Patent Description:
This disclosure relates generally to communication systems, and more specifically to a reflector antenna system and method for manufacture.

Antennas that are designed to communicate long distances, such as to and from satellites, are designed to include a reflector that collimates or focuses an associated radio signal. Such reflector antennas are typically fabricated in panel portions that include a reflector skin formed of a light material (e.g., aluminum). The panel portions are typically aligned in such a manner as to attempt to optimize a parabolic profile, which can typically involve mechanical tuning of the coupling of the panel portions together. To manufacture a panel portion, the reflector skin is typically formed in a reflector profile, such as a parabolic reflector profile, to optimize the collimation or focusing of the radio signal. The reflector skin is typically coupled to a perimeter frame to maintain the reflector profile of the reflector skin, and the perimeter frames of the panel portions can be coupled together to form the reflector antenna.

<CIT> discloses a thin skilled parabolic reflector with radial ribs.

<CIT> discloses a method of manufacturing a parabolic reflector.

<CIT> discloses an antenna reflector <NUM> assembled from a plurality of rigid panels, for example sectors of metal or alloy, releasably secured together.

<CIT> discloses a satellite dish antenna having parabolic-shaped support ribs firmly engaging the sides of adjacent screen-mesh reflected petals along the entire longitudinal length of each petal.

This disclosure relates generally to communication systems, and more specifically to a reflector antenna system and method for manufacture. A reflector antenna system is formed of a plurality of radial antenna portions. Each of the radial antenna portions is formed from a pair of frame members and a reflector skin, and is fabricated using a panel bonding tool. The panel bonding tool can include a pair of sidewalls having fastening features that are arranged in a reflector profile of the reflector antenna. As described herein, the term "reflector profile" describes a cross-sectional radial profile of the reflector of the reflector antenna system. For example, the reflector profile can be a parabolic antenna, such as corresponding to a main reflector or a sub-reflector of an antenna (e.g., a Cassegrain antenna). For example, the reflector profile can be any of a variety of contours, such as concave, convex (e.g., for a sub-reflector), or flat.

To fabricate a radial antenna panel, the frame members are secured to the sidewalls of the panel bonding tool via the fastening features. For example, the fastening features can be arranged as sliding pins (e.g., spring-mounted) that can engage with through-holes (e.g., through-hole slots) along a length of the respective frame members. The frame members can be configured as an extruded material that is selected for stiffness, but can include kerf slits arranged periodically along a longitudinal length, such that the frame members can be bent to form the reflector profile along a surface of the respective frame members. The frame members are therefore included as part of a perimeter frame (e.g., also including interconnecting members between the respective frame members) that is associated with the radial antenna panel and formed on the panel bonding tool. An adhesive is applied to the respective surfaces of the frame members, and the reflector skin is applied to the adhesive. For example, the panel bonding tool can include clamps that can be applied to provide pressure to the reflector skin onto the frame members during curing of the adhesive.

The radial antenna panel can then be removed from the panel bonding tool and can be coupled to one of a respective plurality of ribs coupled to a hub defining an axial center of the reflector antenna. For example, each of the radial antenna panels can be coupled between a pair of ribs, such that each rib supports a pair of radial antenna panels. For example, the through-holes associated with the frame members can facilitate coupling to a through-hole pattern associated with the respective rib, such that a given bolt can pass through a frame member associated with a first radial antenna panel, the respective rib, and a frame member associated with a second radial antenna panel. The through-hole pattern of the respective rib can be approximate the same as the fastening feature pattern of the sidewalls of the panel bonding tool, such that the through-hole pattern of the rib can exhibit the reflector profile of the reflector antenna. For example, the through-hole pattern of the frame members can include a precision through-hole that is most proximal to the hub to radially align the radial antenna panels for optimal metrology of the reflector antenna. The remaining through-holes extending longitudinally along the frame members can correspond to through-hole slots to accommodate thermal effects (expansion and contraction) affecting the radial antenna panel.

<FIG> illustrates an example of an antenna system <NUM>. The antenna system <NUM> is demonstrated in the example of <FIG> in a first isometric view <NUM> corresponding to an anterior view and in a second isometric view <NUM> corresponding to a posterior view. The antenna system <NUM> can be implemented in any of a variety of wireless communications applications that may require a focused or collimated beam, such as satellite communication system.

The antenna system <NUM> includes a hub <NUM> that defines an axial center of the antenna system <NUM>, as well as a plurality of ribs <NUM> that are coupled to and radially extend from the hub <NUM>. The plurality of ribs <NUM> are each also coupled to a respective plurality of radial antenna panels <NUM> that radially extend between adjacent ribs <NUM>. Therefore, a given one of the ribs <NUM> can be coupled to an adjacent pair of the radial antenna panels <NUM>. Each of the radial antenna panels <NUM> is demonstrated as including a perimeter band bracket <NUM>. The perimeter band brackets <NUM> thus collectively surround the perimeter of the antenna system <NUM> and extend in the anterior direction of the antenna system <NUM>. As an example, the perimeter band brackets <NUM> can provide greater structural strength to the antenna system <NUM>, such as to maintain the reflector profile under wind and gravity loading conditions.

As described in greater detail herein, each of the radial antenna panels <NUM> can include a perimeter frame and a reflector skin that is coupled to the perimeter frame, where the reflector skin provides has a surface from which a given radio frequency (RF) signal is reflected for transmission and/or receipt of the RF signal. In the first isometric view <NUM>, the radial perimeters of reflector skins of adjacent radial antenna panels <NUM> are demonstrated as approximately flush, such that the ribs <NUM> are substantially covered by the reflector skin of the respective radial antenna panels <NUM>. Therefore, the anterior surface of the antenna system <NUM> is substantially smooth to mitigate diffraction of the RF signal that reflects from the anterior surface of the antenna system <NUM>.

<FIG> illustrates an example diagram <NUM> of a radial antenna panel. In the example of <FIG>, the radial antenna panel is demonstrated in an anterior view <NUM> and in a posterior view <NUM>. The radial antenna panel can correspond to a given one of the radial antenna panels <NUM> in the example of <FIG>. Therefore, reference is to be made to the example of <FIG> in the following description of the example of <FIG>.

The radial antenna panel includes a first frame member <NUM>, a second frame member <NUM>, and a reflector skin <NUM>. The first and second frame members <NUM> and <NUM> are each coupled to opposite edges of the reflector skin <NUM> and can be fabricated substantially identically, as described in greater detail herein. As an example, the reflector skin <NUM> can be formed in a variety of ways, such as stretch-formed or vacuum-formed. The radial antenna panel also includes a nose bracket <NUM> that interconnects the frame members <NUM> and <NUM> at a first end of the respective frame members <NUM> and <NUM> and a corner bracket <NUM> that interconnects the frame members <NUM> and <NUM> at a second end of the respective frame members <NUM> and <NUM> opposite the first end. The frame members <NUM> and <NUM> and the interconnect members <NUM> and <NUM> can collectively form a perimeter frame for the radial antenna panel to which the reflector skin <NUM> is coupled (e.g., via an adhesive, screws, or rivets) which extends therebetween. In the example of <FIG>, the reflector skin <NUM> is demonstrated as include a set of three guide holes <NUM>, as described in greater detail herein.

For example, the frame members <NUM> and <NUM>, the interconnect members <NUM> and <NUM>, and the reflector skin <NUM> can be formed from a light metallic material, such as aluminum. However, the frame members <NUM> and <NUM>, the interconnect members <NUM> and <NUM>, and the reflector skin <NUM> can alternatively be formed from a non-metal substrate material with a reflector coating (e.g., on only the anterior surface). For example, the non-metal substrate material can be a plastic material that can be solvent bonded, friction welded, or ultrasonic welded to form the radial antenna panel, and a a reflector coating can be applied to the anterior surface of the reflector skin <NUM> via soldering, TIG welding, spot welding, or any other method of bonding. For example, the choice of materials for the frame members <NUM> and <NUM>, the interconnect members <NUM> and <NUM>, and the reflector skin <NUM> can be selected to mitigate shrinkage/warpage, to affect final accuracy, weight, and/or stiffness of the radial antenna panel. As another example, the reflector anterior coating can be selected to effect electromagnetic performance.

<FIG> illustrates an example diagram <NUM> of a frame member <NUM>. The frame member <NUM> can correspond to a given one of the frame members <NUM> and <NUM> in the example of <FIG>. As a result, the frame member <NUM> can correspond to one of two frame members that form an associated radial antenna panel. Therefore, reference is to be made to the example of <FIG> in the following description of the example of <FIG>.

The frame member <NUM> is demonstrated in multiple views in Cartesian coordinate space in the example of <FIG>. The diagram <NUM> demonstrates the frame member <NUM> in a first view <NUM> that demonstrates a longitudinal length of the frame member <NUM>, in a second view <NUM> corresponding to an isometric view, in a first cross-sectional view <NUM> taken along the "A" reference, and in a second cross-sectional view <NUM> taken along the "B" reference. In the example of <FIG>, the frame member <NUM> is formed as a "C-channel" corresponding to an approximate cross-sectional shape, such that the frame member has a top portion <NUM>, a bottom portion <NUM> parallel with the top portion <NUM>, and a lateral portion <NUM> that interconnects the top and bottom portions <NUM> and <NUM>. The frame member <NUM> includes a plurality of kerf slits <NUM> arranged periodically along a longitudinal length of the frame member <NUM>. The kerf slits <NUM> can be arranged, for example, at each of predetermined approximately equal distances along the longitudinal length of the frame member <NUM>, with each of the kerf slits extending through the top portion <NUM> and through substantially an entirety of the lateral portion <NUM>. Thus, the top portion <NUM> is interrupted by each of the kerf slits <NUM> along the longitudinal length of the frame member <NUM>. The kerf slits <NUM> can therefore facilitate bending of the frame members <NUM>, as described in greater detail herein.

The frame member <NUM> also includes a plurality of through-holes arranged as a through-hole pattern along the longitudinal length of the frame member <NUM>. The through-hole pattern includes a precision through-hole <NUM> and a plurality of through-hole slots <NUM>. As described herein, the term "precision" in the context of the through-holes refers to a high-degree of machined tolerance, such as to a precision of at least one-hundredth of an inch (e.g., between approximately <NUM>" (<NUM>) and approximately <NUM>" (<NUM>)). While the through-hole <NUM> and the through-hole slots <NUM> are demonstrated as having rounded edges, it is to be understood that other types of through-holes (e.g., square or diamond) can be implemented. As an example, the precision through-hole <NUM> can be precision located in each of the X-axis and the Y-axis for radially aligning the radial antenna panel about the hub, as described in greater detail herein. As another example, the through-hole slots <NUM> can be precision located along the Y-axis for bending the frame member <NUM> on the associated panel bonding tool to provide an approximation of the reflector profile with respect to the top portion <NUM>, as also described in greater detail herein. The through-hole slots <NUM> can be likewise implemented for coupling the resulting radial antenna panel to the ribs (e.g., the ribs <NUM> in the example of <FIG>).

<FIG> illustrates an example of a panel bonding tool <NUM>. The panel bonding tool <NUM> can be implemented for forming a radial antenna panel, such as the radial antenna panel in the example of <FIG>, as described herein. Therefore, reference is to be made to the example of <FIG> in the following description of the example of <FIG>.

The panel bonding tool <NUM> includes a pair of sidewalls, demonstrated at <NUM> and <NUM>, that includes a plurality of fastening features <NUM> that are configured to engage with the through-hole slots <NUM> of respective frame members <NUM> (the reference to which is interchangeable hereinafter with the frame members <NUM> and <NUM>). In the example of <FIG>, the fastening features <NUM> are demonstrated in greater detail in an exploded view <NUM> as spring-loaded sliding-pins that each extend through the respective one of the sidewalls <NUM> and <NUM> to engage (e.g., extend through) a respective one of the through-hole slots <NUM> of the respective one of the frame members <NUM>. However, the fastening features <NUM> are not limited to the use of sliding pins, and can be any of a variety of ways of fastening the frame members <NUM> to the respective sidewalls <NUM> and <NUM> (e.g., other through-holes to receive a bolt).

As described previously, the frame members <NUM> and <NUM> are coupled to the sidewalls <NUM> and <NUM>, respectively, during fabrication of a given radial antenna panel. In addition, the interconnect members <NUM> and <NUM> can be coupled to the frame members <NUM> and <NUM> (e.g., via an adhesive) to form the perimeter frame of the radial antenna panel. For example, the fastening features <NUM> are arranged along the sidewalls <NUM> and <NUM> in the reflector profile of the reflector antenna system <NUM>. The panel bonding tool <NUM> therefore has a concave contour to a top side of the sidewalls <NUM> and <NUM> to which the frame members <NUM> and <NUM> are coupled. Accordingly, the panel bonding tool <NUM> can be arranged as a "female" panel bonding tool, as opposed to "male" panel bonding tools having a convex topside that is implemented for forming radial antenna panels in a typical reflector antenna assembly methodology. Therefore, when the respective frame members <NUM> and <NUM> are bent to facilitate coupling to the respective sidewalls <NUM> and <NUM>, the top portion <NUM> of the respective frame member <NUM> can approximate the reflector profile of the reflector antenna system <NUM> (e.g., having a parabolic contour).

In the example of <FIG>, the panel bonding tool <NUM> also includes inner clamps <NUM> that are periodically arranged on the interior surfaces of the respective sidewalls <NUM> and <NUM> and outer clamps <NUM> that are periodically arranged on the exterior surfaces of the respective sidewalls <NUM> and <NUM>. The outer clamps <NUM> and inner clamps <NUM> are also arranged on an end wall <NUM> of the panel bonding tool <NUM>. The panel bonding tool <NUM> also includes a set of parallel alignment pins <NUM> arranged between the sidewalls <NUM> and <NUM>, as well as an adjustable center panel gravity stop <NUM>. The inner clamps <NUM> can be engaged to secure the frame members <NUM> and <NUM> to the interior surfaces of the respective sidewalls <NUM> and <NUM> during formation of the perimeter frame on the panel bonding tool <NUM>. Upon forming the perimeter frame via coupling the frame members <NUM> and <NUM> to the respective sidewalls <NUM> and <NUM> and coupling the interconnect members <NUM> and <NUM> to the frame members <NUM> and <NUM>, an adhesive is applied to the perimeter frame.

The reflector skin <NUM> can then be applied to the perimeter frame via the parallel alignment pins <NUM> being provided through the respective guide holes <NUM> formed in the reflector skin <NUM>. As an example, the guide holes <NUM> can also be implemented to establish a fiducial plane for metrology inspection, such as measured to ideal surface profile accuracy, upon completion of the given radial antenna panel. The reflector skin <NUM> can be pressed onto the adhesive that is applied to the surfaces of the top portion <NUM> of the respective frame members <NUM>. As an example, based on the relative dimension of the through-hole slots <NUM> relative to the surface of the top portion <NUM> of the frame members <NUM>, and further relative to the dimension of the respective sidewalls <NUM> and <NUM>, the lateral portion <NUM> of the frame members <NUM> can extend beyond the sidewalls <NUM> and <NUM>, such that the top portion <NUM> of the frame members <NUM> can be elevated relative to a "top" surface of the sidewalls <NUM> and <NUM>. Therefore, in response to the application of the reflector skin <NUM> to the adhesive on the top surface of the top portion <NUM>, any potential "squeeze-out" of the adhesive will not contact any of the portions of the panel bonding tool <NUM>. For example, application of a sufficient amount of adhesive to provide a squeeze-out may ensure that air gaps and voids are not present between the reflector skin <NUM> and frame members <NUM>. Accordingly, the panel bonding tool <NUM> can remain clean without any of the adhesive from squeeze-out curing on any of the surfaces of the panel bonding tool <NUM>.

The center panel gravity stop <NUM> can be adjusted to a predetermined height (e.g., via a screw adjustment). Therefore, when the reflector skin <NUM> is provided onto the adhesive on the perimeter frame, the convex surface (e.g., posterior side) of the reflector skin <NUM> can contact the center panel gravity stop <NUM> to ensure that the reflector skin <NUM> does not experience deformation from gravity-induced droop of the center portion of the reflector skin <NUM>. Upon contacting the adhesive with the reflector skin <NUM>, the outer clamps <NUM> can be engaged to provide pressure of the reflector skin <NUM> onto the adhesive while the adhesive cures. As an example, the adhesive can include one or more physical spacing elements to provide a standoff distance between the surface of the top portion <NUM> of the frame members <NUM> and <NUM> and the opposing surface of the reflector skin <NUM> separated by the adhesive. For example, the physical spacing element(s) can include beads, string, or other rigid physical objects to prevent direct contact between the surfaces of the reflector skin <NUM> and the frame members <NUM> and <NUM>. As a result, the physical spacing element(s) can establish a minimum bonding thickness to establish sufficient bonding between the surfaces of the reflector skin <NUM> and the frame members <NUM> and <NUM>. For example, the bonding thickness can vary from between approximately <NUM>" at an approximate center of the top portion <NUM> between the kerf slits <NUM> and approximately <NUM>" at the top portion <NUM> nearest the kerf slits <NUM> based on a parabolic reflector profile of the reflector skin <NUM>. After the adhesive has cured, the outer clamps <NUM> can be disengaged and the resultant radial antenna panel can be removed from the panel bonding tool <NUM> (e.g., after removing the alignment pins <NUM> to facilitate sliding the radial antenna panel off of the panel bonding tool <NUM>).

<FIG> demonstrate the fabrication of a given radial antenna panel of the reflector antenna system <NUM> in greater detail. The radial antenna panel can correspond to the radial antenna panel of the example of <FIG> using the panel bonding tool <NUM> in the example of <FIG>. Therefore, reference is to be made to the examples of <FIG> in the following description of the examples of <FIG>. Additionally, like reference numbers are used in the examples of <FIG> as provided in the examples of <FIG>.

<FIG> illustrates another example of a panel bonding tool <NUM>. The panel bonding tool <NUM> can correspond to the panel bonding tool <NUM> in the example of <FIG>. However, in the example of <FIG>, the panel bonding tool <NUM> and associated structures of the resultant radial antenna panel are demonstrated in a more simplistic manner. Therefore, certain components (e.g., the clamps <NUM> and <NUM>) are omitted in the example of <FIG> for ease of explanation. The panel bonding tool <NUM> includes the pair of sidewalls <NUM> and <NUM>, that each include the fastening features <NUM> that are configured to engage with the through-hole slots <NUM> of respective frame members <NUM>. For example, the fastening features <NUM> are arranged along the sidewalls <NUM> and <NUM> in the reflector profile (e.g., a parabolic profile) of the reflector antenna system <NUM>. The panel bonding tool <NUM> therefore has a concave contour to a top side of the sidewalls <NUM> and <NUM> to which the frame members <NUM> and <NUM> are coupled. Accordingly, the panel bonding tool <NUM> is arranged as a "female" panel bonding tool, as opposed to "male" panel bonding tools having a convex topside that is implemented for forming radial antenna panels in a typical reflector antenna assembly methodology.

<FIG> illustrates an example diagram <NUM> of fabricating a radial antenna panel. The diagram <NUM> demonstrates the panel bonding tool <NUM> with a perimeter frame <NUM> attached thereto. The perimeter frame <NUM> can include the frame members <NUM> and <NUM> coupled to the respective sidewalls <NUM> and <NUM> via the fastening features <NUM> and the interconnect members <NUM> and <NUM> coupled to each of the frame members <NUM> and <NUM>. For example, the frame members <NUM> and <NUM> are bent (e.g., via the kerf slits <NUM>) to facilitate coupling to the respective sidewalls <NUM> and <NUM>, such that the top portion <NUM> of the respective frame member <NUM> can approximate the reflector profile of the reflector antenna system <NUM> (e.g., having a parabolic contour). As an example, the fastening features <NUM> can correspond to spring-loaded sliding pins that can engage with the through-hole slots <NUM> of the frame members <NUM> to approximate the reflector profile, and the frame members <NUM> can be secured to the inner surfaces of the respective sidewalls <NUM> and <NUM> via the inner clamps <NUM>.

<FIG> illustrates another example diagram <NUM> of fabricating a radial antenna panel. The diagram <NUM> demonstrates the panel bonding tool <NUM> with the perimeter frame <NUM> attached thereto. In the example of <FIG>, an adhesive, demonstrated generally at <NUM>, has been applied to the top surfaces of the perimeter frame <NUM>, including the top surface of the top portion <NUM> of each of the frame members <NUM>. The adhesive <NUM> can correspond to any of a variety of rapid-curing adhesives (e.g., with a working time of less than ten minutes and a curing time of approximately one hour or less). As described previously, based on the relative dimension of the through-hole slots <NUM> relative to the surface of the top portion <NUM> of the frame members <NUM>, and further relative to the dimension of the respective sidewalls <NUM> and <NUM>, the lateral portion <NUM> of the frame members <NUM> can extend beyond the sidewalls <NUM> and <NUM>, such that the top portion <NUM> of the frame members <NUM> can be elevated relative to the top surface of the sidewalls <NUM> and <NUM>.

<FIG> illustrates another example diagram <NUM> of fabricating a radial antenna panel. The diagram <NUM> demonstrates the panel bonding tool <NUM> with the perimeter frame <NUM> attached thereto, and with the reflector skin <NUM> having been positioned in contact with the adhesive <NUM> on the perimeter frame <NUM>. For example, the reflector skin <NUM> can have been applied to the perimeter frame <NUM> via the parallel alignment pins <NUM> being provided through the respective guide holes <NUM> (not shown in the example of <FIG>) formed in the reflector skin <NUM>. The reflector skin <NUM> can be pressed onto the adhesive <NUM> that is applied to the surfaces of the top portion <NUM> of the respective frame members <NUM>. Because the top portion <NUM> of the frame members <NUM> can be elevated relative to the top surface of the sidewalls <NUM> and <NUM>, as described previously, any potential "squeeze-out" of the adhesive <NUM> will not contact any of the portions of the panel bonding tool <NUM>. Additionally, as described previously, the center panel gravity stop <NUM> can have been adjusted to a predetermined height (e.g., via a screw adjustment) prior to application of the reflector skin <NUM> to the adhesive <NUM>. Therefore, when the reflector skin <NUM> is provided onto the adhesive on the perimeter frame, the convex surface (e.g., posterior side) of the reflector skin <NUM> can contact the center panel gravity stop <NUM> to ensure that the reflector skin <NUM> does not experience deformation from gravity-induced droop of the center portion of the reflector skin <NUM>.

<FIG> illustrates another example diagram <NUM> of fabricating a radial antenna panel. The diagram <NUM> demonstrates a cross-sectional view of a sidewall <NUM> of the panel bonding tool <NUM>, which can correspond to one of the sidewalls <NUM> and <NUM> of the panel bonding tool <NUM>. The diagram <NUM> also demonstrates a cross-section of a frame member <NUM> (e.g., one of the frame members <NUM> and <NUM>) secured to an inner surface of the sidewall <NUM> via an inner clamp <NUM> (e.g., one of the inner clamps <NUM>). The frame member <NUM> and the sidewall <NUM> are demonstrated in the diagram <NUM> as including a common fastening, illustrated by dotted lines <NUM>, corresponding to a fastening feature <NUM> engaging one of the through-hole slots <NUM> of the frame member <NUM> along a length of the respective sidewall <NUM> and frame member <NUM>. As described previously, based on the relative dimension of the through-hole slots <NUM> relative to a top surface <NUM> of the frame member <NUM>, and further relative to the dimension of the respective sidewall <NUM>, a lateral portion <NUM> of the frame member <NUM> can extend beyond the sidewall <NUM>, as demonstrated at <NUM>. Therefore, the top surface <NUM> of the frame member <NUM> is demonstrated as elevated relative to a top surface <NUM> of the sidewall <NUM>.

The diagram <NUM> also demonstrates a reflector skin <NUM> coupled to the top surface <NUM> of the frame member <NUM> via an adhesive <NUM>. Because of the extension <NUM> of the frame member <NUM> relative to the sidewall <NUM>, the adhesive <NUM> does not contact the sidewall <NUM> when any of the adhesive <NUM> squeezes out from between the top surface <NUM> of the frame member <NUM> and the reflector skin <NUM>. Upon contacting the adhesive <NUM> with the reflector skin <NUM>, the diagram <NUM> demonstrates an outer clamp <NUM> (e.g., of the outer clamps <NUM>) that is engaged to provide pressure of the reflector skin <NUM> onto the adhesive <NUM> while the adhesive <NUM> cures. As described previously, the adhesive <NUM> can include one or more physical spacing elements to provide a standoff distance between the top surface <NUM> of the frame member <NUM> and the opposing surface of the reflector skin <NUM> separated by the adhesive <NUM>. In addition, the diagram <NUM> demonstrates a release hole, illustrated by dotted lines <NUM>, that facilitates release of the inner clamp <NUM> while the reflector skin <NUM> is adhered to the top perimeter frame that includes the frame member <NUM>. Therefore, the release hole <NUM> provides access to a release handle, demonstrated at <NUM>, for disengaging the inner clamp <NUM> for removing the perimeter frame from the panel bonding tool <NUM>.

<FIG> illustrates another example diagram <NUM> of fabricating a radial antenna panel. The diagram <NUM> demonstrates a fabricated radial antenna panel <NUM> being removed from the panel bonding tool <NUM>. The radial antenna panel <NUM> can therefore correspond to the radial antenna panel demonstrated in the example of <FIG>. The radial antenna panel <NUM> can thus include the reflector skin <NUM> adhered to a perimeter frame that includes the frame members <NUM> and <NUM> and the interconnect members <NUM> and <NUM>. The radial antenna panel <NUM> can be removed from the panel bonding tool <NUM> after the adhesive has cured, and after the inner clamps <NUM> and the outer clamps <NUM> have been disengaged, as well as the fastening features <NUM> on the sidewalls <NUM> and <NUM> of the panel bonding tool <NUM>. The radial antenna panel <NUM> can thus correspond to one of the plurality of radial antenna panels <NUM> that can form the reflector antenna. As an example, each of the radial antenna panels <NUM> can be fabricated as described in the examples of <FIG>, similar to the radial antenna panel <NUM>.

The methodology for fabricating the radial antenna panel <NUM> can therefore correspond to a significantly more efficient manner of fabricating a radial antenna panel than typical processes for fabricating a radial antenna panel. For example, as described previously, a typical radial antenna panel can be fabricated on a male panel bonding tool that implements a vacuum sealing system to vacuum secure a reflector skin onto a convex surface. Such a male panel bonding tool can be significantly more expensive to manufacture than the panel bonding tool <NUM> described herein based on additional materials and based on the inclusion of a vacuum system that is obviated for the design of the panel bonding tool <NUM>. Additionally, for the typical fabrication methodology, the perimeter frame is assembled separately from the male panel bonding tool, and is applied to the adhesive that is provided on the surface of the vacuum-secured reflector skin. As a result, the perimeter frame in the typical fabrication methodology is formed in a manner that does not include fastening features on the panel bonding tool that predefine the reflector profile for the resultant radial antenna panel. Instead, the perimeter frame of the typical fabrication methodology is bent to conform to the reflector profile contour of the reflector skin while it is vacuum-secured to the male panel bonding tool, directly onto the applied adhesive. Such an arrangement can be significantly more time consuming and can provide for more opportunities for errors in assembly of the perimeter frame and the securing of the perimeter frame to the adhesive. Furthermore, when the perimeter frame is pressed onto the adhesive that has been applied to the panel skin in the typical fabrication method, adhesive that squeezes out of the bonding of the perimeter frame to the reflector skin can flow over the perimeter of the reflector skin directly onto the surfaces of the male panel bonding tool. Accordingly, additional cleaning can be required in the typical fabrication methodology. However, the fabrication methodology described in the examples of <FIG> mitigates the inefficiencies of the typical fabrication methodology, for the reasons described herein.

<FIG> illustrates an example of a rib <NUM> of an antenna system. The rib <NUM> can correspond to the ribs <NUM> of the reflector antenna <NUM> in the example of <FIG>. Therefore, reference is to be made to the example of <FIG> in the following description of the example of <FIG>. The rib <NUM> can be coupled to the hub <NUM>, and can be coupled to a pair of the radial antenna panels <NUM>, such as the radial antenna panel <NUM> described previously.

In the example of <FIG>, the rib <NUM> includes a plurality of through-holes, demonstrated as a first set of through-holes <NUM>, an alignment through-hole <NUM>, and a second set of through-holes <NUM>. The first set of through-holes <NUM> can be implemented for coupling the rib <NUM> to the hub <NUM> (e.g., via a respective set of bolts). For example, the topmost and bottommost of the first set of through-holes <NUM> can provide for precision alignment of the rib <NUM> to the hub <NUM>, and the innermost through-hole <NUM> can provide for an increased mounting strength of the rib <NUM> to the hub <NUM>. The alignment through-hole <NUM> and the second set of through-holes <NUM> can define the reflector profile, similar to as described previously with respect to the fastening features <NUM> of the panel bonding tool <NUM>. Therefore, the alignment through-hole <NUM> and the second set of through-holes <NUM> can have a profile that is approximately identical to the profile of the fastening features of the panel bonding tool <NUM>. Accordingly, the alignment through-hole <NUM> and the second set of through-holes <NUM> can be implemented for coupling a given pair of radial antenna panels <NUM> to the rib <NUM> via the precision through-hole <NUM> and the through-hole slots <NUM> of the respective associated frame members <NUM>.

For example, the precision through-hole <NUM> of a frame member <NUM> (e.g., corresponding to the first frame member <NUM>) of a first radial antenna panel <NUM> and the precision through-hole <NUM> of a frame member <NUM> (e.g., corresponding to the second frame member <NUM>) of a second radial antenna panel <NUM> can each be aligned with the alignment through-hole <NUM> of the rib <NUM>. Therefore, a single through-bolt can couple the first and second radial antenna panels <NUM> to the rib <NUM> via the precision through-holes <NUM> and the alignment through-hole <NUM>. For example, because the alignment through-hole <NUM> can be the through-hole most proximal to the hub, the coupling of first and second radial antenna panels <NUM> to the rib <NUM> via the precision through-holes <NUM> and the alignment through-hole <NUM> can radially align the radial antenna panels approximately uniformly about the center axis of the reflector antenna.

Similarly, each of the through-hole slots <NUM> of the frame member <NUM> (e.g., corresponding to the first frame member <NUM>) of the first radial antenna panel <NUM> and the through-hole slots <NUM> of the frame member <NUM> (e.g., corresponding to the second frame member <NUM>) of the second radial antenna panel <NUM> can each be aligned with each of the respective through-holes of the second set of through-holes <NUM> of the rib <NUM>. Therefore, a single through-bolt can couple the first and second radial antenna panels <NUM> to the rib <NUM> via each of the through-hole slots <NUM> and each of the second set of through-holes <NUM>, respectively. For example, each of the through-holes of the second set of through-holes <NUM> can be approximately aligned to a longitudinal center of the respective through-hole slots <NUM>. Therefore, the radial antenna panels <NUM> can radially slide along coupling through-bolt via the respective through-hole slots <NUM> in response to expansion and contraction of the frame members <NUM> and <NUM> of the respective radial antenna panel <NUM>. Accordingly, as described herein, the use of through-bolts for coupling the radial antenna panels <NUM> to the rib <NUM> can provide for a substantially simplistic and uniform manner of assembling the reflector antenna, without having to adjust the individual radial antenna panels to optimize the reflectivity of the resultant reflector antenna, as can be performed in typical reflector antennas.

<FIG> illustrates an example diagram <NUM> of coupling of radial antenna panels to a rib. The diagram <NUM> demonstrates an isometric cross-sectional view of the coupling of a first radial antenna panel <NUM> and a second radial antenna panel <NUM> to a rib <NUM>. The first radial antenna panel <NUM> includes a frame member <NUM> and a reflector skin <NUM>, and the second radial antenna panel <NUM> includes a frame member <NUM> and a reflector skin <NUM>. The diagram <NUM> includes a cross-sectional view of a through-bolt <NUM> extending through a through-hole slot <NUM> of each of the frame member <NUM> and the frame member <NUM>. The diagram <NUM> also includes a through-bolt <NUM> that can extend through a next through-hole slot <NUM> of each of the frame member <NUM> and the frame member <NUM>.

The diagram also demonstrates that the lateral portion <NUM> of each of the frame members <NUM> and <NUM> extends farther along a Y-axis in Cartesian coordinate space than the rib <NUM>. Thus, a peripheral edge of the rib <NUM> is not flush with the top surface of the top portions <NUM> of the respective frame members <NUM> and <NUM>, resulting in the top surface of the top portions <NUM> of the respective frame members <NUM> and <NUM> being elevated greater than the peripheral edge of the rib <NUM> with respect to the Y-axis. Therefore, the reflector skins <NUM> and <NUM> can overlap and substantially cover the peripheral edge of the rib <NUM>. As a result, the associated reflector antenna system <NUM> can have fewer interruptions in the reflective surface formed by the reflector skins <NUM> of each of the radial antenna panels <NUM>, and can therefore exhibit a greater reflectivity for improved performance of the reflector antenna system <NUM>.

In view of the foregoing structural and functional features described above, a methodology in accordance with various aspects of the present invention will be better appreciated with reference to <FIG>. While, for purposes of simplicity of explanation, the methodology of <FIG> is shown and described as executing serially, it is to be understood and appreciated that the present invention is not limited by the illustrated order, as some aspects could, in accordance with the present invention, occur in different orders and/or concurrently with other aspects from that shown and described herein.

<FIG> illustrates an example of a method <NUM> for fabricating a radial antenna panel (e.g., the radial antenna panel <NUM>) of a reflector antenna (e.g., the reflector antenna system <NUM>). At <NUM>, a first frame member (e.g., the first frame member <NUM>) and a second frame member (e.g., the second frame member <NUM>) are each coupled to respective sidewalls (e.g., the sidewalls <NUM> and <NUM>) of a panel bonding tool (e.g., the panel bonding tool <NUM>) via fastening features to engage a through-hole pattern (e.g., the through-holes <NUM> and <NUM>) of each of the respective first and second frame members and bend the first and second frame members to form a perimeter frame (e.g., the perimeter frame <NUM>). A longitudinal surface (e.g., of the lateral portion <NUM>) of each of the first and second frame members extends beyond a longitudinal surface of the respective sidewalls along a length of the respective sidewalls. The longitudinal surface of each of the first and second frame members can correspond to a reflector profile of the reflector antenna. At <NUM>, an adhesive (e.g., the adhesive <NUM>) is applied to each of the first and second frame members of the perimeter frame. At <NUM>, a reflector skin (e.g., the reflector skin <NUM>) is adhered to the perimeter frame via the adhesive to form a radial antenna panel of the plurality of radial antenna panels, the radial antenna panel having the reflector profile. At <NUM>, the radial antenna panel is decoupled from the panel bonding tool upon curing of the adhesive.

Claim 1:
A method for fabricating a radial antenna panel (<NUM>; <NUM>; <NUM>, <NUM>) of a reflector antenna (<NUM>), the method comprising:
coupling (<NUM>) a first frame member (<NUM>; <NUM>; <NUM>) and a second frame member (<NUM>; <NUM>; <NUM>) to respective sidewalls (<NUM>, <NUM>; <NUM>) of a panel bonding tool (<NUM>; <NUM>) via fastening features (<NUM>) to engage a through-hole pattern (<NUM>, <NUM>) of each of the respective first and second frame members and bend the first and second frame members to form a perimeter frame (<NUM>), wherein a longitudinal surface of each of the first and second frame members extends beyond a longitudinal surface of the respective sidewalls along a length of the respective sidewalls, and the longitudinal surface of each of the first and second frame members corresponds to a reflector profile of the reflector antenna;
applying (<NUM>) an adhesive (<NUM>; <NUM>) to each of the first and second frame members of the perimeter frame;
adhering (<NUM>) a reflector skin (<NUM>; <NUM>; <NUM>; <NUM>) to the perimeter frame via the adhesive to form a radial antenna panel of a plurality of radial antenna panels, the radial antenna panel having the reflector profile; and
decoupling (<NUM>) the radial antenna panel from the panel bonding tool upon curing of the adhesive.