Rectangular Phased Array Module With Calibration Gaps

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Solution Overview

Problem

Conventional phased array antennas face challenges in manufacturing and assembly due to tight tolerances, especially in large arrays, where inserting calibration antennas or fasteners between closely spaced antenna modules is difficult without compromising the array's performance or requiring the removal of sub-modules, which leads to a loss of active elements.

Innovation Solution

The solution involves organizing antenna modules into a rectangular lattice pattern with rotated sub-modules, creating gaps for fasteners or calibration antennas, allowing for reduced inter-element spacing while maintaining the same number of active elements, and facilitating easy attachment to a support structure without compromising performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If antenna modules are closely spaced to reduce inter-element spacing, then array density and performance are improved, but it becomes difficult to insert calibration antennas or fasteners without removing sub-modules

Engineering Contradiction:
Improveinter-element spacingVSAvoidaccessibility for calibration
Core Design Contradiction:
Manufacturing precisionVSEase of operation

Solution Approach 1:

The antenna array is divided into multiple sub-modules that can be independently positioned. By segmenting the array into modular units with standardized interfaces, the design allows for strategic spacing between modules to accommodate calibration access while maintaining tight spacing between active elements within each module.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Calibration antennas are positioned as intermediary elements between the main antenna modules. These calibration elements serve as mediators that enable the calibration process without requiring direct access to the tightly spaced active elements, thus resolving the conflict between density and accessibility.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Ease of operation

If sub-modules are removed to access calibration antennas, then accessibility is improved, but active elements are lost and performance degrades

Engineering Contradiction:
Improveaccessibility for calibrationVSAvoidarray performance
Core Design Contradiction:
Ease of operationVSReliability

Solution Approach 1:

The design incorporates preliminary calibration access pathways and positioned calibration elements before final assembly is completed. This allows calibration to be performed during the assembly process itself, eliminating the need to remove sub-modules later and preventing loss of active elements.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The antenna array structure is designed to be self-calibrating through integrated calibration elements that are permanently positioned within the module architecture. The system performs calibration without requiring external intervention that would necessitate disassembly or removal of functional components.

Inventive Principle:
Principle #25Self-service

3Adaptability or versatility

If calibration antennas are inserted between closely spaced modules, then calibration capability is improved, but manufacturing complexity and difficulty increase

Engineering Contradiction:
Improvecalibration capabilityVSAvoidassembly difficulty
Core Design Contradiction:
Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The module interfaces are designed with universal, standardized connection points that serve dual purposes: mechanical attachment and calibration element positioning. This multi-functionality allows the same structural features to facilitate both assembly and calibration operations, reducing manufacturing complexity despite enhanced calibration capability.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Data Source

PatentUS11374314B1Rectangular module arrangement for phased array antenna calibration
Publication Date: 2022.06.28 AMAZON TECH INC
  • US11374314B1 patent drawing
  • US11374314B1 patent drawing
  • US11374314B1 patent drawing

AI summary

Technologies directed to module arrangements for phased array antenna are described. One phased array antenna structure includes an antenna module having a first even number of antenna elements and a second even number of antenna elements, each of the second even number of antenna elements being terminated to a load. The second even number is n/2, where n is a positive integer that is equal to or greater than two and is equal to the square root of the first even number. The antenna module includes multiple sub-modules each having a rectangular lattice withn2×n2+1rectangular pattern. The sub-modules form a gap at a center of the antenna module and at least one of a calibration antenna or a fastener is located in the gap.