Anisotropic Conductive Sheet With Elastomer-Filled Through Holes
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Solution Overview
Problem
Anisotropic conductive sheets used in electrical testing are prone to cracking and peeling of conductive layers due to repeated pressurization and depressurization, leading to poor conduction and variations in resistance values.
Innovation Solution
An anisotropic conductive sheet with a cross-linked conductive elastomer composition filling through holes, featuring conductive particles and an elastomer, which prevents cracking and peeling by maintaining conductivity through the use of conductive fillers and a structured layer configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal thin films are formed on the inner wall surfaces of through holes to provide conductivity, then electrical conduction is achieved, but the conductive layers are prone to cracking and peeling due to repeated pressurization and depressurization
Solution Approach 1:
The patent uses a composite structure consisting of a resin layer and an elastomer layer combined together. The resin layer provides structural support and adhesion to the through hole walls, while the elastomer layer provides elasticity and stress absorption during pressurization cycles. This composite material approach resolves the contradiction by combining materials with complementary properties to achieve both conductivity stability and resistance to cracking/peeling.
Solution Approach 2:
The patent modifies the physical and chemical parameters of the conductive material by using a cross-linked elastomer composition with specific properties (storage elastic modulus between 10^5 to 10^7 Pa, specific glass transition temperature range). The cross-linking degree and elastomer composition are optimized to provide the right balance of flexibility and structural integrity, preventing cracking and peeling while maintaining conductivity under repeated pressurization.
2Ease of operation
If an anisotropic conductive sheet is designed to be readily elastically deformed in the thickness direction to facilitate electrical connection, then ease of operation is improved, but the conductive layers become more susceptible to damage from repeated pressurization
Solution Approach 1:
The patent employs a flexible anisotropic conductive sheet structure where the elastomer layer acts as a flexible component that can be readily deformed during the pushing process to establish electrical connection. The flexibility is carefully controlled through the elastomer composition and cross-linking to allow easy deformation for connection while the resin layer and conductive filler network maintain structural integrity and prevent conductive layer damage during repeated cycles.
3Reliability
If the conductive layer is made thin to reduce resistance, then electrical conductivity is improved, but the layer becomes more vulnerable to cracking and peeling
Solution Approach 1:
The conductive layer is designed as a composite structure with conductive fillers dispersed in the resin and elastomer matrix. This composite approach allows the use of thinner conductive layers with lower resistance while the resin and elastomer components provide mechanical strength and crack prevention. The conductive fillers form a network that maintains conductivity even in thinner configurations.
Solution Approach 2:
The patent optimizes the thickness and composition parameters of the conductive layer by controlling the conductive filler content, particle size distribution, and cross-linking degree of the elastomer. These parameter adjustments enable the conductive layer to achieve low resistance while maintaining sufficient strength to resist cracking and peeling during repeated pressurization cycles.
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
The solution effectively prevents cracking and peeling of the conductive layer, ensuring stable electrical connection and consistent conductivity even after repeated pressurization and depressurization cycles, enhancing the reliability of electrical testing.
Implementation Method 1
each of the plurality of conductive fillers contains a cross-linked product of a conductive elastomer composition that contains a conductive particle and an elastomer
Implementation Method 2
the conductive elastomer composition that contains a conductive particle and an elastomer
Implementation Method 3
An anisotropic conductive sheet has conductivity in the thickness direction thereof and insulating properties in the surface direction
Data Source
AI summary
This anisotropic electroconductive sheet includes: an insulating layer having a first surface, a second surface, and a plurality of through-holes penetrating between the two surfaces; a plurality of electroconductive layers disposed on the inner wall surfaces of each of the plurality of through-holes; and a plurality of electroconductive fillers filled into cavities surrounded by the electroconductive layers inside each of the plurality of through-holes. Each of the plurality of electroconductive fillers contains a crosslinked product of an electroconductive elastomer composition containing electroconductive particles and an elastomer.