Pulsed LED Sintering for Conductive Ink
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Solution Overview
Problem
The existing methods for manufacturing printed circuit boards, such as lithography and additive manufacturing, are time-consuming and costly, and the energy-intensive heat and laser sintering processes for conductive ink compositions with metal nanoparticles require substantial energy and long sintering times, leading to increased production costs and environmental concerns.
Innovation Solution
The use of pulsed light emitting diodes (LEDs) to sinter conductive ink compositions with metal nanoparticles, where the LEDs are configured to emit light at a wavelength corresponding to the metal nanoparticles' surface plasmon resonance peak, allowing for selective heating and rapid densification of the ink without overheating the surrounding dielectric material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heat sintering or laser sintering is used to sinter conductive ink compositions with metal nanoparticles, then the conductive ink can be sintered to form conductive patterns, but the process requires high energy and long sintering times, leading to increased production costs
Solution Approach 1:
The patent changes the wavelength parameter of the light source to match the surface plasmon resonance peak of the metal nanoparticles, enabling resonant heating that significantly reduces energy consumption and sintering time while maintaining reliable conductive pattern formation
Solution Approach 2:
The patent uses pulsed LED illumination instead of continuous illumination, applying energy in periodic pulses that accumulate heat in the metal nanoparticles through repeated cycles, achieving efficient sintering with reduced total energy input
2Reliability
If heat sintering or laser sintering is used to sinter conductive ink compositions with metal nanoparticles, then the conductive ink can be sintered to form conductive patterns, but the sintering process is time-consuming, reducing productivity
Solution Approach 1:
The patent optimizes the wavelength parameter to the surface plasmon resonance peak, which dramatically accelerates heat transfer to the metal nanoparticles, reducing sintering time from minutes to seconds and significantly improving productivity
Solution Approach 2:
The pulsed illumination method applies energy in rapid successive pulses, accumulating heat quickly in the metal nanoparticles while allowing brief cooling intervals, achieving fast sintering without overheating the surrounding dielectric material
3Reliability
If conventional sintering methods are used, then conductive ink can be sintered, but the process generates discharged solution requiring treatment, causing environmental issues and increased manufacturing costs
Solution Approach 1:
The patent replaces thermal field-based sintering with optical field-based sintering, using light at the surface plasmon resonance wavelength to directly heat and sinter metal nanoparticles without generating discharged solution, thereby eliminating environmental contamination and associated treatment costs
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
This method reduces production time and costs by enabling faster and more efficient sintering of conductive ink compositions with metal nanoparticles, using readily available energy sources and minimizing environmental impact.
Implementation Method 1
the LEDs are configured to emit light at a wavelength corresponding to the metal nanoparticles' surface plasmon resonance peak
Implementation Method 2
emitting light at a wavelength corresponding to the metal nanoparticles' average size-dependent (D2,1) surface plasmon resonance (SPR) peak wavelength
Data Source
AI summary
The disclosure relates to systems and methods for photonic sintering of conductive ink compositions with metal nanoparticles. Specifically, the disclosure relates to methods and systems for sintering ink compositions with metal nanoparticles using an illumination source comprising an array of pulsed light emitting diodes (LEDs).