Production of antenna devices

• US 7,480,979 B2
• Filed: 12/21/2001
• Issued: 01/27/2009
• Est. Priority Date: 12/29/2000
• Status: Expired due to Fees

• Current Assignee: Laird Connectivity Sweden AB (DuPont de Nemours, Inc.)
• Original Assignee: AMC Centurion AB (DuPont de Nemours, Inc.)
• Inventors: Morén, Stefan
• Primary Examiner(s): TRINH, MINH N
• Application Number:
  US10/451,437
• Publication Number:
  US 20040060162A1
• Time in Patent Office: 2,594 Days
• Field of Search: 296/00, 296/021, 29830-834, 298/25, 298/29, 343/702, 343872-873, 347/7, 347/19, 340/572.1, 174/250, 174/261
• US Class Current: 29/600
• 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: H05K 3/125 by ink-jet printing
• CPC Class Codes: Y10T 29/49016 Antenna or wave energy "plumbing" making
• CPC Class Codes: Y10T 29/49018 with other electrical component
• CPC Class Codes: Y10T 29/49155 Manufacturing circuit on or in base

Abstract

A method of producing an antenna device for use with a portable radio communication apparatus includes the steps of (i) providing a dielectric substrate, having first and second opposing surfaces; and an ejection apparatus, having a container filled with a liquid conductive substance, an ejection opening in liquid communication with the container, and an implement for ejecting a liquid conductive substance from the opening in the container; (ii) ejecting the liquid electrically conductive substance from the ejecting apparatus, onto the first surface of the dielectric substrate; and (iii) moving the dielectric substrate and the ejection opening relative to each other while ejecting the liquid conductive substance to form, upon being solidified, a conductive antenna pattern on the first surface of the dielectric substrate.

Claims

1. A method of producing an antenna device for use in a portable radio communication apparatus, said method comprising the steps of:

providing a dielectric substrate having a first and a second surface opposite to each other;

said first surface of said dielectric substrate being essentially non-planar;

providing an ejecting apparatus that is adapted to form antenna patters on said dielectric substrate;

ejecting a liqyid electrically conductive substance from said ejecting apparatus onto the first surface of said dielectric substrate, said ejecting apparatus having a container filled with said liquid conductive substance, an ejection opening in liquid communication with said container, and an implement for ejecting liquid conductive substance from said container through said opening; and

moving said dielectric substrate and said ejection opening relative each other while ejecting said liquid conductive substance to thereby form, upon being solidified, a conductive antenna pattern on the first surface of said dielectric substrate.

2. The method of producing as claimed in claim 1 wherein the steps of ejecting and moving are controlled from a control unit.

3. The method of producing as claimed in claim 2 wherein the steps of ejecting and moving are controlled from a microcomputer.

4. The method of producing as claimed in claim 1 wherein said liquid conductive substance solidification is speeded up by heating said liquid conductive substance ejected from said ejecting apparatus onto the first surface of said dielectric substrate.

5. The method of producing as claimed in claim 1 wherein said liquid conductive substance solidification is speeded up by blowing a gas over said liquid conductive substance ejected from said ejecting apparatus onto the first surface of said dielectric substrate.

6. The method of producing as claimed in claim 5 wherein said solidification of said liquid conductive substance is speeded up by blowing dry air over said liquid conductive substance ejected from said ejecting apparatus onto the first surface of said dielectric substrate.

7. The method of producing as claimed in claim 1 wherein said liquid conductive substance is conductive ink and said ejecting apparatus is an ink jet printer.

8. The method of producing as claimed in claim 1 wherein said liquid conductive substanceis any of conductive paint, conductive ink, a conductive resin, and a conductive adhesive, and said ejecting apparatus is any of a drops gun, an atomizer, a blow-by gun, and a paint spray gun.

9. The method of producing as claimed in claim 1 wherein said dielectric substrate constitute part of the outer casing of the portable radio communication apparatus when being attached thereto.

10. The method of producing as claimed in claim 9 wherein said second surface of said dielectric substrate constitute part of the exterior surface of the outer casing of the portable radio communication apparatus when being attached thereto to thereby protect said antenna pattern formed on said first surface of said dielectric substrate from damage.

11. The method of producing as claimed in claim 1 wherein said first surface of said dielectric substrate, is curved.

12. The method of producing as claimed in claim 11 wherein said first surface of said dielectric substrate, is concave.

13. The method of producing as claimed in claim 11 wherein the distance between said first surface of said dielectric substrate and said ejection opening of said ejecting apparatus is substantially constant.

14. The method of producing as claimed in claim 1 wherein said dielectric substrate is any of a SIM-card, a PCB, a casing, a display, a key pad, a battery, and a battery pack comprised in said portable radio communication apparatus.

15. The method of producing as claimed in claim 1 further comprising ejecting liquid conductive substance from said ejecting apparatus onto the second surface of said dielectric substrate while moving said dielectric substrate and the ejection opening of said ejecting apparatus relative each other to thereby form, upon being solidified, a second conductive antenna pattern on the second surface of said dielectric substrate.

16. The method of producing as claimed in claim 15 wherein the step of plating is preceded by the step of etching away a surface portion of said conductive antenna pattern to thereby make the surface thereof rough.

17. The method of producing as claimed in claim 1 wherein a conductive metallic layer is selectively plated on said conductive antenna pattern, said metallic layer having a pattern substantially matching said conductive antenna pattern and overlying the same, to thereby increase the antenna performance of said antenna device.

18. The method of producing as claimed in claim 17 wherein the step of plating is performed by means of any of ion, chemical, and electrolytic plating.

19. A method of producing an antenna device for use in a portable radio communication apparatus, said method comprising the steps of:

providing a dielectric substrate having a first and second surface opposite to each other;

providing an ejecting apparatus that is adapted to form antenna patters on said dielectric substrate;

ejecting a liquid electrically conductive substance from said ejecting apparatus onto the first surface of said dielectric substrate, said ejecting apparatus having a container filled with said liquid conductive substance, an ejection opening in liquid communication with said container, and an implement for ejecting liquid conductive substance from said container through said opening;

moving said dielectric substrate and said ejection opening relative each other while ejecting said liquid conductive substance to thereby form, upon being solidified, a conductive antenna pattern on the first surface of said dielectric substrate.

said dielectric substrate with the antenna pattern formed on said first surface thereof and a portable radio communication apparatus of a particular model are assembled wherein the antenna pattern is electrically connected to an RF feed device of said portable radio communication apparatus of the particular model;

at least one antenna characteristic during operation of said assembled portable radio communication apparatus of the particular model is measured;

said dielectric substrate with said antenna pattern formed on said first surface thereof and said portable radio communication apparatus of the particular model are disassembled wherein the antenna pattern is electrically disconnected from the RF feed device of said portable radio communication apparatus; and

in dependence on said measured antenna characteristic ejecting liquid conductive substance from said ejecting apparatus onto the first surface of said dielectric substrate while moving said dielectric substrate and the ejection opening of said ejecting apparatus relative each other to thereby form, upon being solidified, a modified conductive antenna pattern on the first surface of said dielectric substrate.

20. The method of producing as claimed ut claim 19 wherein the steps of assembling, measuring, disassembling and forming a modified antenna pattern are repeated until said measured antenna characteristic is lying within a predetermined acceptable interval.

21. The method of producing as claimed in claim 19 wherein

said dielectric substrate with the antenna pattern formed on said first surface thereof and said portable radio communication apparatus of the particular model are assembled wherein the antenna pattern is electrically connected to an RF feed device of said portable radio communication apparatus;

at least one antenna characteristic during operation of said assembled portable radio communication apparatus of the particular model is measured;

said dielectric substrate with said antenna pattern formed on said first surface thereof and said portable radio communication apparatus of the particular model are disassembled wherein the antenna pattern is electrically disconnected from the RF feed device of said portable radio communicaton apparatus of the particular model; and

depending on said measured antenna characteristic removing, particularly by means of laser cutting, portions of the antenna pattern formed on the first surface of said dielectric substrate.

22. The method of producing as claimed in claim 21 wherein the step of removing portions of tne antenna pattern formed on the first surface of said dielectric substrate depending on said measured antenna characteristic is performed by means of laser cutting.

23. The method of producing as claimed in claim 19 wherein said modified antenna pattern is used as a template for the mass production of antenna devices for use in portable radio communication apparatus of the particular model.

24. A method of producing an antenna device for use in a portable radio communication apparatus, said method comprising the steps of:

providing a dielectric substrate having a first and a second surface opposite to each other;

said first surface of said dielectric substrate being essentially non-planar

providing an ejecting apparatus that is adapted to form antenna patters on said dielectric substrate;

mounting said dielectric substrate on a bench fixedly, said bench being movable in a plane substantially perpendicular to the direction of the liquid conductive substance to be ejected and being movable in a direction parallel with the direction of the liquid conductive substance to be ejected;

a distance between said first surface of said dielectric substrate and said election opening of said ejecting apparatus being substantially constant;

ejecting a liquid electrically conductive substance from said ejecting apparatus onto the first surface of said dielectric substrate, said ejecting apparatus having a container filled with said liquid conductive substance, an ejection opening in liquid communication with said container, and an implement for ejecting liquid conductive substance from said container through said opening; and

moving said dielectric substrate and side ejection opening relative each other and moving said bench in said plane and said direction while ejecting said liquid conductive substance to thereby form, upon being solidified, said conductive antenna pattern on the first and essentially non-planar surface of said dielectric substrate.