Comsat Corporation

Eric Christopher Kohls

Amir Ibrahim Zaghloul

Bernard D Geller

Francois T Assal

Robert M Sorbello

The invention is a multi-layer printed circuit antenna and a method for developing the antenna for which a screen printing technology is used to deposit conducting material forming the circuit layout directly on low-cost dielectric material, followed by a post-processing step performed on the printed circuit to increase circuit conductivity. In one embodiment, the dielectric material used is a thin layer supported by low-loss, foam-like material for spacing between the antenna layers. In another embodiment, a thick high-density, low-cost low-loss dielectric material acts as both the printing surface and the spacer between the antenna layers. The thick high-density, low-cost low-loss dielectric material allows for saving one layer in every printed circuit. The screen printing or additive process is less expensive than its etching or subtractive counterpart due to the process itself and due to the lower cost of materials. The post-processing of the printed circuit achieves the same level of conductivity as the more expensive etching technique. This allows for low-cost manufacturing for printed circuit antennas for use in, for example, DBS, DTH/TV, MMDS, LMDS and other wireless communications systems.

Multi-layer flat plate antenna with low-cost material and high-conductivity additive processing

In a flat plate antenna, insertion loss is reduced significantly by providing an extensive waveguide structure at the back of the ground plane of the antenna. Depending on antenna size, the waveguide may feed the antenna at one or a plurality of points. According to a preferred embodiment, the transition from waveguide to stripline is made via a coaxial connection, with a quarter-wave transformation, including mode suppression walls to direct the energy more efficiently. Alternatively, a direct waveguide to stripline transition may be provided. The technique has wide applicability to a number of antenna designs, including single- and dual-polarization structures, and linear and circular polarization operation.

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Washington, DC, United States of America

Eric Christopher Kohls