Copper Electrode Manufacturing via Metal Oxide Coated Paste
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Solution Overview
Problem
The oxidation of boron powder during firing in air leads to glassy elution, causing defects such as breaking and open lines in copper electrodes, which is not effectively addressed by existing technologies.
Innovation Solution
A conductive paste comprising copper powder coated with metal oxides like silicon oxide, zinc oxide, or aluminum oxide, combined with boron powder and glass frit, dispersed in an organic vehicle, is fired in air to form a copper electrode, reducing elution and improving conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If boron powder is used in combination with copper powder to reduce copper oxidation during firing, then copper oxidation is reduced, but boron powder oxidizes to cause glassy elution leading to breaking and open lines
Solution Approach 1:
A coating layer comprising a metal oxide is applied to the surface of the copper powder particles. This coating layer acts as an intermediary that prevents direct contact between the boron powder and copper powder, thereby preventing the formation of low-melting-point eutectics that cause glassy elution, while still allowing the boron powder to perform its oxidation protection function for the copper powder during firing in air.
Solution Approach 2:
The copper powder particles are segmented by applying a discrete coating layer of metal oxide on their surfaces. This segmentation creates a physical barrier that separates the copper powder from the boron powder, preventing harmful interactions while maintaining the functional benefits of both materials during the firing process.
2Reliability
If boron powder is used to protect copper from oxidation, then copper oxidation is prevented, but the boron powder itself oxidizes and flows out causing defects
Solution Approach 1:
The metal oxide coating layer on the copper powder surface serves as a protective intermediary that shields the boron powder from direct oxidation. This barrier prevents the boron powder from reacting with oxygen during firing, thereby reducing boron powder loss and preventing the formation of oxidized boron compounds that would otherwise cause glassy elution and electrode defects.
3Ease of manufacture
If uncoated copper powder is used with boron powder, then simplicity is maintained, but glassy elution occurs causing breaking and open lines
Solution Approach 1:
The metal oxide coating is applied to the copper powder particles in advance, before the conductive paste formulation and firing processes. This preliminary action ensures that the protective barrier is already in place when the paste is applied and fired, preventing glassy elution and electrode defects without requiring additional process steps during manufacturing, thus maintaining ease of manufacture while improving electrode integrity.
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 method significantly reduces elution and maintains sufficient conductivity, resulting in a stable and functional copper electrode with improved reliability.
Implementation Method 1
copper powder coated with a metal oxide selected from the group consisting of silicon oxide (SiO2), zinc oxide (ZnO), aluminum oxide (Al2O3), titanium oxide (TiO2), magnesium oxide (MgO) and a mixture thereof
Implementation Method 2
A boron powder is used in a combination with copper (Cu) powder in a conductive paste to form a copper electrode in order to reduce the Cu powder oxidation during firing in air
Implementation Method 3
firing the conductive paste in air
Implementation Method 4
firing the conductive paste layer in air
Data Source
AI summary
A method for manufacturing an electrode comprising the steps of: applying onto a substrate a conductive paste to form a conductive paste layer comprising; (i) 100 parts by weight of a copper powder coated with a metal oxide selected from the group consisting of silicon oxide (SiO2), zinc oxide (ZnO), aluminum oxide (Al2O3), titanium oxide (TiO2), magnesium oxide (MgO) and a mixture thereof; (ii) 5 to 30 parts by weight of a boron powder; and (iii) 0.1 to 10 parts by weight of a glass frit; dispersed in (iv) an organic vehicle; and firing the conductive paste in air.