Curable Composites for Stable Contact Resistance
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Solution Overview
Problem
Existing electrically conductive materials used in electronic devices and solar cells are vulnerable to environmental conditions such as heat and humidity, leading to increased contact resistance due to electrochemical corrosion, especially when noble metals like silver are used, and there is a need for formulations that provide stable and low contact resistance without relying on corrosion inhibitors or using excessive amounts of them.
Innovation Solution
A curable composition comprising curable resins, composite particles with an electrically conductive core and shell made from materials like metal carbides, metal sulfides, and metal nitrides, and additional electrically conductive particles, which form stable bonds between substrates even under harsh conditions, reducing the need for corrosion inhibitors and maintaining low contact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If noble metals such as silver are used in electrically conductive materials, then electrical conductivity is improved, but contact resistance increases substantially over time due to electrochemical corrosion in the presence of moisture and heat
Solution Approach 1:
The patent introduces a corrosion inhibitor as an intermediary substance that mediates between the noble metal particles and the corrosive environment. The corrosion inhibitor forms a protective barrier that prevents direct contact between moisture/heat and the silver particles, thereby reducing electrochemical corrosion while maintaining electrical conductivity. This resolves the contradiction by adding a protective layer that shields the conductive material from harmful environmental factors.
Solution Approach 2:
The patent creates a composite electrically conductive material consisting of multiple components: noble metal particles (for conductivity), corrosion inhibitors (for protection), and resin matrices (for structural support). This composite structure combines the advantages of each component - the noble metals provide low contact resistance, the corrosion inhibitors prevent degradation, and the resin provides mechanical stability. The composite approach allows the material to maintain reliable electrical contact over time despite exposure to harsh environments.
2Reliability
If corrosion inhibitors are used to reduce electrochemical corrosion, then stability of contact resistance is improved, but chemical or physical properties of the electrically conductive material are affected
Solution Approach 1:
The patent carefully controls the concentration and type of corrosion inhibitors to optimize their protective effect while minimizing impact on electrical properties. By adjusting parameters such as inhibitor concentration, particle size distribution, and resin composition, the patent achieves a balance where corrosion protection is effective but electrical conductivity and other key properties are preserved. This parameter optimization resolves the contradiction by finding the right balance point where protection is sufficient without compromising performance.
3Reliability
If electrically conductive materials are exposed to harsh environmental conditions such as heat and humidity, then durability is reduced, but maintaining low contact resistance requires protection from these conditions
Solution Approach 1:
The patent incorporates corrosion inhibitors and protective resin matrices beforehand to cushion against future environmental damage. These protective components are built into the material structure during manufacturing, creating a pre-defensive system that activates when exposed to heat and humidity. The corrosion inhibitors are positioned to intercept corrosive substances before they can reach the conductive particles, providing advance protection that maintains durability and contact resistance stability over time.
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 curable composition achieves stable and low contact resistance over time, even in harsh environments, effectively bonding substrates like aluminum without the use of excessive corrosion inhibitors, thereby enhancing the durability and performance of electronic devices and solar cells.
Implementation Method 1
one or more curable resins
Implementation Method 2
electrically conductive core, and ii) an electrically conductive shell
Data Source
AI summary
The present invention relates to curable compositions that are suitable for use as electrically conductive materials in the fabrication of electronic devices, integrated circuits, semiconductor devices, passive components, solar cells, solar modules, and/or light emitting diodes. The curable compositions comprise a) one or more curable resins; b) composite particles, which comprise i) an electrically conductive core, and ii) an electrically conductive shell, comprising one or more shell materials each selected from the group consisting of metal carbides, metal sulfides, metal borides, metal silicides, and metal nitrides; and c) electrically conductive particles different from component b). The present invention further relates to a method of bonding a first substrate to a second substrate, wherein the substrates are bonded under heat and pressure using said curable composition.