Print-Based Metal Wire Transparent Electrode Manufacturing
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Solution Overview
Problem
The high cost and mechanical instability of indium tin oxide (ITO) transparent electrodes, which are expensive to produce and prone to shattering under external stress, limit their widespread adoption in applications like LCDs and solar cells.
Innovation Solution
A method for manufacturing transparent electrodes using print-based metal wires, where metal wires are formed in specific patterns on synthetic resin or glass substrates and coated with a solution-type transparent electrode, enabling mass production at a lower cost and improved mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ITO is used as transparent electrode material, then high electrical conductivity and transmittance are achieved, but manufacturing cost increases significantly
Solution Approach 1:
The patent changes the material parameter from expensive ITO to cheaper metal paste, and changes the deposition method parameter from vacuum deposition to printing/coating techniques, thereby reducing manufacturing cost while maintaining electrical conductivity through optimized metal wire patterns
Solution Approach 2:
The patent creates a composite structure combining metal wires (for conductivity) with transparent substrates (for transmittance), replacing the homogeneous ITO material. This composite approach allows separate optimization of conductivity and transmittance functions while reducing material cost
2Reliability
If ITO is coated on plastic film, then transparent electrode is formed, but mechanical stability deteriorates under external stress
Solution Approach 1:
The patent uses flexible printing and coating techniques to create metal wire patterns directly on the substrate surface, forming a structure that can bend and deform with the plastic film without shattering like rigid ITO coatings
Solution Approach 2:
The patent divides the continuous ITO coating into discrete metal wire segments arranged in patterns, which can independently accommodate mechanical stress and deformation, preventing catastrophic failure under external impact
3Manufacturing precision
If ITO thin film is formed by vacuum deposition, then transparent electrode is manufactured, but manufacturing complexity and cost increase
Solution Approach 1:
The patent replaces the complex vacuum deposition mechanical system with simpler printing and coating techniques that can be performed in atmospheric conditions, eliminating the need for expensive vacuum equipment while achieving acceptable film uniformity through process optimization
Solution Approach 2:
The patent employs inexpensive printing and coating processes that do not require expensive, complex vacuum deposition equipment, thereby simplifying the manufacturing system and reducing capital investment while achieving functional equivalence
4Reliability
If ITO is used on plastic substrate, then transparent electrode is formed, but electrical characteristics change due to thermal expansion mismatch
Solution Approach 1:
The patent changes the electrode material from rigid ITO to flexible metal wire patterns that can thermally expand and contract with the plastic substrate, matching the thermal expansion parameters and preventing electrical characteristic degradation
Data Source
AI summary
A method for manufacturing a transparent electrode using a print-based metal wire is provided, which enables the mass production of the transparent electrode as a substitute for ITO at low cost. The manufacturing method includes: the first step of forming a metal wire in a pattern set for a transparent substrate; and the second step of coating a solution type transparent electrode on the transparent substrate.