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Contenido archivado el 2024-04-30

In-mould coating techniques for electro-magnetic and radio-frequency shielding of injection mouldings

Objetivo



The industrial objective is to provide a low cost, cleaner process for applying a metallic layer to the inside of injection moulded casings used to house lighting, electronic, IT and telecoms products. Such a process would enable the SME dominated supply chains associated with these components to incorporate an EM/RF shielding layer as an integral part of the injection moulding process, removing the requirement for expensive and environmentally damaging secondary processes such as copper, nickel and silver painting or plating. A low cost and clean alternative is urgently needed to enable European SME injection moulders to compete with lower cost Pacific Rim suppliers when new EMC Legislation (89/336/EEC) is introduced in January 1996, compelling the SME moulders' customer base to ensure their products neither emit RF/EM interference and are affected by interference from other sources. The technical objectives relate to the development of two alternative RF/EM shielding membrane materials together with forming and over-moulding techniques to allow them to be incorporated into the cavity of a mould tool and onto the inner surface of the subsequent moulding. These objectives will be achieved by employing an approach that builds on a platform of developments already carried out by the material suppliers involved and Pera, the selected RTD performer. These developments, combined with techniques developed in other industrial sectors and innovative concepts associated with the moulding process itself, will lead to a novel in-mould shielding technology able to meet the new legislation for a wide range of electrical, electronic and microelectronic products. This will be achieved at a fraction of the cost associated with current technology and without the need for environmentally damaging electroless plating, or high levels of metal paint production. Specific Technical Objectives include: -The development of a CAD/CAM system to produce complex grid patterns that accommodate for the expected frequency of operations and susceptibility of the product to be housed, as well as for the effect of component geometry on the grid pattern during thermoforming. -The development of a rotary screen printing method by which to lay down, onto polymeric film, a complex grid pattern of metallic paint, either nickel, silver, copper or an alloy of these. -The development of a nickel foam or foil annealing process, able to improve ductility and achieve a elongation at break of at least 30%. -The development of an integrated mould tooling and material management system that thermoforms or press forms the printed film or nickel foam foil onto the core of the mould tool. -The development of a polymer injection control system that is able to inject onto the rear of the membrane, initially following polymer into the mould cavity then, using an increasing profile of cavity back pressure flow through the membrane into component features sunk into the core of the mould tool.

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Coordinador

Morning Plastics Ltd.
Aportación de la UE
Sin datos
Dirección
29/33,Holmethorpe Avenue
RH1 2NQ Redhill
Reino Unido

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