Room Temperature Printing of Conductive Inorganic Thin Layers
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Solution Overview
Problem
Existing methods for producing electrotechnical thin layers, such as those used in thin-layer heaters, face challenges including lengthy physical drying processes, high-temperature requirements, and material degradation, which hinder efficient industrial-scale production at room temperature with sufficient conductivity and stability.
Innovation Solution
A method involving the use of electrically conductive and semiconductive inorganic agglomerates in a dispersion, cured at room temperature with a reagent to form a stable, conductive thin layer, utilizing a predominantly aqueous carbon suspension with microscale graphite and metal powders, and accelerated by UV exposure or reductive deposition to create a solderable, printable metal layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If physical drying is used to produce electrotechnical thin layers, then the process is simple, but the production time is very long
Solution Approach 1:
The patent changes the curing parameters from high temperature to room temperature, and introduces chemical acceleration through reagents. This allows the dispersion to cure rapidly at ambient conditions rather than requiring lengthy thermal drying, thus resolving the contradiction between process simplicity and production speed
Solution Approach 2:
The patent introduces curing reagents as intermediaries that accelerate the transformation of the dispersion into a solid layer. These reagents mediate the curing process, enabling rapid room-temperature curing without requiring prolonged heating, thus improving productivity while maintaining ease of manufacture
2Reliability
If high temperature carbonization is used to produce graphite films, then the conductivity is sufficient, but the energy consumption is large
Solution Approach 1:
The patent fundamentally changes the temperature parameter from high temperature (1800°C) to room temperature. By using chemically accelerated curing with reagents, the dispersion achieves sufficient conductivity without requiring energy-intensive high-temperature carbonization, thus resolving the contradiction between reliability and energy consumption
Solution Approach 2:
The patent replaces the thermal field (high temperature heating) with a chemical field (reagent-induced curing). This substitution eliminates the need for energy-consuming thermal processing while achieving the desired conductivity through chemical transformation at room temperature
3Stability of the object's composition
If waterglass is used in the dispersion, then the layer forms a stable matrix, but the electrodes are attacked by the aggressive waterglass
Solution Approach 1:
The patent extracts or removes the harmful waterglass component from the dispersion formulation. By eliminating waterglass, the patent prevents electrode attack while still achieving layer stability through alternative means, thus resolving the contradiction between stability and harmful effects
Solution Approach 2:
The patent converts the potential harm of waterglass by removing it entirely, replacing it with benign aqueous components. This eliminates the harmful effect on electrodes while maintaining the beneficial matrix-forming function through alternative materials, resolving the contradiction between stability and corrosion resistance
4Reliability
If thick layers are used to protect electrodes from waterglass attack, then the electrode thickness increases, but the overall device complexity increases
Solution Approach 1:
The patent removes the harmful waterglass from the dispersion, eliminating the need for thick protective electrode layers. This extraction of the harmful component allows thin electrodes to be used while maintaining protection, thus reducing device complexity while preserving reliability
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
Enables rapid, cost-effective production of electrotechnical thin layers with high conductivity and stability, suitable for various applications, including thin-layer heaters, with production costs as low as 1 to 10 Euros per square meter, and allows for flexible, scalable manufacturing without the need for high temperatures or organic solvents.
Implementation Method 1
curing is conducted at room temperature and the curing is accelerated by contacting with at least one reagent
Implementation Method 2
the curing is accelerated by UV exposure or reductive deposition
Implementation Method 3
the curing is accelerated by UV exposure or reductive deposition to create a solderable, printable metal layer
Data Source
AI summary
Electrotechnical thin layers usable as heating resistance and/or substrate for conductor layers are produced at high cost and extremely slowly in the established methods. Industrial-scale methods that provide sufficient speed at room temperature are not available.This problem is solved by a room temperature printing process, wherein a redox-reactively deposited, graphite-containing base layer printed at room temperature is obtained, onto which a metal, by redox reaction during print, forms a metal layer in the micrometer scale within minutes to a few seconds in a corresponding manner.The double layer thus obtainable in one printing process is highly flexible, allows soldering to copper layers, and can be used particularly advantageously as a thin-layer heater.