Reflective and permeable metalized laminate
An antenna reflector includes a laminated structure including a first layer and a second layer, where the first layer has an electrically conductive and electrically reflective front surface and includes a nonwoven metallized fiber matte and the second layer includes an open weave fabric. The laminated structure is acoustically permeable. In some implementations, a laminated structure is formed by co-curing the first layer and the second layer.
1. An antenna reflector comprising a laminated structure including a first layer and a second layer, wherein:
the first layer is a nonwoven metallized fiber matte including metallized, randomly oriented, short-chopped fibers disposed within a binder, the nonwoven metallized fiber matte having a substantial percentage of open volume provided by randomly dispersed openings, an electrically conductive and electrically reflective front surface, and a rear surface laminated to a front surface of the second layer; and
the second layer includes an open weave fabric.
2. The antenna reflector of claim 1 , wherein the laminated structure is acoustically permeable.
3. The antenna reflector of claim 1 , wherein the first layer and the second layer are co-cured.
4. The antenna reflector of claim 1 , wherein the first layer and the second layer are bonded after curing the open weave fabric.
5. The antenna reflector of claim 1 , wherein each of the first layer and a second layer has a thickness not greater than 0.05 inches.
6. The antenna reflector of claim 1 , further comprising a honeycomb core.
7. The antenna reflector of claim 6 , wherein the honeycomb core is sandwiched between the laminated structure and a rear skin, the laminated structure being disposed proximate to a first surface of the honeycomb core and the rear skin being disposed proximate to a second surface of the honeycomb core, the second surface being opposite to the first surface.
8. The antenna reflector of claim 1 , wherein the fiber matte includes one or more of carbon fibers, carbon composite fibers, polyamide fibers and glass fibers.
9. The antenna reflector of claim 1 , wherein the open weave fabric is triaxially woven.
10. The antenna reflector of claim 1 , wherein the open weave fabric includes one or more of carbon fibers, carbon composite fibers, polyamide fibers and glass fibers.
11. A method of fabricating a laminated structure for an antenna reflector member, the method comprising:
forming a first layer of an electrically conductive and electrically reflective material, the first layer including a first plurality of gores, each gore including a nonwoven metallized fiber matte including metallized, randomly oriented short-chopped fibers disposed within a binder, the nonwoven metallized fiber matte having a substantial percentage of open volume provided by randomly dispersed openings, an electrically conductive and electrically reflective front surface, and a rear surface;
forming a second layer, the second layer including a second plurality of gores, each gore including an open weave fabric; and
laminating the rear surface of the first layer to a front surface of the second layer to form the laminated structure.
12. The method of claim 11 , wherein the laminated structure is acoustically permeable.
13. The method of claim 11 , wherein forming the first layer includes laying the first plurality of gores on a reflector mold.
14. The method of claim 11 , wherein forming the second layer includes laying the second plurality of gores on the first layer.
15. The method of claim 11 , wherein laminating includes co-curing.
16. The method of claim 11 , wherein laminating includes bonding.
17. The method of claim 16 , wherein the first layer and the second layer are bonded after curing the open weave fabric.
18. The method of claim 11 , wherein each of the first layer and a second layer has a thickness not greater than 0.05 inches.
19. The method of claim 11 , further comprising adhering the laminated structure to a honeycomb core.
20. The method of claim 19 , further comprising sandwiching the honeycomb core between the laminated structure and a rear skin, wherein the laminated structure is disposed proximate to a first surface of the honeycomb core, and the rear skin is disposed proximate to a second surface of the honeycomb core opposite to the first surface.