Method to assemble aperture segments of a cylindrical feed antenna

Abstract

A method of assembling an antenna aperture from a plurality of antenna aperture segments is described. The method may include placing a first aperture segment relative to a second aperture segment to partially form the antenna aperture. Furthermore, an overlap of the first aperture segment overlaps a complementary underlap of the second aperture segment at a seam. The method may also include joining the overlap of the first aperture segment to the underlap of the second aperture segment to partially form the antenna aperture.

We claim: 
     
         1 . An apparatus comprising:
 a first aperture segment of an antenna aperture; and   a second aperture segment of the antenna aperture, wherein the first aperture segment and second aperture segments comprises an overlap and an overlap, wherein the overlap of the first aperture segment is complementary and is joined to the underlap of the second aperture segment at a seam to form part of the antenna aperture.   
     
     
         2 . The apparatus of  claim 1 , wherein a conductor of a patch of the first aperture segment overlaps a conductor of an iris of the second aperture segment in an overlap region created when the first aperture segment is joined to the second aperture segment. 
     
     
         3 . The apparatus of  claim 2 , wherein the overlap of the first aperture segment comprises a patch glass and a patch metal under the patch glass, wherein each of the patch glass and the patch metal extend beyond a conductive seal joining the patch with a layer of the first aperture segment,
 wherein the complementary underlap of the second aperture segment comprises an iris glass and an iris metal above the iris glass, wherein each of the iris glass and the iris metal extend beyond a conductive seal joining the iris with a patch of the second aperture segment; and   wherein the patch metal of the first aperture segment overlaps the iris metal of the second aperture segment in the overlap region when the first aperture segment is placed adjacent to the second aperture segment to partially form the antenna aperture.   
     
     
         4 . The apparatus of  claim 1 , further comprising an adhesive to join the first and second aperture segments, the adhesive to act as a barrier between an exterior of the antenna aperture and an interior of the antenna aperture at the seam formed between the first and second aperture segments. 
     
     
         5 . The apparatus of  claim 4 , wherein the adhesive creates a contiguous ground plane between iris layers of first and second aperture segments when joined. 
     
     
         5 . The apparatus of  claim 4 , wherein the adhesive is a conductive adhesive. 
     
     
         6 . The apparatus of  claim 5 , wherein the conductive adhesive creates a contiguous ground plane between iris layers of the first and second aperture segments. 
     
     
         7 . The apparatus of  claim 4 , wherein the adhesive is a non-conductive adhesive. 
     
     
         8 . The apparatus of  claim 7 , wherein the non-conductive adhesive forms a choke that prevents radio frequency (RF) leakage at the seam. 
     
     
         9 . The apparatus of  claim 1 , wherein the antenna aperture is a cylindrical radio frequency (RF) antenna aperture formed by four identical aperture segment quadrants. 
     
     
         10 . An apparatus comprising:
 a plurality of aperture segments joined together for form an antenna aperture, wherein each aperture segment includes radio-frequency (RF) radiating antenna elements and includes an overlap and an underlap, wherein the overlap of one of the aperture segments corresponds to an underlap of another of the aperture segments, wherein a first aperture segment of the plurality of aperture segments is adjacent to a second aperture segment of the plurality of segments and comprises an overlap that overlaps, and is joined to, the complementary underlap of the second aperture segment to partially form the antenna aperture.   
     
     
         11 . The apparatus of  claim 10 , wherein a conductor of a patch of the first aperture segment overlaps a conductor of an iris of the second aperture segment in an overlap region created when the first aperture segment is joined to the second aperture segment. 
     
     
         12 . The apparatus of  claim 11 , wherein the overlap of the first aperture segment comprises a patch glass and a patch metal under the patch glass, wherein each of the patch glass and the patch metal extend beyond a conductive seal joining the patch with a layer of the first aperture segment,
 wherein the complementary underlap of the second aperture segment comprises an iris glass and an iris metal above the iris glass, wherein each of the iris glass and the iris metal extend beyond a conductive seal joining the iris with a patch of the second aperture segment; and   wherein the patch metal of the first aperture segment overlaps the iris metal of the second aperture segment in the overlap region when the first aperture segment is placed adjacent to the second aperture segment to partially form the antenna aperture.   
     
     
         13 . The apparatus of  claim 10 , further comprising an adhesive to join the plurality of aperture segments, the adhesive to act as a barrier between an exterior of the antenna aperture and an interior of the antenna aperture at each seam formed between adjacent aperture segments of the plurality of segments. 
     
     
         14 . The apparatus of  claim 10 , wherein the adhesive creates a contiguous ground plane between iris layers of joined aperture segments. 
     
     
         15 . The apparatus of  claim 10 , wherein the adhesive forms an RF choke to prevent RF leakage at a seam formed between adjacent aperture segments of the plurality of segments. 
     
     
         16 . The apparatus of  claim 10 , wherein the antenna aperture is a cylindrical RF antenna aperture formed by four identical aperture segment quadrants.