Lightweight reflector dishes for radio antennas would be mass-produced cheaply by spin casting of polymers, according to a proposal. These reflector dishes were conceived for compact stowage followed by deployment and operation aboard spacecraft, but might also be useful on Earth in applications in which there are requirements for extremely light weight and stowability but not for highly precise reflector shape.
The spin-cast reflector dishes would be thin and flexible, and thus foldable for compact stowage. In some applications, it could be desirable to rigidize the dishes after deployment. This could be done, for example, by making dishes of an ultraviolet-curable polymer and exposing them to ultraviolet light (e.g., as part of sunlight) immediately after deployment. Alternatively, dishes could be made of a material with a glass-transition temperature above that of the deployment environment; after deployment, these dishes would be allowed to cool naturally, so that they would be rigidized by the rubber-to-glass transition.
This work was done by Celeste Satter of Caltech and Dan Marker of the Directed Energy Directorate, Air Force Research Laboratory, for NASA's Jet Propulsion Laboratory.
NPO-20548
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Lightweight reflector dishes would be made by spin casting
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Overview
The document discusses a proposal for the mass production of lightweight reflector dishes for radio antennas, primarily intended for use in spacecraft but also applicable on Earth. The innovative approach involves using spin casting of polymers to create these dishes, which are designed to be thin, flexible, and easily stowable. This flexibility allows for compact storage during transport, making them ideal for space missions where space and weight are critical factors.
The reflector dishes can be deployed in a flexible form and can be rigidized after deployment. Two methods for achieving this rigidization are proposed: one involves using ultraviolet-curable polymers that can be hardened by exposure to UV light (such as sunlight) after deployment. The other method suggests using materials with a glass-transition temperature higher than the deployment environment, allowing the dishes to cool naturally and transition from a rubbery state to a rigid state.
The document highlights the novelty of this approach compared to existing technologies. Traditional mechanical deployable antennas are often complex, expensive, and may have low reliability during deployment. Inflatable antennas require intricate assembly to achieve the necessary shapes, which adds to their complexity. In contrast, the proposed thin, flexible polymer reflective dishes can be produced cheaply and efficiently through spin casting, addressing the challenges of deployment and reliability.
The work was conducted by Celeste Satter from Caltech and Dan Marker from the Directed Energy Directorate of the Air Force Research Laboratory, under the auspices of NASA’s Jet Propulsion Laboratory. The document also includes a disclaimer stating that references to specific commercial products or processes do not imply endorsement by the U.S. Government or NASA.
Overall, this proposal represents a significant advancement in the field of aerospace technology, offering a practical solution for creating lightweight, deployable antennas that can be utilized in various applications, both in space and on Earth. The potential for mass production and the innovative materials used could lead to more efficient and reliable communication systems in the future.
