Slot Array Antenna Assembly Using Press-Worked Plate Structure
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Solution Overview
Problem
Conventional marine radar antennas, such as patch antennas and waveguide slot array antennas, face challenges in achieving high gain with low loss and cost-effective manufacturing, requiring high-precision processing and expensive components.
Innovation Solution
A slot array antenna design featuring a radiation plate with horn-shaped surfaces and connecting members that are removably inserted into notches on a U-shaped base plate, allowing for assembly without high-precision machining, and optionally including a grating plate for noise suppression, using metal sheets that can be press-worked for easier manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If waveguide slot array antennas are used to achieve low loss and high gain, then antenna performance is improved, but manufacturing cost and processing complexity increase due to high-precision machining requirements
Solution Approach 1:
The antenna structure is divided into separate components (radiation plate with slots, base plate, connecting members) that can be manufactured independently using standard press-working techniques, then assembled together. This segmentation allows each component to be produced with conventional manufacturing methods rather than requiring high-precision machining of the entire waveguide structure.
Solution Approach 2:
The invention replaces expensive, precision-machined waveguide components with cheaper, press-worked metal plate components. The connecting members and notches provide sufficient mechanical and electrical connection without requiring the high manufacturing precision of traditional waveguide slots and covers.
2Reliability
If rectangular waveguide with separate lid and high-precision slot machining is used, then low loss and high gain are achieved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The waveguide structure is segmented into modular components (radiation plate, base plate, connecting members) that can be manufactured using simple press-working techniques and assembled through mechanical insertion, reducing the complexity of manufacturing while maintaining the necessary electrical performance.
Solution Approach 2:
Instead of machining slots into a solid waveguide structure and then attaching a separate lid, the invention inverts the approach by forming the waveguide structure from assembled metal plates with pre-formed notches and connecting members, simplifying the manufacturing process.
3Ease of manufacture
If multiple metal plates are processed and connected with fastening elements, then ease of manufacture is improved, but device complexity increases due to multiple connection elements
Solution Approach 1:
The connecting members serve dual functions: they provide mechanical support and simultaneously act as electrical shorts for the radio waves. The notches in the base plate integrate the functions of mechanical attachment and electrical connection, eliminating the need for separate fastening elements and reducing overall device complexity.
Solution Approach 2:
The connecting members are designed to perform multiple functions: structural support, electrical connection, and electromagnetic termination (acting as shorts). This multi-functionality reduces the number of components needed and simplifies the overall assembly process.
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 design achieves a highly sensitive antenna with improved manufacturability and increased gain compared to conventional patch antennas, at a cost comparable to or less than patch antennas, while reducing manufacturing complexity and costs.
Implementation Method 1
A radiation plate 2 has a first surface 21 that has a plurality of slots 22 to radiate radio waves
Implementation Method 2
the connecting members of the radiation plate act as a short for the radio waves radiating out from the slots
Implementation Method 3
The base plate having first, second, and third surfaces that form a U-shape, and first and second notches respectively at a vicinity of ends of the base plate
Implementation Method 4
second and third surfaces that form a horn shape, and connecting members in a direction opposite to a radiating direction of the radio waves
Data Source
Figure 1
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Figure 3
AI summary
A slot array antenna (4) that includes radiation (2), base (1), and grating (3) plates is disclosed. The radiation plate (2) has a first surface (21) having multiple slots (22) to radiate radio waves, second and third surfaces (23, 24) forming a horn shape, and proximal and distal connecting members (25, 26). The base plate (1) has first, second, and third surfaces (11, 12, 13) forming a U-shape, and notches (14, 15). The connecting members (25, 26) of the radiation are removably insertable into the notches (14, 15) to assemble the slot array antenna (4) for the radiation of the radio waves and to suppress noise signals.