Waveguide Antenna Assembly With Template Alignment for Imaging Radar
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Solution Overview
Problem
Current radar systems for automotive applications face challenges in manufacturing large antennas for imaging radars, which require high resolution and detection range, due to high material and processing costs of special high-frequency substrates, signal losses, and tolerance issues leading to positional errors and phase errors.
Innovation Solution
A production process involving a template and multiple small molded parts with internal waveguides, aligned and connected to a circuit board using soldering or conductive bonding, ensuring precise positioning and low signal loss through metallized surfaces and hollow waveguides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If planar technology with special high-frequency substrates is used for antenna implementation, then antenna performance is improved, but manufacturing cost and processing complexity increase significantly
Solution Approach 1:
The antenna system is divided into separate components: a circuit board with high-frequency components and a plastic waveguide antenna assembly. This segmentation allows each component to be manufactured using optimized processes - the circuit board using standard PCB techniques and the antenna using injection molding - thereby reducing overall manufacturing complexity and cost while maintaining performance.
Solution Approach 2:
A plastic waveguide structure serves as an intermediary between the high-frequency component on the circuit board and the external environment. This waveguide mediates the electromagnetic signal transmission while allowing the use of standard, low-cost circuit board materials instead of expensive special high-frequency substrates.
2Ease of operation
If planar technology with feed lines is used, then antenna implementation is achieved, but signal losses increase which limits detection range
Solution Approach 1:
The traditional planar feed line structure is replaced with a three-dimensional waveguide structure. This substitution changes the electromagnetic field distribution and propagation characteristics, reducing signal losses by eliminating the need for long feed lines on the circuit board and providing a more efficient electromagnetic coupling path between the high-frequency component and the antenna elements.
3Length of stationary object
If multiple molded parts are used to form large antenna, then detection range and resolution are improved, but positional accuracy and phase coherence become difficult to maintain
Solution Approach 1:
Multiple molded parts are merged into a single integrated assembly that is pre-aligned and then mounted as one unit to the circuit board. This merging approach maintains the benefits of using multiple parts for achieving the required antenna aperture size while ensuring precise relative positioning through the integration process, thereby maintaining phase coherence across all antenna elements.
Solution Approach 2:
The alignment and positioning of multiple molded parts is performed in advance during the assembly process, before final mounting to the circuit board. This preliminary action ensures that all parts are precisely positioned relative to each other, establishing the correct phase relationships and geometric configurations required for high-resolution imaging radar operation.
4Ease of manufacture
If standard circuit boards are used instead of special high-frequency substrates, then manufacturing cost is reduced, but signal losses in feed lines increase
Solution Approach 1:
The plastic waveguide structure acts as an intermediary that bridges the gap between standard circuit board technology and high-performance antenna operation. It enables the use of inexpensive standard circuit boards by providing a dedicated electromagnetic transmission path that compensates for the limitations of standard PCB materials, thereby maintaining signal integrity while reducing costs.
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
Enables cost-effective and robust manufacturing of large antennas with reduced signal losses and improved angular accuracy, addressing tolerance and thermal expansion issues, thereby enhancing sensor sensitivity and reliability.
Implementation Method 1
the molded parts are aligned in a defined position relative to each other and/or to the circuit board using a template
Implementation Method 2
A radar system in which the transmission of radar signals between the at least one high-frequency component and the at least one individual antenna on the top side of the molded parts is at least partially realized by internal waveguides
Implementation Method 3
hollow waveguides are formed by a recess in the side of the molded part facing the circuit board and a metallized surface of the circuit board
Implementation Method 4
connected to the circuit board in this position, in particular by soldering, by optionally conductive bonding and/or by crimping
Data Source
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AI summary
Method for producing a radar system for environmental sensing, wherein the radar system comprises a circuit board carrying at least one high-frequency component and several molded parts, each having one or more individual antennas on its upper side for transmitting and/or receiving radar signals, characterized in that the molded parts are aligned in a defined position relative to each other and/or to the circuit board using a template and are connected to the circuit board in this position, in particular by soldering, by optionally conductive bonding and/or by crimping.