This module covers the theoretical fundamentals as well as the practical understanding of the coating and drying processes in the manufacturing of lithium-ion battery electrodes with lithium iron phosphate (LFP) cathodes. The coating and drying step is one of the most important processes in electrode production, as it transforms a metallic current collector foil (provided as roll material) and a pre-mixed battery slurry into a homogeneous, precisely coated electrode ready for further processing. Proper process design significantly influences the coating thickness, layer homogeneity, and the long-term electrochemical performance of the resulting cell.

The session combines theoretical fundamentals with practical process observation using a Matthis coating line equipped with integrated drying modules. Participants gain insight into how coating and drying parameters interact and how they affect the resulting electrode structure. Special attention is given to coating thickness measurement, the definition of a stable process parameter window, the influence of volumetric flow rate on defect generation, and temperature variation across the drying modules. The course also addresses the alternative dry-coating process as an emerging technology and examines the energy profile and efficiency of the drying step.

The practical component covers the examination of real defect samples, the identification and classification of typical coating and drying defects, and the connection of theoretical parameter knowledge to observable outcomes on the electrode surface.

Learning Objectives

  • Participants understand the key process mechanisms of coating and drying LFP battery electrodes and can describe how flow rate, temperature, and layer thickness influence electrode quality.
  • Participants can describe stable process parameter windows and, based on selected deviations in flow rate or temperature, explain which typical coating and drying defects may result.
  • Participants can visually identify and classify common coating and drying defects and link their causes to the resulting effects on electrode quality and process reliability.