Transparent, electroconductive substrate and method for forming the same

• US 5,662,962 A
• Filed: 03/20/1995
• Issued: 09/02/1997
• Est. Priority Date: 10/28/1993
• Status: Expired due to Term

• Current Assignee: Sumitomo Metal Mining Company Limited
• Original Assignee: Sumitomo Metal Mining Company Limited
• Inventors: Yukinobu, Masaya, Kawata, Munekazu
• Primary Examiner(s): UTECH, BENJAMIN L
• Application Number:
  US08/406,408
• Time in Patent Office: 897 Days
• Field of Search: 427/126.2, 427/126.3, 427/240, 427/376.2, 427/427, 427/443.2, 437/228
• US Class Current: 427/126.2
• CPC Class Codes: G02F 1/13439 characterised by their electrical, optical, physical properties; materials therefor; method of making
• CPC Class Codes: H01B 1/08 oxides
• CPC Class Codes: H01L 31/1884 Manufacture of transparent electrodes, e.g. TCO, ITO
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy

Abstract

A transparent, electroconductive ink having therein ultra-fine ITO particles dispersed in a solvent or in a solvent containing a resin dissolved therein is coated and dried on a transparent support, then dried and optionally baked, and thereafter an overcoating liquid consisting essentially of silica sol is coated over the resulting transparent, electroconductive film formed on the support. This is then dried and optionally baked to obtain a transparent, electroconductive substrate having a specific resistance of 0.01 to 0.5 Ω.cm, a haze value of 0 to 2%, and a volume content of the ultra-fine ITO particles in the film of being 40 to 75%. The substrate has a small surface resistivity and has excellent optical characteristics and weather resistance.

Claims

1. A method for forming a transparent, electroconductive substrate, in which a transparent, electroconductive ink, which is a solution having dispersed therein indium-tin oxide particles having a mean particle size of from 0.01 to 0.05 μ

m and a binder, is coated and dried on a support capable of transmitting visible rays therethrough to thereby form thereon a transparent, electroconductive film consisting solely of said indium-tin oxide particles, and thereafter an overcoating sol solution consisting essentially of silica sol is coated on said transparent electroconductive film and then dried or dried and baked.

2. A method for forming a transparent, electroconductive substrate as claimed in claim 1, which uses, as said support capable of transmitting visible rays therethrough, a soda lime glass support, a low-alkali glass support or a non-alkali glass support.

3. A method for forming a transparent, electroconductive substrate as claimed in claim 1, which uses, as said overcoating liquid, a silica sol obtained by hydrolyzing an alkyl silicate and the lower condensate thereof in the presence of a catalyst.

4. The method for forming a transparent, electroconductive substrate as claimed in claim 1, in which the coating of the transparent, electroconductive ink and the overcoating liquid on said support is effected by wire bar coating, doctor blade coating, spin coating, dip coating or spray coating.

5. A method for forming a transparent, electroconductive substrate as claimed in claim 1, wherein said solvent for dispersing therein, said indium-tin oxide particles is water or an organic solvent selected from the group consisting of acetone, methyl ethyl ketone, methyl isobutyl ketone, cyclohexanone, isophorone and diacetone alcohol;

alcohols selected from the group consisting of methyl alcohol, ethyl alcohol, isopropyl alcohol and butyl alcohol;

esters selected from the group consisting of ethyl acetate and butyl acetate;

polyalcohol derivatives selected from the group consisting of cellosolve, butyl cellosolve, butyl carbitol and butyl carbitol acetate;

N-methylpyrrolidone and N, N-dimethylformamide.

6. A method for forming a transparent, electroconductive substrate as claimed in claim 1, wherein the drying of said overcoat film is effected at temperatures of 80 degrees C or higher and the baking thereof is effected at temperatures of 300degrees C or higher.

7. A method for forming a transparent, electroconductive substrate as claimed in claim 1, wherein said solvent for dispersing therein, said indium-tin oxide particles is water or an organic solvent selected from the group consisting of acetone, methyl ethyl ketone, methyl isobutyl ketone, cyclohexanone, isophorone and diacetone alcohol;

alcohols selected from the group consisting of methyl alcohol, ethyl alcohol, isopropyl alcohol or butyl alcohol;

esters selected from the group consisting of ethyl acetate or butyl acetate;

polyalcohol selected from the group consisting of cellosolve, butyl cellosolve, butyl carbitol and butyl carbitol acetate, N-methylpyrrolidone and N, N-dimethylformamide.

8. A method for forming a transparent, electroconductive substrate, in which a transparent, electroconductive ink, which is a solvent having dispersed therein indium-tin oxide particles having a mean particle size of from 0.01 to 0.05 μ

m and is coated on a transparent support capable of transmitting visible rays therethrough and then dried and baked to thereby form transparent, electroconductive film on the support, and thereafter an overcoating sol solution consisting essentially of a silica sol is coated on said transparent, electroconductive film and then dried or dried and baked.

9. A method for forming a transparent, electroconductive substrate as claimed in claim 8, which uses, as said support capable of transmitting visible rays therethrough, a soda lime glass support, a low-alkali glass support or a non-alkali glass support.

10. A method for forming a transparent, electroconductive substrate as claimed in claim 8, which uses, as said overcoating liquid, a silica sol obtained by hydrolyzing an alkyl silicate and the lower condensate thereof in the presence of a catalyst.

11. The method for forming a transparent, electroconductive substrate as claimed in claim 8, in which the coating of the transparent, electroconductive ink and the overcoating liquid on said support is effected by wire bar coating, doctor blade coating, spin coating, dip coating or spray coating.

12. The method for forming a transparent, electroconductive substrate as claimed in claim 8, in which said solvent containing a thermoplastic resin therein is vaporized by heating the coated, transparent substrate in air at about 400°

C.

13. The method for forming a transparent, electroconductive substrate as claimed in claim 8, in which the drying of said overcoat film is effected at temperatures of 80°

C. or higher and the baking thereof is at temperatures of 300°

C. or higher.