Patent Publication Number: US-8120537-B2

Title: Inclined antenna systems and methods

Description:
RELATED APPLICATION 
     This application claims priority to U.S. Provisional Application No. 61/127,087, filed May 9, 2008, and entitled “INCLINED ANTENNA SYSTEMS AND DEVICES”. This application is also a continuation-in-part of and claims priority to U.S. patent application Ser. No. 12/274,994, filed Nov. 20, 2008, and entitled “LOW COST MODULAR SUBARRAY SUPER COMPONENT”, which claims priority to U.S. Provisional Application No. 61/127,071, filed May 9, 2008, and entitled “LOW COST MODULAR SUBARRAY SUPER COMPONENT”, all of which are hereby incorporated by reference. 
    
    
     FIELD OF INVENTION 
     The present invention relates to the structure of a radiating element and to the configuration of an array of radiating elements of a hybrid steerable beam antenna. 
     BACKGROUND OF THE INVENTION 
     Many existing and future mobile vehicular applications require high data rate broadcasting systems ensuring full continental coverage. With respect to terrestrial networks, satellite broadcasting allows having continuous and trans-national coverage of a continent, including rural areas. Among existing satellite systems, Ku-band capacity is widely available in Europe, North America and most of the other regions in the world and can easily handle, at a low cost, fast and high-capacity communications services for commercial, military and entertainment applications. 
     The application of Ku-band to mobile terminals typically requires the use of automatic tracking antennas that are able to steer the beam in azimuth, elevation and polarization to follow the satellite position while the vehicle is in motion. Moreover, the antenna should be “low-profile”, small and lightweight, thereby fulfilling the stringent aerodynamic and mass constraints encountered in the typical mounting of antennas in airborne and automotive environments. 
     Typical approaches for beam steering are full mechanical scan or full electronic scan. The main disadvantages of the first approach for mobile terminals is the bulkiness of the structure due to the size and weight of mechanical parts, the reduced reliability because mechanical moving parts are more subject to wear and tear than electronic components, and high assembling costs making the approach less suitable for mass production. In comparison, the main drawback of fully electronic steering is that the antenna requires the integration of a lot of expensive analog RF electronic components which may prohibitively raise the cost for commercial applications. 
     An advantageous approach is to use a “hybrid” steerable beam antenna implementing a mechanical rotation in azimuth and electronic scanning in elevation. This approach requires only a simple single axis mechanical rotation and a reduced number of electronic components. These characteristics allow for maintaining a low production cost due to reduced mechanical parts and electronic components, reducing the size and the “height” of the antenna which is important in airborne and automotive applications, and having a better reliability factor than a fully mechanical approach due to fewer mechanical parts. 
     The ideal requirement for steerable beam antennas is to be capable of orientating the beam in any direction while maintaining a similar level of performance in all directions. This is possible only with mechanically steerable antennas having the freedom to rotate in any direction. 
     The performances of low-profile planar antennas mounted on a horizontal surface are typically decreased at low elevation angles due to a size reduction of the equivalent surface projected in the direction of the satellite. The use of antenna arrays with a hybrid steering mechanism (azimuth rotation) allows optimization of the radiating element pattern in a preferred direction. 
     Another advantageous antenna configuration is achieved by inclining the radiating elements in order to better focus the radiated power toward low elevation angles. Shaping of the radiation pattern does not allow an increase in the absolute level of the antenna performances, which has a maximum limit imposed by the equivalent surface, but it does allow a reduction in the number of elements in the array and hence reduces the number of electronic components required to electronically steer the beam in elevation. 
     However, the use of inclined radiating elements has generally important limitations on the radiation at low elevation due to the blockage of the field of view for the elements behind the first row. Thus, there is a need for a system and method for increasing the efficiency of an antenna at low elevation scanning. 
     SUMMARY OF THE INVENTION 
     This application presents an approach to design an inclined antenna array with a hybrid mechanical-electronic steering system with improved radiation performances at low elevation angles. The application of original design concepts allows building an antenna joining performances at low elevation angles, low-cost, low-profile and lightweight characteristics. 
     In an exemplary embodiment, a radiating element structure is attached to a mounting surface and includes a patch antenna and a ground plane. The bottom edge of the patch antenna is farther from the mounting surface than the top edge of the patch antenna. If the radiating element structure is used in an inclined array antenna, then the patch antenna has an uncovered view of a low elevation angle. A clear view of the low elevation angle results in increased directivity and increased polarization quality due to reduced signal scattering. 
     In another exemplary embodiment, an inclined element array antenna includes a first radiating element having a first ground plane and a first patch antenna, and a second radiating element having a second ground plane and a second patch antenna. The first radiating element is located in front of the second radiating element on a mounting surface. In the exemplary embodiment, the second patch antenna of the second radiating element is configured to have a clear line of sight to the horizon over the first ground plane of the first radiating element. 
     In yet another exemplary embodiment, an antenna system includes a first row of radiating elements having at least a first and second radiating element, and a second row of radiating elements having at least a third and fourth radiating element. The first and second radiating elements are spaced apart by a distance of at least the width of the third radiating element. Additionally, the third radiating element is aligned with the spacing between the first and second radiating element so that the third radiating element is not blocked by the first row of radiating elements from a frontal perspective. Furthermore, the third and fourth radiating elements are spaced apart by a distance of at least the width of the second radiating element, and the second radiating element is positioned to align with the spacing between the third and fourth radiating elements. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING FIGURES 
       A more complete understanding of the present invention may be derived by referring to the detailed description and claims when considered in connection with the drawing figures, wherein like reference numbers refer to similar elements throughout the drawing figures, and: 
         FIG. 1  shows an exploded view of a prior art example of an antenna module with a coaxial RF connector; 
         FIG. 2  shows two examples of a bar with leads connector; 
         FIG. 3  shows an example graph depicting insertion loss; 
         FIG. 4  shows an exemplary graph depicting return loss; 
         FIG. 5  shows two examples of a printed circuit board; 
         FIG. 6  shows two examples of a bar with leads connector before attachment and two circuit boards with leads attached; 
         FIG. 7  shows a flowchart of a method for attaching multiple leads to a PCB using a bar with leads connector; 
         FIG. 8  shows three examples of support brackets, including an example of a support bracket with an exemplary pick-up tab; 
         FIG. 9  shows an example of multiple antenna modules; 
         FIG. 10  shows an example of an antenna module; 
         FIG. 11  shows two examples of a circuit board panel; 
         FIG. 12  shows a side view of a hybrid phased array antenna constructed with super components partially assembled; 
         FIG. 13  shows an exploded view of an example of an antenna aperture; 
         FIG. 14  shows a perspective view of a close-up example of an antenna module with a leads connection to a steering printed circuit board; 
         FIGS. 15A ,  15 B shows perspective views of an exemplary RF lead interface; 
         FIG. 16  shows a perspective view of an example of an antenna assembly; 
         FIG. 17  shows a flow chart of an example of a manufacturing process flow; 
         FIG. 18  shows an exemplary embodiment of a radiating element structure; 
         FIG. 19  shows an exemplary embodiment of a radiating element structure having multiple patch antennas; 
         FIGS. 20A-20C  show embodiments of radiating element structures with different ground plane configurations; 
         FIG. 21  shows another exemplary embodiment of a radiating element structure having multiple patch antennas; 
         FIG. 22  shows a side view of a typical prior art antenna array layout; 
         FIG. 23  shows a side view of an exemplary embodiment of an antenna array layout; 
         FIG. 24  shows a side view of an exemplary radiating element structure and associated dimensions; 
         FIG. 25  shows a top view of an exemplary embodiment of an antenna array layout with aligned radiating element structures; 
         FIG. 26  shows a top view of another exemplary embodiment of an antenna array layout with interleaved radiating element structures; and 
         FIG. 27  shows a top view of an exemplary embodiment of a dual aperture inclined array antenna system. 
     
    
    
     DETAILED DESCRIPTION 
     While exemplary embodiments are described herein in sufficient detail to enable those skilled in the art to practice the invention, it should be understood that other embodiments may be realized and that logical electrical and mechanical changes may be made without departing from the spirit and scope of the invention. Thus, the following detailed description is presented for purposes of illustration only. 
     In an exemplary embodiment, and with reference to  FIG. 18 , a radiating element structure  1800  comprises a patch antenna  1805 , a dielectric layer  1810 , a ground plane  1820 , and a microstrip line  1830 . The ground plane  1820  is located between microstrip line  1830  and dielectric layer  1810 . In an exemplary embodiment, radiating element structure  1800  is a microstrip-fed aperture-coupled patch antenna. In another embodiment, the patch antenna  1805  could also be at least one of a dipole, a ring, and any other suitable radiating element. In a further exemplary embodiment, radiating element structure  1800  is a dual polarized radiating element with a ground plane  1820 , which comprises an orthogonal slot feed  1825 . For illustration purposes, the dual polarization of the radiating element will be limited to horizontal and vertical polarizations. 
     Radiating element structure  1800  can be configured in different suitable embodiments. For example, in one exemplary embodiment and with reference to  FIG. 19 , a radiating element structure  1900  may comprise a microstrip line  1910 , a microstrip line substrate  1920 , a ground plane  1930 , at least one dielectric layer  1940 , at least one patch substrate  1960 , and at least one patch antenna  1950  with a probe fed excitation  1970 . In a second exemplary embodiment, radiating element structure  1900  comprises two or more dielectric layers  1940 , two or more patch antennas  1950 , two or more patch substrates  1960 , or any combination thereof. Although exemplary structures are described herein for radiating element structure  1900 , it should be understood that many different structures may be used consistent with that which is disclosed herein. 
     The dielectric layer separates other antenna assembly components. In an exemplary embodiment, the dielectric material is a foam material. For example, the foam may be Rohacell HF with a gradient of 31, 51 or 71. Moreover, dielectric material may be any suitable material as would be known in the art. In an exemplary embodiment, dielectric layer  1940  may be air or any material that separates patch antenna  1950  from ground plane  1930  and allows radio frequency (RF) signals to pass. 
     Furthermore, in an exemplary embodiment, radiating element structure  1800 ,  1900  is configured to receive signals in the Ku-band, which is approximately 10.7-14.5 GHz. In another embodiment, radiating element structure  1800 ,  1900  is configured to receive signals in the Ka-band, which is approximately 18.5-30 GHz. In yet another embodiment, radiating element structure  1800 ,  1900  is configured to receive signals in the Q band, which is approximately 36-46 GHz. In other exemplary embodiments, radiating element structures may be configured to receive any suitable frequency band. Additionally, in an exemplary embodiment, radiating element structure  1800 ,  1900  is part of an antenna configured to scan at least 20° above horizon or lower. 
     Furthermore, though the radiating elements and antenna system described herein is referenced in terms of receiving a signal, the antenna system is not so limited. Accordingly, in an exemplary embodiment, the radiating element structures may be configured to transmit a signal at various frequencies, similar to the receiving of signals. In another exemplary embodiment, the radiating element structures may be configured to transmit and receive signals at various frequencies. 
     In an exemplary embodiment, the systems and methods described herein may applicable to linear polarized signals. In another exemplary embodiment, the systems and methods described herein may be applicable to circular polarized signals. Additionally, the systems and methods described herein may be applicable to non-linear polarized signals. 
     In an exemplary embodiment, ground plane  1820  is made of metal. Ground plane  1820  may be a continuous or discontinuous piece of metal. Furthermore, ground plane  1820  may be made of any suitable material that prevents the transmission of spurious radiation as would be known in the art. In an exemplary embodiment, ground plane  1820  is located between, and separates, patch antenna  1805  and the circuitry, all of which are on separate planes. The radiation from patch antenna  1805  does not pass through ground plane  1820 , thereby substantially isolating patch antenna  1805  and microstrip line  1830  from each other. This isolation improves the RF signals by decreasing mutual-inference from circuitry radiation and the patch antenna radiation. 
     In the exemplary embodiment the feed line is below the ground plane, which substantially prevents the feed line from radiating in the direction of the patch antenna. In an exemplary embodiment the aperture coupling mechanism allows the separation between radiating elements and antenna circuitry, such as feed networks and other active components, into at least two separate layers and prevents or substantially prevents the spurious radiation from the antenna circuitry from affecting the radiation pattern of the antenna. In an exemplary embodiment, and with reference to  FIG. 20A , a radiating element structure comprises a ground plane  2010  located below a patch antenna  2015  and above a feed line  2005 . From this arrangement, radiation  2001  from patch antenna  2015  radiates away from ground plane  2010  and radiation  2003  from feed line  2005  radiates in the opposite direction. In contrast, as depicted in  FIG. 20B  and  FIG. 20C , if a feed line  2005  is on the same side of a ground plane  2010  as a patch antenna  2015  with respect to ground plane  2010 , then feed line  2005  can radiate as well as patch antenna  2015 . This can have a very negative effect by affecting the purity of polarization. 
     The complete or substantially complete separation of the feed circuit layer from the radiating circuit layer allows for separately optimizing the materials and the design of the two parts of the antenna. Typically, requirements for microwave circuits and antennas are very different: microwave circuits often use “high permittivity” dielectric substrates to reduce the size of the circuit, reduce the lines&#39; spurious radiated power and the coupling between the lines. On the other hand, patch antennas are typically based on “low-permittivity” dielectric substrates that facilitate higher radiation efficiency, lower losses and larger bandwidth. Further information on permittivity of substrates used in patch antennas is described in a text written by Fred E. Gardiol and Francois Zürcher, entitled “Broadband Patch Antennas”, published by Artech House (1995). 
     The two requirements are clearly in contrast when the radiators and the feed lines are on the same side of the ground plane and are forced to share the same dielectric material. The separation of feed circuit and radiators in two boards may simplify the design because the designer has two complete boards to adjust all components and does not have to heavily consider the possible interactions (couplings) between feed circuits and radiators. This structure facilitates locating lines and/or components very close to the slots without affecting the radiation characteristics. In typical prior art configurations with feed circuit and radiators on the same side of the ground plane, it is preferable to leave empty the whole surface under the patches, which is a larger surface than that occupied by the slots. 
     In accordance with an exemplary embodiment and with renewed reference to  FIG. 18 , ground plane  1820  comprises slot feed  1825 , which allows signals to communicate between patch antenna  1805  and microstrip line  1830 . In an exemplary embodiment, slot feed  1825  excites a very pure resonant mode on the patch antenna with a very low cross polarization component. This excitation method provides much better polarization results than other feed models, such as line feed, coaxial-pin feed, and electromagnetic coupling feed. In an exemplary embodiment, the cross polarization level is below about −15 dB. In another exemplary embodiment, the cross polarization level is below about −25 dB. The cross polarization can be at other levels as well in other exemplary embodiments. 
     The slot feed  1825  is used to couple the power from the microstrip lines to the patch antennas. In one embodiment, the shape of slot feed  1830  may be arbitrary. In an exemplary embodiment, and with reference to  FIG. 18 , the ground plane may include two slots substantially orthogonal to each other. In another embodiment, the ground plane may include an “H”-shaped slot and a “C”-shaped slot, where one slot is horizontally orientated and the other is vertically orientated. Furthermore, in yet another embodiment, slot feed  1830  may be orientated at any angle while the two slots are still substantially orthogonal to each other. This embodiment provides good isolation between the two slots allowing better purity of the polarized signals. In an exemplary embodiment, the size of slot feed  1830  is optimized in order to obtain the best matching. The optimization may be accomplished using computer simulations and optimization. In one embodiment, the length of slot feed  1830  is smaller than half the signal wavelength (λ/2). 
     The benefits of using an “H”-shaped slot include a more compact size compared to a linear slot and offering a smaller required surface for coupling with patch antenna  1805 . The shorter slot length allows a reduction of the direct radiation from the slot itself, which radiates both forward and backward. In other words, an “H”-shaped slot can help to reduce unwanted backward radiation. Moreover, more radiating elements can be fit in the same space with a compact “H”-shaped slot, or any similar compact slot, than with a linear slot or the like. In addition, a compact slot design increases the polarization purity as described above, and ensures a low coupling between two orthogonal polarizations. 
     In accordance with an exemplary embodiment, a radiating element structure, sometimes referred to as a stacked resonator structure, includes more than one radiating element, a ground plane, a feed element, and dielectric layers located between the other components. In accordance with an exemplary embodiment, and with renewed reference to  FIG. 19 , radiating element structure  1900  comprises two coupled radiating elements based on the use of stacked patch antenna resonators  1950 . In an exemplary embodiment, the feed element is one of a line, a waveguide, a coaxial probe, a slot, or any combination thereof. Additionally, in one embodiment, stacked patch antennas  1950  are optimized for transmit frequency bands. In another embodiment, stacked patch antennas  1950  are optimized for receive frequency bands. In yet another exemplary embodiment, stacked patch antennas  1950  are optimized to increase the antenna bandwidth to allow adjacent transmit and receive frequency bands. 
     In another exemplary embodiment and with reference to  FIG. 21 , a radiating element structure  2100  comprises four radiating elements  2101 - 2104 . The two radiating elements  2101  and  2102  positioned farthest from a ground plane  2120  are coupled and may be configured to improve the front-to-back ratio of radiation. The other two radiating elements  2103  and  2104  positioned nearest to ground plane  2120  are coupled and may be configured to improve the bandwidth. 
     Furthermore, in an exemplary embodiment, radiating element structure  2100  comprises multiple radiating elements and may be stacked to facilitate placing at least one radiating element a substantial distance from ground plane  2120  further than otherwise could be done without stacking the components. In an exemplary embodiment, radiating element  2104  is positioned from a feed slot  2125  in the range of approximately 0.05λ-0.25λ. Positioning a radiating element far away from feed slot  2125  results in a considerable reduction of coupled energy. This reduction would result in a loss of efficiency, reduced bandwidth, poor antenna matching, and degraded radiation pattern. 
     In order to increase bandwidth, in an exemplary embodiment, radiating elements  2101 ,  2102  are positioned at a given spacing and have a small difference in size. This spacing allows increasing sensibly the bandwidth of the radiating element. In addition, other factors may be change, such as the shapes of radiating elements  2101 ,  2102  which may differ from each other, or the alignment of radiating elements  2101 ,  2102 . In an exemplary embodiment, each radiating element is optimized to resonate on a specific frequency band, and the combination of the different bands results in a larger bandwidth. This may be a very important characteristic for a receive antenna where more than 20% of bandwidth is required. Furthermore, in an exemplary embodiment, the stacked configuration of radiating elements provides more bandwidth than necessary and hence gives more flexibility in the design of the antenna to meet other design requirements. 
     In an exemplary embodiment, stacked radiating elements  2103 ,  2104  are used to increase the radiation of radiating element structure  2100  in the upper direction and reduce the emitted power in the bottom and side direction. In the exemplary embodiment, placing stacked radiating elements  2103 ,  2104  at a height that pulls the emitted power in the direction of the stack results in a reduction of front-to-back radiation and in an increased directivity. In an exemplary embodiment, the height is optimized by using computer aided simulations and its precision may, for example, be defined within one tenth of lambda. In another embodiment, the shapes of radiating elements  2103 ,  2104  are designed to achieve the same results. In yet another embodiment, the alignment of radiating elements  2101 - 2104  is optimized to shape the radiation pattern in a specific form. 
     Moreover, in an exemplary embodiment the reduction of back radiation is also achieved in part by shaping the coupling slot feed. For example, an H-shaped slot feed allows an equivalent level of coupling between the line and the patch, while limiting the length of the slot, hence limiting resonant effects on the slot and reducing radiation in the backward direction. 
     In addition to reducing back radiation, in an exemplary embodiment, stacked radiating elements are designed to increase the radiation level toward the main direction of interest and reduce the radiation in unwanted directions. In other words, stacked radiating elements may be configured to reduce unwanted radiation. In an exemplary embodiment, the stacked configuration is configured to minimize, or substantially minimize, the radiation close to the zenith direction and in the backward direction. The radiation is maximized, or substantially maximized, in the forward direction, which is the direction of the main beam. In this way, grating lobes that have the effect of reducing the performance of the antenna are cancelled or substantially reduced. 
     In accordance with an exemplary embodiment and with reference to  FIG. 27 , a dual aperture inclined array antenna system comprises multiple arrays of radiating element structures. A first aperture comprises radiating element arrays configured for receiving a signal. A second aperture comprises radiating element arrays configured for transmitting a signal. In various other embodiments, both apertures may be configured for only transmitting a signal, only receiving a signal, or transmitting and receiving a signal in the same aperture. In an exemplary embodiment, a linear antenna array comprises multiple radiating elements assembled in a row. The dual aperture inclined array antenna system may be used as a mobile antenna system, capable of scanning low elevations. 
     In order to scan at low elevation with low profile antenna structures, the inclination of radiating element structures can provide important benefits. Specifically, an array of inclined radiating elements can scan at low elevation with fewer elements than a planar array of radiating elements. One benefit of an inclined array is that in a steerable antenna, less active circuitry is needed in comparison to a planar array. In an exemplary embodiment, no mechanical or electronic scanning is needed to scan at low elevation. In another exemplary embodiment, electronic scanning is implemented to scan at low elevation. In various embodiments, low elevation may include the horizon line, about 0-20 degrees above the horizon line, about 20-30 degrees above the horizon line, or any range within about 0-40 degrees above the horizon line. 
     However, one of the drawbacks of a typical inclined array structure is the blockage of radiation caused by radiating element structures in the rows that are in front of the radiating element, as illustrated in  FIG. 22 . In a typical inclined array structure, the inclined radiating elements are spaced in order to reduce the blockage of a rear radiating element structure  2210  due to a front radiating element structure  2220 . One of the main problems of inclined rows array is that rear radiating element structure  2210  is “covered” by a ground plane  2221  of front radiating element structure  2220  when looking at low elevation angles. In other words, in this typical configuration, ground plane  2221  is between a radiating element “patch”  2211  of rear radiating element structure  2210  and a satellite at low elevation. Patch antenna  2211  ability to receive/transmit radiation at low elevation is limited if behind ground plane  2221 . The main effect is that the power radiated, or power received, by rear radiating element structure  2210  is partially reflected and scattered by ground plane  2221 , therefore a good radiation pattern at low elevation is not achievable in the prior art. Moreover the reflected power tends to radiate in the opposite direction causing a raise in grating lobes and side lobes. 
     In accordance with an exemplary embodiment, a new configuration of radiating elements in an array of inclined elements allows for minimization of the interference of the ground plane and increases the radiation at low elevation. In accordance with an exemplary embodiment and with reference to  FIG. 23 , a rear radiating element structure  2310  comprises a patch antenna  2311  and a ground plane  2312 . Furthermore, a front radiating element structure  2320  is located in front of rear radiating element structure  2310  and also comprises a patch antenna  2321  and a ground plane  2322 . The term “front” denotes a direction towards a source satellite, if the inclined radiating elements are facing the satellite. As illustrated by  FIG. 23 , in an exemplary embodiment, patch antenna  2311  is higher from a mounting surface  2301  in comparison to ground plane  2322 . In this configuration, patch antenna  2311  has a “clear view” of the low elevation and is much less affected by reflection and scattering. In other words, patch antenna has increased directivity at low elevation and increased polarization quality due to reduced signal scattering. A clear view allows an increase in antenna performance at low elevations, and minimization of the interference between the different rows. In one embodiment, a clear view is defined as when the bottom edge  2303  of patch antenna  2311  is positioned completely above the top point  2302  of ground plane  2322  of front radiating element structure  2320 . In another embodiment, a clear view is when any portion of patch antenna  2311  is positioned above the top point  2302  of ground plane  2322 . 
     In yet another embodiment, patch antenna  2311  has a clear view depending on the minimum elevation angle and the percent clearance horizontally over ground plane  2322  of radiating element structure  2320 . In an exemplary embodiment, the minimum elevation angle is a specific angle value in the range of 0-40°, 0-25°, or 0-20°. In an exemplary embodiment, the percent clearance horizontally over ground plane  2322  is a percentage value within at least one of 100% (completely clear), 75-100% clear, 66-100% clear, 50-100% clear, and any range within 50-100% clear. As would be understood by one skilled in the art, various ranges may be considered a “clear view” that provides the benefit of less reflection and scattering affect. 
     Factors that may affect a “clear view” include the size of patch antenna  2311 , the size of ground plane  2322 , the angle of inclination, a minimum scanning elevation, the height of patch antenna  2311  relative to ground plane  2312 , and the spacing between radiating element structures  2310  and  2320 . In an exemplary embodiment, if all these variables are held constant and only the height of patch antenna  2311  relative to ground plane  2322  is increased, the percentage of “clear view” will be increased as much as up to the 100% clear view point. Also, holding all other factors constant, increasing the height of patch antenna  2311  may facilitate lowering the minimum scanning elevation without degradation of performance. The minimum scanning elevation could be any angle within the follow ranges: 0-20°, 20-25°, 25-40° or any suitable minimum scanning elevation. 
     In accordance with an exemplary embodiment, a radiating element structure is designed according to the desired minimum elevation angle and the desired clear view percentage of the patch antenna at the minimum elevation angle. In other words, the radiating element structure may be designed such that the patch antenna has an unimpeded exposure to the desired minimum elevation angle. 
     For example, the radiating element structure may be designed such that an entire patch antenna is not covered by a ground plane at the 0° horizon line. In an exemplary embodiment, and with reference to  FIG. 24 , the dimensions of a radiating element structure  2400  are designed to result in a bottom point of a patch antenna  2420  being uncovered by the top point of a ground plane  2402  in the next row of radiating element structures. In other words, in an exemplary embodiment patch antenna  2420  is designed to have an entirely clear view of the horizon line. In the exemplary embodiment, radiating element structure  2400  comprises a dielectric material  2410  connected between patch antenna  2420  and ground plane  2402 . Specifically, the dimensions of dielectric material  2410  can be determined based on the size of patch antenna  2420  and an angle θ, which is the angle of a mounting surface  2401  to ground plane  2402 . Dielectric material  2410  has a dielectric material height  2411  and a dielectric material width  2412 . Furthermore, patch antenna  2420  has a patch antenna width  2422 . In accordance with the exemplary embodiment, dielectric material  2410  is designed with a minimum height  2411  that is greater than or equal to ½*tan(angle θ)*(patch width  2422 +dielectric material width  2412 ). This formula is based in part on assuming that patch antenna  2420  is centered on dielectric material  2410 , and that dielectric material  2410  is located at the top of ground plane  2402 . Other methods may also be employed to determine a suitable relationship between these factors for designing the radiating element structure to have a desired amount of clear view. 
     The layout of radiating element structures in an antenna system also has an impact on the radiation patterns of the elements. For example, in one exemplary embodiment, and with reference to  FIG. 25 , a first row of radiating element structures  2510  may be positioned directly in front of a second row of radiating element structures  2520 , such that the patch antennas appear “blocked” by the other patch antennas in front. This effect exists indeed but is weaker than the blockage of RF signals by a ground plane because the patch antennas are all resonant at the desired frequency and tend to re-radiate the received power instead to reflect it as the ground plane would. 
     In another exemplary embodiment, and with reference to  FIG. 26 , a further optimized antenna system configuration comprises a first row of radiating element structures  2610  interleaved with respect to a second row of radiating element structures  2620 . For example, in one embodiment, each row is laterally displaced with respect to the next row (for example, displaced by the half of the inter-element distance). This configuration further minimizes the interference between the elements. In another embodiment, an inclined array of patch antennas is staggered such that the patch antennas of the inclined array are not directly located in line with the nearest array of patch antennas. Other aspects may be used to minimize interfere. For example, in an exemplary embodiment, first row of radiating element structures  2610  is configured to receive a signal, and second row of radiating element structures  2620  is configured to transmit a signal. 
     In accordance with an exemplary embodiment, the heights of radiating element structures, or components within the radiating element structures, may vary from row to row. In a first embodiment, the sizes of the ground planes vary from row to row. For example, the ground plane size may increase from front to back, decrease from front to back or alternate from row to row. In this first embodiment, the overall heights of the radiating element structures remain the same. Though the ground plane sizes may vary, the radiating element structures remain configured for increased directivity of the patch antenna to a low elevation angle and less signal interference due to signal scattering. In a second embodiment, the overall heights of the radiating element structures vary, increasing from front to back. In this second embodiment, an increase in the size of radiating element structures, such as the dielectric material, accounts for the increased overall heights. In a third embodiment, the sizes of the radiating element structures are uniform, but the radiating element structures are mounted at different heights. For example, spacers may be used to increase the overall heights, from front to back. Similar to increasing the size of radiating element structures, a patch antenna uncovered by a ground plane has more directivity and less interference. In a fourth embodiment, the radiating element structures are mounted on a tilted surface, resulting in an increase in the overall heights of radiating element structures from front to back. A tilted surface results in a radiating element structure being higher in comparison of another radiating element structure located at a lower point of the tilted surface. In a fifth embodiment, the radiating element structures in different rows are spaced in an up and down fashion in alternating rows such that either the upper edge or lower edge of a patch antenna is uncovered by the row in front. In a sixth embodiment, a combination of two or more of the first five embodiments is applied to achieve radiating element structures with varying heights and/or varying ground plane sizes. 
     In accordance with another exemplary embodiment, radiating elements in a first row have a different shape than radiating elements in a second row. The radiating elements are shaped to reduce interference with the radiating elements in a nearby row. For example, a first row may comprise radiating elements having a “T-shape”, and a second row may comprise radiating elements having a “U-shape”. In an exemplary embodiment, aligning the first and second rows results in lower signal interference between the rows. 
     In another exemplary embodiment, a radiating element is rotated relative to another radiating element. The two radiating elements are inline with one another and directed to the front of an inclined array antenna. For example, a first row may comprise triangle-shaped radiating elements in an upright orientation (▴), and a second row may comprise triangle-shaped radiating elements rotated 180°, resulting in a downward orientation (▾). Furthermore, other shaped radiating elements may be rotated, and may be rotated at various other rotations than 180°. 
     In an exemplary embodiment, the element spacing from an electrical viewpoint is in the range of approximately ½-2 wavelength. In other exemplary embodiments the element spacing may be approximately 0-1 wavelength or even overlapping. Element spacing here refers to the distance between the projection of the patches of a front row and a row behind the front row. In an exemplary embodiment, a staggered layout provides improved radiation patterns and lower side lobes in comparison to a symmetrical alignment. Moreover, the alignment of the radiating elements may be any non-uniform layout or other suitable pattern to improve radiation patterns and lower side lobes. 
     In addition, the interleaving can be described from an antenna array standpoint. In an exemplary embodiment, the spacing of various patch antennas are designed based in part on the position of patch antennas located on other antenna arrays. 
     With reference now to  FIG. 1 , a prior art antenna module  100  includes a coaxial radio frequency (RF) connector  110  and a base metal layer  120 . Some examples of a common coaxial RF connector  110  used in prior art systems include an SMA (subminiature version A) connector, a Molex SSMCX, and a Huber Suhner MMBX. The use of such connections result in a complex assembly because the connectors must be hand-tightened and there are a large number of connectors in a prior art antenna using module  100 . The connections also may result in an overall taller antenna module due to the size of the connectors and space needed to install them. 
     In accordance with an exemplary embodiment of the present invention, and with reference to  FIG. 2 , various exemplary bar with leads connectors are discussed. A bar with leads connector may also be described as a lead frame. For example, bar with leads connector  210 ,  220  may comprise a bar  213  and two or more leads  211 ,  212 . Furthermore, bar with leads connector  210 ,  220  may include a break-away point  240  which is, for example, a point that is scored or etched to provide a suitable point of separation of the bar from the leads. 
     In an exemplary embodiment, bar  213  is flat and configured to provide a flat area for vacuum pick-up implemented by typical pick-and-place machines. Apart from providing a suitable flat area for the pick and place machine, in another embodiment, the bar may be configured to shift the center gravity of the bar with leads connector  210 ,  220  to the flat area. In order to provide a stable place to pick up the bar with leads connector, the bar with leads connector may be designed, for example, so that the center of gravity is not over the leads or edge. 
     In another embodiment, bar  213  also has feet  230 , allowing for bar with leads connector  210 ,  220  to be installed during assembly over other previously installed components. In other words, electrical components and/or printed circuit lines may be present on a printed circuit board (PCB) when bar with leads connector  210 ,  220  is attached. In an exemplary embodiment, bar  213  angles up from the PCB, creating space between bar  213  and the PCB. In the exemplary embodiment, feet  230  extend from bar  213  and provide structural support for the space between bar  213  and the PCB. By providing spacing using feet  230 , the bar with leads does not interfere, and possibly damage, the other components on the PCB. 
     Furthermore, there are many types of leads. Leads  211  may, for example, be direct current lead connections. Leads  212  may, in another example, be RF lead connections. In an exemplary embodiment, the RF lead connections comprise a ground-signal-ground design of leads. In accordance with an exemplary embodiment, bar with leads connector  210 ,  220  may be configured for use on transmit or receive antennas. Thus, for example, bar with leads connector  210  may be configured to attach to a printed circuit board for a receive antenna. In another example, bar with leads connector  220  may be configured to attach to a printed circuit board for a transmit antenna. Furthermore, in an exemplary embodiment, bar with leads connector  210 ,  220  is configured to attach to a printed circuit board for a transceiver antenna. 
     In an exemplary embodiment, bar with leads connector  210 ,  220  is designed with specific spacing of leads  211 ,  212  such that the leads align with lead pads on the surfaces to which the leads are attached. Additionally, in an exemplary embodiment, bar with leads connector  210 ,  220  may be any structure that holds two or more leads for attachment to other structures. 
     Furthermore, in an exemplary embodiment, leads  211 ,  212  are angled or bent. In one embodiment, the leads of bar with leads connector  210 ,  220  are bent to a desired angle to allow connection of an inclined surface and another surface. The inclined surface, for example, is an antenna module and the other is a mounting surface. In another exemplary embodiment, a lead comprises a first end and a second end. The first end of the lead is in one plane and the second end of the lead in is a different plane. In an exemplary embodiment, the leads are bent at an angle in the range of 2 to 90 degrees between the first end and the second end of the lead. In another exemplary embodiment, the leads are bent at any suitable angle for connecting two surfaces as would be known to one skilled in the art. Also, the lead may be bent at any point along the lead, for example it may be bent in the middle or along a third of the lead length. 
     In one embodiment, bar with leads connector  210 ,  220  is made of copper. In another embodiment, bar with leads connector  210 ,  220  may be made of at least one of BeCu and steel. In yet another embodiment, the leads are plated with materials that are conducive to soldering, such as, for example, tin, silver, gold, or nickel. Moreover, bar with leads connector  210 ,  220  may be made of, or plated with, any suitable material as would be known to one skilled in the art. 
     Additionally, in an exemplary embodiment, RF lead connections provide a connection with a broad bandwidth and a low loss. In an exemplary embodiment, broad bandwidth is bandwidth with a range of DC to 15 GHz. In another embodiment, broad bandwidth is bandwidth with a range of DC to 80 GHz or any suitable range in between. Furthermore, in an exemplary embodiment, low loss is loss in the range of 0.01 dB to 1.5 dB as the loss is a function of frequency. Additionally, there may be other suitable ranges of low loss as is known in the art. The RF leads may provide such a connection for at least one of the X band, the Ku band, the K band, the Ka band, and the Q band. Moreover, the RF may provide such a connection for other suitable bands as would be known to one skilled in the art. 
     In addition, in an exemplary embodiment and with reference to  FIG. 3 , the RF lead connections provide a low pass response, e.g., filtering. In an exemplary embodiment, the insertion loss is less than 0.6 dB up to about 15 GHz. Furthermore, in an exemplary embodiment and with reference to  FIG. 4 , the return loss of the interface is more than about 18 dB up to 15 GHz and better than about 20 dB for the range of 11-14.5 GHz. 
     In an exemplary embodiment, and with reference to  FIG. 5 , various printed circuit boards (PCB) are discussed. In one embodiment, a PCB  510 ,  520  comprises tooling holes  511 ,  521  and lead pads  512 ,  522 . Tooling holes may align PCB  510 ,  520  to help test or assemble fixtures. Tooling holes may also align PCB  510 ,  520  to other sub-assemblies or components. Furthermore, in an exemplary embodiment, PCB  510  is a transmit PCB and PCB  520  is a receive PCB. As a transmit PCB, PCB  510  may comprise matching structures and bias feeds. As a receive PCB, PCB  520  may further comprise at least one resistor, at least one capacitor, and/or a low noise amplifier (LNA) transistor(s). In general, PCB  510 ,  520  may be any laminate or substrate that carries signals and holds components. 
     In an exemplary embodiment, and with reference to  FIG. 6 , an exemplary PCB  630  comprises leads  631 ,  632 . Leads  631 ,  632  are attached using a bar with leads such as bar with leads connector  610 . Another exemplary PCB  640  comprises leads  642 . The leads  642  were attached using a bar with leads, such as bar with leads connector  620 . In an exemplary embodiment, lead  631  is a direct current lead. In another exemplary embodiment, leads  632 ,  642  are RF leads. 
     In accordance with an exemplary method, and with reference to  FIG. 7 , a bar with leads connector is attached to a PCB. The exemplary method may comprise designing the spacing of leads of the bar with leads connector such that the spacing of the leads matches the spacing of lead pads on the PCB (Step  700 ). In accordance with various exemplary embodiments, leads and feet are cut, etched, and/or formed on a bar (Step  705 ). The leads may be of any suitable length and spaced apart as desired. The leads of the bar with leads connector are bent to a desired angle (step  710 ). In another exemplary embodiment, the feet may be formed in the same step. The bend of the leads may be configured to allow connection of an antenna module to another surface where the antenna module is inclined relative to the other surface. In an exemplary embodiment, the leads are bent at an angle in the range of 2 to 90 degrees from the bar. In an exemplary embodiment, leads may be bent, formed, or stamped to the desired angle by a machine. In another exemplary embodiment, the bar with leads may then be installed into a tape and reel (Step  715 ). The tape and reel provides another manner of machine handling the bar with leads to feed a pick-and-place machine. Then the bar with leads connector is placed into correct position on the PCB such that the leads are aligned with corresponding lead pads (Step  720 ). This placement may be done, for example, by a machine in a pick-and-place manner. An exemplary method may comprise any combination of the described steps. 
     In an exemplary embodiment, a machine picks and places the bar with leads by suction or a gripping mechanism, using the flat surface of the bar with leads connector. Once the bar with leads connector is correctly positioned, the leads are connected to the PCB (Step  730 ), which may occur through various known techniques. In an exemplary embodiment, bar with leads connector  610  is attached to PCB  630  through reflow solder technique. The specifics of reflow solder technique are known and may not be discussed herein. In another embodiment, the leads of the bar with leads connector are attached to the PCB by an epoxy attachment or through any other suitable method now known or hereinafter devised. For example, a machine may dispense conductive epoxy on the PCB pads prior to placement of the bar with leads connector. In this example, the epoxy cures to attach the leads to the PCB. After the bar with leads connector is connected to the PCB, the bar portion of the bar with leads connector is broken off (Step  740 ), leaving just the leads attached to the PCB. The bar may be broken off or detached either manually or with a machine, using any bending, snapping, cutting, laser or other suitable method. 
     With reference now to  FIG. 8 , an exemplary support bracket  810  is described. In one embodiment, support bracket  810  comprises a pick-up tab  811 . In another embodiment, support bracket  810  further comprises tooling pins  812 , an alignment tab  813 , and alignment pins under feet  814 . 
     In an exemplary embodiment, support bracket  810  is plastic. A plastic support bracket may be molded into a desired shape, and provides a low cost and manufacturability method of supporting the PCB at any angle between 5-90 degrees. Furthermore, support bracket  810  may be made of other light weight materials such as zinc, magnesium, aluminum, and/or ceramic. Moreover, support bracket  810  may comprise any other suitable material as would be known to one skilled in the art. 
     In an exemplary embodiment, support bracket  810  defines the angle of a radiating element in an antenna aperture. In one embodiment, support bracket  810  is configured to support a radiating element at an angle in the range of 30-60 degrees. In another embodiment, support bracket  810  is configured to support a radiating element at an angle of about 45 degrees. Moreover, support bracket  810  may be configured to support a radiating element at any angle suitable for optimal performance of an antenna. 
     Pick-up tab  811  may be used to move support bracket  810 . For example, a machine may clutch or suction onto pick-up tab  811  in order to place support bracket  810  into a desired location. This may be accomplished, for example, by a pick-and-place machine. Moreover, additional techniques to move support bracket  810  are contemplated as would be known to one skilled in the art. 
     In one embodiment, tooling pins  812  are configured to align with holes in various antenna module components, such as a PCB. Tooling pins  812  hold and stack the various antenna module components in place. In one embodiment, an antenna module is machine assembled for attaching a support bracket and the PCB to a steering card prior to attaching a foam radiating element to the support bracket. This is due in part to the heat from reflow soldering of components which might otherwise result in potential damage to a foam component. In another exemplary embodiment, the components of an antenna module may be assembled in any suitable order. This may involve hand assembly and/or the use of heat in such a manner as to not result in any substantial impact on any component. 
     Furthermore, in an exemplary embodiment, alignment pins under feet  814  are protruding shapes along the bottom of support bracket  810 . In another embodiment, alignment pins under feet  814  are metal plated or at least have metal deposits on the bottom of the feet. Alignment pins under feet  814  may assist in guiding support bracket  810  into a correct placement on another surface when, for example, the other surface comprises matching concave areas or placement holes. The alignment pins under feet  814  may be configured to provide additional structural support required in COTM applications. When alignment pins under feet  814  are metal plated, support bracket  810  may become a surface mount component similar to other surface mount components. Furthermore, in an exemplary embodiment, support bracket  810  is self-aligning. When the super component subarray is designed to be light weight, the surface tension of the solder during surface mount reflow may facilitate centering the sub-array super component on the PCB mounting pads. This provides very accurate positioning of the sub-array super component on the steering card. Accurate positioning of the sub-array components helps to facilitate the optimal performance of the antenna. 
     In accordance with an exemplary embodiment, and with reference to  FIG. 9 , a partially assembled antenna module  900  may include a support bracket  910  and a PCB  911  connected to support bracket  910  via tooling pins  912 . 
     Furthermore, in an exemplary embodiment, and with reference to  FIG. 10 , an assembled antenna module  1000  may comprise a support bracket  1010 , a foam component  1020 , and at least one parasitic patch  1021  connected together via tooling pins  1012 . In other embodiments, foam component  1020  may be any other low loss laminate with a low loss tangent. In an exemplary embodiment, parasitic patches  1021  form the desired radiation pattern. Furthermore, foam component  1020  includes holes aligned for tooling pins  1012 . 
     With reference to  FIG. 11 , an exemplary method of assembly includes manufacturing various components in a panel. In other words, multiple antenna modules may be formed on a single panel. In an exemplary embodiment, a matching structure, ground vias, and/or bias feed are printed onto a circuit board. In addition, other structures may be printed on a circuit board as would be known to one skilled in the art. In one embodiment, the PCBs may be separated from the panel and assembly as an individual PCB. In another embodiment, the PCBs are also fully or partially assembled and tested in panel form when attaching the leads, which may be done by machine or by hand. An exemplary method of attaching the leads to a PCB is further discussed with reference to  FIG. 7 . Additionally, other discrete components may be attached to the antenna module while in panel form. The individual PCB&#39;s may then be separated from the panel, after full or partial assembly of the sub-array super component. 
     In accordance with an exemplary embodiment, and with reference to  FIG. 12 , an array of super components  1210  are designed and attached to a mounting plate  1250 . In an exemplary embodiment, a super component includes a PCB  1220  connected to a support bracket  1240 . PCB  1220  may be connected to support bracket  1240  via tooling pins  1230 . In an exemplary embodiment, various scalable designs are assembled from super components without redesigning the sub-array. As shown in  FIG. 12 , twenty-four super components  1210  are arranged on mounting plate  1250 . Other arrangements may be designed using super components as a building block, invoking the benefits of scalable design. 
     Furthermore, in an exemplary embodiment, and with reference to  FIG. 13 , an RF antenna aperture  1300  comprises radiating modules  1310 , a steering card  1320 , a mounting plate  1330 , and a pedestal  1340 . In one embodiment, aperture  1300  includes steering card  1320  and/or mounting plate  1330  formed by multiple pieces. 
     An exemplary embodiment of a steering card  1320  includes an elevation beam forming network, an azimuth beam forming network to perform at least part of the azimuth network, and at least one phase shifter. In an exemplary embodiment, the beam forming network components are splitters. Additionally, steering card  1320  may also include an amplifier, such as a power amplifier for a transmit steering card and a low noise amplifier for a receive steering card. 
     In an exemplary embodiment, RF antenna aperture  1300  further comprises mounting plate  1330 . Mounting plate  1330  provides support structure and may also function to dissipate and spread heat from amplifiers. In addition, mounting plate  1330  provides a clean interface to connect (e.g., bolt, fasten, adhere) to pedestal  1340 . 
     In an exemplary embodiment, pedestal  1340  comprises an edge with teeth to match with gears so that pedestal  1340  may be mechanically rotated by a motor. In another embodiment, pedestal  1340  and mounting plate  1330  are integrated into a single piece. 
     With reference to  FIG. 14 , a radiating module  1410 , such as the exemplary radiating module described with reference to  FIG. 10 , is connected to a steering card  1420  via leads ( 1430  typ.). In an exemplary embodiment, lead  1430  is pre-bent to substantially match the angle between the steering card  1420  and the radiating module  1410 . 
     Furthermore, and with reference to  FIGS. 15A and 15B , an exemplary interface between a steering card  1510  and a radiating element PCB  1520  is shown. In an exemplary embodiment, a microstrip line  1530  is located on steering card  1510  and connects to one or more lead pads  1540 , which in turn connect to a microstrip line  1531  on steering card  1510 . In addition, in another embodiment, ground vias (not shown) are located between lead pads (not shown) and steering card  1510 . In an exemplary embodiment, the lead pads are underneath and connect to a group of leads, which includes two ground leads  1562  and a signal lead  1561 . 
     In an exemplary embodiment, signal lead  1561  facilitates the transmission of a signal between radiating element PCB  1520  and steering card  1510 . In the exemplary embodiment, a first end of signal lead  1561  connects to microstrip line  1530  on steering card  1510 , and a second end of signal lead  1561  connects to microstrip line  1531  on radiating element PCB  1520 . 
     In accordance with an exemplary embodiment and with reference to  FIG. 16 , a full antenna assembly  1600  includes a transmit aperture  1610 , a transmit motor  1615 , a receive aperture  1620 , a receive motor  1625 , an upconvertor  1630 , and a downconvertor  1640 . Transmit motor  1615  and receive motor  1625  power the rotation in the azimuth plane. Upconvertor  1630  frequency converts an intermediate frequency (IF) signal from a modem up to the transmit RF frequency of the aperture. In addition, downconvertor  1640  frequency converts the receive RF signal from the aperture down to the modem IF frequency. 
     Furthermore, an antenna module may be connected to another surface in other assemblies, such as an assembly that communicates a signal from one PCB to another. In an exemplary embodiment, the interface connection may be used in U.S. Monolithics products such as the Ka Band XCVR and Link-16 RF modules. Furthermore, the interface connection may be implemented in non-radio frequency applications, for example in communicating a signal from a digital mother board to a daughter card. 
     In an exemplary method, and with reference to  FIG. 17 , a manufacturing method  1700  is described herein. A steering card bonds to a support plate (Step  1710 ). The support plate ensures the assembly is substantially flat, as well as providing thermal transfer, dissipation and a manner for mechanical attachment to the next higher assembly. Additionally, solder paste is added to the steering card (Step  1720 ). In an exemplary embodiment, the solder paste has a liquidus temperature of about 183° C., thereby allowing attachment of all placed components while not disturbing the solder used to attach components to the radiating element cards. 
     Furthermore, another step is dispensing epoxy into antenna sub-array super component alignment holes (Step  1730 ). In one embodiment, epoxy is added as structural support required by the end use environment. Additionally, one step is the placement of the SMT (surface mount technology) parts and antenna sub-array super components (Step  1740 ) on the steering card. Furthermore, the SMT parts and antenna sub-array super components are attached to the steering card using reflow soldering (Step  1750 ), in one embodiment at a board temperature of about 205° C. Additionally, method  1700  may further comprise inspecting the board (Step  1760 ), functional performance testing (Step  1770 ), and adding foam bricks to the antenna sub-array super component (Step  1780 ). 
     The antenna sub-array super components are assembled using various methods. In one exemplary method of manufacture, the bare element PCBs are created in a panelized form (Step  1741 ) and high temperature solder paste is printed on the element PCBs (Step  1742 ). In an exemplary embodiment, the liquidus temperature of this solder formulation is about 217° C. and is selected so that parts attached to the super component circuit boards with high temperature solder paste will remain substantially unaffected by the additional soldering process temperature described in Step  1750 , wherein steering card components are solder attached in conjunction with the super component leads at a temperature of about 205° C. 
     Another step is the placement of SMT parts and bar with leads connector (Step  1743 ) on the element PCBs. After the placement of SMT parts, reflow soldering occurs (Step  1744 ), in one embodiment at a board temperature of about 235° C. The PCBs are de-paneled, generally once the SMT parts are attached (Step  1745 ). Furthermore, an additional step in this embodiment is the application of a bonding agent (Step  1746 ), and attachment of the support bracket which, working in conjunction with the bar with leads connector, creates the form factor of the radiating element module sub-array super component and allows mounting of a super component PCB. Furthermore, an additional step in this embodiment is placing the super component module in a test/alignment fixture and setting co-planarity of the super component module (Step  1747 ). This method of assembling an antenna sub-array super component may further comprise testing the leads connection from the PCB to a steering card (Step  1748 ). Additionally, by machine assembling various components, the antenna sub-array super component modules may be manufactured with a high rate of throughput. This in turn lowers the cost of assembly and the cost of the antenna device. 
     Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements of any or all the claims. As used herein, the terms “includes,” “including,” “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Further, no element described herein is required for the practice of the invention unless expressly described as “essential” or “critical.”