Injection-molded phased array antenna system

Abstract

An injection molded phased array antenna system such as may advantageously employed on satellites. The antenna system comprises a plurality of metal plated, injection molded plastic horn radiating elements respectively coupled to a plurality of metal plated, injection molded plastic orthomode junctions that produce a corresponding plurality of vertically and horizontally polarized outputs. A metal plated, injection molded plastic vertical and horizontal beamforming networks is coupled to outputs of the plurality of orthomode junctions that establish unique phases and amplitudes that produce two separate outputs associated with two independent beams. The beamforming networks each comprise a plurality of metal plated, injection molded plastic fixed phase shifters respectively coupled to outputs of the plurality of orthomode junctions, a plurality of metal plated, injection molded plastic two-way power combiner-divider networks coupled to adjacent ones of the phase shifters, a plurality of metal plated, injection molded plastic eight-way power combiner-divider networks coupled to the two-way power combiner-divider networks by way of an intermediate structural panel, and a plurality of metal plated, injection molded plastic four-way power combiner-divider networks coupled to the eight-way power combiners by way of a main structural panel. The four-way power combiner-divider networks produce respective vertical and horizontal polarized outputs of the antenna system.