Chilled roller apparatus for achieving desired surface roughness characteristics of an electrode material on a web

An apparatus for achieving desired surface roughness characteristics on an uncured, paste-like electrode material on a substrate web for forming an electrochemical cell, comprising:

• a roller;
• means for rotating the roller;
• nip roller means including a nip roller for pressing electrode material coated on the substrate web against the surface of the roller in a nip defined by the nip roller and the roller so that a surface of the electrode material assumes substantially the same roughness characteristics as the surface of the roller, the nip roller means including means for moving the nip roller toward and away from the roller to adjust a thickness of the electrode material;
• interposed means, between the nip roller means and the roller, the interposed means having a continuous, smooth surface against which the electrode material is pressed by the nip roller means such that a surface of the electrode material assumes substantially the same roughness characteristics as the surface of the interposed means;
• means for applying an electrolyte material on the electrode material coated on the substrate web;
• means for redirecting the interposed means away from the electrode material coated on the substrate web after the pressing means presses the electrode material toward the roller, and the electrolyte applying means being disposed downstream from the means for redirecting the interposed member from the electrode material coated on the substrate web;
• means for cleaning the interposed means after it is redirected away from the electrode material coated on the substrate web;
• and
• means for cooling the roller to a casting temperature for casting the electrode material that has been pressed against and is held against the portion of the roller, the casting of the electrode material causing the electrode material to tend to adhere to the substrate web.