Anisotropic Conductive Sheet Structure for Stable Test Connections
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Solution Overview
Problem
Existing anisotropic conductive sheets face issues with insufficient deformation in the thickness direction, leading to poor handleability and unstable electrical connections due to high thermal expansion coefficients and lack of conductive layers on the surface, resulting in variable conductive path pitches and resistance values during electrical testing.
Innovation Solution
An anisotropic conductive sheet with an elastic insulation layer composed of cross-linked elastomer and heat-resistant resin, featuring through holes with conductive layers on the inner walls and surface, and groove parts to ensure deformation and stable electrical connections, reducing thermal expansion effects and improving handleability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an insulation layer made of silicone rubber is used, then the anisotropic conductive sheet becomes soft and elastic, but it lacks stiffness resulting in poor handleability and has high thermal expansion coefficient causing pitch variation during heating
Solution Approach 1:
The patent uses a composite insulation layer combining a porous layer (providing elasticity and deformation capability) with a heat-resistant resin layer (providing stiffness and low thermal expansion). This composite structure resolves the contradiction by integrating materials with complementary properties: the porous layer enables elastic deformation for good handleability, while the heat-resistant resin layer maintains dimensional stability and reduces pitch variation during thermal processing.
2Ease of operation
If the insulation layer does not include elastomer, then the handleability improves, but the deformation in the thickness direction becomes insufficient leading to poor electrical connection
Solution Approach 1:
The patent applies local quality by providing elasticity only where needed (in the porous layer for deformation) while maintaining stiffness in other regions (heat-resistant resin layer for structural support). The porous layer is specifically designed to be elastic to enable sufficient deformation in the thickness direction for reliable electrical connection, while the heat-resistant resin layer provides the necessary stiffness for good handleability.
3Ease of manufacture
If the conductive layer is only at the inner wall surface of the through hole, then the manufacturing is simplified, but sufficient electrical connection cannot be performed
Solution Approach 1:
The patent extends the conductive layer from a one-dimensional inner wall coating to a two-dimensional structure that includes both the inner wall surface and the surface of the sheet. This dimensional extension ensures sufficient electrical connection by providing conductive pathways at multiple locations, while the manufacturing process remains relatively simple by using conventional plating techniques on the through hole structure.
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 enables sufficient deformation in the thickness direction, reduces conductive path pitch variation due to heat, and achieves low electric resistance values, enhancing handleability and electrical connection reliability between testing apparatus and inspection objects.
Implementation Method 1
an elastic body layer including a cross-linked elastomer composition
Implementation Method 2
a heat-resistant resin layer including a heat-resistant resin composition with a glass transition temperature higher than that of the cross-linked elastomer composition
Implementation Method 3
a plurality of conductive layers disposed at inner wall surfaces of the plurality of through holes
Data Source
AI summary
An anisotropic conductive sheet according to the present invention comprises an insulating layer and a plurality of conductive layers. The insulating layer is elastic, and has a first surface that is positioned on one side in the thickness direction, a second surface that is positioned on the other side in the thickness direction, and a plurality of through holes that penetrate the layer from the first surface to the second surface. The conductive layers are respectively arranged on the inner wall surfaces of the plurality of through holes. The insulating layer comprises an elastic layer that is formed of a crosslinked product of an elastomer composition, and a heat-resistant resin layer that is formed of a heat-resistant resin composition that has a higher glass transition temperature than the crosslinked product of an elastomer composition.