Patent ID: 7982684

Claim:
A method of manufacturing a microwave antenna module, comprising: creating a laminate structure with a top side and a bottom side, by laminating a plurality of conductive layers and dielectric layers between the top side and the bottom side, wherein creating the laminate structure further comprises: forming a first stripline having a first metal layer, a third metal layer, and a second metal layer suspended between the first metal layer and the third metal layer by a first dielectric and adhesive layer, wherein the first metal layer and the third metal layer are ground planes connected by a first via to a plating, to a fourth metal layer and to a sixth metal layer, and wherein the second metal layer is a first radio frequency signal layer; forming a second stripline having the fourth metal layer, the sixth metal layer, and a fifth metal layer suspended between the fourth metal layer and the sixth metal layer by a second dielectric and adhesive layer, wherein the fourth metal layer and the sixth metal layer are ground planes connected by the first via to the plating and the fifth metal layer is a second radio frequency signal layer; forming a seventh metal layer and an eighth metal layer, with a third dielectric layer interposed between the seventh metal layer and the eighth metal layer, wherein the seventh metal layer is a first data layer, and the eighth metal layer is a second data layer, wherein the first metal layer is the top side of the laminate structure and the fourth metal layer is the bottom side of the laminate structure; connecting the first metal layer to the seventh metal layer by a second via; connecting the first metal layer to the eighth metal layer by a third via; connecting the second metal layer to the first metal layer by a first blind via; connecting the fifth metal layer to the first metal layer by a second blind via; affixing the seventh metal layer to the third metal layer by a first prepreg layer; and affixing the eighth metal layer to the sixth metal layer by a second prepreg layer; creating a cutout in the laminate structure, the cutout having a plurality of walls extending from the top side to the bottom side of the laminate structure; plating the plurality of walls of the cutout extending from the top side to the bottom side and grounding the plated walls of the cutout; laminating a base plate to the bottom side of the laminate structure, wherein the baseplate operates as a heat sink; disposing a standoff in the cutout and attaching the standoff to the baseplate; attaching a component to the standoff so as to substantially dispose the component in the cutout and elevate the component to the top side of the laminate structure; and laminating a seal ring to a periphery of the top side of the laminate structure.