Roll-to-roll slot die coating method to create interleaving multi-layered films with chemical slurry coatings

A method for manufacturing a multi-layer barrier film, the method comprising:

• unwinding a separator substrate as a continues web, the separator substrate comprising a polymer and having a first surface opposite a second surface;
• slot-die coating the first surface of the separator substrate with a first slurry to form a first layer thereon;
• applying a first interleaving web from a first supply roll onto the first surface of the separator substrate to sandwich the first layer therebetween, the first interleaving web comprising a first polymer film liner;
• slot-die coating the second surface of the separator substrate with a second slurry to form a second layer thereon;
• applying a second interleaving web from a second supply roll onto the second surface of the separator substrate to sandwich the second layer therebetween, the second interleaving web comprising a second polymer film liner;
• wherein one of the first slurry and the second slurry includes a curable resin slurry and the other of the first slurry and the second slurry includes a curing agent slurry, and wherein one of the first layer and the second layer includes a curable resin layer and the other of the first layer and the second layer includes a curing agent layer, the curing agent layer being capable of reacting with the curable resin layer to seal a perforation of the separator substrate;
• and
• rewinding the separator substrate together with the first interleaving web and the second interleaving web into a wound roll, wherein at least one wrap of the wound roll include the first interleaving web, the first layer, the separator substrate, the second layer, and the second interleaving web as a multi-layer barrier film,
• wherein the separator substrate includes non-metalized polyethylene terephthalate (PET), polyethylene (PE), or polypropylene (PP).