Hybrid Metal Pattern Manufacturing via Wire Explosion and Light-Sintering
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Solution Overview
Problem
Existing methods for manufacturing conductive ink using metal nanoparticles face challenges such as particle oxidation, agglomeration, and high energy requirements, leading to unsuitable particle sizes and low conductivity, especially when using wire explosion methods in gas or liquid environments.
Innovation Solution
A method involving a wire explosion apparatus with adjusted anode-cathode gaps, using a metal wire and dispersant in a solvent to form conductive hybrid ink, which is then printed and light-sintered, controlling particle sizes and preventing agglomeration through specific voltage and dispersant conditions, and optionally adding carbon nanotubes or graphene oxide to enhance dispersion and connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If wire explosion method is performed in gas environment, then particle production is achieved, but particles are easily oxidized and may be deposited
Solution Approach 1:
The patent performs wire explosion in an inert gas environment (such as nitrogen or argon) instead of air to prevent oxidation of metal particles. The inert atmosphere displaces oxygen, eliminating the harmful oxidation effect while maintaining particle production capability.
2Object-affected harmful factors
If wire explosion method is performed in liquid environment, then particle oxidation is reduced, but particles still agglomerate requiring additional dispersion process
Solution Approach 1:
The patent introduces a dispersant as an intermediary substance during the wire explosion process in liquid environment. The dispersant adsorbs onto particle surfaces, providing steric or electrostatic repulsion that prevents agglomeration, thereby eliminating the need for additional dispersion processes.
3Reliability
If particle size is reduced to nano-scale, then conductivity is improved, but sintering energy requirement increases
Solution Approach 1:
The patent employs light-sintering technology that uses optical energy (laser or flash lamp) instead of conventional thermal heating. This changes the sintering parameter from thermal conduction to photothermal conversion, enabling rapid localized heating that reduces total energy consumption while achieving nano-particle sintering.
4Strength
If conventional sintering is used, then particle bonding is achieved, but pores form between particles reducing conductivity
Solution Approach 1:
The patent replaces conventional thermal sintering with light-sintering technology that uses intense pulsed light or laser. This substitution enables rapid heating and cooling cycles that fuse particles together while minimizing pore formation, achieving both strong bonding and high 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
This method produces hybrid metal patterns with excellent conductivity and reduced sintering energy requirements, allowing for efficient mass production of conductive ink with uniform particle sizes, minimizing oxidation and agglomeration, and achieving high-density, flexible, and conductive patterns on large-area, bendable substrates.
Implementation Method 1
forming metal particles from the metal wire by wire explosion performed by applying a voltage between the anode and the cathode
Implementation Method 2
light-sintering the hybrid metal pattern
Data Source
AI summary
The inventive concepts relate to a method of manufacturing a hybrid metal pattern and a hybrid metal pattern manufactured thereby. In the method, the hybrid metal pattern may be manufactured on a substrate (e.g., a flexible substrate), formed of various materials, at room temperature without damaging the substrate, by a wire explosion method in liquid and light-sintering. In more detail, when performing the wire explosion method in liquid according to conditions of the inventive concepts, metal particles having uniform nano-sizes and uniform micro-sizes can be formed by a simple process, and additional dispersing and collecting processes can be omitted. In addition, conductive hybrid ink is formed by adding a metal precursor and then is light-sintered. In this case, the hybrid metal pattern can be manufactured by a very simple process.