Masking of and material constraint for depositing battery layers on flexible substrates

• US 8,062,708 B2
• Filed: 09/26/2007
• Issued: 11/22/2011
• Est. Priority Date: 09/29/2006
• Status: Active Grant

• Current Assignee: Sapurast Research LLC
• Original Assignee: Infinite Power Solutions, Inc. (Apple Inc.)
• Inventors: Zoetewey, Henry L., Brantner, Paul C., Snyder, Shawn W.
• Primary Examiner(s): PARKER, FREDERICK JOHN
• Application Number:
  US11/861,501
• Publication Number:
  US 20080078496A1
• Time in Patent Office: 1,518 Days
• Field of Search: 427/282, 427/272
• US Class Current: 427/282
• 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;

fixing said at least one flexible sheet to place said at least one flexible sheet in tension; and

applying a force to said at least one flexible sheet in a direction substantially tangential to said curved surface.

2. The method of claim 1, wherein said substrate comprises 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 substrate in tension.

6. The method of claim 1, further wherein applying comprises using a mechanism selected from the group consisting of a spring pin and an off-axis roll-down bar.

7. The method of claim 5, further comprising applying a force to said at least one substrate 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 and an off-axis roll-down bar.

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

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

11. The method of claim 1, wherein said at least one flexible sheet comprises a mask.

12. A method for masking a substrate, comprising:

providing at least one substrate;

providing at least one flexible sheet on said at least one substrate; and

creating tension in said at least one flexible sheet or said at least one substrate to form a surface of said flexible sheet or said substrate into a curved shape; and

applying force to said at least one flexible sheet or said at least one substrate in a direction substantially tangential to said surface of said at least one flexible sheet or said substrate.

13. The method of claim 12, wherein said substrate comprises a foil or a strip.

14. The method of claim 12, further comprising providing said curved shape in the form of an arc.

15. The method of claim 12, wherein said flexible sheet comprises a foil or a strip.

16. The method of claim 12, further comprising applying a torque to the at least one substrate.

17. The method of claim 16, wherein applying comprises further using a mechanism selected from the group consisting of a spring pin and an off-axis roll-down bar.

18. The method of claim 12, wherein said at least one flexible sheet comprises a mask.