METHOD AND APPARATUS FOR ASSEMBLY OF A SATELLITE ANTENNA

• US 20130087266A1
• Filed: 10/07/2011
• Published: 04/11/2013
• Est. Priority Date: 10/07/2011
• Status: Active Grant

• Current Assignee: Hughes Network Systems LLC (Echostar Corporation)
• Original Assignee: Hughes Network Systems LLC (Echostar Corporation)
• Inventors: Becerril, Aicsa, Ebrahim, Alfred, Toh, Alex, Sun, Ming
• Granted Patent: US 9,308,713 B2
• Time in Patent Office: Days
• US Class Current: 156/92
• CPC Class Codes: B29C 65/5057 positioned between the surfaces to be joined B29C65/5035 takes precedence
• CPC Class Codes: B29C 65/7814 in the form of inter-cooperating positioning features holding or clamping means cooperating with specially formed features of at least one of the parts to be joined B29C65/7844, e.g. tenons and mortises tenon and mortise joints B29C66/126; tongue and groove joints B29C66/124
• CPC Class Codes: B29C 65/7844 cooperating with specially formed features of at least one of the parts to be joined, e.g. cooperating with holes or ribs of at least one of the parts to be joined parts to be joined comprising holes or slots for the purpose of positioning said parts B29C65/7808; parts to be joined comprising inter-cooperating positioning features B29C65/7814; welding using friction, the welding tool cooperating with specially formed features of at least one of the parts to be joined, e.g. cooperating with holes or ribs of at least one of the parts to be joined B29C65/069
• CPC Class Codes: B32B 37/12 characterised by using adhesives
• CPC Class Codes: B32B 38/10 Removing layers, or parts of layers, mechanically or chemically
• CPC Class Codes: B32B 38/1841 during laying up
• CPC Class Codes: H01Q 1/42 Housings not intimately mechanically associated with radiating elements, e.g. radome
• CPC Class Codes: H01Q 21/0087 Apparatus or processes specially adapted for manufacturing antenna arrays manufacturing waveguides H01P11/00
• CPC Class Codes: H01Q 21/065 Patch antenna array

Abstract

A method of assembling a satellite antenna including placing a first layer PCB including an alignment hole on an assembly fixture including an alignment pole, placing a solid foam spacer including an alignment hole on the assembly fixture, pressing the solid foam spacer onto the first layer PCB to adhere the solid foam spacer to the first layer PCB, removing an adhesive carrier film from a reflector patch of a reflector patch sheet including an alignment hole, placing the reflector patch sheet on the assembly feature, pressing the reflector patch sheet onto the solid foam spacer to adhere the reflector patch to the solid foam spacer, and removing a release liner from the top of the reflector patch sheet to remove excess material from the reflector patch sheet.

Claims

1. A method of assembling a satellite antenna comprising:

placing a first layer PCB comprising at least one alignment hole on an assembly fixture comprising at least one alignment pole;

placing a solid foam spacer comprising at least one alignment hole on the assembly fixture;

pressing the solid foam spacer onto the first layer PCB to adhere the solid foam spacer to the first layer PCB;

removing an adhesive carrier film from a reflector patch of a reflector patch sheet comprising at least one alignment hole;

placing the reflector patch sheet on the assembly feature;

pressing the reflector patch sheet onto the solid foam spacer to adhere the reflector patch to the solid foam spacer; and

removing a release liner from the top of the reflector patch sheet to remove excess material from the reflector patch sheet.

2. The method of claim 1, further comprising:

removing the first layer PCB, solid foam spacer, and reflector patch from the assembly fixture.

3. The method of claim 2, further comprising:

attaching a spacer to the bottom of the first layer PCB; and

attaching the spacer to the top of a base plate.

4. The method of claim 3, wherein the spacer is attached to the first layer PCB and the base plate with an adhesive.

5. The method of claim 3, further comprising:

attaching a radome to the base plate such that the radome covers the first layer PCB, solid foam spacer, and reflector patch.

6. The method of claim 5, wherein the radome is attached to the base plate with metal screws.

7. The method of claim 1, wherein the first layer PCB comprises a feed network and a driver patch.

8. The method of claim 7, wherein the driver patch is a copper driver patch.

9. The method of claim 1, wherein the assembly fixture comprises four alignment poles arranged with one alignment pole at each corner of a base.

10. The method of claim 1, wherein the reflector patch is aluminum.

11. A apparatus for assembling a satellite antenna comprising:

an assembly fixture comprising at least one alignment pole attached to a base;

a first layer PCB comprising a feed network, at least one driver patch, and at least one alignment hole positioned to align with the at least one alignment pole;

a reflector patch sheet comprising a metal sheet with at least one etched reflector patch and at least one alignment hole positioned to align with the at least one alignment pole;

a double sided adhesive layer adhered to the bottom of the reflector patch sheet and precut with a shape of the at least one reflector patch and comprising at least one alignment hole positioned to align with the at least one alignment pole;

an adhesive carrier film covering the bottom of the double sided adhesive layer and precut with the shape of the at least one reflector patch and comprising at least one alignment hole positioned to align with the at least one alignment pole;

a release liner attached to the top of the reflector patch sheet and comprising at least one alignment hole positioned to align with the at least one alignment pole; and

a solid foam spacer comprising at least one cavity and comprising at least one alignment hole positioned to align with the at least one alignment pole.

12. The apparatus of claim 11, further comprising a base plate.

13. The apparatus of claim 11, further comprising a radome.

14. The apparatus of claim 11, wherein the at least one driver patch and at least one reflector patch are positioned such that the at least one driver patch is aligned with the at least one reflector patch when the at least one alignment hole of the reflector patch sheet is aligned with the at least one alignment hole of the first layer PCB.

15. The apparatus of claim 11, wherein the solid foam spacer comprises an adhesive.

16. The apparatus of claim 11, further comprising spacers, wherein the spacers comprise an adhesive on the top and bottom of the spacer.

17. The apparatus of claim 11, wherein the first layer PCB further comprises screen printed markings indicating locations for the placement of spacers.

18. An apparatus for assembling a satellite antenna comprising:

a base; and

a plurality of alignment poles attached to the base, wherein the alignment poles are arranged such that at least two layers of material may be aligned with one another through the use of alignment holes in the two layers of materials corresponding to the alignment poles.

19. The apparatus of claim 18, wherein the base and the alignment poles are constructed of at least one of wood, metal, and plastic.

20. The apparatus of claim 18, wherein the at least two layers of material are layers for the assembly of a satellite antenna.