Hardware and manufacturing methods to coat electrode materials to substrates in secondary ionic battery manufacturing process

Abstract

A counter-rotating roller system for coating electrode materials includes a roll-to-roll apparatus including a dispensing roller that selectively dispenses a conductive substrate from a substrate roll along a first direction towards a receiving roller. A counter-rotating roller module including a counter-rotating roller is stationarily positioned at a predetermined height over the conductive substrate. The direction of the tangential velocity of the counter-rotating roller at an interface between the counter-rotating roller and the conductive substrate is 180 degrees opposite the first direction of travel of the conductive substrate. The system further includes a continuous powder application module positioned on a feed side of the counter-rotating roller to continuously deposit a volume of a dry powder mixture on the conductive substrate prior to contact with the counter-rotating roller. A contact roller scraper contacting the counter-rotating roller removes powder particles from an outer surface of the counter-rotating roller.