Antenna apparatus and manufacturing method thereof

Abstract

A disclosed antenna apparatus includes: a punched out antenna element made of a sheet metal; a punched out ground element made of a sheet metal, the ground element facing the antenna element; and a surface mount type coaxial connector mounted across the antenna element and the ground element.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a configuration diagram as an example of a conventional antenna apparatus;

FIG. 1B is a configuration diagram as another example of a conventional antenna apparatus;

FIG. 2A is a perspective view showing a configuration of a UWB flat antenna apparatus previously applied by the applicants of the present invention;

FIG. 2B is another perspective view showing a configuration of a UWB flat antenna apparatus previously applied by the applicants of the present invention;

FIG. 3 is a perspective view showing a UWB flat antenna apparatus according to example 1 of the present invention;

FIG. 4A is a plan view showing the UWB flat antenna apparatus in FIG. 3;

FIG. 4B is a cross-sectional view of the UWB flat antenna apparatus taken along line B-B in FIG. 4A;

FIG. 5A is a plan view showing a socket-type coaxial connector;

FIG. 5B is a side view showing a socket-type coaxial connector;

FIG. 5C is a plan view showing a socket-type coaxial connector;

FIG. 6 is a diagram showing steps for manufacturing the UWB flat antenna apparatus in FIG. 3;

FIG. 7 is a diagram illustrating a step of press working in FIG. 6;

FIG. 8 is a diagram showing an antenna with link bars;

FIG. 9 is a diagram showing an antenna with link bars on which a socket-type coaxial connector is mounted;

FIG. 10 is a perspective view showing an antenna body;

FIG. 11 is a diagram illustrating a step of insert molding;

FIG. 12 is a perspective view showing a UWB flat antenna apparatus according to example 2 of the present invention;

FIG. 13 is a perspective view showing a UWB flat antenna apparatus according to example 3 of the present invention;

FIG. 14 is a side view showing the UWB flat antenna apparatus in FIG. 13;

FIG. 15 is a diagram showing steps for manufacturing the UWB flat antenna apparatus in FIG. 13;

FIG. 16 is a diagram showing when a resin molding step in FIG. 15 is completed;

FIG. 17 is a perspective view showing a UWB flat antenna apparatus according to example 4 of the present invention;

FIG. 18 is a diagram showing first steps for manufacturing the UWB flat antenna apparatus in FIG. 17;

FIG. 19 is a diagram showing each step in FIG. 18;

FIG. 20A is a diagram illustrating a step of insert molding;

FIG. 20B is a cross-sectional view of the UWB flat antenna apparatus taken along line B-B in FIG. 20A;

FIG. 21 is a diagram showing second steps for manufacturing the UWB flat antenna apparatus in FIG. 17;

FIG. 22 is a diagram showing each step in FIG. 21;

FIG. 23 is a diagram illustrating a step of insert molding;

FIG. 24 is a diagram showing third steps for manufacturing the UWB flat antenna apparatus in FIG. 17;

FIG. 25 is a diagram showing each step in FIG. 24;

FIG. 26 is a diagram illustrating a step of molding a rear face;

FIG. 27 is a diagram illustrating a step of molding a front face;

FIG. 28A is a perspective view showing a UWB flat antenna apparatus according to example 5 of the present invention;

FIG. 28B is a cross-sectional view of the UWB flat antenna apparatus taken along line B-B in FIG. 28A;

FIG. 28C is a cross-sectional view of the UWB flat antenna apparatus taken along line C-C in FIG. 28A;

FIG. 29 is a diagram showing steps for manufacturing the UWB flat antenna apparatus in FIG. 28A;

FIG. 30 is a diagram showing when a step of press punching in FIG. 29 is completed;

FIG. 31A is a diagram showing when a step of press cutting and bending in FIG. 29 is completed;

FIG. 31B is a diagram showing when a step of insert molding in FIG. 29 is completed;

FIG. 32 is a perspective view showing a UWB flat antenna apparatus according to example 6 of the present invention; and

FIG. 33 is a diagram showing when a step of insert molding is completed.

Claims

1. An antenna apparatus comprising: a punched out antenna element made of a sheet metal;a punched out ground element made of a sheet metal, the ground element facing the antenna element; anda surface mount type coaxial connector mounted across the antenna element and the ground element.

2. An antenna apparatus comprising: a punched out antenna element made of a sheet metal;a punched out ground element made of a sheet metal;a surface mount type coaxial connector mounted across the antenna element and the ground element; anda plate-like synthetic resin portion covering the antenna element and the ground element except the coaxial connector and fixing the antenna element and the ground element.

3. An antenna apparatus comprising: a punched out antenna element made of a sheet metal;a punched out ground element made of a sheet metal;a surface mount type coaxial connector mounted across the antenna element and the ground element; anda synthetic resin portion formed on a peripheral portion of the coaxial connector so as to cover portions of the antenna element and the ground element, the synthetic resin portion fixing the antenna element and the ground element.

4. A method for manufacturing an antenna apparatus, comprising the steps of: preparing an antenna with link bars by punching out from a sheet metal, the antenna with link bars having an antenna element, a ground element, link bars linking the antenna element with the ground element, and half-cut portions provided to boundaries between the link bars and the antenna element and boundaries between the link bars and the ground element;mounting a surface mount type coaxial connector on the antenna with link bars such that the surface mount type coaxial connector is disposed across the antenna element and the ground element;removing the link bars by cutting the half-cut portions; andmolding a synthetic resin portion so as to cover entire portions of the antenna element and the ground element except the coaxial connector or a peripheral portion of the coaxial connector.

5. A method for manufacturing an antenna apparatus, comprising the steps of: preparing an antenna with link bars by punching out from a sheet metal, the antenna with link bars having an antenna element, a ground element, link bars linking the antenna element with the ground element, and half-cut portions provided to boundaries between the link bars and the antenna element and boundaries between the link bars and the ground element;mounting a surface mount type coaxial connector on the antenna with link bars such that the surface mount type coaxial connector is disposed across the antenna element and the ground element;molding a synthetic resin portion so as to cover a peripheral portion of the coaxial connector on the antenna element and the ground element except the coaxial connector; andremoving the link bars by cutting the half-cut portions.

6. A method for manufacturing an antenna apparatus including an antenna element prepared by punching out from a sheet metal, a ground element prepared by punching out from a sheet metal, a surface mount type coaxial connector mounted across the antenna element and the ground element, and a plate-like synthetic resin portion covering the antenna element and the ground element except the coaxial connector, the method for manufacturing an antenna apparatus comprising the steps of: preparing a frame member having antenna bodies arranged in the same manner as in the antenna element and the ground element of the antenna apparatus by punching out from a belt-like sheet metal so as to form an antenna element, a ground element, frames on both sides, and rungs extending from the frames on both sides and linked to the antenna element and the ground element, where the antenna element and the ground element are supported on sides thereof by the rungs;molding the plate-like synthetic resin portion by setting the frame member in metal molds and covering the antenna body with synthetic resin; andcutting the rungs protruding from side faces of the plate-like synthetic resin portion.

7. A method for manufacturing an antenna apparatus including an antenna element prepared by punching out from a sheet metal, a ground element prepared by punching out from a sheet metal, a surface mount type coaxial connector mounted across the antenna element and the ground element, and a plate-like synthetic resin portion covering the antenna element and the ground element except the coaxial connector, the method for manufacturing an antenna apparatus comprising the steps of: preparing a frame member having antenna bodies arranged in the same manner as in the antenna element and the ground element of the antenna apparatus by punching out from a belt-like sheet metal so as to form an antenna element, a ground element, frames on both sides, and rungs extending from the frames on both sides and linked to the antenna element and the ground element, where the antenna element and the ground element are supported on sides thereof by the rungs;mounting the coaxial connector on each antenna body of the frame member;molding the synthetic resin portion by setting the frame member on which the coaxial connector is mounted in metal molds and covering the antenna body with synthetic resin; andcutting the rungs protruding from side faces of the plate-like synthetic resin portion.

8. A method for manufacturing an antenna apparatus including an antenna element prepared by punching out from a sheet metal, a ground element prepared by punching out from a sheet metal, a surface mount type coaxial connector mounted across the antenna element and the ground element, and a plate-like synthetic resin portion covering the antenna element and the ground element except the coaxial connector, the method for manufacturing an antenna apparatus comprising the steps of: preparing a frame member having antenna bodies arranged in the same manner as in the antenna element and the ground element of the antenna apparatus by punching out from a belt-like sheet metal so as to form an antenna element, a ground element, frames on both sides, and rungs extending from the frames on both sides and linked to the antenna element and the ground element, where the antenna element and the ground element are supported on sides thereof by the rungs;molding a rear face synthetic resin portion by setting the frame member in metal molds and covering a rear face of the antenna body with synthetic resin; andmolding a front face synthetic resin portion by setting the frame member having the rear face synthetic resin portion in metal molds and covering a front face of the antenna body with synthetic resin, thereby forming the plate-like synthetic resin portion using the rear face synthetic resin portion and the front face synthetic resin portion.

9. An antenna apparatus comprising: an antenna element prepared by punching out from a sheet metal;a ground element prepared by punching out from a sheet metal;a surface mount type coaxial connector mounted across the antenna element and the ground element; anda plate-like synthetic resin portion covering the antenna element and the ground element except the coaxial connector, whereinrungs extending from the antenna element and the ground element are bent upward and have ends on a top face of the plate-like synthetic resin portion.

10. A method for manufacturing an antenna apparatus including an antenna element prepared by punching out from a sheet metal, a ground element prepared by punching out from a sheet metal, a surface mount type coaxial connector mounted across the antenna element and the ground element, a plate-like synthetic resin portion covering the antenna element and the ground element except the coaxial connector, and rungs extending from the antenna element and the ground element, bent upward, and having ends on a top face of the plate-like synthetic resin portion, the method for manufacturing an antenna apparatus comprising the steps of: preparing a frame member having antenna bodies arranged in the same manner as in the antenna element and the ground element of the antenna apparatus by punching out from a belt-like sheet metal so as to form an antenna element, a ground element, frames on both sides, and rungs extending from the frames on both sides and linked to the antenna element and the ground element, where the antenna element and the ground element are supported on sides thereof by the rungs;bending the rungs of the frame member with the antenna bodies downward so that the antenna body is disposed in a lower position relative to the frames;molding the plate-like synthetic resin portion by setting the frame member in metal molds and covering the antenna body with synthetic resin, the antenna body being disposed in a lower position relative to the frames; andcutting the rungs protruding from the top face of the plate-like synthetic resin portion.