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Patent US6690564 - Anisotropically conductive sheet, production process thereof and connector - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inAdvanced Patent SearchPatentsDisclosed herein is an anisotropically conductive sheet that exhibits conductivity in its thickness-wise direction, and is suitably used as a connector. The anisotropically conductive sheet of the first feature may comprise a plurality of columner conductive parts extending in the thickness-wise direction...http://www.google.com/patents/US6690564?utm_source=gb-gplus-sharePatent US6690564 - Anisotropically conductive sheet, production process thereof and connectorAdvanced Patent SearchPublication numberUS6690564 B1Publication typeGrantApplication numberUS 09/662,122Publication dateFeb 10, 2004Filing dateSep 14, 2000Priority dateSep 17, 1999Fee statusPaidAlso published asUS6841876, US20040080048Publication number09662122, 662122, US 6690564 B1, US 6690564B1, US-B1-6690564, US6690564 B1, US6690564B1InventorsYuichi Haruta, Naoshi YasudaOriginal AssigneeJsr CorporationExport CitationBiBTeX, EndNote, RefManPatent Citations (7), Referenced by (20), Classifications (9), Legal Events (4) External Links: USPTO, USPTO Assignment, EspacenetAnisotropically conductive sheet, production process thereof and connector
US 6690564 B1Abstract
Disclosed herein is an anisotropically conductive sheet that exhibits conductivity in its thickness-wise direction, and is suitably used as a connector.
What is claimed is: 1. An anisotropically conductive sheet comprising an anisotropically conductive sheet member having conductivity in its thickness-wise direction and a static charge-eliminating layer integrally provided on at least one surface of the sheet member.
2. An anisotropically conductive sheet comprising an anisotropically conductive sheet member provided with a plurality of conductive parts each extending in the thickness-wise direction of the sheet member in a state mutually insulated by insulating parts, and a static charge-eliminating layer provided on at least one surface of each of the insulating parts in the sheet member.
3. The anisotropically conductive sheet according to claim 2, wherein the static charge-eliminating layer is provided on the insulating parts in the sheet member.
4. The anisotropically conductive sheet according to claim 1, wherein the static charge-eliminating layer is composed of a layer containing a conductive organic substance, anine type organic conductive substance, metal or carbon black, a layer of a thermosetting resin or thermoplastic resin containing a conductive substance therein, or a layer formed of a conductive polymer.
5. The anisotropically conductive sheet according to claim 1, wherein the static charge-eliminating layer is formed of a metallic layer.
6. The anisotropically conductive sheet according to claim 1, wherein the static charge-eliminating layer is formed of a layer, which contains a sodium salt of an alkylsulfonic acid.
7. A process for producing the anisotropically conductive sheet according to claim 1, comprises the steps of coating a sheet member with a flowable composition for forming a static charge-eliminating layer, which contains a conductive substance and a binder or a curable material which will become a binder to form a coating film, and then subjecting the coating film to a drying treatment and/or a curing treatment, thereby forming the static charge-eliminating layer.
8. A process for producing the anisotropically conductive sheet according to claim 1, which comprises the steps of bonding a film for static charge-eliminating layer to become a static charge-eliminating layer to a sheet member, thereby forming the static charge-eliminating layer.
9. A connector formed of the anisotropically conductive sheet according claim 1.
10. A method for inspecting a circuit device, which comprises conducting electrical inspection of the circuit 3 device using the connector according to claim 9.
11. An anisotropically conductive sheet comprising an anisotropically conductive sheet member having conductivity in the thickness-wise direction of the sheet member and formed of an elastic polymeric substance, a conductive part for connection to be connected to an external device or terminal of an electronic part, and at least one conductive part for static-charge elimination to be connected to a ground.
12. The anisotropically conductive sheet according to claim 11, wherein the sheet member is provided with a plurality of conductive parts for connection each extending in the thickness-wise direction of the sheet member in a state mutually insulated by insulating parts, and the conductive part for static-charge elimination is arranged in a blank region outside a region, in which the conductive part for connection is arranged, in the sheet member.
13. The anisotropically conductive sheet according to claim 11, wherein the sheet member is constructed by arranging at least one conductive part for static-charge elimination in a state dispersively in the blank region.
14. The anisotropically conductive sheet according to claim 11, wherein the sheet member is constructed by arranging at least one conductive part for static-charge elimination about the region in which the conductive part for connection is arranged.
15. The anisotropically conductive sheet according to claim 11, wherein the conductive parts for static-charge elimination contains at least one conductive substance selected from among metallic particles, conductive metal oxides, conductive organic substances and carbon black.
16. The anisotropically conductive sheet according to claim 11, wherein the conductive parts for static-charge elimination have the same structure as the conductive part for connection.
17. The anisotropically conductive sheet according to claim 11, wherein the conductive parts for static-charge elimination have the same composition as the conductive part for connection.
18. A connector formed of the anisotropically conductive sheet according claim 11.
19. A method for inspecting a circuit device, which comprises conducting electrical inspection of the circuit device using the connector according to claim 18.
The present invention has been made on the basis of the foregoing circumstances and has as the first object the provision of an anisotropically conductive sheet capable of preventing or inhibiting it from being charged by generation of static electricity on the surface thereof.
The surface resistivity of the semiconductive part may preferably be 10−to 1010 Ω/□ (ohm per square).
FIG. 17 is a cross-sectional view illustrating a state that m ate rial layers for semiconductive part have been formed so as to surround the respective insulating parts in the mold;
The present invention will hereinafter be described in details.
As the metal salt of the alkylsulfonic acid, is preferred an alkali metal salt. Specific examples thereof include sodium 1-decanesulfonate, sodium 1-undecane-sulfonate, sodium 1-dodecanesulfonate, sodium 1-tridecane-sulfonate, sodium 1-tetradecanesulfonate, sodium 1-pentadecanesulfonate, sodium 1-hexadecanesulfonate, sodium 1-heptadecanesulfonate, sodium 1-octadecanesulfonate, sodium 1-nonadecanesulfonate, sodium 1-eicosanedecasulfonate, potassium 1-decanesulfonate, potassium 1-undecanesulfonate, potassium 1-dodecanesulfonate, potassium 1-tridecanesulfonate, potassium 1-tetradecanesulfonate, potassium 1-pentadecanesulfonate, potassium 1-hexadecanesulfonate, potassium 1-heptadecanesulfonate, potassium 1-octadecanesulfonate, potassium 1-nonadecanesulfonate, potassium 1-eicosanedecasulfonate, lithium 1-decanesulfonate, lithium 1-undecanesulfonate, lithium 1-dodecanesulfonate, lithium 1-tridecanesulfonate, lithium 1-tetradecanesulfonate, lithium 1-pentadecanesulfonate, lithium 1-hexadecanesulfonate, lithium 1-heptadecanesulfonate, lithium 1-octadecanesulfonate, lithium 1-nonadecanesulfonate, lithium 1-eicosanedecasulfonate and isomers thereof.
Among these compounds, the sodium salts are particularly preferred in that they are excellent in heat resistance. These salts may be used in combination. The amount of the metal salt of the alkylsulfonic acid added is preferably within a range of 0.1 to 20% by mass based on the polymeric substance forming the base material of the semiconductive parts. The reason for it is that if the content of the metal salt of the alkylsulfonic acid is lower than 0.1% by mass, the antistatic effect achieved may become low in some cases, and if the content exceeds 20% by mass on the other hand, the mechanical strength of the base material of the resulting semiconductive parts may be lowered, or the electric conductivity of the insulating part between adjacent conductive parts may become high to make insulating property between both conductive parts insufficient in some cases.
A pair of electromagnets 59A, 59B are then arranged on the upper surface of the ferromagnetic base plate 51 in the top force 50 and the lower surface of the. ferromagnetic base plate 56 in the bottom force 55 as illustrated in FIG. 4, and the electromagnets 59A, 59B are energized, thereby applying a parallel magnetic field having an intensity distribution, i.e., a parallel magnetic field having high intensity between the ferromagnetic portions 52 in the top force 50 and their corresponding ferromagnetic portions 57 in the bottom force 55, to the sheet-forming material layer 10A in the thickness-wise direction thereof. As a result, in the sheet-forming material layer 10A, the conductive particles dispersed in the sheet-forming material layer 10A are gathered at portions located between the ferromagnetic portions 52 in the top force 50 and their corresponding ferromagnetic portions 57 in the bottom force 55 and at the same time oriented so as to be arranged in the thickness-wise direction of the sheet-forming material layer 10A.
As a means for making the openings 11K in the sheet 10B for semiconductive part, may be used the same means as the means for making the through-holes 11H in the sheet 10B for semiconductive part in the above-described Process A flowable material for conductive part, in which conductive particles exhibiting magnetism are dispersed in a polymer-forming material, is then filled into the openings 11K in the sheet 10B for semiconductive part, thereby forming layers 11A of the material for conductive part in the openings 11K and the sheet 10B for semiconductive part, in which the layers 11A of the material for conductive part have been formed, is arranged in the mold shown in FIG. 2, as illustrated in FIG. 14.
(1) A process in which a flowable composition for forming a static charge-eliminating layer, which contains a conductive substance (selfconductive substance and/or hygroscopic conductive substance), a sheet member is coated with the composition for forming the static charge-eliminating layer to form a coating film, and the coating film is then subjected to a fixing treatment;
(2) A process in which a film for static charge-eliminating layer is formed, and the film for static charge-eliminating layer is bonded to a sheet member;
(3) A process in which a sheet member is subjected to a metal plating treatment such as electroplating, electroless plating, sputtering or vapor deposition; and
(4) A process in which a layer to become a static charge-eliminating layer is formed on the molding surface of a mold, and a sheet member is prepared in the mold.
In Process (1), a proper solvent may be used to impart flowability to the composition for forming the static charge-eliminating layer or control the flowability of the composition for forming the static charge-eliminating layer.
A cross-sectional view illustrating an anisotropically conductive sheet according to Structural Example 1 is shown in FIG. 24. This anisotropically conductive sheet 10 is constructed by a sheet member 20 and a static charge-eliminating layer 30 provided on a surface (the upper surface in FIG. 24) of the sheet member 20 so as to cover another region than the periphery thereof.
For the same reasons, the electric conductivity of the static charge-eliminating layer 30 is preferably 1�10−3to 1�10−5 Ω−m−1 when the thickness of the static charge-eliminating layer 30 is, for example, 1 mm.
A cross-sectional view illustrating an anisotropically conductive sheet according to Structural Example 2 is shown in FIG. 25. This anisotropically conductive sheet 10 has a sheet member 20 composed of a plurality of conductive parts 21 each closely filled with conductive particles and extending in the thickness-wise direction of the sheet member, and insulating parts 22 which mutually insulate these conductive parts 21. In the sheet member 20, high-density conductive part regions 21A, 21B, 21C, in each of which conductive parts 21 are arranged at a small pitch and a high density, are formed.
A cross-sectional view illustrating an anisotropically conductive sheet according to Structural Example 3 is shown in FIG. 26. This anisotropically conductive sheet 10 has a sheet member 20 composed of a plurality of conductive parts 21 each closely filled with conductive particles and extending in the thickness-wise direction of the sheet member, and insulating parts 22 which mutually insulate these conductive parts 21. A static charge-eliminating layer 30, in which openings 31 have been defined according to a pattern corresponding to the pattern of the conductive parts 21, is provided on a surface of the sheet member 20. The respective conductive parts 21 in the sheet member 20 are in a state exposed by the openings 31 in the static charge-eliminating layer 30.
A cross-sectional view illustrating an anisotropically conductive sheet according to Structural Example 4 is shown in FIG. 27. This anisotropically conductive sheet 10 has a sheet member 20 composed of a plurality of conductive parts 21 each closely filled with conductive particles and extending in the thickness-wise direction of the sheet member, and insulating parts 22 which mutually insulate these conductive parts 21. In the sheet member 20, high-density conductive part regions 21A, 21B, 21C, in each of which conductive parts 21 are arranged at a small pitch and a high density, are formed. Recesses 23 are formed in other regions than the high-density conductive part regions 21A, 21B, 21C in a surface of the sheet member 20, and static charge-eliminating layers 30 are provided in the recesses 23.
A cross-sectional view illustrating an anisotropically conductive sheet according to Structural Example 5 is shown in FIG. 28, and a plan view of the anisotropically conductive sheet is shown in FIG. 29. This anisotropically conductive sheet 10 has a sheet member 20 composed of a plurality of conductive parts 21 each closely filled with conductive particles and extending in the thickness-wise direction of the sheet member, and insulating parts 22 which mutually insulate these conductive parts 21. In the sheet member 20, high-density conductive part regions 21A, 21B, 21C, in each of which conductive parts 21 are arranged at a small pitch and a high density, are formed. In the high-density conductive part region 21B, the conductive parts 21 are arranged in an area having a form of a rectangular frame as illustrated in FIG. 29. A high-conductive, static charge-eliminating layer 35, in which openings for exposing the high-density conductive part regions 21A, 21B, 21C have been defined, is provided on a surface of the sheet member 20, and a low-conductive, static charge-eliminating layer 37 is provided in the high-density conductive part region 21B in the form of a rectangular frame, in which the conductive parts 21 are arranged, so as to cover the opening 36 for exposing the high-density conductive part region 21B in the high-conductive, static charge-eliminating layer 35.
The low-conductive, static charge-eliminating layer 37 preferably has a surface resistivity of 1�108 to 1�10 Ω/□ and an electric conductivity of 1�10−4 to 1�10−8 Ω−1m−1, particularly preferably, the surface resistivity is 2.5�109 to 2.5�1011 Ω/□, and the electric conductivity is 1�10−5 to 1�10−7 Ω−1m−1, when the thickness thereof is, for example, 0.1 mm.
A cross-sectional view illustrating an anisotropically conductive sheet according to Structural Example 6 is shown in FIG. 30. This anisotropically conductive sheet 10 has a sheet member 20 composed of a plurality of conductive parts 21 each closely filled with conductive particles and extending in the thickness-wise direction of the sheet member, and insulating parts 22 which mutually insulate these conductive parts 21. In the sheet member 20, high-density conductive part regions 21A, 21B, 21C, in each of which conductive parts 21 are arranged at a small pitch and a high density, are formed. In this example, each of the conductive parts 21 in the sheet member 20 is formed in a state projected from both surfaces of the insulating parts 22.
STRUCTURAL EXAMPLE 7
A cross-sectional view illustrating an anisotropically conductive sheet according to Structural Example 7 is shown in FIG. 31. In this anisotropically conductive sheet 10, a sheet member 20 is constructed by containing conductive particles over the whole base material composed of an elastic polymeric substance so as to be arranged in the thickness-wise direction of the sheet. The anisotropically conductive sheet 10 is such that conductive paths are formed by the conductive particles at any portions, at which the surface of the sheet member 20 is pressurized in the thickness-wise direction.
A composition for forming a static charge-eliminating layer was applied to a surface of a sheet member by brushing and subjected to a drying treatment, thereby forming a static charge-eliminating layer having a thickness of 10 μm, thereby producing an anisotropically conductive sheet according to Structural Example 1.
A static charge-eliminating layer having a thickness of 10 μm was formed on a surface of the sheet member in the same manner as in Example 1 except that an antistatic agent containing a siloxane compound was used as the composition for forming the static charge-eliminating layer, thereby producing an anisotropically conductive sheet according to Structural Example 1.
A static charge-eliminating layer having a thickness of 10 μm was formed on a surface of the sheet member in the same manner as in Example 1 except that an antistatic agent containing an acrylic conductive polymer was used as the composition for forming the static charge-eliminating layer, thereby producing an anisotropically conductive sheet according to Structural Example 1.
A static charge-eliminating layer having a thickness of 10 μm was formed on a surface of the sheet member in the same manner as in Example 1 except that an antistatic agent containing a conductive metal oxide was used as the composition for forming the static charge-eliminating layer, thereby producing an anisotropically conductive sheet according to Structural Example 1.
A static charge-eliminating layer having a thickness of 10 μm was formed on a surface of the sheet member in the same manner as in Example 1 except that an antistatic agent containing sodium alkanesulfonate (CnH2n+1SO3Na(n=12-20) was used as the composition for forming the static charge-eliminating layer, thereby producing an anisotropically conductive sheet according to Structural Example 1.
Each of the anisotropically conductive sheets according to Examples 1 to 5 was fixed to a glass fiber-reinforced epoxy substrate (dimensions: 14 cm�14 cm�1 mm) with the static charge-eliminating layer upward. This was arranged on an aluminum plate (dimensions: 30 cm�30 cm�2 mm) grounded with the anisotropically conductive sheet upward. The anisotropically conductive sheet was then pressurized for 2 seconds under a load of 130 kgf by means of a copper-clad glass fiber-reinforced epoxy substrate (10 cm�10 cm�0.5 mm), on the surface of which a resist layer had been formed, under conditions of a temperature of 28� C. and a relative humidity of about 50%. This process was conducted 200 times in total.
static charge-
parts (MΩ)
A film for static-charge elimination layer having a thickness of 70 μm, in which carbon black was contained in a polyethylene resin, was bonded to the surface of the sheet member by contact bonding, thereby forming a static charge-eliminating layer to produce an anisotropically conductive sheet according to Structural Example 2.
A static charge-eliminating layer was formed in the same manner as in Example 6 except that a film for static-charge elimination layer having a thickness of 100 μm, in which organic conductive fiber was contained in a base material composed of paper, was used, thereby producing an anisotropically conductive sheet according to Structural Example 2.
Each of the anisotropically conductive sheets according to Examples 6 and 7 was fixed to a glass fiber-reinforced epoxy substrate (dimensions: 14 cm�14 cm�1 mm) with the static charge-eliminating layer upward. This was arranged on an aluminum plate (dimensions: 30 cm�30 cm�2 mm) grounded with the anisotropically conductive sheet upward. The anisotropically conductive sheet was then pressurized for 2 seconds under a load of 130 kgf by means of a copper-clad glass fiber-reinforced epoxy substrate (10 cm�10 cm�0.5 mm), on the surface of which a resist layer had been formed, under conditions of a temperature of 27� C. and a relative humidity of about 27%. This process was conducted 50 times in total.
TABLE 2 Surface resistivity
On the other hand, a flowable material 131 for forming antistatic conductive parts, in which a conductive substance is dispersed in a polymer-forming material, is prepared. The material 131 for forming antistatic conductive parts is filled into the through-holes 20H in the sheet member 20 as illustrated in FIG. 38. Thereafter, the material 131 for forming antistatic conductive parts is subjected to a curing treatment, thereby forming antistatic conductive parts 130 to produce an anisotropically conductive sheet 10 of a structure illustrated in FIG. 34.
The electric resistance value of the protective conductive part 140 is preferably at most 100 kΩ, more preferably at most 1 kΩ, still more preferably at most 10Ω. When the electric resistance value of the protective conductive part 140 is at most 100 kΩ, discharge can be completed without affecting the conductive part 21 for connection.
In this case, the electric resistance value of the conductive part for static-charge elimination may amount to at least 10 MΩ when it is not pressurized. However, the electric resistivity value is at most 10 MΩ, generally at most 1Ω when it is pressurized. Therefore, electric charge accumulated on the surface of the anisotropically conductive sheet can be kept at a safe level due to the static-charge elimination when pressurized.
Accordingly, when the anisotropically conductive sheet according to the third aspect of the present invention is used as a connector in electrical inspection of circuit devices such a s printed circuit boards and semiconductor integrated circuits, an adverse influent of static electricity on the conductive part for connection is excluded, and moreover it is unnecessary to stop inspecting operations to conduct static charge-eliminating operation on the anisotropically conductive sheet, so that the electrical inspection of circuit devices can be conducted with high time efficiency and high safety.
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