Antenna Device Terminal Mounting via Segmented Base
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Solution Overview
Problem
Existing antenna device manufacturing methods require complex molds and high-cost materials, particularly due to the need for insert-molding and high-heat-resistant resins, which increase production costs and complexity.
Innovation Solution
The antenna device features a magnetic core with a terminal attachment unit, a coil wound around it, and terminal members that are easily mounted without insert-molding, using a configuration with a flange unit and terminal holes, allowing for the use of lower heat-resistant materials and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If insert-molding is employed to form the plate-shaped mother metal and resin base integrally, then the terminal member can be mounted on the base, but the mold becomes complicated and the cost increases
Solution Approach 1:
The invention divides the base into two separate components: a resin base and a plate-shaped mother metal. The resin base is formed by injection molding without insert-molding, and the plate-shaped mother metal is attached separately to the resin base. This segmentation eliminates the need for complex insert-molding processes while achieving the same functional result of mounting terminal members.
Solution Approach 2:
The plate-shaped mother metal is prepared in advance and then attached to the resin base after the resin base is formed. This preliminary preparation allows the resin base to be molded using a simple mold without the complexity of insert-molding, while still enabling subsequent terminal member mounting through the attached plate-shaped mother metal.
2Ease of manufacture
If a plate-shaped mother metal is formed by pressing or the like before insert-molding, then the terminal member can be mounted, but a lot of portions are cut off and become useless, causing material waste
Solution Approach 1:
The invention separates the resin base formation from the plate-shaped mother metal attachment. The resin base is molded first using injection molding, and then the plate-shaped mother metal is attached to it. This allows the plate-shaped mother metal to be formed separately with minimal material waste, as it can be cut to the exact required shape without the constraints of pre-forming for insert-molding.
3Ease of manufacture
If the plate-shaped mother metal is set in the inside of the mold for injection-molding, then the terminal member can be mounted, but measures must be taken to block the filled resin, making the mold more complicated
Solution Approach 1:
The invention extracts the plate-shaped mother metal from the injection-molding process. Instead of setting it inside the mold for co-molding, the resin base is molded first without the plate-shaped mother metal. After the resin base is formed, the plate-shaped mother metal is attached to it in a separate process. This extraction eliminates the need for complex blocking measures in the mold while achieving the same functional result.
4Reliability
If high-heat-resistant resin is used for the base to endure the reflow furnace temperature, then the electronic component can be soldered, but the cost of the resin increases
Solution Approach 1:
The invention applies different heat resistance requirements to different parts of the structure. The resin base only needs to withstand the injection-molding temperature, which is relatively low. The plate-shaped mother metal, which is attached to the resin base, provides the heat-resistant surface that endures the reflow furnace temperature during soldering. This local differentiation of material properties allows the use of low-cost resin for the base while still achieving the required heat resistance for soldering.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for cost-effective and simplified manufacturing of antenna devices by eliminating the need for complex molds and high-heat-resistant resins, while ensuring reliable electrical connections and component mounting.
Implementation Method 1
a coil which is arranged on the outer circumferential side of the core and concurrently, which is formed by winding a conductive wire
Data Source
AI summary
An antenna device including: a core formed by magnetic material; a terminal attachment unit arranged on one end side of the core; a coil which is arranged on the outer circumferential side of the core and concurrently, which is formed by winding a conductive wire; a plurality of terminal members which are mounted on the terminal attachment unit and concurrently, each of which is electrically connected with a terminal of the conductive wire or an electronic component at any position thereof; a connector connecting unit provided with a connector hole into which an external connector is inserted; and a partition unit partitioning the terminal attachment unit and the connector connecting unit, wherein a terminal hole is provided at the partition unit, and at least two or more of the terminal members are plugged-in into the terminal hole and concurrently, are mounted in a state of protruding toward the connector hole.