CONTINUOUS, SOLVENT-FREE FABRICATION OF ELECTRODES USING DRY POWDER

A manufacturing system for an electrode of a battery cell includes a conveyor belt configured to receive a fiberized powder mixture including an active material, a conductive additive, and a binder. A powder dispensing stage is arranged adjacent to the conveyor belt and configured to dispense the fiberized powder mixture. A pre-forming stage is arranged adjacent to the conveyor belt and configured to receive the fiberized powder mixture dispensed by the powder dispensing stage and to press the fiberized powder mixture into a raw active material layer. N calendaring rollers configured to receive the raw active material layer from the conveyor belt and to calendar the raw active material layer to form an active material layer, where N is an integer greater than one. A pair of laminating rollers is configured to laminate the active material layer to a current collector to form an electrode.