Patent ID: 8062713

Claim:
A method for manufacturing electrodes with a first electrostatic deposition unit that is comprised of a sump, a sleeve, and voltage supply, comprising the steps of: (a) depositing a conductive powder with a charge relaxation time of less than about 1 second onto a substrate with said first electrostatic deposition unit, wherein said conductive powder is mixed with magnetic carrier beads in said sump to form a mixture of conductive powder and magnetic carrier beads, wherein said mixture is fed onto said sleeve, and wherein said mixture forms a magnetic brush on said sleeve; (b) positioning said substrate away from said magnetic brush such that an air gap is disposed between said substrate and said magnetic brush; (c) imposing a voltage between said substrate and said sleeve; and (d) producing a large asymmetry between said magnetic brush and said substrate such that the electric field at said magnetic brush is at least 3.0 times as great as the electric field at such substrate.