Composite Metallic Particles for Low-Cost Conductive Inks
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Solution Overview
Problem
Existing liquid-based methods for producing conductive substrates, such as screen printing or ink jet methods, face challenges in achieving desired conductivity due to high impurity levels and lack of cost-effectiveness.
Innovation Solution
The process involves coating a base material with a composite metallic thin film layer, removing it to form particles, dispersing these particles in a liquid, and using the resulting ink to create a conductive substrate through a patterned layer formation, which can be done using simpler equipment and at lower costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If liquid-based processes (screen printing or ink jet method) are used to make conductive substrates, then manufacturing cost is reduced and equipment complexity is simplified, but the substrates contain vast amounts of impurities and achieve desired conductivity
Solution Approach 1:
The invention uses composite metallic particles consisting of a metal core (high conductivity) coated with a resin or wax layer (low melting point). This composite structure allows the particles to maintain high conductivity while being processable through liquid-based methods. The core-shell structure combines the advantages of both materials: the metal provides electrical conductivity and the coating enables low-temperature processing and dispersion in liquid vehicles.
Solution Approach 2:
The invention changes the physical and chemical parameters of the conductive material by using particles with specific size ranges (0.1-10 μm diameter) and controlled melting points (resin/wax coating melting below 200°C). These parameter changes enable the material to be processed at lower temperatures (100-300°C) while maintaining conductivity, thus achieving both cost reduction and desired conductivity.
2Ease of manufacture
If conventional conductive inks are used in liquid-based processes, then manufacturing cost is reduced, but cost-effectiveness is lacking
Solution Approach 1:
The invention optimizes the particle size parameter to 0.1-10 μm diameter, which provides the optimal balance between conductivity and processability. This size range ensures sufficient surface area for liquid vehicle adhesion while maintaining electrical conductivity. The low melting point coating (below 200°C) enables energy-efficient processing, significantly reducing manufacturing costs while maintaining effectiveness.
Solution Approach 2:
The composite metallic particles with resin or wax coating provide cost-effective conductive inks by combining inexpensive metal cores with low-cost organic coatings. This composite approach enables the use of simple liquid-based application methods (screen printing, ink jet) without requiring expensive vacuum deposition equipment, achieving both cost reduction and practical effectiveness.
3Manufacturing precision
If a composite metallic thin film layer is coated on a base material and then removed to form particles, then highly conductive substrates with reduced impurities are achieved, but the process complexity increases
Solution Approach 1:
The invention performs preliminary coating of the composite metallic thin film layer on a base material sheet before particle formation. This preliminary action allows the composite layer to be formed with controlled composition and structure, ensuring high purity and desired properties. The coating step is performed once, and the resulting composite particles are then easily removed and dispersed, simplifying the overall process despite the initial coating complexity.
Solution Approach 2:
The invention extracts the composite metallic thin film layer from the base material sheet to form free-standing particles. This extraction step separates the composite particles from the substrate, allowing them to be dispersed in liquid vehicles and applied as conductive inks. The extraction process, while adding a step, enables the creation of highly pure particles without contamination from the base material.
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
This method enables the production of highly conductive substrates with reduced impurities and lower manufacturing costs, achieving desired conductivity while simplifying the equipment and process requirements.
Implementation Method 1
Step 2 for removing the composite metallic thin film layer from the sheet
Implementation Method 2
Step 3 for making a dispersion of composite metallic particles by dispersing the composite metallic particles in a liquid
Implementation Method 3
Step 6 for heating the formed patterned conductive layer
Data Source
AI summary
A composite metallic particle made by coating a surface of a base material sheet with a composite metallic thin film layer that contains at least one of a resin layer and a wax layer and at least one of a metal layer and a metal compound layer and step 2 for removing the composite metallic thin film layer from the sheet. The resultant composite metallic particles and conductive ink can be used in a conductive substrate producing apparatus, formed into a pattern on the conductive substrate by screen printing, an ink jet method, or some other liquid-based process.