Conductive Adhesive Film With Cavity-Filled Coating for Lower Material Use
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Solution Overview
Problem
Existing electrically conductive adhesives face a challenge in optimizing both adhesive properties and electrical conductivity, as increasing conductivity often negatively affects cost and performance.
Innovation Solution
The adhesive film comprises a conductive adhesive layer directly on a conductive coating with cavities, allowing the adhesive to fill these cavities during lamination, thereby increasing conductivity while reducing the amount of coating material needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a higher amount of electrically conductive additives is added to increase electrical conductivity, then electrical conductivity is improved, but cost and adhesive properties deteriorate
Solution Approach 1:
The conductive coating is segmented into a three-dimensional structure with cavities and protrusions instead of a flat continuous layer. This segmentation allows the adhesive to access and fill the cavities, creating multiple contact points and conductive pathways through the coating, thereby achieving higher conductivity with less conductive material.
Solution Approach 2:
The conductive coating is designed with a porous structure containing numerous cavities. The adhesive penetrates these cavities and forms conductive networks within the porous structure, enabling efficient electrical conduction while minimizing the amount of conductive additives required in the coating itself.
2Reliability
If a higher amount of electrically conductive additives is added to increase electrical conductivity, then electrical conductivity is improved, but cost deteriorates
Solution Approach 1:
The conductive coating is segmented into a three-dimensional structure with cavities and protrusions instead of a flat continuous layer. This segmentation allows the adhesive to access and fill the cavities, creating multiple contact points and conductive pathways through the coating, thereby achieving higher conductivity with less conductive material.
Solution Approach 2:
The conductive coating is designed with a porous structure containing numerous cavities. The adhesive penetrates these cavities and forms conductive networks within the porous structure, enabling efficient electrical conduction while minimizing the amount of conductive additives required in the coating itself.
3Reliability
If the adhesive layer is made tacky to fill the cavity during lamination, then electrical conductivity and adhesive properties are improved, but manufacturing precision requirements increase
Solution Approach 1:
The adhesive's tackiness parameter is optimized to ensure proper filling of the cavities during lamination. The adhesive is formulated with specific viscosity and tack characteristics that allow it to flow into and fill the cavities under lamination pressure, then maintain stable bonding without requiring excessive precision control during the manufacturing process.
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 approach enhances electrical conductivity and maintains adhesive properties while minimizing material costs, allowing for efficient manufacturing with consistent performance.
Implementation Method 1
the adhesive layer is tacky, allowing for it to be pressed into the cavity during the lamination process
Data Source
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AI summary
The invention relates to an adhesive film comprising an electrically conductive adhesive layer, an electrically conductive coating, and a substrate, wherein the adhesive layer is arranged directly on the coating and the coating is arranged directly on the substrate, and wherein the coating comprises at least one cavity filled by the adhesive layer.