Protected electrode structures and methods
AssigneeSion Power Corporation
InventorsYuriy V. Mikhaylik, Michael G. Laramie, John Joseph Christopher Kopera
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Abstract
An electrode structure and its method of manufacture are disclosed. The disclosed electrode structures may be manufactured by depositing a first release layer on a first carrier substrate. A first protective layer may be deposited on a surface of the first release layer and a first electroactive material layer may then be deposited on the first protective layer. The first release layer may have a low mean peak to valley surface roughness, which may enable the formation of a thin protective layer with a low mean peak to valley surface roughness.
Claims19
A method, comprising:
- providing a first carrier substrate;
- depositing a first release layer on the first carrier substrate, wherein a mean peak to valley roughness of a surface of the first release layer opposite the first carrier substrate is between about 0.1 μm and about 1 μm, and wherein the first release layer has a thickness of greater than or equal to about 2 μm;
- depositing a first protective layer on the surface of the first release layer;
- depositing a first electroactive material layer on the first protective layer,
- wherein an adhesive strength between the first release layer and the first protective layer is greater than an adhesive strength between the first release layer and the first carrier substrate;
- delaminating the first carrier substrate from the first release layer;
- and
- removing the first release layer from the first protective layer by dissolving the first release layer in an electrolyte.
A method, comprising:
- providing a first carrier substrate;
- depositing a first release layer on the first carrier substrate, wherein the first release layer comprises a polymer gel;
- depositing a first protective layer on the surface of the first release layer, wherein a thickness of the first release layer is greater than a mean peak to valley roughness of the first carrier substrate;
- depositing a first electroactive material layer on the first protective layer;
- delaminating the first carrier substrate from the first release layer;
- and
- removing the first release layer from the first protective layer by dissolving the first release layer in an electrolyte.
Dependencies are inferred from the claim text.