RF Substrate Crossovers Outside Phase-Shifting Regions
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Solution Overview
Problem
Existing radio frequency devices face challenges in creating cost-effective and space-saving electrically conductive crossovers between substrate layers without requiring openings, especially when using glass substrates or fluidic dielectric materials, which can lead to unwanted leakage and manufacturing complexities.
Innovation Solution
The use of multiple electrically conductive crossovers arranged outside of the phase shifting region, utilizing electroconductive materials like gold-plated particles or anisotropic conductive films to connect transmission line elements on opposing surfaces of substrate layers, allowing for a dense arrangement of phase shifting and radiating elements while maximizing available space and ensuring mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If openings are made in substrate layers to insert electroconductive connection elements for crossovers, then electrical connection between substrate layers is achieved, but manufacturing complexity increases and leakage may occur with fluidic dielectric materials
Solution Approach 1:
The invention extracts the electroconductive connection function from the substrate layers by placing crossovers on the outer surfaces of the antenna device. This eliminates the need for openings in the substrate layers, thereby reducing manufacturing complexity and preventing leakage issues with fluidic dielectric materials while maintaining reliable electrical connections between transmission line elements on different substrate layers
Solution Approach 2:
The invention introduces an intermediary structure (the crossover element with connection elements) that mediates the electrical connection between substrate layers without requiring direct penetration through the substrates. The crossovers are arranged on outer surfaces and connected via connection elements that extend between substrates, acting as intermediaries that avoid the harmful effects of substrate openings
2Volume of moving object
If crossovers are placed inside the antenna device, then space is saved, but they interfere with phase shifting regions and radiating elements
Solution Approach 1:
The invention extracts the crossovers from the internal phase shifting regions and places them on the outer surfaces of the antenna device. This extraction eliminates interference with phase shifting regions and radiating elements, allowing full utilization of the internal volume for antenna functionality while the crossovers occupy space on the external surfaces
3Reliability
If multiple crossovers are used to connect transmission line elements, then electrical connection reliability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The invention enables the crossovers to serve multiple functions simultaneously: they provide electrical connections between transmission line elements on different substrate layers, act as structural components on the outer surfaces, and eliminate the need for separate opening-making and connection-insertion processes. This self-service approach maintains manufacturing simplicity while achieving reliable electrical connections
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 solution enables a compact, reliable, and efficient connection between transmission line elements on two substrate layers, optimizing radiation characteristics and reducing manufacturing complexity by separating crossover placement from phase shifting regions, thus enhancing the performance and reliability of phased array antennas.
Implementation Method 1
an electroconductive material is arranged between at least a part of the overlapping area of the first and second crossover electrode, whereby the electroconductive material electrically connects the first crossover electrode on the first substrate layer with the second crossover electrode on the second substrate layer
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
A radio frequency device (4) comprises a first substrate layer (2) and a second substrate layer (3) arranged at a distance towards each other, whereby the first and second substrate layer (2, 3) comprise electrically conductive transmission line elements (10, 11, 10', 11') on a first surface (6) of the first substrate layer (2) and on a second surface (8) of the second substrate layer (3) that allow for transmission of a radio frequency signal along a transmission direction. The radio frequency device (4) also comprises more than one electrically conductive crossover (1) between the first surface (6) of the first substrate layer (2) and the second surface (8) of the second substrate layer (3) that provides for an electrically conductive connection of the respective electrically conductive transmission line elements (10, 11) on the first and second substrate layer (2, 3). At least one phase shifting region (12) of the radio frequency device (4) comprises corresponding regions of the respective first and second substrate layers (2, 3) that are used for forming at least one radio frequency phase shifting element arranged on the first and second substrate layer (2, 3). All electrically conductive crossovers (1) are arranged outside of the at least one phase shifting region (12) of the radio frequency device (4), whereby each electrically conductive crossover (1) is electrically connected to a respective phase shifting element.