System for powder coating with intervention unit

Abstract

A dry powder coating system is provided. The system includes sensors configured to detect attributes for a coating comprised of powder particles. The powder particles are deposited onto a web by a powder deposition unit. The system includes a treatment unit disposed downstream of the powder deposition unit and configured to apply a treatment to the coating, and an intervention unit. A processing device is configured to execute instractions stored in a memory to perform operations including, in response to a deviation between the attributes for the coating detected by the one or more sensors and a set of acceptable attributes, activating the intervention unit to at least one of remove a section of the deposited coating from the web causing the deviation, adjust operation of the treatment unit, or adjust operation of the web.

Description

Attorney Docket No. 137174.00110SYSTEM FOR POWDER COATING WITH INTERVENTION UNITCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 737,386, filed on December 20, 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, resulting in a viable alternative for large-scale manufacturing. In particular, the solvent-1MEl\59265743.vlAttorney Docket No. 137174.00110 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 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 tribocharging 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 causes 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 / US24 / 48849, filed on September 27, 2024, which is incorporated herein by reference in its entirety.

[0007] Regardless of whether the wet or dry powder approach of electrode production is taken, as noted herein, conventional techniques for both typically rely on deposition of the electrode material on a contiguous and moving current collector (e.g., a web and / or a thin metal foil), and subsequent calendering of the deposited material to attain a desired thickness and porosity of the deposited electrode material. Various other steps are typically required, and vary depending upon the dry vs. wet nature of the production process.2MEl\59265743.vlAttorney Docket No. 137174.00110

[0008] In particular, with respect to wet processing, drying is typically required after deposition onto the web and before calendering. Further, it is common (and in some instances preferred) for deposition and drying to be performed on a first manufacturing line, and calendering to be performed on a second manufacturing line. This bifurcation of processes between first and second manufacturing lines may have several advantages, including isolation of processes to enable dedicated personnel to perform manufacturing operations with greater visibility, experience, and skill; the staging of materials between operations; specialization of equipment with particular advantage for maintenance and upkeep; and the ability to inspect and stage-gate material after production on the first manufacturing line and before use of the material on the second manufacturing line. However, a crucial disadvantage of the bifurcation of processes is the expense and time required to support a pair of lines, and the necessity to run the same roll of material at least twice: first for deposition / drying, and again for calendering. The bifurcation process can further necessitate additional inspection or qualification.

[0009] In contrast, dry techniques are configured to perform roll manufacturing in one contiguous operation on a unitary system with various modules generally arranged to perform deposition, inspection, calendering, and other required processes. Despite the relative simplicity of the dry based technique, the calendering process is both high performance and extremely sensitive to input variations. For example, the thickness and / or loading of the material deposited on the web must be precisely regulated before entry through the calendering process to avoid damage to the calendering components (e.g., rollers).

[0010] Variations in input of the thickness and / or loading of the material deposited on the web may cause damage to calendering equipment, which is expensive to repair and typically necessitates long lead times until repair can be completed. For example, it is common for calendering roll repairs to take several months, which could be detrimental to the electrode manufacturing facility. Moreover, variations in material input to calender rollers on the order of several hundred microns or less may, e.g., damage calender rollers, damage the resulting electrode by forming wrinkles in the metal foil or web (which itself has a thickness of between about 4 and 20 micrometres), or the like. If a foreign object, such as a washer or bolt, accidentally passes through the calendering process on the web, damage to the surface of the calendering rollers can also occur. Therefore, great care is needed in maintaining variations in the material deposition and conditions of the material3MEl\59265743.vlAttorney Docket No. 137174.00110 coating on the web within acceptable standards to avoid potential equipment damage.SUMMARY

[0011] Embodiments of the present disclosure provide an exemplary dry powder coating system for battery electrode fabrication that includes an intervention unit configured to take action when deviations from accepted or desired attributes are detected in the material coating on the web. The intervention unit ensures that action is taken to avoid damage to treatment equipment, e.g., conditioning assemblies, calendering assemblies, combinations thereof, or the like, by removing the problematic area detected on the web and / or preventing passage of the web through the treatment equipment. The system therefore ensures safe and precise battery electrode fabrication with features that mitigate risks to treatment equipment typically encountered due to input variations of material to the treatment unit.

[0012] In accordance with embodiments of the present disclosure, an exemplary dry powder coating system is provided. The system includes one or more sensors configured to detect attributes for a coating including powder particles. The powder particles are deposited onto a web by a powder deposition unit. The system includes a treatment unit disposed downstream of the powder deposition unit and configured to apply a treatment to the coating. The system includes an intervention unit, and a processing device in communication with the one or more sensors. The processing device is configured to execute instructions stored in a memory to perform operations that include in response to a deviation between the attributes for the coating detected by the one or more sensors and a set of acceptable attributes, activating the intervention unit to at least one of (i) remove a section of the deposited coating from the web causing the deviation, (ii) adjust operation of the treatment unit, or (iii) adjust operation of the web.

[0013] In some embodiments, the acceptable coating attributes can be user-defined as input into the dry powder coating system via a user interface. In some embodiments, the one or more sensors can include at least one of, e.g., a laser line sensor, a confocal optic sensor, a camera with a machine vision system, an X-ray sensor, a beta particle measurement sensor, combinations thereof, or the like. The one or more sensors and the intervention unit can define a feedback control loop for protecting components of the treatment unit.4MEl\59265743.vlAttorney Docket No. 137174.00110

[0014] In some embodiments, the components can include rollers. In some embodiments, the treatment unit can be a conditioning assembly. The conditioning assembly can be configured to spread and / or smoothen the powder particles on the web to form a uniform coating on the web. In some embodiments, the treatment unit can be a calendering assembly including rollers configured to impart a compressive force on the powder particles to bond the powder particles with each other and the web.

[0015] The intervention unit can be disposed between the one or more sensors and the treatment unit. In some embodiments, the attributes can include at least one of, e.g., a local density of the coating, a density variation of the coating, a height average of the coating relative to a surface of the web, a height variation of the coating relative to the surface of the web, a roughness of the coating, a texture of the coating, a profile of the coating, a powder agglomeration in the coating, a void in the coating, combinations thereof, or the like. In some embodiments, the attributes can include existence of a foreign object and / or debris on the web with the powder particles.

[0016] The web can define a lateral width extending in a direction perpendicular to a direction of travel of the web. Removing the section of the deposited coating from the web with the intervention unit can include completely removing an area of the powder particles from the web across the lateral width of the web, the area including the deviation. In some embodiments, the system can include a suction source or blade configured to remove the area of the powder particles. In some embodiments, removing the section of the deposited coating from the web with the intervention unit can include cutting the web across the lateral width to avoid entry of the deviation into the treatment unit.

[0017] In some embodiments, the treatment unit can include a conditioning assembly and / or a calendering assembly with a roller configured to apply pressure to the powder particles on the web. In some embodiments, adjusting operation of the treatment unit can include moving the roller to increase a gap and create clearance between the roller and the powder particles to avoid contact with the powder particles. In some embodiments, adjusting operation of the treatment unit can include reducing the pressure exerted by the roller on the powder particles to open a roller nip to avoid pressure application on the powder particles. In some embodiments, adjusting operation of the web can include stopping movement of the web prior to entry through the treatment unit.5MEl\59265743.vlAttorney Docket No. 137174.00110

[0018] In accordance with embodiments of the present disclosure, an exemplary method of dry powder coating is provided. The method includes depositing powder particles onto a web with a powder deposition unit to form a coating. The method includes detecting attributes in the coating with one or more sensors. The method includes executing instructions stored in a memory with a processing device in communication with the one or more sensors to perform operations that include in response to a deviation between the attributes for the coating detected by the one or more sensors and a set of acceptable attributes, activating the intervention unit to at least one of (i) remove a section of the deposited coating from the web causing the deviation, (ii) adjust operation of the treatment unit, or (iii) adjust operation of the web. The treatment unit is disposed downstream of the powder deposition unit and is configured to apply a treatment to the coating.

[0019] 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

[0020] To assist those of skill in the art in making and using the dry powder coating system, reference is made to the accompanying figures, wherein:

[0021] FIG. 1 is a diagrammatic view of an exemplary dry powder coating system in accordance with embodiments of the present disclosure, including a sensing unit and an intervention unit disposed upstream of a treatment unit in the form of a calendering assembly.

[0022] FIG. 2 is a diagrammatic view of an exemplary dry powder coating system in accordance with embodiments of the present disclosure, including a sensing unit and an intervention unit disposed upstream of a treatment unit in the form of a conditioning assembly.

[0023] FIG. 3 is a diagrammatic view of an exemplary dry powder coating system in accordance with embodiments of the present disclosure, including a sensing unit disposed upstream of a treatment unit in the form of a conditioning assembly and a calendering assembly, and intervention units disposed upstream of the respective conditioning and calendering assemblies.6MEl\59265743.vlAttorney Docket No. 137174.00110

[0024] FIG. 4 is a diagrammatic view of an exemplary dry powder coating system in accordance with embodiments of the present disclosure, including a sensing unit and an intervention unit disposed upstream of each treatment unit in the form of a conditioning assembly and a calendering assembly.

[0025] FIG. 5 is a flowchart of an exemplary method of dry powder coating in accordance with embodiments of the present disclosure.

[0026] FIG. 6 is a block diagram of an exemplary dry powder coating system in accordance with embodiments of the present disclosure.DETAILED DESCRIPTION

[0027] An exemplary system for dry powder coating is provided that includes a response mechanism ensuring safety of the mechanisms involved the powder coating formation. The system monitors attributes of a coating of powder particles on the web as the web moves towards a treatment unit of the system, which can include conditioning rollers, calendering rollers, or both. If the detected attributes of the coating deviate from acceptable coating attributes input into the system, the system can take one or more actions to avoid damage to the equipment associated with the treatment unit. In some embodiments, the system can remove a section of the deposited coating (including any detected foreign objects that may be on the coating) from the web to avoid entry of the coating (and any foreign objects) through the treatment unit. In some embodiments, the system can adjust the equipment associated with the treatment unit to avoid the coating (and any foreign objects), e.g., by raising the rollers to increase a gap between the roller and the web or coating. In some embodiments, the system can stop movement of the web (while simultaneously stopping other operations) to avoid entry of the web into the treatment unit. The system therefore includes an intervention unit that functions to prevent damage to equipment associated with the treatment unit.

[0028] In some embodiments, it may be desirable to execute the intervention unit to remove at least a portion of a powder particle coating on the web even while the presence of the portion of the coating (or an attribute associated with the coating) may not cause damage or otherwise harm equipment associated with the treatment unit. According to some embodiments, if a portion of the coating is identified as having an attribute deviating from preset attributes (e.g., a coating a that is defective, out-of-specification, and / or otherwise different than what may be determined as acceptable) based upon sensor7MEl\59265743.vlAttorney Docket No. 137174.00110 feedback, the intervention unit can be triggered to remove the deviations in the coating. In some embodiments, the removed deviations in the coating can be recycled (e.g., reused) to avoid a costly loss of the powder particle material. Avoidance of such losses can be important for the economical operation of manufacturing lines, as operation costs typically dominate capital costs of installed equipment.

[0029] The term “sensor”, as used herein, refers to any type of detection means known in the industry capable of detecting attributes associated with the web and the coating process. In some embodiments, the sensors used in the exemplary system can include, e.g., a laser line sensor, confocal optics, a camera with a machine vision system, an X-ray sensor, a beta particle measurement sensor, an ultrasonic distance sensor, a radio-frequency sensor, a structured light sensor, a sensor utilizing light interferometry (such as white light interferometry, for example), combinations thereof, or the like.

[0030] The term “powder particles”, as used herein, refers to a mixture of (i) an anode powder with an active material, a binder, and a conductive material, and (ii) a cathode powder with an active material, a binder, and a conductive material. In certain embodiments, these mixtures may be homogeneous mixtures. In some embodiments, the powder particles can be finely-divided, and may generally be less than about 100 um or less. In some embodiments, the size of the active materials, the size of the binder, and / or the size of the conductive additives can be about 50 um or less. In some embodiments, the size of the agglomerates in the mixture can be about, e.g., 50-1000 um.

[0031] The term “powder deposition unit”, as used herein, refers to any dry powder deposition means known in the industry for depositing dry powder particles to a web surface. In some embodiments, the powder deposition unit can include an ESD dry powder coating system. In some embodiments, the powder deposition unit can include a spreader roller coating system. In some embodiments, the powder deposition unit can include, e.g., nozzles for depositing powder particles on the web, a hopper with selective release of powder particles on the web, one or more scattering rollers, or the like. In some embodiments, the powder deposition unit can include a scatterer in the form of a rotating drum with a surface texture upon which powder particles are deposited to reside in the texture. In such embodiments, the rotating drum with the powder particles residing in the texture can be rotated toward a removal apparatus to remove the powder from the texture. The removal apparatus can include at least a brush or similar structure to mechanically interact with the powder particles an texture to dislodge the powder particles from the8MEl\59265743.vlAttorney Docket No. 137174.00110 texture. In some embodiments, the powder deposition unit 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 powder deposition unit can include a reservoir that receives a mixture of the powder particles for dispersion onto the web. In some embodiments, the powder deposition unit can include one or more powder dispersion systems, e.g., nozzles, 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, the powder deposition unit can include one or more deposition 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.

[0032] The term “attributes”, as used herein, refers to detectable conditions associated with the powder particle coating deposited on the web. The attributes can include desired specifications for the powder particle coating at one or more stages of the coating process, e.g., before conditioning, after conditioning, before calendering, after calendering, or the like. In some embodiments, the attributes can include, e.g., a local density (mass or volumetric) of the coating, a density (mass or volumetric) variation of the coating, a height average of the coating, a height variation of the coating, a surface roughness of the coating, a surface appearance of the coating (e.g., waviness, speckles, point defects, line defects, areal defects, or the like), a surface texture of the coating, combinations thereof, or the like. In some embodiments, the attributes can include, e.g., foreign objects, debris, or the like, detected on the web surface. For example, a washer or bolt accidentally located on the web and detectable with the sensors of the system would be considered an attribute. In some embodiments, the attributes to be detected by the system can be input via a user interface. In some embodiments, a user interface can be used to input acceptable attributes (e.g., thresholds acceptable for deviation for the detected attributes), such that the system can determine if the detected attributes warrant action to be taken or if the web can continue to the treatment unit.

[0033] The term “treatment unit”, as used herein, refers to any structure configured to9MEl\59265743.vlAttorney Docket No. 137174.00110 engage with the powder particle coating as the web passes through the system. In some embodiments, the treatment unit can include a conditioning assembly configured to engage with the powder particle coating to spread the powder particles and create a substantially even layer of the coating across the lateral width of the web. In some embodiments, the conditioning assembly can include, e.g., rollers, positioned over the web and configured to engage with the powder particle coating. In some embodiments the conditioning assembly can include, e.g., rollers, configured to apply a pre-compression to the powder particle coating on the web. In some embodiments, the treatment unit can include a calendering assembly configured to apply pressure to the powder particle coating for bonding of the powder particles to each other and the web. In some embodiments, the calendering assembly can include, e.g., rollers, positioned over the web and configured to engage with the powder particle coating. In some embodiments, the conditioning assembly and / or the calendering assembly can include multiple rollers in series to gradually achieve the intended engagement with the coating. In some embodiments, the treatment unit can include a heating assembly configured to apply an amount of heat to the web and / or coating. In some embodiments, the treatment unit can include an additional powder particle deposition unit. In some embodiments, the treatment unit can include an apparatus configured to modulate the surface of the powder on the moving web to selectively, e.g., move, remove, and / or add powder particles. In some embodiments, the treatment unit can include acoustic vibration to manipulate the powder layer. In some embodiments, the treatment unit can include electrodes which apply alternating or direct electric fields to manipulate the coated powder layer.

[0034] The term “intervention unit”, as used herein, refers to any structure or component capable of being executed or operated to affect operation of the system to avoid damage to the treatment unit. In some embodiments, the intervention unit can include a vacuum source configured to remove an entire section of powder particles from the web (and any foreign objects detected on the web). In some embodiments, the intervention unit can include a blade or any other structure configured to pass over the web surface to remove an entire section of powder particles from the web (and any foreign objects detected on the web). In some embodiments, the intervention unit can include a magnet to remove ferrous contaminants in the powder particle coating. In some embodiments, the intervention unit can include a gas source to blow particles away from the surface of the web. In some embodiments, the intervention unit can include a gas source coupled with a vacuum source10MEl\59265743.vlAttorney Docket No. 137174.00110 to enable simultaneous, near simultaneous, staged, or otherwise sequenced blowing and sucking actions to the powder particles on the web to remove particles from the surface of the web. The removed powder can be reclaimed and reused for subsequent coating of the web. In some embodiments, the removed material (which may include powder and contaminants, such as foreign objects) may be filtered to remove at least some amount of foreign objects. In some embodiments, the intervention unit can be in the form of a guard which actuates to block any material on the substrate to proceed forward or in some cases, completely severing the web so that no motion can proceed forward and the line completely shuts down.

[0035] In some embodiments, the intervention unit can be in the form of a processing device or controller configured to communicate with downstream processes or assemblies, such as the conditioning assembly and / or the calendering assembly to adjust the position of rollers of the respective assemblies relative to the web surface. In some embodiments, the intervention unit may disengage a portion of a downstream process or assembly from a surface of the powder coating on the web or a surface of the web. For example, the intervention unit can increase the gap between rollers of a pre-conditioning, pre-calender, and / or calendering unit and the web surface by elevating the rollers to avoid contact with the powder particle coating (and any foreign objects detected on the coating). In some embodiments, the intervention unit can disengage motion or energy directed toward the powder coating; for example, the intervention unit can disrupt a flow of power to a heating apparatus. In some embodiments, the intervention unit can be in the form of one or more 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 intervention unit can be in the form of a processing device or controller configured to communicate with rollers or other structures that regulate movement of the web through the system in order to stop movement of the web, thereby avoiding passage of the web into the treatment unit.|0036| The exemplary dry powder coating system therefore includes features that mitigate risks to treatment equipment that may be caused by input variations of the powder particle coating material. In some embodiments, a powder deposition unit can deposit battery electrode powder onto a moving web, which can then be acted upon by a calender assembly to compress the battery electrode powder on the moving web. In some embodiments, a sensing apparatus or unit can be provided between the powder deposition11MEl\59265743.vlAttorney Docket No. 137174.00110 unit and the calender assembly, and a powder removal apparatus (or other powder adjustment mechanism) can be provided between the sensing unit and the calender assembly. The sensing unit can measure the thickness of the powder and web along the entire width of the web, or at specific locations of the web (which may vary in time), and these values can be compared with a processing device to desired values according to set parameters (such as thickness of the powder and web, for example). In some embodiments, the desired values can include a relative measure of thickness or other quantity (to determine relative high and low points, for example). Upon an indication that a measured value is out of range, a variety of actions can be taken or performed with an intervention unit prior to the out-of-specification material entering the calendering nip or otherwise interacting with the calendering roller.

[0037] In some embodiments, actions that can be taken or performed by the intervention unit can include one or more of, e.g., removing powder particles from the surface of the web, removing powder particles from the entire width of the web, opening the gap of the calender rollers relative to each other and the web, reducing the pressure exerted on the calender rollers (and thus permitting the calender rollers to move in a manner to open the calendering nip), halting the motion of the web, or any other intervention to prevent material from interacting with the calender assembly in a manner which may damage the calender components. It should be understood that similar action can be taken with a conditioning assembly of the system.

[0038] In some embodiments, the sensing unit can sense foreign objects and / or debris on the web or coating. In some embodiments, a puff of gas can be applied with the intervention unit to blow material from the surface of the web (optionally in conjunction with suction of material). In some embodiments, sensing of the web and / or coating can be performed with a variety of sensors, e.g., a laser line sensor, confocal optics, a camera and machine vision system, manually, an x-ray measurement, a beta particle measurement, combinations thereof, or the like.

[0039] In some embodiments, powder removal can be performed during start-up and shut-down of the powder deposition process. For example, in some embodiments, there may be an initial ramp-up or stabilization period during the beginning of a coating operation or during certain instances where parameters, materials, and the like, are adjusted during a fabrication process of battery electrode material. In particular, the cost of the powder materials typically dominates the final cost of the objects fabricated during processing (e.g.,12MEl\59265743.vlAttorney Docket No. 137174.00110 machine / capital costs are smaller than operating costs). Because powdered materials are expensive, any way in which the system can reduce waste and / or recycle material is crucial to enable a competitive system. The start-up and shut-down process may be implemented in addition to sensing and intervention, or sensing and intervention as already described may be utilized to determine when start-up and shut-down phases have ended or begun. Since the system is envisioned and designed to be closed-loop, it may not be necessary to indicate what is start-up or shut-down, although it may be straightforward to make such indications for the system in advance. For example, when the lines are operated, the startup and shut-down periods can be identified and powder is removed from the web during those periods to protect the calender units. In some embodiments, process experimentation can be performed. For example, when performing process experimentation, it may be desirable to intervene and remove powder since the state of the deposited powder will not necessarily be controlled. For at least the reason of cost (as indicated above), it may be desirable to remove and recycle powder during such process experimentation.

[0040] The exemplary system can therefore include a contiguous web moving from an unwind position to a rewind position at opposing ends of the assembly. Between these ends, the system includes a deposition system and calendering system (and / or a conditioning system). Between the calendering system and the deposition system, the system includes a material removal or adjustment apparatus. Between the material removal / adjustment apparatus and the deposition system, the system includes a sensing apparatus. The material removal / adjustment system operates based upon feedback from the sensing apparatus, which can include, e.g., indications of system start-up or shut-down, variations in the coating thickness which are not permitted to enter the calender assembly, sensing of foreign objects or debris, any other deviation from the desired coating material and thickness.

[0041] In some embodiments, the system can be used to manage quality, while also reducing waste. Loading and thickness of the product can be measured and, once in specification, it is released to the calender assembly. Until then, the powder material can be vacuumed by a full web vacuum. The calender roller gap can be maintained offset by a distance from the web until the coating specifications are reached, and then subsequently the rollers can be lowered to engage with the coating. In some embodiments, this functionality can be used during, e.g., start-up and shut-down, but can also be used during steady state operation if the coating is detected to deviate from specification parameters13MEl\59265743.vlAttorney Docket No. 137174.00110(and other feedback controls in the system are not sufficiently fast to respond to adjust the coating to be within the specification parameters before reaching the calendering assembly).

[0042] FIG. 1 is a diagrammatic view of an exemplary system 100 for dry powder coating, including an intervention unit that functions as a feedback loop to prevent damage to treatment unit components associated with the 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 particle coating onto a substrate or web 102, e.g., a continuously moving substrate or web 102. The web 102 includes a top surface and an opposing bottom surface, both of which can be powder coated. In some embodiments, the opposing top and bottom surfaces of the web 102 can be simultaneously coated. In some embodiments, the top surface can be coated first while the web 102 travels along direction 104, and subsequently the bottom surface can be coated while the web 102 travels along an opposing direction (or continues along direction 104). 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.

[0043] The web 102 can be supported by one or more rollers 106, 108. In some embodiments, the rollers 106, 108 can act as spools or unwind / rewind rollers at the proximal and distal ends of the coating assembly. In some embodiments, the rollers 106, 108 can be used to change the direction of the web 102 rotation from direction 104 to an opposing direction. It should be understood that the web 102 can travel either in a horizontal, vertical, or diagonal configuration during the coating process.

[0044] At a starting point, the web 102 is uncoated before entry into a powder deposition unit 110. As the web 102 passes through the powder deposition unit 1 10, a powder particle coating 112 is applied to the surface of the web 102. In some embodiments, the coating 112 is applied across the entire lateral width of the web 102 (as measured perpendicular to direction 104). In some embodiments, the coating 112 can be selectively applied to the surface of the web 102 to form uncoated lanes in the powder particle coating 112, e.g., oriented parallel to direction 104. Attributes for the coating 112 can be input to the system 100 via, e.g., a user interface, such that the powder deposition unit 110 can be regulated to provide the desired coating 112 conditions. The attributes can include, e.g.,14MEl\59265743.vlAttorney Docket No. 137174.00110 desired specifications for the electrode and the coating 112 needed to achieve the desired specifications.

[0045] For example, the thickness of the coating 112 can be selected based on the desired specifications of the electrode. 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 of the web 102. In some embodiments, the powder deposition unit 110 can ensure that a substantially uniform layer and thickness of the powder particles is applied along the entire surface of the web 102 laterally as the web 102 passes through the powder deposition unit 110. In some embodiments, a conditioning unit can be included to spread, smooth and distribute the powder particles on the web 102 after passage of the web 102 through the powder deposition unit 110 to ensure the substantially uniform layer and thickness of the powder particles for the coating 112.

[0046] The system 100 includes a treatment unit in the form of a calendering assembly 114 disposed downstream of the powder deposition unit 110. The calendering assembly 114 is configured to apply compressive forces to one or both sides of the web 102 to achieve the target coating 112 thickness and / or density for the resulting electrode. The calendering assembly 114 can include two rollers 116, 118 disposed on opposing sides of the web 102 for engagement with the coating 112 and / or the web 102. Although two rollers 116, 118 are shown, it should be understood that the calendering assembly 114 can include multiple pairs of rollers and / or supports disposed in series to apply the desired compressive forces on the web 102.

[0047] In some embodiments, the compressive forces applied by the rollers 116, 118 at the calendering assembly 114 can be about, e.g., 1500-5000 N / mm inclusive, 1500-4900N / mm inclusive, 1500-4800 N / mm inclusive, 1500-4700 N / mm inclusive, 1500-4600N / mm inclusive, 1500-4500 N / mm inclusive, 1500-4400 N / mm inclusive, 1500-4300N / mm inclusive, 1500-4200 N / mm inclusive, 1500-4100 N / mm inclusive, 1500-4000N / mm inclusive, 1500-3900 N / mm inclusive, 1500-3800 N / mm inclusive, 1500-3700N / mm inclusive, 1500-3600 N / mm inclusive, 1500-3500 N / mm inclusive, 1500-3400N / mm inclusive, 1500-3300 N / mm inclusive, 1500-3200 N / mm inclusive, 1500-3100N / mm inclusive, 1500-3000 N / mm inclusive, 1500-2900 N / mm inclusive, 1500-2800N / mm inclusive, 1500-2700 N / mm inclusive, 1500-2600 N / mm inclusive, 1500-2500N / mm inclusive, 1500-2400 N / mm inclusive, 1500-2300 N / mm inclusive, 1500-2200N / mm inclusive, 1500-2100 N / mm inclusive, 1500-2000 N / mm inclusive, 1500-190015MEl\59265743.vlAttorney Docket No. 137174.00110N / mm inclusive, 1500-1800 N / mm inclusive, 1500-1700 N / mm inclusive, 1500-1600N / mm inclusive, 1600-5000 N / mm inclusive, 1700-5000 N / mm inclusive, 1800-5000N / mm inclusive, 1900-5000 N / mm inclusive, 2000-5000 N / mm inclusive, 2100-5000N / mm inclusive, 2200-5000 N / mm inclusive, 2300-5000 N / mm inclusive, 2400-5000N / mm inclusive, 2500-5000 N / mm inclusive, 2600-5000 N / mm inclusive, 2700-5000N / mm inclusive, 2800-5000 N / mm inclusive, 2900-5000 N / mm inclusive, 3000-5000N / mm inclusive, 3100-5000 N / mm inclusive, 3200-5000 N / mm inclusive, 3300-5000N / mm inclusive, 3400-5000 N / mm inclusive, 3500-5000 N / mm inclusive, 3600-5000N / mm inclusive, 3700-5000 N / mm inclusive, 3800-5000 N / mm inclusive, 3900-5000N / mm inclusive, 4000-5000 N / mm inclusive, 4100-5000 N / mm inclusive, 4200-5000N / mm inclusive, 4300-5000 N / mm inclusive, 4400-5000 N / mm inclusive, 4500-5000N / mm inclusive, 4600-5000 N / mm inclusive, 4700-5000 N / mm inclusive, 4800-5000N / mm inclusive, 4900-5000 N / mm inclusive, 2000-4500 N / mm inclusive, 2500-4000N / 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 112 layer on the surface of the web 102 (e.g., a compressed coating layer), with powder particles bonded to each other and / or the web 102.

[0048] The system 100 includes a controller 120 in communication with the calendering assembly 114. In some embodiments, the controller 120 can be the primary controller for the system 100. The controller 120 can be configured to independently regulate the position of the rollers 116, 118 relative to the web 102. In some embodiments, the orientation of the longitudinal axis relative to the direction 104 can be varied with the controller 120. In some embodiments, the gap between the rollers 116, 118 and the web 102 can be regulated in a vertical direction perpendicular to the web 102 surface. The controller 120 can therefore be used to regulate the pressure applied to the coating 112 and / or the web 102 with the rollers 116, 118, thereby regulating the type of engagement between the calendering assembly 114 and the coating 112 and / or the web 102.

[0049] The system 100 includes a sensing unit 122 disposed downstream of the16MEl\59265743.vlAttorney Docket No. 137174.00110 powder deposition unit 110 and upstream of the calendering assembly 114. In some embodiments, the sensing unit 122 can include a single sensor assembly 124 disposed above the web 102. In some embodiments, the sensing unit 122 can include separate sensor assemblies 124, 126 on opposing sides of the web 102. The sensing unit 122 is configured to detect attributes associated with the coating 112. The attributes can include characteristics associated with the coating 112, including thickness, density, uniformity, or the like, as well as detection of debris or foreign objects on the web 102. The sensing unit 122 is therefore configured to detect any variations in the coating 1 12 and / or the web 102 that could cause damage to the equipment associated with the calendering assembly 114.

[0050] Data collected from the sensing unit 122 can be transmitted to a processing device, e.g., a controller for the system 100, which is in communication with the sensing unit 122, an intervention unit 128, and / or the controller 120. The processing device determines whether the detected attributes from the sensing unit 122 meet the acceptable attribute thresholds input into the system 100. If the acceptable attributes / thresholds are met, the system 100 can continue operation as normal with the web 102 continuing to travel through the calendering assembly 114. In particular, meeting the acceptable attributes / thresholds indicates that there are no unacceptable variations in the coating 112 and / or the web 102 (or the variations are within acceptable limits), and passage of the web 102 through the calendering assembly 114 is not expected to cause damage to the components of the calendering assembly 114.

[0051] If the processing device determines that the detected attributes deviate from the acceptable attributes / thresholds above a predetermined amount, the processing device can actuate the intervention unit 128 (e.g., a response mechanism) in real-time or substantially real-time to take action to prevent damage to the calendering assembly 114. According to some embodiments, the thresholds may establish go / no-go conditions whereby attributes which lie beyond thresholds are deemed unacceptable and trigger intervention. According to some embodiments, thresholds may be defined based upon a deviation or variation from a target or mean value. For example, and according to certain embodiments, a mean value of X with error bounds of X+x 1 % and X+x2% may define upper and lower bounds between which the measured parameter X is acceptable, but beyond which the parameter is not acceptable and intervention will be triggered. The values of the variation may be different, and at least one of them may be zero (e.g., xl = 0 & x2 !=0, or xl !=0 & x2 = 0, or xl !=0 and x2 !=0, or xl=0 and x2=0; where, != denotes ‘not equal to’). According to some17MEl\59265743.vlAttorney Docket No. 137174.00110 embodiments, asymmetric bounds may be selected about mean values, e.g., bounds of X- 5% and X+10% may be used. According to some embodiments, bounds of X and X+5%, or X-5% and X may be used, for example. The intervention unit 128 is disposed downstream of the sensing unit 122 and upstream of the calendering assembly 114. In some embodiments, the intervention unit 128 can include a single intervention assembly 130 disposed above the web 102. In some embodiments, the intervention unit 128 can include two intervention assemblies 130, 132 disposed on opposing sides of the web 102.

[0052] In some embodiments, the intervention unit 128 can include a powder removal assembly, such as a suction / vacuum source and / or a blade, configured to fully remove a section of the powder particle coating 112 from the web 102. For example, if the sensing unit 122 detects variations in a specific section of the coating 112, the selected or flagged section / area can be mapped and transmitted to the intervention unit 128 to remove the powder particle coating 112 in its entirety in the specific section of the web 102. Such removal of the powder particle coating 1 12 includes removal of the powder particles and any detected foreign objects and / or debris on the web 102. The powder particles can be reclaimed and reused for subsequent coating of the web 102. The powder particle removal step can be performed by the intervention unit 128 without affecting the speed of movement of the web 102 towards the calendering assembly 114. With the selected section of the coating 112 removed, the web 102 can proceed safely to the calendering assembly 114.

[0053] In some embodiments, the intervention unit 128 can communicate with the controller 120 associated with the calendering assembly 114 to regulate the position of one or both rollers 116, 118 relative to the web 102 and / or the coating 112. The variations detected by the sensing unit 122 can be flagged or mapped, and transmitted to the controller 120 such that the controller 120 takes action for avoiding the specific area with the detected variations. For example, if variations in the coating 112 along the top surface of the web 102 are detected, the controller 120 can be used to raise the roller 116 in a direction away from the web 102 by a distance dimensioned to avoid any engagement with the coating 112 (e.g., far enough away that the roller 116 surface does not contact the coating 112).

[0054] As a further example, if a foreign object is detected on the coating 112 and / or the web 102, the controller 120 can be used to raise the roller 116 in a direction away from the web 102 by a distance dimensioned to avoid any contact of the roller 116 with the foreign object. The web 102 can continue movement towards and through the calendering assembly 114 at the normal, unaffected speed, with the raised roller 116 avoiding damage18MEl\59265743.vlAttorney Docket No. 137174.00110 from the detected variation. After the flagged section of the web 102 has passed through the calendering assembly 114, the roller(s) 116, 118 can be repositioned by the controller 120 to apply the desired compressive forces to the coating 112. In some embodiments, after the web 102 has passed through the calendering assembly 114, the system 100 can, e.g., remove the section of powder particles and / or foreign object from the web 102 by suction, blowing or other removal assembly, flip or tilt the web 102 to remove the powder particles and / or foreign object, or combinations thereof.

[0055] In some embodiments, the intervention unit 128 can communicate with the processing device or controller for the system 100 to stop movement of the web 102 entirely to allow for physical correction of the detected deviation in the coating 112 and / or the web 102. For example, the intervention unit 128 can determine that removal of the coating 112 or adjustment of operation of the calendering assembly 114 will not be sufficient to prevent damage with the deviation in the coating 112 to the calendering assembly 114, and stopping of the web 102 is necessary. In such embodiments, one or more other operations (e.g., powder deposition at the unit 110) can be simultaneously stopped until the detected deviation in the coating 112 can be removed or corrected. The system 100 therefore offers various actions to be taken in an automatic manner to detect deviations in the powder particle coating 1 12 and avoid passage of such deviations through the calendering assembly 114, ensuring damage to the calendering assembly 114 is reduced or prevented.

[0056] Although FIG. 1 illustrates a single powder deposition unit 1 10, a single sensing unit 122, and a single intervention unit 128, it should be understood that the system 100 (and any of the systems discussed herein) can include two or more of these components in series (as well as one or more conditioning and / or calendering assemblies). For example, the system 100 can include two powder deposition units 110 in series spaced from each other along the web 102, such that the sensing unit 122 and / or the intervention unit 128 can be disposed upstream of the second powder deposition unit 110, and a second sensing unit 122 and / or intervention unit 128 can be disposed downstream of the second powder deposition unit 110. In some embodiments, two or more powder deposition units 110 can be used in series, and a single pair of the sensing unit 122 and the intervention unit 128 can be disposed downstream of the last powder deposition unit 110. Thus, various rearrangements and duplications of the components discussed for each of the systems are envisioned.

[0057] FIG. 2 is a diagrammatic view of an exemplary system 200 for dry powder19MEl\59265743.vlAttorney Docket No. 137174.00110 coating. The system 200 can be substantially similar in structure and / or function to the system 100, except for the distinctions noted herein. Therefore, same reference numbers are used to refer to the same structures.

[0058] In some embodiments the system 200 can include a treatment unit in the form of both a conditioning assembly 202 and the calendering assembly 114. The conditioning assembly 202 can be disposed downstream of the sensing unit 122 and the intervention unit 128, and upstream of the calendering assembly 114. The conditioning assembly 202 can provide leveling and / or spread of the powder particles of the coating 112 prior to entry into the calendering assembly 114. In some embodiments, the conditioning assembly 202 can include one or more rollers 204, 206, 208, 210 configured to level and / or spread the powder particles applied as the coating 112. Although two rollers 204, 206 above the web 102 and two rollers 208, 210 below the web 102 are illustrated, it should be understood that only a single roller or a single pair of rollers could be used.

[0059] In some embodiments, the conditioning assembly 202 can apply precompression forces to the coating 112 with or without heat. It is understood that the pressure applied by the conditioning assembly 202 is smaller than the pressure applied by the calendering assembly 114. The compressive forces at the conditioning assembly 202 can initiate bonding of the powder particles to each other and the web 102. However, the powder particles remain mobile enough for potential removal of the powder particles before entry into the calendering assembly 114.

[0060] In some embodiments, the compressive force applied by the conditioning assembly 202 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 / mm20MEl\59265743.vlAttorney Docket No. 137174.00110 inclusive. 10-50 N / mm inclusive, 10-20 N / mm inclusive, 20-4000 N / mm inclusive, 30-4000 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 / mm inclusive, 3800-4000 N / mm inclusive, 3900-4000 N / mi n 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, 3100N / 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.

[0061] In operation, as the web 102 departs the powder deposition unit 110 with the coating 1 12, the sensing unit 122 detects attributes of the coating 112. The sensed data can be transmitted to a processing device or controller (e.g., controller 120), which determines if deviations of the detected attributes exceed acceptable attribute thresholds (indicating that damage to the conditioning assembly 202 and / or the calendering assembly 114 could occur). If the deviation exceeds acceptable thresholds, a signal can be transmitted to the intervention unit 128 to adjust operation of the system 200 to avoid damage to the treatment unit components.21MEl\59265743.vlAttorney Docket No. 137174.00110

[0062] Similar to the previously described operation of the intervention unit 128 relative to the calendering assembly 114, one or more actions can be taken by the intervention unit 128 relative to the conditioning assembly 202. Such actions can include, e.g., removal of a section of powder particles from the web, raising one or more of the rollers 204, 206, 208, 210 of the conditioning assembly 202 relative to each other and the web 102 to avoid contact with the coating 112 (and any detected foreign objects / debris), stopping of the web 102, or the like. Thus, before entry into the conditioning assembly 202, action can be taken to prevent damage of the conditioning assembly 202 components if variations in the coating 112 attributes are detected.

[0063] If the problematic variation in the coating 112 is removed from the web 102, the rollers 204, 206, 208, 210 of the conditioning assembly 202 and the rollers 116, 118 of the calendering assembly 114 can remain in a normal operational position and with normal operating parameters (such as pressure or force, for example). However, if adjustment of the conditioning and calendering assemblies 202, 114 is needed, the controller 120 can coordinate such adjustment to both assemblies 202, 114 to ensure damage is prevented to the equipment. A single sensing unit 122 and a single intervention unit 128 can therefore be used to regulate operation of both the conditioning assembly 202 and the calendering assembly 114, as well as the web 102.

[0064] FIG. 3 is a diagrammatic view of an exemplary system 300 for dry powder coating. The system 300 can be substantially similar in structure and / or function to the systems 100, 200, except for the distinctions noted herein. Therefore, same reference numbers are used to refer to the same structures.

[0065] In some embodiments, the system 300 can include a sensing unit 122 that detects attributes of the coating 112 for both the conditioning assembly 202 and the calendering assembly 114, and includes a dedicated intervention unit 128 for the conditioning assembly 202 and a dedicated intervention unit 302 for the calendering assembly 114. The intervention unit 302 can operate in substantially the same manner as the intervention unit 128 and, in some embodiments, can include intervention assemblies 304, 306 disposed on opposing sides of the web 102.

[0066] The intervention unit 128 can be disposed upstream of the conditioning assembly 202, and the intervention unit 302 can be disposed between the conditioning assembly 202 and the calendering assembly 1 14. Data from the sensing unit 122 can be22MEl\59265743.vlAttorney Docket No. 137174.00110 used by the controller 120 to regulate operation of the intervention unit 302 to take action exclusively with respect to the calendering assembly 114 and / or the coating 112 downstream of the conditioning assembly 202. The intervention unit 128 can be used exclusively for taking action with respect to the conditioning assembly 202 and / or the coating 112 upstream of the conditioning assembly 202.

[0067] FIG. 4 is a diagrammatic view of an exemplary system 400 for dry powder coating. The system 400 can be substantially similar in structure and / or function to the systems 100, 200, 300, except for the distinctions noted herein. Therefore, same reference numbers are used to refer to the same structures.

[0068] In some embodiments, the system 400 can include a dedicated sensing unit 122 and intervention unit 128 for the conditioning assembly 202, and a dedicated sensing unit 402 and intervention unit 302 for the calendering assembly 114. The sensing unit 402 can operate in substantially the same manner as the sensing unit 122. In particular, data from the sensing unit 122 can be used to regulate the intervention unit 128 to take action with respect to the conditioning assembly 202 and / or the coating 112 upstream of the conditioning assembly 202. Data from the sensing unit 402 (which can include sensing assemblies 404, 406 disposed on opposing sides of the web 102) can be used to regulate the intervention unit 302 to take action with respect to the calendering assembly 114 and / or the coating 112 downstream of the conditioning assembly 202. In some embodiments, the sensing unit 402 and the intervention unit 302 can be used to resolve any variations induced by the conditioning assembly 202, even if the coating sensed by the sensing unit 122 was detected as being acceptable.

[0069] FIG. 5 is a flowchart of an exemplary process 500 of operating the dry powder coating system discussed herein. At 502, acceptable powder coating attributes can be defined and input into the system. At 504, dry powder is deposited onto the moving web to form a powder coating. At 506, attributes of the deposited powder coating are measured by a sensing unit. At 508, the measured attributes are compared to acceptable attributes (e.g., thresholds) stored in the system.

[0070] At 510, a determination is made by a processing device of the system whether the measured attributes are different or deviate from the acceptable attributes (e.g., relative to a predetermined threshold value). At 512, if the deviation is below a threshold value or if no deviation in attributes is detected, the process can continue. At 514, if a deviation is23MEl\59265743.vlAttorney Docket No. 137174.00110 above a threshold value or detected in general, the system actuates an intervention unit to modify a downstream process to avoid damage to components of the system.

[0071] FIG. 6 is a block diagram of an exemplary dry powder coating system 600 (e.g., systems 100, 200, 300, 400). The system 600 includes a treatment unit 602 in the form of a conditioning assembly 604 and / or a calendering assembly 606. In some embodiments, the treatment unit 602 can include, e.g., one or more lane formation units 628, one or more heating units 630, combinations thereof, or the like. The system 600 include one or more sensors 608 (e.g., a sensing unit) for detection of attributes on a powder particle coating applied to a moving web. Data associated with the detected attributes 610 can be electronically stored in one or more databases 612.

[0072] A processing device 614 (e.g., controller) of the system 600 can receive and compares the detected attributes 610 to acceptable attributes 616 stored in the database 612. The acceptable attributes 616 can be input into the system 600 via, e.g., a graphical user interface 618, or the like. The processing device 614 can determine if any deviation exists between the detected attributes 610 and the acceptable attributes 616, or if the deviation is within acceptable thresholds / limits. The results of this analysis can be stored as deviation details 620 in the database 612.

[0073] If the deviation exceeds acceptable thresholds / limits, the processing device 614 can actuate an intervention unit 622 to take action to one or more operational processes of the system 600. In some embodiments, an alert 626 can be issued to the user interface 618 to warn the user of the detected deviation in the coating. For example, the intervention unit 622 can use a removal assembly 624 to remove one or more sections of the powder particle coating from the web, thereby removing the unacceptable variation in the coating.

[0074] As a further example, the intervention unit 622 can adjust the position of rollers of one or both of the conditioning assembly 604 and the calendering assembly 606 to avoid the unacceptable variation in the coating. As a further example, the intervention unit 622 can stop movement of the web for manual intervention and removal of the unacceptable variation in the coating. The system therefore provides a real-time feedback control loop that prevents undesired variations or irregularities from reaching the conditioning assembly 604 and / or the calendering assembly 606 thereby avoiding damage to expensive equipment associated with the assemblies 604, 606.24MEl\59265743.vlAttorney Docket No. 137174.00110

[0075] 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 and permutations, even if such combinations or permutations are not made express herein, without departing from the spirit and scope of the invention.25MEl\59265743.vl

Claims

Attorney Docket No. 137174.00110CLAIMS:

1. A dry powder coating system, comprising: one or more sensors configured to detect attributes for a coating comprised of powder particles, the powder particles deposited onto a web by a powder deposition unit; a treatment unit disposed downstream of the powder deposition unit and configured to apply a treatment to the coating; an intervention unit; and a processing device in communication with the one or more sensors, wherein the processing device is configured to execute instructions stored in a memory to perform operations comprising: in response to a deviation between the attributes for the coating detected by the one or more sensors and a set of acceptable attributes, activating the intervention unit to at least one of (i) remove a section of the deposited coating from the web causing the deviation, (ii) adjust operation of the treatment unit, or (iii) adjust operation of the web.

2. The dry powder coating system of claim 1 , wherein the acceptable coating attributes are user-defined as input into the dry powder coating system via a user interface.

3. The dry powder coating system of claim 1, wherein the one or more sensors include at least one of a laser line sensor, a confocal optic sensor, a camera with a machine vision system, an X-ray sensor, or a beta particle measurement sensor.

4. The dry powder coating system of claim 1 , wherein the one or more sensors and the intervention unit define a feedback control loop for protecting components of the treatment unit.

5. The dry powder coating system of claim 4, wherein the components include rollers.

6. The dry powder coating system of claim 1, wherein the treatment unit is a conditioning assembly.

7. The dry powder coating system of claim 6, wherein the conditioning assembly is26MEl\59265743.vlAttorney Docket No. 137174.00110 configured to spread and / or smoothen the powder particles on the web to form a uniform coating on the web.

8. The dry powder coating system of claim 1, wherein the treatment unit is a calendering assembly including rollers configured to impart a compressive force on the powder particles to bond the powder particles with each other and the web.

9. The dry powder coating system of claim 1, wherein the intervention unit is disposed between the one or more sensors and the treatment unit.

10. The dry powder coating system of claim 1, wherein the attributes include at least one of a local density of the coating, a density variation of the coating, a height average of the coating relative to a surface of the web, a height variation of the coating relative to the surface of the web, a roughness of the coating, a texture of the coating, a profile of the coating, a powder agglomeration in the coating, or a void in the coating.

11. The dry powder coating system of claim 1, wherein the attributes include existence of a foreign object and / or debris on the web with the powder particles.

12. The dry powder coating system of claim 1, wherein the web defines a lateral width extending in a direction perpendicular to a direction of travel of the web.

13. The dry powder coating system of claim 12, wherein removing the section of the deposited coating from the web with the intervention unit comprises completely removing an area of the powder particles from the web across the lateral width of the web, the area including the deviation.

14. The dry powder coating system of claim 13, comprising a suction source or blade configured to remove the area of the powder particles.

15. The dry powder coating system of claim 13, wherein removing the section of the deposited coating from the web with the intervention unit comprises cutting the web across the lateral width to avoid entry of the deviation into the treatment unit.

16. The dry powder coating system of claim 1, wherein the treatment unit includes a conditioning assembly and / or a calendering assembly with a roller configured to27MEl\59265743.vlAttorney Docket No. 137174.00110 apply pressure to the powder particles on the web.

17. The dry powder coating system of claim 16, wherein adjusting operation of the treatment unit comprises moving the roller to increase a gap and create clearance between the roller and the powder particles to avoid contact with the powder particles.

18. The dry powder coating system of claim 16, wherein adjusting operation of the treatment unit comprises reducing the pressure exerted by the roller on the powder particles to open a roller nip to avoid pressure application on the powder particles.

19. The dry powder coating system of claim 1, wherein adjusting operation of the web comprises stopping movement of the web prior to entry through the treatment unit.

20. A method of dry powder coating, comprising: depositing powder particles onto a web with a powder deposition unit to form a coating; detecting attributes in the coating with one or more sensors; and executing instructions stored in a memory with a processing device in communication with the one or more sensors to perform operations comprising: in response to a deviation between the attributes for the coating detected by the one or more sensors and a set of acceptable attributes, activating the intervention unit to at least one of (i) remove a section of the deposited coating from the web causing the deviation, (ii) adjust operation of the treatment unit, or (iii) adjust operation of the web; wherein the treatment unit is disposed downstream of the powder deposition unit and is configured to apply a treatment to the coating.28MEl\59265743.vl

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