Recently, the Nanomaterials and Device Technology Research Department of the Institute of Solid State Engineering, Hefei Institutes of Physical Science, Chinese Academy of Sciences, in cooperation with the Polymer and Composite Materials Research Department, Guangdong, Hong Kong and Macao Quantum Science Center, etc.,
has made new progress in the rapid preparation and performance research of heterogeneous conductive gold microsphere arrays , and achieved the efficient construction of heterogeneous conductive adhesives for advanced packaging of gold microsphere arrays. The relevant research results were published in
Nature Communications .
Arrayed anisotropic conductive paste (ACF) is a method of configuring conductive microsphere particles in an array on a cross-linked polymer layer. It can effectively solve the problems of random distribution of particles in traditional ACF, leading to lateral short circuits, and ensure more reliable electrical connection. It is a new paradigm for ultra-high density packaging. In 2014, Dexerials Corporation of Japan used metal-plated polymer microspheres as conductive particles and arranged them in a precise array, realizing the commercialization of arrayed ACF for the first time.
However, due to the weak bonding between the metal shell and the polymer, this type of conductive particle faces challenges in bonding under actual deep pressing, which can cause the metal shell to break and detach, affecting the overall conductive performance.
In contrast, ordered arrays of pure metal microspheres, due to their inherent ductility, can theoretically ensure excellent electrical conductivity even under deep lamination, making them ideal next-generation packaging materials. However, due to the limitations of the anisotropic growth law of metals, the large-scale preparation of micron-scale pure metal spheres and their array arrangement has always been a challenging problem in the industry.
In response to the above problems, the researchers developed a simple, fast and efficient strategy based on the positioning transient emulsion self-assembly method proposed by the team in the early stage, combined with nanosecond laser pulse irradiation technology, to achieve the rapid preparation of a new pure gold microsphere array
with uniform size, smooth surface and accurate positioning (Figure 1). This strategy effectively breaks the inertial thinking of "synthesis first and then positioning" in ACF product manufacturing, and provides a new solution for the rapid construction of arrayed ACF.
The key to this strategy is
to use the laser-induced rapid layer-by-layer melting-fusion process to effectively avoid the anisotropic growth of the metal. Theoretical simulations have found that this layer-by-layer melting-fusion is mainly due to the limited skin depth of the laser, which localizes the photothermal effect generated by the gold particles on the surface of the superparticles. In addition, this method is highly universal and suitable for various nanoparticles with strong photothermal effects as assembly primitives, regardless of their size, morphology and composition. For example, the researchers used Au-Pd and Au-Ag-Pt core-shell nanoparticles as assembly primitives to prepare Au-Ag-Pd-Pt alloy microspheres with uniform size and smooth surface (Figure 2), which are expected to be used in the efficient preparation of high-entropy alloy microspheres with uniform particle size.
Compared with commercial gold-plated microspheres, the pure metal microspheres benefit from the excellent ductility and plasticity of pure gold materials, showing ultra-stable conductive properties under deep compression (Figure 3). The pure gold microsphere array
is expected to provide the best solution for ultra-high-density bonding of micro-display μLED chips , thereby promoting the development and application in the field of high-resolution display.