Dielectric support threads for satellite antenna radiating elements and other payloads

Abstract

To provide systems and methods for a radiating element assembly for an antenna.SOLUTION: An antenna assembly 100 includes a radiating element 110 for emitting and / or receiving electromagnetic waves, and a radiating element support system for physically supporting the radiating element when in operation. The radiating element support system includes: a plurality of threads 130 that act as nonlinear structural links which interconnect the radiating element to constrain the radiating element in one or more of axial, radial and torsional directions, where the threads are taut with near zero tension; and at least one central support 120, where the threads interconnect the radiating element with the at least one support to constrain the radiating element in the axial, radial and / or torsional directions. The radiating element support system may be used to constrain other satellite payloads.SELECTED DRAWING: Figure 1A

Description

[Technical field]

[0001] The following relates generally to antenna systems, and more specifically to support structures for satellite antenna radiating elements. [Background technology]

[0002] In the aerospace industry, global coverage antennas, shaped beam antennas, and omnidirectional antennas are typically mounted on spacecraft structures to allow unimpeded communication between other communication points. These types of antennas typically include at least one radiating element wrapped around an elongated dielectric support structure that has very little effect on the transmission of radio frequency (RF) waves. This structure provides support for the flexible radiating element during launch and maintains the shape of the radiating element once operating in orbit.

[0003] The impact of the dielectric support structure on RF performance is a function of the bulk volume it occupies within the antenna's electromagnetic field, as the dielectric material of the support structure can affect the antenna's radiation pattern, cause power loss, and result in sudden electrostatic discharge (ESD) that can damage the payload and render the antenna inoperable.

[0004] Current satellite radiating element assemblies have several structural problems. The support elements are separate from the radiating elements and therefore require additional elements, such as adhesives or other forms of bonding, to connect to the radiating elements and provide support. The materials used to make these connections often have limited power transfer capabilities. Typically, metallic radiating elements are (epoxy) bonded to a dielectric support structure (made of fiberglass fibers, aramid fibers such as Kevlar™ or NOMEX™, polyimides such as Kapton™, etc.). Current methods of manufacturing satellite radiating element assemblies require connecting various flexible (non-rigid) components of the antenna system, which is time consuming, expensive, and makes the assembly method of the system difficult.

[0005] In addition, all exterior surfaces of the antenna assembly must withstand exposure to space for the duration of the mission, preferably without the need for sunshades. Summary of the Invention [Problem to be solved by the invention]

[0006] Thus, there is a need for an improved antenna assembly and antenna radiating element support system that overcomes at least some of the shortcomings of existing systems and methods. [Means for solving the problem]

[0007] Provided herein is a radiating element assembly for an antenna including a radiating element for emitting and / or receiving electromagnetic waves and a radiating element support system for physically supporting the radiating element during operation. The radiating element support system includes a plurality of dielectric support threads acting as nonlinear structural links, which interconnect the radiating elements to constrain the radiating elements in one or more of an axial, radial, and torsional direction, the threads being tensioned with near zero tension. The radiating element support system further includes at least one support. The plurality of dielectric support threads interconnect the radiating elements with the at least one support to constrain the radiating elements in one or more of an axial, radial, and torsional direction.

[0008] The at least one support may include a central support positioned within the radiating element.

[0009] The central support may be fixed to the ground plane at the base of the antenna.

[0010] The central support may be rigid in tension, compression, bending, and torsion.

[0011] The at least one support may include at least one external support positioned outside the radiating element.

[0012] The at least one support may include a central support within the radiating element and at least one external support location outside the radiating element.

[0013] The radiating element and the center support may be manufactured as a single piece.

[0014] The radiating element may be helical.

[0015] The radiating element may be flexible due to the shape of the radiating element.

[0016] The radiating element support system can prevent the radiating element from moving beyond its correct nominal position.

[0017] Each of the dielectric support threads may have a thread diameter in the range of 0.005 to 0.050 inches.

[0018] The dielectric support thread may include a radio frequency (RF) transparent material.

[0019] The dielectric support threads may include glass or aramid fibers.

[0020] Each dielectric support thread may include two or more strands twisted together.

[0021] A satellite payload assembly is also provided. The satellite payload assembly includes a payload on the satellite and a payload support system for physically supporting the payload. The payload support system includes a plurality of dielectric support threads acting as nonlinear structural links, which interconnect the payload to constrain it in one or more of radial, torsional, and axial directions, the threads being tensioned with near zero tension. The payload support system also includes at least one support. The plurality of dielectric support threads interconnect the payload with the at least one support to constrain it in one or more of radial, torsional, and axial directions.

[0022] The at least one support may include a central support positioned within the payload.

[0023] The central support may be secured to a ground surface at the base of the load.

[0024] The at least one support can include at least one external support positioned outside the load.

[0025] The at least one support may include a central support within the load and at least one exterior support location outside the load.

[0026] The payload may be a waveguide.

[0027] Other aspects and features will become apparent to those skilled in the art upon review of the following description of several exemplary embodiments.

[0028] The drawings included herein are intended to illustrate various examples of the articles, methods, and apparatus herein. [Brief description of the drawings]

[0029] [Figure 1A] FIG. 2 is a side perspective view of an antenna assembly having a radiating element support system according to one embodiment. [Figure 1B] FIG. 1B is a side perspective view of the tip portion of the antenna assembly of FIG. 1A, separated. [Figure 1C] FIG. 1B is a side perspective view of the base of the antenna assembly of FIG. 1A, separated. [Figure 1D] FIG. 1B is a top view of the antenna assembly of FIG. 1A. [Diagram 2] FIG. 2 is a side perspective view of an antenna assembly having a radiating element support system according to one embodiment. [Figure 3A] FIG. 2 is a side perspective view of an antenna assembly having a radiating element support system according to one embodiment. [Figure 3B] FIG. 3B is a top view of the antenna assembly of FIG. 3A according to one embodiment. [Figure 4] FIG. 2 is a side perspective view of a single piece radiating element and center support according to one embodiment. [Diagram 5] FIG. 2 is a simplified block diagram of an antenna assembly including a radiating element support system having an external support according to one embodiment. [Figure 6] FIG. 2 is a simplified block diagram of a waveguide of a satellite assembly including a waveguide sled support system according to one embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0030] Various devices or processes are described below to provide examples of each claimed embodiment. The embodiments described below do not limit the claimed embodiments in any way, and any claimed embodiment may cover processes or devices that differ from those described below. The claimed embodiments are not limited to devices or processes having all of the features of any one device or process described below, or to features common to some or all of the devices described below.

[0031] Additionally, although process steps, method steps, algorithms, etc. may be described (in the present disclosure and / or claims) in a sequential order, such processes, methods, and algorithms may be configured to work in alternative orders. In other words, the sequence or order of any steps that may be described does not necessarily indicate a requirement that the steps be performed in that order. Steps of processes described herein may be performed in any order that is practical, and in some cases, certain steps of a process may be omitted. Additionally, some steps may be performed simultaneously.

[0032] It will be readily apparent that when a single device or article is described herein, more than one device / article (whether they cooperate or not) can be used in place of the single device / article. Similarly, it will be readily apparent that when more than one device or article is described herein (whether they cooperate or not), the single device / article can be used in place of the more than one device or article.

[0033] The following relates generally to antenna systems, and more specifically to an antenna radiating element support system for use in a satellite antenna assembly.

[0034] The radiating element support system described herein can be used to support radiating elements that have a helical shape and are therefore flexible. That is, the radiating elements as a whole are inherently flexible due to their helical shape, although the materials they comprise may not be flexible. In other embodiments, the radiating element support system can be employed for radiating elements that do not have a helical shape or form, but are flexible and therefore require support. The use herein of "helical", "spiral", "helical" or similar terms, or discussion of embodiments in which the radiating element is a helix, is not intended to limit the assemblies and systems to only those that include helical radiating elements.

[0035] The physical properties of the helix, such as diameter and pitch, must ensure proper functioning of the antenna within its intended performance limits throughout the gravity ground testing, the vibrating launch, and the on-orbit operation periods. Deformations under gravity can affect ground antenna performance measurements. To survive the vibrations during the test and launch phases, the radiating element requires supports to prevent movement of the helix (or other shape) outside of its correct nominal axial, radial, and torsional positions. Large deformations during the vibration periods can result in failure of the radiating element.

[0036] The radiating element support system of the present disclosure prevents the helix from moving out of its correct nominal position using a small diameter RF dielectric support thread, which in some embodiments connects the helix to a rigid central support at multiple locations, and in some embodiments connects the helix to at least one external support structure at multiple locations. The central support must be stiff enough to provide sufficient constraint to limit the displacement of the radiating element in the required direction. In some embodiments, the radiating element can be connected to both the central support and the external support. The dielectric material is non-conductive and therefore has very little effect on the radiation field of the antenna. To further reduce the effect on the radiation field of the antenna as well as to minimize bulk charging on the dielectric material tracks that can result in electrostatic discharge, the thread diameter is minimized to a diameter range of 0.005'' to 0.050''. The thread material may be "RF transparent", which means that the material has very little effect on the transmission of RF waves and therefore does not affect the performance of the antenna (e.g., does not affect the emission and reception of electromagnetic waves). The thread material may be, for example, glass or aramid fiber (e.g., Nomex®). The dielectric thread is preferably made of two or more strands that are twisted together. The non-uniform nature of the thread made of twisted yarns, as well as its small diameter and stiffness, allows it to remain stiff in tension while being compliant when compressed to avoid failure under kinking that may occur during vibration.

[0037] During assembly, the dielectric support thread is tensioned without tension to achieve consistent stiffness throughout testing, launch, and on-orbit operations. That is, the dielectric support thread should have near-zero tension (e.g., on the order of 20 grams tension) within limits achievable given the assembly operations and consistent with viscoelastic creep minimization. If the support thread is significantly tensioned, the stiffness will be inconsistent due to viscoelastic creep that may occur over time. The support thread acts as a nonlinear structural link during the vibration phase, since it constrains the movement of the radiating element when the thread is under tension, but allows the radiating element to move when under compression (i.e., the thread supports the radiating element in one direction, i.e., thread tension, but not in the other direction, i.e., thread compression). The overall thread configuration is optimized for the radiating element geometry to achieve sufficient stiffness and strength to enable the antenna to withstand vibrations along all directions applied at the base of the antenna. The stiffness of the assembly (of support, threads and radiating element) is obtained by ensuring that the radiating element is constrained by the threads in the axial and / or radial and / or torsional directions by at least two threads, such that at least one thread is in tension at any given time. The thread configuration may or may not require the threads to constrain the twisting motion of the helix, depending on the geometry, size and vibration requirements of the antenna.

[0038] To provide a support interface for the sled to constrain the radiating element, the antenna assembly can include a central support secured to the ground plane at the base of the antenna. The central support is shaped and sized to be sufficiently rigid in tension, compression, bending, and torsion to support the radiating element and sled during ground measurements, vibration testing, launch, and on-orbit operations while having minimal effect on the antenna radiation performance. A support sled interconnects the radiating element to the central support and can also interconnect the radiating element to the radiating element.

[0039] In embodiments in which the antenna assembly includes at least one external support, the external support acts in the same manner as the central support and is sufficiently rigid in tension, compression, bending, and torsion to support the radiating element and sled during ground measurements, vibration testing, launch, and on-orbit operations while having minimal effect on the antenna radiation performance.

[0040] That is, the support for the radiating element may be central (within the radiating element) or external (outside the radiating element), so long as a rigid local support is present to attach the thread and it supports the radiating element at the radiating plane of the helix. As noted above, in some embodiments there may be a central support and an external support.

[0041] The support threads interact together with the rigid central support or external supports to provide bending stiffness and limit the movement of the helix itself. The central support is stiff in tension, compression, bending, and torsion, which helps limit the primary bending modes of the assembly. The support threads limit local helical modes in the axial and / or radial and / or torsional directions of the helix because the thread network stiffens the helix at the thread interface locations where the threads meet the helix. The thread network can also constrain the helix in the torsional direction to help reduce the effects of assembly behavior caused by helical twisting modes.

[0042] The radiating element must comprise a conductive material. In some embodiments, the radiating element may comprise a conductive material throughout. In other embodiments, the radiating element may comprise a non-conductive material coated with a conductive material. The radiating element may be a metal, for example aluminum.

[0043] In some embodiments, the radiating element and the central support can be manufactured as a single piece, a process that can save time and reduce costs compared to manufacturing the radiating element and the central support as two or more pieces.

[0044] In some embodiments, manufacturing or constructing the antenna assembly can include three-dimensional (3D) printing the radiating element alone or together with the central support. For example, the radiating element and the central support can be 3D printed as a single part using aluminum.

[0045] In embodiments in which the central support is manufactured separately from the radiating element, the central support may be the same or a different material as the radiating element.

[0046] As discussed above, current antenna assemblies have several drawbacks: Bulky dielectric support structures interfere with the antenna radiating elements and increase power losses; On-orbit charging can result in sudden electrostatic discharges (ESD) that affect the antenna's ability to operate, for example limiting or stopping the antenna's ability to emit and / or receive electromagnetic waves.

[0047] Existing forms of support elements for antenna radiating elements may require adhesives or other forms of bonding to connect to the radiating elements and provide support. Materials used to make these connections often have limited power transfer capabilities. For example, articles of support structure may be made of Kapton™. The need to connect the various flexible components of the antenna system makes the assembly method of the system difficult, time consuming, and expensive. Additionally, the surfaces of the dielectric support may need to be protected from space exposure via semiconductive coatings and / or sunshades covering the dielectric support material.

[0048] This disclosure provides a solution to these problems. By using a small dielectric thread to support the radiating element, RF performance issues and ESD hazards are mitigated. The dielectric thread can be made of materials (e.g., glass or aramid fiber) that can be exposed to the space environment, eliminating the requirement for coatings and potentially eliminating the requirement for orbit-dependent shading. The radiating element and central support can be 3D printed as a single part, minimizing cost and reducing complexity and time when installing the dielectric thread.

[0049] The technical solutions provided herein can be used in a variety of antenna applications having radiating elements of different sizes and shapes, and may be particularly useful in high power applications.

[0050] 1A-1D, shown therein are various views of an antenna assembly 100 including a radiating element support system in accordance with one embodiment. The antenna assembly 100 may be used in an antenna configured for satellite-based communications.

[0051] Antenna assembly 100 includes a radiating element 110 and a radiating element support system comprising a rigid central support 120 and a plurality of support threads 130 (only three are labeled to reduce clutter). The plurality of support threads 130 may be referred to as a support thread network.

[0052] In the embodiment shown in Figures 1A-1D and 2 below, the threads of the support thread network are attached to the radiating element and the central support through holes present in the radiating element and the support. The threads pass through the holes and are connected to the radiating element and the support in the holes using an adhesive. In other embodiments, any mechanism for attaching the threads to the radiating element and the support is contemplated. For example, in some embodiments, the threads can be connected to the outer surface of the radiating element or the support by an adhesive or other bonding means. In other embodiments, the threads can be wrapped around the radiating element and the support. In some embodiments, no adhesive or other type of bonding is used. In some embodiments, different threads can be connected to the radiating element and supported by different connecting means, including but not limited to those mentioned above.

[0053] In the embodiments shown in Figures 1A-3B, a single thread is often shown to interconnect several turns of the helix. However, in other embodiments, multiple threads can be used to achieve the same support, with a single piece of thread connecting one turn to the next, thus providing support for the helix in the axial direction of the helix using multiple threads. In some embodiments, a single thread can pass unidirectionally from one element to another. In other embodiments, a single thread can pass from one element to another and then loop back to the first element. In some embodiments, there can be a combination of unidirectional and looping threads.

[0054] That is, the embodiments shown in Figures 1A-3B are intended to be exemplary. The connections of the support threads to the radiating element and to the central support or external supports must be sufficient to limit displacement of the radiating element in the axial, radial, and optionally (depending on the size and shape of the radiating element) torsional directions, regardless of how the support connections are established.

[0055] In the embodiment shown in Figures 1A-3B, the central support is designed and shaped to limit its impact on RF transmission. That is, it has a limited external surface area that limits the weight of the central support as well as the surface area / amount of material that may interfere with the reception and / or emission of electromagnetic waves by the antenna. The central support may have any design that allows sufficient support to the radiating element while minimizing the impact on the operation of the antenna.

[0056] The plurality of support threads 130 includes three different support thread configurations: axial support threads 131, radial support threads 132, and torsional support threads 133. The axial support threads 131 manage the on-axis (helical axis) motion of the radiating element by limiting the helical displacement in the axial direction. The radial support threads 132 manage the radial motion of the radiating element by limiting the helical displacement in the radial direction. The torsional support threads 133 manage the torsional motion of the radiating element by limiting the helical displacement in the torsional direction. While the direction in which each type of thread provides support is the primary direction, during operation, each type of thread can provide some additional support in other directions. Only one example of each support thread configuration is labeled in FIG. 1A. The support threads 131, 132, and 133 are made of the same material but provide support in different directions.

[0057] The radiating element 110 is a conical helix wound around a central axis of the helix (helix axis or helical axis) that runs along the length of the helix. In other embodiments, the helix may be conical, cylindrical, or any combination thereof, or the radiating element may not have a helical shape. The central support 120 is positioned such that its long axis is collinear with the helix axis (thus giving the appearance of a helix winding around the central support).

[0058] The radiating element 110 may be helical shaped. The radiating element 110 may be flexible. The radiating element 110 may be manufactured by subtractive or additive methods of material, or by molding or forming from a conductive material (or at least a conductive outer layer). The radiating element 110 may be wrapped around a central support 120.

[0059] The central support 120 can be constructed of a material that allows RF waves to pass through the material or that has very little effect on the transmission of RF waves through the material. The central support 120 can provide support to the flexible radiating element 110 during launch. The central support 120 can provide support to the flexible radiating element 110 to maintain the shape of the radiating element 110 once in orbit operation. The central support 120 of Figures 1A-1D includes a base 121 that is used to mount the central support on the antenna ground plane 140 in operation. An axial support thread 131 is connected to the base 121.

[0060] 1A-1D, the radiating element 110 and the central support 120 are a single component. However, in other embodiments, the radiating element 110 and the central support 120 may be separate components.

[0061] A support thread 130 interconnects the radiating element 110 and the central support 120. The radiating element 110 includes thread interfaces 112 (two thread interfaces 112-1, 112-2 are labeled in FIG. 1A). In the embodiment of FIGS. 1A-1D, the thread interfaces 112 are positioned along the helix 110 every 1 / 6 of a turn, i.e., every 60°. In other embodiments, the thread interfaces 112 may be distributed more or less around the helix.

[0062] 1A-1D, many of the thread interfaces 112 (except for some interfaces on the bottom-most turns of the helix) have a thicker diameter or width than the rest of the helix. This thicker diameter provides support to the helix where the holes are present. In other embodiments, the diameter may not be thicker where the holes are (or there may be no holes at the thread interfaces).

[0063] The helix is ​​connected to the central support 120 by support threads 131 and 132 via thread interface 112-1. As discussed above, in other embodiments, the connection of the threads to the radiating elements and the central support can be accomplished in a number of ways. In FIGS. 1A-1D, each thread interface 112-1 has three holes, but this embodiment is an example. In other embodiments, the thread interfaces can include more or fewer holes for interacting with more or fewer threads. In other embodiments, the thread interfaces may not include holes.

[0064] The thread interfaces 112-2 are connected to the central support by threads 131, 132, and 133. Each thread interface 112-2 has four holes. The thread interfaces 112-1 and 112-2 alternate along the helix.

[0065] Similar to thread interface 112-1, in other embodiments, thread interface 112-2 can include more or fewer holes to connect to more or fewer threads, or may have no holes.

[0066] Axial support threads 131 connect the base 121 of central support 120 along the helical axis to several turns of the helical radiating element 110. In Figure 1A, the bottom eight turns (the eight turns closest to base 121) are interconnected.

[0067] 1A, axial support thread 131 is a single continuous piece thread that passes through holes at thread interfaces 112-1, 112-2 on radiating element 110. In other embodiments, there may be multiple support threads connecting a turn of helix 110 to the top and bottom turns (as applicable).

[0068] 1A, there are twelve axial support threads 131, with two threads connecting each thread interface 112 directly to the top and bottom thread interfaces (except for the tip thread interface which connects only with the bottom thread interface, and the base-most thread interface which connects only with the top thread interface). As discussed above, in other embodiments, any number of threads can be used to make the connections necessary to support the radiating element.

[0069] Radial support threads 132 radially connect radiating elements 110 to elongated elements 122 of central support 120. That is, each thread interface 112 of radiating elements 110 connects to a thread interface 123 on central support 120 that is positioned directly across from thread interface 112-1 along a radius of the helix. In FIG. 1, there is a single radial support thread 132 for each thread interface 112.

[0070] Torsional support threads 133 (blue threads) connect radiating element 110 to elongated elements 122 of central support 120 along radial and torsional directions. Each thread interface 112-2 is connected to two thread interfaces 123 on central support 120 that are positioned along two different chords from thread interface 112-2. That is, each thread interface 112-2 is connected to a thread interface 123 that is connected to an adjacent thread interface 112-1 by a radial support thread 132.

[0071] Specifically, each thread interface 112-2 is connected to three thread interfaces 123 on the central support 120. For a given thread interface 112-2, a radial support thread 132 connects the thread interface 112-2 to the thread interfaces 123 along the radius of the helix from the thread interface 112-2, as described above, and a single torsional support thread 133 connects the thread interface 112-2 from the thread interface 112-1 next to the thread interface 112-2 along the helix to each of the thread interfaces 123 positioned along the radius of the helix. Thus, half of the thread interfaces 123 are connected to a single thread interface 112-1, while the other half of the thread interfaces 123 are connected to a single thread interface 112-1 and two thread interfaces 112-2. In FIG. 1, there is a single torsional support thread 133 that passes through all of the thread interfaces 112-2. In other embodiments, there may be more than one torsional support thread 133.

[0072] FIG 1B is a side view of the tip segment 102 of the antenna assembly 100 of FIG 1A. FIG 1B shows only the antenna assembly 100 of FIG 1A, including a partial view of the radiating element 110. Additionally, the radiating element support system comprises a central support 120 and a number of threads 130 that connect the radiating element 110 to the central support 120. The threads include axial support threads 131, radial support threads 132, and torsional support threads 133, with only one thread of each type labeled in FIG 1B to reduce clutter. The radiating element 110 includes a thread interface 112 having two different types 112-1 and 112-2 (only one of each is labeled to reduce clutter).

[0073] As described above with respect to FIG. 1, axial support thread 131 passes along the helical axis of radiating element 110 and through connection point 112 .

[0074] A radial support thread 132 connects each of the thread interfaces 112 to a thread interface 123 positioned directly across from each thread interface 112 along a radius of the helix of the radiating element 110 .

[0075] The torsion support threads 133 connect a given thread interface 112 to two thread interfaces 123 positioned directly along the radius of the helix from the two thread interfaces 112-1 adjacent to the given thread interface 112-2.

[0076] 1C, there is shown a side view of the bottom segment 104 of the antenna assembly 100 of FIG. 1A.

[0077] 1D, there is shown a top view of the antenna assembly 100 of FIGS. 1A-1C. The antenna assembly 100 includes a radiating element 110 and a radiating element support system comprising a central support 120 and a number of threads 130. There are three different configurations of threads: axial support threads 131, radial support threads 132, and torsional support threads 133, with a single thread of each type labeled in FIG. 1D.

[0078] Each thread interface 112 is connected, where applicable, to a top (closer to the tip) and bottom (closer to the base) thread interface by an axle support thread 131. The thread interface on the turn closest to the tip 102 of the radiating element 110 will only connect with the bottom thread interface, and the thread interface on the turn closest to the bottom 104 of the radiating element 110 will only connect with the top thread interface.

[0079] Each thread interface 112 is connected to the central support 120 by a radial support thread 132 (same as thread interface 123 in Figures 1A-1C, but not explicitly shown in Figure 1D) at a contact point positioned directly across from contact point 112 along the radius of the helix.

[0080] Each thread interface 112-2 is further connected to the central support by a torsional support thread 133 at two connection points positioned directly across from the two thread interfaces 112-1 on either side of the thread interface 112-2 along the helix. In the embodiment of FIG. 1D, there is only a single torsional support thread 133 connecting all of the thread interfaces 112-2. In other embodiments, there may be more than one torsional support thread 133.

[0081] 2 is a side view of an antenna assembly 200 having a radiating element support system according to one embodiment. The antenna assembly 200 includes a radiating element 210 and a radiating element support system comprising a central support 220 and a number of threads 230. The number of threads includes two different configurations of threads: axial support threads 231 and radial support threads 232 (only one of each is labeled to reduce clutter).

[0082] Antenna assembly 200 functions in a similar manner to antenna assembly 100, but is not identical. The central support 220 of antenna assembly 200 has a different design than the central support 120 of FIGS. 1A-1D. There are no torsional support threads in antenna assembly 200. Each turn of helical radiating element 110 of antenna assembly 100 had six thread interfaces for connecting the threads to the central support or other thread interfaces, whereas helical radiating element 210 of FIG. 2 has only three thread interfaces 212 in each turn. Because there are only axial support threads 231 and radial support threads 232, the thread interfaces 212 each have only three holes.

[0083] The axial support thread 231 and the radial support thread 232 operate in the same manner as the antenna assembly 100 of FIGS. 1A-1D. The axial support thread connects a thread interface 212 that is positioned vertically along the helical axis. The radial support thread connects each thread interface 212 to a thread interface 223 on a central support 220 that is positioned along the radius of the helical radiating element 110 from the thread interface 212. The axial support thread 231 connects the helix to the base 221 of the central support 220, and the base 221 is attached to the antenna ground plane 240.

[0084] FIG. 3A is a side view of an antenna assembly having a radiating element support system 300 according to one embodiment, and FIG. 3B is a top view of the antenna assembly having the radiating element support system 300 of FIG. 3A.

[0085] FIGS. 3A and 3B represent yet another embodiment of the antenna assembly, and the central support 320 has a different design than the central support 120 or the central support 220. The helical radiating element 310 of the antenna assembly 300 includes six thread interfaces per turn of the helix (i.e., one thread interface every 60°). The plurality of threads of the radiating element support system also include an axial support thread and a radial support thread, as well as a twist support thread. The axial support thread connects the thread interfaces at the same location around the helix (e.g., connecting all thread interfaces at 0°). The radial support thread connects each thread interface along the radius of the helix to the central support. The twist support thread directly connects a thread interface on the helical radiating element to another thread interface on the helical radiating element. Specifically, every other thread interface is directly connected. That is, for example, in one turn, the 0° thread interface is connected to the 120° thread interface, the 60° thread interface is connected to the 180° thread interface, the 120° thread interface is connected to the 240° thread interface, and so on.

[0086] Figure 4 is a side view of a single piece radiating element 410 and central support 420 of an antenna assembly according to one embodiment. The central support 420 is identical to the central support 220 of Figure 2 and similar to the central support 110 of Figures 1A-1D. By manufacturing the radiating element 410 and central support 420 as a single piece, the complexity and cost of assembling an antenna assembly having a radiating element support system is minimized. The process is simplified by having fewer separate parts to hold together when applying or connecting the dielectric threads that comprise the radiating element support system.

[0087] The single-piece radiating element 410 and central support 420 can be manufactured by 3D printing. The material used for 3D printing can be aluminum.

[0088] In some embodiments, the antenna assembly does not include a central support, but may include supports outside the outer volume of the helix. In the absence of a central support, the radiating element can still be 3D printed.

[0089] While multiple threads are applied to the central support 420 of the radiating element 410 (or in some embodiments simply to the radiating element), additional temporary supports can be used to ensure that the helical radiating element retains the correct shape, position, and location.

[0090] 5, shown therein is a simplified block diagram of an antenna assembly 500 including a radiating element support system with external supports according to one embodiment. The antenna assembly 500 may be used in an antenna configured for satellite-based communications.

[0091] 1A-4 included a central support. Antenna assembly 500 includes an outer support 520 connected to a radiating element 510 by a support thread network 530.

[0092] In Figure 5, the external support comprises a single cup element that surrounds the radiating element. In other external support embodiments, the external support may comprise multiple elements, such as multiple posts. In other external support embodiments, the radiating element support system may also include a central support.

[0093] The embodiment of Figures 1A-5 is directed to supporting radiating elements of a satellite antenna. In other embodiments, other satellite payloads can be supported by a system of sleds. In particular, components with high aspect ratios (length to width), such as waveguides and masts, can be supported by a sled support network to reduce vibration modes of said components. Currently, these components are supported by attaching them to other components of the satellite at multiple locations, which can significantly increase mass and lead to problems such as longer overall assembly response during vibration while degrading overall performance. The sled support network can constrain these components at least in the radial direction. The threads of the sled support network can be similar to those described above.

[0094] FIG. 6 is a simplified block diagram of a satellite assembly waveguide 610 including a waveguide thread support network 630 according to one embodiment.

[0095] Waveguide 610 is supported by three support threads of support thread network 630. Support thread network 630 is connected either to existing components of the satellite or to supports that are added to provide connections and support to support thread network 630 and waveguide 610.

[0096] In other embodiments, payloads other than waveguides may be supported by the support thread network.

[0097] In embodiments having external supports, the external supports may be used to limit the displacement of the radiating element in any or all of the axial, radial and / or torsional directions.

[0098] While the above description provides examples of one or more devices, methods, or systems, it will be understood that other devices, methods, or systems may be within the scope of the claims, as will be understood by one of ordinary skill in the art. [Explanation of symbols]

[0099] 100 Antenna assembly 102 Distal Segment 104 Bottom Segment 110 Radiating element 112 Thread interface, connection point 112-1 Thread Interface 112-2 Thread Interface 120 Center support 121 Base 122 Long and thin elements 123 Thread Interface 130 Support Threads, Support Thread Network 131 Axle support thread 132 diameter support thread 133 Torsion Support Thread 140 Antenna Ground Surface 200 Antenna Assembly 210 Radiating element 212 Thread Interface 220 Center support 221 Base 223 Thread Interface 230 threads 231 Axle Support Thread 232 diameter support thread 240 Antenna Ground Plane 300 Radiating element support system, antenna assembly 310 Spiral Radiating Element 320 Center support 410 Radiating Element 420 Center support 500 Antenna Assembly 520 External support 530 Support Thread Network 610 Waveguide 630 Waveguide thread support network, support thread network

Claims

1. 1. A radiating element assembly for an antenna, comprising: A radiating element for emitting and / or receiving electromagnetic waves, and a radiating element support system for physically supporting the radiating element during operation, comprising: a plurality of dielectric support threads, the plurality of dielectric support threads acting as nonlinear structural links interconnecting the radiating elements to constrain the radiating elements in one or more of an axial, radial, and torsional direction, and tensioned with near zero tension; at least one support, the plurality of dielectric support threads interconnecting the radiating elements at the at least one support to constrain the radiating elements in one or more of the axial, radial, and torsional directions; 16. A radiating element assembly comprising a radiating element support system comprising:

2. The radiating element assembly of claim 1 , wherein the at least one support includes a central support positioned within the radiating element.

3. The radiating element assembly of claim 2 , wherein the center support is fixed to a ground plane at a base of the antenna.

4. 3. The radiating element assembly of claim 2, wherein the central support is rigid in tension, compression, bending, and torsion.

5. The radiating element assembly of claim 1 , wherein the at least one support comprises at least one external support positioned outside the radiating element.

6. 2. The radiating element assembly of claim 1, wherein the at least one support includes a central support within the radiating element and at least one external support location outside the radiating element.

7. The radiating element assembly of claim 2 , wherein the radiating element and the central support are manufactured as a single piece.

8. The radiating element assembly of claim 1 , wherein the radiating element is helical.

9. The radiating element assembly of claim 1 , wherein the radiating element is flexible due to a shape of the radiating element.

10. 10. The radiating element assembly of claim 1, wherein the radiating element support system prevents the radiating element from moving beyond a correct nominal position.

11. 10. The radiating element assembly of claim 1, wherein each of said dielectric support threads has a thread diameter in the range of 0.005 to 0.050 inches.

12. The radiating element assembly of claim 1 , wherein the dielectric support thread comprises a radio frequency (RF) transparent material.

13. 10. The radiating element assembly of claim 1, wherein the dielectric support thread comprises glass or aramid fiber.

14. 10. The radiating element assembly of claim 1, wherein each dielectric support thread comprises two or more strands twisted together.

15. satellite payloads, and a plurality of dielectric support threads, the plurality of dielectric support threads acting as nonlinear structural links interconnecting the load to constrain the load in one or more of radial, torsional, and axial directions, and tensioned with near zero tension; at least one support, the plurality of dielectric support threads interconnecting the load with the at least one support to constrain the load in one or more of the radial, torsional, and axial directions; a load support system for physically supporting the load, comprising:

1. A satellite payload assembly comprising:

16. 16. The satellite payload assembly of claim 15, wherein said at least one support includes a central support positioned within said payload.

17. 17. The satellite payload assembly of claim 16, wherein said central support is secured to a ground surface at a base of said payload.

18. 16. The satellite payload assembly of claim 15, wherein said at least one support includes at least one external support positioned outside of said payload.

19. 16. The satellite payload assembly of claim 15, wherein said at least one support includes a central support within said payload and at least one external support location outside said payload.

20. 16. A satellite payload assembly as claimed in claim 15, wherein said payload is a waveguide.

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