Flat panel array antenna

1. A panel array antenna, comprising:

a waveguide network coupling an input feed to a plurality of primary coupling cavities;

each of the primary coupling cavities provided with four output ports, each of the output ports coupled to a horn radiator;

the waveguide network provided on a second side of an input layer and a first side of a first intermediate layer;

the primary coupling cavities provided on a second side of the first intermediate layer;

the output ports provided on a first side of an output layer, each of the output ports in communication with one of the horn radiators; and

the horn radiators provided as an array of horn radiators on a second side of the output layer.

2. The panel array antenna of claim 1 , wherein the input feed is provided on a first side of the input layer.

3. The panel array antenna of claim 1 , wherein the input feed is provided on a layer sidewall between the input layer and the first intermediate layer.

4. The antenna of claim 1 , further including a plurality tuning features provided on the first side of the output layer;

the tuning features provided for each of the primary coupling cavities.

5. The antenna of claim 1 , further including at least one tuning feature located on at least one sidewall of each primary coupling cavity.

6. The antenna of claim 1 , wherein the primary cavities are rectangular.

7. The antenna of claim 1 , wherein the waveguide network has a rectangular cross section, a long axis of the rectangular cross section normal to a surface plane of the input layer.

8. The antenna of claim 1 , wherein the waveguide network has a rectangular cross section, a long axis of the rectangular cross section parallel to a surface plane of the input layer.

9. The antenna of claim 1 , further including a slot layer between the first intermediate layer and the output layer;

the slot layer provided with a plurality of dumbbell-shaped slots, one of the slots aligned with each of the output ports;

the slots rotated one half a desired rotation angle with respect to a longitudinal axis of the primary coupling cavities; and

the output ports rotated one half the desired rotation angle with respect to a longitudinal axis of the slots.

10. A panel array antenna, comprising:

a waveguide network coupling an input feed to a plurality of primary coupling cavities;

each of the primary coupling cavities provided with four intermediate ports, each of the intermediate ports coupled to a secondary coupling cavity with four output ports, each of the output ports coupled to a horn radiator;

the waveguide network formed on a second side of an input layer and a first side of a first intermediate layer;

the primary coupling cavities provided on a second side of the first intermediate layer;

the intermediate ports provided on a first side of a second intermediate layer;

the secondary coupling cavities provided on a second side of the second intermediate layer;

the output ports provided on a first side of an output layer; and

the horn radiators provided as an array of horn radiators on a second side of the output layer.

11. The panel array antenna of claim 10 , wherein the input feed is provided on a first side of the input layer.

12. The panel array antenna of claim 10 , wherein the input feed is provided on a layer sidewall between the input layer and the first intermediate layer.

13. The antenna of claim 10 , further including a plurality of tuning features provided on the first side of the second intermediate layer and a first side of the output layer;

the tuning features provided on the first side of the second intermediate layer aligned with each of the primary coupling cavities and the tuning features of the first side of the output layer aligned with each of the secondary coupling cavities.

14. The antenna of claim 10 , wherein the primary cavities are rectangular.

15. The antenna of claim 10 , further including at least one side wall tuning feature located on at least one sidewall of each of the primary coupling cavity and at least one sidewall of each of the secondary coupling cavity.

16. A method for manufacturing a panel array antenna, comprising the steps of:

providing a waveguide network coupling an input feed to a plurality of primary coupling cavities;

each of the primary coupling cavities feeding four output ports, each of the output ports feeding a horn radiator;

the input feed provided on a first side of an input layer;

the waveguide network provided on a second side of the input layer and a first side of a first intermediate layer;

the primary coupling cavities provided on a second side of the first intermediate layer;

the output ports provided on a first side of an output layer, each of the output ports in communication with one of the horn radiators; and

the horn radiators provided as an array of horn radiators on a second side of the output layer.

17. The method of claim 16 , wherein the input, intermediate and output layers are formed by injection molding.

18. The method of claim 17 , further including the step of applying a conductive surface to the input, intermediate and output layers.

19. The method of claim 16 , wherein the input, intermediate and output layers are formed by die-casting.

20. The method of claim 16 , further including the step of inserting a slot layer between the first intermediate layer and the output layer;

the slot layer provided with a plurality of dumbbell-shaped slots, one of the slots aligned with each of the output ports;

the slots rotated one half a desired rotation angle with respect to a longitudinal axis of the primary cavities; and

providing the output ports rotated one half a desired rotation angle with respect to a longitudinal axis of the slots.