Patent ID: 9590289
Date: 2017-03-07
CPC Classifications: H01Q

Claim:
1. A method for providing communications antennae suitable for operating in harsh environmental conditions, the method comprising: removably attaching a proximal end of a communications antenna to a mold, the communications antenna comprising a base disposed at the proximal end connected by a mast to an antenna element at a distal end of the communications antenna, the antenna element comprising a conductive trace disposed on a planar dielectric substrate, the planar dielectric substrate having a first side opposing a second side, the mold being configured to provide a form for a monolithic coating to be applied to the communications antenna, the mold comprising ports near the distal end, a given port being configured to accommodate a pin configured to be (1) extended through the given port to contact the antenna element or (2) retracted through the given port to release contact from the antenna element; securing a position of the distal end of the communication antenna within the mold by extending pins from two or more opposing ports so that the pins contact the distal end and hold the distal end in place; introducing a coating material into the mold so that the coating material flows around the communications antenna; and retracting the pins responsive to the coating material flowing around the antenna element at the distal end of the communications antenna so that the position of the antenna element is fixed within the mold, wherein the coating material fills volumes previously occupied by the pins so that a continuous monolithic coating of the communication antenna results after the pins are retracted.