Multiband antenna and manufacturing method thereof

Abstract

A multiband antenna includes a first antenna unit (10) and a second antenna unit (20). The first antenna unit (10) includes a first antenna pattern (11) formed of a conductor and a first substrate (12) formed of a dielectric, for holding the first antenna pattern (11). The second antenna unit (20) includes a second antenna pattern (21) formed of a conductor and a second substrate (22) formed of a dielectric having a dielectric constant different from the dielectric constant of the first substrate (12), for holding the second antenna pattern (21). In the multiband antenna, by injection molding the second substrate (22) with the first antenna unit (10) and the second antenna pattern (21), which being insert components, the first antenna unit (10) and the second antenna unit (20) are integrated.

Claims

1. A multiband antenna, comprising: a first antenna unit comprising: a first antenna pattern formed of a conductive plate; and a first substrate formed of a dielectric, for holding the first antenna pattern; and a second antenna unit comprising: a second antenna pattern formed of a conductive plate separated from the first antenna pattern; and a second substrate formed of a dielectric having a dielectric constant different from the dielectric constant of the first substrate, for holding the second antenna pattern, wherein the first antenna pattern is provided only on a surface of the first substrate, and the second antenna pattern is provided only on a surface of the second substrate, wherein the first substrate of the first antenna pattern is covered with the second substrate of the second antenna pattern from three directions orthogonal to each other so that the multiband antenna is substantially in the shape of a rectangular parallelepiped as a whole, and wherein the first antenna pattern is perpendicular to the second antenna pattern.

2. The multiband antenna according to claim 1, wherein the first antenna unit is formed by injection molding the first substrate with the first antenna pattern, the first antenna pattern being an insert component.

3. The multiband antenna according to claim 2, wherein the first substrate and the second substrate are formed through double molding of resins having different dielectric constants.

4. A method of manufacturing a multiband antenna, the multiband antenna comprising: a first antenna unit comprising: a first antenna pattern formed of a conductive plate; and a first substrate formed of a dielectric, for holding the first antenna pattern; and a second antenna unit comprising: a second antenna pattern formed of a conductive plate separated from the first antenna pattern; and a second substrate formed of a dielectric having a dielectric constant different from the dielectric constant of the first substrate, for holding the second antenna pattern, the first antenna pattern being provided only on a surface of the first substrate, and the second antenna pattern being provided only on a surface of the second substrate, the first substrate of the first antenna pattern is covered with the second substrate of the second antenna pattern from three directions orthogonal to each other so that the multiband antenna is substantially in the shape of a rectangular parallelepiped as a whole, and wherein the first antenna pattern is perpendicular to the second antenna pattern, the method comprising the steps of: forming the first antenna unit; and forming the second antenna unit and integrating the first antenna unit and the second antenna unit by injection molding the second substrate with the first antenna unit and the second antenna pattern, the first antenna unit and the second antenna pattern being insert components.

5. The method of manufacturing a multiband antenna according to claim 4, wherein the forming the first antenna unit comprises injection molding the first substrate with the first antenna pattern, the first antenna pattern being an insert component.

6. The method of manufacturing a multiband antenna according to claim 5, further comprising forming the first substrate and the second substrate through double molding of resins having different dielectric constants.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 is a perspective view of a multiband antenna according to an embodiment of the present invention.

(2) FIG. 2 is a sectional view taken along the plane including the line A-A of the multiband antenna.

(3) FIGS. 3 illustrate a hoop material used in a manufacturing method according to an embodiment of the present invention. FIG. 3(a) illustrates a state after a punching step, FIG. 3(b) illustrates a state after a bending step, FIG. 3(c) illustrates a state after a first substrate is injection molded, FIG. 3(d) illustrates a state after a second substrate is injection molded, and FIG. 3(e) illustrates a state after a separating step.

(4) FIG. 4 is a perspective view of a multiband antenna according to another embodiment of the present invention.

DESCRIPTION OF EMBODIMENTS

(5) Embodiments of the present invention are described in the following with reference to the drawings.

(6) As illustrated in FIG. 1, a multiband antenna 1 according to an embodiment of the present invention is substantially in the shape of a rectangular parallelepiped as a whole. The multiband antenna 1 comprises a first antenna unit 10 and a second antenna unit 20, which are integral with each other. The first antenna unit 10 comprises a first antenna pattern 11 formed of a conductor and a first substrate 12 (illustrated as a densely dotted area) formed of a dielectric. The second antenna unit 20 comprises a second antenna pattern 21 formed of a conductor and a second substrate 22 (illustrated as a sparsely dotted area) formed of a dielectric. The multiband antenna 1 has a length in a longitudinal direction of about 3 to 10 mm. Note that, in the following description, a vertical direction illustrated in FIG. 1 is described as a vertical direction, but this does not mean to limit the use mode of the multiband antenna 1.

(7) The first antenna pattern 11 and the second antenna pattern 21 are formed of a conductive plate, such as a metal plate, specifically, a copper plate, a steel plate, a SUS plate, a brass plate, or the like. The conductive plate may be plated (for example, gold-plated) as necessary. The conductive plate has a thickness of about 0.2 to 0.8 mm. The first antenna pattern 11 is provided on a surface of the first substrate 12 while the second antenna pattern 21 is provided on a surface of the second substrate 22 (see FIG. 2). In order to secure adhesion with respect to the substrates 12 and 22, it is preferred that at least portions of surfaces of the antenna patterns 11 and 21 joined to the surfaces of the substrates 12 and 22, respectively, be rough to some extent, and, for example, are set to have surface roughness (arithmetic mean roughness) Ra of 1.6 or more, preferably 3.2 or more. In this embodiment, as illustrated in FIG. 1, the first antenna pattern 11 is provided only on a side surface on a front side of the multiband antenna 1, and the second antenna pattern 21 is provided only on an upper surface of the multiband antenna 1.

(8) Parts of the antenna patterns 11 and 21 function as feeding terminal portions. In the illustrated example, an end of the first antenna pattern 11 protrudes downward from the first substrate 12, and the protruding portion functions as a feeding terminal portion 11a. A feeding terminal portion 21a is provided at one end of the second antenna pattern 21 in the longitudinal direction. Feeders (not shown) are connected to the feeding terminal portions 11a and 21a, respectively.

(9) The first substrate 12 is formed of a dielectric, for example, a resin or ceramic. The first substrate 12 of this embodiment is an injection molded product of a resin with the first antenna pattern 11 being an insert component. In the illustrated example, the surface of the first substrate 12 and the surface of the first antenna pattern 11 are flush with each other. The first substrate 12 is formed of, for example, a resin having a dielectric constant of 4 or more. Specifically, as a base resin, for example, polyphenylene sulfide (PPS), a liquid crystal polymer (LCP), or the like may be used. Further, a filler to be mixed in the resin is not specifically limited, and, for example, ceramic maybe mixed. Note that, the resin having a dielectric constant of 4 or more is not limited to a resin having a base resin dielectric constant of 4 or more, and a resin having a dielectric constant of 4 or more as a whole through mixture of the filler is also included.

(10) The second substrate 22 is formed of a dielectric having a dielectric constant different from that of the first substrate 12. The second substrate 22 of this embodiment is an injection molded product of a resin with the first antenna unit 10 (first antenna pattern 11 and first substrate 12) and the second antenna pattern 21 being insert components. In the illustrated example, the surface of the second substrate 22 and the surface of the second antenna pattern 21 are flush with each other. Note that, specific examples of a material of the second substrate 22 are similar to those of the first substrate 12, and thus, description thereof is omitted in order to avoid redundancy.

(11) Next, a method of manufacturing the above-mentioned multiband antenna 1 is described with reference to FIGS. 3. The multiband antenna 1 is manufactured through (a) a punching step, (b) a bending step, (c) a first injection molding step, (d) a second injection molding step, and (e) a separating step in this order.

(12) First, in the punching step, the conductive plate is punched into a predetermined shape using a punching press die (not shown). Specifically, as illustrated in FIG. 3(a), a planar development shape 31 is formed in which the first antenna pattern 11 and the second antenna pattern 21 are developed in a plane. In this embodiment, a conductive plate (hoop material 30) in the shape of a long plate is punched so that a plurality of the planar development shapes 31 are arranged in a longitudinal direction. The planar development shape 31 is connected to a frame 33 of the hoop material 30 via bridges 32.

(13) Then, the hoop material 30 is fed in a direction shown by an arrow in FIG. 3 to supply the planar development shape 31 to the bending step. In the bending step, the planar development shape 31 in the hoop material 30 is bent with a bending press die (not shown) to form the first antenna pattern 11 and the second antenna pattern 21 in predetermined shapes (see FIG. 3(b)). The bending step is carried out under a state in which the first antenna pattern 11 and the second antenna pattern 21 are coupled to the frame 33 of the hoop material 30 via the bridges 32. Note that, when the planar development shape 31 is bent, some of the bridges 32 are separated from the antenna patterns, but each of the antenna patterns is connected to the frame 33 via at least one bridge 32. In the illustrated example, the first antenna pattern 11 is connected to the frame 33 of the hoop material 30 via one bridge 32, and the second antenna pattern 21 is connected to the frame 33 of the hoop material 30 via two bridges 32 provided on both ends in the longitudinal direction thereof. This enables the first antenna pattern 11 and the second antenna pattern 21 to be bent keeping the state of being integrated with the hoop material 30. Note that, the bending step may be carried out by pressing once, or may be carried out by pressing a plurality of times.

(14) Then, the hoop material 30 is further fed to supply the first antenna pattern 11 and the second antenna pattern 21 to the injection molding step. In this embodiment, by carrying out the first injection molding step of forming the first substrate 12 and the second injection molding step of forming the second substrate 22 in this order, the first substrate 12 and the second substrate 22 are formed through double molding. Specifically, first, under a state in which the first antenna pattern 11 is placed as an insert component in a cavity of a first injection molding mold (not shown), a resin is injected into the cavity to form the first substrate 12. This forms the first antenna unit 10 (first injection molding step, see FIG. 3(c)). Then, the hoop material 30 is further fed, and, under a state in which the first antenna unit 10 and the second antenna pattern 21 are placed in a cavity of a second injection molding mold (not shown), a resin is injected into the cavity to form the second substrate 22. This forms the second antenna unit 20, and at the same time, the first antenna unit 10 and the second antenna unit 20 are integrated (second injection molding step, see FIG. 3(d)).

(15) Finally, in the separating step, the molded product (multiband antenna 1) is separated from the frame 33 of the hoop material 30 (see FIG. 3(e)). In the illustrated example, the bridge 32 for connecting the first antenna pattern 11 and the frame 33 is cut on a root side (frame 33 side) so as to be integrated with the first antenna pattern 11, and this bridge 32 functions as the feeding terminal portion 11a. The multiband antenna 1 may be separated from the hoop material 30 soon after the injection molding step, or the molded product may be temporarily wound together with the hoop material 30. By winding the multiband antenna 1 together with the hoop material 30, not only storage and conveyance thereof are easy but also the state of the multiband antennas 1 in alignment with one another can be maintained to prevent interference of the multiband antennas 1.

(16) In the manufacturing steps described above, by carrying out pressing with the bending press die and clamping of the first and second injection molding molds by a common driving unit (press machine), the necessity of providing separate driving units for the respective molds can be eliminated to simplify the system. Further, by carrying out the bending with the bending press die and clamping of the first and second injection molding molds at the same time, cycle time can be cut.

(17) The present invention is not limited to the above-mentioned embodiment. Now, description is made of other embodiments of the present invention. Parts having the same functions as those in the above-mentioned embodiment are denoted by the same reference symbols, and redundant description thereof is omitted.

(18) For example, in the above-mentioned bending step, when bending operation is in two stages or when, after the conductive plate is bent with the bending press die, the conductive plate is required to be further bent, the conductive plate may be bent by an actuator (not shown) provided separately from the clamping force on the first and second injecting molding molds. The actuator may be provided inside the bending press die, or maybe provided outside the bending press die. As the actuator, for example, an air cylinder, a hydraulic cylinder, a motor, or the like may be used.

(19) Further, in the embodiment described above, the antenna patterns 11 and 21 are provided on the surfaces of the substrates 12 and 22, respectively, but the present invention is not limited thereto, and part or all of the antenna patterns may be embedded in the substrates (not shown).

(20) Further, in the embodiment described above, a case is described in which the multiband antenna is formed of two antenna units (first antenna unit 10 and second antenna unit 20), but the present invention is not limited thereto, and the multiband antenna may be formed of three or more antenna units (not shown).

(21) Further, in the embodiment described above, a case is described in which each of the first antenna pattern 11 and the second antenna pattern 21 is provided on one side surface of the multiband antenna 1, but the present invention is not limited thereto, and each of the antenna patterns may be provided on a plurality of side surfaces. Further, in the embodiment described above, a case is described in which each of the first antenna pattern 11 and the second antenna pattern 21 is formed of a continuous conductor, but each of the antenna patterns may be formed of a plurality of separate conductors. For example, in a multiband antenna 40 illustrated in FIG. 4, the first antenna pattern 11 is formed of one conductive plate that is continuous over a plurality of side surfaces, and the second antenna pattern 21 is formed of a conductive plate that is continuous over a plurality of side surfaces and a plurality of conductive plates separated therefrom. The multiband antenna 1 can be manufactured by, for example, after the conductive plate (planar development shape 31) is bent to form the first antenna pattern 11 and the second antenna pattern 21 each having a three-dimensional shape in the bending step, carrying out the first injection molding step and the second injection molding step with the three-dimensional antenna patterns 11 and 21 being insert components.

(22) Further, in the embodiment described above, a case is described in which the substrates 12 and 22 are injection molded under a state in which the antenna patterns 11 and 21 are connected to the hoop material 30, but the present invention is not limited thereto. For example, the first antenna unit 10 may be formed in a separate step, and the second antenna unit 20 may be formed by injection molding the second substrate 22 with the first antenna unit 10 being an insert component. In this case, the first substrate 12 of the first antenna unit 10 may be formed of a material that is not suitable for injection molding, for example, ceramic.

REFERENCE SIGNS LIST

(23) 1 multiband antenna

(24) 10 first antenna unit

(25) 11 first antenna pattern

(26) 12 first substrate

(27) 20 second antenna unit

(28) 21 second antenna pattern

(29) 22 second substrate

(30) 30 hoop material