WO2004073106A2 - Conductive thermoplastic compositions and antennas thereof - Google Patents
Conductive thermoplastic compositions and antennas thereof Download PDFInfo
- Publication number
- WO2004073106A2 WO2004073106A2 PCT/US2004/004172 US2004004172W WO2004073106A2 WO 2004073106 A2 WO2004073106 A2 WO 2004073106A2 US 2004004172 W US2004004172 W US 2004004172W WO 2004073106 A2 WO2004073106 A2 WO 2004073106A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- weight
- antenna
- thermoplastic composition
- conductive
- conductive thermoplastic
- Prior art date
Links
- 229920001169 thermoplastic Polymers 0.000 title claims abstract description 143
- 239000000203 mixture Substances 0.000 title claims abstract description 141
- 239000004416 thermosoftening plastic Substances 0.000 title claims abstract description 140
- 239000000835 fiber Substances 0.000 claims abstract description 67
- 229920005989 resin Polymers 0.000 claims abstract description 55
- 239000011347 resin Substances 0.000 claims abstract description 55
- 238000000034 method Methods 0.000 claims abstract description 26
- 238000004519 manufacturing process Methods 0.000 claims abstract description 13
- 229920001577 copolymer Polymers 0.000 claims description 73
- -1 alkyl methacrylate Chemical compound 0.000 claims description 52
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical group C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims description 42
- 239000005977 Ethylene Substances 0.000 claims description 42
- 239000010935 stainless steel Substances 0.000 claims description 29
- 229910001220 stainless steel Inorganic materials 0.000 claims description 29
- CERQOIWHTDAKMF-UHFFFAOYSA-N Methacrylic acid Chemical compound CC(=C)C(O)=O CERQOIWHTDAKMF-UHFFFAOYSA-N 0.000 claims description 28
- 239000011159 matrix material Substances 0.000 claims description 28
- 150000001768 cations Chemical class 0.000 claims description 27
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims description 25
- 229910052725 zinc Inorganic materials 0.000 claims description 25
- 239000011701 zinc Substances 0.000 claims description 25
- 239000002253 acid Substances 0.000 claims description 20
- 239000004698 Polyethylene Substances 0.000 claims description 16
- 125000000217 alkyl group Chemical group 0.000 claims description 16
- 229920000573 polyethylene Polymers 0.000 claims description 16
- 229920000642 polymer Polymers 0.000 claims description 15
- 239000004743 Polypropylene Substances 0.000 claims description 14
- 229910052723 transition metal Inorganic materials 0.000 claims description 14
- 229910052783 alkali metal Inorganic materials 0.000 claims description 13
- 150000001340 alkali metals Chemical class 0.000 claims description 13
- 229910052784 alkaline earth metal Inorganic materials 0.000 claims description 13
- 229920001155 polypropylene Polymers 0.000 claims description 13
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 claims description 12
- 150000003624 transition metals Chemical class 0.000 claims description 11
- 229920000098 polyolefin Polymers 0.000 claims description 9
- 125000002843 carboxylic acid group Chemical group 0.000 claims description 8
- 229920005992 thermoplastic resin Polymers 0.000 claims description 8
- 150000001252 acrylic acid derivatives Chemical class 0.000 claims description 7
- CQEYYJKEWSMYFG-UHFFFAOYSA-N butyl acrylate Chemical compound CCCCOC(=O)C=C CQEYYJKEWSMYFG-UHFFFAOYSA-N 0.000 claims description 7
- 150000001732 carboxylic acid derivatives Chemical class 0.000 claims description 7
- 239000004925 Acrylic resin Substances 0.000 claims description 6
- NLHHRLWOUZZQLW-UHFFFAOYSA-N Acrylonitrile Chemical compound C=CC#N NLHHRLWOUZZQLW-UHFFFAOYSA-N 0.000 claims description 6
- 125000005250 alkyl acrylate group Chemical group 0.000 claims description 6
- 125000004432 carbon atom Chemical group C* 0.000 claims description 6
- 239000003822 epoxy resin Substances 0.000 claims description 6
- 229920006122 polyamide resin Polymers 0.000 claims description 6
- 229920000647 polyepoxide Polymers 0.000 claims description 6
- 229920001225 polyester resin Polymers 0.000 claims description 6
- 239000004645 polyester resin Substances 0.000 claims description 6
- 229920001038 ethylene copolymer Polymers 0.000 claims description 5
- FPYJFEHAWHCUMM-UHFFFAOYSA-N maleic anhydride Chemical compound O=C1OC(=O)C=C1 FPYJFEHAWHCUMM-UHFFFAOYSA-N 0.000 claims description 5
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 claims description 4
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims description 4
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 4
- 239000004917 carbon fiber Substances 0.000 claims description 4
- 229920002313 fluoropolymer Polymers 0.000 claims description 4
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 claims description 3
- 239000004721 Polyphenylene oxide Substances 0.000 claims description 3
- 229920006380 polyphenylene oxide Polymers 0.000 claims description 3
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 claims description 2
- 239000004593 Epoxy Substances 0.000 claims description 2
- 239000004952 Polyamide Substances 0.000 claims description 2
- 239000004793 Polystyrene Substances 0.000 claims description 2
- 229920002396 Polyurea Polymers 0.000 claims description 2
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 claims description 2
- 229920006397 acrylic thermoplastic Polymers 0.000 claims description 2
- 239000004202 carbamide Substances 0.000 claims description 2
- 229910002091 carbon monoxide Inorganic materials 0.000 claims description 2
- 238000007334 copolymerization reaction Methods 0.000 claims description 2
- 229920003229 poly(methyl methacrylate) Polymers 0.000 claims description 2
- 229920002647 polyamide Polymers 0.000 claims description 2
- 239000004417 polycarbonate Substances 0.000 claims description 2
- 229920000515 polycarbonate Polymers 0.000 claims description 2
- 229920000728 polyester Polymers 0.000 claims description 2
- 229920005672 polyolefin resin Polymers 0.000 claims description 2
- 229920002223 polystyrene Polymers 0.000 claims description 2
- 229920002635 polyurethane Polymers 0.000 claims description 2
- 239000004814 polyurethane Substances 0.000 claims description 2
- 229920003048 styrene butadiene rubber Polymers 0.000 claims description 2
- ISXSCDLOGDJUNJ-UHFFFAOYSA-N tert-butyl prop-2-enoate Chemical compound CC(C)(C)OC(=O)C=C ISXSCDLOGDJUNJ-UHFFFAOYSA-N 0.000 claims description 2
- 229920002725 thermoplastic elastomer Polymers 0.000 claims description 2
- 229920013716 polyethylene resin Polymers 0.000 claims 2
- 239000000463 material Substances 0.000 abstract description 38
- 239000000843 powder Substances 0.000 abstract description 5
- 239000012212 insulator Substances 0.000 abstract description 4
- 229910052751 metal Inorganic materials 0.000 description 39
- 239000002184 metal Substances 0.000 description 39
- 229910052799 carbon Inorganic materials 0.000 description 34
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 24
- 239000010949 copper Substances 0.000 description 24
- 229910052802 copper Inorganic materials 0.000 description 21
- 229920000554 ionomer Polymers 0.000 description 21
- 230000005404 monopole Effects 0.000 description 15
- 238000012360 testing method Methods 0.000 description 13
- 239000004020 conductor Substances 0.000 description 10
- 239000011810 insulating material Substances 0.000 description 10
- 239000010410 layer Substances 0.000 description 9
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 9
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 9
- 239000000523 sample Substances 0.000 description 9
- 239000002131 composite material Substances 0.000 description 8
- 238000000748 compression moulding Methods 0.000 description 8
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 7
- 238000001746 injection moulding Methods 0.000 description 7
- 150000002739 metals Chemical class 0.000 description 7
- 229910052700 potassium Inorganic materials 0.000 description 7
- 150000001336 alkenes Chemical class 0.000 description 5
- 229920001400 block copolymer Polymers 0.000 description 5
- 238000004891 communication Methods 0.000 description 5
- 238000007906 compression Methods 0.000 description 5
- 230000006835 compression Effects 0.000 description 5
- 229920005606 polypropylene copolymer Polymers 0.000 description 5
- 238000012545 processing Methods 0.000 description 5
- 229920001897 terpolymer Polymers 0.000 description 5
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 4
- 238000005516 engineering process Methods 0.000 description 4
- 238000001125 extrusion Methods 0.000 description 4
- 238000002347 injection Methods 0.000 description 4
- 239000007924 injection Substances 0.000 description 4
- 238000002156 mixing Methods 0.000 description 4
- 239000000178 monomer Substances 0.000 description 4
- 238000000465 moulding Methods 0.000 description 4
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 4
- 229920003023 plastic Polymers 0.000 description 4
- 239000004033 plastic Substances 0.000 description 4
- 239000010959 steel Substances 0.000 description 4
- 239000012815 thermoplastic material Substances 0.000 description 4
- VXNZUUAINFGPBY-UHFFFAOYSA-N 1-Butene Chemical compound CCC=C VXNZUUAINFGPBY-UHFFFAOYSA-N 0.000 description 3
- 241000935974 Paralichthys dentatus Species 0.000 description 3
- 229920006362 Teflon® Polymers 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- 230000005540 biological transmission Effects 0.000 description 3
- IAQRGUVFOMOMEM-UHFFFAOYSA-N butene Natural products CC=CC IAQRGUVFOMOMEM-UHFFFAOYSA-N 0.000 description 3
- 230000015556 catabolic process Effects 0.000 description 3
- 230000005684 electric field Effects 0.000 description 3
- 238000007765 extrusion coating Methods 0.000 description 3
- 229920001903 high density polyethylene Polymers 0.000 description 3
- 239000004700 high-density polyethylene Substances 0.000 description 3
- 238000010348 incorporation Methods 0.000 description 3
- 229920001684 low density polyethylene Polymers 0.000 description 3
- 239000004702 low-density polyethylene Substances 0.000 description 3
- 238000006386 neutralization reaction Methods 0.000 description 3
- 229920005604 random copolymer Polymers 0.000 description 3
- 150000003839 salts Chemical class 0.000 description 3
- 238000004513 sizing Methods 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- RZVAJINKPMORJF-UHFFFAOYSA-N Acetaminophen Chemical compound CC(=O)NC1=CC=C(O)C=C1 RZVAJINKPMORJF-UHFFFAOYSA-N 0.000 description 2
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 2
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 2
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 description 2
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 2
- BAPJBEWLBFYGME-UHFFFAOYSA-N Methyl acrylate Chemical compound COC(=O)C=C BAPJBEWLBFYGME-UHFFFAOYSA-N 0.000 description 2
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 2
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 2
- 229920006355 Tefzel Polymers 0.000 description 2
- 150000001342 alkaline earth metals Chemical class 0.000 description 2
- 229910052791 calcium Inorganic materials 0.000 description 2
- 239000011575 calcium Substances 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 238000005553 drilling Methods 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- QHSJIZLJUFMIFP-UHFFFAOYSA-N ethene;1,1,2,2-tetrafluoroethene Chemical compound C=C.FC(F)=C(F)F QHSJIZLJUFMIFP-UHFFFAOYSA-N 0.000 description 2
- 239000004744 fabric Substances 0.000 description 2
- 238000009472 formulation Methods 0.000 description 2
- 238000003780 insertion Methods 0.000 description 2
- 230000037431 insertion Effects 0.000 description 2
- 238000003475 lamination Methods 0.000 description 2
- 229910052744 lithium Inorganic materials 0.000 description 2
- 238000003754 machining Methods 0.000 description 2
- 229910052749 magnesium Inorganic materials 0.000 description 2
- 239000011777 magnesium Substances 0.000 description 2
- 230000003472 neutralizing effect Effects 0.000 description 2
- 229910052759 nickel Inorganic materials 0.000 description 2
- 239000008188 pellet Substances 0.000 description 2
- 229920001748 polybutylene Polymers 0.000 description 2
- 238000006116 polymerization reaction Methods 0.000 description 2
- 229920000306 polymethylpentene Polymers 0.000 description 2
- 239000011116 polymethylpentene Substances 0.000 description 2
- 229920005629 polypropylene homopolymer Polymers 0.000 description 2
- 239000011591 potassium Substances 0.000 description 2
- 229920001384 propylene homopolymer Polymers 0.000 description 2
- 229910052709 silver Inorganic materials 0.000 description 2
- 239000004332 silver Substances 0.000 description 2
- 229910052708 sodium Inorganic materials 0.000 description 2
- 239000011734 sodium Substances 0.000 description 2
- 239000000758 substrate Substances 0.000 description 2
- 239000002344 surface layer Substances 0.000 description 2
- 239000000725 suspension Substances 0.000 description 2
- 238000003856 thermoforming Methods 0.000 description 2
- 238000012546 transfer Methods 0.000 description 2
- 229920001862 ultra low molecular weight polyethylene Polymers 0.000 description 2
- 229920001866 very low density polyethylene Polymers 0.000 description 2
- 239000004711 α-olefin Substances 0.000 description 2
- LIKMAJRDDDTEIG-UHFFFAOYSA-N 1-hexene Chemical compound CCCCC=C LIKMAJRDDDTEIG-UHFFFAOYSA-N 0.000 description 1
- KWKAKUADMBZCLK-UHFFFAOYSA-N 1-octene Chemical compound CCCCCCC=C KWKAKUADMBZCLK-UHFFFAOYSA-N 0.000 description 1
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- JIGUQPWFLRLWPJ-UHFFFAOYSA-N Ethyl acrylate Chemical compound CCOC(=O)C=C JIGUQPWFLRLWPJ-UHFFFAOYSA-N 0.000 description 1
- 229920003317 Fusabond® Polymers 0.000 description 1
- 241000237858 Gastropoda Species 0.000 description 1
- 229920010126 Linear Low Density Polyethylene (LLDPE) Polymers 0.000 description 1
- 229920000339 Marlex Polymers 0.000 description 1
- OFOBLEOULBTSOW-UHFFFAOYSA-N Propanedioic acid Natural products OC(=O)CC(O)=O OFOBLEOULBTSOW-UHFFFAOYSA-N 0.000 description 1
- 239000004809 Teflon Substances 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- 239000004775 Tyvek Substances 0.000 description 1
- 229920000690 Tyvek Polymers 0.000 description 1
- 239000004708 Very-low-density polyethylene Substances 0.000 description 1
- 239000011954 Ziegler–Natta catalyst Substances 0.000 description 1
- 230000002378 acidificating effect Effects 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910052788 barium Inorganic materials 0.000 description 1
- DSAJWYNOEDNPEQ-UHFFFAOYSA-N barium atom Chemical compound [Ba] DSAJWYNOEDNPEQ-UHFFFAOYSA-N 0.000 description 1
- 239000006229 carbon black Substances 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 230000001413 cellular effect Effects 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 239000003085 diluting agent Substances 0.000 description 1
- XNMQEEKYCVKGBD-UHFFFAOYSA-N dimethylacetylene Natural products CC#CC XNMQEEKYCVKGBD-UHFFFAOYSA-N 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 230000005670 electromagnetic radiation Effects 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 230000001747 exhibiting effect Effects 0.000 description 1
- 239000002657 fibrous material Substances 0.000 description 1
- 239000010408 film Substances 0.000 description 1
- 239000004811 fluoropolymer Substances 0.000 description 1
- 239000003574 free electron Substances 0.000 description 1
- 239000007792 gaseous phase Substances 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 150000007529 inorganic bases Chemical class 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- VZCYOOQTPOCHFL-UPHRSURJSA-N maleic acid Chemical compound OC(=O)\C=C/C(O)=O VZCYOOQTPOCHFL-UPHRSURJSA-N 0.000 description 1
- 239000011976 maleic acid Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000012968 metallocene catalyst Substances 0.000 description 1
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 1
- 150000007524 organic acids Chemical class 0.000 description 1
- 235000005985 organic acids Nutrition 0.000 description 1
- 229920000620 organic polymer Polymers 0.000 description 1
- 150000002902 organometallic compounds Chemical class 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- YWAKXRMUMFPDSH-UHFFFAOYSA-N pentene Chemical class CCCC=C YWAKXRMUMFPDSH-UHFFFAOYSA-N 0.000 description 1
- PNJWIWWMYCMZRO-UHFFFAOYSA-N pent‐4‐en‐2‐one Natural products CC(=O)CC=C PNJWIWWMYCMZRO-UHFFFAOYSA-N 0.000 description 1
- 238000010094 polymer processing Methods 0.000 description 1
- 239000002952 polymeric resin Substances 0.000 description 1
- 229920005630 polypropylene random copolymer Polymers 0.000 description 1
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 1
- 239000004810 polytetrafluoroethylene Substances 0.000 description 1
- 238000007781 pre-processing Methods 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 238000010526 radical polymerization reaction Methods 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 239000005060 rubber Substances 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 238000005476 soldering Methods 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000001228 spectrum Methods 0.000 description 1
- 229920006301 statistical copolymer Polymers 0.000 description 1
- 229920003002 synthetic resin Polymers 0.000 description 1
- 238000004154 testing of material Methods 0.000 description 1
- 239000010409 thin film Substances 0.000 description 1
- 229910052718 tin Inorganic materials 0.000 description 1
- VZCYOOQTPOCHFL-UHFFFAOYSA-N trans-butenedioic acid Natural products OC(=O)C=CC(O)=O VZCYOOQTPOCHFL-UHFFFAOYSA-N 0.000 description 1
- UARDWXPTHFQYJK-UHFFFAOYSA-K trichlorotitanium(1+) Chemical compound Cl[Ti+](Cl)Cl UARDWXPTHFQYJK-UHFFFAOYSA-K 0.000 description 1
- 239000011800 void material Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
- H01B1/20—Conductive material dispersed in non-conductive organic material
- H01B1/22—Conductive material dispersed in non-conductive organic material the conductive material comprising metals or alloys
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L101/00—Compositions of unspecified macromolecular compounds
- C08L101/12—Compositions of unspecified macromolecular compounds characterised by physical features, e.g. anisotropy, viscosity or electrical conductivity
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
- H01B1/20—Conductive material dispersed in non-conductive organic material
- H01B1/24—Conductive material dispersed in non-conductive organic material the conductive material comprising carbon-silicon compounds, carbon or silicon
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01Q—ANTENNAS, i.e. RADIO AERIALS
- H01Q23/00—Antennas with active circuits or circuit elements integrated within them or attached to them
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01Q—ANTENNAS, i.e. RADIO AERIALS
- H01Q9/00—Electrically-short antennas having dimensions not more than twice the operating wavelength and consisting of conductive active radiating elements
- H01Q9/04—Resonant antennas
- H01Q9/0407—Substantially flat resonant element parallel to ground plane, e.g. patch antenna
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01Q—ANTENNAS, i.e. RADIO AERIALS
- H01Q9/00—Electrically-short antennas having dimensions not more than twice the operating wavelength and consisting of conductive active radiating elements
- H01Q9/04—Resonant antennas
- H01Q9/16—Resonant antennas with feed intermediate between the extremities of the antenna, e.g. centre-fed dipole
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01Q—ANTENNAS, i.e. RADIO AERIALS
- H01Q9/00—Electrically-short antennas having dimensions not more than twice the operating wavelength and consisting of conductive active radiating elements
- H01Q9/04—Resonant antennas
- H01Q9/16—Resonant antennas with feed intermediate between the extremities of the antenna, e.g. centre-fed dipole
- H01Q9/20—Two collinear substantially straight active elements; Substantially straight single active elements
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01Q—ANTENNAS, i.e. RADIO AERIALS
- H01Q9/00—Electrically-short antennas having dimensions not more than twice the operating wavelength and consisting of conductive active radiating elements
- H01Q9/04—Resonant antennas
- H01Q9/30—Resonant antennas with feed to end of elongated active element, e.g. unipole
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2224/00—Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
- H01L2224/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
- H01L2224/26—Layer connectors, e.g. plate connectors, solder or adhesive layers; Manufacturing methods related thereto
- H01L2224/31—Structure, shape, material or disposition of the layer connectors after the connecting process
- H01L2224/32—Structure, shape, material or disposition of the layer connectors after the connecting process of an individual layer connector
- H01L2224/321—Disposition
- H01L2224/32151—Disposition the layer connector connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive
- H01L2224/32221—Disposition the layer connector connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked
- H01L2224/32225—Disposition the layer connector connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked the item being non-metallic, e.g. insulating substrate with or without metallisation
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49016—Antenna or wave energy "plumbing" making
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
- Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
- Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
- Y10T428/249942—Fibers are aligned substantially parallel
- Y10T428/249944—Fiber is precoated
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
- Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
- Y10T428/24995—Two or more layers
- Y10T428/249952—At least one thermosetting synthetic polymeric material layer
Definitions
- This invention relates to conductive polymeric materials comprising a resin-based structural material loaded with micron-sized conductive fibers providing conductive thermoplastic compositions. This invention also relates to antennas comprising this material.
- Antennas are essential parts of electronic communication systems that contain wireless links. Such applications as communications and navigation require reliable and sensitive antennas. Antennas conduct electrical signals and currents so that electromagnetic energy is transmitted and/or received. This requires that the materials of the antennas, especially the antenna elements, be electrically conductive, which in the past required that they be made from metals. Antennas have been typically fabricated from conductive metal antenna elements in a wide variety of configurations. Lowering the cost of antenna materials or production costs in fabrication of antennas offers significant advantages for any applications utilizing antennas.
- Metals typically require high temperatures for fabrication into articles by molding techniques and/or their hardness makes machining articles more difficult, resulting in high fabrication costs. Metals may also be subject to corrosion or other environmental damage, particularly when placed in marine environments such as on boats or ships. Therefore, it is desirable to develop conductive materials other than metals from which to fabricate antennas. It is also desirable to reduce the weight of a wide variety of devices by the replacement of metal parts with lighter-weight components. Thermoplastic polymeric materials have often been used to replace metal parts because of their ease in fabrication and lower weight. However, typical thermoplastic polymers have been found to be nonconductive and therefore unsuitable for antenna applications.
- PCT Patent Application Publication WO 93/26013 describes a telescopic antenna comprising a principal structural component based on a polymeric material associated with or impregnated with conductive material in the form of fibers or particles.
- PCT Patent Application Publication WO 00/33418 describes a bar antenna comprised of an electrically conductive plastic.
- French Patent Application FR2660116 describes antennas comprising thermoplastic material impregnated with conducting material.
- U.S. Patent Application 20020109634 discloses antennas formed of conductive loaded resin-based materials.
- this objective is achieved by fabricating the antenna elements and ground planes from conductive thermoplastic compositions.
- These conductive thermoplastic compositions are thermoplastic resins loaded with conductive materials to provide a resin-based material that is a conductor rather than an insulator.
- the resins provide the structural matrices which, when loaded with micron-sized conductive fibers, become composites that are conductors rather than insulators.
- this invention provides an antenna comprising a conductive thermoplastic composition comprising 15 to 70 weight percent conductive fibers dispersed in a structural matrix comprising at least one thermoplastic structural resin having a dielectric constant of less than about 5.0 at 1 kilohertz; provided
- thermoplastic structural resin when said composition comprises a polyamide resin or an epoxide resin, an additional thermoplastic structural resin must also be present; [0009] (ii) when said composition comprises a polyester resin, an additional thermoplastic structural resin other than an acrylonitrile/styrene/acrylate resin must also be present. [0010] It is another principle objective of this invention to provide methods of forming antennas from the conductive thermoplastic compositions of this invention. This invention provides a method of fabricating an antenna comprising:
- thermoplastic structural resin when said composition comprises a polyamide resin or an epoxide resin, an additional thermoplastic structural resin must also be present;
- thermoplastic composition useful for preparing antennas.
- this invention provides a conductive thermoplastic composition comprising 15 to 70 weight percent conductive fibers dispersed in a structural matrix comprising an ionomeric resin.
- a preferred embodiment of the conductive thermoplastic composition, and antennas thereof, of this invention comprises an ionomeric resin comprising
- E/X/Y copolymers where E is ethylene, X is derived from a C3 to C ⁇ ⁇ , ⁇ ethylenically unsaturated carboxylic acid, and Y is derived from an alkyl acrylate or an alkyl methacrylate wherein the alkyl groups have from 1 to 8 carbon atoms, and wherein X is present in from about 2 to about 30 weight % of the E/X/Y copolymer, Y is present from 0 to about 40 weight % of the E/X/Y copolymer; and the E/X/Y copolymer has a weight average molecular weight of from 80,000 to 500,000 and is at least partially neutralized by one or more alkali metal, transition metal, or alkaline earth metal cations.
- This invention also provides a conductive thermoplastic composition comprising 15 to 70 weight percent conductive fibers dispersed in a structural matrix comprising a polyolefin resin.
- Figure 1 is a cross-sectional view of a dipole antenna of this invention
- Figure 2 is a cross-sectional view of a monopole antenna of this invention.
- Figure 3 is a cross-sectional view of a portable electronic device incorporating a monopole antenna of this invention.
- Copolymer means polymers containing two or more different monomers.
- the terms “dipolymer” and “terpolymer” mean polymers containing only two and three different monomers respectively.
- copolymer of various monomers means a copolymer whose units are derived from the various monomers.
- Thermoplastic resins are polymeric materials that can flow when heated under pressure.
- Melt index (Ml) is the mass rate of flow of a polymer through a specified capillary under controlled conditions of temperature and pressure. Melt indices reported herein are determined according to ASTM 1238 at 190 °C using a 2,160 g weight.
- a dielectric is a material having a relatively low electrical conductivity, i.e. an insulator; or a substance that contains few or no free electrons and which can support electrostatic stresses. Two principal properties of a dielectric are its dielectric constant (the factor by which the electric field strength in a vacuum exceeds that in the dielectric for the same distribution of charge).
- the dielectric constant is the ratio of the capacity of a condenser with a given substance as dielectric to the capacity of the same condenser with a vacuum for dielectric. It is a measure of the amount of electrical charge that a given substance can withstand at a given electric field strength.
- the dielectric constant ( ⁇ ) for a material is a function of temperature and frequency and can be determined according to ASTM method D150.
- Dielectric strength is a measure of the resistance of a dielectric to electrical breakdown under the influence of strong electric fields. It is sometimes referred to as breakdown potential. It is usually expressed in volts per centimeter or volts per mil. It can be measured, for example, according to ASTM D149 at a thickness of 2.286 cm (90 mils).
- this invention provides an antenna comprising a conductive thermoplastic composition comprising 15 to 70 weight percent conductive fibers dispersed in a structural matrix comprising at least one thermoplastic structural resin having a dielectric constant of less than about 5.0 at 1 kilohertz; provided [0027] (i) when said composition comprises a polyamide resin or an epoxide resin, an additional thermoplastic structural resin must also be present;
- thermoplastic structural resins and antennas comprising thermoplastic structural resins having a dielectric constant of less than about 3.0 at 1 kilohertz.
- resins include polyolefins such as polyethylene, polypropylene, polybutylene and polymethylpentene; polyphenylene oxide; fluorinated polymers such as
- Teflon® and Tefzel®; and ionomeric resins More preferred are thermoplastic resins having a dielectric constant of from about 2.0 to about 2.8 at 1 kilohertz. More preferred are polyethylene, polypropylene and ionomeric resins. Particularly preferred are ionomeric resins that are ethylene acid copolymers at least partially neutralized by one or more alkali metal, transition metal, or alkaline earth metal cations. Also particularly preferred is polyethylene and also particularly preferred is polypropylene.
- an antenna comprising a conductive thermoplastic composition comprising 15 to 70 weight percent conductive fibers dispersed in a structural matrix comprising at least one thermoplastic structural resin having a dielectric strength greater than about 450 V/0.0254 cm (450 V/mil.)
- thermoplastic structural resins having a dielectric strength greater than about 450 V/0.0254 cm (450 V/mil) include polyolefins such as polyethylene, polypropylene, polybutylene and polymethylpentene; polyphenylene oxide; fluorinated polymers such as
- an antenna comprising a conductive thermoplastic composition comprising 15 to 70 weight percent conductive fibers dispersed in a structural matrix comprising at least one thermoplastic structural resin having a dielectric strength greater than about 500 V/0.0254 cm, particularly from about 600 to about 1 ,300 V/0.0254 cm, and even more particularly from about 800 to about 1 ,200 V/0.025cm, wherein the structural resin comprises an ionomeric resin comprising ethylene acid copolymers at least partially neutralized by one or more alkali metal, transition metal, or alkaline earth metal cations.
- Ionomeric resins are copolymers of an olefin such as ethylene with a metal salt of an unsaturated carboxylic acid, such as acrylic acid, methacrylic acid, or maleic acid, and optionally softening comonomers. At least one alkali metal, transition metal, or alkaline earth metal cation, such as lithium, sodium, potassium, magnesium, calcium, or zinc, or a combination of such cations, is used to neutralize some portion of the acidic groups in the copolymer resulting in a thermoplastic resin exhibiting enhanced properties.
- an alkali metal, transition metal, or alkaline earth metal cation such as lithium, sodium, potassium, magnesium, calcium, or zinc, or a combination of such cations
- E/(M)AA "Ethylene/(meth)acrylic acid
- E/(M)AA ethylene/methacrylic acid
- MAA ethylene/methacrylic acid
- Terpolymers can also be made from an olefin such as ethylene, an unsaturated carboxylic acid and other comonomers such as alkyl (meth)acrylates providing "softer" resins that can be neutralized to form softer ionomers.
- Ionomers can also be modified by incorporation of organic acids or salts thereof.
- Ionomers useful in this invention include E/(M)AA dipolymers having from about 2 to about 30 weight % (M)AA with a weight average molecular weight of from about 80,000 to about 500,000, at least partially neutralized by one or more alkali metal, transition metal, or alkaline earth metal cations.
- Preferred for preparing conductive thermoplastic compositions, and antennas thereof, are ethylene copolymers having from about 7 to about 20 weight % (M)AA, (with methacrylic acid particularly preferred) at least partially neutralized by one or more alkali metal, transition metal, or alkaline earth metal cations.
- Neutralization can be effected by first making the E/(M)AA copolymer and treating the copolymer with inorganic base(s) with alkali metal, alkaline earth metal or transition metal cation(s).
- a wide range of cations is known for neutralizing acid moieties in the acid copolymer. Typical cations include lithium, sodium, potassium, magnesium, calcium, barium, lead, tin, zinc, aluminum, and combinations of such cations.
- ionomers neutralized with transition metal cations Of particular note are ionomers comprising zinc as a neutralizing cation.
- the degree of neutralization is known to vary over a wide range. Preferably the degree of neutralization is from about 10 to about 70%, and more preferably from about 15 to about 60%. Methods for preparing ionomers from copolymers are well known in the art.
- comonomers such as alkyl (meth)acrylates can be included in the E/(M)AA copolymer to form a terpolymer that can be neutralized with alkali metal, alkaline earth metal or transition metal cations.
- comonomers selected from alkyl acrylate and alkyl methacrylate wherein the alkyl groups have from 1 to 8 carbon atoms, and more preferred are comonomers selected from methyl acrylate, ethyl acrylate and n-butyl acrylate.
- the alkyl (meth)acrylates are included in amounts from 0 to about 30 weight % alkyl (meth)acrylate and more preferably from 0 to 15 weight %.
- the ethylene acid ionomers can be melt- blended with other ionomers or polymers and/or modified by incorporation of other components.
- an ionomer composition can be blended with at least one additional nonionomeric thermoplastic resin selected from the group consisting of polyurethane; polyurea; polyamide; polyester; polycarbonate; polystyrene; acrylics; copoly-ether-ester; copoly- ether-amide; copoly-ether-urethane; copoly-ether-urea; polyolefins; elastomeric polyolefins; polyethylene; polypropylene; ethylene copolymers derived from copolymerization of ethylene and polar comonomers selected from the group consisting of vinyl acetate, alkyl (meth)acrylate, carbon monoxide, and epoxy containing comonomers; maleic anhydride modified polymers; and thermoplastic elastomers based on styren
- the E/X/Y copolymer is blended with polyethylene containing about 1 weight % maleic anhydride comonomer.
- the conductive thermoplastic composition of this invention therefore relates to the above copolymers and blends thereof that are loaded with micron conductive metal fibers.
- ionomers useful in this invention include E/X/Y copolymers selected from the group consisting of a copolymer of ethylene, 9 weight % methacrylic acid, and 24 weight % n-butyl acrylate with the acid 51% (on a molar basis) neutralized (i.e., the carboxylic acid groups being converted to salt) using Zinc(ll) cations; a copolymer of ethylene and 15 weight % methacrylic acid with the acid 58% neutralized using Zinc(ll) cations; and a copolymer of ethylene and 9 weight % methacrylic acid with the acid 18% neutralized using Zinc(ll) cations.
- E/X/Y copolymers selected from the group consisting of a copolymer of ethylene, 9 weight % methacrylic acid, and 24 weight % n-butyl acrylate with the acid 51% (on a molar basis) neutralized (i.e., the carboxylic
- specifically preferred ionomers useful in this invention also include a copolymer of ethylene and 19 weight % methacrylic acid with 36% on a molar basis of the carboxylic acid groups neutralized using Zinc(ll) cations.
- Polyolefins suitable for use in the present invention are selected from polypropylenes, polyethylene polymers and copolymers.
- Polyethylenes useful for use herein can be prepared by a variety of methods, including well-known Ziegler-Natta catalyst polymerization (see U.S. Patent Number 4,076,698 and U.S. Patent Number 3,645,992 for examples), metallocene catalyst polymerization (see U.S. Patent Number 5,198,401 and U.S. Patent Number 5,405,922 for examples) and by free radical polymerization.
- Polyethylene polymers useful herein can include linear polyethylenes such as high density polyethylene (HDPE), linear low density polyethylene (LLDPE), very low or ultralow density polyethylenes (VLDPE or ULDPE) and branched polyethylenes such as low density polyethylene (LDPE).
- the densities of polyethylenes suitable for use in the present invention range from 0.865 g/cc to 0.970 g/cc.
- Linear polyethylenes for use herein can incorporate alpha-olefin comonomers such as butene, hexene or octene to decrease their density within the density range so described.
- Polypropylene (abbreviated PP) polymers useful in the practice of the present invention include propylene homopolymers, random copolymers, block copolymers and terpolymers of propylene, impact modified polypropylene and copolymers of propylene and alpha-olefins.
- Copolymers of propylene include copolymers of propylene with other olefins such as ethylene, 1 -butene, 2-butene and the various pentene isomers, etc. and preferably copolymers of propylene with ethylene.
- Terpolymers of propylene include copolymers of propylene with ethylene and one other olefin.
- Random copolymers also known as statistical copolymers, are polymers in which the propylene and the comonomer(s) are randomly distributed throughout the polymeric chain in ratios corresponding to the feed ratio of the propylene to the comonomer(s).
- Block copolymers are made up of chain segments consisting of propylene homopolymer and of chain segments consisting of, for example, random copolymer of propylene and ethylene.
- polypropylene when used herein is used generically to refer to any or all of the polymers comprising propylene described above.
- Polypropylene homopolymers or random copolymers can be manufactured by any known process.
- polypropylene polymers can be prepared in the presence of catalyst systems of the type known as Ziegler-Natta, based on organometallic compounds and on solids containing titanium(+4) trichloride.
- Block copolymers can be manufactured similarly, except that propylene is generally first polymerized by itself in a first stage and propylene and additional comonomers such as ethylene are then polymerized, in a second stage, in the presence of the polymer obtained during the first.
- propylene is generally first polymerized by itself in a first stage and propylene and additional comonomers such as ethylene are then polymerized, in a second stage, in the presence of the polymer obtained during the first.
- Each of these stages can be carried out, for example, in suspension in a hydrocarbon diluent, in suspension in liquid propylene, or else in gaseous phase, continuously or noncontinuously, in the same reactor or in separate reactors.
- the conductive thermoplastic compositions of this invention comprise micron-sized conductive fibers loaded in a structural resin.
- the micron-sized conductive fibers can be formed of metals such as nickel, copper, silver, stainless steel or the like.
- the micron conductive fibers can be nickel-plated carbon (also known as nickel coated graphite) fibers, stainless steel fibers, copper fibers, silver fibers, carbon fibers, or the like.
- conductive fibers comprising stainless steel.
- stainless steel fibers of a special 304 alloy of stainless steel are stainless steel fibers with a diameter of from about 5 to about 25 microns, particularly of from about 8 to about 11 microns.
- Such fibers with an initial pre-processing length of from about 2 to about 10 mm, particularly from about 4 to about 6 mm.
- Such fibers can be obtained from Bekaert Fibre Technologies under the trade name Beki-Shield .
- conductive carbon fibers are also of note.
- mixtures of conductive fibers and conductive powders in a polymeric structural matrix are mixtures of conductive fibers and conductive powders in a polymeric structural matrix.
- a mixture of carbon conductive fibers and carbon conductive powders in a polymeric structural matrix provides a conductive composition suitable for use as an antenna.
- the polymeric structural matrix can comprise, for example, an ionomer or a polyolefin such as polyethylene.
- Preferred conductive thermoplastic compositions suitable for preparing antennas of this invention are those wherein stainless steel fibers are present in amounts from about 18 weight % to about 60 weight %; more preferably from about 25 weight % to about 50 weight % and even more preferably from about 28 weight % to about 42 weight %.
- the conductive thermoplastic compositions of this invention typically but not exclusively have a volume electrical resistance of less than 100 ohms when measured end to end over a roughly cylindrical volume having a diameter of about 3.81 cm (0.15 inches) to about 1.27 cm (0.5 inches) and a length of 14.47 cm (5.5 inches).
- the conductive thermoplastic compositions of this invention preferably have a conductivity in Siemens/meter of between 100 S/m and 100,000 S/m (i.e., a resistivity of between 1 ⁇ -cm and 0.001 ⁇ -cm).
- the conductive thermoplastic compositions of this invention may also be formed into shapes by, for example, injection molding (i.e. extrusion of the molten composition into molds in a configuration to produce an article comprising the conductive thermoplastic composition in desired shape followed by cooling).
- Sheets of the conductive thermoplastic composition may be produced by extrusion through a laminar die and processing the composition by, for example, cast sheet, extrusion coating or lamination techniques well know in the polymer processing art.
- the conductive thermoplastic compositions of this invention may also be coextruded with other thermoplastic polymers to form multilayer materials.
- the conductive thermoplastic composition can also be formed into multilayer films or sheets by extrusion coating or lamination techniques.
- the antenna elements used to form the antennas are formed of the conductive thermoplastic compositions of this invention and can be formed using methods such as injection molding, compression molding, overmolding, or extrusion.
- the antenna elements can also be stamped to produce the desired shape.
- the conductive thermoplastic composition antenna elements can also be cut or milled as desired.
- the composition of the composite materials can affect the antenna characteristics and must be properly controlled.
- the conductive thermoplastic composition can also be formed into thin films or sheets to provide a cloth-like material which, when properly designed in metal content and shape, can be used to realize a very high performance cloth antenna.
- Such a cloth antenna could be embedded in a person's clothing as well as in insulating materials such as rubber or plastic.
- the conductive cloths could also be laminated
- the conductive thermoplastic composition can be used to form rigid articles consisting essentially of the conductive thermoplastic composition, it can also be laminated, adhered or attached to other rigid materials such as FR-4 copper, or any resin-based hard material to form rigid articles.
- articles comprising the conductive thermoplastic composition of this invention may be further processed.
- portions of the composition may be subjected to thermoforming operations in which the composition is subjected to heat, pressure and/or other mechanical forces to produce shaped articles. Compression molding is an example of further processing.
- This invention provides a method of fabricating an antenna comprising:
- thermoplastic structural resin when said composition comprises a polyamide resin or an epoxide resin, an additional thermoplastic structural resin must also be present;
- thermoplastic structural resin when said composition comprises a polyester resin, an additional thermoplastic structural resin other than an acrylonitrile/styrene/acrylate resin must also be present.
- Almost any type of antenna can be fabricated from the conductive thermoplastic compositions, such as dipole antennas, monopole antennas, conformal antennas, planar antennas, array antennas, direction-finding antennas and the like.
- the conductive thermoplastic compositions of this invention can be molded or extruded to provide an article that is the desired shape for an antenna.
- the conductive thermoplastic compositions of this invention can be cut, injection molded, compression molded, overmolded, laminated, extruded, milled or the like to provide the desired antenna shape and size.
- the antenna characteristics depend on the composition of the conductive thermoplastic compositions, which can be adjusted to aid in achieving the desired antenna characteristics. These antennas can be tuned to a desired frequency range.
- the following embodiments are examples of antennas fabricated using conductive thermoplastic compositions of this invention.
- Preferred antennas comprise the preferred conductive thermoplastic compositions of this invention.
- ground planes are also used and these ground planes can be formed of either conductive thermoplastic compositions or metals.
- the use of these conductive thermoplastic compositions in antenna fabrication significantly lowers the cost of materials and manufacturing processes used in the assembly of antennas and the ease of forming these materials into the desired shapes. These materials can be used to form either receiving or transmitting antennas.
- the antennas and/or ground planes can be formed using methods such as injection molding, compression molding, overmolding, or extrusion of the conductive thermoplastic compositions.
- antennas that comprise the conductive thermoplastic compositions include dipole antennas, monopole antennas, conformal antennas, planar antennas, array antennas and direction-finding antennas.
- the antennas of this invention may be fabricated with additional elements such as ground planes, insulating materials, amplifiers, global positioning system components, connectors and the like to prepare a functional antenna.
- the antennas of this invention can be incorporated with other components into devices that rely on the transmission and/or reception of radio frequency electromagnetic radiation for their function such as radios, wireless communication devices and the like.
- thermoplastic antenna element or a thermoplastic ground plane usually involves the transfer of electrical signals to or from a metal to the thermoplastic material.
- This connection preferably has a relatively large surface area, and preferably involves some pressure in order to obtain a good transfer of electrical signals. Insertion of a metal piece into the thermoplastic is a practical method of achieving this.
- a metal insert useful for attaching to the antenna elements can be copper or other metal and can be formed in a segment of an antenna element.
- the conductive thermoplastic element can be molded around a metal insert.
- the conductive thermoplastic element can be fabricated in a shape with a depression or void in which a metal insert can be fitted.
- a screw such as a sheet-metal screw
- a screw can be used as the metal insert, since it tends to create a good pressure contact point with a large surface area. Due to low melting point of thermoplastics compared to metals, insertion of a hot metal insert into the thermoplastic is another method.
- a screw can be used in the metal insert to aid in electrical connections. Soldering or other electrical connection methods can also be used.
- An example of a dipole antenna of this invention comprises two identical antenna elements that substantially share the same axis, formed from conductive thermoplastic compositions.
- the antenna elements each have a length and a cross section perpendicular to the length. For example, said length may be greater than three multiplied by the square root of the cross sectional area, to form an antenna that has a rod-like form.
- the electrical connections carrying either the transmission or reception signals are connected to the elements of the dipole. In many cases the connection is electrically symmetrical with respect to the system ground, using a balun (balanced-unbalanced transformer).
- Fig. 1 An example of a dipole antenna of this invention is shown in Fig. 1. In Fig.
- the antenna generally designated by the number (1), comprises an optional ground plane (2) that is substantially parallel to the antenna elements (3 and 4) and is separated from the antenna elements by an insulating material (5).
- the insulating material can be used to keep the antenna in place mechanically.
- the thickness of the dielectric insulating material (5) is preferably more than one eighth of the operating wavelength of the antenna.
- Metal inserts (6 and 7) inserted into the antenna elements (3 and 4, respectively) are connected to signal leads (8 and 9, respectively). The metal inserts can be attached to the antenna elements as previously described.
- the signal leads may enter the antenna through an opening (10) in the ground plane (2) via a cable (11).
- the ground plane (2) is optional.
- the ground plane can also be formed of the conductive thermoplastic element of this invention.
- the cable (11) may be attached to the antenna by connecting the cable shield to the conductive ground plane by means of a metal insert (not shown) in the ground plane.
- a monopole antenna of this invention is shown in Fig. 2.
- the antenna generally designated by the number (15)
- the antenna comprises an optional ground plane (16) that is separated from the antenna element (17) by an insulating material (18).
- the antenna element (17) is formed of a conductive thermoplastic composition of this invention and the ground plane (16) may be formed of a conductive thermoplastic composition.
- the insulating material can be used to keep the antenna in place mechanically.
- the radiating antenna element (17) is arranged perpendicular to the ground plane and can be formed as a rod, sheet, shaped element or the like.
- the height of the radiating element is greater than three times the square root of the cross sectional area of the radiating antenna element.
- An example of this antenna with a height of 1.17 inches will perform well at GPS frequencies of about 1.5 GHz.
- a metal insert (19) inserted into the antenna element (17) is connected to a signal lead (20).
- the metal insert can be attached to the antenna element as previously described.
- the signal lead (20) may enter the antenna through an opening (21) in the ground plane via a cable (22).
- the cable (22) may be a coaxial cable and the coaxial cable center conductor (20) may be connected to the antenna element (17) by means of the metal insert (19).
- a ground wire e.g. the shield in the coaxial cable
- An example of a conformal antenna of this invention comprises a radiating antenna element and a ground plane formed from conductive thermoplastic compositions. Conformal antennas are suitable when a "low-profile" antenna or an antenna that can be integrated into the body of an electromagnetic device is desirable.
- a conformal antenna is an antenna that comprises a radiating antenna element and a ground plane each having the shape of a thin plate with a thickness and a separation between the plates provided by insulating standoffs. For example, the square root of the area of the plate forming the radiating antenna element can be greater than three multiplied by the thickness.
- a coaxial cable may enter the conformal antenna through an opening in the ground plane.
- the coaxial cable shield is connected to the ground plane by means of a metal insert in the ground plane.
- the coaxial cable center conductor is connected to the radiating antenna element by means of a metal insert in the radiating antenna element.
- the coaxial cable may enter the antenna between the radiating antenna element and the ground plane.
- the coaxial cable shield is connected to the ground plane by means of a metal insert in the ground plane.
- the coaxial cable center conductor is connected to the radiating antenna element by means of a metal insert in the radiating antenna element.
- antenna structures wherein the insulating material comprises the same polymeric material that forms the matrix of the conductive thermoplastic composition.
- the conductive layers of the radiating elements and ground plane and the insulating layer may be formed independently and then adhesively attached to one another to form the antenna.
- the antenna may also be fabricated by extrusion coating or laminating some or all of the layers onto a substrate.
- the substrate may be, for example, the ground plane.
- Some of the components of the antenna may be formed together by coextrusion, particularly if the components are relatively coplanar.
- a conformal antenna of this invention may comprise a layer of conductive thermoplastic composition, a layer of insulating thermoplastic material and another layer of conductive thermoplastic composition in a multilayer coextruded sheet.
- Additional layers optionally may be coextruded with the antenna components.
- additional layers of thermoplastic resins may be included to provide surface layers to provide protection or improve the appearance of the antenna structure.
- multilayer structures comprising ionomeric materials in the conducting, insulating and surface layers.
- This multilayer structure could be further processed by thermoforming the sheet into a shaped article.
- a sheet of the multilayer structure could be formed into a casing element for a portable communication device or it could be formed into a shaped piece that could be included in an automotive part such as a bumper, fender or panel.
- the use of antennas of this invention in devices can result in lower cost devices by simplifying assembly (for example, by reduction in parts count by incorporation of the antenna material into housing components).
- the use of antennas of this invention in devices can also provide improved performance over devices equipped with conventional metal antennas.
- Antennas of this invention have a number of uses.
- a dipole or a monopole antenna formed of conductive thermoplastic compositions can be embedded in an automobile bumper formed of insulating material.
- antennas of this invention can be used for a number of additional applications.
- the molding of a window of a vehicle such as an automobile or an airplane, can comprise an antenna of this invention wherein an antenna comprising the conductive thermoplastic composition is embedded in the molding or wherein the molding is formed at least partially of the conductive thermoplastic composition.
- Antennas of this invention can be embedded in the plastic housing, or comprise part of the plastic shell itself, of portable electronic devices such as cellular phones, personal computers, or the like.
- a portable electronic device comprises a circuit board (31) to which are attached various electronic components (32).
- the circuit board (31) is housed in a housing or case (33) that is typically fabricated of a nonconductive thermoplastic material.
- a monopole antenna element (34) is embedded in the housing (33) and is attached to the circuit board (31) via a signal lead (35).
- the signal lead is connected to the antenna element (34) by means of a metal insert (36).
- thermoplastic compositions of this invention comprise stainless steel fibers dispersed in a polymeric matrix. See Table 1 below for specific examples. These compositions were prepared by mixing the stainless steel fiber and pellets of resin in a 30 mm twin screw extruder by either: (a) adding both the fiber and the polymer resin together at the rear (i.e., inlet of first zone) of the extruder, or (b) adding the resin at the rear of the extruder and then feeding the fiber separately at a point mid-way along the extruder barrel.
- the conductive thermoplastic composition was extruded through a die and cooled to produce an extruded fiber-polymer composite rope.
- Extruder screw speed was varied in the range of 50 to 150 revolutions per minute (RPM), and the temperature set-points along the extruder barrel were maintained between 180 °C and 260 °C.
- the extruder die temperature was held at 300 °C and melt temperatures were in the range of 230 °C to 310 °C depending on the formulation and screw speed.
- the polymeric materials and the stainless steel fibers used to prepare the example compositions are described in the materials sections below.
- the initially formed composition can be further processed, such as by compression molding or by injection molding.
- Test specimens were also prepared by injection molding using a single-screw injection-molding machine using, typically, the following temperature profile and conditions:
- the electrical resistance was assayed across the length of the 14.47 cm (5.5 inch) rod specimens by drilling a 0.3175 cm (1/8 inch) deep hole in each rod end and inserting a probe at each end from a Fluke multimeter (Model 73-3).
- the electrical resistance of the extruded rope samples was also measured across a 5.5-inch long section of extruded rope.
- the electrical resistance reported in Table 2 is the minimum value displayed on the Fluke multimeter.
- Flexural modulus of the compositions was determined using methods as described in ASTM method D790. Samples were prepared by compression molding, at 180 °C, several 15.24 cm (6 inch) lengths of the extruded rope prepared as described above into 7.62 cm (3 inch) x 15.24 cm (6 inch) x 0.3175 cm (1/8 inch) plaques. These plaques were then die- cut into flex bar specimens to conform to the appropriate dimensions for flexural modulus testing 12.5 cm x 1.27 cm x 0.3175 cm (5 inch x A inch x 1/8 inch) and the results are reported in Table 2.
- the conductive thermoplastic composition by using the least severe processing history capable of making a uniform composite in order to maintain the integrity of the conductive fibers within the matrix.
- the two most conductive examples (Examples 8 and 10) were produced by placing the stainless steel fiber (Material D) into the side of the mixing extruder at the mid-way point of the barrel and using a screw speed of only 50 RPM. These examples exhibited a resistance below the lower limit of the multimeter measuring equipment (i.e. less than 2 ohms). Evaluation of the conductive compositions by the ash method for determining stainless steel content produced steel ash that had a fibrous morphology.
- Example 3 Over processing the mixture can result in degradation of the fibrous nature of the conductive fibers by mechanical grinding and can result in a material that is not highly conducting (Example 3).
- Example 10 the same formulation as Example 10 was used but the stainless steel fiber was subjected to the entire twin-screw barrel length and a screw speed of 100 RPM. This resulted in a material with an electrical resistance that was greater than the maximum measurable by the Fluke multimeter of 32,000,000 ohms.
- Example 3 was the only sample that when evaluated by the ash method produced steel ash that had powder morphology.
- a monopole antenna comprising a conductive thermoplastic composition (CTC) prepared according to Example 8 consisting of a cylinder with the length of 130 mm (5.125 inches), and the cross sectional diameter of 12.7 mm (0.5 inches) was prepared by compression molding. The DC bulk conductivity of this material was measured at 1 ,272 S/m (resistivity of 0.078 Ohm-cm).
- the CTC monopole was placed at the center of a square-shaped copper ground plane with the dimensions of 30.48 cm x 30.48 cm (12 inches x 12 inches), and was insulated from the ground (Example 11).
- the comparison antenna was made of a copper wire with a length of 130 mm (5.125 inches), and a diameter of 0.8 mm (0.032 inches). This metallic antenna shape is commonly used in wireless communication systems.
- the copper antenna was also placed over a ground plane similar to that of the CTC antenna.
- a standard broadband receiving antenna manufactured by Polarad, Model CA-B was used as the receiving antenna.
- a signal generator's output was fed into an amplifier with the gain of 13 dB, and the frequencies of 300 MHz to 1 ,000 MHz at 100 MHz intervals were used.
- the transmitting and receiving antennas were placed 5 meters (15 feet) apart.
- a spectrum analyzer was used to gauge the intensity of the received signal at test frequencies. The results are reported in Table 3.
- Both antennas, at 130 mm, are quarter wavelength long at the frequency of 576 MHz. According to antenna theory and practice, quarter wavelength is the optimum operating condition for a monopole antenna, where the best impedance match to the feed transmission line is obtained.
- CTC antennas of this invention operating from about 300 MHz to about 1 ,000 MHz. The results reported in Table 3 suggest that at frequency range close to 576 MHz the two monopoles have close to equal performance, while outside of this range, where the antennas are not quarter wavelength, the CTC antenna delivers much higher levels of signal. For example, at 300 MHz, where the antennas are at 1/8 (0.125) wavelength, the CTC antenna delivers 2.4 times the signal strength as the metal antenna.
- CTC antennas of this invention operating at less than 1/4 wavelength. This is particularly important in commercial and portable wireless applications where stringent requirements of bulk and mass make the usage of shorter antennas necessary. There are also many applications for longer-than-optimal antennas, and at these conditions the CTC antenna also delivers better performance as suggested by comparison with the copper antenna at 1 ,000 MHz. Of note are CTC antennas of this invention operating at greater than 1/4 wavelength. The above improvements over the existing antenna art are not predicted in the conventional antenna practice, and provide an unexpected advantage.
- the CTC antenna In the optimum quarter-wavelength mode, where the antennas deliver close to equal performance, the CTC antenna has the mechanical advantages over the metal antenna as mentioned before.
- compositions as described in Table 4 were prepared by mixing the materials in an extruder according to techniques similar to those described for Examples 1 through 10. The compositions were injection molded or compression molded according to techniques similar to those described for Examples 1 through 10 into plaques about 5.588 cm+0.254 cm (2.2+0.1 inches) in length, 1.27 cm ⁇ 0.254 cm (0.5+0.05 in) width and 0.3429 cm ⁇ 0.254 cm (0.135+0.01 in) thickness. Conductivity, volume resistivity, and antenna performance were measured on the plaques according to the procedures described above and compared to a copper block of the same dimensions (conductivity 5.8 x 10 7 S/m) and reported in Table 6.
- F Polypropylene homopolymer, density 0.909, Ml of 3.5, available from Phillips Sumika as Marlex HGX-030.
- G Chopped carbon fiber, 95% carbon content, 6mm (0.25 inch) fiber length, Panex 35 grade, available from Zoltek.
- J - Milled carbon powder 99.5% carbon content, about 150 micron (6 mil) standard mean length, Panex 30 grade, available from
- K Low density polyethylene, density 0.930, Ml of 1.5, grade 1078 available from Huntsman.
- Example Composition (weight %) (kpsi)
- Example Composition (weight %) (kpsi)
- Examples 12 through 51 were fabricated into test antennas by machining a block of the material to a block with the following sizes: 57.15 mm long x 12.7 mm wide x 3.18 mm thick (2.25 inch x 0.5 inch wide x 0.12 inch).
- the antennas were used as a monopole on a copper ground plane with the dimensions of 30.48 cm x 30.48 cm (12 inches x 12 inches).
- the long dimension of the test antenna 6.65 cm (2.25 inch) was placed vertical to the ground plane, and a 0.254 cm (0.1 inch) thick layer of PTFE insulation was placed between the antenna and the ground plane.
- test antennas were used to receive a 1.0 GHz signal sent from a transmit antenna which was a wide band Polarad cone antenna (Model C-AB) and placed within the compact range at the distance of 60.96 cm (two feet).
- the length of the monopole antenna (57.15 mm) is about 20% of the wavelength at 1 GHz, which is close to an optimal quarter wavelength monopole.
- All test antennas were compared against a copper block antenna made at the same dimensions as the test antennas. The signal received for each case was compared to the signal received by the copper block antenna in dB, and then converted to percent amplitude below copper (i.e., "dB Signal Below Cu Block” is mathematically converted to "% Amplitude of Copper” as shown in Table 5) using the exponential formula:
- an antenna comprising a conductive thermoplastic composition comprising 15 to 70 weight percent conductive fibers dispersed in a structural matrix, wherein said structural matrix comprises at least one thermoplastic structural resin having a dielectric constant of less than 5.0 at 1 kilohertz, such as E/X/Y copolymers where E is ethylene, X is derived from a C3 to C ⁇ ⁇ , ⁇ ethylenically unsaturated carboxylic acid, and Y is derived from an alkyl acrylate or an alkyl methacrylate wherein the alkyl groups have from 1 to 8 carbon atoms, and wherein X is present in from 2 to 30 weight % of the E/X/Y copolymer, Y is present from 0 to 40 weight % of the E/X/Y copolymer, and said E/X/Y copolymer has a weight average molecular weight of from 80,000 to 500,000, and is at
Abstract
Description
Claims
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JP2006503532A JP2006519558A (en) | 2003-02-12 | 2004-02-10 | Conductive thermoplastic composition and antenna thereof |
EP04709946A EP1593128A2 (en) | 2003-02-12 | 2004-02-10 | Conductive thermoplastic compositions and antennas thereof |
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US44683203P | 2003-02-12 | 2003-02-12 | |
US60/446,832 | 2003-02-12 | ||
US10/767,919 | 2004-01-29 |
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US (1) | US6953619B2 (en) |
EP (1) | EP1593128A2 (en) |
JP (1) | JP2006519558A (en) |
KR (1) | KR20050110624A (en) |
CN (1) | CN100468581C (en) |
TW (1) | TW200503327A (en) |
WO (1) | WO2004073106A2 (en) |
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Also Published As
Publication number | Publication date |
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WO2004073106A3 (en) | 2004-09-23 |
US20040222924A1 (en) | 2004-11-11 |
EP1593128A2 (en) | 2005-11-09 |
KR20050110624A (en) | 2005-11-23 |
CN1751365A (en) | 2006-03-22 |
CN100468581C (en) | 2009-03-11 |
JP2006519558A (en) | 2006-08-24 |
TW200503327A (en) | 2005-01-16 |
US6953619B2 (en) | 2005-10-11 |
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