Method for the production of a sealed conductive part for a base station radio frequency device

Abstract

Embodiments of the present disclosure disclose a preparation method of a sealed conductive component for a base station radio frequency device. A specific implementation of the method comprises selecting a predetermined soft glue material, a nickel-carbon composite material and a silver-aluminum composite material as a sealing strip base material, an absorbing layer base material and a reflecting layer base material respectively; performing melt extrusion on the sealing strip base material, the absorbing layer base material and the reflecting layer base material to obtain an extruded sealing strip, an extruded absorbing layer and an extruded reflecting layer; performing shaping on the extruded sealing strip, the extruded absorbing layer and the extruded reflecting layer to obtain a sealing strip, an absorbing layer and a reflecting layer; performing plasma treatment on the absorbing layer and the reflecting layer to obtain an activated absorbing layer and an activated reflecting layer; performing corona treatment on the sealing strip to obtain an activated sealing strip; stacking the activated sealing strip, the activated absorbing layer and the activated reflecting layer in a positional relationship with the absorbing layer in the middle to obtain a stacked component; and performing composite treatment on the stacked component to obtain a conductive component. The implementation can prolong the service life of the conductive component.

Description

Technical Field

[0001] The embodiments disclosed herein relate to the field of communication technology, and more specifically to a method for preparing a sealed conductive component for a base station radio frequency device. Background Technology

[0002] With the accelerated commercialization of 5G and the advancement of 6G technology research and development, base station radio frequency (RF) devices face stringent challenges in terms of high frequency, integration, and adaptability to extreme outdoor environments. As core components for base station signal transmission and reception, the sealing and conductive shielding performance of RF devices directly determines signal transmission quality, anti-interference capability, and equipment lifespan. Currently, pure silver or copper foil is commonly used as a conductive layer bonded to silicone rubber sealing materials to fabricate conductive components for RF devices.

[0003] However, when the conductive components of radio frequency devices are fabricated using the above method, the poor interfacial compatibility between the conductive layer and the sealing material often leads to delamination of the conductive components under long-term use, resulting in a decrease in shielding effectiveness and a shorter service life for the conductive components.

[0004] The information disclosed in this background section is only intended to enhance the understanding of the background of the present disclosure concept, and therefore may contain information that does not constitute prior art known to those skilled in the art. Summary of the Invention

[0005] The summary portion of this disclosure is intended to provide a brief overview of the concepts, which will be described in detail in the detailed description portion that follows. This summary portion is not intended to identify key or essential features of the claimed technical solutions, nor is it intended to limit the scope of the claimed technical solutions.

[0006] Some embodiments of this disclosure provide a method for fabricating a sealed conductive component for a base station radio frequency device to solve one or more of the technical problems mentioned in the background section above.

[0007] Some embodiments of this disclosure provide a method for fabricating a sealed conductive component for a base station radio frequency device. The method includes: selecting a preset soft rubber material, a nickel-carbon composite material, and a silver-aluminum composite material as a sealing strip substrate, an absorption layer substrate, and a reflective layer substrate, respectively; performing melt extrusion processing on the sealing strip substrate, the absorption layer substrate, and the reflective layer substrate to obtain an extruded sealing strip, an extruded absorption layer, and an extruded reflective layer; performing a shaping process on the extruded sealing strip, the extruded absorption layer, and the extruded reflective layer to obtain a sealing strip, an absorption layer, and a reflective layer; performing plasma treatment on the absorption layer and the reflective layer to obtain an activated absorption layer and an activated reflective layer; performing corona treatment on the sealing strip to obtain an activated sealing strip; stacking the activated sealing strip, the activated absorption layer, and the activated reflective layer according to a preset positional relationship to obtain a stacked component, wherein the absorption layer is located between the reflective layer and the sealing strip; and performing a composite processing on the stacked component to obtain a conductive component.

[0008] Optionally, the above-mentioned nickel-carbon composite material is prepared by the following steps: ball milling nickel powder, carbon nanotubes and silane coupling agent mixed in a preset mass ratio to obtain ball-milled material; pre-pressing the ball-milled material to obtain a pre-pressed green body; sintering the pre-pressed green body under inert gas protection to obtain a sintered green body; crushing the sintered green body to obtain nickel-carbon composite powder; mixing the nickel-carbon composite powder with a molding aid to obtain a mixed material; and granulating the mixed material using a twin-screw granulator to obtain the nickel-carbon composite material.

[0009] Optionally, the above method further includes: shaping the conductive component to obtain a shaped conductive component.

[0010] Optionally, the above-mentioned melt extrusion treatment of the sealing strip substrate, the absorbent layer substrate, and the reflective layer substrate to obtain an extruded sealing strip, an extruded absorbent layer, and an extruded reflective layer includes: melt extruding the sealing strip substrate using a single-screw extruder to obtain an extruded sealing strip, wherein the extrusion temperature is preset to 120~180℃ and the screw speed is preset to 30~60rpm; melt extruding the absorbent layer substrate using a twin-screw extruder to obtain an extruded absorbent layer, wherein the extrusion temperature is preset to 200~260℃ and the screw speed is preset to 50~80rpm; and melt extruding the reflective layer substrate using a twin-screw extruder to obtain an extruded reflective layer, wherein the extrusion temperature is preset to 300~380℃ and the screw speed is preset to 40~70rpm.

[0011] Optionally, the above-mentioned shaping process for the extruded sealing strip, the extruded absorbent layer, and the extruded reflective layer to obtain the sealing strip, the absorbent layer, and the reflective layer includes: introducing the extruded sealing strip into a cooling water tank at a first preset water temperature for cooling treatment to obtain the sealing strip; introducing the extruded absorbent layer into a cooling water tank at a second preset water temperature for cooling treatment to obtain the absorbent layer; and performing segmented cooling treatment on the extruded reflective layer to obtain the reflective layer.

[0012] Optionally, the above-mentioned plasma treatment of the absorption layer and the reflection layer to obtain an activated absorption layer and an activated reflection layer includes: cleaning the surfaces of the absorption layer and the reflection layer to obtain a clean absorption layer and a clean reflection layer; performing plasma treatment on the clean absorption layer using a mixture of argon and oxygen in a first preset volume ratio to obtain an activated absorption layer; and performing plasma treatment on the clean reflection layer using a mixture of argon and nitrogen in a second preset volume ratio to obtain an activated reflection layer.

[0013] Optionally, the above-mentioned corona treatment of the sealing strip to obtain an activated sealing strip includes: cleaning the composite contact surface of the sealing strip to obtain a clean sealing strip, wherein the composite contact surface is the surface used to contact the absorbent layer; and performing corona treatment on the composite contact surface using a corona machine to obtain an activated sealing strip.

[0014] Optionally, the above-mentioned silver-aluminum composite material is prepared by the following steps: selecting silver powder, aluminum powder, copper powder, and cerium powder as raw materials, wherein the particle size of silver powder is 1~5μm, the particle size of aluminum powder is 5~10μm, the particle size of copper powder is 2~5μm, and the particle size of cerium powder is 1~3μm; mixing the components contained in the above-mentioned raw materials according to a preset mass ratio to obtain a mixed raw material; dispersing the above-mentioned mixed raw material using a planetary ball mill to obtain a uniform mixed raw material, wherein anhydrous ethanol is added as a dispersion medium during the dispersion process; drying the above-mentioned uniform mixed raw material using a vacuum drying oven to remove the dispersion medium to obtain a dried raw material; cold pressing the above-mentioned dried raw material to obtain a raw material blank; vacuum sintering the above-mentioned raw material blank to obtain a silver-aluminum composite material blank; and passivating the surface of the above-mentioned silver-aluminum composite material blank to obtain the silver-aluminum composite material.

[0015] Some embodiments of this disclosure provide a method for fabricating a sealed conductive component for base station radio frequency devices, which can extend the service life of the conductive component. Specifically, the reason for the short service life of most conductive components is that currently, pure silver or copper foil is often used as a conductive layer bonded to a silicone rubber sealing material to fabricate the conductive component of the radio frequency device. However, when the conductive component of the radio frequency device is fabricated in the above manner, the poor interfacial compatibility between the conductive layer and the sealing material often leads to delamination of the conductive component under long-term use, resulting in a decrease in its shielding effectiveness and thus a short service life. Based on this, some embodiments of this disclosure provide a method for fabricating a sealed conductive component for a base station radio frequency device. The method includes: selecting a pre-defined soft rubber material, a nickel-carbon composite material, and a silver-aluminum composite material as a sealing strip substrate, an absorption layer substrate, and a reflective layer substrate, respectively; performing melt extrusion processing on the sealing strip substrate, the absorption layer substrate, and the reflective layer substrate to obtain an extruded sealing strip, an extruded absorption layer, and an extruded reflective layer; performing a shaping process on the extruded sealing strip, the extruded absorption layer, and the extruded reflective layer to obtain a sealing strip, an absorption layer, and a reflective layer; performing plasma treatment on the absorption layer and the reflective layer to obtain an activated absorption layer and an activated reflective layer; performing corona treatment on the sealing strip to obtain an activated sealing strip; stacking the activated sealing strip, the activated absorption layer, and the activated reflective layer according to a pre-defined positional relationship to obtain a stacked component, wherein the absorption layer is located between the reflective layer and the sealing strip; and performing a composite processing on the stacked component to obtain a conductive component. Because plasma treatment and corona treatment improve the interfacial compatibility between the layers of the conductive component, the composite strength of the conductive component is improved. Therefore, the service life of the conductive component can be extended. Attached Figure Description

[0016] The above and other features, advantages, and aspects of the embodiments of this disclosure will become more apparent from the accompanying drawings and the following detailed description. Throughout the drawings, the same or similar reference numerals denote the same or similar elements. It should be understood that the drawings are schematic, and elements are not necessarily drawn to scale.

[0017] Figure 1 This is a flowchart of some embodiments of a method for fabricating a sealed conductive component for a base station radio frequency device according to the present disclosure. Detailed Implementation

[0018] Embodiments of this disclosure will now be described in more detail with reference to the accompanying drawings. While some embodiments of this disclosure are shown in the drawings, it should be understood that this disclosure can be implemented in various forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of this disclosure. It should be understood that the accompanying drawings and embodiments of this disclosure are for illustrative purposes only and are not intended to limit the scope of protection of this disclosure.

[0019] It should also be noted that, for ease of description, only the parts relevant to the invention are shown in the accompanying drawings. Unless otherwise specified, the embodiments and features described in this disclosure can be combined with each other.

[0020] It should be noted that the concepts of "first" and "second" mentioned in this disclosure are used only to distinguish different devices, modules or units, and are not used to limit the order of functions performed by these devices, modules or units or their interdependencies.

[0021] It should be noted that the terms "a" and "a plurality of" used in this disclosure are illustrative rather than restrictive, and those skilled in the art should understand that, unless otherwise expressly indicated in the context, they should be understood as "one or more".

[0022] This disclosure will now be described in detail with reference to the accompanying drawings and embodiments.

[0023] Figure 1 A flow chart 100 of some embodiments of a method for fabricating a sealed conductive component for a base station radio frequency device according to the present disclosure is shown. The method for fabricating a sealed conductive component for a base station radio frequency device includes the following steps:

[0024] Step 101: Select a pre-set soft rubber material, a nickel-carbon composite material, and a silver-aluminum composite material as the sealing strip substrate, the absorption layer substrate, and the reflective layer substrate, respectively.

[0025] In some embodiments, a pre-selected soft adhesive material, a nickel-carbon composite material, and a silver-aluminum composite material can be selected as the sealing strip substrate, the absorption layer substrate, and the reflective layer substrate, respectively. The pre-selected soft adhesive material can be a material specifically prepared according to the application scenario of the conductive component, and its specific preparation method will be given below. The sealing strip substrate refers to the material used to process the sealing strip. The absorption layer substrate refers to the material used to process the absorption layer. The reflective layer substrate refers to the material used to process the reflective layer. Using a nickel-carbon composite material as the absorption layer material can achieve the absorption function in electromagnetic shielding, absorbing electromagnetic waves and forming a shielding mechanism in conjunction with the reflective layer. Using a silver-aluminum composite material as the reflective layer material can achieve the reflection function in electromagnetic shielding, reflecting electromagnetic waves; the addition of aluminum can optimize material cost and mechanical properties while ensuring reflection efficiency. The high conductivity of silver allows the reflective layer to maintain good signal reflection capability in 5G or 6G high-frequency scenarios, reducing signal loss.

[0026] Optionally, the above-mentioned nickel-carbon composite material can be prepared by the following steps:

[0027] The first step involves ball milling a mixture of nickel powder, carbon nanotubes, and a silane coupling agent in a preset mass ratio to obtain the ball-milled material. The preset mass ratio can be from 5:5 to 7:3, and is not specifically limited here. The ball-milled material refers to the material obtained after ball milling the mixture of nickel powder, carbon nanotubes, and the silane coupling agent. Ball milling uses mechanical force to uniformly mix the nickel powder and carbon nanotubes. Simultaneously, the silane coupling agent chemically bonds the surfaces of the nickel powder and carbon nanotubes, improving their interfacial compatibility, reducing carbon nanotube agglomeration, and enhancing the interfacial bonding force between nickel and carbon, thereby improving the material's electrical conductivity and mechanical properties.

[0028] In practice, nickel powder, carbon nanotubes, and silane coupling agent in a preset mass ratio can be placed in a ball mill for ball milling to obtain the ball-milled material. For example, a mixture of nickel powder and carbon nanotubes in a mass ratio of 6:5 can be mixed with a silane coupling agent and then added to a ball mill. The ball mill is then controlled to mill the mixture of nickel powder, carbon nanotubes, and silane coupling agent at a speed of 300 rpm for 3 hours to obtain the ball-milled material. The particle size of the nickel powder can be 5-10 μm, the diameter of the carbon nanotubes can be 10-20 nm, and the silane coupling agent can be 3-aminopropyltriethoxysilane, without specific limitations. The amount of silane coupling agent added can be 1% of the total mass of the nickel powder, carbon nanotubes, and silane coupling agent.

[0029] The second step involves pre-compressing the ball-milled material to obtain a pre-compressed green body. This pre-compressing process refers to pressing the ball-milled material into a green body. Pre-compressing reduces voids in the material, allowing particles to initially come into close contact, forming a more stable green body structure, which facilitates heat transfer during subsequent sintering. It also reduces localized overheating or structural inhomogeneity caused by loose material during sintering, improving sintering efficiency and green body density. In practice, a hydraulic press can be used to press the ball-milled material to obtain a green body with a predetermined shape, known as a pre-compressed green body. For example, the ball-milled material can be poured into a mold and held at 20 MPa for 4 minutes to obtain a pre-compressed green body with a diameter of 50 mm and a thickness of 10 mm.

[0030] The third step involves sintering the pre-pressed billet under an inert gas atmosphere to obtain a sintered billet. Sintering allows for the diffusion and welding of nickel powder particles and the embedding of carbon nanotubes into the nickel matrix, forming a more stable nickel-carbon composite structure. The inert gas reduces the likelihood of nickel powder oxidation at high temperatures. Sintering enhances the mechanical strength and electrical conductivity of the nickel-carbon composite material, reduces material property degradation caused by oxidation, and improves the stability of the nickel-carbon composite material. In practice, the pre-pressed billet can be placed in a vacuum sintering furnace, and an inert gas is introduced as a protective gas. The pre-pressed billet is then sintered in the vacuum sintering furnace according to preset conditions to obtain the sintered billet. These preset conditions can include the heating rate, sintering temperature, and holding time of the vacuum sintering furnace. For example, a preset heating rate of 8℃ / min, a sintering temperature of 1000℃, and a holding time of 3 hours can be used; however, these settings are not specifically limited and can be adjusted by the operator according to actual conditions.

[0031] The fourth step is to crush the sintered green body to obtain nickel-carbon composite powder. In practice, a jaw crusher can be used to coarsely crush the sintered green body first, followed by a vibratory mill or air jet mill for fine crushing, to obtain nickel-carbon composite powder with a particle size within a preset range. This preset range can be 5~20μm. For example, the sintered block green body can be coarsely crushed to obtain coarse powder with a particle size of 5mm or less. Then, an air jet mill can be used to further pulverize the coarse powder to a particle size of 5~20μm to obtain nickel-carbon composite powder.

[0032] The fifth step involves mixing the nickel-carbon composite powder with molding aids to obtain a mixed material. The molding aids can adhere to the powder surface, improving its flowability, lubricity, and plasticity, facilitating subsequent granulation. These molding aids may include, but are not limited to, polyethylene wax and zinc stearate; specific limitations are not specified here. The mixed material refers to the mixture of nickel-carbon composite powder and molding aids. In practice, a high-speed mixer can be used to mix the nickel-carbon composite powder and molding aids to obtain the mixed material. For example, nickel-carbon powder and polyethylene wax can be added to a high-speed mixer at a mass ratio of 97:3 and stirred at 800 rpm for 30 minutes to obtain the mixed material.

[0033] The sixth step involves granulating the mixed materials using a twin-screw granulator to obtain the nickel-carbon composite material. In practice, the mixed materials can be added to a twin-screw granulator, where the screws shear and convey the material to plasticize and extrude it. The granules are then cut into pellets by a pelletizer to obtain the nickel-carbon composite material. It should be noted that processing the mixed materials into pellets facilitates storage, transportation, and subsequent extrusion molding.

[0034] Optionally, the above-mentioned silver-aluminum composite material can be prepared by the following steps:

[0035] The first step involves selecting silver powder, aluminum powder, copper powder, and cerium powder as raw materials. The particle size of silver powder can be 1-5 μm, aluminum powder 5-10 μm, copper powder 2-5 μm, and cerium powder 1-3 μm. Using a small particle size of 1-5 μm for silver powder increases the specific surface area, improving the density and conductivity after sintering. Using a medium particle size of 5-10 μm for aluminum powder balances cost and dispersibility, and improves interfacial bonding with silver powder. Using a particle size of 2-5 μm for copper powder, similar to that of silver powder, helps improve the uniformity of dispersion. Adding copper powder to the raw materials enhances the ductility of the material, compensating for the brittleness of aluminum. Cerium powder, as a rare earth element, preferentially oxidizes to form a protective film, reducing the oxidation rate of silver and aluminum.

[0036] The second step is to mix the components of the raw material according to a preset mass ratio to obtain a mixed raw material. This preset mass ratio can be the mass ratio of silver powder, aluminum powder, copper powder, and cerium powder in the mixed raw material. For example, the components of the raw material can be mixed in a mass ratio of 70% silver powder, 25% aluminum powder, 3% copper powder, and 2% cerium powder to obtain the mixed raw material. The preset mass ratio is not specifically limited here, as long as the proportion of silver powder is maximized. The reason for maximizing the proportion of silver powder is that silver is an excellent conductor; a high proportion can improve the conductivity of the composite material, thereby enhancing the shielding performance of the conductive components.

[0037] The third step involves dispersing the mixed raw materials using a planetary ball mill to obtain a homogeneous mixture. Anhydrous ethanol can be added as a dispersion medium during this process. In practice, zirconia balls and the mixed raw materials can be added to the planetary ball mill at a ball-to-material ratio of 10:1 to 20:1, along with anhydrous ethanol as the dispersion medium. The planetary ball mill is then started for dispersion to obtain a homogeneous mixture. The mill speed can be preset to 200-400 rpm, and the milling time to 2-4 hours, with a 5-minute pause every 30 minutes to allow heat dissipation. For example, zirconia balls and the mixed raw materials can be added to the planetary ball mill at a ball-to-material ratio of 15:1, along with 500 mL of anhydrous ethanol. The milling speed is set to 300 rpm for 3 hours to obtain a homogeneous mixture. The advantage of using anhydrous ethanol as the dispersion medium is that its low polarity allows it to wet the powder surface, reducing interparticle friction and minimizing powder agglomeration during milling due to high temperatures. Meanwhile, ethanol is volatile and can be quickly removed through drying, leaving few residual impurities.

[0038] The fourth step involves drying the homogeneous mixture in a vacuum drying oven to remove the dispersion medium and obtain a dried raw material. This dried raw material can be a homogeneous mixture that has already been treated in a vacuum drying oven. In practice, the homogeneous mixture can be placed in a vacuum drying oven. The drying temperature is then set to 60-80°C, and the drying time is 4-6 hours to obtain the dried raw material. The material in the vacuum drying oven can be stirred every 2 hours to increase the evaporation rate of ethanol.

[0039] The fifth step involves cold-pressing the dried raw material to obtain a raw material blank. This raw material blank can be obtained by pressing the dried raw material into a specific shape. In practice, the dried raw material can be placed into a mold and cold-pressed using a hydraulic press to obtain the raw material blank. The molding pressure can be preset to 50-100 MPa, and the holding time to 3-5 minutes. For example, the dried raw material can be filled into a cuboid mold, held at 80 MPa for 4 minutes using a hydraulic press, and then demolded to obtain the raw material blank.

[0040] The sixth step involves vacuum sintering the raw material billet to obtain a silver-aluminum composite billet. In practice, the raw material billet is placed in a vacuum sintering furnace, first evacuated to a furnace pressure of less than or equal to 5 × 10⁻³ Pa, then heated to 700–900 °C at a heating rate of 5–10 °C / min and held for 2–4 hours. After holding, it is cooled to below 100 °C in the furnace to obtain the silver-aluminum composite billet. Evacuating the furnace pressure to less than or equal to 5 × 10⁻³ Pa reduces the oxygen content in the furnace, thereby reducing the possibility of oxidation of silver, aluminum, and copper at high temperatures. At 700–900 °C, silver, aluminum, and copper can undergo diffusion welding, forming a metallurgical bond between particles, which improves the material's density and mechanical strength. The relatively low heating rate of 5–10 °C / min reduces the possibility of thermal stress cracking in the billet.

[0041] Step 7: Passivate the surface of the silver-aluminum composite material blank to obtain the silver-aluminum composite material. In practice, the silver-aluminum composite material blank can be immersed in a passivation solution for 10-20 minutes at room temperature, then rinsed with deionized water until neutral, and finally dried with hot air to form a passivation film on the surface. The passivation solution can be a 5-10% chromate solution, without specific limitations. Passivation treatment generates an oxide film on the material surface, reducing contact between the material and air and moisture, and delaying the degradation of surface conductivity.

[0042] In addressing the aforementioned technical problems using technical solutions, given that base stations are typically located outdoors, such as high-rise buildings or mountain peaks, the following technical problem arises: the soft adhesive material exhibits poor aging resistance in harsh outdoor environments, leading to reduced sealing. A conventional solution to this problem is to add a protective coating to the material surface to improve aging resistance. However, considering the weakness of the coating's adhesion to the substrate, which easily peels off and ultimately reduces the material's aging resistance, and leveraging the advantages of our organization in developing new conductor materials, we decided to adopt the following solution:

[0043] Optionally, the aforementioned pre-designed soft adhesive material can be prepared through the following steps:

[0044] The first step involves mixing vinylidene fluoride (VDF) and hexafluoropropylene (HPP) at a predetermined molar ratio to obtain a fluorocarbon monomer. This predetermined molar ratio can be a pre-set proportion of VDF to HPP by the operator based on the required heat resistance, elasticity, and other parameters of the finished product. For example, the predetermined molar ratio can be from 7:3 to 9:1; no specific numerical limit is imposed on this ratio. The fluorocarbon monomer refers to a homogeneous mixture of VDF and HPP. In practice, VDF and HPP can be poured into a dry mixing container at the predetermined molar ratio and stirred for 5-10 minutes under an inert gas atmosphere to obtain the fluorocarbon monomer.

[0045] The second step involves drying the fluorocarbon monomer to a predetermined level using a molecular sieve, resulting in dried fluorocarbon monomer. The molecular sieve used can be 4A molecular sieve; no specific limitation is made, as long as it effectively dries the fluorocarbon monomer. The dried fluorocarbon monomer refers to the product obtained after drying the fluorocarbon monomer using a molecular sieve. In practice, the fluorocarbon monomer can be placed in a drying container containing a 4A molecular sieve, sealed, and left to stand at room temperature until the moisture content of the fluorocarbon monomer reaches a predetermined level. This predetermined level can be a moisture content of less than or equal to 0.01%, and no specific limitation is made.

[0046] The third step involves adding the dried fluorocarbon monomer and a pre-set material to a high-pressure reactor at a predetermined molar ratio. The pre-set material can be an initiator (such as azobisisobutyronitrile, AIBN). The predetermined molar ratio can be a pre-defined molar ratio of the dried fluorocarbon monomer to the pre-set material, set by the operator. For example, the predetermined molar ratio could be 100:0.1~0.5, and no specific limitation is made here.

[0047] The fourth step involves using perfluorohexane as a solvent and stirring the mixture under preset reaction conditions for 4-6 hours to obtain a reaction solution. These preset reaction conditions can be the pre-defined reaction conditions based on parameters such as temperature and pressure of the high-pressure reactor. For example, the preset reaction conditions could be a reaction temperature of 60-80°C, a pressure of 1-3 MPa, and a stirring speed of 200-300 rpm after stirring is started. The reaction solution refers to the mixed liquid formed in the high-pressure reactor after the fluorocarbon monomers have undergone polymerization in the perfluorohexane solvent, initiated by the initiator. Perfluorohexane is used as the solvent because it is an inert fluorinated solvent, has good compatibility with the fluorocarbon monomers, and does not participate in the reaction. This reduces the viscosity of the system and allows for a more uniform distribution of the fluorocarbon monomers and the initiator. In practice, a preset mass of perfluorohexane can be added to the high-pressure reactor as a solvent, and the mixture can be stirred under preset reaction conditions for 4-6 hours to obtain the reaction solution. The preset mass can be 50% to 100% of the mass of the fluorocarbon monomer, and is not specifically limited here. For example, 80% of the mass of the fluorocarbon monomer in perfluorohexane can be added, the reaction temperature can be set to 70°C, the pressure to 2 MPa, the stirring speed to 250 rpm, and the reaction can be carried out for 5 hours to obtain the reaction solution.

[0048] Step 5: Pour the reaction solution into methanol to precipitate the copolymer. This copolymer can be a polymer formed by the polymerization of vinylidene fluoride and hexafluoropropylene. In practice, the reaction solution can be slowly poured into excess methanol while stirring. The copolymer will precipitate due to its low solubility in methanol, forming a white flocculent precipitate. After standing for a preset time, filter and collect the precipitate to obtain the copolymer. The excess methanol can be 5-10 times the volume of the reaction solution. The preset time can be 30-50 minutes, without a specific limit, as long as the amount of precipitate reaches the target amount.

[0049] Step 6: Wash the copolymer with methanol to obtain a washed copolymer. The washed copolymer can refer to the copolymer after being washed with methanol. In practice, the copolymer can be rinsed with methanol first, and then completely immersed in methanol for a preset time to wash it, thus obtaining a washed copolymer. The preset time can be 1 hour, and is not specifically limited, as long as the residual impurities (such as unreacted fluorocarbon monomers) on the surface of the copolymer are removed to the target degree.

[0050] Step 7: Dry the washed copolymer to obtain a dried copolymer. The dried copolymer can be the washed copolymer that has already undergone drying treatment. In practice, the washed copolymer can be placed in a vacuum drying oven, with the temperature set at 60-80℃ and the vacuum degree ≤-0.09MPa, and dried for 8-12 hours to obtain the dried copolymer. Drying reduces residual methanol and moisture in the washed copolymer, thus lowering the risk of bubbles or performance fluctuations during subsequent processing.

[0051] Step 8 involves annealing the dried copolymer to obtain an annealed copolymer. Annealing reduces internal stress caused by rapid drying, promotes ordered molecular chain arrangement, optimizes the crystalline structure, and thus improves the material's mechanical stability. The annealed copolymer can be the dried copolymer after annealing. In practice, the dried copolymer can be placed in an oven, heated to 100-150°C at a rate of 5-10°C / min under inert gas protection, held for 2-4 hours, and then slowly cooled to room temperature at a rate of 2-5°C / min to obtain the annealed copolymer. For example, it can be heated to 120°C at 8°C / min in a nitrogen atmosphere, held for 3 hours, and then cooled to room temperature at 3°C / min to obtain the annealed copolymer. The heating rate of 5-10°C / min allows the copolymer molecular chains time to gradually adapt to the temperature change, achieving uniform heating and facilitating subsequent molecular chain rearrangement and crystallization optimization. The annealing temperature range of 100-150℃ is higher than the glass transition temperature of fluorocarbon copolymers, which enhances molecular chain mobility and allows for the elimination of internal stress generated during rapid cooling in the drying process through thermal motion. If the annealing temperature is below 100℃, the molecular chain mobility will be insufficient, leading to inadequate stress elimination. If the annealing temperature is above 150℃, it may cause excessive crystallization of the copolymer, which will reduce the material's elasticity and processing performance. The heat preservation stage is crucial for the molecular chains to achieve orderly arrangement and release internal stress through thermal motion. If the heat preservation time is less than 2 hours, there will be more residual internal stress, which may lead to shrinkage or cracking during subsequent processing. While heat preservation for more than 4 hours may not necessarily damage the material itself, it has limited effect on improving the material's performance and increases energy consumption and production cycle. Therefore, 2-4 hours is the more suitable heat preservation duration.

[0052] Step 9 involves homogenizing the annealed copolymer with a crosslinking agent and a catalyst to obtain a homogenized material. This homogenization process can be achieved by mixing the multi-component materials uniformly. The crosslinking agent can be a substance that forms chemical bonds between polymer molecular chains. This crosslinking agent can transform linear polymers into a three-dimensional network structure through crosslinking, thereby improving the polymer's mechanical properties and aging resistance. The crosslinking agent can be dicumyl peroxide, but is not specifically limited here. The catalyst can be a substance that accelerates the crosslinking reaction, lowers the activation energy of the crosslinking reaction, shortens the reaction time, and improves the crosslinking efficiency. The catalyst can be triallyl isocyanurate, but is not specifically limited here. In practice, the annealed copolymer, crosslinking agent, and catalyst can be added to a twin-screw mixer for mixing to obtain the homogenized material. The ratio of the annealed copolymer to the crosslinking agent and catalyst can be annealed copolymer: crosslinking agent = 100:1~3, crosslinking agent: catalyst = 10:1.

[0053] It should be noted that the above homogenization treatment aims to uniformly disperse the crosslinking agent and catalyst within the copolymer matrix, rather than altering the molecular weight or crystallinity of the copolymer itself. Annealed copolymers exhibit lower internal stress and a more uniform structure, resulting in more stable flowability during melt mixing. This reduces shear force fluctuations caused by localized stress, making the mixing process easier to control. Furthermore, annealing optimizes the copolymer's molecular structure, providing a more uniform matrix for subsequent vulcanization and allowing for a more regular distribution of the crosslinking agent within the three-dimensional network structure. Skipping annealing can lead to uneven dispersion of additives during mixing due to internal stress or uneven crystallinity, thus affecting the subsequent vulcanization effect.

[0054] Step 10: Perform compression vulcanization on the homogenized material to obtain the vulcanized material. Compression vulcanization refers to the process of heating and pressurizing the material in a mold to induce a cross-linking reaction and shape it. The vulcanized material can refer to the homogenized material after compression vulcanization. In practice, the homogenized material can be placed in a mold of a flat vulcanizing machine preheated to 160-200°C, pressure of 5-10 MPa applied, and held for 10-30 minutes to allow the homogenized material to cross-link and solidify in the mold. After demolding, the vulcanized material is obtained.

[0055] Step 11: Curing the vulcanized material to obtain the desired soft rubber material. This curing process can refer to a supplementary heat treatment after the vulcanization process, using high temperature to further improve the cross-linking network, eliminate residual stress, and enhance the material's mechanical properties. In practice, the vulcanized material can be placed in an oven at 200-250°C, held for 2-4 hours, and then allowed to cool naturally to room temperature to obtain the desired soft rubber material.

[0056] The above-mentioned optional embodiments, as an inventive point of this disclosure, solve the technical problem of "poor aging resistance of soft rubber materials in harsh outdoor environments, leading to poor sealing performance". The specific factors causing poor aging resistance and poor sealing performance of soft rubber materials are as follows: Currently, protective coatings are usually added to the material surface to improve aging resistance, but the coatings are not firmly bonded to the substrate and are easily detached, failing to effectively block the corrosion of the substrate by outdoor environments (such as high temperature, high humidity, and salt spray) for a long time, ultimately leading to material aging and degradation, elasticity loss, and a decrease in sealing performance. If the above factors are solved, the goal of improving the aging resistance and sealing performance of soft rubber materials in harsh outdoor environments can be achieved. To achieve this goal, this disclosure also provides a solution for optimizing the material itself. On the one hand, annealing treatment optimizes the copolymer crystal structure, reduces internal defects in the material, and improves the aging resistance of the substrate itself; on the other hand, homogenization treatment ensures uniform dispersion of the crosslinking agent and catalyst, providing a more uniform matrix for subsequent vulcanization reactions, enabling the crosslinking agent to be distributed more regularly in the three-dimensional network structure, further improving the material's anti-aging ability. This improves the aging resistance of soft rubber materials in harsh outdoor environments, making them suitable for the use of outdoor equipment such as base station radio frequency devices.

[0057] Step 102: The sealing strip substrate, the absorbent layer substrate, and the reflective layer substrate are subjected to melt extrusion processing to obtain the extruded sealing strip, the extruded absorbent layer, and the extruded reflective layer.

[0058] In some embodiments, the sealing strip substrate, the absorbent layer substrate, and the reflective layer substrate can be melt-extruded separately to obtain an extruded sealing strip, an extruded absorbent layer, and an extruded reflective layer. The extruded sealing strip, the extruded absorbent layer, and the extruded reflective layer can all refer to their state after exiting the extruder but before undergoing a shaping process. In practice, the sealing strip substrate, the absorbent layer substrate, and the reflective layer substrate can be placed in different extruders and melt-extruded separately to obtain the extruded sealing strip, the extruded absorbent layer, and the extruded reflective layer.

[0059] In some optional implementations of certain embodiments, the sealing strip substrate, the absorbent layer substrate, and the reflective layer substrate can be melt-extruded separately through the following steps to obtain an extruded sealing strip, an extruded absorbent layer, and an extruded reflective layer:

[0060] The first step involves melt-extruding the sealing strip substrate using a single-screw extruder to obtain the extruded sealing strip. In practice, the extrusion temperature of the single-screw extruder can be preset to 120~180℃ and the screw speed to 30~60rpm. The sealing strip substrate is then fed into the single-screw extruder for melt-extrusion, and the extruded sealing strip is obtained at the output end of the extruder. For example, the feed temperature of the single-screw extruder can be set to 130℃, the melt temperature to 150℃, the extrusion temperature to 170℃, and the screw speed to 45rpm, resulting in the extruded sealing strip at the output end of the single-screw extruder.

[0061] The second step involves melt-extruding the absorbent layer substrate using a twin-screw extruder to obtain the extruded absorbent layer. In practice, the extrusion temperature of the twin-screw extruder can be preset to 200-260℃ and the screw speed to 50-80 rpm. The absorbent layer substrate is then fed into the twin-screw extruder for melt-extrusion, and the extruded absorbent layer is obtained at the output end of the twin-screw extruder. For example, the feed section of the twin-screw extruder can be set to 210℃, the melting section to 230℃, the mixing section to 245℃, the homogenization section to 255℃, and the die temperature to 255℃, with a screw speed of 65 rpm, resulting in the extruded absorbent layer at the output end of the twin-screw extruder.

[0062] The third step involves melt-extruding the reflective layer substrate using a twin-screw extruder to obtain the extruded reflective layer. In practice, the extrusion temperature of the twin-screw extruder can be preset to 300-380℃ and the screw speed to 40-70 rpm. The reflective layer substrate is then fed into the twin-screw extruder for melt-extrusion, and the extruded reflective layer is obtained at the output end of the twin-screw extruder. For example, the feed section temperature can be set to 310℃, the melting section to 330℃, the mixing section to 350℃, the homogenization section to 370℃, the die temperature to 370℃, and the screw speed to 55 rpm, resulting in the extruded reflective layer at the output end of the twin-screw extruder. It should be noted that melting and plasticizing the high-melting-point silver-aluminum composite material at a high temperature of 300-380℃, combined with the forced conveying and mixing by the twin screw, can improve the uniformity of the silver-aluminum composite material, thereby enhancing the high conductivity and electromagnetic wave reflection performance of the reflective layer.

[0063] Step 103: The extruded sealing strip, extruded absorbent layer and extruded reflective layer are shaped to obtain the sealing strip, absorbent layer and reflective layer.

[0064] In some embodiments, the extruded sealing strip, extruded absorbent layer, and extruded reflective layer can be shaped to obtain the sealing strip, absorbent layer, and reflective layer. In practice, the extruded sealing strip, extruded absorbent layer, and extruded reflective layer can be immersed in cold water for shaping to obtain the sealing strip, absorbent layer, and reflective layer.

[0065] In some optional implementations of certain embodiments, the extruded sealing strip, the extruded absorbent layer, and the extruded reflective layer can be shaped by the following steps to obtain the sealing strip, absorbent layer, and reflective layer:

[0066] The first step involves introducing the extruded sealing strip into a cooling water tank at a preset temperature for cooling, thus obtaining the sealing strip. The preset temperature can be 20-30°C. In practice, the extruded sealing strip can be introduced into the cooling water tank at the preset temperature for a preset cooling time, which can be 10-20 seconds. It should be noted that because the sealing strip is made of soft rubber, a short cooling time of 10-20 seconds can reduce stress concentration caused by rapid cooling and improve its flexibility.

[0067] The second step involves introducing the extruded absorbent layer into a cooling water bath at a second preset temperature for cooling treatment, thus obtaining the absorbent layer. The second preset water temperature can be 40-50℃. In practice, the extruded absorbent layer can be introduced into the cooling water bath at the second preset temperature and cooled for a preset time, which can be 15-25 seconds. It should be noted that because the absorbent layer uses a nickel-carbon composite material, cooling with warm water at 40-50℃ can reduce the risk of structural cracking in the composite material containing carbon nanotube particles due to excessive temperature differences.

[0068] The third step involves segmented cooling of the extruded reflective layer to obtain the reflective layer itself. In practice, the extruded reflective layer can be pre-cooled in a hot water bath at 60-80℃ for 5-10 seconds, followed by final cooling in a cold water bath at 20-30℃ for 10-20 seconds to obtain the reflective layer. It should be noted that the reflective layer uses a silver-aluminum composite material. Silver-aluminum composite material is a high-melting-point metal-based composite material with an extrusion temperature of 300-380℃. If it comes into direct contact with cold water at a high temperature, the large instantaneous temperature difference will cause violent thermal contraction, resulting in huge internal stress in the material, which can easily lead to structural defects such as surface cracking, internal porosity, or delamination. Pre-cooling with hot water at 60-80℃ can slowly reduce the material temperature and decrease the initial cooling rate; then, final cooling with cold water completes the shaping process, gradually releasing thermal stress and reducing the possibility of structural damage caused by rapid contraction.

[0069] Step 104: Perform plasma treatment on the absorption layer and the reflection layer to obtain an activated absorption layer and an activated reflection layer.

[0070] In some embodiments, the absorbing layer and the reflecting layer can be subjected to plasma treatment to obtain an activated absorbing layer and an activated reflecting layer. This plasma treatment can be a technique that uses high-energy plasma to modify the material surface, achieving surface activation through the high-energy characteristics of plasma, thereby optimizing the interfacial bonding performance between the absorbing layer and the reflecting layer. In practice, the contact surface between the absorbing layer and the reflecting layer can be plasma treated to obtain the activated absorbing layer and the activated reflecting layer. The contact surface refers to the surface where the absorbing layer and the reflecting layer come into contact during subsequent composite processes. Plasma treatment only on the contact surface can optimize the interfacial bonding performance between the absorbing layer and the reflecting layer while minimizing the impact on the internal properties of the resulting composite material.

[0071] In some optional implementations of certain embodiments, the above-mentioned absorption layer and reflection layer can be subjected to plasma treatment through the following steps to obtain an activated absorption layer and an activated reflection layer:

[0072] The first step is to clean the surfaces of the absorbing and reflective layers to obtain clean absorbing and reflective layers. In practice, the absorbing and reflective layers are immersed in an ultrasonic cleaner, and the ultrasonic cleaner is controlled to perform ultrasonic cleaning on the absorbing and reflective layers at a preset frequency. Then, the cleaned absorbing and reflective layers are dried under hot air to obtain clean absorbing and reflective layers. For example, the ultrasonic cleaner can be controlled to clean the absorbing and reflective layers at a frequency of 40kHz for 3-5 minutes, and then the cleaned absorbing and reflective layers are removed and dried under hot air at 60-80℃ to obtain clean absorbing and reflective layers.

[0073] The second step involves plasma treatment of the clean absorption layer using a mixture of argon and oxygen at a first preset volume ratio to obtain an activated absorption layer. The first preset volume ratio can be the ratio of the volume of argon to the volume of oxygen. This first preset volume ratio can be between 85:15 and 90:10, and is not specifically limited here. In practice, the clean absorption layer can be plasma treated using a mixture of argon and oxygen at the first preset volume ratio in a plasma surface treatment machine to obtain the activated absorption layer. For example, the first preset volume ratio could be 85:15.

[0074] The third step involves plasma treatment of the clean reflective layer using a mixture of argon and nitrogen gas at a second preset volume ratio to obtain an activated reflective layer. This second preset volume ratio can be the ratio of the volume of argon to the volume of nitrogen. The second preset volume ratio can be between 70:30 and 80:20, and is not specifically limited here. In practice, the clean reflective layer can be plasma treated using a mixture of argon and nitrogen gas at the second preset volume ratio in a plasma surface treatment machine to obtain an activated reflective layer. For example, the second preset volume ratio could be 70:30.

[0075] Step 105: Perform corona treatment on the sealing strip to obtain an activated sealing strip.

[0076] In some embodiments, the sealing strip can be subjected to corona treatment to obtain an activated sealing strip. The corona treatment can be achieved by bombarding the contact surface between the sealing strip and the absorbent layer with high-energy particles generated by high-voltage discharge. Corona treatment can break the surface molecular chains of the sealing strip and introduce polar groups, transforming the surface of the sealing strip from a low-activity state to a high-activity state. This enhances the wettability and adhesion between the sealing strip and the absorbent layer. The activated sealing strip refers to a sealing strip whose surface has been transformed from a low-activity state to a high-activity state through corona treatment. In practice, a corona treatment machine can be used to perform corona treatment on the contact surface between the sealing strip and the absorbent layer to obtain an activated sealing strip.

[0077] In some optional implementations of certain embodiments, the sealing strip can be corona treated to obtain an activated sealing strip:

[0078] The first step is to clean the composite contact surface of the sealing strip to obtain a clean sealing strip. The composite contact surface can be the side of the sealing strip that contacts the absorbent layer. In practice, the sealing strip can be placed in an ultrasonic cleaner for a preset cleaning time to obtain a clean sealing strip. A mixture of deionized water and neutral detergent in a preset mass ratio can be added to the cleaning tank of the ultrasonic cleaner. The preset cleaning time can be 3-5 minutes, without specific limitation. The preset mass ratio can be 90:10-95:5, without specific limitation.

[0079] The second step involves corona treatment of the composite contact surface using a corona machine to obtain an activated sealing strip.

[0080] In addressing the aforementioned technical problems using technical solutions, a second technical problem arises: the sealing strip needs to maintain its interfacial bonding strength with the absorption layer while being subjected to prolonged compression from radio frequency devices (to ensure sealing). This is because the sealing strip needs to withstand prolonged compression to maintain its seal. A conventional solution to this second technical problem is to subject the sealing strip to multiple corona treatments. However, considering the drawbacks of this method—while increasing activation levels—the activation depth is relatively shallow, and the stability of the activated surface-active molecules is poor. Furthermore, leveraging the strengths of our organization in polymer material surface modification research and development, we have decided to adopt the following solution:

[0081] In some optional implementations of certain embodiments, the sealing strip can also be corona treated to obtain an activated sealing strip:

[0082] The first step involves covering the untreated surface of the sealing strip with a polytetrafluoroethylene (PTFE) film to obtain a masked sealing strip. This untreated surface is the side that does not contact the absorbent layer. This untreated surface does not require activation treatment; accidental activation may lead to material embrittlement and a decrease in sealing performance. Therefore, it can be masked with a PTFE film. PTFE film has excellent electrical insulation and chemical stability, which can reduce the effects of corona discharge and ultraviolet energy on the untreated surface. The masked sealing strip refers to a sealing strip where the untreated surface is covered by a PTFE film, leaving only the surface that will subsequently contact the absorbent layer exposed. In practice, a silicone roller can be used to press the PTFE film onto the untreated surface, and it can be fixed with a high-temperature resistant tape similar to polyimide to obtain the masked sealing strip.

[0083] The second step involves cleaning the unmasked surfaces of the masking seal strip with anhydrous ethanol to obtain a clean masking seal strip. This clean masking seal strip refers to a seal strip whose unmasked surfaces have been cleaned with anhydrous ethanol. In practice, a lint-free cloth dampened with anhydrous ethanol can be used to clean the unmasked surfaces of the masking seal strip. The reason for cleaning the unmasked surfaces of the masking seal strip, which are the surfaces to be treated with corona treatment, is that if there are residual stains on these surfaces, it can lead to uneven local discharge during corona treatment, and electric arcs can easily form at the stains, burning the surface of the masking seal strip. Cleaning these surfaces reduces the likelihood of this happening.

[0084] The third step involves pre-corona treatment of the clean masking sealing strip using a corona machine to obtain a pre-corona-treated sealing strip. This pre-corona treatment of the clean masking sealing strip refers to pre-corona treatment of the aforementioned treated surface. This pre-corona treatment can be considered the first corona treatment performed on the treated surface. Performing a corona treatment on the treated surface before the strengthening treatment (see next step) can initially improve the activity state of the treated surface, making subsequent processing steps more efficient. The pre-corona-treated sealing strip refers to the clean masking sealing strip after the aforementioned pre-corona treatment.

[0085] The fourth step is to strengthen the pre-corona-treated sealing strip. This strengthening treatment refers to further enhancing the activation level of the treated surface after the pre-corona treatment. This strengthening treatment may include the following sub-steps:

[0086] The first sub-step involves placing the pre-corona sealing strip into a pre-set chamber. This pre-set chamber can be a sealable metal chamber, such as a cubic stainless steel chamber, without specific limitations. The pre-set chamber may be equipped with a temperature control device, such as an integrated device combining an electric heating rod and a temperature detector. The pre-set chamber may also be connected to an ozone generator, allowing ozone to be introduced into its interior. A vacuum pump may also be connected to the pre-set chamber to control the internal gas pressure, and a pressure sensor may be installed inside the chamber to detect the internal pressure. In practice, the pre-corona sealing strip can be placed into the pre-set chamber and then the chamber can be sealed.

[0087] The second sub-step involves controlling the ozone concentration in the preset chamber to 80-100 mg / m³, and maintaining the chamber pressure at 0.101-0.103 MPa. In practice, the ozone generator can be activated to introduce ozone gas into the preset chamber, and an ozone sensor installed inside the chamber can be used to monitor in real time whether the ozone concentration reaches 80-100 mg / m³. Simultaneously, the pressure sensor can be used to monitor whether the gas pressure in the chamber is maintained at 0.101-0.103 MPa. If the gas pressure is not within the 0.101-0.103 MPa range, it can be adjusted using the vacuum pump. The reason for choosing a pressure range of 0.101-0.103 MPa is that this range can improve the uniformity of ozone diffusion within the chamber and reduce the uneven activation caused by ozone concentration stratification under low pressure.

[0088] The third sub-step involves controlling the temperature within the preset chamber at 40-50°C. In practice, the aforementioned electric heating rod can be used to control the temperature within the preset chamber at 40-50°C. This temperature of 40-50°C increases the molecular motion rate on the treated surface, promoting the reaction between ozone and active molecules, while being below the glass transition temperature reduces the possibility of the soft adhesive softening.

[0089] The fourth sub-step involves irradiating the pre-treated surface with a dual-band ultraviolet lamp installed inside a preset chamber for 60-75 seconds to obtain a reinforced sealing strip. This dual-band ultraviolet lamp can be a mercury lamp capable of simultaneously emitting 185nm vacuum ultraviolet light and 254nm near-ultraviolet light. The 185nm light can photolyze oxygen to generate ozone, while the 254nm light can excite molecular bond vibrations and promote the chemical reaction between ozone and the treated surface. The synergy of these two processes allows for deeper activation. The reinforced sealing strip can refer to a pre-corona-treated sealing strip treated in the first through fourth sub-steps. In practice, under the conditions described in the first through third sub-steps, the pre-corona-treated sealing strip located inside the preset chamber can be irradiated with the aforementioned dual-band ultraviolet lamp for 60-75 seconds to obtain the reinforced sealing strip.

[0090] The fifth step involves subjecting the reinforced sealing strip to a secondary corona treatment, resulting in a secondary corona-treated sealing strip. This secondary corona treatment refers to a corona treatment performed on the reinforced sealing strip after a synergistic enhancement treatment with ultraviolet radiation and ozone. This secondary corona treatment improves the stability of the polar groups on the treated surface. Furthermore, it extends the effective lifespan of the treated surface, allowing sufficient time for subsequent stacking and composite processing. The secondary corona-treated sealing strip can be a reinforced sealing strip that has undergone this secondary corona treatment. In practice, a corona treatment machine can be used to perform the secondary corona treatment on the reinforced sealing strip to obtain the secondary corona-treated sealing strip.

[0091] Step 6: Curing the secondary corona sealing strip to obtain an activated sealing strip. This curing process can be performed under inert gas protection by low-temperature heating of the secondary corona sealing strip. This curing process allows the polar groups on the treated surface to form more stable chemical bonds with the substrate of the sealing strip, further reducing the rate of activity decay. In practice, the secondary corona sealing strip can be placed in an electrically heated drying oven, then the blower function is activated to purge inert gas into the oven, and the heating function is turned on. Once the temperature inside the oven reaches a preset value, it is maintained at that preset value for heat preservation. After the heat preservation time reaches a preset duration, the heating function is turned off, but the inert gas purging function remains on, allowing the secondary corona sealing strip inside the oven to cool to room temperature, thus obtaining the activated sealing strip. The preset value can be any value between 50 and 60°C, and is not specifically limited here. The preset time can be 20 to 25 minutes, and is not specifically limited here.

[0092] The above-described optional embodiments, as an inventive point of this disclosure, solve the technical problem of "poor bonding strength between the sealing strip and other components". The specific factors leading to poor bonding strength between the sealing strip and other components are as follows: Currently, multiple corona treatments are commonly used to improve the activation level of the sealing strip. However, multiple corona treatments mainly act on the material surface, failing to achieve deep activation and failing to effectively stabilize polar groups, resulting in rapid activity decay. If these factors are resolved, the activation depth of the sealing strip can be increased, thereby improving the interfacial bonding strength. To achieve this objective, this disclosure further provides an activation scheme synergistically combining corona treatment, ultraviolet radiation, and ozone. On one hand, pre-corona treatment initially enhances surface activity. On the other hand, ozone-synergistic dual-band ultraviolet radiation improves the material activation depth, and curing treatment stabilizes the activation effect. This enhances the bonding strength between the sealing strip and other components.

[0093] Step 106: Stack the activated sealing strip, activated absorption layer, and activated reflective layer according to a preset positional relationship to obtain a stacked component. The preset positional relationship may involve the absorption layer being positioned between the reflective layer and the sealing strip. The reflective layer can reflect electromagnetic waves through its high conductivity, while the absorption layer can absorb unreflected residual electromagnetic waves through the synergistic effect of nickel and carbon. Placing the absorption layer inside the reflective layer creates a progressive shielding path of reflection followed by absorption, improving the shielding effect. The stacked component may be a combination component obtained by stacking the activated sealing strip, activated absorption layer, and activated reflective layer according to a preset positional relationship. In some embodiments, the activated sealing strip, activated absorption layer, and activated reflective layer may be stacked according to a preset positional relationship to obtain the stacked component.

[0094] Step 107: Perform composite processing on the stacked components to obtain conductive components.

[0095] In some embodiments, the stacked components can be composited to obtain a conductive component. This composited process can involve bonding the stacked components together. For example, nano-silver paste can be applied to the contact surfaces of the activated sealing strip, the activated absorption layer, and the activated reflective layer. Then, a hot press molding machine is used to composite the nano-silver paste-coated stacked components to obtain a conductive component. The nano-silver paste serves as an interface reinforcement layer, reducing the contact resistance between the contact surfaces. The nano-silver paste can be a conductive silver paste. For example, the nano-silver paste can be a sintered silver conductive paste.

[0096] Optionally, the conductive component can be shaped to obtain a shaped conductive component. This shaping process may involve trimming the edges of the conductive component to remove excess material and improve edge smoothness.

[0097] In the process of adopting technical solutions to address the aforementioned technical problems, the following third technical problem arises: insufficient dimensional accuracy of conductive components and residual surface stress lead to poor electromagnetic shielding performance. The conventional solution to this third technical problem is to directly adjust the dimensions using a single machining process. However, considering the drawbacks of this method, such as the tendency to cause edge burrs, internal stress concentration, and insufficient surface smoothness, and taking into account the advantages of our organization in conductive material research and development, we have decided to adopt the following solution:

[0098] In some optional implementations of certain embodiments, the conductive component described above can be shaped using the following steps to obtain the shaped conductive component:

[0099] The first step involves using laser scanning to detect errors in the conductive components and obtain error information. This error information refers to the dimensional deviation between the actual and target dimensions of the conductive component. For example, assuming the actual width of a certain point on the conductive component is 15mm, while the target width is 13mm, the error information at this point is recorded as "2mm overwidth". In practice, a laser 3D scanner can be used to scan the conductive components and obtain the error information.

[0100] The second step is to fix the conductive component onto the CNC machine tool. The surface of the conductive component to be fitted can face upwards and be perpendicular to the feed direction of the CNC machine tool. This surface to be fitted can be a surface with existing errors.

[0101] The third step involves milling the surface to be trimmed based on the error information to obtain the initial trimmed conductive component. This initial trimmed conductive component can be a conductive component whose dimensional deviations have been corrected through milling. In practice, the error information can be input into the CNC machine tool, causing it to mill the surface to be trimmed according to the error information to obtain the initial trimmed conductive component.

[0102] The fourth step involves grinding the edges of the initially trimmed conductive component using a diamond grinding wheel to obtain a first-stage trimmed conductive component. Since burrs may exist on the edges of the initially trimmed conductive component, these burrs can potentially trigger point discharges, affecting the overall shielding performance of the finished conductive component. Therefore, grinding the edges of the initially trimmed conductive component reduces the impact of burrs. This grinding process refers to rounding the edges of the initially trimmed conductive component using a diamond grinding wheel. The first-stage trimmed conductive component can be the initially trimmed conductive component that has undergone this grinding process. In practice, the desired rounded corner size can be preset on a CNC machine tool, allowing the machine tool to drive the diamond grinding wheel to grind the initially trimmed conductive component, resulting in a first-stage trimmed conductive component with a preset rounded corner size. For example, the rounded corner size can be preset to R0.25mm; no specific limitation is made, as long as burrs are eliminated.

[0103] The fifth step involves performing an internal stress release treatment on the primary dressed conductive component to obtain a secondary dressed conductive component. This internal stress release treatment refers to the process of releasing the internal stress generated during grinding in the primary dressed conductive component. The secondary dressed conductive component refers to the primary dressed conductive component that has undergone the internal stress release treatment. In practice, the primary dressed conductive component can be placed in an electrically heated drying oven and kept at 100-120°C for a preset time, followed by cooling to room temperature at a rate of 1°C / min to obtain a secondary dressed conductive component with released internal stress. The preset time can be 2 hours, and is not specifically limited here.

[0104] Step 6: Perform flatness calibration on the secondary-level trimmed conductive component to obtain the tertiary-level trimmed conductive component. The flatness calibration can be achieved by detecting and adjusting the surface of the secondary-level trimmed conductive component to make it smoother. The tertiary-level trimmed conductive component can be the secondary-level trimmed conductive component that has undergone flatness calibration. In practice, a dial indicator can be used to detect the flatness of the secondary-level trimmed conductive component. For areas where the flatness error exceeds a preset threshold, local pressure treatment is applied to obtain the tertiary-level trimmed conductive component. This local pressure treatment can be achieved by placing a counterweight in the area where the flatness error exceeds the preset threshold. Then, the secondary-level trimmed conductive component with the counterweight is placed in an oven for heat preservation. The combined effect of heating and pressure restores the surface of the secondary-level trimmed conductive component to flatness. The counterweight can be a flat-surfaced cubic metal block, without specific limitations. The preset threshold can be 0.03 mm / m, without specific limitations. In the actual use of finished conductive components, low flatness may lead to uneven electromagnetic wave reflection. Therefore, it is necessary to perform flatness calibration on the above-mentioned secondary-level trimmed conductive components.

[0105] Step seven involves stress-relief polishing of the surface of the three-stage dressed conductive component to obtain a four-stage dressed conductive component. This stress-relief polishing can be achieved by using a flexible polishing wheel and fine-grained polishing paste to reduce residual stress on the surface of the three-stage dressed conductive component. The four-stage dressed conductive component refers to the three-stage dressed conductive component that has undergone the stress-relief polishing treatment. In practice, a wool wheel combined with cerium oxide polishing paste can be used to polish the surface of the three-stage dressed conductive component to obtain the four-stage dressed conductive component. The cerium oxide polishing paste is a polishing paste with cerium oxide as the core abrasive.

[0106] Step 8: Perform ultrasonic cleaning on the fourth-stage trimmed conductive components to obtain the shaped conductive components. In practice, the above-mentioned fourth-stage trimmed conductive components can be placed in an ultrasonic cleaner for ultrasonic cleaning to obtain the shaped conductive components.

[0107] The above-described optional embodiments, as an inventive point of this disclosure, solve the technical problem of "poor electromagnetic shielding performance due to insufficient dimensional accuracy of conductive components and residual surface stress". The specific factors leading to insufficient dimensional accuracy of conductive components and residual surface stress resulting in poor electromagnetic shielding performance are as follows: Currently used single machining processes cannot simultaneously address dimensional correction, burr removal, stress release, and surface flatness control, leading to the risk of tip discharge and uneven electromagnetic wave reflection in conductive components. Solving these factors can improve the dimensional accuracy of conductive components, eliminate internal stress, and optimize electromagnetic shielding performance. To achieve this goal, this disclosure also provides a synergistic process of shaping and stress relief. On one hand, dimensional correction is achieved through laser inspection and CNC milling. On the other hand, surface treatment processes such as grinding rounding, stress release, local pressure leveling, and stress-relief polishing are combined to synergistically eliminate microscopic defects and residual stress. This improves the dimensional accuracy and electromagnetic shielding performance of the conductive components.

[0108] Some embodiments of this disclosure provide a method for fabricating a sealed conductive component for base station radio frequency devices, which can extend the service life of the conductive component. Specifically, the reason for the short service life of most conductive components is that currently, pure silver or copper foil is often used as a conductive layer bonded to a silicone rubber sealing material to fabricate the conductive component of the radio frequency device. However, when the conductive component of the radio frequency device is fabricated in the above manner, the poor interfacial compatibility between the conductive layer and the sealing material often leads to delamination of the conductive component under long-term use, resulting in a decrease in its shielding effectiveness and thus a short service life. Based on this, some embodiments of this disclosure provide a method for fabricating a sealed conductive component for a base station radio frequency device. The method includes: selecting a pre-defined soft rubber material, a nickel-carbon composite material, and a silver-aluminum composite material as a sealing strip substrate, an absorption layer substrate, and a reflective layer substrate, respectively; performing melt extrusion processing on the sealing strip substrate, the absorption layer substrate, and the reflective layer substrate to obtain an extruded sealing strip, an extruded absorption layer, and an extruded reflective layer; performing a shaping process on the extruded sealing strip, the extruded absorption layer, and the extruded reflective layer to obtain a sealing strip, an absorption layer, and a reflective layer; performing plasma treatment on the absorption layer and the reflective layer to obtain an activated absorption layer and an activated reflective layer; performing corona treatment on the sealing strip to obtain an activated sealing strip; stacking the activated sealing strip, the activated absorption layer, and the activated reflective layer according to a pre-defined positional relationship to obtain a stacked component, wherein the absorption layer is located between the reflective layer and the sealing strip; and performing a composite processing on the stacked component to obtain a conductive component. Because plasma treatment and corona treatment improve the interfacial compatibility between the layers of the conductive component, the composite strength of the conductive component is improved. Therefore, the service life of the conductive component can be extended.

[0109] The above description is merely a selection of preferred embodiments of this disclosure and an explanation of the technical principles employed. Those skilled in the art should understand that the scope of the invention involved in the embodiments of this disclosure is not limited to technical solutions formed by specific combinations of the above-described technical features, but should also cover other technical solutions formed by arbitrary combinations of the above-described technical features or their equivalents without departing from the above-described inventive concept. For example, technical solutions formed by substituting the above-described features with (but not limited to) technical features with similar functions disclosed in the embodiments of this disclosure.

Claims

1. A method for fabricating a sealed conductive component for a base station radio frequency device, comprising: Pre-selected soft rubber material as the sealing strip substrate, nickel-carbon composite material as the absorption layer substrate, and silver-aluminum composite material as the reflective layer substrate; The sealing strip substrate, the absorbent layer substrate, and the reflective layer substrate are respectively subjected to melt extrusion processing to obtain an extruded sealing strip, an extruded absorbent layer, and an extruded reflective layer; The extruded sealing strip, the extruded absorbent layer, and the extruded reflective layer are subjected to a shaping process to obtain the sealing strip, the absorbent layer, and the reflective layer; The absorption layer and the reflection layer are subjected to plasma treatment to obtain an activated absorption layer and an activated reflection layer; The sealing strip is subjected to corona treatment to obtain an activated sealing strip; The activated sealing strip, the activated absorption layer, and the activated reflective layer are stacked in a preset positional relationship to obtain a stacked component, wherein the absorption layer is located between the reflective layer and the sealing strip; The stacked components are subjected to a composite process to obtain a conductive component.

2. The method according to claim 1, wherein, The nickel-carbon composite material is prepared by the following steps: The nickel powder, carbon nanotubes and silane coupling agent mixed according to a preset mass ratio were ball-milled to obtain the ball-milled material. The ball-milled material is pre-compressed to obtain a pre-compressed blank; The pre-pressed billet is sintered under inert gas protection to obtain a sintered billet; The sintered green body is crushed to obtain nickel-carbon composite powder; The nickel-carbon composite powder is mixed with a molding aid to obtain a mixed material; The mixed material is granulated using a twin-screw granulator to obtain a nickel-carbon composite material.

3. The method according to claim 1, wherein, The method further includes: The conductive component is shaped to obtain a shaped conductive component.

4. The method according to claim 1, wherein, The process of melt-extruding the sealing strip substrate, the absorbent layer substrate, and the reflective layer substrate to obtain an extruded sealing strip, an extruded absorbent layer, and an extruded reflective layer includes: The sealing strip substrate is melt-extruded using a single-screw extruder to obtain an extruded sealing strip, wherein the extrusion temperature is preset to 120~180℃ and the screw speed is preset to 30~60rpm; The absorbent layer substrate is melt-extruded using a twin-screw extruder to obtain an extruded absorbent layer, wherein the extrusion temperature is preset to 200~260℃ and the screw speed is preset to 50~80rpm. The reflective layer substrate is melt-extruded using a twin-screw extruder to obtain an extruded reflective layer, wherein the extrusion temperature is preset to 300~380℃ and the screw speed is preset to 40~70rpm.

5. The method according to claim 1, wherein, The step of shaping the extruded sealing strip, the extruded absorbent layer, and the extruded reflective layer to obtain the sealing strip, absorbent layer, and reflective layer includes: The extruded sealing strip is introduced into a cooling water tank at a first preset water temperature for cooling treatment to obtain the sealing strip; The extruded absorbent layer is introduced into a cooling water tank with a second preset water temperature for cooling treatment to obtain the absorbent layer; The extruded reflective layer is subjected to segmented cooling treatment to obtain the reflective layer.

6. The method according to claim 1, wherein, The plasma treatment of the absorption layer and the reflection layer to obtain an activated absorption layer and an activated reflection layer includes: The absorber layer and the reflective layer are cleaned to obtain a clean absorber layer and a clean reflective layer. The clean absorption layer is subjected to plasma treatment using a mixture of argon and oxygen in a first preset volume ratio to obtain an activated absorption layer. The clean reflective layer is subjected to plasma treatment using a mixture of argon and nitrogen in a second preset volume ratio to obtain an activated reflective layer.

7. The method according to claim 1, wherein, The process of corona treatment on the sealing strip to obtain an activated sealing strip includes: The composite contact surface of the sealing strip is cleaned to obtain a clean sealing strip, wherein the composite contact surface is the surface used to contact the absorbent layer; The composite contact surface is corona treated with a corona generator to obtain an activated sealing strip.

8. The method according to claim 1, wherein, The silver-aluminum composite material is prepared by the following steps: Silver powder, aluminum powder, copper powder and cerium powder are selected as raw materials, wherein the particle size of silver powder is 1~5μm, the particle size of aluminum powder is 5~10μm, the particle size of copper powder is 2~5μm, and the particle size of cerium powder is 1~3μm. The components of the raw material are mixed according to a preset mass ratio to obtain a mixed raw material; The mixed raw materials are dispersed by a planetary ball mill to obtain a uniformly mixed raw material, wherein anhydrous ethanol is added as a dispersion medium during the dispersion process. The uniformly mixed raw material is dried using a vacuum drying oven to remove the dispersion medium and obtain a dried raw material. The dried raw material is subjected to cold pressing to obtain a raw material blank; The raw material blank is subjected to vacuum sintering furnace treatment to obtain a silver-aluminum composite material blank; The surface of the silver-aluminum composite material blank is passivated to obtain the silver-aluminum composite material.

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