BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] The present invention relates to a satellite converter feed horn for receiving satellite
broadcasts.
2. Description of the Related Art
[0002] A related satellite converter feed horn is described with reference to Figs. 7 to
10. Fig. 7 is a schematic side view of a related satellite converter. Fig. 8 is a
perspective view of the related satellite converter feed horn. Fig. 9 is a sectional
view taken along line. IX-IX of Fig. 8. Fig. 10 is a sectional view taken along line
X-X of Fig. 8.
[0003] Referring to the structure of the related satellite converter feed horn shown in
Figs. 7 to 10, a frame 51, which is formed by bending a metallic plate, has a square
shape with open top and bottom portions.
[0004] A cover 52, formed of a metallic plate, is caught by and mounted to the frame 51
so as to close one of the open portions of the frame 51.
[0005] A circuit board 53, or a printed circuit board, has a ground pattern 54 and a wiring
pattern (not shown). The ground pattern 54 is substantially entirely formed on one
of the surfaces of the circuit board 53. The wiring pattern is formed on the other
surface of the circuit board 53, and comprises an electrical circuit for a desired
reception including various electrical parts.
[0006] With the electrical parts (electrical circuit) being positioned in the frame 51,
such a circuit board 53 is mounted to the square frame 51 so as to close the other
open portion of the frame 51.
[0007] When the circuit board 53 is mounted to the frame 51, the ground pattern 54 is exposed
from the frame 51 and shields the inside of the frame 51, so that the electrical circuit
is electrically shielded by the frame 51, the cover 52, and the ground pattern 54.
[0008] A coaxial connector 55 is mounted to the frame 51 in a protruding manner outward
from the frame 51. The electrical circuit is connected to the connector 55 so that
a signal that has been processed by the electrical circuit can be taken out from the
connector 55.
[0009] A square tubular feed horn 56, formed by bending a metallic plate, is soldered and
mounted to the ground pattern 54 perpendicular to the circuit board 53. Satellite
electric waves are received from the feed horn 56.
[0010] As shown, in particular, in Figs. 8 to 10, the feed horn 56 comprises first to fourth
plate sections 57 to 60. The first and second plate sections 57 and 58 are connected
and are at right angles to each other. The third plate section 59 is connected and
is at right angles to the first plate section 57. The fourth plate section 60 is connected
and is at right angles to the second plate section 58.
[0011] The feed horn 56 comprises a square tubular section 61 formed by the first to fourth
plate sections 57 to 60 by connecting ends of the third and fourth plate sections
59 and 60 at right angles to each other.
[0012] At the location where the third and fourth plate sections 59 and 60 are connected
together, the end of the third plate section 59 has a plurality of outwardly protruding
tongues 59a and the end of the fourth plate section 60 has protrusions 60a for catching
the end of the third plate section 59.
[0013] In the third and fourth plate sections 59 and 60 that are at right angles to the
first and second plate sections 57 and 58, respectively, the protrusions 60a are caught
at right angles by end portions of the third plate section 59 that are disposed between
the tongues 59a. In this state, as shown in Fig. 10, each tongue 59a (shown by alternate
long and two short dash lines) is bent in the direction of arrow A and is superimposed
upon the outer surface of the fourth plate section 60.
[0014] Thereafter, by applying solder 62 in a direction of extension of the square tubular
section 61 to the outer periphery of the location where the protrusions 60a of the
fourth plate section 60 and the third plate section 59 are connected together, and
removing a gap between the two, the feed horn 56 is formed.
[0015] Since, in the related satellite converter feed horn, the solder 62 is applied to
the location, which is a narrow portion, where the protrusions 60a of the fourth plate
section 60 and the third plate section 59 are connected together, it is difficult
to apply the solder, thereby reducing work efficiency.
[0016] When the solder is applied to the narrow portion, the solder drips towards the fourth
plate section 60, so that the amount of solder at the location where the fourth plate
section 60 and the third plate section 59 are connected together is reduced, as a
result of which, not only is the solder improperly applied, but also the soldered
portion has a poor appearance.
[0017] When bending the tongues 59a in the direction of arrow A, the fourth plate section
60 is pushed in the direction of arrow B, so that the square tubular section 61 becomes
rhombic.
SUMMARY OF THE INVENTION
[0018] Accordingly, it is an object of the present invention to provide a satellite converter
feed horn which makes it possible to achieve good soldering efficiency and to reliably
perform soldering and whose square tubular section undergoes little deformation.
[0019] According to the present invention, there is provided a satellite converter feed
horn comprising a square tubular feed horn section that is formed of a bent metallic
plate and that comprises a square tubular section including first to fourth plate
sections and having the third and fourth plate sections connected together at right
angles to each other. The first and second plate sections are connected at right angles
to each other. The third plate section is connected at right angles to the first plate
section. The fourth plate section is connected at right angles to the second plate
section. The third plate section has a first strip-shaped connecting section extending
outward from and in a direction of extension of the square tubular section. The fourth
plate section has a second strip-shaped connecting section extending outward from
and in the direction of extension of the square tubular section. The first and second
connecting sections are connected together, with a step being disposed in a direction
perpendicular to the direction of extension of the square tubular section.
[0020] Preferably, one of the first and second connecting sections extends from a portion
of the corresponding plate section in the same plane, and the other of the first and
second connecting sections is at right angles to a portion of the corresponding plate
section.
[0021] Preferably, one of the third and fourth plate sections has a protrusion extending
from a portion of the one of the third and fourth plate sections in the same plane,
the other of the third and fourth plate sections has a hole for fitting the protrusion
thereto, and the protrusion is fitted to the hole in order to connect the third and
fourth plate sections together at right angles to each other.
[0022] Preferably, an end portion of the protrusion is caulked in the direction of extension
of the square tubular section.
[0023] Preferably, either the third plate section or the fourth plate section has a tongue
that protrudes from the outer periphery defining the hole, and the tongue is bent
and superimposed upon the outer surface of either the third plate section or the fourth
plate section having the protrusion.
[0024] Embodiments of the invention will now be described, by way of example only, with
reference to the accompanying drawings, in which:
Fig. 1 is a schematic side view of a satellite converter of the present invention;
Fig. 2 is a perspective view of a satellite converter feed horn of a first embodiment
of the present invention;
Fig. 3 is a sectional view taken along line III-III of Fig. 2;
Fig. 4 is a sectional view taken along line IV-IV of Fig. 2;
Fig. 5 is a sectional view of portions that are connected together of a satellite
converter feed horn of a second embodiment of the present invention;
Fig. 6 is a sectional view of a protrusion of a satellite converter feed horn of a
third embodiment of the present invention;
Fig. 7 is a schematic side view of a related satellite converter;
Fig. 8 is a perspective view of a related satellite converter feed horn;
Fig. 9 is a sectional view taken along line IX-IX of Fig. 8; and
Fig. 10 is a sectional view taken along line X-X of Fig. 8.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Embodiments of a satellite converter feed horn of the present invention are described
with reference to Figs. 1 to 6. Fig. 1 is a schematic side view of a satellite converter
of the present invention. Fig. 2 is a perspective view of a satellite converter feed
horn of a first embodiment of the present invention. Fig. 3 is a sectional view taken
along line III-III of Fig. 2. Fig. 4 is a sectional view taken along line IV-IV of
Fig. 2.
[0026] Fig. 5 is a sectional view of portions that are connected together of a satellite
converter feed horn of a second embodiment of the present invention. Fig. 6 is a sectional
view of a protrusion of a satellite converter feed horn of a third embodiment of the
present invention.
[0027] Referring to the structure of the satellite converter feed horn of the first embodiment
of the present invention shown in Figs. 1 to 4, a frame 1, which is formed by bending
a metallic plate, has a square shape with open top and bottom portions.
[0028] A cover 2, formed of a metallic plate, is caught by and mounted to the frame 1 so
as to close one of the open portions of the frame 1.
[0029] A circuit board 3, or a printed circuit board, has a ground pattern 4 and a wiring
pattern (not shown). The ground pattern 4 is substantially entirely formed on one
of the surfaces of the circuit board 3. The wiring pattern is formed on the other
surface of the circuit board 3, and comprises an electrical circuit for a desired
reception including various electrical parts.
[0030] With the electrical parts (electrical circuit) being positioned in the frame 1, such
a circuit board 3 is mounted to the square frame 1 so as to close the other open portion
of the frame 1.
[0031] When the circuit board 3 is mounted to the frame 1, the ground pattern 4 is exposed
from the frame 1 and shields the inside of the frame 1, so that the electrical circuit
is electrically shielded by the frame 1, the cover 2, and the ground pattern 4.
[0032] A coaxial connector 5 is mounted to the frame 1 in a protruding manner outward from
the frame 1. The electrical circuit is connected to the connector 5 so that a signal
that has been processed by the electrical circuit can be taken out from the connector
5.
[0033] A square tubular feed horn 6, formed by bending a metallic plate, is soldered and
mounted to the ground pattern 4 perpendicular to the circuit board 3. Satellite electric
waves are received from the feed horn 6.
[0034] As shown, in particular, in Figs. 2 to 4, the feed horn 6 comprises first to fourth
plate sections 7 to 10. The first and second plate sections 7 and 8 are connected
and are at right angles to each other. The third plate section 9 is connected and
is at right angles to the first plate section 7. The fourth plate section 10 is connected
and is at right angles to the second plate section 8.
[0035] The feed horn 6 comprises a square tubular section 11 formed by the first to fourth
plate sections 7 to 10 by connecting ends of the third and fourth plate sections 9
and 10 at right angles to each other.
[0036] At the location where the third and fourth plate sections 9 and 10 are connected
together, the third plate section 9 has a pair of holes 9a, a strip-shaped first connecting
section 9b, and tongues 9c. The holes 9a are formed spaced apart near the end of the
third plate section 9. The first connecting section 9b extends from a portion of the
plate section 9 in the same plane. The tongues 9c protrude from the outer periphery
of the holes 9a.
[0037] The first connecting section 9b is formed so as to extend outward from and in a direction
of extension of the square tubular section 11.
[0038] At the location where the third and fourth plate sections 9 and 10 are connected
together, the fourth plate section 10 has protrusions 10a, and a strip-shaped second
connecting section 10b. The protrusions 10a protrude from portions of the plate section
10 in the same plane and are fitted to the holes 9a. The second connecting section
10b is at right angles to one end of the plate section 10.
[0039] The second connecting section 10b is formed so as to extend outward from and in the
direction of extension of the square tubular section 11, and has a larger width than
the first connecting section 9b. (The width is defined as the length in a direction
orthogonal to the direction of extension of the square tubular section 11.)
[0040] The third and fourth plate sections 9 and 10, which are at right angles to the first
and second plate sections 7 and 8, respectively, are connected together at right angles
to each other, and the protrusions 10a are fitted to the respective holes 9a in order
to caulk the ends of the protrusions 10a in the direction of extension of the square
tubular section 11.
[0041] When connecting the third and fourth plate sections 9 and 10, the first and second
connecting sections 9b and 10b are connected together with a step in a direction orthogonal
to the direction of extension of the square tubular section 11.
[0042] In other words, as shown in Fig. 3, the second connecting section 10b protrudes by
a greater amount than the first connecting section 9b, and the first connecting section
9b is positioned towards the square tubular section 11 from the outer end of the second
connecting section 10b.
[0043] In this state, as shown in Fig. 4, each tongue 9c (shown by alternate long and two
short dash lines) is bent in the direction of arrow A and is superimposed upon the
outer surface of the fourth plate section 10.
[0044] At this time, although the fourth plate section 10 is pushed in the direction of
arrow B, since the protrusions 10a are fitted in the respective holes 9a, the fourth
plate section 10 undergoes very little deformation in the direction of arrow B, so
that the square tubular section 11 no longer becomes deformed.
[0045] Thereafter, by applying solder 12 in the direction of extension of the square tubular
section 11 to the step formed by the first connecting section 9b and the second connecting
section 10b, and removing a gap between the two, the feed horn 6 is formed.
[0046] At this time, the second connecting section 10b having the larger width receives
the solder 12, so that it is possible to easily and reliably solder the first and
second connecting sections 9b and 10b, and to prevent dripping of the solder.
[0047] Although, in the first embodiment, the first connecting section 9b extends from a
portion of the plate section 9 in the same plane, and the second connecting section
10b is at right angles to a portion of the plate section 10, the first connecting
section 9b may be at right angles to a portion of the plate section 9, and the second
connecting section 10b may extend from a portion of the plate section 10 in the same
plane.
[0048] Although, in the first embodiment, the protrusions 10a of the fourth plate section
10 are fitted to the respective holes 9a of the third plate section 9, holes may be
formed in the fourth plate section 10 and fitted to protrusions formed on the third
plate section 9.
[0049] Fig. 5 shows a satellite converter feed horn of a second embodiment of the present
invention. In the second embodiment, the width of a strip-shaped first connecting
section 9b of a third plate section 9 is larger than the width of a second connecting
section 10b of a fourth plate section 10, and solder 12 is applied to a step formed
by the first and second connecting sections 9b and 10b.
[0050] The other structural features are the same as those of the first embodiment, and
the same component parts are given the same reference numerals and are not described.
[0051] Fig. 6 shows a satellite converter feed horn of a third embodiment of the present
invention. In the third embodiment, tongues 9c of a third plate section 9 are kept
extended in a straight line, so that they are not bent.
[0052] The other structural features are the same as those of the first embodiment, and
the same component parts are given the same reference numerals and are not described.
[0053] As described above, a satellite converter feed horn of the present invention comprises
a square tubular feed horn section that is formed of a bent metallic plate and that
comprises a square tubular section including first to fourth plate sections and having
the third and fourth plate sections connected together at right angles to each other.
The first and second plate sections are connected at right angles to each other. The
third plate section is connected at right angles to the first plate section. The fourth
plate section is connected at right angles to the second plate section. The third
plate section has a first strip-shaped connecting section extending outward from and
in a direction of extension of the square tubular section. The fourth plate section
has a second strip-shaped connecting section extending outward from and in the direction
of extension of the square tubular section. The first and second connecting sections
are connected together, with a step being disposed in a direction perpendicular to
the direction of extension of the square tubular section.
[0054] By virtue of such a structure, when the step formed by the first and second connecting
sections is soldered, the connecting section having the larger width receives the
solder, so that it is possible to easily and reliably solder the first and second
connecting sections, and to prevent dripping of the solder.
[0055] One of the first and second connecting sections extends from a portion of the corresponding
plate section in the same plane, and the other of the first and second connecting
sections is at right angles to a portion of the corresponding plate section. Therefore,
the first and second connecting sections can be easily processed and reliably superimposed
upon each other.
[0056] One of the third and fourth plate sections has a protrusion extending from a portion
of the one of the third and fourth plate sections in the same plane, the other of
the third and fourth plate sections has a hole for fitting the protrusion thereto,
and the protrusion is fitted to the hole in order to connect the third and fourth
plate sections together at right angles to each other. Therefore, the third and fourth
plate sections are reliably caught at the location where they are connected together,
so that the square tubular section undergoes little deformation.
[0057] An end portion of the protrusion is caulked in the direction of extension of the
square tubular section. Therefore, the square tubular section undergoes little deformation,
and the third and fourth plate sections can be firmly joined together at the location
where they are connected together.
[0058] Either the third plate section or the fourth plate section has a tongue that protrudes
from the outer periphery defining the hole, and the tongue is bent and superimposed
upon the outer surface of either the third plate section or the fourth plate section
having the protrusion. Therefore, the square tubular section undergoes little deformation,
and the third and fourth plate sections can be firmly joined together at the location
where they are connected together.
1. A satellite converter feed horn comprising:
a square tubular feed horn section formed of a bent metallic plate, the feed horn
section comprising a square tubular section including first to fourth plate sections
and having the third and fourth plate sections connected together at right angles
to each other, the first and second plate sections being connected at right angles
to each other, the third plate section being connected at right angles to the first
plate section, the fourth plate section being connected at right angles to the second
plate section,
wherein the third plate section has a first strip-shaped connecting section extending
outward from and in a direction of extension of the square tubular section,
wherein the fourth plate section has a second strip-shaped connecting section extending
outward from and in the direction of extension of the square tubular section, and
wherein the first and second connecting sections are connected together, with a
step being disposed in a direction perpendicular to the direction of extension of
the square tubular section.
2. A satellite converter feed horn according to Claim 1, wherein one of the first and
second connecting sections extends from a portion of the corresponding plate section
in the same plane, and wherein the other of the first and second connecting sections
is at right angles to a portion of the corresponding plate section.
3. A satellite converter feed horn according to either Claim 1 or Claim 2, wherein one
of the third and fourth plate sections has a protrusion extending from a portion of
the one of the third and fourth plate sections in the same plane, wherein the other
of the third and fourth plate sections has a hole for fitting the protrusion thereto,
and wherein the protrusion is fitted to the hole in order to connect the third and
fourth plate sections together at right angles to each other.
4. A satellite converter feed horn according to Claim 3, wherein an end portion of the
protrusion is caulked in the direction of extension of the square tubular section.
5. A satellite converter feed horn according to either Claim 3 or Claim 4, wherein either
the third plate section or the fourth plate section has a tongue that protrudes from
the outer periphery defining the hole, and wherein the tongue is bent and superimposed
upon the outer surface of either the third plate section or the fourth plate section
having the protrusion.