Metal working – Method of mechanical manufacture – Electrical device making
Reexamination Certificate
2001-07-24
2004-04-13
Arbes, Carl J. (Department: 3729)
Metal working
Method of mechanical manufacture
Electrical device making
C029S601000, C029S825000, C029S835000, C029S846000, C029S842000, C343S728000
Reexamination Certificate
active
06718619
ABSTRACT:
FIELD OF THE INVENTION
The present invention is directed to wireless voice and data communications, and more particularly to manufacturing a monopole antenna as a unitary piece.
BACKGROUND
An antenna is a device that transmits electrical signals into free space. The signals may be, for example, received by another antenna in a proximate or a distant location. A common antenna configuration is the well-known monopole antenna. A typical monopole consists of a straight wire mounted above and operating against a ground plane. A transmission arrangement such as a transmission line feeds electrical signals to the monopole with the ground plane serves as the ground potential for the transmission arrangement. An insulator is used to provide electrical separation between the monopole and the ground plane. As is well known in the art, the ground plane provides a mirror image for the monopole mounted above it so that from the perspective of the antenna it is as if another monopole antenna is located below the ground plane. In this way, the ground plane and the monopole antenna mimic a dipole antenna arrangement. For optimum performance of the monopole antenna at a particular frequency ƒ of operation the length of the monopole antenna will be approximately one-quarter of the operating wavelength &lgr; at that operating frequency ƒ, or &lgr;/4.
In general, for an antenna arrangement such as the typical monopole, the operating wavelength &lgr; is related to the operating frequency ƒ through the following relation:
λ
=
c
f
ϵ
r
(
1
)
where c is the speed of light in vacuum and &egr;
r
is a relative permittivity associated with the insulator. Typically the operational frequency ƒ is fixed by the application and the frequency limits design choices for the dimensional properties of the antenna.
Minimization of the space taken up by components is often of paramount importance in the design of devices such as wireless computing and other portable devices. For high-frequency applications that require antennas mounted on printed circuit boards, a typical monopole antenna arrangement may be impractical because of the antenna lengths at the high frequencies. A common substrate used to construct printed circuit boards is FR4® board has a relative permittivity &egr;
r
of approximately 4.25. As an example of an antenna length at a high frequency, assuming that &egr;
r
≅1, at an exemplary frequency of 5.25 GHz (5.25×10
9
Hz) the operating wavelength within the FR4 substrate will be approximately 57 millimeters (mm) and the corresponding &lgr;/4 length of the antenna will be approximately 14 mm. For some applications, antennas with comparable lengths simply consume too much space in the vertical direction relative to the ground plane so as to be prohibitive in terms of their use.
The need to decrease the length of antenna configurations relative to a ground plane has led to a number of antenna arrangements, particularly in instances where horizontal space is available relative the ground plane. One example is the inverted L antenna arrangement. The inverted L is essentially a typical monopole antenna that is bent at approximately 90 degrees. Typically, the total length of the inverted L antenna, including the bent portion, will be &lgr;/4, however a significant portion of that length may be in the bent portion that is approximately parallel to the ground plane. This decreases the length of the antenna portion that protrudes in the vertical direction relative to the ground plane. In most practical cases, this length will be no less than &lgr;/8 due to the need to provide mechanical support for the bent portion of the antenna.
While this inverted L arrangement can achieve significant improvement in length reduction from the typical monopole antenna arrangement, better performance and length reduction can be achieved with the well-known top hat antenna.
FIG. 1
is a diagram illustrating a side view of a traditional top hat antenna
100
mounted on a printed circuit board (PCB)
102
. The top hat antenna
100
includes a disk or circular hat
104
of radius r and diameter d, and a cylindrical stem
106
of height h. Generally, the stem
106
and the circular hat
104
of the top hat antenna
100
are distinct pieces that are fused together via any of a series of well-known manufacturing processes to realize the top hat antenna
100
. The top hat antenna
100
could also be machined from a single piece of metal. The PCB
102
includes a layer
108
of dielectric material, a ground plane
110
, and a microstrip line or feed strip
112
. The thicknesses of the dielectric layer
108
, the ground plane
110
, and the feed strip
112
are exaggerated relative to the top hat antenna
100
and to one another for purposes of illustration. For example, the feed strip
112
and the ground plane
110
are typically microthin layers of metal, for example, copper. The feed strip
112
includes a contact area
114
and forms a microstrip with the ground plane
110
and the dielectric layer
108
to provide electrical signals to the top hat antenna
100
at the contact area
114
where the strip
112
contacts the stem
106
. Typically, the stem
106
of the top hat antenna
100
is soldered or otherwise fused to the feed strip
112
at the contact area
114
. The dielectric layer
108
insulates the top hat antenna
100
from the ground plane
110
. The top hat antenna
100
operates against the ground plane
108
to similarly mimic a dipole antenna effect.
The height h of the stem
106
together with the diameter d of the circular hat
104
are typically equal to one quarter of the operating wavelength &lgr; at the operating frequency ƒ, or &lgr;/4. Typically, this implies that the height h of the stem
106
and thus the top hat antenna
100
approaches as low as &lgr;/12. The top hat antenna
100
is an electrically small antenna, that is, the length of the antenna
100
is much smaller than the operating wavelength &lgr;. In general, the performance of the traditional top hat antenna
100
at a particular operating frequency will vary according to the dimensions d and h of the antenna
100
. Overall, the top hat antenna
100
provides substantial savings in terms of height relative to the ground plane
110
.
One drawback of the traditional top hat antenna arrangement relates to mounting the top hat antenna on a PCB. The antenna is typically soldered or otherwise fused to the top of the PCB and to a microstrip line. Actually soldering the top hat antenna to the PCB is a complicated and mechanically precarious procedure in and of itself. The shape of the top hat antenna requires that an operator or a machine apply the solder at a difficult angle. A traditional monopole antenna does not present the same degree of difficulty in soldering. Soldering either the monopole or the top hat antenna to the top side of the PCB, however, is a process step that might not otherwise be necessary on the top side of the PCB but for the mounting of antennas. Put another way, a top hat antenna or a monopole antenna might be the only element that requires soldering to the top side of the PCB.
It would be desirable to provide a structurally stable arrangement for mounting an antenna that eliminates a soldering process on the top side of a printed circuit board, and that alleviates many of the difficulties inherent in mounting certain types of antennas on the printed circuit board.
An additional drawback of the traditional top hat antenna arrangement relates to manufacturability of the antenna. While a traditional top hat antenna may be machined from a single piece of metal, the antenna is generally formed by soldering, or by otherwise fusing, two distinct pieces of material to each other, one piece representing the circular hat, for example, and one piece representing the stem, for example. A manufacturing process that serves to accomplish this soldering or fusing together of pieces will typically be somewhat complicated and prone to error because of the lengths and the sizes of th
Dao Andy
Lebaric Jovan E.
Arbes Carl J.
Atheros Communications Inc.
Nguyen Tai
Pillsbury & Winthrop LLP
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