Layered Antenna Assembly Using EBG Waveguides and Deformable Fasteners
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Solution Overview
Problem
The assembly of antenna arrays, particularly at millimeter wave frequencies, faces challenges due to demanding manufacturing tolerances and issues with electromagnetic leakage, as conventional attachment methods like screws and soldering are complex, costly, and inefficient.
Innovation Solution
The use of electromagnetic bandgap (EBG) structures in a stacked layered antenna arrangement, combined with fastening members having deformable tails, such as rivets or bosses, to attach layers, reducing manufacturing tolerances and preventing electromagnetic leakage while allowing for low-cost and simple assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional attachment methods (screws or soldering) are used to attach layers in antenna arrays, then reliable electrical contact is achieved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent extracts the electrical contact function from the mechanical attachment function. The EBG structures provide electromagnetic shielding and signal distribution without requiring electrical contact between layers, while separate fastening members provide mechanical attachment. This separation allows each component to be optimized independently, reducing overall manufacturing complexity while maintaining reliability.
Solution Approach 2:
The EBG structures serve multiple functions simultaneously: they provide electromagnetic shielding to prevent leakage, act as signal distribution pathways, and serve as mechanical support structures. This multi-functionality reduces the number of separate components needed, simplifying the overall assembly process and reducing manufacturing complexity.
2Reliability
If conventional attachment methods (screws or soldering) are used to attach layers in antenna arrays, then reliable electrical contact is achieved, but manufacturing cost increases
Solution Approach 1:
The patent employs simple, inexpensive fastening members such as rivets or clips instead of expensive screws or soldering processes. These fastening members are designed for easy, low-cost installation and do not require complex tools or skilled labor, significantly reducing manufacturing costs while maintaining adequate attachment reliability.
Solution Approach 2:
By extracting the electrical contact function from the attachment mechanism, the patent eliminates the need for expensive soldering or precision screw connections. The EBG structures handle electromagnetic functions independently, allowing the use of simple, cost-effective mechanical fastening methods without compromising electrical performance.
3Strength
If conventional attachment methods are used, then layers are securely attached, but electromagnetic leakage occurs
Solution Approach 1:
The EBG structures serve as intermediary elements between the conductive layers, providing electromagnetic shielding that prevents leakage while allowing mechanical fastening members to attach the layers. The EBG structures act as a mediator that decouples the mechanical attachment function from the electromagnetic shielding function, enabling both requirements to be satisfied simultaneously without interference.
Solution Approach 2:
The patent segments the attachment and shielding functions into separate components: simple mechanical fastening members provide attachment strength, while EBG structures provide electromagnetic leakage prevention. This segmentation allows each component to be optimized for its specific function without compromising the other, solving the contradiction between attachment strength and leakage prevention.
4Manufacturing precision
If high manufacturing precision is required for conventional waveguide assembly, then electrical contact is ensured, but productivity decreases
Solution Approach 1:
The patent employs simple, tolerance-friendly fastening members that do not require high precision assembly. These fastening members are designed to accommodate larger tolerances and can be installed quickly using simple tools, significantly increasing assembly speed and productivity while maintaining adequate attachment reliability.
Solution Approach 2:
By segmenting the functions of electrical contact and mechanical attachment, the patent allows the mechanical attachment portion to use simpler, faster assembly methods. The EBG structures handle the electromagnetic functions with relaxed tolerances, enabling faster assembly without compromising overall performance.
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 results in compact designs with low loss and high signal-to-noise ratios, eliminating the need for precise electrical contact and reducing assembly complexity and cost, while maintaining high performance.
Implementation Method 1
The first EBG structure is also arranged to prevent electromagnetic radiation in a frequency band of operation from propagating from the at least one first waveguide in directions other than through the at least one distribution layer feed and the one or more radiation elements
Implementation Method 2
The radiation layer and the distribution layer are attached to each other with one or more fastening members comprising respective deformable tails
Data Source
AI summary
An antenna arrangement having a stacked layered structure. The antenna arrangement includes a radiation layer including one or more radiation elements, and a distribution layer facing the radiation layer. The distribution layer is arranged to distribute a radio frequency signal to the one or more radiation elements. The distribution layer includes at least one distribution layer feed. Any of the distribution layer and the radiation layer includes a first electromagnetic bandgap, EBG, structure arranged to form at least one first waveguide intermediate the distribution layer and the radiation layer. The first EBG structure is arranged to prevent electromagnetic radiation in a frequency band of operation from propagating from the first waveguide in directions other than through the distribution layer feed and the one or more radiation elements. The radiation layer and the distribution layer are attached to each other with one or more fastening members including respective deformable tails.