Broadband multiple layer dielectric resonator antenna and method of making the same

• US 10,601,137 B2
• Filed: 10/26/2016
• Issued: 03/24/2020
• Est. Priority Date: 10/28/2015
• Status: Active Grant

• Current Assignee: Rogers Corporation (Rogers Communications Inc.)
• Original Assignee: Rogers Corporation (Rogers Communications Inc.)
• Inventors: Pance, Kristi, Sprentall, Karl, Williams, Shawn P., Daigle, Robert C.
• Primary Examiner(s): Wollschlager, Jeffrey M
• Application Number:
  US15/334,699
• Publication Number:
  US 20170125909A1
• Time in Patent Office: 1,245 Days
• CPC Class Codes: H01Q 21/30 Combinations of separate antenna units operating in different wavebands and connected to a common feeder system
• CPC Class Codes: H01Q 9/0485 Dielectric resonator antennas
• CPC Class Codes: H01Q 9/0492 circularly polarised

Abstract

A method for the manufacture of a dielectric resonator antenna (DRA) or array of DRAs, the DRA having: an electrically conductive ground structure; a plurality of volumes of dielectric materials disposed on the ground structure having N volumes, N being an integer equal to or greater than 3, disposed to form successive and sequential layered volumes V(i), i being an integer from 1 to N, wherein volume V(1) forms an innermost volume, wherein a successive volume V(i+1) forms a layered shell disposed over and at least partially embedding volume V(i), wherein volume V(N) at least partially embeds all volumes V(1) to V(N−1); and, a signal feed disposed and structured to be electromagnetically coupled to one or more of the plurality of volumes of dielectric materials. The method including molding at least one of the plurality of volumes of the dielectric material, or all of the volumes of the dielectric material.

Claims

1. A method for the manufacture of a dielectric resonator antenna (DRA), or an array of the DRAs, each DRA having:

an electrically conductive ground structure;

a plurality of volumes of dielectric materials disposed on the ground structure comprising N volumes, N being an integer equal to or greater than 3, disposed to form successive and sequential layered volumes V(i), i being an integer from 1 to N, wherein volume V(1) forms an innermost volume, wherein a successive volume V(i+1) forms a layered shell disposed over and at least partially embedding volume V(i), wherein volume V(N) at least partially embeds all volumes V(1) to V(N−

1); and

a signal feed disposed and structured to be electromagnetically coupled to one or more of the plurality of volumes of dielectric materials, the method comprising;

molding at least one volume of the plurality of volumes of the dielectric materials, or all volumes of the plurality of volumes of the dielectric materials;

wherein the molding comprises injection molding at least one volume of the plurality of volumes of the dielectric materials;

wherein the injection molding comprises;

injection molding a first volume of the plurality of volumes of dielectric materials in a first mold having an outer mold form and an inner mold form;

removing the inner mold form and replacing it with a second inner mold form defining an inner dimension of a second volume of the plurality of volumes of dielectric materials; and

injection molding the second volume in the first volume.

2. The method of claim 1, wherein the first volume is the outermost volume V(N).

5. The method of claim 1, wherein the injection molding comprises injection molding a thermosetting composition comprising:

a curable composition, and

a catalyst system effective to cure the composition; and

curing the curable composition to form the at least one volume.

3. A method for the manufacture of a dielectric resonator antenna (DRA), or an array of the DRAs, each DRA having:

an electrically conductive ground structure;

a plurality of volumes of dielectric materials disposed on the ground structure comprising N volumes, N being an integer equal to or greater than 3, disposed to form successive and sequential layered volumes V(i), i being an integer from 1 to N, wherein volume V(1) forms an innermost volume, wherein a successive volume V(i+1) forms a layered shell disposed over and at least partially embedding volume V(i), wherein volume V(N) at least partially embeds all volumes V(1) to V(N−

1); and

a signal feed disposed and structured to be electromagnetically coupled to one or more of the plurality of volumes of dielectric materials, the method comprising;

molding at least one volume of the plurality of volumes of the dielectric materials, or all volumes of the plurality of volumes of the dielectric materials;

wherein the molding comprises injection molding at least one volume of the plurality of volumes of the dielectric materials;

wherein the injection molding comprises;

injection molding a first volume of the plurality of volumes of dielectric materials in a first mold having an outer mold form and an inner mold form;

removing the outer mold form and replacing it with a second outer mold form defining an outer dimension of a second volume of the plurality of volumes of dielectric materials; and

injection molding the second volume onto the first volume.

4. The method of claim 3, wherein the first volume is the innermost volume V(1).

27. The method of claim 3, wherein the injection molding comprises injection molding a thermosetting composition comprising:

a curable composition, and

a catalyst system effective to cure the composition; and

curing the curable composition to form the at least one volume.

6. A method for the manufacture of a dielectric resonator antenna (DRA), or an array of the DRAs, each DRA having:

an electrically conductive ground structure;

a plurality of volumes of dielectric materials disposed on the ground structure comprising N volumes, N being an integer equal to or greater than 3, disposed to form successive and sequential layered volumes V(i), i being an integer from 1 to N, wherein volume V(1) forms an innermost volume, wherein a successive volume V(i+1) forms a layered shell disposed over and at least partially embedding volume V(i), wherein volume V(N) at least partially embeds all volumes V(1) to V(N−

1); and

a signal feed disposed and structured to be electromagnetically coupled to one or more of the plurality of volumes of dielectric materials, the method comprising;

molding at least one volume of the plurality of volumes of the dielectric materials, or all volumes of the plurality of volumes of the dielectric materials;

wherein the molding comprises compression molding at least one volume of the plurality of volumes of dielectric materials;

wherein the compression molding comprises;

compression molding a first volume of the plurality of volumes of dielectric materials in a first mold having an outer mold form and an inner mold form;

removing the inner mold form and replacing it with a second inner mold form defining an inner dimension of a second volume of the plurality of volumes of dielectric materials; and

compression molding the second volume in the first volume.

7. The method of claim 6, wherein the first volume is the outermost volume V(N).

8. A method for the manufacture of a dielectric resonator antenna (DRA), or an array of the DRAs, each DRA having:

an electrically conductive ground structure;

a plurality of volumes of dielectric materials disposed on the ground structure comprising N volumes, N being an integer equal to or greater than 3, disposed to form successive and sequential layered volumes V(i), i being an integer from 1 to N, wherein volume V(1) forms an innermost volume, wherein a successive volume V(i+1) forms a layered shell disposed over and at least partially embedding volume V(i), wherein volume V(N) at least partially embeds all volumes V(1) to V(N−

1); and

a signal feed disposed and structured to be electromagnetically coupled to one or more of the plurality of volumes of dielectric materials, the method comprising;

molding at least one volume of the plurality of volumes of the dielectric materials, or all volumes of the plurality of volumes of the dielectric materials;

wherein the molding comprises compression molding at least one volume of the plurality of volumes of dielectric materials;

wherein the compression molding comprises;

compression molding a first volume of the plurality of volumes of dielectric materials in a first mold having an outer mold form and an inner mold form;

removing the outer mold form and replacing it with a second outer mold form defining an outer dimension of a second volume of the plurality of volumes of dielectric materials; and

compression molding the second volume onto the first volume.

9. The method of claim 8, wherein the first volume is the innermost volume V(1).

10. A method for the manufacture of a dielectric resonator antenna (DRA), or an array of the DRAs, each DRA having a plurality of volumes of dielectric materials comprising N volumes, N being an integer equal to or greater than 3, disposed to form successive and sequential layered volumes V(i), i being an integer from 1 to N, wherein volume V(1) forms an innermost volume, wherein a successive volume V(i+1) forms a layered shell disposed over and at least partially embedding volume V(i), wherein volume V(N) at least partially embeds all volumes V(1) to V(N−

1), the method comprising;

molding at least one volume of the plurality of volumes of the dielectric materials, or all volumes of the plurality of volumes of the dielectric materials;

wherein the molding comprises injection molding at least one volume of the plurality of volumes of the dielectric materials;

wherein the injection molding comprises;

injection molding a first volume of the plurality of volumes of dielectric materials in a first mold having an outer mold form and an inner mold form;

removing the inner mold form and replacing it with a second inner mold form defining an inner dimension of a second volume of the plurality of volumes of dielectric materials; and

injection molding the second volume in the first volume.

11. The method of claim 10, wherein the first volume is the outermost volume V(N).

14. The method of claim 10, wherein the injection molding comprises injection molding a thermosetting composition comprising:

a curable composition, and

a catalyst system effective to cure the composition; and

curing the curable composition to form the at least one volume.

21. The method of claim 10, wherein each of the DRA further has;

an electrically conductive ground structure wherein the plurality of volumes of dielectric materials are disposed on the ground structure, and a signal feed disposed and structured to be electromagnetically coupled to one or more of the plurality of volumes of dielectric materials, the method further wherein;

the at least one volume is molded onto an insert to provide the signal feed or the ground structure.

22. The method of claim 21, further comprising inserting a metal layer into an outer mold portion of the outermost volume V(N), and molding the outermost volume V(N) onto the metal layer to provide the signal feed or the ground structure on the outermost volume V(N).

12. A method for the manufacture of a dielectric resonator antenna (DRA), or an array of the DRAs, each DRA having a plurality of volumes of dielectric materials comprising N volumes, N being an integer equal to or greater than 3, disposed to form successive and sequential layered volumes V(i), i being an integer from 1 to N, wherein volume V(1) forms an innermost volume, wherein a successive volume V(i+1) forms a layered shell disposed over and at least partially embedding volume V(i), wherein volume V(N) at least partially embeds all volumes V(1) to V(N−

1), the method comprising;

molding at least one volume of the plurality of volumes of the dielectric materials, or all volumes of the plurality of volumes of the dielectric materials;

wherein the molding comprises injection molding at least one volume of the plurality of volumes of the dielectric materials;

wherein the injection molding comprises;

injection molding a first volume of the plurality of volumes of dielectric materials in a first mold having an outer mold form and an inner mold form;

removing the outer mold form and replacing it with a second outer mold form defining an outer dimension of a second volume of the plurality of volumes of dielectric materials; and

injection molding the second volume onto the first volume.

13. The method of claim 12, wherein the first volume is the innermost volume V(1).

23. The method of claim 12, wherein each of the DRA further has;

an electrically conductive ground structure wherein the plurality of volumes of dielectric materials are disposed on the ground structure, and a signal feed disposed and structured to be electromagnetically coupled to one or more of the plurality of volumes of dielectric materials, the method further wherein;

the at least one volume is molded onto an insert to provide the signal feed or the ground structure.

24. The method of claim 23, further comprising inserting a metal layer into an outer mold portion of the outermost volume V(N), and molding the outermost volume V(N) onto the metal layer to provide the signal feed or the ground structure on the outermost volume V(N).

28. The method of claim 12, wherein the injection molding comprises injection molding a thermosetting composition comprising:

a curable composition, and

a catalyst system effective to cure the composition; and

curing the curable composition to form the at least one volume.

15. A method for the manufacture of a dielectric resonator antenna (DRA), or an array of the DRAs, each DRA having a plurality of volumes of dielectric materials comprising N volumes, N being an integer equal to or greater than 3, disposed to form successive and sequential layered volumes V(i), i being an integer from 1 to N, wherein volume V(1) forms an innermost volume, wherein a successive volume V(i+1) forms a layered shell disposed over and at least partially embedding volume V(i), wherein volume V(N) at least partially embeds all volumes V(1) to V(N−

1), the method comprising;

molding at least one volume of the plurality of volumes of the dielectric materials, or all volumes of the plurality of volumes of the dielectric materials;

wherein the molding comprises compression molding at least one volume of the plurality of volumes of dielectric materials;

wherein the compression molding comprises;

compression molding a first volume of the plurality of volumes of dielectric materials in a first mold having an outer mold form and an inner mold form;

removing the inner mold form and replacing it with a second inner mold form defining an inner dimension of a second volume of the plurality of volumes of dielectric materials; and

compression molding the second volume in the first volume.

16. The method of claim 15, wherein the first volume is the outermost volume V(N).

19. The method of claim 15, wherein each of the DRA further has;

an electrically conductive ground structure wherein the plurality of volumes of dielectric materials are disposed on the ground structure, and a signal feed disposed and structured to be electromagnetically coupled to one or more of the plurality of volumes of dielectric materials, the method further wherein;

the at least one volume is molded onto an insert to provide the signal feed or the ground structure.

20. The method of claim 19, further comprising inserting a metal layer into an outer mold portion of the outermost volume V(N), and molding the outermost volume V(N) onto the metal layer to provide the signal feed or the ground structure on the outermost volume V(N).

17. A method for the manufacture of a dielectric resonator antenna (DRA), or an array of the DRAs, each DRA having a plurality of volumes of dielectric materials comprising N volumes, N being an integer equal to or greater than 3, disposed to form successive and sequential layered volumes V(i), i being an integer from 1 to N, wherein volume V(1) forms an innermost volume, wherein a successive volume V(i+1) forms a layered shell disposed over and at least partially embedding volume V(i), wherein volume V(N) at least partially embeds all volumes V(1) to V(N−

1), the method comprising;

molding at least one volume of the plurality of volumes of the dielectric materials, or all volumes of the plurality of volumes of the dielectric materials;

wherein the molding comprises compression molding at least one volume of the plurality of volumes of dielectric materials;

wherein the compression molding comprises;

compression molding a first volume of the plurality of volumes of dielectric materials in a first mold having an outer mold form and an inner mold form;

removing the outer mold form and replacing it with a second outer mold form defining an outer dimension of a second volume of the plurality of volumes of dielectric materials; and

compression molding the second volume onto the first volume.

18. The method of claim 17, wherein the first volume is the innermost volume V(1).

25. The method of claim 17, wherein each of the DRA further has;

an electrically conductive ground structure wherein the plurality of volumes of dielectric materials are disposed on the ground structure, and a signal feed disposed and structured to be electromagnetically coupled to one or more of the plurality of volumes of dielectric materials, the method further wherein;

the at least one volume is molded onto an insert to provide the signal feed or the ground structure.

26. The method of claim 25, further comprising inserting a metal layer into an outer mold portion of the outermost volume V(N), and molding the outermost volume V(N) onto the metal layer to provide the signal feed or the ground structure on the outermost volume V(N).