Transferable Conductive Composition for Precise Pattern Transfer
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Solution Overview
Problem
Existing methods for applying conductive patterns to substrates, such as solar cells, face challenges in achieving high precision, uniformity, and efficiency, particularly when the patterns need to be transferred from a separate transfer membrane and require additional steps like sintering to become conductive.
Innovation Solution
A transferable composition comprising a swellable polymer, swelling agent, and decorative or functional particles, including electrically conductive particles, is used to form a pattern on a transfer membrane, which is then transferred to a substrate, with the swelling agent swelling the polymer to disperse the particles effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional conductive compositions are used for direct patterning on substrates, then the conductive pattern can be formed, but the precision and uniformity of the pattern are insufficient
Solution Approach 1:
The patterning process is divided into two independent stages: (1) forming the conductive pattern on a separate transfer membrane with high precision, and (2) transferring the pattern to the substrate. This segmentation allows each stage to be optimized independently, achieving high precision without compromising manufacturing ease.
Solution Approach 2:
A transfer membrane is introduced as an intermediary carrier between the patterning process and the substrate. The conductive composition is first applied to the transfer membrane to form a precise pattern, then the entire pattern is transferred to the substrate in one step, solving both precision and manufacturing complexity issues.
2Reliability
If transferable compositions with polymers are used to enable pattern transfer, then the pattern can be transferred to substrates, but polymer residue remains on the substrate reducing electrical efficacy
Solution Approach 1:
The polymer binder is selectively removed from the transferred pattern through extraction processes such as washing or chemical treatment. This removes the harmful polymer residue that reduces electrical efficacy while preserving the conductive particle structure and pattern integrity.
Solution Approach 2:
The chemical or physical parameters of the polymer binder are changed to enable its selective removal. For example, using polymers that are soluble in specific washing solutions or that can be decomposed under controlled conditions, allowing the polymer to be removed without affecting the conductive particles.
3Strength
If higher amounts of polymer are used in transferable compositions, then the mechanical and transferable properties are improved, but the polymer residue increases reducing electrical efficacy
Solution Approach 1:
The polymer binder is selectively extracted from the transferred pattern through washing or chemical treatment processes. This removes the polymer residue that reduces electrical efficacy while preserving the conductive particle structure, allowing the use of sufficient polymer for mechanical strength without compromising electrical performance.
Solution Approach 2:
The polymer distribution is optimized locally: sufficient polymer is present during the transfer process to ensure mechanical integrity and pattern fidelity, but the polymer is selectively removed from the final pattern on the substrate, creating different polymer concentrations at different stages and locations in the process.
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 composition allows for precise, uniform, and efficient transfer of conductive patterns to substrates, enhancing the conductivity and reducing residual material on the transfer membrane, thereby improving the efficiency of solar cells and other conductive applications.
Implementation Method 1
the swelling agent is capable of swelling the swellable polymer so as to form a premix of a swollen polymer
Implementation Method 2
the particles were generally sintered to render the transferred pattern conductive
Data Source
AI summary
There is disclosed a transferable composition being applicable to a membrane serving to transfer a pattern of the composition to an intended substrate. The transferable composition comprises a swellable polymer swelled by a swelling agent and particles dispersed therein. Methods of preparing the composition, applying it to a transfer membrane as a pattern, and transferring the pattern to a substrate, as well as articles made thereby, are also provided. The transferred patterns may serve a decorative and/or functional purpose and the transferable compositions may accordingly include decorative and/or functional particles. When the functional particles are or can be rendered electrically conductive, a pattern formed therewith can be part of a conductive circuit and can serve, for example, for the manufacturing of a solar cell.