MASKING OF AND MATERIAL CONSTRAINT FOR DEPOSITING BATTERY LAYERS ON FLEXIBLE SUBSTRATES

• US 20080078496A1
• Filed: 09/26/2007
• Published: 04/03/2008
• Est. Priority Date: 09/29/2006
• Status: Active Grant

• Current Assignee: Sapurast Research LLC
• Original Assignee: Infinite Power Solutions, Inc. (Apple Inc.)
• Inventors: SNYDER, SHAWN W., Zoetewey, Henry L., Brantner, Paul C.
• Granted Patent: US 8,062,708 B2
• Time in Patent Office: Days
• US Class Current: 156/212
• CPC Class Codes: C23C 14/042 using masks
• CPC Class Codes: C23C 16/042 using masks
• CPC Class Codes: H01M 4/0421 involving vapour deposition
• CPC Class Codes: H01M 6/40 Printed batteries , e.g. thin film batteries
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10T 156/1028 by bending, drawing or stretch forming sheet to assume shape of configured lamina while in contact therewith

Abstract

The present invention relates to masking techniques and apparatuses, and in particular, to a method and apparatus for masking a flexible substrate to be coated with one or more material layers. The method involves flexing a substrate to provide a curved surface and providing a flexible sheet on the curved surface to properly apply a coating on the surface of the substrate. The apparatus includes a substrate and a flexible sheet. An elastic material, such as a spring pin, or an off-axis roll-down bar may be used to create the tension used to flex the substrate and or flexible sheet.

Claims

1. A method for masking a substrate, comprising:

flexing at least one substrate to provide a curved substrate surface; and

providing at least one flexible sheet on said curved surface.

2. The method of claim 1, wherein said substrate composes a foil or a strip.

3. The method of claim 1, further comprising providing said curved surface in the form of an arc.

4. The method of claim 1, wherein said flexible sheet comprises a foil or strip.

5. The method of claim 1, further comprising placing said at least one sheet in tension.

6. The method of claim 1, further comprising placing said at least one substrate in tension.

7. The method of claim 5, further comprising applying a force to said at least one sheet in a direction substantially tangential to the curved surface.

8. The method of claim 7, further comprising using a mechanism selected from the group consisting of a spring pin mid an off-axis roll-down bar.

9. The method of claim 6, further comprising applying a force to said at least one substrate in a direction substantially tangential to the curved surface.

10. The method of claim 9, further comprising using a mechanism selected from the group consisting of a spring pin and an off-axis roll-down bar.

11. The method of claim 1, former comprising creating tension by applying torque to said at least one substrate.

12. The method of claim 1, further comprising applying a torque to said at least one sheet.

13. A masking apparatus, comprising:

a substrate holder for securing a flexible substrate in a curved state;

a tensioner for creating a tension in a mask placed over a curved surface of the flexible substrate.

14. The apparatus of claim 13, wherein said tensioner comprises:

at least one engaging member that engages with said sheet and is adapted to apply a force in a direction tangential to said curved surface.

15. The apparatus of claim 13, wherein said tensioner is selected from the group consisting of a spring pin and an off-axis roll-down bar.

16. The apparatus of claim 13, wherein said curved state is an arc.

17. The apparatus of claim 13, wherein said tensioner is adapted to apply tension to said substrate.

18. A method for masking a substrate, comprising:

providing at least one substrate;

providing at least one flexible sheet on said substrate; and

creating tension in said at least one sheet or substrate to form a surface of each sheet into a curved shape.

19. The method of claim 18, further comprising applying force to said at least one sheet in a direction substantially tangential to the curved surface.

20. The method of claim 18, further comprising applying force to said at least one substrate in a direction substantially tangential to the curved surface.

21. The method of claim 18, wherein said substrate comprises a foil or a strip.

22. The method of claim 18, further comprising providing said curved shape in the form of an arc.

23. The method of claim 18, wherein said flexible sheet comprises a foil or a strip.

24. The method of claim 18, further comprising applying a torque to the at least one substrate.

25. The method of claim 24, further comprising using a mechanism selected from the group consisting of a spring pin and an off-axis roll-down bar.