Abstract:
The present invention relates to an antenna module for an insert type antenna module for a portable terminal and a method for manufacturing the same. More specifically, the method for manufacturing an insert type antenna module for a portable terminal comprises an antenna radiation part manufacture step wherein an antenna core is manufactured, the antenna core being engaged by an insert so that an antenna radiation part configured in a predetermined shape selected between a plane shape and a curved shape with at least one axis by cutting and bending a conductive metal sheet is exposed toward an outer surface of one side, wherein in the antenna radiation part manufacture step, in the core forming mold is disposed an antenna support protrusion maintaining a gap for the sake of a thickness development of the antenna core.

Description:
CLAIM OF PRIORITY 
       [0001]    This application is a Continuation Application of U.S. patent application Ser. No. 13/139,031, which was filed on Jun. 10, 2011, which makes reference to, incorporates the same herein, and claims all benefits accruing under 35 U.S.C. §119 from applications filed in the Korean Intellectual Property Office on 11 Dec. 2008 and there duly assigned Serial No. 10-2008-0125877, on 31 Mar. 2009 and there duly assigned Serial No. 10-2009-0027587, on 13 Jul. 2009 and there duly assigned Serial No. 10-2009-0063476, and on 2 Sep. 2009 and there duly assigned Serial No. 10-2009-0082243. Furthermore, this application makes reference to, incorporates the same herein, and claims all benefits accruing under 35 U.S.C. §365(c) of my PCT International application entitled ANTENNA MODULE FOR PORTABLE TERMINAL HAVING ANTENNA INSERTED THEREIN AND MANUFACTURING PROCESS OF THE ANTENNA MODULE filed on 11 Dec. 2009 and duly assigned Serial No. PCT/KR2009/007454. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Technical Field 
         [0003]    The present invention relates to an insert type antenna module for a portable terminal and a method for manufacturing the same, and in particular to an insert type antenna module for a potable terminal and a method for manufacturing the same which make it possible to enhance the durability of an antenna module in such a way that an antenna radiation part is made of a conductive metal material in a plane form or in a curve form with at least two axes, and an insert is integrally formed on an outer surface of an antenna module, thus increasing the productivity of an antenna module. 
         [0004]    2. Background Art 
         [0005]    An antenna module, which is generally used for a portable terminal having a wireless communication function like a cellular phone, a PDA, a DMB and a navigation device, uses a road antenna, a helical antenna, and a retractable antenna. 
         [0006]    The conventional antenna module is installed at an outer side of a terminal, which leads to a huge volume problem. In order to improve the problem, an antenna built-in in a terminal like a chip antenna, a ceramic antenna, MP12 (Metal plate antenna), an inverted-F antenna and an inverted-L antenna is developed and at present used. 
         [0007]    The antenna module built-in in the terminal needs a separate space in the interior of the terminal for installing the antenna module or is directly attached to a terminal housing. 
         [0008]    The conventional built-in type antenna module is needed to decrease its weight and volume, while increasing a signal reception performance which is a key function of the antenna, based on the recent trends that most of electronic devices become light and compact-sized. 
         [0009]    Korean patent number 2007-0044140 discloses an antenna in which an antenna radiation part formed of a PCB in part or an antenna radiation part formed of an antenna circuit on a film is integrated in a housing module. The above patent, however, has a lot of problems: a PCB pattern is transformed, housing has a limit in making it smaller and thinner, a curve with at least two axes is impossible to form, which leads to a low signal reception and a high defects in products, a manufacture process is complicated, and its manufacture costs high. 
         [0010]    Korean patent number 2006-0042663 discloses an antenna in which a radiation part is formed of a sheet metal and is attached to an inner side of a terminal; however an antenna radiation part is exposed and fixedly adhered. In this case, a separate installation space and an engaging member are needed for an antenna radiation member and have a lot of problems: an antenna radiation part is exposed, a pattern might be transformed, a curve with at least two axes is not easy to form, which leads to a low signal reception and a higher defect. 
       SUMMARY OF THE INVENTION 
     Disclosure of Invention 
       [0011]    Accordingly, it is an object of the present invention to provide an insert type antenna module for a portable terminal and a method for manufacturing the same which overcomes or improves the problems encountered in a conventional antenna built-in type portable terminal: it is impossible to make a cover of a terminal thinner because an antenna is simply attached or built in, a defect ratio is high, a manufacture process is complicated, and a curve with at least two exes is not easy to form. 
         [0012]    To achieve the above objects, in a manufacture of an antenna module for a portable terminal, there is provided an insert type antenna module for a portable terminal in which an antenna radiation part has a curve with at least one axis an is formed of a conductive metallic sheet, and an antenna core to which an antenna radiation part is engaged is injection-molded, and a cover is injection-molded on an exposed side of an antenna core in a state that an antenna core is inserted. 
       Effects 
       [0013]    In a manufacture of an antenna module for a portable terminal according to the present invention, a cover is injection-molded at one exposed side of an antenna core in a state that an antenna core to which an antenna radiation member is engaged is inserted, so a thickness of an antenna module is uniform, and a weight, volume and area decrease, which leads to a lightness and a compact size of a terminal housing. A plurality of antenna radiation parts can be integrated in one housing, a manufacture process can be simplified as compared to a conventional antenna (each antenna is separately manufactured and attached), thus improving quality and manufacture process in manufacturing a terminal housing. 
         [0014]    The present invention is characterized in that an antenna radiation part is formed of a conductive metal sheet having a curve with at least two axes and an integrated ground terminal, thus improving signal reception efficiency by more than 30%. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]    A more complete appreciation of the invention, and many of the attendant advantages thereof, will be readily apparent as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like reference symbols indicate the same or similar components, wherein: 
           [0016]      FIG. 1  is a view of a manufacture based on an engagement of an antenna radiation part according to an embodiment of the present invention; 
           [0017]      FIG. 2  is a view of a state that an air gap maintaining protrusion is applied to a cover forming mold in the course of a manufacture of  FIG. 1 ; 
           [0018]      FIG. 3  is a view of a state that an air gap maintaining protrusion is applied to an antenna core in the course of a manufacture of  FIG. 1 ; 
           [0019]      FIG. 4  is a view of a state that an antenna radiation part is inserted into an antenna core according to another embodiment of the present invention; 
           [0020]      FIG. 5  is a view of a state that an air gap maintaining protrusion is applied to a forming mild in the course of a manufacture of  FIG. 4 ; 
           [0021]      FIG. 6  is a view of a state that a cover is formed of a portable terminal housing according to the embodiments of the present invention; 
           [0022]      FIG. 7  is a view of a manufacture procedure of  FIG. 6 ; 
           [0023]      FIG. 8  is a view of a state that a radiation accommodation groove is formed at a core forming mold according to the present invention; 
           [0024]      FIG. 9  is a view of a state that a resin leak prevention shoulder is formed at an antenna core according to the present invention; 
           [0025]      FIG. 10  is a perspective view of a manufacture procedure in which only an outer side mold is exchanged without exchanging an inner side mold according to the present invention; 
           [0026]      FIG. 11  is a perspective view of a construction that two antenna cores are used according to the present invention; 
           [0027]      FIG. 12  is a view of a manufacture procedure using a protrusion ascending and descending part according to the present invention; and 
           [0028]      FIGS. 13 to 15  are views of examples of a protrusion ascending and descending part according to the present invention. 
       
    
    
     DESCRIPTIONS OF REFERENCE NUMERALS OF MAJOR ELEMENTS 
       [0000]    
       
         
           
               1 : antenna radiation part manufacture procedure  2 : antenna core manufacture procedure 
               3 : cover forming procedure 
               10 : core forming mold  10   a : core outer side mold  10   b : air gap protrusion forming groove 
               11 : antenna engaging protrusion  12 : antenna support protrusion 
               20 : cover molding mold  20   a : cover outer side mold 
               30 : air gap maintaining protrusion 
               41 : solenoid actuator  42 : hydraulic and pneumatic actuator  43 : support spring 
               100 : antenna radiation part  110 : ground terminal  121 : base mold engaging hole 
               200 : antenna core  211 : antenna engaging protrusion  221 : resin lead prevention shoulder 
               241 : cover mold engaging hole  300 : cover  510 : antenna module engaging groove 
           
         
       
     
       DETAILED DESCRIPTION OF THE INVENTION 
     Modes for Carrying Out the Invention 
       [0039]    The preferred embodiments of the present invention will be described with reference to the accompanying drawings. 
         [0040]    The present invention is directed to forming, in a way of insert-injection, an antenna core to which an antenna radiation part is engaged and manufacturing a cover in a way of insert-injection molding, thus improving a productivity and durability. 
         [0041]    In a manufacture of an antenna module for a portable terminal according to the present invention, as shown in  FIGS. 1 to 7 , the method for manufacturing an insert type antenna module for a portable terminal comprises an antenna radiation part manufacture step  1  in which an antenna radiation part  100  is manufactured by cutting and bending a conductive metal sheet for an antenna radiation part to have a plane and a curve with at least one axis; an antenna core manufacture step  2  in which an antenna core  200  is manufactured, which antenna core is engaged by one among an adhering work, an engaging work, a mounting work, an attaching work and an insert work so that the antenna radiation part  100  is exposed from an outer surface of one side; and a cover formation step  3  in which a cover  300  is inject-formed at an exposed surface of the side of the antenna radiation part  100  of the antenna core  200  in a state that the antenna core  200  is inserted in the cover forming mol  20 . 
         [0042]    As shown in  FIG. 10 , in the cover formation step  3 , the antenna module in which the antenna radiation part is inserted is manufactured by exchanging the core outer side mold  10   a  with the cover outer side mold  20   a  in a state that the antenna core  200  is not separated from the inner side mold after the antenna core manufacture step  2  is performed. 
         [0043]    As shown in  FIGS. 2 ,  3  and  5 , the manufacture procedure of the antenna radiation part is characterized in that a conductive metal sheet such as a copper of 0.08˜0.15 mm or a stainless or iron is cut to form an antenna pattern, and the cut antenna material is bent multiple times depending on a designed shape, thus forming a curve with a plane or a curve with at least one axis. All kinds of materials which can be processed for cutting and bending using a press machine can be used without having any limits in thickness of a conductive metal sheet. 
         [0044]    The ground terminal  110  might be exposed to a side opposed to the side engaged by the antenna radiation part  100  of the antenna core  200  over a right angle bending work performed to have at least two angled portions. 
         [0045]    As shown in  FIG. 3 , the antenna core manufacture procedure  2  is performed in such a way that an air gap protrusion forming groove  10   b  is formed at the core forming mold  10  to form an air gap maintaining protrusion  30 , and a resin is injected, and an antenna core  200  with a thickness less than 0.5 mm is injection-molded, and an antenna engaging protrusion  211  is formed at the antenna core  200  to engage the antenna radiation part  100 . 
         [0046]    As shown in  FIGS. 4 and 5 , according to another embodiment of the antenna core manufacture procedure  2 , the antenna radiation part  100  is engaged to the core forming mold  10  to insert-form the antenna radiation part  100 , and the air gap protrusion forming grove  10   b  is formed to form the air gap maintaining protrusion  30 , and a resin is injected, thus injection-forming the antenna core with a thickness of less than 0.5 mm. 
         [0047]    As shown in  FIG. 7 , an antenna engaging protrusion  11  might be formed at the core forming mold  10  and is to be engaged by the core mold engaging hole  121  formed at the antenna radiation part  100  in order to prevent the movements of the inserted antenna radiation part  100 . 
         [0048]    As shown in  FIG. 7 , the core forming old  10  might include an antenna support protrusion  12  to maintain an air gap from the antenna radiation part  100  to define a thickness of the antenna core  200 . 
         [0049]    As shown in  FIG. 8 , the core forming mold  10  might include a radiation part accommodation groove for the inserted antenna radiation part  100  not to move in the course of the injection forming procedure. 
         [0050]    As shown in  FIG. 9 , in the course of the antenna core manufacture procedure  2 , at an outer rim portion of the antenna core  200  is formed a resin leak prevention shoulder  221  formed to prevent the leak of the resin injected in the course of the injection forming process of the cover  300 . 
         [0051]    As shown in  FIG. 12 , a protrusion ascending and descending part might be provided between the antenna radiation part  100  and an inner side mold to help the protrusions be reliably encased after a certain amount of resin is injected, thus preventing the inserted and formed antenna radiation part  100  from being exposed due to the protrusion grooves along with the antenna engaging protrusion  11  and the antenna support protrusion  12  formed at the inner side mold. 
         [0052]    As shown in  FIGS. 2 ,  3  and  5 , the cover formation procedure  2  is characterized in that the antenna core  200  is insert-engaged so that the antenna radiation part  100  is exposed, and the inserted antenna core  200  is supported by means of a cover air gap maintaining part, and the thickness of the cover  200  is maintained below 0.5 mm, and a resin is injected, thus forming the cover  300 . 
         [0053]    The cover air gap maintaining part comprises an air gap maintaining protrusion  30  which is protruded from one side of the outer side mold  20   a  which corresponds to an outer side of the engagement side of the antenna radiation part  100  of the antenna core  200  and an outer side of the engagement side of the antenna radiation part of the antenna core  200  inserted for the injection of the cover  300  and supports the inserted antenna core  200  and maintains a certain thickness of the cover  300  to be formed. 
         [0054]    As shown in  FIG. 12 , the cover forming procedure  3  of the present invention is characterized in that the antenna engaging protrusion  11  provided at the cover inner side mold and the antenna support protrusion  12  and the air gap maintaining protrusion  30 , which is the air gap maintaining member of the cover outer side mold  20   a , are encased by means of the protrusion ascending and descending part, thus preventing the antenna radiation part from being exposed due to the protrusions. 
         [0055]    As shown in  FIG. 11 , in the course of the cover forming procedure  3  of the present invention, at least two antenna cores  200  with different kinds of engaged antenna radiation parts  100  might be provided. The antenna radiation part  100  might be formed of a GPS antenna, a B/T antenna, etc. along with a main antenna for a wireless communication. 
         [0056]    In the embodiments of the present invention, the antenna core  200  might be formed to act the role of the housing of the portable terminal and includes an antenna module accommodation groove  510  which is grooved as deep as the thickness of the cover  300  inject-formed at the exposed surface of the antenna radiation part  100  of the antenna core  200 , thus allowing the outer surface not to be protruded after the cover  300  is inject-formed. 
         [0057]    The cover  300  might be formed by a housing of the portable terminal. 
         [0058]    The protrusion ascending and descending part serving to ascend and descend the antenna engaging protrusion  11 , the antenna support protrusion  12  and the air gap maintaining protrusion  30  in the courses of the antenna core manufacture process  2  and the cover forming procedure  3  might be formed of the solenoid actuator  41  encasing the protrusion by means of electromagnet of  FIG. 13 , the hydraulic and pneumatic actuator  42  encasing the protrusion by hydraulic and pneumatic pressure of  FIG. 14 , or the support spring  43  which supports the protrusions to be encased by a resin pressure of  FIG. 15 . 
         [0059]    The manufacture process of the present invention will be described. 
         [0060]    The method for manufacturing an insert type antenna module for a portable terminal comprises an antenna radiation part manufacture step  1  in which an antenna radiation part  100  is manufactured by cutting and bending a conductive metal sheet for an antenna radiation part to have a plane and a curve with at least one axis; an antenna core manufacture step  2  in which an antenna core  200  is manufactured, which antenna core is engaged by one among an adhering work, an engaging work, a mounting work, an attaching work and an insert work so that the antenna radiation part  100  is exposed from an outer surface of one side; and a cover formation step  3  in which a cover  300  is inject-formed at an exposed surface of the side of the antenna radiation part  100  of the antenna core  200  in a state that the antenna core  200  is inserted in the cover forming mol  20 . In the above manufacture of the present invention, a conductive metal sheet is cut along a pattern provided based on an antenna design in the course of the antenna radiation part manufacture procedure  1 , and an antenna radiation part  100  is processed along a housing shape of a portable terminal having a plane or various curves with at least two axes via a bending procedure. 
         [0061]    The antenna core  200  is inject-formed via the antenna core manufacture procedure  2 . In the injection mold forming procedure, the antenna core is manufactured by engaging the antenna radiation body  100  by means of one among an adhering work, an engaging work, an attaching work and an insert work so that the antenna radiation part  100  can be exposed from one side surface of the antenna core  200 . 
         [0062]    A resin is coated on the exposed surface of the antenna radiation part  100  expose and engaged to one side surface of the antenna core  200  via the cover forming procedure  2  by a thickness of less than 0.5 mm, and an insert injection formation is conducted in the cover forming mold  20 , thus forming a cover  300 , so the antenna module is finished. 
         [0063]    In the cover forming procedure  3 , the antenna module is manufactured quickly, easily and precisely via the injection forming work of the cover in a state that the core outer side mold  10   a  is exchanged with the cover outer side mold  20   a  without separating the antenna core  200  from the inner side mold. The manufacture of the antenna module can be automatically performed with the aid of a rotary injection mold in which the core outer side mold  10   a  and the cover outer side mold  20   a  are sequentially engaged as the inner side mold rotates depending on the manufacture procedure. 
         [0064]    In the antenna core manufacture procedure  2  and the cover forming procedure  3 , the antenna engaging protrusion  11 , the antenna support protrusion  12  and the air gap maintaining protrusion  30  might be provided. In the antenna core manufacture procedure  2 , the antenna radiation part  100  is engaged at an accurate position, and the antenna core  200  is manufactured, and the thickness of the cover is made uniform by means of the air gap maintaining protrusion  30 . 
         [0065]    When the antenna engaging protrusion  11 , the antenna support protrusion  12  and the air gap maintaining protrusion  30  are constituted to be encased by means of the encasing ascending and descending part, it is possible to prevent the exposures of the grooves and the antenna radiation part  100  due to various protrusions in the antenna core manufacture procedure  2  and the cover forming procedure  3 . 
       INDUSTRIAL APPLICABILITY 
       [0066]    The present invention is characterized in that in a manufacture of an antenna module for a mobile terminal, a cover is inject-formed at an outer surface of the exposed side of an antenna core in a state that an antenna core to which an antenna radiation part is engaged is inserted, which results in manufacturing a uniform thickness of an antenna module and decreasing a weight, volume and area, thus achieving a lighter and thinner terminal housing. Since a plurality of radiation parts can be integrated in one housing, a manufacture process can be more simplified as compared to a conventional antenna manufacture method (each antenna is manufactured and attached), thus obtaining an excellent quality and cost-effective product in a terminal housing manufacture process. 
         [0067]    The present invention is characterized in that an antenna radiation part is formed of a conductive metal sheet which has a curve with at least two axes and an integral ground terminal, thus enhancing signal reception efficiency by more than 30%. 
         [0068]    After the antenna core is inject-formed, it is not separated. Instead the core outer side mold is exchanged with a cover outer side mold, thus manufacturing the antenna module. In the curse of the manufacture, a transformation of the antenna core can be prevented, and a manufacture process is simplified, thus enhancing productivity. 
         [0069]    There are provided the antenna engaging protrusion, the antenna support protrusion and the air gap maintaining protrusions, so the thicknesses of the antenna core and the cover are uniform and the antenna radiation part can be insert-formed at an accurate position, thus enhancing the quality in manufacture. 
         [0070]    The antenna engaging protrusion, the antenna support protrusion and the air gap maintaining protrusions are all encased and operate by means of the encasing ascending and descending part, the exposures of the groove and the antenna radiation part due to the protrusions in the course of the antenna core manufacture and the cover formation are prevented, thus making the antenna module look nice. 
         [0071]    At least two antenna cores are provided, so various kinds of antennas can be integrated in the housing of the portable terminal along with the enhanced functions.