Antenna Carrier Through-Hole Structure for Defect-Free Earbud Molding
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Solution Overview
Problem
During double injection molding of dielectric materials in ear-wearable electronic devices, gas accumulation and stagnant flow can lead to structural defects such as weld lines on the external appearance.
Innovation Solution
Incorporating a second through hole and a groove structure on the antenna carrier to facilitate the flow of dielectric material, preventing stagnation and ensuring smooth injection, while maintaining wireless signal quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dielectric material is injected onto an antenna carrier through double injection molding, then the antenna carrier is encapsulated and protected, but gas accumulates and the dielectric material flow becomes stagnant causing structural defects
Solution Approach 1:
The antenna carrier is divided into multiple segments with through-holes created in the carrier structure. This segmentation allows the dielectric material to flow through multiple pathways during injection molding, preventing stagnant flow and gas accumulation that would otherwise cause weld lines and surface defects.
Solution Approach 2:
The through-holes act as intermediary channels that facilitate the flow of dielectric material between the injection point and the encapsulation area. These channels serve as mediators that guide the material flow, ensuring complete filling without gas entrapment or flow stagnation.
2Manufacturing precision
If the dielectric material flows smoothly during injection molding, then gas is discharged and structural defects are prevented, but the antenna carrier structure becomes more complex
Solution Approach 1:
The antenna carrier incorporates a porous structure with through-holes that enable dielectric material penetration. This porous design facilitates smooth material flow and gas discharge while maintaining structural integrity, achieving surface quality improvement without excessive complexity.
3Ease of manufacture
If through-holes are added to the antenna carrier to improve material flow, then gas discharge is enhanced and defects are prevented, but the antenna carrier design becomes more complicated
Solution Approach 1:
The antenna carrier is segmented with strategically positioned through-holes that divide the injection pathway into multiple channels. This segmentation simplifies the injection molding process by preventing material stagnation and gas accumulation, making manufacturing easier despite the added structural elements.
Data Source
AI summary
An electronic device includes a first housing connected to a second housing having a protrusion configured to be seated on an ear. The electronic device also includes a printed circuit board, a wireless communication circuit, an antenna carrier disposed in internal space defined by the first housing and the second housing. The electronic device also includes a conductive pattern formed over the first surface and the second surface through a first through hole and electrically connected to the wireless communication circuit. The antenna carrier includes a first surface, a second surface opposite to the first surface, and through holes passing through the antenna carrier. The antenna carrier also includes a groove structure including a portion in contact with a second through hole and formed on the second surface of the antenna carrier. The wireless communication circuit transmits and/or receives a wireless signal by providing power to the conductive pattern.