SYSTEMS AND METHODS FOR DRY POWDER COATING LAYERS OF AN ELECTROCHEMICAL CELL
A system for forming a particle layer on a substrate may include at least one sprayer and at least two masks configured to selectively mask a substrate in a first region and second region of the substrate. The at least one sprayer may be configured to spray particles at the substrate, where the at least two masks maintain the first region and second region substantially free of the deposited material. A heater may be employed to heat the substrate as the particles are sprayed by the at least one sprayer onto the substrate.
1 - 22 . (canceled)
23 . A system for forming a particle layer comprising:
a plurality of spray stations, wherein each spray station of the plurality of spray stations comprises at least one sprayer configured to spray particles towards a substrate, the particles comprising at least one selected from the group of an electrochemical material, an ionically conductive material, an electrically conductive material, and a separator material; and
a plurality of electrodes configured to be positioned along a length of the substrate, wherein the plurality of electrodes are configured to apply a first electrical potential and a second electrical potential different from the first electrical potential to the substrate in an alternating arrangement along the length of the substrate to pass current through the substrate to resistively heat the substrate.
24 . The system of claim 23 , wherein the plurality of spray stations includes a first spray station and a second spray station adjacent to the first spray station,
25 . The system of claim 24 , wherein the plurality of electrodes include a first electrode disposed upstream from the first spray station, a second electrode disposed between the first spray station and the second spray station, and a third electrode disposed downstream from the second spray station.
26 . The system of claim 25 , wherein the first electrode and the third electrode are configured to apply the first electrical potential to the substrate and the second electrode is configured to apply the second electrical potential to the substrate.
27 . The system of claim 25 , wherein the first electrical potential is less than the second electrical potential.
28 . The system of claim 25 , wherein the second electrical potential is less than the first electrical potential.
29 . The system of claim 24 , wherein the plurality of electrodes include a first electrode disposed upstream from the first spray station, a second electrode and a third electrode disposed between the first spray station and the second spray station, and a fourth electrode disposed downstream from the second spray station.
30 . The system of claim 29 , wherein the second electrode and the third electrode are configured to apply the same electrical potential to the substrate.
31 . The system of claim 29 , wherein the first electrode and the fourth electrode are configured to apply the first electrical potential to the substrate and the second electrode and the third electrode are configured to apply the second electrical potential to the substrate.
32 . The system of claim 31 , wherein the first electrical potential is less than the second electrical potential.
33 . The system of claim 31 , wherein the second electrical potential is less than the first electrical potential.
34 . The system of claim 29 , further comprising a calendaring roller disposed between the second electrode and the third electrode.
35 . The system of claim 24 , further comprising one or more calendaring rollers disposed between the first spray station and the second spray station.
36 . The system of claim 23 , wherein the plurality of electrodes are clamps configured to move into and out of contact with the substrate.
37 . The system of claim 36 , further comprising actuators configured to actuate the plurality of electrodes into and out of contact with the substrate.
38 . The system of claim 23 , Wherein the plurality of electrodes are configured to mask the substrate.
39 . A method of forming an electrode comprising:
applying a first electrical potential and a second electrical potential different from the first electrical potential to a substrate in an alternating arrangement using a plurality of electrodes positioned along a length of the substrate;
passing current through the substrate between the plurality of electrodes to heat the substrate;
applying particles to the substrate using a plurality of spray stations located along a length of the substrate, wherein the particles applied to the substrate comprise at least one selected from the group of an electrochemical material, an ionically conductive material, an electrically conductive material, and a separator material.
40 . The method of claim 39 , wherein the plurality of spray stations includes a first spray station and a second spray station adjacent to the first spray station,
41 . The method of claim 40 , wherein the plurality of electrodes include a first electrode disposed upstream from the first spray station, a second electrode disposed between the first spray station and the second spray station, and a third electrode disposed downstream from the second spray station.
42 . The method of claim 41 , wherein passing the current through the substrate includes passing a first current between the first electrode and the second electrode through the substrate and a second current between the second electrode and the third electrode through the substrate.
43 . The method of claim 40 , wherein the plurality of electrodes include a first electrode disposed upstream from the first spray station, a second electrode and a third electrode disposed between the first spray station and the second spray station, and a fourth electrode disposed downstream from the second spray station.
44 . The method of claim 43 , wherein passing the current through the substrate includes passing a first current between the first electrode and the second electrode through the substrate and a second current between the third electrode and the fourth electrode through the substrate.
45 . The method of claim 43 , applying the same electrical potential to the substrate with the second electrode and the third electrode.
46 . The method of claim 43 , further comprising calendaring the particles between the second electrode and the third electrode.
47 . The method of claim 39 , further comprising calendaring the particles between the first spray station and the second spray station.
48 . The method of claim 39 , moving the plurality of electrodes into and out of contact with the substrate.
49 . The method of claim 39 , masking the substrate with the plurality of electrodes.