PSAS/ news/ 2003-11-10 - Made 1.277 and 1.575 GHz flat patch antennas to test (build pictures)

Glenn and Andrew got together and made flat patches.

Here's the rough order of steps:

  1. Cut out the patch (pre-etched 5/1000 inch thick FR-4)
  2. Cut out the ground plane, using the patch as a guide (the ground plane is soft copper sheeting 5/1000 inch thick)
  3. Align the PCB and ground plane, and poke through the PCB feed hole with something sharp (e.g., oscilloscope probe) to make an indent.
  4. Drill or use an exacto to cut out a hole just big enough for the center insulation.
  5. Cut back the coax jacket and splay out the braid. Cut and strip the center conductor (although you might have to strip it again later).
  6. Clean up the copper ground plane with nonresidue flux, and solder it on with a big soldering gun. The insulation and center conductor are now sitting poking out through the copper ground plane.
  7. Apply the foam tape. Don't forget to make a hole in the foam tape for the insulation and center conductor.
  9. Slit the plastic tape starting right at the center conductor in a line perpendicular to the long axis of the antenna.
  10. Put the PCB on the center conductor and very carefully hold it down near that point.
  11. If the center conductor's insulation is too long, it will push up on the feedpoint, take off the PCB and trim it down.
  12. You might want to solder it on at this point.
  13. Then, bend the PCB and begin removing the plastic tape. START AT THE BOTTOM OF THE ANTENNA, AND WORK YOUR WAY UP, SMOOTHING OUT THE PCB AS YOU GO UP.
  14. Voila, you've got a flat CPA.