a composite mixture by mixing the precursor, conductive material, and powdered binder using an intensive mixer.

[0109] In addition, the secondary mixing unit (240) can inspect the particle size of the composite mixture and, if it is determined that it does not meet the set size (e.g., particle size of 50 to 500 μm), remixing can be performed using an intensive mixer.

[0110] In addition, during this process, the secondary mixing unit (240) repeats the process of remixing using an intensive mixer until the particle size inspection result of the electrode meets the set size, and the remixing time can be set to automatically change during the repetition.

[0111] Additionally, the secondary mixing unit (240) can be configured to automatically change the operating time of the intensive mixer or the rotation speed of the intensive mixer during the process of repeating remixing using the intensive mixer.

[0112] Next, we will look at the process of homogeneously grinding the binder after adding it as is without pulverizing it.

[0113] The conductive material and binder input section (230) inputs the conductive material and binder into the precursor without pulverizing the binder being input, and the secondary mixing section (240) mixes the precursor, conductive material, and binder to obtain a composite mixture in an initial fiberized state.

[0114] In this process, the secondary mixing unit (240) can inspect the particle size of the composite mixture and, if it is determined that it does not meet the set size (e.g., particle size of 50 to 500 μm), remixing can be performed using an intensive mixer.

[0115] The extrusion molding section (250) can extrude the composite mixture formed through the secondary mixing section (240) and feed it toward the dry electrode forming section (260) described later.

[0116] More specifically, the extrusion molding section (250) can process a composite mixture composed of a precursor (NCM), a conductive material, and a binder to form an electrode shape. Through this, the extrusion molding section (250) can increase the density and uniformity of the composite mixture.

[0117] The extruder of the extrusion molding section (250) can increase the solid density of the composite mixture and control the pore structure by applying pressure while pushing the composite mixture in one direction. The extruder may include a screw rotation process in which a screw inside the extruder rotates to move and compress the mixture in a certain direction, and strong pressure is applied during this process to aggregate the mixture and increase its density; an extrusion die process in which the composite mixture passes through an extrusion die at the end of the extruder and is formed into a desired shape (sheet, film, etc.); and a temperature control process in which the temperature is controlled through an internal cooling system so that the temperature does not rise excessively during the extrusion process, and the material is not deformed or damaged by heat.

[0118] These extruders can continuously extrude composite mixtures to form desired shapes, and their internal structure is precisely designed for efficient mixing and extrusion.

[0119] For example, the extruder may be configured to include a hopper, a barrel, a screw, a heating and cooling system, an extrusion die, a cooling section, a cutting system, etc.

[0120] The hopper is located at the top of the extruder and serves to supply the complex mixture into the equipment. It has a structure that allows for the precise amount to be fed per batch, thereby ensuring that the supply volume remains constant.

[0121] The barrel is a space where a composite mixture supplied from a hopper moves by a screw and is heated, mixed, and compressed. A heating device may be placed inside the barrel to maintain a constant temperature according to the characteristics of the composite mixture. For example, the heating device inside the barrel can maintain the temperature of the composite mixture at 80 to 100 degrees Celsius through heat generation.

[0122] The screw is a key component that rotates inside the barrel to move, compress, and mix the composite mixture; it is broadly divided into a feeding section (where materials are initially supplied), a compression section (where the composite mixture is compressed and its density increases), and a metering section (where it is discharged through the outlet). As the screw rotates, the composite mixture is subjected to shear force and compressed, which controls the viscosity of the mixture and ensures even mixing.

[0123] Heater and cooling systems are installed around the barrel and screw to maintain an appropriate viscosity through the heating and cooling of the composite mixture. Since the extruder generates high heat during extrusion, it is necessary to control the temperature using a cooling system as well as to provide heating when required. In this case, the sections requiring heating or cooling can be set according to the characteristics of the composite mixture.

[0124] The extrusion die refers to the exit section where the composite mixture is molded into a desired shape and emerges; the shape of the extrusion die can be modified as much as desired depending on the desired electrode shape (e.g., sheet, film, etc.). Furthermore, as the section where the composite mixture is finally compressed and shaped before emerging in its final form, the extrusion die is precisely designed to ensure uniform thickness and shape, thereby maintaining the physical properties of the composite mixture.

[0125] Meanwhile, the extrusion molding section (250) can be formed in various structures to ensure a constant feed amount of the composite mixture that is extruded and fed. This is described in more detail as follows.

[0126] FIG. 5 is a diagram showing a structure for feeding a composite mixture at a constant feed amount through an extrusion molding section (250) according to one embodiment, FIG. 6 is a diagram showing a structure for feeding a composite mixture at a constant feed amount through an extrusion molding section (250) according to another embodiment, and FIG. 7 is a diagram showing a structure for feeding a composite mixture at a constant feed amount through an extrusion molding section (250) according to yet another embodiment.

[0127] Referring to FIG. 5(a), the extrusion die of the extrusion molding unit (250) according to one embodiment of the present invention may be positioned above the double rolling device of the dry electrode forming unit (260) described later, and the composite mixture fed through the extrusion die may fall into the double rolling device and be formed into a film.

[0128] At this time, a screw that rotates around the longitudinal axis and a scraper that moves linearly along the screw in the longitudinal direction of the extrusion die may be disposed on the lower side of the extrusion die.

[0129] Therefore, the extruded material that falls and accumulates in the gap between the double rolling devices of the dry electrode forming unit (260) through the extrusion die is evenly spread by the scraper and becomes flat, so that it can be fed into the gap between the double rolling devices.

[0130] Alternatively, as shown in FIG. 5(b), a flexible hose that can be freely positioned and adjusted along the length of the extrusion die may be disposed of in the extrusion die. In this case, the lower end of the flexible hose may freely position itself and supply the extruded material fed from the extrusion die into the gap between the double rolling devices at a constant feed amount.

[0131] Referring to FIG. 6, in the extrusion die of the extrusion molding section (250) according to another embodiment of the present invention, a cylindrical barrel formed corresponding to the longitudinal direction of the extrusion die and having a hollow interior, and a screw that rotates inside the barrel with the longitudinal direction of the barrel as an axis may be disposed therein. At this time, a plurality of feed holes may be drilled at regular intervals on the lower side of the barrel.

[0132] Accordingly, when the screw rotates, the composite mixture is compressed within the barrel, and due to the compressive force, the extruded material is discharged downward through a plurality of feed holes in a constant feed amount, and the extruded material thus discharged can be supplied into the gap between the double rolling devices at the bottom. At this time, the total length of the feed hole line formed by the plurality of feed holes can be formed to be approximately 1200 mm.

[0133] Referring to FIG. 7, in the extrusion die of the extrusion molding section (250) according to another embodiment of the present invention, a cylindrical barrel with a hollow interior formed in a direction corresponding to the length of the extrusion die may be disposed therein. At this time, a feed slit may be formed at a certain interval along the length of the barrel and formed on the lower side of the barrel.

[0134] Accordingly, the extruded material extruded by the extrusion molding unit (250) is discharged downward through the feed slit in a constant feed amount, and the extruded material thus discharged can be supplied to the gap between the double rolling devices at the bottom. At this time, the length of the feed slit can be formed to be approximately 300 mm.

[0135] The dry electrode forming unit (260) can form a dry electrode by forming the extruded material fed from the extrusion molding unit (250) described above into a thin film and adhering it to a current collector supplied in one direction. This is described in more detail as follows.

[0136] FIG. 8 is a schematic diagram showing the configuration of the dry electrode forming unit (260) illustrated in FIG. 4, and FIG. 9 is a diagram showing the double rolling device of the dry electrode forming unit (260).

[0137] Referring to FIGS. 8 and 9, the dry electrode forming unit (260) may include a first rolling device (261) and a second rolling device (262) for forming the extruded material fed from the extrusion molding unit (250) into a film.

[0138] At this time, the first rolling device (261) may be composed of a first roll (261a) and a second roll (261b) that rotate at different speeds. The rotational speeds of the first roll (261a) and the second roll (261b) are within a range between 10:9 and 10:4. Thus, by rotating the first roll (261a) and the second roll (261b) at different rotational speeds, the higher rotational speed results in a thinner dry film having a less distinct corrugated structure or less distinct fibrils, thereby lowering the surface roughness Ra.

[0139] For example, the length of the fibril is 10 μm on average and is formed anisotropically in the direction of travel of the first roll (262a) and the second roll (262b) of the second rolling device (262). As a result of this rotational speed, a shear force is applied in the width direction and fibrillation occurs along the direction of travel.

[0140] In addition, the first and second rolling devices (261, 262) have the same dimensions and operate at the same rotational speed while being arranged in a mirror-symmetric arrangement with respect to each other.

[0141] In addition, a film-like extruded material supplied by the first roll (261a, 262a) is bonded to both sides of a current collector supplied in one direction between the first and second rolling devices (261, 262) to form a roll-shaped dry electrode.

[0142] Meanwhile, a dry electrode coating system (200) according to one embodiment of the present invention may further include a configuration for optimizing the process through AI analysis.

[0143] More specifically, a dry electrode coating system (200) according to one embodiment of the present invention may include a state information collection unit, an inspection result information collection unit, and a process management unit.

[0144] The status information collection unit can collect equipment status information from dry mixing equipment, composite mixing equipment, dry coating equipment, and winder equipment.

[0145] Here, the dry mixing equipment can produce a precursor by mixing precursor materials. Additionally, the dry mixing equipment can produce a granulated precursor by mixing precursor materials using an intensive mixer; to this end, the dry mixing equipment may include an input device for introducing precursor materials into the intensive mixer. Here, the input device can automatically introduce precursor materials of a preset weight into the intensive mixer. Such dry mixing equipment may refer to equipment including the precursor input section (210) and the primary mixing section (220) described above.

[0146] In addition, in one embodiment, the dry mixing equipment can inspect the particle size of the granulated precursor and, if it is determined that it does not meet the set size, remixing can be performed using an intensive mixer.

[0147] To this end, the dry mixing equipment may include a real-time NDT inspection device capable of inspecting the particle size of the precursor.

[0148] In addition, during this process, the dry mixing equipment repeats the process of remixing using an intensive mixer until the particle size inspection result of the precursor meets the set size, and the remixing time can be set to be automatically changed during the repetition.

[0149] In addition, during this process, the dry mixing equipment can be configured to automatically change the operating time or rotation speed of the intensive mixer while repeating remixing using the intensive mixer. The granulated precursor produced through the dry mixing equipment can be fed into the complex mixing equipment.

[0150] In addition, the composite mixing equipment can produce electrodes by introducing and mixing a conductive material and a binder into a precursor generated through dry mixing equipment.

[0151] In the process of mixing a conductive material and a binder by introducing them into a precursor, the binder to be introduced may be powdered before introduction, or it may be homogeneously ground after introduction without being powdered. Here, the composite mixing equipment may refer to a configuration including the conductive material and binder introduction section (230) and the secondary mixing section (240) described above.

[0152] First, let's look at the process of powdering and adding the binder as follows.

[0153] In the process of mixing a conductive material and a binder with a precursor, the composite mixing equipment can pulverize the binder before adding it. At this time, the composite mixing equipment can pulverize the binder using an auxiliary milling process.

[0154] In addition, the composite mixing equipment can produce and secure granulated electrodes by mixing a precursor, a conductive material, and a powdered binder using an intensive mixer.

[0155] At this time, the composite mixing equipment can inspect the particle size of the granulated electrode, and if it is determined that it does not meet the set size, it can perform remixing using an intensive mixer.

[0156] To this end, the composite mixing equipment may include a real-time NDT inspection device for inspecting electrode particles composed of a mixture of a precursor, a conductive material, and a powdered binder.

[0157] In addition, during this process, the composite mixing equipment repeats the process of remixing using an intensive mixer until the particle size inspection result of the electrode meets the set size, and can be set to automatically change the remixing time during the repetition.

[0158] In addition, during this process, the complex mixing equipment may be configured to automatically change the operating time or rotation speed of the intensive mixer while repeating the remixing process using the intensive mixer.

[0159] Next, we will look at the process of homogeneously grinding the binder after adding it as is without pulverizing it.

[0160] In the process of mixing a conductive material and a binder by introducing them into a precursor, the composite mixing equipment can ensure that the binder is introduced without being powdered, thereby securing a mixture in an initial fiberized state.

[0161] In addition, the composite mixing equipment homogeneously grinds this composite mixture (mixture of precursor, conductive material, and binder) and can obtain an extruded electrode using an extruder process.

[0162] In this process, the composite mixing equipment can inspect the particle size of the ground material and, if it is determined that the material does not meet the set size, re-ground the material.

[0163] To this end, the composite mixing equipment may include a real-time NDT inspection device that inspects the particle size of a homogeneously ground powder after mixing a precursor, a conductive material, and a non-powdered binder, or inspects the viscosity of an electrode that is compression-molded according to an extruder process.

[0164] In addition, the composite mixing equipment can inspect the viscosity of the extruded electrode during the extrusion molding process using the Extruder process, and if it is determined that the viscosity does not meet the set viscosity, it can re-extrude the extruded electrode using the Extruder process.

[0165] The dry coating equipment can apply a thick film coating of the electrode produced through the composite mixing equipment described earlier onto the current collector, and the winder can wind the coated current collector.

[0166] In addition, in one embodiment, the dry coating equipment performs a thick film coating on a secured electrode, and inspects the thickness and image of the coating result coated on the current collector. If it is determined that the result does not conform to a set thickness or set image, the coating result is determined to be defective and a processing signal is output. Accordingly, the management terminal can identify coating status defects based on this processing signal.

[0167] In addition, in one embodiment, the status information collection unit provides equipment status information collected from the dry mixing equipment, composite mixing equipment, dry coating equipment, and winder equipment to the process management unit, and the equipment status information can be used to enable process optimization of the dry mixing equipment, composite mixing equipment, dry coating equipment, and winder equipment.

[0168] The inspection result information collection unit can collect inspection result information in real time from dry mixing equipment, composite mixing equipment, and dry coating equipment, including particle size, viscosity, thickness, and images.

[0169] The inspection result information collection unit may include first to third particle size inspection result collection units, viscosity inspection result collection units, and thickness and image inspection result collection units in order to collect inspection result information in real time from a dry mixing equipment, a composite mixing equipment, and a dry coating equipment, which inspects particle size, viscosity, thickness, and images.

[0170] The first particle size inspection result collection unit can collect particle size inspection results of the precursor in real time from the real-time NDT inspection equipment of the dry mixing equipment.

[0171] The real-time NDT inspection equipment included in the dry mixing equipment inspects the particle size of the precursor granulated and mixed through the dry mixing equipment and transmits the inspection results to the first particle size inspection result collection unit in real time.

[0172] The second particle size inspection result collection unit can collect particle inspection results of an electrode composed of a mixture of a precursor, a conductive material, and a powdered binder in real time from the real-time NDT inspection equipment of the composite mixing equipment.

[0173] In addition, the third inspection result collection unit can collect in real time the particle size inspection results of the homogeneously ground powder after mixing the precursor, conductive material, and non-powdered binder from the real-time NDT inspection equipment of the composite mixing equipment.

[0174] That is, the second particle size inspection result collection unit inspects the particle size of the electrode produced during the granulation mixing process of the precursor, conductive material, and powdered binder, and the third particle size inspection result collection unit corresponds to a configuration that inspects the particle size of the powder produced by homogeneously grinding the precursor, conductive material, and non-powdered binder.

[0175] In addition, the viscosity test result collection unit can collect viscosity test results of electrodes compressed and molded according to the extruder process in real time from the real-time NDT inspection equipment of the composite mixing equipment, and the thickness and image inspection result collection unit can collect thickness and image inspection results of the coating result coated on the current collector in real time from the real-time NDT inspection equipment of the dry coating equipment.

[0176] The inspection results collected through the first to third particle size inspection result collection unit, the viscosity inspection result collection unit, and the thickness and image inspection result collection unit are provided to the process control unit and can be used to enable process optimization of the dry mixing equipment, composite mixing equipment, dry coating equipment, and winder equipment.

[0177] The process management department can perform process optimization of dry mixing equipment, composite mixing equipment, dry coating equipment, and winder equipment based on the equipment status information and inspection result information collected through the status information collection department and inspection result collection department mentioned earlier, and control the dry mixing equipment, composite mixing equipment, dry coating equipment, and winder equipment according to the results of the optimization.

[0178] More specifically, the process management unit can obtain at least one piece of information related to the process of producing a coating result by thick-film coating an electrode on a current collector from the status information collection unit and the inspection result information collection unit, and generate a simulation model to which Digital Twin technology is applied.

[0179] In addition, the process management department can establish a process plan for dry mixing equipment, composite mixing equipment, dry coating equipment, and winder equipment based on at least one piece of information, and then execute a simulation according to the process plan using a simulation model.

[0180] At this time, the process management department can verify the process plan by analyzing the result data from the simulation based on an artificial intelligence (AI) model, and perform process optimization of the dry mixing equipment, composite mixing equipment, dry coating equipment, and winder equipment based on the result data from the verification.

[0181] In addition, in one embodiment, when a process problem occurs in the dry mixing equipment, composite mixing equipment, dry coating equipment, and winder equipment, the process management unit may provide an equipment control guide for solving the process problem based on the optimization results, and enable the process problem of the dry mixing equipment, composite mixing equipment, dry coating equipment, and winder equipment to be solved based on the equipment control guide.

[0182] In addition, in one embodiment, the process management unit may establish a standard for good quality for dry mixing equipment, composite mixing equipment, dry coating equipment, and winder equipment based on at least one piece of information, and then perform a simulation according to the standard for good quality.

[0183] At this time, the process control unit can verify the corresponding good product standard by analyzing result data based on simulation using an artificial intelligence model, and the process control unit can determine whether defects occur in each process of the dry mixing equipment, composite mixing equipment, dry coating equipment, and winder equipment by comparing each inspection result collected through the first to third particle size inspection result collection unit, viscosity inspection result collection unit, and thickness and image inspection result collection unit with the corresponding good product standard.

[0184] In addition, in one embodiment, the process management unit may provide in real time to one or more registered management terminals result data in which process problems of the dry mixing equipment, composite mixing equipment, dry coating equipment, and winder equipment are resolved based on result data from simulation, result data from verification of process plan, result data obtained by performing process optimization of the dry mixing equipment, composite mixing equipment, dry coating equipment, and winder equipment based on the result data from verification, and equipment control guide.

[0185] FIG. 10 is a schematic diagram showing the hardware configuration of a dry electrode coating system (200) according to one embodiment of the present invention.

[0186] Referring to FIG. 10, the dry electrode coating system (200) is implemented in the form of a computing device including hardware (200) and may include memory (210), a processor (220), a communication module (230), and an input / output unit (240).

[0187] The memory (210) is a non-transient computer-readable recording medium and may include a permanent mass storage device such as RAM (random access memory), ROM (read only memory), disk drive, SSD (solid state drive), flash memory, etc. Here, the permanent mass storage device such as ROM, SSD, flash memory, disk drive, etc. may be included in the device or server described above as a separate permanent storage device distinct from the memory (210).

[0188] Additionally, the memory (210) may store an operating system and at least one program code (e.g., code for a security module or an application installed to provide a specific service). These software components may be loaded from a computer-readable recording medium separate from the memory (210). This separate computer-readable recording medium may include a computer-readable recording medium such as a floppy drive, disk, tape, DVD / CD-ROM drive, or memory card.

[0189] Additionally, in one embodiment, the memory (210) may include at least one instruction executed by the processor (220).

[0190] Here, at least one command may include a command to collect equipment status information from a precursor input unit (210), a primary mixing unit (220), a conductive material and binder input unit (230), a secondary mixing unit (240), an extrusion molding unit (250) and a dry electrode forming unit (260), a dry mixing equipment, a composite mixing equipment, a dry coating equipment and a winder equipment, a command to collect inspection result information in real time from the dry mixing equipment, the composite mixing equipment and the dry coating equipment, by inspecting particle size, viscosity, thickness and images, a command to perform process optimization of the dry mixing equipment, the composite mixing equipment, the dry coating equipment and the winder equipment based on the equipment status information and inspection result information collected through the status information collection unit and the inspection result collection unit, and a command to control the dry mixing equipment, the composite mixing equipment, the dry coating equipment and the winder equipment according to the result of the optimization.

[0191] In another embodiment, software components may be loaded into memory (210) via a communication module (230) rather than a computer-readable recording medium. For example, at least one program may be loaded into memory (210) based on a computer program installed by files provided over a network by developers or a file distribution system (e.g., an application store service server) that distributes installation files for applications.

[0192] The processor (220) may be configured to process instructions of a computer program by performing basic arithmetic, logic, and input / output operations. Instructions may be provided to the processor (220) by memory (210) or a communication module (230). For example, the processor (220) may be configured to execute instructions received according to program code stored in a recording device such as memory (210).

[0193] The communication module (230) can provide a function for communicating with a user terminal, etc., through a network. Additionally, the communication module (230) can provide a function for communicating with one or more other devices through a wired and / or wireless network. That is, the communication module (230) is a part that realizes each of the aforementioned function modules by having its function controlled by a processor (220) that references the memory (210).

[0194] The input / output unit (240) may be a means for interfacing with an external input / output device (not shown). For example, the external input device may include devices such as a keyboard, mouse, microphone, camera, etc., and the external output device may include devices such as a display, speaker, haptic feedback device, etc. As another example, the input / output unit (240) may be a means for interfacing with a device in which the functions for input and output are integrated into one, such as a touchscreen.

[0195] Additionally, the dry electrode coating system (200) may include more hardware components depending on the nature of the device to which it is applied. For example, it may be implemented to include at least some of the input / output devices described above, or it may include other components such as a transceiver, a GPS (Global Positioning System) module, a camera, various sensors, a DB, etc. As a more specific example, if the terminal device is a smartphone, it may be implemented to include various components such as an accelerometer or gyroscope sensor, a camera module, various physical buttons, buttons using a touch panel, input / output ports, and a vibrator for vibration, which are generally included in smartphones.

[0196] However, the components and forms of the computing device described in this specification are merely exemplary, and the configuration of such computing device may differ from that described in this specification due to the adoption of other known technologies or future advancements in information and communication technology.

[0197] Although the embodiments described above have been described as utilizing aspects of the subject matter currently invented in one or more standalone computer systems, the present invention is not limited thereto and may be implemented in conjunction with any computing environment, such as a network or a distributed computing environment. Furthermore, aspects of the subject matter in the present invention may be implemented in a plurality of processing chips or devices, and storage may be similarly affected across a plurality of devices. Such devices may include PCs, network servers, and portable devices.

[0198] Although the present invention has been described in relation to some embodiments, various modifications and changes may be made without departing from the scope of the invention as understood by a person skilled in the art to which the invention pertains. Furthermore, such modifications and changes should be considered to fall within the scope of the claims appended to this specification.

[0199] Explanation of the symbols

[0200] 100: Dry electrode coating system

[0201] 110: Dry mixing section

[0202] 120: Complex mixing section

[0203] 130: Dry coating section

[0204] 140: Winder

[0205] 200: Dry electrode coating system

[0206] 210: Electrode insertion part

[0207] 220: 1st Mixing Section

[0208] 221: 1st Primary Mixing Section

[0209] 222: 2nd 1st Mixing Section

[0210] 230: Conductive material and binder input section

[0211] 230a: Conductive material input section

[0212] 230b: Binder input section

[0213] 231: First conductive material and binder input section

[0214] 232: Second conductive material and binder input section

[0215] 240: Secondary mixing section

[0216] 241: 1st and 2nd Mixing Sections

[0217] 242: 2nd Secondary Mixing Section

[0218] 250: Extrusion molding section

[0219] 260: Dry electrode forming section

Claims

1. A dry mixing unit (110) that mixes precursor materials to produce an active material; A composite mixing unit (120) that produces an electrode by mixing a conductive material and a binder with the above active material; A dry coating unit (130) that thickly coats the produced electrode onto a current collector; and A winder (140) for winding the entire house after coating is complete, including Dry electrode coating system.

2. In Paragraph 1, The above dry mixing unit (110) is, The method of producing a granulated active material by mixing the above precursor materials using an intensive mixer, Dry electrode coating system.

3. In Paragraph 2, The above dry mixing unit (110) is, Inspecting the particle size of the granulated active material and, if it is determined that it does not meet the set size, performing remixing using the intensive mixer. Dry electrode coating system.

4. In Paragraph 3, The above dry mixing unit (110) is, The process of remixing using the intensive mixer is repeated until the particle size inspection result of the active material meets the set size, and the remixing time is set to be automatically changed during the repetition. Dry electrode coating system.

5. In Paragraph 4, The above composite mixing unit (120) is, A conductive material and a binder are added to the above active material and mixed, wherein the binder is added in powder form. Dry electrode coating system.

6. In Paragraph 5, The above composite mixing unit (120) is, Powdering the input binder using an auxiliary milling process, Dry electrode coating system.

7. In Paragraph 6, The above composite mixing unit (120) is, A method for obtaining a granulated electrode by mixing the active material, conductive material, and powdered binder using an intensive mixer. Dry electrode coating system.

8. In Paragraph 7, The above composite mixing unit (120) is, Inspecting the particle size of the granulated electrode and, if it is determined that it does not meet the set size, performing remixing using the intensive mixer. Dry electrode coating system.

9. In Paragraph 8, The above composite mixing unit (120) is, The process of remixing using the intensive mixer is repeated until the particle size inspection result of the electrode meets the set size, and the remixing time is set to be automatically changed during the repetition. Dry electrode coating system.

10. In Paragraph 4, The above composite mixing unit (120) is, A conductive material and a binder are added to the above active material and mixed, wherein the binder is added without being powdered to secure a mixture in an initial fiberized state. Dry electrode coating system.

11. In Paragraph 10, The above composite mixing unit (120) is, The above mixture is homogeneously ground, and the ground material is extruded using an Extruder process to obtain an electrode. Dry electrode coating system.

12. In Paragraph 11, The above composite mixing unit (120) is, In the homogeneous grinding process of the above mixture, if the particle size of the ground material is inspected and it is determined that it does not conform to a set size, the ground material is re-ground. Dry electrode coating system.

13. In Paragraph 12, The above composite mixing unit (120) is, In the extrusion molding process using the above-mentioned extruder process, if the viscosity of the extruded electrode is inspected and it is determined that it does not meet the set viscosity, the extruded electrode is re-extruded using the above-mentioned extruder process. Dry electrode coating system.

14. In Paragraph 7 or Paragraph 11, The above dry coating part (130) is, A method of thick-film coating a secured electrode, inspecting the thickness and image of the coating result thick-film coated on the current collector, and if it is determined that it does not conform to a set thickness or set image, determining the coating result as defective and outputting a processing signal. Dry electrode coating system.

15. A step of producing an active material by mixing precursor materials through a dry mixing section; A step of producing an electrode by mixing a conductive material and a binder with the active material through a composite mixing unit; A step of thick-film coating the produced electrode onto a current collector through a dry coating section; and A step of winding the entire coated house through a winder; comprising Dry electrode coating method.

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