Flexible Phased-Array Antenna Inkjet Fabrication

Solution Overview

Problem

Conventional methods for fabricating flexible phased-array antennas are complex and costly, requiring separate fabrication and packaging of discrete components, which limits integration with other electronic devices and increases manufacturing complexity.

Innovation Solution

A printed phased-array antenna system is developed, where antenna elements and electronics are integrated on a flexible substrate using ink jet printing, enabling concurrent fabrication and multilayer interconnection to control electronics without complex circuitry, incorporating features like photovoltaic cells, batteries, and RF couplers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If discrete components are fabricated separately and integrated on a flexible substrate, then conformality and functionality are achieved, but fabrication complexity increases and cost increases

Engineering Contradiction:

ImproveconformalityVSAvoidfabrication complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines multiple discrete components (antenna elements, phase shifters, T/R modules, batteries, solar cells, RFID tags) into a single integrated phased-array antenna system on one flexible substrate. This merging eliminates the need for separate fabrication and integration of discrete parts, reducing fabrication complexity while maintaining conformality and functionality.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The flexible substrate serves multiple functions simultaneously: it acts as the mechanical support for the antenna array, the circuit board for electronic components, the flexible platform for conformal mounting, and the substrate for integrating additional devices like batteries and solar cells. This multi-functionality reduces the number of separate components needed.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If discrete components are fabricated separately and integrated on a flexible substrate, then conformality and functionality are achieved, but manufacturing cost increases

Engineering Contradiction:

ImproveconformalityVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent combines multiple discrete components (antenna elements, phase shifters, T/R modules, batteries, solar cells, RFID tags) into a single integrated phased-array antenna system on one flexible substrate. This merging eliminates the need for separate fabrication and integration of discrete parts, reducing fabrication complexity while maintaining conformality and functionality.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS9548543B2Method for fabricating and packaging an M×N phased-array antenna

Publication Date: 2017.01.17 OMEGA OPTICS

AI summary

A method for fabricating an M×N, P-bit phased-array antenna on a flexible substrate is disclosed. The method comprising ink jet printing and hardening alignment marks, antenna elements, transmission lines, switches, an RF coupler, and multilayer interconnections onto the flexible substrate. The substrate of the M×N, P-bit phased-array antenna may comprise an integrated control circuit of printed electronic components such as, photovoltaic cells, batteries, resistors, capacitors, etc. Other embodiments are described and claimed.