The reliability of conductive adhesive electrical interconnections depends on the individual formulation and process employed [55]. In addition, the test vehicle configuration will strongly influence results. No comprehensive studies have been published, however, and no attempts to correlate chemical composition or a specific process variable to reliability performance have been reported.
Most conductive adhesive failures are accelerated by elevated temperature and humidity. In a study of 12 commercially available isotropically conductive adhesives, joint resistance increased between 160 and 35,000% when exposed to 65°C and 85% relative humidity (65/85) [56]. However, some adhesive manufacturers claim resistance change of less than 10% after 1000 h at 60°C and 90% relative humidity [57] and less than 4% after 1000 h at 85/85 [58]. Anisotropically conductive adhesive joints are even more susceptible to early failures under accelerated test conditions due to process variations [16]. Reliability screening tests can be used effectively to iteratively optimize process parameters.