Abstract:
There is provided a mobile apparatus including: a thin film provided as a substrate; at least one conductive pattern formed on at least one surface of the thin film; a circuit part formed on the at least one surface of the thin film to connect to the connect to the conductive pattern; and a housing formed integral with the thin film. Also, there is provided a method of manufacturing the same.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the priority of Korean Patent Application No. 2007-79614 filed on Aug. 8, 2007, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference. 
       BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates to a mobile apparatus and a method of manufacturing the same, and more particularly, to a mobile apparatus utilizing a thin film substrate where a conductor pattern is formed and electronic devices are mounted, and a method of manufacturing the same. 
         [0004]    2. Description of the Related Art 
         [0005]    Recently, with widespread use of a mobile telecommunication terminal such as a global positioning system (GPS), a personal digital assistant (PDA), a cellular phone, and a wireless laptop computer, there has been a rising demand for reducing size and weight thereof. To meet this demand, a research mainly aimed at achieving a less bulky mobile apparatus with various functions has been under way. Particularly, consumers increasingly require the mobile telecommunication terminal to be smaller-sized. 
         [0006]    In a conventional mobile apparatus, active and passive devices are mounted on a printed circuit board (PCB) using surface mount technology (SMT). To form this printed circuit board, typically, a plurality of slurries made of e.g., FR4 or epoxy are deposited and sintered to a thickness of at least 0.8 mm. This thickness has been a hindrance to a smaller size of the mobile apparatus. Besides, the printed circuit board has predetermined hardness due to the sintering. This has restricted freedom in designing the external appearance of the mobile apparatus having the printed circuit board embedded therein. 
       SUMMARY OF THE INVENTION 
       [0007]    An aspect of the present invention provides a mobile apparatus employing a thin film substrate to be reduced in volume and increased in freedom in designing the external appearance thereof, and a method of manufacturing the same. 
         [0008]    According to an aspect of the present invention, there is provided a mobile apparatus including: a thin film provided as a substrate; at least one conductive pattern formed on at least one surface of the thin film; a circuit part formed on the at least one surface of the thin film to connect to the conductive pattern; and a housing formed integral with the thin film. 
         [0009]    The thin film may be a flexible film. 
         [0010]    The thin film may be a polymer-based film. 
         [0011]    The at least one conductive pattern may be an antenna pattern. The antenna pattern may include two antenna patterns formed on both surfaces of the thin film, respectively. The antenna patterns may have an identical shape and size to each other to form a balanced antenna, the antenna patterns being symmetrical with respect to each other. 
         [0012]    The housing may be formed integral with the thin film by in-molding. 
         [0013]    The mobile apparatus may be a mobile communication terminal. 
         [0014]    According to another aspect of the present invention, there is provided a method of manufacturing a mobile apparatus, the method including: forming at least one conductive pattern and at least one electrode connected to the conductive pattern to form a circuit on at least one surface of a thin film; mounting at least one electronic device on the thin film to connect to the at least one electrode to form a circuit part; inserting the thin film into a mold of a housing shape; and injecting a molding material into the mold to form a housing to be integral with the thin film. 
         [0015]    The thin film may be a flexible film. 
         [0016]    The thin film may be a polymer-based film. 
         [0017]    The forming at least one conductive pattern and at least one electrode may include printing a conductive ink. 
         [0018]    The forming at least one conductive pattern and at least one electrode may include performing sputtering. 
         [0019]    The forming at least one conductive pattern and at least one electrode may include bonding a metal foil. 
         [0020]    The forming at least one conductive pattern and at least one electrode may include performing lithography. 
         [0021]    The at least one conductive pattern may be an antenna pattern. 
         [0022]    The antenna pattern may include two antenna patterns formed on both surfaces of the thin film, respectively. 
         [0023]    The antenna patterns may have an identical shape and size to each other to form a balanced antenna, the antenna patterns being symmetrical with respect to each other. 
         [0024]    The mobile apparatus may be a mobile communication terminal. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0025]    The above and other aspects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which: 
           [0026]      FIG. 1A  is a cross-sectional view and  FIG. 1B  is a plan view illustrating a mobile apparatus, respectively according to an exemplary embodiment of the invention; 
           [0027]      FIG. 2A  is a cross-sectional view and  FIG. 2B  is a partial exploded view illustrating a mobile apparatus according to another exemplary embodiment of the invention; and 
           [0028]      FIG. 3A to 3D  sequentially illustrate a method of manufacturing a mobile apparatus according to an exemplary embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0029]    Exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings. 
         [0030]      FIG. 1A  is a cross-sectional view and  FIG. 1B  is a plan view illustrating a mobile apparatus, respectively according to an exemplary embodiment of the invention. 
         [0031]    Referring to  FIGS. 1A and 1B , the mobile apparatus  10  of the present embodiment includes a thin film  11 , a conductive pattern  12  formed on the thin film, a circuit part  13  mounted on the thin film, and a housing  14 . 
         [0032]    In the present embodiment, the thin film  11  can serve as a substrate. That is, the conductive pattern  12  and electrodes  16  for mounting devices thereon can be formed on the thin film  11 . The thin film  11  may be polymer-based. The polymer-based thin film is flexible so as to be positioned with greater freedom than in a case where a conventional printed circuit board (PCB) is employed. 
         [0033]    Moreover, the polymer-based film may be formed to a thickness of 0.1 mm, thereby capable of being mounted with an overall smaller space than in a case where the PCB is employed. 
         [0034]    More than one conductive pattern  12  may be formed on the thin film  11 . 
         [0035]    The conductive pattern  12  may be an antenna pattern. In the present embodiment, the antenna pattern is formed on only one surface of the thin film  11 . Alternatively, two antenna patterns may be formed on both surfaces of the thin film  11 , respectively. Moreover, to achieve multi-band antenna characteristics, a plurality of antenna patterns with different shapes from one another may be formed. 
         [0036]    Electronic devices  13   a,    13   b  and  13   c  may be mounted on the thin film  11  to constitute the circuit part  13 . To allow the electronic devices to be mounted, the plurality of conductive electrodes  16  are formed on the thin film  11 . To ensure electrical connection of the circuit part  13  mounted on the thin film  11 , a circuit pattern may be formed on the thin film to connect the conductive electrodes  16  together. 
         [0037]    As in the present embodiment, the antenna pattern is directly formed on the thin film  11  to have active and passive devices mounted thereon. This reduces volume of a mobile apparatus over the conventional technology using the PCB. 
         [0038]    The thin film  11  may be formed integral with the housing  14 . 
         [0039]    In the present embodiment, the housing  14  may be a case of a mobile telecommunication terminal. The thin film  11  may be bonded onto one surface of the housing  14 . In the present embodiment, the conductive pattern  12  and the electrodes  16  are formed on one of surfaces of the thin film  11  and the housing  14  is formed in contact with another surface of the thin film  11  where the conductive pattern is not formed. However, the conductive pattern may be formed on the another surface where the thin film  11  is brought in contact with the housing  14 . 
         [0040]    The housing  14  may be formed by in-molding. That is, the thin film  11  having the conductive pattern formed thereon and the electronic devices mounted thereon is positioned inside a mold of a housing shape. Then, a liquid molding material is injected into the mold to form a housing. Therefore, even though the conductive pattern is formed on the surface of the thin film  11  in contact with the housing  14 , the housing  14  and the thin film  11  remain bonded together. 
         [0041]      FIG. 2A  is a cross-sectional view and  FIG. 2B  is a partial exploded view illustrating a mobile apparatus according to another exemplary embodiment of the invention. 
         [0042]    Referring to  FIG. 2A , the mobile apparatus  20  of the present embodiment includes a thin film  21 , a conductive pattern  22  formed on the thin film, a circuit part  23  mounted on the thin film and a housing  24 . 
         [0043]    In the present embodiment, the thin film  21  may serve as a substrate. That is, a conductive pattern  22  and electrodes  26  for mounting electronic devices thereon may be formed on the thin film. The thin film  21  may be polymer-based. The polymer-based film is flexible so as to be positioned with greater freedom than in a case where the conventional PCB is utilized. In the present embodiment, the thin film  21  may have a bent portion  21 - 1  formed therein along a bending shape of the housing  24 . 
         [0044]    Also, the polymer-based film can be formed to a thickness of 0.1 mm, thus capable of being mounted with an overall smaller space than in a case where the PCB is employed. 
         [0045]    More than one conductive pattern  22  may be formed on the thin film  21 . 
         [0046]    The conductive pattern  22  may be an antenna pattern. In the present embodiment, first and second antenna patterns  22   a  and  22   b  may be formed on both surfaces of the thin film  21 , respectively. For example, the first and second antenna patterns  22   a  and  22   b  formed on the both surfaces of the thin film  21 , respectively are designed to have an electrical resonant length different from each other to thereby achieve a dual band antenna in a limited area. Alternatively, the first and second antenna patterns  22   a  and  22   b  may be designed to have an identical shape and size to each other and arranged in symmetry with respect to each other. This assures a balanced antenna which is less susceptible to noise or external environment. 
         [0047]    A circuit part  23  may be formed on the thin film  21  to have electronic devices  23   a  and  23   b  mounted thereon. To allow the electronic devices to be mounted, the plurality of conductive electrodes  26  are formed on the thin film  21 . To ensure electrical connection of the circuit part  23  mounted on the thin film  21 , a circuit pattern (not shown) for connecting the conductive electrodes  26  may be formed on the thin film. 
         [0048]    As in the present embodiment, the antenna pattern is directly formed on the thin film  21  to have the electronic devices mounted thereon. This allows the mobile apparatus to be reduced in volume over the conventional technology utilizing the PCB. 
         [0049]    The thin film  21  may be formed integral with the housing  24 . 
         [0050]    In the present embodiment, the housing  24  may be a case of a mobile telecommunication terminal. The thin film  21  may be bonded onto one surface of the housing  24 . 
         [0051]    The housing  24  may be formed by in-molding. That is, the thin film  21  having the conductive pattern formed thereon and the electronic devices mounted thereon is positioned inside a mold of a housing shape. Then, a liquid molding material is injected into the mold and cold-cured to form a housing. 
         [0052]      FIG. 2B  illustrates an arrangement antenna patterns  22   a  and  22   b  formed on the thin film  21 . 
         [0053]    In the present embodiment, to obtain a balanced antenna, the first and second antenna patterns  22   a  and  22   b  formed on both surfaces of the thin film  21 , respectively may be formed in an identical shape to each other. 
         [0054]    The first and second antenna patterns  22   a  and  22   b  may be arranged in symmetry with respect to each other to form the balanced antenna. That is, the first and second antenna patterns  22   a  and  22   b  may have an identical size and shape to each other and be arranged to oppose each other. Moreover, the first and second antenna patterns may have separate feeding terminals to be connected to different polarities, respectively. This as a result realizes the balanced antenna. 
         [0055]    In this balanced antenna, the first and second antenna patterns  22   a  and  22   b  exhibit balanced current characteristics so that outputs therefrom are identical in size but 180 degrees out of phase. This ensures the antenna to be less susceptible to noise and external environment change. 
         [0056]    In the present embodiment, also, to achieve multi-band antenna characteristics, in place of the two antenna patterns  22   a  and  22   b,  a plurality of antenna patterns with different shapes from one another may be formed. 
         [0057]      FIGS. 3A to 3D  sequentially illustrate a method of manufacturing a mobile apparatus according to an exemplary embodiment of the invention. 
         [0058]    In  FIG. 3A , a conductive pattern  32  and electrodes  36  are formed on one surface of a thin film  31 . 
         [0059]    The conductive pattern  32  may be formed uniformly. The electrodes  36  may have electronic devices mounted thereon. The conductive pattern  32  and the electrodes  36  may be connected to each other to form a circuit. 
         [0060]    The conductive pattern  32  and the electrodes  36  can be formed on the thin film  31  by various methods. That is, a conductive ink may be printed on the thin film  31 . Sputtering or lithography may be performed or a metal foil may be bonded. Also, the conductive pattern  32  and the electrodes  36  can be formed simultaneously or separately. 
         [0061]    In  FIG. 3B , electronic devices are mounted on the electrodes formed on the thin film to form a circuit part. 
         [0062]    The circuit part  33  mounted on the thin film  31  may be connected to a circuit pattern (not shown) formed on the thin film by the electrodes  36 . 
         [0063]    In  FIG. 3C , the thin film is inserted into a mold of a housing shape and a molding material is injected into the mold to form a housing to be integral with the thin film. 
         [0064]    In the present embodiment, the mold  37  of a housing shape includes an upper mold  37   a  and a lower mold  37   b.  The upper mold  37   a  supports the thin film  31  and the lower mold  37   b  serves as a frame of the housing to be formed integral with the thin film. 
         [0065]    After the thin film  31  is disposed between the upper mold  37   a  and the lower mold  37   b,  a liquid molding material is injected into the mold through an injection hole  38  formed in the lower mold  37   b.    
         [0066]    Thereafter, the molding material injected is cold-cured to form the housing  34  of a desired shape, and then the mold is removed. 
         [0067]    With the mold removed, as in  FIG. 3D , the thin film  31  having the conductive pattern  32  formed thereon and the circuit part  33  mounted thereon is formed integral with the housing  34  to produce a mobile apparatus. 
         [0068]    An epoxy resin molding material may be filled in an area where the mold is removed to produce the mobile apparatus. 
         [0069]    As set forth above, according to exemplary embodiments of the invention, a thin film has a conductive pattern and electronic devices thereon. This ensures a mobile apparatus to be manufactured with a smaller size and various external shapes. 
         [0070]    While the present invention has been shown and described in connection with the exemplary embodiments, it will be apparent to those skilled in the art that modifications and variations can be made without departing from the spirit and scope of the invention as defined by the appended claims.