Sheet metal waveguide horn antenna

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to FIGS.
2 and 3 of the drawing, there is shown a preferred embodiment of a waveguide horn antenna according to the invention, generally designated as 22.
Waveguide horn antenna 22 has a tapered horn portion (indicated by the arrow 24) of rectangular cross-section attached at its narrower end to a straight waveguide portion (indicated by the arrow 26) of rectangular cross-section.
Waveguide horn antenna 22 is comprised of first section 28, second section 30 and third section 32 shown in detail in FIGS.
5, 7 and 8(a) and (b) respectively.
As depicted in FIG.
5, first section 28 comprises three walls of horn portion 24, preferably the two side walls 34 and 36 and the bottom wall 38.
First section 28 is formed by folding a first pattern 40 of a single sheet of metal, preferably copper, shaped as shown in FIG.
4.
Pattern 40 is a development of the walls of first section 28 which is folded by suitable folding tools along fold lines 42 and 44 to provide the configuration of first section 28 as shown in FIG.
5.
Fastening flanges 46, 48 and 50 having through holes 52 are preferably formed as an integral part of pattern 40 and folded as shown ot provide for assembly of the waveguide horn antenna 22, described subsequently.
Pattern 40 is formed by stamping the sheet metal with an automatic punch press or other suitable stamping equipment.
Second section 30 as shown in FIG.
7 comprises three walls of waveguide portion 26, preferably the top wall 54 and the two side walls 56 and 58, and the fourth wall 60 of the horn portion 24, preferably the top.
Similar to first section 28, second section 30 is also formed of folded sheet metal by folding a second pattern 62 as shown in FIG.
6, pattern 62 being a development of the walls of second section 30.
Pattern 62 is folded along fold lines 64, 65 and 66.
Fastening flanges 68, 70, 72 and 74 having through holes 76 are also formed integrally with pattern 62 to allow for assembly of the waveguide horn antenna 22