Apparatus and method for depositing material onto a substrate using a roll-to-roll mask
First Claim
1. A system for making an RFID device, the system comprising:
- one or more supply reels that feed one or more source substrates;
one or more supply reels that feed at least one electronic circuit and RF antenna;
one or more deposition stations that deposit layers onto the one or more substrates, wherein the layers include;
(i) layers to form a solid-state lithium-based battery, the battery layers including;
a) a cathode layer;
b) an electrolyte layer;
c) an anode layer;
(ii) a wiring layer to couple the battery to the at least one electronic circuit, and to couple the RF antenna to the at least one electronic circuit;
a movable mask strip having a plurality of different mask areas used for different deposition operations;
a supply reel that feeds a peel-and-stick adhesive layer; and
a vacuum chamber that contains the supply reels and the deposition station.
2 Assignments
0 Petitions
Accused Products
Abstract
A battery-operated device provided on a thin-film battery and a method for making. Some embodiments provide a system that includes a vacuum chamber, a plurality of pairs of source and take-up reels within the vacuum chamber, including a first source reel that supplies a first strip of substrate material and a first take-up reel, and a second source reel that supplies a first mask strip having a plurality of different masks and a second take-up reel, a first deposition station configured to deposit material onto the first strip of substrate running between the first source reel and the first take-up reel, as defined by the first mask strip running between the second source reel and the second take-up reel, and a controller operatively coupled to run the first strip of substrate between the first source reel and the first take-up reel at a first independent rate and tension, and to run the mask strip between the second source reel and the second take-up reel.
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Citations
42 Claims
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1. A system for making an RFID device, the system comprising:
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one or more supply reels that feed one or more source substrates; one or more supply reels that feed at least one electronic circuit and RF antenna; one or more deposition stations that deposit layers onto the one or more substrates, wherein the layers include; (i) layers to form a solid-state lithium-based battery, the battery layers including; a) a cathode layer; b) an electrolyte layer; c) an anode layer; (ii) a wiring layer to couple the battery to the at least one electronic circuit, and to couple the RF antenna to the at least one electronic circuit; a movable mask strip having a plurality of different mask areas used for different deposition operations; a supply reel that feeds a peel-and-stick adhesive layer; and a vacuum chamber that contains the supply reels and the deposition station.
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2. An apparatus for forming a device, the apparatus comprising:
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means for providing a flexible substrate; means for moving a mask strip having a plurality of different mask areas used for different deposition operations; means for depositing a battery, including means for depositing an anode, a cathode, and an electrolyte separating the anode and cathode each defined by a different mask area on the mask strip; means for depositing a wiring layer; means for placing an electronic circuit onto the deposited layers, wherein the electronic circuit is operatively connected to the battery by the wiring layer; means for depositing a pressure-sensitive adhesive to allow peel-and-stick applications; and means for covering the device. - View Dependent Claims (3, 4, 5)
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6. An apparatus comprising:
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means for supplying and moving a first strip of substrate material through a deposition station; means for moving a first mask strip through the deposition station in a same direction as the first strip of substrate is moving; means for depositing, while the first strip of substrate is moving, a first layer of material from the deposition station onto the first substrate material in a pattern defined by a first area of the first mask strip; and means for depositing, while the first strip of substrate is moving, a second layer of material from the deposition station onto the first substrate material in a pattern defined by a second area of the first mask strip. - View Dependent Claims (12, 14, 15, 19, 24, 26, 27, 31, 32, 34, 36, 38, 40)
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7. An apparatus comprising:
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means for supplying a first strip of substrate material through a deposition station; means for moving a first mask strip through the deposition station; means for depositing a first layer of material from the deposition station onto the first substrate material in a pattern defined by a first area of the first mask strip; means for depositing a second layer of material from the deposition station onto the first substrate material in a pattern defined by a second area of the first mask strip; means for supplying a second strip of substrate material through the deposition station; means for moving a second mask strip through the deposition station; means for depositing a first layer of material from the deposition station onto the second substrate material in a pattern defined by a first area of the second mask strip; and means for depositing a second layer of material from the deposition station onto the second substrate material in a pattern defined by a second area of the second mask strip. - View Dependent Claims (8, 9, 13, 16, 17, 18, 25, 28, 29, 30, 33, 35, 37, 39, 41)
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10. A system comprising:
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a vacuum chamber; a plurality of pairs of source and take-up reels within the vacuum chamber, including a first source reel that supplies a first strip of substrate material and a first take-up reel, and a second source reel that supplies a first mask strip having a plurality of different masks and a second take-up reel; a first deposition station configured to deposit material onto the first strip of substrate running between the first source reel and the first take-up reel, as defined by the first mask strip running between the second source reel and the second take-up reel; a controller operatively coupled to run the first strip of substrate between the first source reel and the first take-up reel at a first independent rate and tension, and to run the first mask strip between the second source reel and the second take-up reel; and a third deposition station configured to deposit pressure-sensitive adhesive material onto the first strip of substrate.
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11. A system comprising:
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a vacuum chamber; a plurality of pairs of source and take-up reels within the vacuum chamber, including a first source reel that supplies a first strip of substrate material and a first take-up reel, and a second source reel that supplies a first mask strip having a plurality of different masks and a second take-up reel; a first deposition station configured to deposit material onto the first strip of substrate running between the first source reel and the first take-up reel, as defined by the first mask strip running between the second source reel and the second take-up reel; a controller operatively coupled to run the first strip of substrate between the first source reel and the first take-up reel at a first independent rate and tension, and to run the first mask strip between the second source reel and the second take-up reel; and a third source reel that supplies a second strip of substrate material and a third take-up reel, wherein the controller is coupled to run the second strip of substrate between the third source reel and the third take-up reel at a second independent rate and tension, wherein the second strip of substrate material includes a pressure-sensitive adhesive and a release layer, and further comprising an apparatus that attaches the second strip of material to the first strip of material.
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20. An apparatus comprising:
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means for supplying and moving a first strip of substrate material through a deposition station; means for moving a first mask strip through the deposition station in a same direction as the first strip of substrate is moving means for depositing a first layer of material from the deposition station in a same direction as the first strip of substrate is moving onto the first substrate material in a pattern defined by a first area of the first mask strip; means for depositing a second layer of material from the deposition station onto the first substrate material in a pattern defined by a second area of the first mask strip; and means for attaching a peel-and-stick adhesive layer to the first substrate. - View Dependent Claims (21, 22, 23)
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42. A system for making an RFID device, the system comprising:
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one or more supply reels that feed at least one source substrate; one or more supply reels that feed, for placement onto the at least one source substrate, at least one electronic circuit; one or more deposition stations that deposit layers onto the at least one source substrate, wherein the layers include; (iii) layers to form a solid-state lithium-based battery, the battery layers including; a) a cathode layer; b) an electrolyte layer; c) an anode layer; (iv) a wiring layer and an RF antenna, wherein the wiring couples the battery to the at least one electronic circuit, and couples the RF antenna to the at least one electronic circuit; a movable mask strip having a plurality of different mask areas used for different deposition operations; a supply reel that feeds a peel-and-stick adhesive layer; and a vacuum chamber that contains the supply reels and the deposition station.
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Specification