Electroplated Antenna Structure Without PCB Assembly
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Solution Overview
Problem
The existing antenna manufacturing process is costly and complex, requiring multiple components and labor-intensive assembly, which increases production time and error rates.
Innovation Solution
An antenna with an integrally formed plastic main body structure, where a radiation layer and power distribution layer are electroplated directly onto the main body, eliminating the need for a PCB and simplifying assembly, and incorporating a guide sheet and filtering structure for enhanced radiation and frequency adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a PCB is used as the base structure for the antenna, then the antenna can be manufactured with separate components, but the manufacturing cost increases and the overall structure becomes complex
Solution Approach 1:
The patent combines the base structure, radiation element, and guiding structure into a single integrally formed plastic component through injection molding. This merging eliminates the need for separate PCB, plastic supporting structure, and guide sheet components, thereby reducing manufacturing cost and simplifying the overall structure while maintaining ease of manufacture.
Solution Approach 2:
The integrally formed plastic structure serves multiple functions simultaneously: it provides the base structure, supports the radiation element, guides the electromagnetic wave, and provides mechanical strength. This multi-functionality eliminates the need for separate specialized components, reducing both complexity and manufacturing cost.
2Adaptability or versatility
If multiple separate components (PCB, plastic supporting structure, guide sheet, filtering structure) are assembled to form the antenna, then each component can be optimized independently, but the assembly process requires large amounts of working hours and increases production time
Solution Approach 1:
The patent merges the base structure, radiation element, and guiding structure into a single integrally formed component. This eliminates the need for assembling multiple separate components, thereby dramatically reducing production time and increasing productivity while maintaining the ability to optimize the overall structure design.
Solution Approach 2:
The guiding structure and radiation element are pre-integrated into the base structure through injection molding before final assembly. This preliminary integration ensures proper positioning and alignment are built-in during molding, eliminating the need for time-consuming post-assembly adjustments and optimizations.
3Reliability
If multiple separate components are assembled to form the antenna, then each component can be manufactured with specific functions, but the overall assembly becomes complex and prone to manufacturing errors
Solution Approach 1:
The patent combines the base structure, radiation element, and guiding structure into a single integrally formed component. This merging eliminates the interfaces and connections between separate components, thereby reducing assembly complexity and potential error points while maintaining reliable electromagnetic wave guidance and radiation functions through integrated design.
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 reduces manufacturing costs, simplifies the antenna structure, minimizes manual errors, and enhances radiation performance by integrating key components through electroplating and injection molding, resulting in a more efficient and cost-effective production process.
Implementation Method 1
a radiation layer (20), and the radiation layer is electroplated on the first surface (11)... the power distribution layer (30) feeds the radiation layer (20)
Implementation Method 2
a radiation layer (20), and the radiation layer is electroplated on the first surface (11); and a power distribution layer (30), and the power distribution layer is electroplated on the first surface (11)
Data Source
AI summary
The present disclosure provides an antenna. The antenna includes: a main body structure having a first surface, wherein the main body structure is formed by placing a reflective metal plate in a mold and performing injection molding, and the main body structure is of an integrally formed structure; a radiation layer, wherein the radiation layer is electroplated on the first surface; and a power distribution layer, wherein the power distribution layer is electroplated on the first surface, the power distribution layer is electrically connected to the radiation layer, and the power distribution layer feeds the radiation layer.