WO2022258128A1

WO2022258128A1 - Structural element for antenna and method of manufacturing the structural element

Info

Publication number: WO2022258128A1
Application number: PCT/EP2021/065091
Authority: WO
Inventors: Dieter Zierhut; Bernhard Rist; Christian Helbig; Johann Baptist OBERMAIER; Serban REBEGEA; Tekin ÖLMEZ; Liansong WANG; Qiangguo Zhou
Original assignee: Huawei Technologies Co., Ltd.
Priority date: 2021-06-07
Filing date: 2021-06-07
Publication date: 2022-12-15

Abstract

A structural element for an antenna, includes a reflector and a metal housing arranged on one side of the reflector and configured for accommodation of a signal distribution network. The structural element further includes the signal distribution network comprising a flexible plastic foil with metal lines deposited on the flexible plastic foil, and a plastic frame bonded to the flexible plastic foil for keeping the flexible plastic foil straight along a length of the signal distribution network. The structural element provides an improved access to connections for radiators of an antenna. The plastic frame enables easy handling (i.e, holding and moving) of the flexible plastic foil. The flexible plastic foil has a lower cost of assembly.

Description

STRUCTURAL ELEMENT FOR ANTENNA AND METHOD OF MANUFACTURING THE STRUCTURAL ELEMENT

TECHNICAL FIELD

The present disclosure relates generally to the field of antennas for telecommunication; and more specifically, to a structural element for an antenna and a method of manufacturing the structural element for the antenna.

BACKGROUND

New wireless communication technologies, such as fifth generation (5G) communication technology, make use of several frequency ranges, including sub-6 Gigahertz and millimetre-wave bands to transmit and receive radio frequency signals using antennas. In an example, base stations antennas used in mobile communication networks are typically array antennas which consist of several dipoles (i.e., radiators) in a cross-configuration (i.e., cross polarization) in order to generate a positive 45 degrees and negative 45 degrees of polarization.

In some antennas, the radiators are directly or in groups connected to a phase shifter or a distribution network, such as a conventional signal distribution network. Such conventional signal distribution networks, having connection lines for connection with the radiators, are made of sheet metal or Printed Circuit Board (PCB). However, the connection lines in form of sheet metal provide a limited access based on a small width size of the connection lines. Further, such conventional signal distribution networks which are made of sheet metal or PCB are cost intensive and are also not very flexible. As the antenna consists of several parts, the cost of assembly contributes significantly in the overall production costs of the antenna. The conventional signal distribution networks are usually soldered to the dipole to establish a connection and thus there is limited flexibility and accessibility that is available. Further, reliability of the antenna may suffer due to complex structures and difficult production process of its parts and also connection of the parts. Thus, good access to connection points and reliable connection processes are essential. Some of such signal distribution networks are made to slide in a closed housing and are then fixed at a position to this housing. However, in this case, an access to connection area of the signal distribution networks is limited. Thus, the access outside the housing is difficult and large number of resources are needed, for example, a profiled milled reflector. Further, this approach is complex and also results in wastage of space and also increases the size of the antenna. As the height of the antennas is a critical parameter in installation of the antenna, this conventional approach increases complexity and cost and still do not solve the problem adequately. Thus, there exist the technical problem of assembling the signal distribution network in the antenna without increasing complexity, cost of assembly, and production cost as compared to existing solutions.

Therefore, in light of the foregoing discussion, there exists a need to overcome the aforementioned drawbacks associated with the conventional antennas and the signal distribution network.

SUMMARY

The present disclosure seeks to provide to a structural element for an antenna and a method of manufacturing the structural element for the antenna. The present disclosure seeks to provide a solution to the existing problem of complexity in assembling of signal distribution network in an antenna resulting in complex and inefficient connection of signal distribution network with radiators in the antenna, i.e., the problem of how to further improve access and provide reliable connection of signal distribution network with radiators as compared to conventional approaches. An aim of the present disclosure is to provide a solution that overcomes at least partially the problems encountered in prior art, and provide improved signal distribution network that has improved access for connection with radiators (i.e., reliable connection) without increasing structural complexity, and thereby cost of assembly and production cost as compared to existing solutions.

The one or more objects of the present disclosure is achieved by the solutions provided in the enclosed independent claims. Advantageous implementations of the present disclosure are further defined in the dependent claims.

In one aspect, the present disclosure provides a structural element for an antenna, the structural element comprising: a reflector, a metal housing arranged on one side of the reflector and configured for accommodation of a signal distribution network, the signal distribution network comprising a flexible plastic foil with metal lines deposited on the flexible plastic foil, and a plastic frame bonded to the flexible plastic foil for keeping the flexible plastic foil straight along a length of the signal distribution network.

The structural element of the present disclosure provides an improved access to connections for radiators of an antenna in comparison to conventional approach where access is limited. Further, the flexible plastic foil can be easily fixed and assembled in the structural element. The plastic frame enables easy handling (i.e., holding and moving) of the flexible plastic foil. Further, a complete height of cavity of the antenna is utilized by the signal distribution network as the flexible plastic foil consumes the complete height of the cavity without wasting any space. Beneficially, the flexible plastic foil of the present dislcosure has a lower cost of assembly compared to a Printed Circuit Board (PCB) based signal distribution network used conventionaly. Further, the structural element is light in weight, comparatively thin, and has smaller transport size in comparison to such conventional elements.

In an implementation form, the plastic frame comprises two or more plastic rods bonded to both sides of the flexible plastic foil.

The two or more plastic rods provide strength to the flexible plastic foil to enable easy handling (i.e., holding, moving, and assembling) of the flexible plastic foil.

In a further implementation form, the two or more plastic rods and the flexible plastic foil have different coefficients of thermal expansion.

The different coefficients of thermal expansion ensure that the two or more plastic rods can provide strength and stability to the flexible plastic foil even at higher temperatures.

In a further implementation form, the flexible plastic foil is made of a plastic material being resistant to high temperature.

The flexible plastic foil made of the plastic material being resistant to high temperature enables improved handling in case of increased temperature due to heat generated in the metal lines. As a result, the structural element has an improved life time as compared to conventional elements. In a further implementation form, the two or more plastic rods are bonded to both sides of the flexible plastic foil by means of adhesive tape.

By virtue of the adhesive tape, the two or more plastic rods provide strength to the flexible plastic foil to enable easy handling (i.e., holding and moving) of the flexible plastic foil.

In a further implementation form, each plastic rod is bonded to the flexible plastic foil by a piece of adhesive tape of length less than a length of the plastic rod, wherein the piece of adhesive tape is arranged in the middle of the length of the plastic rod.

Thus, the ends of each of the two or more plastic rods are free to move during thermal expansion.

In a further implementation form, each plastic rod is provided with a fixation opening for fixing the plastic frame to the metal housing, wherein the fixation opening passes through the piece of adhesive tape.

By virtue of the fixation opening the plastic frame is fixed to a metal housing. Thus, strength and support is provided to the plastic frame.

In a further implementation form, the plastic frame comprises plastic supports configured for pressing together the two or more plastic rods sandwiching the flexible plastic foil.

The two or more plastic rods are pressed together with plastic supports to have the structural element with stable bonding between the plastic rods and the flexible plastic foil.

In another aspect, the present disclosure provides a method of manufacturing a structural element for an antenna, comprising: arranging a metal housing on one side of a reflector, depositing metal lines on a flexible plastic foil to form a signal distribution network, bonding a plastic frame to the flexible plastic foil, the plastic frame being configured for keeping the flexible plastic foil straight along a length of the signal distribution network, arranging the signal distribution network with the plastic frame inside the metal housing, and fixing the plastic frame to the metal housing.

The method achieves all the advantages and effects of the structural element of the present disclosure. It is to be appreciated that all the aforementioned implementation forms can be combined. It has to be noted that all devices, elements, circuitry, units and means described in the present application could be implemented in the software or hardware elements or any kind of combination thereof. All steps which are performed by the various entities described in the present application as well as the functionalities described to be performed by the various entities are intended to mean that the respective entity is adapted to or configured to perform the respective steps and functionalities. Even if, in the following description of specific embodiments, a specific functionality or step to be performed by external entities is not reflected in the description of a specific detailed element of that entity which performs that specific step or functionality, it should be clear for a skilled person that these methods and functionalities can be implemented in respective software or hardware elements, or any kind of combination thereof. It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.

Additional aspects, advantages, features and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative implementations construed in conjunction with the appended claims that follow.

BRIEF DESCRIPTION OF THE DRAWINGS

The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.

Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:

FIG. 1A is an illustration of a side view of a structural element for an antenna, in accordance with an embodiment of the present disclosure; FIG. IB is an illustration of a top view of a structural element for an antenna, in accordance with an embodiment of the present disclosure;

FIG. 2 is an illustration of plastic rods of a structural element for an antenna, in accordance with an embodiment of the present disclosure;

FIG. 3 is an illustration of a top view of a structural element for an antenna, in accordance with another embodiment of the present disclosure;

FIG. 4 is an illustration of a side view of a structural element for an antenna, in accordance with another embodiment of the present disclosure; and FIG. 5 is a flowchart of a method of manufacturing a structural element for an antenna, in accordance with an embodiment of the present disclosure.

In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non- underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.

DETAILED DESCRIPTION OF EMBODIMENTS

The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible.

FIG. 1A is an illustration of a side view of a structural element for an antenna, in accordance with an embodiment of the present disclosure. With reference to FIG. 1A there is shown an illustration 100A of a structural element 102 for an antenna. The structural element 102 comprises a signal distribution network 104, a flexible plastic foil 106, metal lines 108, a plastic frame 110, a metal housing 112. There is further shown, two or more plastic rods such as plastic rods 114A and 114B.

In one aspect, the present disclosure provides a structural element 102 for an antenna, the structural element 102 comprising: a reflector, a metal housing 112 arranged on one side of the reflector and configured for accommodation of a signal distribution network 104, the signal distribution network 104 comprising a flexible plastic foil 106 with metal lines 108 deposited on the flexible plastic foil 106, and a plastic frame 110 bonded to the flexible plastic foil 106 for keeping the flexible plastic foil 106 straight along a length of the signal distribution network 104.

The structural element 102 for the antenna (not shown) is configured to provide improved signal distribution network that has improved access for connection with radiators (i.e., reliable connection) without increasing structural complexity, and thereby cost of assembly and production cost is less as compared to conventional structural elements. The antenna is used for transmitting or receiving a radio frequency signal, for example, in a cellular communication. The antenna may also be referred to as a radiating element or a radiating device. For example, the antenna may be used in a wireless communication system. In some embodiments, an array of radiators may be used in the antenna. Examples of such wireless communication system include, but is not limited to, a base station (such as an Evolved Node B (eNB), a gNB, and the like), a repeater device, a customer premise equipment, and other customized telecommunication hardware.

The signal distribution network 104 is configured for feeding a transmission signal to radiators (in a transmission mode) or for receiving a reception signal (in a reception mode) from the radiators. The signal distribution network 104 applies a certain individual phase shift to each radiator, e.g., for beam steering. These phases shift associated with the radiators may be adjustable. In other words, the signal distribution network 104 is a network that provides (or distributes) signal feed to one or more radiating elements or radiators (not shown) of an antenna (not shown). The signal distribution network 104 is configured to receive an input (i.e., signal feed) and provide an output to either a single radiator or multiple radiators. In other words, the signal distribution network 104 enables in establishing a connection for providing signal feed to the one or more radiators. In an example, the signal distribution network 104 may provide signal feed to a feeding arrangement of the radiators. In an example, the signal distribution network 104 may provide the signal feed in a way that phase shifting can be executed on the radiators. Such as a first signal feed provided by the signal distribution network 104 to a first radiator may be phase shifted in comparison to a second signal feed provided by the signal distribution network 104 to a second radiator.

The structural element 102 comprises the metal housing 112 that is arranged on one side of the reflector and configured for accommodation of the signal distribution network 104. The metal housing 112 is arranged on one side of the reflector (such as a reflector shown in FIG. IB) to enable providing the signal feed from the signal distribution network 104 to the reflector. The signal distribution network 104 is provided inside a cavity or housing such as the metal housing 112 which is coupled to the reflector. Thus, the signal distribution network 104 can form a part of the antenna in comparison to conventional approach where such signal distribution networks are separate and thus add on to a height of the antenna which is essential during installations of the antennas.

The structural element 102 further comprises the signal distribution network 104 comprising a flexible plastic foil 106 with metal lines 108 deposited on the flexible plastic foil 106. In other words, the signal distribution network 104 provides the flexible plastic foil 106 that allows small metal lines such as the metal lines 108. The flexible plastic foil 106 provides the signal feed to the radiators via the metal lines 108 deposited thereupon. The metal lines 108 are deposited on the flexible plastic foil 106 to enable providing conductive tracks for providing the signal feed to the radiators. Beneficially, the flexible plastic foil 106 can be easily bent or moved (i.e., is flexible) to enable forming a connection with the radiators. Beneficially, a cost and a weight of the signal distribution network 104 of the present disclosure is lower than a conventional signal distribution network which is made of Sheet metal or PCB.

The structural element 102 further comprises the plastic frame 110 bonded to the flexible plastic foil 106 for keeping the flexible plastic foil 106 straight along a length of the signal distribution network 104. The flexible plastic foil 106 is not stable but needs to be fixed, flat, straight and ready to handle (i.e., ready to assemble). This is realized (i.e., stability is provided to the flexible plastic foil 106) by using the plastic frame 110 that is bonded to the flexible plastic foil 106. The plastic frame 110 is configured to provide structural support to the flexible plastic foil 106 so that the flexible plastic foil 106 can easily be used for establishing connection with the radiators. Further, the plastic frame 110 may enable in providing strength to the flexible plastic foil 106 so that there is no breaking during bending of the flexible plastic foil 106. Beneficially, as the flexible plastic foil 106 is placed along the plastic frame 110, there is improved utilization (i.e., less length needed) of the flexible plastic foil 106. The plastic frame 110 provides a non-conductive support to the flexible plastic foil 106 i.e., the plastic frame 110 is electrically non-conductive to the metal lines 108 of the flexible plastic foil 106.

According to an embodiment, the plastic frame 110 comprises two or more plastic rods such as plastic rods 114A and 114B bonded to both sides of the flexible plastic foil 106. In other words, the two or more plastic rods such as plastic rods 114A and 114B are bonded to the flexible plastic foil 106 over a complete length on both sides of the flexible plastic foil 106. The two or more plastic rods such as plastic rods 114A and 114B provide strength to the flexible plastic foil 106 to enable easy handling (i.e., holding, moving and assembling) of the flexible plastic foil 106. Further, the two or more plastic rods such as plastic rods 114A and 114B are pressed to the flexible plastic foil 106 to realize flat edges. As a result, the two or more plastic rods such as plastic rods 114A and 114B makes and keeps the flexible plastic foil 106 straight preventing any unnecessary bending of the flexible plastic foil 106. Further, the two or more plastic rods such as plastic rods 114A and 114B also enables the flexible plastic foil 106 to easily slide into a cavity such as the metal housing 112. The two or more plastic rods such as plastic rods 114A and 114B provides a non-conductive support to the flexible plastic foil 106 i.e., the two or more plastic rods such as plastic rods 114A and 114B are electrically non-conductive to the metal lines 108 of the flexible plastic foil 106.

The structural element 102 of the present disclosure provides an improved access to connections for radiators of an antenna in comparison to conventional approach where access is limited. The flexible plastic foil 106 with plastic frame 110 enables in keeping the flexible plastic foil 106 straight. Further, the flexible plastic foil 106 can be easily fixed and assembled in the structural element 102. The plastic frame 110 enables easy handling (i.e., holding and moving) of the flexible plastic foil 106. Further, a complete height of cavity of the antenna is utilized by the signal distribution network 104 as the flexible plastic foil 106 consumes the complete height of the cavity without wasting any space. Beneficially, the flexible plastic foil 106 of the present dislcosure has a lower cost of assembly (i.e., is cheaper) compared to a Printed Circuit Board (PCB) based signal distribution network used conventionaly. Further, the structural element 102 is light in weight, thin and has smaller transport size in comparison to such conventional elements.

FIG. IB is an illustration of a top view of a structural element for an antenna, in accordance with an embodiment of the present disclosure. FIG. IB is described in conjunction with elements from FIG.1A. With reference to FIG. IB there is shown an illustration 100B of the structural element 102 for the antenna. The structural element 102 comprises a reflector 116, an adhesive tape 118A and 118B, the flexible plastic foil 106, plastic rods such as the plastic rod 114A. It is to be understood that the reflector 116 may not be visible from the top view of the structural element 102 as such, but is shown to be a part of the structural element 102 (e.g., represented using a dotted arrow for representation purpose).

The reflector 116 generally is configured to redirect or reflect electro-magnetic signals to receivers such as user devices. The structural element 102 comprises the metal housing 112 (as shown in FIG. 1A) that is arranged on one side of the reflector 116.

According to an embodiment, the two or more plastic rods such as plastic rods 114A and 114B are bonded to both sides of the flexible plastic foil 106 by means of the adhesive tape 118A and 118B. The adhesive tape 118A and 118B is bonded on a complete length on both sides of the flexible plastic foil 106. The adhesive tape 118A and 118B enables in establishing a connection i.e., joining the two or more plastic rods such as plastic rods 114A and 114B to the flexible plastic foil 106. Thus, by virtue of the adhesive tape 118A and 118B the two or more plastic rods such as plastic rods 114A and 114B provide strength to the flexible plastic foil 106 to enable easy handling (i.e., holding and moving) of the flexible plastic foil 106.

FIG. 2 is an illustration of plastic rods of a structural element for an antenna, in accordance with an embodiment of the present disclosure. FIG.2 is described in conjunction with elements from FIG.1A. With reference to FIG. 2 there is shown an illustration 200 of the plastic rods 114A and 114B. The plastic rods 114A and 114B includes fixation opening

202A and 202B. The fixation opening 202A is provided for the plastic rod 114A. The fixation opening 202B is provided for the plastic rod 114B. In an example, the fixation opening is provided on each of the plastic rod along a complete length of a flexible plastic foil such as the flexible plastic foil 106 (of FIG. 1A). The fixation opening 202A and 202B enable in fixing a plastic frame such as the plastic frame 110 to a metal housing such as the metal housing 112.

FIG. 3 is an illustration of a top view of a structural element for an antenna, in accordance with another embodiment of the present disclosure. FIG. 3 is described in conjunction with elements from FIG.1A and IB. With reference to FIG. 3 there is shown an illustration 300 of the structural element 302 for the antenna. The structural element 302 comprises a piece of adhesive tape 304A and 304B, plastic supports 306A and 306B, the flexible plastic foil 106, plastic rods 308A and 308B and the plastic rods 114A and 114B (of FIG. 1A) and the adhesive tape 118A and 118B. There is further shown a first direction 310A and 310B, and a second direction 312A and 312B.

According to an embodiment, the two or more plastic rods such as plastic rods 114A, 114B, 308A and 308B and the flexible plastic foil 106 have different coefficients of thermal expansion. The different coefficients of thermal expansion ensure that the two or more plastic rods such as plastic rods 114A, 114B, 308A and 308B can provide strength and stability to the flexible plastic foil 106 even at higher temperatures. In an example, different materials lead to different thermal expansion. In an example, a signal distribution network with more than 1 -meter length leads to different expansion of about 4 millimeters (dependent of material combination and length). Conventionally, the metal lines are soldered on the flexible plastic foil 106, as it has to withstand high temperatures which requires conventional foil plastic made of Polyimide material. However, the usage of Polyimide is very expensive. The present disclosure provides a frame design which is independent of different thermal expansion of flexible plastic foil 106 material and plastic frame 110 material. In an example, the two or more plastic rods such as plastic rods 114A, 114B, 308A and 308B is made of elements i.e., dielectric elements which keeps shape and supports the flexible plastic foil 106.

According to an embodiment, the flexible plastic foil 106 is made of a plastic material being resistant to high temperature. As the metal lines 108 provides signal feed to the radiators of the antenna, at times there is heat generated. Thus, the flexible plastic foil 106 made of the plastic material being resistant to high temperature enables improved handling in case of increased temperature due to heat generated in the metal lines 108. As a result, the structural element 302 has an improved life time as compared to conventional elements.

According to an embodiment, each plastic rod such as plastic rods 114A, 114B, 308A and 308B is bonded to the flexible plastic foil 106 by a piece of adhesive tape 304A and 304B of length less than a length of the plastic rod such as plastic rods 114A, 114B, 308A and 308B, wherein the piece of adhesive tape is arranged in the middle of the length of the plastic rod such as plastic rods 114A, 114B, 308A and 308B . In other words, the plastic rods such as plastic rods 114A, 114B, 308A and 308B is not bonded over the hole length to the flexible plastic foil 106 but is bonded over a short length in the middle of plastic rods such as plastic rods 114A, 114B, 308A and 308B. In an example, a piece of adhesive tape 304A is used for bonding the plastic rod 114A to the flexible plastic foil 106 and a piece of adhesive tape 304B is used for bonding the plastic rod 114A to the flexible plastic foil 106. Further, in this case the signal distribution network such as signal distribution network 104 is not positioned and fixed (on bonded areas) to the metal housing such as metal housing 112. Further, the ends of each of the two or more plastic rods such as plastic rods 114A, 114B, 308A and 308B are free to move during thermal expansion

According to an embodiment, the plastic frame such as the plastic frame 110 comprises plastic supports 306A and 306B configured for pressing together the two or more plastic rods such as plastic rods 114A, 114B, 308A and 308B sandwiching the flexible plastic foil 106. The two or more plastic rods such as plastic rods 114A, 114B, 308A and 308B are pressed together with plastic supports 306A and 306B to have a stable frame. In other words, the two or more plastic rods such as plastic rods 114A, 114B, 308A and 308B are pressed together with plastic supports 306A and 306B to have the structural element 302 with stable bonding between the plastic rods and the flexible plastic foil 106. The plastic supports 306A and 306B presses the two or more plastic rods such as plastic rods 114A, 114B, 308A and 308B in the first direction 310A and 310B. In an example, the plastic rods present on both sides of the flexible plastic foil 106 are pressed to enable sandwiching the flexible plastic foil 106. Thus, all the free ends can move which makes the structural element 302 have improved flexibility. Such two or more plastic rods such as plastic rods 114A, 114B, 308A and 308B with plastic supports 306A and 306B keep ends of the structural element 302 flat. Further, there is more stability in handling and assembling the structural element 302. Further, the flexible plastic foil 106 is kept straight and flat. Further, there is improved stability to fix the signal distribution network in the cavity i.e., metal housing 112. There is further shown the second direction 312A and 312B in which the two or more plastic rods such as plastic rods 114A, 114B, 308A and 308B are pressed to enable fixing or bonding the two or more plastic rods such as plastic rods 114A, 114B, 308A and 308B to the flexible plastic foil 106 via the piece of adhesive tape 304A and 304B.

FIG. 4 is an illustration of a side view of a structural element for an antenna, in accordance with another embodiment of the present disclosure. FIG. 4 is described in conjunction with elements from FIG.1A, IB and 3. With reference to FIG. 4 there is shown an illustration 400 of a structural element 402 for an antenna. The structural element 402 comprises the flexible plastic foil 106, the metal lines 108, the plastic rods 114A and 114B. There is shown a first expanded view 404, a second expanded view 406, a third expanded view 408, a fourth expanded view 410, a fifth expanded view 412, a sixth expanded view 414. In the first expanded view 404, there is shown a fixation opening 416A. In the second expanded view 406, there is shown a fixation opening 416B. In the third expanded view 408, there is shown a fixation opening 416C. In the fourth expanded view 410, there is shown an assembling hole 418. In the fifth expanded view 412, there is shown a joint 420. In the sixth expanded view 414, there is shown an adhesive pad 422.

The structural element 402 similar to the structural element 302 has the plastic rods such as plastic rods 114A and 114B not bonded over the hole length to the flexible plastic foil 106 but is bonded over a short length in the middle of plastic rods such as plastic rods 114A and 114B.

According to an embodiment, each plastic rod such as plastic rods 114A and 114B is provided with a fixation opening 416A, 416B, 416C for fixing the plastic frame such as the plastic frame 110 to the metal housing such as the metal housing 112, wherein the fixation opening 416A, 416B, 416C passes through the piece of adhesive tape such as piece of adhesive tape 304A and 304B. The fixation opening 416B is provided for the plastic rod 114A. The fixation opening 416C is provided for the plastic rod 114B. In an example, the fixation opening 416A, 416B, 416C is provided on each of the plastic rod 114A and 114B which is spread along short lengths of the flexible plastic foil 106. The fixation opening 416A, 416B, 416C enable in fixing a plastic frame such as the plastic frame 110 to a metal housing such as the metal housing 112. Thus, strength and support is provided to the plastic frame 110.

The assembling hole 418 may be used for a position jig. The joint 420 may be used for joining the plastic rods 114A and 114B. Further, upon joining the plastic rods 114A and 114B, the other parts such as the flexible plastic foil 106, the metal lines 108, the plastic rods 114A and 114B may be assembled. The adhesive pad 422 similar to the adhesive tape 118A and 118B enables in establishing a connection i.e., joining the two or more plastic rods such as plastic rods 114A and 114B to the flexible plastic foil 106.

FIG. 5 is a flowchart of a method of manufacturing a structural element for an antenna, in accordance with an embodiment of the present disclosure. FIG. 5 is described in conjunction with elements from FIG.1A. With reference to FIG. 5 there is shown a method 500. The method 500 is executed for a signal distribution network described, for example, in Fig. 1A. The method 500 includes steps 502 to 510.

In another aspect, the present disclosure provides a method 500 of manufacturing a structural element 102 for an antenna, comprising: arranging a metal housing 112 on one side of a reflector 116, depositing metal lines 108 on a flexible plastic foil 106 to form a signal distribution network 104, bonding a plastic frame 110 to the flexible plastic foil 106, the plastic frame 110 being configured for keeping the flexible plastic foil 106 straight along a length of the signal distribution network 104, arranging the signal distribution network 104 with the plastic frame 110 inside the metal housing 112, and fixing the plastic frame 110 to the metal housing 112.

At step 502, the method 500 comprises arranging a metal housing 112 on one side of a reflector 116. The method 500 comprises arranging the metal housing 112 on one side of the reflector 116 to enable providing the signal feed from the signal distribution network 104 to the reflector 116. In other words, arranging the metal housing 112 on one side of the reflector 116 enables providing the transmission signal to radiators (in a transmission mode) or for receiving a reception signal (in a reception mode) from the radiators.

At step 504, the method 500 further comprises depositing metal lines 108 on a flexible plastic foil 106 to form a signal distribution network 104. In other words, the method 500 comprises providing the signal distribution network 104 that allows small metal lines such as the metal lines 108. The flexible plastic foil 106 provides the signal feed to the radiators via the metal lines 108 deposited thereupon. The metal lines 108 are deposited on the flexible plastic foil 106 to enable providing conductive tracks for providing the signal feed to the radiators. Beneficially, the flexible plastic foil 106 can be easily bent or moved (i.e., is flexible) to enable forming a connection with the radiators. Beneficially, a cost and a weight of the signal distribution network 104 of the present disclosure is lower than a conventional signal distribution network which is made of Sheet metal or PCB.

At step 506, the method 500 further comprises bonding a plastic frame 110 to the flexible plastic foil 106, the plastic frame 110 being configured for keeping the flexible plastic foil 106 straight along a length of the signal distribution network 104. The method 500 provides the flexible plastic foil 106 which is not stable but needs to be fixed, flat, straight and ready to handle (i.e., ready to assemble). This is realized (i.e., stability is provided to the flexible plastic foil 106) by using the plastic frame 110 that is bonded to the flexible plastic foil 106. The plastic frame 110 is configured to provide structural support to the flexible plastic foil 106 so that the flexible plastic foil 106 can easily be used for establishing connection with the radiators. Further, the plastic frame 110 may enable in providing strength to the flexible plastic foil 106 so that there is no breaking during bending of the flexible plastic foil 106. Beneficially, as the flexible plastic foil 106 is placed along the plastic frame 110, there is improved utilization (i.e., less length needed) of the flexible plastic foil 106. The plastic frame 110 provides a non-conductive support to the flexible plastic foil 106 i.e., the plastic frame 110 is electrically non-conductive to the metal lines 108 of the flexible plastic foil 106.

At step 508, the method 500 further comprises arranging the signal distribution network 104 with the plastic frame 110 inside the metal housing 112. The method 500 comprises providing the signal distribution network 104 inside a cavity or housing such as the metal housing 112 which is coupled to the reflector 116.

At step 510, the method 500 further comprises fixing the plastic frame 110 to the metal housing 112. Thus, the signal distribution network 104 can form a part of the antenna in comparison to conventional approach where such signal distribution networks are separate and thus add on to a height of the antenna which is essential during installations of the antennas.

The method 500 of the present disclosure provides the structural element 102 with an improved access to connections for radiators of an antenna in comparison to conventional approach where access is limited. Further, the method 500 enables easy fixing and assembling of the flexible plastic foil 106 in the structural element 102. The plastic frame 110 enables easy handling (i.e., holding and moving) of the flexible plastic foil 106. Further, a complete height of cavity of the antenna is utilized by the signal distribution network 104 provided by the method 500, as the flexible plastic foil 106 consumes the complete height of the cavity without wasting any space. Beneficially, the method 500 provides the flexible plastic foil 106 that has a lower cost of assembly (i.e., is cheaper) compared to a Printed Circuit Board (PCB) based signal distribution network used conventionaly. Further, the structural element 102 is light in weight, thin and has smaller transport size in comparison to such conventional elements.

Modifications to embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as "including", "comprising", "incorporating", "have", "is" used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural. The word "exemplary" is used herein to mean "serving as an example, instance or illustration". Any embodiment described as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments and/or to exclude the incorporation of features from other embodiments. The word "optionally" is used herein to mean "is provided in some embodiments and not provided in other embodiments". It is appreciated that certain features of the present disclosure, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the present disclosure, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable combination or as suitable in any other described embodiment of the disclosure.

Claims

1. A structural element (102, 302, 402) for an antenna, the structural element (102, 302, 402) comprising: a reflector (116), a metal housing (112) arranged on one side of the reflector (116) and configured for accommodation of a signal distribution network (104), the signal distribution network (104) comprising a flexible plastic foil (106) with metal lines (108) deposited on the flexible plastic foil (106), and a plastic frame (110) bonded to the flexible plastic foil (106) for keeping the flexible plastic foil (106) straight along a length of the signal distribution network (104).

2. The structural element (102, 302, 402) of claim 1, wherein the plastic frame (110) comprises two or more plastic rods (114 A, 114B) bonded to both sides of the flexible plastic foil (106).

3. The structural element (102, 302, 402) of claim 2, wherein the two or more plastic rods (114A, 114B, 308A, 308B) and the flexible plastic foil (106) have different coefficients of thermal expansion.

4. The structural element (102, 302, 402) of claim 3, wherein the flexible plastic foil (106) is made of a plastic material being resistant to high temperature.

5. The structural element (102, 302, 402) of claim 2, wherein the two or more plastic rods (114A, 114B) are bonded to both sides of the flexible plastic foil (106) by means of adhesive tape (118A, 118B, 304A, 304B).

6. The structural element (102, 302, 402) of claim 5, wherein each plastic rod (114A, 114B, 308A, 308B) is bonded to the flexible plastic foil (106) by a piece of adhesive tape (118A, 118B, 304A, 304B) of length less than a length of the plastic rod (114A, 114B, 308A, 308B), wherein the piece of adhesive tape (118A, 118B, 304A, 304B) is arranged in the middle of the length of the plastic rod (114A, 114B, 308A, 308B).

7. The structural element (102, 302, 402) of claim 6, wherein each plastic rod (114A, 114B) is provided with a fixation opening (202A, 202B, 416A, 416B, 416C) for fixing the plastic frame (110) to the metal housing (112), wherein the fixation opening (202A, 202B, 416A, 416B, 416C) passes through the piece of adhesive tape (304A, 304B).

8. The structural element (102, 302, 402) of any of claims 2 to 7, wherein the plastic frame (110) comprises plastic supports (306A, 306B) configured for pressing together the two or more plastic rods (114A, 114B, 308A, 308B) sandwiching the flexible plastic foil (106).

9. A method (500) of manufacturing a structural element (102, 302, 402) for an antenna, comprising: arranging a metal housing (112) on one side of a reflector (116), depositing metal lines (108) on a flexible plastic foil (106) to form a signal distribution network (104), bonding a plastic frame (110) to the flexible plastic foil (106), the plastic frame (110) being configured for keeping the flexible plastic foil (106) straight along a length of the signal distribution network (104), arranging the signal distribution network (104) with the plastic frame (110) inside the metal housing (112), and fixing the plastic frame (110) to the metal housing (112).