Precision multi-layer grids fabrication technique
First Claim
Patent Images
1. A multi-layer grid for a frequency selective surface filter of an antenna comprising:
- a first panel defining a first layer and including;
a first outer film;
a first isotropic foam spacer bonded to the first outer film;
a first adhesive layer for bonding the foam spacer to the first outer film;
a second outer film bonded to the first foam spacer opposite the first outer film; and
a second adhesive layer for bonding the foam spacer to the second outer film;
a second panel defining a second layer and including;
a third outer film;
a second isotropic foam spacer bonded to the third outer film; and
a third adhesive layer for bonding the foam spacer to the third outer film;
a fourth outer film bonded to the second foam spacer opposite the third outer film; and
a fourth adhesive layer for bonding the foam spacer to the fourth outer film; and
a rigid spacer inserted between the first and second panels, the spacer integrates the first and second panels.
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Abstract
A multi-layer grid (20) for an antenna system (10). The multi-layer grid 20 includes a first panel (22) and a second panel (24). Each panel is formed utilizing a pair of outer layers (26, 28) which are adhered to a dielectric foam (30). A low loss adhesive layer (32, 34) enables bonding of dielectric foam (30) to each of respective outer layers (26, 28). A spacer (38) provides a predetermined spacing between first panel (22) and second panel (24). A frequency selective surface filter (38) is disposed on the outer layer (28) of each panel (22, 24).
47 Citations
17 Claims
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1. A multi-layer grid for a frequency selective surface filter of an antenna comprising:
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a first panel defining a first layer and including;
a first outer film;
a first isotropic foam spacer bonded to the first outer film;
a first adhesive layer for bonding the foam spacer to the first outer film;
a second outer film bonded to the first foam spacer opposite the first outer film; and
a second adhesive layer for bonding the foam spacer to the second outer film;
a second panel defining a second layer and including;
a third outer film;
a second isotropic foam spacer bonded to the third outer film; and
a third adhesive layer for bonding the foam spacer to the third outer film;
a fourth outer film bonded to the second foam spacer opposite the third outer film; and
a fourth adhesive layer for bonding the foam spacer to the fourth outer film; and
a rigid spacer inserted between the first and second panels, the spacer integrates the first and second panels. - View Dependent Claims (2, 3, 4, 5, 6)
a first conducive grid disposed on the second outer film for providing a first frequency rejection band; and
a second conductive grid disposed on the third outer film for providing a second frequency rejection band.
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7. A multi-layer grid for a frequency selective surface filter of an antenna comprising:
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a first panel defining a first layer and including;
a first outer film;
a first isotropic foam spacer comprised of one of polymethacrylimide foam and ceramic foam bonded to the first outer film;
a first adhesive layer for bonding the first foam spacer to the first outer film;
a second outer film bonded to the first foam spacer opposite the first outer film; and
a second adhesive layer for bonding the first foam spacer to the second outer film;
a second panel defining a second layer and including;
a third outer film;
a second isotropic foam spacer comprised of one of polymethacrylimide foam and ceramic foam bonded to the third outer film; and
a third adhesive layer for bonding the second foam spacer to the third outer film;
a fourth outer film bonded to the second foam spacer opposite the third outer film; and
a fourth adhesive layer for bonding the second foam spacer to the fourth outer film; and
a rigid spacer inserted between the first and second panels, the spacer integrates the first and second panels.
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8. A multi-layer grid for a frequency selective surface filter of an antenna comprising:
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a first panel defining a first layer and including;
a first outer film;
a first isotropic foam spacer comprised of one of polymethacrylimide foam and ceramic foam bonded to the first outer film;
a first adhesive layer for bonding the first foam spacer to the first outer film;
a second outer film bonded to the first foam spacer opposite the first outer film; and
a second adhesive layer for bonding the first foam spacer to the second outer film;
a second panel defining a second layer and including;
a third outer film;
a second isotropic foam spacer comprised of one of polymethacrylimide foam and ceramic foam bonded to the third outer film; and
a third adhesive layer for bonding the second foam spacer to the third outer film;
a fourth outer film bonded to the second foam spacer opposite the third outer film; and
a fourth adhesive layer for bonding the second foam spacer to the fourth outer film;
a rigid spacer inserted between the first and second panels, the spacer integrates the first and second panels; and
said first and second isotropic foam spacers each comprise a foam material of uniform cross-section.
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9. An antenna comprising:
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a radiating element for radiating electromagnetic radiation;
a circuit for one of generating and accepting signals for respective transmission by and receipt by the radiating element; and
a multi-layer grid for a frequency selective surface filter disposed in communication with the radiating element to provide selective filtering, the multi-layer grid including a plurality of panels, each panel defining a layer and including;
a first outer film;
an isotropic foam spacer bonded to the first outer film; and
a first adhesive layer for bonding the foam spacer to the first outer film;
a second outer film bonded to the foam spacer opposite the first outer film; and
a second adhesive layer for bonding the foam spacer to the second outer film; and
a spacer inserted between each pair of panels of the plurality, the spacer integrates the first and second adhesive layers. - View Dependent Claims (10, 11, 12, 13, 14)
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15. A multi-layer grid for a frequency selective surface filter of an antenna comprising:
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a plurality of panels, each panel defining a layer and including;
a first outer film;
an isotropic foam spacer bonded to the first outer film, the foam spacer being of uniform cross-section;
a first adhesive layer for bonding the foam spacer to the first outer film, the first adhesive layer being a polycyanate film adhesive;
a second outer film bonded to the foam spacer opposite the first outer film;
a second adhesive layer for bonding the foam spacer to the second outer film, the second adhesive layer being a polycyanate film adhesive; and
a rigid spacer inserted between each pair of panels of the plurality, the rigid spacer integrates the first and second layers via the second outer film of each panel. - View Dependent Claims (16)
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17. A method of forming a multi-layer grid for a frequency selective surface filter of an antenna comprising the steps of:
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fabricating a plurality of panels, each panel defining a layer and fabricated by;
providing a first outer film;
bonding an isotropic foam spacer to the first outer film utilizing a first adhesive layer;
providing a second outer film;
bonding the foam spacer opposite the first outer film utilizing a second adhesive layer; and
inserting a spacer between each pair of panels of the plurality, the spacer integrates the first and second layers.
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Specification