Micro-encapsuled composite spheres toward anisotropic conductivity.

• Micro-encapsuled composite spheres were fabricated by spray-drying. • The influence of composition on structure and property was studied. • Anisotropic conduction was demonstrated and mechanism was disclosed. A novel micro-encapsuled composite spheres was fabricated by multi-step process combining with chemical modification, physical deposition as well as spray-drying technique. The microstructure, morphology and compositions were comprehensively investigated. The optimized micro-encapsuled spheres were applied to construct epoxy resin-based anisotropic conductive film (ACF). The dielectric shell of the micro spheres was capable of disintegration under pressure, resulting into electric pathways. The transition from dielectric state to anisotropic conductive state was demonstrated for the microsphere-containing ACF epoxy resin. [ABSTRACT FROM AUTHOR]