US 12,291,781 B2
Hardware and manufacturing methods to coat electrode materials to substrates in secondary ionic battery manufacturing process
Vikram Devaraj, Austin, TX (US); and Varun Devaraj, Chennai (IN)
Assigned to PIXION BATTERIES, INC., Austin, TX (US)
Filed by Pixion Batteries, Inc., Austin, TX (US)
Filed on Apr. 1, 2024, as Appl. No. 18/623,880.
Claims priority of provisional application 63/456,465, filed on Apr. 1, 2023.
Prior Publication US 2024/0327990 A1, Oct. 3, 2024
Int. Cl. C23C 24/08 (2006.01); H01M 4/04 (2006.01); B05D 1/12 (2006.01); B05D 1/40 (2006.01); C23C 24/00 (2006.01); H01M 4/88 (2006.01)
CPC C23C 24/082 (2013.01) [H01M 4/0404 (2013.01); H01M 4/0409 (2013.01); H01M 4/0435 (2013.01); B05D 1/12 (2013.01); B05D 1/40 (2013.01); B05D 2401/32 (2013.01); C23C 24/00 (2013.01); H01M 4/043 (2013.01); H01M 4/886 (2013.01); H01M 4/8896 (2013.01)] 6 Claims
OG exemplary drawing
 
1. A method, comprising:
feeding, at a position upstream of a counter-rotating roller, a conductive substrate in an upwardly inclined direction towards a first curved edge of a stationary orientation maintenance module;
transitioning, after passing the first curved edge, to feeding the conductive substrate over a horizontal surface of the stationary orientation maintenance module along a first direction and towards the counter-rotating roller;
depositing a volume of a dry powder mixture onto a surface of the conductive substrate;
spreading, based at least in part on a counter-rotational movement of the counter-rotating roller, the volume of the dry powder mixture onto the surface of the conductive substrate, wherein a tangential velocity direction 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;
scraping, based on a contact roller scraper contacting the counter-rotating roller, residual powder particles from an outer surface of the counter-rotating roller; and
feeding, at a position downstream of the counter-rotating roller, the conductive substrate in a downwardly declined direction away from a second curved edge of the stationary orientation maintenance module to maintain the conductive substrate in a flat orientation on the horizontal surface of the stationary orientation maintenance module.