Fabrication of Electrically Conductive Metal Patterns at the Surface of Polymer Films by Microplasma-Based Direct Writing

We describe a direct-write process for producing electrically conductive metal patterns at the surface of polymers. Thin films of poly(acrylic acid) (PAA) loaded with Ag ions are reduced by a scanning, atmospheric-pressure microplasma to form crystalline Ag features with a line width of 300 mu m. Materials analysis reveals that the metallization occurs in a thin layer of similar to 5 mu m near the film surface, suggesting that, the Ag ions diffuse to the surface. Sheet resistances of 1-10 Omega/sq are obtained independent of film thickness and Ag volume concentration, which is desirable for producing surface conductivity on polymers while minimizing metal loading.