Tyre Antenna Coating Method for Uniform Conduction
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Solution Overview
Problem
The existing methods for manufacturing helical antennas for electronic devices, particularly those used in tires, face challenges in controlling the coating thickness and composition of brass-coated antennas, leading to high production costs and inefficiencies due to the skin effect and complex geometry.
Innovation Solution
A method involving coating a steel core in a filiform shape with a pure metal like copper before plastic deformation, followed by additional layers for chemical insulation and adhesion, allows for uniform and efficient coating, reducing production time and costs while enhancing the antenna's endurance and adhesion to rubber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the core is coated after plastic deformation to give helical shape, then the coating can be applied to the final antenna shape, but the coating thickness and composition are difficult to control especially inside each turn, leading to long production time and high cost
Solution Approach 1:
The core is coated with conduction layer and chemical insulation layer before plastic deformation to helical shape. This preliminary coating action allows uniform coating application on the straight filiform core, avoiding the complexity of coating after deformation. The coating is then deformed together with the core, maintaining layer integrity while achieving the desired helical antenna shape with controlled coating thickness.
2Reliability
If a brass alloy coating is used to provide both conduction and chemical insulation, then the antenna can function properly, but the exact composition is difficult to control and requires precise regulation of deposition parameters, increasing manufacturing complexity
Solution Approach 1:
The coating is divided into two separate functional layers: a conduction layer made of substantially pure metal (copper, silver, or aluminum) for electromagnetic signal conduction, and a chemical insulation layer made of zinc, nickel, or tin for chemical isolation from rubber. This segmentation allows each layer to be optimized independently for its specific function, eliminating the complexity of controlling alloy composition while ensuring reliable antenna functionality.
3Reliability
If the conduction layer is made of substantially pure metal, then the conduction performance is improved, but the chemical reactions with rubber could damage the tire, requiring additional insulation layers
Solution Approach 1:
A chemical insulation layer consisting of zinc, nickel, or tin is introduced as an intermediary between the conduction layer (pure copper, silver, or aluminum) and the rubber matrix. This intermediary layer prevents direct chemical reactions between the pure metal conduction layer and the rubber, eliminating harmful effects while preserving the excellent conduction performance of the pure metal layer.
4Reliability
If multiple coating layers are applied to provide conduction and chemical insulation functions, then the antenna performance and durability are improved, but the coating process becomes more complex and time-consuming
Solution Approach 1:
The coating process utilizes parameter changes by applying the conduction layer and chemical insulation layer in sequence before plastic deformation, rather than attempting to apply multiple functional layers after deformation. This approach changes the temporal parameters of the coating process, allowing faster coating application on the straight core followed by a single deformation step, thereby improving productivity while maintaining antenna durability.
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 method results in a robust, cost-effective antenna with improved conduction performance and endurance against stresses, enabling faster manufacturing and better integration into tire rubber while preventing chemical reactions that could damage the tire.
Implementation Method 1
the electromagnetic conduction for such an antenna is carried out mainly by a skin effect
Implementation Method 2
the coating step is carried out in an electrolytic bath
Implementation Method 3
at least a portion of the coated core is plastically deformed
Data Source
Figure 1~11
Figure 3~8
AI summary
During the course of the method of manufacturing an antenna (12) comprising a core (18), the antenna being intended to be integrated into a mass of rubber of a tyre, the core is covered in thread-like manner (18) with a covering (20, 22, 24; 26, 28) made from a material different from the material of the core (18). Subsequent to the covering step, at least a portion of the covered core (18) is deformed plastically.