Foldable radome

Abstract

In one embodiment, a foldable radome sub-assembly for an antenna reflector dish has flexible material connected to a plurality of rigid rim segments. Connection elements (e.g., inserts) are configured to interconnect two adjacent rim segments, such that, with the connection elements applied, the radome sub-assembly is configured as a radome connectable to the antenna reflector dish, and, without the connection elements applied, the radome sub-assembly is foldable between adjacent rim segments. The foldable radome sub-assembly can be folded up for efficient storage and shipping, yet is easy to configure in the field into a rigid radome for attachment to an antenna reflector dish.

Claims

1. A foldable radome for an antenna reflector dish, the foldable radome comprising: a radome sub-assembly comprising: a plurality of rigid rim segments; and flexible material connected to the rim segments; and a plurality of connection elements, each configured to interconnect two adjacent rim segments, such that: with the connection elements applied, the radome sub-assembly is configured as a radome connectable to the antenna reflector dish; and without the connection elements applied, the radome sub-assembly is foldable between adjacent rim segments, wherein each connection element is configured such that a diameter of the radome sub-assembly increases as each connection element engages the two adjacent rim segments to remove slack in the flexible material, and wherein one or both of the connection elements and the rim segments have angled surfaces configured to engage corresponding surfaces to increase the diameter of the radome sub-assembly.

2. The foldable radome of claim 1, wherein both the connection elements and the rim segments have the angled surfaces.

3. The foldable radome of claim 1, wherein each connection element is configured such that the connection element locks into place after being applied to the two adjacent rim segments.

4. The foldable radome of claim 3, wherein each connection element locks into place using snap-fit mechanisms.

5. The foldable radome of claim 1, wherein each rim segment comprises a number of slots for receiving tabs of the flexible material by which the flexible material is secured to the rim segment.

6. The foldable radome of claim 1, wherein the radome sub-assembly comprises four rim segments, such that: with the connection elements applied, the radome sub-assembly is configured as a circular radome; and without the connection elements applied, the radome sub-assembly is foldable into a single quadrant shape.

7. A method of assembling a radome for an antenna reflector dish, the method comprising: (a) providing a foldable radome sub-assembly in a folded configuration, the foldable radome sub-assembly comprising: a plurality of rigid rim segments; and flexible material connected to the rim segments; (b) unfolding the foldable radome; and (c) applying a connection element to each pair of adjacent rim segments to configure the radome sub-assembly into the radome connectable to the antenna reflector dish, wherein each connection element is configured such that a diameter of the radome sub-assembly increases as the connection element engages the pair of adjacent rim segments to remove slack in the flexible material, and wherein one or both of the connection elements and the rim segments have angled surfaces configured to engage corresponding surfaces to increase the diameter of the radome sub-assembly.

8. The method of claim 7, wherein both the connection elements and the rim segments have the angled surfaces.

9. The method of claim 7, wherein each connection element is configured such that the connection element locks into place after being applied to the pair adjacent rim segments.

10. The method of claim 9, wherein each connection element locks into place using snap-fit mechanisms.

11. The method of claim 7, wherein each rim segment comprises a number of slots for receiving tabs of the flexible material by which the flexible material is secured to the rim segment.

12. The method of claim 7, wherein the radome sub-assembly comprises four rim segments, such that: with the connection elements applied, the radome sub-assembly is configured as a circular radome; and without the connection elements applied, the radome sub-assembly is foldable into a single quadrant shape.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Other embodiments of the invention will become more fully apparent from the following detailed description, the appended claims, and the accompanying drawings in which like reference numerals identify similar or identical elements.

(2) FIG. 1 is a schematic isometric view of an exemplary foldable radome.

(3) FIG. 2 is a schematic back view of the foldable radome of FIG. 1, face removed for clarity.

(4) FIG. 3 is a schematic back view of a rim segment of the foldable radome of FIG. 1.

(5) FIG. 4 is a schematic isometric view of the rim segment of FIG. 3.

(6) FIG. 5 is a close-up view of an end of the rim segment of FIG. 3.

(7) FIG. 6 is a schematic back view of an insert connector of the foldable radome of FIG. 1.

(8) FIG. 7 is a schematic isometric view of the insert connector of FIG. 6.

(9) FIG. 8 is a close-up view of the foldable radome of FIG. 1, showing detail of the coupling of a radial tab to the radome face.

(10) FIG. 9 is a back view of the foldable radome of FIG. 1, folded into a compact parcel.

(11) FIG. 10 is a side view of an alternative insert connector.

(12) FIG. 11 is a side view of an alternative design for the ends of the peripheral rim segments.

(13) FIG. 12 is an isometric exploded view of the insert connect of FIG. 10 and the ends of two adjacent rim segments of FIG. 11.

(14) FIGS. 13A-13D show a sequence of exemplary steps involved in folding an exemplary foldable radome of the present disclosure.

(15) FIG. 14 is an isometric exploded view of a reflector antenna configured with a foldable radome 1 of the present disclosure.

DETAILED DESCRIPTION

(16) As shown in FIGS. 1-9, a radome 1 with a face 3 of fabric material is provided with a supporting peripheral rim 5 for ease of installation and/or removal as an integral radome assembly. The peripheral rim 5 is formed from a plurality of (in this embodiment, four) rim segments 7 (see FIGS. 3 and 4), each adjacent pair of which may be joined end to end by an insert connector 9 (see FIG. 7) which snap fits into a connector seat 11, best shown in FIG. 5, provided at each end of the rim segments 7. In alternative embodiments, the number of rim segments 7 may be any suitable (e.g., even) number of rim segments greater than one.

(17) The rim segments 7 and/or insert connectors 9 may be cost efficiently manufactured, for example, via injection molding of a suitable polymer material, such as (without limitation) polycarbonate.

(18) As best shown in FIG. 8, the fabric material of the face 3 may be securely coupled to the rim segments by looping radial tabs 13 of the fabric material provided at the fabric material periphery around the rim segments 7, through tab slots 15 of the rim segments 7 and radially inward face to face with the fabric material of the face 3. The radial tabs 13 may be securely coupled to the fabric material of the face 3 by, for example, stud, heat fusing, adhesive, radio frequency or ultrasonic welding, or the like. Alternatively, the fabric of the face 3 may be coupled directly to the rim segments 7 by, for example, heat fusing, adhesive, radio frequency or ultrasonic welding, or the like. The attachment points are arranged and the fabric dimensioned therebetween to tension the face 3 upon assembly of the radome 1 to resist movement of the fabric material of the face 3 in response to winds or the like

(19) With the fabric material of the face 3 pre-attached to the rim segments 7, but the rim segments 7 not yet interconnected end to end, the rim segments 7 and face 3 may be collected into a compact parcel 21 by folding the face 3, for example, into quarters, and aligning the rim segments one upon the other, as shown, for example, in FIG. 9.

(20) At the installation site, the compact parcel of the folded face 3 with attached rim segments 7 is unfolded, and the rim segments aligned spaced apart from one another for interconnection by snap fitting the insert connectors 9 into the connector seats 11 while pulling the rim segments 7 apart from one another, thereby tensioning the central portion of the face 3 between the rim segments 7.

(21) The snap fit between the rim segments 7 and the insert connectors 9 may be, for example, via connection tabs 17 (FIG. 7) protruding from the insert connectors 9 which seat within corresponding sockets 19 (FIG. 4) or shoulders of the ends of the rim segments 7. Alternatively, a wedge shaped insert or cam system may be applied to tension the face 3.

(22) FIGS. 10-12 represent an alternative scheme for interconnecting adjacent rim segments for a foldable radome. As shown in FIG. 10, insert connector 9 includes middle section 2 and two opposing wing sections 4, each having a flexible tab 17. As shown in FIGS. 11 and 12, each rim segment 7 has a slotted end 10 having two side walls 14, one of which has an opening 12 designed to receive flexible tab 17 of insert connector 9. Actually, each rim segment 7 has two slotted ends 10, one on each end, for connecting to two other rim segments 7.

(23) As best seen in FIG. 12, to secure two adjacent rim segments 7 together, each wing section 4 of insert connector 9 is inserted into the slotted end 10 of one of the rim segments 7 until its flexible tab 17 is received within the corresponding opening 12 in a snap-fit manner, thereby securing insert connector 9 in place and maintaining the circumferential alignment between the two rim segments 7.

(24) As shown in FIGS. 10 and 11, the outer edges 6 of the wing sections 4 and the outer walls 8 of the middle section 2 of insert connector 9 are slanted, and the outer edge 16 of each slotted end 10 of each rim segment 7 is similarly slanted, such that, as insert connector 9 is inserted into the slotted ends 10 of two adjacent rim segments 7 (as best seen in FIG. 12), the slanted structures of the insert connector 9 engage corresponding structures on the two rim segments 7 to push the rim segments 7 further apart, thereby increasing the circumference and the diameter of the radome assembly and stretching the radome fabric to achieve a desired level of tension within the radome face 3. FIG. 12 also shows portions 23 and 25 of the fabric material that forms radome face 3. Portion 23 is part of the fabric material that wraps around the radome rim, while portion 25 is a tab of fabric material that aligns with and is fastened to the hole in middle section 2 of insert connector 9 in order to keep the radome face 3 from flapping in the wind.

(25) Referring to FIGS. 13A-13D, the foldable radome 1 of FIG. 13A (with no connection inserts applied) can be folded in half (as in FIG. 13B) and then in half again (as in FIG. 13C). The folded fabric face 3 can then be folded (as in FIG. 13D) to provide an even smaller folded assembly. One skilled in the art will appreciate that the foldable radomes of this disclosure, like radome 1, provide improvements in pre-assembly area, which may reduce inventory and/or shipping costs. Further, the total material requirements may be reduced with respect to traditional rigid and semi-rigid radome configurations, without significantly increasing installation labor requirements.

(26) Unless explicitly stated otherwise, each numerical value and range should be interpreted as being approximate as if the word about or approximately preceded the value or range.

(27) It will be further understood that various changes in the details, materials, and arrangements of the parts which have been described and illustrated in order to explain embodiments of this invention may be made by those skilled in the art without departing from embodiments of the invention encompassed by the following claims.

(28) In this specification including any claims, the term each may be used to refer to one or more specified characteristics of a plurality of previously recited elements or steps. When used with the open-ended term comprising, the recitation of the term each does not exclude additional, unrecited elements or steps. Thus, it will be understood that an apparatus may have additional, unrecited elements and a method may have additional, unrecited steps, where the additional, unrecited elements or steps do not have the one or more specified characteristics.

(29) The use of figure numbers and/or figure reference labels in the claims is intended to identify one or more possible embodiments of the claimed subject matter in order to facilitate the interpretation of the claims. Such use is not to be construed as necessarily limiting the scope of those claims to the embodiments shown in the corresponding figures.

(30) Reference herein to one embodiment or an embodiment means that a particular feature, structure, or characteristic described in connection with the embodiment can be included in at least one embodiment of the invention. The appearances of the phrase in one embodiment in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments necessarily mutually exclusive of other embodiments. The same applies to the term implementation.

(31) The embodiments covered by the claims in this application are limited to embodiments that (1) are enabled by this specification and (2) correspond to statutory subject matter. Non-enabled embodiments and embodiments that correspond to non-statutory subject matter are explicitly disclaimed even if they fall within the scope of the claims.