earticle

영어

In this paper, the structural optimization and experimental validation of lightweight, high stiffness rollers for roll-to-roll(R2R) processing of lithium metal electrodes are presented. Precise dimensional control of electrode thickness below 50㎛ is essential for next-generation high energy density batteries, yet elastic recovery during rolling hinders the achievement of target specifications. To address this challenge, finite element(FE) analysis was employed to determine the optimal rolling gap and roller geometry, and the results were verified through R2R experiments. Simulations indicated that a rolling gap of 153㎛ yielded a final sheet thickness of about 49.6㎛, meeting the design requirement. Experimental results confirmed the validity of the numerical model, with thickness measurements deviating less than ±10% from FE analysis predictions. These findings demonstrate that the proposed roller design not only ensures thickness precision but also improves system efficiency, offering practical guidelines for scalable lithium metal electrode manufacturing.