Flexible RF Assemblies With Heterogeneous Substrates
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Solution Overview
Problem
Current flexible RF antenna substrates, particularly those made from thermoplastic elastomers using FDM, face limitations in RF performance due to suboptimal relative permittivity and loss tangent, leading to low gain and mechanical integrity issues when trying to enhance RF characteristics by varying infill density, which can compromise mechanical durability.
Innovation Solution
A flexible RF antenna assembly featuring a heterogeneous substrate with a flexible framework portion and discrete interior portions, where the framework portion has a lower Young's modulus and yield tensile strength compared to the interior portions, allowing for customizable RF properties such as dielectric constant, loss tangent, and magnetic relative permeability, while maintaining mechanical robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If infill density of TPE material is reduced to improve RF performance, then relative permittivity and loss tangent improve, but mechanical integrity is compromised
Solution Approach 1:
The patent employs composite materials by combining TPE framework with infill materials having different dielectric properties. This allows the substrate to achieve optimal RF characteristics through material composition rather than relying solely on infill density adjustments, thereby maintaining mechanical integrity while improving RF performance.
Solution Approach 2:
The patent applies local quality by varying the infill density and material composition in specific regions of the substrate. Different areas can have optimized properties for either RF performance or mechanical strength depending on their functional requirements, resolving the contradiction between these two parameters.
2Ease of operation
If TPE material is used for flexible substrate, then flexibility and conformability are achieved, but RF performance is limited due to suboptimal relative permittivity and loss tangent
Solution Approach 1:
The patent uses composite materials where the TPE framework provides flexibility and conformability, while the infill materials contribute optimal dielectric properties for RF performance. This composite approach allows both requirements to be satisfied simultaneously.
Solution Approach 2:
Different regions of the substrate have different material compositions optimized for their specific functions: the framework maintains flexibility while infill regions provide optimal RF characteristics, resolving the contradiction between flexibility and RF performance.
Data Source
AI summary
The present application provides flexible radio frequency (RF) assemblies, components thereof and related methods. The present application includes at least one flexible substrate comprising first and second sides, a flexible framework portion comprising a first material composition and a plurality of discrete spaced interior portions comprising second material compositions that differ from that of the flexible framework portion. The framework portion extends fully about a portion of each interior portion. The framework portion comprises a flexibility that is greater than that of the interior portions. Each interior portion and the framework portion comprise a dielectric constant, a loss tangent, a volume resistivity, a surface resistivity and a magnetic relative permeability. At least one of the dielectric constant, the loss tangent, the volume resistivity, the surface resistivity and the magnetic relative permeability of at least one of the interior portions differs from that of the framework portion.