Novel Plastics Allows Complex Circuit Patterns To Be Laser Etched

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September 19, 2005

Novel Plastics Allows Complex Circuit Patterns To Be Laser Etched

Seattle, WA, USA--(Jobwerx News)--Laser structurable liquid crystal polymer forms molded plastics interconnect device in hearing aids, sensors and other electronic components.

As hearing aids grow more powerful, accessing new technologies to miniaturize their components becomes vital. A molded interconnect device (MID) in Acuris® P hearing aids from Siemens is a good example of this. This MID, a key part of the unit's microphone module, was made with Vectra® E820i LDS liquid crystal polymer (LCP), a novel plastic that allows complex, fine-line circuit patterns to be laser etched and then plated. Vectra LCP is made by Ticona, the engineering polymers business of the Celanese Corporation.

Acuris P hearing aids are designed to help those who have moderate to severe hearing loss. The MID is part of a multi-channel, adaptive directional microphone system containing up to three microphones. This system improves the wearer's ability to understand speech by automatically reducing noise from multiple moving or stationary sources. The MID, which measures about 3 mm wide and 25 mm long, connects the microphone module to other electronic components in the unit.

Acuris® hearing aids from Siemens contain a multi-channel, three-microphone system that improves a wearer's ability to understand speech by reducing noise. One of the key elements of this system is a miniaturized molded interconnect device made of Vectra® liquid crystal polymer from Ticona.

Vectra E820i LDS can be molded into thin-walled parts and then processed by laser direct structuring (LDS) to create the intricate circuitry needed in hearing aids, sensors and other electronic components. LDS involves a three-step process that first injection molds the LCP part and then 'draws' a conductor track layout on the part's surface with a computer-controlled laser. In the final step, metal is electroplated on the conductor tracks to create a three-dimensional circuit board on the LCP surface. The laser direct structuring process is available from LPKF Laser & Electronics AG, Garbsen, Germany.

A characteristic feature of liquid crystalline polymers is their molecular structure. They consist of rigid, rod-like macromolecules which align in the melt to produce liquid crystal structures. Important properties of these polymers include: continuous service temperatures up to 240°C (short-term up to 340°C), very low melt viscosity, flash-free injection molding, very high tensile strength and very high elastic modulus in the flow direction, high impact strength and inherent flame retardancy.

The comprehensive range of Vectra® LCP injection molding grades is built around various basic polymers which differ in their melting point, heat resistance, rigidity and flow characteristics. By compounding with a variety of fillers and reinforcing materials, the basic polymers can be tailored to meet the requirements of many different applications. Ticona LCP is used in electrical and electronic components, cables and connectors for fiber optics, telecommunications equipment, automotive and mechanical engineering, shipbuilding and as a film in the electronics and packaging industries.

"Laser direct structuring and our new LCP grade make possible the serial production of injection-molded, three?dimensional circuit boards having a high degree of design flexibility," explains Jörg Schottek, head of Ticona's Vectra business in Europe.

The molded interconnect device in Acuris®) hearing aids is based on Vectra® E820i LDS liquid crystal polymer, which allows circuit conductor tracks to be laser etched and then electroplated.

"This process allows for fine conductor patterns in almost any layout," he adds, "which provides for better space utilization to aid miniaturization, as seen in the new generation of Acuris P hearing aids. It also offers advantages for producing cell phone antenna modules and developing and implementing new mechatronic systems. LDS and Vectra LCP are an ideal combination that can support many of the innovations needed for the next wave of high-tech miniaturization."

Siemens Medical Solutions is a leading global supplier to the healthcare industry. This group is renowned for its innovative products, comprehensive support and consulting services and complete solutions, covering the entire spectrum from imaging systems for diagnosis and therapy, electromedicine and audiology to IT solutions.

Vectra® is a registered trademark of Ticona.
Acuris® is a registered trademark of Siemens.

Photos courtesy of Siemens Medical Solutions and Ticona Technical Polymers.

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