Integrated PCB Phased Array Cards Without RF Connectors
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Solution Overview
Problem
Conventional phased array antennas with printed circuit boards (PCBs) and connectors introduce cost, signal loss, increased size, weight, and reduced reliability due to mechanical assembly and packaging, particularly in circularly polarized antennas.
Innovation Solution
Integration of circularly polarized antennas into printed circuit boards (PCBs) eliminates the need for connectors by using a substrate integrated septum polarizer to convert linearly polarized signals to circularly polarized signals, with substrate extensions acting as impedance matching layers for improved bandwidth and inter-antenna isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional tray-based phased array antennas use separate PCBs and connectors to couple RF power between PCBs and antennas, then the system can be assembled using standard components, but this introduces increased cost, signal loss, increased size, increased weight, reduced reliability, and increased labor expense
Solution Approach 1:
The patent combines the antenna elements and RF circuitry into a single integrated PCB assembly. The antenna elements are directly fabricated on the PCB substrate along with transmission lines, impedance matching networks, and other RF components, eliminating the need for separate antenna components and connectors. This integration reduces the number of interconnections and potential failure points, thereby improving reliability while reducing overall device complexity.
Solution Approach 2:
The patent replaces mechanical connectors and physical coupling mechanisms with integrated circuit board traces and embedded RF structures. Instead of using mechanical connectors to couple RF power between separate PCBs and antenna components, the design uses printed transmission lines and integrated RF circuitry directly on the PCB, substituting mechanical connections with electrical connections through the substrate, thereby improving reliability and reducing complexity.
2Loss of energy
If conventional phased array antennas use hundreds or thousands of connectors to couple RF power between PCBs and antennas, then the system can achieve signal transmission, but this introduces increased signal loss, increased size, and increased weight
Solution Approach 1:
The patent merges the antenna elements with the PCB structure, creating an integrated assembly where RF signals are transmitted through printed transmission lines directly to the antenna elements without requiring external connectors. This integration eliminates numerous RF connectors and associated interconnections, reducing signal loss due to connector interfaces while simultaneously reducing the overall complexity of the RF power coupling system.
Solution Approach 2:
The patent substitutes mechanical RF connectors with integrated PCB transmission lines and embedded RF structures. Instead of using physical connectors to transmit RF power between separate components, the design uses conductive traces, vias, and integrated RF circuitry fabricated directly on the PCB substrate, eliminating connector-related signal loss and reducing system complexity.
3Ease of manufacture
If conventional phased array antennas use mechanical assembly and packaging with connectors, then the system can be constructed using standard manufacturing processes, but this introduces increased cost and increased labor expense
Solution Approach 1:
The patent combines multiple RF components and antenna elements into a single integrated PCB assembly that can be manufactured using standard PCB fabrication processes. The antenna elements, transmission lines, and RF circuitry are all fabricated in the same manufacturing run, eliminating the need for separate assembly steps and connector installation, thereby reducing labor costs while maintaining ease of manufacture through conventional techniques.
Solution Approach 2:
The patent replaces mechanical assembly operations with integrated PCB fabrication processes. Instead of manually or mechanically assembling separate antenna components and connectors, the design uses printed transmission lines and integrated RF structures that are fabricated directly on the PCB substrate using standard PCB manufacturing techniques, reducing labor expense and eliminating connector-related signal loss.
4Weight of moving object
If conventional circularly polarized antennas use separate antenna tiles and connectors, then the system can achieve circular polarization, but this introduces increased size and weight
Solution Approach 1:
The patent integrates circularly polarized antenna elements directly into the PCB structure, combining the antenna radiating elements with the circuit board substrate. The circular polarization is achieved through integrated feed networks and antenna geometries fabricated on the PCB, eliminating the need for separate antenna tiles and connectors, thereby reducing weight while maintaining the required device complexity for circular polarization functionality.
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
This design reduces signal loss, weight, and size while providing wider circularly polarized bandwidth, increased axial ratio bandwidth, and improved thermal characteristics, enabling both transmit and receive operations across various frequency bands.
Implementation Method 1
The septum polarizer may be configured to convert a linearly polarized transverse electric field into a circularly polarized signal and vice versa
Implementation Method 2
A phased array antenna may include a plurality of PCBs or circuit cards arranged vertically relative to a boresight of the antenna
Implementation Method 3
The substrate extension may act as an impedance matching layer enabling a larger operational CP bandwidth across the scan
Data Source
AI summary
A phased array antenna device may include a base including circuitry configured to couple to a backplane and a plurality of circuit cards arranged in parallel and coupled to circuitry of the base. Each circuit card may include an array of circularly polarized unit antenna elements integrated into the circuit card and arranged along an edge of the circuit card. Each circularly polarized unit antenna element of the array may be configured to radiate and receive electromagnetic signals directly from the edge of the circuit card. In some implementations, the edge of each circuit card may include a plurality of substrate extensions with chamfered edges formed from a substrate of the circuit card. At least a portion of some of the chamfered edges may include a metal coating.