NIR Curing Conductive Inks on Heat-Sensitive Substrates
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Solution Overview
Problem
Current curing techniques for electrical conductors on delicate substrates are either time-consuming or damaging due to high temperatures, making it challenging to achieve fast and effective curing without compromising the substrate.
Innovation Solution
Exposing an electrically conductive composition on a substrate to near-infrared (NIR) light to form an electrical conductor, which provides rapid curing and improved electrical properties without damaging heat-sensitive substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional box-oven curing is used, then complete curing of conductive composition is achieved, but the process is time-consuming (up to one hour)
Solution Approach 1:
The patent replaces the conventional thermal box-oven curing system with a photonic flash curing system. The flash lamp emits intense light that cures the conductive composition through photopolymerization or photothermal effects, achieving complete curing in seconds rather than hours. This substitution of the curing mechanism fundamentally resolves the time-consuming nature of box-oven curing while maintaining curing effectiveness.
Solution Approach 2:
The patent employs a flash lamp that delivers curing energy in a brief, intense periodic pulse rather than continuous low-intensity heating. This periodic action concentrates the curing effect into a short time window, achieving complete curing in seconds to minutes while avoiding the prolonged exposure times required by conventional methods.
2Productivity
If IR drying/curing is used to speed up the process, then curing time is reduced, but substrate temperature increases intensely which can damage delicate substrates
Solution Approach 1:
The patent applies curing energy locally and selectively to the conductive composition rather than heating the entire substrate uniformly. The flash lamp targets specifically the ink layer, inducing rapid curing through photonic interaction with the resin components, while the substrate experiences minimal thermal load. This localized curing approach enables fast processing without damaging heat-sensitive substrates.
Solution Approach 2:
The patent changes the fundamental parameter of energy delivery from continuous thermal heating (IR) to intense pulsed photonic radiation. This parameter change allows the curing process to occur on a different timescale and through a different mechanism, achieving rapid curing while controlling the thermal profile to protect the substrate from excessive temperature rise.
3Speed
If photonic flash curing is used, then fast curing is achieved, but it cannot be used alone for high solvent based systems due to incomplete solvent evaporation
Solution Approach 1:
The patent merges two curing approaches into a hybrid process: photonic flash curing followed by brief thermal assistance. The flash lamp performs the primary curing action rapidly, and then mild thermal energy is applied to complete solvent evaporation. This combination leverages the speed advantage of photonic curing while ensuring complete solvent removal through thermal assistance, making the process suitable for high-solvent formulations.
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 NIR curing technique allows for a fast and effective curing process that maintains optimal electrical properties while minimizing exposure to high temperatures, thus protecting delicate substrates.
Implementation Method 1
exposing said electrically conductive composition on the substrate to a near infrared (NIR) light to form an electrically conductive pathway
Data Source
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AI summary
The present invention relates to a process of forming electrical conductor on a substrate comprising the steps of a) providing a substrate; b) providing an electrically conductive composition; c) applying said electrically conductive composition to at least one part of said substrate; and d) exposing said electrically conductive composition on the substrate to a near infrared light to form an electrical conductor. NIR light cure provides improved electrical properties of the cured composition without damaging heat sensitive substrates.