Electro-conductive Adhesive Tape Particle Size Optimization
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Solution Overview
Problem
Electro-conductive pressure-sensitive adhesive tapes face challenges in maintaining sufficient conductivity and adhesive force, especially with reduced adhesive areas in downsized electronic appliances, as increasing conductive particle content can compromise adhesive force and vice versa.
Innovation Solution
An electro-conductive pressure-sensitive adhesive tape with a pressure-sensitive adhesive layer containing a resin component and electro-conductive particles, where the particles have specific size distribution peaks between 15 μm and 50 μm, and 1 μm to 12 μm, and are present in a 40-80% mass ratio, ensuring both conductivity and adhesive force even with small adhesive areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the content of electro-conductive particles in the pressure-sensitive adhesive layer is increased to secure sufficient conductivity, then the conductivity is improved, but the pressure-sensitive adhesive force decreases
Solution Approach 1:
The patent changes the particle size parameter of electro-conductive particles to resolve the contradiction. Specifically, it uses particles with a volume median diameter of 5 μm or more but less than 20 μm, which optimizes the balance between conductivity and adhesive force by reducing excessive particle aggregation while maintaining sufficient conductive pathways.
Solution Approach 2:
The patent employs a composite material approach by combining electro-conductive particles with specific properties (controlled particle size, density of 0.5-8.0 g/cm³) with the pressure-sensitive adhesive matrix. This composite structure allows the system to achieve both adequate conductivity and maintained adhesive force through proper material selection and proportioning.
2Area of moving object
If the adhesive area is reduced for downsized electronic appliances, then the device size is reduced, but the pressure-sensitive adhesive force decreases
Solution Approach 1:
The patent changes the particle size parameter to compensate for reduced adhesive area. By using particles with volume median diameter of 5 μm or more but less than 20 μm, the adhesive achieves higher effectiveness per unit area, allowing sufficient total adhesive force even with smaller bonding surfaces in compact devices.
3Area of moving object
If the adhesive area is reduced for downsized electronic appliances, then the device size is reduced, but the conductivity decreases
Solution Approach 1:
The patent optimizes particle size parameters (volume median diameter: 5 μm or more but less than 20 μm) to enhance conductivity efficiency. This allows sufficient conductive pathways to be formed within smaller adhesive areas, maintaining adequate conductivity in downsized applications without requiring larger bonding surfaces.
Data Source
AI summary
An electro-conductive pressure-sensitive adhesive tape comprises a pressure-sensitive adhesive layer containing a resin component and an electro-conductive particle. The electro-conductive particle has at least one peak top existing in a particle size range from about 15 μm or more to about 50 μm or less and at least one further peak top existing in a particle size range from about 1 μm or more to about 12 μm or less in a particle size distribution curve thereof. The electro-conductive particle is contained in the pressure-sensitive adhesive layer in an amount of 40 mass % or more but 80 mass % or less, and has a true density in a level of larger than zero but smaller than 8 g/cm3.