Patent ID: 7384433

Claim:
A method of manufacturing an electrode product, the method comprising: providing a current collector comprising a first surface; dry mixing dry active electrode material and dry binder; providing a dry film of the dry mixed dry active electrode material and dry binder; stacking the dry film and the current collector so that the first surface is in contact with the dry film; and laminating the current collector and the dry film by pressing the current collector and the dry film to cause the dry film to densify and to adhere to the first surface, thereby obtaining a laminated electrode product; wherein the step of laminating is performed so that the dry film is densified without spreading to an extent necessitating trimming of the dry film after laminating and wherein the step of lamination comprises processing the dry film and the current collector between rolls of a laminator the dry film and the current collector pass between a first laminator roll and a second laminator roll; and the step of processing further comprises setting a gap between the first laminator roll and the second laminator roll so that thickness of the dry film is reduced by between about 30 and about 70 percent, the step of setting a gap being performed before the dry film and the current collector pass between the first and second laminator rolls.