Method of manufacturing antennas using micro-insert-molding techniques

• US 6,822,609 B2
• Filed: 10/02/2002
• Issued: 11/23/2004
• Est. Priority Date: 03/15/2002
• Status: Active Grant

• Current Assignee: OAE Technology Incorporated
• Original Assignee: Etenna Corporation
• Inventors: Lin, Yizhen, Mendolia, Greg S.
• Primary Examiner(s): Ho, Tan
• Application Number:
  US10/263,142
• Publication Number:
  US 20030174091A1
• Time in Patent Office: 783 Days
• Field of Search: 343/700.MS, 343/702, 343/846, 296/00
• US Class Current: 343/700.0MS
• CPC Class Codes: B29C 45/14655 connected to or mounted on a carrier, e.g. lead frame
• CPC Class Codes: B29K 2105/0079 Liquid crystals
• CPC Class Codes: B29L 2031/3456 Antennas, e.g. radomes
• CPC Class Codes: H01Q 1/38 formed by a conductive layer on an insulating support patch antennas H01Q9/0407; microstrip dipole antennas H01Q9/065; microstrip slot antennas H01Q13/106; transmission line microstrip antennas H01Q13/206; manufacturing reflecting surfaces using insulating material for supporting the reflecting surface H01Q15/142
• CPC Class Codes: H01Q 9/0421 with a shorting wall or a shorting pin at one end of the element H01Q9/0414 takes precedence
• CPC Class Codes: H01Q 9/0442 with particular tuning means
• CPC Class Codes: H01Q 9/16 with feed intermediate between the extremities of the antenna, e.g. centre-fed dipole H01Q9/44 takes precedence
• CPC Class Codes: H01Q 9/285 Planar dipole H01Q9/065 takes precedence; patch antenna H01Q9/0407
• CPC Class Codes: H01Q 9/30 with feed to end of elongated active element, e.g. unipole H01Q9/44 takes precedence
• CPC Class Codes: Y10T 29/49016 Antenna or wave energy "plumbing" making

Abstract

An antenna includes a precision micro-molded plastic spacer and a metal insert. The plastic spacer is configured for mounting to a printed circuit board (PCB) to maintain the metal insert a predetermined distance from a ground plane. Micro-insert-molding techniques produce tight mechanical dimensions including those which define the antenna height, ensuring reliable and consistent antenna electrical performance.

Claims

1. An antenna comprising a molded plastic spacer and a metal insert fabricated using micro-insert molding processes, the plastic spacer being table-top shaped with a plurality of legs configured for mounting to a printed circuit board (PCB) to maintain the metal insert a predetermined distance from a ground plane, the antenna further comprising a ground lead and a feed extending on one or more legs of the plurality of legs and configured for electrically connecting the metal insert with the PCB.

2. The antenna of claim 1 wherein the plastic spacer comprises a mounting portion for mechanical engagement with the PCB and wherein the metal insert includes the ground lead and the feed extending along the mounting portion for electrical engagement with the PCB.

3. The antenna of claim 1 wherein the plastic spacer includes a first side molded with the metal insert and a second side including a mounting portion for engagement with the PCB.

4. The antenna of claim 3 wherein the second side of the plastic spacer is molded to define one or more cavities.

5. The antenna of claim 4 wherein the mounting portion comprises the plurality of legs extending from the second side, each leg of the plurality of legs terminating in a surface mountable portion for mechanical engagement with the PCB.

6. The antenna of claim 4 wherein the mounting portion comprises one or more perimeter walls defining a central cavity.

7. An antenna comprising:

an injection molded plastic insert including a body and a mounting portion extending from the body and configured for surface mount engagement with a printed circuit board (PCB) to maintain the body a predetermined distance from a ground plane of the PCB; and

a metal insert including a radiating portion molded with the body of the plastic insert and a ground lead and feed extending along the mounting portion of the plastic insert for electrical engagement with the PCB.

8. The antenna of claim 7 wherein the mounting portion comprises two or more legs extending from one side of the body and, with the body, defining a cavity region.

9. The antenna of claim 7 wherein the metal insert comprises a patterned, planar radiator and a ground lead and a feed extending from the radiator.

10. The antenna of claim 9 wherein the metal insert further comprises a removable lead frame portion.

11. The antenna of claim 10 wherein the metal insert comprises one insert of a reel of substantially identical inserts joined by a lead frame including the removable lead frame portion.

12. An antenna tape and reel package comprising:

a plurality of antennas, each antenna formed by injection molding one metal insert of a tape of substantially identical metal inserts in a plastic insert sized to position the metal insert a predetermined distance from a ground plane when the antenna is assembled with a printed circuit board; and

indexing apparatus for moving the plurality of antennas through an automated printed circuit board assembly system.

13. The antenna tape and reel package of claim 12 wherein the indexing apparatus comprises indexing holes formed in the tape.

14. An antenna manufacturing method comprising:

positioning a metal insert in a mold cavity; and

filling the mold cavity with plastic to form a plastic spacer shaped for positioning the metal insert a predetermined distance from a ground plane of a printed circuit board (PCB) when the plastic spacer is mounted to the PCB.

15. The antenna manufacturing method of claim 14 wherein positioning the metal insert in the cavity comprises pressing the metal insert against a wall forming one side of the cavity.

16. The antenna manufacturing method of claim 14 wherein positioning the metal insert in the cavity comprises:

filling a portion of the mold cavity with plastic to form a first plastic wall; and

pressing the metal insert against the first plastic wall before filling the remainder of the mold cavity with plastic.

17. The antenna manufacturing method of claim 14 wherein positioning the metal insert in a mold cavity comprises positioning one metal insert of a set of substantially identical joined metal inserts in a mold cavity of a set of substantially identical mold cavities and wherein filling the mold cavity with plastic comprises each of the set of mold cavities with the plastic.

18. The antenna manufacturing method of claim 17 further comprising:

separating the metal inserts of the set of metal inserts to form individual antennas.