Anisotropic Conductive Sheet Layout to Prevent Layer Cracking
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Solution Overview
Problem
Anisotropic conductive sheets used in electrical inspections often experience cracks and peeling of the conductive layer due to repeated pressurization and depressurization, leading to conduction failures.
Innovation Solution
An anisotropic conductive sheet design featuring an insulating layer with through holes, continuous conductive layers on the inner walls, and groove parts on the surface to insulate the conductive layers, where the center of gravity of the through hole opening is separated from the conductive layer center, reducing the pushing load and preventing cracking and peeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the center of the terminal of the inspection object is located at the center of each through hole, then electrical connection is achieved, but a large pushing load is applied to the through hole causing cracks and peeling of the conductive layer
Solution Approach 1:
The patent applies asymmetry by intentionally offsetting the center of gravity of the conductive layer from the center of the through hole opening. This asymmetric arrangement causes the pushing load to act on the insulating layer rather than concentrating on the conductive layer, thereby preventing cracks and peeling while maintaining electrical connection reliability
Solution Approach 2:
The insulating layer acts as an intermediary that absorbs and distributes the pushing load. By positioning the conductive layer asymmetrically within the through hole, the insulating layer mediates between the applied load and the conductive layer, preventing direct stress concentration on the conductive material
2Productivity
If pressurization and depressurization are repeated during inspection, then inspection is completed, but cracks and peeling occur at the conductive member leading to conduction failures
Solution Approach 1:
The asymmetric positioning of the conductive layer provides beforehand cushioning by allowing the insulating layer to absorb repeated pressurization loads. This preventive design protects the conductive layer from fatigue-induced cracks and peeling that would otherwise occur during repeated inspection cycles
Solution Approach 2:
The asymmetric arrangement of the conductive layer within the through hole creates a load distribution mechanism that protects against repeated stress. The offset positioning ensures that compressive forces are distributed to the more compliant insulating layer rather than concentrating on the brittle conductive material during pressurization-depressurization 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
This design effectively suppresses cracking and peeling of the conductive layer during repeated pressurization and depressurization, maintaining stable conductivity.
Implementation Method 1
The anisotropic conductive sheet has conductivity in the thickness direction and an insulation property in the surface direction, and is used as a probe (contact) for electrical inspection
Implementation Method 2
a plurality of first groove parts disposed on the first surface between the plurality of conductive layers, and configured to insulate the plurality of conductive layers
Implementation Method 3
it is desirable for the anisotropic conductive sheet to be elastically deformable in the thickness direction
Data Source
AI summary
This anisotropic conductive sheet (10) comprises: an insulating layer (11) having a first surface located on one side in the thickness direction, a second surface located on the other side, and a plurality of through holes (12) penetrating between the first surface and the second surface; a plurality of conductive layers (22) continuously arranged at the inner wall surface of the through holes in each of at least some of the plurality of through holes and around the openings of the through holes on the first surface; and a plurality of first grooves (14) that are arranged between the plurality of conductive layers on the first surface to insulate the conductive layers from each other, wherein the center of gravity (C2) of the opening of each through hole is set apart from the center of gravity (C1) of the respective conductive layer on the first surface.