A multilayer subarray for multibeam phased arrays

A multilayer subarray has been developed for the telemetry band, 2.2 to 2.4 GHz. The scan requirements for the subarray are ±60° in azimuth and ±40° in elevation. The multilayer design consist of 10 printed circuit boards that provide 6 dual polarized independent beams formed by amplifiers, phase shifters and power combiners. The subarray thickness is less than 0.2 inches and is constructed from inexpensive commercial-off-the-shelf components. It can be flush mounted to most vehicles. Special fabrication techniques and materials were required to prevent warping and delamination. The design allows all the discrete components, such as LNAs, varactor diodes, etc., to be mounted by a robotic pick-and-place machine. A unique test probe was designed and developed to test and calibrate the subarray. RF performance and fabrication techniques for the subarray are also included