Conductive Membrane Transfer Sheet for Binder-Free Low-Resistance Films
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Solution Overview
Problem
Existing methods for producing conductive membranes face limitations such as high costs, complex operations, and poor conductivity due to the use of binders and thickening agents, which restrict their application to specific substrates and shapes.
Innovation Solution
A conductive membrane transfer sheet is developed by applying a dispersion liquid containing conductive fibers onto a liquid-permeable release sheet without a thickening agent, allowing solvent removal to create a transferable conductive membrane, utilizing van der Waals forces for bonding to substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional coating method using binder solution and conductive fine particles is employed, then large-area conductive membranes can be formed with simple installation and high productivity, but the conductive membrane shows high electric resistance due to binder blocking contact between particles
Solution Approach 1:
The invention extracts and removes the binder component from the coating composition, using only conductive fine particles dispersed in solvent. This eliminates the insulating barrier that prevents direct particle contact, thereby achieving low electric resistance while maintaining the simplicity and productivity of the coating method.
Solution Approach 2:
The invention changes the composition parameter of the coating material from a binder-based system to a binder-free system, using solely conductive particles and solvent. This parameter change transforms the conductive mechanism from particle-to-particle contact through binder matrix to direct particle contact, achieving high conductivity.
2Reliability
If carbon nanotubes are used as conductive fibers to form contact points more easily, then conductivity improves, but binder must still be used to control film thickness and strength, resulting in low conductivity
Solution Approach 1:
The invention removes the binder component from the coating composition entirely, using only conductive fibers (carbon nanotubes) and solvent. This extraction eliminates the insulating effect of binder while maintaining film integrity through fiber entanglement and van der Waals forces, achieving high conductivity without compromising film formation.
3Reliability
If binder is thermally decomposed and removed to form mono-material membrane of carbon nanotubes, then conductivity improves, but highly heat-resistant substrate is required
Solution Approach 1:
The invention performs preliminary action by directly forming the conductive membrane without binder that would require thermal decomposition. The binder-free composition allows direct deposition on substrates at lower temperatures, expanding substrate compatibility to include heat-sensitive materials while achieving high conductivity from the outset.
4Reliability
If sputtering method is used to form conductive membrane with low surface resistance, then conductivity improves, but large-scaled installation is required and film formation rate is slow
Solution Approach 1:
The invention replaces the mechanical sputtering process with a chemical coating method. Instead of using vacuum equipment and physical sputtering to deposit conductive material, the invention uses liquid coating with conductive particles that can be applied at atmospheric pressure, dramatically increasing film formation rate while achieving comparable or superior conductivity.
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
Enables easy transfer of highly conductive membranes onto various substrates with diverse shapes and materials, achieving low surface resistance and flexibility without special equipment, suitable for applications like antistatic layers and transparent conductors.
Implementation Method 1
a liquid-permeable release sheet
Implementation Method 2
utilizing van der Waals forces for bonding to substrates
Implementation Method 3
allowing solvent removal to create a transferable conductive membrane
Data Source
AI summary
According to an embodiment of the present invention, a conductive membrane transfer sheet including a first release sheet and a conductive membrane is provided. The first release sheet includes a liquid-permeable sheet. The conductive membrane includes a conductive fiber supported on a first major surface of the first release sheet. The first release sheet and the conductive membrane contain a first liquid.