Antenna Module Polymer Composition for Strong LDS Weldlines
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Solution Overview
Problem
Conventional laser direct structured (LDS) compositions for antenna modules face challenges due to spinel crystals, which can adversely impact performance and require glass fiber reinforcement, leading to poor weldline tensile properties and difficulties in mating with other electronic components.
Innovation Solution
The development of an antenna module using a polymer composition with silicate fibers distributed within a thermotropic liquid crystalline polymer matrix, which allows for the formation of conductive elements without compromising other properties, such as weldline tensile strength and melt viscosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If glass fiber reinforcement is added to LDS composition to achieve sufficient strength, then strength is improved, but weldline tensile properties deteriorate and mating with electronic components becomes difficult
Solution Approach 1:
The patent changes the type of reinforcement from glass fibers to silicate fibers (such as wollastonite, tremolite, or chrysotile), which have different physical and chemical properties. This parameter change allows achieving sufficient strength while avoiding the surface extension problem that plagues glass fiber-reinforced compositions, thereby improving weldline tensile properties and ease of mating with electronic components.
Solution Approach 2:
The patent uses composite materials by combining silicate fibers with the polymer matrix (such as PCTA or other polyesters). This composite approach provides both the necessary mechanical strength and the desired surface properties for good weldline tensile strength and component mating, resolving the contradiction between strength and ease of operation.
2Ease of manufacture
If spinel crystals are present in LDS composition to enable laser direct structuring, then conductive element formation is enabled, but performance is adversely impacted
Solution Approach 1:
The patent removes or eliminates spinel crystals from the LDS composition while retaining the ability to form conductive elements through laser direct structuring. This extraction of the harmful component (spinel crystals) allows maintaining the manufacturing capability (conductive element formation) while improving performance and reliability.
Solution Approach 2:
The patent converts the potential harm of spinel crystals by replacing them with alternative materials (such as metal powders or other laser-reactive additives) that provide the same functional benefit (conductive element formation) without the adverse performance impacts. This transforms the problematic ingredient into a beneficial alternative.
3Ease of manufacture
If conventional LDS composition is used to form antenna modules, then antenna elements can be formed, but other properties (weldline tensile strength, melt viscosity) are compromised
Solution Approach 1:
The patent changes the compositional parameters by using silicate fiber-reinforced polymer matrices instead of conventional glass fiber-reinforced or spinel-containing compositions. This parameter change maintains the ability to form antenna elements through laser direct structuring while significantly improving weldline tensile strength and other critical properties.
Solution Approach 2:
The patent employs composite materials with silicate fibers dispersed in polymer matrices (such as PCTA, polyesters, or other engineering plastics). This composite structure provides both the mechanical properties needed for reliable antenna modules (high weldline tensile strength, controlled melt viscosity) and the manufacturability for forming conductive antenna elements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The polymer composition exhibits improved weldline tensile properties, including a weldline tensile break strain of 0.3% or more and a weldline tensile strength of 20 MPa or more, while also maintaining ultralow melt viscosity and excellent thermal properties, enabling the production of small-sized antenna modules with enhanced performance.
Implementation Method 1
a polymer composition with silicate fibers distributed within a thermotropic liquid crystalline polymer matrix, which allows for the formation of conductive elements without compromising other properties, such as weldline tensile strength and melt viscosity
Data Source
AI summary
An antenna module is provided. The antenna module comprises a dielectric on which is disposed one or more antenna elements configured to transmit and/or receive a radiofrequency signal; a communication circuit for processing the radiofrequency signal; an interconnect member that is electrically connected with the communication circuit and the antenna elements, wherein the interconnect member optionally contains a substrate on which a metal coating is disposed; and optionally, a shield member covering the communication circuit that contains a substrate on which a metal coating is disposed. The dielectric, the substrate of the interconnect member, and/or the substrate of the shield member contain a polymer composition comprising silicate fibers distributed within a polymer matrix that includes a thermotropic liquid crystalline polymer.