Microwave antenna and method for making same

摘要

A method for fabricating a microwave horn antenna in which a thermoplastic sacrificial layer is mounted to a thermoplastic horn layer. A heated horn embossing plate having at least one horn shaped embossing element is then moved into the horn layer so that the horn element penetrates through the horn layer and extends partially into the sacrificial layer thus forming a horn opening in the horn layer complementary in shape to the horn element. The horn layer and sacrificial layer are then separated from each other and the horn opening and at least a portion of the back surface of the horn layer is covered with a metal coating. A thermoplastic wave guide layer formed by embossing wave guide channels into the layer is covered with metal and attached to the back side of the horn layer to form the antenna. Alternatively, a portion of the horn and the remaining portion of a microwave channel are formed in both a first and second thermoplastic section. These portions of the microwave guide channel and horn are then coated with a metal material and the sections are secured together in a facing relationship so that the horn portions and wave guide channel portions on both the first and second sections register with each other.