Dynamic Beam-Stabilized, Additive-Printed Flexible Antenna Arrays with On-Chip Rapid Insight Generation

Conformal phased arrays promise shape-changing properties, multiple degrees of freedom to the scan angle, and novel applications in wearables, aerospace, defense, vehicles, and ships. However, they have suffered from two critical limitations. (1) Although most applications require on-the-move communication and sensing, prior conformal arrays have suffered from dynamic deformation-induced beam pointing errors. We introduce a Dynamic Beam-Stabilized (DBS) processor capable of beam adaptation through on-chip real-time control of fundamental gain, phase, and delay for each element. (2) Prior conformal arrays have leveraged additive printing to enhance flexibility, but conventional printable inks based on silver are expensive, and those based on copper suffer from spontaneous metal oxidation that alters trace impedance and degrades beamforming performance. We instead leverage a low-cost Copper Molecular Decomposition (CuMOD) ink with < 0.1% variation per degree C with temperature and strain and correct any residual deformity in real-time using the DBS processor. Demonstrating unified material and physical deformation correction, our CMOS DBS processor is low power, low-area, and easily scalable due to a tile architecture, thereby ideal for on-device implementations.

Real-time Deformation Correction in Additively Printed Flexible Antenna Arrays

Conformal phased arrays provide multiple degrees of freedom to the scan angle, which is typically limited by antenna aperture in rigid arrays. Silicon-based RF signal processing offers reliable, reconfigurable, multi-functional, and compact control for conformal phased arrays that can be used for on-the-move communication. While the lightweight, compactness, and shape-changing properties of the conformal phased arrays are attractive, these features result in dynamic deformation of the array during motion leading to significant dynamic beam pointing errors. We propose a silicon-based, compact, reconfigurable solution to self-correct these dynamic deformation-induced beam pointing errors. Furthermore, additive printing is leveraged to enhance the flexibility of the conformal phased arrays, as the printed conductive ink is more flexible than bulk copper and can be easily deposited on flexible sheets using different printing tools, providing an environmentally-friendly solution for large-scale production. The inks such as conventional silver inks are expensive and copper-based printable inks suffer from spontaneous metal oxidation that alters trace impedance and degrades beamforming performance. This work uses a low-cost molecular copper decomposition ink with reliable RF properties at different temperature and strain to print the proposed intelligent conformal phased array operating at 2.1 GHz. Proof-of-concept prototype $2\times2$ array self-corrects the deformation induces beampointing error with an error $<1.25^\circ$. The silicon based array processing part occupying only 2.56 mm$^2$ area and 78.5 mW power per tile.