Tightly-coupled PCB GNSS circuit and manufacturing method

Abstract

A tightly-coupled printed circuit board (PCB) circuit includes components mounted on a PCB enabling smaller integrations using decoupled lines extending between reference layers, such as ground planes, form isolation islands on the PCB. The decouplers are capacitors, inductors and/or resistors in tandem with ground layers of the PCB. The isolated components can comprise high-frequency RF antennas and receivers, for example in a GNSS antenna-receiver circuit. Multiple antennas can be connected to one for more receivers with multiple, independent RF front end components by RF traces, which are either embedded within the PCB between the ground planes, or by surface microstrip antenna traces.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to printed circuit boards (PCBs), and in particular to a tightly-coupled PCB for mounting one or more receivers with multiple, independent radio frequency (RF) front ends in close proximity to multiple, respective antennas. The circuit is noise-filtered by electrically decoupling and isolating the conductive reference planes of the PCB.

2. Description of the Related Art

PCB manufacturing techniques are well-developed and enable the cost-effective production of circuits with virtually unlimited configurations and combinations of components. Typical PCB construction comprises one or more reference layers, which can provide power and ground (common) planar sources for the entire circuit. Component conductors are connected to the reference layers as required for their operation. Other layers conduct signals, and can be photo-etched with trace conductors linking other component conductors. Still further, microstrip traces can be mounted on the PCB surfaces or within the PCB layers for electrically coupling components.

Signal noise control represents a significant aspect of PCB circuit design. Such considerations are particularly significant in designing circuits with RF receiver and antenna components, because circuit noise from switching components, power sources, “skin effect” conductivity and other noise-producing elements can significantly interfere with the reception and processing of transmitted signals. For example, global navigation satellite system (GNSS, including global positioning system (GPS)) receivers operate in the microwave frequency range, whose high frequencies tend to increase noise-related reception problems and signal interference. For example, such systems are susceptible to multipath signal phenomena, which tend to reduce system accuracy and performance.

A previous solution has been to physically isolate the receiver and antenna components, which can be connected by a shielded RF cable. However, it is often more cost-effective to mount as many system components as possible on a single PCB. Moreover, locating the receiver and its antenna(s) in close proximity tends to improve performance by eliminating relatively lengthy RF connecting cables, provided the potential for noise interference can be controlled. “Smart” antennas combining antennas and receivers at single locations have previously been utilized, but do not electrically decouple the circuit components or utilize the ground reference planes for additional antenna area.

Therefore, the design criteria for GNSS receiver-antenna PCBs would preferably included minimizing overall size, placing the receiver and antenna components in close proximity, accommodating multiple antennas and controlling signal noise. Previous receiver-antenna PCBs and manufacturing methods have not provided the advantages and features of the present invention.

SUMMARY OF THE INVENTION

In the practice of an aspect of the present invention, a PCB is designed in a manner to isolate and control the inter-frequency noise sources, and provides for the use of components for decoupling reference layers thereof, which can further separate and decouple the ground planes. A receiver with multiple, independent RF front end components can be mounted on the PCB in close proximity to multiple antennas. The receiver and antennas are connected by optimized transmission lines embedded within the PCB between the ground planes, or by surface microstrip antenna traces. The impedance of the transmission lines is controlled during the process of manufacturing the PCB.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of a tightly-coupled PCB circuit embodying an aspect of the present invention with a receiver and a pair of antennas located in proximity and trace-connected to each other on the PCB.

FIG. 2 is a schematic diagram of another tightly-coupled PCB circuit embodying another aspect of the present invention with three antennas trace-connected to a receiver on a single PCB.

FIG. 3 is a top schematic diagram of another tightly-coupled PCB embodying another aspect of the present invention with a modified line of decoupling capacitors.

FIG. 4 is a bottom schematic diagram thereof.

FIG. 5 is a top schematic diagram of another tightly-coupled PCB embodying another aspect of the present invention with a modified configuration and layout.

FIG. 6 is a bottom schematic diagram thereof.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

I. Introduction and Environment

As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.

Certain terminology will be used in the following description for convenience in reference only and will not be limiting. For example, up, down, front, back, right and left refer to the invention as oriented in the view being referred to. The words “inwardly” and “outwardly” refer to directions toward and away from, respectively, the geometric center of the embodiment being described and designated parts thereof. Said terminology will include the words specifically mentioned, derivatives thereof and words of similar meaning.

II. Tightly-Coupled PCB Circuit 2

Referring to FIG. 1 of the drawings in more detail, the reference numeral 2 generally designates a tightly-coupled printed circuit board (PCB) circuit embodying an aspect of the present invention. Without limitation on the generality of tightly-coupled PCB circuits for which the present invention can be advantageously applied, the circuit 2 includes a pair of antennas 4 coupled to a sensing receiver 6. By way of example and without limitation, the receiver 6 can comprise a GNSS (e.g., GPS) receiver operating in the microwave frequency range.

The antennas 4 and the receiver 6 are mounted on a multi-layer PCB 8, which can include multiple conductive layers separated by insulating layers formed of epoxy or other suitable material. The conductive layers can include reference layers adapted for powering the circuit 2 via a positive, power layer and one or more ground or common layers providing a ground plane(s) for the circuit. The PCB 8 can also include one or more signal layers, which can be photo-etched in a suitable circuit diagram pattern(s) for electrically coupling the circuit components. For example, the antennas 4 and the receiver 6 can be connected by RF transmission striplines or traces 10, which can be either embedded within the PCB 8 and shielded between the reference layers thereof in a sandwiching construction, or located on the PCB 8 surface and comprise surface microstrip antenna traces. If surface-mounted, the RF transmission striplines 10 would be bottom-shielded by the top layer of the PCB 8. The function of the RF transmission striplines 10 is preferably optimized by controlling impedance (Z), e.g. by varying the thickness of the traces 10.

Multiple decouplers 12 form decoupling lines 14, which extend from the receiver 6 to respective ends 16 of the PCB 8. The lines 14 include bends 18 and form grounded isolation islands 20 which are relatively noise-free by virtue of the electrical decoupling function of the decouplers 12. The RF inputs via the antennas 4 are near the ends 16 of the PCB 8. The decoupling lines 14 can be formed with bends and other configurations as necessary in order to locate the RF input signals as close as possible to the physical RF connectors from within the RF transmission striplines 10 in order to provide optimal RF signal paths from the antennas 4 to the receiver 6. The decouplers 12 can comprise capacitors, resistors or inductors, which are chosen for impedance control based on characteristics and operating parameters of the circuit 2. The configurations and locations of the isolation islands 20 within the PCB also provide impedance control, in conjunction with the decoupling lines 14 and the operating parameters of the circuit 2. Such operating parameters can include such variables as power, voltage, current, frequency and amplitude of the signals encountered by the components of the circuit 2, including the operating ranges of such parameters. Multiple different capacitive values of the decouplers 12 can be utilized to filter specific frequencies between the decoupled component ground planes.

The decouplers 12 and the isolation islands 20 preferably extend between, yet still allow, electrical connections between the reference layers (e.g., ground planes and/or positive reference layer) of the PCB 8. The respective independent ground planes of the circuit components, such as the antennas 4, the receiver 6 and the RF transmission lines 10 are electrically decoupled by the decouplers 12. A relatively large area of isolation is preferably formed in the PCB 8 by the isolation islands 20 in order to maximize the signal noise-isolating operation of the decoupling lines 14.

In operation, the PCB circuit 2 can encounter noise and electrical interference from a variety of internal and external sources. High-frequency receivers, such as those utilized in GNSS (e.g., GPS), are somewhat susceptible to degradation of performance due to such interference, with the potential for resulting inaccuracies in their positioning functions. The isolation islands 20 tend to be relatively free of such noise signals whereby the antennas 4 can be located relatively close to the receiver 6 without being subjected to excessive noise.

The relatively close proximities of the antennas 4 to the receiver 6 tend to minimize signal delays and electromagnetic interference (EMI) problems, which can be associated with greater separation and correspondingly longer RF connecting leads. Noise from such signal sources as multipath signals, PCB skin effect, power source fluctuations, phase noise and EMI in general tend to be effectively dissipated by the impedance (capacitive, inductive and/or resistive) of the decouplers 12. Effective decoupling improves signal quality from the antennas 4 to the receiver 6. In the case of GNSS systems, greater positioning accuracy can be achieved. Another benefit of decoupling the PCB circuit 2 is that the need for sophisticated filtering and processing functions, which are commonly performed by processors using Kalman and other filtering software techniques, can be eliminated or at least reduced. A further advantage of the decoupled PCB circuit 2 is that the PCB ground planes provide additional antenna areas for increasing the effectiveness of the antennas 4. Still further, the additional costs associated with separate circuit boards and standalone components can be avoided by utilizing the decoupled PCB 8.

III. First Alternative Aspect Tightly-Coupled PCB Circuit 52

A tightly-coupled PCB circuit 52 comprising a first alternative aspect or embodiment of the present invention is shown in FIG. 2 and includes an additional antenna 4. Such three-antenna GNSS receiver circuits can be utilized in vehicle guidance systems and machine control applications and are capable of determining vehicle and equipment attitude with respect to three axes.

As shown in FIG. 2, a PCB 58 can be alternatively configured for the third antenna 4 and can assume various other alternative configurations for additional components, including additional antennas, receivers, etc. Still further, additional circuits can be placed on PCBs which are tightly-coupled and create isolation islands according to the present invention. The tightly-coupled decoupled PCB circuit 52 includes decoupling lines 64 of decouplers 62, which form isolation islands 70 in which the antennas 4 are mounted in relatively noise-free isolation. Considerable cost savings can be achieved using the tight coupling of the present invention because the PCBs can be made smaller and components can be combined on single PCBs to form circuits that might have otherwise required physical isolation and separation among different components of a circuit.

IV. Second Alternative Aspect Tightly-Coupled PCB Circuit 102

A tightly-coupled PCB circuit 102 comprising a second alternative aspect or embodiment of the present invention is shown in FIGS. 3 and 4 and includes a PCB 103. The PCB circuit 102 includes a receiver 104, first and second GNSS antennas 106, 108 and a power supply 110. Multiple decoupling capacitors 112 form first and second decoupling lines 114, 116, which generally extend in opposite directions from the receiver 104 towards respective ends of the PCB 103 and define respective isolation islands 118, 120 for the antennas 106, 108 respectively. As shown in FIG. 4, first and second RF striplines or traces 121, 122 are surface-mounted on the bottom surface of the PCB 103 and extend from the receiver 104 to the antennas 106, 108 respectively.

V. Third Alternative Aspect Tightly-Coupled PCB Circuit 152

A tightly-coupled PCB circuit 152 comprising a third alternative aspect or embodiment of the present invention is shown in FIGS. 5 and 6 and includes a PCB 153. The PCB circuit 152 includes a receiver 154, first and second GNSS patch antennas 156, 158 and a power supply 160. Multiple decoupling capacitors 162 form first and second decoupling lines 164, 166, which form generally circular isolation islands 168, 170 at respective ends of the PCB 153 for the antennas 156, 158 respectively. Additional decoupling capacitors 162 are provided adjacent to edges of the PCB 153. A central isolation island 159 is formed for the receiver 154 and a power supply 160. As shown in FIGS. 5 and 6, the isolation island 169 can have an irregular shape. Internal first and second RF striplines or traces 171, 172 are provided within the PCB 153 and extend from the central isolation island 169 to the antennas 156, 158 located in the isolation islands 168, 170 respectively. Alternatively, the RF traces 171, 172 can be surface-mounted.

It is to be understood that the invention can be embodied in various forms, and is not to be limited to the examples discussed above. For example, the PCBs and the isolation islands can be formed in a variety of configurations. Moreover, various components can be assembled in different configurations to form a wide variety of PCB circuits, which can effectively utilize the closely-coupled construction of the present invention with isolation islands. For example, multiple antennas and receivers can be provided. Although GNSS receivers and patch antennas are shown, other RF receivers and antennas can be utilized. The range of components and configurations which can be utilized in the practice of the present invention is virtually unlimited.

Claims

1. A method of tightly coupling a printed circuit board (PCB), which method comprises the steps of: providing a PCB with multiple conductive layers;separating said conductive layers with insulating layers;providing a positive reference layer;providing a ground plane comprising a grounded reference layer;providing a signal layer;photoetching the signal layer to define a circuit;providing electrical components;connecting each electrical component to one or more layers;forming a decoupling line in said PCB; andforming an electrical isolation island in said PCB with said decoupling line.

2. The method of claim 1 wherein one of said components comprises a receiver, which method includes the additional steps of: providing said PCB with a perimeter;connecting said receiver to said PCB; andextending said decoupling line from said receiver to PCB perimeter.

3. The method of claim 2 wherein said components include an antenna, which method includes the additional steps of: providing an RF transmission line connecting said antenna to said receiver; andlocating said antenna in said isolation island.

4. The method of claim 3, which includes the additional steps of: forming an optimal RF path from the antenna to the receiver, thereby creating a decoupling line; andforming said isolation island along said decoupling line path.

5. The method of claim 2, which includes the additional steps of: locating said receiver in an interior area of said PCB;providing a pair of said decoupling lines; andextending said decoupling lines from said receiver to said PCB perimeter.

6. The method of claim 1, which includes the additional step of: forming said decoupling line with a plurality of discrete decouplers each extending through said PCB layers.

7. The method of claim 3, which includes the additional steps of: providing said PCB with three sections each terminating at an outer end;locating said receiver centrally with said PCB sections extending outwardly therefrom;mounting an antenna in each of said sections in proximity to its outer end;extending a pair of said decoupling lines from said receiver to each said PCB section outer end; andforming an isolation island in each said PCB section with said antenna located therein.

8. A method of manufacturing a tightly-coupled PCB circuit with a power supply, a GNSS receiver and first and second GNSS antennas, which method comprises the steps of: providing a PCB with multiple conductive layers;separating said conductive layers with insulating layers;providing a positive reference layer;providing a ground plane comprising a grounded reference layer;providing a signal layer;photoetching the signal layer to define a circuit;providing said PCB with a perimeter;mounting said power supply and said GNSS receiver on said PCB;connecting said power supply and said GNSS receiver to said positive and grounded reference layers;providing multiple decoupling capacitors;connecting each said capacitors to multiple said PCB layers and electrically closely-coupling said PCB layers with said capacitors;determining optimal first and second RF paths from the antennas to the receiver;aligning multiple said decoupling capacitors along said optimal RF paths and thereby creating first and second decoupling lines each extending from said receiver to said PCB edge in proximity to a respective antenna;forming first and second isolation islands along said first and second decoupling line paths respectively;providing first and second RF transmission lines connecting said receiver to said first and second antennas respectively; andlocating said first and second antennas in said first and second isolation islands respectively.

9. A tightly-coupled printed circuit board (PCB) circuit, which includes: multiple conductive layers;insulating layers separating said conductive layers;a positive reference layer;a ground plane comprising a grounded reference layer;a signal layer;a circuit photoetched in the signal layer;multiple electrical components each connected to one or more layers;a decoupling line in said PCB; andan electrical isolation island formed by said decoupling line in said PCB.

10. The circuit of claim 9, which includes: one of said components comprising a receiver;said PCB including a perimeter;said receiver being connected to said PCB; andsaid decoupling line extending from said receiver to said PCB perimeter.

11. The circuit of claim 10, which includes: said components including an antenna located in said isolation island; andan RF transmission line connecting said antenna to said receiver.

12. The circuit of claim 11, which includes: an optimal RF path from the antenna to the receiver,said decoupling line generally following said optimal RF path; andsaid isolation island being formed along said decoupling line path.

13. The circuit of claim 10, which includes: said receiver being located in an interior area of said PCB;a pair of said decoupling lines; andsaid decoupling lines extending from said receiver to said PCB perimeter.

14. The circuit of claim 9, which includes: said decoupling line being formed with a plurality of discrete decouplers each extending through said PCB layers.

15. The circuit of claim 11, which includes: said PCB having three sections each terminating at an outer end;said receiver being located centrally with said PCB sections extending outwardly therefrom;three antennas each mounted in a respective section in proximity to its outer end;a pair of said decoupling lines each extending from said receiver to a respective PCB section outer end; andthree said isolation islands each located in a respective PCB section and each having a respective antenna located therein.