Resin Particle Core-Shell Structure for Protrusion Stability
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Solution Overview
Problem
Resin particles with protrusions used in conductive microparticles face issues of non-uniform protrusion size and distribution density, leading to detachment and instability in conductive connections, which affects light diffusivity and blocking resistance.
Innovation Solution
Designing resin particles with a spherical part and a peripheral part of different compositions, where the peripheral part has a melting point above 200°C and a specific curvature center, to create a core-shell structure that enhances protrusion stability and uniformity, and using these particles as substrates for conductive microparticles with a metal layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resin particles with protrusions are used as substrates for conductive microparticles, then conductive connection can be provided, but the protrusions detach causing instability in conductive connections
Solution Approach 1:
The resin particle is divided into two distinct parts: a spherical core part and a peripheral part containing multiple convex parts (protrusions). This segmentation allows the core to provide structural support while the peripheral part provides the functional protrusions, reducing detachment
Solution Approach 2:
The resin particle uses a composite structure with a spherical core part made of one resin composition and a peripheral part made of a different resin composition. This composite structure provides both structural integrity and functional protrusion stability, preventing detachment during conductive connection applications
2Manufacturing precision
If protrusion size and distribution density are not uniform, then manufacturing is simpler, but light scattering intensity decreases deteriorating light diffusivity
Solution Approach 1:
The peripheral part of the resin particle is designed with specific local characteristics: multiple convex parts with controlled size (0.1-10 μm) and distribution density (0.01-10 per μm²). This local quality control ensures uniform light scattering while maintaining manufacturability through the core-shell structure
3Reliability
If protrusions are used as anti-blocking agents in resin films, then blocking resistance is improved, but detached protrusions cause damage to the surrounding resin film
Solution Approach 1:
By segmenting the resin particle into a robust spherical core and a peripheral layer containing convex parts, the structure ensures that protrusions remain anchored during friction. The core provides structural support that prevents detachment and subsequent damage to the surrounding resin film while maintaining blocking resistance
Solution Approach 2:
The composite structure with different resin compositions in the core and peripheral parts creates optimal mechanical properties: the core provides structural integrity to prevent detachment, while the peripheral part with convex parts provides blocking resistance, eliminating the harmful effect of detached protrusions
Data Source
AI summary
The object of the present invention is to provide a resin particle having a protrusion that is more resistant to the detachment and having a uniform protrusion size and protrusion distribution density. The resin particle of the present invention comprises: a spherical part and a peripheral part having a plurality of convex part formed on the surface of the spherical part, wherein the spherical part and the peripheral part comprise a vinyl polymer and/or a polysiloxane component, the spherical part and the peripheral part are different in the composition, the melting point of the peripheral part is not less than 200° C., and the curvature center of the boundary between the peripheral part and the spherical part determined by a transmission electron microscope observation of the cross-section of the resin particle exists in the spherical part.