NOVELTY - Forming (P1) a conductive particle film involves mixing conductive particles with a binder to form a mixture; aerosolizing the mixture; applying a charge to the aerosol mixture; applying heat to a grounded substrate; and applying the mixture to the heated and grounded substrate by aerodynamic or electrostatic interaction, forming the conductive particle film.    USE - For forming conductive particle film for forming batteries (claimed) e.g. lithium-ion battery.    ADVANTAGE - The single-step deposition technique can be integrated into a fully automated battery manufacturing methodology. The system limits the potential for film contamination, reduces batch-to-batch variations, and ultimately increases product yield. This in turn significantly reduces retail costs to levels that enable the widespread deployment of large batteries for residential usage.    DETAILED DESCRIPTION - Forming (P1) a conductive particle film involves mixing conductive particles with a binder to form a mixture; aerosolizing the mixture; applying a charge to the aerosol mixture; applying heat to a grounded substrate; and applying the mixture to the heated and grounded substrate by aerodynamic or electrostatic interaction, forming the conductive particle film. The substrate is a metal foil heated above the melting point of the binder by resistive, convective, or radiative heating. The conductive particles comprise anodic or cathodic material. The charge is applied to the conductive particles by a corona gun or by triboelectric charging. INDEPENDENT CLAIMS are included for the following:    (1) a system (S1) for forming a conductive particle film comprising a mixer to combine conductive particles with a binder to form a mixture, an aerosolizer to aerosolize the mixture, an electrical charging device to charge the aerosol mixture, a heating device to heat a substrate, and a grounding device to ground the substrate, where the film is applied to the substrate in a continuous process; and    (2) a battery formed by the process (P1) or system (S1).    DESCRIPTION OF DRAWING(S) - The figure shows a schematic view of the process for forming conductive particle film.