Copper Boron Oxide Coated Conductive Paste for Solar Electrodes
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Solution Overview
Problem
Conductive metal oxidation during high-temperature firing in the production of electrodes for solar cells and other applications leads to increased resistivity, which affects the efficiency and durability of the electrodes, and existing alternatives like silver are costly and pose environmental concerns.
Innovation Solution
A conductive paste composition using copper-based particles with partially or entirely coated boron oxide particles is developed, which prevents oxidation and maintains low resistivity even at high temperatures, thereby improving the electrode's weather resistance and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper-based particles are used as conductive metal to replace silver, then cost is reduced and conductivity is improved, but oxidation occurs during high-temperature firing leading to increased resistivity
Solution Approach 1:
A boron oxide coating layer is applied as an intermediary between the copper-based particles and the oxidizing atmosphere during firing. This coating layer acts as a protective barrier that prevents oxygen from reaching and oxidizing the copper particles, while still allowing the copper to maintain its conductive function. The boron oxide layer is specifically chosen because it forms a stable protective barrier at high temperatures without significantly impeding electrical conductivity.
Solution Approach 2:
The boron oxide coating creates a localized inert environment around each copper-based particle, shielding it from the oxidizing atmosphere during high-temperature firing. This effectively isolates the copper from harmful oxidation reactions while allowing the overall firing process to proceed at temperatures necessary for good adhesion and conductivity.
2Manufacturing precision
If high-temperature firing is performed to ensure good adhesion and conductivity, then electrode performance is improved, but conductive metal oxidation increases leading to higher resistivity
Solution Approach 1:
The boron oxide coating serves as a thermal intermediary that allows the particle to withstand high firing temperatures without oxidizing. This protective barrier enables the use of high-temperature firing processes to achieve good adhesion and conductivity while preventing the oxidation that would otherwise increase resistivity.
3Reliability
If silver is used as conductive metal to prevent oxidation, then resistivity remains low and conductivity is maintained, but cost increases significantly
Solution Approach 1:
The invention replaces expensive silver with cheaper copper-based particles. The boron oxide coating acts as a sacrificial protective layer that prevents oxidation of the copper, enabling the use of this cheaper material while maintaining performance characteristics similar to silver.
Solution Approach 2:
The conductive paste composition uses a composite structure combining copper-based particles with boron oxide coating. This composite material achieves the oxidation resistance previously only available from expensive precious metals like silver, while utilizing abundant and cheaper copper as the base material.
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 use of copper-based particles with boron oxide coating in the conductive paste composition reduces electrode resistivity and enhances weather resistance, allowing for cost-effective replacement of silver and maintaining high efficiency and durability.
Implementation Method 1
a conductive paste composition including a copper-based particle; and a boron-based particle of which a surface is partially or entirely coated with boron oxide, wherein the boron-based particle is crystalline boron-based particle or amorphous boron-based particle
Data Source
AI summary
A conductive paste composition, a method for preparing the same, and an electrode formed by the conductive paste composition are disclosed. In one aspect, the conductive paste composition includes a copper-based particle and a boron-based particle of which a surface is partially or entirely coated with boron oxide. The boron-based particle is crystalline boron-based particle or amorphous boron-based particle. The boron-based particle has a content of more than 1 wt % to less than 10 wt % based on a total content of the conductive paste composition.