CN103337300B - 一种利用外电场驱动填充的透明薄膜镶嵌电路制造方法 - Google Patents
一种利用外电场驱动填充的透明薄膜镶嵌电路制造方法 Download PDFInfo
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Abstract
一种利用外电场驱动填充的透明薄膜镶嵌电路制造方法,导电刮板上设计有注料口和出料缝隙,导电刮板既作为导电浆料的通道,又作为电极使用,然后将具有预设腔槽的透明薄膜放置在导电移动台上,导电移动台相对导电刮板做水平移动,导电浆料会从导电刮板的导电刮板出料缝隙中流出,再进行电动力学填充,在导电移动台和导电刮板之间施加电压,电动力会驱动从导电刮板中流出的导电浆料迅速向透明薄膜的腔槽内,实现快速填充,最后固化填充在透明薄膜腔槽内的浆料,固化后即可获得透明导电薄膜,本发明不仅具有填充效率高的优势,而且可以避免气泡裹入、填充不均匀等缺陷,从而提高了电路的质量和成品率。
Description
技术领域
本发明属于微制造技术领域,具体涉及一种利用外电场驱动填充的透明导电薄膜镶嵌电路制造方法。
背景技术
向微米乃至纳米尺寸的腔体中填充液相或高流变性材料,一般用真空填充或常温常压下刮涂的方法实现。真空操作会增加工艺的复杂性,降低生产效率;常压下刮涂时会因腔体分布、材料粘度、刮涂方向等因素导致液体材料在腔体内填充的深度不均匀、有气泡裹入等缺陷。为了减小这种缺陷往往需要降低刮涂速度,但刮涂速度的降低减小了大面积制造的生产效率。
近年来兴起了一种触摸显示屏技术。触摸屏的制造需要用到大量的透明导电薄膜,即含有电路的透明薄膜。传统的透明导电薄膜电路制造方法是在透明薄膜基材表面制作导电箔式电路,例如利用镀膜和刻蚀工艺制作氧化铟锡ITO电路等。但电路易于产生裂纹或从薄膜基材表面剥落,尤其是在柔性显示器件中更为严重。另外一类技术则是利用刮涂的方法,将导电浆料(含各种低维导电材料的液相或高流变性复合物)以刮挤方式填充到透明薄膜的预制腔槽内,再进行后续的固化、烧结和抛光等,最终在透明薄膜基材上形成镶嵌的电路。这种镶嵌在透明薄膜中的电路不易氧化、开裂或掉落,且具有导电率高、透明度好等优点,尤其适用于柔性触摸显示屏。这种刮涂填充的方法和形成的电路具有成本低、工艺简单、环境友好等特点。然而,大面积刮涂填充时,为了减少填充深度不均匀、气泡裹入等引起的缺陷,往往要降低刮涂的移动速度,因而降低了生产效率,且难于保证大面积基材表面上镶嵌电路的质量。
发明内容
为了克服现有技术的缺点,本发明提出了一种利用外电场驱动填充机理在透明薄膜上制作镶嵌电路的方法,利用电动流体力学原理,在电场力和刮板的驱动下,可将各种液相的导电浆料(例如由各种低维纳米材料混合而成的液相或高流变性复合物)快速、均匀地填充到微米尺度乃至纳米尺度的透明薄膜预制腔槽中;其中,微米或纳米尺度预制腔槽的制作可以采用各种商业化的压印技术来实现;导电浆料的填充效果不受腔槽的开口形状、走向、深度和刮板移动方向的影响,可在很大程度上提高透明导电薄膜的生产效率、大面积范围的质量和一致性。
为了达到上述目的,本发明采取的技术方案为:
一种利用外电场驱动填充的透明薄膜镶嵌电路制造方法,包括以下步骤:
1)采用导电刮板1,导电刮板1上设计有注料口和出料缝隙,导电刮板1即作为导电浆料2的通道,又作为电极使用,
2)连续供料,将具有预设腔槽的透明薄膜3放置在导电移动台4上,导电移动台4相对导电刮板1做水平移动,移动速度在0.1mm/min~1m/min,移动过程中导电浆料2会从导电刮板1的导电刮板出料缝隙中流出,
3)电动力学填充,在导电移动台4和导电刮板1之间施加电压,使得导电刮板1和导电移动台4之间的平均电场强度在50V/mm~5KV/mm之间,电压为直流或低频交流,如果采用低频交流电压,则其频率为1K Hz以内,电压所产生的电动力会驱动从导电刮板1中流出的导电浆料2迅速向透明薄膜3的腔槽内,实现快速填充,
4)固化填充在透明薄膜腔槽内的浆料,根据所使用浆料的材料性质不同,采用不同的固化方式,固化方式包括加热固化、紫外光照固化和挥发固化,固化后即可获得透明导电薄膜,如果必要,还要进行后续的烧结处理和泡光处理工艺。
本发明可适应广泛的液相或高流变性导电浆料,包括由各种低维纳米材料(例如纳米金属颗粒和纳米线或、碳纳米管、石墨烯等)合成的水质悬浮液或有机浆料。利用电动流体力学原理,将这类功能性的液相材料填充到透明薄膜的预制腔槽内,不仅具有填充效率高的优势,而且可以避免气泡裹入、填充不均匀等缺陷,从而提高了电路的质量和成品率。
附图说明
图1是电场力驱动的填充原理图,图中的标号1为导电刮板,2为导电浆料、3为具有预制腔槽的透明薄膜、4为导电移动台。
图2是电场力驱动的填充装置示意图。
图3是电场力驱动填充提高效率的对比图。
图4是电场力驱动填充实现各向同性均匀填充的对比图。
具体实施方式
下面结合附图对本发明做进一步详细说明。
一种利用外电场驱动填充的透明导电薄膜制造方法,包括以下步骤:
1)制作导电刮板1,参照图1和图2,导电刮板1内设计有注料口和出料缝隙,导电刮板即作为导电浆料2的通道,又作为电极使用,
2)连续供料,参照附图2,将具有预设腔槽的透明薄膜3放置在导电移动台4上,导电移动台4相对导电刮板1做水平移动,移动速度在0.1mm/min~1m/min,移动过程中导电浆料2会从导电刮板1的供料槽的长条形出料缝隙中流出,
3)电动力学填充,参照附图2,在导电移动台4和导电刮板1之间施加适当电压,使得导电刮板和导电移动台面间的平均电场强度在50V/mm~5KV/mm之间,电压为直流或低频交流,取决于所使用的导电浆料电气特性,如果采用低频交流电压,则其频率为1K Hz以内,电压所产生的电动力会驱动从导电刮板1中流出的导电浆料2迅速向透明薄膜3的腔槽内,实现快速填充,
4)固化填充在透明薄膜腔槽内的浆料,根据所使用浆料的材料性质不同,采用不同的固化方式,固化方式包括加热固化、紫外光照固化和挥发固化等,固化后即可获得透明导电薄膜,如果必要,还要进行后续的烧结处理和泡光处理工艺。
下面结合实施例对本发明做详细描述。
实施例一
为了展示电场力刮涂方法在填充效率和填充效果上的优越性,本实施例使用了紫外光固化导电材料,将紫外光固化的导电材料填充到透明薄膜的腔槽内,然后利用紫外光照进行固化,固化后将其从凹槽内剥离出来,通过观察剥离出的微结构完整性,来评价外电场驱动填充的优越性。图3是外电场提高填充效率的对比图。图3a是传统刮涂方法(即不适加电压时)获得的填充结果,图3b是在施加电压200V的情况下得到的结果。两者的刮涂速度均为0.5mm/min。对比可知,施加电压时,液体材料更容易填充到模具腔体中去。
实施例二
由于实际透明薄膜腔槽的走向多变,利用传统刮涂方法填充时,不同走向的腔槽内填充结果往往会有不同。如图4a所示,利用传统刮涂填充方法,当腔槽相互垂直时,与刮涂方向平行的腔槽更容易被填充,而与刮涂方向垂直的腔槽内往往会有气泡陷入。如图4b所示,利用本发明的外电场驱动填充,相互垂直的腔槽均可被完全填充。在实际的工业实施中,为了避免气泡陷入,传统的刮涂工艺往往需要降低刮板的刮涂速度,这将大大影响生产效率。本发明引入了外电场产生的电动力学效应,可以在很大程度上避免气泡陷入的缺陷,允许以更高的刮涂速度移动刮板,从而提高生产效率。
Claims (1)
1.一种利用外电场驱动填充的透明薄膜镶嵌电路制造方法,其特征在于:
1)采用导电刮板(1),导电刮板(1)上设计有注料口和出料缝隙,导电刮板(1)既作为导电浆料(2)的通道,又作为电极使用,
2)连续供料,将具有预设腔槽的透明薄膜(3)放置在导电移动台(4)上,导电移动台(4)相对导电刮板(1)做水平移动,移动速度在0.1mm/min~1m/min,移动过程中导电浆料(2)会从导电刮板(1)的导电刮板出料缝隙中流出,
3)电动力学填充,在导电移动台(4)和导电刮板(1)之间施加电压,使得导电刮板(1)和导电移动台(4)之间的平均电场强度在50V/mm~5KV/mm之间,电压为直流或低频交流,如果采用低频交流电压,则其频率为1K Hz以内,电压所产生的电动力会驱动从导电刮板(1)中流出的导电浆料(2)迅速向透明薄膜(3)的腔槽内,实现快速填充,
4)固化填充在透明薄膜腔槽内的浆料,根据所使用浆料的材料性质不同,采用不同的固化方式,固化方式包括加热固化、紫外光照固化和挥发固化,固化后获得透明导电薄膜,如果必要,还要进行后续的烧结处理和泡光处理工艺。
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