JPH10247819A - Antenna element and manufacture therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an antenna element at a low cost which withstands shocks and is easily to assemble and to provide a manufacturing method of the antenna element easily manufactured and assembled at a low cost. SOLUTION: A copper foil 5 (radiation conductor element) is inserted between a 1st resin film sheet 1 and a 2nd resin film sheet 2, so that its extension part 6 extends outwards to form a 1st sheet member S1. A copper foil 7 (ground conductor) is inserted between a 3rd resin film sheet 3 and a 4th resin film sheet 4 to form a 2nd sheet member S2. The 2nd sheet member is placed to the 1st sheet member at a prescribed distance. A synthetic resin material, melt- stuck to the 1st to 4th resin sheets, is packed between the 1st sheet member and the 2nd sheet member to form a dielectric layer 8. Then a circuit element CT is adhered to the copper foil 7, the extended part 6 is folded and a tip 6a is connected to a circuit element.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to an antenna element and a method of manufacturing the same, and more particularly, to an antenna element suitable for a GPS antenna and a method of manufacturing the same.

[0002]

2. Description of the Related Art Recently, a global positioning system (GPS) has attracted attention, and various antennas applied to the system have been proposed. For example, Japanese Patent Publication No. 60-4
A microstrip antenna disclosed in Japanese Patent Publication No. 0203 is used, and a commercially available antenna element is configured as shown in FIG. That is, the dielectric layer 2 made of ceramic
The silver paste is vapor-deposited on both surfaces of 8 to form a radiation conductor element 25 and a ground conductor 27. A power supply pin 26 is disposed so as to penetrate these with a predetermined gap therebetween, and one end 26 a of the power supply pin 26 is joined to the radiation conductor element 25 by solder SD. Further, the circuit element CT is joined to the ground conductor 27, and the other end 26b of the power supply pin 26 is connected to a low noise amplifier circuit (not shown) in the circuit element CT. The circuit element CT is connected to the receiver RC via the coaxial cable CB.

[0003]

In the antenna element shown in FIG. 9, after silver paste is vapor-deposited on both surfaces of a ceramic dielectric layer 28, holes through which feed pins 26 are inserted are formed in the dielectric layer 28. Is established. For this reason, the dielectric layer 28 is easily cracked and difficult to process, and the product is weak against impact. In addition, the deposition of silver paste requires special machinery and equipment, and the work is not easy. In addition, the arrangement and joining of the power supply pins 26 are not easy, and assembly is also difficult. As described above, not only is manufacturing and assembly difficult and the manufacturing cost is high, but also the antenna element as a product is fragile and expensive.

Accordingly, an object of the present invention is to provide an antenna element that is inexpensive, resistant to impact, and easy to assemble.
It is another object of the present invention to provide a method for manufacturing an antenna element that can be easily and inexpensively manufactured and assembled.

[0005]

According to a first aspect of the present invention, there is provided an antenna element according to the present invention, comprising: a radiating conductor element having an extension; Is disposed between the first resin sheet and the second resin sheet, and the extending portion is provided between the first resin sheet and the second resin sheet.
A sheet member sandwiched so as to extend outward from the resin sheet, and a dielectric layer of a resin material bonded to one side surface of the sheet member, wherein the extending portion of the radiation conductor element is formed of the dielectric material. It is configured to bend to the layer side.

According to a first aspect of the present invention, there is provided a method for manufacturing an antenna element, wherein a first and a second molds each having a concave portion are joined to form a predetermined mold chamber. In the method of manufacturing an antenna element for forming an antenna element in the mold chamber, a radiating conductor element having an extending portion is disposed between a first resin sheet and a second resin sheet in a film shape, A sheet member is formed by sandwiching the extending portion of the element so as to extend outward from the first resin sheet and the second resin sheet, and at least the sheet member is formed in a recess of the first mold. And the first and second molds are joined so that only the extending portion of the radiation conductor element is in close contact with the first and second molds, and the sheet member and the second mold are joined. In the space defined between the mold and the bottom surface of the concave portion, the first Beauty filled with weldable synthetic resin material to the second resin sheet and cross After forming the dielectric layer, it is desirable to bend the extending portion of the radiating conductor element to the dielectric layer side.

[0007]

Preferred embodiments of the present invention will be described below with reference to the accompanying drawings. FIGS. 1 and 2 relate to an embodiment of an antenna element according to the present invention, in which a copper foil 5 as a radiation conductor element is provided between a first resin sheet 1 and a second resin sheet 2 formed in a film shape from a synthetic resin material. Are sandwiched and tightly joined by an adhesive to form a first sheet member S1 which is a sheet member of the present invention. The copper foil 5 is shown in FIG.
The extended portion 6 is integrally formed as shown by a two-dot chain line and a solid line in FIG. 2, and is folded as shown by a solid line in FIG. To be served.

Further, a second sheet member S2 is arranged at a predetermined distance from the first sheet member S1. This second sheet member S2 is also sandwiched between a third resin sheet 3 and a fourth resin sheet 4 which are formed in a film shape from a synthetic resin material, and a copper foil 7 serving as a ground conductor is tightly joined by an adhesive. Become composed.

[0010] A dielectric layer 8 is formed between the first sheet member S1 and the second sheet member S2. The dielectric layer 8 and the first to fourth resin sheets 1 to 4 are integrally formed of a synthetic resin material which can be welded to each other by a method described later. The fourth resin sheet 4 has a hole 4a for disposing the circuit element CT.
The circuit element CT is bonded to the copper foil 7, and a grounding portion (not shown) in the circuit element CT is connected to the copper foil 7.

The circuit element CT joined to the antenna element AT having the above configuration has a low-noise amplifier circuit (not shown), to which the tip 6a of the extension 6 is connected.
As shown in FIG. 1, the receiver R is connected by a coaxial cable CB.
C to form a GPS antenna. Thus,
The radio wave received by the antenna element AT is amplified by a low-noise amplifier (not shown) in the circuit element CT and supplied to the receiver RC via the coaxial cable CB.

The method of manufacturing the above-described antenna element AT will be described. First, as shown in FIG.
1 and M2, which are respectively provided with concave portions M1c and M2.
c is formed. Then, the following (1) to (7)
The antenna element AT is manufactured according to the steps described above. First,
(1) The first resin sheet 1 and the second resin sheet 2 are tightly bonded with an adhesive in a state where the copper foil 5 is sandwiched between the first resin sheet 1 and the second resin sheet 2 to form a first sheet member S1. At this time, the extension 6 extends outside the first resin sheet 1 and the second resin sheet 2. In addition, (2) the second resin sheet 3 is bonded to the third resin sheet 3 and the fourth resin sheet 4 with an adhesive in a state where the copper foil 7 is sandwiched between the third resin sheet 3 and the fourth resin sheet 4 to form the second sheet member S2.

Next, (3) as shown in FIG. 3, the first sheet member S1 is accommodated in the recess M1c of the first mold M1, and the second sheet member S2 is accommodated in the second mold M2. Recess M2
housed in c. (4) Only the extending portion 6 of the copper foil 5 has the opposing surfaces M1a, M2 of the first and second molds M1, M2.
a, so that a gap is formed between the second resin sheet 2 and the third resin sheet 3, the first mold M1 and the second mold The mold M2 is joined, and the mold chamber MD is formed as shown in FIG.

In this state, (5) between the first sheet member S1 and the second sheet member S2 in the mold chamber MD,
A resin material that can be mutually welded to the first to fourth resin sheets 1 to 4 is injected to form the dielectric layer 8 shown in FIG. At this time, the extension portion 6 includes the first and second molds M1 and M
2 and no gap is formed between them, so that the resin material does not adhere to the extension 6. On the other hand, the second and third resin sheets 2 and 3 and the dielectric layer 8 are welded to each other and firmly joined. (6)
After the dielectric layer 8 is solidified, the first mold M1 and the second mold M2 are retracted as shown in FIG. 5, and the molded antenna element AT is taken out. Then, (7) the circuit element CT is attached to the antenna element AT as shown in FIG. 1, and the extension 6 of the copper foil 5 is bent toward the dielectric layer 8 (from the state of the two-dot chain line in FIG. 1 to the solid line). ), And connected to a low noise amplifier circuit (not shown) of the circuit element CT. Thereby, the extension part 6 can function as a power supply path.

According to the above-mentioned method, the conventional radiation conductor element does not require deposition of silver paste or the like, and also requires processing such as drilling and soldering when inserting and fixing the power supply pin. Without this, the production and assembly can be easily performed by injection molding of the synthetic resin and subsequent bending of the extension portion 6.

FIG. 6 shows a state in which the antenna element AT according to one embodiment of the present invention is embedded in an instrument panel PN of an automobile. Stickiness is obtained.

The above embodiment is suitable, for example, for a frequency (1.75 GHz) for an automobile navigation system, but the present invention is not limited to this, and includes the embodiments described below. I do. That is, in general, the radiation conductor element on the ground side is required to be larger than the radiation conductor element on the reception side, but a higher frequency such as a frequency (5.8 GHz) for an expressway toll collection system is received. In the case of such an antenna element, since the area of the copper foil (indicated by 15 in FIG. 7 to be described later) is relatively small, it may be possible to form the antenna element smaller than the ground portion (not shown) in the circuit element CT. In such a case, the above-mentioned second sheet member S2 can be omitted, and can be configured as shown in FIG.

The antenna element AT2 shown in FIG. 7 has a copper foil 15 interposed between the first resin sheet 11 and the second resin sheet 12, and is bonded in a state in which the extension 16 extends outward. The dielectric layer 18 is formed in a state in which the portion including the extending portion 16 is bent in advance while being tightly joined by an agent.
In FIG. 7, the antenna element AT2, the first resin sheet 11, the second resin sheet 12, the copper foil 15, the extension 1
6, the dielectric layer 18 is the antenna element AT of FIG. 1, the first resin sheet 1, the second resin sheet 2, the copper foil 5, the extension 6,
The other structures correspond to the dielectric layers 8, and the other configurations are the same as those of the embodiment of FIG.

Next, a method of manufacturing the antenna element AT2 shown in FIG. 7 will be described. First, as shown in FIG.
Are prepared, and concave portions M11c and M12c are respectively formed in these molds M11 and M12. Then, the antenna element AT2 is manufactured according to the following steps (1) to (6). First, the copper foil 15 having the bent portion 16 formed in advance is tightly joined with an adhesive while sandwiching the copper foil 15 between the first resin sheet 11 and the second resin sheet 12 (1). The member S11 is formed. Next, (2) FIG.
As shown in (5), the sheet member S11 is housed in the recess M11c of the first mold M11. Then, (3) the first and second molds M11 and M12 are joined so that only the extending portion 16 of the copper foil 15 is in close contact with both the first and second molds M1 and M2, and the molding chamber is formed. (Not shown).

In this state, (4) the first and second resin sheets 11 and 12 can be mutually welded between the sheet member S11 in the mold chamber and the bottom surface of the concave portion 12c of the second mold M12. The dielectric layer 1 shown in FIG.
8 is formed. (5) After the dielectric layer 18 has solidified, the first
The mold M11 and the second mold M12 are retracted, and the antenna element AT2 as a molded product is taken out. And (6) FIG.
The circuit element CT is attached to the antenna element AT as shown in (1), and the extension 16 of the copper foil 15 is connected to a low noise amplifier circuit (not shown) of the circuit element CT.

In the above embodiment, each of the extending portions 6 and 16 is provided with only one, but a plurality of extending portions may be provided. Further, the dielectric layers 8 and 18 are not limited to solid, and may have a honeycomb shape or a hollow shape. By changing the shape of the dielectric layers 8 and 18 as described above, the dielectric constant and the dielectric loss tangent can be adjusted.

[0021]

Since the present invention is configured as described above, the following effects can be obtained. That is, according to the antenna element of the present invention, the radiating conductor element having the extension is disposed between the first resin sheet and the second resin sheet in the form of a film. Comprises a sheet member sandwiched so as to extend outward from the first resin sheet and the second resin sheet, and a dielectric layer of a resin material bonded to one side surface of the sheet member. Since the extension portion is configured to be bent toward the dielectric layer side, a conventional power supply pin is unnecessary, and it is easy to manufacture and assemble, and it is possible to provide an inexpensive and impact-resistant antenna element.

According to a third aspect of the present invention, in the method for manufacturing an antenna element, the radiating conductor element having the extending portion is disposed between the first resin sheet and the second resin sheet. And a sheet member is sandwiched between the first resin sheet and the second resin sheet so that the extension of the radiation conductor element extends outward from the first resin sheet and the second resin sheet. In the first and second molds so that only the extending portion of the radiation conductor element is in close contact with the first and second molds.
And filling a space defined between the sheet member and the bottom surface of the concave portion of the second mold with a synthetic resin material that can be mutually welded to the first and second resin sheets. After the dielectric layer is formed, the extension of the radiation conductor element is bent toward the dielectric layer, so that the silver paste is deposited on the dielectric layer and the feed pin insertion hole is formed in the conventional method. It becomes unnecessary, the manufacturing and assembling operations are easy, and the cost can be greatly reduced.

[Brief description of the drawings]

FIG. 1 is a sectional view of an antenna element according to an embodiment of the present invention.

FIG. 2 is a plan view of an antenna element according to one embodiment of the present invention.

FIG. 3 is a cross-sectional view showing a step of manufacturing the antenna element according to one embodiment of the present invention.

FIG. 4 is a cross-sectional view showing a step of manufacturing the antenna element according to one embodiment of the present invention.

FIG. 5 is a cross-sectional view showing a step of manufacturing the antenna element according to one embodiment of the present invention.

FIG. 6 is a sectional view showing a state in which the antenna element according to the embodiment of the present invention is embedded in an instrument panel of an automobile.

FIG. 7 is a cross-sectional view of an antenna element according to another embodiment of the present invention.

FIG. 8 is a cross-sectional view showing a step of manufacturing an antenna element according to another embodiment of the present invention.

FIG. 9 is a sectional view of a conventional antenna element.

[Explanation of symbols]

 S1 First sheet member S2 Second sheet member S11 Sheet member 1,11 First resin sheet 2,12 Second resin sheet 3 Third resin sheet 4 Fourth resin sheet 5,15 Copper foil (radiation 6, 16 Extension 7 Copper foil (ground conductor) 8, 18 Dielectric layer CT circuit element AT, AT2 Antenna element CT circuit element CB Coaxial cable RC receiver

Claims (2)

[Claims] A radiating conductor element having an extending portion, and the radiating conductor element is disposed between a first resin sheet and a second resin sheet in the form of a film, and the extending portion is formed of the first resin sheet. A sheet member sandwiched so as to extend outward from the sheet and the second resin sheet; and a dielectric layer of a resin material bonded to one side surface of the sheet member; Is bent toward the dielectric layer side. 2. A method of manufacturing an antenna element, comprising joining a first mold and a second mold each having a recess to form a predetermined mold chamber and forming an antenna element in the mold chamber. The radiation conductor element is disposed between the first resin sheet and the second resin sheet in the form of a film, and the extension of the radiation conductor element is formed between the first resin sheet and the second resin sheet.
A sheet member is formed by sandwiching the resin member so as to extend outward from the resin sheet, and at least the sheet member is accommodated in a concave portion of the first mold, and only the extending portion of the radiation conductor element is formed. The first and second molds are joined so as to be in close contact with the first and second molds, and a space defined between the sheet member and the bottom surface of the concave portion of the second mold is provided. Forming a dielectric layer by filling a synthetic resin material that can be welded to the first and second resin sheets with each other, and then bending an extending portion of the radiation conductor element toward the dielectric layer. A method for manufacturing an antenna element.