Waveguide Phased Array Antenna Mass Production
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Solution Overview
Problem
Existing antenna systems for millimeter wave communication face challenges in mass production due to the complexity and cost of assembling large arrays of radiating elements, which are time-consuming and costly, and require innovative solutions for efficient and cost-effective fabrication and assembly.
Innovation Solution
A waveguide antenna element based beam forming phased array system with a unitary body structure, where multiple radiating waveguide antenna cells are fabricated as a single piece, allowing for easier assembly and integration with substrates, and utilizing a dual-band design to support both high and low band resonant frequencies, reducing design and power costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple radiating antenna elements are soldered on a substrate during fabrication, then the antenna array can be assembled, but the total cycle time to produce an antenna array increases and manufacturing complexity increases
Solution Approach 1:
The antenna array is divided into multiple modular antenna elements that can be independently fabricated and then assembled. Each antenna element is designed as a separate unit with standardized connection interfaces, allowing parallel production and reducing the overall manufacturing cycle time compared to soldering all elements onto a substrate.
Solution Approach 2:
Multiple antenna elements are integrated onto a single substrate in a consolidated manufacturing process. The substrate serves as a common platform that mechanically and electrically connects all antenna elements, eliminating the need for separate soldering operations for each element and reducing total assembly time.
2Ease of manufacture
If multiple antenna elements are soldered on a substrate during fabrication, then the antenna array can be assembled, but the manufacturing process becomes time-consuming and complex
Solution Approach 1:
The antenna array is segmented into standardized modular elements with uniform connection interfaces. This segmentation allows for simplified assembly procedures where identical modules can be repeatedly attached using the same process, reducing the complexity of the overall assembly process.
Solution Approach 2:
The substrate is designed with universal connection features that can accommodate multiple antenna element types and configurations. Standardized mounting holes, electrical contacts, and alignment features on the substrate enable the same assembly process to be used across different antenna array designs, reducing manufacturing complexity.
3Adaptability or versatility
If large sized antenna arrays are assembled, then millimeter wave communication capability is achieved, but assembly and packaging become difficult and cost intensive
Solution Approach 1:
The large antenna array is divided into smaller modular sections that can be assembled and tested independently before final integration. This segmentation makes handling, assembly, and packaging more manageable while maintaining the overall millimeter wave communication capability of the complete array.
Solution Approach 2:
Antenna elements are designed with nested or stacked configurations where smaller components are integrated within larger structures. This nesting approach reduces the overall footprint and simplifies packaging requirements while maintaining the functionality of all antenna elements in the array.
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 solution enables cost-effective mass production of millimeter wave antenna systems with reduced assembly time and complexity, while maintaining high radiation efficiency and gain across both frequency bands, facilitating efficient millimeter wave communication.
Implementation Method 1
radiating waveguide antenna cells arranged in a certain layout for millimeter wave communication... radiating electromagnetic waves in millimeter wave frequency
Implementation Method 2
Each radiating waveguide antenna cell may further comprise a plurality of pins that may be connected with a body of a corresponding radiating waveguide antenna cell
Data Source
AI summary
An antenna system includes a first substrate, a plurality of chips, a system board having an upper and lower surface, and a beam forming phased array that includes a plurality of radiating waveguide antenna cells for millimeter wave communication. Each radiating waveguide antenna cell includes a plurality of pins where a first pin is connected with a body of a corresponding radiating waveguide antenna cell and the body corresponds to ground for the pins. A first end of the radiating waveguide antenna cells is mounted on the first substrate, where the upper surface of the system board comprises a plurality of electrically conductive connection points to connect the first end of the plurality of radiating waveguide antenna cells to the ground.