In Situ Sintering of Conductive Ink via Sintering Inducing Agent
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current three-dimensional printing techniques face challenges in effectively sintering conductive ink during the additive manufacturing of three-dimensional objects, particularly in achieving consistent conductivity and structural integrity of conductive elements within the printed layers.
Innovation Solution
The method involves dispensing conductive ink on top of a modeling material layer that includes a sintering inducing agent, which can be either curable or non-curable, allowing for in situ sintering of the conductive ink, either before or after the modeling material is cured, to enhance conductivity and structural integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional three-dimensional printing techniques are used to deposit conductive ink, then the conductive ink can be deposited on the printed layers, but the conductivity of the conductive elements is insufficient and structural integrity is compromised
Solution Approach 1:
A sintering inducing agent is incorporated into the modeling material before printing. This agent is activated after conductive ink deposition to initiate in-situ sintering, thereby preliminarily preparing the material structure to enable effective sintering without requiring complex external equipment
Solution Approach 2:
A sintering inducing agent acts as an intermediary substance between the conductive ink particles and the heating process. This agent facilitates the sintering reaction by lowering the sintering temperature and enabling particle bonding through chemical interaction, thereby improving conductivity without direct high-temperature processing
2Reliability
If high temperature sintering is applied to improve conductivity, then the conductivity increases, but the modeling material structure may be damaged or deformed
Solution Approach 1:
The sintering process parameters are fundamentally changed by incorporating a sintering inducing agent that enables low-temperature sintering. This chemical modification allows sintering to occur at temperatures compatible with the modeling material's thermal stability, thereby achieving high conductivity while preserving structural integrity
Solution Approach 2:
The conventional mechanical/thermal sintering process is replaced with a chemically-assisted sintering mechanism. The sintering inducing agent provides a chemical pathway for particle bonding that occurs at lower temperatures than traditional sintering, thereby avoiding thermal damage to the printed structure
3Reliability
If conductive ink is deposited without a sintering inducing agent, then the printing process is simpler, but the conductivity improvement is minimal
Solution Approach 1:
The sintering inducing agent is merged with the modeling material to create a composite printing material. This integration allows the sintering function to be built into the material itself rather than requiring separate processing steps or additional equipment, thereby achieving enhanced conductivity with minimal system complexity
Solution Approach 2:
The modeling material serves multiple functions: it provides the structural framework of the printed object and simultaneously contains the sintering inducing agent that enables conductive ink sintering. This multi-functionality eliminates the need for separate sintering aids or complex processing equipment
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 approach significantly improves the conductivity of the printed conductive elements by several orders of magnitude, ensuring robust and functional electrical connections within the three-dimensional objects.
Implementation Method 1
a sintering inducing agent, which allows for in situ sintering of the conductive ink
Implementation Method 2
the modeling material is curable... at least partially drying the conductive ink following the dispensing of the conductive ink
Data Source
Figure 1A
Figure 1B
Figure 2~3
AI summary
A method of manufacturing a conductive element is disclosed. The method being executed by an additive manufacturing system and comprises: dispensing a modeling material on a receiving medium to form a layer, and dispensing a conductive ink on the layer of modeling material to form a conductive element. In some embodiments of the invention the modeling material comprises a sintering inducing agent, and in some embodiments of the present invention a sintering inducing composition is dispensed separately from the modeling material and separately from the conductive ink.