Dual polarized patch antenna element and methods of forming antenna array including same

Abstract

Antenna apparatus includes a cup structure formed by a base, at least one peripheral wall surrounding and electrically connected to the base. Annularly distributed and segregated conductive supports are adjacent, and electrically connected to, the at least one peripheral wall. An antenna feed is disposed within the cup structure, and supported by the supports. The antenna feed includes a feed RGB having an upper feeding trace, a lower feeding trace, and a metal layer with a cross-slot formed therein, the metal layer being electrically connected to the supports. At least one patch radiator is spaced above the antenna feed and electromagnetically excited by the antenna feed to transmit and / or receive signals with dual polarization. Multiple cup structures with respective antenna feeds and patch radiators may be integrated, each forming an antenna element of an antenna array. Methods for forming the antenna array also disclosed.

Description

VS2624-WO-1 (8415-25PCT)DUAL POLARIZED PATCH ANTENNA ELEMENT AND METHODS OF FORMING ANTENNA ARRAY INCLUDING SAMETECHNICAL FIELD

[0001] This disclosure relates generally to antennas and more particularly to a dual polarized patch antenna element, an antenna array including the same, and a method of forming the antenna array.DISCUSSION OF RELATED ART

[0002] A microwave patch radiator can be electromagnetically excited by a combination of a “slot plane” (a metal plate I layer with a slot formed therein) and a feeding trace in close proximity to the slot plane. Both the feeding trace and the slot plane are radio frequency (RF) coupled to an RF front end that transmits and / or receive signals to / from the patch radiator. A ground plane is disposed below each of feeding trace and the slot plane. The combination of the slot plane, the feeding trace and the ground plane may be referred to herein interchangeably as an ’’antenna feed”, “antenna feed circuitry” or the like. The patch radiator in conjunction with the antenna feed may be referred to herein as an antenna element. A plurality of such antenna elements may be arranged linearly or in a two dimensional plane, and coupled to one another to form an antenna array.

[0003] Dual polarization, which can be circular polarization or dual linear polarization in orthogonal directions, can be realized by suitable design of the antenna feed. To this end, first and second generally orthogonal feeding traces can be used in conjunction with the slot plane in the form of a “cross-slot”. The cross-slot may have two linear slots orthogonal to and crossing each other, and two RF signals may be coupled to the two feeding traces, respectively. Circular polarization may be attained by offsetting the relative phases of the RF signals by 90 degrees.

[0004] For a wider bandwidth application, two or more patch radiators may be concentrically stacked above the feeding circuitry, and each of the patch radiators may then be designed to resonate at different respective frequencies to realize the overall wider bandwidth.VS2624-WO-1 (8415-25PCT)

[0005] The manufacturing of an antenna array of patch radiators with stringent antenna performance requirements often requires high precision machining of the antenna structures to maintain uniform inter-element spacing with tight tolerances. An ongoing need exists for ways to reduce the cost of such manufacturing. There is also a need for low cost designs to realize requisite antenna pattern specifications such as low sidelobes and uniform azimuthal radiation. The need to reduce cost is a particular concern for lightweight electronically scanned antenna arrays (e.g., phased arrays) with large numbers of antenna elements for space applications (satellites and spacecraft).SUMMARY

[0006] In an aspect of the presently disclosed technology, an antenna apparatus includes a cup structure formed by a base and at least one peripheral wall surrounding and electrically connected to the base (e.g., serving as a ground plane). Annularly distributed and segregated conductive supports are adjacent to, and electrically connected to, the at least one peripheral sidewall tied to ground. An antenna feed is disposed within the cup structure and supported by the supports. The antenna feed includes feed dielectric (e.g., of a PCB), an upper feeding trace, a lower feeding trace, and a metal layer with a cross-slot formed therein, the metal layer being electrically connected to the supports. At least one patch radiator is spaced above the antenna feed and electromagnetically excited by the antenna feed to transmit and / or receive signals with dual polarization.

[0007] Multiple cup structures with respective antenna feeds and patch radiators may be integrated, each forming an antenna element of an antenna array.

[0008] In another aspect, a method of forming an antenna array includes forming a metallic cup structure assembly of N cup structures connected to one another horizontally, where N is two or more, the N cup structures having N bases, respectively, that define a lower surface of the cup structure assembly. Each base has at least one opening. The method further includes: providing a main PCB with a horizontal profile coextensive with the cup structure assembly, and including N first RF connectors; placing the main PCB adjacent to the lower surface of the cup structure so that each ofVS2624-WO-1 (8415-25PCT)the first RF connectors protrudes through a respective one of the openings in the bases; providing N antenna element subassemblies, each including at least one patch radiator spaced above an antenna feed part that includes a cross-slot within a metal layer and a feeding trace for electromagnetically exciting the at least one patch radiator. The antenna feed part includes a second RF connector connected to the feeding trace. The method further involves attaching each of N antenna element subassemblies to a respective cup structure of the N cup structures such that each of the first RF connectors electrically connects to a corresponding one of the second RF connectors and the metal layer electrically connects to the cup structure.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The above and other aspects and features of the disclosed technology will become more apparent from the following detailed description, taken in conjunction with the accompanying drawings in which like reference numerals indicate like elements or features. Various elements of the same or similar type may be distinguished by annexing the reference label with an underscore I dash and second label that distinguishes among the same / similar elements (e.g., _1, _2), or directly annexing the reference label with a second label. However, if a given description uses only the first reference label, it is applicable to any one of the same I similar elements having the same first reference label irrespective of the second label. Elements and features may not be drawn to scale in the drawings.

[0010] FIG. 1 is an exploded view of an antenna apparatus according to an embodiment.

[0011] FIG. 2 is a perspective view of the antenna apparatus of FIG. 1 in an assembled state.

[0012] FIG. 3A is an example cross-sectional view of the assembled antenna apparatus of FIG. 2, with signal input / output connections shown schematically.

[0013] FIG. 3B is a cross-sectional view of the assembled antenna apparatus of FIG. 2 according to an embodiment, including example connections to coaxial input / output cables.VS2624-WO-1 (8415-25PCT)

[0014] FIG. 4 is a perspective view of an antenna apparatus having openings in a cup structure for weight reduction according to an embodiment.

[0015] FIG. 5A is a perspective view of an antenna apparatus having openings in an antenna feed PCB for weight reduction according to an embodiment.

[0016] FIG. 5B is a plan view of an antenna apparatus having corner cutouts in an antenna feed PCB for weight reduction according to an embodiment.

[0017] FIG. 5C is a perspective view of an antenna apparatus having openings in a patch radiator PCB for weight reduction according to an embodiment.

[0018] FIG. 6 depicts example geometric structures for patch radiators that may be included in antennas disclosed herein.

[0019] FIG. 7 is a plan view of an example antenna array including closely spaced subarray tiles according to an embodiment.

[0020] FIGS. 8A, 8B, 8C and 8D illustrate respective configurations of pairs of adjacent antenna elements within an antenna array according to an embodiment.

[0021] FIG. 9 illustrates gaps and sidewall structures between various antenna elements in an antenna array according to an embodiment.

[0022] FIG. 10 is a plan view of an example “slot plane” within the antenna apparatus of FIG. 1, depicting an example configuration of a cross-slot in an antenna feed part.

[0023] FIG. 11 is a plan view of an example antenna feed part within the antenna apparatus, depicting example configurations of upper and lower feed traces in relation to the cross-slot.

[0024] FIG. 12 is a plan view illustrating examples of upper and lower metal patches within the antenna apparatus, having perimeters configured with circumferentially spaced appendages to achieve uniform azimuthal radiation.

[0025] FIGS. 13A and 13B are each an enlarged view of a portion of the plan view of FIG. 12, each depicting a respective example of circumferential appendages of upper and lower metal patches.

[0026] FIG. 14A is a flow chart of a method for forming an antenna array according to an embodiment.VS2624-WO-1 (8415-25PCT)

[0027] FIGS. 14B to 14E are respective perspective views of interim structures formed by steps in the method of FIG. 14A.

[0028] FIGS. 14F through 14H are respective perspective views of example final antenna arrays formed by the method of FIG. 14A.

[0029] FIG. 15A is a flow chart of another method for forming an antenna array according to an embodiment.

[0030] FIGS. 15B to 15F are respective perspective views of interim structures formed by steps in the method of FIG. 15A.

[0031] FIG. 15G is a perspective view of a final antenna array formed by the method of FIG. 15A.DETAILED DESCRIPTION OF EMBODIMENTS

[0032] The following description, with reference to the accompanying drawings, is provided to assist in a comprehensive understanding of certain exemplary embodiments of the technology disclosed herein for illustrative purposes. The description includes various specific details to assist a person of ordinary skill in the art with understanding the technology, but these details are to be regarded as merely illustrative. For the purposes of simplicity and clarity, descriptions of well-known functions and constructions may be omitted when their inclusion may obscure appreciation of the technology by a person of ordinary skill in the art.

[0033] Herein, when two components are said to have “the same” dimensions, they are to be understood to the same within a manufacturing tolerance range expected by a person of ordinary skill in the art.

[0034] FIG. 1 is an exploded perspective view of an antenna apparatus, 100, according to an embodiment. FIG. 2 is a perspective view of the antenna apparatus of FIG. 1 in an assembled state. FIG. 3 is an example cross-sectional view of antenna apparatus 100 in an assembled state, with RF connections to an RF front end 79 depicted schematically. Herein, a Cartesian coordinate system will be used to describe example relative locations of the various components, where the terms “above” and “below” will be used in the context of a vertical direction corresponding to a z direction, and a horizontal plane may be described as an x-y plane in the coordinateVS2624-WO-1 (8415-25PCT)system. Antenna 100 may be described in the context of a stacked vertical structure, and a horizontal direction may be referred to as an azimuthal direction.

[0035] Referring collectively to FIGS. 1 -3, antenna apparatus 100 (interchangeably, “antenna 100”) may include a cup structure 10, an antenna feed part (“antenna feed”) 20, and at least one patch radiator spaced above the antenna feed 20. In the examples shown and described herein, the at least one patch radiator includes a lower (first) patch radiator 40 and an upper (second) patch radiator 60, where upper patch radiator 60 may serve to widen the bandwidth of antenna 100. Lower patch radiator 40 may be configured as a metal patch layer (“metal patch”) 44 printed on a lower dielectric layer 41 (and together referred to as a PCB patch radiator). Likewise, upper patch radiator 60 may be configured as a metal patch layer 64 printed on an upper dielectric layer 61. Antenna feed 20 may be embodied as an integrated structure of “feed dielectric” (i.e., at least one dielectric layer of the antenna feed), upper and lower orthogonal feedlines, a metal layer forming a “slot plane” (discussed below) and connectors connected to the upper and lower feedlines. In an embodiment, the feed dielectric is the dielectric of a multi-layer PCB, and hereafter, the integration of the feed dielectric and the metal layers of the upper and lower feedlines and the slot plane will be referred to as a multi-layer “feed PCB” 21. A subassembly 90 may be defined as including all elements of antenna 100 with the exception of cup structure 10.

[0036] Lower and upper patch radiators 40 and 60 are electromagnetically excited by antenna feed 20 to transmit and / or receive signals with dual polarization. Lower patch radiator 40 may be vertically spaced above antenna feed 20 by a spacer 30, which may be primarily air or may be composed of a dielectric material lower than that of dielectric layer 41. Likewise, upper patch radiator 60 may be vertically spaced above lower patch radiator 40 by a spacer 50, which may be primarily air or may be composed of a dielectric material lower than that of dielectric layer 41. The material used for spacers 30 and 50 may be lightweight, e.g., a closed cell foam material, to minimize the weight of antenna 100, which is a particular consideration for space applications. In an embodiment in which spacer 30 is primarily air, lower patch radiator 40 may be supported by suitable dielectric posts 32 occupying a smaller volume than the air and each attached at opposite ends thereof to PCB 21 and patch radiator 40. InVS2624-WO-1 (8415-25PCT)an embodiment in which spacer 50 is primarily air, lower upper radiator 40 may be supported by suitable dielectric posts 52 occupying a smaller volume than the air and each attached at opposite ends thereof to patch radiators 60 and 40.

[0037] Cup structure 10 may improve cross-polarization performance of antenna 100 as compared to a conventional dual polarization patch antenna, particularly when antenna 100 is used in an array for scanning the antenna beam. Cup structure 10 may include a base 11 and at least one peripheral sidewall, which in this embodiment is N sidewalls 12_1 to 12_N, where N is at least four. Base 11 is metallized and may serve as both an antenna ground plane and an electrical ground (“circuit ground”). Base 11, as well as sidewalls 12, may be composed entirely of metal such as aluminum or copper, or have just a metallized outer surface formed over interior plastic or other non-metallic material. In the embodiments illustrated herein, N=6 and sidewalls 12_1 to 12_6 have the same height and width dimensions such that antenna 100 has a hexagonal profile in the horizontal plane. (The thicknesses of the sidewalls 12 may differ from one another as discussed later.) A plurality of conductive supports 16, e.g., 16_1 to 16_N, are segregated from one another and annularly distributed adjacent to sidewalls 12. Conductive supports 16 are electrically connected to sidewalls 12 and therefore tied to electrical ground. PCB 21, spacers 30 and 50, and dielectric layers 41 and 61 may likewise have respective hexagonal profiles in the horizontal plane as illustrated, each conforming to that of cup structure 10.

[0038] Antenna feed 20 may be attached to and supported by supports 16, as shown in FIGS. 2 and 3. For example, a corner area A3 (adjoining sidewall 12_3 and sidewall 12_4) and a corner area A4 depict respective supports 16_3 and 16_4 supporting corner regions of antenna feed 20. A “slot plane” 25 within antenna feed 20, e.g., a metal layer with a slot 23 formed in a central region thereof, may be at electrical ground and electrically connected to supports 16. For example, FIG. 3 shows a screw 27 passing through slot plane 25, electrically connected to metallization 24 of PCB 21. Supports 16 may be integrally formed with sidewalls 12, e.g., using 3D printing or a mold, to form a continuous metallized structure. Alternatively, supports 16 are attached to sidewalls 12 with screws or the like. In FIG. 1, supports 16 are exemplified as shelves extending from sidewalls 12. In other embodiments, lower portions of supports 16VS2624-WO-1 (8415-25PCT)extend to base 11 (see, e.g., supports 16’ in FIGS. 14C-14D). As mentioned, supports 16 may be disposed in corners between adjacent sidewalls 12 (slot plane 25 is thereby “corner grounded”) and may have a triangular cross section in the horizontal plane. The use of segregated supports 16, rather than a continuous peripheral support for antenna feed 20, allows for facilitated manufacturing of cup structure 10.

[0039] Antenna feed 20 may include multi-layered feed PCB 21 having an upper sub-layer 21 b and a lower sub-layer 21 a separated by slot plane 25. Feed PCB 21 may further include an upper feeding trace 26 on the upper surface of upper sublayer 21 b and a generally orthogonal lower feeding trace 28 on the lower surface of lower sub-layer 21a. Slot plane 25 may be a metal layer with a cross-slot 23 formed therein, and is electrically connected to supports 16 at peripheral regions thereof. For example, a metal screw 27 may be lined with metallic paste 22 and mechanically attach PCB 21 to a corresponding support 16_4. The metallic paste 22 may create an electrical contact between metal layer 25, metallization 24 on the lower surface of PCB 21, and support 16_4. The same attachment and electrical connection technique may be used in relation to the other supports 16.

[0040] Upper and lower feeding traces 26 and 28 may each have at least a portion with a U shape, and optionally a stem connected to the U shape to provide a “tuning fork” shape described further below in connection with FIG. 11. The purpose of the two-prong “tuning fork,” i.e., a pair of transmission lines, as opposed to a single transmission line, is to excite the corresponding slot in the slot plane 25 symmetrically, as opposed to an asymmetric excitation provided by a single transmission line. The U shapes cross each other in an orthogonal manner, which is instrumental in generating the dual polarization of antenna 100. As shown in FIG. 3, feeding points at the stems of lower and upper feeding traces 28 and 26 may connect to an RF front end 79, illustrated schematically. Any suitable type of RF connectors may be used for these connections. For instance, RF front end 79 may be implemented as part of a PCB attached to the lower surface of base 11, and electrical connections to the PCB may be made through openings 13a and 13b within base 11. FIG. 3 illustrates a probe feed type connection in which an inner conductor (signal line) 74_1 originating from a transmission line 77_1 is connected to a feed point of lower feeding trace 28, while an outer (ground) conductorVS2624-WO-1 (8415-25PCT)of transmission line 77_1 is connected directly to base 11. Likewise, inner conductor 74_2 originating from a transmission line 77 _2 is connected to a feeding point of upper feeding trace 26, while the outer conductor of transmission line 77 2 is connected directly to base 11.

[0041] In other embodiments, a series of coaxial connector configurations are substituted for the probe feed. For instance, referring momentarily to FIGS. 14C and 14D, which will be discussed below in further detail, a pair of coaxial connectors 1422A and 1422B extend through openings 13A and 13B of a cup structure 10. These coaxial connectors are part of a PCB 1420, including an RF front end 79, attached to a lower surface of cup structure 10. Coaxial connectors 1442A and 1442B, which are part of antenna feed 20 in this embodiment, have inner conductors attached to the respective feeding points of upper and lower feeding traces 26 and 28. Push-on “bullet” or “barrel” connectors 1432A and 1432B may then be used to provide a mating connection between the PCB connectors 1422A, 1422B and the antenna feed connectors 1442A, 1442B, respectively.

[0042] Antenna 100 may operate as a transmission antenna and / or a receiving antenna. On transmit, when signals S1 and S2 (i.e., the same signal) from transmission lines 77_1 and 77_2 are provided to the feeding points 90° out of phase, antenna 100 operates with circular polarization. When signals S1 and S2 are provided to the feeding points in phase, antenna 100 operates with dual linear polarization.Reciprocal circular polarization or dual linear polarization operation occurs in the receive path due to reciprocity.

[0043] Lower patch metal 44 and upper patch metal 64 may each have circular profiles in the horizontal plane, with radii and associated dielectric layers 41 and 61 configured for particular objectives for resonant frequencies corresponding to each patch. For example, the radii may be the same whereas the respective dielectric constants and thicknesses of dielectric layers 41 and 61 may differ to realize different resonant frequencies for the two patch radiators 40 and 60. Alternatively, the radii may differ whereas the same dielectric constants and thicknesses are used for dielectric layers 41 and 61. As illustrated in FIG. 3, each of antenna feed 20 and lower patch radiator 40 may be disposed within cup structure 10 whereas upper patch radiator 60 isVS2624-WO-1 (8415-25PCT)disposed above cup structure 10. A principal purpose of the cup may be to keep crosspolarized radiation low when antenna 100 is part of an electronically scanned antenna array and the array scans the beam. The height of the cup structure 10 - whether it leaves the upper patch radiator 60 above or below the cup structure 10’s rim - may be a design parameter for keeping the cross-polarized radiation low. Hence, upper patch radiator 60 may be located with respect to the cup structure 10’s rim at a height that is a function of whatever combination of substrate materials, and their respective thicknesses, is used. It is noted here that in alternative configurations, as illustrated in FIG. 6, either one or both of metal patch 44 and metal patch 64 has the shape of a square patch 84 or a disc patch 94.

[0044] In alternative embodiments to those illustrated herein, a continuous peripheral sidewall, such as a cylindrical wall with a circular cross-section, is substituted for the multiple sidewalls 12_1 to 12_N.

[0045] Multiple cup structures with respective antenna feeds and patch radiators may be integrated, each forming an antenna element of an antenna array in which the antenna elements are RF coupled to one another to form one or more antenna beams with higher gain than an antenna element beam. For instance, RF front end 79 may be a part of an “analog PCB” (discussed later) that includes an RF feed network, sometimes called a distribution network or a combiner / divider network of the antenna array. RF front end 79 may further include components such as a transmit / receive (T / R) switch, impedance matching circuitry, phase shifters, amplifiers, and variable attenuators, as known in the art.

[0046] FIG. 4 is a perspective view of an antenna 100’ having openings in a cup structure for weight reduction according to an embodiment. A base 11 and / or sidewalls 12 may include openings to reduce weight, e.g., for a space application.Openings 17 in base 11 are exemplified as circular, and openings 19 in sidewalls 12 are exemplified as square, but other shapes may be substituted. The shapes, sizes, locations, spacings, and number of the openings 17 and 19 may be configured in accordance with any requisite antenna performance tradeoff (antenna performance may be reduced due to the openings).VS2624-WO-1 (8415-25PCT)

[0047] FIG. 5A is a perspective view of an antenna 100” having openings in an antenna feed PCB 21’ for weight reduction according to an embodiment. Openings 27 in an antenna feed PCB 21’ may be in peripheral regions surrounding slot 23 and upper and lower feeding traces 26 and 28. FIG. 5B is a plan view of an antenna 100’” having corner cut-outs 29 in an antenna feed PCB 21” for weight reduction according to an embodiment. FIG. 5C is a perspective view of an antenna 100ivhaving openings 67 in an upper patch radiator 60’ for weight reduction. Openings 67 may also have been formed in a lower patch radiator 40’. As in the example of FIG. 4 noted above, the shapes, spacings, sizes, locations and number of the openings within any of the PCBs and patch metal may be configured in accordance with any requisite antenna performance tradeoff. Other aspects of antennas 100’, 100”, 100’” and 100ivmay be the same as described above for antenna 100.

[0048] FIG. 7 is a plan view of an example planar antenna array 700 including closely spaced subarray tiles 710_1 to 710_4 according to an embodiment. Each tile 710 may include M contiguously arranged and peripherally attached antenna elements 100_1 to 100_M forming a unitary structure. Each antenna element 100 may have the same or approximately the same configuration as any of antennas 100, 100’ 100”, 100’” or 100ivdescribed above. Each tile 710 may form a subarray of antenna array 700 (and each tile 710 may be considered an antenna array in and of itself).Adjacent tiles 710 may be attached to one another via a suitable attachment method such as by individual attachment to a common PCB or beneath tiles 710, and / or through screw attachment between adjacent sidewalls 12 in antenna elements 100 of adjacent tiles 710 and / or through common attachment of adjacent tiles to other suitable attachment structures beneath the tiles 710. The number of antenna elements 100 per tile and the arrangement thereof, the overall planar (horizontal) profile, the number of tiles and the inter-tile arrangement, may vary from embodiment to embodiment in accordance with a desired antenna array performance, e.g., beamwidth, beam steering capability, sidelobes, etc. In the example of FIG. 7, 32 hexagonal antenna elements are arranged staggered in adjacent columns to effectively form an equally spaced lattice of connected triangles, with each point of the lattice corresponding to a central point of aVS2624-WO-1 (8415-25PCT)respective antenna element 100. Alternatively, the antenna elements 100 have a rectangular (e.g., square) or circular horizontal profile.

[0049] A feed network within an “analog PCB” (see, e.g., PCB 1420 in FIGS. 14A-14H) below each tile 700_i (i = 1 to 4) may connect to each antenna element 100_1 to 100_M of that tile 700_i. The feed network may divide a “subarray transmit signal” applied to the tile and provide a divided subarray transmit signal as an “element transmit signal” to each antenna element 100_1 to 100_M, and / or combine a plurality of “element receive signals” provided by each antenna element 100_1 to 100_M of that tile to provide a combined “subarray receive signal”. On transmit, another stage of the feed network (which may be on the same analog PCB or another analog PCB) may divide an input antenna transmit signal into the subarray transmit signals and / or combine the subarray receive signals to output a composite antenna receive signal. Phase shifters and / or amplitude attenuators / amplifiers may be variously employed within RF front ends formed in the analog PCB (e.g., 79 of FIG. 3 and / or in RF integrated circuit (RFIC) chips 1426 of FIGS. 14A-14H) to steer a beam formed by the antenna array 700.Example methods of forming tiles 710 are described later.

[0050] Some of antenna elements 100_1 to 100M of any of the tiles 710 may have sidewalls of different thicknesses with respect to one another. In addition, the antenna elements 100_1 to 100M of a tile 710 may have other slight predetermined dimensional differences in order to configure uniform inter-element spacing for all the antenna elements 100 of the overall antenna array 700. For instance, a centrally located antenna element 100A (“non-edge element”) may share sidewalls with adjacent antenna elements, whereas some sidewalls of “edge elements” 100E that are peripherally located within a tile and respectively face antenna elements of another tile, may be thicker (per antenna element, i.e., thicker than1 / 2 the thickness of a shared sidewall). For example, a shared sidewall, shared between a non-edge element and an adjacent non-edge or edge element, can have the same thickness as a “tile boundary sidewall” of an edge element, which is a sidewall that faces an edge element of another tile. For example, when there are at least seven antenna elements 100 per tile 710 (M>=7), there can be at least one non-edge element and multiple edge elements.VS2624-WO-1 (8415-25PCT)

[0051] A predetermined gap g may exist by design between adjacent tiles 710 in order to absorb the manufacturing tolerances of (1 ) the individual tiles as well as (2) the mutual integration of the tiles for the purpose of forming the antenna array 700., The design of a predetermined gap g, in conjunction with the nominal design of slight differences in dimensions of the edge elements vs. the non-edge elements, may reduce the cost of the manufacturing the overall antenna array 700 while maintaining uniform inter-element spacing in the overall antenna array 700. In practice, the overall horizontal profile of each tile 710 varies due to manufacturing tolerances, and without the provision of the designed gap g between adjacent tiles 710, high precision machining may be required to realize a requisite inter-element spacing throughout the antenna array 700. By configuring the antenna array 700 with the predetermined gap g in conjunction with the slight design differences in non-edge element vs. edge element configurations, such uniform inter-element requirements may be achieved with less precise (and less costly) machining. Sidewall thicknesses and / or PCB dimensions and / or non-uniform spacings between the feed PCB edges and adjacent sidewalls may be designed to ensure the uniform element to element spacing (“lattice spacing”) between all the antenna elements of antenna array 700, as described in detail below. However, it is desirable from a manufacturing standpoint to utilize the same dimensions for feed PCB 21 in each of antenna elements 100.

[0052] FIGS. 8A, 8B, 8C and 8D illustrate respective configurations of pairs of adjacent antenna elements within antenna array 700 according to an embodiment. Referring to FIG. 8A, an example horizontal profile of adjacent non-edge elements 100AJ and 100AJ in the same tile is shown. Non-edge elements 100AJ and 100AJ share a sidewall 12_A of respective cup structures 10. An inter-element spacing between these elements is d1, representing a distance between a center points C_i and CJ of the respective antenna elements.

[0053] Referring to FIG. 8B, an example horizontal profile of adjacent edge elements 100EJ and 100EJ of adjacent tiles is shown. Edge elements 100EJ and 100EJ have respective sidewalls 12_Ei1 and 12_Ej1 facing each other and separated by gap g. To maintain the same inter-element spacing d1 between these elements, the configuration of the cup structures 10 of these edge elements can be slightly differentVS2624-WO-1 (8415-25PCT)than that of the non-edge elements 100AJ and 100AJ (aside from not sharing a sidewall). For example, as indicated by arrow 801, sidewall 12_Ei1 is slightly closer to the center CJ of edge element 100EJ as compared to the distance between the sidewall 12_A and the center C_i of non-edge element 100AJ. Arrow 803 likewise indicates an analogous relative difference in the location of the upper sidewall 12_EJ1 with respect to the center CJ of the edge element 100E. Thus, the same interelement spacing d1 can be maintained between edge elements of adjacent tiles.

[0054] FIGS. 8C and 8D illustrate that an example feed PCB 21 of each cup structure 10 can be made slightly smaller than the associated cup structure profile to compensate for the gap g in conjunction with the sidewalls being shifted inward. This design enables the same dimensions for PCB 21 for each of the antenna elements 10 across the entire antenna array 700’s aperture, regardless of whether an antenna element 10 is an edge element or a non-edge element. For example, in FIG. 8C, non-edge elements 100AJ and 100AJ are the same as those in FIG. 8A and arranged adjacently in the same way. Likewise, in FIG. 8D, edge elements 100E and 100E are the same as those in FIG. 8C and arranged adjacently in the same way.Nevertheless, the PCBs 21 shown in each of the antenna elements 100 FIGS. 8C and 8D have the same dimensions.

[0055] FIG. 9 more clearly illustrates example relationships between edges of feed PCB 21 and the adjacent sidewalls 12 in the different types of antenna elements 100E and 100A. As shown in FIG. 9, feed PCB 21 of each of the non-edge elements is disposed symmetrically with respect to the sidewalls 12 thereof. On the other hand, the PCB 21 of each of the edge elements 100E such as 100E may have a first edge 21_ed facing a first sidewall 12_Ei 1, and an opposite second edge facing a second sidewall 12_Ei2 that is adjacent to the gap g. Here, a distance between the first edge 21_ed and the first sidewall 12_Ei 1 is greater than a distance between the second edge and the second sidewall 12_Ei2. In the non-edge element 100AJ within region K, each of sidewalls 12 may be shared with an adjacent edge element 100E or non-edge element 100A. In non-edge element 100AJ, only sidewalls 12 that are not adjacent to a gap may be shared with an adjacent antenna element 100.VS2624-WO-1 (8415-25PCT)

[0056] FIG. 10 is a plan view (from a distant point along the vertical (z) axis) of an example slot plane 25 within the antenna apparatus 100 of FIG. 1, depicting an example configuration of a cross-slot 23 in antenna feed 20. Cross-slot 23 may include a first slot 23a extending in a first direction (x) and a second slot 23b of an equal length crossing first slot 23a and extending in a second, orthogonal direction (y). A central point C at which the first and second slots 23a, 23b cross may be vertically aligned with a center of base 11 of cup structure 10. Thus, cross-slot 23 of FIG. 10 has quadrant symmetry and is centered within the symmetrically hexagonal profile of cup structure 10. Due to the equal length slots and their midpoints crossing, cross-slot 23 of FIG. 11 also has quadrant symmetry.

[0057] FIG. 11 is a plan view (from a distant point along the vertical (z) axis) of an example antenna feed 20 within antenna apparatus 100, depicting example configurations of upper and lower feed traces 26 and 28 in relation to the cross-slot 23. As illustrated, each of the feed traces 26 and 28 has a longitudinal geometry that is asymmetric with respect to the sidewalls 12 of the cup structure 10. Because cross-slot 23 has quadrant symmetry, cup structure 10 has a symmetrically hexagonal profile, and each of the upper and lower feed traces 26 and 28 is asymmetric with respect to cup structure 10, antenna element 100 may not radiate equally in all azimuthal (horizontal) directions - particularly when the antenna is used in an array to scan the antenna beam -- if patch radiators 40 and 60 are symmetrical in the horizontal plane about the center C of cup structure 10. A solution that allows for equal radiation in all azimuthal directions is presented below.

[0058] In more detail, upper feeding trace 26 may include a first longitudinal U-shaped trace (arm lengths longer than the spacing between arms) having an upper base 26c, a first arm 26a and a second arm 26b of equal lengths L2. The first and second arms 26a and 26b each extend in the x direction and have respective proximal ends 26a2 and 26b2 connected to one another by upper base 26c. A stem portion 26s may have a first end connected to the central region of upper base 26c. An RF feed point of upper feed trace 26 may be at an opposite end of stem portion 26s opposite the first end. Lower feeding trace 28 includes a second longitudinal U-shaped trace a lower base 28c, a third arm 28a and a fourth arm 28b of equal lengths L1. ThirdVS2624-WO-1 (8415-25PCT)and fourth arms 28a, 28b each extend in the y direction and have respective proximal ends 28a2, 28b2 connected to one another by lower base 28c. A stem portion 28s may have a first end connected to the central region of upper base 28c. Lower base 28c and upper base 26c may be connected to receive and / or transmit (e.g., through connectors attached to stems 28s and 26s) the first RF signal S1 and the second RF signal S2, respectively. The first and second U-shaped traces may cross each other over the center of the base 11 of cup structure 10. Each of the first, second, third and fourth arms 26a, 26b, 28a, 28b has a respective distal end 26a1, 26b1, 28a1, 28b1 that is closer, in the horizontal plane, to a point in the horizontal plane that is vertically aligned with the center of the cup structure 10, as compared to distance between the respective proximal end thereof to that point in the horizontal plane. Explained another way, each of the longitudinal U shapes of the upper and lower feedlines 26 and 28 is asymmetric with respect to the geometry of cup structure 10.

[0059] FIG. 12 is a plan view illustrating example horizontal profiles of upper and lower metal patches of patch radiators 60 and 40, which are configured in conjunction with the configuration of antenna feed 20 and cup structure 10 described above to realize symmetrical azimuthal radiation. To this end, an upper metal patch 64’ of upper patch radiator 60 and a lower metal patch 44’ of lower patch radiator 40 may each have an approximately circular profile, but with slight asymmetry by adding circumferentially spaced appendages. The addition of such appendages at strategic locations serves to compensate for the asymmetric azimuthal radiation that would otherwise occur if “purely circular” metal patches (e.g., perfectly circularly but within expected manufacturing tolerances) were to be employed.

[0060] FIGS. 13A and 13B are each an enlarged view of a portion of the plan view of FIG. 12, each depicting a respective example of circumferential appendages of the upper and lower metal patches. In the example of FIG. 13A, an appendage has a peak radial protrusion (and a peak “depth”) at a central portion of the appendage, and in FIG.13B, an appendage has a peak radial protrusion at a peripheral portion (a “wing region”) of the appendage.

[0061] Referring to FIGS. 12, 13A and 13B, lower metal patch 44’ may have an approximately circular profile in the horizontal plane with a first wavy perimeterVS2624-WO-1 (8415-25PCT)including M first appendages G 1 _1 to G1_M annularly alternating with first valleys V1. First valleys V1 may be alternating portions of a first reference circular profile of an otherwise purely circular metal patch with a radius R1 (having normal manufacturing tolerance variations about the circumference). Thus, with respect to a center point C of the first reference circular profile, first appendages G1 include points with radial distances DG1 longer than radius R1. First appendages G1 may each have an arc length LG1 (a running distance along a curve beginning at a first end point beginning separation from a valley point and ending at an opposite end point), and first valleys V1 may each have an arc length LV1.

[0062] Upper metal patch 64’ may have an approximately circular profile in the horizontal plane, concentric with respect to the lower metal patch 44’ and thus having the same center point C in the horizontal plane. Upper metal patch 64’ may have a second wavy perimeter including second appendages G2 annularly alternating with second valleys V2. Second valleys V2 may be alternating portions of a second reference circular profile of an otherwise purely circular metal patch with a radius R2. Thus, with respect to the center C, first appendages G1 include points with radial distances DG2 longer than radius R2. Second appendages G2 may each have an arc length LG2, and second valleys V2 may each have an arc length LV2.

[0063] As illustrated in FIG. 13A, any appendage G1 and / or G2 may each gradually bulge from the corresponding first and second reference circular profiles. Alternatively, as illustrated in FIG. 13B, any appendage G1 and / or G2 may each sharply bulge from the circular profile (corresponding to the adjacent valley) at the peripheral regions, i.e., wing regions WG, and may have a linear or approximately linear central section connecting the wing regions WG. A distance DG1 is a horizontal, radial distance between a furthest point PG1 of any appendage G1 with respect to center point C in the horizontal plane (e.g., in the central region in the example of FIG. 13A or in a wing region WG in FIG. 13B along a radial direction 137). DG2 is a horizontal distance between a furthest point PG2 of any appendage G2 with respect to center point C in the horizontal plane. A peak appendage distance D2=DG2-R2 for the “central bulge” example may be a distance defined from point PG2 to the closest point of the second reference circular profile. (Note that appendage G2 is shown in FIG. 13B with a centralVS2624-WO-1 (8415-25PCT)peak but may be shaped with wing regions WG similar to that of appendage G1 of FIG.13B in other examples.) When an appendage is shaped with wing regions WG and with a generally linear central region (a “linear line”) such as appendage G1 in FIG. 13B, a distance D3 may be defined as a shortest distance between a path orthogonal to the linear line and touching the circumference of the reference circular profile.

[0064] To optimize the uniformity in azimuthal radiation of the overall antenna 100, the appendages G1 and G2 of the two metal patches may be mutually interleaved. Thus, each appendage G1 of lower metal patch 44’ may be radially aligned with a valley V2 of upper metal patch 64’. Therefore, a line drawn in a radial direction from center point C to a middle point of any first appendage G1 may intersect a middle point of a valley V2. Likewise, a line drawn in a radial direction from center point C to a middle point given furthest point PG2 of any second appendage G2 may intersect a middle point of a valley V1.

[0065] As an example, there are 12 first appendages G1 (M=12) in lower metal patch 44’, spaced 30° from one another in a polar coordinate system centered at center point C, and 12 second appendages G2 (M=12) in upper metal patch 64’ spaced 30° from one another. Thus, for the mutual interleaving implementation, the centers of appendages G1 may be aligned at 0°, 30°, 60°,... whereas the centers of appendages G2 may be aligned at 15°, 45°, 75°,....

[0066] In an example, the perimeter of the lower metal patch 44’ and / or the perimeter of the upper patch 66’ is irregular.in this case, the depths D1 and / or D3 of first appendages G1 throughout the perimeter of patch 44’ are non-uniform, and / or the arc lengths LG1 throughout the perimeter of patch 44’ are non-uniform. For example, distance D3 of appendage G 1 _1 is longer or shorter than distance D3 of appendage G1_M. For example, the 12 depths D1 and / or D3 and the 12 arc lengths LG1 of the respective 12 appendages G1 may each be varied as a tuning parameter for realizing a desired uniform azimuthal radiation and / or another antenna radiation pattern (“antenna pattern”) characteristic. Likewise, the 12 depths D2 and / or D3 and the 12 arc lengths LG2 of the respective 12 appendages G2 may each be varied as tuning parameters for realizing the desired uniform azimuthal radiation and / or another antenna pattern characteristic. In general, the depths D1 and / or D3 and D2 and arc lengths LG1 andVS2624-WO-1 (8415-25PCT)LG2 may be tailored to compensate for the asymmetries of the cup structure 10, the crossed-slot 23 and the upper and lower feeding traces 26 and 28. A simulation may be run and / or empirical measurements may be taken in which lower and upper patches 44’ and 64’ are initially set with uniform appendages G1 and / or G2 and valleys V1 and / or V2, and an initial antenna pattern for the overall antenna array is calculated or measured. Thereafter, slight variations are made to the dimensions of one or more appendages or valleys at a time, and the antenna pattern is re-calculated or remeasured. The process may be repeated until a requisite or desired antenna pattern is realized. Some example ranges in the example configurations of FIG. 13B, when all appendages G1 and G2 have wing regions WG are: D3 (of G1 or G2)=(0 - 0.035)(R1 or R2, respectively); LG1=(0.25 - 0.48)R1; LG2=(0.25-0.48)R2.

[0067] As mentioned earlier, it is desirable for upper and lower patch radiators 60 and 40 to resonate at different frequencies so that the overall bandwidth of antenna 100 is widened. The different frequencies of resonance can be achieved by designing the upper and lower patches with different respective diameters and with the same dielectric constants and thicknesses used for the associated dielectric layers 61 and 41. In the above-described example of FIGS. 10-13B, lower metal patch 44’ is shown and described as having a larger diameter than upper metal patch 64’. In other embodiments, lower metal patch 44 or 44’ has a smaller diameter than upper metal patch 64 or 64’. In still other embodiments, lower and upper metal patches 44 or 44’ and 64 or 64’ have the same diameters, but the dielectric layers 61 and 41 have different dielectric constants and / or thicknesses so that the composite upper and lower patch radiators resonate at the desired different respective frequencies.

[0068] FIG. 14A is a flow chart of a method 1400 for forming an antenna array according to an embodiment. FIGS. 14B-14H are perspective views of example interim structures formed at various stages of method 1400. Method 1400 will be described in the context of forming a single tile, such as tile 710 described above, which may be a stand-alone antenna array or a subarray in a larger array.

[0069] Referring to FIGS. 14A-14C, step S140 involves forming a unitary metallic cup structure assembly 1410 of N cup structures 10_1 to 10_N connected to one other horizontally in a coplanar fashion. For example, adjacent cup structures 10VS2624-WO-1 (8415-25PCT)that are used to form “non-edge” antenna elements 100A discussed above may share sidewalls 12 with adjacent cup structures 10. For example, any of the cup structures 10 that is directly connected mechanically to an adjacent cup structure via a sidewall may be so connected via a shared sidewall 12. Cup structure assembly 1410 may be formed by 3D printing or in a mold, and may be composed entirely of metal material such as aluminum or copper, or may be formed with internal plastic, ceramic, etc. but with metallic plating applied to the outer surfaces. The N cup structures may be formed with N respective bases 11 that define a lower surface 1415 of cup structure assembly 1410. Each base 11 has at least one opening, e.g., openings 13A and 13B (see FIG. 14C). As shown in FIG. 14C, supports 16’ for supporting an antenna feed 20 are exemplified as “bench type supports” with lower portions extending to base 11, rather than the shelve-like supports illustrated in FIG. 3.

[0070] Step S142 involves forming a first PCB 1420 with a horizontal profile that may be coextensive with cup structure assembly 1410, and including at least N first RF connectors, e.g., N connectors 1422A and N connectors 1422B. First PCB 1420 may be referred to as an “analog PCB” because it may include a feed network in the form of microstrip, stripline or coplanar waveguide for routing RF signals (e.g., at HF, microwave or millimeter wave frequencies) to and from antenna elements 100. Analog PCB 1420 may further include RF front end components such as impedance matching circuitry, phase shifters, amplifiers, T / R switches, etc. conventionally used in phased arrays.

[0071] At step S144, the analog PCB 1420 is attached to the lower surface 1415 of the cup structure assembly with each of the first RF connectors 1422A, 1422B protruding through a respective one of the openings 13A, 13B in the bases 11. The attachment may be accomplished in conjunction with alignment features, e.g., temporary pins and alignment holes, on PCB 1420 and cup structure assembly 1410. The attachment may include the use of mechanical fasteners, e.g., screws, and / or adhesive bonding.

[0072] FIG. 14C also illustrates that a support 16'-4 may be formed with a vertically oriented channel at its inner surface so that opening 13B may be locatedVS2624-WO-1 (8415-25PCT)directly under the channel and first RF connector 1422B can be inserted into the channel.

[0073] Referring to FIGS. 14A to 14E, at step S146, N antenna element subassemblies 90__1 to 90 N are formed, where each may include all the components of an antenna element 100 described above except for the cup structure 10. These components may be preassembled in a stacked structure to form a subassembly 90. In addition, the antenna feed 20 of each subassembly 90 has a pair of second RF connectors 1442A and 1442B, attached to respective feed traces 26 or 28, and protruding from the lower surface of antenna feed 20. At step S148, each of the N antenna element subassemblies 90__1 to 90__N is individually attached to a respective cup structure 10_1 to 10_N within cup structure assembly 1410. The attachment is made such that the second RF connectors 1442A, 1442B electrically connect to corresponding first RF connectors 1422A, 1422B and the metal layer (slot plane) 25 of antenna feed 20 electrically connects to the cup structure 10. For instance, connectors 1422A, 1422B, 1442A, 1442B can each be male connectors, and push-type bullet adapters 1432A, 1432B (with female to female sockets) may be first connected to connectors 1422A and 1422B. Thereafter, an antenna subassembly 90 may be inserted within the cup structure 10 and as it is inserted, the male pins of connectors 1422A and 1422B may be pushed into the bullet. Attachment of each subassembly 90 may also involve the use of conducting epoxy adhesive in each comer, adhering the upper surface of each support 16 to the lower surface of antenna feed 20.

[0074] FIGS. 14F, 14G and 14H are respective perspective views of a completed tile 710 i (i - any integer) as an example antenna array formed by method 1400. FIG. 14H illustrates that PCB 1420 may include attached RF chips 1426, each including one or more RF front end components such as an amplifier or a phase shifter.

[0075] FIG. 15A is a flow chart of another method 1500 for forming an antenna array according to an embodiment. FIGS. 15B to 15F are respective perspective views of interim structures formed by steps in method 1500, and FIG. 15G is a perspective view of a final antenna array formed by method 1500. Referring collectively to FIGS. 15A-15G, at method step S1510, N antenna element subarrays 90 as described above are formed. At S1520, each of N antenna elements 101 are formed,VS2624-WO-1 (8415-25PCT)each of which is functionally equivalent to an antenna element 100 described above. Antenna element 101 differs from antenna element 100 by substituting a wrapped metal foil 96 for a cup structure 10. Thus, an antenna element 101 may be formed, as illustrated in FIG. 15B, by placing an antenna subassembly 90 over a sheet of metal foil 96, and then folding and wrapping the foil about the sides of antenna subassembly 90, as illustrated by arrows WR. As illustrated in FIG. 15C, metal foil 96 may have openings through which second connectors 1442A, 1442B extending from antenna feed 20 may protrude, which connectors may be connected to bullets or barrels 1432A, 1432B. FIG.15D shows a perspective side view of a completed antenna assembly 101 whereas FIG. 15E is a perspective view of an assembled antenna element 101 showing an example bottom structure with protruding first connectors 1442 and bullets I barrels 1432.

[0076] At step 1530, an analog PCB 1420 as described above is formed and provided as illustrated in FIG. 15F. Lastly, at step S1540, each of the N antenna element assemblies 90 is attached to the analog PCB 1420. The attachment may involve connecting the first RF connectors 1422A, 1422B of analog PCB 1420 to the second RF connectors 1442, and mechanically fastening and / or chemically adhering each individual antenna subassembly 90 to PCB 1420 with conductive epoxy. An example completed antenna array 1501 in the form of a tile formed by method 1500 is shown in FIG. 15G.

[0077] While the technology described herein has been particularly shown and described with reference to example embodiments thereof, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the claimed subject matter as defined by the following claims and their equivalents.

Claims

VS2624-WO-1 (8415-25PCT)CLAIMS1. An antenna apparatus (100, 700) comprising:a cup structure (10) formed by a base (11 ) and at least one peripheral sidewall (12) surrounding and electrically connected to the base;a plurality of annularly distributed and segregated conductive supports (16) adjacent to and electrically connected to the at least one peripheral sidewall;an antenna feed (20) within the cup structure, supported by the supports and comprising an integration of feed dielectric (21), an upper feeding trace (26), a lower feeding trace (28), and a metal layer (25) with a cross-slot (23) formed therein, the metal layer being electrically connected to the supports; andat least one patch radiator (40) above the antenna feed and electromagnetically excited by the antenna feed.

2. The antenna apparatus (100, 700) of claim 1, wherein the at least one peripheral sidewall comprises at least four sidewalls (12_1 to 12_N).

3. The antenna apparatus (100, 700) of claim 2, wherein the at least four sidewalls are six sidewalls (12_1 to 12_6) that form the cup structure with a hexagonal profile in a horizontal plane.

4. The antenna apparatus (100, 700) of claim 2, wherein each of the supports (16) is attached to or integrally formed with the at least four sidewalls in a respective corner area formed by two adjoining sidewalls of the at least four sidewalls.

5. The antenna apparatus (100, 700) of claim 4, wherein each of the supports has a triangular profile in a horizontal plane.

6. The antenna apparatus (100, 700) of claim 1, wherein the metal layer is between the upper feeding trace and the lower feeding trace.VS2624-WO-1 (8415-25PCT)7. The antenna apparatus (100, 700) of claim 1, wherein the at least one patch radiator comprises:a lower patch radiator (44) within the cup structure, integrated with a lower patch PCB (41); andan upper patch radiator (64) above the lower patch radiator and integrated with an upper patch PCB (61).

8. The antenna apparatus (100, 700) of claim 7, wherein:the lower patch radiator is separated from the antenna feed by a space (30) comprised of: (i) primarily air; or (ii) a material having a lower dielectric constant than that of the lower patch PCB; andthe upper patch radiator is separated from the lower patch radiator by a space (50) composed of: (iii) primarily air; or (iv) a material having a lower dielectric constant than that of the upper patch PCB.

9. The antenna apparatus (100, 700) of claim 7, wherein:the cross-slot (23) includes a first slot (23a) extending in a first direction (x) and a second slot (23b) crossing the first slot and extending in a second direction (y) perpendicular to the first direction, wherein a central point at which the first and second slots cross is vertically aligned with a center (c) of the base of the cup structure;the upper feeding trace (26) includes a first U-shaped trace having an upper base (26c), a first arm (26a) and a second arm (26b) of equal lengths (L2), the first and second arms each extending in the first direction and each having a proximal end connected to one another by the upper base;the lower feeding trace (28) includes a second U-shaped trace having a lower base (28c), a third arm (28a) and a fourth arm (28b) of equal lengths (L1), the third and fourth arms each extending in the second direction and each having a proximal end connected to one another by the lower base;the lower base and the upper base are connected to receive a first RF signal (51) and a second RF signal (S2), respectively;VS2624-WO-1 (8415-25PCT)the first and second U-shaped traces cross each other over the center of the base of the cup structure; andeach of the first, second, third and through fourth arms has a respective distal end (26a1, 26b1, 28a1, 28b1 ) that is closer, in a horizontal plane, to a point in the horizontal plane that is vertically aligned with the center of the cup structure, than is the respective proximal end thereof to the point in the horizontal plane.

10. The antenna apparatus (100, 700) of claim 9, wherein the at least one patch radiator includes a metal patch with an approximately circular profile in the horizontal plane with a wavy perimeter that is irregular.

11. The antenna apparatus (100, 700) of any of claims 9 or 10, wherein:the at least one patch radiator includes an upper patch radiator (60) and a lower patch radiator (40);the lower patch radiator includes a metal patch with an approximately circular profile in the horizontal plane with a first wavy perimeter including a plurality of first appendages alternating with first valleys, and, with respect to a center of a first reference circular profile, the first appendages include points with radial distances longer than a first reference radius and the first valleys correspond to portions of the first circular profile; andthe upper patch radiator has an approximately circular profile in the horizontal plane with a second wavy perimeter including a plurality of second appendages alternating with first valleys, and, with respect to a center of a second reference circular profile, the second appendages include points with radial distances longer than a second reference radius and the first valleys correspond to portions of the second circular profile.

12. The antenna apparatus (100, 700) of claim 11, wherein:the center of the first reference circular profile is the same as the center of the second reference circular profile;VS2624-WO-1 (8415-25PCT)each of the first appendages is aligned with a respective one of the second valleys in a radial direction from the center of the first circular profile; andeach of the second appendages is aligned with a respective one of the first valleys in a radial direction from the center of the first circular profile.

13. The antenna apparatus of any of claims 11-12, wherein, with respect to the center of the first reference radius:each of the first appendages has a maximum distance point relative to the first reference radius in a range of (0 - 0.035) times the first reference radius and an arc length in a range of (0.25 - 0.48) times the first reference radius; andeach of the second appendages has a maximum distance point relative to the second reference radius in a range of (0 - 0.035) times the second reference radius and an arc length in a range of (0.2525 - 0.48) times the second reference radius.

14. The antenna apparatus (700) of claim 1, wherein:the cup structure (10), the conductive supports (16), the antenna feed (20) and the least one patch radiator (44) form a first antenna element (100_1 );the antenna apparatus further includes second through Nth antenna elements (100_2 to 100_N) each having a same configuration as the first antenna element, where N is at least seven, the first through Nth antenna elements being arranged horizontally with respect to one another to form a tile (710), and radio frequency, RF, coupled to one another to form an antenna array.

15. The antenna apparatus (700) of claim 14, wherein:the tile is a first tile, and the antenna array is a subarray of a larger antenna array comprising a plurality of tiles, including the first tile, RF coupled to one another, each of the plurality of tiles including a plurality of the antenna elements;each of the plurality of tiles is separated from at least one other one of the plurality of tiles by a predetermined gap;VS2624-WO-1 (8415-25PCT)each of the tiles has, among the antenna elements thereof, at least one edge element disposed adjacent to an edge element of another one of the tiles and having a first inter-element spacing therebetween; andeach of the tiles has, among the antenna elements thereof, at least one nonedge element having the same inter-element spacing with respect to each edge element thereof as the first inter-element spacing.

16. The antenna apparatus (700) of claim 15, wherein within each of the plurality of tiles, each of the at least one non-edge element shares a sidewall with at least one other non-edge element and / or at least one edge element.

17. The antenna apparatus of claim 16, wherein:within each of the plurality of tiles, each of the at least one peripheral wall of each of the antenna elements includes a first sidewall and a second sidewall opposite the first sidewall;feed dielectric of each of the antenna elements has the same dimensions; the feed dielectric of each of the at least one non-edge element is disposed symmetrically with respect to the plurality of sidewalls thereof; andthe feed dielectric of each of the at least one edge element has a first edge facing the first sidewall, and an opposite second edge facing a second sidewall that is adjacent to the gap, and a distance between the first edge and the first sidewall is greater than a distance between the second edge and the second sidewall.

18. A method (1400) of forming an antenna array (710), comprising:forming a metallic cup structure assembly of N cup structures connected to one another horizontally, where N is two or more, the N cup structures having N bases, respectively, that define a lower surface of the cup structure assembly, each said base having an opening;VS2624-WO-1 (8415-25PCT)providing a main printed circuit board, PCB, with a horizontal profile coextensive with the cup structure assembly, and including N first radio frequency (RF) connectors;placing the main PCB adjacent to the lower surface of the cup structure so that each of the RF connectors protrudes through a respective one of the openings in the bases;providing N antenna element subassemblies, each including at least one patch radiator (44) spaced above an antenna feed part (20) that includes a cross-slot within a metal layer and a feeding trace for electromagnetically exciting the at least one patch radiator, the antenna feed part including a second RF connector connected to the feeding trace; andattaching each of N antenna element subassemblies to a respective cup structure of the N cup structures such that each of the first RF connectors electrically connects to a corresponding one of the second RF connectors and the metal layer electrically connects to the cup structure.

19. The method of claim 18, wherein said forming a cup structure assembly is performed by 3D printing.

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