Snap-Fit Modular Connector for Phased Array Antennas
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Additive manufacturing techniques face challenges in integrating coaxial connectors with antenna elements due to brittleness and damage susceptibility, leading to unstable and costly connections, and the inability to reuse or remove connectors.
Innovation Solution
A modular solderless connector integration system using interlocking, snap-fit connections between the antenna aperture and a ground plane layer, featuring flexible hooks and a transition assembly with conductive elements encased in dielectric material for secure and reversible attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional connectors and soldering methods are used with additively manufactured antenna structures, then electrical connection is achieved, but the brittle additively manufactured structure cannot accommodate conventional connectors and the thin metal plating cannot withstand soldering, leading to connection failure
Solution Approach 1:
The connector integration is divided into separate functional components: a connector component with mounting features, a transition assembly with conductive elements, and a ground plane component. This segmentation allows each component to be optimized independently - the connector for electrical connection, the transition assembly for mechanical coupling without soldering, and the ground plane for RF performance - resolving the contradiction between connection reliability and structural strength.
Solution Approach 2:
A transition assembly acts as an intermediary between the additively manufactured antenna elements and conventional connectors. This transition assembly includes conductive elements that provide electrical connection without requiring soldering, and mounting features that accommodate the brittle additively manufactured structure, thereby resolving the contradiction between connection stability and structural ruggedness.
2Ease of manufacture
If integrated PCBs are used to provide soldering surfaces, then connector integration becomes feasible, but the cost and complexity increase significantly
Solution Approach 1:
The ground plane component serves multiple functions simultaneously: it provides the reference plane for RF performance, incorporates mounting features for connectors, and integrates transition assemblies for electrical connection. This multi-functionality eliminates the need for separate PCB structures, reducing both cost and complexity while maintaining ease of manufacture.
Solution Approach 2:
The invention merges the ground plane, connector mounting structure, and transition assembly into an integrated component system. This consolidation eliminates the need for separate PCBs and reduces the number of assembly steps, thereby improving ease of manufacture while reducing device complexity compared to using integrated PCBs.
3Reliability
If permanent connector integration processes are used, then stable connections are achieved, but connectors and associated components cannot be removed or reused
Solution Approach 1:
The mounting features incorporate flexible hooks that can be deflected during assembly to allow insertion, then return to their original shape to provide secure retention. This dynamic mechanism enables stable connections during operation while allowing for controlled disassembly and reuse, resolving the contradiction between connection stability and reusability.
Solution Approach 2:
The snap-fit connection mechanism allows connectors and transition assemblies to be easily removed and recovered for reuse. The flexible hooks maintain secure retention during normal operation but can be deliberately disengaged, enabling component recovery and reuse without damage, thereby resolving the contradiction between connection stability and adaptability.
Data Source
AI summary
A novel, interlocking, snap-fit connection between an antenna aperture and a ground plane layer that contains coaxial connectors is described herein. The snap-fit design provides a simple and solderless transition from the connectors to elements of the antenna aperture. This design facilitates easy assembly and disassembly, allowing parts to be removed, reinstalled and/or reused.