CN116120747A - 一种塑料腔体滤波器用导热超低线性膨胀系数pps复合材料及其制备方法 - Google Patents
一种塑料腔体滤波器用导热超低线性膨胀系数pps复合材料及其制备方法 Download PDFInfo
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- CN116120747A CN116120747A CN202211588344.XA CN202211588344A CN116120747A CN 116120747 A CN116120747 A CN 116120747A CN 202211588344 A CN202211588344 A CN 202211588344A CN 116120747 A CN116120747 A CN 116120747A
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- cavity filter
- expansion coefficient
- linear expansion
- pps
- plastic cavity
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- 239000002131 composite material Substances 0.000 title claims abstract description 32
- 239000004033 plastic Substances 0.000 title claims abstract description 31
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- 229910052500 inorganic mineral Inorganic materials 0.000 claims abstract description 12
- 239000003963 antioxidant agent Substances 0.000 claims abstract description 11
- 230000003078 antioxidant effect Effects 0.000 claims abstract description 11
- 229920006127 amorphous resin Polymers 0.000 claims abstract description 9
- 239000007822 coupling agent Substances 0.000 claims abstract description 9
- 239000000314 lubricant Substances 0.000 claims abstract description 9
- 239000012745 toughening agent Substances 0.000 claims abstract description 8
- 239000004734 Polyphenylene sulfide Substances 0.000 claims description 40
- 229920000069 polyphenylene sulfide Polymers 0.000 claims description 40
- 238000001746 injection moulding Methods 0.000 claims description 19
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- 238000002347 injection Methods 0.000 claims description 8
- 239000007924 injection Substances 0.000 claims description 8
- 238000001035 drying Methods 0.000 claims description 7
- 239000000203 mixture Substances 0.000 claims description 7
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- 239000000835 fiber Substances 0.000 claims description 5
- 229920006380 polyphenylene oxide Polymers 0.000 claims description 5
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims description 4
- 239000004697 Polyetherimide Substances 0.000 claims description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 4
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 claims description 4
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 claims description 4
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 claims description 4
- HQKMJHAJHXVSDF-UHFFFAOYSA-L magnesium stearate Chemical compound [Mg+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O HQKMJHAJHXVSDF-UHFFFAOYSA-L 0.000 claims description 4
- 229920002492 poly(sulfone) Polymers 0.000 claims description 4
- 229920001601 polyetherimide Polymers 0.000 claims description 4
- 229920012287 polyphenylene sulfone Polymers 0.000 claims description 4
- 229920006259 thermoplastic polyimide Polymers 0.000 claims description 4
- 239000005357 flat glass Substances 0.000 claims description 3
- 238000002156 mixing Methods 0.000 claims description 3
- 229910052582 BN Inorganic materials 0.000 claims description 2
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 claims description 2
- OKOBUGCCXMIKDM-UHFFFAOYSA-N Irganox 1098 Chemical compound CC(C)(C)C1=C(O)C(C(C)(C)C)=CC(CCC(=O)NCCCCCCNC(=O)CCC=2C=C(C(O)=C(C=2)C(C)(C)C)C(C)(C)C)=C1 OKOBUGCCXMIKDM-UHFFFAOYSA-N 0.000 claims description 2
- JKIJEFPNVSHHEI-UHFFFAOYSA-N Phenol, 2,4-bis(1,1-dimethylethyl)-, phosphite (3:1) Chemical compound CC(C)(C)C1=CC(C(C)(C)C)=CC=C1OP(OC=1C(=CC(=CC=1)C(C)(C)C)C(C)(C)C)OC1=CC=C(C(C)(C)C)C=C1C(C)(C)C JKIJEFPNVSHHEI-UHFFFAOYSA-N 0.000 claims description 2
- 229920012266 Poly(ether sulfone) PES Polymers 0.000 claims description 2
- 229910052581 Si3N4 Inorganic materials 0.000 claims description 2
- 239000006087 Silane Coupling Agent Substances 0.000 claims description 2
- BGYHLZZASRKEJE-UHFFFAOYSA-N [3-[3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoyloxy]-2,2-bis[3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoyloxymethyl]propyl] 3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoate Chemical compound CC(C)(C)C1=C(O)C(C(C)(C)C)=CC(CCC(=O)OCC(COC(=O)CCC=2C=C(C(O)=C(C=2)C(C)(C)C)C(C)(C)C)(COC(=O)CCC=2C=C(C(O)=C(C=2)C(C)(C)C)C(C)(C)C)COC(=O)CCC=2C=C(C(O)=C(C=2)C(C)(C)C)C(C)(C)C)=C1 BGYHLZZASRKEJE-UHFFFAOYSA-N 0.000 claims description 2
- 229910000019 calcium carbonate Inorganic materials 0.000 claims description 2
- CJZGTCYPCWQAJB-UHFFFAOYSA-L calcium stearate Chemical compound [Ca+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O CJZGTCYPCWQAJB-UHFFFAOYSA-L 0.000 claims description 2
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- 239000008116 calcium stearate Substances 0.000 claims description 2
- 229920001577 copolymer Polymers 0.000 claims description 2
- PMHQVHHXPFUNSP-UHFFFAOYSA-M copper(1+);methylsulfanylmethane;bromide Chemical compound Br[Cu].CSC PMHQVHHXPFUNSP-UHFFFAOYSA-M 0.000 claims description 2
- 229920006227 ethylene-grafted-maleic anhydride Polymers 0.000 claims description 2
- VOZRXNHHFUQHIL-UHFFFAOYSA-N glycidyl methacrylate Chemical compound CC(=C)C(=O)OCC1CO1 VOZRXNHHFUQHIL-UHFFFAOYSA-N 0.000 claims description 2
- HGPXWXLYXNVULB-UHFFFAOYSA-M lithium stearate Chemical compound [Li+].CCCCCCCCCCCCCCCCCC([O-])=O HGPXWXLYXNVULB-UHFFFAOYSA-M 0.000 claims description 2
- 239000000395 magnesium oxide Substances 0.000 claims description 2
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 2
- 235000019359 magnesium stearate Nutrition 0.000 claims description 2
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims description 2
- FPYJFEHAWHCUMM-UHFFFAOYSA-N maleic anhydride Chemical compound O=C1OC(=O)C=C1 FPYJFEHAWHCUMM-UHFFFAOYSA-N 0.000 claims description 2
- 239000000155 melt Substances 0.000 claims description 2
- 239000010445 mica Substances 0.000 claims description 2
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- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 2
- 239000012188 paraffin wax Substances 0.000 claims description 2
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- 239000000843 powder Substances 0.000 claims description 2
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- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 claims description 2
- 239000011787 zinc oxide Substances 0.000 claims description 2
- XOOUIPVCVHRTMJ-UHFFFAOYSA-L zinc stearate Chemical compound [Zn+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O XOOUIPVCVHRTMJ-UHFFFAOYSA-L 0.000 claims description 2
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- 239000000463 material Substances 0.000 abstract description 14
- 238000009713 electroplating Methods 0.000 abstract description 6
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- 229920000642 polymer Polymers 0.000 abstract description 5
- 230000000052 comparative effect Effects 0.000 description 8
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- 238000007747 plating Methods 0.000 description 5
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- 238000004891 communication Methods 0.000 description 3
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- 239000011159 matrix material Substances 0.000 description 3
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- 238000011161 development Methods 0.000 description 2
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- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 2
- 239000012764 mineral filler Substances 0.000 description 2
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- YCKRFDGAMUMZLT-UHFFFAOYSA-N Fluorine atom Chemical compound [F] YCKRFDGAMUMZLT-UHFFFAOYSA-N 0.000 description 1
- 239000012752 auxiliary agent Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
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- 238000013329 compounding Methods 0.000 description 1
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- 239000008358 core component Substances 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- FPAFDBFIGPHWGO-UHFFFAOYSA-N dioxosilane;oxomagnesium;hydrate Chemical compound O.[Mg]=O.[Mg]=O.[Mg]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O FPAFDBFIGPHWGO-UHFFFAOYSA-N 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000011737 fluorine Substances 0.000 description 1
- 229910052731 fluorine Inorganic materials 0.000 description 1
- 238000005187 foaming Methods 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
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- 125000001997 phenyl group Chemical group [H]C1=C([H])C([H])=C(*)C([H])=C1[H] 0.000 description 1
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- 238000005245 sintering Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 125000004434 sulfur atom Chemical group 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
Classifications
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- C—CHEMISTRY; METALLURGY
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- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
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- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
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Abstract
本发明涉及高分子复合材料加工领域，公开了一种塑料腔体滤波器用导热超低线性膨胀系数PPS复合材料及其制备方法。上述改性PPS复合材料各组份以总重量为基准，所述的PPS复合材料各组份如下，按质量百分数计：PPS树脂30‑50%、非晶型树脂5‑20%、玻璃纤维30‑50%、无机矿物5‑40%、增韧剂0‑5%、偶联剂0.1‑0.5%、润滑剂0.1‑2%、抗氧剂0.1‑0.5%。本发明提供的塑料腔体滤波器用导热超低线性膨胀系数PPS复合材料及其制备方法制得的PPS复合材料在降低材料本身线性膨胀系数的同时也具备了导热性和低翘曲性，并保证了塑料腔体滤波器优异的电镀性能，降低了腔体滤波器成品的重量，极大地提高了生产速率。
Description
技术领域
本发明涉及高分子复合材料加工领域，公开了一种塑料腔体滤波器用导热超低线性膨胀系数PPS复合材料及其制备方法。
背景技术
2019年我国进入5G商用时代，自此开启了5G基站的飞速发展建设阶段，我国已经建成全球自大的5G网络。而滤波器作为基站中不可或缺的核心部件，也迎来了空前的爆发期。较4G基站而言，5G基站用滤波器必须具备小型化、集成化、小体积、轻量化的特点，目前5G通讯基站使用的滤波器主要是小型金属腔体滤波器和陶瓷介质滤波器。金属腔体滤波器虽然已经应用的非常成熟，但制品的体积及重量问题无法满足小体积、轻量化的要求。陶瓷介质滤波器的体积及重量可以满足5G基站滤波器的要求，近些年得到了广泛应用。但其制作过程较为复杂，同时陶瓷在烧结过程中，很难保证其产品的均一性，成品率较低。综合以上，5G基站用滤波器除了具有小体积、轻量化以外还要满足可靠性高、低成本的要求，那么尺寸稳定性好、耐高温、电镀镀层结合力好、易加工的特种工程塑料将在腔体滤波器中发挥很好的作用，有着巨大的市场潜能。
聚苯硫醚全称聚亚苯基硫醚，也叫PPS，交替排列的苯环和硫原子组成的分子链，赋予了PPS优异的机械性能及耐热性，其长期使用温度可达200℃，在航空航天、电子电器、汽车零部件等领域有着广泛的应用。PPS较其他工程塑料相比有很好的电镀性和低的线性膨胀系数，较金属腔体滤波器和陶瓷介质滤波器相比，有着质量轻、易加工成型的优势。
塑料腔体滤波器需进行金属化工序，应在保证镀层结合力的同时，也要考虑高温下的尺寸稳定性，以降低制品在工作中产生的温漂现象，影响信号传输的质量。5G通讯高速性的特征，对材料的导热性能提出了要求，如果导热较差，制品在大功率的工作场景中会因导热不良而引起镀层起泡，尺寸变化过大，进而导致温漂过大，甚至出现空气击穿。对于体积较大的制件，尺寸稳定性即制件翘曲度也需要在配方设计中进行考虑。
公布号CN201310289893.1的发明专利一种高导热聚苯硫醚材料的制备方法及制备的材料，该专利通过对碳纤表面金属化后与树脂基体复合获得高导热的材料，但是这款材料电镀后容易形成导电通路，不适合用于塑料腔体滤波器。公布号CN102898835B的发明专利公布了长玻纤增强导热聚苯硫醚复合材料机器制备方法，该专利获得材料的缺口冲击强度较差。公布号CN102311644B的发明专利公布了一种硫酸钙晶须改性复合材料及其制备工艺，导热系数3.72W/mK，但材料机械性能较差。公布号CN111875962A的发明专利低线性膨胀系数聚苯硫醚组合物及其制备方法，所述材料未涉及到导热的问题。
公布号CN111909414A的发明专利公布了一种高分子材料滤波器的制备方法，该专利利用热塑性塑料采用注塑成型或者模压成型的方式制造滤波器基体后，通过表面金属化的方式得到滤波器；公布号CN111211395A的发明专利公布了一种高分子复合材料腔体滤波器的制备方法，该专利通过高分子树脂基体与玻璃纤维进行复合制备成高分子滤波器腔体，以达到轻量化的目的；公布号 CN111253745A的发明专利公布了一种高分子复合材料及滤波器腔体的制备方法，主要包括：腔体的主体由高分子材料组成，其中分散有部分玻璃纤维，腔体表面结合有金属层。但以上三篇专利内容中，并没有考虑制件在大功率的情况下工作时的散热问题，使用普通的玻纤，成品翘曲度也会过大，故应做出调整。公布号CN112592589A的发明专利公开了一种用于制作5G通讯滤波器的改性工程塑料及其制备方法，所述改性工程塑料包括按重量份计的如下组分：基础树脂40-60份，玻璃纤维10-40份，增韧剂1-10份，成核剂0.1-1份，含氟树脂1-15份，导热填料5-20份，填充剂5-20份，偶联剂0.1-2份，润滑剂0.1-1份，抗氧剂0.2-1份。但配方涉及到的材料导热系数较低、电镀效果不理想、体积较大的制件可能会产生翘曲度过大的情况。综上，目前塑料滤波器的材料研发状况仍不能完全满足使用要求，需进行调整。
发明内容
本发明目的在于提供一种塑料腔体滤波器用导热超低线性膨胀系数PPS复合材料，通过在PPS树脂中添加玻纤、矿物和其他助剂，共混挤出造粒后注塑成型为具有导热、易电镀、耐高温、低线性膨胀系数、低翘曲的塑料腔体滤波器。
本发明另一个目的在于提供一种塑料腔体滤波器用导热超低线性膨胀系数PPS复合材料的制备方法。
为实现上述目的，本发明采用如下的技术方案：
一种塑料腔体滤波器用导热超低线性膨胀系数PPS复合材料，涉及的原料包括：PPS树脂、非晶型树脂、玻璃纤维、无机矿物、增韧剂、偶联剂、润滑剂、抗氧剂，按质量百分数计，各组份具体比例如下：
PPS树脂：30-50%
非晶型树脂：5-20%
玻璃纤维：30-50%
无机矿物：5-40%
增韧剂：0-5%
偶联剂：0.1-0.5%
润滑剂：0.1-2%
抗氧剂：0.1-0.3%
根据本发明，所选用聚苯硫醚树脂，所述聚苯硫醚树脂的熔体流动速率为300-1800g/10min（316℃/5kg）。.
根据本发明，所选用非晶型树脂为聚苯醚（PPO）、聚醚酰亚胺（PEI）、聚砜（PSU）、聚亚苯基砜（PPSU）、聚醚砜（PES、PESU）、热塑性聚酰亚胺（TPI）中任一种或者多种。
根据本发明，所选用玻璃纤维为普通玻纤、扁平玻纤中的任一种或者多种， 优选地，玻璃纤维的长度为3-4.5mm，其中扁平纤维的扁平比1:4。
根据本发明，所选用的无机矿物为氧化铝、氮化硼、氧化镁、氧化锌、氮化铝、氮化硅、硫酸钡、碳酸钙、云母片、滑石粉、二氧化硅中任一种或多种。
根据本发明，所选用增韧剂为乙烯-甲基丙烯酸缩水甘油酯共聚物（PE-co-GMA）、乙烯接枝马来酸酐（PE-g-MAH）、聚苯醚接枝马来酸酐（PPO-g-MAH）、聚烯烃接枝甲基丙烯酸缩水甘油酯（POE-g-GMA）中任一种或多种。
根据本发明，所选用偶联剂为硅烷偶联剂KH550、KH560、KH570中任一种或多种。
根据本发明，所选用润滑剂为硬脂酸钙、硬脂酸镁、硬脂酸锌、硬脂酸锂、硅酮粉、天然石蜡中任一种或多种。
根据本发明，所选用抗氧剂为抗氧剂1098、抗氧剂1010、抗氧剂168、抗氧剂9228中任一种或多种。
本发明还提供了上述塑料腔体滤波器用导热超低线性膨胀系数PPS复合材料的制备方法，包括挤预混工艺、挤出造粒工艺和注塑成型工艺。
根据本发明，所述预混工艺为：将PPS树脂、非晶型树脂、玻璃纤维、无机矿物、增韧剂、偶联剂、润滑剂、抗氧剂根据一定比例依次投入到高速混合机中进行混合均匀10min，得到共混物。
根据本发明，所述挤出造粒工艺为：将上述共混物加入到双螺杆挤出机主加料斗中，将玻璃纤维从侧喂料筒中进行加入，设定各区温度、螺杆转速并根据比例分别设置主喂料斗加料和侧喂料斗加料速度，挤出造粒。
优选地，所述双螺杆挤出机长径比为40，设定各区温度依次为：一区180-240℃，二区280-320℃，三区280-330℃，四区280-330℃，五区280-330℃，六区280-320℃，七区280-320℃，八区280-320℃，九区280-320℃，模头280-330℃。螺杆转速250-500r/min，主喂料斗加料速度3-10Hz，侧喂料斗加料速度4-8Hz，进行挤出造粒。
根据本发明，所述挤出注塑工艺为：将上述挤出后粒子干燥后使用单螺杆注塑机中在合适的温度、注射压力和注塑速度下注塑成型，得到所需结构的塑料腔体滤波器制品。
优选地，所述粒子的干燥温度为120-150℃，干燥时间为4-6h。
优选地，所述注塑机设定各区温度为：一区260-280℃，二区280-300℃，三区295-310℃，喷嘴300-310℃。注射压力为40-85MPa，注射速度为30-80%，模具温度120-180℃。
与现有技术相比，本发明有益效果在于：
1）本发明在配方体系中加入导热组份，减小了塑料滤波器在大功率情况工作中，产生的热量难以导出而导致塑料腔体滤波器尺寸变化较大的情况，从而保证了制件高温下的温漂在可控范围内。
2）本发明提供的导热超低线性膨胀系数PPS复合材料，通过多组份的复合调配，能满足塑料腔体滤波器的要求，具有轻量化，高尺寸稳定性，低翘曲性，电镀性能优异，耐高温，加工工艺简单等优点。
3）本发明提供的导热超低线性膨胀系数PPS复合材料的制备方法，挤出造粒工艺和注塑成型工艺分开进行，注塑成型工艺可生产结构复杂的产品，产品一致性高，生产过程简便，大大提高了生产速率。产品可以实施化学镀，镀层结合力高。
具体实施方式
下面通过具体实施例，进一步阐述本发明实质性内容。
实施例1~6
将原料按照一定的配比（除玻纤外）加入到高速搅拌机中混合均匀后，加到双螺杆挤出机的主喂料料斗中，玻璃纤维加入到侧喂料料斗中，设定各区温度依次为：一区180-240℃，二区280-320℃，三区280-330℃，四区280-330℃，五区280-330℃，六区280-320℃，七区280-320℃，八区280-320℃，九区280-320℃，模头280-330℃。螺杆转速250-500r/min，主喂料斗加料速度3-10Hz，侧喂料斗加料速度4-8Hz，进行挤出造粒。
将上述粒子进行120-150℃/4-6h的干燥后，用单螺杆注塑机加工成型，各区温度为：一区260-280℃，二区280-300℃，三区295-310℃，喷嘴300-310℃。注射压力为40-85MPa，注射速度为30-80%，模具温度120-180℃。通过注塑成型获得塑料腔体滤波器。
原料组成以质量份数计，如表1所示：
表1
对比例与实施例的制备方法相同。
对比例1与实施例1树脂及填充份数相同，不同之处是玻璃纤维和无机矿物填料的种类。
对比例2与实施例1树脂及填充份数相同，不同之处是无机矿物填料的种类。
对比例3与实施例6填充物及份数相同，不同之处是高分子树脂和无机矿物的种类。
将上述实施例和对比例制得的样品进行测试，测试结果列于表2中。
表2
根据表2的实施例1-6检测结果可知，本发明提供的配方具有低的线性膨胀系数、高尺寸稳定性，散热性能优良，镀层结合力强，低翘曲的特点。
由对比例1、对比例2和实施例1可知，扁平玻纤及导热填料的加入，对材料翘曲度及线性膨胀系数有着正向的作用，材料的线性膨胀系数降低至接近金属镀层的线性膨胀系数，降低了镀层与基料两种材料之间在高低温变化时，因膨胀和收缩带来的相互作用力，镀层结合力显著提高。导热系数明显提升，散热能力提高，确保了滤波器在大功率情况下工作的散热能力及不良温漂的问题。
由对比例3和实施例6可知，非定型树脂的引入，使得材料的翘曲问题有了明显的改善，避免了体积较大的制件出现翘曲度过大的问题。
以上实施例表明，本发明提供的塑料腔体滤波器用导热超低线性膨胀系数PPS复合材料及其制备方法，通过配方综合调配，制得了具有高耐温、超低的线性膨胀系数、金属结合力强、低翘曲度、导热性能良好、机械性能优异等特点的材料。可通过注塑成型获得可靠性高、质量轻、散热性好、金属镀层结合力强、低翘曲的塑料腔体滤波器，本发明所述的塑料腔体滤波器制备工艺简单、可生产自动化、产品均一性高，完全可以取代通讯基站现用的金属腔体滤波器。
Claims (10)
1.一种塑料腔体滤波器用导热超低线性膨胀系数PPS复合材料，按质量百分比计，所述的PPS复合材料包括：
PPS 30-50%、非晶型树脂5-20%、玻璃纤维35-50%、无机矿物5-40%、增韧剂1-3%、偶联剂0.1-0.5%、润滑剂0.1-2%，抗氧剂0.1-0.5%。
2.根据权利要求1所述的一种塑料腔体滤波器用导热超低线性膨胀系数PPS复合材料，其特征在于，所述PPS树脂在316℃、5kg条件下的熔体流动速率为300-1800g/10min。
3.根据权利要求1所述的一种塑料腔体滤波器用导热超低线性膨胀系数PPS复合材料，其特征在于，所述PPS树脂熔体流动速率（316℃/5kg）为1000-1800g/10min。
4.根据权利要求1所述的一种塑料腔体滤波器用导热超低线性膨胀系数PPS复合材料，其特征在于，所述玻璃纤维为普通短切纤维、扁平玻纤中的任一种或多种。
5.根据权利要求1所述的一种塑料腔体滤波器用导热超低线性膨胀系数PPS复合材料，其特征在于，所述的玻璃纤维的长度为3-4.5mm，扁平纤维的扁平比1:4。
6.根据权利要求1所述的一种塑料腔体滤波器用导热超低线性膨胀系数PPS复合材料，其特征在于，所述的非晶型树脂为聚苯醚（PPO）、聚醚酰亚胺（PEI）、聚砜（PSU）、聚亚苯基砜（PPSU）、聚醚砜（PES、PESU）热塑性聚酰亚胺（TPI）中任一种或者多种。
7.根据权利要求1所述的一种塑料腔体滤波器用导热超低线性膨胀系数PPS复合材料，其特征在于，所述无机矿物为氧化铝、氮化硼、氧化镁、氧化锌、氮化铝、氮化硅、硫酸钡、碳酸钙、云母片、滑石粉、二氧化硅、硫酸钙晶须、玻璃薄片中任一种或多种。
8.根据权利要求1所述的一种塑料腔体滤波器用导热超低线性膨胀系数PPS复合材料，其特征在于，所述增韧剂乙烯-甲基丙烯酸缩水甘油酯共聚物（PE-co-GMA）、乙烯接枝马来酸酐（PE-g-MAH）、聚苯醚接枝马来酸酐（PPO-g-MAH）、聚烯烃接枝甲基丙烯酸缩水甘油酯（POE-g-GMA）中任一种或多种。
9.根据权利要求1所述的一种塑料腔体滤波器用导热超低线性膨胀系数PPS复合材料，其特征在于：
所述偶联剂为硅烷偶联剂KH550、KH560、KH570中任一种或多种；
所述润滑剂为硬脂酸钙、硬脂酸镁、硬脂酸锌、硬脂酸锂、硅酮粉、天然石蜡中任一种或多种；
所述抗氧剂为抗氧剂1098、抗氧剂1010、抗氧剂168、抗氧剂9228中任一种或多种。
10.一种权利要求1所述塑料腔体滤波器用导热超低线性膨胀系数PPS复合材料，其特征在于，所述塑料腔体滤波器用超低线性膨胀系数PPS复合材料的制备方法，包括步骤一预混工艺、步骤二挤出造粒工艺和步骤三注塑成型工艺：
步骤一预混工艺：将PPS树脂、非晶型树脂、无机矿物、玻璃微珠、增韧剂、偶联剂、润滑剂、抗氧剂根据一定比例依次投入到高速混合机中进行混合均匀10min，得到共混物；
步骤二挤出造粒工艺：将共混物加入到双螺杆挤出机主加料斗中，将玻璃纤维从侧喂料筒中进行加入，设定各区温度、螺杆转速并根据比例分别设置主喂料斗加料和侧喂料斗加料速度，挤出造粒；
所述双螺杆挤出机长径比为40，设定各区温度依次为：一区180-240℃，二区280-320℃，三区280-330℃，四区280-330℃，五区280-330℃，六区280-320℃，七区280-320℃，八区280-320℃，九区280-320℃，模头280-330℃；
螺杆转速250-500r/min，主喂料斗加料速度3-10Hz，侧喂料斗加料速度4-8Hz，进行挤出造粒；
步骤三注塑工艺：将挤出造粒制备的粒子干燥后使用注塑机中在合适的温度、注射压力和注塑速度下注塑成型，得到所需结构的塑料腔体滤波器制品；
所述粒子的干燥温度为120-150℃，干燥时间为4-6h；
所述注塑机设定各区温度为：一区260-280℃，二区280-300℃，三区295-310℃，喷嘴300-310℃；
注射压力为40-85MPa，注射速度为30-80%，模具温度120-180℃。
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