Radome Assembly With Adhesive Channel and Clips for Low RF Loss
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Solution Overview
Problem
Existing radomes are susceptible to aging and stress damage from environmental conditions, leading to increased RF transmission losses and requiring heavier constructions that increase costs and reduce receiving sensitivity.
Innovation Solution
A lightweight radome manufacturing method using a monocoque design with a waterproof seal, achieved by mating two housing halves with a peripheral channel and adhesive sealant, and mechanical clip engagement, which reduces weight while maintaining structural integrity and RF performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a heavier construction of radome is used, then structural strength and durability are improved, but RF transmission losses increase and receiving sensitivity decreases
Solution Approach 1:
The radome uses a composite structure combining monocoque housing halves made from lightweight materials with adhesive sealant bonding and mechanical clip engagement. This composite approach achieves structural strength equivalent to heavier constructions while using less material, thereby reducing RF transmission losses without compromising durability
Solution Approach 2:
The monocoque design employs thin-walled housing halves that rely on their geometric shape and bonding system rather than thick material for strength. The adhesive sealant creates a flexible yet strong bond between halves, allowing the use of thinner materials that are transparent to RF waves while maintaining structural integrity
2Weight of moving object
If a monocoque design with adhesive sealant is used, then weight is reduced, but waterproof sealing and structural integrity become more difficult to achieve
Solution Approach 1:
The invention merges two sealing mechanisms: adhesive sealant bonding and mechanical clip engagement. The adhesive provides continuous sealing along the peripheral channel, while the mechanical clips provide discrete reinforcement points. This combination achieves reliable waterproof sealing in a lightweight construction that neither mechanism could achieve alone
Solution Approach 2:
The adhesive sealant acts as an intermediary substance between the monocoque housing halves, creating a waterproof bond that distributes stress and prevents water ingress. The mechanical clips serve as intermediaries that reinforce the bond at critical points, ensuring structural integrity without requiring heavy materials
3Manufacturing precision
If alignment pins are used during assembly, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The assembly process is segmented into distinct stages: alignment using pins, bonding using adhesive sealant, and mechanical securing using clips. This segmentation allows each function to be optimized independently - alignment pins provide precision without requiring permanent features, while clips provide structural reinforcement without interfering with the bonding process
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method results in a lightweight, structurally robust radome with reduced RF transmission losses, lower installation costs, and improved ease of assembly, enhancing antenna performance and installer safety.
Implementation Method 1
applying an adhesive sealant in the front housing-half peripheral channel; moving the rear and front housing-halves towards each other thereby at least partially submerging the rear housing-half peripheral edge in the adhesive sealant received in the front housing-half peripheral channel region to form a waterproof seal and adhesively bond the rear and front housing-halves to each other
Data Source
AI summary
A method of manufacturing an antenna using a radome (10) comprising a front portion (30) and a rear portion (20), the front and rear portions (20, (30) configured to define an interior cavity in which an antenna arrangement is received, the method comprising placing an antenna panel on an inside of one of the front and rear portions, and bringing the portions together, whereby the front portion (30) includes a peripheral channel region (31) configured to contain an adhesive sealant (60) and receive a peripheral edge (21) of the rear portion (20) that is partially submerged in the adhesive sealant (60) before it cures. Additional mechanical fastening clip engagement members (23; 33) are provided inside both the front and rear portions (20; 30) that engage with one another and mechanically secure the radome front and rear portions (20; 30) to each other, in addition to the adhesive joint provided by the adhesive sealant (60) once cured.