Abstract
The invention relates to a roller (1) for use in a dry coating process to produce electrodes, comprising: a roller core (3) consisting of a core material; a roller shell (4) consisting of a shell material, the roller shell surrounding the roller core at least in sections; the shell material having a greater hardness than the core material; and the roller core including a device for tempering the roller shell.
Claims
1. A roller for use in a dry coating process to produce electrodes, comprising: a roller core consisting of a core material; a roller shell consisting of a shell material, the roller shell surrounding the roller core at least in sections; wherein the shell material has a greater hardness than the core material; and wherein the roller core has a device for tempering the roller shell.
2. A roller for use in a dry coating process to produce electrodes, comprising: a roller core consisting of a core material; a roller shell consisting of a shell material, the roller shell surrounding the roller core at least in sections; wherein the shell material has a greater hardness than the core material; wherein the roller shell and the roller core are designed as separate components and the essentially tubular roller shell is attached to the roller core in a force-fit and/or form-fit manner; and wherein the roller shell consists of a curable steel, such as a cold work steel, and is through-hardened on its surface at least to a depth of at least 5 mm.
3. A roller for use in a dry coating process to produce electrodes, comprising: a roller core consisting of a core material; a roller shell) consisting of a shell material, wherein the roller shell surrounds the roller core at least in sections; and wherein the roller core has a device for tempering the roller shell; wherein the device for tempering the roller shell has a plurality of independently segmented tempering zones in the axial direction (X) of the roller, wherein individual temperatures can be set in the individual tempering zones.
4. The roller claim 1, wherein the shell material is applied as a coating to the roller core or the roller shell.
5. The roller of claim 4, wherein the coating comprises chromium, diamond-like carbon, tungsten carbide or a metal matrix composite such as a tungsten carbide/cobalt alloy or a chromium carbide/nickel-chromium composite.
6. The roller of claim 1, wherein the roller shell has a hardness of at least 53 HRC, preferably at least 57 HRC, particularly preferably at least 62 HRC.
7. The roller of claim 1, wherein the roller shell and the roller core are designed as separate components and the essentially tubular roller shell is attached to the roller core in a force-locking and/or form-locking manner.
8. The roller of claim 7, wherein the roller shell is fixed to the roller core by means of shrinking and/or cold expansion.
9. The roller of claim 7, wherein the roller shell is fixed on the roller core by means of a clamping connection.
10. The roller of claim 1, wherein the roller shell has a wall thickness (D) of at least 10 mm, preferably at least 15 mm, particularly preferably at least 20 mm.
11. The roller of claim 1, wherein the roller shell consists of a curable steel, such as a cold work steel, and is through-hardened on its surface to a depth of at least 5 mm.
12. The roller of claim 11, wherein the roller shell is through-hardened across the entire tube wall cross-section.
13. The roller of claim 1, wherein the roller core consists of an easily machinable steel, such as a heat-treatable steel, such as 42CrMo4, or a case-hardening steel.
14. The roller of claim 1, wherein the device for tempering the roller shell comprises at least one heating and/or cooling element integrated in the roller core.
15. The roller of claim 1, wherein the device for tempering the roller shell provides a plurality of independently segmented tempering zones in the axial direction (X) of the roller, wherein individual temperatures can be set in the individual tempering zones.
16. The roller of claim 1, wherein the roller core has an axial bore, in which the heating and/or cooling element is accommodated.
17. The roller of claim 1, wherein the device for tempering the roller shell is an inductive heating element.
18. The roller of claim 1, wherein the device for tempering the roller shell is a temperature radiator received in the axial bore of the roller core.
19. The roller of claim 1, wherein the roller core has functional bores formed as fluid channels, which extend at least in sections on the outer surface of the roller core.
20. A roller assembly for use in a dry coating process for producing electrodes, comprising two rollers forming a roller gap between them, of which at least one roller is designed as a roller of any one of the preceding claims, and further comprising at least two detection devices spaced apart orthogonally to the conveying direction of the electrode for detecting the thickness of the electrode produced in the roller gap, wherein the roller assembly also includes a control device which is designed to compare the at least two detected actual thicknesses with a target thickness and, when a deviation of one of the actual thicknesses from the target thickness is detected, the tempering zone assigned to the respective detection device is actuated by the control device in such a way that the respective actual thickness is brought closer to the target thickness.
21. The roller assembly of claim 20, wherein at least one respective detection device is assigned to each tempering zone.
22. A method of manufacturing an electrode, comprising the steps of: contacting an electrode precursor material with a roller, the roller including: a roller core consisting of a core material; a roller shell consisting of a shell material, the roller shell surrounding the roller core at least in sections; wherein the roller material has a greater hardness than the core material; and wherein the roller core has a tempering device for tempering the roller shell.
23. The method of claim 22, wherein the device for tempering the roller shell has a plurality of independently segmented tempering zones in the axial direction (X) of the roller, wherein individual temperatures can be set in the individual tempering zones, the method further comprising the step of: setting the temperature in at least one tempering zone independently of the other tempering zones.
24. A method of manufacturing an electrode, comprising the steps of: by means of a roller assembly, which has two rollers forming a roller gap between them and at least two detection devices for detecting a thickness: bringing an electrode precursor material into contact with the roller assembly; detecting the thickness of an electrode formed in the roller gap with at least one of the detection devices; and adjusting the temperature of at least one of the rollers based on the detected electrode thickness.
25. An electrochemical laminate comprising at least one electrode layer formed by calendering an electrode precursor material with a roller comprising: a roller core consisting of a core material; a roller shell consisting of a shell material, the roller shell surrounding the roller core at least in sections; wherein the shell material has a greater hardness than the core material; and wherein the roller core has a device for tempering the roller shell.
Description
[0053] FIG. 1 shows a cross-sectional view of an embodiment of the roller according to the invention;
[0054] FIG. 2 shows a perspective view of an embodiment of the roller according to the invention in half section;
[0055] FIG. 3 shows a perspective view of an embodiment of the roller according to the invention;
[0056] FIG. 4 shows a schematic cross-sectional view of an embodiment of the roller according to the invention;
[0057] FIG. 5 shows a detailed view of an embodiment of a tempering zone of the roller according to the invention.
[0058] FIG. 1 shows a cross-sectional view of an embodiment of the roller 1 according to the invention, which can be used in a dry coating process to produce electrodes. The roller 1 has a roller body which is formed by a roller core 3 and a roller shell 4. The roller core 3 essentially consists of a soft core material. The roller core 3 is surrounded by the roller shell 4, which essentially consists of a shell material. An axial bore 8 is provided in the roller core, defining a cavity in the roller core 3. A device 5 for tempering the roller shell 4 is accommodated in the axial bore. The device 5 for tempering the roller shell 4 has a plurality of independently segmented tempering zones 6 in the axial direction X of the roller 1, wherein individual temperatures can be set in the individual tempering zones 6. In the embodiment shown, the device 5 for tempering the roller shell 4 has a total of twelve tempering zones 6, each tempering zone 6 being formed by a separate inductor 9. All inductors 9 have the same dimensions and are spaced apart by the same distance. Furthermore, each inductor 9 has a separate voltage connection 20 and a separate temperature sensor 15 is assigned to each inductor. The recorded temperature data is transmitted via a data cable 23 to a higher-level control unit, which compares the actual values received with the respective target values and consequently regulates the power supply to the individual inductors 9. This makes it possible to set an individual temperature in each tempering zone 6. When the temperature is increased, the material of the roller core 3 and the roller shell 4 expands, so that the outer diameter of the roller 1 is correspondingly increased and, as a result, the roller gap between the two rollers 1, between which the electrode material is passed, is reduced. By providing several individually controllable tempering zones 6, it is therefore possible to individually influence the outer diameter of the roller 1, and accordingly the roller gap, across the entire width of the roller gap in sections in the individual tempering zones 6. The inductors 9 are mounted at regular intervals from one another on a support axis 18, which is accommodated in the axial bore 8 of the roller 1. The support axis 18 is mounted in the axial bore 8 via spherical roller bearings 24, so that the support axis 18 together with the inductors 9 mounted on it can be rotated relative to the roller body. During operation, the roller body, i.e. the roller core 3 together with the roller shell 4 surrounding it, rotate around the stationary support axis 18 with the inductors 9 mounted on it. The support axis 18 itself also has an axial bore, which is used to pass through cooling air to protect the inductors 9 or their electrical connections 20 against overheating. On one end of the roller 1, the support axis 18 has a compressed air connection 22 to feed the axial bore of the support axis 18 with cooling air. On the opposite end, the cooling air duct has radial holes which serve as an air outlet 19 for the compressed air. Axially opposite the roller body are bearing points 14, via which the roller 1 is mounted. A journal 17 protrudes beyond this point in each case. Moreover, a slip ring 21 is mounted on one of the journals 17 shown on the right in the illustration, ensuring electrical power or signal transmission between the components rotating against one another. Connected to the slip ring are data cables 23 for signal transmission between the temperature sensors and the control unit as well as a power connection 25 between the control unit and the individual inductors 9. The roller core 3 also includes cooling bores 16, which run essentially parallel to the roller axis X in the area of the roller body. In the area of the bearing points 14, the cooling bores 16 run at a smaller distance from the roller axis X. Between the cooling bores 16 of the roller core 3 and the cooling bores 16 of the bearing points 14, obliquely extending connecting channels are provided, which connect the cooling bores 16 of the roller core 3 with the cooling bores 16 of the bearing points 14.
[0059] FIG. 2 shows a perspective view of the embodiment of the roller according to the invention from FIG. 1 in half section. The roller 1 has journals 17 at each of its outer ends, which are connected to bearing points 14 which are directly adjacent to the roller body. A slip ring 21 is mounted on the lower journal 17 shown in the figure, to which lines for transmitting electrical power or signals are connected. Also visible is the support axis 18 extending through the roller body, on which the twelve inductors 9 are mounted. It can be seen that the inductors 9 each surround the support axis 18 in a ring shape. The support axis 18 extends on the side of the roller 1 that has the slip ring 21 as far as the end face and protrudes from the journal 17. This is where the air connection 22 for supplying the axial bore of the support axis 18 provided for the air guide with cooling air for cooling the inductors 9 is located. It can also be seen that the bearing points 24 of the support axis 18 are each arranged between the roller body and the bearing points 14 in the axial direction X. It is also visible that the support axis 18 has a plurality of air outlets 19 in the immediate vicinity of the bearing point 24 of the support axis 18, which are aligned radially in different directions.
[0060] FIG. 3 shows a perspective view of an embodiment of the roller 1 according to the invention. It essentially has a roller body consisting of a roller core 3 and a roller shell 4, the roller shell being made of a harder material than the roller core 3. The roller shell 4 provides the roller surface, which is used to generate the electrodes in the roller gap. The roller body is axially connected to bearing points 14, via which the roller 1 can be rotationally supported. One of the bearing points 14 is connected to a journal 17, via which the roller 1 can be driven. The other bearing point 14 is connected to a slip ring 21, into which connections for power and signal transmission lead. On the one hand, a data cable 23 leads into the slip ring, via which the data cable 23 is connected to a control unit. On the other hand, a power cable 25 leads into the slip ring, via which the inductors 9 inside the roller body can be individually supplied with power.
[0061] FIG. 4 shows a schematic cross-sectional view of the roller 1 for use in a dry coating process for producing electrodes 2. It essentially comprises, on the one hand, a roller core 3 consisting of a core material that is an easily machinable steel. The steel of the core material can, for example, be a heat-treatable steel, such as 42CrMo4 in particular, or also a case-hardening steel. On the other hand, the roller 1 comprises a roller shell 4, which surrounds the roller core 3 in a ring. The roller shell 4 consists of a shell material which has a greater hardness than the core material. The hardness of the roller shell 4 is at least 53 HRC (hardness according to Rockwell, scale C), preferably at least 57 HRC, particularly preferably at least 62 HRC. For example, the roller shell 4 can be made of a curable steel, such as a cold work steel. The surface of the roller shell is through-hardened to a depth of at least 5 mm. In the embodiment shown, the roller shell 4 and the roller core 3 are designed as separate components and the tubular roller shell 4 is friction-locked to the roller core 3. The roller shell 4 is fixed to the roller core 3 by shrinking on the roller shell 4 and/or by cold expansion of the roller core 3. The roller shell 4 has a wall thickness D of at least 10 mm, preferably at least 15 mm, particularly preferably at least 20 mm. The roller shell 4 is preferably through-hardened across the entire cross-section of the tube wall.
[0062] FIG. 5 shows a detailed view of an embodiment of the roller 1 according to the invention in half section. It shows in particular a section through the inductor 9 as well as the support axis 18 and its bearing 24. It can be seen that the copper coils or inductors 9 have a plurality of copper wires. The number and thickness of the copper wires per inductor can be determined in such a way that the heating power required to regulate the roller gap can be achieved. Each inductor 9 has its own electrical connection 20 so that each inductor 9 has its own power supply and the resulting different tempering zones 6 can be used to control the deflection of the roller 1. A small distance is provided between each of the inductors. It can be seen that the support axis 18 accommodated in the axial bore 8 of the roller 1 is mounted relative to the roller 1 via a spherical roller bearing 24. The air duct formed in the support axis 18 has a plurality of air outlets 19 extending radially away from the air duct, which open into the interior of the roller 1, in which the inductors 9 are accommodated. The air outlets 19 serve to cool this interior.
[0063] The features of the invention disclosed in the above description, in the figures and in the claims can be essential for the realization of the invention either individually or in any combination.
LIST OF REFERENCE NUMERALS
[0064] 1 roller [0065] 2 electrode [0066] 3 roller core [0067] 4 roller shell [0068] 5 device for tempering the roll shell [0069] 6 tempering zone [0070] 7 heating or cooling element [0071] 8 axial bore [0072] 9 inductor [0073] 10 fluid channels [0074] 11 roller assembly [0075] 12 roller gap [0076] 13 detection device for detecting the thickness of the electrode [0077] 14 bearing point [0078] 15 temperature sensor [0079] 16 cooling bore [0080] 17 journal [0081] 18 support axis [0082] 19 air outlet [0083] 20 electrical connection [0084] 21 slip ring [0085] 22 air connection [0086] 23 data cable [0087] 24 spherical roller bearing [0088] 25 power cable [0089] 26 air duct
