Radome

I found a used book on composites. It indicated that C-glass was the
preferred fiberglass for use in radomes. Googling around, it looks like
the Chinese have flooded the market with C-glass, so I guess that
statement isn't operational anymore.

I found out the AWACS aircraft uses S-2 glass in its radome. Now that
cloth is easily purchased at Tap Plastics (well if you are on the left
coast). The claim is the material is good to 10GHz.
> http://www.agy.com/markets/PDFs/NEW_AGY205AWACS.pdf

They stock the Hexel version. S-2 glass is not very rigid, so you can
make just about any shape you want. Now for the AWACS, they used epoxy
resin. This might be a function of dielectric constant, which doesn't
seem to be listed for any of the resins carried at Tap. I've only used
the marine grade vinyl ester, since it is compatible with all the cloth
they sell. Possibly in manufacturing the radome for the AWACS, they
didn't want to vacuum bag it, so epoxy resin would get around that need.

For DIY construction (i.e. without vacuum bag gear), you just build the
composite so it cures between mylar sheets. The vinyl ester doesn't
really get hard in the presence of air. Given the cost of the resin, you
might as well get the full strength. You don't need a vacuum, but you do
need to restrict the air a bit, hence the mylar.

If anyone gets serious about radoming home brew antennas, I can write up
a bit more on the fabrication. PVC pipe certainly effects the antenna.

> http://www.tapplastics.com/uploads/p...ont-Rev711.pdf

On Tue, 29 Nov 2011 00:59:12 -0800, miso <miso@sushi.com> wrote:
(...)
Very good info if you're going to build a radome from standard
extruded shapes, which are great for wire antennas. Not so good for
flat antennas, that lend themselves to vacuum forming:
<http://en.wikipedia.org/wiki/Vacuum_forming>
<http://www.google.com/search?q=vacuum+forming&tbm=isch>
<http://www.warmplastic.com>
<http://www.build-stuff.com/1001plans_hobby_vac.htm>
Works with ABS, PVC, Styrene, Acrylic, Lexan, HDPE, PET-G, etc.
Acrylic is nice for making see through radomes.


--
Jeff Liebermann jeffl@cruzio.com
150 Felker St #D http://www.LearnByDestroying.com
Santa Cruz CA 95060 http://802.11junk.com
Skype: JeffLiebermann AE6KS 831-336-2558

On 11/29/2011 9:40 AM, Jeff Liebermann wrote:
> On Tue, 29 Nov 2011 00:59:12 -0800, miso<miso@sushi.com> wrote:
> (...)
> Very good info if you're going to build a radome from standard
> extruded shapes, which are great for wire antennas. Not so good for
> flat antennas, that lend themselves to vacuum forming:
> <http://en.wikipedia.org/wiki/Vacuum_forming>
> <http://www.google.com/search?q=vacuum+forming&tbm=isch>
> <http://www.warmplastic.com>
> <http://www.build-stuff.com/1001plans_hobby_vac.htm>
> Works with ABS, PVC, Styrene, Acrylic, Lexan, HDPE, PET-G, etc.
> Acrylic is nice for making see through radomes.
>
>
The vacuum forming links were interesting, but it isn't the same as
vacuum bagging.

I think the goal is to get the dielectric constant as close to free
space as possible. That was the reasoning behind using C-glass. I
suspect S-2 glass was for strength more than RF properties.

I do my composites over a form that can be sacrificed. Foam board for
instance. As long as the surface is reasonably rigid and can be covered
with mylar, it will work. I've also used cardboard tubes. Ideally you
want the form strong enough that you can put pressure on the outside
layer of mylar to compress the layers of cloth and mat.

If you don't need RF transparency, graphite/mat/S-2 sandwich is the way
to go. Graphite is so much stronger than S-2 that it greatly reduces the
number of layers required. Tap also sells graphite tubes that you can
use in your project to act as a spine (maybe rib is a better word), also
reducing the number of layers required. The trick is to get a strong
matrix by whatever means necessary with the minimum number of layers. I
have a feedhorn done using this scheme. Predicting the strength of the
matrix is for the true gurus. For DIY, you can always add another layer
or sandwich if need be. The graphite doesn't absorb much resin, and who
knows where to buy prepreg, so you just add layers of mat on the
graphite. Probably the outer layer too if you worry about abrasion. The
marine vinyl resin has the advantage that it doesn't have to be sanded
to get the next coat to stick, while epoxy needs sanding. I rough it up
anyway just to be sure.

PVC detunes the antennas a bit. It is barely detectable at a gHz, based
on the 1090MHz j-pole I have. The guy who built it did before and after
sweeps.