System for powder coating with edge alignment assembly

Abstract

A system for powder coating with edge alignment is provided. The system includes a coating unit configured to apply a first coating layer on a first surface of a web and apply a second coating layer on a second surface of the web. The second surface opposes the first surface, the first coating layer includes a first coating edge and a second coating edge, and the second coating layer includes a first coating edge and a second coating edge. The system includes a coating edge alignment assembly configured to receive the web and selectively remove a portion of at least one of the first coating layer or the second coating layer to align coating edges of the first coating layer with coating edges of the second coating layer on opposing sides of the web.

Description

Attorney Docket No. 137174.00103SYSTEM FOR POWDER COATING WITH EDGE ALIGNMENT ASSEMBLYCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 716,914, filed on November 6, 2024. The entire content of the foregoing provisional application is incorporated herein by reference in its entirety.BACKGROUND

[0002] A variety of batteries are available in the industry for different uses. Lithium- ion (Li-ion) batteries have generally become the predominant type of battery used in portable consumer electronics and electric vehicles. Fabrication of Li-ion batteries involves numerous steps, each of which can affect the quality of the battery itself, as well as the cost involved in manufacturing the battery. A conventional manufacturing process generally includes formation of an electrode slurry having an active material, a conductive additive, and a binder, mixed in an organic solvent, and the electrode slurry is applied to a metal foil material. Once applied to the foil material, the solvent is dried out or evaporated while the active electrode mixture remains attached to the metal foil material surface. In some instances, the solvent may be toxic and can necessitate additional steps for handling / discarding that increase the overall cost of the manufacturing process. The cost of removing the solvent from the coated material on the metal foil therefore involves an additional step that also increases the overall cost of the manufacturing process.

[0003] An alternative manufacturing technique used in the industry is electrostatic deposition (ESD), which is a solvent-free manufacturing process for electrode coating for Li-ion batteries. (See, e.g., B. Ludwig et al., Solvent-Free Manufacturing of Electrodes for Lithium-ion Batteries, Sci. Rep. 6, Article No. 23150, doi: 10.1038 / srep23150 (2016); M. Wang et al., The Influence of Polyvinylidene Fluoride (PVDF) Binder Properties on LiNio.33Coo.33Mno.33O2 (NMC) Electrodes Made by a Dry-Powder-Coating Process, J. Electrochem. Soc., Vol. 166, No. 10, A2151 (2019); H. Abe et al., Electrostatic Spray Deposition for Fabrication of Li-ion Batteries, Transactions of JWRI, Vol. 44, No. 2 (2015); and U.S. Patent No. 10,547,044). Rather than relying on a solvent mixture, the ESD process uses a dry powder of the active electrode mixture which is applied to the metal foil material. By removing the solvent from the mixture and the drying step from the manufacturing process, the overall process is simplified and becomes more economical,1ME1X58685774. vlAttorney Docket No. 137174.00103 resulting in a viable alternative for large-scale manufacturing. In particular, the solvent- free electrode coating technology is an attractive alternative to traditional manufacturing since it can significantly reduce energy consumption in the manufacturing process and thus significantly reduces the manufacturing cost of batteries.

[0004] In a conventional continuous dry powder ESD coating system, a web (e.g., a grounded electrically conductive substrate) passes continuously through a coating chamber while the dry powder mixture is fluidized and pneumatically conveyed from a hopper to an electrostatic spray gun. The electrostatic spray gun electrostatically charges the powders using tribo-charging or corona charging, and sprays the charged powders onto the web where they are deposited.

[0005] Another conventional manufacturing process for coating of a web is referred to as “spreader roller coating’’. A spreader roller coating system generally includes a reservoir that receives and dispenses powder particles onto a moving web. The web is passed through a pair of spreading rollers to spread and distribute the powder particles uniformly on the surface of the web to achieve a uniform coating on the web. The web is subsequently passed through a pair of calender rollers which compress and densify the powder particles. Such compression and densification causing the powder particles to adhere to each other and the web. Compression and densification performed by the calender rollers with or without heating promotes cohesion and adhesion of the powder particles to the web, and after such process, a dry electrode is produced. Such spreader roller coating technology is described in, e.g., International Patent Application No. PCT / US23 / 69175, which is incorporated herein by reference in its entirety.

[0006] In some instances, the ESD coating method and the spreading roller coating method can be used in conjunction where first an ESD coated layer is produced on the web and then is subsequently refined by a spreading roller (or vice versa), as is described in International Patent Application No. PCT / US 24 / 48849, filed on September 27, 2024, which is incorporated herein by reference in its entirety.

[0007] For both ESD coating and spreader roller coating, the typical process involves coating one side, compressing the coated side, and rewinding the web. In some instances, both sides of the web can be coated). When coating both sides of the web, aligning edges of the coating between a top side (e.g., A side) and a bottom side (e.g., B side) along the length of the web is critical to ensure safe performance of a battery cell formed from the2ME1X58685774. vlAttorney Docket No. 137174.00103 coated web.

[0008] Typically, edge alignment is performed by steering the web laterally during the coating process such that the coating assembly coats the web in the desired locations. However, this approach is limited by mechanical capabilities (e.g., precision and accuracy) of the web steering equipment, as well as the response time from where the web steering equipment is positioned and where the coating is deposited. In systems which coat one side of the web at a time and subsequent alignment of the coating edges is performed, the tolerances on the mechanical capabilities of the web steering equipment are stacking, leading to additional capability losses.

[0009] In slurry-based electrode manufacturing, edge alignment can be performed by positioning of the web and striving for depositing accuracy of the coating assembly. Removal of the coating from the web is generally undesired in slurry-based electrode manufacturing, as such removal would likely irreparably damage the web, which would be unacceptable. Thus, existing manufacturing techniques result in imprecise coating edge alignment and potential damage to the web surface. To resolve the imprecise edge alignment, some coating techniques include a final step of applying a non-conductive edge coating to prevent occurrence of shorting, thereby increasing the manufacturing process.SUMMARY

[0010] Embodiments of the present disclosure provide an exemplary system for battery electrode fabrication including an edge alignment assembly. The system allows the web to be coated on both sides (either simultaneously or in a staggered manner), and includes a coating alignment assembly that precisely removes the coating from the web surface to ensure edge alignment between opposing surfaces. The coating can be performed using any type of coating method (e.g., ESD coating, spreader roller coating, or the like), and results in a precise alignment between opposing edges of the coating along the entire length of the web. The precise coating edge alignment ensures that additional non-conductive edge coating is unnecessary for proper operation of the resulting electrode. By relying on dry powder deposition manufacturing, where the powdered material coating may be weakly adhered to the web at certain times and / or durations of the process, different approaches discussed herein can be taken to improve the alignment control between two edges on opposing sides of the web. As such, optimal performance of the resulting battery electrode can be achieved.3ME1X58685774. vlAttorney Docket No. 137174.00103

[0011] In accordance with embodiments of the present disclosure, an exemplary system for powder coating with edge alignment is provided. The system includes a coating unit configured to apply a first coating layer on a first surface of a web and apply a second coating layer on a second surface of the web. The second surface opposes the first surface, the first coating layer includes a first coating edge and a second coating edge, and the second coating layer includes a first coating edge and a second coating edge. The system includes a coating edge alignment assembly configured to receive the web and selectively remove a portion of at least one of the first coating layer or the second coating layer to align coating edges of the first coating layer with coating edges of the second coating layer on opposing sides of the web.

[0012] Each of the first coating layer and the second coating layer can include powder particles. The powder particles can include (i) an anode powder with an active material, a binder, and a conductive material, and / or (ii) a cathode powder with an active material, a binder, and a conductive material. In some embodiments, the coating unit can include a first coating unit configured to apply the first coating layer on the first surface of the web, and a second coating unit configured to apply the second coating layer on the second surface of the web. In some embodiments, the first and second coating units can be configured to simultaneously apply the first and second coating layers, respectively.

[0013] The system can include a conditioning unit configured to spread or level the first coating layer and the second coating layer prior to entry of the web into the coating edge alignment assembly. The system can include a pre -compression unit configured to apply an initial compressive force to the first and second coating layers for binding powder particles of the first and second coating layers to each other or the web. The system can include a calendering unit configured to compress the first and second coating layers to their target thickness relative to the first and second surfaces of the web. In some embodiments, the calendering unit can include a first calendering roller disposed adjacent to the first surface of the web and an opposing second calendering unit disposed adjacent to the second surface of the web.

[0014] The coating edge alignment assembly can be configured to simultaneously (or substantially simultaneously) remove the portion of at least one of the first coating layer or the second coating layer to align the coating edges of the first coating layer with the coating edges of the second coating layer on opposing sides of the web. In some embodiments, the coating edge alignment assembly can include a slit formation structure configured to form4ME1X58685774. vlAttorney Docket No. 137174.00103 slits in the first coating layer and slits in the second coating layer at or near each of the first and second coating edges of the first and second coating layers. Each slit formation structure can include a blade with a point positioned immediately adjacent to the respective first and second surface of the web.

[0015] In some embodiments, the coating edge alignment assembly can include powder removal units configured to remove the portion of at least one of the first coating layer or the second coating layer between the respective slits and the first and second coating edges of the first and second coating layers to form (i) a first aligned coating edge from the first coating edge of the first coating layer, (ii) a second aligned coating edge from the second coating edge of the first coating layer, (iii) a first aligned coating edge from the first coating edge of the second coating layer, and (iv) a second aligned coating edge from the second coating edge of the second coating layer. The first aligned coating edge of the first coating layer can be aligned with the first aligned coating edge of the second coating layer on opposing sides of the web, and the second aligned coating edge of the first coating layer can be aligned with the second aligned coating edge of the second coating layer on opposing sides of the web.

[0016] In some embodiments, the coating edge alignment assembly can include edge formation structures configured to remove the portion of at least one of the first coating layer or the second coating layer at or near the first and second coating edges of the first and second coating layers to form (i) a first aligned coating edge from the first coating edge of the first coating layer, (ii) a second aligned coating edge from the second coating edge of the first coating layer, (iii) a first aligned coating edge from the first coating edge of the second coating layer, and (iv) a second aligned coating edge from the second coating edge of the second coating layer.

[0017] Removing the portion of at least one of the first coating layer or the second coating layer with the coating edge alignment assembly forms lanes on respective sides of the first and second coating layers. In some embodiments, the system can include an initial powder removal unit configured to partially remove the first coating layer and the second coating layer from the web to form initial lanes on respective sides of the first and second coating layers, the initial lanes including the coating edges of the first and second coating layers. In such embodiments, the coating edge alignment assembly can be configured to selectively remove the portion of at least one of the first coating layer or the second coating layer at the coating edges of the initial lanes to form aligned lanes on respective sides of5ME1X58685774. vlAttorney Docket No. 137174.00103 the first and second coating layers. The aligned lanes can include edges aligned relative to each other on opposing sides of the web.

[0018] In some embodiments, the system can include one or more sensors configured to detect an edge of the web. The system can further include an adjustment mechanism configured to receive real-time signals from the sensor regarding the detected edge of the web to form a closed-loop control. The adjustment mechanism can be configured to automatically adjust a position of the coating edge alignment assembly based on the received real-time signals from the sensor to maintain alignment of the coating edges of the first coating layer with the coating edges of the second coating layer on opposing sides of the web.

[0019] In accordance with embodiments of the present disclosure, an exemplary method of powder coating with edge alignment is provided. The method includes moving a web through or relative to a coating unit to apply a first coating layer on a first surface of the web and apply a second coating layer on a second surface of the web. The second surface opposes the first surface, the first coating layer includes a first coating edge and a second coating edge, and the second coating layer includes a first coating edge and a second coating edge. The method includes moving the web through a coating edge alignment assembly to selectively remove a portion of at least one of the first coating layer or the second coating layer to align coating edges of the first coating layer with coating edges of the second coating layer on opposing sides of the web.

[0020] In accordance with embodiments of the present disclosure, an exemplary system for powder coating with edge alignment. The system includes a coating unit configured to apply a first coating layer on a first surface of a web and apply a second coating layer on a second surface of the web. The second surface opposes the first surface, the first coating layer includes a first coating edge, and the second coating layer includes a first coating edge. The system includes a coating edge alignment assembly configured to receive the web and selectively remove a portion of at least one of the first coating layer or the second coating layer to align the coating edge of the first coating layer with the coating edge of the second coating layer on opposing sides of the web.

[0021] In accordance with embodiments of the present disclosure, an exemplary battery electrode formed from a battery electrode powder is provided. The battery electrode includes a web. The web defines a width measured between opposing first and second6ME1\58685774. vlAttorney Docket No. 137174.00103 lateral edges, a thickness measured between opposing top and bottom surfaces of the web, and a length extending perpendicular to the width. The top surface of the web defines a first coating surface extending the width and the length of the web. The bottom surface of the web defines a second coating surface extending the width and the length of the web. The battery electrode includes a reference position defining a position inset from the first lateral edge of the web. The reference position extends along the length of the web along the top surface of the web. The battery electrode includes a dry battery powder coating adhered to the bottom surface of the web. The dry powder coating includes an active material, a conductive additive, and a binder. A lateral edge of the dry battery powder coating is substantially aligned with the first lateral edge of the web and is within 1 ,000 um of the reference position.

[0022] In some embodiments, the first lateral edge of the dry battery powder coating can be within 500 um of the reference position. In some embodiments, the first lateral edge of the dry battery powder coating can be within 200 um of the reference position. In some embodiments, the first lateral edge of the dry battery powder coating can be within 100 um of the reference position. In some embodiments, the first lateral edge of the dry battery powder coating can be within 50 um of the reference position. The reference position can be coincident with an edge of another dry battery powder coating adhered to the top surface of the web. The lateral edge of the dry battery powder coating can be oriented perpendicular to the bottom surface of the web.

[0023] Any combination and / or permutation of embodiments is envisioned. Other objects and features will become apparent from the following detailed description considered in conjunction with the accompanying drawings. It is to be understood, however, that the drawings are designed as an illustration only and not as a definition of the limits of the present disclosure.BRIEF DESCRIPTION OF THE DRAWINGS

[0024] To assist those of skill in the art in making and using the system for powder coating with edge alignment, reference is made to the accompanying figures, wherein:

[0025] FIG. 1 is a diagrammatic view of an exemplary system for powder coating in accordance with embodiments of the present disclosure, including an edge alignment assembly for dual side coating edge alignment disposed downstream of a pre-compression stage.7ME1\58685774. vlAttorney Docket No. 137174.00103

[0026] FIG. 2 is a diagrammatic view of an exemplary system for powder coating in accordance with embodiments of the present disclosure, including an edge alignment assembly for dual side coating edge alignment disposed upstream of a pre-compression stage.

[0027] FIG. 3 is a diagrammatic view of an exemplary system for powder coating in accordance with embodiments of the present disclosure, including a vertically oriented, simultaneous coating configuration with an edge alignment assembly for dual side coating edge alignment.

[0028] FIG. 4 is a diagrammatic view of an exemplary system for powder coating in accordance with embodiments of the present disclosure, including a vertically oriented, coating configuration with an edge alignment assembly for dual side coating edge alignment and an initial coating removal unit.

[0029] FIG. 5 is a diagrammatic top view of an exemplary system for powder coating in accordance with embodiments of the present disclosure, including stages after an initial coating removal unit and after an edge alignment assembly for dual side coating edge alignment.

[0030] FIG. 6 is a diagrammatic front view of an exemplary system for powder coating in accordance with embodiments of the present disclosure before passage of a web through an edge alignment assembly, including uneven coating edges.

[0031] FIG. 7 is a diagrammatic front view of an exemplary system for powder coating in accordance with embodiments of the present disclosure during passage of a web through an edge alignment assembly.

[0032] FIG. 8 is a diagrammatic front view of an exemplary system for powder coating in accordance with embodiments of the present disclosure during passage of a web through an edge alignment assembly.

[0033] FIG. 9 is a diagrammatic front view of an exemplary system for powder coating in accordance with embodiments of the present disclosure after passage of a web through an edge alignment assembly, including precisely aligned and even coating edges.

[0034] FIG 10. is a diagrammatic perspective view of an edge alignment assembly of an exemplary system for powder coating in accordance with embodiments of the present disclosure.8ME1\58685774. vlAttorney Docket No. 137174.00103

[0035] FIG 11. is a diagrammatic side view of an edge alignment assembly of FIG. 10.

[0036] FIG 12. is a diagrammatic perspective view of an edge alignment assembly disposed on opposing sides of a moving web.

[0037] FIG 13. is a diagrammatic top view of an exemplary edge alignment assembly of FIG. 12.

[0038] FIG 14. is a diagrammatic side view of an exemplary edge alignment assembly of FIG. 12.

[0039] FIG. 15 is a diagrammatic top view of an uncoated web of an exemplary system for powder coating and edge alignment, including a reference position.

[0040] FIG. 16 is a diagrammatic side view of an uncoated web of FIG. 15, including a reference position.

[0041] FIG. 17 is a diagrammatic bottom view of a web of an exemplary system for powder coating and edge alignment, including a reference position and a powder coating on a bottom surface of the web.

[0042] FIG. 18 is a diagrammatic side view of the web of FIG 17, including a reference position and a powder coating on a bottom surface of the web.

[0043] FIG. 19 is a detailed side view of the web of FIG. 17, including a reference position and a lateral coating edge spaced laterally short of a reference position.

[0044] FIG. 20 is a detailed side view of the web of FIG. 17, including a reference position and a lateral coating edge spaced laterally beyond a reference position.DETAILED DESCRIPTION

[0045] An exemplary system for powder coating with an edge alignment assembly is provided. The edge alignment assembly ensures precise alignment of the coating edges on opposing sides of the web, ensuring optimal operation of the resulting battery electrode. In some embodiments, the system can rely on dual sided coating of the web using staggered coating, as described in, e.g., International Patent Application No. PCT / US25 / 29269, filed on May 14, 2025, which is incorporated by reference in its entirety. In some embodiments, the system can rely on simultaneous dual sided coating of the web, as described in, e.g., International Patent Publication No. WO2024 / 182808, filed on March 4, 2024, which is9ME1\58685774. vlAttorney Docket No. 137174.00103 incorporated by reference in its entirety. The alignment assembly discussed herein is configured to accurately align removal features / structures on opposing sides of the web to simultaneously remove the necessary powder for achieving precise coating edge alignment. In some embodiments, a blade can be used to initially create a cut or slit in the coating, and a subsequently vacuum or wiping component an remove the unnecessary / undesired coating from the web surface. In some embodiments, different types of powder coating removal devices can be used, including any devices discussed in International Patent Publication No. WO2024 / 123857, filed on December 6, 2023, which is incorporated by reference in its entirety.

[0046] The examples of operation for the system discussed herein refer to formation of bare areas (e.g., lanes, tabs, or the like) on the edges of the web. However, it should be understood that the system can be similarly used for selective formation of bare areas or lanes offset from the edges of the web. For example, the system can be used to form lanes at the center of the web or at any location offset from the lateral edges of the web. In any coating and lane configuration, due to the coating and lane formation on both sides of the web, alignment of the tabs / lanes is critical.

[0047] After the web has been coated on both sides, the system can be used to precisely define the uncoated lanes at the edges of the web. Defining the edges on both sides simultaneously ensures that alignment of the edge of the top lane and the edge of the bottom lane is extremely precise (e.g., less than about 200 um, 50 um, or less of misalignment). This step of edge alignment and definition can happen at any position or time in the process after the coating has been applied on both sides of the web. In some embodiments, the edge alignment can be performed after conditioning but before pre-compression of the web / coating. In some embodiments, the edge alignment can be performed after conditioning and after pre-compression of the web / coating, but before final compression / calendering of the web.

[0048] The dual side coating edge alignment can create simultaneous edge definition in a variety of ways. In some embodiments, the assembly can first slit a precision line in a well-aligned plane between both sides. This initial line is only a slit in the coating and not in the web itself, which requires precision application position and force. The slitting can be performed via mechanical means, such as a knife, rotating blade, scribe, or the like, or with other means, such as a laser. The target width of the slit line can be less than about, e.g., 50 um, 10 um, or the like. The knife profile for slitting can be designed to optimize a10ME1\58685774. vlAttorney Docket No. 137174.00103 sharp comer profile. After slitting of the coating, the remaining edge coating can be removed using, e.g., a scraper, a vacuum, a brush, a belt, combinations thereof, or the like. The removed coating can be reclaimed by the system for reuse to further coat the web. In some embodiments, the powder can be removed for lane formation without slitting of the coating.

[0049] FIG. 1 is a diagrammatic view of an exemplary system 100 for powder coating including means for core edge alignment (hereinafter “system 100’’). The system 100 can be used to manufacture a coated substrate usable in, e.g., Li-ion batteries, solid state batteries, or the like. The system 100 can be incorporated into a containment enclosure (e.g., a containment chamber) for deposition of the powder coating onto a substrate or web 102, e.g., a continuously moving substrate or web 102. The web 102 includes a top surface 104 and an opposing bottom surface 106, both of which are powder coated. In some embodiments, the surfaces 104, 106 can be simultaneously coated. In some embodiments, the top surface 104 can be coated first while the web 102 travels along direction 108, and subsequently the bottom surface 106 can be coated while the web 102 travels along an opposing direction 110 (or continues along direction 108). The powder coating includes at least a cathode material or an anode material, e.g., for rechargeable lithium batteries, or the like. In some embodiments, a binder material can be included in the powder coating mixture.

[0050] The web 102 can be supported by one or more rollers 1 12, 114, 1 16, 118, 120. In some embodiments, the rollers 112, 120 can act as spools at the proximal and distal ends of the coating assembly. The rollers 114, 116, 118 can be used to change the direction of the web 102 rotation from direction 108 to direction 110 to allow coating of both surfaces 104, 106 of the web 102. However, it should be understood that the web 102 can continue in the same direction for coating of both surfaces 104, 106 simultaneously or in a staggered manner. The web 102 can also travel either in a horizontal, vertical, or diagonal configuration during the coating process.

[0051] At a starting point, the top surface 104 is uncoated before entry into a first coating unit 122 (e.g., coating chamber). The coating unit 122 can be any type of dry powder coating assembly known in the industry, such as ESD coating, spreader roller coating, or the like. For example, the coating unit 122 can include a reservoir that receives a mixture of the powder particles for dispersion onto the web 102. In some embodiments, the coating unit 122 can include one or more powder dispersion systems, e.g., nozzles,11ME1\58685774. vlAttorney Docket No. 137174.00103 rollers, dispensing tubes, mechanical feeders, electrostatic powder feeders, dispersion based on gravimetric or volumetric meter basis, vibratory and / or acoustic dispersion systems, or the like, and any one or combination of the following charging mechanisms, e.g., corona discharge (positive or negative), tribo-charging, direct conduction charging, induction charging, dielectric barrier discharges, other non-thermal plasmas, or the like. In some embodiments, coating unit 122 can include one or more features of those disclosed in International Patent Publication No. WO24 / 006235, filed on June 27, 2023; International Patent Publication No. WO24 / 123857, filed on December 6, 2023; and International Patent Publication No. WO24 / 182808, filed on March 4, 2024, each of which is incorporated herein by reference. In some embodiments, the coating unit 122 can include one or more scattering rollers, one or more spreader rollers, and one or more calendering rollers.

[0052] As the web 102 passes through the first coating unit 122, a first coating layer 124 is applied to the top surface 104 of the web 102. The thickness of the coating layer 124 can be selected based on the desired specifications of the electrode, and can be the same or different on the top and bottom surfaces 104, 106 of the web 102. The type and / or formulation of the powder particles can also be selected based on the desired specifications of the electrode, and can be the same or different on the top and bottom surfaces 104, 106 of the web 102. The coating layer 124 ensures that a substantially uniform layer and thickness of the powder particles i applied along the entire surface 102 of the web 102 laterally as the web 102 passes through the coating unit 122.

[0053] The system 100 can include a conditioning unit 126 disposed downstream of the coating unit 122. In some embodiments, the system 100 can include a heating unit disposed downstream of the coating unit 122 and upstream of the conditioning unit 126 to apply heat to the first coating layer 124. The conditioning unit 126 can include one or more rollers configured to level and / or spread the powder particles applied as the first coating layer 124. In some embodiments, the conditioning unit 126 can apply initial compression to the powder particles, although it is understood that the pressure applied by the conditioning unit 126 is smaller than the pressure of a calendering unit of the system 100. In some embodiments, multiple coating layers can be applied before passing the web 102 to the initial powder removal unit 128.

[0054] In particular, after the conditioning unit 126, the system 100 can include the initial powder removal unit 128 (e.g., a wiping structure). As the web 102 passes through the unit 128, the initial powder removal unit 128 can create one or more lanes 130, 132,12ME1\58685774. vlAttorney Docket No. 137174.00103134 (e.g., uncoated areas) in the first coating layer 124. Although the lanes 130, 132, 134 are formed as precisely as possible, imperfections in the edge alignment relative to the edge of the web 102 may still remain (in addition to misalignment with the second coating layer on the bottom surface 106 discussed below). The powder removal unit 128 can include different types of powder coating removal devices, including any devices discussed in International Patent Publication No. WO2024 / 123857, filed on December 6, 2023, which is incorporated by reference in its entirety. In some embodiments, the system 100 can operate without the powder removal unit 128.

[0055] After passage through the powder removal unit 128, the system 100 includes a pre -compression unit 140 formed by, e.g., rollers 136, 138 disposed above and below the web 102. Although two rollers 136, 138 are shown, it should be understood that more pairs of rollers and / or bottom / top supports can be used to apply compressive forces to the web 102 in series. As the web 102 passes through the pre-compression unit 140, an initial amount of compressive force is applied to the first coating layer 124 to initiate bonding of the powder particles to each other and the top surface 104 of the web 102. However, the powder particles remain mobile enough to allow for removal of the powder particles during the edge alignment process. Thus, the web 102 departs the pre-compression unit 140 with a pre-compressed powder coating layer 142, and (optionally) travels along the rollers 114, 116, 118 in preparation for coating of the bottom surface 106 of the web 102.

[0056] In some embodiments, the compressive force applied by the pre-compression unit 140 can be about, e.g., 10-4000 N / mm inclusive, 10-3900 N / mm inclusive, 10-3800 N / mm inclusive, 10-3700 N / mm inclusive, 10-3600 N / mm inclusive, 10-3500 N / mm inclusive, 10-3400 N / mm inclusive, 10-3300 N / mm inclusive, 10-3200 N / mm inclusive, 10-3100 N / mm inclusive, 10-3000 N / mm inclusive, 10-2900 N / mm inclusive, 10-2800 N / mm inclusive, 10-2700 N / mm inclusive, 10-2600 N / mm inclusive, 10-2500 N / mm inclusive, 10-2400 N / mm inclusive, 10-2300 N / mm inclusive, 10-2200 N / mm inclusive, 10-2100 N / mm inclusive, 10-2000 N / mm inclusive, 10-1900 N / mm inclusive, 10-1800 N / mm inclusive, 10-1700 N / mm inclusive, 10-1600 N / mm inclusive, 10-1500 N / mm inclusive, 10-1400 N / mm inclusive, 10-1300 N / mm inclusive, 10-1200 N / mm inclusive, 10-1100 N / mm inclusive, 10-1000 N / mm inclusive, 10-900 N / mm inclusive, 10-800 N / mm inclusive, 10-700 N / mm inclusive, 10-600 N / mm inclusive, 10-500 N / mm inclusive, 10- 400 N / mm inclusive, 10-300 N / mm inclusive, 10-200 N / mm inclusive, 10-100 N / mm inclusive, 10-50 N / mm inclusive, 10-20 N / mm inclusive, 20-4000 N / mm inclusive, 30-13ME1\58685774. vlAttorney Docket No. 137174.001034000 N / mm inclusive, 40-4000 N / mm inclusive, 50-4000 N / mm inclusive, 100-4000N / mm inclusive, 200-4000 N / mm inclusive, 300-4000 N / mm inclusive, 400-4000 N / mm inclusive, 500-4000 N / mm inclusive, 600-4000 N / mm inclusive, 700-4000 N / mm inclusive, 800-4000 N / mm inclusive, 900-4000 N / mm inclusive, 1000-4000 N / mm inclusive, 1100-4000 N / mm inclusive, 1200-4000 N / mm inclusive, 1300-4000 N / mm inclusive, 1400-4000 N / mm inclusive, 1500-4000 N / mm inclusive, 1600-4000 N / mm inclusive, 1700-4000 N / mm inclusive, 1800-4000 N / mm inclusive, 1900-4000 N / mm inclusive, 2000-4000 N / mm inclusive, 2100-4000 N / mm inclusive, 2200-4000 N / mm inclusive, 2300-4000 N / mm inclusive, 2400-4000 N / mm inclusive, 2500-4000 N / mm inclusive, 2600-4000 N / mm inclusive, 2700-4000 N / mm inclusive, 2800-4000 N / mm inclusive, 2900-4000 N / mm inclusive, 3000-4000 N / mm inclusive, 3100-4000 N / mm inclusive, 3200-4000 N / mm inclusive, 3300-4000 N / mm inclusive, 3400-4000 N / mm inclusive, 3500-4000 N / mm inclusive, 3600-4000 N / mm inclusive, 3700-4000 N / mm3800-4000 N / mm inclusive, 3900-4000 N / mm inclusive, 20-1500 N / mm20-1000 N / mm inclusive, 20-500 N / mm inclusive, 20-300 N / mm inclusive,1000-3000 N / mm inclusive, 1500-2500 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, 90 N / 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, 2100 N / mm, 2200 N / mm, 2300 N / mm, 2400 N / mm, 2500 N / mm, 2600 N / mm, 2700 N / mm, 2800 N / mm, 2900 N / mm, 3000 N / mm, 3100 N / mm, 3200 N / mm, 3300 N / mm, 3400 N / mm, 3500 N / mm, 3600 N / mm, 3700 N / mm, 3800 N / mm, 3900 N / mm, 4000 N / mm, or the like, depending on the desired thickness, the type of powder particles used, or the like.

[0057] The partially coated web 102 is subsequently passed to a second coating unit 144, which is configured to apply a second powder particle coating layer 146 to the bottom surface 106 of the web 102. Coating of the bottom surface 106 can be performed in a substantially same manner as the process for coating of the top surface 104. For example, it should be understood that the coating unit 144 can be any type of coating unit discussed with respect to the coating unit 122, and can be the same or different from the coating unit 122. The powder particles of the coating layer 146 can be the same or different from those applied at the coating layer 124. The thickness of the coating layer 146 can be the same or different from the thickness of the coating layer 124.14ME1\58685774. vlAttorney Docket No. 137174.00103

[0058] In some embodiments, the system 100 can include a second conditioning unit 148 configured to level and / or spread the powder particles of the coating layer 146 to achieve greater uniformity. The conditioning unit 148 can be substantially similar to the conditioning unit 126. Conditioning of the coating layer 146 can be performed with or without heating. The system 100 can include an initial powder removal unit 150 configured to partially remove portions of the powder coating of the layer 146 to form lanes 152, 154, 156 in the coating layer 146. Although the lanes 152, 154, 156 are shown on the edges and a center point of the web 102, it should be understood that powder can be removed at any portion of the web 102.

[0059] After the lane formation, the web 102 travels to a pre-compression unit 158 formed by, e.g., rollers 160, 162. Although two rollers 160, 162 are shown, it should be understood that more pairs of rollers and / or bottom / top supports can be used to apply compressive forces to the web 102 in series. The pre-compression unit 158 can operate in a substantially similar manner to the pre-compression unit 140, with the goal of applying pressure to the second coating layer 146 such that powder particles adhere / bond to each other and / or the web 102. The pre-compression unit 158 outputs a web 102 with a precompressed coating layer 164. Movability of the power particles remains to allow for further removal of the powder particles during the edge alignment process.

[0060] After the pre-compression unit 158, the dual-coated web 102 travels through a dual side edge alignment assembly 166. The alignment assembly 166 includes a first component 168 disposed at or above the top surface 104 of the web 102 for edge alignment of the coating layer 142, and a second component 170 disposed at or above the bottom surface 106 of the web 102 for edge alignment of the coating layer 164. In particular, the alignment assembly 166 ensures that the edge alignment of the lanes in both coating layers 142, 164 are aligned relative to each other in a precise manner.

[0061] The alignment assembly 166 outputs a web 102 having a powder coating layer on both the top and bottom surfaces 104, 106 with uniformity in the lanes 172, 174, 176 on opposing sides of the web 102. After the edge alignment has been completed, the web 102 is passed to a calendering unit 178 formed by rollers 180, 182. The calendering unit 178 is configured to apply compressive forces to both sides of the web 102 to achieve the target coating thickness and / or density for the resulting electrode. Although two rollers 180, 182 are shown, it should be understood that the calendering unit 178 can include multiple pairs of rollers and / or supports to apply the desired compressive forces on the web 102.15ME1\58685774. vlAttorney Docket No. 137174.00103

[0062] The compressive forces applied by the rollers 180, 182 are greater than the compressive forces applied at the pre-compression units 140, 158. For example, in some embodiments, the compressive forces applied at the compression unit 178 can be about, e.g., 1500-5000 N / mm inclusive, 1500-4900 N / mm inclusive, 1500-4800 N / mm1500-4700 N / mm inclusive, 1500-4600 N / mm inclusive, 1500-4500 N / mm inclusive, 1500-4400 N / mm inclusive, 1500-4300 N / mm inclusive, 1500-4200 N / mm inclusive, 1500-4100 N / mm inclusive, 1500-4000 N / mm inclusive, 1500-3900 N / mm inclusive, 1500-3800 N / mm inclusive, 1500-3700 N / mm inclusive, 1500-3600 N / mm inclusive, 1500-3500 N / mm inclusive, 1500-3400 N / mm inclusive, 1500-3300 N / mm inclusive, 1500-3200 N / mm inclusive, 1500-3100 N / mm inclusive, 1500-3000 N / mm inclusive, 1500-2900 N / mm inclusive, 1500-2800 N / mm inclusive, 1500-2700 N / mm inclusive, 1500-2600 N / mm inclusive, 1500-2500 N / mm inclusive, 1500-2400 N / mm inclusive, 1500-2300 N / mm inclusive, 1500-2200 N / mm inclusive, 1500-2100 N / mm inclusive, 1500-2000 N / mm inclusive, 1500-1900 N / mm inclusive, 1500-1800 N / mm inclusive, 1500-1700 N / mm inclusive, 1500-1600 N / mm inclusive, 1600-5000 N / mm inclusive, 1700-5000 N / mm inclusive, 1800-5000 N / mm inclusive, 1900-5000 N / mm inclusive, 2000-5000 N / mm inclusive, 2100-5000 N / mm inclusive, 2200-5000 N / mm inclusive, 2300-5000 N / mm inclusive, 2400-5000 N / mm inclusive, 2500-5000 N / mm inclusive, 2600-5000 N / mm inclusive, 2700-5000 N / mm inclusive, 2800-5000 N / mm inclusive, 2900-5000 N / mm inclusive, 3000-5000 N / mm inclusive, 3100-5000 N / mm inclusive, 3200-5000 N / mm inclusive, 3300-5000 N / mm inclusive, 3400-5000 N / mm inclusive, 3500-5000 N / mm inclusive, 3600-5000 N / mm inclusive, 3700-5000 N / mm inclusive, 3800-5000 N / mm inclusive, 3900-5000 N / mm inclusive, 4000-5000 N / mm inclusive, 4100-5000 N / mm inclusive, 4200-5000 N / mm inclusive, 4300-5000 N / mm inclusive, 4400-5000 N / mm inclusive, 4500-5000 N / mm inclusive, 4600-5000 N / mm inclusive, 4700-5000 N / mm inclusive, 4800-5000 N / mm4900-5000 N / mm inclusive,2000-4500 N / mm inclusive, 2500-4000 N / mm inclusive, 3000-3500 N / mm inclusive, 1500 N / mm, 1600 N / mm, 1700 N / mm, 1800 N / mm, 1900 N / mm, 2000 N / mm, 2100 N / mm, 2200 N / mm, 2300 N / mm, 2400 N / mm, 2500 N / mm, 2600 N / mm, 2700 N / mm, 2800 N / mm, 2900 N / mm, 3000 N / mm, 3100 N / mm, 3200 N / mm, 3300 N / mm, 3400 N / mm, 3500 N / mm, 3600 N / mm, 3700 N / mm, 3800 N / mm, 3900 N / mm, 4000 N / mm, 4100 N / mm, 4200 N / mm, 4300 N / mm, 4400 N / mm, 4500 N / mm, 4600 N / mm, 4700 N / mm, 4800 N / mm, 4900 N / mm, 5000 N / mm, or the like. The result of the compression / calendering stage is a target coating layer on the top surface 104 and a target coating layer on the bottom surface 106 of the web 10216ME1\58685774. vlAttorney Docket No. 137174.00103(e.g., compressed coating layer 184).

[0063] In some embodiments, the dual side edge alignment assembly 166 can be disposed in other parts / stages of the coating process. For example, FIG. 2 is a diagrammatic view of an exemplary system 200 for powder coating that is substantially similar to the system 100, except for the distinctions noted herein. As such, same reference numbers refer to same structures. The coating process of system 200 progresses similarly to the one in system 100 up to the powder removal unit 150. Rather than proceeding to the precompression unit 158, the system 200 can include the alignment assembly 166 upstream of the pre-compression unit 158 to align the coating edges before compression occurs. The alignment assembly 166 therefore creates the uniformly aligned lanes 202, 204, 206 in the top and bottom surface 104, 106 coatings, and subsequently the web 102 is directed to the pre-compression unit 158 to output an initially compressed coating layer 208. The web 102 is then passed through the calendering unit 178 for “final” compression to the coating layer 210. Pre-compression at the unit 140 can still occur before edge alignment in order to allow for flipping of the web 102 for application for the second coating.

[0064] FIG. 3 is a diagrammatic view of a system 300 for powder coating with dual side coating edge alignment (e.g., system 100, system 200, or the like). In particular, system 300 shows a vertical orientation for simultaneously coating both sides of the web 302. The web 302 includes a top surface 304 and an opposing bottom surface 306. As the web 302 travels along a machine direction 308, it is passed simultaneously through first and second coating units 310, 312 such that both surfaces 302, 304 are simultaneously coated with opposing powder coating layers 314, 316. The thickness and / or type of powder coating for the layers 314, 316 can be the same or different, depending on the specifications of the final electrode.

[0065] The coated web 302 is subsequently passed through the dual side edge coating alignment assembly 318, which includes a first assembly or component 320 configured to align and partially remove the powder particles of the coating layer 314, and a second assembly or component 322 configured to align and partially remove the powder particles of the coating layer 316, outputting coating layers 324, 326 with aligned edges. The components 320, 322 therefore operate simultaneously to align edges of lanes formed in the coating layers 314, 316. In some embodiments, an initial powder removal unit can be used to create lanes in the coating layers 314, 316, and the alignment assembly 318 can be used to precisely align edges of the previously created lanes. In some embodiments, the17ME1\58685774. vlAttorney Docket No. 137174.00103 coating layers 314, 316 can fully coat the surfaces 304, 306 and the alignment assembly 318 can be used to both form lanes and precisely align edges of the formed lanes. It should be understood that conditioning, pre-compression and calendering units are omitted for clarity.

[0066] FIG. 4 shows an exemplary system 400 for powder coating including initial powder removal units for formation of lanes before edge alignment is performed. The system 400 can be substantially similar in structure and function to the system 300, except for the distinctions noted herein. As such, same reference numbers refer to same structures. In some embodiments, rather than simultaneous coating of the top and bottom surfaces 302, 306, the coating units 310, 312 can be positioned in a staggered manner such that one surface 304 is coated first, and the other surface 306 is coated downstream.

[0067] Rather than passing directly to the edge alignment, the system 400 can include initial powder removal units 402, 404 disposed on opposing sides of the web 302. The initial powder removal units 402, 404 can include one or more wiping structures (or any lane formation structures) that form one or more lanes in the powder coating layers 314, 316 before edge alignment is performed by the alignment assembly 318, thereby forming coating layers 406, 408 with lanes. After the initial edges have been formed in the coating layers 406, 408, the web 302 is passed to the edge alignment assembly 318, which precisely aligns coating lane edges for the top and bottom surfaces 304, 306, outputting coating layers 410, 412 with aligned lane edges.

[0068] FIG. 5 is a top view of an exemplary system 500 for powder coating and dual side edge coating alignment. FIG. 5 illustrates a web 502 with an initial powder coating layer 504 moving along a machine direction 506. In some embodiments, the system 500 includes an initial coating removal unit 508 through which the web 502 is passed. The removal unit 508 includes, e.g., wipers, cutters, brushes, combinations thereof, or the like, that remove a partial amount of powder particles to form initial lanes 510, 512. As an example, the lanes 510, 512 are formed at the side edges of the web 502, although it should be understood that the lanes could be formed anywhere along the lateral width of the web 502.

[0069] The coating edges 514, 516 at the lanes 510, 512 after the initial formation is typically uneven in at least some areas, which can be problematic for the resulting electrode. For illustration purposes only, the unevenness of the edges 514, 516 is18ME1X58685774. vlAttorney Docket No. 137174.00103 exaggerated. It should be understood that a similar unevenness in coating / lane edges is also formed on the opposing bottom surface of the web 502. To ensure even lane formation for the final electrode, the system 500 includes a dual side edge alignment assembly 518. The alignment assembly 518 aligns the edges 520, 522 of the powder coating 524 such that the final lanes 526, 528 are even and aligned on both sides of the web 502. Such edge 520, 522 aligned on opposing sides of the web 502 ensures optimal performance of the resulting electrode. In addition, due to the even alignment and formation of the lanes 526, 528 on both sides of the web 502, the manufacturing process can optionally exclude the step of applying a non-conductive coating to edges of the web 502 (which is typically applied to avoid shorting), thereby reducing the manufacturing costs associated with the electrode.

[0070] FIGS. 6-9 show different stages and embodiments of dual side edge alignment for a moving web. In the orientation shown in FIGS. 6-9, the web moves in a direction out of the page. FIG. 6 shows the web 600 including a top surface 602 coated with a first coating layer 604 and an opposing bottom surface 606 coated with a second coating layer 608. In particular, FIG. 6 shows the web 600 after coating application and after initial lane 610, 612, 614, 616 formation on edges of each of the coating layers 604, 608. An initial pre-compression or light compression stage may have been applied to the coating layers 604, 608 as well.

[0071] The lane 610 on the top surface 602 includes a coating edge 618 and the lane 612 on the bottom surface 606 includes a coating edge 620, with the edges 618, 620 being misaligned relative to each other. Similarly, the lane 614 on the top surface 602 includes a coating edge 622 and the lane 616 on the bottom surface 606 includes a coating edge 624, with the edges 622, 624 being misaligned relative to each other. As discussed, such misalignment can be problematic for performance of the electrode.

[0072] FIG. 7 shows one embodiment of a dual side edge alignment assembly 630 configured to create alignment between the edges 618, 620 and the edges 622, 624 on opposing sides of the web 600. The assembly 630 can include slit formation structures 632, 634, 636, 638 movably or adjustably disposed relative to the respective edges 618, 620, 622, 624. In some embodiments, the slit formation structures 632-638 can be, e.g., blades, knives, or the like. For example, each slit formation structure 632-638 can include a straight edge 640 configured to be oriented perpendicularly relative to the surface 602, 606 of the web 600. Each slit formation structure 632-638 can include a narrowing or tapering configuration with a pointed end 642 configured to create a slit or cut in the respective19ME1\58685774. vlAttorney Docket No. 137174.00103 coating layer 604, 608. In some embodiments, the slit line formed by the pointed end 642 can be less than about, e.g., 50 um, 10 um, or the like. The slits can be formed simultaneously as the web 600 passes through the assembly 630. The straight edges 640 of the respective slit formation structures 632-638 are aligned vertically relative to the web 600 (to avoid damaging the web 600) and laterally relative to its respective pair to ensure even formation of the slits. As discussed herein, the entire or portions of the assembly 630 can be adjustable in position relative to the web 600 to account for “walking” of the web 600 (see, e.g., FIGS. 10-14).

[0073] Immediately after the slit has been formed, a powder removal device 648, 650, 652, 654 (e.g., a vacuum, a blade, a wiper, a brush, combinations thereof, or the like) can be used to remove the powder remaining in the lane 610-616 to the side of the respective slit. Although a powder removal device 648-654 is illustrated for each edge of the coating layers 604, 608, in some embodiments, a single powder removal device can be disposed on each side of the web 600. The straight edges 640 of the slit formation structures 632-638 are aligned along vertical planes, such that when the powder removal devices 648-654 remove the additional remaining powder, even lanes 610-616 with aligned edges 656, 658, 660, 662 are formed (as shown in FIG. 9).

[0074] The degree of alignment between the edges 656, 658 and the edges 660, 662 can be regulated or adjusted for any electrode, as well as for dry electrode manufacturing specifically. With reference to FIG. 9, two pairs of coating edges 656, 658 and 660, 662 are shown. With respect to the pair of coating edges 656, 658, the edge 656 can be defined or referred to as the first coating edge, and the edge 658 can be defined or referred to as the second coating edge. The first and second coating edges 656, 658 share an edge (the leftmost edge) of the web 600. The first coating edge 656 is located at a first lateral distance from the outermost edge of the web 600 and the second coating edge 658 is located at a second lateral distance from the edge of the web 600.

[0075] In general, the exemplary system maintains the first and second lateral distances equal (or substantially equal) along the length of the web 600. However, as in many manufacturing processes, exact equivalence may be difficult to obtain owing to imperfections in equipment, the process, the environment, and / or other conditions. With specific reference to electrode coating, certain deposition procedures may be inherently limiting (such as slurry or wet coating), owing to the fonu and nature of the deposited material and limitations in the forming (including cutting, trimming, or the like) of the20ME1X58685774. vlAttorney Docket No. 137174.00103 material to form edges after deposition. As such, dry coating edge formation techniques discussed herein can provide substantial improvements to the positioning, alignment, and accuracy of coating edges, including the edge 656, 658, 660, 662 pairs. Although discussed with respect to edges 656, 658, it should be understood that substantially similar dimensions and / or relationships can apply to edges 660, 662.

[0076] In some embodiments, the first coating edge 656 may be desired to be located at a first desired lateral distance from edge of the web 600. and after formation, the edge 656 may be located at a first (actual) lateral distance from the edge of the web 600. A first edge deviation may be defined as the first desired distance less the first distance ([first edge deviation]=[first desired distance]-[first distance]). In some embodiments, a first edge deviation may have an absolute value of, e.g., less than 50 um, between 50 uni and 100 um inclusive, between 100 um and 200 um inclusive, between 200 um and 500 um inclusive, between 500 um and 1 ,000 um inclusive, or the like. In some embodiments, a first edge deviation may have an absolute value of, e.g., less than 50 um, less than 100 um, less than 200 um, less than 500 um, less than 1 mm, or the like.

[0077] In some embodiments, a second coating edge 658 may be desired to be located at a second desired lateral distance from the edge of the web 600, and after formation, the edge 658 may be located at a second (actual) lateral distance from the edge of the web 600. A second edge deviation may be defined as the second desired distance less the second distance ([second edge deviation]=[second desired distance]-[second distance]). In some embodiments, the second edge deviation may have an absolute value of, e.g., less than 50 um, between 50 um and 100 um inclusive, between 100 um and 200 um inclusive, between 200 and 500 um inclusive, between 500 um and 1,000 um inclusive, or the like. In some embodiments, a second edge deviation may have an absolute value of, e.g., less than 50 um, less than 100 um, less than 200 um, less than 500 um, less than 1 mm, or the like.

[0078] In some embodiments, a relative distance between the first and second coating edges 656, 658 may be defined as the lateral distance between a pair of coating edges 656 658, where the lateral distance is measured along a direction aligned in the plane of the web 600 (e.g., parallel to the web 600 surface). In particular, the relative distance can represent the lateral difference in location of the respective edges 656, 658 relative to each other. The relative distance may be defined, in some embodiments, as the first lateral distance less the second lateral distance ([relative distance between first and second coating edges]= [first distance] -[second distance]).21ME1X58685774. vlAttorney Docket No. 137174.00103

[0079] In some embodiments, the relative distance between the first coating edge 656 and the second coating edge 658 may be desired to lie within a specific tolerance range. The tolerance range may be based upon the absolute value (or magnitude) of the relative distance between the first coating edge 656 and the second coating edge 658, may be based upon the signed value of the relative distance between the first coating edge 656 or the second coating edge 658, or any other method of comparison.

[0080] In some embodiments, a relative distance between the first coating edge 656 and the second coating edge 658, when signed, may be, e.g., within + / - 50 um of a desired relative distance, within + / - 100 um of a desired relative distance, within + / - 200 um of a desired relative distance, within + / - 500 um of a desired relative distance, within + / - 1,000 um of a desired relative distance, any other distance required or specified, or the like.

[0081] In some embodiments, a relative distance between the first coating edge 656 and the second coating edge 658, computed using a magnitude, may be, e.g., within 50 um of a desired relative distance, within 100 um of a desired relative distance, within 200 um of a desired relative distance, within 500 um of a desired relative distance, within 1,000 um of a desired relative distance, any other distance required or specified, or the like.

[0082] In some embodiments, computation of a deviation may be specified at specific points along the running length of the web 600, as an average along a specified length of the web 600, as a maximum deviation, or any other method of computation. As used herein, “running length’’ refers to the machine direction or the direction perpendicular to the lateral width of the web 600 illustrated in FIG. 9, for example.

[0083] Certain considerations can be taken for the profile of the cut edges of the coating layers. The electrode edges formed using the methods discussed herein can display significant advantages over existing methods, particularly methods such as slurry casting, which tend to produce edges which may be rounded, curved, radiused, or otherwise exhibiting a deviation from an angular, square-like, or otherwise perpendicular profile. Edges formed in the coating layers (such as edges 656, 658, 660, 662) using the methods described herein may exhibit angular, square-like, or otherwise substantially perpendicular profiles. Such edges may be characterized or described by having a top surface (e.g., the surface furthest from the web 600) which remains substantially parallel to and uniformly offset from the web 600 surface along the length of the web 600, and a side surface or edge which remains substantially perpendicular to the web 600 surface along the length of the22ME1X58685774. vlAttorney Docket No. 137174.00103 web 600.

[0084] In some instances, as the web 600 moves through the assembly 630, the lateral position of the web 600 (e.g., left-to-right direction in FIG. 7) can fluctuate, which is generally referred to as “walking” in the industry. In some embodiments, the web 600 may move vertically up and down as it travels through the system. To adjust for such walking or vertical movement, the system can include adjustment assemblies 644, 646 (e.g., precision moving platforms). Each adjustment assembly 644, 646 can include a feedback control system with sensors configured to detect the position / edge of the web 600 relative to a baseline or target position, and mechanisms to adjust the lateral and / or vertical position of the alignment assembly 630 in real-time to ensure uniform lane width and formation is maintained within a control range throughout the process.

[0085] The adjustment assemblies 644, 646 can ensure that the slit formation or powder removal structures of the assembly 630 can be positioned against or immediately adjacent to the web 600 without damaging the web 600. The adjustment assemblies 644, 646 reduce or prevent errors in placement of the cutting / removal devices by ensuring precise alignment. In some embodiments, the adjustment assemblies 644, 646 can also reduce or prevent motion of the web 600 (or deviation of the position of the web 600) relative to the cutting / removal structures to prevent damage to the web 600. In some embodiments, the adjustment assemblies 644, 646 can include servo motors to adjust the position of the blades / slit formation or powder removal structures relative to the web 600. In some embodiments, the adjustment assemblies 644, 646 can be used to control the position of the edge alignment formation based on different web thicknesses and / or types.

[0086] FIG. 8 shows another embodiment of a dual side edge alignment assembly 670 capable of being used with the systems discussed herein. In some embodiments, the alignment assembly 670 of FIG. 8 can operate in combination with the adjustment assemblies 644, 646. Rather than a slit formation structure, the assembly 670 includes an edge formation structure 672, 674, 676, 678 (e.g., a block, a blade, a wiper, a brush, combinations thereof, or the like) configured to align the edges 618-624 of the coating layers 604, 608. Any powder removal structure can be used, as long as a vertical straight edge 680 is capable of being positioned against the respective surface 602, 606, with the respective straight edges 680 aligned on opposing sides of the web 600 to achieve the precise edge 656-662 alignment of FIG. 9.23ME1\58685774. vlAttorney Docket No. 137174.00103

[0087] As illustrated in FIG. 8, the edge formation structures 672-678 can align relative to each other across the vertical plane formed by the web 600 and can form the uniformly aligned edges 656-662 without initial formation of the slit in the coating layers 604, 608. The width of the formation structures 672-678 over the web 600 defines the amount of powder to be removed and the resulting dimension or width of the lanes 610- 616. Such position of the structures 672-678 can be determined based on specifications of the electrode, or can be adjusted based on sensor detection of the deviations of the coating layer 604, 608 edges 618-624. In some embodiments, the structures 672-678 can remove the powder particles entirely on their own to achieve the even edges 656-662. In some embodiments, powder removal devices 648-654 can be used to assist with removal of the powder particles from the web 600 after passage of the structures 672-678. Depending on the specifications of the electrode, the lane formation can be performed at any point along the width of the web 600. For example, the alignment assembly 670 can include additional lane formation structures 682, 684 aligned to each other along a vertical or perpendicularly plane extending through the web 600 to form lanes in a uniform and aligned edge manner.

[0088] FIGS. 10-14 are views of an exemplary edge alignment assembly 700 capable of being used with the systems discussed herein. The assembly 700 can include a powder removal structure 702 (e.g., a wiping blade, or the like). The structure 702 can be configured to be positioned adjacent to the web 704 surface on opposing sides of the web 704 in order to remove a portion of the power particle coating on the respective web 704 surface as the web 704 travels along a machine direction 706. In some embodiments, the structure 702 can be mounted to a support platform 708 which, in turn, can be coupled to an adjustment mechanism 710. The mechanism 710 is operable to adjust the position of the structure 702 relative to the web 704 (e.g., in real-time).

[0089] As illustrated in FIGS. 12-14, an assembly 700 can be positioned on opposite sides of the web 704 to remove the powder particle coating from the respective side of the web 704. For example, one assembly 700 is positioned to align the left edge of coating side A (e.g., the top surface) and the other assembly is positioned to align the left edge of coating side B (e.g., the bottom surface) of the moving web 704. A mirrored assembly can be used to align the coating edges in this manner. In some embodiments, a combination of both left and right-handed assemblies may be used to align edges that are internal to the coated area in the case of multiple-lane coating patterns.

[0090] The mechanism 710 can include precision positioning platforms and stages24ME1\58685774. vlAttorney Docket No. 137174.00103 used in the mounting path of the assembly 700. The mechanism 710 can be manually adjusted or adjusted in an automated manner to achieve precise alignment between the two powder coating removal assemblies 700. In some embodiments, these adjustments can be made by an automated system including a sensor and controller with a feedback loop. The physical proximity of the two powder removal assemblies 700 allows them to be aligned with, e.g., optical alignment methods, physical gauging, contact sensors, process monitoring sensors that may be in place elsewhere in the system, combinations there, or the like.

[0091] In some embodiments, the mechanism 710 can be a motorized linear stage system. For example, a sensor can detect the location of the edge of the web 704. If the web 704 moves, the sensor detects the distance that the web 704 moved. This distance can then be converted to a number of revolutions that the screw in the linear stage must spin to achieve the detected distance. The attached motor can then be sent a signal to spin that appropriate number of revolutions. A similar approach can be used to refine the accuracy of the edge alignment assembly 700. If the edge of the coating is detected after the alignment assembly 700, the sensor system can determine the offset error between the edge of side A and edge of side B. An adjustment can then be made to one of the powder removal structures 702 in the alignment assembly 700 to eliminate the offset error.

[0092] The mechanism 710 provides means for the general action of moving the position of a lane forming device (e.g., structure 702) in response to a change in position of the web 704 transverse to the travel direction 706. In some embodiments, the lane formation assembly (e.g., assembly 700) can be configured to respond to, and compensate for, motion of the web 704 in directions different than the direction 706 of travel of the web 704. Directions different than the direction 706 of travel of the web 706 can include, e.g., span-wise motions of the web 704 (often termed “web walking” or “web wandering”), motion of the web 704 in directions parallel (or substantially parallel) to a normal vector defined by the upper and lower surfaces of the web 704 (often termed “web flutter”), or any combination of motion that may result in a deviation of position of the web 704 relative to the assembly 700 and / or the structures 702 as the web 704 travels through a battery electrode manufacturing system.

[0093] In some embodiments, the lane formation assembly can be attached to a motion stage (e.g., mechanism 710). The motion stage can be coupled communicatively to a controller 718 (see, e.g., FIG. 14). One or more sensors 720 can be used to sense an25ME1\58685774. vlAttorney Docket No. 137174.00103 instantaneous position or location of the web 704 (such as a transverse position, for example). In some embodiments, the sensing can be performed based upon, e.g., a beambreak sensor, an optical sensor, an ultrasonic sensor, any other sensor capable of determining a position of the web 704, or the like. The sensor 720 can transmit the detected or measured instantaneous position or location of the web 704 to the controller 718, and the controller 718 can compare the instantaneous position or location of the web 704 to a desired or reference position of the web 704 (e.g., a position threshold value or range input into the system). When deviations exist between the detected instantaneous position or location of the web 704 and the desired or reference position of the web 704, the controller 718 can command the motion stage to change its position accordingly. The change in position of the motion stage changes the position of the lane formation apparatus (e.g., structure 702) attached to the motion stage, maintaining a fixed location of the lane formation apparatus (and the lanes thereby formed) relative to a position of the web 704, such as an edge.

[0094] In some embodiments, the adjustment mechanism 710 can operate by adjusting the position of the removal apparatus to compensate for a change in the position of the web. For example, with respect to FIGS. 6 and 7, the web is traveling into or out of the page. If the web “walks” (e.g., moves left and / or right), the distance from the edge of the web and the position of the removal tools (e.g., structures 632, 634, 636, 638) will vary and thus the position of the cut tabs or lanes will vary unacceptably. The mechanism 710 compensates for any walking of the web by adjusting the position of the removal tools relative to a fixed datum on the web itself (e.g., the web edge). This can involve the following steps: defining a datum or reference point on the web (e.g., the web edge), defining a removal region with respect to the datum, providing a removal apparatus to remove material within the removal region, a sensor to sense a position of the web datum (or other object which is defined relative to the datum) which is used to determine any motion of the web, an actuator connected to the removal apparatus, and a controller to command the actuator to maintain a fixed position of the removal apparatus relative to the position of the web datum.

[0095] The assembly 700 can include an incoiporated powder suction component. For example, a vacuum inlet 712 can be disposed immediately adjacent to the structure 702 such that any powder removed from the web 704 is transferred by the structure 702 towards the vacuum inlet 712. The powder can pass through a chamber 714 and through a vacuum outlet 716, which can be connected to a vacuum source. The removed powder particles can26ME1X58685774. vlAttorney Docket No. 137174.00103 be recycled and used to further coat the web 704 at a future point.

[0096] In some embodiments, one or more reference positions can be used for guiding the system in coating the web and / or aligning lateral edges of the coating on opposing sides of the web surface. In some embodiments, the reference position can be a position on one or both surfaces of the web (e.g., the top surface, the bottom surface, or both). In some embodiments, the reference position can be a position relative to a lateral coating edge (e.g., an edge of a coating after lane formation). For example, the lateral coating edge can define a reference position on the top surface for coating of the opposing bottom surface of the web. As another example, the lateral coating edge can define a reference position on the bottom surface for coating of the opposing top surface of the web. Therefore, although coating of the bottom surface is discussed herein with a reference position at the top surface of the web, it should be understood that any combination of reference position(s) and coating edges can be used by the exemplary systems.

[0097] FIGS. 15 and 16 are top and side views of an uncoated web 800. The web 800 defines a first lateral edge 802 (e.g., a side edge), and a second lateral edge 804 (e.g., a side edge) on an opposing side of the web 800. The web 800 defines a leading or front edge 806 extending substantially perpendicularly to the lateral edges 802, 804, and a trailing or rear edge 808 extending substantially perpendicularly to the lateral edges 802, 804. The web 800 has a width 810 as measured from the first lateral edge 802 to the second lateral edge 804.

[0098] The web 800 has a length 812 as measured from the front edge 806 to the rear edge 808. The length 812 extends perpendicularly relative to the width 810. The web 800 has a first coating surface 814 (e.g., a top surface) and a second coating surface 816 (e.g., a bottom surface) opposing the first coating surface 814. The web 800 has a thickness 818 as measured from the surface 814 to the surface 816. Any area defined along the surfaces 814, 816, such as along the entire width 810 and length 812, can be coated with a powder coating for formation of an electrode.

[0099] One or more reference positions 820 can be used by the exemplary system to define a point or plane along which an uncoated lane should be formed, such that the coating on both sides of the web 800 align along the reference position 820. As an example, FIGS. 15 and 16 illustrate a reference position 820 inwardly offset or inset relative to the first lateral edge 802. The reference position 820 is inwardly spaced from the first lateral27ME1\58685774. vlAttorney Docket No. 137174.00103 edge 802 towards the second lateral edge 804 by a predetermined distance, such that the distance between the edge 802 and the reference position 820 defines the width of the uncoated area or lane to be formed.

[0100] Although not shown, a similar reference position inwardly spaced from the second lateral edge 804 by the same or different distance can define the plane or point along which an uncoated area or lane is to be formed adjacent to the edge 804. It should be understood that the reference position 820 on the surface 814 of the web 800 can be used for edge alignment of coatings on both surfaces 814, 816. Similarly, a reference position on the surface 816 can be used for edge alignment of coatings on both surfaces 814, 816.

[0101] FIGS. 17 and 18 show a powder coating 822 disposed on and / or adhered to the surface 816 of the web 800. The powder coating 822 defines a height as measured by the distance from a top surface 824 of the coating 822 to the surface 816 of the web 800. The coating 822 defines a first coating lateral edge 826 and a second coating lateral edge 828 on an opposing side of the coating 822. The edges 826, 828 can be formed by the edge alignment assembly discussed herein by, e.g., selectively removing a portion of the coating 822 to substantially align the edges 826, 828 with reference positions.

[0102] The edges 826, 828 formed, according to some embodiments, with the alignment assembly and removal apparatus discussed herein may produce edges which are substantially perpendicular to both the uncoated areas 830 and the coating top surface 824. The alignment of the edges 826, 828 along the vertical plane represented by the reference position 820 results in a crisp (e.g., perpendicular) profile along the entire height of the edges 826, 828. Thus, the edges 826, 828 do not include concave or convex shapes, and instead define a linear, perpendicular profile relative to the web 800.

[0103] As an example, the coating lateral edge 826 is formed by using the reference position 820 as a guide for the edge alignment assembly to substantially align the edge 826 with the reference position 820, e.g., along the same plane as the reference position 820. The plane defined by the reference position 820 extends substantially parallel to the edge 802 of the web 800 and perpendicular to the surfaces 814, 816 of the web 800. In some embodiments, the edge alignment assembly (and / or the lane formation assembly) can ensure that the lateral coating edge 826 is within a predetermined lateral distance relative to the reference position 820, e.g., within ±1,000 um, within ±800 um, within ±600 um, within ±500 um, within ±400 um, within ±300 um, within ±200 um, within ±100 um,28ME1\58685774. vlAttorney Docket No. 137174.00103 within ±50 urn, within ±25 um, or the like.

[0104] Thus, at least a portion of the powder coating 822 can be removed on opposing lateral sides of the web 800 to form uncoated areas or lanes 830, 832 extending adjacent to the edges 802, 804 along the length 812 of the web 800. Although illustrating a coating 822 for the surface 816, it should be understood that the reference position 820 (or other reference positions) can be similarly used for a powder coating on the surface 814. For example, the lateral coating edge of a powder coating on the surface 814 can be substantially aligned with the reference position 820. In some embodiments, a previously formed lateral coating edge of one powder coating can be used as the reference position for formation of lateral coating edges of a powder coating on the opposing surface of the web 800.

[0105] FIGS. 19 and 20 are detailed views of an area 834 of FIG. 18 illustrating the alignment between the lateral coating edge 826 and the reference position 820. FIG. 19 shows a distance 836 by which the edge 826 is laterally offset away from the edge 802 from the reference position 820. FIG. 20 shows a distance 838 by which the edge 826 is laterally offset beyond the reference position 820 towards the edge 802. Although the optimal position of the edge 826 is to be aligned with the plane of the reference position 820, in some embodiments, as long as the distance 836, 838 is within a predetermined lateral distance threshold value or range, the edge 826 formation can be found acceptable according to manufacturing specifications.

[0106] The systems discussed herein thereby achieve uniform and precise edge alignment of the coating layers on opposing sides of the web. The edge alignment process is performed simultaneously or concurrently, ensuring accuracy in the lane formation. Such precise edge alignment of the coating layers results in optimized performance of the electrode. The systems therefore advantageously improve the manufacturing process of electrodes, as well as the subsequent use of such electrodes.

[0107] While exemplary embodiments have been described herein, it is expressly noted that these embodiments should not be construed as limiting, but rather that additions and modifications to what is expressly described herein also are included within the scope of the invention. Moreover, it is to be understood that the features of the various embodiments described herein are not mutually exclusive and can exist in various combinations and29ME1\58685774. vlAttorney Docket No. 137174.00103 permutations, even if such combinations or permutations are not made express herein, without departing from the spirit and scope of the invention.30ME1\58685774. vl

Claims

Attorney Docket No. 137174.00103CLAIMS:

1. A system for powder coating with edge alignment, the system comprising: a coating unit configured to apply a first coating layer on a first surface of a web and apply a second coating layer on a second surface of the web, wherein (i) the second surface opposes the first surface, (ii) the first coating layer includes a first coating edge and a second coating edge, and (iii) the second coating layer includes a first coating edge and a second coating edge; and a coating edge alignment assembly configured to receive the web and selectively remove a portion of at least one of the first coating layer or the second coating layer to align coating edges of the first coating layer with coating edges of the second coating layer on opposing sides of the web.

2. The system of claim 1, wherein each of the first coating layer and the second coating layer include powder particles.

3. The system of claim 1, wherein the first coating layer and the second coating layer each include powder particles, and the powder particles include (i) an anode powder with an active material, a binder, and a conductive material, and / or (ii) a cathode powder with an active material, a binder, and a conductive material.

4. The system of claim 1, wherein the coating unit includes a first coating unit configured to apply the first coating layer on the first surface of the web, and a second coating unit configured to apply the second coating layer on the second surface of the web.

5. The system of claim 4, wherein the first and second coating units are configured to simultaneously apply the first and second coating layers, respectively.

6. The system of claim 1, comprising a conditioning unit configured to spread or level the first coating layer and the second coating layer prior to entry of the web into the coating edge alignment assembly.

7. The system of claim 1, comprising a pre-compression unit configured to apply an initial compressive force to the first and second coating layers for binding powder particles of the first and second coating layers to each other or the web.31ME1\58685774. vlAttorney Docket No. 137174.001038. The system of claim 1, comprising a calendering unit configured to compress the first and second coating layers to their target thickness relative to the first and second surfaces of the web, wherein the calendering unit includes a first calendering roller disposed adjacent to the first surface of the web and an opposing second calendering unit disposed adjacent to the second surface of the web.

9. The system of claim 1, wherein the coating edge alignment assembly is configured to simultaneously remove the portion of at least one of the first coating layer or the second coating layer to align the coating edges of the first coating layer with the coating edges of the second coating layer on opposing sides of the web.

10. The system of claim 1, wherein the coating edge alignment assembly includes a slit formation structure configured to form slits in the first coating layer and slits in the second coating layer at or near each of the first and second coating edges of the first and second coating layers.

11. The system of claim 10, wherein each slit formation structure includes a blade with a point positioned immediately adjacent to the respective first and second surface of the web.

12. The system of claim 10, wherein the coating edge alignment assembly includes powder removal units configured to remove the portion of at least one of the first coating layer or the second coating layer between the respective slits and the first and second coating edges of the first and second coating layers to form (i) a first aligned coating edge from the first coating edge of the first coating layer, (ii) a second aligned coating edge from the second coating edge of the first coating layer, (iii) a first aligned coating edge from the first coating edge of the second coating layer, and (iv) a second aligned coating edge from the second coating edge of the second coating layer.

13. The system of claim 12, wherein the first aligned coating edge of the first coating layer is aligned with the first aligned coating edge of the second coating layer on opposing sides of the web, and the second aligned coating edge of the first coating layer is aligned with the second aligned coating edge of the second coating layer32ME1\58685774. vlAttorney Docket No. 137174.00103 on opposing sides of the web.

14. The system of claim 1, wherein the coating edge alignment assembly includes edge formation structures configured to remove the portion of at least one of the first coating layer or the second coating layer at or near the first and second coating edges of the first and second coating layers to form (i) a first aligned coating edge from the first coating edge of the first coating layer, (ii) a second aligned coating edge from the second coating edge of the first coating layer, (iii) a first aligned coating edge from the first coating edge of the second coating layer, and (iv) a second aligned coating edge from the second coating edge of the second coating layer.

15. The system of claim 1, wherein removing the portion of at least one of the first coating layer or the second coating layer with the coating edge alignment assembly forms lanes on respective sides of the first and second coating layers.

16. The system of claim 1, comprising an initial powder removal unit configured to partially remove the first coating layer and the second coating layer from the web to form initial lanes on respective sides of the first and second coating layers, the initial lanes including the coating edges of the first and second coating layers.

17. The system of claim 16, wherein the coating edge alignment assembly is configured to selectively remove the portion of at least one of the first coating layer or the second coating layer at the coating edges of the initial lanes to form aligned lanes on respective sides of the first and second coating layers.

18. The system of claim 1, comprising a sensor configured to detect an edge of the web and further comprising an adjustment mechanism configured to receive realtime signals from the sensor regarding the detected edge of the web to form a closed-loop control, wherein the adjustment mechanism is configured to automatically adjust a position of the coating edge alignment assembly based on the received real-time signals from the sensor to maintain alignment of the coating edges of the first coating layer with the coating edges of the second coating layer on opposing sides of the web.33ME1\58685774. vlAttorney Docket No. 137174.0010319. A method of powder coating with edge alignment, comprising: moving a web relative to a coating unit to apply a first coating layer on a first surface of the web and apply a second coating layer on a second surface of the web, wherein (i) the second surface opposes the first surface, (ii) the first coating layer includes a first coating edge and a second coating edge, and (iii) the second coating layer includes a first coating edge and a second coating edge; and moving the web through a coating edge alignment assembly to selectively remove a portion of at least one of the first coating layer or the second coating layer to align coating edges of the first coating layer with coating edges of the second coating layer on opposing sides of the web.

20. A system for powder coating with edge alignment, the system comprising: a coating unit configured to apply a first coating layer on a first surface of a web and apply a second coating layer on a second surface of the web, wherein (i) the second surface opposes the first surface, (ii) the first coating layer includes a first coating edge, and (iii) the second coating layer includes a first coating edge; and a coating edge alignment assembly configured to receive the web and selectively remove a portion of at least one of the first coating layer or the second coating layer to align the coating edge of the first coating layer with the coating edge of the second coating layer on opposing sides of the web.

21. A battery electrode formed from a battery electrode powder, the battery electrode comprising: a web, the web defining a width measured between opposing first and second lateral edges, a thickness measured between opposing top and bottom surfaces of the web, and a length extending perpendicular to the width, wherein: the top surface of the web defines a first coating surface extending the width and the length of the web; and the bottom surface of the web defines a second coating surface extending the width and the length of the web; a reference position defining a position inset from the first lateral edge of the web, the reference position extending along the length of the web along the top surface of the web; and34ME1X58685774. vlAttorney Docket No. 137174.00103 a dry battery powder coating adhered to the bottom surface of the web, the dry battery powder coating including an active material, a conductive additive, and a binder; and wherein a lateral edge of the dry battery powder coating is substantially aligned with the first lateral edge of the web and is within 1,000 um of the reference position.

22. The battery electrode of claim 21, wherein the first lateral edge of the dry battery powder coating is within 500 um of the reference position.

23. The battery electrode of claim 21, wherein the first lateral edge of the dry battery powder coating is within 200 um of the reference position.

24. The battery electrode of claim 21, wherein the first lateral edge of the dry battery powder coating is within 100 um of the reference position.

25. The battery electrode of claim 21, wherein the first lateral edge of the dry battery powder coating is within 50 um of the reference position.

26. The battery electrode of claim 21, wherein the reference position is coincident with an edge of another dry battery powder coating adhered to the top surface of the web.

27. The battery electrode of claim 21 , wherein the lateral edge of the dry battery powder coating is oriented perpendicular to the bottom surface of the web.35ME1\58685774. vl

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