Patent Application
20100033400
1. Field of the Invention
The present invention relates to an antenna fabrication method and more particularly, to a spray non-contact cutting type antenna fabrication method for forming an antenna on a plastic shell by means of spray-painting a metallic spray paint on the plastic shell and then cutting the metallic coating into shape and then covering a cover layer on the plastic shell over the antenna by means of an insert molding technique.
2. Description of the Related Art
Following fast development of wireless communication technology, mobile telephone has become the most important communication tool for most people. From the early mobile telephone designs of big size, exposed antenna, monotonous outer appearance and simple function, modern mobile telephones have light, thin, small and short characteristics with the antenna concealed from sight. Clamshell, slip cover and flip cover mobile telephones are commercially available. Advanced mobile telephones have added functions such as network, camera, MP3 player, and etc. Nowadays, except for message communication, an advanced mobile telephone can function as a multimedia entertainment system.
Following the design trend toward small size and light weight characteristics with built-in multifunction module, the usable internal space of a mobile telephone has been greatly reduced. In consequence, the space for microwave transmitting and receiving radiator (the so-called antenna) is relatively reduced. Therefore, how to provide a fabrication method for making concealed antenna in a device shell to save space occupation is the focal point to be discussed in the present invention.
Conventionally, the installation of a cell phone antenna in a device shell is complicated. After cutting the antenna into the desired shape, a series of procedures including posterior assembly and thermal fusion/ultrasonic sealing must be performed, wasting much manufacturing time and having a defect rate. Therefore, an improvement is this regard is necessary.
U.S. Pat. No. 7,271,099 discloses an antenna fabrication method, entitled “Forming a conductive pattern on a substrate”. This method comprises: a) providing a substrate carrying a conductive layer; b) forming a first portion of the conductive pattern by exposing the conductive layer to a laser and controlling the laser to remove conductive material around the edge(s) of desired conductive region(s) of the first portion; and, c) laying down an etch resistant material on the conductive layer, the etch resistant material defining a second portion of the conductive pattern, removing conductive material from those areas of the second portion not covered by the etch resistant material, and then removing the etch resistant material, wherein the first portion of a conductive pattern is formed at a higher resolution than the second portion of the conductive pattern.
The aforesaid prior art pattern simply provides a method of forming a conductive pattern on a flexible insulative material (such as circuit board) by means of the application of a laser technique. This method is not applicable to the formation of a conductive pattern on a rigid plastic device shell, therefore it is not suitable for antenna fabrication.
The present invention has been accomplished under the circumstances in view. The design concept of the present invention is to form the antenna radiator by means of spray-painting a conducting material onto the surface of the prepared plastic device shell, and then to remove the unnecessary conducting material from the plastic device shell through a posterior processing process, and then to package the antenna radiator in the device shell by means of a 2-step insert molding or spray-painting process.
A spray non-contact cutting type antenna fabrication method according to the present invention comprises the steps of:
a) forming a plastic shell;
b) spray-painting the plastic shell with a metallic spray paint to form a metal coating layer on the plastic shell;
c) cutting the metal coating layer into an antenna subject to a predetermined pattern; and
d) covering the plastic shell with a cover layer to have the antenna be enveloped in the cover layer.
A device shell having a spray non-contact cutting type antenna made according to the present invention has the antenna be incorporated into the plastic shell without occupying any extra space. When compared with conventional manufacturing techniques, the invention eliminates posterior assembly and thermal fusion/ultrasonic sealing processes, saving much manufacturing time and lowering the defect rate.
Referring to
1. form a plastic shell 1, as shown in
2. spray-paint the plastic shell 1 with a metallic spray paint, thereby forming a metal coating layer 2 on the surface of the assigned part of the plastic shell 1, as shown in
3. cut the metal coating layer 2 into an antenna 3 subject to a predetermined pattern by means of, for example, a laser engraving technique, as shown in
4. cover the plastic shell 1 with a cover layer 4 by means of using an insert molding or spray painting technique to have the antenna 3 be enveloped in the cover layer 4, as shown in
Referring to
A device shell having a spray non-contact cutting type antenna made according to the present invention, as shown in
The plastic shell 1 has a feed-in contact hole 11 and a grounding contact hole 12. The antenna 3 is made by means of spray-painting a metallic spray paint onto the surface plastic shell 1 and then cutting the metallic coating into shape. The cover layer 4 is covered on the plastic shell 1 over the antenna 3 through an insert molding technique. Further, the antenna 3 has a feed-in contact 31 and a grounding contact 32 respectively extended to the inside of the feed-in contact hole 11 and grounding contact hole 12 of the plastic shell 1 for electric connection to a respective contact at a circuit board (not shown) inside the plastic shell 1.
A device shell having a spray non-contact cutting type antenna made according to the present invention has the antenna 3 be incorporated into the plastic shell 1 without occupying any extra space. When compared with conventional manufacturing techniques, the invention eliminates posterior assembly and thermal fusion/ultrasonic sealing processes, saving much manufacturing time and lowering the defect rate.
Although a particular embodiment of the invention has been described in detail for purposes of illustration, various modifications and enhancements may be made without departing from the spirit and scope of the invention. Accordingly, the invention is not to be limited except as by the appended claims.
