Monolithic Spiral Antenna Feed Network for Wideband Assembly
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Solution Overview
Problem
Spiral antennas face challenges in manufacturing efficiency and maintaining wideband performance due to the difficulty in connecting a feed network with the antenna element, often requiring separate manufacturing and assembly processes, which increases the overall size of the assembly.
Innovation Solution
The integration of a feed network structure with the supporting structure of the spiral antenna assembly, formed through additive manufacturing and laser direct structuring, creating a monolithic unit that simplifies the manufacturing process and maintains wideband performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the feed network is manufactured separately on a distinct structure and then connected to the antenna element, then the manufacturing process allows for separate optimization of each component, but the overall device complexity and assembly difficulty increase
Solution Approach 1:
The patent merges the feed network and antenna element into a single integrated structure where the feed network is formed directly on the same substrate as the antenna element. This integration eliminates the need for separate manufacturing and assembly processes, reducing device complexity while maintaining manufacturing flexibility.
2Reliability
If the feed network is fed through the cavity of a cavity-backed spiral antenna, then the antenna structure provides shielding and directional radiation, but the overall size of the antenna assembly increases
Solution Approach 1:
The patent transitions from a traditional cavity-backed three-dimensional structure to a planar two-dimensional integrated structure. The feed network is embedded within the same plane as the antenna element, eliminating the need for a deep cavity and significantly reducing the overall volume while maintaining radiation performance.
3Manufacturing precision
If the antenna element is formed on a printed circuit board and the feed network is connected separately, then each component can be optimized independently, but the manufacturing efficiency decreases
Solution Approach 1:
The patent combines the antenna element and feed network into a single monolithic structure formed on the same printed circuit board using the same manufacturing processes. This integration allows both components to be manufactured simultaneously in a single production run, significantly improving productivity while maintaining the manufacturing precision of standard PCB techniques.
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
This integration simplifies the manufacturing process, reduces the complexity of assembly, and maintains the wideband performance of spiral antennas, enhancing manufacturing efficiency while ensuring the feed network projects effectively from the supporting structure.
Implementation Method 1
The supporting structure and the feed network structure may be formed by an additive manufacturing process to present an integrated unit
Implementation Method 2
the electrical components may be formed thereon by a laser direct structuring process
Implementation Method 3
a dielectric separating the first transmission line from the second transmission line
Data Source
AI summary
A spiral antenna assembly with an integrated feed network and method of manufacturing the same are disclosed. The spiral antenna assembly may comprise a supporting structure integrally formed with a feed network structure, thereby presenting a monolithic structure. A spiral antenna element may be disposed on a bottom surface or a top surface of the supporting structure. The feed network structure may comprise the feed network and project from a center of the top surface of the supporting structure. The feed network may comprise a microstrip balun architecture. The spiral antenna assembly may be formed by additively manufacturing the supporting structure and the feed network structure. A laser direct structuring process may write and activate the spiral antenna element on the supporting structure and the feed network on the feed network structure.