Full-Duplex Antenna Subarrays With PCB RF Routing
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Solution Overview
Problem
Conventional radio frequency (RF) antenna arrays for space-deployed satellites face challenges such as increased size, weight, and complexity due to separate Tx and Rx arrays, coaxial interconnect issues, and phase/amplitude tracking errors, leading to high part counts and assembly difficulties.
Innovation Solution
Implementing a full duplex ESA design with a single shared Tx/Rx assembly using high-speed, high-density digital connectors and stripline connections, eliminating coaxial links and enabling simultaneous Tx and Rx operations with reduced size and mass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate Tx and Rx antenna arrays are employed, then transmit and receive functionality is achieved, but size, weight, and complexity increase significantly
Solution Approach 1:
The patent combines separate transmit and receive antenna arrays into a single shared antenna array structure. The same physical antenna elements are used for both Tx and Rx operations, with RF switches routing signals appropriately. This merging eliminates the need for duplicate antenna structures, reducing overall system mass and volume while maintaining full dual-functionality.
Solution Approach 2:
The antenna elements are designed to serve multiple functions - acting as both transmit and receive antennas. The system achieves universal functionality by using the same hardware infrastructure for both Tx and Rx operations, enabled by RF switching networks that direct signals to appropriate processing paths based on operational mode.
2Ease of manufacture
If numerous coaxial connectors and cables are used to interconnect RF components, then component interconnection is achieved, but phase and amplitude tracking errors increase
Solution Approach 1:
The patent replaces the mechanical coaxial cable and connector system with integrated printed circuit board (PCB) trace interconnections. RF signals are routed through controlled-impedance traces on rigid or flexible PCBs rather than through physical coaxial cables. This substitution eliminates mechanical connection points that introduce phase and amplitude variations, providing more stable and predictable signal paths.
Solution Approach 2:
The RF signal path is segmented into modular functional blocks (antenna elements, RF switches, amplifiers, filters) that are interconnected through standardized PCB interfaces. This segmentation allows each module to be independently characterized and calibrated, reducing cumulative phase and amplitude errors that would occur in long coaxial cable runs.
3Adaptability or versatility
If many individual coaxial connections are made, then RF signal routing is achieved, but assembly time and complexity increase
Solution Approach 1:
The patent replaces numerous individual coaxial connections with integrated PCB trace routing. Multiple RF signal paths are etched directly onto the PCB substrate, eliminating the need for manual cable routing and connector installation. This dramatically reduces assembly time while maintaining the flexibility to route signals to multiple destinations through the PCB's conductive pathways.
Solution Approach 2:
The RF signal paths are pre-defined and manufactured into the PCB structure during board fabrication. Complex routing patterns, impedance matching networks, and connection points are all established in advance during PCB manufacturing, eliminating the need for time-consuming field assembly and cable management.
4Ease of operation
If coaxial cables are bent and angled to accommodate routing, then spatial flexibility is achieved, but phase tracking errors increase
Solution Approach 1:
The patent replaces flexible coaxial cable routing with rigid PCB trace routing. The PCB itself provides the spatial flexibility needed to accommodate different mounting configurations and signal paths through its layered conductor structure. Since the traces are fixed to the rigid substrate, they maintain consistent electrical length and phase characteristics regardless of physical orientation or bending.
Data Source
AI summary
Provided herein are various enhancements for aperture antenna arrays and electronically steered arrays (ESAs). A modular subarray is provided that includes horn apertures coupled to corresponding waveguide polarizers coupled to transmit waveguide filters and receive waveguide filters that establish transmit ports and receive ports. The transmit ports and the receive ports are coupled through a waveguide adapter plate to individual isolation cavities each formed in a body of an amplifier-filter module that houses amplifier/filter elements and couple transmit radio frequency signaling and receive radio frequency signaling to coaxial connections penetrating the isolation cavities. The subarray also includes a circuit card assembly comprising the coaxial connections coupled to stripline links formed by a printed circuit board, wherein the stripline links couple to beamforming circuitry, and a high-density digital connector mounted to the circuit card assembly and configured to carry input/output radio frequency signaling for the subarray to/from the beamforming circuitry.