Non-firing Electrode Manufacturing via Composite Paste Pressing
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Solution Overview
Problem
Existing methods for manufacturing non-firing type electrodes face challenges in achieving sufficient electrical properties while minimizing the use of conductive metal powder.
Innovation Solution
A method involving the application of a conductive paste containing a first conductive powder with high Young's modulus and a second conductive powder with lower Young's modulus, along with an organic vehicle, followed by heating and pressing to form an electrode, which reduces the consumption of the first conductive powder and enhances conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conductive paste containing only high Young's modulus conductive powder (silver powder) is used, then the electrode can achieve sufficient electrical conductivity, but the consumption of conductive metal powder increases and cost rises
Solution Approach 1:
The patent uses a composite conductive paste containing both high Young's modulus conductive powder (silver powder) and low Young's modulus conductive powder (copper powder or aluminum powder). This composite approach allows the electrode to achieve sufficient electrical conductivity while reducing the consumption of expensive silver powder, as the lower-cost metals compensate for the reduced silver content through their own conductive properties
Solution Approach 2:
The patent changes the physical and chemical parameters of the conductive paste by controlling the particle size distribution, Young's modulus ratio, and composition proportions of different conductive powders. By optimizing these parameters, the paste achieves good flowability for screen printing while maintaining sufficient electrical conductivity after heating, allowing reduced metal powder consumption without sacrificing electrical performance
2Quantity of substance
If the conductive paste contains low Young's modulus powder only, then the consumption of expensive silver powder is reduced, but the electrode cannot achieve sufficient electrical conductivity and mechanical strength
Solution Approach 1:
The patent creates a composite conductive system where high Young's modulus silver powder provides the primary conductive network and mechanical strength, while low Young's modulus copper or aluminum powder fills the gaps and provides additional conductive pathways. This synergistic composite structure achieves sufficient electrical conductivity with reduced silver content
Solution Approach 2:
The patent applies different conductive powders with different local qualities to different regions of the conductive paste. The high Young's modulus silver powder is distributed to provide structural integrity and primary conductivity, while low Young's modulus powder is distributed to fill voids and enhance conductivity in specific areas, creating a heterogeneous structure with optimized local properties
3Reliability
If heating temperature is increased to improve conductivity, then electrical properties improve, but the organic vehicle may decompose and the substrate may be damaged
Solution Approach 1:
The patent changes the chemical composition parameters of the organic vehicle by selecting resins with high thermal stability (phenoxy resin, polyurethane resin, epoxy resin) that can withstand heating temperatures up to 350°C without decomposition. This allows the heating process to reach temperatures sufficient for forming good electrical conductivity while the specially formulated organic vehicle remains stable and does not damage the substrate
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 effectively forms a non-firing type electrode with sufficient conductivity while reducing the consumption of the first conductive powder, achieving lower resistivity through controlled heating and pressing processes.
Implementation Method 1
heating the applied conductive paste at 50 to 350° C. to form an electrode
Implementation Method 2
pressing the electrode at 10 to 1000 kN/m2 of plane surface pressure or at 5 to 300 kN/m of linear pressure
Data Source
AI summary
A method of manufacturing a non-firing type electrode comprising steps of: (A) applying on a substrate a conductive paste comprising, (a) a conductive powder comprising, (i) a first conductive powder having Young's modulus of 60×109 Pa or higher; and (ii) a second conductive powder having Young's modulus of 5×109 to 50×109 Pa; and (b) an organic vehicle, (B) heating the applied conductive paste at 50 to 350° C. to form an electrode; and (C) pressing the electrode at 10 to 1000 kN/m2 of plane surface pressure or at 5 to 300 kN/m of linear pressure.