Chip Antenna Thick Connection Terminals for Coil Winding Space
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Solution Overview
Problem
Manufacturing solenoid-type chip antennas faces challenges in securing sufficient space for winding the coil, as they require a specific configuration that is difficult to achieve with existing methods.
Innovation Solution
The solution involves using connection terminals with a thickness greater than the coil's winding thickness, which are formed by bending metal plates and press-fitted to the core, allowing for efficient winding and electrical connection of the coil, and applying a protection resin to insulate and protect the coil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If connection terminals with thickness greater than coil winding thickness are used, then sufficient space for coil winding is secured and electrical connection is improved, but manufacturing complexity increases
Solution Approach 1:
The connection terminal utilizes the thickness dimension (z-axis) by extending beyond the coil winding thickness, creating vertical space for reliable electrical connection while maintaining a compact planar footprint. This dimensional approach resolves the space constraint without increasing lateral complexity.
Solution Approach 2:
The connection terminal is divided into distinct functional segments: a first terminal portion for electrical connection extending beyond the coil thickness, and a second terminal portion for mechanical support within the substrate plane. This segmentation allows each portion to optimize its specific function independently.
2Reliability
If connection terminals are formed by bending metal plates and press-fitted to core, then electrical connection and mechanical stability are enhanced, but manufacturing process complexity increases
Solution Approach 1:
The connection terminal is pre-formed by bending the metal plate into the required configuration before press-fitting it to the core. This preliminary shaping ensures precise geometric accuracy and facilitates reliable electrical connection without requiring complex post-assembly operations.
Solution Approach 2:
The traditional multi-step electrical connection process is replaced by a simple press-fitting mechanical operation. The bent metal plate structure inherently provides both mechanical support and electrical connection through a single pressing action, eliminating the need for separate soldering or bonding steps.
3Reliability
If coil is wound around core with proper spacing, then performance is improved, but available winding space is reduced
Solution Approach 1:
The connection terminal extends in the thickness direction (z-axis) beyond the coil winding, providing the necessary electrical connection length without encroaching on the lateral winding space. This vertical extension resolves the conflict between connection requirements and winding space availability.
Solution Approach 2:
The connection terminal exhibits non-uniform thickness distribution: it is thicker at the regions contacting the core to ensure stable electrical connection, and thinner in the regions adjacent to the coil to maximize winding space. This localized quality variation optimizes both connection reliability and winding capacity.
Data Source
AI summary
A chip antenna and a method of manufacturing the same are provided. A chip antenna includes connection terminals disposed on both ends of a core, and a coil wound around the core and having ends thereof connected to the connection terminals, in which the connection terminals include a metal plate, and at least a portion of the connection terminals has a thickness greater than a winding thickness of the coil.