Importance

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Abstract

A directionally conductive polymer (DCP) provides an electrical interconnect between terminal or conductors on a pair of electrical components. The DCP is applied in viscous film form to the interface between the two components. The DCP comprises a resinous matrix containing metal particles in an amount normally causing the film to act as an electrical insulator. Electrical conduction through the film is normally inhibited in an unstressed state. When a stress is applied to the film, the metal particles make contact to form a continuous electrical path through the film in alignment with the applied stress. The metal particles maintain electrical insulating properties in regions of the film not subjected to the applied stress. In one embodiment, the film includes a metal polymer dispersed in a dielectric carrier resin. A first resinous material dissolved in a solvent contains a dispersion of metal particles. The dielectric material comprises a second resinous material dissolved in the same solvent. The second resin in immiscible in the first resin so that application of a compressive force on the film during solvent evaporation reduces the solubility of the solvent in the first resin, causing a collapse of the film in the compressed region, thereby forming a metal-resin composite which is electrically conductive. The regions of the film remote from the compressed regions provide a dimensionally stable electrical insulator.

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First Claim