TWI773290B - Helical antenna assembly and manufacturing method thereof - Google Patents

Abstract

A helical antenna assembly is manufactured using the following method, first of all, an insulating cylindrical body is prepared, and the insulating cylindrical body has a central axis and a peripheral surface; then, a conductive metal layer is formed to cover a peripheral surface of the insulating cylindrical body; then, at least one laser cutting beam projected by at least one laser device is projected onto the conductive metal layer; finally, the insulating cylindrical body is rotated with the central axis as a central axis of rotation, and at least one laser device is insulated from the insulating cylindrical bodies moves along a first direction parallel to the central axis, so that the conductive metal layer is cut into a spiral metal antenna structure by using a laser cutting beam, so that the spiral metal antenna structure and the insulating cylindrical body form a helical antenna assembly.

Description

Helical antenna assembly and method of making the same

The present invention relates to a helical antenna assembly and a manufacturing method thereof, in particular to a helical helical antenna assembly using helical cutting to form a helical metal antenna structure and a manufacturing method thereof.

Generally speaking, a helical antenna is mainly formed by forming a metal wire into a helical coil structure, so as to receive or transmit electromagnetic signals through the coil structure. Among them, since the helical antenna is mainly formed of metal wires, in order to maintain the helical structure of the helical antenna, it is necessary to use a metal wire with a certain wire diameter for winding, so the produced helical antenna often has a certain size, and also increases the overall length as the number of turns of the helix increases.

As mentioned above, since the existing helical antenna usually has a certain size, when the electronic device is to install the helical antenna, it is necessary to vacate the space for the helical antenna to be installed. For the design direction of the existing electronic device that strives for simplicity and portability , the existing helical antenna is completely incompetent.

In view of the fact that in the prior art, in order to maintain the helical structure of the existing helical antenna, the wire diameter of the metal wire constituting the helical antenna often needs to be thick enough, so that the helical antenna occupies a certain space, which is not conducive to the design guidance of precision electronic devices. Therefore, the main purpose of the present invention is to provide a helical antenna assembly and a manufacturing method of the helical antenna assembly, so that the helical metal antenna structure of the helical antenna assembly can still maintain a certain strength in a very small size.

In order to solve the problems of the prior art, the necessary technical means adopted by the present invention is to provide a manufacturing method of a helical antenna assembly, which includes the following steps: firstly, step (a) is to prepare an insulating cylindrical body, and the insulating cylindrical body has a central axis and a peripheral surface; then, step (b) is to form a conductive metal layer covering the peripheral surface of the insulating cylindrical body; then, step (c) is to project at least one laser cutting beam from at least one laser device Projecting onto the conductive metal layer; finally, the step (d) is to rotate the insulating cylindrical body with the central axis as a central axis of rotation, and at least one of the laser device and the insulating cylindrical body to rotate along a parallel to the central axis The first direction is moved so as to use at least one laser cutting beam to cut the conductive metal layer into a helical metal antenna structure, so that the helical metal antenna structure and the insulating cylindrical body form a helical antenna assembly.

In an auxiliary technical means derived from the above-mentioned necessary technical means, the step (b) is to form a conductive metal layer by an electroplating process.

In an auxiliary technical means derived from the above-mentioned necessary technical means, the peripheral surface is sequentially distinguished along the first direction with a first end portion, an antenna forming region and a second end portion, and step (b) is performed at the first end A conductive metal layer is formed at the first end, the antenna forming area and the second end, the step (c) is to project the laser cutting beam to the conductive metal layer covering the antenna forming area, and the step (d) is to use the laser cutting beam to cover the conductive metal layer. The conductive metal layer of the antenna forming region is cut to form at least one helical structure body, so that the helical metal antenna structure includes at least one helical structure body.

Preferably, a step (e) is further included after the step (d), and the step (e) is to form an insulating protective layer on the antenna forming region and cover the helical structure body.

In order to solve the problems of the prior art, another necessary technical means adopted by the present invention is to provide a helical antenna assembly, which includes an insulating cylindrical body and a helical metal antenna structure. The insulating cylindrical body extends along a central axis and has a peripheral surface. The at least one helical metal antenna structure is helically wound around the peripheral surface of the insulating cylindrical body, and is formed by cutting a conductive metal layer covering the peripheral surface of the insulating cylindrical body by at least one laser cutting beam.

In an auxiliary technical means derived from the above-mentioned necessary technical means, the peripheral surface is divided into a first end portion, an antenna forming region and a second end portion in sequence along the first direction, and the helical metal antenna structure further includes at least one The helical structure body is formed in the antenna forming area.

In an auxiliary technical means derived from the above-mentioned necessary technical means, the helical antenna assembly further includes an insulating protective layer which covers the helical structure body in the antenna forming area.

In an auxiliary technical means derived from the above-mentioned necessary technical means, the helical metal antenna structure further comprises a first metal end ring and a second metal end ring, and the first metal end ring and the second metal end ring are respectively covered with At the first end portion and the second end portion, the helical structure body is located between the first metal end ring and the second metal end ring, and is integrally connected to the first metal end ring and the second metal end ring.

In an auxiliary technical means derived from the above-mentioned necessary technical means, the helical structure body has a width, and the width is between 1 μm and 100 μm.

In an auxiliary technical means derived from the above-mentioned necessary technical means, the helical structure body has a helical pitch, and the helical pitch is between 9 μm and 200 μm.

As mentioned above, because the present invention uses the laser cutting beam projected by the laser device to cut the rotating part when at least one of the laser device and the insulating cylindrical body moves along a first direction parallel to the central axis The conductive metal layer generates a helical metal antenna structure, whereby the helical metal antenna structure of the present invention can still maintain the shape of a helical antenna in a very small size.

The specific embodiments adopted by the present invention will be further described by the following embodiments and drawings.

Please refer to Figures 1 to 4. Figure 1 is a schematic three-dimensional view of an insulating cylindrical body prepared in the manufacturing method of the helical antenna assembly of the present invention; Figure 2 is a schematic diagram of the helical antenna assembly of the present invention. In the manufacturing method of the present invention, a three-dimensional schematic diagram of forming a conductive metal layer on the peripheral surface of the insulating cylindrical body; the third diagram shows the laser cutting beam projected by the laser device in the manufacturing method of the helical antenna assembly of the present invention A three-dimensional schematic view projected onto the conductive metal layer; the fourth figure shows that in the manufacturing method of the helical antenna element of the present invention, the insulating cylindrical body is rotated with the central axis as the central axis of rotation, and the insulating cylindrical body is rotated along the first direction A three-dimensional schematic diagram of the helical metal antenna structure by moving the conductive metal layer to be cut.

As shown in the first figure, a manufacturing method of a helical antenna assembly of the present invention firstly prepares an insulating cylindrical body 1, and the insulating cylindrical body 1 has a central axis x and a peripheral surface 11; wherein, the insulating cylindrical body 1 is a Extending along the central axis x, the peripheral surface 11 sequentially defines a first end portion 111 , an antenna forming region 112 and a second end portion 113 along a first direction D1 parallel to the central axis x.

As shown in the first and second figures, after the insulating cylindrical body 1 is prepared in the manufacturing method of the helical antenna assembly of the present invention, a conductive metal layer 20 is formed covering the peripheral surface 11 of the insulating cylindrical body 1 . And the thickness of the conductive metal layer 20 (not shown in the figure) is between 10 μm and 300 μm; in this embodiment, the conductive metal layer 20 is formed on the first end 111 of the peripheral surface 11 by an electroplating process, and the antenna is formed The material of the region 112 and the second end 113, and the conductive metal layer 20 is copper, but not limited thereto, other metals with high electrical conductivity, such as silver or gold, may also be used.

As shown in the first to third figures, after the conductive metal layer 20 is formed in the manufacturing method of the helical antenna element of the present invention, a laser cutting beam 201 projected by a laser device 200 is projected onto the conductive metal Layer 20 ; wherein, the laser cutting beam 201 projected by the laser device 200 of this embodiment is projected to the conductive metal layer 20 at a position adjacent to the second end 113 within the range of the antenna forming region 112 .

As shown in FIGS. 1 to 4, after the laser device 200 is used to project the laser cutting beam 201 to the conductive metal layer 20 in the manufacturing method of the helical antenna element of the present invention, the insulating cylindrical body 1 is arranged to have a center axis x. It rotates along a rotation direction R1 for a rotation center axis, and makes the insulating cylindrical body 1 move along the first direction D1, so as to use the laser cutting beam 201 to cut the conductive metal layer 20 into a helical metal antenna structure 2, and then make the spiral The spiral metal antenna structure 2 and the insulating cylindrical body 1 form a helical antenna assembly 100 .

Please continue to refer to Figures 1 to 6, Figure 5 is a schematic plan view of the helical antenna assembly of the present invention having a helical metal antenna structure; Figure 6 is an enlarged schematic diagram of circle A in Figure 5. As shown in FIGS. 1 to 6 , the helical antenna assembly 100 of this embodiment includes an insulating cylindrical body 1 and a helical metal antenna structure 2 . The insulating cylindrical body 1 extends along the central axis x and has a peripheral surface 11, and the peripheral surface 11 is divided into a first end portion 111, an antenna forming region 112 and a second end in sequence along a first direction D1 parallel to the central axis x. Section 113.

The helical metal antenna structure 2 includes a helical structure body 21 , a second metal end ring 22 and a first metal end ring 23 . The helical structure body 21 is formed in the antenna forming area 112 in a helical extension, and the first metal end ring 23 The first end portion 111 and the second end portion 113 are respectively covered with the second metal end ring 22 , and the spiral structure body 21 is located between the first metal end ring 23 and the second metal end ring 22 and is integrally formed. The ground is connected to the first metal end ring 23 and the second metal end ring 22 .

In more detail, the helical structure body 21 is formed by a strip-shaped conductive metal extending along the helical line on the antenna forming region 112 and wound multiple times, and in this embodiment, the helical structure body 21 has a width w1, w1 is 1 μm to 100 μm, and the helical structure body 21 has a pitch p1, the pitch p1 is the distance between each turn of the helical structure body 21 , and the pitch p1 is 9 μm to 200 μm; wherein, the width w1 is smaller than the pitch p1, and the width The sum of w1 and the pitch p1 is equal to the thickness of the helical structure body 21 (corresponding to the thickness of the above-mentioned conductive metal layer 20 , ie, 10 μm to 300 μm). In addition, in this embodiment, the lengths of the first metal end ring 23 and the second metal end ring 22 in the first direction D1 are both 2 mm, which means that when the laser cutting beam 201 is used to cut the conductive metal layer 20, It is cut from the conductive metal layer 20 at a distance of 2 mm from the end (ie, the junction between the antenna forming area 112 and the second end 113 ) until the conductive metal layer 20 is 2 mm away from the other end (ie, the antenna forming area 112 and the first end. 111 junction).

As mentioned above, in this embodiment, the conductive metal layer 20 is driven to rotate along the rotation direction R1 through the insulating cylindrical body 1 while moving along the first direction D1, and then cooperates with the laser cutting beam 201 of the laser device 200 to cut the coated antenna The conductive metal layer 20 of the region 112 is formed to form the helical metal antenna structure 2, so the user can control the diameter of the laser cutting beam 201 and the rotational speed and moving speed of the insulating cylindrical body 1 to control the helical helical structure body 21. Width w1 and pitch p1.

In practice, since the helical metal antenna structure 2 is cut by the laser cutting beam 201 , the grooves formed between each turn of the helical structure body 21 may also have a trapezoidal cross-sectional shape that is wider outside and narrower inside. It is possible to slightly cut part of the insulating cylindrical body 1 to recess the antenna forming region 112 inward.

As can be seen from the above description, since the helical antenna assembly 100 of the present invention utilizes the helical structure body 21 of the helical metal antenna structure 2 to achieve the function of the helical antenna, the first metal end of the helical structure body 21 can be connected to the first metal end of the helical structure body 21 during use. At least one of the ring 23 and the second metal end ring 22 is electrically connected to an antenna feed point (not shown in the figure), so that the helical metal antenna structure 2 can function as an antenna, but it is not limited to this, in other practical applications In this way, the circuit can also be electrically connected to any point of the helical metal antenna structure 2 according to actual needs, or used in conjunction with other induction coils, or even used to sense and receive charges in the environment.

Please continue to refer to FIG. 7. FIG. 7 is a schematic plan view showing that the helical antenna assembly of the present invention further forms an insulating protective layer covering the helical structure body on the peripheral surface. As shown in FIGS. 5 to 7 , after the conductive metal layer 20 is cut into the helical metal antenna structure 2 , an insulating protective layer 3 may be formed on the peripheral surface 11 to coat the spiral structure with the insulating protective layer 3 The body 21 is used to form another helical antenna assembly 100 ′. Compared with the aforementioned helical antenna assembly 100 , the helical antenna assembly 100 ′ differs only in that the helical antenna assembly 100 ′ further includes a covering helical structure body 21 The insulating protective layer 3 can effectively pass through the insulating protective layer 3 to further reduce the risk of short circuit problems in each turn of the spiral structure body 21 due to the short pitch p1.

Please refer to Figure 3 and Figure 8 together. Figure 8 shows that in the manufacturing method of the helical antenna assembly of the present invention, the insulating cylindrical body is rotated around the central axis of rotation, and the laser device is rotated along the A three-dimensional schematic diagram of the structure of the helical metal antenna by cutting the conductive metal layer in the first direction. When the present invention uses the laser cutting beam 201 of the laser device 200 to cut the conductive metal layer 20 , in addition to controlling the insulating cylindrical body 1 to move along the first direction D1 and rotate along the rotation direction R1 as shown in the third figure above, and then cooperate with the laser In addition to the cutting method of the laser cutting beam 201 of the device 200, as shown in the eighth figure, the insulating cylindrical body 1 can be controlled to rotate along the rotation direction R1, and then the laser device 200 can be controlled to rotate along a first direction opposite to the first direction D1. The two directions D2 move, so that the laser cutting beam 201 cuts the rotating conductive metal layer 20; in addition, in other embodiments, the insulating cylindrical body 1 can also move along the first direction D1, and the laser device 200 is controlled to move along the first direction D1. Move in the second direction D2.

Please refer to FIG. 9 and FIG. 10 together. FIG. 9 is a three-dimensional schematic diagram showing the structure of two helical metal antennas cut from the conductive metal layer by two laser devices in the manufacturing method of the helical antenna element of the present invention. ; Figure 10 is a schematic plan view showing that the helical antenna assembly of the present invention has two helical metal antenna structures. As shown in the ninth figure, in another embodiment of the present invention, two laser devices 200 and 200a can be used to project the laser cutting beams 201 and 201a to the conductive metal layer 20, respectively, so as to generate the laser beams 201 and 201a as shown in the tenth figure. The helical antenna assembly 100a includes the aforementioned insulating cylindrical body 1 and a helical metal antenna structure 2a; wherein, the helical metal antenna structure 2a includes two helical structure bodies 21a and 22a, a second metal end The ring 23a and a first metal end ring 24a, the helical structure bodies 21a and 22a are both formed in the antenna forming region 112 to extend helically, and the helical structure body 21a has a pitch p2, and the helical structure body 22a has a pitch p3, and because The coils of the helical structure bodies 21a and 22a are interlaced with each other, so it is equivalent that the helical structure body 21a extends into the pitch p3 of the helical structure body 22a, and the helical structure body 21a extends into the pitch p2 of the helical structure body 21a. In addition, the spiral structure bodies 21a and 22a are located between the second metal end ring 23a and the first metal end ring 24a, and are integrally connected to the second metal end ring 23a and the first metal end ring 24a, respectively.

To sum up, compared with the existing helical antenna, the size of the helical antenna is often too large because the metal wire is too thick. The projected laser cutting beam cuts the rotating conductive metal layer, which can effectively form a very small helical metal antenna structure. Since the helical metal antenna structure is formed on the insulating cylindrical body, it can effectively The helical metal antenna structure is more stable in structure.

Through the detailed description of the preferred embodiments above, it is hoped that the features and spirit of the present invention can be described more clearly, and the scope of the present invention is not limited by the preferred embodiments disclosed above. On the contrary, the intention is to cover various modifications and equivalent arrangements within the scope of the claimed scope of the present invention.

100, 100', 100a: Helical Antenna Assembly 1: Insulating cylindrical body 11: Surrounding surface 111: First end 112: Antenna forming area 113: Second end 20: Conductive metal layer 2,2a: Helical metal antenna structure 21, 21a, 22a: helical structure ontology 22, 23a: Second metal end ring 23, 24a: First metal end ring 3: Insulation protective layer 200, 200a: Laser Devices 201, 201a: Laser Cutting Beams R1: Rotation direction x: center axis D1: first direction D2: Second direction w1: width p1, p2, p3: pitch

The first figure is a schematic three-dimensional view of the insulating cylindrical body prepared in the manufacturing method of the helical antenna assembly of the present invention; The second figure is a perspective view of forming a conductive metal layer on the peripheral surface of the insulating cylindrical body in the manufacturing method of the helical antenna element of the present invention; Figure 3 is a schematic three-dimensional view of projecting the laser cutting beam projected by the laser device to the conductive metal layer in the manufacturing method of the helical antenna element of the present invention; The fourth figure shows that in the manufacturing method of the helical antenna assembly of the present invention, the insulating cylindrical body is rotated with the central axis as the central axis of rotation, and the insulating cylindrical body is moved along the first direction, so that the conductive metal layer is cut into Three-dimensional schematic diagram of the helical metal antenna structure; Fig. 5 is a schematic plan view showing that the helical antenna assembly of the present invention has a helical metal antenna structure; The sixth picture is an enlarged schematic diagram of circle A in the fifth picture; Fig. 7 is a schematic plan view showing that the helical antenna assembly of the present invention further forms an insulating protective layer covering the helical structure body on the peripheral surface; The eighth figure shows that in the manufacturing method of the helical antenna element of the present invention, the insulating cylindrical body is rotated with the central axis as the central axis of rotation, and the laser device is moved along the first direction to cut the conductive metal layer into Three-dimensional schematic diagram of the helical metal antenna structure; FIG. 9 is a three-dimensional schematic diagram showing two helical metal antenna structures cut from the conductive metal layer by two laser devices in the manufacturing method of the helical antenna element of the present invention; and FIG. 10 is a schematic plan view showing that the helical antenna assembly of the present invention has a double helical metal antenna structure.

100: Helical Antenna Assembly

1: Insulating cylindrical body

112: Antenna forming area

2: Spiral metal antenna structure

21: Spiral structure body

22: Second metal end ring

23: The first metal end ring

200: Laser device

201: Laser Cutting Beam

R1: Rotation direction

x: center axis

D1: first direction

Claims (3)

A manufacturing method of a helical antenna assembly, comprising the following steps: (a) preparing an insulating cylindrical body, and the insulating cylindrical body has a central axis and a peripheral surface, and the peripheral surface is along a first direction parallel to the central axis Distinguish a first end portion, an antenna forming region and a second end portion in sequence; (b) forming a conductive metal layer covering the first end portion, the antenna forming region and the second end portion; ( c) projecting at least one laser cutting beam projected by at least one laser device to the conductive metal layer covering the antenna forming area; (d) making the insulating cylindrical body take the central axis as a central axis of rotation to rotate Rotate and move at least one of the at least one laser device and the insulating cylindrical body along the first direction, so as to use the at least one laser cutting beam to cut the conductive metal layer covering the antenna forming region to form At least one helical structure body, so that the conductive metal layer is cut into a helical metal antenna structure including a first metal end ring, the at least one helical structure body and a second metal end ring, the first metal end ring and the helical metal antenna structure The second metal end ring covers the first end portion and the second end portion respectively, and the at least one helical structure body is located between the first metal end ring and the second metal end ring and is integrally formed. connected to the first metal end ring and the second metal end ring, so that the helical metal antenna structure and the insulating cylindrical body form the helical antenna assembly, wherein the at least one helical structure body has a width and a pitch, The width is between Between 1 μm and 100 μm, the pitch is between 9 μm and 200 μm; and (e) forming an insulating protective layer in the antenna forming area, so that the insulating protective layer is filled into the helical groove of the at least one helical structure body inside, so as to cover the at least one helical structure body. The manufacturing method of the helical antenna element as claimed in claim 1, wherein the step (b) is to form the conductive metal layer by an electroplating process. A helical antenna assembly, comprising: an insulating cylindrical body extending along a central axis and having a peripheral surface, the peripheral surface is sequentially divided along a first direction parallel to the central axis with a first end, an antenna forming area and a second end; a helical metal antenna structure, by rotating the insulating cylindrical body with the central axis as a central axis of rotation, and using at least one laser device and the insulating cylindrical body At least one of them moves along the first direction to cause at least one laser cutting beam projected by the at least one laser device to cut a conductive metal layer covering the peripheral surface of the insulating cylindrical body to form a first metal An end ring, at least one helical structure body and a second metal end ring, the first metal end ring and the second metal end ring are respectively clad on the first end and the second end, the at least one helix The structural body is formed in the antenna forming area between the first metal end ring and the second metal end ring, and is integrally connected to the first metal end ring and the second metal end ring, wherein the at least A helical structure body has a width and a pitch, the width is between 1 μm and 100 μm, the pitch is between 9 μm and 200 μm; and an insulating protection layer is filled with the at least The at least one helical structure body is covered in the helical groove of a helical structure body.

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