US3855027A
Expired / Lapsed
US
⏱️ 0.0 years remaining
On-site fabrication of antennas
Assignee: TDK Micronas GmbH
•
Filing: 1972-06-22
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Granted: 1974-12-17
•
Expires: 1992-06-22
Abstract
Abstract Large parabolic reflectors are constructed on-site from raw materials supplied in a kit, wherein the reflector is formed on an inflatable mold having a convex surface with appropriate contour. Upon inflating the mold, which may be impregnated or initially sprayed with a releasing agent, a layer of ultravioletsensitized polyester gel-coat or polyester resin is spray-applied thereon. Following this a predetermined number of layers of fiberglass-reinforced polyester resin is sprayed-on. Internal reinforcement ribbing pieces (e.g. plywood), having apertures therein and at least one surface corresponding in shape to the mold surface, are then radially arranged on the mold and held in place by polyester resin-sprayed fiberglass attachment fillets. Polyurethane foam is then applied, embedding and foaming in place the reinforcement pieces and also sectional pieces arranged piece by piece in concentric circles on the mold surface, with the apertures therein providing continuity between sections of cast polyurethane foam. Following this, a second laminate layer of fiberglass-reinforced polyester resin is sprayed-on. The mold is then deflated and a reflecting agent (e.g. aluminum) is sprayed onto the reflecting surface.
Inventors
- 👤 M Erdmann
- 👤 J Dolan
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-01 01:17
CPC Classifications
H; H01; H01Q; H01Q15/00; H01Q15/14; H01Q15/141; H01Q15/142; B; B29; B29C; B29C44/00; B29C44/02; B29C44/12; B29C70/00; B29C70/04; B29C70/28; B29L; B29L2011/00; B29L2011/0083
Claims Analysis
Total Claims: 27
Claim 1
Independent Claim
109 words
A METHOD FOR FABRICATING AN ANTENNA REFLECTOR HAVING A REFLECTOR SURFACE OF PREDETERMINED PARAMETERS, COMPRISING THE STEPS OF: A. APPLYING TO A MOLD SURFACE HAVING A CURVATURE CORRESPONDING TO THE PREDETERMINED PARAMETERS OF THE REFLECTOR SURFACE A CONTINOUS LAYER OF POLYESTER MATERIAL OF PREDETERMINED THICKNESS; B. APPLYING A FIRST LAYER OF MATERIAL COMPRISING A FIBERREINFORCED RESINOUS LAMINATE TO A PREDETERMINED THICKNESS; C. REINFORCEMENT INTO PLACE INDIVIDUAL PIECES OF AN INTERNAL REINFORCEMENT RIBBING STRUCTURE OF PREDETERMINED ARRANGEMENT IN A CONTINUOUS FOAMABLE CASTING MATERIAL; D. APPLYING A SECOND LAYER OF MATERIAL COMPRISING A FIBERREINFORCE RESINOUS LAMINATE; AND E. APPLYING TO THE FABRICATED REFLECTOR SURFACE A CONTINOUS LAYER OF A REFLECTING AGENT.
Claim 2
Independent Claim
109 words
A METHOD FOR FABRICATING AN ANTENNA REFLECTOR HAVING A REFLECTOR SURFACE OF PREDETERMINED PARAMETERS, COMPRISING THE STEPS OF: A. APPLYING TO A MOLD SURFACE HAVING A CURVATURE CORRESPONDING TO THE PREDETERMINED PARAMETERS OF THE REFLECTOR SURFACE A CONTINOUS LAYER OF POLYESTER MATERIAL OF PREDETERMINED THICKNESS; B. APPLYING A FIRST LAYER OF MATERIAL COMPRISING A FIBERREINFORCED RESINOUS LAMINATE TO A PREDETERMINED THICKNESS; C. REINFORCEMENT INTO PLACE INDIVIDUAL PIECES OF AN INTERNAL REINFORCEMENT RIBBING STRUCTURE OF PREDETERMINED ARRANGEMENT IN A CONTINUOUS FOAMABLE CASTING MATERIAL; D. APPLYING A SECOND LAYER OF MATERIAL COMPRISING A FIBERREINFORCE RESINOUS LAMINATE; AND E. APPLYING TO THE FABRICATED REFLECTOR SURFACE A CONTINOUS LAYER OF A REFLECTING AGENT.
Claim 3
Independent Claim
136 words
A method for fabricating a dish-shaped antenna reflector having a reflector surface of predetermined parameters, comprising the steps of: a. fabricating an inflatable mold structure which has in the inflated state a mold surface which corresponds to the predetermined parameters of the reflector surface, and inflating the fabricated mold; b. applying to the mold surface a continuous layer of polyester resin gel-coat to a predetermined thickness; c. applying a first layer of material comprising a fiber-reinforced resinous laminate to a predetermined thickness; d. embedding into place radially and concentrically arranged internal reinforcement ribbing pieces in a continuous foamable casting substance; e. applying a second layer of material comprising a fiber-reinforced resinous laminate; and f. deflating the mold and applying to the fabricated reflector surface a reflecting agent which satisfies electrical predetermined parameters of the antenna reflector.
Claim 4
Independent Claim
136 words
A method for fabricating a dish-shaped antenna reflector having a reflector surface of predetermined parameters, comprising the steps of: a. fabricating an inflatable mold structure which has in the inflated state a mold surface which corresponds to the predetermined parameters of the reflector surface, and inflating the fabricated mold; b. applying to the mold surface a continuous layer of polyester resin gel-coat to a predetermined thickness; c. applying a first layer of material comprising a fiber-reinforced resinous laminate to a predetermined thickness; d. embedding into place radially and concentrically arranged internal reinforcement ribbing pieces in a continuous foamable casting substance; e. applying a second layer of material comprising a fiber-reinforced resinous laminate; and f. deflating the mold and applying to the fabricated reflector surface a reflecting agent which satisfies electrical predetermined parameters of the antenna reflector.
Claim 5
Dependent Claim
46 words
The method according to claim 2 wherein the continuous foamable casting substance is polyurethane foam, and further including securing at least the radial ones of said ribbing pieces to the mold surface by way of fiber cloth fillets prior to the application of the polyurethane foam.
Claim 6
Dependent Claim
44 words
The method according to claim 3 wherein the polyurethane foam is sectionally applied, working circumferentially and radially outward from the center of the mold surface to the edges thereof, with the concentrically arranged ribbing pieces being correspondingly arranged in place in the sectional applications.
Claim 7
Dependent Claim
31 words
The method according to claim 4 further including allowing a predetermined time for curing and stabilization to occur before proceeding with the application of said second layer of fiber-reinforced resinous laminate.
Claim 8
Dependent Claim
27 words
The method according to claim 4 further including removing excess polyurethane, dust and loose particles prior to the application of said second layer of fiber-reinforced resinous laminate.
Claim 9
Dependent Claim
32 words
The method according to claim 4 further including constructing the radially and concentrically arranged reinforcement ribbing pieces with apertures therein so as to provide a continuity in the polyurethane foam between sections.
Claim 10
Dependent Claim
15 words
The method according to claim 7 wherein said ribbing pieces are constructed from lightweight plywood.
Claim 11
Dependent Claim
22 words
The method according to claim 7 wherein said ribbing pieces are fabricated by spray-applying a fiber-reinforced resinous material over inflatable rib structures.
Claim 12
Dependent Claim
54 words
The method according to claim 2 wherein the center area of the mold surface corresponds to the vertex of the reflector surface, and further including pLacing a structural mount, for mounting the antenna reflector to a mount assembly, at the vertex and embedding partially into place said structural mount along with said ribbing pieces.
Claim 13
Dependent Claim
43 words
The method according to claim 2 wherein a releasing agent is applied to the mold surface prior to the application of the continuous layer of polyester material thereto, so as to effect a separation of the fabricated reflector from the mold without difficulty.
Claim 14
Dependent Claim
15 words
The method according to claim 11 wherein the mold is impregnated with the releasing agent.
Claim 15
Dependent Claim
52 words
The method according to claim 11 further including providing the inflated mold with a variable pressurization and regulator system for compensating for volume changes in the mold due to leakage of the mold inflatant, temperature or atmospheric pressure changes etc., so as to render the mold shape unchanging in the inflated state.
Claim 16
Dependent Claim
28 words
The method according to claim 11 wherein said continuous layer of polyester material is applied in a plurality of successive layers each having substantially equal and predetermined depth.
Claim 17
Dependent Claim
17 words
The method according to claim 14 wherein an ultraviolet radiation repellant is included with said polyester material.
Claim 18
Dependent Claim
47 words
The method according to claim 11 wherein the resinous laminate of said first and second layers thereof is comprised of polyester resin, and wherein the polyester resin is applied starting substantially at the center of the mold surface and gradually winding radially and circumferentially outward in sections.
Claim 19
Dependent Claim
25 words
The method according to claim 16 wherein the fiber-reinforcement of the resinous laminate is provided by fiberglass strands applied in conjunction with the polyester resin.
Claim 20
Dependent Claim
25 words
The method according to claim 16 wherein the fiber-reinforcement of the resinous laminate is provided by fiberglass cloth laid in conjunction with the polyester resin.
Claim 21
Dependent Claim
25 words
The method according to claim 18 further including rolling and deaerating in conjunction with the application of the polyester resin and the fiberglass cloth reinforcement.
Claim 22
Dependent Claim
38 words
The method according to claim 17 wherein said fiber-reinforced polyester resin is applied in a predetermined number of successive layers each having substantially the same depth, and where said second fiber-reinforced resinous laminate includes an ultraviolet radiation repellant.
Claim 23
Dependent Claim
27 words
The method according to claim 17 further including touching-up the reflector surface, following deflation of the mold, as required with polyester resin containing an ultraviolet radiation repellant.
Claim 24
Dependent Claim
24 words
The method according to claim 19 wherein the reflecting agent is applied on the reflector surface by spray-metalizing with aluminum to a predetermined thickness.
Claim 25
Dependent Claim
46 words
The method according to claim 17 wherein the application of the continuous layer of polyester material on the mold surface, the application of the first and second layers of fiber-reinforced resinous laminate, and the application of the continuous foamable casting substance are effected by spray application.
Claim 26
Independent Claim
123 words
A method for fabricating an antenna reflector having a reflector surface of predetermined parameters, comprising the steps of: a. applying to a mold surface having a curvature corresponding to the predetermined parameters of the reflector surface a continuous layer of polyester material having an ultraviolet radiation repellant to a predetermined thickness; b. applying a first layer of material comprising a fiber-reinforced resinous laminate to a predetermined thickness; c. applying a layer of continuous foamable casting material having a predetermined density and thickness; d. applying a second layer of material comprising a fiber-reinforced resinous laminate to a predetermined thickness, said second layer of material including an ultraviolet radiation repellant; and e. applying to the fabricated reflector surface a continuous layer of a reflecting agent.
Claim 27
Independent Claim
123 words
A method for fabricating an antenna reflector having a reflector surface of predetermined parameters, comprising the steps of: a. applying to a mold surface having a curvature corresponding to the predetermined parameters of the reflector surface a continuous layer of polyester material having an ultraviolet radiation repellant to a predetermined thickness; b. applying a first layer of material comprising a fiber-reinforced resinous laminate to a predetermined thickness; c. applying a layer of continuous foamable casting material having a predetermined density and thickness; d. applying a second layer of material comprising a fiber-reinforced resinous laminate to a predetermined thickness, said second layer of material including an ultraviolet radiation repellant; and e. applying to the fabricated reflector surface a continuous layer of a reflecting agent.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1977-12-16 | 1978-06-17 | 1978-12-17 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1981-12-16 | 1982-06-17 | 1982-12-17 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1985-12-16 | 1986-06-17 | 1986-12-17 | $7700.00 | Window Closed / Lapsed |