Structured Roller Transfer of Polymer Electrode Patches

The patent applies preliminary action by creating a structured roller with recesses that define the desired polymer field geometry before the extrusion process. The roller surface is pre-structured with patterns (lines, dots, grids, or arbitrary shapes) that guide the extruded polymer material into precise configurations, eliminating the need for subsequent punching or laser ablation steps. This preliminary structuring of the application tool enables direct formation of accurately defined polymer fields.

The patent extracts the separation function from the post-extrusion processing stage and integrates it into the extrusion application stage itself. By incorporating a structured roller with geometric patterns directly into the material application process, the separation and definition of polymer fields is achieved during extrusion, removing the need for separate punching or laser ablation operations.

The patent introduces a structured roller as an intermediary element between the extrusion die and the substrate. The roller surface with its precise geometric patterns (lines, dots, grids, or custom shapes) acts as a mediator that receives the extruded polymer material and shapes it into accurately defined fields. The recesses in the roller control the material distribution, enabling precise definition of polymer field length, width, and shape without relying on shutter mechanism timing.

The patent replaces the shutter mechanism control system with a structured roller surface pattern system. Instead of using mechanical shutters to control intermittent material flow and hoping for acceptable dimensions, the invention uses a physically structured roller with predetermined geometric patterns that directly imprint precise dimensions and shapes onto the polymer fields during the extrusion process.