Highly efficient electric-thermal conversion of Silver/PVP composites for micro initiators by direct ink writing

Abstract

Traditional film initiator fabrication techniques were limited by material and process constraints, resulting in restricted ignition capability, durability issues, and complexity in manufacturing. In this study, Metal/polymer composite materials were applied in film initiators in order to enhance the mechanical properties, longevity, and thermal attributes. Silver/polyvinylpyrrolidone composite film bridge (SPB) initiators were fabricated by direct ink writing (DIW). By adjusting the silver loading level and sintering temperature in the Ag nanoparticles/polyvinylpyrrolidone (Ag NPs/PVP) ink formulation, precise control over the structure and resistivity of the SPB was achieved. Compared to single silver film bridge (SFB) initiators prepared by magnetron sputtering (MS), SPBs demonstrated superior heating performance, higher current carrying capacity, and energy utilization under constant current excitation. In capacitor discharge tests, SPBs exhibited superior electric explosion characteristics and plasma properties, with a 25.53% higher energy utilization efficiency compared to SFBs. The peak plasma electron temperature of SPBs reached 7610K, which was 1065K higher than that of SFBs. This makes Silver/polyvinylpyrrolidone composite highly promising practical alternatives for high-efficiency, stable, and reliable ignition processes, with potential widespread applications in the aerospace field.