Modular Antenna Design Using Laser Direct Structuring

Solution Overview

Problem

Existing antenna solutions for wireless devices require customized mechanical components for each configuration, leading to high tooling costs, longer design cycles, and minimal reuse opportunities, resulting in increased labor and product costs due to the need for diverse part numbers, storage, and logistics.

Innovation Solution

A modular and low-cost antenna design featuring a cover element with a cavity, a main radiating element, and a coupling element, where a parasitic radiating element can be formed using laser direct structuring (LDS) on the cover element, allowing for modular construction and array formation with a common feed structure, reducing the need for custom connectors and cables.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If customized mechanical components are designed for each antenna configuration, then antenna performance requirements are met, but tooling costs and design cycle time increase significantly

Engineering Contradiction:

Improveantenna performanceVSAvoiddesign cycle time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The antenna system is divided into standardized modular elements that can be independently designed and manufactured. Each module contains complete antenna functionality, allowing configurations to be achieved through assembly rather than custom design, thereby reducing design cycle time while maintaining performance requirements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A universal mechanical component platform is created that can support multiple antenna configurations through standardized interfaces and mounting mechanisms. This allows the same base components to serve multiple purposes across different configurations, eliminating the need for custom-designed parts for each application.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If customized mechanical components are designed for each antenna configuration, then specific performance attributes are achieved, but manufacturing costs and complexity increase

Engineering Contradiction:

Improveelectrical performanceVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

By segmenting the antenna system into standardized modules, manufacturing complexity is reduced through repetition of proven designs. Each module can be manufactured using the same processes and tools, simplifying production planning and quality control while maintaining electrical performance through optimized module design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Electrical performance is optimized through parameter adjustments within standardized module designs rather than through custom component geometry. This allows performance tuning through configurable arrangements of standard elements, maintaining manufacturing simplicity while achieving required electrical characteristics.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If a wide array of customized designs is supported, then specific configuration requirements are met, but inventory and logistics costs increase

Engineering Contradiction:

Improveconfiguration varietyVSAvoidinventory diversity

Core Design Contradiction:

Adaptability or versatilityVSQuantity of substance

Solution Approach 1:

The antenna system is divided into standardized modular elements that can be independently designed and manufactured. Each module contains complete antenna functionality, allowing configurations to be achieved through assembly rather than custom design, thereby reducing design cycle time while maintaining performance requirements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A universal mechanical component platform is created that can support multiple antenna configurations through standardized interfaces and mounting mechanisms. This allows the same base components to serve multiple purposes across different configurations, eliminating the need for custom-designed parts for each application.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 modular design enables reusable antenna elements with adjustable gain and beam width, simplifying manufacturing and reducing costs by allowing for various configurations without custom designs, while maintaining improved RF performance and environmental robustness.

Implementation Method 1

a parasitic radiating element is formed substantially on or within the cover element; the parasitic radiating element comprises e.g., a laser direct structured (LDS) element formed on an exterior surface of the cover element

Methodology Applied

Scientific EffectLaser direct structuring (LDS): Laser Ablation

Data Source

PatentUS9979078B2Modular cell antenna apparatus and methods

Publication Date: 2018.05.22 CANTOR FITZGERALD SECURITIES

AI summary

Simple, low-cost and modular antenna apparatus and methods associated therewith. In one embodiment, a modular antenna element that can be used either alone or as a basic “building block” for larger arrays and sectorial antennas (i.e., by joining needed number of elements together) is provided. The same parts can be reused for various complete product designs, thereby advantageously reducing the need for customized parts (and the attendant disabilities associated therewith). Moreover, multiple antenna elements can be readily joined together via a common feed network (in one implementation, via the back portion of each element). The antenna gain and beam width are also adjustable through configuration of the array (and the construction of the antenna elements themselves).