Fastener-less Joint for Radar Array Lattice
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Solution Overview
Problem
Existing radar array designs require costly and labor-intensive mechanical fasteners to achieve high stiffness and strength, which increases weight and assembly costs due to the need for extensive L-brackets and fasteners at row/column interfaces, limiting the full mechanical advantage of lattice structures.
Innovation Solution
A fastener-less joint design utilizing geometrically shaped slots and projections in row and column members that interlock to form a stable lattice, allowing continuous force transfer across the depth of the joint, eliminating the need for mechanical fasteners and simplifying assembly by enabling self-fixturing during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If L-brackets and mechanical fasteners are used at row/column interfaces, then joint strength and stiffness are improved, but weight increases and assembly cost increases
Solution Approach 1:
The patent removes mechanical fasteners and L-brackets from the row/column interface, extracting the unnecessary components that add weight and cost. The slot-and-projection geometry alone provides the required structural connection, eliminating the need for separate fastening elements.
Solution Approach 2:
The patent merges the structural connection function and the fastening function into a single integrated slot-and-projection geometry. The interlocking features simultaneously provide mechanical support and structural rigidity that previously required separate L-brackets and fasteners.
2Strength
If L-brackets and mechanical fasteners are used at row/column interfaces, then joint strength and stiffness are improved, but assembly labor cost increases
Solution Approach 1:
The slot-and-projection geometry is designed to self-align and self-locate during assembly. The geometric constraints of the slot edges and projection shapes automatically guide proper positioning without requiring external fixturing or complex assembly procedures, enabling workers to simply mate the components together.
3Ease of manufacture
If slot edges are made smooth, then manufacturing is easier, but assembly alignment precision deteriorates
Solution Approach 1:
The patent employs asymmetric slot geometries where the leading edge has a different profile than the trailing edge. The leading edge features a chamfer or angled surface that guides the projection during insertion, while the trailing edge provides the final positioning constraint. This asymmetric design inherently guides alignment during assembly without requiring precision machining of the entire slot.
4Strength
If geometrically shaped slots and projections are used, then force transfer continuity is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies different geometric features to different portions of the slot: the leading edge has a chamfered or angled geometry for guidance, the intermediate portion has a tapered shape for force distribution, and the trailing portion has a constraining geometry for positioning. This localized differentiation of geometric qualities optimizes each region's function while maintaining overall simplicity.
Data Source
AI summary
An antenna array lattice design is disclosed, comprising a plurality of column and row members that interconnect using a tongue and groove feature to result in a stable lattice arrangement. Each row and column member comprises a plurality of slots configured to receive corresponding slots of opposing row or column members. The slots have surfaces that run approximately one half the length or width of the associated member. The slot surfaces have recesses machined therein, and the recesses are shaped to accept correspondingly shaped projections of the opposing row or column member. In one embodiment, the recesses are T-shaped, as are the associated projections. The slots acts as a guide for the row to column attachment during assembly, while the precise geometry of the groove design allows both tensile and compressive forces to be carried across the entire depth of the joint, thus maximizing the stiffness/weight ratio of the resulting array lattice structure.