Injection Moldable Dielectric Cone Radiator for Antenna Sub-Reflector
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Solution Overview
Problem
Existing dual reflector antennas face challenges in manufacturing cost and electrical performance due to complex machine tool procedures and increased dimensions, which result in RF signal blockage and the need for additional reinforcing structures.
Innovation Solution
A self-supported feed cone radiator design utilizing an injection moldable dielectric cone radiator assembly with radial or longitudinal grooves and a lens bore for impedance matching, allowing for reduced material thickness and simplified manufacturing, enabling efficient RF radiation pattern shaping and cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a dielectric funnel is used to support the sub-reflector, then the sub-reflector is supported, but the dielectric funnel becomes an impedance discontinuity that increases the sub-reflector and reflector dish dimensions, resulting in increased RF signal path blockage
Solution Approach 1:
The patent removes the separate dielectric funnel support structure and integrates its support function directly into the cone radiator body. The cone radiator itself serves as the support structure, eliminating the impedance discontinuity caused by the funnel while maintaining sub-reflector support capability.
Solution Approach 2:
The patent combines the support function and radiation function into a single integrated cone radiator structure. The cone radiator both supports the sub-reflector and serves as the radiating element, eliminating the need for a separate dielectric funnel and reducing RF blockage.
2Strength
If the sub-reflector dimensions are increased to compensate for impedance discontinuity, then the support structure is improved, but RF signal path blockage by the sub-reflector becomes significant
Solution Approach 1:
The patent removes the impedance discontinuity issue by eliminating the separate dielectric funnel, allowing the sub-reflector to maintain smaller dimensions while still providing adequate support through the integrated cone radiator structure.
3Reliability
If complex machine tool manufacturing procedures are used to create angled features and steps in the dielectric block, then the electrical performance is improved, but the manufacturing cost increases
Solution Approach 1:
The patent changes the manufacturing method from complex machine tool procedures to injection molding. The cone radiator is formed as a single molded piece with integrated features, eliminating the need for complex machining operations while maintaining electrical performance through proper geometric design.
Solution Approach 2:
The patent combines multiple features (support structure, radiation elements, and mounting features) into a single injection-molded cone radiator component, simplifying manufacturing while maintaining electrical performance.
4Strength
If the overall dimension of the reflector antenna is increased to accommodate larger sub-reflector, then the support structure is improved, but additional reinforcing structure considerations are required
Solution Approach 1:
The patent removes the need for additional reinforcing structures by eliminating the impedance discontinuity issue at its source (the dielectric funnel). The integrated cone radiator provides adequate support without requiring the antenna overall dimensions to increase, thus avoiding the need for additional reinforcing structures.
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
The design achieves stringent electrical specifications while reducing manufacturing defects and costs, enabling efficient microwave communication link performance with a lightweight and strong antenna structure.
Implementation Method 1
A cone radiator sub-reflector assembly for coupling with a waveguide at a waveguide transition portion of a unitary dielectric block which supports a sub-reflector at a distal end
Data Source
AI summary
A dielectric cone radiator sub-reflector assembly for a reflector antenna with a waveguide supported sub-reflector is provided as a unitary dielectric block with a sub-reflector at a distal end. A waveguide transition portion of the dielectric block is dimensioned for insertion coupling into an end of the waveguide. A sub-reflector support portion of the dielectric block and the waveguide transition portion provided with a plurality of longitudinal ribs and grooves coaxial with a longitudinal axis of the assembly; the longitudinal grooves open to a proximal end of the dielectric block. The unitary dielectric block may be manufactured as a single contiguous monolithic portion of dielectric material via injection molding.