U.S. patent number 9,054,417 [Application Number 13/189,611] was granted by the patent office on 2015-06-09 for manufacturing method of antenna structure.
This patent grant is currently assigned to Auden Techno Corp.. The grantee listed for this patent is Chieh-Ming Lin. Invention is credited to Chieh-Ming Lin.
United States Patent |
9,054,417 |
Lin |
June 9, 2015 |
Manufacturing method of antenna structure
Abstract
A manufacturing method of an antenna structure includes the
following steps: producing a main body by injection molding of a
first plastic, wherein the first plastic is a plating grade
plastic; covering the main body by a second plastic to form a
covering layer, wherein plating can not be done for the first and
second plastics concurrently; removing a pre-determined portion of
the covering layer, wherein a patterned layer is defined by the
unremoved portion of the covering layer, wherein at least one
trench is formed by the exposed portion of the main body and
surrounding patterned layer; and plating an antenna material in the
trench to form an antenna. Thus, the instant disclosure can reduce
the manufacturing cost of the antenna structure. Based on the
preceding manufacturing method, an antenna structure is also
disclosed.
Inventors: |
Lin; Chieh-Ming (New Taipei,
TW) |
Applicant: |
Name |
City |
State |
Country |
Type |
Lin; Chieh-Ming |
New Taipei |
N/A |
TW |
|
|
Assignee: |
Auden Techno Corp. (Taoyuan
County, TW)
|
Family
ID: |
47596789 |
Appl.
No.: |
13/189,611 |
Filed: |
July 25, 2011 |
Prior Publication Data
|
|
|
|
Document
Identifier |
Publication Date |
|
US 20130027252 A1 |
Jan 31, 2013 |
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B29C
45/0053 (20130101); H01Q 1/38 (20130101); B29C
45/16 (20130101); B29L 2031/3456 (20130101); B29L
2031/3481 (20130101); B29C 2045/0079 (20130101); B29C
2045/0058 (20130101); Y10T 29/49016 (20150115) |
Current International
Class: |
H01P
11/00 (20060101); H01Q 1/38 (20060101); B29C
45/16 (20060101); B29C 45/00 (20060101) |
Field of
Search: |
;29/600-601,830,831,846-847,852 ;343/700MS,878,890,713-715 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Trinh; Minh
Attorney, Agent or Firm: Rosenberg, Klein & Lee
Claims
What is claimed is:
1. A manufacturing method of an antenna structure, comprising the
steps of: producing a main body by injection molding of a plating
grade first plastic, wherein the main body has a first surface and
a second surface formed oppositely, at least one through hole being
projected through the first and second surfaces; covering the main
body with a second plastic by injection molding in forming a
covering layer, the second plastic cannot be electroplated with the
first plastic simultaneously, wherein the main body is disposed
inside a mold for forming the covering layer thereon, and wherein
the through hole and the second surface of the main body are fixed
by the mold; removing a pre-determined portion of the covering
layer, the resulting covering layer being defined as a patterned
layer, at least one trench being formed by the surface of the main
body exposed by the removal of the pre-determined portion with the
surrounding patterned layer; and electroplating an antenna material
onto the trench to form an antenna.
2. The manufacturing method as claimed in claim 1, wherein the
pre-determined portion of the covering layer is removed by a laser
light emitted from a laser machine.
3. The manufacturing method as claimed in claim 1, wherein the mold
has at least one positioning element and a supporting column, the
positioning element being projected through the through hole, the
supporting column been abutted to the second surface of the main
body.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The instant disclosure relates to an antenna structure and a
manufacturing method thereof; more particularly, to an antenna
structure having an antenna electroplated on a plastic and a
manufacturing method thereof.
2. Description of Related Art
Regarding the manufacturing of partial fine circuits of antennas or
free-dimensional antennas, the Laser Direct Structuring (LDS)
technique developed by LPKF is heavily favored. The technique
involves three basic steps: producing a thermoplastic part by
injection molding to be laser structured; activating the
thermoplastic by a laser beam; and metalizing the thermoplastic by
electroless plating.
However, when using the LDS technique, the material selection is
restricted and more expensive. In addition, the purchasing cost of
the laser system for applying the LDS technique is very expensive,
at approximately $15,000,000.about.33,000,000 NTD (New Taiwanese
Dollar) each. The steep financial investment is not favorable for
the advancement of antenna industry.
SUMMARY OF THE INVENTION
One object of the instant disclosure is to provide an antenna
structure and a manufacturing method thereof. The antenna structure
can be manufactured by commercially available laser assembly and
materials.
For the manufacturing method, the steps include: producing a main
body using injection molding of a first plastic, which can be
electroplated; covering the main body with a second plastic by
injection molding to form a covering layer, wherein the second
plastic can not be electroplated with the first plastic
simultaneously; removing a pre-determined portion of the covering
layer, wherein the unremoved portion of the covering layer is
referred as a patterned layer, wherein at least one trench is
formed by the exposed portion of the main body and the surrounding
patterned layer; and electroplating an antenna material into the
trench to form an antenna.
The antenna structure includes a main body, a patterned layer, and
an antenna. The patterned layer is disposed on the outer surface of
the main body, wherein at least one trench is formed by the exposed
portion of the main body and the surrounding patterned layer. The
antenna is disposed in the trench.
Based on the above, the antenna structure and the manufacturing
method thereof can reduce the manufacturing cost of the antenna
structure and promote the advancement of antenna industry.
In order to further appreciate the characteristics and technical
contents of the instant disclosure, references are hereunder made
to the detailed descriptions and appended drawings in connection
with the instant disclosure. However, the appended drawings are
merely shown for exemplary purposes, rather than being used to
restrict the scope of the instant disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow diagram illustrating steps of a manufacturing
method of an antenna structure for a first embodiment of the
instant disclosure.
FIG. 2 is a perspective view illustrating a main body of the
antenna structure for the first embodiment of the instant
disclosure.
FIG. 3 is a perspective view illustrating a covering layer disposed
over the main body of the first embodiment of the instant
disclosure.
FIG. 4 is a sectional view illustrating the main body disposed in a
mold of the first embodiment of the instant disclosure.
FIG. 5 is a perspective view illustrating the antenna structure
with a pre-determined portion of the covering layer to be removed
of the instant disclosure.
FIG. 5A is another perspective view illustrating the antenna
structure with pre-determined portions of the covering layer to be
removed of the instant disclosure.
FIG. 6 is a perspective view illustrating the antenna structure
with a trench formed thereon for the first embodiment of the
instant disclosure.
FIG. 6A is another perspective view illustrating the antenna
structure with trenches formed thereon for the first embodiment of
the instant disclosure.
FIG. 7 is a perspective view illustrating the antenna structure
formed with an antenna thereon for the first embodiment of the
instant disclosure.
FIG. 7A is another perspective view illustrating the antenna
structure formed with the antenna thereon for the first embodiment
of the instant disclosure.
FIG. 7B shows a sectional view taken along line 7B-7B in FIG.
7.
FIG. 8 is a perspective view illustrating a plate-like main body of
the antenna structure for the first embodiment of the instant
disclosure.
FIG. 8A is a sectional view taken along line 8A-8A in FIG. 8.
FIG. 9 is a perspective view illustrating an antenna structure for
a second embodiment of the instant disclosure.
FIG. 9A shows a sectional view taken along line 9A-9A in FIG.
9.
FIG. 10 is a perspective view illustrating a plate-like main body
of the antenna structure of the second embodiment of the instant
disclosure.
FIG. 10A shows a sectional view taken along line 10A-10A in FIG.
10.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Please refer to FIG. 1 to FIG. 8A, which show a first embodiment of
the instant disclosure, wherein FIG. 1 shows the steps of a
manufacturing method of an antenna structure, and FIG. 2 to FIG. 8A
illustrate the respective steps, which are described below.
Please refer to FIG. 2, which shows a main body 1 produced by
injection molding of a first plastic. The main body 1 has an
opposing first surface 11 and a second surface 12. The first
plastic is a plating grade plastic, which may be ABS (acrylonitrile
butadiene styrene), PC (poly-carbonate), PS (polystyrene), PE
(polyethylene), PA (polyamide), PMMA (poly-methyl methacrylate),
FPR (fiber reinforced plastic), or other suitable plating grade
plastics. The preceding PA is also called Nylon. Presently, Nylon 6
and Nylon 6,6 are used preferably for electroplating due to better
stability.
Please refer to FIG. 3. The main body 1 is spread with a second
plastic by injection molding, thus forming a covering layer 2. The
thickness of the covering layer 2 can be changed according to the
designer. This second plastic can not be electroplated with the
first plastic simultaneously, i.e., the plating solution of the
second plastic is different versus the first plastic, or the second
plastic is a non-plating grade plastic. If the second plastic is
indeed a non-plating grade plastic, the second plastic may be
rubber, PET (polyethylene terephthalate), or other non-plating
grade plastic.
Please refer to FIG. 4. When forming the main body 1, at least one
through hole 13 is projected through the first and second surfaces
11 and 12. Then, the main body 1 is disposed in a mold 5, and the
second surface 12 and the through hole 13 of the main body 1 are
fixed therein. The mold 5 has at least one positioning element 51
and a supporting column 52. When the second surface 12 and the
through hole 13 of the main body 1 are disposed in the mold 5, the
positioning element 51 passes through the through hole 13 of the
main body 1, and the supporting column 52 abuts the second surface
12 of the main body 1. Thus, the main body 1 can be fixed in the
mold 5 securely, which allows the covering layer 2 to be formed
more steadily. However, in use, the positioning manner of the main
body 1 is not limited thereto.
After the covering layer 2 is formed on the main body 1, the
abutted portion of the second surface 12 by the supporting column
52 is not coated by the covering layer 2. This exposed surface of
the main body 1 and the adjacent deposition of the covering layer 2
define a recessed spot 14, as shown in FIG. 5A.
Please refer to FIGS. 5 to 6A, wherein pre-determined portions 21
of the covering layer 2 are removed off the first and second
surfaces 11 and 12. The untouched portion of the covering layer 2
is referred as patterned layer 3 hereinafter. At least one trench
31 is formed by the exposed portions of the first and second
surfaces 11 and 12 of the main body 1 and the surrounding patterned
layer 3. For this embodiment, separate trenches 31 are formed
regarding the first surface 11 and the second surface 12,
respectively. The trench 31 formed by the exposed portion of the
first surface 11 of the main body 1 communicates with the through
hole 13 of the main body 1. The other trench 31 formed by the
exposed portion of the second surface 12 of the main body 1
communicates with the through hole 13 and the recessed spot 14 of
the main body 1.
The manner for removing the pre-determined portions 21 of the
covering layer 2 is by using a conventional laser machine 6
(approximately $2,000,000.about.3,000,000 NTD) to emit a laser
light 61 with non-specific wavelength on the pre-determined
portions 21 of the covering layer 2, thereby removing the
pre-determined portions 21 of the covering layer 2.
When using the laser machine 6 to remove the pre-determined
portions 21 of the covering layer 2, the path of the laser light 61
can be planed according to the designer, whereby the pre-determined
portions 21 of the covering layer 2 can be a particular pattern, so
as to cause the covering layer 2 be defined as the patterned layer
3. That is to say, the patterned layer 3 is shaped by the trenches
31.
In addition, the manner for removing the pre-determined portions 21
of the covering layer 2 can be done by using traditional technique,
such as using a CNC (computer numerical control) milling machine
(not shown).
Please refer to FIGS. 7 to 7B. An antenna material is electropated
onto the side walls of the trenches 31 and the corresponding
exposed portions of the first and second surfaces 11 and 12, thus
forming an antenna 4. The above electroplating process is done
conventionally involving chemical reactions, that is to say, the
antenna material does not need to be restricted. The shape of the
antenna 4 is substantially equal to the path traversed by the
moving laser light 61. The path is matched by the particular
pattern defined by the trenches 31.
In addition, the shape of the main body 1 can be changed by the
designer, for example: the main body 1 can have a curved shape (as
FIGS. 7 to 7B) or a plate-like shape (as FIGS. 8 and 8A).
Therefore, the manufacturing method of the instant disclosure can
reduce the capital cost compared to the LDS technique of the LPKF,
so as to promote the development of the antenna industry.
According to the above steps, the instant disclosure can produce
the antenna structure having the main body 1, the patterned layer
3, and the antenna 4. The antenna structure is described as
follows.
Please refer to FIGS. 7 to 8A, which correspond to the antenna
structure. The main body 1 has a first surface 11 and a second
surface 12 formed oppositely. At least one through hole 13 is
projected thru the first and second surfaces 11 and 12. The
patterned layer 3 is formed on the outer surface of the main body
1. Two separate trenches 31 are formed by the patterned layer 3
with the exposed portions of the first surface 11 and the second
surface 12 respectively, and both trenches 31 communicate with the
through hole 13. The trenches 31 can have particular patterns. The
antenna 4 is electroplated onto the inner surface of the through
hole 13 and the exposed portions of the first and second surfaces
11 and 12 of the trenches 31 of the main body 1.
Please refer to FIG. 9 to FIG. 10A, which show a second embodiment
of the instant disclosure. The second embodiment discloses an
antenna structure including a main body 1, a patterned layer 3, and
an antenna 4. The shape of the main body 1 can be changed by the
designer, for example: the main body 1 can have a curved shape (as
shown in FIGS. 9 and 9A) or a plate-like shape (as shown in FIGS.
10 and 10A).
The main body 1 has a first surface 11 and a second surface 12
formed oppositely and an end surface 15 bridging the first and
second surfaces 11 and 12. The patterned layer 3 is disposed on the
outer surface of the main body 1. The pattern layer 3 and the
exposed portion of the outer surface of the main body 1 define at
least one trench 31. In this embodiment, the trench 31 is formed by
the patterned layer 13 with the exposed portions of the first,
second, and end surfaces 11, 12, and 15. The trench 31 can have a
specific pattern. The antenna 4 is electroplated onto the main body
1, specifically onto the exposed portions of the first, second and
end surfaces 11, 12, and 15 within the trench 31.
Comparing to related art, the antenna material and the laser
machine of the instant disclosure have fewer restrictions, and the
spending cost of the instant disclosure is cheaper than the LDS
technique. Thus, the cost of the manufacturing method of the
instant disclosure is lower than the LDS technique of the LPKF, so
as to promote the development of the antenna industry. In addition,
the antenna structure of the instant disclosure can be formed as an
antenna having partial fine circuit or a free-dimensional
antenna.
The description above only illustrates specific embodiments and
examples of the instant disclosure. The instant disclosure should
therefore cover various modifications and variations made to the
herein-described structure and operations of the instant
disclosure, provided they fall within the scope of the instant
disclosure as defined in the following appended claims.
* * * * *