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Template-Based Dielectric Resonator Antenna Arrays for Millimeter-Wave Applications

An approach suitable for millimeter-wave dielectric resonator antenna (DRA) arrays is presented. The methodology involves fabricating precise cavities in acrylic templates and filling them with composite dielectric materials to create a monolithic polymer-based DRA (PRA) array layer. The excitation feed lines are fabricated on a separate substrate layer and the two layers are aligned and bonded together to form the PRA antenna array module. The impact of the acrylic frame on the PRA performance is analyzed through simulations. A four-element array operating at 60 GHz is realized to demonstrate the approach. The performance is characterized through simulation and also experimentally verified. The array offers a wide 12% impedance bandwidth at 60 GHz and broadside radiation with 10.5-dBi realized gain and stable radiation patterns. The use of polymer-based materials provides opportunities for cost-effective volume fabrication using molding techniques.