Project Title:

Low Cost, Ultra-Thin, Conformal Active Array Assemblies for Satellite Communications

  94-1	14.03	3200		

  Low Cost, Ultra-Thin, Conformal Active Array Assemblies for 
  Satellite Communications

Abstract:

Foster-Miller, Inc. proposes to develop low cost, ultra-thin, 
conformal, reliable packages for active array antenna assemblies 
with integrated monolithic microwave integrated circuit (MMIC) 
chips and digital control interfaces. The package will be 
fabricated using Foster-Miller's innovative Liquid Crystal 
Polymer (LCP) dielectrics and will incorporate circular patch 
antennas operating at millimeter-wave frequencies. The 
lightweight polymer-based substrate replaces conventional 
ceramic hybrid packaging, meeting all requirements while 
lowering the cost. The complete array system to be designed in 
Phase I and later built in Phase II will make use of the low 
cost multilayer interconnect and assembly features of LCP to 
provide multichip packaging of Gallium Arsenide MMIC digital and 
photonic chips. The LCP will also enable the integration of the 
efficient aperture coupled patch antennas and associated feed 
distribution network, including a coefficient of thermal 
expansion-matched heat sink to make low cost, lightweight 
hermetic packages for active element scanning antenna arrays. 
This integration will permit half wavelength aperture spacing 
resulting in enhanced scan performance.
In the Phase II effort, working with Texas Instruments, we will 
build and test a subarray assembly consisting of several modules 
to demonstrate both electrical and mechanical performance of our 
innovative approach.

This technology has significant commercialization potential for 
use in mobile communications, using the ACTS Satellite as well 
as for other emerging portable communications equipment such as 
GPS based units now beginning to be utilized in the private 
sector. Its low cost, low profile approach makes it suitable for 
a wide range of applications both for other high reliability 
communications such as collision avoidance systems, as well as 
for phased array radar, for example weather tracking.

Key Words

Foster-Miller, Inc.
350 Second Avenue
Waltham, MA 02154-1196