Integrated antenna system

• US 9,270,016 B2
• Filed: 07/15/2011
• Issued: 02/23/2016
• Est. Priority Date: 07/15/2011
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Stoneback, Matthew A., Marshall, Joseph A. IV, Sego, Daniel Joseph, Layton, Otis Franklin, Gaw, Kevin O'Brien
• Primary Examiner(s): Nguyen, Hoang V
• Assistant Examiner(s): Bouizza, Michael
• Application Number:
  US13/183,808
• Publication Number:
  US 20130016019A1
• Time in Patent Office: 1,684 Days
• Field of Search: 343/705, 343/873
• US Class Current: 1/1
• CPC Class Codes: B29C 70/30 Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
• CPC Class Codes: B29C 70/40 Shaping or impregnating by compression B29C70/34 takes precedencenot applied
• CPC Class Codes: B29C 70/865 completely encapsulated
• CPC Class Codes: B29C 70/885 with incorporated metallic wires, nets, films or plates as lost heating elements B29C35/0272, B29C61/0625
• CPC Class Codes: H01Q 1/28 Adaptation for use in or on aircraft, missiles, satellites, or balloons
• CPC Class Codes: H01Q 1/287 integrated in a wing or a stabiliser
• CPC Class Codes: H01Q 1/38 formed by a conductive layer on an insulating support patch antennas H01Q9/0407; microstrip dipole antennas H01Q9/065; microstrip slot antennas H01Q13/106; transmission line microstrip antennas H01Q13/206; manufacturing reflecting surfaces using insulating material for supporting the reflecting surface H01Q15/142
• CPC Class Codes: H01Q 1/40 Radiating elements coated with or embedded in protective material
• CPC Class Codes: H01Q 13/106 Microstrip slot antennas patch antenna elements H01Q9/0407
• CPC Class Codes: Y10T 156/1089 of discrete laminae to single face of additional lamina

Abstract

A method and apparatus comprising a resin layer, a number of conductive elements, and a number of layers of reinforcement material. The number of conductive elements is on the resin layer. The number of conductive elements has a configuration that forms an antenna system. The number of layers of reinforcement material forms a reinforcement for a composite structure, and at least a portion of the resin layer forms a matrix for the composite structure.

Claims

1. An apparatus comprising:

a thermoplastic resin layer;

a number of conductive elements on the thermoplastic resin layer, wherein the number of conductive elements has a configuration that forms an antenna system and the antenna system comprises a slot antenna system;

a number of layers of reinforcement material, wherein the number of layers of reinforcement material form a reinforcement for a composite structure, and at least a portion of the thermoplastic resin layer forms a matrix for the composite structure, the thermoplastic resin layer, the number of conductive elements, and the number of layers of reinforcement material consolidated in a nonplanar configuration; and

a composite layer including a fiberglass layer, a reinforcement layer, a thermoplastic resin layer of the composite layer, and a thermoset resin layer;

wherein the antenna system is integrated into the composite structure, the composite structure comprising a wing of an aircraft such that the number of layers have a surface in a shape of the wing;

wherein the number of conductive elements are formed on the thermoplastic resin layer prior to positioning the thermoplastic resin layer on one of the number of layers of reinforcement material;

wherein the thermoplastic resin layer is flowed into and infused with two layers of the number of layers;

wherein the thermoplastic resin layer is placed onto the composite layer;

wherein the number of layers of reinforcement material are placed over the thermoplastic resin layer; and

wherein the composite layer, the thermoplastic resin layer, and the number of layers of reinforcement material are consolidated to form the composite structure.

2. The apparatus of claim 1, wherein the thermoplastic resin layer is a first thermoplastic resin layer, the number of conductive elements is a first number of conductive elements forming a first antenna, and further comprising:

a second resin layer, wherein at least a portion of the second resin layer is part of the matrix for the reinforcement; and

a second number of conductive elements forming a second antenna, wherein a configuration of the second number of conductive elements on the second resin layer is a part of the antenna system.

3. The apparatus of claim 2, wherein at least one layer in the number of layers of reinforcement material separates the first resin layer and the second resin layer.

4. The apparatus of claim 1, wherein the number of conductive elements comprises at least one of an antenna, a control line, a radio frequency transmission line, a conductive radio frequency transmission line, a conductive trace, a capacitor, a switch, a resistor, and an inductor.

5. The apparatus of claim 1, wherein the resin layer and the number of layers of reinforcement material are consolidated to form a laminate in which the laminate is shaped to have a desired shape to form the composite structure.

6. The apparatus of claim 5, wherein the resin layer is selected from one of a thermoplastic resin layer and a thermoset resin layer.

7. The apparatus of claim 6, wherein thermoplastic resin in the thermoplastic resin layer is selected from at least one of a polyether ketone, a polyolefin, and a polyamide.

8. The apparatus of claim 1, wherein the reinforcement material in the number of layers of reinforcement material is selected from at least one of fiberglass, carbon, and graphite.

9. The apparatus of claim 1, wherein a layer in the number of layers of reinforcement material is in a form selected from one of a cloth, a tape, and woven fibers.

10. The apparatus of claim 1, wherein the antenna system is integrated into an aircraft structure without a pod.

11. The apparatus of claim 1, wherein the wing provides both an antenna function and a wing function.

12. The apparatus of claim 1, wherein the number of conductive elements comprise an antenna, a feed line, a number of capacitors, and a number of switches.

13. The apparatus of claim 2, wherein the composite structure comprises a wing of an unmanned aircraft.

14. A method for operating an antenna integrated into a wing of an aircraft, the method comprising:

generating a signal in a number of conductive elements in a wing composite structure, wherein the wing composite structure comprises a matrix formed from at least a portion of a thermoplastic resin layer and a reinforcement formed from a number of layers of reinforcement material and wherein a configuration of the number of conductive elements forms an antenna system and the antenna system comprises a slot antenna system, wherein the wing composite structure and the antenna system are integrated into an aircraft structure without a pod, the wing composite structure and the antenna system having a nonplanar configuration of a surface of a wing of the aircraft structure, and the number of conductive elements comprising an antenna, a feed line, a number of capacitors, and a number of switches;

wherein the number of conductive elements are formed on the thermoplastic resin layer prior to positioning the thermoplastic resin layer on one of the number of layers of reinforcement material;

wherein the thermoplastic resin layer is flowed into and infused with two layers of the number of layers;

wherein the thermoplastic resin layer is placed onto a composite layer that includes a fiberglass layer, a reinforcement layer, a thermoplastic resin layer of the composite layer, and a thermoset resin layer;

wherein the number of layers of reinforcement material are placed over the thermoplastic resin layer; and

wherein the composite layer, the thermoplastic resin layer, and the number of layers of reinforcement material are consolidated to form the composite structure.

15. The method of claim 14, wherein the signal is generated in the number of conductive elements with an electromagnetic signal received by the antenna system.

16. The method of claim 14, wherein the signal is an electromagnetic signal generated in the number of conductive elements by at least a portion of the number of conductive elements.

17. A method for forming an antenna system in a composite structure of an aircraft, the method comprising:

forming a number of conductive components in a configuration on a thermoplastic resin layer, wherein the configuration of the number of conductive components forms the antenna system and the antenna system comprises a slot antenna system;

positioning the thermoplastic resin layer with the number of conductive components with respect to a number of layers of reinforcement material;

consolidating the thermoplastic resin layer with the number of layers of reinforcement material to form the composite structure, wherein the antenna system is in the composite structure in which the composite structure has a substantially planar shape;

placing the composite structure on a mold; and

changing a shape of the composite structure on the mold into a nonplanar shape for the composite structure to form the composite structure, wherein the nonplanar shape of the antenna system is integrated into the composite structure so as to provide a surface of the aircraft;

wherein the number of conductive components are formed on the thermoplastic resin layer prior to positioning the thermoplastic resin layer on one of the number of layers of reinforcement material;

wherein the thermoplastic resin layer is flowed into and infused with two layers of the number of layers;

wherein the thermoplastic resin layer is placed onto a composite layer that includes a fiberglass layer, a reinforcement layer, a thermoplastic resin layer of the composite layer, and a thermoset resin layer;

wherein the number of layers of reinforcement material are placed over the thermoplastic resin layer; and

wherein the composite layer, the thermoplastic resin layer, and the number of layers of reinforcement material are consolidated to form the composite structure.

18. The method of claim 17, wherein a desired shape for the composite structure is selected from one of a wing, a horizontal stabilizer, a vertical stabilizer, a flap, an engine housing, and a fuselage.

19. The method of claim 17, wherein the thermoplastic resin layer is selected from at least one of a polyether ketone, a polyolefin, and a polyamide.

20. The method of claim 17, wherein the number of layers of reinforcement material is selected from at least one of fiberglass, carbon, and graphite.