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US 11,491,508 B2Granted
Systems and methods for dry powder coating layers of an electrochemical cell
AssigneeDragonfly Energy Corp.
InventorDenis Phares
Life of this patent
Estimating the term…
Abstract
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.
Claims25
A system for forming a particle layer comprising:
- 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;
- a first mask movable to selectively mask the substrate from the particles in a first region of the substrate;
- a second mask movable to selectively mask the substrate from the particles in a second region of the substrate, wherein the at least one sprayer directs the spray of particles towards a portion of the substrate between the first mask and the second mask;
- and
- a heater configured to heat the substrate,
- wherein the first mask is a clamp actuated by an actuator, and wherein the clamp is configured to selectively grasp the substrate.
3 more elements
A system for forming a particle layer comprising:
- 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;
- a first mask movable to selectively mask the substrate from the particles in a first region of the substrate;
- a second mask movable to selectively mask the substrate from the particles in a second region of the substrate, wherein the at least one sprayer directs the spray of particles towards a portion of the substrate between the first mask and the second mask;
- and
- a heater configured to heat the substrate,
- wherein the first mask is a first electrode configured to electrically contact the substrate and the second mask is a second electrode configured to electrically contact the substrate, wherein the heater is configured to pass a current from the first mask to the second mask through the substrate to resistively heat the substrate.
3 more elements
A system for forming a particle layer comprising:
- 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;
- a first mask movable to selectively mask the substrate from the particles in a first region of the substrate;
- a second mask movable to selectively mask the substrate from the particles in a second region of the substrate, wherein the at least one sprayer directs the spray of particles towards a portion of the substrate between the first mask and the second mask;
- a heater configured to heat the substrate;
- and
- a conveyor configured to move at least a portion of the substrate relative to the at least one sprayer,
- wherein the conveyor includes a first roller and a second roller, wherein the first roller and second roller are configured to move the substrate such that at least a portion of the substrate moves from the first roller toward the second roller, wherein the substrate is unwound from the first roller and wound onto the second roller.
4 more elements
A system for forming a particle layer comprising:
- 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;
- a first mask movable to selectively mask the substrate from the particles in a first region of the substrate;
- a second mask movable to selectively mask the substrate from the particles in a second region of the substrate, wherein the at least one sprayer directs the spray of particles towards a portion of the substrate between the first mask and the second mask;
- a heater configured to heat the substrate;
- and
- a conveyor configured to move at least a portion of the substrate relative to the at least one sprayer,
- wherein the conveyor is configured to move the substrate relative to the at least one sprayer while the particles are sprayed toward the substrate, and wherein the first mask and the second mask move in sync with the substrate.
4 more elements
Dependencies are inferred from the claim text.