Lightweight conformal phased array antenna using aerogel substrate
A phased-array, conformal antenna and a method for forming same are disclosed. The method comprises forming a substantially planar layered antenna structure by fabricating a printed circuit board (PCB) on a substantially planar first substrate, adhering the PCB to a second substantially planar substrate, the second substantially planar substrate comprising an aerogel, adhering a plurality of antenna elements to the substantially planar second substrate to form the phased-array, adhering a protective layer to the one or more antenna elements, and shaping the substantially planar layered antenna structure to form a substantially curved layered antenna structure.
1. A method for manufacturing a phased-array, conformal antenna comprising:
forming a substantially planar layered antenna structure by:
fabricating a printed circuit board (PCB) on a substantially planar first substrate;
adhering the PCB to a second substantially planar substrate, the second substantially planar substrate comprising an aerogel;
adhering a plurality of antenna elements to the substantially planar second substrate to form the phased-array;
adhering a protective layer to the one or more antenna elements; and
shaping the substantially planar layered antenna structure to form a substantially curved layered antenna structure.
2. The method of claim 1 , further comprising mounting comprises mounting the substantially curved layered antenna structure on an unmanned aerial vehicle (UAV).
3. The method of claim 1 , wherein the phased-array comprises stacked patch elements and the adhering a plurality of antenna elements to the substantially planar second substrate forms the stacked patch elements.
4. The method of claim 1 , further comprising forming an aperture feed layer that provides aperture coupling through a portion of the aerogel.
5. The method of claim 1 , wherein the aerogel has a dielectric constant between 1.4 Dk and 1 Dk.
6. The method of claim 1 , wherein the aerogel has a loss tangent of between 0.0001 and 0.005.
7. The method of claim 1 , wherein a thickness of the aerogel is 0.8 mm or greater.
8. The method of claim 1 , wherein an average pore size of the aerogel is 1-10 nm.
9. The method of claim 1 , wherein the aerogel has a polyimide structure.
10. The method of claim 1 , wherein the aerogel comprises at least one of 4,4′-oxydianiline (ODA), 2,2′-Dimethylbenzidine (DMBZ), 1,3-Bis(4-aminophenoxy)neopentane (BAPN), 1,5-diamino-2methylpentante (DAMP), and 1,12-diaminodocange (DADD).
11. The method of claim 1 , wherein:
the phased-array, conformal antenna is designed to transmit and receive radiation in a wavelength range; and
an average pore size of the aerogel is smaller than the wavelength range.
12. The method of claim 1 , wherein the adhering the PCB, the adhering the one or more antenna elements, and the adhering a protective layer comprises adhering via pressure sensitive adhesive.
13. The method of claim 1 , wherein the substantially curved layered antenna structure has a radius of curvature of 32 inches or fewer.
14. The method of claim 1 , wherein a density of the aerogel is less than 0.3 g/cm 3 .
15. A phased-array, conformal antenna comprising:
a substantially curved layered antenna structure comprising:
a printed circuit board (PCB);
an aerogel adhered to the PCB;
a plurality of antenna elements forming the phased-array, the plurality of antenna elements adhered to the aerogel; and
a protective layer adhered to the plurality of antenna elements.
16. The antenna of claim 15 , wherein a thickness of the aerogel is 2 mm or greater.
17. The antenna of claim 15 , wherein an average pore size in the aerogel is 1-10 nm.
18. The antenna of claim 15 , wherein the aerogel has a polyimide structure.
19. The antenna of claim 15 , wherein the aerogel comprises at least one of 4,4′-oxydianiline (ODA), 2,2′-Dimethylbenzidine (DMBZ), 1,3-Bis(4-aminophenoxy)neopentane (BAPN), 1,5-diamino-2methylpentante (DAMP), and 1,12-diaminodocange (DADD).
20. The antenna of claim 15 , wherein:
the phased-array, conformal antenna is designed to transmit and receive radiation in a wavelength range; and
an average pore size of the aerogel is smaller than the wavelength range.