INJECTION MOLDABLE, CONTROLLED DIELECTRIC CONSTANT MATERIALS FOR ANTENNAS
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1 INJECTION MOLDABLE, CONTROLLED DIELECTRIC CONSTANT MATERIALS FOR ANTENNAS Dr. Antti Helminen, R&D Manager Mr. Tuomas Kiikka, Business Development Director
2 Let s make a good mix UNIQUE PLASTIC SOLUTIONS
3 PREMIX S Way of Working is Based on 3C S CARING CREATING COMMITTED
4 PREMIX S Location and Position Premix 36% Others 64% The European market of conductive plastics
5 Outline Wireless communication Miniaturization / Energy consumption Available antenna material Benefits of thermoplastic materials Thermoplastics Pyramid Thermoplastics processing Filler technology to control DK Applications Measurement of dielectric properties Design Freedom!
6 THERMOPLASTICS IN WIRELESS COMMUNICATION
7 Typical High Frequency Applications
8 Wireless Communication Material requirements / wishes Miniaturization high DK (dielectric constant) Energy consumption low DF (dielectric loss) Properties stable over conditions (T, RH, frequency,...) Mechanical properties (ductility, rigidity, flexibility,...) No limitation for use or process temperature (solderability) Inflammability Easy to process mass manufacturing, prototypes Low cost Reliable supply
9 Typical High Frequency Applications High frequency laminates (PCB) Typically thermosets with reinforcement Only planar (2D) structures Copper already attached (etching) Some different DK values available Ceramics High DK values available Hard, rigid Slow sintering process to 3D shapes Thermoplastics Easy to process in 3D shapes DK values inherently from 2 to 3 DF high compared to ceramics Low density (~ 1 g/cm 3 ) Low cost Only a few solder resistant grades available
10 Thermoplastics Processing Methods Injection molding for complex 3D shapes Short cycle times, mass production 2-shot molding Extrusion Cast film Sheet extrusion Profile extrusion Machining from a semi-finished block Rapid prototyping with 3D printers
11 Pyramid of Plastics
12 Dielectric Properties of Polymers Low frequency (50 Hz) data is more readily available The high frequency data is not easily available (1+ GHz) Non-polar polymers have inherently low dielectric loss Some materials absorb moisture, which increases the dielectric loss Additives (such as flame retardants) can increase the dielectric loss drastically
13 Dielectric Properties of Plastic DK DF Remarks ABS HDT 100ºC PC 2.8 ~0.005 HDT 130ºC PC/ABS HDT 110ºC ASA HDT 90ºC PPE 2.6 < HDT 180ºC PP 2.2 < HDT 100ºC PP + 30% GF HDT 150ºC
14 Dielectric Properties of Plastic DK DF Remarks PE-HD 2.2 < HDT 80ºC PS 2.4 < HDT 90ºC PP 2.2 < HDT 100ºC COC 2.35 < HDT ºC PPE 2.6 < HDT ºC sps 2.3 < HDT 110ºC, crystalline PS LCP Difficult to bond PEI High water uptake PTFE 2.1 < Difficult to process
15 Advantages of PPE A fully amorphous polymer Enables good dimensional stability due to no warpage in molded parts caused by crystallization Low water absorption Used largely in molded water handling parts Good chemical resistance against alcohols, acids, solvents except aromatic Fast cycle times in injection molding Low density (1.06) compared to most engineering materials
16 FILLER TECHNOLOGY
17 Maximize antenna performance Dissipation factor Careful Filler Selection Offers Unique Dielectric Properties 0,010 0,008 0,006 0,004 Standard PC/ABS Standard LCP Filler A 0,002 0,000 Filler B Dielectric constant (Dk) Minimize antenna size
18 Wavelength in Different Media 100 % 90 % 80 % 70 % 60 % 50 % 40 % 30 % 20 % 10 % 0 % Air (1.0) Elevated dielectric constant material to minimize antenna size DK
19 Effect of DK on Lens Size PTFE dk 2.1 PREPERM dk 4.5 * *K. Piiroinen, Design and measurement of a flat dielectric lens antenna for beam steering, Master s thesis, Aalto University, Espoo, 2013, 68 p.
20 Application Areas for Injection Molded Parts Phase shifters (dielectric loaded) Dielectric resonator antennas (DRA) Lenses Patch antennas Low loss structural parts Beam forming Dielectric loaded filters Radomes Tuning screws Miniaturized hand-set antenna
21 DK/DF at 1 GHz Screening and QC
22 Split Post Dielectric Resonator (5 and 22GHz) DK 1 GHz 5 GHz 22 GHz L L DF 1 GHz 5 GHz 22 GHz L L
23 Waveguide PREPERM L450
24 Water absorption (m-%) Low Water Absorption under Immersion of Different PPE Grades 0,30 % 0,25 % 0,20 % 0,15 % 255 L300 L ,10 % 0,05 % 0,00 % Time (days)
25 PREPERM Miniaturize Antenna size STANDARD GRADES: PREPERM 255 (Dk 2.55) PREPERM L300 (Dk 3.0) PREPERM L330 (Dk 3.3) PREPERM L380 (Dk 3.8) PREPERM L450 (Dk 4.5) PREPERM L570 (Dk 5.7) PREPERM L700HF (Dk 7.0) PREPERM L900HF (Dk 9.0) PREPERM L960HF (Dk 9.6) PREPERM 1000 (Dk 10) PREPERM 2100 (Dk 21) PREPERM 260 LDS (Dk 2.8) PREPERM 280GF20 (Dk 2.8) PREPERM 290GF30 (Dk 2.9) PREPERM PO500 (Dk 5.0) PREPERM PP280GF (Dk 2.8) PREPERM PP300 (Dk 3.0) PREPERM PP500 (Dk 5.0) PREPERM PP500GF (Dk 5.0) PREPERM PC370 (Dk 3.7) PREPERM PC620 (Dk 6.2) Custom dielectric constant grades available.
26 PREMIX Unique PREPERM Material Materials with optimized dielectric properties are now available Outstanding dissipation factor (down to at 1 GHz) Low dielectric constant (2.55) or easily customized to customer requirements Dielectric constant stable over wide frequency range and temperature range Design freedom!
27
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