阅读说明：本技术 超低外形低频天线 (Ultra-low profile low frequency antenna ) 是由 C·卡尼特卡韦萨 F·E·纳瓦罗佩雷斯 J·罗德里格斯 S·科沃斯雷耶斯 A·罗哈斯奎瓦斯 于 2020-02-20 设计创作，主要内容包括：所公开的是一种包括磁芯(10)的超低外形低频天线,该磁芯在相互正交的三个交叉轴向上具有线圈绕组通道,三个交叉轴向限定出X轴(X)、Y轴(Y)和Z轴(Z),线圈绕组通道容纳相应的X线圈(DX)、Y线圈(DY)和Z线圈(DZ)。Z线圈绕组通道(12Z)绕Z轴(Z)环绕磁芯(10),提供被限制在两个平行表面之间的局部凹槽(40)。磁芯(10)在Z轴(Z)上的厚度小于1.2mm。每个局部凹槽(40)在Z轴(Z)上的宽度等于或小于0.4mm且其在垂直于Z轴(Z)的径向方向上的深度至少为其宽度的两倍。Z线圈(DZ)在所述凹槽(40)内部卷绕且从凹槽深度的1/3径向地延伸至2/3。Z线圈的外边缘与凹槽(40)的入口保持一定距离。(Disclosed is an ultra low profile low frequency antenna comprising a core (10) having coil winding channels in three mutually orthogonal cross axes defining an X-axis (X), a Y-axis (Y) and a Z-axis (Z), the coil winding channels housing respective X-coils (DX), Y-coils (DY) and Z-coils (DZ). A Z-coil winding channel (12Z) surrounds the core (10) about the Z-axis (Z), providing a localized groove (40) confined between two parallel surfaces. The thickness of the magnetic core (10) in the Z axis (Z) is less than 1.2 mm. Each partial groove (40) has a width in the Z axis (Z) equal to or less than 0.4mm and a depth in a radial direction perpendicular to the Z axis (Z) of at least twice its width. A Z coil (DZ) is wound inside the groove (40) and extends radially from 1/3 at the groove depth to 2/3. The outer edge of the Z-coil is kept at a distance from the entrance of the groove (40).)

1. An ultra-low profile low frequency antenna comprising a magnetic core made of a soft magnetic non-conductive material, the magnetic core (10) having coil winding channels in three mutually orthogonal cross-axes defining mutually orthogonal X-axis (X), Y-axis (Y) and Z-axis (Z), wherein:

the magnetic core (10) comprising a flat central region (12) and four corner projections (11) spaced from each other around the central region (12), the corner projections (11) defining therebetween an X coil winding channel (12X) encircling the central region (12) around the X axis (X) and a Y coil winding channel (12Y) encircling the central region (12) around the Y axis (Y); and

-a Z-coil winding channel (12Z) surrounding said magnetic core (10) around said Z-axis (Z), said Z-coil winding channel (12Z) being defined by a discontinuous groove confined between two parallel surfaces perpendicular to said Z-axis (Z) so as to form a rectangular cross-section, said discontinuous groove comprising four local grooves (40), each local groove being contained in one of said corner projections (11);

an X coil (DX) wound around the X axis (X) so as to be contained inside the X coil winding channel (12X), a Y coil (DY) wound around the Y axis (Y) so as to be contained inside the Y coil winding channel (12Y), and a Z coil (DZ) wound around the Z axis (Z) so as to be contained inside the Z coil winding channel (12Z); and is

The X coil (DX), the Y coil (DY) and the Z coil (DZ) are made of wires and each have a wire inlet and a wire outlet connected to a respective connection terminal (30),

the method is characterized in that:

the thickness of the magnetic core (10) in the Z-axis (Z) direction is less than 1.2 mm;

each partial groove (40) is narrow and deep, the width of each partial groove (40) in the direction of the Z axis (Z) is equal to or less than 0.4mm, and the depth of each partial groove (40) in the radial direction perpendicular to the direction of the Z axis (Z) is at least twice its width; and is

The Z-coil (DZ) is inserted into the narrow and deep groove (40) and wound inside the Z-coil winding channel (12Z) and extends radially from 1/3 of the depth of the groove (40) to 2/3, and an outer edge of the Z-coil wound in the Z-coil winding channel (12Z) is held at a distance from an entrance of the groove (40) such that the parallel surface extends beyond the outer edge in a cantilevered manner.

2. The antenna according to claim 1, wherein said connection terminal (30) is directly attached to a flat surface of said corner protrusion.

3. The antenna of claim 1, wherein an inner edge of the Z coil is maintained at a distance from the X and Y coils.

4. The antenna of claim 1, wherein the wire is insulated against high heat-ray, resistant up to 220 ℃ and 0.020-0.040 mm in diameter.

5. The antenna of claim 1, wherein the antenna is encapsulated by an insulating resin coating having a coating thickness between 0.2mm and 0.3 mm.

6. The antenna of claim 1, wherein the thickness of the magnetic core is less than 1mm and the width of the partial groove (40) is 0.3 mm.

7. The antenna according to claim 1, wherein the extension of the core in the X-axis direction and the Y-axis direction is preferably equal to or less than 140mm²。

8. The antenna of claim 1, wherein the magnetic core is a high density molded ferrite core or a high density molded ferrite core made of a nickel zinc alloy or a manganese zinc alloy.

9. The antenna according to claim 1, wherein one of the central regions located in the larger face of the core (10) comprises a recess defining the X-coil winding channel 12X, and the opposite region is flat.

10. A method of manufacturing an ultra-low profile low frequency antenna for use in manufacturing the antenna of claim 1, the method comprising:

obtaining a magnetic core by:

compacting a powder of soft magnetic non-conductive material in a mould to shape the core (10), the core comprising a flat central region (12) and four corner projections (11) spaced from each other around the central region (12), the corner projections (11) defining therebetween an X coil winding channel (12X) encircling the central region (12) around the X axis (X) and a Y coil winding channel (12Y) encircling the central region (12) around the Y axis (Y);

-generating a Z-coil winding channel (12Z) around the magnetic core (10) around the Z-axis (Z) by means of a sawing process, the Z-coil winding channel (12Z) being defined by a discontinuous groove (40) confined between two surfaces, the discontinuous groove comprising four partial grooves (40), each partial groove being comprised in one of the corner projections (11);

oven sintering the magnetic core (10) to crystallize, shrink and harden it;

-providing an X-coil (DX) wound around the X-axis (X) to be contained inside the X-coil winding channels (12X), a Y-coil (DY) wound around the Y-axis (Y) to be contained inside the Y-coil winding channels (12Y), and a Z-coil (DZ) wound around the Z-axis (Z) to be contained inside the Z-coil winding channels (12Z); and

connecting a wire inlet and a wire outlet of each of the X-coil, the Y-coil and the Z-coil to respective connection terminals (30),

the method is characterized in that:

each of the four partial grooves (40) of the magnetic core (10) has, before the oven sintering process, a trapezoidal cross section in a radial section plane coinciding with the Z axis (Z), the trapezoidal cross section being produced by a wedge saw during the sawing process and being defined as becoming a rectangular cross section after crystallization, shrinkage and hardening.

11. The method of claim 10, wherein the wire inlet and wire outlet of each of the X, Y and Z coils are connected to the respective connection terminal (30) by a laser welding process.

12. The method of any one of claims 10 or 11, wherein the assembly of core and coil is embedded in a resin housing and connected to a PCB by a reflow soldering process in an oven.

Technical Field

The present invention relates to an ultra low profile tri-axial low frequency antenna which is very small in size to be able to be integrated in a mobile phone, such as a smart phone.

The expression "ultra-low-profile" in this application is to be understood as a thin antenna having an extremely low thickness in the range of less than 1.6mm, preferably less than 1.4mm, which is particularly suitable for being included in a mobile phone. As the tri-axial antenna, it can ensure that signals are received from any direction and/or transmitted to all directions simultaneously. Such an antenna comprises a magnetic core having coil winding channels in three mutually orthogonal cross-axial directions, the coil winding channels accommodating three orthogonal coils (of electrically conductive wire) surrounding the magnetic core.

Low frequency generally refers to radio frequencies in the range of 30kHz to 300 kHz.

The present invention thus provides an antenna which is specifically designed to be small in size, so that the thickness is small enough to allow it to be integrated in a smartphone, and which is able to withstand the requirements of a mobile phone, such as bending resistance.

It will be appreciated that the proposed antenna may also be integrated in other portable devices, such as extended tablets, card keys, etc., where thickness is a relevant design parameter and limits the integration of components therein.

Background

Many three axis antennas are known in the prior art and many different documents face the problem of reducing the antenna height, the solutions disclosed by these documents are directed to RFID keyless entry systems with a 3D antenna assembled into a PCB in the key fob and even to 3D inductive solutions in the card fob; however, to date, no single-chip (single-core) antenna for smart phones has been known that meets the requirements of sensitivity, ultra-low profile, limited area and flexibility necessary for integration in mobile phones.

US7042411 discloses a small three-axis antenna coil for use in a receiver or similar element of a radio controlled keyless entry system. This antenna has a low profile, in this case using a magnetic core having a flat drum shape with three orthogonal coil winding channels around it, and a base fixed to the lower surface of the core. In this example, the magnetic core is shaped by including a peripheral recess defining a coil winding channel for the peripheral Z-coil. Such recesses are extremely difficult to produce in ultra low profile cores by molding because the manufacture of the small cores requires complex molds having at least four separate moving parts and cores of this size may crack during the demolding operation. The above-mentioned recesses cannot be machined, since the magnetic core also breaks during said machining.

Document US2013033408a1 describes a flat triaxial antenna similar to the one described in the preceding document. In US2013033408a1, a magnetic core is obtained by attaching two separate core members, one of which is flat and thin, and the two core members are fixed by means of a bobbin comprising a ring-shaped portion whose function is to serve as a space for arranging a Z-axis coil.

In this solution, the coil or winding is wound around the multilayer magnetic core, and both components of the magnetic core need to include notches for the X and Y windings around the magnetic core. In the region where the Z winding overlaps the X or Y winding, the notch prevents the magnetic core from approaching the Z winding, thus reducing the surface of the magnetic core facing the Z winding and thus creating limited Z winding sensitivity.

Further in US2013033408a1, each individual flat magnetic member of the magnetic core includes a cantilevered region at each corner, the cantilevered regions of one member of the magnetic core being spaced from the cantilevered regions of the other member of the magnetic core so as to define a Z-coil winding channel therebetween. The two members of the core are attached to each other and surrounded by the X-winding and the Y-winding, so the distance between the cantilever areas in the Z-axis direction is smaller than the height of the X-winding and the Y-winding in the Z-axis direction, resulting in the Z-winding having a limited height in the Z-axis direction and thus further reducing the Z-winding sensitivity.

Document JP4007332 by the electrical apparatus company (Denso) claims an integrated low profile antenna; however, this type of antenna is not a monolithic antenna for Low Frequencies (LF) and the proposed solution, although low profile, is extended in other dimensions.

Furthermore, there are a large number of keyless entry systems and antennas for keyless entry systems known in the art, for example US 2017320465; US 2017291579; US 2017282858; JP 2017123547. Likewise, specific inventions of three-axis monolithic antennas have been described for key fobs in keyless entry systems (e.g. Plermer (PREMO) patents EP 2911244; WO2013EP 03888; WO 2017076959; ES 2460368).

Other solutions for the three-axis monolithic antenna have been marketed, for example, by companies such as TDK, epos, Sumida, Toko and Neosid.

However, until now, there has been no known solution that addresses the challenge of integrating an antenna into a smartphone (profile below 1.65mm, area less than 14 x 14mm) subject to bending tests and with minimum sensitivity in the Z-axis exceeding 50 mV/Amv.

The very tight mechanical constraints described above make the Z-axis sensitivity very limited. To maximize Z sensitivity, the prior art includes low profile LF antennas with air coils or flat coreless coils, which are very wide in area. When the overall available area is limited, Z-induction cannot induce a minimum voltage in air, so a relatively high effective permeability is required.

There are low profile solutions on the market for card keyless entry key fobs, which mostly use separate low profile components, typically two identical low profile antennas for the X and Y axes, and which are either flat coreless coils or small low profile Z-axis coils made with ferrite drum cores. None of these solutions is suitable for integration into a smartphone. Even with low profile nanocrystalline or amorphous cores (similar to those provided by Hitachi Metals), the overall surface target is not achieved.

Other known documents are that the Z-winding is wound without including said Z-winding in a peripheral recess of a single-piece magnetic core, but this solution does not provide good sensitivity of the Z-winding exceeding 50 mV/Amv.

Thus, none of the above-cited documents, and other similar documents, provide a solution that can be miniaturized to provide an ultra-low profile antenna with good sensitivity in the Z-winding.

Patent application EP1738280 discloses a solution providing an ultra low profile three axis LF antenna for integration in mobile phones, wherein a coil for a small core is wound in three cross axis directions in a winding groove, and wherein the antenna further comprises a first soft magnetic sheet perpendicular to the Z axis (Z) and attached to a flat face of the core protruding from four corners, said flat face being perpendicular to the Z axis (Z), and an X winding coil (DX) and a Y winding coil (DY) are partially covered by said first soft magnetic sheet, the first soft magnetic sheet having dimensions in the X axis direction and in the Y axis direction covering the Z winding coil DZ, thereby providing a limiting edge for the Z winding (DZ), such that an improved sensitivity of the Z winding coil (DZ) is obtained and a reduced thickness of the antenna in the Z axis (Z) direction.

The present invention provides an alternative structure based on a very small flat drum shaped magnetic core and a method of manufacturing an ultra low profile low frequency antenna, including the manufacture of said small magnetic core.

Disclosure of Invention

According to a first aspect thereof, the present invention relates to an ultra-low profile tri-axial low frequency antenna for integration in a mobile phone, for example in a smartphone.

As previously described, the inclusion of a triaxial low frequency antenna in a mobile phone requires that the thickness of the antenna be reduced while maintaining its performance and without increasing the other dimensions of the antenna. The bending resistance of the antenna must also be improved.

The proposed ultra-low profile tri-axial low frequency antenna comprises (as known in the art):

a flat magnetic core made of soft magnetic non-conductive material having coil winding channels in three intersecting axes defining mutually orthogonal X (X), Y (Y) and Z axes, wherein:

the magnetic core comprises a flat central region and four corner projections spaced apart from each other around the central region, the corner projections defining therebetween an X-coil winding channel encircling the central region around an X-axis (X), and a Y-coil winding channel encircling the central region around a Y-axis (Y), wherein the X-coil winding channel and the Y-coil winding channel are at different heights;

a Z-coil winding channel surrounding the core about the Z-axis (Z), said Z-coil winding channel being defined by a discontinuous groove confined between two parallel surfaces perpendicular to the Z-axis (Z), thereby providing, for example, a rectangular cross-section, said discontinuous groove comprising four partial grooves, each partial groove being contained in one of a plurality of corner projections, the X-coil winding channel, the Y-coil winding channel and the Z-coil winding channel being mutually orthogonal;

an X coil (DX) wound about the X axis (X) to be contained within the X coil winding channel, a Y coil (DY) wound about the Y axis (Y) to be contained within the Y coil winding channel, and a Z coil (DZ) wound about the Z axis (Z) to be contained within the Z coil winding channel, wherein each of these coils comprises an electrically conductive wire; and

the X coil (DX), the Y coil (DY), and the Z coil (DZ) are made of wires, and each have a wire inlet and a wire outlet connected to respective electrical connection terminals.

This arrangement of mutually orthogonal coil winding paths of the plurality of coils around the core determines: when the electromagnetic field passes through X, Y and the Z-coil (DX, DY, DZ) as described above, an electrical potential is generated between the ends of each wire according to faraday's law.

The skilled person will appreciate that when current is circulated through the X, Y and Z coils described above, the structure will also generate an electromagnetic field whose electromagnetic field vector is coaxial with the axis of each winding.

The above features provide a tri-axial antenna that can be optimized for the low frequency range of signals, preferably in the range of 30kHz to 300 kHz.

Starting from this known magnetic core structure and the orthogonal arrangement of the coils thereon, the present invention proposes a series of improvements to achieve the above-mentioned object of designing an antenna to minimize its size, in particular to minimize its height, and to allow its efficient integration into a smartphone.

To this end, according to the invention:

-the thickness of the magnetic core in the direction of the Z axis (Z) is less than 1.2mm and preferably less than 1 mm;

-each discontinuous groove is narrow and deep, each discontinuous groove having a width in the direction of the Z axis (Z) equal to or less than 0.4mm (preferably 0.3mm), and each discontinuous groove having a depth in a radial direction perpendicular to the direction of the Z axis (Z) of at least twice its width; and

the Z-coil (DZ) is wound inside the Z-coil winding channel inserted into the narrow and deep groove and extends radially from one third to two thirds of the depth of the groove, and the outer edge of the Z-coil wound in the Z-coil winding channel is kept at a distance from the entrance of the groove such that the parallel surfaces of the coil winding channel extend in cantilever fashion beyond the outer edge, contributing to an increase in the sensitivity of the Z-coil due to the enlarged cross-section about the Z-axis (Z).

In one embodiment, the inner edge of the Z coil is kept at a distance from the X and Y coils.

In a particular embodiment, the configuration, or additional configurations described herein, provide a Z-winding having a sensitivity in excess of 50 mV/Amv.

Contrary to the solutions disclosed in US7042411 and US2013033408 cited in the present invention, no base or bobbin attached to the magnetic core is used; the electrical connection terminal is directly attached to the flat surface of the corner protrusion. In this way the thickness of the antenna in terms of height is reduced even further.

In one embodiment, the antenna is encapsulated by an electrically insulating resin coating, providing a housing coated to a thickness between 0.2mm and 0.3 mm. Only the connection terminals will be partly uncovered by said electrically insulating material. The connection terminals may be folded against the electrically insulating material so as to define connection terminals that overlap the housing of the antenna.

The wires for the X, Y and Z coils may be insulated high heat resistance wires resistant to temperatures up to 220 c, which is required for the manufacturing method to be described below, and may have a diameter in the range of 0.020mm to 0.040 mm.

The extension of the magnetic core in the X-axis and Y-axis directions is preferably equal to or less than 140mm². As a preferred or specific embodiment, this dimension is 10.60mm by 11.60 mm.

The thickness of the antenna in the Z-axis direction is preferably equal to or less than 1.4mm, i.e. less than 1.6mm, which is the maximum thickness of the elements that can be included in a conventional mobile phone.

Preferably, the magnetic core is a high density ferrite core. Even more preferably, the magnetic core is a ferrite core made of a nickel-zinc alloy or a manganese-zinc alloy.

In a second aspect, the present invention relates to a method for manufacturing an ultra-low profile low frequency antenna, so as to manufacture the aforementioned three-axis antenna according to the first aspect of the present invention. As known in the art, this method comprises:

obtaining a magnetic core by:

compacting an amorphous powder of soft magnetic non-conductive material in a die to shape a flat drum core comprising a flat central region and four corner projections spaced apart from each other around said central region, said corner projections defining therebetween an X coil winding channel encircling said central region around said X axis (X) and a Y coil winding channel encircling said central region around said Y axis (Y);

creating a Z-coil winding channel encircling the magnetic core about the Z-axis (Z) by a cutting or sawing process of the pressed flat magnetic core, said Z-coil winding channel being defined by a discontinuous groove confined between upper and lower surfaces of the core and comprising four discontinuous grooves, each discontinuous groove being contained in one of the corner projections;

baking the magnetic core in an oven to crystallize, shrink and harden the magnetic core;

-providing an X-coil (DX) wound around the X-axis (X) to be contained inside the X-coil winding channels, a Y-coil (DY) wound around the Y-axis (Y) to be contained inside the Y-coil winding channels, and a Z-coil (DZ) wound around the Z-axis (Z) to be contained inside the Z-coil winding channels; and

connecting a wire inlet and a wire outlet of each of the X, Y, and Z coils to respective connection terminals.

Unlike the proposals known in the art, in the method of the present proposal, in order to obtain a magnetic core having the aforementioned dimensions and configuration, each of the four discontinuous grooves is cut into the magnetic core and has, before the oven sintering process, a trapezoidal cross section in a radial section plane coinciding with the Z axis (Z), said trapezoidal cross section being produced by a wedge saw during the sawing process and being defined as the cross section that becomes rectangular (the cross section of the Z coil winding channel) after crystallization, shrinkage and hardening.

In an embodiment, the lead inlet and the lead outlet of each of the X-coil, the Y-coil and the Z-coil (made of an insulating high heat resistant wire resistant to temperature up to 220 ℃ and having a diameter of 0.020mm-0.040 mm) are connected to the respective connection terminals by a laser welding process.

Furthermore, as a final step of the manufacturing method, the assembly of core and coil may be embedded in a resin housing and connected to the PCB by a reflow soldering process in an oven. For this reason, the conductive wires used for the coils must be able to withstand temperatures up to 200 ℃ (even if they are short-lived).

Other features of the present invention will be presented in the following detailed description of the embodiments.

Drawings

The foregoing and other advantages and features will be more fully understood from the following detailed description of the embodiments, which is to be considered as illustrative and not restrictive, with reference to the accompanying drawings, in which:

fig. 1 shows a first perspective view of a low profile antenna of the present invention.

Fig. 2 is a second perspective view of the core showing the opposing larger faces.

Fig. 3 and 4 show the association of the magnetic core with the lead frame providing the connection terminals, and fig. 4 shows the final arrangement of the core in the receiving space of the lead frame.

Fig. 5 is a perspective view showing the arrangement of an extension piece from a lead frame to provide a connection terminal with respect to a magnetic core.

Fig. 6 is a perspective view, which is equivalent to fig. 5, but includes a first X-coil wound around the X-coil winding passage.

Fig. 7 is a perspective view, which is equivalent to fig. 5, but includes both the X-coil and the Y-coil wound around the X-coil winding passage and the Y-coil winding passage, respectively.

Fig. 8 shows another perspective view, which is equivalent to fig. 5 to 7, but in this case, three of the X coil, the Y coil and the Z coil are wound around the X coil winding passage, the Y coil winding passage and the Z coil winding passage, respectively.

Fig. 9 is the same drawing as fig. 8, but shows the layout of the extension pieces of the lead frame (whereby the connection terminals will be formed) as viewed from the bottom.

Fig. 10 shows the assembly of the core with the extension sheet, the core being covered by an epoxy layer, and fig. 11 is an equivalent view, but from the top.

Fig. 12 is equivalent to fig. 10, but in which the extension sheet is cut so as to provide 8 connection terminals.

Fig. 13 is a drawing equivalent to fig. 12, but in which the connection terminals are folded against the housing body provided by the epoxy coating.

Detailed Description

The foregoing and other advantages and features will be more fully understood from the following detailed description of the embodiments, which is to be considered as illustrative and not restrictive, with reference to the accompanying drawings, in which:

fig. 1 and 2 show a magnetic core 10 of the proposed ultra low profile antenna made of a soft magnetic non-conductive material, such as a ferrite made of nickel-zinc alloy or manganese-zinc alloy, the core 10 having coil winding channels 12X, 12Y and 12Z in three mutually orthogonal cross-axial directions.

The magnetic core 10 comprises a central region 12 and four corner projections 11 spaced apart from each other around said central region 12. The corner projections 11 define between them: an X-coil winding channel 12X encircling the central region 12 about the X-axis X; a Y-coil winding passage 12Y surrounding the central region 12 of the core about a Y-axis Y; and a Z-coil winding path 12Z encircling the core 10 about the Z-axis Z, the X-coil winding path 12X, Y being orthogonal to the Z-coil winding path 12Z and the coil winding path 12Y.

The Z-coil winding channel 12Z is defined by a discontinuous groove confined between two parallel upper and lower surfaces of the core 10, perpendicular to the Z-axis Z, to provide a rectangular cross-section, the discontinuous groove comprising four partial grooves 40, each of which is contained in one of the corner projections 11.

As shown in fig. 6, 7 and 8, the X coil DX is wound around the X axis X so as to be contained inside the X coil winding passage 12X, the Y coil DY is wound around the Y axis Y so as to be contained inside the Y coil winding passage 12Y, and the Z coil DZ is wound around the Z axis Z so as to be contained inside the Z coil winding passage 12Z.

The X coil DX, the Y coil DY, and the Z coil DZ are made of wires, and each have a wire inlet and a wire outlet connected to the corresponding connection terminal 30.

According to the teachings of the present invention, the following special features are implemented:

first, the thickness of the magnetic core 10 in the Z-axis Z-direction is less than 1.2mm and preferably equal to or less than 1 mm.

Each partial groove 40 is narrow and deep, the width of each partial groove 40 in the Z-axis Z-direction is equal to or less than 0.4mm, and preferably about 0.3mm, and the depth of each partial groove 40 in the radial direction perpendicular to the Z-axis Z-direction is at least twice the width of the partial groove.

Likewise, a Z-coil DZ is wound inside the Z-coil winding channel 12Z to be inserted into the narrow and deep groove 40 and extends radially from 1/3, the depth of the groove 40, to 2/3. The outer edge of the Z-coil wound in the Z-coil winding channel 12Z is held at a distance from the entrance of the groove 40 (see fig. 8 and 9) such that the above-mentioned parallel surfaces extend beyond the outer edge in a cantilever fashion.

As can also be seen in fig. 8 and 9, the inner edge of the Z coil is kept at a distance from the X and Y coils.

The wire used for the coil is an insulated high heat resistant wire which can withstand up to 220 ℃ and has a diameter comprised in the range between 0.020mm and 0.040 mm.

As can be seen in fig. 1 and 2, one of the central regions located in one of the larger faces of the core 10 includes a recess defining an X-coil winding channel 12X, while the other, opposite central region (see fig. 2) is flat. This allows the magnetic core to be manufactured without risk of breakage in the central portion, since the central portion has a total thickness of about 0.60 mm. In view of the small diameter of the insulated wire and the development of the X-coil and the Y-coil in the width of each, it can be avoided that one of the larger faces of the core has no recess for the X-coil because the coils DX and DY wound in superposition do not cause excessive expansion.

As shown in fig. 5 to 9, the connection terminal 30 is directly attached to the flat surface of the corner protrusion.

Fig. 3 and 4 show how the core 10 is attached to a lead frame 50 from which some extension pieces 51 from which the connection terminals 30 are to be obtained by cutting have been cut out.

The core 10 and its coils DX, DY and DZ are encapsulated by an insulating resin coating 60 having a coating thickness of between 0.2mm and 0.3 mm. This can be seen in fig. 10 to 13.

Fig. 12 and 13 show that the connection terminal 30 is folded against the electrically insulating material, defining a connection terminal overlapping the recessed portion 61 of the housing 60 of the antenna.

A second aspect of the invention relates to a method of manufacturing an ultra-low profile low frequency antenna, the method comprising, according to known procedures:

obtaining a magnetic core by:

compacting an amorphous powder of soft magnetic non-conductive material in a die to shape the magnetic core 10, the magnetic core comprising a flat central region 12 and four corner projections 11 spaced apart from each other around the central region 12, the corner projections 11 defining therebetween an X coil winding passage 12X encircling the central region 12 about the X axis X and a Y coil winding passage 12Y encircling the central region 12 about the Y axis Y;

creating a Z-coil winding channel 12Z around the magnetic core 10 around the Z-axis Z by means of a cutting or sawing process, said Z-coil winding channel 12Z being defined by discontinuous grooves confined between the upper and lower two surfaces of the core 10, said discontinuous grooves comprising four partial grooves 40, each partial groove being contained in one of the corner projections 11;

sintering the magnetic core 10 in an oven to crystallize, shrink and harden the magnetic core;

setting an X coil DX wound around the X axis X so as to be contained inside the X coil winding passage 12X, a Y coil DY wound around the Y axis Y so as to be contained inside the Y coil winding passage 12Y, and a Z coil DZ wound around the Z axis Z so as to be contained inside the Z coil winding passage 12Z; and

the wire inlet and the wire outlet of each of the X-coil, the Y-coil, and the Z-coil are connected to the respective connection terminals 30.

According to the invention and mainly for the purpose of manufacturing a magnetic core having the aforementioned dimensions and configuration, before the oven sintering process is carried out, each of the four partial grooves 40 of the magnetic core 10 is cut so as to have, in a radial section plane coinciding with the Z axis Z, a trapezoidal cross section, produced by a wedge saw during the sawing process, defined as the shape of a rectangular cross section resulting from the oven sintering process after crystallization, shrinkage and hardening.

Further, the connection of the lead inlet and the lead outlet of each of the X-coil DX, Y-coil DY and Z-coil DZ to the corresponding connection terminal 30 may be performed by a laser welding process.

As a final step, the assembly of the core 10 and the coils DX, DY, and DZ may be embedded in the resin case 60 and connected to a PCB (not shown) through a reflow soldering process in an oven.

The ultra-low profile tri-axial antenna of the present invention is specifically designed for integration into smart phones, particularly for operation as a keyless system. Thus, a mobile phone (or other portable computer device) incorporating the proposed antenna will also include a software application installed therein to provide a user interface for controlling the operation of the proposed ultra-low profile tri-axial low frequency antenna.

It is to be understood that various parts of one embodiment of the present invention may be freely combined with parts described in other embodiments even if the combination is not explicitly described as long as such combination is not harmful.

The scope of the invention is defined by the set of appended claims.