Battery electrode calendering machine

01

Size the rolls, line load and speed

The KIT paper describes a Saueressig calender with 700 mm diameter × 500 mm wide rolls, heating up to 90 °C, maximum web speed 30 m/min and a stated maximum line load of 2000 N/mm in its Materials and Methods section. Its results on page 7 nevertheless report loads up to 2229 N/mm. These are inconsistent statements in the paper; obtain clarification of the load basis rather than treating the larger value as a confirmed machine rating. [1] [6]

TOB’s DYG-703BH page lists φ500 × 550 mm rolls, 2–11 rpm, a 0–2 mm gap adjustment, 15 kW, 380 V at 50 Hz and electrode width up to 520 mm. Its “Max work pressure” field is 500–3000 kN: those units describe force, distinct from hydraulic pressure. The TOB-703B page separately lists 400 × 450 mm rolls, 7 rpm, 7.5 kW, 400 mm electrode width and a “200T” pressure designation whose force-unit basis should be confirmed. [3] [4]

Editorial conversion: 2000 N/mm = 20 kN/cm. Separately, assume a total normal nip force of exactly 3000 kN, acting uniformly across one fully loaded width with no other contact load: division by an assumed 550 mm width gives approximately 5.45 kN/mm, or 5455 N/mm; an alternative assumed 520 mm loaded width gives approximately 5.77 kN/mm, or 5769 N/mm. This illustrates the width dependency only. It does not establish the force available to a narrower electrode, the actual nip distribution or TOB’s allowable line-load rating. Request the manufacturer’s definition and limits for the proposed web. [3] [6]

Editorial kinematic calculation: assuming effective roll diameters of exactly 0.500 m and 0.400 m, surface speed is π × diameter × rotational speed. The 0.500 m roll at 2–11 rpm gives approximately 3.14–17.28 m/min; the separate 0.400 m roll at 7 rpm gives approximately 8.80 m/min. Equality with web speed additionally assumes no slip; these are calculated roll-surface speeds, not measured production speeds or proof of thickness capability. [3] [4]

TOB’s 4680-oriented press page lists a maximum 30 m/min with matched upper/lower roll speed, PLC/touch controls and photoelectric web correction with up to 100 mm movement. Its tension row gives both a 2.3–20 kg magnetic-brake adjustment description and a constant-tension set range of 0–50 N. Confirm what each quantity represents and the actual web-tension range; do not convert one into the other as a verified rating. The listed aluminium/copper substrate-thickness ranges also need confirmation against the intended foil and coated electrode. [5]

Give the supplier the electrode materials (anode, cathode), foil type and thickness, coated width and web width, coating thickness before and after calendering, target density or porosity, required line load in N/mm, line speed, roll diameter and face width, roll heating need and temperature, gap and thickness control method, unwinding and rewinding sizes, tension range, web-guiding range, power supply, floor space, and quantity.

02

Set density, roll temperature and thickness control

The KIT study tested NMC811 cathodes in lithium-metal half-cells at coating densities of 2.30, 2.55, 2.80, 3.05 and 3.30 g/cm³. It reports the highest power performance at 2.55 g/cm³ among these tested conditions and the lowest performance up to 2C at 3.30 g/cm³. These results belong to the tested formulation and half-cell procedure. The paper also observes calendering-induced deformation and corrugations that can propagate into cut sheets. [6]

The Warwick NMC622 study used 203 mm lab-calender rolls at 85, 120 or 145 °C, 0.8 m/min and a 4000 psi hydraulic set point. The electrodes were placed between preheated stainless-steel shims and passed 1–3 times until thickness was within ±1 µm of the target, with measurements at 15 positions. That is a sample-processing procedure and target criterion, not a continuous production calender’s automatic thickness-control accuracy. [2]

Editorial density calculation: assume the study’s zero-porosity reference density of 4.458 g/cm³ applies to the coating, excluding the collector foil, and use porosity = 1 − coating density/reference density. Then assumed porosities of 40%, 35% and 30% give 4.458 × 0.60, × 0.65 and × 0.70, or approximately 2.67, 2.90 and 3.12 g/cm³. These are algebraic values under that material basis, not measured trial outcomes or target densities for another electrode recipe. [2]

TOB-703B lists roll cylindricity below 0.003 mm, surface roughness 0.4 µm and HRC62–65 hardness with hardening depth at least 18 mm. DYG-703BH separately lists 0.2 µm surface finish and HRC65–68. Roll cylindricity, hardness and surface finish are roll properties; agree finished-coating thickness, its measurement locations and the accepted web condition separately. Confirm the roughness metric and inspection method rather than assuming that a µm entry states Ra. [4] [3]

03

Continuous web handling and laboratory sample pressing

TOB’s DYG-703BH includes unwinding and rewinding for continuous processing, while its 4680-oriented offer describes tension and web correction. Warwick’s shim-supported laboratory passes have a different handling arrangement. Specify the offered web path, tension controls and gauging, then require trial records for the intended coating. [3] [5] [2]

04

Compression rolls, gap loading and electrode transport

05

Define force, electrode quality and installation data

06

Send the electrode, density target and line data together

Paste it into your enquiry below or into an email to a maker, then replace every bracket.

Electrode: [anode/cathode material; foil; widths; thickness before and after]
Target: [density g/cm³ or porosity %; thickness tolerance]
Rolls: [diameter; face width; hardness; finish; heating °C]
Force: [line load N/mm; gap control]
Line: [speed m/min; unwind/rewind; tension; web guiding]
Site: [power supply; space; quantity]

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