Method and device for in place calender roller dent inspection and repair

A system for mapping a calender roller, the system comprising:

• a calender roll system comprising a calender roller, wherein the calender roller comprises a roller surface and a shaft;
• a surface mapping apparatus comprising a profilometer positioned on a rail parallel to the shaft of the calender roller;
• an attachment means configured to removably attach the surface mapping apparatus to the calender roll system;
• and
• a detecting element configured to coordinate the rotation of the calender roller and the position of the profilometer.

A process for repairing and using a calender roller, the process comprising:

• providing a calender roll system comprising a calender roller;
• mapping a surface profile of the calender roller;
• identifying a dent area on the surface of the calender roller at least partially based on the surface profile;
• depositing a repair material at the dent area, wherein the repair material comprises a metal;
• and
• calendering an electrode film material comprising an electrode active material to form an electrode film, wherein the electrode active material comprises the metal,
• wherein the metal is selected from the group consisting of Co, Ni, Fe, Mn, Mg, Ti, Al, Ca, Ti, Cr, Cu, Si, V, Zn, Au, Ag, W, and combinations thereof.