Nickel Conductive Ink with Polyester Binder
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Solution Overview
Problem
Current nickel conductive inks have high sheet resistance and are costly, with existing suppliers limited due to the high cost of silver inks and the difficulty in producing nickel inks with low oxidation and corrosion resistance, as well as challenges in achieving high conductivity at lower curing temperatures and in thicker coatings.
Innovation Solution
A conductive ink comprising a nickel component, a polycarboxylic acid component, and a polyol component that react to form a polyester, optionally including additives like graphene, graphite, or dimer diamine, to enhance conductivity and printability, with a method of dispersing nickel in a polyol and polycarboxylic acid to form a conductive film with improved properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If nickel inks are used as a cheaper alternative to silver inks, then cost is reduced, but sheet resistance becomes too high (5-300 Ohm/sq/mil)
Solution Approach 1:
The patent combines nickel particles with carbon materials (graphene, carbon nanotubes, or graphite) to create a composite conductive ink. This composite structure allows the nickel component to provide corrosion resistance while the carbon component enhances electrical conductivity, achieving sheet resistance below 1.5 Ohm/sq/mil at room temperature without requiring high curing temperatures.
2Quantity of substance
If copper inks are used to reduce cost, then cost is reduced, but oxidation and corrosion resistance deteriorates
Solution Approach 1:
The patent uses nickel, which is cheaper than silver and provides inherent corrosion and oxidation resistance. The nickel particles serve as a durable, long-lasting component that maintains electrical conductivity and resistance to environmental degradation without requiring protective coatings or frequent replacement.
3Reliability
If nano Ni inks are cured at temperatures above 300 °C to achieve high conductivity, then sheet resistance is reduced, but manufacturing complexity and cost increase
Solution Approach 1:
The patent changes the curing temperature parameter from above 300°C to below 150°C (preferably room temperature). This is achieved by incorporating carbon materials that maintain conductivity at lower temperatures and by optimizing the nickel particle morphology and distribution. The carbon component (graphene, carbon nanotubes, or graphite) provides a conductive network that functions effectively at room temperature, eliminating the need for high-temperature curing processes.
4Adaptability or versatility
If existing Ni inks are used, then availability is improved, but conductivity remains insufficient for thick coatings and low curing temperatures
Solution Approach 1:
The patent creates a composite ink formulation combining nickel particles with carbon materials (graphene, carbon nanotubes, or graphite) and binds them with polyester resin. This composite structure provides a dual-conductive network where both nickel and carbon contribute to electrical conductivity, enabling thick coatings to achieve sheet resistance below 1.5 Ohm/sq/mil at room temperature without requiring high curing temperatures or specialized manufacturing processes.
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 solution achieves a significant reduction in sheet resistance to below 1.5 Ohm/sq/mil, improved adhesion, and the ability to be cured at lower temperatures, making it suitable for various applications including energy storage devices and electromagnetic shielding, while being cost-effective and environmentally friendly.
Implementation Method 1
a polycarboxylic acid component, and a polyol component, the polycarboxylic acid component and the polyol component being reactable to form a polyester component
Data Source
Figure 1A~1B
AI summary
A conductive ink may include a nickel component, a polycarboxylic acid component, and a polyol component, the polycarboxylic acid component and the polyol component being reactable to form a polyester component. The polyester component may be formed in situ in the conductive ink from a polyol component and a polycarboxylic acid component. The conductive ink may include a carbon component. The conductive ink may include an additive component. The conductive ink may include nickel flakes, graphene flakes, glutaric acid, and ethylene glycol. The conductive ink may be printed (e.g., screen printed) on a substrate and cured to form a conductive film. A conductive film may include a nickel component and a polyester component.