Continuous Radome Manufacturing with Integrated Reflective Layer
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Solution Overview
Problem
Existing radome manufacturing methods are cumbersome, result in heavy and costly products with exposed reflective layers prone to corrosion, and require multiple components and labor-intensive assembly, while prior methods for continuous production do not effectively direct radiation beams or provide integrated electromagnetic shielding.
Innovation Solution
A method for manufacturing radomes using pultrusion or extrusion that integrates a reflective layer within the wall of the radome during the forming process, enhancing adhesion through surface structuring and chemical or physical treatments, allowing for a lightweight, single-piece construction with improved radiation directionality and reduced component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a reflective layer is cast onto the wall surface or within the wall of a radome using traditional casting methods, then electromagnetic wave reflection is achieved, but the manufacturing process becomes tedious and inconvenient
Solution Approach 1:
The patent combines the reflective layer application with the radome wall formation process into a single integrated operation. The reflective layer is applied to the inner surface of the radome wall during the extrusion process itself, rather than as a separate post-processing step. This merging of operations eliminates the tedious separate casting or coating steps while ensuring the reflective layer is properly integrated into the radome structure.
Solution Approach 2:
The reflective layer is prepared and positioned in advance during the radome manufacturing process. The layer is applied to the inner surface of the radome wall before the final curing and assembly stages, ensuring it is already in place when the radome is completed. This preliminary action eliminates the need for separate later application steps and ensures proper integration.
2Adaptability or versatility
If a radome is manufactured with separate components and reflective layers applied later, then manufacturing flexibility is maintained, but the resulting unit becomes heavy and the reflective layer is exposed to corrosion
Solution Approach 1:
The patent merges the reflective layer with the radome wall into a single integrated structure. The reflective layer is applied to the inner surface of the wall during the extrusion process, making it an integral part of the radome rather than a separate component. This integration protects the reflective layer from corrosion by embedding it within the wall structure, while maintaining manufacturing flexibility through the continuous extrusion process.
Solution Approach 2:
The patent uses composite material construction where the radome wall and reflective layer form an integrated composite structure. The wall material and reflective layer are combined during manufacturing to create a unified composite component that leverages the properties of both materials while protecting the reflective layer from environmental exposure.
3Adaptability or versatility
If multiple components are assembled to create a radome with reflective layers, then functional requirements are met, but assembly labor and costs increase
Solution Approach 1:
The patent combines multiple functional components into a single integrated radome structure. The wall, reflective layer, and structural elements are all formed together in one continuous extrusion process, eliminating the need for separate assembly operations. This single-step manufacturing approach maintains all necessary functional requirements while completely eliminating assembly labor and associated costs.
Solution Approach 2:
The patent creates a universal radome structure that performs multiple functions simultaneously. The single extruded component provides structural support, electromagnetic wave reflection, and environmental protection all in one integrated piece, eliminating the need for multiple specialized components and their associated assembly operations.
4Strength
If traditional radome manufacturing methods are used, then structural integrity is maintained, but the number of components increases and assembly complexity increases
Solution Approach 1:
The patent merges multiple components into a single integrated structure formed by continuous extrusion. The wall, reflective layer, and structural elements are all created as one unified component, reducing the number of parts from multiple separate components to a single piece while maintaining structural integrity through the continuous manufacturing process.
Solution Approach 2:
The patent uses segmentation in reverse by integrating what would traditionally be separate segments into a single continuous structure. The continuous extrusion process creates an unbroken, integrated structure that eliminates joints and interfaces between components, thereby reducing complexity while maintaining or even improving structural integrity.
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 enables the production of lightweight, cost-effective radomes with enhanced radiation reflection and shielding properties, integrated within a single component, reducing assembly complexity and maintaining structural integrity while directing radiation beams effectively.
Implementation Method 1
pulling resin-wetted continuous fibers, mats or fabrics through one or more guides for preforming and then through a heated forming die
Implementation Method 2
a layer reflective of electromagnetic waves (i.e. electrically conductive) is cast onto the wall surface or within the wall of a radome
Data Source
Figure 1~3
Figure 4
AI summary
The invention relates to a method for manufacturing an antenna radome from composite materials in continuous action by pultrusion technique or extrusion. A layer (9, 9') reflective of electromagnetic radiation is guided within the wall of a product (2) developing in continuous action in a forming die (5, 15) or onto the surface thereof for an integral component of the wall. Finally, the continuous product is chopped up for radomes of appropriate length.