Popup Arrays for Large Space-Borne Apertures

Large apertures in space are critical for high-power and high-bandwidth applications spanning wireless power transfer (WPT) and communication, however progress on this front is stunted by the geometric limitations of rocket flight. We present a light and flexible 10 GHz array, which is composed of dipole antennas co-cured to a glass-fiber composite. The arrays can dynamically conform to new shapes and are flexible enough to fold completely flat, coil into a rocket payload, and pop back up upon deployment in orbit. The array is amenable to scalable, automated manufacturing—a requirement for the massive production necessary for large apertures. Moreover, the arrays passed the standard gamut of space-qualification testing: the antennas can survive mechanical stress, extreme temperatures, high-frequency temperature cycling, and prolonged stowage in the flattened configuration. The elements exhibit excellent electromagnetic performance: a return ratio better than −10 dB over ≈ 1.5 GHz, a single-lobe half-power beamwidth of greater than 110° suitable for broad beamforming, >92% efficiency, and excellent manufacturing consistency. Moreover, its mechanical durability vis-a-vis extreme temperatures and protracted stowage lends itself to demanding space applications. This lightweight and scalable array is equipped to serve a host of new space-based radio frequency technologies and applications which leverage large, stowable, and durable array apertures.