US Patent 11936030 Fabrication process to make electrodes by rolling

A method of manufacturing an electrode for an electrochemical cell includes providing an admixture including an electroactive material, a binder, and a solvent. The method further includes rolling the admixture to form a sheet and forming a multi-layer stack from the sheet. The method further includes forming an electrode film precursor by performing a plurality of sequential rollings, each including rolling the stack through a first gap. The plurality of sequential rollings includes first and second rollings. In the first rolling, the stack is in a first orientation. In the second rolling, the stack is in a second orientation different from the first orientation. The method further includes forming an electrode film by rolling the electrode film precursor through a second gap less than or equal to the first gap. The method further includes drying the electrode film to remove at least a portion of the solvent.