Layered Antenna Array with Perpendicular Feed and Thermal Vias
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Solution Overview
Problem
Conventional phased array antennas face manufacturing and operational challenges when attempting to cover a wide range of frequencies, requiring multiple dedicated antenna apertures and struggling with efficient frequency coverage.
Innovation Solution
A layered antenna assembly with a planar array of elements, a feed arrangement at an angle to the plane of the elements, and thermal management via vias and solder wettings, along with a ground plane box and electrical connector blocks, allows for efficient connection and heat management, enabling broad frequency operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple dedicated antenna apertures are used to cover different frequency ranges, then frequency coverage capability is improved, but device complexity and size increase
Solution Approach 1:
The patent implements a single antenna aperture that can operate across multiple frequency ranges (L, S, C, X bands) by using frequency-selective surfaces and adjustable feed arrangements. The planar array elements and layered structure with holes allow the same physical aperture to handle different frequency bands, eliminating the need for multiple separate apertures while maintaining broad frequency coverage capability
Solution Approach 2:
The patent introduces a vertical dimension to the antenna design by stacking multiple layers with holes at different positions and orientations. This layered structure allows frequency separation in the vertical dimension, where different layers handle different frequency bands, enabling a single aperture to cover multiple frequencies without increasing horizontal footprint or overall complexity
2Ease of manufacture
If conventional assembly techniques are used for wideband phased array antennas, then manufacturing simplicity is maintained, but manufacturing precision and operational reliability deteriorate
Solution Approach 1:
The patent divides the antenna assembly into distinct modular components: planar array elements, layered structures with holes, feed arrangements, and ground plane boxes. Each module can be manufactured and tested independently, then assembled together with precise alignment features. This segmentation maintains manufacturing simplicity while improving overall precision through modular integration
Solution Approach 2:
The patent introduces intermediate connection structures including vias, solder wettings, and thermal pads that mediate between the planar array elements and feed arrangements. These intermediaries provide precise alignment and reliable electrical connections, ensuring manufacturing precision while maintaining ease of assembly through standardized connection interfaces
3Reliability
If thermal management is not integrated into the antenna structure, then structural simplicity is maintained, but temperature control and operational reliability worsen
Solution Approach 1:
The patent merges thermal management functions with the antenna's structural components by integrating thermal pads and heat dissipation paths into the existing layered structure and ground plane box. The vias and metallic layers serve dual purposes: electrical connection and thermal conduction. This integration improves thermal management effectiveness without adding separate thermal control systems or increasing overall structural complexity
Solution Approach 2:
The patent enables the antenna structure to self-manage thermal loads through its inherent metallic components and layered construction. The ground plane box and conductive layers naturally conduct heat away from active elements, and the vias provide thermal pathways without requiring external cooling systems. This self-service thermal management improves reliability while maintaining structural simplicity
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
The solution enables the phased array antenna to function across a range of frequencies, reducing weight, cost, and size while maintaining efficient thermal management and mechanical stability.
Implementation Method 1
the vias are adapted to conduct heat from the thermal pads to the contacts so as to connect the contacts electrically, via the solder wettings, to the feed arrangement
Data Source
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AI summary
An antenna assembly, comprising: a layered structure comprising a planar array of antenna elements (e.g. triangular shaped poles forming dipoles) (100); and a feed arrangement (152) perpendicular to the antenna elements; the layered structure further comprising layers (116, 114) over the planar array of antenna elements with holes (117) provided therethrough to allow the feed arrangement (152) to be connected to contacts (32) for the antenna elements. The layered structure may further comprise vias (110) provided such that heat may be applied remotely to the contacts (32) via the vias (100) to connect the contacts (32) electrically to the feed arrangement (152). Also a fixture securing the planar array of antenna elements (100) and the feed arrangement (152), the fixture comprising a ground plane box (154) comprising a ground plane and sides. Also connector blocks (311 ), with offset apertures (320), providing electrical connection and mechanical fixing.