Soft Hollow Conductive Metal Particles for Stable Pressure Contacts
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Solution Overview
Problem
Conventional hollow metal particles do not provide sufficient contact area for stable conductivity with connection targets, and they have broad particle size distributions leading to uneven participation in connections.
Innovation Solution
The development of hollow conductive metal particles with a softness feature, characterized by a metal layer on a surface with an empty space inside, ensuring the metal layer remains continuous under 20% strain without cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional hollow metal particles are used, then the structure is simple, but the contact area with connection targets is insufficient and conductivity is not stable
Solution Approach 1:
The patent changes the physical state of the hollow metal particles by controlling their softness through specific manufacturing parameters. The particles are designed to have a metal layer thickness and hollow structure that allows them to deform under pressure without breaking, transforming them from rigid to soft. This parameter change enables the particles to increase their contact area with connection targets while maintaining structural integrity, thereby improving conductivity stability.
Solution Approach 2:
The patent employs a thin metal layer structure that acts as a flexible shell. The metal layer is designed with controlled thickness and material properties to allow elastic deformation under compression. When pressed against connection targets, the flexible metal layer deforms to conform to the target surface, maximizing contact area. The hollow interior provides compressibility while the metal layer maintains electrical continuity, solving the contradiction between maintaining simple structure and achieving sufficient contact area.
2Productivity
If hollow metal particles with broad particle size distribution are used, then manufacturing is easier, but particle sizes are non-uniform and only large particles participate in connection
Solution Approach 1:
The patent applies parameter changes to control the particle size distribution during manufacturing. By adjusting parameters such as inner core particle size, metal layer thickness, and drying conditions, the process produces hollow metal particles with narrow size distribution. This ensures uniform particle sizes that all participate effectively in connections, while maintaining manufacturing efficiency through a scalable process.
3Reliability
If the metal layer is made thinner to increase softness, then contact area increases, but the metal layer may crack or break under pressure
Solution Approach 1:
The patent designs the metal layer as a flexible thin film with optimized thickness and material properties. The metal layer is thin enough to allow deformation and increase contact area, but thick enough and structurally sound enough to prevent cracking under compression. The hollow structure provides cushioning that reduces stress concentration, allowing the use of thinner metal layers without compromising integrity.
Solution Approach 2:
The patent creates a composite structure consisting of the metal layer and the hollow interior space. This composite design allows the metal layer to be thin and flexible for good contact, while the hollow structure provides mechanical support and stress distribution. The combination enables the system to achieve both softness for increased contact area and sufficient strength to maintain electrical continuity under pressure.
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
These particles increase the contact area with connection targets, enhancing conductivity by maintaining electrical continuity under pressure, thus improving connection reliability.
Implementation Method 1
when the conductive metal particles are deformed at 20% strain by pressurization, there is no portion in which the metal layer is cracked or broken so that it becomes discontinuous
Implementation Method 2
an inner core particle removal process of heating conductive metal particles in which an inner core particle containing a polymer resin is coated with a metal layer to remove all or part of the inner core particle
Implementation Method 3
an annealing process of heating the conductive metal particles to a temperature equal to or higher than a heating temperature of the inner core particle removal process
Data Source
AI summary
The present invention relates to hollow conductive metal particles with softness properties. The hollow conductive particles with softness properties, of the present invention, are metal particles in which, when external pressure is applied thereto, metal particle metal layers do not break and layers of conductive particles with softness properties change according to the surface morphology of objects to which same is applied. The present invention relates to the hollow conductive metal particles and a preparation method therefor.