Ceramic Antenna Via Structure for Simpler Sidewall Metallization
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Solution Overview
Problem
The manufacturing process of ceramic antennas with vertical metal sidewalls is complex and expensive due to the need for multiple steps of metal plating, which complicates mass production.
Innovation Solution
Replace vertical metal sidewalls with multiple conductive vias that couple the top and bottom metals of the ceramic carrier, simplifying the manufacturing process and reducing costs while maintaining radiation performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vertical metal sidewalls are used in ceramic antennas, then radiation performance is achieved, but manufacturing complexity and cost increase due to multiple metal plating steps
Solution Approach 1:
The patent extracts the essential function of vertical metal sidewalls (providing radiation performance) and removes the complex manufacturing process (multiple metal plating steps). Instead, conductive vias are used to achieve the same electromagnetic radiation effect through a simpler single-step plating process, thereby eliminating manufacturing complexity while preserving radiation performance.
Solution Approach 2:
The patent changes the structural parameter from continuous vertical sidewalls to discrete conductive vias. This parameter change maintains the electromagnetic radiation function while significantly simplifying the manufacturing process, as the via structure can be created in a single plating step rather than requiring multiple sequential plating operations.
2Reliability
If vertical metal sidewalls are used in ceramic antennas, then radiation performance is achieved, but production cost increases due to multiple metal plating steps
Solution Approach 1:
The patent removes the expensive multiple metal plating steps while extracting only the essential radiation function. The conductive via approach achieves the same electromagnetic performance with a single plating step, directly reducing production cost while maintaining radiation performance.
Solution Approach 2:
The patent employs a simpler, more cost-effective structure (conductive vias) that can be manufactured in a single plating step, replacing the expensive and time-consuming vertical sidewall structure. This approach uses a more economical manufacturing method that reduces both material and process costs.
3Reliability
If vertical metal sidewalls are used in ceramic antennas, then radiation performance is achieved, but mass production is complicated
Solution Approach 1:
The patent extracts the radiation function from the complex vertical sidewall structure and implements it through simple conductive vias. This simplification enables more efficient mass production by eliminating multiple sequential plating steps, thereby improving productivity while maintaining radiation performance.
Solution Approach 2:
The patent changes the structural parameter from continuous sidewalls to discrete vias, which fundamentally simplifies the manufacturing process. This parameter change enables streamlined mass production with fewer process steps, directly improving productivity and manufacturing efficiency.
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 use of conductive vias achieves similar radiation performance metrics as traditional vertical sidewalls, reducing production costs and complexity without compromising antenna efficiency.
Implementation Method 1
Antennas can be used to facilitate wireless communication between devices. It can be desirable for antennas to operate with a high antenna radiation efficiency to improve wireless communication between devices.
Data Source
AI summary
An antenna assembly is provided. The antenna assembly includes a ceramic carrier having a first surface and a second surface, the second surface being opposite the first surface. The antenna assembly further includes an antenna pattern. The antenna pattern includes a first antenna portion positioned at least partially on the first surface of the ceramic carrier. The antenna pattern further includes a second antenna portion comprising a plurality of conductive vias extending through the ceramic carrier from the first antenna portion to the second surface of the ceramic carrier.


