Phased-Array Millimeter-Wave Antenna Assembly With Controlled Air Gap
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Solution Overview
Problem
Existing wireless antenna assemblies face challenges in achieving precise antenna geometry and substrate characteristics while balancing fabrication cost and complexity, particularly in supporting high-frequency communications like WiGig, which requires strict tolerances and increased production costs.
Innovation Solution
A radio frequency module design featuring a primary board with a secondary board separated by an air gap, using BGA or LGA elements for spacing, which supports a phased array of antenna elements, allowing for controlled impedance bandwidth and reduced fabrication complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional substrate materials and assembly configurations are used to support antenna elements, then antenna performance can be improved, but fabrication cost and physical footprint increase
Solution Approach 1:
The antenna assembly is divided into separate components: a first substrate containing antenna elements and a second substrate serving as a ground plane, connected through spacing elements. This segmentation allows independent optimization of each component and simplifies fabrication processes while maintaining performance.
Solution Approach 2:
Spacing elements act as intermediaries between the first and second substrates, providing mechanical support and defining the air gap distance. These elements enable precise control of the antenna-to-ground-plane distance without requiring complex substrate integration, reducing fabrication complexity.
2Reliability
If precise antenna geometry and substrate characteristics are achieved, then wireless performance is improved, but fabrication cost increases due to strict tolerances
Solution Approach 1:
By segmenting the antenna assembly into separate substrates and spacing elements, each component can be manufactured with standard tolerances and assembled to achieve the required precision, avoiding the need for expensive single-step fabrication with tight tolerances.
Solution Approach 2:
The design allows the air gap distance to be controlled by selecting spacing elements of appropriate heights, enabling optimization of antenna performance parameters without requiring precise control of substrate thickness or other difficult-to-manage dimensions.
3Manufacturing precision
If air gap distance between antenna elements and ground plane is controlled, then impedance bandwidth is optimized, but assembly complexity increases
Solution Approach 1:
Spacing elements serve as intermediary components that directly establish the air gap distance between the antenna elements and the ground plane. This approach converts the complex task of controlling air gap distance into a simple selection and assembly process using pre-fabricated spacing elements of specific heights.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design achieves full spectrum coverage of WiGig frequencies with reduced fabrication costs and complexity, providing stable antenna performance with controlled air gaps and structural integrity.
Implementation Method 1
a secondary board affixed to the primary board by the plurality of spacing elements, separated from the lower surface of the primary board by an air gap with the predetermined height
Implementation Method 2
the secondary board supporting a phased array of antenna elements electromagnetically coupled with the antenna control elements
Data Source
AI summary
A radio frequency module includes: a primary board including: an upper surface carrying a radio controller; and a lower surface carrying antenna control elements; a plurality of spacing elements affixed to the lower surface and having a predetermined height extending away from the lower surface; and a secondary board affixed to the primary board by the plurality of spacing elements, separated from the lower surface of the primary board by an air gap with the predetermined height; the secondary board supporting a phased array of antenna elements electromagnetically coupled with the antenna control elements.