Hybrid Antenna Structure Using Two-Shot Laser Direct Structuring
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Solution Overview
Problem
Existing antenna manufacturing methods, such as multi-shot injection molding and laser direct structuring, face challenges with high tooling costs and material limitations, particularly in accommodating design changes and achieving optimal mechanical and chemical bonds for conductive traces.
Innovation Solution
A hybrid antenna structure is formed using a combination of two-shot molding with a non-platable plastic base and a conductive trace carrying section made from laser direct structuring material, where the laser-activated areas are plated to create conductive traces, allowing for flexible design changes and improved material properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multi-shot injection molding with selective plating is used, then mechanical strength and chemical bond are improved, but tooling cost and manufacturing complexity increase
Solution Approach 1:
The antenna structure is segmented into two distinct parts: a non-platable base layer providing mechanical strength and a platable substrate layer enabling conductive trace formation. This segmentation allows each layer to be optimized for its specific function while being manufactured through a integrated two-shot molding process, resolving the contradiction between strength and plating capability without requiring complex external tooling
Solution Approach 2:
The patent merges the base layer formation and platable substrate formation into a single two-shot injection molding process. The first shot creates the non-platable base layer, and the second shot directly molds the platable substrate onto it in the same tooling system. This combining eliminates the need for separate tooling changes and reduces manufacturing complexity while maintaining the mechanical and chemical bond requirements
2Adaptability or versatility
If laser direct structuring material is used, then design flexibility and adaptability are improved, but material cost and mechanical properties deteriorate
Solution Approach 1:
The patent applies local quality by making only the necessary portions of the base layer platable through laser direct structuring. The laser selectively activates specific areas of the base layer where conductive traces are needed, while the rest of the base layer retains its original superior mechanical properties. This resolves the contradiction by limiting the use of expensive laser-activated material to only where required for electrical functionality
Solution Approach 2:
The antenna structure uses a composite construction combining a base layer (which can be laser-activated) with a platable substrate layer. The base layer provides mechanical strength and selective laser activation capability, while the platable substrate provides the conductive trace formation capability. This composite approach allows the structure to benefit from both the design flexibility of laser direct structuring and the superior mechanical properties of the base layer material
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
This approach reduces tooling expenses, enhances material properties, and provides a cost-effective method for creating antennas with flexible design capabilities while maintaining mechanical integrity and efficient plating processes.
Implementation Method 1
The laser would be used to selectively activate the material with the radiation pattern desired
Implementation Method 2
a laser direct structuring process. The laser direct structuring process provides an injection molded base of a material that can be selectively activated by a laser
Implementation Method 3
The material is plated such that conductive traces plate to the activated portions
Data Source
AI summary
An electrical component is provided that provides at least a two shot injection molding structure. One of the at least two shots of plastic comprises a laser direct structuring material. Another of the at least two shots of plastic comprises a non-platable plastic. The laser direct structuring material is selectively activated such that a conductive trace can be plated on the laser direct structuring material.