Low-Profile Wideband Phased Array for Additive Manufacturing
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Solution Overview
Problem
Phased array antennas for ultra-wide bandwidth performance are often large, costly, and time-consuming to manufacture due to the use of multiple components made from different materials, requiring complex assembly processes.
Innovation Solution
The phased array antenna is designed with components manufactured from a single piece of conductive material, allowing for additive manufacturing and incorporating clustered pillars for electromagnetic coupling, reducing the number of materials and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional multi-material components are used to achieve ultra-wide bandwidth performance, then the antenna performance is improved, but the manufacturing cost and complexity increase
Solution Approach 1:
The patent merges multiple separate components (radiating element, ground plane, impedance matching structures) into a single integrated antenna element made from one continuous piece of conductive material. This consolidation maintains the electrical functionality required for ultra-wide bandwidth while eliminating the complexity of assembling multiple components made from different materials.
Solution Approach 2:
The single-piece conductive structure performs multiple functions simultaneously: it acts as the radiating element, provides the ground plane, and incorporates impedance matching features. This multi-functionality within a single component reduces manufacturing steps and assembly complexity while maintaining performance.
2Reliability
If multiple separate components are assembled to create the antenna array, then the desired performance is achieved, but the manufacturing time and labor cost increase
Solution Approach 1:
By combining multiple functional components into a single monolithic structure, the patent eliminates the assembly process entirely. The antenna element is manufactured as one piece using additive manufacturing, which dramatically reduces manufacturing time and labor costs compared to traditional multi-component assembly processes.
Solution Approach 2:
The additive manufacturing process allows the antenna structure to be built layer-by-layer in a single continuous operation without requiring intermediate assembly steps. The structure essentially manufactures itself through the layer-by-layer deposition process, improving productivity significantly.
3Reliability
If different materials are used for various antenna components, then the optimal performance for each component is achieved, but the number of materials and assembly steps increase
Solution Approach 1:
The patent uses a single homogeneous conductive material for the entire antenna element, including the radiating portion, ground plane, and impedance matching structures. This eliminates the need to source, process, and assemble multiple different materials, greatly simplifying the manufacturing process while maintaining performance through optimized geometry rather than material diversity.
Solution Approach 2:
While using a single base material, the patent creates functional diversity through the composite structure formed during additive manufacturing, where different regions of the same material serve different electromagnetic functions. The layered construction inherent in additive manufacturing creates effective composite behavior without requiring multiple material types.
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 approach lowers the cost and time required for manufacturing while maintaining performance by enabling efficient production of low-profile, wideband, and modular antenna arrays with improved impedance matching and electromagnetic coupling.
Implementation Method 1
the phased array can be further improved by being configured to include a clustered pillar to promote electromagnetic coupling between adjacent elements of the phase array
Implementation Method 2
the size of the airgap in relation to the size of the post is configured to achieve an optimal level of impedance matching
Data Source
AI summary
A low profile phased array antenna that is configured to be manufactured using additive manufacturing techniques is provided. In one or more embodiments, the phased array can include a plurality of signal ears, ground ears, and clustered pillars that can be arranged in relation to a base plate such that each component of the antenna can be manufactured from a single piece of material, thereby allowing for the use of additive manufacturing techniques which can substantially reduce the cost and time of the manufacturing process. The phased array can include a signal ear that include one or more posts that interface with an airgap located within a base plate of the array, wherein the size of the airgap in relation to the size of the post is configured to achieve an optimal level of impedance matching.