EP1381110A1

EP1381110A1 - Satellite converter feed horn

Info

Publication number: EP1381110A1
Application number: EP03254369A
Authority: EP
Inventors: Keiichiro Sata; Shuji Saito; Satoru Matsuzaki
Original assignee: Alps Electric Co Ltd
Current assignee: Alps Alpine Co Ltd
Priority date: 2002-07-12
Filing date: 2003-07-10
Publication date: 2004-01-14
Also published as: CN1472899A; JP2004048419A; CN1232055C

Abstract

A satellite converter feed horn includes a square tubular feed horn (6) section formed of a bent metallic plate. The feed horn section includes first to fourth plate sections (7-10). The third and fourth plate sections have respective first and second strip-shaped connecting sections (9b,10b) disposed outward from and in a direction of extension of a square tubular section (11). The first and second connecting sections are connected together, with a step being disposed in a direction orthogonal to the direction of extension of the square tubular section. Therefore, the connecting section having the larger width receives solder (12),so that the connecting sections can be easily and reliably soldered.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a satellite converter feed horn for receiving satellite broadcasts.

2. Description of the Related Art

A related satellite converter feed horn is described with reference to Figs. 7 to 10. Fig. 7 is a schematic side view of a related satellite converter. Fig. 8 is a perspective view of the related satellite converter feed horn. Fig. 9 is a sectional view taken along line. IX-IX of Fig. 8. Fig. 10 is a sectional view taken along line X-X of Fig. 8.
Referring to the structure of the related satellite converter feed horn shown in Figs. 7 to 10, a frame 51, which is formed by bending a metallic plate, has a square shape with open top and bottom portions.
A cover 52, formed of a metallic plate, is caught by and mounted to the frame 51 so as to close one of the open portions of the frame 51.
A circuit board 53, or a printed circuit board, has a ground pattern 54 and a wiring pattern (not shown). The ground pattern 54 is substantially entirely formed on one of the surfaces of the circuit board 53. The wiring pattern is formed on the other surface of the circuit board 53, and comprises an electrical circuit for a desired reception including various electrical parts.
With the electrical parts (electrical circuit) being positioned in the frame 51, such a circuit board 53 is mounted to the square frame 51 so as to close the other open portion of the frame 51.
When the circuit board 53 is mounted to the frame 51, the ground pattern 54 is exposed from the frame 51 and shields the inside of the frame 51, so that the electrical circuit is electrically shielded by the frame 51, the cover 52, and the ground pattern 54.
A coaxial connector 55 is mounted to the frame 51 in a protruding manner outward from the frame 51. The electrical circuit is connected to the connector 55 so that a signal that has been processed by the electrical circuit can be taken out from the connector 55.
A square tubular feed horn 56, formed by bending a metallic plate, is soldered and mounted to the ground pattern 54 perpendicular to the circuit board 53. Satellite electric waves are received from the feed horn 56.
As shown, in particular, in Figs. 8 to 10, the feed horn 56 comprises first to fourth plate sections 57 to 60. The first and second plate sections 57 and 58 are connected and are at right angles to each other. The third plate section 59 is connected and is at right angles to the first plate section 57. The fourth plate section 60 is connected and is at right angles to the second plate section 58.
The feed horn 56 comprises a square tubular section 61 formed by the first to fourth plate sections 57 to 60 by connecting ends of the third and fourth plate sections 59 and 60 at right angles to each other.
At the location where the third and fourth plate sections 59 and 60 are connected together, the end of the third plate section 59 has a plurality of outwardly protruding tongues 59a and the end of the fourth plate section 60 has protrusions 60a for catching the end of the third plate section 59.
In the third and fourth plate sections 59 and 60 that are at right angles to the first and second plate sections 57 and 58, respectively, the protrusions 60a are caught at right angles by end portions of the third plate section 59 that are disposed between the tongues 59a. In this state, as shown in Fig. 10, each tongue 59a (shown by alternate long and two short dash lines) is bent in the direction of arrow A and is superimposed upon the outer surface of the fourth plate section 60.
Thereafter, by applying solder 62 in a direction of extension of the square tubular section 61 to the outer periphery of the location where the protrusions 60a of the fourth plate section 60 and the third plate section 59 are connected together, and removing a gap between the two, the feed horn 56 is formed.
Since, in the related satellite converter feed horn, the solder 62 is applied to the location, which is a narrow portion, where the protrusions 60a of the fourth plate section 60 and the third plate section 59 are connected together, it is difficult to apply the solder, thereby reducing work efficiency.
When the solder is applied to the narrow portion, the solder drips towards the fourth plate section 60, so that the amount of solder at the location where the fourth plate section 60 and the third plate section 59 are connected together is reduced, as a result of which, not only is the solder improperly applied, but also the soldered portion has a poor appearance.
When bending the tongues 59a in the direction of arrow A, the fourth plate section 60 is pushed in the direction of arrow B, so that the square tubular section 61 becomes rhombic.

SUMMARY OF THE INVENTION

Accordingly, it is an object of the present invention to provide a satellite converter feed horn which makes it possible to achieve good soldering efficiency and to reliably perform soldering and whose square tubular section undergoes little deformation.
According to the present invention, there is provided a satellite converter feed horn comprising a square tubular feed horn section that is formed of a bent metallic plate and that comprises a square tubular section including first to fourth plate sections and having the third and fourth plate sections connected together at right angles to each other. The first and second plate sections are connected at right angles to each other. The third plate section is connected at right angles to the first plate section. The fourth plate section is connected at right angles to the second plate section. The third plate section has a first strip-shaped connecting section extending outward from and in a direction of extension of the square tubular section. The fourth plate section has a second strip-shaped connecting section extending outward from and in the direction of extension of the square tubular section. The first and second connecting sections are connected together, with a step being disposed in a direction perpendicular to the direction of extension of the square tubular section.
Preferably, one of the first and second connecting sections extends from a portion of the corresponding plate section in the same plane, and the other of the first and second connecting sections is at right angles to a portion of the corresponding plate section.
Preferably, one of the third and fourth plate sections has a protrusion extending from a portion of the one of the third and fourth plate sections in the same plane, the other of the third and fourth plate sections has a hole for fitting the protrusion thereto, and the protrusion is fitted to the hole in order to connect the third and fourth plate sections together at right angles to each other.
Preferably, an end portion of the protrusion is caulked in the direction of extension of the square tubular section.
Preferably, either the third plate section or the fourth plate section has a tongue that protrudes from the outer periphery defining the hole, and the tongue is bent and superimposed upon the outer surface of either the third plate section or the fourth plate section having the protrusion.
Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
Fig. 1 is a schematic side view of a satellite converter of the present invention;
Fig. 2 is a perspective view of a satellite converter feed horn of a first embodiment of the present invention;
Fig. 3 is a sectional view taken along line III-III of Fig. 2;
Fig. 4 is a sectional view taken along line IV-IV of Fig. 2;
Fig. 5 is a sectional view of portions that are connected together of a satellite converter feed horn of a second embodiment of the present invention;
Fig. 6 is a sectional view of a protrusion of a satellite converter feed horn of a third embodiment of the present invention;
Fig. 7 is a schematic side view of a related satellite converter;
Fig. 8 is a perspective view of a related satellite converter feed horn;
Fig. 9 is a sectional view taken along line IX-IX of Fig. 8; and
Fig. 10 is a sectional view taken along line X-X of Fig. 8.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Embodiments of a satellite converter feed horn of the present invention are described with reference to Figs. 1 to 6. Fig. 1 is a schematic side view of a satellite converter of the present invention. Fig. 2 is a perspective view of a satellite converter feed horn of a first embodiment of the present invention. Fig. 3 is a sectional view taken along line III-III of Fig. 2. Fig. 4 is a sectional view taken along line IV-IV of Fig. 2.
Fig. 5 is a sectional view of portions that are connected together of a satellite converter feed horn of a second embodiment of the present invention. Fig. 6 is a sectional view of a protrusion of a satellite converter feed horn of a third embodiment of the present invention.
Referring to the structure of the satellite converter feed horn of the first embodiment of the present invention shown in Figs. 1 to 4, a frame 1, which is formed by bending a metallic plate, has a square shape with open top and bottom portions.
A cover 2, formed of a metallic plate, is caught by and mounted to the frame 1 so as to close one of the open portions of the frame 1.
A circuit board 3, or a printed circuit board, has a ground pattern 4 and a wiring pattern (not shown). The ground pattern 4 is substantially entirely formed on one of the surfaces of the circuit board 3. The wiring pattern is formed on the other surface of the circuit board 3, and comprises an electrical circuit for a desired reception including various electrical parts.
With the electrical parts (electrical circuit) being positioned in the frame 1, such a circuit board 3 is mounted to the square frame 1 so as to close the other open portion of the frame 1.
When the circuit board 3 is mounted to the frame 1, the ground pattern 4 is exposed from the frame 1 and shields the inside of the frame 1, so that the electrical circuit is electrically shielded by the frame 1, the cover 2, and the ground pattern 4.
A coaxial connector 5 is mounted to the frame 1 in a protruding manner outward from the frame 1. The electrical circuit is connected to the connector 5 so that a signal that has been processed by the electrical circuit can be taken out from the connector 5.
A square tubular feed horn 6, formed by bending a metallic plate, is soldered and mounted to the ground pattern 4 perpendicular to the circuit board 3. Satellite electric waves are received from the feed horn 6.
As shown, in particular, in Figs. 2 to 4, the feed horn 6 comprises first to fourth plate sections 7 to 10. The first and second plate sections 7 and 8 are connected and are at right angles to each other. The third plate section 9 is connected and is at right angles to the first plate section 7. The fourth plate section 10 is connected and is at right angles to the second plate section 8.
The feed horn 6 comprises a square tubular section 11 formed by the first to fourth plate sections 7 to 10 by connecting ends of the third and fourth plate sections 9 and 10 at right angles to each other.
At the location where the third and fourth plate sections 9 and 10 are connected together, the third plate section 9 has a pair of holes 9a, a strip-shaped first connecting section 9b, and tongues 9c. The holes 9a are formed spaced apart near the end of the third plate section 9. The first connecting section 9b extends from a portion of the plate section 9 in the same plane. The tongues 9c protrude from the outer periphery of the holes 9a.
The first connecting section 9b is formed so as to extend outward from and in a direction of extension of the square tubular section 11.
At the location where the third and fourth plate sections 9 and 10 are connected together, the fourth plate section 10 has protrusions 10a, and a strip-shaped second connecting section 10b. The protrusions 10a protrude from portions of the plate section 10 in the same plane and are fitted to the holes 9a. The second connecting section 10b is at right angles to one end of the plate section 10.
The second connecting section 10b is formed so as to extend outward from and in the direction of extension of the square tubular section 11, and has a larger width than the first connecting section 9b. (The width is defined as the length in a direction orthogonal to the direction of extension of the square tubular section 11.)
The third and fourth plate sections 9 and 10, which are at right angles to the first and second plate sections 7 and 8, respectively, are connected together at right angles to each other, and the protrusions 10a are fitted to the respective holes 9a in order to caulk the ends of the protrusions 10a in the direction of extension of the square tubular section 11.
When connecting the third and fourth plate sections 9 and 10, the first and second connecting sections 9b and 10b are connected together with a step in a direction orthogonal to the direction of extension of the square tubular section 11.
In other words, as shown in Fig. 3, the second connecting section 10b protrudes by a greater amount than the first connecting section 9b, and the first connecting section 9b is positioned towards the square tubular section 11 from the outer end of the second connecting section 10b.
In this state, as shown in Fig. 4, each tongue 9c (shown by alternate long and two short dash lines) is bent in the direction of arrow A and is superimposed upon the outer surface of the fourth plate section 10.
At this time, although the fourth plate section 10 is pushed in the direction of arrow B, since the protrusions 10a are fitted in the respective holes 9a, the fourth plate section 10 undergoes very little deformation in the direction of arrow B, so that the square tubular section 11 no longer becomes deformed.
Thereafter, by applying solder 12 in the direction of extension of the square tubular section 11 to the step formed by the first connecting section 9b and the second connecting section 10b, and removing a gap between the two, the feed horn 6 is formed.
At this time, the second connecting section 10b having the larger width receives the solder 12, so that it is possible to easily and reliably solder the first and second connecting sections 9b and 10b, and to prevent dripping of the solder.
Although, in the first embodiment, the first connecting section 9b extends from a portion of the plate section 9 in the same plane, and the second connecting section 10b is at right angles to a portion of the plate section 10, the first connecting section 9b may be at right angles to a portion of the plate section 9, and the second connecting section 10b may extend from a portion of the plate section 10 in the same plane.
Although, in the first embodiment, the protrusions 10a of the fourth plate section 10 are fitted to the respective holes 9a of the third plate section 9, holes may be formed in the fourth plate section 10 and fitted to protrusions formed on the third plate section 9.
Fig. 5 shows a satellite converter feed horn of a second embodiment of the present invention. In the second embodiment, the width of a strip-shaped first connecting section 9b of a third plate section 9 is larger than the width of a second connecting section 10b of a fourth plate section 10, and solder 12 is applied to a step formed by the first and second connecting sections 9b and 10b.
The other structural features are the same as those of the first embodiment, and the same component parts are given the same reference numerals and are not described.
Fig. 6 shows a satellite converter feed horn of a third embodiment of the present invention. In the third embodiment, tongues 9c of a third plate section 9 are kept extended in a straight line, so that they are not bent.
The other structural features are the same as those of the first embodiment, and the same component parts are given the same reference numerals and are not described.
As described above, a satellite converter feed horn of the present invention comprises a square tubular feed horn section that is formed of a bent metallic plate and that comprises a square tubular section including first to fourth plate sections and having the third and fourth plate sections connected together at right angles to each other. The first and second plate sections are connected at right angles to each other. The third plate section is connected at right angles to the first plate section. The fourth plate section is connected at right angles to the second plate section. The third plate section has a first strip-shaped connecting section extending outward from and in a direction of extension of the square tubular section. The fourth plate section has a second strip-shaped connecting section extending outward from and in the direction of extension of the square tubular section. The first and second connecting sections are connected together, with a step being disposed in a direction perpendicular to the direction of extension of the square tubular section.
By virtue of such a structure, when the step formed by the first and second connecting sections is soldered, the connecting section having the larger width receives the solder, so that it is possible to easily and reliably solder the first and second connecting sections, and to prevent dripping of the solder.
One of the first and second connecting sections extends from a portion of the corresponding plate section in the same plane, and the other of the first and second connecting sections is at right angles to a portion of the corresponding plate section. Therefore, the first and second connecting sections can be easily processed and reliably superimposed upon each other.
One of the third and fourth plate sections has a protrusion extending from a portion of the one of the third and fourth plate sections in the same plane, the other of the third and fourth plate sections has a hole for fitting the protrusion thereto, and the protrusion is fitted to the hole in order to connect the third and fourth plate sections together at right angles to each other. Therefore, the third and fourth plate sections are reliably caught at the location where they are connected together, so that the square tubular section undergoes little deformation.
An end portion of the protrusion is caulked in the direction of extension of the square tubular section. Therefore, the square tubular section undergoes little deformation, and the third and fourth plate sections can be firmly joined together at the location where they are connected together.
Either the third plate section or the fourth plate section has a tongue that protrudes from the outer periphery defining the hole, and the tongue is bent and superimposed upon the outer surface of either the third plate section or the fourth plate section having the protrusion. Therefore, the square tubular section undergoes little deformation, and the third and fourth plate sections can be firmly joined together at the location where they are connected together.

Claims

A satellite converter feed horn comprising:

a square tubular feed horn section formed of a bent metallic plate, the feed horn section comprising a square tubular section including first to fourth plate sections and having the third and fourth plate sections connected together at right angles to each other, the first and second plate sections being connected at right angles to each other, the third plate section being connected at right angles to the first plate section, the fourth plate section being connected at right angles to the second plate section,

wherein the third plate section has a first strip-shaped connecting section extending outward from and in a direction of extension of the square tubular section,
wherein the fourth plate section has a second strip-shaped connecting section extending outward from and in the direction of extension of the square tubular section, and
wherein the first and second connecting sections are connected together, with a step being disposed in a direction perpendicular to the direction of extension of the square tubular section.
A satellite converter feed horn according to Claim 1, wherein one of the first and second connecting sections extends from a portion of the corresponding plate section in the same plane, and wherein the other of the first and second connecting sections is at right angles to a portion of the corresponding plate section.
A satellite converter feed horn according to either Claim 1 or Claim 2, wherein one of the third and fourth plate sections has a protrusion extending from a portion of the one of the third and fourth plate sections in the same plane, wherein the other of the third and fourth plate sections has a hole for fitting the protrusion thereto, and wherein the protrusion is fitted to the hole in order to connect the third and fourth plate sections together at right angles to each other.
A satellite converter feed horn according to Claim 3, wherein an end portion of the protrusion is caulked in the direction of extension of the square tubular section.
A satellite converter feed horn according to either Claim 3 or Claim 4, wherein either the third plate section or the fourth plate section has a tongue that protrudes from the outer periphery defining the hole, and wherein the tongue is bent and superimposed upon the outer surface of either the third plate section or the fourth plate section having the protrusion.