EP-4737109-A1 - POWDER DISPENSING SYSTEM AND METHOD OF POWDER DISTRIBUTION

Abstract

Generally described, one or more aspects of the present disclosure relate to methods, systems, and devices related to a powder dispensing system, including a pair of calender rolls, a first conical hopper and a second conical hopper positioned above the pair of calender rolls, each hopper having a first temperature controlled fluidized section, a first flow control system in fluidic connection with the first temperature controlled fluidized section, and a second flow control system in fluidic connection with the second temperature controlled fluidized section, a vertical linear actuator configured to adjust a distance between the first conical hopper, the second conical hopper and the pair of calender rolls, and a horizontal linear actuator positioned between the first conical hopper and the second conical hopper.

Inventors

• Laxman Nevase, Shamali
• Grindstaff, Marlena
• Pawar, Nikhil Hemant
• Tsouridis, Sotirios Demetrio
• MATTHEWS, KEVIN CORNELIUS
• KODAM, MADHUSUDHAN

Assignees

• Tesla, Inc.

Dates

Publication Date

20260506

Application Date

20251017

Claims (15)

1. A powder dispensing system, comprising: a pair of calender rolls; a first conical hopper positioned above the pair of calender rolls, the first conical hopper having a first temperature controlled fluidized section; and a vertical linear actuator configured to adjust a distance between the first conical hopper and the pair of calender rolls.
2. The powder dispensing system of claim 1, further comprising: a second conical hopper positioned above the pair of calender rolls, the second conical hopper having a second temperature controlled fluidized section, preferably further comprising a horizontal linear actuator positioned between the first conical hopper and the second conical hopper.
3. The powder dispensing system of claim 2, further comprising a first flow control system in fluidic connection with the first temperature controlled fluidized section, and a second flow control system in fluidic connection with the second temperature controlled fluidized section.
4. The powder dispensing system of any one of claims 1-3, further comprising a powder depth sensor configured to measure a depth of a powder in the first conical hopper.
5. The powder dispensing system of any one of claims 1-4, further comprising a flow control system in fluidic connection with the first temperature controlled fluidized section.
6. The powder dispensing system of any one of claims 1-5, wherein the first temperature controlled fluidized section comprises a temperature controlled flow control.
7. The powder dispensing system of any one of claims 1-6, wherein the first temperature controlled fluidized section comprises an air inlet, an air plenum, and a porous internal wall.
8. A method of powder distribution, the method comprising: loading a conical hopper with a powder, wherein the conical hopper includes a fluidization section; applying a gas from the fluidization section to form a fluidized powder; dispensing the fluidized powder out of the conical hopper at a dispensing rate onto a calender roll system having a nib positioned below the conical hopper; and forming a piled powder supply on the nib; wherein the piled powder supply is consumed by the calender roll system at a consumption rate; and wherein the dispensing rate and the consumption rate are substantially the same.
9. The method of claim 8, further comprising calendering the powder to form a film.
10. The method of claim 8 or 9, wherein the dispensing rate is at least about 200 kg/hour and/or wherein the consumption rate is at least about 200 kg/hour.
11. The method of any one of claims 8-10, further comprising adjusting a distance between the conical hopper and the calender roll system via a linear actuator.
12. The method of any one of claims 8-11, wherein applying a gas from the fluidization section to form a fluidized powder comprises applying a constant flow of the gas.
13. The method of any one of claims 8-12, wherein the powder comprises a dry electrode material, preferably wherein the dry electrode material comprises an anode material and/or a cathode material.
14. The method of any one of claims 8-13, further comprising forming a dry electrode film.
15. The method of any one of claims 8-14, wherein the method is a dry fabrication process.

Description

This application claims the benefit of priority to U.S. Patent Application No. 18/933,553, entitled "CONE FEEDING ELECTRODE POWDER DISTRIBUTION," filed on October 31, 2024. BACKGROUND Field The present disclosure relates generally to a powder dispensing apparatus, particularly a powder dispensing apparatus for dispensing dry electrode powder onto a calender roll. Description of the Related Art Electrode films can be created by calendering a dry electrode powder. The quality of an electrode film is dependent on the distribution of the dry electrode powder onto the calender roll system. The calendering process can consume powder at a specific rate according to yield requirements. Accordingly, there is a need for a powder dispensing apparatus that dispenses dry electrode powders and enables the creation of high-quality energy storage electrode films. SUMMARY For purposes of summarizing the invention and the advantages achieved over the prior art, certain objects and advantages of the invention are described herein. Not all such objects or advantages may be achieved in any particular embodiment of the invention. Thus, for example, those skilled in the art will recognize that the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein. In some aspects, a powder dispensing system is described. The powder dispensing system comprises a pair of calender rolls, a first conical hopper positioned above the pair of calender rolls, the first conical hopper having a first temperature controlled fluidized section, a second conical hopper positioned above the pair of calender rolls, the second conical hopper having a second temperature controlled fluidized section, a first flow control system in fluidic connection with the first temperature controlled fluidized section, and a second flow control system in fluidic connection with the second temperature controlled fluidized section, a vertical linear actuator configured to adjust a distance between the first conical hopper, the second conical hopper and the pair of calender rolls, and a horizontal linear actuator positioned between the first conical hopper and the second conical hopper. In some aspects, the powder dispensing system comprises a pair of calender rolls, a first conical hopper positioned above the pair of calender rolls, the first conical hopper having a first temperature controlled fluidized section, and a vertical linear actuator configured to adjust a distance between the first conical hopper and the pair of calender rolls. In some embodiments, the powder dispensing system further comprises a second conical hopper positioned above the pair of calender rolls, the second conical hopper having a second temperature controlled fluidized section. In some embodiments, the powder dispensing system further comprising a horizontal linear actuator positioned between the first conical hopper and the second conical hopper. In some embodiments, the powder dispensing system further comprising a first flow control system in fluidic connection with the first temperature controlled fluidized section, and a second flow control system in fluidic connection with the second temperature controlled fluidized section. In some embodiments, the powder dispensing system further comprising a powder depth sensor configured to measure a depth of a powder in the first conical hopper. In some embodiments, the powder dispensing system further comprising a flow control system in fluidic connection with the first temperature controlled fluidized section. In some embodiments, the first temperature controlled fluidized section comprises a temperature controlled flow control. In some embodiments, the first temperature controlled fluidized section comprises an air inlet, an air plenum, and a porous internal wall. In some aspects, a method of powder distribution is described. The method comprising loading a conical hopper with a powder, wherein the conical hopper includes a fluidization section, applying a gas from the fluidization section to form a fluidized powder, dispensing the fluidized powder out of the conical hopper at a dispensing rate onto a calender roll system having a nib positioned below the conical hopper, and forming a piled powder supply on the nib, wherein the piled powder supply is consumed by the calender roll system at a consumption rate, and wherein the dispensing rate and the consumption rate are substantially the same. In some embodiments, the method further comprises calendering the powder to form a film. In some embodiments, the dispensing rate is greater than 200 kg per hour. In some embodiments, the consumption rate is greater than 200 kg per hour. In some embodiments, the method further comprises adjusting a distance between the conical hopper and the calender roll system via a linear actuator. In some