A large size flexible microstrip antenna and its assembly method

Abstract

This invention discloses a large-size flexible microstrip antenna and its assembly method, comprising: a reflector, multiple antenna elements, and multiple mounting components. The mounting components are arrayed on the reflector. The multiple antenna elements are connected one-to-one with the mounting components to vertically fix the antenna elements on the reflector. Each mounting component includes multiple non-metallic support mounting interfaces. Each antenna element is provided with a non-metallic support, and the multiple non-metallic supports are fixedly mounted one-to-one on the multiple non-metallic support mounting interfaces. This invention increases the stiffness of the flexible microstrip antenna elements through a non-metallic stiffness-preserving frame, ensuring that the antenna elements do not undergo significant deformation under self-weight loads and wind, rain, and snow loads, thus guaranteeing the antenna elements' telecommunication performance.

Description

Technical Field

[0001] This invention relates to the field of antenna technology, and in particular to a large-size flexible microstrip antenna and its assembly method. Background Technology

[0002] Microstrip antenna elements are typically small in size and operate at higher frequencies. For example, the envelope size of an X-band microstrip antenna element is generally only a few tens of millimeters. These small microstrip antenna elements are usually protected by radomes and are not subjected to external loads such as wind, rain, or snow. In structural design, the inherent structural stiffness of the microstrip antenna element does not become a bottleneck for radar structure design; therefore, special reinforcement to ensure stiffness is not required for the small microstrip antenna element structure.

[0003] However, for some low-frequency microstrip antenna elements, their envelope size is relatively large. The envelope size of some meter-wave microstrip antenna elements can reach hundreds of millimeters to several meters, while the thickness of the antenna element is only 1 to 3 millimeters. Its structural characteristics determine that the structural stiffness of such large microstrip antenna elements is very low. They cannot withstand their own weight load, nor can they withstand external loads such as wind, rain, and snow. Otherwise, it is very easy to cause excessive deformation of the antenna element, which will affect the telecommunication performance of the antenna element or even cause overload damage or even breakage of the antenna element.

[0004] Large microstrip antenna elements have poor stiffness, requiring stiffness-preserving designs. However, there are currently no inventions addressing stiffness-preserving designs for large-size flexible microstrip antenna elements. Increasing the stiffness of a microstrip antenna using metal parts would compromise the antenna element's telecommunication performance. Increasing the stiffness of an antenna element using non-metallic parts requires optimized structural designs using non-metallic parts with high specific stiffness to meet the requirements. Inappropriate structural designs and manufacturing processes can significantly increase manufacturing costs. Summary of the Invention

[0005] To address the technical problems existing in the background art, this invention proposes a large-size flexible microstrip antenna and its assembly method.

[0006] The present invention proposes a large-size flexible microstrip antenna, comprising: a reflector, multiple antenna elements and multiple mounting components, wherein the multiple mounting components are arrayed on the reflector, and the multiple antenna elements are connected one-to-one with the multiple mounting components to vertically fix the multiple antenna elements on the reflector.

[0007] Preferably, the mounting assembly includes multiple non-metallic support mounting interfaces, and each antenna unit is provided with a non-metallic support. The multiple non-metallic supports are fixedly mounted on the multiple non-metallic support mounting interfaces one-to-one.

[0008] Preferably, the antenna unit is assembled from a first non-metallic vertical beam, two second non-metallic vertical beams, and two first non-metallic horizontal beams. The first non-metallic vertical beam, the two second non-metallic vertical beams, and the two first non-metallic horizontal beams are all mounted on a flexible microstrip antenna board. The two second non-metallic vertical beams are arranged in parallel with each other, and the two first non-metallic horizontal beams are arranged in parallel with each other. Each second non-metallic vertical beam is perpendicular to the first non-metallic horizontal beam. One end of each of the two first non-metallic horizontal beams is fixedly mounted on the first non-metallic vertical beam. The first non-metallic vertical beam and the second non-metallic vertical beams are arranged in parallel, and the first non-metallic vertical beam, the two second non-metallic vertical beams, and the two first non-metallic horizontal beams are all located in the same plane.

[0009] Preferably, the first non-metallic vertical beam has an RF connector, and the reflector is arrayed with multiple RF connector mounting interfaces, with each RF connector being connected to one of the multiple RF connector mounting interfaces.

[0010] Preferably, both the first non-metallic crossbeam and the first non-metallic vertical beam are provided with rectangular nuts. The first non-metallic crossbeam is connected to the flexible microstrip antenna plate through the rectangular nuts, and the first non-metallic vertical beam is connected to the reflector plate through the rectangular nuts.

[0011] Preferably, the first non-metallic vertical beam is provided with a plurality of anti-mistake pins, and the reflector is provided with a plurality of anti-mistake pin holes, with the plurality of anti-mistake pins corresponding one-to-one with the plurality of anti-mistake pin holes.

[0012] Preferably, the non-metallic support, the first non-metallic crossbeam, the second non-metallic crossbeam, the first non-metallic vertical beam, and the second non-metallic vertical beam can be made of any one of ABS, PPO, or PC, and the rectangular nut can be made of any one of aluminum alloy, stainless steel, or alloy steel.

[0013] The assembly method for a large-size flexible microstrip antenna includes the following steps:

[0014] S1. Screw the rectangular nut onto the first non-metallic vertical beam, the second non-metallic vertical beam, and the first non-metallic horizontal beam. The two second non-metallic vertical beams and the two first non-metallic horizontal beams form a basic frame. The two basic frames are symmetrically installed on the first non-metallic vertical beam with a gap in between. The gap size is equal to the thickness of the flexible microstrip antenna plate. After inserting the flexible microstrip antenna plate into the gap, fix the two basic frames and the flexible microstrip antenna plate to obtain a rigidity-maintaining structure for the flexible microstrip antenna plate. Install the RF connector on the first non-metallic vertical beam and then connect it to the RF connector mounting interface on the reflector. Seal the connection with sealant.

[0015] S2. Install the non-metallic support onto the reflector plate. The bottom surface of the non-metallic support has an anti-misalignment pin, and the reflector plate has a corresponding anti-misalignment hole. After the pin hole is engaged, screw the non-metallic support onto the reflector plate.

[0016] S3. Install the antenna unit on the non-metallic support, and then screw the rigidity-maintaining structure of the flexible microstrip antenna plate onto the reflector plate.

[0017] S4. Assemble the second non-metallic crossbeam by screwing it between adjacent flexible microstrip antenna plates to enhance the overall structural rigidity.

[0018] This invention proposes a large-size flexible microstrip antenna and its assembly method. The advantages are as follows: This invention utilizes a non-metallic stiffness-preserving frame to enhance the stiffness of the large-size flexible microstrip antenna unit, effectively resisting its own weight and external loads such as wind, rain, and snow, preventing excessive deformation of the antenna unit, and ensuring that it maintains good telecommunication performance even in complex environments, maintaining the stability and efficiency of signal reception / transmission. The non-metallic stiffness-preserving frame and related non-metallic components are made of common plastics such as ABS, PPO, and PC, or composite materials with added non-conductive reinforcing fibers. Some components use glass fiber reinforced epoxy prepreg. Combined with a stiffened beam design, this not only meets the high specific stiffness requirement but also allows for small-batch machining or large-batch injection molding production, balancing low-cost manufacturing and part molding consistency, significantly reducing production costs. Precise positioning during assembly ensures the correct installation direction and position of the antenna unit, effectively avoiding performance problems and rework caused by installation errors, and improving assembly efficiency and installation accuracy. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0020] Figure 2 This is a schematic diagram of the reflector structure of the present invention;

[0021] Figure 3 This is a structural diagram of the internal components of the antenna unit of the present invention;

[0022] Figure 4 This is an assembly diagram of the antenna unit of the present invention. Detailed Implementation

[0023] refer to Figure 1-4 This invention proposes a large-size flexible microstrip antenna, comprising a reflector 1, multiple antenna elements 2, and multiple mounting components. The mounting components are precisely arranged in an array on the surface of the reflector 1. This array arrangement ensures the uniform distribution of the antenna elements 2, achieving stable and balanced overall antenna performance. Each antenna element 2 is connected to a mounting component in a one-to-one correspondence. Through a specific mounting method, the antenna elements 2 are vertically fixed to the reflector 1. This vertical mounting method helps optimize the antenna's radiation direction and signal reception / transmission performance.

[0024] The mounting assembly includes multiple non-metallic support mounting interfaces 21. The positions and dimensions of these interfaces on the reflector 1 are precisely designed and manufactured to fit the non-metallic supports 22 on the antenna unit 2. Each antenna unit 2 is equipped with a non-metallic support 22. During the manufacturing process, the shape, dimensional accuracy, and surface flatness of the non-metallic support 22 are strictly controlled to ensure a tight fit with the non-metallic support mounting interface 21. Multiple non-metallic supports 22 are fixedly mounted one-to-one on multiple non-metallic support mounting interfaces 21. The connection between the antenna unit 2 and the reflector 1 is ensured by screw fastening or other reliable connection methods, preventing loosening due to external loads and affecting antenna performance.

[0025] Antenna unit 2 is assembled from a first non-metallic vertical beam 41, two second non-metallic vertical beams 42, and two first non-metallic horizontal beams 31. During assembly, the connections between components are specially designed, such as using mortise and tenon structures or specific slotted joints, to enhance connection reliability. The first non-metallic vertical beam 41, the two second non-metallic vertical beams 42, and the two first non-metallic horizontal beams 31 are all mounted on the flexible microstrip antenna plate 20. During installation, it is necessary to ensure the fit between each component and the flexible microstrip antenna plate 20 to avoid gaps that could affect structural rigidity and telecommunication performance.

[0026] The two second non-metallic vertical beams 42 are arranged in parallel, with their parallelism error controlled within a very small range, achieved through high-precision machining and assembly processes. The two first non-metallic horizontal beams 31 also maintain a strict parallel relationship. Each second non-metallic vertical beam 42 is perpendicular to the first non-metallic horizontal beam 31; precise control of perpendicularity is one of the key factors ensuring the structural stability of the antenna element. One end of each of the two first non-metallic horizontal beams 31 is fixedly mounted on the first non-metallic vertical beam 41, and the connection method uses high-strength adhesive or a special mechanical connection structure to ensure connection strength. The first non-metallic vertical beams 41 and the second non-metallic vertical beams 42 are arranged in parallel, and the first non-metallic vertical beam 41, the two second non-metallic vertical beams 42, and the two first non-metallic horizontal beams 31 are all located on the same plane. The flatness of this plane has a significant impact on the antenna's radiation characteristics; therefore, precision machining and testing methods are required during manufacturing to ensure that its flatness meets design requirements.

[0027] RF connector connection: An RF connector 24 is provided on the first non-metallic vertical beam 41. The model and parameters of the RF connector 24 are selected according to the antenna's telecommunications performance requirements to ensure the stability and efficiency of signal transmission. Multiple RF connector mounting interfaces 23 are arrayed on the reflector 1. The positions and dimensions of these interfaces are strictly matched with the RF connectors 24. Multiple RF connectors 24 are connected one-to-one to multiple RF connector mounting interfaces 23. Good contact must be ensured during the connection process to avoid signal loss. Sealing measures can be used at the connection points to prevent external environmental factors from affecting signal transmission.

[0028] Rectangular nut connection: Rectangular nuts 43 are provided on both the first non-metallic crossbeam 31 and the first non-metallic vertical beam 41. The specifications and quantity of the rectangular nuts 43 are designed according to the stress conditions of the component connection. The first non-metallic crossbeam 31 is connected to the flexible microstrip antenna plate 20 through the rectangular nuts 43. When connecting, it is necessary to ensure that the tightening torque of the nuts meets the requirements to ensure the tightness of the connection. The first non-metallic vertical beam 41 is connected to the reflector plate 1 through the rectangular nuts 43. Similarly, the tightening torque is strictly controlled to ensure that the antenna unit 2 is stably installed on the reflector plate 1.

[0029] Error-proofing design: Multiple error-proofing pins are installed on the first non-metallic vertical beam 41, each with a unique shape, position, and number. Multiple error-proofing pin holes are installed on the reflector plate 1, with each pin corresponding to one of the holes. During installation, the correct installation direction and position of the antenna unit 2 can only be guaranteed when the error-proofing pins are accurately inserted into their holes, effectively avoiding performance problems and rework costs caused by installation errors.

[0030] The non-metallic support 22, the first non-metallic crossbeam 31, the second non-metallic crossbeam 32, the first non-metallic vertical beam 41, and the second non-metallic vertical beam 42 can be made of any one of ABS, PPO, or PC. These materials have good insulation properties and will not interfere with the antenna's electrical performance; at the same time, they also have a certain mechanical strength and toughness to meet the rigidity requirements of the antenna structure. In practical applications, appropriate materials can be selected according to the specific usage environment, cost requirements, and performance indicators. The rectangular nut 43 can be made of any one of aluminum alloy, stainless steel, or alloy steel. These metal materials have high strength and wear resistance, and can withstand the tightening force and external load during the component connection process, ensuring the reliability of the connection.

[0031] Step S1: Assemble the antenna element stiffness-maintaining structure

[0032] Rectangular nut installation: Screw the rectangular nut 43 onto the first non-metallic vertical beam 41, the second non-metallic vertical beam 42, and the first non-metallic horizontal beam 31. A special tightening tool is required during installation. Tighten the nuts in sequence according to the specified tightening torque to ensure that the nuts are installed firmly and the force is even.

[0033] Basic frame assembly: The two second non-metallic vertical beams 42 and the two first non-metallic horizontal beams 31 are assembled into a basic frame. During assembly, the connection points of each component must be strictly inspected to ensure tight and gapless connections. High-precision measuring tools are used to check the dimensional and shape accuracy of the basic frame to ensure that it meets the design requirements.

[0034] Double-layer frame installation: Two basic frames are symmetrically installed on the first non-metallic vertical beam 41, with a gap in between. The size of the gap is equal to the thickness of the flexible microstrip antenna plate 20. During installation, precise positioning and adjustment are required to ensure the parallelism and symmetry of the two basic frames, ensuring that the flexible microstrip antenna plate 20 can be smoothly inserted.

[0035] Antenna Plate Insertion and Fastening: After inserting the flexible microstrip antenna plate 20 into the gap, secure the two-layer base frame and the flexible microstrip antenna plate 20 using through screws and nuts. During tightening, use a diagonal tightening method, tightening gradually in multiple stages to ensure even force distribution and prevent deformation of the flexible microstrip antenna plate 20 due to uneven force. After fixing, check the firmness and sealing of the connections to ensure there are no loose parts or gaps.

[0036] RF connector installation and connection: Install the RF connector 24 onto the first non-metallic vertical beam 41. During installation, ensure the correct installation orientation of the RF connector 24 and that its interface is precisely aligned with the mounting hole on the first non-metallic vertical beam 41. Then connect the RF connector 24 to the RF connector mounting interface 23 on the reflector plate 1. Ensure good contact during connection; a dedicated testing device can be used for signal transmission testing. Apply sealant to the connection point, ensuring even and appropriate application to guarantee a tight seal and prevent external environmental factors from affecting signal transmission.

[0037] Step S2: Installation of non-metallic supports

[0038] The non-metallic support 22 is installed on the reflector 1. The bottom surface of the non-metallic support 22 has an anti-misalignment pin, and the reflector 1 has a corresponding anti-misalignment hole. Before installation, impurities in the anti-misalignment pin and anti-misalignment hole must be cleaned to ensure they are free of foreign objects. After aligning with the pin hole, the non-metallic support 22 is screwed onto the reflector 1. During installation, a suitable tightening tool must be used to tighten the screw to the specified torque to ensure the non-metallic support 22 is securely installed and accurately positioned. After installation, check that the installation direction and position of the non-metallic support 22 are correct, ensuring that the anti-misalignment pin hole on its top surface accurately aligns with the anti-misalignment pin on the antenna unit 2.

[0039] Step S3: Antenna Unit Installation

[0040] Antenna element 2 is mounted on non-metallic support 22. The top surface of non-metallic support 22 has a square anti-misalignment pin hole. The first non-metallic vertical beam 41 of the rigidity-maintaining structure of the large-size flexible microstrip antenna element also has a square anti-misalignment pin. During installation, align the anti-misalignment pin on antenna element 2 with the anti-misalignment pin hole on non-metallic support 22 and slowly insert it, ensuring the anti-misalignment pin is fully inserted into the hole. Then, screw the rigidity-maintaining structure of flexible microstrip antenna plate 20 onto reflector plate 1. Secure antenna element 2 to reflector plate 1 by tightening the screws. During tightening, ensure that the tightening torque of each screw is consistent to prevent antenna element 2 from tilting or deforming. After installation, check the installation firmness and verticality of antenna element 2 to ensure it meets design requirements.

[0041] Step S4: Assembly of the second non-metallic crossbeam

[0042] Assemble the second non-metallic crossbeam 32 by screwing it between adjacent flexible microstrip antenna panels 20. Before installation, check that the dimensions and shape of the second non-metallic crossbeam 32 meet the requirements and clean any impurities from the installation area. During installation, connect the second non-metallic crossbeam 32 to the flexible microstrip antenna panel 20 using rectangular nuts 43. Tighten the nuts to the specified torque using a tightening tool to ensure a secure connection. The installation of the second non-metallic crossbeam 32 effectively enhances the connection strength between adjacent flexible microstrip antenna panels 20, thereby increasing the overall structural rigidity and improving the stability of the antenna under external loads. After installation, check the installation position and connection security of the second non-metallic crossbeam 32 to ensure there is no loosening.

[0043] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and the inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A large-size flexible microstrip antenna, characterized in that, include: A reflector (1), multiple antenna units (2) and multiple mounting components are arranged in an array on the reflector (1). The multiple antenna units (2) are connected one-to-one with the multiple mounting components to vertically fix the multiple antenna units (2) on the reflector (1). The mounting assembly includes multiple non-metallic support mounting interfaces (21), and each antenna unit (2) is provided with a non-metallic support (22). The multiple non-metallic supports (22) are fixedly installed on the multiple non-metallic support mounting interfaces (21) in a one-to-one correspondence. The antenna unit (2) is assembled from a first non-metallic vertical beam (41), two second non-metallic vertical beams (42) and two first non-metallic horizontal beams (31). The first non-metallic vertical beam (41), two second non-metallic vertical beams (42) and two first non-metallic horizontal beams (31) are all mounted on the flexible microstrip antenna plate (20). The two second non-metallic vertical beams (42) are arranged in parallel with each other, and the two first non-metallic horizontal beams (31) are arranged in parallel with each other. Each second non-metallic vertical beam (42) is arranged perpendicular to the first non-metallic horizontal beam (31). One end of each of the two first non-metallic horizontal beams (31) is fixedly mounted on the first non-metallic vertical beam (41). The first non-metallic vertical beam (41) and the second non-metallic vertical beam (42) are arranged in parallel. The first non-metallic vertical beam (41), two second non-metallic vertical beams (42) and two first non-metallic horizontal beams (31) are all in the same plane. Rectangular nuts (43) are provided on both the first non-metallic crossbeam (31) and the first non-metallic vertical beam (41).

2. The large-size flexible microstrip antenna according to claim 1, characterized in that, The first non-metallic vertical beam (41) has an RF connector (24), and the reflector (1) is arrayed with multiple RF connector mounting interfaces (23), with the multiple RF connectors (24) connected one-to-one to the multiple RF connector mounting interfaces (23).

3. A large-size flexible microstrip antenna according to claim 2, characterized in that, The first non-metallic crossbeam (31) is connected to the flexible microstrip antenna plate (20) by a rectangular nut (43), and the first non-metallic vertical beam (41) is connected to the reflector plate (1) by a rectangular nut (43).

4. A large-size flexible microstrip antenna according to claim 3, characterized in that, The first non-metallic vertical beam (41) is provided with multiple anti-mistake pins, and the reflector plate (1) is provided with multiple anti-mistake pin holes, with each anti-mistake pin corresponding to one of the multiple anti-mistake pin holes.

5. A large-size flexible microstrip antenna according to claim 4, characterized in that, The materials of the non-metallic support (22), the first non-metallic crossbeam (31), the second non-metallic crossbeam (32), the first non-metallic vertical beam (41) and the second non-metallic vertical beam (42) can be any one of ABS, PPO and PC, and the material of the rectangular nut (43) can be any one of aluminum alloy, stainless steel and alloy steel.

6. An assembly method applicable to the large-size flexible microstrip antenna according to any one of claims 1-5, characterized in that, Includes the following steps: S1. Screw the rectangular nut (43) onto the first non-metallic vertical beam (41), the second non-metallic vertical beam (42), and the first non-metallic horizontal beam (31). The two second non-metallic vertical beams (42) and the two first non-metallic horizontal beams (31) form a basic frame. The two basic frames are symmetrically installed on the first non-metallic vertical beam (41) with a gap in the middle. The gap size is equal to the thickness of the flexible microstrip antenna plate (20). After inserting the flexible microstrip antenna plate (20) into the gap, fix the two basic frames and the flexible microstrip antenna plate (20) to obtain the rigidity structure of the flexible microstrip antenna plate (20). Install the radio frequency connector (24) on the first non-metallic vertical beam (41) and connect it to the radio frequency connector mounting interface (23) on the reflector plate (1). Apply sealant to the connection and seal it. S2. Install the non-metallic support (22) on the reflector (1). The bottom surface of the non-metallic support (22) has an anti-misalignment pin, and the reflector (1) has an anti-misalignment hole. After the pin hole is engaged, screw the non-metallic support (22) onto the reflector (1). S3. Install the antenna unit (2) on the non-metallic support (22), and then screw the rigidity structure of the flexible microstrip antenna plate (20) onto the reflector plate (1). S4. Assemble the second non-metallic crossbeam (32) and screw the second non-metallic crossbeam (32) between adjacent flexible microstrip antenna plates (20) to enhance the overall structural rigidity.

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