Multifunctional antenna array platform and manufacturing method

Abstract

The invention discloses a multifunctional antenna array platform and a manufacturing method. The multifunctional antenna array platform comprises a supporting base station made of a low-dielectric-constant material; the plurality of radiation units are distributed on the upper surface and / or the lower surface of the supporting base station in a two-dimensional periodic array form; the plurality of support structures are arranged in gap areas between the adjacent radiation units and respectively extend from the surface of the support base station to the height direction to form a gain unit for improving antenna gain and an isolation unit for inhibiting electromagnetic coupling between the adjacent radiation units; and the metallization layer is at least arranged on the surface of the supporting structure, forms a preset metallization pattern and is used for realizing at least one of electromagnetic isolation, directional diagram regulation and control or gain enhancement functions. The limitation of a traditional antenna in weight, size and performance is solved, and light weight, high performance and flexible manufacturing of an antenna array platform are achieved through three-dimensional decoupling, multifunctional integration, multi-frequency common-caliber design and process compatibility.

Description

Technical Field

[0001] This invention relates to the field of wireless communication design technology, and in particular to a multifunctional antenna array platform and its manufacturing method. Background Technology

[0002] Currently, multilayer patch antenna arrays are widely used in satellite communications, millimeter-wave radar, and high-speed wireless communications. In existing array structures, inter-element coupling and dielectric loss are the main problems affecting antenna performance. Traditional solutions include: using metal cavities or isolation walls to reduce coupling, but these are heavy and complex to manufacture; adding isolation slots or filtering structures to the PCB substrate, but this increases dielectric loss and manufacturing costs; and in some multi-frequency common-aperture antenna applications, different stacked antenna layers are often required, resulting in complex structures and severe mutual interference. Therefore, there is an urgent need for a lightweight, low-coupling, easily integrated array structure suitable for multi-frequency common-aperture applications.

[0003] To address the aforementioned technical bottlenecks, this invention researches and develops a solution for a multifunctional antenna array platform, which can significantly improve the system's integration while meeting the system's requirements for miniaturization, lightweighting, low mutual coupling, and low cost. This solution has significant theoretical and practical application value. Summary of the Invention

[0004] The purpose of this invention is to provide a multifunctional antenna array platform and manufacturing method, which solves the limitations of traditional antennas in terms of weight, size and performance. Through three-dimensional decoupling, multifunctional integration, multi-frequency common aperture design and process compatibility, the antenna array platform is made lightweight, high-performance and flexible to manufacture.

[0005] This invention provides a multifunctional antenna array platform, comprising: A support base made of a low dielectric constant material, the support base including one or more bearing surfaces for supporting radiating elements; Multiple radiating units are distributed in a two-dimensional periodic array on the upper and / or lower surfaces of the support base, and the radiating units are metallized conductive patterns directly formed on the surface of the support base. Multiple support structures are disposed in the gap region between adjacent radiating elements and extend from the surface of the support base in the height direction to form a gain unit for improving antenna gain and an isolation unit for suppressing electromagnetic coupling between adjacent radiating elements. A metallization layer is disposed at least on the surface of the support structure and forms a preset metallization pattern for realizing at least one of the functions of electromagnetic isolation, radiation pattern control, or gain enhancement.

[0006] Preferably, the gain unit is a first support structure extending upward from the upper surface of the support base, which works in conjunction with the radiating surface of the radiating unit to constrain and guide the radiation of electromagnetic waves, thereby improving the directivity and gain of the antenna.

[0007] Preferably, the first support structure is a flared, trumpet-shaped structure with the opening facing away from the support base. Alternatively, the first support structure may have a radiation enhancement pattern to improve radiation directionality or gain.

[0008] Preferably, the isolation unit is a second support structure extending downward from the lower surface of the support base, forming an electromagnetic isolation wall between adjacent radiating units to suppress the propagation of array surface waves, thereby reducing inter-array electromagnetic coupling.

[0009] Preferably, the supporting base is located on the same horizontal plane, and the multiple supporting structures between adjacent radiating units are on the same horizontal plane.

[0010] Preferably, the support base includes at least two bearing surfaces of different heights, and the radiating unit includes at least two radiators with different operating frequencies. The first frequency radiator is disposed on the first bearing surface with a first height, and the second frequency radiator is disposed on the second bearing surface with a second height, forming a multi-frequency common aperture staggered array layout. And / or, the support structure has correspondingly different extension heights to match the height of the plane where the supported radiators are located, wherein the height of the support structure of the low-frequency radiating unit is greater than the height of the support structure of the high-frequency radiating unit.

[0011] Preferably, the relative permittivity εr of the low dielectric constant is ≤6.5.

[0012] Preferably, the support base is a plane or a curved surface, and the multiple bearing surfaces are coplanar or are conformal curved surfaces.

[0013] The present invention also provides a method for manufacturing a multifunctional antenna array platform as described above, characterized by comprising the following steps: preparing a dielectric substrate comprising a support base and a support structure integrally formed by an integral molding process; performing surface metallization on a predetermined area of ​​the dielectric substrate to simultaneously form a metallization layer on the surface of the radiating element and the support structure; and performing patterning processing on the metallization layer to form the preset metallization pattern.

[0014] The present invention also provides an electronic device, characterized in that it includes the multifunctional antenna array platform as described above.

[0015] Compared with the prior art, the present invention has the following beneficial effects: This invention employs a low-dielectric-constant dielectric material as the supporting base and replaces the traditional metal cavity structure with surface metallization, significantly reducing the overall weight of the antenna while simultaneously decreasing the equivalent dielectric constant at the antenna's base. This design not only improves the antenna's radiation efficiency but also reduces structural complexity, making it suitable for weight-sensitive applications. Compared to traditional metal cavity antennas, this invention maintains performance while reducing weight by 30%-50%, and its more compact structure facilitates integration and deployment.

[0016] This invention integrates multiple functions, including electromagnetic isolation, radiation pattern control, and gain enhancement, by designing a pre-defined metallization pattern on the surface of the supporting structure. This design allows the antenna array platform to meet multiple performance requirements within a single structure, reducing the need for additional components. The flexible design of the metallization pattern (such as periodic patches and slot structures) can be adjusted according to specific application scenarios to achieve customized performance optimization, making it suitable for high-performance applications such as 5G / 6G communications and radar systems.

[0017] This invention integrates radiating elements on the upper and lower surfaces of the supporting base and on bearing surfaces at different heights, forming a multi-frequency, co-aperture, high-low staggered array layout. This design not only improves space utilization but also reduces electromagnetic interference between different frequency bands through spatial isolation, thereby enhancing the overall radiation efficiency of the antenna system. It supports multiple manufacturing processes, including injection molding, 3D printing, CNC machining, and metallized plastic (MID) technology, meeting production needs of varying scales and precision. This process compatibility reduces manufacturing costs and shortens the development cycle. Through the synergistic effect of the above design, this invention significantly improves key performance indicators such as gain, isolation, and directivity, while also achieving lightweight, miniaturization, and multi-functional integration. Compared to traditional antenna solutions, this invention can improve gain by 2-3 dB, isolation by 10-15 dB, and has a wider adjustable radiation pattern range, making it suitable for high-performance communication and sensing systems. Attached Figure Description

[0018] Figures 1a-1b This is an example diagram of a multifunctional antenna array platform structure in an embodiment of the present invention; Figure 2 This is a schematic diagram of a two-dimensional periodic array according to an embodiment of the present invention; Figure 3 This is an example diagram of a preset metallization pattern according to an embodiment of the present invention; Figure 4a -c is a planar example diagram of another multifunctional antenna array platform structure according to an embodiment of the present invention; Figure 5a -b is an example diagram of another multifunctional antenna array platform structure surface according to an embodiment of the present invention; Figure 6This is an example diagram of another multifunctional antenna array platform structure according to an embodiment of the present invention. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] The term "comprising" and its variations as used herein are open-ended inclusion, meaning "including but not limited to". The term "based on" means "at least partially based on". The term "one embodiment" means "at least one embodiment"; the term "another embodiment" means "at least one additional embodiment"; the term "some embodiments" means "at least some embodiments". Definitions of other terms will be given in the description below.

[0021] As shown in 1a-1b, embodiments of the present invention provide a multifunctional antenna array platform, including a support base 1, a radiating element 2, a support structure 3, and a metallization layer 4.

[0022] The support base 1 is made of a low dielectric constant material, such as PTFE, LCP, or ceramic-filled polymer, with a relative dielectric constant εr ≤ 6.5. The support base 1 includes one or more bearing surfaces 11 for supporting the radiating element 2. The support base 1 can be planar or curved, and multiple bearing surfaces 11 can be coplanar or conformal curved surfaces. Using a low dielectric constant (εr ≤ 6.5) material as the support base 1 significantly reduces the propagation loss of electromagnetic waves in the medium, making it particularly suitable for millimeter-wave / high-frequency scenarios. This reduces signal attenuation caused by dielectric loss, broadens the antenna's operating bandwidth, and improves the efficiency and stability of the high-frequency band.

[0023] Multiple radiating elements 2 are distributed in a two-dimensional periodic array on the upper and / or lower surface of the support base 1. The radiating elements 2 are metallized conductive patterns directly formed on the surface of the support base 1. The two-dimensional periodic array may be rectangular, hexagonal, or other two-dimensional network forms, such as... Figure 2 As shown. The radiating element 2 may include radiators with different operating frequencies, supporting multi-band operation. The radiating element 2 is a radiating structure of a microstrip patch, slot antenna, or dipole antenna.

[0024] Multiple support structures 3 are disposed in the gap region between adjacent radiating elements 2, and extend from the surface of the support base 1 in the height direction to form a gain unit 31 for improving antenna gain, i.e., the upper part of the support base 1, and an isolation unit 32 for suppressing electromagnetic coupling between adjacent radiating elements 2, i.e., the lower part of the support base 1. A metallization layer 4 is disposed at least on the surface of the support structure 3 and forms a preset metallization pattern for achieving at least one of the following functions: electromagnetic isolation, pattern modulation, or gain enhancement. The support structure 3 may be horn-shaped, columnar, stepped, etc., with a metallization layer 4 on its surface forming a preset metallization pattern such as a periodic patch or slot structure for achieving electromagnetic isolation, pattern modulation, or gain enhancement. The preset metallization pattern is one of a frequency selective surface (FSS) structure, an electromagnetic bandgap (EBG) structure, or a defective ground structure (DGS) for achieving frequency selective isolation or decoupling. Figure 3 As shown, the metallized pattern disposed on the lower part of the isolation unit 32, i.e. the support structure 3, at least covers the sidewall of the support structure 3 facing the adjacent radiation unit 2 and / or the bottom area connected to the support base, so as to form a shielding or reflection structure for the surface waves.

[0025] In this embodiment, the support structure 3 and the metallization layer 4 on its surface are configured as follows: a) In a direction perpendicular to the support base, air is provided for the radiating element 2 to reduce the equivalent dielectric constant of the antenna, thereby widening the operating bandwidth and reducing losses caused by the medium; b) On a plane parallel to the support base, an electromagnetic isolation wall is formed between adjacent radiating elements 2 by a metallization pattern disposed on the lower part of the support structure 3 to suppress the propagation of surface waves of the array, thereby reducing inter-array electromagnetic coupling; c) On the upper part of the support structure 3, by designing the sidewalls of the support structure 3 into a flared horn shape and / or providing radiation-enhancing metallization patterns, in conjunction with the radiating element 2, electromagnetic waves are constrained and guided, thereby improving the radiation directivity and gain of the antenna.

[0026] In one embodiment, the support base 1 is a suspended structure with an air cavity or a metal reflective ground pre-set below it. The air cavity is used to further reduce the equivalent dielectric constant.

[0027] In one embodiment, the gain unit 31 is a first support structure 3 extending upward from the upper surface of the support base 1, which works in conjunction with the radiating surface of the radiating unit 2 to constrain and guide the radiation of electromagnetic waves, thereby improving the directivity and gain of the antenna. The isolation unit 32 of the support structure 3 is located below and forms a continuous grounding barrier through the metallization layer 4, blocking the propagation path of the array surface waves; the periodic slot / EBG structure of the metallization layer 4 disrupts the surface current path, cuts off the electromagnetic coupling channel between units, reduces mutual coupling between adjacent units, weakens the array scanning dead zone effect, and significantly improves the signal-to-noise ratio (SNR), especially in high-density arrays.

[0028] In one embodiment, the first support structure is an outwardly flared horn-shaped structure, with the opening of the horn-shaped structure facing away from the support base 1, meaning its diameter gradually increases upward from the support base to form a horn-shaped waveguide structure for converging the radiated energy of the radiating unit 2. The flared or gradually expanding horn structure guides electromagnetic waves to focus in the normal direction, enhancing the main lobe energy density.

[0029] In another embodiment, the first support structure is provided with a radiation enhancement pattern to improve radiation directivity or gain. The radiation enhancement pattern includes phase correction stripes or fractal geometric patterns that optimize beamforming, suppress sidelobe levels, improve single-array element gain, provide better beam directivity, and enhance sidelobe suppression capabilities, making it suitable for long-distance communication or high-precision direction finding scenarios.

[0030] In one embodiment, the isolation unit 32 is a second support structure extending downward from the lower surface of the support base 1, forming an electromagnetic isolation wall between adjacent radiating units 2 to suppress the propagation of array surface waves, thereby reducing inter-array electromagnetic coupling.

[0031] In one embodiment, the supporting base 1 is located on the same horizontal plane, and multiple supporting structures 3 between adjacent radiating elements 2 are also on the same horizontal plane. As shown in Figure 1, when the bearing surface 11 is at the same height, the supporting structure 3 forms a grid-like structure in the array, dividing the supporting base on it into multiple independent suspended regions, each of which carries one or more radiating elements 2. The upper sidewall can be optionally designed as a horn flare, which works in conjunction with the radiating surface to improve the antenna directivity and gain; the lower sidewall and bottom metallized surface form isolation between elements, further suppressing the propagation of surface waves in the array and reducing inter-array coupling; the lower supporting structure 3 also provides an air medium for the radiating elements 2, effectively reducing the equivalent dielectric constant of the antenna, which helps to broaden the bandwidth while reducing electromagnetic coupling between elements.

[0032] In another embodiment, such as Figures 4a-4cAs shown, the support base 1 includes at least two bearing surfaces 11 of different heights for supporting radiators of different frequencies, so as to meet the different support height requirements of radiators of different frequencies with the same aperture. At the same time, the high and low arrangement can reduce interference between different frequency units. The radiating unit 2 includes at least two radiators with different operating frequencies, wherein the first frequency radiator 21 is disposed on the first bearing surface 11 with a first height, and the second frequency radiator 22 is disposed on the second bearing surface 11 with a second height, forming a multi-frequency common aperture high and low staggered array layout.

[0033] The support structure 3 has correspondingly different extension heights to match the height of the plane supporting the radiator. The support structure 3 for the low-frequency radiating unit 2 is taller than that for the high-frequency radiating unit 2. This can be understood as follows: when the bearing surface 11 is at different heights, the radiating unit 2 operating at a lower frequency is supported on the bearing surface 11 at a higher height, and the radiating unit 2 operating at a higher frequency is supported on the bearing surface 11 at a lower height, forming an array of multi-band radiating units 2 arranged in a staggered, common-aperture configuration. The support structure 3 located in the step regions at different heights matches the height of the corresponding step to ensure that the horn-shaped opening or radiation-enhancing pattern on its upper part maintains the optimal distance for coordinated operation with the radiating unit 2 of the corresponding frequency band.

[0034] Example 1: Planar common aperture array (integrated grid platform) like Figures 1a-1b As shown, in this embodiment, the support base 11 is a single plane, and all bearing surfaces 11 are coplanar. The radiating elements 2 are arranged in a rectangular grid array on the upper surface of the base. The support structure 3 is disposed in the gaps between the elements, forming a grid-like structure that runs through the top and bottom of the base, dividing the base into multiple independent suspended regions, each region bearing one radiating element 2.

[0035] Functional Implementation: Gain Unit 31: The support structure 3 located above the base is designed in a horn shape with metallized sidewalls. Together with the radiating patch below, it forms a quasi-horn antenna, significantly improving gain. Isolation Unit 32: The support structure 3 located below the base has fully metallized sidewalls and bottom, forming a metal isolation wall. Simultaneously, periodic slots can be etched into its sidewalls, forming an EBG structure. This dual isolation mechanism of "metal wall + EBG" can efficiently block surface waves and achieve ultra-low mutual coupling. Vertical Optimization: The space between the radiating unit 2 and the lower metal reflective ground is filled with air and the support structure 3, resulting in a low equivalent dielectric constant, wide bandwidth, and high efficiency.

[0036] Example 2: High-low interleaved multi-frequency common aperture array like Figures 4a-4cAs shown, this embodiment solves the problem that different frequency band radiating units 2 have different requirements for optimal radiation height. The support base 1 is designed with at least two bearing surfaces 11 at different heights. Structural layout: The first radiating unit 2, operating at a lower frequency (first frequency), is positioned on the higher first bearing surface due to its larger physical size. The second radiating unit 2, operating at a higher frequency (second frequency), is positioned on the lower second bearing surface due to its smaller size. This staggered layout not only provides an optimized radiation environment for units of different frequency bands, but also naturally reduces direct coupling and obstruction between units of different frequency bands by utilizing the height difference.

[0037] Support structure 3 matching: The height of support structure 3 is matched to the stepped area it is located in. The support structure 3 located in the high-frequency unit area is lower in height, while the support structure 3 located in the low-frequency unit area is higher in height. This ensures that each gain unit 31 (speaker or radiation enhancement pattern) and its corresponding radiation unit 2 are kept at the optimal distance for cooperative operation, achieving independent optimization of performance in each frequency band.

[0038] Example 3: Double-sided Radiating Array like Figure 6 As shown, this embodiment makes full use of the space of the support base 1. Radiation elements 2 are simultaneously provided on the upper and lower surfaces of the support base 11 to achieve multi-frequency broadband or high-gain characteristics.

[0039] Functionality: Multi-frequency / Broadband: The radiating units 2 on the upper and lower surfaces can operate in completely different frequency bands, enabling independent operation of the dual frequency bands and expanding the system's functionality.

[0040] High gain / specific radiation pattern: The radiating elements 2 on the upper and lower surfaces can be designed to operate in the same frequency band and achieve broadband high gain radiation through coupling; or the shape and positional relationship of the upper and lower radiating elements can be changed to achieve a special shaped radiation pattern, which is suitable for base station coverage or special point-to-point communication.

[0041] The supporting structure 3 is reused: the middle supporting base 1 and its supporting structure 3 simultaneously provide structural support, gain enhancement and isolation functions for the upper and lower radiating units 2, realizing a high degree of structural reuse and integration.

[0042] Example 4: Conformal Surface Array like Figures 5a-5bAs shown, this embodiment demonstrates the significant potential of the invention in non-planar applications. The support base 1 is a conformal curved surface consistent with the shape of the carrier. Multiple bearing surfaces 11 are also part of this conformal curved surface. The support base 1 is a curved surface, and the multiple bearing surfaces 11 are either coplanar or conformal curved surfaces. Conformal to the carrier, it does not disrupt the original aerodynamic shape, is easy to integrate, and is suitable for mobile platforms. Complex curved surface structures can be precisely manufactured using integrated molding processes (such as 3D printing). The support structure 3 extends perpendicular to the local curved surface, and the metallized pattern on it can be adaptively designed according to the curvature of the surface to compensate for the radiation pattern distortion caused by conformality, ensuring good radiation performance even in the curved surface state.

[0043] Based on the same inventive concept, this embodiment provides a method for manufacturing a multifunctional antenna array platform, comprising the following steps: preparing a dielectric substrate comprising a support base 1 and a support structure 3 integrally formed by an integral molding process such as injection molding, CNC machining, 3D printing, or a combination thereof; performing surface metallization on a predetermined area of ​​the dielectric substrate to simultaneously form a metallization layer 4 on the surfaces of the radiating element 2 and the support structure 3; and performing patterning processing on the metallization layer 4 by masking, electroplating, electroless plating, spraying, deposition, printing, or laser removal processes to form the preset metallization pattern. This method has strong process compatibility and is suitable for large-scale production and rapid prototyping.

[0044] This embodiment provides an electronic device such as a 5G terminal, vehicle radar, or satellite communication equipment, including the multi-functional antenna array platform of any of the foregoing embodiments. This electronic device, due to its lightweight and high-performance antenna array platform, significantly improves communication performance, system integration, and user experience.

[0045] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A multifunctional antenna array platform, characterized in that, include: A support base made of a low dielectric constant material, the support base including one or more bearing surfaces for supporting radiating elements; Multiple radiating units are distributed in a two-dimensional periodic array on the upper and / or lower surfaces of the support base, and the radiating units are metallized conductive patterns directly formed on the surface of the support base. Multiple support structures are disposed in the gap region between adjacent radiating elements and extend from the surface of the support base in the height direction to form a gain unit for improving antenna gain and an isolation unit for suppressing electromagnetic coupling between adjacent radiating elements. A metallization layer is disposed at least on the surface of the support structure and forms a preset metallization pattern for realizing at least one of the functions of electromagnetic isolation, radiation pattern control, or gain enhancement.

2. The multifunctional antenna array platform according to claim 1, characterized in that, The gain unit is a first support structure extending upward from the upper surface of the support base. It works in conjunction with the radiating surface of the radiating unit to constrain and guide the radiation of electromagnetic waves, thereby improving the directivity and gain of the antenna.

3. The multifunctional antenna array platform according to claim 2, characterized in that, The first support structure is a flared, trumpet-shaped structure with the opening facing away from the support base. Alternatively, the first support structure may have a radiation enhancement pattern to improve radiation directionality or gain.

4. The multifunctional antenna array platform according to claim 1, characterized in that, The isolation unit is a second support structure extending downward from the lower surface of the support base, forming an electromagnetic isolation wall between adjacent radiating units to suppress the propagation of array surface waves, thereby reducing inter-array electromagnetic coupling.

5. The multifunctional antenna array platform according to claim 1, characterized in that, The supporting base is located on the same horizontal plane, and the multiple supporting structures between adjacent radiating units are on the same horizontal plane.

6. The multifunctional antenna array platform according to claim 1, characterized in that, The supporting base includes at least two bearing surfaces of different heights, and the radiating unit includes at least two radiators with different operating frequencies. The first frequency radiator is disposed on the first bearing surface with a first height, and the second frequency radiator is disposed on the second bearing surface with a second height, forming a multi-frequency common aperture high-low staggered array layout; and / or, the supporting structure has correspondingly different extension heights to match the height of the plane where the supported radiators are located, wherein the height of the supporting structure of the low-frequency radiating unit is greater than the height of the supporting structure of the high-frequency radiating unit.

7. The multifunctional antenna array platform according to claim 1, characterized in that, The relative permittivity εr of the low dielectric constant is ≤6.

5.

8. The multifunctional antenna array platform according to claim 1, characterized in that, The supporting base is a plane or a curved surface, and multiple bearing surfaces are coplanar or multiple bearing surfaces are conformal curved surfaces.

9. A method for manufacturing a multifunctional antenna array platform as described in any one of claims 1-8, characterized in that, Includes the following steps: A medium substrate comprising a support base and a support structure integrally formed using an integral molding process is prepared. Surface metallization is performed in a predetermined area of ​​the dielectric substrate to simultaneously form a metallization layer on the surface of the radiating unit and the supporting structure; the metallization layer is patterned to form the preset metallization pattern.

10. An electronic device, characterized in that, Includes the multifunctional antenna array platform as described in any one of claims 1-9.

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