Method for forming a high frequency antenna

A method for forming a horn-reflector antenna from a mold having at least two horn sections for forming the horn portion of the antenna and a reflector section, said horn sections having an open apex lower end when secured together and said mold further including a bar member and a collar, and said method comprising:

• removable securing said horn sections together;
• removably securing said reflector section to said secured horn sections;
• inserting the bar member through said open apex end;
• securing the bar member inside said secured horn sections so that the lower end of the bar member is on the outside of the horn sections;
• positioning said collar on the lower end of the bar member in contact with the outside of the apex end of the horn sections;
• and
• forming the antenna so that the collar and lower end of the bar member define an union element integrally formed to the apex of the antenna.

A method for forming a horn-reflector antenna from a mold hving at least two horn sections for forming the horn portion of the antenna and a reflector section for forming the reflector portion of the antenna, each of said horn sections having an open apex lower end, and said mold further including a bar member, said antenna including an open area for communicating the inside of the reflector portion with the outside, for transmitting electromagnetic energy waves, said method comprising:

• positioning one of said horn sections closer to said open area to be formed than the other horn section;
• removably securing said horn sections together;
• removably securing the reflector section to said secured horn sections;
• extending said bar through said open apex ends of the horn sections;
• leaving a lower part of said bar outside of said horn sections;
• forming said antenna in a single piece so that the inner surface of said antenna conforms substantially to the outer surface of said attached horn and reflector sections of said mold, without causing permanent attachment of the mold with the formed antenna, and further forming said antenna to include a transitional portion for connecting to a coupling means and said transitional portion being integrally formed to the horn of said antenna, said transitional portion being defined at least in part by said lower part of the bar on the outside of the horn sections;
• removing said bar to define an opening for communicating the inside of said antenna horn portion with an external said coupling means;
• disconnecting the reflector section from said horn sections;
• removing the reflector section from the antenna via said open area;
• disconnecting said horn sections;
• removing said one horn section closer to the open area from the antenna via said open area;
• and
• removing said other horn section from the antenna via said open area.

A method for forming a horn-reflector antenna from a mold having at least two horn sections for forming the horn portion of the antenna and a reflector section for forming the reflector portion of the antenna, said horn sections being substantially identical half shells of a cone and said cone shells being open at the bottom ends and define a hole when secured together to form the cone, said antenna including an open area for communicating the inside of the reflector portion with the outside, for trasmitting electromagnetic energy waves, and said method comprising:

• removably securing said cone shells together;
• removably securing the reflector section to said secured cone shells, so that one of said shells is closer to the front end than the other cone shell;
• inserting a bar member through the hole at the apex end when the cone shells are secured together, so that the lower part of the bar member extends outside from the bottom ends of the cone shells;
• positioning a collar on the lower part of the bar member and in contact with the bottom ends of the secured cone shells;
• securing the bar member on the inside of the cone shells;
• forming said antenna in a single piece, so that the inner surface of the antenna conforms substantially to the outer surface of said attached cone shells and said reflector section and said collar and lower end of the bar member define a union element integrally formed to the bottom end of the horn portion of the antenna;
• disconnecting the bar member from the inside of the horn section of the mold;
• removing the bar member from the antenna via said hole of the mold and the bottom of the antenna;
• disconnecting the reflector section from the horn section of the mold;
• removing the reflector section from the antenna via said open area;
• disconnecting said cone shells;
• lifting said one cone shell upward within the space previously occupied by said reflector section;
• rotating said lifted cone shell toward said open area so that the lower end thereof extends inside the other cone shell;
• removing said one cone shell from the open area of the antenna;
• and
• removing the other cone shell from the open area after said one cone shell has been removed.