petroleurn oil, clearly suggesting substantial oxidation.

This oxidative degradation is not reflected in the power factor curve of the
synthetic, probably because of the very much higher viscosity of
this particular oil cornpared to the petroleurn oil.
Closed systern oxidations are shown in Figure 10, where the rate
of oxygen consurnption is shown. The petroleurn fluid shows essentially no oxygen consurnption whereas the synthetic consurnes
oxygen fair ly rapidly. Exarnination of these oils af ter oxidation
reveals that the acidity and power factor of the synthetic fluid is
higher than the petroleurn fluid, which is an indication of the
oxidative instability of the synthetic fluid.
Open beaker oven aging tests (ASTM-1934-B) for these oils are
surnrnarized in Figure 11. Results are sirnilar to those found for the
pipe type cable oils. Thus, although the power factor of the synthetic remains low cornpared to the petroleurn oil and although the
total acid number is essentially the same at any given time, the
fact that the synthetic has undergone a significant change in viscosity and that a significant quantity of the synthetic has volatilized, attests to the oxidative instabiliy of the synthetic.
The electrical properties of two experirnental petroleurn derived
oils are cornpared to the present commercial oil in Table IV. The
experirnental oils show considerable impravement in electrical
properties over the present commercial oil. Of the two oils,
Experirnental Petroleurn Oil A will likely be the commercial
product.

A DEPWYABLE DIELECTRIC PARABOLIC

ANTENNA REFLECTOR AND RF FEED
SUPPORT
by

WILLIAM KoRVIN, HossEIN BAIIIMAN AND JoHN GATES

Systems Division, NASA

Goddard Space Flight Center
Greenbelt, Maryland
IEEE 32C79-58

TABLE IV
Power Factor of Petroleum Derived lmpregnating Type
Cable Oils
Power Factor at 100C

Present Commercial Oil

Experirnental Petroleurn Oil A
Experirnental Petroleurn Oil B

Initia!
0.0017
0.0008
0.0006

Four Days at l15C,

Copper
0.0357
0.0057

0.0013

Conclusions
The work surnrnarized in this report has uncovered sorne of the
factors which contribute to oil stability and to dielectric loss,
particularly during oil oxidation. This work has resulted in several
irnproved petroleurn derived electrical insulating fluids and we
expect that continued research in the future will continue to contribute to irnproved products for the electrical industry.

Keferences
1. Melchiore, J. J. and Mills, I. W., Journal of the Electrochemical
Society, 112, 390-395 (1965).
2. Insulation, (Directory/Encyclopedia Issue), 112 No. 6, page 66
(1966).

4. Achievernent of tolerances in deployrnent

5. Maintenance of tolerances in the deployed or bi tal operation
and environment
a. axial torsion acceleration
b. lateral torsion accelera ti on
c. hard radiation
d. ultra-violet
e. infrared
f. vacuurn

Introduetion
The basic philosophy governing this development effort was
concentrated on the possibilities of using dielectric material for a
simpie lightweight deployable reflector antenna capable of high
surface accuracies which include consideration of fabrication, assernbly, packaging, deployrnent and operation techniques.
Many reflector design techniques have been or are being evolved
as solutions to the general problern of deployable antennas. The
present systern falls under the subheading of High Modulus rnaterials of the Mernory Techniques, more specifically, lightweight
dielectrics. This rnaterial, in brief, consists of a fiber glass grid
core covered with a thin flexible resin systern plated by a metallic
vacuurn deposit which can be preforrned in the desired shape,
deforrned into a packaged condition and when released, because of
its stored elastic strain energy, resurnes its fabricated original
contour (See Figure 1).
As was indicated previously, this concept is applicable to both
space and transportable tactical ground cornrnunications. Since
major concern at Goddard Space Flight Center is with space
cornrnunications rather than ground based tactical applications, the
design effort was concentrated on space deployable capabilities.
The need and general availability of design restraints and environrnental factors dietate to a large extent the prime design
parameters. Sorne design requirernents and environrnental factors
which must be necessarily taken into account during design consideration are:
1. Achievement of tolerances in fabrication and assembly
2. Preserving integrity and tolerances in the packaged state
during launeh standby environment
3. Preserving integrity during launeh configuration and environment
a. lateral vibration and acceleration
b. axial vibration and acceleration
c. a via! torsion vibration and acceleration

OIELECTRIC FEED
SUPPORT CONE

OIELECTRIC PARABOLle
REFLECTOR
(VACUUM OEPOSITED

METAL SURFACE)

..

OtELECTRIC SUPPORT

INNER PARABOLIC
HUB PLATE

INTERFACE SUPPORT

CYLINDER

Figure 1-Deployable dielectric parabolic antenna system.

163

Figure 4-Fiberglass cloth.

Figure 2-Parabolic mold fabrication.

Rather stringent reflector toleranee requirements are necessary
for high antenna gain using a large (thirty-foo~ diamet~r) :eflector
at a frequency in the vicinity of seven GH~. Smee fa~ncahon of a
full scale antenna system was neither practica! nor des1rable from a
cast viewpoint, a one-fifth scale effort was selected a~ a re~sonable
compromise between size and the scaled frequency (1.e. thlr~y-.five
GHz). This sealing resulted in requiring no peak surfa~e dev1atwns
normal to the theorectical surface g-reater than approx1mately 0.02
inches. Restrietion in the !argest opening in the reflector mesh
should be of the order of 0.03 inches to assure 90 to 95% RF
reflectivity at K-band.
.
The focal length to diameter ratio of the reflector cons1dered for
this design was 0.5.

System Design Approach

To implement this lightweight dieledric high modulus, me'!'ory
material approach for a practica! desig?, a review . of cand1d~te
material properties for the reflector d~s1gn was carned ou~. !'!ot
only did this include physical propert1e~, a~ such, but fabncatwn
techniques and, therefore, structural apphcatwns.

Figure 3-Rib mold.

164

It is believed that functional simplicity is compatible with lightweight and that a flexure joint incorporating its own depJayment
mechanism is more desirabie from a reliability and weight standpoint than that of a meehanical hinge with its accompanying motivating mechanism. Therefore, effort was starled on the design and
fabrication of a single piece, flexible. prefarmed mesh reflector. The
dielectric mesh material configuration was chosen for increased folding ability, lightweight. better fabrication forming of complex
curves, and to alleviate self-shadowing from solar radialion as well
as reducing wind loads in possible ground use.
Since the flexibility of a simpie parabalie dish for packaging
without degradation is not in keeping with the stiffness necessary
(e.g. deployed configuration stability in a one "g" field). radial ribs
of the same material were added. The parabalie dish was designed with marginal ability to maintain its prefarmed configuration without support as were the ribs. however. when assembied
the composite structure became self-supporting. Although the ribs
themselves in the deployed configuration contribute greatly to the
stiffness of the overall structure in radial vertical planes of the
upright parabola, these ribs can be flexed sideways for folding.
The transverse flexing of the ribs reduces the moment of inertia
contributed bv the ribs and thus allows folding and packaging of
the composite. structure.
In order to accommodate a hard interface between the antenna
system and altachment points, to facilitate fabrication, and to .take
actvantage of allowable pre-ereeled portions of the reflector w1thm
shroud restraints, a sheet meta! hub was designed. The. hub also
presents a base for altachment of the feed support. e1the; cassegrainor prime, which although not an ereetabie structure m the
design task, never-the-Jess was approached in a samewhat unorthodox manner. Generally the approach to feed support structures
has been the design use of high strength, metallic or high dielectric
matcrials which presents an RF blockage problem due to the support memhers themselves. Same effort was expended to reduce ~his
blockage problem and at the same time shield the feed mechamsm

Figure 5-Cloth and frame layup.

Figure 8-Hand forming of impregnated cloth on mold.

Figure 6--Cloth impregnated with polysulfide.

from altemating solar radiation (i.e. varying sun angles) with the
use of a hollaw monocoque, conical structure composed to the
maximum extent possible of law dielectric materiaL
The methad of packaging consists of introducing straight radial
folds in the mesh reflector as its periphery is moved from the deployed position of the parabola and inwards toward the focal point.
This package configuration does not take full advantage of possible
packaging compactness but is in keeping with the reliability goal in
depJayment with restrietion to a minimum of sharp inflection fold
lines in the materiaL The convoluted folded periphery is clamped
and held in position with a tension ring. The tension ring is resisted
by a plastic faam f1xture which was formed to receive the fold pattem in a controlled bend radii grasp. DepJayment is initiated when
the tension damp is severed and the stared elastic energy of the
mesh forces the folded periphery away from its packing fixture and
into its deployed state. The edges of the rib soekets do not coincide
with edge of the hard reflector hub surface but rather extend
beyand the meta! hub surface. This allows same transition between
complete restraint (in folding) of the mesh and the sharp bend at
the hard surface of the reflector.
To delermine surface tolerances for RF considerations the as-

Figure 7-Drape of impregnated cloth.

sembled antenna reflector was replaced over the reflective surface

mold before and after packaging in order to estimate any discernibie toleranee deviation. Maximum measured deviation from the
mold was no greater than 0.050 inches for an estimated So/a of the
area and no grcater than 0.010 inches for the remaining area.
Accurate determination of major model frequencies, mode shapes,
and "q" factors bath for the deployed and packaged reflector configurations is believed possible only with full scale testing in view
of the complicated analysis required for the mesh and the possible
non-uniform use of matcrials during fabrication. Although the
resonant frequencies are expected to be law, impravement may be
made by plaeing the mesh under tension in the folded configuration
and by judicious use of additional ribhing (e.g. circumferential ribs)
in the deployed condition.
Ultra-violet radiation is not expected to be a problem because of
the protection affered to the resin system by the over-layer of
vacuum deposited aluminum. Dimensional stapility and brittleness
due to exposure to hard radiation may be a possible problem area

Figure 9-0ven curing of impregnated cloth on mold.

165

Figure 12-Fabricated aluminum hub.

Figure 10-Attachment of rib.

and may necessitate search for an alternate resin system with

similar meehanical charaderistic but greater radiation resistance.
An indication of compatibility of the reflector material and v_acuum
is given in the vacuum deposition process wher~ the mesh 1~ subjected to a pressure of w~ mm of Hg for a penod of 30-mmu~es.
It is estimated that the use of thin, flexible, thermal control coatmg
will limit the maximum temperature rise of the mesh surface to
one-hundred degrees eentigrade or Jess when exposed in orbit to
solar infrared radiation.
Possible conversion of this antenna system to an infrared energy
collector could be accomplished by bonding a preformed parabolk
elastomeric material of minimal thickness to the concave side of the
antenna reflector. This material would of necessity possess adequate
thermal stability. Vacuum deposition o! aluminum on the conc~ve
side of the parabola should then provide the necessary reflechve
qualities.
Fabrication

A six foot diameter mold and ribs were designed and fabricated
(See Figures 2 and 3). The reflector mesh design was based on the

Figure 11-Assembly of parabolic mesh shell with rib

socket and rib.

166

stiffness and flexibility available in material samples produced from

a previous program for the development of self-ereeting materials
and with the possibility in mind that with the variation of the
resin system and glass core used, meehanical properties of the composite material could be varied to suit the design. Design and fabrication of the molds themselves proceeded under assumptions that a
room temperature or near room temperature cured resin could be
utilized in the fabrication of the mesh and also that vacuum
bagging might be necessary to insure proper material conformation.
The parabolk mold surface and the !lange or attachment area of
the rib mold were considered of prime importance with regard to
tolerances. These surfaces were carefully hand finisbed to an
estimated toleranee of 0.005 inches from the theoretica! configuration. Various material and resin systems were sample fabricated
from the molds using a three rib sector of the reflector assembly
(fifteen ribs are used in the complete assembly) in order to evaluate
the physical properties of these variations in the composite assembly
and simultaneously improve the handling and material layup techniques.
Fabrication of the complete assembly model was achieved in the
following manner. The general technique involving the mesh composite material consisted of Jaying the glass cloth across flat frames
slightly larger in area than the mold surface in the desired number
of Jayers and orientation (See Figure 4). The edges of the cloth
were lightly constrained to the frames by the use of tape (See
Figure 5). The glass cloth Jayers were then impregnated with a
thinned polysulfide liquid polymer using band rollers, blotted to
remove the excess resin, and blown with air to eliminate bridging
of the interstices (See Figure 6). The composite was then immediately draped over the male molds and hand shaped to conformation
(See Figures 7 and 8). Curing consisted of raising the. temperat~re
to 160F either in an oven (as was the case of the nbs) or With
overhead heat lamps (as was the case for the parabolic shell) for
approximately seventy-two hours (See Figure 9). During cure,

Figure 13-Applieation of vacuum deposition substrate.

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reflector.

Figure 14--Feed support structure.

damping was applied to a small area of the tips of the rib mold in
order to prevent bridging of the material at a place of compound
curvature. This was also done at the outer edge of the reflector
shell to facilitate proper Jay-down of the material over the whole
paraboloid. Assembly of the ribs to the parabolk shell and then
to the meta! hub was accomplished by bonding with the same resin
system (See Figures 10 and 11). Fabrication of the meta! hub was
done by spinning aluminum sheet to a parabolk surface. The rib
soekets were formed by compressing aluminum sheet over molds

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(See Figure 12). Upon completion of the bonded assembly the

composite mesh structure was processed (metallizing laquer applied
and heat cured) to provide a suitable substrate for vacuum meta!
deposition (See Figure 13). Aluminum was vacuum deposited to
both concave and convex sides of the composite mesh structure to
provide the necessary reflective and UV protection characteristics.
The support structure (See Figure 14) was fabricated and bonded
to the center meta! hub parabolk surface and the circular packaging
fixture for the mesh reflector, shaped from a styrofoam slab was
mounted near the upper end of the feed support (See Figure 15).

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reflector.

167

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sections into a truncated, hollow, thin walled eone and (2) the
casting of a one piece, hollow structure. The dual approach was
taken to study whether the most attractive physical properties
coupled with the least attractive method of assembly (i.e. piece-bypiece) would be equivalent to a one piece molded structure of
samewhat Jess desirabie materials. A one piece molded urethane
foam structure eliminated the subassembly of many bonded joints
and could be produced with a thin outer and inner shell of solid
urethane. These thin shells increased the strength and stiffness of
the structure but at the same time caused degradation of its RF
transparency.
The first fabrication method used six Iongitudial wedge shapes
which were cut from a slab of high density styrofoam (3.3 Ib per
cubic foot density) and were then edge bonded with epoxy to
form the hollow eone frustrum.

The second method necessitated the fabrication of a reusabie

aluminum mold manufactured in a suitable shape. The mold was
charged with a foaming urethane (4.2 Ib per cubic foot density)
which was then cured at room temperature to a rigid state. In
order to enhance the structural properties of solid outer surfaces,
obtainable by this fabrication method, a layer of fiber glass cloth
saturated with epoxy (on the order of 1 mil thick) was plaeed on
the inner mold surfaces and cured. This produced a much higher
strength surface for the support with a small increase in weight
(9%).

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polyurethane feed support eone.
A surface toleranee of lha of the operating frequency wavelength is used to assure a RF reflector efficiency of 50% to 60%.
For 35000 me this is approximately .02 inch. Using a mold, this
is not an extremely difficult task for diameters up to 6 to 9 feet.
However, beyond this diameter extreme care must be taken as far
as the mold material is concerned. The ambient room temperature
and humidity must be controlled to avoid variabie surface tolerances in the mold.
The actual feed support structure fabrication development was
approach using two methods: (1) the lamination of longitudinal

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feed support eone.

168

A static loads test and a vibration test were conducted on a ~

scale model of the proposed antenna feed support structure. The
purpose of these tests was to evaluate the feasibility of using a
urethane foam or a styrofoam conical support for the antenna feed
box. These foam materials have desirabie electrical characteristics,
but their strength and rigidity are questionable.
The model was~ scale of the proposed prototype. It consisted
of a hollow truncated eone 0.6 inch wall thickness, about 36 inches
high, 15 inches diameter at the bottom, and 7 inches diameter at
the top. An aluminum plate was bonded to the bottom, and an
aluminum cap was bonded to the top. Additional weight was
required to bring the weight of the cap up to the scaled antenna
feed weight of 1.6 pounds.
The structural sealing Iaws that give the same stresses in the
model as the prototype are as follows:
Static
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Lateral vibration caused the worst structural Ioads of any launeh

condition (as describ'ed in the following section on tests). This
necessitated additional design development on a minimal weight
basis in order to augment the small material resistance of this
material contiguration to Iow frequency lateral Ioading. lt was
reasoned that the Iargest restraint for the least weight available was
a meta! tension memher applied between the base and the top of
the eone support along the longest diagonal. The lateral component
of restraint of the tension memher would then limit the Iow
frequency tip mass excursions and provide also a means of damping
through the use of interwoven cables.
Ultra-violet protection of the foam eone with minimal RF clegradation was provided by a white paint sprayed to a 10 mil thickness
and dried in an ambient environment. This coating also provided
thermal protection for the eone in an orbital environment (i.e.
estimated running temperature in the minimum eentigrate range).
The resistance of these foam materials to hard radiation (which
normally eauses instability of physical properties) is considered
excellent.

Dynamie (Vibration)
I'
f
Frequcncy
y- I
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a
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a'
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Mass

cfc,= c/c',
m
m'

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where 1-linear dimensions, primed terms refer to model, and

unprimed terms refer to prototype.
The prototype specification has been defined using the combined
environments created by both the Titan IIIC and the Atlas/
Centaur. U sing the above sealing laws, the following model specification has been determined:

I. Static Loads
a. Lateral 24 pounds
b. Thrust 77.5 pounds
(To be applied simultaneously)
II. Dynamie Loads
a. Lateral Axis
5-1250 H, 7.5 g
1250-2000 H, 15 g

2000-5000 H, 3 7.5 g
Sweep rate 2 oct/min.
b. Thrust Axis
5-1250 H, 15 g
1250-2000 H, 18.5 g
2000-5000 H, 37.5 g
Sweep rate 2 oct/min.
Successful axial and lateral !light level vibration tests were
completed which involved the one fifth structural model of reinforced, low dieketric foam eone intended to support feed and
experiment packages for a thirty-foot diameter antenna using a
scaled 200 pound tip mass. This test was performed in the GSFC
Test and Evaluation Division's vibration chambers.
Calculations have shown that lateral vibration is by far the most
critica! structural dynamie test of the three dynamie loadings (axial,
lateral, and torsional) for this eone configuration .
The lateral resonant frequency was found to be approximate ly
40 cps. The eone structure successfully passed the resonant frequency with five g's input with a tip amplification factor of sixteen.
It might be mentioned also that the successful axial testing was
performed. The frequency in both tests ranged from zero to 3000
H,.
RF Characteris tics of the System (Primary and Secondary
Pattern)

To determine the effect of various foam material used for supporting the RF feed at the focal point, several measurement s were
made of the primary feed energy distribution. Idea!ly, its energy
is spread across the reflector aperture such that when it is reflected,
a collimation of the radio frequency energy takes place" producing
a bigbly directive high gain beam. Figure 16 shows what is considered as an optimized primary pattem which distributes energy
across the reflector aperture. Figure 17 shows the resuiting secondary beam.
Measuremen ts made on different foam structures produced the
primary pattem shown in Figures 18 and 19. Secondary patterns
are shown in Figures 20 and 21.
It should be noted that where severe primary pattem dislortion
occurred, the secondary pattem also deteriorated.
Summary

The state of material development has been completed under the

systems feasibility study. The next development a! phase requires
more rigorous material testing as wel! as composite assembly
environment al testing data for an enhanced material development

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support.

and optimized design. Areas of possible material and design improvement include:
1. Resin system development for greater resistance to hard
radialion such as the process use of natura! rubber for coating the fiber glass.
2. A!leviation of creep or plastic flow of the resin system during
prolonged packaging of the composite assembly. This may be
possible with the use of cyrogenic temperatures and/or
lamination of thin narrow radial steel springs between the
ma te rial layers in either the dish or ribs.
3. Improved rib designs to meet special cnvironmen tal specifications such as merging the box rib at the periphery of the
assembly into the flat shell adjacent to the inner parabolk
shell at its edge to provide additional edge stiffness and shape
conformation .
The lightwight, diclectric, memory material described in this
paper a!lows an extremely versatile reflector system to be formed.
The dideetric reflector systems thus formed may be used for RF
and solar concentrator s and in either space applications or for
portable ground systems. It can be made lighter in weight than
other presently developed systems when surface toleranee as a
function of reflector diameters is considered.
For portable ground applications, an antenna of a given size
would be required to be somewhat heavier than those inteneled for
space applications since the antenna must maintain the surface
toleranee in a 1 g field. Since this 1 g field restrietion is removed
in space applications, the reflector can be made much more flexible.
Also important is the capability of packaging the reflector antenna where its deployed diameter is too large to place in a spacccraft of a ground transporting vehicle. Fina!ly, random damage to
a portion of the reflector due to an impact is not as critica! as it
would be for a meta! reflector where an impact would force a
permanent and/or expanded area of deformation.
Acknowlcd gmcnts

I.

Figure 20-Second ary pattern using polyuretha ne feed

support.

Acknowledg ment is given for extremely helpful advice and

services furnished by the following groups at the Goddard Space
Flight Center:
ATS-4 Project Staff
Communieal ions Research Branch
Fabrication Engineering Branch
Fligh t Programs Office
Matcrials Research & Developmen t Branch
Plastics Model Shop
Structural Dynamics Branch
Thermal Systems Branch

169