A 2048-element dual-polarized receive (RX) phased array for Ku-band (10.7–12.7 GHz) satellite communication (SATCOM) is presented in this paper. The design of the multilayer printed circuit board (PCB) it uses adopts a novel copper paste sintering interconnection technology that allows for more flexibility in the design of vias and can reduce the PCB’s lamination number. This technology is more suitable for manufacturing multilayer and complex PCBs than traditional processes. The array is designed to consist of sixteen 8 × 16 element subarrays, each based on the silicon RX beamformer and multilayer PCB. Dual-polarized antenna elements are arranged in a regular rectangle with a spacing of 0.5 for a wavelength of 12.7 GHz, thus achieving a scanning range of ±70° in all planes. By adjusting the amplitude and phase of two line polarizations with cross-polarization levels better than −25 dB at boresight, the array can generate linear or circular polarization. Moreover, the antenna gain-to-noise temperature is above 12 dB/K (Tant = 20 K) at boresight. The aperture of the 2048-element RX phased array is 768 × 450 mm. With its low profile, the array is appropriate for usage in Ku-band SATCOM terminals.
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