Additive Manufacturing Omni Antenna Assembly

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Solution Overview

Problem

Conventional antenna designs for omni-directional antennas require complex manufacturing processes, including post-processing and machining operations, to achieve hemispherical or full spherical coverage, which increases cost and complexity, and often necessitate soldering, plating, and tuning for impedance matching, leading to potential defects and passive intermodulation (PIM) issues.

Innovation Solution

The design employs additive manufacturing to create a single integrated piece antenna assembly with a conical structure, cylindrical shell, coaxial transition, and impedance matching network, eliminating the need for soldering, plating, and tuning, and incorporating a monocone antenna structure with a corrugated section to prevent coupling and achieve impedance matching.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional manufacturing techniques are used for antenna assembly, then the antenna can be constructed with multiple components, but the manufacturing complexity and post-processing operations increase

Engineering Contradiction:

Improveantenna constructionVSAvoidmanufacturing process

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent combines multiple antenna components (radiating elements, impedance matching networks, support structures) into a single monolithic structure fabricated by additive manufacturing. This eliminates the need for separate manufacturing and assembly of individual components, directly resolving the contradiction by improving ease of manufacture while reducing device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The additively manufactured antenna structure integrates multiple functions into a single component: radiation elements for signal transmission, impedance matching networks for signal optimization, and structural support. This multi-functionality approach allows one manufacturing process to achieve what previously required multiple specialized components and operations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If conventional manufacturing with multiple components is used, then the antenna can be assembled from separate parts, but labor and material costs increase

Engineering Contradiction:

Improveantenna assemblyVSAvoidmaterial and labor

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

By merging multiple antenna components into a single additively manufactured part, the patent eliminates the materials required for fasteners, adhesives, and joining fixtures, while also reducing labor for assembly operations. The single-component structure directly addresses both material and labor reduction goals.

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If soldering and plating operations are used for impedance matching, then the antenna can achieve required performance, but defects and passive intermodulation issues increase

Engineering Contradiction:

Improveimpedance matchingVSAvoidantenna performance

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent replaces traditional electrical joining methods (soldering, plating) with additive manufacturing processes that create monolithic integrated structures. The impedance matching features are built directly into the 3D-printed structure as continuous material, eliminating the harmful effects of solder joints and plated interfaces while maintaining precise impedance control through geometric design.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The use of additively manufactured composite or homogeneous material structures allows for integrated impedance matching networks that are inherently part of the antenna body. This eliminates the need for separate plated or soldered matching components, thereby improving reliability by removing potential defect sources while maintaining manufacturing precision through controlled material deposition.

Inventive Principle:

Principle #40Composite materials

4Manufacturing precision

If complex post-processing and machining operations are performed, then the antenna achieves required performance specifications, but the manufacturing time and complexity increase

Engineering Contradiction:

Improveperformance specificationsVSAvoidmanufacturing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The additive manufacturing process performs preliminary shaping and feature creation during the primary fabrication step, rather than requiring subsequent machining operations. The antenna structure, including impedance matching features and radiating elements, is built in its final form directly through additive processes, eliminating time-consuming post-processing while maintaining precision through controlled layer-by-layer construction.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS10651558B1Omni antennas

Publication Date: 2020.05.12 LOCKHEED MARTIN CORP

AI summary

An omni antenna assembly includes two antennas, a dipole antenna and a monocone antenna, to provide full spherical coverage. The dipole cavity for the dipole antenna forms one solid part with the monocone antenna. The monocone antenna also includes a monocone and a cylindrical shell connecting the dipole cavity to the monocone. A coaxial transition extends from the cylindrical shell to a matching network. The antenna assembly may be fabricated using additive manufacturing technology.