THEREOF

FIELD: The present disclosure relates to the field of antennas, and more particularly to mechanically stable antennas of a generally helical configuration, and related methods of construction and manufacturing.

BACKGROUND:

In recent years, the wireless communication market has expanded greatly. Long-range wireless devices such as those used in cellphone towers, etc. are now considered "classical" devices for wireless communication. In these systems, the antenna is a key component for system performance and size.

The most commonly used antennas for many of these applications are arrays of the helical type, wherein individual helical antenna elements are axially connected to the adjacent element. Prior art helical antennas generally comprise several conductive elements, in some cases disposed on a common axis, to form an array. The conductive elements in such designs typically comprise a helical section and a straight section on each end of the helical section. The straight sections are typically oriented along the common axis and connected to a straight section of the adjacent element via connecting components. The impedance of the connecting components between the helical array elements must be matched to the characteristics of the individual helical array elements and/or the total antenna system.

In such cases, the helical array elements are typically composed of a conductive material physically wound to the appropriate geometry. The array elements are then placed axially relative to each other and connected. The impedance of the connecting components between the helical array elements must be matched to the characteristics of the individual array elements and/or the total antenna system. However, the drawback of such helical antenna arrays is their performance instability due to their mechanical instability. Aside from mechanical stability issues, configuration and construction for use in applications necessitating tight geometric tolerances is also very important in order to achieve suitable antenna performance in design environments with such spatial constraints. It is also generally very difficult to achieve tight geometric tolerances using known, wound objects. This includes, for example, using copper coils and wondering the same to precise tolerances so as to achieve particular frequencies.

In this regard, it is noted that known approaches commonly require use of the entire volume occupied by the antenna. There is no passageway or open core through which additional devices or componentry could be routed. This is problematic as it diminishes the capability to provide additional functionality or complementary positioning with other devices in close quarters applications.

These volumetric constraints manifest themselves through additional shortcomings of existing technologies, in terms of lacking ability to provide multilayer, or multi-function antennas. Again, this is of primary concern in compact environments. Furthermore, a minimum thickness of the conductive material along the radial and axial direction of an array is required to achieve a suitable degree of mechanical stability. Because the antenna characteristics are especially sensitive to influence by the dimensions of the conductive material in the radial direction, the requirement to use a thick, conductive material in order to achieve even moderate mechanical stability also has a negative influence on the performance of the antenna.

Winding conductive material over a rigid core, wherein the core has appropriate features, which could serve as fixation points for the conductive material is a known technique for generally overcoming the mechanical instability of such antennas; however, such solution is not without disadvantages. This is, at least, because of the additional costs associated with the manufacture of the rigid core with the appropriated fixation features.

Furthermore, such wound antennas with rigid cores often have and/or develop gaps between the core and the winding, due to differences in thermal expansion and/or contraction between the core and winding. This can result in functional deficiencies and exacerbates the problem of use in geometrically and spatially constrained environments.

In some scenarios, a more stable type of approach is to employ and integrate such antennas using molded interconnected device ("MID") types of antennas. Such technology commonly employs, for example, molded thermoplastic components with integrated antenna componentry.

Methods of MID manufacturing including, as examples, those summarized below:

(1) Laser Direct Structuring: The surface of an "exotic" material is treated by lasers. The laser treated areas become platable. The entire article is immersed in a plating tank and the laser treated areas are selectively plated. (2) Shot Molding: A substrate material (typically polycarbonate) is first molded. Then, a platable material (typically ABS) is molded over it. The entire article is immersed in a plating tank and the laser treated areas are selectively plated.

(3) Film Insert Overmolding: A film preprinted with the appropriate circuitry is placed in the mold. After that, the substrate is injected underneath it. For various reasons, this makes these methods and the resulting products impractical and sufficient for use in devices and applications where cost and/or maximum size limitation is an issue.

Option (1) is impractical due to the relatively high costs of the exotic materials involved.

Option (2) does not allow for any capability to produce lengthy parts, which may be suitable or desirable in certain applications. Similarly, option (2) does not facilitate production of useful, hollow parts. Such a property would be advantageous, as briefly discussed above.

Option (3) precludes the possibility of making the circuit form a spiral without seams.

Further, these types of designs are not suited to applications requiring lengthy, helical antenna arrays (e.g., of a meter or singular lengths, and longer), for at least the reasons noted above.

The above are but exemplary problems in needing of solving and or alleviating. Accordingly, there is a need for an improved antenna. BRIEF SUMMARY

There is disclosed herein an antenna array including a plurality of antenna elements, substantially disposed along a common path, and comprised of conductive materials substantially

continuously attached to a body that is comprised of a non-conductive substrate material.

In another disclosed aspect, the elements comprise substantially helical antenna elements disposed along a common axis.

In another disclosed aspect, the antenna elements are comprised of flexible materials.

In another disclosed aspect, the elements comprise conductive ink adhered to the body.

In another disclosed aspect, the body is generally cylindrical in shaping and comprises a plurality of substantially concentric body segments adhered or friction fit to one another, and each of the segments comprises an inner surface and an outer surface.

In another disclosed aspect, the non-conductive substrate comprises a tube having an outer surface and an inner surface, wherein the inner surface defines a core. In another disclosed aspect, the body comprises a plurality of segments.

In another disclosed aspect, the segments comprise a plurality of similarly shaped pieces adapted for nested engagement with one another. In another disclosed aspect, the antenna elements comprises a plurality of layered elements with non-conductive substrate material interposed therebetween.

There is also disclosed a method of manufacturing an antenna, including the following steps; operationally positioning a workpiece on a work area; setting an antenna application device onto a starting point on a surface of the workpiece; moving the antenna application device along a surface of the workpiece in a direction; repositioning the workpiece in response to a desired differential between the speed of the device and movement of the workpiece; and, detaching the workpiece from the work area.

In another disclosed aspect, the work area comprises a rotary device, wherein the workpiece comprises a tube, wherein the device comprises a printing pen for marking the tube with conductive ink, wherein the direction is an axial direction lengthwise along the tube, wherein the repositioning comprises selectively rotating the tube wherein a differential between the speed of the pen in the axial direction and a rotational speed of the tube will determine the orientation of the ink marking.

In another disclosed aspect, the method also includes the step of curing the ink.

In another disclosed aspect, the method also includes plating marked areas of the tube with a conductive material.

In another disclosed aspect, the method also includes attaching the antenna to an antenna system.

In another disclosed aspect, the method also includes a pre-cleaning step performed in advance of the operationally positioning, wherein in the pre-cleaning step, a cleaning device is operatively engaged with the work piece to remove any debris from the surface thereof. In another disclosed aspect, the cleaning device is a plasma cleaning device.

In another disclosed aspect, the adjustment of the rotation of the tube as compared to the axial movement of the pen will result in ink marking of the tube more in a circumferential direction; and, slower rotation of the tube combined with faster axial movement thereof will result in ink marking more in the axial direction. There is also disclosed an assembly system for making an antenna array comprising a plurality of antenna elements and a body comprising a tube comprising non-conductive substrate, wherein the system comprises: a rotary device for rotating the tube at a rotational speed; a linear motion device, for moving the pen at a line speed, wherein the linear motion device is oriented substantially parallel to an axis of the rotary device and adapted to be synchronized with the rotary device; an ink dispensing system, which may but need not necessarily comprise a pen with a pump, wherein the pump is adapted to synchronize its speed with the line speed;

an attachment device for attaching the pen to the linear motion device and for maintaining pen contact with the tube while the tube and/or pen is moving.

In another disclosed aspect, the system also includes a cleaning device.

In another disclosed aspect, the cleaning device is a plasma cleaning device or a chemical-based cleaning device.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure will now make reference to the accompanying drawings. Any dimensions provided in the drawings are provided only for illustrative purposes, and do not necessarily limit the scope of this disclosure. In the drawings:

Figure 1 is a perspective view of an antenna.

Figure 2A is a perspective view of another antenna.

Figure 2B is a perspective view of the antenna of Figure 2A, with an antenna segment shown in dashed lines. Figure 2C is a perspective view of the antenna of Figure 2A, shown in a partially exploded configuration.

Figure 3 is a perspective view of another antenna. Figure 4 is a block diagram showing the steps of a method. Figure 5 is a schematic presentation of a system herein disclosed.

DESCRIPTION

The present disclosure is directed to a mechanically stable and multi-application purpose antenna, including a helical-type antenna, as well as systems for and methods of manufacturing the same. The present disclosure may also be applicable to other antenna systems and the manufacture thereof.

In a broad aspect of the present invention, and looking to Figure 1, there is provided an antenna 100 comprising one or more antenna elements 104, disposed on a body 102 made of a non- conductive substrate material. At least a portion of the antenna element 104 is made of flexible material and at least a portion thereof is continuously attached to the body 102. Preferably, all or a significant portion of the antenna elements 104 is made of flexible material. The non- conductive substrate material may preferably be a rigid, substantially non-flexible material. However, in some embodiments, the substrate material is a printed circuit board ("PCB"), which may or may not be flexible. In still other embodiments, the substrate materials may be a molded interconnected device ("MID"). The MID may or may not be flexible. Of course, other substrates may be used.

In one embodiment, such as that shown in Figure 1, the antenna elements 104 is disposed over the surface layer 108 of a profile (preferably a convex polygon, more preferably still a cylinder) that goes around a common axis A-A. The axis A-A may in some embodiments not be a straight line, so long as it does not intersect itself. For example, the axis may have the geometry of a helix. The configuration of the antenna elements 104 may be varied, as will be more clearly appreciated upon consideration of Figures 2A-2C, which are described below.

Looking again to Figure 1, the antenna array 100 includes a plurality of helical antenna elements 104 (showing but a single example). The constituent elements of 104 are shown in Figure I as evenly spaced; however, this need not necessarily be the case. Factors including, for example, the geometry of the desired place of implementation, the electrical needs of the application, and the materials used may influence this arrangement. Again, such elements 104 are disposed substantially along a common axis (A- A in Figure 1); however, in embodiments having an at least slightly non-linear shaping of a body (e.g., as compared to the substantially linear body 102 shown in Figure 1), the axis may similarly be, in effect, non-linear. The helical elements 104 may be composed of printed platable materials, such as, for example, silver particles dispersed in a polymer binder. These elements are substantially continuously attached to the body 102. The body 102 is shown in Figure 1 as having a generally cylindrical shape, tapering slightly from a first end 102a to a second end 102b; however, a multitude of possible geometries are contemplated in the present disclosure. Indeed, the disclosure subject matter allows for use in whatever shapings may be supported via use of the substrate material. See, for example, the alternate embodiments shown in Figures 2A-2C and 3. The body 102 is comprised of one of more non-conductive substrate material. Examples of materials suitable for such use include, for example, plastics or ceramics.

Again, the non-conductive substrate body 102 may comprise a tube, in that it has an outer surface 108 and an inner surface 1 10, wherein the inner surface defines a core 106. Is this regard, the core 106 may be substantially hollow and suitable for passage therethrough of various materials, wires, or other items. This is advantageous in, for example, applications featuring tight space constraints. This may also be advantageous for the purposes of reducing overall weight.

Looking to Figures 2A-2C, in another embodiment of the array 200, the body 208 may be provided including a plurality of segments, such as an inner segment 204 and an outer segment 202, that are adhered or otherwise fitted to one another. The segments 202, 204 may be provided as generally cylindrical in shaping and be substantially concentric. Each of the segments 202, 204 has an inner surface and an outer surface. The inner segment 204 has an inner surface 218 (best shown in Figures 2 A and 2B), and an outer surface 216 (best shown in Figure 2B). While two segments 202, 204 are shown, additional segments could be provided, depending on the needs of the particular implementation.

Antenna elements 206 on the outer segment 202 are shown in a substantially helical

configuration, whereas antenna elements 220 on the inner segment 204 are shown as generally stepped in arrangement. Various configurations may be used, depending on the frequency and design needs of the particular embodiment. Capacitors or other tuning devices may be included to assist in precision tuning of the frequencies, such as the capacitor 210 on the outer segment 202 and the capacitor 222 on the inner segment 204.

In some embodiments, the segments 202, 204 are shaped and adapted for nested engagement with one another. In some embodiments, the antenna elements 206, 220 may comprise a plurality of layered elements with non-conductive substrate material interposed therebetween.

As detailed in Figure 4, there is also disclosed a method 300 of manufacturing an antenna, including the following steps:

302: operationally positioning a workpiece on a work area;

304: setting an antenna application device onto a starting point on a surface of the workpiece;

306: moving the antenna application device along a surface of the workpiece in a direction;

308: repositioning the workpiece in response to a desired differential between the speed of the device and movement of the workpiece; and,

310: detaching the workpiece from the work area.

The work area preferably comprises a rotary device; however, more planar embodiments are contemplated, depending on the geometry of the antenna array. The workpiece may preferably comprise a tube, and the application device may preferably comprise an ink dispensing device or a printing pen, adapted to mark the workpiece with conductive ink. The direction may preferably be an axial direction (see C-C in Figure 5) lengthwise along the work piece. The repositioning includes selectively moving the workpiece (e.g., rotating a tubular body) wherein a differential between the speed of the dispensing device in the axial direction C-C and a movement speed of the work piece (e.g., rotation of the tubular body) will determine the orientation, volume and thickness of the ink marking. Adjustment of the movement as compared to the axial movement of the dispensing device will result in ink marking of the tube more in a circumferential direction; and, slower rotation of the tube combined with faster axial movement thereof will result in ink marking more in the axial direction.

In an embodiment wherein the workpiece comprises a tubular body, the method 300 includes operationally positioning a tube (e.g., that described above as a body 102) on a rotary device. The rotary device is adapted to retain and selectively rotate the body 102. The rotary device may be manually controlled or may be controlled via electronic control device (e.g., PLC, etc.). A pen will be positioned on a starting point on the surface 108 of the body 102. The pen will be so positioned via a marking device adapted to vary the position and orientation of the pen (e.g., along a radial axis B-B of the body 102; as well as horizontally or vertically with respect to such axis, and rotational thereabout). The starting point will be determined based on the planned configuration of antenna elements 104 on the body 102. The pen will be moved from the starting point along the surface 108 of the body 102. When referring to the pen, it is understood that any means of selectively delivery the conductive material to the surface may be employed, and the device need not necessary resemble a writing implement. The movement of the pen will be along the body 102 in an axial direction (e.g., parallel to A-A). While above only movement of the pen is discussed, it is understood that certain geometries of body 102 may be suited to movement thereof with the pen effectively maintaining a stationary position. Further, complementary and cooperative movement of both the pen and body 102 is contemplated and disclosed herein.

In this regard, the body may preferably be moved by way of rotation about its axis (e.g., A-A in Figure 1, or C-C in Figure 5). The speed and path of the pen, and any movement and rotational speed of the body will determine the orientation of the ink marking. Constructed antennas will include the conductor wound around the body in a specified configuration. The winding can have variable pitch and sometimes a straight line in axial direction between winding sections. As such, the geometry of the body may be dictated by the application involved, and vice versa. Similarly, these factors will influence the marking of the body. In some embodiments, this may include rotation of the body 102 about its axis A-A and linear movement of the pen along such axis A-A, In this area, fast rotation of the tube vs slow axial movement thereof will result in ink marking more in the circumferential direction; and, slow rotation of the tube combined with fast axial movement thereof will result in ink marking more in the axial direction.

The marked body may then be detached from the rotary device, as the ink (or other marked material) will need to be cured. This may be completed via baking or other means known in the art. The marked areas may then be plated with copper or another suitable conductive material such as silver or gold. The plated areas can be coated with an insulating material in order to protect it from corrosion and/or insulate it electrically. Optionally, the insulating coating can also cover non-plated areas of the body. Interfaces to the remainder of the antenna system may also be attached to the conductive material.

The method may also include a pre-cleaning step performed in advance of the operational positioning of the body. In this step, the head of a plasma cleaning device (or other suitable cleaning device) will move along the surface of the body in, for example, the axial direction. This may be done as the body is rotating and moving along its axis, thereby ensuring cleaning of the entire body. The cleaning process may be adapted in respect of bodies having more complex geometries, so as to ensure cleaning of all surfaces that are to be marked.

Looking next to Figure 5, there is also disclosed an assembly system 500 for making an antenna array 100 comprising a plurality of antenna elements and a body comprising a tube comprising non-conductive substrate. The systems includes a device for moving the workpiece, preferably rotation of a tube, at a speed, preferably of rotation. A linear motion device is also provided for moving a marking or ink dispensing device, preferably a pen, at a line speed. The linear motion device is oriented substantially parallel to an axis C-C of the rotary device and adapted to be synchronized therewith. The marking or ink dispensing device, which may but need not necessarily comprise a pen with a pump, is adapted to synchronize its speed of dispensing with the line speed. An attachment device is also provided for attaching the marking device to the linear motion device and for maintaining contact with the work piece while the workpiece and/or marking device is moving. In an embodiment wherein the workpiece comprises a tubular body, the system will include a rotary device (as described above) for rotating the tube at a rotational speed. A linear motion device will also be included for moving the pen at a line speed. Again, it is understood that movement of the pen need not necessarily be limited to linear movement. In some embodiments, however, the linear motion device may be oriented substantially parallel to the axis of the rotary device, and adapted to be synchronized therewith. An ink dispensing system will be provided. As noted above, this may but need not necessarily comprise a pen with a pump, wherein the pump is adapted to synchronize its speed with the line speed, so as to mark the body in a desired pattern. Again, the movement of these devices may be computer controlled or manually controlled. An attachment device may be provided for attaching the pen to the linear motion device and for maintaining pen contact with the tube while the tube and/or pen is moving. Of course, the attachment device may function beyond attachment and be adapted to facilitate the complementary and cooperating movement discussed above. As noted above, a cleaning device, such as a plasma cleaning device may also be provided. Optionally, the pen can also be held in such a way in order to also move radially as it moves in a sub axial direction. Such freedom of movement by the pen would allow marking of bodies with more complex geometries.

With reference to Figure 1 , for the same geometry of the antenna array including the connecting components between the antenna elements, it can be seen that the configuration of the conductive component over a substantially rigid substrate of the present disclosure is inherently more stable than that of the prior art. In other words, by disposing the conductive component over a rigid substrate, greater mechanical stability is achieved without sacrificing functionality.

In one embodiment, the spirals of the helical elements can be composed of multiple spirals. The configuration of the multi-spiral helix determines the center frequency and the impedance matching. The resonant frequency can be controlled by adjusting the geometry of the spiral segments. The number of and spacing between members (or "spirals") in the multi-spiral serves to magnify the signals sent and/or received thereby. In some embodiments, the antenna elements comprises a plurality of layered elements with non- conductive substrate material interposed therebetween, Construction in this manner may require iterations of certain manufacturing steps, which are detailed below. Further, in an example such as the substantially tubular configuration shown in Figure 1, this may result in substantially concentric, alternating layers of antenna elements and substrate, along with any additional sealing layers (e.g., shrink wrapping) that may be required.

That is to say that, one or more multi-spiral helices may be placed on one layer and one or more multi-spiral helices may be placed on another layer. More than two layers with multi-spiral(s) are possible. The multi -spiral (s) on each layer is placed such that the multi-spiral(s) is magnetically coupled to the multi-spiral(s) of the other plane.

Some embodiments of the antenna will include the conductor wound around the tube in a specified configuration. The winding may have variable pitch and sometimes include a straight line in the axial direction, between winding sections (ie. Sections may be connected but not wholly contiguous). Further, the geometry of the tube need not necessarily be of constant diameter. For example, embodiments of conical or other geometries are contemplated.

To achieve suitable lengths requires joining multiple segments, which results in issues of matching frequencies to suit a particular implementation scenario. Precision of manufacturing and the repeatability thereof for scaling to industrial volumes is advantageous but very difficult to achieve with known antennas. Related assembly and frequency matching procedures are often based on trial and error and can be quite time consuming (e.g., taking upwards of an hour per article).

In some cases additional hardware may be added to facilitate tuning, including lead wires at either operative end of the antenna. The use of substantially unitary antennas, manufactured to tight, repeatable tolerances facilitates precision tuning without need for extensive related operations.

Antennas may be provided printed on the interior surface of the body, and on the outside of the body. Inner body segment may be provided having one or more antenna segments printed on it, and the outer body segment also having one or more antenna segments printed on it.

As discussed above, lumped capacitor element may be provided at one end of the body, for assistance in frequency matching and tuning processes. In some embodiments, the lumped element may be employed to permit switching between a plurality of operative frequencies. In some embodiments, the antenna array may be operable on a plurality of frequencies. Examples of environments where such operation is of interest include an airport whereat communications with more proximal aircraft are on a different frequency than those farther away from the airport. Interposed between the antenna and a power/feed cable (not shown).

Some embodiments may include bodies shaped to diminish wind resistance without sacrificing operational performance. This is preferable to provide stability in long range, high gain environments (and stability in, for example, windy areas, and the like).

Many modifications and other embodiments of the invention will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the disclosure is not necessarily to be limited to the specific embodiments disclosed.

Further, while various embodiments in accordance with the principles disclosed herein have been described above, it should be understood that they have been presented by way of example only, and are not limiting. Thus, the breadth and scope of the invention(s) should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the claims and their equivalents issuing from this disclosure. Furthermore, the above advantages and features are provided in described embodiments, but shall not limit the application of such issued claims to processes and structures accomplishing any or all of the above advantages.

It will be understood that the principal features of this disclosure can be employed in various embodiments without departing from the scope of the disclosure. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, numerous equivalents to the specific procedures described herein. Such equivalents are considered to be within the scope of this disclosure and are covered by the claims. Additionally, the section headings herein are provided as organizational cues. These headings shall not limit or characterize the invention(s) set out in any claims that may issue from this disclosure. Specifically and by way of example, although the headings refer to a "Field of Invention," such claims should not be limited by the language under this heading to describe the so-called technical field. Further, a description of technology in the "Background of the

Invention" section is not to be construed as an admission that technology is prior art to any invention(s) in this disclosure. Neither is the "Summary" to be considered a characterization of the invention(s) set forth in issued claims. Furthermore, any reference in this disclosure to "invention" in the singular should not be used to argue that there is only a single point of novelty in this disclosure. Multiple inventions may be set forth according to the limitations of the multiple claims issuing from this disclosure, and such claims accordingly define the invention(s), and their equivalents, that are protected thereby. In all instances, the scope of such claims shall be considered on their own merits in light of this disclosure, but should not be constrained by the headings set forth herein. The use of the word "a" or "an" when used in conjunction with the term "comprising" in the claims and/or the specification may mean "one," but it is also consistent with the meaning of "one or more," "at least one," and "one or more than one." The use of the term "or" in the claims is used to mean "and/or" unless explicitly indicated to refer to alternatives only or the alternatives are mutually exclusive, although the disclosure supports a definition that refers to only alternatives and "and/or." Throughout this application, the term "about" is used to indicate that a value includes the inherent variation of error for the device, the method being employed to determine the value, or the variation that exists among the study subjects.

As used in this specification and claim(s), the words "comprising" (and any form of comprising, such as "comprise" and "comprises"), "having" (and any form of having, such as "have" and "has"), "including" (and any form of including, such as "includes" and "include") or

"containing" (and any form of containing, such as "contains" and "contain") are inclusive or open-ended and do not exclude additional, un-recited elements or method steps. All of the apparatuses, systems and methods disclosed and/or claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the compositions and methods of this disclosure have been described in terms of preferred embodiments, it will be apparent to those of skill in the art that variations may be applied to the compositions and/or methods and in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit and scope of the disclosure. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope and concept of this disclosure.