Conductive Trace Precursors for In-Process 3D Printing
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Solution Overview
Problem
Existing 3D printing methods require post-printing treatments to sinter metal nanoparticles, which can be time-consuming and inefficient.
Innovation Solution
A method involving the use of a conductive trace precursor composition comprising a metal salt, a reducing solvent, and a fusing agent to form conductive traces directly during the 3D printing process, eliminating the need for post-printing sintering by reducing the metal salt through thermal energy generated by irradiating a radiation absorber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If post-printing sintering processes are used to form conductive traces, then the conductive traces can be formed on the substrate, but the process becomes time-consuming and inefficient
Solution Approach 1:
The patent combines the conductive trace formation process with the 3D printing process by incorporating conductive ink into the printing material itself. This allows conductive traces to be formed during the printing process rather than requiring separate post-printing sintering operations, thereby merging two previously separate processes into one integrated operation that improves productivity while maintaining reliable conductive trace formation.
Solution Approach 2:
The patent applies preliminary action by pre-loading the substrate with conductive ink before or during the printing process. The conductive material is positioned and prepared in advance within the printing material layers, so that when the 3D printing process occurs, the conductive traces are already in place and only require minimal additional processing to become functional, eliminating the need for time-consuming post-printing sintering.
2Ease of manufacture
If traditional 3D printing methods are used, then the printing process is simple, but conductive traces cannot be integrated within the internal structure of the printed object
Solution Approach 1:
The patent applies local quality by incorporating conductive ink selectively into specific regions or layers of the 3D printing material. Rather than making the entire printed object conductive, the conductive properties are localized to specific pathways or structures where electrical conduction is needed, allowing internal trace integration while maintaining the simplicity of the overall printing process.
Solution Approach 2:
The patent uses composite materials by combining conductive ink with the 3D printing material to create a multi-functional composite. This composite material allows the printed object to have both structural properties from the base material and electrical conductive properties from the embedded conductive ink, enabling internal trace integration without complicating the manufacturing process.
3Reliability
If high temperature and pressure sintering is applied, then conductive traces can be formed, but additional equipment and process steps are required
Solution Approach 1:
The patent applies self-service by designing a system where the conductive ink is formulated to self-sinter or self-organize into functional conductive traces during or immediately after the 3D printing process. The conductive material contains its own activation mechanism, eliminating the need for separate high-temperature sintering equipment and reducing device complexity while maintaining reliable conductive trace quality.
Solution Approach 2:
The patent uses parameter changes by modifying the formulation of the conductive ink to enable it to form functional traces at lower temperatures or under different conditions than traditional sintering processes. By changing the chemical or physical parameters of the conductive material itself, the process can achieve reliable trace formation without requiring high-temperature equipment, thereby reducing device complexity.
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 the direct formation of conductive traces within the internal structure of 3D printed objects, reducing the need for post-printing treatments and enhancing the efficiency of the printing process.
Implementation Method 1
The fusing agent comprises a radiation absorber and a liquid carrier, and the conductive trace precursor composition comprises a metal salt and a liquid carrier. The method comprises reducing the metal salt; and irradiating the selectively applied fusing agent to generate thermal energy to coalesce the powder bed material to form a layer of the 3D printed object.
Implementation Method 2
irradiating the selectively applied fusing agent to generate thermal energy to coalesce the powder bed material
Implementation Method 3
reducing the metal salt; and irradiating the selectively applied fusing agent to generate thermal energy to coalesce the powder bed material to form a layer of the 3D printed object
Data Source
AI summary
The present disclosure relates to a conductive trace precursor composition comprising a metal salt; 3 to 15 weight % of a reducing solvent selected from a lactam and/or a polyol, and water. Where the reducing solvent is 2-pyrrolidinone, the 2-pyrrolidinone is not present in an amount of 5 weight % or in an amount of 7.5 weight % of the conductive trace precursor composition.