Low-Temperature Conductive Polymer Compositions for Solar Cells
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Solution Overview
Problem
Conventional electrically conductive polymeric compositions require high temperatures for curing, which is problematic for heat-sensitive electronic devices like solar cells, and often include solvents that complicate processing and increase environmental concerns.
Innovation Solution
A thermally curable composition comprising fatty acid modified epoxy acrylate or methacrylate monomers/oligomers and metallic particles, which can be cured at temperatures below 250°C without solvents, forming a highly conductive layer suitable for electronic assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrically conductive polymeric compositions are used, then high electrical conductivity can be achieved, but high curing temperatures (>700°C) are required which damage heat-sensitive materials
Solution Approach 1:
The patent changes the chemical composition parameters of the polymeric system by using epoxy acrylate oligomers with specific molecular weights (350-2000) and incorporating fatty acid modified components, enabling the curing process to occur at lower temperatures (100-250°C) while maintaining high electrical conductivity through optimized metallic particle content (60-90 wt%)
Solution Approach 2:
The invention creates a composite material system combining epoxy acrylate oligomers, fatty acid modified epoxy acrylate or polyester acrylate monomers/oligomers, metallic particles (silver, aluminum, or their alloys), and free radical initiators. This composite approach allows the material to achieve both low-temperature curability and high electrical conductivity simultaneously
2Ease of operation
If conventional polymeric compositions with solvents are used, then ease of application is improved, but solvent removal operations increase processing time, environmental impact, and manufacturing complexity
Solution Approach 1:
The patent extracts and eliminates the solvent component from the conventional polymeric composition, creating a solvent-free formulation. The composition achieves proper rheology and application characteristics through the inherent properties of epoxy acrylate oligomers and reactive diluents, eliminating the need for solvent removal operations and associated environmental controls
Solution Approach 2:
The invention uses epoxy acrylate oligomers and reactive diluents as intermediary substances that provide the necessary fluidity and workability for application without requiring solvent removal. These intermediaries participate in the curing reaction, contributing to the final network structure while enabling easy application at room or elevated temperatures
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 enables the formation of electrically conductive layers and components at low temperatures, reducing processing time and environmental impact while achieving high electrical conductivity, suitable for applications like solar cells.
Implementation Method 1
comprising (a) an optional reactive diluent, (b) a selection from the group consisting of (i) fatty acid modified epoxy acrylate and/or methacrylate monomer(s) or oligomer(s), (ii) fatty acid modified polyester acrylate and/or methacrylate monomer(s) or oligomer(s), and (iii) combinations of (i) and (ii), (c) metallic particles, and (d) a free radical initiator
Implementation Method 2
heating the applied composition to a temperature less than 250° C. to form the electrically conductive layer
Data Source
AI summary
Electrically conductive polymeric compositions adapted for use in forming electronic devices are disclosed. The compositions are thermally curable at temperatures less than about 250° C. Compositions are provided which may be solvent-free and so can be used in processing or manufacturing operations without solvent recovery concerns. The compositions utilize (i) fatty acid modified epoxy acrylate and/or methacrylate monomer(s) and/or oligomer(s), (ii) fatty acid modified polyester acrylate and/or methacrylate monomer(s) and/or oligomer(s), or combinations of (i) and (ii). Also described are electronic assemblies such as solar cells using the various compositions and related methods.