Anisotropic Conductive Film with Patterned Particle Regions

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Solution Overview

Problem

Conventional anisotropic conductive films used for connecting electronic components to a single substrate have randomly dispersed conductive particles, leading to inefficient use of particles and increased waste, as the number density and arrangement cannot be precisely controlled to match the terminal patterns of different components.

Innovation Solution

The development of an anisotropic conductive film with regularly arranged conductive particles and varying number densities, diameters, and hardnesses in different regions, allowing for optimized connection of electronic components with reduced waste by matching the particle distribution to specific terminal patterns.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conductive particles are randomly dispersed in an insulating resin layer, then the anisotropic conductive film can be easily manufactured, but the number density of conductive particles cannot be precisely controlled, leading to many useless conductive particles

Engineering Contradiction:

Improveease of manufactureVSAvoidprecision of conductive particle distribution

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The conductive particles are preliminarily arranged in a regular pattern within the insulating resin layer before the final lamination process. This preliminary arrangement ensures that when the anisotropic conductive film is applied, the particles are already positioned to match terminal patterns, reducing waste while maintaining manufacturing efficiency

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent creates regions with different number densities of conductive particles within the same anisotropic conductive film. By making different parts of the film have different particle densities, it can adapt to different terminal patterns in various regions, thereby reducing useless particles while maintaining precise control

Inventive Principle:

Principle #3Local quality

2Reliability

If the number density of conductive particles is adapted to the smaller electronic component, then connection can be achieved, but many useless conductive particles remain that do not participate in connection

Engineering Contradiction:

Improveconnection reliabilityVSAvoidwaste of conductive particles

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The anisotropic conductive film is divided into regions with different number densities of conductive particles. Regions corresponding to larger components have higher particle density, while regions for smaller components have lower density. This local differentiation ensures optimal connection for each component size without excessive waste

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The film is segmented into multiple regions with different particle densities, allowing each region to be optimized for specific component types. This segmentation enables the film to serve multiple component sizes effectively, reducing overall particle waste while maintaining connection reliability

Inventive Principle:

Principle #1Segmentation

3Productivity

If one sheet of anisotropic conductive film is used to connect two types of electronic components, then the number of steps and space can be reduced, but the particle arrangement cannot be optimized for each component type

Engineering Contradiction:

Improveconnection efficiencyVSAvoidadaptability to different component types

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

A single anisotropic conductive film sheet is designed to perform multiple functions by incorporating regions with different particle densities. This multi-functional design allows one film to optimally connect different types of electronic components with varying terminal patterns, maintaining productivity while improving adaptability

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

Different regions of the film have tailored particle densities suited for specific component types. This local optimization within a universal film structure enables one sheet to adapt to multiple component configurations, achieving both efficiency and versatility

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS10957462B2Anisotropic conductive film

Publication Date: 2021.03.23 DEXERIALS CORP

AI summary

In a connection structure, a first electronic component having a first terminal pattern and a second electronic component having a second terminal pattern different in size and pitch from the first terminal pattern are anisotropically conductively connected by an anisotropic conductive film to a third electronic component having a terminal pattern corresponding to each of the first terminal pattern and the second terminal pattern. The anisotropic conductive film has at least one of a region in which conductive particles are regularly arranged, and a plurality of regions in which at least one of a number density, a particle diameter, and a hardness of the conductive particles in one region is different from that in the other region.