Conductive Ink Using Metal-Coated Glass Flakes
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Solution Overview
Problem
Current conductive inks for printed electronics face challenges such as high cost, limited conductivity, and the need for high-temperature curing, which restrict their applicability and printability, especially in RFID and transparent applications.
Innovation Solution
A conductive ink composition incorporating glass flakes coated with electrically conductive coatings, combined with additional conductive particles like graphite or graphene, which allows for high conductivity without requiring high-temperature curing and is cost-effective, enabling ink-jet printability and efficient manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If silver nanoparticles are used for RFID antennas, then electrical conductivity is improved, but cost increases significantly
Solution Approach 1:
The patent uses composite conductive structures combining carbon nanoparticles (graphite, graphene, carbon nanotubes) with metal-coated glass flakes. This composite approach achieves high electrical conductivity comparable to silver while using cheaper materials, directly resolving the cost-conductivity contradiction
Solution Approach 2:
The patent replaces expensive silver nanoparticles with cost-effective carbon-based materials and metal-coated glass flakes. These alternative materials provide sufficient conductivity for RFID applications at a fraction of the cost of silver, making the conductive ink economically viable
2Ease of manufacture
If carbon-based conductive inks are used, then cost is reduced, but electrical conductivity is insufficient
Solution Approach 1:
The patent creates a composite system where carbon nanoparticles provide baseline conductivity and metal-coated glass flakes enhance electrical performance. The metal coating (silver, aluminum, or copper) on the glass flakes acts as a conductive bridge, significantly improving overall conductivity while maintaining cost-effectiveness
Solution Approach 2:
The patent optimizes particle size parameters (1-100 μm for glass flakes, smaller for carbon nanoparticles) and metal coating thickness to maximize electrical conductivity. By controlling these parameters, the ink achieves high conductivity without requiring expensive materials or complex processing
3Reliability
If high-temperature curing is applied to carbon-based inks, then electrical conductivity is improved, but applicability is limited
Solution Approach 1:
The patent formulates the ink with optimized particle size distribution, metal coating thickness, and binder composition that enable effective curing at lower temperatures (50-150°C). This parameter optimization allows the ink to achieve high conductivity on temperature-sensitive substrates without requiring harsh thermal processing
Solution Approach 2:
The patent uses binder resins as intermediaries that facilitate conductive network formation at lower temperatures. The binder matrix helps organize the conductive particles and metal-coated flakes into effective conductive pathways, enabling low-temperature curing while maintaining high electrical conductivity
4Ease of manufacture
If carbon nanoparticles are used, then cost is reduced compared to silver, but viscosity of the dispersing liquid increases dramatically
Solution Approach 1:
The patent uses glass flakes with specific size ranges (1-100 μm) and aspect ratios that provide good flow characteristics in the ink vehicle. The metal coating on the glass flakes prevents agglomeration, maintaining low viscosity while preserving cost-effectiveness
Solution Approach 2:
The patent employs dispersants and binder resins as intermediaries that prevent carbon nanoparticle aggregation and ensure uniform distribution. These additives reduce inter-particle interactions that would increase viscosity, maintaining ink flowability while using cost-effective carbon-based conductive materials
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 composition achieves significant reductions in resistance and improved conductivity, making it suitable for various printed electronics applications while being cost-effective and printable without the need for high-temperature curing.
Implementation Method 1
the electrically conductive coating comprises a conductor selected from the group comprising silver, nickel, gold, metal nanoparticles, indium tin oxide, fluorine doped tin oxide
Implementation Method 2
The composition achieves significant reductions in resistance and improved conductivity
Data Source
Figure 1~2D
AI summary
A conductive ink composition is disclosed comprising conductive solids and a medium, wherein the conductive solids comprise glass flakes coated with an electrically conductive coating. Optionally, the electrically conductive coating may comprise a conductor selected from the group comprising silver, nickel, gold, metal nanoparticles, indium tin oxide, fluorine doped tin oxide. The conductive ink composition may comprise a percentage by weight of glass flakes coated with an electrically conductive coating less than or equal to 50%. Also disclosed is a method of manufacturing the conductive ink composition, a printed article, and a method of manufacturing the printed article.