Patent Application
20230318190
The present disclosure generally relates to antenna systems and, more particularly, to a three-dimensional (3D) horn air waveguide antenna made with formed and brazed metal sheets.
Slotted waveguide antennas comprise a plurality of slots that act as a directive array antenna for emitting a narrow fan-shaped beam of microwave and ultra-high frequencies (UHF). Some primary advantages of slotted waveguide antennas include size, design simplicity, and convenient adaptation to mass production (e.g., using printed circuit board, or PCB technology). Slotted waveguide antennas, however, also have disadvantages. In particular, slotted waveguide antennas can suffer from undesirable grating lobes in their far-field three-dimensional (3D) patterns, as shown in
The background description provided herein is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it is described in this background section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.
According to one aspect of the present disclosure, a three-dimensional (3D) horn air waveguide antenna assembly is presented. In one exemplary implementation, the assembly comprises: a bottom stamped metal layer defining a set of electrical connection ports, and a plurality of top stamped metal layers arranged atop the bottom stamped metal layer with a brazing material deposited between each stamped metal layer, the plurality of top stamped metal layers defining a channel area proximate to the bottom stamped metal layer, a horn air waveguide antenna area that widens from a bottom portion to a top portion, and a slot area fluidly connecting the channel and horn air waveguide antenna areas.
In some implementations, the plurality of top stamped metal layers comprises, in order from a bottom: a first top stamped metal sheet that is also formed to create the channel and slot areas, and a second top stamped metal sheet defining at least a first portion of the horn air waveguide antenna area. In some implementations, the plurality of top stamped metal layers further comprises, in order from the bottom, a third top stamped metal sheet defining a second portion of the horn air waveguide antenna area. In some implementations, the top portion of the horn air waveguide antenna area is asymmetric. In some implementations, the top portion of the horn air waveguide antenna area is symmetric and the second portion is wider than the first portion to generate a narrower beam width. In some implementations, wherein the second portion of the horn air waveguide antenna area further defines a wider taper. In some implementations, the channel and slot areas defined by the first top stamped metal sheet include distinct first and second channel and slot areas separated by a third alternate channel and slot area, and the horn waveguide antenna area defined by the second top stamped metal sheet includes distinct first and second horn air waveguide antenna areas separated by a slot air waveguide antenna area, wherein the first and second horn air waveguide antenna areas each further define a wider taper at their top portions. In some implementations, the brazing material is an aluminum brazing material. In some implementations, the assembly further comprises: a printed circuit board (PCB) electrically connected to the set of electrical connection ports, and a pressure-sensitive adhesive (PSA) layer disposed between the bottom stamped metal layer and the PCB.
According to another aspect of the present disclosure, a method of manufacturing a 3D horn air waveguide antenna assembly is presented. In one exemplary implementation, the method comprises: forming a bottom stamped metal layer defining a set of electrical connection ports, and forming a plurality of top stamped metal layers arranged atop the bottom stamped metal layer, including depositing a brazing material between each stamped metal layer, the plurality of top stamped metal layers defining a channel area proximate to the bottom stamped metal layer, a horn air waveguide antenna area that widens from a bottom portion to a top portion, and a slot area fluidly connecting the channel and horn air waveguide antenna areas.
In some implementations, the plurality of top stamped metal layers comprises, in order from a bottom: a first top stamped metal sheet that is also formed to create the channel and slot areas, and a second top stamped metal sheet defining at least a first portion of the horn air waveguide antenna area. In some implementations, the plurality of top stamped metal layers further comprises, in order from the bottom, a third top stamped metal sheet defining a second portion of the horn air waveguide antenna area. In some implementations, the top portion of the horn air waveguide antenna area is asymmetric. In some implementations, the top portion of the horn air waveguide antenna area is symmetric and the second portion is wider than the first portion to generate a narrower beam width. In some implementations, the second portion of the horn air waveguide antenna area further defines a wider taper. In some implementations, the channel and slot areas defined by the first top stamped metal sheet include distinct first and second channel and slot areas separated by a third alternate channel and slot area, and the horn waveguide antenna area defined by the second top stamped metal sheet includes distinct first and second horn air waveguide antenna areas separated by a slot air waveguide antenna area, wherein the first and second horn air waveguide antenna areas each further define a wider taper at their top portions. In some implementations, the brazing material is an aluminum brazing material. In some implementations, the method further comprises: providing a PCB electrically connected to the set of electrical connection ports, and providing a PSA layer disposed between the bottom stamped metal layer and the PCB.
In yet another aspect of the present disclosure, a 3D horn air waveguide antenna assembly is presented. In one exemplary implementation, the assembly comprises: a bottom stamped metal layer means for defining a set of electrical connection ports, and a plurality of top stamped metal layer means for arrangement atop the bottom stamped metal layer with a brazing material means for deposition between each stamped metal layer, the plurality of top stamped metal layer means for defining a channel area means proximate to the bottom stamped metal layer means, a horn air waveguide antenna area means that widens from a bottom portion to a top portion, and a slot area means fluidly connecting the channel and horn air waveguide antenna area means. In some implementations, the plurality of top stamped metal layer means is further for arrangement, in order from a bottom: a first top stamped and formed metal sheet means for creating the channel and slot area means, and a second top stamped metal sheet means for defining at least a first portion of the horn air waveguide antenna area means.
Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the disclosure.
The present disclosure will become more fully understood from the detailed description and the accompanying drawings, wherein:
As previously discussed, there exists an opportunity for improvement in the art of waveguide antennas. In particular, slotted waveguide antennas 100 having slot arrays 110 can suffer from undesirable or unintended beams of radiation in their far-field three-dimensional (3D) patterns 120 (i.e., separate from a mean bean 130), which are also known as grating lobes 140 and are shown in
Accordingly, improved 3D horn air waveguide antenna assemblies formed of stamped metal layers and their methods of manufacture are presented herein. The term ‘horn air waveguide antenna” as used herein refers to a 3D horn structure formed by layering of stamped metal layers, and does not preclude aspects of a slot array waveguide antenna assembly. In other words, the term “horn air waveguide antenna” can include aspects of a slot array waveguide (e.g., a slot fluidly connecting a channel area to the horn waveguide antenna area), and thus this can also be described as a combination or hybrid slot array waveguide and horn air waveguide antenna assembly configuration (e.g., a slot array waveguide with a horn air waveguide top groove, or the like). By leveraging aspects of multiple different antenna technologies, the resulting antenna assemblies described and illustrated herein are capable of increasing performance metrics while mitigating or eliminating the previously-discussed drawbacks or disadvantages. This can make the antenna assembly configurations described herein ideal for a plurality of potential radar applications, ranging from but not limited to, vehicle applications (e.g., autonomous driving features) to aviation and military applications.
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The configuration 200 illustrated in
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Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known procedures, well-known device structures, and well-known technologies are not described in detail.
The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The term “and/or” includes any and all combinations of one or more of the associated listed items. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.
Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.
The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
