Communications: radio wave antennas – Antennas – Microstrip
Reexamination Certificate
1999-08-03
2001-06-05
Le, Hoanganh (Department: 2821)
Communications: radio wave antennas
Antennas
Microstrip
C343S878000
Reexamination Certificate
active
06243040
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates generally to mounting antennas and, more particularly, to a hermetic microwave package with an external patch antenna.
BACKGROUND OF THE INVENTION
Many conventional microwave packages include a ceramic lid that carries circuitry and that has been metalized so as to function as a patch antenna. The lid may also define an opening or receptacle for receiving a coaxial cable. The lid is typically bonded to a metal case with a conductive epoxy. The ceramic lid is brittle and therefore prone to cracking, which can result in failure of the package. For example, one failure mechanism associated with cracking or flexing of the lid is CTE mismatch. That is, because the components of the microwave package have different coefficients of thermal expansion, temperature changes can cause the lid to flex and crack. Additionally, the epoxy seal between the lid and the case is not hermetic, such that moisture and other contaminants may reach the circuitry and cause corrosion and failure of the circuitry.
SUMMARY OF THE INVENTION
The present invention solves the problems identified above, and other problems, by providing improved antenna packages and methods of assembling or sealing the antenna packages.
In accordance with an embodiment of the invention, the antenna package includes a lid-like structure that fits onto an electrically conductive, metallic box-like structure. The lid-like structure includes an electrically conductive, metallic seal member that is connected to an antenna and defines at least one primary opening. The antenna includes a dielectric mounted between an inner metallic layer and an outer metallic layer. The connection between the seal member and the antenna is a substantially hermetic, soldered connection between the seal member and the inner metallic layer. The soldered connection electrically connects the inner metallic layer to the seal member. The soldered connection also secures the antenna to the seal member such that the inner metallic layer occludes the primary opening. However, the outer metallic layer is substantially electrically isolated from the seal member and the box-like structure by the dielectric . A substantially hermetic, fused connection is provided between the periphery of the lid-like structure and the periphery of the box-like structure so that a hermetically sealed chamber is defined within the box-like structure, thereby protecting the interior of the box-like structure from moisture and other contaminants.
In accordance with another aspect of the present invention, electric circuitry is positioned in the chamber and is connected to the antenna. A connector opening or openings are defined through the seal member, and at least one electrical connector, such as a coaxial cable, extends through at least one of the connector openings.
In accordance with one embodiment of the present invention, the lid-like structure is formed by placing solder between the inner metallic layer and the outer surface of the seal member, and thereafter introducing a heating tool into the primary opening to so as to melt the solder and thereby solder the inner metallic layer to the seal member.
Because the lid-like structure includes the seal member, which is preferably constructed of a strong metallic material and extends around the periphery of the antenna, the antenna is less prone to breaking or cracking than the above-discussed prior art lid antennas or the lid undergoes thermal cycling. Additionally, the seal member may define the one or more connector openings, such that the antenna need not itself define the connector openings, which prevents the antenna from having to be weakened by such openings. The soldered connection, which is between the seal member and the antenna, and the fused connection, which is between the lid-like structure and the box-like structure, are hermetic. Those hermetic connections reduce leakage problems that have been encountered in the past with nonhermetic connections. As a result, the circuitry of the present invention is well protected within the chamber of the box-like structure in a manner that seeks to prevent contaminants from reaching the circuitry and causing the circuitry to corrode and fail. Further, the primary opening defined by the seal member optimally provides access to the solder positioned between the seal member and the antenna such that the soldered connection between the seal member and the antenna can be efficiently and effectively formed. Further, the antenna package of the present invention is in the form of an integrated assembly that is smaller than some prior art antenna packages, such that the antenna package of the present invention provides size-related and weight-related advantages.
REFERENCES:
patent: 5019829 (1991-05-01), Heckman et al.
patent: 5023624 (1991-06-01), Heckaman et al.
patent: 5138436 (1992-08-01), Koepf
patent: 5218373 (1993-06-01), Heckaman et al.
patent: 5309163 (1994-05-01), Ngan et al.
patent: 5325103 (1994-06-01), Schuss
patent: 5552633 (1996-09-01), Sharma
patent: 5770816 (1998-06-01), McNulty et al.
Corey Roger L.
Swanson Dale W.
Woolston Francis J.
Alston & Bird LLP
Chen Shih-Chao
Le Hoang-anh
The Boeing Company
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