US 12,066,458 B2
Conductive particle-disposed film having conductive particles disposed within an elastomer film, method for producing the same, test probe unit, and continuity test method
Shinichi Hayashi, Utsunomiya (JP); and Yasushi Akutsu, Utsunomiya (JP)
Assigned to DEXERIALS CORPORATION, Tokyo (JP)
Appl. No. 16/465,012
Filed by DEXERIALS CORPORATION, Tokyo (JP)
PCT Filed Nov. 20, 2017, PCT No. PCT/JP2017/041699
§ 371(c)(1), (2) Date May 29, 2019,
PCT Pub. No. WO2018/101107, PCT Pub. Date Jun. 7, 2018.
Claims priority of application No. 2016-233397 (JP), filed on Nov. 30, 2016.
Prior Publication US 2019/0293683 A1, Sep. 26, 2019
Int. Cl. G01R 1/067 (2006.01); G01R 1/06 (2006.01); G01R 31/26 (2020.01); H01R 11/01 (2006.01); H01R 43/00 (2006.01)
CPC G01R 1/067 (2013.01) [G01R 1/06 (2013.01); G01R 31/26 (2013.01); G01R 31/2601 (2013.01); H01R 11/01 (2013.01); H01R 43/00 (2013.01)] 14 Claims
OG exemplary drawing
 
14. A method for producing the conductive particle-disposed film comprising:
disposing conductive particles in a plurality of concave portions in a transfer mold in which the concave portions are formed in a planar direction;
pressing an elastomer film against a surface of the transfer mold in which the concave portions are formed so as to transfer the conductive particles to the elastomer film;
interposing the elastomer film having the transferred conductive particles between a pair of platens;
subjecting the elastomer film to application of heat and pressure so as to push the conductive particles into the elastomer film and form the thermoset elastomer film, wherein
a thickness t of the thermoset elastomer film approximately coincides with an average particle diameter d of the conductive particles in such a manner that opposite ends of the conductive particles are exposed at respective outermost faces of both surfaces of the thermoset elastomer film,
one end of the conductive particles is exposed at the outermost face of the surface such that an exposed height falls within 30% of the thickness t of the thermoset elastomer film in the thermoset elastomer film, and
95% or more of all of the conductive particles in a rectangular or square area having 2000 or more of the conductive particles are regularly, independently disposed in a planar view of the thermoset elastomer film, and
forming the conductive particle-disposed film by layering a plurality of the thermoset elastomer films together, wherein the conductive particle-disposed film is attachable to and detachable from an electronic circuit substrate.