JPH0750506A - Manufacture of antenna module and manufacturing die - Google Patents

Abstract

PURPOSE:To manufacture stably an antenna module with high precision of dimension by preventing infiltration of a resin at a tip of an antenna element member and a ground member. CONSTITUTION:An antenna element member 8 and a ground member 9 made of a composite member consisting of metallic foil and a plastic film are set to an inside of a female die 6, and a male die 7 is combined to them, and when the antenna module is manufactured by filling a resin in the dies, extension sections 12a, 15a of the plastic film extended from the tip of the metallic foil are provided to a tip of the antenna element member 8 and the ground member 9 and a molten resin is filled while the extension is set so as to be folded along a depth face 6a of the female side die 6.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing an antenna module and a mold used for the method.

[0002]

2. Description of the Related Art Antennas built into mobile phones are
In order to secure the electrical characteristics, high dimensional accuracy is required not only in the outer dimensions but also in the gap dimension between the antenna element and the ground. In order to meet this demand, an antenna module in which an antenna element and a ground are integrated with a resin molding having high dimensional accuracy has been put into practical use.

An example thereof is shown in FIGS. 9 to 11. This antenna module has a hollow box-shaped resin molded body 1 having an opening at one end side, an antenna element 2 made of a metal foil such as copper foil on the upper surface side, and a ground made of the same metal foil on the lower surface side. 3 is integrally provided. The antenna element 2 is double-folded on the side opposite to the opening of the resin molded body 1 to form a hollow loop. Reference numeral 4 is a soldering portion at the end of the antenna element 2.

12 and 13 show another example of a conventional antenna module. In this antenna module, the antenna element 2 is provided on the upper surface side of the resin molded body 1,
The point that the ground 3 is integrally provided on the lower surface side is the same as that described above, but another metal foil 5 is used to form the loop of the antenna element 2. Reference numeral 4 is a soldered portion between the antenna element 2 and the metal foil 5.

Such an antenna module is manufactured by resin injection molding using dies 6 and 7 as shown in FIG. In the manufacturing method, first, the antenna element member 8 and the ground member 9 are set on the inner surface of the female die 6 for molding the outer surface side of the resin molded body 1.

As shown in FIG. 15, the antenna element member 8 is formed by laminating a metal foil 11 and a plastic film 12 together, etching the metal foil 11 into a shape as an antenna element, and forming a molding resin on the surface of the plastic film 12 side. And an adhesive 13 for adhering the plastic film 12 to each other. In addition, as shown in FIG. 16, the ground member 9 is formed by laminating the metal foil 14 and the plastic film 15 to each other.
An adhesive 16 for adhering the molding resin and the plastic film 15 is applied to the side surface.

The antenna element member 8 and the ground member 9 are set with the metal foils 11 and 14 side facing outward (towards the die surface of the female die 6). Then, the resin molding 1
The male die 7 for molding the inner surface side of is closed. The male die 7 is a projecting piece 1 which is inserted between the antenna element member 8 and the ground member 9 with a predetermined space therebetween.
Have 7. When the male die 7 is closed, the protruding piece 17 comes to the position indicated by the alternate long and short dash line in FIG.

In this state, when the cavity formed by both molds is filled with molten resin and solidified, the resin molded body, the antenna element member 8 and the ground member 9 are integrated. After that, if a soldering process for forming a loop of the antenna element is performed, the soldering process shown in FIG.
The antenna module as shown in 2 can be manufactured.

[0009]

In this manufacturing method, since the dimensions are defined by the mold, theoretically high dimensional accuracy should be obtained. However, when it was put to practical use, it was found that there were the following problems.

That is, the antenna element member 8 and the ground member 9 are set as shown in FIG.
When the molten resin is filled in the inside 7, the phenomenon that the resin wraps around the outside of the tip end portions 8 a and 9 a of the antenna element member 8 and the ground member 9 easily occurs in the inner part of the female die 6. As a result, the tip portions 8a, 9a of the antenna element member 8 and the ground member 9 are deformed inward as shown in the drawing, so that an accurate gap size cannot be obtained and the resonance frequency of the antenna varies. First issue).

Further, in recent years, it has been required for this type of antenna to further increase the resonance frequency, and for that purpose, it is necessary to downsize the antenna module. In order to reduce the size of the antenna module, it is necessary to reduce the size of the mold, and the protrusion of the male mold must also be thin.
However, when the thickness of the protruding piece of the male die is reduced, there is a problem that the protruding piece is deformed or damaged by the resin pressure during molding (second problem).

[0012]

In order to solve the above-mentioned first problem, the present invention provides an inner surface of a female die with an antenna element member and a ground member made of a composite material of a metal foil and a plastic film. Set with the foil on the outside, and combine this female mold with a male mold that has a protruding piece that is inserted between the antenna element member and the ground member with a predetermined gap between them. In a method of manufacturing an antenna module in which a resin molded body and an antenna element member and a ground member are integrated by filling a cavity formed by a mold with a molten resin and solidifying the resin, the antenna element member and the ground member are provided. At the tip of the one that is set in the inner part of the female side mold, the extension of the plastic film that extends before the tip of the metal foil The molten plastic is provided with the antenna element member and the ground member set such that the extension of the plastic film is bent along the inner surface of the female die (claim 1). The molten resin is filled in a state in which the antenna element member and the ground member are set so that the tip of the extended portion of the member abuts against the inner surface of the female mold (claim 2).

In order to solve the above-mentioned second problem, the present invention provides an antenna element member and a ground member, which are made of a composite material of a metal foil and a plastic film, on the inner surface of the female die with the metal foil on the outside. Set, this female mold is combined with a male mold having projecting pieces that are inserted between the antenna element member and the ground member with a predetermined gap therebetween, and is formed by both molds. In a method of manufacturing an antenna module in which a resin molded body is integrated with an antenna element member and a ground member by filling a molten resin in a cavity and solidifying the resin, the male side mold is provided with a longitudinal direction of a projecting piece. It is characterized in that a reinforcing rib is formed on or a slit is provided in the longitudinal direction of the projecting piece.
6).

[0014]

When the plastic film is provided with an extension portion at the tip of the antenna element member and the ground member and the extension portion is set so as to be bent along the inner surface of the female die, the extension portion is attached to the female side by the pressure of the resin. Since the resin is pressed against the inner surface of the mold, the resin does not wrap around to the outside of the tips of the antenna element member and the ground member. Therefore, the gap size becomes accurate and the resonance frequency becomes stable.

Further, when the molten resin is filled with the tip of the extension of the plastic film abutting against the inner surface of the female die, the molten resin slightly wraps around from the tip of the plastic film to the outside of the extension. Since the metal foil does not exist in the extension portion of the film, the extension portion of the plastic film is only deformed inward, and the metal foil is not deformed. Therefore, an accurate gap size as an antenna module can be secured and the resonance frequency becomes stable.

Further, when the reinforcing rib is formed on the projecting piece of the male die, the strength of the projecting piece is improved, and even if the projecting piece is thinned, deformation and damage can be prevented. Further, if a slit is formed in the projecting piece of the male mold, the pressure at the time of filling the resin can easily escape, and the projecting piece can be prevented from being deformed or damaged.

[0017]

Embodiments of the present invention will now be described in detail with reference to the drawings. 1 to 3 show an embodiment corresponding to claim 1 of the present invention. In this manufacturing method, the antenna element member 8 and the ground member 9 are set on the inner surface of the female side mold 6, and the male side mold 7 having the protruding piece 17 is combined therewith to form the both side molds 6 and 7. This is the same as the conventional method in that the cavity module is filled with a molten resin and solidified to manufacture an antenna module.

The feature of this manufacturing method is that the antenna element member 8 as shown in FIG. 2 and the ground member 9 as shown in FIG. 3 are used. In the antenna element member 8 of FIG. 2, a metal foil 11 is attached to one surface of a plastic film 12 to form a required pattern, and an adhesive 13 with a molding resin is applied to the other surface.
An extension portion 12a of a plastic film that extends ahead of the tip of the metal foil 11 is provided at the tip portion 8a of the one set in the inner portion of the female die 6.

Similarly, the ground member 9 of FIG. 3 is also one in which the metal foil 14 is adhered to one surface of the plastic film 15 and the adhesive 16 with the molding resin is applied to the other surface thereof. An extension portion 15a of a plastic film that extends ahead of the tip of the metal foil 14 is provided at the tip portion 9a of the one set in the inner part of the mold 6.

In the antenna element member 8 and the ground member 9 formed as described above, the extension portions 12a and 15a of both plastic films are bent along the inner surface 6a of the female die 6 as shown in FIG. And the molten resin is filled in this state. By doing so, the extended portions 12a, 15a of the plastic film are pressed against the inner surface 6a of the female die 6 by the pressure of the filled resin, and the resin is moved to the outside of the tips of the antenna element member 8 and the ground member 9. It will not go around.
Therefore, it is possible to manufacture an antenna module having an accurate gap size.

FIG. 4 shows an embodiment corresponding to claim 2 of the present invention. This embodiment is different from the above-mentioned embodiment in that the antenna element member 8 and the ground member 9 are set so that the extension parts 12a and 12b of the plastic film abut against the inner surface 6a of the female die 6. Other than that is the same as the above-mentioned embodiment.

In this way, the molten resin filled in the molds 6 and 7 slightly wraps around from the tip of the plastic film to the outside of the extension portions 12a and 15a, but the extension portions 12a and 15a of the plastic film are covered with metal. Since there is no foil, even if the resin wraps around, the extensions 12a and 15a of the plastic film are slightly deformed inward, and the metal foils 11 and 14 are not deformed. Therefore, it is possible to secure an accurate gap size as the antenna module.

The variation in the center frequency of the antenna module is most affected by the distance between the tip ends of the antenna element metal foil 11 and the ground metal foil 15, and is not significantly affected by the length. Also, the variation in length can be controlled to be small. Therefore, an antenna module having a stable center frequency can be manufactured by the manufacturing method as shown in FIG.

In addition, in the manufacturing method of FIG.
It is desirable to use the antenna element member 8 and the ground member 9 as shown in FIG. The antenna element member 8 of FIG. 5 has a chamfered portion 11a formed at the tip corner portion of a metal foil 11, and the ground member 9 of FIG. 6 similarly has a chamfered portion 14a formed at the tip corner portion of a metal foil 14. Is.

Since the resin wrapping is most likely to occur at the tip corners of the extended portions 12a, 15a of the plastic film, if the chamfered portions 11a, 14a are formed on the metal foils 11, 14 as described above, It is possible to more reliably prevent the deformation of the metal foils 11 and 14 due to the wraparound of the resin.

FIG. 7 shows an embodiment corresponding to claims 3 and 4 of the present invention. In this embodiment, an antenna element member and a ground member are set on the inner surface of a female side mold (not shown), and a male side mold 7 having a projecting piece 17 is combined therewith to form both molds. When the antenna module is manufactured by filling the cavity with molten resin and solidifying the resin, the male mold 7 is characterized in that the projecting piece 17 is formed with the reinforcing rib 18 in the longitudinal direction. . By doing so, the strength of the projecting piece 17 can be ensured even if the thickness of the projecting piece 17 is reduced in order to miniaturize the antenna module, so that the projecting piece 17 is prevented from being deformed or destroyed by the resin pressure. be able to.

FIG. 8 shows an embodiment corresponding to claims 5 and 6 of the present invention. In this embodiment, an antenna element member and a ground member are set on the inner surface of a female side mold (not shown), and a male side mold 7 having a projecting piece 17 is combined therewith to form both molds. When the antenna module is manufactured by filling the cavity with a molten resin and solidifying the resin, the male mold 7 is characterized in that the projecting piece 17 having the slit 19 in the longitudinal direction is used. In this way, since the resin pressure applied to the projecting piece 17 can be released even if the thickness of the projecting piece 17 is reduced in order to downsize the antenna module, it is possible to prevent the projecting piece 17 from being deformed or destroyed. it can.

[0028]

As described above, according to the present invention, it is possible to prevent the resin from wrapping around the tip end portions of the antenna element member and the ground member or the influence of the wraparound, so that the antenna module with high dimensional accuracy can be stably provided. It can be manufactured. Further, since the antenna module is downsized, it is possible to prevent deformation or damage of the projecting piece due to resin pressure even if the projecting piece of the male die becomes thin.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing a method of manufacturing an antenna module according to an embodiment of the present invention.

FIG. 2 is a perspective view showing an example of an antenna element member used in the manufacturing method of FIG.

FIG. 3 is a perspective view showing an example of a gland member used in the manufacturing method of FIG.

FIG. 4 is a cross-sectional view showing a method of manufacturing an antenna module according to another embodiment of the present invention.

5 is a perspective view showing a preferred example of an antenna element member used in the manufacturing method of FIG.

6 is a perspective view showing a preferred example of a gland member used in the manufacturing method of FIG.

FIG. 7 is a perspective view showing an example of a male die used in the present invention.

FIG. 8 is a perspective view showing another example of the male die used in the present invention.

FIG. 9 is a perspective view showing an example of an antenna module.

10 is a vertical cross-sectional view of the antenna module of FIG.

11 is a cross-sectional view of the antenna module of FIG.

FIG. 12 is a perspective view showing another example of the antenna module.

13 is a vertical cross-sectional view of the antenna module of FIG.

FIG. 14 is a cross-sectional view showing a method of manufacturing a conventional antenna module.

15 is a perspective view of an antenna element member used in the manufacturing method of FIG.

16 is a perspective view of a ground member used in the manufacturing method of FIG.

[Explanation of symbols]

6: Female mold 6a:
Inner surface of female mold 7: Male mold 8: Antenna element member 8a: Tip of antenna element member 9: Ground member 9a: Tip of ground member 11:
Metal foil 12: Plastic film 12a: Extension of plastic film 13: Adhesive 14: Metal foil 15: Plastic film 15a: Extension of plastic film 16: Adhesive 17: Projection 18: Reinforcing rib 19: Slit

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Toshiaki Amano 2-6-1, Marunouchi, Chiyoda-ku, Tokyo Furukawa Electric Co., Ltd. (72) Inventor Mitsuo Inagaki 1015 Uedoda, Nakahara-ku, Kawasaki-shi, Kanagawa Fujitsu Incorporated (72) Inventor Hiroshi Higashiguchi 1015 Kamiodanaka, Nakahara-ku, Kawasaki, Kanagawa Prefecture, Fujitsu Limited (72) Inventor Maeda Health 1015 Kamedotachu, Nakahara-ku, Kawasaki, Kanagawa Prefecture, Fujitsu Limited

Claims (6)

[Claims] 1. An antenna element member and a ground member made of a composite material of a metal foil and a plastic film are set on the inner surface of a female side mold with the metal foil outside, and the antenna element member and the ground member are set in the female side mold. By combining male molds having projecting pieces that are inserted at a predetermined interval for both of them between the ground members, and filling the molten resin in the cavity formed by both molds and solidifying, In a method of manufacturing an antenna module in which a resin molded body, an antenna element member, and a ground member are integrated, a metal is provided at a tip end of one of the antenna element member and the ground member, which is set in the inner part of the female die. Provide an extension of the plastic film that extends ahead of the tip of the foil, and extend this plastic film along the inner surface of the female mold. At setting the antenna element members and the ground member to bend Te, manufacturing method of the antenna module which is characterized in that the filling of the molten resin. 2. An antenna element member and a ground member made of a composite material of a metal foil and a plastic film are set on the inner surface of the female side mold with the metal foil outside, and the antenna element member and the ground element are set in the female side mold. By combining male molds having projecting pieces that are inserted at a predetermined interval for both of them between the ground members, and filling the molten resin in the cavity formed by both molds and solidifying, In a method of manufacturing an antenna module in which a resin molded body, an antenna element member, and a ground member are integrated, a metal is provided at a tip end of one of the antenna element member and the ground member, which is set in the inner part of the female die. An extension of the plastic film that extends ahead of the tip of the foil is provided, and the tip of this extension of the plastic film is deep inside the female mold. Antenna element members and at setting the ground member, the manufacturing method of the antenna module which is characterized in that the filling of the molten resin as impinges on. 3. An antenna element member and a ground member made of a composite material of a metal foil and a plastic film are set on the inner surface of the female side mold with the metal foil outside, and the antenna element member and the ground member are set in the female side mold. By combining male molds having projecting pieces that are inserted at a predetermined interval for both of them between the ground members, and filling the molten resin in the cavity formed by both molds and solidifying, In a method of manufacturing an antenna module in which a resin molded body, an antenna element member, and a ground member are integrated, a male rib having a reinforcing rib formed in a longitudinal direction of a projecting piece is used as the male die. Antenna module manufacturing method. 4. A female die for setting an antenna element member and a ground member made of a composite material of a metal foil and a plastic film on the inner surface with the metal foil on the outside, and between the antenna element member and the ground member. A mold for antenna module manufacturing, comprising: a male mold having projecting pieces inserted at a predetermined distance from both sides, wherein reinforcing ribs are formed in the longitudinal direction of the projecting pieces. 5. An antenna element member and a ground member made of a composite material of a metal foil and a plastic film are set on the inner surface of the female side mold with the metal foil outside and the antenna element member and the ground member are set on the female side mold. By combining male molds having projecting pieces that are inserted at a predetermined interval for both of them between the ground members, and filling the molten resin in the cavity formed by both molds and solidifying, In a method of manufacturing an antenna module in which a resin molded body, an antenna element member and a ground member are integrated, a male piece having a slit formed in a longitudinal direction of a projecting piece is used as the male die. Module manufacturing method. 6. A female die for setting an antenna element member and a ground member made of a composite material of a metal foil and a plastic film on the inner surface with the metal foil on the outside, and between the antenna element member and the ground member. A mold for antenna module manufacturing, comprising a male die having projecting pieces inserted at a predetermined distance to both sides, wherein a slit is formed in a longitudinal direction of the projecting pieces.