Nano-Hybrid Conductive Paste for Low-Cost Stable Conductivity
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Solution Overview
Problem
Conventional silver pastes are expensive due to the high cost of silver and lack stability over time, while copper or nickel pastes lose conductivity, and graphene-silver pastes have compatibility issues.
Innovation Solution
Development of hybrid core-shell particles comprising a nanoparticle core of graphene-containing or dichalcogenide materials encapsulated in a conducting metal or polymer shell, offering improved conductivity, stability, and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional silver paste is used, then high electrical conductivity is achieved, but high cost and scarcity of materials occur
Solution Approach 1:
The patent uses composite materials by combining copper or nickel particles with graphene nanosheets to create a hybrid conductive paste. The copper/nickel particles provide base conductivity while the graphene nanosheets form a conductive network that enhances overall electrical conductivity, allowing silver to be partially or completely replaced while maintaining performance
Solution Approach 2:
The patent changes the material composition parameters by introducing graphene nanosheets with specific properties (high aspect ratio, controlled oxidation level) to transform the conductive mechanism from relying solely on metal particles to a hybrid system where graphene provides conductive pathways, thereby reducing silver content while maintaining conductivity
2Quantity of substance
If copper or nickel paste is used, then cost is reduced, but stability over time deteriorates
Solution Approach 1:
The patent creates a composite structure where copper or nickel particles are combined with graphene nanosheets. The graphene component provides structural stability and prevents oxidation of the copper/nickel particles, thereby maintaining temporal stability while using cheaper materials
Solution Approach 2:
The patent uses inexpensive copper or nickel particles as the base material instead of expensive silver, accepting that these materials alone would have poor stability, but then uses graphene to extend their service life and maintain performance over time
3Reliability
If graphene and silver containing paste is used, then high conductivity and stability are achieved, but compatibility issues occur
Solution Approach 1:
The patent applies local quality by using partially oxidized graphene nanosheets rather than fully oxidized ones. This partial oxidation provides optimal balance between dispersibility (for compatibility) and conductivity (for performance). The oxidation level is controlled to create specific local properties in the graphene structure
Solution Approach 2:
The patent changes the oxidation parameter of graphene nanosheets to optimize compatibility. By controlling the oxidation level rather than using fully oxidized graphene, the material achieves better compatibility with the paste formulation while maintaining sufficient conductivity and stability
Data Source
AI summary
Hybrid particles having improved electrical conductivity and thermal and chemical stabilities are disclosed. The hybrid particles are for use in conductive pastes. The hybrid particles include a nanoparticle selected from a graphene-containing material, a dichalcogenide material, a conducting polymer, or a combination thereof encapsulated in a conducting metal. The hybrid particles include a nanoparticle selected from a graphene-containing material, a dichalcogenide material, or a combination thereof encapsulated in a conducting polymer, and optionally further in a conducting metal. Suitable conducting metals include nickel or silver. Suitable conducting polymers include polyaniline, polypyrrole, or polythiophene. Suitable dichalcogenide materials include MoS2 or MoSe2. The hybrid particles can further include a conducting polymer layer on an outer surface of the conducting metal. Methods of making the hybrid particles are also disclosed.