Laser-Welded Antenna Assembly With Integrated Feed Structure
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Solution Overview
Problem
Existing antenna assemblies require significant space for circuit boards and feeding lines, involve complex and costly manufacturing processes, and suffer from non-uniform soldering issues, leading to assembly defects and increased costs.
Innovation Solution
The antenna assembly is designed with radiation elements and base panels made of metal materials, using die-casting or press molding, and assembled through laser point welding, eliminating the need for separate plating and soldering processes, and incorporating signal coupling strip lines for efficient feeding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If circuit board and feeding line are installed on the rear surface of the reflector, then feeding signal can be provided to radiation elements, but the space required for installation increases
Solution Approach 1:
The patent combines the reflector and base panel into a single integrated structure, eliminating the need for separate circuit boards and feeding lines. The signal coupling strip lines are directly formed on the base panel, merging multiple components into one unified structure that reduces installation space while maintaining feeding signal transmission capability.
Solution Approach 2:
The patent extracts and eliminates unnecessary components such as the separate circuit board and complex feeding line structures. By using signal coupling strip lines directly integrated into the base panel, the design removes redundant elements that occupied excessive space while preserving the essential feeding function.
2Ease of manufacture
If manual stacking and soldering of radiation elements is performed, then assembly can be completed, but manufacturing cost increases and non-uniformity problems occur
Solution Approach 1:
The patent replaces the manual mechanical soldering process with automated laser welding. The laser welding system provides precise, automated joining of radiation elements to the base panel, eliminating manual intervention and ensuring uniform welding quality across all joints, thereby improving manufacturing precision while reducing costs through automation.
Solution Approach 2:
The patent changes the joining method from soldering to laser welding, altering the physical and chemical parameters of the connection process. This parameter change enables automated processing with consistent control over welding temperature, speed, and pressure, resulting in uniform joints without the variability inherent in manual soldering.
3Reliability
If signal coupling strip lines are installed at high position on reflector, then appropriate separation distance is maintained, but device complexity increases
Solution Approach 1:
The patent merges the signal coupling strip lines directly with the base panel structure, eliminating the need for separate support structures to maintain positioning. The strip lines are integrated into the panel itself, reducing device complexity while maintaining the necessary separation distances for stable signal transmission through optimized routing and spacing.
4Ease of manufacture
If multiple soldering points are used to connect radiation elements, then assembly can be achieved, but manufacturing cost increases and non-uniformity causes defects
Solution Approach 1:
The patent replaces the soldering process with laser welding, which provides more reliable and consistent joints. Laser welding creates uniform, controlled connections without the contamination and variability issues of soldering, reducing antenna defects while maintaining assembly feasibility through automated processing.
Solution Approach 2:
The patent changes the joining parameters from soldering temperature and flux application to laser welding parameters such as power, speed, and focal position. This parameter transformation enables precise control over the joining process, ensuring consistent quality and reducing defects caused by non-uniform soldering.
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 approach reduces costs, simplifies assembly, enhances accuracy, and enables automated manufacturing, while minimizing signal interference and phase delays, resulting in a high-gain, compact, and cost-effective antenna solution.
Implementation Method 1
assembled through laser point welding
Data Source
AI summary
The present invention relates to an antenna assembly and a manufacturing method therefor, and particularly, comprises a base panel including: at least one radiation element made of a first metal material; and a fixing member which is made of the first metal material or a second metal material that differs from the first metal material, and which spaces the radiation element from one surface thereof, and thus the advantages of reduced manufacturing costs and manufacturing time are provided.