CN114672806A - 一种天线振子及其制造方法 - Google Patents
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Abstract
本发明涉及一种天线振子及其制造方法,制造方法包括以下步骤:S1注塑成型制得振子本体;S2对振子机械粗化;S3对振子化学粗化;S4用胶体钯或离子钯溶液对振子进行活化处理;S5对振子进行解胶或还原;S6对振子进行化学镀镍,形成化学镍层;S7在振子表面分隔出电镀区和非电镀区;S8在电镀区上电镀铜;S9去除非电镀区上的化学镍层。本发明通过对振子本体先后进行机械粗化和化学粗化,化学镍层在塑料表层附着力强,铜层均匀;再在化学镍层上电镀铜层,制得的天线振子的可靠性更强。此外,化学镀结合电镀的方式可以提高加工的速度,加工效率更高,利于批量生产。
Description
技术领域
本发明涉及通信天线技术领域,尤其涉及一种天线振子及其制造方法。
背景技术
随着4G/5G无线通信行业的不断发展及网络升级,无线通信使用的频率越来越高,需求量越来越多。天线的结构设计、选材、制造方法和组装工艺是天线性能可靠性、稳定性和耐用程度的保障。振子是天线内部最为重要的功能性部件,一般结构设计较为复杂。振子的传统生产制造工艺是采用金属材料(铝合金或锌合金)压铸成型,或是钣金件、塑料固定件和电路板组合的方式。
目前天线行业塑料振子虽然已经导入量产,当前常用的方法为先对塑料表层化学镀镍再镀铜,但是实际使用中,在塑料表层化学镀镍形成的镍层附着度不好,容易脱落,进而导致整个天线振子的可靠性降低。
发明内容
本发明提供了一种天线振子的制造方法,目的在于提高振子的可靠性。
为实现上述技术目的,本发明还公开了一种天线振子制造方法,包括以下步骤:
S1、以塑料为原料注塑成型制得有预定结构的振子本体;
S2、对所述振子本体的表面进行机械粗化处理,然后进行清洗;
S3、采用粗化液对所述振子本体进行化学粗化处理;
S4、采用酸性的钯溶液对所述振子本体进行活化处理;
S5、对所述振子本体进行清洗;
S6、采用碱性离子铜溶液对所述振子本体进行化学镀镍,形成化学镍层;
S7、在所述化学镍层上分隔出电镀区和非电镀区;
S8、在所述振子本体的电镀区上进行电镀铜处理,形成电镀铜层;
S9、去除所述振子本体的非电镀区上的化学镍层。
优选地,步骤S3中,所述粗化液为粗化盐溶液,粗化盐浓度为150~400g/l;化学粗化时间为5~20min,温度为20~45℃。
优选地,步骤S4中,采用胶体钯溶液对所述振子本体进行活化处理,溶液中包含钯15~55ppm、盐酸150~300ml/l、氯化亚锡1~5g/l;活化时间为1~8min,温度为20~45℃;
步骤S5中,采用解胶剂溶液对所述振子本体进行解胶,溶液中解胶剂浓度为10~80ml/l;清洗时间为1~8min,温度为30~60℃。
优选地,步骤S4中,采用离子钯溶液对所述振子本体进行活化处理,溶液中包含钯20~100ppm、硫酸或盐酸8~50ml/l;活化时间为1~8min,温度为20~45℃;
步骤S5中,采用还原剂溶液对所述振子本体进行还原,溶液中还原剂浓度为20~80ml/l,清洗时间为1~8min,温度为30~60℃。
优选地,步骤S6中,所述离子镍溶液包含离子镍1~5g/l、游离碱5~15g/l、游离甲醛10~25ml/l;化学镀铜时间为5~30min,温度为20~35℃;化学镀铜过程中,所述离子镍溶液浓度控制在50~150%,溶液pH=8~14。
优选地,步骤S7中,通过在所述的化学镍层上激光镭雕阻隔线的方式,分隔出电镀区和非电镀区。
优选地,步骤S1中选用PPS塑料或PPO塑料为原料;步骤S2中所述的机械粗化为对所述振子本体的表面进行喷砂处理;步骤S8中所述的电镀铜处理为镀焦铜或镀酸铜。
优选地,还包括在步骤S9之后的步骤S10和S11,步骤S10为第二次电镀铜处理,该电镀铜处理为镀酸铜;步骤S11为在所述的电镀区上增设保护层。
优选地,步骤S11所述的增设保护层为镀锡或镀银。
本发明还公开了一种天线振子,采用上述任一项方法制得。
本发明具有以下有益效果:
通过对振子本体先后进行机械粗化和化学粗化,可以使有效提高镍层的附着力,镍层不容易脱落,使得天线振子的可靠性得以提高。此外,化学镀结合电镀的方式可以提高加工的速度,加工效率更高,利于批量生产。
具体实施方式
为了使本发明的目的、技术方案及优点更加清楚明白,下面结合实施例,对本发明进行进一步详细说明。
实施例一:
一种天线振子的制造方法,以PPS塑料为基材,包括以下步骤:
S1:将PPS塑料注塑成型制得具有预定结构的振子本体。
S2:对所述振子本体的表面进行机械粗化处理,然后进行清洗。机械粗化的目的是为了提高振子本体表面的粗糙度,从而提高铜层的附着力,避免铜层脱落。机械粗化处理方式可以采用喷砂的方式,喷料选用非磁性材料,从而避免残留的喷料附着在振子表面,影响振子成品的电气性能。
S3:采用粗化液对所述振子本体进行化学粗化处理。该粗化液为粗化盐溶液,粗化盐浓度为150g/l;将振子本体浸置在粗化液中,浸置时间5~20min,温度控制在20~45℃。
化学粗化的目的在于进一步提高振子表面的粘附性能。S4:采用胶体钯溶液对所述振子本体进行活化处理。胶体钯溶液包含钯15ppm、盐酸150ml/l、氯化亚锡1g/l,活化时间为1~8min,温度控制在20~45℃。
二价锡呈胶状把钯原子紧紧包裹,使钯的催化作用无法发挥,然后胶体均匀的附着在振子表面,等待下一工序。S5:采用解胶剂溶液对胶体钯溶液活化的所述振子本体进行解胶,溶液中解胶剂浓度为10ml/l,解胶时间为1~8min,温度控制在30~60℃。
解胶剂将振子表面的二价锡清除,使钯原子裸露出来,从而使钯的催化作用发挥出来。
S6:将振子本体浸置在离子镍配置碱性溶液进行化学镀镍,形成化学镍层;离子镍溶液包含离子镍1g/l、游离碱5g/l、游离甲醛10ml/l,反应过程中,溶液浓度控制在50~150%,溶液pH=8~14,时间为5~30min,温度为20~35℃。
化学镀镍的原理为在钯的催化作用下,镍离子很快被二价锡还原为镍原子并紧紧吸附在振子表面。
S7:在所述化学镍层上激光镭雕形成阻隔线,以在所述振子本体表面分隔出电镀区和非电镀区。
激光镭雕时,在阻隔线所要形成的位置上进行激光镭雕,去除阻隔线所要形成的位置上的表层镍膜即可形成阻隔线。阻隔线主要落在非选择区,这样不会破坏或减小选择区的预定形状或面积。激光镭雕处理采用现有技术可以实现。
S8:在所述振子本体的电镀区上进行电镀铜处理,并形成电镀铜层。该步骤中,可电镀焦铜或电镀酸铜,焦铜一般作为中间层,要求振子铜层较厚时,选用电镀焦铜,且后续进行步骤S10。酸铜一般作为用于提高光亮度的外层,振子铜层厚度要求不高时,电镀酸铜即可。本文为了详细介绍以及在各个实施例之间进行对比,S8步骤为电镀焦铜,且都进行S10步骤。电镀铜工艺采用现有技术即可实现,本文不再赘述。
S9:去除所述振子本体的非电镀区上的化学镍层。将非电镀去的化学镍层去掉,露出振子原材,退镍处理采用现有技术如蚀刻等方式进行。
S10:第二次电镀铜处理,该工序为电镀酸铜。
S11:在所述振子本体的电镀区上进行电镀保护层处理,使电镀铜层上形成保护层。在振子的铜层上电镀覆盖一层锡或者银,优选镀锡,成本低。镀锡之后,使用市场可买到的钝化液,使锡层表面形成一层钝化膜保护锡层。锡层对铜层进行保护,可以增加振子的使用的寿命。
实施例二:
本实施例基材仍为PPS塑料,与实施例一的区别在于,将步骤S3中的粗化盐浓度调整为300g/l,其它步骤保持不变。
实施例三:
本实施例基材仍为PPS塑料,与实施例一的区别在于,将步骤S3中的粗化盐浓度调整为400g/l,其它步骤保持不变。
实施例四:
本实施例基材仍为PPS塑料,与实施例一的区别在于,将步骤S4胶体钯溶液中钯的浓度调整为35ppm,盐酸浓度调整为230ml/l,氯化亚锡浓度调整为3g/l;将步骤S5解胶剂浓度调整为45ml/l;其它步骤保持不变。
实施例五:
本实施例基材仍为PPS塑料,与实施例一的区别在于,将步骤S4胶体钯溶液中钯的浓度调整为55ppm,盐酸浓度调整为300ml/l,氯化亚锡浓度调整为5g/l;将步骤S5解胶剂浓度调整为80ml/l;其它步骤保持不变。
实施例六:
本实施例基材仍为PPS塑料,与实施例一的区别在于,将步骤S6离子镍溶液中离子镍浓度调整为3g/l,游离碱浓度调整为10g/l、游离甲醛浓度调整为18ml/l;其它步骤保持不变。
实施例七:
本实施例基材仍为PPS塑料,与实施例一的区别在于,将步骤S6离子镍溶液中离子镍浓度调整为5g/l,游离碱浓度调整为15g/l、游离甲醛浓度调整为25ml/l;其它步骤保持不变。
实施例八:
本实施例基材仍为PPS塑料,与实施例一的区别在于,步骤S4改为采用离子钯溶液对所述振子本体进行活化处理。离子钯溶液包含钯20ppm、硫酸8ml/l,活化时间为1~8min,温度控制在20~45℃。
步骤S5该为采用还原剂溶液对离子钯溶液活化的振子本体进行还原,溶液中还原剂浓度为20ml/l,还原时间为1~8min,温度控制在30~60℃。
本实施例步骤S4和步骤S5的目的在于先使离子钯附着着振子的表面,再通过还原剂把离子钯还原为钯原子,钯就能发挥催化作用。
实施例九:
本实施例基材仍为PPS塑料,与实施例八的区别在于,将步骤S4离子钯溶液中钯浓度调整为60ppm,硫酸浓度调整为30ml/l;将步骤S5还原剂浓度调整为50ml/l;其它步骤保持不变。
实施例十:
本实施例基材仍为PPS塑料,与实施例八的区别在于,将步骤S4离子钯溶液中钯浓度调整为100ppm,硫酸浓度调整为50ml/l;将步骤S5还原剂浓度调整为80ml/l;其它步骤保持不变。
实施例十一:
本实施例基材仍为PPS塑料,与实施例八的区别在于,将步骤S4离子钯溶液中的硫酸用盐酸替代;其它步骤保持不变。
实施例十二:
本实施例基材仍为PPS塑料,与实施例九的区别在于,将步骤S4离子钯溶液中的硫酸用盐酸替代;其它步骤保持不变。
实施例十三:
本实施例基材仍为PPS塑料,与实施例十的区别在于,将步骤S4离子钯溶液中的硫酸用盐酸替代;其它步骤保持不变。
实施例十四:
本实施例与实施例一的区别在于,基材采用PPO塑料;步骤保持不变。
实施例十五:
本实施例与实施例二的区别在于,基材采用PPO塑料;步骤保持不变。
实施例十六:
本实施例与实施例三的区别在于,基材采用PPO塑料;步骤保持不变。
实施例十七:
本实施例与实施例四的区别在于,基材采用PPO塑料;步骤保持不变。
实施例十八:
本实施例与实施例五的区别在于,基材采用PPO塑料;步骤保持不变。
实施例十九:
本实施例与实施例六的区别在于,基材采用PPO塑料;步骤保持不变。
实施例二十:
本实施例与实施例七的区别在于,基材采用PPO塑料;步骤保持不变。
实施例二十一:
本实施例与实施例八的区别在于,基材采用PPO塑料;步骤保持不变。
实施例二十二:
本实施例与实施例九的区别在于,基材采用PPO塑料;步骤保持不变。
实施例二十三:
本实施例与实施例十的区别在于,基材采用PPO塑料;步骤保持不变。
实施例二十四:
本实施例与实施例十一的区别在于,基材采用PPO塑料;步骤保持不变。
实施例二十五:
本实施例与实施例十二的区别在于,基材采用PPO塑料;步骤保持不变。
实施例二十六:
本实施例与实施例十三的区别在于,基材采用PPO塑料;步骤保持不变。
将根据上述26个实施例制得的天线振子进行编号汇总得出表一。
以上所述,仅为本发明较佳的具体实施方式,但本发明的保护范围并不局限于此,任何熟悉本技术领域的技术人员在本发明揭露的技术范围内,可轻易想到的变化或替换,都应涵盖在本发明的保护范围之内。
表一
Claims (10)
1.一种天线振子制造方法,其特征在于,包括以下步骤:
S1、以塑料为原料注塑成型制得有预定结构的振子本体;
S2、对所述振子本体的表面进行机械粗化处理,然后进行清洗;
S3、采用粗化液对所述振子本体进行化学粗化处理;
S4、对所述振子本体进行活化处理;
S5、对所述振子本体进行解胶或还原;
S6、对所述振子本体进行化学镀镍,形成化学镍层;
S7、在所述化学镍层上分隔出电镀区和非电镀区;
S8、在所述振子本体的电镀区上进行电镀铜处理,形成电镀铜层;
S9、去除所述振子本体的非电镀区上的化学镍层。
2.根据权利要求1所述的天线振子制造方法,其特征在于,2.步骤S3中,所述粗化液为粗化盐溶液,粗化盐浓度为150~400g/l;化学粗化时间为5~20min,温度为20~45℃。
3.根据权利要求1所述的天线振子制造方法,其特征在于,步骤S4中,采用胶体钯溶液对所述振子本体进行活化处理,溶液中包含钯15~55ppm、盐酸150~300ml/l、氯化亚锡1~5g/l;活化时间为1~8min,温度为20~45℃;
步骤S5中,采用解胶剂溶液对所述振子本体进行解胶,溶液中解胶剂浓度为10~80ml/l;清洗时间为1~8min,温度为30~60℃。
4.根据权利要求1所述的天线振子制造方法,其特征在于,步骤S4中,采用离子钯溶液对所述振子本体进行活化处理,溶液中包含钯20~100ppm、硫酸或盐酸8~50ml/l;活化时间为1~8min,温度为20~45℃;
步骤S5中,采用还原剂溶液对所述振子本体进行还原,溶液中还原剂浓度为20~80ml/l,清洗时间为1~8min,温度为30~60℃。
5.根据权利要求1所述的天线振子制造方法,其特征在于,步骤S6中,所述离子镍溶液包含离子镍1~5g/l、游离碱5~15g/l、游离甲醛10~25ml/l;化学镀铜时间为5~30min,温度为20~35℃;化学镀铜过程中,所述离子镍溶液浓度控制在50~150%,溶液pH=8~14。
6.根据权利要求1所述的天线振子制造方法,其特征在于,步骤S7中,通过在所述的化学镍层上激光镭雕阻隔线的方式,分隔出电镀区和非电镀区。
7.根据权利要求1所述的天线振子制造方法,其特征在于,步骤S1中选用PPS塑料或PPO塑料为原料;步骤S2中所述的机械粗化为对所述振子本体的表面进行喷砂处理;步骤S8中所述的电镀铜处理为镀焦铜或镀酸铜。
8.根据权利要求1所述的天线振子制造方法,其特征在于,还包括在步骤S9之后的步骤S10和S11,步骤S10为第二次电镀铜处理,该电镀铜处理为镀酸铜;步骤S11为在所述的电镀区上增设保护层。
9.根据权利要求8所述的天线振子制造方法,其特征在于,步骤S11所述的增设保护层为镀锡或镀银。
10.一种天线振子,其特征在于,采用权利要求1~9任一项所述的制造方法制得。。
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JP2005317270A (ja) * | 2004-04-27 | 2005-11-10 | Sekisui Chem Co Ltd | 導電性微粒子及び導電接続構造体 |
CN108425113A (zh) * | 2018-02-13 | 2018-08-21 | 深圳市飞荣达科技股份有限公司 | 振子及其制造方法 |
CN109640539A (zh) * | 2019-01-03 | 2019-04-16 | 深圳市飞荣达科技股份有限公司 | 振子及其制造方法 |
CN112048745A (zh) * | 2020-09-16 | 2020-12-08 | 广东博迅通信技术有限公司 | 一种提高塑料振子表面金属化镀层与塑料基材之间结合力、改善镀层pim值的工艺 |
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JP2005317270A (ja) * | 2004-04-27 | 2005-11-10 | Sekisui Chem Co Ltd | 導電性微粒子及び導電接続構造体 |
CN108425113A (zh) * | 2018-02-13 | 2018-08-21 | 深圳市飞荣达科技股份有限公司 | 振子及其制造方法 |
CN109640539A (zh) * | 2019-01-03 | 2019-04-16 | 深圳市飞荣达科技股份有限公司 | 振子及其制造方法 |
CN112048745A (zh) * | 2020-09-16 | 2020-12-08 | 广东博迅通信技术有限公司 | 一种提高塑料振子表面金属化镀层与塑料基材之间结合力、改善镀层pim值的工艺 |
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