Liquid Metal Anisotropic Conductive Film for Stretchable 3D Contact

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Solution Overview

Problem

Existing anisotropic conductive films (ACFs) face limitations in stretchability and conductivity due to the use of solid conductive particles, leading to issues such as detachment and loss of electrical connection, especially in three-dimensional structures with customized deformations.

Innovation Solution

A stretchable anisotropic conductive film (S-ACF) incorporating liquid metal portions in a stretchable base material, allowing for vertical conductivity and deformation according to electrode shape, using thermoplastic rubber and gallium-based liquid metals with specific size, spacing, and patterning techniques like photolithography and microwaves for conductivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If solid conductive particles are used in ACF, then conductivity is achieved, but stretchability is limited and particles may detach during tension

Engineering Contradiction:

Improveelectrical connection stabilityVSAvoidstretchability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent changes the physical state of conductive particles from solid to liquid metal, which fundamentally alters the material properties. Liquid metal can flow and deform continuously under tension, maintaining electrical connection while accommodating stretchable substrate deformation, thus resolving the contradiction between connection stability and stretchability

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite structure by dispersing liquid metal particles within a stretchable polymer matrix. This composite approach combines the electrical conductivity of liquid metal with the elasticity and deformability of the polymer, achieving both reliable electrical connection and high stretchability simultaneously

Inventive Principle:

Principle #40Composite materials

2Reliability

If solid conductive particles are used in ACF, then conductivity is provided, but resolution is low due to random arrangement

Engineering Contradiction:

ImproveconductivityVSAvoidparticle arrangement regularity

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent applies preliminary patterning to arrange liquid metal particles in regular patterns before the final product formation. By pre-organizing particles through controlled deposition or self-assembly processes, the system achieves high-resolution, uniform conductivity patterns rather than random distributions

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent utilizes the unique properties of liquid metal, such as surface tension and wetting behavior, to control particle arrangement. By adjusting parameters like substrate treatment, deposition conditions, or liquid metal composition, regular patterns emerge that provide both high conductivity and manufacturing precision

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If stretchable polymer is used for ACF, then stretchability is achieved, but conductive particles do not stretch and may detach

Engineering Contradiction:

ImprovestretchabilityVSAvoidparticle attachment

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent changes the state of conductive particles from solid to liquid, which fundamentally resolves the mismatch in deformation behavior. Liquid metal particles can flow and deform continuously with the stretchable polymer substrate, eliminating detachment issues while maintaining electrical connection during stretching

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite where liquid metal particles are embedded in a stretchable polymer matrix. The liquid metal's ability to deform and flow complements the polymer's elasticity, ensuring both materials can stretch together without particle detachment while maintaining reliable electrical connection

Inventive Principle:

Principle #40Composite materials

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 S-ACF maintains stable electrical connections and uniform conductivity, adapting to three-dimensional structures by distributing stress evenly, ensuring reliable electrical contact even under tension and curvature.

Implementation Method 1

liquid metal portions arranged in the stretchable base material... both surfaces of the S-ACF are electrically connected

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

maintain stable contact with the electrode while uniformly dispersing the stress throughout the film during tension

Methodology Applied

Scientific EffectStress distribution:

Implementation Method 3

the stretchable base material may include thermoplastic rubber grafted with maleic anhydride including at least one thermoplastic rubber selected from the group consisting of styrene-ethylene-butylene-styrene (SEBS), styrene-isoprene-styrene (SIS), styrene-butadiene-styrene (SBS)

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS20250357018A1Anisotropic conductive elastic material including liquid metal particles and its manufacturing method

Publication Date: 2025.11.20 MIDAS H&T INC

AI summary

The present invention relates to a stretchable anisotropic conductive film containing liquid metal particles and a manufacturing method therefor. The stretchable anisotropic conductive film according to the present invention includes: a stretchable base material; and a liquid metal portion formed and arranged within the stretchable base material.