Millimeter-wave Phased-Arrays with Pillowed Inverted-L Antennas
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Solution Overview
Problem
Existing wireless antenna arrays face challenges in achieving precise geometry and substrate characteristics necessary for optimal performance, particularly in millimeter-wave phased-arrays, which often result in increased fabrication costs and complexity.
Innovation Solution
The integration of an antenna array with a primary board featuring artificially pillowed inverted-L antennas and passive patch elements, which includes a planar element adjacent to the board's surface and an orthogonal element extending to a feed layer, along with passive patches to mitigate input impedance variations and stabilize radiation patterns across the WiGig frequency band.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If superior substrate materials and assembly configurations are used to achieve optimal antenna performance, then antenna performance is improved, but fabrication cost and complexity increase
Solution Approach 1:
The patent integrates the antenna array directly with the primary board by forming the inverted-L antenna elements using conductive traces on the board's substrate layers. The planar element is formed on one surface while the orthogonal element extends through the substrate to a feed layer, merging the antenna structure with the board's existing layered construction. This integration eliminates the need for separate antenna substrates and reduces assembly complexity while maintaining performance.
Solution Approach 2:
The primary board's substrate layers serve multiple functions: they provide mechanical support for the board, enable signal routing through internal traces, and form the antenna radiating elements. The same substrate material that provides structural integrity also serves as the antenna substrate, eliminating the need for specialized antenna substrates and reducing overall device complexity.
2Reliability
If precise antenna geometry is achieved to optimize performance, then antenna performance is improved, but manufacturing precision requirements increase
Solution Approach 1:
The antenna geometry is formed using standard PCB fabrication processes that create conductive traces on substrate layers. The planar element dimensions and orthogonal element length are defined by standard trace width, trace spacing, and layer thickness parameters that are controlled through conventional manufacturing tolerances rather than requiring specialized high-precision antenna fabrication processes.
Solution Approach 2:
The patent optimizes antenna performance by adjusting standard PCB parameters such as trace width, trace spacing, substrate thickness, and dielectric constant within conventional manufacturing ranges. The inverted-L geometry allows tuning of resonant frequency and impedance by modifying these standard parameters without requiring precision beyond normal PCB fabrication capabilities.
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 configuration enables full spectrum coverage of the WiGig frequency band while reducing fabrication costs and complexity, providing stable performance with a gain of about 15 dBi and a conical scan range of at least ±30 degrees with minimal gain drop at extreme angles.
Implementation Method 1
an inverted-L antenna having a planar element adjacent to the second surface of the primary board, and an orthogonal element extending from the planar element to a feed layer within the primary board
Implementation Method 2
a passive patch element between the planar element and the feed layer
Data Source
AI summary
A wireless communications module includes: a primary board including (i) a first surface bearing a radio controller, and defining a set of control contacts for connection to respective ports of the radio controller, and (ii) a second surface opposite the first surface; an antenna array integrated with the primary board, the antenna array including a plurality of unit cells each having: an inverted-L antenna having a planar element adjacent to the second surface of the primary board, and an orthogonal element extending from the planar element to a feed layer within the primary board; and a passive patch element between the planar element and the feed layer.