Anisotropically conductive polymeric matrix

Claim 2

An anisotropically conductive polymeric matrix comprising a polymeric layer having a plurality of electrically conductive members therethrough, uniformly spaced such that each of said members is electrically isolated from one another, said members comprising a coating of an electrically conductive material extending from one face of said layer substantially through the thickness thereof, whereby electric current can be conducted through the thickness of said polymeric layer by said members.

Claim 3

The conductive polymeric matrix of claim l wherein said conductive material consists of a metal selected from the group consisting of aluminum, copper, nickel, silver, gold, tin, and palladium.

Claim 4

The conductive polymeric matrix of claim 2 wherein said metal has a thickness from about l00 angstroms to about 250,000 angstroms.

Claim 5

The conductive polymeric matrix of claim l wherein said conductive members are tubular.

Claim 6

The conductive polymeric matrix of claim 4 wherein the edge surface of said tubular members define at least one corner.

Claim 7

The conductive polymeric matrix of claim l wherein said polymeric layer comprises an elastomer.

Claim 8

The conductive polymeric matrix of claim l wherein said polymeric layer comprises an adhesive.

Claim 9

The conductive polymeric matrix of claim 7 wherein said adhesive is selected from a polyester and a polyamide adhesive having a glass transition temperature of from about -20°C to about 200°C

Claim 10

The conductive polymeric matrix of claim 7 wherein said adhesive comprises a curable epoxy resin.

Claim 11

l0. The conductive polymeric matrix of claim 7 wherein said adhesive comprises a hot tackifying adhesive which exhibits a probe tack value of at least 75 grams of force at 40°C or more.

Claim 12

The conductive polymeric matrix of claim 7 wherein said adhesive comprises one or more acrylic polymers and l) an acrylic ester monomer provides at least 50 mol percent of the one or more acrylic polymers of said at least one adhesive layer; 2) said one or more acrylic polymers have a T g or a weight-averaged T g of -l0° to 80°C, and 3) said at least one layer has a) a Probe Tack Value of less than 75 gf at 20°C, b) Probe Tack Values of at least 75 gf over a range of at least 50°C, which values remain substantially constant after 30 days at 40°C, and c) a Shear Value of at least 25 minutes at 65°C, and said at least one layer adheres well to a clean substrate upon contact at any temperature within said 50°C range.

Claim 13

The conductive polymeric matrix of claim ll wherein said acrylic polymers are comprised of one or more acrylic copolymers of monomers, up to 50 mol % of which is at least one copolymerizable monomer selected from acrylic acid, methacrylic acid, itaconic, acid, maleic acid, maleic anhydride, amides of said acids, acrylonitrile, methacrylonitrile, and N-vinyl-2-pyrroli­done.

Claim 14

The conductive polymeric matrix of claim ll wherein said acrylic ester monomer is selected from alkyl acrylates having l-8 carbon atoms in their alkyl groups, alkyl methacrylates having l-8 carbon atoms in their alkyl groups, bornyl acrylates, bornyl methacrylates, 2-phenoxyethyl acrylate, 2-phenoxymethyl acrylate, the mono- and di-methyl and ethyl esters of itaconic acid, and the mono- and di-methyl and ethyl esters of maleic acid.

Claim 15

The conductive polymer matrix of claim ll in which at least one of styrene, vinyl acetate and vinyl chloride comprises up to 5 mol percent of the total monomers.

Claim 16

The conductive polymeric matrix of claim l wherein said conductive members have an aspect ratio of from about l to l0 to l0 to l.

Claim 17

The conductive polymeric matrix of claim l wherein said conductive members having a conductive aspect ratio of from about 2 to l to 2000 to l.

Claim 18

A transfer tape wound upon itself in roll form comprising the polymeric matrix of claim l on a releaseable backing.

Claim 19

An electrical connector tape wound upon itself in roll form comprising a backing having, on a major face thereof: a) a plurality of conductive stripes in laterally spaced relation extending the length of said backing, and thereover, b) the polymeric matrix of claim l.

Claim 20

An electronic assembly comprising a first electronic component having a surface with a plurality of conductive areas and a second electronic component having a surface with a plurality of conductive areas wherein the two surfaces are adhered to one another by the polymeric matrix of claim l to thereby allow the conductance of an electric current from said first component to said second component, but not between said conductive areas of each individual component.

Claim 21

A process for preparing an anisotropically conductive polymeric matrix comprising the steps of: a) depositing a coating of electrically conductive material upon at least a portion of a plurality of discrete projections contained on a low surface energy substrate; b) depositing a layer of conductive polymeric material on said substrate, such that said plurality of discrete projections define a plurality of isolated conductive members through said polymeric material; c) removing said substrate from said polymeric material wherein said conductive coating remains with said polymeric material; and d) removing said conductive coating from the surface of said polymeric material between said conductive members.

Claim 22

A process for preparing an anisotropically conductive polymeric matrix comprising the steps of: a) depositing a coating of electrically conductive material upon at least a portion of a plurality of discrete projections contained on a low surface energy substrate; b) depositing a layer of conductive polymeric material on said substrate, such that said plurality of discrete projections define a plurality of isolated conductive members through said polymeric material; c) removing said substrate from said polymeric material wherein said conductive coating remains with said polymeric material; and d) removing said conductive coating from the surface of said polymeric material between said conductive members.

Claim 23

2l. A conductive polymeric matrix comprising a polymeric layer having a plurality of electrically conductive members therethrough, said conductive members being uniformly spaced from each other, said members comprising a coating of an electrically conductive material extending from one face of said layer substantially through the thickness thereof, said members being electrically isolated from one another except in predetermined areas of said matrix.

Claim 24

2l. A conductive polymeric matrix comprising a polymeric layer having a plurality of electrically conductive members therethrough, said conductive members being uniformly spaced from each other, said members comprising a coating of an electrically conductive material extending from one face of said layer substantially through the thickness thereof, said members being electrically isolated from one another except in predetermined areas of said matrix.