Real-time RF Circuit Tuning via Additive Trace Deposition

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Solution Overview

Problem

Current manual methods for tuning RF and microwave electronics circuits are costly, inefficient, and prone to human error, often resulting in suboptimal or non-compliant tunings, especially in applications requiring customized impedance matching.

Innovation Solution

An automated system that measures electrical characteristics of a circuit in real-time and forms a conductive trace connected to the circuit using additive manufacturing and energy sources to adjust the electrical characteristics until they comply with selected criteria.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual tuning methods (conductive paint application, wirebond plucking, material scraping) are used to achieve individualized circuit tuning, then customization precision is improved, but manufacturing cost increases and productivity decreases

Engineering Contradiction:

Improvecircuit tuning precisionVSAvoidtuning throughput

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces manual mechanical tuning operations (paint application, wirebond plucking, material scraping) with an automated system that uses programmable control to deposit conductive material precisely at targeted locations on the circuit board, enabling high-speed automated tuning without human intervention

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system incorporates real-time measurement capabilities that automatically detect circuit performance characteristics and use this feedback to control the deposition process, enabling the system to self-adjust and optimize tuning parameters without external intervention

Inventive Principle:

Principle #25Self-service

2Manufacturing precision

If manual tuning methods are used to achieve individualized circuit tuning, then customization precision is improved, but manufacturing cost increases

Engineering Contradiction:

Improvecircuit tuning precisionVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces costly manual tuning operations with an automated system that uses programmable control and real-time measurement to achieve precise tuning at lower operational costs, eliminating labor-intensive processes while maintaining or improving precision

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system incorporates real-time measurement of circuit electrical characteristics during the tuning process, using this feedback to automatically adjust deposition parameters and achieve optimal tuning results, ensuring high precision while reducing the need for costly iterative manual adjustments

Inventive Principle:

Principle #23Feedback

3Productivity

If one-size-fits-all impedance matching solutions are used, then manufacturing cost decreases and productivity increases, but measurement precision of individual circuit characteristics deteriorates

Engineering Contradiction:

Improvetuning throughputVSAvoidcircuit characteristic accuracy

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The system measures the actual electrical characteristics of each individual circuit board in real-time during production, using this feedback to automatically adjust tuning parameters and deposit conductive material precisely where needed, ensuring each unit is optimized for its specific characteristics while maintaining high throughput

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system applies tuning adjustments locally at specific locations on each circuit board based on real-time measurement of that particular unit's characteristics, rather than applying uniform one-size-fits-all solutions, enabling individualized optimization without sacrificing productivity

Inventive Principle:

Principle #3Local quality

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 efficient, precise, and cost-effective individual tuning of RF and microwave circuits, reducing human error and enabling rapid processing of various designs or units with part-to-part variation.

Implementation Method 1

an additive manufacturing device for depositing a material to form a conductive trace on the circuit board

Methodology Applied

Scientific EffectMaterial deposition: Deposition (physical)

Implementation Method 2

wherein the material is converted to a conductive trace with application of energy

Methodology Applied

Scientific EffectThermal energy conversion: Heating

Data Source

PatentUS20250063672A1Real-time in-situ additive circuit tuning for RF/microwave electronics

Publication Date: 2025.02.20 RAYTHEON CO

AI summary

A method of tuning a circuit includes measuring an electrical characteristic of the circuit and forming, by an automated process, a conductive trace connected to the circuit to adjust the electrical characteristic of the circuit. The steps of measuring the electrical characteristic and forming the conductive trace are conducted simultaneously. The automated process involves adjusting a physical characteristic of the conductive trace in real-time in response to results of measuring the electrical characteristic of the circuit until the electrical characteristic of the circuit complies with a selected criterion.