HOUSING COMPONENT OF A MOBILE TERMINAL

Abstract

A housing component for a mobile terminal such as a smartphone or a laptop computer, includes a carbon fiber reinforced plastic body that is operative to shield components within the housing from electromagnetic radiation. The housing component further includes at least one antenna window. The at least one antenna window is configured to be associated with at least one antenna of the terminal. The at least one antenna window enables the at least one antenna to transmit and receive electromagnetic signals without being shielded or interfering with the operation of the terminal circuitry within the housing.

Claims

1-11. (canceled)

12. Apparatus comprising: a housing component configured for use as part of a housing of a mobile terminal, wherein the mobile terminal is operative to at least one of send and receive electromagnetic signals, and includes at least one antenna, wherein the housing component comprises a body wherein the body is comprised of molded carbon fiber reinforced plastic, wherein the carbon fiber reinforced plastic is operative to substantially prevent electromagnetic radiation on a first side of the body that is configured to be on an external side of the terminal housing, from reaching a second side of the body configured to be on an internal side of the terminal housing, at least one antenna window, wherein the at least one antenna window comprises at least one of a window portion, wherein the window portion is comprised of a further plastic and is in fixed operative connection with the body, wherein the further plastic of the window portion does not prevent electromagnetic radiation on the first side from passing through the window portion, whereby the window portion is configured to enable the at least one antenna to be positioned at least one of within the window portion or in aligned relation with the window portion, and an electrically insulating connecting portion of the housing component, wherein the connecting portion is in fixed connection with the body and extends on the first side in intermediate insulating relation between the at least one antenna and the carbon fiber of the body, whereby the connecting portion is configured to enable the at least one antenna to be exposed to electromagnetic radiation on the first side.

13. The apparatus according to claim 12 wherein the housing component comprises both a window portion and an electrically insulating connecting portion, whereby the window portion is configured to enable a first antenna to at least one of send and receive electromagnetic signals, and the connecting portion is configured to enable a second antenna that is different from the first antenna and in fixed connection with the connecting portion, to at least one of send and receive electromagnetic signals.

14. The apparatus according to claim 12 wherein the at least one antenna window comprises a window portion, wherein the further plastic of the window portion comprises a fiber reinforced further plastic.

15. The apparatus according to claim 12 wherein the at least one antenna window comprises a window portion, wherein the further plastic of the window portion comprises a further fiber reinforced further plastic, wherein the housing component comprises the further fiber reinforced further plastic of the window portion and the molded carbon fiber reinforced plastic in fixed integrally molded connection.

16. The apparatus according to claim 12 wherein the at least one antenna window comprises a window portion, wherein the window portion comprises one of an interengaging projection or recess, and wherein a body portion of the body immediately adjacent to the window portion and comprised of carbon fiber reinforced plastic, includes the other of the projection or recess, wherein the projection and recess are in joined molded interengaged relation.

17. The apparatus according to claim 12 wherein the at least one antenna window comprises a window portion, wherein the window portion comprises one of an interengaging projection or recess, and wherein a body portion of the body immediately adjacent to the window portion and comprised of carbon fiber reinforced plastic, includes the other of the projection or recess, wherein the projection and recess are joined by interengagement of the projection and recess and by engagement with an overmold layer of plastic that extends across at least part of the body portion and at least part of the window portion.

18. The apparatus according to claim 12 wherein the at least one antenna window comprises a window portion, wherein a body portion of the body immediately adjacent to the window portion and comprised of carbon fiber reinforced plastic, is in abutting relation with the window portion, wherein the window portion and body portion are joined by engagement with an overmold layer of plastic that extends across at least part of the body portion and at least part of the window portion.

19. The apparatus according to claim 12 wherein the at least one antenna window comprises a window portion, wherein the window portion is in fixed connection with an immediately adjacent body portion of the body comprised of molded carbon fiber reinforced plastic, by one of the window portion or the body portion being in molded overlying relation of the other of the window portion or the body portion.

20. The apparatus according to claim 12 wherein the at least one antenna window comprises a window portion, wherein the window portion is in fixed outwardly overlying connection with an immediately adjacent body portion of the body comprised of molded carbon fiber reinforced plastic, wherein the window portion outwardly overlies the body portion on the first side.

21. The apparatus according to claim 12 wherein the at least one antenna window comprises a window portion, wherein the window portion is in fixed outwardly overlying connection with an immediately adjacent body portion of the body comprised of molded carbon fiber reinforced plastic, wherein the window portion outwardly overlies the body portion on the first side and has the at least one antenna embedded within the further plastic of the window portion.

22. The apparatus according to claim 12 wherein the at least one antenna window comprises a window portion, wherein the window portion is in fixed outwardly overlying connection with an immediately adjacent body portion of the body comprised of molded carbon fiber reinforced plastic, wherein the window portion outwardly overlies the body portion on the first side and has the at least one antenna embedded within the further plastic of the window portion, wherein the at least one antenna comprises a coil antenna comprised of carbon fiber.

23. The apparatus according to claim 12 wherein the at least one antenna window comprises a window portion, wherein the window portion is in fixed outwardly overlying connection with an immediately adjacent body portion of the body comprised of molded carbon fiber reinforced plastic, wherein the window portion outwardly overlies the body portion on the first side and has the at least one antenna embedded within the window portion, wherein the at least one antenna comprises a coil antenna comprised of carbon fiber, wherein the body portion comprises multi-axial carbon fabric, wherein carbon fiber ends of the coil antenna pass through the multi-axial carbon fabric.

24. The apparatus according to claim 12 wherein the at least one antenna window comprises an electrically insulating connecting portion, wherein the body comprises a recess that extends inwardly on the first side, wherein the electrically insulating connecting portion extends intermediate of the at least one antenna and the recess.

25. The apparatus according to claim 12 wherein the at least one antenna window comprises an electrically insulating connecting portion, wherein the body comprises a recess that extends inwardly on the first side, wherein a plastic overmold layer that extends in overlying relation of the recess includes the electrically insulating connecting portion.

26. The apparatus according to claim 12 wherein the at least one antenna window comprises an electrically insulating connecting portion, wherein the body comprises a recess, wherein a plastic overmold layer that extends on the first side in outwardly overlying relation of the recess includes the electrically insulating connecting portion, wherein the plastic overmold layer outwardly overlies the at least one antenna on the first side.

27. The apparatus according to claim 12 wherein the body comprises a plurality of layers of carbon fiber fabric, wherein the layers are bonded together by a thermoplastic material.

28. The apparatus according to claim 12 wherein the body comprises a plurality of layers of carbon fiber fabric, wherein each layer has a different bidirectional mesh density, wherein the layers are bonded together by a thermoplastic material.

29. The apparatus according to claim 12 wherein the body comprises a plurality of layers of carbon fiber fabric of different bidirectional mesh density, wherein a first layer comprises a carbon fiber fabric with 12,000 carbon fibers per woven strand, wherein a second layer comprises a carbon fiber fabric with 1000 carbon fibers per woven strand, wherein a third layer that extends intermediate of the first layer and the second layer comprises a carbon fiber fabric with 3000 carbon fibers per woven strand, wherein the plurality of layers are bonded together by a thermoplastic material.

30. The apparatus according to claim 12 wherein at least one of the further plastic and the electrically insulating connecting portion is comprised of glass fiber reinforced plastic.

31. The apparatus according to claim 12 wherein the body is comprised of at least one of a formed prepreg and a plurality of carbon fiber filaments coated with thermoplastic.

32. The apparatus according to claim 12 and further comprising: a circuit board, wherein the circuit board is positioned on the second side and is disposed away from the at least one antenna window.

33. Apparatus comprising: a housing component configured for use as part of a housing of a mobile terminal that includes at least one antenna that is usable to send and receive electromagnetic signals, wherein the housing component includes a body, wherein the body is comprised of molded carbon fiber reinforced plastic, wherein the carbon fiber reinforced plastic is operative to substantially prevent electromagnetic radiation from passing from a first side of the body that is configured to be on an external side of the terminal housing, from reaching the second side of the body that is configured to be on an internal side of the terminal housing, at least one antenna window, wherein the at least one antenna window comprises at least one of a window portion that is in fixed molded connection with the body and is comprised of a further plastic that does not prevent passage of the electromagnetic signals through the window portion, and an electrically insulating connecting portion that is in fixed molded connection with the body and extends on the first side and is configured to be in intermediate insulating relation between the at least one antenna and the carbon fiber of the body, whereby the at least one antenna is enabled to communicate electromagnetic signals while being embedded within or positioned in underlying aligned relation with the at least one window portion, or while being in insulated relation from the carbon fiber of the body by the electrically insulating connecting portion.

34. Apparatus comprising: a housing component configured for use as part of a housing of a mobile terminal, wherein the mobile terminal includes at least one antenna that is useable for sending and receiving electromagnetic signals, wherein the housing component comprises: a body, wherein the body includes a body portion comprised of molded carbon fiber reinforced plastic that is operative to substantially prevent electromagnetic radiation on a first side of the body portion that is configured to be on an external side of the terminal housing, from reaching a second side of the body portion which is configured to be internal side of the terminal housing, at least one antenna window, wherein the at least one antenna window is in fixed connection with the body portion and comprises at least one of a window portion comprised of a further plastic through which the electromagnetic signals may pass, and an electrically insulating connecting portion, that is configured to electrically insulate the at least one antenna from the carbon fiber.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0020] FIG. 1 is a back view of a molded part of a smartphone housing from the PRIOR ART, here as a one-piece mold of a housing shell.

[0021] FIG. 2 is a plan view of a housing component including a molded body made of carbon fiber composite material with a recessed antenna window.

[0022] FIG. 3A is a transverse sectional view of an exemplary joint between carbon fiber composite body and an antenna window.

[0023] FIG. 3B is a longitudinal sectional view of the joint of FIG. 3A.

[0024] FIG. 4 is a plan view of a housing component with an embedded antenna in a window portion and a carbon fiber antenna.

[0025] FIG. 5 is an enlarged sectional view along line A-A in FIG. 4.

[0026] FIG. 6 is a plan view of the second side of a further alternative housing component configured to have an alternative antenna window including an electrically insulating connection portion.

[0027] FIG. 7 is a plan view of an exemplary antenna.

[0028] FIG. 8 is a perspective view of the antenna shown in FIG. 7.

[0029] FIG. 9 is a plan view of the second side of the housing component of FIG. 6 with an antenna window that includes an electrically insulating connecting portion which electrically isolates the antenna from the carbon fiber of the body.

[0030] FIG. 10 is a plan view of the first side of the housing component according to the arrangement of FIG. 9, which first side corresponds to an external side of the terminal housing.

[0031] FIG. 11 shows a detail of the side wall of an exemplary housing component with an undercut.

[0032] FIG. 12 shows the detail from FIG. 11, in which the need for the undercut has been avoided by overmolding.

[0033] FIG. 13 is a plan view of an alternative housing component with a molded carbon fiber composite body, a dual antenna window and a high-power antenna.

[0034] FIG. 14 is a plan view of a second side of a housing component including a circuit board, antenna window and an antenna.

DETAILED DESCRIPTION

[0035] FIG. 1 shows a molded part of a known smartphone housing. The molded part has a monocoque structure, which means that it is single-shell and has only a single wall material. The molded part has been produced by known pressing of a prepreg in a mold. Prepregs are fabric mats impregnated with a partially polymerized plastic. The partially polymerized plastic is epoxy resin or a vinyl ester. These are flexible when cold and can be laid in a mold. When hot pressed in a mold, the bonding plastic polymerizes, forming a solid piece with a generally thin wall.

[0036] FIG. 2 shows a housing component 100 according to an exemplary arrangement configured for use as part of a housing of a mobile terminal such as a smartphone or tablet computer. This exemplary housing component 100 consists of two materials. The predominant part of the housing component comprises a carbon fiber reinforced plastic body 101, which may be produced by pressing a prepreg with epoxy resin, with melamine resin or with a vinyl ester resin. Thermoplastic materials may also be used, with the individual carbon fibers being sheathed with a thermoplastic material. Only when the fabric is pressed in a mold under heat does the carbon fiber reinforced molded body form, with the sheaths of adjacent carbon fibers fusing together. In this arrangement the housing component further includes an antenna window 102. In this exemplary arrangement the antenna window comprises a window portion with a wall thickness that is formed in the housing component. In this regard, the exemplary antenna window 102 may be a window portion comprised of glass fiber reinforced epoxy resin, for example, or another plastic that does not prevent electromagnetic radiation from passing therethrough. The exemplary antenna window 102 is positioned at one end of an upright housing component. At this location, in some smartphones, cell phones and/or tablet computers, an antenna for transmitting and receiving signals comprising electromagnetic radiation such as radio signals for communication with remote transmitting and receiving towers may be positioned. In order to match the local mechanical properties of the carbon fiber reinforced plastic body 101 and the glass fiber reinforced epoxy resin of the antenna window 102 in this case, it may be provided that the orientation of the fabric fibers of both types of plastics is aligned.

[0037] In FIGS. 3A and 3B, a joint between the carbon fiber reinforced plastic body 101 and the antenna window 102 in FIG. 2 is shown along the joint edge between the carbon fiber reinforced plastic body 101 and the antenna window 102. In this exemplary arrangement, the carbon fiber reinforced plastic body 101 comprises three layers A, B, and C, which are provided with carbon fiber fabrics of a different bidirectional mesh density. The different layers A, B and C are bonded together via a thermoplastic material TP. Here, the innermost layer A comprises, for example, a carbon fiber reinforced plastic with a carbon fiber fabric with 12,000 carbon fibers per woven strand, which corresponds to a so-called 12K fabric. The middle layer B, for example, comprises a carbon fiber reinforced plastic with a carbon fiber fabric with 3,000 carbon fibers, which corresponds to a so-called 3K fabric. The outermost layer C, for example, comprises a carbon fiber reinforced plastic with a carbon fiber fabric with 1,000 carbon fibers per woven strand, which corresponds to a so-called 1K fabric. To join the carbon fiber reinforced plastic body 101 to the antenna window 102, which in this example arrangement is made of a glass fiber reinforced plastic material, the molded body is removed in the area of the edge of the carbon fiber reinforced plastic body 101 to such an extent that the layer thickness is only about half the total wall thickness of the housing component 100, although part of the thermoplastic material TP joining the layers A and B is left. This thermoplastic material TP connecting layers A and B serves as a connecting surface between the carbon fiber reinforced plastic and the glass fiber reinforced plastic of the antenna window 102. In this example arrangement, a glass fiber reinforced plastic lies on the forming tongue of the carbon fiber reinforced plastic body 101 with about half the wall thickness. The exemplary body and window portion include interengaging projections and recesses. This includes individual undercuts 104 which protrude like pegs from the glass fiber reinforced plastic of the antenna window 102 and, when a prepreg is pressed, pour into corresponding and milled negative shapes of the undercuts 104. When the prepreg of the glass fiber reinforced plastic for the antenna window portion 102 is pressed, the epoxy resin of the glass fiber reinforced plastic of the antenna window 102 bonds with the carbon fiber reinforced plastic of the body 101 of the housing component. To prevent the undercuts from breaking out of the negative molds, an overmold layer 103 is provided, which is applied to the bonding edge of the two different materials during molding by an injection molding system. The overmold layer of this exemplary arrangement overlies and is bonded to at least a part of the body portion and at least a part of the window portion. Of course it should be understood that this approach is exemplary.

[0038] FIG. 4 shows an alternative arrangement of a housing component which comprises a housing component 200. In this exemplary arrangement, an antenna window 202 that comprises a window portion is embedded in a surface that bounds the external side of the carbon fiber reinforced plastic body 201. In this case, the electromagnetic radiation shielding layer of the body underlying the window portion is only about half as thick as the wall thickness of the body 201 in areas away from the window portion. In this case, the antenna window 202 has an embedded antenna 300, which may in some arrangements also be made of carbon fibers. In the exemplary case of the carbon fiber antenna, the ends of the individual fibers which comprise the antenna are passed through the fabric of the carbon fiber reinforced plastic body 201 so that the ends can be connected to appropriate drive electronics and circuitry on an opposed side which corresponds to the internal side of the terminal housing. To illustrate the location of the exemplary embedded antenna 300, a view of cut line A-A in FIG. 4 is shown in FIG. 5. The antenna 300, which may comprise individual carbon fibers, is embedded in the window portion of the antenna window 202, with the antenna window 202 window portion itself embedded in the carbon fiber reinforced plastic body portion 201. The embedding can be achieved by folding together a prepreg for pressing the carbon fiber reinforced plastic body 201 and an antenna 300, wherein when the folded prepregs are pressed together, the plastic portion of the prepregs of the carbon fiber reinforced plastic body 201 and the antenna 300 wraps around the individual carbon fibers in a correspondingly forming manner. In exemplary arrangements the carbon fibers which comprise the antenna are surrounded by a plastic that does not prevent electromagnetic radiation from passing through the window portion to and from the antenna while the underlying carbon fiber reinforced body portion underlying the window portion substantially prevents the electromagnetic radiation on the first side of the body from the antenna and other sources, from reaching the second side of the body which corresponds to the interior area of the device housing. When referred to herein substantially preventing the passage of electromagnetic radiation means the radiation that passes through does not interfere with the operation of circuitry in the terminal housing.

[0039] FIG. 6 shows a view of the inside of a still further exemplary arrangement of a housing component 400. The housing component 400 has a body 401 and an antenna window 402. The exemplary window comprises a recess in the housing component 400. This recess is configured to receive an insert antenna 500, which in an exemplary arrangement may be firmly connected to the body 401 by an overmold layer. For this purpose, the insert antenna 500 is placed in the region of the recess and antenna window 402 includes an electrically insulating connecting portion that is connected to the antenna and extends in intermediate insulating relation of the antenna and the carbon fibers of the carbon fiber reinforced plastic body 401. The exemplary antenna and connecting portion may be held in place by overmolding in an injection mold. In the exemplary arrangement, the insert antenna 500 protrudes from the housing component 400.

[0040] In FIG. 7, the exemplary insert antenna 500 is shown in a top view. An electrical connection 501 and an electrical insulation connecting portion which comprises body 502 for receiving the insert antenna 500 and for electrical insulation with respect to the carbon fibers of the body 401 can be seen from above. The same insert antenna 500 is shown in perspective in FIG. 8, the perspective view revealing the applicative shape of the insulation body 502. The exemplary insert antenna 500 shown here is shown together with the electrical insulation body 502. In some exemplary arrangements, the insert antenna 500 is bonded to the body 401 of housing component 400 by overmolding plastic in the mold, and the electrical insulation body 502 is formed during overmolding which provides an overmold layer.

[0041] FIG. 8 shows a perspective view of the exemplary insert antenna shown in FIG. 7. In an exemplary arrangement this insert antenna 500 is inserted with the narrower side facing into the recess of the antenna window 402 and connected to the body 401 of housing component 400 by overmolding. In the process, the electrical insulation body 502 which comprises the electrically insulating connecting portion of the antenna window is formed.

[0042] FIG. 9 shows a view of the inside of the housing component 400 from FIG. 6 with an insert antenna 500 molded in by overmolding. The exemplary electrical insulation body 502 serves as a connecting portion of the antenna window 402 and insulates the insert antenna 500 from the carbon fibers of the body 401 of the housing component 400. In this view, the insert antenna 500 is shown as a dashed line because the electrical insulation body 502 covers the insert antenna 500. Of course this antenna window and antenna configuration is exemplary and in other arrangements other configurations may be used.

[0043] FIG. 10 shows a view of the outside of the exemplary housing component 400 from FIG. 6 with the insert antenna 500 molded in by an overmold layer. The electrical insulation body 502 serves as a connecting portion of the antenna window and electrically insulates the insert antenna 500 from the carbon fibers of the body 401 of the housing component 400.

[0044] FIG. 11 shows a section through the exemplary housing component 100 in the region of a side wall 110. The exemplary carbon fiber reinforced plastic body 101 may be hot pressed in a mold. In order to have the surface of the housing component be flush with a display 111, it is necessary for the display to lie in an enclosure 112. This exemplary enclosure 112 can be formed in some arrangements by a folded down wall of the side wall 110 of the housing component, as shown in FIG. 10.

[0045] To avoid forming an undercut in the mold that would require a complex mold to demold, an exemplary enclosure 112′ can be injected into the edge of the housing component as an overmold layer 105. The exemplary enclosure 112′ leans against the inner wall of the housing component and forms a enclosure 105′ for a display 111 in the area of the upper wall edge of the side wall 110, as shown in FIG. 12. The enclosure 112′ enables the upper wall edge of the side wall 110 to be pressed in a mold without undercutting and to be easily demolded. Of course it should be understood that this approach is exemplary and in other arrangements other approaches may be used.

[0046] FIG. 13 shows another exemplary arrangement of a housing component 600 with a carbon fiber composite body 601 and a pair of antenna windows. The housing component includes an inset antenna window 602 and a high-power antenna 603. The high-power antenna 603 in an exemplary arrangement may be of metallic construction and may accept and transmit signals for communication of the mobile terminal with a remote transmission tower. In order to galvanically separate the high power antenna 603 from the carbon fibers of the electrically conductive carbon fiber reinforced plastic body 601, it is provided that the plastic material of the antenna window 602 serves an antenna window that electrically isolates, receives and encloses the high power antenna 603 in a side wall 604 of the housing component. In this example, the antenna window 602 serves as a first antenna window with an electrically insulating connecting portion with regard to antenna 603 as well as a second antenna window with a window portion that serves to enable the passage of electromagnetic radiation for lower power transmitting and receiving antennas, such as RFID antennas and antennas for near-field and mid-field communications which may be embedded in or underlying of the window portion. Of course it should be understood that this configuration is exemplary.

[0047] FIG. 14 shows the exemplary housing component 100 of FIG. 2, wherein a circuit board 106 is arranged in the interior housing area on a second side of housing component 100. The circuit board 107 includes circuitry that is connected to an antenna 107. The antenna 107 is arranged in the window portion of the antenna window 102 so that the antenna 107 can transmit and receive electromagnetic signals through the plastic that comprises the window portion without shielding.

[0048] Thus the exemplary arrangements described herein achieve improved operation, eliminate difficulties encountered in the use of prior devices, systems and methods, and attain the useful results described herein.

[0049] In the foregoing description certain terms have been used for brevity, clarity and understanding. However no unnecessary limitations are to be implied therefrom because such terms are used for descriptive purposes and are intended to be broadly construed. Moreover the descriptions and illustrations herein are by way of examples and the new and useful concepts are not limited to the exact features that have been shown and described.

[0050] It should be understood that features and/or relationships associated with one exemplary arrangement can be combined with features and/or relationships from another exemplary arrangement. That is various features and/or relationships from various arrangements can be combined into further arrangements. The new and useful scope of the disclosure is not limited only to the exemplary arrangements that have been shown or described herein.

[0051] Having described the features, discoveries and principles of the exemplary arrangements, the manner in which they are constructed and operated, and the advantages and useful results attained, the new and useful features, devices, elements, configurations, parts, combinations, systems, equipment, operations, methods, processes and relationships are set forth in the appended claims.

REFERENCE LIST

[0052]

TABLE-US-00001 100 housing component 400 housing component 101 carbon fiber reinforced plastic 401 carbon fiber reinforced plastic body portion body portion 102 antenna window 402 antenna window 103 overmold layer 404 electrical connection 104 undercut 500 insert antenna 105 overmold layer 501 electrical connection 105' enclosure 502 electrical insulation body 106 board 600 housing component 107 antenna 601 carbon fiber reinforced plastic 110 side wall body portion 111 display 602 antenna window 112 enclosure 603 high power antenna 112′ enclosure 604 side wall 200 housing component A layer 201 carbon fiber reinforced plastic TP thermoplastic material body portion B layer 202 antenna window C layer 300 coil antenna