MILLIFOAM® Spacer – precise foam sheets for high performance antennas

May 12, 2022 Uncategorized

Introduction

High performance antennas for many different applications like 5G millimeter Wave antennas (Figure 1), phased array antennas for satellite terminals or antennas for land mobile satellite applications, require pr cise internal structures to get the most out of the signals received and transmitted. An important component for achieving the required performance is the use of low loss spacer foams in the internal antenna structure. These specifi c and precise thin foams are used as internal spacers, as carrier structures in patch antennas or tailored cores in radomes.

Methods & Materials

We use a unique skiving method to generate thin and precise low loss foam sheets having a uniform surface structure. The resulting MILLIFOAM® rigid foam sheets have very tight thickness tolerances and are available in a thickness range from 0.5mm up to 5mm (Figure 2). In the course of antenna engineering it is decided which foam type should be used regarding density, dielectric properties and thickness or die cut pattern. Finally the MILLIFOAM® sheets are cut to the desired geometry and delivered in a ready-to-use condition.

Millifoam cutted

Figure 2: MILLIFOAM® low loss and rigid spacer foams

Benefits

The low loss, low dielectric foam type, that is preselected very early in the antenna design process, is provided as a sample which allows rapid performance assessment. This ensures selecting the right foam type and to reach the antenna performance targets. The fi nal spacer is then cut or shaped to be ready for assembly in the production line (Figure 3). MILLIFOAM® spacer foams contribute to protect sensitive antenna designs, whilst enhancing the overall antenna performance.
We use a unique skiving method to generate thin and precise low loss foam sheets having a uniform surface structure. The resulting MILLIFOAM® rigid foam sheets have very tight thickness tolerances and are available in a thickness range from 150µm up to 5mm (Figure 2). In the course of antenna engineering it is decided which foam type should be used regarding density, dielectric properties and thickness or die cut pattern. Finally the MILLIFOAM® sheets are cut to the desired geometry and delivered in a ready-to-use condition.

Figure 3: MILLIFOAM® Spacers delivered directly to assembly lines