Transparent Conductive Coatings Using Aliphatic Isocyanate Polyurethane
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Solution Overview
Problem
Conventional methods for producing transparent conductors face challenges such as high costs, complexity, poor adhesion, brittleness, and spectral uniformity issues, particularly with materials like ITO, which are expensive and difficult to apply to large substrates.
Innovation Solution
The use of aliphatic isocyanate-based polyurethane components in transparent conductive coatings, combined with conductive components and solvents, to form a binder precursor and dispersion that are applied to substrates, resulting in coatings with improved transparency, conductivity, and stability, and strong adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional dry processes (PVD, CVD) are used to form transparent conductive films, then good transparency and conductivity are achieved, but the cost increases and device complexity increases
Solution Approach 1:
The patent replaces complex mechanical vacuum deposition systems (PVD/CVD) with a simple solution-based coating process. The transparent conductive coating is applied as a liquid solution containing conductive particles suspended in a solvent, which is then dried to form the conductive film. This substitution eliminates the need for expensive vacuum chambers and complex deposition equipment while maintaining good transparency and conductivity.
Solution Approach 2:
The patent uses inexpensive conductive particles (such as metal oxides, conductive polymers, or carbon-based materials) suspended in a simple solvent solution. These materials are far cheaper than the ITO or other expensive materials deposited by conventional PVD/CVD methods. The solution can be easily prepared and applied, making the overall process cost-effective.
2Reliability
If conventional dry processes are used for transparent conductive films, then good transparency and conductivity are achieved, but productivity decreases
Solution Approach 1:
The patent replaces time-consuming vacuum deposition processes with a rapid solution-based coating method. The liquid solution can be applied quickly to large substrates using simple techniques such as dip-coating, spray-coating, or roll-coating, followed by rapid solvent evaporation. This dramatically increases production speed and throughput compared to conventional PVD/CVD methods.
Solution Approach 2:
The solution-based coating process allows for continuous processing of substrates. Multiple substrates can be coated in sequence without the need to break vacuum or reconfigure equipment, enabling continuous production and significantly improving productivity.
3Ease of manufacture
If conventional wet processes are used to form conductive coatings, then application is simplified, but adhesion to substrates deteriorates
Solution Approach 1:
The patent uses a composite coating formulation consisting of conductive particles dispersed in a polymer binder solution. The polymer binder (such as polyvinyl alcohol, polyacrylonitrile, or other water-soluble polymers) provides strong adhesion to the substrate, while the conductive particles provide the electrical conductivity. This composite approach combines the advantages of both simple application and strong adhesion.
Solution Approach 2:
The polymer binder acts as an intermediary between the conductive particles and the substrate. It adheres to the substrate surface and provides anchoring points for the conductive particles, ensuring strong overall adhesion of the conductive coating to the substrate while maintaining application simplicity.
4Reliability
If metal oxide materials are used in conventional methods, then conductivity is achieved, but brittleness increases
Solution Approach 1:
The patent creates a flexible composite coating by combining conductive particles (metal oxides, conductive polymers, or carbon materials) with a flexible polymer binder matrix. The polymer matrix provides mechanical flexibility and toughness, while the conductive particles dispersed within provide electrical conductivity. This composite structure eliminates the brittleness of pure metal oxide coatings while maintaining conductivity.
Solution Approach 2:
The patent changes the physical state and composition of the conductive coating from pure crystalline metal oxides (which are brittle) to a composite system with conductive particles embedded in a flexible polymer matrix. This parameter change in material composition and structure transforms the mechanical properties from brittle to flexible while preserving electrical conductivity.
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 solution provides cost-efficient transparent conductors with enhanced transparency, conductivity, and mechanical stability, suitable for various applications, including flexible displays, while maintaining flexibility and adhesion to substrates.
Implementation Method 1
The first solvent is at least partially evaporated from the binder precursor such that the binder remains on the surface of the substrate. The second solvent is at least partially evaporated from the dispersion
Data Source
AI summary
Transparent conductors and methods for fabricating transparent conductors are provided. In one exemplary embodiment, a transparent conductor comprises a substrate having a surface and a transparent conductive coating disposed on the surface of the substrate. The transparent conductive coating has a plurality of conductive components of at least one type and an aliphatic isocyanate-based polyurethane component.