US 12,334,534 B2
Method for manufacturing a dry electrode
Frank Bogenstahl, Ahaus (DE); Rene Wolters, Stadtlohn (DE); Christoph Lansing, Vreden (DE); Kay Wolters, Stadtlohn (DE); Thomas Hackfort, Ahaus-Alstätte (DE); and Jörg Gottszky, Vreden (DE)
Assigned to Matthews International Corporation, Pittsburgh, PA (US)
Filed by Matthews International Corporation, Pittsburgh, PA (US)
Filed on Oct. 7, 2024, as Appl. No. 18/908,224.
Application 18/908,224 is a continuation of application No. 18/731,472, filed on Jun. 3, 2024, granted, now 12,136,727.
Application 18/731,472 is a continuation of application No. 17/422,966, previously published as PCT/US2020/013531, filed on Jan. 14, 2020.
Claims priority of provisional application 62/793,333, filed on Jan. 16, 2019.
Prior Publication US 2025/0029976 A1, Jan. 23, 2025
Int. Cl. H01M 4/04 (2006.01); B05C 11/02 (2006.01); B22F 7/08 (2006.01); B29C 43/58 (2006.01); B29C 65/00 (2006.01); H01G 11/28 (2013.01); H01G 11/86 (2013.01)
CPC H01M 4/0435 (2013.01) [B05C 11/02 (2013.01); B22F 7/08 (2013.01); B29C 43/58 (2013.01); B29C 66/83411 (2013.01); H01G 11/86 (2013.01); H01M 4/0404 (2013.01); B05C 11/025 (2013.01); H01G 11/28 (2013.01)] 31 Claims
OG exemplary drawing
 
1. A method of manufacturing an electrode operatively associated with a system that converts dry powder to two films, said system that calenders those two films to a desired thickness and density, and laminates those two films onto a metal foil substrate without handling a free-standing film, the method comprising:
providing the system in form of a single tool including a first multi roll calender and a second multi roll calendar, said first multi roll calendar including a first plurality of horizontally aligned rolls, a first nip being formed between a first roll and a second roll of the first multi roll calender, and a second nip being formed between a second roll and a third roll of the first multi roll calender;
forming a first film of the two films by providing a first powder to the first nip of the first multi roll calender during operation of the system to form a first film;
compressing the first film at the second nip of the first multi roll calender to form a first compressed film;
providing the second multi roll calender including a second plurality of horizontally aligned rolls, a first nip being formed between a first roll and a second roll of the second multi roll calender, and a second nip being formed between a second roll and a third roll of the second multi roll calender:
forming a second film of the two films by providing a second powder to the first nip of the second multi roll calender during operation of the system to form the second film;
compressing the second film at the second nip of the second multi roll calender to form a second compressed film; and
simultaneously laminating (i) the first compressed film onto a first side of the metal foil substrate and (ii) the second compressed film onto a second side of the metal foil substrate using a laminating nip formed by a final roll of the first multi roll calender and a final roll of the second multi roll calender.