Method of solvent-free manufacturing of composite electrodes incorporating radiation curable binders

A system for making a battery, comprising

• an electrospray apparatus having a first electrode with a first polarity;
• a retaining apparatus for a current collector, the retaining apparatus having a second electrode with a polarity opposite to the polarity of the first electrode;
• an electrode material source for suppling a homogeneous mixture of active material particles, electrically conductive particles, and radiation curable resin precursors;
• the electrospray apparatus directing charged electrode material droplets to the current collector on the retaining apparatus to produce an electrode preform;
• a calender apparatus for applying pressure to the electrode preform;
• and,
• a radiation source for supplying radiation to the electrode preform sufficient to cure the radiation curable resin precursors into a resin.

A method for making a battery, comprising the steps of

• mixing active material particles, radiation curable resin precursors, and electrically conductive particles to create an electrode precursor mixture;
• electrostatically spraying the electrode precursor mixture onto a current collector to provide an electrode preform;
• calendering the electrode preform such that the resin precursors surround the active particles and electrically conductive particles;
• applying radiation to the electrode preform sufficient to cure the radiation curable resin precursors into resin and to provide a finished first electrode;
• providing a second electrode, a separator, and an electrolyte;
• and,
• assembling the first electrode, second electrode, separator, and electrolyte into a battery.