Packaging is the largest technology challenge in realizing affordable,
high performance EHF communication phased-array antennas for mobile S
ATCOM operation. A unique and easy to assemble module-honeycomb antenn
a packaging architecture is described, providing a simple mechanical d
esign and good antenna performance with repeatable access to the modul
es for service when required. The key to affordability and predictable
performance is a low parts count, robust, hermetically sealed, radiat
ion coupled, MMIC module that uses elastomeric connectors for DC and l
ogic interconnections. Antenna assembly and all interconnections are a
chieved by means of mechanical fasteners without the need for wire nor
solder connections. The design has been validated with 19- and 91-ele
ment 20 GHz arrays and a 91-element array at 44 GHz over cone angles t
o 70-degrees from broadside.