Method for making a radiator structure for a helical antenna
An embodiment of the invention is directed to a method for manufacturing a radiator structure for a conical helical antenna that includes: (a) processing a piece of metal so as to produce a first metal structure with conical exterior and interior surfaces, and (b) processing the first metal structure to remove material between the conical exterior and interior surfaces to yield a radiator structure with a conical helical shaped conductor that can be combined with a ground plane to produce a conical helical antenna. In one embodiment, the radiator structure includes a matching structure and a cap with the conical helical conductor, matching structure, and cap being a single piece of metal.
1. A method for making a radiator structure for a helical antenna, comprising:
providing a piece of metal stock;
processing the piece of metal stock to produce a processed piece of metal with a frusto-conical exterior side surface and a frusto-conical interior side surface with the frusto-conical exterior and interior side surfaces defining a frusto-conical side wall, the processed piece of metal having a radiator portion and a non-radiator portion; and
removing metal located between the frusto-conical exterior side surface and the frusto-conical interior side surface and associated with the non-radiator portion to produce a self-supporting conical helix having an upper lateral edge and a lower lateral edge that is separated from the upper lateral edge;
the step of removing includes first removing metal located between the frusto-conical interior side surface and the frusto-conical exterior side surface and associated with the non-radiator portion to define a portion of the upper lateral edge of the conical helix and a portion of the lower lateral edge of the conical helix;
the portion of the upper lateral edge of the conical helix extending partially from one of the frusto-conical exterior side surface and the frusto-conical interior side surface to the other of the frusto-conical exterior side surface and the frusto-conical interior side surface;
the portion of the lower lateral edge of the conical helix extending partially from one of the frusto-conical exterior side surface and the frusto-conical interior side surface to the other of the frusto-conical exterior side surface and the frusto-conical interior side surface; and
the step of removing includes, following the step of first removing, second removing metal associated with the non-radiator portion to define a series of helical voids with one helical void separated from an immediately adjacent helical void by a helical strut that is associated with the non-radiator portion.
2. A method, as claimed in claim 1 , wherein:
the step of second removing includes removing metal extending from a groove base surface to one of the frusto-conical interior side surface and the frusto-conical exterior side surface.
3. A method, as claimed in claim 1 , wherein:
the step of second removing includes removing metal extending from the frusto-conical interior side surface to the frusto-conical exterior side surface.
4. A method, as claimed in claim 1 , wherein:
the step of removing includes, following the step of second removing, third removing each helical strut associated with the non-radiator portion.
5. A method, as claimed in claim 1 , wherein:
the frusto-conical side wall is a side wall of one of: (a) a frustum of a right circular cone, (b) a frustum of an oblique circular cone, (c) a frustum of a right elliptical cone, and (d) a frustum of an oblique elliptical cone.
6. A method, as claimed in claim 1 , further comprising:
removing metal from the frusto-conical exterior side surface to the frusto-conical interior side surface and associated with the non-radiator portion to produce an impedance matching structure.
7. A method, as claimed in claim 6 , wherein:
the conical helix and the matching structure are a single piece of metal.
8. A method for making a radiator structure for a helical antenna, comprising:
providing a piece of metal stock;
processing the piece of metal stock to produce a processed piece of metal with a frusto-conical exterior side surface and a frusto-conical interior side surface with the frusto-conical exterior and interior side surfaces defining a frusto-conical side wall, the processed piece of metal having a radiator portion and a non-radiator portion; and
removing metal located between the frusto-conical exterior side surface and the frusto-conical interior side surface and associated with the non-radiator portion to produce a self-supporting conical helix having an upper lateral edge and a lower lateral edge that is separated from the upper lateral edge;
the step of removing includes first removing metal located between the frusto-conical interior side surface and the frusto-conical exterior side surface and associated with the non-radiator portion to define a portion of the upper lateral edge of the conical helix and a portion of the lower lateral edge of the conical helix;
the portion of the upper lateral edge of the conical helix extending partially from one of the frusto-conical exterior side surface and the frusto-conical interior side surface to the other of the frusto-conical exterior side surface and the frusto-conical interior side surface;
the portion of the lower lateral edge of the conical helix extending partially from one of the frusto-conical exterior side surface and the frusto-conical interior side surface to the other of the frusto-conical exterior side surface and the frusto-conical interior side surface; and
the step of first removing metal establishes a first helical groove in the frusto-conical side wall and a second helical groove in the frusto-conical side wall that is separated from the first helical groove;
wherein the first and second helical grooves each have a first groove side surface, a second groove side surface, and a groove base surface located between the first and second groove side surfaces;
the step of removing includes, following the step of first removing, second removing metal associated with the non-radiator portion to define a series of helical voids with one helical void separated from an immediately adjacent helical void by a helical strut that is associated with the non-radiator portion.
9. A method, as claimed in claim 8 , wherein:
the step of second removing includes removing metal extending from the groove base surface of each of the first and second grooves to one of the frusto-conical interior side surface and the frusto-conical exterior side surface.
10. A method, as claimed in claim 8 , wherein:
the step of second removing includes removing metal extending from the frusto-conical interior side surface to the frusto-conical exterior side surface.
11. A method, as claimed in claim 8 , wherein:
the step of removing includes, following the step of second removing, third removing each helical strut associated with the non-radiator portion.
12. A method for making a radiator structure for a helical antenna, comprising:
providing a piece of metal having a frusto-conical interior side surface and a frusto-conical exterior side surface, the frusto-conical interior and exterior side surfaces defining a frusto-conical side wall, the piece of metal having a radiator portion and a non-radiator portion; and
removing material between the frusto-conical exterior side surface and the frusto-conical interior side surface and associated with the non-radiator portion to produce a self-supporting conical helix having an upper lateral edge and a lower lateral edge that is separated from the upper lateral edge;
the step of removing includes first removing metal located between the frusto-conical interior side surface and the frusto-conical exterior side surface and associated with the non-radiator portion to define a portion of the upper lateral edge of the conical helix and a portion of the lower lateral edge of the conical helix;
the portion of the upper lateral edge of the conical helix extending partially from one of the frusto-conical exterior side surface and the frusto-conical interior side surface to the other of the frusto-conical exterior side surface and the frusto-conical interior side surface;
the portion of the lower lateral edge of the conical helix extending partially from one of the frusto-conical exterior side surface and the frusto-conical interior side surface to the other of the frusto-conical exterior side surface and the frusto-conical interior side surface;
the step of removing includes, following the step of first removing, second removing metal associated with the non-radiator portion to define a series of helical voids with one helical void separated from an immediately adjacent helical void by a helical strut that is associated with the non-radiator portion.
13. A method, as claimed in claim 12 , wherein:
the step of removing includes, following the step of second removing, third removing a helical strut associated with the non-radiator portion.
14. A method for making a radiator structure for a helical antenna, comprising:
providing a piece of metal having a frusto-conical interior side surface and a frusto-conical exterior side surface, the frusto-conical interior and exterior side surfaces defining a frusto-conical side wall, the piece of metal having a radiator portion and a non-radiator portion; and
removing material between the frusto-conical exterior side surface and the frusto-conical interior side surface and associated with the non-radiator portion to produce, in the radiator portion, a self-supporting conical helix having an upper lateral edge and a lower lateral edge that is separated from the upper lateral edge;
the step of removing includes removing metal associated with the non-radiator portion to define, in the non-radiator portion, a series of helical voids with one helical void separated from an immediately adjacent helical void by a helical strut that is associated with the non-radiator portion.
15. A method, as claimed in claim 14 , wherein:
the step of removing includes removing a helical strut associated with the non-radiator portion.
16. A method, as claimed in claim 14 , wherein:
the step of providing includes providing a frusto-conical interior top surface that engages the frusto-conical interior side surface.
17. A method, as claimed in claim 16 , wherein:
the step of providing includes providing a stub extending away from the frusto-conical interior top surface.
18. A method for making a radiator structure for a helical antenna, comprising:
providing a piece of metal having a frusto-conical interior side surface and a frusto-conical exterior side surface, the frusto-conical interior and exterior side surfaces defining a frusto-conical side wall, the piece of metal having a radiator portion and a non-radiator portion; and
removing material between the frusto-conical exterior side surface and the frusto-conical interior side surface and associated with the non-radiator portion to produce a self-supporting conical helix having an upper lateral edge and a lower lateral edge that is separated from the upper lateral edge;
the step of providing includes providing a frusto-conical interior top surface that engages the frusto-conical interior side surface;
the step of providing includes providing a stub extending away from the frusto-conical interior top surface;
removing a portion of the stub to produce a frusto-conical exterior top surface;
the frusto-conical interior and exterior top surfaces defining a frusto-conical top.
19. A method, as claimed in claim 18 , wherein:
the conical helix and the frusto-conical top are a single piece of metal.
20. A method for making a radiator structure for a helical antenna, comprising:
providing a monolithic metal structure having a frusto-conical interior side surface and a frusto-conical exterior side surface that define a frusto-conical side wall that encloses a space and defines intermittent helical voids, the monolithic metal structure having a radiator portion and a non-radiator portion, the intermittent helical voids defining a helical void path that is associated with the non-radiator portion, the intermittent helical voids also defining a portion of an upper lateral edge and a portion of a lower lateral edge of a conical helix that is associated with the radiator portion, the helical void path is located between first and second portions of the conical helix associated with the radiator portion;
the intermittent helical voids comprising a first helical void and a second helical void separated from the first helical void by a helical strut that extends from the first portion of the conical helix to the second portion of the conical helix and is associated with the non-radiator portion; and
removing metal associated with the helical strut to produce the conical helix.
21. A method, as claimed in claim 20 , wherein:
the step of providing comprises processing a piece of metal to produce the frusto-conical exterior side surface.
22. A method, as claimed in claim 20 , wherein:
the step of providing comprises processing a piece of metal to produce the frusto-conical interior side surface.
23. A method, as claimed in claim 20 , wherein:
the step of providing comprises processing a piece of metal to define the intermittent helical voids.
24. A method, as claimed in claim 20 , wherein:
the conical helix is a self-supporting conical helix.
25. A method, as claimed in claim 20 , wherein:
the step of removing includes cutting metal associated with or adjacent to the helical strut.