Multi-layered coated electrode for lithium-ion battery

A lithium-ion battery cell, comprising:

• an anode;
• and
• a cathode,
• wherein one or both of the anode and the cathode comprises a current collector having two sides, the two sides opposite to one another, wherein each respective side of the two sides is configured with:
• a first coating layer disposed in face-sharing contact with the respective side of the current collector, the first coating layer comprising a binder in a first weight ratio and a first conductive additive in a second weight ratio, and
• a second coating layer disposed on the first coating layer opposite to the respective side of the current collector, the second coating layer comprising the binder in a third weight ratio, a second conductive additive in a fourth weight ratio, and an electrochemically active material,
• wherein the first weight ratio is greater than the third weight ratio, and
• wherein the first coating layer comprises no electrochemically active material.

A method, comprising:

• forming a first slurry and a second slurry, where each of the first and second slurries comprise a binder, the second slurry having less of the binder by weight than the first slurry, and an electrochemically active material;
• simultaneously coating a current collector with the first and second slurries to respectively form a first coating layer and a second coating layer by simultaneously:
• disposing the first slurry on the current collector at a first loading to form the first coating layer;
• and
• disposing the second slurry on the first slurry at a second loading to form the second coating layer;
• drying the coated current collector;
• and
• calendering the coated current collector at a predetermined calendering density,
• wherein a ratio of the first loading to the second loading is less than 1:2;
• and
• wherein a thicker coating layer of the first and second coating layers has a lower D50 particle size of the electrochemically active material than a thinner coating layer of the first and second coating layers.