Broadband radome structure

1. A radome structure comprising:

a central core layer comprising a first dielectric constant;

an interior intermediate core layer adjacent to an interior side of the central core layer, comprising a second dielectric constant less than the first dielectric constant;

an exterior intermediate core layer adjacent to an exterior side of the central core layer, comprising a third dielectric constant less than the first dielectric constant; and

an interior outside core layer adjacent to an interior side of the interior intermediate core layer, comprising a fourth dielectric constant less than the second dielectric constant;

wherein the central core layer, interior intermediate core layer, and exterior intermediate core layer comprising woven fiber cloth impregnated with a matrix binder.

2. The radome structure of claim 1 , wherein:

the woven fiber cloth is selected from the group consisting of Astroquartz, E-glass, S-glass, polyethylene, polyamide fibers and combinations thereof.

3. The radome structure of claim 1 , wherein:

the matrix binder is selected from the group consisting of cyanate ester, epoxy, vinyl ester, polyester, and combinations thereof.

4. A radome structure comprising:

a central core layer comprising a first dielectric constant;

an interior intermediate core layer adjacent to an interior side of the central core layer, comprising a second dielectric constant less than the first dielectric constant;

an exterior intermediate core layer adjacent to an exterior side of the central core layer, comprising a third dielectric constant less than the first dielectric constant; and

an interior outside core layer adjacent to an interior side of the interior intermediate core layer, comprising a fourth dielectric constant less than the second dielectric constant;

wherein the interior outside core layer comprises syntactic foam formulated with a mixture of microballoons and fillers embedded in a thermoset or thermoplastic matrix binder to achieve the second dielectric constant.

5. A radome structure comprising:

a central core layer comprising a first dielectric constant;

an interior intermediate core layer adjacent to an interior side of the central core layer, comprising a second dielectric constant less than the first dielectric constant;

an exterior intermediate core layer adjacent to an exterior side of the central core layer, comprising a third dielectric constant less than the first dielectric constant; and

an interior outside core layer adjacent to an interior side of the interior intermediate core layer, comprising a fourth dielectric constant less than the second dielectric constant;

the central core layer comprises syntactic foam formulated with a mixture of microballoons and fillers embedded in a thermoset or thermoplastic matrix binder to achieve the first dielectric constant, and a thickness; and

the interior intermediate core layer comprises syntactic foam formulated with a mixture of microballoons and fillers embedded in said matrix binder to achieve the second dielectric constant, and wherein the exterior intermediate core layer comprises syntactic foam formulated with a mixture of microballoons and fillers embedded in said matrix binder to achieve the third dielectric constant.

6. The radome structure of claim 5 , wherein:

the central core layer comprises a thin layer of dielectrically matched woven fiber and matrix binder juxtaposed with the syntactic foam, wherein the woven fiber and matrix binder form a barrier between one or more syntactic layers to achieve a tailored balance of structural reinforcement and tuned electromagnetic performance;

the interior intermediate core layer comprises a thin layer of dielectrically matched woven fiber and matrix binder juxtaposed with the syntactic foam, wherein the woven fiber and matrix binder form a barrier between one or more syntactic layers to achieve a tailored balance of structural reinforcement and tuned electromagnetic performance; and

the exterior intermediate core layer comprises a thin layer of dielectrically matched woven fiber and matrix binder juxtaposed with the syntactic foam, wherein the woven fiber and matrix binder form a barrier between one or more syntactic layers to achieve a tailored balance of structural reinforcement and tuned electromagnetic performance.

7. A radome structure comprising:

a central core layer comprising a first dielectric constant;

an interior intermediate core layer adjacent to an interior side of the central core layer, comprising a second dielectric constant less than the first dielectric constant;

an exterior intermediate core layer adjacent to an exterior side of the central core layer, comprising a third dielectric constant less than the first dielectric constant; and

an interior outside core layer adjacent to an interior side of the interior intermediate core layer, comprising a fourth dielectric constant less than the second dielectric constant;

said central core layer comprises a dielectric constant of from about 3.5 to 8.5; said interior intermediate core layer comprises a dielectric constant of from about 2.5 to 4.5; said exterior intermediate core layer comprises a dielectric constant of from about 2.5 to 4.5; and said interior outside core layer comprises a dielectric constant of from about 1.5 to 2.5.

8. A radome structure comprising:

a central core layer comprising a first dielectric constant;

an interior intermediate core layer adjacent to an interior side of the central core layer, comprising a second dielectric constant less than the first dielectric constant;

an exterior intermediate core layer adjacent to an exterior side of the central core layer, comprising a third dielectric constant less than the first dielectric constant; and

an interior outside core layer adjacent to an interior side of the interior intermediate core layer, comprising a fourth dielectric constant less than the second dielectric constant;

wherein the exterior outside core layer has a dielectric constant of from about 1.5 to 2.5;

wherein an exterior outside core layer adjacent to an exterior side of the exterior intermediate core layer, comprising a fifth dielectric constant less than the third dielectric constant;

wherein the interior outside core layer comprising syntactic foam formulated with a mixture of microballoons and fillers embedded in a thermoset or thermoplastic matrix binder to achieve a prescribed dielectric constant and thickness.

9. A radome structure comprising:

a central core layer comprising a first dielectric constant;

an interior intermediate core layer adjacent to an interior side of the central core layer, comprising a second dielectric constant less than the first dielectric constant;

an exterior intermediate core layer adjacent to an exterior side of the central core layer, comprising a third dielectric constant less than the first dielectric constant; and

an interior outside core layer adjacent to an interior side of the interior intermediate core layer, comprising a fourth dielectric constant less than the second dielectric constant;

wherein the interior outside core layer comprising a thickness of at least 0.02″ and no more than 0.5″; the interior intermediate core layer comprises a thickness of at least 0.005″ and no more than 0.5″;

wherein the exterior intermediate core layer comprises a thickness of at least 0.005″ and no more than 0.5″; and

wherein the central core layer comprises a thickness of at least 0.005″ and no more than 0.5″.

10. A method of manufacturing a radome structure, the method comprising:

providing a central core layer comprising a first dielectric constant;

providing an interior intermediate core layer adjacent to an interior side of the central core layer, comprising a second dielectric constant less than the first dielectric constant;

providing an exterior intermediate core layer adjacent to an exterior side of the central core layer, comprising a third dielectric constant less than the first dielectric constant; and

providing an interior outside core layer adjacent to an interior side of the interior intermediate core layer, comprising a fourth dielectric constant less than the second dielectric constant;

wherein the central core layer and interior intermediate core layer comprising woven fiber cloth impregnated with a matrix binder.

11. The method of claim 10 , wherein:

the woven fiber cloth is selected from the group consisting of Astroquartz, E-glass, S-glass, polyethylene, polyamide fibers and combinations thereof.

12. The method of claim 10 , wherein:

the matrix binder is selected from the group consisting of cyanate ester, epoxy, vinyl ester, polyester, and combinations thereof.

13. A method of manufacturing a radome structure, the method comprising:

providing a central core layer comprising a first dielectric constant;

providing an interior intermediate core layer adjacent to an interior side of the central core layer, comprising a second dielectric constant less than the first dielectric constant;

providing an exterior intermediate core layer adjacent to an exterior side of the central core layer, comprising a third dielectric constant less than the first dielectric constant; and

providing an interior outside core layer adjacent to an interior side of the interior intermediate core layer, comprising a fourth dielectric constant less than the second dielectric constant;

wherein the interior outside core layer comprises syntactic foam formulated with a mixture of microballoons and fillers embedded in a thermoset or thermoplastic matrix binder to achieve the second dielectric constant, and a thickness.

14. A method of manufacturing a radome structure, the method comprising:

providing a central core layer comprising a first dielectric constant;

providing an interior intermediate core layer adjacent to an interior side of the central core layer, comprising a second dielectric constant less than the first dielectric constant;

providing an exterior intermediate core layer adjacent to an exterior side of the central core layer, comprising a third dielectric constant less than the first dielectric constant; and

providing an interior outside core layer adjacent to an interior side of the interior intermediate core layer, comprising a fourth dielectric constant less than the second dielectric constant;

wherein the central core layer comprises syntactic foam formulated with a mixture of microballoons and fillers embedded in a thermoset or thermoplastic matrix binder to achieve the first dielectric constant, and a thickness; and

wherein the interior intermediate core layer comprises syntactic foam formulated with a mixture of microballoons and fillers embedded in said matrix binder to achieve the second dielectric constant, and wherein the exterior intermediate core layer comprises syntactic foam formulated with a mixture of microballoons and fillers embedded in said matrix binder to achieve the third dielectric constant.

15. The method of claim 14 , wherein:

the central core layer comprises a thin layer of dielectrically matched woven fiber and matrix binder juxtaposed with the syntactic foam, wherein the woven fiber and matrix binder form a barrier between one or more syntactic layers to achieve a tailored balance of structural reinforcement and tuned electromagnetic performance;

the interior intermediate core layer comprises a thin layer of dielectrically matched woven fiber and matrix binder juxtaposed with the syntactic foam, wherein the woven fiber and matrix binder form a barrier between one or more syntactic layers to achieve a tailored balance of structural reinforcement and tuned electromagnetic performance; and

the exterior intermediate core layer comprises a thin layer of dielectrically matched woven fiber and matrix binder juxtaposed with the syntactic foam, wherein the woven fiber and matrix binder form a barrier between one or more syntactic layers to achieve a tailored balance of structural reinforcement and tuned electromagnetic performance.

16. A method of manufacturing a radome structure, the method comprising:

providing a central core layer comprising a first dielectric constant;

providing an interior intermediate core layer adjacent to an interior side of the central core layer, comprising a second dielectric constant less than the first dielectric constant;

providing an exterior intermediate core layer adjacent to an exterior side of the central core layer, comprising a third dielectric constant less than the first dielectric constant; and

providing an interior outside core layer adjacent to an interior side of the interior intermediate core layer, comprising a fourth dielectric constant less than the second dielectric constant;

wherein said central core layer comprises a dielectric constant of from about 3.5 to 8.5;

said interior intermediate core layer comprises a dielectric constant of from about 2.5 to 4.5; said exterior intermediate core layer comprises a dielectric constant of from about 2.5 to 4.5; and said interior outside core layer comprises a dielectric constant of from about 1.5 to 2.5.

17. A method of manufacturing a radome structure, the method comprising:

providing a central core layer comprising a first dielectric constant;

providing an interior intermediate core layer adjacent to an interior side of the central core layer, comprising a second dielectric constant less than the first dielectric constant;

providing an exterior intermediate core layer adjacent to an exterior side of the central core layer, comprising a third dielectric constant less than the first dielectric constant; and

providing an interior outside core layer adjacent to an interior side of the interior intermediate core layer, comprising a fourth dielectric constant less than the second dielectric constant;

providing a protective coating on an interior surface of the radome structure;

providing an exterior outside core layer adjacent to an exterior side of the exterior;

wherein the exterior outside core layer has a dielectric constant of from about 1.5 to 2.5;

wherein the interior outside core layer comprising syntactic foam formulated with a mixture of microballoons and fillers embedded in a thermoset or thermoplastic matrix binder to achieve a prescribed dielectric constant and thickness.

18. A method of manufacturing a radome structure, the method comprising:

providing a central core layer comprising a first dielectric constant;

providing an interior intermediate core layer adjacent to an interior side of the central core layer, comprising a second dielectric constant less than the first dielectric constant;

providing an exterior intermediate core layer adjacent to an exterior side of the central core layer, comprising a third dielectric constant less than the first dielectric constant; and

providing an interior outside core layer adjacent to an interior side of the interior intermediate core layer, comprising a fourth dielectric constant less than the second dielectric constant;

wherein the interior outside core layer comprises a thickness of at least 0.02″ and no more than 0.5″; the interior intermediate core layer comprises a thickness of at least 0.005″ and no more than 0.5″;

the exterior intermediate core layer comprises a thickness of at least 0.005″ and no more than 0.5″; and

the central core layer comprises a thickness of at least 0.005″ and no more than 0.5″.