System for multilayer battery electrode manufacturing

Abstract

A system for multilayer battery electrode manufacturing is provided. The system includes a first spread coating system including a chamber for dispensing first powder particles onto a substrate; a first spread coating assembly for creating a first uniform coating of the first powder particles; and a first calender assembly for creating a first compressed powder coating on the substrate. The system includes a second spread coating system including a chamber for dispensing second powder particles onto the first compressed powder coating; a second spread coating assembly for creating a second uniform coating of the second powder particles; and a second calender assembly for creating a second compressed powder coating on the first compressed powder coating. The first compressed powder coating and the second compressed powder coating define a multilayer coating on the electrode.

Description

Cross-references to related applications

[0001] This application claims the benefit of co-pending, co-assigned U.S. Provisional Patent Application No. 63 / 617,849, filed January 5, 2024. The entire contents of the aforementioned provisional application are incorporated herein by reference. Background Technology

[0002] A wide variety of batteries are available in this industry for different applications. Lithium-ion (Li-ion) batteries have become the dominant battery type used in portable consumer electronics and electric vehicles. The manufacture of lithium-ion batteries involves numerous steps, each of which can affect the quality of the battery itself and the cost of manufacturing it. One common manufacturing process is called "spreader roller coating," which... Figure 1 It is represented in the form of a diagram.

[0003] A conventional spreader roller coating system 10 typically includes a chamber 12 that receives powder particles 14 and distributes the powder particles 14 onto a moving substrate 16. Rollers 18, 20 at opposite ends of the system 10 maintain the movement of the substrate 16 along direction 22. The substrate 16 is passed through a pair of spreader rollers 24, 26 to uniformly spread the powder particles 14 on the surface of the substrate 16, wherein the powder particles 14 are spread on the substrate 16 at a first thickness 28. Subsequently, the substrate 16 is passed through a pair of calender rollers 30, 32, which compress the powder particles 14 to a second thickness 34. The calender rollers 30, 32 densify the powder particles and compress them onto the substrate surface, wherein such compression and densification cause the powder particles to adhere to each other and to the substrate 16. Such spreading roller coating technology is described, for example, in International Patent Application No. PCT / US23 / 69175, the entire contents of which are incorporated herein by reference.

[0004] Another conventional manufacturing process typically involves the formation of an electrode paste containing active materials, conductive additives, and a binder, mixed in an organic solvent; and the application of this electrode paste to a metal foil material. Once applied to the foil material, the solvent is dried or evaporated, while the active electrode mixture remains attached to the surface of the metal foil material. In some cases, the solvent may be toxic, and additional steps for handling / disposal may be required, increasing the overall cost of the manufacturing process. Therefore, the cost of removing solvent from the coated material on the metal foil involves additional steps that also increase the overall cost of the manufacturing process. Summary of the Invention

[0005] According to embodiments of this disclosure, an exemplary system for manufacturing multilayer battery electrodes is provided. In particular, multilayer electrodes for batteries (such as lithium-ion batteries) have attracted particular attention in the industry due to the special properties provided by such multilayer powder coatings. For example, one special property provided by multilayer powder coatings is that the resulting electrodes have layers with different porosities to allow for improved power behavior. Multilayer powder coatings produce gradient electrode structures with tunable powder properties and energy properties. These performance properties replace the need for coupling power cells and energy cells at the module level, thereby simplifying system-level design and the electronic requirements for managing the configuration of both cell designs. The tunability of electrode performance can be achieved by dry coating two chemicals, for example, layers of lithium iron phosphate for power performance and lithium nickel cobalt manganese oxide for energy performance, by using the same chemicals to control the low-density layer for power and the high-density layer for energy, or in a similar manner. Ultimately, multilayer dry-coated electrodes reduce costs and extend battery life.

[0006] Producing multilayer powder coatings using slurry-based electrode coating is challenging. This system provides a spreading roller coating assembly for producing multiple layers of powder particle coating on a substrate. The system can produce each powder particle coating layer with or without heating, the thickness of each coating layer can be customized, and the same or different powder particles can be used for each layer. This system provides an efficient and cost-effective process for manufacturing multilayer electrodes with a variety of thicknesses. Although two stations for coating are discussed herein, it should be understood that the system can include any number of stations to produce two or more powder particle coating layers, depending on the end-user's specifications.

[0007] According to embodiments of this disclosure, an exemplary system for manufacturing multilayer battery electrodes is provided. The system includes a first spreading and coating system comprising a first powder particle chamber, a first spreading and coating assembly, and a first calendering assembly. The first powder particle chamber is configured to receive first powder particles and distribute the first powder particles onto a substrate to define a first coating thickness of the first powder particles on the substrate. The first spreading and coating assembly is configured to receive the substrate therein to spread the first powder particles along the substrate into a first uniform coating having a first intermediate coating thickness. The first intermediate coating thickness is set to be less than the first coating thickness. The first calendering assembly is configured to receive the substrate therein to compress the first uniform coating into a first compressed powder coating (e.g., a first compressed powder coating layer) having a second coating thickness. The second coating thickness is set to be less than the first intermediate coating thickness.

[0008] The system includes a second spreading and coating system comprising a second powder particle chamber, a second spreading assembly, and a second calendering assembly. The second powder particle chamber is configured to receive second powder particles and distribute them onto a first compressed powder coating to define a third coating thickness of the second powder particles on the first compressed powder coating. The second spreading assembly is configured to receive a substrate therebetween to spread the second powder particles along the first compressed powder coating into a second uniform coating having a second intermediate coating thickness. The second intermediate coating thickness is set to be less than the third coating thickness. The second calendering assembly is configured to receive a substrate therebetween to compress the second uniform coating into a second compressed powder coating (e.g., a second compressed powder coating layer) having a fourth coating thickness. The fourth coating thickness is set to be less than the second intermediate coating thickness. The first compressed powder coating and the second compressed powder coating define a multilayer coating on the substrate.

[0009] In some embodiments, the first spreading and coating assembly and the second spreading and coating assembly each include at least one pair of spreading rollers. In some embodiments, the first calendering assembly and the second calendering assembly each include at least one pair of calendering rollers. In some embodiments, multiple pairs of spreading rollers and / or calendering rollers may be used. The first spreading and coating system is disposed proximal to the substrate relative to the second spreading and coating system.

[0010] A first powder particle chamber is disposed proximal to the substrate relative to a first spreading and coating assembly, and the first spreading and coating assembly is disposed proximal to the substrate relative to a first calendering assembly. A second powder particle chamber is disposed proximal to the substrate relative to a second spreading and coating assembly, and the second spreading and coating assembly is disposed proximal to the substrate relative to a second calendering assembly.

[0011] In some embodiments, the first powder particles and the second powder particles comprise at least one of a cathode material or an anode material. In some embodiments, the first powder particles and the second powder particles have the same formulation. In some embodiments, the first powder particles and the second powder particles have different formulations. In some embodiments, the thickness of the first compressed powder coating and the thickness of the second compressed powder coating are equal. In some embodiments, the thickness of the first compressed powder coating and the thickness of the second compressed powder coating are different. In some embodiments, for the first compressed powder coating layer and the second compressed powder coating layer, the density of the coating layer (including unit or powder loading parameter (mg / cm³)) is... 2 (and / or thickness) can be the same or different.

[0012] The substrate may be defined by a length extending between a proximal end and a distal end, and may also be defined by a width transverse to that length. A first uniform coating and a second uniform coating define the uniformity of the respective first and second intermediate coating thicknesses along the width and length of the substrate. During the passage of the substrate through the first and second calendering assemblies, pressure is applied to the respective first and second uniform coatings to produce the respective first and second compressed powder coatings.

[0013] In a first compressed powder coating, first powder particles on a substrate are bonded together to form a first compressed powder coating, and the first compressed powder coating is adhered to the substrate. Second powder particles on the first compressed powder coating are bonded together to form a second compressed powder coating, and the second compressed powder coating is adhered to the first compressed powder coating.

[0014] In some embodiments, the system may include a powder removal component disposed between a first calendering assembly and a second spreading and coating assembly. The powder removal component may be configured to remove uncompressed powder particles from a first compressed powder coating. In some embodiments, the system may include a powder removal component disposed distal to a second calendering assembly. The powder removal component may be configured to remove uncompressed powder particles from a second compressed powder coating. The first and second compressed powder coatings may define densified regions for corresponding first and second powder particles.

[0015] According to embodiments of this disclosure, an exemplary method for manufacturing a multilayer battery electrode is provided. The method includes: distributing first powder particles onto a substrate using a first powder particle chamber of a first spreading and coating system to define a first coating thickness of the first powder particles on the substrate. The method further includes: passing the substrate through a first spreading and coating assembly of the first spreading and coating system to spread the first powder particles along the substrate into a first uniform coating having a first intermediate coating thickness. The first intermediate coating thickness is set to be less than the first coating thickness. The method also includes: passing the substrate through a first calendering assembly of the first spreading and coating system to compress the first uniform coating into a first compressed powder coating having a second coating thickness. The second coating thickness is set to be less than the first intermediate coating thickness.

[0016] The method includes: distributing second powder particles onto a first compressed powder coating using a second powder particle chamber of a second spreading coating system to define a third coating thickness of the second powder particles on the first compressed powder coating. The method further includes: passing a substrate through a second spreading assembly of the second spreading coating system to spread the second powder particles along the first compressed powder coating into a second uniform coating having a second intermediate coating thickness. The second intermediate coating thickness is set to be less than the third coating thickness. The method also includes: passing a substrate through the second spreading coating assembly of the second spreading coating system to compress the second uniform coating into a second compressed powder coating having a fourth coating thickness. The fourth coating thickness is set to be less than the second intermediate coating thickness. The first compressed powder coating and the second compressed powder coating define a multilayer coating on the substrate.

[0017] In some embodiments, the formulations of the first powder particles and the second powder particles may be different. The first powder particles on the substrate in a first compressed powder coating may be bonded together to form a first compressed powder coating, and the first compressed powder coating may be adhered to the substrate. The second powder particles on the first compressed powder coating may be bonded together to form a second compressed powder coating, and the second compressed powder coating may be adhered to the first compressed powder coating. The method may include passing the substrate through or beneath a powder removal assembly to remove uncompressed first or second powder particles from the respective first or second compressed powder coating.

[0018] Any combination and / or substitution of the embodiments is contemplated. Other objects and features will become apparent from the following detailed description taken in conjunction with the accompanying drawings. However, it should be understood that the drawings are intended to be illustrative only and not as definitions of limitations of this disclosure. Attached Figure Description

[0019] To assist those skilled in the art in manufacturing and using systems for fabricating multilayer battery electrodes, reference is made to the accompanying drawings, in which:

[0020] Figure 1 This is a schematic view of a conventional spreader roller coating system.

[0021] Figure 2 This is a schematic view of an exemplary system for fabricating multilayer battery electrodes according to embodiments of the present disclosure. Detailed Implementation

[0022] Figure 2This is a schematic view of an exemplary system 100 (hereinafter referred to as "System 100") for the manufacture of multilayer battery electrodes. System 100 can be used to manufacture multilayer coated substrates usable in, for example, lithium-ion batteries, solid-state batteries, etc. System 100 uses a spreader roller coating electrode manufacturing technique in two or more stations to replicate powder particle coatings after a previous coating has been densified / compressed. System 100 can be incorporated into a receiving enclosure (e.g., a receiving chamber) for depositing the powder coating onto a substrate or web 102 (e.g., a continuously moving substrate or web 102). In some embodiments, the web 102 can be a metal foil.

[0023] The web 102 includes a top surface 104 on which a powder coating is applied. The powder coating includes at least a cathode or anode material, such as that used in rechargeable lithium batteries. A binder material may be applied to the web 102 along with powder particles 118 as part of the dry powder coating. In some embodiments, the bottom surface of the web 102 may also receive the powder coating simultaneously with the top surface, or after the top surface has been coated. Rollers 106 and 108 may be positioned on opposite proximal ends 110 and distal ends 112 of the web 102 and suspend the web 102 as it passes through the receiving closure. The rollers 106 and 108 may rotate in combination to maintain continuous movement of the web 102 through the receiving closure in the web direction 114.

[0024] System 100 includes a first chamber 116 configured to receive powder particles 118 and distribute the powder particles 118 onto the top surface 104 of a web 102 (e.g., a powder storage chamber and a component of a dispensing / dispersing mechanism). The chamber 116 can be used to distribute the powder particles 118 onto the web 102, for example, in a centrally positioned pile form, for subsequent spreading by a first pair of spreading rollers 120, 122. Specifically, system 100 includes a first pair of spreading rollers 120, 122 positioned downstream or distal to the chamber 116. One spreading roller 120 is positioned adjacent to the top surface 104 of the web 102, and the other spreading roller 122 is positioned adjacent to the opposing bottom surface of the web 102, thereby clamping the web 102 between the rollers 120, 122. In some embodiments, system 100 may include two or more pairs of spreading rollers arranged in series, instead of a single pair of spreading rollers 120, 122, for improved spreading of powder particles 118. For example, each set of spreading rollers may progressively spread the powder particles 118 onto the web 102 to ensure a gradual and uniform distribution of the powder particles 118. Such a spreading roller assembly may be referred to as a spreading coating assembly.

[0025] like Figure 2As shown, the initial coating of powder particles 118 produces an uncompressed coating layer 124 of a first thickness, as measured from the top surface 104 of the web 102 to the top of the coating layer 124. In some embodiments, the initial coating layer 124 may be centrally positioned below the chamber 116 without covering the entire surface 104 of the web 102, such as a powder pile. The web 102 moves continuously toward and between spreading rollers 120, 122. As the web 102 passes between the spreading rollers 120, 122, the powder coating layer 124 is distributed along the top surface 104 of the web 102 to produce a uniform or substantially uniform coating layer 126. This uniform coating layer 126 defines a second thickness, which is set to be smaller than the first thickness of the coating layer 124. Spreading rollers 120 and 122 ensure that the powder coating is redistributed or spread over the web 102 to achieve a uniform coating along the entire top surface 104 of the web 102.

[0026] Therefore, after the web 102 passes through the spreading rollers 120, 122, the thickness of the powder coating layer 126 is uniform when viewed laterally across the web 102 (e.g., uniform along both the width and length of the web 102). At this stage of the process, the powder coating can cover the entire top surface 104 of the web 102 without creating uncoated areas. The powder coating also defines a substantially uniform thickness, with minimal thickness variation along both the width and length of the web 102.

[0027] The web 102 moves continuously to pass between a first pair of calendering rolls 128, 130 positioned downstream or distal to the spreading rolls 120, 122. One calendering roll 128 is positioned adjacent to the top surface 104 of the web 102, and the other calendering roll 130 is positioned adjacent to the opposing bottom surface of the web 102, thereby clamping the web 102 between the rolls 128, 130. The calendering rolls 128, 130 are configured to compress and densify the powder coating layer 126 to obtain a compressed powder coating layer 132 having a predetermined third thickness. The thickness of the compressed powder coating layer 132 is set to be less than the thickness of the powder coating layer 126. The densification step of the calendering rolls 128, 130 can be performed with or without heating. In some embodiments, system 100 may include two or more pairs of calendering rolls arranged in series, instead of a single pair of calendering rolls 128, 130, for improved compression and densification of the powder coating layer 126. For example, each set of calendering rolls may incrementally compress and densify the powder particles 118 to ensure gradual and uniform compression / densification of the powder coating layer 126. Such a calendering roll assembly may be referred to as a calendering assembly.

[0028] Prior to densification, the powder coating layer 126 is placed on the web 102 without adhering to it. After densification using calendering rolls 128 and 130, the dry powder coating is adhered to the web 102, and the powder particles 118 in the coating layer 132 are bonded together by the binder material in the coating layer 132 and / or by the mechanical force between the coating layer 132 and the web 102 caused by the compressive force applied to the powder coating. The combination of chamber 116, spreading rolls 120 and 122 and calendering rolls 128 and 130 can define a first spreading system or section of system 100 and is used to form the first layer of the multilayer electrode (i.e., powder coating layer 132).

[0029] Downstream or distal to the calendering rolls 128, 130, system 100 includes a second spreading system or section having a second chamber 134, a second pair of spreading rolls 136, 138, and a second pair of calendering rolls 140, 142. Although each of the spreading components is shown as including a single pair of spreading rolls and a single pair of calendering rolls, in some embodiments (as mentioned above), multiple pairs of spreading rolls and / or calendering rolls may be used. The second spreading system operates in a manner substantially similar to the first spreading system. The second chamber 134 dispenses the initial coating layer 144 of powder particles 146. However, instead of dispensing the powder particles 146 onto the top surface 104 of the web 102, the powder particles 146 are dispensed onto the top surface of the coating layer 132. The powder particles 146 may be the same as or different from the powder particles 118. In some embodiments, different formulations or percentages of powder particles 118, 146 may be used for each layer. The thickness of the initial coating layer 144 may be the same as or equal to the thickness of the coating layer 124. In some embodiments, powder particles 146 may be centrally positioned below the chamber 134 without covering the entire surface of the coating layer 132, such as a powder pile.

[0030] The web 102 moves continuously between spreading rollers 136 and 138. As the web 102 passes between the spreading rollers 136 and 138, a powder coating layer 144 is distributed along the top surface of the coating layer 132 to create a uniform or substantially uniform coating layer 148. This uniform coating layer 148 defines a thickness that is designed to be less than the thickness of the coating layer 144. The spreading rollers 136 and 138 ensure that the powder coating is redistributed or spread over the coating layer 132 to achieve a uniform coating along the entire top surface of the coating layer 132.

[0031] Therefore, after the web 102 passes through the spreading rollers 136, 138, the thickness of the powder coating layer 148 is uniform when viewed laterally across the web 102 (e.g., uniform along both the width and length of the web 102 and the coating layer 132). At this stage of the process, the powder coating can cover the entire top surface 104 of the coating layer 132 without forming uncoated areas. The powder coating also defines a substantially uniform thickness, with minimal thickness variation along both the width and length of the web 102 and the coating layer 132.

[0032] The web 102 moves continuously to pass between a second pair of calender rolls 140, 142 positioned downstream or distal to the spreading rolls 136, 138. One calender roll 140 is positioned adjacent to the top surface 104 of the coating 132, and the other calender roll 142 is positioned adjacent to the opposing bottom surface of the web 102, thereby clamping the web 102 between the rolls 140, 142. The calender rolls 140, 142 are configured to compress and densify the powder coating layer 148 to obtain a compressed powder coating layer 150 with a predetermined compressed thickness. The thickness of the compressed powder coating layer 150 is set to be less than the thickness of the powder coating layer 148. The densification step of the calender rolls 140, 142 can be performed with or without heating.

[0033] Before densification, the powder coating layer 148 rests on the coating layer 132 without adhering to it. After densification using calendering rolls 140, 142, the dry powder coating is adhered to the coating layer 132 (and indirectly to the web 102), and the powder particles 148 in the coating layer 132 are bonded together by the binder material in the coating layer 150 and / or by the mechanical force between the coating layer 150 and the coating layer 132 caused by the compressive force applied to the powder coating.

[0034] The second spreading assembly thus forms a second layer (i.e., powder coating layer 150) on the first layer (i.e., powder coating layer 132) of the multilayer electrode. It should be understood that the type of powder particles used for the different layers and the compression thickness of the different layers can vary depending on the end-user's specifications. If more than two layers are desired, an additional spreading assembly having a powder particle chamber, spreading rollers, and calendering rollers can be incorporated into the system 100 downstream of the second spreading assembly to gradually add more powder coating layers to the electrode. Thus, a multilayer electrode can be manufactured using an efficient and cost-effective process.

[0035] In some embodiments, a powder removal assembly 152 (e.g., a vacuum cleaner, etc.) may be positioned at the distal end 112 of the system 100 to remove any uncompressed powder particles. In some embodiments, the powder removal assembly 152 may be positioned after each set of calendering rolls (e.g., after calendering rolls 128, 130 and after calendering rolls 140, 142) to remove any uncompressed powder particles before a subsequent powder particle layer is deposited onto the previous coating layer.

[0036] In some embodiments, the range of compression force provided by the calendering rolls of system 100 may be, for example, about 10 to 2000 N / mm or higher (inclusive), 10 to 1900 N / mm (inclusive), 10 to 1800 N / mm (inclusive), 10 to 1700 N / mm (inclusive), 10 to 1600 N / mm (inclusive), 10 to 1500 N / mm (inclusive), 10 to 1400 N / mm (inclusive), 10 to 1300 N / mm (inclusive), 10 to 1200 N / mm (inclusive), 10 to 1100 N / mm (inclusive), 10 to 1000 N / mm (inclusive), 10 to 900 N / mm (inclusive), 10 to 800 N / mm (inclusive), 10 to 700 N / mm (inclusive), 10 to 600 N / mm (inclusive). N / mm (inclusive of end values), 10 to 500 N / mm (inclusive of end values), 10 to 400 N / mm (inclusive of end values), 10 to 300 N / mm (inclusive of end values), 10 to 200 N / mm (inclusive of end values), 10 to 100 N / mm (inclusive of end values), 10 to 50 N / mm (inclusive of end values), 10 to 20 N / mm (inclusive of end values), 20 to 2000 N / mm (inclusive of end values), 30 to 2000 N / mm (inclusive of end values), 40 to 2000 N / mm (inclusive of end values), 50 to 2000 N / mm (inclusive of end values), 100 to 2000 N / mm (inclusive of end values), 200 to 2000 N / mm (inclusive of end values), 300 to 2000 N / mm (inclusive of end values), 400 to 2000 N / mm (inclusive of end values), 500 to 2000 N / mm (inclusive of end values). N / mm (inclusive of end values), 600 to 2000 N / mm (inclusive of end values), 700 to 2000 N / mm (inclusive of end values), 800 to 2000 N / mm (inclusive of end values), 900 to 2000 N / mm (inclusive of end values), 1000 to 2000 N / mm (inclusive of end values), 1100 to 2000 N / mm (inclusive of end values), 1200 to 2000 N / mm (inclusive of end values), 1300 to 2000 N / mm (inclusive of end values), 1400 to 2000 N / mm (inclusive of end values), 1500 to 2000 N / mm (inclusive of end values), 1600 to 2000 N / mm (inclusive of end values), 1700 to 2000 N / mm (inclusive of end values), 1800 to 2000 N / mm (inclusive), 1900 to 2000 N / mm (inclusive), 20 to 1500 N / mm (inclusive), 20 to 1000 N / mm (inclusive), 20 to 500 N / mm (inclusive), 20 to 300 N / mm (inclusive), 10 N / mm, 20 N / mm, 30 N / mm, 40 N / mm, 50 N / mm, 60 N / mm, 70 N / mm, 80 N / mm, 90N / mm, 100 N / mm, 200 N / mm, 300 N / mm, 400 N / mm, 500 N / mm, 600 N / mm, 700 N / mm, 800 N / mm, 900 N / mm, 1000 N / mm, 1100 N / mm, 1200 N / mm, 1300 N / mm, 1400 N / mm, 1500 N / mm, 1600 N / mm, 1700 N / mm, 1800 N / mm, 1900 N / mm, 2000 N / mm or above, etc. In some embodiments, the compression force of each pair of calender rolls may be the same. In some embodiments, the compression force of each pair of calender rolls may be different (e.g., depending on the desired thickness, the type of powder particles used, to adapt to the previous coating layer, etc.).

[0037] While exemplary embodiments have been described herein, it should be clearly understood that these embodiments should not be construed as limiting, and additions and modifications to the content expressly described herein are also included within the scope of the invention. Furthermore, it should be understood that the features of the various embodiments described herein are not mutually exclusive and can exist in various combinations and substitutions without departing from the spirit and scope of the invention, even if such combinations or substitutions are not expressly stated herein.

Claims

1. A system for fabricating multilayer battery electrodes, the system comprising: A first spreading and coating system, comprising: (i) A first powder particle chamber configured to receive first powder particles and distribute the first powder particles onto a substrate to define a first coating thickness of the first powder particles on the substrate; (ii) A first spreading and coating assembly configured to receive the substrate therebetween to spread the first powder particles along the substrate into a first uniform coating having a first intermediate coating thickness, wherein the first intermediate coating thickness is set to be smaller than the first coating thickness; and (iii) A first calendering assembly configured to receive the substrate therebetween to compress the first uniform coating into a first compressed powder coating having a second coating thickness, wherein the second coating thickness is set to be smaller than the thickness of the first intermediate coating; and The second spreading and coating system includes: (i) A second powder particle chamber configured to receive second powder particles and distribute the second powder particles onto the first compressed powder coating to define a third coating thickness of the second powder particles on the first compressed powder coating; (ii) a second spreading assembly configured to receive the substrate therebetween to spread the second powder particles along the first compressed powder coating into a second uniform coating having a second intermediate coating thickness, wherein the second intermediate coating thickness is set to be smaller than the third coating thickness; and (iii) A second calendering assembly configured to receive the substrate therebetween to compress the second uniform coating into a second compressed powder coating having a fourth coating thickness, wherein the fourth coating thickness is set to be smaller than the thickness of the second intermediate coating. The first compressed powder coating and the second compressed powder coating define a multilayer coating on the substrate.

2. The system according to claim 1, wherein, The first spreading and coating assembly and the second spreading and coating assembly each include at least one pair of spreading rollers.

3. The system according to claim 1, wherein, The first calendering assembly and the second calendering assembly each include at least one pair of calendering rolls.

4. The system according to claim 1, wherein, The first spreading and coating system is positioned proximal to the substrate relative to the second spreading and coating system.

5. The system according to claim 1, wherein, The first powder particle chamber is disposed proximally to the first spreading and coating assembly along the substrate, and the first spreading and coating assembly is disposed proximally to the first calendering assembly along the substrate.

6. The system according to claim 1, wherein, The second powder particle chamber is disposed proximally to the substrate relative to the second spreading and coating assembly, and the second spreading and coating assembly is disposed proximally to the substrate relative to the second calendering assembly.

7. The system according to claim 1, wherein, The thickness and / or density of the first compressed powder coating is equal to the thickness and / or density of the second compressed powder coating.

8. The system according to claim 1, wherein, The thickness and / or density of the first compressed powder coating is different from that of the second compressed powder coating.

9. The system according to claim 1, wherein, The substrate is defined by a length extending between a proximal end and a distal end, and further defines a width transverse to the length, wherein the first uniform coating and the second uniform coating define uniformity in the corresponding first intermediate coating thickness and second intermediate coating thickness along the width and length of the substrate.

10. The system according to claim 1, wherein, As the substrate passes through the first calendering assembly and the second calendering assembly, pressure is applied to the corresponding first uniform coating and the second uniform coating to produce the corresponding first compressed powder coating and the second compressed powder coating.

11. The system according to claim 1, wherein, The first powder particles on the substrate in the first compressed powder coating are bonded together to form the first compressed powder coating, and the first compressed powder coating is adhered to the substrate.

12. The system according to claim 1, wherein, The second powder particles on the first compressed powder coating are bonded together to form the second compressed powder coating, and the second compressed powder coating is adhered to the first compressed powder coating.

13. The system according to claim 1, comprising: A powder removal component is disposed between the first calendering component and the second spreading and coating component, wherein the powder removal component is configured to remove uncompressed powder particles from the first compressed powder coating.

14. The system according to claim 1, comprising: A powder removal assembly disposed on the distal side of the second calendering assembly, wherein the powder removal assembly is configured to remove uncompressed powder particles from the second compressed powder coating.

15. The system according to claim 1, wherein, The first compressed powder coating and the second compressed powder coating define the densification regions of the corresponding first powder particles and second powder particles.

16. A method for manufacturing a multilayer battery electrode, the method comprising: The first powder particles are distributed onto the substrate using the first powder particle chamber of the first spreading and coating system to define the first coating thickness of the first powder particles on the substrate; The substrate is passed through the first spreading and coating assembly of the first spreading and coating system to spread the first powder particles along the substrate into a first uniform coating having a first intermediate coating thickness, wherein the first intermediate coating thickness is set to be smaller than the first coating thickness. The substrate is passed through a first calendering assembly of the first spreading and coating system to compress the first uniform coating into a first compressed powder coating having a second coating thickness, wherein the second coating thickness is set to be smaller than the thickness of the first intermediate coating. The second powder particles are distributed onto the first compressed powder coating using the second powder particle chamber of the second spreading coating system, thereby defining the third coating thickness of the second powder particles on the first compressed powder coating. The substrate is passed through a second spreading component of the second spreading and coating system to spread the second powder particles along the first compressed powder coating into a second uniform coating having a second intermediate coating thickness, wherein the second intermediate coating thickness is set to be smaller than the third coating thickness; and The substrate is passed through the second spreading and coating assembly of the second spreading and coating system to compress the second uniform coating into a second compressed powder coating having a fourth coating thickness, wherein the fourth coating thickness is set to be smaller than the thickness of the second intermediate coating. The first compressed powder coating and the second compressed powder coating define a multilayer coating on the substrate.

17. The method according to claim 16, wherein, The formulations of the first powder particles and the second powder particles are different.

18. The method according to claim 16, wherein, The first powder particles on the substrate in the first compressed powder coating are bonded together to form the first compressed powder coating, and the first compressed powder coating is adhered to the substrate.

19. The method of claim 16, wherein, The second powder particles on the first compressed powder coating are bonded together to form the second compressed powder coating, and the second compressed powder coating is adhered to the first compressed powder coating.

20. The method of claim 16, comprising: The substrate is passed through or beneath the powder removal assembly to remove uncompressed first or second powder particles from the corresponding first or second compressed powder coating.

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