Non-interactive electrostatic deposition of induction charged conductive powder
First Claim
1. A method for manufacturing electrodes with a first electrostatic deposition unit that is comprised of a sump, a sleeve, and voltage supply, comprising the steps of:
- (a) depositing a conductive powder with a charge relaxation time of less than about 1 second onto a substrate with said first electrostatic deposition unit, wherein said conductive powder is mixed with magnetic carrier beads in said sump to form a mixture of conductive powder and magnetic carrier beads, wherein said mixture is fed onto said sleeve, and wherein said mixture forms a magnetic brush on said sleeve;
(b) positioning said substrate away from said magnetic brush such that an air gap is disposed between said substrate and said magnetic brush;
(c) imposing a voltage between said substrate and said sleeve; and
(d) producing a large asymmetry between said magnetic brush and said substrate such that the electric field at said magnetic brush is at least 3.0 times as great as the electric field at such substrate.
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Accused Products
Abstract
A method for manufacturing electrodes using an electrostatic deposition unit. In the first step of the process a mixture of magnetic carrier beads and a conductive powder is prepared in the sump of the deposition unit; the mixture forms a magnetic brush on the sleeve of the deposition unit. In the second step of the process, the substrate is positioned away from the magnetic brush to form an air gap. In the third step of the process, a voltage is applied between the substrate and the sleeve of the deposition unit in order to produce a large asymmetry between the magnetic brush and said substrate such that the electric field at the magnetic brush is at least 3.0 times as great as the electric field at the substrate. In the fourth step of the process, conductive powder is deposited onto the substrate.
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Citations
43 Claims
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1. A method for manufacturing electrodes with a first electrostatic deposition unit that is comprised of a sump, a sleeve, and voltage supply, comprising the steps of:
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(a) depositing a conductive powder with a charge relaxation time of less than about 1 second onto a substrate with said first electrostatic deposition unit, wherein said conductive powder is mixed with magnetic carrier beads in said sump to form a mixture of conductive powder and magnetic carrier beads, wherein said mixture is fed onto said sleeve, and wherein said mixture forms a magnetic brush on said sleeve; (b) positioning said substrate away from said magnetic brush such that an air gap is disposed between said substrate and said magnetic brush; (c) imposing a voltage between said substrate and said sleeve; and (d) producing a large asymmetry between said magnetic brush and said substrate such that the electric field at said magnetic brush is at least 3.0 times as great as the electric field at such substrate. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43)
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Specification