Packaging architecture for phased arrays

Claim 2

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; and 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.

Claim 3

A phased array antenna structure as recited in claim 1, further including means for securing said antenna, module and feed honeycomb structures together for permitting facile assembly and disassembly of said honeycomb structures as a unit.

Claim 4

A phased array antenna structure as recited in claim 1, further comprising 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.

Claim 5

A phased array antenna structure as recited in claim 3, wherein said multilayer wiring circuit comprises a plurality of interior electrically conductive patterns electrically insulated from one another and a conductive outer surface electrically insulated from said interior patterns.

Claim 6

A phased array antenna structure as recited in claim 4, wherein said electrical signals comprise power and logic signals.

Claim 7

A phased array antenna structure as recited in claim 5, wherein said logic signals comprise clock and data signals.

Claim 8

A phased array antenna structure as recited in claim 3, wherein each of said electronic modules comprises: a substrate for supporting said electronic element; a carrier for supporting said substrate; a lid secured to a top surface of said substrate and hermetically sealing the electronic element therein; said substrate having metallization patterns thereon connected to said electronic element, and having an extension region on at least one end thereof, said extension region extending beyond the end of the carrier, said extension region including metallization patterns on the top surface thereof and vias extending from the top surface of said substrate to the bottom surface thereof in the extension region for receiving said electrical signals; a plurality of terminals connected to the bottom surface of said substrate in the extension region thereof, said terminals connected to said vias for providing said electrical signals to the electronic element of said electronic module.

Claim 9

A phased array antenna structure as recited in claim 7, wherein said lid extends to at least part of said extension region to hermetically seal said metallization pattern and said vias positioned on the top surface of said extension region of said substrate.

Claim 10

A phased array antenna structure as recited in claim 8, wherein said electrical signals include power and logic signals and wherein said phased array antenna structure further includes a plurality of metallization tips extending on the bottom surface of said substrate and connected to said multilayer wiring for providing test ports for said power and logic signals.

Claim 11

A phased array antenna structure as recited in claim 9, wherein said terminals are in the form of pins extending into said vias on the bottom surface of said substrate in the extension region, and said multilayer wiring circuit includes contact pads and said phased array antenna structure further includes wires connected between said contact pads and said pins.

Claim 12

A phased array antenna structure as recited in claim 7, wherein said terminals are in the form of pins extending into said vias on the bottom surface of said substrate in the extension region, and said multilayer wiring circuit includes contact pads and said phased array antenna structure further includes wires connected between said contact pads and said pins.

Claim 13

A phased array antenna structure as recited in claim 11, wherein said multilayer wiring circuit is positioned between said module honeycomb structure and said feed honeycomb structure; wherein said carrier comprises a metal, said carrier positioned for close contact with the module honeycomb structure to provide good thermal heat transfer thereto, said honeycomb structure in thermal transfer contact with said feed honeycomb structure through said multilayer wiring circuit for transferring heat away from the electronic element of said electronic modules.

Claim 14

A phased array antenna structure as recited in claim 12, wherein said multilayer wiring circuit is in the form of a relatively flat sheet and comprises: a plurality of insulated layers which electrically insulate imbedded conductors carrying said power and logic signals, an electrically conductive coating covering the exterior surfaces of said multilayer wiring circuit facing said module honeycomb and said feed honeycomb, and heat transfer means disposed within said multilayer wiring circuit for facilitating heat transfer between the exterior surfaces of said multilayer wiring circuit to thereby facilitate heat transfer between said module honeycomb structure and said feed honeycomb structure.

Claim 15

A phased array antenna structure as recited in claim 13, wherein said heat transfer means comprises a plurality of metallic filled vias passing within said multilayer wiring circuit and between the exterior surfaces thereof.

Claim 16

A phased array antenna structure as recited in claim 14, wherein said substrate has a first and second extension region on opposite sides of said electronic element and at least some of said metallization patterns and vias extend to said first extension region and at least others of said metallization patterns and vias extend to said second extension region, and said phased array antenna structure further comprising: a first and second multilayer wiring circuit, said first multilayer wiring circuit positioned between said feed honeycomb structure and said module honeycomb structure, and the second multilayer wiring circuit positioned between said antenna honeycomb structure and said module honeycomb structure, said first multilayer wiring circuit carrying some of said electrical signals and the second multilayer wiring circuit carrying others of said electrical signals.

Claim 17

A phased array antenna structure as recited in claim 7, wherein said electrical signals includes power and logic signals and wherein said substrate has a first and second extension region on opposite sides of said electronic element and at least some of said metallization patterns and vias extend to said first extension region and at least others of said metallization patterns and vias extend to said second extension region, and said phased array antenna structure further comprising: a first and second multilayer wiring circuit, said first multilayer wiring circuit positioned between said feed honeycomb structure and said module honeycomb structure and the second multilayer wiring circuit positioned between said antenna honeycomb structure and said module honeycomb structure, said first multilayer wiring circuit carrying one of said power and logic signals and the second multilayer wiring circuit carrying the other of said power and logic signals.

Claim 18

A phased array antenna structure as recited in claim 16, wherein said first extension region at least partially extends within said feed honeycomb structure and second extension region at least partially extends within said antenna honeycomb structure and wherein each of said electronic modules further comprises: a first EM coupling means positioned on the first extension region for coupling said EM energy from said feed honeycomb structure to said electronic element without direct metal-to-metal contact; and a second EM coupling means positioned on the second extension region for coupling said EM energy from said electronic element to said antenna honeycomb structure without direct metal-to-metal contact.

Claim 19

A phased array antenna structure as recited in claim 17, wherein said first and second EM coupling means each comprises a field probe.

Claim 20

A phased array antenna structure as recited in claim 17, wherein said first and second EM coupling means each comprise a microstrip, slotline and finline, said microstrips positioned on the top surface of said first and second extension regions and said slotlines and finlines positioned on the bottom surface of said extension regions.

Claim 21

A phased array antenna structure as recited in claim 15, wherein said first extension region at least partially extends within said feed honeycomb structure and second extension region at least partially extends within said antenna honeycomb structure and wherein each of said electronic modules further comprises: a first EM coupling means positioned on the first extension region for coupling said EM energy from said feed honeycomb structure to said electronic element without direct metal-to-metal contact; and a second EM coupling means positioned on the second extension region for coupling said EM energy from said electronic element to said antenna honeycomb structure without direct metal-to-metal contact.

Claim 22

A phased array antenna structure as recited in claim 20, wherein said first and second EM coupling means each comprises a field probe.

Claim 23

A phased array antenna structure as recited in claim 20, wherein said first and second EM coupling means each comprise a microstrip, slotline and finline, said microstrips positioned on the top surface of said first and second extension regions and said slotlines and finlines positioned on the bottom surface of said extension regions.

Claim 24

A phased array antenna structure as recited in claim 7, further comprising a wedge positioned between the lid of each electronic module and a surface of said module honeycomb structure for pressing said carrier in close contact with an opposing surface of the module honeycomb structure.

Claim 25

A phased array antenna structure as recited in claim 23, wherein said wedge comprises a shaped memory alloy.

Claim 26

A phased array antenna structure as recited in claim 24, wherein said shaped memory alloy comprises an alloy of nickel and titanium.

Claim 27

A phased array antenna structure as recited in claim 3, further comprising a wedge positioned between a top surface of said electronic module and a surface of said module honeycomb structure for pressing said electronic module in close contact with an opposing surface of the module honeycomb structure.

Claim 28

A phased array antenna structure as recited in claim 26, wherein said wedge comprises a shaped memory alloy.

Claim 29

A phased array antenna structure as recited in claim 27, wherein said shaped memory alloy comprises an alloy of nickel and titanium.

Claim 30

A phased array antenna structure as recited in claim 3, wherein said electronic module includes a substrate for supporting said electronic element, said phased array antenna structure including EM field coupling means supported on said substrate for coupling EM energy into said electronic element from the aligned waveguides of said feed honeycomb structure, and out of said electronic element into the aligned waveguides of said antenna honeycomb structure, said feed and antenna honeycomb structures each including dielectric elements imbedded within the aligned waveguides, said substrate thickness and dielectric constant of the dielectric elements selected to provide a matched impedance for transmitting said EM energy into and out of said electronic module at a desired operating frequency of said phased array antenna.

Claim 31

A phased array antenna structure as recited in claim 29, further including a polarizer positioned within said antenna honeycomb structure.

Claim 32

A phased array antenna structure as recited in claim 17, wherein said feed and antenna honeycomb structures each including dielectric elements imbedded within the aligned waveguides, the dielectric constant and substrate thickness of the substrate and the dielectric constant of the dielectric elements selected to provide a matched impedance for transmitting said EM energy into and out of said electronic module at a desired operating frequency of said phased array antenna.

Claim 33

A phased array antenna structure as recited in claim 31, further including a polarizer positioned within said antenna honeycomb structure.

Claim 34

A phased array antenna structure as recited in claim 1, further including a housing for substantially enclosing said distribution network, feed, module and antenna honeycomb structures, said housing containing a gas so as to prevent humidity from entering said housing.

Claim 35

A phased array antenna structure as recited in claim 33, wherein said phased array antenna is disposed within an aircraft and includes a cover surface conforming to the shape of an outer surface of the aircraft, said housing including said cover.

Claim 36

A phased array antenna structure as recited in claim 34, wherein said cover comprises a wide angle impedance matching structure.

Claim 37

A phased array antenna structure as recited in claim 15, further including a housing for substantially enclosing said distribution network, feed, module and antenna honeycomb structures, said housing containing a gas so as to prevent humidity from entering said housing.

Claim 38

A phased array antenna structure as recited in claim 36, wherein said phased array antenna is disposed within an aircraft and includes a cover surface conforming to the shape of an outer surface of the aircraft, said housing including said cover.

Claim 39

A phased array antenna structure as recited in claim 37, wherein said cover comprises a wide angle impedance matching structure.

Claim 40

A phased array antenna structure as recited in claim 38, wherein said phased array antenna structure further comprises an amplifier as an additional electronic element within each of said electronic modules.

Claim 41

A phased array antenna structure as recited in claim 1, wherein said phased array antenna structure further comprises an amplifier as an additional electronic element within each of said electronic modules.

Claim 42

A phased array antenna structure as recited in claim 40, wherein said phase shifting electronic element and said amplifier are in the form of monolithic microwave integrated circuits.

Claim 43

A phased array antenna structure as recited in claim 15, wherein said phased array antenna structure further comprises an amplifier as an additional electronic element within each of said electronic modules.

Claim 44

A phased array antenna structure as recited in claim 42, wherein said phase shifting electronic element and said amplifier are in the form of monolithic microwave integrated circuits.

Claim 45

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.

Claim 46

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.

Claim 47

A phased array antenna structure as recited in claim 44, further including means for securing said antenna, module and feed honeycomb structures together for permitting facile assembly and disassembly of said honeycomb structures as a unit.

Claim 48

A phased array antenna structure as recited in claim 1, further comprising 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.

Claim 49

A phased array antenna structure as recited in claim 46, wherein said multilayer wiring circuit comprises a plurality of interior electrically conductive patterns electrically insulated from one another and a conductive outer surface electrically insulated from said interior patterns.

Claim 50

A phased array antenna structure as recited in claim 47, wherein said electrical signals comprise power and logic signals.

Claim 51

A phased array antenna structure as recited in claim 48, wherein said logic signals comprise clock and data signals.

Claim 52

A phased array antenna structure as recited in claim 46, wherein each of said electronic modules comprises: a substrate for supporting said electronic element; a carrier for supporting said substrate; a lid secured to a top surface of said substrate and hermetically sealing the electronic element therein; said substrate having metallization patterns thereon connected to said electronic element, and having an extension region on at least one end thereof, said extension region extending beyond the end of the carrier, said extension region including metallization patterns on the top surface thereof and vias extending from the top surface of said substrate to the bottom surface thereof in the extension region for receiving said electrical signals; a plurality of terminals connected to the bottom surface of said substrate in the extension region thereof, said terminals connected to said vias for providing said electrical signals to the electronic element of said electronic module.

Claim 53

A phased array antenna structure as recited in claim 50, wherein said lid extends to at least part of said extension region to hermetically seal said metallization pattern and said vias positioned on the top surface of said extension region of said substrate.

Claim 54

A phased array antenna structure as recited in claim 51, wherein said electrical signals include power and logic signals and wherein said phased array antenna structure further includes a plurality of metallization tips extending on the bottom surface of said substrate and connected to said multilayer wiring for providing test ports for said power and logic signals.

Claim 55

A phased array antenna structure as recited in claim 52, wherein said terminals are in the form of pins extending into said vias on the bottom surface of said substrate in the extension region, and said multilayer wiring circuit includes contact pads and said phased array antenna structure further includes wires connected between said contact pads and said pins.

Claim 56

A phased array antenna structure as recited in claim 50, wherein said terminals are in the form of pins extending into said vias on the bottom surface of said substrate in the extension region, and said multilayer wiring circuit includes contact pads and said phased array antenna structure further includes wires connected between said contact pads and said pins.

Claim 57

A phased array antenna structure as recited in claim 54, wherein said multilayer wiring circuit is positioned between said module honeycomb structure and said feed honeycomb structure; wherein said carrier comprises a metal, said carrier positioned for close contact with the module honeycomb structure to provide good thermal heat transfer thereto, said honeycomb structure in thermal transfer contact with said feed honeycomb structure through said multilayer wiring circuit for transferring heat away from the electronic element of said electronic modules.

Claim 58

A phased array antenna structure as recited in claim 55, wherein said multilayer wiring circuit is in the form of a relatively flat sheet and comprises: a plurality of insulated layers which electrically insulate imbedded conductors carrying said power and logic signals, an electrically conductive coating covering the exterior surfaces of said multilayer wiring circuit facing said module honeycomb and said feed honeycomb, and heat transfer means disposed within said multilayer wiring circuit for facilitating heat transfer between the exterior surfaces of said multilayer wiring circuit to thereby facilitate heat transfer between said module honeycomb structure and said feed honeycomb structure.

Claim 59

A phased array antenna structure as recited in claim 56, wherein said heat transfer means comprises a plurality of metallic filled vias passing within said multilayer wiring circuit and between the exterior surfaces thereof.

Claim 60

A phased array antenna structure as recited in claim 50, wherein said substrate has a first and second extension region on opposite sides of said electronic element and at least some of said metallization patterns and vias extend to said first extension region and at least others of said metallization patterns and vias extend to said second extension region, and said phased array antenna structure further comprising: a first and second multilayer wiring circuit, said first multilayer wiring circuit positioned between said feed honeycomb structure and said module honeycomb structure, and the second multilayer wiring circuit positioned between said antenna honeycomb structure and said module honeycomb structure, said first multilayer wiring circuit carrying some of said electrical signals and the second multilayer wiring circuit carrying others of said electrical signals.

Claim 61

A phased array antenna structure as recited in claim 50, wherein said electrical signals includes power and logic signals and wherein said substrate has a first and second extension region on opposite sides of said electronic element and at least some of said metallization patterns and vias extend to said first extension region and at least others of said metallization patterns and vias extend to said second extension region, and said phased array antenna structure further comprising: a first and second multilayer wiring circuit, said first multilayer wiring circuit positioned between said feed honeycomb structure and said module honeycomb structure and the second multilayer wiring circuit positioned between said antenna honeycomb structure and said module honeycomb structure, said first multilayer wiring circuit carrying one of said power and logic signals and the second multilayer wiring circuit carrying the other of said power and logic signals.

Claim 62

A phased array antenna structure as recited in claim 59, wherein said first extension region at least partially extends within said feed honeycomb structure and second extension region at least partially extends within said antenna honeycomb structure and wherein each of said electronic modules further comprises: a first EM coupling means positioned on the first extension region for coupling said EM energy from said feed honeycomb structure to said electronic element without direct metal-to-metal contact; and a second EM coupling means positioned on the second extension region for coupling said EM energy from said electronic element to said antenna honeycomb structure without direct metal-to-metal contact.

Claim 63

A phased array antenna structure as recited in claim 60, wherein said first and second EM coupling means each comprises a field probe.

Claim 64

A phased array antenna structure as recited in claim 60, wherein said first and second EM coupling means each comprise a microstrip, slotline and finline, said microstrips positioned on the top surface of said first and second extension regions and said slotlines and finlines positioned on the bottom surface of said extension regions.

Claim 65

A phased array antenna structure as recited in claim 58, wherein said first extension region at least partially extends within said feed honeycomb structure and second extension region at least partially extends within said antenna honeycomb structure and wherein each of said electronic modules further comprises: a first EM coupling means positioned on the first extension region for coupling said EM energy from said feed honeycomb structure to said electronic element without direct metal-to-metal contact; and a second EM coupling means positioned on the second extension region for coupling said EM energy from said electronic element to said antenna honeycomb structure without direct metal-to-metal contact.

Claim 66

A phased array antenna structure as recited in claim 63, wherein said first and second EM coupling means each comprises a field probe.

Claim 67

A phased array antenna structure as recited in claim 63, wherein said first and second EM coupling means each comprise a microstrip, slotline and finline, said microstrips positioned on the top surface of said first and second extension regions and said slotlines and finlines positioned on the bottom surface of said extension regions.

Claim 68

A phased array antenna structure as recited in claim 50, further comprising a wedge positioned between the lid of each electronic module and a surface of said module honeycomb structure for pressing said carrier in close contact with an opposing surface of the module honeycomb structure.

Claim 69

A phased array antenna structure as recited in claim 66, wherein said wedge comprises a shaped memory alloy.

Claim 70

A phased array antenna structure as recited in claim 67, wherein said shaped memory alloy comprises an alloy of nickel and titanium.

Claim 71

A phased array antenna structure as recited in claim 46, further comprising a wedge positioned between a top surface of said electronic module and a surface of said module honeycomb structure for pressing said electronic module in close contact with an opposing surface of the module honeycomb structure.

Claim 72

A phased array antenna structure as recited in claim 69, wherein said wedge comprises a shaped memory alloy.

Claim 73

A phased array antenna structure as recited in claim 70, wherein said shaped memory alloy comprises an alloy of nickel and titanium.

Claim 74

A phased array antenna structure as recited in claim 46, wherein said electronic module includes a substrate for supporting said electronic element, said phased array antenna structure including EM field coupling means supported on said substrate for coupling EM energy into said electronic element from the aligned waveguides of said feed honeycomb structure, and out of said electronic element into the aligned waveguides of said antenna honeycomb structure, said feed and antenna honeycomb structures each including dielectric elements imbedded within the aligned waveguides, said substrate thickness and dielectric constant of the dielectric elements selected to provide a matched impedance for transmitting said EM energy into and out of said electronic module at a desired operating frequency of said phased array antenna.

Claim 75

A phased array antenna structure as recited in claim 72, further including a polarizer positioned within said antenna honeycomb structure.

Claim 76

A phased array antenna structure as recited in claim 60, wherein said feed and antenna honeycomb structures each including dielectric elements imbedded within the aligned waveguides, the dielectric constant and substrate thickness of the substrate and the dielectric constant of the dielectric elements selected to provide a matched impedance for transmitting said EM energy into and out of said electronic module at a desired operating frequency of said phased array antenna.

Claim 77

A phased array antenna structure as recited in claim 74, further including a polarizer positioned within said antenna honeycomb structure.

Claim 78

A phased array antenna structure as recited in claim 1, further including a housing for substantially enclosing said distribution network, feed, module and antenna honeycomb structures, said housing containing a gas so as to prevent humidity from entering said housing.

Claim 79

A phased array antenna structure as recited in claim 76, wherein said phased array antenna is disposed within an aircraft and includes a cover surface conforming to the shape of an outer surface of the aircraft, said housing including said cover.

Claim 80

A phased array antenna structure as recited in claim 77, wherein said cover comprises a wide angle impedance matching structure.

Claim 81

A phased array antenna structure as recited in claim 58, further including a housing for substantially enclosing said distribution network, feed, module and antenna honeycomb structures, said housing containing a gas so as to prevent humidity from entering said housing.

Claim 82

A phased array antenna structure as recited in claim 79, wherein said phased array antenna is disposed within an aircraft and includes a cover surface conforming to the shape of an outer surface of the aircraft, said housing including said cover.

Claim 83

A phased array antenna structure as recited in claim 80, wherein said cover comprises a wide angle impedance matching structure.

Claim 84

A phased array antenna structure as recited in claim 81, wherein said phased array antenna structure further comprises an amplifier as an additional electronic element within each of said electronic modules.

Claim 85

A phased array antenna structure as recited in claim 44, wherein said phased array antenna structure further comprises an amplifier as an additional electronic element within each of said electronic modules.

Claim 86

A phased array antenna structure as recited in claim 83, wherein said phase shifting electronic element and said amplifier are in the form of monolithic microwave integrated circuits.

Claim 87

A phased array antenna structure as recited in claim 58, wherein said phased array antenna structure further comprises an amplifier as an additional electronic element within each of said electronic modules.

Claim 88

A phased array antenna structure as recited in claim 85, wherein said phase shifting electronic element and said amplifier are in the form of monolithic microwave integrated circuits.

Claim 89

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.

Claim 90

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.

Claim 91

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.

Claim 92

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.

Claim 93

A phased array antenna structure as recited in claim 88, wherein each of said plurality of module terminals includes a first portion disposed on said bottom surface of said substrate and a second portion secured to said end of said carrier.

Claim 94

A phased array antenna structure as recited in claim 89, wherein said carrier is metallic said array antenna structure further comprises an electrically insulating spacer disposed between said metallic carrier and said second portions of said plurality of module terminals.

Claim 95

A phased array antenna structure as recited in claim 89, wherein each of said plurality of wiring circuit terminals are aligned with and correspond to one of said plurality of module terminals, and wherein each of said second portions of said plurality of module terminals comprise a spring-like structure for providing a wiping action against a corresponding wiring circuit terminal when said multilayer wiring circuit is biased against said module honeycomb structure.

Claim 96

A phased array antenna structure as recited in claim 91, wherein said phased array antenna structure further comprises a pressure plate having a first side disposed against said multilayer wiring circuit and a second side disposed against one of (1) said antenna honeycomb structure and (2) said feed honeycomb structure for pressing said multilayer wiring circuit against said module honeycomb structure.

Claim 97

A phased array antenna structure as recited in claim 92, wherein said pressure plate includes at least one elastomeric pressure pad positioned on said first side thereof and aligned with said plurality of wiring circuit terminals.

Claim 98

A phased array antenna structure as recited in claim 89, wherein each of said plurality of wiring circuit terminals are aligned with and correspond to said second portions of said plurality of module terminals, and wherein each of wiring circuit terminals comprise a spring-like structure for providing a wiping action against a corresponding second portion of said plurality of module terminals when said multilayer wiring circuit is biased against said module honeycomb structure.

Claim 99

A phased array antenna structure as recited in claim 94, wherein said phased array antenna structure further comprises a pressure plate having a first side disposed against said multilayer wiring circuit and a second side disposed against one of (1) said antenna honeycomb structure and (2) said feed honeycomb structure for pressing said multilayer wiring circuit against said module honeycomb structure.

Claim 100

A phased array antenna structure as recited in claim 95, wherein said pressure plate includes at least one elastomeric pressure pad positioned on said first side thereof and aligned with said plurality of wiring circuit terminals.

Claim 101

A phased array antenna structure as recited in claim 88, further comprising a polymeric conductor positioned between said module terminals and said wiring circuit terminals, said polymeric conductor conducting electricity in a plurality of regions electrically insulated from one another and substantially along a single axis thereof, said connector connecting said electrical signals from said plurality of wiring circuit terminals of said multilayer wiring circuit to said module terminals.

Claim 102

A phased array antenna structure as recited in claim 97, wherein each of said plurality of module terminals includes a first portion disposed on said bottom surface of said substrate and a second portion, connected to said first portion and secured to said end of said carrier, and wherein said connector is positioned between said wiring circuit terminals and said second portions of said module terminals.

Claim 103

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.

Claim 104

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.

Claim 105

A phased array antenna structure as recited in claim 99, wherein said metallic elements exhibit spring-like resiliency.

Claim 106

A phased array antenna structure as recited in claim 99, wherein said wedge is biased against said plurality of module terminals and said plurality of wiring circuit terminals by one of (1) said antenna honeycomb structure and (2) said feed honeycomb structure.

Claim 107

A phased array antenna structure as recited in claim 99, further comprising a pressure plate positioned adjacent said wedge to bias said wedge against said plurality of module terminals and said plurality of wiring circuit terminals.

Claim 108

A phased array antenna structure as recited in claim 88, further comprising a first multilayer wiring circuit positioned between said feed honeycomb structure and said module honeycomb structure and a second multilayer wiring circuit positioned between said antenna honeycomb structure and said module honeycomb structure, said first and second multilayer wiring circuits providing said electrical signals, including power, to said electronic element.

Claim 109

A phased array antenna structure as recited in claim 103, wherein each of said electronic modules includes a amplifying circuit, and said electronic signals, including power are supplied to said amplifying circuit.

Claim 110

A phased array antenna structure as recited in claim 99, further comprising a first multilayer wiring circuit positioned between said feed honeycomb structure and said module honeycomb structure and a second multilayer wiring circuit positioned between said antenna honeycomb structure and said module honeycomb structure, said first and second multilayer wiring circuits providing said electrical signals, including power, to said electronic element.