Copper Particle Synthesis via Chemical Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing copper particles, such as mechanical pulverization and vacuum methods, result in low yields, complex processes, high equipment costs, and difficulty in controlling particle size and shape, making them unsuitable for mass production and industrial use.
Innovation Solution
A method involving a preparation step with a copper compound, a salt of a main group metal, and a polyhydric alcohol, where the mixture is heated to control the particle size and shape of copper particles, utilizing salts like sodium sulfide and polyhydric alcohols like ethylene glycol to produce copper particles with specific size distributions and shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mechanical pulverization method is used, then copper particles can be produced, but the yield is low and particle size/shape cannot be controlled
Solution Approach 1:
The invention changes the chemical parameters of the reaction system by using copper compounds (such as copper sulfate, copper chloride) combined with reducing agents and stabilizers in specific molar ratios. By adjusting parameters like reducing agent to copper compound ratio (0.5-2.0), stabilizer concentration (0.1-5.0 wt%), and reaction temperature (20-100°C), the invention achieves both high yield (90% or more) and precise control of particle size (0.1-10 μm) and shape (spherical, cubic, rod-like), resolving the contradiction between productivity and manufacturing precision
Solution Approach 2:
The invention utilizes phase transition from dissolved copper ions to solid copper particles through controlled reduction reactions. The copper compounds are first dissolved in water to form copper ion solutions, then reduced to metallic copper particles through chemical reduction. This phase transition approach enables controlled nucleation and growth, achieving high yield while maintaining precise control over particle size and shape distribution
2Manufacturing precision
If vacuum method is used, then copper particles can be produced with controlled size, but the process is complicated and requires expensive equipment
Solution Approach 1:
The invention replaces the mechanical vacuum evaporation system with a chemical solution-based system. Instead of using vacuum equipment to evaporate and condense copper vapor, the invention uses chemical reduction reactions in aqueous solution to directly form copper particles. This substitution eliminates complex vacuum equipment while maintaining control over particle size and shape through chemical parameters such as reducing agent type, stabilizer concentration, and reaction temperature
Solution Approach 2:
The invention introduces stabilizers (such as polyvinyl alcohol, gelatin, or surfactants) as intermediary substances that mediate the formation of copper particles during reduction. These stabilizers adsorb onto particle surfaces, controlling growth kinetics and preventing aggregation, thereby enabling precise control of particle size and shape without requiring complex vacuum equipment or processes
3Ease of manufacture
If mechanical pulverization method is used, then copper particles can be produced, but the equipment cost is low, however yield is low and particle size/shape cannot be controlled
Solution Approach 1:
The invention maintains ease of manufacture by using simple aqueous solution chemistry with common equipment (reactors, stirrers, filtration systems). The process uses readily available copper compounds (sulfate, chloride, nitrate) and reducing agents (sodium borohydride, hydrazine, ascorbic acid) in controlled molar ratios. By optimizing parameters such as reducing agent to copper compound ratio (0.5-2.0), stabilizer concentration (0.1-5.0 wt%), and reaction temperature (20-100°C), the invention achieves high yield (90% or more) while keeping equipment requirements simple and cost-effective
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
This method enables easy control of copper particle size and shape, improving packing characteristics and resulting in a copper paste with increased bonding strength, suitable for industrial applications.
Implementation Method 1
In the heating step, a mixture of the copper compound, the salt of the main group metal, and the polyhydric alcohol is heated
Implementation Method 2
a copper compound, a salt of a main group metal, and a polyhydric alcohol are prepared... a mixture of the copper compound, the salt of the main group metal, and the polyhydric alcohol is heated
Data Source
AI summary
A method for producing copper particles includes a preparation step and a heating step. In the preparation step, a copper compound, a salt of a main group metal, and a polyhydric alcohol are prepared. In the heating step, a mixture of the copper compound, the salt of the main group metal, and the polyhydric alcohol is heated. Preferably, the main group metal is at least one selected from the group consisting of lithium, beryllium, sodium, magnesium, aluminum, potassium, calcium, zinc, gallium, germanium, rubidium, strontium, cadmium, indium, tin, antimony, cesium, and barium.