3D Composite Metal Pattern Sandwich for Non-Developable Antennas

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Solution Overview

Problem

Existing manufacturing processes for composite materials with integrated metal patterns are limited to planar shapes and cannot produce non-developable 3D structures with high electromagnetic performance, as they require additional materials and suffer from delamination and performance degradation under mechanical and electromagnetic stress.

Innovation Solution

A process involving partial polymerization, electrochemical etching, and complete polymerization in a mold to create non-developable 3D shapes with precise metal patterns, using a ductile material to maintain deformability during etching and shaping, allowing for precise and repeatable production of composite materials with integrated metal patterns.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If existing manufacturing processes are used to create composite materials with metal patterns, then planar shapes can be produced, but non-developable 3D structures cannot be achieved

Engineering Contradiction:

Improve3D structure capabilityVSAvoidmanufacturing process complexity

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by performing partial polymerization of the composite material before shaping into 3D structures. This intermediate state allows the material to be molded into complex non-developable shapes while maintaining structural integrity, and then completed polymerization occurs after shaping to achieve final electromagnetic performance

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent utilizes parameter changes by controlling the polymerization degree as a variable parameter. By adjusting the polymerization state from partial to complete, the material transitions between deformable and rigid states, enabling 3D shaping while preserving electromagnetic properties

Inventive Principle:

Principle #35Parameter changes

2Reliability

If metal patterns are integrated into composite materials using existing processes, then electromagnetic functionality can be achieved, but delamination and performance degradation occur under stress

Engineering Contradiction:

Improveelectromagnetic performanceVSAvoidmaterial delamination

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent employs composite materials by integrating metal patterns within polymerized composite layers. The composite structure provides mechanical support and electromagnetic functionality simultaneously, while the polymerization process creates strong adhesion between layers, preventing delamination under mechanical and electromagnetic stress

Inventive Principle:

Principle #40Composite materials

3Strength

If additional materials are used in existing manufacturing processes, then planar composite structures can be produced, but structural integrity and electromagnetic performance degrade

Engineering Contradiction:

Improvestructural integrityVSAvoidadditional materials

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

The patent applies merging by combining the metal pattern layer and composite material layer into a single integrated structure through co-polymerization. This eliminates the need for separate additional materials and adhesives, as the metal patterns become intrinsically part of the composite structure, maintaining both structural integrity and electromagnetic performance

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables the production of non-developable 3D composite structures with integrated metal patterns, achieving high electromagnetic performance and structural integrity, suitable for applications like antennas and radomes, by overcoming material delamination and performance issues.

Implementation Method 1

electrochemical etching, and complete polymerization in a mold to create non-developable 3D shapes with precise metal patterns

Methodology Applied

Scientific EffectElectrochemical etching: Electrolysis

Implementation Method 2

A process involving partial polymerization, electrochemical etching, and complete polymerization in a mold

Methodology Applied

Scientific EffectPolymerization: Photopolymerisation

Data Source

PatentUS12496774B23-D object comprising a sandwich of one or more composite layers, of one or more layers of metal patterns and optionally of one or more layers of possibly dense polymers for electromagnetic applications in antennas and/or radomes

Publication Date: 2025.12.16 THALES SA

AI summary

A process for manufacturing a composite material of 3-D shape, includes a stack of layers of resin and fibre, incorporating at least one metal layer, the process comprising the following steps, a standard unit pattern having been determined for the metal layer: i/ computing periodically organized patterns on the 3-D shape, which is non-developable; then projecting, onto a plane, the patterns, thus defining a planar organization of second patterns; ii/ partially polymerizing, flat, first layers, comprising a metal top layer, of the flat composite stack, so as to make it etchable, but to keep it still deformable; iii/ electrochemically etching the organization of second patterns that was defined in step i into the metal top layer of the flat composite stack resulting from step iv/ carrying out polymerization of the etched composite stack after the stack has been placed in a mould having the desired 3-D shape.