Monolithic Phased Array Antenna for Additive Manufacturing
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Solution Overview
Problem
Phased array antennas for ultra-wide bandwidth performance are often large, costly, and time-consuming to manufacture due to the need for multiple components made from different materials, requiring complex assembly processes.
Innovation Solution
A phased array antenna design where all components, including signal ears, ground ears, and clustered pillars, are manufactured from a single piece of conductive material using additive manufacturing techniques, allowing for reduced material variety, simplified assembly, and optimized impedance matching through airgaps and capacitive coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional multi-material components are used to achieve ultra-wide bandwidth performance, then antenna performance is improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The patent merges multiple separate components (signal ear, ground ear, clustered pillars, base plate) into a single monolithic structure manufactured from one piece of conductive material. This integration eliminates the need for complex multi-material assembly while maintaining the electromagnetic performance required for ultra-wide bandwidth operation through carefully designed geometric features and airgaps.
Solution Approach 2:
The single-piece conductive structure performs multiple functions simultaneously: it provides signal transmission paths, ground connections, capacitive coupling elements, and structural support all in one component. This multi-functionality reduces the number of separate parts needed while achieving the same antenna performance characteristics.
2Adaptability or versatility
If multiple different materials are used for antenna components, then functional requirements are met, but manufacturing cost and time increase
Solution Approach 1:
The patent uses a homogeneous conductive material (such as aluminum or copper) for the entire antenna structure instead of combining multiple different materials. This homogeneity enables the use of single-process manufacturing techniques like additive manufacturing or extrusion, significantly reducing manufacturing complexity and cost while meeting all functional requirements through geometric design.
Solution Approach 2:
The patent achieves different functional properties in different regions of the antenna by varying geometric parameters (thickness, shape, spacing, airgap dimensions) rather than changing materials. For example, capacitive coupling is achieved through specific airgap dimensions and electrode geometries, while signal and ground paths are defined by conductive trace patterns, all within a single material system.
3Manufacturing precision
If complex assembly processes are used to manufacture antenna arrays, then component precision is improved, but production time and labor increase
Solution Approach 1:
While the antenna is a single piece, the design incorporates segmented functional regions (signal ears, ground ears, clustered pillars, base plate areas) that are defined during manufacturing. This allows the single-component manufacturing process to produce functionally segmented structures with precise electromagnetic characteristics without requiring post-manufacturing assembly operations.
Solution Approach 2:
The single-piece manufacturing process inherently provides self-alignment and self-assembly of all functional elements. The airgaps, capacitive coupling structures, and conductive paths are all formed in their final positions during the single manufacturing operation, eliminating the need for separate alignment and assembly steps that would increase production time and labor.
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 manufacturing costs, labor, and time while maintaining performance by enabling the use of low-cost, efficient manufacturing processes and achieving optimal impedance matching for wide bandwidth operation.
Implementation Method 1
The phased array can include a signal ear that include one or more posts that interface with an airgap located within a base plate of the array, wherein the size of the airgap in relation to the size of the post is configured to achieve an optimal level of impedance matching.
Implementation Method 2
the phased array can be further improved by being configured to include a clustered pillar to promote electromagnetic coupling between adjacent elements of the phase array
Data Source
AI summary
A low profile phased array antenna that is configured to be manufactured using additive manufacturing techniques is provided. In one or more embodiments, the phased array can include a plurality of signal ears, ground ears, and clustered pillars that can be arranged in relation to a base plate such that each component of the antenna can be manufactured from a single piece of material, thereby allowing for the use of additive manufacturing techniques which can substantially reduce the cost and time of the manufacturing process. The phased array can include a signal ear that include one or more posts that interface with an airgap located within a base plate of the array, wherein the size of the airgap in relation to the size of the post is configured to achieve an optimal level of impedance matching.