Packaging architecture for phased arrays

A phased array antenna structure comprising:

• a) a distribution network for collecting electromagnetic (EM) energy;
• b) a feed honeycomb structure positioned adjacent said distribution network and connected to transmit the EM energy to the distribution network;
• c) a module honeycomb structure positioned adjacent said feed honeycomb structure so as to transmit EM energy to said feed honeycomb structure;
• d) an antenna honeycomb structure positioned adjacent said module honeycomb structure on a side opposite said feed honeycomb structure so as to receive EM energy from an exterior source and transmit same to said module honeycomb structure;
• e) each of said feed, module and antenna honeycomb structures have a plurality of aligned waveguides for transmitting EM energy therealong;
• f) said module honeycomb structure including an electronic module for each waveguide, each electronic module having an electronic element for adjusting at least the phase of said EM energy and transmitting the adjusted phase EM energy to the aligned waveguide of the feed honeycomb structure.

A phased array antenna structure comprising:

• a) a distribution network for distributing or collecting electromagnetic (EM) energy;
• b) a feed honeycomb structure positioned adjacent said distribution network and connected to receive the EM energy from the distribution network or to distribute EM energy to the distribution network;
• c) a module honeycomb structure positioned adjacent said feed honeycomb structure so as to receive EM energy from said feed honeycomb structure or to transmit EM energy to the feed honeycomb structure;
• d) an antenna honeycomb structure positioned adjacent said module honeycomb structure on a side opposite said feed honeycomb structure so as to receive EM energy from said module honeycomb structure or to transmit EM energy to the module honeycomb structure;
• e) each of said feed, module and antenna honeycomb structures have a plurality of aligned waveguides for transmitting EM energy therealong;
• f) said module honeycomb structure including an electronic module for each waveguide, each electronic module having an electronic element for adjusting at least the phase of said EM energy and transmitting the adjusted phase EM energy to the aligned waveguide of the antenna honeycomb structure or the feed honeycomb structure.

A phased array antenna structure comprising:

• a) a distribution network for distributing electromagnetic (EM) energy;
• b) a feed honeycomb structure positioned adjacent said distribution network and connected to receive the EM energy from the distribution network;
• c) a module honeycomb structure positioned adjacent said feed honeycomb structure so as to receive EM energy from said feed honeycomb structure;
• d) an antenna honeycomb structure positioned adjacent said module honeycomb structure on a side opposite said feed honeycomb structure so as to receive EM energy from said module honeycomb structure;
• e) each of said feed, module and antenna honeycomb structures have a plurality of aligned waveguides for transmitting EM energy therealong;
• f) said module honeycomb structure including an electronic module for each waveguide, each electronic module having an electronic element for adjusting at least the phase of said EM energy and transmitting the adjusted phase EM energy to the aligned waveguide of the antenna honeycomb structure;
• g) a multilayer wiring circuit positioned between at least one of (1) said feed honeycomb structure and said module honeycomb structure and (2) said antenna honeycomb structure and said module honeycomb structure, for providing electrical signals to each of said electronic modules;
• h) each of said electronic modules comprises:
• 1) a substantially planar substrate for supporting said electronic element, said substrate having a top and bottom surface;
• 2) a carrier for supporting a portion of said bottom surface of said substrate;
• 3) at least one extension region formed as part of said substrate and extending beyond an end of said carrier and extending into one of said antenna honeycomb structure or said feed honeycomb structure;
• 4) said substrate having a metallization pattern on the top surface thereof for feeding said electronic signals thereto;
• 5) said at least one extension region having a metallization area, connected to said metallization pattern on the top surface thereof and vias extending from the metallization area on the top surface of said substrate to the bottom surface thereof in the extension region for receiving said electrical signals;
• 6) a plurality of module terminals connected to the bottom surface of said substrate in the at least one extension region thereof, each of said module terminals connected to said vias for providing said electrical signals to the electronic element of said electronic module,
• i) said multilayer wiring circuit including a plurality of wiring circuit terminals corresponding to and positioned adjacent said plurality of module terminals for each of said electronic modules, said wiring circuit terminals and said module terminals operative to make electrical contact with one another when said multilayer wiring circuit is biased against said module honeycomb structure and thus to connect said electrical signals from said multilayer wiring circuits to the electronic element of said electronic modules, and to break electrical contact with one another when said multilayer wiring circuit is moved away from said module honeycomb structure.

A phased array antenna structure comprising:

• a) a distribution network for distributing electromagnetic (EM) energy;
• b) a feed honeycomb structure positioned adjacent said distribution network and connected to receive the EM energy from the distribution network;
• c) a module honeycomb structure positioned adjacent said feed honeycomb structure so as to receive EM energy from said feed honeycomb structure;
• d) an antenna honeycomb structure positioned adjacent said module honeycomb structure on a side opposite said feed honeycomb structure so as to receive EM energy from said module honeycomb structure;
• e) each of said feed, module and antenna honeycomb structures have a plurality of aligned waveguides to transmitting EM energy therealong;
• f) said module honeycomb structure including an electronic module for each waveguide, each electronic module having an electronic element for adjusting at least the phase of said EM energy and transmitting the adjusted phase EM energy to the aligned waveguide of the antenna honeycomb structure;
• g) a multilayer wiring circuit positioned between at least one of (1) said feed honeycomb structure and said module honeycomb structure and (2) said antenna honeycomb structure and said module honeycomb structure, for providing electrical signals to each of said electronic modules;
• h) each of said electronic modules comprises:
• 1) a substantially planar substrate for supporting said electronic element, said substrate having a top and bottom surface;
• 2) a carrier for supporting a portion of said bottom surface of said substrate;
• 3) at least one extension region formed as part of said substrate and extending beyond an end of said carrier and extending into one of said antenna honeycomb structure or said feed honeycomb structure;
• 4) said substrate having a metallization pattern on the top surface thereof for feeding said electronic signals thereto;
• 5) said at least one extension region having a metallization area, connected to said metallization pattern on the top surface thereof and vias extending from the metallization area on the top surface of said substrate to the bottom surface thereof in the extension region for receiving said electrical signals;
• 6) a plurality of module terminals connected to the bottom surface of said substrate in the at least one extension region thereof, each of said module terminals connected to said vias for providing said electrical signals to the electronic element of said electronic module,
• i) said multilayer wiring circuit including:
• 1) a plurality of wiring circuit terminals corresponding to and positioned adjacent said plurality of module terminals for each of said electronic modules,
• 2) an elastomeric wedge for each of said plurality of wiring circuit terminal,
• 3) a plurality of metallic elements secured to said wedge, said metallic elements electrically insulated from one another,
• the plurality of metallic elements of said wedge positioned between said plurality of module terminals and said plurality of wiring circuit terminals to connect same when said wedge is biased against said plurality of module terminals and said plurality of wiring circuit terminals and to disconnect same when said wedge is not so biased.