Antenna Case Rib Design for Load Distribution
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Solution Overview
Problem
Existing antenna devices face challenges in enhancing load-bearing capability without increasing the resin amount, leading to higher weight and manufacturing costs, particularly when subjected to heavy loads.
Innovation Solution
The antenna device incorporates a resin-made antenna case with ribs formed on the upper surface and side surfaces, which are continuously extended to improve strength and distribute loads efficiently, while minimizing the resin usage by allowing the rib ends to contact an external member and distributing the load effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of the antenna case is increased to improve load bearing capability, then the load bearing capability is improved, but the resin amount increases leading to increased weight and manufacturing cost
Solution Approach 1:
The antenna case is segmented by adding ribs that divide the case into multiple structural zones. These ribs create a framework structure that distributes mechanical loads across different regions, allowing the case to bear heavy loads without requiring uniform thickness increase throughout the entire case, thus reducing overall resin consumption.
Solution Approach 2:
Instead of uniformly increasing the thickness of the entire antenna case, ribs are strategically positioned at specific locations where load bearing is most critical. This localized reinforcement approach provides enhanced strength exactly where needed while maintaining thinner walls in non-critical areas, optimizing the balance between load bearing capability and resin usage.
2Strength
If the thickness of the antenna case is increased to improve load bearing capability, then the load bearing capability is improved, but the weight of the antenna case increases
Solution Approach 1:
The case structure is segmented into thin-walled sections connected by reinforcing ribs, creating a lightweight framework. This segmentation allows the case to achieve high load bearing capability through structural design rather than mass, significantly reducing the overall weight compared to a uniformly thick case while maintaining strength.
Solution Approach 2:
Ribs are placed only at locations requiring additional strength, creating local quality variations in the case structure. This ensures that material is concentrated where it provides maximum structural benefit, minimizing unnecessary weight in areas where full thickness is not required for load bearing.
3Strength
If the thickness of the antenna case is increased to improve load bearing capability, then the load bearing capability is improved, but the manufacturing cost increases
Solution Approach 1:
The case design with integrated ribs can be manufactured as a single molded piece, segmenting the structural function but not the manufacturing process. This approach maintains ease of manufacture through conventional injection molding while achieving enhanced load bearing capability, avoiding the need for multiple assembly steps that would increase manufacturing cost.
Solution Approach 2:
The rib structures are designed with varying thicknesses and positions optimized for specific load conditions, allowing the case to be manufactured in a single molding operation with localized material distribution. This eliminates the need for post-manufacturing reinforcement additions, keeping manufacturing processes simple and costs low while achieving superior load bearing performance.
Data Source
AI summary
An antenna device is provided that includes an antenna coil, a resin-made antenna case having a body that accommodates the antenna coil, and a rib disposed on an upper surface of the body and on a pair of opposing side surfaces. In the antenna case, the rib is continuously formed from one of the side surfaces, across the upper surface, to the other one of the side surfaces, and both ends of the rib are formed to be flush with a lower surface of the body or so as to extend downward from the lower surface of the body. In addition, both ends of the rib are designed to come into contact with an external member when the antenna device is mounted on the external member.