Substrate and negative imaging method for providing transparent conducting patterns

• US 20080264682A1
• Filed: 04/24/2007
• Published: 10/30/2008
• Est. Priority Date: 04/24/2007
• Status: Abandoned Application

• Current Assignee: E. I. du Pont de Nemours and Company (Corteva, Inc.)
• Original Assignee: E. I. du Pont de Nemours and Company (Corteva, Inc.)
• Inventors: Johnson, Lynda Kaye, Meth, Jeffrey Scott, Gao, Feng, Catron, John, Zane, Stephen G.
• Application Number:
  US11/789,222
• Publication Number:
  US 20080264682A1
• Time in Patent Office: Days
• US Class Current: 174/257
• CPC Class Codes: H01L 31/1884 Manufacture of transparent electrodes, e.g. TCO, ITO
• CPC Class Codes: H05K 2201/0108 Transparent
• CPC Class Codes: H05K 2201/0329 Intrinsically conductive polymer [ICP]; Semiconductive polymer
• CPC Class Codes: H05K 2203/0528 Patterning during transfer, i.e. without preformed pattern, e.g. by using a die, a programmed tool or a laser
• CPC Class Codes: H05K 2203/107 Using laser light shaping a substrate by laser ablation H05K3/0026
• CPC Class Codes: H05K 3/046 by selective transfer or selective detachment of a conductive layer
• CPC Class Codes: H10K 71/18 using non-liquid printing techniques, e.g. thermal transfer printing from a donor sheet
• CPC Class Codes: H10K 71/60 Forming conductive regions or layers, e.g. electrodes
• CPC Class Codes: H10K 71/621 Providing a shape to conductive layers, e.g. patterning or selective deposition
• CPC Class Codes: H10K 77/10 Substrates, e.g. flexible substrates
• CPC Class Codes: Y02E 10/549 Organic PV cells
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product

Abstract

Provided are processes for making a transparent conducting pattern. The invention is also directed to electronic devices containing such transparent conducting patterns. Further provided is a substrate comprising a base film and a transparent conducting layer disposed on the base film; wherein the substrate has an OD of about 0.1 to 0.6 at 830 nm, and the transparent conducting layer comprises polyethylene dioxythiophene and has an OD of less than 0.1 in the range of 400 to 700 nm.

Claims

1. A process for making a transparent conducting pattern comprising:

(a) providing a substrate comprising;

a base film and a transparent conducting layer disposed on the base film wherein the substrate has an OD of about 0.1 to 0.6 at 830 nm, and the transparent conducting layer has an average OD of less than 0.1 in the range of 400 to 700 nm;

(b) contacting the substrate with a receiver, wherein the receiver comprises a base film, to provide an assemblage;

(c) exposing a portion of the assemblage to an IR light beam to provide an exposed substrate having at least one exposed region, and at least one unexposed region having the transparent conducting pattern; and

an exposed receiver;

wherein a ratio of the surface electrical resistance of the exposed region and unexposed region is at least 1000;

1.

2. The process of claim 1, further comprising:

(d) separating the exposed receiver from the exposed substrate to provide a patterned substrate having the transparent conducting pattern.

3. The process of claim 1, wherein the transparent conducting layer is an organic conductor.

4. The process of claim 1, wherein the substrate has an OD of about 0.1 to 0.3 at 830 nm.

5. The process of claim 1, wherein the transparent conducting layer comprises polyethylene dioxythiophene.

6. The process of claim 1, wherein the transparent conducting layer has a thickness of less than 400 nm.

7. The process of claim 1, wherein the substrate further comprises one or more near-IR dye(s) having an absorption maximum in the range of about 600 to about 1200 nm within the donor.

8. The process of claim 7, wherein the one or more near-IR dye(s) is disposed in the transparent conducting layer.

9. The process of claim 7, wherein the substrate further comprises an LTHC layer interposed between the base film and the transparent conducting layer and said LTHC layer comprises one or more dielectric polymers and the one or more near-IR dye(s).

10. The process of claim 1, wherein the transparent conducting layer has a peel force of greater than 100 grams per inch for removing the transparent conducting layer.

11. The process of claim 1, wherein, within the exposed substrate, the unexposed region has an average OD of less than 0.1 in the range of 400 nm to 700 nm and the optical density difference between the unexposed region and exposed region is less than 0.1.

12. The process of claim 2, further comprising:

(e) contacting the patterned substrate with a donor comprising;

a base film and a conducting transfer layer;

(f) transferring at least a portion of the conducting transfer layer onto the patterned substrate by thermal transfer to provide a second assemblage comprising a second patterned substrate having said transparent conducting pattern and a second conducting pattern and a spent donor.

13. The process of claim 12, further comprising:

(g) separating the spent donor from the second patterned substrate.

14. The process of claim 12, wherein the conductive transfer layer comprises conducting nanoparticles selected from the group consisting of:

gold, silver, copper, and alloys thereof;

ITO, ATO, carbon black and carbon nanotubes.

15. The process of claim 12, wherein the conductive transfer layer comprises a conducting composition (A), comprising:

(i) about 65 to about 95 wt %, based on the total weight of the conducting composition, of a conducting nanoparticle fraction selected from the group consisting of;

carbon black;

Ag, Cu and alloys thereof; and

mixtures thereof;

comprising a plurality of nanoparticles having an average longest dimension of about 5 nm to about 1500 nm; and

(ii) about 5 to about 35 wt % of a dispersant comprising one or more resins selected from the group consisting of;

conducting polymers selected from the group consisting of polyaniline, polythiophene, polypyrrole, polyheteroaromatic vinylenes, and their derivatives;

nonconducting polymers selected from the group consisting of acrylic and styrenic-acrylic latexes, and solution-based acrylics and styrenic-acrylic (co)polymers, and combinations thereof;

copolymers of ethylene with one or more monomers selected from the group consisting of (meth)acrylate(s), vinyl acetate, carbon monoxide and (meth)acrylic acid; and

polyvinylacetate and copolymers of vinylacetate.

16. An electronic device made by the process of claim 1.

17. An electronic device made by the process of claim 12.

18. The electronic device of claim 16, wherein within the exposed substrate, the transparent conducting pattern has an average OD of less than 0.1 in the range of 400 nm to 700 nm;

and the optical density difference between the unexposed region and exposed region is less than 0.1.

19. The electronic device of claim 16, wherein within the exposed substrate, the transparent conducting pattern has a sheet resistance of less than 10⁴ Ohms per square.

20. The electronic device of claim 16, that is selected from the group consisting of touchscreen sensor, organic light emitting diode, and photovoltaic current collector.

21. The electronic device of claim 17, wherein within the patterned substrate, the transparent conducting pattern has an average OD of less than 0.1 in the range of 400 nm to 700 nm;

and the optical density difference between the unexposed region and exposed region is less than 0.1.

22. The electronic device of claim 17, wherein within the patterned substrate, the transparent conducting pattern has a sheet resistance of less than 10,000 Ohms per square.

23. A substrate comprising a base film and a transparent conducting layer disposed on the base film, wherein the substrate has an OD of about 0.1 to 0.6 at 830 nm, and the transparent conducting layer comprises polyethylene dioxythiophene and has an OD of less than 0.1 in the range of 400 to 700 nm.

24. The substrate of claim 23, wherein the transparent conducting layer has a peel force of greater than 100 grams per inch for removing the transparent conducting layer.

25. The substrate of claim 23, wherein the transparent conducting layer has a thickness of 400 nm or less.

26. The substrate of claim 23, further comprising one or more near-IR dye(s) having an absorption maximum in the range of about 600 to about 1200 nm within the donor.

27. The substrate of claim 26, wherein the one or more near-IR dye(s) is disposed in the transparent conducting layer.

28. The substrate of claim 26, further comprising an LTHC layer interposed between the base film and the transparent conducting layer and said LTHC layer comprises one or more dielectric polymers(s) and one or more near-IR dye(s).

29. The substrate of claim 26, wherein the one or more near-IR dye(s) is a cyanine compound(s) selected from the group consisting of:

indocyanines, phthalocyanines including polysubstituted phthalocyanines and metal-containing phthalocyanines, and merocyanines.