US20200381815A1

US20200381815A1 - Antenna apparatus housing and components for same

Info

Publication number: US20200381815A1
Application number: US16/893,317
Authority: US
Inventors: David Milroy; Duncan E. Adams; Keith R. Miller; Ersin YETISIR; Anthony Sims; Trevor Cameron; Andrea PAPI
Original assignee: Space Exploration Technologies Corp
Current assignee: Space Exploration Technologies Corp
Priority date: 2019-06-03
Filing date: 2020-06-04
Publication date: 2020-12-03
Also published as: US11652286B2; US20230048947A1; WO2020247558A2; DE112020002719T5; US20200381799A1; WO2020247558A3; US20200381842A1; US20200381814A1; US11322833B2; US11509048B2; US11600915B2; US20200381816A1; US20200381831A1; US20200381817A1; US11843168B2; US20230223680A1

Abstract

In embodiments of the present disclosure, a housing for an antenna system having a plurality of antenna elements defining an antenna aperture includes: a chassis portion; and a radome portion configured for coupling to the chassis portion to define an inner chassis chamber. In some embodiments, the radome portion has a planar top surface. In other embodiments, the chassis portion has an internal support portion for internal components. In other embodiments, an antenna apparatus includes a mounting system for tiltably mounting the housing relative to a horizontal plane.

Description

CROSS-REFEREENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No. 62/856,730, filed Jun. 3, 2019, the disclosure of which is expressly incorporated by reference herein in its entirety.

SUMMARY

Embodiments of apparatuses and methods relate to an antenna apparatus for sending and receiving radio frequency (RF) signals, including components of the antenna apparatus.
In one embodiment of the present disclosure, a housing for an antenna system having a plurality of antenna elements defining an antenna aperture is provided. The housing includes: a chassis portion; and a radome portion configured for coupling to the chassis portion to define an inner chassis chamber, the radome portion having a planar top surface, wherein the radome is configured to have equal spacing between the planar top surface and a top surface of each of the plurality of antenna elements defining the antenna aperture.
In another embodiment of the present disclosure, a housing for an antenna system having a plurality of antenna elements defining an antenna aperture is provided. The housing includes: a chassis portion having an internal support portion for internal components for the plurality of antenna elements including a bonding portion for bonding an internal carrier to the chassis portion; and a radome portion configured for coupling to the chassis portion to define an inner chassis chamber.
In another embodiment of the present disclosure, an antenna apparatus for an antenna system having a plurality of antenna elements defining an antenna aperture is provided. The antenna apparatus includes: a housing including a chassis portion and a radome portion configured for coupling to the chassis portion to define an inner chassis chamber; and a mounting system for tiltably mounting the housing relative to a horizontal plane.
In any of the embodiments described herein, the radome portion may include a first layer and a second layer.
In any of the embodiments described herein, the first layer may be a protective layer.
In any of the embodiments described herein, the first layer may be made from a fiberglass-reinforced epoxy laminate material.
In any of the embodiments described herein, the first layer may have a thickness selected from the group consisting of less than 1.5 mm, less than 0.76 mm, less than 0.51 mm, and less than 0.25 mm.
In any of the embodiments described herein, the first layer may include a hydrophobic outer surface.
In any of the embodiments described herein, the second layer may be a spacing layer.
In any of the embodiments described herein, the second layer may be made from a polymethacrylimide foam.
In any of the embodiments described herein, the second layer may have a thickness selected from the group consisting of greater than 3.0 mm, less than 4.5 mm, or in the range of 3.0 mm to 4.5 mm.
In any of the embodiments described herein, the radome portion may be tilted relative to a horizontal plane.
In any of the embodiments described herein, the radome portion may couple with the chassis portion at a bezel surface on the chassis portion.
In any of the embodiments described herein, the radome portion may be sealed to the chassis portion at a bezel surface on the chassis portion.
In any of the embodiments described herein, an outer edge of the second radome layer may be set inward from the outer edge of the first radome layer to provide an outer radome lip.
In any of the embodiments described herein, the outer radome lip may couple with the chassis portion at a bezel surface on the chassis portion.
In any of the embodiments described herein, the bonding portion may include a plurality of bonding bars.
In any of the embodiments described herein, the plurality of bonding bars may be oriented in a parallel configuration.
In any of the embodiments described herein, the housing may further include a heat sink extending from an external surface of the chassis portion.
In any of the embodiments described herein, the heat sink may include a plurality of fins.
In any of the embodiments described herein, the plurality of fins may be arranged in a parallel configuration.
In any of the embodiments described herein, the plurality of fins may be oriented in an orientation perpendicular to the orientation of the bonding portion including a plurality of bonding bars.
In any of the embodiments described herein, the housing may further include a first pocket configured for receiving a Wi-Fi card and one or more Wi-Fi antennas.
In any of the embodiments described herein, the first pocket may include radio frequency shielding.
In any of the embodiments described herein, the housing may further include a second pocket configured for receiving a power supply.
In any of the embodiments described herein, the second pocket may be offset from a center point of the chassis portion.
In any of the embodiments described herein, the second pocket may include thermal shielding.
In any of the embodiments described herein, the housing may further include a moat section extending around the bonding portion.
In any of the embodiments described herein, the housing may further include city-scaping in the moat section.
In any of the embodiments described herein, the mounting system may include a single leg.
In any of the embodiments described herein, the leg may be mounted at a center point on the chassis portion of the housing.
In any of the embodiments described herein, the mounting system may include a hinge assembly for tiltably mounting the housing relative to a horizontal plane.
In any of the embodiments described herein, the hinge assembly may include a first knuckle portion and a second knuckle portion.
In any of the embodiments described herein, the first knuckle portion may include a channel having a first channel portion and a second channel portion.
In any of the embodiments described herein, the first channel portion may be configured to receive a tilt locking mechanism.
In any of the embodiments described herein, the second channel portion may be configured to receive cabling extending from the mounting system to the inner chassis chamber.
In any of the embodiments described herein, the tilt locking mechanism may include a set screw and a wedge.
In any of the embodiments described herein, the mounting system may be configured to receive the cabling within a leg.
In any of the embodiments described herein, the hinge assembly may include a spring pin.
In any of the embodiments described herein, the mounting system may include a tilt locking mechanism for locking the housing at one or more tilted orientations.
In any of the embodiments described herein, the tilt locking mechanism may include a set screw and a wedge, wherein the wedge is received in a channel.
This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

DESCRIPTION OF THE DRAWINGS

The foregoing aspects and many of the attendant advantages of this disclosure will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:

FIGS. 1 and 2 are isometric views of an antenna apparatus with a housing portion in different configurations relative to a mounting system in accordance with embodiments of the present disclosure;

FIGS. 3 and 4 are exploded views of the antenna apparatus of FIGS. 1 and 2 from respective top and bottom perspectives;

FIG. 5 is a side exploded view of the antenna apparatus of FIGS. 1 and 2;

FIGS. 6 and 7 are respective exploded and partial cross-sectional views of a radome portion of the antenna apparatus of FIGS. 1 and 2;

FIGS. 8 and 9 are respective isometric and top views of a chassis portion of the antenna apparatus of FIGS. 1 and 2;

FIG. 10 is an up-close isometric view of a portion of the chassis portion of the antenna apparatus of FIGS. 1 and 2;

FIGS. 11 and 12 are respective isometric and bottom views of chassis portion of the antenna apparatus of FIGS. 1 and 2 showing a heat sink;

FIGS. 13, 14, and 15 are exploded views of the mounting system of the antenna apparatus of FIGS. 1 and 2;

FIGS. 16 and 17 are partial cross-sectional views of a hinge assembly for a mounting system of the antenna apparatus of FIGS. 1 and 2; and

FIGS. 18A, 18B, and 18C are side views of the antenna apparatus of FIGS. 1 and 2 showing the antenna apparatus in various different tilt positions.

DETAILED DESCRIPTION

Embodiments of apparatuses and methods relate to an antenna apparatus for sending and receiving radio frequency (RF) signals, including components of the antenna apparatus. These and other aspects of the present disclosure will be more fully described below.
While the concepts of the present disclosure are susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will be described herein in detail. It should be understood, however, that there is no intent to limit the concepts of the present disclosure to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives consistent with the present disclosure and the appended claims.
References in the specification to “one embodiment,” “an embodiment,” “an illustrative embodiment,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may or may not necessarily include that particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.
Language such as “top”, “bottom”, “upper”, “lower”, “vertical”, “horizontal”, “lateral”, in the present disclosure is meant to provide orientation for the reader with reference to the drawings and is not intended to be the required orientation of the components or to impart orientation limitations into the claims.
In the drawings, some structural or method features may be shown in specific arrangements and/or orderings. However, it should be appreciated that such specific arrangements and/or orderings may not be required. Rather, in some embodiments, such features may be arranged in a different manner and/or order than shown in the illustrative figures. Additionally, the inclusion of a structural or method feature in a particular figure is not meant to imply that such feature is required in all embodiments and, in some embodiments, it may not be included or may be combined with other features.
Embodiments of the present disclosure are directed to an antenna apparatus 100 including an antenna system designed for sending and/or receiving radio frequency signals to and/or from a satellite or a constellation of satellites. Referring to FIGS. 1-5, the antenna apparatus 100 includes a housing 102, within which an antenna aperture 108 and other electronic components are disposed (see FIG. 3).
The antenna system disposed in the housing 102 may be a phased array antenna system or another antenna system. The antenna system may include other electronic components, including by not limited to a modem, a Wi-Fi card and Wi-Fi antennas, a GPS antenna, etc.
As seen in the exploded views of FIGS. 3-5, the housing 102 of the antenna apparatus 100 includes a chassis portion 104 for supporting the antenna aperture 108 and other electronic components. The housing 102 also includes a radome portion 106 for protecting the antenna aperture 108 and other electronic components. As seen in the illustrated embodiment, the housing 102 is configured for releasably and selectively mounting the chassis portion 104 to a mounting surface (not shown) via a mounting system 110.
The antenna apparatus 100 is configured to be mounted on a mounting surface S for an unimpeded view of the sky. As not limiting examples, the antenna apparatus 100 may be mounted on the roof or wall of a building, a tower, a natural structure, a ground surface, or to any other appropriate mounting surface having unimpeded communication with the sky. In accordance with embodiments of the present disclosure, the antenna apparatus 100 and its housing 102 are designed for durability and reliability in an outdoor environment.

Radome Portion of Housing

Referring to FIGS. 6 and 7, the radome portion 106 of the housing 102 for the antenna apparatus 100 will now be described in greater detail. The radome portion 106 is a structural surface or enclosure that protects the antenna apparatus 100, providing an environmental barrier and impact resistance. The radome portion 106 may incorporate features for snow, rain, and other dirt and moisture mitigation.
In radio frequency communication, the presence of water can attenuate electromagnetic signal transmission and/or reception by the antenna aperture 108. Therefore, radomes in accordance with embodiments of the present disclosure are designed to mitigate the accumulation of snow, rain, and other moisture. In addition to design features for durability in various environmental conditions, radomes in accordance with embodiments of the present disclosure may be constructed from material that minimally attenuates the electromagnetic signal transmitted or received by the antenna system of the antenna apparatus 100.
Referring to FIGS. 3-5, in the illustrated embodiment, the radome portion 106 has a planar top surface 120 extending from a first end 122 to a second end 124. In the illustrated embodiment, the radome portion 106 has a circular planar top surface 120. However, in other embodiments, the radome portion 106 may have another shape for the planar portion of the top surface, such as square, oval, rectangular, polygonal, or another other suitable shape.
In the illustrated embodiment, the first end 122 is on the first outer edge 126 of the radome portion 106 and the second end 124 is on the second outer edge 128 of the radome portion 106. In other embodiments, the planar top surface 120 need not extend from the first outer edge 126 to the second outer edge 128 of the radome portion 106. Instead, the planar top surface 120 may only extend for a portion of the distance from the first outer edge to the second outer edge of the radome portion 106. For example, the planar top surface 120 of the radome portion 106 may have a raised planar top surface between outer edges.
The radome portion 106 is designed and configured to have a uniform thickness from the first end 122 to the second end 124 of the planar top surface 120. Referring to FIGS. 3 and 5, the individual antenna elements 112 in the antenna array defining the antenna aperture 108 of the illustrated embodiment are equally distanced from the planar top surface 120 for the radome portion 106. Referring to FIGS. 4 and 5, the bottom planar surface 130 of the radome portion 106 is designed to be positioned adjacent the antenna aperture 108.
On advantageous effect of a planar top surface 120 for the radome portion 106 is that the flat surface allows for minimal tuning of specific antenna elements 112 in an antenna array to account for differences in radome thickness and/or differences in spacing between the radome portion 106 and each of the individual antenna elements 112 in the antenna array. With a constant thickness of the radome portion 106, all of the antenna elements 112 in the antenna aperture 108 can be tuned the same to account for attenuation of the electromagnetic signal by the radome portion 106 and also for impedance matching between the antenna elements 112 and the radome portion 106.
Referring to FIGS. 6 and 7, which show respective exploded and cross-sectional views of the radome portion 106, the radome portion 106 of the illustrated embodiment includes a plurality of layers 132 and 134. In one non-limiting example, the plurality of layers includes first and second radome layers 132 and 134 for providing mechanical and environmental protection to the antenna aperture 108 and other electrical components inside the housing 102 of the antenna apparatus 100.
In one embodiment of the present disclosure, the first radome layer 132 is designed to be an outer layer, which is exposed to the outdoor environment and has the properties of good strength to weight ratios and near zero water absorption. So as not to impede RF signals, the first radome layer 132 also has a low dielectric constant, a low loss tangent, and a low coefficient of thermal expansion (CTE). In addition, in some embodiments, the first radome layer 132 has bondability for bonding with adhesive. Without such bondability, the radome lay-up can buckle in extreme weather conditions.
The first radome layer 132 is designed to maintain high mechanical values and electrical insulating qualities in both dry and humid conditions over thermal cycles between −40° C. and 85° C. In some embodiments, the first radome layer 132 has high yield strength and a high enough modulus to spread load on the first radome layer 132 to the second radome layer 134. In some embodiments of the present disclosure, the first radome layer 132 has a dielectric constant of less than 4. In some embodiments of the present disclosure, first radome layer 132 has a loss tangent of less than 0.001.
As one non-limiting example, the first radome layer 132 is fiberglass-reinforced epoxy laminate material, such as FR-4 or NEMA grade FR-4. In other embodiments, the first radome layer may be another type of high-pressure thermoset plastic laminate grade, or a composite, such as fiberglass composite, quartz glass composite, Kevlar composite, or a panel material, such as polycarbonate.
In accordance with embodiments of the present disclosure, the first radome layer 132 has a thickness in the range of less than or equal to 60 mil (1.5 mm), less than or equal to 30 mil (0.76 mm), less than or equal to 20 mil (0.51 mm), less than or equal to 10 mil (0.25 mm). Thicker first radome layers 132 may be used in extreme weather conditions, such as hail conditions.
A second radome layer 134 supports the first radome layer 132 in providing mechanical and environmental protection to the antenna aperture 108 and other electrical components inside the housing 102 of the antenna apparatus 100. The second radome layer 134 also provides suitable spacing between the antenna elements of the antenna aperture 108 and the top surface 120 of the first radome layer 132.
As seen in the cross-section view of the illustrated embodiment in FIG. 7, the second radome layer 134 is thicker than the first radome layer 132. In one non-limiting example, the second radome layer 134 is a foam layer having properties of low RF decay, low loss tangent, good compression strength, and a low coefficient of thermal expansion (CTE). In addition, the second radome layer 134 has bondability for bonding with adhesive.
Like the first radome layer 132, the second radome layer 134 is also designed to maintain high mechanical values and electrical insulating qualities in both dry and humid conditions over thermal cycling between −40° C. and 85° C. In some embodiments of the present disclosure, the second radome layer 134 has a dielectric constant of less than 1. In some embodiments of the present disclosure, the second radome layer 134 has a loss tangent of less than 0.001.
As one non-limiting example, the second radome layer 134 is polymethacrylimide (PMI) foam. In other embodiments, the second radome layer 134 may be a honeycombed low-loss material (such as thermoplastic) or another suitable foam material (such as urethane foam). In other embodiments, the second radome layer 134 may be air. For example, the second radome layer 134 may include a spacing configuration to space the first radome layer 132 from the antenna aperture 108 with air.
In accordance with embodiments of the present disclosure, the second radome layer 134 has a thickness in the range of greater than 3.0 mm, less than 4.5 mm, or in the range of 3.0 mm to 4.5 mm. The thickness of the second radome layer 134 is described in greater detail below with reference to EXAMPLE 3.
As seen in FIG. 7, a first layer of adhesive 136 may be provided between the first and second radome layers 132 and 134. In addition, between the second radome layer 134 and the antenna aperture 108, a second layer of adhesive 138 may be provided. The adhesive may be a sheet-formed pressure sensitive adhesive, such as an acrylic adhesive, or a hot melt adhesive.
As seen in the illustrated embodiment of FIG. 7 showing a cross-sectional view of the radome portion 106 coupled with the chassis portion 104, the outer edge 144 of the second radome layer 134 is set inward from the outer edge 126 of the first radome layer 132 to provide an outer radome lip 140. Such lip 140 provides an interface for mating with a bezel surface 142 on the outer perimeter of the chassis portion 104.
When mated with the chassis portion 104, a seal 148 may be formed around the outer radome lip 140 to prevent moisture and dirt ingress at the interface. In one embodiment of the present disclosure, the seal may be a silicone seal. The seal may be formed during manufacture of the antenna apparatus 100 from dispensed material. In the illustrated embodiment of FIG. 7, the seal 148 is shown as being contained between the bezel surface 142 and the bottom surface of the radome lip 140. However, in other embodiments, the seal 148 may extend outwardly or inwardly toward the other surfaces of the chassis 104 to eliminate any gaps between the radome and the chassis bezel.
RF signal attenuation due to gain degradation can be significant as a result of rain or moisture accumulation on the planar top surface 120 of the radome portion 104. Regarding rain and moisture accumulation, water has a significant relative permittivity which can introduce a non-trivial interface for an antenna aperture causing RF reflection. Such RF reflection results in gain degradation in the RF signal.
For moisture mitigation and to aid in the run-off of water or moisture accumulating on the radome portion 104, the planar top surface 120 of the radome portion 104 may include a top hydrophobic layer (not shown) having low surface energy to cause water to bead up and not spread out. Non-limiting examples of a top hydrophobic layer may include a layer having hydrophobic paint or a PTFE coating. In other non-limiting examples, the first radome layer 132 may include additives, such as platicizers, within the first radome layer 132 to cause the first radome layer 132 have hydrophobic properties.
Snow accumulation on the planar top surface 120 of the radome portion 104 was generally not found to be as degrading to the RF signal power as water accumulation. However, snow or ice melt resulting in water accumulation on the on the planar top surface 120 of the radome portion 104 was found to significantly degrade the RF signal power.
In addition to surface treatments for the planar top surface 120 of the radome portion 106, tilting of the radome portion 104, as described in greater detail below, may help to mitigate snow and moisture accumulation.
To mitigate signal attenuation due to the lingering presence of droplets of rain, the top surface 120 of the radome portion 106 can be spaced a predetermined distance from the antenna aperture 108. In accordance with embodiments of the present disclosure, the second radome layer 134 has a suitable thickness (described above) to space the top surface 120 of the radome portion 106 a predetermined distance from the antenna elements 112 of the antenna aperture 108.

EXAMPLE 1

Radome Snow Mitigation

The radome reduces the effect of gain degradation due to snow accumulation. With no radome and 1 inch of snow on the antenna aperture, gain degradation was found to be 4 dB (receiving) and 9 dB (transmitting). With a radome in accordance with embodiments of the present disclosure, gain degradation was reduced to 0.8 dB (receiving) and 2.6 dB (transmitting).

EXAMPLE 2

Radome Rain Mitigation

The radome reduces gain degradation due to snow accumulation. With no radome and water accumulation on the antenna aperture, gain degradation was found to be up to 3 dB. With a radome in accordance with embodiments of the present disclosure, gain degradation was reduced to about 1 dB.

EXAMPLE 3

Radome Optimized Thickness

Four radome spacings were measured (with the spacing distance spanning from the top surface of the radome to the top surface of the antenna aperture) to evaluate the effect on gain degradation as a result of rain accumulation: 1.5 mm, 3.0 mm, 4.5 mm, and 6.0 mm. The data showed significant reductions in gain degradation for a radome thickness of 3.0 mm. For a radome thickness greater than 3.0 mm, additional reductions in gain degradation were nominal.

Chassis Portion of Housing

Referring to FIGS. 8 and 9, the chassis portion 104 of the housing 102 will now be described in greater detail. The chassis portion 104 supports the electronic features of the antenna apparatus 100, including the antenna array, the modem, GPS, Wi-Fi card, Wi-Fi antennas, and other electrical components. In accordance with embodiments of the present disclosure, the antenna lattice defining the antenna aperture 108 may include a plurality of antenna elements 112 arranged in a particular array or configuration on a carrier 114, such as a printed circuit board (PCB), ceramic, plastic, glass, or other suitable substrate, base, carrier, panel, or the like (described herein as a carrier).
As described above with reference to FIG. 7, the chassis portion 104 is designed to mate with the radome portion 106 at the bezel 142 of the chassis portion 106. When mated, the chassis portion 104 and the radome portion 106 define an inner chassis chamber 150 (see also FIG. 8) for supporting the antenna aperture 108 on the carrier 114 and the electronic features of the antenna apparatus 100.
In the illustrated embodiment of FIG. 8, the inner chassis chamber 150 includes an inner wall 152 and a support platform 154. The support platform 154 includes a bonding system shown as a plurality of bonding bars 156 extending therefrom to provide support to the electronic features of the antenna apparatus 100. In the illustrated embodiment, the bonding bars 156 extending laterally, parallel to one another.
The bonding bars 156 of the present disclosure provide multiple points of bonding between the antenna system and the chassis portion 104 to mitigate buckling (as a result of thermal cycling) of the carrier 114 (for example, a printed circuit board (PCB)). In previously designed systems, a printed circuit board (PCB) is generally screwed down to a chassis. Such screw configuration may not be designed to withstand such buckling.
The antenna apparatus 100 may be bonded to the bonding bars 156 using a low stiffness adhesive to further mitigate buckling. In some embodiments of the present disclosure, the adhesive is an acrylic foam adhesive. In some embodiments, the shear modulus of a 0.5 mm bondline of adhesive is less than 0.34 MPa. In some embodiments, the shear strain capability of the bondline is greater than 150%.
Although shown as bonding bars 156, other configurations of chassis bonding systems designed to mitigate buckling of a PCB are within the scope of the present disclosure. As a non-limiting example, the bonding system may include a grid of bonding posts instead of bonding bars.
Extending around at least a portion of the outer perimeter of the support platform 154 is a moat section 158 of the inner chassis chamber 154. The moat section 158 provides spacing for components of the electronic features of the antenna apparatus 100, such as power inductors. Various city-scaping protrusions 178 extend from the moat section to provide additional support and thermal mitigation to the electronic components of the antenna system outside the regions of the bonding bars 156. In one embodiment of the present disclosure, the city-scaping protrusions 178 are made from a metal material, such as aluminum, and provide a thermal path to the heat sink 220.
The chassis portion 104 may be manufactured as a discrete part, for example, by process for integrally forming a part, such as a casting process. The bonding bars 156 and the moat section 158 both add to stiffness of the chassis portion 104. Such stiffness provides advantages in durability. In addition, the bonding bars 156 and the moat section 158 assist with mold flow during manufacturing.
Referring to the illustrated embodiment of FIGS. 8 and 9, in the moat section 158 of the inner chassis chamber 150, a first pocket section 160 is defined in the chassis inner chamber 150 for containing components of the antenna apparatus 100. In one embodiment of the present disclosure, the first pocket section 160 is configured to include one or more antenna pockets (illustrated as two pockets) 162 and 164 and a card pocket 166.
In one non-limiting example, the one or more antenna pockets 162 and 164 may be Wi-Fi antenna 168 pockets and the card pocket 166 may be a Wi-Fi card 186 pocket.
Referring to FIGS. 9 and 10, the antenna pockets 162 and 164 include holes 170 and 172 extending from the support platform 154 of the chassis portion 106. The holes 170 and 172 allow for the insertion of discrete antennas, such as Wi-Fi antennas. Because the antenna pockets 162 and 164 and holes 170 and 172 are oriented on the support platform 154 of the chassis portion 106, Wi-Fi antennas 168 (see FIGS. 2 and 4) can be positioned in the closest position to the mounting surface S (for example, the roof of a building to which Wi-Fi signal is being radiated). In addition, the Wi-Fi antennas radiate toward the building and away from the beams emanating to and from the antenna aperture 108 of the antenna apparatus 100. In addition, the positioning of the Wi-Fi card Wi-Fi antennas 168 in the moat section 158 of the chassis portion 104 is also designed for thermal benefits, such that heat emanating from the Wi-Fi antennas 168 and the Wi-Fi card 186 does not affect other electronic components in the system and vice versa.
In accordance with embodiments of the present disclosure, the Wi-Fi antennas may be plastic pieces printed with antenna electronics. As a non-limiting example, the antennas may be manufactured using a laser direct structuring (LDS) process. Therefore, the antennas may form a cover, the antenna itself, and a seal for the holes 170 and 72 into the inner chassis chamber 152.
The first pocket section 160 may include shielding such that the Wi-Fi signal emanating from the WI-Fi antennas 168 does not interfere with the beams emanating to and from the antenna aperture 108. In the illustrated embodiment, the shielding includes a flange 198 extending around the rim of the upper surface of the first pocket section 160. The flange 198 is designed to interface with the Wi-Fi card 186 to enclose the Wi-Fi antennas 168 within the shielded pocket. The Wi-Fi card 186 is secured to the flange 198 by a series of screws, with the location of the screws shown by the receiving holes 200 in FIG. 10. The screws (not shown) ground the Wi-Fi card 186 to the heat sink 220 and close the gap between the Wi-Fi card 186 and the heat sink 220 to prevent jamming components of the antenna array 108 with out-of-band Wi-Fi signals.
When the antennas 168 are inserted in the antenna pockets 162 and 164 extending through the holes 170 and 172, the antennas 168 are configured to form seals with a flange 202 in each of the antenna pockets 162 and 164. The seals prevent dirt or moisture ingress into the inner chassis chamber 150.
Referring to FIGS. 8 and 9, also in the inner chassis chamber 150, a second pocket section 180 is defined for supporting the power supply 182 to the antenna apparatus 100. The second pocket section 180 is offset from the mounting system 110 (see FIG. 12) to provide ingress of the power cabling 184 to the power supply 182 from the mounting system 110.
In the illustrated embodiment, the power supply 182 has a first end 190 connected to an external power source and a second end 192 coupled to the internal electronic circuitry of the antenna apparatus 100. In accordance with some embodiments of the present disclosure, the second pocket 180 is configured such that the first end 190 of the power supply 182 is positioned adjacent the mounting system 110. In the illustrated embodiment, the mounting system 110 is a center-mounted system (see FIG. 12). Therefore, the second pocket 180 is configured such that the first end 190 of the power supply 182 is positioned adjacent a center point of the chassis portion 104 (see FIG. 9). Such positioning of the second pocket 180 and the power supply 182 allows for a more compact design to reduce the profile of the chassis portion 104 and reduce power supply cable length.
The second pocket section 180 includes a cover 184 (see FIG. 15) for shielding the other electronic components in the antenna apparatus from heat generated by the power supply 182. In addition, the cover 184 or the second pocket section 180 itself may be made from metal and provide a thermal path to the heat sink 220 for heat dissipation.
Referring to FIG. 9, the chassis portion 104 also may include a vent hole 204 for venting air from the inner chassis chamber 150. The vent hole 204 may have a suitable air permeable/water non-permeable cover to prevent the ingress of moisture into the inner chassis chamber 150.

Heat Sink

In the illustrated embodiment of FIG. 2, the chassis portion 104 includes a heat sink 220 extending downwardly from the bottom surface 224 of the chassis portion 104. The heat sink 220 includes a plurality of fins 222 extending downwardly from the bottom surface 224.
In the illustrated embodiment, the fins 222 are equally spaced and parallel to one another and run in a single direction. Comparing FIGS. 3 and 4, the bonding bars 156 in the inner chamber 150 of the chassis portion 104 run in a direction perpendicular to the direction of the fins 222. The cross-directional orientation of the fins 222 and the bonding bars 156 in the illustrated embodiment further adds to stiffness of the chassis portion 104 for durability during use and also helps with mold flow during manufacturing.
Referring to FIG. 5, the fins 222 are designed to be coupled to or integrally manufactured with the chassis portion 104. In the illustrated embodiment of FIG. 5, the fins 222 are designed to have variable lengths to define a curved fin boundary profile. However, in other embodiments, the fins 222 may have the same lengths or may define another different fin boundary profile based on suitable heat dissipation effects.
The fins 222 of the heat sink are made from a metal material suitable to optimizing heat dissipation, such as aluminum. Likewise, if integrally formed, the chassis portion 104 may be made from the same material, such that the chassis portion 104 also enable thermal migration from the chassis portion to the heat sink 220 for further heat dissipation.
Referring to FIG. 2, the mounting system 108 of the antenna assembly 100 allows for the heat sink 220 to be spaced a predetermined distance from the surface S on which the antenna assembly 100 is mounted. Such spacing provides a suitable area for heat dissipation and air mixing.
Moreover, such spacing from the surface on which the antenna assembly 100 is mounted allows the antenna assembly 100 to be located outside the heat boundary layer of the surface S on which it is mounted. For example, if the antenna assembly 100 is mounted on a roof of a building. The external roof surface may be heated by radiating heat from the sun or by conducting heat from inside the building through the surface of the roof. By spacing the antenna assembly 100 a predetermined distance from the surface S on which it is mounted, the heat sink 222 can avoid being heated by the radiation or conduction heat H emanating from the surface S on which it is mounted (see FIG. 2). As one non-limiting example, the leg 230 of the mounting system is at least 14 cm.
Still referring to FIG. 2, as described in greater detail below, tilting the housing 102 of the antenna assembly 100 can help to enhance heat dissipation. In the illustrated embodiment, when tilted, the heat sink fins 22 are oriented perpendicular to the pivot axis Y. Such orientation allows for the fins 222 to provide enhanced natural convection as a result of the buoyancy of air (as it gets heated) for enhanced heat dissipation by the heat sink 220. Referring to FIG. 18A-18C various tilting orientations for the antenna apparatus 100 are provided.

Mounting Device of Antenna Apparatus

Referring to FIGS. 11-17, a mounting system 110 for the housing 102 will now be described in greater detail. In the illustrated embodiment of FIG. 11, the mounting system 110 includes a single leg 230 for mounting the housing 102. As can be seen in FIG. 12, the mounting system 110 of the illustrated embodiment is attached to the chassis portion 104 at a center point of the chassis portion 104. The center mount location allows for symmetry and balance in the mount. However, in other embodiments, the mounting system 110 may be attached to the chassis portion 104 at an offset location depending on the configuration and weighting of the antenna apparatus 100.
As described above with reference to FIG. 2, the mounting system 110 is configured to allow for tilt-ability of the housing 102 relative to the mounting leg 230. Such tilt-ability of the housing 102 allows for not only rain and snow removal and heat dissipation, but also for orientation of the antenna apparatus 100 with the sky for enhanced radio frequency communication with one or more satellites depending on the geolocation of the antenna apparatus 100 and the orbit of the satellite constellation.
Referring to FIGS. 13, 14, and 15, the tilting mechanism 232 of the mounting system 110 is designed and configured for achieving precision in the mounting angle and for a secure mount. In the illustrated embodiment, the tilting mechanism 232 includes a hinge assembly 240 defining a knuckle 242 and having a pin 244. The knuckle 242 includes a first knuckle portion 246 coupled to the chassis portion 106 and a second knuckle portion 248 coupled to the mounting leg 230. The pin 244 is received within the first and second knuckle portions 246 and 248 to form the hinge assembly 240.
Referring to FIG. 13, the first knuckle portion 246 includes a receiving hole 250 configured to receive the pin 244 of the hinge assembly 240. In the illustrated embodiment, the first knuckle portion 246 extends outwardly from the bottom surface 224 of the chassis portion 104. In the illustrated embodiment, the first knuckle portion 246 has a rounded configuration to allow for rotation of the chassis portion 104 and the housing 102 relative to the mounting system 110 over a pivot range (as illustrated in FIGS. 18A-18C).
Referring to FIGS. 14 and 15, the leg 230 is an elongate body extending from a first end 282 to a second end 284. The first end 282 is a base end, and the second end includes a head 286 defining the second knuckle portion 248. The head 286 further includes an interface for the tilt locking mechanism 270 and a stopping surface 272 defining the tilting range of the housing 102 relative to the mounting system 110, both described in greater detail below.
Still referring to FIGS. 14 and 15, the second knuckle portion 248 includes a clevis portion defining first and second receiving holes 260 and 262 for aligning with the receiving hole 250 of the first knuckle portion 246 to receive pin 244 of the hinge assembly 240. When coupled together, the first knuckle portion 246, the second knuckle portion 248, and the pin 244 form the hinge assembly 240 to allow for rotation of the chassis portion 104 and the housing 102 relative to the mounting system 110 over a pivot range (as illustrated in FIGS. 18A-18C).
As seen in the illustrated embodiment, the pin 244 may be a roll pin (or a spring pin) to add resistance to the hinge assembly 240, allowing for achieving precision in the mounting angle.
Referring to FIGS. 16 and 17, the body of the first knuckle portion 246 includes a channel 252 along the rounded surface of the first knuckle portion 246. The channel 252 includes a first portion 266 (see FIG. 14) for interfacing with a tilt locking mechanism 270 and a second portion 268 (see FIG. 15) which is designed and configured to receive the cabling 196 that extends to the first end 190 of the power supply 182 disposed in the second pocket 180. The cabling 196 may be configured to extend through first and second holes 254 and 256 in mounting leg 230 (see FIG. 15) so as to be concealed within the mounting leg 230, and then to run inside the second portion 268 of the channel 252. In other embodiments, the cabling 196 may extend external to the mounting leg 230.
As mentioned above, the first portion 266 of the channel 252 of the first knuckle portion 246 is designed to provide an interface for a tilt locking mechanism 270 for the tilt-able mounting system 110. The tilt locking mechanism 270 includes a set screw 234 which is received within a hole 288 defining the tilt locking mechanism 270 in the head 186 of the leg 230. The set screw 234, when tightened, is configured to press against a wedge 236, such that the wedge 236 interfaces with the channel 252 of the first knuckle portion 246 (see FIG. 17). In this manner, the tilt locking mechanism 270 is designed and configured for achieving a secure mount under considerable load.
At the base of the leg 230, a mounting device 280 similar to a bicycle seat mounting device provides for a secure mount to a roof receiver (not shown).
Now referring to FIGS. 18A-18C, the limits of the tilt-about mounting system 100 will be described in greater detail. Referring to FIG. 18A, the housing 102 is tilted to full vertical relative to the mounting system 110. Referring to FIG. 18C, the housing 102 is tilted such that the bottom surface of the heat sink 220 engages with stopping surface 272. FIG. 18B is a middle position. Other positions are within the scope of the present disclosure.
After the antenna apparatus 100 is mounted on an external surface of a building, the cabling can be connected to an outlet external to the building.
While illustrative embodiments have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the disclosure.

Claims

1. A housing for an antenna system having a plurality of antenna elements defining an antenna aperture, the housing comprising:

a chassis portion; and

a radome portion configured for coupling to the chassis portion to define an inner chassis chamber, the radome portion having a planar top surface, wherein the radome portion is configured to have equal spacing between the planar top surface and a top surface of each of the plurality of antenna elements defining the antenna aperture.

2. The housing of claim 1, wherein the radome portion includes a first layer and a second layer.

3. The housing of claim 2, wherein the first layer is a protective layer.

4. The housing of claim 3, wherein the first layer is made from a fiberglass-reinforced epoxy laminate material.

5. The housing of claim 3, wherein the first layer has a thickness selected from the group consisting of less than 1.5 mm, less than 0.76 mm, less than 0.51 mm, and less than 0.25 mm.

6. The housing of claim 3, wherein the first layer includes a hydrophobic outer surface.

7. The housing of claim 2, wherein the second layer is a spacing layer.

8. The housing of claim 7, wherein the second layer is made from a polymethacrylimide foam.

9. The housing of claim 7, wherein the second layer has a thickness selected from the group consisting of greater than 3.0 mm, less than 4.5 mm, or in the range of 3.0 mm to 4.5 mm.

10. The housing of claim 1, wherein the radome portion is tilted relative to a horizontal plane.

11. The housing of claim 1, wherein the radome portion couples with the chassis portion at a bezel surface on the chassis portion.

12. The housing of claim 1, wherein the radome portion is sealed to the chassis portion at a bezel surface on the chassis portion.

13. The housing of claim 1, wherein an outer edge of a second radome layer is set inward from the outer edge of a first radome layer to provide an outer radome lip.

14. The housing of claim 13, wherein the outer radome lip couples with the chassis portion at a bezel surface on the chassis portion.

15. A housing for an antenna system having a plurality of antenna elements defining an antenna aperture, the housing comprising:

a chassis portion having an internal support portion for internal components for the plurality of antenna elements including a bonding portion for bonding an internal carrier to the chassis portion; and

a radome portion configured for coupling to the chassis portion to define an inner chassis chamber.

16. The housing of claim 15, wherein the bonding portion includes a plurality of bonding bars.

17. The housing of claim 16, wherein the plurality of bonding bars is oriented in a parallel configuration.

18-26. (canceled)

19. The housing of claim 15, further comprising a moat section extending around the bonding portion.

20. The housing of claim 27, further comprising city-scaping in the moat section.

21. An antenna apparatus for an antenna system having a plurality of antenna elements defining an antenna aperture, the antenna apparatus comprising:

a housing including a chassis portion and a radome portion configured for coupling to the chassis portion to define an inner chassis chamber; and

a mounting system for tiltably mounting the housing relative to a horizontal plane.

22. The antenna apparatus of claim 29, wherein the mounting system includes a single leg.

23. The antenna apparatus of claim 30, wherein the single leg is mounted at a center point on the chassis portion of the housing.

24. The antenna apparatus of claim 29, wherein the mounting system includes a hinge assembly for tiltably mounting the housing relative to a horizontal plane.

25-37. (canceled)

26. The antenna apparatus of claim 30, wherein the mounting system is configured to receive the cabling within the single leg.

27. (canceled)

28. The antenna apparatus of claim 29, wherein the mounting system includes a tilt locking mechanism for locking the housing at one or more tilted orientations.

29. (canceled)