Method for manufacturing a dry electrode

A method of manufacturing an electrode operatively associated with a system that converts dry powder to two films, said system that calenders those two films to a desired thickness and density, and laminates those two films onto a metal foil substrate without handling a free-standing film, the method comprising:

• providing the system in form of a single tool including a first multi roll calender and a second multi roll calendar, said first multi roll calendar including a first plurality of horizontally aligned rolls, a first nip being formed between a first roll and a second roll of the first multi roll calender, and a second nip being formed between a second roll and a third roll of the first multi roll calender;
• forming a first film of the two films by providing a first powder to the first nip of the first multi roll calender during operation of the system to form a first film;
• compressing the first film at the second nip of the first multi roll calender to form a first compressed film;
• providing the second multi roll calender including a second plurality of horizontally aligned rolls, a first nip being formed between a first roll and a second roll of the second multi roll calender, and a second nip being formed between a second roll and a third roll of the second multi roll calender:
• forming a second film of the two films by providing a second powder to the first nip of the second multi roll calender during operation of the system to form the second film;
• compressing the second film at the second nip of the second multi roll calender to form a second compressed film;
• and
• simultaneously laminating (i) the first compressed film onto a first side of the metal foil substrate and (ii) the second compressed film onto a second side of the metal foil substrate using a laminating nip formed by a final roll of the first multi roll calender and a final roll of the second multi roll calender.