CN116600487A - Curved surface conformal antenna and manufacturing method thereof - Google Patents
Curved surface conformal antenna and manufacturing method thereof Download PDFInfo
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- CN116600487A CN116600487A CN202310486113.6A CN202310486113A CN116600487A CN 116600487 A CN116600487 A CN 116600487A CN 202310486113 A CN202310486113 A CN 202310486113A CN 116600487 A CN116600487 A CN 116600487A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 34
- 239000003973 paint Substances 0.000 claims abstract description 68
- 238000005507 spraying Methods 0.000 claims abstract description 23
- 238000000034 method Methods 0.000 claims description 54
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 claims description 23
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 9
- 229910052709 silver Inorganic materials 0.000 claims description 9
- 239000004332 silver Substances 0.000 claims description 9
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 8
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 6
- 239000010949 copper Substances 0.000 claims description 6
- 229910052802 copper Inorganic materials 0.000 claims description 5
- 229910052782 aluminium Inorganic materials 0.000 claims description 4
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 4
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 claims description 4
- 229910052737 gold Inorganic materials 0.000 claims description 4
- 239000010931 gold Substances 0.000 claims description 4
- 229910052751 metal Inorganic materials 0.000 claims description 4
- 239000002184 metal Substances 0.000 claims description 4
- 229910052759 nickel Inorganic materials 0.000 claims description 4
- 229910021393 carbon nanotube Inorganic materials 0.000 claims description 3
- 239000002041 carbon nanotube Substances 0.000 claims description 3
- 239000000919 ceramic Substances 0.000 claims description 3
- 239000004020 conductor Substances 0.000 claims description 3
- 239000011521 glass Substances 0.000 claims description 3
- 229910021389 graphene Inorganic materials 0.000 claims description 3
- 229910002804 graphite Inorganic materials 0.000 claims description 3
- 239000010439 graphite Substances 0.000 claims description 3
- 239000004033 plastic Substances 0.000 claims description 3
- NEIHULKJZQTQKJ-UHFFFAOYSA-N [Cu].[Ag] Chemical compound [Cu].[Ag] NEIHULKJZQTQKJ-UHFFFAOYSA-N 0.000 claims description 2
- 238000007641 inkjet printing Methods 0.000 description 19
- 230000000052 comparative effect Effects 0.000 description 12
- 239000002994 raw material Substances 0.000 description 12
- 238000004891 communication Methods 0.000 description 7
- 230000001788 irregular Effects 0.000 description 7
- 239000007921 spray Substances 0.000 description 7
- 238000009966 trimming Methods 0.000 description 7
- 239000002904 solvent Substances 0.000 description 6
- 239000000463 material Substances 0.000 description 5
- 238000007639 printing Methods 0.000 description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 5
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 4
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
- 238000005259 measurement Methods 0.000 description 4
- 239000000523 sample Substances 0.000 description 3
- 239000000969 carrier Substances 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- YCKOAAUKSGOOJH-UHFFFAOYSA-N copper silver Chemical compound [Cu].[Ag].[Ag] YCKOAAUKSGOOJH-UHFFFAOYSA-N 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 230000002349 favourable effect Effects 0.000 description 2
- 238000004513 sizing Methods 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 229910000881 Cu alloy Inorganic materials 0.000 description 1
- 229910000640 Fe alloy Inorganic materials 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 230000000903 blocking effect Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 238000003912 environmental pollution Methods 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 238000003698 laser cutting Methods 0.000 description 1
- 238000010295 mobile communication Methods 0.000 description 1
- 238000007747 plating Methods 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
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Classifications
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/10—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern
- H05K3/14—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern using spraying techniques to apply the conductive material, e.g. vapour evaporation
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01Q—ANTENNAS, i.e. RADIO AERIALS
- H01Q1/00—Details of, or arrangements associated with, antennas
- H01Q1/36—Structural form of radiating elements, e.g. cone, spiral, umbrella; Particular materials used therewith
- H01Q1/38—Structural form of radiating elements, e.g. cone, spiral, umbrella; Particular materials used therewith formed by a conductive layer on an insulating support
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/02—Details
- H05K1/09—Use of materials for the conductive, e.g. metallic pattern
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- Engineering & Computer Science (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Manufacturing & Machinery (AREA)
- Details Of Aerials (AREA)
Abstract
The invention relates to the field of antennas and discloses a curved conformal antenna and a manufacturing method thereof; the manufacturing method comprises the following steps: forming a mask layer on the carrier, wherein the mask layer is provided with a hollowed-out pattern area; spraying conductive paint on the pattern area to form an antenna circuit on the carrier; and curing the antenna circuit to obtain the curved conformal antenna. The curved conformal antenna manufactured by the manufacturing method has the advantages of uniform thickness, low cost and high efficiency.
Description
Technical Field
The invention relates to the technical field of antennas, in particular to a curved conformal antenna and a manufacturing method thereof.
Background
The conformal antenna is an antenna attached to the surface of the carrier and attached to the carrier. With the development of wireless communication technology, the communication frequency band is increased, the difficulty of antenna preparation is higher and higher, antenna wiring is performed on the internal fittings of limited mobile terminal products, and the curved conformal antenna is more important. Mobile communication terminal products such as mobile phones, smart watches, tablets, computers and the like are designed variously, the shapes of the curved conformal antennas are varied widely, and the manufacturing process flow is also important. The currently mainstream LDS antenna technology is mature, but has the characteristics of specificity, complexity and environmental protection: the process is complex, and relates to environmental pollution links such as chemical plating, spraying and the like.
Although the method for manufacturing the curved conformal antenna by adopting the ink-jet printing process is relatively simple and more environment-friendly, as the antenna carrier such as the mobile phone shell, the smart watch shell and the like has curved structures such as convex surfaces, grooves and inclined surfaces, and the fluid characteristic of the sizing agent used for forming the antenna by adopting the ink-jet printing process, the sizing agent easily generates irregular flow in an irregular area in the antenna printing forming process, so that the thickness consistency of the formed antenna is low, and the communication function of the antenna is further influenced.
Disclosure of Invention
The invention aims to solve the problem that the thickness consistency of a curved conformal antenna prepared by an ink-jet printing method in the prior art is low.
In order to achieve the above object, a first aspect of the present invention provides a method for manufacturing a curved conformal antenna, which is characterized by comprising:
(1) Forming a mask layer on the carrier, wherein the mask layer is provided with a hollowed-out pattern area;
(2) Spraying conductive paint on the pattern area to form an antenna circuit on the carrier; wherein the sheet resistance of the conductive paint is 0.005-0.05 omega/sq/mil, and the viscosity is 100-200 mPa.S;
(3) And curing the antenna circuit to obtain the curved conformal antenna.
As an improvement of the above scheme, the target thickness of the curved conformal antenna is X, the target width is Y, the width of the pattern area is a, where a > Y, and the distance between the edge of the pattern area and the edge of the curved conformal antenna is B, then b=x (3-10).
As an improvement of the above-mentioned scheme, the method for spraying the conductive paint on the pattern area in the step (2) includes: (21) Spraying the conductive paint on the pattern area by adopting spraying equipment; (22) The nozzle and/or the carrier are moved relatively along the trajectory of the antenna track.
As an improvement to the above, the distance between the nozzle and the carrier in step (22) is kept consistent;
and/or the distance between the nozzle and the carrier is 5-15 cm;
and/or the caliber of the nozzle is 0.3-3 mm.
As an improvement of the scheme, the caliber of the nozzle is 0.3-1.2 mm, and the distance between the nozzle and the carrier is 5-15 cm; preferably, the caliber of the nozzle is 0.3-0.8 mm, and the distance between the nozzle and the carrier is 5-15 cm;
and/or the caliber of the nozzle is 2-3 mm, and the distance between the nozzle and the carrier is 8-12 cm; preferably, the caliber of the nozzle is 2-3 mm, and the distance between the nozzle and the carrier is 10-11 cm.
As an improvement of the scheme, the thickness of the curved conformal antenna is more than or equal to 15 mu m; preferably 20 to 200 μm.
As an improvement of the scheme, in the step (1), the mask layer is made of metal, plastic, glass or ceramic;
and/or, the mask layer comprises an upper mask layer and a lower mask layer, and the carrier is wrapped by the upper mask layer and the lower mask layer in a magnetic attraction, buckling or bonding mode.
As an improvement of the scheme, the conductive paint contains one or more conductive materials of nickel, aluminum, gold, silver, copper, graphene, graphite and carbon nano tubes; preferably, the conductive paint contains silver or silver copper;
and/or, the conductive paint is aqueous; preferably, the conductive paint is an aqueous silver conductive paint.
As an improvement of the above-mentioned scheme, the conditions for curing the antenna line in step (3) include: the curing temperature is 50-70 ℃, and the curing time is 10-30 min; preferably, the curing temperature is 55-65 ℃ and the curing time is 15-20 min.
In a second aspect, the present invention provides a curved conformal antenna, which is made by any of the methods described above.
Through the technical scheme, the invention has the following advantages:
compared with an ink-jet printing method, the method for manufacturing the curved conformal antenna by adopting the combination of the conductive paint, the mask layer and the spraying process not only can obtain the curved conformal antenna with uniform thickness, but also can improve the manufacturing efficiency and reduce the cost; in addition, the manufacturing method of the invention can manufacture the curved conformal antenna on carriers with more materials. Because the curing temperature of the conductive paint is low, the manufacturing method of the invention can form a curved conformal antenna on a carrier with a thermal deformation temperature lower than the curing temperature of conductive silver paste adopted by the existing ink-jet printing method.
Drawings
FIG. 1 is a schematic diagram of a mask layer according to embodiment 1 of the present invention;
fig. 2 is a physical diagram of a curved conformal antenna according to embodiment 1 of the present invention.
Description of the embodiments
The endpoints and any values of the ranges disclosed herein are not limited to the precise range or value, and are understood to encompass values approaching those ranges or values. For numerical ranges, one or more new numerical ranges may be found between the endpoints of each range, between the endpoint of each range and the individual point value, and between the individual point value, in combination with each other, and are to be considered as specifically disclosed herein.
The invention provides a manufacturing method of a curved conformal antenna, which comprises the following steps:
1. forming a mask layer on the carrier, wherein the mask layer is provided with a hollowed-out pattern area;
the mask layer is made of metal, plastic, glass or ceramic. Wherein the metal can be one or more of gold, silver, copper, iron, aluminum and nickel. Preferably, the mask layer is made of copper, iron or aluminum alloy. More preferably, the mask layer is made of copper.
The mask layer comprises an upper mask layer and a lower mask layer, and the carrier is wrapped by the upper mask layer and the lower mask layer in a magnetic attraction, buckling, bonding and other modes. In addition, after the upper mask layer and the lower mask layer are attached to the carrier, the upper mask layer and/or the lower mask layer is provided with a hollowed-out pattern area so as to expose the area, on the carrier, where the antenna needs to be formed. One mask layer may be provided with one or several pattern areas.
The upper mask layer and the lower mask layer are formed in an integrated forming mode, an injection molding mode, a pressing die mode and the like respectively, the hollowed-out pattern area can be formed in an integrated forming mode when the upper mask layer and the lower mask layer are formed, and can also be formed through laser cutting, cutter cutting, water jet cutting and the like after the upper mask layer and the lower mask layer are formed.
2. Spraying conductive paint on the pattern area to form an antenna circuit on the carrier;
the method for spraying the conductive paint on the pattern area comprises the following steps: (1) positioning a nozzle of a spray device against the pattern area; (2) The nozzle and/or the carrier are moved relatively along the trajectory of the antenna track.
Preferably, the distance between the nozzle and the carrier is kept consistent.
Preferably, the carrier is fixed on a moving platform, and the moving platform is used for driving the carrier to move in the 360-degree direction. When the nozzle is fixed, the carrier moves along the track of the antenna circuit, and keeps a fixed distance from the nozzle, and the conductive paint sprayed on the carrier forms the antenna circuit.
It should be noted that keeping the distance between the nozzle and the carrier uniform can improve the uniformity of the thickness of the curved conformal antenna. Preferably, the distance between the spray head and the carrier is 5-15 cm. When the distance between the spray head and the carrier is set to be 5cm, and the carrier moves along the track of the antenna circuit, the distance between the spray head and the carrier is always kept to be 5cm.
The thickness consistency of the curved conformal antenna formed by the existing ink-jet printing method is poor, and the thickness of the antenna is 50-200 mu m. Since the viscosity range of the conductive silver paste adopted in the ink-jet printing method is between 10 and 3000cps, in order to ensure that the conductive silver paste has good fluidity and adhesive force, the adhesion of the conductive silver paste needs to be controlled between 100 and 1000cps, but in the antenna printing forming process, the conventional conductive silver paste easily generates irregular flow in an irregular area, so that the thickness consistency of the formed antenna is low, wherein the thickness difference between the middle part and the edge part of an antenna circuit can reach more than 50 mu m, and even the thickness difference between the two parts exceeds the target thickness of the antenna.
The uneven thickness of the antenna can affect the resistance of the antenna circuit, thereby affecting the communication function of the antenna. In addition, the existing ink-jet printing method is limited by the relation between the size of a spray head and the viscosity of conductive silver paste, and the thickness of a curved conformal antenna formed by the method is more than 50 mu m, so that the requirements of antenna lines with the thickness less than 50 mu m cannot be met. Different from the existing oily conductive silver paste, the invention adopts the water-based conductive paint with low viscosity to manufacture the antenna circuit, the thickness of the antenna circuit can be less than 50 mu m, and in addition, the problem of uneven thickness of the nozzle blocking and the curved surface conformal antenna is solved.
The thickness of the curved conformal antenna is more than or equal to 15 mu m, and the thickness consistency is +/-3 mu m.
Specifically, the conductive paint is mainly different from conductive silver paste adopted by an inkjet printing method in that: the conductive paint is water-based, the sheet resistance of the conductive paint is 0.005-0.05 omega/sq/mil, and the viscosity is 100-200 mPa.S.
Preferably, the sheet resistance of the conductive paint is 0.005-0.03 ohm/sq/mil.
Preferably, the viscosity of the conductive paint is 120-180 mPa.S.
The conductive paint contains one or more conductive materials selected from nickel, aluminum, gold, silver, copper, graphene, graphite and carbon nano tubes.
Besides the difference between the conductive ink and the existing conductive silver paste, the antenna circuit is different in equipment for manufacturing the antenna circuit, and particularly, the spraying equipment adopted by the invention is a spray gun and a disc atomizer, and the conductive paint can be sprayed on the pattern area in a manual spraying and automatic spraying mode. The main difference between the spraying equipment adopted by the invention and the ink-jet printing equipment adopted by the existing ink-jet printing method is that: the caliber of the nozzle is 0.3-3 mm, and the distance between the nozzle and the carrier is 5-15 cm.
The low viscosity aqueous conductive paint is not suitable for manufacturing antenna circuits by an inkjet printing method, but is more suitable for manufacturing antenna circuits by spraying equipment. The distance between the nozzle and the carrier and the caliber of the nozzle have a further improvement effect on the thickness uniformity of the antenna circuit. The inventors found that the smaller the caliber of the nozzle in the range of 0.3-3 mm, the more the distance between the nozzle and the carrier is selected between 5-15 cm, and the larger the caliber of the nozzle, the more the distance between the nozzle and the carrier is selected towards the intermediate value. And the size of the nozzle is related to the viscosity of the conductive paint.
Preferably, the caliber of the nozzle is 0.3-1.2 mm, and the distance between the nozzle and the carrier is 5-15 cm.
Preferably, the caliber of the nozzle is 2-3 mm, and the distance between the nozzle and the carrier is 8-12 cm.
More preferably, the caliber of the nozzle is 0.3-0.8 mm, and the distance between the nozzle and the carrier is 5-15 cm.
More preferably, the caliber of the nozzle is 2-3 mm, and the distance between the nozzle and the carrier is 10-11 cm.
It should be noted that whether the edges of the antenna circuit are clean or not plays an important role in the communication function of the antenna. The antenna circuit formed by the existing ink-jet printing method has the defects of saw teeth, waves, scattered points and the like at the edge of the circuit. Although the mask layer method can improve the problem of irregular line edges, the requirement of the antenna line cannot be met.
The method of combining the conductive paint, the mask layer and the spraying process can not only manufacture the curved conformal antenna with the thickness smaller than 50 mu m, but also solve the problem of poor thickness uniformity of the curved conformal antenna. Although the edge of the curved conformal antenna manufactured by the method is tidier than the edge of the curved conformal antenna manufactured by the ink-jet printing method, in order to better meet the communication function of the curved conformal antenna, the method comprises the following steps before or after the antenna line is solidified: trimming the edge of the antenna line. Trimming refers to removing irregular portions of the antenna wire edges. The irregular edge part of the antenna circuit is also a part with thinner line thickness, and in order to ensure that the actual width of the trimmed antenna circuit is consistent with the target width, the invention also needs to design the size of the pattern area according to the target width of the curved conformal antenna when the mask layer is manufactured. According to the research of the inventor, a certain relation exists among the target thickness of the curved conformal antenna, the target width of the curved conformal antenna, the width of the pattern area and the width of the antenna line edge which needs to be removed.
As shown in fig. 1, assuming that the target thickness of the curved conformal antenna 1 is X, the target width is Y, and the width of the pattern area 21 of the mask layer 2 is a, where a > Y, the distance between the edge of the pattern area and the edge of the curved conformal antenna (i.e. the width of the antenna line to be removed) is B, b=x (3-10).
For example, if the target thickness X of the curved conformal antenna is 20 μm and the target width Y is 3mm, the distance B between the edge of the pattern area and the edge of the curved conformal antenna is 60 to 200 μm according to the formula, i.e. the width a of the pattern area is 3.12 to 3.4mm.
3. Solidifying the antenna circuit to obtain a curved conformal antenna;
through solidifying the antenna circuit, be favorable to volatilizing of solvent in the conductive paint and the levelling of conductive paint, can effectively reduce the production of antenna surface bubble, improve its planarization on surface, further promote the yield of antenna, be favorable to further guaranteeing the good communication function of antenna.
Preferably, the conditions for curing the antenna line include: the curing temperature is 50-70 ℃, and the curing time is 10-30 min.
More preferably, the conditions for curing the antenna line include: the curing temperature is 55-65 ℃ and the curing time is 15-20 min.
The conductive paint disclosed by the invention has the advantages that the curing temperature is obviously lower than the curing temperature (90-100 ℃) of the existing conductive silver paste, and the curing time is also shorter than the curing time (30-150 min) of the existing conductive silver paste.
Compared with an ink-jet printing method, the method for manufacturing the curved conformal antenna by adopting the combination of the conductive paint, the mask layer and the spraying process not only can obtain the curved conformal antenna with uniform thickness, but also can improve the manufacturing efficiency and reduce the cost; in addition, the manufacturing method of the invention can manufacture the curved conformal antenna on carriers with more materials. Because the curing temperature of the conductive paint is low, the manufacturing method of the invention can form a curved conformal antenna on a carrier with a thermal deformation temperature lower than the curing temperature of conductive silver paste adopted by the existing ink-jet printing method.
Correspondingly, the invention also provides a curved surface conformal antenna which is prepared by the manufacturing method of the curved surface conformal antenna, and has the thickness of more than or equal to 15 mu m and the thickness consistency of +/-3 mu m.
The present invention will be described in detail by examples.
In the following examples and comparative examples, various materials and instruments used were commercially available unless otherwise specified. Wherein:
conductive paint raw material 1: the resistance of the water-based pure silver conductive paint is 0.005-0.01 ohm/sq/mil;
conductive paint raw material 2: the sheet resistance of the water-based copper-silver conductive paint is 0.01-0.03 ohm/sq/mil;
conductive paint raw material 3: the sheet resistance of the aqueous copper-silver conductive paint is 0.03-0.05 omega/sq/mil.
The raw materials of the conductive paint are required to be diluted before use, so that the conductive paint with the performance meeting the requirements is obtained. The viscosity of the conductive paint was measured using a viscometer and the sheet resistance was measured using a four probe tester.
Example 1
A manufacturing method of a curved conformal antenna comprises the following steps:
forming a mask layer on the carrier, wherein the mask layer is provided with a hollowed-out pattern area;
the mask layer comprises an upper mask layer and a lower mask layer, the upper mask layer and the lower mask layer wrap the carrier in a buckling mode, the hollowed-out pattern area exposes a region on the carrier, which needs to form the curved conformal antenna, and the width of the pattern area is 3.2mm;
spraying conductive paint on the pattern area by adopting a spray gun, and forming an antenna circuit on the carrier;
the size of the nozzle is 0.5mm, and the distance between the nozzle and the carrier is 15cm;
alcohol is adopted to mix the conductive paint raw material 1 according to the conductive paint raw material: solvent=1:0.4, the viscosity of the resulting conductive paint at room temperature is 170mpa·s, and the sheet resistance is 0.007 Ω/sq/mil;
solidifying the antenna circuit to obtain a curved conformal antenna;
wherein the curing temperature is 60 ℃ and the curing time is 15min.
Trimming the edge of the curved conformal antenna by adopting an infrared skin second laser emitter (rated power is 30W) to remove the edge with the width of 100 mu m;
the parameters are as follows: the output power was 15W, the pulse frequency was 300Hz, and the speed was 500mm/s.
Example 2
The procedure of example 1 was followed, except that:
in the step (2), alcohol is adopted to mix the conductive paint raw material 2 according to the conductive paint raw material: the solvent=1:0.2 mass ratio, the viscosity of the obtained conductive paint at room temperature is 200 mPas, and the sheet resistance is 0.02 ohm/sq/mil;
the size of the nozzle is 2mm, and the distance between the nozzle and the carrier is 10cm;
in the step (3), the curing temperature is 50 ℃ and the curing time is 25min.
Example 3
The procedure of example 2 was followed, except that:
in the step (2), the distance between the nozzle and the carrier is 15cm;
in the step (3), the curing temperature is 70 ℃ and the curing time is 10min.
Example 4
The procedure of example 1 was followed, except that:
in the step (2), alcohol is adopted to mix the conductive paint raw material 3 according to the conductive paint raw material: the solvent=1:0.7 mass ratio, the viscosity of the obtained conductive paint at room temperature is 100 mPas, and the sheet resistance is 0.04 Ω/sq/mil;
the size of the nozzle is 1mm, and the distance between the nozzle and the carrier is 5cm;
in the step (3), the curing temperature is 65 ℃ and the curing time is 30min.
Example 5
The procedure of example 4 was followed, except that:
in the step (2), the size of the nozzle is 3mm, and the distance between the nozzle and the carrier is 10cm;
in the step (3), the curing temperature is 70 ℃ and the curing time is 30min.
Example 6
The procedure of example 1 was followed, except that:
in the step (1), the width of the pattern area is 3mm;
in step (3), no edge trimming is performed after curing.
Example 7
The procedure of example 2 was followed, except that:
in the step (2), the size of the nozzle was 1mm, and the distance between the nozzle and the carrier was 25cm.
Comparative example 1
(1) Forming a mask layer on the carrier, wherein the mask layer is provided with a hollowed-out pattern area;
the mask layer comprises an upper mask layer and a lower mask layer, the upper mask layer and the lower mask layer wrap the carrier in a buckling mode, the hollowed-out pattern area exposes a region on the carrier, which needs to form the curved conformal antenna, and the width of the pattern area is 3.1mm;
(2) Printing conductive silver paste on a pattern area by adopting an ink-jet printing method, and forming an antenna circuit on a carrier;
wherein, the viscosity of the conductive silver paste is 71 dPa.s, and the sheet resistance is 0.06 ohm/sq/mil; the conditions of inkjet printing were: the ejection flow rate of the ink droplets was 15 mg/sec; the printing rate was 50 mm/sec; the number of printing layers is 1;
(3) Solidifying the antenna circuit to obtain a curved conformal antenna;
wherein the curing temperature is 100 ℃ and the curing time is 15min.
Trimming the edge of the curved conformal antenna by adopting an infrared skin second laser emitter (rated power is 30W) to remove the edge with the width of 100 mu m;
the parameters are as follows: the output power was 16W, the pulse frequency was 280Hz, and the speed was 560mm/s.
Comparative example 2
The procedure of example 2 was followed, except that:
in the step (2), alcohol is adopted to mix the conductive paint raw material 2 according to the conductive paint raw material: solvent=1:0.9 mass ratio, the viscosity of the obtained conductive paint at room temperature is 80 mPas, and the sheet resistance is 0.015 Ω/sq/mil;
in the step (3), the curing temperature is 70 ℃ and the curing time is 30min.
Referring to fig. 2, a region C in fig. 2 is a curved conformal antenna formed corresponding to the mask layer pattern region in embodiment 1; 3 samples were prepared by the methods of examples 1 to 7 and comparative examples 1 to 2, respectively, for a total of 27 samples; wherein, each sample of examples 1-7 and comparative examples 1-2 was tested for antenna thickness at 5 points arbitrarily selected in the C region, and each sample of examples 3 and 6 was tested for edge thickness at the marked 1, 2, 3, 4 positions in fig. 2. The antenna thickness was tested using a two-dimensional measurement device and the results are shown in tables 1 and 2.
Table 1 random point thickness measurements for curved conformal antenna samples
As can be seen from the results of examples 1 to 7 and comparative example 1 in Table 1, compared with the conventional curved conformal antenna prepared by ink-jet printing, the curved conformal antenna with the thickness smaller than 50 μm can be prepared by adopting the method of combining the conductive paint, the mask layer and the spraying process, the thickness of the curved conformal antenna prepared in comparative example 1 is only 53 μm at minimum, and the average thickness of three samples reaches 69.33 μm.
From the results of example 2 and comparative example 2 in table 1, it is known that the viscosity of the conductive paint of the present invention and the spraying process are matched to obtain a curved conformal antenna with good target thickness and thickness uniformity. Comparative example 2 the base paint material 2 was prepared from the base paint materials: the mass ratio of solvent=1:0.9 is diluted, the viscosity of the obtained conductive paint at room temperature is 80mpa·s, the viscosity of the conductive paint is obviously less than 100-200 mpa·s defined by the application, and therefore, the standard deviation of the thickness of the curved surface conformal antenna of the comparative example 2 is 5.30 which is obviously greater than the standard deviation of the thickness of the curved surface conformal antenna of the example 2 by 1.12, and therefore, the thickness uniformity of the curved surface conformal antenna of the example 2 is obviously better than that of the curved surface conformal antenna of the comparative example 2.
From the results of examples 2 and 7 in table 1, it is apparent that the aperture of the nozzle and the distance between the nozzle and the carrier of the present invention are matched to obtain a curved conformal antenna with good target thickness and thickness uniformity. The nozzle diameter of example 7 was 1mm, and the distance between the nozzle and the carrier was 25cm, although the diameter was within the range of 0.3 to 3mm defined in the present invention, and the distance was 5 to 15cm beyond the preferable range. The average thickness of the curved conformal antenna of example 7 is 27.13 μm, which is much higher than the average thickness of the curved conformal antenna of example 2 by 22.73, and more importantly, the standard deviation of the thickness of the curved conformal antenna of comparative example 1 is 3.26, which is significantly greater than the standard deviation of the thickness of the curved conformal antenna of example 2 by 1.12, so that the thickness uniformity of the curved conformal antenna of example 2 is significantly better than that of the curved conformal antenna of example 7.
Table 2 edge thickness measurement results for curved conformal antenna samples
Table 2 the edge thickness measurement results of the curved conformal antenna samples are that the curved conformal antennas of examples 1 to 7 have a target thickness of 20 μm and a target width of 3mm, and the width of the mask layer pattern region is 3.2mm according to b=x (3 to 10), i.e., b=20×5=100 μm=0.1 mm.
The width of the pattern area of the mask layer of example 1 was set to 3.2mm, i.e. the edge of the antenna line was reserved for trimming by a width of 0.1 mm. As can be seen from the results in tables 1 and 2, in example 1, by trimming the edge of the predetermined width of the antenna line, the thickness of the edge of the curved conformal antenna was consistent with the average thickness of the whole, and the uniformity of the edge thickness was good. The width of the mask layer pattern area in the embodiment 6 is 3mm, the edge of the antenna circuit is not trimmed by reserved width, and the overall average thickness of the curved conformal antenna in the embodiment 6 is obviously higher than that in the embodiment 1 by 3.4 mu m than the preset target thickness; in addition, the thickness of the edge of the curved conformal antenna is inconsistent with the average thickness of the whole, and the uniformity of the thickness of the edge is obviously inferior to that of the embodiment 1.
The preferred embodiments of the present invention have been described in detail above, but the present invention is not limited thereto. Within the scope of the technical idea of the invention, a number of simple variants of the technical solution of the invention are possible, including combinations of the individual technical features in any other suitable way, which simple variants and combinations should likewise be regarded as being disclosed by the invention, all falling within the scope of protection of the invention.
Claims (10)
1. A method of making a curved conformal antenna, comprising:
(1) Forming a mask layer on the carrier, wherein the mask layer is provided with a hollowed-out pattern area;
(2) Spraying conductive paint on the pattern area to form an antenna circuit on the carrier; wherein the sheet resistance of the conductive paint is 0.005-0.05 omega/sq/mil, and the viscosity is 100-200 mPa.S;
(3) And curing the antenna circuit to obtain the curved conformal antenna.
2. The method for manufacturing a curved conformal antenna according to claim 1, wherein the curved conformal antenna has a target thickness of X and a target width of Y, the width of the pattern area is a, wherein a > Y, and the distance between the edge of the pattern area and the edge of the curved conformal antenna is B, and b=x (3-10).
3. The method of manufacturing a curved conformal antenna according to claim 1 or 2, wherein the method of spraying the conductive paint on the pattern area in the step (2) comprises: (21) Spraying the conductive paint on the pattern area by adopting spraying equipment; (22) The nozzle and/or the carrier are moved relatively along the trajectory of the antenna track.
4. The method of claim 3, wherein the nozzle is spaced a uniform distance from the carrier in step (22);
and/or the distance between the nozzle and the carrier is 5-15 cm;
and/or the caliber of the nozzle is 0.3-3 mm.
5. The method for manufacturing the curved conformal antenna according to claim 4, wherein the caliber of the nozzle is 0.3-1.2 mm, and the distance between the nozzle and the carrier is 5-15 cm; preferably, the caliber of the nozzle is 0.3-0.8 mm, and the distance between the nozzle and the carrier is 5-15 cm;
and/or the caliber of the nozzle is 2-3 mm, and the distance between the nozzle and the carrier is 8-12 cm; preferably, the caliber of the nozzle is 2-3 mm, and the distance between the nozzle and the carrier is 10-11 cm.
6. The method for manufacturing the curved conformal antenna according to claim 1, wherein the thickness of the curved conformal antenna is not less than 15 μm; preferably 20 to 200 μm.
7. The method of claim 1, wherein in step (1), the mask layer is made of metal, plastic, glass or ceramic;
and/or, the mask layer comprises an upper mask layer and a lower mask layer, and the carrier is wrapped by the upper mask layer and the lower mask layer in a magnetic attraction, buckling or bonding mode.
8. The method for manufacturing the curved conformal antenna according to claim 1, wherein the conductive paint contains one or more conductive materials selected from nickel, aluminum, gold, silver, copper, graphene, graphite and carbon nanotubes; preferably, the conductive paint contains silver or silver copper;
and/or, the conductive paint is aqueous; preferably, the conductive paint is an aqueous silver conductive paint.
9. The method of claim 1, wherein the curing conditions for the antenna line in step (3) include: the curing temperature is 50-70 ℃, and the curing time is 10-30 min; preferably, the curing temperature is 55-65 ℃ and the curing time is 15-20 min.
10. A curved conformal antenna, characterized in that it is made by the method of any one of claims 1-9.
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| CN202310486113.6A CN116600487A (en) | 2023-05-04 | 2023-05-04 | Curved surface conformal antenna and manufacturing method thereof |
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| CN202310486113.6A CN116600487A (en) | 2023-05-04 | 2023-05-04 | Curved surface conformal antenna and manufacturing method thereof |
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