Conductive Polymer Composite for PV Metallization
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Solution Overview
Problem
The high cost of silver-based metallization in photovoltaic cells and other applications due to its substantial portion of the manufacturing cost, necessitates the development of alternative compositions and conductors for efficient current transport and electrical connection.
Innovation Solution
A composition comprising a metal powder, a solder powder with a lower melting temperature, a polymer, a carboxylated-polymer, a dicarboxylic acid, and a monocarboxylic acid, which forms a conductor suitable for various applications such as busbars, contact pads, and electrodes, utilizing a process that eliminates the need for pre-fluxing and allows for direct soldering without additional steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If silver-based metallization is used for current transport and electrical connection, then excellent conductivity is achieved, but manufacturing cost increases substantially
Solution Approach 1:
The patent uses a composite material system consisting of metal powder (silver, copper, or aluminum), solder powder, polymer, and carboxylated-polymer. This composite formulation allows the conductor to achieve excellent conductivity through the metal powder while the polymer and carboxylated-polymer matrix provide structural integrity, adhesion, and fluxing capabilities, thereby reducing reliance on expensive pure silver metallization
Solution Approach 2:
The patent changes the physical and chemical parameters of the conductor by using metal powder particles embedded in a polymer matrix rather than continuous silver layers. The carboxylated-polymer cross-linking creates a three-dimensional network structure that enhances mechanical properties while maintaining electrical conductivity through the distributed metal powder particles
2Reliability
If traditional metallization processes are used, then electrical connection is achieved, but additional processing steps (pre-fluxing, additional soldering steps) increase device complexity
Solution Approach 1:
The patent merges multiple functions into a single integrated composition: the metal powder provides conductivity, the solder powder enables bonding, the polymer provides structural support and adhesion, and the carboxylated-polymer serves as both binder and flux. This consolidation eliminates the need for separate pre-fluxing and soldering steps, reducing processing complexity while maintaining reliable electrical connections
Solution Approach 2:
The carboxylated-polymer component performs multiple functions simultaneously: it acts as a binder holding the metal and solder powders together, provides fluxing action to facilitate soldering, and forms a cross-linked network for structural integrity. This multi-functionality reduces the number of separate materials and processing steps required
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 solution reduces manufacturing costs by providing a conductive material with excellent adhesive and cohesive properties, improving the efficiency of current transport and electrical connections while maintaining conductivity over time, as demonstrated by increased open-circuit voltage and short-circuit current density in photovoltaic cells.
Implementation Method 1
The carboxylated-polymer is useful for fluxing the metal powder and cross-linking the polymer
Implementation Method 2
The composition further comprises a dicarboxylic acid and a monocarboxylic acid for fluxing the metal powder
Implementation Method 3
The composition further comprises a solder powder which has a lower melting temperature than a melting temperature of the metal powder
Data Source
Figure 1~2
Figure 3A~3B
Figure 4~6
AI summary
A composition comprises a metal powder. The composition further comprises a solder powder which has a lower melting temperature than a melting temperature of the metal powder. The composition further comprises a polymer and a carboxylated-polymer different from the polymer. The carboxylated-polymer is useful for fluxing the metal powder and cross-linking the polymer. The composition further comprises a dicarboxylic acid and a monocarboxylic acid. The acids are useful for fluxing the metal powder. The composition may be used for forming a conductor. The conductor may be used for current transport and/or electrical connection. An article comprises a substrate and the conductor disposed on and in electrical contact with the substrate. The article may be used for various applications, such as for converting light of many different wavelengths into electricity. Examples of such articles include photovoltaic (PV) cells and circuit boards.