# US 2020/0395673 A1 · Dielectric reflectarray antenna and method for making the same

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- Number: US 2020/0395673 A1
- Document ID: US20200395673A1
- Status: Published application
- Kind: A1
- Application number: 16/441,323
- Filed: 2019-06-14
- Published: 2020-12-17
- Earliest claimed: 2019-06-14
- Assignees: City University of Hong Kong
- Applicants: City University of Hong Kong
- Inventors: Kwok Wa Leung; Yuxiang Sun
- Web page: https://patentgrep.com/patent/US20200395673A1

## CPC

- H01Q 3/46: Active lenses or reflecting arrays
- H01Q 19/10: using reflecting surfaces
- H01P 11/001: {Manufacturing waveguides or transmission lines of the waveguide type}
- H01Q 15/141: {Apparatus or processes specially adapted for manufacturing reflecting surfaces}
- H01Q 21/0087: {Apparatus or processes specially adapted for manufacturing antenna arrays (manufacturing waveguides H01P11/00)}
- H01Q: ANTENNAS, i.e. RADIO AERIALS (radiators or antennas for microwave heating H05B6/72)
- H01P: WAVEGUIDES; RESONATORS, LINES, OR OTHER DEVICES OF THE WAVEGUIDE TYPE (operating at optical frequencies G02B)

## Abstract

The invention relates to a method for making a dielectric reflectarray antenna, and a dielectric reflectarray antenna made using such method. The method includes removing, from a substrate having a dielectric layer and a first outer metallic layer arranged on one side of the dielectric layer, the first outer metallic layer to form an intermediate substrate. The method also includes cutting the intermediate substrate to integrally form a dielectric reflectarray with an array of dielectric reflector elements of the dielectric reflectarray antenna.

## Claims

### Claim 1

A method for making a dielectric reflectarray antenna, comprising:
removing, from a substrate having a dielectric layer and a first outer metallic layer arranged on one side of the dielectric layer, the first outer metallic layer to form an intermediate substrate; and
cutting the intermediate substrate to integrally form an array of dielectric reflector elements of the dielectric reflectarray antenna.

### Claim 2 (depends on 1)

The method of claim 1, wherein the substrate further includes a second outer metallic layer arranged on the other side of the dielectric layer; the intermediate substrate includes the dielectric layer and the second outer metallic layer; and the array of dielectric reflector elements includes the dielectric layer and the second outer metallic layer that have not been cut.

### Claim 3 (depends on 2)

The method of claim 2, wherein the substrate consists only of: the dielectric layer, the first outer metallic layer, and the second outer metallic layer.

### Claim 4 (depends on 1)

The method of claim 1, wherein the substrate is a single PCB substrate.

### Claim 5 (depends on 1)

The method of claim 1, wherein the first outer metallic layer is a copper cladding layer.

### Claim 6 (depends on 2)

The method of claim 2, wherein the first outer metallic layer is a copper cladding layer and the second outer metallic layer is a copper cladding layer.

### Claim 7 (depends on 1)

The method of claim 1, wherein the dielectric layer has a dielectric constant of at least 5.

### Claim 8 (depends on 1)

The method of claim 1, wherein the removing step comprises laser-etching the first outer metallic layer.

### Claim 9 (depends on 1)

The method of claim 1, wherein the removing step comprises chemically-etching the first outer metallic layer.

### Claim 10 (depends on 1)

The method of claim 1, wherein the cutting step comprises cutting the intermediate substrate using a milling cutter.

### Claim 11 (depends on 1)

The method of claim 1, wherein the cutting step comprises cutting the intermediate substrate using a computer-numerical-controlled milling cutter.

### Claim 12 (depends on 1)

The method of claim 1, wherein each of the dielectric reflector elements includes a reflector portion for controlling a reflection phase response and a connection portion for directly connecting with at least one other adjacent dielectric reflector element.

### Claim 13 (depends on 12)

The method of claim 12, wherein the connection portion includes one or more arms extending from the reflector portion.

### Claim 14 (depends on 12)

The method of claim 12, wherein the connection portion of at least some of the dielectric reflector elements includes a plurality of arms extending from the reflector portion, the plurality of arms being spaced apart evenly.

### Claim 15 (depends on 12)

The method of claim 12, wherein the reflector portion is generally cylindrical, and the connection portion includes one or more arms extending radially from the reflector portion.

### Claim 16 (depends on 1)

The method of claim 1, further comprising:
attaching a conductive layer to the array of dielectric reflector elements.

### Claim 17 (depends on 16)

The method of claim 16, wherein the conductive layer comprises a conductive bonding film.

### Claim 18 (depends on 2)

The method of claim 2, further comprising:
attaching a conductive layer to the second outer metallic layer of the array of dielectric reflector elements.

### Claim 19 (depends on 2)

A dielectric reflectarray antenna formed using the method of claim 2.

### Claim 20 (depends on 19)

The dielectric reflectarray antenna of claim 19, wherein the dielectric layer has a dielectric constant of at least 5.

### Claim 21 (depends on 19)

The dielectric reflectarray antenna of claim 19, wherein each of the dielectric reflector elements includes a reflector portion for controlling a reflection phase response and a connection portion for directly connecting with at least one other adjacent dielectric reflector element.

### Claim 22 (depends on 21)

The dielectric reflectarray antenna of claim 21, wherein the connection portion includes one or more arms extending from the reflector portion.

### Claim 23 (depends on 21)

The dielectric reflectarray antenna of claim 21, wherein the connection portion of at least some of the dielectric reflector elements includes a plurality of arms extending from the reflector portion, the plurality of arms being spaced apart evenly.

### Claim 24 (depends on 21)

The dielectric reflectarray antenna of claim 21, wherein the reflector portion is generally cylindrical, and the connection portion includes one or more arms extending radially from the reflector portion.

### Claim 25 (depends on 19)

The dielectric reflectarray antenna of claim 19, further comprising:
a conductive layer attached to the second outer metallic layer of the array of dielectric reflector elements.

### Claim 26 (depends on 25)

The dielectric reflectarray antenna of claim 25, wherein the conductive layer comprises a conductive bonding film.

### Claim 27 (depends on 19)

The dielectric reflectarray antenna of claim 19, wherein the dielectric reflectarray antenna is a millimeter-wave dielectric reflectarray antenna.

### Claim 28 (depends on 19)

A communication apparatus comprising the dielectric reflectarray antenna of claim 19.