Wireless Communication Card Antenna Interference Mitigation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Metal-based wireless communication cards face issues with electrical interference affecting antenna operation and manufacturing complexity, leading to restrictions in RF functions and aesthetics.
Innovation Solution
A wireless communication card design that incorporates an antenna inlay layer, insulating layer, and PVC insert within a Chip-On-Board accommodation space to block electrical interference and improve manufacturing efficiency, using a metal sheet with a stainless steel material and heat treatment for durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a metal sheet is used to create a wireless communication card, then the card has aesthetic appeal and weight characteristics of metal, but electrical interference occurs between the antenna and metal material causing abnormal operation
Solution Approach 1:
An insulating layer is introduced as an intermediary between the antenna and the metal sheet. This insulating layer prevents electrical interference while allowing the metal sheet to maintain its aesthetic appearance and weight characteristics. The insulating layer acts as a mediator that enables both the antenna to function properly and the metal to provide its desired visual and tactile properties.
2Ease of manufacture
If traditional manufacturing methods are used for metal cards, then the process is simple, but it is difficult to form patterns and characters on the surface and ensures normal information storage
Solution Approach 1:
The card is divided into multiple functional layers including the metal sheet layer, insulating layer, antenna layer, and PVC insert layer with COB accommodation space. This segmentation allows each layer to be manufactured and processed independently with appropriate precision, while the overall assembly maintains manufacturing efficiency. The PVC insert specifically addresses the need for precise pattern formation and information storage capabilities.
3Quantity of substance
If the metal card uses thin metal sheet or metal powder coating, then the manufacturing cost is reduced, but it makes it difficult to form patterns and characters on the surface
Solution Approach 1:
The metal sheet is used selectively in specific areas where aesthetic appearance and weight are desired, rather than covering the entire card surface. The PVC insert with COB accommodation space is introduced in areas requiring precise pattern formation and information storage capabilities. This local quality approach allows each material to be used where it provides the most benefit.
4Reliability
If a PVC insert with COB accommodation space is added to block electrical interference, then information storage and processing is ensured, but the device complexity increases
Solution Approach 1:
The PVC insert serves multiple functions simultaneously: it provides electrical insulation between the antenna and metal sheet, creates the COB accommodation space for information storage, and supports the overall card structure. This multi-functionality reduces the need for separate components, thereby limiting the increase in device complexity while ensuring reliable information storage and processing.
Data Source
AI summary
In a wireless communication card and a manufacturing method thereof according to an embodiment of the present invention, the method comprises the steps of: processing an antenna inlay layer including an antenna coil; stacking a first overlay layer that covers a top surface of the antenna inlay layer; processing a PVC insert inserted in a chip-on-board (COB) accommodation space, which is formed by milling a specific area of the first overlay layer, and provided with an accommodation groove in which a lower portion of a pad of the COB is supported; passing both ends of the antenna coil drawn out from the antenna inlay layer through the PVC insert, and connecting the antenna coil to contact areas of the COB; and mounting the COB in the PVC insert inserted in the COB accommodation space.