Chip antenna and method of manufacturing the same

A chip antenna and a method of manufacturing the same are provided. A chip antenna includes connection terminals disposed on both ends of a core, and a coil wound around the core and having ends thereof connected to the connection terminals, in which the connection terminals include a metal plate, and at least a portion of the connection terminals has a thickness greater than a winding thickness of the coil.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application claims the benefit under 35 USC 119(a) of Korean Patent Application No. 10-2015-0086536 filed on Jun. 18, 2015 and Korean Patent Application No. 10-2015-0153721, filed on Nov. 3, 2015, in the Korean Intellectual Property Office, the entire disclosure of which is incorporated herein by reference for all purposes.

BACKGROUND

The following description relates to a chip antenna and a method of manufacturing the same.

2. Description of Related Art

Mobile communications terminals that support wireless communications, such as mobile phones, personal digital assistants (PDAs), navigation devices, laptop computers, and the like, have the capability to provide functions such as code division multiple access (CDMA), digital multimedia broadcasting (DMB), a wireless local area network (WLAN), near field communications (NFC), and the like. The capability for wireless communications may be provided by an antenna disposed in the mobile communications terminals.

Among various types of antenna, a chip antenna is generally directly mounted on a surface of a circuit board to perform its function.

A chip antenna is also appropriate for miniaturization and slimness, and may be manufactured by stacking patterns in a ceramic material.

However, when a chip antenna is manufactured to be of a solenoid type, it is difficult to secure a space in which a coil is wound.

SUMMARY

In one general aspect, a chip antenna includes connection terminals disposed on both ends of a core, and a coil wound around the core and having ends thereof connected to the connection terminals, in which the connection terminals include a metal plate, and at least a portion of the connection terminals has a thickness greater than a winding thickness of the coil.

The connection terminals may include a sleeve shape enclosing the core.

The connection terminals may include a disconnected ring shape.

End portions of the connection terminals may be disposed to face each other.

End portions of the connection terminals may be respectively disposed on different surfaces of the core.

The connection terminals may include an upper surface part contacting an upper surface of the core, a lower surface part contacting a lower surface of the core, and a connection part extending between the upper surface part and the lower surface part.

The connection parts of the connection terminals may be each disposed to cover a distal end of the core.

The connection terminals may include metal plates that are elastically deformed and coupled to the core.

The general aspect of the chip antenna may further include a protection resin disposed on at least one surface of the core where the coil is wound around.

In another general aspect, a method of manufacturing a chip antenna involves preparing a core having a bar shape; coupling connection terminals to both ends of the core, respectively, the connection terminals each being formed by bending a metal plate; and winding a coil around the core and connecting both ends of the coil to the connection terminals.

The coupling of the connection terminals may involve press-fitting both ends of the core into the respective connection terminals.

A thickness of a portion of the connection terminal disposed below the core may be greater than a winding thickness of the coil.

The general aspect of the method may further involve forming a protection resin on at least one surface of the core where the coil is wound around.

In another general aspect, a method of manufacturing a chip antenna involves coupling a bent conductive plate to a core to form a connection terminal, and electrically connecting a coil wound around the core with the connection terminal to establish an electrical connection.

The coil may be wound in a helical shape around the core, and two connection terminals may be disposed on two respective areas of the core to be electrically connected with respective end portions of the coil.

The coupling of the bent conductive plate may involve press-fitting a distal end of the core into a bent metal plate to form the connection terminal.

The general aspect of the method may further involve mounting the core on which the connection terminal is formed on a board, in which a thickness of a portion of the connection terminal disposed between the core and the board may be greater than a winding thickness of the coil.

DETAILED DESCRIPTION

Throughout the specification, it is to be understood that when an element, such as a layer, region or substrate, is referred to as being “on,” “connected to,” or “coupled to” another element, it can be directly “on,” “connected to,” or “coupled to” the other element or other elements intervening therebetween may be present. In contrast, when an element is referred to as being “directly on,” “directly connected to,” or “directly coupled to” another element, other elements or layers intervening therebetween cannot be present. Like numerals refer to like elements throughout. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

Although terms such as “first,” “second,” and “third,” may be used herein to describe various members, components, regions, layers and/or sections, these members, components, regions, layers, or sections are not to be limited by these terms. These terms are only used to distinguish one member, component, region, layer or section from another member, component, region, layer or section. Thus, a first member, component, region, layer or section discussed in examples below may also be referred to as a second member, component, region, layer or section without departing from the teachings of the examples.

Spatially relative terms, such as “above,” “upper,” “below,” and “lower” may be used herein for ease of description to describe one element's relationship to one or more other elements as shown in the figures. It is to be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as being “above” another element or being an “upper” element will then be “below” the other element or will be a “lower” element. Thus, the term “above” can encompass both the above and below orientations depending on a particular direction of the figures. The device may also be oriented in other ways (for example, rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein are to be interpreted accordingly.

The terminology used herein describes various examples only and is not to be used to limit the present disclosure. As used herein, the singular terms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. Further, as used herein, the terms “include,” “comprises,” and “have” specify the presence of stated features, numbers, operations, members, elements, and/or combinations thereof, but do not preclude the presence or addition of one or more other features, operations, members, elements, and/or combinations thereof.

Hereinafter, examples will be described with reference to schematic diagrams. In the drawings, due to manufacturing techniques and/or tolerances, for example, modifications of the shape shown may be estimated. Thus, this examples described herein are not to be construed as being limited to the particular shapes of regions shown herein, but are to be construed as including changes in shape that occur during manufacturing. The features of the examples described herein may be combined in various ways as will be apparent to one of ordinary skill in the art. Further, although the examples described below have a variety of configurations, other configurations are possible as will be apparent to one of ordinary skill in the art.

FIG. 1illustrates a perspective view of an example of a chip antenna according to the present disclosure, andFIG. 2illustrates an exploded perspective view of an example of a chip antenna according toFIG. 1.FIG. 3illustrates a side view of an example of a chip antenna according toFIG. 1.

According to one example, a solenoid winding space may be secured in a chip antenna in an efficient manner during a manufacturing process of producing a chip antenna.

Referring toFIGS. 1 through 3, an example of a chip antenna10according to the present disclosure includes a core100, a coil200, and connection terminals300.

The core100may be formed of ferrite or a ferrite mixture. In one example, the core100may be formed by sintering ferrite powders, or may be formed by injection-molding a resin mixture containing ferrite powders.

In addition, the core100may be prepared by stacking a plurality of ceramic sheets containing ferrite as a main component and then compressing/sintering the plurality of ceramic sheets.

In this example, the core100has a bar shape with a quadrangular cross section, but the shape of the core100is not limited thereto. That is, in another example, the core100may another shape, depending on a design requirement or structural requirement of the chip antenna.

The coil200is wound around the core100. For example, the coil200may be wound in a helical shape along a length direction of the core100. However, a shape in which the coil is wound is not limited thereto.

In addition, the coil200is connected to the connection terminals300disposed at both ends of the core100. For example, both ends of the coil200may be bonded to the connection terminals300, respectively, through soldering.

Herein, various terms indicating directions will be defined. A length direction of the core100refers to an x-axis direction inFIG. 1, a width direction of the core100refers to a y-axis direction inFIG. 1, and a thickness direction of the core100refers to a z-axis direction inFIG. 1.

Referring toFIG. 1, the coil200has a wire shape, and is wound around the core100. However, a shape of the coil200is not limited thereto, and may be an edgewise coil shape in another example.

In this example, both end portions of the coil200are bonded to the connection terminals300. Both end portions of the coil200are further disposed on the same surface of the core100. However, the configuration of the end portions of the coil200is not limited thereto. In another example, the end portions of the coil200may be disposed on different surfaces.

In addition, an example in which the end portions of the coil200are disposed on an upper surface of the core100has been described by way of example inFIG. 1. However, in another example, various modifications may be made. For instance, in one example, the end portions of the coil200may be disposed on a lower surface of the core100.

Referring toFIG. 1, the connection terminals300for electrical connection to a main board20are coupled to both end portions of the core100, respectively.

The connection terminal300may serve as a terminal bonded to the main board20through a conductive adhesive such as a solder. Therefore, a lower surface of the connection terminal300may be used as a bonded surface bonded to the main board20.

The connection terminals300may be formed by bending a flat conductive plate such as a metal plate or performing press processing, and may be coupled to the core100to enclose the core100at two opposing ends of the core100.

Referring to the example illustrated inFIG. 2, the connection terminal300includes an upper surface part301coupled to the upper surface of the core100while contacting the upper surface of the core100, a lower surface part303coupled to the lower surface of the core100while contacting the lower surface of the core100, and a connection part302connecting the upper surface part301and the lower surface part303to each other.

The connection terminal300may be formed in a sleeve shape or a disconnected ring shape accommodating the core100therein. Further, according to one example, a cut part305cutting through the connection terminal300may be formed in the upper surface part301of the connection terminal300, as illustrated inFIG. 2.

Referring to the example illustrated inFIG. 2, both ends of the connection terminal300are disposed to be spaced apart from each other by the cut part305by a predetermined distance. To form a chip antenna in which both ends of the connection terminal300are spaced apart from each other, according to one example of a method of manufacturing the same, a metal plate or the like may be elastically deformed and firmly coupled to the core100by elastic force depending on the elastic deformation to form the connection terminal300.

However, a configuration of the connection terminal300is not limited thereto, and may be variously modified. For example,FIG. 4Cillustrates an embodiment in which the connection terminal300is formed in a sleeve shape without including the cut part305.

In addition, according to one example, a thickness of a portion or an entirety of the connection terminal300may be set to be thicker than a winding thickness of the coil200.

Referring to the example illustrated inFIG. 3, the coil200has a predetermined diameter R which is smaller than a distance between the core100and the bonded surface of the connection terminal300. For instance, for a single layer coil, the diameter of a wire that forms the coil may have the predetermined diameter R. If the distance between the core100and the bonded surface of the connection terminal300was set be smaller than the diameter R of the coil200, the coil200and the main board20would contact each other when the chip antenna10is mounted on the main board20, deteriorating the performance of the chip antenna10.

Therefore, in the chip antenna10according to the illustrated embodiment, a thickness T2of the connection terminals300disposed at both ends of the core100is set to be thicker than a winding thickness T1of the coil200.

The winding thickness T1of the coil200refers to a maximum distance between a surface of the coil200disposed at the outermost portion and the core100. In this example, the coil200is wound around the core100as a single layer. Therefore, the diameter R of the coil200is equal to the winding thickness T1of the coil200. However, in another example, two or more layers may be wound around the core100.

Meanwhile, in this example, the connection terminal300has the same thickness around all directions of the core100. Therefore, all of the connection part302and the upper surface part301as well as the lower surface part303may be formed at a thickness of T2. However, the thicknesses of the connection part302and the upper surface part301are not limited thereto. That is, the connection part302and the upper surface part301are not limited to the illustrated thicknesses or shapes as long as the thickness of the lower surface part303may be thicker than the winding thickness T1of the coil200.

Due to the configuration described above, a space S is provided in the chip antenna10, and the coil200passes through the space S. A height of the space S in the thickness direction is greater than the winding thickness T1of the coil200due to the thickness T2of the connection terminal300, and thus, the coil200wound around the core100does not contact the main board20.

A protection resin400may be disposed on the core100to insulate and protect the coil200. In this example, the protection resin400is disposed on the core100so as to cover the coil200.

However, in another example, the protection resin400may be applied on all surfaces of the core100. In the illustrated example, the protection resin400is applied on only one surface of the core100. That is, the protection resin400is applied on the upper surface of the core100. In this example, the upper surface of the core100corresponds to the surface of the core100that is disposed on an opposite side from the main board20when the chip antenna10is mounted on the main board20.

The protection resin400may be formed by applying a liquid-phase resin and then hardening the liquid-phase resin. As a material of the protection resin400, a resin such as epoxy or a mixture of ferrite powders having a magnetic property and a resin may be used. However, a material of the protection resin400is not limited thereto.

Hereinafter, modified examples of the connection terminal300will be described.

FIGS. 4A through 4Care schematic side views illustrating modified examples of the connection terminal300according to the present disclosure.

Referring toFIG. 4A, in one example, at least one of the connection terminals300may be provided as two members spaced apart from each other.

The connection terminal300according toFIG. 4Aincludes a first connection terminal310and a second connection terminal320.

In this example, the first connection terminal310and the second connection terminal320partially enclose an outer peripheral surface of the core100, and end portions of the first connection terminal310and the second connection terminal320are disposed to face each other.

Referring toFIG. 4B, the two end portions of the connection terminal300are disposed on different surfaces of the core100, respectively.

In this example, one end portion of the connection terminal300is disposed on the upper surface of the core100, and the other end portion thereof is disposed on a side surface of the core100.

Referring toFIG. 4C, the connection terminal300is formed in a sleeve shape that does not have a cut part. In this case, an adhesion member500is interposed between the connection terminal300and the core100in order to firmly couple the connection terminal300to the core100.

However, a method of firmly coupling the connection terminal300to the core100is not limited thereto, and may be variously modified. For example, the connection terminal300may be firmly coupled to the core100by disposing the core100in the connection terminal300and then pressing/bending the connection terminal300.

Meanwhile, respective embodiments illustrated inFIGS. 4A through 4Cmay be combined with each other.

Next, an example of a method of manufacturing a chip antenna will be described.

FIGS. 5A through 5Dare perspective views illustrating states of respective operations of an example of a method of manufacturing a chip antenna according to the present disclosure.

First, the core100is prepared (seeFIG. 5A). As described above, the core100may be formed by sintering ferrite, or may be formed of a ferrite mixture. In addition, the core100may be prepared by stacking a plurality of ceramic sheets containing ferrite as a main component.

Then, the connection terminals300are coupled to both ends of the core100in the length direction (seeFIG. 5B).

The connection terminals300may be separately manufactured and coupled to the core. For example, the connection terminal300may be formed by press-working or bending a flat conductive plate such as a metal plate.

In this example, the connection terminals300are coupled to the core100to enclose the core100at both ends of the core100.

The connection terminals300may be coupled to the core100in a state in which the connection terminals300are elastically deformed by further increasing an interval of the cut part305. Therefore, the connection terminals300may be firmly coupled to the core100by elastic force.

However, a method of coupling the connection terminals300to the core100is not limited thereto, and may be modified into various methods well-known in the related art, such as a bonding method by an adhesive, a press-fitting method, and the like.

After the connection terminals300are coupled to the core100, the coil200is wound around the outer peripheral surface of the core100(seeFIG. 5C).

In this example, the coil200has a helical shape that goes around the outer peripheral surface of the core100. In addition, both ends of the coil200are bonded and electrically connected to the connection terminals300disposed at both ends of the core100. According to one example, the coil200may be bonded to the connection terminals300by soldering.

In the connection terminal300according toFIG. 5C, a portion of the connection terminal300disposed below the core100has a greater thickness than the winding thickness T1(seeFIG. 3) of the coil200that wraps around the core100. Therefore, the lower surface of the connection terminal300(for example, the bonded surface bonded to the main board) is disposed at a position lower than that of a lower surface formed by the coil200.

Then, the protection resin400is formed on an outer surface of the core100(seeFIG. 5D). The protection resin400may be disposed to cover at least a portion of the coil200.

In this example, the protection resin400is disposed on at least one surface of the core100where the coil200is wound around. The protection resin400may be formed by applying and then hardening a liquid-phase resin. An epoxy resin may be used as the resin for forming the protection resin400.

However, the protection resin400is not limited thereto. For example, the protection resin400may also be formed of an epoxy resin containing ferrite powders. In addition, various other modifications may be made. For instance, in yet another example, the protection resin may be formed using a sheet in a semi-hardened state and may then be attached onto the core100, or a completely hardened protection resin may be adhered to the core100using the adhesion member500.

In the chip antenna according to the present embodiment, the connection terminals300may be separately manufactured and then be coupled to the core100. Therefore, the connection terminals are more easily manufactured as compared to the related art in which the connection terminals300are directly formed on the core100. This will be described in detail below.

In a case of the related art, the connection terminals300may be formed by partially plating end portions of the core100. In this case, bonded surfaces of the connection terminals300need to be disposed at a position lower than that of the lower surface of the coil200. To this end, electrode terminals may be formed by attaching separate members having a predetermined thickness to both ends of the core100and then performing plating on surfaces of the separate members. Therefore, a manufacturing process of the connection terminals300may be very complicated.

On the other hand, in the chip illustrated inFIGS. 5A to 5D, the formation of the connection terminals300is completed only by coupling the connection terminals300to the core100without partially plating the end portions of the core100. Therefore, a complicated process such as plating may not additionally be required, and a thickness of the connection terminal300itself may be thicker than the winding thickness. Thus, the separate member described above is not required. Therefore, it may be appreciated that the connection terminal is very easily manufactured.

Meanwhile, the present disclosure is not limited to the above-mentioned embodiments, and may be variously modified.

Chip antennas disclosed below may be similar to the chip antenna according to the examples described above except for a structure of a connection terminal. Therefore, a detailed description will be omitted for the same or similar features as that described above, and only a connection terminal that is different from that of the examples above will be described in detail.

FIG. 6is a side view schematically illustrating another example of a chip antenna according to the present disclosure.

Referring toFIG. 6, a coil200is wound in a plurality of layers around the core100. Therefore, a winding thickness T1of the coil200, which corresponds to the total thickness of the wires on a surface of the core100, may be larger than a diameter of a wire of the coil200.

The connection terminal300according to the illustrated example has a thickness T2that is greater than the winding thickness T1of the coil200.

As described above, the connection terminal300may have various thicknesses depending on a winding configuration of the coil200.

FIG. 7is a perspective view schematically illustrating another example of a chip antenna according to the present disclosure.

Referring toFIG. 7, in the chip antenna according to the illustrated embodiment, a connection terminal300does not have a sleeve shape, but may instead have a “” shape or a “U” shape. In another example, the connection terminal300may have a bracket shape that surrounds the end portions of the cord.

The connection terminal300includes an upper surface part301coupled to the upper surface of the core100while contacting the upper surface of the core100, a lower surface part303coupled to the lower surface of the core100while contacting the lower surface of the core100, and a connection part302connecting the upper surface part301and the lower surface part303to each other and disposed at an end portion of the core100.

In the embodiment described above, the connection terminals300are coupled to the core100to enclose outer peripheral surfaces of the core100. Therefore, the end portion of the core100may be externally exposed.

However, the connection terminal300is coupled to the core100to enclose the end portion of the core100. Therefore, at least a portion or the entirety of the end portion of the core100is covered by the connection terminal300.

As described above, the connection terminal300may be variously modified.

As set forth above, in the chip antenna according to an embodiment in the present disclosure, the connection terminal may be separately manufactured and may be then coupled to the core. Therefore, the connection terminal may be more easily manufactured as compared to the related art in which the connection terminal is directly formed on the core.

Although an embodiment in which the connection terminal is generally formed with the same thickness has been described by way of example, the connection terminal is not limited thereto. That is, other portions of the connection terminal may be formed at various thicknesses regardless of the winding thickness of the coil as long as a thickness of a portion of the connection terminal disposed at a lower end of the core may be thicker than the winding thickness of the coil.