molded interconnect devices applied to smart systems - … · project co-operation organization...

MIDASS : Molded Interconnect Devices

Applied to Smart Systems

JT Plastronics PEP 2010 - MIDASS - All rights reserved

09 December 2010, PEP (OYONNAX – FRANCE)

PLASTRONICS TECHNOLOGIES or how Plastics allow Elec tronics to access the third dimension

� PROJECT PRESENTATION AND MANUFACTURING PROCESSES

� Molded Interconnect devices

� Main axes of MIDASS

� MIDASS organization

� Materials, Compounds, Manufacture and Plating process

� PROJECT TEST VEHICLES

� Coaxial Plastic Connector

9 December, 2010 JT Plastronics PEP 2010 - MIDASS - All rights reserved

2

Coaxial Plastic Connector

� MID Antenna on Polymer

� MID Antenna on Ceramic

� Microwave component on ceramic

� MID development in progress

� Vehicular AM/FM antennas

� PROJECT DEMONSTRATOR

� PMR Handheld antennas

� Project co-operation organization

MIDASS : Molded Interconnect Devices Applied to Sma rt Systems

Research Development

- New Materials, composites,…- Characterization, test- New rules for RF design

Manufacturing Process

- Molding, Plating,…- Design methods,…

Solution Provider

- Antennas,- Interconnect devices- PMR equipment

Research Development

- New Materials, composites,…- Characterization, test- New rules for RF design

Manufacturing Process

- Molding, Plating,…- Design methods,…

Solution Provider

- Antennas,- Interconnect devices- PMR equipment


3

- New rules for RF design - PMR equipment- New rules for RF design - PMR equipment

H. TUDORPEPRADIALL

PEPRADIALL

CASSIDIANFICOSARADIALL

MIDASS : Molded Interconnect Devices Applied to Sma rt Systems

STATE OF THE ART ST UDY

SP2 :2. 1 Mat erials & co mpou nds2. 2 Proces s & techniqu es2. 3 Mech anical & ele ctrical fu nctions

SP1MANAGEM ENT

1.1Con sortium

Co- ord ination

36 m

onth

s

M ANUF ACTURING & DESIGN METHO DSIM PLEMENT AT ION

SP3 :3. 1 Mat erials & co mpou nds ch aract erisation3. 2 Imp lemen tation of MID m anu factu ring p rocesse s3. 3 Design techniq ues fo r 3D

SP6VALUE ANALYSIS

&DISSEMINATION

6.1Bu sin essRelevan ce

12 m

onth

s15

mon

ths

36 m

onth

s

� Project structure and timing


4

1.2Rep ort in g toEURIPIDES

&au thor it ie s

DEMONSTRATO R INTEGRATION

SP5 :5. 1 Demo nstr ator design5. 2 Demo nstr ator ch ara cterizat io n5. 3 Tr ansfe r & imp rovem ent c apability an alysis

36 m

onth

s

3. 3 Design techniq ues fo r 3D h etero gene ous syste ms

UNITARY TEST VEHICLES

SP4 :4. 1 Unitar y test ve hicle sele ct ion4. 2 Detailed specificat io n4. 3 Design & concept ion4. 4 Te st

6.2Dissemin ation

18 m

onth

s11

mon

ths

36 m

onth

s

MIDASS Materials, Compounds, Manufacture and Platin g process

� Selected materials� LCP, because of its dielectrical properties and soldering flexibility (only material available in 2-shot moulding)� PC-ABS : for passive components (antennas)� Other plateable totally

� Selected MID processes� Laser ablation� 2-shot injection moulding� LPKF-LDS


5

� Selected plating processes� Total electroless plating� Selective electroless plating

� Full characterization of raw and plated parts : mechanical, thermal and electrical properties to design components.

GPS/Galileo Bi-Band Antenna : Direct Laser ablation Advantages : unique process, 3D conception (plated h oles)

After copper coating After Electrolytic finishing

MIDASS test vehicles : MID Antenna on Polymer

Electrical and mechanical design


6

Frequency bands: 1227.6MHz; 1575.42 MHz (±15 MHz)VSWR: 2:1Radiation: AxialPolarization: Right hand circular polarization (RHCP)

• Excellent selective plating and easy process (3 steps only)

• Light etching of substrate by the laser beam but without consequence on product functioning

• 2,5D design which needs coating inside the holes.

GPS Planar Antenna : laser activationAdvantage : flexibility of the design, plated holes

• Excellent selective plating and easy process (2 steps only)

• Adhesion metal/substrate not yet mastered (study in progress)

Aspect after laser

activation

Aspect after

selective plating

MIDASS test vehicles : MID Antenna on Ceramic

Frequency band: 1575.42 ± 15 MHzVSWR: 2:1Radiation: AxialPolarization: Right hand circular polarization (RHCP)


7

Return LossRadiation pattern

Aspect after laser

activation

Pass-Band Filters : laser activationAdvantages : precision, flexibility of the process, plated holes, cost reduction

MIDASS test vehicles : Microwave component on ceram ic


8

Aspect after

selective plating

Pass Band: 7.9 – 18 GHz3dB cut off frequency: 7.5 GHzVoltage Standing Wave Ratio (7.9-18 GHz) ≤ 1.5Insertion Loss (7.9-18 GHz): 2.1 dB maxiAverage power: 4 WattRejection (DC - 5GHz): 80 dB mini

Return Loss / Insertion Loss

In order to prove feasibility of introducing AM/FM services in small rear-view mirrors by means of using MID technology, it wasagreed to prepare a demo-car with AM / FM in the left mirror bracket of a passenger vehicle.

MIDASS test vehicles : Vehicular AM/FM antennas

OBJECTIVES


9

SYSTEM CONFIGURATION

LEFT MIRROR:AM / FM

(bracket)



10

SERVICES TO BE INSTALLED IN THE CAR:

AM � from 0.15 MHz to 2 MHzFM � from 87 MHz to 108 MHz

CURRENT PRODUCT DEFINITION

Amplifier

Amplifier fixing screw

Antenna (flexible foil)



11

Ground wire

Ground terminal

Ground fixing screwFakra Connector

Coaxial wire

Chassis support

PROPOSED PRODUCT DEFINITION

GOAL: Substitute the external flexible PCB corresponding to AMFM fractal antenna from the Rear-View Mirror and have conductive tracks directly to the plastic piece.

PROCESS:

1. The moulded piece material (PC/ABS) is substituted by PC/ABS Xantar LDS3710

2. Activation and etching

3. Assembly in final mirror



12

1 2 3

The demonstrator is based upon a PMR handheld designed by CASSIDIAN

MIDASS Demonstrator : PMR Handheld antennas


13

Current productDemonstrator

MID functions are : Bluetooth antenna : replacement of the PIFA antenna by laser activation

Revelation with laser of Bluetooth antenna on

the rear cover Bluetooth antenna

Rear cover



14

OBJECTIVE: To create the antenna pattern on the plastic cover to avoid the manual integration of this antenna and remove metal part (and tool).

PMR antenna : on the rear cover and laser activation

Revelation with laser of

PMR antenna PMR antenna



15

OBJECTIVE: create the antenna pattern on the plastic cover to integrate PMR antenna :�Save cost

�Easily adapt the design to new frequency band by changing simply the Laser activation�Increase of product resistance (antenna design is fragile)�Reduction of product dimensions

GPS antenna : patch on the top of the handheld

Over-moulding GPS antenna



16

OBJECTIVE: Function added without putting external antenna. Integrated solution for the same reason as PMR antenna.

Cover + Antennas + Laser activation = 1 cover with 4 fonctionnalities

Several functions in one part :

PMR antenna

GPS antenna

Wlan Antenna

Packaging functions

Advantages

Cost save

Weight save 1. Electrical and

2. Injection simulations



171709/11/2010

Weight save

QoS improvement

ROHS compliance

1. Electrical and Mechanical design

3. 1st Injection

4. 2nd Injection5. Laser Activation6. Plating

Thank you for your attention!


18

The reproduction, distribution and utilization of this document as well as the communication of its contents to others without express authorization is prohibited.Offenders will be held liable for the payment of damages.

All rights reserved in the event of the grant of a patent, utility model or design.

molded interconnect devices applied to smart systems - … · project co-operation organization...

Documents