Additively Manufactured Vivaldi Antenna for Thermal and Power Handling

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Solution Overview

Problem

Existing Vivaldi antennas face challenges in thermal management and packaging active electronics due to limited fabrication techniques, which affect their performance in high power applications and integration of low loss interconnects.

Innovation Solution

The fabrication of Vivaldi antennas using additive manufacturing processes, allowing for the creation of a single contiguous structure with integrated thermal management features and impedance matching, enabling high precision and reduced design costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If traditional fabrication techniques are used for Vivaldi antennas, then manufacturing simplicity is maintained, but thermal management capability and integration of active electronics are limited

Engineering Contradiction:

Improvethermal management capabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The patent merges the antenna structure with thermal management features and electronic component integration into a single monolithic component fabricated via additive manufacturing. The feed block contains integrated cooling channels and mounting features for active electronics, eliminating the need for separate thermal management subsystems and simplifying assembly while enhancing thermal dissipation capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The feed block serves multiple functions simultaneously: it provides the radiating aperture, contains thermal management channels for heat dissipation, provides mounting structures for active electronics, and maintains structural integrity. This multi-functionality resolves the contradiction by integrating previously separate subsystems into a single universal component.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If traditional fabrication techniques are used, then manufacturing process simplicity is maintained, but integration of low loss interconnects and active electronics is difficult

Engineering Contradiction:

Improveintegration of low loss interconnectsVSAvoidintegration complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The interconnects and active electronics are merged into the feed block structure itself. The additive manufacturing process allows direct formation of low-loss interconnect pathways within the feed block, eliminating the need for separate connection components and reducing integration complexity while improving reliability.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If additive manufacturing is used, then thermal management features and electronics integration are enhanced, but manufacturing process complexity increases

Engineering Contradiction:

Improveintegration capabilityVSAvoidfabrication complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent replaces traditional mechanical fabrication processes (CNC machining, assembly operations) with additive manufacturing technology. This substitution enables complex geometries with thermal channels and integrated electronics to be fabricated as monolithic structures in a single process, improving adaptability while the automation of additive manufacturing mitigates the increase in fabrication complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Power

If conventional fabrication methods are used, then manufacturing simplicity is maintained, but handling of high power applications is limited due to voltage breakdown

Engineering Contradiction:

Improvehigh power handling capabilityVSAvoidfabrication complexity

Core Design Contradiction:

PowerVSEase of manufacture

Solution Approach 1:

The feed block is designed as a monolithic structure that integrates the radiating elements, thermal management channels, and electrical interconnects. This merging eliminates gaps and discontinuities that would cause voltage breakdown in conventional assembled structures, enabling high power handling while the additive manufacturing process manages the fabrication complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent utilizes conductive materials with high breakdown voltage characteristics fabricated through additive manufacturing. The composite structure combines conductive pathways for high power transmission with integrated thermal management, resolving the contradiction between power handling capability and fabrication complexity.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS12469985B2Additively manufactured antenna with Vivaldi element

Publication Date: 2025.11.11 BAE SYSTEMS INFORMATION ANDELECTRONIC SYSTEMS INTEGRATION INC

AI summary

An antenna assembly includes a first flare arm, a second flare arm located adjacent to the first flare arm, a feed block having an opening therein, a feed slot extending from the opening to an outer periphery of the feed block, and a feed line integral with the feed block as a contiguous unitary component. The first flare arm and the second flare arm are symmetric about the feed block. The feed line can have a first portion integrated into the feed block and a second portion at least partially extending across the feed slot. A method of fabricating an antenna assembly includes additively manufacturing a feed block having a feed slot adjacent to a first flare arm and a second flare arm, and additively manufacturing a feed line having a first portion integral with the feed block, and a second portion at least partially extending across the feed slot.