Lamination of polymer thick film conductor compositions

1. An electrical device comprising an electrical conductor formed from a polymer thick film solder alloy conductor composition, said polymer thick film solder alloy conductor composition comprising:

(a) 65 to 95 wt % SAC solder alloy powder consisting of tin, silver, and copper, wherein said tin is greater than 90 wt % of said SAC solder alloy powder, and said SAC solder alloy powder possessing an average particle size of 2 to 18 μm and a surface area/mass ratio in the range of 0.2 to 1.3 m 2 /g; dispersed in

(b) 5 to 35 wt % organic medium comprising:

(i) a vinyl co-polymer resin of vinylidene chloride and acrylonitrile, dissolved in

(2) organic solvent comprising a dibasic ester;

wherein the wt % of said SAC solder alloy powder and said organic medium are based on die total weight of the polymer thick film solder alloy conductor composition and wherein said electrical conductor has been subjected to lamination.

2. An electrical device comprising an electrical conductor formed from a polymer thick film conductor composition, wherein said polymer thick film conductor composition is a polymer thick film solder alloy/metal conductor composition comprising:

(a) 35 to 94 wt % solder alloy powder selected from the group consisting of (i) SAC solder alloy powder consisting of a tin, silver, and copper alloy powder, wherein said tin is greater than 90 wt % of said SAC solder alloy powder, (ii) a tin and bismuth alloy powder, wherein said tin is at least 40 wt % of said tin and bismuth alloy powder, and (iii) mixtures thereof, said alloy powder consisting of particles possessing an average particle size of 2 to 18 μm and a surface area/mass ratio in the range of 0.2 to 13 m 2 /g;

(b) 1 to 30 wt % metal selected from the group consisting of silver, copper, gold, aluminum and mixtures thereof, said metal consisting of particles possessing an average particle size of 2 to 18 μm and a surface area/mass ratio in the range of 0.1 to 2.3 m 2 /g; and

(c) 5 to 35 wt % organic medium comprising:

(1) a resin that is a vinyl co-polymer resin of vinylidene chloride and acrylonitrile or a thermoplastic resin; dissolved in

(2) organic solvent comprising a dibasic ester or glycol ether;

with the proviso that if said thermoplastic resin is a phenoxy resin said metal is silver; wherein said solder alloy powder and said metal are dispersed in said organic medium, wherein the wt % of said solder alloy powder, said metal and said organic medium are based on the total weight of the polymer thick film conductor composition and wherein said electrical conductor has been subjected to lamination.

3. An electrical device comprising an electrical conductor formed by a method comprising:

a) providing a substrate;

b) providing a polymer thick film solder alloy conductor composition comprising:

(i) 65 to 95 wt % SAC solder alloy powder consisting of tin, silver, and copper, wherein said tin is greater than 90 wt % of said SAC solder alloy powder, and said SAC solder alloy powder possessing an average particle size of 2 to 18 μm and a surface area/mass ratio in the range of 0.2 to 1.3 m 2 /g; dispersed in

(ii) 5 to 35 wt % organic medium comprising:

(1) a vinyl co-polymer resin of vinylidene chloride and acrylonitrile, dissolved in

(2) organic solvent comprising a dibasic ester, wherein the wt % of said SAC solder alloy powder and said organic medium are based on the total weight of the polymer thick film solder alloy conductor composition;

c) applying said thick fl 1 m conductor composition onto said substrate; and

d) subjecting said thick film conductor composition to lamination to form said electrical conductor.

4. The electrical device of claim 3 , said method further comprising a step of drying said thick film conductor composition, wherein said step of drying is carried out following step (c) but before step (d).

5. An electrical device comprising an electrical conductor formed by a method comprising:

(a) providing a substrate;

(b) providing a polymer thick film solder alloy/metal conductor composition comprising:

(1) 35 to 94 wt % solder alloy powder selected from the group consisting of (i) SAC solder alloy powder consisting of a tin, silver, and copper, wherein said tin is greater than 90 wt % of said SAC solder alloy powder, (ii) a tin and bismuth alloy powder, wherein said tin is at least 40 wt % of said tin and bismuth alloy powder, and (iii) mixtures thereof, said alloy powder consisting of particles possessing an average particle size of 2 to 18 μm and a surface area/mass ratio in the range of 0.2 to 1.3 m 2 /g;

(2) 1 to 30 wt % metal selected from the group consisting of silver, copper, gold, aluminum and mixtures thereof, said metal consisting of particles possessing an average particle size of 2 to 18 μm and a surface area/mass ratio in the range of 0.1 to 2.3 m 2 /g; and

(3) 5 to 35 wt % organic medium comprising:

(i) a resin that is a vinyl co-polymer resin of vinylidene chloride and acrylonitrile or a thermoplastic resin; dissolved in

(ii) organic solvent comprising a dibasic ester or glycol ether, with the proviso that if said thermoplastic resin is a phenoxy resin said metal is silver, wherein said solder alloy powder and said metal are dispersed in said organic medium and wherein the wt % of said solder alloy powder, said metal and said organic medium are based on the total weight of the polymer thick film conductor composition;

c) applying said thick film conductor composition onto said substrate; and

d) subjecting said thick film conductor composition to lamination to form said electrical conductor.

6. The electrical device of claim 5 , said method further comprising a step of drying said thick film conductor composition, wherein said step of drying is carried out following step (c) but before step (d).