# US 5,817,374 A · Process for patterning powders into thick layers > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 5,817,374 A - Document ID: US5817374A - Status: Granted - Kind: A - Application number: 08/656,089 - Filed: 1996-05-31 - Granted: 1998-10-06 - Earliest claimed: 1996-05-31 - Assignees: Electrox Corporation - Inventors: Robert H. Detig; William A. Hendrickson - Web page: https://patentgrep.com/patent/US5817374A ## CPC - B05C 19/00: Apparatus specially adapted for applying particulate materials to surfaces - B05D 1/007: {using an electrostatic field (B05D1/02 - B05D1/16 take precedence)} - B05D 1/32: using means for protecting parts of a surface not to be coated, e.g. using stencils, resists - B05D 5/067: {Metallic effect} - D21H 19/68: uneven, broken, discontinuous - H05K 3/102: {by bonding of conductive powder, i.e. metallic powder (H05K3/12 takes precedence)} - D21H 23/50: Spraying or projecting (D21H23/44, D21H23/66 take precedence) - D21H 23/64: the material being non-fluent at the moment of transfer, e.g. in form of preformed, at least partially hardened coating - B05C: APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (spraying apparatus, atomising apparatus, nozzles B05B; plant for applying liquids or other fluent materials to objects by electrostatic spraying B05B5/08) - B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02) - D21H: PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR - H05K: PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS ## Abstract Particles are applied to the surfaces of materials, especially in the form of discontinuous or patterned coatings on the surfaces of sheet materials by a process comprising the steps of: a) providing a support, b) placing a bed of non-adhered particles on the support, the particles being capable of being moved by an electric field of less than 100 KV/cm, c) placing a mask with a first and second surface over the bed of non-adhered particles, the mask having holes which pass from the first to the second surface, the first surface facing the bed of non-adhered particles without the mask touching the bed of non-adhered particles, the holes in the mask having a size which would allow passage of individual particles from the bed of non-adhered particles through the holes, d) placing a receptor material capable of at least temporarily retaining an electric charge adjacent to the second surface of the mask, which second surface faces away from the bed of non-adhered particles, e) applying an electrical charge to the receptor material which is at least temporarily retained by the receptor material, f) applying an electrical field between the mask and the support, the electrical field being of at least sufficient strength to cause individual particles from the bed of non-adhered particles to move off the first substrate and impact the mask, g) allowing some of the individual particles which move off of the support to enter the holes in the mask and contact the receptor material, and h) the contract by individual particles to the receptor material causing at least some of the particles contacting the receptor material to adhere to the receptor material at least by charge attraction of the individual particles to charge on the receptor material. ## Claims ### Claim 1 A process for applying a discontinuous coating of particulates to a surface comprising the steps of: a) providing a support, b) placing a bed of non-adhered particles on said support, said particles being capable of being moved by an electric field of less than 100 KV/cm, c) placing a mask with a first and second surface over said bed of non-adhered particles, said mask having holes which pass from said first to said second surface, said first surface facing said bed of non-adhered particles without said mask touching said bed of non-adhered particles, said holes in said mask having a size which would allow passage of individual particles from said bed of non-adhered particles through said holes, d) placing a receptor material capable of at least temporarily retaining an electric charge in contact with said second surface of said mask, which second surface faces away from said bed of non-adhered particles, e) applying an electrical charge to said receptor material which is at least temporarily retained by said receptor material, f) applying an electrical field between said mask and said support, said electrical field being of at least sufficient strength to cause individual particles from said bed of non-adhered particles to move off said support and impact said mask, g) allowing some of said individual particles which move off said support to enter said holes in said mask and contact said receptor material, and h) said contact by individual particles to said receptor material causing at least some of said particles contacting said receptor material to adhere to said receptor material at least by charge attraction of said individual particles to charge on said receptor material. ### Claim 2 (depends on 1) The process of claim 1 wherein said receptor material is a dielectric material. ### Claim 3 (depends on 1) The process of claim 1 wherein said particles in said particles bed are electrically conductive particles. ### Claim 4 (depends on 2) The process of claim 2 wherein said particles in said particles bed are electrically conductive particles. ### Claim 5 (depends on 1) The process of claim 1 wherein said electrical field applied in step f) causes particles with an electrical charge opposite that of the charge provided on said receptor material to move towards said receptor material, and causes particles with an electrical charge similar to that of provided on said receptor material to move away from said receptor material. ### Claim 6 (depends on 5) The process of claim 5 wherein the movement of particles towards and away from said receptor material produces a cloud of moving particles between said first substrate and said mask. ### Claim 7 (depends on 1) The process of claim 1 wherein particles passing through said holes in said mask form patterns of particles of at least three particle diameters in thickness. ### Claim 8 (depends on 7) The process of claim 7 wherein the thickness of individual segments of said pattern of particles have thicknesses of at least five diameters of particles. ### Claim 9 (depends on 2) The process of claim 2 wherein particles passing through said holes in said mask form patterns of particles of at least three particle diameters in thickness. ### Claim 10 (depends on 9) The process of claim 9 wherein the thickness of individual segments of said pattern of particles have thicknesses of at least five diameters of particles. ### Claim 11 (depends on 3) The process of claim 3 wherein particles passing through said holes in said mask form patterns of particles of at least three particle diameters in thickness. ### Claim 12 (depends on 11) The process of claim 11 wherein the thickness of individual segments of said pattern of particles have thicknesses of at least five diameters of particles. ### Claim 13 (depends on 6) The process of claim 6 wherein particles passing through said holes in said mask form patterns of particles of at least three particle diameters in thickness. ### Claim 14 (depends on 13) The process of claim 13 wherein the thickness of individual segments of said pattern of particles have thicknesses of at least five diameters of particles. ### Claim 15 (depends on 1) The process of claim 1 wherein said particles have an average diameter of between 5 micrometers and 5 millimeters. ### Claim 16 (depends on 1) The process of claim 1 wherein said particles have an electrical resistivity of less than 10.sup.+10 ohm-centimeters. ### Claim 17 (depends on 13) The process of claim 13 wherein said particles have an average diameter of between 5 micrometers and 5 millimeters and said particles have an electrical resistivity of less than 10.sup.+10 ohm-centimeters. ### Claim 18 A process for applying a discontinuous coating of particulates to a surface comprising the steps of: a) providing a support, b) placing a bed of non-adhered particles on said support, said particles being capable of being moved by an electric field of less than 100 KV/cm, c) placing a mask with a first and second surface over said bed of non-adhered particles, said mask having holes which pass from said first to said second surface, said first surface facing said bed of non-adhered particles without said mask touching said bed of non-adhered particles, said holes in said mask having a size which would allow passage of individual particles from said bed of non-adhered particles through said holes, d) placing a receptor material capable of at least temporarily retaining an electric charge adjacent said second surface of said mask, which second surface faces away from said bed of non-adhered particles, e) applying an electrical charge to said receptor material which is at least temporarily retained by said receptor material, f) applying an electrical field between said mask and said support, said electrical field being of at least sufficient strength to cause individual particles from said bed of non-adhered particles to move off said support and impact said mask, g) allowing some of said individual particles which move off said support to enter said holes in said mask and contact said receptor material, and h) said contact by individual particles to said receptor material causing at least some of said particles contacting said receptor material to adhere to said receptor material at least by charge attraction of said individual particles to charge on said receptor material, wherein a conductive element is placed against a side of said receptor material which faces away from said first substrate after step h. ### Claim 19 (depends on 18) The process of claim 18 wherein after said conductive material is placed against said receptor material, said receptor material is pulled away from said mask and said receptor material carries with it a discontinuous pattern of particles adhered to said receptor material. ### Claim 20 (depends on 19) The process of claim 19 wherein particles passing through said holes in said mask form patterns of particles of at least three particle diameters in thickness. ### Claim 21 (depends on 20) The process of claim 20 wherein the thickness of individual segments of said pattern of particles have thicknesses of at least five diameters of particles. ### Claim 22 A process for applying a discontinuous coating of particulates to a surface comprising the steps of: a) providing a support, b) placing a bed of non-adhered particles on said support said particles being capable of being moved by an electric field of less than 100 KV/cm. c) placing a mask with a first and second surface over said bed of non-adhered particles, said mask having holes which pass from said first to said second surface, said first surface facing said bed of non-adhered particles without said mask touching said bed of non-adhered particles, said holes in said mask having a size which would allow passage of individual particles from said bed of non-adhered particles through said holes, d) placing a receptor material capable of at least temporarily retaining an electric charge adjacent said second surface of said mask, which second surface faces away from said bed of non-adhered particles, e) applying an electrical charge to said receptor material which is at least temporarily retained by said receptor material, f) applying an electrical field between said mask and said support, said electrical field being of at least sufficient strength to cause individual particles from said bed of non-adhered particles to move off said support and impact said mask, g) allowing some of said individual particles which move off said support to enter said holes in said mask and contact said receptor material, and h) said contact by individual particles to said receptor material causing at least some of said particles contacting said receptor material to adhere to said receptor material at least by charge attraction of said individual particles to charge on said receptor material, wherein said receptor material comprises organic polymeric film. ### Claim 23 A process for applying a discontinuous coating of particulates to a surface comprising the step of: a) providing a support, b) placing a bed of non-adhered particles on said support, said particles being capable of being moved by an electric field of less than 100 KV/cm. c) placing a mask with a first and second surface over said bed of non-adhered particles, said mask having holes which pass from said first to said second surface, said first surface facing said bed of non-adhered particles without said mask touching said bed of non-adhered particles, said holes in said mask having a size which would allow passage of individual particles from said bed of non-adhered particles through said holes, d) placing a receptor material capable of at least temporarily retaining an electric charge adjacent said second surface of said mask, which second surface faces away from said bed of non-adhered particles, e) applying an electrical charge to said receptor material which is at least temporarily retained by said receptor material, f) applying an electrical field between said mask and said support, said electrical field being of at least sufficient strength to cause individual particles from said bed of non-adhered particles to move off said support and impact said mask, g) allowing some of said individual particles which move off said support to enter said holes in said mask and contact said receptor material, and h) said contact by individual particles to said receptor material causing at least some of said particles contacting said receptor material to adhere to said receptor material at least by charge attraction of said individual particles to charge on said receptor material, wherein said receptor material comprises organic polymeric film, wherein said electrical field applied in step f) causes particles with an electrical charge opposite that of the charge provided on said receptor material to move towards said receptor material, and causes particles with an electrical charge similar to that provided on said receptor material to move away from said receptor material, wherein the movement of particles towards and away from said receptor material produces a cloud of moving particles between said support and said mask, wherein the thickness of individual segments of said pattern of particles have thicknesses of at least five diameters of particles, and wherein said particles have an average diameter of between 5 micrometers and 5 millimeters and said particles have an electrical resistivity of less than 10.sup.+10 ohm-centimeters. ### Claim 24 (depends on 23) The process of claim 23 wherein said particles are selected from the group consisting of metals, metal alloys, glass, ceramics, inorganic compounds, and organic materials. ### Claim 25 A process for applying a discontinuous coating of particulates to a surface comprising the steps of: a) providing a support, b) placing a bed of non-adhered particles on said support, said particles being capable of being moved by an electric field of less than 100 KV/cm, c) placing a mask with a first and second surface over said bed of non-adhered particles, said mask having holes which pass from said first to said second surface, said first surface facing said bed of non-adhered particles without said mask touching said bed of non-adhered particles, said holes in said mask having a size which would allow passage of individual particles from said bed of non-adhered particles through said holes, d) placing a receptor material capable of at least temporarily retaining an electric charge in contact with said second surface of said mask, which second surface faces away from said bed of non-adhered particles, e) applying an electrical charge to said receptor material which is at least temporarily retained by said receptor material, f) applying an electrical field between said mask and said support, said electrical field being of at least sufficient strength to cause individual particles from said bed of non-adhered particles to move off said support and impact said mask, g) allowing some of said individual particles which move off said support to enter said holes in said mask and contact said receptor material, and h) said contact by individual particles to said receptor material causing at least some of said particles contacting said receptor material to adhere to said receptor material at least by charge attraction of said individual particles to charge on said receptor material wherein said particles comprise a core of material having a conductivity and a shell of greater conductivity than the conductivity of said core. ### Claim 26 (depends on 25) The process of claim 25 wherein said mask is in contact with said receptor material when step f) is performed. ### Claim 27 A process for applying a discontinuous coating of multiple layers of particles to a surface comprising the steps of: a) providing a support, b) placing a bed of non-adhered particles on said support, said particles being capable of being moved by an electric field of less than 100 KV/cm, c) placing a mask with a first and second surface with holes in the mask over said bed of non-adhered particles, said first surface facing said bed of non-adhered particles without said mask touching said bed of non-adhered particles, said holes in said mask having a size which would allow passage of individual particles from said bed of non-adhered particles through said holes, d) placing a receptor material capable of at least temporarily retaining an electric charge in contact with said second surface of said mask, which second surface faces away from said bed of non-adhered particles, e) applying an electrical charge to said receptor material which is at least temporarily retained by said receptor material, f) applying an electrical field between said mask and said support, said electrical field being of at least sufficient strength to cause individual particles from said bed of non-adhered particles to move off said support and impact said mask, g) allowing some of said individual particles which move off said support to enter said holes in said mask and contact said receptor material, and h) said contact by individual particles to said receptor material causing at least some of said particles contacting said receptor material to adhere to said receptor material only by charge attraction of said individual particles to charge on said receptor material. ### Claim 28 A process for applying a discontinuous coating of particles to a surface comprising the steps of: a) providing a support, b) placing a bed of non-adhered particles on said support, said particles being capable of being moved by an electric field of less than 100 KV/cm, c) placing a mask with a first and second surface with holes in the mask over said bed of non-adhered particles, said first surface facing said bed of non-adhered particles without said mask touching said bed of non-adhered particles, said holes in said mask having a size which would allow passage of individual particles from said bed of non-adhered particles through said holes, d) placing a receptor material capable of at least temporarily retaining an electric charge in contact with said second surface of said mask, which second surface faces away from said bed of non-adhered particles, e) applying an electrical charge to said receptor material which is at least temporarily retained by said receptor material, f) applying an electrical field between said mask and said support, said electrical field being of at least sufficient strength to cause individual particles from said bed of non-adhered particles to move off said support and impact said mask, g) allowing some of said individual particles which move off said support to enter said holes in said mask and contact said receptor material, and h) said contact by individual particles to said receptor material causing at least some of said particles contacting said receptor material to adhere to said receptor material at least by charge attraction of said individual particles to charge on said receptor material.