Monolithic Antenna Feedboards via Laser Direct Structuring

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Solution Overview

Problem

Conventional base station antennas require numerous components and solder joints, leading to increased assembly time and cost, as well as potential passive intermodulation (PIM) distortion issues.

Innovation Solution

The development of monolithic radiating elements and feedboard assemblies formed by selectively depositing conductive traces on injection molded plastic frames, reducing the number of parts and solder joints, and using techniques like laser direct structuring for metallization to enhance electrical properties and reduce PIM distortion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional base station antennas use multiple separate components and solder joints for assembly, then the antenna can be constructed with traditional manufacturing methods, but the assembly time and cost increase significantly

Engineering Contradiction:

Improvemanufacturing methodVSAvoidassembly time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The patent combines multiple separate components (radiating elements, feed networks, ground planes, and support structures) into a single monolithic substrate structure. This integration eliminates the need for assembling multiple discrete parts and solder joints, directly resolving the contradiction between traditional manufacturing ease and assembly time consumption.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of manufacture

If conventional base station antennas use numerous solder joints for component assembly, then the antenna can be constructed using traditional electronics assembly, but the cost and potential PIM distortion issues increase

Engineering Contradiction:

Improveassembly methodVSAvoidPIM distortion

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The monolithic substrate structure merges all conductive elements into a single piece of material, eliminating solder joints entirely. This resolves the contradiction by maintaining manufacturing feasibility while removing the source of PIM distortion that arises from imperfect solder connections between multiple components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent removes solder joints (eliminating the harmful factor) by using a monolithic structure where conductive elements are formed as integral parts of the substrate rather than separate components requiring soldering. This converts the manufacturing challenge of creating complex shapes into a benefit by eliminating PIM distortion sources.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of manufacture

If conventional base station antennas use multiple separate components, then the antenna can be assembled using traditional methods, but the number of parts and assembly complexity increase

Engineering Contradiction:

Improveassembly processVSAvoidnumber of components

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent integrates radiating elements, feed networks, ground planes, and mechanical support structures into a single monolithic substrate, reducing the component count from multiple separate parts to one integrated structure. This directly addresses the contradiction between traditional assembly processes and the complexity introduced by numerous discrete components.

Inventive Principle:

Principle #5Merging (Combining)

4Ease of manufacture

If conventional base station antennas use traditional assembly methods with multiple components, then the antenna can be manufactured with standard processes, but the reliability decreases due to more solder joints

Engineering Contradiction:

Improvemanufacturing processVSAvoidantenna reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The monolithic substrate structure merges all functional elements into a single piece, eliminating solder joints that are potential failure points. This resolves the contradiction by maintaining manufacturability through standard substrate fabrication processes while significantly improving reliability by removing weak connections between multiple components.

Inventive Principle:

Principle #5Merging (Combining)

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 significantly reduces assembly time and cost, minimizes PIM distortion testing, and results in improved antenna performance with fewer components and enhanced reliability.

Implementation Method 1

These radiating elements and feedboard assemblies may be formed by selectively depositing conductive traces and other conductive features on injected molded plastic frames

Methodology Applied

Scientific EffectLaser direct structuring: Laser Ablation

Implementation Method 2

using techniques like laser direct structuring for metallization to enhance electrical properties

Methodology Applied

Scientific EffectSelective metallization: Physical Vapour Deposition

Data Source

PatentUS11069959B1Monolithic radiating elements and feedboard assemblies for base station antennas formed via laser direct structuring and other selective metallization techniques

Publication Date: 2021.07.20 OUTDOOR WIRELESS NETWORKS LLC

AI summary

A method of fabricating a monolithic feedboard assembly for a base station antenna, the method comprises injection molding a unitary frame that includes a feedboard section and at least one radiating element section and then selectively depositing metal on the unitary frame to form radio frequency transmission lines and radiators on the unitary frame to provide the monolithic feedboard assembly.