# US 10,320,075 B2 · Monolithic phased-array antenna system > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,320,075 B2 - Document ID: US10320075B2 - Status: Granted - Kind: B2 - Application number: 14/837,954 - Filed: 2015-08-27 - Published: 2017-03-02 - Granted: 2019-06-11 - Earliest claimed: 2015-08-27 - Assignees: Northrop Grumman Systems Corporation - Applicants: Victor C. Sanchez - Inventors: Victor C. Sanchez - Web page: https://patentgrep.com/patent/US10320075B2 ## CPC - H01Q 3/26: varying the relative phase or relative amplitude of energisation between two or more active radiating elements; varying the distribution of energy across a radiating aperture ({H01Q3/12,} H01Q3/22, H01Q3/24 take precedence) - H01Q 1/50: Structural association of antennas with earthing switches, lead-in devices or lightning protectors - H01Q 13/085: {Slot-line radiating ends} - H01Q 21/0087: {Apparatus or processes specially adapted for manufacturing antenna arrays (manufacturing waveguides H01P11/00)} - H01Q 21/0093: {Monolithic arrays} - H01Q 21/064: {using horn or slot aerials (slotted waveguides arrays H01Q21/005)} - H01Q 21/067: {using endfire radiating aerial units transverse to the plane of the array} - H01Q 21/24: Combinations of antenna units polarised in different directions for transmitting or receiving circularly and elliptically polarised waves or waves linearly polarised in any direction {(circularly polarised patch antennas H01Q9/0428; circularly polarised horns H01Q13/0241; cross-polarised horns H01Q13/0258; polarisation converters H01Q15/242; cross-polarised rear feeds H01Q19/136; crossed polarisation dual antenna H01Q25/001)} - H01Q 21/293: {one unit or more being an array of identical aerial elements (adaptive arrays H01Q3/2605)} - B33Y 10/00: Processes of additive manufacturing - B33Y 50/02: for controlling or regulating additive manufacturing processes - B33Y 80/00: Products made by additive manufacturing - H01Q: ANTENNAS, i.e. RADIO AERIALS (radiators or antennas for microwave heating H05B6/72) - B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING ## Abstract One embodiment describes a phased-array antenna system that is formed as a monolithic structure of a unitary conductive material. The system includes a ground plane and a plurality of antenna transformer elements formed in an array and conductively coupled to a first surface of the ground plane. The system also includes a plurality of connectors formed and conductively coupled to a second surface of the ground plane opposite the first surface, the plurality of connectors being configured to propagate radio frequency signals to or from respective ones of the plurality of antenna transformer elements. ## Claims ### Claim 1 A phased-array antenna system that is formed as a monolithic structure of a unitary conductive material, the system comprising: a ground plane; a plurality of antenna transformer elements formed in an array and conductively coupled to a first surface of the ground plane; a plurality of connectors formed and conductively coupled to a second surface of the ground plane opposite the first surface, the plurality of connectors being configured to propagate radio frequency signals to or from respective ones of the plurality of antenna transformer elements; and a signal conductor conductively coupled to an associated one of the plurality of antenna transformer elements and extending in free space from a sidewall of the associated one of the plurality of antenna transformer elements through a sidewall of an adjacent one of the plurality of antenna transformer elements, wherein the plurality of antenna transformer elements are dimensioned to form a balun cavity between respective pairs of the plurality of antenna transformer elements with respect to the ground plane. ### Claim 2 (depends on 1) The system of claim 1, wherein the plurality of antenna transformer elements are dimensioned to form a transformer gap between respective pairs of the plurality of antenna transformer elements to provide impedance matching to free-space. ### Claim 3 (depends on 1) The system of claim 1, wherein each of the plurality of antenna transformer elements comprises a plurality of sidewalls that each extend in respective directions away from the ground plane, with each of the plurality of sidewalls comprises a pattern of holes through the respective one of the plurality of sidewalls. ### Claim 4 (depends on 1) The system of claim 1, wherein the signal conductor is formed from the unitary conductive material and extends through the ground plane from the first surface to the second surface beneath the adjacent one of the plurality of antenna transformer elements. ### Claim 5 (depends on 1) The system of claim 1, wherein the signal conductor is a first signal conductor that extends in a first direction in free space between the associated one of the plurality of antenna transformer elements and a first adjacent one of the plurality of antenna transformer elements, wherein a second signal conductor extends in a second direction in free space between the associated one of the plurality of antenna transformer elements and a second adjacent one of the plurality of antenna transformer elements, the second direction being orthogonal with respect to the first direction to provide respective first and second orthogonal polarizations of the signal. ### Claim 6 (depends on 1) The system of claim 1, wherein the signal conductor is arranged as an inner conductor of a coaxial connection between the respective one of the plurality of connectors and the adjacent one of the plurality of antenna transformer elements, wherein the associated one of the plurality of antenna transformer elements is arranged as an outer conductor of the coaxial connection. ### Claim 7 (depends on 6) The system of claim 6, wherein the adjacent one of the plurality of antenna transformer elements comprises a conductive coupling to the ground plane that substantially surrounds the signal conductor as the signal conductor extends through the adjacent one of the plurality of antenna transformer elements, the conductive coupling corresponding to the outer conductor of the coaxial connection. ### Claim 8 (depends on 1) The system of claim 1, wherein the ground plane, the plurality of antenna transformer elements, and the plurality of connectors are formed from an additive manufacturing process to form the ground plane, the plurality of antenna transformer elements, and the plurality of connectors as the monolithic structure. ### Claim 9 (depends on 8) The system of claim 8, wherein the monolithic structure is formed from a dielectric material via the additive manufacturing process, wherein the unitary conductive material is formed over the dielectric material via a metallization process. ### Claim 10 A phased-array antenna system comprising: a ground plane; a plurality of antenna transformer elements formed in an array and conductively coupled to a first surface of the ground plane, each of the plurality of antenna transformer elements being dimensioned to form a balun cavity between respective pairs of the plurality of antenna transformer elements with respect to the ground plane and to form a transformer gap between respective pairs of the plurality of antenna transformer elements to provide impedance matching to free-space; a plurality of connectors formed and conductively coupled to a second surface of the ground plane opposite the first surface, the plurality of connectors being configured to propagate radio frequency signals to or from respective ones of the plurality of antenna transformer elements; and a plurality of coaxial connections between the plurality of connectors and the plurality of transformer elements, each of the plurality of connectors being associated with one of the plurality of antenna transformer elements and comprising a signal conductor that is formed from the unitary conductive material as an inner conductor of a respective one of the plurality of coaxial connections and extending from a sidewall of an associated one of the plurality of antenna transformer elements through a sidewall of an adjacent one of the plurality of antenna transformer elements that is coupled to an outer conductor of the respective one of the plurality of coaxial connections, wherein the phased-array antenna system is formed as a monolithic structure of unitary conductive material. ### Claim 11 (depends on 10) The system of claim 10, wherein the signal conductor associated with the respective one of the plurality of coaxial connections extends in free space between the associated one of the plurality of antenna transformer elements and the adjacent one of the plurality of antenna transformer elements to provide excited interaction between the signal conductor and the associated one and the adjacent one of the plurality of antenna transformer elements to wirelessly transmit or receive the signal. ### Claim 12 (depends on 11) The system of claim 11, wherein the signal conductor is a first signal conductor that extends in a first direction in free space between the associated one of the plurality of antenna transformer elements and a first adjacent one of the plurality of antenna transformer elements, wherein a second signal conductor extends in a second direction in free space between the associated one of the plurality of antenna transformer elements and a second adjacent one of the plurality of antenna transformer elements, the second direction being orthogonal with respect to the first direction to provide respective first and second orthogonal polarizations of the signal.