Rogers Corporation

Stephen O'Connor

Kristi Dhimiter Pance

Karl Edward Sprentall

Gianni Taraschi

Shawn P Williams

Murali Sethumadhavan

Roshin Rose George

William Blasius

Dirk M Baars

Robert C Daigle

Christopher Brown

Trevor Polidore

Bruce B Fitts

Michael S White

Shailesh Pandey

Michael Lunt

Sam Henson

John Dobrick

Jared DuPerre

Allen F Horn, Iii

Sergio Clavijo

A cured, shaped dielectric component, including a crosslinked product of a composite comprising a thermoplastic polymer, an optional crosslinking co-agent, an optional cure initiator, an optional additive composition, and a ceramic filler composition; wherein the cured, shaped dielectric component has a permittivity of 1.1 to 20 at 10 GHz; and wherein the cured, shaped dielectric component has no melt flow index when tested at 190° C., 2.16 kg, in accordance with ASTM D1238-20.

Shaped dielectric component cross-linked via irradiation and method of making thereof

A method of making a dielectric, Dk, electromagnetic, EM, structure, includes: providing a first mold portion comprising substantially identical ones of a first plurality of recesses arranged in an array; filling the first plurality of recesses with a curable first Dk composition having a first average dielectric constant greater than that of air after full cure; placing a substrate on top of and across multiple ones of the first plurality of recesses filled with the first Dk composition, and at least partially curing the curable first Dk composition; and, removing the substrate with the at least partially cured first Dk composition from the first mold portion, resulting in an assembly having the substrate and a plurality of Dk forms including the at least partially cured first Dk composition, each of the plurality of Dk forms having a three dimensional, 3D, shape defined by corresponding ones of the first plurality of recesses.

Dielectric electromagnetic structure and method of making the same

An electromagnetic, EM, device, includes: a substrate having a dielectric layer and a first conductive layer at a first side of the substrate, the substrate having a via that extends at least partially through the substrate from the first side toward an opposing second side of the substrate; at least one dielectric structure having at least one non-gaseous dielectric material that forms a first dielectric portion that extends outward from the first side of the substrate, the first dielectric portion having a first average dielectric constant, the at least one dielectric structure further having a second dielectric portion that is contiguous with the first dielectric portion; wherein the second dielectric portion extends into the via of the substrate, the via having a mechanical interlock surface; and wherein the at least one dielectric structure includes a mechanical interlock between the second dielectric portion and the mechanical interlock surface of the via of the substrate.

Electromagnetic dielectric structure adhered to a substrate and methods of making the same

A dielectric resonator antenna (DRA) includes: a volume of a dielectric material configured to be responsive to a signal feed, the signal feed being productive of a main E-field component having a defined direction &#x112; in the DRA; wherein the volume of a dielectric material includes a volume of non-gaseous dielectric material having an inner region having a dielectric medium having a first dielectric constant, the volume of non-gaseous dielectric material that is other than the inner region having a second dielectric constant, the first dielectric constant being less than the second dielectric constant; wherein the volume of non-gaseous dielectric material has a cross sectional overall height Hv as observed in an elevation view of the DRA, and a cross sectional overall width Wv in a direction parallel to the defined direction &#x112; as observed in the plan view of the DRA; and wherein Hv is greater than Wv/2.

Dielectric resonator antenna and method of making the same

A connected dielectric resonator antenna array (connected-DRA array) operational at an operating frequency and associated wavelength, includes: a plurality of dielectric resonator antennas (DRAs), each of the plurality of DRAs having at least one volume of non-gaseous dielectric material; wherein each of the plurality of DRAs is physically connected to at least one other of the plurality of DRAs via a relatively thin connecting structure, each connecting structure being relatively thin as compared to an overall outside dimension of one of the plurality of DRAs, each connecting structure having a cross sectional overall height that is less than an overall height of a respective connected DRA and being formed from at least one of the at least one volume of non-gaseous dielectric material, each connecting structure and the associated volume of the at least one volume of non-gaseous dielectric material forming a single monolithic portion of the connected-DRA array.

Connected dielectric resonator antenna array and method of making the same

In an embodiment, an electromagnetic device, comprises a substrate a substrate comprising a dielectric layer and a first conductive layer; at least one dielectric structure comprising at least one non-gaseous dielectric material that forms a first dielectric portion that extends outward from the first side of the substrate, the first dielectric portion having an average dielectric constant and an optional second dielectric portion that extends into an optional via. The at least one dielectric structure is bonded to the substrate by at least one of: a mechanical interlock between the second dielectric portion and the substrate due to the at least one interlocking slot comprising a retrograde surface; an intermediate layer located in between the dielectric structure and the substrate having a roughened surface; or an adhesive material located in between the dielectric structure and the substrate. A method of making the device can comprise injection molding a dielectric composition onto the substrate to form the dielectric substrate.

In an embodiment, a thermoplastic composite comprises a thermoplastic polymer; and a dielectric filler having a multimodal particle size distribution; wherein a peak of a first mode of the multimodal particle size distribution is at least seven times that of a peak of a second mode of the multimodal particle size distribution; and a flow modifier.

Melt processable thermoplastic composite comprising a multimodal dielectric filler

An electromagnetic, EM, device includes: a 3D body made from a dielectric material having a proximal end and a distal end; the 3D body having a first region toward the center of the 3D body made from a dielectric material having a first average dielectric constant, the first region extending at least partially to the distal end of the 3D body; and the 3D body having a second region outboard of the first region made from a dielectric material other than air having a second average dielectric constant that is greater than the first average dielectric constant, the second region extending from the proximal end to the distal end of the 3D body.

Electromagnetic device

A dielectric resonator antenna (DRA) operable at a defined frequency includes: at least one volume of a dielectric material configured and structured to be responsive to a signal feed when electromagnetically coupled to the at least one volume of a dielectric material, the signal feed when present and electrically excited being productive of a main E-field component having a defined direction, &#x112;, in the DRA as observed in a plan view of the DRA; wherein the at least one volume of a dielectric material includes a non-gaseous dielectric material having a defined dielectric constant, the non-gaseous dielectric material having an inner region having a dielectric medium having a dielectric constant that is less than the dielectric constant of the non-gaseous dielectric material, at the defined frequency; wherein the inner region has a cross sectional overall height Hr as observed in an elevation view of the DRA, and a cross sectional overall width Wr in a direction parallel to the direction &#x112; as observed in the plan view of the DRA; and wherein Hr is greater than Wr/2.

A dielectric resonator antenna (DRA) includes a plurality of volumes of dielectric materials having N volumes, N being an integer equal to or greater than 3, disposed to form successive and sequential layered volumes V(i), i being an integer from 1 to N, and a signal feed disposed to produce a main E-field component having a defined direction, &#x112;, in the DRA. The N volumes include a non-gaseous dielectric material, and have an inner region with a dielectric constant that is less than the dielectric constant of the non-gaseous dielectric material. The inner region has a cross sectional overall height Hr, and a cross sectional overall width Wr in a direction parallel to &#x112;, and the volume of non-gaseous dielectric material has a cross sectional overall height Hv, and a cross sectional overall width Wv in a direction parallel to &#x112;, wherein Hr is greater than Wr/2.

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West Roxbury, MA, United States of America

Stephen O'Connor