Flexible Phased Array Antenna on Curvilinear Surfaces
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Solution Overview
Problem
Conventional phased array antennas are rigid, thick, and heavy, making them unsuitable for curvilinear surfaces and increasing production costs, as they do not conform well to the shape of platforms and result in negative drag and integration challenges.
Innovation Solution
A phased array antenna is fabricated using additive processes with multiple layers, including a radiating layer, feed layer, power and control layer, and ground layer, all formed from liquid crystal polymer, which allows for a thin, lightweight, and flexible design that can conform to curvilinear surfaces by using an adhesive to couple the layers and a direct write process for deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional phased array antennas are assembled as monolithic structures with multilayer printed circuit boards, then structural strength and electrical connectivity are improved, but weight, thickness, and rigidity increase making them unsuitable for curvilinear surfaces
Solution Approach 1:
The antenna is divided into multiple flexible substrate layers (first substrate, second substrate, third substrate) that can be separately fabricated and then assembled. This segmentation allows each layer to be optimized independently and enables the overall structure to be flexible and conformable to curved surfaces while maintaining structural integrity through controlled assembly with adhesive layers.
Solution Approach 2:
The patent uses composite material structures combining flexible substrates with dielectric layers and conductive traces. The flexible substrates are made from materials that provide both mechanical flexibility and electrical properties, creating a composite structure that is lightweight yet structurally sound and adaptable to curvilinear surfaces.
2Reliability
If conventional phased array antennas use thick multilayer printed circuit board structures, then electrical connectivity and signal transmission are improved, but the antenna thickness increases and flexibility decreases
Solution Approach 1:
The patent transitions from a traditional three-dimensional thick PCB structure to a multi-layer planar flexible substrate architecture. By distributing electrical connectivity functions across multiple thin layers connected through controlled vias and adhesive layers, the design achieves reliable electrical connectivity while maintaining minimal overall thickness and enabling flexibility.
Solution Approach 2:
The electrical connectivity function is segmented across multiple thin substrate layers rather than concentrated in a single thick PCB. Each layer handles specific signal routing and connection functions, with adhesive layers providing both mechanical bonding and electrical pathways, thereby achieving reliable connectivity with reduced thickness.
3Manufacturing precision
If conventional phased array antennas are designed with rigid structures, then manufacturing precision and assembly ease are improved, but adaptability to curvilinear surfaces and integration with platforms deteriorates
Solution Approach 1:
The antenna structure transitions from a rigid static design to a flexible dynamic architecture using thin flexible substrates that can be conformally mounted on curved surfaces. The segmented multi-layer design with adhesive bonding allows the antenna to adapt to various platform geometries while maintaining precise electrical connections through controlled vias and registration features.
Solution Approach 2:
The patent employs flexible substrate layers that act as thin films capable of conforming to curvilinear surfaces. These flexible substrates maintain structural integrity for precise manufacturing and assembly while enabling adaptability to various platform shapes through their inherent flexibility and conformability.
4Ease of manufacture
If conventional phased array antennas are mounted protruding from platform surfaces, then ease of installation is improved, but aerodynamic drag increases and integration complexity increases
Solution Approach 1:
The antenna design adopts a conformal geometry that follows the curvature of the platform surface rather than protruding outward. This curved integration reduces aerodynamic drag by streamlining the platform's external contour while maintaining full antenna functionality through the flexible multi-layer substrate structure that can be mounted flush against the surface.
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 solution results in a planar and flexible phased array antenna that can be mounted on curved surfaces, reducing weight and power consumption while providing enhanced directivity and communication capabilities, and integrating efficiently with vehicle structures without the need for dedicated structural components.
Implementation Method 1
An adhesive layer operationally couples the feed layer to the power and control layer
Implementation Method 2
The first and second dielectric layers are formed of liquid crystal polymer
Implementation Method 3
a plurality of layers fabricated using an additive process
Data Source
Figure 1A~1B
Figure 1C
Figure 1D~1G
AI summary
A phased array antenna (PAA) is provided. The PAA includes a plurality of layers fabricated using an additive process such that the PAA conforms to a curvilinear surface (101A). The plurality of layers include: a radiating layer (102) placed on a first surface of a first dielectric layer (104); a feed layer (106) operationally coupled to a second surface of the first dielectric layer (104); and a second dielectric layer (112) having a first surface operationally coupled to a power and control layer (110) and a second surface operationally coupled to a ground layer (114). An adhesive layer (108) operationally couples the feed layer to the power and control layer.