Injection Molded Case Antenna Pattern Integration

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Solution Overview

Problem

Conventional methods for forming antenna patterns in injection-molded cases of portable communication devices require two separate insert injection molding processes, increasing manufacturing costs and time due to the complexity of the process.

Innovation Solution

The formation of antenna patterns is achieved through a single insert injection molding process by fabricating antenna patterns with specific fixing holes and using an injection mold with guide rails and magnetic parts to secure the patterns during the molding process, eliminating the need for additional molds and processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If two separate insert injection molding processes are used to form antenna patterns in injection-molded cases, then the antenna patterns can be securely integrated, but the manufacturing process becomes complex and time-consuming

Engineering Contradiction:

Improveintegration accuracy of antenna patternsVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines two separate insert injection molding processes into a single integrated process. The antenna patterns are formed directly within the injection mold cavity during the same cycle that forms the case structure, eliminating the need for separate mounting operations. This merging of operations maintains secure integration while dramatically simplifying the manufacturing process.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The antenna patterns are formed as preliminary features directly within the injection mold cavity before the final case structure is completed. By pre-forming the antenna patterns as integral parts of the mold cavity, the patent eliminates subsequent mounting operations and ensures precise integration from the outset.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If two separate insert injection molding processes are used to form antenna patterns, then secure integration is achieved, but manufacturing time increases

Engineering Contradiction:

Improveintegration accuracy of antenna patternsVSAvoidmanufacturing time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent merges the antenna pattern formation and case structure manufacturing into a single injection molding cycle. Both operations occur simultaneously within the same mold cavity, eliminating the time required for separate mounting operations and reducing total manufacturing time while maintaining integration accuracy.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The injection molding process continues uninterrupted to form both the case structure and antenna patterns in a single continuous operation. The molten material flows continuously to form all features, eliminating idle time between separate operations and maximizing production efficiency.

Inventive Principle:

Principle #20Continuity of useful action

3Reliability

If additional insert injection molding processes are used, then antenna patterns can be securely mounted, but manufacturing costs increase due to additional molds and processes

Engineering Contradiction:

Improvemounting security of antenna patternsVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges antenna pattern formation with the main case structure manufacturing into a single injection molding process. This eliminates the need for additional molds, tooling, and mounting operations, significantly reducing manufacturing costs while ensuring secure integration of the antenna patterns as integral features.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The injection mold is designed to perform multiple functions simultaneously: forming the case structure, creating antenna patterns, and ensuring their secure integration all in one operation. This multi-functionality eliminates the need for separate dedicated molds and processes, reducing overall manufacturing cost.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 time and costs by simplifying the process to a single step, ensuring accurate and secure integration of antenna patterns within the injection-molded case.

Implementation Method 1

an injection mold with guide rails and magnetic parts to secure the patterns during the molding process

Methodology Applied

Scientific EffectMagnetic force: Magnetism

Data Source

PatentUS9199397B2Injection molded case having antenna pattern and manufacturing method thereof

Publication Date: 2015.12.01 SAMSUNG ELECTRONICS CO LTD

AI summary

An injection-molded case and a manufacturing method thereof having antenna patterns are formed in the injection-molded case by only one insert injection molding process, without a second insert injection molding process as required in the conventional manufacture. The injection-molded case preferably includes: one or more antenna patterns fabricated by a press process; and an injection-molded case part having the antenna patterns provided therewithin, which is fabricated by fixing the antenna patterns on an injection mold and carrying out only one insert injection molding process.