Manufacturing tolerances impact on millimeter wave enhanced gain patch antenna performance

Rojansky and Winebrand (1997) validated the feasibility of a Ka-band rectangular patch antenna gain enhancement method, based on substrate-superstrate resonance. Substantial consonance between theoretical and sample antenna measurement results was observed. A thorough study of the manufacturing tolerances impact on the antenna performance is presented in this paper. The following factors affecting the gain of the antenna operating in the upper Ka frequency band are covered: (a) substrate-superstrate distance deviation from the nominal one; (b) superstrate tilt relative to substrate and (c) superstrate surface roughness. Allowable ranges of the manufacturing tolerances considering the above parameters are established. These tolerances are well inside the limits of the modern manufacturing capabilities. Therefore, the enhanced gain patch antenna operating at millimeter waves (Ka frequency band) can be easily manufactured and happens to be a comprehensive and cost effective solution for various applications.