Systems and Methods for Manufacturing a Dry Electrode

Patent metadata

Field	Value
Publication number	US-2025273647-A1
Application number	US-202519208739-A
Country	US
Kind code	A1
Filing date	May 15, 2025
Priority date	Jan 16, 2019
Publication date	Aug 28, 2025
Grant date	—

Abstract

A system and methods for manufacturing a dry electrode for an energy storage device are disclosed. The system includes a first dry electrode material delivery system configured to deliver a dry electrode material, a first calendering roll, a second calendering roll, and a controller. The second calendering roll is configured to form a first nip between the first calendering roll and the second calendering roll. The first nip is configured to receive the dry electrode material from the first dry electrode material delivery system, and form a dry electrode film from the dry electrode material. The controller is configured to control a rotational velocity of the second calendering roll to be greater than a rotational velocity of the first calendering roll.

First claim

1 . A system for manufacturing a dry electrode for an energy storage device, comprising:
a first calendar system comprising a first set of horizontally aligned rolls that includes at least four rolls, wherein two rolls of the first set of rolls form a first film creation nip configured to receive first powder and compress the first powder into a first film; and a second calendar system comprising a second set of horizontally aligned rolls that includes at least four rolls, wherein two rolls of the second set of rolls form a second film creation nip configured to receive second powder and compress the second powder into a second film; a current collector unwind station that provides a current collector to a lamination nip where the first film and the second film are simultaneously laminated onto the current collector at the lamination nip; and a rewind station that winds the laminated current collector from the lamination nip onto a roll.

2 . The system of claim 1 , wherein the lamination nip is configured to laminate the first film onto a first side of the current collector and laminate the second film onto a second side of the current collector.

3 . The system of claim 1 , further comprising:
a first powder hopper configured to guide the first powder into the first film creation nip; and a second powder hopper configured to guide the second powder into the second film creation nip.

4 . The system of claim 3 , wherein the first powder hopper and the second powder hopper are funnel-shaped.

5 . The system of claim 1 , further comprising:
a motor system that individually addresses rolls of the system to rotate at different speeds.

6 . The system of claim 1 , wherein the current collector comprises a metal foil.

7 . The system of claim 1 , wherein the current collector is pre-coated with adhesive.

8 . The system of claim 1 , wherein the two rolls of the first set of rolls that form the first film creation nip are smaller in diameter than the other rolls of the first set of rolls.

9 . The system of claim 8 , wherein the two rolls of the second set of rolls that form the second film creation nip are smaller in diameter than the other rolls of the second set of rolls.

10 . The system of claim 1 , wherein the first calendar system and the second calendar system are positioned on either side of the current collector.

11 . A method of manufacturing an electrode using a single tool that converts dry powder to two films and laminates those two films onto a metal foil substrate, the method comprising:
operating a first calendar system comprising a first set of at least four horizontally aligned rolls, wherein two rolls of the first set form a first nip, wherein the first calendar system is operated by providing a first powder to the first nip of the first calendar system to form a first film; operating a second calendar system comprising a second set of at least four horizontally aligned rolls, wherein two rolls of the second set form a second nip, wherein the second calendar system is operated by providing a second powder to the second nip of the second calendar system to form a second film; providing the foil substrate to a laminating nip from a foil roll positioned on an unwind station; using the laminating nip to simultaneously laminate (i) the first film onto a first side of the foil substrate and (ii) the second film onto a second side of the foil substrate; and rewinding the laminated foil substrate onto an electrode roll positioned on a rewind station.

12 . The method of claim 11 , further comprising:
using a first powder hopper to guide the first powder into the first nip; and using a second powder hopper to guide the second powder into the second nip.

13 . The method of claim 12 , wherein the first powder hopper and the second powder hopper are funnel-shaped.

14 . The method of claim 11 , further comprising:
using a motor system to individually address rolls of the tool to rotate at different speeds.

15 . The method of claim 11 , wherein the foil substrate is pre-coated with adhesive.

16 . The method of claim 11 , wherein the two rolls of the first set of rolls that form the first nip are smaller in diameter than the other rolls of the first set of rolls.

17 . The method of claim 16 , wherein the two rolls of the second set of rolls that form the second nip are smaller in diameter than the other rolls of the second set of rolls.

18 . The method of claim 11 , wherein the first calendar system and the second calendar system are positioned on either side of the foil substrate.

19 . A method of manufacturing a dry electrode for an energy storage device in a multi-roll calender system, comprising:
providing the multi-roll calender system including a first calendering roll, a second calendering roll downstream from the first calendering roll and a third calendering roll downstream from the second calendering roll; rotating the first calendering roll at a first rotational velocity; rotating the second calendering roll at a second rotational velocity; rotating the third calendering roll at a third rotational velocity; configuring the multi-roll calender system to form a first nip between the first calendering roll and the second calendering roll, and a second nip between the second calendering roll and the third calendering roll; providing a first dry electrode material and delivering the first dry electrode material by the multi-roll calender system to the first to form a dry electrode film; and providing delivering the dry electrode film by the multi-roll calender system to the second nip to form a first tuned dry electrode film; wherein the second rotational velocity is greater than the first rotational velocity, and wherein the third rotational velocity is greater than the second rotational velocity of the second calendering roll.

20 . (canceled)

21 . (canceled)

22 . The method of claim 19 ,
wherein the configuring the multi-roll calender system further comprises a third nip between the third calendering roll and a calendering roll positioned adjacent to the third calendering roll.

23 . The method of claim 22 , further comprising:
supplying a current collector from a current collector source to the third nip; and laminating the current collector to the first tuned dry electrode film at a position of the third nip to form the dry electrode.

24 . The method of claim 22 , further comprising:
providing a second dry electrode material and delivering the second dry electrode material by the multi-roll calender system to the first tuned dry electrode film at the third nip, wherein the first and second dry electrode materials are provided to the third nip to form an electrode film.

25 . (canceled)

26 . The method of claim 19 , further comprising:
rotating a fourth calendering roll, wherein the configuring of the multi-roll calender system further comprises a fourth nip between the fourth calendering roll and a calendering roll positioned adjacent to and downstream of the fourth calendering roll.

27 . The method of claim 26 , further comprising providing a second dry electrode material and delivering the second dry electrode material by the multi-roll calender system to the fourth nip to form a second dry electrode film.

28 . The method of claim 27 , wherein the calendering roll positioned adja

Assignees

• Matthews Int Corp

Inventors

• Bogenstahl Frank
• Wolters Rene
• Lansing Christoph
• Wolters Kay
• Hackfort Thomas
• Gottszky Jörg

Classifications

• H01M4/8896

  Pressing, rolling, calendering (membrane electrode assemblies H01M8/1004) · CPC title

• H01M4/139

  Processes of manufacture · CPC title

• H01M4/0404

  by coating on electrode collectors · CPC title

• H01G11/86

  specially adapted for electrodes (carbonisation or activation of carbon for the manufacture of electrodes H01G11/34) · CPC title

• H01G11/28

  arranged or disposed on a current collector; Layers or phases between electrodes and current collectors, e.g. adhesives · CPC title