Adhesive-Based Electrical Contact Formation
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Solution Overview
Problem
The existing methods for electrical contacting of conductive parts with electrical insulation require additional steps to remove or avoid insulation at contact points, complicating the process and making it difficult to achieve desired connections.
Innovation Solution
A method using an adhesive that is brought into a tacky and flowable state to form an electrical contact between conductive parts, which is then converted into a non-tacky state, allowing for simultaneous mechanical and electrical connection without the need to remove or avoid insulation, using heat, solvents, or other physical influences to control the adhesive's state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulation is removed at contact points or selectively applied, then electrical contact can be made, but the process becomes more complex and time-consuming
Solution Approach 1:
The patent combines the electrical insulation layer and the adhesive layer into a single integrated layer. This unified structure eliminates the need for separate insulation and adhesive application steps, thereby reducing process complexity while ensuring both electrical insulation and reliable adhesive bonding functions are achieved simultaneously.
Solution Approach 2:
The adhesive layer is designed to serve multiple functions: it provides electrical insulation, mechanical bonding, and controlled electrical contact at specific points. By making the adhesive layer multi-functional, the patent eliminates the need for separate insulation layers and complex selective application processes, simplifying the overall manufacturing process while maintaining contact reliability.
2Reliability
If insulation is removed at contact points, then electrical contact can be made, but additional work steps are required
Solution Approach 1:
The adhesive layer is pre-configured with raised connecting surfaces at the intended contact points before the bonding process. This preliminary structuring eliminates the need for post-application insulation removal, as the conductive paths are already prepared in advance, thereby reducing process time while ensuring contact reliability.
Solution Approach 2:
By merging the insulation and adhesive functions into one layer with pre-formed raised surfaces, the patent eliminates the sequential steps of applying insulation, then removing it at contact points. The combined structure enables direct electrical contact through the raised surfaces without requiring additional time-consuming removal operations.
3Strength
If adhesive is pressed out of contact area with NCA adhesive, then mechanical connection is achieved outside contact area, but electrical connection is only possible with ACA or ICA adhesive
Solution Approach 1:
The patent applies different adhesive types to different regions: NCA (non-conductive adhesive) is used in areas where only mechanical connection is needed, while ACA (anisotropically conductive adhesive) or ICA (isotropically conductive adhesive) is used where electrical connection is required. This localized differentiation allows optimization of each region's function while maintaining overall system performance.
Solution Approach 2:
The adhesive application is segmented into different functional zones within the same layer. The raised connecting surfaces are selectively treated with different adhesive types based on the required function (mechanical only or mechanical plus electrical), allowing the patent to achieve both strong mechanical connection and reliable electrical contact where needed without compromising versatility.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method simplifies the connection process by allowing electrical contact formation without disturbing insulation, maintaining insulation outside the contact area, and enabling selective connection formation using different adhesives with varying properties.
Implementation Method 1
The insulating material is preferably brought into the sticky and flowable state by supplying heat.
Implementation Method 2
the process of setting the adhesive in the tacky state also results in bringing it into a flowable state in which it can be pressed out of the contact area or compressed in the contact area by pressing against one another. If an NCA adhesive is used, it is pushed out of the contact area, and if an ACA adhesive or ICA adhesive (isotropically conductive adhesive) is used, it is at least compressed, so that in any case there is an electrical connection between the conductive parts
Implementation Method 3
If a heat-curing adhesive is used, the transition to the non-tacky state (curing) also takes place at elevated temperature.
Implementation Method 4
The heat can be supplied by increasing the temperature of the surrounding space, but also specifically by the action of infrared or light rays, ultrasound and magnetic or electric fields.
Implementation Method 5
The heat can be supplied by increasing the temperature of the surrounding space, but also specifically by the action of infrared or light rays, ultrasound and magnetic or electric fields.
Implementation Method 6
A volatile solvent can be added to the insulating material to cause this condition.
Implementation Method 7
After electrical contact is made by applying pressure, the solvent evaporates while maintaining the pressure until the insulating material resolidifies.
Data Source
Figure 1~2
Figure 3(a)~3(b)
AI summary
The invention relates to a method for connecting two parts (2, 4), which overlap each other only partially and have electrically conducting structures, mechanically and electrically at the same time. For purposes of electrical insulation and/or for mechanical and/or chemical protection, at least one of the conductors is extensively covered with an electrically insulating material (1) beyond the overlapping area and including the connection surface. In order to establish the connection, the conducting parts are pressed against each other in the area of the connection surfaces of said conducting parts and in the area surrounding said connection surfaces. An adhesive is used as the electrically insulating material. Said adhesive is put into a sticky state during the connection, thereby forming an electrical contact (6) between the electrical connection surfaces and in the area surrounding said electrical connection surfaces, after which the adhesive is brought into a permanently adhering state.