Wide-Scanning Patch Antenna Array With Cavity-Coupled PCB Layers
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Solution Overview
Problem
Existing millimeter-wave antenna arrays face limitations such as small scanning angles, significant gain degradation due to parasitic surface waves, asymmetric structure leading to power leakage, and complex manufacturing requirements, which hinder their application in wide beam scanning and dual-polarization systems.
Innovation Solution
A dual-polarized antenna array design with a cavity structure in the middle layer and non-galvanic connections between PCBs, featuring symmetrical patch elements and plated VIAs to reduce surface wave propagation and power leakage, allowing for wide-angle scanning and low loss operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional patch antenna arrays are used, then manufacturing is simple using PCB technology, but scanning angle is limited and gain degradation occurs at large angles
Solution Approach 1:
The antenna element is divided into two separate patch structures located on different PCB layers, with each patch contributing to the overall radiation pattern. This segmentation allows independent optimization of each patch while maintaining manufacturability through standard PCB layering techniques.
Solution Approach 2:
The invention transitions from a single-plane patch antenna to a three-dimensional structure by placing patches on different PCB layers and using vertical vias for connection. This dimensional transition enables wider scanning angles while maintaining PCB manufacturing compatibility.
2Adaptability or versatility
If dual-polarized asymmetric antenna elements are used, then polarization diversity is achieved, but power leakage to the second polarization port increases
Solution Approach 1:
The invention employs asymmetric patch geometries with different dimensions along orthogonal axes, where each patch is optimized for a specific polarization. The asymmetry is strategically designed to maximize coupling for the intended polarization while minimizing coupling to the orthogonal polarization, thereby reducing power leakage.
Solution Approach 2:
The patent introduces a dual-feed network with independent impedance matching circuits for each polarization port. This intermediary feeding structure allows precise control of power distribution and isolation between polarization ports, preventing power leakage while maintaining dual-polarization functionality.
3Adaptability or versatility
If antenna arrays are designed for wide scanning, then beam coverage is improved, but manufacturing precision requirements become extremely stringent
Solution Approach 1:
The invention employs standard PCB manufacturing features (traces, vias, ground planes) to serve multiple functions: mechanical support, electrical connection, and positioning reference. This universality allows wide scanning capability to be achieved using conventional PCB manufacturing processes without requiring ultra-precise custom fabrication.
Solution Approach 2:
The patent optimizes the spacing and dimensions of patch elements and feeding structures to achieve wide scanning angles while maintaining tolerance to manufacturing variations. By carefully selecting geometric parameters and element spacing, the design achieves robust wide-angle performance that is insensitive to typical PCB manufacturing tolerances.
4Adaptability or versatility
If more antenna arrays are deployed to achieve full 360-degree scanning, then coverage is complete, but system complexity increases
Solution Approach 1:
The invention implements dynamic beam steering capability within a single antenna array platform, allowing electronic scanning across wide angular ranges without mechanical movement or additional arrays. This dynamic beam control achieves comprehensive coverage while maintaining a compact, fixed-structure system with reduced complexity.
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 design achieves symmetric radiation patterns and high gain with reduced power loss, enabling scanning up to ±60 degrees and operating in a wide frequency range, suitable for mass production and applications in 5G, 6G, and wireless power transmission systems.
Implementation Method 1
surface wave propagation in antennas' PCBs, significant gain degradation at great scan angles
Implementation Method 2
power flow to the 2nd polarization ports, asymmetric structure, which can exacerbate these effects
Data Source
AI summary
The disclosure relates to a wide scanning antenna array. The technical result consists in increasing the beam scanning range of the antenna array and the operating frequency range, simplifying the design of the antenna array and reducing losses. An antenna array is provided. The antenna array includes a plurality of antenna array elements. Each antenna array element of the plurality of antenna array elements includes a main printed circuit board (PCB) over which a middle layer and an additional PCB are arranged. A first patch element is disposed at the main PCB, and a second patch element is disposed at the additional PCB. The antenna array element further includes a cavity in the middle layer to reduce coupling between the antenna array element and at least another antenna array element of the plurality of antenna array elements. The cavity in the middle layer includes a hole that supports coupling between the first patch element and the second patch element. The main PCB, the middle layer and the additional PCB are interconnected by means of a no galvanic connection.