Statistical Analysis of Screen-printed Ag Patterns Sintered by Intense Pulsed Light (IPL)

This study investigated effects of energy levels, pulse durations, and pulse frequencies during an IPL (Intense Pulsed Light) sintering process on surface morphology and resistance of screen-printed Ag patterns on PET substrates. Surface characteristics, including primary profile (Pa), roughness (Ra), thickness, and sheet resistance, were measured before and after sintering. At fixed energy levels (13.18, 32.96, and 46.14 kW), increasing pulse counts (2, 5, and 7) at 6 ms durations significantly increased Pa and thickness, while Ra was not changed. In contrast, higher pulse counts (4, 10, and 14) at 3 ms durations improved surface roughness by reducing Ra. Statistical analysis (Paired T-test) confirmed these results. Sheet resistance analysis showed that lower pulse counts at 6 ms caused greater variability in resistance, stabilizing with higher counts. At 3 ms, surface resistance decreased with higher pulse counts, showing reduced variability. These results suggest that adjusting pulse conditions and counts during the sintering process can optimize both electrical properties and uniformity. Additionally, morphological changes before and after sintering indicated that these adjustments might influence upper-layer printability in multilayer printing. The study highlights the importance of considering both functional and morphological characteristics during sintering for optimized production of printed electronic devices.