Liquid Metal Transparent Electrode Patterning Against Surface Tension

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Solution Overview

Problem

Existing methods for manufacturing transparent electrodes using liquid metal in solar cells face challenges due to surface tension issues during deposition and patterning processes, leading to damage and inefficiencies.

Innovation Solution

A method involving sequential deposition of sacrificial and protective layers, patterning, and integration of liquid metal and polymer materials to form a transparent conductive layer, minimizing surface tension effects through the use of a hydrophobic polymer layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If liquid metal is deposited using conventional solution processes, then the deposition and patterning can be performed, but droplets of liquid metal are removed by surface tension and the structure is damaged

Engineering Contradiction:

Improvedeposition and patterning processVSAvoidliquid metal structure integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent introduces a hydrophobic polymer layer as an intermediary between the liquid metal and the solution environment. This mediator prevents direct contact between the liquid metal and aqueous solutions, thereby eliminating surface tension effects that cause droplet formation and structural damage during deposition and patterning processes

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent changes the surface energy parameters of the substrate by applying a hydrophobic polymer coating. This parameter change creates a low-surface-energy environment that repels aqueous solutions and prevents capillary action, allowing liquid metal to maintain its structural integrity during subsequent processing steps

Inventive Principle:

Principle #35Parameter changes

2Illumination intensity

If the line width and pitch of liquid metal pattern are reduced to increase transparency, then transmittance increases, but manufacturing precision becomes more challenging

Engineering Contradiction:

ImprovetransmittanceVSAvoidpattern line width control

Core Design Contradiction:

Illumination intensityVSManufacturing precision

Solution Approach 1:

The patent replaces conventional mechanical lithography methods with a self-aligned patterning approach using hydrophobic domains. The pattern is defined by the hydrophobic polymer structure itself rather than mechanical masking, enabling precise sub-10 micrometer line widths without the limitations of traditional photolithography

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses a thin hydrophobic polymer film to define pattern boundaries. This flexible thin film approach allows for precise pattern formation through controlled hydrophobic domain creation, achieving high manufacturing precision for narrow line widths while maintaining flexibility in pattern design

Inventive Principle:

Principle #30Flexible shells and thin films

3Area of stationary object

If large-area transparent electrodes are manufactured using liquid metal, then the electrode area increases, but surface tension effects in solution processes become more pronounced

Engineering Contradiction:

Improveelectrode areaVSAvoidsurface tension effects

Core Design Contradiction:

Area of stationary objectVSObject-affected harmful factors

Solution Approach 1:

The hydrophobic polymer layer serves as a continuous intermediary across the entire large-area substrate, creating a solution-resistant barrier that prevents capillary action and surface tension effects throughout the large area. This mediator enables uniform liquid metal deposition and patterning across extensive surfaces without the harmful surface tension effects that plague conventional large-area processing

Inventive Principle:

Principle #24Intermediary (Mediator)

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 enables the production of a large-area transparent electrode with improved process yield, reduced damage to liquid metal, and enhanced electrochemical performance, maintaining high transparency and low sheet resistance.

Implementation Method 1

there is a problem in that droplets of liquid metal are removed by surface tension in other fluids or the structure thereof is damaged during the process

Methodology Applied

Scientific EffectSurface tension: Surface Tension

Implementation Method 2

A portion of the surface of the protective layer is exposed by removing a part of the upper sacrificial layer in a specific pattern shape

Methodology Applied

Scientific EffectChemical etching:

Data Source

PatentUS20250324808A1Method of manufacturing transparent eletrode for solar cell using liquid metal

Publication Date: 2025.10.16 HYUNDAI MOTOR CO LTD

AI summary

A method for manufacturing a transparent electrode for a solar cell includes forming sequential layers: a lower sacrificial layer, a protective layer, and an upper sacrificial layer on a substrate. The upper sacrificial layer is partially removed to expose the protective layer, and a liquid metal layer is deposited on the exposed surfaces. The metal layer remains in a specific pattern after removing the upper sacrificial layer. A polymer layer is formed around the patterned metal layer, and the protective, metal, and polymer layers are separated from the substrate by removing the lower sacrificial layer. Finally, the protective layer is removed to produce the liquid metal transparent electrode.