Antenna Pattern Through-Hole Formation for Precise Line Spacing
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Solution Overview
Problem
Conventional manufacturing methods for wireless power transmission/reception antennas struggle to precisely form line spacing or line width as the antenna thickness increases, leading to reduced charging efficiency and potential heat generation issues.
Innovation Solution
A method involving a punching process to form a first half groove and an etching process to form a second half groove, allowing for the creation of a through hole that precisely defines the line spacing, using a metal sheet with a thickness of 70 μm or more, and applying a rust-resistant film to the surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the thickness of the antenna is increased to suppress heat generation, then heat generation suppression is improved, but the manufacturing precision of line spacing and line width deteriorates
Solution Approach 1:
The through hole formation process is segmented into two distinct stages: first, a punching process creates a first half groove from one surface of the metal sheet; second, an etching process creates a second half groove from the opposite surface. These two grooves meet to form the complete through hole. This segmentation allows each process to be optimized independently, achieving both precise dimensional control and effective heat suppression with thicker antennas.
2Ease of manufacture
If conventional manufacturing methods are used, then manufacturing simplicity is maintained, but the precision of line spacing and line width formation deteriorates when antenna thickness increases
Solution Approach 1:
The punching process performs a preliminary action by creating the first half groove that defines part of the through hole geometry before the etching process begins. This preliminary structuring allows the subsequent etching process to complete the through hole with precise dimensional control, achieving both manufacturing simplicity and high precision line spacing formation.
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
The method reduces the line spacing and line width by about 50% compared to conventional methods, enabling the production of antennas with line spacing of 80% to 120% of the metal sheet thickness, enhancing design freedom and performance optimization.
Implementation Method 1
punching a second surface of the metal sheet facing the first surface to form a first half groove recessed in an inward direction of the metal sheet from the second surface of the metal sheet
Implementation Method 2
half-etching the first surface of the metal sheet to form a second half groove recessed in an inward direction of the metal sheet from the first surface of the metal sheet
Implementation Method 3
surface-treating the first surface of the metal sheet in which the second half groove is formed, wherein the surface-treating of the first surface of the metal sheet may include forming a rust-resisting film on the first surface of the metal sheet
Data Source
AI summary
The present disclosure presents an antenna pattern manufacturing method which, by forming a through hole in a metal sheet via a punching and an etching process, enables the precise formation of the line spacing of an antenna pattern. The presented antenna pattern manufacturing method comprises forming a first half groove in one surface of a metal sheet via a punching process and a second half groove in the other surface of the metal sheet via an etching process, wherein the first half groove and the second half groove at least partially overlap to form a through hole penetrating through the metal sheet.