Design and Realization of a Low Cross-Polarization Conical Horn with Thin Metasurface Walls

A Ku -band low cross-polarization conical horn based on thin metasurface (MTS) walls is presented in this article, along with the relevant design method. The necessary boundary conditions are realized by printing a tensor MTS on the internal walls of the horn, which yields a radiation performance similar to a standard corrugated Gaussian horn yet with the benefits of thin walls. The design method is based on the adiabatic approximate solution for the hybrid mode of a conical waveguide with generic balanced impedance walls, which allows the determination of the impedance profile supporting a single balanced mode. The impedance design is based on the usual locally flat approximation of the wall and on the assumption of plane wave incidence. This approach results in an analytic design method that requires no optimization. The design has been first validated by solving the problem with homogenized impedance boundary conditions through a body of revolution (BoR) method of moments. The actual structure, including impedance wall implementation, is then simulated in full detail with a full-wave fast code. Finally, the horn has been realized and experimentally characterized; measurements show excellent agreement both with theory and with simulations, with a cross-polarization level below -20 dB over a 2 GHz bandwidth.