Conductive Adhesive Film With 3D Metal Network for Low Contact Resistance
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Solution Overview
Problem
Conductive adhesive films face challenges in achieving high conductivity due to contact resistance between conductive particles, which affects their electrical conductivity.
Innovation Solution
A conductive adhesive film with a three-dimensional porous network of metal coatings or hollow tubular metal structures embedded in an adhesive base layer, where discrete particles are connected by metal coatings or binders to form a continuous electrically and mechanically connected network between major surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If discrete conductive particles are used in an adhesive layer, then the adhesive film can be manufactured with conventional processes, but contact resistance between particles reduces electrical conductivity
Solution Approach 1:
The conductive structure is segmented into discrete particles that are distributed throughout the adhesive layer. These particles are connected through metal coatings to form conductive paths while maintaining the adhesive's flexibility and manufacturability.
Solution Approach 2:
The invention uses composite structures where conductive particles with metal coatings are embedded in an adhesive matrix. This combines the adhesive properties of the polymer material with the conductive properties of the metal-coated particles, achieving both manufacturability and electrical conductivity.
2Reliability
If metal coatings are applied to particles to form continuous networks, then electrical conductivity is improved, but manufacturing complexity increases
Solution Approach 1:
Metal coatings serve as an intermediary layer on the conductive particles, facilitating electrical contact between adjacent particles. This intermediary layer enables continuous conductive networks to form throughout the adhesive layer, improving electrical conductivity while maintaining a relatively simple overall structure.
3Reliability
If contact resistance between particles is reduced, then electrical conductivity increases, but achieving continuous metal paths requires complex particle arrangements
Solution Approach 1:
The metal coatings provide localized conductive quality at the particle surfaces and contact points. This local enhancement of conductivity at critical interfaces allows continuous conductive paths to form through the adhesive layer without requiring complex overall particle arrangements, as the metal coatings ensure reliable contact where particles meet.
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 provides a conductive adhesive film with high conductivity by minimizing contact resistance and ensuring continuous electrical and mechanical connectivity, enabling efficient electrical conduction between surfaces.
Implementation Method 1
the metal coatings are connected with one another and are extended between the first and second major surfaces, such that an electrically and mechanically continuous three-dimensional porous network of the metal is formed
Implementation Method 2
outer surfaces of the particles are coated with metal at least in part to form metal coatings
Implementation Method 3
a continuous unitary three-dimensional network of hollow tubular metal structures which are electrically and mechanically connected with one another, the hollow tubular metal structures being embedded in the adhesive base layer and being extended between the first and second major surfaces
Implementation Method 4
a binder couples adjacent particles in the chain
Data Source
AI summary
A conductive adhesive film according to an embodiment includes: an adhesive base layer including first and second major surfaces facing each other; and a plurality of discrete individual particles distributed in the adhesive base layer, wherein outer surfaces of the particles are coated with metal at least in part to form metal coatings, and the metal coatings are connected with one another and are extended between the first and second major surfaces, such that an electrically and mechanically continuous three-dimensional porous network of the metal is formed.