Mica-foil laminations

Claim 3

A method as defined in claim 1 in which the thermoplastic pressure sensitive adhesive comprises a methyl phenyl polysiloxane adhesive.

Claim 4

A method as defined in claim 1, in which step (b) comprises bonding a metallic sheet to each face of the mica sheet, and step (c) comprises selectively removing portions of each metallic sheet to create first and second electrode patterns on opposite faces of the mica sheet.

Claim 5

The method of claim 1, in which step (a) comprises immersing said mica sheet in a bath of thermoplastic pressure sensitive adhesive, and withdrawing the mica sheet from the adhesive bath at a controlled speed to form a thermoplastic pressure sensitive adhesive layer of desired thickness.

Claim 6

A method as defined in claim 1 in which step (c) comprises the steps of: applying a layer of photoresist to said metallic sheet, placing a photomask patterned in accordance with said electrode pattern over the photoresist, and exposing the resulting structure to ultraviolet radiation.

Claim 7

A method as defined in claim 1, in which said metallic sheet comprises a sheet of stainless steel foil.

Claim 8

A method as defined in claim 1 in which step (a) comprises coating the entire mica sheet, including the edges, with a layer of thermoplastic pressure sensitive adhesive.

Claim 9

A method as defined in claim 1 further comprising the step of applying a protective tape to the edges of said mica sheet.

Claim 10

A method as defined in claim 1 further comprising the step of bonding a heat sink to the laminate subsequent to step (c).

Claim 11

A method as defined in claim 1 in which step (a) comprises applying to the mica sheet a layer of liquid thermoplastic pressure sensitive adhesive having a viscosity in the range 10 centipoise-100 centipoise.

Claim 12

A dielectric-electrode laminate produced by the method of claim 1.

Claim 13

A dielectric-electrode laminate comprising: a mica sheet; at least one electrode bonded to a face of said mica sheet, said electrode being comprised of a metallic sheet, the bond between said electrode and said mica sheet being accomplished by a layer of thermoplastic pressure sensitive adhesive comprising an organopolysiloxane pressure sensitive adhesive, wherein the dielectric-electrode laminate resists delamination due to moisture, and erosion due to ozone and nitric acid.

Claim 14

A dielectric-electrode laminate comprising: a mica sheet; at least one electrode bonded to a face of said mica sheet, said electrode being comprised of a metallic sheet, the bond between said electrode and said mica sheet being accomplished by a layer of thermoplastic pressure sensitive adhesive comprising an organopolysiloxane pressure sensitive adhesive, wherein the dielectric-electrode laminate resists delamination due to moisture, and erosion due to ozone and nitric acid.

Claim 15

A dielectric-electrode laminate as defined in claim 12 wherein said thermoplastic pressure sensitive adhesive comprises a methyl phenyl polysiloxane adhesive.

Claim 16

A laminate as defined in claim 12, in which the metallic sheet comprises a foil of a material selected from the classes consisting of stainless steel, copper, nickel, titanium, and tantalum.

Claim 17

A laminate as defined in claim 12 in which said metallic sheet has a thickness in the range from 6 microns-50 microns.

Claim 18

A laminate as defined in claim 15 in which said metallic sheet has a thickness around 25 microns.

Claim 19

A laminate as defined in claim 12 in which said thermoplastic pressure sensitive adhesive layer has a thickness in the range 0.5 microns-5 microns.

Claim 20

A laminate as defined in claim 17 in which said thermoplastic pressure sensitive adhesive layer has a thickness in the range 0.6 microns-2.5 microns.

Claim 21

A laminate as defined in claim 12 in which said mica sheet has a thickness in the range from 2-75 microns.

Claim 22

A laminate as defined in claim 19 in which said mica sheet has a thickness in the range 10-15 microns.

Claim 23

A laminate as defined in claim 12 in which said mica sheet has a thickness in the range from 10-15 microns, said metallic sheet has a thickness in the range from 6-50 microns, and said layer of pressure sensitive adhesive has a thickness in the range from 0.5-5 microns.

Claim 24

A laminate as defined in claim 12 in which electrodes are bonded to both faces of said mica sheet.

Claim 25

A laminate as defined in claim 22 wherein the first electrode comprises a series of selector bars, and the second electrode comprises a series of finger electrodes aligned transversely to said selector bars, said finger electrodes having apertures at crossover locations with respect to said selector bars.

Claim 26

A dielectric-electrode laminate comprising: a mica sheet having a thickness in the range from 2-75 microns; at least one electrode bonded to a face of said mica sheet, said electrode being comprised of a metallic sheet, the bond between said electrode and said mica sheet being accomplished by a layer of pressure sensitive adhesive selected from the class consisting of solutions of organopolysiloxane resins and acrylic-based pressure sensitive adhesives, said adhesive layer having a thickness in the range from 0.5 microns-5 microns, wherein the dielectric-electrode laminate resists delamination due to moisture, and erosion due to ozone and nitric acid.

Claim 27

A dielectric-electrode laminate comprising: a mica sheet having a thickness in the range from 2-75 microns; at least one electrode bonded to a face of said mica sheet, said electrode being comprised of a metallic sheet, the bond between said electrode and said mica sheet being accomplished by a layer of pressure sensitive adhesive selected from the class consisting of solutions of organopolysiloxane resins and acrylic-based pressure sensitive adhesives, said adhesive layer having a thickness in the range from 0.5 microns-5 microns, wherein the dielectric-electrode laminate resists delamination due to moisture, and erosion due to ozone and nitric acid.

Claim 28

A dielectric-electrode laminate as defined in claim 24 wherein said pressure sensitive adhesive comprises a methyl phenyl polysiloxane pressure sensitive adhesive.