Tile Sub-Array Architecture for Phased Array Antenna Weight Reduction
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Solution Overview
Problem
Conventional phased array antennas are large, heavy, and expensive due to the inclusion of phase shifter and amplitude control circuits, making them costly and difficult to deploy in space-constrained applications, particularly in defense and commercial electronic systems.
Innovation Solution
The development of a tile sub-array architecture for Active Electronically Scanned Arrays (AESAs) that uses a package-less Transmit/Receive (T/R) channel and multi-layer printed circuit board structures, eliminating the need for expensive T/R module packages and associated assembly costs, while integrating RF, DC, and logic signal distribution with an embedded circulator layer, and employing RF matching pads to eliminate back-drill and back-fill operations, thereby reducing manufacturing costs and improving RF performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If phase shifter circuits and amplitude control circuits are included in a phased array antenna, then the antenna can perform electronic beam steering and control, but the antenna becomes relatively large, heavy and expensive
Solution Approach 1:
The patent divides the phased array antenna into modular tile sub-arrays, where each tile contains a subset of antenna elements and associated phase shifter circuits. This segmentation allows the system to achieve electronic beam steering while keeping individual module weights manageable and enabling selective deployment based on mission requirements.
Solution Approach 2:
The patent transitions from a conventional two-dimensional brick architecture to a three-dimensional tile architecture with multiple layers stacked vertically. This dimensional change allows RF circuitry to be distributed in planes parallel to the antenna aperture, reducing the overall profile and weight while maintaining electronic beam steering functionality.
2Ease of operation
If phase shifter circuits and amplitude control circuits are included in a phased array antenna, then the antenna can perform electronic beam steering and control, but the antenna becomes large and expensive
Solution Approach 1:
The patent merges the antenna elements, phase shifter circuits, and amplitude control circuits into integrated tile sub-arrays. Each tile is a self-contained module that combines multiple functions, reducing overall system complexity while maintaining electronic beam steering capability. The RF circuitry is integrated within the same structural framework as the antenna elements.
Solution Approach 2:
The tile sub-array design creates universal building blocks that can be used in various configurations and applications. Each tile is designed to perform multiple functions (radiation, phase shifting, amplitude control) and can be assembled into different array sizes and shapes, reducing overall system complexity through standardization.
3Ease of manufacture
If a brick type architecture is used with RF signals distributed perpendicular to the antenna aperture, then the antenna can be constructed with separated signal paths, but the antenna is limited to single polarization and becomes large and heavy
Solution Approach 1:
The patent changes the signal distribution from a perpendicular (orthogonal) arrangement to a parallel arrangement where RF circuitry is distributed in planes parallel to the antenna aperture. This dimensional change enables support for multiple polarizations while maintaining manufacturability through standardized tile assemblies.
Solution Approach 2:
The patent employs composite multi-layer printed circuit board structures that integrate RF signal paths, power distribution, and grounding in a unified composite architecture. This composite approach enables complex signal routing and multiple polarization support while simplifying the manufacturing process through integrated construction.
4Ease of manufacture
If conventional T/R module packages are used in phased array antennas, then the antenna can be assembled with standardized components, but the antenna becomes expensive with high assembly costs
Solution Approach 1:
The patent extracts the phase shifter circuits and amplitude control circuits from conventional separate T/R module packages and integrates them directly into the tile sub-array structure. This extraction eliminates the need for expensive packaged modules and their associated assembly processes, reducing both component cost and assembly complexity.
Solution Approach 2:
The patent merges the T/R module functionality directly into the tile sub-array construction, combining the antenna elements, phase shifters, and control circuits into a unified structure. This integration eliminates separate packaging and assembly steps, reducing manufacturing cost while maintaining standardized production capabilities.
Data Source
AI summary
A radiator includes a waveguide having an aperture and a patch antenna disposed in the aperture. In one embodiment, an antenna includes an array of waveguide antenna elements, each element having a cavity, and an array of patch antenna elements including an upper patch element and a lower patch element disposed in the cavity.