Patent ID: 7168152
Filing Date: 2007-01-30
Classification: H01Q,Y10T

Abstract:
1. A method for making an integrated active antenna array element, said method comprising the steps of: placing partially within a first mold at least a first power electrical conductor set extending to a first location adjacent a predetermined location; placing at least partially within said mold at least one heat pipe extending to a second location adjacent said predetermined location; filling said first mold with solid dielectric material in such a manner as to define a first planar surface; defining in said first planar surface a first elongated cavity extending from an edge of said solid dielectric to a third location adjacent said predetermined location within said solid dielectric material, a second elongated cavity extending from a fourth location adjacent said predetermined location within said solid dielectric to another edge of said solid dielectric material, and also defining at least a first recess adjacent said first, second, third and fourth locations within said solid dielectric material; applying an electrically conductive material to said first planar surface, and to said first and second elongated cavities; placing at least partially within said first recess a solid-state active device defining a power terminal adjacent said first location, and first and second RF ports adjacent said third and fourth locations, with said power conductor connected to a power terminal thereof, and with said first and second RF ports, respectively, adjacent to said first and second elongated cavities at said third and fourth locations, respectively; filling said second mold with second solid dielectric molding material in such a manner as to define a second planar surface; defining in said second planar surface a third elongated cavity extending from an edge of said second solid dielectric to a fifth location within said second solid dielectric, and a fourth elongated cavity extending from a sixth location within said second solid dielectric to another edge of said second solid dielectric, said first and second planar surfaces being juxtaposed, with said third and fourth elongated cavities registered with said first and second elongated cavities, respectively, to define electromagnetic waveguides extending from said first and second edges to said first and second RF ports of said active device, respectively, and coupled thereto.