Method and apparatus for folded antenna components

• US 10,249,956 B2
• Filed: 11/20/2017
• Issued: 04/02/2019
• Est. Priority Date: 05/05/2014
• Status: Active Grant

• Current Assignee: Fractal Antenna Systems Inc.
• Original Assignee: Fractal Antenna Systems Inc.
• Inventors: Cohen, Nathan, Salkind, Philip
• Primary Examiner(s): Levi, Dameon E
• Assistant Examiner(s): Lotter, David
• Application Number:
  US15/818,086
• Publication Number:
  US 20180090845A1
• Time in Patent Office: 498 Days
• CPC Class Codes: B29K 2995/0005 Conductive
• CPC Class Codes: B29L 2009/005 coated
• CPC Class Codes: B29L 2031/3456 Antennas, e.g. radomes
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: H01Q 1/00 Details of, or arrangements associated with, antennas arrangements for varying orientation of directional pattern H01Q3/00
• CPC Class Codes: H01Q 9/28 Conical, cylindrical, cage, strip, gauze, or like elements having an extended radiating surface; Elements comprising two conical surfaces having collinear axes and adjacent apices and fed by two-conductor transmission lines waveguide horns or mouths H01Q13/00; slot antennas H01Q13/00
• CPC Class Codes: H01Q 9/40 Element having extended radiating surface

Abstract

Method and apparatus for making antennas and antenna components suitable for wideband transmission and reception are disclosed. Material accretion devices or apparatus such as a 3D printer can be used to form the antennas and antenna components. The antenna and antenna components can include pleated and/or self-similar features.

Claims

1. A method for producing an antenna component, the method comprising:

with a material accreting device, accreting material in a plurality of layers, wherein each layer defines a separate portion of a predetermined three-dimensional shape of a folded antenna component feature, and wherein a material used for at least one layer is different than a material used for an adjacent layer;

by successive accretions of each of the plurality of layers, combining the plurality of layers, thereby forming a complete folded antenna component having the predetermined three-dimensional shape that is substantially non-planar; and

painting the complete folded antenna component with a conductive paint for at least a portion of the component;

wherein the complete folded antenna component includes a self-similar shape for at least a portion of the component, and wherein one or more of the plurality of layers are painted with the conductive paint and adjacent to layers that are not painted with the conductive paint.

2. The method of claim 1, wherein the complete folded antenna component comprises a horn.

3. The method of claim 1, further comprising incorporating the complete folded antenna component into an antenna.

4. A method for producing an antenna component, the method comprising:

(A) with a material accreting device, accreting material in a plurality of layers, wherein each layer defines a separate portion of a predetermined three-dimensional shape of a folded antenna component feature;

(B) by successive accretions of each of the plurality of layers, combining the plurality of layers, thereby forming a first complete folded antenna component having the predetermined three-dimensional shape that is substantially non-planar;

(C) painting the first complete folded antenna component with a conductive paint for at least a portion of the component;

wherein the first complete folded antenna component includes a self-similar shape for at least a portion of the component;

(D) repeating steps (A)-(C) to form a second complete folded antenna component; and

(E) attaching the first complete folded antenna component to the second complete folded antenna component.

5. The method of claim 4, wherein the first complete folded antenna component comprises a horn.

6. The method of claim 4, further comprising incorporating the first and second completed folded antenna components into an antenna.

7. The method of claim 4, wherein the first and second completed folded antenna components have the same shape.

8. The method of claim 4, wherein the first and second completed folded antenna components each have a different shape.