Folded Flexible Circuit for RF Antenna Weight Reduction
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Solution Overview
Problem
Current active array architectures for space and airborne antennas are heavy, costly, and non-conformal, making them unsuitable for next-generation large area multifunction applications, and lightweight materials used to address these issues pose challenges in achieving sufficient performance for radar and communication systems.
Innovation Solution
The development of a radiator transition assembly for exciting long slot radiators in RF antennas, utilizing a folded flexible circuit substrate with microstrip transmission lines and excitation circuitry, which reduces weight and complexity by integrating electrical and mechanical functions through 3-D circuitry, allowing for up to a 75% reduction in dielectric, conductor, and adhesive layers, and innovative folding techniques to route RF, signal, and power lines on a single layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current active array architecture is used, then sufficient performance for radar and communication systems is achieved, but weight and cost increase and conformality is reduced
Solution Approach 1:
The patent employs flexible circuit substrates with integrated microstrip transmission lines and excitation circuitry that can be conformally mounted to antenna structures. This flexible film approach replaces heavy rigid multilayer panels, achieving weight reduction while maintaining RF performance and enabling conformal antenna applications on curved surfaces.
2Weight of moving object
If lightweight materials are used, then weight is reduced, but performance sufficiency for radar and communication systems becomes challenging
Solution Approach 1:
The patent combines excitation circuitry, microstrip transmission lines, and RF signal routing into an integrated flexible circuit assembly that directly interfaces with the antenna radiator. This merging of functions into a single lightweight flexible structure maintains adequate performance while achieving significant weight reduction compared to traditional separate heavy components.
3Reliability
If multilayer active panel array is used, then performance is improved, but device complexity and cost increase
Solution Approach 1:
The patent transitions from traditional planar multilayer PCB architectures to a three-dimensional flexible circuit configuration with folds and layers that can be stacked and folded. This dimensional change allows complex RF signal routing and excitation functions to be achieved in a compact, lower-profile structure with reduced overall complexity.
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 solution results in a lightweight, conformal, and high-performance RF antenna structure that meets the weight requirements for airship and space platforms, offering improved structural integrity and efficiency in radar and communication systems while minimizing the number of vias and traces.
Implementation Method 1
a microstrip transmission line coupled to the excitation circuitry and positioned along the folded flexible circuit substrate, where the microstrip transmission line extends across an opening of the long slot radiator
Data Source
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AI summary
Systems and methods for exciting long slot radiators of an RF antenna are provided. In one embodiment, the invention relates to a radiator transition assembly for exciting a long slot radiator of an antenna, the transition assembly including a folded flexible circuit substrate including at least two folds forming a long slot radiator, an excitation circuitry configured to generate signals for exciting the long slot radiator, and a microstrip transmission line coupled to the excitation circuitry and positioned along the folded flexible circuit substrate, where the microstrip transmission line extends across an opening of the long slot radiator.