Protruding Dielectric Signal Element for Compact Component Carriers
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Solution Overview
Problem
Component carriers with electromagnetic functionalities face challenges in achieving optimal signal transmission and mechanical robustness while maintaining compactness and low height, especially in miniaturized devices, due to weak coupling between antenna components and the carrier, and increased height from surface-mounted components.
Innovation Solution
A component carrier with a dielectric signal element of higher permittivity protruding from an electrically insulating or conductive layer stack, surrounded by a surrounding material forming a discontinuous layer structure, enables efficient electromagnetic coupling and protection without increasing height, using established manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If externally assembled antenna components are mounted on the component carrier, then electromagnetic functionality is provided, but the coupling between antenna and carrier is weak due to landing pads and long feeding line distance
Solution Approach 1:
The antenna component and component carrier are merged into a single integrated structure where the dielectric signal element protrudes directly from the outermost layer of the stack, eliminating the need for separate mounting and feeding lines, thereby achieving strong electromagnetic coupling without increased distance
Solution Approach 2:
The signal element extends in the vertical dimension (z-direction) from the layer stack surface, creating a three-dimensional structure that reduces the effective coupling distance compared to planar surface-mounted components, improving electromagnetic interaction
2Reliability
If surface-mounted components are used to provide electromagnetic functionality, then antenna functionality is achieved, but the overall system height increases
Solution Approach 1:
The dielectric signal element is nested within or integrated with the existing layer stack structure, with the surrounding material forming a discontinuous layer that encapsulates the signal element without adding significant vertical height, achieving compact integration
3Reliability
If the signal element is surrounded by surrounding material forming a discontinuous layer structure, then the signal element is protected and electromagnetic coupling is improved, but manufacturing complexity increases
Solution Approach 1:
The surrounding material is applied selectively only in regions where protection and electromagnetic coupling enhancement are needed, forming a discontinuous layer structure rather than a complete encapsulation, thereby providing targeted functionality while minimizing manufacturing complexity
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 solution improves signal quality by reducing the distance for electromagnetic coupling and protects the signal element while maintaining a compact design, suitable for integration into existing production lines.
Implementation Method 1
The signal element comprises a dielectric material and comprises a permittivity that is different, in particular higher, than a permittivity of a medium that directly surrounds the at least one signal element
Data Source
Figure 1~4c
AI summary
There is described a component carrier (100), comprising: i) a stack (101) comprising at least one electrically insulating layer structure (102) and/or at least one electrically conductive layer structure (104); ii) at least one signal element (150), wherein the signal element (150) protrudes from the outermost layer structure (102, 104) of the stack (101); and iii) a surrounding material (140) arranged on the outermost layer structure (102, 104) of the stack (101) and at least partially surrounding the at least one signal element (150). The signal element (150) comprises a dielectric material and comprises a permittivity that is different, in particular higher, than a permittivity of a medium that directly surrounds the at least one signal element (150).