CONFORMAL ANTENNA DEVICE

A conformal antenna device is provided that includes a conformance panel, an antenna array, a combiner board, and a plurality of slats. The conformance panel has an inner radial surface, an outer radial surface, a width extending between first and second axial ends, and a length extending between first and second lateral ends. The conformance panel extends linearly in a widthwise direction and extends arcuately in a lengthwise direction. The conformance panel includes a plurality of apertures extending between the inner and outer radial surfaces. The antenna array is attached to the outer radial surface. The slats extend between the combiner board and the conformance panel in a spoke arrangement. Each slat includes a first plate and a second plate, and each second plate includes electrical circuitry and one or more components and is in signal communication with the antenna array.

BACKGROUND OF THE INVENTION

1. Technical Field

The present disclosure relates to conformal active electronically scanned arrays in general, and to architectures for conformal active electronically scanned arrays in particular.

2. Background Information

An active electronically scanned array (AESA) is a type of phased array antenna that is a computer-controlled array antenna in which the beam of radio waves can be electronically steered to point in different directions without moving the antenna. In an AESA, each antenna element is connected to a solid-state transmit/receive module (TRM) under the control of a computer that performs the functions of transmitter and/or receiver for the antenna.

A planar ultrawideband modular antenna (PUMA) array is a type of ultrawideband (UWB) array that may utilize etched circuits and vias fabricated as a multilayer printed circuit board (PCB). A PUMA array may be described as having feed layers, dipole layers, and a wide-angle impedance matching (WAIM) layer.

A slat array architecture is an array architecture that includes a series of slats that are conventionally arranged perpendicular to the face of the array. Each slat provides a large surface area on which TRM modules and supporting components can be attached.

A conformal antenna or conformal array may be a flat array antenna that conforms to a prescribed shape, such as a curved surface. The multiple individual antennas mounted on or in the curved surface work together as a single antenna to transmit or receive radio waves.

SUMMARY

According to an aspect of the present disclosure, a conformal antenna device is provided that includes a conformance panel, an antenna array, a combiner board, and a plurality of slats. The conformance panel (CP) has an CP inner radial surface, a CP outer radial surface, a width extending between a first axial end and a second axial end, and a length extending between a first lateral end and a second lateral end. The conformance panel extends linearly in a widthwise direction and extends arcuately in a lengthwise direction. The conformance panel includes a plurality of apertures extending between the CP inner radial surface and the CP outer radial surface. The antenna array is attached to the outer radial surface of the conformance panel. The plurality of slats extend between the combiner board and the conformance panel in a spoke arrangement. Each slat includes a first plate and a second plate. Each second plate includes electrical circuitry and one or more components and is in signal communication with the antenna array.

In any of the aspects or embodiments described above and herein, the slats of the plurality of slats may be spaced apart from one another by one or more CB inter-slat spacings proximate the combiner board, and the plurality of slats may be spaced apart from one another by one or more CP inter-slat spacings proximate the combiner board, and each of the one or more CP inter-slat spacings may be greater than each of the one or more CB inter-slat spacings.

In any of the aspects or embodiments described above and herein, the one or more CP inter-slat spacings may be uniform, and the one or more CB inter-slat spacings may be uniform.

In any of the aspects or embodiments described above and herein, the combiner board may include a CB outer radial surface that extends arcuately between lengthwise ends, and the CB outer radial surface may have a CB arcuate configuration.

In any of the aspects or embodiments described above and herein, the conformance panel extending arcuately in a lengthwise direction is a CP arcuate configuration, and the CB arcuate configuration may nest with the CP arcuate configuration.

In any of the aspects or embodiments described above and herein, the CP arcuate configuration may be disposed at a first radius, and the CB arcuate configuration may be disposed at a second radius, and the second radius may be less than the first radius.

In any of the aspects or embodiments described above and herein, the conformance panel may include a plurality of slat tab rows extending outwardly from the CP inner radial surface, and the slat tab rows may extend between the first axial end and the second axial end of the conformance panel, and each slat tab row may include a plurality of slat tabs.

In any of the aspects or embodiments described above and herein, the antenna array may have an inner radial side, an outer radial side, and a plurality of finger interfaces extending out from the inner radial side. Each finger interface of the plurality of finger interfaces may extend through a respective aperture extending between the CP inner radial surface and the CP outer radial surface, and outwardly from the inner radial surface of the conformance panel. The second plate of each slat may be in signal communication with one or more of the finger interfaces.

In any of the aspects or embodiments described above and herein, the finger interfaces of the plurality of finger interfaces may be disposed in rows parallel to the slat tab rows, and each respective slat tab row may be spaced apart a distance from a respective finger interface row. Each slat of the plurality of slats may be disposed between a respective slat tab row and a finger interface row. Each finger interface may be in signal communication with the second plate of the slat disposed between the respective slat tab row and a finger interface row.

In any of the aspects or embodiments described above and herein, the antenna array may be a planar ultrawideband modular antenna (PUMA) array attached to the outer radial surface of the conformance panel. The PUMA array may have an inner radial side, an outer radial side, a first PA axial end, and a second PA axial end.

In any of the aspects or embodiments described above and herein, the PUMA array may include a plurality of finger interfaces extending out from the inner radial side. Each finger interface may extend through a respective aperture extending between the CP inner radial surface and the CP outer radial surface, and outwardly from the inner radial surface of the conformance panel. The second plate of each slat may be in signal communication with one or more of the finger interfaces.

In any of the aspects or embodiments described above and herein, the PUMA array (PA) may include rows of PA apertures extending through the PUMA array. The rows of PA apertures may extend between the first PA axial end and the second PA axial end.

In any of the aspects or embodiments described above and herein, the PUMA array may include a stack of feed layers, dipole layers, and a wide-angle impedance matching (WAIM) layer disposed between the inner radial side and the outer radial side. The PUMA array may include a plurality of channels disposed in the feed layers or the WAIM layer. The channels may extend between the first PA axial end and the second PA axial end, and the plurality of channels may be disposed in both the feed layers and the dipole layers.

In any of the aspects or embodiments described above and herein, the PUMA array may extend linearly in a widthwise direction and extend arcuately in a lengthwise direction and may be configured to mate with the conformance panel.

In any of the aspects or embodiments described above and herein, the second plate of each slat may be a printed wire board or a printed circuit.

In any of the aspects or embodiments described above and herein, the first plate of each slat may be configured as a thermal sink and may be configured to carry a ground connection between the conformance panel and the combiner board.

In any of the aspects or embodiments described above and herein, the conformance panel may be attached to each respective slat by one or more fasteners engaged with the first panel of the respective slat.

The foregoing features and elements may be combined in various combinations without exclusivity, unless expressly indicated otherwise. For example, aspects and/or embodiments of the present disclosure may include any one or more of the individual features or elements disclosed above and/or below alone or in any combination thereof. These features and elements as well as the operation thereof will become more apparent in light of the following description and the accompanying drawings. It should be understood, however, the following description and drawings are intended to be exemplary in nature and non-limiting.

DETAILED DESCRIPTION

Referring toFIGS.1-3, the present disclosure is directed to a conformal wideband active electronically scanned array (AESA) antenna device20that includes an antenna array such as a planar ultrawideband modular antenna (PUMA) array22, a plurality of slats38, a conformance panel40, and a combiner board80. The present disclosure is not limited to use with a PUMA array22. Alternative embodiments may include a patch antenna array or the like. To facilitate the description herein, the antenna array will be described in terms of a PUMA array22.

The PUMA array22is an ultrawideband (UWB) array comprised of unit cells. Collectively, the PUMA array22may be described as having an outer radial side24, an inner radial side26, a first axial end28, a second axial end30, a first lateral end32, and a second lateral end34. The PUMA array22shown inFIGS.1and2is a section of array; hence, the first and second axial ends28,30and the first and second lateral ends32,34shown may not be the respective axial ends and lateral ends of a full PUMA array22.

Each of the unit cells in the PUMA array22includes circuits and vias fabricated as a multilayer printed circuit board (PCB), and at least one signal connector (e.g., a finger interface36) for signal connection with a slat38as will be described herein. Each unit cell may be described as having feed layers22A, dipole layers22B, and a wide angle impedance matching (WAIM) layer22C. The aforesaid layers22A-C in each unit cell are disposed in a stacked configuration such that the dipole layers22B are disposed between the feed layers22A and the WAIM layer22C, with the feed layers22A defining the inner radial side26of the array22and the WAIM layer22C defining the outer radial side24of the array22. A radome23is typically disposed outside of the WAIM layer22C. The first and second axial ends28,30of the PUMA array22are disposed on opposite axial ends (which may be referred to as the widthwise ends-extending along a Y-axis) and the first and second lateral ends32,34of the PUMA array22are disposed on opposite lateral ends (which may be referred to as the lengthwise ends—extending along an X-axis). The inner radial side26of the PUMA array22is disposed contiguous with and is attached to the conformance panel40; e.g., the PUMA array22may be bonded to the conformance panel40. The feed layers22A, the dipole layers22B, and the WAIM layer22C of the unit cells may collectively be referred to as the “radiator” of the PUMA array22. The WAIM layer22C is adhered, or bonded, or otherwise attached to the dipole layers22B. The radome23may have an interior surface that is faceted for interface with the WAIM layer22C of the PUMA array22.

FIG.3illustrates a non-limiting example of a PUMA array22, including the specific layers within the respective feed layers22A, dipole layers22B, and WAIM layer22C. This example of a PUMA array22is provided to illustrate a PUMA array22and the present disclosure is not limited to any particular PUMA array configuration.

Referring toFIG.4, the conformance panel40is configured to have a width42that extends linearly (i.e., extends along a straight line between two points, along a Y-axis) between axial ends54,56, and is configured to have a length44that extends arcuately between lengthwise ends58,60. The arcuate lengthwise shape of the conformance panel40may be described as an arcuate configuration within the X-Z plane. The feed layers22A and the dipole layers22B are configured to permit the PUMA array22to assume the widthwise linear configuration and the lengthwise arcuate configuration in the X-Z plane of the conformance panel40.

As shown inFIG.3, the feed layers22A may include one or more laminate layers, one or more bondply layers, one or more ground plane layers, and the like. According to the present disclosure these layers may be disposed in an arcuate configuration within the X-Z plane to create the conformal antenna. The aforesaid feed layers22A may be formed having the desired X-Z plane lengthwise arcuate configuration, or the aforesaid layers may be configured to be disposable in (e.g., bendable to) the desired X-Z plane lengthwise arcuate configuration. The dipole layers22B may include one or more bondply layers, an outer dipole layer, and inner dipole layer, and a dielectric layer disposed between the inner and outer dipole layers. The inner and outer dipole layers and the dielectric layer may be formed to have a lengthwise arcuate configuration within the X-Z plane, or the aforesaid layers may be configured to be disposable in (e.g., bendable to) the aforesaid X-Z plane lengthwise arcuate configuration. Regarding the latter, the layers (e.g., the dielectric layers, the dipole layers, and the like) may comprise material having sufficient flexibility to permit the layers to be bent into the desired X-Z plane lengthwise arcuate configuration. As an example, the dipole layers22B may comprise thin rolled copper layers that can be bent into the desired X-Z plane arcuate configuration.

Referring toFIG.4, the PUMA array22includes rows of through holes46extending through the feed layers22A, the dipole layers22B, and the WAIM layer22C, i.e., through the radiator. The through holes46are configured for tuning and to facilitate attaching the conformance panel40(and the PUMA array22attached thereto) to the slats38. The rows of through holes46may be described as being arranged in widthwise rows (i.e., rows extending between the first and second axial ends28,30). In some embodiments, the PUMA array22may include rows of widthwise extending channels48disposed in the feed layers22A and the WAIM layer22C. The widthwise extending channels48may include inner radial portions48A and outer radial portions48B. The inner and outer radial channel portions48A,48B may be aligned with one another. The widthwise channels48are configured to facilitate the lengthwise arcuate configuration in the X-Z plane; e.g, to provide flexibility within the feed layers22A and the WAIM layer22C in the X-Z plane. In the embodiment shown inFIG.4, each of the through holes46in a given widthwise row is in communication with a respective widthwise extending channel48.

The WAIM layer22C has an interior surface and an opposite exterior surface. The WAIM layer22C interior surface is contiguous with and attached to the dipole layers22B. The WAIM layer22C may be produced having the desired X-Z plane lengthwise arcuate configuration, or the WAIM layer22C may be configured to be disposable (e.g., bendable) in the desired X-Z plane arcuate configuration.

The radome23is a protective structure that is transparent to electromagnetic/RF signals. The term “transparent” is used here to mean that the radome23is configured to not appreciably attenuate electromagnetic/RF signals passing there through.

Referring toFIGS.5-8, the conformance panel40includes an outer radial surface50, an inner radial surface52, a first axial end54, a second axial end56, a first lateral end58, and a second lateral end60. The conformance panel40extends widthwise between the first and second axial ends54,56and lengthwise between the first and second lateral ends58,60. The conformance panel40extends linearly in the widthwise direction between the axial ends54,56(i.e., extends along a straight line between two points, along a Y-axis), and extends arcuately between the lengthwise ends58,60(i.e., along an arcuate line within the X-Z plane). In some embodiments, the lengthwise arcuate configuration of the conformance panel40in the X-Z plane may be a constant radius. In some embodiments, the lengthwise arcuate configuration of the conformance panel40in the X-Z plane is not a constant radius; e.g., the lengthwise arcuate configuration of the conformance panel40in the X-Z plane may include a plurality of different radii.

The conformance panel40includes a plurality of slat tabs62extending outwardly from the inner radial surface52. The slat tabs62may be arranged in rows extending between the first and second axial ends54,56of the conformance panel40. The slat tab rows may be oriented perpendicular relative to the first and second axial ends54,56. The slat tab62in each row may be a single continuous slat tab62extending between the first and second axial ends54,56, or there may be a plurality slat tabs62disposed in each row.

Each slat tab62has a length64that extends from the inner radial surface52to a distal end66. Each slat tab62has a first lateral surface68and an opposite second lateral surface70. As will be disclosed herein, the second lateral surface70of each slat tab62is disposed contiguous with a slat38. In some embodiments, a slat tab62may include a chamfer72extending between the second lateral surface70and the distal end66.

The conformance panel40includes rows of apertures74extending through the inner and outer radial surfaces52,50. In some embodiments, the apertures74may have a slot configuration (e.g., oval, rectangular, or the like) having a major axis and a minor axis. The major axis is greater than the minor axis. The present disclosure is not limited to any particular aperture74geometry. The aperture74rows may extend parallel with the slat tab62rows.

The conformance panel40may include rows of fastener apertures76extending through the inner and outer radial surfaces52,50. Each row of fastener apertures76extends between the first and second axial ends54,56and includes a plurality of fastener apertures76. Each fastener aperture76row may be oriented perpendicular relative to the first and second axial ends54,56. Each fastener aperture76is configured to receive a fastener78that is used to secure a respective slat38to the conformance panel40and to carry a ground connection therebetween. In some applications, each fastener aperture76is configured such that the head of the fastener78is countersunk when installed and therefore does not extend above the outer radial surface50of the conformance panel40; e.g., an aperture configured to receive a bevel head fastener.

The slats38extend between the combiner board80and the conformance panel40. Each slat38includes a first plate (which may be referred to hereinafter as a “cold plate82”) and a second plate (which may be referred to hereinafter as a “circuit board84”). The cold plate82and the circuit board84of each slat38may be attached to one another. The circuit board84includes electrical circuitry and components. The electrical circuitry and components may be attached to a substrate, or the electrical circuitry and components may be integral; e.g., in the form of a printed wire board (PWB) or a printed circuit board (PCB), or the like. The circuit board84of each slat38is configured for signal communication to and from the PUMA array22and to and from external devices. The cold plate82provides an electrical ground path between the PUMA array22and the combiner board80. The cold plate82may be configured to function as a thermal energy sink, accepting thermal energy transfer from the circuit board84(and/or components attached thereto) and dissipating that thermal energy. The cold plate82may also be configured to provide structural support to the circuit board84. Each slat38has a height86extending between an outer end surface88and an inner end surface90, and a width92extending between a first axial end94and a second axial end96. Embodiments of the present disclosure may utilize different slat heights86, and the present disclosure is not therefore limited to any particular slat height86. The circuit board84is configured to create a signal connection with the feed layers of the PUMA array22. For example, finger interfaces36that extend outwardly from each unit cell of the PUMA array22may engage with the circuit board84to permit signal communication between the circuit board84and the PUMA array22. Although finger interfaces36provide a desirable means of providing signal connection, the present disclosure is not limited thereto. The circuitry within the circuit board84may be configured (e.g., configured to include microstrip tapering) to provide impedance matching between the circuit board84, the finger interfaces36and the PUMA array22.

The combiner board80may be a printed wire board (PWB) or a printed circuit board (PCB) that is configured to establish signal communication with the slats38and external components used in the operation of the present disclosure AESA antenna device20. The combiner board80has an outer surface98, an inner surface100, a width102that extends linearly (i.e., extends along a straight line between two points, along a Y-axis), and a length104. The outer surface98extends arcuately between lengthwise ends. The lengthwise arcuate configuration of the outer surface98may be described as an arcuate configuration within the X-Z plane. Like the conformance panel40, the outer surface98of the combiner board80may have a lengthwise arcuate configuration in the X-Z plane that is a constant radius, or it may have a lengthwise arcuate configuration in the X-Z plane that includes a plurality of different radii. The outer surface lengthwise arcuate configuration may be described as having a nested relationship with the X-Z plane lengthwise arcuate configuration of the conformance panel40and the PUMA array22. For example, in some embodiments the X-Z plane lengthwise arcuate configuration of the present disclosure AESA antenna device20components (e.g., the outer surface98of combiner board80, the conformance panel40, and the PUMA array22) may share a point of origin, with the lengthwise arcuate configuration of each component having a different radius. In other embodiments, the relative arcuate configurations of the outer surface98of the combiner board80and the conformance panel40are such that the spacing therebetween is constant at any particular lengthwise position. In other words, the curvature of the outer surface98of the combiner board80may not be parti-circular and the curvature of the conformance panel40may not be parti-circular, but the aforesaid curvatures track with one another. In still other embodiments, the relative arcuate configurations of the outer surface98of the combiner board80and the conformance panel40may not track exactly with each other and the relative spacing therebetween may vary.

In some embodiments, the combiner board80may be configured for mechanical attachment with each respective slat38; e.g., the combiner board80may include physical features (e.g., slots), or a fastener element (e.g., mechanical fasteners like a screw or a bonding agent, or the like), or some combination that facilitates attachment between the slats38and the combiner board80.

In some embodiments, the present disclosure AESA antenna device20may include a base plate106(e.g., seeFIGS.1and2) attached to the combiner board80. The base plate106may be configured to facilitate mounting of the AESA antenna device20, or to facilitate connection of the present disclosure AESA antenna device20to components external to the AESA antenna device20, or the like, or any combination thereof.

The slats38extend between the combiner board80and the conformance panel40in a spoke-like fashion. The inter-spoke spacing at the combiner board80is less than the inter-spoke spacing at the conformance panel40. The slats38may be uniformly spaced relative to one another. For example, in some embodiments the inter-spoke spacing at the combiner board80may be uniform, and/or in some embodiments the inter-spoke spacing at the conformance panel40may be uniform. The present disclosure is not, however, limited to uniform inter-spoke spacing at the combiner board80or uniform inter-spoke spacing at the conformance panel40. The inter-spoke spacing may be, but is not required to be, uniform in the widthwise direction between the first and second axial ends94,96,54,56of the combiner board80and the conformance panel40.

The architecture of present disclosure AESA antenna device20facilitates the production of the device20, decreases the time and money associated with producing the device20, and lends the device20to modular configuration. The PUMA array22is attached to the outer radial surface50of the conformance panel40with the finger interfaces36(or other connectors) extending outwardly from the array22and through the apertures74within the conformance panel40so that the finger interfaces36extend outwardly from the inner radial surface52of the conformance panel40. The PUMA array22(i.e., the feed layers22A, the dipole layers22B, and WAIM layer22C) is configured to permit the PUMA array22to assume an arcuate configuration in the X-Z plane. As stated herein, the inner and outer dipole layers and the dielectric layers may be produced to have an arcuate configuration within the X-Z plane that mates with the curvature of the conformance panel40, or the aforesaid layers may be configured (e.g., bendable) to be disposable in the aforesaid X-Z plane arcuate configuration. In either of these configurations, some embodiments of the PUMA array22may include rows of widthwise extending channels48disposed in the feed layers22A and the WAIM layer22C to facilitate the X-Z plane arcuate configuration.

Each slat38is inserted in a respective region disposed at the inner radial surface52of the conformance panel40, between a respective slat tab62row and the finger interfaces36associated with the row (e.g., seeFIG.8). Once the slat38is inserted, the finger interfaces36extending out from the PUMA array22that are associated with that row may be biased against the circuit board of that slat38to create a connection that permits signal communication between the circuit board of that slat38and the unit cells of the PUMA array22of that row. In the process of inserting the slat38or subsequent to the slat38insertion, fasteners78may be disposed through the fastener apertures76within the conformance panel40for engagement with the cold plate82portion of the respective slat38. In this manner, each respective slat38is secured to the conformance panel40, the circuit board84portion of the slat38is placed in signal communication with the PUMA array22via the finger interfaces36(or other connectors), and a ground connection is established through the cold plate82portion of the slat38. As stated above, the rows of through holes46extending through the feed layers22A, dipole layers22B, and WAIM layer22C facilitate attachment between the conformance panel40and the slats38by providing ready access to the fastener apertures76disposed in the conformance panel40. Once the slats38are secured to the conformance panel40, the radome23may be disposed/attached outside of the PUMA array22. Before or after the slats38are attached to the conformance panel40, the slats38may be attached to and placed in signal communication with the combiner board80.

The present disclosure AESA antenna device20architecture is scalable to cover different frequencies and thereby be broadly applicable across multiple platforms. For example in a first embodiment, the present disclosure AESA antenna device20may be configured with a PUMA array22curvature, slat height86(i.e., the distance between the inner and outer end surfaces88,90), and inter-slat spacing associated with a first frequency range, and in a second embodiment the present disclosure AESA antenna device20may be configured with a PUMA array22curvature, associated slat height86, and inter-slat spacing associated with a second frequency range, and so on. As a specific example, a present disclosure AESA antenna device20with a four-inch (4 in.) radius curvature may be configured for use with frequencies in the V-band range (˜40-75 GHZ). As another example, a present disclosure AESA antenna device20with a six-inch (6 in.) radius curvature may be configured for use with frequencies in the X-band range (˜8-12 GHz). As another example, a present disclosure AESA antenna device20with an eight-inch (8 in.) radius curvature may be configured for use with frequencies in the KA-band range (˜27-40 GHz). These examples are intended to illustrate that the architecture of the present disclosure is readily scalable. The present disclosure architecture also permits unit cell spacing to be varied (which may implicate slat spacing) to vary frequency characteristics of the antenna.

While various inventive aspects, concepts and features of the disclosures may be described and illustrated herein as embodied in combination in the exemplary embodiments, these various aspects, concepts, and features may be used in many alternative embodiments, either individually or in various combinations and sub-combinations thereof. Unless expressly excluded herein all such combinations and sub-combinations are intended to be within the scope of the present application. Still further, while various alternative embodiments as to the various aspects, concepts, and features of the disclosures—such as alternative materials, structures, configurations, methods, devices, and components, and so on—may be described herein, such descriptions are not intended to be a complete or exhaustive list of available alternative embodiments, whether presently known or later developed. Those skilled in the art may readily adopt one or more of the inventive aspects, concepts, or features into additional embodiments and uses within the scope of the present application even if such embodiments are not expressly disclosed herein. For example, in the exemplary embodiments described above within the Detailed Description portion of the present specification, elements may be described as individual units and shown as independent of one another to facilitate the description. In alternative embodiments, such elements may be configured as combined elements. It is further noted that various method or process steps for embodiments of the present disclosure are described herein. The description may present method and/or process steps as a particular sequence. However, to the extent that the method or process does not rely on the particular order of steps set forth herein, the method or process should not be limited to the particular sequence of steps described. As one of ordinary skill in the art would appreciate, other sequences of steps may be possible. Therefore, the particular order of the steps set forth in the description should not be construed as a limitation.