Two-Step Pressurization for Conductive Pattern Densification
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Solution Overview
Problem
Conventional methods for forming conductive patterns in printed electronics often result in voids due to the removal of dispersion agents, leading to reduced conductivity and strength, and require significant heating energy for densification, either during or after the burning process.
Innovation Solution
A two-step pressurization method where the precursor is first pressurized at a lower force to remove the dispersion medium and then at a higher force to achieve densification, reducing the need for excessive heating energy and minimizing pattern disturbance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pressurization is performed after burning to assist densification, then densification is improved, but a large amount of heating energy is needed to heat the burned conductive member again to a melting level
Solution Approach 1:
The patent applies preliminary pressurization to the precursor before burning occurs. By pressurizing the precursor while it is still in a relatively soft state (before complete burning and sintering), the metal particles are pre-positioned and pre-densified. This preliminary action eliminates the need for subsequent high-energy heating to achieve densification, as the particles are already in optimal contact positions after the initial burn.
Solution Approach 2:
The patent replaces the thermal-mechanical process (heating to melting level followed by pressurization) with a primarily mechanical process (pressurization of precursor). Instead of using thermal energy to soften and densify the burned material, the invention uses mechanical pressurization on the unburned or partially burned precursor, substituting thermal energy consumption with mechanical work.
2Manufacturing precision
If a large amount of heating energy is applied to dry the dispersion medium before burning, then drying is improved, but it is difficult to perform the burning and reliably dry the dispersion medium due to energy variations
Solution Approach 1:
The patent applies preliminary pressurization to the precursor before burning to remove excess dispersion medium and improve drying efficiency. By pressurizing the precursor, the dispersion medium is forced out more effectively, creating a more uniformly distributed precursor layer that dries more completely and uniformly during the subsequent burning process.
Solution Approach 2:
The patent changes the physical state and distribution parameters of the precursor through pressurization. By applying pressure, the precursor's density and dispersion medium distribution are modified, creating optimal conditions for subsequent drying and burning. This parameter change enables more reliable and complete drying with reduced energy input.
3Reliability
If the dispersion agent is removed to allow metal particles to contact each other, then conductivity is improved, but voids are produced that lower denseness, conductivity and strength
Solution Approach 1:
The patent applies preliminary pressurization to the precursor before burning to pre-densify the metal particle arrangement. This preliminary action ensures that when the dispersion agent is removed and particles contact each other during burning, they are already in optimal contact positions, minimizing void formation and maximizing both conductivity and denseness.
Solution Approach 2:
The patent changes the physical state of the precursor through pressurization, transforming it from a loose dispersion to a pre-densified structure. This parameter change in density and particle arrangement before burning ensures that subsequent removal of the dispersion agent creates minimal voids, as particles are already closely packed.
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 effectively densifies the conductive particles without requiring large amounts of heating energy, ensuring sufficient conductivity and strength while minimizing pattern disruption.
Implementation Method 1
a first pressurization step of pressurizing the precursor heated to a burning temperature or above; and a second pressurization step of pressurizing, after the first pressurization step, the precursor with a pressurization force higher than a pressurization force in the first pressurization step
Implementation Method 2
the precursor heated to a burning temperature or above
Data Source
AI summary
There is provided a burning method of burning, on a base member, a precursor in which conductive particles are dispersed in a dispersion medium, and the burning method includes: a first pressurization step of pressurizing the precursor heated to a burning temperature or above; and a second pressurization step of pressurizing, after the first pressurization step, the precursor with a pressurization force higher than a pressurization force in the first pressurization step.