The present disclosure relates to an antenna protection structure and a method for manufacturing the same and, more particularly, to a technique for improving the radio wave transmission characteristics of the antenna protection structure.
The antenna unit may be accommodated in a protection structure (radome) for protecting the antenna unit. The radome may be a dedicated member for protecting the antenna unit or may be a housing to accommodate the antenna unit together with another device.
U.S. Pat. No. 8,917,220 specification (Patent Document 1) discloses a sandwich type radome having a multilayer structure for an antenna that radiates radio waves in microwave bands and millimeter-wave bands. The radome in U.S. Pat. No. 8,917,220 specification (Patent Document 1) has a four-layer structure in which two matching layers are formed inside a structural layer and one matching layer is further formed outside the structural layer.
Patent Document
An antenna unit may be used in a mobile device represented by a mobile phone or a smartphone. In the mobile device above, there is still a high demand for reduction in size, thickness, and weight. With this, the height of a protection structure (a housing, for example) for protecting an antenna unit is also preferably reduced. Further, the protection structure preferably has high transmittance in order to transmit a radio wave radiated from the antenna unit disposed therein with low loss.
It is basically premised that the radome disclosed in U.S. Pat. No. 8,917,220 specification (Patent Document 1) is installed on a large structure such as an aircraft. The total thickness of the radome in U.S. Pat. No. 8,917,220 specification (Patent Document 1) is approximately 10 to 16.5 mm, which can make it hard to apply the radome to the mobile device as described above.
The present disclosure has been made to solve the problem described above, as well as other issues, and one aspect thereof is to provide an antenna protection structure with increased transmittance while minimizing a total thickness.
An antenna protection structure according to an aspect of the present disclosure includes a first dielectric layer, a second dielectric layer disposed on the first dielectric layer, and a third dielectric layer disposed on the second dielectric layer. A elative permittivity of the second dielectric layer is higher than a relative permittivity of the first dielectric layer and the relative permittivity of the second dielectric layer is higher than a relative permittivity of the third dielectric layer. A thickness of the second dielectric layer is smaller than a thickness of the first dielectric layer in a lamination direction and the thickness of the second dielectric layer is smaller than a thickness of the third dielectric layer in the lamination direction.
An antenna protection structure according to an aspect of the present disclosure has a three-layer structure in which a second dielectric layer is sandwiched between a first dielectric layer and a third dielectric layer, and the inner second dielectric layer is made of a material with higher permittivity than other dielectric layers and is formed thinner than other dielectric layers. With the configuration above, high transmittance may be achieved while a thickness of the entire protection structure can be minimized.
Hereinafter, embodiments of the present disclosure will be described in detail with reference to the drawings. Note that the same or corresponding portions in the drawings are denoted by the same reference signs, and the description thereof will not be repeated.
(Basic Configuration of Communication Device)
The protection structure 50 according to Embodiment 1 accommodates an antenna module 100. In the example of Embodiment 1, an example of a frequency band of a radio wave used in the antenna module 100 is a radio wave in a millimeter-wave band having a center frequency of 28 GHz, 39 GHz, 60 GHz, or the like, for example. However, a radio wave in frequency bands other than the above may be used.
According to
Note that, although the RFIC 110 is included in the antenna module 100 in the example of
In
The RFIC 110 includes switches 111A to 111D, 113A to 113D, and 117, power amplifiers 112AT to 112DT, low-noise amplifiers 112AR to 112DR, attenuators 114A to 114D, phase shifters 115A to 115D, a multiplexer/demultiplexer 116, a mixer 118, and an amplifier 119.
When a radio frequency signal is transmitted, the switches 111A to 111D and 113A to 113D are switched to the sides of power amplifiers 112AT to 112DT, and the switch 117 is connected to the transmission-side amplifier in the amplifier 119. When a radio frequency signal is received, the switches 111A to 111D and 113A to 113D are switched to the sides of the low-noise amplifiers 112AR to 112DR, and the switch 117 is connected to the reception-side amplifier in the amplifier 119.
A signal transferred from the BBIC 200 is amplified by the amplifier 119 and is up-converted by the mixer 118. A transmission signal, which is an up-converted radio frequency signal, is divided into four waves by the multiplexer/demultiplexer 116. The waves pass through four signal paths and are fed to the feed elements 121 different from one another. At this time, the directivity of the antenna unit 120 may be adjusted by individually adjusting the phase shift in the phase shifters 115A to 115D disposed in the respective signal paths.
Reception signals, which are the radio frequency signals received by the feed elements 121, respectively go through four different signal paths and are combined by the multiplexer/demultiplexer 116. The combined reception signal is down-converted by the mixer 118, amplified by the amplifier 119, and transferred to the BBIC 200.
The RFIC 110 is formed as, for example, a single chip integrated circuit component including the circuit configuration described above. Alternatively, devices (switch, power amplifier, low-noise amplifier, attenuator, and phase shifter) supporting each feed element 121 in the RFIC 110 may be formed as a single chip integrated circuit component for each corresponding feed element 121.
(Configuration of Housing and Antenna Module)
According to
Examples of the dielectric substrate 130 include: a low temperature co-fired ceramics (LTCC) multilayer substrate, a multilayer resin substrate formed by laminating a plurality of resin layers made of a resin such as epoxy or polyimide, a multilayer resin substrate formed by laminating a plurality of resin layers made of a liquid crystal polymer (LCP) with further lower permittivity, a multilayer resin substrate formed by laminating a plurality of resin layers made of a fluorine-based resin, and a ceramics multilayer substrate other than LTCC. Note that the dielectric substrate 130 does not necessarily have a multilayer structure and may have a single-layer substrate.
The dielectric substrate 130 has a substantially rectangular shape in plan view from a normal direction (Z-axis direction), and the feed element 121 is disposed on a side of an upper surface 131 (surface in the positive direction of the Z-axis) of the dielectric substrate 130 to face the ground electrode GND. The feed element 121 may be exposed on a surface of the dielectric substrate 130 or may be disposed in an inner layer of the dielectric substrate 130 as in the example of
The parasitic element 122 is disposed to face the ground electrode GND in a layer closer than the feed element 121 to a side of the ground electrode GND. In other words, the parasitic element 122 is disposed in a layer between the feed element 121 and the ground electrode GND. The parasitic element 122 overlaps the feed element 121 in plan view of the dielectric substrate 130. A size of the feed element 121 is smaller than a size of the parasitic element 122, and a resonant frequency of the feed element 121 is higher than a resonant frequency of the parasitic element 122. That is, a frequency of a radio wave radiated from the feed element 121 is higher than a frequency of a radio wave radiated from the parasitic element 122. For example, a center frequency of the radio wave radiated from the feed element 121 is 39 GHz, and a center frequency of the radio wave radiated from the parasitic element 122 is 28 GHz.
A radio frequency signal is transferred to the feed element 121 from the RFIC 110 via the feed line 140. The feed line 140 starts from the RFIC 110, penetrates through the ground electrode GND and the parasitic element 122, and is connected to a feed point SP1 from the lower surface side of the feed element 121. That is, the feed line 140 transfers a radio frequency signal to the feed point SP1 of the feed element 121.
The feed point SP1 is disposed at a position offset from a center of the feed element 121 in a negative direction of the X-axis. When a radio frequency signal corresponding to the resonant frequency of the feed element 121 is supplied to the feed line 140, a radio wave having a polarization direction in the X-axis direction is radiated from the feed element 121. Further, when a radio frequency signal corresponding to the resonant frequency of the parasitic element 122 is supplied to the feed line 140, the feed line 140 and the parasitic element 122 are electromagnetically coupled to each other at the penetration position of the parasitic element 122, and the parasitic element 122 is excited. Thus, a radio wave having a polarization direction in the X-axis direction is radiated from the parasitic element 122.
That is, the antenna module 100 is a so-called dual-band antenna module capable of radiating radio waves in two different frequency bands.
The housing, which is an example of the protection structure 50, has a structure in which three dielectric layers are laminated or disposed. Specifically, a dielectric layer 52 is laminated or disposed on a dielectric layer 51, and a dielectric layer 53 is further laminated or disposed on the dielectric layer 52. A thickness (d2) of the dielectric layer 52 is smaller than a thickness (d1) of the dielectric layer 51 and a thickness (d3) of the dielectric layer 53 (that is, d2<d1 and d2<d3). Further, relative permittivity (ε2) of the dielectric layer 52 is higher than relative permittivity (ε1) of the dielectric layer 51 and relative permittivity (ε3) of the dielectric layer 53 (that is, ε2>ε1 and ε2>ε3).
Note that, in the example of
(Description of Transmittance of Housing Having Three-Layer Structure)
Next, a method of determining the permittivity of a dielectric having a three-layer structure will be described with reference to
As illustrated in
[Formula 1]
sin θ0=ε1 sin θ1=ε2 sin θ2=ε3 sin θ3. (1)
Accordingly, the refraction angle θk in the dielectric (k) may be expressed as Equation (2).
That is, the refractive index within each dielectric is independent from the permittivity of other dielectrics. Further, the angle of emission from the dielectric (3) is equal to the angle of incidence from the air to the dielectric (1).
When transmission and reflection in a multilayer dielectric film are determined, a characteristics matrix method is used in many cases (a document “Design of Thin-Film Optical Filters”, Kobiyama Mitsunobu, Optronics Co., LTD., 2006, for example). In the characteristics matrix method, a characteristics matrix Mk of a dielectric (k) is defined as following Equation (3).
Here, δk represents a phase shift amount in the dielectric (k) and is defined by following Equation (4).
Further, ηk is referred to as gradient admittance and is defined as in Equation (5). Note that ηk* in an upper part of Equation (5) is gradient admittance when an electric field of an incident wave is perpendicular to an incident surface (that is, paper surface), and ηkp in the lower part of Equation (5) is gradient admittance when an electric field of an incident wave is parallel to an incident surface. In a case of an air layer (k=0, ε0=1), it is defined as Equation (6).
The matrix product P for three layers of the characteristics matrix defined as above is defined as following Equation (7).
Here, when each component of the matrix product P is defined as in Equation (8), a transmittance T and a phase φt of the power of an electromagnetic wave may be expressed as in following Equation (9) and Equation (10).
Note that, when variables are defined as in Equation (11), each component of the matrix product P of Equation (8) may be expressed as in Equation (12).
When an electromagnetic wave is perpendicularly incident on a dielectric from a front direction (that is, incident angle θi=0), amplitude reflectance ρ may be expressed as in following Equation (13).
In a case of the perpendicular incidence, the transmittance T in Equation (9) is expressed as Equation (14) using the amplitude reflectance ρ.
T=|p|
2 (14)
Here, in a case that the transmittance T is 1, that is, in order to satisfy ρ=0, it is necessary that the numerator of Equation (13) is 0, and thus following Equation (15) holds.
That is, when following Equation (16) is satisfied, the transmittance becomes 1.
Since there are six independent variables d1, d2, d3, ε1, ε2, and ε3 in the three-layer dielectric structure, four-dimensional degrees of freedom remain under the condition of two equations in Equation (16). That is, when four of the six variables are designated, the remaining two variables are determined. However, in an actual design, since a usable range (restriction condition) is given to each variable, there may be a case that a solution satisfying Equation (16) does not exist depending on the restriction condition. Further, since a periodic function is included in Equation (16), when a solution exists, an infinite number of discrete solutions may exist in many cases.
In a situation that an actual product is designed, there may be often cases that it is unable to set the transmittance to 1 over an entire predetermined frequency band, depending on a required specification (restriction condition). That is, in practice, it is required to maximize a specific characteristics index (such as angle characteristics and frequency characteristics of transmittance, for example) in a given specification.
In the present embodiment, a condition is examined in which the transmittance in a target frequency band is maximized within an achievable range of the relative permittivity, while the total thickness is constrained which is often restricted by characteristics such as strength, weight, and design in many cases.
d
total
=d
1
+d
2
+d
3 (17)
Accordingly, each vertex of the triangle corresponds to a case that one dielectric occupies all the thickness. Further, each side corresponds to a case that the thickness of one dielectric is 0. For example, in a case of the vertex A, a protection structure is formed only by the dielectric (2), and in a case of being on the side AB, a protection structure is formed by the dielectric (2) and the dielectric (3).
In
At the point A1 close to the vertex A having the maximum transmittance, (d1, d2, d3)=(0.05 mm, 1.9 mm, 0.05 mm), and the transmittance is −0.248 dB. Further, the relative permittivity at that case is expressed as (ε1, ε2, ε3)=(38.1, 2.0, 38.1). Further, at the point P1, (d1, d2, d3)=(0.85 mm, 0.3 mm, 0.85 mm), and the transmittance is −0.237 dB. The relative permittivity at that case is expressed as (ϵ1, ε2, ε3)=(9.97, 100, 9.97).
Note that, in both cases of the point A1 and the point P1, the maximum transmittance is achieved when the thicknesses and relative permittivity of the dielectric layers (1) and (3) on outer sides are equal to each other. Not limited to this example, when the combination of the thicknesses of the three layers is varied, the maximum transmittance is achieved when the dielectric layers (1) and (3) on the outer sides are equal to each other. When a configuration with the maximum transmittance is determined, therefore, it is sufficient to search under the condition that the dielectric layers (1) and (2) on the outer sides are equal to each other. This condition corresponds to a condition being on a perpendicular line extending from the vertex A to the side BC in
In
In the parameters of
In
As described above, a single-band antenna protection structure formed of three dielectric layers may achieve high transmittance while minimizing a thickness of the entire protection structure with the configuration as follows. The relative permittivity of an inner dielectric layer is made higher than the relative permittivity of the outer dielectric layers, the thickness of the inner dielectric layer is made smaller than the thicknesses of the dielectrics of the outer dielectric layers, and the parameters indicated in
In the first configuration example described above, a method for optimally setting a protection structure for a single-band antenna has been described. In a second configuration example and a third configuration example to be described next, examples will be described in which the protection structure of a dual-band antenna is optimally designed by the same method as described above.
As described above, the condition under which the transmittance in the front direction is 1 at a specific single frequency is Equation (16) described above. Here, as illustrated in
In a case of a dual-band antenna, the relationship in Equation (18) holds for two different frequencies. Here, from the relationship of d1=d3 and ε1=ε3, the variables to be determined are four variables of d1, d2, ε1, and ε2. Since the Equation (18) holds for two frequencies, the degree of freedom is 2 as a result. Accordingly, when two of the variables d1, d2, ε1, and ε2 are given, the remaining two variables are determined.
According to
According to
As described above, a dual-band antenna protection structure formed of three dielectric layers may also achieve high transmittance while minimizing a thickness of the entire protection structure with the configuration as follows. The relative permittivity of an inner dielectric layer is made higher than the relative permittivity of outer dielectric layers, the thickness of the inner dielectric layer is made smaller than the thicknesses of the outer dielectric layers, and the parameters are set within the predetermined ranges indicated in
In a third configuration example, an example is described in which a total thickness is set to 4.0 mm in a protection structure for a dual-band antenna.
According to
According to
In
As described above, a dual-band antenna protection structure having a thickness different from that of the second configuration example may also achieve high transmittance while suppressing a thickness of the entire protection structure with the configuration as follows. As same as the second configuration example, the relative permittivity of the inner dielectric layer is made higher than the relative permittivity of outer dielectric layers, the thickness of the inner dielectric layer is made smaller than the thicknesses of the outer dielectric layers, and the parameters are set within the predetermined ranges indicated in
(Manufacturing Process)
With reference to
According to
In the process of
When the ceramic 330 is disposed on the lower mold 320, the upper mold 310 and the lower mold 320 are brought into close contact with each other in the process of
In the state above, a resin is injected into the space 340 formed between the upper mold 310 and the lower mold 320 through a cavity 325 formed in the lower mold 320. At this time, since the protrusions 311 and 321 are present, the resin is also injected into the gap between the ceramic 330 and the upper mold 310 and the gap between the ceramic 330 and the lower mold 320. Thus, a three-layer structure is formed having a first resin layer between the lower mold 320 and the ceramic 330, a ceramic layer, and a second resin layer between the upper mold 310 and the ceramic 330.
Then, in the process of
At this time, the formed protection structure 50A may be made capable of achieving the characteristics described in each configuration example of Embodiment 1 with the configuration as follows. A material with higher permittivity than the relative permittivity of a resin is used as the ceramic 330, and further, each of the protruding amount of the protrusions 311 and 321 is made larger than the thickness of the ceramic 330, so that the thickness of the ceramic 330 is smaller than the thicknesses of the first resin layer and the second resin layer.
In Embodiment 1, a configuration has been described in which a housing itself of a communication device forms a protection structure having three dielectric layers. In Embodiment 2, a configuration will be described in which a three-layer protection structure is formed by molding between a housing and an antenna module with a resin.
A housing 50B is formed of a single-layer dielectric. A ceramic 330 is disposed on an inner wall of the housing 50B, and a space between the antenna module 100A and the housing 50B is molded using a resin 400 such that the feed element 121 faces the ceramic 330. With this, the protection structure 500 having a three-layer structure is formed by the housing 50B, the ceramic 330, and the resin 400.
At this time, a protection structure having characteristics similar to those of Embodiment 1 may be achieved by making relative permittivity of the ceramic 330 as the inner layer of the three-layer structure higher than relative permittivity of the housing 50B and relative permittivity of the resin 400 and making the thickness of the ceramic 330 smaller than the thicknesses of the housing 50B and the resin 400.
Note that, as described in Embodiment 1, the transmittance may be increased by using materials for the housing 50B and the resin 400 having the same relative permittivity and forming the housing 50B and the resin 400 to have the same thickness.
In Embodiment 1 and Embodiment 2, the configurations have been described in which a protection structure is provided separately from an antenna module. In Embodiment 3, a configuration will be described in which the protection structure as described above is formed in an antenna module.
The dielectric substrate 130A has a three-layer structure including a first dielectric layer 135, a second dielectric layer 136 laminated or disposed on the first dielectric layer 135, and a third dielectric layer 137 laminated or disposed on the second dielectric layer 136. The feed element 121 is formed inside the first dielectric layer 135. In the first dielectric layer 135, the ground electrode GND is disposed to face the feed element 121 in a layer closer than the feed element 121 to a side of a back surface 132A of the dielectric substrate 130A.
The RFIC 110 is connected to the back surface 132A of the dielectric substrate 130A via solder bumps 150. The feed line 140 starts from the RFIC 110, penetrates through the ground electrode GND, and is connected to the feed element 121. When a radio frequency signal from the RFIC 110 is transferred to the feed element 121 by the feed line 140, a radio wave is radiated from the feed element 121.
In the dielectric substrate 130A of the antenna module 100B, a three-layer structure of the first dielectric layer 135, the second dielectric layer 136, and the third dielectric layer 137 is formed in a region RG1 in a direction to which a radio wave is radiated from the feed element 121 (that is, a direction from the feed element 121 toward a front surface 131A of the dielectric substrate 130A). Then, the region RG1 of the three-layer structure may be defined as the protection structure 50C having the similar characteristics as those of Embodiment 1 and Embodiment 2 with the configuration as follows. The relative permittivity of the second dielectric layer 136 is made higher than the relative permittivity of the first dielectric layer 135 and the relative permittivity of the third dielectric layer 137, and further, the thickness of the second dielectric layer 136 is made smaller than the thicknesses of the first dielectric layer 135 and the third dielectric layer 137.
With the configuration above, an antenna module including a protection structure with high transmittance may be realized.
(Modification 1)
Also in the configuration above, as same as the antenna module 100B of Embodiment 3, an antenna module including a protection structure with high transmittance may be realized.
Note that, an example of the protection structure 50C may have a configuration as follows. The first dielectric layer 135 is a protection film for protecting the exposed feed element 121, the third dielectric layer 137 is a housing (resin case) of the communication device 10, and the second dielectric layer 136 with high permittivity is disposed therebetween. Further, in
(Modification 2)
In the antenna module 100D, a radio wave radiated from the feed element 121 passes through an air layer of the space 160 and dielectric layers of a three-layer structure of the protection structure 50C and is radiated to the outside of the antenna module 100D.
Also in the configuration in which a space is formed inside the dielectric substrate as in Modification 2, an antenna module including a protection structure with high transmittance may be realized by forming the protection structure as the configuration described above.
Note that the feed element 121 may be formed on the surface of the dielectric layer 139 or may be formed inside the dielectric layer 139. Further, the relative permittivity of the dielectric layer 139 may be the same as or different from that of the first dielectric layer 135.
Note that, in the antenna module 100D, a case has been described in which an air layer is formed between the first dielectric layer 135 and the feed element 121. However, instead of the air layer, a dielectric layer with the relative permittivity lower than the relative permittivity of the first dielectric layer 135 may be formed.
The “space 160 (air layer)” and the “dielectric layer with the relative permittivity lower than the relative permittivity of the first dielectric layer 135” in Modification 2 correspond to a “fifth dielectric layer” of the present disclosure.
Note that it is sufficient that, in the protection structure illustrated in each of the embodiments described above, the radiating element is included within a range of the protection structure when the antenna module is viewed in plan view. That is, the size of the protection structure in plan view of the antenna module may be larger than or equal to the size of the radiating element.
Further, the protection structure is not limited to a flat shape as illustrated in each of the embodiments described above and may have a shape in which a curved surface is partially formed. For example, a portion of a protection structure overlapping a feed element, in plan view of the protection structure from a normal direction (Z-axis direction in the drawing), may be formed in a dome shape that protrudes in the positive direction or the negative direction of the Z-axis direction.
It should be understood that the embodiments disclosed herein are illustrative and non-restrictive in all respects. It is intended that the scope of the present disclosure be indicated by the appended claims rather than the foregoing description of the embodiments and that all changes within the meaning and range of equivalency of the appended claims shall be embraced therein.
Number | Date | Country | Kind |
---|---|---|---|
2020-042751 | Mar 2020 | JP | national |
The present application is a continuation application of International Patent Application No. PCT/JP2021/000191, filed Jan. 6, 2021, which claims priority to Japanese Patent Application No. 2020-042751, filed Mar. 12, 2020, the entire contents of each of which being incorporated herein by reference.
Number | Date | Country | |
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Parent | PCT/JP2021/000191 | Jan 2021 | US |
Child | 17941043 | US |