DE102022128049A1 - Method and device for the additive manufacturing of electrochemical devices - Google Patents

Abstract

Manufacturing method for the additive manufacture of at least one component of an electrochemical device, preferably an electrochemical energy storage device, in particular an accumulator, preferably a Li-ion accumulator, and/or an electrolysis cell, at least partially by layer-by-layer application and subsequent, in particular selective, solidification of a, preferably powdered, building material, comprising the steps: - applying at least one layer of the building material to a carrier device, - at least partially solidifying, in particular selectively solidifying, the building material on the carrier device by means of at least one first irradiation unit (10), wherein the first irradiation unit (10) has a plurality of individual radiation exit sections, preferably arranged in at least one row and/or at least one column, in particular a plurality of laser diodes and/or radiation line ends.

Description

The invention relates to a manufacturing method and a manufacturing device for the additive manufacture of at least one component of an electrochemical device, preferably an electrochemical energy storage device, in particular an accumulator, preferably a Li-ion accumulator, and/or an electrolysis cell.

Manufacturing devices and corresponding methods for (additive) manufacturing of components by layer-by-layer application and locally selective solidification of a construction material are generally known from the prior art. For layer-by-layer application, at least one corresponding coating unit is usually provided. For locally selective solidification, at least one corresponding irradiation unit (e.g. comprising at least one laser) is usually provided. These features can also be partially or completely implemented in the invention.

In principle, it has already been proposed to use such a process for additive manufacturing in the production of batteries. For example, US 2020/0411838 A1 describes a manufacturing process for a component of an electrical storage system, whereby a substrate is coated with a particulate construction material, whereby the construction material is solidified by a laser unit after coating. Further layers are then applied in the usual way and each one is solidified. This procedure - based on the usual procedure in the field of laser sintering processes and similar - is perceived as comparatively complex and sometimes also restrictive (in particular as comparatively slow and expensive) with regard to the production of large quantities, especially for battery components.

It is therefore an object of the invention to propose a manufacturing method and a corresponding manufacturing device, wherein an electrochemical device to be manufactured, preferably an electrochemical energy storage device, in particular an accumulator, preferably a Li-ion accumulator, and/or an electrolysis cell, can be manufactured in a comparatively simple and yet precise manner (in particular also in large quantities and/or with a high throughput, for example measured as manufactured area per minute).

This object is solved in particular by the features of claim 1.

• - Bereitstellen einer (vorzugsweise zumindest abschnittsweise flexiblen) Trägereinrichtung in Form eines (vorzugsweise zumindest abschnittsweise flexiblen) Trägerbandes (oder ein solches umfassend), insbesondere umfassend oder gebildet durch eine, vorzugsweise metallene (insbesondere zu mindestens 30 Gew.-%, vorzugsweise mindestens 50 Gew.-%, weiter vorzugsweise mindestens 80 Gew.-% Metall aufweisende), Trägerfolie,
• - Aufbringen mindestens einer (insbesondere trockenen) Schicht des Aufbaumaterials auf das Trägerband,
• - (sukzessives, vorzugsweise kontinuierliches) Zuführen des Aufbaumaterials in einen Bestrahlungsbereich mindestens einer ersten, vorzugsweise stationären, Bestrahlungseinheit und zumindest teilweises Verfestigen, insbesondere selektives Verfestigen, des Aufbaumaterials auf dem Trägerband mittels der mindestens einen ersten Bestrahlungseinheit.

In particular, the object is achieved according to a first aspect by a manufacturing method for the additive manufacture of at least one component of an electrochemical device (device for an electrochemical application), in particular an electrochemical cell, preferably (at least one component) of an electrochemical energy storage device, in particular an accumulator, preferably a Li-ion accumulator, (for example an accumulator cell structure and/or an electrode structure of an accumulator or an accumulator cell, in particular a lithium-ion accumulator), and/or an electrolysis cell, at least partially by layer-by-layer application and subsequent, in particular selective, solidification of a, preferably powdery, building material, preferably by (in particular selective) irradiation, preferably by at least one laser, comprising the steps:

• - Providing a (preferably at least partially flexible) carrier device in the form of a (preferably at least partially flexible) carrier tape (or comprising such a tape), in particular comprising or formed by a, preferably metallic (in particular containing at least 30 wt. %, preferably at least 50 wt. %, more preferably at least 80 wt. %) carrier film,
• - Applying at least one (particularly dry) layer of the building material to the carrier tape,
• - (successive, preferably continuous) feeding of the building material into an irradiation area of at least one first, preferably stationary, irradiation unit and at least partial solidification, in particular selective solidification, of the building material on the carrier tape by means of the at least one first irradiation unit.

One idea of the first aspect is to use a (preferably flexible) carrier device for the (additive) manufacturing process, preferably in the form of a carrier tape - or comprising such a tape - which is (successively) introduced into an irradiation area of the irradiation unit. In this way, comparatively flat electrochemical components or component parts (in particular accumulator components) can be produced in a simple manner. Furthermore, they can be moved or irradiated comparatively quickly. In particular, one or more layers with a special structure (e.g. directed porosity and/or special chemical composition) can be produced. For example, after the (respective) layer has solidified, a (e.g. through the carrier device) device or the carrier film) are moved further so that an area of the carrier material covered with solidified building material is led out of the irradiation area, wherein preferably at the same time a further section of the carrier material (on which there is no solidified building material yet) is moved into the irradiation area. In this way (successively, preferably continuously) a large area of the carrier material can be provided with solidified building material (in particular printed).

Overall, large areas can be provided with a structure in a simple and quick manner or (e.g. by separating or splitting individual sections of solidified build-up material and/or of carrier material supporting solidified build-up material) large quantities can be achieved for a specific component to be manufactured.

• - Aufbringen mindestens einer Schicht des Aufbaumaterials auf eine Trägereinrichtung,
• - zumindest teilweises Verfestigen, insbesondere selektives Verfestigen, des Aufbaumaterials auf der Trägereinrichtung mittels mindestens einer ersten Bestrahlungseinheit, wobei die erste Bestrahlungseinheit eine Vielzahl von einzelnen, vorzugsweise in mindestens einer Zeile und/oder (besonders bevorzugt: und) mindestens einer Spalte angeordneten, Strahlungsaustrittsabschnitten aufweist, insbesondere eine Vielzahl von Laserdioden und/oder Strahlungsleitungs-Enden. Insoweit hier und weiter unten eine Anordnung in Zeilen bzw. Spalten erläutert wird, liegen vorzugsweise mindestens 5 oder mindestens 10 oder mindestens 50 Zeilen vor und/oder mindestens 5 oder mindestens 10 oder mindestens 50 Spalten.

In particular, the object is achieved according to a second aspect (generally independent, but preferably to be combined with the first aspect) by a manufacturing method for the additive manufacture of at least one component of an electrochemical device, preferably (at least one component) of an electrochemical energy storage device, in particular an accumulator, preferably a Li-ion accumulator, and/or an electrolysis cell, at least partially by layer-by-layer application and subsequent, in particular selective, solidification of a, preferably powdered, construction material, comprising the steps:

• - applying at least one layer of the building material to a carrier device,
• - at least partial solidification, in particular selective solidification, of the construction material on the carrier device by means of at least one first irradiation unit, wherein the first irradiation unit has a plurality of individual radiation exit sections, preferably arranged in at least one row and/or (particularly preferably: and) at least one column, in particular a plurality of laser diodes and/or radiation line ends. Insofar as an arrangement in rows or columns is explained here and further below, there are preferably at least 5 or at least 10 or at least 50 rows and/or at least 5 or at least 10 or at least 50 columns.

One idea of the second aspect is to carry out solidification for the (additive) manufacturing process by means of a (first) irradiation unit which has a large number of radiation exit sections (for example at least 5 or at least 10 or at least 50 radiation exit sections). A radiation exit section is preferably understood to be a section of the respective (for example first) irradiation unit at which the beam (e.g. light beam, in particular of a laser) (finally) leaves the irradiation unit, whereby a final exit is preferably understood to mean that the beam (light beam) no longer comes into contact (or interacts) with a solid body until it hits the construction material to be solidified (whereby a transparent intermediate structure which at least does not significantly shape the beam path should preferably be disregarded). Above and below, the respective radiation can preferably be electromagnetic radiation, in particular visible and/or infrared light, preferably from a laser and/or a laser diode.

In principle, a plurality of radiation exit sections can be created by a plurality of radiation sources (e.g. laser diodes) and/or a splitting of a beam from a (common) radiation source.

A radiation line end is preferably understood to mean the end of a (physical) radiation line, for example a light guide. A plurality of radiation exit sections can also be created with the aid of at least one prism and/or at least one lens, in particular a microlens, and/or at least one mirror, in particular a micromirror.

Overall, the special configuration of the irradiation unit according to the second aspect allows large areas to be provided with a structure in a relatively simple manner (in particular when the construction material is at least one metal) in a simple and quick manner, or (by separating or separating individual sections of solidified construction material and/or of carrier material carrying solidified construction material) large quantities can be achieved for a specific component to be produced (similar to the first aspect). In particular, a combination of the first and second aspects can therefore enable improved production in this respect in a synergistic manner. In this case, a relatively large area can be irradiated (simultaneously) and (selectively) solidified particularly advantageously with the large number of radiation exit sections and the use of a moving carrier belt, whereby the use of the carrier belt can easily lead to solidifying build-up material can be added.

The following explanations refer (unless the context indicates otherwise) to the first and second aspects (as respective optional further training courses of the first or second aspects or as further training courses of a combination of the two aspects).

A further (second) irradiation unit may, but does not have to, be provided.

The (respective) carrier device preferably comprises a carrier material, which can be formed, for example, by the carrier tape, in particular the carrier film. The carrier device can be supported at least in sections by a base. The base can have a belt (e.g. conveyor belt) and/or a processing and/or carrier table and/or at least one roller and/or at least one support slat, preferably a plurality - of e.g. at least 5 or at least 10 or at least 20 - support slats. The (respective) carrier device is to be understood in particular as a device to which the construction material is (directly) applied. The (respective) carrier device can have a single-layer or multi-layer structure. The (respective) carrier device can be constructed in one piece, possibly monolithic, or in multiple pieces. Alternatively or in addition to a carrier tape, a (possibly non-flexible or conventional) construction platform can also be used as a carrier device. Such a construction platform can, for example, be less than 10 times or less than 2 times as long as it is wide, whereby a length (here and below) is to be understood as the longest extension along an axis of symmetry, preferably in plan view (vertical viewing angle from above, isometric), or (if no axis of symmetry is formed) the distance of the pair of points which has the greatest distance between all pairs of points, and whereby the width is to be understood as the (maximum) extension perpendicular to the length.

The (respective) carrier device, preferably carrier film, can be manufactured partially or completely additively, for example to achieve porous structures in order to reduce weight if necessary

In principle, it is possible for only one layer of the building material to be applied to the carrier device (in particular the carrier material) and then solidified (there). The steps of applying a layer of the building material and subsequent (at least partial) solidification, in particular selective solidification, can, however, be repeated at least once, possibly at least twice or at least five times (whereby the carrier device or the carrier material can be moved further for this purpose or can be located at the same location where an underlying layer has also been solidified, which will be explained in more detail below).

The solidification process is preferably a (selective) laser sintering or laser melting process.

A flexible carrier material is preferably a dimensionally unstable material, for example such that the material (at 20 °C) can be placed around a straight circular cylinder with a diameter of 20 cm without tearing, preferably without it (after such an arrangement) moving away from the straight circular cylinder due to elastic restoring forces. A flexible carrier material can alternatively or additionally be a material in which a square section of the same with an edge length of 10 cm bends by at least 1 mm or at least 1 cm due to its own weight when the square section is supported on two support lines that extend along two opposite edges of the square. If the resulting flexibility is not uniform across the carrier material, this condition should apply in particular to at least one square section (edge length 10 cm), preferably to corresponding square sections that cover a total of at least 50% of the area of the carrier material (if necessary for the entire carrier material or all corresponding sections). The (flexible) carrier material can have a thickness of preferably less than 2.0 mm, more preferably less than 1.00 mm, even more preferably less than 0.50 mm, possibly less than 0.050 mm or less than 0.015 mm or less than 0.008 mm or even less than 0.004 mm. Alternatively or additionally (unless logically excluded by the preceding upper limit values), a thickness of at least 0.001 mm, preferably at least 0.005 mm, possibly at least 0.010 mm can be present. Each of the upper and each of the lower limit values can be linked to a corresponding range (unless logically excluded).

The carrier material is in particular a (metallic) foil (carrier foil). The carrier material (in particular the carrier foil) preferably comprises aluminum (in particular at least 50% by weight or at least 80% by weight), preferably to produce a cathode, and/or copper (in particular at least 50% by weight or at least 80% by weight), preferably to produce an anode.

The additively manufactured component can be, for example, a (functional) layer of the electrochemical device and/or, for example, an anode and/or cathode and/or a separator of a rechargeable battery.

In embodiments, for example, at least 10 wt. %, preferably at least 30 wt. %, optionally at least 60 wt. % of the electrochemical device (e.g. the accumulator) can be or have been produced by the production method according to the invention.

The electrochemical device can be an electrochemical device, an electrochemical component and/or an electrochemical part, in particular an electrochemical cell, preferably a battery cell, fuel cell and/or electrolysis cell.

The carrier material (or the carrier film) can in principle be (partially or completely) a component of the additively manufactured component (or remain in/on the component or a corresponding part), for example be a component of an electrode (cathode or anode) of a rechargeable battery, or be (at least partially) removed at a later point in time (i.e. in particular only - or at least partially only - used as a transport base or transport film).

Preferably, selective solidification takes place (so that not the entire respective layer is solidified). Alternatively, however, the entire layer of the building material can be solidified by the irradiation unit during solidification. Any non-solidified portions of the building material can be removed from the solidified components in a subsequent step (e.g. by suction, in particular by means of at least one suction nozzle).

In the area of (optionally selective) solidification, the entire material (in the respective layer) can be melted or only part of the material. If a material mixture is present, for example, only one component of the material mixture can be melted, for example a binder (in particular a polymer binder), for example to connect (not per se, at least not completely) melted metal particles (in particular particles with at least 50 wt.% or at least 80 wt.% metal).

A binder (in particular a polymer binder), in particular the one mentioned above, is preferably configured such that it adheres to the carrier device, in particular the carrier film, during melting and thereby bonds with it.

In general, non-solidified building material can be returned to a cycle, preferably to produce a new layer or a new cell, preferably a pouch cell and/or a cylindrical cell. Returning unconsolidated powder (building material) can, for example, involve pneumatic conveying and, if necessary, adding fresh powder.

The solidification step can also include a step of bonding the construction material to the carrier material, which is particularly advantageous if the carrier material is to be part of the component of the electrochemical device (or the corresponding electrochemical component). However, even if the carrier material is removed from the construction material in a subsequent manufacturing step, bonding (at least relatively loosely) can be advantageous, for example for further transport. If necessary, in such a case (or also in general), an intermediate layer can be provided between the carrier material and the construction material, which makes it easier to subsequently separate the construction material from the carrier material.

Preferably, there is a relative movement between the carrier device and the coating unit (during coating) and/or between the carrier material and the irradiation unit (during irradiation). For this purpose, the carrier device can be moved and the coating unit or the irradiation unit can remain stationary, or vice versa. Alternatively, both the coating unit or the irradiation unit and the carrier device can move. If here and in the following, without explicit indication to the contrary, a movement (progression) is mentioned, preferably (as long as nothing else is indicated in the context) a movement perpendicular to a construction direction (z-direction) is meant.

A stationary irradiation unit is understood to mean, in particular, an irradiation unit that is not moved (or not moved at all) when the building material is solidified (in absolute terms, in particular in relation to a reference point that, during use, is part of the substrate on which the production device is arranged). The solidifying radiation (e.g. the respective laser beam) can move (also in absolute terms) or remain stationary (in both cases, a (possibly additional) relative movement to the building material can be achieved by moving the same forward).

Optionally, a (respective) radiation exit section (possibly several radiation exit sections) of the irradiation unit can always irradiate the same (sub-) area of an irradiation area. This does not necessarily have to apply to the irradiation unit as a whole, for example if individual radiation exit sections are switched on and individual radiation exit sections (possibly several radiation exit sections) are switched off.

In any case, the irradiation itself can (optionally) move locally, for example by moving a laser beam, in particular by deflecting it (for example in a scanning manner). A laser beam can be moved, for example, by MEMs (MEM = micro-electromechanical-mirror).

The manufacturing process is preferably a continuous process, in particular a conveyor belt process. A corresponding continuous carrier can be provided for this purpose. Alternatively or additionally (in the sense of a hybrid process), the manufacturing process can also run discontinuously, so that, for example, building material is built up on a (single) carrier device (or is solidified there), then removed (together with the carrier device or at least parts thereof) from the solidification area and then another (new) carrier device is brought into an irradiation area and there again provided with building material (which is solidified there).

According to the embodiment, the carrier material (or the carrier tape or the carrier film) is in an initial state preferably at least 2 times, preferably at least 5 times, even more preferably at least 10 times and/or at most 100,000 times as long as it is wide.

Preferably, the carrier material is provided in tape form (in the form of a tape, preferably a film tape).

According to the embodiment, the carrier material (or the carrier tape and/or its carrier film) is preferably provided in an at least partially rolled-up state (possibly completely in the initial state). Alternatively or additionally, the carrier material (or the carrier tape and/or its carrier film) can be provided in a folded state (for example folded at least twice or at least five times or at least ten times), or also partially rolled-up and partially folded. This allows the carrier material to be provided in a space-saving manner.

The carrier material (or the carrier tape and/or its carrier film) can (after solidification of the build-up material) be at least partially rolled up and/or folded, if necessary together with the build-up material (or at least parts of the build-up material) or without the build-up material.

Rolling or folding together with the construction material is particularly advantageous if the carrier material is to be part of the electrochemical device. However, even if the carrier material (or the carrier tape and/or its carrier film) is not part of the construction material, it can initially be rolled or folded together (for example for transport and/or storage purposes).

In embodiments, the build-up material can be transferred after solidification from a carrier material of the carrier tape, preferably formed by the carrier film - hereinafter also referred to as the first carrier material - to another, possibly flexible, second carrier material, preferably in a roll-to-roll process, or remain on the first carrier material. Alternatively, the build-up material can also remain on/on the (first) carrier material (and become part of the electrochemical device to be produced). The second carrier material can optionally be of the type described in connection with the first carrier material (above and/or below).

Alternatively or additionally, a layer structure (sandwich), comprising in particular a carrier material (carrier film) of the carrier tape or the carrier tape itself and the (solidified) construction material, can be cut into at least two (smaller) strips or divided into individual (e.g. rectangular) plates (in particular for pouch cells).

Preferably, a back side of the carrier tape and/or its carrier film is also provided with a (particularly selectively) solidified layer of a construction material. In order to be able to irradiate the back side using the irradiation unit, a deflection roller can be provided, for example. In this way, an accumulator (battery), for example, can be manufactured in a particularly effective manner.

In embodiments, the application can be carried out by means of a stationary coating unit. Alternatively or additionally, the solidification can be carried out by means of a stationary irradiation unit (in particular as defined above).

A stationary coating unit is understood to mean in particular a unit that does not move (itself) during the coating process, so that, for example, a coating is carried out by the carrier material (or carrier tape or at least its carrier film) being moved beneath the coating unit. Alternatively, the coating unit can also be moved (at least partially), in particular a coating arm thereof.

The irradiation unit can have a plurality of individual radiation exit sections (preferably arranged in at least one row and/or in at least one column), in particular a plurality of laser diodes and/or radiation line ends.

Specifically, the irradiation unit can have a matrix of radiation exit sections. If a plurality of radiation exit sections is provided, a matrix of impact points can be made possible, with each impact point being associated in particular with a corresponding radiation exit section (wherein the impact point is an area of the construction material or construction field that is irradiated by the respective radiation exit section).

If several impact points are arranged one behind the other in a longitudinal direction (or direction of travel of the construction material), they can be aligned (in the longitudinal direction; with at least one nearest neighbor). In such a case, however, there can advantageously also be an offset to at least one nearest neighbor in the width direction (in particular such that at least two impact points that follow one another in the longitudinal direction are not aligned with one another in the longitudinal direction). The same can also apply to the radiation exit sections, although there does not have to be a mandatory connection here (for example, if angles of rays assigned to corresponding radiation exit sections differ from one another, so that there is no offset in the width direction with respect to the radiation exit sections, but there is with respect to the impact points). Overall, it can apply to at least 30% or at least 50% of all impact points and/or radiation exit sections that they are arranged offset with respect to at least one neighbor that is closest in the longitudinal direction (that precedes and/or follows in the longitudinal direction).

With such an offset, gradations (steps) can be reduced or avoided in a simple and thus advantageous manner, which can arise in particular when a large number of radiation exit sections irradiate the same line (in the longitudinal direction).

The respective radiation exit section can preferably be configured for constant (stationary) irradiation.

Preferably, the carrier material (or the carrier tape) moves through the irradiation unit during irradiation. In this case, the movement of the carrier tape or carrier material is used in a synergistic way in two ways, namely on the one hand to transport the carrier material further and on the other hand to be able to (selectively) introduce structures into the construction material. Alternatively, the carrier material can also be at rest (relative to the irradiation unit or exposure unit) during irradiation. Corresponding (selective) structures can be achieved, for example, by switching individual radiation exit sections (e.g. laser diodes) on or off and/or (in a conventional manner) by scanning using one or more laser beams (as in the case of a moving carrier material).

The irradiation unit preferably comprises at least one laser. The irradiation unit further preferably comprises at least one VCSEL (=Vertical Cavity Surface Emitting Laser) and/or VECSEL (Vertical External Cavity Surface Emitting Laser). The irradiation unit further preferably comprises a VCSEL and/or VECSEL arrangement, preferably comprising a multiplicity of VCSEL and/or VECSEL diodes, in particular in a matrix arrangement with a multiplicity of rows and columns. A wavelength of the respective laser diode is 405-1400 nm, preferably 900-1000 nm, particularly preferably 940-980 nm. The wavelength can further preferably be adapted to an absorption band of a construction material.

Alternatively or additionally, the irradiation unit can also comprise one or more lasers, which are moved (in a scanning manner) over the construction field or the irradiation area, for example by means of a number of (polygon) scanners.

Preferably, in addition to a first irradiation unit with a plurality of individual radiation exit sections (preferably arranged in at least one row and/or at least one column), an auxiliary irradiation unit (preferably at least one, in particular scanning, auxiliary laser unit) is used, such as a CO, CO ₂ , fiber and/or Nd:YAG laser. The scanning can be carried out in particular by means of a galvanometer scanner and/or polygon scanner and/or a micromirror Arrays. Alternatively or additionally, a beam can be moved over the construction field or the irradiation area using a single or multi-axis linear drive. In general, a micro-electro-mechanical system (MEM) can be used.

For certain applications (component structures) it can be advantageous not only to irradiate/solidify in a raster fashion (with a constant or variable raster size), as is possible with a matrix exposure unit or a polygon scanner, but also to form curved solidification paths, e.g. using a galvanometer mirror. Alternatively or additionally, a light guide (possibly a light guide line or a light guide array) can be provided, which can be moved in the x/y direction relative to the construction field, e.g. using a two-axis linear drive (which can be achieved, e.g., by movement alone or by interaction with a movement of the carrier device).

Furthermore, structuring (e.g. introducing local holes) can be interesting. Specifically, the laser beam can be moved from position to position and remain in one place for a short, defined time.

The above auxiliary irradiation unit (or complementary irradiation unit, in particular complementary laser) can be, for example, a CO ₂ or Nd:YAG laser (e.g. with scanner-based control), in particular for melting metals and/or polymers that cannot be melted with the wavelength and/or power of a VCSEL and/or VECSEL or another diode laser, for example due to insufficient absorption of introduced energy. In particular, the emission wavelengths of a CO laser (in the mid-infrared range 4.8-8.3 µm) and/or a CO ₂ laser (in the mid-infrared range in particular 9.4 and 10.6 µm) are suitable for processing (solidifying) metal-containing, in particular lithium-containing, ceramics and oxides. Even if, for example, conductive carbon black is added as an absorber, it may not be possible (without such a measure) to melt all conceivable building materials satisfactorily.

Preferably (in particular in the second aspect, possibly also in the first aspect) the application is carried out by means of a movable coating unit. Alternatively or additionally (in particular in the second aspect, possibly also in the first aspect) the solidification is carried out by means of a movable irradiation unit. A movable coating unit is preferably understood to mean that the coating unit (as a whole), i.e. not just a coating arm, for example, can be moved in such a way that it can be arranged over different areas (for example different individual construction fields), for example in order to apply several components (of the same or different shape) in one plane. The process is preferably carried out translationally in one direction, particularly preferably alternating between two end positions that are at or near the ends of the construction field.

If necessary, the coating unit can be moved in such a way that different layers (for example arranged at the same height) can be applied. In particular, the mobility is not limited (solely) to a process being carried out for the purpose of applying the layer. In general, however, the coating unit can be one that is moved (if necessary exclusively) for the purpose of applying the layer. The (movable) irradiation unit is preferably configured in such a way that it can be moved (as a whole), for example in order to (selectively) solidify the aforementioned adjacent layers that were applied by the coating unit. By means of such a movable coating unit and/or such a movable irradiation unit, comparatively large areas of a carrier material can be provided with a (selectively) solidified building material. Separation can then be carried out, for example, by separating the carrier material (including building material) or separating the building material.

A construction field for consolidation is preferably rectangular, circular, circular segment-shaped, circular sector-shaped, annular or annular segment-shaped.

In embodiments, a rotary (continuous) coating is carried out. For example, a rotating coating device can be designed for this purpose. This can result in a helical solidification.

A coating unit for applying the building material preferably comprises at least one roller (possibly exactly two or exactly three or more rollers), wherein preferably at least one of the possibly several rollers is assigned a drive unit. Further preferably, a peripheral speed of the (respective) roller can be adjustable in relation to a (relative) travel speed of the substrate material relative to the respective roller. For example, the peripheral speed of the roller can be the same as the travel speed of the substrate material relative to the respective roller. Alternatively, the peripheral speed of the roller can be different from (lower or higher than) the travel speed of the substrate material relative to the respective roller. The Movement of the circumference of the (respective) roller in a portion facing the substrate material is preferably adjustable. For example, it can be in the same or in the opposite direction relative to the movement of the substrate material.

The (respective) roller of the coating unit can have a diameter of 10 mm - 200 mm. as well as mention the direction of rotation and speed.

Two rollers can be arranged at different z-height levels. An applying roller can form a level layer with a first height from dosed powder. A following compacting roller can compress the leveled layer because it is lowered. In alternating operation (alternating application), the rollers can swap their height position layer by layer.

The (respective) roller can be designed as a roller (in particular for compacting an applied layer).

The (respective) roller (cage) may comprise an adhesion reducing agent for reducing adhesion of build material to the roller surface.

At least one roll can extend at least substantially over the entire width of the carrier material, in particular over at least 70% or at least 90% or at least 99% of the width.

The (respective) roller can vibrate (during coating) or at least be set into vibration.

A scraper can be assigned to the (respective) roll in order to remove build-up material adhering to the roll.

Furthermore, the (respective) roller can have a fluidizing device, which for example comprises channels for supplying a (possibly pressurized) gas. This can, for example, loosen powder bridges and/or enable the build-up material (powder) to continue to flow.

A distance between at least one roller and a carrier material (or the carrier film) can be adjustable, for example in a range of 5-500 µm, preferably 10-100 µm, particularly preferably 50-70 µm. This allows a layer thickness to be set in a simple manner.

The coating unit can be designed as a multi-chamber coater (e.g. for locally targeted dosing and for applying at least two building materials). The coating unit can have at least one dosing unit, which preferably comprises at least one chamber dosing device and/or one or more controllable outlets. The dosing unit can extend at least substantially (i.e. in particular at least 70% or at least 90% or at least 99% of the width) over the entire width of the carrier material. The dosing unit can vibrate (at least in sections) during coating or at least be set into vibration. Alternatively or additionally, the dosing unit can have a fluidizing device which, for example, comprises a plurality of channels through which gas (in particular under pressure) can be supplied.

If the dosing unit comprises several controllable outlets, these can preferably be (selectively) opened (or selectively - partially or completely - closed) so that dosing is or can be varied across the width of the carrier material.

Solidification can take place in a process chamber. A process gas atmosphere (in particular a process gas atmosphere in the process chamber) can be essentially oxygen-free (e.g. have an oxygen content of less than 10,000 ppm, preferably less than 1,000 ppm, more preferably less than 500 ppm, particularly preferably less than 200 ppm). Alternatively or additionally, the process gas atmosphere can comprise at least 50 vol.%, preferably at least 90 vol.%, more preferably at least 99 vol.% of at least one inert gas, such as nitrogen and/or at least one noble gas, such as Ar or He.

A process gas flow (in particular a protective gas flow) over the respectively applied layer of the building material can preferably take place at least substantially perpendicular to a conveying direction of the building material and/or a coating direction of the building material.

A monitoring unit can be designed which can detect defects and/or abnormalities or deviations, for example delamination.

Such a monitoring unit can preferably be based on optical tomography, ie a spatially resolved measurement of thermal radiation emitted from the construction site. The monitoring unit can, for example, be of the same be designed for the selective solidification of (in weight percent predominantly) metallic and (in weight percent predominantly) polymeric construction material, for which, for example, a correspondingly high sensitivity can be guaranteed, especially in a lower temperature range. It would also be conceivable to work with two separate monitoring units or to design a monitoring unit with a common optics that can be connected via two signal processing strands (which, for example, are optimized in one case for a comparatively high temperature range and in another case for a comparatively low temperature range and/or have different bandpass filters).

Alternatively or in addition, active tomography can be used, particularly to check adhesion to a carrier film. Energy (e.g. flashlight) can be applied to the carrier film and the layer can be recorded with a thermal camera. Wherever the layer has not bonded cleanly, it becomes warmer because it cannot transfer the energy to the substrate/film.

The carrier material or carrier tape can run completely or partially within the process chamber or process gas atmosphere. For example, the carrier material or carrier tape can be introduced into the process chamber on one side and led out again on the other side.

The irradiation unit can comprise at least one radiation source, in particular at least one laser device, which is designed to emit bundled radiation that impinges on the building material in a localized manner. This is to be understood in particular as an irradiation in which no mask is used in order to allow a broadly scattered irradiation to impinge only selectively on the building material.

At least one solidification zone in which the building material is solidified can preferably be heated or cooled (directly or indirectly), more preferably by heating or cooling the carrier device and/or by heating or cooling a base (e.g. a carrier table) for the carrier device and/or by heating or cooling the building material, for example by means of radiation, possibly by means of the irradiation unit for solidification and/or a further irradiation unit, e.g. an infrared radiation source or a number of VCSEL radiators. Heating can also alternatively or additionally take place by means of at least one resistance heating device, for example for heating the base.

By heating (warming) and/or cooling, corresponding differences, for example with regard to a melting temperature, can be compensated in a simple manner, particularly when using different materials (e.g. in different layers), especially when the same irradiation unit is used. For example, when melting a first layer, additional heat irradiation can be used for heating (tempering), and when melting a second layer, such irradiation can be omitted or only carried out to a reduced extent, and/or cooling can be carried out. The first layer can comprise metal (at least 30% by weight or at least 50% by weight or at least 70% by weight or at least 90% by weight) and the second layer can comprise polymer (at least 30% by weight or at least 50% by weight or at least 70% by weight or at least 90% by weight); or vice versa. Heating (warming) or cooling is preferably understood to mean active heating or cooling. (Active) heating can be carried out, for example, by means of at least one resistance heater and/or one radiant heater. Alternatively or additionally, (active) heating and/or cooling can be carried out, for example, by means of at least one heat pump and/or by means of at least one Peltier element.

For example, the respective building material can be heated to a temperature just below the melting temperature (e.g. to a temperature that is a maximum of 10% below the melting temperature when this is expressed in °C). Here (above and below), a melting temperature is to be understood in particular as a temperature at which the respective building material has a viscosity that is below 25,000 mPas, possibly below 5,000 mPas (preferably measured in accordance with EN ISO 3219, as valid at the time of priority or filing).

In particular, in the case of an irradiation unit which has a plurality of (in particular individually controllable) radiation exit sections (e.g. individual laser diodes), the power of individual radiation exit sections (laser diodes) can be controlled in such a way that only the construction material is heated, while others are in turn controlled in such a way that (at least in cooperation with further radiation exit sections or laser diodes) melting occurs.

The build-up material can be applied after (initial) application and (if necessary selective) solidification of the build-up material and optionally before (if necessary selective) application of another build-up material selectively removed, in particular by suction, further preferably by means of at least one suction unit, preferably a suction nozzle arrangement, wherein the suction nozzle arrangement preferably comprises a plurality of suction nozzles, preferably arranged in rows and/or columns, and/or wherein the suction unit is preferably arranged on the coating unit.

Specifically, a suction nozzle row and/or matrix can be provided for targeted (local) suction of unsolidified build-up material. Particularly preferably, in those areas in which build-up material has been (locally) suctioned off, another (in particular different) build-up material can be applied so that, if necessary, different build-up materials can be (selectively) solidified in the same plane (or layer).

A suction resolution of the suction device in the longitudinal direction and/or width direction and/or vertical direction is preferably a maximum of 100 times, more preferably a maximum of 20 times, more preferably a maximum of 5 times, more preferably a maximum of 2 times, even more preferably a maximum of 1 time as large as a resolution of the irradiation unit.

The building material can be applied or layered (coated) in a dry state. The building material can comprise particles or be formed from a powder, in particular at least substantially dry. The particles of the building material can have an (average) particle size of at least 1 nm, preferably at least 100 nm, more preferably at least 1 µm and/or of at most 200 µm, preferably at most 10 µm, more preferably at most 5 µm.

The grain size or particle size can be determined using laser diffraction methods (in particular using laser diffraction measurement in accordance with ISO 13320 or ASTM B822). Alternatively or additionally, the particle sizes can be determined by measuring (e.g. using a microscope) and/or using dynamic image analysis (preferably in accordance with ISO 13322-2, if necessary using the CAMSIZER @ XT from Retsch Technology GmbH). If the particle size is determined from a 2-dimensional image (e.g. from a microscope, in particular an electron microscope, if necessary a scanning electron microscope), the respective diameter (maximum diameter or equivalent diameter) resulting from the 2-dimensional image is preferably used.

The (average) grain size or particle size of the individual particles of the building material is preferably a d50 particle size. For the average particle size, the d (numerical value) stands for the number of particles (in mass and/or volume percent) that are smaller than or equal to the specified grain size or particle size (i.e. with a d50 of 50 µm, 50% of the particles have a size of ≤ 50 µm). The grain size is preferably determined via the diameter of an individual particle, which in turn can be the respective maximum diameter (= supremum of all distances between any two points of the particle) or a sieve diameter or an equivalent sphere diameter (in particular volume-related). If the particles are at least partially agglomerated, the size of the individual particle in the respective agglomerate (primary particle size) should be used as the respective particle size (grain size).

The individual particles of the building material can be (at least approximately) the same size or there can be a particle size distribution.

Specifically, the building material can comprise a powder and/or a particle suspension (nanoparticle suspension).

Alternatively or additionally, the build-up material can be (at least partially) liquid, e.g. made of a synthetic resin in its original state, or it can be pasty.

Alternatively or additionally, the build-up material may comprise at least one coherent body (which may be pre-solidified, e.g. by pressure during coating).

The construction material can be provided and used in different variants (cumulatively or individually).

The building material can be a metal-containing building material and can comprise at least one pure metal and/or at least one compound containing at least one metallic element. Preferably, a metal-containing construction material comprises lithium, for example in the form of pure lithium and/or LFP (lithium iron phosphate), LCO (lithium cobalt oxide), and/or NMC (lithium nickel manganese cobalt oxide) and/or NCA (lithium nickel cobalt aluminum oxide) and/or LAGP (lithium aluminum germanium phosphate) and/or LATP (lithium aluminum titanium phosphate) and/or LLTO (lithium lanthanium titanium oxide) and/or LLZO (lithium lanthanium zirconium oxide), all of these materials optionally in the form of metal-containing solid electrolyte ceramics. A metal-containing construction material can also comprise aluminum, for example in the form of pure aluminum, and/or cobalt, for example in the form of pure cobalt and/or nickel, for example in the form of pure nickel, and/or copper, for example in the form of pure copper. Such a metal-containing construction material can comprise at least one metal and/or a compound containing at least one metallic element to the extent of at least 30% by weight or 50% by weight or 70% by weight or 90% by weight or to the extent of at least approximately 100% by weight.

The building material can be a polymer-containing building material and comprise at least one polymer, preferably PVDF (polyvinylidene difluoride) and/or and/or PVDF-HFP (polyvinyldenedifluoride-co-hexafluoropropylene) and/or PEO (polyethylene oxide) and/or Nafion, optionally in the form of solid electrolyte polymers. In particular, at least one polymer in the polymer-containing building material can be a binder, e.g. PVDF. Such a polymer-containing building material can comprise at least one polymer to at least 50% by weight or at least 70% by weight or at least 90% by weight or at least approximately 100% by weight.

The construction material can be a low-metal and low-polymer construction material and can comprise non-metallic elements and/or semiconductors (elements) and/or ceramics and/or oxides (apart from oxides containing metallic elements). Preferably, a low-metal and low-polymer construction material can comprise carbon, for example in the form of conductive carbon black and/or graphite, and/or silicon, for example in the form of pure (elemental) silicon and/or in the form of silicon oxide, and/or. Such a low-metal and low-polymer construction material can be at least substantially non-metallic and at least substantially comprise no polymer (preferably consisting of at least 50% by weight or at least 70% by weight or at least 90% by weight or at least approximately 100% by weight of non-metallic and non-polymeric substances, e.g. ceramics and/or oxides and/or carbon and/or silicon). Particularly preferably, the metal- and polymer-poor construction material comprises carbon (at least 50% by weight or at least 70% by weight or at least 90% by weight or at least approximately 100% by weight). In connection with the metal- and polymer-poor construction material, "carbon" should mean the carbon that is present in pure form (e.g. as graphite and/or as conductive carbon black, i.e. not molecularly bound, for example in a polymer).

Furthermore, the construction material can comprise a metal-containing and/or a polymer-containing and/or a metal- and polymer-poor construction material. If a construction material comprises construction materials with different compositions, these construction materials with different compositions are also referred to below as construction material components. This means that a construction material can comprise a metal-containing and/or a polymer-containing and/or a metal- and polymer-poor component, wherein a metal-containing, a polymer-containing and a metal- and polymer-containing construction material component is formed in accordance with a metal-containing, a polymer-containing and a metal- and polymer-poor construction material. Active materials are also described below, particularly with reference to the component of an electrochemical device. An active material is a component of an electrochemical device that results from the processing (e.g. from solidification by irradiation) of a construction material and/or a construction material component. For example, a metal-containing active material results from the processing of a metal-containing building material or a metal-containing building material component (the same applies to the other building materials or building material components mentioned above and the corresponding active materials).

The build material may comprise additives (e.g. a flow aid and/or an absorber), which may be in the form of separate particles and/or fibers or as part of composite particles. In particular, the build material may comprise a binder, which is optionally part of a polymer-containing build material.

The construction material can comprise particles which at least partially have a metal and a polymer portion and/or a ceramic and a polymer portion or a metal and a ceramic portion (e.g. metal particles coated with a polymer binder). For example, metal particles and polymer particles (granules) and metal- and polymer-free particles can be mixed together, preferably in the weight ratios given above. Instead of or in combination with particles, fibers, e.g. carbon and/or ceramic and/or oxide fibers, can be used.

A metal-containing building material (or a metal-containing building material component) can comprise particles consisting at least partially of pure metal (e.g. lithium, copper, aluminum, cobalt, nickel) and/or particles consisting at least partially of a compound containing at least one metallic element (e.g. LFP, NMC, NCA, LCO, LAGP, LATP, LLTO, LLZO) and particles consisting of non-metallic and/or polymeric materials, which particles can be mixed with one another according to the weight ratios specified above. Alternatively or additionally, a metal-containing construction material can comprise particles consisting at least partially of pure metal (e.g. lithium, copper, aluminum, cobalt) and/or particles consisting at least partially of a compound containing at least one metallic element (e.g. LFP NMC, NCA, LCO, LAGP, LATP, LLTO, LLZO), which particles can additionally comprise non-metallic and/or polymeric materials. For example, a metal-containing particle core can be coated with a non-metallic and/or a polymeric material. Conversely, a non-metallic and/or polymeric particle core can be coated with a metal-containing material. The metal-containing portion (metal-containing particle core or metal-containing coating) and the non-metallic and/or polymeric portion (non-metallic and/or polymeric particle core or non-metallic and/or polymeric coating) are preferably in the weight ratios given above.

A polymer-containing construction material (or a polymer-containing construction material component) can comprise particles consisting at least partially of a polymer material (e.g. PVDF, PEO, Nafion) and particles consisting of non-metallic and/or metal-containing materials, which particles can be mixed with one another in the weight ratios given above. Alternatively or additionally, a polymer-containing construction material can comprise particles consisting at least partially of a polymer (e.g. PVDF, PEO, Nafion), which particles can additionally comprise non-metallic and/or metal-containing materials. For example, a polymer particle core can be coated with a non-metallic and/or a metal-containing material. Conversely, a non-metallic and/or metal-containing particle core can be coated with a polymer material. The polymer-containing portion (polymer particle core or polymer coating) and the non-metallic and/or metal-containing portion (non-metallic and/or metal-containing particle core or non-metallic and/or metal-containing coating) are in the percentage weight ratios given above.

A low-metal and low-polymer construction material (or a low-metal and low-polymer construction material component) can comprise at least partially particles made of a low-metal and low-polymer material (e.g. ceramic, oxides, apart from oxides containing metallic elements, carbon, in particular conductive carbon black and/or graphite, silicon) and particles made of polymeric and/or metal-containing materials, which particles can be mixed with one another according to the weight ratios given above. Alternatively or additionally, a low-metal and low-polymer construction material can comprise at least partially particles made of a low-metal and low-polymer material (e.g. ceramic, oxides, apart from oxides containing metallic elements, carbon, in particular conductive carbon black and/or graphite, silicon), which particles can additionally comprise polymeric and/or metal-containing materials. For example, a metal- and polymer-free particle core can be coated with a polymeric and/or metal-containing material. Conversely, a polymeric and/or metal-containing particle core can be coated with a low-metal and low-polymer material. The metal- and polymer-free portion (metal- and polymer-free particle core or metal- and polymer-free coating) and the polymeric and/or metal-containing portion (polymeric and/or metal-containing particle core or polymeric and/or metal-containing coating) are in the percentage weight ratios given above.

• ein Kathoden-Aktivmaterial (z.B. LFP, NMC, NCA und/oder LCO), optional einen Binder (z.B. PVDF, insbesondere 2-15 wt.-%, bevorzugt 3-5 wt.-%) und Leitruß (insbesondere 0,1-10 wt.-%, vorzugsweise 0,1-5 wt.-%) und/oder
• ein Anoden-Aktivmaterial (typischerweise Graphit, ggf. mit Anteilen von z. B. 1-60 wt.-%, ggf. 10-15 wt.-% Silizium, und/oder, ggf. zumindest im Wesentlichen reines, Silizium), Binder (z.B. PVDF, insbesondere 5-15 wt.-%) und Leitruß (insbesondere 0,1-10 wt.-%, vorzugsweise 0,1-5 wt.-%) und/oder
• ein Feststoffzellenanoden-Aktivmaterial (z. B. Lithium, insbesondere Lithiumpulver, vorzugsweise ohne Binder) und/oder
• ein Feststoffelektrolytmaterial (z. B. ein polymerenthaltender Feststoffelektrolyt, umfassend PVDF-HFP, PEO und/oder Nafion, und/oder ein Feststoffelektrolyt, umfassend LAGP, LATP, LLTO und/oder LLZO).

Alternatively or additionally, the construction material may comprise at least one active material specific to the component/part of the electrochemical device, in particular:

• a cathode active material (e.g. LFP, NMC, NCA and/or LCO), optionally a binder (e.g. PVDF, in particular 2-15 wt.%, preferably 3-5 wt.%) and conductive carbon black (in particular 0.1-10 wt.%, preferably 0.1-5 wt.%) and/or
• an anode active material (typically graphite, optionally with proportions of e.g. 1-60 wt.%, optionally 10-15 wt.% silicon, and/or, optionally at least substantially pure silicon), binder (e.g. PVDF, in particular 5-15 wt.%) and conductive carbon black (in particular 0.1-10 wt.%, preferably 0.1-5 wt.%) and/or
• a solid cell anode active material (e.g. lithium, in particular lithium powder, preferably without binder) and/or
• a solid electrolyte material (e.g., a polymer-containing solid electrolyte comprising PVDF-HFP, PEO and/or Nafion, and/or a solid electrolyte comprising LAGP, LATP, LLTO and/or LLZO).

Alternatively or additionally, the construction material can comprise: A separator, in particular for a (classic) battery. This can be designed as a (thin) polymer film. The polymer can comprise (possibly at least 50% by weight or 80% by weight) polyolefin, e.g. polyethylene and/or polypropylene, and/or polyamide, e.g. PA 6 and/or PA 12 and/or PA 6.6, and/or polyester.

When using solid electrolyte polymers, comparatively good ion conductivity, good processability and high flexibility can be expected when, for example, lithium metal anodes expand. If, for example, the anode expands, it is preferable if the separator (e.g. made of one or more solid electrolyte polymers) can absorb forces and give way flexibly.

A solid electrolyte ceramic or a corresponding oxide has the advantage of high stability over time and comparatively good performance. On the other hand, a comparatively high energy input is necessary to enable (at least partial) melting during the (selective) solidification. The measures suggested above and below (for example heating a powder bed and/or an auxiliary irradiation unit, e.g. an auxiliary laser and/or a binder) can counteract such a fundamentally existing disadvantage.

In general, it is preferable to use a binder that has a comparatively high lithium-ion conductivity.

The carrier material (in particular for producing a cathode structure) can be an aluminum foil (for example with a thickness of 5-50 µm, in particular 10-15 µm, possibly also less than 8 µm or even less than 5 µm). Alternatively, the carrier material can be a copper foil with a thickness of 5-20 µm, in particular 10-15 µm, for example approximately at least 10 µm, possibly also less than 8 µm or even less than 5 µm.

At least one further layer of a building material can be applied to the (at least partially) solidified (first) layer, which is also solidified (fully or selectively). This can be repeated at least once (or as often as desired).

The construction material of a respective (further) layer can differ from the construction material of the first layer (or a layer applied before or after), in particular with regard to a chemical composition and/or a structure, or can be identical to this construction material. The further layer can be applied using a further and/or the same coating unit (with which the first layer was applied). The further layer can be solidified using a further or the same irradiation unit (with which the first or another layer was solidified). This can influence the properties and/or structure of the respective layer, for example. For example, a directed porosity and/or a porosity that changes across the layer can be created.

By repeating the coating and irradiation (exposure), it is easy to apply, for example, stronger or thicker layers of the same material and/or different types of layers. Alternatively, stronger or thicker layers can be created by applying a thicker or higher layer of build-up material and solidifying this layer with appropriately adjusted energy input parameter values of the irradiation unit.

During the (additive) manufacturing process, non-solidified build-up material can be returned to the manufacturing process and used in a further solidification process. Before the build-up material is used in a further solidification process, it can be treated if necessary and/or mixed with fresh powder.

Preferably, the solidification of a building material, in particular a polymer-containing building material and/or a building material comprising a polymer-containing building material component, takes place by (selectively) melting at least one polymer material. Particularly preferably, the solidification of a building material takes place by (selectively) melting a binder. By melting and successively solidifying a binder or a polymer material, other (not per se, at least not completely) melted (in particular metal-containing and/or non-metallic and/or low in metal and polymer) material components can be connected to the binder or polymer material and/or to one another.

The solidification of a construction material by melting a polymer material or a binder can be particularly advantageous because chemical and/or physical properties (e.g. electrical conductivity, electron and/or ion transport capacity, crystal and/or lattice structure) of other construction materials, in particular a metal-containing construction material and/or a metal- and polymer-poor construction material, remain unchanged. A change (deterioration) in their chemical and/or physical properties could occur through the (partial) melting (phase change) of construction materials, in particular metal-containing and/or metal- and polymer-poor construction materials.

In embodiments, a layer application of at least one metal-containing building material and at least one polymer-containing building material and at least one metal- and polymer-poor building material is carried out at least partially by means of the same coating unit.

Alternatively or additionally, at least one metal-containing building material, and at least one polymer-containing building material, and at least one metal- and polymer-free building material are solidified at least partially by means of the same irradiation unit, preferably laser unit, and/or with radiation of the same wavelength.

Particularly preferably, the coating unit or irradiation unit is configured such that at least two of a metal-containing build material, a polymer-containing build material and a metal- and polymer-poor build material can be processed using the same respective unit. If necessary, additional measures can be carried out for this purpose, such as the use of an auxiliary irradiation unit, heating (warming) or cooling the build material and/or the use of a binder. This is a departure from the usual approach in which significantly different configurations are used for additive manufacturing for different materials (e.g. metal and polymer).

Preferably, a coating direction corresponds to an irradiation direction (or is opposite thereto). A coating direction is to be understood in particular as a direction that corresponds to the direction of movement of a coating unit relative to the building material (which does not mean that the coating unit - in absolute terms - has to move, for example when the building material itself moves). An irradiation direction is to be understood in particular as a direction of movement of a radiation impact area relative to the building material (again in relative terms). The term irradiation direction can refer to an average direction in which an area of a component cross-section to be solidified is scanned with the beam. It therefore does not necessarily refer to the direction of an individual solidification path or scan vector, which can under certain circumstances be arranged transversely, e.g. perpendicularly, to the coating direction, in particular if the irradiation unit is coupled to a corresponding scanner/beam deflection unit or another drive. If the exposure direction (irradiation direction) and coating direction are the same, particularly precise (selective) solidification can take place.

Preferably, adhesion of additively manufactured layers made of different materials occurs, if necessary supported by process-related interlocking of the surfaces.

The component (of the electrochemical device) is preferably made from at least one metal-containing construction material and/or at least one polymer-containing construction material and/or at least one metal- and polymer-poor construction material, wherein preferably different layer thicknesses can be set for at least one layer made up of a polymer-containing construction material and/or for at least one layer made up of a metal-containing construction material and/or for at least one layer made up of a metal-containing construction material and/or for at least one layer made up of a metal- and polymer-poor construction material.

By solidifying, porosity can be introduced into the component in a targeted manner. Porosity can be specifically adjusted (at least locally). The porosity can have a gradient. Specifically, a number (or density, i.e. number of pores per volume) and/or size (for example total volume or average pore size) can be adjusted, and in particular (locally) varied.

Alternatively, however, no porosity (apart from the usual minor porosity in an additive manufacturing process) can be introduced (intentionally), for example in electrochemical devices in which lithium ions are conducted in a solid electrolyte.

A gradient of the deliberately introduced porosity preferably runs in the z-direction (i.e. along a surface normal to the plane of the surface of the carrier device or the carrier material; construction direction).

Porosity can be introduced (in a desired distribution), for example, by varying process parameter values, e.g. a scanning speed, a beam power or laser power, a scan vector distance and/or a beam shaping. Alternatively or additionally, porosity can be introduced subsequently using a laser (e.g. using a polygon scanner). The laser can create a large number of small pores in the layer to increase the tortuosity and thus improve Li-ion transport.

Preferably, the component is made from a first construction material and at least one second construction material, wherein the higher melting material (i.e. the material that has a higher melting temperature) is preferably applied and irradiated before the lower melting material. This makes it easy to reduce the risk that when the higher melting construction material is melted, an underlying layer of the lower melting construction material is (unintentionally) melted again.

For example, a separator comprising polymer (preferably predominantly in weight percent) can be printed after an electrode for a rechargeable battery comprising a metal-containing and/or a low-metal and polymer-containing and/or a polymer-containing construction material (preferably predominantly in weight percent). This makes it easy to prevent damage to the separator structure due to possibly higher laser intensities for melting metal (particularly if the separator has a porosity that is to be retained in terms of its structure or distribution). In this case, the separator material is preferably only layered after the electrode (cathode or anode) has solidified. If, for example, a separator made of ceramic (or at least 50% by weight of ceramic) is used, the reverse can also be advantageous.

Preferably, a progress speed of the carrier material is controlled depending on an exposure time (irradiation time) and/or power of the irradiation unit (and/or vice versa). As a result, the progress speed of the building material can be adapted to an irradiation time (exposure time) or power.

Alternatively or additionally, a switching speed of laser device(s) (laser diodes) can be taken into account in the progress speed or the progress speed of the build material can be adapted to the (maximum) switching speed and/or controlled depending on this.

The above-mentioned object is further achieved in particular by a manufacturing device, preferably configured to carry out the above manufacturing method, for the additive manufacture of at least one component of an electrochemical energy storage device, in particular an accumulator, preferably a Li-ion accumulator, at least partially by layer-by-layer application and subsequent, in particular selective, solidification of a, preferably powdery, building material, comprising a receiving unit for receiving a carrier device in the form of a carrier tape, in particular formed by or comprising a carrier film, a coating unit for applying a layer of the building material to the carrier tape, an irradiation unit for at least partially solidifying, in particular selectively solidifying, the building material on the carrier tape and a conveyor unit for moving the carrier tape relative to at least one first, preferably stationary, irradiation unit.

Alternatively or additionally, the above object is achieved in particular by a manufacturing device, in particular with the features of the immediately preceding paragraph, preferably configured to carry out the above manufacturing method, for the additive manufacture of at least one component of an electrochemical energy storage device, in particular an accumulator, preferably a Li-ion accumulator, at least partially by layer-by-layer application and subsequent, in particular selective, solidification of a, preferably powdery, building material, comprising a carrier device, a coating unit for applying a layer of the building material to the carrier device, an irradiation unit for at least partially solidifying, in particular selectively solidifying, the building material on the carrier device, wherein the irradiation unit has a plurality of individual radiation exit sections, preferably arranged in at least one row and/or at least one column, in particular a plurality of laser diodes and/or radiation line ends.

• mindestens eine, insbesondere zwei oder mehr, Rolle/n, wobei vorzugsweise mindestens einer der ggf. mehreren Rollen eine Antriebseinheit zugeordnet ist, wobei weiter vorzugsweise eine Umfangsgeschwindigkeit und/oder Drehrichtung einstellbar oder eingestellt ist, die gleich oder höher oder niedriger liegt als eine relative Verfahrgeschwindigkeit des Substratmaterial gegenüber der jeweiligen Rolle und/oder wobei sich zumindest eine Rolle zumindest im Wesentlichen über die gesamte Breite des Trägermaterials erstreckt und/oder vibriert oder zumindest in Vibration versetzbar ist, und/oder
• mindestens eine Dosiereinheit, die vorzugsweise einen Kammerdosierer und/oder einen oder mehrere steuerbare Auslässe umfasst und/oder die sich zumindest im Wesentlichen über die gesamte Breite des Trägermaterials erstreckt und/oder zumindest teilweise vibriert oder zumindest in Vibration versetzbar ist.

Preferably, the coating unit comprises:

• at least one, in particular two or more, roller(s), wherein preferably at least one of the possibly several rollers is assigned a drive unit, wherein further preferably a peripheral speed and/or direction of rotation is adjustable or set which is equal to or higher or lower than a relative travel speed of the substrate material with respect to the respective roller and/or wherein at least one roller extends at least substantially over the entire width of the carrier material and/or vibrates or at least can be set to vibrate, and/or
• at least one dosing unit, which preferably comprises a chamber dosing device and/or one or more controllable outlets and/or which extends at least substantially over the entire width of the carrier material and/or at least partially vibrates or at least can be set into vibration.

The (respective) roller and/or the dosing unit may comprise a fluidizing device for fluidizing building material, as described in connection with the above method.

The dosing unit may alternatively or additionally comprise a rotary valve.

Alternatively or in addition to one or more rollers, at least one doctor blade and/or at least one blade and/or at least one brush and/or at least one rake may be provided.

The dosing unit can also have an agitator and/or a scraper in order to be able to transport adhering build-up material further.

The irradiation unit can have a plurality of individual radiation exit sections (light exit sections), preferably arranged in at least one row and/or at least one column, in particular a plurality of laser diodes and/or radiation line ends.

Preferably, in addition to the (first) irradiation unit, a plurality of individual radiation exit sections, preferably arranged in at least one row and/or at least one column, an auxiliary irradiation unit, preferably at least one, in particular scanning, auxiliary laser unit, such as a CO, CO ₂ , fiber and/or Nd:YAG laser, is provided.

A scanning auxiliary laser unit can be designed as described above in connection with the method, in particular coupled to a galvanometer scanner and/or polygon scanner and/or micromirror array.

Preferably, the manufacturing device has at least one common coating unit which is configured for applying layers of at least one metal-containing building material and/or at least one polymer-containing building material and/or at least one metal- and polymer-poor building material.

Alternatively or additionally, the manufacturing device has a common irradiation unit, preferably a laser unit, which is configured for fastening at least one metal-containing building material and/or at least one polymer-containing building material and/or at least one metal- and polymer-poor building material.

The (common) irradiation unit can be assigned, for example, a filter device (for reducing the power of the radiation when it hits the construction material) or a beam splitter with a beam trap, which can preferably be brought into a beam path selectively, for example when a comparatively low-melting material is to be melted.

The manufacturing device can have at least one (further) coating unit for applying a further layer of a building material and/or at least one further irradiation unit for solidifying a/the further layer.

For example, two coating units can be provided before and after the (respective) irradiation unit. This means that with an irradiation unit moving back and forth, irradiation can take place on each pass or a new layer can be (selectively) solidified.

The manufacturing device preferably comprises at least one control and/or monitoring unit which is configured to control and/or monitor at least one parameter, in particular a flatness and/or a bulk density and/or a temperature or temperature distribution of building material applied to the carrier device and/or a flatness and/or a density and/or porosity and/or a temperature or temperature distribution of the component during production, wherein the building material preferably comprises both a polymer-containing building material component and/or at least one metal-containing building material component and/or at least one metal- and polymer-poor building material component.

Preferably, the manufacturing device comprises at least one (active) heating and/or cooling unit for the indirect or direct temperature control, in particular heating or cooling, of a solidification zone in which the building material is solidified, preferably by heating or cooling the carrier device and/or by heating or cooling a base for the carrier device and/or by heating or cooling the building material, for example by means of radiation, wherein the heating and/or cooling unit is optionally provided at least partially by the irradiation unit for solidification and/or a heating unit provided in addition to the irradiation unit, e.g. additional irradiation unit, for example an infrared radiation source.

Preferably, tempering is carried out to, for example, a constant temperature (plateau temperature) or to a temperature according to a predefined curve, in particular with the aim of homogeneous temperature conditions for all components to be manufactured (of the same material). A heating and/or cooling unit can be used to compensate for corresponding differences, for example with regard to a melting temperature, in a simple manner, in particular when using different materials (e.g. in different layers). For example, when melting a layer consisting of a metal-containing construction material, additional heat radiation can be used for heating (tempering) and when melting a layer consisting of a polymer-containing construction material, such radiation can be omitted or only reduced, or cooling can take place. Alternatively, when melting a layer consisting of a polymer-containing construction material, additional heat radiation can be used for heating (tempering) and when melting a layer consisting of a metal-containing construction material, such radiation can be omitted or only reduced, or cooling can take place.

A gas (process gas) is preferably operated in recirculation mode (as a closed system).

An oxygen content is preferably monitored. Alternatively or additionally, laser smoke can be filtered. For this purpose, the following can preferably be provided: appropriate pipes, a filter chamber with storage filter and/or cleanable filters (which is preferred), a fan for circulation, and an oxygen, temperature, pressure and/or volume flow sensor.

The manufacturing device can have at least one suction unit, preferably a suction nozzle arrangement, comprising a plurality of suction nozzles, preferably arranged in rows and/or columns.

Alternatively or additionally, at least one suction unit can be provided which is designed to be stationary (in absolute terms, in particular in relation to a reference point which, in use, is part of the substrate on which the manufacturing device is arranged). Alternatively or additionally, the suction unit can be designed to be stationary relative to the coating unit and/or irradiation unit. Within the above method, a suction unit can accordingly be configured to be stationary (in absolute terms) or remain stationary in this sense during the manufacturing process. Alternatively or additionally, in the above manufacturing process, the suction unit can remain stationary relative to the coating unit and/or irradiation unit (during the manufacturing process).

Further features of the manufacturing device emerge from the above explanation of the method. The method steps explained there can be implemented by corresponding devices that are configured to carry out the respective method step. Furthermore, the manufacturing device can comprise the carrier material (described above and/or below) and/or the construction material (described above and/or below).

The above-mentioned object is further achieved in particular by a system comprising the above manufacturing device and the carrier material and/or the building material.

The above-mentioned object is further achieved by the use of the above manufacturing device and/or the above system for the additive manufacturing of at least one component of an electrochemical device, preferably an electrochemical energy storage device, in particular an accumulator, preferably a Li-ion accumulator, and/or an electrolysis cell.

Preferably, the respective electrochemical device is manufactured additively to at least 10 wt.%, preferably at least 30 wt.%, optionally at least 50 wt.% or at least 90 wt.%.

Further features emerge from the subclaims.

• 1 eine erfindungsgemäße Herstellvorrichtung in einer schematischen Ansicht;
• 2 eine schematische Darstellung eines Verfahrens zur Herstellung eines strukturierten, dreidimensionalen Schichtverbundes;
• 3 eine schematische Darstellung einer additiven Herstellung (beispielsweise einer Feststoff-Akkumulatorzelle);
• 4 ein Beispiel für die Fertigung einer elektrochemischen Einrichtung;
• 5 ein weiteres Beispiel für die Fertigung einer elektrochemischen Einrichtung; und
• 6 ein weiteres Beispiel für die Fertigung einer elektrochemischen Einrichtung.

The invention is described below using embodiments, which are explained in more detail using the figures. Here:

• 1 a manufacturing device according to the invention in a schematic view;
• 2 a schematic representation of a process for producing a structured, three-dimensional layer composite;
• 3 a schematic representation of an additive manufacturing process (e.g. a solid-state battery cell);
• 4 an example of the manufacture of an electrochemical device;
• 5 another example of the manufacture of an electrochemical device; and
• 6 another example of the manufacturing of an electrochemical device.

1 shows a manufacturing device for manufacturing components in a schematic side view. The manufacturing device comprises an irradiation unit 10 and a coating unit 11. The coating unit 11 comprises a dosing device 12 and a coating roller (roller) 13 and a counter roller 14. A (e.g. powdery) building material can be dosed in the direction of the coating roller 13 and counter roller 14 via the dosing device 12. The coating roller 13 is arranged or operated in such a way that it sets a thickness of the material application of the building material 15 on a carrier material 16. The carrier material 16 is a strip (in particular a film strip) that can be unrolled from a roll (supply roll) 17. A deflection can be carried out, for example, via a (possibly driven) deflection roller 18. A deflection function is not mandatory. A thickness of the material application can be determined by adjusting the height of the coating unit 11 or the distance between the coating roller 13 and the carrier material 16. Furthermore, the density of the material application can be determined by the ratio between a peripheral speed of the coating roller 13 and a travel speed of the carrier material (which can be adjusted, for example, by a rotational speed of the roller 20, see below). Preferably, the peripheral speed of the coating roller 13 is greater than the travel speed of the carrier material 16. This advantageously allows a higher density to be achieved. Alternatively or additionally, the movement of the circumference (direction of rotation) of the coating roller 13 is adjustable. In 1 the movement of the circumference of the coating roller 13 is the same as the movement (process direction) of the carrier material 16. Preferably, the circumference of the coating roller 13 is moved (rotated) in the opposite direction to the movement (process direction) of the carrier material 16. This advantageously allows a higher density to be achieved. In an irradiation area 19, the building material 15 on the carrier material 16 is then irradiated and (selectively) solidified. The carrier material 16 with the (selectively) solidified building material 15 thereon can then be rolled up on a further roller 20. Between the deflection roller 18 and a further roller 21 there is an (optionally heatable) processing table 22.

The exposure unit (irradiation unit) 10 is preferably a VCSEL exposure unit. Binders and/or other materials can be melted or structured relatively quickly using a VCSEL exposure unit. Shape-bound electrodes (for battery production) can be printed in a simple manner. This enables new cell geometries that can be adapted to the installation space, for example, and/or have integrated cooling in the cell.

• - Einer, vorzugsweise porösen, Kathode, bestehen aus einem metallenthaltenden Aktivmaterial, das aus der Verarbeitung (mittels Bestrahlung) eines metallenthaltenden Aufbaumaterial resultiert, das Aufbaumaterial umfassend überwiegend (insbesondere 75-97,9 wt.-%, vorzugsweise 90-96 wt.-%) zumindest ein metallenthaltendes Material (z.B. LFP, NMC, NCA und/oder LCO) und Leitruß (insbesondere 0,1-10 wt.%, vorzugsweise 1-5 wt.-%), optional weiter umfassend einen (polymeren) Binder (z.B. PVDF, insbesondere 2-15 wt.-%, bevorzugt 3-5 wt.-%).
• - Einem Separator, insbesondere für eine (klassische) Batterie. Dieser kann als (dünne) Polymerfolie ausgebildet werden. Das Polymer kann umfassen (ggf. zu mindestens 50 Gew.-% oder 80 Gew.-%).Polyolefin, z. B. Polyethylen und/oder Polypropylen, und/oder Polyamid, z. B. PA 6 und/oder PA 12 und/oder PA 6.6, und/oder Polyester.
• - Einer, vorzugsweise porösen, insbesondere mit einer Porosität von zumindest 20 vol.-%, ggf. von zumindest 40 vol.-%, Anode, bestehend aus einem metall- und polymerarmen Aktivmaterial, das aus der Verarbeitung (mittels Bestrahlung) eines metall- und polymerarmen Aufbaumaterial resultiert, wobei das metall- und polymerarme Aktivmaterial überwiegend Kohlenstoff, vorzugsweise in Form von Leitruß und/oder Graphit (besonders vorzugsweise in Form von Graphitpartikeln), und/oder einen Binder (z.B. PVDF, insbesondere 5-15 wt.-%) umfasst. Vorzugsweise enthält das Aktivmaterial im Kohlenstoff/--Anteil 0,1-10 wt.-%, besonders vorzugsweise 1-5 wt.-%, Leitruß. Weiter vorzugsweise enthält das Aktivmaterial im Kohlenstoff--Anteil einen Anteil (0,1-60 wt.-%, besonders vorzugsweise 10-15 wt.-%), Silizium in Form von zumindest im Wesentlichen reinem (elementarem) Silicium und/oder Silicium Oxide, bspw. in Form von Si- und/oder SiO₂-Partikeln. Optional kann der Kohlenstoff-Anteil zumindest im Wesentlichen durch einen Si- und/oder einen SiO2-Anteil ersetzt werden, sodass das metall- und polymerarme Aktivmaterial überwiegend Silicium und/oder Silicium Oxide, vorzugsweise zumindest 60 wt.-%, besonders vorzugsweise zumindest 90 wt.-% und/oder einen Binder (z.B. PVDF, insbesondere 5-20 wt.-%) und/oder Leitruß (insbesondere 5-20 wt.-%) umfasst.

In the 1 The manufacturing device shown can preferably be used for the production of an electrochemical cell comprising or consisting of:

• - A, preferably porous, cathode, consisting of a metal-containing active material which results from the processing (by means of irradiation) of a metal-containing building material, the building material comprising predominantly (in particular 75-97.9 wt.%, preferably 90-96 wt.%) at least one metal-containing material (e.g. LFP, NMC, NCA and/or LCO) and conductive carbon black (in particular 0.1-10 wt.%, preferably 1-5 wt.%), optionally further comprising a (polymeric) binder (e.g. PVDF, in particular 2-15 wt.%, preferably 3-5 wt.%).
• - A separator, in particular for a (classic) battery. This can be designed as a (thin) polymer film. The polymer can comprise (if necessary at least 50% by weight or 80% by weight) polyolefin, e.g. polyethylene and/or polypropylene, and/or polyamide, e.g. PA 6 and/or PA 12 and/or PA 6.6, and/or polyester.
• - An anode, preferably porous, in particular with a porosity of at least 20 vol. %, optionally of at least 40 vol. %, consisting of an active material with a low metal and polymer content, which results from the processing (by means of irradiation) of a construction material with a low metal and polymer content, wherein the active material with a low metal and polymer content predominantly comprises carbon, preferably in the form of conductive carbon black and/or graphite (particularly preferably in the form of graphite particles), and/or a binder (e.g. PVDF, in particular 5-15 wt. %). The active material preferably contains 0.1-10 wt. % conductive carbon black in the carbon/carbon content, particularly preferably 1-5 wt. %. The active material further preferably contains a proportion (0.1-60 wt.%, particularly preferably 10-15 wt.%) of silicon in the form of at least substantially pure (elemental) silicon and/or silicon oxides, for example in the form of Si and/or _SiO2 particles, in the carbon proportion. Optionally, the carbon proportion can be at least substantially replaced by a Si and/or a SiO2 proportion, so that the active material with low metal and polymer content predominantly comprises silicon and/or silicon oxides, preferably at least 60 wt.%, particularly preferably at least 90 wt.% and/or a binder (e.g. PVDF, particularly 5-20 wt.%) and/or conductive carbon black (particularly 5-20 wt.%).

Preferably, according to 1 a (classic) electrochemical Li-ion cell or components thereof can be produced. Such a cell can have one or more porous layers and/or a liquid electrolyte.

Such an electrochemical cell can be produced starting from a foil strip that comprises an aluminum layer (as a first collector). The cathode, and successively the separator and the anode, can be built on this aluminum layer (collector) (in particular cathode and anodes) and/or applied (in particular separator). A copper layer (as a second collector) can then be applied to the electrochemical cell thus constructed. Alternatively, the aluminum layer and/or the copper layer (collectors), for example from a metal-containing construction material, in particular containing at least essentially pure aluminum or copper, can be produced additively by means of the irradiation unit (10). The production of a layer (collector) consisting essentially of pure metal (aluminum or copper) can be carried out by means of a thermal conduction welding process, a deep welding process and/or a combination thereof, in particular for achieving a certain material density and/or crystal structure and/or porosity.

Thermal conduction welding is considered to be a process in which the radiation power per unit area introduced into the build-up material by the radiation is too low to cause the build-up material to evaporate. The energy spreads into the build-up material via thermal conduction, which leads to a smaller expansion of the melt pool created by the radiation in a direction perpendicular to the surface. In contrast, in a deep welding process, a sufficiently high radiation power per unit area is achieved so that material transport also takes place in a direction perpendicular to the surface. This means that build-up material is evaporated and that at the same time material processed (solidified) in the previous exposure processes is (re)melted (which leads to the formation of a so-called "keyhole"). In particular, the build-up material can advantageously be processed in a thermal conduction welding process if a high surface quality (homogeneity) and/or a homogeneous crystal structure must be achieved, while processing the build-up material in a deep welding process can be advantageous if a strong bond between the layers of the electrochemical cell (together and/or to a substrate) must be achieved. Such a strong bond is provided by the simultaneous melting of different layers/build-up materials.

2 shows a method for producing a structured, three-dimensional layer composite that forms an electrochemical device (e.g. a pouch accumulator or an accumulator in a cylinder design) in a continuous process. First, a (e.g. band-shaped) carrier material 16 (substrate) is brought into a process chamber (not shown). For this purpose, a movable table or a (conveyor) belt can be used, for example. Alternatively or additionally, the carrier material 16 itself can be built up additively (e.g. in the process chamber). An arrow 23 shows the direction of movement (transport direction) of the carrier material 16 (and thus also of the further layers successively built up on it). Left in 2 First, a first building material 15a is applied to the carrier material 16 and smoothed by means of a first smoothing device (e.g. rake) 24a (whereby a layer thickness can be adjusted at the same time).

The applied layer of the first building material 15a is selectively solidified by means of a first irradiation unit 10a (whereby non-solidified building material can be sucked off, for example, in particular selectively sucked off, which is not in 2 shown). A second building material 15b is then applied to the carrier material 16 and the first building material 15a, smoothed by means of a second smoothing device 24b (or a layer thickness is set accordingly) and selectively solidified by means of a second irradiation unit 10b. These steps are repeated successively for a third building material 15c and a fourth building material 15d by means of a third and fourth smoothing device 24c and 24d and a third and fourth irradiation device 10c and 10d. The subsequent building material can be applied above and/or next to a previously applied building material and selectively solidified (if, for example, suction, for example selective suction, takes place). At the end of the process, a structured, three-dimensional body can be present in which, for example, five different materials (each on its own) have been particularly selectively solidified.

The (respective) irradiation unit 10a-10d can, for example, be an irradiation unit that applies several laser beams next to one another (in the Y and/or X direction). The X direction is preferably the direction of movement of the build material (opposite the respective irradiation unit). The Z direction is the build direction. The Y direction is a direction perpendicular to the X and Z directions.

Deviating from the 4-stage structure shown, fewer (e.g. two or three) or more (e.g. 5 or more) stages (with corresponding smoothing devices or coating devices and irradiation units) can also be provided. Different layers or additional building material can also be solidified in separate processes with a respective irradiation unit (e.g. the first irradiation unit 10a), for example if a corresponding section of the carrier material 16 comes into an irradiation area of the respective irradiation unit several times (which can be achieved, for example, by returning the carrier material 16 or a circulating carrier material 16).

3 shows a schematic representation of an additive manufacturing process (for example of a solid-state battery cell). A coating unit 11 and an irradiation unit 10 can be moved within a process chamber 30. A respective direction of movement is shown by means of the arrows 31. Preferably, the coating unit 11 and the irradiation unit 10 can be moved along a corresponding guide (in particular linear guide) 32.

The process chamber can be flooded with inert gas (e.g. argon) via an inert gas supply 42. The gas in the process chamber can leave the process chamber via a gas outlet 33. Optionally, sensors, for example a pressure sensor 34, an oxygen detection sensor 35 and a temperature sensor 36 can be provided in order to measure various parameters within the process chamber (for example a pressure, an oxygen content and/or a temperature of the gas in the process chamber). Optionally, a monitoring unit 39 is designed which can detect, for example, defects and/or abnormalities or deviations, for example delamination.

The coating unit 11 here comprises (by way of example) three dosing units 12a, 12b and 12c, so that different construction materials 15a-15c can be applied. A layer composite is successively applied to a construction platform 37 (which is adjustable in height) (by irradiation using the irradiation unit 10 following the respective coating process). The irradiation unit 10 can have a plurality of radiation exit sections 38. A respective suction device 43a, 43b is optionally provided on the sides of the coating unit 11. These make it possible to remove powder that has not been melted.

In a preferred embodiment, two coating units are provided (not in 3 shown), whereby the irradiation unit 10 can be located between the two coating units 11, so that exposure can be carried out comparatively efficiently. A respective coating chamber or a multi-chamber coater can be filled, for example, in an end position.

• - Einem erstem Kollektor, z.B. basierend auf Aluminium (insbesondere für eine Komposit-Kathode). Dieser aluminiumbasierte Kollektor kann durch die Verarbeitung (Verfestigung mittels Bestrahlung) eines überwiegend aus reinem Aluminium bestehenden metallenthaltenden, vorzugsweise pulverförmigen, Aufbaumaterial ausgebildet werden.
• - Einer Kathode, umfassend mindestens ein oder mindestens oder genau zwei metallenthaltende Aktivmaterialien, das/die aus der Verarbeitung (mittels Bestrahlung) eines metallenthaltenden Aufbaumaterials resultiert/- en, wobei mindestens ein erstes metallenthaltendes Aktivmaterial und/oder LATP und/oder LLTO und/oder LLZO umfassen kann und/oder mindestens eine zweites metallenthaltendes Aktivmaterial LFP und/oder NMC und/oder NCA und/oder LCO. Vorzugsweise besteht die Kathode überwiegend (75-99 wt.-%, vorzugsweise 90-95 wt.-%) aus einem oder mehreren der o.g. Materialien. Optional kann das Kathoden-Aktivmaterial zumindest einen Binder (bspw. PVDF, ggf. zu 1-25 wt.-% oder vorzugsweise 5-10 wt.-%) umfassen.
• - einem Elektrolytmaterial, insbesondere ein polymerenthaltendes Elektrolytmaterial, bspw. umfassend PVDF-HFP, PEO und/oder Nafion, und/oder insbesondere ein metallenthaltendes, vorzugweise ein Lithiumenthaltendes Elektrolytmaterial, bspw. LAGP, LATP, LLTO und/oder LLZO. Optional kann das Elektrolytmaterial ausgehend aus einem polymerenthaltenden und einem metallenthaltenden Aufbaumaterial, d.h. aus einem Aufbaumaterial, das eine polymerenthaltende und eine metallenthaltende Aufbaumaterialkomponente umfasst, hergestellt werden. Vorzugsweise ist das Elektrolytmaterial als Festelektrolytmaterial ausgebildet. Das bedeutet insbesondere, dass das Elektrolytmaterial eine geringfügige Porosität ausweist.
• - Einer Anode, z.B. basierend auf Lithium. Diese lithiumbasierte Anode kann durch die Verarbeitung (Verfestigung mittels Bestrahlung) eines überwiegend aus reinem Lithium bestehenden metallenthaltenden, vorzugsweise pulverförmigen, Aufbaumaterial ausgebildet werden. Vorzugsweise ist die Anode als Feststoffzelleanode ausgebildet; das bedeutet insbesondere, dass die Anode eine geringfügige Porosität ausweist.
• - Einem zweiten Kollektor, z.B. basierend auf Kupfer. Dieser kupferbasierte basierte Kollektor kann durch die Verarbeitung (Verfestigung mittels Bestrahlung) eines überwiegend aus reinem Kupfer bestehenden metallenthaltenden, vorzugsweise pulverförmigen, Aufbaumaterial ausgebildet werden.

In the 3 The manufacturing device shown can preferably be used for the production of an electrochemical cell comprising or consisting of:

• - A first collector, e.g. based on aluminum (in particular for a composite cathode). This aluminum-based collector can be formed by processing (solidification by irradiation) a metal-containing, preferably powdered, construction material consisting predominantly of pure aluminum.
• - A cathode comprising at least one or at least or exactly two metal-containing active materials resulting from the processing (by means of irradiation) of a metal-containing construction material, wherein at least a first metal-containing active material and/or LATP and/or LLTO and/or LLZO can comprise and/or at least a second metal-containing active material LFP and/or NMC and/or NCA and/or LCO. Preferably, the cathode consists predominantly (75-99 wt.%, preferably 90-95 wt.%) of one or more of the above-mentioned materials. Optionally, the cathode active material can comprise at least one binder (e.g. PVDF, optionally 1-25 wt.% or preferably 5-10 wt.%).
• - an electrolyte material, in particular a polymer-containing electrolyte material, for example comprising PVDF-HFP, PEO and/or Nafion, and/or in particular a metal-containing, preferably a lithium-containing electrolyte material, for example LAGP, LATP, LLTO and/or LLZO. Optionally, the electrolyte material can be produced from a polymer-containing and a metal-containing construction material, ie from a construction material that comprises a polymer-containing and a metal-containing construction material component. The electrolyte material is preferably designed as a solid electrolyte material. This means in particular that the electrolyte material has a slight porosity.
• - An anode, e.g. based on lithium. This lithium-based anode can be produced by processing (solidifying by irradiation) a predominantly pure lithium anode. metal-containing, preferably powdered, construction material. The anode is preferably designed as a solid cell anode; this means in particular that the anode has a slight porosity.
• - A second collector, e.g. based on copper. This copper-based collector can be formed by processing (solidification by means of irradiation) a metal-containing, preferably powdered, construction material consisting predominantly of pure copper.

Particularly preferred is 3 for a ceramic-based solid-state cell. Such a cell can be designed without porosity in the individual active layers. Alternatively or additionally, the anode can contain (pure) lithium or be made from it. (Pure) lithium is advantageously processed under inert gas due to its reactivity in air, which is possible in the device of the 3 in a simple manner. Alternatively or additionally, the cathode can be a composite of lithium-ion conductor and lithium-ion storage material (active material).

Alternatively or additionally, the construction material can comprise a separator, in particular for a (classic) battery. This separator can be designed as a (thin) polymer film. The polymer can comprise (if necessary at least 50% by weight or 80% by weight), e.g. polyethylene and/or polypropylene, and/or polyamide, e.g. PA 6 and/or PA 12 and/or PA 6.6, and/or polyester. In particular, in some applications the separator can replace the solid electrolyte material. The production of a component of an electrochemical cell consisting essentially of pure metal (e.g. lithium, aluminum or copper) can be carried out by means of a thermal conduction welding process, a deep welding process and/or a combination thereof, in particular for achieving a certain material density and/or crystal structure and/or porosity. In particular, the build-up material can advantageously be processed in a thermal conduction welding process if a high surface quality (homogeneity) and/or a homogeneous crystal structure must be achieved, while processing the build-up material in a deep welding process can be advantageous if a strong bond between the layers (components) of the electrochemical cell must be achieved. Such a strong bond is particularly present when different layers/build-up materials are melted simultaneously.

The 4-6 show various examples for the production of an electrochemical device, specifically an accumulator. In 4 For example, a large number of cathode structures 41 (e.g. LFP, for example with a thickness of 45 µm) are produced on a carrier film 40 (e.g. aluminum carrier film, for example 12 µm thick). Solidification can be carried out (locally) using a number of VCSEL exposure units, for example already in the form of (later) pouch cells. Material that has not melted can be sucked off if necessary and possibly returned.

5 corresponds to the embodiment according to 4 with the following differences. In 5 A continuous exposure is carried out to produce cathode strips for the production of (later) cylindrical battery cells. The corresponding irradiation (exposure) can be carried out continuously.

In a subsequent step, the back side can be irradiated (exposed) (basically in an identical manner), calendered if necessary and then optionally cut into “daughter rolls”.

6 shows an embodiment which in turn 4 with the following differences. How to 6 recognizes, a different (more complicated) shape can be selected for the cathode structures 41 using the manufacturing process proposed here. This enables ergonomic and space-saving production. Cooling can also be integrated, for example.

At this point, it should be noted that all parts and functions described above are considered to be essential to the invention when viewed individually and in any combination, particularly the details shown in the drawings. Modifications to this are familiar to those skilled in the art.

It is also pointed out that the aim is to achieve the broadest possible scope of protection. In this respect, the disclosure contained in the claims can also be made more precise by features that are described with further features (even without these further features necessarily being included). It is explicitly pointed out that round brackets and the term "in particular" are intended to emphasize the optionality of features in the respective context (which does not mean, conversely, that without such identification a feature is to be considered mandatory in the corresponding context).

Reference symbols

10a-d

Irradiation unit (exposure unit)

11

Coating unit

12a-c

Doser (dosing device)

13

Coating roll

14

Counter role

15a-d

Construction material

16

Carrier material

17

role

18

(Deflection) roller

19

Irradiation area

20

role

21

role

22

Processing table

23

Direction of movement

24a-d

Smoothing device

25

collector

26

cathode

27

Solid electrolyte

28

anode

29

collector

30

Irradiation unit

31

Shift direction

32

guide

33

Gas outlet

34

Pressure sensor

35

Oxygen detection sensor

36

Temperature sensor

37

Construction platform

38

Radiation exit section

39

Monitoring unit

40

Carrier film

41

Cathode structure

42

Inert gas supply

43a, 43b

Extraction device

QUOTES INCLUDED IN THE DESCRIPTION

This list of documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions.

Cited patent literature

• US 20200411838 A1 [0003]

Claims (30)

Manufacturing method for the additive manufacture of at least one component of an electrochemical device, preferably an electrochemical energy storage device, in particular an accumulator, preferably a Li-ion accumulator, and/or an electrolysis cell, at least partially by layer-by-layer application and subsequent, in particular selective, solidification of a, preferably powdered, building material, comprising the steps: - applying at least one layer of the building material to a carrier device, - at least partially solidifying, in particular selectively solidifying, the building material on the carrier device by means of at least one first irradiation unit (10), wherein the first irradiation unit (10) has a plurality of individual radiation exit sections, preferably arranged in at least one row and/or at least one column, in particular a plurality of laser diodes and/or radiation line ends. Manufacturing method according to one of the preceding claims, wherein the irradiation unit comprises at least one VCSEL and/or VECSEL. Manufacturing method according to one of the preceding claims, wherein in addition to a first irradiation unit with a plurality of individual radiation exit sections, preferably arranged in at least one row and/or at least one column, an auxiliary irradiation unit, preferably at least one, in particular scanning, auxiliary laser unit, such as a CO, CO2, fiber and/or Nd:YAG laser, is used. Manufacturing method according to one of the preceding claims, wherein the application is carried out by means of a movable coating unit and/or wherein the solidification is carried out by means of a movable irradiation unit. Manufacturing method according to one of the preceding claims, wherein a construction field for solidification is rectangular, circular, circular segment-shaped, circular sector-shaped, annular or ring segment-shaped. Manufacturing method according to one of the preceding claims, wherein a rotary coating is carried out. Manufacturing method according to one of the preceding claims, characterized in that a coating unit (11) for applying the building material comprises: at least one, in particular two, preferably three, or more, roller(s) (13, 14), wherein preferably at least one of the possibly several rollers (13) is assigned a drive unit, and/or at least one dosing unit (12) for dosing the building material onto the carrier device, which preferably comprises a chamber doser and/or one or more controllable outlets and/or at least partially vibrates or can be at least partially set into vibration. Manufacturing method according to one of the preceding claims, wherein the solidification takes place in a process chamber and/or under a preferably substantially oxygen-free process gas atmosphere, comprising, for example, nitrogen and/or at least one noble gas, such as in particular argon and/or helium. Manufacturing process according to Claim 1 , characterized in that the irradiation unit comprises at least one radiation source, in particular at least one laser device, which is designed to emit bundled radiation which impinges on the building material in a localized manner. Manufacturing method according to one of the preceding claims, characterized in that a solidification zone in which the building material is solidified is heated or cooled directly or indirectly, preferably by heating or cooling the carrier device and/or by heating or cooling a base for the carrier device and/or by heating or cooling the building material, for example by means of radiation, optionally by means of the irradiation unit for solidification and/or a further irradiation unit, e.g. an infrared radiation source. Manufacturing method according to one of the preceding claims, characterized in that the building material is removed selectively, in particular by suction, after an initial application and optionally selective solidification of the building material and optionally before a possible selective application of a further building material, further preferably by means of at least one suction unit, preferably suction nozzle arrangement, wherein the suction nozzle arrangement preferably comprises a plurality of suction nozzles, preferably arranged in rows and/or columns, and/or wherein the suction unit is arranged on the coating unit. Manufacturing method according to one of the preceding claims, wherein the building material comprises particles, wherein the particles of the building material preferably have an average particle size of at least 1 nm, preferably at least 100 nm, more preferably at least 1 µm and/or at most 200 µm, preferably at most 10 µm, more preferably at most 5 µm, wherein the building material in particular comprises a powder and/or a particle suspension (nanoparticle suspension), and/or wherein the building material is liquid, e.g. made up of a synthetic resin in its initial state, or is pasty, and/or wherein the building material comprises at least one coherent, possibly pre-solidified, body. Manufacturing method according to one of the preceding claims, wherein the construction material comprises a specific active material, preferably: a cathode active material (e.g. LFP, NMC, NCA and/or LCO), optionally a binder (e.g. PVDF, in particular 2-15 wt.%, preferably 3-5 wt.%) and conductive carbon black (in particular 0.1-10 wt.%, preferably 0.1-5 wt.%) and/or an anode active material (typically graphite, optionally with small proportions of e.g. 10-15 wt.% silicon, and/or silicon), binder (e.g. PVDF, in particular 5-15 wt.%) and conductive carbon black (in particular 0.1-10 wt.%, preferably 0.1-5 wt.%) and/or a solid cell anode active material (e.g. lithium, in particular lithium powder, preferably without binder) and/or a solid electrolyte material (e.g. a Solid electrolyte polymer, such as PVDF-HFP, PEO and/or Nafion, and/or a solid electrolyte ceramic and/or oxide, such as LAGP, LATP, LLTO and/or LLZO). Manufacturing method according to one of the preceding claims, wherein at least one further layer of a building material is applied to the at least partially solidified layer - layer hereinafter also referred to as the first layer - wherein the building material of the further layer can be different from the building material of the first layer or can be identical to it; and/or wherein the further layer can be applied by means of a further and/or the same coating unit (11); and/or wherein the further layer can be solidified by means of a further or the same irradiation unit (10). Manufacturing method according to one of the preceding claims, wherein non-solidified building material is returned to the manufacturing process and used in a further solidification process. Manufacturing method according to one of the preceding claims, wherein the solidification takes place by means of melting a polymer-containing building material, preferably a binder. Manufacturing method according to one of the preceding claims, wherein a layer application of at least one metal-containing building material, and/or at least one polymer-containing building material, and/or a metal- and polymer-poor building material is carried out at least partially by means of the same coating unit and/or wherein a solidification of at least one metal-containing building material, and/or at least one polymer-containing building material, and/or a metal- and polymer-poor building material is carried out at least partially by means of the same irradiation unit, preferably laser unit, and/or with radiation of the same wavelength. Manufacturing method according to one of the preceding claims, wherein a coating direction corresponds to an irradiation direction. Manufacturing method according to one of the preceding claims, wherein an adhesion of additively manufactured layers made of different materials takes place, optionally supported by a process-related interlocking of the surfaces. Manufacturing method according to one of the preceding claims, wherein the component is manufactured from at least one metal-containing construction material and/or at least one polymer-containing construction material and/or at least one metal- and polymer-poor construction material, wherein different layer thicknesses are set for at least one layer constructed from a metal-containing construction material and/or for at least one layer constructed from a polymer-containing construction material and/or for at least one layer constructed from a metal- and polymer-free construction material. Manufacturing method according to one of the preceding claims, wherein by solidification a porosity is deliberately introduced into the component and/or at least locally deliberately adjusted, wherein the porosity preferably has a gradient. Manufacturing method according to one of the preceding claims, wherein the component is manufactured from at least a first construction material and at least a second construction material, wherein the higher-melting material is irradiated before the lower-melting material. Manufacturing device, preferably configured to carry out the manufacturing method according to one of the preceding claims, for the additive manufacture of at least one component of an electrochemical device, preferably of a electrochemical energy storage device, in particular an accumulator, preferably a Li-ion accumulator, and/or an electrolysis cell, at least partially by layer-by-layer application and subsequent, in particular selective, solidification of a, preferably powdery, building material, comprising a carrier device, a coating unit (11) for applying a layer of the building material to the carrier device, an irradiation unit for at least partially solidifying, in particular selectively solidifying, the building material on the carrier device, wherein the irradiation unit (10) has a plurality of individual radiation exit sections, preferably arranged in at least one row and/or at least one column, in particular a plurality of laser diodes and/or radiation line ends. Manufacturing device according to the immediately preceding claim, characterized in that the coating unit (11) comprises: at least one dosing unit (12), which preferably comprises a chamber doser and/or one or more controllable outlets and/or one or more controllable rows and/or columns of outlets. Manufacturing device according to one of the Claims 23 or 24 , wherein in addition to a first irradiation unit (10) with a plurality of individual radiation exit sections, preferably arranged in at least one row and/or at least one column, an auxiliary irradiation unit, preferably at least one, in particular scanning, auxiliary laser unit, such as a CO, CO2, fiber and/or Nd:YAG laser, is provided. Manufacturing device according to one of the Claims 23 until 25 , wherein a common coating unit is provided which is configured for applying layers of at least one metal-containing building material, and/or at least one polymer-containing building material, and/or a building material low in metal and polymer, and/or wherein a common irradiation unit, preferably a laser unit, is provided which is configured for solidifying at least one building material which comprises at least 50% by weight of metal, and at least one building material which comprises at least 50% by weight of polymer. Manufacturing device according to one of the preceding Claims 23 until 26 , comprising at least one further coating unit for applying a further layer of a building material and/or at least one further irradiation unit for solidifying a/the further layer. Manufacturing device according to one of the preceding Claims 23 until 27 , comprising at least one control and/or monitoring unit which is configured to control and/or monitor at least one parameter, in particular a flatness and/or a bulk density and/or a temperature or temperature distribution of building material applied to the carrier device and/or a flatness and/or a density or porosity and/or a temperature or temperature distribution of the component during production, wherein the building material preferably comprises at least one metal-containing building material component and/or at least one polymer-containing building material component and/or at least one metal- and polymer-poor building material component. Manufacturing device according to one of the preceding Claims 23 until 28 , characterized in that at least one heating and/or cooling unit is provided for the indirect or direct temperature control, in particular heating or cooling, of a solidification zone in which the building material is solidified, preferably by heating or cooling the carrier device and/or by heating or cooling a base for the carrier device and/or by heating or cooling the building material, for example by means of radiation, wherein the heating and/or cooling unit is optionally provided at least partially by the irradiation unit for solidification and/or a heating unit provided in addition to the irradiation unit, e.g. additional irradiation unit, for example an infrared radiation source. Manufacturing device according to one of the preceding Claims 23 until 29 , characterized in that at least one suction unit, preferably suction nozzle arrangement, is provided, wherein the suction nozzle arrangement preferably comprises a plurality of suction nozzles, preferably arranged in rows and/or columns, and/or wherein the suction unit is arranged on the coating unit.

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