Non-penetrating RF coupling pad for conductive antenna body
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Solution Overview
Problem
The existing methods for connecting antennas or passive elements made of conductive polymeric compositions require additional steps and increase manufacturing complexity and cost due to the need for penetrating metallic elements, which is undesirable.
Innovation Solution
A non-penetrating coupling structure using a conductive pad with a shape corresponding to a predetermined area on the antenna body, positioned in non-penetrating contact, facilitating capacitive reactive impedance for electromagnetic energy transfer at radio frequencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metallic connecting element is inserted into the conductive polymeric body to achieve mechanical attachment and electrical connection, then reliable electrical connection is achieved, but manufacturing complexity and cost increase due to additional penetration steps
Solution Approach 1:
The invention extracts the metallic connecting element from the interior of the conductive polymeric body and relocates it to the exterior surface. The metallic element is positioned in a recess or depression on the surface, allowing electrical connection without penetrating through the body material. This eliminates the need for drilling, threading, or embedding operations while maintaining reliable electrical connection between the antenna and the device.
Solution Approach 2:
Instead of inserting the metallic element into the body from the interior (conventional approach), the invention inverts the approach by placing the metallic element on the exterior surface and having it contact the conductive polymeric body from the outside. This reversal of the connection direction simplifies manufacturing by eliminating penetration steps while achieving the same electrical connection function.
2Strength
If a metallic element is embedded into the conductive polymeric composition to connect the antenna, then mechanical attachment is achieved, but the number of manufacturing steps increases
Solution Approach 1:
The invention incorporates the metallic connecting element into the mold during the injection molding process itself, before the conductive polymeric material is injected. The metallic element is pre-positioned in the mold cavity, and the conductive polymeric material is then injected around it. This preliminary positioning eliminates subsequent assembly steps for attaching the metallic element, thereby improving manufacturing efficiency and productivity.
Solution Approach 2:
The invention merges the antenna body formation and the metallic element attachment into a single integrated manufacturing process. By incorporating the metallic element into the mold and injecting the conductive polymeric material around it in one operation, the patent combines what would traditionally be separate steps (forming the antenna body and then attaching the metallic element) into a single co-molding operation, thereby improving productivity.
3Strength
If drilling and threading operations are performed to insert metallic elements into the antenna body, then secure mechanical connection is achieved, but manufacturing cost increases
Solution Approach 1:
The invention replaces the mechanical drilling and threading operations with a mold-based insertion system. Instead of using drills and taps to create holes and threads in the antenna body after formation, the metallic element is positioned in a pre-formed recess or depression during the injection molding process. The conductive polymeric material is then injected around the metallic element, creating a mechanical interlock without requiring any post-forming machining operations, thereby reducing manufacturing cost.
Solution Approach 2:
The invention performs the function of creating the connection interface during the antenna body formation process itself. By incorporating the metallic element into the mold and forming the recess or depression simultaneously with the antenna body, the patent eliminates the need for subsequent drilling and threading operations. This preliminary creation of the connection interface during molding significantly reduces manufacturing cost by eliminating expensive post-processing steps.
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 reduces manufacturing complexity and cost by enabling efficient electromagnetic energy transfer between the antenna body and the conductive pad, maintaining a capacitive reactive impedance, thus effectively connecting devices without penetrating the antenna body.
Implementation Method 1
the pad is electrically coupled to the body through an impedance that is substantially capacitive reactive in nature, thereby facilitating the transfer of electromagnetic energy at the operating radio frequency between the body and the pad
Data Source
AI summary
A coupling structure for coupling a device operable at a radio frequency with a body is formed of a polymeric material loaded with a conductive filler. A portion of the surface of the body defines a coupling area of a predetermined shape that receives a conductive pad having a shape and area corresponding to the predetermined shape and coupling area. The conductive pad is positioned on the surface of the body in non-penetrating contact with the body such that, in use, the pad and the body have an impedance, substantially capacitively reactive in nature, defined therebetween that is less than the impedance of the body at the operating frequency, thereby facilitating the transfer of electromagnetic energy at the operating radio frequency between the body and the pad.