Transceiver antenna for wireless charging, apparatus and method of manufacturing the same

According to one embodiment of the present disclosure, an antenna device, an apparatus for manufacturing the same, and a method for manufacturing the same are disclosed. The antenna device according to one embodiment of the present disclosure comprises an antenna substrate sheet and an antenna pattern. A connecting PCB is attached on the antenna substrate sheet. The antenna pattern starts from one of a plurality of connecting terminals of the connecting PCB and ends at another one of the plurality of connecting terminals. The antenna pattern comprises a plurality of wires which functions as one line and a bridge. The plurality of wires is embedded on the antenna substrate sheet. The bridge connects the connecting PCB and a point where winding of the plurality of wires on the antenna substrate sheet is completed.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a U.S. National Phase Application under 35 U.S.C. § 371 of International Application No. PCT/KR2020/007735 filed Jun. 15, 2020, which claims priority to Korean Patent Application No. 10-2019-0069837 filed Jun. 13, 2019, the disclosures of each of which are incorporated herein by reference in their entirety.

TECHNICAL FIELD

The present disclosure relates to a transceiver antenna for wireless charging, an apparatus and a method of manufacturing the transceiver antenna, and more particularly, to an antenna device including an antenna substrate sheet to which a connecting PCB (Printed Circuit Board) and an antenna pattern which starts from one of a plurality of connecting terminals of the connecting PCB and ends at another one of the plurality of connecting terminals. The antenna pattern includes a plurality of wires playing the role of one line embedded in the antenna substrate sheet, and a bridge which connects a point where winding of the plurality of wires is completed on the antenna substrate sheet and the connecting PCB.

BACKGROUND ART

Generally, wireless charge technology for charging electronic equipment is being developed in accordance with the evolution of wireless charge technology in modern electronic equipment. Various antennas are developed and used for improving efficiency of communication between a transmission module (Tx, Transmitter) and a reception module (Rx, Receiver). Particularly, due to the development of wireless devices, demand for short range wireless communication antennas is rapidly increasing. Methods of forming short range wireless communication antennas and antennas for wireless charging includes a dry method, a wet etching method, a method in which an antenna is formed by punching a copper foil, and a method in which a copper wire is embedded in a substrate as a conductor of an antenna coil. Currently, since the wet etching method is to form an antenna pattern by corroding parts except for an antenna wire by using strong acidic chemicals, not only excessively high cost is required but also strong acidic chemicals are used, thereby causing environmental pollution which requires installation of separate anti-pollution facilities and pollution neutralizing systems. On the other hand, the dry etching method and the method of manufacturing an antenna by punching a copper foil, which are similar to the wet etching method regarding a shape of the formed antenna shape, compensate for a disadvantage of the wet etching method by allowing the antenna pattern to be generated mechanically without using chemical substances. Therefore, forming antennas by dry etching and forming antennas by the mechanical method of punching copper foil have been widely used in recent years. However, whether using the dry etching method or the method of bonding an antenna by punching copper foil, the use of adhesives is inevitable in order to attach antenna coils on a substrate, resulting in poor durability. Particularly, in order to increase efficiency between transmitting and receiving antennas, such as for wireless charging, a stack is formed in which several layers of copper foil antennas are stacked to expand the surface of the antenna coil (conductor). In order to stack several layers of copper foil antennas, high-efficiency adhesives are used to securely attach each layer. At this time, there are disadvantages of loss of charging efficiency due to the adhesives, which is a dielectric material that impairs the efficiency between transmission and reception, an additional process, an increase in defect rate, and an increase in production cost due to purchase of the adhesives. On the other hand, the method of embedding one line of copper wire as a conductor of the antenna coil is advantageous in that it is easy to manufacture; and since it is formed as a single layer and thus there are no inter-layer interfering materials, it is possible to increase efficiency between transmission and reception. However, since antenna diameter should be increased enough to widen the antenna surface area, this method may not be suitable for miniaturization of electronic devices due to increased thickness of the antenna device.

Referring toFIG.1, a conventional art of manufacturing a wireless charging antenna includes preparing a circuit substrate (S100), cutting a copper foil sheet into a predetermined shape by a cutting device such as a laser (S102), and attaching the cut copper foil sheet to the circuit substrate after applying an adhesive under the cut copper foil sheet (S103).

Further, a method of attaching a copper foil on a substrate by applying the adhesive after punching the copper foil using a punching tool is widely used, instead of a physical/chemical cutting method.

However, the above dry etching method or a punching method is mainly used as the method of manufacturing the conventional wireless charging antenna. These methods use fine and elaborate processes to securely attach an elaborately processed copper sheet antenna coil on a base film, which increases manufacturing cost. In addition, due to the application of the adhesive between layers, current loss occurs due to dielectric properties of the adhesive and since it is a method of forming a single antenna coil by cutting a thin sheet of 20-30 microns, the antenna coil can be easily damaged by a small force. Thus, the manufacturing process, such as having to form a separate protective film to protect the antenna coil, is very complicated and all subsidiary materials such as copper foil, adhesives, and base films must also use high-purity materials, thereby increasing manufacturing cost.

Further, the above conventional art requires a broader antenna coil surface to obtain a higher charging current at a time of charging. When using the copper foil sheet as the antenna coil (including in the etching methods and the punching method), the antenna coil surface is improved by stacking two or three layers. The antenna patterns between the layers should be matched with each other to reduce interference between antenna patterns. Thus, the stacking process is an elaborate process, which may increase process steps of the processes and defect rates. Also, the greater demands for electric energy for the wireless charging is at a time of wireless charging, the higher the elaboration required.

DISCLOSURE

Technical Problem

Accordingly, the present disclosure, whose purpose is to solve the above problems, provides a manufacturing apparatus for a wireless charging antenna, a method of manufacturing the same, and the wireless charging antenna to improve antenna efficiency and reduce manufacturing cost as well.

Another purpose of the present disclosure is to provide a manufacturing apparatus for the wireless charging antenna, a method of manufacturing the same, and the wireless charging antenna, which can significantly improve antenna manufacturing yield, by minimizing errors in the manufacturing process due to an increase in the thickness of the overlapping area because the bridge is processed with thin copper foil at the overlapping portion of the wire in the manufacturing process.

Technical Solution

In one aspect of the present disclosure, an antenna manufacturing apparatus comprising: a base frame on which an antenna substrate sheet is mounted; a center frame disposed on a center portion of the base frame; an embedding head structure coupled to the center frame and for embedding a plurality of wires on the antenna substrate sheet in parallel simultaneously; a welding module structure coupled to the center frame and welding antenna patterns including the plurality of wires to a connecting printed circuit board (PCB); and a copper foil attaching structure forming a bridge for connecting an end terminal of the plurality of wires and the connecting PCB.

In an embodiment, the bridge comprises a copper foil or a composite including at least the copper foil.

In an embodiment, the embedding head structure comprises an embedding head module supplying the plurality of wires, and an ultrasonic vibration member coupled to the embedding head module and generating a predetermined energy via ultrasonic vibration to melt the antenna substrate sheet.

In an embodiment, the embedding head structure comprises: a plurality of wire spools at its upper end, each of the plurality of wire spools supplying each of the wires, and a wire supply rotation plate member being configured to be rotatable.

In one aspect of the present disclosure, a method of manufacturing an antenna device comprising: embedding a plurality of wires on an antenna substrate sheet in parallel simultaneously; forming a bridge for connecting an end terminal of the plurality of wires and a connecting printed circuit board (PCB); and welding a starting terminal of the plurality of wires and both terminals of the bridge.

In an embodiment, the method further comprises, prior to any one of the embedding the plurality of wires, the forming the bridge and the welding the starting terminal and the both terminals, attaching the connecting PCB on the antenna substrate sheet.

In an embodiment, the method further comprises, prior to the embedding the plurality of wires, forming one or more openings on the antenna substrate sheet.

In an embodiment, at least one of a plurality of connecting terminals of the connecting PCB is positioned in the one or more openings.

In one aspect of the present disclosure, an antenna device comprising: an antenna substrate sheet to which a connecting printed circuit board (PCB) is attached; and an antenna pattern which starts from one of a plurality of connecting terminals of the connecting PCB and ends at another one of the plurality of connecting terminals, wherein the antenna pattern comprises a plurality of wires which functions as one line embedded on the antenna substrate sheet, and a bridge for connecting the connecting PCB and the plurality of wires embedded on the antenna substrate sheet.

In an embodiment, one or more openings are formed on the antenna substrate sheet and at least one of the plurality of connecting terminals of the connecting PCB is positioned in the one or more openings.

In an embodiment, a starting terminal of the plurality of wires and both terminals of the bridge are welded.

In one aspect of the present disclosure, an antenna device comprising: an antenna substrate sheet to which a connecting printed circuit board (PCB) is attached; and an antenna pattern which starts from one of a plurality of connecting terminals of the connecting PCB and ends at another one of the plurality of connecting terminals. The antenna pattern includes a plurality of wires which functions as one line embedded in the antenna substrate sheet. The starting terminal of the plurality of wires is welded at a position of a first terminal of the connecting PCB, and a point where winding of the plurality of wires on the antenna substrate sheet is completed is welded at a position of terminal2of the connecting PCB.

Advantageous Effects

According to one embodiment of the present disclosure, a hybrid process in which a rotatable embedding head module and a co-rotating wire supply module in synchronization with the rotatable embedding head module are provided is used to manufacture a wireless charging antenna. In the embodiment, a plurality of wires is parallelly embedded on a substrate sheet to function as one line and a copper foil is bridged at the end terminal of the wires without the wires being crossed over each other. Thus, charging efficiency of the wireless charging antenna is improved and manufacturing cost for the wireless charging antenna is reduced as well.

In addition, since the wire is bridged with a thin copper foil at the overlapping portion of the wire, the thickness of the overlapping portion is thinned, so that the antenna according to an exemplary embodiment of the present disclosure can be used in a slim electronic device.

DESCRIPTION

Various modification would be applied to the present disclosure, and the present disclosure can have many embodiments. Specific embodiments are illustrated as figures and explained in the description. These do not restrict the present disclosure with the specific embodiments, but it should be understood that concepts, all modifications included in technological boundary, equivalent and substitute of the present disclosure are included in the present description. Where it is believed that specific explanations for related conventional art might make the present disclosure vague, the specific explanations are omitted.

The terms such as ‘a first,’ ‘a second,’ etc., can be used for explaining various components, but the components are not limited to the term. The term is only used for distinguishing one component from another.

The language used in the description is only for explaining specific embodiments but not limiting the present disclosure. A singular number includes expressions of plural numbers except that the singular number is used explicitly in the context. In the description, a term “include,” or “have,” etc., is used for indicating existence of features, numbers, steps, actions, components, elements, parts or combinations thereof not for excluding the existence or possibility of adding one or more other features, numbers, steps, actions, components, elements, parts or combinations thereof.

Further, where it is believed that specific explanations for related conventional art might make the present disclosure vague, the specific explanations are omitted.

FIG.2is a schematic view of an apparatus for manufacturing a wireless charging antenna in accordance with an embodiment of the present disclosure.FIG.3is a schematic side view of an apparatus for manufacturing a wireless charging antenna in accordance with an embodiment of the present disclosure.FIG.4is a partially enlarged view of a portion of an embedding head structure in accordance with an embodiment of the present disclosure.FIG.5Ais a schematic view of peripheral portions of the embedding head structure in accordance with an embodiment of the present disclosure.FIG.5Bis a schematic view explaining peripheral portions of a copper foil attaching structure and a welding module structure in accordance with an embodiment of the present disclosure.FIGS.6A to6Dare schematic views illustrating a wire nozzle of the embedding head structure in accordance with an embodiment of the present disclosure.FIGS.7A and7Bare a partially enlarged view of a cross section of the wire nozzle inFIGS.6A to6D.FIG.8is a partially enlarged view illustrating the welding module structure in accordance with an embodiment of the present disclosure.FIG.9is a flow chart explaining a method of manufacturing the antenna device in accordance with an embodiment of the present disclosure.FIGS.10A to10Gare a view further specifically explaining manufacturing processes of a receiving antenna device for wireless charging in accordance with an embodiment of the present disclosure.FIG.11is a view explaining embedding processes embedding the plurality of wires simultaneously by the embedding head module in the manufacturing processes shown inFIGS.10A to10G.

A manufacturing apparatus200for a receiving antenna for hybrid wireless charging in accordance with the present disclosure comprises a base frame unit4, a center frame unit10, one or more embedding head structure12, a copper foil attaching structure14, a welding module structure16, and a control unit17. The base frame unit4is formed as a box-shape with a predetermined size, as illustrated inFIGS.2and3, and an antenna substrate sheet2is mounted on an upper plate1of a body of the base frame unit4. The base frame unit4moves a back and forward direction along a guide rail3installed at a lower portion of the body of the base frame unit4. Screw rods5A,5B are installed on a center portion of the base frame4in an upper and a lateral direction with a certain interval. The center frame unit10is formed to be coupled with a first transfer coupling member8of a first transfer plate member6and a second transfer coupling member9of a second transfer plate member7, respectively, with a screw method with screw rods5A,5B. The embedding head structure12embeds a plurality of wires11a-11n(e.g., three, five, seven wires, etc.; five wires inFIG.11), which functions as one line and moves in an upper, lower, left and right direction on the antenna substrate sheet2, in parallel simultaneously. One or more embedding head structure12are installed on the first transfer plate member6with a certain interval and move in the back and forward direction. One or more copper foil attaching structure14are installed on the second transfer plate member7with a certain interval and are mounted on the base frame unit4. The copper foil attaching structure14moves in the upper, lower, left, and right direction on an end terminal of the wires11a-11nof the antenna substrate sheet2where the wires11a-11nare embedded. The copper foil attaching structure14attaches a cooper foil or a composite including at least the copper foil to form a bridge13without crossover of the wires11a-11n. One or more welding module structure16are installed on the second transfer plate member7with a certain interval and are mounted on the base frame unit4. The welding module structure16welds a connecting PCB (which is also referred as “a finger PCB”) of the antenna substrate sheet2where the bridge13had been formed with a cooper foil by moving the connecting PCB in the upper, lower, left, and right direction. The control unit17controls processes for manufacturing the wireless charging antenna in accordance with a program. The program is set to embed the plurality of wires11a-11n(e.g., three, five, seven wires, etc.) in parallel simultaneously on the antenna substrate sheet2by the embedding head structure12; form the bridge13with the copper foil on the antenna substrate sheet2where the embedding of the wires is completed by the copper foil attaching structure14; and weld the connecting PCB15of the antenna substrate sheet2where the bridge13had been formed by the welding module structure16. (For convenience, the welding module structure16is illustrated on a right upper side ofFIG.3because the copper foil attaching structure14hides the welding module structure16inFIG.3.)

For example, the composite including the copper foil has a structure where the copper foil is attached to a flexible printed circuit board (FPCB).

Further, the embedding head structure12, as illustrated inFIG.4, includes an embedding head module18, an ultrasonic vibration member19, a wire supply rotation plate member22, an embedding rotation motor24, and an embedding pneumatic cylinder26. The embedding head module18embeds the plurality of wires11a-11bin parallel on the antenna substrate sheet2according to control of the control unit17. The plurality of wires11a-11nis inserted at a lower portion of a body of the embedding head module18. The embedding head module18is 360 degrees rotatable. The ultrasonic vibration member19is coupled to an upper portion of the embedding head module18. The ultrasonic vibration member19generates energy on an end-most portion of the embedding head module18via ultrasonic vibration according to the control of the control unit17to liquefy the antenna substrate sheet2instantaneously. The wire supply rotation plate member22is coupled to an upper portion of the ultrasonic vibration member19with bearings21a,21band is 360 degrees rotatable in conjunction with the embedding head module18. The wire supply rotation plate member22is disk-shaped. Wire spools20a-20nfor supplying the plurality of wires11a-11nto the embedding head module18are formed on the wire supply rotation plate member22. The embedding rotation motor24rotates the embedding head module18and the wire supply rotation plate member22in a predetermined angle under the control of the control unit17. The embedding rotation motor24is coupled to the wire supply rotation plate member22at the center of the wire supply rotation plate member22with the bearings21a,21b. The embedding pneumatic cylinder26is coupled to an upper portion of the embedding rotation motor24with a coupling fixing member25and transfers the body of the embedding head structure12fixed on the coupling fixing member25in an upper and lower direction under the control of the control unit17with pneumatic pressure.

Here, the coupling fixing member25, as illustrated inFIGS.4,5A,5B, an upper portion of a body of the coupling fixing member25is coupled to a pneumatic rod27of the embedding pneumatic cylinder26and the upper portion of the embedding rotation motor24is coupled to an opposite lower portion of the embedding pneumatic cylinder26with screw coupling. Thus, the coupling fixing member25is installed to be movable together with an entire body of the embedding head structure12. As illustrated inFIGS.6A-6D, a plurality of insertion holes28(e.g., five holes) to which wires are supplied from the wire spool20a-20eis formed on a side circumference of the body of the embedding head module18. Holes30a-30n, which form, for example, a hexagonal shape, are formed on a cross section of a lowermost wire nozzle29of the embedding head module18as illustrated inFIGS.7A and7B. It is preferred that a distance (A) between the holes30aand30bis smaller than a diameter (R) of the holes. The numbers or the shape of the holes30aand30bcan be various and modified although the above descriptions explain that five holes30a-30nare formed in the hexagonal shape.

Detection sensors31a-31nare installed on the base frame unit4and the center frame unit10, respectively. The detection sensors31a-31ndetects detection points set by the control unit17or upper, lower, left and right moving traces of the embedding head module18, the copper foil attaching structure14and the welding module structure16; and send the detection points to the control unit17.

The copper foil attaching structure14has a plurality of vacuum adsorption nozzles32for adsorbing an object with vacuum and is located under a body thereof, as illustrated inFIGS.2,3,5B. The copper foil attaching structure14further includes a copper attaching module33and a copper pneumatic pressure cylinder34. The copper attaching module33attaches the copper foil, etc., to form a bridge without crossover of the wires while moving in the upper, lower, left and right directions at an end terminal of the wires of the antenna substrate sheet2where the multiple wires are embedded under the control of the control unit17. The copper attaching module33is 360 degrees movable. The copper pneumatic pressure cylinder34is fixed on the upper portion of the copper attaching module33via the coupling fixing member25. The copper pneumatic pressure cylinder34moves the body of the copper attaching module33fixed on the coupling fixing member25in au upper and lower direction by pneumatic pressure under the control of the control unit17.

In an embodiment of the present disclosure, the welding module structure16further includes, as illustrated inFIGS.3,5B,8, a laser welding module35and a welding pneumatic cylinder36. The laser welding module35welds the connecting PCB15by laser beam while moving the connecting PCB15of the antenna substrate sheet2, where the bridge has been formed, in the upper, lower, left, and right directions. The welding pneumatic cylinder36is coupled to an upper portion of the laser welding module35via the coupling fixing member25and moves the body of the laser welding module35fixed on the coupling fixing member25in an upper and lower direction by pneumatic pressure under the control of the control unit17.

In an embodiment of the present disclosure, a space for mounting the antenna substrate sheet2, the connecting PCB15, and the bridge13is formed on the base frame unit4; and an adhesive supply device37for applying adhesive to the connecting PCB15and the bridge13may be prepared on the base frame unit4.

Meanwhile, it is preferred that the embedding head module18is configured to prevent twisting of the multiple wires11a-11n, for example, to connect the wires11a-11nin parallel and form an antenna having a loop-pattern. The embedding head module18delivers ultrasonic vibrations transferred from the ultrasonic vibration member19to the antenna substrate sheet2with inserting the antenna wires11a-11ninto the holes30a-30nformed in a head of the embedding head module18. That is, when seen from above the antenna substrate sheet, the embedding head module18moves in x, y, and z directions and rotates.

In an embodiment, the laser welding module35includes a laser nozzle38. As illustrated inFIG.8, the laser welding module35irradiates a laser beam41with pressing the wires11a-11nand the bridge13, and wires11a-11n, and the connecting PCB15with a welding head39in a welding process using the laser nozzle38. A lower portion of the welding head39has a diameter which is 1.5-2.5 times larger than that of the antenna wire. An upper portion of the welding head39is coupled to a lower portion of the laser nozzle38. It is preferred that the pressure for pressing the welding head39is about 10-25 kg/cm2.

Here, it is preferred that the wires11a-11nare thin coils positioned in parallel in order to make them thinner and wider like an etched or punched copper foil antenna.

Meanwhile, the base frame unit4may include a pinion gear member40for moving the base frame unit4in the back and forward direction in conjunction with the guide rail3installed at the lower portion of the body of the base frame unit4. When embedding the wires11a-11nis completed, the base frame unit4moves to an opposite side with reference to the center frame unit10to form the bridge13and to perform the welding process.

FIG.9is a flow chart explaining a method of manufacturing the antenna device in accordance with the present disclosure.

Referring toFIG.9, the method may comprise embedding the plurality of wires11a-11non the antenna substrate sheet2in parallel simultaneously (S1), forming the bridge13for connecting the connecting PCB (for example, “terminal1” inFIG.10G)15and the end terminal (“C” inFIG.10G) of the plurality of wires11a-11n(S2), and welding a starting terminal (“B” inFIG.10G) of the plurality of wires11a-11nand both end terminals of the bridge13(“terminal2” and “C” inFIG.10G) (S3).

In an embodiment, prior to any one of S1, S2, and S3, the method may comprise attaching the connecting PCB15to the antenna substrate sheet2.

In an embodiment, the method may comprise, prior to S1, forming one or more openings (“101,” “102” inFIGS.10B-10G) in the antenna substrate sheet2. Referring toFIG.10G, opening may not be necessary because the bridge13is located on the antenna substrate sheet2. However, in case of disposing the bridge13on the lower portion of the antenna substrate sheet2, the bridge13may be attached to the antenna substrate sheet2by welding the openings101,102, i.e., both terminals (“terminal2” and “C” inFIG.10G) of the bridge13.

In another embodiment, a single longitudinal opening, instead of circular openings101,102, is formed; the connecting PCB15is disposed at the lower portion of the antenna substrate sheet2; and terminals1and2of the connecting PCB15may be positioned in the single longitudinal opening. That is, all terminals1and2are disposed in the single longitudinal opening in this embodiment, instead of positioning only terminal2in the opening101. In this case, the bridge13may be disposed on the antenna substrate sheet2.

In an embodiment of the present disclosure, the antenna substrate sheet2, to which a wire embedding may be applied by ultrasonic wave, is prepared prior to S1. The antenna substrate sheet2may comprise material such as PVT, PET, Teslin, etc.

In an embodiment of the present disclosure, the method may comprise a hole punching step (FIG.10B) forming a hole whose diameter is similar to a thickness of the wires10a-11bby punching the openings (“101” and “102” inFIG.10B) with a laser tool or a punching tool (not shown) on the antenna substrate sheet2in case of disposing the bridge13on the lower portion of the antenna substrate sheet2. Thus, the connecting PCB15may be attached as illustrated inFIG.10C.

As illustrated inFIGS.10D and11, for example, the antenna may be formed by the following processes. A section “a” starting from point A with five parallel wires is formed. When the wires11a-11narrive at point A′, the embedding head module18is driven to hold the antenna wires11a-11nand lifts the wires11a-11nwith a height higher than the thickness of the connecting PCB15such that the wires11a-11nare positioned on the connecting PCB15(at this time, the wires11a-11nare not embedded on the connecting PCB15). Then, the antenna is formed by lowering the wires11a-11nwith a height of point A′ when the wires11a-11narrive at point B. When the wires11a-11narrive at point C, forming of the antenna is stopped.

During these processes, the wires11a-11nare formed in parallel on the antenna substrate sheet2mounted in the base frame unit4which moves in the back and forward direction under the embedding pneumatic cylinder26by moving the embedding pneumatic cylinder26coupled to the upper portion of the embedding head module18. The control unit17moves the first transfer coupling member8of the first transfer plate member6which is screw-coupled to the screw rods5A,5B formed on the center frame unit10such that the embedding pneumatic cylinder26coupled to an upper end of the embedding head module18moves up and down while moving the embedding head module18coupled to the first transfer plate member6in the left and right direction. As a result, the wires11a-11nare formed in parallel on the antenna substrate sheet2. At this time, the embedding head module18, as illustrated inFIG.11, forms, for example, five wires; and at the same time the control unit17drives the ultrasonic vibration member19located on the upper end of the embedding head module18to generate a predetermined energy by ultrasonic vibration. The energy instantaneously melts the antenna substrate sheet2and the wires11a-11noutputted from the embedding head module18to embed the wires11a-11non the antenna substrate sheet2.

The antenna formed by, for example, the five wires11a-11nin parallel functions as one line in case of being embedded by each of the embedding head modules18. The antenna is wound multiple times on the antenna substrate sheet2(FIG.10G).

The control unit17controls the embedding head module18to rotate along an angle and a direction as the same as those of wires11a-11nas illustrated inFIG.10E. That is, the control unit17drives the embedding rotation motor24to rotate the embedding head module18along an angle and a direction of the wires11a-11nwith 360 degrees, and at the same time the wire supply rotation plate member22on the embedding head module18rotates 360 degrees in conjunction with the embedding head module18to unwind the wires11a-11nfrom the wire spools20a-20n. Thus, since the embedding head module18and the wire supply rotation plate member22rotate in conjunction with each other to form one turn of the antenna wires11a-11n, the wires11a-11ndo not overlap or twist each other even when the antenna wires having a circular shape11a-11nare embedded on the antenna substrate sheet2. When the embedding of antenna wires11a-11nis completed by rotation of the embedding head module18, the control unit17stops an operation of the embedding head module18. Then, a cutting knife (not shown) attached to an axis (not shown) of the embedding head module18moves down and cuts the end terminal of the antenna wires11a-11n. Thereafter, the control unit17moves the embedding head module18to a starting point for a next process.

Further, the control unit17moves the second transfer coupling member9of the second transfer plate member7screw-coupled to the screw rod5B formed on the center frame unit10, as illustrated inFIG.5B, moves the copper foil attaching module33coupled to the second transfer plate member7in the left and right direction, and moves the copper foil pneumatic cylinder34coupled to the upper portion of the copper foil attaching module33up and down. Thus, the bridge13which has been transferred at a predetermined position is adsorbed by the vacuum adsorption nozzle32positioned at the lower portion of the copper foil attaching module33. Then, the bridge13is transferred on the antenna substrate sheet2mounted in the base frame unit4which moves in the back and forward direction under the copper foil attaching module33. Thereafter, the bridge13is attached to the end terminal of the wires11a-11nof the antenna substrate sheet2where the multiple wire embedding process is completed without crossover of the wires11a-11n.

More particularly, the process of forming the bridge13includes forming the bridge13between point C and terminal2point of the connecting PCB15, as illustrated inFIG.10Fby the copper foil attaching module33. The thickness of the bridge may be about 10 to 40 μm and the size of the bridge13has a sufficient size not to lose current generated from the antenna.

The control unit17drives the welding module structure16to weld the connecting PCB5, which is a connecting terminal of the antenna substrate sheet2where the bridge13has been formed. As a result, the wireless charging antenna100is formed. The control unit17moves the laser welding module35coupled to the second transfer plate member7in the left and right direction and moves the welding pneumatic cylinder36coupled to the upper end of the laser welding module35up and down by transferring the second transfer coupling member9of the second transfer plate member7screw-coupled to the screw rods5A,5B formed on the center frame unit10. Then, the connecting PCB5positioned under the laser welding module35, which is a connecting terminal of the antenna substrate sheet2where the bridge13has been formed, is welded to form the wireless charging antenna100. As illustrated inFIG.10G, the welding process welds terminal1(point B) and terminal2of the connecting PCB15, and point C with a laser compression method to form the wireless charging antenna100.

In an embodiment of the present disclosure, the punching process may use a punching mold (not shown) which fits a product standard at a completed antenna sheet.

The antenna device100manufactured by an embodiment of the present disclosure comprises the antenna substrate sheet2to which the connecting PCB15is attached and the antenna pattern which starts from one (terminal1) of a plurality of connection terminals of the connecting PCB15and ends at another (terminal2) of the plurality of connection terminals. The antenna pattern may comprise the plurality of wires11a-11nwhich functions as one line embedded in the antenna substrate sheet2and the bridge13, which connects terminal2of the connecting PCB and the point (e.g., point “C” inFIG.10G) where the winding of the plurality of wires11a-11nis completed on the antenna substrate sheet2.

In an embodiment, the one or more openings101,102may be formed through the antenna substrate sheet2; at least one (terminal2) of the plurality of terminals of the connecting PCB15may be positioned in the opening101; and the bridge13may be located on the lower portion of the antenna substrate sheet2.

In an embodiment, the starting point (B or terminal1) of the wires11a-11nand both end terminals (C and terminal2) of the bridge13may be welded.

In an embodiment, one single longitudinal opening (not shown) instead of the circular openings101,102may be formed. The connecting PCB15may be located on the lower portion of the antenna substrate sheet2and all terminals including terminals1and2of the connecting PCB15may be in the longitudinal opening. At this time, the bridge may be on the antenna substrate sheet2.

In an embodiment, the process for forming the bridge13may be omitted. The antenna device (not shown) of this embodiment may comprise the antenna substrate sheet2to which the connecting PCB15is attached and the antenna pattern which starts from one (terminal1) of a plurality of connection terminals of the connecting PCB15and ends at another (terminal2) of the plurality of connection terminals. The antenna pattern may comprise the plurality of wires11a-11nwhich functions as one line embedded in the antenna substrate sheet2. The starting point of the wires11a-11nis welded at a position of terminal1of the connecting PCB15. A point where winding of the plurality of wires11a-11nis completed on the antenna substrate sheet2is welded at a position of terminal2of the connecting PCB15.

In an embodiment, a thickness of the antenna device where the plurality of wires is overlapped may be increased. However, the omission of the process for forming the bridge13may decrease production time and cost.

Although various embodiments are illustrated and described, the present invention is not limited to the described embodiments, and it is obvious to those skilled in the art that various modifications and variations can be made without departing from the spirit and scope of the present invention. Therefore, it is to be understood that the present invention may be embodied in many other specific forms without departing from the technical idea or essential characteristics thereof, and the embodiments are to be considered in all respects as illustrative and not restrictive.