| With the improvement of the design flexibility and miniaturization of mechatronics equipment,more and more attention has been paid to conformal circuits.The conformal circuit is directly attached to the shell of mechanical structural parts and is often used in medical equipment,automotive electronics,aerospace and other fields.Compared with the traditional planar printed circuit board or independent conductor,conformal circuit has the characteristic of integrated structure and function,which greatly reduces the independent components in the equipment and improves the reliability of the equipment.With the development of conformal circuit forming technologies such as3D molding interconnection and 3D printing,the application field of conformal circuits has been further expanded.In this paper,a new method of 3D conformal circuit forming based on surface partition and its corresponding mechanism are proposed,aiming at the two major problems of the surface conformal circuit forming of complex 3D structural parts and the interface enhancement of organic polymer/metal dissimilar materials.On this basis,the traditional screen printing process was improved,and a new flexible screen printing technology with low cost,high efficiency,strong forming capacity and good process compatibility was obtained.In ZL104 aluminum alloy structure surface,using PUA as circuit insulation layer and protective layer material,was prepared with different particle size of Ag paste the actual complex three-dimensional structure of high conductive conformal circuit,and is applied to the design and manufacture of high power LED underwater lamps,lamps and lanterns of the miniaturization,lightweight and good electrical performance.In this paper,the conformation circuit is made by using the flexible screen printing process based on surface partition,and the relation between the geometric characteristic parameters of the substrate surface and the tension of the wire mesh is fully considered.A complex three-dimensional conformal circuit with circuit width deviation greater than±50 m was fabricated on the surface of structural parts with gaussian curvature range of-2.2×10-3～1.11×10-3 mm-2.To ensure good adhesion of conformal circuit on the surface of structural parts,the microstructure of the interface between PUA insulation layer and Ag conductive layer with different curing degrees and its influence on adhesion property were studied.Nano-Ag and PUA permeate each other perpendicular to the interface direction near the PUA/nano-Ag interface,which increases the interface area,and forms an effective mechanical interlock.The interface shear strength is higher than 5 MPa.Under such conditions,the nano-Ag conductive layer prepared under the high temperature of 150℃and 72 hours of loading did not have any defects such as peeling and arching,showing high reliability.On the basis of ensuring the adhesion of conformal circuit and good insulation performance between the circuit and the structure,this paper designs and produces a new type of high-power underwater LED lamps based on three-dimensional conformal circuit.The conformal circuit on the inner wall of the sleeve connects multiple groups of high-power LED beads.The three-dimensional layout of the LED beads saves the internal space of the lamp and enhances the heat dissipation performance of the lamp.The light guide plate mixes the light emitted by the LED beads and guides to the light outlet window.Meanwhile,it provides mechanical support for the light outlet window to improve the pressure resistance performance of the lamp.The whole lamp produces uniform and adjustable light,with a design power of up to 94 W,a maximum outside diameter of only 10 cm,and a land weight of only 1 kg.The lamp has a simple structure,and it is easy to assemble and maintain and have high reliability. |
PDF Full Text Request