Low-Loss Antenna PCB Using Low-Cost Plastic Base Materials
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Solution Overview
Problem
The high manufacturing costs of specialized printed circuit boards (PCBs) used in microwave and antenna applications are due to stringent requirements for dielectric constant, dielectric loss tangent, and heat expansion, limiting their availability and increasing costs, while existing PCBs for consumer electronics are not suitable for satellite and microwave applications that require heat, shock, and vibration resistance.
Innovation Solution
A method for producing microwave or antenna PCBs using a low-cost, low-loss material, involving a plastic base with directly formed circuit patterns and a ground plane, along with a polarizer spacer and polarizer, connected to a PCB circuit assembly, utilizing conductive ink and 3D printing or conventional fabrication techniques to achieve the required design specifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If specialized PCBs with stringent dielectric constant and loss tangent requirements are used for microwave and antenna applications, then performance and reliability are improved, but manufacturing cost increases
Solution Approach 1:
The patent changes the material parameters by using standard FR-4 PCB material instead of specialized low-loss materials, and modifies the geometric parameters of the antenna design to achieve optimal performance with cost-effective materials
Solution Approach 2:
The patent employs inexpensive standard PCB materials and conventional manufacturing processes to create functional microwave antennas, replacing expensive specialized materials with affordable alternatives that meet performance requirements
2Reliability
If existing microwave PCBs designed for heat, shock, and vibration resistance are used, then reliability under extreme conditions is improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The patent applies local quality by designing the antenna structure to concentrate electromagnetic fields in specific regions, allowing standard PCB materials to perform adequately without requiring uniform high-performance characteristics throughout the entire PCB
Solution Approach 2:
The patent uses standard consumer-grade PCB materials that are inexpensive and readily available, replacing military-grade or specialized microwave PCBs with cost-effective alternatives suitable for consumer satellite terminal applications
3Manufacturing precision
If specialized PCBs with controlled dielectric properties are used, then antenna gain and geometry precision are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent changes the design parameters by optimizing trace widths, spacing, and antenna geometry to compensate for the less precise dielectric properties of standard PCB materials, achieving acceptable performance through geometric optimization rather than material precision
Data Source
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AI summary
An apparatus and method for producing a low loss printed circuit board (PCB). The PCB includes an antenna patch, a ground plane, and a polarizer. The antenna patch consists of a plastic base having a first plurality of circuit patterns formed directly on its top surface. The ground plane is formed directly on a bottom surface of the plastic base used for the antenna patch, and contains one or more coupling circuit patterns. A polarizer spacer is provided on the antenna patch to provide separation from the polarizer. The polarizer also consists of a second plastic base having a second plurality of circuit patterns formed directly thereon.