Direct coating of electrodes in silicon-dominant anode cells

Abstract

Systems and methods are provided for high volume roll-to-roll direct coating of electrodes for silicon-dominant anode cells.

1 . A system for continuous roll-to-roll electrode processing, the system comprising:
 one or more components configured for receiving at least one precursor composite roll that comprises precursor composite film coated on a current collector; and   a heat treatment oven for applying heat treatment to the precursor composite roll, to convert the precursor composite film into a pyrolyzed composite film coated on the current collector;   wherein the system is configured for processing the precursor composite roll in continuous manner.   
     
     
         2 . The system of  claim 1 , wherein the heat treatment oven is configured to apply the heat treatment in reducing atmosphere. 
     
     
         3 . The system of  claim 1 , wherein the heat treatment oven is configured to create reducing atmosphere related conditions, the reducing atmosphere related conditions comprising at least one of inert atmosphere, a vacuum, flowing of one or more reducing gases. 
     
     
         4 . The system of  claim 1 , comprising one or more moving components configured for moving the precursor composite roll through the heat treatment oven. 
     
     
         5 . The system of  claim 1 , comprising one or more feeding components configured for feeding the current collector with the coated precursor composite film into the heat treatment oven from the precursor composite roll. 
     
     
         6 . The system of  claim 5 , wherein the one or more feeding components are configured for feeding the current collector with the coated composite film from the heat treatment oven into a composite electrode roll. 
     
     
         7 . The system of  claim 1 , wherein the heat treatment oven is configured for applying heat treatment in each of a plurality of temperature zones. 
     
     
         8 . The system of  claim 7 , wherein the heat treatment oven is configured for applying different heat treatments in at least two different ones of the plurality of temperature zones. 
     
     
         9 . The system of  claim 1 , wherein the heat treatment oven is configured for applying cooling in at least one portion of the heat treatment oven. 
     
     
         10 . The system of  claim 1 , wherein the heat treatment oven comprises one or more atmosphere isolation chambers. 
     
     
         11 . A method for continuous roll-to-roll electrode processing, the method comprising:
 applying to a current collector film, at least one precursor composite film;   rolling the current collector film into a precursor composite roll; and   applying heat treatment to the current collector film, wherein the heat treatment is configured for converting at least one precursor composite film to a pyrolyzed composite film;   wherein applying the heat treatment comprises one or both of:
 applying the heat treatment to the precursor composite roll in whole; and 
 applying the heat treatment to the current collector film, with the coated at least one precursor composite film, as it is continuously fed from the precursor composite roll. 
   
     
     
         12 . The method of  claim 11 , comprising applying the heat treatment in reducing atmosphere. 
     
     
         13 . The method of  claim 12 , comprising creating reducing atmosphere related conditions during the heat treatment, the reducing atmosphere related conditions comprising at least one of inert atmosphere, a vacuum, flowing of one or more reducing gases. 
     
     
         14 . The method of  claim 11 , comprising moving the precursor composite roll in whole through a heat treat oven during the heat treatment. 
     
     
         15 . The method of  claim 11 , comprising feeding the current collector with the coated precursor composite film, from the precursor composite roll, into a heat treat oven during the heat treatment. 
     
     
         16 . The method of  claim 11 , comprising rolling the current collector with the coated pyrolyzed composite film into a composite electrode roll. 
     
     
         17 . The method of  claim 11 , comprising applying the heat treatment separately in each of a plurality of temperature zones. 
     
     
         18 . The method of  claim 17 , comprising applying the heat treatment differently in at least two different ones of the plurality of temperature zones. 
     
     
         19 . The method of  claim 11 , wherein the heat treatment comprises applying cooling.