WO2006090245A2 - Ink jet printable compositions for preparing electronic devices and patterns - Google Patents

Ink jet printable compositions for preparing electronic devices and patterns Download PDF

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Publication number
WO2006090245A2
WO2006090245A2 PCT/IB2006/000364 IB2006000364W WO2006090245A2 WO 2006090245 A2 WO2006090245 A2 WO 2006090245A2 IB 2006000364 W IB2006000364 W IB 2006000364W WO 2006090245 A2 WO2006090245 A2 WO 2006090245A2
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WO
WIPO (PCT)
Prior art keywords
composition according
composition
ink jet
metal powder
viscosity
Prior art date
Application number
PCT/IB2006/000364
Other languages
French (fr)
Other versions
WO2006090245A3 (en
Inventor
Fernando De La Vega
Claudio Rottman
Original Assignee
Cima Nano Tech Israel Ltd
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Filing date
Publication date
Application filed by Cima Nano Tech Israel Ltd filed Critical Cima Nano Tech Israel Ltd
Priority to JP2007556675A priority Critical patent/JP2008535940A/en
Priority to EP06710431A priority patent/EP1858992A4/en
Priority to US11/816,990 priority patent/US20090053400A1/en
Publication of WO2006090245A2 publication Critical patent/WO2006090245A2/en
Publication of WO2006090245A3 publication Critical patent/WO2006090245A3/en
Priority to IL185404A priority patent/IL185404A0/en

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Classifications

    • H—ELECTRICITY
    • H04—ELECTRIC COMMUNICATION TECHNIQUE
    • H04N—PICTORIAL COMMUNICATION, e.g. TELEVISION
    • H04N21/00—Selective content distribution, e.g. interactive television or video on demand [VOD]
    • H04N21/40—Client devices specifically adapted for the reception of or interaction with content, e.g. set-top-box [STB]; Operations thereof
    • H04N21/43—Processing of content or additional data, e.g. demultiplexing additional data from a digital video stream; Elementary client operations, e.g. monitoring of home network or synchronising decoder's clock; Client middleware
    • H04N21/431—Generation of visual interfaces for content selection or interaction; Content or additional data rendering
    • H04N21/4312—Generation of visual interfaces for content selection or interaction; Content or additional data rendering involving specific graphical features, e.g. screen layout, special fonts or colors, blinking icons, highlights or animations
    • H04N21/4316—Generation of visual interfaces for content selection or interaction; Content or additional data rendering involving specific graphical features, e.g. screen layout, special fonts or colors, blinking icons, highlights or animations for displaying supplemental content in a region of the screen, e.g. an advertisement in a separate window
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D11/00—Inks
    • C09D11/30—Inkjet printing inks
    • C09D11/32—Inkjet printing inks characterised by colouring agents
    • C09D11/322—Pigment inks
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
    • H01B1/20—Conductive material dispersed in non-conductive organic material
    • H01B1/22—Conductive material dispersed in non-conductive organic material the conductive material comprising metals or alloys
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
    • H01B1/20—Conductive material dispersed in non-conductive organic material
    • H01B1/24—Conductive material dispersed in non-conductive organic material the conductive material comprising carbon-silicon compounds, carbon or silicon
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01C—RESISTORS
    • H01C17/00—Apparatus or processes specially adapted for manufacturing resistors
    • H01C17/06—Apparatus or processes specially adapted for manufacturing resistors adapted for coating resistive material on a base
    • H01C17/065—Apparatus or processes specially adapted for manufacturing resistors adapted for coating resistive material on a base by thick film techniques, e.g. serigraphy
    • H01C17/06506—Precursor compositions therefor, e.g. pastes, inks, glass frits
    • H01C17/06513—Precursor compositions therefor, e.g. pastes, inks, glass frits characterised by the resistive component
    • H01C17/06526—Precursor compositions therefor, e.g. pastes, inks, glass frits characterised by the resistive component composed of metals
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
    • H01G4/00—Fixed capacitors; Processes of their manufacture
    • H01G4/002—Details
    • H01G4/018—Dielectrics
    • H01G4/06—Solid dielectrics
    • H01G4/08—Inorganic dielectrics
    • H—ELECTRICITY
    • H04—ELECTRIC COMMUNICATION TECHNIQUE
    • H04N—PICTORIAL COMMUNICATION, e.g. TELEVISION
    • H04N21/00—Selective content distribution, e.g. interactive television or video on demand [VOD]
    • H04N21/40—Client devices specifically adapted for the reception of or interaction with content, e.g. set-top-box [STB]; Operations thereof
    • H04N21/43—Processing of content or additional data, e.g. demultiplexing additional data from a digital video stream; Elementary client operations, e.g. monitoring of home network or synchronising decoder's clock; Client middleware
    • H04N21/435—Processing of additional data, e.g. decrypting of additional data, reconstructing software from modules extracted from the transport stream
    • H—ELECTRICITY
    • H04—ELECTRIC COMMUNICATION TECHNIQUE
    • H04N—PICTORIAL COMMUNICATION, e.g. TELEVISION
    • H04N21/00—Selective content distribution, e.g. interactive television or video on demand [VOD]
    • H04N21/40—Client devices specifically adapted for the reception of or interaction with content, e.g. set-top-box [STB]; Operations thereof
    • H04N21/43—Processing of content or additional data, e.g. demultiplexing additional data from a digital video stream; Elementary client operations, e.g. monitoring of home network or synchronising decoder's clock; Client middleware
    • H04N21/443—OS processes, e.g. booting an STB, implementing a Java virtual machine in an STB or power management in an STB
    • H04N21/4438—Window management, e.g. event handling following interaction with the user interface
    • H—ELECTRICITY
    • H04—ELECTRIC COMMUNICATION TECHNIQUE
    • H04N—PICTORIAL COMMUNICATION, e.g. TELEVISION
    • H04N21/00—Selective content distribution, e.g. interactive television or video on demand [VOD]
    • H04N21/40—Client devices specifically adapted for the reception of or interaction with content, e.g. set-top-box [STB]; Operations thereof
    • H04N21/47—End-user applications
    • H04N21/472—End-user interface for requesting content, additional data or services; End-user interface for interacting with content, e.g. for content reservation or setting reminders, for requesting event notification, for manipulating displayed content
    • H04N21/47202—End-user interface for requesting content, additional data or services; End-user interface for interacting with content, e.g. for content reservation or setting reminders, for requesting event notification, for manipulating displayed content for requesting content on demand, e.g. video on demand
    • H—ELECTRICITY
    • H04—ELECTRIC COMMUNICATION TECHNIQUE
    • H04N—PICTORIAL COMMUNICATION, e.g. TELEVISION
    • H04N21/00—Selective content distribution, e.g. interactive television or video on demand [VOD]
    • H04N21/40—Client devices specifically adapted for the reception of or interaction with content, e.g. set-top-box [STB]; Operations thereof
    • H04N21/47—End-user applications
    • H04N21/482—End-user interface for program selection
    • H04N21/4825—End-user interface for program selection using a list of items to be played back in a given order, e.g. playlists
    • H—ELECTRICITY
    • H04—ELECTRIC COMMUNICATION TECHNIQUE
    • H04N—PICTORIAL COMMUNICATION, e.g. TELEVISION
    • H04N21/00—Selective content distribution, e.g. interactive television or video on demand [VOD]
    • H04N21/80—Generation or processing of content or additional data by content creator independently of the distribution process; Content per se
    • H04N21/81—Monomedia components thereof
    • H04N21/812—Monomedia components thereof involving advertisement data
    • H—ELECTRICITY
    • H04—ELECTRIC COMMUNICATION TECHNIQUE
    • H04N—PICTORIAL COMMUNICATION, e.g. TELEVISION
    • H04N21/00—Selective content distribution, e.g. interactive television or video on demand [VOD]
    • H04N21/80—Generation or processing of content or additional data by content creator independently of the distribution process; Content per se
    • H04N21/81—Monomedia components thereof
    • H04N21/8126—Monomedia components thereof involving additional data, e.g. news, sports, stocks, weather forecasts
    • H04N21/8133—Monomedia components thereof involving additional data, e.g. news, sports, stocks, weather forecasts specifically related to the content, e.g. biography of the actors in a movie, detailed information about an article seen in a video program
    • H—ELECTRICITY
    • H04—ELECTRIC COMMUNICATION TECHNIQUE
    • H04N—PICTORIAL COMMUNICATION, e.g. TELEVISION
    • H04N21/00—Selective content distribution, e.g. interactive television or video on demand [VOD]
    • H04N21/80—Generation or processing of content or additional data by content creator independently of the distribution process; Content per se
    • H04N21/85—Assembly of content; Generation of multimedia applications
    • H04N21/854—Content authoring
    • H04N21/8545—Content authoring for generating interactive applications
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/02—Details
    • H05K1/09—Use of materials for the conductive, e.g. metallic pattern
    • H05K1/092—Dispersed materials, e.g. conductive pastes or inks
    • H05K1/097—Inks comprising nanoparticles and specially adapted for being sintered at low temperature
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2203/00—Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
    • H05K2203/01—Tools for processing; Objects used during processing
    • H05K2203/0104—Tools for processing; Objects used during processing for patterning or coating
    • H05K2203/013—Inkjet printing, e.g. for printing insulating material or resist
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00—Apparatus or processes for manufacturing printed circuits
    • H05K3/10—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern
    • H05K3/12—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern using thick film techniques, e.g. printing techniques to apply the conductive material or similar techniques for applying conductive paste or ink patterns
    • H05K3/1241—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern using thick film techniques, e.g. printing techniques to apply the conductive material or similar techniques for applying conductive paste or ink patterns by ink-jet printing or drawing by dispensing
    • H05K3/125—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern using thick film techniques, e.g. printing techniques to apply the conductive material or similar techniques for applying conductive paste or ink patterns by ink-jet printing or drawing by dispensing by ink-jet printing

Definitions

  • This invention relates to ink jet printable compositions for printing electronic devices and patterns on a substrate.
  • InkJet printing is a widely used printing technique. Inks based on nano materials are suitable for ink jetting. The particle size and viscosity of the ink influence the suitability of the ink for ink jet printing.
  • compositions of different nano materials can be ink jetted to form electronic devices and patterns on a variety of substrates.
  • the compositions can be dispersions or inks which can be composed of a nano metal for printing conductors, a mixture of a nano metal and a conductivity lowering material (i.e., a material that lowers the conductivity of the ink relative to its conductivity in the absence of the material) for printing resistors, a dielectric nano additive for printing capacitors, a semiconductor nano additive for printing transistors and other devices, and the like.
  • the conductive dispersions and inks include nano metal powders dispersed in a liquid carrier, as described in a previous application entitled "Ink Jet Printable Compositions" submitted on the 14 th of September 2004 (serial number 60/609,750), hereby incorporated by reference in its entirety.
  • the nano metal powders which are produced by the Metallurgic Chemical Process (MCP) process described herein, have special properties, enabling the dispersion and de- agglomeration of the powder in a liquid carrier (organic solvent, water, or any combination thereof), with or without additives.
  • the present compositions include these nano metal powders in combination with a conductivity lowering additive.
  • the compositions also have properties that render them ink jettable (e.g., the ability to be printed through ink jet print heads that possess small nozzles, usually in the micron range). These properties include the following: low viscosities between 1 and 200 cP (at room temperature or at jetting temperature), surface tension between 20 - 37 dyne/cm for solvent based dispersions and 30 - 60 dyne/cm for water based dispersions, loadings of metal nano particles between 1% and 70% (weight by weight), and low particle size distribution of the metal nano particles having a particle size distribution (PSD) D90 below 150 nm, preferably below 80 nm.
  • PSD particle size distribution
  • compositions have stabilities sufficient to enable jetting with minimum settling, and without clogging the print head or changing the properties of the compositions.
  • the compositions can be printed by different technologies including continuous ink jet technologies, drop on demand ink jet technologies (such as piezo and thermal) and also additional techniques like air brush, flexo, electrostatic deposition, wax hot melt, etc.
  • ink jet printable compositions that include a nano powder other than an electrically conductive metal nano powder that is dispersed in a liquid carrier.
  • the compositions have viscosities no greater than about 200 cP at ink jet printing temperatures.
  • suitable non-electrically conductive metal nano powders include dielectric nano powders, semiconducting nano powders, and the like.
  • Devices that can be prepared by ink jet printing these compositions onto a substrate include capacitors, transistors, and the like.
  • Dispersions and inks containing electrically conductive nano metal particles generally have conductivities that are too high for preparing devices such as resistors, capacitors, transistors, and the like. It is undesirable to lower the conductivity by reducing the amount of deposited electrically conductive material. This is because when the total amount of conductive material is too low, it is difficult to accurately control the amount deposited. In addition, it is also possible that not enough metal will be deposited to obtain percolation, and as a result the resistance will be infinite, rather than within a defined range.
  • the additive has an electrical conductivity that is lower than the electrical conductivity of the nano metal particle, thereby reducing the overall electrical conductivity of the composition.
  • suitable electrical conductivity lowering additives include electrically conductive carbon black, electrically conductive organic polymers, and the like.
  • the amount of the additive is selected to achieve the desired electrical conductivity for the intended application of the ink because the ratio between the highly conductive nano metal and the electrical conductivity lowering additive will determine the ultimate resistance obtained. Regardless of the application, however, the amount of electrically conductive nano metal particles is sufficient to achieve percolation.
  • a second way of addressing this problem involves dispersing a nano powder other than an electrically conductive metal nano powder in a liquid carrier.
  • the compositions have viscosities no greater than about 200 cP at ink jet printing temperatures.
  • suitable non-electrically conductive metal nano powders include dielectric nano powders, semiconducting nano powders, and the like. Specific examples include metal oxides such as antimony oxide and indium tin oxide.
  • nano metal particles examples include silver, silver-copper alloys, silver-palladium alloys, and other metals and metal alloys produced by the process described in US 5,476,535 ("Method of producing high purity ultra-fine metal powder") and PCT application WO 2004/000491 A2 ("A Method for the Production of Highly Pure Metallic Nano-Powders and Nano-Powders Produced Thereof), both of which are hereby incorporated by reference in their entirety.
  • Highly conductive dispersions and inks incorporating these nano metal particles have been described in a provisional patent application entitled "Ink Jet Printable Compositions" submitted on the 14 th of September 2004 (serial number 60/609,750) and hereby incorporated by reference entirely.
  • the dispersions can be prepared as described in the patents hereby cited or can be prepared by mixing dispersions of the separate nano additives.
  • the compositions can be printed by different technologies including continuous ink jet technologies, drop on demand ink jet technologies (such as piezo, thermal and continuous) and also additional techniques like air brush, fiexo, electrostatic deposition, wax hot melt, etc.
  • the resulting printed patterns produced hereby can be treated post printing in any suitable way to adjust their conductivity.
  • the treatments may be any of the following methods or combinations thereof: methods described in PCT applications WO 2004/005413 Al ("Low Sintering Temperatures Conductive Inks - a Nano Technology Method for Producing Same") and WO03/106573 ("A Method for the Production of Conductive and Transparent Nano-Coatings and Nano-Inks and Nano-Powder Coatings and Inks Produced Thereby"), application of radiation, microwave, light, flash light, laser sintering, applying pressure, rubbing, friction sintering, thermal heat (applied in any form, e.g. forced air oven, hot plate, etc), continuous radiation, scanned beam, pulsed beam, etc.
  • the treatment may also be a "chemical sintering method” (CSM) described in a provisional patent application No. 60/609,751 entitled “Low Temperature Sintering Process for Preparing Conductive Printed Patterns on Substrates, and Articles Based Thereon” filed September 14, 2004, and in WO 03/106573.
  • CSM chemical sintering method
  • the dispersions and inks may be printed onto a wide range of surfaces, including flexible, rigid, elastic, and ceramic surfaces. Specific examples include paper, polymer films, textiles, plastics, glass, fabrics, printed circuit boards, epoxy resins, and the like.
  • Disperbyk® 163 (available from BYK-Chemie, Wesel Germany) and 0.28 % BYK® 333 (also available from BYK-Chemie) were added to a solvent mixture of 36.11% BEA (Ethylene glycol butyl ether acetate) and 36.11% PMA (Propylene glycol mono methyl ether acetate), and stirred with a magnetic stirrer until all the additives completely dissolved. Next, 0.62% Butvar ® B-76 (available from Solutia) was added slowly. To enhance its dissolution, the addition was performed in an ultrasonic bath.
  • BEA Ethylene glycol butyl ether acetate
  • PMA Propylene glycol mono methyl ether acetate
  • the viscosity was measured with a Brookfield RVDV-II + Viscometer and found to be 3.9 cP (at 25 0 C).
  • the dispersion was used to coat a Kapton ® film (35 ⁇ m wet thickness using a wire wound rod) and sintered at 15O 0 C for 60 minutes.
  • the resistance of the resulting coating was 14.5 ⁇ /D.
  • the conductive dispersion prepared as in Example 1 was mixed with 10.00 % of conductive carbon ink R-4148 BGA Black (available from Degussa). Ultrasonic energy was applied to the mixture until complete de-agglomeration, as measured by the particle size distribution, occurred. Particle size distribution measurements were performed using Coulter LS laser diffraction equipment and demonstrated a D90 of 0.053 ⁇ m. The viscosity was measured with a Brookfield RVDV-II + Viscometer and found to be 5.7 cP (at 25 0 C). The dispersion was used to coat a Kapton ® film (35 ⁇ m wet thickness using a wire wound rod) and sintered at 150°C for 60 minutes. The resistance of the resulting coating was measured using a four probe method and found to be 414 ⁇ /o. The resistance of the conductive carbon ink (25% carbon) when measured under the same conditions was over 2000 ⁇ /D.
  • the conductive dispersion prepared as in Example 1 was mixed with 30.00 % of conductive carbon ink R-4148 BGA Black (available from Degussa). Ultrasonic energy was applied to the mixture until complete de-agglomeration, as measured by the particle size distribution, occurred. Particle size distribution measurements were performed using Coulter LS laser diffraction equipment and demonstrated a D90 of 0.053 ⁇ m. The viscosity was measured with a Brookfield RVDV-II + Viscometer and found to be 10.7 cP (at 25 0 C). The dispersion was used to coat a Kapton ® film (35 ⁇ m wet thickness using a wire wound rod) and sintered at 150°C for 60 minutes. The resistance of the resulting coating was measured using a four probe method and found to be 660 ⁇ / ⁇ .

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Multimedia (AREA)
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  • Microelectronics & Electronic Packaging (AREA)
  • Dispersion Chemistry (AREA)
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  • Spectroscopy & Molecular Physics (AREA)
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  • Manufacturing & Machinery (AREA)
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  • Business, Economics & Management (AREA)
  • Marketing (AREA)
  • Nanotechnology (AREA)
  • Databases & Information Systems (AREA)
  • Computer Security & Cryptography (AREA)
  • Software Systems (AREA)
  • Inks, Pencil-Leads, Or Crayons (AREA)
  • Conductive Materials (AREA)
  • Ink Jet Recording Methods And Recording Media Thereof (AREA)
  • Two-Way Televisions, Distribution Of Moving Picture Or The Like (AREA)
  • Parts Printed On Printed Circuit Boards (AREA)

Abstract

In jet printable compositions that include nano particles in a liquid carrier.

Description

INK JET PRINTABLE COMPOSITIONS FOR PREPARING ELECTRONIC
DEVICES AND PATTERNS
TECHNICAL FIELD
This invention relates to ink jet printable compositions for printing electronic devices and patterns on a substrate.
BACKGROUND
InkJet printing is a widely used printing technique. Inks based on nano materials are suitable for ink jetting. The particle size and viscosity of the ink influence the suitability of the ink for ink jet printing.
SUMMARY
We have discovered that compositions of different nano materials can be ink jetted to form electronic devices and patterns on a variety of substrates. The compositions can be dispersions or inks which can be composed of a nano metal for printing conductors, a mixture of a nano metal and a conductivity lowering material (i.e., a material that lowers the conductivity of the ink relative to its conductivity in the absence of the material) for printing resistors, a dielectric nano additive for printing capacitors, a semiconductor nano additive for printing transistors and other devices, and the like.
In one aspect, the conductive dispersions and inks include nano metal powders dispersed in a liquid carrier, as described in a previous application entitled "Ink Jet Printable Compositions" submitted on the 14th of September 2004 (serial number 60/609,750), hereby incorporated by reference in its entirety. The nano metal powders, which are produced by the Metallurgic Chemical Process (MCP) process described herein, have special properties, enabling the dispersion and de- agglomeration of the powder in a liquid carrier (organic solvent, water, or any combination thereof), with or without additives. Taking advantage of these attributes we have been able, with the MCP -produced nano metal powders, to design compositions with very low viscosities, as required for ink jet printing at high metal concentrations, by selecting appropriate combinations of the nano metal powder, liquid carrier, and, optionally, additives. The ability to combine high metal concentrations with very low viscosities makes the compositions particularly useful for ink jet printing.
The present compositions include these nano metal powders in combination with a conductivity lowering additive. The compositions also have properties that render them ink jettable (e.g., the ability to be printed through ink jet print heads that possess small nozzles, usually in the micron range). These properties include the following: low viscosities between 1 and 200 cP (at room temperature or at jetting temperature), surface tension between 20 - 37 dyne/cm for solvent based dispersions and 30 - 60 dyne/cm for water based dispersions, loadings of metal nano particles between 1% and 70% (weight by weight), and low particle size distribution of the metal nano particles having a particle size distribution (PSD) D90 below 150 nm, preferably below 80 nm. The compositions have stabilities sufficient to enable jetting with minimum settling, and without clogging the print head or changing the properties of the compositions. The compositions can be printed by different technologies including continuous ink jet technologies, drop on demand ink jet technologies (such as piezo and thermal) and also additional techniques like air brush, flexo, electrostatic deposition, wax hot melt, etc.
In a second aspect, ink jet printable compositions are described that include a nano powder other than an electrically conductive metal nano powder that is dispersed in a liquid carrier. The compositions have viscosities no greater than about 200 cP at ink jet printing temperatures. Examples of suitable non-electrically conductive metal nano powders include dielectric nano powders, semiconducting nano powders, and the like. Devices that can be prepared by ink jet printing these compositions onto a substrate include capacitors, transistors, and the like.
The details of one or more embodiments of the invention are set forth in the description below. Other features, objects, and advantages of the invention will be apparent from the description, and from the claims. DETAILED DESCRIPTION
Dispersions and inks containing electrically conductive nano metal particles generally have conductivities that are too high for preparing devices such as resistors, capacitors, transistors, and the like. It is undesirable to lower the conductivity by reducing the amount of deposited electrically conductive material. This is because when the total amount of conductive material is too low, it is difficult to accurately control the amount deposited. In addition, it is also possible that not enough metal will be deposited to obtain percolation, and as a result the resistance will be infinite, rather than within a defined range.
One way of addressing this problem is to combine highly conductive nano metal particles with an electrical conductivity lowering additive. The additive has an electrical conductivity that is lower than the electrical conductivity of the nano metal particle, thereby reducing the overall electrical conductivity of the composition. At the same time, the properties that enable the composition to be ink jet printable are retained. Examples of suitable electrical conductivity lowering additives, which or may not be in the form of nano powders, include electrically conductive carbon black, electrically conductive organic polymers, and the like. The amount of the additive is selected to achieve the desired electrical conductivity for the intended application of the ink because the ratio between the highly conductive nano metal and the electrical conductivity lowering additive will determine the ultimate resistance obtained. Regardless of the application, however, the amount of electrically conductive nano metal particles is sufficient to achieve percolation.
A second way of addressing this problem involves dispersing a nano powder other than an electrically conductive metal nano powder in a liquid carrier. The compositions have viscosities no greater than about 200 cP at ink jet printing temperatures. Examples of suitable non-electrically conductive metal nano powders include dielectric nano powders, semiconducting nano powders, and the like. Specific examples include metal oxides such as antimony oxide and indium tin oxide. Examples of suitable nano metal particles include silver, silver-copper alloys, silver-palladium alloys, and other metals and metal alloys produced by the process described in US 5,476,535 ("Method of producing high purity ultra-fine metal powder") and PCT application WO 2004/000491 A2 ("A Method for the Production of Highly Pure Metallic Nano-Powders and Nano-Powders Produced Thereof), both of which are hereby incorporated by reference in their entirety. Highly conductive dispersions and inks incorporating these nano metal particles have been described in a provisional patent application entitled "Ink Jet Printable Compositions" submitted on the 14th of September 2004 (serial number 60/609,750) and hereby incorporated by reference entirely.
The dispersions can be prepared as described in the patents hereby cited or can be prepared by mixing dispersions of the separate nano additives. The compositions can be printed by different technologies including continuous ink jet technologies, drop on demand ink jet technologies (such as piezo, thermal and continuous) and also additional techniques like air brush, fiexo, electrostatic deposition, wax hot melt, etc.
The resulting printed patterns produced hereby can be treated post printing in any suitable way to adjust their conductivity. The treatments may be any of the following methods or combinations thereof: methods described in PCT applications WO 2004/005413 Al ("Low Sintering Temperatures Conductive Inks - a Nano Technology Method for Producing Same") and WO03/106573 ("A Method for the Production of Conductive and Transparent Nano-Coatings and Nano-Inks and Nano-Powder Coatings and Inks Produced Thereby"), application of radiation, microwave, light, flash light, laser sintering, applying pressure, rubbing, friction sintering, thermal heat (applied in any form, e.g. forced air oven, hot plate, etc), continuous radiation, scanned beam, pulsed beam, etc. The treatment may also be a "chemical sintering method" (CSM) described in a provisional patent application No. 60/609,751 entitled "Low Temperature Sintering Process for Preparing Conductive Printed Patterns on Substrates, and Articles Based Thereon" filed September 14, 2004, and in WO 03/106573.
The dispersions and inks may be printed onto a wide range of surfaces, including flexible, rigid, elastic, and ceramic surfaces. Specific examples include paper, polymer films, textiles, plastics, glass, fabrics, printed circuit boards, epoxy resins, and the like.
The invention will now be described further by way of the following examples. All amounts are weight percent and are calculated based upon the weight of the final dispersion unless otherwise noted.
EXAMPLES
Example 1 (Comparative)
1.88 % Disperbyk® 163 (available from BYK-Chemie, Wesel Germany) and 0.28 % BYK® 333 (also available from BYK-Chemie) were added to a solvent mixture of 36.11% BEA (Ethylene glycol butyl ether acetate) and 36.11% PMA (Propylene glycol mono methyl ether acetate), and stirred with a magnetic stirrer until all the additives completely dissolved. Next, 0.62% Butvar®B-76 (available from Solutia) was added slowly. To enhance its dissolution, the addition was performed in an ultrasonic bath. Next, 25.0 % by weight of silver nano powder (prepared as described in US 5,476,535 and PCT application WO 2004/000491 A2) was added in portions while mixing with a magnetic stirrer. Next, an ultrasonic device, Bandelin Sonopuls Ultrasonic, was applied to the dispersion according to the following profile: 3 consecutive times at 50% for 2 min, followed by 60% for 2 min, then at 70% for 2 min and finally at 80% for 2 min (taking care to prevent the temperature from rising above 50-60°C). Particle size distribution measurements were performed by using Coulter LS laser diffraction equipment and demonstrated a D90 of 0.053 μm . The viscosity was measured with a Brookfield RVDV-II + Viscometer and found to be 3.9 cP (at 25 0C). The dispersion was used to coat a Kapton ® film (35 μm wet thickness using a wire wound rod) and sintered at 15O0C for 60 minutes. The resistance of the resulting coating, measured using a four probe method, was 14.5 Ω/D.
Example 2
The conductive dispersion prepared as in Example 1 was mixed with 10.00 % of conductive carbon ink R-4148 BGA Black (available from Degussa). Ultrasonic energy was applied to the mixture until complete de-agglomeration, as measured by the particle size distribution, occurred. Particle size distribution measurements were performed using Coulter LS laser diffraction equipment and demonstrated a D90 of 0.053 μm. The viscosity was measured with a Brookfield RVDV-II + Viscometer and found to be 5.7 cP (at 25 0C). The dispersion was used to coat a Kapton ® film (35 μm wet thickness using a wire wound rod) and sintered at 150°C for 60 minutes. The resistance of the resulting coating was measured using a four probe method and found to be 414 Ω/o. The resistance of the conductive carbon ink (25% carbon) when measured under the same conditions was over 2000 Ω/D. Example 3
The conductive dispersion prepared as in Example 1 was mixed with 30.00 % of conductive carbon ink R-4148 BGA Black (available from Degussa). Ultrasonic energy was applied to the mixture until complete de-agglomeration, as measured by the particle size distribution, occurred. Particle size distribution measurements were performed using Coulter LS laser diffraction equipment and demonstrated a D90 of 0.053 μm. The viscosity was measured with a Brookfield RVDV-II + Viscometer and found to be 10.7 cP (at 25 0C). The dispersion was used to coat a Kapton ® film (35 μm wet thickness using a wire wound rod) and sintered at 150°C for 60 minutes. The resistance of the resulting coating was measured using a four probe method and found to be 660 Ω/π.
A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims.

Claims

WHAT IS CLAIMED IS:
L A composition comprising 1 -70% by weight of a nano metal powder and 1—70% by weight of an electrical conductivity lowering additive, dispersed in a liquid carrier, wherein the composition has a viscosity no greater than about 200 cP at ink j et printing temperatures and is ink j et printable. 2. A composition according to claim 1 where the electrical conductivity lowering additive comprises carbon black. 3. A composition according to claim 1 where the electrical conductivity lowering additive comprises indium tin oxide. 4. A composition according to claim 1 where the electrical conductivity lowering additive comprises antimony tin oxide. 5. A composition according to claim 1 where the electrical conductivity lowering additive comprises a metal oxide. 6. A composition according to claim 1 where the electrical conductivity lowering additive comprises an electrically conductive organic polymer. 7. A composition according to claim 1 wherein the composition has a viscosity of 1-200 cP at ink jet printing temperatures. 8. A composition according to claim 1 wherein the composition has a viscosity of 1-100 cP at ink jet printing temperatures. 9. A composition according to claim 1 wherein the composition has a viscosity of 2-20 cP at ink jet printing temperatures. 10. A composition according to claim 1 comprising 10-60% by weight of the nano metal powder. 11. A composition according to claim 1 comprising 20-60% by weight of the nano metal powder. 12. A composition according to claim 1 comprising about 60% by weight nano metal powder and having a viscosity of about 18 cP at ink j et printing temperatures. 13. A composition according to claim 1 wherein the composition has a viscosity no greater than about 200 cP at room temperature. 14. A composition according to claim 1 wherein the composition has a viscosity of 1-200 cP at room temperature. 15. A composition according to claim 1 wherein the composition has a viscosity of 1 - 100 cP at room temperature. 16. A composition according to claim 1 wherein the composition has a viscosity of 2-20 cP at room temperature. 17. A composition according to claim 1 comprising about 60% by weight nano metal powder and having a viscosity of about 18 cP at room temperature. 18. A composition according to claim 1 wherein the liquid carrier comprises water and the composition has a surface tension of about 30-60 dynes/cm. 19. A composition according to claim 1 wherein the liquid carrier comprises an organic solvent and the composition has a surface tension of about 20-37 dynes/cm. 20. A composition according to claim 1 wherein the nano metal powder has an average particle size no greater than about 150 nm. 21. A composition according to claim 1 wherein the nano metal powder has an average particle size no greater than about 100 nm. 22. A composition according to claim 1 wherein the nano metal powder has an average particle size no greater than about 80 nm. 23. A composition according to claim 1 wherein the nano metal powder is prepared according to the MCP process. 24. A composition according to claim 1 or 14 wherein the nano metal powder comprises silver. 25. A composition according to claim 1 or 14 wherein the nano metal powder comprises a silver-copper alloy. 26. A composition according to claim 1 or 14 wherein the nano metal powder comprises non-uniform spherical particles and includes up to about 0.4% by weight aluminum. 27. A composition according to claim 1 wherein the composition is stable against particle settling. 28. A composition according to claim 1 wherein the liquid carrier comprises (a) at least one organic solvent and (b) at least one agent selected from the group consisting of surfactants, wetting agents, rheology modifying agents, adhesion promoters, humectants, binders, and combinations thereof. 29. A composition according to claim 1 wherein the liquid carrier comprises (a) water, a water-miscible organic solvent, or combination thereof and (b) at least one agent selected from the group consisting of surfactants, wetting agents, rheology modifying agents, adhesion promoters, humectants, binders, and combinations thereof. 30. A composition according to claim 1 wherein the liquid carrier comprises (a) at least one organic solvent, (b) a curable monomer, and (c) at least one agent selected from the group consisting of surfactants, wetting agents, rheology modifying agents, adhesion promoters, humectants, binders, and combinations thereof. 31. A method comprising printing the composition of claim 1 onto a substrate using an ink jet printer. 32. A method according to claim 31 wherein the ink jet printer is a continuous ink jet printer. 33. A method according to claim 31 wherein the ink jet printer is a drop on demand ink jet printer. 34. A method according to claim 31 wherein the substrate is selected from the group consisting of paper, polymer films, textiles, plastics, glass, printed circuit boards, epoxy resins, and combinations thereof. 35. A method according to claim 31 comprising sintering the composition after applying it to the substrate. 36. A composition comprising 1-70% by weight of a nano powder other than an electrically conductive nano metal powder, dispersed in a liquid carrier, wherein the composition has a viscosity no greater than about 200 cP at ink jet printing temperatures and is ink jet printable. 37. A composition according to claim 8 where the nano powder comprises a dielectric material. 38. A composition according to claim 8 where the nano powder comprises a semiconducting material.
PCT/IB2006/000364 2005-02-23 2006-02-22 Ink jet printable compositions for preparing electronic devices and patterns WO2006090245A2 (en)

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