Method and apparatus for assembly of a satellite antenna
First Claim
1. A method of assembling a satellite antenna comprising:
- placing a first layer PCB comprising a plurality of driver patches and 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;
precutting through an adhesive carrier film, a double sided adhesive layer, and a reflector patch sheet in a shape of a plurality of separate reflector patches in the reflector patch sheet;
removing a plurality of separate portions of the adhesive carrier film from the plurality of separate reflector patches of the reflector patch sheet, which includes at least one alignment hole;
placing the reflector patch sheet on the assembly fixture;
pressing the reflector patch sheet onto the solid foam spacer to adhere the plurality of separate reflector patches 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.
5 Assignments
0 Petitions
Accused Products
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.
12 Citations
17 Claims
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1. A method of assembling a satellite antenna comprising:
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placing a first layer PCB comprising a plurality of driver patches and 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; precutting through an adhesive carrier film, a double sided adhesive layer, and a reflector patch sheet in a shape of a plurality of separate reflector patches in the reflector patch sheet; removing a plurality of separate portions of the adhesive carrier film from the plurality of separate reflector patches of the reflector patch sheet, which includes at least one alignment hole; placing the reflector patch sheet on the assembly fixture; pressing the reflector patch sheet onto the solid foam spacer to adhere the plurality of separate reflector patches 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. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. An apparatus for assembling a satellite antenna comprising:
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an assembly fixture comprising at least one alignment pole attached to a base; a first layer PCB comprising a feed network, a plurality of driver patches, 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 a plurality of etched separate reflector patches 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 plurality of separate reflector patches 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 to include a plurality of separate portions of the adhesive carrier film with the shape of the plurality of separate reflector patches 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. - View Dependent Claims (12, 13, 14, 15, 16, 17)
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Specification