WO2014148121A1 - 構造体、無線通信装置および構造体の製造方法 - Google Patents
構造体、無線通信装置および構造体の製造方法 Download PDFInfo
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- WO2014148121A1 WO2014148121A1 PCT/JP2014/052212 JP2014052212W WO2014148121A1 WO 2014148121 A1 WO2014148121 A1 WO 2014148121A1 JP 2014052212 W JP2014052212 W JP 2014052212W WO 2014148121 A1 WO2014148121 A1 WO 2014148121A1
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- resin layer
- conductive pattern
- region
- resin
- exposed region
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/0011—Working of insulating substrates or insulating layers
- H05K3/0014—Shaping of the substrate, e.g. by moulding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/16—Making multilayered or multicoloured articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/16—Making multilayered or multicoloured articles
- B29C45/1671—Making multilayered or multicoloured articles with an insert
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01Q—ANTENNAS, i.e. RADIO AERIALS
- H01Q1/00—Details of, or arrangements associated with, antennas
- H01Q1/12—Supports; Mounting means
- H01Q1/22—Supports; Mounting means by structural association with other equipment or articles
- H01Q1/24—Supports; Mounting means by structural association with other equipment or articles with receiving set
- H01Q1/241—Supports; Mounting means by structural association with other equipment or articles with receiving set used in mobile communications, e.g. GSM
- H01Q1/242—Supports; Mounting means by structural association with other equipment or articles with receiving set used in mobile communications, e.g. GSM specially adapted for hand-held use
- H01Q1/243—Supports; Mounting means by structural association with other equipment or articles with receiving set used in mobile communications, e.g. GSM specially adapted for hand-held use with built-in antennas
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- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04M—TELEPHONIC COMMUNICATION
- H04M1/00—Substation equipment, e.g. for use by subscribers
- H04M1/02—Constructional features of telephone sets
- H04M1/0202—Portable telephone sets, e.g. cordless phones, mobile phones or bar type handsets
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- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04M—TELEPHONIC COMMUNICATION
- H04M1/00—Substation equipment, e.g. for use by subscribers
- H04M1/02—Constructional features of telephone sets
- H04M1/0202—Portable telephone sets, e.g. cordless phones, mobile phones or bar type handsets
- H04M1/0249—Details of the mechanical connection between the housing parts or relating to the method of assembly
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/02—Details
- H05K1/0284—Details of three-dimensional rigid printed circuit boards
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/02—Details
- H05K1/03—Use of materials for the substrate
- H05K1/0313—Organic insulating material
- H05K1/032—Organic insulating material consisting of one material
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/02—Details
- H05K1/11—Printed elements for providing electric connections to or between printed circuits
- H05K1/119—Details of rigid insulating substrates therefor, e.g. three-dimensional details
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/36—Assembling printed circuits with other printed circuits
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/0053—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping
- B29C2045/0079—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping applying a coating or covering
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/16—Making multilayered or multicoloured articles
- B29C2045/1687—Making multilayered or multicoloured articles preventing leakage of second injected material from the mould cavity
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2055/00—Use of specific polymers obtained by polymerisation reactions only involving carbon-to-carbon unsaturated bonds, not provided for in a single one of main groups B29K2023/00 - B29K2049/00, e.g. having a vinyl group, as moulding material
- B29K2055/02—ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2069/00—Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2009/00—Layered products
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/34—Electrical apparatus, e.g. sparking plugs or parts thereof
- B29L2031/3456—Antennas, e.g. radomes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/34—Electrical apparatus, e.g. sparking plugs or parts thereof
- B29L2031/3481—Housings or casings incorporating or embedding electric or electronic elements
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/16—Printed circuits incorporating printed electric components, e.g. printed resistor, capacitor, inductor
- H05K1/165—Printed circuits incorporating printed electric components, e.g. printed resistor, capacitor, inductor incorporating printed inductors
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/09—Shape and layout
- H05K2201/09009—Substrate related
- H05K2201/09018—Rigid curved substrate
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/09—Shape and layout
- H05K2201/09009—Substrate related
- H05K2201/09045—Locally raised area or protrusion of insulating substrate
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/09—Shape and layout
- H05K2201/09009—Substrate related
- H05K2201/09118—Moulded substrate
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/09—Shape and layout
- H05K2201/09209—Shape and layout details of conductors
- H05K2201/09372—Pads and lands
- H05K2201/09472—Recessed pad for surface mounting; Recessed electrode of component
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/09—Shape and layout
- H05K2201/09818—Shape or layout details not covered by a single group of H05K2201/09009 - H05K2201/09809
- H05K2201/09827—Tapered, e.g. tapered hole, via or groove
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/09—Shape and layout
- H05K2201/09818—Shape or layout details not covered by a single group of H05K2201/09009 - H05K2201/09809
- H05K2201/09845—Stepped hole, via, edge, bump or conductor
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/09—Shape and layout
- H05K2201/09818—Shape or layout details not covered by a single group of H05K2201/09009 - H05K2201/09809
- H05K2201/0999—Circuit printed on or in housing, e.g. housing as PCB; Circuit printed on the case of a component; PCB affixed to housing
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
- H05K2201/10007—Types of components
- H05K2201/10098—Components for radio transmission, e.g. radio frequency identification [RFID] tag, printed or non-printed antennas
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
- H05K2201/10227—Other objects, e.g. metallic pieces
- H05K2201/10265—Metallic coils or springs, e.g. as part of a connection element
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/20—Details of printed circuits not provided for in H05K2201/01 - H05K2201/10
- H05K2201/2036—Permanent spacer or stand-off in a printed circuit or printed circuit assembly
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2203/00—Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
- H05K2203/13—Moulding and encapsulation; Deposition techniques; Protective layers
- H05K2203/1305—Moulding and encapsulation
- H05K2203/1322—Encapsulation comprising more than one layer
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2203/00—Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
- H05K2203/14—Related to the order of processing steps
- H05K2203/1476—Same or similar kind of process performed in phases, e.g. coarse patterning followed by fine patterning
Definitions
- the present invention relates to a structure including a conductive pattern, a wireless communication device including the structure, and a method for manufacturing the structure.
- Patent Document 1 a technique for forming a conductive pattern integrally with a casing has been developed in order to reduce the thickness of an electronic device and simplify the configuration thereof.
- Patent Document 1 discloses a casing in which a first injection layer, a second injection layer, an antenna radiator, and an outer layer are stacked in this order.
- a conductive connection part for exchanging signals with the antenna radiator is insert-molded.
- Patent Document 1 when any of the layers is formed, if resin flows out between the antenna radiator and the conductive connection portion, the conductive surface is covered with the resin, and the antenna radiator is conductively connected. There is a risk of poor continuity with the part.
- This invention is made
- the conductive pattern is to suppress poor conduction at a contact point for electrically connecting to another member.
- a structure according to one embodiment of the present invention is formed by forming a second resin layer on a first resin layer having a conductive pattern formed on a surface thereof so as to sandwich the conductive pattern.
- the first resin layer has a covered region covered with the second resin layer and an exposed region not covered with the second resin layer, and the conductive pattern is formed in the exposed region. It has a contact portion where a contact for electrical connection to another member is disposed, and the surface of the first resin layer is bent between the boundary between the covering region and the exposed region and the contact portion. It is characterized by having a bent portion.
- the bent portion is provided between the boundary between the covered region and the exposed region and the contact portion, when the second resin layer is formed, the bent portion faces the contact portion.
- the resin flowing out is blocked and the formation of burrs on the contact portion can be suppressed.
- the conduction defect in the contact for electrically connecting a conductive pattern to another member can be suppressed suitably.
- FIG. 1 is a side sectional view schematically showing a schematic configuration of a wireless communication apparatus according to an embodiment (Embodiment 1) of the present invention. It is a side sectional view explaining typically each process of a manufacturing method of a structure concerning one embodiment (embodiment 1) of the present invention. It is side sectional drawing which shows the variation of the shape of the structure which concerns on one Embodiment (Embodiment 1) of this invention.
- FIG. 6C is a side cross-sectional view schematically illustrating one step of the method for manufacturing the structure according to FIG. 5C, and FIG. It is a side sectional view showing typically the state at the time.
- (A) is side sectional drawing which shows typically schematic structure of the structure which concerns on one Embodiment (Embodiment 3) of this invention,
- (b) is one Embodiment (Embodiment 3) of this invention. It is a sectional side view explaining typically one process of the manufacturing method of the structure concerning).
- the structure according to the present invention is incorporated in a general electronic device that requires a conductive pattern as an antenna element, a signal transmission path, a power transmission path, and the like, thereby providing the conductive pattern to the electronic device.
- a structure according to the present invention is incorporated in a wireless communication device and provides an antenna element of an antenna included in the wireless communication device.
- the structure according to the present invention may be incorporated in an electronic device, for example, to provide a signal transmission path, a power transmission path, and the like that connect a circuit board and other electronic components, or a circuit. A path for connecting the substrate and the ground may be provided.
- the structure according to the present invention may be fixed to the electronic device or may be detachably attached.
- the structure concerning the present invention may constitute at least a part of the case of an electronic device.
- the structure according to the present invention can constitute a conductive pattern forming housing.
- the casing refers to a member that stores an electronic component included in the electronic device
- the conductive pattern forming casing refers to a casing in which a conductive pattern is formed.
- the structure according to the present invention is not limited to this, and may be a member other than the casing included in the electronic device.
- the conductive pattern is sandwiched between the first resin layer and the second resin layer, exposure of the conductive pattern to the outside can be suppressed. Thereby, aesthetics can be secured and damage, deformation, deterioration, etc. of the conductive pattern can be prevented.
- Both the first resin layer and the second resin layer are injection molded products, and may be made of the same resin or different resins.
- the resin constituting the first resin layer and the second resin layer is not limited to these.
- acrylonitrile-butadiene-styrene resin ABS
- polycarbonate-acrylonitrile-butadiene-styrene resin PC-ABS
- One or more resins selected from polycarbonate (PC), acrylonitrile-styrene resin (AS), polyethylene (PE), polypropylene (PP), polystyrene (PS), methacrylic resin (PMMA) and the like can be used. These resins may be mixed with other materials such as glass in order to increase the strength.
- a resin having higher heat resistance than the resin constituting the second resin layer may be used as the resin constituting the first resin layer.
- a resin having higher heat resistance than the resin constituting the second resin layer may be used as the resin constituting the first resin layer.
- PC can be used as the resin constituting the first resin layer
- ABS can be used as the resin constituting the second resin layer.
- the conductive pattern is a pattern made of a conductor formed on the surface of the first resin layer.
- the kind of the conductor is not particularly limited as long as it has conductivity, and metals such as copper, iron, nickel, and gold, conductive polymers, conductive carbon, and the like can be used.
- the method for forming the conductive pattern is not particularly limited.
- the conductive pattern may be formed by plating a metal on the surface of the first resin layer, or a conductive paste containing a conductor
- a conductive pattern may be formed by printing on the surface of one resin layer, or a conductive pattern by sticking a flexible thin film conductive material such as copper foil to the surface of the first resin layer. May be formed.
- the conductor used for forming the conductive pattern is not limited to one type.
- a conductive pattern may be formed by combining a plurality of conductors such as gold plating on a copper pattern.
- the conductive pattern can be formed using an LDS (Laser Direct Structure) method. That is, an organic metal is mixed with the resin constituting the first resin layer, and the region on the surface of the first resin layer where the conductive pattern is formed is irradiated with laser. Thereby, an organic metal is deposited on the laser irradiation portion, and the laser irradiation portion is finely roughened (unevenness is formed), and the organic metal is bonded to the laser irradiation portion, thereby suitably forming a conductive pattern. be able to.
- the conductive pattern may be formed using a DPA (Direct Printed Antenna) method.
- the DPA method is a method in which a printing plate for preparing a conductive pattern is prepared in advance, and the shape of the conductive pattern is transferred from the plate to a resin surface with a pad or the like.
- the conductive pattern is generated on the surface of the first resin layer by laser irradiation, the first resin layer and the conductive pattern adhere very strongly.
- the first resin layer has a covered area covered with the second resin layer and an exposed area not covered with the second resin layer. In the exposed region, the conductive pattern and other members are electrically connected.
- positioned is called a contact part.
- the contact portion can be provided at any position within the exposed region.
- a member that is electrically connected to the conductive pattern at the contact point is not particularly limited, and may be a connection member such as a conductive spring member.
- the structure according to the present invention can be manufactured, for example, as follows. First, a first resin layer is formed into a desired shape using a known injection molding technique (first resin layer forming step). Next, a conductive pattern is formed on the surface of the first resin layer using the method described above (conductive pattern forming step).
- a second resin layer is laminated on the first resin layer so as to sandwich the conductive pattern (lamination process).
- the second resin layer is insert-molded so as to be molded integrally with the already formed first resin layer. That is, by molding the second resin layer with the first resin layer disposed on the mold (insert molding), the first resin layer and the second resin layer are placed in a region where no conductive pattern exists. Good adhesion (adhesion) can be achieved.
- the resin forming the second resin layer may flow from the covered region to the exposed region through the gap between the first resin layer and the mold.
- burrs are formed on the contact portion in the exposed region due to the resin that has flowed into the exposed region, there is a possibility that poor conduction occurs in the contact.
- the bent portion is provided between the boundary between the covering region and the exposed region and the contact portion, the resin flowing out from the boundary toward the contact portion is blocked. It is possible to suppress the formation of burrs on the contact portion. Thereby, the conduction defect in the contact for electrically connecting a conductive pattern to another member can be suppressed suitably. As a result, reliability is improved and yield is improved.
- bending indicates that the sheet is bent discontinuously, more preferably 3 degrees or more and 90 degrees or less, and particularly preferably 20 degrees or more and 90 degrees or less.
- FIG. 1 is a side sectional view showing a schematic configuration of a structure 10 according to an embodiment (Embodiment 1) of the present invention.
- the structure 10 includes a first resin layer 1, a second resin layer 2, and a conductive pattern 3.
- the second resin layer 2 is formed so as to sandwich the conductive pattern 3 on the first resin layer 1 on which the conductive pattern 3 is formed.
- the first resin layer 1 has a covered region covered with the second resin layer 2 and an exposed region 1a not covered with the second resin layer 2, and the conductive pattern 3 is in the exposed region 1a. It has the contact part 1b by which the contact for electrically connecting to this member is arrange
- the second resin layer 2 surrounds the entire periphery of the exposed region 1a.
- the 1st resin layer 1 has the bending part 1c where the surface of the 1st resin layer 1 bends between the boundary of the coating
- the structure 10 can be incorporated in the wireless communication device 40.
- the structure 10 constitutes a casing (conductive pattern forming casing) of the wireless communication device 40 together with the upper casing 30, and stores the circuit board 31 on which a wireless circuit and the like are mounted.
- the circuit board 31 is electrically connected to the conductive pattern of the structure 10 at the contact point disposed on the contact point part 1 b via the connection member 32.
- the connection member 32 is electrically connected to the circuit board 31 and can be, for example, a spring member.
- the wireless communication device 40 uses the conductive pattern of the structure 10 as an antenna element.
- the wireless communication device 40 includes a housing including the structure 10 and an antenna including a conductive pattern.
- the structure according to the present invention is not limited to this, and may be incorporated in an electronic device other than the wireless communication device.
- FIG. 3 is a side cross-sectional view schematically illustrating each step of the method for manufacturing the structure 10 according to the first embodiment.
- Embodiment 1 after molding the first resin layer 1 (see FIG. 3B) using the mold 50 and the mold 51 (see FIG. 3A), the first resin layer 1 is formed. A conductive pattern 3 is formed on the substrate (see FIG. 3C). Then, the first resin layer 1 on which the conductive pattern 3 is formed is put so that the molding die 52 and the convex portion of the exposed region are fitted (see FIGS. 3D and 3G), and the second resin The layer 2 is molded so as to be integrated with the first resin layer 1 (see FIG. 3E), and the structure 10 is completed (see FIG. 3F).
- FIG. 11 is a side cross-sectional view schematically illustrating each step of the manufacturing method of the structure according to the reference technique in which the bent portion 1c does not exist unlike the present invention.
- the first resin layer 7 is molded (see FIG. 11B) using the molding die 54 and the molding die 55 (see FIG. 11A)
- the first resin layer 7 is formed.
- a conductive pattern 9 is formed on the substrate (see FIG. 11C).
- the first resin layer 7 on which the conductive pattern 9 is formed is placed in the mold 56 and the mold 57 (see FIG. 11D), and the second resin layer 8 is integrated with the first resin layer 7. (See (e) of FIG. 11) to complete the structure 27 (see (f) of FIG. 11).
- the second resin layer 8 is molded (see FIG. 11E), from the boundary Y between the covered region where the second resin layer is formed and the exposed region where the second resin layer is formed.
- the resin that forms the second resin layer may flow out toward the exposed region, resulting in burrs Z (see (g) of FIG. 11).
- this burr Z reaches the contact portion 7b, the electrical connection between the conductive pattern 9 on the contact portion 7b and another member is hindered.
- the outflow of the resin from the boundary Y to the contact portion 7b is not limited to the structure 27 in which the conductive pattern 9 of the first resin layer 7 is formed as shown in FIG. This can also occur in the configuration shown in FIG. That is, the resin can flow out from the boundary Y to the contact portion 7b even in the structure 28 in which the contact portion 7b of the first resin layer 7 is flush with the second resin layer 8 as shown in FIG. Also, in the structure 29 in which the contact portion 7b of the first resin layer 7 is located closer to the first resin layer 7 than the second resin layer 8 as shown in FIG. 12B, the boundary Y to the contact portion 7b. The resin can flow out.
- a bent portion 1c is provided between the boundary between the covered region and the exposed region 1a and the contact portion 1b. Therefore, as shown in FIG. 3 (g), when the second resin layer 2 is molded, the resin flowing out from the boundary A toward the contact portion 1b is successfully transferred at the position indicated by the broken-line circle in the figure. It can block well and can suppress a burr
- the exposed region 1a has a convex portion, and the concave portion of the molding die 52 is fitted to this, so that the contact portion 1b is completely covered by the molding die 52, and the second contact portion 1b is reached. The inflow of the resin forming the resin layer 2 can be suppressed.
- the structure of the contact part 1b can be reduced in size.
- the structure 10 when the structure 10 is incorporated in the wireless communication device 40, poor conduction between the antenna including the conductive pattern 3 and the wireless circuit (circuit board 31) included in the wireless communication device 40 is caused. It can suppress suitably.
- the second resin layer 2 when observed from the second resin layer 2 side (the upper side in the drawing), the second resin layer 2 is not necessarily provided around the entire exposed region 1a. It is not necessary that the second resin layer 2 be provided on at least a part of the periphery of the exposed region 1a. In the present invention, when the second resin layer 2 provided on at least a part of the periphery of the exposed region 1a is close to the contact portion 1b, the burr is prevented from flowing into the contact portion 1b. It is the purpose.
- FIG. 5A is a side sectional view showing a schematic configuration of the structure 13 according to one embodiment (second embodiment) of the present invention.
- region 1a has a recessed part which is concave with respect to the adjacent coating
- the bent portion 1c is provided between the boundary A of the covered region and the exposed region and the contact portion 1b, the second resin When the layer 2 is molded, the resin flowing out from the boundary A toward the contact portion 1b can be successfully blocked, and the formation of burrs on the contact portion 1b can be suppressed.
- the exposed region has a concave portion
- the contact portion 1b is completely covered with the molding die 52 by fitting the convex portion of the molding die 52 to the concave portion.
- the inflow of the resin forming the two resin layer 2 can be suppressed.
- the second resin layer 2 surrounds the entire periphery of the exposed region, but this embodiment is not limited to this.
- the second resin layer 2 only needs to be provided on at least a part of the periphery of the exposed region.
- the circuit board 31 and the second resin layer 2 are preferably brought into contact with each other. Thereby, the distance between the circuit board 31 and the structure 13 can be maintained, the connection member 32 can be prevented from being crushed and deformed more than necessary, and the circuit board 31 and the conductive pattern 3 can be connected well.
- FIG. 6A is a side sectional view showing a schematic configuration of the structure 14 according to one embodiment (third embodiment) of the present invention.
- the contact portion 1 b and the second resin layer 2 are flush with each other.
- the resin forming the second resin layer 2 may flow into the contact portion 1b.
- a bent portion 1c is formed between the boundary A of the covered region and the exposed region 1a and the contact portion 1b.
- the second resin layer 2 surrounds the entire periphery of the exposed region 1a, and notches B are provided around the entire exposed region 1a.
- the present embodiment is not limited to this, and the second resin layer 2 is provided on at least a part of the periphery of the exposed region 1a, and the second resin layer 2 is exposed to the exposed region 1a.
- the notch B should just be provided in a boundary.
- FIG. 7 is a side sectional view showing a variation of the shape of the structure according to the third embodiment.
- the bottom surface of the notch B may be the top surface of the first resin layer 1.
- the bottom surface of the notch B may be a recess provided in the first resin layer 1.
- the depth of the notch B may be different depending on the location.
- the shape of the notch B is not particularly limited as long as the exposed region 1a and the mold can be fitted.
- FIG. 8A is a side sectional view showing a schematic configuration of the structure 19 according to one embodiment (Embodiment 4) of the present invention.
- the contact portion 1 b is located on the first resin layer 1 side (downward in the drawing) with respect to the second resin layer 2.
- the resin forming the second resin layer 2 may flow into the contact portion 1b.
- a bent portion 1c is provided between the boundary A of the covered region and the exposed region and the contact portion 1b, as shown in FIG. 8B.
- a concave portion surrounded by the convex portion C can be formed in the exposed region and can be fitted to the convex portion of the mold 52.
- the convex portions C are provided on the entire periphery of the outer edge of the exposed region, and the second resin layer 2 surrounds the entire periphery.
- the present embodiment is not limited to this, and the convex portion C is provided on at least a part of the outer edge of the exposed region, and the second resin layer 2 is provided so as to be adjacent to the convex portion C. It only has to be.
- FIG. 9 is a side sectional view showing a variation of the shape of the structure according to the fourth embodiment.
- the convex portion C is provided in the portion (L1) where the distance between the contact portion 1b and the second resin layer 2 is short, but the contact portion 1b and the second resin layer are provided.
- the configuration may be such that the convex portion C is not provided. That is, even if the resin forming the second resin layer 2 flows out, the convex portion C is formed on the portion where the distance between the contact portion 1b and the second resin layer 2 is long and no burr is formed up to the contact portion 1b. It does not have to be provided.
- the structure 21 shown in FIG. 9B is also the same.
- FIG. 10A is a side sectional view showing a schematic configuration of the structure 22 according to one embodiment (fifth embodiment) of the present invention.
- the 2nd resin layer 2 may be provided with the columnar part 2a which protrudes on the opposite side (paper surface upper direction) from the 1st resin layer 1.
- FIG. The columnar portion 2a is provided around the contact portion 1b.
- the wireless communication device when the circuit board is not incorporated as expected and the structure is incorporated, when the contact height of the connecting member (spring member) is shifted, or after the structure is incorporated, In the case where the contact portion is locally pushed with a very large force in response to an impact or the like, in the case where the position of the circuit board is momentarily displaced due to the impact or the like and bent toward the structure side, etc. In some cases, the amount of pushing pushed into the contact portion exceeds the allowable range, and the connecting member (for example, a spring member) is crushed and deformed, resulting in contact failure.
- the connecting member for example, a spring member
- connection member 32 can be prevented from being crushed more than necessary and deformed, and the circuit board and the conductive pattern can be satisfactorily connected.
- part which protrudes is not limited to columnar shape, For example, a wall shape may be sufficient.
- FIG. 13 shows a modification having such a configuration.
- FIG. 13A is a side sectional view showing a schematic configuration of a structure 24 according to a modification.
- the columnar portion 2a is provided on the side of the first resin layer 1 where the contact portion 1b is provided, and the second resin layer 2 is laminated on the opposite side. Then, as in the structure 22 according to the fifth embodiment, the columnar portion 2a and the circuit board 31 come into contact with each other, and the circuit board 31 and the conductive pattern 3 are avoided by preventing the connecting member 32 from being crushed and deformed more than necessary. And can be connected well.
- the bent portion 1c is provided between the boundary A of the covered region and the exposed region and the contact portion 1b, the second resin layer 2 is formed.
- the resin flowing out from the boundary A toward the contact portion 1b can be successfully blocked, and burrs can be prevented from being formed on the contact portion 1b.
- molding die 52 has can be fitted successfully.
- a structure according to one embodiment of the present invention is a structure formed by forming a second resin layer on a first resin layer having a conductive pattern formed on a surface thereof so as to sandwich the conductive pattern.
- One resin layer has a covering region covered by the second resin layer and an exposed region not covered by the second resin layer, and the conductive pattern is electrically connected to another member in the exposed region. And a bent portion where the surface of the first resin layer is bent between the boundary between the covered region and the exposed region and the contact portion.
- the bending part is provided between the boundary of a covering area
- the resin to be blocked is blocked, and the formation of burrs on the contact portion can be suppressed.
- the conduction defect in the contact for electrically connecting a conductive pattern to another member can be suppressed suitably.
- the exposed region may have a convex portion that is convex with respect to the adjacent covered region.
- the exposed region may have a recess that is recessed with respect to the adjacent coating region.
- the second resin layer may include a columnar portion that protrudes on the opposite side to the first resin layer.
- the columnar portion is brought into contact with the circuit board electrically connected to the conductive pattern, thereby supporting the circuit board and maintaining the distance between the circuit board and the structure.
- the circuit board and the conductive pattern can be satisfactorily connected.
- a wireless communication device includes a housing including the structure according to one aspect of the present invention and an antenna including the conductive pattern.
- the wireless communication apparatus may further include a circuit board and a connection member that is electrically connected to the circuit board and electrically connected to the conductive pattern at the contact point.
- the circuit board and the conductive pattern can be suitably connected.
- connection member is a spring member, and when the spring member is electrically connected to the conductive pattern at the contact, the circuit board is attached to the second resin layer. You may come to contact
- the circuit board and the conductive pattern can be prevented by keeping the distance between the circuit board and the structure by contacting the circuit board with the circuit board, and avoiding the spring member being crushed and deformed more than necessary. And can be connected well.
- a method for manufacturing a structure according to one embodiment of the present invention is a method for manufacturing a structure according to one embodiment of the present invention, wherein the first resin layer on which the conductive pattern is formed is placed in a mold, and A molding step is included in which the second resin layer is molded integrally with the first resin layer in a state where the molding die and the exposed region are fitted.
- the present invention can be used in the field of manufacturing a structure including a conductive pattern and a wireless communication device including the structure.
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Abstract
Description
本発明に係る構造体は、アンテナエレメント、信号伝送経路、電力伝送経路等としての導電パターンを必要とする電子装置一般に組み込まれることで、当該電子装置に当該導電パターンを提供するものである。例えば、一実施形態において、本発明に係る構造体は、無線通信装置に組み込まれ、当該無線通信装置が備えるアンテナのアンテナエレメントを提供するようになっている。本発明に係る構造体は、また、例えば、電子装置に組み込まれ、回路基板と他の電子部品とを接続する信号伝送経路、電力伝送経路等を提供するようになっていてもよいし、回路基板とグランドとを接続する経路を提供するようになっていてもよい。
図1は、本発明の一実施形態(実施形態1)に係る構造体10の概略構成を示す側方断面図である。図1に示すように、構造体10は、第一樹脂層1、第二樹脂層2および導電パターン3を備えている。第二樹脂層2は、導電パターン3が形成された第一樹脂層1上に、導電パターン3を挟むように成形されたものである。
まず、本発明における屈曲部が無い場合の問題について図面を参照して説明する。図11は、本発明とは異なり、屈曲部1cが存在しない参考技術に係る構造体の製造方法の各工程を模式的に説明する側方断面図である。当該参考技術では、成形型54および成形型55を用いて(図11の(a)参照)、第一樹脂層7を成形した後(図11の(b)参照)、第一樹脂層7上に導電パターン9を形成する(図11の(c)参照)。そして、成形型56および成形型57内に、導電パターン9が形成された第一樹脂層7を入れ(図11の(d)参照)、第二樹脂層8を、第一樹脂層7と一体になるように成形し(図11の(e)参照)、構造体27が完成する(図11の(f)参照)。
図3の(h)の左側に示すように、第二樹脂層2が、露出領域が有する凸部の側壁の一部まで延在していたとしても、被覆領域および露出領域の境界Aと接点部1bとの間に屈曲部1cが存在すれば、実施形態1と同等の効果を得ることができる。図4の(a)に示す構造体11のように、第二樹脂層2が露出領域1aの側壁の両側まで延在していたとしても同様である。
図5の(a)は、本発明の一実施形態(実施形態2)に係る構造体13の概略構成を示す側方断面図である。図5の(a)に示すように、構造体13では、露出領域1aは隣接する被覆領域に対して凹となっている凹部を有している。このような構造であっても、図5の(b)に示すように、被覆領域および露出領域の境界Aと、接点部1bとの間に屈曲部1cが設けられているため、第二樹脂層2を成形するときに、当該境界Aから接点部1bへ向かって流出する樹脂を首尾よく塞き止め、接点部1b上にバリが形成されることを抑制することができる。なお、実施形態2では、露出領域が凹部を有しており、これに、成形型52の凸部が嵌合することによって、接点部1bを成形型52によって完全に覆い、接点部1bまで第二樹脂層2を形成する樹脂が流入することを抑制することができる。
図6の(a)は、本発明の一実施形態(実施形態3)に係る構造体14の概略構成を示す側方断面図である。構造体14では、接点部1bと、第二樹脂層2とが面一になっている。このような場合、図12の(a)に示す構造体28のように、接点部1bまで第二樹脂層2を形成する樹脂が流入するおそれがあるが、実施形態3に係る構造体14では、露出領域1aの周りにノッチ(溝)Bを設けることにより、図6の(b)に示すように、被覆領域および露出領域1aの境界Aと、接点部1bとの間に屈曲部1cを設ける。すなわち、第二樹脂層2にノッチBを設けることによって、露出領域1aにおいて、隣接する被覆領域に対して凸となっている凸部が形成され、成形型52の凹部と嵌合させることができる。これにより、接点部1bの位置を、第二樹脂層2と同じ高さにする必要がある場合であっても、接点部1bまで第二樹脂層2を形成する樹脂が流入することを抑制することができる。
図8の(a)は、本発明の一実施形態(実施形態4)に係る構造体19の概略構成を示す側方断面図である。構造体19では、接点部1bが、第二樹脂層2よりも第一樹脂層1側(紙面下方)に位置している。このような場合、図12の(b)に示す構造体29のように、接点部1bまで第二樹脂層2を形成する樹脂が流入するおそれがあるが、実施形態4に係る構造体19では、露出領域1aの外縁部に凸部Cを設けることにより、図8の(b)に示すように、被覆領域および露出領域の境界Aと、接点部1bとの間に屈曲部1cを設ける。すなわち、露出領域に、凸部Cに囲まれた凹部を形成し、成形型52の凸部と嵌合させることができる。これにより、接点部1bの位置を、第二樹脂層2よりも第一樹脂層1側にする必要がある場合であっても、接点部1bまで第二樹脂層2を形成する樹脂が流入することを抑制することができる。
図10の(a)は、本発明の一実施形態(実施形態5)に係る構造体22の概略構成を示す側方断面図である。図10の(a)に示すように、第二樹脂層2は、第一樹脂層1とは反対側(紙面上方)に突出する柱状部2aを備えていてもよい。柱状部2aは、接点部1bの周囲に設けられている。そして、構造体22を、図2に示すような無線通信装置に組み込んだとき、導電パターン3に電気的に接続される回路基板31に対して、柱状部2aを当接させることにより、回路基板31を支えるとともに、回路基板31と構造体22との距離を保ち、回路基板31と導電パターン3とを良好に接続することができる。
なお、第二樹脂層2を、第一樹脂層1よりも外側(例えば、図2に示すように無線通信装置に組み込まれたときの外部側)に配置してもよい。言い換えれば、第一樹脂層1における接点部1bが設けられている側とは反対側に、第二樹脂層2を積層してもよい。
本発明の一態様に係る構造体は、その表面に導電パターンが形成された第一樹脂層上に、当該導電パターンを挟むように第二樹脂層を成形してなる構造体であって、第一樹脂層は、第二樹脂層によって覆われている被覆領域および第二樹脂層によって覆われていない露出領域を有し、当該露出領域に、該導電パターンが他の部材に電気的に接続するための接点が配置される接点部を有し、かつ該被覆領域および該露出領域の境界と、該接点部との間に、第一樹脂層の表面が屈曲する屈曲部を有している。
1a 露出領域
1b 接点部
1c 屈曲部
2 第二樹脂層
2a 柱状部
3 導電パターン
10~23 構造体
31 回路基板
32 接続部材
40 無線通信装置
50~53 成形型
A 境界
B ノッチ
C 凸部
Claims (5)
- その表面に導電パターンが形成された第一樹脂層上に、当該導電パターンを挟むように第二樹脂層を成形してなる構造体であって、
第一樹脂層は、
第二樹脂層によって覆われている被覆領域および第二樹脂層によって覆われていない露出領域を有し、
当該露出領域に、該導電パターンが他の部材に電気的に接続するための接点が配置される接点部を有し、かつ
該被覆領域および該露出領域の境界と、該接点部との間に、第一樹脂層の表面が屈曲する屈曲部を有していることを特徴とする構造体。 - 上記露出領域は、隣接する上記被覆領域に対して凸になっている凸部を有していることを特徴とする請求項1に記載の構造体。
- 上記露出領域は、隣接する上記被覆領域に対して凹になっている凹部を有していることを特徴とする請求項1に記載の構造体。
- 請求項1~3の何れか一項に記載の構造体を含んでなる筐体と、
上記導電パターンを含んでなるアンテナと、を備えていることを特徴とする無線通信装置。 - 請求項1~3の何れか一項に記載の構造体を製造する方法であって、
上記導電パターンが形成された第一樹脂層を成形型内に入れ、当該成形型と上記露出領域とを嵌合させた状態で、第二樹脂層を第一樹脂層と一体に成形する成形工程を包含することを特徴とする構造体の製造方法。
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Also Published As
Publication number | Publication date |
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CN105265027A (zh) | 2016-01-20 |
US9736944B2 (en) | 2017-08-15 |
JP6092674B2 (ja) | 2017-03-08 |
US20160029492A1 (en) | 2016-01-28 |
JP2014187549A (ja) | 2014-10-02 |
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