A vertically integrated Ka-band active electronically scanned antenna including, among other things, a transitioning RF
waveguide relocator panel located behind a radiator faceplate and an array of
beam control tiles respectively coupled to one of a plurality of
transceiver modules via an RF manifold. Each of the
beam control tiles includes a respective plurality of high power transmit / receive (T / R) cells as well as
dielectric waveguides, RF
stripline and
coaxial transmission line elements. The
waveguide relocator panel is preferably fabricated by a
diffusion bonded
copper laminate stack up with
dielectric filling. The
beam control tiles are preferably fabricated by the use of multiple
layers of low temperature co-fired
ceramic (LTCC) material laminated together. The
waveguide relocator panel and the beam control tiles are designed to
route RF signals to and from a respective
transceiver module of four
transceiver modules and a quadrature array of antenna radiators matched to
free space formed in the faceplate. Planar
type metal spring gaskets are provided between the
interfacing layers so as to provide and ensure
interconnection between mutually facing waveguide ports and to prevent RF leakage from around the perimeter of the waveguide ports. Cooling of the various components is achieved by a pair of planar
forced air heat sink members which are located on either side of the array of beam control tiles. DC power and control of the T / R cells is provided by a printed circuit wiring board
assembly located adjacent to the array of beam controlled tiles with solderless DC connections being provided by an arrangement of “fuzz button”
electrical connector elements.