Multi-Curved Radome Patterning via Profilometer Feedback
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Solution Overview
Problem
Creating seamless frequency selective surfaces on multi-curved radomes is challenging due to the difficulty in maintaining continuous conductive patterns, especially with mechanical machining techniques that can be expensive and time-consuming, and fail to compensate for size and contour variations.
Innovation Solution
A system comprising a multiple-axis robot, patterning tool, and profilometer coupled with a computing system that measures the radome's contour, derives a pattern model, adjusts dimensions, and forms conductive or dielectric patterns using electrical simulation and lithographic processes to ensure continuous patterns on multi-curved surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mechanical machining techniques are used to create conductive patterns on radomes, then the patterns can be formed on multi-curved surfaces, but the process is expensive and time-consuming
Solution Approach 1:
The patent replaces mechanical machining techniques with a lithographic patterning process. A profilometer measures the radome surface contour, a computing system generates adjusted pattern dimensions based on the measured geometry, and a lithographic tool deposits conductive material according to the adjusted pattern. This substitution eliminates the need for expensive and slow mechanical machining while maintaining pattern accuracy on multi-curved surfaces.
2Manufacturing precision
If mechanical machining techniques are used to create conductive patterns on radomes, then the patterns can be formed, but the process is time-consuming
Solution Approach 1:
The computing system performs preliminary calculations to determine adjusted pattern dimensions before the lithographic patterning process. Based on the profilometer measurements of the radome's multi-curved geometry, the system pre-computes the exact pattern dimensions needed to achieve continuous conductive paths. This preliminary action allows the lithographic process to directly deposit material in the correct positions without time-consuming mechanical adjustments during pattern formation.
Solution Approach 2:
The patent replaces time-consuming mechanical machining with a rapid lithographic deposition process. The lithographic tool can quickly deposit conductive material according to the pre-calculated pattern dimensions, eliminating the slow mechanical material removal process while ensuring pattern continuity through precise digital control.
3Manufacturing precision
If traditional patterning methods are used, then conductive patterns can be formed on radomes, but size and contour variations cannot be compensated
Solution Approach 1:
The system uses a profilometer to measure the actual radome surface contour and dimensions, then feeds this information back to the computing system. The computing system processes the measured geometry data and generates adjusted pattern dimensions that compensate for the specific radome's size and contour variations. This feedback loop ensures that each radome receives a customized pattern design that accounts for its unique geometry, achieving both precision and adaptability.
Solution Approach 2:
The computing system dynamically adjusts the pattern dimensions as parameters based on the measured radome geometry. Instead of using fixed pattern dimensions, the system modifies the pattern parameters (such as element size, spacing, and curvature) to match the specific radome's contour and size variations. This parameter adjustment ensures continuous conductive patterns are formed regardless of manufacturing tolerances or radome variations.
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 system enables the formation of continuous patterns on radomes with adaptive dimensional scaling, enhancing electromagnetic performance and reducing unwanted detection, while being more efficient and cost-effective than traditional methods.
Implementation Method 1
a profilometer coupled with a computing system that measures the radome's contour
Implementation Method 2
forms conductive or dielectric patterns using electrical simulation and lithographic processes
Data Source
Figure 1~2B
Figure 2A
Figure 3
AI summary
According to one embodiment, a pattern forming system (10) includes a patterning tool (14), a multi-axis robot (12), a profilometer (16) and a simulation tool (26) that are coupled to a pattern forming tool (24) that is executed on a suitable computing system. The pattern forming tool (24) receives a contour measurement from the profilometer (16) and transmits the measured contour to the simulation tool (26) to model the electrical characteristics of a conductive pattern or a dielectric pattern on the measured contour. Upon receipt of the modeled characteristics, the pattern forming system (10) may adjust one or more dimensions of the pattern according to the model, and subsequently create, using the patterning tool (14), the corrected pattern on the surface.