Conformal Antenna Additive Manufacturing for Aerial Vehicle Drag Reduction
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Solution Overview
Problem
Conventional vertically aligned antennas on aerial vehicles experience drag effects, reduced fuel efficiency, and shadowing issues due to limited placement options, while conformal antennas are costly and have low transmission/reception efficiency due to complex manufacturing processes and design tradeoffs.
Innovation Solution
A conformal antenna design using additive manufacturing with an infinite balun and integrated impedance-producing elements as chokes, allowing for low-cost production in arbitrary shapes, reducing drag and shadowing effects by integrating conductive regions directly onto vehicle structures, and enhancing signal strength and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional vertically aligned antennas are used on aerial vehicles, then vertical polarization is achieved, but drag effects increase and fuel efficiency decreases
Solution Approach 1:
The patent applies curvature by transitioning from straight vertical antenna elements to curved conformal antenna elements that follow the aerodynamic contours of the aerial vehicle body. This curvature allows the antenna to integrate with the vehicle's streamlined shape, reducing drag while maintaining vertical polarization through the overall orientation of the curved elements.
Solution Approach 2:
The patent moves the antenna from a protruding three-dimensional vertical structure into the two-dimensional surface of the vehicle body. By embedding conformal antenna elements within the vehicle's skin or surface contours, the antenna occupies less external space and reduces aerodynamic interference while maintaining functionality.
2Reliability
If conventional vertically aligned antennas are used on aerial vehicles, then vertical polarization is achieved, but shadowing issues occur due to limited placement options
Solution Approach 1:
The patent utilizes the vehicle body surface as a mounting dimension, allowing antennas to be placed on curved contours and distributed across multiple locations. This surface integration provides versatile placement options including top, bottom, and side surfaces, enabling optimization of signal strength by selecting locations with minimal shadowing from other vehicle components.
Solution Approach 2:
The patent changes the placement parameters from fixed vertical positions to variable surface coordinates that can be optimized for signal propagation. By adjusting the position, curvature, and orientation of conformal antenna elements across the vehicle surface, the system adapts to minimize shadowing effects from fuselage, wings, and other structural elements.
3Reliability
If conformal antennas are manufactured using conventional processes, then complex shapes are achieved, but manufacturing cost increases and transmission/reception efficiency decreases
Solution Approach 1:
The patent combines multiple antenna elements and their support structures into a single integrated conformal unit that is manufactured as one piece using additive manufacturing. This merging eliminates the need for separate manufacturing and assembly steps for individual antenna elements, reducing production cost while maintaining the complex curved shapes needed for vehicle surface integration and optimal signal transmission.
Solution Approach 2:
The patent changes the manufacturing approach from subtractive or formative processes to additive manufacturing, which enables complex three-dimensional shapes to be built layer by layer. This parameter change in manufacturing methodology reduces tooling costs, eliminates assembly requirements, and maintains the precise geometric parameters needed for high transmission/reception efficiency in conformal antenna designs.
4Ease of manufacture
If additive manufacturing is used for conformal antennas, then manufacturing cost decreases and complex shapes are enabled, but manufacturing precision challenges arise
Solution Approach 1:
The patent optimizes the geometric parameters of antenna elements for additive manufacturing by designing features that are naturally suited to layer-by-layer fabrication. This includes incorporating appropriate minimum feature sizes, avoiding overly thin walls that would be difficult to print accurately, and designing support structures that facilitate precise printing while maintaining the essential curved conformal shapes needed for antenna performance.
Data Source
Figure 1
Figure 2A~2D
Figure 3A~3C
AI summary
According to some aspects, an antenna is provided comprising a substrate, a first conductive region disposed on a first side of the substrate, a second conductive region disposed on a second side of the substrate, and a coaxial transmission line, an inner conductor of the coaxial transmission line electrically coupled to the first conductive region and an outer conductor of the coaxial transmission line electrically coupled to the second conductive region, wherein the second conductive region includes at least one structural feature that functions as a choke when the first and second conductive regions are operated together as an antenna. According to some aspects, an aerial vehicle comprising a conformal antenna is provided.