CN104205497B - 可注射成型的锥形辐射器次反射器组件 - Google Patents

可注射成型的锥形辐射器次反射器组件 Download PDF

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CN104205497B
CN104205497B CN201380017752.2A CN201380017752A CN104205497B CN 104205497 B CN104205497 B CN 104205497B CN 201380017752 A CN201380017752 A CN 201380017752A CN 104205497 B CN104205497 B CN 104205497B
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secondary reflectors
cone
distal end
radiation device
dielectric block
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CN104205497A (zh
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A·赖特
J·柯伦
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TE Connectivity Corp
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Tyco Electronics Corp
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01Q—ANTENNAS, i.e. RADIO AERIALS
    • H01Q15/00—Devices for reflection, refraction, diffraction or polarisation of waves radiated from an antenna, e.g. quasi-optical devices
    • H01Q15/14—Reflecting surfaces; Equivalent structures
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01Q—ANTENNAS, i.e. RADIO AERIALS
    • H01Q19/00—Combinations of primary active antenna elements and units with secondary devices, e.g. with quasi-optical devices, for giving the antenna a desired directional characteristic
    • H01Q19/10—Combinations of primary active antenna elements and units with secondary devices, e.g. with quasi-optical devices, for giving the antenna a desired directional characteristic using reflecting surfaces
    • H01Q19/18—Combinations of primary active antenna elements and units with secondary devices, e.g. with quasi-optical devices, for giving the antenna a desired directional characteristic using reflecting surfaces having two or more spaced reflecting surfaces
    • H01Q19/19—Combinations of primary active antenna elements and units with secondary devices, e.g. with quasi-optical devices, for giving the antenna a desired directional characteristic using reflecting surfaces having two or more spaced reflecting surfaces comprising one main concave reflecting surface associated with an auxiliary reflecting surface
    • H01Q19/193—Combinations of primary active antenna elements and units with secondary devices, e.g. with quasi-optical devices, for giving the antenna a desired directional characteristic using reflecting surfaces having two or more spaced reflecting surfaces comprising one main concave reflecting surface associated with an auxiliary reflecting surface with feed supported subreflector

Abstract

提供了一种用于具有波导支撑的次反射器的反射器天线的电介质锥形辐射器次反射器组件，作为在远端具有次反射器的单元电介质块。电介质块的波导过渡部分的尺寸被形成为插入耦接于波导的端部之内。电介质块的次反射器支撑部分和波导过渡部分设置有与组件的纵轴同轴的多个纵向筋条和凹槽；纵向的凹槽向电介质块的近端敞开。单元电介质块可以经由注射成型制造为单个邻接的单块电介质材料部分。

Description

可注射成型的锥形辐射器次反射器组件
技术领域
本发明涉及微波双反射器天线。更特别地，本发明为此类适合于经由注射成型进行的有成本效益制造的天线提供自支撑馈电锥形辐射器。
背景技术
采用自支撑馈电的双反射器天线将入射到主反射器上的信号引导到安装于主反射器的焦点区域的相邻处的次反射器上，该次反射器进而典型地经由接收器的第一级的馈电喇叭或孔口将信号引导到波导传输线之内。当双反射器天线被用来传输信号时，信号经由波导从发射系统的末级传播到馈电孔口、次反射器和主反射器以释放空间。
反射器天线的电性能的特征典型地在于其增益、辐射图、交叉极化和回波损耗性能-效率增益、辐射图及交叉极化特性对于高效的微波链路规划和协调是必需的，然而良好的回波损耗对于高效的无线电操作是必要的。
这些主要特性由结合主反射器轮廓而设计的馈电系统确定。
在2000年8月22日颁发的、题目为“Dual-Reflector Microwave Antenna”的共同所有的美国专利6,107,973示出了一种馈电组件，在该馈电组件中次反射器由与支撑波导的端部耦接的电介质漏斗支撑。仅起着支撑结构的作用，电介质漏斗变得阻抗不连续，该阻抗不连续必须要进行补偿，因为次反射器及反射器圆盘的表面轮廓和直径单独地被用来使RF路径成形，从而导致次反射器和/或反射器圆盘的增大直径。随着次反射器尺寸增加，由沿着反射器天线的视轴的次反射器引起的RF信号路径堵塞变得显著。此外，所产生的反射器天线的增大的整体尺寸需要对反射器天线以及反射器天线可以安装于其上的支撑结构进行的附加的增强结构考虑。
深圆盘型反射器是其中使反射器焦距(F)与反射器直径(D)之比变得小于或等于0.25(与典型地见于更常规的圆盘设计中的0.35的F/D相反)的反射器圆盘。配置用于与深圆盘型反射器一起使用的电介质锥形馈电次反射器组件的实例被公开于在2005年7月19日颁发给Hills的、题目为“Tuned Perturbation Cone Feed for Reflector Antenna”的共同所有的美国专利6,919,855中，该专利全文以提及方式并入本文。US 6,919,855使用具有次反射器表面和导入锥表面的电介质块锥形馈电，该前导锥表面具有关于电介质块的纵轴同心的多个向下倾斜的非周期性扰动。但是，在电介质块中的该多个成角的特征和/或台阶需要可能增加总制造成本的复杂的机床制造过程。
因此，本发明的目的是提供用于克服现有技术的局限的装置，并且在这样做时给出允许这样的馈电设计提供满足在用于典型的微波通信链路的整个工作频段之上的最严格的电气规范的反射器天线特性的解决方案。
附图说明
并入并构成本说明书的一部分的附图示出了本发明的实施例，其中相同的附图标记在附图中指的是同一特征或元件并且可以不针对它们出现于其中的每个附图进行详细描述，并且连同以上给出的关于本发明的一般描述以及以下给出的关于实施例的详细描述一起用来解释本发明的原理。
图1是示例性的可注射成型的电介质锥形辐射器组件的示意性剖切面等轴视图。
图2是图1的可注射成型的电介质锥形辐射器组件的示意性正视图。
图3是沿图2的直线A-A截取的图1的可注射成型的电介质锥形辐射器组件的示意性剖切面视图。
图4是具有分离的次反射器盘的可替换的示例性可注射成型的电介质锥形辐射器组件的示意性剖切面等轴视图。
图5是图4的可注射成型的电介质锥形辐射器组件的示意性正视图。
图6是沿图5的直线A-A截取的图4的可注射成型的电介质锥形辐射器组件的示意性剖切面视图。
图7是可替换的电介质块配置的示意性剖切面等轴视图。
图8是次反射器耦接于远端的图7的电介质块的远端视图。
图9是沿图8的直线A-A截取的图8的电介质块和次反射器的示意性侧剖面全貌图。
具体实施方式
本发明人已经认识到，利用单元电介质块进行的锥形辐射器次反射器组件设计的改进典型地由于这些设计的增加的尺寸和复杂性而需要通过机械加工来制造电介质块。
当在现有的电介质块类型的锥形辐射器次反射器组件设计上尝试制造的注射成型和/或铸造法时，增大的尺寸会产生电介质聚合物材料的凝结方面的问题，例如，空洞、裂纹、表面缩凹、维度弯曲和/或流挂。此外，在设计使用用于抑制模具分离的特征(例如，悬突于相对边之上和/或与它们紧密靠近)的情形中，所需要的模型，如果有可能，可能会变得太过复杂以致没有成本效益。
如图1-6所示，锥形辐射器次反射器组件1可以被配置用于在用于在远端20处支撑次反射器15的单元电介质块10的波导过渡部分5处与馈电臂波导(feed boom waveguide)的端部耦接。次反射器15和支撑次反射器的支撑部分30为了降低次反射器溢失(spill-over)而设置有放大的直径。
电介质辐射器部分25位于波导过渡部分5与次反射器支撑部分30之间。多个褶皱沿着电介质辐射器部分的外径而设置，作为径向凹槽35。在本实施例中，该多个凹槽是两个径向凹槽35。电介质辐射器部分25的远端凹槽40可以设置有用于发起次反射器支撑部分30的远端侧壁45。为了能够使模具分离变得顺利，凹槽40可以设置有锥度，该锥度使凹槽宽度朝着电介质辐射器部分25的外径而增大。
次反射器组件1的波导过渡部分5可以适合于与所期望的圆形波导内直径匹配，使得次反射器组件1可以适配于波导端部之内并由其保持，该波导端部支撑在反射器天线的圆盘反射器内的紧邻圆盘反射器的焦点的次反射器组件1。波导过渡部分5可以插入波导3之内，直到波导的端部邻接波导过渡部分5的肩部55。
肩部55可以将尺寸形成为使电介质辐射器部分25与波导端部间隔开。
在波导过渡部分5的近端65处的一个或多个阶梯60可以应用于电介质块10的透镜膛孔70，以为了在波导与电介质块10的电介质材料之间的阻抗匹配目的而形成反转阻抗变换器(inverted impedance transformer)75。
透镜膛孔70从电介质块10的近端65向电介质块10的远端20至少延伸到次反射器支撑部分30。由此，形成在波导3与电介质辐射器部分25之间的直接路径，从而允许通过例如应用于径向凹槽35的深度和/或电介质辐射器部分25的直径来调整经由该直接路径发射出的辐射图。优选地，如同图3和6最佳示出的，径向凹槽35径向向内扩展到比波导端部的内径小的直径。
本领域技术人员应当理解，电介质辐射器部分25与穿过其中的透镜膛孔70结合产生了电介质透镜效果，在该电介质透镜效果中电介质辐射器部分25的尺寸增强了穿过电介质辐射器部分25从次反射器组件1安装于其内的反射器圆盘投射到次反射器15的或者从次反射器15投射到反射器圆盘的主辐射图，由此帮助次反射器组件1的RF辐射图的成形并减小次反射器15的直径。
如图4-6所示，可以设置完全延伸穿过在近端65与远端20之间的电介质块10的透镜膛孔70。
如同图3最佳示出的，次反射器15可以通过将金属沉积、膜、板或其他RF反射涂层施加于电介质块10的远端20而形成。作为选择，如图4和6所示，次反射器15可以单独地形成为例如座落于电介质块10的远端上的金属圆盘80。圆盘80可以包含用于与透镜膛孔70键锁在一起以将次反射器15同轴定位于电介质块10的远端20之上的键部分85。
作为在电介质块10的截面的边界之内的潜在最大直径的内切圆M而示出的，该圆的中心点一般是距电介质块10的边缘最远的点，最大的材料厚度。因而，中心点是电介质材料在电介质块10的注射成型的过程中通常将最后固化/凝固的位置。最大的材料厚度在图3和6的实施例中出现于远端侧壁45与远端20之间的位置处。相比之下，单块电介质块锥的先前实施例的最大材料厚度大得多，典型为至少波导端部的整个内径。本领域技术人员应当理解，透镜膛孔70与加深的径向凹槽35的结合可以显著地减小电介质块10的最大材料厚度，从而能够经由注射成型来制造具有减少的空洞、裂纹、表面缩凹、维度弯曲和/或流挂缺陷的电介质块10。作为选择，电介质块10可以通过铸造和/或机械加工来制造，所述铸造和/或机械加工方法可以类似地获益于所需要的模具/工具分离/接近的共同角度、较浅边缘角和/或表面过渡数量。
本领域技术人员应当理解，电介质块10作为选择可以形成为具有纵向凹槽而不是径向凹槽，以进一步简化通过具有减小的最大材料厚度的注射成型进行的制造。如同例如图7和9所示的，多个纵向凹槽90和纵向筋条95在它们之间可以被施加为与电介质块10的纵轴同轴的。鉴于由纵向凹槽90而非径向凹槽进行的电介质块10的分割，波导过渡部分5和次反射器支撑部分30的特征分别是内同轴部分和外同轴部分，被形成尺寸以座落于例如波导的内径之内的用于与其耦接的波导过渡部分5的外径以及在电介质块10的这些表面和外围之间的部分作为次反射器支撑部分30来起作用。
纵向凹槽90每个均朝电介质块10的近端65敞开。因而，在电介质块10的注射成型的过程中，在纵向凹槽90与近端65之间不存在悬突特征物的情况下，模具分离可以沿着电介质块10的纵轴，从而允许两个部分的模具并且局部化可能出现于电介质块10的外围的任意模具溢料(mold flash)，而不是潜在地难以沿着可能存在于图3和6的径向凹槽实施例的电介质块10内的每个凹槽纵向地去除溢料。为了便于模具分离，纵向凹槽90可以设置有锥度。
波导过渡部分5的纵向筋条95和/或纵向凹槽90的纵向长度(longitudinalextent)可以被选择以为了在波导与电介质块10的电介质材料之间的阻抗匹配目的而提供阻抗变换器75。
朝向电介质块10的近端65的次反射器支撑部分30的纵向筋条95的纵向长度在次反射器支撑部分30的内径和外围之间缩短。此外，可以使次反射器支撑部分的纵向筋条的前导边缘形成角度以形成最大直径朝向远端20的大体为圆锥形的表面，该多个纵向筋条95共同形成了用于次反射器支撑部分的大体为圆锥形的表面轮廓。作为选择，纵向筋条95可以将尺寸形成为根据电性能的需要创建可替换的表面轮廓，包括，例如，交错式或平面式表面轮廓。
如图9所示，例如，在电介质块10的最大材料厚度M出现于一对纵向凹槽90的远端20与次反射器15之间的情况下，纵向凹槽90的深度可以被选择以获得在电性能、必要强度和最大材料厚度之间的平衡。
如同径向凹槽的实施例那样，在纵向凹槽的实施例中，次反射器15可以被提供作为在电介质块10的远端20之上的金属涂层或者作为与电介质块10的远端20耦接的单独的金属盘。纵轴模具分离还使得次反射器15能够适配于电介质块模具之内并且通过注射成型而与其耦接。
根据上文，应当清楚，本发明为本技术领域带来了用于具有显著有制造成本效益的潜力的反射器天线的次反射器组件1。根据本发明的次反射器组件1是坚固的、重量轻的并且可以经由例如注射成型技术以很高的精度水平来重复地、有成本效益地制造。
部件表
1 次反射器组件
5 波导过渡部分
10 电介质块
15 次反射器
20 远端
25 电介质辐射器部分
30 次反射器支撑部分
35 径向凹槽
40 远端凹槽
45 远端侧壁
55 肩部
60 阶梯
65 近端
70 透镜膛孔
75 阻抗变换器
80 圆盘
85 键部分
90 纵向凹槽
95 纵向筋条
在前述描述已经参照了具有已知的等效形式的材料、比率、整数或构件的情况下，则这样的等效形式就如同单独阐述那样并入此处。
虽然本发明已经通过关于其实施例的描述进行了说明，并且虽然这些实施例已经进行了相当详细的描述，但是本申请人的目的并不是要将所附权利要求书的范围约束于或以任何形式限制于这样的细节。另外的优点和修改对本领域技术人员而言将是显而易见的。因此，本发明在其更宽泛的方面中并不限制于所示出的及所描述的具体的细节、有代表性的装置、方法和说明性的实例。因此，在不脱离本申请人的总体发明概念的精神或范围的情况下，可以对这样的细节进行更改。此外，应当理解，在不脱离由所附权利要求书所限定的本发明的范围或精神的情况下，可以对本发明进行改进和/或修改。

Claims (14)

1.一种锥形辐射器次反射器组件，用于具有由波导支撑的次反射器的反射器天线，包括：
单元电介质块；
设置于所述单元电介质块的远端的次反射器；
所述单元电介质块的波导过渡部分，其尺寸被形成为插入耦接到所述波导的端部中；以及
支撑所述次反射器的所述单元电介质块的次反射器支撑部分；
其中所述次反射器支撑部分和所述波导过渡部分设置有与所述锥形辐射器次反射器组件的纵轴同轴的多个纵向筋条和纵向凹槽；其中该纵向凹槽朝所述单元电介质块的近端敞开；其中朝向所述电介质块的所述近端的所述次反射器支撑部分的所述纵向筋条的纵向长度在所述次反射器支撑部分的内径和外围之间缩短；并且其中所述次反射器支撑部分的所述纵向筋条的前导边缘被形成角度以形成朝向所述单元电介质块的所述远端的具有最大直径的锥形表面。
2.根据权利要求1所述的锥形辐射器次反射器组件，其中所述波导过渡部分的所述纵向筋条的纵向长度的尺寸被形成为提供阻抗变换器。
3.根据权利要求1所述的锥形辐射器次反射器组件，其中所述单元电介质块的最大材料厚度出现于一对所述纵向的凹槽的远端与所述次反射器之间。
4.根据权利要求1所述的锥形辐射器次反射器组件，其中所述纵向的凹槽是锥形的。
5.根据权利要求1所述的锥形辐射器次反射器组件，其中所述次反射器是在所述单元电介质块的所述远端之上的金属涂层。
6.根据权利要求1所述的锥形辐射器次反射器组件，其中所述次反射器是与所述单元电介质块的所述远端耦接的单独的金属盘。
7.一种用于制造根据权利要求1的锥形辐射器次反射器组件的方法，该锥形辐射器次反射器组件用于具有由波导支撑的次反射器的反射器天线，所述方法包括以下步骤：
将所述单元电介质块注射成型；以及
将所述次反射器耦接至所述单元电介质块的所述远端。
8.根据权利要求7所述的方法，其中所述次反射器的耦接经由应用在所述单元电介质块的所述远端之上的金属沉积来进行。
9.根据权利要求7所述的方法，其中所述次反射器是与所述电介质块的所述远端耦接的单独的金属盘。
10.根据权利要求7所述的方法，其中所述单元电介质块的最大材料厚度出现于所述纵向的凹槽之一的远端与所述次反射器之间。
11.根据权利要求7所述的方法，其中所述纵向的凹槽是锥形的。
12.根据权利要求7所述的方法，其中所述次反射器的耦接经由将单独的金属次反射器定位于所述单元电介质块的所述远端之上来进行。
13.根据权利要求7所述的方法，其中所述次反射器的耦接经由将所述次反射器插入用于形成所述电介质块的注射成型模具之内来进行。
14.根据权利要求7所述的方法，其中所述电介质块的注射模具具有沿着所述电介质块的所述纵轴分离的两个部分。
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