Monolithic Phased-Array Antenna System Additive Manufacturing
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Solution Overview
Problem
Conventional phased-array antenna systems require printed circuit boards and separate balun members for signal conversion, which can complicate manufacturing and increase weight, while also limiting the ability to form monolithic structures for broadband wireless and radar applications.
Innovation Solution
A monolithic phased-array antenna system formed from a unitary conductive material using additive manufacturing, where antenna transformer elements and connectors are fabricated in a contiguous structure on a ground plane, eliminating the need for printed circuit boards and enabling conductive coupling for efficient signal propagation and impedance matching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional phased-array antenna systems use printed circuit boards and separate balun members, then signal conversion and transmission are achieved, but manufacturing complexity increases and weight increases
Solution Approach 1:
The patent combines the ground plane, antenna transformer elements, and connectors into a single monolithic structure formed from unitary conductive material. This merging eliminates the need for separate printed circuit boards and balun members, directly resolving the contradiction by reducing both manufacturing complexity and system complexity while maintaining signal conversion and transmission functions.
Solution Approach 2:
The monolithic structure serves multiple functions simultaneously: it provides the ground plane for reference potential, forms antenna transformer elements for impedance transformation and balun functionality, and includes integrated connectors for signal propagation. This multi-functionality eliminates the need for separate specialized components, addressing the contradiction by simplifying manufacturing and reducing overall system complexity.
2Weight of moving object
If conventional phased-array antenna systems use printed circuit boards and separate components, then signal transmission is achieved, but weight increases
Solution Approach 1:
By merging all conductive components into a single monolithic structure from unitary conductive material, the patent eliminates the weight of multiple separate components including printed circuit boards and balun members. The integrated structure maintains reliable signal transmission through direct conductive coupling, resolving the contradiction between weight reduction and transmission reliability.
Solution Approach 2:
The use of unitary conductive material throughout the monolithic structure provides consistent electrical properties and reliable signal transmission paths. This composite approach ensures that despite the simplified single-piece construction, the signal transmission reliability is maintained through the inherent conductive properties of the material and the direct coupling between components.
3Productivity
If additive manufacturing is used to form monolithic structures, then manufacturing efficiency improves and weight reduces, but the ability to form complex phased-array structures must be maintained
Solution Approach 1:
The patent employs additive manufacturing parameters and material properties that enable the formation of precise phased-array structures. By controlling the manufacturing parameters of the additive process, the system achieves the required structural precision for antenna element positioning and dimensions while maintaining high manufacturing efficiency through the monolithic formation process.
Data Source
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AI summary
One embodiment describes a phased-array antenna system that is formed as a monolithic structure of a unitary conductive material. The system includes a ground plane and a plurality of antenna transformer elements formed in an array and conductively coupled to a first surface of the ground plane. The system also includes a plurality of connectors formed and conductively coupled to a second surface of the ground plane opposite the first surface, the plurality of connectors being configured to propagate radio frequency signals to or from respective ones of the plurality of antenna transformer elements.