Radiating elements having a radiator and a molded plastic substrate and related antenna arrays and methods

Abstract

An antenna array, comprising: a plurality of dipole radiating elements that each comprise a first unitary sheet metal dipole element, a second unitary sheet metal dipole element, and a first molded plastic substrate that is configured to hold the first unitary sheet metal dipole element in place adjacent the second unitary sheet metal dipole element; and a second molded plastic substrate that at least partially surrounds each of the plurality of dipole radiating elements and directly contacts the first molded plastic substrate of each of the plurality of dipole radiating elements.

Description

Attorney Docket No. 1534.7461.WORADIATING ELEMENTS HAVING A RADIATOR AND A MOLDED PLASTIC SUBSTRATE AND RELATED ANTENNA ARRAYS AND METHODSCROSS-REFERENCE TO RELATED APPLICATION

[0001] The present application claims the benefit of priority to U.S. Provisional Application No. 63 / 748,529, filed on January 23, 2025, in the United States Patent and Trademark Office, and the entire contents of the above-identified application are incorporated by reference as if set forth herein.FIELD OF THE INVENTION

[0002] The present invention generally relates to wireless communications and, more particularly, to radiating elements (e.g., a dipole radiating elements) suitable for use in an antenna array.BACKGROUND OF THE INVENTION

[0003] A wireless local area network refers to a network that operates in a limited geographic area (e.g., within a home, school, store, campus, shopping mall, etc.) that interconnects two or more electronic devices using wireless radio frequency ("RF") communications. Electronic devices owned or controlled by users of a wireless local area network, such as smartphones, computers, tablets, printers, appliances, televisions, lab equipment and the like (herein "client electronic devices"), can communicate with each other and / or access other networks (e.g., the Internet) over the wireless local area network. Since wireless communications are used, the client electronic devices can move throughout the area covered by the wireless local area network (e.g., as the users of the client electronic devices move) and remain connected to the network Many wireless local area networks operate under a family of standards promulgated by the Institute of Electrical and Electronics Engineers (IEEE) that are referred to as the IEEE 802.11 standards. Wireless local area networks operating under the IEEE 802.11 family of standards are commonly referred to as Wi-Fi networks. ClientAttorney Docket No. 1534.7461.WOelectronic devices that include a networking subsystem that includes a Wi-Fi network interface can communicate over Wi-Fi networks.

[0004] A Wi-Fi network includes one or more access points (also referred to as hotspots) that are typically installed at fixed locations throughout the area covered by the Wi-Fi network. Each access point may include a networking subsystem that has an IEEE 802.11 -based network interface. The Wi-Fi network can include a single access point that provides coverage in a very limited area or may include tens, hundreds or thousands of access points that provide in-building and / or outdoor coverage to a large campus or region. A client electronic device "associates" with an access point in order to gain access to the Wi-Fi network. Client electronic devices communicate with each other and / or with wired devices that are connected to the Wi-Fi network through the access points. The Wi-Fi network typically includes one or more gateways that may be used to provide Internet access to the client electronic devices.

[0005] Wireless local area networks that operate under the IEEE 802.11 standard have been widely deployed. The access points in these networks are typically controlled by one or more on-premise controllers, off-premise controllers and / or Cloud-based controllers. The access points may communicate with these controllers through wired and / or wireless connections. Modem access points may support Wi-Fi communications in one or more of the 2.401-2.484 GHz frequency band (herein "the 2.4 GHz frequency band"), the 5, 170-5.835 GHz frequency band (herein "the 5 GHz frequency band") and the 5.15-7.125 GHz frequency band (herein "the 6 GHz frequency band").

[0006] Wi-Fi access points often include printed circuit board (PCB) based radiating elements such as PCB-based dipole or monopole radiating elements. In many cases, the PCBs are formed using conventional FR-4 substrate material because such PCBs are low cost.Unfortunately, dipole radiating elements formed on PCBs that use FR-4 as the dielectric substrate have relatively high signal losses, and these losses tend to increase with increasing frequency. Now that many Wi-Fi access points are configured to operate at high frequencies, such as frequencies in 6 GHz frequency band , the impact of these signal losses is increasing. These signal losses may be exacerbated in access points that include larger multi-row, multi-column antenna arrays, as additional signal losses may be incurred in power dividers and the (longer) transmission lines that feed the dipole radiating elements in the antenna arrays.Attorney Docket No. 1534.7461.WO

[0007] To improve (e.g., to reduce) signal losses at higher frequencies, dielectric substrates having lower signal losses than regular FR-4 substrate material may be used, such as RF-quality PCB material. The dielectric substrates used in RF-quality PCB material have lower dielectric loss tangent (Df) values than those of regular FR-4 material. RF-quality PCB material, however, is more expensive and hence may not be a realistic alternative due to cost considerations in many applications.SUMMARY OF THE INVENTION

[0008] The inventive concept may provide a radiating element (e.g., a dipole radiating element) of an antenna array having unitary sheet metal dipole elements and a dielectric substrate for wireless communications networks and methods of manufacturing the radiating element and the antenna array.

[0009] In addition, the technical goals to be achieved by the inventive concept are not limited to the technical goals mentioned above, and other technical goals may be clearly understood by one of ordinary skill in the art from the following descriptions.

[0010] According to an aspect of the present inventive concepts, a radiating element is provided that includes a sheet metal or metal wire radiator and a first molded plastic substrate that at least partially surrounds the sheet metal or metal wire radiator.

[0011] In some embodiments, the sheet metal or metal wire radiator comprises a sheet metal dipole radiator that comprises a first unitary sheet metal dipole element that includes a first dipole arm and a first feed line and a second unitary sheet metal dipole element that includes a second dipole arm and a second feed line. At least a portion of the first molded plastic substrate may extend in between the first feed line and the second feed line, and may be configured to hold the first unitary sheet metal dipole element and the second unitary sheet metal dipole element together.

[0012] In some embodiments, the first molded plastic substrate is configured to space the first unitary sheet metal dipole element apart from the second unitary sheet metal dipole element at a predetermined distance.

[0013] In some embodiments, the first molded plastic substrate may comprise a first liquid crystal polymer substrate. In some embodiments, the first molded plastic substrate may cover at least a portion of a rear side of the first dipole arm and at least a portion of a rear side ofAttorney Docket No. 1534.7461.WOthe second dipole arm, and the first molded plastic substrate may comprise a first part that is mounted behind the first and second dipole arms and a second part that extends rearwardly from the first part between the first and second feed lines.

[0014] In some embodiments, the radiating element may further comprise a second molded plastic substrate that covers at least a portion of a front side of the first dipole arm and at least a portion of a front side of the second dipole arm.

[0015] In some embodiments, the first feed line may extend through a first opening in the first molded plastic substrate and / or the second feed line may extend through a second opening in the first molded plastic substrate.

[0016] In some embodiments, the sheet metal or metal wire radiator is at least one helical metal wire dipole radiator.

[0017] In some embodiments, the radiating element is a first radiating element and is provided in combination with a second radiating element, and a second molded plastic substrate may at least partially surrounds both the first and second radiating elements. The first molded plastic substrate and the second molded plastic substrate may, but need not, comprise the same material. In some embodiments, the first molded plastic substrate and the second molded plastic substrate comprise respective first and second molded liquid crystal polymer substrates.

[0018] In some embodiments, the first and second radiating elements may comprise respective first and second sheet metal dipole radiators that each comprise a first unitary sheet metal dipole element that comprises a first dipole arm and a first feed line and a second unitary sheet metal dipole element that comprises a second dipole arm and a second feed line.

[0019] In some embodiments, the second molded plastic substrate may completely cover the first molded plastic substrate.

[0020] According to an aspect of the present inventive concepts, antenna arrays are provided that comprise: a plurality of dipole radiating elements that each comprise a first unitary sheet metal dipole element, a second unitary sheet metal dipole element, and a first molded plastic substrate that is configured to hold the first unitary sheet metal dipole element in place adjacent the second unitary sheet metal dipole element. These antenna arrays further comprise a second molded plastic substrate that at least partially surrounds each of the plurality of dipole radiating elements and directly contacts the first molded plastic substrate of each of the plurality of dipole radiating elements.Attorney Docket No. 1534.7461.WO

[0021] Tn some embodiments, each first unitary sheet metal dipole element comprises a first dipole arm and a first feed line, and each second unitary sheet metal dipole element comprises a second dipole arm and a second feed line.

[0022] In some embodiments, each first molded plastic substrate comprises a first liquid crystal polymer substrate that is between the first feed line and the second feed line and that is configured to support the first dipole arm and the second dipole arm of a respective one of the plurality of dipole radiating elements.

[0023] In some embodiments, the second molded plastic substrate comprises a second liquid crystal polymer substrate that is configured to hold the plurality of dipole radiating elements in a spaced-apart relationship.

[0024] In some embodiments, each first liquid crystal polymer substrate comprises a first part that is mounted behind the first and second dipole arms and a second part that extends rearwardly from the first part between the first and second feed lines.

[0025] In some embodiments, the antenna array is mounted to extend forwardly from a main printed circuit board of a Wi-Fi access point.

[0026] In some embodiments, each first molded plastic substrate has a T-shaped crosssection.

[0027] According to an another aspect of the present inventive concepts, methods of forming antenna arrays are provided that comprise forming a sheet metal radiator via stamping, and then placing the sheet metal radiator in a mold and molding a first plastic substrate to at least partially surround the sheet metal radiator to form the radiating element. In some embodiments, the sheet metal radiator may be a sheet metal dipole radiator that comprises a first unitary sheet metal dipole element that comprises a first dipole arm and a first feed line and a second unitary sheet metal dipole element that comprises a second dipole arm and a second feed line.

[0028] In some embodiments, at least a portion of the first plastic substrate extends in between the first feed line and the second feed line.

[0029] In some embodiments, the first plastic substrate is configured to hold the first unitary sheet metal dipole element and the second unitary sheet metal dipole element together and spaces the first and second feed lines apart by a predetermined distance.

[0030] In some embodiments, the first molded plastic substrate covers at least a portion of a rear side of the first dipole arm and at least a portion of a rear side of the second dipole arm,Attorney Docket No. 1534.7461.WOand the first molded plastic substrate comprises a first part that is mounted behind the first and second dipole arms and a second part that extends rearwardly from the first part between the first and second feed lines.

[0031] In some embodiments, the first feed line extends through a first opening in the first plastic substrate and the second feed line extends through a second opening in the first plastic substrate.

[0032] In some embodiments, the radiating element is a first radiating element, and the method further comprises forming a second radiating element by: forming a second sheet metal radiator via stamping, and placing the second sheet metal radiator in the mold and molding a second plastic substrate to at least partially surround the second sheet metal radiator.

[0033] In some embodiments, the method further comprises forming an antenna array by placing the first and second radiating elements in a second mold and molding a third plastic substrate to at least partially surround the first and second radiating elements.

[0034] In some embodiments, the first and second radiating elements comprise respective first and second sheet metal dipole radiators that each comprise: a first unitary sheet metal dipole element that comprises a first dipole arm and a first feed line and a second unitary sheet metal dipole element that comprises a second dipole arm and a second feed line.BRIEF DESCRIPTION OF THE FIGURES

[0035] FIG. 1 A is a perspective view illustrating an antenna array according to embodiments of the present invention.

[0036] FIG. IB is a cross-sectional view, which is taken along a line A-A' of the antenna array of FIG. 1A.

[0037] FIG. 2 is a perspective view illustrating a unitary sheet metal dipole element according to embodiments of the present invention.

[0038] FIG. 3 is a perspective view illustrating a radiating element according to embodiments of the present invention.

[0039] FIG. 4A is a perspective view illustrating a plurality of radiating elements according to embodiments of the present invention.

[0040] FIGS. 4B and 4C are front and rear perspective views illustrating an antenna array according to embodiments of the present invention.Attorney Docket No. 1534.7461.WO

[0041] FIG. 5 is a flow chart of a manufacturing method of an antenna array according to embodiments of the present invention.

[0042] FIGS. 6A, 6B, 6C, and 6D are views illustrating antenna arrays according to further embodiments of the present invention.

[0043] FIGS. 7A, 7B, 7C, and 7D are views illustrating antenna arrays according to still further embodiments of the present invention.

[0044] FIG. 8 is a perspective view illustrating a helical antenna according to embodiments of the present invention.DETAILED DESCRIPTION OF THE INVENTION

[0045] Pursuant to embodiments of the inventive concept, radiating elements are provided that comprise a sheet metal or metal wire radiator and a first molded plastic substrate material (e.g., a liquid crystal polymer (LCP) or another low-loss dielectric) that at least partially surrounds the sheet metal or metal wire radiator and holds the radiator in place. In some example embodiments, each radiator may comprise first and second unitary sheet metal dipole elements that together form a dipole radiator. The plastic substrate (e.g., the LCP) material may be molded around the first and second unitary sheet metal dipole elements to hold the two unitary sheet metal dipole elements in their proper positions. The plastic substrate material may exhibit low losses at high frequencies, and hence the radiating elements according to embodiments of the present invention may exhibit reduced insertion losses. Moreover, the plastic substrate material may have a dielectric constant (e.g., a dielectric constant between 2 and 5 in example embodiments) that is significantly higher than the dielectric constant of air (a dielectric constant of 1). Hence, compared to metal dipole radiators that are self-supporting, the radiating elements according to embodiments of the present invention — which may have plastic substrate material surrounding much or even all of the metal radiators - may have reduced size. Moreover, when compared to dipole radiators that are formed on PCBs (which typically only have a dielectric substrate on one side of the dipole radiators), the radiating elements according to embodiments of the present invention may have similar or even reduced size, and may be less expensive to implement since they can be implemented using low-cost sheet metal and molded plastic. Moreover, while it is possible to implement dipole radiators using PCB technology where the metal dipole radiators are implemented between two dielectric substrates in order toAttorney Docket No. 1534.7461.WOreduce the length of the dipole arms, this further increases the cost of the radiating element and is prohibitively expensive in most applications. Thus, the radiating elements according to embodiments of the present invention may exhibit reduced cost and / or reduced size as compared to many conventional radiating element designs.

[0046] In an example embodiment, each unitary sheet metal dipole element of the metal radiator may comprise a dipole arm and a feed line. The greater the extent to which the plastic substrate material is formed around each dipole arm, the more the size of the dipole arm can be reduced. The same is true with respect to the feed lines. Thus, in some embodiments, each unitary sheet metal dipole element may be (at least partially) embedded in the plastic substrate (e.g., using over-molding techniques) which allows the size of the radiating elements to be reduced, thereby miniaturizing the antenna array. In some embodiments, a first molding process may be used to form the individual radiating elements (e g., dipole radiating elements), comprising the radiators (each comprising, for example, the first and second unitary sheet metal dipole elements) and first plastic substrates, and then a second molding process may be used to form a unitary array of multiple radiating elements that are held together by a second plastic substrate. Providing unitary arrays of radiating elements may simplify mounting the radiating elements in an access point, base station antenna or the like. Aspects of the inventive concepts will now be described more fully with reference to the accompanying drawings, in which example embodiments are shown.

[0047] To reduce the signal loss at high(er) frequencies, compared to, for example, FR-4 PCB material, embodiments of the present inventive concepts provide radiating elements (e.g., dipole radiating elements) that use (moldable) plastic materials, such as LCPs, as a substrate material. The radiating elements according to embodiments of the inventive concepts may be used in wireless access points, base station antennas and the like. In some embodiments, a plurality of the radiating elements according to embodiments of the present invention may be formed into one or more unitary antenna arrays that each include a plurality of the radiating elements.

[0048] FIG. 1 A is a schematic perspective view of an antenna array 100 according to embodiments of the present invention. FIG. IB is a cross-sectional view, which is taken along a line A-A' in FIG. 1A. The antenna array 100 may be used, for example, in a Wi-Fi access point, but is not limited thereto.Attorney Docket No. 1534.7461.WO

[0049] Referring to FIGS. 1 A and IB, the antenna array 100 may, for example, be mounted on a main printed circuit board 120 of a wireless access point. While FIGS. 1 A and IB illustrate a case where the antenna array 100 is part of a wireless access point, it will be appreciated that embodiments of the present invention are not limited thereto. For example, in other embodiments, the radiating elements and / or antenna arrays disclosed herein may be used in other applications such as in base station antennas. In base station antenna embodiments, the antenna array 100 (or individual ones of the radiating elements included in the antenna array 100) would typically extend forwardly from a feedboard printed circuit board and / or from a reflector.

[0050] The antenna array 100 comprises a plurality of (dipole) radiating elements 140 that each have a (dipole) radiator 142 that is positioned forwardly of the main printed circuit board 120, and one or more first (molded) plastic substrates 160 that extend around (e g., at least partially surrounding or enclosing) the radiating elements 140. In some embodiments, the first plastic substrate 160 may be configured to hold the plurality of radiating elements 140 in a spaced-apart relationship. The radiating elements 140 may, for example, be directly mounted on the main printed circuit board 120. In example embodiments, the radiator 142 may be sheet metal radiator such as a dipole radiator or a patch radiator or may be a metal wire radiator such as a dipole or helical wire radiator, but it will be appreciated that embodiments of the present invention are not limited thereto. In some embodiments, the radiator 142 may comprise a pair of unitary sheet metal dipole elements 142 (collectively referred to as the radiator 142).

[0051] The radiating elements 140 may be arranged and spaced apart from each other in a first direction DI and a second direction D2. For example, the radiating elements 140 may be arranged in rows and columns, as shown. Although the radiating elements 140 in FIG. 1A are arranged in a 4><3 matrix, the number of radiating elements 140 and the arrangement thereof may vary. The first direction DI and the second direction D2 may intersect each other. The first direction DI and the second direction D2 may be perpendicular to each other. In some embodiments, the first direction DI and the second direction D2 may each be parallel to an upper surface of the main printed circuit board 120. In the depicted embodiment, the radiating elements 140 are arranged in perfect rows and columns. It will be appreciated, however, that embodiments of the inventive concepts are not limited thereto. For example, the radiatingAttorney Docket No. 1534.7461.WOelements 140 adjacent columns and / or rows may be staggered to increase the distance between radiating elements 140 in adjacent columns and / or rows.

[0052] Each of the radiating elements 140 may be mounted to extend forwardly from (the front surface of) the main printed circuit board 120. For example, each of the radiating elements 140 may protrude from the front surface of the main printed circuit board 120 in a third direction D3. The third direction D3 may be perpendicular to both the first direction DI and the second direction D2. In some embodiments, the third direction D3 may be perpendicular to the front surface of the main printed circuit board 120. It should be noted that herein the surface of the main printed circuit board 120 on which the radiating elements is mounted is referred to the "front" surface for convenience. It will be appreciated that Wi-Fi access points, base station antennas and other wireless communication systems that use the radiating elements according to embodiments of the inventive concepts may be mounted in many different orientations, and hence the "front" surface of the main printed circuit board 120 may be an upper surface, a lower surface or the like when the antenna array 100 is mounted for use.

[0053] In some embodiments, the radiating elements 140 may be electrically and / or mechanically connected to the main printed circuit board 120. For example, the main printed circuit board 120 may include a plurality of slots (e.g., recesses or openings) arranged and spaced apart from each other in the first direction DI and the second direction D2 according to the predetermined arrangements and distances. The radiating elements 140 may be positioned (inserted) in respective pairs of the slots. In some embodiments, a portion (e g., a lower portion) of each radiating element 140 may be inserted in (the respective slot of) the main printed circuit board 120. In some embodiments, once the radiating elements 140 are inserted into the slots in the main printed circuit board 120, solder joints may be applied that electrically connect the radiating elements 140 to the main printed circuit board 120 and that mechanically hold the radiating elements 140 in place on the main printed circuit board 120.

[0054] In some embodiments, each of the radiating elements 140 may comprise (at least) first and second unitary sheet metal dipole elements 142 (which may collectively referred to herein as a radiator 142). The first and second unitary sheet metal dipole elements 142 may be spaced apart from each other at a predetermined distance in a direction (e.g., the first direction DI). In some embodiments, the first and second unitary sheet metal dipole elements 142 may beAttorney Docket No. 1534.7461.WOarranged to have a mirror-image symmetric shape to each other in the direction (e.g., the first direction DI).

[0055] Each of the radiating elements 140 may further include a first plastic substrate 144 that is interposed between the pair of the unitary sheet metal dipole elements 142 (in the first direction DI). The first plastic substrate 144 may comprise a molded plastic substrate. In a cross-sectional view, the first plastic substrate 144 may have a T-shape in example embodiments.

[0056] In some embodiments, the radiating elements 140 may be arranged and spaced apart from each other in the second direction D2 to form an antenna array (corresponding to an antenna array 400 described later with respect to FIGS. 4B and 4C). A plurality of the antenna arrays 400 may be arranged in the first direction DI on the main printed circuit board 120. A second plastic substrate 160 may extend around (e.g., at least partially surround or enclose) a plurality of radiating elements 140 to form an antenna array. The second plastic substrate 160 may also be a molded plastic substrate in some embodiments. In cross-sectional view, the second plastic substrate 160 may have a T-shape. For example, each of the radiating elements 140 may be (at least partially) disposed in the respective first plastic substrate 160.

[0057] In some embodiments, the first plastic substrates 144 and / or the second plastic substrates 160 may comprise a LCP and may be formed by molding. LCP is a type of thermoplastic material that can be used in low-cost and high-volume electronics. LCP may have stable electrical and thermal properties. In some embodiments, LCP may have a dielectric constant (Dk) value of about 3 and a loss tangent (Df) value of about 0.002 at frequencies in the 6 GHz frequency band (5.15-7.125 GHz). The thermal coefficient expansion (CTE) of LCP may be, for example, as low as 8-17x 106 / K. However, the embodiments of the properties of the (moldable) plastic materials are not limited to the above. Herein, the first plastic substrates 144 and the second plastic substrates 160 may be referred to as a "LCP substrates" when formed of an LCP.

[0058] In some embodiments, the second plastic substrate 160 may be on (e.g., at least partially cover or overlap in the third direction D3) front surfaces of the respective radiating elements 140. However, embodiments of the second plastic substrate 160 are not limited thereto. For example, a front surface of the second plastic substrate 160 may be coplanar with the front surfaces of the respective radiating elements 140, so that or the front surfaces of the respective radiating elements 140 may be exposed (i.e., not covered by) the second plastic substrate 160.Attorney Docket No. 1534.7461.WOAs used herein, "an element A overlapping an element B in a direction X" (or similar language) means that there is at least one line that extends in the direction X and intersects both the elements A and B.

[0059] FIG. 2 is a perspective view illustrating a unitary sheet metal dipole element 142 according to certain embodiments of the present invention.

[0060] Referring to FIG. 2, the unitary sheet metal dipole element 142 may include a dipole arm 142a and a feed line 1421. As shown, the dipole arm 142a may be a planar element that extends in the first direction DI and the second direction D2 in some embodiments. It will be appreciated, however, that the dipole arm 142a may be angled upwardly or downwardly so that the base of the dipole arm 142a (i.e., the portion of the unitary sheet metal dipole element 142 that connects to the feed line 1421) is at a different distance from the main printed circuit board (FIGS. 1 A-1B) in the third direction D3. In a plan view, the dipole arm 142a may have various shapes, such as a circle, an oval, an ellipse, and polygon, but not limited thereto. The feed line 1421 may extend from the dipole arm 142a in the third direction D3. For example, the feed line 1421 may extend rearwardly from the dipole arm 142a toward the main printed circuit board 120.

[0061] The dipole arm 142a may be connected to the feed line 1421 to form a unitary structure (the unitary sheet metal dipole element 142). Herein, a unitary structure (e.g., the unitary sheet metal dipole element 142) may refer to a structure (e.g., a continuum) without a (visible) boundary between its sub-structures (e.g., the dipole arm 142a and the feed line 1421) formed by a same process or a same series of processes. For example, the unitary sheet metal dipole element 142, including the dipole arm 142a and the feed line 1421, may be formed from a single piece of metal, such as aluminum. The dipole arm 142a and the feed line 1421 may be formed by a same process (e.g., a single metal stamping process) or a same series of processes (e.g., multiple metal stamping and / or bending processes).

[0062] FIG. 3 is a perspective view illustrating the dipole radiating element 140 according to embodiments of the present invention. FIG. 4A is a perspective view illustrating a plurality of dipole radiating elements 140 according to embodiments of the present invention. FIGS. 4B and 4C are front and rear perspective views illustrating an antenna array 400 according to embodiments of the present invention. FIG. 5 is a flow chart 500 of a method for manufacturing an antenna array according to embodiments of the present invention.Attorney Docket No. 1534.7461.WO

[0063] Referring to FIG. 3, the radiating element 140 may include a radiator 142 that comprises (at least) first and second unitary sheet metal dipole elements 142. While the depicted radiating element 140 includes a pair of the unitary sheet metal dipole elements 142, it will be appreciated that more than two unitary sheet metal dipole elements 142 may be included in each radiating element 140. For example, a cross-dipole radiating element may include four unitary sheet metal dipole elements 142. It will also be appreciated that the radiating element may comprise radiators other than dipole radiators. For example, the radiator 142 may be a helical metal wire radiator, as discussed in further detail below with respect to FIG. 8.

[0064] As shown in FIG. 3, the first and second unitary sheet metal dipole elements 142 may be arranged and spaced apart from each other at a predetermined distance in a direction (e.g., the first direction DI). The first and second unitary sheet metal dipole elements 142 may be adjacent each other in the direction (e.g., the first direction DI). The first plastic substrate 144 may be configured to hold the first and second unitary sheet metal dipole elements 142 adjacent each other. For example, the first and second unitary sheet metal dipole elements 142 may be arranged to have a mirror-image symmetric shape to each other in the direction (e.g., the first direction DI).

[0065] In some embodiments, the dipole arm 142a and the feed line 1421 of each unitary sheet metal dipole element 142 may be formed by a same process or a same series of processes. For example, the unitary sheet metal dipole element 142, including the dipole arm 142a and the feed line 1421, may comprise a single piece of metal, such as aluminum, and may be formed by a single metal stamping / bending process or multiple metal stamping / bending processes (Block S520 of the flow chart 500 in FIG. 5).

[0066] The radiating element 140 further includes the first (molded) plastic substrate 144 that is positioned in between the pair of the unitary sheet metal dipole elements 142 (in the first direction DI). In some embodiments, the first plastic substrate 144 may include a first part 144a that is adjacent the dipole arms 142a and a second part 1441 that is adjacent the feed lines 1421. In some embodiments, the second part 1441 may extend in the third direction D3 from the first part 144a. For example, the second part 1441 may extend rearwardly (between the respective feed stalks 1421) from the first part 144a toward the main printed circuit board 120. The first part 144a and the second part 1441 may be connected to each other to form a unitary structure (the first plastic substrate 144). As noted above, in some embodiments, the first plastic substrateAttorney Docket No. 1534.7461.WO144 may comprise a liquid crystal polymer (LCP). In some embodiments, the second part 1441 and the respective feed lines 1421 may form an RF transmission line for the radiating element 140. The second part 1441 and the respective feed lines 1421 therefore may together form a feed stalk of the radiating element 140.

[0067] The radiating element 140 may be formed by molding (e.g., injecting) the LCP between the pair of the unitary sheet metal dipole elements 142 to form the first plastic substrate 144 between the pair of the unitary sheet metal dipole elements 142 (Block S540 of the flow chart 500 in FIG. 5). For example, the first part 144a and the second part 1441 of the first plastic substrate 144 may be formed by a same process or a same series of processes.

[0068] The first plastic substrate 144 may be configured to hold the first and second unitary sheet metal dipole elements 142 in place. For example, the feed line 1421 of each unitary sheet metal dipole element 142 may extend through a respective opening of the first plastic substrate 144. If the radiating element includes more than two unitary sheet metal dipole elements 142, the first plastic substrate 144 may be configured to hold all of the unitary sheet metal dipole elements 142 in place in example embodiments. In some embodiments, the first part 144a of the first plastic substrate 144 may extend around (e.g., at least partially surround or enclose) at least a portion of each of the feed lines 1421 of the unitary sheet metal dipole elements 142. For example, the first plastic substrate 144 (e.g., the dielectric arm 144a) may extend around (e.g., at least partially surround or enclose) at least a portion of each of the first and second unitary sheet metal dipole elements 142. The first plastic substrate 144 may be configured to hold the first and second unitary sheet metal dipole elements 142 in place in a spaced apart relationship from each other at a predetermined distance in a direction (e.g., the first direction DI).

[0069] The first parts 144a of the first plastic substrates 144 may be configured to support at least a portion of each of the dipole arms 142a of respective ones of the plurality of the unitary sheet metal dipole elements 142 (e.g., the pair of the unitary sheet metal dipole elements 142) in some embodiments. In some embodiments, the first part 144a may overlap the dipole arms 142a in the third direction D3. For example, the dipole arms 142a may be on (a front surface of) the first part 144a. In other words, the first part 144a of the first plastic substrate 144 may be mounted behind (on the rear surfaces of) the dipole arms 142a. In some embodiments, the first part 144a may cover at least a portion of each of the rear surfaces of the dipole armsAttorney Docket No. 1534.7461.WO142a. However, the relative positions of the dipole arms 142a and the first part 144a of the first plastic substrate 144 are not limited to the above. For example, the first part 144a may alternatively or additionally be mounted forwardly of the dipole arms 142a. The first part 144a may extend around (e.g., at least partially surround or enclose) at least a portion of each of the dipole arms 142a of the unitary sheet metal dipole elements 142 (e.g., the pair of the unitary sheet metal dipole elements 142). The first part 144a may overlap the dipole arms 142a in the first direction DI and / or the second direction D2. In some embodiments, at least portions of the dipole arms 142a may be completely surrounded by the first part 144a so that the at least portions of the dipole arms 142a are at least partially embedded within the first plastic substrate 144. In some embodiments, at least a portion of each of the front surfaces of the dipole arms 142a may be exposed without the first part 144a thereon. In some embodiments, (a portion of) the first plastic substrate 144 (e.g., the first part 144a) may be on (e.g., at least partially cover or overlap) the front surfaces of the dipole arms 142a. The first plastic substrate 144 (e.g., the first part 144a) may extend around (e.g., at least partially surround or enclose) the feed lines 1421 of respective ones of the unitary sheet metal dipole elements 142.

[0070] The second part 1441 of the first plastic substrate 144 may extend along the (respective) feed line(s) 1421. For example, the second part 1441 may extend in the third direction D3 from the first part 144a. In some embodiments, the second part 1441 may be positioned between the feed lines 1421 of the first and second unitary sheet metal dipole elements 142 (in the first direction DI). In some embodiments, a length of each feed line 1421 in a direction (e.g., the third direction D3) may be greater than a length of the second part 1441 in the direction. For example, ends (e.g., lower ends) of the feed lines 1421 may be exposed from the second part 1441. In other words, the ends of the feed lines 1421 may not be on (e.g., covered or overlapped by) the first plastic substrate 144.

[0071] The (moldable) plastic material that is used to form the first plastic substrate 144 may have a Dk value greater than that of air. In some embodiments, the Dk value of the plastic material may be less than that of a regular FR-4 material. For example, the Dk value of the plastic material (in the operating frequency range or at the center frequency of the operating frequency range of the antenna array 400) may be less than the Dk values of the regular FR-4 material in the main printed circuit board 120 at the same frequency. For example, the Dk value of the plastic material in the operating frequency range or at the center frequency of the operatingAttorney Docket No. 1534.7461.WOfrequency range of the antenna array 400 may be between (about) 1.0 and (about) 4.3. In certain embodiments, the Dk value of the plastic material in the operating frequency range or at the center frequency of the operating frequency range of the antenna array 400 may be between 2.5 and 3.5.

[0072] The plastic material of the first plastic substrate 144 may have a Df value less than that of the regular FR-4 material in the operating frequency range or at the center frequency of the operating frequency range of the antenna array 400. In some embodiments, the Df value of the plastic material may be less than (about) 0.02 in the operating frequency range or at the center frequency of the operating frequency range of the antenna array 400. For example, the Df value of the plastic material may be (about) 0.005 or less or even (about) 0.002 or less at the relevant frequency. For example, the plastic material in the first plastic substrate 144 may be LCP. However, the embodiments of the properties of the plastic material are not limited to the above.

[0073] Referring to FIGS. 4A, 4B, 4C, and 5, a plurality of the radiating elements 140 may be arranged and spaced apart from each other in the second direction D2 to form the antenna array 400.

[0074] The antenna array 400 includes a plurality of the radiating elements 140 and a second (molded) plastic substrate 160, which is used to hold the radiating elements 140 in place. For example, the second plastic substrate 160 may be formed between (may extend around or at least partially surround) adjacent ones of the plurality of radiating elements 140. The second plastic substrate 160 may be configured to hold and separate the radiating elements 140 apart from each other at a predetermined distance. In some embodiments, the second plastic substrate 160 may include a first part 160a and a second part 1601. In some embodiments, the second part 1601 may extend in the third direction D3 from the first part 160a. For example, the second part 1601 may extend rearwardly from the first part 160a toward the main printed circuit board 120. The first part 160a and the second part 1601 may be connected to each other to form a unitary structure (the second plastic substrate 160). In some embodiments, the second plastic substrate 160 may comprise a liquid crystal polymer (LCP).

[0075] The antenna array 400 may be formed by molding (e.g., injecting) the LCP among the plurality of radiating elements 140 to form the second plastic substrate 160 (Block S560 of the flow chart 500 in FIG. 5). For example, the first part 160a and the second part 1601Attorney Docket No. 1534.7461.WOof the second plastic substrate 160 may be formed by a same process or a same series of processes.

[0076] The second plastic substrate 160, comprising the first part 160a and the second part 1601, may be configured to hold the plurality of radiating elements 140. In some embodiments, the first part 160a may be configured to support the dipole arms 142a and the first parts 144a of the first plastic substrates 144, and the second part 1601 may be configured to hold the feed lines 1421 and the second parts 1441 of the first plastic substrates 144. In some embodiments, the first part 160a and the second part 1601 may extend around (e.g., at least partially surround or enclose) at least a portion of each of the dipole arms 142a of the plurality of radiating elements 140 and / or at least a portion of each of the feed lines 1421 of the plurality of radiating elements 140.

[0077] In some embodiments, (a portion of) the second plastic substrate 160 (e.g., the first part 160a) may be on (e.g., at least partially cover or overlap) the front surfaces of the dipole arms 142a. In some embodiments, each of the dipole arms 142a of the plurality of radiating elements 140 may be completely within (enclosed by) the first part 160a of the second plastic substrate 160. In some embodiments, the second plastic substrate 160 may completely cover the first plastic substrates 144. For example, the second plastic substrate 160 may be in direct contact with each first plastic substrate 144. In some embodiments, the first parts 144a of each first plastic substrate 144 may be completely within (enclosed by) the first part 160a of the second plastic substrate 160. For example, the first part 160a may be on (e.g., at least partially cover or overlap in the third direction D3) the dipole arms 142a and the first parts 144a of the first plastic substrates 144. For example, the dipole arms 142a may be on (an upper surface of) the first part 160a. However, the embodiments of the relative positions of the dipole arms 142a, the first parts 144a of the first dielectric substrates, and the first part 160a of the first plastic substrate 160 are not limited to the above. For example, the first part 160a may overlap the dipole arms 142a and / or the first parts 144a in the first direction DI and / or the second direction D2. In some embodiments, at least portions of the dipole arms 142a and the first parts 144a may be disposed in the first part 160a of the second plastic substrate 160.

[0078] The second part 1601 of the second plastic substrate 160 may extend along the second parts 1441 of the first plastic substrates 144 and the feed lines 1421. For example, the second part 1601 may extend in the third direction D3 from the first part 160a. In someAttorney Docket No. 1534.7461.WOembodiments, a length of each feed line 1421 in a direction (e.g., the third direction D3) may be greater than that of the second part 1601. For example, an end (e.g., a lower end) of each feed line 1421 may be exposed from the second part 1601 of the second plastic substrate 160. In other words, the ends of the feed lines 1421 may not be on (e.g., covered or overlapped by) the second part 1601 of the second plastic substrate 160.

[0079] The (moldable) plastic material in the second plastic substrate 160 may have a Dk value greater than that of air (at the high(er) frequency in the broadened operating bandwidth of antenna array 400). In some embodiments, the Dk value of the plastic material may be less than that of a regular FR-4PC material (within the operating bandwidth of antenna array 400). For example, the Dk value of the LCP in the second plastic substrate 160 may be less than that of the regular FR-4 material in the main printed circuit board 120 (at the higher frequency in the broadened operating bandwidth of antenna array 400).

[0080] The plastic material in the second plastic substrate 160 may have a Df value less than that of the regular FR-4 material (in the operating bandwidth or at the center frequency of the operating bandwidth of antenna array 400). For example, the Df value of the LCP in the second plastic substrate 160 may be less than that of the regular FR-4 material in the main printed circuit board 120. In some embodiments, the Df value of the plastic material may be less than (about) 0.02. For example, the Df value of the plastic material may be (about) 0.005 or less or even (about) 0.002 or less. For example, the plastic material in the second plastic substrate 160 may be LCP. However, the properties of the plastic material are not limited to the above.

[0081] In some embodiments, a plurality of the antenna arrays 400 may be arranged and spaced apart from each other in a direction (e.g., the first direction DI) on the main printed circuit board 120. For example, the plurality of the antenna arrays 400 may be (electrically) connected to the main printed circuit board 120. The plurality of the antenna arrays 400 may be positioned (inserted) in the plurality of slots (e.g., recesses or openings) of the main printed circuit board 120. In some embodiments, a portion (e.g., the exposed ends of the feed lines 1421) may be inserted in (the slots of) the main printed circuit board 120. Referring back to FIGS. 1 A and IB, the antenna array 100 may be formed by inserting the plurality of the antenna arrays 400 in the slots of the main printed circuit board 120.

[0082] FIGS. 6A, 6B, 6C, and 6D are views illustrating an antenna array 600 according to further embodiments of the present invention. In the description of the followingAttorney Docket No. 1534.7461.WOembodiments, descriptions overlapping those described above with reference to FIGS. 1 A, IB, 2, 3, 4A, 4B, and 4C may be omitted.

[0083] The antenna array 600 may include a plurality of radiating elements 640, which comprises radiators 642 and first plastic substrates 644. The antenna array 600 may, for example, be mounted on the main printed circuit board 620 of a wireless access point. The antenna array 600 may further comprise a second plastic substrate 660 extending around the plurality of radiating elements 640. The antenna array 600, antenna array the radiating elements 640, the radiators 642 (comprising dipole arms 642a and feed lines 6421), the first plastic substrates 644 (comprising first parts 644a and second part 6441), and the second plastic substrate 660 (comprising first parts 660a and second parts 6601) may respectively correspond to the antenna array 100, the radiating elements 140, the radiators 142, the first plastic substrates 144, and the second plastic substrate 160 (comprising first parts 160a and second parts 1601) described above with reference to FIGS. 1A, IB, 2, 3, 4A, 4B, and 4C.

[0084] In some embodiments, the plurality of radiating elements 640 may be arranged in a direction (e.g., the second direction D2). In addition, the dipole arm 642a of the radiator 642 (e.g., unitary sheet metal dipole element 642) may have a shape elongated in the same direction (e.g., the second direction D2). Referring to FIG. 6B, the second plastic substrate 660 may extend along the contour of (the front surfaces of) the radiators 642 (e.g., the dipole arms 642a). The antenna array 600 may be formed by the same or (substantially) similar processes forming the antenna array 100, including forming the radiators via stamping the unitary sheet metal dipole elements and molding plastic substrates extending around the unitary sheet metal dipole elements. However, the shapes, relative locations, and the arrangements of the radiating elements 640, the radiators 642, the first plastic substrates 644, and the second plastic substrate 660 are not limited to the embodiments described above.

[0085] FIGS. 7A, 7B, 7C, and 7D are views illustrating an antenna array 700 according to additional embodiments of the present invention. In the description of the following embodiments, descriptions overlapping those described above with reference to FIGS. 1A, IB, 2, 3, 4A, 4B, and 4C may be omitted.

[0086] The antenna array 700 may include a plurality of radiating elements 740, which comprises radiators 742 and first plastic substrates 744. The radiating elements 740 are mounted on a printed circuit board 720, which may be, for example, a main printed circuit board of aAttorney Docket No. 1534.7461.WOwireless access point. The antenna array 700 may further comprise a second plastic substrate 760 extending around the plurality of radiating elements 740. The antenna array 700, the radiating elements 740, the radiators 742 (comprising dipole arms 742a and feed lines 7421), the first plastic substrates 744 (comprising first parts 744a and second parts 7441), and the second plastic substrate 760 (comprising first parts 760a and second parts 7601) may respectively correspond to the antenna array 100, the radiating elements 140, the radiators 142 (comprising dipole arms 142a and feed lines 1421), the first plastic substrates 144, and the second plastic substrate 160 described above with reference to FIGS. 1A, IB, 2, 3, 4A, 4B, and 4C.

[0087] In some embodiments, the radiating elements 740 may be arranged in a direction. For example, the radiating elements 740 may be arranged in the second direction D2. In addition, the dipole arm 742a of the radiator 742 (e.g., unitary sheet metal dipole element 742) may have a shape elongated in a direction that intersects the direction in which the plurality of radiating elements 740 are arranged. For example, the dipole arm 742a may have a shape elongated in the first direction DI. Referring to FIG. 7B, the second plastic substrate 760 may extend along the contour of (the front surfaces of) the radiators 742 (e.g., the dipole arms 742a). The antenna array 700 may be formed by the same or (substantially) similar processes forming the antenna array 100, including forming the radiators via stamping the unitary sheet metal dipole elements and molding plastic substrates extending around the unitary sheet metal dipole elements. However, the shapes, relative locations, and the arrangements of the radiating elements 740, the radiators 742, the first plastic substrates 744, and the second plastic substrate 760 are not limited to the embodiments described above.

[0088] FIG. 8 is a perspective view illustrating an antenna array800 according to still further embodiments of the present invention. In the description of the following embodiments, descriptions overlapping those described above with reference to FIGS. 1A, IB, 2, 3, 4A, 4B, and 4C may be omitted.

[0089] Referring to FIG. 8, the antenna array 800 may include a plurality of radiating elements 840, where each radiating element 840 comprises a radiator (not visible in FIG. 8) and a first plastic substrate 844. The radiator (not visible) may comprise a metal wire or sheet metal that is bent into a helical shape and may have the same shape as the first plastic substrates 844 shown in FIG. 8. A respective first plastic substrate 844 may be conformally formed on each radiator so that each first plastic substrate 844 and its corresponding radiator have the sameAttorney Docket No. 1534.7461.WOshape, with each first plastic substrate 844 enclosing its associated radiator. The first plastic substrates 844 may have a dielectric constant that is greater than 1.0 and hence may allow the size of the helical radiators to be reduced as compared to helical radiators that are implemented as metal wires that are surrounded by air. A second plastic substrate 860 may be provided that, for example, interconnects end portions of the first plastic substrates 844. This may ensure that a desired spacing between the helical radiators is maintained. The first plastic substrates 844 and the second plastic substrate may be formed in different operations or in a single operation.

[0090] The antenna array 800 may be formed by the same or (substantially) similar processes forming the antenna array 100, including forming the radiators via metal stamping and / or metal bending and molding plastic substrates extending around the radiators. However, the shapes, relative locations, and the arrangements of the radiating elements 840, the radiators, and first and second plastic substrates 844, 860 are different, as shown in FIG. 8.

[0091] The embodiments of the present inventive concepts may include using a metal stamping process to form radiators (e.g., unitary sheet metal dipole elements) and an LCP molding process to hold and arrange them. The metal stamping process may be relatively inexpensive compared to a conventional printed circuit board method for the radiating elements, especially when a lower Dk value material is needed. The LCP molding process may be relatively inexpensive, more productive, and more readily available than a soldering (e.g., a hand soldering) method for holding and arranging the radiating elements on the conventional printed circuit board.

[0092] To use the metal stamping process and the LCP molding method, three (3) manufacturing tools may be needed. The first manufacturing tool may be a sheet metal tool used to stamp and form unitary sheet metal dipole elements into the desired geometry. The second manufacturing tool may be used to mold LCP around the plurality of (e g., two) unitary sheet metal dipole elements to create the radiating element. In this tool, the plurality of unitary sheet metal dipole elements may be secured and positioned precisely relative to each other before LCP is injected into the tool. Once LCP solidifies, it locks the plurality of unitary sheet metal dipole elements together. The third tool may be a larger injection molding tool than the second tool. The third tool may combine the plurality of radiating elements by injecting LCP. Once LCP cools and solidifies in this third tool, the plurality of radiating elements may have both theAttorney Docket No. 1534.7461.WOsubstrate material and the mechanical support to keep them in the precise location in an antenna array.

[0093] Assembly of the antenna array on a conventional printed circuit board can be expensive. In particular, the horizontally placed antenna arrays on the vertical transmission lines may require hand soldering with precision. The LCP molding process may eliminate the need for hand soldering and provide the benefits of precision and simplicity in the antenna array placement.

[0094] While embodiments of the present invention have been described primarily with reference to antennas and antenna arrays in access points for wireless local area networks, it will be appreciated that the techniques described herein may be implemented in other electronic devices. For example, in other embodiments, the devices described above may comprise antennas and antenna arrays in base stations.

[0095] Embodiments of the present invention have been described above with reference to the accompanying drawings, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers may refer to like elements throughout unless described otherwise or clearly implied otherwise based on the contexts.

[0096] The terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting of the disclosure. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and / or "comprising," when used in this specification, specify the presence of stated operations, elements, and / or components, but do not preclude the presence or addition of one or more other operations, elements, components, and / or groups thereof. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. Like reference numbers signify like elements throughout the description of the figures.

[0097] It will be understood that when an element is referred to as being "on," "coupled to" or "connected to" another element, the element may be formed directly on, coupled to or connected to the other element, or there may be one or more intervening elements therebetween.Attorney Docket No. 1534.7461.WO

[0098] Terms such as "top," "bottom," "upper," "lower," "above," "below," and the like are used herein to describe the relative positions of elements or features. For example, when an upper part of a drawing is referred to as a "top" and a lower part of a drawing is referred to as a "bottom" for the sake of convenience, in practice, the "top" may also be called a "bottom" and the "bottom" may also be a "top" without departing from the teachings of the inventive concept.

[0099] It will be understood that, although the terms "first," "second," etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. Thus, a first element could be termed a second element without departing from the teachings of the inventive concept.

[0100] Aspects and elements of all of the embodiments disclosed above can be combined in any way and / or combination with aspects or elements of other embodiments to provide a plurality of additional embodiments.

[0101] The description of the present disclosure has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the disclosure in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the disclosure. The aspects of the disclosure herein were chosen and described in order to best explain the principles of the disclosure and the practical application, and to enable others of ordinary skill in the art to understand the disclosure with various modifications as are suited to the particular use contemplated.

Claims

1. Attorney Docket No. 1534.7461.WOWHAT TS CLAIMED TS:

1. A radiating element, comprising:a sheet metal or metal wire radiator; anda first molded plastic substrate that at least partially surrounds the sheet metal or metal wire radiator.

2. The radiating element of Claim 1, wherein the sheet metal or metal wire radiator is a sheet metal dipole radiator that comprises:a first unitary sheet metal dipole element that comprises a first dipole arm and a first feed line; anda second unitary sheet metal dipole element that comprises a second dipole arm and a second feed line.

3. The radiating element of Claim 2, wherein at least a portion of the first molded plastic substrate extends in between the first feed line and the second feed line.

4. The radiating element of Claim 3, wherein the first feed line, the second feed line and the first molded plastic substrate form a feed stalk for the radiating element.

5. The radiating element of any of Claims 2-4, wherein the first molded plastic substrate is configured to hold the first unitary sheet metal dipole element and the second unitary sheet metal dipole element together.

6. The radiating element of Claim 5, wherein the first molded plastic substrate is configured to space the first unitary sheet metal dipole element apart from and the second unitary sheet metal dipole element at a predetermined distance.

7. The radiating element of any of Claims 1-4, wherein the first molded plastic substrate comprises a first molded liquid crystal polymer substrate.Attorney Docket No. 1534.7461.WO8. The radiating element of any of Claims 2-4, wherein the first molded plastic substrate covers at least a portion of a rear side of the first dipole arm and at least a portion of a rear side of the second dipole arm, and the first molded plastic substrate comprises a first part that is mounted behind the first and second dipole arms and a second part that extends rearwardly from the first part between the first and second feed lines.

9. The radiating element of any of Claims 2-4, further comprising a second molded plastic substrate that covers at least a portion of a front side of the first dipole arm and at least a portion of a front side of the second dipole arm.

10. The radiating element of any of Claims 2-4, wherein the first feed line extends through a first opening in the first molded plastic substrate and the second feed line extends through a second opening in the first molded plastic substrate.

11. The radiating element of any of Claims 1-4, wherein the sheet metal or metal wire radiator comprises at least one helical metal wire radiator.

12. The radiating element of any of Claims 1-4, wherein the radiating element is a first radiating element and is provided in combination with a second radiating element according to Claim 1 and a second molded plastic substrate that at least partially surrounds both the first and second radiating elements.

13. The radiating element of Claim 12, wherein the first molded plastic substrate and the second molded plastic substrate comprise a same material.

14. The radiating element of Claim 13, wherein the first molded plastic substrate and the second molded plastic substrate comprise respective first and second molded liquid crystal polymer substrates.

15. The radiating element of Claim 13, wherein the first and second radiating elements comprise respective first and second sheet metal dipole radiators that each comprise:Attorney Docket No. 1534.7461.WOa first unitary sheet metal dipole element that comprises a first dipole arm and a first feed line; anda second unitary sheet metal dipole element that comprises a second dipole arm and a second feed line.

16. The radiating element of Claim 13, wherein the second molded plastic substrate completely covers the first molded plastic substrate.

17. An antenna array, comprising:a plurality of dipole radiating elements that each comprise a first unitary sheet metal dipole element, a second unitary sheet metal dipole element, and a first molded plastic substrate that is configured to hold the first unitary sheet metal dipole element in place adjacent the second unitary sheet metal dipole element; anda second molded plastic substrate that at least partially surrounds each of the plurality of dipole radiating elements and directly contacts the first molded plastic substrate of each of the plurality of dipole radiating elements.

18. The antenna array of Claim 17, wherein each first unitary sheet metal dipole element comprises a first dipole arm and a first feed line, and each second unitary sheet metal dipole element comprises a second dipole arm and a second feed line.

19. The antenna array of Claim 18, wherein each first molded plastic substrate comprises a first liquid crystal polymer substrate that is between the first feed line and the second feed line and that is configured to support the first dipole arm and the second dipole arm of a respective one of the plurality of dipole radiating elements.

20. The antenna array of any of Claims 17-19, wherein the second molded plastic substrate comprises a second liquid crystal polymer substrate that is configured to hold the plurality of dipole radiating elements in a spaced-apart relationship.Attorney Docket No. 1534.7461.WO21. The antenna array of Claim 19, wherein each first liquid crystal polymer substrate comprises a first part that is mounted behind the first and second dipole arms and a second part that extends rearwardly from the first part between the first and second feed lines.

22. The antenna array of any of Claims 17-19, wherein the antenna array is mounted to extend forwardly from a main printed circuit board of a Wi-Fi access point.

23. The antenna array of any of Claim 17-19, wherein each first molded plastic substrate has a T-shaped cross-section.

24. A method of forming a radiating element, the method comprising:forming a sheet metal radiator via stamping;placing the sheet metal radiator in a mold and molding a first plastic substrate to at least partially surround the sheet metal radiator to form the radiating element.

25. The method of Claim 24, wherein the sheet metal radiator is a sheet metal dipole radiator that comprises:a first unitary sheet metal dipole element that comprises a first dipole arm and a first feed line; anda second unitary sheet metal dipole element that comprises a second dipole arm and a second feed line.

26. The method of Claim 25, wherein at least a portion of the first plastic substrate extends in between the first feed line and the second feed line.

27. The method of any of Claims 25 or 26, wherein the first plastic substrate is configured to hold the first unitary sheet metal dipole element and the second unitary sheet metal dipole element together and spaces the first and second feed lines apart by a predetermined distance.Attorney Docket No. 1534.7461.WO28. The method of Claim 27, wherein the first plastic substrate covers at least a portion of a rear side of the first dipole arm and at least a portion of a rear side of the second dipole arm, andwherein the first plastic substrate comprises a first part that is mounted behind the first and second dipole arms and a second part that extends rearwardly from the first part between the first and second feed lines.

29. The method of Claim 25, wherein the first feed line extends through a first opening in the first plastic substrate and the second feed line extends through a second opening in the first plastic substrate.

30. The method of any of Claims 24-26, wherein the radiating element is a first radiating element, the method further comprising forming a second radiating element by:forming a second sheet metal radiator via stamping; andplacing the second sheet metal radiator in the mold and molding a second plastic substrate to at least partially surround the second sheet metal radiator.

31. The method of Claim 30, further comprising forming an antenna array by placing the first and second radiating elements in a second mold and molding a third plastic substrate to at least partially surround the first and second radiating elements.

32. The method of Claim 31, wherein the first and second radiating elements comprise respective first and second sheet metal dipole radiators that each comprise:a first unitary sheet metal dipole element that comprises a first dipole arm and a first feed line; anda second unitary sheet metal dipole element that comprises a second dipole arm and a second feed line.

Images