Three-dimensional circuit manufacturing process and composite components of laser plastic material and manufacturing method

[0094] Implementation Example 1: Active GPS Plastic Antenna

[0095] like figure 2 shown, the active antenna consists of the antenna ( figure 2 A and figure 2 D) Add the antenna amplification part ( figure 2 C) composition, antenna metal pattern ( figure 2 D) Arranged on the laser plastic with polyethylene (PE) or syndiotactic polystyrene (SPS) as the carrier masterbatch ( figure 2 A), the composite components in the carrier masterbatch are: 1-10 grams of surfactants; 5-200 grams of compatibilizers; 0.1-5 grams of light absorbers; 0.5-30 grams of viscosity reducers; 5-750 grams of inorganic fillers ; Modified organometallic compound 30-50 grams; the rest are carrier masterbatch. The sum of the composite components must meet 100%.

[0096] The three-dimensional circuit manufacturing process is adopted, and the laser machine uses near-infrared laser (1064nm) or ultraviolet laser scanning; then rapid chemical copper plating; finally, the lead and the amplifier circuit are crimped together; the inorganic fillers are nickel-zinc ferrite powder and ceramic powder, Its effective permittivity is 4-8, and its effective permeability is 1.1-1.3. amplifying circuit( figure 2 C) Directly welded on the laser plastic ( figure 2 B), its carrier masterbatch is nylon PA6, and its composite components are: 1000 grams of laser plastic containing, 1-10 grams of surfactant; 5-200 grams of compatibilizer; 0.1-5 grams of light absorber ; Viscosity reducer 0.5-30 g; Inorganic functional filler 5-700 g; Modified organometallic compound 30-50 g; The rest are carrier masterbatches. The sum of the composite components must meet 100%

[0097] It is made by three-dimensional circuit technology, and the inorganic fillers are nucleating agents and glass fibers; the laser machine uses ultraviolet laser scanning; and then chemically plated copper, nickel, and gold. The finished product has no printed circuit board and traditional ceramic antenna, its performance reaches and exceeds the traditional ceramic antenna index, and it is cost-effective. Used in mobile handsets.

[0098] Example 2: Multi-faceted high-power LED plastic lamp holder

[0099] The traditional LDE lamp holder is a ceramic base, which adopts the traditional chip ceramic resistance-capacitance process, sinters the terminal electrodes on the insulating ceramic chip, and then chemically plated copper, nickel, and gold. The ceramic process cannot make complex polyhedral shapes.

[0100] However, the luminous characteristics of LED lamps are direct light. Generally, high-power lamps are composed of several LEDs. In order to distribute the light sources in the hemispherical space, such as image 3 shown, the ideal arrangement of LED lights ( image 3 A) is a polyhedron arrangement, which is molded or injected into a plastic base with a thermally conductive laser plastic ( image 3 B).

[0101] The example of the present invention adopts the thermal conductive laser plastic raw material. One component is: the carrier masterbatch is CBT, and the composite components are: 1000 grams of laser plastic containing 1-10 grams of surfactant; 5-200 grams of compatibilizer; Light absorber 0.1-5 g; viscosity reducer 0.5-30 g; inorganic filler 5-750 g; modified organometallic compound 30-50 g;

[0102] Here, the inorganic functional filler contains at least two kinds of materials, thermal conductive material and glass fiber. The thermally conductive material can be selected from alumina microspheres with a diameter of about 2 microns with good thermal conductivity, or other aluminum nitride powders with good thermal conductivity. Depending on the thermal conductivity requirements of the product, the proportion of thermally conductive materials added can reach 60% of the laser plastic raw materials.

[0103] Its manufacturing process is: using the above-mentioned components and the method of the present invention to synthesize the laser plastic, opening a mold, injection molding or die-casting into a polyhedral plastic part ( image 3 B), then laser scanning metal electrodes; electroless copper, nickel, gold. Solder LED lights ( image 3 A) The final product is then put on a transparent plastic cover. The polyhedral LED lamp of the present invention ( image 3 ), due to the copper wire ( image 3 C) It can be bent and folded into a space structure for heat dissipation ( image 3 E), and the space on the back of the LED lamp holder can deposit a large area of ​​copper layer ( image 3 D), making the thermal resistance smaller than the ceramic LTCC process pedestal. The polyhedral LED plastic lamp holder involved in the present invention is particularly suitable for the fields of automobile LED lamps, aircraft LED lamps, and household lighting LED high-power lamps with more than 15W.

[0104] Implementation Example 3: Applications in the fields of automobiles and aircrafts

[0105] Automobiles, airplanes, train cars, etc. have large plastic parts and need to arrange a large number of cables to transmit various electronic signals. The traditional cables are combined with plastic through bolts, screws and hardware, which are heavy and easy to move during movement. It emits a sound. For products that are particularly sensitive to weight, such as airplanes, it is a very good measure to use the stereo circuit technology of the present invention to pre-embed a large number of signal lines in the plastic parts, which not only reduces the failure rate but also reduces the weight, and Easy to maintain. The main function of plastics used in automobiles is to lighten the weight of automobiles, so as to achieve the purpose of fuel saving and high speed. Developed countries regard the amount of plastic used in automobiles as an important indicator to measure the level of automobile design and manufacturing. Germany has the largest single consumption of automobile plastics in the world, and the amount of plastics accounts for more than 15% of the overall material. In recent years, my country's automobile industry has developed rapidly. At present, the annual output of automobiles exceeds 4 million. According to the forecast of plastic consumption in the industry, the annual use of modified plastics in the automobile industry is more than 1 million tons. For example, the following parts are made of polymer plastics: dashboard, Car ignition, accelerator and clutch pedal, antifreeze plate, door handle, drain plate, bracket, steering column cover, trim panel, air conditioning system accessories, car exterior parts, car body panel, car side guard, fender , car door frame, etc., license plate cover, wheel cover, mirror shell, tail light cover, etc., automobile fender, headlight glass groove, tail light shell, connection box, fuse box, circuit breaker shell, etc., large baffle, buffer pad , rear spoiler, etc. The development direction of the automobile industry is high-grade, miniaturization, light weight and diversification, and the research of replacing steel with plastic in automobile application has become very important.

[0106] Many of the above plastic parts are combined with automotive electronics, so the invention can reduce the number of cables and connectors, and can design innovative automotive parts. Another application is pre-embedded wires to adapt to changes in the after-installation and configuration of in-vehicle electrical appliances.

[0107] Figure 4 As shown in A, metallized circuits are embedded in the plastic parts inside the car doors to realize the interconnection of electrical appliances in the car doors and reduce cables. Figure 4 As shown in B, the embedded metal wire of the present invention can be used on the inner side of the plastic part of the interior decoration of the automobile.

[0108] At present, there are more and more electronic devices in the aircraft. Passengers need to surf the Internet, play games, watch TV, and make phone calls. The era of allocating an LCD screen to each person has come, and a large number of cables have plagued aircraft designers and maintainers.

[0109] like Figure 4 As shown in C, on the inside of the plastic shell of the seat armrest of the aircraft, metal lines are deposited to replace the traditional cables, which reduces the weight of the aircraft and reduces the failure rate, and facilitates maintenance. The structure can be quickly disassembled, eliminating the time to find cable faults.