Alignment and constraining devices for maintaining positional optimizations between antenna array components
Dielectric inserts providing positional support for components of antenna arrays. A system includes a coaxial pin in electromagnetic communication with an antenna array, and a dielectric insert configured to provide positional support for the coaxial pin. The dielectric insert includes a shaft comprising a central hollow space defined by a wall, and further includes a plurality of fins attached to the shaft. The system is such that the dielectric insert forms an interference fit with one or more of the coaxial pin or the antenna array.
1 . A system comprising:
a coaxial pin in electromagnetic communication with an antenna array, wherein the antenna array comprises one or more nubs attached to a metal component of the antenna array that protrude from a surface of the metal component; and
a dielectric insert configured to provide positional support for the coaxial pin, wherein the dielectric insert comprises:
a shaft comprising a central hollow space defined by a wall; and
a plurality of fins attached to the shaft;
wherein the dielectric insert forms an interference fit with one or more of the coaxial pin or the antenna array; and
wherein a protuberance of the one or more nubs of the antenna array is optimized to form the interference fit between the dielectric insert and the antenna array.
2 . The system of claim 1 , wherein the wall of the shaft comprises one or more of a hollow cylindrical geometry or a hollow conical frustum geometry, and wherein an inner diameter of the wall is optimized for receiving the coaxial pin.
3 . The system of claim 1 , wherein the coaxial pin comprises a substantially cylindrical geometry; and
wherein the coaxial pin comprises one or more nubs attached to an outer wall of the substantially cylindrical geometry that protrude outward relative to the outer wall.
4 . The system of claim 3 , wherein a protuberance of the one or more nubs is optimized to form the interference fit between the dielectric insert and the coaxial pin.
5 . The system of claim 1 , further comprising a spring pin configured to be disposed around at least a portion of the coaxial pin, wherein the spring pin enables the coaxial pin to maintain electromagnetic communication with an electrically conductive pad of a circuit board.
6 . The system of claim 5 , wherein the wall of the shaft comprises one or more of a hollow cylindrical geometry or a hollow conical frustum geometry; and
wherein a diameter of the central hollow space defined by the wall is optimized for forming the interference fit between the coaxial pin and the dielectric insert.
7 . The system of claim 1 , wherein the interference fit between the dielectric insert and the antenna array is formed where a sidewall of at least one of the plurality of fins touches at least one of the one or more nubs attached to the metal component of the antenna array.
8 . The system of claim 1 , wherein the antenna array is manufactured using metal additive manufacturing techniques; and
wherein the one or more nubs of the antenna array is printed on to the metal component using the metal additive manufacturing techniques such that the antenna array and the one or more nubs of the antenna array form a single metal element.
9 . The system of claim 8 , wherein the single metal element further comprises the coaxial pin such that each of the coaxial pin, the antenna array, and the one or more nubs of the antenna array is manufactured using the metal additive manufacturing techniques such that manufacturing the single metal element does not require a separate joining process for joining separate components.
10 . The system of claim 9 , wherein the coaxial pin further comprises one or more nubs attached to a surface of the coaxial pin that protrude outward relative to an outer surface of the coaxial pin; and
wherein the single metal element further comprises the one or more nubs of the coaxial pin.
11 . The system of claim 1 , wherein the dielectric insert is manufactured of a dielectric material, and wherein each of the coaxial pin and the antenna array is manufactured of an electrically conductive material.
12 . The system of claim 1 , wherein at least one of the plurality of fins comprises a chamfered edge.
13 . The system of claim 1 , wherein the wall of the shaft comprises one or more of a hollow cylindrical geometry or a hollow conical frustum geometry; and
wherein each of the plurality of fins extends radially outward relative from the wall of the shaft.
14 . The system of claim 13 , wherein the dielectric insert comprises three or more fins attached to the shaft; and
wherein each of the three or more fins forms an interference fit with one or more components of the antenna array that is disposed around the coaxial pin.
15 . The system of claim 14 , wherein the dielectric insert is disposed within the antenna array such that a negative airspace is formed between the dielectric insert and the one or more components of the antenna array that is disposed around the coaxial pin.
16 . The system of claim 1 , wherein the coaxial pin is manufactured as a component of the antenna array utilizing metal additive manufacturing techniques;
wherein the dielectric insert is manufactured utilizing injection molding techniques with a dielectric material;
wherein the antenna array comprising the coaxial pin is manufactured separately from the dielectric insert; and
wherein the dielectric insert is releasably pressed into the antenna array to maintain optimized positioning between the coaxial pin and one or more other components of the antenna array surrounding the coaxial pin.
17 . The system of claim 1 , wherein the wall of the shaft comprises a hollow conical frustum geometry;
wherein the hollow conical frustum geometry comprises a proximal inner diameter disposed nearer to a point where the coaxial pin is attached to the antenna array;
wherein the hollow conical frustum geometry comprises a distal inner diameter disposed farther from the point where the coaxial pin is attached to the antenna array;
wherein the proximal inner diameter is greater than the distal inner diameter.
18 . The system of claim 1 , wherein the wall of the shaft comprises one or more of a hollow cylindrical geometry or a hollow conical frustum geometry;
wherein the wall of the shaft comprises a chamfered edge that broadens an inner diameter of the shaft to reduce friction between the coaxial pin and the dielectric insert when initially installing the dielectric insert within the antenna array.
19 . The system of claim 1 , wherein the antenna array comprises a conductive element, and wherein one or more of an interference fit or a slip fit is formed between the conductive element of the antenna array and an outer wall of the one of the plurality of fins.