Copper ink

This application is a National Entry of International Application PCT/162018/055727 filed Jul. 31, 2018, and claims the benefit of United States Provisional Application U.S. Ser. No. 62/539,610 filed Aug. 1, 2017.

This application relates to printing inks, particularly to printing inks for printed electronics.

Low price, high conductivity and oxidation resistance are important targets for inks in printed electronics. Gold and silver are expensive but stable, i.e. resistant to oxidation. Compared to gold and silver, copper is cheaper and has a similar conductivity; however, the similar conductivity is often not achieved via printing and the copper is prone to oxidation, which reduces conductivity over time. The main types of copper inks used are metal nanoparticle-based inks, metal-organic decomposition (MOD) inks, copper flake inks and silver-coated copper flake inks.

Nanoparticle-based copper inks are generally expensive but are easily oxidized and require sintering at very high temperatures and or need laser/flash light sintering. Inexpensive versions (e.g. Novacentrix™) only screen print well on cardboard and must be photo-sintered. To prevent oxidation, bimetallic Ag—Cu nanoparticle inks have been proposed; but, such inks are still relatively expensive.

MOD inks enable thermal sintering at lower temperature but expensive copper precursors such as copper formate are typically used. Also, MOD inks are not typically viscous, which precludes screen printing. Corrosion caused by strong acid vapor i.e. formic acid and poor conductivity due to low metal content are other limitations often seen with Cu MOD inks. The main advantage of MOD inks over conventional flake/nanoparticle inks is that MOD compounds allow smooth films at low temperature sintering and produce high resolution features. However, MOD inks are mixtures of expensive metal salts, e.g. copper formate, and organic components, where copper loading in the ink formulation is low and can result in lower electrical conductivities of printed traces. Also, the slow reactivity of copper traces to atmospheric oxygen (i.e. oxidation) results in a decrease in conductivity of traces overtime.

Therefore, there is need for a low cost, high conductivity and oxidation resistant screen-printable ink that can be thermally and/or photo-sintered to produce conducting traces. Low cost copper inks that are screen-printable on plastic and can be photo-sintered or thermally sintered would have immediate commercial value.

In one aspect, there is provided a copper-based ink comprising copper hydroxide and diethanolamine.

In another aspect, there is provided a method of producing a conductive copper coating on a substrate, the method comprising: coating a substrate with a copper-based ink comprising copper hydroxide and diethanolamine; and, decomposing the ink on the substrate to form a conductive copper coating on the substrate.

Advantageously, the ink is low cost and is capable of being formulated for screen printing applications. Micron-thick traces of the ink may be screen printed and thermally sintered in the presence of up to about 500 ppm of oxygen or photo-sintered in air to produce highly conductive copper features. Sintered copper traces produced from the ink have improved air stability compared to traces produced from other copper inks. The sintered copper traces have good adhesion strength. Copper nanoparticles and/or silver salts may be included to further increase conductivity and/or oxidation resistance of sintered copper traces, and/or to further enhance screen printability of the ink. Sintered copper traces having sheet resistivity of about 20 mΩ/□/mil or less may be obtained for 5-20 mil wide screen-printed lines with excellent resolution.

Further features will be described or will become apparent in the course of the following detailed description. It should be understood that each feature described herein may be utilized in any combination with any one or more of the other described features, and that each feature does not necessarily rely on the presence of another feature except where evident to one of skill in the art.

For clearer understanding, preferred embodiments will now be described in detail by way of example, with reference to the accompanying drawings, in which:

FIG. 1 depicts thermograms of various inks comprising copper hydroxide monohydrate (Cu(OH) 2 .H 2 O) and diethanolamine.

FIG. 2 depicts thermograms of an ink comprising copper hydroxide monohydrate (Cu(OH) 2 .H 2 O) and diethanolamine as a function of storage time.

FIG. 3 depicts a graph of resistance (Ω) vs. substrate temperature (° C.) for tape cast traces (5 μm thick, 10 cm long) on a Kapton™ substrate prepared from various inks comprising copper hydroxide monohydrate (Cu(OH) 2 .H 2 O) and diethanolamine thermally sintered at different temperatures under N 2 with 500 ppm O 2 .

FIG. 4 depicts scanning electron microscopy (SEM) (top) and energy dispersive spectroscopy (EDS) (bottom) analyses of a copper film (5 μm thick, 1 cm 2 area) on a Kapton™ substrate prepared using a copper ink comprising Cu(OH) 2 .H 2 O and diethanolamine (1:3).

FIG. 5 depicts scanning electron microscopy (SEM) (top) and energy dispersive spectroscopy (EDS) (bottom) analyses of a copper film (5 μm thick, 1 cm 2 area) prepared on a Kapton™ substrate using a copper ink comprising Cu(OH) 2 .H 2 O and diethanolamine (1:3) and copper nanoparticles (10 wt % of the Cu from Cu(OH) 2 .H 2 ).

FIG. 6 depicts scanning electron microscopy (SEM) (top) and energy dispersive spectroscopy (EDS) (bottom) analyses of a copper film (5 μm thick, 1 cm 2 area) on a Kapton™ substrate prepared using a copper ink comprising Cu(OH) 2 .H 2 O and diethanolamine (1:3) and silver nitrate (10 wt % of the Cu from Cu(OH) 2 .H 2 O).

FIG. 7 depicts scanning electron microscopy (SEM) (top) and energy dispersive spectroscopy (EDS) (bottom) analyses of a copper film (5 μm thick, 1 cm 2 area) on a Kapton™ substrate prepared using a copper ink comprising Cu(OH) 2 .H 2 O and diethanolamine (1:3) and copper nanoparticles (10 wt % of the Cu from Cu(OH) 2 .H 2 O) and silver nitrate (10 wt % of the Cu from Cu(OH) 2 .H 2 O).

The copper-based ink comprises copper hydroxide and diethanolamine. The diethanolamine (HN(CH 2 CH 2 H) 2 ) is a readily available organic compound. The copper hydroxide (Cu(OH) 2 ) is a readily available inorganic compound and may be hydrated or not hydrated. Hydrated copper hydroxide may comprise a monohydrate (Cu(OH) 2 .H 2 O), which is convenient to use and less expensive than anhydrous copper hydroxide. In the ink, copper hydroxide and diethanolamine form a complex. The copper hydroxide is preferably present in the ink in an amount that provides about 5 wt % to about 40 wt % of copper, based on total weight of the ink. The amount of copper, which the copper hydroxide provides is more preferably in a range of about 10 wt % to about 30 wt %, based on total weight of the ink. Preferably, the copper hydroxide and diethanolamine are in the ink in a molar ratio of about 1:2.5 to about 1:3.5. More preferably, the molar ratio of copper hydroxide to diethanolamine is about 1:3. Such molar ratios are particularly advantageous for improving conductivity of conductive copper traces formed from the ink.

The ink may also comprise one or more other components useful for the formulation of inks for specific purposes or for improving electrical, physical and/or mechanical properties of conductive traces formed from the ink. In various embodiments, the ink may comprise one or more of a filler, a binder, a surface tension modifier, a defoaming agent, a thixotropy modifying agent, a solvent, or any mixture thereof.

The filler, for example another metal-containing compound or a mixture of other metal-containing compounds, may be present in the ink to improve conductivity of conductive traces formed from the ink. The filler may comprise copper nanoparticles (CuNP) or a metal salt. Copper nanoparticles (CuNP) are copper particles having an average size along a longest dimension in a range of about 1-1000 nm, preferably about 1-500 nm, more preferably about 1-100 nm. The copper nanoparticles, may be flakes, nanowires, needles, substantially spherical or any other shape. The metal salt is preferably a silver or gold salt, more preferably a silver salt. The metal salt comprises one or more anions, preferably anions derived from mineral acids. The anions in the metal salts are preferably oxide, chloride, bromide, sulfate, carbonate, phosphate, acetate or nitrate. Nitrates are particularly preferred. A particularly preferred metal salt filler is silver nitrate. The filler is preferably present in the ink in an amount of up to about 40 wt %, based on weight of copper from the copper hydroxide in the ink. Preferably, the amount of filler is in a range of about 1 wt % to about 40 wt %, or about 5 wt % to about 30 wt %, or about 10 wt % to about 30 wt %, based on weight of copper from the copper hydroxide in the ink.

The binder, for example an organic polymer binder, may be present in the ink as a processing aid for particular deposition processes. The organic polymer binder may be any suitable polymer, preferably a thermoplastic or elastomeric polymer. Some non-limiting examples of binders are cellulosic polymers, polyacrylates, polystyrenes, polyolefins, polyvinylpyrrolidone, polypyrrolidone, polyvinyl acetals, polyesters, polyimides, polyether imides, polyols, silicones, polyurethanes, epoxy resins, phenolic resins, phenol formaldehyde resins, styrene allyl alcohols, polyalkylene carbonates, fluoroplastics, fluoroelastomers, thermoplastic elastomers and mixtures thereof. The organic polymer binder may be homopolymeric or copolymeric. A particularly preferred binder comprises a polyester, polyimide, polyether imide or any mixture thereof. The polymeric binder preferably comprises a polyester. Suitable polyesters are commercially available or may be manufactured by the condensation of poly alcohols with poly carboxylic acid and respectively their anhydrides. Preferred polyesters are hydroxyl and/or carboxyl functionalized. The polyester may be linear or branched. Solid or liquid polyesters as well as diverse solution forms may be utilized. In a particularly preferred embodiment, the polymeric binder comprises a hydroxyl- and/or carboxyl-terminated polyester, for example Rokrapol™ 7075. The polymeric binder may be present in the ink in any suitable amount. The organic polymer binder may be present in the ink in any suitable amount, preferably in a range of about 0.05 wt % to about 10 wt %, based on total weight of the ink. More preferably, the amount is in a range of about 0.05 wt % to about 5 wt %, or about 0.2 wt % to about 2 wt %, or about 0.2 wt % to about 1 wt %. In one embodiment, the polymeric binder is present in the ink in an amount of about 0.02-0.8 wt %, more preferably about 0.05-0.6 wt %.

The surface tension modifier may be any suitable additive that improves flow and leveling properties of the ink. Some non-limiting examples are surfactants (e.g. cationic or anionic surfactants), alcohols (e.g. propanol), glycolic acid, lactic acid and mixtures thereof. The surface tension modifier may be present in the ink in any suitable amount, preferably in a range of about 0.1 wt % to about 5 wt %, based on total weight of the ink. More preferably, the amount is in a range of about 0.5 wt % to about 4 wt %, or about 0.8 wt % to about 3 wt %. In one especially preferred embodiment, the amount is in a range of about 1 wt % to about 2.7 wt %.

The defoaming agent may be any suitable anti-foaming additive. Some non-limiting examples are fluorosilicones, mineral oils, vegetable oils, polysiloxanes, ester waxes, fatty alcohols, glycerol, stearates, silicones, polypropylene based polyethers and mixtures thereof. Glycerol and polypropylene based polyethers are particularly preferred. In the absence of the defoaming agent, some printed traces may tend to retain air bubbles following printing, resulting in nonuniform traces. The defoaming agent may be present in the ink in any suitable amount, preferably in a range of about 0.0001 wt % to about 3 wt %, based on total weight of the ink. More preferably, the amount is in a range of about 0.005 wt % to about 2 wt %.

The thixotropy modifying agent may be any suitable thixotropy-modifying additive. Some non-limiting examples are polyhydroxycarboxylic acid amides, polyurethanes, acrylic polymers, latex, polyvinylalcohol, styrene/butadiene, clay, clay derivatives, sulfonates, guar, xanthan, cellulose, locust gum, acacia gum, saccharides, saccharide derivatives, cassein, collagen, modified castor oils, organosilicones and mixtures thereof. The thixotropy modifying agent may be present in the ink in any suitable amount, preferably in a range of about 0.05 wt % to about 1 wt %, based on total weight of the ink. More preferably, the amount is in a range of about 0.1 wt % to about 0.8 wt %. In one especially preferred embodiment, the amount is in a range of about 0.2 wt % to about 0.5 wt %.

The solvent may be an aqueous solvent or an organic solvent. In some instances, a mixture of one or more organic solvents with an aqueous solvent may be utilized. Aqueous solvents include, for example, water and solutions, dispersions or suspension of compounds in water. The organic solvent may be aromatic, non-aromatic or a mixture of aromatic and non-aromatic solvents. Aromatic solvents include, for example, benzene, toluene, ethylbenzene, xylenes, chlorobenzene, benzyl ether, anisole, benzonitrile, pyridine, diethylbenzene, propylbenzene, cumene, isobutylbenzene, p-cymene, tetralin, trimethylbenzenes (e.g. mesitylene), durene, p-cumene or any mixture thereof. Non-aromatic solvents include, for example, terpenes, glycol ethers (e.g. dipropylene glycol methyl ether, methylcarbitol, ethylcarbitol, butylcarbitol, triethyleneglycol and derivatives thereof), alcohols (e.g. methyicyclohexanois, octanois, heptanols) or any mixture thereof. Dipropylene glycol methyl ether is preferred. The solvent may be present in the ink in any suitable amount, preferably in a range of about 1 wt % to about 50 wt %, based on total weight of the ink. More preferably, the amount is in a range of about 2 wt % to about 35 wt %, or about 5 wt % to about 25 wt %. The solvent generally makes up the balance of the ink.

The ink may be formulated by mixing the components together in a mixer. Generally, any mixing process is suitable. However, planetary centrifugal mixing (e.g. in a Thinky™ mixer) is particularly useful. Mixing time may have some impact on the electrical properties of conductive traces formed from the ink. Properly mixing the ink ensures good electrical properties of the conductive traces. The mixing time is preferably about 25 minutes or less, or about 20 minutes or less, or about 15 minutes or less. The mixing time is preferably about 1 minute or more, or about 5 minutes or more.

Prior to decomposition, the ink is deposited on a substrate to coat the substrate. Suitable substrates may include, for example polyethylene terephthalate (PET) (e.g. Melinex™), polyolefin (e.g. silica-filled polyolefin (Teslin™)), polydimethylsiloxane (PDMS), polystyrene, acrylonitrile/butadiene/styrene, polycarbonate, polyimide (e.g. Kapton™), polyetherimide (e.g. Ultem™), thermoplastic polyurethane (TPU), silicone membranes, printed wiring board substrate (e.g. FR4), wool, silk, cotton, flax, jute, modal, bamboo, nylon, polyester, acrylic, aramid, spandex, polylactide, paper, glass, metal, dielectric coatings, among others.

The ink may be coated on the substrate by any suitable method, for example printing. Printing methods may include, for example, screen printing, stenciling, inkjet printing, flexography printing, gravure printing, off-set printing, stamp printing, airbrushing, aerosol printing, typesetting, or any other method. It is an advantage of the process that an additive method such as screen printing or stenciling are particularly useful. For printed electronic devices, the ink may be coated on the substrate as traces.

After coating the substrate with the ink, the ink on the substrate may be dried and decomposed to form a copper metal coating on the substrate. Drying and decomposition may be accomplished by any suitable technique, where the techniques and conditions are guided by the type of substrate and the particular composition of the ink. For example, drying and decomposing the ink may be accomplished by heating and/or photonic sintering.

In one technique, heating the substrate dries and sinters the ink coating to form metallic copper. Heating may be performed at a temperature of about 100° C. or higher, about 140° C. or higher, or about 165° C. or higher, or about 180° C. or higher, while producing conductive copper coatings that have good oxidation stability. The temperature may be in a range of about 140° C. to about 300° C., or about 150° C. to about 280° C., or about 160° C. to about 270° C., or about 180° C. to about 250° C. Heating is preferably performed for a time in a range of about 1-180 minutes, for example 5-120 minutes, or 5-90 minutes. Heating may be performed in stages to first dry the ink coating and then sinter the dried coating. Drying may be performed at any suitable temperature, for example at a temperature in a range of about 100° C. to about 150° C. Drying may be performed for any suitable length of time, for example about 1-180 minutes, or 5-90 minutes, or 10-45 minutes. Sintering is performed at a sufficient balance between temperature and time to sinter the ink to form conductive copper coatings. Drying and/or sintering may be performed with the substrate under an inert atmosphere (e.g. nitrogen and/or argon gas). However, improved air stability of the ink permits sintering in the presence of oxygen, for example in an atmosphere comprising up to about 500 ppm of oxygen. The type of heating apparatus also factors into the temperature and time required for drying and sintering.

In another technique, the ink coating may be dried with heat and then photonically sintered. Drying may be performed at any suitable temperature, for example at a temperature in a range of about 100° C. to about 150° C. Drying may be performed for any suitable length of time, for example about 1-180 minutes, or 5-90 minutes, or 10-45 minutes. A photonic sintering system may feature a high intensity lamp (e.g. a pulsed xenon lamp) that delivers a broadband spectrum of light. The lamp may deliver about 5-30 J/cm 2 in energy to the traces. Pulse widths are preferably in a range of about 0.58-1.5 ms. Photonic sintering nay be performed in air, or in an inert atmosphere. Laser sintering may be utilized, if desired. Photonic sintering is especially suited when polyethylene terephthalate or polyimide substrates are used.

A sintered copper coating formed from the ink may have a sheet resistivity of about 20 mΩ/□/mil or less, even about 15 mΩ/□/mil or less, for 5-20 mil wide screen-printed lines. Further, line resolution is excellent with changes in line width after sintering for 5-20 mil wide screen-printed lines of less than about 17%, or less than about 10%, or less than about 5%, or less than about 2.5%. Even when line widths are as low as about 5 mil, the change in line width after sintering may be less than about 17%, even less than about 5%, or even less than about 2.5%. Furthermore, the sintered copper coatings formed from the ink may be flexible, being able to pass the ASTM F1683-02 flex & crease test without any open circuit breaks (i.e. without open fails). A change in resistivity (R) of 20% or less is considered to be a pass in the ASTM F1683-02 flex & crease test. Open circuit breaks are defined as a total loss in conductivity (i.e. infinite resistivity).

The substrate having sintered copper coatings thereon may be incorporated into an electronic device, for example electrical circuits (e.g. printed circuit boards (PCBs), conductive bus bars (e.g. for photovoltaic cells), sensors (e.g. touch sensors, wearable sensors), antennae (e.g. RFID antennae), thin film transistors, diodes, smart packaging (e.g. smart drug packaging), conformable inserts in equipment and/or vehicles, and multilayer circuits and MIM devices including low pass filters, frequency selective surfaces, transistors and antenna on conformable surfaces that can withstand high temperatures.