Antenna for Communication Terminal Using Segmented Radiator Layer
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Solution Overview
Problem
Existing methods for manufacturing antennas for communication terminals, such as in-mold injection and Laser Direct Structuring, face challenges with low mechanical strength and high defective rates when forming antennas on the curved surfaces of communication terminal cases, particularly due to high manufacturing costs.
Innovation Solution
A method involving a radiator layer made of metal material formed on the inner curved surface of a communication terminal case, with a magnetic layer composed of magnetic material powder and binder resin, and adhesive layers for bonding, allowing the antenna to be securely attached and enhancing performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If in-mold injection technology or LDS technology is used to form antenna on curved surface, then antenna can be mounted on rear surface of communication terminal case, but manufacturing cost increases and mechanical strength decreases
Solution Approach 1:
The antenna structure is divided into separate components: a flexible substrate layer, conductor pattern, and magnetic shielding layer. These segmented layers are independently manufactured and then assembled together, allowing each layer to be optimized separately and reducing the complexity of forming conductors directly on curved surfaces.
Solution Approach 2:
The invention transitions from attempting to form conductors directly on the curved surface (2D constraint) to creating a multi-layer flexible structure that can conform to the curved surface (adding the Z-dimension). The flexible substrate allows the antenna to bend and adapt to the curved geometry without requiring direct formation on the curve.
2Ease of manufacture
If in-mold injection technology or LDS technology is used to form antenna on curved surface, then antenna can be mounted on rear surface of communication terminal case, but defective rate increases
Solution Approach 1:
By segmenting the antenna into separate manufacturable layers (substrate, conductor, magnetic layer) that are assembled rather than formed in-situ, the invention avoids the high defective rates associated with attempting to directly form conductors on curved surfaces using injection molding or LDS processes.
Solution Approach 2:
The flexible substrate acts as an intermediary carrier that allows the conductor pattern and magnetic layer to be manufactured separately under controlled conditions and then assembled together. This intermediary approach eliminates the need to perform complex formation processes directly on the curved surface, reducing defects.
3Ease of manufacture
If conventional antenna formation methods are used, then manufacturing process is simpler, but antenna cannot be formed on inner curved surface part of communication terminal case
Solution Approach 1:
The invention uses a flexible substrate (such as flexible PCB or thin film material) to carry the conductor pattern and magnetic layer. This flexible structure can be bent and conform to the inner curved surface of the communication terminal case, providing the needed adaptability while maintaining a relatively simple manufacturing process through layer-by-layer assembly.
Solution Approach 2:
The invention adds the dimension of flexibility by using a bendable substrate, allowing the antenna structure to adapt to curved surfaces without requiring complex curved-surface formation processes. This enables conventional manufacturing techniques to be used on flat layers that are then adapted to curved geometries.
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
The solution enables the formation of antennas on curved surfaces with improved mechanical strength, reduced size, increased bandwidth, and potential for wireless charging, while minimizing defects and manufacturing costs.
Implementation Method 1
a magnetic layer formed of a magnetic material composition containing a magnetic material powder and a binder resin
Implementation Method 2
a first adhesive material layer for bonding the radiator layer to the communication terminal case
Data Source
AI summary
Provided are an antenna for a communication terminal, and a method of manufacturing the same, the antenna including: a communication terminal case; and a radiator layer formed of a metal material in an inner curved surface part of the communication terminal case.