TW201006561A

TW201006561A - Feeding system for coating multiphase liquids

Info

Publication number: TW201006561A
Application number: TW098114830A
Authority: TW
Inventors: Dmitry Lekhtman; Jacob Gilan; La Vega Fernando De; Kenichi Nakata
Original assignee: Cima Nanotech Israel Ltd
Priority date: 2008-05-05
Filing date: 2009-05-05
Publication date: 2010-02-16
Also published as: WO2009136288A3; WO2009136288A2

Abstract

A system and process are disclosed for the continuous coating of an emulsion onto a moving substrate that allows the homogenized emulsion to be coated at a relatively constant pre-determined flow rate without significant destabilization of the emulsion. The system and process are particularly suited for use with emulsions containing fine conductive particles.

Description

201006561 六、發明說明：【發明所屬之技術領域】本發明係關於加工及輸送用於在基板上連續塗覆之乳液 : 的系統及方法。本申請案根據35 USC § 119(e)主張2008年5月5曰申請之美國臨時申請案第61/050,347號之優先權，其全文以引用的方式併入本文中。【先前技術】美國專利申請案 2005/215689、2005/238804及 2005/214480 ❹ 描述當塗佈於基板時自組裝為導電透明塗層之奈米粒子乳液。礼液較佳為油包水乳液，其中使奈米粒子分散於乳液之有機相中。上述乳液以及有或無經分散微粒材料之其他乳液可易於發生可干擾乳液之均勻塗層形成的相分離。詳言之，當以連續、捲軸式塗覆方法塗覆乳液時，需要在整個過程中維持礼液之穩定性以最大化塗層之品質且最小化所得薄膜中之缺陷。201006561 VI. INSTRUCTIONS OF THE INVENTION: TECHNICAL FIELD OF THE INVENTION The present invention relates to systems and methods for processing and transporting emulsions for continuous coating on substrates. The present application claims priority to U.S. Provisional Application Serial No. 61/050,347, filed on Jan. 5, 2008. [Prior Art] US Patent Application Nos. 2005/215689, 2005/238804, and 2005/214480 ❹ describe nanoparticle emulsions that self-assemble into a conductive clear coating when applied to a substrate. The liquid is preferably a water-in-oil emulsion in which the nanoparticles are dispersed in the organic phase of the emulsion. The above emulsions, as well as other emulsions with or without dispersed particulate material, are susceptible to phase separation which can interfere with the formation of a uniform coating of the emulsion. In particular, when the emulsion is applied by a continuous, roll coating process, it is desirable to maintain the stability of the liquor throughout the process to maximize the quality of the coating and minimize defects in the resulting film.

【發明内容】本發明提供—種用於將乳液連續塗佈於基板之系統，其 i s . (a)具有混合機構之貯槽，該貯槽經調適以接收及加工至少兩種不可混溶液體以產生不可混溶液體之混合物； (b)經調適以接收及加工該混合物以產生或維持包含不可混溶液體中之—者之連續相及包含另—不可混溶液體之小液滴之不連續相的乳液之高剪切均質機，該等小液滴實質上 140236.doc •4· 201006561 均勻且在預定尺寸範圍内；（c)經調適以將乳液自均質機輸送至基板之表面的分配機構，其包含⑴至少一個分配貯槽及（U)用於將乳液驅動至基板的驅動機構；及（句與驅動機構操作性連接以⑴提供小於乳液之不穩定化時間的乳液在刀配機構内之滯留時間且⑼將流經分配機構之乳液的流動速率控制在預定範圍内之控制器。在實鉍例中，藉由均質機產生之乳液的平均小液滴尺寸為小於20微米，通常小於1〇微米且甚至小於5微米。在一實施例中，對來自分配貯槽之乳液的流動速率之控制係藉由較佳經調適以接收製程輸入（流動速率、壓力等）且對分配構件進行任何必要調整以使流動速率在預定範圍内之控制器（諸如可程式化邏輯控制器（PLC))來進行。-般需要將流動速率控制在（例如，流動速率設定值或平均量 ^流動速率之）5%之内，較佳在3%之内且最佳在2%之内。流經分配機構之乳液的流動速率可藉由熟習此項技術者熟知之途徑來控制，諸如使用控制閥門及/或藉由控制分配貯槽中之壓力及/或調整抽汲裝置之速度。在系統之一實施例中’存在兩個或兩個以上分配貯槽， /、、’’呈組釔以並聯方式操作，以便可藉由在不中斷乳液之流動下將礼液輸送自第一分配貯槽切換至第二分配貯槽而進 4T連續塗覆。在自第二分配貯槽輸送乳液期間，準備第一分配貯槽以用於乳液輸送之另一循環。在系統之另一實施例中，存在單一分配貯槽以及泵以控制乳液至塗覆裝置之進料速率。 140236.doc 201006561 在系統之一實施例中’分配機構内乳液之滯留時間小於乳液的不穩定化時間之75%。在一實施例中，該系統進一步包括可變壓降元件，諸如在分配貯槽之下游沿分配機構安置之過遽器。若乳液含有大於所要粒度之經分散微粒材料，則該等過濾器尤其有用。控制器及分配機構經調適以實現對乳液流動速率之精確控制’甚至在（例如）歸因於下游過濾單元之部分堵塞而發生下游壓頭（head downstream)改變時亦如此。因此，即使當可變壓降元件導致分配貯槽中之壓力與大氣壓之間的壓力差變化時，控制器及分配機構仍可維持流動速率在 (例如，流動速率設定點之）5%内，通常在3%内且時常在 2%内’同時實質上維持乳液之物理及化學特性。可依據體積或重量參數量測流動速率。在一實施例中，分配機構進一步包含用於將乳液塗佈於基板上之塗覆裝置《在一較佳實施例中，塗覆裝置包含模具、最佳為狹縫模。在一實施例中，塗佈於基板之乳液含有分散粒子、較佳為導電粒子（諸如銀、銀銅合金、碳黑或石墨該等粒子 —般在至少一個維度上具有小於約3微米、較佳小於約1〇微米、更佳小於約〇 . 5微米且最佳小於約〇 _ 1微米（1 〇〇奈米）之平均粒度。在較佳乳液中，將粒子分散於油包水乳液之有機相中。如美國專利申請案2〇〇5/215689、2〇〇5/2388〇4 及2005/214480中所述使用該等乳液於基板上形成自組裝透明導電塗層，該等申請案以引用的方式併入本文中。 140236.doc 201006561 本發明亦提供一種用於在基板上連續形成透明導電塗層之方法，該方法包含：（a)形成至少兩種不可混溶液體與精、-田導電粒子之说合物；（b)使該混合物經受高剪切均質化以產生或維持包含連續相（含一種不可混溶液體）及不連續相 (含其他不可混溶液體之小液滴）的作為乳液之混合物，該小液滴尺寸在預定尺寸範圍内；⑷將該均質化乳液以使得在乳液不穩定化之前將乳液塗覆於基板上之實質恆定預定流動速率連續分配至塗覆裝置中；（d)將均f化乳液連續塗覆於基板上；且⑷自乳液中蒸發液體以於基板上形成透明導電塗層’其中塗層在基板之表面上呈界定隨機形狀空隙之精細粒子的互連跡線之網路樣圖案形式。在該方法之-實施例中，導電粒子為銀粒子、銀銅合金粒子、碳黑粒子或石墨粒子。導電粒子之平均粒度一般小於約3微米、較佳小於約微米、更佳小於約〇 5微米且最佳小於約0.1微米（100奈米）。較佳乳液為油包水乳液較籲佳由導電粒子分散於乳液之連續、有機相中而形成。在均質化之後不連續相之小液滴尺寸較佳小於20微米。流動速率-般控制在經設定的流動速率之5%、較佳3%且最佳2% 内。該系統及方法尤其適用於搖轡、.志釭八银燹減黏流體、剪切變稀流體及不穩定流體。該系統及方法尤其適用於含右八 3有刀散粒子、較佳精細金屬粒子且最佳奈米尺寸金屬粒子之乳液。可利用該系統及方法以獲得許多優勢。視其實踐者如何 140236.doc 201006561 選擇對其進行組態而定，該系統及該方法使得在合理成本下乳液（有或無分散液）生產及輪送***的構造及操作有可月匕八有以下優勢中之一或多者：⑴對上游壓頭(例如，歸因於混合貯槽中之混合物高度)及下游壓頭(例如，歸因於 y游過ϋ單元之各種改變）之改變的優良容許度；（2)長期操作同時在寬塗覆速度之範_維持實f上⑨定流動速率及-致乳液特性(密度、黏度、小液滴尺寸等)之能力；及 (3)穩固的製程控制。根據以下圖式及實施方式，其他特徵及優勢將變得顯而易見。【實施方式】可參看圖式及隨附描述較佳理解本發明之系統及方法的原理及操作。在詳細關明本發明之至少—種實施例之前，應瞭解系統及方法在其應用中不限於以下說明書中所陳述或圖式中所說明之構造之細節及組件之配置。該系統及該方法能夠具有其他實施例或能夠以多種方式實踐或實施。此外，應瞭解本文所用之措辭及術語僅為描述之目的且不應視為^制本文。如本說明書中所用，術語「乳液」係指—種液體之小液滴或小球（不連續相）於第二液體（連續相）中之懸浮液，該等液體實質上不可混溶H亦可含有分散於其中之精細粒子。如本說明書中所用，關於流體或乳液之術語「搖變減 140236.doc 201006561 黏」係指如一些非牛頓（non-Newtonian)假塑性流體之展示黏度之時間相依變化之流體或乳液：流體或乳液經受剪切應力時間愈長，其黏度愈低。當引入剪切速率之步進改變時’搖變減黏流體需要有限量之時間達到平衡黏度。許多凝膠及膠體均為搖變減黏材料，其靜止時展現穩定形式，但攪拌時變為流體。重要的疋注意搖變減黏流體與剪切變稀流體之間的區SUMMARY OF THE INVENTION The present invention provides a system for continuously applying an emulsion to a substrate, wherein: (a) a sump having a mixing mechanism adapted to receive and process at least two immiscible liquids to produce a mixture of immiscible liquids; (b) adapted to receive and process the mixture to produce or maintain a discontinuous phase comprising a continuous phase of the immiscible liquid and a small droplet comprising another immiscible liquid High shear homogenizer of the emulsion, the droplets are substantially 140236.doc •4· 201006561 uniform and within a predetermined size range; (c) a dispensing mechanism adapted to transport the emulsion from the homogenizer to the surface of the substrate And comprising (1) at least one distribution sump and (U) a drive mechanism for driving the emulsion to the substrate; and (the sentence is operatively coupled to the drive mechanism to (1) provide an emulsion less than the destabilization time of the emulsion in the knife-fit mechanism The residence time and (9) the controller that controls the flow rate of the emulsion flowing through the distribution mechanism within a predetermined range. In the actual example, the average droplet size of the emulsion produced by the homogenizer It is less than 20 microns, typically less than 1 〇 microns and even less than 5 microns. In one embodiment, the control of the flow rate of the emulsion from the dispensing sump is preferably adapted to receive process input (flow rate, pressure, etc.) And performing any necessary adjustments to the dispensing member to cause the flow rate to be within a predetermined range of controllers, such as programmable logic controllers (PLCs). It is generally desirable to control the flow rate (eg, flow rate setpoint) Or within 5% of the average amount of flow rate, preferably within 3% and optimally within 2%. The flow rate of the emulsion flowing through the dispensing mechanism can be obtained by those skilled in the art. Control, such as using a control valve and/or by controlling the pressure in the dispensing sump and/or adjusting the speed of the twitching device. In one embodiment of the system 'there are two or more dispensing sump, /,, '' The group 钇 is operated in parallel so as to be continuously coated by 4T by transferring the ritual liquid from the first dispensing sump to the second dispensing sump without interrupting the flow of the emulsion. During the delivery of the emulsion, a first dispensing sump is prepared for another cycle of emulsion delivery.In another embodiment of the system, there is a single dispensing sump and a pump to control the feed rate of the emulsion to the coating device. 140236.doc 201006561 In one embodiment of the system, the residence time of the emulsion within the dispensing mechanism is less than 75% of the destabilization time of the emulsion. In one embodiment, the system further includes a variable pressure drop element, such as a distribution along the downstream of the dispensing sump The filter is especially useful if the emulsion contains dispersed particulate material larger than the desired particle size. The controller and the dispensing mechanism are adapted to achieve precise control of the emulsion flow rate' even at (for example) This is also the case when a downstream head change occurs due to partial blockage of the downstream filter unit. Thus, even when the variable pressure drop element causes a change in pressure differential between the pressure in the distribution sump and atmospheric pressure, the controller and the dispensing mechanism can maintain the flow rate within 5% (eg, the flow rate set point), typically Within 3% and often within 2% 'at the same time, the physical and chemical properties of the emulsion are substantially maintained. The flow rate can be measured based on volume or weight parameters. In one embodiment, the dispensing mechanism further comprises a coating device for applying the emulsion to the substrate. In a preferred embodiment, the coating device comprises a mold, preferably a slot die. In one embodiment, the emulsion applied to the substrate contains dispersed particles, preferably conductive particles (such as silver, silver-copper alloy, carbon black or graphite) having less than about 3 microns in at least one dimension. Preferably less than about 1 〇 micron, more preferably less than about 〇 5 μm and most preferably less than about 〇 1 μm (1 〇〇 nanometer) of average particle size. In a preferred emulsion, the particles are dispersed in a water-in-oil emulsion. The use of such emulsions to form self-assembled transparent conductive coatings on substrates as described in U.S. Patent Application Serial Nos. 5,5,215,689, 2, 5, 2,,,,,,,,,,,, Incorporated herein by reference. 140236.doc 201006561 The present invention also provides a method for continuously forming a transparent conductive coating on a substrate, the method comprising: (a) forming at least two immiscible liquids and fines, - (b) subjecting the mixture to high shear homogenization to produce or maintain a continuous phase (containing an immiscible liquid) and a discontinuous phase (containing other liquids of the immiscible liquid) Drip) as a mixture of emulsions a small droplet size within a predetermined size range; (4) continuously distributing the homogenized emulsion to a coating device at a substantially constant predetermined flow rate of the emulsion applied to the substrate prior to destabilization of the emulsion; d) continuously applying a uniform emulsion to the substrate; and (4) evaporating the liquid from the emulsion to form a transparent conductive coating on the substrate, wherein the coating has fine particles defining a random shape void on the surface of the substrate In the method-embodiment of the method, the conductive particles are silver particles, silver-copper alloy particles, carbon black particles or graphite particles. The average particle size of the conductive particles is generally less than about 3 microns, preferably less than Preferably, the micron, more preferably less than about 微米5 μm and most preferably less than about 0.1 μm (100 nm). The preferred emulsion is a water-in-oil emulsion which is preferably formed by dispersing conductive particles in a continuous, organic phase of the emulsion. The droplet size of the discontinuous phase after homogenization is preferably less than 20 microns. The flow rate is generally controlled within 5%, preferably 3% and optimally 2% of the set flow rate. The system and method are particularly suitable It is used for shaking, 釭釭燹燹燹燹燹燹、、燹燹燹。。。。。。。。。。该该该该该该该该该该该该该该该该该该该Emulsions of rice-sized metal particles. The system and method can be utilized to obtain a number of advantages. Depending on how the practitioner chooses it, 140236.doc 201006561 chooses to configure it, the system and the method make the emulsion at a reasonable cost (with or The construction and operation of a non-dispersive liquid production and delivery system may have one or more of the following advantages: (1) upstream pressure head (eg, due to the height of the mixture in the mixing tank) and downstream head (for example, excellent tolerance due to changes in y swimming through the various changes in the unit); (2) long-term operation while maintaining a constant flow rate and maintaining the characteristics of the emulsion The ability to density, viscosity, droplet size, etc.; and (3) robust process control. Other features and advantages will become apparent from the following drawings and embodiments. [Embodiment] The principles and operation of the system and method of the present invention are best understood by reference to the drawings and the accompanying drawings. Before the at least one embodiment of the present invention is described in detail, it should be understood that the system and method are not limited in its application to the details of the construction and the configuration of the components as illustrated in the following description. The system and method can have other embodiments or can be practiced or carried out in various ways. In addition, the wording and terminology used herein is for the purpose of description and should not be construed as As used in this specification, the term "emulsion" means a suspension of a liquid droplet or a small sphere (discontinuous phase) in a second liquid (continuous phase) which is substantially immiscible. It may contain fine particles dispersed therein. As used in this specification, the term "shake reduction 140236.doc 201006561 viscous" with respect to a fluid or emulsion refers to a fluid or emulsion that exhibits a time-dependent change in the viscosity of a non-Newtonian pseudoplastic fluid: fluid or The longer the emulsion is subjected to shear stress, the lower its viscosity. When the step of changing the shear rate is introduced, it takes a finite amount of time to reach the equilibrium viscosity. Many gels and colloids are shake-reducing materials that exhibit a stable form at rest but become fluid upon agitation. Important note to note the zone between the shake-reduced fluid and the shear-thinning fluid

別。搖變減黏流體展示在恆定剪切速率下黏度隨時間降低’而剪切變稀流體展示黏度隨剪切速率增加而降低。如本文所用之關於乳液之術語「不穩定化時間」係指直至乳液出現物理特性改變之最大時間，其中物理特性之改變係以不利方式影響經塗覆乳液之所要特性。此外，關於用於形成透明導電塗層之乳液（諸如美國專利申請案 2005/215689、2005/238804及2005/214480 中所述之彼等乳液）的不穩定化時間係指乳液形成後在其内可將乳液塗覆於基板上以提供合適透明及導電網路樣圖案之最大時間。不穩疋化時間之判定必須與所得塗層之特性相關。在一些情況下’乳液流體之可量測物理特性似乎無法展示隨著時間之顯著改變’然而所得塗層之特性不合乎需要。此情況亦指示加卫時間大於為不穩定化時間之最大所要時間。如本月θ所用’術語「不穩定乳液」係指具有小於分鐘之不穩定化㈣的乳液1本㈣之㈣及方法加工 =一些MIL具有小㈣分鐘且在n兄下小於7 /刀鐘之不穩定化㈣。對於將乳液進料至模具之各種應用 140236.doc 201006561 而言’乳液通常具有小於5分鐘且通常約2-5分鐘之不穩定化時間。在所有情況下，乳液在分配機構中之滯留時間係小於乳液之不穩定化時間。如本文所用，乳液在自均質機排出與經由塗覆裝置 (「分配機構」）自系統排出之間存在於系統中之時間稱為「滞留時間」。在大多數情況下，稱為「分配貯槽滯留時間」之乳液處於分配貯槽中的滯留時間的部分幾乎與滞留時間相同，此係因為一旦乳液自分配貯槽排出，其就藉由塗覆裝置快速塗佈於基板上。如本說明書所用’關於在分配貯槽與塗覆裝置之間經由系統傳輸之乳液的術語「流動速率」係指在至少丨_5秒之時間間隔内取樣之所量測的流動速率。現參看圖式，圖1為如以上參考且以引用的方式併入本文中之美國專利申請案2005/215689 、 2005/238804及 2〇05/214480中所述一用於製備透明導電塗層之方法之實施例的示意方塊圖。在可與步驟2組合之步驟1中，將諸如精細金屬粉末之精細粉末及液體載劑混合於—起以形成八散液。在步驟2中，使分散液（或液體及粉末）與實質上與分散液之液體載劑（或第一液體）不可混溶之第二液體組人以形成在此階段一般（而非一定）呈乳液形式之混合物。用於形成透明導電塗層之合適分散液及乳液的製備係描述於上述專利申請案中。將混合物不斷混合以維持均質性。隨後，使混合物經受高剪切均質化（步驟3)，以產生或維持一 140236.doc -10· 201006561 具有連續相及包含在相對窄的預定尺寸範圍内之小液滴之不連續相的乳液。該乳液可為油包水乳液或水包油乳液，但油包水乳液較佳，且較佳具有分散於油相中之粉末。將均質化乳液以使均質化乳液在乳液不穩定化之前塗覆於基板上的實質上恆定之預定流動速率連續分配（步驟4)至塗覆裝置中。將乳液連續塗覆（步驟5)於基板上，且蒸發乳液之液體（步驟6)以便使分散於步驟丨中之精細粉末以界定隨機形狀空隙之粉末互連跡線的網路樣圖案形成在基板之表面 β 上。在圖2及圖2a之系統之背景下進一步詳細闡述此方法。圖2為用於乳液製備及處理及將乳液輸送至模具以產生塗層之系統1 00的示忍圖。乳液可含有精細分散之固體。系統100中進行之主要單元操作包括混合乳液組份、使用高剪切均質機產生或維持乳液及將乳液精確/準確輸送至塗覆模或其他下游裝置以用於將乳液塗佈於基板表面。 ❹ f見此等單元操作之主要設備可包括經攪動進料竚槽同剪切均質機及/或乳化器50、至少-個如分配貯槽 60a及60b所示之分配貯槽6〇，及模具7〇。 =乳液之組份引人至經設計以產生或實質上維持混合物 a觀句貝J·生的經撥動進料貯槽4G中，該混合物包括實質 f不可：溶之含油相及水相。對於含有精細分散之固體的礼液而e ’在引入至進料貯槽4〇之前將固體分散於此等相 (液體）中之-者中可為有益的或甚至必要的。進料貯槽如可有利地配備有具有葉輪44(諸如錯型葉輪） 140236.doc 201006561 ^犯合器42，諸如低功率、低剪切混合器。混合器42係由安置於進料貯槽40上方之馬達46驅動（諸如氣動馬達）。較佳地，將視特定應用而定可為乳液或可能不為乳液之在經授動進料貯槽4〇中職生之混合物連續輸送至高剪切 2質機5G中。在—些情況下，在均質機50巾施用高剪切之前降低進料貯槽4〇中之液體之黏度可為有利的。均枭機50用以維持及/或產生具有小於2〇微米且通常小於微米或甚至小於5微米之平均特徵小液滴直徑之乳液，且Μ以維持小液滴尺寸在窄範㈣。若固體材料係存在於自進料貯槽40接收之混合物中，則高剪切均質機5〇經調適以維持及/或更好地產生精細固體粒子於乳液中之分散液。儘管對於熟習此項技術者各種類型之高剪切均質機5〇可為顯而易見的，但尤其合適的高剪切均質機包括錐形或盤形轉子，其藉由密切控制之轉子-定子間隙與互補的液冷定子分離。當轉子以高速旋轉時，其在轉子之外表面與定子之内表面之間抽汲流體且間隙中所產生之剪切力加工該流體。雖然各種類型之均質機均可適用作均質機5〇，但已發現高RPM、同軸、轉子-定子類型尤其適用於維持及/或產生具有小於20微米且甚至小於1 〇微米或5微米或小於5微米之平均小液滴尺寸之乳液。一種尤其合適、可購得之高剪切均質機為 MEGATRON® MT 3_(Kinematica，Switzerland)。將由均質機50產生之乳液（產物流）之一部分再循環至進 140236.doc •12· 201006561 料貯槽4。通常為有利的。將乳液之剩餘部分輸送至下游。在許多應用中，以；1夠Μ而適合製程要求之流動速率實現均質機50對乳液的排出。然而，通常，製程要求規定將供應至塗覆裝置之乳液的流動速率維持在極窄限制内。句質機50般不適於滿足該等要求，此尤其係因為藉由均質機50輸送之流動速率係強烈地視上游壓頭及下游塵頭而定。舉例而言，進料貯槽40中流體水平面影響上游壓頭。 τ游壓頭可視具體應用而極Α地改變。若將藉由均質機5〇排出之乳液直接镇入模具中，則模具可能提供大部分下游壓降，以使得模具操作中之小變化可實現乳液流動速率之深刻改變。類似地，當均質機50排出物流經過遽器時，壓降可為很大的，且更重要地在整個運作中壓降一般增加，此係因為過濾器變得阻塞且較少過濾面積可用於^液流經。歸因於_、器床中之通道或裂叙通道效應亦可在運作過程中引起壓降改變。 Φ 因此，系統有利地在均質機5〇與將乳液塗佈於基板之塗覆裝置之間提供額外組件以確保連續、高精度乳液塗層。在中間步驟中，將均質機50之排出物引入至至少一個分配貯槽60中。在圖2中圖示兩個分配貯槽6〇&及6〇b。使用多組件流體分配系統以將乳液自均質機5〇輸送至諸如模具70之下游塗覆裝置且接著至基板之表面。通常，首先使乳液流經過濾單元65以移除任何大的、不合乎需要之粒子。與每一各別分配貯槽60a、60b聯結者為用於驅動乳液離 140236.doc •13- 201006561 開各別分配貯槽之驅動機構61a、6ibe在—較佳實施例中，驅動機構61a、61b包括與各別分配貯槽連通以便向分配貯槽60提供超大氣壓（較佳（但不限於）高於大氣壓5至15do not. The shake-reduced viscous fluid exhibits a decrease in viscosity over time at a constant shear rate, while the shear-thinning fluid exhibits a decrease in viscosity as the shear rate increases. As used herein, the term "destabilization time" with respect to emulsion refers to the maximum time until the physical properties of the emulsion change, wherein the change in physical properties adversely affects the desired properties of the coated emulsion. In addition, the destabilization time with respect to the emulsions used to form the transparent conductive coatings, such as those described in U.S. Patent Application Nos. 2005/215,689, 2005/238,804 and 2005/214,480, is incorporated herein by reference. The emulsion can be applied to the substrate to provide the maximum time for a suitable transparent and conductive network-like pattern. The determination of the instability time must be related to the properties of the resulting coating. In some cases, the measurable physical properties of the emulsion fluid do not appear to exhibit significant changes over time. However, the properties of the resulting coating are undesirable. This situation also indicates that the guard time is greater than the maximum time required for the destabilization time. As used in this month, the term 'unstable emulsion' refers to an emulsion with less than a minute of destabilization (4). (4) (4) and method processing = some MILs have small (four) minutes and less than 7 / knives under n brothers Destabilization (4). For various applications in which the emulsion is fed to the mold 140236.doc 201006561 The emulsion typically has an unstable time of less than 5 minutes and typically about 2-5 minutes. In all cases, the residence time of the emulsion in the dispensing mechanism is less than the destabilizing time of the emulsion. As used herein, the time that the emulsion is present in the system between the discharge from the homogenizer and the discharge from the system via the coating device ("Distribution Mechanism") is referred to as the "residence time". In most cases, the portion of the emulsion called the "distribution tank residence time" in the distribution tank is almost the same as the residence time, because once the emulsion is discharged from the distribution tank, it is quickly coated by the coating device. Deployed on the substrate. As used herein, the term "flow rate" with respect to the emulsion transferred between the dispensing tank and the coating device via the system refers to the measured flow rate sampled over a time interval of at least 丨5 seconds. Referring now to the drawings, FIG. 1 is used to prepare a transparent conductive coating as described in US Patent Application Nos. 2005/215689, 2005/238804, and 2,05/214,480, which are incorporated herein by reference. A schematic block diagram of an embodiment of a method. In the step 1 which can be combined with the step 2, a fine powder such as a fine metal powder and a liquid carrier are mixed to form an eight-liquid dispersion. In step 2, the dispersion (or liquid and powder) is combined with a second liquid that is substantially immiscible with the liquid carrier (or first liquid) of the dispersion to form a general (not necessarily) at this stage. A mixture in the form of an emulsion. The preparation of suitable dispersions and emulsions for forming transparent conductive coatings is described in the above patent application. The mixture was continuously mixed to maintain homogeneity. Subsequently, the mixture is subjected to high shear homogenization (step 3) to produce or maintain a 140236.doc -10·201006561 emulsion having a continuous phase and a discontinuous phase comprising small droplets within a relatively narrow predetermined size range . The emulsion may be a water-in-oil emulsion or an oil-in-water emulsion, but a water-in-oil emulsion is preferred, and preferably has a powder dispersed in the oil phase. The homogenized emulsion is continuously dispensed (step 4) into the coating apparatus at a substantially constant predetermined flow rate applied to the substrate prior to destabilization of the emulsion. The emulsion is continuously coated (step 5) onto the substrate and the liquid of the emulsion is evaporated (step 6) so that the fine powder dispersed in the step 形成 is formed in a network-like pattern defining the powder interconnect traces of the randomly shaped voids. On the surface β of the substrate. This method is further elaborated in the context of the system of Figures 2 and 2a. Figure 2 is a representation of a system 100 for emulsion preparation and processing and delivery of the emulsion to a mold to produce a coating. The emulsion can contain finely divided solids. The main unit operations performed in system 100 include mixing the emulsion components, using a high shear homogenizer to produce or maintain the emulsion, and accurately/accurate delivery of the emulsion to a coating die or other downstream device for application of the emulsion to the substrate surface.主要 f The main equipment for the operation of such units may include agitating the feed chute with the shear homogenizer and/or the emulsifier 50, at least one of the distribution chutes 6 如 as shown in the distribution sump 60a and 60b, and the mold 7 Hey. The composition of the emulsion is introduced into a dialed feed sump 4G designed to produce or substantially maintain the mixture, which comprises a substantial f-soluble oil-soluble phase and an aqueous phase. It may be beneficial or even necessary to disperse the solids in the phase (liquid) prior to introduction into the feed sump 4 for a ritual liquid containing finely divided solids. The feed sump can be advantageously equipped with an impeller 44 (such as a misaligned impeller) 140236.doc 201006561 ^Cruiser 42 such as a low power, low shear mixer. The mixer 42 is driven by a motor 46 (such as a pneumatic motor) disposed above the feed sump 40. Preferably, the mixture, which may be an emulsion or may not be an emulsion, is continuously delivered to the high shear mass machine 5G depending on the particular application. In some cases, it may be advantageous to reduce the viscosity of the liquid in the feed sump 4 before the homogenizer 50 applies high shear. The homogenizer 50 is used to maintain and/or produce emulsions having an average characteristic dropletlet diameter of less than 2 microns and typically less than a micron or even less than 5 microns, and to maintain a small droplet size in a narrow range (four). If the solid material is present in the mixture received from the feed sump 40, the high shear homogenizer 5 is adapted to maintain and/or better produce the dispersion of fine solid particles in the emulsion. Although it will be apparent to those skilled in the art of various types of high shear homogenizers, particularly suitable high shear homogenizers include tapered or disk rotors that are closely controlled by rotor-stator gaps. Complementary liquid cooled stator separation. When the rotor is rotated at a high speed, it draws fluid between the outer surface of the rotor and the inner surface of the stator and shear forces generated in the gap process the fluid. While various types of homogenizers can be used as homogenizers, it has been found that high RPM, coaxial, rotor-stator types are particularly suitable for maintaining and/or producing having less than 20 microns and even less than 1 〇 microns or 5 microns or less. An emulsion of an average small droplet size of 5 microns. A particularly suitable, commercially available high shear homogenizer is MEGATRON® MT 3_ (Kinematica, Switzerland). A portion of the emulsion (product stream) produced by the homogenizer 50 is recycled to the 140236.doc •12·201006561 stock tank 4. It is usually advantageous. The remainder of the emulsion is delivered downstream. In many applications, the homogenizer 50 discharges the emulsion at a flow rate that is sufficient to meet the process requirements. However, in general, process requirements dictate that the flow rate of the emulsion supplied to the coating apparatus be maintained within extremely narrow limits. The serine machine 50 is generally unsuitable for meeting such requirements, in particular because the flow rate delivered by the homogenizer 50 is strongly dependent on the upstream head and the downstream head. For example, the fluid level in the feed sump 40 affects the upstream head. The τ swimming head can be changed drastically depending on the specific application. If the emulsion discharged by the homogenizer 5〇 is directly seduce into the mold, the mold may provide most of the downstream pressure drop so that small changes in mold operation can achieve profound changes in the emulsion flow rate. Similarly, when the homogenizer 50 exits the stream through the crucible, the pressure drop can be large and, more importantly, the pressure drop generally increases throughout the operation, as the filter becomes clogged and less filter area is available ^ Liquid flows through. Attributable to _, the channel in the bed or the crack channel effect can also cause a pressure drop change during operation. Φ Thus, the system advantageously provides additional components between the homogenizer 5 and the coating device that applies the emulsion to the substrate to ensure a continuous, high precision emulsion coating. In an intermediate step, the effluent of the homogenizer 50 is introduced into at least one of the distribution sump 60. Two distribution reservoirs 6〇& and 6〇b are illustrated in FIG. A multi-component fluid dispensing system is used to deliver the emulsion from the homogenizer 5 to a downstream coating device such as mold 70 and then to the surface of the substrate. Typically, the emulsion is first passed through a filtration unit 65 to remove any large, undesirable particles. The drive mechanism 61a, 6ibe is coupled to each of the individual distribution tanks 60a, 60b for driving the emulsion away from the 140236.doc • 13-201006561. In the preferred embodiment, the drive mechanisms 61a, 61b include Communicating with the respective distribution sump to provide super-atmospheric pressure to the distribution sump 60 (preferably, but not limited to, above atmospheric pressure 5 to 15)

Psi)之加麼氣體（較佳具有高達高於大氣壓乃ρ"之塵力）源。在分配貯槽60a、60b之下游分別安置閥門62a及閥門 62b’該㈣門較佳為控制閥門。當閥門—開啟時，驅動機構61a將壓力施加至分配貯槽6〇a令之乳液的頂部，從而驅動乳液離開貯槽60a經由輸送管線63到達可與輸送管線 63及分配貯槽60a、60b流體連通之下游應用。通常，對於給定流動速率而言，下游應用具有與長度及管道尺寸呈函數關係之可變線性壓降。在其他應用中^將諸如過濾單元65之可變非線性壓降元件安置於分配貯槽 60a ' 60b與下游應用之間線上。與每一各別分配貯槽60a、6〇b聯結者為至少一個較佳經調適以連續稱重各別分配貯槽之稱重元件，諸如荷重4 64a、64b。荷重計64a、64b較佳產生對應於各別分配貯槽之重量或與其相關聯之輸出’將該輸出輸送至圖3中所示之中央處理單元（PLC)80。較佳將PLC 80程式化以基於輸入（諸如特定乳液之不穩疋化時間及比重）測定分配貯槽60a、60b之最大填充重量。在所有情況下，將乳液在分配貯槽中之滯留時間設定為小於乳液之不穩定化時間，且較佳小於或等於乳液之不穩定化時間的75%。 140236.doc •14· 201006561 替代地或額外地，較佳將PLC 80程式化以基於輸入值 (諸如特定乳液之不穩定化時間及比重及貯槽之尺寸）測定分配貯槽60a、60b之最大填充高度。在此情況下，貯槽可有利地配備有至少一個位準感應器，諸如差壓計。對於一般熟習此項技術者而言’其他類型之合適感應器及其類似物為顯而易見的。使用如上文所述之該等感應器及輸入值，可將PLC 8〇程式化以平行方式操作分配貯槽60a、60b。可藉由控制/切換第一分配貯槽（諸如分配貯槽6〇a)至第二分配貯槽（諸如分配貯槽60b)之乳液輸送（例如，藉助於pLC 8〇)而實現連續運作。在自第二分配貯槽輸送乳液期間，準備第一分配貯槽以用於另一乳液輸送之循環。該準備可包括經由具有控制閥門69a之受控管線67a或經由具有控制閥門69b之受控管線 67b沖洗貯槽，將貯槽中之任何剩餘材料丟棄或經由受控回流管線48傳回至製程（例如經攪動進料貯槽4〇)中。乳液之分配可經由分配貯槽藉由壓力或藉由合適泵或其他合適構件而進行，以提供來自分配貯槽之乳液之連續流動速率m動速率- &地控制在（例>流動速率設定點之）5%内、通常在3%内且時常在2%内，同時即使當可變髮降元件導致貯槽壓力與大氣之間的壓差變化時仍維持乳液之連續流動速率。顯著地，在長期操作期間實現此對流經分配貯槽之下游輸送管線（及視情況流經可變料元件）之流動速率的一致 140236.doc 15· 201006561 :制’歷時乳液之滯留時間之至少1.5倍、較佳乳液之、.帶留時間之至少2俾曰、s $达 < 成之滞 α且通㊉為乳液之滯留時間之至少4倍之時在各種運作中，即使在將乳液輸送自一個分配貯槽切 2至另Γ分配貯槽之時期中，仍使乳液之連續流動速率係持在机動速率設定點之5%内（且時常在2%内），歷時乳液之滞留時間之2〇倍以上，且甚至4〇倍以上之時間。此外，維持乳液之連續流動速率，同時實質上維持乳液之物理及化學特性。，驅動機構61a、61b之操作可有利地與流經輸送管線㈠之乳液机動速率相聯結。舉例而言，驅動機構61 &、6丨b可根據來自安置於輸送管線63上之流量計或流量指示器66之輸 <響應（例如，經由pLC 8〇)，以使得所量得乳液之流動速率的降低可導致驅動機構6〗a或6lb之驅動力增加，或反之亦然。因此，當驅動機構61a、61b之驅動力包括各別分配貯槽之麼力時，乳液之所量測流動速率的降低可導致分配貯槽内所施加之壓力藉由與分配貯槽流體連通之壓力來源，諸如超大氣氣體（空氣、氮氣等）而增加，以便校正乳液之流動速率。或者’分配貯槽内所施加之壓力的增加可藉助於與分配貯槽聯結之浮動活塞或薄膜（未圖示）而達成，其中與分配貯槽聯結之外部壓力源’諸如超大氣氣體或液體係作用於活塞或薄膜以增加分配貯槽内之壓力。上述驅動機構之尤其有利之處係在於將壓力以實質上均 140236.doc -16- 201006561 勻之方式施加於貯槽中乳液之整個表面積上。此最小化關於乳液之各種有害效應，包括不連續相之局部聚結及/或聚集分散粒子之凝聚。此外彳多乳液對其所接觸之表面中的凹凸敏感（例各種類型之螺桿）β與各種習知乳液輸送機構之接觸面積相比’上述驅動機構不具有接觸面積或具有相對小之接觸面積。 t將諸如過濾單元65之可變壓降元件安置於分配貯槽參60a 60b與下游應用之間線上時，量測穿過可變麼降元件之壓降可為尤其有益的。在圖2中，料量测儀器包括安置於輸送管線63上在可變壓降元件兩側之麼力傳感器68。除圖示替代分配機構之外，圖2a之系統類似於圖2之系統。經攪動進料貯槽40,混合器42、葉輪44、馬達牝、受控回流管線48及高剪切均質機/乳化器5〇係如上文關於圖2 所述。 ❼在圖2a中，經由開/關輸入閥門69a將均質機5〇之排出物進料至單一分配貯槽6〇a中。分配貯槽6〇a較佳具有相對小工作體積以使乳液在貯槽中之滞留時間相對短，藉此降低沈積。分配貯槽60a之内部較佳塗覆有鐵氟龍（Tefl〇n)且配備有混合器（未圖示）。將進料貯槽6〇a置於荷重計64a上。分配貯槽60a並未配備有如圖2中所示之雙分配貯槽6〇& 及60b中之機械分配構件。更確切地，乳液在其離開分配貯槽60a之後經由受控出口開/關閥門62a流至泵72。如所示分配貯槽60a較佳高於泵72。輸入閥門69a與輸出閥門62& 140236.doc -17- 201006561 均由中央處理單元控制。泵72經由輸送管線63對塗覆模7〇提供精確乳液進料。雖然可使用各種泵，但需要選擇對乳液之穩定性具有最小影響之泵。合適泵之一實例為齒輪泵，諸如市售之c〇lePsi) is a source of gas (preferably having a dust force higher than atmospheric pressure or ρ"). A valve 62a and a valve 62b' are disposed downstream of the distribution sump 60a, 60b, respectively. The (4) door is preferably a control valve. When the valve is opened, the drive mechanism 61a applies pressure to the top of the emulsion of the dispensing sump 6a, thereby driving the emulsion away from the sump 60a via the transfer line 63 to the downstream of the fluid communication with the transfer line 63 and the distribution sump 60a, 60b. application. Typically, for a given flow rate, the downstream application has a variable linear pressure drop as a function of length and pipe size. In other applications, a variable non-linear pressure drop element, such as filter unit 65, is disposed between the distribution sump 60a' 60b and the downstream application. Each of the individual distribution chutes 60a, 6b is coupled to at least one weighing element, such as a load 4 64a, 64b, preferably adapted to continuously weigh the respective storage tanks. The load cells 64a, 64b preferably produce an output corresponding to the weight of the respective dispensing sump or associated therewith' to deliver the output to the central processing unit (PLC) 80 shown in Figure 3. Preferably, the PLC 80 is programmed to determine the maximum fill weight of the dispense tanks 60a, 60b based on inputs such as the instability time and specific gravity of the particular emulsion. In all cases, the residence time of the emulsion in the distribution tank is set to be less than the destabilization time of the emulsion, and preferably less than or equal to 75% of the unstabilization time of the emulsion. 140236.doc •14· 201006561 Alternatively or additionally, PLC 80 is preferably programmed to determine the maximum fill height of dispense tanks 60a, 60b based on input values such as destabilization time and specific gravity of the particular emulsion and the size of the sump. . In this case, the sump can advantageously be equipped with at least one level sensor, such as a differential pressure gauge. Other types of suitable inductors and the like are readily apparent to those of ordinary skill in the art. Using the inductors and input values as described above, the PLC 8 can be programmed to operate the dispensing sump 60a, 60b in a parallel manner. Continuous operation can be achieved by controlling/switching the emulsion delivery of the first dispensing sump (such as dispensing sump 6A) to the second dispensing sump (such as dispensing sump 60b) (e.g., by means of pLC 8 〇). During the delivery of the emulsion from the second dispensing tank, a first dispensing tank is prepared for use in another emulsion delivery cycle. This preparation may include flushing the sump via controlled line 67a with control valve 69a or via controlled line 67b with control valve 69b, discarding any remaining material in the sump or passing it back to the process via controlled return line 48 (eg, via Stir the feed tank 4)). The dispensing of the emulsion can be carried out via a dispensing sump by pressure or by means of a suitable pump or other suitable means to provide a continuous flow rate of the emulsion from the dispensing sump - & control at (example > flow rate set point) Within 5%, typically within 3% and often within 2%, while maintaining a continuous flow rate of the emulsion even when the variable drop element causes a change in pressure differential between the sump pressure and the atmosphere. Significantly, the flow rate of the downstream transfer line (and optionally through the variable element) flowing through the distribution sump is achieved during long-term operation. 140236.doc 15· 201006561: at least 1.5 of the residence time of the 'duration emulsion' Double, better emulsion, at least 2 带, s $ reach < into lag α and pass 10 at least 4 times the residence time of the emulsion in various operations, even in the emulsion delivery The continuous flow rate of the emulsion is maintained within 5% of the maneuvering rate set point (and often within 2%) from the time when one of the distribution tanks is cut 2 to the other, and the residence time of the emulsion is 2〇. More than twice, and even more than 4 times longer. In addition, the continuous flow rate of the emulsion is maintained while substantially maintaining the physical and chemical properties of the emulsion. The operation of the drive mechanisms 61a, 61b can advantageously be coupled to the emulsion maneuver rate flowing through the transfer line (i). For example, the drive mechanisms 61 &, 6丨b may be responsive (eg, via pLC 8〇) from a flow meter or flow indicator 66 disposed on the transfer line 63 to cause the emulsion to be measured. A decrease in the flow rate may result in an increase in the driving force of the drive mechanism 6 a or 6 lb, or vice versa. Thus, when the driving force of the drive mechanisms 61a, 61b includes the force of the respective dispensing sump, the decrease in the measured flow rate of the emulsion can result in the pressure applied within the dispensing sump being sourced by the fluid in fluid communication with the dispensing sump. It is increased, such as by super-atmospheric gases (air, nitrogen, etc.), in order to correct the flow rate of the emulsion. Alternatively, the increase in pressure applied in the distribution tank can be achieved by means of a floating piston or membrane (not shown) associated with the distribution tank, wherein an external pressure source associated with the distribution tank, such as a superatmospheric gas or liquid system, acts upon A piston or membrane to increase the pressure within the distribution sump. The above described drive mechanism is particularly advantageous in that the pressure is applied to the entire surface area of the emulsion in the sump in a manner that is substantially uniform at 140236.doc -16 - 201006561. This minimization is associated with various detrimental effects of the emulsion, including local coalescence of the discontinuous phase and/or agglomeration of the aggregated dispersed particles. In addition, the multi-emulsion is sensitive to the unevenness in the surface to which it is contacted (e.g., various types of screws) β compared to the contact areas of various conventional emulsion delivery mechanisms. The above-described driving mechanism does not have a contact area or has a relatively small contact area. When placing a variable pressure drop element such as filter unit 65 between the distribution sump 60a 60b and the downstream application, it may be particularly advantageous to measure the pressure drop across the variable drop element. In Fig. 2, the material measuring instrument includes a force sensor 68 mounted on the transfer line 63 on either side of the variable pressure drop element. The system of Figure 2a is similar to the system of Figure 2, except for the alternative distribution mechanism illustrated. The feed sump 40, the mixer 42, the impeller 44, the motor enthalpy, the controlled return line 48, and the high shear homogenizer/emulsifier 5 are agitated as described above with respect to Figure 2. In Fig. 2a, the effluent of the homogenizer 5 is fed into the single distribution sump 6A via the on/off input valve 69a. The distribution sump 6A preferably has a relatively small working volume to allow the residence time of the emulsion in the sump to be relatively short, thereby reducing deposition. The interior of the distribution tank 60a is preferably coated with Teflon and equipped with a mixer (not shown). The feed sump 6A is placed on the load meter 64a. The dispensing sump 60a is not equipped with mechanical dispensing members in the dual dispensing sumps 6A & and 60b as shown in FIG. More specifically, the emulsion flows to the pump 72 via the controlled outlet opening/closing valve 62a after it leaves the dispensing sump 60a. The distribution sump 60a is preferably higher than the pump 72 as shown. The input valve 69a and the output valve 62 & 140236.doc -17- 201006561 are both controlled by the central processing unit. Pump 72 provides a precise emulsion feed to coating die 7 via transfer line 63. Although a variety of pumps can be used, it is desirable to have a pump that has minimal impact on the stability of the emulsion. An example of a suitable pump is a gear pump, such as the commercially available c〇le

Parmer 數位齒輪泵（型號 7521 1_35，60_3600 rpm)〇泵 72 之另一實例為螺桿泵，諸如NEMO泵。在NEMO泵之情況下’較佳將其置於傾斜台上以消除氣泡及沈積。齒輪栗與螺桿泵均提供與轉速成比例之非脈動恆定流率。此等泵處理乳液而不會使其不穩定，且甚至在低塗覆速度下仍提供怪定流動速率。可將一或多個過濾器65包括於泵72與塗覆模70之間的流動管線中。此外’包括一或多個流量計68及壓力傳感器以提供輸入至PLC 80。亦可能需要在系統中正好在塗覆模之刖包括靜態混合器（未圖示）’以在塗佈於基板之前提供乳液之求終均質化。圖3為展示輸入至PLC 80之類比及數位輸入之實例及自 pLC 80輸出之類比及數位輸出之實例的示意方塊圖。至PLC 80之各種固定輸入參數可包括以下：流動速率設疋點；進料貯槽（諸如貯槽4〇)初始重量；進料貯槽最小重量；壓力貯槽（諸如貯槽60a、60b)最大重量；壓力貯槽最小重量；在貯槽（諸如貯槽60a、60b)之間切換期間出口闊門時間；最初設定點起始壓力；最大製程壓力位準（安全切斷標準）；再充填壓力貯槽之前高剪切均質機（諸如均質機5 0)之「打開」標準（基於壓力貯槽最小重量）；用於切換 140236.doc -18· 201006561 過濾器（諸如過濾器65)之壓力改變標準；内部pLC指令，諸如資料登入器記錄時間。圖2&中所示之系統的輸入至 PLC 80之輸人參數包括離㈣72之乳液的所要流動速率之設定點。 • 適用於本發明之各種系統及過程的例示性市售pLC為Parmer digital gear pump (model 7521 1_35, 60_3600 rpm) 另一 Another example of pump 72 is a screw pump, such as a NEMO pump. In the case of NEMO pumps, it is preferably placed on a tilting table to eliminate air bubbles and deposits. Both the gear pump and the screw pump provide a non-pulsating constant flow rate proportional to the rotational speed. These pumps treat the emulsion without rendering it unstable and provide a strange flow rate even at low coating speeds. One or more filters 65 may be included in the flow line between the pump 72 and the coating die 70. In addition, one or more flow meters 68 and pressure sensors are included to provide input to the PLC 80. It may also be desirable to include a static mixer (not shown) in the system just prior to the coating die to provide for the final homogenization of the emulsion prior to application to the substrate. 3 is a schematic block diagram showing an example of an analog and digital input to the PLC 80 and an analog and digital output from the pLC 80 output. Various fixed input parameters to PLC 80 may include the following: flow rate set point; initial weight of feed sump (such as sump 4 ;); minimum weight of feed sump; maximum weight of pressure sump (such as sump 60a, 60b); pressure sump Minimum weight; outlet wide door time during switching between storage tanks (such as storage tanks 60a, 60b); initial set point starting pressure; maximum process pressure level (safety cutoff standard); high shear homogenizer before refilling pressure storage tank (opening) standard (such as homogenizer 50) (based on the minimum weight of the pressure tank); used to switch the pressure change standard of 140236.doc -18· 201006561 filter (such as filter 65); internal pLC instruction, such as data login Record the time. The input parameters to the PLC 80 of the system shown in Figures 2 & include the set point of the desired flow rate from the emulsion of (46) 72. • An exemplary commercially available pLC suitable for use in the various systems and processes of the present invention is

Unitronics V280(Quincy’ MA)。本發明之系統及方法可有效用於多種乳液，該等乳液包括油包水乳液、水包油乳液、搖變減黏乳液、剪切變稀乳 ® 液及具有大範圍傳輸特性之乳液。關於黏度，在產生、維持及傳輸具有小於約1〇〇〇厘泊 (cp)且更通常小於100 cp或5〇 cp黏度之乳液中本發明之系統及方法可能尤其有效❶其亦尤其適用於具有約1〇邛及小於約10 cp之黏度的乳液。如上文所簡要描述，將乳液最終輸送至諸如包括模具之塗覆裝置之下游應用。塗覆裝置可為此項技術中已知之 φ 多種接觸或非接觸塗覆機中之任一者，諸如間歇塗覆機' 模塗機、凹版式塗覆機、逆轉輥式塗覆機、到刀塗覆機、棒式塗覆機、擠壓塗覆機、簾式塗覆機或任何其他塗覆或預計量裝置。狭縫模式塗覆機為較佳應用。如圖4A所示，狹縫模包括接收乳液之腔室且經由該腔室將乳液輸送至模具之模唇。在狹縫模方法中，乳液係藉由重力或在壓力下經由狹縫擠出且擠於基板（參見圖4B)上。引入至模具中之乳液可包括精細導電粒子之分散液。在一較佳實施例中，精細導電粒子為（或包括）銀、銀鋼合 U0236.doc •19- 201006561 金、奴黑或石墨。將導電粒子分散於乳液之液體相中之一者、較佳油包水乳液之連續油相中。在已將乳液塗覆或以其它方式塗佈於基板上之後，將液體蒸發以於基板上形成精細導電粒子之網路樣圖案。產生精細導電粒子之自組裝、網路樣圖案尤其有利。實例目前參考以下實例，其連同以上描述以非限制性方式說明本發明。自用圖2所說明之系統進行的9個塗覆運作收集資料。用於所有運作之乳液為含有分散於連續油相中之銀奈米粒子之油包水乳液。調配物類似於美國專利申請案2〇〇5/215689、 2005/238 894及2005/214480之實例26 »液體包括甲苯（55- 60重量％)、環己酮（4-8重量％)及水（29-34重量。/。”乳液含有3.6-5·〇重量％之根據美國專利申請案2006/1 12785製造之銀奈米粒子，其中90%粒子之直徑等於或小於〇3微米，且 50/。粒子之直徑等於或小於〇·73微米。將乳液塗覆於聚對苯二甲酸乙二醇酯（ΡΕΤ)基板上。將母運作分成兩個區域。第一區域為達到穩態流動之時間。第二區域為達成穩態流動之後的其餘運作。運作中之8個為約一小時長’而一個運作幾乎兩小時長。對於一小時運作而言每秒且對於兩小時運作而言每兩秒收集關於流動之資料。資料之來源為位於過濾器之後且恰好在模具之則的具有脈衝波輸出之渦輪型流量計（由圖2中之標號66 所不）。所記錄之資料包括以下：以毫升/分鐘計之所要流 140236.doc 201006561 動速率（「設定點」）；穩態流動區域中之最大流動速率 (最大值」）；穩態區域中之最小流動速率（「最小值」）；穩態區域中之平均流動速率（「平均值」）；穩態區域中之流動速率的標準偏差（「⑽」）；及以平均流動速率之百分比計之穩態區域中之流動速率的標準偏差 (「STD%」）。在乳液第一次離開模具之後亦用數位熱電偶記錄乳液之溫度。在塗覆運作期間監視兩個乳液參數：黏度（根據astm標準測試方法 D4212 「Vise()sity by Dip_Type ViseQsityUnitronics V280 (Quincy’ MA). The system and method of the present invention is effective for use in a variety of emulsions, including water-in-oil emulsions, oil-in-water emulsions, shake-reduced emulsions, shear-thinning creams, and emulsions having a wide range of transport characteristics. With regard to viscosity, the systems and methods of the present invention may be particularly effective in producing, maintaining and transporting emulsions having a viscosity of less than about 1 centipoise (cp) and more typically less than 100 cp or 5 cp cp. An emulsion having a viscosity of about 1 Torr and less than about 10 cp. As described briefly above, the emulsion is ultimately delivered to a downstream application such as a coating apparatus including a mold. The coating apparatus can be any of a variety of contact or non-contact coating machines known in the art, such as batch coaters, die coaters, gravure coaters, reverse roll coaters, to Knife coater, bar coater, extrusion coater, curtain coater or any other coating or pre-measurement device. Slit mode coaters are a preferred application. As shown in Figure 4A, the slot die includes a chamber that receives the emulsion and delivers the emulsion through the chamber to the lip of the mold. In the slot die method, the emulsion is extruded through a slit by gravity or under pressure and extruded onto a substrate (see Fig. 4B). The emulsion introduced into the mold may comprise a dispersion of fine conductive particles. In a preferred embodiment, the fine conductive particles are (or include) silver, silver steel, U0236.doc • 19-201006561 gold, slave black or graphite. The conductive particles are dispersed in one of the liquid phases of the emulsion, preferably in the continuous oil phase of the water-in-oil emulsion. After the emulsion has been coated or otherwise applied to the substrate, the liquid is evaporated to form a network-like pattern of fine conductive particles on the substrate. Self-assembly, network-like patterns that produce fine conductive particles are particularly advantageous. EXAMPLES Reference is now made to the following examples, which illustrate the invention in a non-limiting <RTIgt; Data was collected from nine coating operations performed using the system illustrated in Figure 2. The emulsion used for all operations is a water-in-oil emulsion containing silver nanoparticles dispersed in a continuous oil phase. Formulations are similar to Examples 26 of U.S. Patent Application Nos. 2,5/215,689, 2005/238,894, and 2005/214480. »Liquid includes toluene (55-60% by weight), cyclohexanone (4-8% by weight), and water. (29-34% by weight.) The emulsion contains 3.6-5. % by weight of silver nanoparticles produced according to US Patent Application No. 2006/1 12785, wherein 90% of the particles have a diameter equal to or less than 〇3 microns, and 50% The diameter of the particles is equal to or less than 73·73 μm. The emulsion is coated on a polyethylene terephthalate substrate. The mother operation is divided into two regions. The first region is to achieve steady state flow. Time. The second area is the rest of the operation after achieving steady state flow. Eight of the operations are about one hour long and one operation is almost two hours long. For one hour operation per second and for two hours of operation The data on the flow is collected in two seconds. The source of the data is a turbine-type flowmeter with a pulsed wave output (not indicated by reference numeral 66 in Figure 2) located behind the filter and just at the mold. The recorded data includes the following : the desired flow in milliliters per minute 140236.doc 201006561 Movement rate ("set point"); maximum flow rate (maximum flow rate) in steady flow region; minimum flow rate in steady state region ("minimum"); average flow in steady state region Rate ("average"); the standard deviation of the flow rate in the steady-state region ("(10)"); and the standard deviation of the flow rate ("STD%") in the steady-state region as a percentage of the average flow rate. The emulsion temperature was also recorded with a digital thermocouple after the emulsion left the mold for the first time. Two emulsion parameters were monitored during the coating operation: viscosity (according to the astm standard test method D4212 "Vise()ity by Dip_Type ViseQsity

Cups γ之贊恩杯方法（Zahn c叩及密度（如由比重瓶所判定之以g/ml計之恆定體積之重量）。在將乳液進料至系統之刖及在離開模具之後量測兩參數。在最初乳化之後 ^在進料至圖2中所不之系統之前）且接著在模具（圖2中之標號7〇)之後在—小時運作之5、15、3G及45分鐘時量測黏度及密度:對於兩小時運作而言，在最初乳化之後在進料至系統之則且接著在模具之後在運作之5、3G及9〇分鐘夺及在運作、’Ό束時量測此等參數。亦視覺上觀察乳液流經模具之流動。運乍在運作的15分鐘及3〇分鐘之後含有30秒暫停。在運作8及運作9中，Α ^ 在不中斷乳液流動之情況下將過濾器變換3次。礼液之不穩定化時間—般在⑴分鐘之間，從而需要如上文所述使用兩個以交替組態安置之小分配貯槽。因此， 140236.doc •21 · 201006561 頻繁在分配貯槽之間切換乳液至模具之流動，以確保乳液之滞留時間完全小於不穩定化時間，且維持至模具之實質上均勻流動速率。以下表1提供運作1 -9之乳液流動資料。表1 :流動資料，運作1-9 運作編號時間達到 SS 運作小時:分鐘:秒設定點 ml/分鐘平均值 ml/分鐘流率最小值 ml/分鐘最大值 ml/分鐘 STD ml/分鐘 STD % 1 0:02:48 0:57:21 180 178.7 174 188 2.0 1.1 2 0:02:26 0:57:28 180 178.4 174 189 2.2 1.3 3 0:02:25 0:53:20 180 178.8 172 187 2.1 1.2 4 0:03:46 0:54:26 180 178.8 174 185 1.9 1.1 5 0:03:38 0:54:05 180 179 175 186 1.7 0.9 6 0:02:50 0:16:17 180 179 175 188 2.0 1.0 在15分鐘之後暫停 0:03:54 0:18:03 180 179.4 175 186 1.7 1.0 在30分鐘之後暫停 0:02:26 0:11:20 180 180.4 175 185 2.3 1.0 7 0:01:27 1:47:02 180 179.1 172 188 1.8 1.0 8 0:03:24 0:56:03 180 178.9 174 188 2.2 1.2 9 0:02:23 0:54:02 180 178.7 174 189 2.5 1.4 注意：SS-穩態流動以下表2提供運作1-9之乳液的贊恩杯黏度。 140236.doc •22- 201006561 表2 :贊恩杯黏度，運作1-9 運作編號溫度(C)±0.1 E0-1 平均值黏度(贊恩最小值 (秒）杯1號）最大值 STD STD % 1 22.8 43.5 43.2 42.5 44.0 0.7 1.6 2 22.5 45.0 44.3 43.7 45.0 0.6 1.3 3 22.4 45.0 44.6 43.0 45.8 1.3 2.9 4 22.1 45.0 44.9 43.7 45.7 0.9 1.9 5 20.3 56.0 56.0 56.0 56.0 0.0 0.0 6 21.2 49.0 48.9 47.0 51.8 1.7 3.4 7 22.2 52.0 53.7 52.1 54.5 0.9 1.7 8 22.5 45.1 44.6 43.4 45.7 1.1 2.4 9 21.2 45.7 46.2 45.4 47.4 0.9 1.80% 以下表3提供運作1-9之乳液的密度。表3 :乳液密度，運作1-9 運作編號溫度 C ±0.1 E0-1 平均值密度最小值 g/ml 最大值 STD STD % 1 22.8 0.92 0.92 0.92 0.92 0.00 0.00 2 22.5 0.92 0.92 0.92 0.92 0.00 0.00 3 22.4 0.92 0.92 0.92 0.92 0.00 0.00 4 22.1 0.93 0.93 0.92 0.93 0.01 0.60 5 20.3 0.92 0.92 0.92 0.92 0.00 0.00 6 21.2 0.92 0.92 0.91 0.92 0.00 0.00 7 22.2 0.90 0.92 0.91 0.92 0.00 0.00 8 22.5 0.93 0.93 0.92 0.93 0.01 0.50 9 21.2 0.93 0.93 0.92 0.93 0.01 0.50 140236.doc -23- 201006561 圖。，$間運作（運作7)之乳液流動速率對時間之曲線 1游的巧冑及圖7中提供使用本發明之系統及方法加工之子的乳液流動速率對時間之例示性曲線圖。等運作所獲得之資料及所得到之觀測資料指示使用該系統之㈣間運作為可行的。經由模具達錢良的均勾及連續机動。所有量測結果均在±5%範圍之内，且大多數量測結果在±3% H圍之内。流動速率之標準偏差低於 1，5%’平均流率極接近設定點。系統在約2至5分鐘内達成穩態流動速率。大面積過渡器改良效能，在過滤器之前及之後壓力之變化小。乳液之密度保持恆定。在製程中藉由贊恩杯I測所判定之乳液之黏度相對但定。對於圖2a中所示之包含齒輪泵之系統而言，用先前實例中所用之相同類型之油包水乳液使用c〇le Parmer數位齒輪泵（型號75211-35，60-3600 RPM)進行49分鐘之運作，將該齒輪泵之流動速率設定為69 ml/分鐘。圖8及以下表4提供此運作之乳液流動資料。獲得極佳流動速率控制以使得整個運作中之平均流動速率為68.95 ml/分鐘，具有0.21 mi/ 分鐘之標準偏差。因此標準偏差對應於平均流動速率之 0.3%。此外，系統在運作開始2.5分鐘内達成穩態流動。 140236.doc • 24- 201006561 表4:具有齒輪泵之進料系統之乳液流動速率資料運作時間，分鐘 49 設定點*，mL/分鐘 69 最小流率，mL/分鐘 68 最大流率，mL/分鐘 69 平均值/運作，mL/分鐘 68.95 STD，mL/分鐘 0.21 STD，％ 0.3 儘&本發明已結合其具體實施例加以描述，但顯然許多替代形S、修改形式及變化形式對熟習此項技術者顯而易見。因此，意欲包含適合附加之申請專利範圍之精神及廣泛範疇之所有該等替代形式、修改形式及變化形式。【圖式簡單說明】圖1為本發明之方法的示意流程圖；圖2為本發明之系統之實施例的示意圖；圖2a為具有替代分配機構之本發明之系統的示意圖；圖3為控制乳液自分配貯槽至塗覆裝置之流動速率之中央處理單元的示意圖；圖4a為用於將乳液塗佈至基板之狹縫式塗覆機模之說明；圖4b說明經由模具將乳液塗佈於基板上；圖5為使用本發明之系統的以下實例中所述之塗覆運作7 140236.doc -25- 201006561 之乳液流動速率對時間之圖表；及圖6、圖7及圖8為使用本發明之系統的三種代表性塗覆運作之乳液流動速率對時間之圖表。【主要元件符號說明】 40 進料貯槽 42 混合器 44 葉輪 46 馬達 48 受控回流管線 50 高剪切均質機及/或乳化器 60 分配貯槽 60a 分配貯槽 60b 分配貯槽 61a 驅動機構 61b 驅動機構 62a 閥門 62b 閥門 63 輸送管線 64a 荷重計 64b 荷重計 65 過濾單元 66 流量計或流量指示器 67a 受控管線 67b 受控管線 140236.doc -26- 201006561 68 壓力 69a 控制 69b 控制 70 模具 72 泵 100 系統傳感器閥門/開/關輸入閥門閥門Cups gamma cup method (Zahn c叩 and density (such as the weight of a constant volume in g/ml as determined by a pycnometer). Measured after feeding the emulsion to the system and after leaving the mold Parameters: after initial emulsification ^ before feeding to the system not shown in Figure 2) and then measured at 5, 15, 3, and 45 minutes of the hour-hour operation after the mold (labeled 7〇 in Figure 2) Viscosity and Density: For two-hour operation, after the initial emulsification, after feeding to the system and then after the mold, at 5, 3G and 9 minutes after operation, the operation is measured, and the measurement is carried out at the end of the operation. parameter. The flow of the emulsion through the mold was also visually observed. The operation has a 30-second pause after 15 minutes and 3 minutes of operation. In Operation 8 and Operation 9, Α ^ The filter was changed 3 times without interrupting the emulsion flow. The destabilizing time of the ritual fluid is generally between (1) minutes, requiring the use of two small dispensing sumpes arranged in an alternating configuration as described above. Therefore, 140236.doc •21 · 201006561 Frequent switching of the emulsion to the mold flow between the distribution tanks ensures that the residence time of the emulsion is completely less than the destabilization time and maintains a substantially uniform flow rate to the mold. Table 1 below provides information on the flow of emulsions for operations 1-9. Table 1: Flow data, operation 1-9 Operation number time reaches SS operation hours: minutes: seconds set point ml/minute average ml/minute flow rate minimum ml/min maximum ml/min STD ml/min STD % 1 0:02:48 0:57:21 180 178.7 174 188 2.0 1.1 2 0:02:26 0:57:28 180 178.4 174 189 2.2 1.3 3 0:02:25 0:53:20 180 178.8 172 187 2.1 1.2 4 0:03:46 0:54:26 180 178.8 174 185 1.9 1.1 5 0:03:38 0:54:05 180 179 175 186 1.7 0.9 6 0:02:50 0:16:17 180 179 175 188 2.0 1.0 Pause after 15 minutes 0:03:54 0:18:03 180 179.4 175 186 1.7 1.0 Pause after 30 minutes 0:02:26 0:11:20 180 180.4 175 185 2.3 1.0 7 0:01:27 1 :47:02 180 179.1 172 188 1.8 1.0 8 0:03:24 0:56:03 180 178.9 174 188 2.2 1.2 9 0:02:23 0:54:02 180 178.7 174 189 2.5 1.4 Note: SS-steady state Flow Table 2 below provides the Zane cup viscosity for the 1-9 emulsion. 140236.doc •22- 201006561 Table 2: Zane Cup Viscosity, Operation 1-9 Operation Number Temperature (C) ± 0.1 E0-1 Average Viscosity (Zane Minimum (Second) Cup No. 1) Maximum STD STD % 1 22.8 43.5 43.2 42.5 44.0 0.7 1.6 2 22.5 45.0 44.3 43.7 45.0 0.6 1.3 3 22.4 45.0 44.6 43.0 45.8 1.3 2.9 4 22.1 45.0 44.9 43.7 45.7 0.9 1.9 5 20.3 56.0 56.0 56.0 56.0 0.0 0.0 6 21.2 49.0 48.9 47.0 51.8 1.7 3.4 7 22.2 52.0 53.7 52.1 54.5 0.9 1.7 8 22.5 45.1 44.6 43.4 45.7 1.1 2.4 9 21.2 45.7 46.2 45.4 47.4 0.9 1.80% Table 3 below provides the density of the emulsions of operations 1-9. Table 3: Emulsion Density, Operation 1-9 Operation No. Temperature C ± 0.1 E0-1 Average Density Minimum G/ml Maximum STD STD % 1 22.8 0.92 0.92 0.92 0.92 0.00 0.00 2 22.5 0.92 0.92 0.92 0.92 0.00 0.00 3 22.4 0.92 0.92 0.92 0.92 0.00 0.00 4 22.1 0.93 0.93 0.92 0.93 0.01 0.60 5 20.3 0.92 0.92 0.92 0.92 0.00 0.00 6 21.2 0.92 0.92 0.91 0.92 0.00 0.00 7 22.2 0.90 0.92 0.91 0.92 0.00 0.00 8 22.5 0.93 0.93 0.92 0.93 0.01 0.50 9 21.2 0.93 0.93 0.92 0.93 0.01 0.50 140236.doc -23- 201006561 Picture. , Inter-Functional Operation (Operation 7), Emulsion Flow Rate vs. Time 1 Traveling and Figure 7 provides an exemplary plot of emulsion flow rate versus time for processing using the systems and methods of the present invention. The information obtained from the operation and the observations obtained indicate that the operation of (4) using the system is feasible. Through the mold, Da Qianliang's hook and continuous maneuver. All measurements were within ± 5% and most measurements were within ± 3% H. The standard deviation of the flow rate is less than 1,5% 'the average flow rate is very close to the set point. The system achieves a steady state flow rate in about 2 to 5 minutes. Large-area transitioners improve performance with little change in pressure before and after the filter. The density of the emulsion remains constant. In the process, the viscosity of the emulsion determined by the Zahn Cup I test is relatively constant. For the system containing the gear pump shown in Figure 2a, the same type of water-in-oil emulsion used in the previous example was used for 49 minutes using a c〇le Parmer digital gear pump (model 75211-35, 60-3600 RPM). For operation, the gear pump flow rate was set to 69 ml/min. Figure 8 and Table 4 below provide information on the emulsion flow for this operation. Excellent flow rate control was obtained such that the average flow rate throughout the run was 68.95 ml/min with a standard deviation of 0.21 mi/min. Therefore the standard deviation corresponds to 0.3% of the average flow rate. In addition, the system achieves steady state flow within 2.5 minutes of the start of operation. 140236.doc • 24-201006561 Table 4: Emulsion flow rate data operating time with gear pump feed system, minutes 49 set point*, mL/min 69 Minimum flow rate, mL/min 68 Maximum flow rate, mL/min 69 Mean/Operation, mL/min 68.95 STD, mL/min 0.21 STD, % 0.3 The present invention has been described in connection with its specific embodiments, but it is obvious that many alternative forms, modifications and variations are familiar to the subject. The technology is obvious. All such alternatives, modifications and variations are intended to be included within the scope of the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic flow chart of a method of the present invention; FIG. 2 is a schematic view of an embodiment of the system of the present invention; FIG. 2a is a schematic diagram of a system of the present invention having an alternative distribution mechanism; Schematic diagram of a central processing unit for the flow rate of the emulsion from the dispensing tank to the coating device; Figure 4a is an illustration of a slot coating machine for applying an emulsion to a substrate; Figure 4b illustrates the application of the emulsion to the mold via a die Figure 5 is a graph of emulsion flow rate versus time for the coating operation 7 140236.doc -25-201006561 described in the following example using the system of the present invention; and Figures 6, 7 and 8 are used A graph of emulsion flow rate versus time for three representative coating operations of the inventive system. [Main component symbol description] 40 Feed storage tank 42 Mixer 44 Impeller 46 Motor 48 Controlled return line 50 High shear homogenizer and / or emulsifier 60 Distribution tank 60a Distribution tank 60b Distribution tank 61a Drive mechanism 61b Drive mechanism 62a Valve 62b Valve 63 Transfer line 64a Load meter 64b Load meter 65 Filter unit 66 Flow meter or flow indicator 67a Controlled line 67b Controlled line 140236.doc -26- 201006561 68 Pressure 69a Control 69b Control 70 Mold 72 Pump 100 System sensor valve / on / off input valve valve

140236.doc -27-140236.doc -27-

Claims

201006561 七、申請專利範圍： 1. 一種用於將乳液連續塗佈於基板上之系統，該系統包含： ’ (a) 經調適以接收及加工至少兩種不可混溶液體之貯槽，該貯槽具有混合機構，該貯槽及該機構係經調適以產生該等不可混溶液體之混合物； (b) 經調適以接收該混合物且對該混合物起作用以產生或維持—包含該等不可混溶液體中之-者之連續相及 ® 3其他不可混溶液體之小液滴之不連續相的乳液之高剪切均質機，該等小液滴實質上均勾且在預定尺寸範圍内； (c)經調適以將該乳液自該均質機輸送至該基板之表的刀配機構’其包含⑴至少—個分配貯槽及（H)用於將該乳液驅動至該基板的驅動機構；及201006561 VII. Patent Application Range: 1. A system for continuously applying an emulsion onto a substrate, the system comprising: '(a) a storage tank adapted to receive and process at least two immiscible liquids, the storage tank having a mixing mechanism, the tank and the mechanism being adapted to produce a mixture of the immiscible liquids; (b) adapted to receive the mixture and act on the mixture to produce or maintain - including the immiscible liquids a high shear homogenizer of the continuous phase of the continuous phase and the discontinuous phase of the small droplets of the other 3 immiscible liquids, the droplets being substantially hooked and within a predetermined size range; (c) a knives mechanism adapted to transport the emulsion from the homogenizer to the surface of the substrate, comprising: (1) at least one distribution sump and (H) a drive mechanism for driving the emulsion to the substrate;

⑷與該驅動機構操作性地聯結以⑴提供小於該乳液之不穩定化時間的該乳液在該分配機構内之滯留時間且 (:)將該乳液流經該分配機構之該流動速率控制在預定範圍内之控制器。 2.如請求項1之系統米0 3 ·如請求項2之系統米。 4.如請求項1之系統器。其中該平均小液滴尺寸係小於2〇微其中該平均小液滴尺寸係小於10微其中該控制器為可程式化邏輯控制 140236.doc 201006561 5·如請求項丨之系統，其中將該乳液流經該分配系統之該流動逮率維持在預定流動速率之5%内。月求項5之系統，其中將該乳液流經該分配系統之該流動逮率維持在預定流動速率之3%内。 7’如凊求項1之系統，其中存在兩個或兩個以上之分配貯槽且其係經組態以並聯方式操作，以便藉由在不中斷該 =液之流動的情況下自—個分配貯槽切換至另—者而進行該乳液流經該分配機構之連續流動。 8. 月求項1之系統’其中存在一個分配貯槽且該驅動機構為位於該分配貯槽與該基板之間的泵。 9. 如喷求項8之系統’其中該泵為齒輪果或螺桿栗。 1〇.如凊求項1之系統’其中該乳液在該分配機構内之該滯時間係小於该乳液之該不穩定化時間的750/。。 11. 如咱求項!之系統，其中該分配機構進一步包含在該分配貯槽下游之可變壓降元件。 13. 如請求項1之系統子。 14. 如請求項13之系統 15. 如請求項14之系統 12. 如明求項"之系統，其中該可變壓降元件為過濾器。其中該混合物進一步包含分散粒其中該等分散粒子為導電粒子。 .. 其中該等導電粒子為選自銀、銀銅 5金、碳黑或石墨之粒子。 16. 如請求項13之系統，再中尨寺刀散粒子在一個維度上具有小於3微米之平均粒度。 17. 如W之系統’其中該等分散粒子在_個維度上具 140236.doc 201006561 有小於1微米之平均粒度。 .5微米如請求項17之系統’其中該等分散粒子具有小於〇之平均粒度。 -微米 19.如請求項18之系統，其中該等. 刀欺粒子具有小於0.1, 之平均粒度。 20如請求項1之系統，其中該分 -機構包含用於將該乳液塗佈至該基板之塗覆裝置。參 21. 如請求項20之系統’其中該塗覆裝置包含模且。 22. -㈣於在基板上連續形成透明導電塗層之方法，其包含： ⑷形成至少兩種不可混溶液體及精細導電粒子之混合物； (b)使該混合物經受高剪切均質化以產生或維持一包含連續相及非連續相之乳液，該連續相包含—種不可混溶液體，且該非連續相包含其他不可混溶液體之小液滴，該小液滴尺寸係在預定尺寸範圍内； (e)將該均質化乳液以使得在該乳液不穩定化之前將該礼液塗覆於該基板上之實質怪定預定流動速率連續分配至塗覆裝置； (d)將該均質化乳液連續塗覆於基板上；且 ()自》亥乳液中蒸發該液體以於該基板上形成透明導電塗層，其中該塗層在該基板之表面上係呈界定隨機形狀空隙之精細粒子互連跡線之網路樣圖案形式。 23.如請求項22之方法，其中該乳液為油包水乳液。 140236.doc 201006561 24_如請求項23之方法，其中將該等精細導電粒子係分散於該乳液之油相中。 25. 如請求項24之方法，其中該等精細導電粒子在至少一個方向上具有小於3.0微米之平均粒度。 26. 如請求項24之方法，其中該等精細導電粒子在至少一個方向上具有小於1 ·0微米之平均粒度。 27. 如請求項24之方法’其中該精細導電粉末在至少一個方向上具有小於0.5微米之平均粒度。 28. 如§青求項25之方法’其中該等精細導電粒子在至少一個方向上具有小於0.1微米之平均粒度。 29. 如凊求項22之方法，其中該等精細導電粒子係選自銀、銀銅合金、碳黑及石墨。 140236.doc(4) operatively coupled to the drive mechanism to (1) provide a residence time of the emulsion within the dispensing mechanism that is less than the destabilizing time of the emulsion and (:) control the flow rate of the emulsion through the dispensing mechanism to be predetermined Controller within range. 2. System of claim 1 m 0 3 • System of claim 2 m. 4. The system of claim 1 is as follows. Wherein the average small droplet size is less than 2 〇 micro, wherein the average small droplet size is less than 10 micro, wherein the controller is programmable logic control 140236.doc 201006561 5 · as requested in the system, wherein the emulsion The flow rate through the dispensing system is maintained within 5% of the predetermined flow rate. The system of claim 5, wherein the flow rate of the emulsion flowing through the dispensing system is maintained within 3% of the predetermined flow rate. 7' The system of claim 1, wherein there are two or more distribution tanks configured and operated in parallel to allow for self-distribution without interrupting the flow of the liquid The sump is switched to another and the emulsion is continuously flowed through the dispensing mechanism. 8. The system of claim 1 wherein there is a distribution sump and the drive mechanism is a pump located between the distribution sump and the substrate. 9. The system of claim 8 wherein the pump is a gear fruit or a screw. The system of claim 1 wherein the lag time of the emulsion in the dispensing mechanism is less than 750/ of the destabilizing time of the emulsion. . 11. The system of claim 1, wherein the dispensing mechanism further comprises a variable pressure drop element downstream of the dispensing sump. 13. As requested in item 1. 14. The system of claim 13 15. The system of claim 14 12. The system of claim 1, wherein the variable pressure drop element is a filter. Wherein the mixture further comprises dispersed particles wherein the dispersed particles are electrically conductive particles. . . wherein the conductive particles are particles selected from the group consisting of silver, silver, copper, gold, carbon, or graphite. 16. The system of claim 13 wherein the Zhongyusi knife particles have an average particle size of less than 3 microns in one dimension. 17. The system of W, wherein the dispersed particles have an average particle size of less than 1 micron in the dimension of 140236.doc 201006561. .5 microns. The system of claim 17 wherein the dispersed particles have an average particle size less than 〇. - Micron 19. The system of claim 18, wherein the knife particles have an average particle size of less than 0.1. 20. The system of claim 1 wherein the sub-mechanism comprises a coating device for applying the emulsion to the substrate. The system of claim 20 wherein the coating device comprises a mold. 22. - (d) a method of continuously forming a transparent conductive coating on a substrate, comprising: (4) forming a mixture of at least two immiscible liquids and fine conductive particles; (b) subjecting the mixture to high shear homogenization to produce Or maintaining an emulsion comprising a continuous phase comprising a non-mixable solution, and the discontinuous phase comprising small droplets of other immiscible liquid, the droplet size being within a predetermined size range (e) continuously distributing the homogenized emulsion to the coating device at a predetermined flow rate that is applied to the substrate before the emulsion is destabilized; (d) the homogenized emulsion Continuously applied to the substrate; and () evaporating the liquid from the emulsion to form a transparent conductive coating on the substrate, wherein the coating is a fine particle interconnect defining a random shape void on the surface of the substrate A network-like pattern of traces. 23. The method of claim 22, wherein the emulsion is a water-in-oil emulsion. The method of claim 23, wherein the fine conductive particles are dispersed in the oil phase of the emulsion. 25. The method of claim 24, wherein the fine conductive particles have an average particle size of less than 3.0 microns in at least one direction. 26. The method of claim 24, wherein the fine conductive particles have an average particle size of less than 1.0 micron in at least one direction. 27. The method of claim 24 wherein the fine conductive powder has an average particle size of less than 0.5 microns in at least one direction. 28. The method of claim 25, wherein the fine conductive particles have an average particle size of less than 0.1 micron in at least one direction. 29. The method of claim 22, wherein the fine conductive particles are selected from the group consisting of silver, silver copper alloy, carbon black, and graphite. 140236.doc