Antenna radome
A one-piece, plate-shaped antenna radome with multiwall and folding sections addresses high tooling and transportation costs in multi-part designs by enabling flat assembly and controlled deformation, enhancing durability and reducing costs.
Patent Information
- Application Number
- PCT/EP2024/069398
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2024-07-09
- Publication Date
- 2026-01-15
AI Technical Summary
Current antenna radomes, particularly multi-part designs, incur high tooling and transportation costs due to their complex, 2-dimensional structure and require costly joining processes, which can lead to random deformations and durability issues.
A one-piece, plate-shaped antenna radome composed of multiwall sections and folding sections, allowing for controlled deformation during bending, reduces tooling and transportation costs by enabling flat assembly on the production line, with thermoplastic deformation ensuring stability and durability.
The solution simplifies manufacturing, reduces costs, and enhances durability by minimizing random deformations, while maintaining structural integrity and ease of assembly.
Smart Images
Figure EP2024069398_15012026_PF_FP_ABST
Abstract
Description
[0001] Antenna Radome
[0002] Technical field
[0003] The invention is referring to the technical field of antenna radomes and methods for manufacturing antenna radomes.
[0004] Background
[0005] Antenna radomes according to the art are typically formed from multiple elements, wherein the elements are formed such that their cross section is forming a half shell. Also, antenna radomes are known that are formed from a single element, for example by cold-drawing.
[0006] The multi-part nature of current radomes places high demands on toolmaking, especially in the multiwall radome version, and entails high tooling costs. Multiwall parts are preferably 2-dimen- sional objects - i.e. flat and also more likely to be used as semi-finished products (Greenhouse panels). It is therefore not sensible (not favourable) to generate several complex, 2-dimension- ally shaped individual components that are to be joined together later to form a closed radome. Especially if the joining process takes place lengthwise over the entire length of the radome (up to 2.6 metres).
[0007] An antenna radome according to the invention comprises a sheet element, wherein the sheetelement is a plate-shaped element that comprises multiwall sections and at least one folding section. The folding section is aligned in between two multiwall sections, wherein the folding section and the multiwall sections are extending in parallel in a first direction. The multiwall sections comprise an upper wall and a lower wall, wherein the upper wall of the multiwall sections is connected to the lower wall of the multiwall sections by multiple connecting walls. The folding section is a section that is configured for bending the sheet element. The sheet element is bent in the folding section to form the antenna radome.
[0008] The plate-shaped element can be a multiwall sheet, wherein parts of the multiwall sheet are formed to be configured for bending. A section can be seen as configured for bending if it comprises a structure that comprises elements that will align in a pre-defined way during a bending process or in that less force has to be applied for bending when compared to the multiwall sections. The bending process leads to a detectable deformation of the plate-shaped element that can be identified after bending. The bending is performed such that a line in which a bending curvature is located is parallel to the multiwall sections.
[0009] It is one advantage of a radome according to the invention that the initial plate-shaped element can be flat before bending. This allows a transport of the non-bent radome by using a minimal amount of space. This reduces costs in the manufacturing process.
[0010] Simplification of an antenna housing, here also referred to as antenna radome, construction is achieved by combining quasi one-dimensional individual components into one component.
[0011] In order to utilise the advantages and expertise of the multiwall parts already available on the market and thereby reduce the complexity of the tools and thus the tool costs, as well as to further reduce the transport volume with flat parts and thus save transport and storage costs, it is advantageous to produce the antenna radome in flat parts and only erect them in the warehouse. To reduce costs (tooling costs, storage costs, transport costs, handling costs), it makes sense to generate individual components that are as flat as possible, quasi one-dimensional, and to join them into a closed radome by erecting them directly on the production line. Preferably at the sides, but other joining positions are also conceivable and advantageous.
[0012] The dependent claims define advantageous features of the invention.
[0013] In particular, the folding section is configured for bending by having a structure that leads to a controlled deformation of the folding section in a bending process. Multiwall plates without folding sections tend to have random deformations of the walls after bending, which can lead to small indentations that can have a negative impact on the durability of the radome, for example as water might collect in the indentations. A controlled deformation is a deformation that leads to a predefined form after bending.
[0014] In particular, the structure of the folding section is different over a structure of the multiwall sections. The material that is used for forming the plate-shaped element can be the same over the entire plate-shaped element. The use of different structures in the multiwall sections and the folding sections will ensure that that less force has to be applied for bending when compared to the multiwall sections.
[0015] In particular, the folding section comprises a section in which the sheet element comprises only a single layer. The single layer is a single wall of solid material. A single layer can be optionally achieved in a manufacturing process by compressing a multiwall plate under the application of heat such that an upper wall and a lower wall of the multiwall plate are getting compressed into one common wall.
[0016] In particular, the folding section comprises an upper wall and a lower wall, wherein the upper wall of the folding section is connected to the lower wall of the folding section by multiple connecting walls, wherein the upper wall of the folding section and / or the lower wall of the folding section is forming an arch for connecting adjacent connecting walls of the folding section. The arch can be in particular a trianglar arch or a round arch. The arch allows a decompression or extension of the material of the upper wall or lower wall of the sheet element when the sheet element is bent. For example, an arch can be compressed in case that it is forming a wall of the sheet element that is aligened towards a center of the curve that is bent. In the alternative, an arch can be pulled apart during bending in case that it is forming a wall of the sheet element that is aligened away from center of the curve that is bent.
[0017] In particular, the folding section comprises an upper wall and a lower wall, wherein the upper wall of the folding section is connected to the lower wall of the folding section by multiple connecting walls, wherein the upper wall of the folding section and / or the lower wall of the folding section is forming an arch for connecting adjacent connecting walls of the folding section, wherein the arch is extending towards a center between the upper wall of the folding section and the lower wall of the folding section.
[0018] In particular, the sheet element is made of a thermoplastic material. With this, the bending can be a thermoplastic deformation, which allows to achieve a stable shape of the radome after bending.
[0019] In particular, the sheet element is a one-piece element. In particular, the sheet element is formed from a single multi-wall sheet that had a forming procedure applied for forming the folding section.
[0020] In particular, the antenna radome comprises a tube, wherein the entire tube or a part the tube is formed from the sheet element or from multiple ones of the sheet element. This allows to easily use the radome in combination with base station antennas according to the art.
[0021] In particular, opposing ends of the sheet element are connected to each other, preferably connected to each other by a connecting element. In particular, the sheet element comprises at least four multiwall sections and at least four folding sections, the at least four folding sections including the first folding section. This allows to fold an entire tube by using a single sheet element.
[0022] A base station antenna that comprises the antenna radome according to the invention is suitable to achieve all advantages of the antenna radome.
[0023] A method for manufacturing an antenna radome according to an aspect of the invention comprises forming a sheet element, wherein the sheet element is a plate-shaped element that comprises multiwall sections and at least one folding section, wherein the folding section is aligned in between two multiwall sections, wherein the folding section and the multiwall sections are extending in parallel in a first direction, wherein the multiwall sections comprise an upper wall and a lower wall, wherein the upper of the multiwall sections is connected to the lower wall of the multiwall sections by multiple connecting walls, wherein the folding section is a section that is configured for bending the sheet element; and bending the sheet element in first folding section to form the antenna radome. The method is suitable to manufacture the antenna radome. That is, the antenna radome according to the invention is obtained from the method.
[0024] In particular, the method comprises, before bending the sheet element, transporting the sheet element sheet in a stack of flat multiwall sheets. This allows a reduction of transport costs, in particular when multiple antenna radomes are to be built.
[0025] In particular, the bending the sheet element comprises a thermoplastic deformation of the sheet element. That is, it is preferable that heat is applied to the folding sections during and / or in preparation for bending the sheet element.
[0026] Brief description of the drawings
[0027] Fig. 1a shows a sheet element comprising multiwall sections and folding sections in a first view, fig. 1b shows the sheet element comprising multiwall sections and folding sections in a second view, fig. 1c shows an antenna radome that is manufactured from the sheet element by bending the folding sections, fig. 2 shows an exemplary antenna radome according to the invention, fig. 3 shows embodiments of folding sections according to the invention, fig. 4 shows a flow diagram of a method for manufacturing a radome according to the invention, fig. 5 shows an exemplary antenna radome according to the invention together with a sheet element for forming this antenna radome; and fig. 6 shows a further exemplary antenna radome according to the invention together with a sheet element for forming this antenna radome.
[0028] Detailed description
[0029] Figs. 1a and 1b show a sheet element 2 comprising multiwall sections 3a, 3b, 3c, 3d, 3e and folding sections 4a, 4b, 4c, 4d, wherein fig. 1a is showing the sheet element 2 in a first view and fig. 1b is showing the sheet element in a second view. The first view shows the sheet element 2 in a xz-plane. The second view shows the sheet element 2 in a xy-plane. That is, fig. 2 is a view of the sheet element 2 of fig. 1a after a 90-degree rotation.
[0030] The sheet element 2 is a one-piece element that is made of a thermoplastic material. The sheet-element 2 is a plate-shaped element that comprises the multiwall sections 3a, 3b, 3c, 3d, 3e and the folding sections 4a, 4b, 4c, 4d. The multiwall sections 3a, 3b, 3c, 3d, 3e comprise a first multiwall section 3a, a second multiwall section 3b, a third multiwall section 3c, a fourth multiwall section 3d and a fifth multiwall section 3e. The multiwall sections 3a, 3b, 3c, 3d, 3e are extending in parallel in a z-direction. The folding sections 4a, 4b, 4c, 4d comprise a first folding section 4a, a second folding section 4b, a third folding section 4s and a fourth folding section 4d. The folding sections 4a, 4b, 4c, 4d are extending in parallel in the z-direction. Thus, the folding sections 4a, 4b, 4c, 4d are extending in parallel to the multiwall sections 3a, 3b, 3c, 3d, 3e. Consequently, a transition is formed between adjacent multiwall sections 3a, 3b, 3c, 3d, 3e and folding sections 4a, 4b, 4c, 4d. These transitions are forming parallel lines in the z-direction.
[0031] The first folding section 4a is aligned in between two multiwall sections 3a, 3b, that is in between the first multiwall section 3a and the second multiwall section 3b. The first folding section 4a and the multiwall sections 3a, 3b are extending in parallel in the z-direction, wherein the z- direction is a first direction. The second folding section 4b is aligned in between two multiwall sections 3b, 3c, that is in between the second multiwall section 3b and the third multiwall section 3c. The third folding section 4b is aligned in between two multiwall sections 3e, 3e, that is in between the fourth multiwall section 3d and the fifth multiwall section 3e. The fourth folding section 4d is aligned in between two multiwall sections 3e, 3a, that is in between the fifth multiwall section 3e and the first multiwall section 3a.
[0032] The multiwall sections 3a, 3b, 3c, 3d, 3e are sections that are not foreseen to be bent to the same degree as the folding sections 4a, 4b, 4c, 4d. The folding sections are configured for bending the sheet element 2. For this, the folding sections 4a, 4b, 4c, 4d comprise a structure that leads to a controlled deformation of each folding section in a bending process. Exemplary structures are shown in fig. 3.
[0033] A structure of each folding section 4a, 4b, 4c, 4d is different over a structure of the multiwall sections 3a, 3b, 3c, 3d, 3e. The structure of the folding section 4a, 4b, 4c, 4d allows a bending of the folding sections 4a, 4b, 4c, 4d with less force when compared to the multiwall sections 3a, 3b, 3c, 3d, 3e that are not foreseen to be bent.
[0034] Fig. 1c shows an antenna radome 1 that is manufactured from the sheet element 2 by bending the sheet element 2 in each one of the folding sections 4a, 4b, 4c, 4d. A cross sectional view of the antenna radome 1 in the xy-plane is shown. The antenna radome 2 has the shape of a tube, wherein the entire tube is formed from the one sheet element 2. A central axis of the tube is ex- tending in the z-direction. For closing the tube, opposing ends of the sheet element 2 are connected to each other, wherein the opposing ends are connected to each other by a connecting element 20.
[0035] Fig. 2 shows an antenna radome 1 according to embodiment of the invention. The antenna radome 2 corresponds to the antenna radome that is shown with figs. 1a to 1c, wherein the sheet element 2 comprises two additional multiwall sections 3f, 3g and two additional folding sections 4e, 4f.
[0036] Fig. 2 shows that the multiwall sections 3a, 3b, 3c, 3d, 3e, 3f, 3g comprise an upper wall 5 and a lower wall 6, wherein the upper wall 5 of the multiwall sections 3a, 3b, 3c, 3d, 3e, 3f, 3g is connected to the lower wall 6 of the multiwall sections 3a, 3b, 3c, 3d, 3e, 3f, 3g by multiple connecting walls 7. In this example, the upper wall 5 is an outer wall of the antenna radome 1 and the lower wall 6 is an inner wall of the antenna radome 1.
[0037] In the folding sections, a thickness of the sheet element 2 is reduced in the, such that the folding sections 4a, 4b, 4c, 4d, 4e, 4f are reduced to a single layer 11. Thus, each folding section 4a, 4b, 4c, 4d, 4e, 4f comprises a section in which the sheet element 2 comprises only the single layer 11.
[0038] The antenna radome 2 optionally comprises supporting elements 12, 13 that are aligned inside the antenna radome 2. The supporting elements 12, 13 are in contact with the inner wall of the antenna radome 1 that is formed by the sheet element 2 and is in contact with more than two of the multiwall sections 3a, 3b, 3c, 3d, 3e, 3f, 3g, which allows to stabilize the antenna radome 1, as the supporting elements 12, 13 will not allow any further bending of the folding sections 4a, 4b, 4c, 4d, 4e, 4f once the sheet element 2 has been bent into its final shape, here the tubular shape:
[0039] The connecting element 20 is an element that interacts with the edge portions of the multiwall sections 3f, 3g that are to be connected to each other. The connecting element 20, a part of a reflector plate or can be a multiwall sheet that is configured to slide into nudges at the sidewalls of the edge portions of the multiwall sections 3f, 3g that are to be connected to each other.
[0040] Fig. 3 shows embodiments of folding sections according to the invention. The depicted structures can be applied to any folding section 4a, 4b, 4c, 4d, 4e, 4f, wherein different types of structures can be combined. Fig. 3 shows in option a) that a folding section 4a comprises a section in which the sheet element 2 comprises only a single layer 11 . This corresponds with the exemplary embodiment of the folding sections 4a, 4b, 4c, 4d, 4e, 4f of fig 3.
[0041] Fig. 3 shows in option b) that a folding section 4a comprises an upper wall 8 and a lower wall 9, wherein the upper wall 8 of the folding section 4a is connected to the lower wall 9 of the folding section 4a by multiple connecting walls 10. This means that the folding section 4a is also a multiwall element. However, the upper wall 8 is not parallel to the lower wall 9 but the lower wall 9 of the folding section 4a is forming an arch for connecting adjacent connecting walls 10 of the folding section 4a. Each connecting walls 10 is connected to its neighbouring connecting walls 10 via a respective arch. Option b) discloses circular arches. In case that the lower wall 9 is forming an inner wall of the antenna radome 1 , the arches will be compressed such that the sheet element 2 can be bent in the folding section 4a. In the alternative the upper wall 8 of the folding section 4a is forming an arch for connecting adjacent connecting walls 10 of the folding section 4a. In case that the upper wall 8 is forming an outer wall of the antenna radome 1 , the arches will be expanded such that the sheet element 2 can be bent in the folding section 4a. In the example according to option b), the arches are extending away from a center between the upper wall 8 of the folding section 4a and the lower wall 9 of the folding section 4a. That is, the arches are extending outwards from a surface that will be forming the inner wall of the antenna radome 1 or outwards from a surface that will be forming the outer wall of the antenna radome. In the alternative, the arches are extending towards a center between the upper wall 8 of the folding section 4a and the lower wall 9 of the folding section 4a. That is, the arches are extending inwards from a surface that will be forming the inner wall of the antenna radome 1 or inwards from a surface that will be forming the outer wall of the antenna radome 1. This alternative option has the advantage that the arches can be formed into the sheet element by applying a pressure under thermal influence from the outside of the sheet element 2.
[0042] In the alternative, the arches can be formed to be triangular arches. That is, each one of th arches comprises two flat surfaces that are connected to each other. The triangular arches can be formed and aligned in the same way as the described circular arches. In particular, the triangular arches are extending away from a center between the upper wall 8 of the folding section 4a and the lower wall 9 of the folding section 4a, as shown in options c). In particular, the triangular arches are extending towards a center between the upper wall 8 of the folding section 4a and the lower wall 9 of the folding section 4a, as shown in options d) and e). The arches according to all options b), c), d) and e) can be formed in the upper wall 8 and / or the lower wall 9. Fig. 4 is illustrating a method for manufacturing the antenna radome 1 according to any of the embodiments.
[0043] In a first step 101, the sheet element 2 is formed. The sheet element 2 is a plate-shaped element that comprises multiwall sections 3a, 3b and at least one folding section 4a, wherein the folding section 4a is aligned in between two multiwall sections 3a, 3b, wherein the folding section 4a and the multiwall sections 3a, 3b are extending in parallel in a first direction z. The multiwall sections 3a, 3b comprise an upper wall 5 and a lower wall 6, wherein the upper wall 5 of the multiwall sections 3a, 3b is connected to the lower wall 6 of the multiwall sections 3a, 3b by multiple connecting walls 7, wherein the folding section 4a is a section that is configured for bending the sheet element 2. The sheet element 2 can be formed from a multiwall plate, wherein a process for forming the folding section 4a is exclusively applied to the specific area that is forming the folding section 4a and is not applied to the areas that are forming the multiwall sections 3a, 3b.
[0044] In an optional second step 103, and therefore before bending the sheet element 2, the sheet element is transported from a location of performing the first step to a location of performing a third step 104, wherein the sheet element 2 is transported in a stack of flat multiwall sheets. This allows an effective transport of sheet plates for manufacturing multiple antenna radomes.
[0045] In the third step 104, the sheet element 2 is bent in first folding section 4a, preferably in all folding sections of the sheet element 2, to form the antenna radome 1. This can be done under the application of heat. In this case, bending the sheet element 2 comprises a thermoplastic deformation of the sheet-element 2. In the alternative, the sheet element 2 is bent in first folding section 4a without applying heat, that is a process of cold-bending is applied to the sheet element 2.
[0046] Fig. 5 shows an embodiment of the antenna radome 1 that is also described in view of fig. 2. In addition, the sheet element 2 that is used for manufacturing the antenna radome 1 is shown before the sheet element 2 is bent to form the tube.
[0047] Fig. 6 shows an alternative embodiment of the antenna radome 1 that essentially corresponds to the embodiment of fig. 3. In this embodiment, the antenna radome 1 comprises two halfshells, wherein each half-shell is formed from a sheet element. In this case, each sheet element is a a plate-shaped element that comprises multiwall sections 3a, 3b and at least one folding section 4a; wherein the folding section 4a is aligned in between two multiwall sections 3a, 3b, wherein the folding section 4a and the multiwall sections 3a, 3b are extending in parallel in a first direction (z); wherein the multiwall sections 3a, 3b comprise an upper wall 5 and a lower wall 6, wherein the upper wall 5 of the multiwall sections 3a, 3b is connected to the lower wall 6 of the multiwall sections 3a, 3b by multiple connecting walls 7; wherein the folding section 4a is a section that is configured for bending the sheet element 2. Each sheet element 2 is bent to form one of the halt shells and the half shells are connected to form the antenna radome 1.
Claims
Claims1. Antenna radome (1), comprising: a sheet element (2), wherein the sheet-element is a plate-shaped element that comprises multiwall sections (3a, 3b) and at least one folding section (4a); wherein the folding section (4a) is aligned in between two multiwall sections (3a, 3b), wherein the folding section (4a) and the multiwall sections (3a, 3b) are extending in parallel in a first direction (z); wherein the multiwall sections (3a, 3b) comprise an upper wall (5) and a lower wall (6), wherein the upper wall (5) of the multiwall sections (3a, 3b) is connected to the lower wall (6) of the multiwall sections (3a, 3b) by multiple connecting walls (7); wherein the folding section (4a) is a section that is configured for bending the sheet element (2); and wherein the sheet element (2) is bent in the folding section (4a) to form the antenna radome (1).
2. Antenna radome (1) according to claim 1, wherein the folding section (4a) is configured for bending by having a structure that leads to a controlled deformation of the folding section in a bending process.
3. Antenna radome (1) according to any one of claims 1 or 2, wherein a structure of the folding section (4a) is different over a structure of the multiwall sections (3a, 3b).
4. Antenna radome (1) according to any one of claims 1 to 3, wherein the folding section (4a) comprises a section in which the sheet element (2) comprises only a single layer (11), and / or wherein the folding section (4a) comprises an upper wall (8) and a lower wall (9), wherein the upper wall (8) of the folding section (4a) is connected to the lower wall (9) of the folding section (4a) by multiple connecting walls (10), wherein the upper wall (8) of the folding section (4a) and / or the lower wall (9) of the folding section (4a) is forming an arch for connecting adjacent connecting walls (10) of the folding section (4a).
5. Antenna radome (1) according to any one of claims 1 to 3, wherein the folding section (4a) comprises an upper wall (8) and a lower wall (9), wherein the upper wall (8) of the folding section (4a) is connected to the lower wall (9) of the folding section (4a) by multiple connecting walls (10), wherein the upper wall (8) of the folding section (4a) and / or the lower wall (9) of the folding section (4a) is forming an arch for con-necting adjacent connecting walls of the folding section, wherein the arch is extending towards a center between the upper wall (8) of the folding section (4a) and the lower wall (9) of the folding section (4a).
6. Antenna radome (1) according to any one of the previous claims, wherein the sheet element (2) is made of a thermoplastic material.
7. Antenna radome (1) according to any one of the previous claims, wherein the sheet element (2) is a one-piece element.
8. Antenna radome (1) according to any one of the previous claims, wherein the antenna radome (1) comprises a tube, wherein the entire tube or a part the tube is formed from the sheet element (2) or from multiple ones of the sheet element (2).
9. Antenna radome (1) according to claim 8, wherein opposing ends of the sheet element (4a) are connected to each other, preferably connected to each other by a connecting element (20).
10. Antenna radome (1) according to any one of the previous claims, wherein the sheet element (2) comprises at least four multiwall sections (3a, 3b, 3c, 3d) and at least four folding sections (4a, 4b, 4c, 4d), the at least four folding sections (4a, 4b, 4c, 4d) including the first folding section (4a).
11. Base station Antenna (20), wherein the base station antenna (20) comprises the antenna radome (1) according to any one of the preceding claims.
12. Method (100) for manufacturing an antenna radome, the method comprising: forming (101) a sheet element (2), wherein the sheet element (2) is a plate-shaped element that comprises multiwall sections (3a, 3b) and at least one folding section (4a), wherein the folding section (4a) is aligned in between two multiwall sections (3a, 3b), wherein the folding section (4a) and the multiwall sections (3a, 3b) are extending in parallel in a first direction (z), wherein the multiwall sections (3a, 3b) comprise an upper wall (5) and a lower wall (6), wherein the upper wall (5) of the multiwall sections (3a, 3b) is connected to the lower wall (6) of the multiwall sections (3a, 3b) by multiple connecting walls (7),wherein the folding section (4a) is a section that is configured for bending the sheet element (2); and bending (102) the sheet element (2) in first folding section (4a) to form the antenna radome (1).
13. The method (100) according to claim 12, the method (100) further comprising: before bending the sheet element, transporting (103) the sheet element in a stack of flat multiwall sheets.
14. The method (100) according to any one of claims 12 and 13, wherein bending the sheet element comprises a thermoplastic deformation of the sheet-element.
15. Antenna radome (1), wherein the antenna radome (1) is obtained from the method (100) of any of claims 12 to 14.