Phased Array Antenna Aperture Assembly Using Sacrificial Matrix
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Solution Overview
Problem
The labor-intensive and costly process of inserting dielectric material into thousands of small microwave holes in phased array antennas, which requires precise alignment and is time-consuming, leading to increased assembly time and cost due to potential damage and the need for adhesive contamination prevention.
Innovation Solution
A method involving forming a matrix of dielectric loads joined by planar sacrificial interconnecting material, inserting the matrix into aperture elements, and removing the interconnecting material, which allows for precise alignment and efficient assembly by pressing the matrix into the aperture plate and machining away the sacrificial material, reducing labor time and ensuring a snug fit without adhesive issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dielectric material is inserted into thousands of small microwave holes individually, then precise alignment and fit can be achieved, but the process becomes labor intensive and time consuming
Solution Approach 1:
Multiple dielectric loads are merged into a single matrix structure where adjacent dielectric loads share common sacrificial interconnecting material. This allows multiple dielectric loads to be inserted simultaneously as one unit rather than individually, dramatically increasing assembly speed while maintaining precise alignment through the matrix structure.
Solution Approach 2:
The sacrificial interconnecting material is pre-formed between adjacent dielectric loads before insertion. This preliminary action creates pre-aligned groups of dielectric loads that can be inserted together, eliminating the need for individual alignment operations during assembly and significantly reducing labor time.
2Manufacturing precision
If dielectric material is inserted individually into each aperture element, then precise placement can be achieved, but assembly cost increases due to labor intensity
Solution Approach 1:
Adjacent dielectric loads are combined into a matrix structure with shared sacrificial interconnecting material, allowing simultaneous insertion of multiple dielectric loads. This reduces the number of individual insertion operations required, directly lowering labor costs while maintaining precise placement through the pre-formed matrix structure.
Solution Approach 2:
The sacrificial interconnecting material is pre-formed to create precisely positioned groups of dielectric loads before insertion. This preliminary grouping eliminates the need for costly individual alignment and placement operations during final assembly, significantly reducing manufacturing costs while ensuring precise placement.
3Strength
If adhesive is used to secure dielectric material in aperture elements, then secure attachment can be achieved, but contamination risk increases
Solution Approach 1:
The adhesive is completely removed from the system and replaced with a mechanical interference fit between the dielectric loads and aperture elements. The sacrificial interconnecting material is also removed after insertion, leaving no adhesive or foreign material that could contaminate the aperture plate or dielectric loads, thereby eliminating contamination risk while maintaining secure attachment through precise dimensional tolerances.
Data Source
AI summary
A system and method for assembling an antenna comprising an aperture plate having a plurality of aperture elements therethrough is disclosed. The method comprises forming a matrix of the at least a subset of the dielectric loads, each dielectric load having a longitudinal axis, the matrix of the at least a subset of the dielectric loads joined together by planar sacrificial interconnecting material perpendicular to the longitudinal axis of each dielectric load of the subset of dielectric loads, inserting the matrix of the at least a subset of the dielectric loads in at least a subset of the plurality of aperture elements, and removing planar sacrificial interconnecting material. Another embodiment is evidenced by an antenna produced by the foregoing steps. Multiple embodiments are disclosed.