Mechanistic Study on Regulating the Aspect Ratio of Silver Lines in Dry Aerosol Jet Printing via Focusing Ratio

Le résumé fourni par la source

This study systematically investigated the regulatory mechanism of the focusing ratio σ (σ = sheath gas flow rateQs/ carrier gas flow rateQc) on the morphology of conductive silver lines, aiming to achieve high resolution and high aspect ratio in dry aerosol jet printing (DAJP). Combining flow field simulations with experimental process analysis revealed that increasing σ significantly enhanced the aerodynamic focusing effect, narrowing the particle stream trajectory and consequently improving line resolution. At the same σ, deposited line width remained largely consistent under differentQc, indicating that σ was a dimensionless parameter controlling line width independently ofQc. Experimental results showed that the line width (W) correlated negatively with both σ and the stage velocity (Vs), but positively withQc; the line height (H) correlated positively with σ andQc, and negatively withVs. Under a fixed σ, increasingQcwhile decreasingVseffectively enhancedH, achieving high resolution and high aspect ratio (AR). Based on the maximum flow threshold and the critical stage velocity, an optimized process window forQc= 200 sccm was established, successfully fabricating high-quality silver lines withW= 103.34 μm,H= 7.82 μm, andAR= 7.56%. Subsequently, post-treatment by muffle furnace sintering (200°C, 60 min) reduced the resistivity to 23.51 μΩ·cm, meeting the conductivity requirements for flexible electronic devices. This study provided a theoretical foundation for parameter design and process control of high-precision three-dimensional metallic structures using DAJP.

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