Foldable Antenna Assembly for Compact Shipping and Fast Installation
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Solution Overview
Problem
Satellite antennas are bulky and require on-site assembly, leading to complex and time-consuming installation processes, high shipping costs, and risks of misalignment due to separate packaging of components.
Innovation Solution
A lay flat antenna assembly with pivots and swivel plates that allow components to be rotated and locked into a compact configuration for shipping and easily unfolded into a functional configuration for installation, reducing the need for separate packaging and on-site assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If antenna components are shipped separately and assembled on-site, then shipping costs and packaging material usage are reduced, but installation time and complexity increase
Solution Approach 1:
The antenna system is divided into modular components (reflector, feed arm, LNB, backing structure) that can be independently packaged and shipped, then easily assembled on-site using simple attachment hardware. This segmentation allows reduced shipping volume while maintaining ease of assembly.
Solution Approach 2:
Components are pre-configured with attachment hardware (bolts, nuts, screws) and alignment features during manufacturing, so that on-site assembly requires only simple fastening operations rather than complex alignment and preparation steps.
2Manufacturing precision
If antenna components are assembled on-site, then shipping costs are reduced, but alignment precision and installation quality decrease
Solution Approach 1:
Alignment features and attachment points are designed with specific local geometries (through-holes, threaded holes, mounting brackets) that ensure precise positioning of components relative to each other, while the overall assembly process remains simple for installers.
Solution Approach 2:
The antenna components are designed with self-aligning features and standardized attachment mechanisms that allow the system to self-correct minor positioning errors during assembly, reducing the skill level required while maintaining alignment precision.
3Productivity
If antenna systems are preassembled, then installation time is reduced, but shipping costs and packaging requirements increase
Solution Approach 1:
The antenna system is segmented into compact modular components that can be shipped in space-efficient packaging, then quickly assembled on-site. This avoids the need to ship entire preassembled systems while maintaining fast installation through pre-configured attachment features.
4Ease of operation
If antenna components are shipped separately, then shipping costs are reduced, but installation complexity and labor requirements increase
Solution Approach 1:
Attachment hardware, alignment features, and mounting brackets are pre-installed on components during manufacturing, so that on-site assembly requires only simple fastening operations rather than complex preparation steps.
Solution Approach 2:
The design includes self-aligning features and standardized connection interfaces that guide proper assembly without requiring specialized tools or expertise, allowing consumers to easily install the system themselves.
Data Source
AI summary
An antenna includes a folding mechanism for configuring the antenna into at least one of a first configuration and a second configuration. When in the first configuration, the antenna is configured for operational use. When in the second configuration, the antenna is configured for shipping in a package. A locking apparatus secures the antenna in either configuration. The folding mechanism and the locking mechanism configure the antenna into the first configuration. A method for preparing for shipment an antenna having a reflector with a width, a height, and depth, a backing structure coupled to the reflector, a first swivel plate, coupled to the backing structure, a feed arm bracket coupled to the first swivel plate, and a feed arm coupled to the feed arm bracket. The first swivel plate facilitates yaw rotations of the feed arm bracket, relative to the backing structure.