SYSTEM AND METHOD OF MANUFACTURING ELECTRODES USING GRADIENT ROLLER SIZES

A system and method for manufacturing an electrode sheet. The system includes groups of rollers having increasing diameter gradient to calendar an active material film having an initial thickness to a predetermined production thickness. The initial thickness is continually reduced as the active material film is calendared through the group of rollers. The groups of rollers includes a first group of rollers and a second group of rollers disposed immediately downstream of the first group of rollers. The first group of rollers includes a first roller radius and the second group of rollers includes a second roller radius greater than the first roller radius. The first group of rollers includes a first gap between adjacent rollers and the second group of rollers includes a second gap between adjacent rollers, in which the second gap is equal to or less than the first gap.