Waveguide Radiation Assembly for Low Cross-Polarization Arrays
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Solution Overview
Problem
Traditional waveguide array antennas face challenges with poor manufacturing accuracy, leading to poor cross polarization and failure to meet Class 3 requirements of the European Standards Institute (ETSI), due to limitations in aperture radiation efficiency and side lobe levels.
Innovation Solution
A radiation assembly for waveguide array antennas is proposed, comprising a first radiation layer with metal grids dividing the windows into two holes and a second layer without grids, manufactured independently and connected via vacuum diffusion welding, improving polarization purity and reducing side lobe levels without compromising gain.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional waveguide array antennas use integrated radiation units processed by opening molds, then manufacturing is simpler, but manufacturing accuracy is poor leading to poor cross polarization
Solution Approach 1:
The radiation unit is divided into two separate radiation layers (first radiation layer with metal grid and second radiation layer without metal grid), each manufactured independently with high precision etching or laser engraving, then combined through vacuum diffusion welding. This segmentation allows each layer to be processed separately to achieve better manufacturing accuracy and cross polarization performance while meeting ETSI Class 3 requirements.
2Loss of energy
If traditional patch array antennas use single-layer or multi-layer PCB structure, then weight is light and integration is easy, but transmission loss is too large and mutual coupling exists reducing aperture radiation efficiency
Solution Approach 1:
The patent replaces the traditional PCB mechanical structure with a waveguide-based structure using metal layers and vacuum diffusion welding. This substitution eliminates the high transmission loss and mutual coupling issues inherent in PCB structures at millimeter wave frequencies, achieving better aperture radiation efficiency while managing the increased structural complexity through standardized manufacturing processes.
3Manufacturing precision
If traditional waveguide slot array uses air waveguide transmission, then transmission loss is low, but array element spacing limits the number of elements and field distribution uniformity is poor
Solution Approach 1:
The patent introduces a vertical dimension by stacking two radiation layers with different thicknesses (first radiation layer thinner, second radiation layer thicker) and connecting them through vacuum diffusion welding. This three-dimensional configuration improves field distribution uniformity and allows for higher array element density within a limited area, overcoming the constraints of traditional planar waveguide slot arrays.
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 solution enhances antenna cross polarization (XPD) index and meets ETSI level 3 requirements by optimizing aperture radiation efficiency and reducing side lobe levels, while also improving manufacturing accuracy and reducing costs through etching or laser engraving and vacuum diffusion welding.
Implementation Method 1
a first radiation layer having a plurality of first radiation windows, and each of the plurality of first radiation windows has a metal grid that divides the corresponding first radiation window into two radiation holes
Implementation Method 2
the first radiation layer and the second radiation layer are manufactured independently of each other... connected by way of vacuum diffusion welding
Data Source
AI summary
The present disclosure relates to a radiation assembly, a waveguide antenna sub-arrays, and a waveguide array antenna. The radiation assembly for the waveguide array antenna comprises: a first radiation layer having a plurality of first radiation windows, each of the plurality of first radiation windows has a metal grid that divides the corresponding first radiation window into two radiation holes; and a second radiation layer having a plurality of second radiation windows, the plurality of second radiation windows has a one-to-one correspondence with the plurality of first radiation windows, and the plurality of second radiation windows of the second radiation layer do not have a metal grid. The thickness of the second radiation layer is greater than the thickness of the first radiation layer, and the first radiation layer and the second radiation layer are manufactured independently of each other.