DE10118866A1 - Radar antenna with metal foil coating is made by separate injection molding of plastic part and electroforming of metal foil and joining them with adhesive - Google Patents

Radar antenna with metal foil coating is made by separate injection molding of plastic part and electroforming of metal foil and joining them with adhesive

Info

Publication number
DE10118866A1
DE10118866A1 DE2001118866 DE10118866A DE10118866A1 DE 10118866 A1 DE10118866 A1 DE 10118866A1 DE 2001118866 DE2001118866 DE 2001118866 DE 10118866 A DE10118866 A DE 10118866A DE 10118866 A1 DE10118866 A1 DE 10118866A1
Authority
DE
Germany
Prior art keywords
metal foil
metal
openings
injection molded
radar antenna
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
DE2001118866
Other languages
German (de)
Inventor
Johannes Hackl
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
SWOBODA KG, 87487 WIGGENSBACH, DE
Original Assignee
Swoboda Geb GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Swoboda Geb GmbH filed Critical Swoboda Geb GmbH
Priority to DE2001118866 priority Critical patent/DE10118866A1/en
Publication of DE10118866A1 publication Critical patent/DE10118866A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01QANTENNAS, i.e. RADIO AERIALS
    • H01Q1/00Details of, or arrangements associated with, antennas
    • H01Q1/36Structural form of radiating elements, e.g. cone, spiral, umbrella; Particular materials used therewith
    • H01Q1/38Structural form of radiating elements, e.g. cone, spiral, umbrella; Particular materials used therewith formed by a conductive layer on an insulating support
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01QANTENNAS, i.e. RADIO AERIALS
    • H01Q15/00Devices for reflection, refraction, diffraction or polarisation of waves radiated from an antenna, e.g. quasi-optical devices
    • H01Q15/14Reflecting surfaces; Equivalent structures
    • H01Q15/141Apparatus or processes specially adapted for manufacturing reflecting surfaces
    • H01Q15/142Apparatus or processes specially adapted for manufacturing reflecting surfaces using insulating material for supporting the reflecting surface
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00Apparatus or processes for manufacturing printed circuits
    • H05K3/0058Laminating printed circuit boards onto other substrates, e.g. metallic substrates
    • H05K3/0064Laminating printed circuit boards onto other substrates, e.g. metallic substrates onto a polymeric substrate
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00Apparatus or processes for manufacturing printed circuits
    • H05K3/10Apparatus 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
    • H05K3/20Apparatus 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 by affixing prefabricated conductor pattern
    • H05K3/202Apparatus 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 by affixing prefabricated conductor pattern using self-supporting metal foil pattern
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00Printed circuits
    • H05K1/02Details
    • H05K1/03Use of materials for the substrate
    • H05K1/0393Flexible materials
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2203/00Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
    • H05K2203/01Tools for processing; Objects used during processing
    • H05K2203/0191Using tape or non-metallic foil in a process, e.g. during filling of a hole with conductive paste
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00Apparatus or processes for manufacturing printed circuits
    • H05K3/38Improvement of the adhesion between the insulating substrate and the metal
    • H05K3/386Improvement of the adhesion between the insulating substrate and the metal by the use of an organic polymeric bonding layer, e.g. adhesive

Abstract

The invention relates to a method for producing a radar antenna (1), consisting of an injection molded part (2) and a metal layer with openings. The object of the invention is to propose a method for producing a radar antenna which is suitable for industrial production. This object is achieved in that a metal foil (3) with openings (4) is used as the metal layer with openings and the manufacture of the radar antenna (1) comprises the following sub-steps: DOLLAR A È manufacture of the metal foil (3); DOLLAR A È injection molding of a plastic part (2); DOLLAR A È Applying adhesive to the injection molded part (2) using the tampon print process; DOLLAR A È positioning of the metal foil (3); DOLLAR A È lifting the metal foil (3) with vacuum and transport to the injection molded part (2); DOLLAR A È Blow off the metal foil (3).

Description

The invention relates to a method for producing a radar antenna, consisting of an injection molded part and metal layer with openings. Usually, electrically non- conductive plastics related. First on these injection molded parts a thin layer of metal is deposited and then galvanized Procedure is reinforced. This metal layer is continuous and points no breakthroughs. The breakthroughs are usually by means of a laser with a metal layer after completion of the injection molded part brought in. The problem with the known method is that the injection molded part on the back of the metal layer through the Laser processing of the metal layer can be damaged if the Breakthroughs are to be made in the finished metal layer. The The reason for this is the high power of the laser that is needed to Make openings in the finished metal layer. Besides, it can to contaminate the metal layer surface by splashing Plastic come.

As is known, this problem is solved in that the Metal layer in several by means of the galvanic process Partial steps is generated. After the metal layer has a certain The breakthroughs have been reached using a laser lower power introduced. This will damage the Injection molded part advantageously avoided. This process has to be repeated be repeated. Therefore, this process is for an industrial one Manufacturing not suitable because the manufacturing of the radar antenna exists made of injection molded part and metal layer with openings very time consuming and is therefore expensive.  

The object of the invention is a method for the production propose a radar antenna for industrial manufacturing suitable is.

This object is achieved in that a metal foil with openings is used as the metal layer with openings, and the manufacture of the radar antenna comprises the following sub-steps:
Production of the metal foil with openings; Injection molding of a plastic part; Applying adhesive to the injection molded part using the tampon print process; Positioning of the metal foil; Lifting the metal foil with vacuum and transport to the injection molded part; Blow off the metal foil. This process completely separates the production of the metal foil with openings and the production of the injection molded part. The openings are already made in the prefabricated metal foil, or a metal foil with openings is produced directly. The metal foil is advantageously glued to the finished injection molded part with the aid of adhesive. The problem with the adhesive process is that the side of the metal foil facing away from the injection molded part must not be contaminated with adhesive. In conventional methods for applying adhesive, the adhesive layer is so thick that it would pass through the openings in the metal foil, which would result in contamination of the surface of the metal foil. For this reason, the tampon print process is used.

This process uses a specially made for the injection molded part Immersed the tampon in a container filled with adhesive and then on the surface of the injection molded part to be glued pressed. The applied adhesive layer is even and extremely thin, so that a passage of adhesive through the openings is advantageously avoided in the metal foil.  

So that the metal foil in a precisely defined position on the plastic part comes to rest, is a positioning or an orientation of the Metal foil necessary. This positioning happens either at Transport of the metal foil to the injection molded part or before. So that Metal foil applied to the predetermined position on the plastic part can, it is necessary to lift the metal foil and to Transport injection molded part. It is advantageous to lift the Metal foil with the help of vacuum. To the metal foil from one Applying the transport device to the injection molded part is an advantage provided that the metal foil is blown off. That possibility is of great advantage, since vacuum or Compressed air hoses are available.

In an advantageous development of the method it is provided that the production of the metal foil with breakthroughs in electroforming Procedure is carried out. In the electroforming process, a surface is created with Painted photoresist. The photoresist is then exposed according to a template of the metal foil with openings. The Network exposed areas of the photoresist. In the other places, preferably in the later breakthroughs, the photoresist is removed. This is followed by the application of a metal layer with known ones galvanic methods. With the help of the electroforming process achieved that no laser technology has to be used. The Production of the metal foil using the electroforming process is very accurate and quick and inexpensive compared to laser technology.

It is advantageously provided that the metal foils with openings that have a length of approximately 1.5 mm and a width of 0.2 mm, getting produced. Metal foils with breakthroughs that this Having dimensions are particularly suitable for radar antennas.  

The openings have a lateral distance of 0.8 mm from one another and a distance of 0.1 mm in length.

To achieve that the metal foil is not removable with the injection molded part glued, it is advantageously provided that the metal foil after the Blow off with a tampon is pressed onto the injection molded part.

This tampon has the same dimensions as the tampon used for the tampon print process is used. This ensures that the tampon is adapted to the contours of the metal foil.

An expedient embodiment of the method provides that as Adhesive a one-component, UV-curing epoxy is used. The use of such an adhesive has the advantage that the Curing can be controlled specifically. The adhesive is removed using the Tampon print process applied to the plastic part. Immediately then the adhesive is activated with UV light. Then a positioned metal foil with openings on the plastic part with Blown off the adhesive and pressed on with a tampon. The Glue hardens quickly. Metal foil and plastic part are now inseparable.

Another way to control the gluing process is that a one-component, light-activated epoxy is used. The Activation of the epoxy with light radiation is advantageously carried out shortly before the application of the metal foil with openings.

In an advantageous development of the method according to the invention provided that the metal foil is made of nickel. The material Nickel fulfills the demands and demands placed on a radar antenna takes over the corrosion protection. Furthermore, the manufacture of the Metal foil with openings in the electroforming process made of nickel Surprisingly, particularly unproblematic.  

In an embodiment of the method it is advantageously provided that the Metal foil in a thickness of about 20 to 40 microns, especially 30 microns will be produced. Such thin metal foils are particularly suitable for Use in radar antennas. The metal foils in this thickness can in very tight tolerances can be produced in the electroforming process.

To make the radar antenna insensitive to large The injection molded part is used to ensure temperature fluctuations Advantage made from PBT GF 30%. This is a Polyester with a glass fiber content of 30%.

The process of making a radar antenna becomes special economical if the metal foils with openings in a magazine are stored. The metal foils are advantageously separated from the Magazine by shearing. Here come mainly rubberized rollers for use. The shearing off of the metal foils has the advantage that the Surface of the metal foils is not damaged. Furthermore, the Separation with a high number of cycles.

According to a further embodiment of the method according to the invention it is provided that the separation of metal foils from a Magazine electrostatically. Electrostatic separation is particularly gentle on the sensitive metal foil surface.

To simplify the positioning or alignment of the metal foils, recesses are advantageously provided in the metal foil. This Recesses serve for the engagement of positioning devices. With The recesses are an advantage in the electroforming process brought in by non-exposure.

To make sure that the radar antenna for practical use, For example, in vehicles, is advantageous  Embodiment of the method provided that the radar antenna after completion in a climate test with changing temperatures, subjected in particular in the range between -40 ° C and + 105 ° C becomes.

A possible embodiment of the method according to the invention is described in the drawings described in more detail.

Show it:

Fig. 1 is a plan view of a radar antenna with a metal layer and

Fig. 2 is a side view of the radar antenna.

In Fig. 1 a radar antenna 1 is shown consisting of an injection-molded part 2 and a metal foil 3 with perforations. 4 The openings 4 of the metal foil 3 have the dimensions XY and are distributed symmetrically in several parallel rows 5 in the metal foil 3 . The top view of the injection molded part in FIG. 1 has an essentially round base. In the middle part of the injection molded part 2 there is a cylindrical depression 6 with a bottom surface 7 , to which the metal foil 3 is applied. In this exemplary embodiment, the metal foil has a thickness of 30 μm. The metal foil 3 has two recesses 8 for positioning.

The radar antenna 1 is manufactured as follows:
The metal foil 3 is produced in an electroforming process. For this purpose, a flat photoresist layer is exposed with openings 4 in accordance with the template of a metal foil 3 , as a result of which the exposed areas of the photoresist crosslink. The remaining photoresist is removed and a metal layer is applied to the exposed, crosslinked areas of the photoresist using the galvanic process. The openings have a length of 1.5 mm and a width of 0.2 mm. The lateral distance to each other is 0.8 mm. The length distance is 0.1 mm. Not all breakthroughs are shown in FIG. 1.

At the same time, an injection molded part 2 is made from the particularly temperature-insensitive plastics PBT GF 30%. This is a polyester with a glass fiber content of 30%. The metal foils 3 made available in a magazine are separated. After the metal foil 3 has been separated , the metal foil is positioned in a desired position by a positioning device engaging in the recesses 8 of the metal foil 3 and aligning it in accordance with the target value.

After positioning, the metal foil 3 is raised with the aid of a vacuum suction device and transported to the injection molded part via transport arms. The bottom surface 7 of the injection molded part 2 is wetted with adhesive in the tampon print process. The adhesive is a one-component, UV-curing epoxy. This adhesive has a particularly high modulus of elasticity in order to adapt to the different expansions of the metal foil and the injection molded part in the event of temperature fluctuations.

After activation of the adhesive by means of UV light, the metal foil 3 is transported over the bottom surface 7 . The metal foil 3 is blown off by means of compressed air from a short distance from the bottom surface 7 . The metal foil 3 is then pressed further onto the base surface 7 by means of a tampon. A difficult-to-detachable connection between the metal foil 3 and the injection molded part 2 was thus produced.

Finally, the radar antenna 1 is subjected to a climate test with changing temperatures, in particular in the range between -40 ° C and + 105 ° C. This climate test shows whether the radar antenna manufactured meets the strict requirements.

LIST OF REFERENCE NUMBERS

1

radar antenna

2

injection molding

3

metal foil

4

breakthroughs

5

string

6

deepening

7

floor area

8th

recess

Claims (15)

1. A method for producing a radar antenna consisting of an injection molded part and a metal layer with openings, characterized in that a metal foil ( 3 ) with openings ( 4 ) is used as the metal layer with openings and the production of the radar antenna ( 1 ) comprises the following substeps:
  • - Manufacturing the metal foil ( 3 );
  • - Injection molding of a plastic part ( 2 );
  • - Applying adhesive to the injection molded part ( 2 ) using the tampon print process;
  • - positioning of the metal foil ( 3 );
  • - Lifting the metal foil ( 3 ) with vacuum and transport to the injection molded part ( 2 );
  • - Blow off the metal foil ( 3 ).
2. The method according to claim 1, characterized in that the production of the metal foil ( 3 ) with openings ( 4 ) takes place in the electroforming process.
3. The method according to any one of claims 1 or 2, characterized in that the metal foils ( 3 ) with openings ( 4 ) having a length of about 1.5 mm and a width of 0.2 mm are made.
4. The method according to any one of claims 1 to 3, characterized in that the metal foil ( 3 ) is pressed onto the injection molded part ( 2 ) after blowing with a tampon.
5. The method according to any one of claims 1 to 4, characterized characterized that a one-component, UV curing epoxy is used.
6. The method according to claim 5, characterized in that the one-component, UV-curing epoxy is activated before the application of the metal foil ( 3 ) by means of UV radiation.
7. The method according to any one of claims 1 to 4, characterized characterized in that the adhesive is a one-component, light-activated epoxy is used.
8. The method according to claim 7, characterized in that the one-component, light-activatable epoxy is activated before the application of the metal foil ( 3 ) by means of light irradiation.
9. The method according to any one of claims 1 to 8, characterized in that the metal foil ( 3 ) is made of nickel.
10. The method according to any one of claims 1 to 9, characterized in that the metal foil ( 3 ) is produced in a thickness of about 20 to 40 microns, in particular 30 microns.
11. The method according to any one of claims 1 to 10, characterized in that the injection molded part ( 2 ) is made from PPT GF 30%.
12. The method according to any one of claims 1 to 11, characterized in that the separation of metal foils ( 3 ) from a magazine takes place by shearing.
13. The method according to any one of claims 1 to 12, characterized in that the separation of metal foils ( 3 ) from a magazine is carried out electrostatically.
14. The method according to any one of claims 1 to 13, characterized in that the metal foils ( 3 ) are made with recesses for positioning.
15. The method according to any one of claims 1 to 14, characterized in that the radar antenna ( 1 ) is subjected to a climate test with changing temperatures, in particular in the range between -40 ° C and + 105 ° C after completion.
DE2001118866 2001-04-18 2001-04-18 Radar antenna with metal foil coating is made by separate injection molding of plastic part and electroforming of metal foil and joining them with adhesive Withdrawn DE10118866A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
DE2001118866 DE10118866A1 (en) 2001-04-18 2001-04-18 Radar antenna with metal foil coating is made by separate injection molding of plastic part and electroforming of metal foil and joining them with adhesive

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE2001118866 DE10118866A1 (en) 2001-04-18 2001-04-18 Radar antenna with metal foil coating is made by separate injection molding of plastic part and electroforming of metal foil and joining them with adhesive
PCT/EP2001/009776 WO2002085083A1 (en) 2001-04-18 2001-08-24 Method for bonding flexible printed circuit boards and/or metal foils

Publications (1)

Publication Number Publication Date
DE10118866A1 true DE10118866A1 (en) 2002-10-24

Family

ID=7681757

Family Applications (1)

Application Number Title Priority Date Filing Date
DE2001118866 Withdrawn DE10118866A1 (en) 2001-04-18 2001-04-18 Radar antenna with metal foil coating is made by separate injection molding of plastic part and electroforming of metal foil and joining them with adhesive

Country Status (2)

Country Link
DE (1) DE10118866A1 (en)
WO (1) WO2002085083A1 (en)

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102007063020A1 (en) * 2007-12-21 2009-06-25 Tesa Ag Method for producing an antenna system
CN103507212B (en) * 2013-09-24 2015-12-23 北京经纬恒润科技有限公司 A kind of Planar Slot Antenna and processing technology thereof

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE9001255U1 (en) * 1990-02-03 1990-04-05 Hagenbusch, Guenther, 7313 Reichenbach, De
EP0595418A1 (en) * 1992-10-28 1994-05-04 Di. W.S. PLASTIC S.r.l. Reflecting parabolic antenna for e.m. wave reception and related manufacturing method

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Publication number Priority date Publication date Assignee Title
DE2029235A1 (en) * 1970-06-13 1971-12-30 Licentia Gmbh
US4935090A (en) * 1981-09-03 1990-06-19 Gte Products Corporation Photoflash array quick-cure laminating process
JPS62118609A (en) * 1985-11-18 1987-05-30 Matsushita Electric Works Ltd Manufacture of plane antenna
GB2189350B (en) * 1986-04-16 1989-11-29 Marconi Electronic Devices Electrical circuits
DE4232666C1 (en) * 1992-09-29 1994-03-24 Presskon Ges Fuer Elektronisch Process for the production of printed circuit boards
GB2305018A (en) * 1995-08-23 1997-03-26 Brian Hallett Printed circuit boards having circuitry on an insulating sheet
EP0902609A1 (en) * 1997-09-05 1999-03-17 Ascom Hasler AG Process for manufacturing a circuit board, circuit board and device for carrying out the process
EP1028483B1 (en) * 1999-02-10 2006-09-27 AMC Centurion AB Method and device for manufacturing a roll of antenna elements and for dispensing said antenna elements
ES2153323B1 (en) * 1999-06-07 2001-07-16 Univ Madrid Politecnica Flat reflectors in multi-paper printed technology and its design procedure.
US6391138B1 (en) * 1999-09-20 2002-05-21 Molex Incorporated Method of fabricating a laminated circuit assembly and product thereof

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE9001255U1 (en) * 1990-02-03 1990-04-05 Hagenbusch, Guenther, 7313 Reichenbach, De
EP0595418A1 (en) * 1992-10-28 1994-05-04 Di. W.S. PLASTIC S.r.l. Reflecting parabolic antenna for e.m. wave reception and related manufacturing method

Also Published As

Publication number Publication date
WO2002085083A1 (en) 2002-10-24

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Legal Events

Date Code Title Description
OM8 Search report available as to paragraph 43 lit. 1 sentence 1 patent law
8110 Request for examination paragraph 44
8127 New person/name/address of the applicant

Owner name: SWOBODA KG, 87487 WIGGENSBACH, DE

R119 Application deemed withdrawn, or ip right lapsed, due to non-payment of renewal fee

Effective date: 20111101