Modeling of unit pressure distribution and roll stress analysis during lithium-ion battery electrode calendering

Calendering is a critical manufacturing step for lithium-ion batteries, where precise control of process parameters significantly influences the electrode structure and battery performance. However, existing studies lack a well-established theoretical model that can accurately predict the calendering force and unit pressure distribution. To fill this gap, a mechanistic model was developed based on the Kuhn yield criterion to predict the unit pressure distribution, which was further validated through experimental measurements. Building upon this model, the characteristics of unit pressure distribution within the roll gap were analyzed. The effects of the compression rate and roll diameter on the unit width calendering force and unit pressure distribution were also investigated. Furthermore, the obtained unit pressure was used as a boundary condition to analyze roll stress. The study focused on the roll stress distribution characteristics during the electrode calendering, and the influences of compression rate and roll diameter on the maximum von Mises stress within the roll were evaluated. The proposed model and corresponding findings provide useful insights for optimizing the calendering process of battery electrodes and offer guidance for the design of related manufacturing equipment.