Method of manufacturing a dry electrode
A method for manufacturing a dry electrode via a multi-roll calender system including providing the multi-roll calender system including a first, second, and third calendering rolls, each roll downstream from the next, where a first nip is formed between the first and second calendering rolls, and a second nip is formed between the second and third calendering rolls, rotating the first calendering roll at a first rotational velocity, rotating the second calendering roll at a second rotational velocity greater than the first rotational velocity, rotating the third calendering roll at a third rotational velocity greater than the second rotational velocity, delivering a first dry electrode material to the first nip to form a dry electrode film, delivering the dry electrode film to the second nip to form a tuned dry electrode film, and laminating the tuned dry electrode film to a current collector to form the dry electrode.
1 . A method of manufacturing a dry electrode via 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, wherein a first nip is formed between the first calendering roll and the second calendering roll, and a second nip is formed between the second calendering roll and the third calendering roll;
rotating the first calendering roll at a first rotational velocity;
rotating the second calendering roll at a second rotational velocity that is greater than the first rotational velocity;
rotating the third calendering roll at a third rotational velocity that is greater than the second rotational velocity;
delivering a first dry electrode material by the multi-roll calender system to the first nip to form a dry electrode film;
delivering the dry electrode film by the multi-roll calender system to the second nip to form a first tuned dry electrode film; and
laminating the first tuned dry electrode film to a current collector to form the dry electrode.
2 . The method of claim 1 , wherein the first dry electrode material is in free flowing particle form.
3 . The method of claim 1 , wherein the dry electrode film adheres to the second calendering roll during the delivering of the first dry electrode material to the first nip.
4 . The method of claim 1 , wherein a diameter of the first calendering roll is substantially equal to a diameter of the second calendering roll and the diameter of the second calendering roll is substantially equal to a diameter of the third calendering roll.
5 . The method of claim 1 , wherein a linear velocity of an outer surface of the second calendering roll is greater than a linear velocity of an outer surface of the first calendering roll, and a linear velocity of an outer surface of the third calendering roll is greater than the linear velocity of the outer surface of the second calendering roll.
6 . The method of claim 1 , further comprising generating a first shear force in the first dry electrode material at the first nip and generating a second shear force in the dry electrode film at the second nip.
7 . The method of claim 1 ,
wherein a third nip is formed between the third calendering roll and a calendering roll positioned adjacent to the third calendering roll.
8 . The method of claim 7 , further comprising:
supplying the 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.
9 . The method of claim 7 , further comprising:
delivering a 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 delivered to the third nip to form an electrode film.
10 . The method of claim 9 , wherein the first and second dry electrode materials are different materials.
11 . The method of claim 1 , further comprising:
rotating a fourth calendering roll, wherein a fourth nip is formed between the fourth calendering roll and a calendering roll positioned adjacent to and downstream of the fourth calendering roll.
12 . The method of claim 11 , further comprising delivering a second dry electrode material by the multi-roll calender system to the fourth nip to form a second dry electrode film.
13 . The method of claim 12 , wherein the first dry electrode material and the second dry electrode material are the same material.
14 . The method of claim 12 , wherein the calendering roll positioned adjacent to and downstream of the fourth calendering roll is a fifth calendering roll.
15 . The method of claim 14 , further comprising rotating the fourth calendering roll at a fourth rotational velocity; and rotating the fifth calendering roll at a fifth rotational velocity, wherein the fifth rotational velocity is greater than the fourth rotational velocity.
16 . The method of claim 15 , further comprising:
a fifth nip formed between a sixth calendering roll and the fifth calendering roll, and delivering the second dry electrode film to the fifth nip to form a second dry tuned electrode film.
17 . The method of claim 16 , wherein the providing the system further comprises providing a third nip positioned between the third calendering roll and a calendering roll positioned adjacent to the third calendering roll, and the method further comprises:
delivering the second dry tuned electrode film by the multi-roll calender system to the third nip; and
supplying the current collector from a current collector source to the third nip;
wherein laminating the first tuned dry electrode film to a current collector to form a dry electrode further comprises laminating the current collector to the first tuned dry electrode film and the second dry tuned electrode film at a position of the third nip to form a dual sided dry electrode.
18 . The method of claim 11 , wherein the providing the system further comprises providing the fourth calendering roll positioned adjacent to and downstream of the third calendering roll.
19 . The method of claim 18 , further comprising rotating the fourth calendering roll at a fourth rotational velocity, wherein the fourth rotational velocity is greater than the third rotational velocity.
20 . The method of claim 1 , further comprising providing the first dry electrode material to the multi-roll calender system by scatter coating.
21 . The method of claim 1 , further comprising providing the first dry electrode material to the multi-roll calender system by a moving belt system.
22 . The method of claim 21 , wherein the moving belt system is a continuous moving belt.
23 . The method of claim 21 , wherein the moving belt system comprises a rewind roll.
24 . The method of claim 1 , further comprising rewinding the dry electrode to form a rolled dry electrode.
25 . The method of claim 1 , further comprising calendering, via a continuous belt, calendaring device the first dry electrode material prior to delivering the first dry electrode material by the multi-roll calender system to the first nip.