Reduced Surface Area Antenna with Crosshatch Pattern
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Solution Overview
Problem
Current antenna manufacturing processes for wireless devices are costly and energy-intensive, particularly due to the need for large surface areas and complex geometries, which limits design flexibility and increases production costs.
Innovation Solution
The development of a reduced surface area antenna apparatus using a cross-hatch pattern with metal-free portions and strategically placed conductive crosslinks, manufactured through techniques like laser direct structuring (LDS) and direct metal deposition (DMD), which reduces the metal surface area by up to 60% and simplifies the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional planar metal radiator antennas are used, then electrical performance is maintained, but manufacturing cost and energy consumption increase significantly
Solution Approach 1:
The antenna radiator is segmented into multiple discrete conductive elements (crosslinks) distributed across the substrate rather than using a continuous metal radiator. This segmentation reduces the total metal surface area required while maintaining the antenna's electrical performance through strategic placement of conductive elements that create the necessary current paths for radiation.
Solution Approach 2:
Instead of uniformly distributing metal across the entire antenna surface, conductive crosslinks are strategically placed at specific locations where they most effectively contribute to the antenna's electrical performance. This local quality approach ensures that metal is applied only where needed, reducing overall material usage and manufacturing cost while maintaining functionality.
2Productivity
If large surface area antennas are manufactured using LDS or DMD processes, then electrical performance is achieved, but manufacturing time and cost increase
Solution Approach 1:
Metal-free portions are extracted or removed from the antenna structure, leaving only the essential conductive crosslinks needed for electrical performance. This extraction reduces the total surface area that requires manufacturing processing, thereby reducing manufacturing time and cost while maintaining the antenna's functional performance through the remaining strategic conductive elements.
Solution Approach 2:
Rather than applying metal deposition or laser structuring across the entire antenna surface area, the process is applied only to the partial areas where conductive crosslinks are needed. This partial action approach reduces processing time and material consumption while achieving the necessary electrical performance with fewer processed locations.
3Adaptability or versatility
If complex 3D geometries are used for antennas, then design flexibility improves, but manufacturing complexity and cost increase
Solution Approach 1:
The antenna design transitions from complex 3D geometries to a 2D planar configuration with strategically placed conductive crosslinks on the substrate surface. This dimensionality change simplifies the manufacturing process while maintaining design flexibility, as the crosslinks can be positioned at various locations and orientations on the 2D plane to achieve different antenna patterns and performance characteristics without requiring complex 3D structuring.
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
This approach significantly reduces antenna manufacturing time and cost while maintaining comparable electrical performance to traditional antennas, offering greater design flexibility and improved manufacturing efficiency.
Implementation Method 1
The doped metal additive is activated by means of a laser in a process known as laser direct structuring (LDS)
Implementation Method 2
an electrolytic copper bath followed by successive additive layers such as nickel or gold are then added to complete the construction of the antenna
Data Source
AI summary
Space- and cost-efficient antenna apparatus and methods of making and using the same. Antenna may comprise one or more planar radiator elements fabricated from an electrically conductive material. Surface area of the antenna radiator metallized portion may be reduced by utilizing a crosshatch pattern. The pattern may comprise of one or more metal-free elements disposed within the outline of the radiator. The elements may be interconnected by conductive crosslinks. The antenna may be coupled to radio electronics at one or more connection points. At least one of a size and/or a placement of the crosslinks may be configured based on distance from the connecting points. Crosslink size and/or placement may be configured to provide a prescribed current flow within the antenna. Reducing surface area of the antenna radiator may reduce manufacturing time and/or cost compared with prior art antenna design approaches.