Composite Conductive Particle Core-Shell Structure
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Solution Overview
Problem
Conductive resin compositions face challenges with high production costs due to the need for excessive silver usage and poor filling properties when using silica or resin core particles, and existing techniques either increase costs or compromise conductivity.
Innovation Solution
A composite conductive particle with a larger first conductive particle and smaller second conductive particles adhering to its surface, both coated with metal, achieving high conductivity and filling properties while optimizing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Cu particles are used as core particles to achieve excellent conductivity and corrosion resistance, then conductivity and corrosion resistance are improved, but specific gravity increases causing sedimentation and poor operability
Solution Approach 1:
The patent applies the nesting principle by forming a multi-layer structure where a Cu core particle is nested within an Ag coating layer. The Cu core provides excellent conductivity and corrosion resistance, while the Ag coating reduces specific gravity to prevent sedimentation. This nested structure allows the inner Cu particle to be protected and functionalized by the outer Ag layer, resolving the contradiction between reliability and ease of operation.
Solution Approach 2:
The patent uses composite materials by combining Cu and Ag in a core-shell structure. The Cu core provides electrical conductivity and corrosion resistance, while the Ag shell reduces density and prevents sedimentation. This composite approach allows the material to exhibit properties of both components, achieving excellent conductivity, corrosion resistance, and operability simultaneously.
2Ease of operation
If Ag coating is applied on silica or resin core particles to reduce specific gravity, then operability is improved, but production cost increases due to excessive Ag usage
Solution Approach 1:
The patent applies local quality by creating a core-shell structure where the Ag coating is localized only on the outer shell rather than uniformly distributed throughout the entire particle volume. The Cu core provides the necessary conductivity, while the Ag shell is minimized to just enough to reduce specific gravity and prevent sedimentation. This localized approach reduces overall Ag usage and production cost while maintaining operability.
Solution Approach 2:
The patent uses partial action by applying Ag coating only to the extent necessary to achieve the desired specific gravity reduction and prevent sedimentation, rather than completely coating all particles with thick Ag layers. The Cu core provides the primary conductivity function, so Ag coating is applied partially to achieve the balance between operability and cost-effectiveness.
3Manufacturing precision
If surface treatment using silicon-based polymer compound or silane coupling agent is applied to silica particles, then metal precipitation is improved, but production cost increases
Solution Approach 1:
The patent applies self-service by utilizing the natural reducing properties of the Cu core particle surface to directly precipitate Ag metal without requiring preliminary surface treatment with silicon-based polymer compounds or silane coupling agents. The Cu surface naturally facilitates Ag precipitation through displacement reaction, eliminating the need for additional costly surface treatment steps while achieving effective metal precipitation.
4Reliability
If projections are formed on composite conductive particles to increase surface area, then conductivity is improved, but filling property decreases
Solution Approach 1:
The patent applies spheroidality by forming smooth spherical composite particles with the Cu core and Ag coating structure. The spherical shape provides good flowability and high filling properties in the conductive resin composition. The smooth curved surface eliminates projections while maintaining excellent conductivity through the Cu-Ag core-shell structure, resolving the contradiction between conductivity and filling property.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composite conductive particle achieves high conductivity and filling properties while reducing production costs by optimizing the ratio and size of adhering particles and their metal coatings, enhancing the performance of conductive resin compositions.
Implementation Method 1
a second conductive particle adhering to a surface of the first conductive particle
Implementation Method 2
a first metal coating covering a surface of the first particle, and a second metal coating covering a surface of the second particle
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A composite conductive particle according to the present invention includes a first conductive particle having a particle diameter of greater than or equal to 0.1 µm and less than or equal to 50 µm; and a second conductive particle adhering to the surface of the first conductive particle and having a particle diameter of greater than or equal to 50 nm and less than or equal to 1000 nm, and the first conductive particle is composed of a first particle and a first metal coating covering the surface of the first particle, the second conductive particle is composed of a second particle and a second metal coating covering the surface of the second particle, a particle diameter of the first conductive particle is larger than a particle diameter of the second conductive particle, and an adhering rate of the second conductive particle to the first conductive particle is greater than or equal to 2% and less than or equal to 40%. As a result, it is possible to provide a composite conductive particle having high conductivity and high filling property.