Low-Temperature Curable Conductive Polymer for Solar Cells
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Solution Overview
Problem
Conventional electrically conductive polymeric compositions require high temperatures for curing, which is problematic for applications like solar cells that need to maintain low processing temperatures to avoid degrading heat-sensitive materials and ensure efficient electrical conductivity.
Innovation Solution
Development of a curable conductive polymeric composition using core-shell conductive particles and a curable polymer capable of being cured at 250°C or less, allowing for the formation of electrically conductive layers and bus bars in solar cells without damaging the passivation layer or compromising electrical conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high temperature firing is used to form conductive compositions, then electrical conductivity is improved, but heat-sensitive materials are degraded
Solution Approach 1:
The patent changes the curing temperature parameter from conventional high temperatures (>700°C) to low temperatures (≤250°C) by using a novel curable polymer composition with core-shell conductive particles, enabling the formation of electrically conductive layers without degrading heat-sensitive materials while maintaining acceptable electrical conductivity
Solution Approach 2:
The patent uses a composite material system consisting of core-shell conductive particles embedded in a curable polymer matrix, where the core provides electrical conductivity and the shell enables low-temperature curing, combining the benefits of high conductivity and thermal sensitivity preservation
2Object-affected harmful factors
If low temperature curing is used, then heat-sensitive materials are preserved, but electrical conductivity deteriorates
Solution Approach 1:
The patent employs a composite structure with conductive metal cores providing electrical pathways and polymer shells enabling low-temperature curing, achieving a balance where the metal cores maintain conductivity even at low curing temperatures while the polymer matrix provides structural integrity
Solution Approach 2:
The patent applies local quality by having the core-shell particles distributed throughout the polymer matrix, where the conductive cores are concentrated in specific regions to create conductive pathways, while the polymer shell provides the curing functionality, creating localized conductive networks that achieve overall electrical conductivity
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 formation of high-efficiency solar cells with improved back surface field coverage and reduced contact resistance, preserving the integrity of heat-sensitive materials and achieving efficient electrical conductivity at lower temperatures.
Implementation Method 1
an effective amount of a curable polymer composition capable of being cured at 250° C. or less
Implementation Method 2
electrically conductive particles, the particles comprising a core and a shell
Data Source
AI summary
Electrically conductive polymeric compositions adapted for use in forming electronic devices are disclosed. The compositions are thermally curable at temperatures less than about 250° C. Compositions are provided which may be solvent-free and so can be used in processing or manufacturing operations without solvent recovery concerns. Core-shell conductive particles provide the conductivity of the compositions and devices contemplated herein.